Opel Agila Suzuki Wagon R User Manual

IMPORTANT

WARNING/ CAUTION/NOTE

Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.

NOTE:
Indicates special information to make mainte­nance easier or instructions clearer.

WARNING:
For vehicles equipped with a Supplemental
Restraint Air Bag System:
D Service on and around the air bag system

components or wiring must be performed
only by an authorized SUZUKI dealer.
Please observe all WARNINGS and CAU­TIONS in SECTION 10B and Precautions, Air
Bag System Components and Wiring Loca­tion View in SECTION 10B or before perform­ing service on or around the air bag system
components or wiring. Failure to follow
WARNINGS could result in unintentional ac­tivation of the system or could render the
system inoperative. Either of these two
conditions may result in severe injury.

D If the air bag system and another vehicle sys-

tem both need repair, Suzuki recommends
that the air bag system be repaired first, to
help avoid unintended air bag deployment.

D Do not modify the steering wheel, instru-

ment panel or any other air bag system com­ponent (on or around air bag system compo­nents or wiring). Modifications can adverse­ly affect air bag system performance and
lead to injury.

D If the vehicle will be exposed to tempera-

tures over 93_C (200_F)(for example, during
a paint baking process), remove the air bag
system components (air bag (inflator) mod­ules, SDM and/or seatbelt with pretension­er) beforehand to avoid component damage
or unintended deployment.

WARNING:
Indicates a potential hazard that could result in
death or injury.

CAUTION:
Indicates a potential hazard that could result in
vehicle damage.

WARNING:
This service manual is intended for authorized
Suzuki dealers and qualified service mechan­ics only. Inexperienced mechanics or mechan­ics without the proper tools and equipment
may not be able to properly perform the ser­vices described in this manual.
Improper repair may result in injury to the me­chanic and may render the vehicle unsafe for
the driver and passengers.

FOREWORD

This manual contains procedures for diagnosis, maintenance, adjustments, minor service op­erations, replacement of components (Service) and for disassembly and assembly of major com­ponents (Unit Repair-Overhaul).

Applicable model: RB413

The contents are classified into sections each of which is given a section number as indicated
in the Table of Contents on following page. And on the first page of each individual section is an
index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the
vehicle.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine
parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest
product information available at the time of publication approval. And used as the main subject
of description is the vehicle of standard specifications among others. Therefore, note that illustra­tions may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.

Related Manual

Manual Name

Manual No.

RB413 WIRING DIAGRAM MANUAL 99512-83E00-669

OVERSEAS SERVICE DEPARTMENT

 COPYRIGHT MAGYAR SUZUKI CORPORATION 1999

TRANSMISSION, CLUTCH
AND DIFFERENTIAL

Manual Transmission
Automatic Transmission

(4A/T)
Clutch

TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION

7A

7B

7C

HEATING AND AIR
CONDITIONING

Heater and Ventilation
Air Conditioning

(If Equipped)

1A

1B

STEERING, SUSPENSION,
WHEELS AND TIRES

Steering, Suspension,
Wheels and Tires

Front End Alignment
Manual Rack and Pinion
Electrical Power Steering

System (If Equipped)
Steering Wheel and Column
Front Suspension
Rear Suspension
Wheels and Tires

3

3A
3B

3B1

3C
3D
3E

3F

DRIVE SHAFT AND
PROPELLER SHAFT

Front Drive Shaft

4

BRAKES

Brake Pipe/Hose / Master
Cylinder

Front Brakes
Parking and Rear Brakes
Antilock Brake System

5

5A

5B
5C

5E1

ENGINE

General Information and
Engine Diagnosis

Engine Mechanical
Engine Cooling
Engine Fuel
Engine and Emission

Control System
Ignition System
Cranking System

(1.2kW Reduction Type)
Cranking System

(0.9kW No-Reduction Type)
Charging System
Exhaust System

6

6A1

6B
6C

6E

6F1

6G

6G1

6H
6K

GENERAL INFORMATION

General Information
Maintenance and Lubrication

0A
0B

BODY ELECTRICAL SYSTEM

Wiring Diagram
Lighting System
Instrumentation/Driver

Information
Windows, Mirrors, Security

and Lock
Immobilizer Control System

8
8A
8B

8C

8D

8G

BODY SERVICE

9

RESTRAINT SYSTEM

Seat Belt
Air Bag System

10

10A
10B

0A

0B

1A

1B

3C1

3D

3E

3F

4

5

5B

6

6A1

6B

6C

6E3

3A

3B

3B1

3C

3D

3E

3F

4

5

5A

5B

5C

5E1

6F1

6G

6G1

6H

6K

7A

7B

7C

8

8A

8B

8C

8D

8G

9

10

10A

10B

NOTE:
The screen toned Section 8A WIRING DIAGRAM is not contained in this manual.
The Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in FOREWORD of this manual.

0A

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

CONTENTS

HOW TO USE THIS MANUAL 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Vehicle Equipped with a Supplemental Restraint System 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing and Handling 0A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Precautions 0A- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Catalytic Converter 0A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Electrical Circuit Service 0A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Circuit Inspection Procedure 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intermittents and Poor Connection 0A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION INFORMATION 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Identification Number 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine ldentification Number 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Identification Number 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNING, CAUTION AND INFORMATION LABELS 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE LIFTING POINTS 0A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL 0A-20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Abbreviations 0A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols 0A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METRIC INFORMATION 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fasteners 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fasteners Strength Identification 0A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Tightening Torque 0A-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6) Install oil pump. Refer to “Oil pump”.

7) Install flywheel (for M/T vehicle) or drive plate (for A/T ve­hicle).
Using special tool, lock flywheel or drive plate, and tighten fly­wheel or drive plate bolts to specified torque.

Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N

.

m (7.8 kg-m, 56.0 lb-ft)

1. Flywheel bolts or drive plate bolts for A/T vehicle

1, (c)

0A-2 GENERAL INFORMATION

HOW TO USE THIS MANUAL

1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.

2) Each section of this manual has its own pagination. It is indicated
at the top of each page along with the Section name.

3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are
given as shown in figure below.

4) A number of abbreviations are used in the text.
For their full explanations, refer to “ABBREVIATIONS MAY BE
USED IN THIS MANUAL” of this section.

5) The SI, metric and foot-pound systems are used as units in this
manual.

6) DIAGNOSIS are included in each section as necessary.

7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT­ENING TORQUE SPECIFICATIONS that should be used for the
servicing work described in that section.

1. Air bag wire harness

2. Passenger air bag
(inflator) module
(if equipped)

3. SDM

4. Contact coil

5. Driver air bag
(inflator) module

6. Seat belt pretensioner

GENERAL INFORMATION 0A-3

PRECAUTIONS

PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
SYSTEM

WARNING:
D The configuration of air bag system parts are as shown in

the figure. When it is necessary to service (remove, rein­stall and inspect) these parts, be sure to follow proce­dures described in SECTION 10B. Failure to follow proper
procedures could result in possible air bag system activa­tion, personal injury, damage to parts or air bag system
being unable to activate when necessary.

D If the air bag system and another vehicle system both

need repair, Suzuki recommends that the air bag system
be repaired first, to help avoid unintended air bag system
activation.

D Do not modify the steering wheel, dashboard, or any other

air bag system components. Modifications can adversely
affect air bag system performance and lead to injury.

D If the vehicle will be exposed to temperatures over 93°C

(200°F) (for example, during a paint baking process), re­move the air bag system components beforehand to avoid
component damage or unintended air bag system activa­tion.

DIAGNOSIS

D When troubleshooting air bag system, be sure to follow

“DIAGNOSIS” in SECTION 10B. Bypassing these proce­dures may result in extended diagnostic time, incorrect diag­nosis, and incorrect parts replacement.

D Never use electrical test equipment other than that specified

in this manual.

WARNING:
Never attempt to measure the resistance of the air bag (in­flator) modules (driver and passenger) and seat belt pre­tensioners (driver and passenger). It is very dangerous as
the electric current from the tester may deploy the air bag
or activate the pretensioner.

ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY.

ALWAYS PLACE AIR BAG (INFLATOR) MODULE
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.

1. Slit on workbench

2. Workbench vise

3. Lower mounting bracket

2

3

3

0A-4 GENERAL INFORMATION

SERVICING AND HANDLING

WARNING:
Many of service procedures require disconnection of “AIR
BAG” fuse and all air bag (inflator) module(s) from initiator
circuit to avoid an accidental deployment.
Driver and Passenger Air Bag (Inflator) Modules
D For handling and storage of a live air bag (inflator) module,

select a place where the ambient temperature below 65°C
(150°F), without high humidity and away from electric
noise.

D When carrying a live air bag (inflator) module, make sure

the bag opening is pointed away from you. In case of an
accidental deployment, the bag will then deploy with mini­mal chance of injury. Never carry the air bag (inflator)
module by the wires or connector on the underside of the
module. When placing a live air bag (inflator) module on
a bench or other surface, always face the bag up, away
from the surface. As the live passenger air bag (inflator)
module must be placed with its bag (trim cover) facing up,
place it on the workbench with a slit or use the workbench
vise to hold it securely at its lower mounting bracket. This
is necessary so that a free space is provided to allow the
air bag to expand in the unlikely event of accidental de­ployment. Otherwise, personal injury may result.

D Never dispose of live (undeployed) air bag (inflator) mod-

ules (driver and passenger). If disposal is necessary, be
sure to deploy them according to deployment procedures
described in SECTION 10B before disposal.

D The air bag (inflator) module immediately after deploy-

ment is very hot. Wait for at least 10 minutes to cool it off
before proceeding the work.

D After an air bag (inflator) module has been deployed, the

surface of the air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to lubri­cate the bag as it inflates) and by-products of the chemical
reaction. As with many service procedures, gloves and
safety glasses should be worn.

GENERAL INFORMATION 0A-5

WARNING:
SDM
D During service procedures, be very careful when handling

a Sensing and Diagnostic Module (SDM). Never strike or
jar the SDM.

D Never power up the air bag system when the SDM is not

rigidly attached to the vehicle. All SDM fasteners must be
carefully torqued and the arrow must be pointing toward
the front of the vehicle to ensure proper operation of the
air bag system. The SDM could be activated when pow­ered while not rigidly attached to the vehicle which could
cause deployment and result in personal injury.

WARNING:
Driver and Passenger Seat Belt Pretensioners
D For handling and storage of a live seat belt pretensioner,

select a place where the ambient temperature below 65°C
(150°F), without high humidity and away from electric
noise.

D Never carry the seat belt pretensioner by the wires or con-

nector on the underside of the pretensioner.

D When placing a live seat belt pretensioner on the work-

bench or other surface, it is also prohibited to put a seat
belt pretensioner on top of another. Otherwise, personal
injury may result.

D Never dispose of live (inactivated) seat belt pretensioners

(driver and passenger). If disposal is necessary, be sure
to activate them according to activation procedures de­scribed in SECTION 10B before disposal.

D The seat belt pretensioner immediately after activation is

very hot. Wait for at least 10 minutes to cool it off before
proceeding the work.

D With many service procedures, gloves and safety glasses

should be worn to prevent any possible irritation of the
skin or eyes.

0A-6 GENERAL INFORMATION

CAUTION:
D Even when the accident was light enough not to cause air

bags to activate, be sure to inspect system parts and other
related parts according to instructions under “Repair and
Inspection Required after an Accident” in SECTION 10B.

D When servicing parts other than air bag system, if shocks

may be applied to air bag system component parts, re­move those parts beforehand.

D When handling the air bag (inflator) modules (driver and

passenger), seat belt pretensioners (driver and passen­ger) or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., for air bag (in­flator) modules and SDM; dropped from a height of 90 cm
(3 feet) or more, for seat belt pretensioners; a height of 30
cm (1 foot) or more), never attempt disassembly or repair
but replace it with a new one.

D When grease, cleaning agent, oil, water, etc. has got onto

air bag (inflator) modules (driver and passenger) or seat
belt pretensioners (driver and passenger), wipe off im­mediately with a dry cloth.

D Air bag wire harness can be identified easily as it is cov-

ered with a yellow protection tube. Be very careful when
handling it.

D When an open in air bag wire harness, damaged wire har-

ness, connector or terminal is found, replace wire har­ness, connectors and terminals as an assembly.

D Do not apply power to the air bag system unless all com-

ponents are connected or a diagnostic chart requests it,
as this will set a diagnostic trouble code.

D Never use air bag system component parts from another

vehicle.

D When using electric welding, be sure to temporarily dis-

able air bag system referring to “Disabling Air Bag Sys-
tem” described in “Service Precautions” in SECTION 10B.

D Never expose air bag system component parts directly to

hot air (drying or baking the vehicle after painting) or
flames.

D WARNING/ CAUTION labels are attached on each part of

air bag system components. Be sure to follow the instruc­tions.

D After vehicle is completely repaired, perform “Air Bag

Diagnostic System Check” described in “Diagnosis” in
SECTION 10B.

GENERAL INFORMATION 0A-7

GENERAL PRECAUTIONS

The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.

WARNING:
D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING

POINTS” on SECTION 0A.

D When it is necessary to do service work with the engine running, make sure that the parking brake

is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic
transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts when the
engine is running.

D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced to stream

outdoors.

D Do not perform service work in areas where combustible materials can come in contact with a hot

exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant),
make sure that the area you work in is well-ventilated.

D To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail-

pipe, muffler, etc.

D New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or

used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing engine oil.
If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags
if wet with oil, recycle or properly dispose of used oil and filters.

CAUTION:
D Before starting any service work, cover fenders, seats and

any other parts that are likely to get scratched or stained dur­ing servicing. Also, be aware that what you wear (e.g. but­tons) may cause damage to the vehicle’s finish.

D When performing service to electrical parts that does not re-

quire use of battery power, disconnect the negative cable of
the battery.

“A”

0A-8 GENERAL INFORMATION

D When removing the battery, be sure to disconnect the nega-

tive cable first and then the positive cable. When reconnect­ing the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.

D When removing parts that are to be reused, be sure to keep

them arranged in an orderly manner so that they may be rein­stalled in the proper order and position.

D Whenever you use oil seals, gaskets, packing, O-rings, lock-

ing washers, split pins, self-locking nuts, and certain other
parts as specified, be sure to use new ones. Also, before
installing new gaskets, packing, etc., be sure to remove any
residual material form the mating surfaces.

D Make sure that all parts used in reassembly are perfectly

clean.

D When use of a certain type of lubricant, bond or sealant is

specified, be sure to use the specified type.

“A”: Sealant 99000-31150

D Be sure to use special tools when instructed.

Special Tool
(A): 09917-98221
(B): 09916-58210

GENERAL INFORMATION 0A-9

D When disconnecting vacuum hoses, attach a tag describing

the correct installation positions so that the hoses can be re­installed correctly.

D After servicing fuel, oil, coolant, vacuum, exhaust or brake

systems, check all lines related to the system for leaks.

D For vehicles equipped with fuel injection systems, never dis-

connect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.

PRECAUTIONS FOR CATALYTIC CONVERTER

For vehicles equipped with a catalytic converter, use only un­leaded gasoline and be careful not to let a large amount of un­burned gasoline enter the converter or it can be damaged.
– Conduct a spark jump test only when necessary, make it as

short as possible, and do not open the throttle.

– Conduct engine compression checks within the shortest

possible time.

– Avoid situations which can result in engine misfire. (e.g.

starting the engine when the fuel tank is nearly empty.)

0A-10 GENERAL INFORMATION

PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE

D When disconnecting and connecting coupler, make sure to

turn ignition switch OFF, or electronic parts may get dam­aged.

D Be careful not to touch the electrical terminals of parts which

use microcomputers (e.g. electronic control unit like as
ECM, PCM, P/S controller, etc.). The static electricity from
your body can damage these parts.

D When disconnecting couplers, don’t pull wire harness but

make sure to hold coupler itself. With lock type coupler, be
sure to unlock before disconnection. Attempt to disconnect
coupler without unlocking may result in damage to coupler.
When connecting lock type coupler, insert it till clicking
sound is heard and connect it securely.

D Never connect any tester (voltmeter, ohmmeter, or whatever)

to electronic control unit when its coupler is disconnected.
Attempt to do it may cause damage to it.

D Never connect an ohmmeter to electronic control unit with

its coupler connected to it. Attempt to do it may cause dam­age to electronic control unit and sensors.

D Be sure to use a specified voltmeter/ohmmeter. Otherwise,

accurate measurements may not be obtained or personal in­jury may result. If not specified, use a voltmeter with high im­pedance (MΩ/V minimum) or a digital type voltmeter.

D When taking measurements at electrical connectors using a

tester probe, be sure to insert the probe (2) from the wire har­ness side (backside) of the connector (1).

GENERAL INFORMATION 0A-11

D When connecting meter probe (2) from terminal side of cou-

pler (1) because it can’t be connected from harness side, use
extra care not to bend male terminal of coupler of force its fe­male terminal open for connection.
In case of such coupler as shown connect probe as shown
to avoid opening female terminal.
Never connect probe where (3) male terminal is supposed to
fit.

D When checking connection of terminals, check its male half

for bend and female half for excessive opening and both for
locking (looseness), corrosion, dust, etc.

D Before measuring voltage at each terminal, check to make

sure that battery voltage is 11V or higher. Such terminal volt­age check at low battery voltage will lead to erroneous diag­nosis.

ELECTRICAL CIRCUIT INSPECTION
PROCEDURE

While there are various electrical circuit inspection methods, de­scribed here is a general method to check its open and short circuit
by using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows. As the cause is
in the connector or terminal in many cases, they need to be checked
particularly carefully.

D Loose connection of connector
D Poor contact of terminal (due to dirt, corrosion or rust on it, poor

contact tension, entry of foreign object etc.)

D Wire harness being open

0A-12 GENERAL INFORMATION

1. Check for loose connection

Sensor

ECM

Check contact tension by
Inserting and removing just for
once

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)

When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to per­form careful check, starting with items which are easier to check.

1) Disconnect negative cable from battery.

2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.

3) Using a test male terminal, check both terminals of the circuit be­ing checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.

4) Using continuity check or voltage check procedure described in
the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.

Continuity check

1) Measure resistance between connector terminals at both ends
of the circuit being checked (between A-1 and C-1 in the figure).
If no continuity is indicated (infinity or over limit), that means that
the circuit is open between terminals A-1 and C-1.

2) Disconnect the connector included in the circuit (connector-B in
the figure) and measure resistance between terminals A-1 and
B-1.
If no continuity is indicated, that means that the circuit is open
between terminals A-1 and B-1. If continuity is indicated, there
is an open circuit between terminals B-1 and C-1 or an ab­normality in connector-B.

2V voltage drop

To other
parts

Other parts

GENERAL INFORMATION 0A-13

Voltage check

If voltage is supplied to the circuit being checked, voltage check can
be used as circuit check.

1) With all connectors connected and voltage applied to the circuit
being checked, measure voltage between each terminal and
body ground.

If measurements were taken as shown in the figure at the left and
results were as listed below, it means that the circuit is open be­tween terminals B-1 and A-1.

Voltage Between:

C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V

Also, if measured values were as listed below, it means that
there is a resistance (abnormality) of such level that corre­sponds to the voltage drop in the circuit between terminals A-1
and B-1.

Voltage Between:

C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: Approx. 3V

SHORT CIRCUIT CHECK (Wire harness to ground)

1) Disconnect negative cable from battery.

2) Disconnect connectors at both ends of the circuit to be checked.

NOTE:
If the circuit to be checked is connected to other parts, dis­connect all connectors of those parts.
Otherwise, diagnosis will be misled.

3) Measure resistance between terminal at one end of circuit (A-1
terminal in figure) and body ground. If continuity is indicated, it
means that there is a short to ground between terminals A-1 and
C-1 of the circuit.

To other
parts

0A-14 GENERAL INFORMATION

4) Disconnect the connector included in circuit (connector B) and
measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to the
ground between terminals A-1 and B-1.

INTERMITTENTS AND POOR CONNECTION

Most intermittents are caused by faulty electrical connections or
wiring, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:

D Poor mating of connector halves, or terminals not fully seated in

the connector body (backed out).

D Dirt or corrosion on the terminals. The terminals must be clean

and free of any foreign material which could impede proper termi­nal contact.
However, cleaning the terminal with a sand paper or the like is
prohibited.

D Damaged connector body, exposing the terminals to moisture

and dirt, as well as not maintaining proper terminal orientation
with the component or mating connector.

1. Check contact tension by inserting and removing
just once.

2. Check each terminal for bend and proper alignment.

GENERAL INFORMATION 0A-15

D Improperly formed or damaged terminals.

Check each connector terminal in problem circuits carefully to en­sure good contact tension by using the corresponding mating ter­minal.
If contact tension is not enough, reform it to increase contact ten­sion or replace.

D Poor terminal-to-wire connection.

Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.

D Wire insulation which is rubbed through, causing an intermittent

short as the bare area touches other wiring or parts of the vehicle.

D Wiring broken inside the insulation. This condition could cause

continuity check to show a good circuit, but if only 1 or 2 strands
of a multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.

For M/T

For A/T

0A-16 GENERAL INFORMATION

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is located on the front dash panel
in the engine room.

ENGINE IDENTIFICATION NUMBER

The number is punched on the cylinder block.

TRANSMISSION IDENTIFICATION NUMBER

The number is located on the transmission case.

Air bag caution label

Tire information placard

Seat belt pretensioner warning label on retracter

Air bag warning label on
passenger air bag (inflator) module

Air bag warning label on SDM

Air bag warning label on air bag harness
(If equipped)

Air bag warning label on contact coil and
combination switch assemblies

Air bag warning label on driver air bag
(inflator) module

GENERAL INFORMATION 0A-17

WARNING, CAUTION AND INFORMATION LABELS

The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/ CAUTION instructions printed on labels.
If any WARNING/ CAUTION label is found stained or damaged, clean or replace it as necessary.

When using frame contact hoist:

1. Front left tire

2. Rear left tire

3. Front

: Support position for frame contact hoist and safety stand.

: Floor jack position

0A-18 GENERAL INFORMATION

VEHICLE LIFTING POINTS

WARNING:
D Before applying hoist to underbody, always take vehicle balance throughout service into consider-

ation. Vehicle balance on hoist may change depending on what part to be removed.

D Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,

fuel pipe, bracket or any other part.

D When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the

vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to
move vehicle body in both ways. Work can be started only after this confirmation.

D Make absolutely sure to lock hoist after vehicle is hoisted up.

When using floor jack:

Front

Rear

2

1

1

GENERAL INFORMATION 0A-19

In raising front or rear vehicle end off the floor by jacking, be sure
to put the wooden block (5) on the jack against front jacking bracket
(1) or the center portion of rear axle (2).

CAUTION:
D Never apply jack against suspension parts (i.e., stabilizer

(3), etc.), front bumper (4) or vehicle floor, otherwise it may
get deformed.

WARNING:
D If the vehicle to be jacked up only at the front or rear end,

be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.

To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands (1) under body so that body is se­curely supported. And then check to ensure that body does not slide
on safety stands and the vehicle is held stable for safety’s sake.

0A-20 GENERAL INFORMATION

A

ABS : Anti-lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A/T : Automatic Transmission
A/C : Air Conditioning
ABDC : After Bottom Dead Center
A/F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency

Locking Retractor

B

B+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center

C

CKT : Circuit
CMP Sensor : Camshaft Position Sensor

(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch

(Clutch Switch, Clutch Start

Switch)
CPU : Central Processing Unit
CRS : Child Restraint System

D

DC : Direct Current
DLC : Data Link Connector

(Assembly Line Diag. Link,

ALDL, Serial Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code

(Diagnostic Code)

E

EBCM : Electronic Brake Control

Module, ABS Control

Module
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature

Sensor (Water Temp.

Sensor, WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor

(Recirculated Exhaust Gas

Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation

Heater (Positive Temperature

Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electrical Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission

Canister (Charcoal Canister)

F

4WD : 4 Wheel Drive

G

GEN : Generator
GND : Ground

H

HC : Hydrocarbons
HO2S : Heated Oxygen Sensor

I

IAC Valve : Idle Air Control Valve (Idle

Speed Control Solenoid

Valve, ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature

Sensor (Air temperature

Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator

(Motor)
ISO : International Standards

Organization

J

JIS : Japanese Industrial Standard

ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL

ABBREVIATIONS

L

LH : Left Hand
LSPV : Load Sensing Proportioning

Valve

M

MAF Sensor : Mass Air Flow Sensor

(Air Flow Sensor, AFS, Air
Flow Meter, AFM)

MAP Sensor : Manifold Absolute Pressure

Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection

(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
M/T : Manual Transmission

N

NOx : Nitrogen Oxides

O

OBD : On-Board Diagnostic System

(Self-Diagnosis Function)
O/D : Overdrive
OHC : Over Head Camshaft

P

PNP : Park/Neutral Position
P/S : Power Steering
PSP Switch : Power Steering Pressure

Switch (P/S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation

R

RH : Right Hand

S

SAE : Society of Automotive

Engineers
SDM : Sensing and Diagnostic

Module
SFI : Sequential Multiport Fuel

Injection
SOHC : Single Over Head Camshaft

T

TBI : Throttle Body Fuel Injection

(Single-Point Fuel Injection,

SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module

(A/T Controller, A/T Control

Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve

(Thermal Vacuum Switching

Valve, TVSV, Bimetal Vacuum

Switching Valve, BVSV)
TWC : Three Way Catalytic

Converter (Three Way

Catalyst)
2WD : 2 Wheel Drive

V

VIN : Vehicle Identification

Number
VSS : Vehicle Speed Sensor

W

WU-OC : Warm Up Oxidation Catalytic

Converter
WU-TWC : Warm Up Three Way

Catalytic Converter

GENERAL INFORMATION 0A-21

0A-22 GENERAL INFORMATION

SYMBOLS

SYMBOL DEFINITION SYMBOL DEFINITION

Tightening torque Apply SUZUKI BOND

NO. 1216 99000-31160

Apply oil (Engine, transmission,
transfer, differential)

Apply SILICONE SEALANT
99000-31120

Apply fluid (Brake, power steering
or automatic transmission fluid)

Apply SEALING COMPOUND
366E 99000-31090

Apply SUZUKI SUPER
GREASE A 99000-25010

Apply SUZUKI SUPER
GREASE C 99000-25030

Apply THREAD LOCK
1322 99000-32110

Apply SUZUKI SUPER
GREASE E 99000-25050

Apply THREAD LOCK
1333B 99000-32020

Apply SUZUKI SUPER
GREASE H 99000-25120

Apply THREAD LOCK
1342 99000-32050

Apply SUZUKI SUPER
GREASE I 99000-25210

Apply SUZUKI BOND NO.
1215 99000-31110

Do not reuse

Apply SUZUKI BOND NO.
1207C 99000-31150

Note on reassembly

METRIC BOLTS-IDENTIFICATION CLASS NUMBERS
OR MARKS CORRESPOND TO BOLT
STRENGTH-INCREASING NUMBERS REPRESENT
INCREASING STRENGTH.

NUT STRENGTH
IDENTIFICATION

GENERAL INFORMATION 0A-23

METRIC INFORMATION

METRIC FASTENERS

Most of the fasteners used for this vehicle are JIS-defined and ISO­defined metric fasteners. When replacing any fasteners, it is most
important that replacement fasteners be the correct diameter,
thread pitch and strength.

CAUTION:
Even when the nominal diameter (1) of thread is the same,
the thread pitch (2) or the width across flats (3) may vary be­tween ISO and JIS. Refer to JIS-TO-ISO Main Fasteners
Comparison Table below for the difference.
Installing a mismatched bolt or nut will cause damage to the
thread.
Before installing, check the thread pitch for correct match­ing and then tighten it by hand temporarily. If it is tight, re­check the thread pitch.

JIS-TO-ISO Main Fasteners Comparison Table

Nominal diameter

Standard

M6M8M10

M12

M14

Thread pitch 1.0 1.25 1.25 1.25 1.5

JIS

Width
across flats

10 12 14 17 19

Thread pitch 1.0 1.25 1.5 1.5 1.5

ISO

Width
across flats

10 13 16 18 21

FASTENER STRENGTH IDENTIFICATION

Most commonly used metric fastener strength property classes are
4T, 6.8, 7T, 8.8 and radial line with the class identification embossed
on the head of each bolt. Some metric nuts will be marked with
punch, 6 or 8 mark strength identification on the nut face. Figure
shows the different strength markings.
When replacing metric fasteners, be careful to use bolts and nuts
of the same strength or greater than the original fasteners (the
same number marking or higher). It is likewise important to select
replacement fasteners of the correct diameter and thread pitch.
Correct replacement bolts and nuts are available through the parts
division.

0A-24 GENERAL INFORMATION

Self-lock
nut

STANDARD TIGHTENING TORQUE

Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi­cation is provided, refer to the following 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:
D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque

given in the chart below.

D The chart below is applicable only where the fastened parts are made of steel or light alloy.

Tightening torque chart

Thread Diameter (Nominal Diameter)

(mm)

4 5 6 8 10 12 14 16 18

Strength

A equivalent of 4T strength
fastener

N.m 1.5 3.0 5.5 13 29 45 65 105 160

kg-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16

lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0

A equivalent of 6.8 strength
fastener without flange

N.m 2.4 4.7 8.4 20 42 80 125 193 280

g

kg-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28

lb-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5

A equivalent of 6.8 strength
fastener with flange

N.m 2.4 4.9 8.8 21 44 84 133 203 298

g

kg-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8

lb-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5

A equivalent of 7T strength
fastener

N.m 2.3 4.5 10 23 50 85 135 210 240

kg-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24

lb-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

A equivalent of 8.8 strength
fastener without flange

N.m 3.1 6.3 11 27 56 105 168 258 373

g

kg-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3

lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0

A equivalent of 8.8 strength
fastener with flange

N.m 3.2 6.5 12 29 59 113 175 270 395

g

kg-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5

lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

0B

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
D Service on and around the air bag system components or wiring must be performed only by an autho-

rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener­al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau­tions” under “On-Vehicle Service” in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

D 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 disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CONTENTS

MAINTENANCE SCHEDULE 0B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SERVICE 0B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 0B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emission Control System 0B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake 0B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis and Body 0B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Inspection 0B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOMMENDED FLUIDS AND LUBRICANTS 0B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0B-2 MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE

NORMAL CONDITION SCHEDULE

Interval:

This table includes services as scheduled up to 90,000 km
(54,000 miles) mileage. Beyond 90,000 km (54,000 miles),
carry out the same services at the same intervals respectively.

This int

erval should be judged by odometer

km (x 1,000) 15 30 45 60 75 90

reading or months, whichever comes first

.

Miles (x 1,000) 9 18 27 36 45 54

Months 12 24 36 48 60 72

1. ENGINE

1-1. Drive belt (tension, damage) V-rib belt — — I — — R

1-2. Camshaft timing belt Replace every 100,000 km (60,000 miles)

1-3. Valve lash (clearance) — I — I — I

1-4. Engine oil and

When SG, SH or SJ grade oil is used. R R R R R R

Engine oil filter

When SE or SF grade oil is used.

Replace every 10,000 km (6,000 miles)

or 8 months

1-5. Engine coolant — R — R — R

1-6. Exhaust system (leakage, damage, tightness) — I — I — I

2. IGNITION SYSTEM

2-1. Spark plugs When unleaded fuel is used — — R — — R

3. FUEL SYSTEM

3-1. Air cleaner filter

Paved-road I I R I I R

Dusty condition Refer to “Severe Driving Condition” schedule

3-2. Fuel lines (deterioration, leakage, damage) — I — I — I

3-3. Fuel tank — — I — — I

4. EMISSION CONTROL SYSTEM

4-1. PCV (Positive Crankcase Ventilation) valve — — — — — I

4-2. Fuel evaporative emission control system — — — — — I

5. BRAKE

5-1.

Brake discs and pads (thickness, wear, damage) I I I I I I

Brake drums and shoes (wear, damage) — I — I — I

5-2. Brake hoses and pipes (leakage, damage, clamp) — I — I — I

5-3. Brake fluid — R — R — R

5-4. Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles) only

MAINTENANCE AND LUBRICATION 0B-3

Interval:

This table includes services as scheduled up to 90,000 km
(54,000 miles) mileage. Beyond 90,000 km (54,000 miles),
carry out the same services at the same intervals respectively.

This i

nterval should be judged by odometer

km (x 1,000) 15 30 45 60 75 90

reading or months, whichever comes first

.

Miles (x 1,000) 9 18 27 36 45 54

Months 12 24 36 48 60 72

6. CHASSIS AND BODY

6-1. Clutch pedal (For manual transmission) — I — I — I

6-2. Tires/wheel discs (wear, damage, rotation) I I I I I I

6-3. Drive shaft boots (breakage, damage) — — I — — I

6-4. Suspension system (tightness, damage, rattle, breakage) — I — I — I

6-5. Steering system (tightness, damage, breakage, rattle) — I — I — I

6-6.

Manual transmission oil (leakage, level) (“I”: 1st 15,000 km
only)

I — R — — R

6-7. Automatic transmission

Fluid level

— I — I — I

Fluid change

Replace every 160,000 km (100,000 miles)

6-8. All latches, hinges and locks — I — I — I

6-9. Ventilator air filter (if equipped) — I R — I R

NOTES:

D “R”: Replace or change
D “I”: Inspect and correct or replace if necessary
D For Sweden, item 2-1, 4-1 and 4-2 should be performed by odometer reading only.

0B-4 MAINTENANCE AND LUBRICATION

MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS

If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the chart
below.

Severe condition code

A – Repeated short trips
B – Driving on rough and/or muddy roads
C – Driving on dusty roads
D – Driving in extremely cold weather and/or salted roads
E – Repeated short trips in extremely cold weather
H – Trailer towing (if admitted)

Severe

Condition Code

Maintenance

Maintenance

Operation

Maintenance Interval

I

Every 15,000 km
(9,000 miles) or 12 months

– B C D – – – –

Drive belt (V-rib belt)

R

Every 45,000 km
(27,000 miles) or 36 months

A – C D E – – H Engine oil and oil filter R

Every 5,000 km
(3,000 miles) or 4 months

A B C – E – – H Spark plugs R

Every 10,000 km
(6,000 miles) or 8 months

*

I

Every 2,500 km
(1,500 miles)

– – C – – – – –

Air cleaner filter *1

R

Every 30,000 km
(18,000 miles) or 24 months

– B – – E – – H Manual transmission oil R

Every 30,000 km
(18,000 miles) or 24 months

– B – – E – – H Automatic transmission fluid R

Every 30,000 km
(18,000 miles) or 24 months

– B C D – – – H Wheel bearings I

Every 15,000 km
(9,000 miles) or 12 months

*

pp

I

Every 15,000 km
(9,000 miles) or 12 months

– – C D – – – –

Ventilator air filter *2 (if equipped)

R

Every 45,000 km
(27,000 miles) or 36 months

NOTES:

D “R”: Replace or change
D “I”: Inspect and correct or replace if necessary
D *1: Inspect or replace more frequently if necessary.
D *2: Clean or replace more frequently if the air from the ventilator decreases.

1. Generator pulley

2. Water pump pulley 3. Crankshaft pulley

1. A /C compressor pulley

2. Blank

3. Tension pulley

4. Crankshaft pulley

MAINTENANCE AND LUBRICATION 0B-5

MAINTENANCE SERVICE

ENGINE

ITEM 1-1
Drive Belt Inspection and Replacement

WARNING:
Disconnect negative cable at battery before checking and
adjusting belt tension.

Water pump belt inspection

1) Remove engine under cover of right side from vehicle body.

2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
Replace, if necessary.

3) Check pump belt for tension and adjust it as necessary.

Water pump belt tension “a”:
8 – 10 mm (0.32 – 0.39 in.) deflection under 100 N, 10 kg or
22 lb pressure

NOTE:
When replacing belt with a new one, adjust belt tension to
6 – 7 mm (0.24 – 0.27 in.).

A/C compressor drive belt inspection (If equipped)

1) Hoist vehicle and remove engine under cover of right side from
vehicle body.

2) Inspect belt for wear, deterioration and tension.
Replace or adjust, if necessary.

A/C compressor drive belt tension “a”:
7 – 9 mm (0.28 – 0.35 in.) deflection under 100 N, 10 kg or
22 lb pressure

A/C compressor drive belt replacement

1) Disconnect negative cable from battery.

2) Remove engine under cover of right side.

3) Loosen belt tension and replace belt with new one.

4) Adjust belt tension to specification.

5) Install engine under cover and connect negative cable to battery.

Water pump belt replacement

Replace belt with new one. Refer to SECTION 6B for replacement
procedure of pump belt.

1. Thickness gauge

IN

EX

Proper Engine Oil Viscosity Chart

PREFERRED

1, (a)

0B-6 MAINTENANCE AND LUBRICATION

ITEM 1-2
Camshaft Timing Belt Replacement

Replace belt with new one. Refer to SECTION 6A1 for replacement
procedure.

CAUTION:

D Do not bend or twist timing belt.
D Do not allow timing belt to come into contact with oil, wa-

ter, etc.

ITEM 1-3
Valve Lash Inspection

1) Remove cylinder head cover.

2) Inspect intake and exhaust valve lash and adjust as necessary.
Refer to SECTION 6A1 for valve lash inspection and adjustment
procedure.

When cold

(

Coolant temperature

When hot

(

Coolant temperature

Valve

(

is 15 – 25_C or

59 – 77_F)

(

is 60 – 68_C or

140 – 154_F)

lash

specification

Intake

0.13 – 0.17 mm

(0.005 – 0.007 in)

0.17 – 0.21 mm

(0.007 – 0.008 in)

Exhaust

0.23 – 0.27 mm

(0.009 – 0.011 in)

0.27 – 0.31 mm

(0.011 – 0.012 in)

Special Tool
(A): 09917-18210

Tightening Torque
(a): 12 N

.

m (1.2 kg-m, 8.5 lb-ft)

3) Install cylinder head cover and tighten bolts to specification.

ITEM 1-4
Engine Oil and Filter Change

WARNING:
New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in SEC-
TION 0A and observe what in written there.

Use engine oil of SE, SF, SG, SH or SJ grade.
Select the appropriate oil viscosity according to the left chart.
For ambient temperature between –20_C (–4_F) and 30_C (86_F),
it is highly recommended to use SAE 10 W – 30 oil.

Before draining engine oil, check engine for oil leakage. If any evi­dence of leakage is found, make sure to correct defective part be­fore proceeding to following work.

1) Drain engine oil by removing drain plug (1).

2) After draining oil, wipe drain plug clean. Reinstall drain plug, and
tighten it securely as specified below.

Tightening Torque
(a): 50 N

.

m (5.0 kg-m, 36.5 lb-ft)

1. Full level mark (hole)

2. Low level mark (hole)

NOTE:
Engine oil capacity is specified as left table.
However, note that amount of oil required when actually
changing oil may somewhat differ from data in left table de­pending on various conditions (temperature, viscosity,
etc.).

9) Check oil filter and drain plug for oil leakage.

3 /4 turn

MAINTENANCE AND LUBRICATION 0B-7

3) Loosen oil filter (1) by using oil filter wrench (Special tool).

Special Tool
(A): 09915-47330

4) Apply engine oil to new oil filter “O” ring.

5) Screw new filter on oil filter stand by hand until filter “O” ring con­tacts mounting surface.

CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which filter “O” ring first contacts
mounting surface.

6) Tighten filter 3/4 turn from the point of contact with mounting sur­face using an oil filter wrench.

Special Tool
(A): 09915-47330

Tightening Torque
(a): 14 N

.

m (1.4 kg-m, 10.5 lb-ft)

7) Replenish oil until oil level is brought to FULL level mark (1) on
dipstick (Oil pan and oil filter capacity). Filler inlet is at the top of
cylinder head cover.

8) Start engine and run it for three minutes. Stop it and wait another
5 minutes before checking oil level. Add oil, as necessary, to
bring oil level to FULL level mark on dipstick.

Engine oil capacity

Oil pan capacity

about 3.1 liters

(6.5/5.5 US /Imp pt.)

Oil filter capacity

about 0.2 liters

(0.4/0.3 US /Imp pt.)

Others

about 0.3 liters

(0.6/0.5 US /Imp pt.)

Total

about 3.6 liters

(7.5/6.3 US /Imp pt.)

0B-8 MAINTENANCE AND LUBRICATION

ITEM 1-5
Engine Coolant Change

WARNING:
To help avoid danger of being burned, do not remove radia­tor cap while engine and radiator are still hot. Scalding fluid
and steam can be blown out under pressure if cap is taken
off too soon.

CAUTION:
When changing engine coolant, use mixture of 50% water
and 50% ethylene-glycol base coolant (Anti-Freeze/Anti­corrosion coolant) for the market where ambient tempera­ture falls lower than –16_C (3_F) in winter and mixture of
70% water and 30% ethylene-glycol base coolant for the
market where ambient temperature doesn’t fall lower than
–16_C (3_F).
Even in a market where no freezing temperature is antici­pated, mixture of 70% water and 30% ethylene glycol base
coolant should be used for the purpose of corrosion protec­tion and lubrication.

Refer to SECTION 6B of this manual for COOLANT CAPACITY.

1) Remove radiator cap when engine is cool.

2) Loosen radiator drain plug (1) to drain coolant.

3) Remove reservoir and drain.

4) Tighten drain plug securely. Also install reservoir.

5) Slowly pour specified amount of coolant to the base of radiator
filler neck, and run engine, with radiator cap removed, until ra­diator upper hose is hot. This drives out any air which may still
be trapped within cooling system. Add coolant as necessary un­til coolant level reaches filler throat of radiator. Reinstall radiator
cap.

6) Add coolant to reservoir so that its level aligns with FULL level
line (1). Then, reinstall cap (2) to reservoir aligning match marks
(3) on the reservoir and cap.

MAINTENANCE AND LUBRICATION 0B-9

ITEM 1-6
Exhaust System Inspection

WARNING:
To avoid danger of being burned, do not touch exhaust sys­tem when it is still hot.
Any service on exhaust system should be performed when
it is cool.

When carrying out periodic maintenance or vehicle is raised for oth­er service, check exhaust system as follows:

D Check rubber mountings for damage and deterioration.
D Check exhaust system for leakage, loose connections, dents,

and damages.
If bolts or nuts are loose, tighten them to specification.
Refer to SECTION 6K for torque specification of bolts and nuts.

D Check nearby body areas for damaged, missing or mispositioned

parts, open seams, holes, loose connections or other defects
which could permit exhaust fumes to seep into vehicle.

D Make sure that exhaust system components have enough clear-

ance from underbody to avoid overheating and possible damage
to floor carpet.

D Any defects should be fixed at once.

0B-10 MAINTENANCE AND LUBRICATION

IGNITION SYSTEM

ITEM 2-1
Spark Plugs Replacement

Replace spark plugs with new ones referring to Section 6F1.

FUEL SYSTEM

ITEM 3-1
Air Cleaner Filter Inspection

1) Unclamp air cleaner case clamps.

2) Take cleaner filter out of air cleaner case.

3) Visually check that air cleaner filter is not excessively dirty, dam­aged or oily.

4) Clean filter with compressed air from air outlet side of filter.

5) Install air cleaner filter into case referring to Section 6A1.

6) Clamp case securely.

Air Cleaner Filter Replacement

Replace air cleaner filter with new one according to procedure de­scribed in Section 6A1.

ITEM 3-2
Fuel Lines Inspection

Check fuel lines for loose connection, deterioration or damage
which could cause leakage. Make sure all clamps are secure.
Replace any damaged or deteriorated parts.
There should be no sign of fuel leakage or moisture at any fuel con­nection.

ITEM 3-3
Fuel Tank Inspection

Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.

MAINTENANCE AND LUBRICATION 0B-11

EMISSION CONTROL SYSTEM

ITEM 4-1
PCV (Positive Crankcase Ventilation) Valve Inspection

Check crankcase ventilation hoses and PCV hoses for leaks,
cracks or clog, and PCV valve (1) for stick or clog. Refer to Section
6E for PCV valve checking procedure.

ITEM 4-2
Fuel Evaporative Emission Control System Inspection

WARNING:
DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside
EVAP canister is harmful.

Check EVAP (Evaporative Emission) canister for damage, clog and
operation referring to SECTION 6E1.
If a problem is found, replace.

BRAKE

ITEM 5-1
Brake Discs, Pads, Drums and Shoes Inspection
Brake discs and pads

1) Remove wheel and caliper but don’t disconnect brake hose from
caliper.

2) Check front disc brake pads and discs for excessive wear, dam­age and deflection. Replace parts as necessary. For the details,
refer to SECTION 5B.

3) Install caliper and wheel.

Brake drums and shoes

1) Remove wheel and brake drum.

2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed.
At the same time, check wheel cylinders for leakage.
Replace as necessary.
For the details, refer to SECTION 5C.

3) Install brake drum and wheel.

0B-12 MAINTENANCE AND LUBRICATION

“a”

“a”: Parking brake lever stroke:

4 – 9 notches
(with 20 kg or 44 lbs of
pull pressure)

ITEM 5-2
Brake Hoses and Pipes Inspection

Perform this inspection where there is enough light and use a mirror
as necessary.
D Check brake hoses and pipes for proper hook-up, leaks, cracks,

chafing, wear, corrosion, bends, twists and other damage.
Replace any of these parts as necessary.

D Check all clamps for tightness and connections for leakage.
D Check that hoses and pipes are clear of sharp edges and inse-

cure parts.

CAUTION:
After replacing any brake pipe or hose, be sure to carry out
air purge operation.

ITEM 5-3
Brake Fluid Change

CAUTION:
Do not use old or used brake fluid, or any fluid from any un­sealed container.

Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
above recommended fluid and carry out air purge operation.
For air purging procedure, refer to SECTION 5.

ITEM 5-4
Brake Lever and Cable Inspection
Parking brake lever

D Check tooth tip of each notch for damage or wear. If any damage

or wear is found, replace parking lever.

D Check parking brake lever for proper operation and stroke, and

adjust it if necessary.
For checking and adjusting procedures, refer to PARKING
BRAKE INSPECTION AND ADJUSTMENT in SECTION 5C.

Parking brake cable

Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.

MAINTENANCE AND LUBRICATION 0B-13

1. Wear
indicator

CHASSIS AND BODY

ITEM 6-1
Clutch Pedal Free Travel Inspection (Cable type only)

Check clutch pedal free travel “a”. Refer to SECTION 7C for proce­dure to check and adjust it.

ITEM 6-2
Tire/Wheel Disc Inspection

[Tire inspection]

1) Check tire for uneven or excessive wear, or damage. If defec­tive, replace.

2) Check inflating pressure of each tire and adjust pressure to
specification as necessary.

NOTE:
D Tire inflation pressure should be checked when tires are

cool.

D Specified tire inflation pressure should be found on tire

placard or in owner’s manual which came with vehicle.

[Wheel disc inspection]
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.

[Tire rotation]
Rotate tires.
For details of the steps, refer to SECTION 3F.

0B-14 MAINTENANCE AND LUBRICATION

Wheel Bearing Inspection

1) Check front wheel bearing for wear, damage, abnormal noise or
rattles. For details, refer to FRONT SUSPENSION INSPEC­TION of SECTION 3D.

2) Check rear wheel bearing for wear, damage abnormal noise or
rattle. For details, refer to REAR SUSPENSION INSPECTION
of SECTION 3E.

ITEM 6-3
Drive Shaft (Axle) Boot Inspection

Check drive shaft boots (wheel side and differential side) for leak­age, detachment, tear or any other damage.
Replace boot as necessary.

ITEM 6-4
Suspension System Inspection

D Inspect front struts & rear shock absorbers for evidence of oil

leakage, dents or any other damage on sleeves; and inspect an­chor ends for deterioration.
Replace defective parts, if any.

D Check front and rear suspension systems for damaged, loose or

missing parts; also for parts showing signs of wear or lack of lu­brication.
Repair or replace defective parts, if any.

D Check front suspension arm ball joint stud dust seals for leakage,

detachment, tear or any other damage.
Replace defective boot, if any.

ITEM 6-5
Steering System Inspection

1) Check steering wheel for play and rattle, holding vehicle straight
on ground.

Steering wheel play “a”: 0 – 30 mm (0 – 1.1 in.)

2) Check bolts and nuts for tightness and retighten them as neces­sary. Repair or replace defective parts, if any.

MAINTENANCE AND LUBRICATION 0B-15

1. Tie-rod end boot

2. Steering gear case boot

3. Universal joint

3) Check steering linkage for looseness and damage. Repair or re­place defective parts, if any.

4) Check boots of steering linkage and steering gear case for dam­age (leaks, detachment, tear, etc.). If damage is found, replace
defective boot with new one.
If any dent is found on steering gear case boots, correct it to orig­inal shape by turning steering wheel to the right or left as far as
it stops and holding it for a few seconds.

5) Check universal joints of steering shaft for rattle and damage. If
rattle or damage is found, replace defective part with a new one.

6) Check that steering wheel can be turned fully to the right and left.
Repair or replace defective parts, if any.

7) If equipped with power steering system, check also, in addition
to above check items, that steering wheel can be turned fully to
the right and left more lightly when engine is running at idle
speed than when it is stopped. Repair, if found faulty.

8) Check wheel alignment referring to Section 3A.

ITEM 6-6
Manual Transmission Oil Inspection and Change

[Inspection]

1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level check.

3) Remove oil filler /level plug (1) of transmission.

4) Check oil level.
Oil level can be checked roughly by means of filler/level plug
hole. That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified oil up to level hole.
For specified oil, refer to description of oil change under On-Ve­hicle Service in Section 7A.

5) Apply sealant to filler /level plug and tighten it to specified torque.

[Change]

1) Place the vehicle level and drain oil by removing drain plug (2).

2) Apply sealant to drain plug after cleaning it and tighten drain plug
to specified torque.

3) Pour specified oil up to level hole.

4) Tighten filler plug to specified torque.
For recommended oil, its amount and tightening torque data, re­fer to On-Vehicle Service of Section 7A.

1. Dipstick

2. Clamp

3. FULL HOT mark

4. LOW HOT mark

1. Drain plug

2

1

1

0B-16 MAINTENANCE AND LUBRICATION

ITEM 6-7
Automatic Transmission Fluid Inspection and Change

[Fluid level inspection]

1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.

2) Make sure that vehicle is placed level for fluid level check.

3) Unclamp dipstick and pull out it. Check fluid level.
For fluid level checking procedure, refer to SECTION 7B and be
sure to perform it under specified conditions. If fluid level is low,
replenish specified fluid.

[Fluid change]

1) Perform steps 1) and 2) of above Fluid Level Inspection.

2) Change fluid with new specified fluid referring to SECTION 7B.

ITEM 6-8
All Latches, Hinges and Locks Inspection
Doors

Check that each door of front, rear and back doors opens and
closes smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair door
lock system.

Engine hood

Check that secondary latch operates properly (check that second­ary latch keeps hood from opening all the way even when pulling
hood release handle inside vehicle.) Also check that hood opens
and closes smoothly and properly and hood locks securely when
closed.
If any malfunction is found, lubricate hinge and latch, or repair hood
lock system.

MAINTENANCE AND LUBRICATION 0B-17

ITEM 6-9
Ventilator Air Filter (if equipped)

Inspection

1) Remove air filter from air inlet box or cooling unit referring to Sec­tion 1B.

2) Check filter for dirt. Replace excessively dirty filter.

3) Blow off dust by compressed air from air outlet side of filter.

4) Install filter to air inlet box or cooling unit referring to Section 1B.

Replacement

Replace ventilator air filter with new one referring to Section 1B.

WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats

Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.

Seat Belt

Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked.

Battery Electrolyte Level Check

Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat­tery condition by the indicator.

Accelerator Pedal Operation

Check that pedal operates smoothly without getting
caught or interfered by other part.

Engine Start

Check engine start for readiness.

On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo­tor should crank only in “P” (Park) or “N” (Neutral).
On manual transmission vehicles, place the shift le­ver in “Neutral”, depress clutch pedal fully and try to
start.

Exhaust System Check

Check for leakage, cracks or loose supports.

Clutch (For Manual transmission)

Check for the following.
D Clutch is completely released when depressing

clutch pedal,

D No slipping clutch occurs when releasing the clutch

pedal and accelerating,

D Clutch itself is free from any abnormal condition.

Gearshift or Select Lever (Transmission)

Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis­sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.

Brake

[Foot brake]
Check the following;

D that brake pedal has proper travel,
D that brake works properly,
D that it is free from noise,
D that vehicle does not pull to one side when brake is

applied,
D and that brake do not drag.
[Parking brake and automatic transmission “P” (Park)
mechanism]
Check that parking brake lever has proper travel.

FINAL INSPECTION

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
Make sure that vehicle is at complete stop when se­lect lever is shifted to “P” range position and all brakes
are released.

WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly even
if vehicle should start to move.

0B-18 MAINTENANCE AND LUBRICATION

WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the car could move without warning
and possibly cause personal injury or proper­ty damage.

MAINTENANCE AND LUBRICATION 0B-19

Body, Wheels and Power Transmitting
System

Check that body, wheels and power transmitting sys­tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.

Meters and Gauge

Check that speedometer, odometer, fuel meter, tem­perature gauge, etc. are operating accurately.

Lights

Check that all lights operate properly.

Windshield Defroster

Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to “HI” position for this check.

Steering

D Check to ensure that steering wheel is free from in-

stability, or abnormally heavy feeling.

D Check that the vehicle does not wander or pull to

one side.

Engine

D Check that engine responds readily at all speeds.
D Check that engine is free from abnormal noise and

abnormal vibration.

RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil

SE, SF, SG, SH or SJ (Refer to engine oil viscosity chart in
item 1-4.)

Engine coolant (Ethylene glycol base coolant) “Anti-freeze /Anti-corrosion coolant”

Brake fluid DOT4 or SAE J1704

Manual transmission oil API GL-4, SAE75W-90 (Refer to Section 7A for detail)

Automatic transmission fluid An equivalent of DEXRON

R

-III

Door hinges

Hood latch assembly

Engine oil or water resistance chassis grease

Key lock cylinder Spray lubricant

1A

HEATER AND VENTILATION 1A-1

SECTION 1A

HEATER AND VENTILATION

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
D Service on and around the air bag system components or wiring must be performed only by an autho-

rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener­al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau­tions” under “On-Vehicle Service” in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

D 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 disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
The link mechanism of the heater varies depending on the specifications.

CONTENTS

GENERAL DESCRIPTION 1A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 1A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis Table 1A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Circuit 1A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON VEHICLE SERVICE 1A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Unit 1A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Motor 1A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Motor Resistor 1A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Control Lever Assembly 1A- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Fan & Defogger Switch 1A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Inlet Box 1A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation Louver 1A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Heater Unit

2. Air inlet box

3. Ventilator duct

4. Defroster nozzle

5. Ventilator outlet

6. Side ventilation air

7. Foot air

8. Front defroster air

9. Side defroster air

10. Fresh air

11. Recirculation air

12. Center ventilation air

13. Air inlet select door

14. Blower motor

15. Heater core (heater radiator)

16. Temperature control door

17. Foot air control door

18. Defroster air control door

19. Ventilation air control door

20. Side ventilation control door

1A-2 HEATER AND VENTILATION

GENERAL DESCRIPTION

The heater and ventilation consist of the following parts.

HEATER AND VENTILATION 1A-3

1. Blower motor

2. Blower motor resistor

3. Blower switch

4. Ignition switch

5. Lighting relay

6. A / C relay (if equipped with A/ C)

Main 80A

Main
60A

Main
60A

to
lighting
switch

LICENCE
10A

To IG fuse

To A / C
switch

HEATER
25A

DIAGNOSIS

DIAGNOSIS TABLE

Trouble Possible Cause Remedy

Heater blower won’t work
even when its switch is
ON.

D Blower fuse blown

D Blower resistor faulty
D Blower switch faulty
D Blower motor faulty
D Wiring or grounding faulty

Check for short to ground and replace
fuse.
Check resistor.
Check blower switch.
Replace motor.
Repair as necessary.

Incorrect temperature
output.

D Control cables broken or binding
D Temperature control lever faulty
D Control cable clamp position is faulty
D Air damper broken
D Air ducts clogged
D Heater radiator leaking or clogged
D Heater hoses leaking or clogged
D Thermostat faulty

Check cables.
Check control lever.
Check and adjustment.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
Check thermostat.

When mode control lever
is changed, air outlet port
is not changed or lever
position disagree with air
outlet port.

D Control cables broken or binding
D Air damper broken
D Air ducts clogged
D Air damper broken
D Air ducts leaking or clogged

Check cable.
Check control lever.
Check and adjustment.
Repair damper.
Repair air ducts.

WIRING CIRCUIT

1A-4 HEATER AND VENTILATION

1. Heater core

2. Blower motor assembly

3. Blower resistor

4. Temperature door assembly

5. Mode door assembly

6. Mode lever

7. Temperature lever

8. Heater case

ON VEHICLE SERVICE

HEATER UNIT

REMOVAL

1) Disconnect negative (–) cable at battery.

2) If equipped with air bag system, disable air bag system.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.

3) Drain engine coolant and disconnect heater hoses (1) from
heater unit.

4) Remove instrument panel.
Refer to INSTRUMENT PANEL in Section 9.
Loosen air inlet box (cooling unit) mounting nut (2), and remove
mounting nut (3).

5) Remove bolts (4), nuts (5) and screws (6).

6) Remove heater unit (7).

HEATER AND VENTILATION 1A-5

LH handle vehicle



INSTALLATION

Install heater unit by reversing removal procedure, noting the fol­lowing items.
D When installing each part, be careful not to catch any cable or wir-

ing harness.

D Adjust heater control cable (refer to heater control lever assembly

in this section).

D Fill engine coolant to radiator.
D If equipped with air bag system, enable air bag system. Refer to

“ENABLING AIR BAG SYSTEM” in Section 10B.

BLOWER MOTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system, if equipped.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.

3) Remove column hole cover.

4) Remove clutch pedal assembly (RH steering vehicle) or brake
pedal assembly (1) and accelerator pedal (2) (LH steering ve­hicle). Refer to “BRAKE PEDAL” in Section 5A and “CLUTCH
PEDAL” in Section 7C.

5) Disconnect blower motor couplers.

6) Remove blower motor (1).

INSPECTION

1) Check continuity between two terminals as shown in figure.
If there is no continuity, replace blower motor.

2) Connect battery (1) to blower motor connector (2) as shown,
then check that the blower motor operates smoothly.
If blower motor operates do not smoothly, replace blower motor.

Reference current data: Approx. 13 – 20 A at 12 V

1A-6 HEATER AND VENTILATION

INSTALLATION

1) Reverse removal procedure for installation.

2) Enable air bag system, if equipped.
Refer to ENABLING AIR BAG SYSTEM in Section 10B.

BLOWER MOTOR RESISTOR

INSPECTION

Measure each terminal-to-terminal resistance on resistor.

Resistance H – Mh : Approx. 0.6 Ω

Mh – Ml: Approx. 1.0 Ω
Ml – L : Approx. 1.8 Ω

If measured resistance is incorrect, replace heater blower motor re­sistor.

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system, if equipped.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.

3) Remove clutch pedal bracket (RH steering vehicle), if neces­sary.
Refer to “CLUTCH PEDAL” in Section 7C.

4) Disconnect resistor coupler.

5) Remove blower motor resistor (1).

INSTALLATION

1) Reverse removal procedure for installation.

2) Enable air bag system, if equipped.
Refer to ENABLING AIR BAG SYSTEM in Section 10B.

1. Heater control body assembly

2. Temperature control knob assembly
(& A /C switch, if equipped)

3. Blower fan & defogger switch assembly

4. Bulb

5. Fresh air control cable

6. Mode control cable

7. Temperature control cable

8. Fresh air control knob assembly

9. Mode control knob assembly

HEATER AND VENTILATION 1A-7

HEATER CONTROL LEVER ASSEMBLY

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system, if equipped.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.

3) Remove ashtray, center upper garnish (1), center lower garnish
(2), heater control knob (3), instrument lid (4) and radio or acces­sory case (if equipped).

4) Disconnect each heater control cables (mode control, tempera­ture control and fresh air control) from heater unit and air inlet
box.

5) Disconnect blower fan switch coupler and A /C switch coupler (if
equipped).

6) Remove heater control lever assembly (5).

7) Remove blower fan switch.

1A-8 HEATER AND VENTILATION

LH VEHICLE

RH VEHICLE

INSTALLATION

1) Reverse removal procedure for installation.

2) Adjust cables as follows.
i) Move mode control knob (a), temperature control knob (b)

and fresh air control knob (c) fully in arrow direction as shown
in figure.

ii) Push mode lever (d), temperature lever (e) and door link (f)

fully in arrow direction and fix cable with clamp in position as
shown in figure.

NOTE:
After installing control cables, be sure that control levers
move smoothly and stop at proper position.

3) If equipped with air bag, enable air bag system. Refer to “ENAB-
LING AIR BAG SYSTEM” in “AIR BAG SYSTEM” section.

HEATER AND VENTILATION 1A-9

TERMINAL

POSITION

BLOWER FAN & DEFOGGER SWITCH

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Remove ashtray, instrument center upper garnish (1), heater
control knob (3), instrument center lower garnish (2) and radio
or accessory case (if equipped).

3) Disconnect blower fan switch coupler.

4) Remove blower fan switch (4) with unlocked the locking part (5)
as shown in figure.

INSTALLATION

Reverse removal sequence to install blower fan switch.

INSPECTION OF BLOWER FAN SWITCH

Check blower fan switch for each terminal-to-terminal continuity.
For the detail refer to “WIRING CIRCUIT” earlier in this section.

E L M

L

M

H

H

OFF

1

2

3

4

1. Cooling unit packing

2. Dash packing

3. Packing

4. Drain hose

5. Blank

6. Door link

7. Air inlet door

8. Evaporator case

9. Air resistance board

2. Rag

1A-10 HEATER AND VENTILATION

AIR INLET BOX

REMOVAL AND INSTALLATION

Refer to “COOLING UNIT” in “AIR CONDITIONING” section.

VENTILATION LOUVER

REMOVAL AND INSTALLATION

Remove ventilation louver (1) as shown in figure, and reverse re­moval sequence to install ventilation louver.

1B

AIR CONDITIONING (OPTIONAL) 1B-1

GENERAL DESCRIPTION 1B- 2. . . . . . . . . . . . . .

Refrigerant Flow of Air Conditioning

System 1B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Major Components and Location 1B- 3. . . . . . .

DIAGNOSIS 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Diagnosis Table 1B- 4. . . . . . . . . . . . . .

Quickly Checking of Refrigerant Charge 1B- 6.

Diagnosis Test 1B- 7. . . . . . . . . . . . . . . . . . . . . . .

Wiring Circuit 1B-11. . . . . . . . . . . . . . . . . . . . . . . .

A/ C System Inspection of ECM and

Its Circuits 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . .

A/ C Compressor Drive Belt Inspection 1B-14. .

RECOVERY, EVACUATION AND

CHARGING 1B-15. . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Recovery 1B-15. . . . . . . . . . . . . . . . .

Evacuating and Charging 1B-15. . . . . . . . . . . . . .

ON-VEHICLE SERVICE 1B-16. . . . . . . . . . . . . . . .

A/ C Condenser Assembly 1B-16. . . . . . . . . . . . .

Receiver/ Dryer 1B-17. . . . . . . . . . . . . . . . . . . . . .

Radiator (and Condenser) Cooling Fan

Motor 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Unit 1B-19. . . . . . . . . . . . . . . . . . . . . . . . .

A/ C Evaporator Thermistor 1B-20. . . . . . . . . . . .

Expansion Valve 1B-21. . . . . . . . . . . . . . . . . . . . .

Dual Pressure Switch 1B-21. . . . . . . . . . . . . . . . .

A/ C Switch 1B-22. . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator (and Condenser) Cooling Fan

Relay 1B-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A/ C Blower Fan Relay 1B-23. . . . . . . . . . . . . . . .

Compressor 1B-24. . . . . . . . . . . . . . . . . . . . . . . . .

Magnet Clutch 1B-26. . . . . . . . . . . . . . . . . . . . . . .

REQUIRED SERVICE MATERIALS 1B-31. . . . . .

SPECIAL TOOLS 1B-31. . . . . . . . . . . . . . . . . . . . . .

SECTION 1B

AIR CONDITIONING (OPTIONAL)

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
D Service on and around the air bag system components or wiring must be performed only by an autho-

rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener­al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau­tions” under “On-Vehicle Service” in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

D 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 disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of A /C:
one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte­nance. For identification between these two types, refer to the description in page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/ C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CONDI­TIONING BASIC MANUAL (99520-02130).

CONTENTS

: Superheated Vapor

1. Compressor

2. Magnet clutch

3. Condenser

4. Receiver / dryer

5. Pressure switch

6. Expansion valve

7. Evaporator

State of Refrigerant

Condenser
Cooling Air

HFC-134a

(R-134a)

2

CFC-12

(R-12)

: Liquid

: Vapor

1B-2 AIR CONDITIONING (OPTIONAL)

GENERAL DESCRIPTION

Whether the A/C in the vehicle being serviced uses HFC-134a
(R-134a) or CFC-12 (R-12) is indicated on LABEL (1) on the com­pressor. Also, it can be checked by the shape of the service
(charge) valve (2).

REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM

1. Cooling unit

2. Compressor

3. Condenser assembly

4. Receiver / dryer

5. Discharge hose

6. Suction hose

7. Liquid pipe

8. Expansion valve

9. Side ventilation air

10. Center ventilation air

11. Foot air

12. Front defroster air

13. Side defroster air

14. Fresh air

15. Recirculation air

16. Evaporator

11

7

1

AIR CONDITIONING (OPTIONAL) 1B-3

MAJOR COMPONENTS AND LOCATION

1B-4 AIR CONDITIONING (OPTIONAL)

DIAGNOSIS

GENERAL DIAGNOSIS TABLE

Condition Possible Cause Correction

Cool air does not come
out (A/ C system
improper operative)

A/ C system inoperative

D No refrigerant
D Fuse blown

D A/ C switch faulty
D Blower fan switch faulty
D A/ C thermistor faulty
D Dual pressure switch faulty
D Wiring or grounding faulty
D ECT sensor faulty
D ECM faulty

Recover, evacuation and charging.
Check “IG COIL” fuse, “HEATER” fuse
and check for short circuit to ground.
Check A/ C switch.
Check blower fan switch.
Check A/ C thermistor.
Check dual pressure switch.
Repair as necessary.
Check ECT sensor.
Check ECM.

Compressor inoperative (dose not
rotate)

D Magnet clutch faulty
D Drive belt loose or broken
D Compressor faulty
D ECM faulty

Check magnet clutch.
Adjust or replace drive belt.
Check compressor.
Check ECM.

Radiator (and condenser), cooling
fan motor inoperative

D Fuse blown

D Radiator cooling fan relay faulty
D Wiring or grounding faulty
D Radiator cooling fan motor faulty
D ECM faulty

Check RDTR fuse and check short
circuit to ground.
Check radiator cooling fan relay.
Repair as necessary.
Check radiator cooling fan motor.
Check ECM.

Blower motor inoperative

D Fuse blown

D Blower resistor faulty
D Blower fan switch faulty
D Wiring or grounding faulty
D Blower motor faulty

Check “HEATER” fuse and check for
short circuit to ground.
Check blower motor resistor.
Check blower fan switch.
Repair as necessary.
Check blower motor.

When the blower fan
switch is OFF position,
blower motor does not
operate at A/ C switch is
ON

D A/ C blower motor relay faulty
D Wiring or grounding faulty
D A/ C switch faulty

Check A/ C blower motor relay.
Repair as necessary.
Check A/ C switch.

Cool air does not come
out or insufficient
cooling (A/ C system
normal operative)

D Insufficient or excessive charge of

refrigerant

D Condenser clogged
D Evaporator clogged or frosted

D A/ C thermistor faulty
D Expansion valve faulty
D Receiver/ dryer clogged
D Drive belt slipping
D Magnetic clutch faulty

Check charge of refrigerant.
Check system for leaks.
Check condenser.
Check evaporator and position of A/ C
thermistor.
Check A/ C thermistor.
Check expansion valve.
Check receiver/ dryer.
Check or replace drive belt.
Check magnetic clutch.

AIR CONDITIONING (OPTIONAL) 1B-5

Condition Possible Cause Correction

Cool air does not come
out or insufficient
cooling (A/ C system
normal operative)

D Compressor faulty
D Air in A/ C system

D Air leaking from cooling unit or air duct
D Heater and ventilation system faulty

D Blower motor faulty
D Excessive compressor oil existing in

A/ C system

Check compressor.
Replace receiver/ dryer, and
evacuation and charging.
Repair as necessary.
Check air inlet box assembly.
Check heater control lever assembly.
Check heater assembly.
Check blower motor.
Evacuate and charge system.

Cool air does not comes
out only intermittently

D Wiring connection faulty
D Expansion valve faulty
D Excessive moisture in A/ C system

D Magnetic clutch faulty
D Excessive charge of refrigerant

Repair as necessary.
Check expansion valve.
Replace receiver/ dryer, and
evacuation and charging.
Check magnetic clutch.
Check charge of refrigerant.

Cool air comes out only
at high speeds

D Condenser clogged
D Insufficient charge of refrigerant
D Air in A/ C system

D Drive belt slipping
D Compressor faulty

Check condenser.
Check charge of refrigerant.
Replace receiver/ dryer, and
evacuation and charging.
Check or replace drive belt.
Check compressor.

Cool air does not come
out only at high speeds

D Excessive charge of refrigerant
D Evaporator frosted

Check charge refrigerant.
Check evaporator.

Insufficient velocity of
cooled air

D Evaporator clogged or frosted
D Air leaking from cooling unit or air duct
D Blower motor faulty
D Wiring or grounding faulty
D Air filter element clogged

Check evaporator.
Repair as necessary.
Check blower motor.
Repair as necessary.
Check air filter element.

1B-6 AIR CONDITIONING (OPTIONAL)

QUICKLY CHECKING OF REFRIGERANT
CHARGE

CHARGE OF REFRIGERANT

When the A/ C inlet temperature is within 30 – 35_C.
The following procedure can be used for quickly checking whether
the A/ C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A/ C at its maximum cooling ca­pacity for a few minutes. Then, look at the sight glass (1) on liquid
pipe (2) and compare what is observed with the symptoms listed in
“CHECKING REFRIGERANT CHARGE” table given below.

CHECKING REFRIGERANT CHARGE

Item

No.

Symptom Charge of refrigerant Correction

1 Bubbles observed in sight glass Insufficient charge of

refrigerant in system

Check system for leaks with a
leak tester.

2 No bubbles observed in sight glass No or insufficient charge of

refrigerant in system

Refer to the items 3 and 4.

3 No temperature difference

between compressor inlet and
outlet

Empty or nearly empty system Evacuate and charge system

and then check it for leaks with
a leak tester.

4 Noticeable temperature difference

between compressor inlet and
outlet

Proper or too much charge of
refrigerant in system

Refer to the items 5 and 6.

5 When A /C is turned OFF,

refrigerant in sight glass clears
immediately and remains clear

Too much charge of refrigerant
in system

Discharge excess charge of
refrigerant to adjust it to a
specified charge.

6 When A /C is turned OFF,

refrigerant in sight glass once
produces bubbles and then clears

Proper charge of refrigerant in
system

NO CORRECTION NEEDED
BECAUSE CHARGE OF
REFRIGERANT IS NORMAL.

AIR CONDITIONING (OPTIONAL) 1B-7

DIAGNOSIS TEST

1) Confirm that vehicle and environmental conditions are as follows.

– Vehicle is not exposed to direct sun.
– Ambient temperature is within 15_C – 35_C (59_F – 95_F).

2) Make sure that high pressure valve (1) and low pressure valve
(2) of manifold gauge are firmly closed.

3) Connect high pressure charging hose (3) to high pressure ser­vice valve (5) on vehicle, and connect low pressure charging
hose (4) to low pressure service valve (6) on vehicle.

4) Bleed the air in charging hoses (3), (4) by loosening their respec­tive nuts on manifold gauge, utilizing the refrigerant pressure.
When a hiss is heard, immediately tighten nut.

CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.

5) Warm up engine to normal operating temperature and keep it at
specified idle speed.

6) Turn A/ C switch ON, and set blower switch at “HI”, temperature
control knob at “COOL”, mode control knob at “FACE”, fresh/ cir­culation control lever at “CIRCULATION”. (Confirm that A/ C
compressor and condenser fan are working.)

7) Keep all windows, doors and engine hood open.

A/ C inlet air temperature

15 – 35_C (59 – 95_F)
Engine rpm Keep 1500 rpm
Blower switch Max.
Temperature control Max. cold
Doors All open
Air inlet damper position Recirculation

8) With about 20 mm (0.8 in.) of dry bulb thermometer inserted into
center duct air outlet and another one set near evaporator air in­let, read temperature indicated on each thermomenter.

Ambient Temperature

Pressure of Low

Pressure Gauge

Pressue of High Pressure

Gauge

Temp. at Evaporator Air Inlet

Temp. at Center Duct Air Outlet

_F

1B-8 AIR CONDITIONING (OPTIONAL)

9) Check for each pressure of low side and high side if it is within
shaded range of left graph.

NOTE:
Pressure registered on gauge varies with ambient temper­ature. Therefore, use left graphs when determining if pres­sures are normal or not.

Example:

Gauges should read as follows when ambient
temperature is 30_C

Pressure on high pressure
gauge (HI):

1400 – 1750 kPa

14.0 – 17.5 kg/ cm

2

Pressure on low pressure
gauge (LO):

230 – 350 kPa

2.3 – 3.5 kg/ cm

2

If each gauge reading is out of specified pressure, correct de­fective part referring to following Test Diagnosis table.

10) Check inlet port temperature-to-outlet port temperature rela­tionship using graph at the left.
For example, if evaporator inlet port temperature is 25_C
(77_F) and center duct air outlet temperature is 8_C (46.4_F),
their crossing point is within acceptable range as shown in
graph at the left.
In this case, cooling performance is satisfactory and proper.

11) If crossing point is out of acceptable range, diagnose trouble
referring to following Test Diagnosis table.

AIR CONDITIONING (OPTIONAL) 1B-9

HIGH PRESSURE GAUGELOW PRESSURE GAUGE

THERMOMETER AT

CENTER DUCT

Insufficient
cooling of
condenser

DIAGNOSIS TEST TABLE

TESTING RESULTS POSSIBLE CAUSE REMEDY

Pressure high
(“A” area of high side
graph)

D Refrigerant overcharged
D Expansion valve frozen or clogged
D Clogged refrigerant passage of high side
D Condenser fan malfunction

D Dirty or bent condenser fins
D Compressor malfunction (Insufficient oil etc.)
D Engine overheat

D Recharge
D Check expansion valve
D Clean or replace
D Check condenser fan

D Clean or repair
D Check compressor
D Check engine cooling

system

Pressure low
(“B” area of high side
graph)

D Insufficient refrigerant (Insufficient charge or

leakage)

D Expansion valve malfunction (valve opens too

wide)

D Compressor malfunction (Insufficient

compression)

D Check for leakage, repair

if necessary and
recharge

D Check expansion valve

D Check compressor

Pressure high
(“A” area of high side
graph)

D Expansion valve malfunction (valve opens too

wide)

D Compressor malfunction (Insufficient

compression)

D Check expansion valve

D Check compressor

Pressure low
(“B” area of high side
graph)

D Insufficient refrigerant (Insufficient charge or

leakage)

D Expansion valve malfunction (valve opens too

narrow)

D Clogged refrigerant passage (crashed pipe)

D Check for leakage, repair

if necessary and
recharge

D Check expansion valve

D Repair or replace

Outlet air temperature
at center duct is high
(Crossing point is in
area “A”)

D Insufficient or excessive charge of refrigerant

D Dirty or bent evaporator fins
D Air leakage from cooling (heater) unit or air duct
D Malfunctioning, switchover function of damper

in cooling (heater) unit

D Compressor malfunction

D Check refrigerant

pressure

D Clean or repair
D Repair or replace
D Repair or replace

D Check compressor

Outlet air temperature
at center duct is low
(Crossing point is in
area “B”)

D Insufficient air volume from center duct (Heater

blower malfunction)

D Compressor malfunction

D Check blower motor and

fan

D Check compressor

If ambient temperature is within 30 – 35_C (86 – 95_F), it is possible to do using next page table for detail diagnosis.

1B-10 AIR CONDITIONING (OPTIONAL)

DETAIL DIAGNOSIS TABLE AT AMBIENT TEMPERATURE WITHIN 30 – 35_C (85 – 95_F)

MANIFOLD

GAUGE

MPa

kg/ cm

2

psi

CONDITION CAUSE CORRECTION

Lo Hi

0.23 – 0.35

2.3 – 3.5
33 – 50

1.4 – 1.75
14 – 17.5

200 – 249

Normal condition.

––––––––– –––––––––

Negative
pressure

0.5 – 0.6
5 – 6

71.2 – 85.3

D The low pressure side

reads a negative
pressure,and the high
pressure side reads an
extremely low pressure.

D Presence of frost around

tubing to and from
receiver/ dryer and
expansion valve.

D Dust particles or

water droplets are
either stuck or frozen
inside expansion
valve, preventing the
refrigerant from
flowing.

D Clean expansion valve.

Replace it if it cannot be
cleaned.

D Replace receiver /dryer.
D Evacuate the A /C

system and recharge
with fresh refrigerant.

Normal:

0.23 – 0.35

2.3 – 3.5
33 – 50

Abnormal:
Negative
pressure

Normal:

1.4 – 1.75
14 – 17.5

200 – 249

Abnormal:

0.69 – 0.98
7 – 10

100 – 142

D During A /C operation,

the low pressure side
sometimes indicates
negative pressure, and
sometimes normal pres­sure. Also high pressure
side reading fluctuates
between the abnormal
and normal pressure.

D Expansion valve is

frozen due to
moisture in the
system, and
temporarily shuts off
the refrigeration
cycle.

D Replace expansion

valve.

D Replace receiver /dryer.
D Evacuate A /C system

and recharge with fresh
refrigerant.

0.05 – 0.15

0.5 – 1.5

4.2 – 21.3

0.69 – 0.98
7 – 10

100 – 142

D Both low and high

pressure sides indicate
low readings.

D Continuous air bubbles

are visible through sight
glass.

D Output air is slightly cold.

D Insufficient

refrigerant in system.
(Refrigerant leaking)

D Using a gas leak

detector, check for leaks
and repair as necessary.

D Recharge refrigerant to

a specified amount.
If the pressure reading is
almost 0 when the
manifold gauges are at­tached, check for any
leaks, repair them, and
evacuate the system.

0.4 – 0.6
4 – 6

56.9 – 85.3

D Pressure on low

pressure side is high.

D Pressure on high pressure

side is low.

D Both pressure becoming

equal right after A/ C is
turned OFF.

D Internal leak in

compressor.

D Inspect compressor

and repair or replace
as necessary.

0.35 – 0.45

D High pressure reading

on both low and high
pressure sides.

D Air bubbles are not

visible even when
engine rpm is lowered.

D Overcharged A /C

system.

D Faulty condenser

cooling operation.

D Faulty condenser fan

operation.

D Adjust refrigerant to

specified amount.

D Clean condenser.
D Inspect and repair

condenser fan.

035 0 5

3.5 – 4.5

50 – 64

1.96 – 2.45
20 – 25

285 – 355

D High pressure reading

on both low and high
pressure sides.

D Low pressure side tubing

is not cold when touched.

D Air bubbles are visible

through sight glass.

D Presence of air in

A/ C system.
(Improperly evacuated)

D Replace receiver /dryer.
D Inspect quantity of com-

pressor oil and presence
of contaminants in oil.

D Evacuate system and

recharge with fresh
refrigerant.

0.45 – 0.55

4.5 – 5.5
64 – 78

D High pressure reading

on both low and high
pressure sides.

D Large amount of frost or

dew on the low pressure
side tubing.

D Faulty expansion

valve.

D Refrigerant flow is not

regulated properly.

D Replace expansion

valve.

1. Blower motor

2. Blower resistor

3. Blower fan switch

4. Dual pressure switch

5. A / C switch

6. A / C blower motor relay

7. Radiator (and condenser) cooling fan relay

8. Radiator (and condenser) cooling fan motor

9. Compressor

10. Main relay

11. Ignition switch

12. A / C evaporator thermistor

13. ECT sensor

Main
80A

Main
30A

Main
20A

Main
60A

IG
COIL
15A

HEATER
25A

AIR CONDITIONING (OPTIONAL) 1B-11

WIRING CIRCUIT

1. Blower motor

2. A / C blower motor relay

3. Dual pressure switch

4. A / C switch

5. A / C evaporator thermistor

6. ECT sensor

7. Radiator fan relay

8. Radiator fan

9. Compressor

10. Main relay

11. Engine earth

12. Blower motor switch

a. To ignition switch
b. To main fuse
c. To main relay (to d)
d. To radiator fan relay (to c)

Fig. A

Fig. B

TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)

1B-12 AIR CONDITIONING (OPTIONAL)

A/C SYSTEM INSPECTION OF ECM AND ITS
CIRCUITS

ECM and its Circuits can be checked at ECM wiring couplers by
measuring voltage.

CAUTION:
ECM cannot be checked by itself. It is strictly prohibited to
connect voltmeter or ohmmeter to ECM with couplers dis­connected from it.

Voltage Check

1) Remove ECM (1) from vehicle.

2) Connect ECM (1) couplers to ECM.

3) Check voltage at each terminal of couplers connected.
Refer to next page and “Inspection of ECM and its circuit” in EN­GINE AND EMISSION CONTROL SYSTEM section.

NOTE:
As each terminal voltage is affected by the battery voltage,
confirm that it is 11V or more when ignition switch is ON.

AIR CONDITIONING (OPTIONAL) 1B-13

ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL

Terminal Wire Circuit

Measurement

ground

Normal value Condition

E21-01 B

ECM ground for
sensor circuit
(E21-10, E23-10)

Ground to body
(Fig A)

–0.5 – 0 volt Ignition switch ON

E21-02 B/Y

ECM ground for
power circuit

Ground to body
(Fig A)

–0.5 – 0 volt Ignition switch ON

E21-03 B/Y

ECM ground for
power circuit

Ground to body
(Fig A)

–0.5 – 0 volt Ignition switch ON

E21-10 Br /W Sensor ground

Ground to body
(Fig A)

–0.5 – 0 volt Ignition switch ON

Engine coolant

p

Ground to engine

0.71 – 0.76 volts
(290 – 320 Ω)

Engine coolant temperature at
Approx. 80_C (176_F) with
ignition ON

E21-14

Y/G

temperature

sensor input

g

(Fig B)

0.35 – 0.37 volts
(136 – 144 Ω)

Engine coolant temperature at
Approx. 110_C (230_F) with
ignition ON

Compressor

Ground to engine

10 – 14 volts

Blower switch and A/ C switch
ON with engine running

E22-01

B/Y

magnet clutch

output

g

(Fig B)

0 – 1 volt

Except the above-mentioned
with engine running

E22-05 B/R

Power supply for
engine control

Ground to engine
(Fig B)

10 – 14 volts Ignition switch ON

E22-06 B/R

Power supply for
engine control

Ground to engine
(Fig B)

10 – 14 volts Ignition switch ON

Ground to engine

0 – 1 volt Ignition switch ON

E22-10

Bl/ B

Main relay

g

(Fig B)

10 – 14 volts Ignition switch OFF

p

Ground to engine

0 – 1 volt

Blower switch and A/ C switch
ON with ignition switch ON

E22-16

Lg/ R

A/C switch input

g

(Fig B)

10 – 14 volts

Blower switch or A/ C switch
OFF with ignition switch ON

E22-18 Bl

Radiator
(condenser)
cooling fan relay

Ground to engine
(Fi

g

B)

0 – 1 volt

Blower switch and A/ C switch
ON or engine coolant temp.
sensor more than 98_C (208_F)
with engine running

gy

output

(g)

10 – 14 volts

Except the above-mentioned
with engine running

E23-10 Br /W Sensor ground

Ground to body
(Fig A)

–0.5 – 0 volt Ignition switch ON

0 – 2 volt

Blower switch 2nd or 3rd or 4th
position with ignition switch ON

E23-13 P/Bl

Blower fan speed
input

Ground to engine
(Fig B)

3 – 5 volts

Blower switch 1st position with
ignition switch ON

10 – 14 volts

Blower switch OFF position with
ignition switch ON

Evaporator

p

Ground to engine

2.0 – 2.3 volts

(1800 – 2200 Ω)

Evaporator thermistor temp. at
Approx. 25_C (77_F) with
ignition switch ON

E23-14

G/R

thermistor temp

.

input

g

(Fig B)

3.5 – 3.6 volts

(6300 – 7000 Ω)

Evaporator thermistor temp. at
Approx. 0_C (32_F) with ignition
switch ON

2

1

“a”

1B-14 AIR CONDITIONING (OPTIONAL)

A/C COMPRESSOR DRIVE BELT INSPECTION

1) Check belt for wear and cracks, and replace as required.

2) Check belt tension by measuring how much it deflects when
pushed at intermediate point between compressor pulley (1)
and crankshaft pulley (2) with about 100 N (10 kg, 22 lbs) force.

“a” :7 – 9 mm (0.27 – 0.35 in.) as deflection/

100N (10 kg, 22 lbs)

If belt tension is without above specification, adjust belt tension
by according to following items.
i) Loosen tension pulley bolt (3).
ii) Adjust belt tension by tighten or loosen tension pulley adjust

bolt (4).
iii) Tighten tension pulley bolt (3).
iv) Turn the crank pulley one revolution, then check belt tension.

Start evacuatingStart evacuatingStart evacuatingStart evacuatingStart evacuating

Performance test

Inspect and repair connections

Recharge 475 ± 25 g of

refrigerant in gas form

Stop evacuating

Check system for

pressure tightness

Recharge A/ C with

refrigerant

Check system for refrigerant

leaks and refrigerant

charging quantity

If gauge shows
abnormal conditions

15 minutes (above 750 mmHg)

Wait 10 minutes

A: High pressure service valve
B: Low pressure service valve

1. Manifold gauge set

2. Low pressure gauge

3. High pressure gauge

4. Recovery equipment

AIR CONDITIONING (OPTIONAL) 1B-15

RECOVERY, EVACUATION AND CHARGING

OPERATION PROCEDURE FOR CHARGING A/ C WITH REFRIGERANT

REFRIGERANT RECOVERY

When discharging refrigerant out of A/ C system, always recover it
by using refrigerant recovery and recycling equipment.
Discharging it into atmosphere would cause adverse effect to envi­ronments.

NOTE:
When handling recovery and recycling equipment, be sure to
follow the instruction manual for the equipment.

EVACUATING AND CHARGING

Refer to AIR CONDITIONING BASIC MANUAL (99520-02130).

NOTE:
Specified amount of refrigerant: 475 ± 25 g

1. Suction hose:
Apply compressor oil
(refrigerant oil) to O-ring

2. Discharge hose:
Apply compressor oil
(refrigerant oil) to O-ring

3. Liquid pipe:
Apply compressor oil
(refrigerant oil) to O-ring

4. Expansion valve:
Apply compressor oil
(refrigerant oil) to O-ring

1B-16 AIR CONDITIONING (OPTIONAL)

ON-VEHICLE SERVICE

NOTE:
When refrigerant line must be disconnected and connected to remove and reinstall any component of A/ C
system, be sure to observe the following instructions.
D When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immedi-

ately.

D When connecting hoses and pipes to each other respectively, previously apply a few drops of compres-

sor oil (refrigerating oil) to O-ring.

A/C CONDENSER ASSEMBLY

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.

3) Remove front bumper. Refer to FRONT BUMPER in BODY
SERVICE Section.

4) Loosen discharge hose bolt (1) and liquid pipe bolt (2).

5) Loosen condenser mounting bolts (3).

6) Remove condenser assembly (4).

AIR CONDITIONING (OPTIONAL) 1B-17

INSTALLATION

Reverse removal sequence to install condenser, noting the follow­ing point.
D If replace condenser, pour 15 cc of refrigerating oil to compressor

suction-side.

D Evacuate and charge system according to previously described

procedure.

INSPECTION

Check the following.

D Condenser fins for leakage, blockage and damage
D Condenser fittings for leakage

Clogged condenser fins should be washed with water, and should
be dried with compressed air.

NOTE:
Be careful not to damage condenser fins. If condenser fin is
bent, straighten it by using a screwdriver or pair of pliers. If any
leakage is found from fitting or tube, repair or replace con­denser.

RECEIVER/DRYER

REMOVAL

1) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.

2) Remove A / C condenser assembly. Refer to A/ C condenser as­sembly in this section.

3) Loosen receiver /dryer attachment bolts (1), (2).

4) Remove receiver /dryer (3).

INSTALLATION

Reverse removal sequence to install receiver/ dryer noting the fol­lowing points.
D If receiver/ dryer (3) is replaced, pour 20 cc of refrigerating oil to

compressor suction-side.

D Evacuate and charge system according to previously described

procedure.

1B-18 AIR CONDITIONING (OPTIONAL)

RADIATOR (AND CONDENSER) COOLING
FAN MOTOR

INSPECTION

1) Check continuity between each two terminals.
If there is no continuity, replace radiator (and condenser) cooling
fan motor.

2) Connect battery (1) to radiator (and condenser) cooling fan mo­tor coupler (2) as shown in figure, then check that the radiator
(and condenser) cooling fan motor operates smoothly.
If radiator (and condenser) cooling fan motor does not operates
smoothly, replace motor.

Reference current data: Approx. 8.5 – 11.5 A at 12 V

1. Evaporator

2. Expansion valve

3. Evaporator case

4. Packing

5. Drain hose

6. Air inlet door

7. Evaporator thermistor

4

AIR CONDITIONING (OPTIONAL) 1B-19

COOLING UNIT (EVAPORATOR)

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.

3) Disable air bag system, if equipped.

4) Remove heater control cable, main harness clamp.

5) Loosen suction hose & liquid pipe bolt (4).

6) Loosen cooling unit bolt (1), nuts (2) and screw (3) as shown in
figure.

7) Remove cooling unit (5).

INSPECTION

Check the following

D Evaporator fins for leakage, blockage and damage.
D Evaporator fitting for leakage.

Clogged evaporator fins should be washed with water, and should
be dried with compressor air.

NOTE:
Be careful not to damage evaporator fins. If evaporator fin is
bent, straighten it by using a screwdriver or pair of pliers.
If any leakage is found from fitting or tube, repair or replace
evaporator.

Resistance (k )

Ω

1B-20 AIR CONDITIONING (OPTIONAL)

INSTALLATION

Reverse removal sequence to install cooling unit, noting the follow­ing points.
D If cooling unit or evaporator is replaced, pour 25 cc of refrigerating

oil to compressor suction-side.

D Install uniformly the padding (1) to installation hole.

D Evacuate and charge system according to previously described

procedure.

D Adjust heater control cable, refer to HEATER CONTROL LEVER

ASSEMBLY in HEATER AND VENTILATION section.

D Enable air bag system, if equipped.

A/C EVAPORATOR THERMISTOR

Check resistance between evaporator thermistor (1) terminals.

Sensor Temperature (_C (_F))

Resistance (kΩ)

0 (32) 6.3 – 7.0

25 (77) 1.8 – 2.2

If check results are as not specified, replace evaporator thermistor.

NOTE:
When the evaporator thermistor removed, its should be rein­stalled in original position.

Continuity

No continuity

Pressure

AB

CD

1

AIR CONDITIONING (OPTIONAL) 1B-21

EXPANSION VALVE

INSPECTION

Refer to “Troubleshooting Procedure Using Manifold Gauge Set”
earlier in this section for inspection.

REMOVAL

1) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.

2) Loosen liquid pipe mounting bolt (1).

3) Loosen expansion attaching bolts (2) and remove expansion
valve (3).

INSTALLATION

Reverse removal procedure for installation, noting the following
points.
D Apply compressor oil to expansion valve O-ring and connecting

hose and pipe O-ring.

D Evacuate and charge system according to previously described

procedure.

DUAL PRESSURE SWITCH

INSPECTION

1) Check dual pressure switch (1) for continuity at normal tempera­ture (approx. 25_C (77_F)) when A/C system has a proper
charge of refrigerant and when A/ C system (compressor) is un­der operation. In each of these cases, switch should show prop­er continuity.

2) Check switch for continuity at specified pressure as shown.

A: Approx 200 KPa (2.0 kg/ cm

2

)

B: Approx 3200 KPa (32 kg/ cm

2

)

C: Approx 230 KPa (2.3 kg/ cm

2

)

D: Approx 2800 KPa (28 kg/ cm

2

)

REMOVAL

1) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.

2) Disconnect negative (–) cable at battery.

3) Remove dual pressure switch.

INSTALLATION

Reverse removal procedure for installation, noting the following points.

D Apply compressor oil to dual pressure switch O-ring.
D Evacuate and charge system according to previously described

procedure.

Tightening torque for pressure sensor
11 N

.

m (1.1 kg-m, 8.0 lb-ft)

1B-22 AIR CONDITIONING (OPTIONAL)

1. Heater control lever assembly

A. Radiator (and condenser) cooling fan fuse

1

A/C SWITCH

INSPECTION

1) Remove heater control lever assembly, refer to “HEATER CON-
TROL LEVER ASSEMBLY” in Section 1A.

2) Check following points for A /C switch.
D Pull A/ C Switch nob and check it there is continuity between

terminals “A” and “B”.

D With battery voltage (+) connected to terminal “C” and (–) to

terminal “A”, pull A/ C Switch nob and check it indicator lamp
lights.

REMOVAL AND INSTALLATION

Refer to “HEATER CONTROL LEVER ASSEMBLY” in Section 1A
for A/ C Switch (1) removal and installation.

RADIATOR (AND CONDENSER) COOLING
FAN RELAY

INSPECTION

1) Disconnect negative cable at battery.

2) Remove radiator cooling fan relay (1) from vehicle.

3) Check that there is no continuity between terminal “c” and “d”.
If there is continuity, replace relay.

4) Connect battery positive (+) terminal to terminal “b” of relay.
Connect battery negative (–) terminal “a” of relay.
Check continuity between terminal “c” and “d”.
If there is no continuity when relay is connected to the battery,
replace relay.

AIR CONDITIONING (OPTIONAL) 1B-23

A/C BLOWER FAN RELAY

INSPECTION

1) Disconnect negative cable at battery.

2) Remove A /C blower fan relay (1) from vehicle.

3) Check that there is no continuity between terminal “c” and “d”.
If there is continuity, replace relay.

4) Connect battery positive (+) terminal to terminal “b” and connect
battery negative terminal to terminal “a”.
Check continuity between terminal “c” and “d”.
If there is no continuity when relay is connected to the battery,
replace relay.

1. New compressor

2. Removed
compressor

3. Excess oil (A – B)

A

B

2

1B-24 AIR CONDITIONING (OPTIONAL)

COMPRESSOR

REMOVAL

1) RUN engine at idle speed with air conditioning ON for 10 min­utes. After that stop the engine.

2) Disconnect negative (–) cable at battery.

3) Recover refrigerant from refrigeration system by using recov­ery and recycling equipment.

4) Remove front bumper.

5) Remove engine front cover.

6) Disconnect magnet clutch lead wire and undo lead wire clamp.

7) Remove compressor drive belt by loosening tension pulley bolt
(1) and adjust bolt (2).

8) Disconnect suction and discharge hoses from compressor.

NOTE
Cap open fittings immediately to keep moisture out of sys­tem.

9) Remove compressor with magnet clutch assembly (1) from its
mount by loosening mounting bolts (2).

10) If compressor is replaced.
Drain oil from compressor, and measure its amount.

11) Remove compressor mount (1) by loosening mount bolts (2).

INSTALLATION

Reverse removal procedure noting the following point.
D If compressor is replaced, pour new compressor oil with the same

amount as that drained from compressor in REMOVAL.
Refer to “REPLENISHING COMPRESSOR OIL” in this section.

D Evacuate and charge system according to previously described

procedure.

1. New compressor

2. Removed compressor

3. Excess oil (A – B)

A

B

c

AIR CONDITIONING (OPTIONAL) 1B-25

D Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION”

in this section.

CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

NOTE:
Compressor assembly supplied from factory is filled up with
the following amount of oil.
Oil amount in compressor: 120 cm

3

(120 cc, 7.5 in3)

REPLENISHING COMPRESSOR OIL

When replacing air conditioning parts with new ones, it is necessary
to replenish oil by the amount supposedly remaining in each part.

When changing gas only

When it is unavoidable to change gas without replacing any compo­nent part for engine removal and installation or for some other rea­son, replenish 50 cc oil. When replenishing gas only, oil replenish­ment is not necessary.

When replacing compressor

Compressor oil is sealed in each new compressor by the amount
required for air conditioner cycle. Therefore, when using a new
compressor for replacement, drain oil from it by the amount calcu­lated as follows.

“C” = “A” – “B”
“C”: Amount of oil to be drained
“A”: Amount of oil sealed in a new compressor
“B”: Amount of oil remaining in removed compressor

When replacing other part

Part replaced

Amount of compressor

oil to be replenished

Evaporator 25 cc

Condenser 15 cc

Receiver/dryer 20 cc

Hoses 10 cc each

Pipes 10 cc each

: Tightening Torque

a. Front head bolt
b. Front head bolt

: Tighten bolt (a) first, and

next (b).

c. Armature plate bolt

1. Thermal switch

2. Compressor body

3. O-ring

4. Lip type seal

5. Front head

6. Clutch coil

7. Clutch pulley

8. Circlip

9. Circlip

10. Clutch plate

7

1B-26 AIR CONDITIONING (OPTIONAL)

MAGNET CLUTCH

INSPECTION

D Check clutch plate and clutch pulley for wear and oil soaked

conditions respectively.

D Check clutch pulley bearing for noise, wear and grease leakage.
D Measure clutch coil for resistance at 20_C.

Standard Resistance: 3.4 – 4.1 Ω

If the measured resistance does not remain within above toler­ance, replace magnet clutch assembly.

D Use an ohmmeter to check thermal switch for continuity.

If it is no continuity, replace it.

1. Snap ring

2. Clutch coil

3. Compressor assembly

AIR CONDITIONING (OPTIONAL) 1B-27

REMOVAL

1) Remove compressor from vehicle. Refer to COMPRESSOR in
this section.

2) Fix clutch plate (1) with special tool (A) and remove clutch plate
bolt (2) and washer (3).

Special Tool
(A): 09991-06020

3) Using special tool (B) if necessary, remove clutch plate (1).

Special Tool
(B): 09991-06030

4) Remove shims from shaft.

5) Using special tool (C), remove circlip.

Special Tool
(C): 09900-06107

6) Remove clutch coil read wire clamp by loosening its screw and
disconnect clutch coil read wire from thermal switch read wire.

7) Remove clutch pulley (2) with puller (1).

NOTE:
Be careful not to damage pulley when tapping clutch
pulley.

8) Remove clutch coil.

9) Remove circlip (1) by using special tool (C).

10) Remove clutch coil (2) from compressor (3).

1. Armature plate

3. Washer

1B-28 AIR CONDITIONING (OPTIONAL)

INSTALLATION

1) Install clutch coil (2).
Protrusion on under side of clutch coil must match hole in com­pressor (3) to prevent movement and correctly locate lead wire.

2) Using special tool (C), install circlip (1) as shown.

Special Tool
(C): 09900-06107

3) Install clutch pulley (1).
(I) Set clutch pulley (1) squarely over clutch pulley installation

boss.

(II) Place special tool (D) onto clutch coil bearing.

Ensure that edge rests only on inner race of bearing.

(III) Install circlip.

Special Tool
(D): 09991-06010

CAUTION:
Be careful not to scratch bearing seal.

4) Adjust clearance, between clutch plate (1) and clutch pulley (2)
by putting shim on compressor shaft.

Standard clearance “a”: 0.3 – 0.6 mm (0.012 – 0.024 in.)

5) Tighten new clutch plate bolt (2) as specified below.

Tightening Torque
(a): 14 N

.

m (1.4 kg-m, 10.5 lb-ft)

Special Tool
(A): 09991-06020

PUSH

3. Cylinder

4. Case

5. O-ring

Obverse side Back side

(G)

(E)

2

AIR CONDITIONING (OPTIONAL) 1B-29

LIP SEAL

REMOVAL

1) Remove magnet clutch, referring to “MAGNET CLUTCH” in this
section.

2) Remove front head (1) mounting bolts (a), (b).

3) Remove front head (1) by pushing cylinder shaft (2).

NOTE:
Be careful not to remove cylinder from front head.

4) Remove O-ring.

5) Remove lip seal from front head using special tool (G).

Special Tool
(G): 09923-73210

INSTALLATION

1) Press-fit lip seal (1) into front head (2) using special tool (E).

Special Tool
(E): 09991-06050

CAUTION:
Do not reuse mechanical seal once removed from com­pressor.

1B-30 AIR CONDITIONING (OPTIONAL)

2) Coat special tool (F) surface with oil and place it on the shaft.

Special Tool
(F): 09991-06040

3) Install O-ring (2) to case.

4) Apply compressor oil to lip seal and O-ring.

5) Install front head (1).

Special Tool
(F): 09991-06040

6) Tighten front head mounting bolts (a), (b).

Tightening Torque
(a): 14 N·m (1.4 kg-m, 10.5 lb-ft)
(b): 23 N·m (2.3 kg-m, 17.0 lb-ft)

NOTE:

D Be sure to use new front head mounting bolts.
D Tighten bolt (a) first, and next (b).

AIR CONDITIONING (OPTIONAL) 1B-31

09900-06107
Snap ring pliers
(Opening type)

09900-06010
Magnet clutch pulley installer

09991-06020
Armature plate spanner

09991-06030
Armature plate remover

09991-06040
Lip type seal protector

09991-06050
Lip type seal installer

09923-73210
Bearing remover

REQUIRED SERVICE MATERIALS

MATERIALS

RECOMMENDED

SUZUKI PRODUCT

USE

Compressor oil
(Refrigerant oil)

COMPRESSOR OIL RS20 (150 cc)
99000-99088

D O-ring
D Each Component

Refrigerant

REFRIGERANT DRUM (200 g)
95794-50G00

D Refrigerant charge

SPECIAL TOOLS

3

STEERING, SUSPENSION, WHEELS AND TIRES 3-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES

DIAGNOSIS 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT END ALIGNMENT SECTION 3A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL RACK AND PINION SECTION 3B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL POWER STEERING (P/ S) SYSTEM (IF EQUIPPED) SECTION 3B1. . . . . . . . . . . . . . . . . . .

AIR BAG STEERING WHEEL AND COLUMN SECTION 3C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT SUSPENSION SECTION 3D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SUSPENSION SECTION 3E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEELS AND TIRES SECTION 3F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTS

DIAGNOSIS

GENERAL DIAGNOSIS 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRE DIAGNOSIS 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Irregular and/ or Premature Wear 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear Indicators 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radial Tire Waddle 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radial Tire Lead 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIBRATION DIAGNOSIS 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 STEERING, SUSPENSION, WHEELS AND TIRES

DIAGNOSIS

GENERAL DIAGNOSIS

Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered
when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with
the following preliminary inspection and correct any defects which are found.

1) Inspect tires for proper pressure and uneven wear.

2) Raise vehicle on a hoist and inspect front and rear suspension and rack and pinion for loose or damaged parts.

3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and /or rough wheel
bearings.

GENERAL DIAGNOSIS TABLE

Condition Possible Cause Reference Item

Vehicle Pulls (Leads) D Mismatched or uneven tires

D Tires not adequately inflated
D Broken or sagging springs

D Radial tire lateral force
D Disturbed front end alignment
D Disturbed rear wheel alignment
D Brake dragging in one road wheel
D Loose, bent or broken front or rear

suspension parts

Replacement tires in Section 3F
Inflation of tires in Section 3F
Strut damper assembly in Section 3D or
coil spring in Section 3E
Replacement tires in Section 3F
Section 3A
Check and adjust rear wheel alignment
Refer to Section 5
Tighten or replace suspension parts

Abnormal or
Excessive Tire Wear

D Broken or sagging spring

D Tire out of balance

D Disturbed front or rear end alignment
D Faulty strut (shock absorber)
D Hard driving
D Overloaded vehicle
D Not rotating tire

D Worn or loose road wheel bearing
D Wobbly wheel or tire

D Tires not adequately inflated

Strut damper assembly in Section 3D or
coil spring in Section 3E
General balance procedure or
replacement tires in Section 3F
Section 3A
Strut damper assembly in Section 3D
Replacement tires in Section 3F
Replacement tires in Section 3F
Replacement tires or tire rotation in
Section 3F
Knuckle/ bearing in Section 3D
Replacement wheels or tires in Section
3F
Inflation of tires in Section 3F

Wheel Tramp D Blister or bump on tire

D Improper strut (shock absorber) action

Replacement tires in Section 3F
Strut damper assembly in Section 3D

STEERING, SUSPENSION, WHEELS AND TIRES 3-3

Condition Possible Cause Reference Item

Shimmy, Shake or
Vibration

D Tire or wheel out of balance

D Loosen wheel bearings

D Worn tie rod ends
D Worn lower ball joints
D Excessive wheel runout

D Blister or bump on tire
D Excessively loaded radial runout of

tire/ wheel assembly

D Disturbed front end alignment
D Loose or worn steering linkage
D Loose steering gear case bolts

Balance wheels or general balance
procedure in Section 3F
Knuckle/ Bearing in Section 3D and / or
wheel bearing and wheel stud in Section
3E
Tie rod end in Section 3B
Suspension arm/ bushing in Section 3D
Replacement wheels or tires in Section
3F
Replacement tires in Section 3F
Replacement wheels or tires in Section
3F
Section 3A
Section 3B and 3C
Manual rack and pinion assembly in
Section 3B

Hard Steering D Tire not adequately inflated

D Malfunctioning Electrical power

steering system

D Bind in tie rod end ball studs or lower ball

joints

D Disturbed front end alignment
D Rack and pinion adjustment
D Bind in steering column

Inflation of tires in Section 3F
Refer to “Diagnosis” in Section 3B1

Tie rod end in Section 3B or suspension
arm/ bushing in Section 3D
Section 3A
Steering rack plunger in Section 3B
Steering column in Section 3C

Too Much Play in
Steering

D Wheel bearings worn
D Loose steering gear case bolts

D Rack and pinion adjustments

(Manual steering only)

D Worn steering shaft joints
D Worn tie rod ends or tie rod inside ball

joints

D Worn lower ball joints

Knuckle/ Bearing in Section 3D
Manual rack and pinion assembly in
Section 3B
Section 3B

Steering lower shaft joint in Section 3C
Tie rod end or rack boot/ tie rod in Section
3B
Suspension arm/ bushing in Section 3D

Poor Returnability D Bind in tie rod end ball studs

D Bind in ball joints

D Bind in steering column
D Poorly lubricated rack and pinion

D Disturbed front end alignment
D Rack and pinion adjustment
D Tires not adequately inflated

Tie rod end in Section 3B
Rack boot/ tie rod, tie rod end in Section
3B and suspension arm/ bushing in
Section 3D
Steering column in Section 3C
Steering pinion or steering rack in
Section 3B
Section 3A
Steering rack plunger in Section 3B
Inflation of tires in Section 3F

3-4 STEERING, SUSPENSION, WHEELS AND TIRES

Condition Possible Cause Reference Item

Rack and Pinion
Noise

(Rattle or Chuckle)

D Loose steering gear case bolts

D Worn rack bush
D Rack and pinion adjustment

Manual rack and pinion assembly in
Section 3B
Rack bushing in Section 3B
Steering rack plunger in Section 3B

Abnormal Noise,
Front End

D Worn, sticky or loose tie rod ends, lower

ball joints, tie rod inside ball joints or
drive shaft joints

D Damaged struts or mountings
D Worn suspension arm bushings
D Loose or worn stabilizer bar mountings
D Loose wheel nuts
D Loose suspension bolts or nuts
D Broken or otherwise damaged wheel

bearings

D Broken suspension springs

D Poorly lubricated or worn strut bearings

Rack boot/ tie rod, tie rod end in Section
3B, suspension arm in Section 3D or
drive shaft in Section 4
Strut damper assembly in Section 3D
Suspension arm/ bushing in Section 3D
Stabilizer bar and/ or bushings
Section 3F
Section 3D or 3E
Knuckle/ bearing in Section 3D or wheel
bearing and wheel stud in Section 3E
Strut damper assembly in Section 3D or
coil spring in Section 3E
Strut damper assembly in Section 3D

Wander or Poor
Steering Stability

D Mismatched or uneven tires

D Loosen ball joints and tie rod ends

D Faulty struts or mounting
D Loose stabilizer bar

D Broken or sagging springs

D Rack and pinion adjustment
D Front end alignment

Replacement tires or inflation tires in
Section 3F
Suspension arm/ bushing in Section 3D
and tie rod end in Section 3B
Strut damper assembly in Section 3D
Stabilizer bar and/ or bushing in Section
3D
Strut damper assembly in Section 3D or
coil spring in Section 3E
Steering rack plunger in 3B
Section 3A

Erratic Steering
When Braking

D Worn wheel bearings

D Broken or sagging springs
D Wheel tires are inflated unequally
D Disturbed front end alignment
D Brakes not working in unison
D Leaking wheel cylinder or caliper
D Warped discs
D Badly worn brake linings
D Drum is out of round in some brakes
D Defective wheel cylinders

Knuckle/ bearing in Section 3D and / or
wheel bearing and wheel stud in Section
3E
Strut damper assembly in Section 3D
Inflation of tire in Section 3F
Section 3A
Refer to Section 5
Refer to Section 5B or 5C
Refer to Section 5B
Refer to Section 5C
Refer to Section 5C
Refer to Section 5C

STEERING, SUSPENSION, WHEELS AND TIRES 3-5

Condition Possible Cause Reference Item

Low or Uneven Trim
Height

Right-to-left trim
height (H) difference
should be within
10 mm (0.4 in.) with
curb weight.

*Same with rear side.

D Broken or sagging springs

D Over loaded
D Incorrect springs

Strut damper assembly in Section 3D or
coil spring in Section 3E
Check loading
Strut damper assembly in Section 3D or
coil spring in Section 3E

Ride Too Soft D Faulty struts (shock absorber) Strut damper assembly in Section 3D

Suspension Bottoms D Overloaded

D Faulty struts (shock absorber)
D Incorrect broken or sagging springs

Check loading
Strut damper assembly in Section 3D
Strut damper assembly in Section 3D or
coil spring in Section 3E

Body Leans or Sways
in Corners

D Loose stabilizer bar

D Faulty struts (shock absorbers) or

mounting

D Broken or sagging springs

D Overloaded

Stabilizer bar and/ or bushing in Section
3D
Strut damper assembly in Section 3D

Strut damper assembly in Section 3D or
coil spring in Section 3E
Check loading

Cupped Tires D Front struts defective

D Worn wheel bearings

D Excessive tire or wheel run-out
D Worn ball joints
D Tire out of balance

Strut damper assembly in Section 3D
Knuckle/ bearing in Section 3D or wheel
bearing and wheel stud in Section 3E
Replacement tires in Section 3D
Suspension arm/ bushing in Section 3D
General balance procedures in Section
3F

D Hard Cornering
D Under Inflation
D Lack of tire Rotation

D Incorrect Wheel Alignment
D Tire Construction not Uniform
D Wheel Heavy Acceleration

3-6 STEERING, SUSPENSION, WHEELS AND TIRES

TIRE DIAGNOSIS

IRREGULAR AND/ OR PREMATURE WEAR

Irregular and premature wear has many causes. Some of them are:
incorrect inflation pressures, lack of tire rotation, driving habits, im­proper alignment.
If the following conditions are noted, rotation is necessary:

1) Front tire wear is different from rear.

2) Uneven wear exists across the tread of any tire.

3) Front tire wear is unequal between the right and left.

4) Rear tire wear is unequal between the right and left.

5) There is cupping, flat spotting, etc.

A wheel alignment check is necessary if following conditions are
noted:

1) Front tire wear is unequal between the right and left.

2) Wear is uneven across the tread of any front tire.

3) Front tire treads have scuffed appearance with “feather” edges
on one side of tread ribs or blocks.

WEAR INDICATORS

Original equipment tires have built-in tread wear indicators to show
when they need replacement.
These indicators will appear as 12 mm (0.47 in.) wide bands when
the tire tread depth becomes 1.6 mm (0.063 in.).
When the indicators appear in 3 or more grooves at 6 locations, tire
replacement is recommended.

RADIAL TIRE WADDLE

Waddle is side to side movement at the front and/or rear of the ve­hicle. It is caused by the steel belt not being straight within the tire.
It is most noticeable at a low speed, 8 to 48 km/ h (5 to 30 mph).
It is possible to locate the faulty tire by road testing the vehicle. If
it is on the rear, the rear end of the vehicle shakes from side to side
or “waddles”. To the driver in his seat, it feels as though someone
is pushing on the side of vehicle.
If the faulty tire is on the front, waddling is more visual. The front
sheet metal appears to be moving back and forth and the driver
feels as though he is at the pivot point in vehicle.
Waddle can be quickly diagnosed by using Tire Problem Detector
(TPD) and following the equipment manufacture’s recommenda­tions.
If TPD is not available, an alternative method of substituting known
good tire/ wheel assemblies can be used as follows, although it
takes a longer time.

INFLATE TIRES TO RECOMMENDED

PRESSURE

SWITCH FRONT TIRES

SIDE TO SIDE AND
ROAD TEST AGAIN

INSTALL A KNOWN GOOD TIRE

ON ONE FRONT SIDE

ROAD TEST VEHICLE ON LEVEL

UNCROWNED ROAD IN

BOTH DIRECTIONS

LEAD CORRECTED IF

ROUGHNESS RESULTS.

REPLACE TIRES

PUT TIRES BACK IN

ORIGINAL POSITION

AND CHECK ALIGNMENT

LEADS IN SAME

DIRECTION

LEAD REVERSES

DIRECTION

LEAD REMAINS

INSTALL A KNOWN GOOD TIRE IN

PLACE OF OTHER FRONT TIRE

LEAD CORRECTED

REPLACE TIRE

LEAD REMAINS

KNOWN GOOD TIRES ARE NOT GOOD

LEAD CORRECTED

REPLACE TIRE

STEERING, SUSPENSION, WHEELS AND TIRES 3-7

1) Ride vehicle to determine whether the front or rear waddles.

2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end of ve­hicle. If waddling end cannot be identified, substitute rear ones.

3) Road test again. If improvement is noted, reinstall originals one at a time till waddle causal tire is found. If no
improvement is noted, install known good tires in place of all four. Then reinstall originals in the same manner
as above.

TIRE OUT

OF

ROUND

TIRE
STIFFNESS
VARIATION

RIM BENT

OR

OUT OF ROUND

SMOOTH ROAD

SUSPENSION MOVEMENT

(Loaded Runout)

Caused by

3-8 STEERING, SUSPENSION, WHEELS AND TIRES

RADIAL TIRE LEAD

“Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel.
Lead is usually caused by:

1) Incorrect alignment

2) Uneven brake adjustment

3) Tire construction
The way in which a tire is built can produce lead in a vehicle. An example of this is placement of the belt. Off center
belts on radial tires can cause the tire to develop a side force while rolling straight down the road. If one side of
the tire has a little larger diameter than the other, the tire will tend to roll to one side. This will develop a side force
which can produce vehicle lead.
The procedure in above figure (Lead Diagnosis) should be used to make sure that front alignment is not mistaken
for tire lead.

1) Part of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner and
service manuals. If a medium to high mileage tire is moved to the other side of the vehicle, be sure to check
that ride roughness has not developed.

2) Rear tires will not cause lead.

VIBRATION DIAGNOSIS

Wheel unbalance causes most of the highway speed vibration problems. If a vibration remains after dynamic bal­ancing, its possible causes are as follows.

1) Tire runout

2) Wheel runout

3) Tire stiffness variation

Measuring tire and/ or wheel free runout will uncover only part of the problem. All three causes, known as loaded
radial runout, must be checked by using a Tire Problem Detector (TPD). If TPD is not available, alternative method
of substituting known good tire and wheel assemblies on the problem vehicle can be used, although it takes a long­er time.

3A

FRONT END ALIGNMENT 3A-1

DIAGNOSIS SECTION 3. . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION 3A-1. . . . . . . . . . . . . .

Toe Setting 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . .

Camber 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preliminary Checks Prior to Adjusting

Front Alignment 3A-2. . . . . . . . . . . . . . . . . . . . .

Toe Adjustment 3A-2. . . . . . . . . . . . . . . . . . . . . .

Camber and Caster Adjustment 3A-2. . . . . . . .

Steering Angle 3A-3. . . . . . . . . . . . . . . . . . . . . . .

FORWARD “A”

CENTER LINE
OF WHEEL

WHEEL TOE-IN

TOP VIEW

“B”

“B” – “A” = Toe-in

Body
Center

CAMBER ANGLE

90_

POSITIVE
CAMBER

Alignment service data

Toe-in

–3.0 ± 1 mm

(–0.118 ± 0.039 in.)

Camber

Caster

Kingpin
inclination

–0_20’ ± 1_

3_40’ ± 1_

11_50’ ± 1_

NOTE:
Toe-in value given above was mea­sured by using a toe-in gauge.

SECTION 3A

FRONT END ALIGNMENT

CONTENTS

GENERAL DESCRIPTION

Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts
and the ground. Generally, the only adjustment required for front alignment is toe setting.
Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the damage
caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be deter­mined. If the body is damaged, it should be repaired and if suspension is damaged, it should be replaced.

TOE SETTING

Toe is the turning in or out of the front wheels. The purpose of a toe specification is to ensure parallel rolling of the
front wheels (Excessive toe-in or toe-out may increase tire wear).
Amount of toe can be obtained by subtracting “A” from “B” as shown in above figure and therefore is given in mm
(in.).

CAMBER

Camber is the tilting of the front wheels from the vertical, as viewed from the front of the vehicle. When the wheels
tilt outward at the top, the camber is positive. When the wheels tilt inward at the top, the camber is negative. The
amount of tilt is measured in degrees.