Suzuki Ignis 2000, Ignis User Manual

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MANUAL LIST

HOW TO FIND APPLICABLE MANUALS

1. Identify the model category which contains the VIN of the vehicle under repair.

Refer to the “VIN TABLE”

2. Refer to the corresponding service manuals in the Applicable Manual Group column.

The numbers shown in the column show manual group in the “MANUAL LIST”.

3. Search necessary information in the reverse order of manual group number.

Model Category Language

Model A
IGNIS
(RM413)
2003-

Model B
IGNIS
(RM415)
2003-

Model C
IGNIS
(RM413D)
2003-

E, F, G, D, B, S

E, F, G, D, B, S

E, F, G, D, B, S

Applicable Manual Group (NO. : (1) - (4))

Service Manual

(1) (4)

(1),(2)

(1),(2),(3),(5)

Wiring Diagram Manual

(4)

(4)

VIN TABLE

E BDF

English ItalianDutchFrench German Spanish

G

S

MANUAL LIST

TOP

Manual

Group

(1)

(2)

Manual Part Name Manual Part Number

IGNIS
(RM413)
Service Manual

IGNIS
(RM415/RM413D)
Supplementary Service Manual

Language

E

F

G

D

B

S

E

F

G

D

B

99500U86G00-01E

99500U86G00-01F

99500U86G00-01G

99500U86G00-01D

99500U86G00-01B

99500U86G00-01S

99501U86G10-01E

99501U86G10-01F

99501U86G10-01G

99501U86G10-01D

99501U86G10-01B

(3)

(4)

()5

IGNIS/wagon R+
(RM413D/RB413D)
Supplementary Service Manual

IGNIS (RM413/415/413D)
Wiring Diagram Manual

IGNIS/wagon R+
(RM413D/RB413D)
Supplementary Service Manual

S

E

F

G

D

B

S

E,F,G,D,B,S

E

F

G

D

99501U86G10-01S

99501U86G20-01E

99501U86G20-01F

99501U86G20-01G

99501U86G20-01D

99501U86G20-01B

99501U86G20-01S

99512U86G20-669

99501U86G30-01E

99501U86G30-01F

99501U86G30-01G

99501U86G30-01D

B

S

E BDF

English ItalianDutchFrench German Spanish

HOW TO FIND APPLICABLE MANUALS

G

99501U86G30-01B

99501U86G30-01S

S

VIN TABLE

Model A:

The VIN within the range shown in the table are categorized as “Model A”

TSMMHY51S00100001 ~
TSMMHX51S00100001 ~

Model B:

The VIN within the range shown in the table are categorized as “Model B”

TSMMHY81S00100001 ~
TSMMHX81S00100001 ~

Model C:

The VIN within the range shown in the table are categorized as “Model C”

TSMMHX91S00100001 ~

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MANUAL LIST

HOW TO APPLICABLE

SERVICE MANUAL

SERVICE MANUAL

99500-80G00-01E

99500-80G00-01E

D

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words

WARNING, CAUTION

these signal words.

WARNING:

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

CAUTION:

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

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.

and

NOTE

have special meanings. Pay special attention to the messages highlighted by

WARNING:

For vehicles equipped with a Supplemental Restraint (Air Bag) System:

• Service on and around the air bag system components or wiring must be performed only by an
authorized 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.

• 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.

• Do not modify the steering wheel, instrument 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.

• 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 (air bag (inflator) modules, SDM and/or seat belt
with pretensioner) beforehand to avoid component damage or unintended activation.

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: RG413

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.

RG413 Wiring Diagram Manual 99512-80G00-015

© COPYRIGHT SUZUKI MOTOR CORPORATION 2000

TABLE OF CONTENTS

GENERAL INFORMATION ENGINE 0A 6

General Information
Maintenance and Lubrication

HEATING AND AIR CONDITIONING

Heater and Ventilation
Air Conditioning

STEERING, SUSPENSION, WHEELS
AND TIRES

Steering, Suspension, Wheels and Tires
Front End Alignment
Manual Rack and Pinion
Power Steering System
Steering Wheel and Column
Front Suspension
Rear Suspension
Wheels and Tires

DRIVE SHAFT AND PROPELLER SHAFT

Front Drive Shaft
Propeller Shaft

BRAKE SYSTEM

Brakes
Antilock Brake System

0A
0B

1A
1B

3
3A
3B TRANSMISSION, CLUTCH AND

3B1

3C
3D
3E
3F

4A ELECTRICAL SYSTEM
4B

5
5E BODY SERVICE 9

General Information and Diagnosis
Engine Mechanical
Engine Cooling
Engine Fuel
Engine and Emission Control System
Ignition System
Cranking System
Charging System
Exhaust System

DIFFERENTIAL

Manual Transmission
Automatic Transmission
Clutch
Transfer
Differential (Rear)(4WD)

Body Electrical System
Wiring Diagram
Immobilizer Control System (if equipped)

RESTRAINT SYSTEM

Restraint System
Air Bag System (if equipped)

6

6A1

6B

6C
6E1
6F1 3 6G

6G

6H

6K

7A 3E 7C

7B

7C

7D

7F

8
8A 5E
8G

10

10B

0B 6A1

6B
1A 6C
1B 6E1

6F1

3A 6H
3B 6K

3B1 6B

3C 7A
3D 7B

3F 7D

7F
4A
4B 8

8A

5 8G

10

10B

9

NOTE:

The screen toned Section 8A is in Wiring Diagram Manual mentioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

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

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

PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT

(AIR BAG) SYSTEM .....................................0A-3

DIAGNOSIS .............................................. 0A-3

SERVICING AND HANDLING ..................0A-4

GENERAL PRECAUTIONS .......................... 0A-6

PRECAUTIONS FOR CATALYTIC

CONVERTER................................................0A-9

PRECAUTION FOR INSTALLING MOBILE

COMMUNICATION EQUIPMENT.................0A-9

PRECAUTION IN SERVICING FULL-TIME

4WD VEHICLE ............................................0A-10

PRECAUTIONS FOR ELECTRICAL

CIRCUIT SERVICE .....................................0A-11

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE ............................................. 0A-13

OPEN CIRCUIT CHECK .........................0A-13

CONTINUITY CHECK .............................0A-14

VOLTAGE CHECK .................................. 0A-15

CONTENTS

INTERMITTENT AND POOR

CONNECTION ............................................ 0A-16

IDENTIFICATION INFORMATION................. 0A-18

VEHICLE IDENTIFICATION NUMBER ...... 0A-18

ENGINE IDENTIFICATION NUMBER ........ 0A-18

TRANSMISSION IDENTIFICATION

NUMBER .................................................... 0A-18

WARNING, CAUTION AND INFORMATION

LABELS.......................................................... 0A-19

VEHICLE LIFTING POINTS ...........................0A-20

ABBREVIATIONS AND SYMBOLS MAY

BE USED IN THIS MANUAL.......................... 0A-22

FASTENER INFORMATION .......................... 0A-25

METRIC FASTENERS................................ 0A-25

FASTENER STRENGTH

IDENTIFICATION ....................................... 0A-25

STANDARD TIGHTENING TORQUE......... 0A-25

SHORT CIRCUIT CHECK (WIRE

HARNESS TO GROUND)....................... 0A-16

0A

6F2

6G
6H
6K

7A
7A1
7B1
7C1

7D

7E

7F

8A

8B

8C

8D

8E

9

10
10A
10B

0A-2 GENERAL INFORMATION

HOW TO USE THIS MANUAL

1) There is a “TABLE OF CONTENTS” 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 the figure.

4) A number of abbreviations and symbols are used in the text.For their full explanations, refer to “ABBREVIA­TIONS AND SYMBOLS MAY BE USED IN THIS MANUAL” in 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 TOOL”, “REQUIRED SERVICE MATERIAL”
and “TIGHTENING TORQUE SPECIFICATION” that should be used for the servicing work described in that
section.

GENERAL INFORMATION 0A-3

PRECAUTIONS

PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM

WARNING:

• 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

5

1

6

3

2

4

4

system activation, personal injury, damage to parts or
air bag system being unable to activate when neces­sary.

• 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.

• 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.

• 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.

1. Air bag wire harness 4. Seat belt pretensioner

2. Passenger air bag (inflator) module 5. Contact coil

3. SDM 6. Driver air bag (inflator) module

DIAGNOSIS

• 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.

• 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.

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

• 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.

• 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.

• Never dispose of live (undeployed) air bag (inflator)
modules (driver and passenger). If disposal is neces­sary, be sure to deploy them according to deployment
procedures described in SECTION 10B before dis­posal.

• The air bag (inflator) module immediately after deploy­ment is very hot. Wait for at least half an hour to cool it
off before proceeding the work.

• 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.

[A] : ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG

OPENING) AWAY FROM BODY.

[B] : 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

GENERAL INFORMATION 0A-5

WARNING:

SDM

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

• During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM).
Never strike or jar the SDM.

• Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and
mounting bracket 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
(If equipped)

• 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.

• Never carry seat belt pretensioner by wire or connec­tor of pretensioner. When placing a live seat belt pre­tensioner on the workbench or some place like that, be
sure not to lay it with its exhaust hole (1) provided side
facing down. It is also prohibited to put something on
its face with an exhaust hole or to put a seat belt pre­tensioner on top of another. Otherwise, personal injury
may result.

• Never dispose of live (inactivated) seat belt pretension­ers (drive and passenger). If disposal is necessary, be
sure to activate them according to activation proce­dures described in SECTION 10B before disposal.

• The seat belt pretensioner immediately after activation
is very hot. Wait for at least half an hour to cool it off
before proceeding the work.

• With many service procedures, gloves and safety
glasses should be worn to prevent any possible irrita­tion of the skin or eyes.

• 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.

• When servicing parts other than air bag system, if shocks may be applied to air bag system compo­nent parts, remove those parts beforehand.

• 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, never attempt disassembly or repair but replace it with a new one.

• When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and pas­senger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth.

0A-6 GENERAL INFORMATION

• Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very
careful when handling it.

• When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.

• Do not apply power to the air bag system unless all components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.

• Never use air bag system component parts from another vehicle.

• When using electric welding, be sure to temporarily disable air bag system referring to “DISABLING
AIR BAG SYSTEM” in Section 10B.

• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.

• WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to fol­low the instructions.

• After vehicle is completely repaired, perform “AIR BAG DIAGNOSTIC SYSTEM CHECK” in SECTION
10B.

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:

• Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” in this section.

• 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.

• When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

• 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.

• To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail
pipe, muffler, etc.

• New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory 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 dish washing 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.

• Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpect­edly during driving, obstructing your view and resulting in an accident.

GENERAL INFORMATION 0A-7

• 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.

• When performing service to electrical parts that does
not require use of battery power, disconnect the nega­tive cable of the battery.

• When removing the battery, be sure to disconnect the
negative 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.

• 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.

• Whenever you use oil seals, gaskets, packing, O-rings,
locking washers, split pins, self-locking nuts, and cer­tain other parts as specified, be sure to use new ones.
Also, before installing new gaskets, packing, etc., be
sure to remove any residual material from the mating
surfaces.

0A-8 GENERAL INFORMATION

• Make sure that all parts used in reassembly are perfectly
clean.
When use of a certain type of lubricant, bond or sealant
is specified, be sure to use the specified type.

“A” : Sealant 99000-31150

• Be sure to use special tools when instructed.

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

• When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that the
hoses can be reinstalled correctly.

• After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system for
leaks.

• For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and
injector without first releasing the fuel pressure, or fuel
can be sprayed out under pressure.

• When performing a work that produces a heat exceeding
80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.

GENERAL INFORMATION 0A-9

• Use care not to expose connectors and electrical parts
to water which will be a cause of a trouble.

• Always be careful not to handle electrical parts (com­puter, relay, etc.) in a rough manner or drop them.

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.)

PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT

When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-tele­phone, be sure to observe the following precautions.
Failure to follow cautions may adversely affect electronic control system.

• Keep the antenna as far away as possible from the vehicle’s electronic control unit.

• Keep the antenna feeder more than 20 cm (7.9 in) away from electronic control unit and its wire har­nesses.

• Do not run the antenna feeder parallel with other wire harnesses.

• Confirm that the antenna and feeder are correctly adjusted.

0A-10 GENERAL INFORMATION

PRECAUTION IN SERVICING FULL-TIME 4WD
VEHICLE

This full-time 4WD vehicle can not be converted to 2WD man­ually.
Observe the following caution in servicing. Otherwise, front
wheels drive rear wheels or vise-versa and vehicle acci­dents, drivetrain damage and personal injury may result.

• Never perform any of the following types of service
work.
[A] : Testing with 2-wheel chassis dynamometer, speed­ometer tester or brake tester.
[B] : Driving front wheels, which are jacked up.
[C] : Towing under the condition where either front or
rear wheels can not rotate.

• When testing with 2-wheel chassis dynamometer,
speedometer tester or brake tester, be sure to make the
vehicle as front wheel drive by removing propeller shaft.

• When using On-vehicle type wheel balancing equipment
(1), be sure to jack up all four wheels, off the ground
completely and support vehicle with safety stands (2).
Be careful of the other wheels, which will rotate at the
same time.

• This vehicle should be towed under one of the following
conditions :

– With all wheels on a flatbed truck.
– With front or rear wheels lifted and a dolly under the

other wheels.

GENERAL INFORMATION 0A-11

PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE

• When replacing a fuse, make sure to use a fuse of the
specified capacity. Use of a fuse with a larger capacity
will cause a damage to the electrical parts and a fire.

• When disconnecting and connecting coupler, make sure
to turn ignition switch OFF, or electronic parts may get
damaged.

• When disconnecting connectors, never pull the wiring
harness. Unlock the connector lock first and then pull
them apart by holding connectors themselves.

• When connecting connectors, also hold connectors and
put them together until they lock securely (a click is
heard).

0A-12 GENERAL INFORMATION

• When installing the wiring harness, fix it with clamps so
that no slack is left.

• When installing vehicle parts, be careful so that the wir­ing harness is not interfered with or caught by any other
part.

• To avoid damage to the harness, protect its part which
may contact against a part forming a sharp angle by
winding tape or the like around it.

• 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.

• 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.

• 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.

Be sure to use a specified voltmeter/ohmmeter. Other-

•

wise, accurate measurements may not be obtained or
personal injury may result. If not specified, use a volt­meter with high impedance (M

V minimum) or a digital

Ω/

Ω/

Ω/Ω/

type voltmeter.

GENERAL INFORMATION 0A-13

• 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).

• When connecting meter probe (2) from terminal side of
coupler (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 male terminal is supposed
to fit.

• 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.

• Before measuring voltage at each terminal, check to
make sure that battery voltage is 11 V 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.

• Loose connection of connector

• Poor contact of terminal (due to dirt, corrosion or rust on it,

poor contact tension, entry of foreign object etc.)

• Wire harness being open

0A-14 GENERAL INFORMATION

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.

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

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

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)

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.

GENERAL INFORMATION 0A-15

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 C­1 or an abnormality in connector-B.

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.

a) If measurements were taken as shown in the figure 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. 5 V
B-1 and body ground : Approx. 5 V
A-1 and body ground : 0 V

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

0A-16 GENERAL INFORMATION

SHORT CIRCUIT CHECK (WIRE HARNESS TO
GROUND)

1) Disconnect negative (–) cable at 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
(1), 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 the 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.

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.

1. To other parts

INTERMITTENT AND POOR CONNECTION

Most intermittent 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 :

• Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).

• 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.

• Damaged connector body, exposing the terminals to mois­ture and dirt, as well as not maintaining proper terminal ori­entation with the component or mating connector.

GENERAL INFORMATION 0A-17

• 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.

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

2. Check each terminal for bend and proper alignment.

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

• Wire insulation which is rubbed through, causing an intermit­tent short as the bare area touches other wiring or parts of
the vehicle.

• 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.

0A-18 GENERAL INFORMATION

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

The number is punched on front dash panel in engine room.

ENGINE IDENTIFICATION NUMBER

The number is punched on cylinder block.

TRANSMISSION IDENTIFICATION NUMBER

The automatic transmission identification number is located on
transmission case.

GENERAL INFORMATION 0A-19

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.

1. Air bag label on back side of engine hood (if equipped)

2. Air bag label on sun visor (if equipped)

3. Radiator cap label

4. Engine cooling fan label

5

1. Air bag label on driver air bag (inflator) module 4. Air bag label on SDM

2. Air bag label on combination switch and contact coil assembly 5. Pretensioner label on seat belt retractor

3. Air bag label on passenger air bag (inflator) module [A] : These labels are attached on vehicle equipped with air bag system only.

0A-20 GENERAL INFORMATION

VEHICLE LIFTING POINTS

WARNING:

• Before applying hoist to underbody, always take vehicle balance throughout service into consider­ation. Vehicle balance on hoist may change depending on what part to be removed.

• 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.

• When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by try­ing to move vehicle body in both ways. Work can be started only after this confirmation.

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

WHEN USING FRAME CONTACT HOIST

1. Vehicle front

2. Support position for frame contact hoist and safety stand

3. Floor jack position

4. Embossed-mark

GENERAL INFORMATION 0A-21

WHEN USING FLOOR JACK

WARNING:

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.

CAUTION:

Never apply jack against suspension parts (i.e., stabi­lizer, etc) or vehicle floor, or it may get deformed.

In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the front jacking bracket (1), the center por­tion of rear axle (2) (2WD vehicle) or rear axle housing (3) (4WD
vehicle).

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

[A] : Front

[B] : Rear

2. Embossed mark

0A-22 GENERAL INFORMATION

ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL

ABBREVIATIONS

ABS Anti-lock Brake System
ATDC After Top Dead Center
API American Petroleum Institute
ATF Automatic Transmission Fluid EPS Electronic Power Steering
ALR Automatic Locking Retractor EVAP Evaporative Emission
AC Alternating Current EVAP Canister Evaporative Emission Canister

A

A/T Automatic Transmission
A/C Air Conditioning
ABDC After Bottom Dead Center GND Ground
A/F Air Fuel Mixture Ratio
A-ELR Automatic-Emergency Locking

Retractor

B+ Battery Positive Voltage

B

BTDC Before Top Dead Center
BBDC Before Bottom Dead Center IAT Sensor Intake Air Temperature Sensor
CKT Circuit
CKP sensor Crankshaft Position Sensor ICM Immobilizer Control Module
CMP sensor Camshaft Position Sensor IG Ignition
CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator

C

CPP switch Clutch Pedal Position Switch

(Clutch Switch, Clutch Start

Switch)
CPU Central Processing Unit
CRS Child Restraint System
DC Direct Current
DLC Data Link Connector (Assembly

Line Diag. Link, ALDL, Serial Data

Link, SDL)

D

DOHC Double Over Head Camshaft MFI Multiport Fuel Injection
DOJ Double Offset Joint
DRL Daytime Running Light MIN Minimum
DTC Diagnostic Trouble Code (Diag-

nostic Code)
EBCM Electronic Brake Control Module,

ABS Control Module M/T Manual Transmission
EBD Electronic Brake Force Distribu-

tion
ECM Engine Control Module
ECT sensor Engine Coolant Temperature Sen-

E

EGR Exhaust Gas Recirculation OHC Over Head Camshaft
EGRT sensor EGR Temperature Sensor (Recir-

sor (Water Temp. Sensor, WTS)

culated Exhaust Gas Temp. Sen-

sor, REGTS)

EFE Heater Early Fuel Evaporation Heater

(Positive Temperature Coefficient,
PTC Heater)

E

(Charcoal Canister)

F

4WD 4 Wheel Drive
GEN Generator

G

HC Hydrocarbons

H

HO2S Heated Oxygen Sensor
IAC Valve Idle Air Control Valve (Idle Speed

Control Solenoid Valve ISC Sole­noid Valve)

I

LH Left Hand

L

LSPV Load Sensing Proportioning Valve

MAF Sensor Mass Air Flow Sensor (Air Flow

MAP Sensor Manifold Absolute Pressure Sen-

Max Maximum

M

MIL Malfunction Indicator Lamp

NOx Nitrogen Oxides

N

OBD On-Board Diagnostic System

O

O/D Overdrive

O2S Oxygen Sensor
PNP Park/Neutral Position

P

P/S Power Steering

(Air temperature Sensor, ATS)

Sensor, AFS, Air Flow Meter,
AFM)

sor (Pressure Sensor, PS)

(Multipoint Fuel Injection)

(“SERVICE ENGINE SOON”
Light)

(Self-Diagnosis Function)

PSP Switch Power Steering Pressure Switch

P

PCM Powertrain Control Module

(P/S Pressure Switch)

PCV Positive Crankcase Ventilation

R

RH Right Hand
SAE Society of Automotive Engineers
SDM Sensing and Diagnostic Module

(Air bag controller, Air bag con-

S

trol module)

SFI Sequential Multiport Fuel Injec-

tion
SOHC Single over Head Camshaft
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

T

TVV Thermal Vacuum Valve (Ther-

mal Vacuum Switching Valve,

TVSV, Bimetal Vacuum Switch-

ing Valve, BVSV)
TWC Three Way Catalytic Converter

(Three Way Catalyst)
2WD 2 Wheel Drive
VIN Vehicle Identification Number

V

VSS Vehicle Speed Sensor
WU-OC Warm Up Oxidation Catalytic

W

WU-TWC Warm Up Three Way Catalytic

Converter

Converter

GENERAL INFORMATION 0A-23

0A-24 GENERAL INFORMATION

SYMBOLS

SYMBOL DEFINITION SYMBOL DEFINITION

Tightening torque Apply SUZUKI BOND NO. 1216

99000-31160

Apply oil (engine, transmission, trans­fer, differential)

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

Apply SUZUKI SUPER GREASE A
99000-25010

Apply SUZUKI SUPER GREASE C
99000-25030

Apply SUZUKI SUPER GREASE E
99000-25050

Apply SUZUKI SUPER GREASE H
99000-25120

Apply SUZUKI SUPER GREASE I
99000-25210

Apply SUZUKI BOND NO. 1215
99000-31110

Apply SUZUKI BOND NO. 1207C
99000-31150

Apply SILICONE SEALANT
99000-31120

Apply SEALING COMPOUND 366E
99000-31090

Apply THREAD LOCK 1322
99000-32110

Apply THREAD LOCK 1333B
99000-32020

Apply THREAD LOCK 1342
99000-32050

Do not reuse

Note on reassembly

WIRE COLOR SYMBOLS

Symbol Wire Color Symbol Wire Color

B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White

GGRN Green Y YEL Yellow

Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure).

GENERAL INFORMATION 0A-25

FASTENER INFORMATION

METRIC FASTENERS

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

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.

Metric bolts : Identification class numbers or marks correspond to bolt strength (increasing numbers represent
increasing strength).

1. Nut strength identification

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:

• 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.

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

0A-26 GENERAL INFORMATION

Tightening torque chart :

A equivalent of 4T strength
fastener

Thread Diameter (Nominal Diameter) (mm)

4 5 6 8 10 12 14 16 18

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

Strength

A equivalent of 6.8 strength
fastener without flange

A equivalent of 6.8 strength
fastener with flange

A equivalent of 7T strength
fastener

A equivalent of 8.8 strength
fastener without flange

N·m 2.4 4.7 8.4 20 42 80 125 193 280

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

N·m 2.4 4.9 8.8 21 44 84 133 203 298

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

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

N·m 3.1 6.3 11 27 56 105 168 258 373

A equivalent of 8.8 strength
fastener with flange

✱: Self-lock nut

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

N·m 3.2 6.5 12 29 59 113 175 270 395

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

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System:

• Service on and around the air bag system components or wiring must be performed only by an

authorized 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.

• 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 SCHEDULE UNDER

NORMAL DRIVING CONDITIONS .............. 0B-2

MAINTENANCE RECOMMENDED UNDER

SEVERE DRIVING CONDITIONS ............... 0B-4

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

ENGINE ....................................................... 0B-5

DRIVE BELT ............................................ 0B-5

VALVE LASH (CLEARANCE) .................. 0B-6

ENGINE OIL AND OIL FILTER ................ 0B-6

ENGINE COOLANT ................................. 0B-8

EXHAUST SYSTEM............................... 0B-10

IGNITION SYSTEM ................................... 0B-10

SPARK PLUGS ...................................... 0B-10

FUEL SYSTEM .......................................... 0B-10

AIR CLEANER FILTER .......................... 0B-10

FUEL LINES AND CONNECTIONS....... 0B-11

FUEL FILTER ......................................... 0B-11

FUEL TANK............................................ 0B-12

EMISSION CONTROL SYSTEM ............... 0B-12

PCV VALVE ........................................... 0B-12

FUEL EVAPORATIVE EMISSION

CONTROL SYSTEM .............................. 0B-12

BRAKE ....................................................... 0B-12

BRAKE DISCS AND PADS (FRONT).... 0B-12

BRAKE DRUMS AND SHOES

(REAR)................................................... 0B-13

BRAKE HOSES AND PIPES ................. 0B-13

BRAKE FLUID........................................ 0B-13

BRAKE LEVER AND CABLE................. 0B-13

CHASSIS AND BODY ............................... 0B-14

CLUTCH................................................. 0B-14

TIRES / WHEELS .................................. 0B-14

SUSPENSION SYSTEM........................ 0B-15

STEERING SYSTEM ............................. 0B-15

DRIVE SHAFT (AXLE) BOOTS /

PROPELLER SHAFTS (4WD) ............... 0B-16

MANUAL TRANSMISSION OIL ............. 0B-17

AUTOMATIC TRANSMISSION FLUID .. 0B-17
TRANSFER OIL (4WD) AND REAR

DIFFERENTIAL OIL (4WD) ................... 0B-18

ALL LATCHES, HINGES AND

LOCKS ................................................... 0B-19

FINAL INSPECTION ..................................... 0B-19

RECOMMENDED FLUIDS AND

LUBRICANTS................................................ 0B-21

0A 6F1
0B

1A 6H
1B 6K

37A

3A 7A1
3B1 7B1
3C1 7C1

3D 7D

3E 7E

3F 7F

4A2 8A

4B 8B

58D
5A 8E
5B
5C 9
5E

5E1 10

610B

6-1
6A1
6A2
6A4

6B

6C
6E1
6E2

0B
6G

8C

10A

0B-2 MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS

NOTE:

• This interval should be judged by odometer reading or months, whichever comes first.

• This table includes service 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.

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

Interval

ENGINE

Drive belt –– I ––R
Valve lash (clearance) – I – I – I
Engine oil and oil filter R R R R R R
Engine coolant ––R ––R
Exhaust system – I – I – I

IGNITION SYSTEM

✱Spark plugs When

unleaded
fuel is used

When leaded fuel is used, refer to “MAINTENANCE RECOMMENDED UNDER SEVERE
DRIVING CONDTION” in this section.

FUEL SYSTEM

Air cleaner filter Paved-road I I R I I R

Fuel lines and connections – I – I – I
Fuel filter Replace every 105,000 km (63,000 miles)
Fuel tank –– I –– I

EMISSION CONTROL SYSTEM

✱PCV valve Vehicle without HO2S –– I –– I

✱Fuel evaporative emission control system ––––– I

Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72

Vehicle without
HO2S
Vehicle with

HO2S

Vehicle with HO2S ––––– I

Nickel plug – R – R – R
Iridium plug –––R ––
Nickel plug ––R ––R
Iridium plug Replace every 105,000 km (63,000 miles) or

84 months

Dusty conditions Refer to “MAINTENANCE RECOM-

MENDED UNDER SEVERE DRIVING CON­DITIONS” in this section.

NOTE:

• “R” : Replace or change

• “I” : Inspect and correct, replace or lubricate if necessary

• For Sweden, items with

• For spark plugs, replace every 50,000 km if the local law requires.

• Nickel spark plug : BKR6E-11 (NGK) or K20PR-U11 (DENSO)

• Iridium spark plug : IFR5E11 (NGK)

(asterisk) should be performed by odometer reading only.

✱✱✱✱

MAINTENANCE AND LUBRICATION 0B-3

Km (x 1,000) 153045607590

Interval

Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72

BRAKE

Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage) – I – I – I
Brake hoses and pipes (leakage, damage, clamp) – I – I – I
Brake fluid – R – R – R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles only)

CHASSIS AND BODY

Clutch (pedal height and travel) – I – I – I
Tires (wear, damage, rotation) /wheels (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage) – I – I – I
Steering system (tightness, damage, breakage, rattle) – I – I – I
Drive shaft (axle) boots/Propeller shafts (4WD) –– I –– I
Manual transmission oil (leakage, level) (I : 1st 15,000 km only) I – R ––R
Automatic transmission
fluid

Fluid level – I – I – I

Fluid change Replace every 165,000 km (99,000 miles)
Transfer oil (4WD) (leakage, level) I – I – I –
Rear differential oil (4WD) (leakage, level) (R : 1st 15,000 km
only)

R or I – I – I –

All latches, hinges and locks – I – I – I

NOTE:

• “R” : Replace or change

• “I” : Inspect and correct or replace if necessary

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 shown in the
following table.

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
F : Leaded fuel use
G : – – – – –
H : Towing a trailer (if admitted)

Severe

Condition Code

– B C D – – – – Drive belt

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

– – C – – – – – Air cleaner filter ✱1

A B C – E F – H Spark plugs

– B C D – – – H Wheel bearings I

– B – D E – – H Drive shafts and propeller shafts (4WD) I

– B – – E – – H

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

Manual transmission, transfer (4WD) and
differential oil (4WD)

Maintenance

Nickel spark plug

Iridium spark plug

Maintenance

Operation

Maintenance Interval

I

R

I

R

R

R

R

Every 15,000 km
(9,000 miles) or 12 months
Every 45,000 km
(27,000 miles) or 36 months
Every 5,000 km
(3,000 miles) or 4 months
Every 2,500 km
(1,500 miles)
Every 30,000 km
(18,000 miles) or 24 months
Every 10,000 km
(6,000 miles) or 8 months
Every 30,000 km
(18,000 miles) or 24 months
Every 15,000 km
(9,000 miles) or 12 months
Every 15,000 km
(9,000 miles) or 12 months
Every 30,000 km
(18,000 miles) or 24 months
Every 30,000 km
(18,000 miles) or 24 months

NOTE:

• “I” : Inspect and correct or replace if necessary

• “R” : Replace or change

•

1 : Inspect more frequently if the vehicle is used under dusty conditions.

✱✱✱✱

MAINTENANCE SERVICE

ENGINE

DRIVE BELT

WARNING:

All inspection and replacement are to be performed with
ENGINE NOT RUNNING.

WATER PUMP AND GENERATOR DRIVE BELT INSPEC­TION

1) Disconnect negative (–) cable at battery.

2) Inspect belt for cracks, cuts, deformation, wear and cleanli­ness. If any defect exists, replace.
Check belt for tension.

Water pump and generator belt tension
“a” : 4.5 - 5.5 mm (0.18 - 0.22 in.) deflection under 100 N
(10 kg, 22 lb) pressure

MAINTENANCE AND LUBRICATION 0B-5

NOTE:

When replacing belt with a new one, adjust belt tension
to 3 - 4 mm (0.12 - 0.16 in.)

3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.

4) Tighten alternator adjusting bolts and pivot bolt.

5) Connect negative (–) cable to battery.

WATER PUMP AND GENERATOR DRIVE BELT REPLACE­MENT

Replace belt with new one referring to “WATER PUMP BELT” in
Section 6B.

0B-6 MAINTENANCE AND LUBRICATION

A/C COMPRESSOR DRIVE BELT (IF EQUIPPED) INSPEC­TION

1) Disconnect negative (–) cable at battery.

2) Inspect belt for cracks, cuts, deformation, wear and cleanli­ness. If any defect exists, replace.
Check belt for tension.
If belt tension is out of specification, adjust it referring to
“COMPRESSOR DRIVE BELT” in Section 1B.

A/C compressor drive belt tension
“a” : 3 - 5 mm (0.12 - 0.20 in.) deflection under 100 N
(10 kg, 22 lb) pressure

3) Connect negative (–) cable to battery.

REPLACEMENT

Replace belt with new one referring to “COMPRESSOR DRIVE
BELT” in Section 1B.

VALVE LASH (CLEARANCE)

INSPECTION

1) Inspect intake and exhaust valve lash and adjust as neces­sary.
Refer to “VALVE LASH” in Section 6A1 for valve lash
inspection and adjustment procedure.

1. Camshaft

2. Thickness gauge

ENGINE OIL AND OIL FILTER

REPLACEMENT

WARNING:

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

• Step 1) - 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

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 the following work.

MAINTENANCE AND LUBRICATION 0B-7

1) Drain engine oil by removing drain plug.

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

Tightening torque
Engine oil drain plug (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)

3) Loosen oil filter by using oil filter wrench (special tool).

Special tool
(A) : 09915-47330

NOTE:

Before fitting new oil filter, be sure to oil its O-ring. Use
engine oil for this purpose.

4) Screw new filter on oil filter stand by hand until the filter O­ring contacts the mounting surface.

CAUTION:

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

5) Tighten the filter (1) 3/4 turn from the point of contact with
the mounting surface using an oil filter wrench (2).

Tightening torque
Oil filter (b) : 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference)

0B-8 MAINTENANCE AND LUBRICATION

6) Replenish oil until oil level is brought to FULL level mark on
dipstick. (oil pan and oil filter capacity). The filler inlet is at
the top of the cylinder head cover.
It is recommended to use engine oil of SE, SF, SG, SH or SJ
grade. Select the appropriate oil viscosity according to the
proper engine oil viscosity chart [A].

NOTE:

For ambient temperature between –20°C (–4°F) and 30°C
(86°F), it is highly recommended to use SAE 10W – 30 oil.

Engine oil specification

Oil pan capacity About 3.6 liters (7.6/6.3 US/lmp pt.)
Oil filter capacity About 0.2 liter (0.4/0.3 US/lmp pt.)
Others About 0.3 liter (0.6/0.5 US/lmp pt.)
Total About 4.1 liters (8.7/7.2 US/lmp pt.)

NOTE:

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

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

8) Start engine and run it for 3 minutes. Stop it and wait 5 min­utes before checking oil level. Add oil, as necessary, to bring
oil level to FULL level mark on dipstick.

1. Full level mark (hole)

2. Low level mark (hole)

ENGINE COOLANT

REPLACEMENT

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.

MAINTENANCE AND LUBRICATION 0B-9

CAUTION:

When changing engine coolant, use mixture of 50% water
and 50% ANTIFREEZE/ANTICORROSION COOLANT for
the market where ambient temperature falls lower than –
16°C (3°F) in winter, and mixture of 70% water and 30%
ANTIFREEZE/ANTICORROSION 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% ANTIFREEZE/ANTI­CORROSION COOLANT should be used for the purpose
of corrosion protection and lubrication.

1) Remove radiator cap when engine is cool.

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

3) Remove reservoir and drain.

4) Tighten plug securely. Also reinstall reservoir.

5) Fill radiator with specified amount of coolant, and run engine
for 2 or 3 minutes at idle. This drives out any air which may
still be trapped within cooling system. STOP ENGINE.
Add coolant as necessary until coolant level reaches the
filler throat of radiator. Reinstall radiator cap.

6) Add coolant to reservoir so that its level aligns with Full
mark. Then, reinstall cap aligning arrow marks on reservoir
and cap.

1. Reservoir

2. Reservoir cap

3. FULL level marks

4. Arrow marks

0B-10 MAINTENANCE AND LUBRICATION

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 the vehicle is raised
for other service, check exhaust system as follows:

• Check rubber mountings for damage, deterioration, and out
of position.

• Check exhaust system for leakage, loose connections, dents
and damages.
If bolts or nuts are loose, tighten them to specification.

• 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 the
vehicle.

• Make sure that exhaust system components have enough
clearance from the underbody to avoid overheating and pos­sible damage to the floor carpet.

• Any defects should be fixed at once.

IGNITION SYSTEM

SPARK PLUGS

REPLACEMENT

Replace spark plugs with new ones referring to “SPARK PLUG”
in Section 6F1.

FUEL SYSTEM

AIR CLEANER FILTER

INSPECTION

1) Remove air cleaner case clamps.

2) Take air cleaner filter out of case.

3) Check that filter is not excessively dirty, damaged or oily,
clean filter with compressed air from air outlet side of filter.

MAINTENANCE AND LUBRICATION 0B-11

4) Install air cleaner filter fitting protrusion (1) of filter into
groove (2) of case and clamp upper case securely.

REPLACEMENT

Replace air cleaner filter with new one according to steps 1), 2)
and 4) of inspection procedure.

FUEL LINES AND CONNECTIONS

INSPECTION

Visually inspect fuel lines and connections for evidence of fuel
leakage, hose cracking and damage. Make sure all clamps are
secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.

FUEL FILTER

REPLACEMENT

WARNING:

This work must be performed in a well ventilated area
and away from any open flames (such as gas hot water
heaters).

Fuel filter (1) is installed in fuel pump assembly (2) in fuel tank.
Replace fuel filter with new one, referring to “FUEL PUMP
ASSEMBLY” in Section 6C for proper procedure.

0B-12 MAINTENANCE AND LUBRICATION

FUEL TANK

INSPECTION

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

EMISSION CONTROL SYSTEM

PCV VALVE

INSPECTION

Check crankcase ventilation hose and PCV hose for leaks, cracks
or clog, and PCV valve for stick or clog. Refer to “PCV SYSTEM”
of Section 6E1 for PCV valve checking procedure.

FUEL EVAPORATIVE EMISSION CONTROL SYSTEM

INSPECTION

1) Visually inspect hoses for cracks, damage, or excessive
bends. Inspect all clamps for damage and proper position.

2) Check EVAP canister for operation and clog, referring to
“EVAP CONTROL SYSTEM” in Section 6E1.

If a malfunction is found, repair or replace.

BRAKE

BRAKE DISCS AND PADS (FRONT)

INSPECTION

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
details, refer to “FRONT DISC BRAKE PAD” in Section 5.
Be sure to torque caliper pin bolts to specification.

MAINTENANCE AND LUBRICATION 0B-13

BRAKE DRUMS AND SHOES (REAR)

INSPECTION

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 leaks. Replace
these parts as necessary.
For details, refer to “BRAKE DRUM” in Section 5.

BRAKE HOSES AND PIPES

INSPECTION

Perform this inspection where these is enough light and use a
mirror as necessary.

• Check brake hoses and pipes for proper hookup, leaks,
cracks, chafing and other damage.

• Check that hoses and pipes are clear of sharp edges and
moving parts.

Repair or replace any of these parts as necessary.

CAUTION:

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

BRAKE FLUID

REPLACEMENT

Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
specified fluid and carry out air purge operation.
For air purging procedure, refer to “BLEEDING BRAKES” in Sec­tion 5.

BRAKE LEVER AND CABLE

INSPECTION

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

0B-14 MAINTENANCE AND LUBRICATION

2) Check tooth tip of each notch for damage or wear. If any
damage or wear is found, replace parking lever.

3) 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 5.

Parking brake lever stroke
“a” :4 - 9 notches (with 20 kg (44 lbs) of pull pressure)

CHASSIS AND BODY

CLUTCH

INSPECTION

Check clutch pedal for height and free travel (1) referring to
“CLUTCH PEDAL HEIGHT CHECK” and “CLUTCH PEDAL
FREE TRAVEL CHECK” in Section 7C. Adjust or correct if neces­sary.

TIRES / WHEELS

TIRES INSPECTION

1) Check tires for uneven or excessive wear, or damage.
If defective, replace.
Refer to “TIRE DIAGNOSIS” in Section 3 for details.

1. Wear indicator

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

NOTE:

• Tire inflation pressure should be checked when tires
are cool.

• Specified tire inflation pressure should be found on
tire placard or in owner’s manual which came with the
vehicle.

3) Rotate tires.
For details, refer to “TIRE ROTATION” in Section 3F.

MAINTENANCE AND LUBRICATION 0B-15

WHEEL DISCS INSPECTION

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

WHEEL BEARING INSPECTION

1) Check front wheel bearing for wear, damage, abnormal
noise or rattles. For details, refer to “WHEEL DISC, NUT
AND BEARING CHECK” in Section 3D.

2) Check rear wheel bearing for wear, damage, abnormal noise
or rattles. For details, refer to “WHEEL DISC, NUT AND
BEARING CHECK” in Section 3E.

SUSPENSION SYSTEM

INSPECTION

• 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.

• 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.

• Check front suspension arm ball joint stud dust seals for
leakage, detachment, tear or any other damage.
Replace defective boot, if any.

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.

0B-16 MAINTENANCE AND LUBRICATION

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

4) Check boots (1) and (2) of steering linkage and steering gear
case for damage (leak, 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 (3) 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.

DRIVE SHAFT (AXLE) BOOTS / PROPELLER SHAFTS
(4WD)

DRIVE SHAFT (AXLE) BOOTS INSPECTION

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

PROPELLER SHAFTS (4WD) INSPECTION

1) Check propeller shaft connecting bolts for looseness. If
looseness is found, tighten to specified torque.

2) Check propeller shaft joints for wear, play and damage.
If any defect is found, replace.

3) Check propeller shaft center support for biting of foreign mat­ter, crack, abnormal noise and damage. If any defect is
found, replace.

MAINTENANCE AND LUBRICATION 0B-17

MANUAL TRANSMISSION OIL

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 “MANUAL TRANSMISSION OIL
CHANGE” in Section 7A.

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

REPLACEMENT

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 “MANUAL TRANSMISSION OIL CHANGE” in Sec­tion 7A.

AUTOMATIC TRANSMISSION FLUID

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) Pull out dipstick and check fluid level.
For fluid level checking procedure, refer to “A/T FLUID
LEVEL” in Section 7B and be sure to perform it under speci­fied conditions. If fluid level is low, replenish specified fluid.

1. Dipstick

2. Clamp

3. FULL HOT mark

4. LOW HOT mark

0B-18 MAINTENANCE AND LUBRICATION

REPLACEMENT

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) Change fluid. For its procedure, refer to “CHANGING A/T
FLUID” in Section 7B.

1. Drain plug

TRANSFER OIL (4WD) AND REAR DIFFERENTIAL
OIL (4WD)

INSPECTION

1) Check transfer case or differential for evidence of oil leak­age.
Repair leaky point if any.

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

3) Remove level plug of transfer or differential and check oil
level.
Oil level can be checked roughly by means of 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 amount of specified
oil referring to “TRANSFER OIL CHANGE” in Section 7D or
“DIFFERENTIAL OIL CHANGE” in Section 7F.

[A] : Transfer

[B] : Rear differential

1. Oil level/filler plug

2. Drain plug

4) Tighten level plug to specified torque referring to “TRANS-
FER OIL CHANGE” in Section 7D or “CHANGING DIFFER­ENTIAL OIL” in Section 7F.

REPLACEMENT

Change transfer oil and differential oil with new specified oil refer­ring to “TRANSFER OIL CHANGE” in Section 7D or “DIFFEREN-
TIAL OIL CHANGE” in Section 7F.

MAINTENANCE AND LUBRICATION 0B-19

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.

FINAL INSPECTION

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. If “REPLACE BELT” label on front seat belt is visible, replace belt.

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 any other part.

0B-20 MAINTENANCE AND LUBRICATION

ENGINE START

Check engine start for readiness.

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 vehicle could
move without warning and possibly cause personal injury or property damage.

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 any try to start.

EXHAUST SYSTEM CHECK

Check for leakage, cracks or loose supports.

CLUTCH (FOR MANUAL TRANSMISSION)

Check for the following.

• Clutch is completely released when depressing clutch pedal,

• No slipping clutch occurs when releasing pedal and accelerating.

• 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.
With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting select
lever to “P” range position and release all brakes.

BRAKE

Foot Brake

Check the followings:

• that brake pedal has proper travel,

• that brake works properly,

• that it is free from noise,

• that vehicle does not pull to one side when brake is applied.

• and that brake do not drag.

Parking Brake

Check that lever has proper travel.

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.

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.

MAINTENANCE AND LUBRICATION 0B-21

STEERING

• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.

• Check that the vehicle does not wander or pull to one side.

ENGINE

• Check that engine responds readily at all speeds.

• Check that engine is free from abnormal noise and abnormal vibration.

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 mode control lever to defroster position and fan switch lever to “HI” position for this check.

RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil SE, SF, SG, SH or SJ grade (Refer to “ENGINE OIL AND OIL FILTER”

in this section for engine oil viscosity.)
Engine coolant
(Ethylene glycol base coolant)
Brake fluid DOT 3
Manual transmission oil Refer to “M/T OIL CHANGE” in Section 7A.
Transfer oil (4WD) Refer to “TRANSFER OIL CHANGE” in Section 7D.
Differential oil (4WD) Refer to “DIFFERENTIAL OIL CHANGE” in Section 7F.
Automatic transmission fluid

Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

“Antifreeze/Anticorrosion coolant”

An equivalent of DEXRON

®

-III

0B-22 MAINTENANCE AND LUBRICATION

HEATER AND VENTILATION 1A-1

SECTION 1A

HEATER AND VENTILATION

WARNING:

For vehicles equipped with Supplement Restraint (Air Bag) System

• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in Section 10B 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 Section 10B 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 or these two conditions may result
in severe injury.

• Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is 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.

6F1
6F2

6G

1A

6K

7A
7A1
7B1
7C1

7D

7E

7F

8A

8B

8C

8D

8E

9

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

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

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

WIRING CIRCUIT ........................................ 1A-4

ON-VEHICLE SERVICE .................................. 1A-5

HEATER UNIT ............................................. 1A-5

CONTENTS

BLOWER FAN MOTOR............................... 1A-7

BLOWER FAN MOTOR RESISTOR ........... 1A-8

HEATER CONTROL ASSEMBLY ............... 1A-9

AIR INLET BOX ......................................... 1A-12

VENTILATION LOUVER............................ 1A-13

REQUIRED SERVICE MATERIALS ............. 1A-14

10
10A
10B

1A-2 HEATER AND VENTILATION

GENERAL DESCRIPTION

1. Heater unit 5. Ventilation louver 9. Demister air 13. Heater core

2. Air inlet box 6. Ventilation air 10. Fresh air

3. Ventilator duct 7. Foot air 11. Recirculation air

4. Defroster nozzle 8. Defroster air 12. Blower fan motor assembly

DIAGNOSIS TABLE

Condition Possible Cause Correction
Heater blower fan
motor won’t work even
when its switch is
operating position.

Heater blower fan
won’t work when its
switch is maximum
position.

Incorrect temperature
output.

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

HEATER AND VENTILATION 1A-3

DIAGNOSIS

Fuse blown Check “HEATER” fuse, main heater

fuse and check for short circuit to

ground.
Blower main relay faulty Check blower main relay.
Blower fan motor resistor faulty Check resistor.
Blower fan motor switch faulty Check blower fan switch.
Blower fan motor faulty Replace motor.
Wiring or grounding faulty Repair as necessary.
Blower maximum relay faulty Check blower maximum relay.
Blower fan motor switch faulty Check blower fan switch.
Wiring or grounding faulty Check wiring, grounding and repair

as necessary.
Control cables broken or binding Check cables.
Temperature control lever faulty Check control lever.
Position of control cable clamp is faulty Check and adjustment.
Temperature door assembly broken Repair temperature door assembly.
Air ducts clogged Repair air ducts.
Heater core leaking or clogged Replace core.
Heater hoses leaking or clogged Replace hoses.
Thermostat faulty Check thermostat by referring to

Section 6B.
Control cable broken or binding Check cable.
Mode control lever faulty Check control lever.
Position of control cable clamp is faulty Check and adjust clamp posi-

tion.Check and adjustment.
Air damper broken Repair damper.
Air ducts leaking or clogged Repair air ducts.

1A-4 HEATER AND VENTILATION

WIRING CIRCUIT

1. Main fuse box 4. Lighting switch 7. Blower fan switch 10. To ECM

2. Ignition switch 5. Blower fan motor 8. To ECM (idle up signal)

3. Circuit fuse box 6. Blower fan motor resistor 9. Generator

HEATER UNIT

HEATER AND VENTILATION 1A-5

ON-VEHICLE SERVICE

1. Heater core 4. Temperature door assembly 7. Temperature lever assembly Do not reuse

2. Blower fan motor assembly 5. Air outlet control door assembly 8. Packing

3. Blower fan motor resistor 6. Air outlet control lever assembly 9. Demistor air outlet case

1A-6 HEATER AND VENTILATION

REMOVAL

1) Disconnect negative (–) cable at battery.

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

3) Remove heater unit mounting nut (2).

4) Remove instrument panel by referring to “INSTRUMENT
PANEL” in Section 9.

5) Disconnect blower motor and resistor couplers from heater
unit.

6) Remove bolts (1), nuts (2) and screws (3) as shown.

7) Remove cooling unit (4) and heater unit (5) from vehicle.

INSTALLATION

Reverse removal procedure to install heater unit noting the follow­ing instructions.

• When installing each part, be careful not to catch any cable
or wiring harness.

• Adjust heater control cable by referring to “HEATER CON-
TROL LEVER ASSEMBLY” in this section.

• Fill engine coolant to radiator.

HEATER AND VENTILATION 1A-7

BLOWER FAN MOTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Remove steering column hole cover.

3) Remove brake and clutch pedals bracket from vehicle body.

4) Disconnect blower motor coupler (1).

5) Remove blower fan motor (2).

INSPECTION

1) Check continuity between two terminal as shown.
If check results are no continuity, replace blower fan motor
assembly (1).

2) Check operate and current.

a) Fix blower fan motor assembly (1) by using vise.
b) Connect battery to blower fan motor assembly (1) as

shown.
c) Check that there is smoothly operates and no noise.
d) Check that ammeter indicates specified current.

If measure current is incorrect, replace blower fan motor.

Blower fan specified current at 12V
: 18 A maximum

INSTALLATION

Reverse removal procedure for installation.

1A-8 HEATER AND VENTILATION

BLOWER FAN MOTOR RESISTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disconnect blower fan motor resistor coupler.

3) Remove blower fan motor resistor (1) as shown.

INSPECTION

Measure each terminal-to-terminal resistance on resistor
If measured resistance is incorrect, replace blower motor resistor.

Blower fan motor resistor resistance
H–MH : approximately 0.5
H–ML : approximately 1.5
H–L : approximately 3.0

at 25°C (77°F)

ΩΩΩΩ

at 25°C (77°F)

ΩΩΩΩ

at 25°C (77°F)

ΩΩΩΩ

INSTALLATION

Reverse removal procedure for installation.

CAUTION:

When the heater unit is disassembled and reassembled,
locking force of the heater case lock may reduce. In such
a case, tighten the heater case with a tapping screw (1) of
M4 x L16 as shown in the figure, or air may leak from its
joint section.

1

HEATER AND VENTILATION 1A-9

HEATER CONTROL ASSEMBLY

1. Heater control assembly 3. A/C switch LED (if equipped) 5. Fresh air control cable 7. Temperature control cable

2. A/C switch knob (if equipped) 4. Bulb 6. Air outlet control cable 8. Heater control knob

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Remove steering column hole cover.

3) Remove heater control knob (1), center upper garnish (2),
center lower garnish (3) and glove box.

4) Disconnect air outlet control (3), temperature control (2) and
fresh air control (1) cables.

5) Remove heater control assembly (1), and then disconnect
blower fan switch connector (2) after unlock locking part (3)
as shown.

1A-10 HEATER AND VENTILATION

INSTALLATION

1) Reverse removal procedure for installation.

2) Adjust the following items.

a) Move air outlet control dial (1), temperature control dial (2)

and fresh air control lever (3) fully in arrow direction as
shown in figure.

[A] : For LH model

[B] : For RH model

b) Push air outlet lever (4), temperature lever (5) and door link

(6) fully in arrow direction and fix air outlet control cable (7),
temperature control cable (8) and fresh air control cable (9)
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.

[A] : For LH model

[B] : For RH model

INSPECTION

Check blower fan switch for each terminal-to terminal continuity.

Circuit table of blower fan switch

1

1

POSITION

OFF

ML

MH

2

TERMINAL

L

H

HEATER AND VENTILATION 1A-11

E

LMLMHH

ILM S/W

GND

1. Terminal arrangement of blower fan switch

2. Blower fan switch

1A-12 HEATER AND VENTILATION

AIR INLET BOX

4

3

5

2

10

7

1. Resistance board 4. Fresh air duct packing 7. Air inlet door 10. Cable clamp

2. Air inlet case
: Apply sealant 99000 - 31160 to hatched part “A”

3. Fresh air duct case 6. Heater unit packing 9. Dash packing

8

2

1

5. Door link 8. Clip : Do not reuse

6

“A”

9

REMOVAL

NOTE:

If vehicle equipped with A/C, refer to “COOLING UNIT” in
Section 1B.

1) Disconnect negative (–) cable at battery.

2) Remove glove box.

3) Disable air bag system by referring to “DISABLING AIR BAG
SYSTEM” in Section 10B. (if equipped)

4) Disconnect fresh air control cable (1) from air inlet box.

HEATER AND VENTILATION 1A-13

5) Remove air inlet box mounting nuts (1) and screws (2).

6) Remove air inlet box (3).

INSTALLATION

Reverse removal procedure to install air inlet box noting the fol­lowing instructions.

• Adjust fresh air control cable referring to “INSTALLATION”
under “HEATER CONTROL ASSEMBLY” in this section.

• Enable air bag system by referring to “ENABLING AIR BAG
SYSTEM” in Section 10B. (if equipped)

VENTILATION LOUVER

REMOVAL

1) Remove ventilation louver (1) as shown in figure.

2: Rag

2) Remove ventilation louver holder (1) from ventilation louver
(2).

1A-14 HEATER AND VENTILATION

INSTALLATION

Reverse removal procedure to install ventilation louver noting the
following instruction.

• Be sure to install ventilation louver holder (1) to proper direc­tion as shown.

REQUIRED SERVICE MATERIALS

Material

Sealant

Recommended SUZUKI product

(Part Number)

SUZUKI BOND No. 1216B

99000 – 31160

Use

• Air inlet box

AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

AIR CONDITIONING (OPTIONAL)

WARNING:

For vehicles equipped with Supplemental Restraint (Air Bag) System :

• Service on and around the air bag system components or wiring must be performed only by an
authorized 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.

• 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 HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used before any service work including inspection and mainte­nance. For identification between these two types, refer to “REFRIGERANT TYPE” in this section.
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.

6F1
6F2

6G

1B

7A
7A1
7B1
7C1

7D

7E

7F

8A

8B

8C

8D

8E

9

10
10A
10B

NOTE:

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

CONTENTS

GENERAL DESCRIPTION .............................. 1B-3

REFRIGERANT CIRCULATION .................. 1B-3

REFRIGERANT TYPE ................................. 1B-3

MAJOR COMPONENTS AND

LOCATION ................................................... 1B-4

DIAGNOSIS ..................................................... 1B-5

GENERAL DIAGNOSIS TABLE................... 1B-5

ABNORMAL NOISE DIAGNOSIS ................ 1B-7

QUICKLY CHECKING OF REFRIGERANT

CHARGE ...................................................... 1B-9

PERFORMANCE DIAGNOSIS .................. 1B-10

PERFORMANCE DIAGNOSIS TABLE .. 1B-12
DETAIL DIAGNOSIS TABLE (AMBIENT

TEMPERATURE AT 30°C (86°F)) ......... 1B-13

COMPRESSOR DRIVE BELT ................... 1B-15

ELECTRICAL DIAGNOSIS ........................... 1B-16

WIRING DIAGRAM .................................... 1B-16

A/C SYSTEM INSPECTION OF ECM AND

ITS CIRCUITS ........................................... 1B-17

REFRIGERANT RECOVERY, EVACUATING

AND CHARGING........................................... 1B-20

OPERATION PROCEDURE FOR

REFRIGERANT CHARGING..................... 1B-20

RECOVERY ............................................... 1B-21

REPLENISHING COMPRESSOR OIL ...... 1B-21

EVACUATING............................................ 1B-22

EVACUATING PROCEDURE................ 1B-22

CHECKING SYSTEM FOR PRESSURE

LEAKS.................................................... 1B-23

CHARGING................................................ 1B-24

CHARGING PROCEDURE.................... 1B-24

1B-2 AIR CONDITIONING (OPTIONAL)

REMOVING MANIFOLD GAUGE SET ...... 1B-26

LEAK TEST................................................ 1B-26

LIQUID LEAK DETECTORS.................. 1B-26

ON-VEHICLE SERVICE ................................ 1B-27

SERVICE PRECAUTION........................... 1B-27

REFRIGERANT LINE ............................ 1B-27

HANDLING REFRIGERANT HFC-134a

(R-134a) ................................................. 1B-28

REFRIGERANT RECOVERY ................ 1B-28

REFRIGERANT CHARGE ..................... 1B-28

CONDENSER ASSEMBLY........................ 1B-28

RECEIVER/DRYER ................................... 1B-30

RADIATOR/CONDENSER COOLING FAN

MOTOR...................................................... 1B-31

COOLING UNIT (EVAPORATOR) ............ 1B-32

A/C EVAPORATOR TEMPERATURE

SENSOR.................................................... 1B-34

EXPANSION VALVE ................................. 1B-34

A/C REFRIGERANT PRESSURE

SWITCH..................................................... 1B-35

A/C SWITCH.............................................. 1B-36

RADIATOR/CONDENSER COOLING FAN

MOTOR RELAY No.1, No.2 and No.3 ....... 1B-36

COMPRESSOR ......................................... 1B-36

MAGNET CLUTCH .................................... 1B-38

LIP TYPE SEAL ......................................... 1B-41

REQUIRED SERVICE MATERIAL ............... 1B-43

SPECIAL TOOL ............................................ 1B-44

GENERAL DESCRIPTION

REFRIGERANT CIRCULATION

AIR CONDITIONING (OPTIONAL) 1B-3

1. Compressor 4. Receiver/dryer 7. Evaporator

2. Magnet clutch 5. A/C refrigerant pressure switch

3. Condenser assembly 6. Expansion valve

REFRIGERANT TYPE

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

1B-4 AIR CONDITIONING (OPTIONAL)

MAJOR COMPONENTS AND LOCATION

1. Cooling unit 7. Condenser outlet pipe 13. Demister air 19. High pressure charge valve

2. Compressor 8. Liquid pipe 14. Fresh air 20. Sight glass

3. Condenser assembly 9. Expansion valve 15. Recirculation air [A] : LH model

4. Receiver/dryer 10. Ventilation air 16. Heater unit [B] : RH model

5. Discharge hose 11. Foot air 17. A/C refrigerant pressure switch

6. Suction pipe 12. Defroster air 18. Low pressure charge valve

GENERAL DIAGNOSIS TABLE

Condition Possible Cause Correction
Cool air won’t come
out (A/C system won’t
operative)

Cool air won’t come
out (A/C compressor
won’t operative)

Cool air won’t come
out (A/C condenser
cooling fan motor
won’t operative)

Cool air won’t come
out (Blower fan motor
won’t operative)

No refrigerant Perform recover, evacuation and charging.
Fuse blown Check fuses in circuit fuse and main fuse

A/C switch faulty Check A/C switch.
Blower fan switch faulty Check blower fan switch referring to Sec-

A/C evaporator temperature sensor
faulty
A/C refrigerant pressure switch faulty Check A/C refrigerant pressure switch.
Wiring or grounding faulty Repair as necessary.
ECT sensor faulty Check ECT sensor referring to Section

ECM and its circuit faulty Check ECM and its circuit referring to Sec-

ECM faulty Check ECM and its circuit referring to Sec-

Magnet clutch faulty Check magnet clutch.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Compressor thermal switch faulty Check compressor thermal switch
Fuse blown Check fuses in circuit fuse and main fuse

Wiring or grounding faulty Repair as necessary.
Radiator/condenser cooling fan motor
relay faulty
Radiator/condenser cooling fan motor
faulty
ECM faulty Check ECM and its circuit referring to Sec-

Fuse blown Check “HTR” fuse in circuit fuse box and

Blower fan motor resistor faulty Check blower fan motor resistor to Section

Blower fan switch faulty Check blower fan switch referring to Sec-

Wiring or grounding faulty Repair as necessary.
Blower fan motor faulty Check blower fan motor referring to Sec-

AIR CONDITIONING (OPTIONAL) 1B-5

DIAGNOSIS

boxes, and check short circuit to ground.

tion 1A.
Check A/C evaporator temperature sen­sor.

6E1.

tion 6E1.

tion 6E1.

boxes, and check short circuit to ground.

Check radiator/condenser cooling fan
motor relay No.1, No.2 and No.3.
Check radiator/condenser cooling fan
motor.

tion 6E1.

main fuses, and check short circuit to
ground.

1A.

tion 1A.

tion 1A.

1B-6 AIR CONDITIONING (OPTIONAL)

Condition Possible Cause Correction
Cool air won’t come
out or insufficient
cooling (A/C system
normal operative)

Insufficient or excessive charge of
refrigerant
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator

A/C evaporator temperature sensor
faulty
Expansion valve faulty Check expansion valve.
Receiver/dryer clogged Check receiver/dryer.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Magnetic clutch faulty Check magnetic clutch.
Compressor faulty Check compressor.
Air in A/C system Replace dryer, and perform evacuation

Air leaking from cooling unit or air duct Repair as necessary.
Heater and ventilation system faulty Check air inlet box (cooling unit), heater

Blower fan motor faulty Check blower fan motor referring to Sec-

Excessive compressor oil existing in A/
C system

Cool air won’t come
out only intermittently

Wiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace dryer, and perform evacuation

Magnetic clutch faulty Check magnetic clutch.
Excessive charge of refrigerant Check charge of refrigerant.

Cool air comes out
only at high speed

Condenser clogged Check condenser.
Insufficient charge of refrigerant Check charge of refrigerant.
Air in A/C system Replace dryer, and perform evacuation

Compressor drive belt loosen or broken Adjust or replace drive belt.
Compressor faulty Check compressor.

Cool air won’t come
out only at high speed

Insufficient velocity of

Excessive charge of refrigerant Check charge of refrigerant.
A/C evaporator frosted Check A/C evaporator and A/C evaporator

A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator

cooled air

Air leaking from cooling unit or air duct Repair as necessary.
Blower fan motor faulty Check blower fan motor referring to Sec-

Wiring or grounding faulty Repair as necessary.

Check charge of refrigerant and system for
leaks.

temperature sensor.
Check A/C evaporator temperature sen­sor.

and charging.

control assembly and heater unit referring
to Section 1A.

tion 1A.
Pull out compressor oil in A/C system cir­cuit, and check compressor.

and charging.

and charging.

temperature sensor.

temperature sensor.

tion 1A.

AIR CONDITIONING (OPTIONAL) 1B-7

ABNORMAL NOISE DIAGNOSIS

There are various types of noise, ranging from those produced in the engine compartment to those from the
passenger compartment, also from rumbling noises to whistling noises.

ABNORMAL NOISE FROM COMPRESSOR

Condition Possible Cause Correction
During compressor
operation, a rumbling
noise is heard propor­tional to engine
revolutions.
A loud noise is heard
at a certain rpm, dis­proportionately to
engine revolution.
A loud rattle is heard
at low engine rpm.

Inadequate clearance in piston area (piston or
swash-plate)

Loose or faulty compressor drive belt Adjust drive belt tension, or replace

Loose compressor mounting bolts Retighten mounting bolts.

Loose compressor clutch plate bolt Retighten clutch plate bolt.

Repair or replace compressor as
necessary.

drive belt.

Replace compressor if it was oper­ated in this condition for a long
time.

ABNORMAL NOISE FROM MAGNETIC CLUTCH

Condition Possible Cause Correction
A rumbling noise is
heard when compres­sor is not operating.
A chattering noise is
heard when compres­sor is engaged.

Worn or damaged bearings Replace magnet clutch assembly.

Faulty clutch clearance (excessive) Adjust clutch clearance.
Worn clutch friction surface Replace magnet clutch assembly.
Compressor oil leaked from lip type seal, con­taminating the friction surface

ABNORMAL NOISE FROM TUBING

Condition Possible Cause Correction
A droning noise is
heard inside vehicle,
but not particularly
noticeable in engine
compartment.

Faulty tubing clamps Reposition clamps or increase the

Resonance caused by pulsation from variations
in refrigerant pressure

ABNORMAL NOISE FROM CONDENSER

Replace compressor body assem­bly.

number of clamps.
Attach a silencer to tubing, or mod­ify its position and length.

Condition Possible Cause Correction
Considerable vibra­tion in condenser.

Resonance from condenser bracket and body Firmly insert a silencer between

condenser bracket and body.

1B-8 AIR CONDITIONING (OPTIONAL)

ABNORMAL NOISE FROM CRANKSHAFT PULLEY

Condition Possible Cause Correction

A large rattling noise

Loosen crankshaft pulley bolt Retighten bolt.

is heard at idle or sud­den acceleration.

ABNORMAL NOISE FROM TENSION PULLEY

Condition Possible Cause Correction

Clattering noise is

Worn or damaged bearing Replace tension pulley.

heard from pulley.
Pulley cranks upon

Cracked or loose bracket Replace or retighten bracket.

contact.

ABNORMAL NOISE FROM A/C EVAPORATOR

Condition Possible Cause Correction
Whistling sound is
heard from A/C evapo­rator.

Depending on the combination of the interior/
exterior temperatures, engine rpm and refriger­ant pressure, the refrigerant flowing out of the
expansion valve may, under certain conditions,
make a whistling sound

At times, slightly decreasing refrig­erant volume may stop this noise.
Inspect expansion valve and
replace if faulty.

ABNORMAL NOISE FROM BLOWER FAN MOTOR

Condition Possible Cause Correction
Blower fan motor
emits a chirping

Worn or damaged motor brushes or commuta­tor

sound in proportion to
its speed of rotation.
Fluttering noise or
large droning noise is

Leaves or other debris introduced from fresh air
inlet to blower fan motor

heard from blower fan
motor.

Repair or replace blower fan motor.

Remove debris and make sure that
the screen at fresh air inlet is intact.

CHECKING REFRIGERANT CHARGE

AIR CONDITIONING (OPTIONAL) 1B-9

QUICKLY CHECKING OF REFRIGERANT
CHARGE

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 condenser outlet pipe (2) and
compare what is observed with the symptoms listed in below.

[A] : LH model 3. Bubbles

[B] : RH model 4. A/C refrigerant pressure switch

Item

No.

1 Bubbles observed in sight glass Insufficient charge of refrigerant

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

Symptom Charge of refrigerant condi-

tion

in system

Correction

Check system for leaks with a
leak tester.
Refer to the items 3 and 4.

refrigerant in system

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 out-

Proper or too much charge of
refrigerant in system

Refer to the items 5 and 6.

let

5 When A/C is turned OFF, refriger-

ant in sight glass clears immedi-

Too much charge of refrigerant
in system

Recharge with specified amount
of refrigerant.

ately and remains clear

6 When A/C is turned OFF, refriger-

ant in sight glass once produces

Proper charge of refrigerant in
system

No correction needed because
charge of refrigerant is normal.

bubbles and then clears

NOTE:

For specified amount of refrigerant, refer to “OPERATION PROCEDURE FOR A/C WITH REFRIGER­ANT” in this section.

1B-10 AIR CONDITIONING (OPTIONAL)

PERFORMANCE DIAGNOSIS

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

• Vehicle is not exposed to direct sun.

• Ambient temperature is within 15 – 35°C (59 – 95°F).

2) Make sure that high pressure valve (1) and low pressure
valve (2) of manifold gauge set (3) are firmly closed.

3) Connect high pressure charging hose (4) to high pressure
service valve (5), and connect low pressure charging hose
(6) to low pressure service valve (7).

4) Bleed the air in charging hoses (4), (6) by loosening their
respective nuts on manifold gauge set (3), utilizing the refrig­erant pressure. When a hissing sound 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 (engine
coolant temperature at 80 – 90°C (176 – 194°F)) and keep it
at specified idle speed. (Radiator cooling fan should not be
working when checking pressure and temperature.)

6) Turn A/C switch to ON position, and set blower fan switch at
“H” (4th position), temperature dial at “COOL”, air outlet con-
trol dial at “FACE” and fresh/recirculation control dial at
“RECIRCULATION”. (Confirm that A/C compressor and radi­ator/condenser cooling fan are working.)
Keep all windows, doors and engine food open.

Performance diagnosis condition

Ambient temperature 15 – 35°C (59 – 95°F)
Engine rpm Keep to 1,500 rpm.
Blower fan switch “H” (4th position)
Temperature control “Cool”
Air outlet control “Face”
Vehicle Doors All open
Air inlet door position Recirculation

7) With dry bulb thermometer (1) inserted into center duct air
outlet and another one set near evaporator air inlet, read
temperature indicated on each thermometer.

AIR CONDITIONING (OPTIONAL) 1B-11

8) Check for each pressure of low side and high side if it is
within shaded range of graph.
If each gauge reading is out of specified pressure, correct
defective part referring to “PERFORMANCE DIAGNOSIS
TABLE”.

NOTE:

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

Low side and high side pressure example :

Gauges should read as follows when ambient tempera­ture is 30°C (86°F).

1400 – 1750 kPa

Pressure
on high pressure gauge

14.0 – 17.5 kg/cm

2

199.1 – 248.9 psi
230 – 350 kPa

Pressure
on low pressure gauge

2.3 – 3.5 kg/cm

2

32.7 – 49.8 psi

9) Check inlet port temperature-to-outlet port temperature rela­tionship using graph.
For example, if evaporator inlet port temperature is 25°C
(75°F) and center duct air outlet temperature is 8°C (46°F),
their crossing point is within acceptable range as shown in
graph.
If crossing point is out of acceptable range, diagnose trouble
referring to “PERFORMANCE DIAGNOSIS TABLE”.

1B-12 AIR CONDITIONING (OPTIONAL)

PERFORMANCE DIAGNOSIS TABLE

NOTE:

If ambient temperature is approximately 30°C (86°F), it is possible to diagnose A/C system in detail
referring to “DETAIL DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30 °C (86°F))” under “PER­FORMANCE DIAGNOSIS” in this section.

HIGH PRESSURE GAUGE

Condition Possible Cause Correction

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

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

Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high side Clean or replace.
Radiator/condenser cooling fan malfunction (Insufficient

cooling of condenser)
Dirty or bent condenser fins (Insufficient cooling of con-

denser)
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system referring to

Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary

Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.

Check radiator/condenser cooling fan.

Clean or repair.

Section 6B.

and recharge.

LOW PRESSURE GAUGE

Condition Possible Cause Correction

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

Pressure low
(“D” area of low side
graph)

Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.

Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary

Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.

THERMOMETER AT CENTER DUCT

Condition Possible Cause Correction

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

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

Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in cooling

(heater) unit
Compressor malfunction Check compressor.
Insufficient air volume from center duct (Heater blower

malfunction)
Compressor malfunction Check compressor.

and recharge.

Repair or replace.

Check blower motor and fan.

AIR CONDITIONING (OPTIONAL) 1B-13

DETAIL DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30°C (86°F))

Condition

MANIFOLD

GAUGE

Lo Hi

0.23 – 0.35
(2.3 – 3.5)
(33 – 50)

Negative
pressure

Normal :

0.23 – 0.35
(2.3 – 3.5)
(33 – 50)

↑ ↓

↑ ↓

↑ ↓↑ ↓

Abnormal :
Negative
pressure

0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)

0.4 – 0.6
(4 – 6)
(56.9 – 85.3)

MPa

2

(kg/cm

(psi)

1.4 – 1.75
(14 – 17.5)
(200 – 249)

0.5 – 0.6
(5 – 6)
(71.2 – 85.3)

Normal :

1.4 – 1.75
(14 – 17.5)
(200 – 249)

↑ ↓

↑ ↓

↑ ↓↑ ↓

Abnormal :

0.7 – 1.0
(7 – 10)
(100 – 142)

0.7 – 1.0
(7 – 10)
(100 – 142)

)

Normal condition

The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
Presence of frost around
tubing to and from receiver/
dryer and expansion valve.

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.

Both low and high pressure
sides indicate low readings.
Continuous air bubbles are
visible through sight glass.
Output air is slightly cold.

Pressure on low pressure
side is high.
Pressure on high pressure
side is low.
Both pressure becoming
equal right after A/C is
turned OFF.

Detail

Possible Cause Correction

––

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

Expansion valve is frozen due
to moisture in the system, and
temporarily shuts off the
refrigeration cycle

Insufficient refrigerant in sys­tem
(Refrigerant leaking)

Internal leak in compressor Inspect compressor and

Clean expansion valve.
Replace it if it cannot be
cleaned.
Replace receiver/dryer.
Evacuate the A/C system and
recharge with fresh refriger­ant.

Replace expansion valve.
Replace receiver/dryer.
Evacuate A/C system and
recharge with fresh refriger­ant.

Using leak detector, check for
leaks and repair as neces­sary.
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.

repair or replace as neces­sary.

1B-14 AIR CONDITIONING (OPTIONAL)

Condition

MANIFOLD

GAUGE

MPa

(kg/cm

(psi)

2

)

Lo Hi

0.35 – 0.45
(3.5 – 4.5)
(50 – 64)

2.0 – 2.5
(20 – 25)
(285 – 355)

0.45 – 0.55
(4.5 – 5.5)
(64 – 78)

Detail

High pressure reading on
both low and high pressure
sides.
Air bubbles are not visible
even when engine rpm is
lowered.

High pressure reading on
both low and high pressure
sides.
Low pressure side tubing is
not cold when touched.
Air bubbles are visible
through sight glass.

High pressure reading on
both low and high pressure
sides.
Large amount of frost or
dew on the low pressure
side tubing.

Possible Cause Correction

Overcharged A/C system Adjust refrigerant to specified

amount.

Faulty condenser cooling

Clean condenser.

operation
Faulty radiator/condenser

cooling fan operation
Presence of air in A/C system

(Improperly evacuated)

Inspect and repair radiator/
condenser cooling fan.

Replace receiver/dryer.
Inspect quantity of compres­sor oil and presence of con­taminants in oil.
Evacuate system and
recharge with fresh refriger­ant.

Faulty expansion valve

Replace expansion valve.
Refrigerant flow is not regu­lated properly

AIR CONDITIONING (OPTIONAL) 1B-15

COMPRESSOR DRIVE BELT

INSPECTION

• Check compressor drive belt (6) for wear and cracks, and
replace as required.

• Check compressor drive belt (6) tension by measuring how
much it deflects when pushed at intermediate point between
compressor pulley (1) and tension pulley (2) with about 100
N (10 kg) force after crankshaft pulley 1 rotating.
If belt tension is without specification, adjust belt tension
referring to below procedures.

Compressor drive belt tension
“a” : 3 – 5 mm (0.12 – 0.20 in.)
New compressor drive belt tension
“a” : 2 – 4 mm (0.08 – 0.16 in.)

ADJUSTMENT

1) Loosen tension pulley nut (3).

2) Adjust belt tension by tighten or loosen tension pulley adjust­ing bolt (4).

3) Tighten tension pulley nut (3).

4) Turn the crank pulley (5) 1 revolution, then check belt ten­sion.

REPLACEMENT

1) Loosen tension pulley nut (3).

2) Loosen belt tension by loosen tension pulley adjusting bolt
(4).

3) Remove compressor drive belt (6).

4) Install new compressor drive belt.

5) Adjust belt tension referring to above procedure.

1B-16 AIR CONDITIONING (OPTIONAL)

WIRING DIAGRAM

ELECTRICAL DIAGNOSIS

1. Blower fan motor 6. Radiator/condenser cooling fan relay No.2 11. Ignition switch 16. Main fuse box

2. Blower fan motor resistor 7. Radiator/condenser cooling fan relay No.3 12. A/C evaporator temperature sensor 17. Generator

3. Blower fan switch and A/C switch 8. Radiator/condenser cooling fan motor 13. ECT sensor 18. Compressor

4. A/C refrigerant pressure switch 9. Compressor thermal switch 14. Lighting switch

5. Radiator/condenser cooling fan relay No.1 10. Main relay 15. Circuit fuse box

AIR CONDITIONING (OPTIONAL) 1B-17

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 from vehicle by referring to “ECM (PCM)
REMOVAL AND INSTALLATION” in Section 6E1.

2) Connect ECM couplers (1) to ECM (2).

3) Check voltage at each terminal of couplers connected.

NOTE:

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

[A] : Fig. A

[B] : Fig. B

1B-18 AIR CONDITIONING (OPTIONAL)

System Circuit

1. Blower fan motor 8. Main relay A. To “HTR” fuse (25 A) in circuit fuse box

2. Blower fan switch 9. Radiator/condenser cooling fan motor relay No.1 B. To main fuse (15 A)

3. A/C switch 10. Radiator/condenser cooling fan motor relay No.2 C. To main fuse (30 A)

4. A/C refrigerant pressure switch 11. Radiator/condenser cooling fan motor relay No.3

5. Compressor 12. Radiator/condenser cooling fan motor

6. A/C evaporator temperature sensor 13. Engine earth

7. ECT sensor 14. ECM

Terminal arrangement of ECM coupler (Viewed from harness side)

ECM Voltage Values Table for Relation of A/C Control

AIR CONDITIONING (OPTIONAL) 1B-19

Terminal Wire Circuit Measurement

ground

C41-1 PNK/BLK Compressor magnet

C41-5 BLK/RED Main power supply for

C41-6 BLK/RED Main power supply for

C41-10 BRN/

WHT

C41-16 YEL/GRN A/C switch input Ground to engine

C41-18 BLU Radiator/condenser

C42-1 BLK/ORN Main ground for ECM Ground to body

C42-2 BLK ECM ground for

C42-3 BLK/ORN ECM ground for

C42-10 ORN Sensor ground for

C42-14 LT GRN/

BLK

C42-18 PNK/GRN Medium pressure

G02-3 PPL/YEL Radiator/Condenser

G02-10 ORN Sensor ground for A/C

G02-13 PNK/BLU Blower fan speed

G02-14 WHT/BLK A/C evaporator tem-

clutch output

ECM

ECM
Main relay drive Ground to engine

cooling fan relay out­put 1

power circuit

power circuit

ECT sensor
ECT sensor input Ground to engine

switch input

cooling fan relay out­put 2

evaporator tempera­ture sensor

input

perature sensor input

Ground to engine
(Fig B)

Ground to engine
(Fig B)

Ground to engine
(Fig B)

(Fig B)

(Fig B)

Ground to engine
(Fig B)

(Fig A)
Ground to body

(Fig A)
Ground to body

(Fig A)
Ground to body

(Fig A)

(Fig B)

Ground to engine
(Fig B)

Ground to engine
(Fig B)

Ground to engine
(Fig A)

Ground to engine
(Fig B)

Ground to engine
(Fig B)

Normal value Condition

12 – 15 V Except the above-mentioned condition with engine

0 – 1 V Blower fan switch and A/C switch ON with engine

10 – 14 V Ignition switch ON with engine stopped

10 – 14 V Ignition switch ON with engine stopped

0.5 – 1.2 V Ignition switch ON with engine stopped
10 – 14 V Ignition switch OFF
12 – 15 V Blower fan switch or A/C switch OFF with engine

0 – 1 V Blower fan switch and A/C switch ON with engine

0 – 1 V Blower fan switch and A/C switch ON

12 – 15 V Blower fan motor switch or A/C switch OFF

–0.5 – 1 V Engine running

–0.5 – 1 V Engine running

–0.5 – 1 V Engine running

–0.5 – 1 V Engine running

0.71 – 0.75 V

(298 – 320 Ω)

0.35 – 0.37 V

(135 – 144 Ω)

–0.5 – 1 V Medium pressure switch of A/C refrigerant pres-

12 – 15 V Medium pressure switch of A/C refrigerant pres-

0 – 1 V Blower fan motor switch ON, A/C switch ON and

12 – 15 V Blower fan motor switch OFF, A/C switch OFF or

–0.5 – 1 V Engine running

0 – 1 V Blower fan motor switch “ML”, “MH”, or “H” with

4 – 7 V Blower fan motor switch “L” position with engine

12 – 15 V Blower fan motor switch OFF with engine running

2.09 – 2.17 V

(1940 – 2060 Ω)

3.52 – 3.59 V

(6450 – 6850 Ω)

running

running

running

running

Engine coolant temperature at more than 97.5°C
(207.5°F) with engine running

Engine coolant temperature at less than 97.5°C
(207.5°F) with engine running

Engine coolant temperature at approximately 80°C
(176°F) with engine running

Engine coolant temperature at Approximately
110°C (230°F) with engine running
If the temperature is more than 114°C (232°F),
compressor and condenser cooling fan should be
stop (come back at less than 112°C (230°F))

sure switch ON

sure switch OFF

medium pressure switch OFF
Engine coolant temperature at more than 102.5°C

(216.5°F) with engine running

medium pressure switch ON
Engine coolant temperature at less than 102.5°C

(216.5°F) with engine running

engine running

running

A/C evaporator temperature at approximately 25°C
(77°F) with engine running

A/C evaporator temperature at approximately 0°C
(32°F) with engine running
If the temperature is less than approximately 2.5°C
(36.5°F), compressor and condenser cooling fan
should be stop (come back at more than approxi­mately 4°C (39.2°F)

1B-20 AIR CONDITIONING (OPTIONAL)

REFRIGERANT RECOVERY, EVACUATING AND CHARGING

WARNING:

• Your eyes should not be exposed to refrigerant (liquid).
Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately
–6°C (32°F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a
serious injury. To protect your eyes against such accident, it is necessary to always wear goggles.
Should it occur that HFC-134a (R-134a) strikes your eyes, consult a doctor immediately.
– Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to

splash it over the affected area to gradually raise temperature of such area above freezing point.

– Obtain proper treatment as soon as possible from a doctor or eye specialist.

• Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.

• Refrigerant must not be handled near where welding or steam cleaning is performed.

• Refrigerant should be kept at a cold and dark place. It should never be stored where a high temper­ature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).

• Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazard­ous to health.

OPERATION PROCEDURE FOR REFRIGERANT CHARGING

Replenish compressor oil

Start evacuating

15 minutes (below –760 mmHg)

Stop evacuating

Wait 10 mintues

Check system for

pressure tightness

Check A/C system

With refrigerant

Check system for refrigerant

leaks and refrigerant

charging quantity

Performance test

If gauge shows
abnormal conditions

Inspect and repair connections

Charge 360 ± 30 g of

refrigerant in gas form

AIR CONDITIONING (OPTIONAL) 1B-21

RECOVERY

REFRIGERANT RECOVERY

When discharging refrigerant out of A/C system, always recover it
by using refrigerant recovery and recycling equipment. Discharg­ing refrigerant HFC-134a (R-134a) into atmosphere would cause
adverse effect to environments.

NOTE:

• After recovery refrigerant from system, the amount of
removed compressor oil must be measured for replen­ishing compressor oil.

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

REPLENISHING COMPRESSOR OIL

It is necessary to replenishing specified amount of compressor oil
to compressor (1) from compressor suction side hole (2) before
evacuating and charging refrigerant.

WHEN CHARGING REFRIGERANT ONLY

When charging refrigerant without replacing any component part,
replenish the same amount of measured oil when recover refrig­erant (if not measure, replenish 30 cc oil).

1B-22 AIR CONDITIONING (OPTIONAL)

WHEN REPLACING COMPRESSOR

CAUTION:

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

Compressor oil is sealed in each new compressor by the amount
required for A/C system. 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

NOTE:

Compressor assembly supplied from factory is filled up
with the following amount of oil.

Oil amount in compressor

: 120 cm

3

(120 cc, 7.32 cu-in)

1. New compressor

2. Removed compressor

3. Excess oil (“A” – “B”)

WHEN REPLACING OTHER PART

Replenish the following amount of oil to compressor.

Amount of compressor oil to be replenished

Replaced part Amount of compressor oil

Evaporator

Condenser

Dryer

Hoses

Pipes

10 cm

10 cm

3

25 cm

15 cm

20 cm

(25 cc, 1.53 cu-in)

3

(15 cc, 0.92 cu-in)

3

(20 cc, 1.22 cu-in)

3

(10 cc, 0.61 cu-in) each

3

(10 cc, 0.61 cu-in) each

EVACUATING

EVACUATING PROCEDURE

CAUTION:

Do not evacuate before recovering refrigerant in system.

NOTE:

Whenever opened (exposed to atmospheric air), air con­ditioning system must be evacuated by using a vacuum
pump. The A/C system should be attached with a mani­fold gauge set, and should be evacuated for approxi­mately 15 minutes.

AIR CONDITIONING (OPTIONAL) 1B-23

1) Connect high charging hose (1) and low charging hose (2) of
manifold gauge set (3) respectively as follows :
High charging hose (1) → High pressure charging valve (4)
on condenser outlet pipe
Low charging hose (2) → Low pressure charging valve (5)
on suction pipe

2) Attach center charging hose (6) of manifold gauge set (3) to
vacuum pump (7).

3) Operate vacuum pump (7), and then open discharge side
valve (Hi) (8) of manifold gauge set (3).
If there is no blockage in the system, there will be an indica­tion on high pressure gauge (9).
In this case, open the other side valve (Lo) (10) of the set
and repair the system.

4) Approximately 10 minutes later, low pressure gauge (11)
should show a vacuum lower than –760 mmHg providing no
leakage exists.

NOTE:

• If the system does not show a vacuum below –760
mmHg, close both valves, stop vacuum pump and
watch movement of low pressure gauge.

• Increase in the gauge reading suggests existence of
leakage. In this case, repair the system before continu­ing its evacuation.

• If the gauge shows a stable reading (suggesting no
leakage), continue evacuation.

5) Evacuation should be carried out for a total of at least 15
minutes.

6) Continue evacuation until low pressure gauge (9) indicates a
vacuum less than –760 mmHg, and then close both valves
(8), (10).

7) Stop vacuum pump (7). Disconnect center charging hose (6)
from pump inlet. Now, the system is ready for charging
refrigerant.

CHECKING SYSTEM FOR PRESSURE LEAKS

After completing the evacuation, close manifold gauge high pres­sure valve and low pressure valve and wait 10 minutes. Verify
that low pressure gauge reading has not changed.

CAUTION:

If the gauge reading moves closer to “0”, there is a leak
somewhere. Inspect the tubing connections, make nec­essary corrections, and evacuate system once again,
making sure that there are no leaks.

1B-24 AIR CONDITIONING (OPTIONAL)

CHARGING

CAUTION:

• Always charge through low pressure side of A/C system at after the initial charging is performed
from the high pressure side with the engine stopped.

• Never charge to high pressure side of A/C system with engine running.

• Do not charge while compressor is hot.

• When installing tap valve to refrigerant container to make a hole there through, carefully follow
directions given by manufacturer.

• A pressure gauge should always be used before and during charging.

• The refrigerant container should be emptied of refrigerant when discarding it.

• The refrigerant container should not be heated up to 40°C (104°F) or over.

• Refrigerant container should not be reversed in direction during charging. Reversing in direction
causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid
refrigerant and the like.

NOTE:

The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning system with refrigerant from the refrigerant
service container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recy­cling refrigerant), follow the procedure described in the equipment manufacturer’s instruction man­ual.

CHARGING PROCEDURE

The initial charging of the A/C system is performed from the high
pressure side with the engine stopped.
And next, this method must be followed by charging from the low
pressure side with the engine running.

1) Check to make sure that hoses are routed properly after
evacuating the system.

2) Connect Low charging hose (1) and High charging hose (2)
of the manifold gauge set (3) in position. Thus open refriger­ant container valve (4) to purge the charging line.

3) Open the high pressure side valve (5) and charge refrigerant
to system.

4) After a while, open the low pressure side valve (6) and close
the high pressure side valve (5).

WARNING:

Make sure that high pressure side valve is closed
securely.

5) Start engine and keep engine speed at 1500 r/min. Then,
operate air conditioning.

6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container (4) should be held upright.

AIR CONDITIONING (OPTIONAL) 1B-25

7) When refrigerant container (1) is emptied, use the following
procedure to replace it with a new refrigerant container (1).

a) Close low pressure valve.
b) Replace empty container (1) with a refrigerant container

which has been charged with refrigerant. When using
refrigerant container tap valve (2), use the following proce­dure for replacement.

i) Retract needle (3) and remove refrigerant container tap

valve (2) by loosening its plate nut (4).

ii) Install previously-removed refrigerant container tap valve

(2) to a new refrigerant container (1).

c) Purge any air existing in center charging hose

When using refrigerant container tap valve, use the follow­ing procedure to purge air.

i) Once fully tighten refrigerant container tap valve (1), and

then loosen (open) plate nut (2) slightly.

ii) Open low pressure side valve (3) of manifold gauge set

(4) a little.

iii) As soon as refrigerant comes out with a “hiss” through a

clearance between refrigerant container and tap valve,
tighten plate nut (2) as well as low pressure side valve (3).

iv) Turn handle of tap valve (1) clockwise so that its needle is

screwed into the new container to make a hole for refriger­ant flow.

8) After the system has been charged with specified amount
(330 – 390 g) of refrigerant or when low pressure gauge (1)
and high pressure gauge (2) have indicated the following
specified amount, close low pressure side valve (3) on mani­fold gauge set (4). At this time, look into the sight glass (5) of
condenser outlet pipe (6) and check that there are no bub­bles (7) in it, which means that the system is fully charged.

Low side and high side pressure example

Gauges should read as follows when ambient tempera­ture is 30°C (86 °F).

1400 – 1750 kPa

Pressure
on high pressure gauge

14.0 – 17.5 kg/cm

2

199.1 – 248.9 psi
230 – 350 kPa

Pressure
on low pressure gauge

2.3 – 3.5 kg/cm

2

32.7 – 49.8 psi

1B-26 AIR CONDITIONING (OPTIONAL)

REMOVING MANIFOLD GAUGE SET

WARNING:

High pressure side is naturally under high pressure. So, care must be used to protect your eyes and
skin.

When A/C system has been charged with a specified amount of refrigerant, remove manifold gauge set as fol­lows :

1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously
during the process of charging.)

2) Close refrigerant container valve.

3) Stop engine.

4) Using shop rag, remove charging hoses from service valves. This operation must be performed rapidly.

5) Put caps on service valves.

LEAK TEST

Whenever a refrigerant leak is suspected in the system or any
service operation has been performed which may result in dis­turbing lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general,
depend upon the nature of a complaint and the type of a service
performed on the system.

LIQUID LEAK DETECTORS

WARNING:

• To prevent explosions or fires, make sure that there
are no flammables in the vicinity.

• When exposed to fire, the refrigerant turns into a poi­sonous gas (phosgene). Do not inhale this gas.

There are a number of fittings and places throughout the air con­ditioning system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a
swab, such as attached to the cap of a vial, bubbles will form
within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con­denser, an electronic (refrigerant) leak detector is more practical
for determining leaks.

Special tool
(A) : 09990 - 86011

AIR CONDITIONING (OPTIONAL) 1B-27

ON-VEHICLE SERVICE

WARNING:

Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.

• Do not use your hand to rub affected eye(s). Instead, use quantities of fresh cold water to splash it
over affected area to thus gradually raise its temperature above the freezing point.

• Obtain proper treatment as soon as possible from a doctor or eye specialist. Should liquid refriger­ant HFC-134a (R-134a) get on your skin, such affected part should be treated in the same manner as
when skin is frostbitten or frozen.

SERVICE PRECAUTION

When servicing air conditioning system, note the following instructions.

REFRIGERANT LINE

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

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

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

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

5. A/C refrigerant pressure switch:
Apply compressor oil (refrigerant oil) to O-ring.

• Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.

• Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,

install a blind plug or cap to the fitting immediately.

• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling
nuts and O-ring.

• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.

• Tighten flared nuts by the following specified torque.

Tightening torque
8 mm pipe : 13 N·m (1.3 kg-m, 9.5 lb-ft)
12 mm pipe : 23 N·m (2.3 kg-m, 16.6 lb-ft)

14.5 mm pipe : 33 N·m (3.3 kg-m, 23.8 lb-ft)

1B-28 AIR CONDITIONING (OPTIONAL)

• Route drain hose so that drained water does not make any contact to vehicle components.

• If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side by
referring to “REPLENISHING COMPRESSOR OIL” in this section.

HANDLING REFRIGERANT HFC-134a (R-134a)

• Always wear goggles to protect your eyes.

• Avoid you direct contact to liquid refrigerant.

• Do not heat refrigerant container higher than 40°C (104°F).

• Do not discharge refrigerant into atmosphere.

• Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and

will tarnish surfaces of bright metals including chrome.

REFRIGERANT RECOVERY

When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environ­ments.

REFRIGERANT CHARGE

After perform replenishing compressor oil and evacuating, charge a proper amount of refrigerant to A/C system
referring to “CHARGING” in this section.

CAUTION:

Do not perform an additional refrigerant charging to A/C system. This cause it to overcharge.

CONDENSER ASSEMBLY

CAUTION:

Be careful not to damage condenser fins. If condenser fin
is bent, straighten it by using flat head screwdriver or
pair of pliers.

INSPECTION

Check the following.

• Clog of condenser fins.
If, any clogs are found, condenser fins should be washed
with water, and should be dried with compressed air.

• Condenser fins for leakage and breakage.
If any defects are found, repair or replace condenser.

• Condenser fittings for leakage.
If any defects are found, repair or replace condenser.

AIR CONDITIONING (OPTIONAL) 1B-29

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.

NOTE:

The amount of removed compressor oil must be mea­sured for replenishing compressor oil.

3) Remove front bumper referring to “FRONT BUMPER” in
Section 8.

4) Remove front cross member cover (1) and engine food
cover (2) from vehicle body.

5) Disconnect discharge hose (1) and condenser outlet pipe (2)
from condenser (3).

6) Remove condenser mounting bolts (4).

7) Remove condenser (3).

INSTALLATION

Reverse removal procedure to install condenser noting the follow­ing instructions.

• Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES­SOR OIL” in this section.

• Evacuate and charge refrigerant by referring to “EVACUAT­ING” and “CHARGING” in this section.

1B-30 AIR CONDITIONING (OPTIONAL)

RECEIVER/DRYER

REMOVAL

1) Remove condenser assembly referring to “CONDENSER
ASSEMBLY” in this section.

2) Remove condenser mounting bracket (1) from condenser (2)
as shown.

3) Remove receiver/dryer cap (3) using a hexagon wrench.

4) Remove filter (1) from the receiver/dryer (2).

5) Remove dryer (1) using a plier.

INSTALLATION

Reverse removal procedure to install receiver/dryer noting the fol­lowing instructions.

• Do not remove dryer from the plastic bag until just before
inserting it into the receiver.

• Install dryer (1) with its double-layer portion facing the bot­tom of the receiver.