Suzuki Ignis rm413 Service Manual

IMPORTANT

WARNING/CAUTION/NOTE

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

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 “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 beforehand to avoid component damage or unin­tended activation.

The circle with a slash in this manual means “Do not do this” or “Do not let this happen”.

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 Repair­Overhaul).

Applicable model: RM413

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.

IGNIS (RM413/415/413D) Wiring Diagram Manual 99512U86G20-669

© COPYRIGHT MAGYAR SUZUKI CORPORATION 2003

TABLE OF CONTENTS

1

1

1

1

1

B

GENERAL INFORMATION ENGINE 0A 6

GENERAL INFORMATION 0A ENGINE GENERAL INFORMATION
MAINTENANCE AND LUBRICATION 0B 6B
HEATING AND AIR CONDITIONING ENGINE MECHANICAL (M13 ENGINE) 6A1
HEATER AND VENTILATION 1A ENGINE COOLING 6B
AIR CONDITIONING (OPTIONAL) 1B ENGINE FUEL 6C 6F

STEERING, SUSPENSION, WHEELS AND
TIRES

STEERING, SUSPENSION, WHEELS
AND TIRES
FRONT WHEEL ALIGNMENT 3A CRANKING SYSTEM 6G
MANUAL RACK AND PINION 3B CHARGING SYSTEM 6H
ELECTRICAL POWER STEERING (P/S)
SYSTEM
STEERING WHEEL AND COLUMN 3C TRANSMISSION, CLUTCH AND
FRONT SUSPENSION 3D
REAR SUSPENSION 3E MANUAL TRANSAXLE 7A1
WHEELS AND TIRES 3F CLUTCH 7C1 4A 8
DRIVE SHAFT AND PROPELLER SHAFT TRANSFER 7D
FRONT DRIVE SHAFT 4A REAR DIFFERENTIAL 7F
PROPELLER SHAFTS 4B ELECTRICAL SYSTEM
BRAKE SYSTEM BODY ELECTRICAL SYSTEM 8
BRAKES 5
BRAKES PIPE / HOSE / MASTER CYL­INDER
FRONT BRAKE

PARKING AND REAR BRAKE

ANTILOCK BRAKE SYSTEM (ABS) 5E IMMOBILIZER CONTROL SYSTEM 8G

3

3B1

5A

5B

5C

AND DIAGNOSIS

ENGINE AND EMISSION CONTROL
SYSTEM
IGNITION SYSTEM (ELECTRONIC
IGNITION SYSTEM)

EXHAUST SYSTEM

DIFFERENTIAL

Wiring Diagram 8A 5B 8G
LIGHTING SYSTEM

INSTRUMENTATION/DRIVER INFOR­MATION
WINDOWS, MIRRORS, SECURITY AND
LOCKS

BODY SERVICE 9
RESTRAINT SYSTEM

RESTRAINT SYSTEM 10
AIR BAG SYSTEM 10B

6

6E1

6F1

6K

8B

8C

8D

0B 6A

1A 6C
1B 6E

3 6G

3A 6H

3B 6K

3B1

3C 7A

3D 7C

3E 7D
3F 7F

4B 8A

8B

5 8C

5A 8D

5C

5E 9

10

10

NOTE:

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

SECTION 0A

GENERAL INFORMATION

CONTENTS

GENERAL INFORMATION 0A-1

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

Precaution for Wheel (with Tire) Removal .... 0A-9

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

Precaution for Installing Mobile

Communication Equipment ...........................0A-9

Precaution in Servicing Full-Time 4WD

Vehicle ..........................................................0A-9

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

Electrical Circuit Inspection Procedure .......0A-13

Open circuit check...................................0A-13

Continuity check......................................0A-14

Voltage check..........................................0A-14

Short circuit check (wire harness to

ground).................................................... 0A-15

Intermittent and Poor Connection ............... 0A-15

Identification Information.............................0A-17

Vehicle Identification Number ..................... 0A-17

Engine Identification Number...................... 0A-17

Warning, Caution and Information

Labels ............................................................0A-18

Vehicle Lifting Points ...................................0A-19

When using frame contact hoist.............. 0A-19

When using floor jack.............................. 0A-20

Abbreviations and Symbols May be

Used in This Manual .....................................0A-21

Abbreviations ..............................................0A-21

Symbols ......................................................0A-23

Wire Color Symbols .................................... 0A-23

Fastener Information ....................................0A-24

Metric Information ....................................... 0A-24

Fastener Strength Identification.................. 0A-25

Standard Tightening Torque ....................... 0A-25

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 sys-

2

5

3

6

1

8

7

4

7

8

4

tem 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 (in floor harness) 5. Contact coil

2. Passenger air bag (inflator) module 6. Driver air bag (inflator) module

3. SDM 7. Side air bag (inflator) module

4. Seat belt pretensioner 8. Side sensor (if equipped)

(if equipped)

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, passenger and side) 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

[A]

[B]

[C]

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, Passenger and side 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 (1) or use the workbench vise (2) to
hold it securely at its lower mounting bracket (3). The
front seat back with the live air bag (inflator) module
must be placed with its frontal seat cover facing up. It
is also prohibited to place anything on top of the trim
cover and stack air bag (inflator) modules. 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, passenger and side). 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 open-

ing) up, away from loose objects.

[C] : Always place with its frontal seat cover facing up, away from loose objects.

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, never put something on seat belt pre­tensioner. 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 “Repairs and Inspections
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, passenger and side), seat belt pretensioners
(driver and passenger), side sensors 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, passen­ger and side) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth.

• Air bag wire harness is included in floor and instrument panel wire harnesses. Air bag wire harness
branched off from floor and instrument panel wire harnesses can be identified easily as it is covered
with a yellow protection tube and it has yellow connectors. 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 disconnect all air bag (inflator) module connectors and pre­tensioner connectors from air bag wire harness respectively.

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

0A-6 GENERAL INFORMATION

• 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.

• 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.

GENERAL INFORMATION 0A-7

• 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.

• 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 99000-31250

• Be sure to use special tools when instructed.

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

0A-8 GENERAL INFORMATION

• 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.

• 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.

GENERAL INFORMATION 0A-9

Precaution for Wheel (with Tire) Removal

Each wheel of this vehicle is installed using wheel bolts. When removing any of these wheels, never
remove all wheel bolts at the same time. Leave at least 1 bolt for each wheel as it is to prevent wheel
from dropping. When removing this remaining 1 bolt, hold wheel and tire so as not to allow them to
come off.

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.

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.

0A-10 GENERAL INFORMATION

• 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.

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.

GENERAL INFORMATION 0A-11

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

• 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.

0A-12 GENERAL INFORMATION

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

• 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.

GENERAL INFORMATION 0A-13

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

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)

0A-14 GENERAL INFORMATION

Continuity check

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

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

GENERAL INFORMATION 0A-15

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.

0A-16 GENERAL INFORMATION

• 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.

Identification Information

Vehicle Identification Number

The number is punched on front dash panel in engine room and it
is also on the left side of instrument panel depending on the vehi­cle specification.

Engine Identification Number

The number is punched on cylinder block.

GENERAL INFORMATION 0A-17

0A-18 GENERAL INFORMATION

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

2

5

1. Air bag label on back side of engine hood (if equipped) 4. Engine cooling fan label

2. Air bag label on sun visor (if equipped) 5. Steering shaft joint cover label (if equipped)

3. Radiator cap label

1

1

4

6

5

1. Air bag label on driver air bag (inflator) module 5. Pretensioner label on seat belt retractor

2. Air bag label on combination switch and contact coil assembly 6. Child seat label

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

4. Air bag label on SDM

GENERAL INFORMATION 0A-19

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

0A-20 GENERAL INFORMATION

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

Abbreviations and Symbols May be Used in This Manual

Abbreviations

GENERAL INFORMATION 0A-21

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 F 4WD 4 Wheel Drive
ABDC After Bottom Dead Center
A/F Air Fuel Mixture Ratio GND Ground
A-ELR Automatic-Emergency Locking

Retractor
B+ Battery Positive Voltage
BTDC Before Top Dead Center

B

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

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)
DOHC Double Over Head Camshaft MFI Multiport Fuel Injection

D

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

ECT sensor Engine Coolant Temperature

E

EGR Exhaust Gas Recirculation O2S Oxygen Sensor
EGRT sensor EGR Temperature Sensor (Recir-

Sensor (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)

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

ISC Actuator Idle Speed Control Actuator
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

N NOx Nitrogen Oxides

OBD On-Board Diagnostic System

O/D Overdrive

O

OHC Over Head Camshaft

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)ECM Engine Control Module

0A-22 GENERAL INFORMATION

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

S

(Air bag controller, Air bag control

module)
SFI Sequential Multiport Fuel Injection
SOHC Single Over Head Camshaft
TBI Throttle Body Fuel Injection (Sin-

gle-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 (Thermal

Vacuum Switching Valve, TVSV,

Bimetal Vacuum Switching Valve,

BVSV)

TWC Three Way Catalytic Converter

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

V

VSS Vehicle Speed Sensor
VVT Variable Valve Timing
WU-OC Warm Up Oxidation Catalytic

W

WU-TWC Warm Up Three Way Catalytic

Converter

Converter

GENERAL INFORMATION 0A-23

Symbols

SYMBOL DEFINITION SYMBOL DEFINITION

Tightening torque Apply SEALANT 1216B

99000-31230

Apply oil (engine, transmission, trans-

fer, differential)

Apply fluid (brake, power steering or

automatic transmission fluid)

Apply GREASE A 99000-25010

Apply GREASE C 99000-25030 Apply THREAD LOCK 1322

Apply GREASE E 99000-25050 Apply THREAD LOCK 1333B

Apply GREASE H 99000-25120 Apply THREAD LOCK 1342

Apply GREASE I 99000-25210

Apply SEALANT 1215 99000-31110 Do not reuse

Apply SEALANT 1207F 99000-31250 Note on reassembly

Apply SILICONE SEALANT
99000-31120

Apply SEALING COMPOUND 366E
99000-31090

99000-32110

99000-32020

99000-32050

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

G GRN 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).

0A-24 GENERAL INFORMATION

Fastener Information

Metric Information

Metric Fasteners

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

CAUTION:

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

JIS-TO-ISO Main Fasteners Comparison Table

Standard

JIS

ISO

Nominal diameter

Thread pitch 1.0 1.25 1.25 1.25 1.5
Width
accross flats
Thread pitch 1.0 1.25 1.5 1.5 1.5
Width
accross flats

M6 M8 M10 M12 M14

10 12 14 17 19

10 13 16 18 21

GENERAL INFORMATION 0A-25

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)

45681012141618

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

SECTION 0B

MAINTENANCE AND LUBRICATION 0B-1

0B

MAINTENANCE AND LUBRICATION

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 “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 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

Drive Belt Inspection .....................................0B-5

Water pump and generator drive belt

inspection ..................................................0B-5

A/C Compressor drive belt (if equipped)

inspection ..................................................0B-5

Drive Belt Replacement ................................0B-5

Water pump and generator drive belt

replacement...............................................0B-5

A/C Compressor drive belt (if equipped)

replacement...............................................0B-5

Valve Lash (Clearance) Inspection ...............0B-6

Engine Oil and Oil Filter Replacement .......... 0B-6

Engine Coolant Replacement .......................0B-8

Exhaust System Inspection........................... 0B-8

Spark Plugs Replacement.............................0B-9

Air Cleaner Filter Inspection..........................0B-9

Air Cleaner Filter Replacement .....................0B-9

Fuel Lines and Connections Inspection ........0B-9

Fuel Tank Inspection...................................0B-10

PCV Valve Inspection .................................0B-10

Fuel Evaporative Emission Control

System Inspection.......................................0B-10

Brake Discs and Pads (Front) Inspection
Brake Drums and Shoes (Rear) Inspection

Brake Hoses and Pipes Inspection ............. 0B-11

Brake Fluid Replacement............................0B-11

Brake Lever and Cable Inspection.............. 0B-11

Clutch Inspection ........................................0B-12

Tires Inspection...........................................0B-12

Wheel Discs Inspection...............................0B-13

Wheel Bearing Inspection ...........................0B-13

Suspension System Inspection................... 0B-13

Steering System Inspection ........................ 0B-13

Drive Shaft (Axle) Boots Inspection ............ 0B-14

Propeller Shafts (4WD) Inspection.............. 0B-14

Manual Transmission Oil Inspection........... 0B-15

Manual Transmission Oil Replacement ......0B-15

Transfer Oil (4WD) and Rear

Differential Oil (4WD) Inspection................. 0B-15

Transfer Oil (4WD) and Rear

Differential Oil (4WD) Replacement............ 0B-16

All Latches, Hinges and Locks Inspection

Doors.......................................................0B-16

Engine hood............................................ 0B-16

Air Conditioning Filter (If Equipped)

Inspection.................................................... 0B-16

Air Conditioning Filter (If Equipped)

Replacement............................................... 0B-16

Final Inspection ............................................0B-17

Recommended Fluids and Lubricants........ 0B-18

....... 0B-10

...... 0B-11

...... 0B-16

1A
1B

3
3A
3B

3B1

3C
3D
3E
3F

4A
4B

5
5A
5B
5C
5E

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

FUEL SYSTEM

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

Fuel lines and connections – I – I – I
Fuel tank – – I – – I

EMISSION CONTROL SYSTEM

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

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

When
unleaded
fuel is used

When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Condi­tions” in this section.

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

Vehicle with­out HO2S

Vehicle with
HO2S

Vehicle with HO2S – – – – – I

Iridium plug

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

Dusty conditions Refer to “Maintenance Recommended

–––R––

84 months

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 ✱ (asterisk) should be performed by odometer reading only.

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

• Iridium spark plug: IFR6J11 (NGK)

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
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
Air conditioning filter (if equipped) – I R – I R

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 Iridium spark plug R

– B C D – – – H Wheel bearings I

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

– B – – E – – H

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

Maintenance

Maintenance

Operation

Maintenance Interval

I

R

I

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 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
First time only: 15,000 km
(9,000 miles) or 12 months
Second time and after:
Every 30,000 km
(18,000 miles) or 24 months
reckoning from 0 km (0
miles) or 0 month

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

Drive Belt Inspection

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

NOTE:

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

MAINTENANCE AND LUBRICATION 0B-5

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.

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 tension” 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.

Drive Belt Replacement

Water pump and generator drive belt replacement

Replace belt with new one referring to “Water Pump/Generator
Drive Belt Removal and Installation” in Section 6B.

A/C Compressor drive belt (if equipped) replacement

Replace belt with new one referring to “Compressor Drive Belt
Replacement” in Section 1B.

0B-6 MAINTENANCE AND LUBRICATION

Valve Lash (Clearance) Inspection

1) Inspect intake and exhaust valve lash and adjust as neces­sary.
Refer to “Valve Lash (Clearance) Inspection” 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 Precautions 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.

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

MAINTENANCE AND LUBRICATION 0B-7

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)

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 SG, SH, SJ or SL
grade. Select the appropriate oil viscosity according to the
proper engine oil viscosity chart [A].

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.

0B-8 MAINTENANCE AND LUBRICATION

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.

CAUTION:

When changing engine coolant, use mixture of 50% spec­ified water and 50% ANTIFREEZE / ANTICORROSION
COOLANT for the purpose of corrosion protection and
lubrication.

Change engine coolant with new one referring to “Cooling System
Flush and Refill” in Section 6B.

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.

MAINTENANCE AND LUBRICATION 0B-9

Spark Plugs Replacement

Replace spark plugs with new ones referring to “Spark Plugs
Removal and Installation” in Section 6F1.

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.

4) Install air cleaner filter and clamp upper case securely.

Air Cleaner Filter 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.

0B-10 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.

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 VALVE”
under “PCV system inspection” 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 CANISTER” under “Evaporative emission control
system inspection” in Section 6E1.

If a malfunction is found, repair or replace.

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 Inspection” and “Front
Brake Disc Inspection” in Section 5B.
Be sure to torque caliper pin bolts to specification.

MAINTENANCE AND LUBRICATION 0B-11

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 “Drum Brake Component Parts Inspec­tion” in Section 5C.

Brake Hoses and Pipes Inspection

Perform this inspection where there 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 “Air Bleeding of Brake System”
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-12 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)

Clutch Inspection

Check clutch pedal for height and free travel (1) referring to
“Clutch pedal height” and “Clutch pedal free travel” in Section 7C.
Adjust or correct if necessary.

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-13

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, Bolt and
Bearing Check” in Section 3D.

2) Check rear wheel bearing for wear, damage, abnormal noise
or rattles. For details, refer to “Wheel Disc, Bolt 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-14 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 “Front Wheel Alignment
Inspection and Adjustment” in Section 3A.

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-15

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 Transaxle Oil Change” in
Section 7A.

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

Manual Transmission Oil 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 Transaxle Oil Change” in Section 7A.

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 “Rear
Differential Gear 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 “Transfer
Oil Change” in Section 7D or “Rear Differential Gear Oil
Change” in Section 7F.

0B-16 MAINTENANCE AND LUBRICATION

Transfer Oil (4WD) and Rear Differential Oil
(4WD) Replacement

Change transfer oil and differential oil with new specified oil refer­ring to “Transfer Oil Change” in Section 7D or “Rear Differential
Gear Oil Change” in Section 7F.

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.

Air Conditioning Filter (If Equipped) Inspection

1) Remove the air conditioning filter from the cooling unit refer­ring to “Air Conditioning Filter (If Equipped) Replacement” in
this section.

2) Check for dirt and dust. If the air conditioning filter is exces­sively dirty, replace the air conditioning filter with the new
one. If not, go to the next step.

3) Blow compressed air on the air outlet side of the air condi­tioning filter for removing dust.

4) Install the air conditioning filter into the cooling unit by
reversing the removal procedure.

Air Conditioning Filter (If Equipped) Replacement

1) Remove the air conditioning filter door (1) from the cooling
unit (2).

2) Remove the air conditioning filter from the cooling unit.

3) Install the new air conditioning filter into the cooling unit.

4) Install the air conditioning filter door onto the cooling unit.

MAINTENANCE AND LUBRICATION 0B-17

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.

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.

0B-18 MAINTENANCE AND LUBRICATION

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.

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 SG, SH, SJ or SL grade (Refer to “Engine Oil and Oil Filter

Replacement” in this section for engine oil viscosity.)
Engine coolant (Ethylene glycol base coolant) “Antifreeze / Anticorrosion coolant”
Brake fluid DOT 4 or SAE J1704
Manual transmission oil Refer to “Manual Transaxle Oil Change” in Section 7A.
Transfer oil (4WD) Refer to “Transfer Oil Change” in Section 7D.
Differential oil (4WD) Refer to “Rear Differential Gear Oil Change” in Section 7F.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

SECTION 1A

HEATER AND VENTILATION 1A-1

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 “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 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).

CONTENTS

General Description........................................1A-2

Heater and Ventilation Construction .............1A-2

Heater and Ventilation Wiring Circuit

Diagram.........................................................1A-3

Diagnosis.........................................................1A-4

Heater and Ventilation System Symptom

Diagnosis ......................................................1A-4

On-Vehicle Service..........................................1A-5

Heater Unit Components...............................1A-5

Heater Unit Removal and Installation............1A-5

Blower Motor Removal and Installation.........1A-6

Blower Motor Inspection................................1A-7

Blower Motor Resistor Removal and

Installation .....................................................1A-8

Blower Motor Resistor Inspection ................. 1A-8

Heater Control Lever Assembly

Components.................................................. 1A-9

Heater Control Lever Assembly

Removal and Installation............................... 1A-9

Blower Speed Selector Inspection .............. 1A-11

Rear Defogger Switch Inspection ...............1A-12

Air Inlet Box Components ........................... 1A-13

Air Inlet Box Removal and Installation ........ 1A-13

Center Ventilation Louver Removal and

Installation.................................................. 1A-14

Side Ventilation Louver Removal and

Installation................................................... 1A-14

1A

1B

3
3A
3B

3B1

3C
3D
3E
3F

4A
4B

5
5A
5B
5C
5E

1A-2 HEATER AND VENTILATION

General Description

Heater and Ventilation Construction



1. Heater unit 6. Side ventilation air 11. Recirculation air 16. Temperature control door

2. Air inlet box 7. Foot air 12. Center ventilation air 17. Foot air control door

3. Ventilator duct 8. Front defroster air 13. Air inlet select door 18. Ventilation defroster air control door

4. Defroster nozzle 9. Side defroster air 14. Blower motor 19. Side ventilation control door

5. Ventilator outlet 10. Fresh air 15. Heater core

Heater and Ventilation Wiring Circuit Diagram

HEATER AND VENTILATION 1A-3

1. Ignition switch 4. Lighting controller 7. Junction connector

2. Blower motor 5. Rear defogger relay 8. Rear defogger

3. Heater control panel 6. Blower motor resistor a: To lighting switch

1A-4 HEATER AND VENTILATION

Diagnosis

Heater and Ventilation System Symptom Diagnosis

Condition Possible Cause Correction
Blower motor dose
not work even when
its switch is at operat­ing position.

Blower speed selec­tor dose not work
when its switch is at
maximum air flow
position.
Incorrect temperature
output.

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

Fuse blown Check “HEATER” fuse and main

Blower motor resistor faulty Check blower motor resistor.
Blower speed selector faulty Check blower speed selector.
Blower motor faulty Replace blower motor.
Wiring or grounding faulty Repair as necessary.
Blower speed selector faulty Check blower speed selector.
Wiring or grounding faulty Check wiring and grounding, and

Control cables broken or binding Check control cables.
Temperature control lever faulty Check temperature control lever.
Position of control cable clamp is faulty Check position and adjust it as nec-

Temperature control door assembly broken Repair temperature control door

Air ducts clogged Repair air ducts.
Heater core leaking or clogged Replace heater core.
Heater hoses leaking or clogged Replace heater hoses.
Thermostat faulty Check thermostat by referring to

Control cable broken or binding Check control cable.
Airflow control lever faulty Check air flow control lever.
Position of control cable clamp is faulty Check position and adjust it as nec-

Control doors broken Repair control doors.
Air ducts leaking or clogged Repair air ducts.

heater fuse, and then check for
short circuit to ground.

then repair as necessary.

essary.

assembly.

Section 6B.

essary.

Heater Unit Components

HEATER AND VENTILATION 1A-5

On-Vehicle Service

1. Heater core 4. Temperature control door assembly 7. Temperature control lever

2. Blower motor assembly 5. Air flow control door assembly 8. Heater case

3. Blower motor resistor 6. Air flow control lever

Heater Unit Removal and Installation

REMOVAL

1) Disconnect negative (–) cable at battery.

2) If equipped with air bag system, disable air bag system refer­ring to “Disabling air bag system” in Section 10B.

1A-6 HEATER AND VENTILATION

6

6

2

3

5

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

4) Remove instrument panel referring to “Instrument Panel
Removal and Installation” in Section 9.

4

7

5) Loosen air inlet box (cooling unit) mounting nut (2), and
remove mounting nut (3).

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

7) Remove heater unit (7).

1

INSTALLATION

Reverse removal procedure install heater unit noting the following
instructions.

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

•

Adjust control cables by referring to “Heater Unit Removal and
Installation”

in this section.

• Fill engine coolant to radiator.

• If equipped with air bag system, enable air bag system refer­ring to “Enabling air bag system” in Section 10B.

Blower Motor Removal and Installation

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system (if equipped) referring to “Disabling
air bag system” in Section 10B.

3) Remove column hole cover.

4) Remove the pedal.

• For RH steering vehicle, remove clutch pedal assembly.

• For LH steering vehicle, remove accelerator pedal (1)
assembly.

1

HEATER AND VENTILATION 1A-7

1

2

6) Remove blower motor (2).

INSTALLATION

1) Reverse removal procedure for installation.

2) Enable air bag system (if equipped) referring to “Enabling air
bag system” in Section 10B.

Blower Motor Inspection

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

5) Disconnect blower motor coupler (1).

2) Check operation and current.

a) Fix blower motor (1) by using vise.

1

b) Connect battery to blower motor (1) as shown.
c) Check if blower motor operates smoothly without abnormal

noise.

2

d) Check if ammeter indicates specified current.

If measured current is incorrect, replace blower motor.

1

Blower specified current at 12 V
18 A maximum

1A-8 HEATER AND VENTILATION

1

Blower Motor Resistor Removal and Installa­tion

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system (if equipped) referring to “Disabling
air bag system” in Section 10B.

3) Remove clutch pedal bracket (RH steering vehicle only).

4) Disconnect blower motor resistor coupler.

5) Remove blower motor resistor (1).

INSTALLATION

1) Reverse removal procedure for installation.

2) Enable air bag system (if equipped) referring to “Enabling air
bag system” in Section 10B.

Blower Motor Resistor Inspection

Measure each terminal-to-terminal resistance on resistor.

H

MI

Mh

L

If measured resistance is incorrect, replace blower motor resistor.

Resistance

H – Mh: Approx. 0.4 Ω at 20 – 25 °C (68 – 77 °F)
Mh – Ml: Approx. 0.6 Ω at 20 – 25
Ml – L: Approx. 1.0 Ω at 20 – 25

°C (68 – 77 °F)

°C (68 – 77 °F)

Heater Control Lever Assembly Components

7

HEATER AND VENTILATION 1A-9

1

4

10

2

8

3

9

1. Heater control body assembly 4. Bulb 7. Airflow control cable 10. A/C switch

2. Airflow selector 5. Air intake control cable 8. Air intake selector 11. Rear defogger switch

3. Blower speed selector 6. Temperature control cable 9. Temperature selector

11

6

5

Heater Control Lever Assembly Removal and
Installation

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system (if equipped) referring to “Disabling
air bag system” in Section 10B.

3) Remove center garnish (1) and radio or accessory case (if
equipped).

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

5) Disconnect blower speed selector coupler and rear defogger
(and A/C) switch coupler.

1

1A-10 HEATER AND VENTILATION

1

a

6) Remove heater control lever assembly (1).

INSTALLATION

NOTE:

When installing heater control lever assembly, be careful
not to damage the unit by taping (a) the unit for prorec­tion.

1) Reverse removal procedure for installation.

[A]

[B]

a

2) Adjust cables as follows.

a

2

3

1

A/C

c

a

2

3

1

A/C

b

a) Move airflow selector (a), temperature selector (b) and air

intake selector (c) fully in arrow direction as shown in figure.

4

b

4

c

A: LH steering vehicle

B: RH steering vehicle

HEATER AND VENTILATION 1A-11

b) Push airflow control lever (d), temperature control lever (e)

d

and door link (f) fully in arrow direction and fix cable with
clamp in position as shown in figure.

NOTE:

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

3) If equipped with air bag, enable air bag system referring to
“Enabling air bag system” in Section 10B.

e

ML

MH

f

Blower Speed Selector Inspection

L

H

GND

I

Check blower speed selector for each terminal-to-terminal conti­nuity.

TERMINAL

POSITION

OFF

1
2
3
4

GND I L ML MH H

O
OOO
OO O
OO O
OO O

1A-12 HEATER AND VENTILATION

Rear Defogger Switch Inspection

BCA

Check for continuity between terminals at each switch position by
referring to the table below.

TERMINAL

ABC

POSITION

OFF

[a]

ON

[b]

[a]: Switch button released

[b]: Switch button kept in push

Air Inlet Box Components

HEATER AND VENTILATION 1A-13

1

5

6

1. Air inlet box 4. Grommet 7. Air inlet door

2. Dash packing 5. Air filter (if equipped) 8. Air inlet box

3. Packing 6. Door link 9. Air resistance board

Air Inlet Box Removal and Installation

Refer to “Cooling Unit (Evaporator) Removal and Installation” in
Section 1B.

1A-14 HEATER AND VENTILATION

1

Center Ventilation Louver Removal and
Installation

REMOVAL

1) Remove center garnish (1).

2

1

INSTALLATION

Reverse removal procedure for installation.

Side Ventilation Louver Removal and Installa­tion

REMOVAL

1) Remove ventilation louver (1) as shown.

2. Rag

2) Remove center ventilation louver (1) from center garnish (2).

1

INSTALLATION

Reverse removal procedure for installation.

2

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 “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 CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte­nance. For identification between these two types, refer to “Refrigerant Type Construction” in page
1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

1B

For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CON­DITIONINGBASIC MANUAL (P/No: 99520-02130).

CONTENTS

General Description........................................1B-3

Refrigerant Type Construction ......................1B-3

Air Conditioning System Description.............1B-3

Major Components of A/C System................1B-4

A/C System Wiring Circuit Diagram .............. 1B-5

Diagnosis.........................................................1B-6

A/C System Symptom Diagnosis ..................1B-6

Abnormal Noise Diagnosis of A/C System.... 1B-9

Abnormal noise from compressor .............1B-9

Abnormal noise from magnetic clutch ....... 1B-9

Abnormal noise from tubing ......................1B-9

Abnormal noise from condenser

assembly ...................................................1B-9

Abnormal noise from crankshaft pulley ... 1B-10

Abnormal noise from tension pulley ........ 1B-10

Abnormal noise from A/C evaporator......1B-10

Abnormal noise from blower motor ......... 1B-10

A/C System Performance Inspection.......... 1B-11

Performance diagnosis table................... 1B-12

A/C System Inspection of ECM................... 1B-16

Voltage check.......................................... 1B-16

On-Vehicle Service .......................................1B-18

Operation Procedure for Refrigerant

Charge ........................................................1B-18

Recovery.................................................1B-19

Replenishing compressor oil................... 1B-19

When replacing other part....................... 1B-20

Evacuation of A/C system....................... 1B-20

A/C system check for pressure leaks...... 1B-21

Charge .................................................... 1B-22

Removing manifold gauge set................. 1B-24

Leak test..................................................1B-24

1B-2 AIR CONDITIONING (OPTIONAL)

Precautions on Servicing A/C System ........ 1B-25

Refrigerant line........................................ 1B-25

Handling refrigerant HFC-134a

(R-134a)..................................................1B-26

Refrigerant recovery ...............................1B-26

Refrigerant charge ..................................1B-26

Condenser Assembly On-Vehicle

Inspection.................................................... 1B-26

Condenser Assembly Removal and

Installation................................................... 1B-26

Receiver / Dryer Removal and

Installation................................................... 1B-28

Condenser Cooling Fan Motor

On-Vehicle Inspection................................. 1B-28

Condenser Cooling Fan Assembly

Removal and Installation............................. 1B-29

Cooling Unit (Evaporator) Components ...... 1B-30

Cooling Unit (Evaporator) Removal and

Installation................................................... 1B-30

Cooling Unit (Evaporator) Inspection .......... 1B-31

Evaporator Thermistor (Evaporator
Temperature Sensor) Removal and

Installation................................................... 1B-31

Evaporator Thermistor (Evaporator

Temperature Sensor) Inspection ................ 1B-32

Expansion Valve Inspection........................ 1B-32

Expansion Valve Removal and

Installation................................................... 1B-33

Dual Pressure Switch Inspection................ 1B-33

Dual Pressure Switch Removal and

Installation .................................................. 1B-34

A/C Switch Inspection................................. 1B-34

Condenser Cooling Fan Relay

(No.1 and No.2) Inspection......................... 1B-35

Compressor Relay Inspection..................... 1B-36

Compressor Assembly Removal and

Installation .................................................. 1B-36

Compressor Drive Belt Inspection and

Adjustment.................................................. 1B-37

Compressor Drive Belt Replacement ......... 1B-38

Compressor Assembly Components .......... 1B-38

Magnet Clutch Inspection ........................... 1B-39

Magnet Clutch Removal and

Installation .................................................. 1B-39

Thermal Switch Inspection.......................... 1B-41

Thermal Switch Removal and

Installation .................................................. 1B-41

Relief Valve Inspection ............................... 1B-42

Relief valve Removal and Installation......... 1B-42

Specifications ............................................... 1B-43

Tightening Torque Specifications ............... 1B-43

Special Tools and Equipment ..................... 1B-43

Required Service Material .......................... 1B-43

Special Tool................................................ 1B-43

General Description

Refrigerant Type Construction

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

AIR CONDITIONING (OPTIONAL) 1B-3

Air Conditioning System Description

[A]: Liquid 1. Compressor 4. Receiver / dryer 7. Evaporator

[B]: Vapor 2. Magnet clutch 5. Pressure switch

[C]: Superheated vapor 3. Condenser 6. Expansion valve

1B-4 AIR CONDITIONING (OPTIONAL)

Major Components of A/C System

12 12

1313



1

15

7

14

16

8

3

5

4

2

7

6

5

6

1

11 11

8

9

10

9

4

2

3

1. Cooling unit 5. Discharge hose 9. Side ventilation air 13. Side defroster air

2. Compressor 6. Suction hose 10. Center ventilation air 14. Fresh air

3. Condenser assembly 7. Liquid pipe 11. Foot air 15. Recirculation air

4. Receiver / dryer 8. Expansion valve 12. Front defroster air 16. Evaporator

A/C System Wiring Circuit Diagram

AIR CONDITIONING (OPTIONAL) 1B-5

1B-6 AIR CONDITIONING (OPTIONAL)

1. Ignition switch 7. Junction connector 13. Condenser cooling fan

2. Blower motor 8. Rear defogger 14. Radiator cooling fan relay 20. ECT sensor

3. Heater control panel 9. Dual pressure switch 15. Condenser cooling fan

4. Lighting controller 10. ECM 16. Condenser cooling fan

5. Rear defogger relay 11. Main relay 17. Compressor relay

6. Blower motor resistor 12. Radiator cooling fan motor 18. Compressor

relay No.2

motor

relay No.1

19. A/C evaporator thermistor

a: To lighting switch

Diagnosis

A/C System Symptom Diagnosis

Condition Possible Cause Correction
No cool air comes out
(A/C system does not
operate)

No cool air comes out
(A/C condenser cool­ing fan motor does not
operate)

No refrigerant Perform recovery, evacuation and charge.
Fuse blown Check related fuses, and check short cir-

cuit to ground.
A/C switch faulty Check A/C switch.
Blower speed selector faulty Check blower speed selector referring to

“Blower Speed Selector Inspection” in

Section 1A.
A/C evaporator temperature sensor
faulty

Check A/C evaporator temperature sen-

sor.
Dual pressure switch faulty Check dual pressure switch.
Wiring or grounding faulty Repair as necessary.
ECT sensor faulty Check ECT sensor referring to Section

6E1.
ECM and/or its circuit faulty Check ECM and its circuit referring to Sec-

tion 6E1.
Magnet clutch faulty Check magnet clutch.
Compressor drive belt loosened or bro-

Adjust or replace drive belt.
ken
Compressor faulty Check compressor.
Compressor relay faulty Check compressor relay.
Fuse blown Check related fuses, and check for short

circuit to ground.
Wiring or grounding faulty Repair as necessary.
Condenser cooling fan motor relay

Check condenser cooling fan motor relay.
faulty
Condenser cooling fan motor faulty Check condenser cooling fan motor.
ECM and/or its circuit faulty Check ECM and its circuit referring to Sec-

tion 6E1.

Condition Possible Cause Correction
No cool air comes out
(Blower motor does
not operate)

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

Cool air does not
come out only inter­mittently

AIR CONDITIONING (OPTIONAL) 1B-7

Fuse blown Check related fuses, and check for short

circuit to ground.

Blower motor resistor faulty Check blower motor resistor referring to

“Blower Motor Resistor Inspection” in Sec­tion 1A.

Blower speed selector faulty Check blower speed selector referring to

“Blower Speed Selector Inspection” in

Section 1A.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower

Motor Inspection” in Section 1A.
Insufficient or excessive charge of
refrigerant

Check charge of refrigerant and system for

leaks.
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator

temperature sensor.
A/C evaporator temperature sensor
faulty

Check A/C evaporator temperature sen-

sor.
Expansion valve faulty Check expansion valve.
Desiccant clogged Check receiver / dryer
Compressor drive belt loosened or bro-

Adjust or replace drive belt.
ken
Magnetic clutch faulty Check magnetic clutch.
Compressor faulty Check compressor.
Air in A/C system Replace desiccant, and perform evacua-

tion and charge.
Air leaking from heater and cooling unit

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

control assembly and heater unit.
Blower motor faulty Check blower motor referring to “Blower

Motor Inspection” in Section 1A.
Excessive compressor oil existing in
A/C system

Pull out excess compressor oil in A/C sys-

tem circuit, and check compressor.
Wiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace receiver / dryer, and perform

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

1B-8 AIR CONDITIONING (OPTIONAL)

Condition Possible Cause Correction
Cool air comes out
only at high speed

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

Compressor drive belt loosened or bro­ken
Compressor faulty Check compressor.
Condenser cooling fan motor faulty Check condenser cooling fan motor.
Condenser cooling fan motor relay
faulty
Condenser cooling fan blade faulty Check condenser cooling fan blade.

Cool air does not
come out only at high

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

speed
Insufficient airflow of

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 motor faulty Check blower motor referring to “Blower

Wiring or grounding faulty Repair as necessary.

evacuation and charge.
Adjust or replace drive belt.

Check condenser cooling fan motor relay.

temperature sensor.

temperature sensor.

Motor Inspection” in Section 1A.

Abnormal Noise Diagnosis of A/C System

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.

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.

Inadequate clearance in scroll area Replace compressor.

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

Loose compressor mounting bolts Tighten mounting bolts.
Loose compressor clutch plate bolt Tighten clutch plate bolt.

Worn or damaged bearings Replace magnet clutch assembly.

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

AIR CONDITIONING (OPTIONAL) 1B-9

drive belt.

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

Adjust magnet clutch clearance.

Replace compressor body assem­bly.

Abnormal noise from tubing

Condition Possible Cause Correction
A droning noise is heard
from inside of the 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 assembly

Condition Possible Cause Correction
Considerable vibration in
condenser assembly

Resonance from condenser assembly
bracket and body

Loose condenser cooling fan mount­ing bolts
Faulty condenser cooling fan blade Replace condenser cooling fan

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

Firmly insert a silencer between
condenser assembly bracket and
body.
Tighten mounting bolts.

blade.

1B-10 AIR CONDITIONING (OPTIONAL)

Abnormal noise from crankshaft pulley

Condition Possible Cause Correction
A loud rattling noise is heard
at idle or sudden accelera­tion.

Loosen crankshaft pulley bolt Tighten bolt.

Abnormal noise from tension pulley

Condition Possible Cause Correction
Clattering noise is heard
from pulley.
Pulley cranks upon contact. Cracked or loose bracket Replace or tighten bracket.

Worn or damaged bearing Replace tension pulley.

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 motor

Condition Possible Cause Correction
Blower motor emits a chirp­ing sound in proportion to its
speed of rotation.
Fluttering noise or loud dron­ing noise is heard from
blower motor.

Worn or damaged motor brushes or
commutator

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

Replace blower motor.

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

AIR CONDITIONING (OPTIONAL) 1B-11

A/C System Performance Inspection

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

– Vehicle is not exposed to direct sun.
– Ambient temperature is within 15

°F).

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

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

4

3

cle.

4) Bleed the air in charging hoses (3) and (4) by loosening their
nuts respectively on manifold gauge, utilizing the refrigerant

5

6

pressure. When a hiss is heard, immediately tighten nut.

CAUTION:

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

°C – 35 °C (59 °F – 95

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

6) Turn A/C switch ON, and set blower selector at “4” maxi­mum, temperature selector at maximum cold, airflow selec­tor at face, air intake selector at recirculation position.
(Confirm that A/C compressor and condenser fans are work­ing.)

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

Performance diagnosis condition

A/C inlet air temperature

15 – 35

°C (59 – 95 °F)

Engine rpm Keep 1,500 r/min.
Blower fan switch “4” (maximum position)
Temperature control Maximum cold
Air outlet control Face
Vehicle Doors All open
Air inlet door position Recirculation

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

1B-12 AIR CONDITIONING (OPTIONAL)

9) Check for each pressure of low side and high side if it is
within shaded range of left graph.
If each gauge reading is out of specified pressure, correct
defective part referring to following Test Diagnosis table.

NOTE:

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

Example:

Gauges should read as follows when ambient tempera­ture is 30

Pressure on high pres­sure gauge (HI):
Pressure on low pressure
gauge (LO):

°C (86 °F)

1400 – 1750 kPa

14.0 – 17.5 kg/cm
230 – 350 kPa

2.3 – 3.5 kg/cm

2

2

10) Check inlet port temperature-to-outlet port temperature rela­tionship using graph at the left.
For example, if evaporator inlet port temperature is 25

°C (77

°F) and center duct air outlet temperature is 8 °C (46.4 °F),

their crossing point is within acceptable range as shown in
graph at the left.
In this case, cooling performance is satisfactory and proper.

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

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 “DETAILED DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30°C (86°F))” under “A/C
System Performance Inspection” in this section.

HIGH PRESSURE GAUGE

Condition Possible Cause Correction
Pressure high
(“A” 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.
Condenser cooling fan malfunction (Insufficient
cooling of condenser)
Dirty or bent condenser fins (Insufficient cooling
of condenser)
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system refer-

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

Insufficient refrigerant (Insufficient charge or
leakage)
Expansion valve malfunction (valve opens too
wide)
Compressor malfunction (Insufficient compres­sion)

AIR CONDITIONING (OPTIONAL) 1B-13

Check condenser cooling fan.

Clean or repair.

ring to Section 6B.
Check for leakage, repair if neces­sary and recharge.
Check expansion valve.

Check compressor.

LOW PRESSURE GAUGE

Condition Possible Cause Correction
Pressure high
(“C” area of low side
graph)

Expansion valve malfunction (valve opens too
wide)
Compressor malfunction (Insufficient compres­sion)

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

Insufficient refrigerant (Insufficient charge or
leakage)
Expansion valve malfunction (valve opens too
narrow)
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”)

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.

Outlet air temperature
at center duct is low
(Crossing point is in

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

area “F”)

Check expansion valve.

Check compressor.

Check for leakage, repair if neces­sary and recharge.
Check expansion valve.

Repair or replace.

Check blower motor and fan.

1B-14 AIR CONDITIONING (OPTIONAL)

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

Condition

MPa

Manifold

Gauge

(kg/cm

2

)

Detail

Possible Cause Correction

(psi)

Lo Hi

0.23 – 0.35
(2.3 – 3.5)
(33 – 50)
Negative
pressure

1.4 – 1.75
(14 – 17.5)
(200 – 249)

0.5 – 0.6
(5 – 6)
(71.2 – 85.3)

Normal condition

The low pressure side
reads a negative pres­sure, and the high pres­sure side reads an
extremely low pres-

––

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

sure.
Presence of frost
around tubing to and
from receiver / dryer
and expansion valve.

Normal :

0.23 – 0.35
(2.3 – 3.5)
(33 – 50)

↑ ↓

Abnormal :
Negative
pressure

Normal :

1.4 – 1.75
(14 – 17.5)
(200 – 249)

↑ ↓

Abnormal :

0.7 – 1.0
(7 – 10)
(100 – 142)

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

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

pressure.

0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)

0.7 – 1.0
(7 – 10)
(100 – 142)

Both low and high pres­sure sides indicate low
readings.

Insufficient refrigerant in
system
(Refrigerant leaking)

Continuous air bub­bles are visible through
sight glass.
Output air is slightly
cold.

0.4 – 0.6
(4 – 6)
(56.9 – 85.3)

Pressure on low pres­sure side is high.
Pressure on high pres-

Internal leak in compres­sor

sure side is low.
Both pressure becom­ing equal right after A/C
is turned OFF.

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.
Inspect compressor and
repair or replace as nec­essary.

Manifold

Gauge

Lo Hi

0.35 – 0.45
(3.5 – 4.5)
(50 – 64)

0.45 – 0.55
(4.5 – 5.5)
(64 – 78)

Condition

MPa

(kg/cm

2

(psi)

2.0 – 2.5
(20 – 25)
(285 – 355)

)

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.

AIR CONDITIONING (OPTIONAL) 1B-15

Possible Cause Correction

Overcharged A/C system Adjust refrigerant to

specified amount.

Faulty condenser cool-

Clean condenser.
ing operation
Faulty condenser cool­ing fan operation
Presence of air in A/C
system
(Improperly evacuated)

Inspect and repair con-

denser cooling fan.

Replace receiver / dryer.

Inspect quantity of com-

pressor oil and presence

of contaminants in oil.

Evacuate system and

recharge with fresh refrig-

erant.

Faulty expansion valve
Refrigerant flow is not

Replace expansion

valve.
regulated properly

1B-16 AIR CONDITIONING (OPTIONAL)

A/C System Inspection of ECM

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

CAUTION:

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

Voltage check

1) Remove ECM (1) from vehicle.

2) Connect ECM couplers (2) to ECM.

3) Check voltage at each terminal of couplers connected. Refer
to “Fuel injector on-vehicle inspection” in Section 6E.

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

3. C64-2

Terminal arrangement of ECM coupler (viewed from harness side)

C64 C63 G91

1234567

891011121314151617
18192021222324252627
28293031323334

35

1234567

8910111213141516171819
2021222324252627
28293031323334

123456

78910111213141516

1718192021222324252627

35

28293031323334

ECM voltage values table for relation of A/C control

AIR CONDITIONING (OPTIONAL) 1B-17

Termi-

nal

C63-16 LT GRE Engine cool-

C63-28 ORN Sensor ground Ground to

C64-2 BLK ECM ground

C64-5 GRN/

C64-11 PNK/

C64-12 PNK Condenser

C64-15 BRN/

G91-4 BRN Radiator cool-

G91-6 BLK/

G91-13 YEL Blower fan

G91-15 WHT/

Wire Circuit Measure-

ment

Ground

Ground to

engine (Fig B)

engine (Fig B)

Ground to

body (Fig A)

Ground to

engine (Fig B)

Ground to

engine (Fig B)

Ground to

engine (Fig B)

engine (Fig B)

Ground to

engine (Fig B)

Ground to

engine (Fig B)

Ground to

engine (Fig B)

Ground to

engine (Fig B)

YEL

BLK

WHT

RED

BLK

ant tempera­ture sensor
input

for sensor cir­cuit
Condenser
cooling fan
relay No.2 out­put

Magnet clutch
relay output

cooling fan
relay No.1 out­put

Main relay Ground to

ing fan relay
output
Power supply
for engine con­trol

switch

Evaporator
thermistor
temp. input

Normal

Value

3.7 – 3.85 V

1.45 – 1.6 V

0.4 – 0.5 V

–0.5 – 0 V Ignition switch ON

–0.5 – 0 V Ignition switch ON

0 – 1 V Ignition switch ON, Engine coolant temper-

10 – 14 V Ignition switch ON, Engine coolant temper-

0 – 1 V Engine running, A/C request signal low

10 – 14 V Engine running, A/C request signal high

0 – 1 V Ignition switch ON, Engine coolant temper-

10 – 14 V Ignition switch ON, Engine coolant temper-

0 – 1 V Ignition switch ON

10 – 14 V Ignition switch OFF

0 – 1 V

10 – 14 V

10 – 14 V Ignition switch ON

0 – 2 V Blower fan switch 2nd or 3rd or 4th position

3 – 6 V Blower fan switch 1st position with ignition

10 – 14 V Blower fan switch OFF position with ignition

1.9 – 2.3 V
(1940 –

2060 Ω)

3.3 – 3.8 V
(6450 –

6850 Ω)

Ignition switch ON, ECT at 0
Ignition switch ON, ECT at 50
Ignition switch ON, ECT at 100

ature more than 110
request signal low input

ature under 113
signal high input

input and engine coolant temperature less
than 110

input and engine coolant temperature more
than 113

ature more than 110
request signal low input

ature under 113
signal high input

with ignition switch ON

switch ON

switch ON
Evaporator thermistor temperature at
approximately 25 °C (77 °F) with ignition
switch ON
Evaporator thermistor temperature at
approximately 0 °C (32 °F) with ignition
switch ON

°C (230 °F)

°C (235 °F)

Condition

°C (32 °F)

°C (122 °F)

°C (212 °F)

°C (230 °F) or A/C

°C (235 °F) or A/C request

°C (230 °F) or A/C

°C (235 °F) or A/C request

1B-18 AIR CONDITIONING (OPTIONAL)

Termi-

nal

Wire Circuit Measure-

ment

Normal

Value

Condition

Ground

G91-30 YEL/

GRN

A/C switch
input

Ground to

engine (Fig B)

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

ignition switch ON

10 – 14 V Blower fan switch and A/C switch OFF with

ignition switch ON

G91-35 PNK/

BLU

Blower fan
speed input

Ground to

engine (Fig B)

–0.5 – 0 V Ignition switch ON

On-Vehicle Service

Operation Procedure for Refrigerant Charge

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 (21 °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.

Start evacuation

10

Stop evacuation

Recharge A/C system with
refrigerant

Check A/C system for refrigerant
leaks and amount of refrigerant
charged

760

430

20

AIR CONDITIONING (OPTIONAL) 1B-19

Recovery

REFRIGERANT RECOVERY

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

NOTE:

• After recovering 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 replenish 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 recovering
refrigerant (if not measured, replenish 30 cc oil).

1B-20 AIR CONDITIONING (OPTIONAL)

WHEN REPLACING COMPRESSOR

CAUTION:

Be sure to use P/N: 99000-99085-00A compressor oil or
an equivalent 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

90

± 10 cm

1. New compressor

2. Removed compressor

3

(90 ± 10 cc, 5.49 ± 0.61 in3)

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 in3)

3

(15 cc, 0.92 in3)

3

(20 cc, 1.22 in3)

3

(10 cc, 0.61 in3) each

3

(10 cc, 0.61 in3) each

Evacuation of A/C system

EVACUATING PROCEDURE

CAUTION:

Do not evacuate before recovering refrigerant in system.

NOTE:

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

AIR CONDITIONING (OPTIONAL) 1B-21

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

2

5

1

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.

4

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 (11) 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.

A/C system check 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-22 AIR CONDITIONING (OPTIONAL)

Charge

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 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 charge 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 if hoses are routed properly after evacuating the sys­tem.

3

5

6

4

2) Connect low charging hose (1) and high charging hose (2) of
the manifold gauge set (3) in position. Then, open refrigerant
container valve (4) to purge the charging line.

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

1

2

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-23

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

4

1

3

2

(430

± 20 g) of refrigerant or when low pressure gauge (1)

and high pressure gauge (2) have indicated the following
specified value, close low pressure side valve (3) on mani­fold gauge set (4).

Low side and high side pressure example
Gauges should read as follows when ambient tempera­ture is 30 °C (86 °F).

Pressure
on high pressure gauge

1400 – 1750 kPa

14.0 – 17.5 kg/cm

2

199.1 – 248.9 psi
Pressure
on low pressure gauge

230 – 350 kPa

2.3 – 3.5 kg/cm

2

32.7 – 49.8 psi

1B-24 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-25

Precautions on Servicing A/C System

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.

Refrigerant line

OIL

2

OIL

5

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.

OIL

1

OIL

3

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.

OIL

4

• Never use heat for bending pipes. When bending a pipe, try to make its bending angle as smooth 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.

• 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” under “Operation Procedure for Refrigerant Charge” in this sec­tion.

• 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-26 AIR CONDITIONING (OPTIONAL)

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 “Charge” under “Operation Procedure for Refrigerant Charge” in this section.

CAUTION:

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

Condenser Assembly On-Vehicle 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.

Condenser Assembly Removal and Installa­tion

CAUTION:

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

AIR CONDITIONING (OPTIONAL) 1B-27

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Recover refrigerant from A/C system by referring to “Recov­ery” under “Operation Procedure for Refrigerant Charge” 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 and Rear
Bumper Removal and Installation” in Section 9.

4) Disconnect condenser cooling fan motor coupler (1).

4

2

4

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

6) Remove condenser assembly mounting bolts (4).

7) Remove condenser assembly (3).

1

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”
under “Operation Procedure for Refrigerant Charge” in this
section.

• Evacuate and charge refrigerant by referring to “Evacuation
of A/C system” and “Charge” under “Operation Procedure for
Refrigerant Charge” in this section.

1B-28 AIR CONDITIONING (OPTIONAL)

1

2

a

a < b

Receiver / Dryer Removal and Installation

REMOVAL

1) Remove condenser assembly referring to “Condenser
Assembly Removal and Installation” in this section.

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

3) Remove receiver / dryer (3).

3

INSTALLATION

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

• Replenish specified amount of compressor oil to compressor
suction side by referring to “Replenishing compressor oil”
under “Operation Procedure for Refrigerant Charge” in this

b

1

section.

• Be sure to install receiver / dryer (1) to proper direction as
shown.

• Evacuate and charge refrigerant by referring to “Evacuation
of A/C system” and “Charge” under “Operation Procedure for
Refrigerant Charge” in this section.

Condenser Cooling Fan Motor On-Vehicle
Inspection

1) Check condenser cooling fan motor for continuity between
terminal “a” and “b” as shown.
If there is no continuity, replace condenser cooling fan
motor.

AIR CONDITIONING (OPTIONAL) 1B-29

2) Connect battery to condenser cooling fan motor terminal “a”
and “b” as shown in figure, then check that the condenser
cooling fan motor operates smoothly.

Reference:
Condenser cooling fan specified current at 12 V
8 A maximum.

3) Check condenser cooling fan blade for damage. If any mal­function is found replace condenser cooling fan.

Condenser Cooling Fan Assembly Removal
and Installation

REMOVAL

3

1

3

1) Remove condenser assembly referring to “Condenser
Assembly Removal and Installation” in this section.

2) Remove condenser outlet pipe mounting bolts (1) and con­denser outlet pipe (2).

3) Remove condenser cooling fan assembly mounting bolts (3).

4) Remove condenser cooling fan assembly from condenser.

3

2

1

INSTALLATION

Reverse removal procedure to install condenser cooling fan
motor nothing the following instructions.

• Replenish specified amount of compressor oil to compressor
suction side by referring to “Replenishing compressor oil”
under “Operation Procedure for Refrigerant Charge” in this
section.

• Evacuate and charge refrigerant by referring to “Evacuation
of A/C system” and “Charge” under “Operation Procedure for
Refrigerant Charge” in this section.

1B-30 AIR CONDITIONING (OPTIONAL)

Cooling Unit (Evaporator) Components

4

5

1. Evaporator 3. Evaporator case 5. Drain hose 7. Evaporator temperature sensor

2. Expansion valve 4. Packing 6. Air inlet door

Cooling Unit (Evaporator) Removal and
Installation

REMOVAL

1) Disconnect negative (–) cable at battery.

2) If equipped with air bag system, disable air bag system refer­ring to “Disabling air bag system” in Section 10B.

3) Recover refrigerant from refrigeration system by using
recovery and recycling equipment referring to “Operation
Procedure for Refrigerant Charge” in this section.

4) Remove heater control cable, main harness clamp.

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

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

7) Remove cooling unit (5).

3

1

7

5

2

4

AIR CONDITIONING (OPTIONAL) 1B-31

INSTALLATION

Reverse removal sequence to install cooling unit, noting the fol­lowing points.

• If cooling unit or evaporator is replaced, pour 25 cc of refrig­erating oil to compressor suction-side.

1

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

• Evacuate and charge system according to previously
described procedure.

• Adjust heater control cable, referring to “Heater Control
Lever Assembly Removal and Installation” in Section 1A.

• Enable air bag system, if equipped.

Cooling Unit (Evaporator) Inspection

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

• A/C evaporator fins for leakage and breakage
If any defects are found, repair or replace A/C evaporator.

• A/C evaporator fittings for leakage
If any defects are found, repair or replace A/C evaporator.

Evaporator Thermistor (Evaporator Tempera­ture Sensor) Removal and Installation

REMOVAL

1) Remove evaporator referring to “Cooling Unit (Evaporator)
Removal and Installation” in this section.

2) Remove evaporator thermistor.

INSTALLATION

Reverse removal sequence to install cooling unit, noting the fol­lowing points.

Install Evaporator thermistor (Evaporator temperature sensor) (3)

1

2

a

a'

3

to its original position. When its original position is not sure, install
to the center of evaporator referring to figure.

1. Cooling unit

2. Evaporator

a = a’

b = b’

bb'

1B-32 AIR CONDITIONING (OPTIONAL)

1

Evaporator Thermistor (Evaporator Tempera­ture Sensor) Inspection

Check resistance between terminals for evaporator thermistor (1).
If check results are as not specified, replace evaporator ther­mistor.

Evaporator thermistor resistance

Sensor Temperature (°C(°F)) Resistance (kΩ)

0 (32) 6.5 – 6.8

25 (77) 1.9 – 2.1

NOTE:

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

Expansion Valve Inspection

Refer to “A/C System Performance Inspection” earlier in this sec­tion.

AIR CONDITIONING (OPTIONAL) 1B-33

Expansion Valve Removal and Installation

REMOVAL

1) Recover refrigerant from refrigeration system by using
recovery and recycling equipment referring to “Operation
Procedure for Refrigerant Charge” in this section.

2) Loosen liquid pipe mounting bolt (1).

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

2

1

3

INSTALLATION

Reverse removal procedure for installation, noting the following
points.

• Apply compressor oil to expansion valve O-ring and con­necting hose and pipe O-ring.

• Evacuate and charge system according to previously
described procedure.

Dual Pressure Switch Inspection

1) Check dual pressure switch (1) for continuity at normal temper-

1

ature (approx. 25

charge of refrigerant and A/C system (compressor) is under

operation. In each of these cases, switch should show proper
continuity.

°C (77 °F)) when A/C system has a proper

2) Check continuity between high and low pressure switch ter­minals at specified pressure as shown.

High and low pressure switch specification

A: Approximately 200 KPa (2.0 kg/cm2, 28.5 psi)
B: Approximately 230 KPa (2.3 kg/cm
C: Approximately 2600 KPa (26 kg/cm
D: Approximately 3200 KPa (32 kg/cm

2

, 32.5 psi)

2

, 370 psi)

2

, 455 psi)

1B-34 AIR CONDITIONING (OPTIONAL)

Dual Pressure Switch Removal and Installa­tion

REMOVAL

1) Recover refrigerant from refrigeration system by using
recovery and recycling equipment referring to “Operation
Procedure for Refrigerant Charge” in this section.

2) Disconnect negative (–) cable at battery.

3) Remove dual pressure switch.

INSTALLATION

Reverse removal procedure for installation, noting the following
points.

• Apply compressor oil to dual pressure switch O-ring.

• Evacuate and charge system according to previously
described procedure.

Tightening torque
Pressure sensor:

11 N·m (1.1 kg-m, 8.0 lb-ft)

A/C Switch Inspection



B

AC

Check for continuity between terminals at each switch position by
referring to the table below.
If continuity is not indicated as specified below, replace.

TERMINAL

ABC

POSITION

OFF

[a]

ON

[b]

[a]: Switch button released

[b]: Switch button kept in push

AIR CONDITIONING (OPTIONAL) 1B-35

Condenser Cooling Fan Relay (No.1 and No.2)
Inspection

1) Disconnect negative cable at battery.

2) Remove condenser cooling fan relay No.1 (1) and No.2 (2)
from relay box.

3) Check condenser cooling fan relay No.1.

a) Check that there is no continuity between terminal “c” and

“d”.
If there is continuity, replace relay.

b) Connect battery positive (+) terminal to terminal “b” of relay.

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

4) Check condenser cooling fan relay No.2.

a) Check that there is continuity between terminal “i” and “f”.

If there is no continuity, replace relay.

b) Check that there is no continuity between terminal “i” and

“h”.
If there is continuity, replace relay.

c) Connect battery positive (+) terminal to terminal “e” of relay.

Connect battery negative (–) terminal “g” of relay.
Check if there is no continuity between terminal “i” and “f”.
If there is continuity when relay is connected to the battery,
replace relay.
Check if there is continuity between terminal “i” and “h”.
If there is no continuity when relay is connected to the bat­tery, replace relay.

1B-36 AIR CONDITIONING (OPTIONAL)

Compressor Relay Inspection

1) Disconnect negative (–) cable at battery.

1

2) Remove compressor relay (1) from main fuse box.

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

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

Compressor Assembly Removal and Installa­tion

REMOVAL

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

2) Disconnect negative (–) cable at battery.

3) Remove front bumper by referring to “Front Bumper and
Rear Bumper Removal and Installation” in Section 9.

4) Remove condenser assembly referring to “Condenser
Assembly Removal and Installation” in this section.

3

2

1

6

5

4

9

7

ley nut (2) and adjusting bolt (3).

6) Disconnect magnet clutch lead wire coupler (4).

7) Remove magnet clutch lead clamp (5).

8) Disconnect suction pipe (6) and discharge hose (7) from
compressor (8).

NOTE:

Cap open fittings immediately to keep moisture out of

5) Remove compressor drive belt (1) by loosening tension pul-

8

system.

9) Remove compressor mounting bolts (9), and then remove
compressor (8) from its bracket.

9

AIR CONDITIONING (OPTIONAL) 1B-37

INSTALLATION

Reverse removal procedure to install compressor noting the fol­lowing instructions.

• If compressor is replaced, pour new compressor oil by refer­ring to “Replenishing compressor oil” under “Operation Pro­cedure for Refrigerant Charge” in this section.

• Evacuate and charge system by referring to “Recovery”
under “Operation Procedure for Refrigerant Charge” in this
section.

• Adjust drive belt tension by referring to “Compressor Drive
Belt Inspection and Adjustment” in this section.

Compressor Drive Belt Inspection and
Adjustment

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
tension pulley (2) and crank pulley (5) with about 100 N
(10 kg) force after crankshaft pulley 1 rotating.
If belt tension is without specification, adjust belt tension
referring to procedures below.

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.