Suzuki RA410 User guide

Page 1

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 mean- ings. 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: D Service on and around the air bag system

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

D If the air bag system and another vehicle

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

D Do not modify the steering wheel, instru-

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

D If the vehicle will be exposed to tempera-

tures over 935C (2005F) (for example, during a paint baking process), remove the air bag system components (air bag (inflator) modules, SDM and/or seatbelt with pretensioner) beforehand to avoid component damage or unintended deployment.

Page 2

FOREWORD

This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components and for disassembly and assembly of major components.

Applicable model: RA410

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

RA410 WIRING DIAGRAM MANUAL 99512-77G10

Service Manual No.

OVERSEAS SERVICE DEPARTMENT

Page 3

SECTIONTABLE OF CONTENTS

GENERAL INFORMATION

General Information Maintenance and Lubrication

HEATING AND AIR CONDITIONING

Heater and Ventilation Air Conditioning (If Equipped)

STEERING, SUSPENSION, WHEELS AND TIRES

Steering, Suspension, Wheels and Tires Front End Alignment Manual Rack and Pinion Electrical Power Steering System (If Equipped) Steering Wheel and Column Front Suspension Rear Suspension Wheels and Tires

DRIVE SHAFT AND PROPELLER SHAFT

Front Drive Shaft

BRAKE SYSTEM

Brakes

0A 0B

1A 1B

3A 3B

3B1

3C 3D 3E 3F

ENGINE

General Information and Diagnosis Engine Mechanical (Type: K10A) Engine Cooling Engine Fuel Engine and Emission Control System Ignition System Cranking System Charging System Exhaust System

TRANSMISSION, CLUTCH AND DIFFERENTIAL

Manual Transmission Automatic Transmission (3A/T) Clutch

ELECTRICAL SYSTEM

Electrical System Wiring Diagram

BODY SERVICE

RESTRAINT SYSTEM

Restraint System Air Bag System

6A4

6B 6C

6E1

6F1

6G 6H 6K

7A 7B

8 8A

10B

3B1

6A4

6E1

6F1

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

10B

Page 4

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

CONTENTS

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

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

Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System 0A- 3. . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Precaution for Installing Mobile Communication Equipment 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION INFORMATION 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Identification Number 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Identification Number 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Identification Number 0A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNING, CAUTION AND INFORMATION LABELS 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE LIFTING POINTS 0A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METRIC INFORMATION 0A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fasteners 0A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fasteners Strength Identification 0A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Tightening Torque 0A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5

0A-2 GENGERAL INFORMATION

HOW TO USE THIS MANUAL

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

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

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

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

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

7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle).

Using special tool, lock flywheel or drive plate, and tighten

flywheel or drive plate bolts to specified torque.

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

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

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

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

6) DIAGNOSIS are included in each section as necessary.

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

Page 6

1. Air bag wire harness

2. Passenger air bag (inflator) module

3. SDM

4. Contact coil

5. Driver air bag (inflator) module

6. Seat belt pretensioner

GENERAL INFORMATION 0A-3

PRECAUTIONS

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

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

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

parts or air bag system being unable to activate when necessary.

D If the air bag system and another vehicle system both

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

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

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

D If the vehicle will be exposed to temperatures over

935C (2005F) (for example, during a paint baking process), remove the air bag system components beforehand to avoid component damage or unintended air bag system activation.

DIAGNOSIS

D When troubleshooting air bag system, be sure to follow

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

D Never use electrical test equipment other than that speci-

fied in this manual.

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

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0A-4 GENGERAL INFORMATION

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

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

SERVICING AND HANDLING

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

module, select a place where the ambient temperature below 655C (1505F), without high humidity and away from electric noise.

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

sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3). This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result.

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

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

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

ment is very hot. Wait for at least half an hour to cool it off before proceeding the work.

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

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

Page 8

GENERAL INFORMATION 0A-5

WARNING: SDM D For handling and storage of a SDM, select a place

where the ambient temperature below 655C (1505F), without high humidity and away from electric noise.

D During service procedures, be very careful when han-

dling 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) D For handling and storage of a live seat belt pretension-

er, select a place where the ambient temperature below 655C (1505F), without high humidity and away from electric noise.

D Never carry seat belt pretensioner by wire or connec-

tor of pretensioner. When placing a live seat belt pretensioner on the workbench or some place like that, be sure not to lay it with its exhaust hole (1) provided side facing down. It is also prohibited to put something on its face with an exhaust hole or to put a seat belt pretensioner on top of another. Otherwise, personal injury may result.

D Never dispose of live (inactivated) seat belt preten-

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

D The seat belt pretensioner immediately after activation

is very hot. Wait for at least half an hour to cool it off before proceeding the work.

D With many service procedures, gloves and safety

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

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0A-6 GENGERAL INFORMATION

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

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

D When servicing parts other than air bag system, if

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

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

and passenger), seat belt pretensioners (driver and passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied, never attempt disassembly or repair but replace it with a new one.

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

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

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

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

D 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.

D 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.

D Never use air bag system component parts from

another vehicle.

D When using electric welding, be sure to temporarily

disable air bag system referring to “Disabling Air Bag System” described in “Service Precautions” under “On-Vehicle Service” in SECTION 10B.

D Never expose air bag system component parts directly

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

D WARNING/ CAUTION labels are attached on each part

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

D After vehicle is completely repaired, perform “Air Bag

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

Page 10

GENERAL INFORMATION 0A-7

GENERAL PRECAUTIONS

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

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

POINTS” on SECTION 0A.

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

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

D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. D Do not perform service work in areas where combustible materials can come in contact with a hot

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

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

tailpipe, muffler, etc.

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

or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as 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.

D 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.

CAUTION:

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

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

D When performing service to electrical parts that does not

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

Page 11

0A-8 GENGERAL INFORMATION

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

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

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

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

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

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.

D Make sure that all parts used in reassembly are perfectly

clean.

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

specified, be sure to use the specified type.

“A”: Sealant 99000-31150

D Be sure to use special tools when instructed.

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

Page 12

GENERAL INFORMATION 0A-9

D When disconnecting vacuum hoses, attach a tag describ-

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

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

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

D For vehicles equipped with fuel injection systems, never

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

PRECAUTIONS FOR CATALYTIC CONVERTER

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

short as possible, and do not open the throttle.

– Conduct engine compression checks within the shortest

possible time.

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

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

Page 13

0A-10 GENGERAL INFORMATION

PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE

D When disconnecting and connecting coupler, make sure to

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

D Be careful not to touch the electrical terminals of parts

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

D Never connect any tester (voltmeter, ohmmeter, or whatev-

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

D Never connect an ohmmeter to electronic control unit with

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

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

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

D When taking measurements at electrical connectors using

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

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

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

Page 14

GENERAL INFORMATION 0A-11

D When checking connection of terminals, check its male half

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

D Before measuring voltage to check for electrical system,

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

ELECTRICAL CIRCUIT INSPECTION PROCEDURE

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

OPEN CIRCUIT CHECK

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

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

contact tension, entry of foreign object etc.)

D Wire harness being open

Sensor

1. Check for loose connection

ECM

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.

Page 15

0A-12 GENGERAL INFORMATION

Check contact tension by inserting and removing just for once

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

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

1. Looseness of crimping

2. Open

3. Thin wire (single strand of wire)

Continuity check

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

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

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.

Page 16

GENERAL INFORMATION 0A-13

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

Voltage Between:

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

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

Voltage Between:

C-1 and body ground: Approx. 5V B-1 and body ground: Approx. 5V 2V voltage drop A-1 and body ground: Approx. 3V

SHORT CIRCUIT CHECK (wire harness to ground)

1) Disconnect negative cable from battery.

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

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

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

1. Other parts

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

Page 17

0A-14 GENGERAL INFORMATION

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:

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

the connector body (backed out).

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

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

D Damaged connector body, exposing the terminals to moisture

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

1. Check contact tension by inserting and removing just once

2. Check each terminal for bend and proper alignment

D Improperly formed or damaged terminals.

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

D Poor terminal-to-wire connection.

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

D Wire insulation which is rubbed through, causing an intermittent

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

D Wiring broken inside the insulation. This condition could cause

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

Page 18

GENERAL INFORMATION 0A-15

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. D Keep the antenna as far away as possible from the vehicle’s

electronic control unit.

D Keep the antenna feeder more than 20 cm (7.9 in) away from

electronic control unit and its wire harnesses.

D Do not run the antenna feeder parallel with other wire har-

nesses.

D Confirm that the antenna and feeder are correctly adjusted.

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

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

ENGINE IDENTIFICATION NUMBER

The number is punched on the cylinder block.

TRANSMISSION IDENTIFICATION NUMBER

The automatic transmission identification number is located on the transmission case.

Page 19

0A-16 GENGERAL 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.

NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.

Air bag label on sunvisor

Engine cooling fan label

Radiator cap label

Air bag label on pasenger air bag (inflator) module

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

Air bag label on SDM

Seat belt pretensioner label

Page 20

GENERAL INFORMATION 0A-17

VEHICLE LIFTING POINTS

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

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

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

fuel pipe, bracket or any other part.

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

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

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

When using frame contact hoist:

1. Front left tire

2. Rear left tire

3. Front

: Support position for frame contact hoist and safety stand.

: Floor jack position

Page 21

0A-18 GENGERAL INFORMATION

When using floor jack:

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

WARNING: D Never apply jack against suspension parts (i.e., stabi-

lizer, etc.) or vehicle floor, or it may get deformed.

D If the vehicle to be jacked up only at the front or rear

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

Front

Rear

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

Page 22

GENERAL INFORMATION 0A-19

ABBREVIATIONS MAY BE USED IN THIS MANUAL

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

Locking Retractor

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

CKT : Circuit CMP Sensor : Camshaft Position Sensor

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

(Clutch Switch, Clutch Start

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

DC : Direct Current DLC : Data Link Connector

(Assembly Line Diag. Link,

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

(Diagnostic Code)

EBCM : Electronic Brake Control

Module, ABS Control

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

Sensor (Water Temp.

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

(Recirculated Exhaust Gas

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

Heater (Positive Temperature

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

Canister (Charcoal Canister)

4WD : 4 Wheel Drive

GEN : Generator GND : Ground

HC : Hydrocarbons HO2S : Heated Oxygen Sensor

IAC Valve : Idle Air Control Valve (Idle

Speed Control Solenoid

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

Sensor (Air temperature

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

(Motor)

Page 23

0A-20 GENGERAL INFORMATION

LH : Left Hand LSPV : Load Sensing Proportioning

Valve

MAF Sensor : Mass Air Flow Sensor

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

MAP Sensor : Manifold Absolute Pressure

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

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

NOx : Nitrogen Oxides

OBD : On-Board Diagnostic System

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

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

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

TBI : Throttle Body Fuel Injection

(Single-Point Fuel Injection,

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

(A/ T Controller, A/ T Control

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

(Thermal Vacuum Switching

Valve, TVSV, Bimetal Vacuum

Switching Valve, BVSV) TWC : Three Way Catalytic

Converter (Three Way

Catalyst) 2WD : 2 Wheel Drive

VIN : Vehicle Identification

Number VSS : Vehicle Speed Sensor

WU-OC : Warm Up Oxidation

Catalytic Converter WU-TWC : Warm Up Three Way

Catalytic Converter

RH : Right Hand

SAE : Society of Automotive

Engineers

SDM : Sensing and Diagnostic

Module (Air bag controller, Air bag control module)

SFI : Sequential Multiport Fuel

Injection

SOHC : Single Over Head Camshaft

Page 24

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

GENERAL INFORMATION 0A-21

METRIC INFORMATION

METRIC FASTENERS

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

FASTENER STRENGTH IDENTIFICATION

Most commonly used metric fastener strength property classes are 4T, 7T and radial line with the class identification embossed on the head of each bolt. Some metric nuts will be marked with punch 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 size. Correct replacement bolts and nuts are available through the parts division.

STANDARD TIGHTENING TORQUE

Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.

NOTE:

D For the flanged bolt and nut, add 10% to the tightening torque given in the chart below. D The chart below is applicable only where the fastened parts are made of steel or light alloy.

STRENGTH

THREAD DIAMETER (mm)

Conventional bolt “4T” bolt

N.m kg-m lb-ft N.m kg-m lb-ft

“7T” bolt

4 1.5 0.15 1.0 2.3 0.23 2.0

5 3.0 0.30 2.5 4.5 0.45 3.5

6 5.5 0.55 4.0 10 1.0 7.5

8 13 1.3 9.5 23 2.3 17.0

10 29 2.9 21.0 50 5.0 36.5

12 45 4.5 32.5 85 8.5 61.5

14 65 6.5 47.0 135 13.5 98.0

16 105 10.5 76.0 210 21 152.0

Page 25

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

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

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

D Technical service work must be started at least 90 seconds after the ignition switch is turned to

the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

CONTENTS

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

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

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

Ignition System 0B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 0B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emission Control System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Chassis and Body 0B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

RECOMMENDED FLUIDS AND LUBRICANTS 0B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 26

0B-2 MAINTENANCE AND LUBRICATION

This int

reading or months, whichever comes first

MAINTENANCE SCHEDULE

NORMAL CONDITION SCHEDULE

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

Interval:

erval should be judged by odometer

1. ENGINE

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

1-2. Valve lash (clearance) — I — I — I

1-3. Blank

same services at the same intervals respectively.

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

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

Months 12 24 36 48 60 72

V belt I R I R I R

1-4. Engine oil and Engine oil filter Replace every 10,000 km (6,000 miles) or 8

months

1-5. Engine coolant — — R — — R

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

2. IGNITION SYSTEM

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

2-2. Distributor cap and rotor (crack, wear) — — I — — I

3. FUEL SYSTEM

3-1. Air cleaner filter Paved-road I I R I I R

Dusty condition Refer to “Severe Driving Condition” schedule

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

3-3. Fuel filter Replace every 105,000 km (63,000 miles)

3-4. Fuel tank — — I — — I

4. EMISSION CONTROL SYSTEM

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

4-2. Fuel evaporative emission control system (if equipped) — — — — — I

5. BRAKE

5-1. Brake discs and pads (thickness, wear, damage) I I I I I I

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

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

5-3. Brake fluid — R — R — R

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

Page 27

MAINTENANCE AND LUBRICATION 0B-3

This int

reading or months, whichever comes first

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

Interval:

erval should be judged by odometer

6. CHASSIS AND BODY

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

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

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

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

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

6-6. Manual transmission oil (leakage, level) I — R I ' R

6-7. Automatic transmission Fluid level ' I ' I ' I

same services at the same intervals respectively.

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

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

Months 12 24 36 48 60 72

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

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

NOTES:

“R”: Replace or change

“I”: Inspect and correct or replace if necessary

Page 28

0B-4 MAINTENANCE AND LUBRICATION

Drive belt (V-rib belt)

Air cleaner filter 1

Manual transmission oil

MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS

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

Severe condition code

A – Repeated short trips B – Driving on rough and/or muddy roads C – Driving on dusty roads D – Driving in extremely cold weather and/or salted roads E – Repeated short trips in extremely cold weather

Severe

Condition Code

– B C D –

A – C D E Engine oil and oil filter R

A B C – E Spark plugs R

– – C – –

– B – –

Maintenance

Operation

Maintenance Interval

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

Every 2,500 km (1,500 miles)

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

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

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

– B – – E Automatic transmission fluid R

– B C D – Wheel bearings I

NOTES:

“R”: Replace or change

“I”: Inspect and correct or replace if necessary

*1: Inspect or replace more frequently if necessary.

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

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

Page 29

MAINTENANCE AND LUBRICATION 0B-5

MAINTENANCE SERVICE

ENGINE

ITEM 1-1 Drive Belt Inspection and Replacement

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

Water pump belt inspection

1) Inspect belt for cracks, cuts, deformation, wear and cleanliness. Replace if any defect exists.

2) Check pump belt for tension and adjust if it is out of specification.

Water pump belt tension “a”: 12 – 15 mm (0.47 – 0.59 in.) deflection under 10 kg or 22 lb pressure

1. Water pump pulley

Vehicle with A/C

NOTE: When replacing belt with a new one, adjust belt tension to 8 – 9 mm (0.31 – 0.35 in.).

Water pump belt replacement

Replace belt referring to “Water Pump Belt Removal and Installation” in Section 6B.

A/C compressor drive belt inspection (If equipped)

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

A/C compressor drive belt tension “b”: 8 – 9 mm (0.31 – 0.35 in.) deflection under 10 kg or 22 lb pressure

1. A/C compressor pulley

A/C compressor drive belt replacement

1) Disconnect negative cable from battery.

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

3) Adjust belt tension to specification.

4) Connect negative cable to battery.

Page 30

0B-6 MAINTENANCE AND LUBRICATION

1. Camshaft

2. Thickness gauge

Proper Engine Oil Viscosity Chart

ITEM 1-2 Valve Lash Inspection

Inspect intake and exhaust valve lash and adjust as necessary. Refer to Section 6A4 for valve lash inspection and adjustment procedure.

ITEM 1-4 Engine Oil and Filter Change

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

Use engine oil of SG, SH or SJ grade. Select the appropriate oil viscosity according to the left chart. For ambient temperature between –20 C (–4 F) and 30 C (86 F), it is highly recommended to use SAE10W-30 oil.

1, (a)

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 (1).

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

Tightening Torque (a): 50 N·m (5.0 kg-m, 36.0 lb-ft)

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

Special Tool (A): 09915-47340

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

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

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

Page 31

(A)

MAINTENANCE AND LUBRICATION 0B-7

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

Special Tool (A): 09915-47340

Tightening Torque (Reference) (a): 14 N·m (1.4 kg-m, 10.5 lb-ft)

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

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

Engine oil capacity

Oil pan capacity

Oil filter capacity

Others

Total

1. Low level mark

2. Full level mark

about 3.2 liters

(6.8/5.6 US/lmp pt.)

about 0.2 liter

(0.4/0.3 US/lmp pt.)

about 0.1 liter

(0.21/0.17 US/lmp pt.)

about 3.5 liters

(7.4/6.2 US/lmp pt.)

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

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

ITEM 1-5 Engine Coolant Change

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

1) Remove radiator cap when engine is cool.

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

3) Remove reservoir and drain.

4) Tighten drain plug securely. Also install reservoir.

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

necessary until coolant level reaches filler throat of radiator. Reinstall radiator cap.

Page 32

0B-8 MAINTENANCE AND LUBRICATION

6) Add coolant to reservoir so that its level aligns with Full mark.

Then, reinstall cap to reservoir aligning match marks (1) on the reservoir and cap.

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

corrosion protection and lubrication.

Refer to Section 6B of this manual for coolant capacity.

ITEM 1-6 Exhaust System Inspection

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

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

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

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

D Check nearby body areas for damaged, missing or misposi-

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

D Make sure that exhaust system components have enough clear-

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

D Any defects should be fixed at once.

Page 33

MAINTENANCE AND LUBRICATION 0B-9

IGNITION SYSTEM

ITEM 2-1 Spark Plugs Replacement

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

ITEM 2-2 Distributor Cap and Rotor Inspection

1) Remove air cleaner case.

2) Inspect distributor cap and rubber caps for cracks.

3) Inspect center electrode and terminals for wear.

4) Inspect rotor for cracks, and its electrode for wear.

5) Repair or replace as necessary any component which is found to be in malcondition as described above.

NOTE: Dust and stains found within distributor can be cleaned by using a dry, soft cloth.

6) Install air cleaner case.

FUEL SYSTEM

ITEM 3-1 Air Cleaner Filter Inspection

1) Unclamp air cleaner case clamps.

2) Take cleaner filter out of air cleaner case.

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

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

5) Install air cleaner filter into case referring to Section 6A4.

6) Clamp case securely.

Air Cleaner Filter Replacement

Replace air cleaner filter with new one according to procedure described in Section 6A4.

Page 34

0B-10 MAINTENANCE AND LUBRICATION

ITEM 3-2 Fuel Lines Inspection

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

ITEM 3-3 Fuel Filter Replacement

WARNING: This work must be performed in a well ventilated area and

away from any open flames (such as gas hot water heaters).

Fuel filter (1) is installed in fuel pump assembly (2). Replace fuel filter with new one, referring to Section 6C for removal and installation.

ITEM 3-4 Fuel Tank Inspection

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

EMISSION CONTROL SYSTEM

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

Check crankcase ventilation hoses and PCV hoses for leaks, cracks or clog, and PCV valve (1) for stick or clog. Refer to Section 6E1 for PCV valve checking procedure.

ITEM 4-2 (Fuel Evaporative Emission) Control System (if equipped)

Check EVAP (Evaporative Emission) canister for damage, clog and operation referring to Section 6E1.

Page 35

MAINTENANCE AND LUBRICATION 0B-11

BRAKE

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

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

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

3) Install caliper and wheel.

Brake drums and shoes

1) Remove wheel and brake drum.

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

3) Install brake drum and wheel.

ITEM 5-2 Brake Hoses and Pipes Inspection

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

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

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

parts.

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

Page 36

0B-12 MAINTENANCE AND LUBRICATION

ITEM 5-3 Brake Fluid Change

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 Section 5.

“a”

“a”: Parking brake lever stroke:

7-9 notches (With 20 kg or 44 lbs of pull pressure)

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

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

or wear is found, replace parking lever.

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

adjust it if necessary. For checking and adjusting procedures, refer to of Section 5.

Parking brake cable

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

CHASSIS AND BODY

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

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

Page 37

1. Wear indicator

MAINTENANCE AND LUBRICATION 0B-13

ITEM 6-2 Tire and Wheel Disc Inspection

[Tire inspection]

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

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

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

cool.

D Specified tire inflation pressure should be found on tire

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

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

[Tire rotation] Rotate tires referring to Section 3F.

Wheel Bearing Inspection

1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to Section 3D.

2) Check rear wheel bearing for wear, damage abnormal noise or rattle. For details, refer to Section 3E.

ITEM 6-3 Drive Shaft (Axle) Boot Inspection

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

Page 38

0B-14 MAINTENANCE AND LUBRICATION

ITEM 6-4 Suspension System Inspection

D Inspect front strut and rear shock absorber for evidence of oil

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

D Check front and rear suspension systems for damaged, loose

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

D Check front suspension arm ball joint stud dust seals (boots) for

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

“a”

ITEM 6-5 Steering System Inspection

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

on ground.

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

2) Check bolts and nuts for tightness and retighten them as neces-

sary. Repair or replace defective parts, if any.

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 (leaks, detachment, tear, etc.). If damage is found, replace it with new one.

5) Check universal joints (3) of steering shaft for rattle and dam-

age. If rattle or damage is found, replace it 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. For the details of wheel alignment, re-

fer to Section 3A.

Page 39

MAINTENANCE AND LUBRICATION 0B-15

ITEM 6-6 Manual Transmission Oil Inspection and Change

[Inspection]

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

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

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

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

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

[Change]

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

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

3) Pour specified oil up to level hole.

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

ITEM 6-7 Automatic Transmission

[Fluid level inspection]

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

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

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

1. Fluid level gauge

2. FULL HOT mark

3. LOW HOT mark

Page 40

0B-16 MAINTENANCE AND LUBRICATION

1. Drain plug

[Fluid change]

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

2) Change fluid with new specified fluid. For its procedure, refer to

Section 7B.

ITEM 6-8 All Latches, Hinges and Locks Inspection

Doors

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

Engine hood

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

Page 41

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. If “REPLACEBELT” label on front seat belt is visible, replace belt. Check that seat belt is securely locked.

Battery Electrolyte Level Check

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

Accelerator Pedal Operation

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

Exhaust System Check

Check for leakage, cracks or loose supports.

Clutch (For Manual transmission)

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

clutch pedal,

D No slipping clutch occurs when releasing pedal and

accelerating,

D Clutch itself is free from any abnormal condition.

Gearshift or Select Lever (Transmission)

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

Brake

[Foot brake] Check the following;

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

applied,

D and that brake do not drag.

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 and try to start.

[Parking brake and automatic transmission “P” (Park) mechanism] Check that parking brake 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. Make sure that vehicle is at complete stop when shifting select lever to “P” range position and release all brakes.

Page 42

0B-18 MAINTENANCE AND LUBRICATION

Engine oil or water resistance chassis grease

Steering

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

stability, or abnormally heavy feeling.

D Check that the vehicle does not wander or pull to

one side.

Engine

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

abnormal vibration.

Body, Wheels and Power Transmitting System

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

Meters and Gauge

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

Lights

Check that all lights operate properly.

Windshield Defroster

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

RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil

Engine coolant (Ethylene glycol base coolant) “Antifreeze/Anticorrosion coolant”

Brake fluid DOT3

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

Automatic transmission fluid

Door hinges

Hood latch assembly

Key lock cylinder Spray lubricant

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

An equivalent of DEXRON -IIE

Page 43

SECTION 1A

HEATER AND VENTILATION 1A-1

HEATER AND VENTILATION

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

D Technical service work must be started at least 90 seconds after the ignition switch is turned to

the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

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

CONTENTS

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

Heater Unit 1A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Inlet Box 1A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Control Lever Assembly 1A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 1A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis Table 1A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Circuit 1A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON VEHICLE SERVICE 1A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Blower Fan Switch 1A- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Unit 1A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Page 44

1A-2 HEATER AND VENTILATION

GENERAL DESCRIPTION

The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets at places, right and left, along the windshield glass. The heater and ventilation consist of the following parts.

1. Heater Unit

2. Air inlet box

3. Ventilator duct

4. Defroster nozzle

5. Ventilator outlet

6. Ventilation air

7. Foot air

8. Defroster air

9. Demister air

10. Fresh air

11. Recirculation air

Page 45

HEATER UNIT

HEATER AND VENTILATION 1A-3

1. Heater core

2. Blower motor assembly

3. Blower motor resistor

4. Temp door assembly

5. Mode door assembly

6. Mode lever

7. Temp lever assembly

8. Heater case

Page 46

1A-4 HEATER AND VENTILATION

AIR INLET BOX

HEATER CONTROL LEVER ASSEMBLY

1. Cooling unit packing

2. Dash packing

3. Packing

4. Drain packing

5. Air resistance board

6. Door link

7. Air inlet door

8. Evaporator case

1. Heater control lever assembly

2. Heater control panel

3. Blower fan switch assembly

4. Bulb

5. Fresh air control cable

6. Mode control cable

7. Temperature control cable

8. A/C switch plug

Page 47

DIAGNOSIS TABLE

HEATER AND VENTILATION 1A-5

DIAGNOSIS

Trouble

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

Incorrect temperature output.

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

Possible Cause Remedy

Blower fuse blown

Blower motor resistor faulty

Blower fan switch faulty

Blower motor faulty

Wiring or grounding faulty

Control cables broken or binding

Temperature control lever faulty

Control cable clamp position is faulty

Air damper broken

Air ducts clogged

Heater core leaking or clogged

Heater hoses leaking or clogged

Thermostat faulty

Control cables broken or binding

Air damper broken

Air ducts clogged

Air damper broken

Check for short to ground and replace fuse.

Check resistor.

Check blower fan switch.

Replace motor.

Repair as necessary.

Check cables.

Check control lever.

Check and adjustment.

Repair damper.

Repair air ducts.

Replace core.

Replace hoses.

Check thermostat.

Check cable.

Check control lever.

Check and adjustment.

Repair damper.

WIRING CIRCUIT

Air ducts leaking or clogged

Repair air ducts.

TO ECM

1. Blower motor

2. Blower motor resister

3. Blower fan switch

4. Ignition switch

Page 48

1A-6 HEATER AND VENTILATION

ON VEHICLE SERVICE

BLOWER MOTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system, if equipped.

Refer to DISABLING AIR BAG SYSTEM in Section 10B.

3) Remove column hole cover.

4) Disconnect blower motor coupler.

5) Remove blower motor.

INSPECTION

Check continuity between two terminal as shown in figure. If check results are continuity, proceed to next operation check, if not replace.

Connect battery to blower motor as shown, then check that the blower motor operates smoothly.

INSTALLATION

1) Reverse removal procedure for installation.

2) Enable air bag system, if equipped.

Refer to ENABLING AIR BAG SYSTEM in Section 10B.

BLOWER MOTOR RESISTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system, if equipped.

Refer to DISABLING AIR BAG SYSTEM in Section 10B.

3) Disconnect resistor coupler.

4) Remove blower motor resistor (1) as shown in figure.

Page 49

HEATER AND VENTILATION 1A-7

INSPECTION

Measure each terminal-to-terminal resistance on resistor

Resistance Me – Lo : 1.5–3.0 at 255C (775F)

Me – Hi : 0.5–1.5 at 255C (775F)

If measured resistance is incorrect, replace blower motor resistor.

INSTALLATION

1) Reverse removal procedure for installation.

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

HEATER CONTROL LEVER ASSEMBLY

REMOVAL

1) Disconnect negative (–) cable at battery.

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

3) Remove meter cluster hood, ashtray, center garnish, instru-

ment glove box and radio or accessory case (if equipped).

4) Disconnect each heater control cables (mode (1), temperature (2) and fresh air control).

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

6) Remove heater control lever assembly (3).

7) Remove blower fan switch. Refer to BLOWER FAN SWITCH in this section.

Page 50

1A-8 HEATER AND VENTILATION

INSTALLATION

1) Reverse removal procedure for installation.

2) Adjust the following items.

i) Move mode control lever (a), temperature control lever (b)

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

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

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

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

3) Enable air bag system, if equipped with air bag. Refer to “ENAB-

LING AIR BAG SYSTEM” in section 10B.

1. Heater unit

2. Air inlet box

3. Mode control cable

4. Temperature control cable

5. Fresh air control cable

BLOWER FAN SWITCH

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Remove meter cluster hood, ashtray, center garnish and radio

or accessory case (if equipped).

3) Remove heater control panel (1) as shown.

Disconnect blower fan switch coupler. Loosen blower fan switch screw (2) and them remove blower fan switch (3) as follows.

INSTALLATION

Reverse removal sequence to install blower fan switch.

Page 51

HEATER AND VENTILATION 1A-9

INSPECTION

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

POSITION

TERMINAL

B E I L M H

OFF

HEATER UNIT

REMOVAL

1) Disconnect negative (–) cable at battery.

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

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

4) Remove instrument panel. Refer to INSTRUMENTPANEL in BODY SERVICE section.

5) Remove bolts (2), nuts (3) and screws (4) as shown.

6) Remove heater unit (5).

INSTALLATION

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

wiring harness.

D Adjust heater control cable (refer to heater control lever assem-

bly in this section).

D Fill engine coolant to radiator. D Enable air bag system, if equipped. Refer to “ENABLING AIR

BAG SYSTEM” in Section 10B.

Page 52

1A-10 HEATER AND VENTILATION

VENTILATION LOUVER

REMOVAL AND INSTALLATION

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

2. Rag

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

Page 53

AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

AIR CONDITIONING (OPTIONAL)

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

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

D Technical service work must be started at least 90 seconds after the ignition switch is turned

to the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

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

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

CONTENTS

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

Refrigerant Flow of Air Conditioning

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

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

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

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

Quickly Checking of Refrigerant Charge 1B- 6. . . Troubleshooting Procedure Using

Manifold Gouge Set 1B- 7. . . . . . . . . . . . . . . . . . . .

Wiring Circuit 1B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

A/C System Inspection of ECM and

Its Circuits 1B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

A/C Compressor Drive Belt Inspection 1B-11. . . . .

RECOVERY, EVACUATION

AND CHARGING 1B-12. . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Recovery 1B-12. . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 1B-13. . . . . . . . . . . . . . . . . . .

A/C Condenser Assembly 1B-13. . . . . . . . . . . . . . . .

Receiver/Driver 1B-14. . . . . . . . . . . . . . . . . . . . . . . . .

Radiator (and Condenser) Cooling

Fan Motor 1B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Unit 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

A/C Evaporator Thermistor 1B-17. . . . . . . . . . . . . . .

Expansion Valve 1B-18. . . . . . . . . . . . . . . . . . . . . . . .

Dual Pressure Switch 1B-18. . . . . . . . . . . . . . . . . . . .

A/C Switch 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator (and Condenser) Cooling

Fan Relay 1B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor 1B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnet Clutch 1B-21. . . . . . . . . . . . . . . . . . . . . . . . . .

PERFORMANCE TEST 1B-26. . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1B-29. . . . . . . . . . . . . . . . . . . . . . . . .

Page 54

1B-2 AIR CONDITIONING (OPTIONAL)

HFC-134a

GENERAL DESCRIPTION

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

CFC-12

1. Compressor label

2. Service valve

REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM

1. Compressor

2. Magnet clutch

3. Condenser assembly

4. Receiver/dryer

5. Dual pressure switch

6. Expansion valve

7. Evaporator

State of Refrigerant

: Liquid

: Vapor

: Superheated Vapor

Condenser Cooling air

Page 55

MAJOR COMPONENTS AND LOCATION

AIR CONDITIONING (OPTIONAL) 1B-3

1. Cooling unit

2. Compressor

3. Condenser assembly

4. Receiver/dryer

5. Discharge hose

6. Suction hose

7. Receiver dryer outlet hose

8. Liquid pipe

9. Expansion valve

10. Ventilation air

11. Foot air

12. Defroster air

13. Demister air

14. Fresh air

15. Recirculation air

16. Heater unit

Page 56

1B-4 AIR CONDITIONING (OPTIONAL)

GENERAL DIAGNOSIS TABLE

DIAGNOSIS

Condition

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

Possible Cause Correction

A/C system inoperative

D No refrigerant D Fuse blown

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

Compressor inoperative (dose not rotate)

D Magnet clutch faulty D Drive belt loosen or broken D Compressor faulty

Radiator (and condenser) cooling fan motor inoperative

D “RDTR” fuse blown

D Radiator (and condenser) cooling fan

relay faulty

D Wiring or grounding faulty D Radiator fan relay signal faulty D Radiator (and condenser) cooling fan

motor faulty

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

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

Replace fuse and check short circuit to ground. Check radiator cooling fan relay

Repair as necessary Check radiator fan relay signal Check radiator cooling fan motor.

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

Blower motor inoperative

D Fuse blown

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

D Insufficient or excessive charge of re-

frigerant

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

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

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

Page 57

AIR CONDITIONING (OPTIONAL) 1B-5

Condition

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

Cool air does not comes out only intermittently

Possible Cause Correction

D Compressor faulty D Air in A/C system

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

D Blower motor faulty D Excessive compressor oil existing in

A/C system

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

D Magnetic clutch faulty D Compressor thermal protector faulty D Excessive charge of refrigerant

Check compressor. Replace receiver/dryer, and evacuation and charging. Repair as necessary. Check air inlet box. Check heater control lever assembly. Check heater unit. Check blower motor. Pull out compressor oil in A/C system circuit, and replace compressor.

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

Cool air comes out only at high speeds

Cool air does not come out only at high speeds

Insufficient velocity of cooled air

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

D Drive belt slipping D Compressor faulty

D Excessive charge of refrigerant D Evaporator frosted

D Evaporator clogged or frosted

D Air leaking from cooling unit or air duct D Blower motor faulty D Wiring or grounding faulty

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

Check charge refrigerant. Check evaporator. Check A/C thermistor.

Check evaporator. Check A/C thermistor. Repair as necessary. Check blower motor. Repair as necessary.

Page 58

1B-6 AIR CONDITIONING (OPTIONAL)

QUICKLY CHECKING OF REFRIGERANT CHARGE

CHARGE OF REFRIGERANT

The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its max. cooling capacity for a few minutes. Then, look at the sight glass (1) on receiver/dryer outlet pipe (2) and compare what is observed with the symptoms

3. Bubbles

listed in “CHECKING REFRIGERANT CHARGE” table given below.

CHECKING REFREGERANT CHARGE

Item

No.

1 Bubbles observed in sight glass Insufficient charge of refrigerant

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

3 No temperature difference between

compressor inlet and outlet

Symptom Charge of refrigerant Correction

in system

refrigerant in system

Empty or nearly empty system Evacuate and charge system

Check system for leaks with a leak tester.

Refer to the items 3 and 4.

and then check it for leaks with a leak tester.

4 Noticeable temperature difference

between compressor inlet and outlet

5 When A/C is turned OFF,

refregerant in sight glass clears immediately and remains clear

6 When A/C is turned OFF,

refregerant in sight glass once produces bubbles and then clears

Proper or too much charge of refrigerant in system

Too much charge of refrigerant in system

Proper charge of refrigerant in system

Refer to the items 5 and 6.

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

NO CORRECTION NEEDED BECAUSE CHARGE OF REFRIGERANT IS NORMAL.

Page 59

AIR CONDITIONING (OPTIONAL) 1B-7

TROUBLESHOOTING PROCEDURE USING MANIFOLD GAUGE SET

This procedure enables the technician to discover and repair cool-

ing problems by having the pressures of both the high and low pressure sides indicated on the respective gauges of the manifold gauge set.

ATTACHING MANIFOLD GAUGE SET

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

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

3) Bleed the air in charging hoses (3), (4) by loosening their re-

spective nuts on manifold gauge, utilising the refrigerant pressure. When a hiss is heard, immediately tighten nut.

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

TROUBLESHOOTING INFORMATION

1) Beginning on the next page, the manifold gauge pressure values shown have been obtained under conditions listed below. However, keep in mind that the actual on-the-vehicle readings are somewhat affected by the ambient temperature.

A/C inlet air temperature

Engine rpm (with A/C idle up) 950 r/min.

Blower switch Max.

Temperature control Max. cooling

Doors All open

Air inlet damper position Recirculation

30 – 355C (86 – 955F)

2) Since the operating pressure for the HFC-134a refrigerant at high temperatures is higher than that of the CFC-12, the gauge readings will be slightly higher.

CORRECTIVE MEASURES FOR MALFUNCTION SYMPTOMS

Starting on the next page, gauge readings, conditions, causes, and measures (classified according to malfunction symptoms) will be discussed.

Page 60

1B-8 AIR CONDITIONING (OPTIONAL)

2.5

MPa

MANIFOLD kg/cm

GAUGE psi

Lo Hi

CONDITION CAUSE CORRECTION

0.15 – 0.25

1.5 – 2.5

21.3 – 35.5

Negative pressure

Normal:

0.15 – 0.25

1.5 – 2.5

21.4 – 35.5

Abnormal: Negative pressure

0.05 – 0.1

0.5 – 1.0

4.2 – 14.2

1.37 – 1.57 14 – 16

200 – 227

0.5 – 0.6 5 – 6

71.2 – 85.3

Normal:

1.37 – 1.57 14 – 16

200 – 227

Abnormal:

0.69 – 0.98

7 – 10

100 – 142

0.69 – 0.98

7 – 10

100 – 142

Normal condition.

D The low pressure side

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

D Presence of frost around

tubing to and from receiver/ dryer and expansion valve.

D During A/C operation, the

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

D Both low and high pres-

sure sides indicate low readings.

D Continuous air bubbles

are visible through sight glass.

D Output air is slightly cold.

D Dust particles or water

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

D Gas leak from heat-

sensitising tube is preventing refrigerant flow.

D Expansion valve is fro-

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

D Insufficient refrigerant

in system.

(Refrigerant leaking)

D Clean expansion valve.

Replace it if it cannot be cleaned.

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

and recharge with fresh refrigerant.

D If heat-sensitizing tube is

defective, replace expansion valve.

D Replace expansion valve. D Replace receiver/dryer. D Evacuate A/C system and

recharge with fresh refrigerant.

D Using a gas leak detector,

check for leaks and repair as necessary.

D Recharge refrigerant to a

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

0.4 – 0.6 4 – 6

56.9 – 85.3

0.25 – 0.3 – 3.

35.6 – 42.6

0.3 – 0.4

3.0 – 4.0

42.7 – 56.8

1.96 – 2.45 20 – 25

285 – 355

D Pressure on low pressure

side is high.

D Pressure on high pressure

side is low.

D Both pressure becoming

equal right after A/C is turned OFF.

D High pressure reading on

both low and high pressure sides.

D Air bubbles are not visible

even when engine rpm is lowered.

D High pressure reading on

both low and high pressure sides.

D Low pressure side tubing

is not cold when touched.

D Air bubbles are visible

through sight glass.

D High pressure reading on

both low and high pressure sides.

D Large amount of frost or

dew on the low pressure side tubing.

D Internal leak in com-

pressor.

D Overcharged A/C sys-

tem.

D Faulty condenser cool-

ing operation.

D Faulty condenser fan

operation.

D Presence of air in A/C

system.

(Improperly evacuated)

D Faulty expansion valve

or improper attachment of heat-sensitizing tube.

D Refrigerant flow is not

regulated properly.

D Inspect compressor and

repair or replace as necessary.

D Adjust refrigerant to speci-

fied amount.

D Clean condernser. D Inspect and repair con-

dernser fan.

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

pressor oil and presence of contaminants in oil.

D Evacuate system and re-

charge with fresh refrigerant.

D Inspect if heat-sensitizing

tube is properly attached.

D Replace expansion valve.

Page 61

WIRING CIRCUIT

AIR CONDITIONING (OPTIONAL) 1B-9

R/B

G/W

G/Or

P/BI

Br/W

P/B

1. Blower motor

2. Blower resistor

3. Blower & A/C switch

4. Dual pressure switch

5. ECT sensor

6. A/C Evaporator thermistor

7. Radiator (and condenser) cooling fan relay

8. Radiator (and condenser) cooling fan motor

9. Compressor

10. Main relay

11. Ignition switch

Page 62

1B-10 AIR CONDITIONING (OPTIONAL)

A/C SYSTEM INSPECTION OF ECM AND ITS

CIRCUITS

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

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

Voltage Check

1) Remove ECM (1) from vehicle.

2) Connect ECM (1) couplers to ECM.

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

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

C20

C21

C14

A12

TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)

CCC

CCC CCCCC

AAAAAAA A

Page 63

AIR CONDITIONING (OPTIONAL) 1B-11

TERMINAL CIRCUIT CONDITION NORMAL VALUE

C5 Radiator (and condens-

er) cooling fan motor relay output

C14 Sensor ground Ignition switch ON or OFF 0 volt

C20 Blower fan speed input

C21 A/C switch input

A3 Engine coolant temper-

ature sensor input

A/C switch ON and Blower fan switch ON with engine running or engine coolant temperature higher than preset temperature with ignition switch ON

Except the above condition at ignition switch ON 10 – 14 volts

Blower fan switch OFF with ignition switch ON 10 – 14 volts

Blower fan switch at Lo position with ignition switch ON

Blower fan switch at Me or Hi position with ignition switch ON

A/C switch ON, Blower switch ON and Dual pressure switch normal condition (switch ON) with ignition switch ON

Except the above condition with ignition switch ON 10 – 14 volts

Engine coolant temperature at approx. 805C (1765F) with ignition switch ON

Engine coolant temperature at approx. 1105C (2305F) with ignition switch ON

0 – 1 volt

3.5 – 5.5 volts

0 – 1.5 volts

0 – 1 volt

0.7 – 0.8 volts/ 303 – 326 W

0.35 – 0.4 volts/

138 – 145 W

A4 A/C Evaporator thermistor

input

A12 Compressor output

A/C Evaporator thermistor temperature at approx. 255C (775F) with ignition switch ON

A/C Evaporator thermistor temperature at approx. 05C (325F) with ignition switch ON

A/C switch input 0 – 1 volt with engine running 10 – 14 volts

Except the above-mentioned with engine running 0 volt

1.1 – 1.35 volts/

1.8 – 2.2 kW

2.5 – 2.7 volts/

6.3 – 7 kW

A/C COMPRESSOR DRIVE BELT INSPECTION

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

“a” : 8 – 9 mm (0.31 – 0.35 in.) as deflection/100N (10 kg, 22 lbs)

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

Page 64

1B-12 AIR CONDITIONING (OPTIONAL)

RECOVERY, EVACUATION AND CHARGING

OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT

Recharge 530 + 30 g of

refrigerant in gas form

REFRIGERANT RECOVERY

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

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

EVACUATING AND CHARGING

Refer to AIR CONDITIONING BASIC MANUAL

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

1. Manifold gauge set

2. Low pressure gauge

3. High pressure gauge

4. Recovery equipment

(99520-02130).

NOTE: Specified amount of refrigerant: 530  30g

Page 65

AIR CONDITIONING (OPTIONAL) 1B-13

ON-VEHICLE SERVICE

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

mediately.

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

frigerating oil to seats of coupling nuts and O-ring.

D When tightening or loosening a fitting, use two wrenches, one for turn and the other for support. D Tighten flared nuts to the following specifications.

8 mm pipe: 13 N·m (1.3 kg-m, 9.5 lb-ft)

14.5mm pipe: 32 N·m (3.2 kg-m, 23.0 lb-ft)

A/C CONDENSER ASSEMBLY

REMOVAL

1) Disconnect negative (–) cable at battery.

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

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

4) Remove left side head light assembly (1).

5) Loosen radiator mounting bolt (2).

6) Disconnect discharge hose (3) and condenser outlet pipe (4).

7) Loosen condenser mouting bolt (5).

8) Remove condenser assembly (6).

INSTALLATION

Reverse removal sequnce to install condenser, noting the following point. D If condenser is replaced, pour 15 cc of refrigerating oil to com-

pressor suction-side.

D Evacuate and charge system according to previously described

procedure.

Page 66

1B-14 AIR CONDITIONING (OPTIONAL)

INSPECTION

Check the following.

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

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

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

“a”

RECEIVER/DRYER

(1)

“b”

REMOVAL

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

2) Disconnect receiver outlet hose (1) and condenser outlet pipe (2) from receiver/dryer (3).

3) Loosen receiver/dryer bracket bolt (4).

4) Remove receiver/dryer with its bracket.

INSTALLATION

Reverse removal sequence to install receiver/dryer noting the following points. D If receiver/dryer (1) is replaced, pour 20 cc of refrigerating oil to

compressor suction-side.

D Evacuate and charge system according to previously described

procedure.

D Install receiver/dryer (1) to its bracket (2) as shown in figure.

“a” 355 “b” 58 – 59 mm (2.28 – 2.32 ln)

Page 67

AIR CONDITIONING (OPTIONAL) 1B-15

RADIATOR (AND CONDENSER) COOLING

1. Radiator (and condenser) cooling fan motor

FAN MOTOR

INSPECTION

Check continuity between each two terminals. If check results are continuity, proceed to next operation check. If not, replace.

Connect battery to radiator (and condenser) cooling fan motor (1) as shown, then check that the radiator (and conderser) cooling fan motor operates smoothly.

Reference current : approx 8.5 – 11.5 A at 12 V

Page 68

1B-16 AIR CONDITIONING (OPTIONAL)

COOLING UNIT (EVAPORATOR)

REMOVAL

1. Evaporator

2. A/C Evaporator thermistor (Evaporator temperature sensor)

3. Expansion valve

4. Evaporator case

5. Packing

6. Drain hose

7. Air inlet door

8. O-ring

1) Disconnect negative (–) cable at battery.

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

3) Disable air bag system, if equipped.

4) Remove heater control cable (1), main harness clamp (2) and disconnect evaporator thermistor coupler (3).

5) Loosen suction hose (4) & liquid pipe (5) bolt (6).

6) Loosen cooling unit bolt, nut and screw as shown.

7) Remove cooling unit (7).

INSTALLATION

Reverse removal sequence to install cooling unit, noting the follow-

ing points. D If cooling unit or evaporator is replaced, pour 25 cc of refrigerat-

ing oil to compressor suction-side.

D Install uniformly the packing (1) to installation hole as shown in

figure.

Page 69

AIR CONDITIONING (OPTIONAL) 1B-17

procedure.

D Adjust heater control cable, refer to HEATER CONTROL LE-

VER ASSEMBLY in HEATER AND VENTILATION section.

D Enable air bag system, if equipped. D Install the cutting part of drain hose (2) downward as shown in

figure.

INSPECTION

Check the following

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

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

NOTE: D Be careful not to damage evaporator fins. If evaporator fin

is bent, straighten it by using a screwdriver or pair of pliers, If any leakage is found from fitting or tube, repair or replace evaporator.

D When the thermistor removed, its should be reinstalled in

original position.

D Evacuate and charge system according to previously described

Resistance (kW)

6.65

A/C EVAPORATOR THERMISTOR

Check resistance between terminals.

Sensor Temperature (5C (5F)) Resistance (kW)

0 (32) 6.3 – 7.0

25 (77) 1.8 – 2.2

If check results are as not specified, replace thermistor.

0 5 10 15 20 25_C–5

30 40 50 60 70 77_F23

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

Page 70

1B-18 AIR CONDITIONING (OPTIONAL)

1. Expansion valve

EXPANSION VALVE

Refer to “Troubleshooting Procedure Using Manifold Gauge Set” earlier in this Section,

Continuity

Noncontinuity

DUAL PRESSURE SWITCH

INSPECTION

1) Check dual pressure switch (1) for continuity at normal temperature (approx. 255C (775F)) when A/C system has a proper charge of refrigerant and when A/C system (compressor) is under operation. In each of these cases, switch should show proper continuity.

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

A: Approx 200 KPa (2.0 kg/cm2)

Pressure

B: Approx 320 KPa (32 kg/cm C: Approx 230 KPa (2.3 kg/cm2) D: Approx 2800 KPa (28 kg/cm

Tightening torque for dual pressure switch 11 N·m (1.1 kg-m, 8.0 lb-ft)

)

A/C SWITCH

REMOVAL AND INSTALLATION

Refer to “HEATER CONTROL LEVER ASSEMBLY” in Section 1A.

INSPECTION

D Press A/C Switch button and check if there is continuity between

terminals “A” and “B”.

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

minal “A”, press A/C Switch button and check if indicator lamp lights.

Page 71

AIR CONDITIONING (OPTIONAL) 1B-19

RADIATOR (AND CONDENSER) COOLING FAN RELAY

INSPECTION

1) Disconnect negative (–) cable at battery.

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

3) 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,

2. Radiator (and condenser) cooling fan fuse

replace relay.

COMPRESSOR

REMOVAL

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

2) Disconnect negatige (–) cable at battery.

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

4) Remove front bumper.

5) Disconnect magnet clutch lead wire (1) and undo lead wire clamp (2).

6) Disconnect suction and discharge hoses from compressor.

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

7) Remove compressor drive belt by loosening compressor bolt.

8) Remove compressor with magnet clutch assembly (3) from its mount as shown.

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

1. New compressor

2. Removed compressor

3. Excess oil (A–B)

INSTALLATION

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

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

D Evacuate and charge system according to previously described

procedure.

Page 72

1B-20 AIR CONDITIONING (OPTIONAL)

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

in this Section.

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

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

(120 cc, 7.5 in3)

REPLENISHING COMPRESSOR OIL

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

When changing gas only

When it is unavoidable to change gas without replacing any component part for engine removal and installation or for some other reason, replenish 100cc oil. When replenishing gas only, oil replenishment is not necessary.

1. New compressor

2. Removed compressor

3. Excess oil (A–B)

When replacing compressor

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

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

When replacing other part

Part replaced

Evaporator 25 cc

Condenser 15 cc

Receiver/dryer 20 cc

Hoses 10 cc each

Pipes 10 cc each

Amount of compressor

oil to be replenished

Page 73

MAGNET CLUTCH

REMOVAL AND INSTALLATION

Refer to AIR CONDITIONING BASIC MANUAL (99520-02130)

b 23 N·m (2.3 kg-m)

AIR CONDITIONING (OPTIONAL) 1B-21

a 14 N·m (1.4 kg-m)

a. Front head bolt b. Front head bolt

c 14 N·m (1.4 kg-m)

: Tightening Torque

: Tighten bolt (a) first, and

next (b).

c. Armature plate bolt

1. Thermal switch

2. Compressor

3. O-ring

4. Lip type seal

5. Front head

6. Clutch coil

7. Compressor pulley

8. Circlip

9. Circlip

10. Armature plate

INSPECTION

D Check pressure plate and rotor for wear and oil soaked condi-

tions respectively.

D Check clutch bearing for noise, wear and grease leakage. D Measure stator coil for resistance at 205C.

Standard Resistance: 3.4 – 4.1 W

If the measured resistance does not remain within above tolerance, replace coil.

D Use an ohmmeter to check thermal switch for continuity.

If it is no continuity, replace it.

Page 74

1B-22 AIR CONDITIONING (OPTIONAL)

1. Armature plate

2. Screw

3. Washer

REMOVAL

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

2) Fix armature plate with special tool (A) and remove armature plate screw.

Special Tool (A): 09991-06020

NOTE: Do not reuse armature plate nut.

3) Using special tool (B), remove armature plate.

Special Tool (B): 09991-06030

1. Armature plate

4) Remove lead wire clamp.

5) Remove felt ring and shims from shaft.

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

Special Tool (C): 09900-06107

7) Remove magnet clutch lead wire clamp screw, and disconnect magnet clutch read wire.

8) Remove magnet clutch with puller.

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

9) Remove magnet clutch coil.

1. Puller

2. Compressor

Page 75

AIR CONDITIONING (OPTIONAL) 1B-23

INSTALLATION

1) Install magnet clutch coil. Protrusion on under side of coil ring must match hole in compressor assembly to prevent movement ant correctly locate lead wire.

2) Using special tool (C), install snap ring as shown.

1. Snap ring

2. Clutch coil

2. Compressor assembly

Special Tool (C): 09900-06107

3) Clamp covering portion of lead wire.

4) Install magnet clutch. (1) Set magnet clutch squarely over clutch installation boss. (2) Place special tool (D) onto clutch bearing.

Ensure that edge rests only on inner race of bearing.

(3) Install snap ring.

Special Tool (D): 09991-06010

CAUTION: Be careful not to scratch bearing seal.

1. Armature plate

2. Screw

3. Washer

5) Adjust clearance, between armature plate and magnet clutch by putting shim on compressor shaft.

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

6) Tighten new armature plate nut as specified below.

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

Special Tool (A): 09991-06020

Page 76

1B-24 AIR CONDITIONING (OPTIONAL)

LIP TYPE SEAL (SEIKO SEIKI COMPRESSOR)

REMOVAL

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

2) Remove front head mounting screw (10 pcs).

1. Front head

3) Remove front head by pushing cylinder shaft.

NOTE: Be careful not to remove cylinder from case.

4) Remove O-ring.

1. Front head

2. Cylinder shaft

3. Cylinder

4. Case

5. O-ring

1. Front head

2. Bearing puller

5) Remove lip seal from front head.

INSTALLATION

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

Special Tool (E): 09991-06050

1. Lip type seal

2. Front head

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

Page 77

AIR CONDITIONING (OPTIONAL) 1B-25

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

Special Tool (F): 09991-06040

3) Install O-ring to case.

4) Apply A/C oil to lip seal and O-ring.

5) Install front head assembly.

1. Front head

2. O-ring

1. Front head

6) Tighten front head bolt.

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

NOTE:

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

Page 78

1B-26 AIR CONDITIONING (OPTIONAL)

PERFORMANCE TEST

1) Confirm that vehicle and environmental conditions are as follows. – Vehicle is not exposed to direct sun. – Ambient temperature is within 155C – 355C (595F – 955F)

2) Connect high and low side charging hoses of manifold gauge to hose fittings of A/C component.

3) Warm up engine to normal operating temperature and keep it at specified idle speed. (Radiator cooling fan should not be working when checking pressure and temperature.)

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

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

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

1. Thermometer

kPa kg/cm

2000 20

1900 19

1800 18

1700 17

1600 16

1500 15

1400 14

1300 13

1200 12

1100 11

1000 10

900 9

Pressure of High Pressure

gauge

800 8

700 7

600 6

500 5

400 4

300 3

200 2

100 1

Pressure of Low

Pressure Gauge

15 20 25 30 355C 59 68 77 86 955F

“A”

Ambient Temperature

“B”

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

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

Example:

Gauges should read as follows when ambient temperature is 305C

Pressure on high pressure gauge (HI):

Pressure on low pressure gauge (LO):

1400 – 1750 kPa

14.0 – 17.5 kg/cm

230 – 350 kPa

2.3 – 3.5 kg/cm

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

Page 79

AIR CONDITIONING (OPTIONAL) 1B-27

5F 5

68 20

66.2 19

64.4 18

62.6 17

60.8 16

59 15

57.2 14

55.4 13

53.6 12

51.8 11

50 10

48.2 9

46.4 8

44.6 7

Temp. at Center Duct Air Outlet

42.8 6

41.0 5

39.2 4

37.4 3

35.6 2

33.8 1

15 20 25 30 355C 59 68 77 86 955F

“A”

Temp. at Evaporator Air Inlet

8) Check inlet port temperature-to-outlet port temperature relationship using graph at the left.

For example, if evaporator inlet port temperature is 255C (775F) and center duct air outlet temperature is 85C (46.45F), their crossing point is within acceptable range as shown in graph at the left. In this case, cooling performance is satisfactory and proper.

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

“B”

Page 80

1B-28 AIR CONDITIONING (OPTIONAL)

TESTING RESULTS POSSIBLE CAUSE REMEDY

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

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

HIGH PRESSURE GAUGELOW PRESSURE GAUGE

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

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

Insufficient cooling of condenser

D Compressor malfunction (Insufficient oil etc.) D Engine overheat

D Insufficient refrigerant (Insufficient charge or

leakage)

D Expansion valve malfunction (valve opens too

wide)

D Compressor malfunction (Insufficient

compression)

D Expansion valve malfunction (valve opens too

wide)

D Thermister (heat sensing tube) of expansion

valve improperly mounted (poor contact, poor insulation)

D Compressor malfunction (Insufficient

compression)

D Recharge D Check expansion valve D Clean or replace D Check condenser fan D Clean or repair D Check compressor D Check engine cooling

system

D Check for leakage, repair

if necessary and recharge

D Check expansion valve

D Check compressor

D Check expansion valve

D Check thermister

D Check compressor

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

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

Outlet air temperature

CENTER DUCT

at center duct is low

THERMOMETER AT

(Crossing point is in area “B”)

D Insufficient refrigerant (Insufficient charge or

leakage)

D Expansion valve malfunction (valve opens too

narrow)

D Clogged refrigerant passage (crashed pipe)

D Insufficient or excessive charge of refrigerant

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

cooling (heater) unit

D Compressor malfunction

D Insufficient air volume from center duct (Heater

blower malfunction)

D Thermister (heat sensing tube) malfunction

D Check for leakage, repair

if necessary and recharge

D Check expansion valve

D Repair or replace

D Check refrigerant

pressure

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

D Check compressor

D Check blower motor and

fan

D Check thermister

Page 81

09900-06107 Snap ring pliers (Opening type)

SPECIAL TOOLS

09991-06010 Magnet clutch pulley installer

09991-06020 Armature plate spanner

AIR CONDITIONING (OPTIONAL) 1B-29

09991-06030 Armature plate remover

09991-06040 Lip type seal protector

09991-06050 Lip type seal installer

Page 82

STEERING, SUSPENSION, WHEELS AND TIRES 3-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES

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

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

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

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

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

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

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

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

CONTENTS

DIAGNOSIS

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

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

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

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

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

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

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

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

Page 83

3-2 STEERING, SUSPENSION, WHEELS AND TIRES

DIAGNOSIS

GENERAL DIAGNOSIS

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

1) Inspect tires for proper pressure and uneven wear.

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

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

DIAGNOSIS TABLE

Condition

Vehicle Pulls (Leads) D Mismatched or uneven tires.

D Tires not adequately inflated. D Broken or sagging springs. D Radial tire lateral force. D Disturbed front end alignment. D Disturbed rear wheel alignment. D Brake dragging in one road wheel. D Loose, bent or broken front or rear sus-

pension parts.

Abnormal or Excessive Tire Wear

D Sagging or broken spring. D Tire out of balance. D Disturbed front or rear end alignment. D Faulty strut (shock absorber). D Hard driving. D Overloaded vehicle. D Not rotating tire. D Worn or loose road wheel bearing. D Wobbly wheel or tire. D Tires not adequately inflated.

Possible Cause Correction

Replace tire. Adjust tire pressure. Replace spring. Replace tire. Check and adjust front end alignment. Check and adjust rear wheel alignment. Repair front brake. Tighten or replace suspension parts.

Replace spring. Adjust balance or replace tire. Check and adjust front end alignment. Replace strut. Replace tire. Replace tire. Replace or rotate tire. Replace wheel bearing. Replace wheel or tire. Adjust tire pressure.

Wheel Tramp D Blister or bump on tire.

D Improper strut (shock absorber) action.

Replace tire. Replace strut.

Page 84

STEERING, SUSPENSION, WHEELS AND TIRES 3-3

Condition

Shimmy, Shake or

D Tire or wheel out of balance.

Possible Cause Correction

Vibration

D Loosen wheel bearings. D Worn tie rod ends. D Worn lower ball joints. D Excessive wheel runout. D Blister or bump on tire. D Excessively loaded radial runout of tire/

wheel assembly.

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

Hard Steering D Tire not adequately inflated.

D Malfunction of power steering system.

(Power steering only.)

D Bind in tie rod end ball studs or lower

ball joints.

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

Balance wheels or replace tire and/or wheel. Replace wheel bearing. Replace tie rod end. Replace front suspension arm. Repair or replace wheel and/or tire. Replace tire. Replace tire or wheel.

Check and adjust front end alignment. Tighten or replace steering linkage. Tighten case bolts.

Inflate tires to proper pressure. Check and correct.

Replace tie rod end or front suspension arm. Check and adjust front end alignment. Check and adjust rack and pinion torque. Repair or replace.

Too Much Play in Steering

D Wheel bearings worn. D Loose steering gear case bolts. D Rack and pinion adjustments. D Worn steering shaft joints. D Worn tie rod ends or tie rod inside ball

joints.

D Worn lower ball joints.

Poor Returnability D Bind in tie rod end ball studs.

D Bind in ball joints. D Bind in steering column. D Poorly lubricated rack and pinion. D Disturbed front end alignment. D Rack and pinion adjustment. D Tires not adequately inflated.

Replace. Tighten. Check and adjust rack and pinion torque. Replace joint. Replace tie rod end or tie rod.

Replace front suspension control arm.

Replace tie rod end. Replace. Repair or replace. Check, repair or lubricate rack and pinion. Check and adjust front end alignment. Check and adjust rack and pinion torque. Adjust tire pressure.

Page 85

3-4 STEERING, SUSPENSION, WHEELS AND TIRES

Condition

Rack and Pinion Noise (Rattle or Chuckle)

Abnormal Noise, Front End

Wander or Poor Steering Stability

Possible Cause Correction

D Loose steering gear case bolts. D Worn rack bush. D Rack and pinion adjustment.

D Worn, sticky or loose tie rod ends, lower

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

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

bearings.

D Broken suspension springs. D Poorly lubricated or worn strut bearings.

D Mismatched or uneven tires. D Loosen ball joints and tie rod ends. D Faulty struts or mountings. D Loose stabilizer bar. D Broken or sagging springs. D Rack and pinion adjustment. D Front end alignment.

Tighten. Replace. Check and adjust rack and pinion torque.

Replace tie rod end, suspension arm, tie rod or drive shaft joint.

Repair or replace. Replace. Tighten bolts or nuts, replace bushes. Tighten wheel nuts. Tighten suspension bolts or nuts. Replace.

Replace. Replace strut bearing.

Replace or inflate tires to proper pressure. Replace suspension arm or tie rod end. Replace strut or repair mounting. Tighten or replace stabilizer bar or bush. Replace spring. Check and adjust rack and pinion torque. Check and adjust front end alignment.

Erratic Steering When Braking

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

Replace. Replace coil spring. Inflate tires to proper pressure. Check and adjust front end alignment. Refer to Section 5. Repair or replace wheel cylinder or caliper. Replace brake disc. Replace brake shoe lining. Replace brake drum. Replace or repair wheel cylinder.

Page 86

STEERING, SUSPENSION, WHEELS AND TIRES 3-5

Condition

Low or Uneven Trim Height

Right-to-left trim height

D Broken or sagging springs. D Over loaded. D Incorrect springs.

Possible Cause Correction

Replace. Check loading.

Replace. (H) difference should be within 10 mm (0.4 in.) with curb weight.

*Same with rear side.

Ride Too Soft D Faulty struts (shock absorber). Replace strut.

Suspension Bottoms D Overloaded.

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

Check loading.

Replace strut.

Replace.

Body Leans or Sways

D Loose stabilizer bar.

in Corners

D Faulty struts (shock absorbers) or

mountings.

D Broken or sagging springs. D Overloaded.

Cupped Tires D Front struts defective.

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

Tighten stabilizer bar bolts or nuts, or re-

place bushes.

Replace strut or tighten mounting.

Replace.

Check loading.

Replace.

Replace tire or wheel disc.

Replace front suspension arm.

Adjust tire balance.

Page 87

3-6 STEERING, SUSPENSION, WHEELS AND TIRES

D Hard Cornering D Under Inflation D Lack of tire Rotation

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

TIRE DIAGNOSIS

IRREGULAR AND/OR PREMATURE WEAR

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

1) Front tire wear is different from rear.

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

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

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

5) There is cupping, flat spotting, etc.

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

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

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

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

WEAR INDICATORS

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

RADIAL TIRE WADDLE

Waddle is side to side movement at the front and/or rear of the vehicle. It is caused by the steel belt not being straight within the tire. It is most noticeable at a low speed, 5 to 30 mph. It is possible to locate the faulty tire by road testing the vehicle. If it is on the rear, the rear end of the vehicle shakes from side to side or “waddles”. To the driver in his seat, it feels as though someone is pushing on the side of vehicle.

If the faulty tire is on the front, waddling is more visual. The front sheet metal appears to be moving back and forth and the driver feels as though he is at the pivot point in vehicle. Waddle can be quickly diagnosed by using Tire Problem Detector (TPD) and following the equipment manufacture’s recommendations. If TPD is not available, an alternative method of substituting known good tire/wheel assemblies can be used as follows, although it takes a longer time.

Page 88

STEERING, SUSPENSION, WHEELS AND TIRES 3-7

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

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

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

INFLATE TIRES TO RECOMMENDED

PRESSURE

ROAD TEST VEHICLE ON LEVEL

UNCROWNED ROAD IN

BOTH DIRECTIONS

LEADS IN SAME

DIRECTION

PUT TIRES BACK IN

ORIGINAL POSITION

AND CHECK ALIGNMENT

SWITCH FRONT TIRES

SIDE TO SIDE AND

ROAD TEST AGAIN

LEAD CORRECTED IF

ROUGHNESS RESULTS.

REPLACE TIRES

LEAD CORRECTED

REPLACE TIRE

LEAD CORRECTED

REPLACE TIRE

LEAD REVERSES

DIRECTION

INSTALL A KNOWN GOOD TIRE

ON ONE FRONT SIDE

LEAD REMAINS

INSTALL A KNOWN GOOD TIRE IN

PLACE OF OTHER FRONT TIRE

LEAD REMAINS

KNOWN GOOD TIRES ARE NOT GOOD

Page 89

3-8 STEERING, SUSPENSION, WHEELS AND TIRES

RADIAL TIRE LEAD

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

1) Incorrect alignment.

2) Uneven brake adjustment.

3) Tire construction.

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

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

2) Rear tires will not cause lead.

VIBRATION DIAGNOSIS

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

1) Tire runout.

2) Wheel runout.

3) Tire stiffness variation.

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

SUSPENSION MOVEMENT

(Loaded Runout)

Caused by

TIRE OUT OF

ROUND

SMOOTH ROAD

TIRE STIFFNESS

VARIATION

RIM BENT OR

OUT OF ROUND

Page 90

SECTION 3A

FRONT END ALIGNMENT

CONTENTS

FRONT END ALIGNMENT 3A-1

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

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

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

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

GENERAL DESCRIPTION

Preliminary Checks Prior to Adjusting

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

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

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

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

Alignment service data

Toe-in

Camber

Caster

Kingpin inclination

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

0 mm (0 in.)

0510’

3535’

11540’

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

TOE SETTING

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

CAMBER

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

Page 91

3A-2 FRONT END ALIGNMENT

PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT

Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel. Section 3 of this manual contains a procedure for determining the presence of a tire lead problem. Before making any adjustment affecting toe setting, the following checks and inspections should be made to ensure correctness of alignment readings and alignment adjustments:

1) Check all tires for proper inflation pressures and approximately the same tread wear.

2) Check for loose of ball joints. Check tie rod ends; if excessive looseness is noted, it must be corrected before adjusting.

3) Check for run-out of wheels and tires.

4) Check vehicle trim heights; if out of limits and a correction is to be made, it must be made before adjusting toe.

5) Check for loose of suspension arms.

6) Check for loose or missing stabilizer bar attachments.

7) Consideration must be given to excess loads, such as tool boxes. If this excess load is normally carried in vehicle, it should remain in vehicle during alignment checks.

8) Consider condition of equipment being used to check alignment and follow manufacturer’s instructions.

9) Regardless of equipment used to check alignment, vehicle must be on a level surface both fore and aft and transversely.

TOE ADJUSTMENT

Toe is adjusted by changing the tie rod length. Loosen right and left tie rod end lock nuts first and then rotate right and left tie rods by the same amount to align toe-in to specification. In this adjustment, right and left tie rods should become equal in length (“A” in left figure). Before rotating tie rods, apply grease between tie rods and rack boots so that boots won’t be twisted. After adjustment, tighten lock nuts to specified torque and make sure that rack boots are not twisted.

Tightening Torque (a): 45 N·m (4.5 kg-m, 32.5 lb-ft)

CAMBER AND CASTER ADJUSTMENT

Should camber or caster be found out of specifications upon inspection, locate its cause first. If it is in damaged, loose, bent, dented or worn suspension parts, they should be replaced. If it is in vehicle body, repair it so as to attain specifications. To prevent possible incorrect reading of camber or caster, vehicle front end must be moved up and down a few times before inspection.

Page 92

FRONT END ALIGNMENT 3A-3

STEERING ANGLE

When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length “A”.

NOTE: If tie rod lengths were changed to adjust steering angle, reinspect toe-in.

Steering angle inside : 445 + 35

outside : 375 + 35

Reference Information: Side slip:

For inspecting front wheel side slip with side slip tester:

Side slip limit : Less than 3 mm/m

(Less than 0.118 in/3.3 ft)

If side slip exceeds above limit, toe-in or front wheel alignment may not be correct.

Page 93

MANUAL RACK AND PINION 3B-1

SECTION 3B

MANUAL RACK AND PINION

NOTE: D All steering gear fasteners are important attaching parts in that they could affect the performance

of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of these parts.

D Although the figures in this section show only the left-hand steering vehicle, the same work proce-

dure and data apply to the right-hand steering vehicle.

CONTENTS

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

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

Diagnosis Table 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Wheel Check 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Rack Boot Check 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tie Rod End Boot Check 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Shaft Joint Check 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tie Rod End Check 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Rack and Pinion Assembly 3B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REQUIRED SERVICE MATERIALS 3B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 3B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION

The rack and pinion steering system consists of two main components, the rack and the pinion. When the steering wheel is turned, the motion is transmitted to the steering shaft, shaft joint and then to the pinion. Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear motion. The force is then transmitted through the tie rods to the steering knuckles which turn wheels.

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3B-2 MANUAL RACK AND PINION

DIAGNOSIS

DIAGNOSIS TABLE

Refer to Section 3.

STEERING WHEEL CHECK

Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground.

Steering wheel play “a”: 0 – 30 mm (0 – 1.18 in)

If steering wheel play is not within specification, inspect as follows and replace if found defective. D Tie rod end ball stud for wear (ball stud should move when more

than 2 kg-cm torque is applied.)

D Lower ball joint for wear D Steering shaft joint for wear D Steering pinion or rack gear for wear or breakage D Each part for looseness

STEERING RACK BOOT CHECK

Hoist vehicle.

Inspect each boot for tear. A torn boot allows entry of dust and water which can cause wear to steering rack and pinion to produce noise as well as rust to result in malfunction of steering system. If even a small tear is noted, replace with new one.

Boots should be visually inspected for any damage and tear during every periodical inspection at specified intervals and whenever vehicle is hoisted for any other purpose.

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MANUAL RACK AND PINION 3B-3

TIE ROD END BOOT CHECK

Inspect each boot for tear. If even a small tear is noted, replace with new one.

STEERING SHAFT JOINT CHECK

Check shaft joint for wear, breakage and other damage and replace if any defect exists.

TIE ROD END CHECK

D Inspect for play in ball joint. D Inspect for play in rack end ball joint.

In either case, if found defective, replace.

ON-VEHICLE SERVICE

LUBRICATION

When inner parts of the steering gear case were disassembled, they should be washed clean before reassembly. It is recommended to use the grease as given at the right where grease application is indicated in the text.

SUZUKI SUPER GREASE E (99000-25050) or Lithium grease (applicable for –405C ~ 1305C (–405F ~ 2665F))

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3B-4 MANUAL RACK AND PINION

19 25 N·m (2.5 kg-m)

43 N·m (4.3 kg-m)

3 85 N·m (8.5 kg-m)

1. Steering rack : Apply SUZUKI SUPER GREASE E

99000-25050 to entire surface of rack.

2. Tie-rod lock washer

3. Steering tie-rod : Apply SUZUKI SUPER GREASE E

99000-25050 to rack end ball joint.

4. Tie-rod end

5. Boot : Apply SUZUKI SUPER GREASE E

99000-25050 to contacting part of tie-rod and boot.

6. Steering pinion : Apply SUZUKI SUPER GREASE E

99000-25050 to all around pinion teeth and mating surface of pinion needle bearing.

7. Steering gear case oil seal : Apply SUZUKI SUPER GREASE E

99000-25050 to oil seal lip.

8. Pinion bearing plug : Fill SUZUKI SUPER GREASE E

99000-25050 to inside of pinion bearing.

45 N·m (4.5 kg-m)

40 N·m (4.5 kg-m)

9. O-ring

10. Steering pinion needle bearing

11. Rack damper screw : Apply SUZUKI BOND No. 1207C

99000-31150 to thread of damper screw.

12. Rack plunger spring

13. Steering rack plunger : Apply SUZUKI SUPER GREASE E

99000-25050 to slinding part of plunger.

14. Steering rack housing and gear case

15. Steering rack side mount

16. Steering pinion side mount

17. Pinion bearing : Apply SUZUKI SUPER GREASE E

99000-25050 to rollers of pinion bearing.

95 N·m (9.5 kg-m)

25 N·m (2.5 kg-m)

: Tightening Torque

: Do not reuse

Page 97

MANUAL RACK AND PINION 3B-5

MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE)

REMOVAL

1) Remove steering joint cover (1).

2) Loosen steering shaft upper joint bolt (1). Then remove steering

shaft lower joint bolt (2).

3) Remove steering lower joint from steering pinion.

4) Hoist vehicle and remove wheels.

5) Disconnect both tie rod ends (1) from knuckles (2), using puller.

6) Remove steering gear case (1).

NOTE: If it is hard to remove steering gear case, disconnect exhaust pipe (1) from exhaust manifold.

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3B-6 MANUAL RACK AND PINION

DISASSEMBLY

1) Remove steering gear case.

2) For ease of adjustment after installation, make marking (1) on tie rod end lock nut position of tie rod thread.

3) Loosen tie rod end lock nut and remove tie rod end.

4) Remove boot wire (1) and clip (2).

5) Remove boot from tie rod.

6) Unbend bent part of tie rod lock washer (1) and remove tie rod (2) from rack (3).

1. Rack damper screw

2. Rack plunger spring

3. Rack plunger

4. Lock nut

7) Remove parts as shown.

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MANUAL RACK AND PINION 3B-7

8) Remove pinion bearing plug (1) with special tool.

Special Tool (43 mm socket) (A): 09944-26011

(A)

9) Tap on position as shown with plastic hammer (2) to separate pinion assembly (1) from housing.

10) Remove pinion assembly.

11) Remove rack from gear case (1). Direction for rack removal is as shown.

CAUTION: Inside of steering rack bushing is coated with special coating. As it is damageable, be very careful not to cause damage to it when removing rack from steering gear case.

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3B-8 MANUAL RACK AND PINION

(A)

(B)

12) Pull out pinion bearing (1) from gear case with special tools.

Special Tools

(A): 09921-20200 (B): 09930-30102

13) Remove oil seal (1) with special tool.

Special Tool (A): 09913-50121

(A)

Suzuki RA410 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual