Suzuki RB413 4WD Model Service Manual 99501U83E00-01E

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 meanings. Pay special attention to the messages highlighted by these signal words.

WARNING:

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

CAUTION:

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING:

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

WARNING:

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

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

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, instrument panel or any other air bag system component (on or around air bag system components or wiring). Modifications can adversely affect air bag system performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking process), remove the air bag system components (air bag (inflator) modules, SDM and/or seat belt with pretensioner) beforehand to avoid component damage or unintended activation.

Page 2

Foreword

This SUPPLEMENTARY SERVICE MANUAL is a supplement to RB413 SERVICE MANUAL. It has been prepared exclusively for the following applicable model.

Applicable model: RB413 4WD model

If describes only different service information of RB413 4WD model as compared with RB413 SERVICE MANUAL. Therefore, whenever servicing RB413 4WD model, consult this supplement first. And for any section, item or description not found in this supplement, refer to the related service manual below.

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

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

Related Manual:

Manual Name Manual No. RB413 SERVICE MANUAL 99500-83E00-01E RB310/413 WIRING DIAGRAM MANUAL 99512U83E10-669

Page 3

Page 4

GENERAL INFORMATION TRANSMISSION, CLUTCH AND

General Information 0A Maintenance and Lubrication 0B Manual Transmission 7A

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 3E Wheels and Tires

DRIVE SHAFT AND PROPELLER SHAFT

Front Drive Shaft

Propeller Shaft 4B

BRAKES 5

Brake Pipe/Hose/Master Cylinder 5A Front Brakes Parking and Rear Brakes 5C Antilock Brake System 5E1

ENGINE

General Information and Engine Diagnosis Engine Mechanical 6A1 Engine Cooling Engine Fuel Engine and Emission Control System Ignition System Cranking System (1.2kW Reduction Type) Cranking System (0.9kW No-Reduction Type) Charging System Exhaust System

1A Clutch 7C 1B 7F 1B Transfer 7D

3 Wiring Diagram 8A 3B 8B 3A 3B

3B1

3C BODY SERVICE 9 3F 9 3D RESTRAINT SYSTEM 10

4 5

5B 5E1

6B 6F1

6C 6G

6E 6G1

6F1 6H

6G1

6H 6K

DIFFERENTIAL

Automatic Transmission (4A/T)

Rear Differential 7F

BODY ELECTRICAL SYSTEM 8

Lighting System Instrumentation/Driver Information Windows, Mirrors, Security and Lock Immobilizer Control System

Seat Belt Air Bag System

7B 1A 7D

8B 3B1 8C 8C 3C 8D 8D 3D 8G 8G 3E

10A 4 10 10B 4B 10A

0A 7A 0B 7B

3 8

3A 8A

10B

6A1

6B 6C 6E

NOTE:

For the screen toned sections in the above table, refer to the same section of Service Manual mentioned in FOREWORD of this manual.

Page 5

Page 6

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

NOTE:

For descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

CONTENTS

Precautions......................................................0A-2

Precaution in Servicing Full-Time

4WD Vehicle .................................................0A-2

Vehicle Lifting Points .....................................0A-3

Page 7

0A-2 GENERAL INFORMATION

Precautions

Precaution in Servicing Full-Time 4WD Vehicle

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

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

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

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

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

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

other wheels.

Page 8

GENERAL INFORMATION 0A-3

Vehicle Lifting Points

WARNING:

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

• Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.

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

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

what part to be removed.

1. Front left tire

2. Rear left tire

3. Front

Page 9

0A-4 GENERAL INFORMATION

WARNI NG:

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

CAUTION:

• Never apply jack against suspension parts (i.e., stabilizer (3), etc.), front bumper (4) or vehicle floor, otherwise it may get deformed.

When lifting front vehicle end with floor jack, be sure to put the wooden block (5) on the jack against front jacking bracket (1). When lifting rear vehicle end with floor jack, be sure to put the jack against the center portion of rear axle (2) (2WD vehicle) or rear axle housing (6) (4WD vehicle).

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

Page 10

MAINTENANCE AND LUBRICATION 0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

WARNING:

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

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

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

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

CONTENTS

Maintenance Schedule .................................. 0B-2

Normal Condition Schedule ......................... 0B-2

Maintenance Recommended under Severe

Driving Conditions ........................................ 0B-4

Maintenance Service...................................... 0B-5

Chassis and Body........................................ 0B-5

Drive Shaft (Axle) Boots /

Propeller Shafts (4WD) ............................ 0B-5

Transfer Oil (4WD) and Rear

Differential Oil (4WD) ............................... 0B-6

Recommended Fluids and Lubricants......... 0B-6

Page 11

0B-2 MAINTENANCE AND LUBRICATION

Maintenance Schedule

Normal Condition Schedule

This table includes services as scheduled up to 90,000 km Interval: This interval should be judged by odometer reading or months, whichever comes first.

1. ENGINE

1-1. Drive belt (tension, damage) V-rib belt –– I ––R 1-2. Camshaft timing belt Replace every 100,000 km (60,000 miles) 1-3. Valve lash (clearance) – I – I – I 1-4. Engine oil and When SG, SH or SJ grade oil is used. R R R R R R

Engine oil filter When SE or SF grade oil is used. Replace every 10,000 km (6,000 miles) or

1-5. Engine coolant – R – R – R 1-6. Exhaust system (leakage, damage, tightness) – I – I – I

2. IGNITION SYSTEM

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

3. FUEL SYSTEM

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

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

4. EMISSION CONTROL SYSTEM

4-1. PCV (Positive Crankcase Ventilation) valve ––––– I 4-2. Fuel evaporative emission control system ––––– I

5. BRAKE

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

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

(54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively. km (x 1,000) 153045607590 Miles (x 1,000) 9 18 27 36 45 54 Months 12 24 36 48 60 72

8 months

Dusty condition Refer to “Severe Driving Condition” schedule

Page 12

MAINTENANCE AND LUBRICATION 0B-3

This table includes services as scheduled up to 90,000 km (54,000 Interval: This interval should be judged by odometer reading or months, whichever comes first.

miles) mileage. Beyond 90,000 km (54,000 miles), carry out the

same services at the same intervals respectively.

km (x 1,000) 153045607590

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

Months 12 24 36 48 60 72

6. CHASSIS AND BODY

6-1. Clutch pedal (For manual transmission) – I – I – I 6-2. Tires/wheel discs (wear, damage, rotation) I I I I I I 6-3. Drive shaft boots (breakage, damage) / Propeller shaft

(4WD)

6-4. Suspension system (tightness, damage, rattle, break-

age)

–– I –– I

– I – I – I

6-5. Steering system (tightness, damage, breakage, rattle) – I – I – I 6-6. Manual transmission oil (leakage, level)

(“I”: 1st 15,000 km only)

I – R ––R

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

Fluid change Replace every 165,000 km (99,000 miles) 6-7-1. Transfer oil (4WD) (leakage, level) I – I – I – 6-7-2. Rear differential oil (4WD) (level)

(“R”: 15,000 km only)

R or I – I – I –

6-8. All latches, hinges and locks – I – I – I 6-9. Ventilator air filter (if equipped)

– IR– IR

NOTE:

•“R”: Replace or change

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

• For Sweden, item 2-1, 4-1 and 4-2 should be performed by odometer reading only.

• For Item 1-2. Camshaft timing belt: This belt may be replaced every 90,000 km (54,000 miles)

according to customer’s maintenance convenience.

Page 13

0B-4 MAINTENANCE AND LUBRICATION

Maintenance Recommended under Severe Driving Conditions

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

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

Severe

Condition Code

– B C D – – – –

A – C D E – – H

A B C – E – – H

– – C – – – – –

– B – D E – – H

– B – – E – – H

– B C D – – – H

– – C D – – – –

Maintenance

ITEM 1-1 Drive belt (V-rib belt)

ITEM 1-4 Engine oil and oil filter ITEM 2-1 Spark plugs

ITEM 3-1 Air cleaner filter *1

ITEM 6-3 Drive shafts and propeller shafts (4WD) ITEM 6-6, 6-7-1, 6-7-2 Manual transmission oil, transfer oil (4WD) and differential oil (4WD) ITEM 6-7 Automatic transmission fluid ITEM 6-2 Wheel bearings

ITEM 6-9 Ventilator air filter *2 (if equipped)

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

Every 30,000 km (18,000 miles) or 24 months Every 15,000 km (9,000 miles) or 12 months Every 15,000 km (9,000 miles) or 12 months Every 45,000 km (27,000 miles) or 36 months

NOTE:

•“R” : Replace or change

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

• *1 : Inspect or replace more frequently if necessary.

• *2 : Clean or replace more frequently if the air from the ventilator decreases.

Page 14

Maintenance Service

Chassis and Body

Drive Shaft (Axle) Boots / Propeller Shafts (4WD) (ITEM 6-3)

DRIVE SHAFT (AXLE) BOOTS INSPECTION

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

PROPELLER SHAFTS (4WD) INSPECTION

MAINTENANCE AND LUBRICATION 0B-5

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

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

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

Page 15

0B-6 MAINTENANCE AND LUBRICATION

Transfer Oil (4WD) and Rear Differential Oil (4WD) (ITEM 6-7-1 and -2)

INSPECTION

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

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

3) Remove level plug of transfer or differential and check oil level. Oil level can be checked roughly by means of level plug hole. That is, if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled. If oil is found insufficient, pour specified amount of specified oil referring to “TRANSFER OIL CHANGE” in Section 7D or “DIFFERENTIAL OIL CHANGE” in Section 7F.

[A] : Transfer

[B] : Rear differential

1. Oil level/filler plug

2. Drain plug

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

REPLACEMENT

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

Recommended Fluids and Lubricants

Engine oil SE, SF, SG, SH or SJ (Refer to engine oil viscosity chart in item 1-4.) Engine coolant (Ethylene glycol base coolant) Brake fluid DOT4 or SAE J1704 Manual transmission oil API GL-4, SAE75W-90 (Refer to Section 7A for detail) Transfer oil (4WD) Refer to “OIL CHANGE” in Section 7D Differential oil (4WD) Refer to “OIL CHANGE” in Section 7F

Automatic transmission fluid Door hinges

Hood latch assembly Key lock cylinder Spray lubricant

“Anti-freeze / Anti-corrosion coolant”

An equivalent of DEXRON

-III

Engine oil or water resistance chassis grease

Page 16

REAR SUSPENSION 3E-1

SECTION 3E

REAR SUSPENSION

NOTE:

• All suspension fasteners are an important attaching part in that it 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 this part.

• Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage to the part may result.

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

On-Vehicle Service......................................... 3E-2

Rear Axle Shaft and Wheel Bearing ............ 3E-3

Rear Axle Shaft Oil Seal .............................. 3E-7

Rear Axle Housing ....................................... 3E-8

CONTENTS

Required Service Material........................... 3E-14

Special Tool.................................................. 3E-14

Page 17

3E-2 REAR SUSPENSION

On-Vehicle Service

1. Rear coil spring 10. Brake drum 19. Shock absorber lower bolt

2. Rear bump stopper

: Apply soap water, when installing.

3. Rear spring upper seat 12. Spacer

4. Rear shock absorber 13. Oil seal protector 22. Brake back plate bolt

5. Lateral rod 14. LSPV bracket (only vehicle with LSPV) 23. Bearing retainer ring (without ABS)

6. Trailing arm 15. Brake back plate 24. Bearing retainer ring (with ABS)

7. Rear axle shaft 16. Lateral rod axle housing side nut Tightening torque

8. Rear axle housing

: Apply water tight sealant 99000-31090 to joint of plate and axle housing.

9. Bearing

: Seal side of bearing comes inside of brake drum.

11. Oil seal 20. Trailing arm front bolt

: The tapered side of spacer inner diameter directed toward outside (brake drum side).

17. Lateral rod body side bolt : Insert from the direction as shown.

18. Shock absorber upper bolt : Insert from vehicle outside.

: Insert from vehicle inside.

21. Trailing arm rear bolt : Insert from vehicle inside.

Do not reuse

Page 18

REAR SUSPENSION 3E-3

Rear Axle Shaft and Wheel Bearing

REMOVAL

1) Hoist vehicle and remove rear wheels.

2) Remove rear brake drum by using 8 mm bolts. For details referring to Section 5C.

1. 8 mm bolt

3) Drain gear oil from rear axle housing by loosening drain plug (1).

2. Level plug

4) Disconnect parking brake cable from parking brake shoe lever (2) and remove parking brake cable (1) from brake back plate.

5) Disconnect brake pipe (1) from wheel cylinder and put wheel cylinder bleeder plug cap (2) onto pipe to prevent fluid from spilling.

6) Remove wheel speed sensor from axle housing (if equipped with ABS).

7) Remove brake back plate bolts from axle housing.

Page 19

3E-4 REAR SUSPENSION

8) Using special tools indicated, draw out axle shaft with brake back plate.

Special tool (A) : 09942-15511 (B) : 09943-17912

9) In order to remove the retainer ring (1) from the axle shaft (2), grind (3) with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin.

CAUTION:

Be careful not to go so far as to grind the shaft.

A : Without ABS

B : With ABS

10) Break with a chisel the thin ground retainer ring, and it can be removed.

Page 20

REAR SUSPENSION 3E-5

11) Using special tools, remove bearing (1) from shaft and then remove brake back plate (2).

Special tool (D) : 09927-18411 (E) : 09921-57810

12) Remove stud bolts (1) by using hydraulic press (2).

INSTALLATION

1) Aligning serrations between new stud bolts (1) and flange (4), install new stud bolts by tightening nut as shown.

2. Nut

3. Washer

Page 21

3E-6 REAR SUSPENSION

2) Press in a new bearing (2) and retainer ring (3) in order by using an hydraulic press (4).

NOTE:

• Install wheel bearing spacer (1) with the tapered side of its inner diameter directed toward outside (axle shaft flange side).

• Install wheel bearing with its sealed side directed toward outside (axle shaft flange side).

• Use care not to cause any damage to outside of retainer ring and wheels sensor ring (if equipped with ABS).

A : Tapered side

B : Sealed side

C : Differential side

D : Without ABS

E : With ABS

3) Inspect axle shaft length.

Rear axle shaft length “a” Right side : 657.5 mm (25.9 in.) Left side : 785.5 mm (30.9 in.)

4) Apply grease to axle shaft oil seal (1) lip as shown.

“A” : Grease 99000-25010

5) Apply sealant to mating surface (2) of axle housing and brake back plate.

NOTE:

Make sure to remove old sealant before applying it anew.

“B” : Sealant 99000-31090

6) Install rear axle shaft to rear axle housing and tighten brake back plate bolts to specified torque.

NOTE:

When installing rear axle shaft, be careful not to cause damage to oil seal lip in axle housing.

Tightening torque Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

Page 22

REAR SUSPENSION 3E-7

7) Connect brake pipe to wheel cylinder and tighten brake pipe flare nut to specified torque.

Tightening torque Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

8) Tighten oil drain plug to specified torque and refill rear axle (differential) housing with new specified gear oil and tighten oil filler plug to specified torque. Refer to Section 7F for tightening torque data and refill.

9) Connect parking brake cable (1) to parking brake shoe lever. Install brake shoes and secure parking brake cable to brake back plate with clip (2). Install wheel speed sensor (if equipped with ABS).

CAUTION:

Check to ensure that clip is in good condition before installing it. If deformed or broken, replace.

10) Install brake drum (1) (right & left) after marking sure that inside of brake drum and brake shoes are free from dirt and oil. Then tighten wheel nuts (2) temporarily by hand.

11) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, refer to “BLEEDING BRAKES” in Sec- tion 5.)

12) Install wheel and tighten wheel nuts to specified torque.

13) Upon completion of all jobs, pull parking brake lever with about 20 kg, (44 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable (for adjustment, refer to “PA R K - ING BRAKE INSPECTION AND ADJUSTMENT” in Section

5).

14) Check to ensure that brake drum is free from dragging and proper braking is obtained.

15) Perform brake test (foot brake and parking brake). (For brake test, see Section 5.)

16) Check each installed part for oil leakage.

Rear Axle Shaft Oil Seal

REMOVAL

1) Remove rear axle shaft. For details, refer to steps 1) to 8) of “REAR AXLE SHAFT AND WHEEL BEARING” in this section.

Page 23

3E-8 REAR SUSPENSION

2) Remove rear axle shaft oil seal (1) by using special tool.

Special tool (A) : 09913-50121

2. Axle housing

INSTALLATION

1) Using special tool, drive in oil seal (1) until it contacts oil seal protector (2) in axle housing.

NOTE:

• Make sure that oil seal is free from inclination as it is installed.

• Refer to figure so that oil seal is installed in proper direction.

Special tool (A) : 09924-84510-004 (B) : 09913-75821

“A” : Grease 99000-25010

A : Differential side

2) For procedure hereafter, refer to steps 4) to 16) of “REAR AXLE SHAFT AND WHEEL BEARING” in this section.

Rear Axle Housing

REMOVAL

1) Remove rear axle shaft referring to item 1) to 8) of “REAR AXLE SHAFT AND WHEEL BEARING” in this section.

2) Disconnect brake pipes (2) (right & left) from flexible hoses (1) and remove E-rings (3).

3) Remove brake pipes from wheel cylinders (right & left).

4) Remove wheel speed sensors (right & left) and release clamps from axle housing (if equipped with ABS).

5) Remove LSPV adjust nut and detach spring end from rear axle housing (if equipped with LSPV).

Page 24

REAR SUSPENSION 3E-9

6) Before removing propeller shaft, give match marks (1) on joint flange and propeller shaft (2) as shown.

7) Remove propeller shaft.

8) For jobs hereafter, support rear axle housing by using floor jack (1) under axle housing (2) and remove differential carrier assembly.

9) Remove lateral rod (1).

10) Loosen trailing arm rear mounting nuts (3) (right & left) from axle housing, but don’t remove bolts.

11) Remove shock absorber lower mounting bolts (1).

12) Lower floor jack until tension of suspension coil spring becomes a little loose and remove trailing arm rear mounting bolts (2) (right & left).

13) Lower rear axle housing gradually and remove coil springs.

Page 25

3E-10 REAR SUSPENSION

14) Remove axle housing.

INSTALLATION

Install removed parts in reverse order of removal, noting the following.

1) Place rear axle housing on floor jack. Then install rear trailing arm bolts (1) (right & left) in proper direction as shown. Then tighten nuts (2) temporarily by hand.

A : Vehicle out side

B : Vehicle center side

2) Install coil springs (3) (right & left) on spring seat (2) of axle housing (1) and raise axle housing.

NOTE:

When seating coil spring (3), mate spring end with stepped part (4) of rear axle spring seat as shown.

A : Upper side

“a” :Small

“b” : Large

3) Install shock absorber (1) (right and left) to axle housing (2) and install bolts in proper direction as shown. Then tighten bolts (3) (right & left) temporarily by hand.

Page 26

REAR SUSPENSION 3E-11

4) Install lateral rod (1) and bolt (3) in proper direction as shown. Then tighten nuts (4) temporarily by hand.

2. Vehicle body

A : Forward

5) Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side.

“A” : Sealant 99000-31110

6) Install differential carrier assembly to axle housing and tighten carrier bolts to specified torque.

Tightening torque Rear differential carrier bolts : 23 N·m (2.3 kg-m, 17.0 lb-ft)

7) Install propeller shaft to joint flange aligning match marks (1) and tighten flange bolts to specified torque.

Tightening torque Companion flange bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

8) Install LSPV spring to rear axle. Tighten LSPV adjust nut temporarily at this step. (if equipped with LSPV).

9) Install wheel speed sensor and clamp wire securely (right & left) (if equipped with ABS).

10) Remove floor jack from axle housing.

11) Connect brake flexible hoses (1) (right & left) to bracket on rear axle and secure it with E-rings (3) (right & left).

12) Connect brake pipes to brake flexible hoses (1) and tighten brake pipe flare nuts (2) to specified torque.

Tightening torque Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

Page 27

3E-12 REAR SUSPENSION

13) Apply grease to axle shaft oil seals (1) lip (right & left).

“A” : Grease 99000-25010

14) Clean mating surfaces (2) (right & left) of axle housing and brake back plate and apply water tight sealant as shown in figure.

“B” : Sealant 99000-31090

15) Install rear axle shaft (right & left) to rear axle housing and tighten brake back plate bolts to specified torque.

Tightening torque Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

16) Connect brake pipes (3) to wheel cylinders (1) (right & left) and tighten brake pipe flare nuts (2) to specified torque.

Tightening torque Brake pipe flare nuts (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

17) Apply water tight sealant where brake back plate (1) and parking brake cable contact. Connect parking brake cable (2) to brake back plate (right & left) and secure it with clip (3).

“A” : Sealant 99000-31090

NOTE:

Check to ensure that clip is in good condition before installing it. If deformed or broken, replace.

18) Install brake shoes (right & left) referring to “BRAKE SHOE” in Section 5C.

19) Install brake drums (1) (right & left) after making sure that inside of brake drum and brake shoes are free from dirt and oil. Then tighten wheel nuts (2) temporarily by hand.

20) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, refer to Section 5.)

21) Refill differential gear housing with new specified gear oil. Refer to Section 7F.

A : Forward

Page 28

REAR SUSPENSION 3E-13

22) Install wheels and tighten wheel nuts to specified torque.

Tightening torque Wheel nuts (f) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

23) Upon completion of all jobs, pull parking brake lever with about 20 kg, (44 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable referring to “PARKING BRAKE” in Section 5C.

24) Lower hoist.

25) Tighten right and left trailing arm nuts (1) and shock absorber lower bolts (2) to specified torque. Tighten lateral rod nuts (3) to specified torque.

NOTE:

When tightening these bolts and nuts, be sure that vehicle is off hoist and in non loaded condition.

Tightening torque Rear trailing arm nuts (a) : 80 N·m (8.0 kg-m, 58.0 lb-ft) Rear shock absorber lower bolts (b) : 63 N·m (6.3 kg-m, 45.5 lb-ft) Lateral rod axle housing side nut (c) : 50 N·m (5.0 kg-m, 36.5 lb-ft) Lateral rod body side nut (d) : 100 N·m (10.0 kg-m, 72.5 lb-ft)

26) Check to ensure that brake drum is free from dragging and proper braking is obtained.

27) Perform brake test (foot brake and parking brake).

28) If equipped with LSPV, check and adjust LSPV spring referring to “LSPV INSPECTION AND ADJUSTMENT” in Section 5A and perform “FLUID PRESSURE TEST” in Section 5.

29) Check each installed part for oil leakage.

Page 29

3E-14 REAR SUSPENSION

Required Service Material

Material

Lithium grease SUZUKI SUPER GREASE (A)

Sealant SUZUKI BOND NO. 1215

Gear oil For gear oil information, refer to Section 7F. • Differential gear (Rear axle housing) Water tight sealant

Recommended SUZUKI product

(Part Number)

(99000-25010)

(99000-31110)

SUZUKI SEALING COMPOUND 366E (99000-31090)

Use

• Axle shaft oil seal

• Wheel bearing

• Joint seam of differential carrier and axle

housing

• Joint seam of axle housing and brake back plate

Special Tool

09927-18411 09913-50121 09942-15511 09943-17912 Universal puller Oil seal remover Sliding hammer Brake drum remover

09921-57810 09924-84510-004 09913-75821 Bearing remover Oil seal installer Installer attachment

Page 30

SECTION 4B

PROPELLER SHAFTS

CONTENTS

PROPELLER SHAFTS 4B-1

General Description....................................... 4B-1

Diagnosis........................................................ 4B-1

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

Propeller Shaft Joint Check.......................... 4B-2

On-Vehicle Service ........................................ 4B-2

Tightening Torque Specification.................. 4B-6

Required Service Material............................. 4B-6

General Description

Most universal and constant velocity joints require no maintenance. They are lubricated for life and can not be lubricated on the vehicle. If universal and constant velocity joints becomes noisy or worn, it must be replaced. The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained. A viscous coupling is used for the coupling system which distributes an optimum driving force to the front and rear wheels according to the driving conditions. It is located at the center of the propeller shaft.

Diagnosis

Diagnosis Table

Condition Possible Cause Correction

Abnormal noise • Loose universal joint bolt Tighten universal joint bolt.

• Spider bearing worn out or stuck Replace.

• Worn or broken constant velocity joint Replace.

• Worn or broken center support bearing Replace.

• Broken center support rubber Replace.

• Wear spider Replace propeller shaft.

Vibration • Performed propeller shaft Replace.

Page 31

4B-2 PROPELLER SHAFTS

Propeller Shaft Joint Check

If universal joints are suspected of producing chattering or rattling noise, inspect them for wear. Check to see if cross spider rattles in yokes and replace defective propeller shaft with new one. Noise coming from universal joint can be easily distinguished from other noises because rhythm of chattering or rattling is in step with cruising speed. Noise is pronounced particularly on standing start or in coasting condition (when braking effect of engine is showing in the drive line).

On-Vehicle Service

23 N·m (2.3 kg-m)

1. Propeller shaft No.1 with center support

2. Viscous coupling with center support

3. Propeller shaft No.2

4. Forward

5. Propeller shaft No.2 bolt : Apply thread lock 99000-32110 to thread.

6. Washer (if equipped)

Tightening torque

23 N·m (2.3 kg-m)

55 N·m (5.5 kg-m)

23 N·m (2.3 kg-m)

PRECEDENTIAL INSPECTION

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

• Check propeller shaft joints for wear, rattle and damage. If any defect is found, replace.

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

Page 32

PROPELLER SHAFTS 4B-3

REMOVAL

1) Hoist vehicle.

2) Before removing propeller shafts, give match marks (1) on yoke (3) of propeller shaft No.2 (4) and companion flange (2) of differential as shown. Also give match marks (1) on propeller shaft No.2 yoke (5), viscous coupling with center support (6), yoke (7) of propeller shaft No.1 with center support (8) and transfer output flange (9).

CAUTION:

Don’t damage joint seal (10) to prevent lubrication defect of joint.

3) Loosen propeller shaft bolt at front and rear end, and separate propeller shafts from transfer and rear differential.

4) If disassembling propeller shaft assembly is necessary, loosen propeller shaft No.2 bolts (1) and viscous coupling nuts (2) to facilitate subsequent disassembling, but keeping each connection provisionally.

Page 33

4B-4 PROPELLER SHAFTS

5) Loosen center support bolts (1), then remove propeller shaft No.1 with center support (2), propeller shaft No.2 (3) and viscous coupling with center support (4) all together.

6) Disconnect propeller shaft No.1 with center support and propeller shaft No.2 from viscous coupling with center support.

INSPECTION

• Inspect propeller shaft and flange yoke for damage.

• Inspect propeller shaft for runout.

If damage is found or shaft runout exceeds its limit, replace.

Propeller shaft runout Limit : 0.7 mm (0.028 in.)

Page 34

PROPELLER SHAFTS 4B-5

INSTALLATION

Reverse removal procedure to install propeller shafts noting following point.

• When installing propeller shafts and viscous coupling with center support, align the match marks (1). Otherwise, vibration may occur during driving.

• Apply thread lock cement to thread of propeller shaft No.2 bolts.

“A” : Cement 99000-32110

• Use following specification to torque bolts.

Tightening torque Propeller shaft bolts (a) : 23 N·m (2.3 kg-m, 17.0 Ib-ft) Center support bolts (b) : 55 N·m (5.5 kg-m, 40.0 lb-ft) Viscous coupling nuts (c) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

2. Propeller shaft No.2

3. Viscous coupling with center support

4. Propeller shaft No.1 with center support

5. Washer (if equipped)

Page 35

4B-6 PROPELLER SHAFTS

Tightening Torque Specification

Fastening portion

Propeller shaft bolts 23 2.3 17.0 Center support bolts 55 5.5 40.0 Viscous coupling nuts 23 2.3 17.0

N•m kg-m lb-ft

Tightening torque

Required Service Material

Material

Thread lock cement THREAD LOCK CEMENT 1322

Recommended SUZUKI Material

(Part Number)

(99000-32110)

Use

• Propeller shaft No.2 bolt

Page 36

BRAKES 5-1

SECTION 5

BRAKES

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

• All brake 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 replace with one of same part number or with an equivalent part if replacement becomes necessary. D 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

CONTENTS

Check and Adjustment .................................... 5-2

Fluid Pressure Test (If Equipped with LSPV) . 5-2

Tightening Torque Specification.................... 5-4

Special Tool...................................................... 5-4

Page 37

5-2 BRAKES

Check and Adjustment

Fluid Pressure Test (If Equipped with LSPV)

Test procedure for LSPV assembly is as follows.

Before testing, confirm the following.

• Fuel tank is filled with fuel fully.

• Vehicle is equipped with spare tire, tools, jack and jack han-

dle.

1) Place vehicle on level floor and set approximately about 1,000 N (100 kg, 220 lbs) weight (1) on rear housing center so that rear axle weighs 4,500 N (450 kg, 992 lbs).

Rear axle weight “L” : 4,500 N (450 kg, 992 lbs)

2) Install special tool to front and rear brake.

NOTE:

Pressure gauge should be connected to bleeder plug hole of front (left side brake) and rear (right side brake). After testing front left side and rear right side, test front right side and rear left side in the same way.

Special tool Front brake (A) : 09956-02310 (B) : 09952-36310 (C) : 55473-82030 (Air bleeder plug as a spare part)

NOTE:

For front brake, use special tool (B) instead of thread diameter 10 mm attachment included in special tool (A).

Rear brake (A) : 09956-02310 (C) : 55473-82030 (Air bleeder plug as a spare part) (D) : 09952-48320

Page 38

BRAKES 5-3

3) Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake then. It should be within specification given below.

Front brake Rear brake

7,500 kPa

75 kg/cm

1,067 psi

4,000 – 5,500 kPa

40 – 55 kg/cm

569 – 782 psi

4) As done above, apply 100 kg/cm

pressure to front brake and check that rear brake pressure then is within specification as given below.

Front brake Rear brake

10,000 kPa

100 kg/cm

1,422 psi

4,700 – 6,200 kPa

47 – 62 kg/cm

668 – 882 psi

5) If rear brake pressure is not within specification, adjust it by changing bolt (2) position as follows.

• If rear brake pressure is higher than specification, move bolt and nut (1) center side “a” and if it is lower, out side “b”.

• Repeat steps 3) and 4) until rear brake pressure is within specification.

• After adjustment, be sure to torque nut (1) to specification.

Tightening torque LSPV nut (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

6) Upon completion of fluid pressure test, bleed brake system and perform brake test.

Page 39

5-4 BRAKES

Tightening Torque Specification

Fastening part

Brake pipe flare nut 16 1.6 11.5 Brake bleeder plug (Front caliper) 6.5 0.65 5.0 Brake bleeder plug (Wheel cylinder) 8.5 0.85 6.5 LSPV spring adjust nut 25 2.5 18.0

N•m kg-m lb-ft

Tightening torque

Special Tool

09956-02310 09952-36310 09952-48320 Fluid pressure gauge Pressure gauge attach-

ment

Pressure gauge attachment

Page 40

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-1

SECTION 5A

BRAKES PIPE/HOSE/MASTER CYLINDER

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

• All brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

6F1 6F2

6G 6H 6K

7A 7A1 7B1 7C1

10 10A 10B

CONTENTS

General Description....................................... 5A-2

LSPV (Load Sensing Proportioning Valve)

Assembly (if equipped)................................. 5A-2

On-Vehicle Service......................................... 5A-3

Rear Brake Hose/Pipe

(For Vehicle with LSPV)............................... 5A-3

LSPV (Load Sensing Proportioning Valve)

Assembly (if equipped) ................................ 5A-4

Special Tool.................................................... 5A-6

Page 41

5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER

General Description

LSPV (Load Sensing Proportioning Valve) Assembly (if equipped)

As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.

1. LSPV assembly

2. Spring

3. Adjust nut

4. Brake pipe flare nut

Page 42

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3

On-Vehicle Service

CAUTION:

• Do not use lubricated shop air on brake parts as damage to rubber components may result.

• If any hydraulic component is removed or brake line disconnected, bleed the brake system.

• The torque values specified are for dry, unlubricated fasteners.

• Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid.

Rear Brake Hose/Pipe (For Vehicle with LSPV)

REMOVAL

1) Raise and suitably support vehicle. Remove tire and wheel.

2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.

INSTALLATION

Reverse removal procedure for brake hose or pipe installation procedure.

• Install clamps properly referring to figure below.

• When installing hose, make sure that it has no twist or kink.

• Fill and maintain brake fluid level in reservoir. Bleed brake system.

• Perform brake test and check each installed part for fluid leakage.

1. 4 way joint A : Viewed from A

2. LSPV assembly F : Front side

3. Rear brake hose L : Left side

4. To left rear wheel cylinder R : Right side

5. To right rear wheel cylinder T : Top side

6. From master cylinder (Primary) a – f : Clamp

7. From master cylinder (Secondary) Tightening Torque

Page 43

5A-4 BRAKES PIPE/HOSE/MASTER CYLINDER

LSPV (Load Sensing Proportioning Valve) Assembly (if equipped)

25 N·m(2.5 kg-m)

1. LSPV assembly

2. Spring

3. Adjust nut

4. Brake pipe

Tightening Torque

25 N·m(2.5 kg-m)

4 16 N·m(1.6 kg-m)

CAUTION:

• Never disassemble LSPV assembly. Disassembly will spoil its original performance. Replace with new one if defective.

• Observe CAUTION at the beginning of ON-VEHICLE SERVICE.

REMOVAL

1) Clean around reservoir cap and take out fluid with syringe or such.

2) Hoist vehicle.

3) Disconnect brake pipes from LSPV assembly (1).

Special tool (A) : 09950-78230 (10 x 11 mm)

Page 44

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-5

4) Remove nut (2) and detach spring end from bracket (3).

5) Remove LSPV assembly (1) with spring (4) from vehicle body.

INSTALLATION

1) Install LSPV assembly with spring to vehicle body.

2) Tighten brake pipe flare nuts and LSPV adjusting nut (1) to specified torque.

Special tool (A) : 09950-78230 (10 x 11 mm)

Tightening torque LSPV adjust nut (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft) Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

3) Fill reservoir with specified fluid and bleed air from brake system.

4) After bleeding air, check that LSPV is installed properly referring to following “INSPECTION & ADJUSTMENT”.

INSPECTION & ADJUSTMENT

1) Confirm the following before inspection and adjustment.

• Fuel tank is filled with fuel fully.

• Vehicle is equipped with spare tire, tools, jack and jack han-

dle.

• Vehicle is free from any other load.

• Vehicle is placed on level floor.

Page 45

5A-6 BRAKES PIPE/HOSE/MASTER CYLINDER

2) Push up LSPV lever with finger till it stops and measure length of coil spring (“a” in figure).

3) Spring length “a” should be as specified.

Spring length “a” : 4WD : 148 mm (5.83 in.)

4) If it isn’t, adjust it to specification by changing LSPV adjust- ing bolt and nut position as shown in figure. After adjustment, tighten nut (1) to specified torque.

Tightening torque LSPV adjust nut (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)

NOTE:

Check to make sure that LSPV body and brake pipe joints are free from fluid leakage. Replace defective parts, if any.

5) Confirm fluid pressure referring to “Fluid Pressure Test” in Section 5.

09950-78230 Flare nut wrench (10 x 11 mm)

Special Tool

Page 46

PARKING AND REAR BRAKE 5C-1

SECTION 5C

PARKING AND REAR BRAKE

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

• All brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

CONTENTS

On-Vehicle Service......................................... 5C-2

Brake Drum .................................................. 5C-2

Brake Back Plate ......................................... 5C-3

Page 47

5C-2 PARKING AND REAR BRAKE

On-Vehicle Service

Brake Drum

REMOVAL

1) Hoist vehicle and remove wheel.

2) Release parking brake lever.

3) Remove brake drum. If brake drum can not be removed easily, increase clearance between brake shoes and drum as follows.

a) Remove console box and loosen parking brake cable

adjusting nut (1).

b) Pull brake drum (1) off by using 8 mm bolts.

INSTALLATION

1) Put flat head rod or the like between rod (1) and ratchet (2) and pull ratchet as shown to maximize clearance between shoe and drum.

2) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil.

3) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable. (For adjustment, see PARKING BRAKE INSPECTION AND ADJUSTMENT in Section 5.)

4) Install console box if removed.

Page 48

PARKING AND REAR BRAKE 5C-3

5) Install wheel and tighten wheel nuts to specified torque.

Tightening torque Wheel nut (b) : 85 N·m (8.5 kg-m, 61.5 lb-ft)

6) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (foot brake and parking brake).

Brake Back Plate

REMOVAL AND INSTALLATION

Refer to “REAR AXLE SHAFT AND WHEEL BEARING (4WD VEHICLE)” in Section 3E.

Page 49

5C-4 PARKING AND REAR BRAKE

Page 50

ANTILOCK BRAKE SYSTEM (ABS) 5E1-1

SECTION 5E1

ANTILOCK BRAKE SYSTEM (ABS)

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

• All brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

CONTENTS

General Description..................................... 5E1-2

Components and Parts Location................ 5E1-2

System Schematic ..................................... 5E1-3

System Circuit ............................................ 5E1-4

Diagnosis...................................................... 5E1-6

Diagnostic Trouble Code (DTC) Table....... 5E1-6

On-Vehicle Service ...................................... 5E1-8

Rear Wheel Speed Sensor ........................ 5E1-8

Rear Wheel Speed Sensor Ring................ 5E1-9

G Sensor (For 4WD Vehicle Only)........... 5E1-10

Tightening Torque Specification.............. 5E1-11

5E2

5E1

Page 51

5E1-2 ANTILOCK BRAKE SYSTEM (ABS)

General Description

Components and Parts Location

The ABS (Antilock Brake System) controls the fluid pressure applied to the Wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS has also the following function. While braking is applied, but before ABS control becomes effective, braking force is distributed between the front and rear so as to prevent the rear wheels from being locked too early for better stability of the vehicle. The main component parts of this ABS include the following parts in addition to those of the conventional brake system.

• Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.

•“ABS” warning lamp which lights to inform abnormality when system fails to operate properly.

• ABS hydraulic unit/control module assembly is incorporated ABS control module, ABS hydraulic unit (actua-

tor assembly), fail-safe relay and pump motor relay.

– ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to

each wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.

– ABS hydraulic unit which operates according to signal from ABS control module to control fluid pressure

applied to wheel cylinder of each 4 wheels.

– Fail-safe relay (solenoid valve relay) which supplies power to solenoid valve in ABS hydraulic unit. – Pump motor relay which supplies power to pump motor in ABS hydraulic unit.

• G sensor which detects vehicle deceleration speed. (For 4WD model only)

This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sensor independently of change of load due to load capacity and so on. And if the EBD system fails to operate properly, the brake warning lamp lights to inform abnormality.

[A] : LH steering vehicle shown 2. Combination meter 4. Wheel speed sensor ring 6. G sensor

1. ABS hydraulic unit/control module assembly 3. Wheel speed sensor 5. Monitor coupler

Page 52

System Schematic

ANTILOCK BRAKE SYSTEM (ABS) 5E1-3

1. ABS hydraulic unit/control module assembly 7. “ABS” warning lamp 13. Wheel speed sensor (Right-front)

2. ABS control module 8. “EBD” warning lamp (Brake warning lamp) 14. Wheel speed sensor (Left-front)

3. ABS hydraulic unit 9. Lamp driver module 15. Wheel speed sensor (Right-rear)

4. Fail safe relay 10. ECM 16. Wheel speed sensor (Left-rear)

5. Pump motor relay 11. Data link connector 17. G sensor

6. Stop lamp switch 12. Monitor coupler

Page 53

5E1-4 ANTILOCK BRAKE SYSTEM (ABS)

System Circuit

Page 54

ANTILOCK BRAKE SYSTEM (ABS) 5E1-5

1. Battery 9. ABS hydraulic unit/control module assembly 17. Left-rear wheel speed sensor

2. Main fuses 10. Terminal arrangement of ABS hydraulic unit/control

3. Ignition switch 11. ABS fail-safe relay (Solenoid valve relay) 19. Left-front wheel speed sensor

4. Circuit fuses 12. ABS pump motor relay 20. Data link connector

5. Combination meter 13. Pump motor 21. To ECM, SDM and EPS controller (if equipped)

6. “ABS” warning lamp 14. Solenoid valves 22. Stop lamp

7. “EBD” warning lamp (Brake warning lamp) 15. Diagnosis monitor coupler 23. Stop lamp switch

8. Warning lamp driver module (for ABS) 16. Right-rear wheel speed sensor 24. G sensor

module assembly

18. Right-front wheel speed sensor

Wire color

B : Black Br : Brown R : Red B/R : Black/Red G : Green V/W : Violet/White B/W : Black/White G/R : Green/Red W/B : White/Black Bl/B : Blue/Black G/W : Green/White W/Bl : White/Blue Bl/R : Blue/Red Or : Orange W/R : White/Red Bl/W : Blue/White Or/Bl : Orange/Blue

TERMINAL CIRCUIT

E20-1 ––– E20-2 Stop lamp switch E20-3 Right-front wheel speed sensor (+) E20-4 Right-front wheel speed sensor (–) E20-5 ––– E20-6 Right-rear wheel speed sensor (–) E20-7 Right-rear wheel speed sensor (+) E20-8 –––

E20-9 ––– E20-10 “EBD” warning lamp (Brake warning lamp) E20-11 G sensor E20-12 Diagnosis switch terminal E20-13 Ground (for G sensor) E20-14 “ABS” warning lamp E20-15 Left-front wheel speed sensor (+) E20-16 Left-front wheel speed sensor (–) E20-17 ––– E20-18 Ignition switch E20-19 Left-rear wheel speed sensor (+) E20-20 Left-rear wheel speed sensor (–) E20-21 Data link connector E20-22 Ground (for ABS pump motor) E20-23 ABS pump motor relay E20-24 Ground (for ABS control module) E20-25 ABS fail-safe relay

Page 55

5E1-6 ANTILOCK BRAKE SYSTEM (ABS)

Diagnosis

Diagnostic Trouble Code (DTC) Table

CAUTION:

Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” referring to Section 5E1 of the Service Manual mentioned in FOREWORD of this manual before starting diagnosis.

DTC

(displ ayed on

SUZUKI

scan tool)

NO DTC 12 Normal

C1013 13 ABS control module

C1015 15 G sensor circuit

C1021 21 RF

C1025 25 LF

C1031 31 RR

C1035 35 LR

DTC

(indicated by

“ABS” warn-

ing lamp)

ABS warning lamp flashing

pattern

Wheel speed sensor circuit

DIAGNOSTIC ITEMS

C1022 22 RF

C1026 26 LF

Wheel speed sensor circuit or sensor ring

C1032 32 RR

C1036 36 LR

C1041 41

C1042 42 Outlet solenoid valve circuit

C1045 45

C1046 46 Outlet solenoid valve circuit

Inlet solenoid valve circuit

Page 56

ANTILOCK BRAKE SYSTEM (ABS) 5E1-7

DTC

(displayed on

SUZUKI

scan tool)

C1051 51

DTC

(indicated by

“ABS” warn-

ing lamp)

ABS warning lamp flashing

pattern

DIAGNOSTIC ITEMS

Inlet solenoid valve circuit

C1052 52 Outlet solenoid valve circuit

C1055 55

Inlet solenoid valve circuit

C1056 56 Outlet solenoid valve circuit

C1057 57 Power source

C1061 61 ABS pump motor and/or motor relay circuit

C1063 63 Fail safe-relay

C1071 71 ABS control module

Page 57

5E1-8 ANTILOCK BRAKE SYSTEM (ABS)

Rear Wheel Speed Sensor

On-Vehicle Service

1. Rear wheel speed sensor (right side) 4. Rear axle housing

2. Trailing arm 5. Forward

3. Sensor coupler 6. Vehicle inside

OUTPUT VOLTAGE INSPECTION

1) Turn ignition switch “OFF”.

2) Hoist vehicle.

3) Disconnect connector of wheel speed sensor.

4) Connect voltmeter between connector (1) terminals.

5) While turning wheel at a speed of approximately 1/2 to 1 rotation per second, check AC voltage of sensor. If measured voltage is not as specified, check sensor, rotor and their installation conditions.

Output AC voltage at 1/2 to 1 rotation per second 106 mV or more

2. Rotate by hand

Tightening torque

Page 58

ANTILOCK BRAKE SYSTEM (ABS) 5E1-9

Reference

When using oscilloscope for this check, check if peak-to-peak voltage (1) meets specification and waveform is complete.

Peak-to-peak voltage at 1/2 to 1 rotation per second 150 mV or more at 20 Hz

SENSOR INSPECTION

• Check sensor for damage.

• Check sensor for resistance and continuity.

If the check result is not as specified and any malcondition is found, replace.

Between both terminals of sensor

1.2 – 1.6 k

at 20°C (68°F)

ΩΩΩΩ

Between sensor terminal and sensor body No continuity

Rear Wheel Speed Sensor Ring

INSPECTION

• Check rotor serration (teeth) for being missing damaged or deformed.

• Turn wheel and check if rotor rotation is free from eccentricity and looseness.

• Check that no foreign material is attached.

• If any faulty is found, repair or replace.

REMOVAL/ INSTALLATION

NOTE:

The rear wheel speed sensor ring can not be removed or replaced alone. If rear wheel speed sensor ring needs to be replaced, replace it as a retainer ring of rear axle shaft.

For removal and installation of retainer ring of rear axle shaft, refer to “REAR AXLE SHAFT AND WHEEL BEARING” in Section 3E.

Page 59

5E1-10 ANTILOCK BRAKE SYSTEM (ABS)

G Sensor (For 4WD Vehicle Only)

REMOVAL

1) Turn ignition switch OFF and disconnect battery negative cable.

2) Remove center console box.

3) Remove G sensor (1) from floor.

4) Disconnect connector from sensor.

CAUTION:

Sensor must not be dropped or shocked. It will affect its original performance.

2. Label

3. Forward

INSPECTION

Connect positive cable of 12 volt battery to “A” terminal of sensor and ground cable to “C” terminal. Then using voltmeter, check voltage between “B” terminal and “C” terminal.

G sensor specification When placed horizontally : 2 – 3 V When placed upright with arrow upward : 3 – 4 V When placed upright with arrow downward : 1 – 2 V

If measured voltage is not as specified, replace sensor.

[A] : Horizontal

[B] : Upright with arrow upward

[C] : Upright with arrow downward

INSTALLATION

1) Connect connector to sensor securely.

2) Install sensor onto floor so that arrow mark (1) directs vehicle forward (2). Tighten bolts to specified torque.

Tightening torque G sensor bolt (a) : 3.0 N·m (0.3 kg-m, 2.2 lb-ft)

3) Install rear console box.

4) Connect negative cable at battery.

Page 60

ANTILOCK BRAKE SYSTEM (ABS) 5E1-11

Tightening Torque Specification

Fastening part

G sensor bolt 3.0 0.3 2.2

N•m kg-m lb-ft

Tightening torque

Page 61

5E1-12 ANTILOCK BRAKE SYSTEM (ABS)

Page 62

ENGINE MECHANICAL 6A1-1

SECTION 6A1

ENGINE MECHANICAL

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

6F1

6G 6H 6K

7A 7A1 7B1 7C1

6A1

CONTENTS

Unit Repair Overhaul ....................................6A1-2

Engine Mounting .........................................6A1-2

Engine Assembly ........................................ 6A1-3

10B 6A1

Page 63

6A1-2 ENGINE MECHANICAL

Engine Mounting

Unit Repair Overhaul

1. Right mounting 10. Transfer to engine stiffener (if equipped) 19. Transfer to engine stiffener No.1 bolt (if equipped)

2. Right mounting swing bracket 11. Transfer stiffener bolt 20. Left mounting nut

3. Right mounting bracket 12. Rear mounting 21. Rear mounting bracket bolt

4. Left mounting body bracket 13. Right mounting body bolt 22. Rear mounting bracket nut

5. Left mounting 14. Right mounting bracket & swing bolt 23. Rear mounting bush bolt

6. Left mounting bracket 15. Right mounting bracket & swing nut 24. Rear mounting body bolt

7. Transfer stiffener 16. Right mounting bush bolt 25. Transfer to engine stiffener No.2 bolt (if equipped)

8. Left mounting bracket stiffener 17. Right mounting bracket bolt Tightening Torque

9. Rear mounting bracket 18. Left mounting bush bolt

Page 64

ENGINE MECHANICAL 6A1-3

Engine Assembly

REMOVAL

1) Release fuel pressure in fuel feed line by referring to Section 6 of the Service Manual mentioned in the FOREWORD of this manual.

2) After disconnect negative and positive cables at battery, remove battery and battery tray.

3) Remove engine hood after disconnecting windshield washer hose.

4) Drain cooling system.

WARNING:

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

5) Disconnect radiator inlet hose from thermostat case and outlet hose from water inlet pipe.

6) Remove air cleaner outlet No.1 hose (1) and No.2 hose (2) with air intake joint (3).

7) Remove suction pipe (5) and remove air cleaner assembly (4) by removing its fastening bolt (6).

8) Disconnect the following cables.

• Accelerator cable (1) from throttle body (2).

• Clutch cable from transmission.

• Gear shift and select control cables from transmission.

9) Disconnect the following vacuum hose.

• Brake booster hose (1) from intake manifold.

• Canister purge hose (2) from EVAP canister purge valve.

Page 65

6A1-4 ENGINE MECHANICAL

10) Disconnect the following electric wires:

• Back-up light switch

• Battery negative cable from transmission

• Vehicle speed sensor

• e.t.c.

and release above wire harness from clamps.

11) Disconnect fuel feed hose (1) from fuel delivery pipe.

12) Disconnect heater inlet and outlet hoses.

13) Remove right and left engine under covers.

14) Disconnect oxygen sensor No.2 (1) coupler and remove exhaust No.1 pipe (2).

15) Drain engine oil, transmission oil and transfer oil.

16) Remove propeller shafts referring to Section 4B.

17) Remove stabilizer bar (1) referring to Section 3D of the Service Manual mentioned in the FOREWORD of this manual.

18) Remove drive shaft joints from differential gear of transmission and intermediate shaft of transfer. Refer to Section 4 of the Service Manual mentioned in the FOREWORD of this manual for procedure to disconnect drive shaft joint. For engine and transmission removal, it is not necessary to remove drive shafts from steering knuckle.

Page 66

ENGINE MECHANICAL 6A1-5

19) Disconnect A/C suction and discharge hoses and then remove A/C compressor and its bracket (if equipped), refer to Section 1B of the Service Manual mentioned in the FOREWORD of this manual.

20) Install support device.

21) Remove the following bolts and nuts referring to the figure of “Engine Mounting” in this section.

a) Remove engine rear mounting bush bolt. b) Remove engine left mounting nuts. c) Remove engine right mounting bracket bolts and nut.

22) Before removing engine with transmission and transfer from body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transmission.

23) Lower engine with transmission and transfer from body.

Page 67

6A1-6 ENGINE MECHANICAL

INSTALLATION

1) Lift engine with transmission and transfer into engine compartment, but do not remove support device.

2) Install engine right mounting bracket bolts and nut.

3) Install engine left mounting nuts.

4) Install engine rear mounting bush bolt.

5) Tighten bolts and nuts to specified torque referring to the figure of “Engine Mounting” in this section.

6) Remove support device.

7) Reverse removal procedures for installation of remainder.

• Install A/C compressor bracket and A/C compressor and connect A/C suction and discharge hoses, refer to Section 1B of the Service Manual mentioned in the FOREWORD of this manual.

• Push in each drive shaft joint fully so that snap ring engages with differential gear and intermediate shaft of transfer. Use care not to damage oil seal lip when inserting.

• Install stabilizer bar, refer to Section 3D of the Service Manual mentioned in the FOREWORD of this manual.

• Install exhaust No.1 pipe.

• Install right and left engine under covers.

• Connect each hoses securely.

• Clamp electric wire securely.

8) Adjust clutch pedal free travel, referring to Section 7C of the Service Manual mentioned in the FOREWORD of this manual. Connect gear shift and select control cables referring to Section 7A.

9) Refill transmission with gear oil referring to Section 7A of the Service Manual mentioned in the FOREWORD of this manual.

10) Refill engine with engine oil, referring to Section 0B of the Service Manual mentioned in the FOREWORD of this manual.

11) Refill cooling system, referring to Section 6B of the Service Manual mentioned in the FOREWORD of this manual.

12) Adjust A/C compressor belt (if equipped), referring to Section 1B of the Service Manual mentioned in the FOREWORD of this manual.

13) Upon completion of installation, verify that there is no fuel leakage, coolant leakage, transmission oil leakage or exhaust gas leakage at each connection.

14) Adjust accelerator cable play, referring to Section 6E of the Service Manual mentioned in the FOREWORD of this manual.

Page 68

MANUAL TRANSMISSION 7A-1

SECTION 7A

MANUAL TRANSMISSION

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

6F2

6G 6H 6K

7A1 7B1 7C1

7D 7E 7F

8A 8B 8C

General Description....................................... 7A-2

Construction and Servicing .......................... 7A-2

On-Vehicle Service......................................... 7A-4

Differential Side Oil Seal .............................. 7A-4

Gear Shift Control Lever and Cable ............. 7A-6

Unit Repair Overhaul ..................................... 7A-8

CONTENTS

Sub Assembly Service............................... 7A-15

Assembling Unit......................................... 7A-17

Tightening Torque Specification................ 7A-20

Required Service Materials......................... 7A-21

Special Tools................................................ 7A-21

10 10A 10B

Differential assembly.............................. 7A-15

Fifth gears .............................................. 7A-17

Page 69

7A-2 MANUAL TRANSMISSION

General Description

Construction and Servicing

The transmission provides five forward speeds and one reverse speed by means of three synchronizer mesh devices and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.

The low speed synchronizer mesh device is mounted on counter shaft and engaged with counter shaft first gear or second gear, while the high speed synchronizer mesh device is done on input shaft and engaged with input shaft third gear or fourth gear. The fifth speed synchronizer mesh device on input shaft is engaged with input shaft fifth gear mounted on the input shaft.

The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of shifting to 2nd gear.

The countershaft turns the final gear and differential assembly, thereby turning the front drive shafts which are attached to the front wheels.

4WD model is equipped with transfer assembly on transmission being mated to right side of differential output in transmission.

For servicing, it is necessary to use genuine sealant or its equivalent on mating surfaces of transmission case which is made of aluminum. The case fastening bolts must be tightened to specified torque by means of torque wrench. It is also important that all parts are thoroughly cleaned with cleaning fluid and air dried before reassembling.

Further, care must be taken to adjust preload of counter shaft taper roller bearings. New synchronizer rings are prohibited from being lapped with respective gear cones by using lapping compound before they are assembled.

Page 70

MANUAL TRANSMISSION 7A-3

1. 5th speed sleeve & hub 7. Reverse gear shaft 13. Countershaft 4th gear 19. Final gear

2. Input shaft 5th gear 8. Reverse idler gear 14. Countershaft 20. Differential case

3. Input shaft 4th gear 9. Input shaft 15. Countershaft 3rd gear 21. Vehicle speed sensor

4. High speed sleeve & hub 10. Right case 16. Countershaft 2nd gear 22. Transfer assembly

5. Input shaft 3rd gear 11. Side cover 17. Low speed sleeve & hub

6. Left case 12. Countershaft 5th gear 18. Countershaft 1st gear

Page 71

7A-4 MANUAL TRANSMISSION

On-Vehicle Service

Differential Side Oil Seal

REPLACEMENT

1) Lift up vehicle and drain transmission and transfer oil.

2) Remove wheel, and then remove tie-rod end nut.

3) Disconnect tie-rod end from knuckle by using puller (1).

4) Remove two stabilizer mount brackets from vehicle body.

5) Remove ball stud bolt and then separate suspension arm from knuckle.

6) Separate transfer from transmission assembly. For detail, refer to Section 7D.

7) By using large size screwdrivers (2), pull out drive shaft joint (1) so as to release snap ring fitting of joint spline at differential side. Pushing knuckle portion outward, detach drive shaft at differential side.

8) Remove oil seal (1) and install a new one until it becomes flush with case surface by using special tool and hammer.

NOTE:

When installing oil seal, face its spring side inward.

Special tool (A) : 09913-75510 (LH) (A) : 09951-46010 (RH)

9) Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make sure of its smoothness.

“A” : Grease 99000-25010

10) Install transfer to transmission referring to Section 7D.

Page 72

MANUAL TRANSMISSION 7A-5

11) Insert drive shaft joint to differential gear.

CAUTION:

• Be careful not to scratch oil seal lip with drive shaft joint while inserting.

• Make sure to insert drive shaft joint fully and seat its snap ring as it was.

• Do not hit joint boot with hammer or the like. Nothing but hands is allowed to use when inserting joint.

12) Connect ball stud with knuckle and fasten with bolt to specification referring to Section 3D of the Service Manual mentioned in the FOREWORD of this manual.

13) Connect tie-rod end with knuckle and fasten new nut to specified torque referring to Section 3D of the Service Manual mentioned in the FOREWORD of this manual.

14) Install stabilizer mount brackets, fasten bolts to specified torque referring to Section 3D of the Service Manual mentioned in the FOREWORD of this manual.

15) Pour transmission oil and transfer oil as specified and make sure that oil has been sealed with oil seal.

Page 73

7A-6 MANUAL TRANSMISSION

Gear Shift Control Lever and Cable

1. Gear shift control lever knob 5. Gear select control cable 8. Cable nut

2. Lever boot holder 6. Gear shift control cable guide nut 9. Cable mounting bolt

3. Gear shift lever boot 7. Gear shift control lever assembly

4. Gear shift control cable

: Apply grease 99000-25010 to pin ends to which shift and select cables are connected.

Tightening Torque

Page 74

MANUAL TRANSMISSION 7A-7

REMOVAL

1) Remove console box.

2) Disconnect gear shift and select control cables (1) from gear shift control lever assembly (2).

a) Disconnect cable end from pivot while pushing cable end

bush (4).

b) Detach cable from bracket (5) while pulling pin (6).

3) Remove gear shift control lever assembly mounting nuts (3) and gear shift lever assembly from body.

4) Disconnect shift and select cables from transmission in the same manner as step 2).

5) Remove cable grommet and cable clamp, and then remove shift and select cables from body.

INSTALLATION

Reverse removal procedure for installation and note as follows.

• Apply grease to pin ends (1) before installing shift and select cable ends to pin ends.

“A” : Grease 99000-25010

• Tighten gear shift control lever assembly mounting nuts to specified torque.

Tightening torque Gear shift control lever assembly nuts (a) : 13 N·m (1.3 kg-m, 9.5 lb-ft)

Page 75

7A-8 MANUAL TRANSMISSION

Unit Repair Overhaul

[A] : TRANSMISSION CASE 6. Back up light switch 11. VSS

1. Transmission right case 7. O-ring 12. Oil gutter bolt

2. Transmission left case : Apply sealant 99000-31230 to mating surface of left case and right case.

3. Gear shifter assembly 9. Oil level/filler plug

4. Transmission left case plate 10. Oil drain plug

5. Transmission side cover : Apply sealant 99000-31230 to mating surface of side cover and left case.

8. Differential assembly 13. Left case plate bolts and screw

: Apply sealant 99000-31230 to all around thread part of plug.

: Apply thread lock 99000-32110 to all around thread part of bolt.

Tightening Torque

Do not reuse.

Page 76

MANUAL TRANSMISSION 7A-9

Page 77

7A-10 MANUAL TRANSMISSION

1. Input shaft 17. 5th synchronizer spring 34. Needle bearing (separated steel cage type)

2. Oil seal : Apply grease 99000-25010 to oil seal lip.

3. Input shaft right bearing 19. 5th synchronizer key 35. Countershaft 2nd gear

4. Input shaft 3rd gear 20. 5th synchronizer hub plate 36. Countershaft 3rd gear

5. Needle bearing (resin cage type) 21. Circlip 37. 3rd & 4th gear spacer

5-1. Needle bearing (resin cage type) 22. Reverse gear shaft 38. Countershaft 4th gear

6. High speed synchronizer r ing 23. Reverse idler gear 39. Countershaft left bearing

7. High speed synchronizer spring 24. Reverse shaft washer 40. Bearing set shim

8. High speed sleeve & hub 25. Countershaft right bearing 41. Countershaft 5th gear

9. High speed synchronizer key 26. Countershaft 42. Countershaft nut

10. Circlip 27. Countershaft 1st gear 43. Reverse shaft bolt

11. Input shaft 4th gear 28. 1st gear synchronizer ring 44. Washer

12. Input shaft left bearing 29. Low speed synchronizer spring 45. Center cone

13. Input shaft 5th gear 30. Low speed sleeve & hub 46. 2nd gear synchronizer inner ring

14. 5th gear spacer 31. Low speed synchronizer key Apply transmission oil.

18. 5th speed sleeve & hub 34-1. Needle bearing (steel cage type)

: After tightening nut to specified torque, caulk nut securely.

: Apply thread lock cement 99000-32110 to thread.

15. 5th gear needle bear ing (separated steel cage type)

16. 5th speed synchronizer ring 33. 2nd gear synchronizer outer ring Do not reuse.

32. Circlip Tightening Torque

Page 78

MANUAL TRANSMISSION 7A-11

Page 79

7A-12 MANUAL TRANSMISSION

[A] : GEAR SHIFTER 10. Reverse gear shift lever 21. Differential case

[B] : DIFFERENTIAL 11. 5th & reverse gear shift guide shaft 22. Final gear

1. Gear shift & select shaft 12. Reverse gear shift ar m 23. 5th to reverse interlock guide bolt

2. 5th & reverse gear shift cam 13. 5th gear shift fork 24. Gear shift interlock bolt

3. Gear shift interlock plate 14. Side gear washer 25. Reverse gear shift lever bolt

4. Gear shift & select lever 15. Differential side pinion gear 26. 5th gear shift fork plug

5. Shift cable lever 16. Differential side gear 27. Final gear bolt

6. Select cable lever 17. Side gear washer Apply transmission oil.

: Apply sealant 99000-31230 to bolt thread.

: Apply thread lock 99000-32110 to all around thread part of bolt.

: Apply thread lock 99000-32110 to all around thread part of plug.

: Apply thread lock 99000-32110 to all around thread part of bolt.

7. Low speed gear shift shaft 18. Differential side oil seal

8. High speed gear shift shaft 19. Differential side bear ing Do not reuse.

9. 5th & reverse gear shift shaft 20. Speed sensor ring

: Apply grease 99000-25010 to oil seal lip.

Tightening Torque

Page 80

MANUAL TRANSMISSION 7A-13

DISMOUNTING

Under hood

1) Disconnect negative cable at battery.

2) Undo wiring harness clamps, disconnect back up light switch coupler, VSS coupler and ground cable.

3) Disconnect clutch cable from clutch release lever and bracket.

4) Disconnect gear shift and select control cables.

5) Remove bolt (2), and loosen bolt (1) which is unable to be removed due to interference of water pipe.

6) Remove starting motor taking out its bolts. Starting motor plate should also come down.

7) Support engine by using lifting device.

On lift

8) Drain transmission oil referring to Section 7A of the Service Manual mentioned in the FOREWORD of this manual.

9) Drain transfer oil referring to Section 7D.

10) Remove left and right drive shaft referring to Section 4 of the Service Manual mentioned in the FOREWORD of this manual.

11) Remove left side of engine under cover.

12) Remove transfer referring to Section 7D.

13) Remove clutch housing lower plate (1).

14) Remove transfer referring to Section 7D.

15) Remove transmission to engine bolt and nut.

16) Lower vehicle and support transmission with transmission jack.

Page 81

7A-14 MANUAL TRANSMISSION

17) Remove engine left mounting (1) with bracket (2).

18) Remove other attached parts from transmission, if any.

19) Pull transmission out so as to disconnect input shaft from clutch disc and then lower it.

REMOUNTING

CAUTION:

Care should be taken not to scratch oil seal lip with drive shaft while raising transmission. Do not hit drive shaft joint with hammer when installing it into differential gear.

Remount transmission in reverse order of dismounting procedure noting the following.

• Set bolt (1) to the original position of transmission before mounting transmission assembly to engine assembly.

• Refer to the first figure of “UNIT REPAIR OVERHAUL” in Section 7A of the Service Manual mentioned in the FOREWORD of this manual for fastener specified torque.

• Refer to Section 7D for installing transfer.

• Push in drive shaft joints (right & left) fully so as to snap ring

of shaft engages with differential gear.

• Set each clamp for wiring securely.

• After connecting clutch cable, be sure to adjust its play prop-

erly. Refer to Section 7C of the Service Manual mentioned in the FOREWORD of this manual.

• Fill transmission and transfer with oil as specified.

• Connect battery and check function of engine, clutch and

transmission.

Page 82

MANUAL TRANSMISSION 7A-15

Sub Assembly Service

Differential assembly

ADJUSTMENT AND REASSEMBLY

Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean.

1) Assemble differential gear and measure thrust play of differential gear as follows.

Differential gear thrust play

0.03 – 0.31 mm (0.001 – 0.012 in.)

Left side

• Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear.

• Using 2 screwdrivers (1), move gear (2) up and down and read movement of dial gauge pointer.

Special tool (A) : 09900-20607 (B) : 09900-20701

Right side

• Using similar procedure to the above, set dial gauge tip to gear (1) shoulder.

• Move gear up and down by hand and read dial gauge.

Special tool (A) : 09900-20607 (B) : 09900-20701

2) If thrust play is out of specification, select suitable thrust washer from among the following available size, install it and check again that specified gear play is obtained.

Available thrust washer thickness

0.9, 0.95, 1.0, 1.05, 1.1, 1.15 and 1.2 mm (0.035, 0.037, 0.039, 0.041, 0.043, 0.045, and 0.047 in.)

Page 83

7A-16 MANUAL TRANSMISSION

3) Drive in new differential side pinion shaft pin (2) till the depth from differential case (3) surface is about 1 mm (0.04 in.).

4) Press-fit new sensor rotor (1) with groove (4) side downward as shown by using special tools and copper hammer.

Special tool (A) : 09913-75510 (B) : 09940-54910

5) Press-fit left bearing by using special tools and copper hammer.

6) Support differential assembly (1) as illustrated so as to left bearing (2) is floating, and then press-fit right bearing (3) like left bearing in Step 5).

Special tool (C) : 09951-76010 (D) : 09951-16060

7) Hold differential assembly with soft jawed vise (3), install final gear (2) as shown in figure and then tighten bolts (1) with thread lock cement applied to specified torque.

NOTE:

Make sure to install final gear in correct installing direction.

CAUTION:

Use of any other bolts than specified ones is prohibited.

“A” : Thread lock cement 99000-32110

Tightening torque Final gear bolts (a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)

4. Groove

Page 84

MANUAL TRANSMISSION 7A-17

Assembling Unit

Fifth gears

1) To seat countershaft left bearing cup (1) to bearing cone, tap cup by using special tool and plastic hammer.

Special tool (A) : 09913-84510

2) Put a shim (2) on bearing cup (3) provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure “a” (Clearance between case sur- face (4) and straight edge) by using feeler gauge (5).

Clearance between case surface and straight edge “a” : 0.13 – 0.17 mm (0.0051 – 0.0067 in.) (Shim protrusion)

3) By repeating above step, select a suitable shim which adjusts clearance “a” to specification and put it on bearing cup.

NOTE:

Insert 0.15 mm (0.0059 in.) feeler to know whether or not a shim fulfills specification quickly.

Available shim thickness

0.40, 0.45, 0.50, 0.55, 0.6, 0.65,0.7, 0.75, 0.8, 0.85, 0.9, 0.95,

1.0, 1.05, 1.1 and 1.15 mm (0.015, 0.017, 0.019, 0.021, 0.023, 0.025, 0.027, 0.029, 0.031,

0.033, 0.035, 0.037, 0.039, 0.041, 0.043 and 0.045 in.)

Page 85

7A-18 MANUAL TRANSMISSION

4) Place left case plate (4) inserting its end in groove of shift guide shaft (6) and then tighten it with new screw (1) and bolts (2) with adhesive pre-coated temporarily with less than specified torque.

CAUTION:

Do not reuse left case plate screw and bolts. Be sure to use new screw and bolts with adhesive pre-coated. Otherwise, they may loosen.

5) Tighten new screw and bolts to specified torque finally in the order of circled numbers shown in figure.

NOTE:

After tightening screw and bolts, make sure that countershaft can be rotated by hand feeling certain load.

Tightening torque Left case plate screw and bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)

3. Input shaft

5. Countershaft

6) Assemble 5th speed synchronizer sleeve (4) and hub (3) with keys (2) and springs (1).

NOTE:

Short side C in keys, long boss D in hub and chamfered spline F in sleeve should face inward (5th gear side).

Synchronizer key installation position A = B

[A] : Short side C

[B] : Long side

C : Short side (Inward)

D : Long boss (Inward)

E : Key way

F : Chamfered spline (Inward)

7) Install 5th gear (1) to counter shaft facing machined boss A inward.

A : Machined boss (Inside)

B : No machining (Outside)

Page 86

MANUAL TRANSMISSION 7A-19

8) Install needle bearing of separated steel cage type to input shaft, apply oil then install 5th gear (1) and special tool to stop shaft rotation.

Special tool (B) : 09927-76010

9) Install new countershaft nut (2) and tighten it to specification.

Tightening torque Countershaft nut (b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)

10) Remove special tool, then caulk nut at C with caulking tool and hammer.

11) Install synchronizer ring (2).

12) Fit 5th gear shift fork (1) to sleeve & hub assembly (3) and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.

NOTE:

Long flange of hub faces inward (gear side).

A : Oil groove (Align with B)

B : Punch mark

C : Caulking

13) Drive in spring pin facing its slit A outward.

A : Pin slit (Face outward)

14) Install steel ball, tighten shift fork plug (3) to which thread lock cement has been applied.

“A” : Cement 99000-32110

Tightening torque 5th shift fork plug (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

15) Fit hub plate (1) and fix it with new circlip (2).

16) Install new circlip (4) to the end of 5th & reverse gear shift guide shaft.

CAUTION:

• Coat shift fork plug with thread lock cement reasonably. If it is done to much, excess may interfere in ball movement and cause hard shift to 5th speed.

• Make sure circlip is installed in shaft groove securely.

Page 87

7A-20 MANUAL TRANSMISSION

17) Clean mating surface of both left case (2) and side cover (1), coat mating surface with sealant evenly, mate it with left case and then tighten bolts.

“B” : Sealant 99000-31230

Tightening torque Side cover No. 1 bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) Side cover No. 2 bolts (b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

Tightening Torque Specification

Fastening portion

Transmission oil level/filler and drain plugs 21 2.1 15.5 Gear shift control lever assembly nut 13 1.3 9.5 Final gear bolts 90 9.0 65.0 Reverse gear shift lever bolts 23 2.3 17.0 Transmission case bolts 19 1.9 14.0 Reverse shaft bolt 23 2.3 17.0 Locating spring bolts 13 1.3 9.5 Left case plate bolts and screw 11 1.1 8.0 Countershaft nut 60 6.0 43.5 5th shift fork plug 10 1.0 7.5 Side cover No.1 bolts 10 1.0 7.5 Side cover No.2 bolts 23 2.3 17.0 Guide case bolts 23 2.3 17.0 Gear shift interlock bolt 23 2.3 17.0 5th to reverse interlock guide bolt 23 2.3 17.0 Backup lamp switch 19 1.9 14.0

N•m kg-m lb-ft

Tightening torque

Page 88

Required Service Materials

Material Recommended SUZUKI Material Use

Lithium grease SUZUKI SUPER GREASE A

(99000-25010)

Sealant SUZUKI BOND NO.1216B

(99000-31230)

Thread lock cement THREAD LOCK 1322

(99000-32110)

MANUAL TRANSMISSION 7A-21

• Oil seal lips

• Oil drain plug and filler / level plug

• Gear shift shaft bolt

• Mating surface of transmission case

• Mating surface of side cover

• Gear shift interlock bolt

• 5th to reverse interlock guide bolt

• Reverse gear shift lever bolts

• Oil gutter bolt

• Left case plate screws

• Shift fork plug

• Reverse shaft bolt

Special Tools

09900-06107 09900-20607 09900-20701 09913-60910 Snap ring pliers (Opening type)

Dial gauge Magnetic stand Bearing puller

09913-75510 09913-80113 09913-84510 09922-85811 Bearing installer Bearing installer Bearing installer Spring pin remover

4.5 mm

Page 89

7A-22 MANUAL TRANSMISSION

09923-74510 09923-78210 09924-74510 09925-18011 Bearing remover Bearing installer Installer attachment Bearing installer

09925-68210 09925-78210 09925-88210 09925-98221 Bearing outer race

Spring pin remover 6 mm Bearing puller attachment Bearing installer

installer

09927-76010 09930-30104 09940-53111 09940-54910 Gear holder Sliding shaft Bearing installer Sensor rotor installer

09951-46010 09951-16060 09951-76010 Oil seal installer Bush remover Bearing installer

Page 90

SECTION 7C

CLUTCH 7C-1

CLUTCH

WARNING:

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

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser- vice 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.

may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual.

CONTENTS

Unit Repair Overhaul ..................................... 7C-2

Clutch Release System................................ 7C-2

Tightening Torque Specification .................. 7C-4

Required Service Materials........................... 7C-5

Special Tool.................................................... 7C-5

7A1 7B1 7C1

7D 7E 7F

8A 8B 8C 8D 8E

10 10A 10B

Page 91

7C-2 CLUTCH

Unit Repair Overhaul

Clutch Release System

REMOVAL

1) Remove ß-pin from release shaft.

2) Remove release lever by loosening its nut.

3) Take out release bearing by turning release shaft (1).

4) Unhook return spring by using pliers.

5) Drive out No.2 bush by using special tool and hammer. Release shaft seal will also be pushed out.

Special tool (A) : 09922-46010

6) Remove release shaft and return spring.

7) Install tap (M16 X 1.5) (1) to clutch release shaft No.1 bush.

8) Pull out No.1 bush by using tap (1) and special tools.

Special tool (B) : 09923-46020 (C) : 09930-30104

INSPECTION

Clutch release bearing

Check clutch release bearing for smooth rotation. If abnormality is found, replace it.

CAUTION:

Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage.

Page 92

CLUTCH 7C-3

Clutch release shaft

Check clutch release shaft and its pin for deflection or damage. If abnormality is found, replace it.

INSTALLATION

1) Drive in a new No.1 bush (1) by using special tools and then apply grease to bush inside.

Special tool (A) : 09930-30104 (B) : 09923-46030

“A” : Grease 99000-25010

2) Install release shaft with return spring applied to it.

3) Apply grease to No.2 bush (1) inside and press-fit it by using the same special tool as in removal.

“A” : Grease 99000-25010

Special tool (C) : 09922-46010

4) Coat grease to shaft seal (2) lip and then install it till it is flush with case surface. Use special tool for this installation and face seal lip downward (inside).

“A” : Grease 99000-25010

Special tool (D) : 09925-98221

5) Caulk seal at A by using caulking tool and hammer.

Page 93

7C-4 CLUTCH

6) Hook return spring.

7) Apply grease to release bearing (1) inside and release shaft arm (2), then set bearing.

“A” : Grease 99000-25010

8) Apply small amount of grease to input shaft (3) spline and front end as well.

“B” : Grease 99000-25210

9) Set release lever to release shaft aligning their punch marks (1), then tighten nut.

Tightening torque Release lever nut (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

10) Install ß-pin (2) to release shaft.

Tightening Torque Specification

Fastening portion

Clutch cable bolts 11 1.1 8.0 Flywheel bolts 76 7.6 55.0 Clutch cover bolts 23 2.3 16.5 Release lever nut 23 2.3 16.5

N•m kg-m lb-ft

Tightening torque

Page 94

Required Service Materials

CLUTCH 7C-5

Material

Lithium grease

Recommended SUZUKI product

(Part Number)

SUZUKI SUPER GREASE A (99000-25010)

SUZUKI SUPER GREASE I (99000-25210)

Special Tool

Use

• Cable end hook and joint pin.

• Release shaft bushes and seal.

• Release shaft arm.

• Release bearing inside.

Input shaft spline and front end.

09917-58010 09922-46010 09923-36330 09923-46020 Bearing remover Bush remover Clutch center guide Joint pipe

09923-46030 09924-17811 09925-98210 09925-98221 Joint pipe Flywheel holder Input shaft bearing

installer

Bearing installer

09930-30104 Sliding shaft

Page 95

7C-6 CLUTCH

Page 96

TRANSFER 7D-1

SECTION 7D

TRANSFER

General Description........................................7D-2

Diagnosis.........................................................7D-2

On-Vehicle Service..........................................7D-3

Oil Change ....................................................7D-3

Unit Repair Overhaul ......................................7D-4

Unit Dismounting...........................................7D-5

Unit Disassembly ..........................................7D-6

Transfer assembly.....................................7D-6

Reduction driven gear assembly...............7D-7

Intermediate shaft......................................7D-9

Transfer output retainer assembly.............7D-9

Component Inspection ................................7D-10

CONTENTS

Unit Assembly ............................................. 7D-11

Unit Installation ........................................... 7D-22

Tightening Torque Specification................. 7D-24

Required Service Material............................7D-24

Special Tool...................................................7D-25

Reduction driven gear assembly.............7D-11

Bevel gear shim ......................................7D-12

Transfer output retainer assembly .......... 7D-13

Right case ............................................... 7D-17

Left case..................................................7D-18

Transfer assembly................................... 7D-19

Bevel gear back lash...............................7D-20

6F1 6F2

6G 7D 6K 7D

7A 7A1 7B1 7C1

10 10A 10B

Page 97

7D-2 TRANSFER

General Description

The transfer is mounted on transmission case by fastening bolts with reduction drive gear in transfer and differential case in transmission coupled by involute spline. Driving force from transmission is transmitted to propeller shaft through reduction drive gear, reduction driven gear and bevel gears in transfer. As bevel gears, which change the direction of driving torque axis to the direction of the angle with 90 degrees, hypoid gears are provided. Hypoid gears have an advantage of preventing gear noise, at the same time, they require accurate adjustment of tooth contact and backlash.

1. Inter mediate shaft 6. Shim 11. Transfer output retainer

2. Left case 7. Reduction driven gear 12. Flange

3. Reduction drive gear 8. Bevel gear (hypoid gear) ✱ :Forward

4. Circlip 9. Bevel pinion shaft (hypoid gear)

5. Right case 10. Pinion shaft spacer

Diagnosis

Condition Possible Cause Correction

Noise Inadequate or insufficient lubricant Replenish.

Damaged or worn bearing(s) Replace. Damaged or worn gear(s) Replace. Damaged or worn chamfered tooth on sleeve or gear Replace. Preload of taper roller bearing is reduced Adjust.

Page 98

On-Vehicle Service

Oil Change

1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.

2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct or repair it.

3) Drain old oil, tighten drain plug (2) after applying sealant to its thread and pour new specified oil as shown below by specified amount (roughly up to level hole).

“A” : Sealant 99000-31230

Tightening torque Transfer oil drain plug (a) : 21 N·m (2.1 kg-m, 15.5 lb-ft)

NOTE:

• It is highly recommended to use SAE 80W-90 Hypoid gear oil API GL-5.

• Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage.

TRANSFER 7D-3

Transfer gear oil : Hypoid gear oil API GL-5 For oil viscosity, refer to the chart.

Oil Capacity : 0.5 liters (1.1/0.9 US/lmp. pt)

4) Torque level/filler plug (3) as specified below after applying sealant to its thread.

“A” : Sealant 99000-31230

Tightening torque Transfer oil level / filler plug (b) : 21 N·m (2.1 kg-m, 15.5 lb-ft)

1. Transfer

4. Drive shaft

Page 99

7D-4 TRANSFER

Unit Repair Overhaul

1. Transfer left case 11. Bevel gear shim 21. Driven gear bearing

2. Transfer right case 12. Bevel gear (Hypoid gear) 22. Reduction drive gear bearing

3. Transfer output retainer 13. Bevel pinion shaft (Hypoid gear) 23. Flange nut

4. O-ring : Apply grease 99000-25010 to all around surface.

5. Bevel pinion shim 15. Flange 25. Intermediate shaft right bearing

6. Drain plug : Apply sealant 99000-31230 to all around thread part of drain plug.

7. Level/filler plug : Apply sealant 99000-31230 to all around thread part of level plug.

8. Intermediate shaft 18. Circlip Apply transfer oil.

9. Oil seal : Apply grease 99000-25010 to oil seal lip.

10. Pinion shaft bearing 20. Bevel gear nut

14. Reduction driven gear 24. Transfer stiffener

16. Pinion shaft spacer Do not reuse.

17. Reduction drive gear Tightening torque

19. Snap ring

: After tightening nut to specified torque, caulk nut securely.

: After tightening nut so as rotation torque of bevel pinion shaft to be in specified value, caulk nut securely.

Page 100

TRANSFER 7D-5

Unit Dismounting

DISMOUNTING

1) Disconnect negative cable at battery.

2) Hoist vehicle and remove wheels.

3) Drain transaxle oil and transfer oil

4) Remove exhaust pipe (1).

5) Remove propeller shaft referring to Section 4B.

6) Remove right side drive shaft (1) referring to Section 4A.

7) Disconnect breather hose from transfer assembly.

8) Remove transfer stiffener (2).

1. Transfer

9) Remove transfer to engine stiffener (1) by removing its 5 bolts, if equipped.

Suzuki RB413 4WD Model Service Manual 99501U83E00-01E

Specifications and Main Features

Frequently Asked Questions

User Manual

Important

WARNING/CAUTION/NOTE

Foreword

Table of Contents

GENERAL INFORMATION

Precautions

Vehicle Lifting Points

MAINTENANCE AND LUBRICATION

Maintenance Schedule

Normal Condition Schedule

Maintenance Recommended under Severe Driving Conditions

Maintenance Service

Chassis and Body

Drive Shaft (Axle) Boots / Propeller Shafts (4WD) (ITEM 6-3)

Transfer Oil (4WD) and Rear Differential Oil (4WD) (ITEM 6-7-1 and -2)

Recommended Fluids and Lubricants

REAR SUSPENSION

On-Vehicle Service

Rear Axle Shaft and Wheel Bearing

Rear Axle Shaft Oil Seal

Rear Axle Housing

Required Service Material

Special Tool

PROPELLER SHAFTS

General Description

Diagnosis

Diagnosis Table

Propeller Shaft Joint Check

On-Vehicle Service

Tightening Torque Specification

Required Service Material

BRAKES

Check and Adjustment

Fluid Pressure Test (If Equipped with LSPV)

Tightening Torque Specification

Special Tool

BRAKES PIPE/HOSE/MASTER CYLINDER

General Description

LSPV (Load Sensing Proportioning Valve) Assembly (if equipped)

On-Vehicle Service

Rear Brake Hose/Pipe (For Vehicle with LSPV)

LSPV (Load Sensing Proportioning Valve) Assembly (if equipped)

Special Tool

PARKING AND REAR BRAKE

On-Vehicle Service

Brake Drum

Brake Back Plate

ANTILOCK BRAKE SYSTEM (ABS)

General Description

Components and Parts Location

System Schematic

System Circuit

Diagnosis

Diagnostic Trouble Code (DTC) Table

Rear Wheel Speed Sensor

On-Vehicle Service

Rear Wheel Speed Sensor Ring

G Sensor (For 4WD Vehicle Only)

Tightening Torque Specification

ENGINE MECHANICAL

Engine Mounting

Unit Repair Overhaul

Engine Assembly

MANUAL TRANSMISSION

General Description

Construction and Servicing

On-Vehicle Service

Differential Side Oil Seal

Gear Shift Control Lever and Cable

Unit Repair Overhaul

Sub Assembly Service

Differential assembly

Assembling Unit

Fifth gears

Tightening Torque Specification

Required Service Materials