Suzuki Vitara 1998 User Manual

Page 1

Page 2

IMPORTANT

W ARNING/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 “OnVehicle 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, instru-

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

 If the vehicle will be exposed to tempera-

tures over 93 C (200 F) (for example, during a paint baking process), remove the air bag system components (air bag (inflator) module, sensing and diagnostic module (SDM), seat belt pretensioner (if equipped) beforehand to avoid component damage or unintended activation.

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FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to SQ416/SQ420/SQ625 SERVICE MANUAL. It has been prepared exclusively for the following applicable model.

Applicable model: SQ416/SQ420 Canvas Top Model

It describes only different service information of SQ416/SQ420 canvas top model as compared with SQ416/SQ420/SQ625 SERVICE MANUAL. Therefore, whenever servicing SQ416/SQ420 canvas top 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 (lubricants, 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 unit of standard specifications among others. Therefore, note that illustrations may differ from the unit being actually serviced. The right is reserved to make changes at any time without notice.

RELATED MANUAL:

Manual Name Manual No. SQ416/SQ420/SQ625 Service Manual 99500-65D00 SQ416/SQ420/SQ625 Unit Repair Manual for Manual

Transmission, Automatic Transmission, Transfer and Differential

SQ416/SQ420/SQ625 Wiring Diagram Manual 99512-65D01

99501-65D00

OVERSEAS SERVICE DEP AR TMENT

 COPYRIGHT SUZUKI MOTOR CORPORATION 1998

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TABLE OF CONTENTS SECTION

GENERAL INFORMATION

General Information

HEATING AND AIR CONDITIONING

Air Conditioning

STEERING, SUSPENSION, WHEELS AND TIRES

Power Steering (P/S) System Air Bag Steering Wheel and

Column Front Suspension Rear Suspension Wheel and Tires

DRIVE SHAFT/PROP. SHAFT

Front Drive Shaft/Shaft Bearing, Oil Seal

BRAKES

Brake Pipe/Hose/Master Cylinder

ENGINE

General Information and Diagnosis

Engine and Emission Control System (SFI for G16/J20)

Charging System

TRANSMISSION, CLUTCH AND DIFFERENTIAL

Automatic Transmission

3B1 3C1

3D 3E 3F

4A2

6E1

7B1

3B1

3C1

4A2

6E1

7B1

BODY ELECTRICAL SYSTEM

Lighting System Instrumentation/Driver

Information Windows, Mirrors, Security

and Lock

BODY SERVICE RESTRAINT SYSTEM

Seat Belt Air Bag System

8B 8C

10A 10B

10A

10B

Page 5

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

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

PRECAUTIONS 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System 0A- 2. . . . . . . . . . . . . . . .

Diagnosis 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing and Handling 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 6

0A-2 GENERAL INFORMATION

PRECAUTIONS

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

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

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

 If the air bag system and another vehicle system both

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

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

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

 If the vehicle will be exposed to temperatures over 93C

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

1. Air bag wire harness

2. Passenger air bag (inflator) module

3. SDM

4. DLC

5. Contact coil

6. Driver air bag (inflator) module

7. Seat belt pretensioner (if equipped)

DIAGNOSIS

 When troubleshooting air bag system, be sure to follow

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

 Never use electrical test equipment other than that specified

in this manual.

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

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GENERAL INFORMATION 0A-3

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

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

SERVICING AND HANDLING

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

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

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

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

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

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

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

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

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

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

1. Slit on workbench

2. Workbench vise

3. Lower mounting bracket

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0A-4 GENERAL INFORMATION

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

a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system. The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury.

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

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

 Never carry seat belt pretensioner by wire or connector of

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

 Never dispose of live (inactivated) seat belt pretensioners

NGNG

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

 The seat belt pretensioner immediately after activation is

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

 With many service procedures, gloves and safety glasses

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

1. Exhaust hole

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GENERAL INFORMATION 0A-5

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

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

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

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

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

passenger), seat belt pretensioners (driver and passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied (e.g., dropped from a height of 91.4 cm (3 feet) or more), never attempt disassembly or repair but replace it with a new one.

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

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

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

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

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

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

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

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

 Never use air bag system component parts from another

vehicle.

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

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

 Never expose air bag system component parts directly to

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

 WARNING/CAUTION labels are attached on each part of

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

 After vehicle is completely repaired, perform “Air Bag

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

Page 10

AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

AIR CONDITIONING (OPTIONAL)

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

rized SUZUKI dealer. Refer to “Air Bag System Components and W iring 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.

 T echnical service work must be started at least 90 seconds after the ignition switch is turned to the

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

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

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

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

Major Components and Refrigerant

Flow of Air Conditioning System 1B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Location in Engine Room 1B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOVERY, EVACUATION AND CHARGING 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure of Charging 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 1B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant System 1B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compression System 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 11

1B-2 AIR CONDITIONING (OPTIONAL)

GENERAL DESCRIPTION

Whether the A/C in the vehicle being serviced uses R-134a or R-12 is indicated on LABEL on the compressor. Also, it can be checked

1. Compressor label

2. Service valve

MAJOR COMPONENTS AND REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM

by the shape of the service (charge) valve.

1. Compressor

2. Magnet clutch

3. Condenser

4. Receiver

5. Dual pressure switch

6. Expansion valve

7. Evaporator

8. Blower motor

9. Heater core

10. Dryer

State of Refrigerant

Liquid Vapor Superheated Vapor

Condenser Cooling air

Page 12

COMPONENT LOCATION IN ENGINE ROOM

G16 LH steering vehicle

AIR CONDITIONING (OPTIONAL) 1B-3

J20 LH steering vehicle

1. Liquid pipe

2. Compressor suction hose

3. Dual pressure switch

4. Condenser outlet pipe

5. Condenser

6. Compressor delivery hose

7. Compressor

8. Suction pipe

9. High pressure service valve

10. Low pressure service valve

Page 13

1B-4 AIR CONDITIONING (OPTIONAL)

G16 LH steering vehicle shown

1. Manifold gauge set

2. High pressure side (Delivery side hose)

3. Low pressure side (Suction side pipe)

RECOVERY, EVACUATION AND CHARGING

PROCEDURE OF CHARGING

1) Make sure that hoses are routed properly after evacuating the system.

2) Connect the manifold gauge set in position. Thus open refrigerant container valve to purge the charging line. Then open the low pressure-side valve.

WARNING: Make sure that high pressure-side valve is closed securely.

3) Start engine and keep engine speed at 1,000 r/min. Then, operate air conditioning.

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

1. Needle

2. Plate nut

3. Refrigerant container

4. Handle

5) When refrigerant container is emptied, use following procedure to replace it with a new refrigerant container. a. Close low pressure valve. b. Replace empty container with a refrigerant container which

has been charged with refrigerant. When using refrigerant container tap valve, use following procedure for replacement. i) Retract needle and remove refrigerant container tap valve

by loosening its plate nut.

ii) Install previously-removed refrigerant container tap valve

to a new refrigerant container.

c. Purge any air existing in center charging hose.

When using refrigerant container tap valve, use following procedure to purge air. i) Once fully tighten refrigerant container tap valve and then

loosen (open) plate nut slightly. ii) Open low pressure valve of manifold gauge set a little. iii) As soon as refrigerant comes out with a “hiss” through a

clearance between refrigerant container and tap valve,

tighten plate nut as well as manifold gauge set low pres-

sure valve. iv) Turn handle of tap valve clockwise so that its needle is

screwed into the new container to make a hole for refriger-

ant flow.

1. “Hiss”

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AIR CONDITIONING (OPTIONAL) 1B-5

6) After the system has been charged with specified amount (350 – 450 g, 12.3 – 16.0 oz.) of refrigerant or when low and high pressure gauges have indicated specified value below respectively , close low pressure side valve of manifold gauge set.

Low pressure gauge when charged with specified amount

About 200 – 300 kPa (2 – 3 kg/cm

, 29 – 43 psi)

(At A/C inlet temperature 30 – 35_C, 86 – 95_F) High pressure gauge when charged with specified amount

About 1370 – 1670 kPa (14 – 17 kg/cm

, 200 – 244 psi)

(At A/C inlet temperature 30 – 35_C, 86 – 95_F)

Page 15

1B-6 AIR CONDITIONING (OPTIONAL)

ON-VEHICLE SERVICE

REFRIGERATING SYSTEM

CHECK AND SUPPLEMENT OF REFRIGERANT

To check if refrigerant is properly charged or not, perform “CORRECTIVE MEASURES FOR MALFUNCTION SYMPTOMS” in this section. As a result, if adjustment a proper amount of refrigerant is necessary for refrigerant system. Charge a proper amount of refrigerant to refrigerant system according to charging procedure described in recovery, evacuation and charging.

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

1. Lower stay

2. Bolt

CONDENSER ASSEMBLY

INSPECTION

Check a) condenser fins for blockage, b) condenser fittings for leakage, and c) condenser fins for damage. Clogged condenser fins should be washed with water, and should be dried with compressed air.

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

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.

3) Remove front bumper assembly and lower stay (Refer to Section 9 “BODY SERVICE”).

1. Compressor delivery hose

4) Disconnect compressor delivery hose from condenser inlet fittings.

NOTE: As soon as above hose and pipe are disconnected, cap opened fittings so that moisture and dust do not enter condenser.

Page 16

1. Dual pressure switch

2. Condenser cooling fan motor coupler

3. Condenser outlet pipe

AIR CONDITIONING (OPTIONAL) 1B-7

5) Disconnect coupler from dual pressure switch.

6) Disconnect condenser outlet pipe.

7) Disconnect condenser cooling fan motor coupler.

8) Remove condenser with fan.

NOTE: Be careful not to damage fins of condenser and radiator.

9) Remove cooling fan from condenser.

INSTALLATION

Reverse removal sequence to install condenser, noting following point.

1) When replacing condenser, add 20 to 30 cc of refrigerating oil from compressor suction-side.

2) Evacuate and charge system according to previously-described procedure.

REPLACEMENT OF CONDENSER DRYER

REMOVAL

1) Remove condenser assembly from vehicle (refer to “CONDENSER ASSEMBLY REMOVAL” in this section).

1. Condenser assembly

2. Condenser dryer section

2) Remove the cap using a hexagon wrench.

3) Remove the filter from the receiver.

1. Filter

Page 17

1B-8 AIR CONDITIONING (OPTIONAL)

1. Dryer

4) Remove the dryer using a plier.

INSTALLATION

Reverse removal sequence to install condenser dryer, according to instruction manual with supply parts.

NOTE:  When replacing condenser dryer, add 40 cc of refrigerating

oil the same as compressor oil.

 Do not remove the dryer from the plastic bag until just before

inserting it into the receiver.

 Install the condenser dryer with its double-layer portion fac-

ing the bottom of the receiver.

LH steering vehicle shown

Cap Tightening Torque

: 12.5  2.5 N

m : 1.25  0.25 kg-m : 9  1.8 lb-ft

FILTER ELEMENT

REMOVAL

1) Disconnect negative cable at battery.

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

3) Pull down glove box.

1. Glove box

Page 18

AIR CONDITIONING (OPTIONAL) 1B-9

LH steering vehicle shown

4) Remove filter cover.

1. Filter cover

5) Pull out filter element. Pull out upper filter first then the lower one.

1. Filter element

LH steering vehicle shown

1. Ears

CLEAN

Blow off dust by compressed air from air outlet side of the filter element.

1. Air flow

INST ALLA TION

Reverse removal procedure for installation noting the followings:  Install filter into cooling unit directing arrow mark on its end face

to heater unit.

 Enable air bag system after installation. Refer to ENABLING AIR

BAG SYSTEM in Section 10B.

EVAPORATOR (COOLING UNIT)

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disable air bag system. Refer to “Disabling Air Bag System” in Section 10B.

3) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.

Page 19

1B-10 AIR CONDITIONING (OPTIONAL)

1. Suction pipe

2. Liquid pipe

4) Disconnect suction pipe, and liquid pipe from evaporator (cooling unit).

NOTE: As soon as above hose and pipe are disconnected, cap opened fittings so that moisture and dust may not enter cooling unit.

5) Remove blower motor unit. Refer to Section 1A “HEATER AND VENTILA TION”.

6) Disconnect thermistor wire coupler.

7) Remove evaporator with evaporator case.

LH steering vehicle

1. Cover

2. Filter

3. Evaporator assembly

LH steering vehicle

DISASSEMBLY

1) Remove filter assembly (if equipped).

2) Remove screws to separate evaporator upper and lower cases from each other.

1. Screw

LH steering vehicle

1. Upper case

2. Evaporator

3. Lower case

4. Thermistor

5. Expansion valve

3) Remove upper case and remove evaporator from lower case.

4) Remove following components from evaporator.

 Expansion valve  Thermistor

Page 20

AIR CONDITIONING (OPTIONAL) 1B-11

INSPECTION

1) Check evaporator fins for blockage. If found clogged, use compressed air to clean the fins.

NOTE: Do not use water for cleaning of evaporator.

2) Check inlet and outlet fittings for crack or scratch. Repair them as required.

ASSEMBLY AND INSTALLATION

1) Reverse removal sequence to install evaporator.

2) Enable air bag system. Refer to “Enabling Air Bag System” in Section 10B.

3) Evacuate and charge system according to previously described procedure.

1. Suction pipe

2. Liquid pipe

EXPANSION VALVE

INSPECTION

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

REMOVAL

1) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.

2) Remove front grill.

3) Disconnect suction pipe, and liquid pipe from evaporator (Cooling unit).

NOTE: As soon as above hose and pipe are disconnected, cap opened fittings so that moisture and dust may not enter cooling unit.

1. Suction hose

2. Condenser outlet pipe

3. Pipe clamp

4) Disconnect suction pipe, and liquid pipe from suction hose and condenser outlet pipe.

5) Remove pipe clamp then remove suction pipe and liquid pipe.

Page 21

1B-12 AIR CONDITIONING (OPTIONAL)

1. Expansion valve

6) Remove expansion valve.

INSTALLATION

1) Reverse removal sequence to install expansion valve.

2) Evacuate and charge system according to previously described procedure.

Page 22

AIR CONDITIONING (OPTIONAL) 1B-13

G16 LH steering vehicle

1. Manifold gauge set

2. High pressure side (Delivery side hose)

3. Low pressure side (Suction side pipe)

COMPRESSION SYSTEM

COMPRESSOR

INSPECTION

1) Install manifold gauge set as illustrated.

2) Close Hi and Lo hand valves.

3) Run engine at fast idle.

4) Check compressor for following: a. High pressure gauge reading is not low and low pressure

gauge reading is not higher than normal. b. Metallic sound. c. Leakage from shaft seal. If any of the above checks indicated a defect, repair compressor.

REMOV AL

1) Run engine at idle with A/C ON for 10 minutes.

2) Disconnect negative cable at battery.

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

NOTE: The amount of compressor at removed must be measured and the same amount must be poured when installing the compressor.

4) Disconnect thermal protector lead wire.

5) Disconnect suction and discharge hoses from compressor.

NOTE: Cap open fitting immediately to keep moisture out of system.

6) For G16 engine: Remove compressor drive belt by loosening compressor mounting bolts.

For J20 engine:

Remove generator belt. Refer to Section 6H for details.

7) Remove compressor with clutch assy from its mount.

8) Drain oil from compressor, and measure its amount.

Page 23

1B-14 AIR CONDITIONING (OPTIONAL)

G16 engine

J20 engine

(b)

INST ALLA TION

1) Pour new compressor oil. The amount must be the same with the amount measured in REMOVAL.

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

Amount of oil in compressor: 120 cm

(120 cc, 7.5 in3)

2) For G16 engine: Install compressor temporarily to bracket, then install compressor drive belt.

For J20 engine:

Install compressor to its bracket. Tighten bolts (a) first, then (b).

Tightening Torque (a), (b): 23 N

m (2.3 kg-m, 17.0 lb-ft)

3) Connect suction and discharge hoses to compressor.

4) For G16 engine: T ension compressor drive belt by tightening compressor mounting bolts. Refer to Section 3B1 for drive belt tension. Tighten bolt (a) first, then (b).

1. Generator belt

2. Compressor drive belt

3. Compressor pulley

4. Crankshaft pulley

Tightening Torque (a): 23 N

m (2.3 kg-m, 17.0 lb-ft)

For J20 engine:

Install generator belt. Refer to Section 6H for details.

5) Connect thermal protector lead wire.

6) Evacuate and charge system according to previously described procedure.

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

Page 24

MAGNET CLUTCH

AIR CONDITIONING (OPTIONAL) 1B-15

1. Armature plate bolt

2. Armature plate

3. Circlip

4. Magnet clutch

5. Shim

6. Magnet clutch coil

7. Compressor body assembly

1. Armature plate

INSPECTION

a. Inspect pressure plate and rotor for signs of oil. b. Check clutch bearings for noise and grease leakage. c. Using and ohmmeter, measure resistance of stator coil between

clutch lead wire and ground.

If measured resistance is not within tolerance, replace coil.

Standard resistance: 3.9 – 4.3  at 20 _C, 68 _F

REMOVAL

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

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

Special Tool (A):09991-06020

NOTE: Do not reuse armature plate bolt.

1. Armature plate

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

Special Tool (B):09991-06030

Page 25

1B-16 AIR CONDITIONING (OPTIONAL)

4) Remove shims from shaft.

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

Special Tool (C):09900-06107

6) Remove magnet clutch lead wire clamp screw, and remove magnet clutch read wire ground terminal.

7) Remove magnet clutch with puller.

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

1. Puller

2. Compressor

1. Snap ring

2. Clutch coil

3. Compressor assembly

8) Remove magnet clutch coil.

Special tool (C):09900-06107

INST ALLATION

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

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

Special Tool (C):09990-06107

3) Install clamp portion and ground terminal of lead wire.

Page 26

AIR CONDITIONING (OPTIONAL) 1B-17

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

Ensure that edge rests only on inner race of bearing.

(3)Install snap ring.

Special Tool (D):09991-06010

CAUTION: Be careful not to scratch bearing seal.

1. Armature plate

“a”

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

Standard clearance “a”: 0.3 – 0.5 mm (0.012 – 0.02 in.)

6) Tighten new armature plate nut as specified below.

Tightening Torque (a): 14 N

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

Special Tool (A):09991-06020

Page 27

1B-18 AIR CONDITIONING (OPTIONAL)

09900-06107 Snap ring pliers (Opening type)

09991-06010 Magnet clutch pulley installer

SPECIAL TOOLS

09991-06020 Armature plate spanner

09991-06030 Armature plate remover

Page 28

SECTION 3B1

POWER STEERING (P/S) SYSTEM 3B1-1

POWER STEERING (P/S) SYSTEM

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 autho-

 T echnical 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.

 Power Steering Gear Box cannot be disassembled or adjusted.  All steering gear fasteners are important attaching parts in that they could affect the performance of vital

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

3B1

CONTENTS

GENERAL DESCRIPTION 3B1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 3B1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rack Boot/Tie-rod 3B1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Steering Pump 3B1- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE SPECIFICATIONS 3B1- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOL 3B1- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 29

3B1-2 POWER STEERING (P/S) SYSTEM

GENERAL DESCRIPTION

The power steering (P/S) system in this vehicle reduces the driver ’s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all built in the steering gear box.

1. Power steering gear box

2. Power steering pump

3. Oil tank

Page 30

1. Tie-rod

2. Steering rack

3. Boot

4. Mark

POWER STEERING (P/S) SYSTEM 3B1-3

ON-VEHICLE SERVICE

RACK BOOT/TIE-ROD (LH STEERING VEHICLE)

REMOVAL

1) Remove steering gear case, refer to POWER STEERING GEAR BOX ASSEMBLY REMOVAL.

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

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

4) Remove boot band and clip.

5) Remove boot from tie-rod.

1. Tie-rod lock washer

2. Tie-rod

3. Steering rack

4. Aluminium plate

5. Vise

6) Unbend washer (2 places), and remove tie-rod from rack.

1. Tie-rod lock washer

INSTALLATION

1) Install new tie-rod lock washer and tie-rod to rack.

2) Tighten tie-rod ball nut to specified torque.

Tightening Torque (a): 85 N

m (8.5 kg-m, 61.5 lb-ft)

3) Bend lock washer 2 place at the flat part of tie-rod ball nut.

Page 31

3B1-4 POWER STEERING (P/S) SYSTEM

(A)

4) Apply grease to “A” indicated in figure.

5) Position boot properly in grooves of gear case and tie-rod. Check to ensure that boot is free from twist and dent.

6) Fasten boot with new clamp and clip securely.

Special Tool (A):09943-55010

“A”

7) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking made in removal.

NOTE: When tie-rod was replaced, measure length “A” on removed tie-rod and use it on new replacement tie-rod so as to position lock nut properly.

1. Mark

8) Install steering gear case. Refer to POWER STEERING GEAR BOX ASSEMBLY INSTALLATION in this section.

Page 32

POWER STEERING PUMP

POWER STEERING (P/S) SYSTEM 3B1-5

[A]

Tightening Torque (a):60 N.m (6.0 kg-m, 43.5 lb-ft)

m (2.5 kg-m, 18.5 lb-ft)

(b):25 N (c):55 N.m (5.5 kg-m, 40.0 lb-ft)

m (3.5 kg-m, 25.5 lb-ft)

(e):35 N

m (4.0 kg-m, 29.0 lb-ft)

(f): 40 N

[B]

[A]: G16 Type engine [B]: J20 Type engine

1. Power steering pump assembly

2. Bracket

3. Power steering oil tank

4. High pressure hose & pipe

5. Suction hose

6. Low pressure return hose

7. Oil tank bracket

Page 33

3B1-6 POWER STEERING (P/S) SYSTEM

Fastening arts

Pump bracket bolt

TIGHTENING TORQUE SPECIFICATIONS

Tie-rod (LH steering vehicle) 85 8.5 61.5

G16 Type engine 55 5.5 40.0 J20 Type engine 25 2.5 18.5

N.m kg-m lb-ft

Tightening torque

SPECIAL TOOL

09943-55010 Boot clamp plier

Page 34

AIR BAG STEERING WHEEL AND COLUMN 3C1-1

SECTION 3C1

AIR BAG STEERING WHEEL AND COLUMN

WARNING:  Service on and around the air bag system components or wiring must be performed only by an autho-

rized SUZUKI dealer. 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.

 The procedures in this section must be followed in the order listed to disable the air bag system tem-

porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could result in possible activation of the air bag system, personal injury or otherwise unneeded air bag system repairs.

CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called out. The correct torque value must be used when installing fasteners that require it. If the above procedures are not followed, parts or system damage could result.

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.

3C1

CONTENTS

GENERAL DESCRIPTION 3C1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driver air bag (inflator) module 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 35

3C1-2 AIR BAG STEERING WHEEL AND COLUMN

GENERAL DESCRIPTION

1. Driver air bag (inflator) module

2. Steering wheel

3. Steering wheel nut

4. Contact coil and combination switch assembly

5. Steering column upper cover

6. Steering column lower cover

7. Steering column assembly

8. Steering lock assembly

9. Steering column hole cover

10. Steering shaft joint

11. Steering lower shaft assembly

12. Adjustable steering column release lever

13. Steering column lower seal

14. Cap

Page 36

AIR BAG STEERING WHEEL AND COLUMN 3C1-3

ON-VEHICLE SERVICE

DRIVER AIR BAG (INFLATOR) MODULE

WARNING: When handling an air bag (inflator) module, be sure to read “Service Precautions” under “On-Vehicle Service” in SECTION 10B and observe each instruction. Failure to follow them could cause a damage to the air bag (inflator) module or result in personal injury.

REMOVAL

1) Disconnect negative battery cable at battery terminal.

2) Disable air bag system. Refer to “Disabling Air Bag System” under “Service Precautions” in SECTION 10B.

3) Remove mounting bolt hole caps (2pcs).

4) Loosen 2 bolts mounting driver air bag (inflator) module till it turns freely, pull them out and fix them to bolt clamps.

5) Remove air bag (inflator) module from steering wheel.

1. Mounting bolt

6) Remove driver air bag (inflator) module (yellow) connector and horn connector from steering wheel.

7) Disconnect driver air bag (inflator) module (yellow) connector of driver air bag (inflator) module and horn connector as shown in the figure.

ii) Release locking of lever.

ii) After unlocked, disconnect connector.

WARNING: Special care is necessary when handling and storing a live (undeployed) air bag (inflator) module. Observe “Service Precautions” under “On-Vehicle Service” in SECTION 10B. Otherwise, personal injury may result.

1. Driver air bag (inflator) module connector

2. Horn connector

3. Driver air bag (inflator) module

4. Steering wheel

Page 37

3C1-4 AIR BAG STEERING WHEEL AND COLUMN

1. Trim cover (pad surface)

2. Inflator case

3. Wire harness

INSPECTION

WARNING: Never disassemble air bag (inflator) module or measure its resistance. Otherwise, personal injury may result.

CAUTION: If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced.

Check air bag (inflator) module visually and if any of the following is found, replace it with a new one.

 Air bag being deployed  Trim cover (pad surface) being cracked  Wire harness or connector being damaged  Air bag (inflator) module being damaged or having been exposed

to strong impact (dropped)

INSTALLATION

1) Connect horn connector securely.

2) Connect yellow connector of driver air bag (inflator) module connector as shown in the figure securely.

ii) Connect connector.

ii) Lock connector with lock lever.

3) Install horn connector and driver air bag (inflator) module connector.

4) Install driver air bag (inflator) module to steering wheel, taking care so that no part of wire harness is caught between them.

5) Make sure that clearance between module and steering wheel is uniform all the way.

6) Tighten driver air bag (inflator) module mounting bolt (left side) to specified torque first and then driver air bag (inflator) module mounting bolt (right side) to specified torque.

Tightening Torque (a): 9 N

m (0.9 kg-m, 6.5 lb-ft)

7) Install mounting bolt hole caps (2 pcs).

8) Connect negative battery cable.

9) Enable air bag system. Refer to “Enabling Air Bag System” under “Service Precautions” in SECTION 10B.

6, (a)

1. Driver air bag (inflator) module connector

2. Horn connector

3. Driver air bag (inflator) module

4. Steering wheel

5. Mounting bolt (left side)

6. Mounting bolt (right side)

Page 38

FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION

CAUTION:  All front 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. T orque values must be used as specified during reassembly to assure proper retention of this part.

 Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or

damage to the part may result.

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

ON-VEHICLE SERVICE 3D- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coil Spring 3D- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Knuckle/Wheel Spindle 3D- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE SPECIFICATIONS 3D- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 39

3D-2 FRONT SUSPENSION

ON-VEHICLE SERVICE

COIL SPRING

REMOVAL

1) Hoist vehicle, allowing front suspension to hang free.

2) Remove wheels.

3) Remove axle shaft drive flange.

4) Remove front drive shaft circlip and washer.

1. Front wheel speed sensor

2. Harness clamp bolt

1. Circlip

2. Washer

5) Remove caliper bolts and suspend caliper with a wire hook.

CAUTION: Hang removed caliper with a wire hook so as to prevent brake hose from bending and twisting excessively or being pulled. Don’t operate brake pedal with pads removed.

1. Wire

6) If equipped with ABS, remove harness clamp bolt and remove front wheel speed sensor from knuckle.

CAUTION:  Do not pull wire harness when removing front wheel

speed sensor.

 Do not cause damage to surface of front wheel speed

sensor and do not allow dust, etc. to enter its installation hole.

7) Remove brake disc.

NOTE: If brake disc can not be removed by hand, use 8 mm bolts as shown.

Page 40

FRONT SUSPENSION 3D-3

8) Remove stabilizer bar, refer to steps 2) to 5) of item ST ABILIZER BAR/BUSHINGS REMOV AL in this section.

9) Disconnect tie rod end from knuckle by using puller.

10) Support lower arm, using jack as shown.

11) Remove strut bracket bolts.

12) Remove ball stud nut.

13) Using puller, disconnect knuckle from ball stud.

1. Coil spring

14) Remove knuckle and wheel hub comp, while lowering jack.

15) Remove coil spring.

Page 41

3D-4 FRONT SUSPENSION

INSTALLATION

Reverse removal procedure to install coil spring.

NOTE: Upper and lower diameters of coil spring are different. Bring larger diameter end at bottom and set its open end in place on spring seat.

1. Spring seat

“a” < “b”

 Be sure to use specified torque for tightening each fastener.

Refer to torque specification chart at the end of this section.

 As for ball stud nut, be sure to use new nut.  Tighten tie-rod end nut with pushing ball stud to upper side so as

not ball stud to be rotated.

 Apply lithium grease to front drive shaft washer and front wheel

spindle outer.

“A”: Grease 99000-25010

“A”

1. Circlip

2. Large diameter

2, (a)

 When installing circlip to drive shaft, utilize screw hole in drive

shaft to pull it out and bring large diameter of circlip at right as shown.

 When installing axle shaft drive flange to wheel hub, apply sealant

to mating surface of axle shaft drive flange and tighten flange bolt to specified torque.

“A”: Sealant 99000-31090 Tightening Torque

(a): 48 N

m (4.8 kg-m, 35.0 lb-ft)

1. Axle shaft drive flange

2. Bolt

Page 42

FRONT SUSPENSION 3D-5

 Check that no foreign material is attached to sensor and rotor.

Install wheel speed sensor and its harness clamp.

1. Front wheel speed sensor

2. Bolt

2, (b)

Tightening Torque (a): 10 N

(b): 23 N

m (1.0 kg-m, 7.5 lb-ft)

m (2.3 kg-m, 17.0 lb-ft)

CAUTION:  Do not pull wire harness or twist more than necessary

when installing front wheel speed sensor.

 Fit harness grommet to inner fender securely.

 Check that there is no clearance between sensor and knuckle.

Page 43

3D-6 FRONT SUSPENSION

KNUCKLE/WHEEL SPINDLE

REMOVAL

1) Hoist vehicle and remove wheel.

2) Remove axle shaft drive flange, drive shaft circlip and washer. Refer to steps 3) to 4) of item COIL SPRING REMOV AL in this section.

3) Remove wheel hub. Refer to steps 3) to 9) of item WHEEL HUB/BEARING/OIL SEAL REMOVAL in this section.

4) Disconnect tie-rod end from knuckle.

1. Strut

2. Knuckle

5) Remove ball stud nut.

6) Support lower arm with jack.

7) Remove strut bracket bolts from strut bracket.

8) By using puller, disconnect knuckle from ball stud.

1. Dust cover

2. Wheel spindle

3. Knuckle

4. Inner oil seal

9) While lowering jack, remove knuckle/wheel spindle comp.

10) Remove inner oil seal, dust cover and wheel spindle.

Page 44

1. Wheel spindle

2. Drive shaft bearing

1. Wheel spindle

2. Drive shaft bearing

3. Front drive shaft thrust washer

4. Inner oil seal

FRONT SUSPENSION 3D-7

11) Remove drive shaft bearing by using special tool.

Special Tool (A):09923-74510 (B):09930-30102

INSTALLATION

Reverse removal sequence to install knuckle, wheel spindle oil seal and drive shaft bearing,noting following points.  Install front drive shaft thrust washer with its chanfered side facing

to drive shaft side.

“A”

 Install drive shaft bearing by using special tool.

Special Tool (A):09913-80112

Depth “a”: 1.75 – 2.50 mm (0.069 – 0.098 in.)

1. Drive shaft bearing

2. Wheel spindle

NOTE:  When installing wheel spindle to knuckle, coat their mating

surfaces with sealant. “A”: Sealant 99000-31110

 Also, fill recess in wheel spindle with about 10 g lithium

grease.

“B”

“B”: Grease 99000-25010

 Tighten wheel spindle nut to specified torque.

Tightening Torque (a): 50 N

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

Page 45

3D-8 FRONT SUSPENSION

 Press-fitting inner oil seal.

Drive in inner oil seal until its end contacts stepped surface of knuckle using special tools.

Special Tool (B):09944-66010 (C):09924-74510

 Apply lithium grease to oil seal lip and into its hollow to fill more

than 60% of its vacant space.

“B”: Grease 99000-25010

 Press-fit front drive shaft thrust washer to drive shaft, if it is re-

moved.

1. Thrust washer

(a)

 Tighten control arm ball stud nut.

When tightening ball stud nut, use new nut and tighten it to specified torque.

Tightening Torque (a): 60 N

m (6.0 kg-m, 43.5 lb-ft)

 When installing axle shaft drive flange to wheel hub, apply sealant

to mating surface of axle shaft drive flange.

“A”: Sealant 99000-31090 Tightening Torque

(a): 48 N

m (4.8 kg-m, 35.0 lb-ft)

 For installation procedures following the above, refer to WHEEL

HUB/BEARING/OIL SEAL INSTALLATION of this section.

 Tightening torque.

For any tightening torque other than those specified in text, refer to torque specification table at the end of this section.

Page 46

[D]

FRONT SUSPENSION 3D-9

TIGHTENING TORQUE SPECIFICATIONS

60 N.m

[A]

[C]

48 N.m

[B]

Page 47

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

 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.

CONTENTS

ON-VEHICLE SERVICE 3E- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shock Absorber 3E- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Rod 3E- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Axle Shaft Inner Oil Seal 3E- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOL 3E- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 48

3E-2 REAR SUSPENSION

ON-VEHICLE SERVICE

SHOCK ABSORBER

The shock absorber is non-adjustable, non-refillable, and cannot be disassembled. The only service the shock absorber requires is replacement when it has lost its resistance, is damaged, or leaking fluid.

REMOV AL

1) Hoist vehicle and remove rear wheel.

2) Support rear axle housing by using floor jack to prevent it from lowering.

Upper side

Lower side

1. Rear axle housing

2. Floor jack

1. Blank

2. Absorber nut

3. Upper support

4. Rubber bush

5. Lower support

6. Shock absorber

7. Bolt

3) Remove absorber nut.

4) Remove lower mounting bolt.

5) Remove shock absorber.

INSTALLATION

1) Install shock absorber. Refer to figure for proper installing direction of lower mounting bolt.

2) Remove floor jack.

3) Lower hoist.

4) Tighten nuts to specified torque.

NOTE:  Tighten lower nut with vehicle off hoist and in non-loaded

condition.

 Use new absorber nut. Tightening Torque

(a): 29 N (b): 85 N

m (2.9 kg-m, 21.0 lb-ft)

m (8.5 kg-m. 61.5 lb-ft)

* Body Outside

Page 49

1. Axle housing

2. Floor jack

REAR SUSPENSION 3E-3

LOWER ROD

REMOVAL

1) Hoist vehicle and remove rear wheel.

2) Support rear axle housing by using floor jack.

3) Remove lower rod front mount bolt.

1. Lower rod

2. Rear mount nut

1. Lower rod

2. Front mount bolt

Body side Axle side

1. Lower rod

2. Front bolt

3. Rear bolt

4. Vehicle body

5. Axle housing

6. Body center

7. Body out side

4) Remove lower rod rear mount bolt.

INSTALLATION

1) Install lower rod to chassis frame and axle housing, referring to figure for proper installing direction of bolts.

Nuts should not be tightened.

2) Remove floor jack from rear axle housing.

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

Tightening Torque for wheel nuts

95 N

m (9.5 kg-m, 69.0 lb-ft)

4) Lower hoist and with vehicle in non loaded condition, tighten front bolts and rear bolts and nuts of lower rod to specified torque.

Tightening Torque (a): 90 N

m (9.0 kg-m, 65.0 lb-ft)

Page 50

3E-4 REAR SUSPENSION

REAR AXLE SHAFT INNER OIL SEAL

REMOVAL

1) Remove rear axle shaft. For details, refer to steps 1) to 7) of REAR AXLE SHAFT REMOVAL in this section.

2) Fix brake back plate by inserting screwdriver to the hole for bearing retainer mounting.

3) Remove rear axle shaft inner oil seal.

1. Inner oil seal

2. Axle housing

* Body center

1. Oil seal protector

2. Oil seal

NOTE: Take care not to bend the brake pipe.

INSTALLATION

1) Using special tool drive in oil seal until it contacts oil seal protector 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 direc-

tion.

Special Tool (A):09913-75510 “A”: Grease 99000-25010

2) For procedure hereafter, refer to steps 6) to 11) of REAR AXLE SHAFT INSTALLATION in this section.

09913-75510 Oil seal installer

SPECIAL TOOL

Page 51

WHEELS AND TIRES 3F-1

SECTION 3F

WHEELS AND TIRES

NOTE:  All wheel fasteners are important attaching parts in that they could affect the performance of vital parts

and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary . Do not use a replacement part of lesser quality or substitute design. T orque 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

GENERAL DESCRIPTION 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tires 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheels 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 3F- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tire 3F- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION

TIRES

This vehicle is equipped with following tire, depending on vehicle specification. P205/75 R15 (1.6) or P215/65 R16 (2.0) The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressure. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration, and unnecessary sharp braking increase tire wear.

WHEELS

Standard equipment wheels are following steel wheels. 15 x 5 1/2 JJ (1.6) or 16 x 6 1/2 J (2.0)

Page 52

3F-2 WHEELS AND TIRES

ON-VEHICLE SERVICE

TIRE

MOUNTING AND DEMOUNTING

Use tire changing machine to mount or demount tires. Follow equipment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim. Rim bead seats should be cleaned with wire brush or coarse steel wool to remove lubricants, old rubber and light rust. Before mounting or demounting tire, bead area should be well lubricated with approved tire lubricant. After mounting, inflate to 240 kPa (35 psi) so that beads are completely seated. Then adjust pressure to specified shown on tire placard.

WARNING: Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety hump and cause serious personal injury. Do not exceed 240 kPa (35 psi) pressure when inflating. If 240 kPa (35 psi) pressure will not seat beads, deflate, re-lubricate and reinflate. Over inflation may cause bead to break and cause serious personal injury.

Install valve core and inflate to proper pressure.

TIRE REPAIR

There are many different materials and techniques on the market to repair tires. As not all of these work on all types of tires, tire manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer.

Page 53

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-1

SECTION 4A2

FRONT DRIVE SHAFT/SHAFT BEARING,

OIL SEAL

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

ON-VEHICLE SERVICE 4A2- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Shaft 4A2- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A2

Page 54

4A2-2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL

ON-VEHICLE SERVICE

DRIVE SHAFT

REMOVAL (LEFT SIDE)

1) Hoist vehicle and remove wheel.

1. Oil filler/level plug

2. Front drain plug

2) Remove axle shaft drive flange.

3) Remove drive shaft circlip and washer.

1. Drive shaft flange bolts and nuts

1. Circlip

2. Washer

4) Remove drive shaft flange bolts and nuts.

5) Remove drive shaft assembly to differential side as shown in left figure.

CAUTION: T o prevent breakage of boots (wheel side and differential side), be careful not to bring them into contact with other parts when removing drive shaft assembly.

1. Oil seal

6) Remove drive shaft thrust washer from drive shaft and remove drive shaft oil seal as shown in figure.

CAUTION: Be careful not to cause damage to drive shaft joint.

Page 55

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-3

REMOVAL (RIGHT SIDE)

1) Hoist vehicle and remove wheel.

2) Drain differential gear oil.

1. Oil filler/level plug

2. Front drain plug

3) Remove axle shaft drive flange.

4) Remove drive shaft circlip and washer.

5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and

9) to 14) of item COIL SPRING REMOVAL in Section 3D.

1. Circlip

2. Washer

1. Differential side joint

2. Tire lever

3. Front differential assembly

6) Remove drive shaft assembly. To detach snap ring fitted on the spline of differential side joint (inboard joint) from differential side gear , pull inboard joint by using a tire lever.

CAUTION: T o prevent breakage of boots (wheel side and differential side), be careful not to bring them into contact with other parts when removing drive shaft assembly.

1. Oil seal

7) Remove drive shaft thrust washer from drive shaft and remove drive shaft oil seal as shown in figure.

CAUTION: Be careful not to cause damage to drive shaft joint.

Page 56

4A2-4 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL

DISASSEMBLY

1) Remove boot band of differential side joint.

2) Slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race.

1. Boot

2. Snap ring

1. Circlip

2. Snap ring plier

3. Cage

3) Remove circlip and then cage.

4) Remove inside and outside boots from shaft.

CAUTION:  Do not disassemble wheel side joint (outboard joint). If

any malcondition is found in joint, replace it as assembly .

 Do not disassemble ball joint of differential side joint.

If any malcondition is found in ball joint, replace differential side joint assembly.

INSPECTION

 Check boots for breakage or deterioration. Replace them as nec-

essary .

 Check circlip, snap ring and boot bands for breakage or deforma-

tion. Replace as necessary.

CLEANING

 Wash disassembled parts (except boots) in degreaser. After

washing, dry parts completely by blowing air.

 Clean boots with cloth. DO NOT wash boots in degreaser, such

as gasoline or kerosene, etc.. Washing in degreaser causes deterioration of boot.

Page 57

1. Boot

2. Boot band

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-5

ASSEMBLY

1) Fully apply joint grease to wheel side joint. Use joint grease in the tube included in spare part or joint grease (99000-25120).

2) Fit wheel side boot on shaft. Fill up inside of boot with joint grease of about 85 gram. Before fixing boot band, insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.

3) Fixing boot band.

4) Install boot onto drive shaft till its small diameter side fits to shaft groove and fix there with boot band.

1. Cage

1. Circlip

5) Install cage to shaft.

CAUTION: Install cage directing smaller outside diameter side to shaft end.

6) Install circlip by using snap ring plier.

7) Apply grease to entire surface of cage. Use joint grease in tube included in spare part or joint grease (99000-25120).

Page 58

4A2-6 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL

8) Insert cage into outer race and fit circlip into groove of outer

1. Circlip

9) Apply grease to inside of outer race, and fit boot to outer race.

10) Fitting boot to outer race, adjust so that measurements “b” and

race.

CAUTION: Position opening of circlip “a” so that it will not be lined up with a ball.

Fill up inside of boot with joint grease.

“A”: Joint Grease 99000-25120

“c” become as indicated in figure.

Length “b”: 203.2 – 213.2 mm (8.00 – 8.40 in.)

Length “c”: 125.5 – 135.5 mm (4.94 – 5.33 in.)

“A”: Fill grease 85 g (3.0 oz)

Before fixing boot band, insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.

11) Clamp boot band. Check boots for distortion or dent.

Page 59

1. Drive shaft oil seal

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-7

INSTALLATION

Install drive shaft assembly by reversing removal procedure and noting following points.  Clean front drive shaft oil seal and then apply lithium grease to oil

seal and DOJ shaft.

“A”: Grease 99000-25010

 Check oil seal for breakage or deterioration.

Replace it as necessary.

 Drive in oil seal until its end contacts stopped surface of drive

shaft joint by using a pipe whose inner diameter is 76 mm (2.992 in.) or more and outer diameter is 80 mm (3.150 in.) or less.

Diameter “a”: 76 mm (2.992 in.) or more Diameter “b”: 80 mm (3.150 in.) or less

1. Drive shaft joint

2. Oil seal

3. Pipe

4. Thrust washer

 Drive in drive shaft thrust washer.

 RH Side

Push differential side joint by hand until it is positioned by snap ring fitted to its spline.

LH Side Connect drive shaft flange bolts and nuts.

Tightening Torque (a): 50 N

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

 When installing axle shaft drive flange to wheel hub, apply sealant

to mating surface of axle shaft drive flange.

“A”: Sealant 99000-31090 Tightening Torque (b): 48 N

m (4.8 kg-m, 35.0 lb-ft)

CAUTION:  To prevent breakage of boots (wheel side and differen-

tial side), be careful not to bring them into contact with other parts when installing drive shaft assembly.

 Do not pull housing of differential side joint.

If housing is pulled, it may be detached from drive shaft.

 Apply chassis grease to spline of sliding yoke.

2, (b)

1. Drive shaft flange bolt and nut

2. Axle shaft drive flange

 Fill specified differential gear oil into differential case to specified

level.

Page 60

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 autho-

 T echnical 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:

 When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E1 first.  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

CHECK AND ADJUSTMENT 5- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Pressure Test 5- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE SPECIFICATIONS 5- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 61

5-2 BRAKES

80 kg/cm

kg/cm

100 kg/cm

kg/cm

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 handle.

1) Stop vehicle on level floor and place approximately about 200 kg (441 lbs) weight on rear housing so that rear axle weighs 800 kg (1764 lb).

Rear axle weight “L”: 800 kg (1764 lb)

2) Install special tool to front and rear brake.

NOTE: Special tool should be connected to breather of front (driver’s side brake) and rear brakes.

1. Air bleeder plug

2. Weight

3. Attachment

Special Tool Front brake (A):09956-02310

“L”

(C):55473-82030 (Air bleeder plug supplied as a spare part) Rear brake

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

NOTE: Special tool (B) is used instead of thread diameter 10 mm attachment of special tool (A). So remove the attachment from (A) and install (B) as shown in figure.

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

8,000 kPa

Rear brake

6,000 – 7,300 kPa

– 73

1,138 psi

853 – 1,038 psi

As done above, apply 100 kg/cm2 pressure to front brake and check that rear brake pressure then is within specification as given below.

Front brake 10,000 kPa

1,422 psi

Rear brake

6,500 – 8,000 kPa

–

– 80

924 – 1,138 psi

Page 62

1. LSPV lever

Fastening arts

2.3

17.0

2. LSPV spring

“a”

3. LSPV stay

(a)

“b”

3, “A”

BRAKES 5-3

4) If rear brake pressure is not within specification, adjust it by changing stay “A” position as follows.

Tightening Torque (a): 23 N

m (2.3 kg-m, 17.0 lb-ft)

 If rear brake pressure is higher than specification, move stay

“A” to direction “a” and if it is lower, to direction “b”.

 Repeat steps 3) and 4) until rear brake pressure is within spec-

ification.

 After adjustment, be sure to torque nut to specification.

5) Disconnect brake pipe (connecting between master cylinder secondary side and 4-way joint) from master cylinder. Tighten plug (special tool) to master cylinder. Depress brake pedal. If rear brake pressure is 95 – 100 kg/cm when front brake pressure is 100 kg/cm2, it means that front failsafe system functions properly.

1. Master cylinder

2. Disconnect brake pipe (for LH steering vehicle)

3. Disconnect brake pipe (for RH steering vehicle)

TIGHTENING TORQUE SPECIFICATIONS

Front brake

10000 kPa

100 kg/cm

1422 psi

Rear brake

9500 – 10000 kPa

95 – 100 kg/cm

1350 – 1422 psi

Special Tool (A):09956-02210

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

Tightening torque

N.m kg-m lb-ft LSPV mounting bolt LSPV stay bolt

Page 63

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 autho-

 T echnical 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:  All brake fasteners are important attaching parts in that they could affect the performance of vital parts

 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 5A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LSPV (Load Sensing Proportioning Valve) Assembly 5A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE SPECIFICATIONS 5A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 64

5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER

1. LSPV

2. Brake pipe

ON-VEHICLE SERVICE

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

REMOVAL

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

2) Hoist vehicle.

3) Disconnect brake pipes from LSPV.

4) Remove LSPV assembly from vehicle body.

NOTE: As shown in figure left, LSPV assembly should be removed together with its spring and stay installed or rear axle housing.

5) Remove spring and stay from lever.

1. LSPV assembly

2. LSPV spring

3. LSPV stay

4. Bolt

CAUTION:  LSPV assembly must not be disassembled.

Replace with new one if defective.

 Stopper bolt should not be loosened or tightened.

INSTALLATION

CAUTION: Refer to above CAUTION.

Install by reversing removal procedure, noting the following.

1) Apply multi-purpose grease to upper and lower joint of coil spring.

“A”: Apply grease

Page 65

1, (a)

1. LSPV stay bolt

2. LSPV bolt

3. Brake pipe flare nut

4. Air bleeding plug

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3

2) Torque each bolt and nut to specification as indicated respectively in figure left.

Tightening Torque (a): 23 N (b): 16 N (c): 7.5 N

m (2.3 kg-m, 17.0 lb-ft)

m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)

m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)

3) Upon completion of installation, fill reservoir tank with specified fluid and bleed air from brake system.

NOTE: Make sure to bleed air from LSPV bleeder without failure.

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

INSPECTION & ADJUSTMENT

Confirm the following before inspection and adjustment.

 Fuel tank is filled with fuel fully.  Vehicle is equipped with spare tire, tools, jack and jack handle.  Vehicle is free from any other load.

With vehicle in above conditions;

1) Place it on level floor.

2) Push up LSPV lever with finger till it stops and measure length of coil spring (“L” in below figure) as it is pulled.

3) Spring length “L” should be the value specified below.

Spring length (between spring ends)

“L”: 103 mm (4.06 in.)

1. LSPV stay bolt

2. LSPV stay

4) If it isn’t, adjust it to specification by changing stay positions as shown in left figure. After adjustment, tighten bolt to specified torque. For details, refer to left figure.

Tightening Torque (a): 23 N

m (2.3 kg-m, 17.0 lb-ft)

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

Page 66

5A-4 BRAKES PIPE/HOSE/MASTER CYLINDER

Fastening arts

2.3

17.0

TIGHTENING TORQUE SPECIFICATIONS

LSPV mounting bolt LSPV stay bolt

Tightening torque

N.m kg-m lb-ft

Page 67

ENGINE GENERAL INFORMATION (G16/J20/H25 ENGINE) 6-1

SECTION 6

ENGINE

(G16/J20/H25 ENGINE)

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 autho-

 T echnical 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 description (items) not found in this section, refer to the same section of the Service Manual mentioned in FOREWORD of this manual.

CONTENTS

GENERAL INFORMATION 6- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information on Engine Service 6- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pressure relief procedure 6- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 68

6-2 ENGINE GENERAL INFORMATION (G16/J20/H25 ENGINE)

Left hand steering vehicle

1. Fuel pump relay

2. Junction (Fuse) box

Right hand steering vehicle

GENERAL INFORMATION

GENERAL INFORMATION ON ENGINE SERVICE

FUEL PRESSURE RELIEF PROCEDURE

CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.

After making sure that engine is cold, relief fuel pressure as follows.

1) Place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A /T vehicle), set parking brake, and block drive wheels.

2) Remove fuel pump relay from connector.

3) Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it.

4) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2 – 3 times of about 3 seconds each time to dissipate fuel pressure in lines. Fuel connections are now safe for servicing.

5) Upon completion of servicing, install fuel pump relay to connector.

1. Fuel pump relay

2. Junction (Fuse) box

Page 69

ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINE) 6E1-1

SECTION 6E1

ENGINE AND EMISSION CONTROL SYSTEM

(SEQUENTIAL MULTIPORT FUEL INJECTION FOR

G16/J20 ENGINE)

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 autho-

 T echnical 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.

 Whether the following systems (parts) are used in the particular vehicle or not depends on specifica-

tions. Be sure to bear this in mind when performing service work. – EGR valve – Heated oxygen sensor or CO adjusting resistor – Three way catalytic converter

6E1

GENERAL DESCRIPTION 6E1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRONIC CONTROL SYSTEM 6E1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 6E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On-Board Diagnostic System 6E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions in Diagnosing Troubles 6E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1 Fuel Pump Circuit Check 6E1- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of PCM (ECM) and Its Circuit 6E1- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6E1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL DELIVERY SYSTEM 6E1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injector (Inspection) 6E1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRONIC CONTROL SYSTEM 6E1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Relay (Inspection) 6E1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump Relay (Inspection) 6E1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTS

Page 70

6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (G16/ J20 ENGINE)

GENERAL DESCRIPTION

ELECTRONIC CONTROL SYSTEM

The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and

3) various controlled devices. Functionally, it is divided into the following sub systems:

 Fuel injection control system  Heated oxygen sensor heater control system (if

equipped)

G16 ENGINE

 Idle air control system  Fuel pump control system  Evaporative emission control system  Ignition control system  EGR system (if equipped)

Also, with 4 A/T model, PCM controls A/T .

INFORMATION SENSORS

1. MAF sensor

2. VSS

3. Heated oxygen sensor (if equipped)

4. Power steering pressure switch (if equipped)

5. ECT sensor

6. Battery

7. TP sensor

8. Transmission range switch (A/T only)

9. Camshaft position sensor (CMP sensor)

10. IAT sensor

11. Ignition timing adjusting resistor

12. CO adjusting resistor (if equipped)

13. ABS control module (if equipped)

14. A/C amplifier (if equipped)

15. Monitor connector

CONTROLLED DEVICES a : Fuel pump relay b : Injectors c : EGR valve (if equipped) d : Idle air control valve e : Ignition coil assemblies g : Malfunction indicator lamp

: (“CHECK ENGINE” light)

h : Main relay i : EV AP canister purge valve j : A/C condenser fan motor relay

: (if equipped)

OTHERS A : PCM/ECM B : EVAP canister C : Data link connector D : Combination meter

NOTE: Above figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the other side.

Page 71

J20 ENGINE

ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINE) 6E1-3

INFORMATION SENSORS

1. IAT sensor

2. MAF sensor

3. Power steering pressure switch (if equipped)

4. Heated oxygen sensor (if equipped)

5. Monitor connector

6. ABS control module (if equipped)

7. Camshaft position sensor (CMP sensor)

8. ECT sensor

9. TP sensor

10. Battery

11. CO adjusting resistor (if equipped)

CONTROLLED DEVICES a : Idle air control valve b : A/C condenser fan motor relay

: (if equipped)

c : EVAP canister purge valve d : Ignition coil assemblies e : Main relay f : Fuel pump relay g : Malfunction indicator lamp

: (“CHECK ENGINE” light)

h : Injectors i : EGR valve (if equipped)

OTHERS A : ECM (PCM) B : EVAP canister C : Data link connector D : Combination meter

NOTE: Above figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the other side.

Page 72

6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (G16/ J20 ENGINE)

DIAGNOSIS

The engine and emission control system in this vehicle are controlled by ECM/PCM. ECM/PCM has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “On-Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis according to “Engine Diagnostic Flow Table” in Section 6.

ON-BOARD DIAGNOSTIC SYSTEM

ECM/ PCM performs on-board diagnosis (self-diagnosis) on the system and operates “CHECK ENGINE” lamp (malfunction indicator lamp) as follows.  Malfunction indicator lamp (“CHECK ENGINE” light) lights when

the ignition switch is turned ON (but the engine at stop) regardless of the condition of Engine and emission control system. This is only to check the malfunction indicator lamp (“CHECK ENGINE” light) bulb and its circuit.

 If the areas monitored by ECM/PCM is free from any trouble after

the engine start (while engine is running), malfunction indicator lamp (“CHECK ENGINE” light) turns OFF.

 When ECM / PCM detects a trouble which has occurred in the

areas, it makes malfunction indicator lamp (“CHECK ENGINE” light) turn ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the exact trouble area in ECM/PCM back-up memory.

PRECAUTIONS IN DIAGNOSING TROUBLES

 Before identifying diagnostic trouble code, don’t disconnect cou-

plers from ECM/PCM, battery cable from battery, ECM/PCM ground wire harness from engine. Such disconnection will erase memorized trouble in ECM/PCM memory.

 Be sure to read “Precautions for Electrical Circuit Service” in Sec-

tion 0A before inspection and observe what is written there.

 ECM/PCM replacement

When substituting a known-good ECM/PCM, check for following conditions. Neglecting this check may cause damage to knowngood ECM/PCM. – Resistance value of all relays, actuators is as specified re-

spectively.

– TP sensor and fuel tank pressure sensor (if equipped) are in

good condition and none of power circuits of these sensors is shorted to ground.

Page 73

B-1 FUEL PUMP CIRCUIT CHECK

ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINE) 6E1-5

M/T Vehicle : ECM

A/T Vehicle : (PCM)

A2 (B6)

A14 (B17)

A15 (B26)

1. Main fuse box

2. “IG” fuse

3. “FI” fuse

4. Ignition switch

5. “IG” circuit fuse

6. Main relay

7. Fuel pump relay

8. Fuel pump

9. ECM (PCM)

STEP ACTION YES NO

1 Is fuel pump heard to operate 3

seconds after ignition switch ON?

2 1) With ignition switch OFF, remove

fuel pump relay from connector.

2) Using service wire, connect two terminals of relay connector as

Fuel pump and its circuit are in

Go to Step 2.

good condition. Go to Step 3. “P/B” or “B” wire open,

poor fuel pump relay-tocoupler connection or faulty fuel pump.

shown in figure.

Is fuel pump heard to operate with ignition switch ON?

3 1) Check fuel pump relay, referring

to p.6E1-12 in this manual.

Is it in good condition?

Poor fuel pump relay-to-coupler connection, “W/G” wire open or poor A13 (A23) connection.

Faulty fuel pump relay.

If wire and connection are OK, substitute a known-good ECM (PCM) and recheck.

Fig. for Step 2

Left hand steering vehicle Right hand steering vehicle

1. Service wire

Page 74

6E1-6 ENGINE AND EMISSION CONTROL SYSTEM (G16/ J20 ENGINE)

INSPECTION OF PCM (ECM) AND ITS CIRCUITS

PCM (ECM) and its circuits can be checked at PCM (ECM) wiring couplers by measuring voltage and resistance.

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

M/T Vehicle

A/T Vehicle

1. PCM (ECM)

2. PCM (ECM) connector (Viewed from harness side)

Voltage Check

Refer to the same item of the Service Manual mentioned in Foreword of this manual.

Page 75

ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINE) 6E1-7



Resistance Check

1) Disconnect couplers from ECM/PCM with ignition switch OFF.

CAUTION: Never touch terminals of ECM/PCM itself or connect voltmeter or ohmmeter.

2) Check resistance between each pair of terminals of disconnected couplers as listed in following table.

CAUTION:  Be sure to connect ohmmeter probe from wire harness

side of coupler.

 Be sure to turn OFF ignition switch for this check.  Resistance in table represents that when parts temper-

ature is 20C (68F).

1. ECM/PCM coupler disconnected

2. Ohmmeter

M/T VEHICLE

TERMINALS CIRCUIT

A3 – A1 Main relay 79 – 95 

A13 – B15 Fuel pump relay 79 – 95  A26 – B15 A/C fan motor relay (if equipped) 75 – 1 10 

D1 – B8 Fuel injector No.2 D2 – B8 Fuel injector No.1 D3 – B8 IAC valve (stepper motor coil 2) D4 – B8 IAC valve (stepper motor coil 1)

D7 – B8

D8 – B8

D9 – B15 Heater of HO2S (if equipped) 11.7 – 14.3  D12 – B8 Fuel injector No.4 D13 – B8 Fuel injector No.3 D14 – B8 IAC valve (stepper motor coil 4) D15 – B8 IAC valve (stepper motor coil 3)

D18 – B8

D19 – B8 D20 – B8 EVAP canister purge valve 28 – 35 

A2 – Body ground Ground Continuity A14 – Body ground Ground Continuity A15 – Body ground Ground Continuity

EGR valve (stepper motor coil 2, if equipped)

EGR valve (stepper motor coil 1, if equipped)

EGR valve (stepper motor coil 4, if equipped)

EGR valve (stepper motor coil 3, if equipped)

STANDARD RESISTANCE

– 16

– 43

– 24

– 16

– 43

– 24

CONDITION

Battery disconnected and ignition switch ON

Page 76

6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (G16/ J20 ENGINE)



A/T VEHICLE

TERMINALS CIRCUIT

STANDARD RESISTANCE

A9 – A2 Main relay 79 – 95  A22 – B20 A/C fan motor relay (if equipped) 75 – 1 10  A23 – B20 Fuel pump relay 79 – 95 

B6 – Body ground Ground Continuity B17 – Body ground Ground Continuity B26 – Body ground Ground Continuity

C1 – Body ground Shift solenoid B

C2 – Body ground Shift solenoid A

11 – 15 

C8 – Body ground TCC solenoid

D1 – B4 Fuel injector No.2 D2 – B4 Fuel injector No.1

– 16

D3 – B4 IAC valve (stepper motor coil 1) 35 – 43 

D4 – B20 Heater of HO2S (if equipped) 11.7 – 14.3 

D8 – B4 Fuel injector No.4 D9 – B4 Fuel injector No.3

– 16

D10 – B4 IAC valve (stepper motor coil 4) D1 1 – B4 IAC valve (stepper motor coil 3)

35 – 43 

D12 – B4 IAC valve (stepper motor coil 2) D13 – B4

D14 – B4

D15 – B4

D16 – B4

EGR valve (stepper motor coil 4, if equipped)

EGR valve (stepper motor coil 3, if equipped)

EGR valve (stepper motor coil 2, if equipped)

EGR valve (stepper motor coil 1, if equipped)

– 24

D17 – B4 EVAP canister purge valve 28 – 35 

CONDITION

Battery disconnected and ignition switch ON

Page 77

ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINE) 6E1-9

ON-VEHICLE SERVICE

FUEL DELIVERY SYSTEM

FUEL INJECTOR

Inspection

WARNING: As fuel is injected in this inspection, perform in a well ventilated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery.

1) Install injector and fuel pressure regulator to special tool (injector checking tool).

Special Tool (A):09912-58421

2) Connect special tools (hoses and attachment) to hose and pipe of vehicle.

1. Fuel feed pipe and hose

2. Fuel injector

3. Fuel pressure regulator

4. Fuel return pipe

Left hand steering vehicle

Right hand steering vehicle

1. Fuel pump relay connector

2. Service wire

3. Junction (Fuse) box

Special Tool (B):09912-58431

3) Connect special tool (test lead) to injector.

Special Tool (D):09930-88530

4) Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting.

5) Put graduated cylinder under injector as shown.

6) Remove fuel pump relay.

7) To operate fuel pump and apply fuel pressure to injector, using wire harness as thick as the one used for fuel pump circuit, connect two terminals of relay connector as shown in figure.

CAUTION: Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to PCM (ECM), wire harness, etc.

1. Injector

2. Battery

3. Keep as far apart as possible

Turn ignition switch ON.

8) Apply battery voltage to injector for 15 seconds and measure injected fuel volume with graduated cylinder. Test each injector two or three times. If not within specification, replace injector.

Injected fuel volume: 42 – 52 cc/15 sec. (1.42/1.48 – 1.75/1.83 US/lmp. oz/15 sec.) for G16 engine. 55 – 62 cc/15 sec. (1.94/2.09 – 2.18/2.36 US/lmp. oz/15 sec.) for J20 engine.

Page 78

6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (G16/ J20 ENGINE)

1. Injector

2. Vinyl tube

3. Less than one fuel drop/min

4. Graduated cylinder

9) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should be at work). If fuel leaks more than the following specifications, replace.

Fuel leakage: Less than 1 drop/min.

Page 79

ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINE) 6E1-11

Left-hand steering vehicle

Right-hand steering vehicle

ELECTRONIC CONTROL SYSTEM

MAIN RELAY

Inspection

1) Disconnect negative cable at battery.

2) Remove main relay from connector.

1. Main relay

2. Junction (Fuse) box

3) Check resistance between each two terminals as in table below. TERMINALS

RESIST ANCE Between A and B  (Infinity) Between C and D 79 – 95  at 20_C, 68_F

If check results are as specified, proceed to next operation check. If not, replace.

4) Check that there is continuity between terminals “A” and “B” when battery is connected to terminals “C” and “D”. If malfunction is found, replace.

Page 80

6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (G16/ J20 ENGINE)

Left-hand steering vehicle

Right-hand steering vehicle

FUEL PUMP RELAY

Inspection

1) Disconnect negative cable at battery.

2) Remove fuel pump relay from connector.

3) Structure of fuel pump relay is the same as that of main relay. Check its resistance and operation using the same procedure as that for main relay. If malfunction is found, replace.

1. Fuel pump relay

2. Junction (Fuse) box

Page 81

CHARGING SYSTEM 6H-1

SECTION 6H

CHARGING SYSTEM

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 autho-

 T echnical 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.

 As regards items for 70A type generator which are not found in this section of this manual, refer to each

item applicable to 60A type generator described in the same section of the Service Manual mentioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION 6H- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR [70 A type] 6H- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICA TIONS 6H- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BA TTERY 6H- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERA TOR 6H- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 82

6H-2 CHARGING SYSTEM

GENERATOR [70 A type]

GENERAL DESCRIPTION

1. Pulley

2. Pulley nut

3. Rotor fan

4. Stator coil

5. Stator core

6. Field coil

7. Regulator

8. Brush

9. Front housing

10. Rear housing

B : Generator output (Battery terminal) E : Ground IG : Ignition terminal L : Lamp terminal

1. Generator with regulator ass’y

2. I.C. regulator

3. Stator coil

4. Diode

5. Field coil (rotor coil)

6. Charge indicator light

7. Main switch

8. Battery

Page 83

CHARGING SYSTEM 6H-3

SPECIFICATIONS

BATTERY

NOTE: The battery used in each vehicle is one of the following three types, depending on specification.

Group Cold Cranking Ampere (A) 390 550 Load Test (A) 190 220 Rated Capacity (AH/5HR, 12 Volts) 36 48

GP26R GP85R

GENERATOR

NOTE: The generator used in each vehicle is one of the following two types, depending on specification.

Type Rated voltage 12 V Nominal output 60 A 70 A Permissible max. speed 18000 r/min. No-load speed 1300 r/min (rpm) Setting voltage 14.4 to 15.0 V Permissible ambient

temperature Polarity Negative ground Rotation Clockwise viewed from pulley side

60 A type 70 A type

–30 to 90_C (–22 to 194_F)

Page 84

AUTOMATIC TRANSMISSION (4 A/T) 7B1-1

SECTION 7B1

AUTOMATIC TRANSMISSION

(4 A/T)

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 autho-

 T echnical 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

ON-VEHICLE SERVICE 7B1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Selector Assembly (For LH Vehicle) 7B1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key Interlock Cable (If Equipped) 7B1- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B1

Page 85

7B1-2 AUTOMATIC TRANSMISSION (4 A/T)

ON-VEHICLE SERVICE

MANUAL SELECTOR ASSEMBLY (FOR LH VEHICLE)

1. Manual selector assembly (Select lever assembly)

2. Manual lever assembly

3. Select cable bracket

4. Select indicator

5. Slide cover

6. Select lever knob

7. Spring

8. Knob button

9. Shift lock solenoid rod

10. Shift lock solenoid

11. Cover

12. Illumination lamp

13. Interlock cam

Tightening Torque (Manual selector assembly bolts) (a): 18 N

m (1.8 kg-m, 13.5 lb-ft)

1. Interlock cam pin (only for new selector assembly)

REMOVAL

1) Disconnect negative cable at battery.

2) Remove console box.

3) Disconnect connector for illumination lamp, shift lock solenoid (if equipped) and overdrive OFF switch.

4) Disconnect interlock cable from interlock cam of selector assembly (if equipped).

5) Remove selector assembly mounting bolts.

6) Disconnect select cable from lever of selector assembly.

INSTALLATION

NOTE: If equipped with brake interlock system, new selector assembly is supplied with held interlock cam at interlock cable connecting position with pin. Remove this pin after connecting interlock cable to interlock cam and tightening cable nut.

Reverse removal procedure to install noting the followings.  Connect interlock cable end to cam referring to “Interlock Cable

Installation” section (if equipped).

 Upon completion of installation, confirm that brake (key) interlock

system operates properly (if equipped).

Page 86

AUTOMATIC TRANSMISSION (4 A/T) 7B1-3

KEY INTERLOCK CABLE (IF EQUIPPED)

NOTE: Don’t bend interlock cable excessively when removing and installing it, or system will not operate correctly.

Removal

1) Disconnect negative (–) cable from battery.

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

3) Remove steering column hole cover.

4) Tilt steering column if steering column is adjustable. If no adjustable, loosen steering column bolts.

5) Remove steering column cover.

Ignition switch side

1. Ignition switch ass’y

2. Clamp screw

3. Interlock cable

Select lever side

1. Inner end of interlock cable

2. Interlock cam

3. Stud bolt

6) Remove interlock cable clamp screw located at ignition switch ass’y.

7) Remove disconnect interlock cable inner end. (Ignition switch side.)

8) With console box removed, take out interlock cable by loosening lock nuts.

9) Detach cable end from interlock cam while pressing claws of interlock cam boss. At this time, be careful not to cause damage to its claws.

4. Cam boss

5. Claw

1. Ignition switch ass’y

2. Clamp screw

3. Outer end

Installation

1) Shift select lever to “N” range and turn ignition key to “ACC” position.

2) Connect inner end of interlock cable to key interlock lever (Ignition switch side).

3) Install outer end bracket of interlock cable to ignition switch assembly, and tighten screw to specified torque.

Tightening Torque (a): 2.2 N

m (0.22 kg-m, 1.5 lb-ft)

Page 87

7B1-4 AUTOMATIC TRANSMISSION (4 A/T)

1. Interlock cable

2. Steering column

3. Steering column holder

4) Pass and connect interlock cable as shown at the left figure.

5) Fix interlock cam by inserting pin with about 4 mm (0.15 in.) dia. into holes of cam and lever plate.

6) Install cable end to interlock cam and stud bolt and after making sure that cable outer is pushed in arrow direction B by leaf spring, tighten mounting nut to specified torque. Remove pin.

Tightening Torque (a): 13 N

m (1.3 kg-m, 9.5 lb-ft)

1. Interlock cam

2. Lever plate

3. Interlock cable

4. Pin with 4 mm (0.15 in.) dia.

7) Turn ignition key to “ACC” position and shift select lever to “N” range, and check for followings. a. When select lever is shifted at “P” range with knob button

depressed, ignition key can not be turned from “ACC” to “LOCK” position.

b. When knob button is released, ignition key can be turned to

“LOCK” position.

c. When ignition key is at “LOCK” position, select lever can not

be shifted from “P” to any other range.

8) Install console box.

9) Install steering column cover and steering column hole cover.

10) Adjust steering column or tighten steering column bolts.

11) If equipped with air bag system, enable air bag system. Refer to “Enabling Air bag System” in Section 10B.

Page 88

LIGHTING SYSTEM 8B-1

SECTION 8B

LIGHTING SYSTEM

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 autho-

 T echnical 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 Service Manual mentioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE 8B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard Relay 8B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 89

8B-2 LIGHTING SYSTEM

Type A

ON-VEHICLE SERVICE

HAZARD RELAY

INSPECTION

Connect battery and tester as shown. Unless a continued click sound is heard, replace relay.

Type B

332

1. Hazard relay

2. Junction box

3. Fuse box

Page 90

INSTRUMENTATION/ DRIVER INFORMATION 8C-1

SECTION 8C

INSTRUMENTATION/DRIVER INFORMATION

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 autho-

 T echnical 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 Service Manual mentioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION 8C- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combination Meter 8C- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 91

8C-2 INSTRUMENTATION/DRIVER INFORMATION

GENERAL DESCRIPTION

COMBINATION METER

NOTE: Terminal arrangement of coupler viewed from harness side.

Coupler A Coupler B Coupler C

1. Blank

2. Blank

3. T o ignition switch B/W

4. Blank

5. T o ABS control module Bl /O

6. To PCM (A/T vehicle only) Gr/Bl

7. Blank

8. To VSS Bl/Y

9. T o combination switch G/R

10. To SDM Y/G

11. To main fuse W/Bl

12. To fuse box W

13. T o combination switch R

14. Blank

15. To ECM (PCM for A/T vehicle) V /Y

16. To 4WD controller O/ B

1. To door switch (driver side) B/Bl

2. To shift switch (A/T vehicle only) L G/Bl

3. To shift switch (A/T vehicle only) 2 G/O

4. To shift switch (A/T vehicle only) D Y/G

5. To shift switch (A/T vehicle only) N O/ Bl

6. To shift switch (A/T vehicle only) P O/G

7. To shift switch (A/T vehicle only) R R

8. T o ground B

9. To PCM (A/T vehicle only) W/B

10. To ECT sensor Y /W

11. To fuel level gauge Bl/W

12. T o ground B/Y

13. T o combination switch G/Y

1. T o ground B

2. To ECM (PCM for A/T vehicle) Br

3. T o ignition switch V/R

4. To brake fluid level switch R/B

5. To parking brake switch V

6. To seat belt switch (if equipped) Gr/R

7. T o generator W/ R

8. To oil pressure switch Y/B

9. T o combination switch R/Y

10. Blank

Page 92

WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-1

SECTION 8D

WINDOWS, MIRRORS, SECURITY AND LOCKS

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 autho-

 T echnical 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 Service Manual mentioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE 8D- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Wiper 8D- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 93

8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS

Type A

Type B

Type C

ON-VEHICLE SERVICE

WINDSHIELD WIPER

INSPECTION Wiper Motor

1) As illustrated, use a 12 V battery to connect its (+) terminal to ter-

minal “A”, and its (–) terminal to Black lead wire. If motor rotates at a low revolution speed of 45 to 55 rpm, it is proper. For high speed check, connect battery (+) terminal to terminal “B”, and its (–) terminal to Black lead wire. If motor rotates at a high revolution speed of 67 to 83 rpm, it is proper.

Type A

Type B

Type C

2) Testing automatic stop action.

a) Connect 12 V battery (+) terminal to terminal “A” of wiper mo-

tor and (–) terminal to Black lead wire and let the motor turn. b) Disconnect terminal “A” from battery, and let the motor stop. c) Connect terminal “A” and “D” with a jumper wire, and connect

terminal “C” to battery (+) terminal. Observe the motor turns

once again then stops at a given position. d) Repeat a) thru c) several times and inspect if the motor stops

at the given position every time.

1. Battery

2. Wiper motor

3.  -Red lead

4.  -Black lead

5. Jumper

Page 94

BODY SERVICE 9-1

SECTION 9

BODY SERVICE

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 autho-

 T echnical 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).

 When body servicing, if shock may be applied to air bag system component parts, remove those parts

beforehand. (Refer to Section 10B.)

NOTE:  For the descriptions (items) not found in this section, refer to the same section of Service Manual men-

tioned in FOREWORD of this manual.

 Fasteners are important attaching parts in that they could affect the performance of vital components

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

CONTENTS

BODY STRUCTURE 9- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Fender 9- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Bumper 9- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Body Dimensions 9- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEA T 9- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Seat 9- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAINT AND COATINGS 9- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metal Replacement Parts Finishing 9- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERTIBLE TOP 9-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canvas Top And T opbow Frames 9-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTERIOR AND INTERIOR TRIM 9-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floor Carpet 9-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roof Trim 9-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 95

9-2 BODY SERVICE

FRONT FENDER

BODY STRUCTURE

1. Front fender

2. Front fender lining

3. Fender attaching bolts

4. Fender lining attaching screws

1. Side body

2. Fender

3. Pad

REMOVAL

1) Remove front bumper.

2) Remove fender splush guard (H25 engine).

3) Remove front fender lining.

4) Remove front fender.

INSTALLATION

1) Remove pad from side body and (or) fender, using care not to damage painted surface.

1. Side body

2. Pad

3. Knife

2) Attach new pad cutting appropriately size temporarily and adjust height with a knife so that fender becomes flush with side body .

3) Reverse removal procedure for installation.

NOTE: If paint on fender bolt is peeled off, be sure to apply paint again.

Page 96

REAR BUMPER

BODY SERVICE 9-3

1. Rear bumper

2. Rear bumper member

3. Rear bumper garnish (if equipped)

Page 97

9-4 BODY SERVICE

BODY DIMENSIONS

Canvas top model

Hole to hole distance a – c : 981 mm (38.62 in.) b – b’ : 1390 mm (54.72 in.) b – c’ : 1404 mm (55.28 in.) c – c’ : 1008 mm (39.69 in.) e – e’ : 1110 mm (43.70 in.) e – i : 1036 mm (40.79 in.) f – i : 688 mm (27.09 in.)

a. Garnish installation clip hole b (b’). Front end of front windshield lower installation section c (c’). Front end of front windshield upper installation section d. Hole in F door lower hinge at rear e. Trim installation clip hole f (f’). Scuff installation hole (at rearmost end) g (g’). Trim installation hole h (h’). 11 jig hole i. Installation hole for F seat front inside j. Installation hole for F seat rear inside k (k’). F seat belt installation hole l (l’). Innermost end of side body installation section

g – g’ : 1145 mm (45.08 in.) g – h : 1017 mm (40.04 in.) g – j : 1078 mm (42.44 in.) h – h’ : 1338 mm (52.68 in.) h – j : 1459 mm (57.44 in.) j – k : 548 mm (21.57 in.) l – l’ : 956 mm (37.64 in.)

Page 98

BODY SERVICE 9-5

Hole to hole distance a – d : 1154 mm (45.43 in.) a – f : 1150 mm (45.28 in.) b – f : 1165 mm (45.87 in.) c – e : 1142 mm (44.96 in.) c – g : 1246 mm (49.06 in.) d – e : 1146 mm (45.12 in.)

a. Hole in door upper hinge at rear b. Hole in door lower hinge at rear c. Trim installation clip hole d. 7 jig hole e. Scuff installation hole (rearmost end) f. Door striker lower section installation hole g. F seat belt installation hole

Page 99

9-6 BODY SERVICE

Hole to hole distance a – a’ : 1112 mm (43.78 in.) a – f’ : 1134 mm (44.65 in.) a – g’ : 796 mm (31.34 in.) a’ – f : 1156 mm (45.51 in.) a’ – g : 824 mm (32.44 in.) b – d : 1229 mm (48.39 in.) c – d : 1324 mm (52.13 in.) e – e’ : 1544 mm (60.79 in.) f – f’ : 1029 mm (40.51 in.)

a (a’). Trim installation clip hole b. Installation hole in uppermost part of upper hinge c. Installation hole in outside part of lower hinge d. Installation hole in uppermost part of rear gate striker e (e’). Installation hole in outer upper section of R-COMB R (L) lamp f (f’). Innermost end of rear floor tail member installation section g (g’). Garnish installation clip hole

Page 100

REAR SEAT

1. Seat cushion

2. Seat back

3. Seat auto lock release handle

4. Seat hinge male

5. Hinge male cover

BODY SERVICE 9-7

SEAT

REMOVAL

1) Remove four mounting bolt to remove seat cushion.

2) Remove four mounting bolts to remove seat back.

3) Disassemble and repair seat as necessary.

INSTALLATION

Reverse removal procedure to install rear seat. Torque to specifications, as shown.

Tightening Torque (a): 35 N

m (3.5 kg-m, 25.5 lb-ft)

Suzuki Vitara 1998 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual