Suzuki Vitara 1998 User Manual

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.

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

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

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

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

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.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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”

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)

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.

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

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

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.

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

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.

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.

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.

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.

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

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.

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

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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.

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