Page 2 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.
Page 3: Table Of Contents
TABLE OF CONTENTS SECTION GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS PERIODIC MAINTENANCE SERVICE TROUBLE SHOOTING ENGINE FUEL SYSTEM (CARBURETOR, AIR CLEANER FUEL PUMP AND FUEL FILTER) EMISSION CONTROL SYSTEM ENGINE COOLING SYSTEM CAR HEATER IGNITION SYSTEM CRANKING SYSTEM CHARGING SYSTEM CLUTCH GEAR SHIFTING CONTROL TRANSMISSION...
Page 4 SECTION 0 GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS CONTENTS 0-1. IDENTIFICATION NUMBER ....... . . 0-2.
Page 5 O-2. STANDARD SHOP PRACTICES 4. To perform service with either front or rear car end jacked up, be sure to place safety 1. Protect painted surfaces of the body, and stands under chassis frame so that body is avoid staining or tearing seats. When working securely supported.
Page 6 Use of imitation parts is a big gamble on When using frame contact hoist: and performance. Use genuine safety SUZUKI parts and live up to the trust your customer places on you. 11. Special tools save time and ensure good workmanship: They are available from SUZUKI.
Page 7 12. Refer to the contents of this MANUAL as often as practical, and do each job properly as prescribed. NOTE: Engine cylinders are identified by numbers. See Fig. O-9. Counting from the front end, the cylinders are referred to as No. 1, No. 2, No. 3 and No.
Page 8 O-3. SPECIAL TOOLS Special tools assure three things: 1) improved workmanship; 2) speedy execution of jobs for which they are meant; and 3) protection of parts and components against damage. Here are the special tools pres- cribed for this Model:...
Page 14 0-10...
Page 15 0-11...
Page 16 O-5. METRIC INFORMATION METRIC FASTENERS FASTENER STRENGTH IDENTIFICATION Most of the fasteners used for this vehicle are Most commonly used metric fastener strength metric. When replacing any fasteners, it is most property classes are 4T, 7T and radial line with important that replacement fasteners be the the class identification embossed on the head of correct diameter, thread pitch and strength.
Page 17 STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 18: Periodic Maintenance Service
SECTION 1 PERIODIC MAINTENANCE SERVICE CONTENTS 1-1. MAINTENANCE SCHEDULE ........1-2.
Page 21 MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the car is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the below chart. Severe condition code A -Towing a trailer E - Driving in extremely cold weather and/or...
Page 22 1-2. ENGINE AND EMISSION CONTROL [REPLACEMENT] 1) Disconnect negative battery lead at battery. 1. WATER PUMP BELT INSPECTION 2) Loosen alternator adjusting bolt and pivot AND REPLACEMENT bolts. 3) Replace water pump belt. 4) Adjust belt tension to specification and tighten alternator adjusting bolt and pivot bolts.
Page 23 5) Remove timing belt outside cover. Inspect 9) Adjust valve lash to specification. the belt for damage or wear. When any 10) Install cylinder head cover and torque bolt damage or wear is found on the belt, replace to specification. 11) Install timing belt outside cover and torque If belt replacement is necessary, be sure to bolts and nut to specification.
Page 24 NOTE: 5. COOLING SYSTEM HOSES AND CONNECTIONS INSPECTION Steps 1) - 6) outlined above must be performed with ENGINE NOT RUNNING. For step 7), 1) Visually inspect cooling system hoses for any be sure to have adequate ventilation while evidence of leakage and cracks. Examine them engine is running for damage, and check connection clamps for tightness.
Page 25 4) Screw new filter on oil filter stand by hand 4. ENGINE OIL AND FILTER CHANGE until the filter “0” ring contacts the mounting Before draining engine oil, check engine for oil surface. leakage. If any evidence of leakage is found, make sure to correct defective part before CAUTION: proceeding to the following work.
Page 26 CAUTION: When changing engine coolant, use mixture CRUISER of 56% water and 50% GOLDEN for the market where ambient tem- 1200 perature falls lower than -16°C (3°F) in winter and mixture of 70% water and 30% GOLDEN CRUISER 1200 for the market where ambient temperature doesn’t fall lower than -16°C (3”...
Page 27 8. PCV VALVE REPLACEMENT fold. 1) Disconnect crankcase ventilation hose from PCV valve. tighten it to specification. 2) Remove PCV valve from intake manifold. 3) Wind sealing tape on thread of the new valve 55 N-m Tightening torque and install it securely. 4.5 - 5.5 kg-m sensor...
Page 28 13. EXHAUST GAS RECIRCULATION (EGR) 1. CHARCOAL CANISTER REPLACEMENT SYSTEM INSPECTION WARNING: The following cautions should be always NOTE: observed. Before checking, confirm that altitude is not Disconnect negative cable at battery. higher than 1,220 m (4,088 ftt) (atmospheric DO NOT smoke and place “NO SMOK- pressure is below 680mmHg) and gear shift ING”...
Page 29 15. WIRING HARNESS AND CONNECTIONS INSPECTION 1) Visually inspect all wires located in engine compartment for evidence of breakage. Inspect the condition of the insulation (cracks). All clips and clamps should have solid connections to wires. 2) Replace any wires in a deteriorated or other- wise defective condition.
Page 30 NOTE: 18. IGNITION WIRING REPLACEMENT When replacing plugs, make sure to use new plugs of specified heat range and size. plugs, ignition coil and distributor. and clamp them securely. DO NOT push PLUG SPECIFICATION cords for connection. Push boots. 3) Install new spark plugs. Tighten plugs to specification.
Page 31 21. FUEL TANK CAP GASKET INSPECTION 25. FUEL FILTER REPLACEMENT AND REPLACEMENT Visually inspect gasket of fuel tank cap. If it is This work must be performed in a well damaged or deteriorated, replace it with new one. 1) Disconnect negative cable from battery. 22.
Page 32 1) Replace fuel hoses (pipe to fuel pump, pipe to 28. IDLE MIXTURE INSPECTION fuel filter and breather hose) in fuel feed and 1) Warm up engine to normal operating tem- return lines with new ones. perature. 2) Remove seal rubber of duty check coupler 2) Remove fuel tank.
Page 33 10) With engine running at idle speed, adjust idle mixture adjusting screw slowly in small incre- ment allowing time for duty to stabilize after turning screw to obtain duty of 10 - 50. If duty is too low, back screw out; if too high, screw it in.
Page 34 1-3. CHASSIS AND BODY FLUID INSPECTION AND 33. BRAKE CHANGE 30. CLUTCH PEDAL INSPECTION [INSPECTION] 1) Check clutch pedal height. It should be the same as brake pedal height. 1) Check around master cylinder and reservoir 2) Check clutch pedal free travel. for fluid leakage.
Page 35 If grease is deteriorated, remove grease tho- roughly and apply enough amount of new SUZUKI SUPER GREASE A or wheel bearing grease. If grease is found insufficient, add some more. 1-18...
Page 36 3) Install spindle, bearings, wheel hub, bearing nut and brake disc referring to INSTALLA- Drill hole with approx- TION (p. 17-12) of SECTION 17. imately 3 mm (0.12 in.) 4) Adjust bearing preload and then tighten diameter. bearing lock nut to specification. Refer to MAINTENANCE (p.
Page 37 3) Check propeller shaft (No. 1, No. 2, No. 3) flange yoke bolts for tightness, and retighten them as necessary: kg-m lb-ft Tightening torque 23 - 30 2.3 - 3.0 17.0 - 21.5 42. TRANSMISSION, TRANSFER, DIFFERENTIAL OIL INSPECTION AND CHANGE [I nspectionl 1) Inspect transmission case, transfer case and differential housing for evidence of oil leakage.
Page 38 3) Check bolts and nuts for tightness and retigh- Oil filler and ten them as necessary. Repair or replace level plug defective parts, if any. Refer to MAINTENANCE SERVICE on p. 18-18 for particular check points. 4) Inspect steering gear box for evidence of oil leakage.
Page 39 FINAL INSPECTION Carry out road test in safe place. WARNING: When carrying out the following road tests, select a safe place where no man or no running car is seen so as to prevent any accident. 1) Engine start Check engine start for readiness. 2) Clutch Check the following: that clutch is completely released when...
Page 40: Trouble Shooting
SECTION 2 TROUBLE SHOOTING CONTENTS 2-1. ENGINE ........... 2-2.
Page 41: Engine
2-1. ENGINE Correction Possible cause Cond it ion Starter will not run Poor starting Replace 1. Main fuse blown off (Hard starting) Repair or replace 2. Contact not closing in main switch, or this switch open-circuited Recharge 3. Run-down battery Replace 4.
Page 42 Condition Possible cause Correction 6. Broken valve timing belt Replace Poor starting 7. Poor valve seating Repair or replace (Hard starting) 8. Wrong kind of engine oil Replace 9. Burnt valves Replace 10. Sticky valve stem Correct or replace valve and guide Emission control 1.
Page 43 Correction Possible cause Condition Not enough power Emission control Check and replace as necessary. 1. Malfunctioning EGR valve Check and replace as necessary. 2. Malfunctioning bowl vent solenoid valve. Check and replace as necessary 3. Malfunctioning high altitude switch. Check nad replace as necessary 4.
Page 44 Possible cause Correction Condition Fuel system out of order Surges (Engine power varia- 1. Clogged fuel filter Replace tion under steady 2. Kinky, leaky or damaged fuel hoses and lines Check and replace as throttle or cruise. necessary Feels like the car 3.
Page 45 Correction Possible cause Condition Erratic idling Abnormal condition in fuel system (Improper engine Clean 1. Clogged carburetor jets idling) Adjust 2. Incorrect idle adjustment Clean or replace 3. Clogged air cleaner element Replace 4. Leaky manifold, carburetor or cylinder head gaskets Adjust 5.
Page 46 Cond it ion Possible cause Correction Overheating Abnormal condition in ignition system 1. Improper ignition timing Adjust 2. Wrong heat value of spark plugs Change heat value Abnormal condition in fuel systems 1. Float level set too low Adjust 2. Clogged jets in carburetor Clean 3.
Page 47 Correction Possible cause Condition High fuel consumption Abnormal condition ignition system Adjust 1. Improper ignition timing Repair or replace 2. Leak or loose connection of high tension cord Clean, adjust or replace 3. Defective spark plug (improper gap, heavy deposits, and burned electrodes, etc..) Replace 4.
Page 48 Condition Possible cause Correction Excessive engine oil “Oil pumping” (Oil finding its way into consumption combustion chambers.) 1. Sticky piston ring Remove carbon and replace rings 2. Worn piston ring groove and ring Replace piston and ring 3. Worn pistons or cylinders Replace pistons and rebore as necessary Oil leakage along valve stems...
Page 49 Correction Possible cause Condition Adjust free travel 1. Improper clutch pedal free travel Dragging clutch Replace 2. Weakened diaphragm spring, or worn spring Replace 3. Damaged or worn splines of transmission input shaft Replace 4. Front input shaft bearing worn or broken Replace 5.
Page 50 Correction Possible cause Condition Replenish Excessive gear noise 1. Not enough oil in transmission Replace 2. Defective synchronizer Replace 3. Gears rattling in thrust direction Replace 4. Broken or worn bearings Replace 5. Damaged or worn gears Hard shifting Adjust as prescribed 1.
Page 51 2-7. PROPELLER SHAFTS Correction Possible cause Condition Replace Vibration and noise 1. Broken or worn bearings of universal joint spider Replace 2. Distorted propeller shaft Replace 3. Unbalanced propeller shaft Retighten 4. Loose propeller shaft Replace Noise occurring at 1. Worn or damaged universal joint Replace standing start or 2.
Page 52 Possible cause Correction Condition Check diagonal brake systems and Excessive pedal travel 1. Partial brake system failure repair as necessary (Pedal stroke too large) Fill reservoirs with approved brake 2. Insufficient fluid in master fluid. Check for leaks and air in cylinder reservoirs brake systems.
Page 53 2-9. SUSPENSION, STEERING SYSTEM AND TIRES Possible cause Correction Condition Hard steering 1. Wheel tires not adequately inflated Adjust the pressure Replace 2. Bind in tie rod end ball stud 3. Linkage connections tending to seize Repair or replace Adjust as prescribed 4.
Page 54 Condition Possible cause Correction 5. Wheel tires improperly “rotated“ to Rapid wear or uneven Adjust wear of wheel tires result in unbalance (Abnormal or excessive 6. Disturbed front wheel alignment Adjust as prescribed tire wear) 7. Hard driving Replace tire 1.
Page 55 Possible cause Correction Condition Wander or poor 4. Loose stabilizer bar Tighten or replace stabilizer steering stability bar or bushs Replace spring 5. Broken or sagging springs 6. Steering gear box adjustment Check or adjust steering gear box torque 7. Front wheel alignment Check front wheel alignment Low or uneven trim Replace...
Page 56 Possible cause Correction Condition Starter will not run Magnet switch trouble at all, or runs but 1. Lead wire socket loose in place Retighten runs too slow to 2. Burnt contact plate, or poor contacting Replace, or repair crank with full action force 3.
Page 57 2-12. WIPER MOTOR Correction Possible cause Condition Wiper will not run Tighten or replace Fuse set loose or blown off Repair 2. Incomplete metal-to-metal contact in con- nector. Replace or repair 3. Worn or floating brushes Repair or replace 4. Dirty or burnt commutator Replace 5.
Page 58 2-14. SPEEDOMETER Condition Possible cause Correction Faulty indication 1. Damaged speedometer drive or driven gear Replace Replace 2. Defective drive cable 3. Drive cable incompletely or imporperly Set right tied into the meter 4. Defective speedometer Replace Speedometer noise Lubricate or replace 1.
Page 59 SECTION 3 ENGINE CONTENTS 3-1. GENERAL DESCRIPTION ........3-2 3-2.
Page 60 3-1. GENERAL DESCRIPTION 1) Engine The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its S.O.H.C (Single overhead camshaft) valve mechanism arranged for “V’‘-type valve configuration. This single overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing belt, and no push rods are provided in the valve train system.
Page 61 2) Engine Lubrication The oil pump is of a trochoid type, and mounted on the crankshaft at the crankshaft pulley side. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block. In one path, oil reaches the crankshaft journal bearings.
Page 62 3) Cylinder Head and Valve Train The cylinder head is made of cast aluminum alloy and has four combustion chambers arranged in-line. Each combustion chamber has an intake and an exhaust ports. Moreover, as shown in Figure 3-l-3, the air induction nozzle is provided near each intake valve. During intake stroke of the engine, air/fuel mixture enters into the combustion chamber from carburetor through intake manifold and intake valve.
Page 63 3-2. ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL The following parts of components do not require engine removal to receive services (replacement, inspec- tion or adjustment): Part or Component Nature of Service 1. Spark plug Replacement or inspection 2. Distributor Replacement, inspection or adjustment 6.
Page 64 3-3. ENGINE REMOVAL 1) Disconnect negative (-) and positive (+) cords from battery terminals. From starter motor terminals, disconnect black/yellow lead wire and positive (+) battery cord. Disconnect coupler and white lead wire from alternator terminals. Disconnect lead wires from water tempera- ture gauge and thermal switch.
Page 65 26) Disconnect clutch cable from engine mount- 19) Disconnect brake booster vacuum hose from pipe. ing bracket and clutch release lever. 27) Loosen drain plug to drain transmission 20) Disconnect coupler of lead wire (black) oil. from distributor gear case. 28) Remove propeller shaft interconnecting 21) Remove 4 bolts fastening gear shift lever transmission case and transfer case.
Page 66 32) Lower vehicle and remove 4 bolts securing right and left engine mounting brackets (body side). Fig. 3-3-10 34) Remove clutch lower plate. 35) Separate transmission from engine. Fig. 3-3-8 CAUTION: Throughout this MANUAL, 4 cylinders of Before lifting engine and transmission, engine are identified by numbers: No.
Page 67 3-4. ENGINE DISASSEMBLY 3) Remove distributor assembly. NOTE: Observe critically before starting to remove a component or part by loosening bolts, nuts and the like. What you may find before and during disassembly is valuable information necessary for sucessful reassembly. Be careful in .handling aluminum-alloy parts.
Page 68 6) Take down alternator and water pump pulley. Fig. 3-4,9 (A) Flywheel holder (Special tool 09924-17810) Fig. 3-4-6 8) Remove outside cover on timing belt. Fig. 3-4- 10 Fig. 3-4-7 7) Remove crankshaft pulley by removing 4 9) Loosen tensioner bolt and stud, and remove pulley bolts, with special tool (A) hitched to belt from crank timing belt pulley and cam- flywheel so that crankshaft will not turn.
Page 69 10) Remove timing belt tensioner, tensioner 13) Remove crankshaft timing belt pulley key. plate, and tensioner spring. 14) Remove timing belt inside cover. 11) Remove camshaft timing belt pulley by lock- ing camshaft (insert general rod into the cam- shaft hole) as shown below. Fig.
Page 70 18) Using special tool (C), remove oil filter. 22) Remove water inlet pipe. NOTE: Be careful not to spill oil when removing filter. Fig. 3-4120 head 23) Take off cylinder cover. Fig. 3-4- 17 (C) Oil filter wrench (099 15-473 10) 19) Draw water hoses off water pump inlet pipe.
Page 71 25) Loosen rocker arm shaft securing screws 28) Remove cylinder head. (10 PCS). Fig. 3-4-26 Fig. 3-4-23 a) Use valve lifter (D), (E) to compress valve 26) While drawing out rocker arm shaft, separate spring in order to free valve cotter pieces valve rocker arms and rocker arm springs.
Page 72 b) Remove valve stem oil seal from valve guide, NOTE: and then valve spring seat. Place disassembled parts except valve stem seal and valve guide in order, so that they can be NOTE: installed in their original positions. Do not reuse oil seal once disassembled. Be sure to use new oil seal when assembling.
Page 73 34) Install guide hose over threads of rod bolts. 31) Take down oil pan. This is to prevent damage to bearing journal and cylinder wall when removing connecting rod. Fig. 3-4-32 32) Remove oil pump strainer. Fig. 3-4-35 35) Decarbon top of cylinder bore, before removing piston from cylinder.
Page 74 a) Remove oil pump rotor plate. Piston Arrow mark Piston pin remover and installer (Special tool 09910-38210) Fig. 3-4-36 plate Rotor Fig. 3-4-39 Press Driver handle Piston Piston pin b) Remove outer rotor and inner rotor. 4. Piston pin guide Base 6.
Page 75 3-5. INSPECTION OF ENGINE COMPONENTS NOTE: During and immediately after disassembly, inspect cylinder block and head for evidence of water leakage or damage and, after washing them clean, inspect more closely. Wash all disassembled parts clean, removing grease, slime, carbon and scales, before inspecting them to determine whether repair is necessary or not.
Page 76 Flatness of gasketed surface: Distortion of manifold seating faces: Using a straightedge and thickness gauge, Check seating faces of cylinder head for check surface at a total of 6 locations. If the manifolds, using a straightedge and thickness limit stated below, is exceeded, correct gauge, in order to determine whether these faces should be corrected or cylinder head...
Page 77 Rocker-Arm Shaft and Rocker Arms Shaft-to-arm clearance (IN & EX): Using a micrometer and a bore gauge, measure The difference between two readings is the specified. If the limit is exceeded, replace shaft or arm, Item Standard L i m i t Rocker arm 16.000 - 16.018 mm I.D.
Page 78 Standard Limit Item 6.965 - 6.980 mm Valve (0.2742 - 0.2748 in.) stem diameter 6 . 9 5 0 6 . 9 6 5 m (0.2737 - 0.2742 in.) 7 . 0 0 0 7 . 0 1 5 m Valve (0.2756 - 0.2761 in.) guide...
Page 79 Check end face of each valve stem for wear. The pattern produced on seating face of valve This face meets rocker arm intermittently must be a continuous ring without any break, ‘in operation, and might become concaved or and width 6@ of pattern must be within otherwise irregular.
Page 80 Valve seat repair: the same as for exhaust valve seats but the Valve seat not producing uniform contact second angle is (60” ). with its valve or showing width @ of seating contact that is off the specified range must be repaired by regrinding or by cutting and Seat width @I for regrinding and finished by lapping.
Page 81 Fig. 3-5-19 Contactpattern @ uniform in width Fig. 3-5-21 Measuring spring preload Valve Springs Spring squareness: Referring to the criterion-data given below, Use a square and surface plate to check each check to be sure that each spring is in sound spring for squareness in terms of clearance condition, free of any evidence of breakage or between the end of valve spring and square.
Page 82 Camshaft Journal wear: Runout of camshaft: Measure journal diameter in two directions at Hold camshaft between two “V” blocks, and two places (total of 4 readings) on each measure runout by using a dial gauge. journal as shown in Fig. 3-5-25, and also by If runout exceeds its limit, replace camshaft.
Page 83 Cylinder bore dia. exceeds its limit. Difference of measurements at two positions exceeds taper limit. Difference between thrust and axial measure- ments exceeds out-of-round limit. Fig. 3-5-26 NOTE: If any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance.
Page 84 Piston and Piston Rings Honing or reboring cylinders: Clean carbon from piston head and ring grooves, using a suitable tool. cylinders must also be rebored at same time. Inspect piston for faults, cracks or other damage. 2) Select oversized piston according to amount Damaged or faulty piston should be replaced.
Page 85 Ring groove clearance: Before checking, piston grooves must be clean, dry and free from carbon. Fit new piston ring into piston groove, and measure clearance between ring and ring land by using thickness gauge. If the clearance is out of specification, replace piston.
Page 86 Rod bearing clearance : Connecting rod alignment: 1) Before checking bearing clearance, clean Mount connecting rod on aligner to check bearing and crank pin. it for bow and twist and, if either limit is 2) Install bearing in connecting rod and bear- exceeded, replace it.
Page 87 5) Remove cap and using scale on gaging bIastic Crankshaft thrust play : envelope, measure gaging plastic width at Measure this play with crankshaft set in the widest point. cylinder block in the normal manner, that is, If the clearance exceeds its limit, use a new with thrust bearing fitted and journal bearing standard size bearing and remeasure clea- caps installed.
Page 88 Crankshaft Main (Journal) Bearings General informations: Service main bearings are available in standard- size and 0.25 mm (0.0098 in) undersize, and each of them has 5 kinds of bearings differ- ing in tolerance. The upper half of bearing has oil groove as indicated in Fig.
Page 89 2) Next, check bearing cap bore diameter with- 3) There are five kinds of standard bearings out bearing. differing in thickness. To distinguish them, they are painted in following colors at the On mating surface of cylinder block, five position indicated in Fig. 3-5-47. alphabets are stamped as shown in Fig.
Page 90 3) There are five kinds of standard bearings 2) Next, check bearing cap bore diameter with- differing in thickness. To distinguish them, out bearing. they are painted in following colors at the On mating surface of cylinder block, five position indicated in Fig. 3-5-47. alphabets are stamped as shown in Fig.
Page 91 Numerals stamped on crank webs (Journals diameter) Green Black Colorless Alphabets A stamped B Black Colorless Yellow on mating surface Colorless Yellow Blue New standard bearing to be installed. 5) Using gaging plastic, check bearing clearance 1. Paint with new standard bearing selected. Fig.
Page 92 Measured journal diameter 44.732 - 44.738 mm 44.738 - 44.744 mm 44.744 - 44.750 mm (1.7612 - 1.7614 in.) (1.7614 - 1.7616 in.) (1.7616 - 1.7618 in.) Green & Red Black & Red Red only Alphabets stamped I A on mating surface Red only Black &...
Page 93 Oil sliding and rubbing surfaces of engine parts just before using them in reassembly. Use engine oil (Refer to page l-8). Have liquid packing ready for use. SUZUKI BOND NO. 1215 is specified for it. Use it wherever its use is specified in order to ensure leak-free (oil and water) workmanship of reassembly.
Page 94 Crankshaft 3) Install thrust bearings to cylinder block 1) Install main bearings to cylinder block. between No. 2 and No. 3 cylinders. Face oil groove sides to crank webs. NOTE: If main bearing replacement is necessary, select such bearing as to allow proper clearance as described on p.
Page 95 Oil Pump NOTE: Reassemble components of oil pump assembly according to following procedure, if disassem- bled. a) Wash, clean and then dry all disassembled parts. outer rotors, oil seal lip portion, and inside surfaces of oil pump case and plate. d) Install gear plate.
Page 96 Piston, Connecting Rod and Piston Rings 3) Install oil pump to crankshaft and cylinder block. install No. 1 and No. 2 bolts as shown NOTE: in Fig. 3-6-7, and tighten them to specified Two sizes of piston are available as standard size torque.
Page 97 Use a number 2 stamped piston for installa- tion if cylinder is identified with number 2 and a number 1 piston for cylinder with number 1. Crankshaft pulley side 1. Piston 2. Arrow mark 3. Connecting rod 4. Oil hole (Oil hole should come on intake side) Fig.
Page 98 2) Install piston rings to piston. As indicated in Fig. 3-6-16, 1st and 2nd rings have “R” or “T” mark. Installing these piston rings to piston with marked side of each ring faced foward top of piston. 1st ring differs from 2nd ring in thickness, shape and color of the surface contacting cylinder wall.
Page 99 3) install piston and connecting rod assembly into cylinder bore. compress rings. Guide connecting rod into @Apply engine oil to pistons, rings, cylinder place on the crankshaft. walls, connecting rod bearings and crank- Using a hammer handle, tap piston head to pins.
Page 100 Oil Pump Strainer 2) Install oil pan to cylinder block. After fitting oil pan to block, run in secur- Install seal in the position shown in Fig. 3-6-22. ing bolts and start tightening at the center: Tighten strainer bolt first and bracket bolt to move wrench outward, tightening one bolt specified torque.
Page 101 Heat cylinder head uniformly at a tempe- rature of 80 to 100°C (176 to 212”F), using care not to distort head, and drive new valve guide into hole with special tools. Refer to Fig. 3-6-27. Drive in new valve guide until valve guide After installation, make sure that valve guide protrudes by 14 mm from cylinder head (Fig.
Page 102 2) Install valve spring seat to cylinder head. 3) Install new valve stem seal to valve guide. After applying engine oil to seal and spindle of valve stem seal installer (special tool), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand.
Page 103 8) Install cylinder head onto cylinder block. 6) Using special tool (Valve lifter), compress valve spring and fit two valve totters to Tighten cylinder head bolts gradually with a torque groove provided in valve stem. wrench, following sequence in Fig. 3-6-34. Finally tighten bolts to specified torque.
Page 104 Rocker-Arm Shafts 1) Apply engine oil to rocker arms and rocker arm shafts. 2) install rocker arms, springs and rocker arm shafts. The two rocker arm shafts are not identical. To distinguish between the two, dimensions of their stepped ends differ as shown in Fig.
Page 105 Water pump 1) Install water pump gasket to cylinder block. Use new gasket. NOTE: Clean cylinder block mating surface with gasket before installation. 2) Install water pump to cylinder block. 3) Tighten bolts and nuts to specified torque. Tightening torque N.m I b-ft for water pump 0.9 -...
Page 106 Timing Belt Inside Cover, Belt Pulleys, Tensioner, Timing Belt and Outside Cover 1) install timing belt inside cover to cylinder head. pulley. Refer to Fig. 3-6-42 for proper installation of these parts. Install timing belt guide in such a way that its concave side faces oil pump.
Page 107 6) Before installing timing belt to camshaft 4) Install timing belt tensioner plate to tensio- pulley and crankshaft timing belt pulley, ner. loosen all valve adjusting screws of intake Insert lug of tensioner plate into hole of and exhaust rocker arms fully, or check to tensioner.
Page 108 8) Turn crankshaft clockwise, fitting 17 mm NOTE: wrench to crankshaft timing belt pulley When installing timing belt, match arrow mark bolt, and align punch mark on timing belt pulley with arrow mark on oil pump as crankshaft. shown in Fig. 3-6-49. crankshaft clockwise fully twice after install- ing belt.
Page 109 1. Key 2. Crankshaft pulley ‘3 Fig. 3-6-53 Pulley bolt Fig. 3-6-52 Installing crankshaft pulley Fuel Pump Install fuel pump rod, gasket and fuel pump to 2) Install alternator assembly. cylinder head. Tighten alternator ass’y securing bolts (3pcs) Apply engine oil to rod @ before installation. only to the extent to allow alternator to be Use new gasket.
Page 110 Clutch Disc and Cover Valve Lash (Clearance) Adjustment Install clutch disc and cover. Adjust valve lash of all intake and exhaust For installation, refer to p. 11-7 of SECTION 11 valves to specification, referring to description CLUTCH in this manual and torque each bolt to on valve lash on p.
Page 111: Emission Control System
3-7. ENGINE INSTALLATION 3-8. ENGINE MAINTENANCE SERVICE 1) Lower engine with transmission into vehicle, Belt but do not remove lifting device. Adjust belt tension as outlined in SECTION 6 2) Tighten engine mounting bracket bolts ENGINE COOLING SYSTEM (p. 6-10). (right and left) and transmission mounting Ignition Timing bolts to specification.
Page 112 1) Remove cylinder head cover. 2) Remove ignition timing check window rubber plug from clutch housing of trans- mission case. 3)Turn crankshaft clockwise (viewing from crankshaft pulley side) to the extent that line @above “T” mark punched on fly- wheel is aligned with match mark @ on transmission case as shown below, i.e.
Page 113: Engine Cooling System
Engine Coolant 5) Disengage clutch (to lighten starting load on This subject is covered in SECTION 6 ENGINE engine), and depress accelerator pedal all COOLING SYSTEM. the way to make throttle full-open. 6) Crank engine with fully charged battery, and read the highest pressure on compression Exhaust Line and Muffler gauge.
Page 114 1) Disconnect lead wire from oil pressure 6) After checking oil pressure, stop engine and switch. remove oil pressure gauge. 2) Remove oil pressure switch from cylinder 7) Before reinstalling oil pressure switch, be block. sure to wrap its screw threads with sealing tape and tighten switch to specified torque.
Page 115 Oil Filler Cap 3) Run engine at specified idling speed and, The cap has a packing. Be sure that packing is in under this running condition, read vacuum good condition, free of any damage and signs of gauge. Vacuum should not be lower than deterioration, and is tight In place: it is replacea- cm Hg (17.7 in.
Page 116 3-9. RECOMMENDED TORQUE SPECIFICATIONS Tightening torque Fastening parts kg-m lb-ft 1. Cylinder head bolt 63-70 6.3 - 7.0 Cylinder head cover bolt 4 - 5 0.4 - 0.5 3.0 - 3.5 Spark plug 2 0 - 3 0 2.0 - 3.0 14.5 - 21.5 Distributor gear case 0.8 - 1.2...
Page 117 SECTION 4 FUEL SYSTEM CONTENTS 4-1. CARBURETOR ..........4-2 GENERAL DESCRIPTION.
Page 118 4-1. CARBURETOR GENERAL DESCRIPTION General This 2-barrel downdraft type carburetor has 1. Air horn 2. Float chamber primary and secondary systems. 3. Throttle chamber The primary system operates under normal 4. Pump boot driving condition, and the secondary system 5. Pump lever 6.
Page 119 Fig. 4-1-1 Carburetor exploded view...
Page 120 Fig. 4- l-2 Carburetor cross-section...
Page 121 Float System The float system consists of a float chamber, a float, a float needle valve and seat, and needle valve filter. Fuel from the fuel pump enters the float chamber, passing through the needle valve filter and the needle valve. The float’s function is to maintain a constant level in the chamber.
Page 122 [Switch vent solenoid] Primary System Provided on top of the float chamber is a switch [Primary slow system] vent solenoid which is connected to the ignition switch through ECM. As the ignition switch is metered by the primary slow jet, then mixed operated, the solenoid opens and closes its valve with the air from the primary slow air No.
Page 123 Since the mixture control solenoid valve is [Fuel cut system] factory adjusted, it must not be overhauled The primary slow system incorporates the fuel or its jets must not be removed. cut system with the fuel cut solenoid valve Since the mixture adjust screw is also factory which is operated by the ignition switch and the adjusted, it must not be adjusted at the field ECM.
Page 124 system1 Secondary System [Primary main The fuel metered by the primary main jet is mix- [Secondary slow system] ed with the air from the primary main air bleeder This system operates during the transition and then is discharged into the carburetor bore period from the primary main system to the through the main discharge nozzle.
Page 125 [Secondary main system] Acceleration Pump System Operation of the secondary throttle valve is also This system operates to supply extra fuel to the controlled by the VTV and VSV. When the VSV primary side only during the acceleration. is closed, the vacuum to be applied to the When the primary throttle valve closes, the secondary diaphragm passes the VTV side and return spring pushes up the pump piston.
Page 126 1) When coolant temperature is low: Choke System As the thermo-wax is contracted and the This choke system is provided with a thermo- plunger is retracted, the choke valve linked wax which operates according to the heat from with the fast idle cam is closed. When the the engine coolant, causing the choke valve to engine is started in this state, the intake open and close as well as the fast idle system to...
Page 127 2) When car is at a high altitude (higher than 1,220 m (4,000 ft) and HAC is ON). 3) When temperature in engine room is cold (below 7°C (44°F) and thermal switch is ON). 4) When engine speed after engine start is lower than 1,500 r/min.
Page 128 REMOVAL AND INSTALLATION 9) Disconnect vacuum hoses from idle up actuator and carburetor. 10) To release the pressure in fuel tank, remove Removal and installation of carburetor fuel tank filler cap and then, reinstall it. 11) Disconnect fuel inlet hose from carburetor. place where no fire is used around.
Page 129 UNIT REPAIR OVERHAUL Connect accelerator cable to carburetor. With This section outlines procedure to be used for the accelerator pedal released, adjust the cable overhauling carburetor as removed from engine. play to specification. This adjustment can be For removal and installation of carburetor from made by turning the adjusting nut.
Page 130 2) Remove air horn from float chamber after 3) Remove float and needle valve from air horn disconnecting three hoses and pump lever and and then needle valve seat and filter. removing five screws of air horn. Loosen idle up bracket screw. 1.
Page 131 5) Remove two drain plugs and then primary 2) Blow compressed air into all passages to and secondary main jets in float chamber clean. through plug’s holes, using a negative screw 3) Clean bottom of float chamber. driver. NOTE: 1) Don’t immerse following parts in carburetor cleaner.
Page 132 Assembly 3) Install spring washer as below figure, and 1) Install insulator to float chamber as shown in torque four screws to specification. below figure. 4 - 7 N-m Tightening torque 0.4 - 0.7 kg-m for screws 3 - 5 lb-ft 1.
Page 133 5) Install gaskets and drain plugs, after installing main jets. 1. Drain plug 1. Micro switch bracket 2. Spring 3. screw Fig. 4- l-3 1 Installing drain plugs Fig, 4- l-33 Ins tailing bracket and springs 6) Install level gauge seal. 8) Install jets and air bleeders to float chamber.
Page 134 9) Install balls, injector spring and weights to accelerator pump. Direct “U” bent end side control solenoid valve seal before installing air horn to float chamber. of piston return spring downward as shown in below figure. NOTE: Be sure to use silicone oil that will not affect rubber.
Page 135 MAINTENANCE SERVICES 16) Clamp wire harness securely. Before checking or adjusting the carburetor as the cause of poor engine performance or rough idle, check the followings for malconditions. Ignition system including distributor, timing, spark plugs and wires. Air cleaner including thermostatically control- led air cleaner system.
Page 136 Float Adjustment l)The fuel level in float chamber should be within round mark at the center of level gauge. 1. Air horn 2. Float 3. Float level 4. Tongue Fig. 4- l-43 Float level 1. Level gauge 2. Round mark 3.
Page 137 4) With lights (head light) turned “ON”, check [Checking TWSV circuit] engine rpm (idle-up speed). Be sure that 1) Warm up engine to normal operating tempe- heater fan, rear defogger (if equipped), and rature. air conditioner (if equipped) are all turned 2) Stop engine and disconnect TWSV coupler.
Page 138 Ambient temperature Clearance NOTE: As ambient temperature or engine coolant temperature rises high, clearance increases. Fig. 4-l-47 Choke Adjustment Perform following check and adjustments with air intake case removed when engine is cold. Fig. 4- 149 Choke valve to carbure tar bore [Choke valve] clearance 1) Check choke valve for smooth movement by...
Page 139 5) If clearance is still out of specification even [Choke piston] after lubrication in step 4), remove carburetor Check choke piston as follows. from intake manifold and remove idle-up 1) Disconnect choke piston hose at throttle actuator from carburetor. chamber. Then, turn fast idle cam counterclockwise and 2) With choke valve pushed down to its closing insert a pin available into holes in cam and...
Page 140 3) Disconnect vacuum hose from TWSV and connect special tool (vacuum pump gauge) to its hose. 2. Choke piston rod 3. Screw driver 4. Choke valve to carburetor bore clearance Fig. 4- l-54 Moving choke piston rod T w s v Vacuum hose Fast Idle Adjustment Idle up actuator...
Page 141 4) If clearance is out of specification, adjust by Checking Secondary System bending the unloader arm indicated in below 1) Remove air intake case. figure. 2) Disconnect hose @ from 3 way joint, and connect vacuum pump gauge. Choke valve to carbu- 2.5 - 3.2 3) Open primary throttly valve fully.
Page 142 With vacuum pump gauge set at Black side of Idle Speed Adjustment VTV, when pump is operated, pointer moves NOTE: Before starting engine, place transmission gear considerably but moves back to zero position as shift lever in “Neutral”, and set parking brake soon as pump operation is stopped.
Page 143 3) Set tachometer. 4) Run engine at 1,500 - 2,000 r/min for 30 seconds and bring it to idle speed. 5) Check duty at specified idle speed. If it is out of specification, adjust it to specification ac- cording to following adjustment procedure. I O - 5 0 Specified Duty at 750 - 850 r/min.
Page 144 3) Reinstall carburetor following normal service procedures. Connect emission control system hoses and lead wires. Make specified play on accelerator cable and refill cooling system. 4) Place transaxle gear shift lever in “Neutral”, set parking brake and block drive wheels. 5) Start engine, and warm it up to normal operating temperature, stop engine.
Page 145: Air Cleaner
4-2. AIR CLEANER GENERAL DESCRIPTION In the air cleaner case, a dry-type air cleaner element is provided for filtering.out dirt and dust from air being drawn into the engine for combustion. A damaged element must be replaced with a new one, since it allows dust particles to enter the engine if used as it is.
Page 146 3) Install new element and cap by fitting cap 2) Take out air cleaner element from air cleaner groove to case securely, and be sure to clamp case and blow off dust with compressed air’ from inside of element. cap. 4) Install air cleaner outlet hose.
Page 147 4-3. FUEL PUMP, FILTER AND LINES GENERAL DESCRIPTION The main components of the fuel system are fuel tank, fuel pump and fuel filter and it includes three lines; fuel feed line, fuel return line and fuel vapor line. Fig. 4-Z-5 4-31...
Page 148 Fuel Pulp Fuel Filter A mechanical fuel pump is mounted on the Fuel filter is located at the front part of fuel cylinder head. tank, inside the right-hand side of chassis. The diaphragm in fuel pump is actuated from Fuel enters the filter through its inlet hose and, the cam on the engine camshaft, through a fuel after passing through filtering element, comes pump rod and a rocker arm of fuel pump.
Page 149 Fuel Filler Cap REMOVAL AND INSTALLATION The fuel tank filler neck has a pressure-vacuum cap. A ratchet tightening device on the threaded fuel Before attempting. service of any type on filler cap reduces the chances of incorrect fuel system, the following cautions should installation, which would prevent sealing fuel be always observed.
Page 150 Fuel Filter [Removal] 1) Disconnect negative cable from battery. 1) Disconnect negative cable from battery. 2) Remove fuel filler cap to release fuel vapor 2) Remove fuel filler cap from fuel filler neck to release fuel vapor pressure in fuel tank. After pressure in fuel tank.
Page 151 [Fuel tank purging procedure] WARNING: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank where heat or flame is required, as an explosion resulting in personal injury cou Id occur. The following procedure is used for purging the fuel tank.
Page 152: Accelerator Pedal
4-4. ACCELERATOR PEDAL PRECAUTIONS TO BE TAKEN IN ACCELERATOR PEDAL INSTALLATION Apply grease to accelerator Install accelerator pedal return spring securely as shown in figure. Adjustment of full open position pedal by turning bolt and then loosen bolt by 2 tums. Fig.
Page 153 SECTION 5 EMISSION CONTROL SYSTEM CONTENTS 5-1. GENERAL ........5-4 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM .
Page 156 VEHICLE EMISSION CONTROL INFORMATION LABEL The Vehicle Emission Control Information Label is located under hood. The label contains important emission specifications and setting procedures, as well as a vacuum hose schematic with emission compo- nents identified. When servicing the engine or emission systems, the Vehicle Emission Control Information Label should be checked for up-to-date information.
Page 157 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM (Blow-by gas recycling system) The blow-by gas in the crankcase flows through the passage in the cylinder block into the cylinder head. The oil particles are separated from the blow-by gas by the oil separating unit in the cylinder head cover. The gas is then returned together with the fresh air coming from the air cleaner through the PCV valve into the intake manifold for recombustion.
Page 158 THERMOSTATICALLY CONTROLLED AIR CLEANER (TCAC) SYSTEM This system helps to improve fuel vaporization by controlling the temperature of the intake air almost at a constant level automatically regardless of driving conditions and outside temperature, to distribute the mixture to each cylinder evenly and to stabilize the air/fuel mixture ratio. It consists of the therm0 sensor (therm0 valve) and the Air Control Actuator (ACA).
Page 159 EVAPORATIVE EMISSION CONTROL SYSTEM An evaporative emission control system is used to prevent emission of fuel vapors from the vehicle fuel system. The system allows evaporating fuel vapors to be stored, when the engine is not running. This is accomplished by venting the fuel tank and carburetor float chamber through a vapor storage canister containing activated charcoal.
Page 160 HOT IDLE COMPENSATOR (HIC) HIC attached to the air intake case serves to provide the optimum air/fuel mixture during hot idle so as to ensure stable idle speed. by this, the valve in HIC starts to open and it reaches to the full open state at about 70°C (158” F). While the engine at idle, the throttle valve is closed and the vacuum in the intake manifold stays high.
Page 161 DECELERATION MIXTURE CONTROL SYSTEM This system consists of a MCV (Mixture Control Valve), jet and vacuum hoses. This system is designed to introduce fresh air into the intake manifold to reduce generation of excessive HC and CO emission caused by temporary rich air-fuel ratio while rapid deceleration. The MCV has a pressure balancing orifice and check valve on its diaphragm, and closes when manifold vacuum is constant.
Page 162 COMPUTER CONTROLLED EMISSION CONTROL SYSTEM [Feed back system] A prime purpose of this system is to maintain a controlled air fuel ratio, allowing the catalyst to reduce oxides of nitrogen, hydrocarbons, carbon monoxide and to improve fuel economy simultaneously. The electronic control module (ECM) and the oxygen sensor are provided in this system. The oxygen sensor mounted on the exhaust manifold monitors the exhaust gas air fuel ratio and signals to the ECM.
Page 163 1. ECM 1. Thermal switch 2. Instrument panel Fig. 5- l-9 ECM 2. Intake manifold Fig, 5- I- 17 Thermal switch The ECM sensed parameters are as follows: Exhaust Oxygen Concentration. Throttle position. It is sensed by the oxygen sensor installed on It is sensed by the micro switches (wide open the exhaust manifold.
Page 164 Gear position. Engine room temperature compensation. It is sensed by the fifth switch located on the Sensing the air temperature in the engine transmission. The switch turns “ON” when room the thermal engine room switch sends the gear shift lever is shifted to fifth gear an electric signal to ECM to compensate the position and “OFF”...
Page 165 FUEL CUT SYSTEM As shown in the figure, the fuel cut solenoid valve is provided in the primary slow system of the carbure- tor to open and close the fuel passage of the slow system. As turning the ignition switch “OFF” cuts off the electric current to the solenoid, the solenoid closes the fuel passage.
Page 166 EXHAUST GAS RECIRCULATION (EGR) SYSTEM This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber through the intake manifold. The diaphragm mounted in the EGR modulator is operated by back pressure of the exhaust gas to open and close the valve.
Page 167 5-2. DIAGNOSIS POSSIBLE CAUSES OF EMISSIONS TEST FAILURES Possible Causes Explanation Excessive Emission Engine not at normal operating temperature Excessive hydrocarbons are Hydrocarbons (HC) caused by an air/fuel mixture Disconnected, obstructed, leaking, or misrouted that is not burning completely. vacuum hoses Vacuum leaks Maladjusted idle mixture Improper adjusted/sticking choke...
Page 168 EGR DIAGNOSIS Correction Condition Possible Cause EGR valve vacuum hoses mis- Check EGR valve vacuum hose routing. Engine idles abnormally rough routed. Correct as required. and/or stalls. Leaking EGR valve. Check EGR valve for correct operation. Check EGR attaching bolts for tightness. EGR valve gasket failed or loose EG R attaching bolts.
Page 169 Condition Possible Cause Correction EGR valve hoses misrouted. Check EGR valve hose routings. Engine starts but immediately stalls when cold. BVSV is out of order. Check BVSV. Replace as necessary. NOTE: Stalls after start can also be caused by carburetor problems. PCV SYSTEM DIAGNOSIS Condition Possible Cause...
Page 170 5-3. MAINTENANCE SERVICE 4) After checking vacuum, stop engine and check PCV valve for sticking. With engine stopped, ‘remove PCV hose and GENERAL connect a new hose to PCV valve. If the emission control hoses were disconnected Blow air into new hose and check that air and any system component was removed for flows with difficulty from cylinder head side service, be sure to reinstall the component...
Page 171 TCAC SYSTEM 3) Check that when engine is started (and run at idle speed) under the condition that air Checking TCAC System cleaner is cool, valve on warm air side becomes 1) Check vacuum hose for connection, deterio- fully open and one on fresh air inhaling side ration or damage.
Page 172 NOTE: 3) Install check valve with its orange side directed To check therm0 sensor for operation at toward therm0 valve. higher than 40°C (104” F) temperature when remove therm0 sensor from air cleaner cap EVAPORATIVE EMISSION CONTROL and warm it up with hair drier or photo light SYSTEM before checking.
Page 173 DECELERATION MIXTURE CONTROL [Hoses] SYSTEM Visually inspect hoses and pipe for cracks, damage, or excessive bends, and hose connec- Checking tion for tightness. [Hoses] Inspect each hose for pinholes, cracks or damage. Also check to ensure that each joint is securely connected.
Page 174 1) Remove jet. 2) When blowing air into pipe 0, air should come out of pipe 0. Replace clogged jet. 3) Install jet with its gray side directed toward 1. Pipe (Gray side) MCV. 2. Pipe 3. Jet Fig. 53- 13 4.
Page 175 Checking feed back system Defective oxygen sensor 1) Operate (turn ON) cancel switch or check Defective mixture control solenoid valve switch located at the place shown in below Defective carburetor or maladjusted idle figure. mixture Defective thermal switch Disconnected or loosely connected electric lead wires of emission control systems Defective ECM Defective micro switches (idle and wot)
Page 176 THROTTLE VALVE 3) Connect ohmmeter to terminals of idle micro INDICATOR POSITION switch. Check for continuity between termi- MOVEMENT nals. When throttle valve is at idle position, Swing Idle position ohmmeter should indicated “zero” ohm. Stay after deflection 4) Open throttle valve by l/4 to l/2, and ohm- Swing Full open meter indicator should indicate infinity.
Page 177 1. Primary throttle valve 2. Clearance Fig. 5-3-24 Clearance between throttle valve 1. Lever and carburetor bore Fig. 5-3-22 Lever [Wide open micro switch] 1) Connect ohmmeter to wide open micro switch as indicated in below figure. At this time, ohmmeter indicator should indicate “zero”...
Page 178 4) Using couplers of the same shape as that 6) Turn ignition switch “ON” and “OFF” mentioned in step 3) or 1P couplers, connect repeatedly (without starting engine) and only mixture control solenoid valve wire check if MCSV. operating sound is heard as terminals (Yellow/Black terminal of coupler ignition switch is operated.
Page 179 1. Thermal switch 2. Cool water 3. Thermometer 1. Thermal engine room switch Fig. 5-3-30 Checking thermal switch in cool Fig. 5-3-32 Checking thermal engine room water switch 4) Heat switch to above 46.5”C (116”F), and check that there is no continuity between Checking high altitude compensator terminals.
Page 180 4) While keeping the engine running at 1,500 - Checking oxygen sensor 2,000 rpm, turn the wide open micro switch 1) Warm up the engine to normal operating “OFF” by moving the lever with the finger as temperature. shown in below figure. Then take the reading 2) Disconnect the connector of the oxygen of the voltmeter to make sure it is about 0.8V.
Page 181 Checking feed back system circuits When the feed back system does not seem to operate properly even after each of its components has been checked and proved normal, it is necessary to check each circuit of the feed back system. The checking procedure of each circuit is described here.
Page 182 4) If the measured resistance between each terminal ( @ and @ 1 and the body is “ZERO (0)” ohm, the ECM is grounded securely at two points. If the resistance is not “ZERO (0)” ohm, the possibility is that the lead wire between the terminal (0 or @ ) and the ground is not securely grounded or disconnected.
Page 183 [Checking ECM power circuits] Connected to the ECM are the ignition coil and solenoids or solenoid valves. If a disconnection or a failure of contact occurs within a circuit (power circuit) including any of these coil or solenoids or sole- noid valves, signals will not be sent to the ECM and as a result, the feed back system will not operate properly.
Page 184 [Checking sensors and their lead wires] The sensors constituting the feed back system are; wide open micro switch, idle micro switch, thermal switch, high altitude compensator, thermal engine room switch and fifth switch. If of the above sensors malfunctions or if the sensor circuit has some trouble, signals are not sent to the ECM and conse- quently the feed back system will not function properly.
Page 185 [Checking function of oxygen sensor and feed back system1 If oxygen sensor fails to send signal to the ECM, the feed back system does not operate. While the feed back system is at work, the ECM sends out the feed back signal, and in this condition, after warming up engine to normal operating temperature, when the cancel switch or check switch, is turned ON, the “CHECK ENGINE”...
Page 186 7) After it isconfirmed through steps 1) to 5) that oxygen sensor sends signals to ECM properly, check feed back signal according to the following procedure. If feed back system operates properly, ECM should send out feed back signal. a) Connect an ohmmeter between terminal @I and body (ground). Be sure to connect positive (+) prod of the ohmmeter to body (ground) and negative (-) prod to terminal @J as shown in below figure and never connect the other way around.
Page 187 [Checking idle-up signal] The idle-up system operates when any of the small lights (such as tail light, side marker light and license light), heater fan and rear defogger is put in operation. If the idle-up actuator fails to operate even when any of such equipments is put in operation, check if signal is sent to the ECM according to the following procedure.
Page 188 [Replacing ECMI FUEL CUT SYSTEM If a malcondition such as those listed below still Checking fuel cut system occurs even after confirming proper function 1) Make sure that fuel cut solenoid valve makes a and condition of the sensors of the feed back clicking sound when ignition switch is turned system and their circuits through the above to “ON”...
Page 189 EXHAUST GAS RECIRCULATION (EGR) SYSTEM Checking EGR system NOTE: Before checking, confirm that altitude is not higher than 1,220 m (4,000 ft) (atmospheric pressure is below 680mmHg) and gear shift lever is at neutral position. When performing this check at higher than 1,220 m (4,000 ft) altitude, be sure to dis- connect HAC coupler.
Page 190 [Bi-metal vacuum switching valve (BVSV)] 1) Check filter for contamination and damage. NOTE: Using compressed air, clean filter. For the rough check of the operation, BVSV can be checked by warming up or cooling down the engine without being removed from the intake manifold.
Page 191 3)Connect vacuum pump gauge to nozzle @ 3) Disconnect coupler and connect 12V-battery and plug nozzle @ with your finger. to TWSV terminals. In this state, blow hose While blowing air into nozzle 0, operate vacuum pump gauge and check that vacuum out of hose 0.
Page 192 SECTION 6 ENGINE COOLING SYSTEM C O N T E N T S 6-l. GENERAL DESCRIPTION ..... ..m..*..6-2 6-2. REMOVAL ..........6.3.
Page 193 During normal temperatures (thermostat open), The cooling system consists of the radiator cap, coolant takes the same basic route but is now radiator, water reservoir tank, hoses, water allowed to flow past the thermostat, the inlet pump, cooling fan & clutch, thermostat. The hose and the radiator, and then back to the radiator is of tube-and-fin type.
Page 194 Radiator Cap A pressure-vent cap is used on the radiator. The cap contains a pressure valve and vacuum valve. The pressure valve is held against its seat by a spring of pre-determined strength which protects the cooling system by relieving the pressure if the pressure in cooling system rises by 0.9 ’...
Page 195 In the top portion of the thermostat, an air Water Pump bleed valve is provided; this valve is for venting The centrifugal type water pump is used in the out the gas or air, if any, that is accumulated in cooling system.
Page 196 6-2. .REMOVAL 3. Water Pump Drive Belt 1) Loosen water pump drive belt tension. 2) Remove belt. WARNING: Check to make sure that cooling water 4. Cooling Fan, Fan Clutch and Water Pump temperature is cold before removing any Pulley part of cooling system components.
Page 197 6 . T h e r m o s t a t Drain cooling system. 2) Disconnect thermostat cap from intake manifold. 1. Crankshaft pulley 2. Crankshaft pulley bolt Crank timing belt pulley bolt Fig. 6- 12 Fig. 6-10 5) Remove timing belt outside cover. 3) Remove thermostat.
Page 198 6-3. INSPECTION OF COMPONENTS 6) Loosen tensioner bolt and stud, and remove belt from crank timing belt pulley and Thermostat camshaft pulley after pushing up tensioner 1) Make sure that air bleed valve of thermostat plate fully with finger as shown in Figure. is clear.
Page 199 Radiator Water Pump If the water side of the radiator is found exces- NOTE: sively rusted or covered with scales, clean it Do not disassemble water pump. by flushing with the radiator cleaner compound. If any repair is required on pump, replace it This flushing should be carried out at regular as assembly.
Page 200 Thermostat 1) When positioning the thermostat on the REINSTALLATION intake manifold, be sure to bring its air brea- Water Pump ther valve (iJ to front side of the engine. 1) Install new pump gasket to cylinder block. 2) Install water pump to cylinder block. Tightening torque 1 .O - 1.3 kg-m for bolts &...
Page 201 6-5. MAINTENANCE SERVICE Radiator 1) Tighten bolts securely for proper installa- tion. Also, fix joints of 2 hoses with clamps. Water Pump Belt 1) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If it is necessary to replace belt, refer to ~6-5 for procedure. 2) Check belt for tension.
Page 202 Coolant The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is collected in the reservoir tank. When the system cools down, the coolant is 0.6 liters drawn back into the radiator. Reservoir tank The cooling system has been filled at the factory with a quality coolant that is either 50/50 4.8 liters...
Page 203 Fig. 6-26 Installation of radiator cap 2. Arrow mark Fig. 6-25 Cooling System, Flush and Refill 1) Remove radiator cap when engine is cool: Cooling System Service WARNING: Cooling system should be serviced as follows. To help avoid danger of being burned, do 1) Check cooling system for leaks or damage.
Page 204 4) Close drain plug. Add water until system is filled and run engine until upper radiator hose is hot again. 5) Repeat steps 3) and 4) several times until drained liquid is nearly colorless. 6) Drain system and then close radiator drain plug tightly.
Page 205: Car Heater
SECTION 7 CAR HEATER CONTENTS ..........7-2 DESCRIPTION ELECTRICAL CIRCUIT 7-2.
Page 206 The car heater is of a hot water type and operates quietly. The air is heated by the engine coolant and the warm air is blown into the car interior by the blower motor. The blower motor is driven electrically, independent of engine speed, and operates effectively even when the engine speed is low.
Page 207: Electrical Circuit
7-2. ELECTRICAL CIRCUIT The circuit diagram (Fig. 7-2) shows how the blower motor is controlled. Turn the main switch to “ON”, turn (slide) the blower switch lever on one step, and voltage is applied across the blower motor. The current is small because of the resistor provided in the circuit (indicated as “blower motor resistance” in the diagram).
Page 208 7-3. HEATER SERVICES Heater hoses Check heater hoses for the connection con- Blower resistor dition, breakage, cracks and other damage and This resistor is on heater case. Check it for signs replace if necessary. of cracking or breakage and replace as necessary. If blower motor will not run or when resistor is replaced, check continuity between Blue/White and Blue/Black terminals using a circuit tester.
Page 209 7-4. REMOVAL AND INSTALLATION 2) If equipped with radio and cigarette lighter, disconnect radio and cigarette lighter lead Removal wires, and pull out radio case with radio [Heater and blower motor] and cigarette lighter after loosening case 1. Disconnect battery negative cable. stay screw, and remove radio case bracket.
Page 210 6. Disconnect heater blower motor and resistor 4. When connecting heater hoses, route them lead wires at the coupler. correctly making sure they are free from 7. Loosen heater case securing nut on the engine twist. room side. [For right hand steering vehicle] Heater valve Heater outlet hose Fig.
Page 211 NOTE: Upon completion of all jobs, perform following checks. Check to ensure that every joint of each heater hose and pipe is free from leakage of cooling water. Check to ensure that each control lever operates smoothly and that car heater operates correctly to each control lever position.
Page 212: Ignition System
SECTION 8 IGNITION SYSTEM CONTENTS 8-1. GENERAL DESCRIPTION ........8-2 DISTRIBUTOR .
Page 213 The ignition system is of contact-pointless type (full-transistorized type). The principal components of the ignition system are spark plugs, ignition coil, and distributor. The distri- butor has a rotor, an ignitor, a signal generator, a vacuum advancer and a centrifugal advancer. The signal generator is to generate the ignition signal and consists of a signal rotor, a magnet and a pickup coil.
Page 214 Distributor 1. Vacuum ControlJer 2. Distributor cap 3. Seal 4. Distributor housing 5. Distributor driven gear 6. Pin 7. O-ring 8. Rotor 9. Signal generator dust cover 10. lgnitor dust cover 11. Signal generator 12. lgnitor 13. Generator base plate 14.
Page 215 Ignition Coil The ignition coil is a sort of miniature transfor- mer and, as such, has an iron core around which two coils are wound - primary and secondary windings mentioned above. The two are so close Insulator to each other that a sudden change in the Copper core magnetic flux produced by “primary current”...
Page 216 8-2. MAINTENANCE SERVICE Ignition Coil Disconnect negative cable at battery. Disconnect lead wires and high tension cord from ignition High Tension Cords coil. Remove ignition coil, and check it as Check cord terminals for corrosion, breaks and follows. distortion, and cords for crack or deterioration. Replace cord as necessary.
Page 217 Cleanliness is very important for the distributor 3. If air gap is out of specification, adjust it. cap. With a clean dry cloth, wipe off dust or Remove distributor and then ignitor. grime, if any, and inspect for any damaged Loosen 2 screws securing generator.
Page 218 [ Ignitorl Generator (Pickup 130 - 190 ohms 1. Disconnect negative cable at battery. Remove coil) resistance distributor, and then ignitor and generator. 2. Remove dust cover from ignitor. 3. Disconnect red and white wires from ignitor. 4. Connect an ohmmeter, a bulb and 12 voltage battery to ignitor as shown in Figure 8-16.
Page 219 [Distributor driven gear] 5. After checking, connect red and white wires Inspect gear teeth for wear, and see if the of generator to ignitor and install dust cover backlash is normal or not. Excessive backlash on ignitor. can be told by turning the shaft back and forth, Refer to Fig.
Page 220 Turning housing counterclockwise advances Ignition Timing timing, and vice versa. After adjustment, tighten flange bolt and recheck timing. Ignition timing 800 * 50 r/min l - 3 - 4 - 2 When checking and adjusting ignition timing, be sure to use timing light (09900-27301 or 09900-27311).
Page 221 [Checking vacuum advancer] Remove distributor cap. Disconnect vacuum hose from vacuum hose 3 way joint, and connect vacuum pump gauge (0991747910) to its hose. Apply vacuum (ab- out 400 mmHg). And then with pump stopped, check to ensure that vacuum pump gauge indicator remains at the same level, and release it.
Page 222 8-3. IMPORTANT REMINDERS FOR distributor is inserted properly, position of distributor rotor becomes as shown in figure. INSTALLATION Secure distributor in place tentatively by Distributor making mounting screw finger-tight. When re-installing distributor, be sure to insert it into distributor gear case in the following sequence: 1.
Page 223: Cranking System
SECTION 9 CRANKING SYSTEM CONTENTS GENERAL DESCRIPTION .,..,......, 9-1. SPECIFICATIONS ......... . 9-2.
Page 224 9-1. GENERAL DESCRIPTION To distributor Magnetic switch Pull in coil Hold in coil Magnetic switch contacts Plunger clutch ..i+rh Pinion 84 Over running Starting motor clutch Fig. 9 1 Cranking circuit CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, clutch switch and related electrical wiring.
Page 225 1. Drive housing cover 2. Drive bushing 3. Drive housing 4. Armature ring 5. Armature stop ring 6. Over-running clutch 7. Pinion drive lever 8. Magnetic switch 9. Commutator end cover 10. Brush spring 11. Brush holder 12. Brush 13. Washer 14.
Page 226 9-2. SPECIFICATIONS 12 volts Voltage output 0.9 kW 30 seconds Rating Clockwise as viewed from pinion side Direction of rotation 17 mm (0.67 in.) Brush length Number of pinion teeth 60 A maximum at 11.5 volts, 6,600 r/min minimum No-load characteristic 150 A maximum at 9 volts and 0.29 kg-m torque, Load characteristic 1.900 r/min minimum...
Page 227 Grease 3) Remove two starting motor mount bolts. 4) Remove starting motor. 5) To install, reverse the above procedure. Fig. 54 Starting motor mounting Bearing grease SUZUKI SUPER GREASE A Fig. 9-3 Starting motor greasing poin t...
Page 228 9-5. DISASSEMBLY 3) Loosen 2 bolts and 2 screws to remove commutator end cover. NOTE: 4) Separate drive housing and armature from Before disassembling starting motor, be sure to yoke. put match marks at two tocations ( @ and @I ) as shown in the figure below so that any possible mistakes can be avoided.
Page 229 96. STARTING MOTOR INSPECTION Inspect commutator for wear. If below limit, replace armature. 1) Inspect Commutator Inspect commutator for dirt or burn. Correct Standard Limit with sandpaper or lathe, if necessary. 32 mm 31 mm (1.26 in.) (1.22 in.) Fig. 9- 11 Check commutator for uneven wear.
Page 230 2) Inspect Field Coil Ground test Check commutator and armature coil core. If Open circuit test there is continuity, armature is grounded and Check for continuity between brush and bare must be replaced. surface. If there is continuity, field windings are grounded.
Page 231 4) Inspect Brush Holder and Spring Inspect pinion for wear, damage or other ab- Check movement of brush in brush holder. If normal conditions. Check that clutch locks up brush movement within brush holder is sluggish, when turned in direction of drive and rotates check brush holder for distortion and sliding smoothly in reverse direction.
Page 232 8) Inspect Magnetic Switch Hold in coil open circuit test Push in plunger and release it. The plunger Check for continuity across magnetic switch ‘S’ should return quickly to its original position. terminal and coil case. If no continuity exists, Replace if necessary.
Page 233 3) Check Plunger Return 9-7. PERFORMANCE TEST Disconnect negative lead from switch body. Check that plunger returns inward. IMPORTANT: If plunger does not return, replace magnetic These tests must be performed within 3 - switch. 5 seconds to avoid burning out the coil. 1) Pull-in Test Connect battery to magnetic switch as shown.
Page 234 9-8. CLUTCH SWITCH Install clutch switch in such a way that clearance between thread end of clutch switch and clutch pedal (distance 3 in Fig. 9-32)‘satisfies following specification when clutch pedal is depressed fully. Tighten clutch switch lock nut to specified torque.
Page 235: Charging System
SECTION 10 CHARGING SYSTEM C O N T E N T S 10-l. ALTERNATOR ....L......:. . . 10-2 .
Page 236 10-l. ALTERNATOR GENERAL DESCRIPTION 1. Rotor 2. Field-coil (Rotor coil) 3 . Stator 4. Regulator Battery terminal (+) 5. Brush Field terminal 6. Pulley fig. 10-1 The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown below, 1.
Page 237 The alternator features a solid state regulator Noisy Alternator Noise from the alternator may be caused by a that is mounted inside the alternator. All regula- loose drive pulley, loose mounting bolts, worn tor components are enclosed into a solid mold, or dirty bearings, defective diode, or defective and this unit along with the brush holder assemb- ly is attached to the slip ring end frame.
Page 238 A. Faulty Indicator Lamp Operation Possible cause Problem Check fuse Fuse blown Charge light does not light with ignition ON and engine Replace light Light burned out Tighten loose connections Wiring connection loose Replace IC regulator Adjust or replace drive belt Drive belt loose or worn Charge light does not go out with engine running...
Page 239 b. Load check Run engine at 2,000 r/min (rpm) and turn on headlamps and heater motor. Measure current and if less than 20A, repair alternator. 15.02 C. Overcharged Battery 1) If an obvious overcharge condition exists as evidenced by excessive spewing of elec- trolyte, proceed to DISASSEMBLY under ALTERNATOR SERVICE on p.
Page 240 ALTERNATOR SERVICE REMOVAL 1) Remove battery (-) terminal. 2) Disconnect alternator lead wires (coupler & white lead wire). 3) Unclamp brake pipe from pipe clamp on radiator under cover and remove radiator under cover. 4) Remove alternator mounting bolts and alternator drive belt adjusting bolt. 5) Take down alternator.
Page 241 7) Loosen alternator pulley nut and take off 10) When removing rear bearing, use bearing puller. pulley. Fig. lo- 11 Fig. 108 8) Remove rotor from drive end frame. Fig. 109 9) When. removing front end bearing, remove 4 4-mm bearing retainer screws. 1.
Page 242 INSPECTION 1) Check stator for no open circuits Rotor Using an ohmmeter, check all leads for con- 1) Check rotor for no open circuits tinuity. If there is no continuity, replace Using an ohmmeter, check for continuity between slip rings. Fig.
Page 243 Condenser Brush and Brush holder Check condenser capacity in regulator. Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush with holder. Service limit Standard Brush length 5 mm (0.20 in) 11 mm (0.43 in) Fig.
Page 244 3) Make sure to assemble stator terminal 10-2. BATTERY insulator properly. GENERAL DESCRIPTION The battery has three major functions in the electrical system. First, it is a source of electrical energy for cranking the engine. Second it acts as a voltage stabilizer for the electrical system. And third, it can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Page 245 [Carrier and hold-down] [Jump starting in case of emergency with The battery carrier and hold-down clamp should auxiliary (booster) battery] be clean and free from corrosion before instal- NOTE: ling the battery. The carrier should be in good Do not push or tow the vehicle to start. condition so that it will support the battery Damage to the emission system and/or to securely and keep it level.
Page 246 3) Attach the end of one jumper cable to the REMOVE AND REPLACE positive terminal of the booster battery and When handling a battery, the following safety the other end of the same cable to the positive precautions should be followed: terminal of the discharged battery.
Page 247 SECTION 11 CLUTCH CONTENTS 11-l. GENERAL DESCRIPTION ........11-2 11-2 11-2.
Page 248 11-l. GENERAL DESCRIPTION The clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of a tapering- finger type, which is a solid ring in the outer diameter part, with a series of tapering fingers pointing inward.
Page 249 No. 2 bushing Clutch disc Clutch release shaft Clutch cover Return spring Lock washer No. 1 bushing Cover bolt Shaft seal Clutch release bearing 12. Shaft cowr Clutch release fork pin Fig. 1 l-2 11-3...
Page 250 11-2. REMOVAL Input Shaft End Bearing Use bearing remover (special tool) for removal Removal of clutch presupposes that the trans- of this bearing. mission has been dismounted according to the method outlined in SECTION 13 TRANS- MISSION. Clutch Cover and Disc Remove 6 bolts securing clutch cover to fly- wheel, and take off clutch cover and disc.
Page 251 11-3. INSPECTION OF COMPONENTS Backlash in Disc Setration Fit Check backlash by turning disc back and forth Clutch Disc Facing Surface Condition as mounted on transmission input shaft. Replace A burnt or glazed (glass-like surface) facing can disc assembly if backlash is noted to exceed be reconditioned by grinding it with No.
Page 252 Release Bearing Flywheel Replace release bearing if it sticks, rattles or Check surface contacting clutch disc for any makes abnormal noise when spun anaturned by wear or damage. hand. Fig. 11-12 Fig. 11-10 Input Shaft Bearing Replace input shaft bearing if it sticks, rattles or makes abnormal noise when spun and turned by hand.
Page 253 Before installing retainer, apply grease to its 2) Install input shaft end bearing to flywheel inner surface. using bearing installer (special tool). Fig. 1 I- 15 @ Grease (SUZUKI SUPER GREASE “A’,) 1. Input shaft bearing 2. Special tool (Input shaft bearing installer 09925-98210) Fig.
Page 254 Adjust height of clutch pedal with clutch pedal stop bolt so that pedal is level with brake pedal. Tighten lock nut after adjusting. Fig. I l- 16 @ Grease (SUZUKI SUPER GREASE “‘A “) 2. Lock nut 3. Adjust bolt Fig.
Page 255 2) If free travel is out of specification, adjust it Clutch Cable Lubrication with clutch cable outer nuts. Apply grease to hook part @ of clutch cable. NOTE: After adjusting free travel, make sure that the Clutch cable clutch cable end protrudes at least 5 mm from joint nut Fig.
Page 256 2) For right-hand side steering vehicle. Air cleaner outlet hose Air cleaner outlet hose Radiator outlet Clutch cable 40 - 60 N.m 4.0 - 6.0 kg-m Viewed from arrow “A” Viewed from arrow “ 6 ” Radiator Viewed from arrow “C” Fig.
Page 257: Gear Shifting Control
SECTION 12 GEAR SHIFTING CONTROL CONTENTS ....... 12-1. GENERAL DESCRIPTION 12-2 12-2.
Page 258 12-1. GENERAL DESCRIPTION In this gear shifting control system, by its mechanical structure, the movement of the gear shift lever, which is located beside the driver’s seat, directly actuates the gear shift fork shaft to shift the gear into the selected position.
Page 259 12-2. REMOVAL Gear Shift Lever 1) Remove bolts tightening gear shift lever boot No. 2 and take boot off floor center tunnel. Fig. 12-4 Gear Shift Lever Select Guide Pins 1) After gear shift lever is removed according to foregoing steps 1) through 4), remove gear Fig.
Page 260 12-3. INSPECTION OF COMPONENTS Move shaft and check low speed select guide pin for smooth movement without rattle. If found defective, replace it and apply grease to Gear Shift Lever Check lower end of gear shift lever where gear pin. shift fork shaft contact, @ and 0, for wear and any kind of damage.
Page 261: Transmission
When installing lever case to transmission Fig. 12- 11 extension case, clean joint faces, and then apply sealant (SUZUKI BOND NO. 1215, 99009 When fitting low speed select guide pin into 31110) to joint faces. gear shift lever case, tighten locating bolt while pushing pin so that bolt goes in the groove provided in the pin.
Page 262 Gear Shift Control Lever Seat SUZUKI SUPER GREASE A(99000-25010). Make sure to fit control lever seat @I into gear shift lever case so that locating bolt @ from case, be sure to apply locking agent goes in the groove of control lever seat. And (THREAD LOCK CEMENT SUPER “1333B”...
Page 263 SECTION 13 TRANSMISSION CONTENTS 13-l. GENERAL DESCRIPTION ........13-1 TRANSMISSION GEAR RATIO .
Page 264 3rd gear Low soeed qear shift fork High speed gear shift fork Reduction drive gear Low gear Input shaft Counter shaft Fig. 13-2 13-2...
Page 265 Reverse gear shift fork Reverse gear 5th gear Counter shaft 5th gaar Counter shaft reverse gear Reverse idle gear 13-2. TRANSMISSION GEAR RATIO Primary gear ratio Primary speed ratio 1.521 Second Third Fourth Fifth Gear ratio Secondary ratios 0.935 1.280 2.277 2.400 0.568...
Page 266 Under Engine 13-3. DISMOUNTING 7) Remove drain plug to drain oil in transmis- In Passenger Compartment sion. 1) Loosen 4 bolts fastening gear shift lever boot 8) Disconnect clutch wire from clutch release No. 2 and move boot upward. lever. 9) Remove propeller shaft No.
Page 267 13-4. DISASSEMBLY Replacing Clutch Release Shaft Bush 1) Remove clutch release bearing from input shaft bearing retainer. Fig. 13-3-Z 4) Take out the other bush, too. Fig. 13-3 2) Remove a part of spring from clutch release shaft lever. Fig. 13-3-3 5) Precautions on bush reinstallation: Make sure to apply grease to inside of bushes.
Page 268 Fig. 13-3-5 After installing seal, caulk transmission case against seal at two points. Fig. 13-4-2 Separating Upper Case from Lower Case 1) Remove clutch release bearing from trans- mission input shaft. 4) Remove bolts fastening upper and lower cases together, separate the two, and take out main shaft assembly.
Page 269 3) Remove counter-shaft 5th gear and counter- shaft reverse gear. Fig. 13-5-2 Fig. 13-8 Removing Countershaft 1) Remove reverse gear shaft with gear. 4) Remove circlip from countershaft. Push out countershaft to extension case side by using hydraulic press, remove bearing, and take countershaft assembly out of case.
Page 270 Removing Main Shaft and Input Shaft l)Take out input shaft by hand, taking care not to let high-speed synchronizer ring fall off. Fig. 13-12 Bearing puller (B) (09913-65135) Fig. 13-10 2) Remove circlip retaining hub of high-speed synchronizer sleeve, and slide off sleeve hub, third driven gear and needle bearing from main shaft.
Page 271 5) Remove circlip retaining the reverse synchro- Hydraulic press nizer hub on main shaft. Bush Fig. 13-17 8) Remove ball and main shaft (center) bearing Fig. 13-15 by using hydraulic press. NOTE: 6) Remove reverse synchronizer hub, reverse In the state as shown below, there is a ball in gear and reverse gear needle bearing.
Page 272 10) Remove low gear bush, low speed synchro- nizer hub, ring, spring, 2nd gear and 2nd gear bearing by using hydraulic press. Hydraulic press Bush Fig. 13-22 [Gear shift fork and shaft] Before starting removal, make sure that all shift fork shafts in place are in neutral position and remove each fork and shaft according to Fig.
Page 273 2) Using the same special tool (C), mentioned 3) Drive yoke pin out of low speed gear shift above, drive out yoke pin on high speed fork as in above step 2) and pull out fork gear shift fork, and pull out shift shaft. shaft and fork.
Page 274 13-5. INSPECTION OF COMPONENTS Gears Check each part for wear, damage or discolora- tion. Replace if found defective. Fig. 13-31 Main Shaft Check each part of shaft for wear, discoloration or damage. Replace shaft if any part is found defective. Fig.
Page 275 Inspect external cone (of gear) and internal Input Shaft cone (of ring) for abnormal wear. Be sure that Referring to Fig. 13-34, inspect cone @ and contact patterns on these surfaces indicate toothed ring @ for wear and damage. uniform full-face contact, and that surfaces are free from any wavy wear.
Page 276 By friction between the gear cone and ring Synchronizer Rings cone (internal), the ring begins to rotate but Inspect each synchronizer ring for wear of its is copposed by the hub because of keys. In key slots by measuring width of each slot. other words, the ring is at this time twisted, If width reading exceeds limit, replace ring.
Page 277 13-6. IMPORTANT STEPS IN Gear Shift Shafts INSTALLATION Check the part of shaft as indicated in below figure for uneven wear. Replace shaft if uneven NOTE: wear is noted. Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear.
Page 278 1) Install 2nd gear bearing, 2nd gear, spring, synchronizer ring and low speed synchroni- zer hub/sleeve onto main shaft, using care for installing direction of synchronizer sleeve. After putting on each synchronizer, be sure that 3 keys mounted on hub fit snugly into slots cut in ring.
Page 279 5) Press-fit reverse gear bush, preventing ball 7) Fit reverse hub circlip into groove in main installed in step 4) from coming off. shaft. Bearing installer (D) (09925-l 8010) Fig. 13-50 zer ring and 5th gear. Then install ball and washer, making oil groove of washer face 5th 6) Install reverse gear bearing, reverse gear and gear.
Page 280 11) Install synchronizer ring, needle bearing and input shaft. Fig. 13-53 10) Install 3rd gear bearing, 3rd gear, high speed Fig. 13-56 synchronizer ring and hub/sleeve. When installing hub, direct the side with larger outer diameter boss to 3rd gear side. Then Counter Shaft and Reverse Idle Gear fit circlip into groove in main shaft.
Page 281 2) Fit counter shaft front circlip into groove in shaft. Fig. 13-60 Fig. 13-58 3) Install counter shaft reverse gear and 5th gear onto counter shaft. And then drive counter shaft rear bearing onto it. Fig. 13-61 Shifter Forks, Shafts and Yokes [Forks and Shafts] Fig.
Page 282 Fig. 13-63 1. Locating spring 2. Locating ball @ 3. Upper case NOTE: Gear shift fork Fig. 13-65 the same. Note that 3 shift shafts individually have a 2) Insert low speed gear shift shaft into upper locating ball and locating spring, and that 2 case and low speed shift fork in the direction interlock balls and an interlock roller are used as shown in Fig.
Page 283 Fig. 13-67 4) Install interlock ball ( @ in Fig. 1364) and [Yokes] locating ball ( @ in Fig. 13-64) in upper case. 1) Install low speed .gear shift yoke as shown After installing interlock roller ( @ in Fig. below, using care for its direction.
Page 284 Fig. 13:74 Main shaft and input shaft assembly Fig. 13-72 Transmission Lower Case and Upper Case 1) With counter shaft ass’y, reverse idle gear and reverse gear shaft installed in lower case, check to ensure that bearing stopper rings @ are fitted in both sides of lower case as shown below.
Page 285 4) Uniformly apply sealant (SUZUKI BOND Extension Case NO. 1215, 99000-31110) to mating surface 1) Check to ensure that knock pins @ are of lower case. fitted. Fig. 13-79 Fig. 13-77 5) Install upper case to lower case by matching 3 shift forks with 3 grooves in synchronizer A 99000-25010) to oil seal lip.
Page 286 99000-25010) to oil seal lip. Input shaft Before remounting transmission ass’y to engine transmission case and uniformly apply and car body, apply grease (SUZUKI SUPER sealant (SUZUKI BOND No. 1215, 99000- GREASE I, 99000-25210) to input shaft. 31110). Fig. 13-82 1.
Page 287 13-7. MAINTENANCE SERVICES After filling transmission with oil, torque oil filler and drain plugs to specification. Transmission Oil Before changing oil, check for oil leakage first torque N.m Tightening kg-m lb-ft and correct defects, if any. Fill specified new oil for oil drain and 1 8 - 2 8 1 .
Page 288 13-8. RECOMMENDED TORQUE SPECIFICATION Be sure to torque each bolt and nut according to specification given below, whenever loosened. Fastening parts System Gear shifting control 8. Extension case bolt Transmission 13-25...
Page 289: Transfer Gear Box
SECTION 14 TRANSFER GEAR BOX CONTENTS GENERAL DESCRIPTION ....... . . 14-2 14-l.
Page 290: Propeller Shafts
14-1. GENERAL DESCRIPTION The transfer gear box is an auxiliary transmission for on-off control of two-speed drive transmitted to both front and rear axles concurrently and provides additional speed reductions, HIGH and LOW, for any selection of main transmission gears. The functions of this auxiliary transmission are mainly two-selection between four-wheel drive (front and rear axles) and two-wheel drive (rear axle) and between HIGH and LOW for four-wheel drive.
Page 291 14-2. SELECTIVE FLOWS OF TRANSFER DRIVE 2-Wheel Drive (Rear-Wheel Drive) Rear shifter fork pushes rear clutch sleeve into “high” gear, thus coupling the gear to output rear shaft. Drive flows from input shaft to output rear shaft through big gear, “high” gear and rear clutch. Gear shift control lever position (Rear wheel drive) Fig.
Page 292 4-Wheel Drive LOW (All-Wheel Drive on LOW) Front shifterforkactuates front clutch to couple rear shaft to front shaft; and rear shifter fork actuates rear clutch to couple “low” gear to rear shaft. Front shaft and rear shaft run together on From LOW.
Page 293 14-4. TRANSFER SERVICES NOT REQUIRING TRANSFER REMOVAL Following parts or components do not require transfer removal to receive services (replacement, inspec- tion) : Nature of Service Part or Component 1. Universal-joint yoke flanges Replacement or inspection 2. Front drive shift shaft fork Replacement or inspection 3.
Page 294 14-5. REMOVAL 1) Lift up car and remove securing bolts from each universal-joint flange connection to sever 3 propeller shafts from transfer gear box. Fig. 14-7 4) Drain out oil from gear box by loosening its drain plug. Fig. 14-5 2) Remove clamp @ and boot @ from transfer gear box.
Page 295 6) Disconnect 4WD switch lead wire at coupler. 7) Remove 3 mounting nuts securing gear box chassis, and take down gear box. Fig. 14-11 14-7...
Page 296 14-6. DISASSEMBLY Universal-Joint Yoke Flanges There are 3 flanges to be removed: one from input shaft and other from output front and rear shafts. Lock flange so that it will not turn, and loosen and remove nut holding flange to the shaft.
Page 297 After removing oil seal, remove circlip and drive bearing out of front case by using bearing installer (special tool). Bearing installer 0 : (09913-76010) Fig. 14-21 Fig. 14-19 Transfer Center Case Remove bolts fastening center case and rear case together. loosen bolt @ at point.
Page 298 2) Using spring pin remover (special tool), drive 2 spring pins out of front drive shift shaft remover @ : (09922-85811). Spring pin Fig. 14-26 bearings and spacer. 5) Pull out counter gear, from center case by Remove counter shaft lock plate bolt.
Page 299 7) Remove output shaft rear bearing and retainer together by using bearing puller. After removing bearing, speedometer drive gear, thrust washer, output low gear and needle roller bearing can be removed. Fig. 14-31 Fig. 14-29 10) When input shaft is removed or center case and rear case are separated, input shaft 8) Remove front drive clutch hub circlip and bearings may come off.
Page 300 14-7. INSPECTION OF COMPONENTS 11) When input shaft is removed, front bearing may be left in case. In this case, after remov- Gear Teeth ing oil seal and circlip, bearing can be taken Inspect gear teeth 0, internal teeth of rear out of case by using bearing installer (special clutch sleeve @ and clutch teeth of gear 3.
Page 301 Fig. 14-37 Fig. 14-39 Output high gear Bearings Check each bearing by spinning its outer race by hand to “feel” smoothness of rotation. Replace bearing if noted to exhibit sticking, resistance or abnormal noise when spun or rotated by hand. Fig.
Page 302 Oil or grease sliding and rubbing surfaces of transfer components just before using them in reassembly with gear oil and SUZUKI SUPER GREASE A (99000-25010). Oil seals, “0” rings, gaskets and similar sealing members must be in perfect condition. For these members, use replacement parts in stock.
Page 303 2) Fit circlip @ securely into groove in shaft. Output Rear Shaft Install following parts onto shaft in such order and directions as prescribed in the figure. Fig. 14-46 3) After installing sleeve, bearing (short), low gear and thrust washer, press-fit speedometer drive gear by using bearing installer (special tool).
Page 304 Shim Adjustment of Input and Output Shafts Clearance in thrust direction of both input and output shafts is adjusted by putting shims between input shaft rear bearing and rear case for input shaft and between output shaft rear bearing and rear case for output shaft. As thrust clearance is specified as follows determine shim thickness to meet specification according to the following procedures.
Page 305 5) When shim thickness is determined, select proper shim(s) from among the following shims and use it (them) between input shaft rear bearing and rear case when matching center case and rear case. Available shim 0.1, 0.3,0.5 mm size (thickness) [Output shaft] Just as with input shaft, take measurements of “...
Page 306 Center Case Rear Case 1) Install oil seal in rear case and apply grease 1) Install input shaft front bearing circlip and to oil seal lip. oil seal in center case. Snap ring pliers @ : (09900~6108) Fig. 14-49 Fig. 14-51 2) Install counter shaft thrust washer to rear 2) Install input shaft to center case.
Page 307 4) Install the counter shaft thrust washer to center case. For installation, apply ample amount of grease to both faces of the washer so as to lubricate sliding surfaces and prevent it from moving out of place or slipping off and bring its face without depressions against center case, and fit its bent portion into groove in case securely.
Page 308 Center and Rear Cases 1) Check center case (or rear case) to ensure that it is provided with 2 dowel pins 0. Fig. 14-61 Fig. 14-59 2) Put gasket on center case. Bring rear case and center case into match and apply uniform force gradually all around rear case with a plastic hammer.
Page 309 Front Case 1) Install bearing, circlip and oil seal to front case. Apply grease to oil seal lip and install output front shaft using bearing installer (special tool). Bearing installer (A) : (09913-76010) Fig. 14-66 5) When installing speedometer driven gear and its gear case in rear case, apply grease to 0 ring and oil seal lip, and align bolt holes in rear case and driven gear case.
Page 310 Replenish oil if noted as NOTE: insufficient. When installing oil filler and drain plugs to transfer case, apply sealant (SUZUKI BOND No.1215, 99000-31110) to thread part of plug. Oil and Oil Capacity Whenever car is lifted up for any service includ- ing oil change, make sure to check around transfer gear box for oil leakage.
Page 311: Tightening Torque
14-10. TIGHTENING TORQUE Fastening parts Front case bolt Center case bolt Counter shaft lock Counter shaft lock plate bolt Universal joint flange Universal joint flange nut Transfer mounting bracket bolt Transfer mounting nut Cross joint bolt & nut Oil filler and drain plug 14-23...
Page 312 SECTION 15 PROPELLER SHAFTS CONTENTS 15-2 15-1. GENERAL DESCRIPTION ........15-2.
Page 313: Differential
151. GENERAL DESCRIPTION These automobiles, covered in this manual are four-wheel drive machines and, as such, use three propeller shafts designated as No. 1, No. 2 and No. 3. No, 1 propeller shaft transmits drive from the transmission to the transfer gear box. No. 2 shaft and No. 3 shaft extend from the transfer gear box, the former driving the front axle and the latter the rear axle.
Page 314 15-2. REMOVAL 15-3. INSTALLATION 1) Hoist car. The installing procedure is reverse of the removal 2) Loosen propeller shaft nuts and bolts. procedure. Be sure to adhere to following 3) Remove propeller shaft. instructions when installing shafts: Transmission-side end of No. 1 shaft has Flange tightening torque no flange piece;...
Page 315 15-4. MAINTENANCE SERVICES Joint sheath rubber has a large diameter in one end and a small diameter in the other. Lubrication Be sure to fit sheath rubber with its large Inside yoke of each universal joint has a grease diameter end brought to joint yoke side. nipple.
Page 316 15-5. TIGHTENING TORQUE Bolts & Nuts bolts and nuts for tightness Check following and retighten them as necessary: kg-m Fastening parts 2.3 - 3.0 Propeller shaft bolt 23 - 30 (17.0 - 21.5) Fig. 15-10 15-5...
Page 317 15-6. DISASSEMBLY 3) Tapping yoke with a hammer, completely remove bearing race. Disassembling on propeller shaft yoke side. 1) Using snap ring pliers (Special tool), remove 2 circlips. Special tool 09900-06 106 Fig. 15-13 4) Take out bearing race on the other side in the same way as in 2) and 3).
Page 318 1) Insert bearing race into yoke, tapping it with 15-7. REASSEMBLY a hammer, until it is flush with yoke face. NOTE: When doing this, insert spider into bearing Make certain that rollers inside spider bearing race to prevent rollers in bearing race from race are all in place.
Page 319 6) inspect propeller shaft and flange yoke for damage, and propeller shaft for runout If damage is found or shaft runout exceeds specifications, replace. 0.8 mm Runout limit (0.031 in.) Fig. 15-19 15-8...
Page 320 SECTION 16 DIFFERENTIAL CONTENTS 16-1. GENERAL DESCRIPTION ....... 16-2 16.2. REMOVAL ......... . . 16-3 16-3.
Page 321 16-1. GENERAL DESCRIPTION The two axles, front and rear, are identical as far as the designs of pinion-and-gear drive and differential gearing are concerned. The major difference in this limited sense lies in the shape of the housing. Each axle may be regarded as consisting, speaking roughly, of supporting parts (axle sleeves, differential housing and carrier case) and drive transmitting parts (bevel pinion and gear, differential gearing and live axle shafts).
Page 322 16-2. REMOVAL At each tie rod end, remove nut and disconnect the end from steering knuckle using special tool 1. Loosen, but do not remove, wheel nuts of front or rear wheels, and raise car off the floor by jacking. Rest car steady on safety stands.
Page 323 Fig. 16-8 Fig. 16-6 For Rear Differential Draw out live axle shaft from axle housing. After taking down rear wheels, remove brake NOTE: drums by using special tools. At this time, lower kingpin bearing sometimes NOTE: falls off. So remove bearing while pulling off knuckle gradually.
Page 324 Fig. 16-19-1 Fig. 16-10 09922-66010) 09943-355 7 1) 09942-15510) Disconnect brake pipe from wheel cylinder. Disconnect propeller shaft as in the case of front Have a small plug ready for use when disconnect- axle, and detach and take down differential ing pipe.
Page 325 16-3. DISASSEMBLY Lock flange immovable by using special tool, and remove nut from the end of bevel pinion shank. Fig. 16-14 Remove 10 bolts securing bevel gear to diffe- rential case, and separate gear from case. Fig. 16-12 @ Special tool (Rotor holder 09930- 40 113) Scribe marks on each cap bolted to the saddle portion of carrier case and holding down the...
Page 326 16-4. INSPECTION AND ADJUSTMENT Remove side gears, differential pinions and OF COMPONENTS thrust washers. Side Gear Thrust Play To check thrust play, assemble differential gearing and case, as shown in Fig. 16-19, fasten- ing together two case halves by tightening securing bolts to prescribed torque.
Page 327 Determination of Shim Thickness for Bevel 2) Feed dummy pinion with bearings into the Pinion carrier, positioning it properly, and install Thickness of shims to be used on the bevel joint flange. pinion varies from one vehicle to another on And then tighten bevel pinion nut until account of factors involved in machining and specified starting torque of bevel pinion is...
Page 328 1) Install pinion bearings, spacer, bevel pinion, Rest dummy with dial indicator on surface oil seal and universal joint flange to diffe- plate, and the dial indicator pointer may have rential carrier. deflected from “0” mark to show a certain At this time, be sure to apply gear oil to value;...
Page 329 CAUTION: Bevel Gear Backlash Adjustment Adjust preload on side bearing during Backlash between bevel gear and pinion is back-lash adjustment: mount special tool checked as shown in Fig. 16-24. Note that on drive bevel pinion as shown in Fig. differential case assembly is mounted in the 16-23 and measure using spring balance normal manner, and fastened down by tighten- ing the side bearing cap bolts to 1.0 - 2.0 kg-m...
Page 330 Pinion-to-gear Tooth Contact Pattern Check and Adjustment In addition to proper backlash, proper tooth contact must be secured in the mesh of bevel pinion and gear, so that there will be no “gear noise” coming from the axle and that the hypoid teeth will not be overstressed in transmitting drive.
Page 331 Contact patterns Diagnosis, and what to do These contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) carrier is not true and square, or 3) gear is not properly seated on differential case.
Page 332 16-5. REASSEMBLY Reverse disassembly procedure for reassembly, noting the following. NOTE: Bevel pinion and bevel gear are supplied as a set. Even when only bevel pinion or bevel gear replacement is necessary, be sure to replace both as a set. Fig.
Page 333 3) After installing proper bevel pinion shim(s), Bevel Pinion Bearings press-fit inner race to bevel pinion using A press must be used to install two tapered special tools. roller bearings on bevel pinion. Outer races are press-fitted into the differential carrier and inner races onto the pinion.
Page 334: Suspension
Fig. 16-31 0 Scribed match marks Fig. 16-32 @ Sealant (SUZUKI BOND NO. 1215 99000-31110) Front Axle Shaft and Steering Knuckle For installation them, refer to “Front Suspen- sion Installation”...
Page 335: Maintenance Services
16-7. MAINTENANCE SERVICES 16-8. RECOMMENDED TORQUE SPECIFICATIONS Inspection Inspect differential and differential housing for Tightening torque evidence of oil leakage. Fastening parts Oil level ‘is checked by means of its oil level 70 - 100 7.0 - 10.0 51 .O - 72.0 Side bearing cap bolt plug.
Page 336 SECTION 17 SUSPENSION CONTENTS 17-1. FRONT SUSPENSION........17-2 17-15 17-2.
Page 337 17-1. FRONT SUSPENSION GENERAL DESCRIPTION The front suspension consists of the double-acting shock absorbers, stabilizer bar, semi-elliptical leaf springs, axle housing, etc. as shown below. The Barfield universal joints are used in the front axle to enable the axle shafts to drive the front wheels while allowing the wheels to be steered.
Page 338 9. Oil seal 1. Front brake disc 10. Steering knuckle 2. Wheel bearing 11. Disc brake holder 3. Axle shaft drive flange 12. Disc brake caliper 4. Wheel hub 13. Shock absorber 5. Dust cover 14. Spring bumper 6. Oil seal 15.
Page 339 BARFIELD JOINT CONSTRUCTION AND OPERATION The major parts of the Barfield joint are the outer race (integral with wheel spindle, to which the wheel disc is splined), inner race (splined to the live axle shaft), six steel balls disposed between the two races, and cage (holding the steel balls in a single row lying in a plane).
Page 340 REMOVAL 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. Shackle 1. Hoist car. 2. Loosen lower and upper mounting nuts and remove shock absorber.
Page 341 4. Remove brake disc. Front Wheel Hub 81 Bearing 1. Loosen the five nuts securing the wheel. NOTE: Raise the front end by jacking. If brake disc can not be removed by hand, use Rest the machine steady on safety stands. 8 mm bolts as shown below.
Page 342 [For car not equipped with free wheeling hub] 5. Remove the front axle shaft cap. 6. Remove the circlip retaining the front axle shaft drive flange on front drive shaft, using the circlip remover @. Fig. 17-1-15 Special tool @ (Front Wheel Bearing Nut Socket Wrench 09941-58010) 9.
Page 343 11. Remove oil seal and outer race of inner bearing or outer bearing from wheel hub. Fig. 17-1-20 Fig. 17-1-18 4. Remove tie rod end castle nut and disconnect tie rod end from steering knuckle with special tool @. Steering Knuckle 1.
Page 344 6. Remove lower and upper kingpins. Front Axle Shaft Joint 1. To remove axle shaft joint, carry out steps 1 NOTE: through 7 of steering knuckle removal (p. Upper and lower kingpins, when removed, 17-8 and 17-9) and then follow steps 2 and must be marked off one from the other.
Page 345 Barfield Joint INSPECTION OF COMPONENT To be checked on this joint is its axial play, Stabilizer and its Bush which shows up when a push-and-pull motion is Inspect stabilizer for damage or deformation. given to live axle shaft and wheel spindle held in If defective, replace.
Page 346 Kingpins and Bearings Check the oil seal for wear or damage. If defec- Inspect each kingpin closely for dents, signs of tive, replace with new one. cracking, distortion or any other damage. Replace the kingpins found in defective condi. tion. Fig.
Page 347 Fig 17-1-34 17-12...
Page 348 17-13...
Page 349 Stabilizer Stabilizer bolt & lock washer Tighten to the following specified torque in unloaded condition. 70 - 90 N.m 7.0 - 9.0 kg-m 51 .O - 65.0 lb-ft Install lock washer in body outer side. 1.8 - 2.8 kg-m 13.5 - 20.0 lb-ft Tighten to the following specified torque in unloaded condition.
Page 350 17-2. REAR SUSPENSION GENERAL DESCRIPTION The rear suspension consists of leaf springs, axle housing, axle shafts and shock absorbers as shown below. The leaf springs are attached to the chassis frame through rubber bushes located at their both ends as shown.
Page 351 Rear Axle Shaft REMOVAL 1) Remove rear brake drum. Refer to item 19-3 Shock Absorber “REAR DRUM BRAKE”. The shock absorber is non-adjustable, non- refillable, and cannot be disassembled. The only service the shock absorber requires is replace- ment when it has lost its resistance, is damaged, or leaking oil or gas.
Page 352 4) Using special tools indicated below, draw out each axle shaft with brake backing plate. Rear wheel bearing retainer ring Rear axle shaft Fig. 17-2-9 Break with a chisel the thin ground retainer Fig. 17-2-7 @ Special Tool (Rear Axle ring, and it can be removed.
Page 353 Fig. 17-2-12 17-18...
Page 354 17-19...
Page 355: Steering System
17-3. MAINTENANCE SERVICES Leaf Spring and Bumper 1) Inspect leaf spring for crack, wear and damage. Shock Absorber 1) Inspect for deformation or damage. NOTE: 2) Inspect bushings for wear or damage. Special attention must be paid to that part as 3) Inspect for evidence of oil leakage.
Page 356: Brakes
1) Shake wheel in the direction indicated by an arrow in below figure to see if bearing rattles. Fig. 17-3-7 Fig. 17-3-5 1 .O - 3.0 kg Wheel bearing starting (2.2 - 6.6 lb) preload 2) Shake wheel in the direction indicated by an arrow in below figure to see if bearing rattles.
Page 357 King Pin Where tapered roller bearings holding 2 kingpins at each front wheel are in good and properly preloaded (tightened) condition, there will be no appreciable rattle of wheel. To check king- pins and their tapered roller bearings, jack up the front end and shake wheel to feel any rattle, as shown in figure.
Page 358 Steering Knuckle Oil Seal Before giving a test pull to knuckle arm with a spring balance in the alternative method, in- The oil seal used at the spherical sliding joint stall a large amount of shims on each kingpin to between knuckle and inner case accomplishes lighten preload on tapered roller bearing.
Page 359 . SEALING COMPOUND “CEMEDINE” 366E (99000-31090) Bolts and Nuts . SUZUKI SUPER GREASE H Check following bolts and nuts for tighteness 99000-25120). and retighten them to specified torque as necessary.
Page 360 Fig. 17-3-19 Fig. 17-3-23 Fig. 17-3-20 Fig. 17-3-24 Fig. 17-3-21 Fig. 17-3-22 17-25...
Page 361 17-4. RECOMMENDED TORQUE SPECIFICATIONS Fastening parts Front wheel bearing lock nut Differential oil drain plug 1 8 - 2 5 1.8 - 2.5 13.5 - 18.0 Differential oil filler & level plug 3.5 - 5.0 25.5 - 36.0 Rear hub nut 5 0 - 8 0 5.0 - 8.0 36.5 - 57.5...
Page 362 17-5. FRONT FREE WHEELING HUB (OPTIONAL) General Description This section describes operation, installation and maintenance of free wheeling hub. Be sure to refer to this section carefully for proper service. Operation A free wheeling hub should be fitted onto each of the right and left front wheel hubs. The free wheeling hub has a knob and two embossed marks, “FREE”...
Page 363 Installation Instruction After removing front axle shaft drive flange, install parts (shown in below figure) in accor- dance with the following procedure. Cone washer Cover Gasket “A” Clutch Fig. 17-5-5 4) Put bolt @ into front axle shaft and pull out the shaft and fit snap ring in the groove of axle shaft.
Page 364 “LOCK” positions and by rotating wheel by hand. Should the check result be unsatisfactory, remove free wheeling hub cover and grease each sliding surface with SUZUKI SUPER GREASE A (99000-25010) or multipurpose grease after cleaning each sliding part. If faulty operation is still noted even after greasing, correct defective part or replace it with a new one.
Page 365 SECTION 18 STEERING SYSTEM CONTENTS 18-1. GENERAL DESCRIPTION ....... 18-4 18-2.
Page 366 18-1. GENERAL DESCRIPTION The rotary motion of the steering handwheel is carried to the steering shaft upper, steering shaft lower, steering gear box and pitman arm. Then as the pitman arm moves, the drag rod is caused to move linearly, actuating the tie rod to turn the wheels, right and left, through their knuckle arms.
Page 367 [Left-hand steering vehicle] Steering wheel upper shaft Steering lower shaft Steering gaar box Steering damper Drag Fig. 18-1-1 18-3...
Page 368 18-2. SPECIFICATIONS AND DATA Recirculating ball-and-nut type Steering gear box Gear ratio 15.6 - 18.1 Steering angle, inside 29” + 3” Steering angle, outside Steering wheel diameter 400 mm (15.74 in.) Minimum turning radius 5.1 m (16.73 ft.) Toe-in 2 - 6 mm (0.079 - 0.236 in.) Camber 1 degree (1”) + 45’...
Page 369 18-4. REMOVAL NOTE: When removing the column assembly from the car, special care must be taken in handling it Use of a steering wheel puller other than the steering wheel remover recommended in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly is prohibited.
Page 370 3) Remove the bolt joining steering shafts in engine room. Fig. 18-6 Fig. 18-9 4) Remove steering column ass’y. NOTE: Don’t separate steering column assembly into steering column and shaft. If column or shaft is defective, replace as an assembly. Fig.
Page 371 3) Remove the bolt joining steering shafts in engine room. Fig. 18-6 Fig. 18-9 4) Remove steering column ass’y. NOTE: Don’t separate steering column assembly into steering column and shaft. If column or shaft is defective, replace as an assembly. Fig.
Page 372 Steering Lock 3) Steering gear box is secured in place by mounting bolts. Remove these bolts and 1) After removing steering column, loosen and take down gear box. remove steering lock mounting bolts. Use care not to damage aluminum part of steering center punch.
Page 373 18-5. INSPECTION OF COMPONENTS Steering Gear Box [Oil level] Oil surface should be up to the level as shown in below figures. If not, add prescribed gear oil, SAE 90. Right hand steering vehicle 35mm (1.4 in.) Fig. 18-19 (1)Adjusting bolt Make an adjustment according to the following procedure.
Page 374 4) If worm shaft starting torque is checked all 3) Measure worm shaft starting torque from its right, another check should be carried out on position in the straightforward state in 2), worm shaft operating torque in its entire using a spring balance and string as shown in below figure.
Page 375 18-6. CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE Cars involved in accidents resulting in body damage or where the steering column has been impacted may also have a damaged or misalign- ed steering column. 635.5 mm (25.02 in.) Checking Procedure 1) Check capsules on steering column bracket; all should be within 1.0 mm (0.039 in) from Fig.
Page 376 18-7. IMPORTANT STEPS IN REINSTALLATION NOTE: For installation, it is important that only the specified screws, bolts, and nuts be used as designated and that they are tightened to the specified torque. Reverse removal procedure for installation, noting the following. Steering Lock Fig.
Page 377 Steering Damper install steering damper with larger diameter hole end directed toward pitman arm and hole in outer shell downward. Install steering damper stay, directing its circular boss side upward. Mount steering damper and steering damper stay bolts from the top. Torque steering damper pin nut and damper nut to specification while directing steering to straightforward state (with pitman arm in...
Page 378 Steering Column Steering wheel slip ring Apply SUZUKI SUPER GREASE A (99000-25010) all around slip ring Steering column bolt tightening torque Steering column seal rubber When installing the steering column, make sure to fit seal rubber in the p o s i t i o n a s i l l u s t r a t e d...
Page 379 Steering Lower Shaft and Joint Universal joint rubber joint bolt 11.0-18.0lb-ft Steering rubber Fig. 18-31 18-15...
Page 380: Wheel Alignment
Steering Handwheel 18-8. WHEEL ALIGNMENT Two requirements must be met, among others, Front alignment refers to the angular relation- in installing and setting steering wheel: 1) check ship between the front wheels, the front to be sure that handwheel play meets specifica- suspension attaching parts and the ground.
Page 381 Camber Camber is the tilting of the front wheels from the vertical, as viewed from the front of the car. When the wheels tilt outward at the top, the camber is positive. When the wheels tilt inward at the top, the camber is negative. The amount of tilt is measured in degrees.
Page 382 Steering Rubber joint 189. MAINTENANCE SERVICES Inspect rubber joint for evidence of crack or Steering Handwheel Play breakage, and make sure that its bolts are tight. The wheel play is proper if it is anywhere between 10 and 30 mm (0.4 and 1.2 in.). An unusually large play means that the ball-and- socket joints are loose or that the wear in the steering gear box is excessively large.
Page 383 50-80 Steering Gear Box Tightening torque 5.0 - 8.0 kg-m Check steering gear box for evidence of oil for wheel nuts (36.5 - 57.5 lb-ft) leakage. If leakage is found, repair or replace and then refill specified oil to specified level. “18-5 INSPECTION OF COMPO- Refer to NENT”...
Page 384 NOTE: Before installing wheels, remove any build-up of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which can later allow a wheel to come off while the car is moving.
Page 385 Inflate to specified pressure. [Tire repair] There are many different materials and techni- ques on the market to repair tires. As not all of these work on all types of tires, tire manufactu- Limit rers have published detailed instructions on how and when to repair tires.
Page 386 18-10. RECOMMENDED TORQUE SPECIFICATIONS Tightening torque Fastening parts kg-m 25 - 40 2.5 - 4.0 18.5 - 28.5 Steering shaft nut 1 5 - 2 5 Steering shaft rubber joint bolt Steering shaft joint flange bolt 20 - 30 2.0 - 3.0 14.5 - 21.5 Steering gear box nut 7 0 - 9 0...
Page 387 SECTION 19 BRAKES CONTENTS 19-1. GENERAL DESCRIPTION ....... . . 19-2 19-2.
Page 388 19-1. GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. Two brake pipes are connected to the master cylinder and they make two independent circuits.
Page 389 MASTER CYLINDER 1. Brake master cylinder assembly 2. Brake master cylinder piston set 3. Piston stopper circlip 4. Secondary piston stopper bolt 5. Seal ring 6. Piston stopper seal ring 7. Cylinder cup 8. Master cylinder seal ring 9. Connector screw 10.
Page 390 MASTER CYLINDER ASSEMBLY [GENERAL DESCRIPTION] The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the below figure) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on the front wheel brakes (right & left). Also, the hydraulic pressure produced in the secondary chamber (“b”) acts on the rear wheel brakes (right &...
Page 391 One-circuit operation (Primary chamber “a” circuit failure) Depressing the brake pedal forces the primary piston “A” to move as described previously, but since the brake circuit connected to the chamber “a” cannot hold the pressure, no pressure is produced in the fluid immediately ahead of the piston “A”.
Page 392 DISC BRAKE CALIPER ASSEMBLY [GENERAL DESCRIPTION] This caliper has a single 51.1 mm (2.012 in.) bore and is mounted to the brake caliper holder with two mounting bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction.
Page 393 [Caliper OPERATION] Piston seal Piston seal Cylinder Single piston floating caliper type (Rubber seal) Winder (Rubber seal) The single piston floating caliper type brake is employed in this model. One cylinder and one piston are used for this type. (The cylinder is constructed as a monoblock with the caliper.) Fluid pressure generated in the cylinder causes the pad (1) on the piston side to press against...
Page 394 DRUM BRAKE ASSEMBLY (Rear Wheel Brake) [GENERAL DESCRIPTION] The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. For details, refer to OPERATION in the next page. NOTE: Replace all components included in repair kits used to service this drum brake. Lubricate parts as specified. WARNING: When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by clean- ing wheel brake parts with a dry brush or with compressed air.
Page 395 At this time, the distance the brake shoe moves [Rear brake OPERATION] is “B”, that is, the distance that “A” (the end of With the general drum brake type, when the the long hole made in the brake shoes web) brake pedal is depressed, two pistons in the moves till it contacts the lever (1) which is fitted wheel cylinder force the brake shoes outward,...
Page 396 The distance the lever (1) moves corresponds to the amount of wear. In accordance with the lever (1) movement, the fan-shaped ratchet (2) also moves, for they are assembled as a unit. The lever (1) and ratchet (2) remain in the positions as they moved until the shoe-to-drum clearance becomes even larger.
Page 397 BOOSTER ASSEMBLY [GENERAL DESCRIPTION] The booster is located between the master cylinder and the brake pedal. It is so designed that the force created when the brake pedal is depressed is mechanically increased combined with the engine vacuum. The booster has a diaphragm of 4 180 mm effective diameter. Its operation is described in the following pages. NOTE: Use all components included in repair kits to service this booster.
Page 398 [Booster OPERATION] 1. Booster No. 1 body 2. Booster No. 2 body 3. Valve operating rod 4. Air cleaner element 5. Air cleaner separator 6. Air valve spring retainer 7. Air valve return spring 8. Control valve spring retainer 9. Control valve spring 10.
Page 399 When foot brake pedal is depressed When foot brake pedal is released Being pushed by the operating rod, the booster When the brake pedal is released, the booster air air valve moves to the left as shown. Then the valve returns to the right by the master cylinder control valve is pushed against the booster piston return force and the air valve return piston seat closely by the valve spring force.
Page 400 19-2. FRONT DISC BRAKE 4) Remove caliper (cylinder). REMOVAL NOTE: During removal, be careful not to damage brake 1) Loosen, but do not remove, front wheel nuts. flexible hose. 2) Hoist car. Also, don’t depress brake pedal. take 3) Remove wheel nuts and off front wheels.
Page 401 6) Blow compressed air into cylinder through Caliper After taking down the wheel, remove piston and bolt hole where flexible hose was fitted. With piston seal according to the following procedure, this air pressure, the piston can be pushed out of cylinder.
Page 402 INSPECTION OF COMPONENTS Disc 1) After taking down the wheel, remove caliper Brake Pad assembly by loosening carrier bolts (2 pcs). Check pad lining for wear. When wear exceeds its limit, replace with a new one. CAUTION: During removal, be careful not to damage brake flexible hose and not to depress brake pedal.
Page 403 Brake Disc Cylinder Slide Bush Check disc surface for scratches in wearing parts. Check bush for smooth movement as shown. If Scratches on disc surface noticed at the time of it is found faulty, replace guide pin or guide specified inspection or replacement are normal pin sleeve.
Page 404 PRECAUTIONS ON INSTALLATION 3) Insert piston into cylinder by hand and fit Reassemble front brake in the reverse order boot in- boot groove in piston. of disassembly, using care for the following points. CAUTION: Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.
Page 405 Fig. 19-36 Front Brake Disc and Pad Use care not to scratch or put oil or grease on sliding surface of disc and pad during installation work. After installing brake disc to wheel hub properly, tighten wheel nuts to specified torque.
Page 406 19-3. REAR DRUM BRAKE Inspection for Front Brake After installing Mount tires and make certain that they rotate REMOVAL smoothly, with a force of less than 3.0 kg (6.6 Brake Drums lb). 1) Remove wheel center cap. NOTE: 2) Loosen, but do not remove, rear wheel nuts For the above check, the following must be and brake drum nuts.
Page 407 8) Remove brake drum by using special tools. INSPECTION OF COMPONENTS Brake Drum Inspect drum for cleanliness. Check its braking surface for wear by measuring its inside diameter. Fig. 19-42 Brake Shoes and Strut 1) Remove brake drum referring to REMOVAL on previous page.
Page 408 Brake Shoe and Rim Wheel Cylinder If lining is worn out beyond service limit, When removing brake drum, check wheel replace shoe. cylinder for oil leakage. If any leakage is found, replace wheel cylinder inner parts. Brake Service Standard Inspect wheel cylinder disassembled parts for lining limit wear, cracks, corrosion or damage.
Page 409 Springs 3) Install parking brake shoe lever stopper plate. Inspect for damage or weakening. NOTE: inspect each part for rust. If found defective, Make sure to install this plate. replace. Upper side Brake back - plate side lever stopper plate 2.
Page 410 PRECAUTIONS ON INSTALLATION 6) Remove brake drum and check fan-shaped ratchet position. Wheel Cylinder 1) Tighten wheel cylinder to brake back plate to If it has shifted off its previous position in step specified torque. 2) when it was pushed down, it proves proper 2)Tighten flare nut of brake pipe to specified operation of shoe adjusting system.
Page 411 2) Install shoe hold down springs by pushing 2) Connect brake cable joint to parking brake them down in place and turning hold down shoe lever by using joint pin. pins. Insert joint pin down from the top and install clip into joint pin hole securely. NOTE: Check to ensure that clip is in good condition before installing it.
Page 412 NOTE: 4) Before installing brake drum, to maximize If brake backing plate was removed from wheel brake shoe-todrum clearance, put screw driver between rod and ratchet and push cylinder or brake pipe was disconnected from wheel cylinder. Bleed air from brake system. down ratchet as shown in figure.
Page 413 DISASSEMBLY 19-4. MASTER CYLINDER 1) Remove circlip. REMOVAL 2) Remove primary piston by using compressed 1) Clean outside of reservoir. air as shown. Be cautious during removal as 2) Take out fluid with a syringe or such. primary piston will jump out. 3) Remove reservoir connector screw.
Page 414 INSPECTION OF COMPONENTS Reservoir Master Cylinder Inner Parts NOTE: Inspect all disassembled parts for wear or Do not use shock absorber fluid or any other damage, and replace parts if necessary. fluid which contains mineral oil. Do not use a NOTE: container which has been used for mineral oil or Wash disassembled parts with brake fluid.
Page 415 PRECAUTION OF INSTALLATION ASSEMBLY NOTE: NOTE: See NOTE at the beginning of this section. Before assembling, wash each part in fluid Adjust clearance between booster piston rod recommended to use for the car. and primary piston with special tool (See page 1) Assemble secondary piston as shown below.
Page 416: Brake Booster
19-5. BRAKE BOOSTER DISASSEMBLY REMOVAL 1) Take out fluid from master cylinder with a syringe or such. 2) Disconnect 2 brake pipes from master cylinder and remove master cylinder from booster. 3) Disconnect vacuum hose from booster. 4) Disconnect push rod clevis from brake pedal arm.
Page 417 3) Set booster to special tool (A) as shown. Make match marking NOTE: When setting, check to be sure that booster vacuum check valve is not in faulty contact with base of special tool. Tighten 2 nuts on upper part of special tool evenly to specified torque.
Page 418 with fingers. Booster air valve assembly Fig. 19-74 11) Remove oil seal from booster No. 2 body with special tools as shown. NOTE: Fig. 19-72 Removed oil seal must not be reused. 9) Remove diaphragm from pressure plate. NOTE: Don’t use screwdriver or any other tool for removal.
Page 419 INSPECTION Inner Parts NOTE: After disassembly, soak all metal parts in ethyl alcohol. Wipe rubber diaphragm and plastic parts with a clean cloth. Use ethyl alcohol damped cloth to wipe out heavy dirt Application of much ethyl alcohol especially to rubber parts is prohibited.
Page 420 BOOSTER INSPECTION TABLE Part Inspect For Corrective Action Cracks, distortion or damage. Replace. 1. Booster piston 2. Air valve ass’y Damaged or worn seal surfaces. Replace. (Control valve spring) Damage or wear. Replace. 3. Reaction disc 4. Diaphragm and boot Damage.
Page 421 ASSEMBLY 3) Compress air valve assembly and insert valve stopper key. NOTE: See NOTE at the beginning of this section. NOTE: Be sure to use silicon grease wherever appli- Be sure that valve assembly is in piston “A” cation of grease is instructed during assembly. as indicated in figure.
Page 422 2. Diaphragm aligning markings made before disassembly. 3. Pressure plate Holding No. 2 body with upper plate (special tool) as shown, torque 2 nuts equally to specification. Check all around booster No. 2 body to make sure kg-m lb-ft that diaphragm is seated Special tool nuts securely in its outer tightening torque...
Page 423 INSTALLATION 13) Remove booster from special tool and install push rod clevis so that below measure- NOTE: ment “A” is obtained and torque nut to See NOTE at the beginning of this section. specification. Adjust clearance between booster piston rod and master cylinder piston with special tool.
Page 424 19-6. PARKING BRAKE Fig. 19-6-1 19-38...
Page 425 19-7. BRAKE PIPES AND HOSES NOTE: Be sure to install brake flexible hose E-ring INSTALLATION REMOVAL AND into hose groove. 1) Take out fluid with a cyringe or such. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
Page 426 B-way joint Clamp Upper side View from arrow @ “A” From master cylinder From master cylinder P & B valve (Primary side) (Secondary side) Fuel pipe Body side bracket Hitch lug “B” of brake pipe clamp to groove “A” of body side bracket and fix clamp to bodv side bracket with its screw.
Page 427 Clamp Brake pipes (Right Install brake pipe to When installing backing plate Up side wheel cylinder pro- Up side axle housing, apply onto perly using care for SEALING COMPOUND 366E its installing posi- to mating sur- tion. faces of both parts. Brake backing plate Brake pipe cylinder...
Page 428 19-8. MAINTENANCE SERVICE FILL RESERVOIR ROAD TESTING BRAKES CAUTION: Brakes should be tested on dry, clean, smooth Do not use shock absorber fluid or any and reasonably level roadway which is not other fluid which contains mineral oil. Do crowned. Road test brakes by making brake not use a container which has been used for applications with both light and heavy pedal mineral oil or a container which is wet...
Page 429 EXCESSIVE PEDAL TRAVEL CHECK BRAKE PEDAL FREE HEIGHT ADJUSTMENT if brake pedal 1) Start the engine. Brake pedal height is normal 2) Depress brake pedal a few times. as high as clutch pedal. has been 1) When booster push rod clevis 3) With brake pedal depressed with approximate- ly 30 kg (66 Ibs) load, measure pedal arm to reinstalled, it is important that measurement...
Page 430 DISC INSPECTION BRAKE HOSE AND PIPE INSPECTION Inspect disc periodically according to mainte- Hose nance schedule. The brake hose assembly should be checked for For more information, refer to p. 19-17. road hazard damage, for cracks and chafing of outer cover, for leaks and blisters. A light and REAR BRAKE SHOE &...
Page 431 2) Parking brake lever stroke adjustment BRAKE PEDAL PLAY INSPECTION a) If parking brake lever stroke was found out of Pedal play should be within below specification. specification when checked as described on If out of specification, check stop light switch the previous page, adjust parking brake cable.
Page 432 BLEEDING BRAKES 1. Plug cap See-through tube 2. Vinyl tube NOTE: 3. Container Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. With this vehicle, air bleeding is required at four places: right and left front wheels, P &...
Page 433 INSPECT BOOSTER OPERATION 5) Repeat this operation until there are no more air bubbles in hydraulic line. There are two ways to perform this inspection, 6) When bubbles stop, depress and hold brake with and without a tester. Ordinarily, it is possi- pedal and tighten bleeder plug.
Page 434 4) If pedal travel doesn’t change, air tightness isn’t obtained. Fig. 19-8-19 Check Air Tightness Under Load 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal 1 St, 2nd. 3rd depressed. NO GOOD Fig. 19-8-17 NOTE: If defective, inspect vacuum lines and sealing parts, and replace any faulty part.
Page 435 19-9. TORQUE SPECIFICATION Tightening torque Fastening parts kg-m lb-ft 1. Brake caliper holder bolt 40 - 60 4.0 - 6.0 29.0 - 43.0 2. Brake carrier bolt 70 - 100 7.0 - 10.0 51 .O - 72.0 3. Brake caliper guide pin 25 - 30 18.5 - 21.5...
Page 436: Body Service
SECTION 20 BODY SERVICE CONTENTS 20-1. FRONT DOOR ......... . .20-2 20-2 DESCRIPTION .
Page 437: Front Door
20-1. FRONT DOOR DESCRIPTION 1. Door open stopper band garnish 2. Door open stopper band 3. Trim protector 4. Front door panel 5. Door trim clip 6. Door lower hinge 7. Door upper hinge 8. Door weatherstrip 9. Door trim board 10.
Page 438 REMOVAL 4) Loosen two screws securing the stopper band, and take off the band. Door Window Glass 5) Remove door trim board. 1) Remove door window regulator handle. Fig. 20-1-5 Fig. 20-1-2 6) Remove the door water proof film. 2) Remove inside handle case. Fig.
Page 439 8) Remove 2 screws securing the door window regulator roller holder (lower side). Fig. 20-1-10 2) Remove 4 screws securing the window regula- Fig. 20-1-8 tor. 9) Take out the glass. Fig. 20-1-11 Fig. 20-1-9 3) Remove the window regulator. 10) Detach glass from bottom channel.
Page 440 INSTALLATION Door Window Glass or Regulator Reverse the removal sequence to install the door window glass or regulator. However, be careful of the following points. [Door window regulator] When installing door window regulator to door panel, apply multi-purpose grease to the sliding parts.
Page 441 When it is hard to raise and lower the door glass, the glass may be slanting towards the door sash. If this is the case, loosen the screws fastening the door regulator roller holder, move the holder up and down so that the glass and sash are brought in parallel.
Page 442 [Door lock striker] [Door lock inside handle] Increase or decrease striker spacers fitted in “A” Fit the inside handle, adjusting the clearance position behind the striker to adjust dimensions between inside open lever @I and outside open to below values as shown in below figure. lever @I of the door lock to 0 - 2 mm (0 - After adjustment, check the difference in level 0,079 in) by moving the inside handle remote...
Page 443 20-2. WINDSHIELD The windshield glass is bonded to the window panel (body) with weatherstrip in position. When replacing the glass, it is necessary to perform correct operation and adhesive selection so that adequate bonding strength can be obtained. 2. Windshield weatherstrip Fig.
Page 444 I N S T A L L A T I O N The installation sequence is shown in the Block Diagram below. Drying Solvent cleaning Drying Solvent 10 -11 Solvent Bonding Installation Ooze Temporary wiping cleaning (Cord drawing) agent installation cleaning filling When installing the glass-and-weatherstrip...
Page 445 7) Fill bonding agent completely between the glass and the weatherstrip and also between the window panel (body) and the weather- strip. To confirm this condition, bonding agent should be oozed out of position. 1. Windshield glass 2. Windshield weatherstrip 3.
Page 446 20-3. BACK DOOR (APPLICABLE TO HARD TOP VEHICLE) 9. Outside handle 2. Door balancer 10. Outside handle rod 3. Back window glass 11. Back door lock 4. Window weatherstrip 12. Control rod 5. Door upper hinge 13. Door lock key set 6.
Page 447 Door Lock Stricker Handling of Back Door Balancer. After reinstalling the door lock striker or door WARNING: lock which was once removed, adjust dimension Handle the balancer carefully. Do not “C” in Fig. 20-3-3 to 1.0 mm (0.04 in) by mov- scar or scratch the exposed surface of ing the striker up and down.
Page 448 20-13...
Page 449 SECTION 21 BODY ELECTRICAL EQUIPMENT CONTENTS 21-1. COMBINATION METER ........21-2 HEAD LIGHT .
Page 450 21-2...
Page 451 11. 4WD light 50,000 mile, 80,000 mile and 12. Noise’suppressor 100,000 mile sensor switch Wire color 13. Turn signal pilot light (RI Turn signal pilot light (Lb Orange 14. Beam pilot light Cancel switch 15. Fuel level meter Seat belt warning light White 16.
Page 452 21-2. HEAD LIGHT WIRING CIRCUIT Lighting switch Dimmer & passing switch Meter pilot light (Beam) Headlight Headlight To license light, illumination light, meter illumination light To right side position & tail light and side marker RIG Wire color lights B ..Black To left side position 81 .
Page 453 HEADLIGHT INSPECTION Lighting (Low beam, High beam, Passing) 2. Mounting Dirt and cracks on lenses Main beam axis direction and brightness HEADLIGHT BEAM SETTING (STANDARD PROCEDURE) Before setting the headlight beams, adjust air pressures of four tires to a specified value respectively. Move the vehicle up and down by hand to settle its attitude.
Page 454 MAINTENANCE (1) Headlight adjustment There are two screws (1)and (2)which can be used for adjustment. Use these screws to adjust the headlight position for the vertical and horizontal alignment of each beam. Fig. 21-6 Switch connector (2) Head light dimmer switch Using circuit tester, check each circuit for continuity by putting tester probe pins to the terminals shown in Fig.
Page 455 21-3. TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT CIRCUIT DESCRIPTION 1 Right turn signal 8. Green/Yellow 15. Meter pilot light (Right) 9. White/Yellow 16. Meter pilot light (Left) 3. Battery 10. Yellow 17. White/Green 4. Main switch 11. Yellow/Blue 5. Fuse 12.
Page 456 INSPECTION 1) Trouble diagnosis Symptom Possible cause 1. Lights will not come on in either left or Fusible link is blown off. right group of light. 2. Hazard light comes on but turn signal Open circuit (due to poor point contact) in turn lights will not.
Page 457 21-4. WINDSHIELD WIPER MOTOR CIRCUIT DESCRIPTION The circuit is designed so that, when the Wiper Switch is turned “OFF”, the blade will automatically return to the horizontal position. In Fig. 21-11, when the Wiper Switch is turned “ON” while the Main Switch is “ON”, current is supplied to the Wiper Motor from the Battery, the motor rotates and the blade moves.
Page 458 3-speed type Wire color : Black BI : Blue - - m - - e - - - - J Battery 2. Main switch 3. Fuse box 4. Wiper motor 5. Wiper & washer switch 6. Washer motor Fig. 21-12 MAINTENANCE 1) Wiper trouble diagnosis c) Break in wiper motor armature or poor...
Page 459 21-5. WATER TEMPERATURE METER 3) Automatic stop action test Connect yellow terminal of motor to positive AND GAUGE The water temperature meter is located in the between Blue/White (Blue/Black) and Blue combination meter and its gauge unit on the terminals to see if motor output shaft comes inlet manifold.
Page 460 21-6. FUEL LEVEL METER AND GAUGE [Gauge unit] Warm up gauge unit. Thus make sure its resis- tance is decreased with increase of temperature. The fuel level meter circuit consists of the fuel Temperature and resistance relationship can be level meter installed inside the combination plotted in a graph as shown below.
Page 461 21-7. BRAKE WARNING LAMP [Gauge unit] Use ohmmeter to confirm that level gauge unit The brake warning lamp system consists of the changes in resistance with change of the float brake fluid level switch installed to the master position. Float position-to-resistance relation- cylinder reservoir and the lamp inside the ship can be plotted in a graph as shown below.
Page 462 INSPECTION 21-8. OIL PRESSURE LAMP [Brake fluid level switch] consists The oil pressure lamp circuit of the oil Use ohmmeter to check switch for resistance pressure switch installed to the cylinder block and continuity. and the lamp (warning lamp) inside the combi- If found defective, replace switch.
Page 463 21-9. 4 WHEEL DRIVE LAMP 21-10. SEAT BELT WARNING LAMP/ BUZZER The 4 wheel drive lamp circuit consists of the 4 The seat belt warning lamp/buzzer circuit is a wheel drive indicator lamp switch installed to system to light and sound the lamp and buzzer the transfer and the lamp inside the combination respectively for several seconds, urging the meter.
Page 464: Illumination Controller
21-13. REAR DEFOGGER (OPTIONAL 21-11. MAIN SWITCH KEY WARNING FOR HARD TOP MODEL) BUZZER The Defogger circuit for the rear window glass The main switch key warning buzzer circuit is a heating wires is as follows: system to sound the buzzer if the driver leaves the car with the main switch key inserted in place, urging him to take it out of place.
Page 465 DEFOGGER WIRE b) Set the voltmeter negative (-) lead with a foil strip to the heat wire positive terminal NOTE: When cleaning the rear window glass, use a end to then move it along the wire to the dry cloth to wipe it along the wire direction. negative terminal end.
Page 466 21-14. FUSE BOX The fuses in the fuse box is wired as follows. Fuse box Head light (R) Head light (L) Battery Horn, Interior light, Door warning buzzer, ctock (optional) Stop light Hazard warning light - W / G I Main switch Cigarette lighter (optional),...
Page 467 21-15. WIRING HARNESS ROUTING When reinstalling wire harness, be careful for the following. When doing wiring harness related work, make always sure to disconnect battery negative cable from battery. Clamp wire harness securely at prescribed positions. Try to route wire harness so as to avoid contact with other parts as much as possible. Use special care not to let it contact sharp edges of body or other parts.
Page 468 Fig. 21-38 21-20...
Page 469 1. Wire harness No. 2 2. Side marker light 3. Head light 4. Earth 5. Washer motor 6. To oil pressure gauge 7. To combination light Fig. 21-39 Instrument Panel Wiring 1. Wire harness No. 1 15. Door warning buzzer 8.
Page 470 8. Defroster hose 1. Instrument panel 9. Brake pedal 2. Steering column 10. Clutch pedal 3. Steering column holder 11. Clamp lead wires of ignition switch and combination switch, 4. Wiring harness No. 1 using care not to allow lead wires to contact the edge of steer- 5.
Page 471: Service Data
SECTION 22 SERVICE DATA CONTENTS 22-1 22-1. SPECIFICATIONS........22-4 22-2.
Page 472 Models Convertible/Hardtop ITEM Tail/Brake light Side marker light License plate light Back-up light Interior light Meter pilot light 0.5 mm2 (fusible link) Main fuse Fuse box POWER TRANSMISSION Dry, single disc Clutch type Transmission type 3.727 Final reduction ratio 3.652 1.947 1.423 Gear ratios...
Page 473 Convertible/Hard Top WHEEL AND SUSPENSION Tire size: front and rear front 140 kPa (1.40 kg/cm’, 20 psi) Tire pressure 140 kPa (1.40 kg/cm’, 20 psi)-unladen rear 180 kPa (1.80 kg/cm*, 26 psi)-laden Leaf spring front Suspension type rear Leaf spring STEERING Turning radius 5.1 m (16.7ft)
Page 474 22-2. SERVICE DATA ENGINE Standard Service Limit Item 12.0 kg/cm2 (170.0 psi)/400 14.0 kg/cm2 (199.0 psi)/400 r/min (rpm) r/m in (rpm) COMPRESSION PRESSURE Difference between 1 .O kg/cm2 (14.2 psi)/400 r/n cylinders Cold Inlet (0.0051 - 0.0067 in.) (When cooi- ant temper- ature is 15 Exhaust...
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Page 482 Prepared by MOTOR Technical Department Automobile Service Division 1st Ed. November, 1987 Printed in Japan...

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