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Suzuki Manuals
Automobile
Swift SF413
Service manual
Table Of Contents - Suzuki SF413 Service Manual
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User manual
(558 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
Table Of Contents
2
Table Of Contents: General Information
4
Vehicle Identification
4
Engine And Transmission Identification
5
Metric Fasteners
6
Fastener Strength Identification
6
Bolt Strength Markings
6
Standard Tightening Torque
7
Vehicle Lifting Points
8
Precaution Against Tipping
8
Front/Rear Support Locations
8
Table Of Contents: Maintenance And Lubrication
10
Maintenance Schedule: Normal Condition
11
Maintenance Recommended Under Severe Driving Conditions
13
Water Pump Belt Inspection And Replacement
14
Engine Oil And Filter Change
14
Engine Maintenance Service
14
Engine Oil Capacity
15
Cooling System, Hoses And Connections Inspection
16
Engine Coolant Change
16
Exhaust Pipes And Mountings Inspection
17
Wiring Harness And Connections Inspection
17
Ignition System Maintenance
18
Spark Plugs Inspection And Replacement
18
Plug Specification
18
Distributor Cap And Rotor Inspection
18
Ignition Wiring Inspection And Replacement
19
Carburetor Choke System Inspection
19
Air Cleaner Element Replacement
19
Air Cleaner Element Inspection
19
Engine Idle Speed And Idle Mixture Inspection
20
Fuel Tank, Cap Gasket And Fuel Lines Inspection
20
Fuel Filter Replacement
20
Emission Control System Maintenance
21
Brake Maintenance
21
Brake Hoses And Pipes Inspection
22
Brake Fluid Inspection And Change
22
Brake Lever And Cable Inspection
22
Brake Pedal Inspection
22
Chassis And Body Maintenance
23
Clutch Pedal Free Travel Inspection
23
Tire And Wheel Disc Inspection
23
Drive Axle Boot, Suspension System Inspection
23
Steering System Inspection
24
Transmission Oil Inspection And Change
24
Automatic Transmission Inspection
25
Door Hinges, Gear Shift Control Lever And Shaft Lubrication
25
Final Inspection: Body Parts Operation
25
Owner Inspections And Services: Before Operating Your Car - Outside
26
Owner Inspections And Services: Before Operating Your Car - Inside
26
Owner Inspections And Services: Before Operating Your Car - Under Hood
27
Owner Inspections And Services: While Operating Your Car
28
Recommended Fluids And Lubricants
29
Table Of Contents: Heater And Ventilation
30
Heater Overview
31
Heater Control Operation
32
Heater Diagnosis
33
On Car Service: Heater Blower Motor Overview
33
On Car Service: Heater Blower Motor Removal, Installation
34
On Car Service: Heater Blower Motor Resistor Removal, Inspection, Installation
34
On Car Service: Heater Blower Motor Switch Removal, Inspection, Installation
35
On Car Service: Heater Control Cables Removal, Installation
36
On Car Service: Heater Unit Overview
37
On Car Service: Heater Unit Removal, Installation
38
Table Of Contents: Bumpers And Sheet Metal
39
Front Bumper Removal, Installation
40
Rear Bumper Removal, Installation
41
Hood Removal, Adjustment
42
Front Fender Removal, Installation
43
Removing Small Light
43
Replacement Fender
43
Steering, Suspension, Wheel And Tires: Table Of Contents
44
Steering, Suspension, Wheel And Tires: General Diagnosis
45
Tire Diagnosis
49
Irregular And/Or Premature Wear
49
Wear Indicators
49
Radial Tire Waddle
49
Lead Diagnosis
50
Radial Tire Lead
51
Vibration Diagnosis
51
Front End Alignment: Table Of Contents
52
Preliminary Checks Prior To Adjusting Front Alignment
53
Toe Adjustment
53
Camber And Caster Adjustment
53
Steering Angle
54
Manual Rack And Pinion: Table Of Contents
55
General Description Of Steering System
56
Exploded View Of Manual Rack And Pinion
57
On-Car Service: Lubrication
57
Remove And Install Tie Rod End
58
Remove And Install Manual Rack And Pinion Assembly (Steering Gear Case)
59
Remove And Install Rack Boot/Tie Rod
61
Remove And Install Steering Rack Plunger
63
Remove And Install Steering Pinion
64
Remove And Install Steering Rack
65
Remove And Install Pinion Bearing
66
Remove And Install Rack Bushing
67
Rack And Pinion Inspection: Steering Rack Boots
68
Rack And Pinion Inspection: Steering Shaft Joint
68
Rack And Pinion Inspection: Tire Rod End/Boots
68
Rack And Pinion Inspection: Rack Plunger
68
Rack And Pinion Inspection: Steering Pinion/ Bearing
69
Rack And Pinion Inspection: Steering Rack/Bushing
69
Rack And Pinion Inspection: Steering Wheel
69
Recommended Torque Specifications
70
Required Service Materials
70
Manual Rack And Pinion: Special Tools
71
Steering Wheel And Column: Table Of Contents
72
Steering Wheel And Column Overview
73
Remove And Install Sterring Wheel
74
Remove And Install Combination Switch
75
Remove And Install Steering Column
76
Steering Column Assembly
76
Remove And Install Steering Lock
78
Remove And Install Steering Shaft Lower Joint
79
Checking Steering Column For Accident Damage
80
Checking Tilt Steering Column
81
Recommended Torque Specifications: Tilt Steering Column
81
Front Suspension: Table Of Contents
82
Front Suspension General Description And Overview
83
Remove And Install Stabilizer Bar And/Or Bushings
85
Remove And Install Strut Damper Assembly
86
Disassembly And Assembly Strut Damper
87
Remove And Install Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race
89
Remove And Install Suspension Arm/Bushing
91
Remove And Install Knuckle/Bearing
93
Remove Oil Seals, Snap Ring And Wheel Bearing
95
Install Oil Seals, Snap Ring And Wheel Bearing
95
Front Suspension Inspection: Stabilizer Bar And/Or Bushing
96
Front Suspension Inspection: Strut Damper
96
Front Suspension Inspection: Suspension Arm/Arm Bracket/Knuckle Arm
97
Front Suspension Inspection: Suspension Arm Joint
97
Front Suspension Inspection: Suspension Arm Bushing
97
Front Suspension Inspection: Wheel Disc, Nut And Bearing
97
Front Suspension Inspection: Recommended Torque Specifications
98
Front Suspension Inspection: Required Service Materials
98
Rear Suspension: Table Of Contents
100
Rear Suspension: General Description
101
Remove And Install Control Rod
102
Remove And Install Coil Spring And Suspension
104
Rear Strut Assembly Remove And Install
107
Rear Suspension Knuckle Remove And Install
109
Wheel Bearing Remove And Install
112
Rear Suspension Inspection
113
Strut Damper
113
Suspension Control Arm, Coil Spring And Knuckle Arm
113
Control Rod
113
Rear Suspension Fasteners
114
Wheel Disc, Nut And Bearing
114
Rear Wheel Alignment
115
Toe Setting
115
Toe Inspection And Adjustment
115
Wheels And Tires: Table Of Contents
118
Wheels And Tires: General Description
118
Wheel Maintenance
119
Matched Tires And Wheels
120
Inflation Of Tires
120
Tire Placard
120
Tire Rotation
121
Metric Lug Nuts And Wheel Studs
121
Wheel Removal
121
Tire Mounting And Demounting
122
Tire Repair
122
Balancing Wheels
122
Static Unbalance/Dynamic Unbalance Correction
122
General Balance Procedures
123
Wheels And Tires Recommended Torque Specifications
123
Front Drive Shaft: Table Of Contents
124
Front Drive Shaft: General Description
124
Left Side Shaft Removal On Floor
125
Left Side Shaft Removal On Lift
125
Removing Drive Shaft Nut
125
Detaching Suspension Arm From Knuckle/Snap Ring From Differential
125
Right Side Shaft Removal On Floor
126
Right Side Shaft Removal On Lift
126
Drive Shaft Disassembly
127
Drive Shaft Inspection
128
Center Shaft And Center Bearing Support Disassembly
128
Drive Shaft Reassembly
128
Center Shaft And Center Bearing Support Reassembly
131
Center Shaft And Center Bearing Support Installation
132
Center Shaft And Center Recommended Torque Specifications
132
Front Drive Shaft (Tripod Joint Type): Table Of Contents
134
Front Drive Shaft (Tripod Joint Type): General Description
134
Front Drive Shaft (Tripod Joint Type): Removal
135
Front Drive Shaft Disassembly
135
Front Drive Shaft Inspection
135
Brakes: Table Of Contents
138
Brakes: General Description
139
Disc Brake Caliper Assembly
140
Front Caliper Assembly
140
Caliper Operation
141
Clearance Correction
141
Drum Brake Assembly: General Description
142
Rear Brake Operation
143
Rear Brake Clearance Correction
143
Master Cylinder Assembly: General Description
145
Master Cylinder Assembly: Operation
145
Booster Assembly General Description And Overview
147
Booster Operation
148
Vacuum Booster Assembly
148
When Foot Brake Pedal Is Not Depressed
148
When Foot Brake Pedal Is Depressed
149
When Foot Brake Pedal Is Released
149
Diagnosis
150
Road Testing Brakes
150
Substandard Or Contaminated Brake Fluid
150
Break Fluid Leaks
150
Brake Diagnosis Chart
151
Break Pedal Free Height Adjustment
153
Excessive Pedal Travel Check
153
Stop Light Switch Adjustment
153
Rear Brake Shoe Inspection
154
Brake Pedal Play Inspection
154
Rear Drum Brake Shoe Adjustment
154
Master Cylinder Inspection
154
Disc Inspection
155
Pad Lining Inspection
155
Parking Brake Inspection And Adjustment
155
Flushing Brake Hydraulic System
156
Bleeding Brakes
156
Brake Hose And Pipe Inspection
158
Brake Fluid Level Inspection
158
Remove And Install Front Brake Hose/Pipe
159
Remove And Install Rear Brake Hose/Pipe
160
Precaution For Installation: Rear Brake Hose/Pipe
160
Remove And Install Parking Brake Lever
161
Remove And Install Parking Brake Cable
162
Remove And Install Pad (Shoe And Lining)
165
Remove And Install Caliper Assembly
166
Remove And Install Seal, Piston, Dust Boot And Bleeder Screw
167
Remove And Install Disc
169
Disc Brake Inspection
170
Inspect Brake Pad Lining
170
Inspect Brake Caliper Inner Parts
170
Inspect Brake Disc
171
Remove And Install Brake Drum
172
Remove And Install Brake Shoe
176
Remove And Install Wheel Cylinder
177
Remove And Install Brake Back Plate
178
Brake Drum And Components Inspection
180
Inspect Brake Drum
180
Inspect Brake Shoe And Lining
180
Inspect Wheel Cylinder
181
Inspect Springs
181
Inspect Brake Strut
181
Inspect Parking Shoe Lever
181
Master Cylinder Repair
182
Remove And Install Master Cylinder Reservoir
182
Remove And Install Master Cylinder Assembly
183
Disassembly And Assembly Of Master Cylinder
184
Inspect Master Cylinder
185
Master Cylinder: Fill Reservoir
185
Remove And Install Booster
186
Disassemble And Assemble Booster
187
Brake Booster Inspection And Adjustment
193
Inspect Booster Inner Parts
193
Inspect/Adjust Clearance Between Booster Piston Rod And Master Cylinder Piston
193
Inspect Booster Operation
194
Inspection Without Tester
194
Check Operation
195
Check Air Tightness Under Load
195
Booster Inspection Table
196
Booster Recommended Torque Specifications
197
Booster: Requires Service Materials
198
Booster: Special Tools
199
Engine: Table Of Contents
200
Engine: Statement On Cleanliness And Care
200
General Information On Engine Service
201
Engine: Hose Connection
202
Engine Diagnosis
203
Engine Mechanical: Table Of Contents
210
Engine Construction: General Description
211
Engine Lubrication
212
Cylinder Head And Valve Train
213
Cylinder Block
213
Crankshaft And Main Bearings
213
Piston, Rings, Piston Pins And Connecting Rods
213
Compression Check
214
Engine Vacuum Check
214
Oil Pressure Check
215
Valve Lash Specifications
216
Valve Lash Checking And Adjusting Procedures
216
Air Cleaner Element
217
Air Cleaner Assembly
218
Cylinder Head Cover: Remove Or Disconnect
219
Cylinder Head Cover: Install Or Connect
219
Carburetor And Intake Manifold: Remove Or Disconnect
220
Carburetor And Intake Manifold: Install Or Connect
221
Exhaust Manifold Remove Or Disconnect
222
Exhaust Manifold Install Or Connect
222
Remove Or Disconnect Timing Belt And Belt Tensioner
223
Removing Fender Apron Extension
223
Crankshaft Pulley And Pulley Bolts
223
Timing Belt And Belt Tensioner Inspection, Installation, Connection
224
Locking Crankshaft For M/T And A/T Models
224
Removing The Timing Belt
224
Loosening Timing Belt Pulley Bolt
224
Tensioner Installation
225
Valve Adjusting Screw And Lock Nut
225
Timing Marks
225
Installing Timing Belt
226
Tensioner Bolt And Stud
226
Tightening Pulley Bolt
227
Oil Pan And Oil Pump Strainer: Remove And Disconnect
227
Oil Pan And Oil Pump Strainer: Clean
227
Oil Pan And Oil Pump Strainer: Install Or Connect
227
Applying Sealant To Oil Pan
228
Oil Pump: Remove Or Disconnect
228
Oil Pump: Disassemble
229
Oil Pump: Measure
230
Oil Pump: Inspect
230
Oil Pump: Install Or Connect
230
Oil Pump: Assemble
230
Oil Seal Guide Installation
231
Installing Rubber Seal
231
Cutting Edge Of Gasket
231
Oil Pump Bolts
231
Installing Guide, Key And Pulley
232
Rocker Arms, Rocker Arm Shafts And Camshaft Overview
233
Rocker Arms, Rocker Arm Shafts And Camshaft Remove And Disconnect
233
Rocker Arm Shaft Screws Removal
233
Adjusting Screw And Lock Nut
233
Rocker Arm Shaft Removal
234
Camshaft Removal
234
Adjusting Screw And Rocker Arm
234
Locking Camshaft
234
Rocker Arm Shaft Runout
235
Measuring Runout
235
Measuring Cam Height
235
Measuring Shaft Dia. And Arm I.d.
235
Camshaft Runout
236
Camshaft Runout Measurement
236
Camshaft Journal Wear
236
Camshaft Journal Dia. Measurement
236
Journal Bore Dia. Measurement
237
Pulley Pin, Slot And Pulley Bolt
237
Camshaft Installation
237
Rocker Arm Shafts Installation
237
Rocker Arms, Springs, Rocker Arm Shafts And Screws Installation
238
Valves And Cylinder Head: Remove Or Disconnect
239
Valve
239
Special Tool (Valve Lifter) Installation
240
Special Tool (Forceps) And Valve Cotters
240
Valve Stem Oil Seal Removal
240
Valve Guide Removal
240
Valve Stem End Deflection Measurement
241
Valve Head Thickness
241
Radial Runout Measurement
242
Valve Seating Contact Width
242
Valve Seat Cutting
243
Valve Seat Angles For Exhaust Valve
243
Measuring Surface Of Intake Manifold Seating Face
244
Surface Measurement
244
Measuring Surface Of Exhaust Manifold Seating Face
244
Valve Springs
244
Measuring Free Length Of Spring
245
Measuring Spring Squareness
245
Measuring Spring Preload
245
Valve Guide Assembly
245
Reaming Valve Guide Bore
246
Valve Seal Installation
246
Valve Installation
246
Installing Valve Spring
247
Valve Cotters Installation
247
Cylinder Head Gasket Installation
247
Tightening Sequence Of Cylinder Head Bolts
247
Pistons, Piston Rings, Connecting Rods And Cylinders: Remove Or Disconnect
248
Pistons, Piston Rings, Connecting Rods And Cylinders: Clean
249
Pistons, Piston Rings, Connecting Rods And Cylinders: Disassembly
249
Pistons, Piston Rings, Connecting Rods And Cylinders: Inspect
249
Pistons To Be Measured
249
Measuring Cylinder Bore With Cylinder Gauge
250
Measuring Piston Diameter With Micrometer
250
Measuring Ring Groove Clearance
250
Piston Pin, Piston Rings
251
Connecting Rod
251
Crank Pin And Connecting Rod Bearings
251
Measuring Piston Ring End Gap
251
Rod Bearing Clearance
252
Piston, Piston Rings, Connecting Rods And Cylinders: Assembly
253
Piston-To-Cylinder Orientation
253
Fitting Connecting Rod To Piston
253
Fitting Piston To Special Tool
254
Installing Piston Pin
254
Installing Piston Rings
254
Line Marked On Driver Handle
254
Piston Ring End Gaps Positions
255
Piston, Piston Rings, Connecting Rods And Cylinders: Install Or Connect
255
Direction Of Arrow Mark On Piston Head
255
Installing Bearing Cap
255
Unit Repair Overhaul
257
Engine Assembly Dismounting
257
Engine Assembly Remounting
258
Main Bearings, Crankshaft And Cylinder Block Overview
260
Main Bearings, Crankshaft And Cylinder Block Remove And Disconnect
261
Inspecting Crankshaft Runout
261
Out-Of-Round And Taper Of Journals
262
Main Bearings General Information
262
Inspecting Main Bearing Clearance
262
Selection Of Main Bearings
263
Stamped Alphabets On Cylinder Block
264
Paint On Standard Bearing
264
Paints On Undersize Bearing
265
Rear Oil Seal
266
Flywheel (M/T Model Only)
266
Distortion Of Gasket Surface
266
Honing Or Reboring Cylinders
266
Installing Thrust Bearings
267
Installing Main Bearing Caps
268
Engine Cooling: Table Of Contents
273
Engine Cooling System Circulation
274
Radiator Cap
275
Water Reservoir Tank
275
Water Pump
276
Thermostat
276
Cooling Fan
277
Water Temp Gauge
277
Thermo Switch
277
Engine Cooling Diagnosis
278
Engine Cooling Maintenance
278
Coolant
278
Anti-Freeze Proportioning Chart
278
Coolant Capacity
279
Coolant Level
279
Cooling System Service
280
Cooling System Flush And Refill
280
Installation Of Radiator Cap
280
Radiator Drain Plug
280
Water Pump Belt Tension
281
Coolant Draining
282
Cooling Water Pipes Or Hoses Removal
282
Thermostat Removal
282
Cooling Water Pipes Or Hoses Installation
282
Air Bleed Valve Of Thermostat
283
Checking Thermostat Valve Operation
283
Thermostat Installation
283
Water Pump Belt Removal
284
Water Pump Belt Installation
284
Fan Thermo Switch Removal, Installation, Inspection
284
Checking Fan Thermo Switch
284
Radiator Removal, Clean
285
Radiator Installation, Inspection
285
Water Pump Inspection, Installation
286
Engine Fuel: Table Of Contents
288
Fuel System Overview And General Description
288
Fuel Tank And Fuel Pump
289
Fuel Filter
289
Fuel Filler Cap
289
Fuel Filter Cap Cross-Section
289
Fuel Lines Inspection
290
Fuel Pipe Remove Or Disconnect
291
Fuel Pipe Install Or Connect
291
Installing, Removing Clamp
291
Detaching Clamp With Pipes
291
Fuel Filler Cap Removal And Replacement
292
Fuel Filter: Remove Or Disconnect
292
Fuel Filter: Install Or Connect
292
Fuel Tank Remove Or Disconnect
293
Disconnecting Couplers
293
Breather And Filler Hoses
293
Disconnecting Hoses
293
Fuel Tank Purging Procedure
294
Fuel Tank Install Or Connect
294
Fuel Level Gauge Remove Or Install
294
Fuel Pump Remove Or Install
295
Carburetor: Table Of Contents
296
Carburetor: General Description
297
Carburetor Scheme
298
Float System
299
Primary Slow System
299
Primary Main System
299
Secondary Main System
300
Secondary Slow System
300
Acceleration Pump System
301
Choke System
301
At Cold Engine Start
302
Immediately After Engine Start
303
Fast Idle Cam Opener Operation
303
Release Of Choke
303
Summary Of Choke System Operation
304
Idle Up System
305
Accelerator Cable Play
306
Float Level Inspection, Adjustment
306
Idle Speed And Idle Mixture
307
Idle Up (For Manual Transmission) Inspection
309
Idle Up (For Manual Transmission) Adjustment
309
Idle Up (For Automatic Transmission) Inspection
310
Idle Up (For Automatic Transmission) Adjustment
311
Choke System Inspection
311
Fast Idle
314
Secondary Diaphragm Inspection
315
Unloader System Inspection
315
Fuel Cut System Inspection
315
Accelerator Pump Inspection
316
Throttle Sensor (For Automatic Transmission) Inspection
317
Throttle Sensor (For Automatic Transmission) Removal
318
Throttle Sensor (For Automatic Transmission) Installation
318
Carburetor Removal And Installation
320
Carburetor Disassembly
321
Carburetor Cleaning
322
Carburetor Inspection
323
Carburetor Assembly
323
Float Chamber Cover
323
Bimetal Case
323
Ignition System: Table Of Contents
328
Ignition System: General Description
328
Ignition Circuit Diagram
329
Ignition Diagnosis
329
Power Supply For Ignition Coil
330
High Tension Cords
330
Checking Power Supply To Distributor
330
Measuring High Tension Cord Resistance
330
Spark Plugs
331
Ignition Coil
331
Checking Spark Plug Gap
331
Measuring Ignition Coil Resistance
331
Distributor: Centrifugal Advancer
332
Distributor: Vacuum Advancer
332
Ignition Timing
332
Distributor Components
333
Distributor Removal
334
Distributor Disassembly
334
Distributor Inspection
335
Checking Centrifugal Advancer
335
Distributor Reassembly
336
Distributor Installation
336
Aligning Camshaft To Tdc Compression
336
Aligning Distributor Coupling
337
Cranking System (0.8, 0.9, 1.0 Kw Type): Table Of Contents
338
Cranking System (0.8, 0.9, 1.0 Kw Type): Circuit
338
Cranking System (0.8, 0.9, 1.0 Kw Type): Starting Motor
338
Basic Cranking Circuit
339
Cranking System Specifications
339
Convertional Type Starting Motor
340
Reduction Type Starting Motor
341
Starting System Diagnosis
342
Cranking System (0.8, 0.9, 1.0 Kw Type) Dismounting And Remounting
343
Conventional Type Starting Motor
344
Magnetic Switch Assembly
344
Removing Magnetic Switch
344
Installing Magnetic Switch
344
Motor Assembly: Disassembly, Reassembly
345
Installing Overrunning Clutch
346
Installing Brush Holder
346
Installing Armature
346
Installing Commutator End Cap
346
Reduction Type Starting Motor Overview
347
Reduction System Disassembly Procedure
347
Reduction System Reassembly
348
Assembling Internal Gear
348
Inspection And Correction Of Armature
348
Checking Coil Ground
348
Checking Open Circuit
349
Checking Commutator Diameter
349
Checking Commutator Run-Out
349
Checking Mica Depth
349
Checking Yoke, Brush, Brush Holder
350
Checking Overrunning Clutch, Shaft And Bush
350
Cranking System (0.8, 0.9, 1.0 Kw Type) Performance Test
351
Cranking System (1.2 Kw Type): Table Of Contents
352
Cranking System (1.2 Kw Type) General Description
352
Cranking System (1.2 Kw Type) Diagnosis
353
Starter Motor Overview
353
Magnetic Switch Assembly: Removal And Installation
354
Motor Brush Removal
354
Armature Removal
355
Over-Running Clutch Removal
355
Armature Inspection And Correction
358
Ground Inspection And Correction
359
Plunger Inspection And Correction
359
Open Circuit Inspection And Correction
359
Brush Inspection And Correction
359
Brush Holder And Spring Inspection And Correction
360
Pinion And Over-Running Clutch Inspection And Correction
360
Armature Shaft Bearing Inspection And Correction
360
Magnetic Switch Inspection And Correction
361
Gears Inspection And Correction
361
Pull-In Coil Open Circuit Test
361
Pull-In/Hold-In Tests
362
Check Plunger Return
362
Charging System: Table Of Contents
363
Battery General Description
363
Electrolyte Freezing
364
Carrier And Hold-Down
364
Visual Inspection Of Battery
364
Care Of The Battery
364
Jump Starting In Case Of Emergency
366
Remove And Replace Battery
367
Battery Cables
367
Generator General Description And Overview
368
Generator Schematic
369
Generator Specifications
369
Generator Diagnosis
370
Faulty Indicator Lamp Operation
370
Undercharged Battery
370
Overcharged Battery
371
Generator Exploded View
372
Dismounting And Remounting Generator
373
Generator Disassembly
373
Removing Rectifier
373
Removing Pulley Nut
373
Generator Reassembly
374
Inspection And Correction: Rotor, Fan, Bearing, Starter, Rotor
375
Inspection And Correction: Rectifier
376
Inspection And Correction: Brush
376
Inspection And Correction: Condenser
376
Emission Controls: Table Of Contents
377
Emission Controls: General Description
377
Emission Controls For Vehicle With Manual Transmission: Scheme
378
Emission Controls For Vehicle With Automatic Transmission: Scheme
379
Positive Crankcase Ventilation Pcv System
380
Throttle Positioner System
381
Intake Air Temperature Control System
382
Exhaust Gas Recirculation (Egr With Egr Modulator) System
383
Pulse Air Control System
384
Fuel Cut System
385
Evaporative Emission Control System
386
Hot Idle Compensator (Hic)
387
Catalyst
387
Emission Controls Diagnosis
388
Pcv Hose Inspection
389
Checking Pcv Valve For Sticking
389
Checking Throttle Positioner System
390
Intake Air Temperature Control System Checking Procedure
391
Checking Hot Idle Compensator (Hic)
392
Checking Exhaust Gas Recirculation (Egr) System
392
Thermal Vacuum Switching Valve (Tvsv)
393
Checking Egr Modulator
394
Checking Pulse Air Control System
395
Checking Fuel Cut System
396
Checking Fuel Controller
396
Checking Evaporative Emission Control System
397
Exhaust System: Table Of Contents
399
Exhaust System: General Description
399
Exhaust System: Maintenance
400
Exhaust System: Recommended Torque Specifications
400
Manual Transmission: Table Of Contents
401
Manual Transmission: Construction And Servicing
401
Manual Transmission Cutaway
402
Manual Transmission Exploded View
403
Gear Shift Mechanism
404
Gear Shifting Pattern
404
Manual Transmission Diagnosis
406
Oil Change
407
Differential Side Oil Seal
407
Detaching Snap Ring From Differential
407
Gear Shift Control Components
409
Gear Shift Control Removal
410
Gear Shift Control Installation
410
Installing Shift Control Lever
411
Speedometer Driven Gear Removal
411
Dismounting Of Transmission Under Hood
412
Remounting Of Transmission
413
Disassembling Unit Fifth Gear
414
Sub Assembly Service: Right Case
418
Sub Assembly Service: Left Case
419
Input Shaft Assembly
420
Checking Gear And Synchonizer Ring
421
Assembling High Speed Sleeve And Hub
421
Press-Fitting Input Shaft R Bearing
421
Air Checking Oil Holes
421
Countershaft Assembly
423
Gear Shifter
426
Differential Assembly
428
Measuring Gear Thrust Play
429
Tightening Final Gear Bolts
429
Press-Fitting Differential Side Bearing
429
Assembling Unit: Differential To Left Case
430
Assembling Unit: Fifth Gears
431
Counter Shaft 5Th Gear
433
Tightening Countershaft Nut
433
Installing 5Th Speed Sleeve And Hub
433
Gear Shift And Select Shaft Assembly
434
Manual Transmission Recommended Torque Specifications
436
Automatic Transmission: Table Of Contents
440
Automatic Transmission: General Description
441
Automatic Transmission: Torque Converter
441
Planetary Gear Units
442
Direct Clutch Cross Section
443
Forward Clutch Cross Section
444
Second Brake
445
First And Reverse Brake
446
One-Way Clutch
446
Power Flow
447
Automatic Transmission Components Operation Chart
452
Oil Pressure Control System Diagram
453
Valve Body
454
Oil Pump
454
Manual Valve
455
Throttle Valve
455
Primary Regulator Valve
455
Secondary Regulator Valve
456
Cooler By-Pass Valve
456
1-2 Shift Valve
456
2-3 Shift Valve
457
Direct Clutch And 2Nd Brake Solenoids
457
Oil Circuit In "N" Range
458
Oil Circuit In "D" Or "2" Range
459
Oil Circuit In "D" Or "2" Range (2Nd Gear)
460
Oil Circuit In "D" Range (3Nd Gear)
461
Oil Circuit In "L" Range
462
Oil Circuit In "R" Range
463
Oil Cooling System
463
Electric Shift Control System
464
A/T Control Module (Controller)
464
Gear Shift Control System
464
Throttle Position Sensor (Tps)
464
Shift Lever Switch
465
Operation Of Direct Clutch And 2Nd Brake Solenoids
465
Speed Sensor
466
Automatic Shift Diagram
466
Transmission Unit: Systematic Troubleshooting
467
Stall Test And Line Pressure Test
468
Manual Road Test
468
Line Pressure Test And Road Test
469
Stall Test
470
Line Pressure Test
470
Road Test
471
Engine Brake Test
472
Shift Solenoid Check
473
Electric Shift Control System Wiring Diagram
474
Electric Shift Control System Self-Diagnosis
475
Electric Shift Control Systematic Troubleshooting
476
Shift Lever Switch Checking Procedure
479
Speed Sensor Checking Procedure
482
Shift Solenoid Checking Procedure
483
Throttle Valve Opening Signal Checking Procedure
484
Hot Level Check At Normal Operating Temperature
485
Cold Level Check At Room Temperature About 25C
486
Oil Cooler Hoses
486
Oil Pan Gasket Removal, Installation
487
Oil Strainer
488
Shift Solenoids Removal, Installation
488
Oil Pressure Control Cable Removal, Installation, Adjustment
489
Select Cable Components
490
Select Cable Components Removal
491
Select Cable Components Installation
491
Shift Lever Switch Removal And Installation
491
Shift Lever Switch Joint
492
Adjusting Shift Lever Switch Position
492
Manual Selector Removal
493
Manual Selector Installation
493
Manual Selector Components
494
Transmission Unit Repair Overhaul
495
Automatic Transmission Construction
495
Transmission Unit Dismounting
496
Transmission Unit Remounting
497
Cooler Line Flushing
498
Torque Converter Diagnosis
498
Transmission Unit Disassembly
499
Removing Torque Converter
499
Removing Solenoid Couplers
499
Removing Oil Filler Tube
499
Removing Oil Tubes
500
Removing Oil Pressure Control Cable
500
Removing Accumulator Pistons
500
Removing Lower Valve Body
500
Measuring Piston Rod Stroke
501
Removing Second Brake Piston
501
Removing Solenoid Wiring Harness
502
Removing Transmission Case Housing
502
Removing Second Brake Band Pin
502
Removing Oil Pump
502
Removing Direct Clutch And Input Shaft
503
Removing Front Planetary Gear
503
Removing Direct Clutch
503
Removing Front Planetary Ring Gear And Bearing
503
Removing One-Way Clutch Snap Ring
504
Removing Rear Planetary Ring Gear
504
Measuring 1St-Reverse Brake Clearance
504
Removing One-Way Clutch
504
Removing Snap Rings, Rear Cover
505
Removing 1St-Reverse Brake
505
Uncaulking Reduction Driven Gear Nut
505
Removing Reduction Driven Gear
506
Removing Output Shaft
506
Removing Countershaft
506
Removing Parking Lock Pawl
506
Removing Parking Lock Pawl Sleeve
507
Removing Snap Ring
507
Removing 1St-Reverse Brake Piston
507
Removing Return Spring Assembly
507
Clutch And Brake Parts Diagnosis
508
Sub Assembly Service
508
Oil Pump Components
509
Checking Gear-To-Body/Side/Tip Clearance
510
Installing Pump Body Oil Seal
511
Tightening Pump Cover Bolts
511
Direct Clutch Components
511
Measuring Direct Clutch Clearance
512
Removing Direct Clutch Piston
512
Removing Flange, Discs And Plates
512
Checking Check Ball Leakage
513
Installing Piston To Drum
513
Installing Spring Seat
513
Checking Piston For Movement
514
Forward Clutch Exploded View
515
Forward Clutch: Preliminary Check
515
Forward Clutch: Removal
515
Forward Clutch: Inspection
516
Forward Clutch: Installation
516
Installing Piston Return Springs
516
Removing Clutch Piston
516
Upper Valve Body Components
517
Lower Valve Body Components
518
Important Steps In Disassembly And Reassembly Of Valve Bodies
519
Installing Four Steel Balls
519
Installing Upper Valve Body Bolts
519
Countershaft And Output Shaft
520
Countershaft Bearings Removal
520
Countershaft Bearings Installation
521
Output Shaft Bearings Removal
521
Output Shaft Bearings Installation
522
Differential Gear Components
523
Differential Gear Disassembly
524
Differential Gear Adjustment And Reassembly
524
Differential Gear Assembly
525
Thrust Bearings And Races
526
Planetary Gears And Related Parts
527
Second Brake Components
528
Installing 2Nd Brake Piston And Piston Cover
528
Manual Shift Shaft
529
Installing Manual Shift Shaft And Manual Detent Spring
529
Upper And Lower Nuts
530
Installing Lock Pawl Shaft And Lock Pawl Spring
530
Installing Parking Lock Pawl Sleeve
530
Installing 1St-Rev Brake Piston
530
Installing Snap Ring, Output Shaft
531
Tightening Driven Gear Nut
531
Installing Countershaft
531
Caulking Driven Gear Nut
532
Searing Output Shaft In Rear Cover
532
Installing Discs, Plates And Flange
533
Installing Damper Plate
533
Measuring 1St-Reverse Brake Clutch Clearance
533
Checking 1St-Reverse Brake Piston Movement
534
Installing Rear Planetary Ring Gear Bearing
534
Checking Free Rotation Of One-Way Clutch
534
Installing Rear Planetary Ring Gear
534
Installing Rear Planetary Thrust Washers
535
Installing One-Way Clutch
535
Checking Rear Planetary Gear Rotation
535
Installing Rear Planetary Gear Assembly
535
Installing One-Way Clutch Race Snap Ring
536
Installing Sun Gear Assembly
536
Installing Sun Gear Pin And Thrust Washer
536
Installing Front Planetary Gear Bearing
536
Installing Ring Gear Races And Bearing
537
Installing Front Planetary Gear Assembly
537
Installing Front Planetary Ring Gear Assembly
537
Installing 2Nd Brake Band
538
Installing Input Shaft Seal Rings
538
Checking Output Shaft Seal Ring
538
Installing Direct Clutch Washer
538
Assembling Direct Clutch And Input Shaft
539
Installing Input Shaft And Direct Clutch
539
Installing Ring Gear Bearing
539
Installing Gasket And Case Housing
540
Measuring Distance Between Case End Surface And Input Shaft Flange
540
Installing Second Brake Band Pin
540
Installing Case Housing Bolts
540
Installing Another Input Shaft Bearing Race
541
Measuring Thrust Play Of Input Shaft
542
Installing Solenoid Wiring Harness
542
Checking Second Brake Band Alignment
543
Installing Accumulator Pistons And Spring
543
Installing Second Brake Cover
543
Installing Valve Body
544
Installing Oil Tubes
544
Connecting Oil Pressure Control Cable
544
Connecting Solenoid Wires
544
Installing Oil Strainer
545
Installing Oil Pan Bolts
545
Installing Magnet In Oil Pan
545
Installing Torque Converter
546
Dimension Data
547
Clutch: Table Of Contents
552
Clutch: General Description
552
Clutch Cutaway
553
Clutch Diagnosis
554
Clutch Pedal Height
555
Clutch Pedal Free Travel
555
Clutch Switch Adjustment
555
Clutch Cable Removal, Inspection, Installation
556
Clutch Cover, Clutch Disc And Flywheel: Unit Repair Overhaul
557
Clutch Cover, Clutch Disc And Flywheel Removal
557
Clutch Cover, Clutch Disc And Flywheel Inspection
558
Clutch Cover, Clutch Disc And Flywheel Installation
558
Installing Flywheel
558
Clutch Release System Removal
559
Installing Clutch Disc And Cover
559
Lubricating Input Shaft
559
Clutch Release System Inspection
560
Clutch Release System Installation
560
Lubricating Release System And Input Shaft
561
Installing Clutch Release Arm
561
Body Electrical System: Table Of Contents
564
Body Electrical System General Description
564
Body Electrical System Wiring
564
Main Fuse Block Circuit
565
Junction/Fuse Block Circuit And Fuse Block Designations
565
Junction/Fuse Block Circuit And Color Codes
566
Ignition Switch Inspection, Installation, Removal
567
Ignition Switch: Checking Continuity Between Terminals
567
Combination Switch Inspection
567
Combination Switch Couplers
567
Illumination Controller Inspection
568
Instruments And Gauges
569
Combination Meter Wiring
569
Body Electrical System Trouble Diagnosis
570
Fuel Level Meter And Gauge Unit: Description Of Circuit
571
Fuel Level Meter And Gauge Unit: Inspection
571
Gauge Unit Inspection
572
Water Temperature Meter And Gauge Unit Circuit
572
Checking Water Temperature Unit
573
Oil Pressure Light: Description Of Circuit
574
Checking Oil Pressure Switch
574
Brake Fluid Level Warning Light: Description Of Circuit
575
Brake Fluid Level Warning Light: Operation
576
Brake Fluid Level Warning Light: Inspection Of Brake Fluid Level Switch
576
Seat Belt Warning Light/Buzzer: Description Of Circuit
576
Seat Belt Warning Light/Buzzer: Inspection
576
Lighting Systems: Headlights Wiring Circuit
577
Lighting Systems: Headlights Trouble Diagnosis
577
Lighting Systems: Headlights Inspection
578
Setting Headlight Beams
578
Headlight Adjustment
579
Dim-Dip System (For England Only)
580
Turn Signal And Hazard Warning Light: Wiring Circuit
580
Headlight Trouble Diagnosis
581
Headlight Inspection
581
Back-Up Lights Wiring Circuit
582
Back-Up Lights Trouble Diagnosis
582
Stop Lights: Wiring Circuit
583
Stop Lights Trouble Diagnosis
583
Small, Tail And License Light: Wiring Circuit
584
Small, Tail And License Light: Trouble Diagnosis
584
Cigar Lighter And Radio (Optional): Wiring Circuit
585
Cigar Lighter And Radio (Optional): Trouble Diagnosis
585
Interior (Dome) Light: Wiring Circuit
585
Interior (Dome) Light: Trouble Diagnosis
585
Front Window Wiper (Windshield Wipers) And Washer
586
Windshield Wiper Circuit
587
Intermittent Wiper Relay Circuit
587
Wiper And Washer Wiring Circuit
588
Wiper And Washer Trouble Diagnosis
589
Wiper/Washer Switch Inspection
589
Wiper Motor Inspection
590
Washer Pump Inspection
591
Intermittent Wiper Relay Inspection
591
Rear Window Defogger (If Equipped): Wiring Diagram
592
Rear Window Defogger (If Equipped): Trouble Diagnosis
592
Defogger Switch Inspection
593
Defogger Wire Inspection
593
Defogger Circuit Repair
594
Defogger Installation And Removal
594
Rear Window Wiper And Washer (If Equipped) Circuit
595
Rear Window Wiper And Washer (If Equipped) Inspection
596
Wiring Harness Routing: Left Side Fender Apron Wiring
598
Right Side Inner Fender Wiring
599
Cowl Top Panel Wiring
599
Engine Wiring
600
Manual Transmission Wiring
601
Automatic Transmission Wiring
601
Cowl Upper Wiring
602
Instrument Panel Wiring
603
Floor Wiring
604
Rear Body Wiring
605
Back Door Wiring
605
Back Door Wiring Protector
606
Battery Wiring
606
Grounding Poitns
607
Body Service: Table Of Contents
608
Front Door Assembly
609
Door Glass Removal
609
Removing Door Trim
609
Door Glass Installation
610
Door Window Regulator Removal
611
Door Window Regulator Inspection
611
Door Window Regulator Installation
611
Front Door Lock Assembly
612
Front Door Lock Removal
612
Front Door Lock Installation
613
Front Door Assembly Removal
614
Front Door Assembly Installation
615
Rear Door Assembly
616
Rear Door Glass Removal
616
Rear Door Glass Installation
617
Door Window Regulator Removal, Installation
618
Rear Door Lock Assembly Removal/Installation
619
Rear Quarter Window Assembly Removal, Installation
620
Windshield
626
Windshield Removal
627
Windshield Installation
628
Back Door Assembly Removal, Installation
631
Back Door Balancer Removal, Installation
633
Back Door Glass Removal
634
Back Door Glass Installation
635
Front Seat Removal, Installation
637
Rear Seat Assembly
637
Rear Seat Cushion Removal, Installation
638
Rear Seatback Removal, Installation
638
Seat Belts
638
Front And Rear Seat Belt Assemblies
639
Servicing Seat Belts
639
Seatbelts Removal And Installation
639
Seat Belts Inspection
640
Front Floor Carpet Removal And Installation
641
Luggage Floor Carpet Removal And Installation
641
Head Lining Removal And Installation
642
Headlining Wrinkle Removal
643
Head Lining To Flange Overhang
643
Head Lining Hem Cutting
643
Anti-Corrosion Treatment
644
Metal Replacement Parts Finishing
645
Sealer Application Areas
646
Undercoating Application Areas
649
Application Of Anti-Corrosion Compound And Chip Resistant Material
650
Plastic Parts Finishing
651
Underbody Dimensions
652
Body Dimensions
654
Side Molding Installation
658
Key Coding
659
Key Usage And Identification
659
Junction/Fuse Block Circuit
660
Automatic Transmission Brake Interlock System: General Description
661
Automatic Transmission Brake Interlock System: Operations
661
Shift Lock Solenoid
662
Interlock Cable Removal And Installation
663
Interlock Cable Adjustment
663
Stop Light Switch Removal And Installation
663
Interlock Cable System Inspection
664
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Troubleshooting
Transmission Unit: Systematic Troubleshooting
467
Electric Shift Control Systematic Troubleshooting
476
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