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SUZUKI
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SQ 416-420-625
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M.Y 1998 - 2005
SERVICE MANUAL
VOLUME 1
- CHASSIS SECTIONS
- ELECTRICAL
- BODY SECTIONS

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Summary of Contents for Suzuki sq-416-420-625

  • Page 1 SUZUKI ──────────── SQ 416-420-625 ──────────── M.Y 1998 - 2005 SERVICE MANUAL VOLUME 1 - CHASSIS SECTIONS - ELECTRICAL - BODY SECTIONS...
  • Page 2 RELATED MANUAL MANUAL NAME MANUAL NO. APPLICABILITY SQ416/SQ420/SQ625 99501-65D01-xxx Transmission, Transfer and Differentials Unit Repair Manual (Front and Rear) of SQ series. SQ416/SQ420/SQ625 99512-65D10-015 Applicable model mentioned in FOREWORD Wiring Diagram Manual of this manual. SQ416/SQ420/SQ625 99500-65D00-xxx Vehicles before the vehicle identification number Service Manual mentioned in FOREWORD of this manual.
  • Page 3 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION ENGINE GENERAL INFORMATION General Information and General Information Diagnosis (G16/J20) Maintenance and Lubrication General Information and HEATING AND AIR Diagnosis (H25) CONDITIONING Engine Mechanical (G16) Heater and Ventilation Engine Mechanical (H25) Air Conditioning Engine Mechanical (J20) STEERING, SUSPENSION, Engine Cooling...
  • Page 4: Table Of Contents

    GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ............. . . 0A- 2 PRECAUTIONS .
  • Page 5: How To Use This Manual

    0A-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
  • Page 6: Precautions

    D If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 7: Servicing And Handling

    0A-4 GENERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY WARNING: FROM BODY. Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment.
  • Page 8 GENERAL INFORMATION 0A-5 WARNING: D During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
  • Page 9 0A-6 GENERAL INFORMATION CAUTION: D Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in SECTION 10B. D When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, re- move those parts beforehand.
  • Page 10: General Precautions

    GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
  • Page 11 0A-8 GENERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position.
  • Page 12: Precautions For Catalytic Converter

    GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never dis- connect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
  • Page 13: Precautions For Electrical Circuit Service

    0A-10 GENERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g.
  • Page 14 GENERAL INFORMATION 0A-11 D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage at each terminal, check to make sure that battery voltage is 11V or higher. Such terminal volt- age check at low battery voltage will lead to erroneous diag- nosis.
  • Page 15: Electrical Circuit Inspection Procedure

    0A-12 GENERAL INFORMATION ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various electrical circuit inspection methods, de- scribed here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.
  • Page 16 GENERAL INFORMATION 0A-13 Continuity Check 1) Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1. 2) Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance between terminals A-1 and B-1.
  • Page 17 0A-14 GENERAL INFORMATION SHORT CIRCUIT CHECK (Wire harness to ground) To other 1) Disconnect negative cable from battery. parts 2) Disconnect connectors at both ends of the circuit to be checked. NOTE: If the circuit to be checked is connected to other parts, dis- connect all connectors of those parts.
  • Page 18: Intermittent And Poor Connection

    GENERAL INFORMATION 0A-15 INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
  • Page 19: Precaution For Installing Mobile Communication Equipment

    0A-16 GENERAL INFORMATION D Poor terminal-to-wire connection. Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. D Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle.
  • Page 20: Identification Information

    GENERAL INFORMATION 0A-17 IDENTIFICATION INFORMATION BODY NUMBER The vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side. It is possible to identify the country of origin (the production plant) of the vehicle by the first three digits of the body number as shown below.
  • Page 21: Warning, Caution And Information Labels

    0A-18 GENERAL INFORMATION WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
  • Page 22: Vehicle Lifting Points

    GENERAL INFORMATION 0A-19 VEHICLE LIFTING POINTS WARNING D When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to move vehicle body in both ways.
  • Page 23 0A-20 GENERAL INFORMATION In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the jack against the center portion of the front suspension frame or rear axle housing. WARNING: D Never apply jack against suspension parts (i.e., stabilizer, etc.) or vehicle floor, or it may get deformed.
  • Page 24: Abbreviations May Be Used In This Manual

    GENERAL INFORMATION 0A-21 ABBREVIATIONS MAY BE USED IN THIS MANUAL : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Electric Brake force Distribution : Automatic Locking Retractor : Engine Control Module : Alternating Current...
  • Page 25 0A-22 GENERAL INFORMATION : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch : Transmission Control Module MAF Sensor : Mass Air Flow Sensor (A/T Controller, A/T Control (Air Flow Sensor, AFS, Air Module) Flow Meter, AFM)
  • Page 26: Metric Information

    GENERAL INFORMATION 0A-23 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt.
  • Page 27: Standard Tightening Torque

    0A-24 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation 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 fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
  • Page 28 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 29: 0B-2 Maintenance And Lubrication

    0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry Interval: out the same services at the same intervals respectively. This interval should be judged by This interval should be judged by (x 1,000)
  • Page 30 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry Interval: out the same services at the same intervals respectively. This interval should be judged by This interval should be judged by (x 1,000) odometer reading or months, whichever comes first.
  • Page 31: Maintenance Recommended Under Severe Driving Conditions

    0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
  • Page 32: Maintenance Service

    MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt (G16 and H25 engines) Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
  • Page 33 0B-6 MAINTENANCE AND LUBRICATION Water pump, generator, power steering and/or A/C compressor (if equipped) drive belt (J20 engine) Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace. Also, check belt for tension.
  • Page 34 MAINTENANCE AND LUBRICATION 0B-7 Power steering pump and/or A/C compressor drive belts (if G16 with P / S equipped) for G16 and H25 engines. Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any defect exists, replace.
  • Page 35 0B-8 MAINTENANCE AND LUBRICATION ITEM 1-2 Camshaft Timing Belt Replacement (G16 engine only) Replace timing belt referring to Section 6A1. ITEM 1-3 Valve Lash Inspection (G16 engine only) 1) Remove cylinder head cover. 2) Inspect intake and exhaust valve lash and adjust as necessary. Refer to Section 6A1 for valve lash inspection and adjustment procedure.
  • Page 36 MAINTENANCE AND LUBRICATION 0B-9 3) Loosen oil filter by using oil filter wrench (special tool). Special Tool (A): 09915-47310 (H25 engine) 09915-47330 (G16 and J20 engines) NOTE: Before fitting new oil filter, be sure to oil its O-ring. Use engine oil for this purpose.
  • Page 37 0B-10 MAINTENANCE AND LUBRICATION NOTE: Engine oil capacity is specified. However, note that the amount of oil required when actually changing oil may somewhat differ from the data in the table depending on various conditions (temperature, viscosity, etc.). 7) Check oil filter and drain plug for oil leakage. 8) Start engine and run it for three minutes.
  • Page 38 MAINTENANCE AND LUBRICATION 0B-11 6) Add coolant to reservoir so that its level aligns with Full mark. 1. Reservoir Then, reinstall cap aligning arrow marks on reservoir and cap. 2. FULL level mark 3. LOW level mark 4. Arrow mark NOTE: 5.
  • Page 39: Ignition System

    0B-12 MAINTENANCE AND LUBRICATION IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1 or 6F2. FUEL SYSTEM ITEM 3-1 Air Cleaner Filter Inspection 1) Remove air cleaner case clamps. 2) Take cleaner filter out of air cleaner case. 3) Check air cleaner filter for dirt.
  • Page 40 MAINTENANCE AND LUBRICATION 0B-13 ITEM 3-3 Fuel Filter Replacement WARNING: This work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter is located at the front part of fuel tank, inside the right- hand side of chassis.
  • Page 41: Emission Control System

    0B-14 MAINTENANCE AND LUBRICATION EMISSION CONTROL SYSTEM ITEM 4-1 Crankcase Ventilation Hoses and Connections Inspection (Vehicle not equipped with oxygen sensor) Refer to the following item 4-2, PCV valve inspection. ITEM 4-2 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog.
  • Page 42: Chassis And Body

    MAINTENANCE AND LUBRICATION 0B-15 CHASSIS AND BODY ITEM 6-1 Clutch Pedal inspection Check clutch pedal for height and free travel referring to Section 7C1. Adjust or correct if necessary. 1. Clutch pedal free travel Fluid inspection 1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct.
  • Page 43 0B-16 MAINTENANCE AND LUBRICATION ITEM 6-3 Brake Hoses and Pipes Inspection Check brake hoses and pipes for proper hookup, leaks, cracks, chafing and other damage. Replace any of these parts as necessary. CAUTION: After replacing any brake pipe or hose, be sure to carry out air purge operation.
  • Page 44 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-6 Tire Inspection and Rotation 1) Check tires for uneven or excessive wear, or damage. If defective, replace. Refer to Section 3 for details. 1. Wear indicator 2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
  • Page 45 0B-18 MAINTENANCE AND LUBRICATION ITEM 6-8 Suspension System Inspection Check suspension bolts and nuts for tightness and retighten them as necessary. Repair or replace defective parts, if any. NOTE: For details of check points, refer to tables of Tightening Torque Specification in Section 3D and 3E.
  • Page 46 MAINTENANCE AND LUBRICATION 0B-19 11) Check coil spring, upper rod, lower rod and lateral rod for de- formation and damage. 12) Check upper rod, lower rod and lateral rod bushings and bump stopper for wear, damage and deterioration. 13) Check other suspension parts for damage, loose or missing parts;...
  • Page 47 0B-20 MAINTENANCE AND LUBRICATION ITEM 6-10 Type 1 Manual Transmission Oil Inspection and Change Inspection 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove level plug of transmission.
  • Page 48 MAINTENANCE AND LUBRICATION 0B-21 Change 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Change fluid. For its procedure, refer to On-vehicle service in Section 7B1.
  • Page 49 0B-22 MAINTENANCE AND LUBRICATION ITEM 6-14 Steering System Inspection 1) Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.2 in.) 2) Check universal joints of steering shaft for rattle and damage. If The figure shows right-hand steering vehicle rattle or damage is found, replace defective part with a new one.
  • Page 50 MAINTENANCE AND LUBRICATION 0B-23 3) Visually check pump drive belt for cracks and wear. 4) Check belt for tension, referring to item 1-1. If necessary, have belt adjusted or replaced. ITEM 6-16 All Hinges, Latches and Locks Inspection Doors Check that each door of front, rear and back doors opens and closes smoothly and locks securely when closed.
  • Page 51: Final Inspection

    0B-24 MAINTENANCE AND LUBRICATION FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual transmission) When carrying out road tests, select a safe Check for the following: place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.
  • Page 52: Recommended Fluids And Lubricants

    MAINTENANCE AND LUBRICATION 0B-25 Steering D Check to ensure that steering wheel is free from in- stability, or abnormally heavy feeling. D Check that the vehicle does not wander or pull to one side. Engine D Check that engine responds readily at all speeds. D Check that engine is free from abnormal noise and abnormal vibration.
  • Page 53 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 54: General Description

    1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets at places, right and left, along the windshield glass.
  • Page 55: Body Ventilation

    HEATER AND VENTILATION 1A-3 BODY VENTILATION The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
  • Page 56: Wiring Circuit

    1A-4 HEATER AND VENTILATION WIRING CIRCUIT FOR LH VEHICLE FOR RH VEHICLE 1. From ignition switch 1 6. Blower motor relay 11. To illumination controller 15. TAIL fuse 15 A 2. From ignition switch 2 7. Blower motor switch (if equipped) or body ground 16.
  • Page 57: On-Vehicle Service

    HEATER AND VENTILATION 1A-5 ON-VEHICLE SERVICE BLOWER UNIT 1. Blower unit 2. Blower motor resistor 3. Blower motor relay 4. Blower fan 5. Blower motor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B.
  • Page 58 1A-6 HEATER AND VENTILATION 6) Remove cooling unit (If equipped). Refer to item COOLING UNIT (EVAPORATOR) REMOVAL in Section 1B. 7) Disconnect fresh air control cable from blower motor case. 8) Remove blower motor unit (1) by removing its fastening nuts (2).
  • Page 59: Blower Motor

    HEATER AND VENTILATION 1A-7 BLOWER MOTOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove ECM with bracket from blower motor unit. 4) Disconnect harness clamps from dash panel. 5) Loosen three nuts fastening blower unit.
  • Page 60: Blower Motor Relay

    1A-8 HEATER AND VENTILATION BLOWER MOTOR RELAY REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Open glove box, then remove screw. 4) Remove glove box. 5) Disconnect relay coupler.
  • Page 61: Blower Motor Resistor

    HEATER AND VENTILATION 1A-9 BLOWER MOTOR RESISTOR REMOVAL 1) Disconnect negative (–) cable (2) at battery (1). 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Open glove box (1), then remove screw (2). 4) Remove glove box.
  • Page 62: Heater Mode Control Switch

    1A-10 HEATER AND VENTILATION HEATER MODE CONTROL SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove meter cluster hood (1) by removing its mounting screws (2).
  • Page 63 HEATER AND VENTILATION 1A-11 7) Disconnect heater blower motor switch connector (1). 8) Remove mode control switch with heater control lever assem- bly from the removed hole in mentioned step (5). 9) Pull off heater control lever knob. 10) Remove heater mode control switch (2) with heater control panel (3) from heater control lever assembly (1).
  • Page 64: Heater Mode Control Actuator

    1A-12 HEATER AND VENTILATION INSTALLATION 1) Install in reverse order of removal procedure. 2) Adjust cables as follows. (1) Move control lever fully in arrow direction. 1. Temperature control lever 2. Fresh air control lever (2) Push heater lever fully in arrow direction and fix cable with clamp in position as shown in left figure.
  • Page 65 HEATER AND VENTILATION 1A-13 4) Disconnect heater mode control actuator coupler (1). 5) Disconnect heater mode control actuator rod (2) from heater unit. 6) Remove heater mode control actuator from heater unit by re- moving its mounting screw (3). INSPECTION 1) Connect battery voltage (+) to terminal “b’”...
  • Page 66: Heater Control Lever Assembly

    1A-14 HEATER AND VENTILATION HEATER CONTROL LEVER ASSEMBLY REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove mode control switch. Refer to item HEATER MODE CONTROL SWITCH in this section.
  • Page 67: Heater Control Cables

    HEATER AND VENTILATION 1A-15 HEATER CONTROL CABLES 1. Heater unit 2. Blower unit 3. Fresh air control cable 4. Temperature control cable 5. Heater control lever assembly REMOVAL 1) Remove heater control lever assembly. Refer to HEATER CONTROL LEVER ASSEMBLY in this sec- tion.
  • Page 68: Heater Unit

    1A-16 HEATER AND VENTILATION HEATER UNIT 1. Heater unit 2. Heater core 3. Damper 4. Heater mode control actuator 5. Heater mode control switch 6. Heater control lever assembly...
  • Page 69 HEATER AND VENTILATION 1A-17 REMOVAL WARNING: Failure to follow the following procedure and WARNING may cause air bag deployment, personal injury, damage to parts, or air bag being unable to deploy. D Never rest a steering column assembly on steering wheel with air bag (inflator) module face down and column verti- cal.
  • Page 70 1A-18 HEATER AND VENTILATION 11) Remove heater core pipe clamps (1) and grommet (2). 12) Pull out heater core (1) from unit (2). INSTALLATION 1) Install heater unit by reversing removal procedure, noting the following items. D When installing each part, be careful not to catch any cable or wiring harness.
  • Page 71: Rear Duct

    HEATER AND VENTILATION 1A-19 REAR DUCT 1. Heater unit 2. Rear duct 3. SDM REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove front seat. 3) Remove console box. 4) Take off carpet till rear duct is totally exposed. 5) Remove rear duct.
  • Page 72 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 73 1B-2 AIR CONDITIONING (OPTIONAL) Condenser Dryer (Receiver/Dryer) ..1B-36 A/C Compressor Relay and A/C Condenser Cooling Fan Relay ..1B-48 Air Filter Element ..... 1B-37 Compressor Assembly .
  • Page 74: General Description

    AIR CONDITIONING (OPTIONAL) 1B-3 GENERAL DESCRIPTION The air conditioning system of this model differs by the country of origin (the production plant.). One is Japan (IWATA) produced, other one is Canada (CAMI) produced. For the details of the identification, please refer to IDENTIFICATION INFORMATION of Section 0A in this manual. The compressor used of Japan (IWATA) produced vehicle is made of SEIKO SEIKI and the compressor used of Canada (CAMI) produced vehicle is made of DENSO.
  • Page 75: Refrigerant Flow Of Air Conditioning System

    1B-4 AIR CONDITIONING (OPTIONAL) REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM : Liquid : Vapor : Superheated vapor 1. Compressor 2. Magnet clutch 3. Condenser assembly 4. Receiver / dryer 5. Dual pressure switch 6. Expansion valve 7. Evaporator...
  • Page 76: Major Components And Location

    AIR CONDITIONING (OPTIONAL) 1B-5 MAJOR COMPONENTS AND LOCATION CAMI PRODUCTION VEHICLE IWATA PRODUCTION VEHICLE 1. Cooling unit 9. Expansion valve 17. Air inlet box 2. Compressor 10. Ventilation air 18. Dual pressure switch 3. Condenser assembly 11. Foot air 19. Low pressure charge valve 4.
  • Page 77: Diagnosis

    1B-6 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL Condition Possible Cause Correction D No refrigerant Cool air won’t come out Recover, evacuation and charging. D Fuse blown (A /C system won’t Check “IG METER” fuse, “REAR DEFG” operative) fuse, and “A/C FUSE” and check for short circuit to ground.
  • Page 78 AIR CONDITIONING (OPTIONAL) 1B-7 Condition Possible Cause Correction D Compressor faulty Cool air does not come Check compressor. D Air in A/C system out or insufficient Replace condenser dryer, and cooling (A/C system evacuation and charging. D Air leaking from cooling unit or air normal operative) Repair as necessary.
  • Page 79: Diagnosis Of Abnormal Noise

    1B-8 AIR CONDITIONING (OPTIONAL) DIAGNOSIS OF ABNORMAL NOISE There are various types of noise, ranging from those produced in the engine compartment to those from the pas- senger compartment, also from rumbling noises to whistling noises. ABNORMAL NOISE FROM COMPRESSOR Condition Possible Cause Correction...
  • Page 80 AIR CONDITIONING (OPTIONAL) 1B-9 ABNORMAL NOISE FROM CRANKSHAFT PULLEY Condition Possible Cause Correction D A large rattling noise is heard at D Loosen pulley mounting bolt. D Retighten bolt. D Worn or broken bearings. D Replace bearings. idle or sudden acceleration. ABNORMAL NOISE FROM TENSION PULLEY Condition Possible Cause...
  • Page 81: Quickly Checking Of Refrigerant Charge

    1B-10 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT 3. Bubbles CHARGE (IF EQUIPPED WITH SIGHT GLASS) CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its max.
  • Page 82: Compression System Diagnosis

    AIR CONDITIONING (OPTIONAL) 1B-11 COMPRESSION SYSTEM DIAGNOSIS Compressor troubles are mainly following three types: gas leakage, noise and insufficient pressure. Compressor gas leakages in most cases develop from the shaft seal. When detecting gas leakage, always use a leak tester. If a small amount of oil seeps out from the shaft seal, there is no necessity of replacing the seal. The shaft seal has been designed to allow a small amount of oil to leak out for lubricating purpose.
  • Page 83: Performance Diagnosis

    1B-12 AIR CONDITIONING (OPTIONAL) PERFORMANCE DIAGNOSIS For CAMI production vehicle 1) Confirm that vehicle and environmental conditions are as fol- lows. D Vehicle is not exposed to direct sun. D Ambient temperature is within 15_C – 35_C (59_F – 95_F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
  • Page 84 AIR CONDITIONING (OPTIONAL) 1B-13 9) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct de- fective part referring to following Test Diagnosis table. Example: Gauges should read as follows when ambient temperature is 30DC.
  • Page 85 1B-14 AIR CONDITIONING (OPTIONAL) PERFORMANCE DIAGNOSIS TABLE TESTING RESULTS POSSIBLE CAUSE REMEDY D Refrigerant overcharged D Recharge Pressure high D Expansion valve frozen or clogged D Check expansion valve (“A” area of high side D Clogged refrigerant passage of high side D Clean or replace graph) D Condenser fan malfunction...
  • Page 86 AIR CONDITIONING (OPTIONAL) 1B-15 AMBIENT TEMPERATURE WITHIN 30 – 35_C (85 – 95_F) CONDITION MANIFOLD (kg / cm CAUSE CORRECTION GAUGE DETAIL (psi) 0.23 – 0.35 1.4 – 1.75 (2.3 – 3.5) (14 – 17.5) Normal condition. —— —— (33 – 50) (200 –...
  • Page 87: Wiring Circuit

    1B-16 AIR CONDITIONING (OPTIONAL) WIRING CIRCUIT FOR LH VEHICLE 1. Blower motor main relay 10. Compressor relay 19. Battery 2. Blower motor 11. Compressor 20. Generator 3. Blower motor resistor 12. Condenser cooling fan relay 21. Ignition main fuse 60 A 4.
  • Page 88 AIR CONDITIONING (OPTIONAL) 1B-17 FOR RH VEHICLE 1. Blower motor main relay 10. Compressor relay 19. Battery 2. Blower motor 11. Compressor 20. Generator 3. Blower motor resistor 12. Condenser cooling fan relay 21. Ignition main fuse 60 A 4. Blower motor switch 13.
  • Page 89: Inspection Of A/C Controller And Its Circuits

    1B-18 AIR CONDITIONING (OPTIONAL) INSPECTION OF A/C CONTROLLER AND ITS CIRCUITS CAUTION: A/C controller and ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to A/C controller and ECM with couplers disconnected from it. A/C controller (1) and its circuits can be checked at A/C controller wiring couplers by measuring voltage.
  • Page 90 AIR CONDITIONING (OPTIONAL) 1B-19 SYSTEM CIRCUIT H25 engine E61-27 G16, J20 engines E61-8 H25 engine E61-28 G16, J20 engines E61-17 H25 engine E61-5 G16, J20 engines E61-22 A. To heater fuse 1. Blower motor relay 7. Dual pressure (refrigerant 11. Condenser fan motor relay B.
  • Page 91 1B-20 AIR CONDITIONING (OPTIONAL) A/C CONTROLLER VOLTAGE VALUES TABLE Measurement Terminal Wire Circuit Normal value Condition ground Controller main Ground to Ignition switch ON with engine AC1-1 10 – 14 volts power supply engine (Fig. B) stopped Controller main Ground to body AC1-2 –...
  • Page 92 AIR CONDITIONING (OPTIONAL) 1B-21 Measurement Terminal Wire Circuit Normal value Condition ground Ground to body AC2-1 L / Y Sensor ground – 0.4 – 0 volt Engine running (Fig. A) Evaporator thermistor temperature at 1.5 volts approx. 15_C (59_F) with engine (3150 f) running Evaporator thermistor temperature at...
  • Page 93: Drive Belt

    1B-22 AIR CONDITIONING (OPTIONAL) DRIVE BELT G16 engine INSPECTION For G16 and H25 engines Refer to Section 3B1 for details. For J20 engine Refer to Section 6H for details. J20 engine H25 engine 1. Generator belt 3. Compressor pulley 2. Compressor drive belt 4.
  • Page 94: Refrigerant Recovery, Evacuation And Charging

    AIR CONDITIONING (OPTIONAL) 1B-23 REFRIGERANT RECOVERY, EVACUATION AND CHARGING WARNING: D Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6_C (42.8_F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a seri- ous injury.
  • Page 95: Recovery

    1B-24 AIR CONDITIONING (OPTIONAL) RECOVERY For CAMI production vehicle NOTE: D When discharging refrigerant out of A/C system, always re- cover it by using refrigerant recovery and recycling equip- ment (1). Discharging it into atmosphere would cause ad- verse effect to environments. D When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
  • Page 96: Evacuating

    AIR CONDITIONING (OPTIONAL) 1B-25 EVACUATING EVACUATING PROCEDURE CAUTION: For CAMI production vehicle Do not evacuate before recovering refrigerant in system. NOTE: Whenever opened (exposed to atmospheric air), air condition- ing system must be evacuated by using a vacuum pump. The A/C system should be attached with a manifold gauge set, and should be evacuated for approx.
  • Page 97: Charging

    1B-26 AIR CONDITIONING (OPTIONAL) CHARGING CAUTION: D ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A/C system at after the initial charging is per- formed from the high-pressure side with the engine stopped. D NEVER CHARGE TO HIGH PRESSURE-SIDE of A/C system with engine running. D Do not charge while compressor is hot.
  • Page 98 AIR CONDITIONING (OPTIONAL) 1B-27 7) When refrigerant container (3) is emptied, use following proce- dure to replace it with a new refrigerant container (3). a. Close low pressure valve. b. Replace empty container (3) with a refrigerant container which has been charged with refrigerant. When using refrig- erant container tap valve (4), use following procedure for re- placement.
  • Page 99 1B-28 AIR CONDITIONING (OPTIONAL) 8) After the system has been charged with specified amount of re- For CAMI production vehicle frigerant or when low pressure gauge (1) and high pressure gauge (2) have indicated about 2 and 15 kg/cm respectively, close low pressure side vale (3) of manifold gauge set (4).
  • Page 100: Removing Manifold Gauge Set

    AIR CONDITIONING (OPTIONAL) 1B-29 REMOVING MANIFOLD GAUGE SET When A/C system has been charged with a specified amount of re- frigerant, remove manifold gauge set as follows: 1) Close low pressure-side valve of manifold gauge set, (The high pressure-side valve is closed continuously during the process of charging.).
  • Page 101: On-Vehicle Service

    1B-30 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE WARNING: Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately. D DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
  • Page 102 AIR CONDITIONING (OPTIONAL) 1B-31 D Tighten flared nuts to specified torque. Tightening Torque (Flared Nut Used for) 8 mm pipe: 13 N m (1.3 kg-m, 9.5 lb-ft) 14.5 mm pipe: 23 N m (2.3 kg-m, 16.6 lb-ft) 16 mm pipe: 33 N m (3.3 kg-m, 23.8 lb-ft) D Route drain hose so that drained water does not make any contact to vehicle components.
  • Page 103 1B-32 AIR CONDITIONING (OPTIONAL) REPLENISHING COMPRESSOR OIL When replacing air conditioning parts with new ones, it is necessary to replenish oil by the amount supposedly remaining in each part. When changing gas only When it is unavoidable to change gas without replacing any compo- nent part for engine removal and installation or for some other rea- son, replenish 20 cc oil.
  • Page 104: A/C Condenser Assembly

    AIR CONDITIONING (OPTIONAL) 1B-33 A/C CONDENSER ASSEMBLY INSPECTION Check a) condenser fins for blockage b) condenser fittings for leakage c) condenser fins for damage Clogged condenser fins should be washed with water, and should be dried with compressed air. CAUTION: Be careful not to damage condenser fins.
  • Page 105 1B-34 AIR CONDITIONING (OPTIONAL) 5) Disconnect coupler from dual pressure switch (1). 6) Disconnect condenser outlet pipe (3). 7) Disconnect condenser cooling fan motor coupler (2). 8) Remove condenser with fan. NOTE: Be careful not to damage fins of condenser and radiator. 9) Remove A/C condenser cooling fan assembly from condenser.
  • Page 106: Condenser Cooling Fan Assembly

    AIR CONDITIONING (OPTIONAL) 1B-35 CONDENSER COOLING FAN ASSEMBLY INSPECTION D Remove condenser assembly (Refer to “A/C CONDENSER AS- SEMBLY REMOVAL” in this section). D Check continuity between terminal to terminal as shown. If check results are continuity, proceed to next operation check. If not, replace.
  • Page 107: Condenser Dryer (Receiver/Dryer)

    1B-36 AIR CONDITIONING (OPTIONAL) CONDENSER DRYER (RECEIVER/DRYER) REMOVAL 1) Remove A/C condenser assembly (1) from vehicle (Refer to “A/C CONDENSER ASSEMBLY REMOVAL” in this section.). 2) Remove the condenser dryer cap from condenser. 2. Condenser dryer section 3) Remove the filter (1) from the condenser (2). 4) Remove the dryer (1) using a plier (2).
  • Page 108: Air Filter Element

    AIR CONDITIONING (OPTIONAL) 1B-37 AIR FILTER ELEMENT REMOVAL 1) Disconnect negative (–) cable at battery. 2) For vehicle with air bag system, disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” in Section 10B. 3) Pull down glove box (1) by pushing the shown part (a). 4) Remove filter cover (1).
  • Page 109 1B-38 AIR CONDITIONING (OPTIONAL) CLEAN Blow off dust by compressed air from air outlet side of the filter ele- ment. 1. Air flow INSTALLATION Reverse removal procedure for installation noting the followings: D Install filter into cooling unit directing arrow mark on its end face to heater unit.
  • Page 110: Cooling Unit (Evaporator)

    AIR CONDITIONING (OPTIONAL) 1B-39 COOLING UNIT (EVAPORATOR) REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system. Refer to “Disabling Air Bag System” in Section 10B. 3) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.
  • Page 111 1B-40 AIR CONDITIONING (OPTIONAL) 3) Remove upper case (1) and remove evaporator (2) from lower case (3). 4) Remove following components from evaporator. D Expansion valve (5) D Thermistor (evaporator temperature sensor) (4) DISASSEMBLY (FOR IWATA PRODUCTION VEHICLE) 1) Remove filter (2) from cooling unit (3) assembly by removing fil- ter cover (1).
  • Page 112 AIR CONDITIONING (OPTIONAL) 1B-41 INSPECTION 1) Check evaporator fins for blockage. If found clogged, use com- pressed air to clean the fins. CAUTION: Do not use water for cleaning of evaporator. Be careful not to damage evaporator fins. If evaporator fin is bent, straighten it by using a screwdriver or pair of pliers.
  • Page 113: Expansion Valve

    1B-42 AIR CONDITIONING (OPTIONAL) EXPANSION VALVE INSPECTION Refer to “Troubleshooting Procedure Using Manifold Gauge Set” in this section. REMOVAL 1) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.
  • Page 114: A/C Evaporator Thermistor (Evaporator Temperature Sensor)

    AIR CONDITIONING (OPTIONAL) 1B-43 A/C EVAPORATOR THERMISTOR (EVAPORATOR TEMPERATURE SENSOR) A thermistor is a temperature sensor to sense the temperature of air discharged from evaporator. The electrical characteristic is shown in the figure. When temperature is lower than preset temperature, amplifier makes magnet clutch turn off to prevent evaporator from frosting.
  • Page 115: Refrigerant Pipes And Hoses

    1B-44 AIR CONDITIONING (OPTIONAL) REFRIGERANT PIPES AND HOSES INSPECTION 1) Use a leak tester to check hoses and pipes for any gas leakage. 2) Check each hose or pipe clamp for tightness. Retighten or replace loose clamp as required, if any. REMOVAL 1) Recover refrigerant by using recovery and recycling equipment.
  • Page 116: A/C Switch

    AIR CONDITIONING (OPTIONAL) 1B-45 A/C SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” in Section 10B. 3) Remove mode control switch (Refer to “MODE CONTROL SWITCH”...
  • Page 117: A/C Controller

    1B-46 AIR CONDITIONING (OPTIONAL) A/C CONTROLLER REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to “DISABLING AIR BAG SYSTEM” in Section 10B. 3) Open glove box, then remove screw. 4) Remove glove box. 5) Disconnect A/C controller coupler (2), evaporator thermistor coupler (3).
  • Page 118: Dual Pressure Switch

    AIR CONDITIONING (OPTIONAL) 1B-47 DUAL PRESSURE SWITCH INSPECTION 1) Check dual pressure switch (1) on liquid pipe for continuity at normal temperature (approx. 25_C (77_F)) when A/C system has a proper charge of refrigerant and when A/C system (com- pressor) is under operation. In each of these cases, switch should show proper continuity.
  • Page 119: A/C Compressor Relay And A/Ccondenser Cooling Fan Relay

    1B-48 AIR CONDITIONING (OPTIONAL) A/C COMPRESSOR RELAY AND A/C CONDENSER COOLING FAN RELAY INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove condenser cooling fan motor relay (2) and/or compres- sor relay (1) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
  • Page 120: Compressor Assembly

    AIR CONDITIONING (OPTIONAL) 1B-49 COMPRESSOR ASSEMBLY CAUTION: None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a). For identification between these two types, refer to page 1B-2. When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
  • Page 121 1B-50 AIR CONDITIONING (OPTIONAL) REMOVAL 1) Run engine at idle with A/C ON for 10 minutes. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system using recovery and recycling equipment. NOTE: The amount of compressor oil at removed must be mea- sured and the same amount must be poured when installing the compressor.
  • Page 122 AIR CONDITIONING (OPTIONAL) 1B-51 INSTALLATION G16 engine FOR IWATA PRODUCTION VEHICLE 1) Pour new compressor oil. The amount must be the same with the amount measured in REMOVAL. NOTE: Compressor assembly supplied from factory is filled up with following amount of oil. Amount of oil in compressor: 120 cm (120 cc, 7.5 in 2) For G16 engine:...
  • Page 123 1B-52 AIR CONDITIONING (OPTIONAL) FOR CAMI PRODUCTION VEHICLE G16 engine 1) Pour new compressor oil. The amount must be the same with the amount measured in REMOVAL. NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Amount of oil in compressor: 120 cm (120 cc, 7.5 in 2) For G16 engine:...
  • Page 124: Magnet Clutch Assembly

    AIR CONDITIONING (OPTIONAL) 1B-53 MAGNET CLUTCH ASSEMBLY (FOR DENSO) 1. Clutch plate bolt 2. Clutch plate 3. Circlip 4. Clutch pulley 5. Shim 6. Clutch coil 7. Compressor INSPECTION D Inspect clutch plate and clutch pulley for signs of oil. D Check clutch pulley for noise and grease leakage.
  • Page 125 1B-54 AIR CONDITIONING (OPTIONAL) 4) Remove shims from shaft. 5) Using special tool (C), remove circlip. Special Tool (C): 09900-06107 6) Remove clutch coil lead wire clamp screw, and remove clutch coil read wire ground terminal. 7) Remove clutch pulley with puller (1) from compressor (2). NOTE: Be careful not to damage pulley when tapping magnet clutch assembly.
  • Page 126 AIR CONDITIONING (OPTIONAL) 1B-55 4) Clutch pulley (1). (1) Set clutch pulley squarely over clutch pulley installation boss. (2) Place special tool (D) onto clutch pulley bearing. Ensure that edge rests only on inner race of bearing. (3) Install snap ring. Special Tool (D): 09991-06010 CAUTION:...
  • Page 127: Magnet Clutch Assembly

    1B-56 AIR CONDITIONING (OPTIONAL) MAGNET CLUTCH ASSEMBLY (FOR SEIKO SEIKI) 1. Clutch plate bolt 2. Clutch plate 3. Circlip 4. Clutch pulley 5. Washer 6. Shim 7. Oil felt ring 8. Clutch coil 9. Lip type seal 10. Compressor front head 11.
  • Page 128 AIR CONDITIONING (OPTIONAL) 1B-57 3) Using special tool (B), remove clutch plate (1). Special Tool (B): 09991-06030 4) Disconnect clutch coil lead wire from compressor thermal switch led wire. 5) Remove felt ring (if equipped) and shims from shaft. 6) Using special tool (C), remove circlip. Special Tool (C): 09900-06107 7) Remove clutch coil lead wire clamp screw.
  • Page 129 1B-58 AIR CONDITIONING (OPTIONAL) 4) Install clutch pulley (1). (1) Set clutch pulley squarely over clutch pulley installation boss. (2) Place special tool (D) onto clutch pulley bearing. Ensure that edge rests only on inner race of bearing. (3) Install snap ring. Special Tool (D): 09991-06010 CAUTION:...
  • Page 130: Lip Type Seal (For Seiko Seiki)

    AIR CONDITIONING (OPTIONAL) 1B-59 LIP TYPE SEAL (FOR SEIKO SEIKI) REMOVAL 1) Remove magnet clutch assembly, referring to “MAGNET CLUTCH ASSEMBLY” in this section. 2) Remove compressor front head (1) mounting bolt (10 pcs.). 3) Remove compressor front head (1) by pushing cylinder shaft PUSH (2).
  • Page 131 1B-60 AIR CONDITIONING (OPTIONAL) 2) Coat special tool (F) surface with oil and place it on the shaft. Special Tool (F): 09991-06040 3) Install O-ring (2) to case. 4) Apply compressor (refringent) oil to lip seal and O-ring. 5) Install compressor front head (1). 6) Tighten compressor front head bolt.
  • Page 132: Required Service Material

    AIR CONDITIONING (OPTIONAL) 1B-61 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D O-ring Compressor oil for DENSO COMPRESSOR OIL (ND-OIL 8, 250 cc) D Each component compressor (Refrigerant oil) 99000-27080 Compressor oil for D O-ring COMPRESSOR OIL RS20 (150 cc)
  • Page 133: Wheels And Tires

    STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ..............FRONT END ALIGNMENT .
  • Page 134 3-2 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction D Sagging or broken springs. Abnormal or Replace spring. D Tire out of balance. Excessive Tire Wear Adjust balance or replace tire. D Disturbed front end alignment. Check front end alignment. D Faulty shock absorber.
  • Page 135 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Correction D Wheel bearings worn. Too Much Play in Replace wheel bearing. D Loose steering gear case bolts. Steering Tighten. D Rack and pinion not properly adjusted. Check and adjust rack and pinion (if equipped with manual steering gear torque.
  • Page 136 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction D Mismatched or uneven tires. Wander or Poor Replace tire or inflate tires to Steering Stability proper pressure. D Loose ball joints and tie rod Replace suspension control arm or ends.
  • Page 137 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Condition Possible Cause Correction D Loose stabilizer bar. Body Leans or Sways Tighten stabilizer bar bolts or in Corners replace bushes. D Faulty shock absorbers, struts Replace shock absorber, strut or or mounting. tighten mounting. D Broken or sagging springs.
  • Page 138 3-6 STEERING, SUSPENSION, WHEELS AND TIRES TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many possible causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, rotation is in order: 1.
  • Page 139 STEERING, SUSPENSION, WHEELS AND TIRES 3-7 1. Ride vehicle to determine if the waddle is coming from the front or rear. 2. Install tires and wheels that are known to be good (on similar ve- hicle) in place of those on the offending end of the vehicle. If the waddle cannot be isolated to front or rear, substitute the rears.
  • Page 140 3-8 STEERING, SUSPENSION, WHEELS AND TIRES RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level road with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment. 3) Tire construction.
  • Page 141 STEERING, SUSPENSION, WHEELS AND TIRES 3-9 SUSPENSION MOVEMENT (Loaded Runout) SMOOTH ROAD Caused by TIRE OUT TIRE RIM BENT STIFFNESS ROUND VARIATION OUT OF ROUND...
  • Page 142 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ................GENERAL INFORMATION .
  • Page 143 3A-2 FRONT END ALIGNMENT CAMBER Camber is the tilting of the front wheels from the vertical, as viewed from the front of the vehicle. 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 144 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod end was replaced, check toe and then also steering angle with turning radius gauges. If steering angle is not correct, check if right and left tie-rods are equal in length (“A” in left figure). Steering angle 35D X 3D inside:...
  • Page 145 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 146: General Description

    3B1-2 POWER STEERING (P / S) SYSTEM GENERAL DESCRIPTION POWER STEERING SYSTEM The power steering (P/S) system in this vehicle reduces the driver’s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all built in the steering gear box.
  • Page 147: Steering Gear Box

    POWER STEERING (P / S) SYSTEM 3B1-3 STEERING GEAR BOX The steering gear box consists of two sections: one including a cyl- inder and the other a valve. Main components of the cylinder sec- tion are a gear box, a rack and a tube and those of the valve section are a valve case, a sleeve and a stub shaft.
  • Page 148: Power Steering (P/S) Pump

    3B1-4 POWER STEERING (P / S) SYSTEM POWER STEERING (P/S) PUMP The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft. 1. Suction connector 2. O-ring 3. Pressure switch 4. Flow control valve (Relief valve) 5.
  • Page 149: Diagnosis

    POWER STEERING (P / S) SYSTEM 3B1-5 DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction D Fluid deteriorated, low viscosity, different Steering wheel Replace fluid. feels heavy type of fluid mixed D Pipes or hoses deformed, air entering (at low speed) Replace defective part.
  • Page 150 3B1-6 POWER STEERING (P / S) SYSTEM Condition Possible Cause Correction D Mismatched or uneven tire Vehicle pulls to Replace tire. D Low or uneven tire inflation pressure one side during Inflate tires to proper pressure or straight driving adjust right & left tires inflation pressure.
  • Page 151: Steering Wheel

    POWER STEERING (P / S) SYSTEM 3B1-7 STEERING WHEEL STEERING WHEEL PLAY CHECK Check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. Check steering wheel for play, holding car in straight forward condi- tion on the ground and with engine stopped.
  • Page 152: Power Steering Pump Drive Belt

    3B1-8 POWER STEERING (P / S) SYSTEM POWER STEERING PUMP DRIVE BELT NOTE: For J20 Type engine, refer to Section 6H “GENERATOR BELT”. INSPECTION Check that belt is free from any damage and properly fitted in pulley groove. BELT TENSION CHECK Check belt tension by measuring how much it deflects when pushed at intermediate point between pulleys with about 10 kg (22 lb) force.
  • Page 153: Idle Up System

    POWER STEERING (P / S) SYSTEM 3B1-9 IDLE UP SYSTEM IDLE UP SYSTEM CHECK 1) Warm up engine to normal operating temperature. 2) Turn A/C switch OFF, if equipped. 3) Turn steering wheel fully and check idle speed. Engine idle speed drops a little momentarily when steering wheel is turned fully but returns to its specified level immediately.
  • Page 154: Hydraulic Pressure In P/S Circuit

    3B1-10 POWER STEERING (P / S) SYSTEM HYDRAULIC PRESSURE IN P/S CIRCUIT HYDRAULIC PRESSURE CHECK 1) After cleaning joint of high pressure hose and P/S pump thor- oughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose). Tighten each flare nut to specified torque.
  • Page 155: Boot

    POWER STEERING (P / S) SYSTEM 3B1-11 5) Check relief pressure D Increase engine speed to about 1,500 r/min (rpm). Close gauge valve gradually while watching pressure increase indi- cated by gauge and take reading of relief pressure (maximum hydraulic pressure). Relief pressure: 6200 –...
  • Page 156: Tie-Rod End Boot Check

    3B1-12 POWER STEERING (P / S) SYSTEM TIE-ROD END BOOT CHECK Check boot for crack and damage and if any, replace it with a new one. AIR BLEEDING PROCEDURE 1) Hoist the front end of vehicle and apply safety stands. 2) Fill P/S fluid reservoir with fluid up to specified level.
  • Page 157: On-Vehicle Service

    POWER STEERING (P / S) SYSTEM 3B1-13 ON-VEHICLE SERVICE TIE-ROD END REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove tie-rod end nut. 1. Tie-rod end 2. Knuckle 3. Nut 3) Disconnect tie-rod end by using puller. 4) To facilitate adjustment after installation, put a mark on tie-rod thread indicating position of tie-rod end lock nut.
  • Page 158: Power Steering Gear Box Assembly

    3B1-14 POWER STEERING (P / S) SYSTEM 3) After installing wheels, lower vehicle and tighten wheel nuts to specified torque. Tightening Torque (a): 100 N m (10.0 kg-m, 72.5 lb-ft) 4) Check that proper amount of toe-in is obtained by referring to “FRONT WHEEL ALIGNMENT”.
  • Page 159 POWER STEERING (P / S) SYSTEM 3B1-15 7) Remove steering gear box mounting bolts and then remove steering gear box from vehicle. Steering gear box found to be in defective condition should be replaced with a new one. CAUTION: Never disassemble P/S gear box. If perform this prohib- ited service, it will affect original performance.
  • Page 160: Rack Boot And Tie-Rod (Except Canvas Top Lh Model)

    3B1-16 POWER STEERING (P / S) SYSTEM RACK BOOT AND TIE-ROD (EXCEPT CANVAS TOP LH MODEL) REMOVAL CAUTION: Never disassemble tie-rod except for canvas top LH model. Performing this prohibited service will affect original per- formance. 1) Remove steering gear box by referring to “POWER STEERING GEAR BOX ASSEMBLY REMOVAL”...
  • Page 161: Rack Boot And Tie-Rod (For Canvas Top Lh Model)

    POWER STEERING (P / S) SYSTEM 3B1-17 2) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to the mark made in removal. 3) Install steering gear box assembly by referring “POWER STEERING GEAR BOX ASSEMBLY INSTALLATION” in this section.
  • Page 162 3B1-18 POWER STEERING (P / S) SYSTEM INSTALLATION 1) Install new tie-rod lock washer and tie-rod to rack. 2) Tighten tie-rod ball nut to specified torque. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) 3) Bend lock washer 2 place at the flat part of tie-rod ball nut. 1.
  • Page 163: Power Steering Pump

    POWER STEERING (P / S) SYSTEM 3B1-19 POWER STEERING PUMP [G16 ENGINE MODEL] Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) (b):25 N m (2.5 kg-m, 18.5 lb-ft) (c): 55 N m (5.5 kg-m, 40.0 lb-ft) (d):11 N m (1.1 kg-m, 8.0 lb-ft) (e): 35 N m (3.5 kg-m, 25.5 lb-ft)
  • Page 164 3B1-20 POWER STEERING (P / S) SYSTEM REMOVAL NOTE: Be sure to clean each joint of suction and discharge sides thoroughly before removal. 1) Remove suction hose from pump, then disconnect battery nega- tive cable. 1. P/S fluid 2) Remove P/S fluid reservoir with suction hose. reservoir 2.
  • Page 165 POWER STEERING (P / S) SYSTEM 3B1-21 INSPECTION Pump Body, Cover, Side Plate and Shaft Check sliding surfaces of each part for wear and damage. If any defect is found, replace pump assembly. Cam Ring Check vane sliding surface of cam ring for wear and damage. If any defect is found, replace pump assembly.
  • Page 166 3B1-22 POWER STEERING (P / S) SYSTEM D Check free length of relief valve spring. Free length: Standard 22.0 mm (0.866 in.) Limit 19.0 mm (0.748 in.) Replace if any defective is found. 1. Flow control spring ASSEMBLY Reverse disassembly procedure for assembly, noting the following. 1) Apply grease to oil seal lip and apply power steering fluid to slid- ing surface of the shaft then insert pulley’s shaft from oil seal side of the pump body.
  • Page 167 POWER STEERING (P / S) SYSTEM 3B1-23 7) Apply power steering fluid to sliding surface of cam ring. 8) Install cam ring to pump body. The tapered end of cam ring should face the side plate. 1. Cam ring 2. Side plate 9) Apply power steering fluid to each vane.
  • Page 168 3B1-24 POWER STEERING (P / S) SYSTEM 15) Gradually tighten new pump cover bolts to specified torque. NOTE: After installing pump cover, check to make sure that shaft can be turned by hand. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 1.
  • Page 169 POWER STEERING (P / S) SYSTEM 3B1-25 INSTALLATION Reverse removal procedure, and then noting the following instruc- tions. D For tightening torques, refer to structural diagram on previous page. D Adjust power steering pump drive belt by referring to “BELT TEN- SION ADJUSTMENT”...
  • Page 170: Tightening Torque Specification

    35.0 Tie-rod (for canvas top LH model only) 61.5 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT SUPER GREASE (A) D Oil seal lip of P/S pump pulley shaft Lithium grease (99000-25010) D To fill P/S fluid reservoir An equivalent of DEXRON...
  • Page 171 STEERING WHEEL AND COLUMN 3C-1 SECTION 3C STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) NOTE: All steering wheel and column fasteners are important parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 172: Diagnosis

    3C-2 STEERING WHEEL AND COLUMN 1. Steering wheel pad 2. Steering wheel pad screw 3. Steering wheel nut 4. Steering wheel 5. Combination switch 6. Steering column upper cover 7. Steering column lower cover 8. Steering column assembly 9. Steering lock assembly 10.
  • Page 173: On-Vehicle Service

    STEERING WHEEL AND COLUMN 3C-3 ON-VEHICLE SERVICE STEERING WHEEL REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Remove steering wheel pad screw. 3) Remove steering wheel pad and disconnect horn harness. 1. Steering wheel 2. Steering wheel pad 3.
  • Page 174: Combination Switch

    3C-4 STEERING WHEEL AND COLUMN COMBINATION SWITCH REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Remove steering wheel from steering column. Refer to “STEERING WHEEL” in this section. 3) Remove steering column hole cover. 1. Steering column hole cover : If equipped 4) Remove steering column cover screws (3 pieces).
  • Page 175: Steering Column Assembly

    STEERING WHEEL AND COLUMN 3C-5 3) Install steering column upper and lower cover. 4) Tighten steering column cover screws. CAUTION: When installing lower cover and upper cover, be careful so that combination switch lead wire is not caught be- tween covers. 1.
  • Page 176 3C-6 STEERING WHEEL AND COLUMN 2) Remove steering wheel and combination switch, if necessary. Refer to “STEERING WHEEL” and “COMBINATION SWITCH” in this section. Perform the following procedure if not removing steering wheel and/or combination switch. i) Turn steering wheel so that vehicle’s front tires are at straight- ahead position.
  • Page 177 STEERING WHEEL AND COLUMN 3C-7 7) Remove steering column mounting bolts (6 pieces). 1. Steering column 2. Steering column mounting bolt 3. Steering column lower seal 8) If equipped with shift (key) interlock cable, remove shift (key) in- terlock cable screw and then disconnect its cable from ignition switch.
  • Page 178 3C-8 STEERING WHEEL AND COLUMN 4) Check steering column lower seal for breakage or deformation. If found defective, replace. 1. Steering column lower seal 5) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play. If anything is found faulty, replace as steering lower shaft assem- bly or steering column assembly.
  • Page 179 STEERING WHEEL AND COLUMN 3C-9 4) Install steering shaft joint to steering shaft by matching it to marks made before removal. 1. Steering shaft joint 2. Steering shaft (column side) 3. Marks 5) Install shaft joint bolt (column side) to steering shaft joint. Tighten shaft joint bolt (column side) to specified torque first and then shaft joint bolt (lower shaft assembly side) to specified torque.
  • Page 180: Steering Lock Assembly (Ignition Switch)

    3C-10 STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column. Refer to “STEERING COLUMN” in this section. 1. Steering column 2. Steering lock 2) Using center punch as shown, loosen and remove steering lock mounting bolts. NOTE: Use care not to damage aluminum part of steering lock body with center punch.
  • Page 181: Steering Lower Shaft Assembly

    STEERING WHEEL AND COLUMN 3C-11 STEERING LOWER SHAFT ASSEMBLY REMOVAL 1) Turn steering wheel so that vehicle’s front tires are at straight- ahead position. 2) Turn ignition switch to “LOCK” position and remove key. 3) Make alignment marks on shaft joint and shaft (column side) for a guide during reinstallation.
  • Page 182 3C-12 STEERING WHEEL AND COLUMN INSTALLATION 1) Be sure that front wheels and steering wheel are in straightfor- ward position. 2) Align flat part “A” of lower shaft assembly with bolt hole “B” of shaft joint as shown. Then insert shaft joint into lower shaft as- sembly.
  • Page 183: Checking Steering Column For Accident Damage

    STEERING WHEEL AND COLUMN 3C-13 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted, may have a dam- aged or misaligned steering column. CHECKING PROCEDURE 1) Check that two capsules are attached to steering column brack- et securely.
  • Page 184: Adjustable Steering Column Release Lever

    3C-14 STEERING WHEEL AND COLUMN ADJUSTABLE STEERING COLUMN RELEASE LEVER INSPECTION Check to make sure that the following: D Steering column moves smoothly when adjustable steering col- umn release lever is at lower position (i.e., steering column is not locked). D Steering column is fixed securely when adjustable steering col- umn release lever is at higher position (i.e., steering column is locked).
  • Page 185 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system compo- nents or wiring.
  • Page 186: General Description

    3C1-2 AIR BAG STEERING WHEEL AND COLUMN GENERAL DESCRIPTION This double tube type steering column has the following three important features in addition to the steering function: D The column is energy absorbing, designed to compress in a front-end collision. D The ignition switch and lock are mounted conveniently on this column.
  • Page 187: Diagnosis

    AIR BAG STEERING WHEEL AND COLUMN 3C1-3 DIAGNOSIS For diagnosis of the steering wheel and steering column, refer to Section 3. For diagnosis of the air bag system, refer to Section 10B. INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and repairs described under “CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE”...
  • Page 188: Driver Air Bag (Inflator) Module

    3C1-4 AIR BAG STEERING WHEEL AND COLUMN DRIVE AIR BAG (INFLATOR) MODULE WARNING: When handling an air bag (inflator) module, be sure to read “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B and observe each instruction. Failure to fol- low them could cause a damage to the air bag (inflator) mod- ule or result in personal injury.
  • Page 189 AIR BAG STEERING WHEEL AND COLUMN 3C1-5 INSPECTION WARNING: Never disassemble air bag (inflator) module or measure its resistance. Otherwise, personal injury may result. CAUTION: If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module visually and if any of the following is found, replace it with a new one.
  • Page 190: Steering Wheel

    3C1-6 AIR BAG STEERING WHEEL AND COLUMN STEERING WHEEL CAUTION: Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the combination switch) more than allowable number of turns (about two and a half turns from the center position clockwise or counter- clockwise respectively), or coil will break.
  • Page 191: Contact Coil And Combination Switch Assembly

    AIR BAG STEERING WHEEL AND COLUMN 3C1-7 INSTALLATION 1) Check that vehicle’s front tires are at straight-ahead position and contact coil is centered. Refer to “CENTERING CONTACT COIL” in this section. CAUTION: These two conditions are prerequisite for installation of steering wheel.
  • Page 192 3C1-8 AIR BAG STEERING WHEEL AND COLUMN 6) Remove contact coil and combination switch assembly from steering column. 1. Contact coil and combination switch assembly 2. Screw INSPECTION Check contact coil and combination switch wire harness for any signs of scorching, melting or other damage. If it is damaged, re- place.
  • Page 193: Steering Column

    AIR BAG STEERING WHEEL AND COLUMN 3C1-9 3) Connect all connectors that have been removed in removal. 4) Install steering column upper and lower cover, and then tighten steering column cover screws. CAUTION: When installing lower cover and upper cover, be careful so that contact coil and combination switch lead wire is not caught between covers.
  • Page 194 3C1-10 AIR BAG STEERING WHEEL AND COLUMN REMOVAL WARNING: Never rest a steering column assembly on the steering wheel with air bag (inflator) module face down and column vertical. Otherwise personal injury may result. 1) Disconnect negative battery cable at battery terminal. 2) Disable air bag system.
  • Page 195 AIR BAG STEERING WHEEL AND COLUMN 3C1-11 8) Remove steering column mounting bolts (6 pieces). 1. Steering column 2. Steering column mounting bolt 3. Steering column lower seal 9) If equipped with shift (key) interlock cable, remove shift (key) interlock cable screw and then disconnect its cable from igni- tion switch.
  • Page 196 3C1-12 AIR BAG STEERING WHEEL AND COLUMN 4) Check steering column lower seal for breakage or deformation. If found defective, replace. 1. Steering column lower seal 5) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play. If anything is found faulty, replace as steering lower shaft assem- bly or steering column assembly.
  • Page 197 AIR BAG STEERING WHEEL AND COLUMN 3C1-13 4) Install steering shaft joint to steering shaft by matching it to marks made before removal. 1. Steering shaft joint 2. Steering shaft (column side) 3. Marks 5) Install shaft joint bolt (column side) to steering shaft joint. Tighten shaft joint bolt (column side) to specified torque first and then shaft joint bolt (lower shaft assembly side) to specified torque.
  • Page 198: Steering Lock Assembly (Ignition Switch)

    3C1-14 AIR BAG STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column. Refer to “STEERING COLUMN” in this section. 1. Steering column 2. Steering lock 2) Using center punch as shown, loosen and remove steering lock mounting bolts.
  • Page 199: Steering Lower Shaft Assembly

    AIR BAG STEERING WHEEL AND COLUMN 3C1-15 STEERING LOWER SHAFT ASSEMBLY CAUTION: Never turn steering wheel while steering lower shaft assem- bly is removed. Should it have been turned and contact coil (on combina- tion switch) have got out of its centered position, it needs to be centered again.
  • Page 200 3C1-16 AIR BAG STEERING WHEEL AND COLUMN INSTALLATION 1) Be sure that front wheels and steering wheel are in straight ahead position. 2) Align flat part “A” of lower shaft assembly with bolt hole “B” of shaft joint as shown. Then insert shaft joint into lower shaft as- sembly.
  • Page 201: Checking Steering Column For Accident Damage

    AIR BAG STEERING WHEEL AND COLUMN 3C1-17 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering col- umn.
  • Page 202: Adjustable Steering Column Release Lever

    3C1-18 AIR BAG STEERING WHEEL AND COLUMN ADJUSTABLE STEERING COLUMN RELEASE LEVER INSPECTION Check to make sure that the following: D Steering column moves smoothly when adjustable steering col- umn release lever is at lower position (i.e., steering column is not locked).
  • Page 203: Front Suspension

    FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION CAUTION: D All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 204: General Description

    3D-2 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the body by a strut support. The strut and strut support are isolated by a rubber mount. The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached to the stud of a ball joint which is incorporated in a unit with a suspension control arm.
  • Page 205: Diagnosis

    FRONT SUSPENSION 3D-3 DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STABILIZER BAR AND BUSHING CHECK Inspect for damage or deformation. If defective, replace. BUSHING Inspect for damage, wear or deterioration. If defective, replace. STRUT DAMPER AND/OR COIL SPRING CHECK 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
  • Page 206: Suspension Control Arm Joint Check

    3D-4 FRONT SUSPENSION SUSPENSION CONTROL ARM JOINT CHECK 1) Check for smoothness of rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. Replace any parts found defective in steps 1) – 3). SUSPENSION CONTROL ARM BUSHING CHECK Inspect for damage, wear or deterioration.
  • Page 207: On-Vehicle Service

    FRONT SUSPENSION 3D-5 ON-VEHICLE SERVICE STABILIZER BAR/BUSHINGS REMOVAL 1) Hoist vehicle. 2) Remove stabilizer bar mount bush bracket bolts. 3) Remove stabilizer ball joint nuts, washers and bushings. 4) Remove stabilizer bar with its ball joints. 5) Disconnect stabilizer ball joints from stabilizer bar. 1.
  • Page 208: Strut Damper

    3D-6 FRONT SUSPENSION STRUT DAMPER REMOVAL 1) Remove strut tower bar (if equipped). 1. Strut tower bar 2) Hoist vehicle, allowing front suspension to hang free. 3) Remove wheel. 4) Remove E-ring securing brake hose and take brake hose off strut bracket as shown.
  • Page 209 FRONT SUSPENSION 3D-7 INSTALLATION 1) Install strut by reversing removal steps 1) – 8). Insert bolts in such a direction as shown. 2) Torque all fasteners to specifications. Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 lb-ft) (b): 95 N m (9.5 kg-m, 69.0 lb-ft) (c): 50 N m (5.0 kg-m, 36.5 lb-ft)
  • Page 210: Coil Spring

    3D-8 FRONT SUSPENSION COIL SPRING REMOVAL 1) Hoist vehicle, allowing front suspension to hang free. 2) Remove wheels. 3) Remove axle shaft drive flange (For 4WD vehicle). 4) Remove front drive shaft circlip and washer (For 4WD vehicle). 1. Circlip 2.
  • Page 211 FRONT SUSPENSION 3D-9 8) Remove stabilizer bar, refer to steps 2) to 5) of item STABILIZ- ER BAR/BUSHINGS REMOVAL in this section. 9) Disconnect tie rod end from knuckle by using puller. 10) Support lower arm, using jack as shown. 11) Remove strut bracket bolts.
  • Page 212 3D-10 FRONT SUSPENSION INSTALLATION Reverse removal procedure to install coil spring. NOTE: Upper and lower diameters of coil spring are different. “a” < “b” Bring larger diameter end at bottom and set its open end in place on spring seat. 1.
  • Page 213: Bump Stopper/Spring Rubber Seat

    FRONT SUSPENSION 3D-11 D Check that no foreign material is attached to sensor and rotor. Install wheel speed sensor and its harness clamp. 2, (b) Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) (b): 23 N m (2.3 kg-m, 17.0 lb-ft) CAUTION: D Do not pull wire harness or twist more than necessary when installing front wheel speed sensor.
  • Page 214: Wheel Hub (Included Wheel Bearing)

    3D-12 FRONT SUSPENSION WHEEL HUB (INCLUDED WHEEL BEARING) REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove axle shaft drive flange (4WD vehicle) or hub cap (2WD vehicle). 1. Axle shaft drive flange 3) If equipped with ABS, remove wheel speed sensor from knuckle and harness clamp from strut.
  • Page 215 FRONT SUSPENSION 3D-13 NOTE: If wheel hub can not be removed by hand, use special tools as shown. Special Tool (B): 09943-35512 (C): 09942-15510 CAUTION: If wheel bearing inner race remains on wheel spindle when removing wheel hub, which means break of wheel bearing, replace wheel hub component (included wheel bearing).
  • Page 216 3D-14 FRONT SUSPENSION 2) Install new sensor rotor by using special tool (if equipped with ABS). NOTE: Use care not to insert wheel hub diagonally. Special Tool (A): 09952-86510 (B): 09924-74510 Wheel speed sensor rotor installing position Reference Dimension “a” : 4.9 8 0.1 mm (0.19 8 0.004 in.) 1.
  • Page 217 FRONT SUSPENSION 3D-15 7) For 4WD vehicle, apply lithium grease to front drive shaft wash- er and front wheel spindle outer. “A”: Grease 99000-25010 8) For 4WD vehicle, when installing circlip to drive shaft, utilize screw hole in drive shaft to pull it out and bring large diameter of circlip at right as shown.
  • Page 218 3D-16 FRONT SUSPENSION 11) Apply sealant and install axle shaft drive flange or hub cap. For 4WD vehicle D For 4WD vehicle Apply sealant mating surface of axle shaft drive flange, then install axle shaft drive flange and tighten flange bolt to speci- fied torque.
  • Page 219: Knuckle/Wheel Spindle

    FRONT SUSPENSION 3D-17 KNUCKLE/WHEEL SPINDLE REMOVAL 1) Remove wheel hub. Refer to “WHEEL HUB (INCLUDED WHEEL BEARING)” in this section. 2) Remove front drive shaft circlip and front spindle thrust washer (for 4WD vehicle) or front hub cap (for 2WD vehicle). 1.
  • Page 220 3D-18 FRONT SUSPENSION 11) For 4WD vehicle Remove drive shaft bearing by using special tool. Special Tool (A): 09923-74510 (B): 09930-30102 1. Wheel spindle 2. Drive shaft bearing INSTALLATION Reverse removal sequence to install knuckle, wheel spindle oil seal and drive shaft bearing,noting following points. Type A Type B 1.
  • Page 221 FRONT SUSPENSION 3D-19 D Tighten wheel spindle nut to specified torque. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) D For 4WD vehicle Press-fitting inner oil seal. Drive in inner oil seal until its end contacts stepped surface of knuckle by using special tools.
  • Page 222 3D-20 FRONT SUSPENSION D Tighten control arm ball stud nut When tightening ball stud nut, use new nut and tighten it to speci- fied torque. Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) D For 2WD vehicle Apply water tight sealant to mating surface of wheel hub and install hub cap to wheel hub.
  • Page 223: Suspension Control Arm/Bushings

    FRONT SUSPENSION 3D-21 SUSPENSION CONTROL ARM/BUSHINGS Cut off flange REMOVAL 1) Remove coil spring. Refer to COIL SPRING in this section. 2) Remove control arm bolts and nuts. Then remove control arm. 3) Cut flange part of control arm bush (rubber and steel) with using care not to damage control arm end surface.
  • Page 224 3D-22 FRONT SUSPENSION INSTALLATION 1) Front bushing Press-fit front bushing until its flange contacts housing edge of control arm, use special tools as shown. Special Tool (C): 09951-16060 (F): 09913-85210 NOTE: When press-fitting bushing, compounding oil or soap water applied to inside of control arm housing will facilitate work. 1.
  • Page 225: Tightening Torque Specifications

    FRONT SUSPENSION 3D-23 TIGHTENING TORQUE SPECIFICATIONS...
  • Page 226: Required Service Materials

    REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Bearing inner oil seal/drive shaft oil seal Recess of wheel spindles SUZUKI SUPER GREASE (A) Spindle outer washer Lithium grease Spindle part of drive shaft (99000-25010) Spindle bush (inside and flange part) Spindle inner washer SUZUKI BOND NO.
  • Page 227: Special Tools

    FRONT SUSPENSION 3D-25 SPECIAL TOOLS 09923-74510 09930-30102 09924-74510 09941-66010 Bearing remover Sliding shaft Bearing installer handle Bump stopper wrench 09944-66010 09942-15510 09943-35512 Wheel hub / knuckle oil 09944-68210 Sliding hammer Brake drum remover seal installer Bearing & oil seal installer 09951-16060 09951-16050 Control arm bush remover...
  • Page 228: Rear Suspension

    REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 229: General Description

    The shock absorber is installed between the body and axle to absorb up-and-down movement of the vehicle body. NOTE: When installing differential gear oil drain plug, clean the thread portion of the plug and then apply sealant (SUZUKI BOND No. 1215, 99000-31110) to the portion. 1. Rear axle housing 2. Coil spring 3.
  • Page 230: Diagnosis

    REAR SUSPENSION 3E-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. SHOCK ABSORBER CHECK D Inspect for deformation or damage. D Inspect bushings for wear or damage. D Inspect for evidence of oil leakage. Replace any defective part. WARNING: When handling rear shock absorber in which high-pressure gas is sealed, make sure to observe the following precau- tions.
  • Page 231: Bearing Retainer & Axle Shaft Inner Oil Seal Check

    3E-4 REAR SUSPENSION REAR SUSPENSION FASTENERS Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to “TIGHT- ENING TORQUE SPECIFICATIONS” of this section. BEARING RETAINER AND AXLE SHAFT INNER OIL SEAL CHECK D When brake drum has been removed, check inside of brake drum for gear oil leakage.
  • Page 232: On-Vehicle Service

    REAR SUSPENSION 3E-5 ON-VEHICLE SERVICE SHOCK ABSORBER The shock absorber is non-adjustable, non-refillable, and cannot be disassembled. The only service the shock absorber requires is replacement when it has lost its resistance, is damaged, or leaking fluid. REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack to prevent it from lowering.
  • Page 233: Coil Spring

    3E-6 REAR SUSPENSION COIL SPRING REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack. 1. Rear axle housing 2. Floor jack 3) Disconnect parking brake cable hanger from chassis frame and clamp from cross member. 1.
  • Page 234 REAR SUSPENSION 3E-7 INSTALLATION 1) Install coil spring on spring seat of axle housing and then raise axle housing. NOTE: When seating coil spring, mate spring end with stepped part of rear axle spring seat as shown. 1. Rear axle housing 2.
  • Page 235: Lower Rod

    3E-8 REAR SUSPENSION LOWER ROD REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack. 1. Axle housing 2. Floor jack 3) Remove lower rod front mount bolt. 1. Lower rod 2. Front mount bolt 4) Remove lower rod rear mount bolt.
  • Page 236: Upper Rod

    REAR SUSPENSION 3E-9 UPPER ROD REMOVAL 1) Hoist vehicle and remove rear wheel. 2) If equipped with ABS, disconnect wheel speed sensor harness clamp from left upper rod. 1. Clamp 2. Upper rod 3) Remove upper rod. 1. Upper rod 2.
  • Page 237: Lateral Rod

    3E-10 REAR SUSPENSION LATERAL ROD REMOVAL 1) Hoist vehicle. 2) Remove lateral rod mounting bolts. 3) Remove lateral rod. 1. Bolt 2. Washer 3. Lateral rod INSTALLATION 1) Install lateral rod to rear axle, and vehicle body. 2) Lower hoist. 3) Tighten lateral rod mounting bolts to specified torque.
  • Page 238 REAR SUSPENSION 3E-11 4) Remove wheel speed sensor from rear axle housing (if equipped with ABS). CAUTION: D Do not pull wire harness or twist more than necessary when removing rear wheel speed sensor. D Do not cause damage to surface of rear wheel speed sensor or pole piece and do not allow dust, etc.
  • Page 239 3E-12 REAR SUSPENSION 9) Break with a chisel the thin ground sensor rotor, and it can be removed (if equipped with ABS). 10) In order to remove the retainer ring from the shaft, grind with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin.
  • Page 240 REAR SUSPENSION 3E-13 INSTALLATION Install removed parts in reverse order of removal procedure, noting the following. 1) Apply grease to oil seal lip as shown and install it to axle shaft. NOTE: Amount of grease applied to hollow in oil seal should be more than 60% of its vacant space.
  • Page 241 3E-14 REAR SUSPENSION 5) For vehicle with ABS, press-fit new sensor rotor as shown. NOTE: Use care not to cause any damage to outside of retainer ring. 1. Sensor rotor 6) Apply grease to axle shaft inner oil seal lip as shown. “A”: Grease 99000-25010 1.
  • Page 242: Rear Axle Shaft Inner Oil Seal

    REAR SUSPENSION 3E-15 REAR AXLE SHAFT INNER OIL SEAL REMOVAL 1) Remove rear axle shaft. For details, refer to steps 1) to 7) of REAR AXLE SHAFT REMOVAL in this section. 2) Fix brake back plate by inserting screwdriver to the hole for bear- ing retainer mounting.
  • Page 243: Rear Axle Housing

    3E-16 REAR SUSPENSION REAR AXLE HOUSING REMOVAL 1) Drain differential gear oil. Carry out steps 2) to 7) and 15) to 18) on both right and left wheels. Note that left wheel and its related parts are used in illustrations in this section.
  • Page 244 REAR SUSPENSION 3E-17 7) Using special tools (B) & (C) indicated below, draw out axle shafts. For vehicle equipped with ABS, remove wheel speed sensor from axle housing before drawing out axle shaft. NOTE: Use care not to pull brake back plate along with shaft. Special Tool (C): 09943-35512 (B): 09942-15510...
  • Page 245 3E-18 REAR SUSPENSION 13) For jobs hereafter, support rear axle housing by using floor jack under axle housing. 1. Axle housing 2. Jack 14) Remove differential carrier assembly. 1. Differential carrier assembly 2. Differential carrier nut 15) Loosen rear mount nut of upper rod but don’t remove bolt. 16) Loosen rear mount nut of lower rod but don’t remove bolt.
  • Page 246 REAR SUSPENSION 3E-19 INSTALLATION Install removed parts in reverse order of removal, noting the follow- ing. 1) Place rear axle housing on floor jack. Then install upper/lower rod rear mounting bolts (right & left) in proper direction as shown (refer to UPPER ROD INSTALLATION for upper rod bolts). At this time, mount nuts but don’t tighten them.
  • Page 247 3E-20 REAR SUSPENSION 7) For vehicle with ABS, connect wheel speed sensor coupler and install harness. 8) Install propeller shaft and torque nuts to specification. Tightening Torque (b): 50 N m (5.0 kg-m, 36.5 lb-ft) 9) Remove floor jack from axle housing and connect breather hose onto axle housing and clamp it securely.
  • Page 248 REAR SUSPENSION 3E-21 16) Apply sealant to mating surface of bearing retainer with brake back plate. NOTE: Make sure to remove old sealant before applying it anew. “B”: Sealant 99000-31110 1. Bearing retainer 17) Install rear axle shaft to rear axle housing and tighten bearing retainer nuts to specified torque.
  • Page 249 3E-22 REAR SUSPENSION 23) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (h): 100 N m (10.0 kg-m, 72.5 lb-ft) 24) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to ten times so as to obtain proper drum- to-shoe clearance.
  • Page 250: Tightening Torque Specifications

    16.0 Wheel nut 10.0 72.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Oil seal lip (99000-25010) Brake fluid DOT 3 Brake reservoir tank D Joint seam of axle and brake back SUZUKI BOND NO. 1215...
  • Page 251: Special Tools

    3E-24 REAR SUSPENSION SPECIAL TOOLS 09924-74510 09926-88310 09942-15510 09943-35512 Bush remover handle Oil seal installer Sliding hammer Brake drum remover 09913-75510 Oil seal installer...
  • Page 252: Wheels And Tires

    WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 253: Tires

    3F-2 WHEELS AND TIRES The metric term for tire inflation pressure is the kilopascal (kPa). kgf/cm Tire pressures will usually be printed in both kPa and psi on the Tire Placard. Metric tire gauges are available from tool suppliers. The chart, left table, converts commonly used inflation pressures from kPa to psi.
  • Page 254: Diagnosis

    WHEELS AND TIRES 3F-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. BALANCING WHEELS There are two types of wheel and tire balance: static and dynamic. Static balance, as shown in left figure, is equal distribution of weight [A]: Before correction [B]: Corrective weights around wheel.
  • Page 255: Maintenance And Minor Adjustments

    3F-4 WHEELS AND TIRES MAINTENANCE AND MINOR ADJUSTMENTS WHEEL AND TIRE Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced. STUDS If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure. MATCHED TIRES AND WHEELS (For vehicle equipped with steel wheels) Tires and wheels are matchmounted at the assembly plant.
  • Page 256 WHEELS AND TIRES 3F-5 TIRE PLACARD The tire placard is located on the driver’s side door lock pillar and should be referred to for tire information. The placard lists the maxi- mum load, tire size and cold tire pressure where applicable. TIRE ROTATION To equalize wear, rotate tires periodically as shown in figure.
  • Page 257: On-Vehicle Service

    3F-6 WHEELS AND TIRES ON-VEHICLE SERVICE WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180D (half a rotation). 2) Hoist vehicle. 3) Remove wheel. NOTE: Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings.
  • Page 258: Tire

    WHEELS AND TIRES 3F-7 TIRE MOUNTING AND DEMOUNTING Use tire changing machine to mount or demount tires. Follow equip- ment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim.
  • Page 259: Tightening Torque Specifications

    3F-8 WHEELS AND TIRES TIGHTENING TORQUE SPECIFICATIONS Tightening Torque for wheel nut (a): 100 N m (10.0 kg-m, 72.5 lb-ft)
  • Page 260: General Description

    FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-1 SECTION 4A2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL CONTENTS GENERAL DESCRIPTION ..............4A2- 1 DIAGNOSIS .
  • Page 261: Diagnosis

    4A2-2 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction D Loose wheel nuts. When starting: Tighten wheel nuts. D Loose drive shaft flange bolts. Abnormal Noise Tighten drive shaft flange bolts. D Broken or otherwise damaged wheel Replace or change.
  • Page 262: On-Vehicle Service

    FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3 ON-VEHICLE SERVICE DRIVE SHAFT REMOVAL (LEFT SIDE) 1) Hoist vehicle and remove wheel. 1. Oil filler / level plug 2. Front drain plug 2) Remove axle shaft drive flange. 3) Remove drive shaft circlip and front spindle thrust washer. 1.
  • Page 263 4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL REMOVAL (RIGHT SIDE) 1) Hoist vehicle and remove wheel. 2) Drain differential gear oil. 1. Oil filler / level plug 2. Front drain plug 3) Remove axle shaft drive flange. 4) Remove circlip and front spindle thrust washer. 5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and 9) to 14) of item COIL SPRING REMOVAL in Section 3D.
  • Page 264 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5 DISASSEMBLY 1) Remove boot band of differential side joint. 2) Slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race. 1.
  • Page 265 4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL ASSEMBLY CAUTION: D To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed. D For M/T vehicle with H25 engine To ensure full performance of joint as designed, be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint.
  • Page 266 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7 7) Apply grease to entire surface of cage. Use joint grease in tube included in spare part or joint grease (99000-25120). 8) Insert cage into outer race and fit circlip into groove of outer race.
  • Page 267 4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. D Clean front drive shaft oil seal and then apply lithium grease to oil seal and DOJ shaft. “A”...
  • Page 268: Shaft Bearing/Oil Seal

    FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-9 SHAFT BEARING/OIL SEAL REMOVAL 1) Remove drive shaft assembly. Refer to item DRIVE SHAFT REMOVAL (LEFT and RIGHT) in this section. For right side shaft bearing/oil seal removal, drain differential gear oil. 2) Remove left drive shaft by using tire lever.
  • Page 269 4A2-10 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL INSTALLATION 1) Clean drive shaft oil seal and then apply lithium grease. “A”: Grease 99000-25010 Check oil seal for breakage or deterioration. Replace it as necessary. “A” 2) Drive in drive shaft bearing with special tool (A) (on left hand side).
  • Page 270: Tightening Torque Specifications

    Refer to standard tightening torque specifications, if no description or specification is provided. REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT Joint grease SUZUKI SUPER GREASE H Drive axle joint (Molybdenum grease) (99000-25120) Drive shaft oil seal SUZUKI SUPER GREASE A...
  • Page 271: Propeller Shafts

    PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: D All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
  • Page 272 4B-2 PROPELLER SHAFTS DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction D Loose universal joint bolt. Abnormal noise Tighten universal joint bolt. D Spider bearing worn out or stuck. Replace. D Wear spider. Replace propeller shaft. D Deformed propeller shaft. Vibration Replace.
  • Page 273: Propeller Shaft

    PROPELLER SHAFTS 4B-3 ON-VEHICLE SERVICE PROPELLER SHAFT REMOVAL 1) Hoist vehicle. 2) Drain transfer oil only when servicing front propeller shaft. 3) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown. 4) Remove propeller shaft. 1.
  • Page 274 4B-4 PROPELLER SHAFTS 5) Push out bearing race on flange yoke side as described in 1) and 2), and then, holding bearing race in a vise, tap flange yoke and take out race. (Refer to the figure.) Remove bearing race on the opposite side in the same way. NOTE: D Take care not to lose rollers in spider bearing race when removing it.
  • Page 275 PROPELLER SHAFTS 4B-5 1) Insert bearing race into yoke, tapping it with a hammer, until it is flush with yoke face. When doing this, insert spider into bearing race to prevent rollers in bearing race from coming out. 1. Copper hammer 2.
  • Page 276 Tightening torque Fastener Fastener kg-m lb-ft Propeller shaft nut/Center support bolt 36.5 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUPER GREASE C Lithium grease To apply to spider bearing race. (99000-25030) SPECIAL TOOLS 09900-06108 09926-48010 Snap ring pliers Universal joint...
  • Page 277 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 278: General Description

    5-2 BRAKES 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. Brake pipes are connected to the master cylinder and they make two independent circuits.
  • Page 279: Diagnosis

    BRAKES 5-3 DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE FLUID Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid test brakes by making brake applications with both may cause the brake fluid to boil or the rubber compo- light and heavy pedal forces at various speeds to de- nents in the hydraulic system to deteriorate.
  • Page 280: Diagnosis Table

    5-4 BRAKES DIAGNOSIS TABLE Condition Possible Cause Correction D Brake oil leakage from brake lines. Not enough brak- Locate leaking point and repair. D Brake disc or pads stained with oil. ing force Clean or replace. D Overheated brakes. Determine cause and repair. D Poor contact of shoes on brake drum.
  • Page 281 BRAKES 5-5 Condition Possible Cause Correction D Partial brake system failure. Excessive pedal Check brake systems and repair as travel (Pedal necessary. D Insufficient fluid in master cylinder stroke too large) Fill reservoirs with approved brake reservoirs. fluid. Check for leaks and air in brake systems.
  • Page 282 5-6 BRAKES Condition Possible Cause Correction D Parking brake applied. Brake warning light Release parking brake and check turns on after that brake warning light turns off. D Insufficient amount of brake fluid. engine start Add brake fluid. D Brake fluid leaking from brake line. Investigate leaky point, correct it and add brake fluid.
  • Page 283: Check And Adjustment

    BRAKES 5-7 CHECK AND ADJUSTMENT BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: For vehicle equipped with ABS, make sure that ignition switch turns off.
  • Page 284 5-8 BRAKES 4) When fluid pressure in the cylinder is almost depleted, retigh- ten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hy- draulic line. 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug.
  • Page 285: Brake Pedal Free Height Check

    BRAKES 5-9 BRAKE PEDAL FREE HEIGHT CHECK Remove foot rest and displace carpet and dash silencer(s) so as to measure brake pedal free height between pedal face and asphalt sheet installed on dash panel. Brake pedal free height “a” from asphalt sheet: 208 –...
  • Page 286: Brake Pedal Play Check

    5-10 BRAKES BRAKE PEDAL PLAY CHECK Pedal play should be within speci