Suzuki SQ416 Service Manual

Suzuki SQ416 Service Manual

Volume 1 of 2 chassis/electrical/body
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Summary of Contents for Suzuki SQ416

  • Page 4 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION ENGINE GENERAL INFORMATION General Information and General Information Diagnosis Maintenance and Lubrication Engine Mechanical (G16) HEATING AND AIR Engine Mechanical (H25) CONDITIONING Engine Mechanical (J20) Heater and Ventilation Engine Cooling Air Conditioning Engine Fuel STEERING, SUSPENSION, Engine and Emission Control...
  • Page 34 0B-6 MAINTENANCE AND LUBRICATION Water pump, generator, power steering and/or Type A Type B A/C compressor (if equipped) drive belt (J20 engine) Dark green in Yellow in pulley color pulley color 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 belt.
  • Page 85 AIR CONDITIONING (OPTIONAL) 1B-11 MANIFOLD GAUGE kg/cm CONDITION CAUSE CORRECTION 0.15 – 0.25 1.37 – 1.57 1.5 – 2.5 14 – 16 Normal condition. 21.3 – 35.5 200 – 227 D The low pressure side reads D Dust particles or water D Clean expansion valve.
  • Page 90 1B-16 AIR CONDITIONING (OPTIONAL) PROCEDURE OF CHARGING LH steering vehicle shown The initial charging of the A/C system is performed from the high- pressure side with the engine stopped. And next, this method must be followed by charging from the low- pressure side with the engine running.
  • Page 91 AIR CONDITIONING (OPTIONAL) 1B-17 7) When refrigerant container is emptied, use following procedure to replace it with a new refrigerant container. a. Close low pressure valve. b. Replace empty container with a refrigerant container which has been charged with refrigerant. When using refrigerant container tap valve, use following procedure for replace- ment.
  • Page 92: Leak-Testing Refrigerant System

    1B-18 AIR CONDITIONING (OPTIONAL) b) Close refrigerant container valve. c) Stop engine. d) Using shop rag, remove charging hoses from service valves. This operation must be performed rapidly. WARNING: High-pressure side is naturally under high pressure. So, care must be used to protect your eyes and skin. e) Put caps on service valves.
  • Page 95: Refrigerating System

    AIR CONDITIONING (OPTIONAL) 1B-21 REFRIGERATING SYSTEM LH steering vehicle shown CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether A/C system with proper charge of refrigerant or not. 1) Run engine at idle speed. 2) Operate A/C system at the following conditions for a few min- utes.
  • Page 97: Installation

    AIR CONDITIONING (OPTIONAL) 1B-23 INSTALLATION Reverse removal sequence to install condenser, noting following point. 1) When replacing condenser, add 20 to 30 cc of refrigerating oil from compressor suction-side. 2) Evacuate and charge system according to previously-described procedure. RECEIVER/DRYER (IF RECEIVER/DRYER IS INDEPEND OF CONDENSER) INSPECTION Use a leak tester to check for gas leakage, sight glass and fittings.
  • Page 98 1B-24 AIR CONDITIONING (OPTIONAL) DESICCANT (IF RECEIVER/DRYER IS INTEGRATED WITH CONDENSER) REMOVAL 1) Remove A/C condenser assembly from vehicle. Refer to “Con- denser” in this section for detail. 2) Remove receiver/dryer cap from condenser. 1. A / C condenser assembly 2.
  • Page 99 AIR CONDITIONING (OPTIONAL) 1B-25 4) Remove filter cover. 1. Filter cover 5) Pull out filter element. Pull out upper filter first then the lower one. 1. Filter element CLEAN Blow off dust by compressed air from air outlet side of the filter ele- ment.
  • Page 130 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 151: Installation

    3B1-22 POWER STEERING (P / S) SYSTEM INSTALLATION Reverse removal procedure. NOTE: D Fill specified power steering fluid after installation and bleed air without failure. (Refer to item AIR BLEEDING PROCE- DURE in this section) D For tightening torques, refer to structural diagram on pre- vious page.
  • Page 183: 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 197 FRONT SUSPENSION 3D-19 D Press-fitting inner oil seal. Drive in inner oil seal until its end contacts stepped surface of knuckle using special tools. Special Tool (B): 09944-66010 (C): 09924-74510 D Apply lithium grease to oil seal lip and into its hollow to fill more than 60% of its vacant space.
  • Page 213 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 218: Rear Axle Housing

    3E-16 REAR SUSPENSION REAR AXLE HOUSING REMOVAL 1) Drain differential gear oil. Carry out steps 2) to 8) and 16) to 19) on both right and left wheels. Note that left wheel and its related parts are used in illustrations in this section.
  • Page 226: 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 09913-85210 Oil seal installer...
  • Page 260: Brake Pedal Free Height Check

    BRAKES 5-9 BRAKE PEDAL FREE HEIGHT CHECK Check brake pedal free height. 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”...
  • Page 276: Installation

    BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7 INSTALLATION NOTE: See NOTE at the beginning of this section. 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then press-fit grommets to mas- ter cylinder.
  • Page 306: Installation

    5C-8 PARKING AND REAR BRAKE Cracked, Scored, or Grooved Drum A cracked, drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will probably be necessary to re- surface drum braking surface.
  • Page 311: Brake Back Plate

    PARKING AND REAR BRAKE 5C-13 4) Install bleeder plug cap taken off from pipe back to bleeder plug. 5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE INSTALLATION. NOTE: Be sure to bleed brake system. (for bleeding operation, see page 5-7) BRAKE BACK PLATE REMOVAL...
  • Page 314: Tightening Torque Specifications

    SEALING COMPOUND 366E sealant 99000-31090 plate and rear wheel cylinder. D To apply to mating surfaces of brake back SUZUKI BOND NO. 1215 plate and rear axle housing. Sealant D To apply mating surfaces of brake back 99000-31110 plate and rear wheel bearing retainer.
  • Page 462 7E-8 DIFFERENTIAL (FRONT) ON-VEHICLE SERVICE MAINTENANCE SERVICE NOTE: D When having driven through water, check immediately if wa- ter has entered (if so, oil is cloudy). Water mixed oil must be changed at once. D Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breather hoses.
  • Page 566: Installation

    BODY SERVICE 9-13 5) Remove outer weatherstrip. CAUTION: Using a tape-wrapped putty knife (or tape-wrapped screwdriver), pry off weatherstrip. Use of an unwrapped tool will cause damage to painting. 1. Door outer weathership 2. Screw 6) Remove glass fitting screws. Then down door glass. 7) Detach rear part of glass run from center sash.
  • Page 578 BODY SERVICE 9-25 UNDER BODY DIMENSION a. Front bumper side installation hole i. 3rd mounting installation hole b. 1st mounting installation hole j. Lower rod installation hole c. Suspension frame front installation hole k. Upper rod installation hole d. Front strut installation outside hole l.
  • Page 726 POWER STEERING (P / S) SYSTEM 3B1-1 Service Bulletin SECTION 3B1 POWER STEERING (P/S) SYSTEM SUBJECT: P/S GEAR BOX RACK BOOT SERVICE PROCEDURE Removal and installation of rack boot for P/S gear box with “NPSK” ID label IDENTIFICATION The boot for the “NPSK” labeled P/S gear box can be identified by the manufacture’s logo “NDK”. Do not mix up the above boot with one whose logo is “TRW Koyo”...
  • Page 727 3B1-2 POWER STEERING (P / S) SYSTEM INSTALLATION 1) Visually inspect that rack and rack end ball joint are free from dirt or foreign matters. Clean thoroughly with cloth or such. Position boot properly in grooves of gear case and tie-rod and clamp it with wire and clip.
  • Page 730 Prepared by Overseas Service Department 1st Ed. Jan., 1998 3rd Ed. Oct., 2001 Printed in Japan Printing:...

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