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Summary of Contents for Suzuki SY413

  • Page 2 OPERATING INSTRUCTION CONTENTS ACROBAT READER SCREEN DISPLAY HOW TO READ MANUAL DATA...
  • Page 3 ACROBAT READER SCREEN DISPLAY...
  • Page 4 Page only display Only a page is displayed on the entire screen. Bookmark and page display A bookmark is displayed in the left of the screen and a page in the right. Thumbnails and page display Thumbnails are displayed in the left of the screen and a page in the right.
  • Page 5 HOW TO READ MANUAL DATA 1. By opening (i.e. double-click the icon) the “TOP.pdf” file on CD-ROM, the Acro- bat Reader is automaticaly booted and the title screen shown below. Example: 2. Click on the title screen then, the Manual List displays below. From the list, select the number assigned to the manual to be displayed and click the part number.
  • Page 6 3. Then, the “Important” page of each manual displays. At the same time, a “Book- mark” frame also displays on the left side of the screen. Example: “Important” page “Bookmark” frame...
  • Page 7 4. Click (left-button) “Foreword” in the Bookmark and “Foreword” page displays. Example: “Foreword” “Important” page “Foreword” “Foreword” page...
  • Page 8 5. Click (left-button) “Table of Contents” in the Bookmark, “Table of Contents” page displays. Example: “Table of Contents” “Foreword” page “Related manuals” “Table of Contents” page “Table of Contents” • To jump to a reference manual On the “Foreword” page, the link is pasted from manual name and manual part number of the “Related Manuals”.
  • Page 9 6. Perform the following procedure ((1) or (2)) to jump from “Table of Contents” page to first page contents of a section. (1) Click (Left-button) in the appropriate link jumps to that section (Linked at the loca- tion, at which the pointer “ ”...
  • Page 10 7. From here on, the following operations can be executed. Select the appropriate operation according to your needs. • To jump to a page that contains a title Jump to the first page of each section, on which linked to the page that contains each title.
  • Page 11 • To print the data (1) On a specific page or pages: Refer to the page number (“B”) given on the bottom of the screen and take note of it. Select “Print” (“A”) in the File menu and specify the page number(s) to be printed.
  • Page 12 3. Search necessary information in the reverse order of manual group number. For Petrol (Gasoline) Engine Model Applicable Manual Group (No.: (1) - (14)) Language Model Category Service Manual Wiring Diagram Manual Model A: SY413/SY416 (1), (3), (4) 1995-1996 Model B: SY418 1995-1996 (1), (2), (3), (4) Model C:...
  • Page 13 For Petrol (Gasoline) Engine Model Applicable Manual Group (No.: (1) - (14)) Language Model Category Service Manual Wiring Diagram Manual Model G: SY413/SY416/SY418 (13), (14) 2000 Face Lifting (1), (2), (3), (4), (6), (7), (8), (10) English French German Spanish...
  • Page 14 VIN TABLE Model A: The VIN within the range shown in the table are categorized as “Model A” GA11S-100001 GA11S-140000 GA31S-100001 GA31S-140000 GC11S-100001 GC11S-140000 GC31S-100001 GC31S-140000 JS2GA21HS 5100001 JS2GA21HS 5140000 JS2GA21HT 5100001 JS2GA21HT 5140000 JS2GA31HS 5100001 JS2GA31HT 5100001 JS2GA31HV 5100001 JS2GA21SS 5100001 JS2GA21ST 5100001 JS2GA31SS 5100001...
  • Page 15 Model C: The VIN within the range shown in the table are categorized as “Model C” JSAEGA11S00108641 JSAEGA11S00140000 JSAEGA31S00107758 JSAEGA31S00140000 JSAEGB31S00100224 JSAEGB31S00140000 JSAEGC11S00109524 JSAEGC11S00140000 JSAEGC31S00121188 JSAEGC31S00140000 JSAEGD31S00100366 JSAEGD31S00140000 Model D: The VIN within the range shown in the table are categorized as “Model D” GC31W-100001 GC31W-140000 GC41W-100001...
  • Page 16 Model E: The VIN within the range shown in the table are categorized as “Model E” GA11S-140001 GA11S-160000 GA31S-140001 GC11S-140001 GC11S-160000 GC31S-140001 GC31S-160000 GC31W-140001 GC31W-160000 GD31W-140001 JSAEGA11S00140001 JSAEGA11S00160000 JSAEGA31S00140001 JSAEGA31S00160000 JSAEGB31S00140001 JSAEGB31S00160000 JSAEGC11S00140001 JSAEGC11S00160000 JSAEGC31S00140001 JSAEGC31S00160000 JSAEGC31SV5140001 JSAEGC31SW0140001 JSAEGC31SW5160000 JSAEGD31S00140001 JSAEGD31S00160000 JSAEGC41S00140001 JSAEGC41S00160000...
  • Page 17 Model F: The VIN within the range shown in the table are categorized as “Model F” GA11S-160001 GA11S-200000 GC11S-160001 GC11S-200000 GC31S-160001 GC31S-200000 GC31W-160001 GC31W-200000 JSAEGA11S00160001 JSAEGA11S00200000 JSAEGA31S00160001 JSAEGA31S00200000 JSAEGB31S00160001 JSAEGB31S00200000 JSAEGC11S00160001 JSAEGC11S00200000 JSAEGC31S00160001 JSAEGC31S00200000 JSAEGC31SW5160001 JSAEGC31SX0160001 JSAEGD31S00160001 JSAEGD31S00200000 JSAEGC41S00160001 JSAEGC41S00200000 JSAEGC51S00160001 JSAEGC51S00200000 JSAEGC51SX0160001...
  • Page 18 Model G: The VIN within the range shown in the table are categorized as “Model G” GA11S-200001 GC11S-200001 GC31S-200001 GC31W-200001 JSAEGA11S00200001 JSAEGA31S00200001 JSAEGB31S00200001 JSAEGA41S00200001 JSAEGC11S00200001 JSAEGC31S00200001 JSAEGC31S15200001 JSAEGC31S10200001 JSAEGD31S00200001 JSAEGC41S00200001 JSAEGC51S00200001 JSAEGC51S10200001 JSAEGC11W00200001 JSAEGC31W00200001 JSAEGC31W15200001 JSAEGC31W10200001 JSAEGD31W00200001 JSAEGC41W00200001 JS2GA11S 15200001 JS2GA31S 15200001 JS2GA41S 15200001 JS2GB31S 15200001...
  • Page 19 NEXT MANUAL LIST Manual Language Manual Part Name Manual Part Number Group 99500-60G00-01E 99500-60G00-01F SY413/SY416 99500-60G00-01G Service Manual 99500-60G00-01S 99500-60G00-01D 99501-62G00-01E 99501-62G00-01F SY418 Service Manual 99501-62G00-01G 99501-62G00-01S 99501-60G01-01E 99501-60G01-01F SY416/SY418 99501-60G01-01G Supplementary Service Manual (for suspension control system) 99501-60G01-01S 99501-60G01-01D...
  • Page 20 BACK NEXT MANUAL LIST Manual Language Manual Part Name Manual Part Number Group 99501-60G20-18E SY413/SY416 99501-60G20-18F Supplementary Service Manual 99501-60G20-18G (for oxygen sensor heater 99501-60G20-18S equipped vehicle) 99501-60G20-18D 99501-60G30-01E 99501-60G30-01F SY416/SY418 99501-60G30-01G Supplementary Service Manual (for wagon) 99501-60G30-01S 99501-60G30-01D 99501-60G41-01E...
  • Page 21 BACK MANUAL LIST Manual Language Manual Part Name Manual Part Number Group SY413/SY416/SY418 99500-60G20-01E Service Manual 99501-60G60-01F SY413/SY416/SY418 (10) 99501-60G60-01G Supplementary Service Manual 99501-60G60-01S 99501-66G00-01E 99501-66G00-01F SY419 99501-66G00-01G (11) Supplementary Service Manual 99501-66G00-01S 99501-66G00-01D 99500-66G10-01E 99500-66G10-01F SY419 (12) Service Manual...
  • Page 22 SERVICE MANUAL 99500-60G00-01E...
  • Page 1367 Prepared by SUZUKI MOTOR CORPORATION Automobile Department Overseas Service Department 1st Ed, Feb., 1995 2nd Ed, Oct., 2001 Printed in Japan Printing: 1360...
  • Page 1370 D Service on or around the air bag system ings. Pay special attention to the messages high- components must be performed only by lighted by these signal words. an authorized SUZUKI dealer. Please ob- serve all WARNINGS, CAUTIONS and WARNING: “Service Precautions” under “On-Vehicle Indicates a potential hazard that could result Service”...
  • Page 1371 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
  • Page 1372 TABLE OF CONTENTS TABLE OF CONTENTS SECTION SECTION ENGINE GENERAL INFORMATION Engine (G13/G16 Engine without General Information WU-TWC) Maintenance and Lubrication Engine General Information and HEATING AND VENTILATION Diagnosis (G13/G16 Engine with WU-TWC) Heater and Ventilation Engine General Information and Air Conditioning (Optional) Diagnosis STEERING, SUSPENSION,...
  • Page 1373 GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ....0A- 2 Identification Whether Vehicle Equipped With WU-TWC or Not ....0A-16 PRECAUTIONS .
  • Page 1374: How To Use This Manual

    0A-2 GENGERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the first page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a TABLE OF CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
  • Page 1375 D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
  • Page 1376 0A-4 GENGERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BO- WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules D For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature...
  • Page 1377 GENERAL INFORMATION 0A-5 WARNING: D During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. D Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mount- ing bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the ve- hicle to ensure proper operation of the air bag system.
  • Page 1378 0A-6 GENGERAL 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 un- der “Repair and Inspection Required after an Acci- dent”...
  • Page 1379: 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 1380 0A-8 GENGERAL 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 re- installed in the proper order and position.
  • Page 1381 GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describ- ing the correct installation positions so that the hoses can be reinstalled 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 disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
  • Page 1382 0A-10 GENGERAL INFORMATION D Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. PRECAUTION FOR CATALYTIC CONVERTER For vehicles equipped with a catalytic converter, use only un- leaded gasoline and be careful not to let a large amount of un- burned gasoline enter the converter or it can be damaged.
  • Page 1383 GENERAL INFORMATION 0A-11 D When connecting connectors, also hold connectors and put them together until they lock securely (a click is heard). D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, TCM, ABS control module, SDM etc).
  • Page 1384 0A-12 GENGERAL INFORMATION 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 voltage check at low battery voltage will lead to erroneous diagnosis.
  • Page 1385: Precaution For Installing Mobile Communication Equipment

    GENERAL INFORMATION 0A-13 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-telephone, be sure to ob- serve the following precautions. Failure to follow cautions may adversely affect electronic con- trol system. D Keep the antenna as far away as possible from the vehicle’s electronic control unit.
  • Page 1386 0A-14 GENGERAL INFORMATION PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE When performing any of the following types of work, be sure to make the vehicle as front wheel drive by cutting transmission of driving force to the rear wheels. Otherwise, rear wheels are driven and vehicle accidents, damage and personal injury may result.
  • Page 1387: Intermittent And Poor Connection

    GENERAL INFORMATION 0A-15 INTERMITTENT AND POOR CONNECTION Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diag- nostic flow chart, 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 1388 0A-16 GENGERAL INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The number is located on the front dash panel in the engine room. IDENTIFICATION WHETHER VEHICLE G13/G16 EQUIPPED WITH WU-TWC OR NOT It can be identified by the shape of exhaust manifold (1) and ex- haust pipe (2).
  • Page 1389 GENERAL INFORMATION 0A-17 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 1390: Vehicle Lifting Points

    0A-18 GENGERAL INFORMATION VEHICLE LIFTING POINTS FOR 2WD VEHICLE : Support position for frame contact hoist and safety stand : Floor jack position FOR 4WD VEHICLE : Support position for frame contact hoist and safety stand : Floor jack position...
  • Page 1391 GENERAL INFORMATION 0A-19 When using frame contact hoist: WARNING: D Before applying hoist to underbody, always take ve- SUPPORT LOCATION: Forward of embossed- hicle balance throughout service into consideration. mark Vehicle balance on hoist may change depending on what part to be removed. D Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 1392: Abbreviations And Symbols May Be Used In This Manual

    0A-20 GENGERAL INFORMATION ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL ABBREVIATIONS : Anti-Lock Brake System, EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control Module : American Petroleum Institute : Engine Control Module : Automatic Transmission Fluid ECT Sensor : Engine Coolant Temperature...
  • Page 1393 GENERAL INFORMATION 0A-21 : Junction Box (Junction Block) : Throttle Body Fuel Injection (Single-Point Fuel Injection, SPI) : Left Hand : Torque Converter Clutch LSPV : Load Sensing Proportioning : Transmission Control Module Valve (A/T Controller, A/T Control Module) MAF Sensor : Mass Air Flow Sensor TP Sensor : Throttle Position Sensor...
  • Page 1394 0A-22 GENGERAL INFORMATION WIRE COLOR SYMBOLS Symbol Wire Color Symbol Wire color Black Orange Blue Brown White Green Yellow Gray Pink LT BLU Light blue Violet LT GRN Light green There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire.
  • Page 1395: Metric Fasteners

    GENERAL INFORMATION 0A-23 FASTENER INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replace- ment 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 em- bossed on the head of each bolt.
  • Page 1396: Standard Tightening Torque

    0A-24 GENGERAL 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 1397 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
  • Page 1398 0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at Interval: the same intervals respectively. This interval should be judged by This interval should be judged by ( 1,000) odometer reading or months,...
  • Page 1399 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 out the same services at Interval: the same intervals respectively. This interval should be judged by This interval should be judged by ( 1,000) odometer reading or months, whichever comes first.
  • Page 1400 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 1401 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and adjusting belt tension. 1.3L, 1.6L Engine Vehicle with A/C A/C Compressor and/or Power Steering Pump Drive Belt Inspection (If equipped) 1) Detach air cleaner assembly from vehicle body and shift its position.
  • Page 1402 0B-6 MAINTENANCE AND LUBRICATION Water Pump Belt Replacement Replace belt with new one. Refer to SECTION 6B for replacement procedure of pump belt. NOTE: When replacing belt with a new one, adjust belt tension to 5 – 7 mm (0.20 – 0.27 in.). 1.
  • Page 1403 MAINTENANCE AND LUBRICATION 0B-7 ITEM 1-3 (Except 1.8L Engine model) Valve Lash Inspection 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 adjust- ment procedure. When cold (Cool- When hot (Cool- ant temperature...
  • Page 1404 0B-8 MAINTENANCE AND LUBRICATION 4) Apply engine oil to new oil filter O-ring. 5) Screw new filter on oil filter stand by hand until filter O-ring con- tacts mounting surface. CAUTION: To tighten oil filter properly, it is important to accurate- ly identify the position at which filter O-ring first con- tacts mounting surface.
  • Page 1405 MAINTENANCE AND LUBRICATION 0B-9 ITEM 1-5 1.3L and 1.6L Engine model Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot. Scald- ing fluid and steam can be blown out under pressure if cap is taken off too soon.
  • Page 1406 0B-10 MAINTENANCE AND LUBRICATION When carrying out periodic maintenance or vehicle is raised for other service, check exhaust system as follows: D Check rubber mountings for damage and deterioration. D Check exhaust system for leakage, loose connections, dents, and damages. If bolts or nuts are loose, tighten them to specification.
  • Page 1407: Emission Control System

    MAINTENANCE AND LUBRICATION 0B-11 ITEM 3-2 Fuel Lines Inspection D Check fuel lines for loose connection, deterioration or damage which could cause leakage. Make sure all clamps are secure. D Replace any damaged or deteriorate parts. There should be no sign of fuel leakage or moisture at any fuel connection.
  • Page 1408 0B-12 MAINTENANCE AND LUBRICATION BRAKE ITEM 5-1 Brake Discs, Pads, Drums and Shoes Inspection Brake discs and pads 1) Remove wheel and caliper but don’t disconnect brake hose from caliper. 2) Check disc brake pads and discs for excessive wear, damage and deflection.
  • Page 1409 MAINTENANCE AND LUBRICATION 0B-13 ITEM 5-3 Brake Fluid Change Change brake fluid as follows. Drain existing fluid from brake system completely, fill system with specified fluid and carry out air purge operation. For air purging procedure, refer to SECTION 5. ITEM 5-4 “a”: Parking brake lever stroke: Brake Lever and Cable Inspection...
  • Page 1410 0B-14 MAINTENANCE AND LUBRICATION ITEM 6-2 Tire and Wheel Disc Inspection [Tire inspection] 1) Check tire for uneven or excessive wear, or damage. If defec- tive, replace. 1. Wear indicator 2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
  • Page 1411 MAINTENANCE AND LUBRICATION 0B-15 ITEM 6-3 Propeller Shaft Inspection (4WD vehicle only) 1) Check propeller shaft connecting bolts for looseness. If loose- ness is found, tighten to specified torque. 2) Check propeller shaft joints for wear, play and damage. If any defect is found, replace.
  • Page 1412 0B-16 MAINTENANCE AND LUBRICATION 2) Check steering linkage for looseness and damage. Repair or replace defective parts, if any. 3) Check boots of steering linkage and steering gear case for dam- age (leaks, detachment, tear, etc.). If damage is found, replace defective boot with new one.
  • Page 1413 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-7 Rear Differential Oil Inspection and Change (4WD vehicle only) [Inspection] 1) Inspect rear differential case for evidence of oil leakage. Repair leaky point, if any. 2) Make sure that the vehicle is placed level for oil level check. 3) Remove level plug of differential.
  • Page 1414 0B-18 MAINTENANCE AND LUBRICATION [Fluid cooler hose change] 4-speed A/T Replace inlet and outlet hoses of cooler hose and their clamps. For replacement procedure, refer to ON-VEHICLE SERVICE in SECTION 7B or 7B1. 1. Radiator 2. Inlet hose (Outlet from oil cooler) 3.
  • Page 1415 MAINTENANCE AND LUBRICATION 0B-19 FINAL INSPECTION On automatic transmission vehicles, try to start the en- gine in each gear. The starter should crank only in “P” WARNING: (Park) or “N” (Neutral). When carrying out road tests, select a safe On manual transmission vehicles, place the shift lever place where no man or no running vehicle is in “Neutral,”...
  • Page 1416 0B-20 MAINTENANCE AND LUBRICATION [Parking brake] Body, Wheels and Power Transmitting System Check that lever has proper travel. Check that body, wheels and power transmitting sys- tem are free from abnormal noise and abnormal vibra- WARNING: tion or any other abnormal condition. With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any personal injury or property damage.
  • Page 1417 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
  • Page 1418 1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION COMPONENTS 1. Side face air 2. Demister air 3. Center face air 4. Foot air 5. Defroster air 6. Heater unit 7. Air duct 8. Blower motor unit 9. Control lever assembly 10. Defroster nozzle 11.
  • Page 1419 HEATER AND VENTILATION 1A-3 WIRING CIRCUIT For LH vehicle 1. Main fuse box 2. Generator 3. Cassette fuse 4. Fuse and relay box 5. Ignition switch 6. Junction box (J/B) 7. Blower fan motor relay 8. Blower fan motor 9. Blower fan motor resistor 10.
  • Page 1420 1A-4 HEATER AND VENTILATION For RH vehicle 1. Main fuse box 2. Generator 3. Cassette fuse 4. Fuse and relay box 5. Ignition switch 6. Junction box (J/B) 7. Blower fan motor relay 8. Blower fan motor 9. Blower fan motor resistor 10.
  • Page 1421 HEATER AND VENTILATION 1A-5 HEATER CONTROL OPERATION The heater and ventilation provide temperature control, ventilation and defrosting functions. Their operation is controlled by selecting the positions of the control levers and mode select switch on the instrument panel. Each lever / switch position and function of heater and ventilation are as given below. Switch Lever C Lever B...
  • Page 1422 1A-6 HEATER AND VENTILATION BODY VENTILATION The body ventilation system of this vehicle is equipped with air conditioning that consists of a fresh air intake lo- cated at the cowl top panel. Ventilating air is drawn into the interior from the intake grille and drawn out from the ventilator outlet provided at each side of the body outer panel.
  • Page 1423 HEATER AND VENTILATION 1A-7 DIAGNOSIS Trouble Possible cause Remedy D Fuse blown D Replace fuse to check for short. Heater blower won’t work D Blower resistor faulty D Check continuity. even when its switch is ON. D Blower motor faulty D Replace motor.
  • Page 1424 1A-8 HEATER AND VENTILATION ON-VEHICLE SERVICE BLOWER FAN MOTOR 1. Blower fan motor unit 2. Blower fan motor resistor 3. Blower fan motor relay 4. Blower fan 5. Blower fan motor assembly REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system.
  • Page 1425 HEATER AND VENTILATION 1A-9 BLOWER FAN MOTOR RESISTOR REMOVAL 1) Disconnect resistor coupler. 2) Remove heater blower fan motor resistor. INSPECTION Check blower fan motor resistor for each terminal-to-terminal con- tinuity. If there is no continuity, replace blower fan motor resistor. INSTALLATION Reverse removal procedure for installation.
  • Page 1426: Heater Unit

    1A-10 HEATER AND VENTILATION HEATER UNIT For LH vehicle For RH vehicle 1. Heater case 2. Damper 3. Heater core 4. Control lever 5. Mode actuator...
  • Page 1427 HEATER AND VENTILATION 1A-11 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 col- umn vertical.
  • Page 1428 1A-12 HEATER AND VENTILATION 8) Pull out heater core from unit. 1. Heater core INSTALLATION Reverse removal procedure for installation, and then noting the fol- lowing instructions. D When installing each part, be careful not to catch any cable or wiring harness.
  • Page 1429 HEATER AND VENTILATION 1A-13 HEATER CONTROL LEVER ASSEMBLY REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag, disable air bag system. Refer to “Disab- ling Air Bag System” in SECTION 9J. 3) Remove control lever knobs and center garnish mounting screw.
  • Page 1430 1A-14 HEATER AND VENTILATION HEATER CONTROL CABLES 1. Heater unit 2. Blower fan motor unit 3. Fresh air control cable 4. Air control cable 5. Heater control lever assembly REMOVAL 1) Remove control lever assembly. Refer to “HEATER CONTROL LEVER ASSEMBLY” in this section. 2) Remove heater control cables from control lever assembly.
  • Page 1431 HEATER AND VENTILATION 1A-15 D Fresh Air Control (FRESH-CIRC Selector) Cable – Move control lever to “CIRCULATION” position as full as pos- sible. – Push lever fully in arrow direction and fix cable with clamp in position as shown. D After installing control cables, be sure that control knobs move smoothly and stop at proper position.
  • Page 1432 1A-16 HEATER AND VENTILATION INSPECTION Mode Control Switch D Check if continuity exists between each pair of terminals listed below when mode control button is pressed. Indicator lamp Mode Mode control switch terminals FACE F – M BI-LEVEL F – N FOOT F –...
  • Page 1433 HEATER AND VENTILATION 1A-17 MODE ACTUATOR 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 9J. 3) Disconnect mode actuator coupler. 4) Disconnect mode actuator rod from heater unit. 5) Remove mode actuator from heater unit.
  • Page 1434 1A-18 HEATER AND VENTILATION REAR DUCT (EXCEPT HATCH-BACK MODEL) 1. Rear duct 2. Rear hose LH 3. Rear hose RH 4. Heater unit REMOVAL 1) Remove front seat. 2) Remove console box, parking brake lever cover and console box front extension. 3) Take off carpet till rear duct is totally exposed.
  • Page 1435 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
  • Page 1436 1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION The present vehicle can be optionally provided with an air conditioning. This Section covers the description, charg- ing of refrigerant, etc. of the air conditioning. MAJOR COMPONENTS AND REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM For LH Vehicle For RH Vehicle : Liquid...
  • Page 1437 AIR CONDITIONING (OPTIONAL) 1B-3 FUNCTION OF EACH COMPONENT COMPRESSOR Compresses the gas vaporized in the evaporator. Thus compressed gas is sent to the condenser where it is changed into liquid refrigerant whose heat of vaporization can be reused. Compressors used for the air conditioning of vehicle include recip- rocating-, vane rotary-, swash plate-, and wobble plate- types.
  • Page 1438 1B-4 AIR CONDITIONING (OPTIONAL) DUAL PRESSURE SWITCH A control switch to stop further rotation of the compressor by turn- ing OFF the electric circuits of the magnetic clutch and condenser cooling fan when the cycling refrigerant is abnormally dropped or risen in pressure.
  • Page 1439 AIR CONDITIONING (OPTIONAL) 1B-5 WIRING CIRCUIT For LH model 1. Main fuse box 11. Mode controller 2. Fuse and relay box 12. A/C amplifier 3. Cassette fuse 13. ECM 4. Junction box (J/B) 14. Condenser fan motor relay 5. Ignition switch 15.
  • Page 1440 1B-6 AIR CONDITIONING (OPTIONAL) For RH model 1. Main fuse box 11. Mode controller 2. Fuse and relay box 12. A/C amplifier 3. Cassette fuse 13. ECM 4. Junction box (J/B) 14. Condenser fan motor relay 5. Ignition switch 15. Compressor relay 6.
  • Page 1441 AIR CONDITIONING (OPTIONAL) 1B-7 FUNCTION OF EACH CONTROL COMPONENT D A/C ON-OFF control: RELAY (condenser fan/magnet clutch) High refrigerant pressure: A relay to operate the condenser fan motor and mag- above 3140 kPa netic clutch. The motor continues operation as long as (32 kg/cm , 455 psi) .
  • Page 1442: Refrigerant Recovery

    1B-8 AIR CONDITIONING (OPTIONAL) RECOVERY, EVACUATION AND CHARGING REFRIGERANT RECOVERY When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharg- ing it into atmosphere would cause adverse effect to environments. NOTE: When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
  • Page 1443 AIR CONDITIONING (OPTIONAL) 1B-9 CHARGING SYSTEM WITH REFRIGERANT The air conditioning system contains HFC-134a (R-134a). Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service con- tainer. When charging refrigerant recovered by using the refrigerant recovery and recycling equipment (when recycling refrigerant), follow the procedure described in the equipment manufacturer’s instruction manual.
  • Page 1444 1B-10 AIR CONDITIONING (OPTIONAL) PROCEDURE OF CHARGING 1) Check to make sure that hoses are routed properly after eva- cuating the system (see left figure). 2) Connect the manifold gauge set in position. Thus open refriger- ant container valve to purge the charging line. Then open the low pressure-side valve.
  • Page 1445 AIR CONDITIONING (OPTIONAL) 1B-11 6) After the system has been charged with specified amount (600 g, 21.0 oz) of refrigerant or when low and high pressure gauges have indicated specified value below respectively, close low pressure side valve of manifold gauge set. At this time, look into the sight glass of receiver/dryer and check that there are no bubbles in it, which means that the system is fully charged.
  • Page 1446 1B-12 AIR CONDITIONING (OPTIONAL) LEAK-TESTING REFRIGERANT SYSTEM Whenever a refrigerant leak is suspected in the system or any ser- vice operation has been performed which may result in disturbing lines or connections, it is advisable to test for leaks. Common sense should be used in performing any refrigerant leak test, since the need and extent of any such test will, in general, depend upon the nature of a complaint and the type of a service performed on...
  • Page 1447 AIR CONDITIONING (OPTIONAL) 1B-13 DIAGNOSIS Condition Possible cause Correction No cooling or warm air. Magnetic clutch does not engage properly a) Fuse blown Replace fuse and check for short. b) Magnet clutch faulty Check clutch. c) A/C switch faulty Check switch. d) thermistor faulty Check thermistor.
  • Page 1448 1B-14 AIR CONDITIONING (OPTIONAL) TROUBLESHOOTING PROCEDURE USING MANIFOLD GAUGE SET This procedure enables the technician to discover and repair cool- ing problems by having the pressures of both the high and low pressure sides indicated on the respective gauges of the manifold gauge set.
  • Page 1449 AIR CONDITIONING (OPTIONAL) 1B-15 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 1450 1B-16 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE NOTE 1/2 inch pipe : 20 – 25 N·m (2.0 – 2.5 kg-m, 14.5 – 18.0 lb-ft) When servicing air conditioning system, the following 5/8 inch pipe : 30 – 35 N·m rules must be observed. (3.0 –...
  • Page 1451 AIR CONDITIONING (OPTIONAL) 1B-17 REFRIGERATING SYSTEM 1. Receiver/Dryer 2. Sight glass 3. Bubbles A. 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. cooling capacity for a few minutes.
  • Page 1452 1B-18 AIR CONDITIONING (OPTIONAL) B. CONDENSER Inspection Check a) condenser fins for blockage, b) condenser fittings for leakage, and c) condenser fins for damage. Clogged condenser fins should be washed with water, and should be dried with compressed air. NOTE: Be careful not to damage condenser fins.
  • Page 1453 AIR CONDITIONING (OPTIONAL) 1B-19 9) Disconnect fan motor wire at coupler. 10) Remove condenser together with fan and receiver/dryer. NOTE: Be careful not to damage fins of condenser and radiator. 11) Remove cooling fan and receiver/dryer from condenser. Installation Reverse removal sequence to install condenser, noting following point.
  • Page 1454 1B-20 AIR CONDITIONING (OPTIONAL) D. EVAPORATOR (COOLING UNIT) Removal 1) Disconnect negative (–) cable at battery. 2) Disable air bag system. Refer to “Disabling Air Bag System” in Section 9J. 3) Recover refrigerant by using recovery and recycling equip- ment. Be sure to follow the instruction manual for the equip- ment.
  • Page 1455 AIR CONDITIONING (OPTIONAL) 1B-21 Inspection 1) Check evaporator fins for blockage. If found clogged, use com- pressed air to clean the fins. NOTE: Do not use water for cleaning of evaporator. 2) Check inlet and outlet fittings for crack or scratch. Repair them as required.
  • Page 1456 1B-22 AIR CONDITIONING (OPTIONAL) F. EVAPORATOR THERMISTOR A thermistor is a temperature sensor to sense the temperature of air discharge from evaporator. The electrical characteristic is shown left. When temperature is lower than specified, amplifier makes mag- net clutch turn off to prevent evaporator from frosting. Removal Refer to items REMOVAL and DISASSEMBLY in the section of EVAPORATOR.
  • Page 1457 AIR CONDITIONING (OPTIONAL) 1B-23 G. REFRIGERANT LINES 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 equip- ment.
  • Page 1458 1B-24 AIR CONDITIONING (OPTIONAL) ADJUSTMENT OF IDLE SPEED WITH A/C ON Refer to “6E1” or “6E2” of ELECTRONIC FUEL INJECTION sec- tion. DUAL PRESSURE SWITCH This vehicle is equipped with switch which operates according to high or low pressure. Inspection 1) Check switches for continuity at normal temperature (approx.
  • Page 1459 AIR CONDITIONING (OPTIONAL) 1B-25 COMPRESSION SYSTEM General Information When servicing the compressor, keep dirt or foreign The operations described below are based on bench material away from getting on or into the compressor overhaul with compressor removed from the vehicle, parts and system.
  • Page 1460 1B-26 AIR CONDITIONING (OPTIONAL) A. COMPRESSOR Inspection 1) Install manifold gauge set, referring to “Troubleshooting pro- cedure using manifold gauge set” in this section. 2) Run engine at fast idle. 3) Check compressor for the following: i) High pressure gauge reading is not low and low pressure gauge reading is not higher than normal.
  • Page 1461 AIR CONDITIONING (OPTIONAL) 1B-27 Installation Reverse removal procedure noting the following point. 1) Tighten (a) first, and then (b). Tightening Torque (a), (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) 2) Pour new compressor oil by the same amount as that drained from compressor.
  • Page 1462 1B-28 AIR CONDITIONING (OPTIONAL) C. DRIVE BELT (FOR 1.3L and 1.6L ENGINE MODELS) Inspection 1) Check belt for wear and crack, and replace it as required. 2) Check belt tension by measuring how much it deflects when pushed at intermediate point between Power Steering (P/S) pump pulley and crank pulley with about 100 N (10 kg, 22 Ib) force.
  • Page 1463 AIR CONDITIONING (OPTIONAL) 1B-29 E. MAGNET CLUTCH 1. Armature plate screw 2. Armature plate 3. Circlip 4. Magnet clutch 5. Washer 6. Shim 7. Oil felt ring 8. Magnet clutch coil 9. Lip type seal 10. Compressor front head 11. Compressor body assembly 12.
  • Page 1464 1B-30 AIR CONDITIONING (OPTIONAL) 4) Remove lead wire clamp. 5) Remove felt ring and shims from shaft. 6) Using special tool (C), remove circlip. Special Tool (C): 09900-06107 7) Remove magnet clutch lead wire clamp screw, and disconnect magnet clutch read wire. 8) Remove magnet clutch with puller.
  • Page 1465 AIR CONDITIONING (OPTIONAL) 1B-31 5) Adjust clearance, between armature plate and magnet clutch by putting shim on compressor shaft. Standard clearance “a”: 0.3 – 0.5 mm (0.012 – 0.020 in.) 6) Tighten new armature plate screw as specified below. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) Special Tool (A): 09991-06020...
  • Page 1466 1B-32 AIR CONDITIONING (OPTIONAL) F. LIP TYPE SEAL Removal 1) Remove magnet clutch, referring to “C. MAGNET CLUTCH” in this section. 2) Remove front head mounting screw (8 pcs). 1. Case 2. Front head 3) Remove front head pushing cylinder shaft. NOTE: Be careful not to remove cylinder from case.
  • Page 1467 AIR CONDITIONING (OPTIONAL) 1B-33 2) Coat special tool (F) surface with oil and install it to the shaft. Special Tool (F): 09991-06040 3) Install O-ring to case. 4) Apply A/C oil to lip seal and O-ring. 5) Install front head assembly. 1.
  • Page 1468 1B-34 AIR CONDITIONING (OPTIONAL) PERFORMANCE TEST After finishing all repairs, make sure to carry out performance test of air conditioning system as follows. PROCEDURE 1) Connect high and low side charging hose of manifold gauge set to hose fittings of compressor. 2) Run engine, and keep compressor speed at 2,000 rpm.
  • Page 1469 AIR CONDITIONING (OPTIONAL) 1B-35 HOW TO READ RELATIVE HUMIDITY (5F) Measure wet-bulb temperature and dry-bulb temperature on the psychrometer at the evaporator air inlet, follow lines at those temperatures and read the relative humidity curve at their intersection. Example: If dry-bulb temperature is 905F and wet-bulb temperature is 785F, the relative humidity is HOW TO READ RELATIVE HUMIDITY (5C) Measure wet-bulb temperature and dry-bulb...
  • Page 1470 1B-36 AIR CONDITIONING (OPTIONAL) SPECIAL TOOLS 09900-06107 09900-06108 Snap ring pliers Snap ring pliers 09991-06030 09991-06040 (Opening type) (Closing type) Armature plate remover Lip type seal protector 09991-06050 09991-06020 09991-06010 Lip type seal installer Armature plate spanner Magnet clutch pulley installer...
  • Page 1471 D Service on or around Air Bag System Components or Wiring must be performed only by an au- thorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in SEC- TION 9J under “On-Vehicle Service” and the Air Bag System Component and Wiring Location view in SECTION 9J before performing service on or around Air Bag System Components or Wiring.
  • Page 1472 3-2 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) GENERAL DIAGNOSIS Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
  • Page 1473 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) 3-3 GENERAL DIAGNOSIS CHART B Condition Possible Cause Correction Shimmy, Shake or 1. Tire or wheel out of balance. Balance wheels or replace tire and/or wheel. Vibration 2. Loose wheel bearings. Replace wheel bearing. 3.
  • Page 1474 3-4 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) GENERAL DIAGNOSIS CHART C Condition Possible Cause Correction Rack and Pinion Noise 1. Loose steering gear case bolts. Tighten. (Rattle or Chuckle) 2. Worn rack bush. Replace. 3. Rack and pinion adjustment. Check and adjust rack & pinion torque. (Manual steering only.) Abnormal Noise, 1.
  • Page 1475 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) 3-5 GENERAL DIAGNOSIS CHART D Condition Possible Cause Correction Low or Uneven Trim 1. Broken or sagging springs. Replace. Height 2. Over loaded. Check loading. Right-to-left trim height 3. Incorrect springs. Replace. (H) difference should be within 15 mm (0.6 in) with curb weight.
  • Page 1476: Wear Indicators

    3-6 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, im- proper alignment. If the following conditions are noted, rotation is necessary: 1) Front tire wear is different from rear.
  • Page 1477 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) 3-7 1) Ride vehicle to determine whether the front or rear waddles. 2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end of ve- hicle.
  • Page 1478 3-8 STEERING, SUSPENSION, WHEELS AND TIRES (DIAGNOSIS) RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment.
  • Page 1479 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ......Preliminary Checks Prior to Adjusting Front Alignment .
  • Page 1480 3A-2 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel.
  • Page 1481 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length ( “A”...
  • Page 1482 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are per- forming service on or near the air bag system components or wiring.
  • Page 1483 3B-2 MANUAL RACK AND PINION GENERAL DESCRIPTION The rack and pinion steering system consists of two main components, the rack and the pinion. When the steering wheel is turned, the motion is transmitted to the steering shaft, shaft joint and then to the pinion. Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear motion.
  • Page 1484 MANUAL RACK AND PINION 3B-3 ON-VEHICLE SERVICE LUBRICATION *SUZUKI SUPER GREASE (E) 99000-25050, When inner parts of the steering gear case were or Lithium grease (applicable for -405C  1305C disassembled, they should be washed clean be- or -405F  2665F) fore reassembly.
  • Page 1485 3B-4 MANUAL RACK AND PINION REMOVE AND INSTALL MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL 1) Slide driver’s seat as far back as possible. 2) Pull off front part of floor mat on driver’s side and remove steer- ing shaft joint covers.
  • Page 1486 MANUAL RACK AND PINION 3B-5 INSTALLATION 1) Mount steering gear case to body and tighten gear case mount bolts to specified torque. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) 1. Vehicle body 3. Case mount bolt 2. Steering gear case 4.
  • Page 1487 3B-6 MANUAL RACK AND PINION REMOVE AND INSTALL RACK BOOT/TIE REMOVAL 1) Remove steering gear case by performing Steps 1) to 8) in STEERING GEAR CASE REMOVAL of this section. 2) For ease of adjustment after installation, make marking of tie rod end lock nut position of tie rod thread.
  • Page 1488 MANUAL RACK AND PINION 3B-7 INSTALLATION 1. Steering rack 2. Tie rod lock washer 1) Install new tie rod lock washer as shown and tie rod to rack. 3. Tie rod Align straight part “A” of washer with flat part “B” of rack. 2) Tighten tie rod inside ball to specified torque.
  • Page 1489 4. Rack damper screw lock nut INSTALLATION 1) Apply grease lightly to sliding part of plunger against rack. Grease: SUZUKI SUPER GREASE E (99000-25050) 2) Install rack plunger, rack plunger spring, rack damper screw to steering case in direction shown. Tighten rack damper screw to specified torque.
  • Page 1490 MANUAL RACK AND PINION 3B-9 REMOVE AND INSTALL STEERING PINION REMOVAL 1) Remove rack plunger. 2) Remove bearing plug with special tool (A). Special Tool (43 mm socket) (A): 09944-26011 3) Tap on position as shown with plastic hammer to separate pin- ion assembly from housing.
  • Page 1491 3B-10 MANUAL RACK AND PINION REMOVE AND INSTALL STEERING RACK REMOVAL 1) Remove steering gear case. 2) Remove boot wires and clips. 3) Move both boots toward tie rod end. 4) Unbend bent part of tie rod lock washers and remove tie rods from right and left sides of steering rack.
  • Page 1492 MANUAL RACK AND PINION 3B-11 REMOVE AND INSTALL PINION BEARING REMOVAL 1) Remove rack from steering gear case, referring to STEERING RACK REMOVAL of this section. 2) Pull out pinion bearing from gear case with special tools (A)and (B) as shown. Special Tools (A): 09921-20200 (B): 09930-30104...
  • Page 1493 3B-12 MANUAL RACK AND PINION REMOVE AND INSTALL RACK BUSHING REMOVAL NOTE: When removing rack bushing, be careful not to pull out bush- ing by holding gear case in a vise. Or housing (pipe) may come off gear case. For this work, be sure to use the specified spe- cial tool.
  • Page 1494 MANUAL RACK AND PINION 3B-13 RACK AND PINION INSPECTION STEERING RACK BOOT Hoist vehicle. Inspect each boot for tear. A torn boot allows entry of dust and wa- ter which can cause wear to steering rack and pinion to produce noise as well as rust to result in malfunction of steering system.
  • Page 1495: Steering Rack

    3B-14 MANUAL RACK AND PINION RACK PLUNGER 1) Inspect rack plunger for wear or damage. 2) Inspect rack plunger spring for deterioration. In either case, if found defective, replace. 1. Rack plunger 2. Plunger spring STEERING PINION 1) Inspect pinion teeth surface for wear or damage. 2) Inspect oil seal for damage.
  • Page 1496 MANUAL RACK AND PINION 3B-15 STEERING WHEEL Check steering wheel for play and rattle, holding car in straight for- ward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.2 in.) If steering wheel play is not within specification, inspect as follows and replace if found defective.
  • Page 1497 3B-16 MANUAL RACK AND PINION REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Sliding part of rack against steering hous- ing (All around rack plunger, rack bushing and rack) D Sliding part against steering pinion (Oil seal Lithium grease SUPER GREASE (E)
  • Page 1498 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are per- forming service on or near the air bag system components or wiring.
  • Page 1499 3B1-2 POWER STEERING (P/S) SYSTEM GENERAL DESCRIPTION The power steering (P/S) system in this vehicle reduces the driver’s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all built in the steering gear box.
  • Page 1500 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 1501 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 1502 POWER STEERING (P/S) SYSTEM 3B1-5 FLOW CONTROL VALVE As the discharge rate of the P/S pump increases in proportion to the pump revolution speed, a flow control valve is added to control it so that the optimum amount of fluid for steering operation is sup- plied according to the engine speed (driving condition).
  • Page 1503 3B1-6 POWER STEERING (P/S) SYSTEM RELIEF VALVE The relief valve located in the flow control valve controls the maxi- mum hydraulic pressure. The steel ball in the relief valve is under the hydraulic pressure in the circuit coming through orifice A .
  • Page 1504 POWER STEERING (P/S) SYSTEM 3B1-7 DIAGNOSIS Condition Possible Cause Correction D Fluid deteriorated, low viscosity, different type of Steering wheel feels Replace fluid. heavy fluid mixed D Pipes or hoses deformed, air entering through (at low speed) Replace defective part. joint D Insufficient air purging from P/S circuit Purge air.
  • Page 1505 3B1-8 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 1506 POWER STEERING (P/S) SYSTEM 3B1-9 ON-VEHICLE SERVICE INSPECTION STEERING WHEEL PLAY 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 1507 3B1-10 POWER STEERING (P/S) SYSTEM POWER STEERING BELT For vehicle equipped with A/C (1.3 L and 1.6 L engine models) 1) Detach air cleaner assembly from body and shift its position. Push 2) Check that belt is free from any damage and properly fitted in pulley groove.
  • Page 1508 POWER STEERING (P/S) SYSTEM 3B1-11 GENERATOR BELT (1.8 L engine model) Vehicle without A/C 1) Remove engine under cover of right side from vehicle body. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found replace generator belt by refer- ring to “GENERATOR BELT”...
  • Page 1509 3B1-12 POWER STEERING (P/S) SYSTEM FLUID LEAKAGE Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided. Then visually check gear box, P/S pump and P/S fluid reservoir themselves and each joint of their connecting pipes for leakage.
  • Page 1510 POWER STEERING (P/S) SYSTEM 3B1-13 HYDRAULIC PRESSURE IN P/S CIRCUIT [1.3 L and 1.6 L engine models] 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 1511 3B1-14 POWER STEERING (P/S) SYSTEM 5) Check relief pressure D Increase engine speed to about 1,500 r/min (rpm). Close gauge valve gradually while watching pressure increase in- dicated by gauge and take reading of relief pressure (maxi- mum hydraulic pressure). Relief pressure: 7200 –...
  • Page 1512 POWER STEERING (P/S) SYSTEM 3B1-15 TIE ROD END BOOT Check boot for crack and damage and if any, replace it with a new one. STEERING SHAFT JOINT Check each shaft joint for wear, breakage and any other damage and if any, replace it with a new one. AIR BLEEDING PROCEDURE 1) Jack up the front end of vehicle and apply safety stands.
  • Page 1513 3B1-16 POWER STEERING (P/S) SYSTEM REMOVE, INSPECT AND INSTALL TIE ROD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove split pin and tie rod end castle nut. 1. Tie rod end 2. Knuckle 3. Castle nut 4. Split pin 3) Using special tool, remove tie rod end from knuckle.
  • Page 1514 POWER STEERING (P/S) SYSTEM 3B1-17 3) Bend split pin as shown in figure. 1. Castle nut 2. Split pin 4) After installing wheels, lower vehicle and tighten wheel nuts to specified torque. 5) Check that proper amount of toe-in is obtained. (Refer to FRONT WHEEL ALIGNMENT.) 6) After confirming proper amount of toe-in, tighten tie rod end lock nut to specified torque.
  • Page 1515 3B1-18 POWER STEERING (P/S) SYSTEM REMOVE AND INSTALL POWER STEERING GEAR BOX POWER STEERING GEAR BOX COMPONENTS [1.3 L and 1.6 L engine models] [1.8 L engine model] 1. Steering pinion side mount 2. Steering rack side mount 3. Gasket 4.
  • Page 1516 POWER STEERING (P/S) SYSTEM 3B1-19 REMOVAL 1) Take out fluid in P/S fluid reservoir with syringe or such. 2) After removing joint covers, loosen steering shaft upper joint bolt (but it must not be removed) and remove lower joint bolt. CAUTION: Be sure to set front wheels (tires) in straight direction and remove ignition key from key cylinder before the...
  • Page 1517 3B1-20 POWER STEERING (P/S) SYSTEM 8) [1.8 L engine model] [1.8 L engine model] i) Remove engine under cover (both sides), exhaust pipe No.2 and mounting member. ii) Remove exhaust pipe rear stiffener. iii) Remove engine rear mounting bracket No.2 with engine rear mounting bracket from engine block and transmission case.
  • Page 1518 POWER STEERING (P/S) SYSTEM 3B1-21 D Use specified torque as given below. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) (b): 20 N·m (2.0 kg-m, 14.5 lb-ft) (c): 33 N·m (3.3 kg-m, 24.0 lb-ft) (d): 35 – 55 N·m (3.5 – 5.5 kg-m, 25.5 – 39.5 lb-ft) (e): 25 N·m (2.5 kg-m, 18.0 lb-ft) D For installing each part, refer to respective section as indicated be- low.
  • Page 1519 3B1-22 POWER STEERING (P/S) SYSTEM REMOVE AND INSTALL TIE ROD/RACK BOOT REMOVAL Make marking here. 1) Remove steering gear box from vehicle referring to STEERING GEAR BOX REMOVAL in this section. 2) For ease of adjustment after installation, make marking of tie rod end lock nut position of tie rod thread.
  • Page 1520 POWER STEERING (P/S) SYSTEM 3B1-23 5) Install tie rod end lock nut and tie rod end to tie rod. Position lock nut to marking made in removal. Marking made in removal. NOTE: When tie rod was replaced, measure length “A” on re- moved tie rod and use it on new replacement tie rod so as to position lock nut properly.
  • Page 1521 3B1-24 POWER STEERING (P/S) SYSTEM REMOVE AND INSTALL POWER STEERING PUMP COMPONENTS [1.3 L and 1.6 L engine models] Tightening Torque (a) : 55 N·m (5.5 kg-m, 40.0 lb-ft) (b) : 10 N·m (1.0 kg-m, 7.5 lb-ft) (c) : 35 N·m (3.5 kg-m, 25.5 lb-ft) (d) : 65 N·m (6.5 kg-m, 47.5 lb-ft) [1.8 L engine model] 1.
  • Page 1522 POWER STEERING (P/S) SYSTEM 3B1-25 REMOVAL (1.3 L and 1.6 L engine models) NOTE: Be sure to clean each joint of suction and discharge sides thoroughly before removal. 1) Remove engine under cover of right side, loosen belt tension pulley and remove P/S V-ribbed belt. 2) Disconnect high pressure hose and suction hose from pump.
  • Page 1523 3B1-26 POWER STEERING (P/S) SYSTEM 4) Disconnect high pressure hose and suction hose from power steer- ing pump. As fluid flows out of disconnected joints, put a container under joints or a plug to hose. CAUTION: When disconnecting, take care not to cause damage to generator.
  • Page 1524 POWER STEERING (P/S) SYSTEM 3B1-27 DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DISASSEMBLY 1) Clean its exterior thoroughly. 2) With aluminum plates placed on vise first, grip pump body with 3) Remove suction connector bolt, suction connector and O-ring from pump body. 4) Remove power steering pressure switch (terminal set) from pump body.
  • Page 1525 3B1-28 POWER STEERING (P/S) SYSTEM Rotor and Vane D Check sliding surfaces of rotor and vane for wear and damage. D Check clearance between rotor and vane. Clearance: Standard 0.01 mm (0.0004 in.) Limit 0.06 mm (0.0023 in.) Replace pump assembly if any defect is found in above checks. 1.
  • Page 1526 POWER STEERING (P/S) SYSTEM 3B1-29 REASSEMBLY Reverse disassembly procedure for assembly, noting the follow- ing. 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 1527 3B1-30 POWER STEERING (P/S) SYSTEM 9) Apply power steering fluid to each vane. 10) Install vanes (10 pieces) to rotor. 1. Rotor 2. Vane 11) Apply power steering fluid to O-ring. 12) Install O-ring to pump body. 1. O-ring 13) Apply power steering fluid to sliding surface of pump cover and rotor.
  • Page 1528 POWER STEERING (P/S) SYSTEM 3B1-31 16) Apply power steering fluid to O-ring of terminal switch. 1. Pressure switch 17) Install pressure switch to pump body. Tightening Torque (b): 28 N m (2.8 kg-m, 20.0 lb-ft) 18) Apply power steering fluid to relief valve (flow control valve). 19) Install relief valve (flow control valve) to pump body.
  • Page 1529 3B1-32 POWER STEERING (P/S) SYSTEM TORQUE SPECIFICATIONS Tightening torque Fastening Parts Fastening Parts N·m kg-m lb-ft 1. Gear box mounting bolts 40.0 2. Gear box cylinder pipe flare nuts 14.5 3. Gear box high & low pressure pipe flare nuts 24.0 4.
  • Page 1530 POWER STEERING (P/S) SYSTEM 3B1-33 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 Sliding part of rack against steering housing Lithium grease D Steering rack and pinion gear teeth...
  • Page 1531 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-1 SECTION 3C STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) NOTE: D 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 1532 3C-2 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) GENERAL DESCRIPTION The double tube type steering column has three important features in addition to the steering function: 1) The column is energy absorbing, designed to compress in a front-end collision to minimize the possibility of an injury to the driver of the vehicle.
  • Page 1533 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-3 For 4-spoke type For 4-spoke type steering wheel and tilt steering column 1. Steering wheel pad 2. Steering wheel nut 3. Steering wheel bumper 4. Steering wheel 5. Steering wheel lower cover 6.
  • Page 1534 3C-4 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) ON-VEHICLE SERVICE STEERING WHEEL For 3-spoke type REMOVAL 1) Disconnect negative battery cable. 2) Pull out steering wheel pad, and then remove it by turning it counterclockwise. 1. Pad 3) Remove screw of horn harness. 4) Remove steering wheel bumper from Steering wheel.
  • Page 1535 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-5 For 4-spoke type REMOVAL 1) Disconnect negative battery cable. 2) Remove pad screw. 3) Remove pad by pulling it upward and disconnect horn harness. 4) Remove steering shaft nut. 5) Make alignment marks on steering wheel and shaft for a guide during reinstallation.
  • Page 1536 3C-6 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) COMBINATION SWITCH REMOVAL 1) Disconnect negative battery cable. 2) Before removing this switch, remove steering wheel. Refer to “STEERING WHEEL” earlier in this section. 3) Remove hole cover. 1. Hole cover 4) Remove steering column cover screws (3 pcs).
  • Page 1537 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-7 10) Remove combination switch from steering column. 1. Combination switch assembly INSPECTION Check combination switch wire harness for any signs of scorching, melting or other damage. If it is damaged, replace. INSTALLATION 1) Install combination switch to steering column.
  • Page 1538 3C-8 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 7) Install hole cover. 1. Hole cover 8) Install steering wheel to its shaft. Refer to “STEERING WHEEL” earlier in this section. 9) Connect battery negative cable. STEERING COLUMN CAUTION: D Once the steering column is removed from the vehicle, the column is extremely susceptible to damage.
  • Page 1539 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-9 3) Remove hole cover. 1. Hole cover 4) Loosen clamp. 5) Remove band binding steering column and harness (for com- bination switch). 6) Disconnect white 4-P connector (for auto cruise, optional). 7) Disconnect three connectors for combination switch wire har- ness from junction/fuse block.
  • Page 1540 3C-10 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 11) Remove steering column mounting nuts (4 pcs). 12) If equipped with shift (key) interlock cable, remove shift (key) interlock cable screw and then disconnect its cable from igni- tion switch with ignition switch turned at “ACC” position. After disconnecting, turn ignition switch to “LOCK”...
  • Page 1541 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-11 2) Take measurement “b” as shown. If it is shorter than specified length, replace column assembly with new one. Length “b”: 513 mm (20.20 in.) 3) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play.
  • Page 1542 3C-12 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 5) Install bolt to steering shaft upper joint and tighten it to speci- fied torque. NOTE: After tightening column nuts, bolt to steering shaft upper joint should be tightened. Tightening Torque (c): 25 N·m (2.5 kg-m, 18.0 lb-ft) 1.
  • Page 1543 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-13 STEERING LOCK (IGNITION SWITCH) REMOVAL 1) Disconnect negative battery cable. 2) Remove steering column. Refer to “STEERING COLUMN” ear- lier in this section. 1. Steering column 2. Steering lock 3) Using center punch as shown, loosen and remove steering lock 1.
  • Page 1544 3C-14 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) STEERING SHAFT LOWER JOINT 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) Remove hole cover. 1.
  • Page 1545 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-15 INSTALLATION 1) Align flat part of lower joint shaft with bolt hole of upper joint as shown. Then insert lower joint shaft into upper joint. 2) Be sure that front wheels and steering wheel are in straight- for- ward state and insert lower joint into steering pinion shaft.
  • Page 1546 3C-16 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) CHECKING STEERING COLUMN FOR AC- CIDENT 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 1547 STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) 3C-17 TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts N·m kg-m lb-ft 1. Steering shaft nut 23.5 2. Steering shaft joint bolts 18.0 3. Steering column mounting nuts 10.5 SPECIAL TOOL 09944-36011 Steering wheel remover...
  • Page 1548 AIR BAG STEERING WHEEL AND COLUMN 3C1-1 SECTION 3C1 AIR BAG STEERING WHEEL AND COLUMN WARNING: The procedures in this section must be followed in the order listed to temporarily disable the Air Bag System and prevent false diagnostic codes from setting. Failure to follow procedures could result in possible air bag deployment, personal injury or other- wise unneeded air bag system repairs.
  • Page 1549 3C1-2 AIR BAG STEERING WHEEL AND COLUMN GENERAL DESCRIPTION STEERING COLUMN This double tube type steering column has following three important features in addition to the steering function: D The column is energy absorbing type, designed to contract in a front-end collision. D The ignition switch and lock are mounted conveniently on this column.
  • Page 1550: Service Precautions

    AIR BAG STEERING WHEEL AND COLUMN 3C1-3 ON-VEHICLE SERVICE SERVICE PRECAUTIONS D WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions. WARNING: When performing service on or around air bag system components or air bag system wiring, follow the procedures listed below to temporarily disable the air bag system.
  • Page 1551 3C1-4 AIR BAG STEERING WHEEL AND COLUMN ENABLING AIR BAG SYSTEM 1) Turn ignition switch to “LOCK” and remove key. 2) Connect Yellow connector of passenger air bag (inflator) mod- ule and Yellow connector of driver air bag (inflator) module re- spectively, and be sure to lock each connector with lock lever.
  • Page 1552 AIR BAG STEERING WHEEL AND COLUMN 3C1-5 D When grease, cleaning agent, oil water, etc., got on the air bag ALWAYS CARRY AIR BAG (INFLATOR) MODULE (inflator) modules (driver and passenger), wipe it off immediately WITH TRIM COVER with a dry cloth. (AIR BAG OPENING) AWAY FROM BODY.
  • Page 1553 3C1-6 AIR BAG STEERING WHEEL AND COLUMN Contact Coil and Combination Switch Assembly Do not turn contact coil (on combination switch) more than allow- able number of turns (about two and a half turns from the center positIon clockwise or counterclockwise respectively), or coil will break.
  • Page 1554 AIR BAG STEERING WHEEL AND COLUMN 3C1-7 DRIVER AIR BAG (INFLATOR) MODULE WARNING: When handling an air bag (inflator) module, be sure to read “HANDLING PRECAUTIONS” given earlier in this section and observe each instruction. Failure to follow them could cause a damage to the air bag (inflator) mod- ule or result in personal injury.
  • Page 1555 3C1-8 AIR BAG STEERING WHEEL AND COLUMN Check air bag (inflator) module visually and if any of the following is found, replace it with a new one. D Air bag being deployed D Trim cover (pad surface) being cracked D Wire harness or connector being damaged D Air bag (inflator) module being damaged or having been ex- posed to strong impact (dropped) 1.
  • Page 1556 AIR BAG STEERING WHEEL AND COLUMN 3C1-9 STEERING WHEEL CAUTION: Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the com- bination switch) more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively), or coil will break.
  • Page 1557 3C1-10 AIR BAG STEERING WHEEL AND COLUMN 3) Turn contact coil counterclockwise slowly with a light force till contact coil will not turn any further. NOTE: Contact coil can turn about 5 turns at maximum, that is, if it is at the center position, can turn about two and a half turns both clockwise and counterclockwise.
  • Page 1558 AIR BAG STEERING WHEEL AND COLUMN 3C1-11 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY CAUTION: Do not turn contact coil (on 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 1559 3C1-12 AIR BAG STEERING WHEEL AND COLUMN 10) Disconnect three connectors for contact coil and combination switch wire harness from junction/fuse block. 1. Junction/fuse block 11) Remove contact coil and combination switch assembly from steering column. 1. Contact coil and combination switch assembly INSPECTION Check contact coil and combination switch wire harness for any signs of scorching, melting or other damage.
  • Page 1560 AIR BAG STEERING WHEEL AND COLUMN 3C1-13 3) Connect three connectors for contact coil and combination switch wire harness to junction/fuse block. 1. Junction/fuse block 4) Connect yellow connector (for air bag) and white 4-P connec- tor (for auto cruise, optional). 5) Tighten clamp and band for contact coil and combination switch wire harness.
  • Page 1561 3C1-14 AIR BAG STEERING WHEEL AND COLUMN STEERING COLUMN CAUTION: D Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. D Dropping the column assembly on its end could col- lapse the steering shaft. D Loosen the plastic shear pins which maintain column length.
  • Page 1562 AIR BAG STEERING WHEEL AND COLUMN 3C1-15 8) Disconnect three connectors for contact coil and combination switch assembly wire harness from junction/fuse block. 1. Junction/fuse block 9) Disconnect three connectors for ignition switch wire harness from junction/fuse block. 1. Junction/fuse block 10) Remove steering joint upper cover.
  • Page 1563 3C1-16 AIR BAG STEERING WHEEL AND COLUMN 14) Remove steering column from vehicle. WARNING: Never rest a steering column assembly on the steer- ing wheel with the air bag (inflator) module face down and column vertical. Otherwise, personal inju- ry may result. INSPECTION NOTE: Vehicles involved in accidents resulting in body damage,...
  • Page 1564 AIR BAG STEERING WHEEL AND COLUMN 3C1-17 INSTALLATION 1) Align flat part “A” of lower joint shaft with bolt hole “B” of upper side joint of steering column as shown. Then insert upper side joint of steering column into lower joint shaft. 1.
  • Page 1565 3C1-18 AIR BAG STEERING WHEEL AND COLUMN 7) Connect three connectors for ignition switch wire harness from junction/fuse block. 8) If contact coil and combination switch assembly is removed, install contact coil and combination switch assembly. Refer to “Contact Coil and Combination Assembly” earlier in this section.
  • Page 1566 AIR BAG STEERING WHEEL AND COLUMN 3C1-19 STEERING LOCK (IGNITION SWITCH) REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Disable air bag system. Refer to “Disabling Air Bag System” un- der “Service Precautions” earlier in this section. 3) Remove steering column. Refer to “STEERING COLUMN” ear- lier in this section.
  • Page 1567 3C1-20 AIR BAG STEERING WHEEL AND COLUMN STEERING SHAFT LOWER JOINT CAUTION: Never turn steering wheel while steering shaft lower joint 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 1568 AIR BAG STEERING WHEEL AND COLUMN 3C1-21 TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts N·m kg-m Ib-ft 1. Steering shaft nut 23.5 2. Steering shaft joint bolts 18.0 3. Steering column mounting nuts 10.5 4. Driver air bag (inflator) module bolts 17.0 SPECIAL TOOLS 09944-36011...
  • Page 1569: Front Suspension

    FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: 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 1570 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 vehicle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the rubber mount.
  • Page 1571 FRONT SUSPENSION 3D-3 1. Nut 2. Support 3. Bearing 4. Coil spring upper seat 5. Coil spring seat 6. Dust cover 7. Bump stopper 8. Coil spring 9. Coil spring lower seat 10. Strut...
  • Page 1572 3D-4 FRONT SUSPENSION ON-VEHICLE SERVICE REMOVE AND INSTALL STABILIZER BAR AND/OR BUSHINGS 1. Stabilizer bar 2. Mount bush 3. Mount bracket 4. Joint 5. Joint nut 6. Link washer 7. Link cushion 8. Centering washer 9. Mount bolt 10. Link nut REMOVAL 1) Remove stabilizer link nuts, washers and cushions.
  • Page 1573 FRONT SUSPENSION 3D-5 REMOVE AND INSTALL STRUT ASSEMBLY NOTE: When disassembling strut assembly, loosen strut nut a little before removing strut assembly from vehicle. This will make disassembly easier. Note, however, nut must not be removed at this point. REMOVAL 1) Hoist vehicle, allowing front suspension to hang free.
  • Page 1574 3D-6 FRONT SUSPENSION INSTALLATION 1) Install strut assembly by reversing REMOVAL Steps 1) – 7). Insert bolts in such a direction as shown. 2) Torque all fasteners to specification. Tightening Torque (a): 28 N·m (2.8 kg-m, 20.5 lb-ft) (b): 90 N·m (9.0 kg-m, 65.0 lb-ft) NOTE: Don’t twist brake hose when installing it.
  • Page 1575 FRONT SUSPENSION 3D-7 DISASSEMBLE AND ASSEMBLE STRUT ASSEMBLY DISASSEMBLY 1) With special tool (A) placed to spring as shown, turn special tool bolts alternately until spring tension is released. Whether it is re- leased or not can be known by whether strut turns lightly while strut spring is held stationary.
  • Page 1576 3D-8 FRONT SUSPENSION 2) Install coil spring lower seat and compressing coil spring, and mate spring end with stepped part of lower seat as shown. 3) Install bump stopper and dust cover onto strut rod. For installing direction, refer to above figure in DISASSEMBLY. 4) Pull strut rod as far up as possible and use care not to allow it to retract into strut.
  • Page 1577 FRONT SUSPENSION 3D-9 REMOVE AND INSTALL WHEEL HUB, WHEEL STUD/WHEEL BEARING OUTSIDE INNER RACE REMOVAL 1) Hoist vehicle and remove wheel. 2) Uncalk drive shaft nut. 1. Drive shaft nut 3) Depress foot brake pedal and hold it there. Remove drive shaft nut.
  • Page 1578 3D-10 FRONT SUSPENSION 10) Remove wheel bearing inner race. Special Tools (C): 09913-65810 (D): 09913-85230 1. Bearing inner race INSTALLATION 1. Oil hydraulic press 2. Rod Install Hub Bolts 3. Hub bolt Insert new stud in hub hole. Rotate stud slowly to assure serration are aligned with those made by original bolt.
  • Page 1579 FRONT SUSPENSION 3D-11 4) Install brake disc. Tightening Torque (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 5) Install brake caliper/caliper carrier. 6) Tighten caliper carrier bolts to specified torque. Tightening Torque (b): 85 N·m (8.5 kg-m, 61.5 lb-ft) 7) Depress foot brake pedal and hold it there. Tighten new drive shaft nut to specified torque.
  • Page 1580 3D-12 FRONT SUSPENSION REMOVE AND INSTALL SUSPENSION ARM / BUSHING REMOVAL 1) Hoist vehicle and remove wheels. 2) Remove stabilizer link nut, washer and cushion. 3) Remove ball stud bolt. 4) Remove suspension arm front bushing bolt. 5) Remove suspension arm rear bracket bolt and nut. 6) Remove rear bracket and suspension arm.
  • Page 1581 FRONT SUSPENSION 3D-13 INSTALLATION 1) Install front bushing. Before installing bushing, apply soap water on its circumfer- ence to facilitate installation Install bushing in such direction shown in figure. 1. Press 2. Front bushing 3. Suspension arm 2) Install rear bushing to suspension arm as follows. First, push in rear bushing in such direction and angle as shown in figure (A) and drive it into such position as shown in figure (B).
  • Page 1582 3D-14 FRONT SUSPENSION REMOVE AND INSTALL KNUCKLE/BEARING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove wheel hub. Refer to Step 2) – 8) in WHEEL HUB RE- MOVAL of this section. 3) Disconnect tie-rod end from knuckle with special tool (A). Special Tool (A): 09913-65210 1.
  • Page 1583 FRONT SUSPENSION 3D-15 3) Connect tie-rod end to knuckle and tighten tie-rod end castle nut to specified torque. Install new split pin. 4) For installation procedures following the above, refer to Steps 2) – 9) in WHEEL HUB INSTALLATION of this section. Split pin 1.
  • Page 1584 3D-16 FRONT SUSPENSION REMOVE OIL SEALS, SNAP RING AND WHEEL BEARING Once bearing outer race is removed, bearing set (outer race, bear- ings and inner races) should be replaced with new one. D Remove outside oil seal, snap ring, outside bearing and inside oil seal in that order.
  • Page 1585 FRONT SUSPENSION 3D-17 Inside Oil Seal With hole in inside oil seal matched with projection on knuckle (for vehicle without ABS) or wheel speed sensor installation hole in knuckle (for vehicle with ABS), drive in Oil seal until its stepped sur- face contacts knuckle by using special tools (C) and (E).
  • Page 1586 3D-18 FRONT SUSPENSION REMOVE AND INSTALL SUSPENSION FRAME 1. Stabilizer bar 2. Suspension arm (Left) 3. Suspension arm (Right) 4. Engine rear mounting 5. Mounting member-2WD vehicle only 6. Suspension frame 7. Washer 2WD vehicle 8. Cushion only 9. Spacer 10.
  • Page 1587 FRONT SUSPENSION 3D-19 INSTALLATION 1. Suspension frame 1) Install suspension frame to body, and tighten bolt to specified torque. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 2) Install mounting member, spacers and cushions to suspension frame if removed and tighten bolts and nuts to specified torque. Tightening Torque (b): 55 N·m (5.5 kg-m, 40.0 lb-ft) (g): 45 N·m (4.5 kg-m, 33.0 lb-ft)
  • Page 1588 3D-20 FRONT SUSPENSION FRONT SUSPENSION INSPECTION STABILIZER BAR AND/OR BUSHING Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. 2. Stabilizer bar mount bush 3. Link cushion STRUT ASSEMBLY 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
  • Page 1589 FRONT SUSPENSION 3D-21 SUSPENSION ARM/STEERING KNUCKLE Inspect for cracks, deformation or damage. SUSPENSION ARM BUSHING Inspect for damage, wear or deterioration. SUSPENSION ARM JOINT 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. NOTE: Suspension arm and arm joint cannot be separated.
  • Page 1590 3D-22 FRONT SUSPENSION WHEEL DISC, NUT & BEARING 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) Check wheel nuts for tightness and, as necessary retighten them to specification. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 3) Check wheel bearing for wear.
  • Page 1591 FRONT SUSPENSION 3D-23 TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts kg-m lb-ft 1. Strut Bracket nut 65.0 2. Strut nut 47.0 3. Strut support nut 20.5 4. Ball stud nut 43.5 5. Suspension arm rear bracket bolt and nut 27.0 6.
  • Page 1592 3D-24 FRONT SUSPENSION REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Lithic wheel bearing SUPER GREASE (A) Wheel bearing, wheel bearing oil grease (99000-25010) seal lip SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09913-65810 09913-85230 Hexagon wrench bit 09913-65210...
  • Page 1593 REAR SUSPENSION (2WD VEHICLE) 3E-1 SECTION 3E REAR SUSPENSION (2WD VEHICLE) 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 1594 3E-2 REAR SUSPENSION (2WD VEHICLE) GENERAL DESCRIPTION The rear suspension is a strut type independent suspension equipped with control rods (dual-link) and a trailing rod. The upper end of the strut is anchored to the vehicle body by the strut support. The strut and strut support are isolated by a rubber mount.
  • Page 1595 REAR SUSPENSION (2WD VEHICLE) 3E-3 ON-VEHICLE SERVICE REMOVE AND INSTALL REAR STRUT ASSEMBLY 1. Strut assembly 2. Strut upper cap 3. Strut support nut 4. Strut bracket bolt 5. Strut bracket nut 6. Rear knuckle REMOVAL NOTE: When servicing component parts of strut assembly, loosen strut upper nut a little before removing strut assembly.
  • Page 1596 3E-4 REAR SUSPENSION (2WD VEHICLE) 4) Remove strut bracket bolts and nuts. And then take brake hose off strut bracket using care not to de- form brake pipe. 5) Remove strut support nuts. Hold strut by hand so that it will not fall off. 6) Remove strut assembly.
  • Page 1597 REAR SUSPENSION (2WD VEHICLE) 3E-5 DISASSEMBLE AND ASSEMBLE REAR STRUT ASSEMBLY 1. Strut upper cap 2. Strut upper nut 3. Strut support 4. Spring upper seat 5. Spring (rubber) seat 6. Strut dust cover 7. Bump stopper 8. Coil spring 9.
  • Page 1598 3E-6 REAR SUSPENSION (2WD VEHICLE) ASSEMBLY 1) Compress spring with special tool (A) until total length becomes about 290 mm (11.42 in.) as shown. Length “a”: 290 mm (11.42 in.) A: Upper side (small diam.) B: Lower side (large diam.) 2) Install coil spring lower seat and compressing coil spring, mate large-dia.
  • Page 1599 REAR SUSPENSION (2WD VEHICLE) 3E-7 8) Put strut support on spring upper seat. Tighten strut upper nut to specified torque and then apply water- proof coating (paint or lacquer) all around nut and strut rod thread. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) 9) Loosen and remove special tool (A) from compressing coil spring.
  • Page 1600 3E-8 REAR SUSPENSION (2WD VEHICLE) REMOVE AND INSTALL STABILIZER BAR AND/OR BUSHINGS (IF EQUIPPED) 1. Stabilizer bar 2. Mount bush 3. Mount bracket 4. Joint 5. Joint nut 6. Link nut 7. Mount bolt REMOVAL CAUTION: To avoid the risk of being burned, start your work after the exhaust system has cooled down.
  • Page 1601 REAR SUSPENSION (2WD VEHICLE) 3E-9 REMOVE AND INSTALL CONTROL ROD WITH STABILIZER WITHOUT STABILIZER 1. No.1 control rod 5. Control rod inner bolt (inner bolt) 10. Suspension frame cap 2. No.2 control rod 6. No.2 control rod bolt (inner bolt) 11.
  • Page 1602 3E-10 REAR SUSPENSION (2WD VEHICLE) 5) Remove suspension frame cap. 6) Remove No.2 control rod from suspension frame and knuckle. 7) Remove No.1 control rod from suspension frame and knuckle. 1. Suspension frame 2. Suspension frame cap 3. No.1 control rod 4.
  • Page 1603 REAR SUSPENSION (2WD VEHICLE) 3E-11 3) For vehicles equipped with ABS, attach ABS wheel speed sen- 1. No.2 control rod 2. ABS sensor pipe sor pipe to No.2 control rod. (if equipped) 4) Install stabilizer bar (if equipped). Refer to Step 1) thru 3) in STA- BILIZER BAR INSTALLATION of this section.
  • Page 1604 3E-12 REAR SUSPENSION (2WD VEHICLE) REMOVE AND INSTALL TRAILING ROD REMOVAL 1) Hoist vehicle. 2) Detach parking brake cable clamp from trailing rod. 3) Remove trailing rod bolts and trailing rod. 1. Trailing rod 2. Parking brake cable 3. Bolt INSTALLATION 1) Install trailing rod and tighten bolts by hand.
  • Page 1605 REAR SUSPENSION (2WD VEHICLE) 3E-13 REMOVE AND INSTALL SUSPENSION FRAME WITHOUT STABILIZER BAR WITH STABILIZER BAR 1. Suspension frame 5. No.2 control rod 2. Suspension frame cap 6. Rear strut damper 3. Suspension frame bolt 7. Stabilizer bar 4. No.1 control rod REMOVAL 1) Hoist vehicle and remove rear wheels.
  • Page 1606 3E-14 REAR SUSPENSION (2WD VEHICLE) 8) Remove suspension frame bolts and suspension frame. 9) Remove rear strut damper. 1. Suspension frame 2. Bolt 3. Fuel tank INSTALLATION 1) Install rear strut damper. Tightening Torque for rear strut damper 30 N·m (3.0 kg-m, 22.0 lb-ft) 2) Install suspension frame and tighten suspension frame bolts to specified torque.
  • Page 1607 REAR SUSPENSION (2WD VEHICLE) 3E-15 REMOVE AND INSTALL WHEEL HUB (WHEEL BEARING) ASSEMBLY AND WHEEL STUD (HUB BOLT) Wheel bearing and wheel hub form a solid unit. When wheel bearing is found defective and its replacement is nec- essary, replace hub assembly. REMOVAL 1) Hoist vehicle and remove brake disc or brake drum referring to SECTION 5.
  • Page 1608 3E-16 REAR SUSPENSION (2WD VEHICLE) INSTALLATION 1) Install hub bolts. Refer to FRONT WHEEL STUD INSTALLATION in SECTION 3D in the Service Manual mentioned in FOREWORD of this manual for installation procedure. 2) For ABS equipped vehicle, check ABS wheel speed sensor ro- tor for damage.
  • Page 1609 REAR SUSPENSION (2WD VEHICLE) 3E-17 REMOVE AND INSTALL KNUCKLE REMOVAL 1) Hoist vehicle and remove wheel hub referring to WHEEL HUB REMOVAL of SECTION 3E or 3E1. 2) Remove E ring securing brake hose. 1. E ring 2. Brake hose bracket 3) Disconnect brake pipe from wheel cylinder and put wheel cylin- der bleeder plug cap onto pipe to prevent fluid from spilling.
  • Page 1610 3E-18 REAR SUSPENSION (2WD VEHICLE) INSTALLATION 1) Install rear knuckle to strut, and connect control rods and trail- ing rod to knuckle. At this point, temporarily tighten them by hand. 2) Tighten strut bracket bolts and nuts to specified torque. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 3) Apply water tight sealant to mating surfaces of brake back...
  • Page 1611 REAR SUSPENSION (2WD VEHICLE) 3E-19 11) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable. (For adjustment, see SECTION 12) Tighten parking brake lever cover screws.
  • Page 1612 3E-20 REAR SUSPENSION (2WD VEHICLE) REMOVE AND INSTALL KNUCKLE REMOVAL 1) Hoist vehicle and remove wheel hub referring to WHEEL HUB REMOVAL in this section. 2) If the vehicle is equipped with ABS, remove rear wheel speed sensor, refer to SECTION 5B of Service Manual mentioned in FOREWORD of this manual.
  • Page 1613 REAR SUSPENSION (2WD VEHICLE) 3E-21 INSTALLATION 1) Install rear knuckle to strut, and connect control rods and trail- ing rod to knuckle. At this point, temporarily tighten them by hand. 2) Tighten strut bracket bolts and nuts to specified torque. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 lb-ft) 1.
  • Page 1614 3E-22 REAR SUSPENSION (2WD VEHICLE) REAR SUSPENSION INSPECTION STRUT ASSEMBLY 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled. 2) Strut function check Check and adjust tire pressure as specified. Bounce vehicle body three or four times continuously by pushing rear end on the side with strut to be checked.
  • Page 1615 REAR SUSPENSION (2WD VEHICLE) 3E-23 Stabilizer joint (if equipped) 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. NOTE: Stabilizer joint cannot be disassembled. If there is any damage to either, stabilizer joint assembly must be replaced as a complete unit.
  • Page 1616 3E-24 REAR SUSPENSION (2WD VEHICLE) REAR SUSPENSION FASTENERS Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to TORQUE SPECIFICATIONS of this section. WHEEL DISC, NUT & BEARING D Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced.
  • Page 1617: Rear Wheel Alignment

    REAR SUSPENSION (2WD VEHICLE) 3E-25 REAR WHEEL ALIGNMENT Among factors for rear wheel alignment, only toe setting can be ad- justed. Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the damage caused by haz- ardous road conditions or collision, whether the damage is in body or in suspension should be determined and damaged body should be repaired or damaged suspension should be replaced.
  • Page 1618 3E-26 REAR SUSPENSION (2WD VEHICLE) ADJUSTMENT 1) Loosen right and left No.2 control rod inner nuts. 2) Adjust toe to satisfy specification by turning right and left No.2 control rod inner bolts (cam bolts) by the same amount. 3) After adjustment, tighten right and left nuts to specified torque while holding cam bolt with another wrench to prevent it from turning.
  • Page 1619 61.5 Wheel speed sensor bolt 17.0 (For vehicles equipped with ABS) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Indicated on reservoir tank cap or Brake fluid described in owner’s manual of ve- Brake reservoir tank hicle SEALING COMPOUND 366E Joint seam of knuckle and brake...
  • Page 1620 3E-28 REAR SUSPENSION (2WD VEHICLE) SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09943-17912 Hexagon wrench bit 09942-15511 09940-71431 Rear wheel hub remover (Brake drum remover) 6 mm Sliding hammer Spring compressor 09945-26010 Socket wrench 17 mm...
  • Page 1621 REAR SUSPENSION (4WD VEHICLE) 3E1-1 SECTION 3E1 REAR SUSPENSION (4WD VEHICLE) NOTE: D For the items not found in this section, refer to the SECTION 3E (2WD vehicle) of this manual. 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.
  • Page 1622 3E1-2 REAR SUSPENSION (4WD VEHICLE) GENERAL DESCRIPTION 1. Vehicle body 2. Strut assembly 3. Rear knuckle 4. Suspension frame 5. Control rod 6. Trailing rod 7. Brake drum 8. Wheel bearing 9. Brake back plate 10. Drive shaft 11. ABS wheel speed sensor (if equipped)
  • Page 1623 REAR SUSPENSION (4WD VEHICLE) 3E1-3 ON-VEHICLE SERVICE REMOVE AND INSTALL SUSPENSION FRAME 1. Suspension frame 2. No.1 control rod 3. No.2 control rod 4. Differential 5. Differential mounting 6. Differential mounting bracket REMOVAL 1) Hoist vehicle and remove wheels (right and left). 2) Drain differential oil.
  • Page 1624 3E1-4 REAR SUSPENSION (4WD VEHICLE) 9) To facilitate reinstallation, put match marks on No.2 propeller shaft flange and differential flange. Disconnect No.2 propeller shaft from differential. 10) Remove differential, differential mounting and mounting bracket from suspension frame. 11) Remove suspension frame from vehicle body. 1.
  • Page 1625 REAR SUSPENSION (4WD VEHICLE) 3E1-5 REMOVE AND INSTALL WHEEL HUB, WHEEL STUD/WHEEL BEARING OUTSIDE INNER RACE REMOVAL 1) Hoist vehicle and remove wheel. 2) Uncaulk drive shaft nut. 3) Pull up parking brake lever fully and remove drive shaft nut. 4) Remove brake drum referring to BRAKE DRUM REMOVAL of SECTION 5.
  • Page 1626 3E1-6 REAR SUSPENSION (4WD VEHICLE) INSTALLATION 1) Install hub bolts. Refer to FRONT WHEEL STUD INSTALLATION in SECTION 3D for installation procedure. 2) Install outside inner race to wheel hub using special tool. Installing direction is as shown. Special Tool (E): 09940-53111 1.
  • Page 1627 REAR SUSPENSION (4WD VEHICLE) 3E1-7 REMOVE AND INSTALL KNUCKLE, WHEEL BEARING/OIL SEAL REMOVAL Once bearing outer race is removed, bearing set (outer race, bear- ings and inner races) should be replaced with new one. 1) Remove wheel hub referring to WHEEL HUB REMOVAL of this section.
  • Page 1628 Tightening torque Fastening parts Fastening parts kg-m lb-ft Rear suspension frame bolt 65.0 Rear drive shaft nut 17.5 126.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUPER GREASE A Lithic wheel bearing grease Wheel bearing, wheel bearing oil seal lip (99000-25010)
  • Page 1629 REAR SUSPENSION (4WD VEHICLE) 3E1-9 SPECIAL TOOLS 09924-84510-004 09925-88210 09913-65810 09913-75520 Bearing installer adapter (C) Bearing puller attachment Bearing puller Bearing installer 09940-53111 09942-15511 09943-17912 09944-78210 Bearing installer Sliding hammer Brake drum remover Bearing installer support 09951-18210 Oil seal remover & installer No.2...
  • Page 1630: 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 1631: Replacement Tires

    3F-2 WHEELS AND TIRES GENERAL DESCRIPTION TIRES This vehicle is equipped with following tire. 175/70 R13, 185/60 R14 or 195/55 R15 The tire is of tubeless type. The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures.
  • Page 1632 WHEELS AND TIRES 3F-3 REPLACEMENT WHEELS Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, air leak through welds, have elongated bolt holes, if lug nuts won’t stay tight, or if they are heavily rusted. Wheels with greater runout than specification may cause objec- tional vibrations.
  • Page 1633 3F-4 WHEELS AND TIRES MATCHED TIRES AND WHEELS (For vehicle equipped with steel wheels) Tires and wheels are matchmounted at the assembly plant. This means that the radially stiffest part of the tire, or “high spot”, is matched to the smallest radius or “low spot” of the wheel. This is done to provide the smoothest possible ride.
  • Page 1634 WHEELS AND TIRES 3F-5 TIRE PLACARD The tire placard is located on the left door (right door for right-hand side steering vehicle) lock pillar and should be referred to for tire information. The placard lists the maximum load, tire size and cold tire pressure where applicable.
  • Page 1635 3F-6 WHEELS AND TIRES Wheel nuts must be tightened in sequence given in figure and to proper torque to avoid bending wheel or brake disc. NOTE: Before installing wheels, remove any build-up of corrosion on wheel mounting surface and brake disc mounting surface by scraping and wire brushing.
  • Page 1636: Balancing Wheels

    WHEELS AND TIRES 3F-7 TIRE REPAIR There are many different materials and techniques on the market to repair tires. As not all of these work on all types of tires, tire manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from each tire manufacturer.
  • Page 1637 3F-8 WHEELS AND TIRES WARNING: Wheel spin should be limited to 35 mph (55 km/h) as indicated on speedometer. This limit is necessary because speedometer only indicates one-half of actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped. Unless care is taken in limiting drive wheel spin, spinning wheel can reach excessive speeds.
  • Page 1638 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
  • Page 1639 3G-2 SUSPENSION CONTROL SYSTEM GENERAL DESCRIPTION The suspension control system consists of front and rear adjustable shock absorbers, shock absorber adjusting actuators, a mode selector switch and a suspension control module. The suspension control system is capable of setting the vehicle suspension to various damping positions by use of the mode selector switch and automatically depending on sensed informations input to the suspension control module.
  • Page 1640 SUSPENSION CONTROL SYSTEM 3G-3 Mode selector Mode “SPORT” “SPORT” light “SPORT” “AUTO” or switch judgment signal lights light “SPORT” signal Speedometer Vehicle speed Vehicle speed “AUTO” or “SPORT” signal (VSS) signal judgment Brake light Brake ON Dive condition switch signal judgment Ignition coil or Engine speed...
  • Page 1641 3G-4 SUSPENSION CONTROL SYSTEM Suspension control module and “SPORT” light operation Mode selector “SPORT” indicator light Vehicle condition Vehicle condition Mode Mode Damping force Damping force switch Diag. switch OFF Diag. switch ON For 2 seconds after Holding state be- Depending on ignition switch is SPORT/AUTO...
  • Page 1642 SUSPENSION CONTROL SYSTEM 3G-5 GRAVITY SENSOR Gravity sensor is installed in front of shift lever (selector lever for A/T) and consists of weight, piezoelectric element, amplifier, filter. As weight moves up and down in accordance with vertical move- ment (vibration) of vehicle, that movement, after being converted into electric signal by piezoelectric element, is transmitted through amplifier and filter to suspension control module as voltage signal.
  • Page 1643 3G-6 SUSPENSION CONTROL SYSTEM ENGINE SPEED SIGNAL This signal is sent from the ECM. Receiving this signal, suspension control module detects the en- gine speed. 1. Suspension control module 2. ECM 3. Tachometer VEHICLE SPEED SENSOR The vehicle speed sensor, located on the transmission, generates a signal in proportion to the vehicle speed (Signal À).
  • Page 1644 SUSPENSION CONTROL SYSTEM 3G-7 DIAGNOSIS SWITCH TERMINAL 1. Diagnosis connector 1 The diagnosis switch terminal is included in the diagnosis connec- 2. Diagnosis connector 2 tor 2 in the relay box. When diagnosis switch terminal is grounded, 3. Relay box 4.
  • Page 1645 3G-8 SUSPENSION CONTROL SYSTEM SUSPENSION CONTROL (AUTO MODE ONLY) ROLLING CONTROL DURING QUICK STEER- This control function suppresses rolling which occurs when vehicle enters a corner to improve steering stability by increasing damping force of absorber according to steering angle speed, engine speed and vehicle speed.
  • Page 1646 SUSPENSION CONTROL SYSTEM 3G-9 DIAGNOSIS Suspension control module has on-board diagnostic system (a system with self-diagnosis function) as described previously. Investigate where the trouble is by referring to “DIAGNOSTIC FLOW CHART” and “DIAGNOSTIC TROUBLE CODE TABLE” on later pages. PRECAUTIONS IN DIAGNOSING TROUBLES Refer to Section 0A of Service Manual mentioned in Foreword of this manual.
  • Page 1647 3G-10 SUSPENSION CONTROL SYSTEM DIAGNOSTIC FLOW CHART START Does “SPORT” light turn ON for 2 seconds when ignition switch is turned ON and mode selector switch is in AUTO mode? “SPORT” light “SPORT” (“SPORT” light turns OFF or flashes) doesn’t light doesn’t Ground diagnosis switch terminal turn OFF...
  • Page 1648 SUSPENSION CONTROL SYSTEM 3G-11 DIAGNOSTIC TROUBLE CODE TABLE EXAMPLE: When throttle opening signal is failure (Code No.21) DIAGNOSTIC “SPORT” LIGHT TROUBLE DIAGNOSTIC ITEM DIAGNOSIS FLASHING PATTERN CODE NO. Steering sensor Gravity sensor Throttle opening signal Diagnose trouble according to “DIAGNOS- TIC FLOW CHART”...
  • Page 1649 3G-12 SUSPENSION CONTROL SYSTEM CODE NO.13 STEERING SENSOR CIRCUIT (SENSOR CIRCUIT OPEN: SIGNAL VOLTAGE HIGH) 1. Steering sensor 2. Steering sensor coupler 3. Suspension control module coupler 4. Suspension control module Terminal arrangement of suspension control module (Viewed from harness side) 1.
  • Page 1650 SUSPENSION CONTROL SYSTEM 3G-13 CODE NO.14 GRAVITY SENSOR CIRCUIT (SENSOR CIRCUIT OPEN OR SHORTED TO GROUND SIGNAL VOLTAGE HIGH OR LOW) 1. Gravity sensor 2. Gravity sensor coupler 3. Suspension control module coupler 4. Suspension control module Terminal arrangement of suspension control module coupler (Viewed from harness side) 1.
  • Page 1651 3G-14 SUSPENSION CONTROL SYSTEM CODE NO.21 THROTTLE OPENING SIGNAL CIRCUIT (THROTTLE POSITION SENSOR CIRCUIT OR THROTTLE OPENING CIRCUIT FAULTY) 1. Throttle position sensor 2. ECM 3. ECM coupler 4. Suspension control module coupler 5. Suspension control module Terminal arrangement of suspension control module coupler Terminal arrangement of ECM coupler (Viewed from harness side) with WU TWC...
  • Page 1652 SUSPENSION CONTROL SYSTEM 3G-15 CODE NO.22 VEHICLE SPEED SENSOR CIRCUIT (VEHICLE SPEED SIGNAL NOT INPUTTED ALTHOUGH ENGINE SPEED IS HIGHER THAN ABOUT 3,000 R/MIN. AND THROTTLE OPENING IS LESS THAN 10 DEG. FOR LONGER THAN 4 SECONDS) 1. Vehicle speed sensor 2.
  • Page 1653 3G-16 SUSPENSION CONTROL SYSTEM CODE NO.23 ENGINE SPEED SIGNAL CIRCUIT (ENGINE SPEED SIGNAL NOT INPUTTED ALTHOUGH VEHICLE SPEED IS HIGHER THAN 10 KM/H FOR LONGER THAN 20 SECONDS) (For 1.6 L engine model) 1. Suspension control module 2. To tachometer 3.
  • Page 1654 SUSPENSION CONTROL SYSTEM 3G-17 CODE NO.31 ACTUATOR CIRCUIT (ACTUATOR CIRCUIT OPEN OR SHORTED GROUND) 1. Suspension control module 2. Front left actuator 3. Front right actuator 4. Rear left actuator 5. Rear right actuator Terminal arrangement of suspension control module coupler (Viewed from harness side) 1 Disconnect suspension control module coupler with ignition switch OFF.
  • Page 1655 3G-18 SUSPENSION CONTROL SYSTEM SUSPENSION CONTROL MODULE AND ITS CIRCUIT CHECK Suspension control module can be checked at suspension control module couplers by measuring voltage and resistance. CAUTION: Suspension control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to suspension control module with coupler discon- nected from it.
  • Page 1656 SUSPENSION CONTROL SYSTEM 3G-19 TERMI- STANDARD CIRCUIT CONDITION VOLTAGE Power source for back-up circuit 10 – 14V Ignition switch ON and OFF Front actuator 1 Rear actuator 2 4 – 8V Ignition switch ON Front actuator 2 Rear actuator 3 Rear actuator 1 Power source 10 –...
  • Page 1657 3G-20 SUSPENSION CONTROL SYSTEM RESISTANCE CHECK 1) Disconnect suspension control module couplers from suspen- sion control module with ignition switch OFF. CAUTION: Never touch terminals of suspension control module itself or connect voltmeter of ohmmeter. 2) Check resistance of each two terminals of disconnected cou- plers.
  • Page 1658 SUSPENSION CONTROL SYSTEM 3G-21 TROUBLE DIAGNOSIS This section describes trouble diagnosis of suspen- When diagnostic trouble code No.12 is indicated by sion control system parts whose trouble is not indi- the on-board diagnostic system (self-diagnosis func- cated on-board diagnostic system tion) and assuredly those suspension basic parts as (self-diagnostic function).
  • Page 1659 3G-22 SUSPENSION CONTROL SYSTEM ON-VEHICLE SERVICE SUSPENSION CONTROL MODULE REMOVAL 1) Disconnect negative cable at battery. 2) Remove parking brake cover. 3) Disconnect couplers. 4) Remove suspension control module. 1. Suspension control module 2. Parking brake lever INSTALLATION Reverse removal procedure for installation. STEERING SENSOR ON-VEHICLE INSPECTION 1) Disconnect steering sensor coupler with ignition switch OFF.
  • Page 1660 SUSPENSION CONTROL SYSTEM 3G-23 INSTALLATION For installation, reverse removal procedure, surely referring to Section 3C (without air bag) or 3C1 (with air bag). GRAVITY SENSOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove parking brake cover front extension. 3) Remove front console silensor.
  • Page 1661 3G-24 SUSPENSION CONTROL SYSTEM MODE SELECTOR SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove mode selector switch from parking brake cover. 3) Disconnect mode selector switch coupler. 1. Screw driver 2. Selector switch INSPECTION Check continuity between mode selector switch terminals. Mode selector switch position Ohmmeter indicator AUTO...
  • Page 1662 SUSPENSION CONTROL SYSTEM 3G-25 INSPECTION 1) Check resistance between each two terminals of actuator cou- pler. Terminals Standard resistance 1 and 2 2 and 3 4.6 – 14W 3 and 1 If check results are as specified, proceed to next operation 1.
  • Page 1663 3G-26 SUSPENSION CONTROL SYSTEM STRUT ASSEMBLY INSPECTION 1) Remove absorber adjusting actuator. 2) Check to make sure that damping force is changed depending on absorber adjusting rod position. If not, replace strut. NOTE: Turn absorber adjusting rod by using long nosed plier or the like.
  • Page 1664 FRONT DRIVE SHAFT 4-1 SECTION 4 FRONT DRIVE SHAFT (Double Offset Joint (DOJ) Type) NOTE: The DOJ type drive shaft can be identified by the outside shape of the differential side joint which has no dent. CONTENTS GENERAL DESCRIPTION ............... 4- 2 REMOVAL (Left side shaft) .
  • Page 1665 4-2 FRONT DRIVE SHAFT GENERAL DESCRIPTION A constant velocity ball joint is used on the wheel side of front drive shaft and a constant velocity double offset joint (DOJ) on the differential side. [1.3 L and 1.6 L engine models] [1.8 L engine model] 1.
  • Page 1666 FRONT DRIVE SHAFT 4-3 REMOVAL (Left Side Shaft) ON FLOOR Undo caulking and remove drive shaft nut and washer. 1. Drive shaft nut A: Undo caulking ON LIFT 1) Drain transmission oil. 2) By using large size screwdrivers, pull out drive shaft joint so as to release snap ring fitting of joint spline at differential side.
  • Page 1667 4-4 FRONT DRIVE SHAFT REMOVAL (Right Side Shaft) ON FLOOR Undo caulking and remove drive shaft nut and washer. 1. Drive shaft nut A: Undo caulking ON LIFT 1) By using plastic hammer, drive out drive shaft joint so as to re- lease snap ring fitting of joint spline at center shaft.
  • Page 1668 FRONT DRIVE SHAFT 4-5 DISASSEMBLY (Drive Shaft) 1) Remove boot band of differential side joint. 1. Boot band 2) Slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race. 1.
  • Page 1669 4-6 FRONT DRIVE SHAFT INSPECTION D Check boots for breakage or deterioration. Replace them as necessary. D Check circlip, snap ring and boot bands for breakage or de- formation. Replace as necessary. DISASSEMBLY (Center Shaft and Center Bearing Support) [1.3 L and 1.6 L Engine Models] 1) Remove right side oil seal from center bearing support.
  • Page 1670 FRONT DRIVE SHAFT 4-7 3) Remove bearing support circlips. 4) Remove center bearing from center bearing support. 1. Circlip REASSEMBLY (Drive Shaft) 1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air. 2) Clean boots with cloth. Do not wash boots in degreaser, such as gasoline or kerosene, etc.
  • Page 1671 4-8 FRONT DRIVE SHAFT 6) Apply grease to entire surface of cage. Use joint grease in tube included in differential side boot set or DOJ set of spare parts. 7) Insert cage into outer race and fit snap ring into groove of outer race.
  • Page 1672 FRONT DRIVE SHAFT 4-9 LEFT SIDE DRIVE SHAFT Differential side Dimensions to use when fixing boot with boot band. *Fill grease [1.3 L and 1.6 L engine model] 80 – 100 g (2.8 – 3.5 oz) [1.8 L engine model] 70 –...
  • Page 1673 4-10 FRONT DRIVE SHAFT D When installing right side oil seal, use care so that it is in proper direction by referring to left figure. “A”: Grease 99000-25010 1. Right side oil seal [1.8 L Engine Model] Install center shaft by reversing removal procedure and noting the following points.
  • Page 1674 FRONT DRIVE SHAFT 4-11 INSTALLATION Install drive shaft assembly by reversing removal procedure and noting the following points. D Clean front wheel bearing oil seal and then apply grease. Replace it if required. “A”: Grease 99000-25010 1. Front wheel bearing D Install wheel side joint to steering knuckle first and then DOJ to oil seal 2.
  • Page 1675 Center bearing support bolt 36.5 Stabilizer joint nut 20.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) SUZUKI BOND NO. 1215 Sealant Oil drain plug for manual transmission (99000-31110) SPECIAL TOOL...
  • Page 1676 FRONT DRIVE SHAFT 4A-1 SECTION 4A FRONT DRIVE SHAFT (Tripod Joint Type) NOTE: The tripod joint type drive shaft can be identified by 3 dent lines on outside of differential side joint (cylin- der shape). CONTENTS GENERAL DESCRIPTION ............... 4A- 1 REMOVAL .
  • Page 1677 4A-2 FRONT DRIVE SHAFT REMOVAL RIGHT SIDE SHAFT WITH CENTER SHAFT AND LEFT SIDE SHAFT Refer to REMOVAL description in SECTION 4 of this manual. RIGHT SIDE SHAFT WITHOUT CENTER SHAFT 1) Undo caulking and remove drive shaft nut and washer. 2) With vehicle lifted up, remove wheel.
  • Page 1678 FRONT DRIVE SHAFT 4A-3 DISASSEMBLY DRIVE SHAFT (4 A/T MODEL) 1) Remove tripod joint boot band, then take out tripod joint hous- ing. 1. Tripod joint housing 2) Remove grease from shaft and take off circlip by using special tool, then pull out spider from shaft. Special Tool (A): 09900-06107 CAUTION:...
  • Page 1679 4A-4 FRONT DRIVE SHAFT 2) Remove grease from shaft and take off circlip by using special tool. Special Tool (A): 09900-06107 1. Spider 2. Bearing 3. Circlip 3) Draw away spider by using bearing puller as shown. CAUTION: D When removing a spider, be sure to use bearing puller with 3 arms.
  • Page 1680 FRONT DRIVE SHAFT 4A-5 REASSEMBLY Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly and tripod joint housing are washed thoroughly and air dried, and boots are cleaned with cloth if they are to be reused.
  • Page 1681 4A-6 FRONT DRIVE SHAFT v) Cut off boot band at about 7 mm (0.28 in.) from clip. 1. Metal fixture 2. Clip vi) Clamp boot band with clip. 3. Boot band vii)Fix small diameter side of boot with boot band by repeating sequence i) to v).
  • Page 1682 FRONT DRIVE SHAFT 4A-7 10) Before fixing boot band, insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure. 11) Fixing boot with boot band, referring to sequence i) to vii) of Step 4).
  • Page 1683 4A-8 FRONT DRIVE SHAFT 7) Facing its chamfered spline inward (wheel side), then fasten it with circlip. Special Tool (A): 09900-06107 8) Fill up differential side boot inside with grease, then install hous- ing and joint it with boot. 9) Fasten boot with bands. 1.
  • Page 1684 FRONT DRIVE SHAFT 4A-9 CENTER SHAFT AND CENTER BEARING SUPPORT Install center shaft by reversing removal procedure and noting fol- lowing points. D When installing bearing support circlip, make sure that it fits in circlip groove in center bearing support securely as shown. 1.
  • Page 1685 4A-10 FRONT DRIVE SHAFT INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. D Clean front wheel bearing oil seal and then apply grease. Replace it if required. “A”: Grease 99000-25010 1. Front wheel bearing oil seal 2.
  • Page 1686 20.5 Tie-rod end nut 32.5 Wheel nut 61.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) SUZUKI BOND NO. 1215 Sealant Oil drain plug for manual transmission (99000-31110) SPECIAL TOOLS 09900-06107...
  • Page 1687: Propeller Shafts

    PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS CONTENTS GENERAL DESCRIPTION ............... . . 4B-1 CONSTRUCTION AND OPERATION .
  • Page 1688 4B-2 PROPELLER SHAFTS CONSTRUCTION AND OPERATION RBC (ROTARY BLADE COUPLING) The main components of the rotary blade coupling are: pressure generation section (silicon chamber) and torque transmission section (multi-plate clutch). The pressure generation section consists of a blade which is in mesh with the coupling shaft at the output side through spline and silicon oil filling the section with a small amount of air.
  • Page 1689 PROPELLER SHAFTS 4B-3 ON-VEHICLE SERVICE REMOVAL 1) Hoist vehicle. 2) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown. 3) Separate No.2 propeller shaft from rear differential case. 4) Remove No.1 propeller shaft from transmission case flange. 5) Remove propeller shaft center support brackets from vehicle body.
  • Page 1690 4B-4 PROPELLER SHAFTS INSTALLATION 1) Reverse removal procedure to install propeller shaft, noting fol- lowing point. D When installing propeller shaft, align the match marks. Otherwise, vibration may occur during driving. D Use following specification to torque universal joint flange. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 Ib-ft) (b): 50 N·m (5.0 kg-m, 36.5 Ib-ft)
  • Page 1691 REAR DRIVE SHAFT 4C-1 SECTION 4C REAR DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ............... . . 4C-1 Removal .
  • Page 1692 4C-2 REAR DRIVE SHAFT REMOVAL 1. Washer 2. Nut 1) Remove caulking of spindle nut and then remove spindle nut and washer. 2) Remove tire and drain rear differential oil. 3) Hoist vehicle. 4) Remove parking brake wire mounting bolt, ABS wheel speed sensor wire bracket mounting bolt (if equipped), rear control rod outer bolts and rear trailing rod rear bolt.
  • Page 1693 REAR DRIVE SHAFT 4C-3 INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. D Be sure to use new drive shaft center nut. Tightening Torque (a): 90 N·m (9.0 kg-m, 65.0 Ib-ft) (b): 175 N·m (17.5 kg-m, 126.5 Ib-ft) D Clean front wheel bearing oil seal and then apply grease.
  • Page 1694 65.0 Rear trailing rod rear bolt Drive shaft center nut 17.5 126.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Differential oil seal lips (99000-25010) SUZUKI BOND NO. 1215 Sealant Differential oil drain plug (99000-31110)
  • Page 1695 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
  • Page 1696 5-2 BRAKES PARKING BRAKE LEVER/CABLE ..5-31 REAR DISC BRAKE INSPECTION ..5-64 Parking Brake routing ....5-31 Inspect Brake Pad Lining .
  • Page 1697 BRAKES 5-3 GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and two in rear). The master cylinder is a tandem master cylinder. The brake pipes are connected to the master cylinder and they make two independent circuits.
  • Page 1698 5-4 BRAKES FOR LEFT-HAND STEERING VEHICLES WITH ABS [For vehicles equipped with P valve] Right Side FRONT Left Side 1. Brake booster 2. Master cylinder 3. Secondary side 4. Primary side 5. Proportioning valve 6. 4-way joint 7. Parking brake lever [For vehicles equipped with LSPV] 8.
  • Page 1699 BRAKES 5-5 FRONT DISC BRAKE CALIPER ASSEMBLY This caliper has a single bore. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
  • Page 1700 5-6 BRAKES REAR DRUM BRAKE ASSEMBLY The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main- tained appropriate at all times. NOTE: Replace all components included in repair kits to service this drum brake. Lubricate parts as specified. WARNING: If any hydraulic component is removed or brake line disconnected, bleed the brake system.
  • Page 1701 BRAKES 5-7 REAR DISC BRAKE CALIPER ASSEMBLY This caliper assembly serves for both foot brake and parking brake. It has a single floating piston and a self pad-disc clearance adjusting system which maintains appropriate pad-disc clearance at all time. This caliper assembly also has a manual adjustment gear which ables the adjustment of self pad-disc clearance manually.
  • Page 1702 5-8 BRAKES MASTER CYLINDER ASSEMBLY The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the below figure) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on left front wheel brake (caliper) and right rear wheel brake (caliper).