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Suzuki SY419 Supplementary Service Manual
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Suzuki SY419 Supplementary Service Manual

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  • Page 3 RELATED MANUALS men- tioned below. BRAKE SYSTEM Brakes When replacing parts or servicing by disas- ENGINE sembling, it is recommended to use SUZUKI General Information genuine parts, tools and service materials Engine Mechanical (lubricants, sealants, etc.) as specified in Engine Cooling each description.
  • Page 17 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” under “Gen- eral Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 18 1B-2 AIR CONDITIONING (OPTIONAL) CONTENTS GENERAL DESCRIPTION ....1B- 2 A/C Engine Coolant Temperature Switch ..1B- 7 Wiring Circuit .
  • Page 27 AIR CONDITIONING (OPTIONAL) 1B-11 3) Remove shims from shaft. 4) Remove drive clutch. Using special tool (C), remove circlip. Special Tool (C): 09900-06107 5) With special tool (D) in place, remove magnet clutch with puller. Special Tool (D): 09951-65510 NOTE: Be careful not to damage pulley when tapping drive clutch.
  • Page 28 1B-12 AIR CONDITIONING (OPTIONAL) 4) Align keyway of armature plate with keyway of shaft. 5) Drive in armature plate by using a pipe whose inner diameter is 8.5 mm (0.335 in.) or more and outer diameter is 19 mm (0.748 in.) or less. Diameter “a”: 8.5 mm (0.335 in.) or more Diameter “b”: 19 mm (0.748 in.) or less 1.
  • Page 29 AIR CONDITIONING (OPTIONAL) 1B-13 MECHANICAL SEAL 1. Oil felt retainer 2).Compressor REMOVAL 1) Remove magnet clutch, referring to “MAGNET CLUTCH” in this section. 2) Pry out retainer with oil felt, by using special tool (C). Special Tool (C): 09900-06107 3) Remove key. 1.
  • Page 42 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” un- der “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 43 5-2 BRAKES ON-VEHICLE SERVICE EXCESSIVE PEDAL TRAVEL CHECK 1) Start engine. 2) Depress brake pedal a few times. 3) With brake pedal depressed with approximately 30 kg (66 lbs) load, measure brake pedal to wall clearance “c”. Clearance “c”: Over 70 mm ( in.) 4) If clearance “c”...
  • Page 52 6A4-2 ENGINE MECHANICAL ON-VEHICLE SERVICE COMPRESSION CHECK Check compression pressure referring to “Procedure 024” in “All models diesel diagnosis manual”. Special tool (A): 09912-57820 (B): 09912-57830 OIL PRESSURE CHECK Check engine oil pressure. Refer to “Checking oil pressure” in “Overhaul checking turning manual”. Special tool (A): 09915-76530/OUT0000057 When installing oil pressure switch, use a new gasket.
  • Page 53 ENGINE MECHANICAL 6A4-3 6) Start engine and warm it up to normal operating temperature. 7) Drive with 3rd gear at idle speed. 8) Depress the accelerator fully. 9) During the acceleration, measure turbocharger pressure when the engine speed reaches 2000 – 3000 r/min. Turbocharger pressure should be 20 to 55 kPa.
  • Page 58 6A4-8 ENGINE MECHANICAL INSTALLATION 1) Reverse removal procedure when installation. NOTE: Use new gasket. Apply sealant between air inlet pipe and intake manifold. “A” Sealant: LOCTITE 518 Tightening torque: (a): 9 N·m (0.9 kg-m) 2) Tighten bolts and nuts to specified torque. Tightening torque: (a): 25 N·m (2.5 kg-m) (b): 15 N·m (1.5 kg-m)
  • Page 59 ENGINE MECHANICAL 6A4-9 DISASSEMBLING, INSPECTION AND REASSEMBLING 1) Disassemble, inspect and reassembling cylinder head. Refer to the following items in “Overhaul checking tuning manual”. Use special tool when removing and installing valve. Special tool: (A): 09916-14510 (B): 09916-14910 “Cylinder head” “Valves”...
  • Page 61 ENGINE MECHANICAL 6A4-11 INSTALLATION 1) Install swirl chambers, so that swirl chamber protrusion en- gages cylinder head recess. 2) Reverse removal procedure. 1. Swirl chamber 2. Protrusion PLUG BALL There are 6 plug balls in cylinder head. Their locations are indicated in left figure. 1.
  • Page 64 6A4-14 ENGINE MECHANICAL 4) Remove 2 relays, grow-plug control module and main fuse 1. Main fuse box 2. Glow plug control module box. 3. Relay 5) Disconnect 2 couplers from main harness. 4. Coupler 6) Remove fuel filter assembly from bracket with hoses still con- nected.
  • Page 65 ENGINE MECHANICAL 6A4-15 INSTALLATION For installation, reverse the removal procedure. However, pay attention to the following points. D Be sure to clamp hoses securely. D For adjustment of throttle cable, refer to “Injection pump setting: LUCAS equipment (Non-industrial setting)” in “Overhaul check- ing tuning manual”.
  • Page 66 6A4-16 ENGINE MECHANICAL SPECIAL TOOL 09910-26510 09910-26520 09911–16510 09911-16520 (OUT0000005) (OUT0000015) (OUT0000002) (OUT0000011) Dial gauge support TDC rod positioner Rear oil seal installer Rear main seal installer 09911–16530 09912-57830 (OUT0000013) Compression gauge 09918-18111 09912-57820 Front seal installer attachment Air pressure regulator Compression gauge 1.
  • Page 67 ENGINE MECHANICAL 6A4-17 09917-96520 09918-96510 09919-46510 09919-56510 (OUT0000021) (OUT0000136) (OUT0000110) (OUT0000062) Stem seal remover Plug ball installer kit Clamp pliers Tightening angle gauge 09915-78220 Pressure gauge attachment...
  • Page 68 6A4-18 ENGINE MECHANICAL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE FASTENING PARTS FASTENING PARTS N·m kg-m lb-ft Cylinder block oil gallery plug (oil filter side) 20.0 14.7 Cylinder block oil gallery plug (flywheel side) 38.0 28.0 Cylinder block plug plate bolt (flywheel side) Cylinder block water drain plug (intake manifold side) 38.0 28.0...
  • Page 70 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” un- der “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 80 ENGINE COOLING 6B-11 CLEANING Clean frontal area of radiator cores. INSTALLATION Reverse removal procedures. NOTE: D Refill cooling system with proper coolant referring to COOLANT item of MAINTENANCE. D After installation, check each joint for leakage. WATER PUMP Refer to “DISMANTLING THE ENGINE” and “INSTALLING THE TIMING BELT”...
  • Page 84 6E3-4 ENGINE AND EMISSION CONTROL SYSTEM FUEL DELIVERY SYSTEM 1. Fuel tank 6. Fuel hose (to fuel filter) Tightening torque 2. Fuel net filter 7. Fuel hose (to fuel injection pump) (a) : 1.6 N·m (0.2 kg-m) 3. Fuel feed line 8.
  • Page 85 ENGINE AND EMISSION CONTROL SYSTEM 6E3-5 ELECTRIC CONTROL SYSTEM 1. Battery 2. Main fuse box 3. Ignition switch 4. Fuse (20 A) 5. Glow plug 6. Glow plug control unit 7. Glow plug indicator lamp 8. Relay (glow plug control) 9.
  • Page 86 Perform “Shut off valve check”. (Refer to “Shut off valve check” in section 8A of this manual.) Special tool (A): 09931-76011 (SUZUKI scan tool) (B): Mass storage cartridge (C): 09931-76030 (16/14 pin DLC cable) 1. DLC Repair or replace any defective parts Is operation of shut off valve in good condition? referring to section 8A of this manual.
  • Page 113 ENGINE AND EMISSION CONTROL SYSTEM 6E3-33 SPECIAL TOOLS 09910-26520 09912-56510 09912-56520 09913-16520 (OUT0000015) (OUT0000077) (OUT0000119) (OUT0000073) TDC rod positioner Vacuum pressure gauge set Fuel injection pump wrench Injector flange 1. Storage case 2. Operator’s manual 3. Tech 1A 4. DLC cable 5.
  • Page 121 8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCTS D Front and rear bush. D Plunger. D Pinion drive lever. SUZUKI SUPER GREASE A D Internal gear. Lithium grease (99000-25010) D Planetary carrier shaft. D Planetary gear D Ball SPECIAL TOOL...
  • Page 130 CHARGING SYSTEM 6H-9 REMOUNTING Reverse removal procedure for installation noting the followings. D Tighten generator bolts and its terminal as follows. Tightening Torque (a): 50 N m (5.0 kg-m, 36.2 lb-ft) (b): 10.0 N m (1.0 kg-m, 7.2 lb-ft) (c): 4.0 N m (0.4 kg-m, 2.9 lb-ft) D Adjust accessory drive belt tension, referring to “AC- CESSORY DRIVE BELT INSTALLATION”...
  • Page 141 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “System Components and Wiring Location View” under “Gen- eral Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 156 7A-16 MANUAL TRANSMISSION GEAR SHIFTER Gear Shift and Select Shaft Assembly 1) To disassemble component parts, use special tools and 2.8 – 3.0 mm (0.11 in.) pin remover in addition. Special Tool (A): 09922-85811(4.5 mm) (B): 09925-78210 (6.0 mm) 2) Clean all parts thoroughly, inspect them and replace with new ones as required.
  • Page 157 MANUAL TRANSMISSION 7A-17 5) Using special tool and hammer, drive out differential side pinion 1. Differential case shaft pin and then disassemble component parts. 2. Differential gear 3. Differential Special Tool pinion shaft (C): 09922-85811 (4.5 mm) Adjustment and Reassembly Left side Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly,...
  • Page 158 7A-18 MANUAL TRANSMISSION 3) Drive in spring pin from right side till it is flush with differential case surface. 4) Using special tool and copper hammer, press-fit new sensor ro- tor, directing as shown. Special tool (A): 09913-75520 1. Sensor rotor (B): 09940-54910 2.
  • Page 160 6) Clean mating surfaces of both right and left cases, coat mating surface of left case with sealant evenly then mate it with right case. Sealant: SUZUKI BOND No.1215, 99000-31110 7) Tighten case bolts from outside to specified torque. Tightening Torque (b): 19 N·m (1.9 kg-m, 14.0 Ib-ft)
  • Page 163 MANUAL TRANSMISSION 7A-23 RECOMMENDED MATERIALS SUZUKI PRODUCTS D Final gear bolts THREAD LOCK CEMENT Thread lock cement SUPER 1333B (99000-32020) SPECIAL TOOLS 09900-06107 Snap ring pliers 09900-20606 09900-20701 09913-60910 (Opening type) Dial gauge Magnetic stand Bearing puller 09922-85811 Spring pin remover...
  • Page 164 7A-24 MANUAL TRANSMISSION 09930-30102 09940-53111 09940-54910 09951-16060 Sliding shaft Bearing installer Sensor rotor installer Bush remover 09951-76010 Bearing installer...
  • Page 183 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8A-3 DIAGNOSIS PRECAUTIONS IN DIAGNOSING TROUBLES PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE D Before identifying diagnostic trouble code indicated by malfunc- tion indicator lamp (“CHECK ENGINE” light), do not disconnect coupler from immobilizer control module, battery cable from bat- tery, immobilizer control module ground wire harness.
  • Page 195 1) Prepare SUZUKI scan tool and cartridge for immobilizer control system of this vehicle. 2) With ignition switch OFF, connect SUZUKI scan tool to DLC lo- cated on underside of instrument panel at driver’s seat side. (A): 09931-76011 (SUZUKI scan tool)
  • Page 201 3) Using SUZUKI scan tool, register fuel pump/immobilizer control module code in immobilizer control module by executing “F1: RECORD ECU” command in SELECT MODE menu. NOTE: For operation procedure of SUZUKI scan tool, refer to SU- ZUKI scan tool operator’s manual. SPECIAL TOOLS 1. Storage case 2.
  • Page 206 AIR CONDITIONING (OPTIONAL) S-1B-1 SECTION S-1B AIR CONDITIONING (OPTIONAL) SUBJECT : CHANGE OF A/C COMPRESSOR ASSEMBLY APPLICABLE MODEL : SY416 4WD (BALENO DIESEL SEDAN / WAGON) EFFECTIVE ENGINE OR FRAME NO. : X JSAEGC51S00180436 X~ X JSAEGC51W00180362 X~ NOTE: The air compressor manufacturer has been changed from SANDEN to SEIKO SEIKI on and after above frame No.
  • Page 207 S-1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION D Whether the A/C equipped with the vehicle being serviced uses refrigerant R-134a or R-12 is indicated on the LABEL installed the compressor. Also, it can be identified by the shape of the service (charge) valve.
  • Page 208 AIR CONDITIONING (OPTIONAL) S-1B-3 ON-VEHICLE SERVICE COMPRESSION SYSTEM COMPRESSOR INSPECTION 1) Install manifold gauge set, referring to “ Troubleshooting proce- dure using manifold gauge set” in the same section of the Ser- vice Manual as mentioned in FOREWORD of this manual. 2) Run engine at idle.
  • Page 209 S-1B-4 AIR CONDITIONING (OPTIONAL) 7) Loosen compressor mounting bolt (1), then remove compres- sor with magnet clutch assembly (2) from its mounting bracket. NOTE: When removing compressor, be careful not to damage fins of condenser. 8) Drain oil from compressor, and measure its amount. INSTALLATION Reverse removal procedure noting following point.
  • Page 210 AIR CONDITIONING (OPTIONAL) S-1B-5 COMPRESSOR MOUNTING BRACKET INSPECTION 1) Remove compressor. Refer to COMPRESSOR in this section. 2) Check mounting bolts and nuts for looseness. 3) Check mounting bracket for crack and deformation. If there is defect for its bracket, replace compressor mounting bracket.
  • Page 211 S-1B-6 AIR CONDITIONING (OPTIONAL) MAGNET CLUTCH 1. Clutch plate bolt 2. Clutch plate 3. Circlip 4. Clutch pulley 5. Washer 6. Shim 7. Diode component 8. Clutch coil 9. Lip type seal 10. Compressor front head 11. Compressor body assembly 12.
  • Page 212 AIR CONDITIONING (OPTIONAL) S-1B-7 3) Check both directions by reversing probes of ohmmeter (1) and there should be only one-way continuity for diode component (2). If check result is not satisfactory, replace magnet clutch compo- nent. REMOVAL 1) Remove compressor. Refer to “A. COMPRESSOR” in this sec- tion.
  • Page 213 S-1B-8 AIR CONDITIONING (OPTIONAL) 8) Remove clutch pulley with puller. NOTE: Be careful not to damage pulley when tapping clutch pulley. 1. Puller 2. Compressor 9) Remove circlip (1) by using special tool (C). 10) Remove clutch coil (2) from compressor assembly (3). Special Tool (C): 09900-06107 INSTALLATION...
  • Page 214 AIR CONDITIONING (OPTIONAL) S-1B-9 5) Adjust clearance, between clutch plate (1) and clutch pulley (2) by putting shim on compressor shaft. Standard clearance “a”: 0.3 – 0.5 mm (0.012 – 0.020 in.) 6) Tighten new clutch plate bolt (2) as specified torque. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 Ib-ft) Special Tool...
  • Page 215 S-1B-10 AIR CONDITIONING (OPTIONAL) INSTALLATION 1) Press-fit lip seal into front head by using special tool (E). Special Tool (E): 09991-06050 CAUTION: Do not reuse mechanical seal once removed from 1. UP type seal compressor. 2. Front head 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.
  • Page 216 AIR CONDITIONING (OPTIONAL) S-1B-11 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT D O-ring Compressor oil for SEIKO SEIKI COMPRESSOR OIL (RS-20, 150 cc) D Each component (Refrigerant oil) 99000-99088-00D0 REFRIGERANT DRUM (200 g) D Refrigerant charge Refrigerant 95794-50G00-0000 SPECIAL TOOLS...
  • Page 239 Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 1st Ed. January, 1999 2nd Ed. Oct., 2001 Printed in Japan Printing:...