MARUTI SUZUKI Maruti 800 Service Manual
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MARUTI SUZUKI Maruti 800 Service Manual

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Table of Contents

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IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special mean-
ings. Pay special attention to the messages high-
lighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for autho-
rized Maruti dealers and qualified service
mechanics only. Inexperienced mechanics
or mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle un-
safe for the driver and passengers.

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Do you have a question about the Maruti 800 and is the answer not in the manual?

Questions and answers

Aju
March 23, 2025

Maruthi 800 petrol distributore timing digree?

0
1 comments:
Mr. Anderson
March 23, 2025

The ignition timing for the Maruti 800 petrol engine is about 8° BTDC (Before Top Dead Center) at idle.

This answer is automatically generated

0
Ali Bachir
February 21, 2025

Quelle Bougie utiliser?!

0
1 comments:
Mr. Anderson
February 21, 2025

The following spark plugs are compatible with the Maruti Suzuki Maruti 800:

1. NIKAVI SP07 Power Spark Plug
2. Bosch F 002 G40265-079 Spark Plug (Set of 3)

Both options are suitable for the vehicle.

This answer is automatically generated

0

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Summary of Contents for MARUTI SUZUKI Maruti 800

  • Page 1 IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special mean- ings. Pay special attention to the messages high- lighted by these signal words. WARNING: Indicates a potential hazard that could result in death or injury.
  • Page 2 FOREWORD This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul). Applicable model: MB308 The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on next page.
  • Page 3 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION GENERAL INFORMATION ENGINE General Information Engine Diagnosis Maintenance and Lubrication Engine Mechanical (F8B Engine) HEATING AND AIR CONDI- Engine Mechanical TIONING (F8D Engine) Heater and Ventilation Engine Cooling Air Conditioning Engine Fuel (If Equipped) Engine and Emission Control STEERING, SUSPENSION,...

  • Page 4: Table Of Contents

    GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ..............0A- 2 PRECAUTIONS .

  • Page 5: How To Use This Manual

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

  • Page 6: Precautions

    GENERAL INFORMATION 0A-3 PRECAUTIONS 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 7 0A-4 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 8: Precautions For Catalytic Converter

    GENERAL INFORMATION 0A-5 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 9: Precautions For Electrical Circuit Service

    0A-6 GENGERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P/S controller, etc.).

  • Page 10: Electrical Circuit Inspection Procedure

    GENERAL INFORMATION 0A-7 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 to check for electrical system, 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 11 0A-8 GENGERAL INFORMATION 3) Using a test male terminal, check both terminals of the circuit being checked for contact tension of its female terminal. Check contact tension by inserting and removing just for Check each terminal visually for poor contact (possibly caused once by dirt, corrosion, rust, entry of foreign object, etc.).
  • Page 12 GENERAL INFORMATION 0A-9 If measurements were taken as shown in the figure at the left and results were as listed below, it means that the circuit is open be- tween terminals B-1 and A-1. Voltage Between: C-1 and body ground: Approx. 5V B-1 and body ground: Approx.

  • Page 13: Intermittent And Poor Connection

    0A-10 GENGERAL INFORMATION INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).

  • Page 14: Precaution For Installing Mobile Communication Equipment

    GENERAL INFORMATION 0A-11 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Cit- izens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely affect electronic control system. D Keep the antenna as far away as possible from the vehicle’s electronic control unit.

  • Page 15: Vehicle Lifting Points

    0A-12 GENGERAL INFORMATION VEHICLE LIFTING POINTS WARNING: D Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending of 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 16 GENERAL INFORMATION 0A-13 In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the jack against the center portion of front cross member (1) or rear axle (2). WARNING: D Never apply jack against suspension parts (i.e., stabi- lizer, etc.) or vehicle floor, or it may get deformed.

  • Page 17: Abbreviations May Be Used In This Manual

    0A-14 GENGERAL INFORMATION ABBREVIATIONS MAY BE USED IN THIS MANUAL : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Engine Control Module : Automatic Locking Retractor ECT Sensor : Engine Coolant Temperature...
  • Page 18 GENERAL INFORMATION 0A-15 : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch : Transmission Control Module MAF Sensor : Mass Air Flow Sensor (A/T Controller, A/T Control (Air Flow Sensor, AFS, Air Module) Flow Meter, AFM)

  • Page 19: Metric Information

    0A-16 GENGERAL INFORMATION METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric. When replac- ing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 7T and radial line with the class identification embossed on the head of each bolt.
  • Page 20 MAINTENANCE AND LUBRICATION 0B-1 SECTION 0B MAINTENANCE AND LUBRICATION CONTENTS PERIODIC MAINTENANCE SCHEDULE ............0B- 2 MAINTENANCE SERVICE .

  • Page 21: Periodic Maintenance Schedule

    0B-2 INSPECTION AND MAINTENANCE PERIODIC MAINTENANCE SCHEDULE This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals Interval: respectively. This interval should be judged by odometer reading or months, which- Km (x 1,000) ever comes first.
  • Page 22 INSPECTION AND MAINTENANCE 0B-3 This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals Interval: respectively. This interval should be judged by odometer reading or months, which- Km (x 1,000) ever comes first.
  • Page 23 0B-4 INSPECTION AND MAINTENANCE This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals Interval: respectively. This interval should be judged by odometer reading or months, which- Km (x 1,000) ever comes first.

  • Page 24: Maintenance Service

    MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and replacing belt tension. Water pump/generator belt inspection 1) Disconnect negative cable from battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. Replace if any defect exists.
  • Page 25 0B-6 MAINTENANCE AND LUBRICATION Camshaft Timing Belt Replacement Replace belt with new one. Refer to SECTION 6A or 6A1 for re- placement procedure. CAUTION: D Do not bent or twist timing belt. D Do not allow timing belt to come into contact with oil, water, etc.
  • Page 26 MAINTENANCE AND LUBRICATION 0B-7 Proper Engine Oil Viscosity Chart Engine Oil and Filter Change WARNING: New and used engine oil can be hazardous. Be sure to read “WARNING” in General Precaution in Section 0A and observe what in written there. Use engine oil of SE, SF, SG, SH or SJ grade.
  • Page 27 0B-8 MAINTENANCE AND LUBRICATION 7) Replenish oil until oil level is brought to FULL level mark on dip- stick (oil pan and oil filter capacity). Filler inlet is at the top of cyl- inder head cover. 8) Start engine and run it for three minutes. Stop it and wait another 5 minutes before checking oil level.
  • Page 28 MAINTENANCE AND LUBRICATION 0B-9 1) Remove radiator cap when engine is cool. 2) Loosen radiator drain plug (1) to drain coolant if radiator is equipped with drain plug. If radiator is not equipped with drain plug, disconnect outlet hose from radiator to drain coolant. 3) Remove reservoir and drain.

  • Page 29: Ignition System

    0B-10 MAINTENANCE AND LUBRICATION Exhaust System Inspection WARNING: To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. 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.

  • Page 30: Fuel System

    MAINTENANCE AND LUBRICATION 0B-11 FUEL SYSTEM Air Cleaner Filter Inspection 1) Remove air cleaner case bracket bolts and unclamp case clamps. 2) Take cleaner filter out of air cleaner case. 3) Visually check that air cleaner filter is not excessively dirty, dam- aged or oily.

  • Page 31: Emission Control System

    0B-12 MAINTENANCE AND LUBRICATION Fuel Tank Inspection Check fuel tank for damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace. Fuel Tank Cap Inspection Check fuel filler cap (1) for malfunction and damage, gasket (2) for even filler neck imprint, deterioration and damage.

  • Page 32: Brake

    MAINTENANCE AND LUBRICATION 0B-13 BRAKE 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 front disc brake pads and discs for excessive wear, dam- age and deflection.

  • Page 33: Chassis And Body

    0B-14 MAINTENANCE AND LUBRICATION Brake Fluid Change CAUTION: Since brake system of this vehicle is factory-filled with brake fluid indicated on reservoir tank cap, do not use or mix different type of fluid when refilling; otherwise seri- ous damage will occur. Do not use old or used brake fluid, or any fluid from a un- sealed container.
  • Page 34 MAINTENANCE AND LUBRICATION 0B-15 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. NOTE: D Tire inflation pressure should be checked when tires are cool.
  • Page 35 0B-16 MAINTENANCE AND LUBRICATION Suspension System Inspection D Inspect front strut and rear shock absorber for evidence of oil leakage, dents or any other damage on sleeves; and inspect an- chor ends for deterioration. Replace defective parts, if any. D Check front and rear suspension systems for damaged, loose or missing parts;...
  • Page 36 MAINTENANCE AND LUBRICATION 0B-17 5-Speed M/T Manual Transmission Oil Inspection and Change Oil Inspection for 5-speed M/T 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove oil filler/level plug (1) of transmission.
  • Page 37 0B-18 MAINTENANCE AND LUBRICATION Oil change for 4-speed M/T 1) Place vehicle level and drain by removing two drain plugs (1). 2) Apply sealant to drain plug after cleaning it and tighten drain plug to specified torque. 3) Pour specified oil up to specified level. For specified oil, its amount and tightening torque, refer to On- Vehicle Service of Section 7A.

  • Page 38: Final Inspection

    MAINTENANCE AND LUBRICATION 0B-19 FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.

  • Page 39: Recommended Fluids And Lubricants

    0B-20 MAINTENANCE AND LUBRICATION Steering Meters and Gauge D Check to ensure that steering wheel is free from in- Check that speedometer, odometer, fuel meter, tem- stability, or abnormally heavy feeling. perature gauge, etc. are operating accurately. D Check that the vehicle does not wander or pull to Lights one side.
  • Page 40 HEATER AND VENTILATION 1A-1 SECTION 1A HEATER (OPTIONAL) AND VENTILATION NOTE: The link mechanism of the heater varies depending on the specifications. CONTENTS GENERAL DESCRIPTION ............... . 1A- 2 DIAGNOSIS .

  • Page 41: Heater (Optional) And Ventilation

    1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heater and ventilation consist of the following parts. 1. Heater unit 2. Air inlet box or cooling unit 3. Ventilator duct 4. Defroster nozzle 5. Ventilation louver 6. Ventilation air 7. Foot air 8.

  • Page 42: Diagnosis Table

    HEATER AND VENTILATION 1A-3 DIAGNOSIS DIAGNOSIS TABLE Trouble Possible Cause Remedy Heater blower fan motor won’t Fuse blown Check “HTR” fuse, and check for work even when its switch is short circuit to ground. operating position. Blower fan motor resistor faulty Check resistor.

  • Page 43: Wiring Circuit

    1A-4 HEATER AND VENTILATION WIRING CIRCUIT 1. Blower fan motor 2. Blower fan motor resistor 3. Blower fan motor switch 4. Ignition switch 5. To A/C switch (if equipped) 6. To ECM (Idle up signal)

  • Page 44: On Vehicle Service

    HEATER AND VENTILATION 1A-5 ON VEHICLE SERVICE HEATER UNIT 1. Heater core 2. Blower fan motor assembly 3. Blower fan motor resistor 4. Temperature door assembly 5. Air outlet control door assembly 6. Air outlet control lever 7. Temperature control lever 8.
  • Page 45 1A-6 HEATER AND VENTILATION REMOVAL 1) Disconnect negative (–) cable at battery. 2) Drain engine coolant and disconnect heater hoses (1) from heater unit. 3) Remove instrument panel. 4) Disconnect each couplers (blower motor, resistor) from heater unit. 5) Remove bolts (2), nuts (3) and screws (4) (if vehicle equipped with A/C) as shown.

  • Page 46: Blower Fan Motor

    HEATER AND VENTILATION 1A-7 BLOWER FAN MOTOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disconnect blower motor coupler. 3) Loosen water valve by removing its attaching screws (1). 4) Remove blower fan motor (2) by removing it attaching screws (3).

  • Page 47: Blower Fan Motor Resistor

    1A-8 HEATER AND VENTILATION BLOWER FAN MOTOR RESISTOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disconnect resistor coupler (1). 3) Remove blower motor resistor (2) by removing its mounting screw (3). INSPECTION Measure each terminal-to-terminal resistance on resistor Me –...

  • Page 48: Heater Control Lever Assembly

    HEATER AND VENTILATION 1A-9 HEATER CONTROL LEVER ASSEMBLY 1. Heater control lever assembly 2. Bulb 3. Fresh air control cable 4. Air outlet control cable 5. Temperature control cable 6. Temperature control knob 7. Air outlet control knob 8. Fresh air control knob REMOVAL 1) Disconnect negative (–) cable at battery.
  • Page 49 1A-10 HEATER AND VENTILATION 7) Remove heater control lever assembly (1) by removing mount- ing screws. INSTALLATION 1) Reverse removal procedure for installation. 2) Adjust the following items. i) Move air outlet control knob (a), temperature control knob (b) and fresh air control knob (c) fully in arrow direction as shown in figure.

  • Page 50: Blower Fan Motor Switch

    HEATER AND VENTILATION 1A-11 BLOWER FAN MOTOR SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disconnect heater control panel illumination coupler and A/C switch coupler (if equipped). 3) Loosen steering column assembly, refer to STEERING COL- UMN in section 3C. 4) Remove temperature control knob (1), air outlet control knob (2) and blower fan motor switch knob (3).

  • Page 51: Air Inlet Box

    1A-12 HEATER AND VENTILATION AIR INLET BOX REMOVAL NOTE: If vehicle is equipped with air conditioning, refer to COOLING UNIT in Section 1B. 1) Remove fresh air control cable (1) from air inlet box (2). 2) Open glove box lid (4). 3) Loosen air inlet box mounting nut (1) and screws (2).
  • Page 52 AIR CONDITIONING (OPTIONAL) 1B-1 SECTION 1B AIR CONDITIONING (OPTIONAL) CAUTION: The air conditioning system of this vehicle uses refrigerant CFC-12 (R-12). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).

  • Page 53: General Description

    1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on LABEL on the compres- sor. Also, it can be checked by the shape of the service (charge) valve.

  • Page 54: Major Components And Location

    AIR CONDITIONING (OPTIONAL) 1B-3 MAJOR COMPONENTS AND LOCATION 1. Cooling unit 2. Compressor 3. Condenser assembly 4. Receiver/dryer 5. Discharge hose 6. Suction hose 7. Receiver/dryer outlet pipe 8. Condenser outlet pipe 9. Expansion valve 10. Ventilation air 11. Foot air 12.

  • Page 55: Diagnosis

    1B-4 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction Cool air won’t come out No refrigerant Recover, evacuation and charging. (A/C system won’t Fuse blown Check “HEATER” fuse and check short operative) circuit to ground. A/C switch faulty Check A/C switch.
  • Page 56 AIR CONDITIONING (OPTIONAL) 1B-5 Condition Possible Cause Correction Cool air won’t come out or Insufficient or excessive charge of Check charge of refrigerant. insufficient cooling (A/C refrigerant Check system for leaks. system normal operative) Condenser clogged Check condenser. Evaporator clogged or frosted Check evaporator and A/C thermistor.

  • Page 57: Quickly Checking Of Refrigerant Charge

    1B-6 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT CHARGE 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 58: Diagnosis Test

    AIR CONDITIONING (OPTIONAL) 1B-7 DIAGNOSIS TEST 1) Confirm that vehicle and environmental conditions are as fol- lows. – Vehicle is not exposed to direct sun. – Ambient temperature is within 15 5C – 35 5C (59 5F – 95 5F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
  • Page 59 1B-8 AIR CONDITIONING (OPTIONAL) 9) Check for each pressure of low side and high side if it is within shaded range of left graph. NOTE: Pressure registered on gauge varies with ambient tem- perature. Therefore, use left graphs when determining if pressures are normal or not.
  • Page 60 AIR CONDITIONING (OPTIONAL) 1B-9 DIAGNOSIS TEST TABLE TESTING RESULTS POSSIBLE CAUSE REMEDY Pressure high Refrigerant overcharged Recharge (“A” area of high side Expansion valve frozen or clogged Check expansion valve graph) Clogged refrigerant passage of high side Clean or replace Condenser fan malfunction Insufficient Check condenser fan...
  • Page 61 1B-10 AIR CONDITIONING (OPTIONAL) DETAIL DIAGNOSIS TABLE AT AMBIENT TEMPERATURE WITHIN 30 – 35 5C (85 – 95 5F) MANIFOLD kg/cm CONDITION CAUSE CORRECTION GAUGE 0.2 – 0.3 1.18 – 1.47 2.0 – 3.0 12.0 – 15.0 Normal condition. 28.4 – 42.6 170 –...

  • Page 62: Wiring Circuit

    AIR CONDITIONING (OPTIONAL) 1B-11 WIRING CIRCUIT 1. Blower fan motor 2. Blower fan motor resistor 3. Blower fan motor switch 4. Dual pressure switch 5. A/C Switch 6. Fuse box 7. Radiator (and condenser) cooling fan relay 8. Radiator (and condenser) cooling fan motor 9.

  • Page 63: A/C System Inspection Of Ecm And Its Circuits

    1B-12 AIR CONDITIONING (OPTIONAL) A/C SYSTEM INSPECTION OF ECM AND ITS Fig. A CIRCUITS ECM and its Circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from it.
  • Page 64 AIR CONDITIONING (OPTIONAL) 1B-13 ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL Measurement Terminal Wire Circuit Normal value Condition ground Ground to E32-301 ECM main ground –0.4 – 0 volt Engine running body (Fig A) Main power supply Ground to Ignition switch ON with engine E32-302 10 –...

  • Page 65: A/C Compressor Drive Belt Inspection

    1B-14 AIR CONDITIONING (OPTIONAL) A/C COMPRESSOR DRIVE BELT INSPEC- TION 1) Check belt for wear and cracks, and replace as required. 2) Check belt tension by measuring how much it deflects when pushed at intermediate point between compressor pulley (1) and crankshaft pulley (2) with about 100 N (10 kg, 22 lbs) force.

  • Page 66: Recovery, Evacuation And Charging

    AIR CONDITIONING (OPTIONAL) 1B-15 RECOVERY, EVACUATION AND CHARGING OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT Recharge 600 60 g of refrigerant in gas form REFRIGERANT RECOVERY When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharging it into atmosphere would cause adverse effect to envi- ronments.

  • Page 67: On-Vehicle Service

    1B-16 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE NOTE: When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe the following instructions. When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immedi- ately.

  • Page 68: Receiver/Dryer

    AIR CONDITIONING (OPTIONAL) 1B-17 INSTALLATION Reverse removal sequence to install condenser, noting the follow- ing point. If condenser is replaced, pour 15 cc of refrigerating oil to com- pressor suction-side. Evacuate and charge system according to previously described procedure. INSPECTION Check the following.

  • Page 69: Radiator (And Condenser) Cooling Fan Motor

    1B-18 AIR CONDITIONING (OPTIONAL) RADIATOR (AND CONDENSER) COOLING FAN MOTOR INSPECTION Check continuity between each two terminals about the radiator (and condenser) cooling fan motor (1). If check results are continuity, proceed to next operation check. If not, replace. Connect battery to radiator (and condenser) cooling fan motor (1) as shown in figure, then check that the radiator (and condenser) cooling fan motor operates smoothly.

  • Page 70: Cooling Unit

    AIR CONDITIONING (OPTIONAL) 1B-19 COOLING UNIT (EVAPORATOR) 1. Evaporator 2. A/C Evaporator thermistor (Evaporator temperature sensor) 3. Expansion valve 4. Evaporator case 5. Packing 6. Drain hose 7. Air inlet door REMOVAL 1) Disconnect negative (–) cable at battery. 2) Recover refrigerant from refrigeration system by using recovery and recycling equipment.

  • Page 71: A/C Evaporator Thermistor

    1B-20 AIR CONDITIONING (OPTIONAL) Evacuate and charge system according to previously described procedure. Adjust fresh air control cable, refer to HEATER CONTROL LE- VER ASSEMBLY in HEATER AND VENTILATION section. Install the cutting part of drain hose (1) downward as shown in figure.

  • Page 72: Expansion Valve

    AIR CONDITIONING (OPTIONAL) 1B-21 EXPANSION VALVE INSPECTION Refer to “Troubleshooting Procedure Using Manifold Gauge Set” earlier in this Section. DUAL PRESSURE SWITCH INSPECTION 1) Check dual pressure switch (1) for continuity at normal temper- ature (approx. 255C (775F)) when A/C system has a proper charge of refrigerant and when A/C system (compressor) is un- der operation.

  • Page 73: Radiator (And Condenser) Cooling Fan Relay And Compressor Relay

    1B-22 AIR CONDITIONING (OPTIONAL) RADIATOR (AND CONDENSER) COOLING FAN RELAY AND COMPRESSOR RELAY INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove radiator cooling fan relay (1) and compressor relay (2) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.

  • Page 74: Compressor

    AIR CONDITIONING (OPTIONAL) 1B-23 COMPRESSOR REMOVAL 1) RUN engine at idle speed with air conditioning ON for 10 min- utes. After that stop the engine. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system by using recov- ery and recycling equipment.
  • Page 75 1B-24 AIR CONDITIONING (OPTIONAL) Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION” in this Section. CAUTION: Be sure to use CFC-12 (R-12) compressor oil. NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Oil amount in compressor: 60 –...

  • Page 76: Magnet Clutch

    AIR CONDITIONING (OPTIONAL) 1B-25 MAGNET CLUTCH 1. Pressure plate 2. Shim 3. Circlip 4. Drive clutch 5. Magnetic clutch coil 6. Compressor 7. Pressure plate nut INSPECTION a. Inspect clutch plate and clutch pulley for signs of oil. b. Check clutch pulley bearings for noise and grease leakage. c.
  • Page 77 1B-26 AIR CONDITIONING (OPTIONAL) 3) Remove shims from shaft. 4) Remove circlip by using special tool (C). Special Tool (C): 09900-06107 5) Whith special tool (D) in place, remove drive clutch (3) from compressor (2) with puller (1). 6) Disconnect coil lead wire from compressor housing. 7) Remove circlip by using special tool (C).

  • Page 78: Disassembly Of Compressor

    AIR CONDITIONING (OPTIONAL) 1B-27 DISASSEMBLY OF COMPRESSOR 10. Cylinder seal 11. Compressor cylinder 12. Cylinder seal 13. Suction valve 14. Valve front plate 15. Reed valve 1. Joint service connector 16. Front gasket 2. Diffuser seal 17. Cylinder front head 3.
  • Page 79 1B-28 AIR CONDITIONING (OPTIONAL) 1) Pry out oil ring (1) by using like a screwdriver, and then remove oil felt (2). 2) Remove key (1) from shaft by using a hammer and punch. 3) Remove circlip (1) by using special tool (E). Special Tool (E): 09900-06108 4) Apply compressor oil to inner bore.
  • Page 80 AIR CONDITIONING (OPTIONAL) 1B-29 b. Turn special tool (F) unit its protrusion (1) engages with the groove (3) provided on lip seal (2). c. Check that special tool (F) goes down slightly when the protru- sion (1) and groove (3) are engaged. d.
  • Page 81 1B-30 AIR CONDITIONING (OPTIONAL) 10) Remove front housing (2) by prying its protrusion (1). NOTE: Be careful not to scratch sealing surface of front housing. 11) Remove front valve plate (2). Remove two pins (1) from cylinder block. 12) Remove the rear housing (2) by prying its protrusion (1). NOTE: Be careful not to scratch sealing surface of rear housing.

  • Page 82: Checking Components

    AIR CONDITIONING (OPTIONAL) 1B-31 CHECKING COMPONENTS Clean all parts with cleaning solvent and apply compressor oil to them. PARTS NAME CHECK POINT REMEDY 1. Check sealing surface for scratches and corro- Replace Lip seal sion. 1. Check both surfaces for scratches and corro- Replace or polish with Valve plate sion.

  • Page 83: Assembly Of Compressor

    1B-32 AIR CONDITIONING (OPTIONAL) ASSEMBLY OF COMPRESSOR NOTE: Do not re-use gasket shaft seal, O-rings, or washers. Use overhaul gasket kit. Before starting assembly, make sure all parts and work- bench are clean. 1) Install rear valve plate (2) on rear cylinder. a.
  • Page 84 AIR CONDITIONING (OPTIONAL) 1B-33 2) Install rear housing (2) on rear cylinder. Housing protrusion (1) is positioned at the top. 3) Install front valve plate (2) on front cylinder. a. Install two pins in front cylinder. b. Lubricate new O-ring with compressor oil. Install O-ring in front cylinder.
  • Page 85 1B-34 AIR CONDITIONING (OPTIONAL) 5) Install lip seal. a. Coat special tool (G) surface with oil and install it to the shaft (1). Special Tool (G): 09990-58230 b. Apply oil lip seal O-ring and install it over special tool (E). When fitting lip seal over the special tool, care should be taken so as not to confuse its designated direction.
  • Page 86 AIR CONDITIONING (OPTIONAL) 1B-35 8) Install new oil felt (1) to inside the bore, and then install ring (2) to inside the bore. 2. Ring 9) Pour compressor oil into compressor. NOTE: Compressor assembly supplied from factory is filled up with 60 –...

  • Page 87: Assembly Of Magnetic Clutch

    1B-36 AIR CONDITIONING (OPTIONAL) ASSEMBLY OF MAGNETIC CLUTCH 1) Install magnetic clutch coil (5). 2) Install drive clutch (4). a. Install drive clutch (4) to compressor (6) shaft. b. Using snap ring pliers, install snap ring (3). 1. Pressure plate 2.

  • Page 88: Required Service Materials

    AIR CONDITIONING (OPTIONAL) 1B-37 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Compressor oil O-ring COMPRESSOR OIL DENSO : ND-OIL6 (Refrigerant oil) Each component REFRIGERANT DRUM Refrigerant Refrigerant charge 95793-60D00-000 SPECIAL TOOLS 09900-06108 09900-06107 Snap ring pliers 09990-28210 Snap ring pliers 09990-48220 (Closing type) Key pressor...
  • Page 89 STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ............... FRONT END ALIGNMENT .
  • Page 90 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 91 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Correction Shimmy, Shake or Tire or wheel out of balance. Balance wheels or replace tire and/or Vibration wheel. Loosen wheel bearings. Replace wheel bearing. Worn tie rod ends. Replace tie rod end. Worn lower ball joints.
  • Page 92 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction Rack and Pinion Loose steering gear case bolts. Tighten. Noise Worn rack bush. Replace. (Rattle or Chuckle) Rack and pinion adjustment. Check and adjust rack and pinion torque. Abnormal Noise, Worn, sticky or loose tie rod ends, lower Replace tie rod end, suspension arm, tie Front End...
  • Page 93 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Condition Possible Cause Correction Low or Uneven Trim Broken or sagging springs. Replace. Height Overloaded. Check loading. Right-to-left trim height Incorrect springs. Replace. “h” difference should be within 15 mm (0.6 in.) with curb weight. *Same with rear side.
  • Page 94 3-6 STEERING, SUSPENSION, WHEELS AND TIRES 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 95 STEERING, SUSPENSION, WHEELS AND TIRES 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 96 3-8 STEERING, SUSPENSION, WHEELS AND TIRES TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level road even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment. 3) Tire construction.
  • Page 97 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ......Preliminary Checks Prior to Adjusting Front Alignment .
  • Page 98 3A-2 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUST- ING FRONT ALIGNMENT Steering and vibration complaints are not always the result of im- proper 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 with- out hand pressure on the steering wheel.
  • Page 99 FRONT END ALIGNMENT 3A-3 TOE ADJUSTMENT Toe is adjusted by changing the tie rod (1) length. Loosen right and left tie rod end lock nuts (2) first and then rotate right and left tie rods by the same amount to align toe-in to specification. In this adjust- ment, right and left tie rods should become equal in length “a”...
  • Page 100 3A-4 FRONT END ALIGNMENT Reference Information: Side slip: For inspecting front wheel side slip with side slip tester: Side slip limit : Less than 3 mm/m (Less than 0.118 in./3.3 ft) If side slip exceeds above limit, toe-in or front wheel alignment may not be correct.
  • Page 101 MANUAL RACK AND PINION 3B-1 SECTION 3B MANUAL RACK AND PINION NOTE: All steering gear 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 102: Diagnosis

    3B-2 MANUAL RACK AND PINION DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STEERING WHEEL CHECK Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.18 in) If steering wheel play is not within specification, inspect as follows and replace if found defective.

  • Page 103: Tie Rod End Boot Check

    MANUAL RACK AND PINION 3B-3 TIE ROD END BOOT CHECK Inspect each boot for tear. If even a small tear is noted, replace with new one. STEERING SHAFT JOINT CHECK Check shaft joint for wear, breakage and other damage and re- place if any defect exists.
  • Page 104 3B-4 MANUAL RACK AND PINION 1. Steering lower shaft 10. Rack damper screw: 21. Steering rack: 2. Steering lower shaft lower bolt Note the installing procedure, and the Apply SUZUKI SUPER GREASE E 3. Steering gear case oil seal: detail refer to page 3B-12. 99000-25050 to entire surface of rack.

  • Page 105: Manual Rack And Pinion Assembly

    MANUAL RACK AND PINION 3B-5 MANUAL RACK AND PINION ASSEMBLY REMOVAL 1) Remove steering joint cover. 2) Loosen steering lower shaft upper bolt (1), but don’t remove. 3) Remove steering lower shaft lower bolt (2) and disconnect steering lower shaft from steering pinion shaft. 4) Hoist vehicle and remove front wheels.

  • Page 106: Disassembly

    3B-6 MANUAL RACK AND PINION 9) Disconnect gear shift control shaft (1) and extension rod (2) from transmission assembly (3). 10) Support engine with transmission jack (1) as shown. 11) Remove engine member rear bolts (2). 12) Lower engine, and then remove manual rack and pinion as- sembly (3) as shown.
  • Page 107 MANUAL RACK AND PINION 3B-7 5) Unbend bent part of tie rod lock washer (1) and remove tie rod (2) from steering rack (3). 6) Remove rack damper screw cap (1), rack damper screw (2), rack plunger spring (3), and rack plunger (4). 7) Remove pinion bearing plug (1) using special tool.
  • Page 108 3B-8 MANUAL RACK AND PINION 9) Remove rack (1) from gear case (2) as shown. CAUTION: Inside of steering rack bushing is coated with spe- cial coating. As it is damageable, be very careful not to cause damage to it when removing rack from steering gear case.

  • Page 109: Inspection

    MANUAL RACK AND PINION 3B-9 13) Remove gear case oil seal (1) using special tool. Special Tool (A): 09913-50121 14) Remove gear case O-ring (2). INSPECTION Rack Plunger Inspect rack plunger (1) for wear or damage. Inspect rack plunger spring (2) for deterioration. If found defective, replace.

  • Page 110: Reassembly

    3B-10 MANUAL RACK AND PINION Steering Rack Bushing Inspect rack bushing for wear or damage. If found defective, replace. REASSEMBLY Install in reverse order of disassembly, noting the following points. Install pinion bearing oil seal to pinion bearing plug (1) using spe- cial tool.
  • Page 111 MANUAL RACK AND PINION 3B-11 Apply grease to rollers of pinion needle bearing (1). Grease: 99000-25050 Press-fit pinion needle bearing (1) into gear case (2) using spe- cial tool. After press-fitting, make sure that bearing rollers are installed properly. Special Tool (A): 09943-88211 Apply grease to entire teeth surface of steering rack (1) and its periphery.
  • Page 112 3B-12 MANUAL RACK AND PINION Apply grease lightly to sliding part of plunger (1) against rack. “A”: Grease 99000-25050 Install rack plunger (1), rack plunger spring (2) and rack damper screw (3) and adjust rotation torque of pinion as follows. i) After tightening rack damper screw (3) to the tightest point, turn it back by 0 –...

  • Page 113: Installation

    MANUAL RACK AND PINION 3B-13 Before installing boot to steering rack housing (1), make sure that rack side mount (2) is positioned as shown. Distance “a” 1.0 – 2.0 mm (0.04 – 0.08 in.) Position boot (1) properly in grooves of gear case and tie rod, and then clamp it with wire (2) and clip (3).
  • Page 114 3B-14 MANUAL RACK AND PINION Connect extension rod (1) and gear shift control shaft (2) to transmission assembly. Tightening Torque (a): 6 N m (0.6 kg-m, 4.5 lb-ft) (b): 33 N m (3.3 kg-m, 24.0 lb-ft) Install new exhaust pipe gasket and exhaust pipe (1). Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 lb-ft)

  • Page 115: Required Service Materials

    MANUAL RACK AND PINION 3B-15 Be sure that steering wheel and brake discs (right and left) are all straight ahead driving state and then insert steering lower shaft into steering pinion shaft. Tighten steering lower shaft bolts to specified torque (Lower bolt (1) first, and then upper bolt (2)).

  • Page 116: Special Tool

    3B-16 MANUAL RACK AND PINION SPECIAL TOOL 09913-50121 09913-65210 09921-20200 09925-98210 Oil seal remover Tie-rod end remover Bearing remover Bearing installer 09944-18211 09944-26011 Pinion torque checking Pinion bearing plug 09930-30104 09943-88211 socket socket (43 mm) Sliding shaft Bearing installer 09944-48210 Rack bush remover...
  • Page 117 STEERING WHEEL AND COLUMN 3C-1 SECTION 3C STEERING WHEEL AND COLUMN CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that ap- plication.

  • Page 118: General Description

    3C-2 STEERING WHEEL AND COLUMN GENERAL DESCRIPTION These are two types of steering column for this vehicle. They are double tube type and single tube type. These steering columns have the following important features in addition to the steering function: The ignition switch and lock are mounted conveniently on this column.

  • Page 119: On-Vehicle Service

    STEERING WHEEL AND COLUMN 3C-3 DIAGNOSIS For maintenance service of the steering wheel and column, refer to SECTION 0B. For diagnosis of the steering wheel and column, refer to SECTION 3. INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT After an accident be sure to perform checks, inspections and repairs referring to CHECKING STEERING COL- UMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE in this section.

  • Page 120: Steering Wheel

    3C-4 STEERING WHEEL AND COLUMN STEERING WHEEL REMOVAL 1) Check that vehicle’s front tires are at straight-ahead position. 2) Disconnect negative cable at battery. 3) Remove steering wheel pad (1) from steering wheel (2). 4) Remove horn switch assembly (1) from steering wheel (2). 5) Remove steering wheel nut (3).

  • Page 121: Combination Switch Assembly

    STEERING WHEEL AND COLUMN 3C-5 3) Install steering wheel (1) onto shaft (2), aligning them by match marks (3). 4) Tighten steering wheel nut (4) to specified torque. Tightening Torque (a): 33 N·m (3.3 kg-m, 24.0 lb-ft) 5) Install steering wheel pad. COMBINATION SWITCH ASSEMBLY REMOVAL 1) Remove steering wheel from steering column referring to...

  • Page 122: Steering Column Assembly And Steering Lower Shaft

    3C-6 STEERING WHEEL AND COLUMN INSTALLATION 1) Check to make sure that vehicle’s front tires are set at straight- ahead position and then ignition switch is at “LOCK” position. 2) Install combination switch assembly (1) to steering column. 3) Connect lead wire of combination assembly at coupler. 4) Clamp lead wire of combination switch assembly using clamp.
  • Page 123 STEERING WHEEL AND COLUMN 3C-7 REMOVAL 1) Be sure that front wheels and steering wheel are in straight for- ward state. 2) Disconnect negative cable at battery. 3) Remove steering column cover screws (1). 4) Separate upper column cover (2) and lower column cover (3), then remove them.
  • Page 124 3C-8 STEERING WHEEL AND COLUMN INSTALLATION CAUTION: After tightening steering column upper and lower nuts, steering lower shaft bolts should be tightened. Wrong tightening order above could cause a damage to steering lower shaft. 1) Be sure that front wheels and steering wheel are in straight for- ward state.
  • Page 125 STEERING WHEEL AND COLUMN 3C-9 7) Tighten steering column upper and lower nuts (1, 2 and 3) to specified torque in the order (1) – (2) – (3) indicated in figure. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) 8) Tighten joint bolt (pinion shaft side) (4) and joint bolt (steering column side) (5) to specified torque in the order (4) –...

  • Page 126: Steering Lock Assembly (Ignition Switch)

    3C-10 STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column assembly (1) referring to REMOVAL of STEERING COLUMN ASSEMBLY AND STEERING LOW- ER SHAFT in this section. 2) Using center punch (1), loosen and remove steering lock mounting bolts (2).

  • Page 127: Checking Steering Column Assembly And Lower Shaft For Accident Damage

    STEERING WHEEL AND COLUMN 3C-11 CHECKING STEERING COLUMN AS- SEMBLY AND LOWER SHAFT FOR AC- CIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted may have a dam- aged or misaligned steering column. CHECKING PROCEDURE 1) Check that each capsule (1) is attached to steering column bracket (2) securely, if equipped.

  • Page 128: Required Service Material

    3C-12 STEERING WHEEL AND COLUMN REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT SUZUKI GREASE CE-T Grease Contact plate. (99000-25290) SPECIAL TOOL 09944-36011 Steering wheel remover...
  • Page 129 FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: 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 130: General Description

    3D-2 FRONT SUSPENSION GENERAL DESCRIPTION Front suspension is Macpherson (strut) type independent suspension system, and consists of coil springs, front suspension struts, steering knuckles, stabilizer bar, and front suspension arms. 1. Front coil spring 2. Front suspension strut 3. Steering knuckle 4.

  • Page 131: Diagnosis

    FRONT SUSPENSION 3D-3 DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STABILIZER BAR AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. STRUT ASSEMBLY CHECK Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.

  • Page 132: Suspension Control Arm And Bushing Check

    3D-4 FRONT SUSPENSION SUSPENSION CONTROL ARM AND BUSHING CHECK Inspect for cracks, deformation or damage. SUSPENSION CONTROL ARM JOINT CHECK Check for smooth rotation. Inspect ball stud for damage. Inspect dust cover for damage. NOTE: Suspension control arm and arm joint cannot be separated as shown “A”...

  • Page 133: On-Vehicle Service

    FRONT SUSPENSION 3D-5 ON-VEHICLE SERVICE STRUT ASSEMBLY 1. Strut nut 2. Strut lock washer 3. Strut inner support 4. Strut rebound stopper 5. Strut support 6. Strut mount 7. Strut mount seat 8. Strut bearing seat 9. Strut bearing 10. Spring upper seat 11.
  • Page 134 3D-6 FRONT SUSPENSION REMOVAL 1) Hoist vehicle, allowing front suspension to hang free. 2) Remove wheel. 3) Remove E ring (1) securing brake hose and take brake hose off strut bracket as shown. 4) Remove strut bracket bolts (1). 5) Remove strut support nuts (1). Hold strut by hand so that it will not fall off.
  • Page 135 FRONT SUSPENSION 3D-7 DISASSEMBLY 1) Placing special tool 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. Special Tool (A): 09940-71430 2) While keeping spring compressed with special tool as shown...
  • Page 136 3D-8 FRONT SUSPENSION 3) Install bump stopper onto strut rod. For installing direction, refer to the figure on previous page. 4) Pull strut rod as far up as possible and use care not to allow it to retract into strut. 5) Install spring seat (2), mating stepped part of seat with spring upper end (1) as shown.
  • Page 137 FRONT SUSPENSION 3D-9 INSTALLATION 1) Install strut by reversing the REMOVAL steps 1) to 6). Insert bolts in such a direction as shown. 2) Tighten all fasteners to specified torque. Tightening Torque (a): 27 N·m (2.7 kg-m, 19.5 lb-ft) (b): 80 N·m (8.0 kg-m, 58.0 lb-ft) 3) Install brake hose(1).

  • Page 138: Stabilizer Bar And/Or Bushings

    3D-10 FRONT SUSPENSION STABILIZER BAR AND/OR BUSHINGS 1. Split pin 2. Castle nut 3. Stabilizer bar washer 4. Stabilizer bar bush 5. Suspension control arm 6. Stabilizer bar: Be sure that color paint on stabi- lizer bar aligns with mount bush, both right and left.
  • Page 139 FRONT SUSPENSION 3D-11 Install painted side to suspension control arm (1) on the right. Install mount bracket (2) so that its oblong hole drilled side of bracket to the rear. Tighten mount bracket bolt (3) to specified torque. Tightening Torque (a): 43 N·m (4.3 kg-m, 31.0 lb-ft) Painted “A”: Upper side...

  • Page 140: Wheel Hub, Wheel Stud And Wheel Bearing Outside Inner Race

    3D-12 FRONT SUSPENSION WHEEL HUB, WHEEL STUD AND WHEEL BEARING OUTSIDE INNER RACE 1. Steering knuckle 4. Hub bolt 2. Wheel bearing: 5. Wheel hub Apply lithic grease (SUZUKI SUPER GREASE A 6. Brake disc bolt 99000-25010) to balls and oil seal lips. 7.
  • Page 141 FRONT SUSPENSION 3D-13 7) Remove hub bolts (1). CAUTION: Never remove bolt unless replacement is necessary. Be sure to use a new bolt for replacement. 8) Remove wheel bearing inner race (1). Special Tools (A): 09913-61110 (B): 09925-88210 INSTALLATION 1. Oil hydraulic press 2.
  • Page 142 3D-14 FRONT SUSPENSION 3) Apply grease to outside bearing (1), outside inner race (3) and oil seal lip (2). “A”: SUZUKI SUPER GREASE A 99000-25010 4) Install brake disc (1) to wheel hub (2). Tighten disc bolts only lightly. 5) Install wheel hub (1) to knuckle by tightening new drive shaft nut. Do not tap wheel hub.

  • Page 143: Suspension Control Arm/Bushing

    FRONT SUSPENSION 3D-15 SUSPENSION CONTROL ARM/BUSHING 1. Stabilizer bar 2. Ball stud bolt 3. Knuckle 4. Ball stud 5. Stabilizer bar mount bracket bolt 6. Control arm bolt 7. Suspension control arm 8. Stabilizer bar bushing 9. Washer 10. Castle nut 11.
  • Page 144 3D-16 FRONT SUSPENSION ASSEMBLY Before installing bushing (1), apply soap water on its circumfer- ence to facilitate installation and then installing bushing with spe- cial tool and hydraulic press (2) as shown. Special Tool (A): 09943-77910 CAUTION: Be sure to use new bushing. NOTE: When installed, bush should be equal dimensions “A”...
  • Page 145 FRONT SUSPENSION 3D-17 3) Install stabilizer bar to control arm and then bushing, washer and nut to stabilizer bar. Tighten nut to the extent to be turned by hand. 4) Tighten stabilizer bar mount bracket bolts to specified torque. Before tightening, check if stabilizer bar is properly centered, side-to-side, refer to STABILIZER BAR AND/OR BUSHINGS in this section.

  • Page 146: Knuckle And Bearing

    3D-18 FRONT SUSPENSION KNUCKLE AND BEARING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove wheel hub. Refer to step 2) – 5) of WHEEL HUB, WHEEL STUD AND WHEEL BEARING OUTSIDE INNER RACE REMOVAL in this section. 3) Disconnect tie rod end (1) from knuckle (2) with special tool. Special Tool (C): 09913-65210 4) Remove ball stud bolt (1).
  • Page 147 FRONT SUSPENSION 3D-19 2) Remove bearing outer race using special tool and hydraulic press (1). Special Tool (C): 09913-75520 3) Remove wheel bearing inner race from wheel hub referring to step 8) of WHEEL HUB, WHEEL STUD AND WHEEL BEAR- ING OUTSIDE INNER RACE REMOVAL in this section.
  • Page 148 3D-20 FRONT SUSPENSION 6) Drive in new inside oil seal (1) until seal is flush with stopped sur- face of knuckle (2) by using special tool. NOTE: When driving in oil seal, be careful not to deform or tilt it or not to cause damage to rubber part.

  • Page 149: Required Service Material

    FRONT SUSPENSION 3D-21 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithic wheel bearing grease Wheel bearing (99000-25010) SPECIAL TOOL 09913-61110 09913-65210 09913-75520 09924-74510 Bearing puller Tie rod end remover Bearing installer Bearing installer handle 09940-71430 09925-88210 09942-15510 09943-17912 Spring compressor...
  • Page 150 REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION (LEAF SPRING TYPE) NOTE: All rear 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 151: General Description

    3E-2 REAR SUSPENSION GENERAL DESCRIPTION Rear suspension consists of leaf springs, bump stoppers, and shock absorbers. 1. Leaf spring: 5. Wheel bearing Apply silicone grease 99000-25190 6. Brake drum to shackle pin bushes. 7. Spindle cap 2. Bump stopper 8. Spindle nut 3.

  • Page 152: Diagnosis

    REAR SUSPENSION 3E-3 DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. REAR SHOCK ABSORBER CHECK Inspect for deformation or damage. Inspect bushings for wear or damage. Inspect for evidence of oil leakage. Replace any defective part. WARNING: When handling rear shock absorber in which high-pres- sure gas is sealed, make sure to observe the following precautions.

  • Page 153: Wheel Disk, Nut And Bearing Check

    3E-4 REAR SUSPENSION WHEEL DISC, NUT AND BEARING CHECK Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Check wheel hub nuts for tightness and, as necessary, retighten to specification. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) Check wheel bearings for wear.

  • Page 154: On-Vehicle Service

    REAR SUSPENSION 3E-5 ON-VEHICLE SERVICE SHOCK ABSORBER 1. Shock absorber upper bolt 2. Shock absorber assembly 3. Upper lock washer 4. Upper nut 5. Lower bolt 6. Lower lock washer 7. Lower nut : Tightening Torque REMOVAL 1) Hoist vehicle. 2) Remove lower mounting bolt and nut.

  • Page 155: Leaf Spring

    3E-6 REAR SUSPENSION LEAF SPRING 1. Leaf spring 2. Bump stopper 3. Bump stopper bracket 4. Rear axle 5. Rear axle spring seat 6. U-bolt 7. Shackle pin : Tightening Torque REMOVAL 1) Raise vehicle. In this operation, garage jack or hoist must not be positioned against rear suspension related parts.
  • Page 156 REAR SUSPENSION 3E-7 INSTALLATION 1) Before installing leaf spring, apply silicone grease by spreading it hard into thin coat over the entire area. (Be sure to use silicone grease that will not affect rubber.) “A” : Silicone grease 99000-25190 2) Install front bolt (1) and shackle pins (2) in the direction as shown.

  • Page 157: Rear Axle

    3E-8 REAR SUSPENSION REAR AXLE NOTE: See NOTE at the beginning of this section. In removing and installing rear axle, the same procedure is re- quired on both the right and left sides. The procedure de- scribed here is a representative one. If it is used on one side, it must be used in symmetry on the other side.
  • Page 158 REAR SUSPENSION 3E-9 INSTALLATION 1) Place bump stopper (2) on leaf spring (4), aligning projection of bump stopper to recess in spring. 2) Fit pin (7) (projection) on under side of leaf spring into hole (8) in spring seat (6) of rear axle (1). 3) Tightening U-bolt nuts (5) to specified torque.
  • Page 159 3E-10 REAR SUSPENSION 4) Apply water tight sealant to joint seam of axle and mating sur- faces of brake back plate. “C” : Sealant 366E, 99000-31090 5) Install brake back plate to rear axle and tighten back plate bolts to specified torque. Tightening Torque (b) : 23 N·m (2.3 kg-m, 16.5 lb-ft) 6) Put brake hose/pipe through hole in bracket on axle and se-...

  • Page 160: Wheel Bearing And Wheel Stud

    REAR SUSPENSION 3E-11 WHEEL BEARING AND WHEEL STUD REMOVAL 1) Hoist vehicle and remover rear wheel. 2) Remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause damage to seat- ing part of cap).
  • Page 161 3E-12 REAR SUSPENSION 6) Pull brake drum (1) off by using special tools. Special Tool (A) : 09942-15510 (B) : 09943-17912 7) Remove wheel bearing. 8) Remove wheel stud (1) by using hydraulic press (2) and general rod (3). INSTALLATION NOTE: See NOTE at the beginning of this section.
  • Page 162 REAR SUSPENSION 3E-13 2) Install wheel bearing by using special tool. Special Tool (A) : 09913-76010 NOTE: When installing bearings: Direct stamped side of bearing towards outside. Refer to figure for installing direction of spacer (1). Direct inner bearing sealed side (2) outward. Fill the space indicated by “A”...
  • Page 163 3E-14 REAR SUSPENSION 8) Install spindle cap. NOTE: When installing spindle cap, hammer lightly several locations on the collar of cap unit the collar comes closely into contact with brake drum. If fitting part of cap is deformed or damaged or if it is fitted loosely, replace with new one.

  • Page 164: Required Service Materials

    REAR SUSPENSION 3E-15 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Brake fluid DOT3 Brake reservoir tank SEALING COMPOUND 366E Water tight sealant Joint seam of rear axle and brake back plate (99000-31090) SILICONE GREASE By spreading leaf spring hard into thin coat over –...
  • Page 165 REAR SUSPENSION 3E1-1 SECTION 3E1 REAR SUSPENSION (COIL SPRING TYPE) NOTE: All rear 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 166: General Description

    3E1-2 REAR SUSPENSION GENERAL DESCRIPTION Rear suspension consists of coil springs, rear axle, shock absorbers, lateral rod and trailing arms. The lateral rod is installed to the body and axle by using bushes so as to prevent axle movement in the lateral direction.
  • Page 167 REAR SUSPENSION 3E1-3 1. Rear coil spring 9. Bearing 2. Rear bump stopper 10. Spacer 3. Rear spring upper seat 11. Brake drum 4. Rear shock absorber 12. Split pin 5. Lateral rod 13. Castle nut 6. Trailing arm 14. Spindle cap 7.

  • Page 168: Diagnosis

    3E1-4 REAR SUSPENSION DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. REAR SHOCK ABSORBER CHECK Inspect for deformation or damage. Inspect bushings for wear or damage. Inspect for evidence of oil leakage. Replace any defective part. WARNING: When handling rear shock absorber in which high pres- sure gas is sealed, make sure to observe the following precautions.

  • Page 169: Bump Stopper/Spring Upper Seat Check

    REAR SUSPENSION 3E1-5 BUMP STOPPER/SPRING UPPER SEAT CHECK Inspect for cracks, deformation or damage. Replace any defective part. WHEEL DISC, NUT AND BEARING CHECK Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. Check wheel hub nuts for tightness and, as necessary, retighten to specification.

  • Page 170: On-Vehicle Service

    3E1-6 REAR SUSPENSION ON-VEHICLE SERVICE LATERAL ROD REMOVAL 1) Hoist vehicle. 2) Remove lateral rod nuts (1) and bolt (2). 3) Remove lateral rod (3). INSTALLATION 1) Install lateral rod (1) to rear axle (2) and vehicle body (3) refer- ring to figure for proper installing direction of nuts (4), bolt (5) and washer (6).

  • Page 171: Rear Shock Absorber

    REAR SUSPENSION 3E1-7 REAR SHOCK ABSORBER REMOVAL 1) Hoist vehicle. 2) Support center of rear axle by using floor jack to prevent it from lowering. 3) Remove lower mounting bolt (1). 4) Remove upper mounting bolt (2) and nut (3). Then remove shock absorber (4).
  • Page 172 3E1-8 REAR SUSPENSION 5) Loosen trailing arm front bolt (1) and remove trailing arm. 6) Remove trailing arm bushes (1) by using hydraulic press and special tools. Special Tool (A): 09924-74510 Front side (B): 09951-16060 Rear side (C): 09951-16030 INSTALLATION 1) Press fit bushes by using hydraulic press and special tools.

  • Page 173: Wheel Bearing And Wheel Stud

    REAR SUSPENSION 3E1-9 6) Install wheel (1) and tighten wheel nuts (2) to specified torque. Tightening Torque (d): 55 N·m (5.5 kg-m, 40.0 lb-ft) 7) Lower vehicle. WHEEL BEARING AND WHEEL STUD REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Remove spindle cap (1) as shown by hammering lightly at 3 locations around it so as not to deform or cause damage to seat- ing part of cap.
  • Page 174 3E1-10 REAR SUSPENSION 4) Release parking brake lever (1) to cancel rear brake. 5) Loosen parking brake cable lock nuts (2). FRONT 6) Pull brake drum (1) off by using special tools. Special Tool (A): 09942-15510 (B): 09943-17912 7) Remove wheel bearing (1). 8) Remove wheel stud (1) by using hydraulic press (2) and general rod (3).
  • Page 175 REAR SUSPENSION 3E1-11 INSTALLATION 1) Insert new stud (1) in drum (4) hole after rotate stud slowly to assure the serrations are aligned with those mode by the origi- nal bolt by using hydraulic press (3) and general rod (2). 2) Install wheel bearing by using special tool.
  • Page 176 3E1-12 REAR SUSPENSION 6) Install split pin (1) securely as shown. 7) Install spindle cap. NOTE: When installing spindle cap, hammer lightly several locations on the collar of cap until the collar comes closely into contact with brake drum. If fitting part of cap is deformed or damaged or if it is fitted loosely, replace with new one.

  • Page 177: Rear Axle

    REAR SUSPENSION 3E1-13 REAR AXLE NOTE: In removing and installing the rear axle, the same procedure is required on both the right and left sides. The procedure de- scribed here is a representative one. If it is used on one side, it must be used in symmetry on the other side.
  • Page 178 3E1-14 REAR SUSPENSION 9) Remove lateral rod. 10) Remove shock absorber lower mount bolt (1). 11) Loosen trailing arm front nut (2). 12) Lower rear axle by releasing floor jack gradually till tension of suspension spring is relieved, and then remove spring. 13) Remove trailing arm front bolt and take down rear axle with trailing arm.
  • Page 179 REAR SUSPENSION 3E1-15 3) Support rear axle (1) by using floor jack. 4) Install coil spring (3) on rear axle spring seat (2). NOTE: When installing coil spring, insert it with its flat face side to top. When seating coil spring, mate spring end with stepped part (4) of rear axle seat as shown.
  • Page 180 3E1-16 REAR SUSPENSION 9) Apply water tight sealant to joint seam of axle and brake back plate and tighten bolts to specified torque. “A” : Sealant 366E, 99000-31090 Tightening Torque (f): 23 N·m (2.3 kg-m, 16.5 Ib-ft) 10) Put brake flexible hose (1) to bracket on axle and secure it with E-rings (4) and remove breather plug cap from end of pipe.

  • Page 181: Required Service Materials

    REAR SUSPENSION 3E1-17 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Brake fluid DOT3 Brake reservoir tank SEALING COMPOUND 366E Water tight sealant Joint seam of rear axle and brake back plate (99000-31090) SPECIAL TOOLS 09913-76010 09924–74510 09951-16030 09951-16060 Rear wheel bearing Bearing installer handle Bearing installer ( 51) Bearing installer ( 45)
  • Page 182 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 183 3F-2 WHEELS AND TIRES kgf/cm WARNING: Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emer- gencies, because handling may be seriously affected and may result in loss of control. It is recommended that new tires be installed in pairs on the same axle.

  • Page 184: Tires

    WHEELS AND TIRES 3F-3 MAINTENANCE AND MINOR ADJUSTMENTS WHEEL MAINTENANCE Wheel repairs that use welding, heating, or peening are not ap- proved. All damaged wheels should be replaced. WHEEL ATTACHING STUDS If a broken stud is found, refer to WHEEL BEARING AND WHEEL STUD in Section 3D (front) or 3E, 3E1 (rear) for replacement of it.

  • Page 185: Inflation Of Tires

    3F-4 WHEELS AND TIRES INFLATION OF TIRES The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread wear, tire life and resistance to bruises. Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should be checked monthly or before any extended trip.

  • Page 186: On-Vehicle Service

    WHEELS AND TIRES 3F-5 ON-VEHICLE SERVICE SERVICE OPERATIONS METRIC LUG NUTS AND WHEEL STUDS All models use metric lug nuts and wheel studs (size: M12 1.25). WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180 (half a rotation). 2) Hoist vehicle. 3) Remove wheel.

  • Page 187: Tire Repair

    3F-6 WHEELS AND TIRES After mounting, inflate to specified pressure shown on tire placard so that beads are completely seated. WARNING: Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety hump and cause seri- ous personal injury.

  • Page 188: General Balance Procedures

    WHEELS AND TIRES 3F-7 GENERAL BALANCE PROCEDURES Deposits of mud, etc. must be cleaned from inside of rim. WARNING: Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain good balance. Each tire should be inspected for any damage, then balanced according to equipment manufacturer’s recommen- dation.
  • Page 189 FRONT DRIVE SHAFT 4-1 SECTION 4 FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ................DIAGNOSIS .

  • Page 190: General Description

    4-2 FRONT DRIVE SHAFT GENERAL DESCRIPTION The drive shaft joint is a constant velocity joint (C.V joint) which slides in the axial direction. The joint is composed of an outer race, cage, inner race and balls. In the turning direction, the joint rotates in the same way as a ball bear- ing.
  • Page 191 FRONT DRIVE SHAFT 4-3 ON-VEHICLE SERVICE DRIVE SHAFT ASSEMBLY REMOVAL 1) Undo caulking and remove drive shaft nut (1) and washer. A: Undo caulking 2) Hoist vehicle. 3) Remove wheel. 4) Remove tie-rod end split pin (1) and castle nut (2). 5) Disconnect tie-rod end (3) from steering knuckle (4) by using special tool.
  • Page 192 4-4 FRONT DRIVE SHAFT DISASSEMBLY 1) Wipe outer surface of drive shaft with a cloth and disassembly in the following manner. 2) Remove boot band (1) of differential side joint. 3) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race (3).
  • Page 193 FRONT DRIVE SHAFT 4-5 ASSEMBLY CAUTION: Wash all part before installation. Wipe out boot with a cloth. 1) Fit a boot (1) on drive shaft and, fitting small diameter side of the boot to shaft groove, fix with a boot band (2). 2) Install cage (1) on drive shaft.
  • Page 194 4-6 FRONT DRIVE SHAFT 6) Apply grease to inside of outer race (1) and fit boot (2) to outer race. After fitting boot, insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot be- comes the same as atmospheric pressure.
  • Page 195 FRONT DRIVE SHAFT 4-7 INSTALLATION CAUTION: To avoid excessive expansion of boot and consequen- tial disconnection of joint in boot, do not pull differen- tial side joint housing. Protect oil seals and boots from any damage, prevent- ing them from unnecessary contact while installing drive shaft.
  • Page 196 4-8 FRONT DRIVE SHAFT REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Oil seal lips (99000-25010) Lithium grease Lithium grease SUZUKI SUPER GREASE H Entire surface of the cage and the outer race on (99000-25120) drive shaft assembly SUZUKI BOND NO.
  • Page 197 BRAKES 5-1 SECTION 5 BRAKES NOTE: All brake 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 same part number or with an equivalent part if replacement becomes necessary.

  • Page 198: General Description

    5-2 BRAKES GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. Four brake pipes are connected to the master cylinder and they make two independent circuits.

  • Page 199: Front Disc Brake Caliper Assembly

    BRAKES 5-3 FRONT DISC BRAKE CALIPER ASSEMBLY This caliper has a single 51.1 mm (2.012 in.) bore and is mounted to the brake caliper holder with two mounting bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hy- draulic 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 200: Diagnosis

    5-4 BRAKES DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE Brakes should be tested on dry, clean, smooth and FLUID reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid test brakes by making brake applications with both may cause brake fluid to boil or rubber components light and heavy pedal forces at various speeds to de- in the hydraulic system to deteriorate.

  • Page 201: Diagnosis Table

    BRAKES 5-5 DIAGNOSIS TABLE Condition Possible Cause Correction Not enough Brake oil leakage from brake lines. Locate leaking point and repair. braking force Brake disc or pads stained with oil. Clean or replace. Overheated brakes. Determine cause and repair. Poor contact of shoes on brake drum. Repair for proper contact.
  • Page 202 5-6 BRAKES Condition Possible Cause Correction Dragging Master cylinder pistons not returning correctly. Repair master cylinder. brakes Restricted brake pipes or hoses. Check for soft hoses or damaged pipes (A very light and replace with new hoses and/or new drag is present brake piping.

  • Page 203: On-Vehicle Service

    BRAKES 5-7 ON-VEHICLE SERVICE BRAKE PEDAL FREE HEIGHT ADJUSTMENT Brake pedal height is normal if brake pedal is as high as clutch ped- When stop light switch has been removed, refer to the following STOP LIGHT SWITCH ADJUSTMENT for proper installation. BRAKE PEDAL PLAY INSPECTION Pedal play should be within below specification.

  • Page 204: Front Brake Pad Inspection

    5-8 BRAKES FRONT BRAKE PAD INSPECTION Inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end (or hole) of caliper and check lining thickness of outside and inside pads. If lining is worn and its thickness (“d”) in figure is less than limit, all pads must be replaced at the same time.

  • Page 205: Parking Brake Inspection And Adjustment

    BRAKES 5-9 PARKING BRAKE INSPECTION AND AD- JUSTMENT INSPECTION Hold center or parking brake lever grip and pull it up with 20 to 25 kg (44 to 55f lbs) force. With parking brake lever pulled up as above, count ratchet notches in “A”...

  • Page 206: Master Cylinder And Brake Fluid Level Inspection

    5-10 BRAKES MASTER CYLINDER AND BRAKE FLUID LEVEL INSPECTION 1) Check master cylinder and reservoir tank for crack, damage and brake fluid leakage. If any faulty condition exists, correct or replace. 2) Check that brake fluid level is between MAX and MIN marks on reservoir tank.

  • Page 207: Bleeding Brakes

    BRAKES 5-11 BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Left wheel cylinder Left brake caliper A bleeding operation is necessary to remove air whenever it is introduced into the hydraulic brake system.
  • Page 208 5-12 BRAKES 4) When the fluid pressure in the cylinder is almost depleted, re- tighten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hy- draulic line. 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug.

  • Page 209: Brake Hose/Pipe And Parking Brake Cable

    BRAKES 5-13 BRAKE HOSE/PIPE AND PARKING BRAKE CABLE REMOVAL 1) Raise and support vehicle properly. Remove tire and wheel. 2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose or pipe. 3) Remove parking brake cable.
  • Page 210 5-14 BRAKES Rear suspension for DEAD AXLE type 1. Primary side 12. Washer 23. Clamp K 2. Secondary side 13. Clamp A 24. Clamp K (right hand steering vehicle) 3. For right hand steering vehicle 14. Clamp B 25. Clamp K (left hand steering vehicle) 4.

  • Page 211: Front Disc Brake

    BRAKES 5-15 FRONT DISC BRAKE 1. Caliper pin bolt 8. Piston seal: 2. Caliper pin: Apply brake fluid. Apply rubber grease 9. Disc brake piston: to sliding surface of caliper pin. Apply brake fluid. 3. Boot 10. Cylinder boot 4. Disc brake pad 11.

  • Page 212: Brake Pad

    5-16 BRAKES BRAKE PAD REMOVAL 1) Loosen wheel nuts and with vehicle lifted up, remove wheels. 2) Remove caliper pin bolt (1). 3) Remove caliper (1) from caliper carrier (2). NOTE: Hang removed caliper (1) with a wire hook or the like so as to prevent brake hose from bending and twisting exces- sively or being pulled.
  • Page 213 BRAKES 5-17 INSTALLATION 1) Set brake pad springs (1) and install brake pads (2). 2) Install caliper and tighten caliper pin bolt (1) to specified torque. Tightening Torque (a): 27 N·m (2.7 kg-m, 19.5 lb-ft) 3) Tighten wheel temporarily and lower lift. 4) Tighten wheel nuts (1) to specified torque.

  • Page 214: Caliper Assembly

    5-18 BRAKES CALIPER ASSEMBLY REMOVAL 1) Loosen wheel nuts and with vehicle lifted up, remove wheels. 2) Remove flexible hose bolt (1) and washer. CAUTION: Keep end or disconnected hose in a container (2) so that brake fluid will not get on vehicle body or floor. 3) Remove caliper pin bolt (1) and remove caliper (2) from caliper carrier (3).
  • Page 215 BRAKES 5-19 2) Remove piston seal using a thin blade like a thickness gauge, etc. CAUTION: Be careful not to damage inside (bore side) of cylin- der. INSPECTION Pin Boot and Cylinder Boot Check boots for breakage, crack and damage. If defective, re- place.
  • Page 216 5-20 BRAKES ASSEMBLY Assemble parts in reverse order of disassembly, observing follow- ing instructions. CAUTION: D Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir. D Never use other fluid or thinner. D Before installing piston and piston seal to cylinder, ap- ply fluid to them.
  • Page 217 BRAKES 5-21 Fit boot as it is in figure into boot groove in cylinder with fingers. Insert piston into cylinder by hand and fit boot in boot groove in piston. To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.

  • Page 218: Brake Disc

    5-22 BRAKES BRAKE DISC REMOVAL Refer to WHEEL HUB, KNUCKLE AND BEARING in Section 3D. INSPECTION Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replace- ment are normal and the disc is not defective if these are not seri- ous.

  • Page 219: Rear Drum Brake

    BRAKES 5-23 REAR DRUM BRAKE 1. Brake back plate: Apply water tight sealant 366E 99000-31090 to mating surfaces of brake back plate and rear axle. 2. Brake shoe 3. Shoe return spring 4. Brake strut 5. Shoe return spring 6. Rod spring 7.

  • Page 220: Brake Drum

    5-24 BRAKES BRAKE DRUM REMOVAL 1) With parking brake pulled up, hoist vehicle and remove wheels. 2) Remove spindle cap (1). When removing cap with a chisel, tap it lightly at about 3 locations using care not to damage seat face of cap.
  • Page 221 BRAKES 5-25 8) Insert new stud in drum hole and rotate it slowly to assure serra- tions are aligned with those made by replaced bolt. INSPECTION Inspect drum for cleanliness. Check its braking surface for wear by measuring its inside diameter. Drum inside diameter “a”...
  • Page 222 5-26 BRAKES 5) Bend split pin (1) securely as shown. 6) Install spindle cap (when installing spindle cap, hammer lightly several locations on the collar of cap until the collar comes closely into contact with brake drum) and tighten wheel nuts (1) to specified torque.

  • Page 223: Brake Shoe

    BRAKES 5-27 BRAKE SHOE REMOVAL 1) Remove brake drum, refer to BRAKE DRUM in this section. 2) Remove shoe hold down springs by turning shoe hold down pins as shown. 3) Disconnect parking brake cable (1) from parking brake shoe le- ver (2) and remove brake shoes.

  • Page 224: Wheel Cylinder

    5-28 BRAKES Springs Inspect for damage, corrosion or weakening. Inspect each part with arrow for rust. If found defective, replace. INSTALLATION Install parts in reverse other of removal. Install shoe hold down springs by pushing down them in place and turning hold down pins. For procedure hereafter, refer to BRAKE DRUM in this section.
  • Page 225 BRAKES 5-29 INSTALLATION 1) Before installing wheel cylinder to back plate, apply water tight sealant to contact surface of wheel cylinder. “A”: Sealant 366E 99000-31090 2) Take off breeder plug cap from brake pipe and connect pipe to wheel cylinder just enough to prevent fluid from leaking. 3) Tighten wheel cylinder to brake back plate (1) to specified torque.

  • Page 226: Brake Back Plate

    5-30 BRAKES BRAKE BACK PLATE REMOVAL 1) Remove brake drum, refer to BRAKE DRUM in this section. 2) Remove brake shoe, refer to BRAKE SHOE in this section. 3) Remove wheel cylinder, refer to WHEEL CYLINDER in this sec- tion. 4) Remove parking brake cable securing clip (1) and disconnect brake cable (2) from brake back plate (3).
  • Page 227 BRAKES 5-31 3) Apply water tight sealant where plate and cable contact, and run parking cable (1) through brake back plate (2) and secure it with clip (3). “A” : Sealant 366E 99000-31090 4) Install wheel cylinder, refer to WHEEL CYLINDER in this sec- tion.

  • Page 228: Master Cylinder

    5-32 BRAKES MASTER CYLINDER 1. Reservoir cap 2. Master cylinder reservoir 3. Reservoir bolt 4. Grommet: Apply brake fluid. 5. Master cylinder body 6. Secondary piston assembly: Apply brake fluid. 7. Primary piston assembly: Apply brake fluid. 8. Piston stopper circlip 9.

  • Page 229: Master Cylinder Assembly

    BRAKES 5-33 MASTER CYLINDER ASSEMBLY REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir (1). 3) Take out fluid with a syringe or such. 4) Remove reservoir connector screws (2). 5) Remove reservoir. 6) Disconnect brake pipes (4) from master cylinder (3). CAUTION: Do not allow brake fluid to get on painted surfaces.
  • Page 230 5-34 BRAKES NOTE: Do not loosen lock nut (1) of push rod. Should it be loosened, be sure to adjust and secure lock nut at the position within the measurement “a”. Data in figure does not include gasket thickness. Length “a”: 102.0 – 103.0 mm (4.016 – 4.055 in.) INSPECTION Inspection all disassembled parts for wear or damage, and replace parts if necessary.
  • Page 231 BRAKES 5-35 1) Assemble secondary piston as shown in figure. 1. Secondary piston return spring 2. Return spring seat 3. Piston cup 4. Secondary piston 5. Piston pressure cap 2) Install secondary piston assembly into cylinder. 3) Install primary piston in cylinder. 4) Depress using a rod (1), and install circlip (2).
  • Page 232 5-36 BRAKES INSTALLATION 1) Install master cylinder (3) as shown and tighten attaching nuts (1) to specified torque. Tightening Torque (a) : 13 N·m (1.3 kg-m, 9.5 lb-ft) 2) Install master cylinder push rod to brake pedal and bend split pin securely.

  • Page 233: Required Service Materials

    BRAKES 5-37 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of master cylinder Brake fluid DOT 3 caliper and wheel cylinder when they are disassembled. D To apply to mating surfaces of brake back plate and rear axle.
  • Page 234 ENGINE DIAGNOSIS 6-1 SECTION 6 ENGINE DIAGNOSIS CONTENTS GENERAL INFORMATION ................6- 1 ENGINE DIAGNOSIS .
  • Page 235 6-2 ENGINE DIAGNOSIS Throughout this manual, the four cylinders of the engine are identified by numbers: No.1, No.2, and No.3 as counted from crankshaft pulley side to flywheel side. 1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder GENERAL INFORMATION ON ENGINE SERVICE THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN...
  • Page 236 ENGINE DIAGNOSIS 6-3 PRECAUTION ON FUEL SYSTEM SERVICE Work must be done with no smoking, in a well-ventilated area and away from any open flames. As fuel feed line (between fuel pump and fuel pressure regula- tor) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or dis- connected.
  • Page 237 6-4 ENGINE DIAGNOSIS FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, relief fuel pressure as follows. 1) Place transmission gear shift lever in “Neutral”, set parking brake, and block drive wheels.
  • Page 238 ENGINE DIAGNOSIS 6-5 ENGINE DIAGNOSIS This vehicle is equipped with an engine and emission control system, which controls the A/F mixture, ignition tim- ing, emission, etc. suitably to engine conditions by ECM. ECM has an On-Board Diagnostic system which detects a malfunction in this system.
  • Page 239 6-6 ENGINE DIAGNOSIS ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) Check, Record and 1) Print DTC or Go to Step 4.
  • Page 240 ENGINE DIAGNOSIS 6-7 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal- ysis and diagnosis.
  • Page 241 6-8 ENGINE DIAGNOSIS 2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE First, check DTC referring to “DTC Check” in Section 6E1. If DTC is indicated, print it or write it down and then clear it by referring to “DTC Clearance” in Section 6E1. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
  • Page 242 ENGINE DIAGNOSIS 6-9 5. TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” in Section 6E1. 6. and 7. RECHECKING AND RECORD OF DTC Refer to “DTC Check”...
  • Page 243 6-10 ENGINE DIAGNOSIS 9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in Section 6E1, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and repair or replace faulty parts.
  • Page 244 ENGINE DIAGNOSIS 6-11 Condition Possible Cause Reference Item Engine has no power Engine overheating. Refer to “Overheating” Section. Ignition system out of order. Defective spark plug Spark plugs in Section 6F. Faulty ignition coil Ignition coil in Section 6F. Fuel system out of order. Fuel pressure out of specification Diag.
  • Page 245 6-12 ENGINE DIAGNOSIS Condition Possible Cause Reference Item Engine hesitates Ignition system out of order. (Momentary lack of Spark plug faulty or plug gap as out Spark plugs in Section 6F. response as the of adjustment accelerator is depressed. Fuel system out of order. Can occur at all Fuel pressure out of specification Diag.
  • Page 246 ENGINE DIAGNOSIS 6-13 Condition Possible Cause Reference Item Excessive detonation Engine overheating Refer to “Overheating” Section. (The engine makes Ignition system out of order. sharp metallic knocks Faulty spark plug Spark plugs in Section 6F. that change with Improper ignition timing Ignition timing in Section 6F.
  • Page 247 6-14 ENGINE DIAGNOSIS Condition Possible Cause Reference Item Excessive engine oil Oil entering combustion chamber consumption Sticky piston ring Piston cleaning in Section 6A or 6A1. Worn piston and cylinder Cylinders, pistons and piston rings inspection in Section 6A or 6A1. Worn piston ring groove and ring Pistons and piston rings inspection in Sec- tion 6A or 6A1.
  • Page 248 ENGINE DIAGNOSIS 6-15 Condition Possible Cause Referring Item Excessive Ignition system out of order hydrocarbon (HC) Defective spark plug emission or Excessive carbon Fuel system out of order monoxide (CO) Fuel pressure out of specification Fuel pressure check in Section 6E1. emission Engine and Emission control system out of order.
  • Page 249 ENGINE MECHANICAL (F8B ENGINE) 6A-1 SECTION 6A ENGINE MECHANICAL (F8B ENGINE) CONTENTS GENERAL DESCRIPTION ....6A- 2 Oil Pan ......6A-38 Engine .

  • Page 250: General Description

    6A-2 ENGINE MECHANICAL (F8B ENGINE) GENERAL DESCRIPTION Engine The engine is a water-cooled, in-line 3 cylinders, The single overhead camshaft (S.O.H.C.) is mounted 4-stroke cycle gasoline unit with its S.O.H.C. (single over the cylinder head; it is driven from crankshaft overhead camshaft) valve mechanism arranged for through timing belt.

  • Page 251: Engine Lubrication

    ENGINE MECHANICAL (F8B ENGINE) 6A-3 Engine Lubrication The oil pump is of a internal gear type, and mounted on rod to lubricate piston, rings, and cylinder wall. the crankshaft at the crankshaft pulley side. In another path, oil goes up to the cylinder head and lu- Oil is drawn up through the oil pump strainer and bricates rocker arms, valves and camshaft, etc., after passed through the pump to the oil filter.

  • Page 252: Engine Services Not Requiring Engine Removal

    6A-4 ENGINE MECHANICAL (F8B ENGINE) ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL The following parts or components do not require engine removal to receive services (replacement, inspection or adjustment): Part or Component Nature of Service 1. Spark plug Replacement or inspection 2.

  • Page 253: Dismounting Engine

    ENGINE MECHANICAL (F8B ENGINE) 6A-5 DISMOUNTING ENGINE 1) Release fuel pressure in fuel feed line, refer to Section 6. 2) Disconnect negative cable at battery. 3) Remove engine hood after disconnecting windshield washer hose. 4) Remove front bumper, refer to Section 9. 5) Drain cooling system.
  • Page 254 6A-6 ENGINE MECHANICAL (F8B ENGINE) 10) Disconnect the following electric wires. Radiator fan Distributor (High-tension cord and terminal) Starter motor Generator Back-up light switch Oil pressure switch Oxygen sensor ECT sensor Right side of engine harness Ground wire from cylinder block Ground wire from transmission case A/C compressor (if equipped) 11) Remove exhaust center pipe.
  • Page 255 ENGINE MECHANICAL (F8B ENGINE) 6A-7 16) Draw right and left drive shafts out of differential side gears. NOTE: Be careful not to damage brake flexible hose. 17) Remove water pump and A/C compressor belts (if equipped). When removing A/C compressor belt, first remove water pump pulley.

  • Page 256: Engine Disassembly

    6A-8 ENGINE MECHANICAL (F8B ENGINE) ENGINE DISASSEMBLY NOTE: D Observe critically before starting to remove a component or part by loosening bolts, nuts and the like. What you may find before and during disassembly is valuable information necessary for successful reassembly. D Be careful in handling aluminum-alloy parts.
  • Page 257 ENGINE MECHANICAL (F8B ENGINE) 6A-9 4) Remove distributor cap (2) and then remove distributor assem- bly (1). 5) Remove distributor case (1). 6) Remove generator (1), refer to Section 6H. 7) Remove generator brackets (1).
  • Page 258 6A-10 ENGINE MECHANICAL (F8B ENGINE) 8) Remove crank pulley (1) similarly, by using special tool hitched to flywheel (2) so that crankshaft will not turn. Special Tool (A): 09924-17810 9) Remove water pump pulley and then remove timing belt cover (1).
  • Page 259 ENGINE MECHANICAL (F8B ENGINE) 6A-11 12) Remove camshaft timing belt pulley, by using special tool at- tached, as shown, to lock camshaft. Special Tool (A): 09930-40113 13) Similarly remove crankshaft timing belt pulley (1). 14) After removing pulley key, take out timing belt guide (1). 15) Remove timing belt inside cover (1).
  • Page 260 6A-12 ENGINE MECHANICAL (F8B ENGINE) 17) Remove exhaust manifold covers (1) and exhaust manifold (2). 18) Remove oil filter by using special tool. NOTE: Be careful not to spill the oil when removing filter. Special Tool (A): 09915-47310 19) Disconnect PCV outlet hose (1) and bypass hose (2). 20) Remove intake manifold (1) with throttle body (2).
  • Page 261 ENGINE MECHANICAL (F8B ENGINE) 6A-13 22) Remove water inlet pipe (1). 23) Remove cylinder head cover (1). 24) Loosen valve adjusting screws (1) fully. Leave the screws in place. 25) Loosen rocker arm shaft securing screws (1). 26) While drawing out rocker arm shaft (1), separate valve rocker arms (2) and rocker arm springs.
  • Page 262 6A-14 ENGINE MECHANICAL (F8B ENGINE) 27) Remove camshaft thrust plate (1), and draw camshaft (2) out toward distributor gear case side. 28) Remove cylinder head (1). a) Using special tool (valve lifter) to compress valve spring and then remove valve cotters (1) by using special tool (Forceps).
  • Page 263 ENGINE MECHANICAL (F8B ENGINE) 6A-15 NOTE: Place disassembled parts except valve stem oil seal and valve guide in order, so that they can be installed in their original positions. 29) Remove flywheel by using special tool as shown. Special Tool (A): 09924-17810 30) Remove oil level gauge and then remove oil pan (1).
  • Page 264 6A-16 ENGINE MECHANICAL (F8B ENGINE) 34) Decarbon top of cylinder bore, before removing piston from cylinder. 35) Push piston and connecting rod assembly out through the top of cylinder bore. CAUTIONS: D Before pushing piston out, scribe cylinder number on its crown. D Be sure to identify each bearing cap for its con- necting rod by using cylinder number.
  • Page 265 ENGINE MECHANICAL (F8B ENGINE) 6A-17 a) Remove oil pump gear plate (1). b) Take out inner gear (2) and outer gear (1). 37) Remove oil seal housing (1). 38) Remove crankshaft bearing caps (1), and take out crankshaft (2).

  • Page 266: Inspection Of Engine Components 6A-18

    6A-18 ENGINE MECHANICAL (F8B ENGINE) INSPECTION OF ENGINE COMPONENTS NOTE: During and immediately after disassembly, inspect cylinder block and head for evidence of water leakage or damage and, after washing them clean, inspect more closely. Wash all disassembled parts clean, removing grease, slime, carbon and scales, before inspecting them to deter- mine whether repair is necessary or not.
  • Page 267 ENGINE MECHANICAL (F8B ENGINE) 6A-19 Distortion of gasketed surface: Using a straightedge and thickness gauge, check the flatness at a total of 6 locations. If the limit, stated below, is exceeded, cor- rect the gasketed surface with a surface plate and abrasive pa- per of about # 400 (waterproof silicon carbide abrasive paper): place the paper on and over the surface plate, and rub the gas- keted surface against the paper to grind off high spots.

  • Page 268: Rocker-Arm Shaft And Rocker Arms

    6A-20 ENGINE MECHANICAL (F8B ENGINE) Rocker-arm shaft and rocker arms Wear: Check these parts for wear and, as necessary, replace them. The extent of wear is determined on the basis of two readings, one on rocker arm I.D. and the other on shaft diameter. NOTE: Use a micrometer on rocker-arm shaft and a bore gauge rocker arm.

  • Page 269: Valve Guides

    ENGINE MECHANICAL (F8B ENGINE) 6A-21 Valve guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to determine the stem clearance in the guide. Be sure to take a reading at more than one place along the length of each stem and guide.

  • Page 270: Valve Seats

    6A-22 ENGINE MECHANICAL (F8B ENGINE) Check the end face of each valve stem for wear. This face meets the rocker arm intermittently in operation, and might become concaved or otherwise irregular. As necessary, smoothen the end face with an oil stone and, if this grinding removes the end stock by as much as 0.5 mm (0.0196 in.) (as measured from the original face), replace the valve.
  • Page 271 ENGINE MECHANICAL (F8B ENGINE) 6A-23 Valve seat repair: A valve seat not producing a uniform contact with its valve or showing a width of the seating contact that is off the specified range must be repaired by regrinding or by cutting and regrind- ing and finished by lapping.

  • Page 272: Valve Springs

    6A-24 ENGINE MECHANICAL (F8B ENGINE) Valve springs Referring to the criterion data given below, check to be sure that each spring is in sound condition, free of any evidence of break- age or weakening. Remember, weakened valve springs can be the cause of chatter, not to mention the possibility of reducing the power output due to gas leakage caused by decreased seating pressure.

  • Page 273: Cylinder Block

    ENGINE MECHANICAL (F8B ENGINE) 6A-25 Thrust clearance: Using a thickness gauge (1), measure this clearance as shown in figure, at the thrust plate. If the limit is exceeded, replace thrust plate or camshaft. Item Standard Limit 0.050 – 0.150 mm 0.300 mm Thrust clearance (0.002 –...

  • Page 274: Piston And Piston Rings

    6A-26 ENGINE MECHANICAL (F8B ENGINE) Cylinder bore: Using a cylinder bore gauge, measure the diameter of each bore in two directions, longitudinal and transverse, at three places, top, middle and bottom, to obtain a total of 6 readings. On the ba- sis of these readings taken on each bore, determine whether the maximum difference in diameter between any two bores ex- ceeds the limit.
  • Page 275 ENGINE MECHANICAL (F8B ENGINE) 6A-27 Inspect the outer surface of each cylinder for evidence of burn and for scratch or groove marks. Minor flaws can be removed by grinding with fine-grain sandpaper. De-carbon the piston crown and ring grooves, using a soft-metal scraping tool.

  • Page 276: Connecting Rods

    6A-28 ENGINE MECHANICAL (F8B ENGINE) Connecting rods Big-end thrust clearance: Check the big end of each connecting rod for thrust clearance, with the rod fitted and connected to its crank pin in the normal manner. If the clearance measured is found to exceed the limit, the connecting rod or the crankshaft, whichever is responsible for the excessive clearance, must be replaced.
  • Page 277 ENGINE MECHANICAL (F8B ENGINE) 6A-29 Crankpin-to-bearing clearance: Check this clearance by using gaging plastic (1). Here’s how to use gaging plastic: 1) Prepare, by cutting, a length of gaging plastic roughly equal to bearing width and place it axially on crankpin, avoiding the oil hole.

  • Page 278: Crankshaft

    6A-30 ENGINE MECHANICAL (F8B ENGINE) Crankshaft Runout: Check the crankshaft for runout and if the dial gauge reading ex- ceeds the limit, replace the crankshaft. Limit on crankshaft runout 0.06 mm (0.002 in.) NOTE: Measure the runout at the center journal. Rotate the crank- shaft slowly.

  • Page 279: Crankshaft Journal Bearings

    ENGINE MECHANICAL (F8B ENGINE) 6A-31 Crankshaft journal bearings Inspect the bearing shells for signs of fusion, pitting, burn or flak- ing and observe the contact pattern. Defective shells must be re- placed. CAUTION: As in the case of connecting-rod bearings, the journal bearing shells are not meant to be repaired by scrap- ing or grinding with sandpaper or by any machining.

  • Page 280: Flywheel

    6A-32 ENGINE MECHANICAL (F8B ENGINE) 4) If the limit is exceeded, re-grind the journals to the undersize and use the undersize bearing. Bearing size Journal diameter 49.982 – 50.000 mm Standard (1.9678 – 1.9685 in.) 49.744 – 49.750 mm 0.25 mm undersize (1.9584 –...

  • Page 281: Timing Belt And Timing Pulleys

    ENGINE MECHANICAL (F8B ENGINE) 6A-33 Timing belt and timing pulleys Inspect the belt and pulleys for wear, cracks and signs of failure. Replace them as necessary. CAUTION: Do not bend the belt. Keep away oil and water from the belt. The belt must be kept clean. The pulleys and belt tensioner, too, must be kept clean and free of oil and water.

  • Page 282: Engine Reassembly

    6A-34 ENGINE MECHANICAL (F8B ENGINE) ENGINE REASSEMBLY NOTE: All parts to be used in reassembly must be perfectly clean. Oil the sliding and rubbing surfaces of engine parts just be- fore using them in reassembly. Use engine oil (Refer to Sec- tion 0B).

  • Page 283: Oil Seal Housing

    ENGINE MECHANICAL (F8B ENGINE) 6A-35 Thrust bearings (1) for the crankshaft are an item prone to escape the attention: be careful not to leave them out. These bearings go into place with their oil groove side facing the crank web. Be sure to oil crankshaft journals as shown.

  • Page 284: Oil Pump

    6A-36 ENGINE MECHANICAL (F8B ENGINE) Oil Pump NOTE: Reassemble components of oil pump assembly according to following procedure, if disassembled. a) Wash, clean and then dry all disassembled parts. b) Apply thin coat of engine oil to inner and outer gears, oil seal lip portion, and inside surfaces of oil pump case and plate.
  • Page 285 ENGINE MECHANICAL (F8B ENGINE) 6A-37 Before fitting rings to piston, check to be sure that first ring (1) has 3. Oil ring 4. Arrow mark RN mark and second ring (2) R mark. After mounting the three 5. Crankshaft pulley rings, distribute their end gaps as illustrated in figure.

  • Page 286: Connecting Rods

    6A-38 ENGINE MECHANICAL (F8B ENGINE) Connecting rods Two stoppers (1), (2) determine the position of each big-end bear- ing cap relative to the big end. At the time of installing these caps, be sure to locate stopper (1) of cap in the direction of stopper (2). NOTE: The two stoppers do not coincide in longitudinal direction: the coincidence is meant in the direction shown in figures.

  • Page 287: Flywheel

    ENGINE MECHANICAL (F8B ENGINE) 6A-39 2) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque. Tightening torque for drain plug: 50 N·m (5.0 kg-m, 36.5 Ib-ft) Flywheel 1) Check to be sure that locating pin (1) is studded in the crank- shaft.
  • Page 288 6A-40 ENGINE MECHANICAL (F8B ENGINE) c) Ream valve guide (1) bore with special tool (7 mm reamer). After reaming, clean bore. Special Tool (A): 09916-34520 2) Install valve spring seat to cylinder head. 3) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (valve stem seal installer), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand.
  • Page 289 ENGINE MECHANICAL (F8B ENGINE) 6A-41 6) Using special tool (Valve lifter), compress valve spring and fit two valve cotters (1) to groove provided in valve stem. Special Tool (A): 09916-14510 (B): 09916-48210 (C): 09916-84511 2. Valve spring retainer 7) Be sure that locating pins (3) are in place and then install new head gasket, in such a way that “TOP”...

  • Page 290: Camshaft

    6A-42 ENGINE MECHANICAL (F8B ENGINE) Camshaft The camshaft goes into cylinder head from distributor gear case side. Before inserting it, be sure to oil its journals. Be careful not to leave out the thrust plate (1) when installing the camshaft. After setting this shaft in place, with its thrust plate prop- erly fitted, turn the shaft by hand to be sure it rotates smoothly.

  • Page 291: Crankshaft Timing Belt Guide

    ENGINE MECHANICAL (F8B ENGINE) 6A-43 Timing belt inside cover When reinstalling the inside cover (1) to cylinder head, apply seal- ant to the threads of upper side screws (2) as shown, because the bolt holes for the two extend into the interior of cylinder head. “A”...
  • Page 292 6A-44 ENGINE MECHANICAL (F8B ENGINE) 2) Timing belt inside cover has an embossed mark (4). Turn camshaft timing belt pulley to the position where punch- mark (1) meets mark (4). 3) The inside cover has another embossed mark (5). Turn crank- shaft to match key-way (3) and punch-mark (2) of crankshaft timing belt pulley to mark (5).

  • Page 293: Distributor Gear Case

    ENGINE MECHANICAL (F8B ENGINE) 6A-45 Crank Pulley Install crank shaft pulley (1) by using special tool hitched to fly- wheel (2) so that crakshaft will not turn. Special tool (A): 09924-17810 Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 Ib-ft) Distributor gear case Bolts (1) are for securing this gear case to the cylinder block.

  • Page 294: Mounting Engine

    6A-46 ENGINE MECHANICAL (F8B ENGINE) MOUNTING ENGINE 1) Install transmission to engine. Tightening Torque (a): 50 N·m (5.0 kg-m, 36.5 Ib-ft) 2) Install engine member to engine and then install engine assem- bly to vehicle. Install transmission left side mounting to transmission case and body.
  • Page 295 ENGINE MECHANICAL (F8B ENGINE) 6A-47 6) Install right and left drive shafts, refer to Section 4. 7) Install stabilizer bar, refer to Section 3D. 8) Connect gear shift control shaft and extension rod to transmis- sion case. 9) Install exhaust center pipe. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 Ib-ft) (b): 55 N·m (5.5 kg-m, 40.0 Ib-ft)

  • Page 296: Maintenance Services

    6A-48 ENGINE MECHANICAL (F8B ENGINE) MAINTENANCE SERVICES Water pump belt Adjust the belt tension as outlined in the SECTION 0B MAINTE- NANCE SERVICE. Ignition timing Refer to SECTION 6F IGNITION SYSTEM. Valve clearance (lash) When cold (Coolant When hot (Coolant temperature is 15 –...
  • Page 297 ENGINE MECHANICAL (F8B ENGINE) 6A-49 Turn over the crankshaft 240 from “T” mark, check and adjust the valves (5) and (6). Turn over the crankshaft 240 from “3” mark, check and adjust the valves (3) and (4). Measuring valve clearance Adjusting valve clearance...

  • Page 298: Oil Pump Discharge Pressure Measurement

    6A-50 ENGINE MECHANICAL (F8B ENGINE) Oil pump discharge pressure measurement NOTE: Prior to checking oil pressure, check the following. Oil level in oil pan. If level is low, add oil up to Full level hole on oil level gauge. Oil quality. If oil is discolored, or deteriorated, change oil.

  • Page 299: Compression Pressure Measurement

    ENGINE MECHANICAL (F8B ENGINE) 6A-51 Compression pressure measurement Check the compression pressure on all three cylinders, as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral” and set parking brake and block drive wheels.

  • Page 300: Vacuum Measurement

    6A-52 ENGINE MECHANICAL (F8B ENGINE) Vacuum measurement The vacuum that develops in the intake line is a good indicator of the condition of the engine. It is for this reason that the vacuum is measured. The measuring procedure is as follows: 1) Warm up engine until it is normal operating temperature.

  • Page 301: Engine Oil

    ENGINE MECHANICAL (F8B ENGINE) 6A-53 Engine oil Refer to the SECTION 0B MAINTENANCE SERVICE. Engine oil filter The methods of servicing the oil filter are outlined under SECTION 0B MAINTENANCE SERVICE. Engine coolant This subject is covered in the SECTION 6B for ENGINE COOLING SYSTEM.

  • Page 302: Required Service Materials

    6A-54 ENGINE MECHANICAL (F8B ENGINE) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Mating surfaces around the oil discharging SUZUKI BOND No. 1215 port of oil pump case and cylinder block Sealant D Threads of timing belt inside cover stud bolts (99000-31110) D Threads of distributor gear case bolts SPECIAL TOOLS...
  • Page 303 ENGINE MECHANICAL (F8B ENGINE) 6A-55 09917-98210 09918-08210 09924-17810 09926-18210 Valve stem seal installer Vacuum gauge hose joint Flywheel holder Oil seal guide (Vinyl resin) 09930-40113 Camshaft lock holder...
  • Page 304 ENGINE MECHANICAL (F8D ENGINE) 6A1-1 SECTION 6A1 ENGINE MECHANICAL (F8D ENGINE) CONTENTS GENERAL DESCRIPTION ............... 6A1- 2 Engine .

  • Page 305: General Description

    6A1-2 ENGINE MECHANICAL (F8D ENGINE) GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 3 cylinders, 4 The single overhead camshaft is mounted over the stroke cycle gasoline unit equipped with its S.O.H.C. cylinder head: it is driven from crankshaft through tim- (Single Overhead Camshaft) valve mechanism ar- ing belt and opens and closes its valves via the rocker ranged for “V”-type valve configuration and 12 valves...

  • Page 306: Engine Lubrication

    ENGINE MECHANICAL (F8D ENGINE) 6A1-3 ENGINE LUBRICATION The oil pump for pressure-feeding lubrication oil to the running parts of the engine is of an internal gear type, in which an outer ring-like gear is internally meshed with an inner gear, there being a separating crescent-like stator between the two.

  • Page 307: On-Vehicle Service

    6A1-4 ENGINE MECHANICAL (F8D ENGINE) ON-VEHICLE SERVICE COMPRESSION CHECK Check compression pressure on all three cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral” and set parking brake and block drive wheels.

  • Page 308: Engine Vacuum Check

    ENGINE MECHANICAL (F8D ENGINE) 6A1-5 8) Crank engine with fully charged battery, and read the highest pressure on compression gauge. NOTE: For measuring compression pressure, crank engine at least 250 r/min. by using fully charged battery. Compression pressure 1350 kPa Standard (13.5 kg/cm , 192.0 psi)

  • Page 309: Oil Pressure Check

    6A1-6 ENGINE MECHANICAL (F8D ENGINE) 2) With engine stopped, disconnect canister purge control vacu- um hose from canister purge control valve and connect 3-way joint, hose and special tool (vacuum gauge and joint) to canister purge control valve and vacuum hose disconnected. Special Tool (A): 09915-67310 (B): 09918-08210...
  • Page 310 ENGINE MECHANICAL (F8D ENGINE) 6A1-7 1) Hoist vehicle. Remove oil pressure switch from cylinder block. 2) Install special tool (Oil pressure gauge) to vacated threaded hole. Then lower vehicle. Special Tool (A): 09915-77310 (B): 09915-78211 3) Start engine and warm it up to normal operating temperature. NOTE: Be sure to place transmission gear shift lever in “Neutral”...

  • Page 311: Valve Lash (Clearance)

    6A1-8 ENGINE MECHANICAL (F8D ENGINE) VALVE LASH (CLEARANCE) 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to CYLINDER HEAD COVER in this section. 3) Remove distributor cap (1), rotor (2) and cover (3). 4) Using 17 mm wrench, turn crankshaft pulley clockwise until lug of signal rotor aligned to CMP sensor as shown in figure.

  • Page 312: Air Cleaner Filter

    ENGINE MECHANICAL (F8D ENGINE) 6A1-9 7) After checking and adjusting valve lashes at valves (1) and (4), rotate crankshaft pulley clockwise until lug “C” of signal rotor aligned to CMP sensor and check the same valves at (3) and (6). Adjust them as necessary. 8) After checking and adjusting valve lashes at valves (3) and (6), rotate crankshaft pulley clockwise until lug “B”...

  • Page 313: Cylinder Head Cover

    6A1-10 ENGINE MECHANICAL (F8D ENGINE) CYLINDER HEAD COVER REMOVAL 1) Disconnect negative cable at battery. 2) Remove high-tension cords. 3) Disconnect PCV valve and breather hoses from head cover. 4) Remove cylinder head cover. INSTALLATION 1) Install O-rings (2) and cylinder head cover gasket (1) to cylinder head cover (3).

  • Page 314: Throttle Body And Intake Manifold

    ENGINE MECHANICAL (F8D ENGINE) 6A1-11 THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 2. Throttle body 3. Gasket 4. Fuel pressure regulator 5. Fuel delivery pipe 6. Fuel injector 7. Stiffener : Tightening Torque : Do not reuse REMOVAL 1) Relieve fuel pressure according to fuel pressure relief proce- dure described in Section 6.
  • Page 315 6A1-12 ENGINE MECHANICAL (F8D ENGINE) 6) Disconnect accelerator cable from throttle body. 7) Disconnect following hoses: Canister purge hose from canister purge control valve Engine cooling water (coolant) hoses from throttle body PCV hose from intake manifold Fuel return and inlet hoses from each pipe 8) Remove intake manifold stiffener (1).

  • Page 316: Exhaust Manifold

    ENGINE MECHANICAL (F8D ENGINE) 6A1-13 EXHAUST MANIFOLD 1. Exhaust manifold 2. Exhaust manifold cover 3. Gasket 4. Oxygen sensor 5. Exhaust manifold bolt and nut 6. Exhaust pipe bolt : Tightening Torque : Do not reuse WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot.
  • Page 317 6A1-14 ENGINE MECHANICAL (F8D ENGINE) INSTALLATION 1) Install new gasket (1) to cylinder head. 2) Install exhaust manifold (2). Tighten bolts and nuts to specified torque. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 3) Install pipe gasket and install exhaust pipe to exhaust manifold. Before installing pipe gasket, check it for deterioration or dam- age, and replace as necessary.

  • Page 318: Timing Belt And Belt Tensioner

    ENGINE MECHANICAL (F8D ENGINE) 6A1-15 TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Crank shaft pulley 4. Camshaft timing belt pulley 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Inside cover 9. Outside cover seal 10.
  • Page 319 6A1-16 ENGINE MECHANICAL (F8D ENGINE) 7) Remove timing belt outside cover. 8) For installation of timing belt, align 4 timing marks (1), (2), (3), (4) as shown in figure by turning crankshaft. 9) Remove timing belt tensioner (5) and timing belt (6). CAUTION: After timing belt is removed, never turn camshaft and crankshaft independently more than such an...
  • Page 320 ENGINE MECHANICAL (F8D ENGINE) 6A1-17 Inspect tensioner for smooth rotation. INSTALLATION 1) Install crank pulley key (2) to crankshaft. Install crankshaft timing belt pulley (1) to crankshaft, if removed. 2) Install tensioner (2). Do not tighten tensioner bolt (1) with wrench yet. Hand tighten only at this time.
  • Page 321 6A1-18 ENGINE MECHANICAL (F8D ENGINE) 5) Check to ensure that valve clearance is adjusted correctly. 6) Remove spark plugs. 7) Install timing belt. With two sets of marks (1), (2) and (3), (4) aligned, install timing belt on two pulleys in such a way that drive side (5) of belt is free from any slack.
  • Page 322 ENGINE MECHANICAL (F8D ENGINE) 6A1-19 9) Install spark plugs. 10) Install timing belt outside cover. Before installing, make sure that seal is between water pump and oil pump case. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 11) Install crankshaft pulley (1). Install crankshaft timing belt pulley with crankshaft locked, and tighten pulley bolts to specified torque.

  • Page 323: Oil Pan And Oil Pump Strainer

    6A1-20 ENGINE MECHANICAL (F8D ENGINE) OIL PAN AND OIL PUMP STRAINER 1. Oil pan: Apply SUZUKI BOND No. 1207C 99000-31150 to mating surface. 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. Oil pan bolt and nut 7.
  • Page 324 ENGINE MECHANICAL (F8D ENGINE) 6A1-21 CLEANING Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. Clean oil pump strainer screen. INSTALLATION 1) Apply sealant to oil pan mating surface continuously as shown in figure.
  • Page 325 6A1-22 ENGINE MECHANICAL (F8D ENGINE) 2) Install oil pump strainer (1) and oil pan (2). Install new O-ring (3) to oil pump strainer in the position as shown in figure. Install strainer to cylinder block, then tighten strainer bolt to spe- cified torque.

  • Page 326: Oil Pump

    ENGINE MECHANICAL (F8D ENGINE) 6A1-23 OIL PUMP 1. Rotor plate: Apply thin coat of engine oil. 2. Outer rotor: Apply thin coat of engine oil. 3. Inner rotor: Apply thin coat of engine oil. 4. Gasket 5. Pin 6. Oil seal: Apply thin coat of engine oil.
  • Page 327 6A1-24 ENGINE MECHANICAL (F8D ENGINE) INSPECTION Check oil seal lip for fault or other damage. Replace as neces- sary. Special Tool (A): 09913-75520 NOTE: When installing oil seal, press-fit it till its end face is flush with oil pump case end face. Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
  • Page 328 ENGINE MECHANICAL (F8D ENGINE) 6A1-25 INSTALLATION 1) Install two oil pump pins (2) and oil pump gasket to cylinder block. Use a new gasket. 2) To prevent oil seal lip from being damaged or upturned when installing oil pump to crankshaft, fit special tool (Oil seal guide) to crankshaft (1), and apply engine oil to special tool.

  • Page 329: Rocker Arms, Rocker Arm Shaft And Camshaft

    6A1-26 ENGINE MECHANICAL (F8D ENGINE) ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT 1. Camshaft 2. Camshaft oil seal 3. Rocker arm shaft 4. Rocker shaft bolt 5. Rocker arm No.1 (IN) 6. Rocker arm No. 2 (IN) 7. Valve adjusting screw 8.
  • Page 330 ENGINE MECHANICAL (F8D ENGINE) 6A1-27 7) Remove rocker arm shaft (1) with intake rocker arms (2) and rocker arm spring (3). 8) Remove camshaft housing (1), camshaft (2) and distributor. For distributor removal, refer to Section 6F. NOTE: To remove camshaft housing bolts, loosen them in such or- der as indicated in figure, a little at a time.
  • Page 331 6A1-28 ENGINE MECHANICAL (F8D ENGINE) Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm l.D. Difference between two readings is arm-to-shaft clearance on which a limit is specified. If limit is exceeded, replace shaft or arm, or both. Item Standard Limit...
  • Page 332 ENGINE MECHANICAL (F8D ENGINE) 6A1-29 Check clearance by using gaging plastic. The procedure is as follows. 1) Clean housing and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of cam- shaft (parallel to camshaft).
  • Page 333 6A1-30 ENGINE MECHANICAL (F8D ENGINE) INSTALLATION 1) Fill small amount of engine oil into arm pivot holding part of cylin- der head. Install rocker arm (exhaust side) (1). 2) Apply engine oil to cams and journals on camshaft and put cam- shaft on cylinder head.
  • Page 334 ENGINE MECHANICAL (F8D ENGINE) 6A1-31 5) Apply engine oil to rocker arm shaft and rocker arms. 6) Install rocker arm shaft, rocker arm (intake side) and rocker arm spring. 7) Install rocker arm shaft bolts and tighten them to specified torque.

  • Page 335: Valves And Cylinder Head

    6A1-32 ENGINE MECHANICAL (F8D ENGINE) VALVES AND CYLINDER HEAD 1. Valve cotters 2. Valve spring retainer 3. Valve spring 4. Valve stem seal 5. Valve spring seat 6. Exhaust valve 7. Intake valve 8. Cylinder head 9. Cylinder head gasket 10.
  • Page 336 ENGINE MECHANICAL (F8D ENGINE) 6A1-33 5) Remove timing belt, timing belt inside cover rocker arm shaft with, intake rocker arms, exhaust rocker arms and camshaft as previously outlined. 6) Disconnect exhaust pipe from exhaust manifold. 7) Loosen cylinder head bolts in such order as indicated in figure and remove them.
  • Page 337 6A1-34 ENGINE MECHANICAL (F8D ENGINE) 5) Remove valve stem oil seal (1) from valve guide, and then valve spring seat (2). NOTE: Do not reuse oil seal once disassembled. Be sure to use new oil seal when assembling. 6) Using special tool (Valve guide remover), drive valve guide out from combustion chamber side to valve spring side.
  • Page 338 ENGINE MECHANICAL (F8D ENGINE) 6A1-35 Valves Remove all carbon from valves. Inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it. Measure thickness of valve head. If measured thickness ex- ceeds limit, replace valve. Valve head thickness Standard Limit...
  • Page 339 6A1-36 ENGINE MECHANICAL (F8D ENGINE) Valve seat repair: A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
  • Page 340 ENGINE MECHANICAL (F8D ENGINE) 6A1-37 Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive pa- per of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
  • Page 341 6A1-38 ENGINE MECHANICAL (F8D ENGINE) Spring squareness: Use a square and surface plate to check each spring for square- ness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit given below must be replaced.
  • Page 342 ENGINE MECHANICAL (F8D ENGINE) 6A1-39 4) Install valve spring seat to cylinder head. 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit stem seal to spindle, and then install seal to valve guide by pushing special tool by hand.
  • Page 343 6A1-40 ENGINE MECHANICAL (F8D ENGINE) 9) Install rocker arms, springs and rocker arm shaft as previously outlined. 10) Install intake manifold, exhaust manifold and thermostat case. INSTALLATION 1) Remove old gasket and oil on mating surfaces and install new head gasket as shown in figure, that is, “TOP” mark (1) pro- vided on gasket comes to crankshaft pulley side (2), facing up (toward cylinder head side).
  • Page 344 ENGINE MECHANICAL (F8D ENGINE) 6A1-41 4) Reverse removal procedure for installation. 5) Adjust water pump drive belt tension, referring to Section 6B. 6) Adjust A/C compressor belt tension, if equipped. Refer to sec- tion 0B. 7) Adjust intake and exhaust valve lashes as previously outlined. 8) Adjust accelerator cable play.

  • Page 345: Piston, Piston Rings, Connecting Rods And Cylinders

    6A1-42 ENGINE MECHANICAL (F8D ENGINE) PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10.
  • Page 346 ENGINE MECHANICAL (F8D ENGINE) 6A1-43 DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. Ease out piston pin circlips (1), as shown. Force piston pin out. CLEANING Clean carbon from piston head and ring grooves, using a suitable tool.
  • Page 347 6A1-44 ENGINE MECHANICAL (F8D ENGINE) INSPECTION Cylinders Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. Using a cylinder gauge, measure cylinder bore in thrust and ax- ial directions at two positions as shown in figure.
  • Page 348 ENGINE MECHANICAL (F8D ENGINE) 6A1-45 Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance : 0.025 –...
  • Page 349 6A1-46 ENGINE MECHANICAL (F8D ENGINE) Piston Rings To measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge (1). If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
  • Page 350 ENGINE MECHANICAL (F8D ENGINE) 6A1-47 Crank Pin and Connecting Rod Bearings Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crank- shaft or regrind crank pin referring to following step 6) of Rod bearing clearance.
  • Page 351 6A1-48 ENGINE MECHANICAL (F8D ENGINE) 5) Remove cap and using a scale on gaging plastic envelope, measure gaging plastic (1) width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit...
  • Page 352 ENGINE MECHANICAL (F8D ENGINE) 6A1-49 1) Install piston pin to piston (1) and connecting rod: After applying engine oil to piston pin and piston pin holes in pis- ton and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin circlips (3).
  • Page 353 6A1-50 ENGINE MECHANICAL (F8D ENGINE) 3) When installing piston and connecting rod assembly into cylin- der bore, point arrow mark (2) on piston head to crankshaft pulley side (1). 4) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft.

  • Page 354: Unit Repair Overhaul

    ENGINE MECHANICAL (F8D ENGINE) 6A1-51 UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL AND INSTALLATION Refer to Section 6A.

  • Page 355: Main Bearings, Crankshaft And Cylinder Block

    6A1-52 ENGINE MECHANICAL (F8D ENGINE) MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 6. Timing pulley key 11. Oil seal housing gasket 2. Oil filter 7. Crankshaft: 12. Oil seal housing 3. Main bearing: Apply engine oil to crankshaft 13.
  • Page 356 ENGINE MECHANICAL (F8D ENGINE) 6A1-53 REMOVAL 1) Remove engine assembly with transmission and engine mem- ber from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (1). Special Tool (A): 09924-17810 3) Remove crankshaft pulley, timing belt, timing belt inside cover and crankshaft timing pulley.
  • Page 357 6A1-54 ENGINE MECHANICAL (F8D ENGINE) INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing (1) and journal bearing caps installed.
  • Page 358 ENGINE MECHANICAL (F8D ENGINE) 6A1-55 Main Bearings General information Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. Upper half of bearing (2) has oil groove (3) as shown in figure. Install this half with oil groove to cylinder block (1).
  • Page 359 6A1-56 ENGINE MECHANICAL (F8D ENGINE) 5) Remove cap and using scale on gaging plastic envelope, mea- sure gaging plastic (1) width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
  • Page 360 ENGINE MECHANICAL (F8D ENGINE) 6A1-57 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, four numerals are stamped as shown in figure. Three kinds of numerals (1, 2 and 3) represent following cap bore diameters. Bearing cap bore diameter Numeral stamped (without bearing)
  • Page 361 6A1-58 ENGINE MECHANICAL (F8D ENGINE) 4) From numerals stamped on crank webs of No.1 and No.2 cylin- ders and the numerals stamped on mating surface of cylinder block, determine new standard bearing to be installed to jour- nal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
  • Page 362 ENGINE MECHANICAL (F8D ENGINE) 6A1-59 If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 49.732 – 49.750 mm (1.9580 – 1.9586 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
  • Page 363 6A1-60 ENGINE MECHANICAL (F8D ENGINE) Flywheel If ring gear is damaged, cracked or worn, replace flywheel. If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout: 0.2 mm (0.0078 in.) Cylinder Block Distortion of gasketed surface...
  • Page 364 ENGINE MECHANICAL (F8D ENGINE) 6A1-61 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing. INSTALLATION NOTE: All parts to be installed must be perfectly clean.
  • Page 365 6A1-62 ENGINE MECHANICAL (F8D ENGINE) 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3 and 4, starting from pulley side. Tighten bearing cap bolts in such order as shown in figure a little at a time and repeat it till they are tightened to specified torque.
  • Page 366 ENGINE MECHANICAL (F8D ENGINE) 6A1-63 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously outlined. NOTE: Tighten cylinder head bolts to specified torque as pre- viously outlined.

  • Page 367: Required Service Materials

    6A1-64 ENGINE MECHANICAL (F8D ENGINE) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Mating surfaces of cylinder block and oil pan. SUZUKI BOND NO. 1207C Sealant Mating surface of camshaft housing No.1. (99000-31150) Cylinder head cover gasket and cylinder head side seal. SUZUKI SUPER GREASE A O-rings of plug cap.
  • Page 368 ENGINE MECHANICAL (F8D ENGINE) 6A1-65 09916-58210 Valve guide installer 09916-77310 09917-68221 09917-18210 handle Piston ring compressor Camshaft pulley holder Tappet adjuster wrench 09926-18210 09917-98221 Oil seal guide 09924-17810 09918-08210 Valve stem seal installer (Vinyl resin) Flywheel holder Vacuum gauge hose joint...
  • Page 369 ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS GENERAL DESCRIPTION ............... . 6B- 2 Cooling System Circulation .

  • Page 370: General Description

    6B-2 ENGINE COOLING GENERAL DESCRIPTION The cooling system mainly consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. COOLING SYSTEM CIRCULATION 1) While the engine is warmed up (thermostat closed), coolant circulates as follows. (F8B engine) Throttle body Water pump...

  • Page 371: Diagnosis

    ENGINE COOLING 6B-3 DIAGNOSIS Symptom Possible Cause Remedy Engine overheats Loose or broken water pump belt Adjust or replace. Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace. Faulty water pump Replace. Dirty or bent radiator fins Clean or remedy.

  • Page 372: Maintenance

    6B-4 ENGINE COOLING MAINTENANCE COOLANT done even if freezing temperatures are not ex- pected. The coolant recovery system is standard. The coolant Add ethylene glycol base coolant when coolant has in the radiator expands with heat, and the overflow is to be added because of coolant loss or to provide collected in the reservoir tank.

  • Page 373: Coolant Level

    ENGINE COOLING 6B-5 COOLANT LEVEL Coolant Level To check level, lift hood and look at “see-through” coolant reservoir tank. It is not necessary to remove radiator cap to check coolant level. WARNING: To help avoid danger of being burned: do not remove reservoir tank cap while coolant is boil- ing, and do not remove radiator cap while engine and radiator are still hot.

  • Page 374: Cooling System Flush And Refill

    6B-6 ENGINE COOLING 4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity about 90 kPa (0.9 kg/cm 12.8 psi). If replacement of cap is required, use a proper cap for this vehicle. NOTE: After installing radiator cap to radiator, make sure that the ear of cap lines is parallel to radiator.

  • Page 375: Water Pump Belt Tension

    ENGINE COOLING 6B-7 7) Remove reservoir tank (1) and remove cap (2) from reservoir tank and pour out any fluid, scrub and clean inside of tank with soap and water. Flush it well with clean water and drain. Reinstall tank. 8) Add 50/50 mixture of good quality ethylene glycol antifreeze and water to radiator and tank.

  • Page 376: On-Vehicle Service

    6B-8 ENGINE COOLING ON-VEHICLE SERVICE WARNING: Check to make sure that engine coolant temperature is cold before removing any part of cooling system. Also be sure to disconnect negative cord from battery terminal before removing any part. COOLING SYSTEM DRAINING 1) Remove radiator cap.

  • Page 377: Thermostat

    ENGINE COOLING 6B-9 THERMOSTAT F8B engine REMOVAL 1) Drain coolant and tighten drain plug. 2) Remove air cleaner case together with air inlet hose. 3) Remove thermostat cap (1) with air cleaner case bracket. 4) Remove thermostat (2) and gasket. F8D engine INSPECTION 1) Make sure that air bleed valve (1) of thermostat is clean.

  • Page 378: Water Pump Belt

    6B-10 ENGINE COOLING INSTALLATION F8D engine 1) When positioning thermostat (1) on thermostat case (2), be sure to position it so that air bleed valve (3) aligns with arrow mark on case as shown in figure (F8D engine). 2) Install new gasket. 3) Install thermostat cap to thermostat case.

  • Page 379: Radiator

    ENGINE COOLING 6B-11 RADIATOR F8D engine REMOVAL 1) Disconnect cables at battery and remove battery and its tray. 2) Drain cooling system by loosening drain plug or disconnecting radiator outlet hose. 3) Disconnect coupler of cooling fan motor. 4) Remove radiator bolts. 5) Disconnect radiator inlet and outlet hoses and reservoir tank hose from radiator.

  • Page 380: Water Pump

    6B-12 ENGINE COOLING WATER PUMP REMOVAL F8B engine 1) Disconnect negative cable at battery. 2) Drain cooling system. 3) Remove A/C compressor drive belt (if equipped) and water pump drive belt. Remove water pump pulley. 4) Remove crankshaft pulley (1). Remove timing belt and tensioner according to procedure de- scribed in TIMING BELT AND TENSIONER of SECTION 6A.
  • Page 381 ENGINE COOLING 6B-13 INSPECTION NOTE: Do not disassemble water pump. If any repair is required on pump, replace it as assembly. Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, re- place it.

  • Page 382: Required Service Materials

    6B-14 ENGINE COOLING F8D engine 1) Install new pump gasket (1) to cylinder block. 2) Install water pump (1) to cylinder block. Tightening Torque (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) 3) After installing water pump, install rubber seal (2). 4) Install belt tensioner and timing belt and adjust timing belt ac- cording to procedure described in item TIMING BELT AND TENSIONER of SECTION 6A1.
  • Page 383 ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CONTENTS GENERAL DESCRIPTION ....6C- 1 ON-VEHICLE SERVICE ....6C- 3 Fuel System .

  • Page 384: Fuel Tank

    6C-2 ENGINE FUEL F8B engine F8D engine 1. Fuel tank 2. Fuel pump 3. Fuel level gauge 4. Fuel feed line 5. Fuel return line 6. Fuel filter FUEL TANK The fuel tank is located under the rear of the vehicle. The fuel pump and fuel level gauge are installed on the upper part of fuel tank.

  • Page 385: On-Vehicle Service

    ENGINE FUEL 6C-3 ON-VEHICLE SERVICE With short pipe, fit hose as far as it reaches pipe joint as shown. Hose WARNING: Before attempting service of any type on fuel system, fol- lowing cautions should be always observed. Pipe Disconnect negative cable at battery. DO NOT smoke, and place “NO SMOKING”...

  • Page 386: Fuel Pipe

    6C-4 ENGINE FUEL FUEL PIPE REMOVAL WARNING: A small amount of fuel may be released after fuel hose is disconnected. In order to reduce the chance of personal injury, cover hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved con- tainer when disconnection is completed.

  • Page 387: Fuel Filter

    ENGINE FUEL 6C-5 FUEL FILTER REMOVAL WARNING: A small amount of fuel may be released after fuel hose is disconnected. In order to reduce the chance of personal injury, cover hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved con- tainer when disconnection is completed.
  • Page 388 6C-6 ENGINE FUEL 4) Disconnect fuel filler hose (1) and breather hose (2) from filler neck. 5) As fuel tank has no drain plug, drain fuel tank by pumping fuel through fuel tank filler. Use hand operated pump device to drain fuel tank. CAUTION: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
  • Page 389 ENGINE FUEL 6C-7 FUEL TANK PURGING PROCEDURE WARNING: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank using heat of flame as an explosion resulting in personal injury could occur. Following procedure is used for purging fuel tank. 1) After removing fuel tank, remove all hoses, pipes, fuel cut valves, fuel pump and fuel level gauge from fuel tank.
  • Page 390 6C-8 ENGINE FUEL FUEL PUMP WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section. REMOVAL 1) Remove fuel tank from vehicle. Refer to FUEL TANK RE- MOVAL in this section. 2) Remove fuel pump assembly (1) from fuel tank. INSPECTION Check fuel pump assembly for damage.
  • Page 391 ENGINE AND EMISSION CONTROL SYSTEM 6E1-1 SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM CONTENTS GENERAL DESCRIPTION ....6E1- 2 B-10 Fuel Cut Operation Check ..6E1-42 Air Intake System .
  • Page 392 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM GENERAL DESCRIPTION The engine and emission control system has 4 major Fuel delivery system includes fuel pump, delivery sub-systems: air intake system, fuel delivery system, pipe, fuel pressure regulator, fuel injectors, etc. electronic control system and emission control sys- Electronic control system includes ECM, various sen- tem.
  • Page 393 ENGINE AND EMISSION CONTROL SYSTEM 6E1-3 1. Air Cleaner 23. ECM 24. Radiator fan 2. EVAP canister purge valve 25. Radiator fan control relay 3. IAT sensor 26. VSS in combination meter 4. TP sensor 27. A/C compressor control relay 5.
  • Page 394 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM AIR INTAKE SYSTEM The main components of the air intake system are air uted by the intake manifold and finally drawn into each cleaner, air cleaner outlet hose, throttle body, IAC combustion chamber. valve and intake manifold. When the IAC valve is opened according to the signal The air (by the amount corresponding to the throttle from ECM, the air bypasses the throttle valve through...
  • Page 395 ENGINE AND EMISSION CONTROL SYSTEM 6E1-5 ELECTRONIC CONTROL SYSTEM D Fuel injection control system The electronic control system consists of 1) various D Idle speed control system sensors which detect the state of engine and driving D Fuel pump control system conditions, 2) ECM which controls various devices D Ignition control system according to the signals from the sensors and 3) vari-...
  • Page 396 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM...
  • Page 397 ENGINE AND EMISSION CONTROL SYSTEM 6E1-7 TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE) 1. Fuel injector No.1 CIRCUIT TERMINAL TERMINAL CIRCUIT 2. Fuel injector No.2 E34-1 E32-301 Blank Ground 3. Fuel injector No.3 4. Blank E34-2 E32-302 IAC valve Power source 5.
  • Page 398 6E1-8 ENGINE AND EMISSION CONTROL SYSTEM Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Ï Î Î Ï Ï Ï Ï Ï Ï Î...
  • Page 399 ENGINE AND EMISSION CONTROL SYSTEM 6E1-9 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE INFORMATION SENSORS (input) CONTROL DEVICE (output) Fuel injector IAC valve Fuel pump relay Igniter EVAP canister purge valve Radiator fan relay A/C compressor relay...
  • Page 400 6E1-10 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSIS The engine and emission control system in this vehicle are con- trolled by ECM. ECM has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of ON-BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diag- nosis according to ENGINE DIAGNOSTIC FLOW TABLE in SEC-...
  • Page 401 ENGINE AND EMISSION CONTROL SYSTEM 6E1-11 MALFUNCTION INDICATOR LAMP (MIL) CHECK 1) Turn ON ignition switch (but engine at stop) and check that mal- function indicator lamp lights up. If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1 in this section.
  • Page 402 6E1-12 ENGINE AND EMISSION CONTROL SYSTEM [Not using SUZUKI scan tool] 1) Check malfunction indicator lamp (1) referring to MALFUNC- TION INDICATOR LAMP (MIL) CHECK in this section. 2) Using service wire, ground diagnosis switch terminal in monitor coupler (2). 3) Read DTC from flashing pattern of malfunction indicator lamp.
  • Page 403 ENGINE AND EMISSION CONTROL SYSTEM 6E1-13 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using SUZUKI scan tool] 1) Turn ignition switch OFF. 2) Connect SUZUKI scan tool to data link connector (DLC) in the same manner as when making this connection for DTC check. 3) Turn ignition switch ON.
  • Page 404 6E1-14 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSTIC TROUBLE CODE NO. MALFUNCTION INDICATOR DIAGNOSTIC ITEM DIAGNOSTIC ITEM DIAGNOSIS DIAGNOSIS LAMP FLASHING PATTERN SUZUKI SCAN TOOL Manifold absolute pressure P0105 sensor P0120 Throttle position sensor P0130 Oxygen sensor Diagnose trouble according to DIAG- P0340 Camshaft position sensor...
  • Page 405 ENGINE AND EMISSION CONTROL SYSTEM 6E1-15 A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK (MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON.) 1. Battery positive voltage 2. Blank 3. Ignition switch 4. Fuse 5. Malfunction indicator lamp 6. Monitor connector 7.
  • Page 406 6E1-16 ENGINE AND EMISSION CONTROL SYSTEM A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK (MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON.) 1. Battery positive voltage 2. Blank 3. Ignition switch 4. Fuse 5. Malfunction indicator lamp 6. Monitor connector 7. ECM 8.
  • Page 407 ENGINE AND EMISSION CONTROL SYSTEM 6E1-17 A-3 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK (MALFUNCTION INDICATOR LAMP DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUND- ING DIAGNOSIS SWITCH TERMINAL.) 1. Battery positive voltage 2. Blank 3. Ignition switch 4. Fuse 5.
  • Page 408 6E1-18 ENGINE AND EMISSION CONTROL SYSTEM A-4 ECM POWER AND GROUND CIRCUIT CHECK (Page 1 of 2) (MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON AND ENGINE DOES NOT START THOUGH IT IS CRANKED UP.) 1. Battery positive voltage 2.
  • Page 409 ENGINE AND EMISSION CONTROL SYSTEM 6E1-19 A-4 ECM POWER AND GROUND CIRCUIT CHECK (Page 2 of 2) STEP ACTION ECM Power Circuit Check Check ground circuits Go to Step 6. 1) Using service wire, ground terminal E32-319 and “Bl/B” and “B” for open. measure voltage between terminal E32-302 If OK, then substitute a (E32-315) and ground at ignition switch ON.
  • Page 410 6E1-20 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.11 (P0105) MAP SENSOR CIRCUIT (SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/G” wire is open or “E34-22” terminal connections are poor.
  • Page 411 ENGINE AND EMISSION CONTROL SYSTEM 6E1-21 Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3 NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-30 to confirm that the trouble has been corrected.
  • Page 412 6E1-22 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.13 (P0120) TP SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/G” wire is open or “E34-22” terminal connection are poor.
  • Page 413 ENGINE AND EMISSION CONTROL SYSTEM 6E1-23 Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3 NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-30 to confirm that the trouble has been corrected.
  • Page 414 6E1-24 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.14 (P0130) OXYGEN SENSOR CIRCUIT (SIGNAL VOLTAGE DOESN’T CHANGE) NOTE: D Before diagnosing trouble according to flow table given below, check to make sure that following sys- tem and parts other than Electronic Fuel Injection system are in good condition.
  • Page 415 ENGINE AND EMISSION CONTROL SYSTEM 6E1-25 Fig. for STEP 1 1. ECM coupler connected 2. Body ground NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-30 to confirm that the trouble has been corrected.
  • Page 416 6E1-26 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.15 (P0340) CMP SENSOR CIRCUIT (SENSOR SIGNAL NOT INPUTTED FOR 2 SECONDS AT ENGINE CRANKING) 1. ECM 2. CMP sensor 3. Rotor 4. CMP sensor coupler NOTE: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even through CMP sensor is in good condition.
  • Page 417 ENGINE AND EMISSION CONTROL SYSTEM 6E1-27 CODE NO.16 (P0500) VSS CIRCUIT (VSS SIGNAL NOT INPUTTED ALTHOUGH FUEL IS KEPT CUT AT LOWER THAN 4000 R/MIN. FOR LONGER THAN 4 SECONDS) 1. ECM 2. Speedometer 3. Meter coupler (G01) STEP ACTION D “V”...
  • Page 418 6E1-28 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.18 (P0110) IAT SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/G” wire is open or “C52-9” terminal connections are poor.
  • Page 419 ENGINE AND EMISSION CONTROL SYSTEM 6E1-29 CODE NO.19 (P0115) ECT SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is pos- sible that “B/G” wire is open or “E34-22” terminal connection is poor.
  • Page 420 6E1-30 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a safe place where there is not traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
  • Page 421 ENGINE AND EMISSION CONTROL SYSTEM 6E1-31 B-1 FUEL PUMP AND ITS CIRCUIT CHECK 1. ECM 2. Fuel pump relay 3. Fuel pump 4. Main relay 5. Ignition switch STEP ACTION Is fuel pump heard to operate 2 se- Fuel pump and its circuit are in good Go to Step 2.
  • Page 422 6E1-32 ENGINE AND EMISSION CONTROL SYSTEM B-2 FUEL INJECTOR AND ITS CIRCUIT CHECK 1. Battery positive voltage 2. Blank 3. “FI” fuse in fuse/relay box 4. Main relay 5. ECM 6. No.1 injector 7. No.2 injector 8. No.3 injector STEP ACTION Check each injector for operating sound at engine Fuel injector circuit is in...
  • Page 423 ENGINE AND EMISSION CONTROL SYSTEM 6E1-33 Blank...
  • Page 424 6E1-34 ENGINE AND EMISSION CONTROL SYSTEM B-3 FUEL PRESSURE CHECK (Page 1 of 2) 1. Fuel Injector 2. Delivery pipe 3. Fuel regulator 4. Fuel filter 5. Fuel pump Special Tool (A) Gauge (09912-58441) (B) Hose (09912-58431) (C) 3-way joint (09912-58490) STEP ACTION 1) Release fuel pressure from fuel feed line.
  • Page 425 ENGINE AND EMISSION CONTROL SYSTEM 6E1-35 B-3 FUEL PRESSURE CHECK (Page 2 of 2) STEP ACTION Was no fuel pressure applied in step 1? Go to Step 8. Go to Step 9. With fuel pump operated and fuel return hose blocked Faulty fuel pressure Shortage of fuel or fuel by pinching it, is fuel pressure applied?
  • Page 426 6E1-36 ENGINE AND EMISSION CONTROL SYSTEM B-4 IDLE AIR CONTROL SYSTEM CHECK (Page 1 of 2) 1. Battery positive voltage 2. Blank 3. “FI” fuse in fuse/relay box 4. Main relay 5. ECM 6. IAC valve 7. Throttle body 8. Engine coolant 9.
  • Page 427 ENGINE AND EMISSION CONTROL SYSTEM 6E1-37 B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK 1. To throttle body 6. EVAP canister purge valve 2. To fuel tank 7. Main relay 3. EVAP canister 8. Sensed information 4. Air 9. ECM 5. Air and vapor 10.
  • Page 428 6E1-38 ENGINE AND EMISSION CONTROL SYSTEM B-6 ENGINE START SIGNAL CHECK 1. ECM 2. ECM coupler 3. Main switch 4. To starting motor STEP ACTION D “B/Y” wire open or 1) With ignition switch OFF, disconnect couplers from ECM. Engine starter D Poor “E34-13”...
  • Page 429 ENGINE AND EMISSION CONTROL SYSTEM 6E1-39 B-7 RADIATOR FAN CONTROL SYSTEM CHECK 1. Radiator fan motor 2. Radiator fan control (RFC) relay 3. ECM 4. Main relay 5. Engine coolant temp. (ECT) sensor 6. Vehicle speed sensor 7. A/C signal STEP ACTION Check radiator fan control system referring to...
  • Page 430 6E1-40 ENGINE AND EMISSION CONTROL SYSTEM B-8 A/C CONTROL SIGNAL CHECK (IF EQUIPPED) 1. Battery 2. Main fuse box 3. Ignition switch 4. “HEATER” fuse 5. Blower fan motor 6. Blower fan switch 7. A/C switch 8. Dual pressure switch 9.
  • Page 431 ENGINE AND EMISSION CONTROL SYSTEM 6E1-41 B-9 ELECTRIC LOAD SIGNAL CIRCUITS CHECK 1. Ignition switch 2. Blower fan motor 3. Blower fan switch 4. Heater blower register 5. Clearance light 6. From battery 7. Clearance light switch STEP ACTION D “Br/R” wire open or Check voltage at E34-18 terminal under each condition given Go to Step 2.
  • Page 432 6E1-42 ENGINE AND EMISSION CONTROL SYSTEM B-10 FUEL CUT OPERATION CHECK 1. ECM 2. ECM coupler 3. TP sensor STEP ACTION Check fuel cut operation referring FUEL CUT OPERA- Fuel cut operation is Go to step 2. TION INSPECTION in this section. in good condition.
  • Page 433 ENGINE AND EMISSION CONTROL SYSTEM 6E1-43 INSPECTION OF ECM AND ITS CIRCUITS ECM and its circuits can be checked at ECM wiring couplers by measuring voltage and resistance. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from it.
  • Page 434 6E1-44 ENGINE AND EMISSION CONTROL SYSTEM TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION E34-1 Blank — — E34-2 IAC valve — — E34-3 Blank — — E34-4 Blank — — E34-5 Blank — — E34-6 Blank 10 – 14 V Ignition switch ON, selector lever: “L” range 4.5 –...
  • Page 435 ENGINE AND EMISSION CONTROL SYSTEM 6E1-45 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION E33-211 CMP sensor (–) About 0 V — E33-212 Blank — — Deflect between 0 E33-213 Oxygen sensor Engine running, after engine warmed up and 1 V 2.0 – 2.5 V IAT sensor ambient temp.: at 205C E33-214 E33-214...
  • Page 436 6E1-46 ENGINE AND EMISSION CONTROL SYSTEM RESISTANCE CHECK 1) Disconnect ECM couplers from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itself or connect volt- meter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in following table.
  • Page 437 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-47 ON-VEHICLE SERVICE 1. MAP sensor 2. EVAP canister 3. EVAP canister purge valve (if equipped) 4. PCV valve...
  • Page 438 6E1-48 ENGIINE AND EMISSION CONTROL SYSTEM GENERAL When hoses are disconnected and system components are re- moved for service, reinstall components properly, and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of hoses. ACCELERATOR CABLE ADJUSTMENT 1) With throttle valve closed, check accelerator pedal play which should be within the following specification.
  • Page 439 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-49 IDLE SPEED/IAC DUTY INSPECTION Before idle speed/IAC duty check, make sure of the following. Lead wires and hoses of Electronic Fuel Injection system is con- nected securely. Accelerator cable has some play, that is, it is not tight. Valve lash is checked and adjusted according to maintenance schedule.
  • Page 440 6E1-50 ENGIINE AND EMISSION CONTROL SYSTEM [Not using SUZUKI scan tool] 1) Using service wire, ground diagnosis switch terminal in monitor connector. 2) Connect duty meter between duty output terminal and ground terminal of monitor connector. 3) Set tachometer. 4) Start engine and warm it up to normal operating temperature. 5) Confirm that all accessories (light, A/C, blower fan, etc.) are out of service.
  • Page 441 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-51 AIR INTAKE SYSTEM THROTTLE BODY CAUTION: Do not remove or adjust throttle stop screw as it is factory adjusted precisely : Tightening torque : Do not reuse CAUTION: Do not disassemble IAC 1. Throttle body valve.
  • Page 442 6E1-52 ENGIINE AND EMISSION CONTROL SYSTEM 5) Disconnect couplers from TP sensor, MAP sensor and IAC valve. 6) Remove throttle body from intake manifold. 7) Disconnect engine coolant hoses and EVAP canister purge valve hose from throttle body. 1. Engine coolant hose 2.
  • Page 443 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-53 INSTALLATION 1) Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket. 2) Install throttle body to intake manifold. 3) Connect engine coolant hoses and EVAP canister purge valve hose. 4) Connect couplers to TP sensor, MAP sensor and IAC valve se- curely.
  • Page 444 6E1-54 ENGIINE AND EMISSION CONTROL SYSTEM IAC VALVE REMOVAL 1) Remove throttle body from intake manifold referring to “Throttle Body Removal” section. 2) Remove IAC valve from throttle body. INSPECTION 1) Remove IAC valve (1) from throttle body. 2) Connect each connector to IAC valve, MAP sensor, TP sensor and IAT sensor.
  • Page 445 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-55 FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to FUEL PRES- SURE RELIEF PROCEDURE in SECTION 6.

  • Page 446: Fuel Pump

    6E1-56 ENGIINE AND EMISSION CONTROL SYSTEM 9) Remove special tools from fuel delivery pipe. 10) Connect fuel feed hose to fuel delivery pipe and clamp it se- curely. 11) With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP ON-VEHICLE INSPECTION CAUTION:...
  • Page 447 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-57 FUEL PRESSURE REGULATOR ON-VEHICLE INSPECTION Perform fuel pressure inspection according to procedure de- scribed in FUEL PRESSURE INSPECTION in this section. REMOVAL 1) Relieve fuel pressure according to procedure described in Sec- tion 6. 2) Disconnect battery negative cable at battery.
  • Page 448 6E1-58 ENGIINE AND EMISSION CONTROL SYSTEM FUEL INJECTOR ON-VEHICLE INSPECTION 1) Using sound scope or such, check operating sound of injector when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, preform B-2 FUEL IN- JECTOR AND ITS CIRCUIT CHECK in this section.
  • Page 449 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-59 1) Install injector (1) and fuel pressure regulator (2) to special tool (injector checking tool). Special Tool (A): 09912-58421 2) Connect special tools (hoses and attachment) to pipes of ve- hicle. Special Tool (B): 09912-58431 3) Connect special tool (test lead) to injector.
  • Page 450 6E1-60 ENGIINE AND EMISSION CONTROL SYSTEM 9) Check fuel leakage from injector nozzle. Do not operate injector 1. Injector 2. Vinyl tube for this check (but fuel pump should be at work). If fuel leaks 3. Less than one fuel more than following specification, replace.
  • Page 451 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-61 ELECTRONIC CONTROL SYSTEM CAUTION: As ECM consists of precision parts, be careful not to ex- pose it to excessive shock. REMOVAL 1) Disconnect battery negative cable at battery. 2) Remove ECM from body. 3) Disconnect couplers from ECM. INSTALLATION 1) Install ECM to body.
  • Page 452 6E1-62 ENGIINE AND EMISSION CONTROL SYSTEM 4) Check output voltage at coupler terminal E33-205. Note that it varies with atmospheric pressure and altitude. Also, start engine, it it can, and check if output voltage varies. Output voltage (ECM supply voltage 4.75 – 5.25 V, ambient temp.
  • Page 453 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-63 2) Arrange 3 new 1.5 V batteries in series (2) (check that total volt- age is 4.5 – 5.0 V) and connect its positive terminal to “Vcc” ter- minal of MAP sensor (1) and negative terminal to “Ground” terminal.
  • Page 454 6E1-64 ENGIINE AND EMISSION CONTROL SYSTEM TP SENSOR INSPECTION 1) Disconnect negative cable at battery and coupler from TP sen- sor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. TERMINAL RESISTANCE Between “Vcc” and 4 –...
  • Page 455 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-65 ADJUSTMENT 1) Warm up engine to normal operating temperature. 1) Loosen TP sensor screws. 3) [Using SUZUKI scan tool] [Not using SUZUKI scan tool] Connect SUZUKI scan tool to DLC with ignition switch OFF and TERMINAL ARRANGEMENT OF ECM check “TP SENSOR VOLT”...
  • Page 456 6E1-66 ENGIINE AND EMISSION CONTROL SYSTEM IAT SENSOR REMOVAL 1) Disconnect battery negative cable at battery. 2) Disconnect coupler from IAT sensor (1). 3) Remove IAT sensor from air cleaner outlet hose. INSPECTION Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
  • Page 457 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-67 ECT SENSOR REMOVAL 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to Section 6B. WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure it cap is taken off too soon.
  • Page 458 6E1-68 ENGIINE AND EMISSION CONTROL SYSTEM MAIN RELAY/FUEL PUMP RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove ECM main/fuel pump relay from main fuse box after disconnecting its coupler. 3) Check resistance between each two terminals as in table below. If check results are as specified, proceed to next operation check.
  • Page 459 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-69 OXYGEN SENSOR INSPECTION Inspect oxygen sensor referring to flow table of diagnostic trouble code No. 14 (P0130). REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool.
  • Page 460 6E1-70 ENGIINE AND EMISSION CONTROL SYSTEM FUEL CUT OPERATION INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up. 1) Warm up engine to normal operating temperature.
  • Page 461 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-71 RADIATOR FAN CONTROL SYSTEM SYSTEM INSPECTION WARNING: Keep hands, tools and clothing away from engine cool- ing fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch in the “ON”...
  • Page 462 6E1-72 ENGIINE AND EMISSION CONTROL SYSTEM VEHICLE SPEED SENSOR (VSS) INSPECTION 1) Remove combination meter from instrument panel. 2) Connect ohmmeter between vehicle speed sensor terminal and ground terminal of combination meter and turn cable joint of speedometer with a screwdriver. Ohmmeter indicator should move back and forth between conti- nuity and infinity 4 times while cable joint is turned one full revo- lution.
  • Page 463 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-73 EVAP CONTROL SYSTEM EVAP CANISTER PURGE INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up. F8D engine 1.
  • Page 464 6E1-74 ENGIINE AND EMISSION CONTROL SYSTEM VACUUM PASSAGE INSPECTION Start engine and run it at idle speed. Disconnect vacuum hose from EVAP canister purge valve. With finger placed against hose dis- connected, check that vacuum is applied. If it is not applied, clean vacuum passage by blowing compressed air.
  • Page 465 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-75 6) Open EVAP canister purge valve using “MISC TEST” mode of SUZUKI scan tool with ignition switch ON. In this state, blow hose “A”. Air should come out of nozzle “B”. WARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful.
  • Page 466 6E1-76 ENGIINE AND EMISSION CONTROL SYSTEM 6) Connect vacuum hoses. 7) Connect EVAP canister purge valve coupler securely. EVAP CANISTER/1-WAY VALVE INSPECTION WARNING: DO NOT SUCK nozzles on canister/1-way valve. Fuel va- por inside canister/1-way valve is harmful. 1) Disconnect vacuum hoses from EVAP canister. 2) When air is blown into pipe “A”, there should be no restriction of flow through purge pipes “B”...
  • Page 467 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-77 TANK PRESSURE CONTROL VALVE INSPECTION 1) Remove tank pressure control valve installed on the side of EVAP canister. 2) Air should pass through valve smoothly from fuel tank side (3) (black side (2) of check valve) to orange side (1) when blown hard.
  • Page 468 6E1-78 ENGIINE AND EMISSION CONTROL SYSTEM PCV SYSTEM NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty, for ob- structed PCV valve or hose hampers its accurate checking. PCV HOSE INSPECTION Check hoses for connection, leakage, clog and deterioration.
  • Page 469 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-79 SPECIAL TOOLS 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 4. Checking tool set 09912-58421 4-1. Tool body & washer 4-2. Body plug 4-3. Body attachment 4-4. Holder 4-5.
  • Page 470 IGNITION SYSTEM 6F-1 SECTION 6F IGNITION SYSTEM CONTENTS GENERAL DESCRIPTION ....6F- 2 Spark Plugs ......6F- 7 Components .

  • Page 471: Components

    6F-2 IGNITION SYSTEM GENERAL DESCRIPTION The ignition system used for this vehicle has an electronic ignition control system and consists of the following parts. It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter.

  • Page 472: System Wiring

    IGNITION SYSTEM 6F-3 SYSTEM WIRING 1. Battery 7. Noise suppressor 2. Main fuse box 8. Distributor 3. Ignition switch 9. Distributor rotor 4. Main relay 10. Signal rotor 5. Ignition coil 11. CMP sensor 6. Igniter 12. Spark plug...

  • Page 473: Diagnosis

    6F-4 IGNITION SYSTEM DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil Replace not start or hard to start Loose connection or disconnection of lead wire or Connect securely high-tension cord(s) Faulty high-tension cord(s) Replace Faulty spark plug(s) Adjust, clean or replace Cracked rotor or cap...
  • Page 474 IGNITION SYSTEM 6F-5 STEP ACTION Ignition Coil Power Supply And Ground Circuit Check Go to Step 8. Repair or replace. 1) Check ignition coil power supply (“B/W” wire) circuit for open and short. Are circuits in good condition? Ignition Coil Check Go to Step 9.

  • Page 475: Ignition Spark Test

    6F-6 IGNITION SYSTEM IGNITION SPARK TEST 1) Disconnect injector couplers (1) from injectors. WARNING: Without disconnection of injector coupler, combus- tible gas may come out from spark plug holes during this test and may get ignited in engine room. 2) Remove spark plugs and connect them to high-tension cords, and then ground spark plugs.

  • Page 476: Spark Plugs

    IGNITION SYSTEM 6F-7 6) If resistance exceeds specification, inspect distributor terminal and replace high-tension cord(s) and/or distributor cap as re- quired. CAUTION: Never attempt to use metal conductor high-tension cords as replacing parts. Insert each cap portion fully when installing high- tension cords.

  • Page 477: Noise Suppressor

    6F-8 IGNITION SYSTEM INSTALLATION 1) Install spark plugs and torque them to specification. Tightening Torque for spark plug 15 N·m (1.5 kg-m, 10.5 lb-ft) ..F8D engine 25 N·m (2.5 kg-m, 18.0 lb-ft) ..F8B engine 2) Install high-tension cords, referring to HIGH-TENSION CORDS under ON-VEHICLE SERVICE earlier in this section.

  • Page 478: Ignition Coil

    IGNITION SYSTEM 6F-9 3) Arrange 3 new batteries in series (1) (check total voltage is above 4.7V) 4) Connect light bulb (2) between “c” terminal of igniter (3) and bat- tery (4) positive (+) terminal, then connect battery negative (–) terminal to igniter body.
  • Page 479 6F-10 IGNITION SYSTEM Signal Rotor Air Gap 1) Remove distributor cap and rotor. 2) Using thickness gauge, measure air gap, between signal rotor tooth (2) and CMP sensor (generator) (1). Signal rotor air gap “a”: 0.2 – 0.4 mm (0.008 – 0.016 in.) 3) If gap is out of specification, loosen CMP sensor (signal genera- tor) securing screws (3).

  • Page 480: Ignition Timing

    IGNITION SYSTEM 6F-11 IGNITION TIMING NOTE: Before starting engine, place transmission gear shift lever in “Neutral” and set parking brake. INSPECTION AND ADJUSTMENT 1) When using SUZUKI scan tool, connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (when using SUZUKI scan tool) (A): 09931-76011 (SUZUKI scan tool) (B): Mass storage cartridge (C): 09931-76030 (16/14 pin DLC adapter)
  • Page 481 6F-12 IGNITION SYSTEM 7) Using timing light (1), check that timing is within specification. F8B engine Initial ignition timing (Test switch terminal grounded or fixed by scan tool): 1 BTDC (at idle speed) Ignition order 1-3-2 F8D engine 8) If ignition timing is out of specification, remove air cleaner as- sembly then loosen flange bolts (1), adjust timing by turning distributor assembly (2) while engine is running, and then tighten bolts (1).

  • Page 482: Distributor Unit

    IGNITION SYSTEM 6F-13 DISTRIBUTOR UNIT 1. Cap 2. Cap seal 3. Cap screw 4. Rotor 5. CMP sensor (Signal generator) 6. Housing 7. O-ring REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect distributor connector. 3) Disconnect high tension cords from distributor cap. 4) Remove distributor cap.
  • Page 483 6F-14 IGNITION SYSTEM INSTALLATION 1) If distributor rotor has not been positioned at No.1 terminal of distributor cap in distributor removal, perform following step. a) Turn over crankshaft in normal direction (clockwise as viewed from crankshaft pulley side) until Timing notch (2) on pulley aligns with timing mark “0”...

  • Page 484: Special Tools

    IGNITION SYSTEM 6F-15 SPECIAL TOOLS 09900-27301 09930-76420 09900-25002 Timing light (DC 12 V) Timing light (Dry cell type) Pocket tester...
  • Page 485 CRANKING SYSTEM 6G-1 SECTION 6G CRANKING SYSTEM CONTENTS GENERAL DESCRIPTION ....6G-2 Brush holder ..... . 6G- 9 Cranking Circuit .

  • Page 486: General Description

    6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT The magnetic switch coils are magnetized when the ignition switch is closed.

  • Page 487: Diagnosis

    CRANKING SYSTEM 6G-3 DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: Starting motor does not run (or runs slowly) Starting motor runs but fails to crank engine Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..in battery, wiring harness, (including starting motor switch), starting motor or engine.
  • Page 488 6G-4 CRANKING SYSTEM Condition Possible Cause Correction Starting motor If battery and wiring are satisfactory, inspect running but too starting motor slow (small torque) Insufficient contact of magnetic switch main contacts Replace magnetic switch. Layer short-circuit of armature Replace. Disconnected, burnt or worn commutator Repair commutator or replace armature.

  • Page 489: Unit Repair Overhaul

    CRANKING SYSTEM 6G-5 UNIT REPAIR OVERHAUL 1. Drive housing assembly 2. Blank 3. Snap ring 4. Pinion stop ring 5. Over-running clutch assembly: Apply grease A 99000-25010 to inside and outside of spline. 6. Armature: Apply grease A 99000-25010 to joint of drive housing bush, over-running clutch and armature shaft bush.

  • Page 490: Dismounting And Remounting

    6G-6 CRANKING SYSTEM DISMOUNTING AND REMOUNTING 1) Disconnect negative cable at battery. 2) Remove A/C compressor (if equipped), refer to SECTION 1B. 3) Disconnect magnetic switch lead wire and battery cable from starting motor terminals. 4) Remove 2 mounting bolts. 5) Remove starting motor.

  • Page 491: Reassembly

    CRANKING SYSTEM 6G-7 REASSEMBLY 1) Inspect component parts (Refer to INSPECTION) and replace with new ones as necessary. 2) Before installing over-running clutch (2) to armature (1), apply grease as shown in figure and then fasten stop ring (3) with snap ring (4).

  • Page 492: Inspection

    6G-8 CRANKING SYSTEM 7) Hook magnetic switch plunger (3) with drive lever and then fas- ten magnetic switch assembly (1) with nuts (4). 8) Connect lead wire (5) as it was and then check magnetic switch for operation. NOTE: Before installing nuts, make sure that plunger hook is connected with drive lever without fail.

  • Page 493: Brush

    CRANKING SYSTEM 6G-9 Hold-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’ terminal (1) and coil case. If no continuity exists, coil is open and should be re- placed. BRUSH Measure length of brushes and replace them as necessary. Brush length Limit : 6.0 mm (0.236 in.) BRUSH HOLDER...

  • Page 494: Yoke

    6G-10 CRANKING SYSTEM Check commutator for run-out with armature (1) supported on V-blocks (2). Correct it by using lathe, if required. Commutator out of round Limit (maximum value): 0.4 mm (0.015 in.) Check for wear and replace armature if diameter is below limit. Commutator outside diameter Limit (minimum value): 27 mm (1.063 in.) Correct and clean surface by using #400 emery cloth.

  • Page 495: Performance Test

    CRANKING SYSTEM 6G-11 PERFORMANCE TEST CAUTION: Each test must be performed within 3 – 5 seconds to avoid coil from burning. PULL-IN TEST Connect test leads as shown in figure and check that pinion (over- running clutch) move outward. If it does not, replace magnetic switch.

  • Page 496: Pinion Return Test

    6G-12 CRANKING SYSTEM PINION (PLUNGER) RETURN TEST As a next step to the above, disconnect negative lead and check to make sure that pinion returns inward quickly. NO-LOAD PERFORMANCE TEST Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out.

  • Page 497: Specifications

    CRANKING SYSTEM 6G-13 SPECIFICATIONS Voltage 12 volts Output 0.6 kW Rating 30 seconds Clockwise as viewed from pinion side (F8D engine) Direction of rotation Counterclockwise as viewed from pinion side (F8B engine) Brush length 10.0 mm (0.394 in.) Number of pinion teeth Performance Condition Guarantee...
  • Page 498 CHARGING SYSTEM 6H-1 SECTION 6H CHARGING SYSTEM CONTENTS GENERAL DESCRIPTION ..............6H- 2 Battery .

  • Page 499: General Description

    6H-2 CHARGING SYSTEM GENERAL DESCRIPTION BATTERY The battery has three major functions in the electrical system. D It is a source of electrical energy for cranking the engine. D It acts as a voltage stabilizer for the electrical system. D It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
  • Page 500 CHARGING SYSTEM 6H-3 CARE OF BATTERY WARNING: Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted area with water immediately and thor- oughly.

  • Page 501: Generator

    6H-4 CHARGING SYSTEM GENERATOR The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown below figure. The generator features are as follows: Solid state regulator is mounted inside the generator. All regulator components are enclosed into a solid mold.
  • Page 502 CHARGING SYSTEM 6H-5 1. Pulley 2. Pulley nut 3. Rotor fan 4. Stator coil 5. Stator core B : Generator output (Battery terminal) 6. Field coil D : Dummy terminal 7. Regulator E : Ground 8. Brush F : Field coil terminal IG : Ignition terminal 9.

  • Page 503: Diagnosis

    6H-6 CHARGING SYSTEM DIAGNOSIS BATTERY VISUAL INSPECTION Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious damage is noted, replace battery. Determine cause of damage and correct as needed. HYDROMETER TEST The direct method of checking the battery for state of charge is to carry out a high rate discharge test, which involves a special pre-...

  • Page 504: Generator

    CHARGING SYSTEM 6H-7 GENERATOR CAUTION: Do not mistake polarities of IG terminal and L terminal. Do not create a short circuit between IG and L termi- nals. Always connect these terminals through a lamp. Do not connect any load between L and E. When connecting a charger or a booster battery to ve- hicle battery, refer to this section describing battery charging.
  • Page 505 6H-8 CHARGING SYSTEM UNDERCHARGED BATTERY This condition, as evidenced by slow cranking can be caused by one or more of the following conditions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and amme- ter.
  • Page 506 CHARGING SYSTEM 6H-9 Higher Voltage If voltage is higher than standard value, check ground of brush. If brush ground is correct, replace IC regulator. Lower Voltage If voltage is lower than standard value, proceed to following check. 2) Ground F terminal and start engine, then measure voltage at B terminal as shown in figure.

  • Page 507: On-Vehicle Service

    6H-10 CHARGING SYSTEM ON-VEHICLE SERVICE BATTERY JUMP STARTING IN CASE OF EMERGENCY WITH AUXILIARY (BOOSTER) BATTERY Both booster and discharged battery should be treated carefully when using jumper cables. Follow procedure outlined below, being careful not to cause sparks. WARNING: Departure from these conditions or procedure de- scribed below could result in: 1) Serious personal injury (particularly to eyes) or...

  • Page 508: Removal

    CHARGING SYSTEM 6H-11 With Charging Equipment CAUTION: When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equip- ment can cause serious damage to electrical system or electronic parts.

  • Page 509: Generator

    6H-12 CHARGING SYSTEM GENERATOR 1. Adjusting bolt 2. Generator 3. Pivot bolt 4. “B” terminal wire 5. Coupler 6. Nut : Tightening Torque REMOVAL 1) Disconnect negative cable (1) at battery (2). 2) Remove front bumper. 3) Disconnect “B” terminal wire (3) and coupler (4) from generator (5).

  • Page 510: Generator (Water Pump) Belt

    CHARGING SYSTEM 6H-13 GENERATOR (WATER PUMP) BELT BELT TENSION INSPECTION 1) Inspect belt cracks, cuts, deformation, wear and cleanliness. 2) Check belt for tension. Belt is in proper tension when it deflects 12 to 15 mm (0.47 – 0.59 in.) under thumb pressure (1) (about 10 kg or 22 lb.).

  • Page 511: Unit Repair Overhaul

    6H-14 CHARGING SYSTEM UNIT REPAIR OVERHAUL GENERATOR : Tightening Torque 1. Pulley nut 2. Pulley 3. Drive end frame 4. Stator 5. Stud bolt 6. Drive end bearing 7. Bearing retainer 8. Rotor 9. Bearing cover 10. End housing bearing 11.

  • Page 512: Disassembly

    CHARGING SYSTEM 6H-15 DISASSEMBLY 1) Remove B terminal inner nut (1) and insulator (2). 2) Remove 3 screws (3) and remove rear end cover (4). 3) Remove 2 screws (1) and pull out brush holder assembly (2). 4) Remove 3 screws (3) and IC regulator (4). 5) Remove brush holder cover from brush holder.
  • Page 513 6H-16 CHARGING SYSTEM 12) If required, use bearing puller (2) to remove end housing bear- ing (1) and bearing cover (3). CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller. 13) If required, remove 4 screws, retainer plate (1) and then drive out drive end bearing (2).

  • Page 514: Inspection

    CHARGING SYSTEM 6H-17 INSPECTION Rotor Open Circuit Using ohmmeter, check for continuity between slip rings of rotor (1). If there is no continuity, replace rotor. Standard resistance: About 2.9 Ground Using ohmmeter, check that there is no continuity between slip ring and rotor (1).
  • Page 515 6H-18 CHARGING SYSTEM Brush Exposed Brush Length Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush. Refer to “Replace Brush” in this section. Exposed brush length “a” Standard : 10.5 mm (0.413 in.) Limit : 1.5 mm (0.059 in.)

  • Page 516: Replace Brush

    CHARGING SYSTEM 6H-19 Bearing Drive End Bearing Check that bearing is not rough or worn. End Housing Bearing Check that bearing is not rough or worn. When removal is necessary, refer to disassembly of UNIT REPAIR OVERHAUL. REPLACE BRUSH 1) Unsolder and remove brush and spring. 2) Run wire of new brush through the hole in the brush holder, and insert spring and brush into brush holder.

  • Page 517: Assembly

    6H-20 CHARGING SYSTEM ASSEMBLY 1) If end housing bearing (1) is removed, install it. 2) Check end housing bearing turns smoothly. 3) If stator (2) is removed, install stator and tighten stud bolts (1). 4) If drive end bearing (3) is removed, install it. 5) Check drive end bearing turns smoothly.
  • Page 518 CHARGING SYSTEM 6H-21 10) Install rectifier holder (1). Curl stator leads (2) as shown in fig- ure. CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades. Tightening Torque (a): 2.0 N m (0.2 kg-m, 1.5 lb-ft) 11) Install brush holder cover to brush holder.

  • Page 519: Specifications

    6H-22 CHARGING SYSTEM SPECIFICATIONS BATTERY Rated capacity 28 AH / 5 HR, 12 Volts Electrolyte 2.5 L (5.28 / 4.40 US / lmp pt) Electrolyte S.G. 1.24 when fully charged at 20 C (68 F) GENERATOR NOTE: The generator used in each vehicle is one of the following two types, depending on specification. Type 40 A type 50 A type...
  • Page 520 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS GENERAL DESCRIPTION ..............6K-2 MAINTENANCE .
  • Page 521 6K-2 EXHAUST SYSTEM GENERAL DESCRIPTION The exhaust system consists of an exhaust manifold, exhaust pipes, a catalyst case a muffler and seal, gaskets and etc., and catalyst case has the three-way catalytic converter (TWC). The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
  • Page 522 EXHAUST SYSTEM 6K-3 MAINTENANCE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. At every interval of periodic maintenance service, and when ve- hicle is raised for other service, check exhaust system as follows: Check rubber mountings for damage, deterioration, and out of position.
  • Page 523 6K-4 EXHAUST SYSTEM ON-VEHICLE SERVICE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. EXHAUST MANIFOLD Refer to Section 6A for removal and installation procedures of ex- haust manifold.
  • Page 524 MANUAL TRANSMISSION (4-SPEED) 7A-1 SECTION 7A MANUAL TRANSMISSION (4-SPEED) CONTENTS GENERAL DESCRIPTION ..............7A- 2 Components .
  • Page 525 7A-2 MANUAL TRANSMISSION (4-SPEED) GENERAL DESCRIPTION COMPONENTS The transmission is fully synchronized and provides four forward speeds and one reverse speed by means of two synchronizers and two shafts – input shaft and countershaft. Gears on both shafts (input and counter) are always meshed. The low-speed synchronizer on the counter shaft is engaged either with the low driven gear or second driven gear.
  • Page 526 MANUAL TRANSMISSION (4-SPEED) 7A-3 : Tightening Torque : Do not reuse : Apply SUZUKI SUPER GREASE A (99000-25010) 1. Speedometer driven gear 13. Synchronizer ring spring 26. Synchronizer ring 39. Pin case 14. Synchronizer spring 27. Synchronizer spring 40. Plug 2.
  • Page 527 7A-4 MANUAL TRANSMISSION (4-SPEED) DIAGNOSIS Condition Possible Cause Correction Gears slipping out of mesh Worn shift fork shaft Replace. Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating springs Replace. Worn bearings on input shaft or countershaft Replace. Worn chamfered tooth on sleeve and gear Replace sleeve and gear.
  • Page 528 MANUAL TRANSMISSION (4-SPEED) 7A-5 ON-VEHICLE SERVICE TRANSMISSION OIL Check the transmission for oil leakage, each time when vehicle is on hoist. Check the oil level according to the following procedures. 1) Take out the oil level gauge (1) from the transmission case and wipe off the oil.
  • Page 529 7A-6 MANUAL TRANSMISSION (4-SPEED) GEAR SHIFT CONTROL 1. Gear shift control lever knob 2. Gear shift control lever 3. Lever cover 4. Lever boot 5. Dust cover 6. Lever housing 7. Lever seat 8. Dust seal 9. Guide plate 10. Extension rod 11.
  • Page 530 MANUAL TRANSMISSION (4-SPEED) 7A-7 Removal Gearshift control lever Remove the gearshift control lever (1) according to the following procedure. 1) Remove gearshift control lever housing nuts (4 pcs) and bolts (2 pcs). 2) Lift the front end of vehicle by jacking, and support it on safety stands.
  • Page 531 7A-8 MANUAL TRANSMISSION (4-SPEED) Adjustment 1. Guide plate bolt 2. Guide plate Gear shift control lever adjustment 3. Gear shift control lever When each shift stroke is short, or when gears are not in complete 4. Right angle 5. Front side mesh, adjust the gear shift lever position as follows.
  • Page 532 MANUAL TRANSMISSION (4-SPEED) 7A-9 UNIT REPAIR OVERHAUL DISMOUNTING/REMOUNTING Dismount or mount transmission with engine referring to SECTION 6A “ENGINE MECHANICAL”, and separate or combine transmis- sion and engine. DISASSEMBLY 1) Remove back up light switch. 2) Remove clutch release bearing (1). 3) Remove clutch release shaft return spring (1) from release lever (2).
  • Page 533 7A-10 MANUAL TRANSMISSION (4-SPEED) 5) Remove bolts fastening upper and lower cases. 6) Detach lower and upper transmission cases. 7) When upper case is removed, all parts should be left on the lower case. 8) Remove input shaft assembly (1) from the lower case. 9) Remove counter shaft assembly (1) from the lower case.
  • Page 534 MANUAL TRANSMISSION (4-SPEED) 7A-11 11) Draw out 3 shift fork shafts in the order of low speed gear shift fork shaft, high speed gear shift fork shaft and reverse gear shift fork shaft. NOTICE: The 2 shafts should be positioned at neutral when re- moving shift fork shafts.
  • Page 535 7A-12 MANUAL TRANSMISSION (4-SPEED) INSPECTION OF TRANSMISSION COM- PONENTS Reverse gears and idle gear Inspect the chamfered edges (1) of gear teeth of the three gears- driving and driven gears (of input shaft and countershaft) and idle gear. If the edges are worn badly, replace the gears. Abnormal noise of gear slipping in reverse drive is often due to worn tooth edges of these gears.
  • Page 536 MANUAL TRANSMISSION (4-SPEED) 7A-13 Chamfered tooth ends of ring (external teeth) and sleeve (in- ternal teeth) Synchronizer ring and hub have three slots each, in which keys are carried as backed by expanding springs, so that hub and its two rings, one on each end, are capable of running together.
  • Page 537 7A-14 MANUAL TRANSMISSION (4-SPEED) Synchronizer rings Inspect each synchronizer ring for key slot wear by measuring the width of each slot. If the width reading exceeds the limit, replace the ring. Key slot width Standard Service Limit 8.0 mm 8.3 mm Low gear (0.31 in.) (0.32 in.)
  • Page 538 MANUAL TRANSMISSION (4-SPEED) 7A-15 Gear backlash Check the backlash of gears with a fuse wire-element or dial gauge and replace if the backlash exceeds the specified service limit. Gear backlash Gear Standard Service Limit 0.05 – 0.10 mm 0.30 mm Low &...
  • Page 539 7A-16 MANUAL TRANSMISSION (4-SPEED) Differential side pinion & gear Measure the backlash of side pinion and side gear. To measure backlash, insert a thin fuse between pinion and gear and measure the thickness of the crushed fuse. 0.05 – 0.10 mm Side gear back lash specification (0.002 –...
  • Page 540 MANUAL TRANSMISSION (4-SPEED) 7A-17 IMPORTANT STEPS IN REASSEMBLY NOTICE: Wash all parts and apply gear oil to sliding surfaces. When installing each parts on counter shaft, be careful for installing direction and position of each washer, gear, syn- chronizer ring, hub and sleeve. Refer to figures in p.
  • Page 541 7A-18 MANUAL TRANSMISSION (4-SPEED) Synchronizer ring Three types of synchronizer ring are used. Be sure to install them in place. 1. Low gear synchronizer ring 2. 2nd gear synchronizer ring 3. 3rd & top gear synchronizer ring Be sure that three keys mounted on hub fit snugly into the slots pro- vided in ring.
  • Page 542 MANUAL TRANSMISSION (4-SPEED) 7A-19 Low gear thrust washer ball After installing low gear bush, bearing and low gear, install ball on counter shaft. Counter shaft bearing To drive bearing into the counter shaft, use special tool. Special Tool (A): 09913-80112 Counter shaft nut Fit special tool on low speed synchronizer sleeve and fix it securely with a vice as shown below.
  • Page 543 7A-20 MANUAL TRANSMISSION (4-SPEED) In order to lock countershaft nut firmly, caulk nut with a chisel or the like as its part over the groove in countershaft, as shown below. NOTE: The nut once used should never be used again. 1.
  • Page 544 MANUAL TRANSMISSION (4-SPEED) 7A-21 Insert interlock steel balls through shaft hole. Through this hole, in- sert one ball between each of 2 adjacent shafts. Use interlock steel balls with an outside diameter of 9.5 mm (0.374 in. ). NOTICE: Be sure to put in pin for preventing two shafts from getting shifted at the same time.
  • Page 545 7A-22 MANUAL TRANSMISSION (4-SPEED) Reverse gear shifter lever When installing reverse gear shifter lever, adjust dimension “a” as illustrated below to 5 mm (0.197 in.) with gear shifter lever bolt (1). This is necessary to keep the clearance between lever and second gear on input shaft to more than 2 mm (0.078 in.) when shifting gear into reverse.
  • Page 546 MANUAL TRANSMISSION (4-SPEED) 7A-23 Differential side bearing Press-fit differential side bearing with a hydraulic press using spe- cial tool. Direct the seal side (1) of the bearing (iron plate side) in- ward (transmission oil side). Special Tool (A): 09913-75810 Differential case bolts Special bolts are used for the differential case because of the high torsional load.
  • Page 547 7A-24 MANUAL TRANSMISSION (4-SPEED) Reverse gear shaft pin Do not forget to install reverse gear shaft pin. After installation, ap- ply grease to the hole into which pin has been inserted to prevent the pin from coming out when combining upper and lower cases. Do not install reverse idle gear in the wrong direction.
  • Page 548 MANUAL TRANSMISSION (4-SPEED) 7A-25 [Input shaft bearing retainer] Bear in mind the following points when installing input shaft bearing retainer. Apply grease to oil seal lip. Lithium Grease : SUZUKI SUPER GREASE A (99000-25010) Install O-ring (1) in the groove of retainer and then apply sealant to a part of the retainer that is lined up with the joint of upper and lower transmission cases.
  • Page 549 7A-26 MANUAL TRANSMISSION (4-SPEED) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS SUZUKI SUPER GREASE A Oil seal lips (99000-25010) Gear shift control lever Lithium grease Gear shift control shaft bushes SUZUKI SUPER GREASE I Input shaft spline and front end (99000-25210) Oil drain plug Gear shift shaft bolt...
  • Page 550 MANUAL TRANSMISSION 7A1-1 SECTION 7A1 MANUAL TRANSMISSION (5-SPEED) CONTENTS GENERAL DESCRIPTION ... 7A1- 2 Sub Assembly Service ... . . 7A1-15 Right case .

  • Page 551: General Description

    7A1-2 MANUAL TRANSMISSION GENERAL DESCRIPTION The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shafts – input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
  • Page 552 MANUAL TRANSMISSION 7A1-3 1. Input shaft 17. Washer 32. Low speed synchronizer key 2. Oil seal 33. Circlip 18. 5th synchronizer spring 3. Input shaft right bearing 19. 5th speed sleeve & hub 34. 2nd gear synchronizer ring 4. Input shaft 3rd gear 20.
  • Page 553 7A1-4 MANUAL TRANSMISSION GEAR SHIFT MECHANISM Movement of gear shift control lever is transmitted to gear shift shaft through gear shift control shaft, and gear shift & select shaft through gear shift arm and gear shift yoke, and then gear shift & select lever to each gear shift yoke, shaft and fork or arm.
  • Page 554 MANUAL TRANSMISSION 7A1-5 1) When gear is shifted to 5th speed, 5th & reverse gear shift cam 4. Gear shift guide (2) turns clockwise with gear shift & select shaft (1) and it is case plate 5. REV select spring pushed up by cam guide return spring (3) to the position where (Compressed) interlock guide bolt (7) prevents the cam from being shifted to re-...

  • Page 555: Diagnosis

    7A1-6 MANUAL TRANSMISSION DIAGNOSIS Condition Possible Cause Correction Gears slipping out of Worn shift fork shaft Replace. mesh Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating springs Replace. Worn bearings on input shaft or countershaft Replace. Worn chamfered tooth on sleeve and gear Replace sleeve and gear.

  • Page 556: On-Vehicle Service

    MANUAL TRANSMISSION 7A1-7 ON-VEHICLE SERVICE OIL CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it. 3) Drain old oil and torque drain plug (2) as specified below. Apply sealant to thread of drain plug before installation.

  • Page 557: Differential Side Oil Seal

    7A1-8 MANUAL TRANSMISSION DIFFERENTIAL SIDE OIL SEAL REPLACEMENT 1) Lift up vehicle and drain transmission oil. 2) Remove wheel, and disconnect tie-rod end from knuckle refer- ring to SECTION 3D. 3) Remove stabilizer referring to SECTION 3D. 4) Remove ball stud bolt and then separate suspension arm from knuckle.

  • Page 558: Gear Shift Control

    MANUAL TRANSMISSION 7A1-9 8) Insert drive shaft joint to differential gear. Refer to Section 4. CAUTION: Be careful not to scratch oil seal lip with drive shaft joint while inserting. Make sure to insert drive shaft joint fully and seat its snap ring as it was.

  • Page 559: Unit Repair Overhaul

    7A1-10 MANUAL TRANSMISSION UNIT REPAIR OVERHAUL DISMOUNTING/REMOUNTING Dismount or mount transmission with engine, referring to SEC- TION 6A “ENGINE MECHANICAL”, and separate or combine transmission and engine. DISASSEMBLING UNIT FIFTH GEARS 1) Remove 8 bolts and take off transmission side cover. 2) Using special tool, remove circlip (1) and then hub plate (2).

  • Page 560: Gear Shifter, Main Shaft And Countershaft

    MANUAL TRANSMISSION 7A1-11 7) Remove counter shaft nut (1) as follows: a. Shift low speed gear shift shaft (2) to 1st gear position and high speed gear shift shaft (3) to 3rd gear position. b. Loosen nut with above double engagement. NOTE: Do not reuse counter shaft nut.
  • Page 561 7A1-12 MANUAL TRANSMISSION 3) Remove gear shift fork shaft bolt (1) with washer, then take out locating spring and steel ball. 4) Remove 4 bolts from gear shift guide case (2), and then re- move wiring harness clamp bracket and guide case. 5) Remove gear shift interlock bolt (3) with washer.

  • Page 562: Right Case

    MANUAL TRANSMISSION 7A1-13 12) Remove gear shift yoke (1). 13) Pull out reverse gear shaft (2) with washer, then take off re- verse idler gear (3). 14) Pull out 5th & REV gear shift guide shaft (4) together with 5th &...
  • Page 563 7A1-14 MANUAL TRANSMISSION 3) Remove input shaft oil seal (1) by using special tools (combina- tion of bearing remover and sliding shaft). Special Tools (A): 09930-30102 (B): 09923-74510 4) Also pull out countershaft R bearing cup (2) by using bearing re- mover 09941-64511 with sliding shaft 09930-30102.

  • Page 564: Sub Assembly Service

    MANUAL TRANSMISSION 7A1-15 SUB ASSEMBLY SERVICE RIGHT CASE 1) Install input shaft oil seal (1) facing its spring side upward. Use special tool and hammer for installation and apply grease to oil seal lip. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09951-76010 2) Install countershaft R bearing cup (2) by using special tools and...

  • Page 565: Left Case

    7A1-16 MANUAL TRANSMISSION 6) Insert gear shift arm (1) in gear shift shaft (2), then fasten them with bolt applied with thread lock cement. Tightening Torque (c): 34 N m (3.4 kg-m, 24.5 lb-ft) “A”: Thread lock 1322, 99000-32110 LEFT CASE 1) If input oil gutter has been removed, install it with bolt applied with thread lock cement.
  • Page 566 MANUAL TRANSMISSION 7A1-17 2) Drive out 5th gear spacer (1), L bearing (2) and 4th gear (3) all at once by using puller (4) and press. CAUTION: To avoid gear tooth from being damaged, support it at flat side of bearing puller. Stop press work in the middle way and take out 5th gear bush to prevent it from being compressed and then continue to remove bearing with gear.
  • Page 567 7A1-18 MANUAL TRANSMISSION 4) Fit high speed synchronizer sleeve (1) to hub (2), insert 3 keys 1. Sleeve 2. Hub 3. Key 4. High speed synchronizer spring (3) in it and then set springs (4) as illustrated left. NOTE: No specific direction is assigned to high speed synchro- nizer sleeve or each key but it is assigned as assembly.

  • Page 568: Countershaft Assembly

    MANUAL TRANSMISSION 7A1-19 9) Press-fit L bearing (1) by using special tool and hammer. Special Tool (C): 09925-98221 10) Using the same special tool, drive in 5th gear spacer. CAUTION: To prevent 5th gear spacer from being distorted be- cause of excessive compression, do not press-fit it with L bearing at once.
  • Page 569 7A1-20 MANUAL TRANSMISSION 5) Apply puller (1) to 1st gear (2) and drive out low speed synchro- nizer sleeve & hub assembly (3) with gear by using press. 6) Disassemble synchronizer sleeve & hub assembly (3). 7) Take out needle bearing from shaft. 8) Remove R bearing cone (1) by using puller (2), metal stick (3) and press.
  • Page 570 MANUAL TRANSMISSION 7A1-21 5) Install R bearing cone (1) by using special tool and hammer. Special Tool (A): 09923-78210 6) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring (1). NOTE: Key slot width of 1st synchronizer ring is smaller than that of 2nd synchronizer ring (2).

  • Page 571: Gear Shifter

    7A1-22 MANUAL TRANSMISSION 9) Press-fit 3rd gear (1) and spacer (2) by using special tool and press. NOTE: It is recommended to press-fit spacer and 3rd gear first, and then 4th gear later separately so that countershaft will not be compressed excessively. Special Tools (A): 09923-78210 3.
  • Page 572 MANUAL TRANSMISSION 7A1-23 High Speed and Low Speed Gear Shift Shafts Inspection 1) Using feeler gauge, check clearance between fork and sleeve and replace those parts if it exceeds limit of 1.0 mm (0.039 in.) NOTE: For correct judgement of parts replacement, carefully in- spect contact portion of fork and sleeve.

  • Page 573: Differential Assembly

    7A1-24 MANUAL TRANSMISSION DIFFERENTIAL ASSEMBLY Disassembly 1) Using special tool, remove right bearing (1). Special Tools (A): 09913-65810 (B): 09925-88210 2) Remove speedometer drive gear (2). 3) Remove left bearing using puller while supporting its center shaft as described above. 4) Support differential case with soft jawed vise and remove 8 final gear bolts then take out final gear.
  • Page 574 MANUAL TRANSMISSION 7A1-25 Right side Right side 1. Differential gear Using similar procedure to the above, set dial gauge tip to gear shoulder. Move gear up and down by hand and read dial gauge. 2) If thrust play is out of specification, select suitable thrust washer from among following available size, install it and check again that specified gear play is obtained.

  • Page 575: Assembling Unit

    7A1-26 MANUAL TRANSMISSION ASSEMBLING UNIT DIFFERENTIAL TO LEFT CASE 1) Install differential assembly into right case (1). 2) Insert speedometer driven gear (2) applied with oil to its O-ring, then tighten it with bolt. CAUTION: While inserting case assembly into transmission, turn final gear by hand slightly so that gear can mesh easily.
  • Page 576 MANUAL TRANSMISSION 7A1-27 5) Install reverse gear shift lever (2). Apply thread lock to bolts. Reverse gear shift arm (5) has to be joined with reverse gear shift lever (2) at the same time. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 6) Make reverse idler gear (1) with reverse gear shift lever (2), in- sert reverse gear shaft (3) into case (4) through idler gear (1) and then align A in shaft with B in case.
  • Page 577 7A1-28 MANUAL TRANSMISSION 11) Check locating spring for deterioration and replace with new one as necessary. Service Locating spring free length Standard Limit 5th & REV 33.8 mm 32.7 mm (Pink painted) (1.331 in.) (1.287 in.) High speed, Low speed 33.6 mm 32.5 mm (Green painted)

  • Page 578: Fifth Gears

    MANUAL TRANSMISSION 7A1-29 FIFTH GEARS 1. Input shaft 1) To seat countershaft L bearing cup (2) to bearing cone, tap cup by using special tool and plastic hammer. Special Tool (A): 09913-84510 2) Put a shim on bearing cup provisionally, place straight edge over it and compress it by hand through straight edge, and then mea- sure “a”...
  • Page 579 7A1-30 MANUAL TRANSMISSION 5) Assemble 5th speed synchronizer sleeve (1) and hub (2) with keys (3) and springs (4). NOTE: Short side C in keys, long boss D in hub and chamfered spline F in sleeve should face inward (5th gear side). A = B C: Short side (Inward) D: Long boss (Inward)
  • Page 580 MANUAL TRANSMISSION 7A1-31 10) Caulk nut at C with caulking tool and hammer. 11) Install synchronizer ring (1). 12) Fit 5th gear shift fork (2) to sleeve & hub assembly (3) and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.
  • Page 581 7A1-32 MANUAL TRANSMISSION GEAR SHIFT & SELECT SHAFT ASSEMBLY 1) If gear shift guide case (1) has been disassembled or replaced, tighten bolts as specified below. Also check breather (2) hole for clog. Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) (b): 23 N m (2.3 kg-m, 17.0 lb-ft) 2) Clean mating surface of guide case and coat it with sealant...

  • Page 582: Required Service Materials

    MANUAL TRANSMISSION 7A1-33 11) Check input shaft for rotation in each gear position. 12) Also confirm function of back up light switch in reverse position by using ohmmeter. REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS Oil seal lips SUZUKI SUPER GREASE A Lithium grease Gear shift control lever (99000-25010)

  • Page 583: Special Tools

    7A1-34 MANUAL TRANSMISSION SPECIAL TOOLS 09900-06107 Snap ring pliers 09900-20606 09900-20701 09913-65810 (Opening type) Dial gauge Magnetic stand Bearing puller 09913-75810 09913-75520 09913-80112 09913-84510 Bearing installer Bearing installer Bearing installer Bearing installer 09916-46010 09917-58010 09922-85811 09923-73210 Valve guide remover Bearing remover Spring pin remover 4.5 mm Bearing remover 09923-74510...
  • Page 584 MANUAL TRANSMISSION 7A1-35 09925-58210 09925-68210 09925-78210 09925-88210 Oil seal installer Bearing outer race installer Spring pin remover 6 mm Bearing puller attachment 09925-98221 09930-30102 09940-53111 09941-64511 Bearing installer Sliding shaft Bearing installer Bearing remover 09951-16060 09951-76010 Bush remover Bearing installer...
  • Page 585 CLUTCH 7C-1 SECTION 7C CLUTCH CONTENTS Clutch Cover, Clutch Disc and GENERAL DESCRIPTION ....7C- 2 Flywheel ......7C- 7 DIAGNOSIS .

  • Page 586: General Description

    7C-2 CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm-spring clutch of a dry single Depressing the clutch pedal causes the release bear- disc type. The diaphragm spring is of a tapering-finger ing to advance and pushes on the tips of the tapered type, which is a solid ring in the outer diameter part, fingers of the diaphragm spring.
  • Page 587 CLUTCH 7C-3 [4-speed Manual Transmission] 1. Clutch cover 2. Pressure plate 3. Diaphragm spring 4. Release bearing 5. Release shaft Apply lithium grease 99000-25010 to pin for release bearing 6. Transmission lower case 7. Clutch disc 8. Torsional spring 9. Input shaft bearing 10.
  • Page 588 7C-4 CLUTCH DIAGNOSIS Condition Possible Cause Correction Slipping Improper clutch pedal free travel Adjust free travel. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel surface Replace disc, clutch cover or flywheel. Weakened diaphragm spring Replace clutch cover.

  • Page 589: On-Vehicle Service Maintenance Service

    CLUTCH 7C-5 ON-VEHICLE SERVICE MAINTENANCE SERVICE CLUTCH PEDAL CLUTCH PEDAL HEIGHT Measure pedal height difference “a” using measure (3) and adjust clutch pedal (1) height so that it becomes almost same as brake pedal (2) height. Height difference “a”: 0 mm (0 in.) If clutch pedal height is not as specified above, adjust it by turning pedal stopper bolt (4).

  • Page 590: Clutch Cable

    7C-6 CLUTCH CLUTCH CABLE REMOVAL 1) Disconnect negative cable at battery. 2) Remove clutch cable joint nut (1). 3) Remove joint pin (2) from clutch release arm (3). 4) Remove 2 bolts at dash panel. INSPECTION Inspect clutch cable and replace it for any of the following condi- tions.

  • Page 591: Unit Repair Overhaul

    CLUTCH 7C-7 UNIT REPAIR OVERHAUL CLUTCH COVER, CLUTCH DISC AND FLYWHEEL [5-speed Manual Transmission] [4-speed Manual Transmission] 1. Clutch disc 7. Clutch release shaft No.1 bush. Apply lithium grease 99000-25210 to Apply lithium grease 99000-25010 to inside spline of input shaft 8.
  • Page 592 7C-8 CLUTCH 2) Pull out input shaft bearing (1) from flywheel (2) using special tool and wrench. Special Tool (B): 09917-58010 (For 5-speed transmission) (B): 09921-20200 (For 4-speed transmission) INSPECTION Input Shaft Bearing Check input shaft bearing (1) for smooth rotation and replace it if abnormality is found.
  • Page 593 CLUTCH 7C-9 INSTALLATION NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly. 1) Install flywheel (1) to crankshaft and tighten bolts (2) to specifi- cation. Special Tool (A): 09924-17810 Tightening Torque (a): 42 N m (4.2 kg-m, 30.5 lb-ft) 2) Using special tool, install a new input shaft bearing to flywheel...
  • Page 594 7C-10 CLUTCH 4) Slightly apply grease to input shaft (1), then joint transmission assembly with engine. “A”: Grease 99000-25010 “B”: Grease 99000-25210 NOTE: Turn crankshaft with wrench from front while inserting transmission input shaft to clutch disc until splines mesh.
  • Page 595 CLUTCH 7C-11 CLUTCH RELEASE SYSTEM [FOR 5-SPEED TRANSMISSION] REMOVAL 1) Remove release arm by loosening its bolt. 2) Take out release bearing by turning release shaft. 3) Unhook return spring (1) using pliers. 4) Drive out No.2 bush using special tool and hammer. Release shaft seal will also be pushed out.
  • Page 596 7C-12 CLUTCH INSPECTION Clutch release bearing Check clutch release bearing (1) for smooth rotation. If abnormality is found, replace it. CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage. Clutch release shaft Check clutch release shaft (1) and its pin for deflection or damage. If abnormality is found, replace it.
  • Page 597 CLUTCH 7C-13 5) Caulk seal (1) at A using caulking tool and hammer. A: Caulking 6) Hook return spring (1). 7) Apply grease to release bearing (2) inside and release shaft arm (3), then set bearing. “A”: Grease 99000-25010 8) Apply small amount of grease to input shaft spline (4) and front end as well.

  • Page 598: Required Service Materials

    7C-14 CLUTCH REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT Clutch cable hook and joint pin SUZUKI SUPER GREASE A Release shaft bushes and seal Release shaft bushes and seal. (99000-25010) Release shaft arm. Lithium grease SUZUKI SUPER GREASE I Input shaft spline front end. (99000-25210) SPECIAL TOOLS 09917-58010...
  • Page 599 BODY ELECTRICAL SYSTEM 8-1 SECTION 8 BODY ELECTRICAL SYSTEM CONTENTS GENERAL DESCRIPTION ..............8- 2 Cautions in Servicing .

  • Page 600: General Description

    8-2 BODY ELECTRICAL SYSTEM GENERAL DESCRIPTION The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery. The electrical system utilizes negative ground polarity. CAUTIONS IN SERVICING When performing works related to electric systems, observe fol- lowing cautions for the purpose of protection of electrical parts and prevention of a fire from occurrence.
  • Page 601 BODY ELECTRICAL SYSTEM 8-3 When installing the wiring harness, fix it with clamps so that no slack is left. When installing vehicle parts, be careful so that the wiring har- ness is not interfered with or caught by any other part. To avoid damage to the harness, protect its part which may con- tact against a part forming a sharp angle by winding tape or the like around it.

  • Page 602: Wire Color Symbols

    8-4 BODY ELECTRICAL SYSTEM When performing a work that produces a heat exceeding 80 C in the vicinity of the electrical parts, remove the heat sensitive electrical part(s) beforehand. Use care not to expose connectors and electrical parts to water which will be a cause of a trouble.

  • Page 603: Combination Meter

    BODY ELECTRICAL SYSTEM 8-5 COMBINATION METER NOTE: Terminal arrangement of coupler viewed from harness side. Coupler K Coupler L COUPLER K COUPLER L 1. To lighting switch 1. To alternator 2. Blank 2. To parking brake switch 3. To ground 3.

  • Page 604: Diagnosis

    8-6 BODY ELECTRICAL SYSTEM DIAGNOSIS HEADLIGHT Trouble Possible Cause Correction Headlights do not light up Bulb blown Replace bulb Headlight switch faulty Replace headlight switch HEAD R and L fuses blown Replace fuses to check for short Wiring or grounding faulty Repair circuit Only one headlight does Bulb blown...

  • Page 605: Back-Up Light

    BODY ELECTRICAL SYSTEM 8-7 BACK-UP LIGHT Trouble Possible Cause Correction Back-up lights do not light Bulb(s) blown Replace bulb (s) TURN BACK fuse blown Replace fuse to check for short Back-up light switch faulty Replace switch Wiring or grounding faulty Repair circuit Back-up lights stay on Back-up light switch faulty...

  • Page 606: Brake And Parking Brake Warning Light

    8-8 BODY ELECTRICAL SYSTEM BRAKE AND PARKING BRAKE WARNING LIGHT Trouble Possible Cause Correction Brake warning light does Bulb in combination meter blown Replace bulb not light up when fluid low IG-COIL fuse blown Replace fuse to check for short level Printed plate in combination meter Replace printed plate...

  • Page 607: On-Vehicle Service

    BODY ELECTRICAL SYSTEM 8-9 ON-VEHICLE SERVICE HEADLIGHT HEADLIGHT SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below. If check result is not as specified, replace. Lighting switch Terminal Switch Position...
  • Page 608 8-10 BODY ELECTRICAL SYSTEM BULB REPLACEMENT WARNING: To avoid danger of being burned, don’t touch when the bulb is hot. 1) Disconnect negative cable at battery. 2) Disconnect harness from bulb. 3) Remove socket cover (1) and bulb (2). 4) Replace bulb and assemble all removed parts. HEADLIGHT AIMING WITH SCREEN NOTE: Unless otherwise obligated by local regulations, adjust...

  • Page 609: Turn Signal And Hazard Warning Light

    BODY ELECTRICAL SYSTEM 8-11 TURN SIGNAL AND HAZARD WARNING LIGHT TURN SIGNAL LIGHT SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below. If check result is not as specified, replace. Terminal Turn Hazard...

  • Page 610: Ignition Switch

    8-12 BODY ELECTRICAL SYSTEM IGNITION SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect ignition main switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below. If check result is not as specified, replace. Terminal Position LOCK...

  • Page 611: Fuel Meter/Fuel Gauge Unit

    BODY ELECTRICAL SYSTEM 8-13 FUEL METER/FUEL GAUGE UNIT FUEL METER INSPECTION 1) Remove rear seat cushion. Refer to REAR SEAT in Section 9. 2) Disconnect Y/R lead wire coupler under the rear seat cushion. 3) Turning switch ON, and check that fuel meter indicates E. 4) Turn ignition switch OFF.

  • Page 612: Engine Coolant Temperature (Ect) Meter And Sensor Unit

    8-14 BODY ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) METER AND SENSOR UNIT ENGINE COOLANT TEMPERATURE (ECT) METER INSPECTION 1) Disconnect Y/W lead wire going to ECT sensor. 2) Turn ignition switch ON, and check that ECT meter indicates COOL. 3) Turn ignition switch OFF. 4) Ground Y/W lead wire through a 3.4 W test bulb (1) as illus- trated.

  • Page 613: Oil Pressure Warning Light

    BODY ELECTRICAL SYSTEM 8-15 OIL PRESSURE WARNING LIGHT OIL PRESSURE SWITCH INSPECTION 1) Disconnect oil pressure switch (1) lead wire. 2) Check for continuity between oil pressure switch terminal (2) and cylinder block (3) as shown. During Engine Running No continuity At Engine Stop Continuity If check result is not as specified, replace oil pressure switch (1).

  • Page 614: Wipers And Washers

    8-16 BODY ELECTRICAL SYSTEM WIPERS AND WASHERS COMPONENTS FRONT WIPER FRONT WASHER FRONT WIPER/WASHER SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position as shown below. If check result is not as specified, replace switch.
  • Page 615 BODY ELECTRICAL SYSTEM 8-17 INTERMITTENT WIPER RELAY CIRCUIT INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Turn the front wiper switch to INT position. 4) Connect battery positive terminal to terminal “N” and battery negative terminal to terminal “R”.
  • Page 616 8-18 BODY ELECTRICAL SYSTEM WASHER LINKED OPERATION INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Make sure that front wiper switch is at OFF position. 4) Connect battery positive terminal to terminal “N” and battery negative terminal to terminal “R”.

  • Page 617: Door Switch

    BODY ELECTRICAL SYSTEM 8-19 FRONT WASHER PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Remove washer tank fitting screws. 3) Disconnect pump lead wire and hoses. 4) Remove washer tank (1). 5) Remove pump (2) from tank. INSPECTION Connect battery (+) and (–) terminals to pump (+) and (–) terminals respectively to check pumping rate.
  • Page 618 BODY SERVICE 9-1 SECTION 9 BODY SERVICE CONTENTS FRONT AND REAR DOOR ............... . 9- 2 Front Door Glass and Window Regulator .
  • Page 619 9-2 BODY SERVICE FRONT AND REAR DOOR FRONT DOOR GLASS AND WINDOW REGULATOR 1. Door panel 10. Door inside handle 2. Door glass 11. Window regulator 3. Door outer weatherstrip Apply SUZUKI SUPER GREASE A 4. Door inner weatherstrip (99000-25010) to moving section. 5 Door sealing cover 12.
  • Page 620 BODY SERVICE 9-3 7) Remove glass bottom channel attaching screws (1). 8) Take out the door glass together with the bottom channel. 9) Detach the glass from the bottom channel. 10) Loosen door window regulator attaching screws (six places) and take out the regulator through the hole “A”. INSPECTION Check the window regulator gear for wear or damage.
  • Page 621 9-4 BODY SERVICE 2) When installing the glass to the bottom channel (1), coat the For 3-door model channel with soapy water to tap it with a plastic hammer. Glass-fitted position of the bottom channel is as shown. For 5-door model 3) When you feel hard to raise and lower the door glass, it is pos- sible that the glass is tilted toward the door sash.
  • Page 622 BODY SERVICE 9-5 5) After installing the door outer weather strip, securely fix its rear end with adhesive. 1. Front door outer weather strip rear end 6) Install the door window regulator handle (1) so that it has a 45 angle when the glass is fully closed, as illustrated below.
  • Page 623 9-6 BODY SERVICE REAR DOOR GLASS AND WINDOW REGULATOR REMOVAL 1) Remove inside handle bezel. 2) Remove door armrest. 1. Door panel 11. Window regulator 2. Door glass Apply SUZUKI SUPER 3. Door outer weatherstrip GREASE A (99000- 4. Door inner weatherstrip 25010) to moving sec- 5.
  • Page 624 BODY SERVICE 9-7 7) Remove door center sash (4) (by removing two screws (1) with the door glass lowered all the way down). 8) Remove partition glass (3). 2. Door glass 9) Putting the regulator arm roller (2) out of the bottom channel (3), take out the door glass (1) together with the bottom chan- nel.
  • Page 625 9-8 BODY SERVICE 2) When installing the glass (2) to the bottom channel (1), coat the channel with soapy water to tap it with a plastic hammer. Glass-fitted position of the bottom channel is as shown below. 3) To install the glass, lower the regulator arm so that the regulator arm roller (1) can go into the bottom channel (2).
  • Page 626 BODY SERVICE 9-9 DOOR LOCK Front door lock 1. Outside handle 2. Door lock key cylinder 3. Door inside handle 4. Door latch ass’y 5. Door latch striker 6. Door rear sash Rear door lock 1. Outside handle 2. Inside handle bezel 3.
  • Page 627 9-10 BODY SERVICE REMOVAL 1) Remove inside handle bezel. 2) Remove door armrest. 3) Remove window regulator handle. Pull off the snap with a cloth to remove the regulator handle. 4) Remove door trim. 5) Remove door sealing cover. 6) Remove front door rear sash. (Applicable to front door only) 7) Remove door inside handle and door latch ass’y.
  • Page 628 BODY SERVICE 9-11 2) Door lock inside handle Front Door Lock When fitting the door inside handle in position, move the inside handle (control link (2)) toward the arrows-pointed directions to adjust to 0 to 2 mm (0 to 0.08 in.) the clearance “B” between the inside opening lever (1) and the outside opening lever (or door lock opening lever pin) (3).
  • Page 629 9-12 BODY SERVICE Move the door latch striker (3) sideways to adjust to 0 mm the door surface-to-body surface difference with the door closed. 1. Body 2. Door 4. Front side In order to correctly obtain the door latch striker (1) position in the fore-and-aft direction, increase or decrease the number of spacers inserted between the body and the striker to adjust it.
  • Page 630 BODY SERVICE 9-13 2) Support the door panel using a jack with a piece of wood placed (2) between the jack and the panel. 3) Remove the door assembly by loosening the hinge mounting bolts. 1. Rags INSTALLATION Reverse the removal sequence to install the front door. When the weatherstrip is hardened, water leak may develop.
  • Page 631 9-14 BODY SERVICE REAR QUARTER WINDOW For 5-door model NOTE: If the weatherstrip is hardened, water leak may develop. In this case, renew the weatherstrip if possible. 1. Glass 2. Weatherstrip NOTE: After installing the glass, securely fix the weather strip up- per front end (A) with adhesive.
  • Page 632 BODY SERVICE 9-15 BACK DOOR 1. Back door window glass 2. Back door window weatherstrip 3. Back door panel 4. Back door opening weatherstrip 5. Back door trim 6. Back door sealing cover 7. Back door balancer 8. Back door lock cylinder 9.
  • Page 633 9-16 BODY SERVICE To adjust the door latch and the striker with each other in the door up-and-down direction, insert a proper number of shims below the bottom of the striker as illustrated. 1. Shim...
  • Page 634 BODY SERVICE 9-17 SEAT FRONT SEAT 1. Headrestraint assembly 8. Reclining knob 2. Front seat back 9. Front seat frame 3. Front seat cushion 10. Front seat assembly bolt 4. Front seat inside adjuster 11. Front seat adjuster bolt 5. Front seat outside adjuster 12.
  • Page 635 9-18 BODY SERVICE REAR SEAT [A]: Bench type [B]: Separate type 1. Rear seat back 2. Rear seat cushion 3. Right rear seat back 4. Left rear seat back 5. Knob 6. Rear seat back lock assembly 7. Rear seat back lock striker 8.
  • Page 636 BODY SERVICE 9-19 BODY DIMENSION m(M) DETAIL T(t) DETAIL V(v) DETAIL o(O) DETAIL MEASUREMENT MEASUREMENT MEASUREMENT LENGTH, MM (in.) NO. LENGTH, MM (in.) NO. LENGTH, MM (in.) POSITION POSITION POSITION M – m 804 (31.65) S – s 930 (36.61) T –...
  • Page 637 9-20 BODY SERVICE G DETAIL H DETAIL I DETAIL MEASUREMENT MEASUREMENT MEASUREMENT LENGTH, MM (in.) NO. LENGTH, MM (in.) NO. LENGTH, MM (in.) POSITION POSITION POSITION A – a 840 (33.07) D – F 666 (26.22) K – L 826 (32.52) A –...
  • Page 638 BODY SERVICE 9-21 Unit : mm SIDE MOLDING INSTALLATION 1) Bonding surfaces should be cleaned throughly. 2) Follow the above-illustrated bonding positions to install the side moldings. 3) If adequate adhesive force is unobtainable, use urethane adhesive. 1. Front fender molding 2.
  • Page 639 RESTRAINT SYSTEM 10-1 SECTION 10 RESTRAINT SYSTEM CAUTION: When fasteners are removed, always reinstall them at the same location from which they were re- moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
  • Page 640 10-2 RESTRAINT SYSTEM GENERAL DESCRIPTION SEAT BELT WITH ELR The seat belt with emergency locking retractor (ELR) is designed so that it locks immediately (to prevent the web- bing from being pulled out of the retractor any further) when any of the following items is detected as exceeding each set value;...
  • Page 641 RESTRAINT SYSTEM 10-3 FRONT SEAT BELT WARNING: Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. REMOVAL Remove front seat belts. 1. Upper anchor 2. Lower anchor 3. Retractor assembly 4.
  • Page 642 10-4 RESTRAINT SYSTEM INSPECTION Seat belts and attaching parts can affect the vital components and systems of a vehicle. Therefore, they should be inspected carefully and replaced with genuine parts only. D Seat belt Its webbing or strap should be free from damage. D Retractor assembly It should lock webbing when pulled quickly.
  • Page 643 RESTRAINT SYSTEM 10-5 REAR SEAT BELT WARNING: Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. REMOVAL Remove rear seat belts. 1. Anchor bolt 2. Spring washer 3. Setting washer 4.
  • Page 644 Prepared by Overseas Service Department 1st Ed. October, 1999 Printing:...

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