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Please see this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special awareness of the messages highlighted by
Indicates a possible hazard which could result in death or injury.
Indicates a possible hazard that may result in vehicle damage.
Indicates special information to produce maintenance easier or instructions clearer.
This service manual was created for authorized Suzuki dealers and qualified service mechanics only.
properly perform the skills described on this manual.
authorized SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under
vice on or at the air bag system components or wiring. Please observe all WARNINGS and Ser-
on or round the air bag system components or wiring. Failure to check out WARNINGS could bring about
unintentional activation in the system or could render the machine inoperative. Either of such two
conditions may bring about severe injury.
If air bag system and another vehicle system both need repair, Suzuki recommends that the oxygen
bag system be repaired first, to aid avoid unintended air bag system activation.
Do not get a new steering wheel, instrument panel and other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and result in injury.
If the automobile will be encountered with temperatures over 93 C 200 F, by way of example, within a paint baking
process, remove air bag system components, that is certainly air bag or inflator modules, SDM and/or
seat belt with pretensioner, beforehand to stop component damage or unintended activation.
Suzuki sq416; suzuki sq420 119 pages
Either of the two conditions may end in severe injury. If mid-air bag system and another vehicle system both need repair, Suzuki recommends that mid-air bag system be repaired first, to aid avoid unintended air bag system activation.
Strict observance on the so specified items will enable anyone to obtain the full performance with the vehicle. When replacing parts or servicing by disassembling, it truly is recommended make use of SUZUKI genuine parts, tools and service materials lubricant, sealants, etc. as specified by each description.
TABLE OF CONTENTS General Information GENERAL INFORMATION Maintenance and Lubrication Heater and Ventilation HEATING AND AIR CONDITIONING Air Conditioning Optional Steering, Suspension, Wheels and Tires Front Wheel Alignment Steering Gear Box Manual Type and Linkage Power Steering P/S System if equipped STEERING, SUSPENSION, WHEELS AND TIRES Steering Wheel and
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS How to Use This 0A-2 Identification 0A-17 0A-3 Body 0A-17 Engine Identification 0A-17 Precaution for Vehicles Equipped using a Transmission Identification 0A-17 Supplemental Restraint Air Bag System.0A-3 0A-3 Warning, Caution and Information Servicing and
0A-2 GENERAL INFORMATION How to Use This Manual 1 There is usually a Table of Contents about the third page on this manual, whereby you can certainly find the section that provides the information you may need. Also, there is usually a CONTENTS on the 1st page of the section, the place that the main pieces of that section are listed.
If air bag system and another vehicle system both need repair, SUZUKI recommends that the oxygen bag sys- tem be repaired first, to help you avoid unintended air bag system activation.
0A-4 GENERAL INFORMATION Servicing and handling WARNING: Many of service procedures require disconnection of Air Bag fuse and all sorts of air bag inflator modules from initia- tor circuit in order to avoid an accidental deployment. Driver and Passenger Air Bag Inflator Modules For handling and storage of an live air bag inflator module, decide on a place in which the ambient temperature below 65 C 150 F, without mugginess and clear of electric noise.
GENERAL INFORMATION 0A-5 WARNING: During service procedures, take care when getting through a Sensing and Diagnostic Module SDM. Never strike or jar the SDM. Never power up the environment bag system if your SDM will not be rigidly attached to the automobile. All SDM and mounting bracket fasteners should be carefully torqued and also the arrow need to be pointing toward the front with the vehicle to make sure proper operation with the air bag system.
0A-6 GENERAL INFORMATION CAUTION: Even if your accident was light enough not to ever cause air bags to activate, you'll want to inspect sys- tem parts and other connected parts as outlined by instructions under Repair and Inspection Required after an Accident in Section 10B.
GENERAL INFORMATION 0A-7 General Precautions The WARNING and CAUTION below describe some general precautions that you can observe when servic- ing a car or truck. These general precautions connect with many from the service procedures described in this particular manual, and they're going to not necessarily be repeated with each procedure this agreement they apply. WARNING:
0A-8 GENERAL INFORMATION When detaching the battery, you'll want to disconnect the negative cable first so the positive cable. When reconnecting the car battery, connect the positive cable first and so the negative cable, and replace the terminal cover.
GENERAL INFORMATION 0A-9 When disconnecting vacuum hoses, attach a tag describing the appropriate installation positions so how the hoses might be reinstalled correctly. After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the computer for leaks.
0A-10 GENERAL INFORMATION Precautions For Catalytic Converter For vehicles furnished with a catalytic converter, just use unleaded gasoline and become careful never to let a substantial amount of unburned gasoline enter in the converter or it might be damaged. Conduct a spark jump test as long as necessary, help it become as short as it can be, and don't open the throttle.
GENERAL INFORMATION 0A-11 When connecting connectors, also hold connectors and push them together until they lock securely a click is heard. When installing the wiring harness, correct it with clamps making sure that no slack is left. When installing vehicle parts, be aware so which the wir- ing harness isn't interfered with or caught by any part.
0A-12 GENERAL INFORMATION Never connect any tester voltmeter, ohmmeter, or what- ever to electronic control unit when its coupler is dis- connected. Attempt to practice it may cause destruction of it. Never connect an ohmmeter to electronic control unit featuring its coupler linked with it.
GENERAL INFORMATION 0A-13 Electrical Circuit Inspection Procedure While there are lots of electrical circuit inspection methods, described here is usually a general approach to check its open and short circuit upon an ohmmeter as well as a voltmeter. Open circuit check Possible causes with the open circuit are highlighted below. As the cause is incorporated in the connector or terminal many times, they need to become checked particularly carefully.
0A-14 GENERAL INFORMATION CONTINUITY CHECK 1 Measure resistance between connector terminals at both ends on the circuit being checked between A-1 and C-1 inside the figure. If no continuity is indicated infinity or older limit, that means how the circuit is open between terminals A-1 and C-1. 2 Disconnect the connector included inside circuit connector-B inside figure and measure resistance between terminals A-1 and B-1.
GENERAL INFORMATION 0A-15 Short circuit check wire harness to ground 1 Disconnect negative cable from battery. 2 Disconnect connectors at both ends from the circuit for being checked. NOTE: If the circuit to become checked is attached to other parts 1, disconnect all connectors of people parts.
0A-16 GENERAL INFORMATION Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to be sure good contact tension when using the corresponding mating terminal. If contact tension will not be enough, reform it to improve contact tension or replace. 1.
GENERAL INFORMATION 0A-17 Identification Information Body Number The vehicle body number is punched about the chassis from the tire housing around the right rear side. 1. Right rear tire Engine Identification Number The number is punched within the cylinder block. M 13- Serial number Engine
0A-18 GENERAL INFORMATION Warning, Caution and Information Labels The figure below shows main labels and others that are linked to vehicle component parts. When servicing and handling parts, talk about WARNINGCAUTION instructions printed on labels. If any WARNINGCAUTION label is located stained or damaged, clean or put it back as necessary. NOTE: Air bag CAUTIONWARNING labels are attached on the auto equipped with air bag system only.
GENERAL INFORMATION 0A-19 Vehicle Lifting Points WARNING: Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change according to what part to become removed. Before lifting up the auto, check to become sure that end of hoist arm just isn't in contact with brake pipe, fuel pipe, bracket or other part.
0A-20 GENERAL INFORMATION When Using Floor Jack WARNING: If the vehicle to get jacked up only at top or back, make sure to block the wheels on ground in order to make sure safety. After the car is jacked up, make sure you support it on stands.
GENERAL INFORMATION 0A-21 Abbreviations May Be Used In This Manual Abbreviations Anti-lock Brake System EBCM Electronic Brake Control Module, ATDC After Top Dead Center ABS Control Module American Petroleum Institute Engine Control Module Automatic Transmission Fluid ECT Sensor Engine Coolant Temperature Automatic Locking Retractor Sensor Water Temp.
0A-22 GENERAL INFORMATION Left Hand Throttle Body Fuel Injection LSPV Load Sensing Proportioning Valve Single-Point Fuel Injection, SPI Torque Converter Clutch MAF Sensor Mass Air Flow Sensor Transmission Control Module Air Flow Sensor, AFS, Air Flow A/T Controller, A/T Control Mod- Meter, AFM MAP Sensor Manifold Absolute
GENERAL INFORMATION 0A-23 SYMBOLS SYMBOL DEFINITION SYMBOL DEFINITION Tightening torque Apply SUZUKI BOND NO. 1216 99000-31160 Apply oil engine, transmission, trans- Apply SILICONE SEALANT fer, differential 99000-31120 Apply fluid brake, power steering or Apply SEALING COMPOUND 366E automatic transmission fluid
0A-24 GENERAL INFORMATION Fasteners Information Metric Fasteners Most from the fasteners used by this vehicle are metric fasteners. When replacing any fasteners, it can be most impor- tant that replacement fasteners be the right diameter, thread pitch and strength. Fastener Strength Identification Most commonly used metric fastener strength property is 4T, 6.8, 7T, 8.8 and radial line with all the class identification embossed about the head of each and every bolt.
GENERAL INFORMATION 0A-25 Tightening torque chart Thread Diameter Nominal Diameter mm An same as 4T strength N m fastener kg-m 0.15 0.30 0.55 10.5 lb-ft 21.0 32.5 47.0 76.0 116.0 An equal of 6.8 strength N m fastener without flange kg-m 0.24 0.47 0.84 12.5 19.3 lb-ft 14.5 30.5 58.0 90.5 139.5
Service on and throughout the air bag system components or wiring should be performed only by an accredited SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section so that you can confirm if you are performing ser- vice on or at the air bag system components or wiring.
0B-2 MAINTENANCE AND LUBRICATION Maintenance Schedule Maintenance Schedule Under Normal Driving Conditions NOTE: This interval needs to be judged by odometer reading or months, whichever comes first. This table includes service as scheduled approximately 90, 000 km 54, 000 miles mileage. Beyond 90, 000 km 54, 000 miles, perform the same services at a similar intervals respectively.
MAINTENANCE AND LUBRICATION 0B-3 Km x 1, 000 Interval Miles x 1, 000 Months CHASSIS AND BODY Clutch pedal height and travel Brake discs and pads thickness, wear, damage Brake drums and shoes wear, damage Brake hoses and pipes leakage, damage, clamp
0B-4 MAINTENANCE AND LUBRICATION Maintenance Recommended Under Severe Driving Conditions If your vehicle is usually used underneath the conditions corresponding to any severe condition code given below, it can be recommended that applicable maintenance operation be performed on the particular interval as shown inside fol- lowing table.
MAINTENANCE AND LUBRICATION 0B-5 Maintenance Service Engine Drive Belt WARNING: All inspection and replacement are for being performed with ENGINE NOT RUNNING. WATER PUMP AND GENERATOR DRIVE BELT INSPEC- TION 1 Disconnect negative cable at battery. 2 Inspect belt for cracks, cuts, deformation, wear and cleanli- ness.
0B-6 MAINTENANCE AND LUBRICATION 3 Check belt for tension. Power steering pump and/or A/C compressor drive belt tension a : 6 9 mm 0.24 0.35 in. deflection under 100 N 10 kg, 22 lb pressure. 4 If belt tension may be out of above specification, adjust it making reference to Compressor Drive
MAINTENANCE AND LUBRICATION 0B-7 1 Drain engine oil by removing drain plug. 2 After draining oil, wipe drain plug clean. Reinstall drain plug, and tighten it securely as specified below. Tightening torque a: 50 N m 5.0 kg-m, 36.5 lb-ft 3 Loosen oil filter by employing oil filter wrench special tool.
0B-8 MAINTENANCE AND LUBRICATION 6 Replenish oil until oil level is dropped at FULL level mark on dipstick. oil pan and oil filter capacity. The filler inlet is with the top on the cylinder head cover. It is recommended to make use of engine oil of SE, SF, SG, SH, SJ or SL grade.
MAINTENANCE AND LUBRICATION 0B-9 When doing periodic maintenance, or the auto is raised for other service, check exhaust system as follows: Check rubber mountings for damage, deterioration, and away from position. Check exhaust system for leakage, loose connections, dents and damages.
0B-10 MAINTENANCE AND LUBRICATION REPLACEMENT Replace home air cleaner filter with new one in line with steps 1, 2 and 5, 6 of inspection procedure. Fuel Lines and Connections INSPECTION 1 Visually inspect fuel lines and connections for evidence fuel leakage, hose cracking and damage. Make sure all clamps feel secure.
MAINTENANCE AND LUBRICATION 0B-11 PCV Positive Crankcase Ventilation Valve INSPECTION Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog. Refer to PCV System of Section 6E for PCV valve checking procedure. Fuel Evaporative Emission Control System INSPECTION 1 Visually inspect hoses for cracks, damage, or
0B-12 MAINTENANCE AND LUBRICATION Brake Drums and Shoes INSPECTION 1 Remove wheel and brake drum. 2 Check rear brake drums and brake linings for excessive wear and damage, while wheels and drums are removed. At the identical time, check wheel cylinders for leaks. Replace these parts as necessary.
MAINTENANCE AND LUBRICATION 0B-13 Parking Brake Lever and Cable INSPECTION 1 Inspect brake cable for damage and smooth movement. Replace cable if it really is in deteriorated condition. 2 Check tooth tip of every notch for damage or wear. If any damage or wear is available, replace parking lever.
0B-14 MAINTENANCE AND LUBRICATION 3 Rotate tires. For details, make reference to Tire Rotation in Section 3F. WHEEL DISCS INSPECTION Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition should be replaced. WHEEL BEARING INSPECTION 1 Check front wheel bearing for wear, damage, abnormal noise or rattles.
MAINTENANCE AND LUBRICATION 0B-15 REAR 1 Check shock absorber 1 for damage, deformation, oil leak- age and operation. 2 Check bushings for wear and damage. 3 Check coil spring 4, trailing arm 6 and lateral rod 5 for deformation and damage. 4 Check trailing arm 6 and lateral rod bushings and bump stopper 2 for wear, damage and deterioration.
0B-16 MAINTENANCE AND LUBRICATION Manual Transmission Oil INSPECTION 1 Inspect transmission case for proof oil leakage. Repair leaky point if any. 2 Make sure that vehicle is defined level for oil level check. 3 Remove level plug 2 of transmission. 4 Check oil level.
MAINTENANCE AND LUBRICATION 0B-17 FLUID COOLER HOSE CHANGE Replace inlet and outlet hoses of cooler hose in addition to their clamps. For replacement procedure, consider Oil Cooler Hoses in Section Transfer and Differential Oil INSPECTION 1 Check transfer case and differential for proof oil leak- age.
0B-18 MAINTENANCE AND LUBRICATION Steering System INSPECTION 1 Check leader for play and rattle, holding vehicle in hassle-free condition for the ground. Steering wheel play a : 0 30 mm 0 1.2 in. 2 Check universal joints of steering lower shaft 1 for rattle and damage.
MAINTENANCE AND LUBRICATION 0B-19 Power Steering P/S System if equipped INSPECTION 1 Visually check power steering system for fluid leakage and hose for damage and deterioration. Repair or replace defective parts, if any. 2 With engine stopped, check fluid level indicated on fluid tank or level gauge of tank cap, which really should be between MAX and MIN marks.
0B-20 MAINTENANCE AND LUBRICATION Final Inspection WARNING: When executing road tests, opt for a safe place where no man or no running vehicle is viewed so as to prevent any accident. SEATS Check that seat slides smoothly and locks securely at any position. Also make certain reclining mechanism of front seat back allows it for being locked at any angle.
MAINTENANCE AND LUBRICATION 0B-21 GEARSHIFT OR SELECTOR LEVER TRANSMISSION Check gear shift or selector lever for smooth shifting to everyone positions and for good performance of transmission in different position. With automatic transmission equipped vehicle, also make certain shift indicator indicates properly based on which position selector lever is moved to.
An equal to DEXRON - II, DEXRON - IIE or DEXRON - III Clutch linkage pivot points Water resistance chassis grease SUZUKI SUPER GREASE A 99000-25010 Steering knuckle seal Door hinges Engine oil or water proofing chassis grease Hood latch assembly Key lock
Service on and across the air bag system components or wiring has to be performed only by a certified SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under General Description in Section 10B so as to confirm if you are performing service on or at the air bag system components or wiring.
1A-2 HEATER AND VENTILATION General Description The heater, an inside and outside air selectable-type domestic hot water heater, is really constructed that it's possible to ensure an agreeable ventilation constantly by providing the ventilator air outlets with the center and either side right and left from the instrument panel, the new air outlet in a place near the feet of front passengers, plus the defroster air outlets at places, left and right, over the windshield glass.
HEATER AND VENTILATION 1A-3 Diagnosis Diagnosis Table Condition Possible Cause Correction Heater blower won t Blower fuse blown Replace fuse to evaluate for short. work regardless of whether its Blower resistor faulty Check resistor. switch is ON. Blower fan switch faulty Check blower fan switch. Blower motor faulty Replace motor.
1A-4 HEATER AND VENTILATION On Vehicle Service Heater Blower Motor REMOVAL 1 Disconnect negative cable at battery. 2 Disable air bag system, if equipped. Refer to Disabling Air Bag System in Section 10B. 3 Remove column hole cover. 4 Disconnect blower motor couplers. 5 Remove blower motor 1.
HEATER AND VENTILATION 1A-5 Heater Blower Resistor REMOVAL 1 Disconnect negative cable at battery. 2 Disable air bag system, if equipped. Refer to Disabling Air Bag System in Section 10B. 3 Disconnect resistor coupler. 4 Remove blower motor resistor 3 as shown figure. 1.
1A-6 HEATER AND VENTILATION 4 Disconnect blower fan switch coupler and A/C switch coupler if equipped 5 Disconnect each heater control cables. 6 Remove heater control lever assembly 1. 7 Remove blower fan switch screw 3. 8 Remove blower fan switch 2 as shown figure. 1.
HEATER AND VENTILATION 1A-7 Heater Blower Fan Switch INSPECTION Check blower fan switch for each and every terminal-to-terminal continuity. For the detail reference Wiring Circuit earlier on this section. TERMINAL POSITION Heater Unit/Boost Ventilation REMOVAL 1 Disconnect negative cable at battery. 2 If pre-loaded with air bag system disable air bag system.
1A-8 HEATER AND VENTILATION CAUTION: When the heater unit is disassembled and reassembled, locking force from the heater case lock may reduce. In such a case, tighten the heater case that has a tapping screw of M4 L16 1 as shown within the figure, or air may leak by reviewing the joint section.
Service on and about the air bag system components or wiring has to be performed only by an accredited SUZUKI dealer. Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section so as to confirm if you are performing ser- vice on or nearby the air bag system components or wiring.
AIR CONDITIONING OPTIONAL 1B-3 General Description Major Components and Location 1. Cooling unit 6. Suction hose 11. Foot air 16. Heater unit 2. Compressor 7. Receiverdryer outlet pipe 12. Defroster air 17. A/C evaporator 3. Condenser assembly 8. Condenser outlet pipe 13.
1B-4 AIR CONDITIONING OPTIONAL Refrigerant Circulation A: Liquid 1. Compressor 4. Receiverdryer 7. Evaporator B: Vapor 2. Magnet clutch 5. Dual pressure switch C: Superheated vapor 3. Condenser assembly 6. Expansion valve Refrigerant Type Whether the A/C in the auto being serviced uses HFC-134a R-134a or CFC-12 R-12 is indicated on compressor label 1.
AIR CONDITIONING OPTIONAL 1B-5 Diagnosis General Diagnosis Table Condition Possible Cause Correction Cool air won t come No refrigerant Perform recover, evacuation and charging. out A/C system won t Fuse blown Check fuses in leading and circuit fuse operative boxes, and appearance short circuit to ground. A/C switch faulty Check A/C switch.
1B-6 AIR CONDITIONING OPTIONAL Condition Possible Cause Correction Cool air won t come Insufficient or excessive control of Check power over refrigerant and system for out or insufficient refrigerant leaks. cooling A/C system Condenser clogged Check condenser. normal operative A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator thermistor.
AIR CONDITIONING OPTIONAL 1B-7 Abnormal Noise Diagnosis There are various varieties of noise, between those produced from the engine compartment to individuals from the passenger compartment, also from rumbling noises to whistling noises. Abnormal noise from compressor Condition Possible Cause Correction During compressor Inadequate clearance in piston area piston
1B-8 AIR CONDITIONING OPTIONAL Abnormal noise from crankshaft pulley Condition Possible Cause Correction A large rattling noise Loosen crankshaft pulley bolt. Retighten bolt. is heard at idle or sud- den acceleration. Abnormal noise from tension pulley Condition Possible Cause Correction Clattering noise is Worn or damaged bearing.
AIR CONDITIONING OPTIONAL 1B-9 Quick Checking of Refrigerant Charge The following procedure is usually used for quickly checking whether or not the A/C system features a proper power over refrigerant or otherwise not. Run engine at fast idle, and operate A/C at its maximum cooling ability to a few minutes.
1B-10 AIR CONDITIONING OPTIONAL Performance Diagnosis 1 Confirm that vehicle and environmental conditions are as fol- lows. Vehicle is not come across direct sun. Ambient temperature was in 15 35 C 59 95 F. 2 Make sure that underhand valve 1 and low pressure valve 2 of manifold gauge set 3 are firmly closed.
AIR CONDITIONING OPTIONAL 1B-11 8 Check if each pressure on low side and so on high side was in shaded range in the graph. If each gauge reading no longer has enough specified pressure, correct defective part talking about Performance Diagnosis Table with this section.
1B-12 AIR CONDITIONING OPTIONAL Performance diagnosis table NOTE: If ambient temperature is approximately 30 C 86 F, it really is possible to diagnose A/C system in detail speaking about Detail Diagnosis Table Ambient Temperature At 30 C 86 F under Performance
1B-14 AIR CONDITIONING OPTIONAL Condition MANIFOLD Possible Cause Correction kg/cm GAUGE Detail psi Both low and high pres- Insufficient refrigerant in Using leak detector, sure sides indicate low system. look for leaks and repair readings. Refrigerant leaking as necessary. Continuous air bub- Recharge refrigerant to some 0.05
AIR CONDITIONING OPTIONAL 1B-15 Compressor Drive Belt INSPECTION Check belt for wear and cracks, and replace as required. Check belt tension by measuring just how much it deflects when pushed at intermediate point between compressor pulley 1 and crankshaft pulley 2 with approximately 100 N 10 kg, 22 lb force.
1B-16 AIR CONDITIONING OPTIONAL Electronical Diagnosis Wiring Diagram A: 4WD model 4. Dual pressure switch 9. Thermal switch 14. Circuit fuse box B: 2WD model 5. 4WD controller 10. Ignition switch 15. Main fuse box 1. Blower fan motor 6. Condenser cooling fan motor relay 11.
AIR CONDITIONING OPTIONAL 1B-17 A/C System Inspection of ECM and ITS Cir- cuits ECM as well as circuits might be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM is not checked themselves. It is strictly prohibited for connecting voltmeter or ohmmeter to ECM with couplers disconnected from ECM.
1B-18 AIR CONDITIONING OPTIONAL 1. Blower fan motor 8. Compressor A: To A/C fuse 25A in leading fuse box 2. Dual pressure switch 9. Thermal switch B: To HEATER fuse 20A in circuit fuse box 3. A/C switch 10. Main relay C: To
1B-20 AIR CONDITIONING OPTIONAL Measurement Terminal Wire Circuit Normal value Condition ground Engine coolant temperature at 0.73 0.83 volts approximately 80 C 176 F with 315 355 engine running Engine coolant temperature at ECT sensor Ground to approximately 110 C 230 F with E19-14
AIR CONDITIONING OPTIONAL 1B-21 Refrigerant Recovery, Evacuating and Charging WARNING: Your eyes should not be encountered with refrigerant liquid. Any liquid HFC-134a R-134a escaping by mistake shows a temperature as little as approximately 6 C 21 F below freezing point. Should liquid HFC-134a R-134a enter into your eyes, it might result in a serious injury.
1B-22 AIR CONDITIONING OPTIONAL Recovery REFRIGERANT RECOVERY When evacuating A/C system, always recover refrigerant through the use of equipment 1 for refrigerant recovery and recycling. Discharging refrigerant HFC-134a R-134a into atmosphere would cause adverse effect to environments. NOTE: After recover refrigerant from system, how much removed compressor oil has to be measured for replen- ishing compressor oil.
AIR CONDITIONING OPTIONAL 1B-23 WHEN REPLACING COMPRESSOR Compressor oil is sealed in each new compressor with the amount essential for A/C system. Therefore, when working with a new compres- sor for replacement, drain oil from new compressor with the amount calculated as follows.
1B-24 AIR CONDITIONING OPTIONAL 1 Connect high charging hose 1 and low charging hose 2 of manifold gauge set 3 respectively as follows: High charging hose 1 High pressure charging valve 4 on discharge hose Low charging hose 2 Low pressure charging valve 5 on suction hose 2 Attach center charging hose 6 of manifold gauge set 3 to vacuum pump 7.
AIR CONDITIONING OPTIONAL 1B-25 Charging CAUTION: Always charge through low pressure side of A/C sys- tem at following the initial charging is performed on the high pressure side while using engine stopped. Never charge to questionable side of A/C system with engine running.
1B-26 AIR CONDITIONING OPTIONAL 2 Connect Low charging hose 1 and High charging hose 2 from the manifold gauge set 3 available. Thus open refriger- ant container valve 4 to purge the charging line. 3 Open the high-pressure side valve 5 and charge refrigerant to system.
AIR CONDITIONING OPTIONAL 1B-27 8 After the device has been faced with specified amount 500 600 g of refrigerant or when low pressure gauge 1 and underhand gauge 2 have indicated the subsequent specified amount, close low pressure side valve 3 on mani- fold gauge set 4.
1B-28 AIR CONDITIONING OPTIONAL Removing Manifold Gauge Set When A/C system is charged using a specified number of refrigerant, remove manifold gauge set as follows: 1 Close low pressure side valve of manifold gauge set. The high-pressure side valve is closed continuously during the process of charging. 2 Close refrigerant container valve.
AIR CONDITIONING OPTIONAL 1B-29 On-Vehicle Service Service Precaution When servicing ac system, note these instructions. Refrigerant line 1. Suction hose: 4. Condenser outlet pipe: Apply compressor oil to O-ring. Apply compressor oil to O-ring. 2. Discharge hose: 5. Expansion valve: Apply compressor oil to O-ring.
1B-30 AIR CONDITIONING OPTIONAL Handling refrigerant HFC-134a R-134a WARNING: Should refrigerant HFC-134a R-134a strike the eye area, consult a health care professional immediately. Do not use your hand to rub affected eyes. Instead, use quantities of fresh cold water to splash it over involved area to thus gradually raise its temperature across the freezing point.
AIR CONDITIONING OPTIONAL 1B-31 Condenser Assembly CAUTION: Be careful not to ever damage condenser fins. If condenser fin is bent, straighten it through the use of flat head screwdriver or two of pliers. INSPECTION Check these. Check clog of condenser fins. If, any clogs are normally found, condenser fins must be washed with water, and needs to be dried with compressed air.
1B-32 AIR CONDITIONING OPTIONAL ReceiverDryer REMOVAL 1 Recover refrigerant from A/C system by talking about Recov- ery with this section. NOTE: The quantity of removed compressor oil need to be mea- sured for replenishing compressor oil. 2 Remove front bumper talking about Front Bumper in Section 3 Disconnect receiverdryer outlet hose 1 and condenser outlet pipe 2 from receiverdryer 3.
AIR CONDITIONING OPTIONAL 1B-33 Condenser Cooling Fan Assembly ASSEMBLY CAUTION: Be careful never to damage condenser fins. If condenser fin is bent, straighten condenser fin by employing flat head screwdriver or set of pliers. INSPECTION 1 Check continuity between each two terminals concerning the con- denser cooling fan motor 1.
1B-34 AIR CONDITIONING OPTIONAL Cooling Unit Evaporator CAUTION: Be careful never to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten A/C evaporator fin through the use of flat head screwdriver or two of pliers. 1. A/C evaporator 3. Expansion valve 5.
AIR CONDITIONING OPTIONAL 1B-35 3 Drain engine coolant and disconnect heater hoses 1 from heater unit. 4 Disable air bag system talking about Disabling Air Bag Sys- tem in Section 10B if equipped. 5 Remove attaching bolt 1. 6 Disconnect suction hose 2 and receiverdryer outlet pipe 3 from expansion valve 4.
1B-36 AIR CONDITIONING OPTIONAL INSTALLATION Reverse removal procedure to setup cooling unit, after which noting this instructions. If A/C evaporator thermistor removed, its ought to be rein- stalled in original position. Install uniformly the packing 1 to installation hole.
AIR CONDITIONING OPTIONAL 1B-37 A/C Evaporator Thermistor A/C Evaporator Temperature Sensor INSPECTION Check resistance between terminals for A/C evaporator ther- mistor 1. If check email address details are as not specified, replace thermistor. A/C evaporator temperature sensor resistance Sensor Temperature C F Resistance k 0 32 6.4
1B-38 AIR CONDITIONING OPTIONAL INSTALLATION Reverse removal means of installation, and note the fol- lowing instructions. Replenish specified level of compressor oil to compressor suction side by discussing Replenishing Compressor Oil within this section. Evacuate and charge refrigerant by speaking about Evacuation and
AIR CONDITIONING OPTIONAL 1B-39 A/C Switch REMOVAL AND INSTALLATION Refer to Heater Control Lever Assembly in Section 1A. INSPECTION Press A/C switch button and view if there is continuity between terminals A and B. With battery voltage linked with terminal C also to terminal A, press A/C Switch button and blower fan switch the signal from
1B-40 AIR CONDITIONING OPTIONAL 4 Remove compressor drive belt 1 as follows. For vehicle with P/S Loosen tension pulley bolts 2. For vehicle without P/S Loosen tension pulley tightening nut 3 and adjusting bolt 4. A: Vehicle with P/S B: Vehicle without P/S 5 Disconnect thermal switch connector.
AIR CONDITIONING OPTIONAL 1B-41 Magnet Clutch 1. Thermal switch 6. Magnet clutch coil a. Front head bolt: Tighten bolt the first, followed by b. 2. Compressor body assembly 7. Compressor pulley b. Front head bolt: Tighten bolt economic crisis, and then suddenly b. 3.
1B-42 AIR CONDITIONING OPTIONAL INSPECTION Check clutch plate and clutch pulley for leaks of compressor oil. Check clutch bearing of compressor pulley for noise, wear and grease leakage. Measure resistance of magnet clutch coil 1 between mag- net clutch lead wire 2 and compressor body assembly.
AIR CONDITIONING OPTIONAL 1B-43 4 Remove circlip 1 using special tool. Special tool A: 09900-06107 5 Remove magnet clutch lead wire clamp screw, and discon- nect magnet clutch lead wire. 6 Remove magnet clutch pulley 1 by utilizing a puller 2. NOTE:
1B-44 AIR CONDITIONING OPTIONAL 3 Install magnet clutch. a Set magnet clutch squarely over clutch installation boss. b Place special tool onto clutch bearing. Ensure that edge rests only on inner race of bearing. Special tool A: 09991-06010 4 Install snap ring 1 using special tool. Special tool A: 09900-06107
AIR CONDITIONING OPTIONAL 1B-45 Lip Type Seal REMOVAL 1 Remove magnet clutch discussing Magnet Clutch on this section. 2 Remove front head products 10 pcs. 1. Front head 3 Remove front head 1 by pushing compressor shaft 2. NOTE: Be careful never to remove cylinder 3 from compressor body assembly 4.
1B-46 AIR CONDITIONING OPTIONAL 2 Coat special tool surface with compressor oil and it on compressor shaft 1. Special tool A: 09991-06040 3 Install O-ring 1 to compressor body assembly 2. 4 Apply compressor oil to lip type seal and O-ring 1. 5 Install front head 3 to compressor body assembly 2.
STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES 3-1 FRONT END ALIGNMENT.
3-2 STEERING, SUSPENSION, WHEELS AND TIRES General Diagnosis Since the problems in steering, suspension, wheels and tires involve several systems, they should all be consid- ered when diagnosing a complaint. To avoid while using wrong symptom, always road test the auto first. Proceed while using following preliminary inspections and correct any defects which are only.
STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Correction Shimmy, Shake or Tire or wheel outside of balance Balance wheels or replace tire Vibration and/or wheel. Loose wheel bearings Replace wheel bearing. Loose wheel hub nuts Retighten. Worn tie rod ends Replace tie rod end.
3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction Abnormal Noise, Worn, sticky or loose tie rod ends, drug rod ball Replace tie rod end, king pin bear- Front End joints, king pin bearings or axle shaft joints ing or axle shaft joint. Damaged shock absorbers or mountings Replace or repair.
STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Tire Diagnosis Irregular and/or Premature Wear Irregular and premature wear has several possible causes. Some of them are: incorrect inflation pressures absence of tire rotation, driv- ing habits, improper alignment. If these conditions are noted rotation would help:
3-6 STEERING, SUSPENSION, WHEELS AND TIRES 1 Ride vehicle to discover whether leading or rear waddles. 2 Install tires and wheels which might be known to become good on similar vehicle in place of such on wadding end of vehicle. If wadding end is not identified, substitute rear ones. 3 Road test again.
STEERING, SUSPENSION, WHEELS AND TIRES 3-7 Radial Tire Lead Lead would be the deviation in the vehicle from your straight path over a level rod despite the presence of no pressure on the controls. Lead is generally caused by: 1 Incorrect alignment. 2 Uneven brake adjustment.