Lue! si At Tay 4al-} SUZUKI MOTOR CO.,LTD. Sa eeu ee ce b Toll “ fi Ey s 5 m F > 3 fa P= fa A A i eet ar co)FOREWORD ‘This manual containe procedures for diagnosis, imeintanance adjustments, minor service operations, feplacement of components (Service) and for dis ‘assembly and assembly of major components {Unit Repoir-Overhaut ‘The contents are classified into sections each of whieh is given a section number a indicated in the ‘Table of Contents on this page. And on the first page of each Individual seetion i an index of that This manual should be kept in a handy place for ready reference of the service work, Stret observa te of the s0 specified items will enable one to ob {in the full performance of the vehicle When replacing parte or servicing by disassembling, itis recommended to use SUZUKI genuine parts, tools and service materials (lubricants, sealants, tc) 35 specified in each description. set a sre Me eet Srna aha eet pa ee kn hen et | ere Aa ae ect See ea eee ea ee Te Se eee naa in eo ‘CAUTION: Iti important to note that, during any vehicle maintenance procedures, replacement faston- frs must have the same measurements 25 those removed. Mismatehod or incorrect fastaners can result in vehicle damage or malfunction, oF possible personal injury. ‘Therefor, fasteners removed from the vehicle should be saved for esse whenever possible. Where the fasteners are not satisfactory for | reuse, cae should be taken to select areplace- ‘mont that matches the origina ‘Additional information concerning this subjoct tall be found in the section OA (METRIC. INFORMATION). SUZUKI MOTOR CO.,LTD. TECHNICAL DEPARTMENT AUTOMOBILE SERVICE DIVISION \S COPYRIGHT SUZUKI MOTOR CO. LTD, 1688 TABLE OFCONTENTS [SECTION] ‘GENERAL INFORMATION General Information 0A “Maintenance and Lubrication | _ 08 HEATING AND AIR CONDI: TIONING | Heating and Ventilation 1a Air Conditioner 6 ‘ir Conditioner Compressor Overhaul a BUMPER AND SHEET METAL 2 ‘STEERING, SUSPENSION, A WHEELS AND TIRES: Front End Alignment 3A, Manual Rack and Pinion 38 Steering Whee! and Columa 3c Front Suspension 30 Fear Suspension 3e Wheel and Tiros 3F DRIVE SHAFT Front Drive Shaft a (Double Offset Joint Typed Front Drive Shaft _ (Tripod Joint Type) an BRAKES 5 ENGINE General Information and Diagnosis c Engine Mechanical 6A Engine Cooling 68 Engine Fuel 6c Electronic Fue Injection (EFI) Sysern 3 Ignition System oF Cranking System 6c Charging Systern oH Emission Controls a Exhaust System 6k. "TRANSMISSION AND CLUTCH Manual Transmission ™ ‘Automatic Transmission 8 Cluteh |e ‘BODY ELECTRICAL SYSTEM s | BODY SERVICE D3GENERAL INFORMATION 04:1 SECTION OA GENERAL INFORMATION CONTENTS GENERAL INFORMATION oat Fastener Strength Identification ons Vehicle Identifieation 0a ‘Standard Tightening Torque ona Engine and Transmission léentification, 08-2 ere Enna SounTs| oas METRIC INFORMATION ons Metric Fasteners 0A3 GENERAL INFORMATION VEHICLE IDENTIFICATION ‘The vehicle identification number is on the loft front top of the instrument panel. Refer to Fig, (08.1 for its location and Fig, 082 for detailed VIN code information, Vehicle Identification Number W924 2.48.01 § 100001 ~ at Yar = 087, 188 868+ 180 | — —— Biv Tyee Lin ori anutecurer tartar(942 GENERAL INFORMATION ENGINE AND TRANSMISSION IDENTIFICATION Refer to Fig. OA-3 and OA-4 for engine and transmission identiieation numbers and ther locations. Engine Identification Number Location 13 K 100001 TTP sequent number Mods! Your (eer VIN designation) ‘Transmission Identification Number Location J. 100001——(M/T) 4 880001 {a/T) Sela Number Model Year (Refer o VIN Oesigation! Manat Traneninion Automate Teanminion Fig 04-4 Traamiaien aeneion Number Lecation GENERAL INFORMATION 0A METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric. When replacing any fasteners, itis most important thet replacement fasteners be the correct diameter, thread pitch and strength, FASTENER STRENGTH IDENTIFICATION ‘Most commonly used metric fastener strength Droperty classes are 47, 7T and radial line with ‘the cae identification embossed on the head of each bolt. Some metric nuts will be marked with punch mark strength identification on the nut face. Fig. OAS shows the different strength markings When replacing metric fasteners, be careful to Use bolts and nuts of the same strength or sreater than the xiginal fasteners (the same number marking or higher). Its ikewise impor tant to select replacement fasteners of the correct size, Correct replacement bolts and nuts are avsilable through the pats division, BOLT STRENGTH METRIC BOLTS — IDENTIFICATION CLASS NUMBERS OR MARKS CORRESPOND TO INCREASING NUMBERS REPRESENT INCREASING STRENGTH, NuT STRENGTH Fig. OA Bolt Stongih Markings ——SSSOSCS~S~S~S(044 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastoner should be tightened to the torque specified in each section ofthis manual. If no description fr specification is provided, refer to the following tightening torque chart for the applicable torque for ‘each fastener. When a fastenor of greater strength than the orginal one is used, however, use the torque specified for the original fastener, Note: ‘© For the flanged bolt and nut, add 10% to the tightening torque given in the below chart. ‘© The below chart is applicable only where the fastened parts are made of steel or light alloy 5 DP § \ Y © Sy pane. \ Connon bit “4 ot “bl oe areas aaa oe et aa a tae a oe pee a : oeet aw for ae i eee a Se ee 2 350-400 | 70-100 | 70-100 | 05-725] a eg ee 3 Se ee vata satan wees ase fe sae eae Fig OA Tipionng Forge Chart GENERAL INFORMATION 0A. VEHICLE LIFTING POINTS Fig. 0A-7 and OA indicate the methods of lift: ing the vehicle using @ hoist, and Fig. OA and {08.10 show additional locations for lifting with 2 floor jack, WARNING: || When using frome contact hoist, apply hoist as shown below (right and left at the same position). Lift up the car til 4 ‘ees ara litle of the ground and mal sure thatthe car will not fal off by tying ‘10 mow car body in both ways. Work ‘an be started only after this confirma, Before applying hoist to underbody, always take car balance throughout servi 2 into consideration. Car balance on hoist may change depending of what art to be removed. 1+ Make absolutely sure to lock hoist after car ishoisted up, + If the vehicte to be jacked up only at the ‘ont or rear end, be sure to block dhe ‘wheels in order to ensure safety. Aftor the vehicle is jacked up, be sure to support it on stands. It i extreme dangerous to do any work on the vehicle raised on jac alone. PRECAUTION AGAINST TIPPING On front.nheel drive vehicles, the centerline of aravty is further forward than on rear-wheel drive vehicle. Therefore, whenever removing ‘major components from the rear of the vehicle, While supported on a hoist, it is mandatory to support the vehicle in @ menner to prevent the possibility ofthe vehicle tipping forward, ‘When using frame contact hoist: iI / f Bolt ISS Z Fig. 87 Front Support Location J 3mWhen using floor jack Fig O49 Front Suppor Location Fig 08-10 Rew Suppor Location MAINTENANCE AND LUBRICATION 06-1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS MAINTENANCE SCHEDULE MAINTENANCE SERVICE Engine Ignition System Fuel Systom Brake Chassis and Body Final Inspection OWNER INSPECTIONS AND SERVICES RECOMMENDED FLUIDS AND LUBRICANTS 8. 08. 8. 8. 08: 08. 9 1 08-10 06-13 08-14 08-1708.2 MAINTENANCE AND LUBRICATION MAINTENANCE AND LUBRICATION 08:3 MAINTENANCE SCHEDULE MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS NORMAL CONDITION SCHEDULE Felon his whee youre amen opertud unr lings mp operation n topandg> Halt ] Ths ble tudes woes a edule up to 0,000 me (100,000 TWuninon uipssrees fn & nee omer Suse shoud a0 be followed ifthe car isusd for el co La TW Saeiae Wonkette) EPS a ener orem enone ‘Thisintera should be judged by odo rere opacity _| {ind outedetemperetures remain below freezing. retreingermonou.smanoar” | Mies00| 78 | 16 [225 | 90 [ars | a6 [sas | 0 Tai aa a NGG wp BDA ie TTT comer [ee aunt a Paet Lee [we fon ‘ico Beyond Sis oo mcr cue one Morte 78 spa loete [ae ie secovese [anette nasi 1 ENGINE - [os] [a cz} ee ‘rsa hv batt e-T 1.00 [3] ahaa haha fo 1. ae po bel fin dm STE comet * a_i oie 12. & 3. Ergin il and Engine i fier tis pn 6 UO se (boa ed 1 Fa Se Fonts |9) 6 orien zd olee see 1-4. Goolngsyrtem,howsandonnections leakage, damow)] = [ "I | = ~["T-1[0 SL ENGINE 15. Ergine cote =[= t= Te T= =p Tae pone Ba rn So 18 Ete ae STS Et HE 4 12 Ege fie ~ 17. Wins are ad comes Pete t= tet ett Et] 13 Ergo [2 onion verew | 1 Colne es dco Oe oo) fol= Falla l-[ el Plf eld [2S pw a TE 15 Engr cot Se EEE EERE ERE EEE Eel 1. Eehus syste Teka, args Han) [22 ion wa TT EFET Sst 2. FUEL SYSTEM SSS 77 Wig ares nd conection SEESEEEEEEE! S.A cane tiweenent [rwatvest | - [-]-] a] =] >]) 2] e Z.1GNITION SYSTEM — . [Fel nk, copie nap, don) tee tet 4 21. Suk ae EEE EEEEEEREEEEEEE ["4. BRAKE 2. ton wg EEEEEEEEEE-EEEEEEEI bk sn si hin wae dager T [3. euet svsrew 42 Bake hows and ies eso, droge cm) | 1) = [| = SHE 31 Ale eda [ 43. ete tie 32 Fak in Ug, 4-4, Brake lever and cable (damage, stroke, operation) ——_ 4. BRAKE — | rake pe “Fra dis edo ko, we S. CHASSIS AND BODY _ “4-2. Brake hoses and pipes (leakage, damage, clamp) 5:1. Giutch (For manuel transmission pedal Fre Wo ft Tyo n 49. Brake fuel _ [52-Trevn des oar, apron) Co 14. ke von ale aa, Gop 13. rive nl boots (eka, mips) Cote pepe pee “45, Brake peal PEPER EEE EEEEP EEE | £4. Suspension systam (Tightnss, damage, rattia,brakage) [1 Tt fo ba pao a 5. CHASSIS AND BODY _ 55. Stering system lightens. damage breakage, rate) | 1 | I]t |) tt fap 1 Cuch For anal tension) peda oe waved [-[¥[-[1 [=v ET 6. Manual vanniion ol (eke o chapepe pote EE. Tred ds (we, dea, ratio] Eel Efe fog fa pape pepo 2h bars Vo, we, ri, as =EEHERE Ee 5:7. Automatic transmission Fluid chonge | __ Replace every 100,000 mies (760,000 ka) 15. Drive acl boots (breakge, damage) Ener - |__ [reistow T= J -T-[-[=] a] To 4. Supensyt hie, ama er) [=[1 [=|] Ee $8 Door ng Gor wit conan opweton | |r Patt pa petra Sern stm ee, damage takage ete) —1=[0 [= [1] Ele ores: TT a menmnanad aah no 6. Nonultsmisiono hay le vtal=[1 | Ele CRE: Replace or change ~ - Fiuid level [1 |—[1 ]-[1|— [0 “1" Inspect and correct or repisce if necessary 15:7, Automatic transmission Fiuid change _|—|—|-|-A|-| [-[R Fut toe EEE EI f EE 59, orig & Gao con wia Efe her ebeh ei elet NOTES: "8°": Replace change “1” : Inspect and correct or pice if neces084 MAINTENANCE AND LUBRICATION MAINTENANCE SERVICE ENGINE 1 ‘Water Pump Bolt Inspection WARNING: ] Disconnect negative cable a battery before ‘Winspect belt for cracks, cuts, deformation, wear and cleanliness. Replace, if necessary, 2) Check pump belt for tension and adjust it as necessary. Refer to SECTION 68 for its procedure ata Engine Ol and Filter Change Ieisrecommended to use engine oll of API grade SF or SF/CC cas. ‘Always change oil and oil iter a s00n 3s poss: ble after driving ina dust storm, See your Owner's Manual fr further details Note: For temperature below 22°F (0°CI, itis highly recommended to use SAE 5W — 20 ol, Proper Engine Oil Viscosity Chart L couSWeatwen Before draining engine oil, check engine for oi! leakage. If any evidence of leskage is found, make sure 10 correct detective part before pro ceeding to following work. 1) Drain engine oil by removing deain plug. 2)After draining oil, wipe drain plug clen. Reinstall drain plug, and tighten it securely a8, specified in figure below. CAUTION: To tighten ol filter propery, itisimportant ‘to accurately identity the positon at which filter "0" ring fest contacts mounting surface 5) Using ol filter wrench, tighten fiter 3/4 turn ‘rom contact point described above 3) Loosen oil filter by using ol filter wranch (Special too! Fg 08-13 NOTE: Before fitting new oil filter, be sure to apply engine oil to its "0" ring. 4) Secew now filter on oll filter stand by hand Until fier "O" ring contacts. mounting surface, | Fig oo Fig OTE 6) Replenish oll until ol lve isbroughtto FULL level mark on dipstick, (about 3.3 lites oF 6.9/5.8 US/Imp pt.).Fillrinlot is at the top ‘of cylinder head cover 7)Stare engine and run it for three minutes Stop it and wait another 3 minutes before checking oil lovel, Add oil, as necessary, tO bring oll level to FULL level mark on dip stick, Fp oBTs MAINTENANCE AND LUBRICATION 08.5 Engine oll capacity about 3.1 liters Oil pan eapscity [about 02 fers it tte capacity | 49,403 UsiImp pt) ‘about 0.3 liters Others | (0.60.5 usvime pt.) . ‘about 3.6 ters Tol | (7576.3 usiimp pt) NoTE: Engine oil capacity is specified as above However, note that amount of oll required when ‘actually changing oll may somewhat differ from data in above table depending on various condi- tions (temperature, viscosity ec.) {8} Check ol filter and drain plug for oll leakage. 14 Cooling System, Hoses and Connections Inspection 1) Vieualy inspect cooling system hoses for any evidence of leakage and cracks. Examine them for damage, and check connection clamps for tightness Fg ders 2) Replace all hoses which show evidence of leakage, cracks or other damage, Replace all clamps which cannot maintain proper tight(08.6 MAINTENANCE AND LUBRICATION 3) Clean frontal area of radiator cor. 4) Test system and radiator cap for proper pres sure holding capacity, 0.9 kg/em* (12.8 psi replacement cap is needed, use a cap desing. 3 for cooling system of this car. 8) Check coolant level and concentration. ‘Add if necessary, Refer to COOLANT LEVEL of SECTION 68 for procedure of level check, 1s Erin Coolant Change WARNING 7 To elo aol dan of being tured, do | tat ramove rat sp wile eres | Pitre hot Sag a | | aac be ows ou unde rie top tana oo won 1) Remove radiator cap when engine is coo 2) Loosen radiator drain plug to drain coolant, 23) Remove reservoir tank, and drain, 4) Tighten plug securely. Also reinstall reservoir tank Fig B77 5) Fill radiator with specified amount of coolant, {and run engine for 2 or 3 minutes at idle ‘This drives out any air which may still be trap. ed within cooling system, STOP ENGINE. ‘Add coolant as necessary until coolant level reaches filler throst of radiator. Reinstall radiator cap, 6) Add coolant to reservoir tank 30 tat its level aligns with Full mark, Then, reinstall cap aligning arrow marks on tank and cap, [ caution: | ten ching engine col, se mixture 10% weer and 0 tog ba ccotnan nce/Anteoronon cot) forte mrtt wre ombartwrnere_| tia tover tn “160 (SF nara | Inu o 70% wet snd 308 ene Shel bose soln forte make we | init tmp soon fa | forces Even in a market where no freezing tempe- | tna sani, iar of Tt | Season ehyontyn one coor | Sout bet hero coon | | Beton en reat Refer to SECTION 68 of this manual for COOLANT CAPACITY. 16 Exhaust syste Inspection WARNING: To avoid danger of being burned, do not touch axhaust system when its stil hot. ‘Any service on exhaust system should be |_ performed when it is cool When carrying out periodic maintenance, or ear is rated for other service, check exhaust system 28 follows: © Check rubber mountings for damage and deterioration. + Check muffler pipe for leakage, loose connec tions, dents, and damages. If bolts or nuts are loose, tighten them to specification. Refer to SECTION 6K (p. 6-2) for torque specification of bolts and nuts 1 Check nearby body areas for damaged, miss: jing, ot misositioned parts, open seams, holes, Joos connections or other defects which could permit exhaust furmes to step into ca. ‘¢ Make sure that exhaust system components have enough clearance from underbody to avoid overheating and possible damage to floor carpet. # Any defects should be fined at once w Wiring Harness and Connections Inspection 1) Viaually inspect all wires in engine compart ‘ment for evidence of breakage. Inspect condition of insulation (cracks). All clipe and clamps should have solid connections towires 2) Replace any wices in a detariorated or other wise defective condition. MAINTENANCE AND LUBRICATION 08:7 IGNITION SYSTEM 2a ‘Spark Plugs Replacement Replace spark plugsas follows: 1) Dust off eylinder head around spark plugs. 2) Disconnect high tension cords at spark plugs To avoid inside damage of cords, D0 NOT pul on cords for disconnection. Pull on boots Fig BET 23) Using a spark plugwrench, remove spark plugs. 4) Check plug gaps of new spark plugs, and adjust them to specification as necessary, Spark Plug Specifications | Nok aprees Plug vee DENSO W20EPRU “oan 07-08 mm oe (0.027 - 0.031 in) — 26 —30.Nm Tightening torque | (2.5-3.0kem) (18.0 ~ 215 fost) 5) Install new spark plugs. Tighten plugs to spe cifiation. 46) Connect high tension cords to spark plugs DO NOT push cords for connection. Push boots22 Ignition Witing (hightension cord) Replacement 1) Disconnect high tension cords from spark lugs, ignition coll and distributor. 2) Connect new high tension cords and clamp ‘them securely. DO NOT push cords for con: nection. Push boots, Refer to SECTION 6F for high-tension cords distribution, FUEL SYSTEM a ‘Air Cleaner Element Replacement Note: Replace more often under dusty conditions. ‘Ask your dealer for proper replacement interval {or your driving conditions. Replace air cleaner element with new one according to procedure described in SECTION 6A, Air Cleaner Element Inspection 1 Viaually check that air cleaner element is not excessively dirty, damaged or oly. 2) lean element with compressed ar from inside of element, Nore: {fear is used in dusty area, clean every 5,000 km (3,000 miles) oF more frequently. Fig 5 32 Fuel Tank, Cap Gasket and Fuol Lines Inspection Check fuel tank, fuel filler cap and fuel lines for loose connection, deterioration or damage which could cause leakage Make sure all clamps are secure, * Check fue filler cap gasket for an even filler neck imprint or any damage. *# Replace any damaged or deteriorated pars ‘There should be no sign of fuel leakage or moisture at any fue! connection, BRAKE a1 {Brake Diss and Pads Inspection 1) Remove whee! and caliper but don't discon eet brake hose from caliper. 2) Check dise brake pads and discs for excessive wear, damage and deflection, Replace parts 25 necessary, For the details, refer to SECTION 5. Be sure to torque caliper pin bolts to specif: Fig 0832 Fig (B42 Rear Bake MAINTENANCE AND LUBRICATION 08:9 Nore: 1 noise is heard from front brake when pedal is depressed, check brake pad wear If itis worn, both right and left brake pads should be replaced with new ones, [eaurion [After replacing any brake pipe or hose, be sure to cary out air purge operation. 42 Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use a mirrr as necossary. 1 Check brake hoses and pipes for proper hook ‘up, leaks, racks, chefing, wear, corrosion bends, twists and other damage. Replace any ofthese parts as necessary. ‘Check al clamps for tightness and connections for leakage 1 Cheok that hoses and pipes are clear of sharp edges, moving parts 43 Brake Fluid Inspection and Change Unspection] 1) Check around master cylinder and reservoir {or fluid leakage. found leaky, correct. 2) Check fluid level I fluid lev! is lower than the minimum lov of reservoir, filing i necessary. Fil reservoir with specified brake fui. Speifation DoT’ Brake fiuid | For the detals, refer to ON-CAR SERVICE (of SECTION 5.8:10 MAINTENANCE AND LUBRICATION ‘CAUTION: | ‘Since brake system of this car is factory: | filled with glycol-base brake fluid, do not so or mix diferent type of fluid when re- | titing; otherwise serious damage will occur. Do not use old or used brake fluid, or un: | |_ seated container. (Change) Change brake fluid a follows Drain existing fluid from brake system complete- ly, fill system with above recommended fluic and carry out air purge operation. For air purging procedure eter to SECTION 5. 44 Brake Lever and Cable Inspection Parking brake lever * Check tooth tip of each notch for damage or weer. If any damage or wear i found, replace parking lever ‘© Check parking brake lover for proper opera: tion and stroke, and adjust tif necessary, For checking and adjusting procedures, refer to PARKING BRAKE INSPECTION AND ADJUSTMENT of SECTION 5. Parking brake eable Inspect brake cable for damage and smooth ‘movement. Replace cable if i is in deteriorated condition, 45 Brake Pedal Inspection Check brake pedal travel For checking procedure, refer to PEDAL TRA. VEL CHECK of SECTION 5. CHASSIS AND BODY 61 Clutch Pedal Free Travel Inspection Check clutch peal fre travel. Refer to SECTION 7C for procedure to check and adjust it 52 Tire and Wheel Dise Inspection (Tire inepaction] 1 Check tire for uneven or excessive wear, oF damoge. If detective, replace © Check inflating pressure ofeach ticeand adjust pressure to specification as necessary, ion pressure should bechecked when tees are cool, ‘Specified tire inflation pressure should be found on tire placard or in owner's manu which came with car. [Wheel disc inspection} Inspect each wheel dite for dens, distortion and cracks. A disc in badly damaged condition must be repiaced, {Tire tation] Rotate tires. For details of above steps, refer to SECTION 3F 52 Whee! Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise of rattles. For details refer to FRONT SUSPENTION INSPECTION of SECTION 20. 2) Check rear wheel bearing for wear, damage abnormal noise or rattle. For details, refer to WHEEL BEARING INSPECTION of SEC. TION 3E. MAINTENANCE AND LUBRICATION 06-11 1 Check front and rear suspension systems for damaged, loose of missing parts; also for parts showing signs of wear of lack of lubrication. Repair or replace defective parts if any. © Check front suspension arm ball joint stud dust seals for leakage, detachment, tear, or any other damage Replace defective boot, if any. 5a Drive Axle Boot Inspection Check drive axle boots (whee! side and differen tial side) for leakage, detachment, tear or any other damage Replace boot as necessry. Fig 087 Fig 5S 54 Suspension System Inspection Inspect front & rear struts for evidence of oi 55 ‘Steoring System Inspection 1) Check stering whee! for play and rattle, hold {ng car straight on grouns. leakage, dents or any othor darrage on sleeves and inspect anchor ends for deterioration Replace defective parts, if any. Steering wheelplay | 0-S0mm “An | @~12iny08-12 MAINTENANCE AND LUBRICATION 2)check string linkage for looseness and damage. Repair or replace defective parts, if any. 3) Check boots of steering linkage and steering gear case for damage (leaks, detachment, tar, tc). If damage is found, replace defective boot with new one, 4) Chock universal joints of steering shafe for rattle and damage. If rattle or damage it found, replace defective part with a new one, RK rd “Toh. Fg 0655 56 Manual Transmission Ol Inspection and (Change {Unspection) 1 inspect transmission case for evidence of oil leakage. Repair leaky point it any. 2)Make sure that car is placed level for oil level check: 3) Remove level plug of transmission, 4) Check oil evel it level can be checked coughly by means of filler/ievel plug hole. That i, if oil flows out ff level plug hole or ol evel is found up to hhole when level plug is removed, cil i pro: perl filled It oil is found insufficient, pour specified oil upto level hole, For specified oll, refer to description of oil change (p. 7A7) under ON:CAR SERVICE in SECTION 7, [change) 1) Place the car level and drain oil by removing drain lus 2)Anply sealant to. drain plug and tighten drain plug to specified torque. 3) Pour specified oil up to level hole. 4) Tighten filer plug to specified toraue For recommended oil its amount and tighten ing torque data, refer to ON-CAR SERVICE (6. 7A) of SECTION 7A. 57 ‘Automatic Transmission (Fluid level inspection) 1 Inspect transmission case for evidence of fuid leakage. Repair leaky point, if any. 2)Make sure that car is placed level for fluid level check 3) Check fluid level For fluid lavol checking procedure, refer to ON-CAR SERVICE in SECTION 7B and be sure to perform it under specified conditions If fluid level is low, replenish specified tui [Fluid change) 1) Perform steps 1) and 2) of above Fluid Level inspection, 2) Change fluid. For its procedure refer to ON. CAR SERVICE in SECTION 78, [ caution: Use of specified fluid absolutely neces: sary [Fluid cooler hose change! Replace inlet and outlet hoses of cooler hose and theie clamps. For replacement procedure, refer to ON-CAR SERVICE in SECTION 78, 58 Door Hinges, Gear Shift Control Lover and Shaft Inspection Check thet doors and gear shift control lever move smoothly without abnormal nose If defective, lubricate a follows. Wipe off dirt of door hinges and apply a thin coat of engine ol. Open and close door several times to insure that oil has worked ineffectivaly Lubricate lever seat and shaft bushings with water resistant chaste gree FINAL INSPECTION ‘BODY PARTS OPERATION Hood Latch (Check thet hood opens and closes smoothiy and properly. Alzo check that it locks securly when closed Doors CCheck that aach door opens and closes smoothly and locks seourely when closed, Seats CCheck that seat slides smoothly and locks securely at any position. Also check that rect ing mechanism of front seat back allows it to be lacked at any angle [ warnine: ee leicistemasana es pee neneael| Engine Start CCheck engine start fr eadiness Ccutch (For Manual transmission) (Check forthe following. + Clutch is completely released when depressing clutch pedal, No slipping clutch oceurs when releasing pedal and accelerating Clutch itself is free from any sbnormal condition. Gearshift or Selector Lover (Transmission) (Chock gearshift or selector lever for smooth shift ing to all positions and for good performance of transmission in any postion, With automstic transmission equipped car, also check that shift indicator indistes properly according 0 which position selector lever is shifted to. ‘CAUTION: With automatic make sure that cris at come shitting selector lver to “P” MAINTENANCE AND LUBRICATION 08-13 Brake [Foot brake] Check the following when depressing brake pedal while driving f= that brake works propery, 1 that itis eee from noise, ‘© and that braking force is applied equally on all hes (arcing brake] Check to ensure that parking brake is fully effective when the car i stopped on the slope ‘and brake lever is pulled all the way. Steering 1 Check to ensure that steering wheel is tree from instability, or abnormally heavy feeling while driving ‘+ Check thatthe car does not wander or pull to cone side, Engine = Chack that engine responds readily at all speeds ‘Check that engine is free from abnormal noise ‘and abnormal vibration. ‘Body, Wheels and Power Transmitting System Check that body, wheels and power transmit: ting system are free from abnormal noise and abnormal vibration or any other abnormal condition, Meters and Gauge CCheck that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately. Lights Check that al lights operate propery. ‘Seat Belt Inspect belt system, including webbing, buckles, latch plates, retractorsand anchors ‘Check thet seatbelts securely locked WARNING: | For this tes, select a safe place without any running eat $0 95 to prevent any secident. ‘And again make sure that no man or no other ear is seen in front or behind and use ‘reat care to the surroundings when carry ing out the test.(08.16 MAINTENANCE AND LUBRICATION OWNER INSPECTIONS AND ‘SERVICES Listed below are items which should be checked and serviced by either the owner himself or 2 {qualified technician daily or periodically to help ensure safety and dependability of each car Should any problem occur, contact nearby desler (ra quaifiod technician for proper service advice. For the safety of the driver himself and others, be sure to inspect any safery-elated parts that ould have been damaged in any accident and take corrective measures for whatever in need of repair before using car again BEFORE OPERATING YOUR CAR [OUTSIDE CAR] Fluid Leak Check. Check for fuel, coolant, ail, or other fluid leakage by looking at surface beneath car after it has been parked fora while. Water dripping from air conditioning system after use is normal. If getoling fume of fluid i noted at any time, Inverstigate its cause and correct it at once, Door Operation (Check that sl doors including back door operate smoothly, and that ll doors close and all latches lock securely ‘Tire, Wheel and Whee! Nut Inspection © Check pressure as shown on tire placard (including spare tie). Pressure should be checked when tires ae “cold 1 Check tire for cuts, damage or excessive wear. 1 Check whee! nuts for looseness of for missing ruts. If necessary, tighten ther, INSIDE CAR} Seat Adjuster Operation # Move seat back and forth and check that seat adjuster operates smoothly and locks properly ‘and securely ‘© Check that seat back canbe reclined smoothly «and locked securely at eny anal, Warning Light, Buzzer and Tone Operation CCheck all warning lights, buzzers and interior Indicator lights for operation. For details, refer to Owner's Manual Glass, Mirror, Light and/or Reflector Condition Check each glass, miror, light and reflector for breakage, sratch, dit or any other damage which could reduce driver's view or visibility or cause injury. Replace, clean or repair promptly, if necessary, Rear View Mirror and Sun Visor Operation CChec that friction joints hold mirrors and sun Visors in place, ‘Seat Belts Condition and Operation CCheck belt system including webbing, buckles, latch plates, retractors, uide loops, and anchors for proper operation, damage and/or wear Light Operation Check license plate lights, headlights, small Nights, tailights, brake lights, turn signals, back: up lights, instrument panel’ lights snd interior lights, hazard warning flashers and other lights Have ‘headlight aim checked at once if beams seem Improperly aimed. ‘Clutch Pedal Free Travel Check. Check fre travel and adjust as necessary. * Check pedal for smooth operation ‘Accelerator Pedal Operation ‘Check that pedal operates smoothly without get: ting caught or interfered by any ather par. Exhaust System Check Check for leakage, cracks of loose support. ‘Brake Pedal Check * Check pedal for smooth operation * Check pedal travel (pedal-‘o-nal clearance. For checking procedure, refer to PEDAL TRAVEL CHECK of SECTION 5, ‘Check brake booster function. Parking Brake Lever Travel Check (Check that lever has proper travel ‘Automatic Transmission Shit Indicator and Patk Machanism Operation ‘© Move selector lever and check that indieator points to exact ger as chosen, ‘= Chack the lack release button of the selector lever for proper and smooth operation [UNDER HOOD] Engine Hood Latch Operation CCheck that hood closes firmly. Check for damaa fd, loose, oF missing parts thet might prevent tight latching. Make sure secondary latch keeps hood from opening all the way when primery latch is elased Engine Oil Level Check CCheck engine oil on the dipstick with the engine turned off and add if necessary. See your Owner's Manu. note: 4 large loss in this system may indicate 3 pro: ‘lem. Have it inspected and repaired at once. Engine Coolant Level and Condition When engine is 001, check coolant level in reser: voir tank and add if neces. Inspect coolant and replace if dirty or rusty. ‘A. normal coolant level should be between “EULL" and "LOW" marks on reservoir tank ‘See Owner's Manual Nore: A large loss in this system may indicate a pro bom. Have it inspected and repaired at once. Windshield Washer Fluid Lovel Check Check washer fluid level in tank and ade if necessary, Brake Master Cylinder Fluid Level Check. CCheck reservar tank fluid level in accordance with Owner's Manual and keep a proper lev. Nore: A large loss in this system may indicate a pro blom. Have it inspected and repaired at once. MAINTENANCE AND LUBRICATION 00415 Battory Electrolyte Level Check Check that the electrolyte level of all battery cls is between the upper and lower level lines fon the case Engine Drive Bets) Inspection Inspect all belts for cracks, fraying and wear. Adjust oF replace as needed WHILE OPERATING YOUR CAR Horn Operation Check to make sure that horn works when its button is pushed at itsany part Windshield Wiper and Washer Operation Check wipers and washer for proper operation Also chack spray direction of washer fui. CCheck wiper bisdes for wear or cracks whenever ‘thay fall to wine clean If necessary, replace. Windshield Defroster Periodically check that air comes out from defroster Outlet when operating heater or air ‘conditioner. Set fan switch lever to "HI" position for this check. ‘Steering System Operation Be alert for any changes in stering action, An inspection or sevice is needed when: the stor ing wheel is harder to turn oF has too much free play, ori there are strange sounds when turning Brake System Operation Be alert to abnormal noise, increase in brake pedal travel or repeated pull to one side when braking When any of such conditions is noted, check brake system, If brake warning light stays on or keeps flashing, there may be some trouble in brake system. ‘Also, test parking brake by pulling parking brake lever.08-16 MAINTENANCE AND LUBRICATION Exhaust System Operation Be alert for any changes in the sound of the ex hhaust system oF any smell of fumes. These are signs the system may be leaking or overhesting Have it check and/or repaired at once. Tire and Whee! Operation Be alert to vibration of the steering whee! or seat at normal highway speeds. This may mean 2 whee! balance is needed, Also, pull right or lft (na straight, level road may show the need for 2 tice presure adjustment or whee alignment. IT IS RECOMMENDED TO CHECK FOLLOW. ING ITEMS AT LEAST ONCE A YEAR Starter Safety Switch Operation WARNING: Before performing the following safety switch check, be sre to have enough room | round the car. Then, firmly apply both ‘tho parking brake (see your Owner’sManual_| for procedure) and the raglar rakes. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition promptly. Take these precautions bacause the ear could move without warning and possibly cause personel injury or property damage. (On automate transmission care, try to start the engine in each gear. The starter should crank coniy in "P" (Park) or “N" (Neutral On manual transmission cars, place the shift lever in "Neutral," push the cluteh halfway and {ey to start. Tho starter should erank only when the clutch is fully depressed, Parking Brake and Transmission “Park Mechanism Operation WARNING: | With cat parked on a fairly steep slope, make sure nothing isin the way downhill to avoid any personal injury or property damage. Be prepared to apply regular brake ‘icky To check holding ability of parking brake, start engine shift gear to neutral position and release regular brake gradually till aris held by parking brake only To check automatic transmission “Park” mache nism holding ability, shift selector lever to Park’* Position and release al brakes. Under Body Flushing ‘At least once a year in spring, lush underbody with water to remove corrosive deposits such as Toad salt and dirt. Use special cae to clean any area where mad and dust can collect easily. Take ‘out dust packed in closed place bafore flushing Check coolant and its untireeze property. If it is contaminated or rusty, drain, flush with water and refill new coolant, Maintain coolant at such mixture ratio as specified in Ownee’s Manual, thereby freezing and corrosion is avoided and engine operating tempersture is properly con: ‘rolled. Check hosse and reploce if cracked, swollen hardened or otherwise deteriorated, Tighten hose clamps. Clean outside of radiator and air conditioning condensor. Wath radiator filler cap and neck For coolant change interval, refer to Maintenance ‘Schedule Table. MAINTENANCE AND LUBRICATION 08:17 RECOMMENDED FLUIDS AND LUBRICANTS Engine coolant {long life coolant) [Brake tis Manual transmission oil ‘Automatic vansmission Gearshift contol lover and shaft Door hing Hood latch assembly Koy lock evlinder SF or SFIGG, SAE BW-30 (Refer to Fig. OB-1) Ethylene lycol base coolant ("Antifreeze/Anticorrosion coolant” GOLDEN CRUISER 1200) ors __ "Se oi carton pa 7A7 omic warsmision id DEXRON 4 [Water eionce chs rene (GUzUEI SUPER GREASE A9800025010) ol En Engine oil ‘Spray lubricant Fig 088SECTION 1A HEATER AND VENTILATION CONTENTS GENERAL DESCRIPTION. 14 Body Ventilation, 1A Heater 1A2 Heater Control Operation 1A3 DIAGNOSIS. 14 ON-CAR SERVICE aaa Heater Blower Motor. 1A Heater Blower Motor Resistor 1AS Hester Blower Motor Switch 1A6 Heater Convo! Cables 17 Heater Unit. 103. GENERAL DESCRIPTION BODY VENTILATION “The body ventilation system of thiscar fs equipped with air conditioning that consists of a fresh ar intake located at the cowl top panel. Ventilating air is drawn into the interior from the intake grille and drawn cout from the ventilator outlet provided at wach side ofthe body outer panel1A2 HEATER AND VENTILATION HEATER ‘The heater and ventilation ofthis car consist of such mein components as control levers, blower motor, heater core and air ducts, The blower motor runs on electricity to send ar inside, Inthe heater core, the cooling water warmed by the engine keeps circulating. Each contral lever controls the blower moter speed, temperature and operation of the dampers in the air ducts so that the air is deliverod where necessary, HEATER AND VENTILATION 142 HEATER CONTROL OPERATION ‘The heater and ventilation provide temperature control, ventilation and defrosting functions. Their ope ration is controlled by selecting the postions of the contol levers on the instrument panel. Each lever position and funetion of heater and ventilation areas given below. Laer Lever 8 Lever B Fresh ae control lever. Lever A Hester control levee PB [venation (Ar Foe) [A a crcuvaTion [et] | | L us from center, FRESH AIR 32] So josewes (‘Stopes ) [ea] b See Nod | wear (Roroutn”) 83] Temperature control lever [pel ueeanen (settee) coon Tea | /Air flows from front) | | Lever D WH [ernosren [iim saear) |¢8] lower motored mieton e. Sha Fig TAPAd HEATER AND VENTILATION DIAGNOSIS ble Possible cause Heater blower won't Blower fuse blown work even when its ero Blower reister faulty Blower motor faulty Wiring or grounding faulty Incorrect tempera | | Control cables Broken or binding | Air camper broken Air ducts clogged Heater radistor leaking or clogged Heater hoses leaking or clogged Re Replace fuse to check for sort. (Check continuity. Replace moter. Repair Check cables Repair damper. Repair or ducts Replace radiator. Replace hoses, ON-CAR SERVICE HEATER BLOWER MOTOR REMOVAL 1) Disconnect bettery {-) leadwire 2)Diconneet blower motor and resister lead Wires nt couplers 3) Disconnect fresh sir control cable from motor 4) Remove blower mater unit after removing love box upper panel and bolts as shown below. (ee Fig ta 5) Remove blower motor. Fig Tab INSTALLATION Reverse removal procedure for installation. HEATER AND VENTILATION 14:5 HEATER BLOWER MOTOR RESISTOR. REMOVAL 1} Remove blower motor unt as previously out ined, 2) Remove heater blower motor resistor. INSPECTION Check blower motor register for each terminal toterminal continuity. If there is no continuity, replace blower motor resistor. INSTALLATION Reverse removal procedure for installation,HEATER BLOWER MOTOR SWITCH REMOVAL 1) Remove console box. 2) Remove ashtray and ashtray upper plat, 43) Remove eigarate lighter. {4} Remave contral lever knobs and control panel garish 5) Remove control panel. 6) Disconnect leadwire from blower motor switch at couple. 7) Disconnect control eables from blower motor unit and heater unit 8) Remove contro! leer ay 9) Remove blower motor switch INSPECTION Heater blower motor switch is connected between battery and blower motor, through fuse and resistor a8 shown below. {Check switch for each terminal-toterminal continuity. If there is no continuity, replace blower motor site, gO [FA INSTALLATION Install in the coverse order of removal es HEATER CONTROL CABLES HEATER AND VENTILATION 147 Fin tab REMOVAL 1) Remove console box. 2} Remove ashtray and ashtray upper late. 3) Remove cigarette lighter. 44) Remove control lever knobs and control ane garnish 5} Remove control pane! 6) Disconnect leadwire from blower motor switch at coupler 7) Disconnect control cables from blower motor unit and heater unit £8) Remove control lever as. 9} Disconnect control eables from contro lever. INSTALLATION Install control cables by reversing removal procedure, nating the following point. After installing control cables to control levers, ‘move contrl levers to such position as to pull cables fully, then connect and clamp control ‘ables to heater unit and blower motor unit levers as shown, installing control cables, be sure that control knobs move smoothly and stop st proper position,{148 HEATER AND VENTILATION. HEATER UNIT Fig ta10 REMOVAL 1) Disconnect batary (~| leadwire, drain coolant and disconnect 2 water hoses from heater uit. 2) Remove console box. 3) Disconnect wires and eables from heater and blower unit. 4) Remove steering whee, steering column unit and steering joint upper bolt. (Refer to p. 3c) 5) Disconnect speedometer cable and remove speedometer assy 66) Remove speaker garnish (R, L) and conter 7) Remove instrument panel member mounting bolts. £8) Remove instrument panel together with instru ‘ment pane! member HEATER AND VENTILATION 149 10) Remove heater unit clips ond serews to separate heater unit, Fig RIS 11) Pull our heater core from unit, Fa tara INSTALLATION Install heater unit by reversing removal pro: cedure, noting the following items. 1) Adjust control cables. (Refer to p. 1A7) 2) Fill coolant to reistor. NOTE: © When installing each part, be careful not to catch any cable or wiring harness. © When installing steering shaft to storing shaft joint, set front wheels (right and left) in the ‘straight ahead state and check to make sure ‘that steering wheel aio in that state. ‘When fastening steering column assy 0 car body, start with lower nuts on coluran and ‘then upper nuts. Be sure to tighten them to specified torque. (Refer to p. 3C6 for details.)SECTION 1B AIR CONDITIONER (OPTIONAL) CONTENTS GENERAL DESCRIPTION Major Components and Retrigerant Flow of Aie Conditioning System Function of Each Component Wiring Diagram Function of Each Control Component INSTALLATION Preparation Prior to Installation Precaution for Servicing Installation For installation and its procedure INSTALLATION INSTRUCTION MANUAL is packed with aircon parts EVACUATION AND CHARGING Evacvating System Handling Can Tep Valve Charging System with Refrigerant Procedure af Charging Removing Manifold Gauge Set Leak-Testng Refrigrant System SERVICING Trouble Diagnosis ON-CAR SERVICE Note Inspection and Repairing Rerigerating Syste |A.Charge of Refrigerant B.Condensor C. Receiver/Dryer D.€vaporator (Cooling Unit) E.Expansion Valve F Evaporator Thermister G.Water Temp. Switch H Refrigerant Lines 1. Electrica! Circuit J. Miscellaneous PREFORMANCE TEST 18 1B 18 18 12 18 18 18 1B Te 18 18 18 18 1810 18.10 te ten i812 1812 1813 1843 reas 18-14 18.14 1816 18417 1817 1847 1848 1e19 1820182 AIR CONDITIONER (OPTIONAL) AIR CONDITIONER (OPTIONAL) ‘The present car can be optionally provided with an sir conditioner. This Section cavers the descrntion, charging of refrigerant, ete. of the ar conditioner. GENERAL DESCRIPTION MAJOR COMPONENTS AND REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM a [ 4 —zs| se | 22. 2 UT FUNCTION OF EACH COMPONENT ‘COMPRESSOR. CCompresies the gos vaporized in the evaporator. ‘Thus compressed ges is sent to the condenser where it i changed into liquid refrigerant whose heat of vaporization can be reused. Compressors used for the air conditioning of ear include reciprocating, swash plate, and wobble plate types. This madel employs the swash plate-type less in vibration and excellent in durability. MAGNETIC CLUTCH {A device used, with the engine running, for ope rating the compressor only when the air condi tioning is needed and stopping it otherwise Employsa powerful electromagnet. CONDENSER Serves to change the compressor-comprossd, high temparature/high pressure-obtained re frigerant into liquid refrigerant by forcibly taking heat therefrom. Constructionally the same as the radiator. Installed at the frontmast of the ‘car for increased heat radiation, and cooled compulsorily by the cooling fen. RECEIVER/ORYER The receiveriéryer has the three roles as des cribed below: |A) The receiver section serves as 2 temporary storage container of condenser liqueied re frigerant 20 tha i is posible to supply the evaporator with the condenser-liquetied refrigerant just conforming to the demand of the cooling load, 8) The dryer section serves to remove the dirt and water mixed in the cycling refrigerant bby meons of the fiter and desicant sealed therein, C) The sight glass, installed atop the receiver, serves 10 look at thereby the flowing state of the refrigerant [AIR CONDITIONER (OPTIONAL) 192 Fa 182 DUAL PRESSURE SWITCH ‘A contral suiteh to stop further rotation ofthe ‘compresor by turning OFF the electric circuits ‘of the magnetic clutch end condenser cooling fan when the cycling rerigeant is abnormally dropped or rison in pressure, EXPANSION VALVE {A device to eject the recever/dryer-pased liquid refrigerant fram fine hole for sudden expansion to produce atomized refrigerant of low tempera ture and low pressure, EVAPORATOR Pastes therethrough the cold atomized refrigerant 10 lower the ambient temperature. The refrige: rant, now changed into hot gas, is sent 0 the Ccompresior. Functionally, the evaporator acts just inversely to the condenser. (The refrigerant takes a state of liquid when en tering the evaporator and @ sate of gas when leaving therefrom)18-4 AIR CONDITIONER (OPTIONAL) AIR CONDITIONER (OPTIONAL) 185 WIRING DIAGRAM r FUNCTION OF EACH CONTROL ‘COMPONENT RELAY (condenser fan/mognetie clutch) [A relay to operate the condenser fan motor and magnetic clutch, The motor continues opera tion as long at the air condltioner (compressor) is under operation. MAGNETIC CLUTCH [A device used, with the engine running, for ‘operating the alr conditioner only when needed, ‘and controlled by the A/C amplifier. EVAPORATOR THERMISTER When the eveporative temperature of a refige: rant draps ta 1°C (38°F) or bolow, the vapors tor fins get stuck with frost or ice, reducing the airflow, lowering the cooling capecity. The thermister is a sensor which is used to prevent this frosting or icing, ‘The thermister installed to evaporator converts the evaporative temperature into a resistance value and sand it 10 A/C amplifier, WATER TEMP SWITCH [A switch to stop compressor operation when the coolant temperature exceeds 108°C (226" DUAL PRESSURE SWITCH ‘A contral switch to stop the compressor opera tion when the cycling refrigerant is dropped in pressure due to its leakage, lack of refrigerant ‘0 has reached too high aleve ‘The switch is installed in the high pressure line bind the receiver dryer. \VSV [VACUUM SWITCHING VALVE) “The VSV opens and cioses according to the signal from A/C amplifier. When it opens, the ai issup- plied to the intake manifold passing through the SV in addition to air passing through the idle port and the ISC solenoid valve, and the engine Speed rises alittle higher than the specified idle sted AIR-CON AMPLIFIER Aircon amplifier is installed to the lower eve ‘orator eas. controls operation of the VSV, compressor magnetic clutch and condenser fan motor accord: ing to the signals from the sensors which detect the state of the engine and driving conditions Main system control functions are as follows (at A/C switch ON). + lle speed control idle-up) Mognetie clutch delay control: 08 second delay after V.SV. on. «Aircon ON — OFF contol High refrigerant pressure tsbove 27 kg/om? (383 ps)... OFF below 21 kg/em? (209 pai)... ON Low refrigerant pressure: ‘below 2.1 ko/em? (28.8 pa) .... OFF above 2.4 kglem? (34.1 psi)... ON Coolant water temperature ‘above 108°C (226°F) OFF below 105°C (221°F) on While engine eranking with arter Ose oFF Evaporative temperature below 1° (34°F) oFF While aooetrating rapidly: (when throttle opened 90% within «pane At a zone of clotexo-ling, low revolution 1O-seconds).. +++. OFF hie 8 Sy Bf speeds as used while driving through congested 2 Soemeanoe EE Sores filme Sion hots, prking or doing the Ike, o at Semen B Seocma a EN See the ll sped the ngs output oso smal ht & Mereteeincrey 1 Parmar Si: me Yee any attempt to operate the compressor under Store for MT mode arty) 6 © Lansareen YB Yelowisocs, ‘the above condition applies unreasonable load ESStemaomaie yp Weoot tothe engi, causing ts overheating or saling Ries. | Corday, MSV indie to open or ut thea pasmge to intake manifold Fig Ba186 AIR CONDITIONER (OPTIONAL INSTALLATION PREPARATION PRIOR TO INSTALLATION A.INSPECTION AND ADJUSTMENT OF ‘CAR Before installing air conditioner, check and adjust following items 1) Engine ignition ving, 2) Engine cooling system, 3) Battery electrolyte and charging system. 4) Passenger compartment sealing 5) Fuel system. 6) Goneral car conditions B. PREPARATION OF AIR CONDITIONER COMPONENTS: When unpacking parts kit, arrange unpacked Parts in the order of installation At this time, you have to make sure the kit hos ‘no missing or defective rts. And, when instal! ing ir conditioner, you have to use covers for protection of fender and seat, PRECAUTION FOR SERVICING 1)Battery negative terminal should be dis connected 2) Engine-installed air conditioner components should be tightened by specified torque using bolts supplied in the kit, Air conditioning lines and wire harnesses should, when installed, be routed correctly 50 as not to interfere with peripheral parts 4) Hoses and tubes should be connected with each other respectively after applying two to three drops of refrigerant to seats of flared 5) Line fitings should be tightened or loosened Using two wrenches so thet they are supported evenly during such tightening oF loosening. 6) Flared nuts should be tightened by specified torque, ‘71Until it becomes possible to connect eoch component into position, blind plugs of _attaching portions should not be removed. NOTE: Remove plugs from compressor carefully toallow refrigerant t0 escape slowly. This is necessary because compressor is shipped out from factory With a slight charge of refrigerant 10 prevent its seals from corroding. 8) When handling refrigerant-12, you should always wear safety goggles and also use care that it wll not gat on your skin. 9) Retrigerent-12 can should be kept at about 40°C (100°) by putting it in hot water. INSTALLATION When installing ar conditioner, refer to instruc tion manual which is packed with al-con parts, EVACUATION AND CHARGING EVACUATING SYSTEM 1) Whenever opened (exposed to atmospheric air, air conditioning system must be evacuated by using @ vacuum pump. The A/C system should be attached with a manifold gauge st, and should be evacuated for approx. 15, 2) Connect high and low cherging hoses of mat old gauge set respectively as follows High Charging Hose mp Compressor Delivery Hove Low Charing Hose =p Compressor Suction Hose 3) Attach center charging hose of manifold ‘gauge set to vacuum pump. 44) Operate vacuum pump, and then open suction: side valve (Lo} of manifold gauge set. If there is no blockage in the system, there will be an indication on high pressure auege. When this occurs, open the othersde valve (Hi) ofthe set [AIR CONDITIONER (OPTIONAL) 18:7 S5)Approx. 10 minutes later, low pressure gauge should show a vacuum lower than 760 mmHg providing no leskage exists NOTE: ‘+ Ifthe system does not show a vacuum below 760 mmHg, clove both valves, stop vacuum pump and watch movement of low pressure a0. Increase in the gauge reading suagests existen- ce of leakage. In this case, repair the system before continuing its evacuation If the gauge shows a stable reading (suggesting no leakage), continue evacuation. 6) Evacuation should be carried out for 3 total of atleast 15 minutes. 7) Continue evacuation until low pressure gauge indicates a vacuum less than 760 mmHg, and then elose both valves. £8) Stop vacuum pump. Disconnect center charg ing hose from pump inet. Now, the system i ready for charging refrigerant. Fy 18s{488 AIR CONDITIONER (OPTIONAL) HANDLING CAN TAP VALVE 1) The can tap valve should, before put on 2 refrigerant can, be turned counterclockwise by its handle until its needle is fully retracted Fa 86 2) Turn plate nur counterclockwise until it re aches its highest position relative to can tap valve. Then screw ean tapvalve into refrigerant 3} Turn plate nut clockwise fully to thus install center charging hose to fitting of can tap valve. 4) Tighten plate nut suficienty by hand. 5) Charging of refrigerant should be caried out according to following procedure. CHARGING SYSTEM WITH REFRIGERANT ‘CAUTION: © ALWAYS CHARGE THROUGH LOW: SIDE of A/C system. + NEVER CONNECT ON HIGHSIDE of AIC system. Do not charge while compressor is hot When installing can tap valve to refrige- rant can to make 2 hole therethrough, carefully follow directions given by | manufacturer + A pressure gauge should always be used before and during charging. | ‘© Tho refrigerant can should be emptied of refrigerant before disarding it. Tho refrigrant can should not be heated Lup to 40°C (100°F) or over. ‘© Refrigorant should not be roversed in direction during charging. Reversing in direction causes liquid. refrigerant’ to enter compressor, causing troubles, such ‘5 compression of liquid refrigerant and the like, * Your eyes should not be exposed to re- ‘rigerant (quid) Any liquid Refrigerant-12 escaping by | accident shows 2 temperature as low at ‘approx. ~6°C (21°F) below treezing point. Should liquid R-12 get into your yes, it may couse a serous injury. To protect your eyes against such acct dent, it is necessary to always wear ‘goggles. Should it occur that R12 strikes your eyels), consult a doctor immediately. DO NOT USE YOUR HAND To RUB THE AFFECTED EYE(S). INSTEAD, use quantities of fresh ald unter tn splash it over the affected area to gradual ly raise temperature of such area above freezing point, Obtain proper treatment as soon as possible from a doctor or eye specialist. ‘Should the R-12 liquid come into con- tact with your skin, the affected area should be treated in the same manner as when skin isfrostbiten oF frozen. ‘© Refrigerant must not be handled near were welding or steam cleaning is performed. Rotrigerant should be kept at cold and dark place. It should never be stored where a high temperature is anticipated, 2. where exposed to direct sun light, close to fire or inside car (including trunk room) ‘Avoid breathing fumes produced when R12 i burned. Such fumes may be hazardous to health PROCEDURE OF CHARGING 1) Cheek to make sure that hoses are routed pro: erly after evacuating the system (see Fig, 187) 2) Connect the manifold gouge set in position ‘Thus slacken the handle of the refrigerant can tap valve to purge the charging line. Then ‘optn the low pressure side valve. eo | Fig. 187 WARNING: Make sure that high pressureside valve is closed securly AIR CONDITIONER (OPTIONAL 198 Fa 8S «Install previously removed refrigerant can tap valve to anew refrigerant can. 4. Use following procedure to purge any air ‘existing in center charging ose. © Once fully tighten refrigerant can tap velve and then loosen (open) i slightly. @ Open low pressure valve of mainfold gaupe sata tite, @) As soon as refrigerant comes out with a “hiss” through a elearance between refrige rant ean and refrigerant can tap valve, close refrigerant can tap valve as well at manifold gauge set low pressure valve. 23) Star engine and keep engine speed at 1000 min, Then, operate air conditioner 4) Charge A/C’ system with refrigerant in vapor state, At this time, efrigerent can should be held upright, '5] When refrigerant can ie emptied, use follow ing procedure to replace it wth a new refrige: 2, Close low pressure valve. , Retract needle and remove refrigerant can tap vale by loosening its pate nut.18-10 AIR CONDITIONER (OPTIONAL @ Turn handle of can tap valve clockwise so that its needle Is serewed into the new ean 10 make a hole for refrigerant flow. 6) After the system has been charged with spe cified amount (500 gor 17.6 o2) of otrigerant or when low and high pressure gauges have Indicated about 2and 18 kg/cm? (28 and 213 pail respectively, close low pressure side valve ‘of manifold gauge set. At this time, look into ‘the sight glass of receiver/dryer and check that there are no bubbles in it, which means ‘that the system is fully charge. Fa 1810 REMOVING MANIFOLD GAUGE SET When A/C system has been charged witha spe ified amount of refrigerant, remove manifold gauge set as follows: 1)Close low pretsureside valve of manifold gauge set. (The high pressureside valve is closed continuously during the process of charging.) 2)Fully tighten handle of refrigerant can tap valve, 3) Stop engine. 4)Using shop rag, remove charging hoses from service valves, This operation must be per formed rapidly. 5) Put eaps on service valves, WARNING: High pressureside is naturally under high pressure. So, care must be used to protect your eyes and ski, LEAK-TESTING REFRIGERANT SYSTEM Whenever @ refrigerant lek is suspected in the system or any service operation has been per formed which may result in disturbing lines or connections, it is advisable to test for leaks Common sense should be used in performing any refrigerant leak test, since the need and ‘extent of any such test wil, in general, depend ‘upon the nature of @ complaint and the type of 18 service performed on the system, Liauio Leak DETECTORS: ‘There ae a number of fittngsand places through: ‘ut the air conditioning system where a liquid leak detector solution may be used to pinpoint refrigerant leaks, By merely applying the solution to the area in question with a snab, such as attached to the ap of 2 vial, bubbles will form within seconds if there is leak For confined areas, such at sections of the ‘evaporator and condenser, an electronic (gos) leak detector i more practical for determining leaks. SERVICING [AIR CONDITIONER (OPTIONAL) 1 TROUBLE DIAGNOSIS ool air comes out only b) Magnetic clutch faulty €} A/C switch faulty 6) Theemistr faulty fe} Dual presure switch faulty 1) Wiring oF grounding faulty 4} No refrigerant hh) A/Camplifer faulty Compresior is not rotating properly. 2} Drive belt loose or broken '. Compressor faulty Blower inoperative Expansion valve faulty Lak in system FRcever/dryer having blown fusible plug or clogged serew Magnetic clutch slipping AlCamplifer faulty Expansion vale faulty Wiring connection faulty Excessive moisture in system Trouble Possible cause T Remedy No cooling or | Magnetic clutch doesnot engage properly warm ai. 2) Fuse blown Replace fuse and check for short Check elute heck switch CGheck thermister, Check switch pair as necessary. Cheek AVC circuit Replace A/C amplifier. ‘Tighten or replace drive belt (Check compressor Check blower. ‘Check expansion valve (Check system fo lakes. Check receiver /aryer. ‘Chock magnetic clutch, Replace A/C amplifier. Check expansion vave Repair as necessary, Evacuate and charge system. | ‘oot air comes ‘out only at high speeds, Condenser clogged Drive tt lipping Compressor Faulty Insufficient or excessive charge of refrigerant Air in yster ‘Check condense. Check or replace drive belt Check compressor. Check charge of cetigerant, Evacuate and charge system Tsfficient cooling Tnaificient velocity of cooled ait | Evaporator clogged or frosted Condenser clogged Drive tt slipping Magnetic clutch faulty Compressor faulty Expansion vale faulty “Thermister faulty Insufficient or excessive charge of refrigerant Airor excessive compressor il existing in system Receiver/dryer clogged Air leaking from cooling unit or air duct Air init blocked Blower motor faulty (Check condenser. CCheck or replace drive belt, (Check magnetic ctutch Check compressor. Check expansion valve Check thermister. (Check charge of ratrigrant. Evacuate and charge system, (Check recsver/dryer. (Check evaporator. Repair as necessary, Repair as necessary, Replace blower motor.18:12 AIR CONDITIONER (OPTIONAL) ON-CAR SERVICE NOTE When servicing air conditioning system, follow ing instructions must be obsorved. WIRING: 1) Disconnect battery negative terminal to pre vent any short circu 2} Connect wire connectors securely. 3) When routing a wire harness through a panet hole, previously insert @ rubber bushing into the hole fr its protection, 44) Use a viny! tape or orginal clamps to connect air conditioner wire harness to. main wire harness. 5) f original harness has been disconnected or removed while servicing, ceturn it toa proper Position 6) During their installation, be careful not to pinch original ard air conditioner wire har 7) When adding lead wires to wire harness by soldering, use those lead wires which share ‘the same diameter and tape each connection 8)Keep wire harness anay from any com ponents moving or subjected to high tempera ‘re, 8) eep connecting portions away from fuel ines. 10) Make sure that wire harness makes no contact toa sharp edge or corner, REFRIGERANT LINES: 1) Never use heat for bending pipes. When bending a pip, try to make 9 bend as slight as possible. 2) Keep internal parts of air conditioner free ‘rom moisture and dus. When disconnecting any line from system, insall a blind plug or cap to fitting of such Tine immeditely 3} When connecting hoses and pipes to each other respectively, previously apply 8 few crops of retrgerating oll to seats of coupling ruteand Oring, 4) When ‘tightening or loosening 2 fitting, use ‘wo wrenches, one for turn and the other {or support. 65) Recelveridryer ile Fitting must be connected to the pipe from condenser outlet fitting 6) Tighten flared nuts according to following table of Tightening Torque. ‘Coupling Nut a ares Tightening Torque Tw 15Nem 1/4 inch pipe (1.00 1.5kam) (7.7 t0 11.0 wt) 20:10 30 Nan 3/8 inch pipe (2010305) i (14510 21.5 bt) 30 to 40 Nem 1/2 neh pine (3.0 t0 40 kgm) (21.510 28.0 tot) 40% 60m 578 inch ple (4.010 505m) (29.0 0 36.0 bt) 7) Route drain hose so thet drained water does ‘ot meke any contact to ear components HANDLING REFRIGERANT:12: 1) When handling cefrigorant, alwayswesr goggles to protect your eyes 2} Avoid your direct contacto liquid refrigerant, 31.0 not heat retrigerant ean higher than 40°C (100°. 4) Do not discharge refrigerant into the enclosed area having open flame. 5} Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture Js corrosive and will tarnish surfaces of bright ‘metas including chrome, {1 When purging retrigeating system, dizcherge refrigerant very slowly. Otherwise, retrigeat ing oil will be discharged together with re ‘rigerant. 7)When discharging refrigerant from system, cover the end of charging hose with @ rag oF place such end ina container WARNING: Should Refrigerant-12 strike your eyels), consult doctor immediatly * DO NOT USE YOUR HAND To RUB. AFFECTED EVE(S). Instead, use quant: ties of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point, '* Obtain proper ‘westment s# s00n a possible from a doctor or eye specialist Should liquid R12 get on your skin, such affected part should be treated in the same manner ae when skin i fost bitan otro Use the following table when checking charged state of refrigerant and correct it s necessary. [AIR CONDITIONER (OPTIONAL) 18:13 INSPECTION AND REPAIRING REFRIGERATING SYSTEM A.CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Fun engine at fast idle, and operate air condi tioner at its max. cooling capacity for a few ‘minutes. Then, look atthe sight glasson receiver dyer to check charge of retigerant, Fig 1892 Bs symptom charg oftware farey 1 [Bobbie cbsewed insist a [nme charge of | Chek ator eke with ak reign in system | tester oben obmrved wight | Noo nic charge | Rler tte ert Sand & 2 sie eetrinar nay No temperature aiference | Empty or nary empty” | Eecsteard charge vem and 3. |beowencomprenor inet | sytem ‘hem check It or lnk th ok sndoutiet ten Noticeable temperature inlet and outlet Proper or too much char. | Refer to the items Sand 6, 4 | difference between compressor | ge of refrigerant in system When air conditioners turned | Too much charge of OFF, refrigerant insight glass refrigerant in system ‘Discharge excess charge of rerge rant to adjust it to specified ‘once produces bubbles and then clears 5 clears immediately and charge. remains ch When air conditioner is turned | Proper charge of rerige | NO CORRECTION NEEDED «5. | OFF. refrigerant insight lass | rant in system BECAUSE CHARGE OF REFRI GERANT IS NORMAL.18:14 AIR CONDITIONER (OPTIONAL) B. CONDENSER Inspection Check a) condenser fins for blockage, b) con: denser fittings for leakage, and c) condenser fins for damage. (Clogged condenser fins should be washed with water, and should be dried with compressed air. NOTE: Be careful not to damage condenser fins. ‘condanser fin is bent, svaighten it by using @ seremdriver or pair of pliers. If any leakage is ound from fitting oF tube, repair or replace condense. Removal 1) Slowly discharge retrigerant from high pressureside service valve, Quick discharge ‘causes compressor ol to escape together with refrigerant. So, care must be used to avoid any quick discharge 2)Disconnect compressor delivery hote from ‘condenser inte fittings 3) Disconnect receiver/éryer outlet pipe at NoTE: {As soon as above hose and pipeare disconnected, ap opened fittings so that moisture and dust do rot enter condense. 4) Remove hood latch and hood lock member. 5) Disconnect fan mator wire at coupler. 6) Remove its attaching bolts 7)Remove condenser together with fan and recever/dryer. Nore: Be careful not to damage fins of condenser and diator. 88) Remove cooling fan and recuver/dryer from condenser Installation 1) Reverse removal saquence to install condense. Nore: When replacing condenser, add 20 to 30 cc of ‘afrigeating ol from compressor suction side. 2) Evacuate and charge system according to previously described procedure, ©. RECEIVER/DRYER, Inspection Use a Teak tester to check for ga lakes alse, fusible plug and fittings, sight Removal 1) Slowly discharge refrigerant from high pres suressde service valve. Quick discharge causes compressor oil to escape together with re {rigerant So, care must be used to avoid any quick discharge. 2} Disconnect liquid line pipes. '3} Remove recever/dryer from its holder. Installation 1) Reverse removal sequence to install eceiver/ dryer. Nore: ‘© When replacing receivridryer, add 10 cc of Fefrigerating oll fram compressor suction: fide ‘Blind plugs of recelverideyer should not be removed until just before receiver/dryer is 2) Evacuate and charge system according to pre: Viously described procedure, D.EVAPORATOR (COOLING UNIT) Removal 1) Disconnect the battery (—) terminal 2)Slowly discharge refrigerant from high ares sureside service valve, Quick dlacharge causes compressor oil to escape together with re frigerant, So, care must be used to avoid any auick discharge, 3)Disconnect blower motor and resister wire couplers. 4) Disconnect fresh air control cable from blower 5)Remove blower motor unit after removing glove box upper panel and bolts as shown below. 6) Disconnect A/C amplifier and thermistor wire couplers. 7) Disconnect compressor suction pipe, receiver! dryer outlet pipe and drain hose from eva porator (cooling uit) Note: [As soon a: above hose and pipeare disconnected, cap opened fittings 90 that moisture and dust ‘may not enter cooling unit. £8) Remove evaporator with evaporator case 9) Remove A/C ampltir from lower cas. Disassombly 1) Detach clamp to separate evaporator upper and lower cases from each other. AIR CONDITIONER (OPTIONAL) 18.15 2) Take off case cover and remove evaporator cout of postion. Fig 16518 23) Detach following components from evapors: Expansion valve, © Thermister. Inspection 1} Check evaporator fins for blockage. 1 found ‘logged, use compressad arto clean the fins Nore: Do not use water for cleaning of evaporator. 2) Check inlet and outlet fittings for crack or ‘serach, Repair them as required16 AIR CONDITIONER (OPTIONAL! E. EXPANSION VALVE Inspection Prior to Removal 1) Connect manifold gauge st to servic valves. 2) Run engine at 1000 r/min with A/C switched on, 3) Check that low pressure gauge shows a read ing of 05 to 6.0 kg/cm? (7 1071 pi) properly If the reading is too low (below 0.5 kg/em*, 7 psi, check expansion valve and/or receiver] dryer, and replace as necessary. If the reading is too high (above 5.0 kg/em* 70 pai) tighten remote bulb holder or replace expansion valve Fig 1876 Removal Reter to items REMOVAL and DISASSEMBLY inthe previous section EVAPORATOR (COOL ING UNIT), Inspection 1) Connect manifold gauge st to expansion valve {and its charging hose to refrigerant can, Fig 187 2) Soak remote bulb of expansion valve in water contained ina water pan 3) Previously close both low and high pressure valves, 4)Use a can tap valve to pierce refrigerant can 1 release its presure, 5} Open high preccura vali ta alist pressire to approx. 5 ka/em? (70 psi, 6) Road the pressure incicated on low pressure gauge. At the same time, use a thermomater 10 measure water temperature 7) Use the Chart asshown below to check whether above measurements fal within shaded accep table range, Installation 1} Reverse removal sequence to instal expansion valve. 2) Evacuate and charge system according to pre viously described procedure, F. EVAPORATOR THERMISTER AA thermister is & temperature sensor to sence ‘the temperature of air discharge from evapora tor. The electrical characteristic is shown blow. [AIR CONDITIONER (OPTIONAL) 18:17 ‘When temperature is lower than specified, am plifier makes magnetic clutch tuen off to prevent evaporator from frosting Removal Refer to tems REMOVAL and DISASSEMBLY inthe saction of EVAPORATOR. Inspection Check resistance if i i within the shaded range of above raph. Installation 1) Reverse removal sequence to install thermister. 2)Evacuate and charge system eccording to previously described procedure, G.WATER TEMP. SWITCH Inspection Warm switch and check for continuity. It isin {0d concition f continuity appearsatand above below specified temperature. Continuity should exist at and above pecekaela H.REFRIGERANT LINES Inspection 1) Use a Ink testa ta. chack hosts and pipes for any gas eakag 2).Chack each hose oF pipe clamp for tightness. Retighton or replace loose clamp as required, itary, Removal 1) Slowly discharge refrigerant from high pres- ‘sures sarvce valve. Quick discharge causes compressor oil to escape together with re {rigerant. So, care must be used to avoid any quick discharge. 2) Replace defective hose or pipe. NOTE: [As soon as the above hose or pipe is disconncet: fd, cap its opened fitting to prevent mols and dust from entry. Installation 1) Reverse removal procadure to install refrige rant line 2) Evacuate and charge system sccording to pre viously desribed procedure,18.18 AIR CONDITIONER (OPTIONAL) |. ELECTRICAL CIRCUIT Alc SWITCH Inspection 1) Disconnect the battery (—) cable. 2) Remove heater convo! knobs and panel 3) Disconnect A/C switch connector to remove AIC switch. 4)Use an obmmeter to check A/C switch for proper continuity between each terminal. Pink/Black | Blue | Black OFF: on oto IFAIC switch shows no continuity, replace DUAL PRESSURE SWITCH This car is equipped with switch which oporates according to high or low pressure Fin 1o2; Inspection 1) Check switches for continuity at normal tem: perature (approx. 25°C, 77°F) when A/C system has 9 proper charge of refrigerant and when A/C system (compressor) isunder opera tion, In each of these ease, witches should show proper continuity, 2)When pressure is 2.11 kg/em? (30 pall or below, low pressure switch should show no continuity. When pressure is 27.0 ka/em? (383 psi) oF above, high pressure switch should show na continuity VSv (VACUUM SWITCHING VALVE) Inspection 1) Disconnect vacuum hose and connector from vsv. 2)Check VSV for proper vacuum circuit conti ruity. 4) Check VSV for open circu. Mesure resistance between two terminals of vsv. Specified Resistance | 24103002 MAGNETIC CLUTCH Inspection 1) Check pressure plate end rotor for wear and oil soaked conditions respectively 2)Check clutch bearing for noise, wear, and rate leakage 3)Measure stator coll for resistence at 25°C orl, Standard Resisance | 322020 Fig 1022 3) Check VSV for short circuit, No continuity should exist between each ter minal nd VSV body. Uf the measured resistance does not remain within above tolerance, replace cil RELAY 1) Disconnect the battery (—) cable. 2) Disconnect its connector to remove reley out of positon 4) Wie as shown below to check whether proper continuity is obtained betwoon terminals 3 and 4. (ay [AIR CONDITIONER (OPTIONAL) 10-18 J. MISCELLANEOUS DRIVE BELT Inspection 1) Check belt tension, and adjust it as necessary. Fig BE Belt Tension as Loaded | with 10 kg THUMB PRESSURE 510 6.5 mm {0:20 — 0.25 in) 2) Check belt for wear and crack, and replace it asrequire, ‘COMPRESSOR MOUNT Inspection 1) Check mounting bolt for looseness. 2) Check mounting bracket for crack or fracture. When retightening the bolt, use specified torque, Ce Fig Tea Uf found defective with no continuity, replace relay. ‘Smm Bolt 25 10 30N-m [25 0 30kgm| 1010 22 TO mm Bolt 40 0 50.Nm [4.0 t0 50 kam] 3010 40 ADJUSTMENT OF IDLE SPEED WITH AIR: CON ON Refer to “GE” of EF. section18:20 AIR CONDITIONER (OPTIONAL) PERFORMANCE TEST [After Finishing all repairs, make sure to carry out performance test of air conditioning system as follows. PROCEDURE 1) Connect high and low side charging hoses of manifold gauge set to hose fittings of com: pressor. 2)Run engnie, and keep compressor speed at 2,000 rpm. 3) Operste air conditioner, and set blower switch at"HI", temperature lever at “COOL”, 4) Keep all windows and doors open. 5) Insert a dry bulb thermometer in cool air out let, and place paychrometer (dry and wet bulb thermometer) close to inlet of cooling unit. Fig 1826 6) The high pressure gauge reading should be Within specified pressure range, 14.0 to 15.5 lem (200 to 220 psi Nore: 1 the gauge indicates too high, pour water on condenser or if itis too low, cover front surface of condenser. 7) The dry bulb thermometer at air inlet should be within 25 t0 35°C (77 to 95°F) Under above conditions, operate air condition ing system until a stabilized condition on high and low pressure gauges and thermometers has been established, HOW TO READ THE STANDARD PERFOR. MANCE CURVE 1) Read peychrometer reading at the inet, and get relative humidity from psychrometric chart. (See Fig. 18-28 or 18-28) 2) Measure dry bulb temperature at cool ar out let, then find out the difference between inlet and outlet temperatures. Ai CONDITIONE; (OPTIONAL) 18:21 HuMorry CF) WOW TO READ RELATIVE Gry temparatre on the Sy Inlet, follow nas at hose tem pereues and. read the rlstve 1 rytulb temperature is 90°F wet bulb temperature is 78°F, the eltve hit i 60%. JE ajc) << TNE oid 522) x ic 2 ong : x at an 52" | 4 50 6 7 8 6-90 100 10 120 get DRY-BULB TEMPERATURE °F be 4 Fa ea 7 ow ro READ RELATIVE wombir¥ ee) Meow we ul empeeie and Fig 18-27 ‘dry-bulb temperature on the psy: 3) Check the relative humidity-to-temperature lfference relationship using the above graph. ‘As an example of 17°C (62.6°F) temperature difference and 60% relative humidity shown in it, if thelr crossing point falls within the area between two lines, cooling performance then i satisfactory and proper. chometer at the eraporstor at Ina follow ines ot those empeo- rbd the elaine Bai ‘nd wt bly temperature ‘he lative humility Is 6%. Fae at D ve ne 5 us eo — sO a a ORY-BULB TEMPERATURE)[AIR CONDITIONER COMPRESSOR OVERNAUL (OPTIONAL) 1C-1 SECTION 1C AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) CONTENTS GENERAL INFORMATION 11 (CHECKING COMPONENTS 1c 9 ‘TROUBLE DIAGNOSIS. 101 [ASSEMBLY OF COMPRESSOR 1c-10 ON-CAR INSPECTION 10-2 ‘ASSEMBLY OF MAGNETIC REMOVAL OF COMPRESSOR 1c-2 eLuTcH tera INSTALLATION OF COMPRESSOR .. 10- 3 FINISH 1015 DISASSEMBLY OF MAGNETIC PERFORMANCE TEST OF cLuTcH 103 ‘COMPRESSOR, 1015 DISASSEMBLY OF COMPRESSOR ... 10. 5 SPECIAL TOOLS 10-16 GENERAL INFORMATION When servicing the compressor, keep dirt or foreign material from getting On oF into the ‘compressor parts and system. Clean tools and a ‘lean work area are important for proper service. ‘The compressor connection and the outside of the compressor should be cleaned before any “on-car” repair, oF before removal of the com: pressor. The parts must be kept clean at all times and any parts to be reassembled should be clean with Trichloroethane, naphtha, kerosene oF ‘equivalent solvent and dried with dry sir. Use coniy lint free cloths to wipe parts ‘The operations described below are based on bench overhaul with compressor removed from the car, except asnoted. They have been prepared in order of accessibility of the components. When compressor is removed from the car for servicing, the oil remaining in the compressor should be discerdad and new refrigerant oll added to the comprestor. Minor repair procedures may be done on the car without discharging the system. Major repair procedures require thatthe system be discharged of refrigerant. TROUBLE DIAGNOSIS Compressor troubles are mainly following three types: ga leakage, noise and insufficient pressure Compressor gas leskages in most casos develop from the shaft sal. When detecting gas leakage, always use a leak tester. Ita small amount of oil seeps ut from the shaft sal, theres no necessity of replacing the seal, The shaft seal has been esigned to allow a small amount of ol to leak ‘out for lubricating purpose, Thus, the shaft seal should be replaced only when a large amount of compressor el is leaking out or wher gas leakage Isdiscovered by using gas tester In regard to nolse and insufficient pressure, re pairs should be made only after diagnosing the ‘rouble propery.162 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL! Tem PROBLEM POSSIBLE CAUSES ‘CORRECTION 1 | Noise from compressor | 1. Defective piston/shoe Replace 2. Detective bearing Replace 3. Defective cylinder and/or shaft Replace 2 | Noise from magnetic | 1. Defective bearing eplac clutch 2. Defective clutch face Replace 2 | tneuficient cooling 1. Defective gasket Feplace 2. Defective reed valve Replace 4 | Notrotating 1. Locked by item 1-1 9 13and 32. Replace 2. Seized magnetic clutch Replace or repair | 3. Rotating parts seized due to insufficient | Replace or repair 5 | Oitand/orgas leakage | 1. Defective seal Replace 2. Defective "0" ring Replace 1) Install manifold gauge set as shown below. 2) Close Hiand Lo hand valves, 3) Run engine a fast ile 44) Check comprestor for following: 18, High pressure gauge reading is not low and low pressure gauge reading is not higher than normal b. Metalic sound, «Leakage from shaft sel If any of the above checks indicates a defect, repair compressor. ON-CAR INSPECTION 5) Check magnetic clutch. 4, Inspect pressure plate and rotor for signs 'b, Check clutch bearings for noise and grease leakage. «, Using an ohmmeter, measure resistance of stator coil between clutch lead wire and ‘round at 25°C (77°F), IF resistance is not within specification, repiaee coil Standard resistance | 3.202 ohms REMOVAL OF COMPRESSOR 1) Run engine at idle with air conditioning on for 10 minutes 2) Disconnect battery negative (—) termina 3) Discharge refrigerant very slowly from re ‘tigeration system, 4) Disconnect eluteh stator lead wire from A/C wire harness. 5) Disconnect suction and discharge flexible hoses from compressor [AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) 163, 6) Remove O rings from hoses. Nore: Cap open fittings immediately to keep moisture ut of system. ‘TiHoist car and remove front fender apron ‘extention (Rand ol Filter. 8} Loosen compressor drive belt, then remove compressor mounting bolts. 9} Remove compresior with clutch as from its DISASSEMBLY OF MAGNETIC CLUTCH NOTE: When removing compresior, be careful not ‘0 damage fins of condenser. INSTALLATION OF COMPRESSOR 1) Revers removal sequence to install eampressor asy. 2) Add engine ol B)Evacuate and charge systom according to previously decribed procedure, Fig 102 1) Remove pressure plate nut Fig 103 2) Using pressure plate remover, remove pressure plate16-4 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) 3) Remove shims from shaft. 44) Remove drive clutch, Using snap ring pliers, remove ciclip. aie Using plastic hammer, tap drive clutch off from shaft, Fin 107 Remove clutch col 6) Inspect pressure plate, drive clutch and clutch 4, Inspact pressure plate and drive clutch surfaces for wear and scoring. Replace if b, Check drive eluten bearings for wesr and leakage of grease. Replace if necessary. «. Chack elutch coil for resistance using ohm- meter. Replace if necesary. Standard resistance 324020 Fig 108 Nore: Be careful not to damage pulley when tapping drive elute, 5) Remove clutch coil Disconnect oll lead wire from compressor housing. Using snap rng pliers, remove etclip. Alf CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) 165 DISASSEMBLY OF COMPRESSOR -———— Fin ico |166 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL! 1) Remove oil fet. Using» screw driver, pry out oil ft Fa tee 2) Remove key. Using a hammer and punch, drive key from shat. 3) Remove ciclo, Using snap ring pliers, remove ctclip {4} Apply compressor oll to inner bore Fig fT 5) Using sal plate remover (Special too), remove seal plate 6) Using shat seal remover (Special tool), remove that sa [AIR CONDITIONER COMPRESSOR OVERHAUL OPTIONAL) 167. 7) Remove joint srvice connector, Fig 1016 Remove "0" rings from service valve and discard them, £8) Drain il into container, Foie Fa 107 9} Remove front housing, NOTE: Do not reuse five washers. Fig 1018 Remove front housing by prying it at its prowusion Fig 1079 note: Be cereful not to scratch sealing surface of front housing.16.8 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) [AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) 169) 10) Remove front valve pate 12) Remove rear valve plate CHECKING COMPONENTS. Remove two pins from cylinder block. Remove two pins fom rear housing Ccean all parts with cleaning solvent and apply compressor ol to them. PART NAME (CHECK POINT REMEDY Shaft seal 1. Check lapping surface of carbon dsc for Replace : cracks and scratches, 2. Check rubber sea fr eracks and hardening. | Replace 3. Check spring action Replace : Seal plate 1. Check sealing surfaces for seratches and Replace Figo Fig 0 Valve pate 1. Check both surfaces for sratches and | Replace or polish with 5 corrosion. fine oil stone. 11) Remvoe rear housing by prying it at its 13) Remove front and rear "0" rings from ey: protrusion, inde block and discard them. 7 ] Reed vive 1, Check reed for cracks, scratches, deforma | Replace @e ‘Hon and corrosion, Front housing 1, Check sealing surface for eracksseratches and | Replace deformation tsk Piaton eylinder block | 1. Cheek oylinder bore for scratches and Replace Fig 107 Fig 1028 2. Check racial bearings for poor contact, worn- | Replace out needle, scoring or pit 23. Check shaft for excessive axial play. Replace 4. Check piston for excesive axial play. Replace NoTE: _ - 4 Be careful not to seratch sealing surface of rear Rear housing 1. Check sealing surface for cracks, scratches | Replace housing and deformation46.10 AIR CONDITIONER CON ASSEMBLY OF COMPRESSOR NOTE: ‘+ Do not rouse gasket shaft seal, O-rings, oF ‘washers. Use overhaul gasket it. + Before starting assembly, make sure all parts ‘as well as work-bench are elean. 1 Install rear valve plate on rear cylinder. 4, Install wo pins in rer cylincer 1. Lubricate new Oxing with compressor oll and Install in rear oylinder. «Install suction reed valve, rear valve plate, and discharge reed valve to rear cylinder top. For installation locations, refer to figure below. note: ‘© Front and rear reed. valves (suction and S90 OVERHAUL (OPTIONAL) Lubricate gasket with compressor oil and Ingtall it to valve plate, Nore: Front and rear gaskets aren't the same, s0 do not Interchange them. 2) Install ear housing to rear cylinder. Protrusion of housing should come atthe top. 3) Install front valve plate on front cylinder. 2 Install two pins in font cylinder . Lubricate new O-ring with compressor cil Install it in front eylinder ©. Install suction reed valve, front valve plate, and discharge reed valve Onto front eylinder top. For installation locations, refer to figure Fig 10? Nore: ‘Assemble gaskets 20 that their protruded surfaces ‘ace upward !ONER COMPRESSOR OVERHAUL (OPTIONAL) 16-11 Nore: ‘¢ Front and rear reod valves (suction and dis charge) are the same. ‘+ Front valve plate is marked “F™, 4d. Lubricate gasket with compressor oil and install itt valve pate. Fig 1090 Note: ‘© Front and rear gaskets aren't the same, s0.d0 not interchange them, (To differentiate them, refer to description on rar valve plate.) * Assemble gaskets so that heir protruded sur ‘aces face upward. 4) Install front housing front cylinder and tighten five through bots 8. Using @ torque wrench and hexagon wrench ‘gradually tighten five through bolts. [xm [om [or 25— 2725-27] 181-108]16-12 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) NoTE: Protrusion of housing should come at the top. Fig 1031 15) neta hat eal 2, Lubricate shaft seal with compressor oil and ‘i it to shaft seal remover (Special too Fig 102 . Apply ol to bore. Insert shaft seal remover, and turn it to the left while lightly pressing. Then pull up shaft seal mover. Fae 6) Ineal set plate. 2. Lubricate O-ring with compressor ol. Put seal plate. Press eal plate pressor by hand [AIR CONDITIONER COMPRESSOR OVERNAUL (OPTIONAL) 16.13, Fe 1035 £8) Install key in shaft groove. 8, Using aplastic hammer and key installing tool (Special tool, tap key lightly 9) Instat oi ot 2. Put new cil felt to inside of bore Fae 10) Pour compressor ol into compresor. ‘Additional oi after 0c compressor overhauling | (2 ev. in.) Oil capacity of air 80+ 20ce conditioner system | (4.9 0.1 cu. in.) NOTE: Compressor assy supplied from factory is filled with 80 c¢ oil. Therefore, when replacing only compressor assy with new one, dain 40 ec oil from i. ‘The rest 40 ce oll remain in other parts than compressor.16:14 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) 11) Install service valves, ‘8, Lubricate new O-rings with compressor oil and install them in service connector. », Install service connector to compressor. j2s—27 [181195] Fg oso Nore: Suction port has larger internal opening than discharge port. 12) Check shaft rotating torque. Less than Sartingtora4e | 50 kg-cm (2.2 Ist) ASSEMBLY OF MAGNETIC CLUTCH (S00 Fig. 162) 1 stall magnetic clutch coil Install elutch coll to compressor. 2) Install drive clutch. 4. Install drive clutch on compressor shat. Using snap ring pliers, install snap ring, 3) Install pressure plate 4, Adjust clearance between pressure plate and drive clutch by putting shims on compressor shaft. EEE wn (04-07 mm Standardcteaance | ig os6 000 in -b, Tighten pressure plate fixing aut Te [se |e Tightening oree [16—175[15-178] 11.0129] [AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) 16.15, FINISH 1) Performance gas lak test a, Put caps on joint service connectors “As compressor as'y supplied trom factory has cape, keep and use these caps for this test and storing a repaired compressor. . Charge compressor with refrigerant through charging valve until 3 kg/em? (45 psi presure is obtained, «. Using gas leak detector, check compressor for teak. IH leek is found, check and replace gasket, (O-ring or shaft se ] 2) Evauate compressor and charge with origerant Make sure cape ate tight and free from mois: ture and dust. PERFORMANCE TEST OF COMPRESSOR Performance test of repaired compressor is made by installing compressor on car and checking pressure measured with gauge manifold while ‘operating ar conditioning system. For mounting method of gauge manifold, refer to evacuating procedure as described previously, NORMAL OPERATION Measure pressures with suction port alr temper ture set at sround 30° to 35°C (86° to 95°F}, engine spaed at 2,000 rpm, and at strongest cooling setting. ‘Standard Pressures T15=20Kgiem" | Low presuresige | 15 20 ale (21.3284 psih 145 — 15 kglem™ High pressure side | MSS No ee16:16 AIR CONDITIONER COMPRESSOR OVERHAUL (OPTIONAL) NoTE: When storing compressor for an extended period, charge compressor with refrigerant or dry nitrogen gas to prevent corrosion. If low pressure side reads to high or high pressure ‘sie too low, probable cause is leakage from reed ‘valve inside compressor or @ broken sliding part (pieton,eylinder, or others). In such a case, ds assemble compressor and make a recheck. SPECIAL TOOLS NO. TOOL NAME TOOL NO. USE Pressure plate remover (09990-58210 _| To remove magnetic clutch plate 1 Z._| Seal plate remover 09990-48210 | To remove seal plate [3 sfar sat vemever | 09090-38210 | To removeinstll shafts | “4 [Sea plate pret 0990068210 | To instal sal pate 5. Key pressor (09990-28210 | To install key 6. [ Oilfilter wrench | _09018.47310 | To remove/insal oil filter ERS AND SHEET METAL 2.1 SECTION 2 BUMPERS AND SHEET METAL CONTENTS BUMPERS: 24 Hoop 7 24 FRONT FENDER 25 BUMPERS Note: Fasteners are important attaching parts in that they could affect the performance of vital components ‘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. Do not use a replacement part of estar quality or ubstitute design. Torque values must be used as speci during reassembly to assure proper retention of these parts,22. BUMPERS AND SHEET METAL FRONT BUMPER REAR BUMPER BUNPERS AND SHEET METAL 23 faa REMOVAL 1) Remove font fender lining and disconnect {og light couplers. 2) Remove front turn signal lights 3) Remove bumper fitting bolts and nuts shown in Fig. 22. Fig? 4) Side burmper (with bumper member) forward INSTALLATION 1) Connect fog light couples. 2)Slide bumper onto bumper side attachments ‘on both fenders. 3) Use burnper bolts and nuts to fix bumper in position. 4) Ital front turn signal lights REMOVAL 41) Remove rear combination light fitting sews 2) Remove bumper fitting bolts and nuts shown in Fig. 24. Fda 3) Temporarily install rear combination lights In position with srews, 4)Slide bumper (with bumper member) back- ward to remove it INSTALLATION 1 Slide bumper onto side attachments on both fenders. 2) Install removed parts in reverse order of removal2.4 BUMPERS AND SHEET METAL, HOOD REMOVAL Remove four mounting bolts to detach hood. a B. Vertical adjustment If only one sie (right or left} of hood is not lovel with front fender, make it level by tigh ‘ening or loosening hood cushion. Fig 25 Food Wauntng Ba igh Sida) ADJUSTMENT ‘A. Fore-and.aft and rightand lft adjustment Slacken four mounting bots for adjustment. Fig, 26 Hood Mounting Bole (Rigi Sie) Fig 7 Varia Hood Aan Fig. 38 Wood Latch Adusinart FRONT FENDER BUMPERS AND SHEET METAL 25, REMOVAL 1) Remove front bumper (Refer top. 22) 2) Remove clearance lights Fig B10 Removing Gewance Lpht 3) Remove front fender. INSTALLATION 1. Reverse removal procedure for installation NOTE: When replacing front fender, be sure to apply anti-corrosve treatment to replacement fender. Fig B17 Replocomant ForderSECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS, a FRONT END ALIGNMENT aaa MANUAL RACK AND PINION 381 STEERING COLUMN 3ct FRONT SUSPENSION 204 REAR SUSPENSION . 364 WHEELS AND TIRES . oF CONTENTS GENERAL DIAGNOSIS cH dial Tire Waddle 36 TIRE DIAGNOSIS. 36 Radial Tire Lead 38 Irraguar and/or Premature Wear 36 VIBRATION DIAGNOSIS 38 Wear indicators 36 GENERAL DESCRIPTION Since the problems in steering, suspension, wheels and tres involve several systems, they must all be con sided when diagnosing a complaint. To avoid using the wrong symptom, always road test theca frst Proceed with the following preliminary inspections and correct any defects which ae found, 1) inspect tires for proper pressure and uneven weer. 2) Raise car on a hoist and Inspect front and rear suspension and rack and pinion for loose or damaged parts. 3) Spin front wheels. Inspect for outofround tires, outof-bslance tires, bent rims, loose and/or rough winel bearings. GENERAL DIAGNOSIS CHART A Condition Possible Cause Correction Car Pulls (Leads) 1. Mismatehed or uneven tres. | Replace tire. 2, Tires not adequately inflated. | Adjust tir pressure 3. Broken or sagging srings Replace spring 4. Radial tice lateral fre Replace tire. 5. Disturbed front end alignment. | Check and adjust front end align 6. Disturbed rear wheel alignment. | Check and adjust ear whee! align 7. Brake dragging inone road wheel, | Repair front brake, £8. Loose, bent or broken front or | Tighten or replace suspension parts. rear suspension parts.GENERAL DIAGNOSIS CHART B GENERAL DIAGNOSIS CHART C Condition Vibration Hard Steering ‘Abnormal or Excessive Tire Wear a | orecton Repos sing, Adj tae or ele te, | cece and ada tron nd align | 1 Seana or broken orn. | 2 Tre out of aes 3. Disturbed front or rear end alignment. | ment. 4. Faulty strut (shock absorber). | Replace strut. 5. Hard driving Replace tie. 6. Overloaded car. Replace tre, 7. Not rotating tre, Replace or otate tre. £8, Worn or loose road wheel bearing. Replace wheel bearing. 8. Wobbly wheel or tr, | 10. Tires not adequately inflated, Replace wheel or tre. Adjust tee pressure, 1. Blister or bump on tire, Replace tie 2 nprope st sk stot | Ree st | 1. Tie or whee out of balance, | Balance wheels or enlace tie | | andor whee 2, Loose whoa bearings | Replace hes bearing | Worm rod eres Replace te od ond | ‘4. Worn ower ball joins. | Reoce tom spersion rm 5. Excesve wheel runout Repeir or replace wheel andr te 6. Blister or bump on tir. | Replace te 7. Excesivel loaded rac unout | Replace te or whet of tree ase 8. Disturbed front end alignment. | Check and adjust front end align 8. Loose or worn steering linkage. | Tighten or replace tering linkage. | 10, Loos steering gar case ots. | Tighten cae bolts | 1. Bind in tie rod end ball studs oF lower bal joints. place tie rod endo front suspen- | sion arm. |_ 2: Disturbed front end alignment, | Check and adjust front end align ment | 2. Rescand pinion adjustment, | Chest and et ack & pon | | torque. 4, Tite not adequately inflated. | Inflate tres to proper pressure. 5. Bind in steering column, | Repair or replace Condition | Too Much Play tn Steering Poor Returnebil (Rattle or Chuckle) [ Rack and Pinion Noise [Possible Cause 1. Wheel bearings worn, 2. Rack and pinion attachments 3, Rack and pinion adjustments. 4 Worn steering shaft joints, 5. Worn tie rad ands or tie rod | P inside bat joints 6. Worn lower ball joints. 1, Bind in tie rod end bal studs. 2. Bind in bal joints. 3. Bind in steering column 4. Poorly lubricated rack and pinion. 5. Disturbed frontend alignment. 6, Rack and pinion adjustment. 7. Tires not adequately intiated. Rack and pinion attachments 2, Worn rack bush, 3, Rack and pinion adjustment. ‘Correction Replace Tighten or eps. Ccheck and adjust rack & pinion torque. Replace joint. Replace tle rod end or te rod. Replace front suspension contro! Replace te rod end. Replace. Repair or replece. Check, repair or lubricate r pinion. Check and adjust front end align ‘Check and adjust rack & pinion torave. K & Tighten storing gear case mounting bolts. Replace. Check and adjust rack & pinion torque. End ‘Abnormal Noise, Front 1. Warn, stieky or loose tie rod tends, lower ball jot, tie rod Inside ball joints or drive shaft joints, 9. Damaged struts or mountings. Worn suspension arm bushings 4, Loose stabilizer bar. 5, Loose wheel nus 6, Loote suspension bolts or nuts. 7. Broken or otherwise damaged whee! bearings Broken suspension springs. Poorly lubricated or worn strut bearings. 10, Worn or sticky stabilizer joints. Replace tie rod end, suspension arm, tie rod or driveshaft joint. Repair or replece. Replace Tighten bolts or nuts, replace bushes Tighten whee! nuts “Tighten suspension bolts or nuts. Replace, Replace Lubricate or replace strut bearing Replace.Diacnosis 35 24 o1aGnosis GENERAL DIAGNOSIS CHART D GENERAL DIAGNOSIS CHART E Condition — Possible Cause ] "Correction Condition Possible Cause Correction Wander Or Poor Steering | 1. Mismatched or uneven tires, | Replace or inflate tires to proper | Body Leans Or Sways in| 1. Loose stabilizer bar. Tighten stabilizer bar bolts or nuts, Stability pressure, Comers, cor replace bushes or joint. 2. Loose ball ointsand tierod ends, | Replace suspension armor tie rod end} 3. Faulty struts or mounting. | Replace strut or repair mounting, 4, Loose stabilize bar, ‘Tighten or replace stabilizer bar or bush, 5. Broken or sagging springs. Replace spring 6. Rack and pinion adjustment. | Check and adjust rack and pinion torque. 7. Front end alignment. Check and adjust front end align 8. Loose stabilizer joins | Replace joint. Errati Steering When Worn wieel bearings. Replace Braking ‘Low Or Uneven Trim Height Right.toreft trim height (H) difference should be within 15 mm (0.6 in) with curb weight. 1 2, Broken or sging springs. Replace coll spring 23. Whee tices are inflated unequally. Inflate ties to proper presur 4, Disturbed front end slignment. | Check and adjust frontend align 5. Brakes not working in unison, | Refer to Section 5, 1. Broken or sagging springs. Replace, 2. Overloaded. Check loading 3. Incorrect springs. Replace, Ride Too Soft Faulty struts (shock absorbers). | Reploce strut. 1 ‘Suspension Bottoms 1. Overloaded. ‘Check loading. 2. Faulty struts (shock absorbers). | Replace tut. 3. Incorrect broken or sagging | Replace sorings. 2. Faulty struts (shock absorbers)_| Replace strut or tighten ‘or mounting. ‘mounting 3, Broken oF 899Ing springs. | 4. overioaded Check loading ‘Cupped Tires 1. Front Sts defective, Replace, | 2. worn whee! bearings. Replace, 3, Excessive tire or wheel run-out. | Replace tre or whee dsc. 4. Worn ball joints. Replace front suspension arm 5, Tire out of balance. Aajust tir balance.25 DIAGNOSIS TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature weer has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. {If the following conditions are noted, rotation Isnecesary: 1. Front tre wear is different from cea. 2. Uneven wear exists across the tread of any tre. 23. Front tice wear is unequal between the right and tft 4. Rear tice wear is unequal betwo and lft 5. Thore is cupping, flat spotting, ete the right Fig 31 Tie Wear Dingross ‘A wheel alignment check is necessary if follow: ing conditions are noted: 1. Front tire wear is unequal between the right and let. 2. Wear is uneven across the tread of any front tire, 3. Front tire treads have scuffed appearance with "feather" edges on one side of tread ribs ‘or biocks. WEAR INDICATORS (FIG. 3.2) Orginal equipment tices have builtin tread wear indicators to show when they need replacement. ‘These indicators will appear as 12mm (0.47 inch) wide bands when the tire tread depth becomes 1.8 mm (0,063 inch). When the incicatorsappear Jn 3 or more grooves a 6 locations, tire replace: ‘ment i commended. Fig 92 Ti Wer Iiator RADIAL TIRE WADDLE (FIG. 33) Waddle is side to side movement at the front ‘and/or rear of the ca. It is caused by the steel belt not being straight within the tie. It is most noticeable at alow speed, 5 to 30 mph, It is possible 10 locate the faulty tire by road ‘testing the car. If itis on the rear, the rear end fof the vehicle shakes from side to side or “waddles". To the driver in his sat, it feels as though someone is pushing on the side of the vehicle If the faulty tire is on the front, wadding is more visual. The front sheet metal appears to be ‘moving back and forth and the driver fels as ‘though he sat the pivot point inthe car Waddle can be quickly diagnosed by using Tire Problem Detector (TPO) and following the equip- ‘ment manufacturer's recommendations IE TPD is not available, an alternative method of substituting known good tire/whes! assemblies can be used az follons although it takes a longer time, DiaGNosis 27 1. Ride car to determine whether the front or rear woddles, 2. Install tires and wheels that are known to be sod fon similar ear) in place of those on \wadeling end of ear. If wadding end cannot be identified, substitute rear ones. 3. Road twst again. IH improvement is noted, reinstall originals one at a time till waddle causal tre ie found. If no improvement is noted, install known good ties in place of al four. Then reinstall originals in the same manner as above INFLATE TIRES TO RECOMMENDED _ PRESSURE ip 53 Redd Tre Wade ROAD TEST CAR ON LEVEL | 'UNCROWNED ROAD IN BOTH DIRECTIONS ROAD TEST AGAIN ‘SWITCH FRONT TIRES SIDE TOSIDE AND [_ = = LEAD CORRECTED LEAD REVERSES | \F ROUGHNESS RESULTS. DIRECTION. LEADS IN SAME RECTION. [REPLACE TIRES PUT TIRES BACK IN INSTALL A KNOWN GOOD TIRE ON ORIGINAL POSITION ‘ONE FRONT SIDE | | ano check ALIGNMENT _ — (EAD CORRECTED ‘LEAD REMAINS REPLACE TIRE INSTALL A KNOWN GOOD TIRE IN | "PLACE oF OTHER FRONT TIRE oo ‘LEAD CoMRECTED LEAD REMAINS REPLACE TIRE KNOWN GOOD TIRES ARE NOT GOOD Fig. 34 Lend Dngron28 p1AGnosis RADIAL TIRE LEAD ‘Lead’ isthe deviation ofthe car from astraight path on @ level road even with no pressure on the steering whee. Led is usally caused by: 1) incorrect alignment. 2) Uneven brake adjustment 23) Tie construction. ‘The way in which 2 tee i built can produce lead in a car. An example of this is placoment of the belt, OFF center belts on ragial tires can cause the ‘tice t0 develop a side force while rolling straight down the road. If one side of the tire has alittle larger diameter than the other, the tire will tend t0 roll to one side. This will velop aside force which can produce car lead ‘The procedure in Fig. 34 should be used to make sure that front alignment is not mistaken for tre lad, 1) Part of the lead diagnosis procedure is difer lent fram the proper tre rotation pattern cur ently in the owner and service manuals. 4 medium to high mileage tice is moved to the ather side ofthe car, be sure to check that Fide roughness has not develope. 2) Rear tees wil nt cause lea, Fig 35 Vibration VIBRATION DIAGNOSIS Wheel unbalance causes most of the highway speed vibration problems, Ifa vibration remains after dynamic balancing, its posible causes are asfollons. 4) Tire runout 2} Whee runout. 23) Tire stifness variation, Measuring tire and/or wheel free runout will uncover only part of the problem. All three causes, known as loaded radial runout, must be checked by using a Tire Problem Detector (TPD). 1 TPD is not available, alternative method of substituting known good tire and ‘wheel assemblies on the problem car can be Used, although i takes @ longer time. SUSPENSION MOVEMENT (Coosa nest SMOOTH ROAD sriFFNess ‘oR VARIATION ‘our oF ROUND FRONT END ALIGNMENT 341 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS a Preliminary Checks Prior to Adjusting GENERAL DESCRIPTION aaa Front Alignment os 302 “Toe Setting ~ Figure 3A-1 3M Toe Adjustment 3n2 camber ~ Figure 341 aad Comber and Caster Adjustment 3A2 Steering Angle 2a GENERAL DESCRIPTION Fig GT Toon and Cuba Front alignment refers tothe angular relationship boetwoon the front wheels, the front suspension attaching parts and the gfound. Generally, the only adjustment required for font alignment is ‘oe setting, Camber and caster can't be adjusted Therefore, should camber or caster be out of specification due to the demage caused by hazardous road conditions or collision, whether the damage isin body or in suspension should bbe determined first and damaged body should be repaired or damaged suspension should be replaced torn | (0a70~Soore oer corer sa | | ore {181mm 065 nd losirve| elton we sees ‘TOE SETTING-FIGURE 3A-1 Toe is the turning in or out of the front wheels, ‘The purpose of 3 toe specification is to ensure parallel rolling of the front wheels Excessive {oe.in or toe-out may increase tire wea). Amount of tov can be obtained by subtracting "A" from “8 as shown in Fig. 3A-1 and there fore i given in me fi.) CAMBER-FIGURE 3A-1 Camber is the titing of the front whebls from the vertical, as viewed from the front of the car When the wheels tilt outward at the top, the camber is postive. When the wheels tlt inward at the top, the camber is negative. The amount ‘of tilt is measured in degree,242 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional Item to be checked is possibility of tre lead due to worn or improperly manufactured tires, “Lead isthe deviation of the car froma straight path on a level road without hand pressure on ‘the stering wheel, Section 3 of this manual con: tains a procedure for determining presence of @ tire lead problem. Before making any adjustment affecting toe fetting, following checks and inspections should bbe made to insure correctness of alignment re dings and lignment adjustments: 1) Check all tires for proper infation pressures and approximately the same tread wear. 2) Check ball joins for looseness. Check tie rod fends; if excessive looseness in noted, it must be corrected before adjusting 2) Check wheels and ties for un out 44) Check car trim height. If ts out of limit and Correction is necessary, It must be made before adjusting toe (Refer to p. 3.4) ') Check suspension arms for looseness 16) Check for loose oF missing stabilizer bor at tachment. 7)Consideration must be given to excess loads, such a tool boxes, If this excess load is nor mally carted in car, it should remain there ‘uring alignment checks. 8) Consider the condition of the equipment ‘being used to check alignment and follow its manufacturer's instructions 9) Whatever equipment is used to check align ment, car must be placid on level surface TOE ADJUSTMENT Toe is adjusted by changing tie rod length. Loosen right and left te rod end lock nuts frst ‘and then rotate right and left tie rods by the same amount to align toen to specification. In this adjustment, right and left tie rods should become equal in length ("A in Fig. 382) Before rotating tie rods, apply grease between tie rods and rack boots so that boots won't be twisted After adjustment, tighten lock nuts to specified torque and make sure that rack boots are not twist, Fig A? Tow Ajurtmone CAMBER AND CASTER ADJUSTMENT ‘Should camber or caster be found out of specif cations upon inspection, locate its cause first. I itis in damaged, loose, bent, dented or worn suspension parts, they should be replaced. Ii is In car body, repair it soas to attain specifications. To prevent posible incorrect reading of camber fr caster, car front end must be moved up and down a few times before inspection ‘STEERING ANGLE inaie = outside az ‘Steering angle When tie rod or tie rod end was replaced, check toe and then slso steering angle with turning radius gauge. I steering angle is not corract, chock if right and left te ros are equal in length (“A in Fig, 34 3) Nore tie rod longths were changed to adjust steering angle, reinspect toe. Fig a Seana Re Teoston Referrence information: SIDE SLIP: For inspecting front whe side sip with side slip tester: Side slip limit: Less than 3 men/m (Less than 0.118 in/3 FU) If side slip exceeds above limit, te. or front heel alignment may not be correct. FRONT END ALIGNMENT 203MANUAL RACK AND PINION 20-4 SECTION 3B MANUAL RACK AND PINION Nore: All string gear fasteners are important attaching part 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 fame part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lester quality oF substitute design. Torque values must be used as specified during reessembly to ‘assure proper retention ofthese parts conenrs GENERAL DESCRI 3B 2 Rack 3811 nee arena SS in oats Rod i ee 387 REQUIRED SERVICE MATERIAL 38-16 Plunger 38 9 5, Remove and Install Steering Pinion 38:10{38.2 MANUAL RACK AND PINION, GENERAL DESCRIPTION “The rack and pinion steering system consists of two mein components, the rack and the pinion. When the steering wheel is turned, the motion is transmitted tothe steering shat, shaft joint and then to the pinion Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear motion, The force is then transmitted through the tie rods tothe steering knuckles which turn wheels NOTE: ‘Although the figura below show only the lefthand side steering car, the same work procedure and data ‘apply to the righthand side steering car. MANUAL RACK AND PINION 36:3 ON-CAR SERVICE LUBRICATION When inner parts of the steering gear case were disassembled, they should be washed clean be fore reassembly. It is recommended to use the raat at given atthe right whore greaee applica: ‘om i indicated inthe text. “SUZUKI SUPER GREASE (&) 99000. | 25060, or Lithium grease (applicable for 40°C ~ 120°C or ~40"F ~ 266°F) Fig 38-1 General Decriton of Sworn Sram ig 382 Exploded View of Manual Rack and Prion384 MANUAL RACK AND PINION 1, REMOVE AND INSTALL TIE ROD REMOVAL 1) Hoist car and remove wheel. 2) Remove split pin and tie rod end castle nut END INSTALLATION 4) Install tie rod end lock nut end te rod end to tie rod. Align lock mut with mark on tie rod thresd. 2) Connect ti rod end to kruckle. Tighten castle rut until holes for split pin are aligned, but ‘only within specified torque. 3) Bend spit pin as shown below. 4) Inspect for proper toe (Refer to FRONT END ALIGNMENT), 5) Alter confirming proper toe, tighten tie rod fend lock nut to specified torque 6) Tighten wheel to specified torque and lower hoi. 3) Disconnect tie rod end from knuckle, using special to9! (A Fi 304 4)For ease of adjustment after installation, make marking of tie rod end lock nut position fm tie rod thread. Then loosen lock nut and remove tle rod end from te ro, = MANUAL RACK AND PINION 38.5 2. REMOVE AND INSTALL MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL 1) Slide driver's seat a fr back as possible, 2}Pull off front part of floor mat on driver's side and remove steering shaft joint cover. 43} For ease of instalation, loosen steering shaft upper joint bolt but don’t remove, 4) Remove steering shaft lower joint bolt and lisconnect lower joint from pinion. 7) Disconnect both tie rod ends from knuckles, using special too! (A), 8) Remove steering gear case mount bolts, gear ‘case brackets and then gear cas. '5) Hoist car and remove both wheels, 8) Remove spit pins and tie rod castle nuts from both knuckles, iame 5{28.6 MANUAL RACK AND PINION INSTALLATION 1) Mount steering gear case to body and tighten eer case mount bolts to specified toraue, 65) Reinstall cover removed previously to steer ing shat joint. 7 iis, Fp B17 2) Install tie rod ends to knuckles (R & L). Tighten each castle nut until holes for split pin align but within specified torque and then bee split pin as shown Fae 3)Be sure that steering wheel and brake discs (F & L) areall straightahead driving state and ‘then insert steering lower joint into steering pinion shat, 4) Tighten stering shaft joint bolts to specified torque (Lower side first and then upper side. Fg 308 Fig. 38-14 61 Put back floor mat a it was 7) Install both wheels and tighten wheel nuts to specified torque, Wm ten |b 70 | 40-70 | 260-505 8) Lower hoist. 9) Check toe setting, Adjust as required (Refer FRONT END ALIGNMENT), 10} Tighten both te rod end lock nuts to specif od torque, Fig 8 MANUAL RACK AND PINION 387 3. REMOVE AND INSTALL RACK BOOT/TIE ROD REMOVAL 1) Remove steering gear case by performing Steps 1) — 8) in Item 2 REMOVAL of this section 2)For ease of adjustment after instalation, ‘make marking of tie rod end lock nut pos tion on te rod thread Fae 3) Loosen tie rod end lock nut and remove tie rod end 4) Remove boot wie and clip. Fa tei 5) Remove boot from te rod 6) Unbend bent part of tie rod lock washer and remove tie od from rack a Fg 828.8 MANUAL RACK AND PINION INSTALLATION 1) Insta tie rod lock washer and te ro to rack. Align straight part "A" of washer with fiat part “B" of rack Fa B9 2) Tighten tie rod inside ball nut to specified torque, New ke-m be 70-100 | 70-100 | v0 720 3) Bend lock washer to tie rod side as shown below. Fg 4) Position boot properly in grooves of gear case and tie rod and clamp it with wire ad clip. Wire should be new and should go around twice and be tightened with its both ends twisted together. The twistd ends should be bent in the circumferential direction, After this, check to ensure that boot is free from twist and dent. Fp 3B 5} Install tie rod end lock nut and te rod end to tierod, Position lock nut to marking made inremoval Nore: When tie rod was replaced, measure length “A” ‘on removed te rod and use ton new replacement tie rod 50 as to position lock nut propery. Fig SB 6) For installation procedures following the shove, use Steps 1) ~ 10), INSTALLATION, of STEERING GEAR CASE on p. 38.6. MANUAL RACK AND PINION 362 4, REMOVE AND INSTALL STEERING RACK PLUNGER REMOVAL 1) Remove parts as shown below. Fig 3825 INSTALLATION, 1) Apply grease lightly to sliding part of plunger against rack 2) Install parts 2s shown. 3) After tightening rack damper screw to the tightest point, turn it back by 0 — 90° and check for rotation torque of pinion, Also, check if rack asa whole movessmoothly. Pinion torque Nem km be 08-13 | 008-013 | 058-094 4) After adjustment, put rack damper serew cap ts deeply as posible.28:10 MANUAL RACK AND PINION, 5. REMOVE AND INSTALL STEERING PINION REMOVAL 1) Remove rack plunger as shown Item 4, 2) Remove gear case packing 2) Remove bearing plug with special too! (C). 4) Tap on position as shown with pastichammer to separate pinion assembly from housine. INSTALLATION T)Apply grease to all around pinion teeth, pinion needle bearing and gear case ol eal lip. 2) Insal pinion assembly. 3)Tighten pinion bearing plug to. specified Nm kam bi 0-110 | 80-110 | 580-705 case packing 5) Insta rack plunger as described in Item 4 MANUAL RACK ANO PINION 36-11 6. REMOVE AND INSTALL STEERING RACK REMOVAL 1) Remove boot wires and clips Fi, 35-30 2) Move both boots toward tie rod end. '3) Unbend bent part of tie rod lock washers and remove tie rods from right and lett sides of steering rack. 4) Mack left and right te rods accordingly ———— 5) Remove rack plunger and pinion assembly ‘rom gear case by performing Steps 1) —5} in tem § STEERING PINION REMOVAL of this ection, {8)Remove rack from gear case, Direction for rack removal isa shown below. INSTALLATION 1) Apply grease to ent and its periphery. 2) Slide rack into steering gear casein the direc tion as shown below. teeth surace of rack. ‘CAUTION: Inside of steering rack bushing is costed | with special coating. As itis damageable, be very careful not to cause damage to it tng rack into steering gear cas. Fis. 28.38 3) Install pinion assembly to grar case by per forming Steps 1) ~ 4) in tem 5 STEERING PINION INSTALLATION ofthis section 4) Perform Steps 1) ~ 4) in Item 4 STEERING RACK PLUNGER INSTALLATION of this 5) Before installing boot to steeringrack housing, make sure that rack side mount is positioned fas shown below, Install tie rads to rack by performing Steps 1) ~ 6) in Item 3 RACK BOOT/TIE ROD INSTALLATION of this tection _ Fp BH38:12 MANUAL RACK AND PINION, 7. REMOVE AND INSTALL PINION BEARING REMOVAL 1) Remove rack from stering gear case, referring to Item 6 STEERING RACK REMOVAL of this section 2} Pull out pinion bearing from gear case with special tools (D and E} as shown INSTALLATION 1) Apply grease to rolers of pinion bearing, 2)Pressfit pinion bearing into gear case with special tool (F) a8 shown. Atter pressfitting, make sure that bearing rollers are installed properly, 3} Follow Stape 1) ~ 5) in Item 6 STEERING RACK INSTALLATION of this section to complete insallation, MANUAL RACK ANO PINION 20-13, 8. REMOVE AND INSTALL RACK BUSHING REMOVAL 1) Remove rack from steering gear cas, referring to Item 6 STEERING RACK REMOVAL of this section, noTe: When removing rack bushing, be careful not to pull out bushing by holding gear case ina vse. F housing (pipe) may come off gear case. For this work, be sure to use the below specified scial too 2) Remove snap ring, Fg 3) Pull out bushing from rack housing with spe: €ial too (G) as shown, Fig 88 INSTALLATION VApply greate lightly to entire inner surface of bushing 2) Presefit bushing as for into rack housing as shown below by using special tool (H), ‘CAUTION: Inside of bushing i coated with special coating. As itis damageable, be sure to use | specait too! and special care not to cause damage to inside of bushing when press fitting it ab Fa 3) Install enap ring 4) Follow Steps 1 ~ 5) in Item 6 STEERING RACK INSTALLATION of this section to complet installation.38.14 MANUAL RACK AND PINION, RACK AND PINION INSPECTION STEERING RACK BOOTS Hoist car Inspect each boot for tear. A torn boot allows lontry of dust and water which can couse wear to steering rack and pinion to produce noise as, well ag rust t0 result in malfunction of steering system. H even a small tear is noted, replace with new Boots shouldbe visually inspected for any dams: 42 and tear during every periodical inspection at specified intervals and whenever car is hoisted for any other purpose. STEERING SHAFT JOINT ‘Check shaft joint for wear, breakege and other damage and replace i any detect exists, Fig 36-40 TIE ROD END BOOTS Inspect esch boot for tear. If even a smell tear isnoted, replace with new one Fa BE TIE ROD END 1 Inspect for playin ball joint. 2) Inspect for play in rack end ball joint. In either ease if found detective, replace. oq MS RACK PLUNGER 1) lnspect rack plunger for wear or damage 2) Inspect rack plunger spring for deeriration. In either case if found detective, replace, © 1 necro Fig Soa STEERING PINION ‘inspect pinion teeth surface for weer or damage, 2) Inspect oil sal for damage 53) Inspect gear case packing for damage. Replace any part found defective =<» | 9 © Fg teas ‘STEERING PINION BEARING check rotation conition of bearing and inspect for wear. If found defective, replace, STEERING RACK Inspect for deflection, teth wear, or damage back surface wear or damage Limit of rack mm (0.016 in) Seflection 080 If deflection exceods limit, replace rack. ‘bo not ve a wire brash when cating Fg Ba MANUAL RACK AND PINION 38:15 STEERING RACK BUSHING Inspect rack bushing for wear or damage H found def ace. 5 BT STEERING WHEEL Check steering wheel for play end ratte, holding car in straightforward condition on the ground. 030mm (= 1.210) ‘Steering whee! lay (A) l Fig 3048 It steering wheal play isnot within specification, inspect as follows and replace if found detective. © Tierod end ball stud for wear (ball stud should move when more than 2 kg-em torque isappiied.) E ‘© Lower ball joint for weer ‘Steering sha joint for wear 1 Steering pinion or rack gear for weer or breakeoe © Each part for looseness38-16 MANUAL RACK AND PINION, RECOMMENDED TORQUE SPECIFICATIONS MANUAL RACK AND PINION 98-17 SPECIAL TOOLS Festening parts Tightening torque ibe “i. Sterng shat aint bolts [2 Suworing gor case bots 23. Tierod end est [a Terod end ack nuts 145-215) 5, Steering pinion bea 80-110 795 [e.Tierod 70 — 100 —[s10-720_| 7. Wheel nut ‘50-70 365 — 505 REQUIRED SERVICE MATERIALS waren | aOR Lithium Grease (Should be applicable for 40°C ~ 130°C), (99000-25050) SUZUKI PRODUCT ‘SUZUKI SUPER GREASE (E}) + Filed into pinion bearing cap Use ‘Sliding part of rack against steering | Fousing (Al around rack plunge, rack Bushing and rack) Sliding part against steering pinion (ii sea ip, needle bearing} ‘tearing rack and pinion gear teeth Contacting pars of trod and rack side boots Fack end bal joint ovo1368210 S ZF o2ea0 20102 Siding st Fig B80 of ovona18211 090426210 Pirin torque checking [43mm Socket socket (Pinion bearing plug remover —_ ‘00821-20200 Pinion bering remover = ork oko 08211 Pinan bearing instal 906448210 04278210 ack sh italSTEERING WHEEL AND COLUMN 26:1 SECTION 3C STEERING WHEEL AND COLUMN Nore: All steering wheel and column fasteners are important pars in that they could affect the performance of vital parts and systems, and/or could resut in major repair expense. They must be replaced with one of the same part number or with an equivalent ment part of ‘0 assure proper retention of this part rt if replacement becomes necessary. Do not use a rplace- ser quality of substitute design, Torque values must be used as specified during reassembly CONTENTS DIAGNOSIS 34 65, Remove and Install Steering GENERAL DESCRIPTION 3c1 Shaft Lower Joint ac 8 EN CANTER IGE 30a 8. checking Sowing Cuma for 1, Remove and Install Stering Wheel .. 363 cider Damage 2. Remove and install Combination RECOMMENDED TORQUE sSwiteh aca SPECIFICATIONS acto 3, Remove and Install Storing SPECIAL TOOL 3c-10 Column acs 4, Remove and Install Steering Lock : 307 GENERAL DESCRIPTION ‘The ball and double tube type steering column includes following three important features in addition to the steering function: 1. The column is energy absorbing, designed to compress in @ frontend collision to minimize the possibilty ofan injury to the driver of the 2.The ignition switch and lock are mounted conveniently on this column. 3. With the column mounted lock, the ignition land steering operations can be locked to in hibit thett ofthe car This column may be easly removed and install fd, To insure the energy absorbing action, itis important that only the specified screws, bolts, land nuts be used as designated and that they ‘are tightened tothe specified torque ‘When the column assambly ie removed from the car, special care must be taken in handling it Use ofa steering wheel puller othér than the one recommended in this manuel ora sharp blow on the end of the stering shaft, leaning on the assembly, or dropping the assembly could shear the plastic sheer pins whieh maintain column length202 STEERING WHEEL AND COLUMN Fig, 301 Storing Whee and Cour - STEERING WHEEL AND COLUMN 363 ON-CAR SERVICE 1, REMOVE AND INSTALL STEERING WHEEL REMOVAL 1) Disconnect negative battery cable 2} Remove pad by pulling it upward. '3) Remove stering wheel upper cover and ster ing shat aut. 4) Make alignment marks on steering wheel and shaft for @ guide during reinstallation Fg sca 5} Remove steering wheel with special too! (A Fino INSTALLATION instal steering whee! onto shaft, aligning alignment marks on them. 2) Torque steering shaft nut to specification as sien b 3) Connect wire to stoering wheel and then, 14 wheel upper cover and pad, 4) Connect negative batery cable.204 STEERING WHEEL AND COLUMN STEERING WHEEL AND COLUMN 36:5 2. REMOVE AND INSTALL COMBINATION SWITCH REMOVAL 1) Disconnect negative battery cable, 2) Before removing this switch, remove steering wheel, Refer to STEERING WHEEL RE- MOVAL. 3} Remove column covers (under and lower) Fig 308 4) Disconnect lead wire from combination switch at coupler. 5) Loosen wire bands 6) Remove combination switeh assembly from steering column, INSTALLATION 1) stall combination switch 2) Connect lead wite from thisswitch at coupler 23) Tighten wire bands. 4) Install column lower cover and under cover. Nore: When tightening lower cover and upper cover, be careful so that combination switch lead wiee js not caught between covers 65) Install teering wheel. Refer to step 1) through 4) under STEERING WHEEL INSTALLA. TION. Fine 3, REMOVE AND INSTALL STEERING COLUMN Nore: ‘Once the stering column is removed from the car, the column is extremely susceptible to damage. Dropping the column assembly on its fend could collapse the steering shaft or loosen the plastic shear pins which maintain column length. Leaning on the column assembly could ‘cause the jacket to bend or deform. Any of the ‘above damage could impair the column's col lapsible design. If it ie necessary to remove the steering wheel, use steering wheel remover. Under no condition should the end of the shaft be hammered upon as hammering could loosen ‘the plastic shear pins which maintain column lenath REMOVAL 1) Disconnact negative battery cable. 2) Remove steering wheel, Refer to STEERING WHEEL REMOVAL. '3)Remove combination switch, Refer to Steps 3 through 6 under COMBINATION SWITCH REMOVAL. 44) Disconnect lead wires from ignition switeh {and ignition key warning switch at coupler. 5} Pull off floor mat atthe foot of stering shaft And remove steering joint cover. 16) Remove stearing shaft joint upper side bolt. Fig 508 '8}When working on ear with automat trans mission remove back drive cable from stoering ‘clumn assembly 9) Remove steering colurnn assembly. NOTE: Don't disassemble steering column assembly into column and shaft. If steering colurnn or shaft is found defective, replace as an assembly. See p. Fig 3010 Storing Corn Barly1206 STEERING WHEEL AND COLUMN INSTALLATION 1) When working on ear with automatic tran ‘mission, install back drive cable to steering column assembly. 6) ah 1) Fig 30107 Bh to 2)Align fat part “A” of lower joint shaft with bolt hole "3" of upper side joint ae ehown Then inset upper side joint into lower joint shat. Fig 3079 3) Install steering column assembly to lower and upper brackets, Torque steering column nuts to specifications as given below. ‘Tighten nuts (al first to specified torque ‘© Then tighten nuts (b} to specified torque. py Loo Fig soe 4 Install bolt to steering shaft upper jin ard tighten it to specified torque Nore: After tightening column nuts, bolt 1 should te ‘tightened. Fig 3078 5) Install steering joint cover and put floor mat back as it was originally {6} Connect lead wires from ignition switch and ignition key warning switch at coupler. 7) Inetall combination switch. Refer to Steps 1 through 4 under COMBINATION SWITCH INSTALLATION. )insall steering wheel, Refer to Stops 1 through 4 under STEERING WHEEL STALLATION STEERING WHEEL AND COLUMN 36.7 4, REMOVE AND INSTALL STEERING LOCK (Applicable tocar equipped with steering lock.) REMOVAL 1) Remove stearing column. Refer to STEER ING COLUMN REMOVAL. Faaore 2)Using center punch as shown, loosen and re ‘move steering lock mounting bolts. Use care ot to damage aluminum pact of steering lock body with eenter punch. Fac 3) Turn ignition key to “ACC” or “ON” position and remove steeting lock assembly from steer ing column, INSTALLATION 1) Position oblong hole of stering shaft in the canter of hoe in column, /_/} Fig, 3018 2) Tuen ignition key to "ACC" or “ON position and instal steering lock assembly onto column. 3)Now turn ignition key to "LOCK" postion and pull it out. 4) Align hub on lock with oblang hale of steer: ing shaft and rotate shaft to assure tat soot ing shattis locked. Fig 3017 5) Tighten two new bolts until head of each bolt it broken off Fig s018 £6) Turn ignition key to "ACC" or “ON” position and check tobe sure that steering shaft rotates, smoothly. Also check for lock operation, ‘THnaall steering column, Refer to Steps 1) ‘hrough 8) under STEERING COLUMN IN: STALLATION30.8 STEERING WHEEL AND COLUMN, 5. REMOVE AND INSTALL STEERING SHAFT LOWER JOINT REMOVAL 1) Set front wheels in straightforward state and remove steering shaft joint cover 2) Remove steering shaft joint bots 23) Remove stering shat lowe joint Its hard to remove, loosan steering column rmouning nutsa little INSTALLATION 1) Align flat part of lower joint shaft with bolt hole of upper joint as shown, Then insert lower joint shaft into upper joint. rd Fig 020 2)Be sure that front wheels and steering whee! joint into steering pinion shaft 23)1f steering column nuts were loosened in re moval, torque lower bracket nuts to below specification first. Nm kom bf w-7 | t-17 | 80-120 ‘And then torque upper bracket nuts to specific Nm om ib new | 7 0-120 4) Torque steering shaft joint bolts t0 specif Nm kgm be | 20-90 | 20-30 | 145-215 £5) Install steering shaft joint cover. STEERING WHEEL AND COLUMN 209 6. CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: (cars involved in accidents resulting in body damage oF where the stering column hae been impacted may alo have a damaged or misaligned steering column, CHECKING PROCEDURE 1) Check capsules on steering column bracket all should be contacting the bottom of slots. If nat, steering column assembly should be replaced, Use thickness gauge for convenience, Fig, 3621 Checking Steering Column 2) Take measurement ““A" as shown. If it is shorter than spectied length, replace column assembly with new one 3) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction lor excessive play. If anything is found faulty, Fig 5028 4) Check steering shaft for smooth rotation. If found defective, replace as column assembly 5) Check steering shaft and column for bend, cracks or deformation. If found defective, replace36:10 STEERING WHEEL AND COLUMN RECOMMENDED TORQUE SPECIFICATIONS T ightening tor Fastening arts siti Lica) _ a Xm om [BR 1. Steering shaft nut [3-40 25-40 | 185-285 2. Searing sae ont bok z0-30 | 20-30 | 5-715 5, Steering colun nuts =| 1a=17_| 89-120 Fig 0m 09984-36010 ‘Stetng wheel emover, Fig 3025 FRONT SUSPENSION 30-1 SECTION 3D FRONT SUSPENSION Nore: «> 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. Donot use replace. ment part of lesser quality or substitute design. Torque values must be used as specified during reassem- bly to assure proper retention of this pa «Never attempt to eat, quench or straighten front suspension part. Replace it with anew part, or dam 2 to the part may result. CONTENTS GENERAL DESCRIPTION 30-2 ON CAR SERVICE aD 4 1. Remove and Install Stabilizer Bor and/or Bushings a : 30-4 2, Remmuve and Install Strut Domper Azcembly 20.5 23. Disnsembly and Assembly Strut Damper 30.6 {4 Remove and Install Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Rece 20.8 5, Remove and Install Suspension Arm/Bushing 3040 6, Remove and Install Keuckle/Bearing 30412 7. Front Suspension Inspection + 345 RECOMMENDED TORQUE SPECIFICATIONS 3047 REQUIRED SERVICE MATERIALS 3047 SPECIAL TOOLS 30418302 FRONT SUSPENSION GENERAL DESCRIPTION ‘The front suspension isthe strut type independent suspension. The upper end ofa strut is anchored to the car body by @ strut support. The strut and strut support are isolated by @ rubber mount. A strut bearing it ‘als installed litte lower to the rubber mount. ‘The lower end of the strut is connected to the upper end ofa steering knuckle and lower end of knuckle is atached to the strud ofa ball joint which is incorporated ina unit with a suspension control arm. And ‘connected to this steering knuckle is the tie-rod end ‘Thus, movement of the steving wheel i transmitted tothe ti-rod end and then to the knuckle, eventual. ly causing the wheelanttire to move In this operation, with the movement of the kruckle, the strut aso rotates by maans of the strut bearing and lower ball joint \ caer FRONT SUSPENSION 203 Fig 304 Fig 302 Fron Superson20.4 FRONT SUSPENSION ON-CAR SERVICE 1, REMOVE AND INSTALL STABILIZER BAR AND/OR BUSHINGS REMOVAL INSTALLATION 1) Remove stabilizer link nuts, washers and 1)When installing stabilizer, losely assemble all cushions components while insuring that stabil 2) Remove stabilizer mount brackets, 3) Remove stabilizer. 4) Remove stabilizer joints from stabilizer. centered, side-to-side. Refer to figure “A” below for ts check, For correct installation in vertical direction, Reter to figure "6" 2) Install parts by reversing Steps 1) — 3) of REMOVAL, e880 IW Ns LF ise BENS 'S _— For careetinnlition of sabilze bt, side s0- Blgns wth mount tue, both rght ad If, 3 \. FRONT SUSPENSION 30.5, 2, REMOVE AND INSTALL STRUT DAMPER ASSEMBLY tom a ) i \f tes nah ah Ome Fig DT 4} Remove strut bracket bots Fig S024 _ NoTE: Fig 22 Don’t twist brake hose when installing it Install E ring as for ast fits to bracket as shown 5) Remove strut support nuts. tel Hold strut by hand so that it will not fll off. Fp DIT Fp TF Fae Fig 028 6) Remove strut assembly.206 FRONT SUSPENSION 3. DISASSEMBLY AND ASSEMBLY STRUT DAMPER DISASSEMBLY 1) With special too! (A) placed to spring as shown, turn special tool bolts alternately unti spring tension is released, Whether it ie releas. fed o not can be known by whether strut turns lightly while strut spring is held sta tionary. Fig 37 2) While keeping spring compressed with special tool as shown above, remove strut nut and then disassemble pats ASSEMBLY 1) Compress spring with special tool (A) until total length becomes about 230 mm (9.06 in} ae shown Fig FS 2) Mate spring end with stepped part of lower seat a shown, Fig 34 3} Install bump stopper onto strut rod. For in stalling direction, eter tothe figure atthe lft 4)Pull strut rod as far up es possible and use care not to allow it to retract into strut. 5} Install spring sest, bearing spacer and strut cover to spring upper seat and then install strut bracket with its center aligned with “A mark on spring upper seat, Fig 35 FRONT SUSPENSION 30.7 6) Wesh bearing lower washer and instal it 7iWash strut bearing and apply grease, Install ion bearing lower wast {8} Wash besring upper washer and install it 9} Install bearing seal, bearing sest, strut support, inner spacer, washer and strut nut in this sequence. Be careful for installing directions ‘Tighten strut nut to specified torque and then apply waterproof coating (paint or lacquer) all araund nut and strut rod thread. 10) Loosen and remove special too! (A) com: pressing coil sing. While loosening special tool, recheck that stepped part of spring seat and spring and are in place to each other as descrived in foregoing Step 2), 11) Install strut to oar body, Refer to STRUT DAMPER INSTALLATION of this section Fig 3037208 FRONT SUSPENSION 4, REMOVE AND INSTALL WHEEL HUB, WHEEL STUD/WHEEL BEARING OUTSIDE INNER RACE REMOVAL £8) Pullout whee! hub with special tools (8) and 1) Hoist car and remove wheel. ©. 2) Uncalk drive shat nut INSTALLATION Install Hub Bolts insert new stud in hub hole, Rotate stud slowly to assure serrations are aligned with those made by original bol 3) Depress foot brake pedal and hold it there. { Remove drive shaft nut 44) Remove caliper carrer bolts. @ rama 19) Remove hub bolts Fig D4 a 5) Remove caliper with carer. 8) Remove aise serows. 17) Pull brake dise off by using two 8 mm bolts. Fa s48 1) install outside inner race to wheel hub using special tool (G). Installing direction is as shown. Fea 2) Apply grease to outside bearing, outside inner ‘ace and ol lp. Fig 42 Fgaoae FRONT SUSPENSION 20.9 3) Install wheel hub to knuckle by tightening driveshaft nut, Don’t tap wheel hub. Fig 45 4) Install brake de 5} Install brake caliper/clipor carrier. 6) Tighten caliper carrie bolts to specified torque ‘7)Denress foot brake pedal and hold it there Tighten drive shaft nut and broke disc serews to specified torque. £8) Cal driveshaft nut as shown below. Fig 30410 9) Install wheel and lower hoist.20-10 FRONT SUSPENSION 5. REMOVE AND INSTALL SUSPENSION ARM/BUSHING REMOVAL, 1) Hoist car and remove whee! 2) Remove stabilizer link nut, washer and cushion 3) Remove bal stud bot. 4) Remove suspension arm bracket nut. 5) Remove suspension arm bracket bolts. 66) Remove rear bracket and suspension am, 7) Remove resr bushing with hydraulic press as shown, Fig 3057 £8). Cut off flange of front bushing 9s shwon in below figure “A” and then push out frant bushing by using hydraulic press as shown in figure INSTALLATION 1) install front bushing Before installing bushing, apply soap water on its circumference to facilitate instalation, 2) Install ear bushing to suspension arm as fol- rows. First, push in rear bushing in such direc: tion and angle as shown in below figure “A” land drive it into such position as shown in figure “B". When installed, bush should be equal on the Fight and left of arm as shown, Fp v0.55 ips. / em, || 7 Fa DEE Fig 2057 3) Fit suspension arm bracket 10 suspension arm in such direction as shown in Fig, 30-59 and hand/-tighten bracket mut lightly and then in fall suspension arm bracket 10 car body. At this point, tighten bracket bolt only lightly by hana, 4) Ineal ball stud to knuckle Align ball stud groove with kuckle bolt hole 4 shown in figure. Then dive in ball stud bolt from the direction as shown and instal washer and nut ERONT SUSPENSION 20:11 ree Fp 058 5) Install suspension arm rear bracket. 6) Insta stabilizer cushion, washer and tink rut. Link nut tightening torque 18-28N-m(18-28kgm,13.5~200 lott) 7) Tighten all bolts and nuts in figure to each specifies torque. 4) Install wheel and lower hoist. 9) Check toe seating and adjust a required : oo q |20.12 FRONT SUSPENSION 6. REMOVE AND INSTALL KNUCKLE/BEARING REMOVAL 1) Hoist car and remove whee! 2) Remove wheel hub. Refer to Step 2) ~ 8) in Item 4 of WHEEL HUB REMOVAL of this 3 Disconnect tievod end from knuckle with special tool (H) INSTALLATION 1) Install knuckle to ball stud on su dnd strut bracket, Installing dir bolt is as shwon. Align knuckle bolt hole with ball stud groove as shown and install bal stud bolt. Tighten each nuts to specified torque, Fig 5061 4) Remove strut bracket bolts from strut bracket ‘nd then ball stud bolt S ot 5) Remove knuckle Fig 6H 2} Connect vierad end to knuckle and tighten tiezod end castle rut to specified torque. Install slit pin Fig EA 3)For instalation procedures following the above, refer to Steps 1)—8) in Item 4, WHEEL, HUB INSTALLATION of this section, For tightening torque refer to next page. FaasREMOVE OIL SEALS, SNAP RING AND WHEEL BEARING Once bearing outer race is removed, bearing set (outer race, bearings and inner races) should be ‘eplaced with new one. ‘© Remove outside oil sel, snap ring outside bearing, inside oil seal and inside bearing in that order Fig 3065 ‘© Remove besring outer race/inner bearing using special too! (1) and (J), and hydraulic ress. Fg 87 INSTALL OIL SEALS, SNAP RING AND WHEEL BEARING When replacing bearing, inner bearing or outer bearing, be sure to replace them with new ones asa ont 1 Preset beating outer race/inner bearing using special tools (J), (K) and (L Fea5e ‘© Aftor greasing (lithic grease) bearing outer ace, bearings and oll seal li, install ther. Inside Oi Seat Drive in Oi seal until seal i flush with stopped surface of knuckle by using special too! (L). Outside it Seat Drive in oll seal unti its end contacts snap ring using special tools (J), (K) and (L). As for its installing direction, refer to Fig. 30-6-10, Fig 610 7. FRONT SUSPENSION INSPECTION STABILIZER BAR AND/OR BUSHING Ber Inspect for damage of deformation. If defective, replace. Fie 3077 Bushing Inspect for damage, wear or deterioration. If ® 8 8 @ 9 bes Fig 072 FRONT SUSPENSION 20:15 STRUT DAMPER 1) Inspect strut for oll leakage, If strut is found faulty, replace it as an assembly unit, because ican not be diassembled, Fig O75 2) Strut function cheek Chock and adjust tire pressures a5 specified. Bounce car body three or four times con- tinuously by pushing front end on the side with strut to be checked. Apply the same amount of force at each push and note strut resistance both when pushed and rebounding Also, ote how many timescar body rebounds before coming to stop after hands are off. Do the same for strut onthe other sie. Compare strut resistance and number of re bound on the right with those on the left ‘And they must be equal in both. With proper strut, car body should come to stop the moment hands are off or after only one for two small rebounds, If struts are suspect: ‘compare them with known good car or 3) Inspect for damage or deformation 4) Ingpect bearing for weer, abnormal noise or srinping 5) Inspect for cracks or deformation in spring 6) Inspect for deteriaration of bump stopper. 7) Ingpect rebound stopper and strut mount for waar, cracks or deformation. Replace any parts found defective in Steps 2) ~ ?.{20.16 FRONT SUSPENSION SUSPENSION ARM/ARM BRACKET/ KNUCKLE ARM Inspect for eracks, deformation or damage, Fig 30.74 ‘SUSPENSION ARM JOINT 1) Check for smooth rotation 2) Inspect ball stud for damage. 3) Inspect dust cover for damage, Note: ‘Suspension arm and arm joint cannot be sepa od If there is any damage to either, control arm assembly must be replaced asa complete unit. Fig 3078 ‘SUSPENSION ARM BUSHING Inspect for damage, wear or deterioret RECOMMENDED TORQUE SPECIFICATIONS 2) Check wheel nuts for tightness and, as neces sary retighten them to specification, ce ] tcrwsenmee_[50~70)50~ 70365505] ‘3}Check whee! bearing for wear. When measur ing thrust play, apply a dial gauge to whee! hub center after removing wheel canter cap rom whee! dee Thrust play mit | 0.4 mm (0.016 in) When measurement exceeds limit, replace bearing 4)8y rotating wheel actuslly, check whee! bearing for noise and smooth rotation. If defective, replace bearing. “Toning ora Fastening pats — ct = [Seat bracket [70-90 | 70-90 | 605-650 2 siut nut 40-60 | 40-60 | 700-430 [3 Strut support nut - 21-33 21-33 | 155-235 4. Bal stud nat s0-70 | 50-70 | 965605 [5 Suspension arm rear bracket bole 30-65 | 30-85 | 220-905 | 6. Suspension arm bracket bolt 85-100 8.5 — 10.0 61.5 -72.0 |7. Bracket nut | i00 7150 10.0-15.0 | 725-1080 Fig 3076 8. Stabilizer joint nut 40-60 4.0-6.0 29.0 — 43.0 [/ 9. Stabilizer link nut 1828 18-28 | 135—200 WHEEL Disc, NUT & BEARING 70: Stabilizer bracket Bo is—28 | 18-28 | 138-200 "inspect each wheel die for dents, distortion a (ia0= com Kino =sn0m|lions=1a50) ae ec 72. Tie rod end castle nut 30-55 30-55 | 220-390 eas ba relces. 13. Wheel nut 50 70, 5.0-7.0 36.5 — 50.5 dy grease (99000-25010) Fp DFS REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS: sUzuK! PRODUCT use ‘SUZUKI SUPER GREASE (A) Lithium grease Peery Strut bearing Lithie wheel bearing | SUZUKI SUPER GREASE (A) | Wheel bearing, whool bearing oll sal lip30:18 FRONT SUSPENSION REAR SUSPENSION 36 SECTION 3E REAR SUSPENSION Note: + All suspension fastaners are an important attaching part in that it could affect the performance of vital perts and systems, and/or eould result in major ropa expense. They must be replaced with one of the Spenaconsesor | ranted hub Siig horn Seedecennom Some part number or with an equivalent part if replacement becomes neesary. Dp not us replace too an mae tmont prt of leser quality or substitute dexgn Torque valves mur be used a pecitind ding resem ———— a biy to are proper retention of this prt. | «Never attempt to hest, quench or straighten any suspension part. Replace it with anew part, or damage to the part may result | | | CONTENTS | 2000 06108 noi. 76210 00013-95200 | coorseri10 Sap ig ir pie Refer to SECTIONS Semmernoros | Seance attan | Ree Basen le GENERAL DeecrurrioN are - — ON.CAR SERVICE (Remove and net) we Control Rod 3E.3 | | | Coil Spring and Suspension Arm 3E 5 | Rear Strut Assembly 3E 8 y Whos! Hub and Keuckle 3E10 Wheel Bearing 3614 | | Stabilizer Bar 3E14 | REAR SUSPENSION INSPECTION 3416 | | REAR WHEEL ALIGNMENT see conteasro, | gomneis0 «555116000 oneua-scoro Toe Inspection and Adjustment 318 Brerng nar inalrhrde | Bes miner | Ot nar REGOMIE NED TORGLIE SPECInIERTIONS) 2649 REQUIRED SERVICE MATERIAL 3620 SPECIAL TOOLS 36:20 oo0s-68510 Fa 7926.2 REAR SUSPENSION GENERAL DESCRIPTION ‘The upper end of the strut i installed to the car body with a rubber mount inbetween and its lower side to the rear knuckle, whose lower end is connected to the suspension arm through the rubber bush, There | coil spring between the suspension arm and car body. ‘Shown in the figure below are main components of the rear suspension Fig 31 REAR SUSPENSION 36.9 ON-CAR SERVICE (REMOVE AND INSTALL) CONTROL ROD REMOVAL 1) Hoist car and remove wheel _2)Disconnect brake flexible hose from control Fig ie? 3)To fecilitate toe adjustment after reinstala tion, take folowing preparatory step before removing control rod, Confirm which one of the closest con car body lines stamped on washer alignment with stamped li ‘or put match marks. 4} Remove contro rod outside nut. 5) Loosen Control rod inside nut (body center ice) Hold inside bolt with enother wrench to pre vent it from turning as nut i turned, 66) Remove control rod inside bolt and control = even INSTALLATION Install in roverse order of removal procedure, noting fallowing items 1)To determine insaling direction of control ‘od, use installed position and shape of brake flexible hose mounting bracket welded on it referring to Fig, 36-5 which shows both con: trol rodsas installed re < Fig se5264 REAR SUSPENSION 2) Install control rod inside bot with its cam ' faced down at shown below. Fig 6 3) Tighten control rod nuts (inside & outside) to such extent that they can be turned by hana. 4) Connect brake flexible hose to bracket secure v I! wheel and tighten wheel nuts to spe cified torque (Refer to Fig, 3-53). 6) Lower hoist. 7)Tighten control rod outside nut and inside rut to specified torque Ik is the most desirable to have ear off hoist 4nd in non-leaded condition when tightening them. ‘nut with line “A” stamped on body aligned with such line as confirmed before removal oF match marks aligned. COIL SPRING AND SUSPENSION ARM REMOVAL 1) Hoist car and remove whee! 2)To facilitate toe adjustment after reinstalla tion, confirm which one of lines stamped on washer isin the closest alignment with stamp: fd line “A” on control rod inside mount part of ear body or put match marks. ‘Then remove control rod inside bolt (body center side), Fn ee 8) Check rear 100 and ajust it as necessary. For check and adjustment procedures, Refer top. 36-18, 3) Remove outside (wheel side) of control rod from rear kauekle stud bolt and disconnect stabilizer bar from suspension arm, Fp 3670 4) Loosen rear mount nut of suspension arm, Nore: But don't remove bolt. Fig eT 5) Loosen front nut of suspension arm and di connect parking brake cable clamp from suspension arm. 6) After loosening lower mount nut of knuckle, place jack under suspension arm to prevent it from lowering suddenly and then remove ower mount nut of knuckle,35.6 REAR SUSPENSION 7) Raise jack placed under suspension arm a little and remove lower mount bolt of knuckle Fig 3 8)Move brake discforake back plate toward outside of car body {in arrow direction} to separate lower mount part of knuckle from suspension arm as shown below. Then lower Jack gradually and romove col zpring Pip SEIS Fig TE INSTALLATION 1) When installing front mount bush to suspen son arm, set it so that its slit "A" (as shown in figure) faces outside of body. Also, make sure that it is installed properly in regerd to its vertical direction, reterrng to igure below. Fig 7 2) Tighten front mounting bracket bolts to spe ified torque, Tighten rear and front mount: ing nuts to sich extent that they can be tur fed by hand, Chock to make sure that front ‘mounting washer Is installed in proper direc: tion referring t figure below. Bs 8am 3) Place jack under suspension arm. 4) Install col spring an spring stat of suspension Note: ‘When seating coil spring, mate spring end with stopped part of suspension arm spring seat as shown. Fp seTo REAR SUSPENSION 26:7 5) Install lower mount bolt of knuckleand torque rut to specification fetehe,, Slo | 6) Remove jack from under suspension arm and install stabilizer bar to suspension arm and torque its bolts and nuts 0 specification (Refer to p. 36-15) 7) Install both inside and outside of contro ro. When installing its inside bot, refer to Control Rod INSTALLATION 2} on p. 36-4 Install parking brake cable clamp 10 susper 8) Install whee! and tighten wheel nuts to speci fied torque. (Refer 10 Fig. 36:63) 8) Lower hoist. 10)TTighten control rod outside nut and inside nut to specified torque, When tightening ther, i isthe most desirable 10 have car off hoist and in non-loaded state Also, whan tightening inside mut, align line "A" stamped on body with such stamped line ‘on washer as confirmed before removal or align match marks if marked.264 REAR SUSPENSION Fn BB 11) Tighten suspension arm front nut and rear rut to specified torque. It is desirable to have car off hoist and in non-oaded state when tightening them. ZZ Lacon at Fig 32 — 12) After tightening suspension arm front nut, check to make sure that washer as showin below isnot tited 13) Check rear toe and adjust it as necessary. For check and adjustment procedures, refer 10 p. 3618. REAR STRUT ASSEMBLY REMOVAL 1) Hoist cr and remove whee! 2)Plece jack under suspension arm so that it willbe supported when it lowers. 3) Remove strut support nuts and push down strut fully a¢ arrow shows in figure below, Fa sem 4) Remove strut lower mount bolt. 15) Remove strut from knuckle by pulling it up from upper side of knuckle. Make strut a¢ short as posible for removal It it is hart to remove it, open lit of knuckle a litle by inserting @ wedge as shown. WARNING: Do not lower jack more than necessary for | strut removal, for coil spring may come off, (oF so much as to make brake flexible hose Fae Fig TERT Fig sear INSTALLATION 1) Make stu short by pushing it 7 | Fig 3628 2) Install strut to knuckle Bring projection “A” on strut against sit of knuckle and push strut into knuckle il upper fond of ‘knuckle contacts “Bon strut as shown in figure below. torque. its lotion26:10 REAR SUSPENSION 4) With strut extended fully, install upper part ‘of strut to car body and tighten support nuts to specified torque. |f upper part of strut doesnot reach car body, ‘aig ack under suspension arm a ltl. ds Fig 391 5] Remove jack from under suspension arm. 6)Tignten wheel nuts to specified torque (Refer to Fig. 3653) 7) Lower hoist. WHEEL HUB AND KNUCKLE REMOVAL 1)Perform Steps 1) to 5) of brake disc RE MOVAL on page 5:35. 2) Remove spindle cap as shown (by hammering lightly 8t 3 locations around it so as not to deform or cause damage to seating part of cap) 3) Uncalk spindle nut and romove spindle nut and washer. Fp EB 4) Pull whee! hub off by using special tools. 65) Disconnect brake hose bracket from knuckle. NOTE: Dring removal, be careful not to damape brake Fig EST 16) Remove brake dise dust cover and caliper car fier from knuckle, Fig EGP 7) Place jack under suspension arm so as to pre vent it fom lowering, 8) Remove nut and washer from inside (body center side) of control rod. As preparatory step of this removal, check stamped line on \washer to use for uide in reinstallation. Refer to SUSPENSION ARM REMOVAL 2) on p. 365 for details 9) Remove outside (wheel side) of control rod from rear knuckle stud bol Fig 66 10) Remove srut lower mount bot EAR SUSPENSION 36:11 Fg eS 11) Remove knuckle lower mount bo. Fn 12) Disconnect knuckle from suspension arm and remove knuekle from strut. If it i hard to remove knuckle from strut, ‘open it of knuckle a litle by inserting wedge thera as shown below. [ caution: Don’t open slit wie than necessary.36-12 REAR SUSPENSION. INSTALLATION 1) Install knuckle to str Bring projection "A" on strut against sit of -ouckle and push strut into knuekle till upper fend of knuckle contacts “B on strut as shown in figure below. 2) Insal strut lower mount bolt. 3) Install lower mount part of knuckle to suspen: 4) Tighten strut lower mount bolt to specified torque. For torque data refer to Fig 36-41 '5) Remove jack from under suspension arm. 6) Torque lower mount nut of knuckle t0 spe cification, 9) Install brake caliper carier and dust cover and tighten dust cover bolts to specifiod torque, Refer to Fig, 3E-43 for installation direction of brake caliper earir. 0-00 \e come ' 25882.) Fig ata eo ‘7Vinsall conteol rod and conteol rod nuts {inside & outside) and tighten them to such ‘extent that they can be turned by hand, 8) Install brake hose bracket to knuckle and stabilizer bar to suspension arm (refer to Fig. 36-46.3). 10) Install wheel hub, washer and nut 11) Tighten spindle nut to specified torque Fig E44 12)Calk spindle nut as shown, Note: Removed spindle nut should be replaced with REAR SUSPENSION 36-19 Fig aT 13) Install spindle cap. Nore: «When installing spindle cap, hammer lightly several locations on the collar of cap until collar comes closely into contact with wheel hub. + If fitting part of cap it deformed or damaged (ori itis fitted loosly, replace with new one 14) Install brake dise and tighten serews Fig Sea35-14 REAR SUSPENSION 15) Install brake caliper (Refer to Step 2) of Its INSTALLATION on page 535 of this rmanwal). 16) Install wheel and tighten wheel nuts to spe: cif torque. (Refer to Fig, 3-53.) 17) Check to ensure that brake disc ie fee from dragging end proper braking is obtained. 18) Lower host. 19) Tighten outside and inside nuts of control rod to specified torque. When tightening Inside nut, refer to CONTROL ROD IN STALLATION 7) on p. 36-4. Then check toe. 20} Perform brake test (foot brake and parking brake. 21) Check each installed part for fluid leakage WHEEL BEARING REMOVAL Perform Steps 1) t0 4) of whee! hub REMOVAL, fon p.3E-10, Wheel besring and wheel hub form a solid unit, When whee! bearing is found defective and its replacement is necessary, replace hub assambly. Fig BE INSTALLATION 1 install_wheel hub, brake dis, caliper and heel, (Refer to Stens 10) to 17) of WHEEL. HUB INSTALLATION on p. 3-12) 2) Lower hoist. 23) Perform brake test (foot brake and parking brakel. STABILIZER BAR REMOVAL T)Hoist car and remove stabilizer bar nuts (eight & let) 2) Remove stabilizer bar brackets and stabilizer Fig 96467 INSTALLATION 41) When inetalling stabilizer, loosely assemble all components while insuring that stabilizer is centered, side-toside, Refer to Fig, 9€-46-2 for its check, 2)install parts by reversing REMOVAL pro- cedure 3) Torque stabilizer nuts and bolts to specifica: tion, (Refer to Fig, 3€-46:3) For intling directors (nd poston) of aunt athe ond wasters, fr t below gure, Fig 36468 ge ea Fig EBD eo Seam LA26.16 REAR SUSPENSION REAR SUSPENSION INSPECTION STRUT DAMPER 1) Inspect strut for oil leakage, If strut is found faulty, replace it as an assembly unit, because ican not be disassembled 2) Strut function check Check and adjust tie pressures as specified. Bounce car body three or four times con tinuously by pushing rear end on the side with strut to be checked. Apply the same ‘amount of force at each push and note strut resistance both when pushed and rebounding. Also, note how many times car body rebounds before coming to stop after hands are off. Do the same for strut on the other side Compare strut resistance and number of re bound on the right with those on the lof. ‘And they must be equal in both. With proper strut, caf body should come to stop the ‘moment hands are off or after only one or two small rebounds, If struts are suspected, ‘compare them with known good car or strut. 3) Inspect for demage or deformation. 4) Inspect for abnormal noise. 5) Ingpect for cracks or deformation in spring 6) Inspect for deterioration of bump stopper. ‘Tngpect strut mount for wear, cracks or de formation Replace any parts found detective in Steps 2) — n SUSPENSION CONTROL ARM, COIL SPRING AND KNUCKLE ARM «© Inspect for racks, deformation or damape. «Inspect bushing for damage, wear or breakage Fig 36477 Roplace any defective part. CONTROL ROD «Inspect for racks, deformation or damage. ‘+ Inspect bushings for wear and breakage, Fig sae Replace any defective part REAR SUSPENSION FASTENERS CCheck each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to Fig, 36-53 of this WHEEL DISC, NUT & BEARING Inspect each wheel dise for dents, distortion and cracks. A disc in badly damaged condi tion must be replaced Check whee! hub nuts for tightness and, as necessary, retighten to specification (Refer to Fig, 3-53), 1 Check whee! besrings for wear. When measur ing thrust play, apply a dial gauge to spindle cap center. Thrust play limit | Rear | 0.3 mm (0.012 in) When measurement exceeds limit, replace beat ing, ‘By rotating wheel actually, check whee! bear ing for noise and smooth rotation. If itis defective, replace bearing [REAR SUSPENSION 36-17 STABILIZER BAR, JOINT AND/OR BUSHING BAR Inspect for damage or deformation. If detective, replace. BUSHING Inspect for damage, wear or deterioration. If defective, repace. Fig 349236-18 REAR SUSPENSION REAR WHEEL ALIGNMENT ‘Among factors for rear wheel alignment, only toe setting can be adjusted. (Camber and caster can't be adjusted, Theretore, should camber or caster be out of specification ‘due to the damage caused by hazardous road Conditions or collision, whether the damage i in ‘body ar in suspension should be determined and damaged body should be repaired or damaged suspension should be replaced. TOE SETTING ‘Amount of toe can be obtained by subtracting “a from "8" as shown in Fig, E-50 and there Fig FED TOE INSPECTION AND ADJUSTMENT Preperation for toe inspection and adjustment ‘= Place car in nomloaded state on level floor. ‘Set steering wheal in straight state, 1 Cheok that inflation pressure of each tie is adjusted properly and dise whe is free from deflection, © Check that each suspension part i free from bbend, dent, wear or damage in any other form, Chock that ground clearance at the right and lett is just about the same. INSPECTION Measure toe with toe:n gauge. “To® should be within following specification, Tosm [2=Fm no7e- oe) REAR SUSPENSION 36:19 RECOMMENDED TORQUE SPECIFICATIONS Fasting parts Tightening oraue Side stip | (.070+ 0.118 iv ts) If toesn or side sup Is out of above correspond Ing specification, adjust toe propery. ADJUSTMENT 1) Loosen right and left control rod ins nuts 2) Adjust toe to satisfy specification by turning right and left control rod inside bolts (cam bolts) by the same amount 3) After adjustment, tighten right and tet inside ruts to specified torque while holding cam bolt with another wrench to prevent it from turning —& tee eee iim kom eit 1. Control red outside nut - 70-90 yo-20 | s10-e50 2. Control rod inside nut '3, Suspension arm mounting bracket bolt 3555 35-55 | 255-35 4, Suspension arm front nut 50-70 50-70 | 365-505 '5. Suspension arm reer nut 0-60 ‘40-80 | 200-420 6. Knuckle arm lower mount nut [7 Strut support nut 28-38 28-38 20.5 ~ 27.0 [8 Suut upper nut 40-60 40-60 | 230-430 1 Tesinerwe 9, Strut lower mount bolt 50-70 50-70 36.5 — 50.5 a | 10. Rear spindle nut 150-200 | 150-200 | 1085-1445 "T. Brake dite dust cover balt When checked with side slip tester, side lin 40-60 40-60 | 290-430 should satisty following specification, ta aks expert te 13. Wheel nut 0-70 50-70 | 365—505 2eSmmimREQUIRED SERVICE MATERIAL MATERIAL, RECOMMENDED ] SUZUKI PRODUCT Brake fluid [bors Use “| Broke reservoir tank SPECIAL TOOLS ova 7011 0904218610 Brake chum remover Sing hammer WHEELS AND TIRES 36-4 SECTION 3F WHEELS AND TIRES Note: All wheo! fasteners are important attaching parts in that they could affect the performance of vital parts {and system, and/or could result in major repair xpense. They must be replaced with one of the same part ‘number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure ‘proper retention ofall parts “There isto be no welding as it may result in extensive damage and weakening of the metal CONTENTS DiAGNosis 3s Tire Rotation ar GENERAL DESCRIPTION 3e4 ON CAR SERVICE = Fa Tires BF Service Operations 3F4 Whos oF Metric lug nuts end wheel studs... 3-4 Replacement Tires 3F4 Wheel Removal 3F4 Replacement Wheels 3F2 Tire mounting nd demounting =... 3F-5 MAINTENANCE AND MINOR Tire repair 3Fs ADJUSTMENTS +32 Balancing Whosie aes Whee! Maintenance 3F2 General balance procedures». 3F6 Wheel attaching suds 3F3 Off-ar balancing 2F6 Matched tres and wheels 3F3 On-ar balancing 3F6 Inflation of tres 3F3 TORQUE SPECIFICATION oF Tire placard : 3F3 GENERAL DESCRIPTION TIRES This aris equipped with P175/608 14 tra, The tie is of tubeless type. The tire i designed ‘to operate satisfactorily with loads upto the full ‘ated load capacity when inflated to the recom ‘mended inflation pressures. Correct tre presures and driving habits have an important influence on tir life. Heevy corner: ing, excessively rapid acceleration, and unneses sary arp braking increase tre wear. WHEELS: Standard equipment wheels re 14 x 54 steel or ‘sluminum wheels REPLACEMENT TIRES When replacement is necessary, the original ‘equipment type tire should be used. Refer to the Tire Placard Replacement tires should be of the same size, load range and construction as those originally ‘on the car. Use of any other size or type tire may affectrie, handling, seedometer/odometer ‘calibration, car ground clearance and tre or snow cain clearance to the body and chassis.WARNING: Do not mix different types of tres on the same car such a radia, bias and bia belted ‘res except in emergencies, because handl: ing may be seriously affected and may it in loss of control. L_eestintessefconmol It is recommended that new tres be installed in pairs on the same axle. If necessary to replace only one tire it should be paired with the tire hhaving the most tread, to equalize braking trac: The metric term for tre inflation pressure ie the kilopascal (KPa). Tice pressures is usually printed in both kPa and psi on the Tire Placard, Metric ie gages ae available from too! supplies, Tho chart in Fig. 3F-1 converts commonly used inflation pressures from kPa op, Fig. 91 Tire Prszire Canverson Ove REPLACEMENT WHEELS Wheels must be replaced if they are bent, dented, have excestve lateral or radial runout, air leak through welds, have elongated bolt holes, i lug nuts won't stay tight, orf they are heavily rusted. Wheels with greater runout than shown in Fig. 3F-2 may cause objectiona vibra Replacement whesls must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset and mounting con figuration, A wheel of improper size or type may affect whee! and bearing lf, brake cooling, speedometer/odometer calibration, eat ground clearance and tre clearance to body and chassis, HOW TO MEASURE WHEEL RUNOUT To measure the wheel runout, itis necessary to use an accurate aia indicator. The tie may be fon or off the wheel. The wheel should be in stalled to the wheel balancer of the like for pro er measurement. Take measurements of both lateral runout and radial runout at both inside and outside of the rim flange. With the gil indicator set in place securely, tun the wheel one full revolution slowly and record every ceading ofthe indicator. When the measured runout exceeds the specif cation and correction by the balancer adjust ment is impossible, replace the wheel. If the Feading is affected by welding, paint or seratch, it should be ignored, “TOTAL INDICATOR READING IGNORE INDICATOR “UMS” DUE TOWELD SEAMS, PAINT RUNS, SCRATCHES, EYC. Fig 3F2 Whee! Runt Tadol | teat rumour tint | runout ie Serves! | @aasin) | assim) Rinioan | 070mm | 070mm wie” | foo2sim | eazein) MAINTENANCE AND MINOR ADJUSTMENTS WHEEL MAINTENANCE Whee! repairs that use welding heating, oF pee: ing are not approved, ll damaged wheels should be repced, WHEEL ATTACHING STUDS If a broken stud is found, se Section 3E (rear) ‘oF Seetion 3D (front) fer Note and Replacement procedure. MATCHED TIRES AND WHEELS (For car equipped with stel wheels) Tires and. wheels are matchmounted st the assembly plant. This means that the radially stifest part of the tire, or "high spot”, Is matched to the smallest radius or “low spot" ofthe whee! ‘his is done to provide the smoothest posible fide. ‘The “high spot of the tire is originally marked by paint dot on the oueboard sidewall. This paint dot will eventually wash off the tre. ‘The “low spat” of the whee! is orginally marked Dy paint dot on the wheel rimlange. Properly assembled, the whee! rims’ paint dot should be aligned with the ties’ paint dot as shown in Fig. 9-3 Whenever a tire is dismounted from its wheel, t should be remounted so that the tire and whee fare matched. If the tre's paint dot cannot be located, @ line should be seribed on the tre and wheel before dismounting to assure that it is Temounted in the same postion, Fig BF Meched Trerand Wel WHEELS AND TIRES 36.9 INFLATION OF TIRES “The pressure recommended for any model is carefully caleulated to give a satisfactory ride, stability, stoering, teed wear, tire life and re: sistance to bruises Tire pressure, with ties cold, (after car has set for three hours or more, oF driven less than one mile) should be checked monthly or before any extended trip. Set to the specifications on the tire placerd located on the left door (right door {or right-hand side storing car lock pillar. Ws normal for tive pressure to increase to 28 Pe (4 psi when the ties become hot during driving, Da nat bleed or reduce tie pressure after driving, Bleeding reduces the "Cold Inflation Pressure”. Higher than recommended pressure can cause 1. Hard cide 2. Tite bruising or carcass damage 4. Rapid tead wear at conte of tre Lower than recommended pressure can cause: 1 Tire squeal on turns 2, Hata Steering 3. Rapid and uneven wear on the edges of the tread 4, Tire rim bruises and rupture 5. Tire cord breakage 6. High tre tomperature 7. Reduced handling 8. High fuel consumption Unequal pressure on same axle can cause 1. Uneven braking 2, Steering lad 2. Reduced handling 4, Swerve on acceleration \Valve cape should be on the valves to ket and water out. ust TIRE PLACARD “The tre placard is located on the let door (right door for right-hand side steering ear) lock pillar land should be referred to for tire information The placard liste the maximurn load, tie size and cod tre pressure where applicable.2F4 WHEELS AND TIRES: TIRE ROTATION To equalize wear, rotate tires according to Fig F-4, Racial tres should be rotated at the first 12,000 km (7,500 miles) and after that, tire rotation at last every 7,500 milesisrecommend: fd, Set tre pressure, design, radial tres tend to wo faster in the shoulder area, particularly in front positions. This makes ropular rotation expecially necessary. Fig Fa Tre Rosato ON-CAR SERVICE ‘SERVICE OPERATIONS METRIC LUG NUTS AND WHEEL STUDS Al models use metric lug nuts and wheel studs si2e: M12 x 1.25, Fig 3F5 Were Sead nd ak WHEEL REMOVAL, 1) Loosen whee! nuts by approximately 180° (balf 2 rotation). 2) Hoist car. 3) Remove whee! CAUTION: Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings. Wheel nuts must be tightened in sequence and to proper torque to avoid bending wheel or broke dis, Fig, 3F-7. Fig, 3-7 Whee! Nat Tightening Sequence Nore: Before installing wheels, remove any build-up of corrosion on wheel mounting surface and brake dise. mounting surface by scraping and wire brushing, Installing whools without good metal- ‘o-metal contact at mounting surfaces can cause whoo! nuts to loosen, which can later allow a ‘wheel to come off while ear is moving. ‘TIRE MOUNTING AND DEMOUNTING Use attire changing machine to mount or demount tires, Follow equipement manufacturer's instruc tions. Do not use hand tools or tte irons alone to change tires as they may damage tre beads or whee! rim, Fim bead seats should be clesned with © wire brush or coarse steel woo! to remove lubricants, ‘old rubber and light rust. Befere mounting or ddemounting a tire, bead ares should be well lubricated with approved tire lubricant. ‘After mounting, inflate to specified pressure shown on tte aracard so that bests are com: pletely seated. eres Install valve core and inflate to proper pressure TIRE REPAIR There ate many different materials and techni: ques on the market to repair tires. As notall of these work onalltypesof tires, tre manufacturers have published detailed instructions on how and when to repair tires. These instructions ean be ‘obtained from each tire manufacturer WHEELS AND TIRES 365 BALANCING WHEELS ‘Thera are two types of wheel and tire balance: static and dyramic. Static balance, Fig. 3F8, is the equal distribution of weight around the wheel. Wheels thet are statically unbalanced cause @ bouncing action called tramp, This eon: ‘dition wil eventually cause uneven tre wear ‘Dynamic balance, Fig. 2F-9, I the equa distribu tion of weight on each side of the whee! center line $0 that whan the tire spins there is no tendency for the assembly to move from side to side, Wheels that are dynamically unbalanced may cause shimmy. Fig 9F- Satie Unbatrce Correction Fig 69 Dynamic Unbalance Corecvon35-6 WHEELS AND TIRES. GENERAL BALANCE PROCEDURES Deposits of mud, etc. must be cleaned from inside of rim. ‘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, thon balanced according to equipment manufac ‘turers recommendation | WARNING: OFF-CAR BALANCING Most electronic off-car balancers are more ec curate than the on-ar spin balancers. They are ‘easy to use and give @ dynemic (two plane) balance. Although they do not correct for ‘drum or disc unbalance as does on-car sin blane: ing, this is overcome by their accuracy, usually 10 within 1/8 ounce, ON-CAR BALANCING Onear balancing methads vary with equipment and tool manufacturers, Be sure to follow each manufacturer's instructions during. balancing operation WARNING Wet sn shouldbe tnd Yo 35 mh {55 kmh) winced on sponte Ths lin i eco besa sendometar sniy inet oneal of ast whe Speed ‘when one trv whl snng Si the obo eve wel is ope | Ube eke iting rie hel es hel ean seth cee speeds. This can result in possible tire isintagration or differential failure, which ‘could cause serious personal injury oF ‘extansve car damoge, RECOMMENDED TORQUE SPECIFICATIONS Wheel nuts: 60 ~ 70 Nem (5,0 ~7,0 kam, 36.5 ~ 505 Ibs) SECTION 4 FRONT DRIVE SHAFT (Double Offset Joint (DOJ) Type) note: This type of front dive shat is used for manual transmission models, CONTENTS GENERAL DESCRIPTION a REMOVAL (Loft side shaft) 42 REMOVAL (Right side shaft) 43 DISASSEMBLY (Drive shaft) 44 INSPECTION. . 45 DISASSEMBLY (Center shaft and conter bearing support) 45 REASSEMBLY (Driv shaft) , 45 REASSEMBLY (Center shaft and contor bearing supprt) 48 INSTALLATION a 49 RECOMMENDED TORQUE SPECIFICATIONS . 40 49 REQUIRED SERVICE MATERIALS GENERAL DESCRIPTION ‘A constant velocity ball join is used on the wheel side of front drive shat and a constant velocity double offset joint (DOU) on the differential side. Fig 41 Fron Drive Saf Asa442 FRONT OnE SHAFT REMOVAL (Left Side Shaft) ON FLOOR Undo caulking and remove drive shaft nut and washer Fig 42 Reming Drive Sia Nak ON LIFT 1. Drain transmission ol 2. By using large size screwdrivers, pull out drive shaft joint s0 a8 to release snap rng iting of joint spline at differential sie. Fig 3 Batacira Sas Bing rom Dire 3. Disconnect stabilizer joint from suspension 4, Remove ball stud bolt end nut, and then separate suspension arm from knuckle Fig 44 Detaching Svzoiion Arm Tam Kraehe 5.To remove drive shaft assembly, pull out in- board joint from differential side and then hel side joint from staring ke ‘CAUTION: To prevent breakage of boots, be careful not to bring them into contact with other arts, when removing driveshaft assembly. | REMOVAL (Right Side Shaft) ON FLOOR Undo caulking and remove drive shaft nut and washer. ON LIFT 1 By using plastic hammer, drive out drive shaft joint so as to release snap ing fitting of joint spline a center shaft FRONT DRIVESHAFT 43, 2.Disconneet steilizer joint from suspension 4, Remove ball stud bolt and nut, and then spa rate suspension arm from knuckle, 4.To remove drive shaft assembly, pull out inboard Joint from center shaft’ and. then whee side joint from stering knuckle. ‘CAUTION: To prevent breakage of boots, be careful rot to bring them into contact with other parts, when drive shat assembiy. 5, Drain wansmisson oil 6. Loaten center bearing support bolts and Femove center shaft from differential side ea.44 FRONT DRIVE SHAFT DISASSEMBLY (Drive Shaft) 1, Remove boot band of diferential side joint. Fin ad 2, Slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race. Fg a70 3, Wipe off grease and remove cirelip use to fic cage by using special tl (A) Fatt 4. Draw anay cage and boot from shaft INSPECTION # Cheek boots for breakage or deterioration. Replace ther as necessary. ‘© Check citelip, snap ring and boot bands for breakage or deformation, Replace as necessary, DISASSEMBLY (Center Shaft and Center Bearing Support) 1. Remove right sde oil seal from center beering support 2. Remove circlip. \ Fess 3. By using hydraulic res, draw out center shaft from canter bearing, FRONT ORIVE SHAFT 45, 4, Remove left side ol sal from center bearing support. 5, Remove bearing suppor ciel, Fina 6. Remove center bearing from center bearing support. REASSEMBLY (Drive Shaft) 4.Wash disassembled parts (except boots). [After washing, dry parts completely by biow- inga. 2. Clean boots with cloth. DO NOT wash boots in degreaser, such a gasoline or kerosene, etc. ‘Washing in degreaser causes deterioration of boot. Fg aie Note: Do not disassemble whee! side joint (outboard joint) 1f any maleondition is found in any joint, replace it as assembly.146 FRONT DRIVE SHAFT 3, Install boot onto drive sheft tll its small di- meter side fits to shaft groove and fix there with boot band. Fig 7 4. Install cage to shaft, 5. Install circlip by using special too! (A, 1. Appiy areas to entire surface of cage Use joint grease in tube included in differenti side boot set or DOS set of spare parts CAUTION: Install cage lecting smaller outside dia meter side to shaft ond, \ Wy MW 1} i !O lo Al iH Fin o18 “insert cage into outer race and fit snap ring into groove of outer race. [ caution: Position opening of sn ll not be lined up wit (A) so that it FRONT ORIVE SHAFT 47 8. Apply grease to Inside of outer race, and fit boot o outer race, [After fitting boot, inser: serew driver into ‘boot on outer race sido and allow air to enter boot 20 that air presure in boot becomes the same a atmospheric pressure. Fig 2 indieated in figure below. Fy aes 8.When fixing boot to outer race with boot band, adjust so that measurements (A) and (B) become as — | al Fig ae I ql 7 Nott ie48 FRONT DnIVE suAET REASSEMBLY (Center Shaft and Center Bearing Support) Install center shaft by reversing removal peo cedure snd noting following points * When installing beating support ciectip, make sure that it fits in cirlip groove in eanter bear Ing support securely as shown below. Fea 1 When installing left side oll seal, use care so that it i in proper direction by referring to below figure. ard Alter pressfitting canter shaft from lft side oil seal side, fit eeeip into groove in shaft securely -———— Fig 428 ‘© When installing right side ol seal, use care so that i is in proper dicection by referring to below figure aed FRONT DRIVE SHAFT 49 INSTALLATION '@ Install wheel side joint to steering knuckle first and than 004 to differential side Install drive shaft essembly by reversing removal ‘Apply sealant to drain plug for manual tans procedure and nating following points. mission Fill transmission with oll as specified # Clean front wheel bearing oll seal and then apply grease, Replace iti aquired carrion # Protect oil seals and boots from any damage, preventing them from unneces sary contact while installing drive shat * Do not hit joint boot with hammer. In: serting joint only by hands i allowed. ‘© Make sure that diferental side joint is inerted fully and its snap ring Is seated Fig 428 Labretng Sl with Grease RECOMMENDED TORQUE SPECIFICATIONS age “Tightening torque —__] Te nm | oa tas 215 Oilin pha eerie | [era eel ag 255-200 _| Ball oint st bolt and na 65 — 505 [Driveshaft ut toa — 445 | Center bearing BpOFTBOIe =e | 40-60 | 290-«20 Stabzerointrut— [ote-2e [tea | 135-200 pam RECOMMENDED TEL _SUZUKI PRODUCT. "| suzuki sure GREASEA | (9900026010) | ‘SUZUKI BOND NO. 1215 lan i rain plug for manual transmission | Seclant (99000:311101 9 a Oil seal tipsFRONT DIVE SHAFT 441 SECTION 4A FRONT DRIVE SHAFT (Tripod Joint Type) nore: This type of front driveshafts used for automatic transmission models, CONTENTS GENERAL DESCRIPTION be aaa aad REMOVAL, . we — cee coves AAD DISASSEMBLY (Driveshaft) 5 , cee ses AAD DISASSEMBLY (Center shaft and center bearing support) 4a2 INSPECTION «22.2. 5 . 4n2 REASSEMBLY (Driveshaft) 5. .0200200 _ cee se AAD REASSEMBLY (Center shaft and conter beating uppOF) «22+ cee 4nd INSTALLATION eS 5 5 : 44 REQUIRED SERVICE MATERIALS bee pouoso808 4a4 GENERAL DESCRIPTION [A constant velocity ball joint is used on the ‘rive shaft can slide through the tripod joint in ‘wheel side of front drive shaft and 9 constant the extension/eontraction direction. Yelocity tripod jaint on the ciffeental side. The | Fig Gat Front ie Sat Anmbiy442 FRONT DRIVE SHAFT REMOVAL ‘When removing deve shaft (whether itis left side one or right side one, reer to REMOVAL description in Section 4 of this manual for its removal procedure, DISASSEMBLY (Drive Shaft) 1. Remove tripod joint boot band, then take out tripod joint housing Fig 442 Removing Tripod Joint Mosing 2. Remove grease from shaft and take off eiclip by using special tool, chen pull out spider from shaft ‘CAUTION: To prevent needle bearing of joint from being degreased, do not wash it fits to be sd. 3. Remove boot band, then pull out differentia side boot from shaft. 4, Undo band of dynamic damper, then pull out ‘damper through shaft. 5. Undo boot bande of wheel sie joint boot then pull out boot through sha. DISASSEMBLY (Center Shaft and Center Bearing Support) For diaassembly procedure of these parts, refer to DISASSEMBLY description in Section 4 of this manual INSPECTION © Check boots for breakage or deterioration place them as necessary. 1 Check cirelip, snap ring and boot bands for ‘breakage or deformation. Replace asnecessary. REASSEMBLY (Drive Shaft) Judging from abnormality noted before dis- ‘asembly and whet is found through visual check ‘of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that whee! side joint assambly and tripod joint housing are wathed thoroughly and air dried, and boots are cleaned with cloth if they are tobe reused. 1-Apply grease to wheel side joint. Use black {reas in tube included in whee! side boot oe 2. Ineal wheel side boot on shat. 3. Fill up boot inside with grease and then fasten ‘boot with bands. 4. Install dynamie damper on shaft. 5. Install differentia side boot on shaft ‘Apply gress to tripod joint. Ute yellow grease In tube included in differential side boot sot fr differential side joint assembly of spare parts 6. Install tripod joint spider on shaft, facing its chamfered spline inward (wheel side), then fasten it wth clip. FRONT DRIVE SHAFT 443 7.Fll_ up iffrential side boot inside with srase, then install housing and joint it with boot. 8, Fasten boot with bands ‘CAUTION: * To prevent any problem caused by washing solution, do not wash joint ‘boots and tripod joint except itshousing, Degreasing of those parts with cloth is allowed, '¢ To ensure full performance of joint as designed, be sure to distinguish between ‘wo. types of grease in repair sat and apply specified volume to respective Joint, ie, black grease (130 9 tube) to wheel side joint and yellow one (130 g tube) to tripod joint ‘+ Bend each boot band agsinst forward rotation. 1 Do not squeeze or distort boot when astoing it with bands. Distorted boot caused by squeezing a may reduce is durability.REASSEMBLY (Center Shaft and Center Bearing Support) For reassambly procedure ofthese parts refer to REASSEMBLY description in Section 4 of this manual. INSTALLATION Install rive shaft assembly by reversing removal Procedure and noting following points. ‘Clean front whee! bearing oil seal and then apply greas. Replace it if required. 2 este gm ene 2210) Fig 445 Lubreting 01 Sel with Gress * Install wheel side joint to steering knuckle first and then tripod joint to differential side, ‘CAUTION: ‘consequential disconnection of joint in| | boot, do not pull trod joint housing aaa ees | sorting joint only by hands i allowed. | eee ee ew | ‘Tighten each bolt and nut to specified torque. For torque data, refer to RECOMMENDED TORQUE SPECIFICATION table in Section 4of this manual. ‘© Fill transmission with ol at specified. NOTE: For automatic transmission, carry out full sep ‘of Tid fevel check procedure Le. ROOM TEM: PERATURE LEVEL CHECK firs, and then NORMAL OPERATING TEMPERATURE LEVEL CHECK, referring to p. 78-46. REQUIRED SERVICE MATERIALS T RECOMMENDED eS SUZUKI PRODUCT es SUZUKI SUPER GREASE A | Seemeonrs Use | il sal tips BRAKES 53 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. Do not use a replacement part of lesser quality of substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts, Ther i to be no welding a it may result in extensive damage and weakening CONTENTS GENERAL DESCRIPTION 5 2 FRONT DISC BRAKE R&I 527 Front Disc Brake Caliper Assembly... -5 31. Remove and Install Pad Rar Disc Brake Caliper Assembly 55 (Shoe & Lining) 527 Master Cylinder Assembly 5 8 2, Romovoand Insal Caliper Assembiy 5-28, Booster Assembly 5 10 3, Remove and Install Sea, Piston, Dust Boot and Bloser Seow ons 529 Diagnosis 5:13 4, Remove and inal Disc = [331 Road Testing Brakes 513 perenne veo £13 FRONT DISC BRAKE INSPECTION ......532 Substandard or Contaminated Brake 1 Inspect rake Fad Lining 522 ay 5:13. 2 Inspect Bake Caliper Inner Paris 532 Brake diagnosis Ghent Big 2 Inepact rake Disc 533 Brake Diagnosis Chart 8 515 REAR DISCBRAKE R&I 534 ENCAR sanvicel 16 1s Remove nd Install Brake Pad t Srake Pedal Free veight Adjustment ....846 (Shoe & Lining) «=... +=... 534 2. Stop Light Switeh Adjustment 816 2 flemoveand Insal Brake Disc 535 Sree tea rrenl oie £16 3. Removoand Install Caliper Assombiy 5-36. AE ees £19 4. Remove and instal Seal, Piston, Dust Boot 5. Front Brake Pad Lining lnepection |... 5-17 __ 806 Parking Brake Com 538 6. Brake Pedal Ply Inspection 5:17 REAR BRAKE INSPECTION . 5.43 1 Master Cylinder Inspection 5.17 “I. Inspect Brake Pad Lining . 1543 8, Rear Brake Dise Inspection 518 2 Inspect Brake Caliper Inner Par 543 8, Rear Brake Pad Lining Iepocton 5:18 3, Inspect Brake Dise Bas 10, Parking Brake Inspection and MASTER CYLINDER REPAIR 5-45 Aaustment 5.18 "Remove and Insal Master Cylinder 11. Fusing rake Hyrule System 5:19 | Resrvoir 545 12, Bleeing Brakes 5:19 2. Remove and install Maier Cylindor 13, Brake Hose and Pipe inspection 521” Assembly 5.46 18, Brake Fluid Level Inspection 521 9, Dissamble and Asimble Mosier BRAKE HOSE/PIPE R&I 522 Cylinder sar 1. Remove and Install Front Brake MASTER CYLINDER INSPECTION 5.48 2. Remove od instal Rear Brae 5% gaake BOOSTER REPAIR 549 nore 5231. Remove and Insal Booster 549 ‘ce Levenicapie we 2 Dieasemble and Aasombie Booster =. 550 PMmore sve nsavarungsioce + SRAKE SOOSTER INSPECTION AND ate 5.24 ADJUSTMENT 556 2, Remove and install Parking Brake RECOMMENDED TORQUE Cable 525 SPECIFICATIONS 5.60 REQUIRED SERVICE MATERIALS 560 SPECIAL TOOLS 561GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the mester cylinder to actuate pistons (two infront and two In ea ‘The master cylinder i @ tandem master cylinder, Three brake pipes are connected to the matter eylinder and they make two independent circuits. One connects front right & rear leftbrakesand the other connects front let & rear right brakes. The proportioning valve (P valve is included in these circuits between the master cylinder and rear wheels In this brake system, the disc brake type is used for the front and rear wheel brake. The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable land mechanical lnkege system. The same brake pods are used for both parking and foot brakes. = => pean 27 [esa Fa St r BRAKES 52 FRONT DISC BRAKE CALIPER ASSEMBLY 1 Sri hsing ne ale ec by pring fora ee il ened Tutt acon terse cee at epitome ae Uren te pte etn anon is te eo nmr, reign damping ae i cmpng tan ores pats ing] pit he da, tng ection 0 sep Wetter OPERATION in he ot Pe. noTe Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo- ents may result. f-eny component is removed or line disconnected, bleed the ce system, Replace pads in axe sets only. The torque values specified are for dr, unlubricated fastners Fig 5 Front Calor BabyCaliper OPERATION Single piston floting caliper type The single piston floating caliper type brake is employed in this model. One eylinder and one Piston are used for this type. (The cylinder is ‘constructed as a monablock with the caliper.) Fluid pressure generated in the cylinder causes ‘the pad (1) on the piston side to press against the disc. At the same time, the floating type caliper body is moved to the right by the eylin: er pressure, as shown in below figure, which pulls pad (2) against the de and sa brakes the whee Fp 53 “The dis brake has no serv assistance asin drum braking, ad itis necessary to inrease the wark: ing pressure of the piston and pad. For this pur ose, the wheel cylinder has a large bore. Even ‘only a little chang® in clearance between the dise and ped has therefore a large influence on the brake pedal stroke, It is necessary to keep the clearance adjusted tothe minimum at all times, ‘by means ofthe piston (rubber! seal BRAKES 58 REAR DISC BRAKE CALIPER ASSEMBLY GENERAL DESCRIPTION ‘This caliper assembly is a single piston floating caliper type. It consists of such components as shown below and serves as foot brake and parking brake. Nore: Replace all components included in repair kts to service this dis brake, Lubricate parts as specified. Clearance correction When oil pressure i applied to the piston, the piston moves forward. The rubber seal, which ‘exerts considerable pressure agaist the piston, moves with the evlinder. However. asa part of the rubber seal has been fixed into @ groove in the cylinder, the shape ofthe rubber seal is dis: torted toward internal end of the eylinder, at shown in above figure. When pressure is token ‘off from the foot brake pedal and fluid pressure is released from the piston, 2 restoring foree is ‘generated atthe seal and pushes the piston back. [As the pads wear away and the clearance be: tween the disc and pads becomes larger, the piston moves a larger distance. The seal then could change in shape further but, since the end Of the seal is fixed into the groove in the yin Ger, the distortion is limited tothe same amount ‘2s previously described. The piston moves further 10 cover the distance of clearance. The piston returns by the sare distance and the rubber ‘zal recovers its shape as described sbove and ‘hus the clearance between the disc and pads is maintained in adjustment, WARNING: It any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque values specified ar for dry, unlubricate fs "| rr iOyinde) 1. CioSTRUCTURE ‘As shown below, the piston has a nut, bearing land washer in it.The nut is pushed 9 tapered part (clutch face which Is A figure below) of the piston by the wave washer via the inbetween bearing. ‘The screw part ("8 od is engoged with the nut and the col sring force is applied to the push rod, which then pushes the rod toward the camshaft. ‘As the push rod is tightly fitted with the key Plate, it ean nat turn, OPERATION [Foot brake} When the brake pedal is depressed, the hydraulic pressure generated In the master cylinder makes the nut in the eaiper (cylinder) and piston move in the rod direction by the amount of builtin Clearance at the srew part af the push rod, As ‘the nut does not turn in ths state, It does not act as an automatic adjust device, When the dise-to-pad clearance grows larger and exceeds the built in clearance st the screw part ‘of the pushrod, the piston moves away from the rutin the rod direction (ta the leftin the figure) ‘Then due to the screw torque (which causes the ‘ut to turn) generated by the hydraulic pressure, ‘the nut turns and moves in the rod diection for adjustment tll nutto-pston clearance is gone. Even won the clearance is gone, as long a8 the torque generated on the clutch face (“A in Fig. 5.6) is smaller than that atthe serew part of the nut ("B" in Fig. 5-6) the nutto-pston clearence Js adjusted on the basis of such conditions 2s deformation, ee, As the hydreulic pressure increases, the torque generated at the sorew part ("B") increases and when it exceeds thet generated on the clutch face ("A"), the nut does not tuen and the push Tod compresses the spring and moves with the ‘ut In the rod direction by the amount corre- sponding to the piston stroke caused by deforma For the process after the piston has moved to the left til the brake force occur, refer to the Aescription under FRONT BRAKE in this When the foot is taken off the brake padi and the hydraulic pressure inthe brake system lowers, ‘the piston in the caliper moves back with the help of the piston seal and coil spring for the proper pad:-to-dise clearance, ‘This clearance is determined by the builtin ler: ance generated between the nut and the screw Dart of the pushrod, (parking bral Yinen the parking brake lever is pull wp, i Cains he lever onthe raur brake eipertomove ott) though sedi Ws the lover mode 2 part of the case ‘tic sine nthe take aie elder Scam fons te mover Shown nthe tia ety th casa hat am laconic hol in cone frm), hereby the estat movement (rotvon I converted imo ae nar moverant of the push rod inthe tou ection hough tered Fig 58 “The push rod is meshed with the nut and the ‘outer part ofthe nut is pushed against the taper fet part (“A” in Fig, 56) of the piston as des- cribed previously. Thus the push rod movernent is transmitted to the piston through the nut In other words, the movement (rotation) of the lever on the caliper causes the piston to move {orward (toward the pad). Then inthe same way fas with the foot brake, the inner and outer pads hold the die between them to brake the ear toa stop,MASTER CYLINDER ASSEMBLY GENERAL DESCRIPTION The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary ("in the below figure) end secondary (“b") chambers, The hydraulic pressure produced in the primary chamber ("3") acts onthe right front wheel brake end left rear wheel brake. Also, the hydraulic pressure produced in the secondary chamber ("b") acts on the left front wheel brake and right reer whee! brake, NoTE: Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage torubber ‘components may result. If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque values specified are for dry, unlubricate farteners rk i; Reema \ 2S Fe 5o Master Cylinder OPERATION Normal operation Depressing the brake pedal forces the primary piston “A” to mave to the left in the below figure and ‘consequently the hydraulic pressure is produced in the chamber "a. By means of this pressure and the return spring fore, the secandry piston “8 and thus the hydraulic pressure is produced in the chamber “b’ Isalso pushed to the left BRAKES 5:9 COnecircuit operation (Primary chamber “a circuit filure) Depresing the Brake pedsl forces the primary piston “A” to move as deerbed previously, but since the elke cirouit connected to the chamber “a” cannot hold the pressure, no presture is produced inthe fluid rxtdiately ahead of the piston "A". The piston “A keeps moving while compressing the spring and sro amches the retainer, the piston “B's pushed and begins to move. This causes the pressure to rise ‘tne chamber" and the pressure acts on the left front wheel brake and right rear whee! brake Fig5tt pcre en in "a ch Fig 610 Fig 512BOOSTER ASSEMBLY GENERAL DESCRIPTION “The booster is located between the master cylinder and the brake pedal. I is 30 designed that the force created when the brake pedel is depressed is mechanically increased combined with the engine vacuum. ‘The booster has @ diaphragm of ¢ 185 mm (6 in.) effective diameter. Is operation is described in te fo! owing pages. NoTE: ‘Use all components included in repair kits to service this booster, Lubricate rubber parts, where indicat: ‘2, with silicone grease provided in kits. The torque values specified ae for dry, unlubrcated |f any hydraulic component is removed or brake line disconnected, bleed the brake system. ‘Never lubricate any hydraulic component with silicone grease, L re BRAKES 5:11 Booster OPERATION Fig, 5-14 Vacuum Booster Assombly ‘when the brake pedal is depressed, the fore is transmitted to the piston of the mester cylinder through the valve operating rod, booster ai valve, reaction diss and piston rod. At the same time, the force of the booster piston developed due ta the pressure difference between the two chambers “A” and "8 in the above figure is ade to it ‘The end of the booster control valve has a double function of vacuum valve and air valve. That i, 25 shown inthe figue, the booster control valve closes between the "A" and "B"” chambers as is outer end ""C" contacts the booster piston seat and opens as "Cleaves the booster piston seat (vacuum valve Fune: tion). Also it closes between the 8” chamber and outside air as its inner end “D" contacts the air valve seat and opens ag “D” leaves the air valve seat (sr valve function), When foot brake pedal is not depressed “The valve operating rod is pushed to the right by the spring force as shown. The it valve is also enough to the right to contact the valve stopper key as shovin, In this state, the vacuum valve (control valve “C") Is ‘open and the air valve (contro valve “D") is closed. Thus the chambers “A' and "B" conduct and share the same negetive pressure (becouse of no pressure diference) which ellows the return spring to push the booster piston tothe ight. [ ar5:22 oraKes When foot brake pedal is depressed Being pushed by the operating rod, the booster Bir valve moves to the let as shown. Then the ‘control valve is pushed against the booster piston ‘stat closely by the vale spring force, Thus the vacuum valve (control valve °C") is closed to cut fff between the chambers "A and “B". At thie time the sir valve (control valve “D") fs stil closed. i —_— a > ‘© Fin 516 ‘As the booster air valve moves further tothe ett, it leaves the conto! valve and the ae valve (con trol valve "0" opens to alow the air to flow Into the chamber "B”. The entry of sir causes 0 dlfference in. pressures between the chambers “A and "B". When this pressure difference ‘grows greater than the piston return spring force, the booster piston moves to the left and the booster control valve also moves to the left ‘The resulting. air valve (control valve “D") closure sto9s the airflow into the chamber “8” and its pressure remains iti. In this way, @ small brake pedal depressing force is made into 2 strong push to the master cylinder push rod to produce high hydreulc pressure, ‘When foot brake pedal i relented When the brake pedal is released, the booster air valve returns to the right By the master cylinder piston retuen force and the air valve return Spring force as shown, Then the vacuum valve {control valve "C") opens and causes negative pressure in the chamber "B". The result i that the master cylinder piston and booster piston return to their orginal positions. This is the same state at deseribed under "When foot brake pedal is not depressed” Reference Should any of the vacuum rested parts inthe booster be faulty, the brake force i not increas: fd. Even then, howover, the brake depressing force is transmitted t0 the valve operating rad, booster ar valve, valve stopper key and booster Piston in that order, to push the mester cylinder sh rod. Thus, the braking operation itself wil not fal — _ BRAKES 513 DIAGNOSIS ROAD TESTING BRAKES Brakes should be tested on dry, clean, smooth and reasonebly level roadway which ienot crown: 16. Road test brakes by making brake applica tions with both light and heavy pedal forces at \atious speeds to determine f the cr stops evenly and effectively ‘Also dtive car to sae if it leads to one side or ‘he other without brake application. If it does, check the tire pressure, frontend alignment and front suspension attachments for looseness. ‘See diagnosis chart for other causes. BRAKE FLUID LEAKS Check the master cylinder fluid lvels. While @ slight drop in reservoir level does result from ‘normal lining wear, an abnormally Low love i dicates 2 leak in the system. In such scase, check the ote brake system fr leakage. If even & tight evidence of leakage is noted, the cause should be corrected or defective parts should be replaced, SUBSTANDARD OR CONTAMINATED BRAKE FLUID Improper brake fluid, mineral oil or water inthe fluid may cause the brake fluid 10 boil or the rubber components in the hydraulic system to deteriorate 1 deterioration of rubber is evident, disassemble all hydraulic parts and wash with aleohol, Dry these parts with compres sir before assembly to keep alcohol out of the system. Replece all rubber parts in the system, including hoses. Also, when working on the brake mechanisms, check for fluid on the linings. excessive fluids found, replace the pads. 1 master eylinder piston seals are satisfactory, check for leakage or excessive heat conditions. HH condition i not found, drain fluid, flush with brake fluid, refill and bleed system, “The system must be flushed if there is any doubt as to the grade of fluid in the system ori fluid has been used which contained parts that have been subjected to contaminated fluid5:14 oRAKES BRAKES 518 BRAKE DIAGNOSIS CHART A Condition Possible Cause Correction BRAKE DIAGNOSIS CHART B Condition Possible Cause Correction ‘Not enough braking force 1. Brake ol leakage from brake lines, 2. Brake disc or pads stained with ol 3. Overhested brakes. 4. Badly worn brake pad linings 5. Malfunetioning calipr assembly ‘Locate leaking point and repair. Clean oF replace. Determine cause and repair. Replace Repair or replace, ‘3 Wheel tres ae infloted unequally. 4. Malfunctioning caliper pistons. 5. Disturbed frontend alignment. 1. Unmatched tres on seme axle 7. Restrctea brake tubes or noses, 8. Malfunctioning caliper assembly, 8. Loose suspension part 10. Loose calipers. 6. Air in system. Bleed system. ‘Brake pul (Brakes not | 1. Pad linings are wet with water or | Replace working in unison) stained with oil in same brakes, 2. Dise is out of round in some brakes, | Replace. Inflate equally. Repair or replace, Adjust as prescribed, ites with approximately the same amount of tread should be used on the same axle Check for soft hotes and damaged tines. Replace with new hoses and new double-walled stel brake tubing. CCheck for stuck or slug Pistons and proper lubrica tion of caliger side bush Caliper should slide Check al suspension mount ings. Check and torque bolts to specifications Noise (high pitched squeak without brake applied) 1. Front lining worn out, Replace linings. | Excessive peda trav {Pedal stroke too large) 1. Partial brake eystem failure 2, Insufficient fluid in master cylinder 3. Air in system, (pedal soft/spongy) ‘Check brake systems and repair as necessary, Fill reservoirs with approves brake fluid, Check for leaks and air in brake systems. Check warning light. Bleed system if required. Bleed system, Drageing brakes (A very Tight drag is resent in all die brakes immedi. ‘oly after pedal is ‘elossea) Pedal pulsation (Pedal palsates when depressed for braking.) 1. Master eylinder pistons not eturning corecty 2. Restricted brake tubes or hoses. 3, Incorrect parking brake adjustment. 4, Badly worn piston soal inthe caliper. 5. Sluggish parking brake cables or Tinkage 6. Caliper piston sticking, 1. Damaged or ioose wheel Bearings 2. Distorted steering kruckle or rear whee! spindle 3, Excessive disc lateral runout 4, Parallelism not within specifications. Repair master eylinder. Check for oft hoses or damag od tubes and replace with new hoses and/ornew double walled steel brake tubing Check and adjust to correct specifications. Replace, Repair or replece, Repair at necessary. Replace wheel bearings. Replace knuckle or rear whee! spindle. Check per instructions. If not within specifications, replace for machine the disc Check per instrvetions. f not within specifications, replace for machine the dis Braking noise 1. Glazed pad linings, oF foreign matters stuck to linings, 2, Worn or distorted pad linings. 3, Loose frant wheel bearings. 4, Loose mounting bots. Repair or replace pad place pad. Replace wheel bearing Retighten securing bolts.ON CAR SERVICE 1. BRAKE PEDAL FREE HEIGHT ADJUSTMENT For right-hand steering vehicle Height of brake pedal is normal if itis as high as cluteh peda For left-hand steering vehicle: Height of brake pedal is normal if it is about {8 mm (0.3 in.) lower than clutch pedel 1) When booster push rod clavis has been rein stalled, it Is important that measurement be ‘ween booster mounting surface and center of levis pin hole is adjusted within 114.5 — 115.5 mm (451 ~ 4.54 in), See page 5-5. 2) When stop light switch hasbeen removed, refer to the following STOP LIGHT SWITCH AD. JUSTMENT for proper instalation, Services in above steps 1) and 2) may affect brake pedi height. 2. STOP LIGHT SWITCH ADJUSTMENT Adjustment should be made as follows when installing switen, Pull up brake pedal toward you and while hold ing it there, edjustswitch postion so that learan ce betwoen end of thread and brake pedal feturn cushion (shown ag “A” in figure) is Within 0.5 — 1.0 mm (0.02 ~ 0.08 in.) Then tighten lock nut to specifi torque. Fig 520 3. EXCESSIVE PEDAL TRAVEL CHECK 1) Start engine 2) Depress brake pedal afew times, 3) With brake petal depressed with approximate |y 30 kg (66 lbs) load, measure pedal arm to wall clearance “B". It mustn't be less than 60 mem (2.38 in) 4) If clearance “Bis lss than 60 mm (2.36 in), the most possible cause is either rear brake shoes are worn out beyond limit or aris in ines. Should clearance “8” remain lee than 60 mm (2.26 in even after replacement of brake shoes and bieeding of system, other possible but infrequent cause is malfunction of rear brake shoe adjusters or booster push rod length out of adjustment forthe vehicle with brake booster. + See page 5-19 fo bleeding brake system, Fr 4, FRONT BRAKE DISC INSPECTION Refer to page 6:23 of thie section for inspection point and procedure 6. FRONT BRAKE PAD LINING INSPECTION Inspect pad linings periodically sccording to maintenance schedule whenever wheels are re: moved (far tie rotation oF other reason). Take a Took through each end (or hole of caliper anc chek lining thickness of outside and inside pads. If Lining is worn and ts thickness ("Cin figure) is less than 3 mm (0.12 in), all pads must be replaced atthe same time 6. BRAKE PEDAL PLAY INSPECTION RAKES 5:17 aie Mr bakes Fig 528 7. MASTER CYLINDER INSPECTION CCheck for 8 eracked master cylinder casting or brake fluid around the master cylinder. Leaks ace indicated only if there is atleast a drop of ‘uid, A damp condition is not abnormal. Pedal play should be within below specification out of specification, check stop light switch for proper instalation position and adjust if necessary. Also check padal shaft bolt end master cylinder Bin installation for looseness and replace detec: tive.8. REAR BRAKE DISC INSPECTION Refer to page 5:44 ofthis section for inspection point and procedure. 9. REAR BRAKE PAD LINING INSPECTION Inspect pad ning periodically sccording to ‘maintenance schedule whenever wheels are re ‘moved (for tire rotation or other reason. Take @ look through each end of caliper and check lining thickness of outside and inside pads. If lining is worn and ite thickness ("C” in figure is less than 1-mm (0.04 in), all pads must be replaced atthe same time, poe 10. PARKING BRAKE INSPECTION AND ADJUSTMENT 8) Inspection Hold center of parking brake lever grip and pull itup with 20 to 25 kg (44 to 55 Ibs) foree. With parking brake lever pulled up as above, Count ratchet notches in “A as shown in figure. ‘There should be 4 to 9 notches Also, check if both right and lett rear wheels are locked firmly. To count number of notches easily, listen t0 ‘lick sounds that ratchet makes while pulling parking brake lever without pressing its button ‘One click sound corresponds to one notch, Fig 528 If number of notches is out of specification, ad just eable by referring to adjustment procedure described on the following step b) £0 a8 to obtain specified parking brake stroke Note: CCheck tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking brake lever. b) Adjustment NoTE: Make sure for following conditions before cable adjustment. ‘+ No iris trapped in brake system. ‘© Brake pedal travel is proper. ‘Brake pedal hae been depressed e few times ‘with about 30 kg (66 Ibs) load. * Parking brake levr has been pulled up 2 few ‘times with about 20 kg force + Rear brake pads are not worn beyond limit. [After confirming that sbove 5 conditions ae al satisfied, adjust parking brake lever stroke by Foosening oF tightening self locking mut (3 in figure below). note: (Check brake dise for dragging after adjustment. Fata area] cpnabta te Fig ba 11, FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that entre hydraulic system bbe thoroughly flushed with clean brake fluid whenever new parts are installed in hydraulic system, Periodical change of brake fluid is also recom mended, 12, BLEEDING BRAKES Nore: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Bleeding operation is necessary to remove sir whenever it entered hydraulic brake system Hydraulic lines of brake system are based on the ciagonal split system, When a brake pipe or hose \was disconnected at the whee, bleding opera tion must be performed at both ends of the line fof the removed pipe or hose. When any joint part of the master cylinder or other joint part between the master cylinder and each brake (wheel) was removed, the hydraulicbrake system rust be bled a ll 4 whee! brakes, NOTE: Perform bleeding operation starting with rear ier farthest from master cylinder and then at front caliper of the same brake line. Do the same on the othe brake li 1) Fil master cylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding operation. 2} Remove bleeger plug cap, ‘Attach a vinyl tube to bleeder plug ot wee fylinder, and insert the ether end into con: Fig 628520 onaKes 3) Depress brake pedal saveral times, and then while holding it depressed, loosen bieeder plug about one third t0 one-half turn, Fig 530 4) When fluid pressure in the cylinder i almost pleted, rotighten bleeder plug Fin 57 5) Repent this operation unti there are nomore 2ir bubbles in hydraulic line. {When bubbles stop, depress and hold bra pedal and tighten bleeder plug. (For tightening torque specification of air bleeder plug, see page 5-60.) 12) Then attach bleeder plug cap. Fig 62 8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage 9} Replenish fluid into reservoir upto specified level Fp 6 10} Check brake pedal for “sponginess” I found spongy, repeat entire procedure of bleeding 13. BRAKE HOSE AND PIPE INSPECTION Hose “The brake hose assembly should be checked for road hazard damage, for cracks and chafing of the outer cover, for leaks and blisters. A light and mirrar may be needed for an adequate in spection, If any of the above conditions are ob- served on the brake hose, it is necessary to re place it a g Fig 538 PIPE Inspect the tube for damage, cracks, dents and corrosion. If any defect ie fount, eeplce it Fig 55 BRAKES 521 14, BRAKE FLUID LEVEL INSPECTION {Be sure to use particular brake fivi ether asin dicated on resorvoir cap of that car oF recom: mended in owner's manual which comes along swith that car Use of any other fluid i stretly prohibited, Fluid level should be between MIN and MAX lines marked on reservoir. When warning light lights sometimes during rivng, replenish fluid to MAX tne When fluid decreases quickly, inspect brake sys- tem for leakage. Corract leaky points and then refill to specified level Fg 536 CAUTION: Do not use shock absorber fluid or any other fluid which contains mineral oil. Do ot use a container which has been used for mineral oil or a container which is wet from water. Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and water mixed into broke ‘uid will lower fluid boiling point. Keep ‘uid containers capped to prevent contami5:22 oRAKES BRAKE HOSE/PIPE R & | 1. REMOVE AND INSTALL FRONT BRAKE HOSE/PIPE 1 Rai anc sub sipport ca. Ramet and whe Ths opin i not reentry we ramon pi ° es coneting mater elndr and Pa 2) Glen ctand foreign materi rom both how en or pn ond tng. Remove breke ho o pe. 2 Reve bak how inetalaton roca Feria, mae ture ht sexing hel i sain in alors poston and how aso tit or kink Cac to mate ste tt hose dem’ contact any part of ssenon, both mn extree hand examen condos. tH doer any poi, ove and erect il ond meta level in reservoir. Bleed brake system, " brketiis Tavewraoave he [ en [er BRAKES 523 2. REMOVE AND INSTALL REAR BRAKE HOSE/PIPE 1) Raise and sultably support car. Remove tte and wheel. 2} Glean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. 3) Rowse brake hove installation procedure, Fill and maintain brake fluid level in reservoir. Bleed brake system PRECAUTION FOR INSTALLATION “+ Never reuse protector nut once removed. Be sure to use a new one. {Install clamps property refering to figure below and tighten bolts. When installing hose, make sure that it has no twist 0° kink “To remove brake pie sinlated in figure, disconnect ts front Bacar edn de gy oT, oo For ternal 9nd retalstonprocedres fom and tocar body, fete to SECTION GC ENGINE FUEL on. 60 tom we ig 557 Front Brae Howie RT Fig 58 Pear Baka HowePne RT5:24 BRAKES PARKING BRAKE LEVER/CABLE R & | 1, REMOVE AND INSTALL PARKING BRAKE LEVER REMOVAL 1) Remove parking brake lover cover 2) Disconneet lead wire of parking brake switch at coupler. 3) Remove parking brake cable locking put. '4)Remove parking brake lever bolts and then remove parking brake lever assembly from equalize. '5} Remove equalizer from parking brake cable. NOTE: Don’t dssssemble parking brake lever switch. It ‘must be removed and installed as a complete switch assembly. Fa 539 INSTALLATION 1 Install in reverse order of REMOVAL pro cedure, 2) Alter all parts are installed, parking brake lever needs to be adjusted. Refer to PARKING BRAKE INSPECTION AND ADJUSTMENT in thi section (page 5-18) 3) Check rear brakes for dragging and brake system for proper performance. 2. REMOVE AND INSTALL PARKING REMOVAL 1) Remove parking brake lever cover 2) Disconnect lead wire of parking brake switch at coupler. 3) Loosen parking brake cable locking nut 44) Remove parking brake lever mounting bolts. 5) Disconnect brake cable from equalize. 6) Hoist car and remove wheel 7) Remove rer brake caliper pin bolts Fn 8) Remove caliper from earir. 9) Remove parking brake cable E:ring, 10) Disconnect brake cable from lever on the caliper. Fig bat Rakes 525 BRAKE CABLE INSTALLATION Install parts in reverse order of removal proce ure, noting the folowing ‘install brake cable stopper E-ing to bracket surly at shown in figure below. 2}Connect cable to brake lever and install con rector pin and clip securely as shown in figure below. Fig 62 3) Insta caliper to carrier and torque cal bolts to spectiation. \ Bake, 4) Install wheel and torque wheel nuts to spect 5) Lower hoist.8)For proper routing and secure clamping of parking brake eabl, rete to figure below. 71 For installation of cable to parking brake ever, rafer to PARKING BRAKE LEVER INSTAL: LATION of this section, page 5:24 8) Upon competion of instalation, aust cable, (Refer to PARKING BRAKE INSPECTION AND ADJUSTMENT of this section, page 5-18.) Then check rer brake for dragging and brake system for proper performance. After removing car from hoist, brake test should be performed, FRONT DISC BRAKE R&I 4, REMOVE AND INSTALL PAD (SHOE & LINING) REMOVAL INSTALLATION Note: ‘See NOTE at the beginning of this section. f = ‘oy, 1) Install pad tips and pads canes Fron soe = > seansie comet S| abn Fee Fe 67 3} Remove caliper from caliper carter. 2) Install caliper end torque caliper pin bolts to nore specification. and twisting 5voly or being pulled, Fig 548 ot 3) Torque front wheel nuts to specification. (Refer to Fig. 5-149) 4) Upon completion of installation, perform brake test,528 enaKes 2, REMOVE AND INSTALL CALIPER REMOVAL 1) Hoist car and remove wheel 2)Remove brake flexible hose mounting bolt ‘rom caliper. As this will allow fluid t0 flow ‘ut of hose, have container ready beforehand, Fig a8 '3) Remove caliper pin bolts. Fa 650 44) Remove caliper from cari. ASSEMBLY INSTALLATION 1) Install caliper to caliper earir. 2) Torque caliper pin bolts to specification BLEEDER SCREW REMOVAL Before disassembly, clean all around ealiper with brake fui 11Blow compressed air into cylinder through bolt hole where flexible hose was fitted. With this air pressure, piston can be pushed out of cylinder. WARNING: Do not apply too highly compressed air which will cause piston to jump out of cy: 5. It should be taken out gradually with moderately compressed air. Do not place your fingers in front of piston when using compressed ai. Fa bai 3) Install brake flexible hose at shown and torque hose mounting bolt to specification, Fig 62 4) Torque whee! nuts to specification. (Refer to Fig. 5-149) S)AKter completing installation, fill reservoir with brake fluid and bleed brake system. Perform brake test and check each installed part for oil leakage, Fe oss 2} Remove piston seal using @ thin blade lke a thickness gouge, ee NOTE: Be careful not to damage inside (bore side) of eylinde: BeaKes 629 REMOVE AND INSTALL SEAL, PISTON, DUST BOOT AND INSTALLATION Reaseemble front brake in reverse order of diss ‘sembly, noting the following points. | caution: ‘= Wash each part cleanly before installation | in the same fluid as the one used in mas- ter eylindr reservoir. ‘+ Never use other fluid or thinner. ‘© Before installing piston and 1 cylinder, apply fluid to them. ‘+ After reassembling brake lines, bleed air from thom ton seal Piston Seal Piston seal i used to seal piston and cylinder and to adjust clearance between pad and disc Replace with @ new one at every overhaul. Fit piston seal into groove in cylinder taking care Piston and Boot 1) Before inserting piston into cylinder, install ‘boot onto piston as shown below. Fig BB 2) Fit boot as itis in above figure into boot groove in cylinder with fingers Fig 5B520 eRaKes 3) Insert piston into cylinder by hand and fit boot in boot groove in piston, 44) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take i all out. Fig B58 5) Insert piston into cylinder by hand. Caliper Before installing calioer leylinder body! to carrer, check to ensure that guide pin inserted in each caliper eatrier hole ean be moved smooth Iy in thrust erection. Nore: Where temperature gots as low as ~30°C in cold ‘weather, use rubber grease whote viscosity varies very little even at ~40°C (40°F) Fg 55D 4, REMOVE AND INSTALL DISC REMOVAL 1) Hoist ear and remove whe. 2) Remove caliper assembly by loosening carrier bolts (2 pos ‘CAUTION: During removal, be careful not to damage brake flexible hose and not to depress Fig 567 BRAKES 531 4) Pullbrake dis off by using 8 mm bots (2 pes. Fig 52 INSTALLATION NOTE: ‘See NOTE at the beginning ofthis section. 41) tal ise to whee hub. 2) instal caliper assembly to steering knuckle. 3) Torque caliper carrer bolts to specification Fp 563 4) Torque front wheel nuts to specification. (Refer to Fig. 5-149) '5)Upon completion of installation, perform brake test532 oRAKES FRONT DISC BRAKE INSPECTION 1. INSPECT BRAKE PAD LINING CCheck pad lining for weer. When wear exceeds Timit, replace with new one. Fig 564 ‘CAUTION: Never polish pad lining with sardpaper. 1 linings polished with sandpaper, hard particles of sandpaper willbe depoited in Hining and_may damage dis. When pad | lining requires correction, replace it with one | Pedrow | Se [Ui Mining + pad rim) 160mm | &Omm | (0.630 in) | (0.316 in) NOTE: ‘When pads are removed, visually inspect caliper for brake fluid leak. Correct leaky point, if any. 2. INSPECT BRAKE CALIPER INNER PARTS Cylinder Slide Guide Pin Check guide pin for smooth movement as shown, If itis found faulty, correct or replace. Apply rubber grease to guide pin outer surface. Rubber ‘grease should be the one whose viscosity i lest affected by such low temperature as —40°C (20°F, Fig 555 Bush Dust Boot and Cylinder Boot Check boots for breakage, crack and damage. IY fective, replace Lot | “oe LW | Fig 555 Piston Seal Excesive or uneven wear of pad lining may in dicate unsmooth return of the piston In such & cate, replace rubber sel. Fin 67 3, INSPECT BRAKE DISC Before this inspection, brake pads must be re- ‘moved (according to steps 1) to 4) on page 27) Check dise surface for seratches in wearing parts Seratches on dite surface noticed atthe time of specified inspection or replacement are normal and diac is not defective uness they are serious, But when there are deep scratches or soratches all over dise surface, replace it. When only one side is sratched, polish and correct that side [ Sanded [tin Disc thickness | 185mm | 185 mm to7sin) | tossin) To measure deflection of dis, take measurement at 2 points on its periohery and center with dial (gauge while rotating it. Limit on ise deflection | 0.1 mm (0.0038 in.) Nore: Check front wheel bearing for looseness before Fig 659 rakes 632534 aRAKES REAR DISC BRAKE R & I 1, REMOVE AND INSTALL BRAKE PAD (SHOE & LINING) REMOVAL 1) Hoist car and remove whee. 2) Remove eaiper pin bots Fp o7T 3) Release parking brake iver 44) Remove caliper trom caliper carrer. NoTE: Hang removed calipar with a wire hook or the like so as to provent brake hose from bending ‘and twisting xcosively or being pulled Do not operate brake pedal with pads removed. INSTALLATION NOTE: ‘See NOTE atthe beginning of this section, 1) stall pad eins and pads to caliper carrier. Fig 573 2) Turn brake caliper piston clockaviee to obtain clearance between brake dise and pad. gare 5) Remove pads. Fg ore 3) Insal caliper and torque caliper pin bolts to specication. (Refer to Fig. 5-71.) 4) Torque wheel nuts to specification. 5) Upon completion of all jobs, depress brake Pedal with about 30 kg (66 Ibs) load three to five times s9 as to obtain proper disc-o-pad clearance, CCheck to ensure thet brake disc Is free trom dragging and proper braking is obtained. Then remove car from holst and perform brake test (foot brake and parking brake. BRAKES 595 2, REMOVE AND INSTALL BRAKE DISC REMOVAL 1) Hoist car and remove whet 2) Remove brake dae serews. F575 3) Release parking brake lever 44) Remove brake caliper assembly by loosening carer bots ‘CAUTION: moval, be careful not to damage le hose and not to dep Fig 578 INSTALLATION NOTE: ‘See NOTE at the beginning ofthis ection. 1) install beake disc to wheel hub. 2) Install caliper astembly and torque caliper carrier bolts to specification. Note: ‘When it is hard to install caliper assembly to brake dite, increase dise-to-pad clearance to fac: litate installation referring to 2) on page 5-34. £3) Torque wheel nuts to specification. 44) Upon completion of all jobs, depress brake pedal with about 30 kg (68 tbs) load three to five times sas to obtain proper disco: ad clearance. 5) Check to ensure that brake drum i ree from ‘ragging and proper braking is obtained. ‘Then remove ear from holst and perform brake test (foot brake and parking brake).5.98 BRAKES 3. REMOVE AND INSTALL CALIPER ASSEMBLY REMOVAL 1) Hoist car and remove wheel. 2}Remove brake flexible hose mounting bolt from caliper. As this will allow fluid to flow ‘out of hose, have a container ready before: hand. Fig 578 23) Release parking brake lever and remove cal: per pin bolts. Fp 50 4) Remove eaiper from ea 5) Remove parking brake cable Eng, Fig 687 6) Disconnect parking brake cable from lever on caliper. FpBe 7) Remove cover. Fig BRAKES 537 INSTALLATION Reasoemble rear brake caliper in reverse order of dizassambly, noting the following. 1) Install cover to caliper. (Refer to Fig. 5-83.) 2) Connect parking brake cable to camshaft lever and cable bracket. ‘Atter connecting cable to camshaft lever, be sure to install clip ss shown below. Also, insall Eing securely to its bracket side. Fin 658 2) Install ealiper to cartier and torque eliper pin bolts For ie installation procedure and torque data {or pin bolt, refer to 2) and 3) of BRAKE PAD INSTALLATION on page 5-34 4) Install brake flexible hose to caliper and ‘ighten hose bolt to specified torque. 5)Upon completion of installing all parts, fll reservoir tank with specified fluid and bleed brake system of entrapped {6).Check to make sure that system is free from fluid leakage. 7) Depress brake pedal wth about 30 kg (68 toe) load thre to five times so as to obtain proper dis to pad clearance. 8) Check to ensure that broke drum is fee from ° pow rave im] tm BR CD) 500 [ae air sin bot ad m-® | 32-22 | 180-780 2. rae ap rat ron 70-100} 70=100 | 81.0=720_| 7 3. Flexible hose bole (Front & rer brake] 20=25 | 20-25 | 145-180 GB Shae 4. rae caper pnb Rw) mm | 22-22 | wo-200 || ~ 5. Master cylinder nut or booster nut 10~16 10-16 75-115) 09943-17911 Booster No. oS 6. Brake pipe ay ji bot J“ e-12 | oa-r2 | eo-as ee) | __Sanenmar | Beonerptnodonge | tte Ro? 7. Proportioning valve bolt - - ~ {Fron ee i eomoret 5 a ‘8. Brake pipe flare nut 14-18, 14-18 10.5 — 13.0, 5 6 t rake pal aft 1-7 | 1a=28 | 198-200 10, Re spine nat Wom | veo=200 [ioes=tes] [Front caliper) > arkeniewerove EERE 4g 719 | e758 [Rear caliper) _| | Bea ot S| M=7) | O70 Ew] 12: Front ve sah at ve0= 200 | 60-200 | Toas= 144s] nn cera | oieczossi Fan ; +3 | f (09945-16040) ene | JZ Sool > cob impten REQUIRED SERVICE MATERIALS | ce - cease seni om d et) RECOMMENDED | | Serer nton od om MATERIALS |

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