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.