Suzuki Cults Sf310 Service Manual

SUZUKI TRE LL SERVICE MANUALFOREWORD This manual contains procedures for diagnosis, maintenance adjustments, minor service operations, replecemnent of components (Service) and for dis: ssembly and assembly of major components (Unit Repair-Overhaul), ‘The contents are classified into sections each of hich is given a section number as indicated in the ‘Table of Contents on this page. And on the first age of each individual section is en index of that section, This manual should be kept in @ handy place for ready reference uf the service work. Strict observan- ified items will enable one to obtain the full performance of the vehicle, When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricants, sealants, ‘tc,) as specified in each description. All information, lustrations and specifications Product information available at the time of publi- cation approval. The right is reserved to make changes at any time without notice, CAUTION: {tis important to note that, during any vehicle maintenance procedures, replacement fasten ers must have the same measurements as those removed, Mismatched ot incorrect fasteners can result icle damage or malfunction, or possible ‘Therefore, fasteners removed from the vehicle should be saved for re-use whenever possible, Where the fasteners are not satisfactory for re-use, care should be taken to select areplace- ment that matches the original, Additional information concerning this subject will be found in the section OA (METRIC TABLE OF CONTENTS SECTION] GENERAL INFORMATION General Information 0A Maintenance and Lubrication oB HEATING AND AIR CONDI- TIONING Heating and Ventilation 1A BUMPER AND SHEET METAL 2 STEERING, SUSPENSION, 3 WHEELS AND TIRES Front End Alignment 3A Manual Rack and Pinion 38 Steering Wheel and Column 3c Front Suspension 3D Rear Suspension 3E Wheel and Tires 3F FRONT DRIVE SHAFT 4 BRAKES 5 ENGINE General Information and 5 Diagnosis INFORMATION). NOTE: ‘The carburetor model, by definition as used in this manual, has an emi ithough ‘with or without one depends on specifications) and carburetor, and the Electronic Fuel Injection ‘model has an emission control system and injector. BOOPYRIGHT SUZUKI MOTOR CO,, LTO. 1988 a Pl 6A Engine Cooling 6B Engine Fuel 6c Carburetor 6D Electronic Fuel Injection oe ‘System Ignition System oF Cranking System 6G Charging System 6H Emission Controls ed (for carburetor model) Emission Controls eli (for EP! model) Exhaust System 6K TRANSMISSION AND CLUTCH ‘Manual Transmission 7A Automatic Transmission 78 Clutch 7 BODY ELECTRICAL SYSTEM a BODY SERVICE 9 SUZUKI MOTOR CO.,LTD. TECHNICAL DEPARTMENT AUTOMOBILE SERVICE DIVISION IGENERAL INFORMATION GA-t SECTION OA GENERAL INFORMATION CONTENTS GENERAL INFORMATION OAT Fastener Strength Identification OAS Vehicle Identification... .. tla Standard Tightening Torqu 0A4 Engine and Transmission Identification. OA-2 VEHICLE LIFTING POINTS . OAS METRIC INFORMATION ............ 0&3 Metric Fasteners ..........00.22+.+ OAS GENERAL INFORMATION VEHICLE IDENTIFICATION Refer to Fig. DA-1 for vehicle identification numbers (body numbers) location. Fig. OA-1 Vehicle Identification Number LocationOA2 GENERAL INFORMATION ENGINE AND TRANSMISSION IDENTIFICATION Refer to Fig. 0A-2 and 0A:3 for engine and transmission identification numbers and their locations, Engine Identification Number Location 1. cylinder bloek 2 ollfiter Fig. 04-2 Engine Identification Number Location Transmission Identification Number Location Manual Transmission ‘Automatic Transmission Fig. 0A-3 Transmission Identification Number LocationGENERAL INFORMATION 0&3 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for thiscar are metric, When replacing any fasteners, it is most import- ‘ant that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 47, 7T and radial line with ‘the class identification embossed on the head of each bolt, Some metric nuts will be marked with punch mark strength identification on the nut face. Fig. OA-4 shows the different. strength markings. When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the original fasteners (the same number marking or higher), It is likewise important to select replacement fasteners of the correct size. Correct replacement bolts and nuts are available through the parts division. METRIC BOLTS — IDENTIFICATION CLASS NUMBERS OR MARKS CORRESPOND TO BOLT STRENGTH — INCREASING NUMBERS REPRESENT INCREASING STRENGTH. NUT STRENGTH IDENTIFICATION Zz Fig. OAA Bolt Strength MarkingsOA-4 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is, provided, refer to the following tightening torque chart for the applicable torque for ‘each fastener, When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener. NOTE: aesvor the flanged bolt and nut, add 10% to the tightening torque given in the below chert. 2 [Re betow chart i applicable only where the fastened parts are made of stl or light alloy. {\ srmenora 1 Tana Conventional bole "47" bol "TP" ble id Wm kom br Nm em ibe é LE A Soest oar en foae= ae a= 8 [os — 08 | 20-48 8 Se Tan Reg TO] ee) eas te | 80 88 a A 0 eae | aa as |aeo= 250-| 40 - eo” | 40 = 60 | 0-48 12 35- 55 35- 55 25.0— 40.0 | 70 ~100 | 7.0 —100 50.5— 72.5 “4 co. a, | 50-80 | 269-580 [110 -t6 [119 -160 | 795 — N60 16 Feriae{rao=10 | sue= ees [170 — 200 [170 —750 | 225-1010 os oo [tao =90| 4.0 187.5 |z00_— 200 “land —2a0, | 1405-2000 Fig. OA-5 Tightening Torque ChartGENERAL INFORMATION 04-5 VEHICLE LIFTING POINTS Fig. 0A-6 and 0A-7 indicate the methods of lifting the car using a hoist, and Fig. 0A-8 and 0A-9 show additional locations for lifting with a floor jack. WARNING | © When using frame contact hoist, apply hoist as shown below (right and left at the same position). Lift up the car till 4 es are a little off the ground and make sure that the car will not fall off by trying ‘to move car body in both ways. Work can be started only after this confirma- tion. | © Before applying hoist to underbody, | always take car balance throughout servi- | ce into consideration. Car balance on hoist may change depending of what Part to be removed. © Make absolutely sure to lock hoist after car is hoisted up. © If the car to be jacked up only at the front or rear end, be sure to block the wheels in order to ensure safety. After the car is jacked up, be sure to support it fon stands. It is extremely dangerous to | do any work on the car raised on jack | alone. PRECAUTION AGAINST TIPPING On frontwheel drive cars, the centerline-of- gravity is further forward than on rear-wheel rive car. Therefore, whenever removing major components from the rear of the car, while supported on a hoist, it is mandatory to support the car in @ manner to prevent the possibility of the car tipping forward. When using frame contact hoist: SUPPORT LOCATION: 41, Front ltt tre Forward of embossed 2. Front fencer let penel mark 3. Embossedsmark Fig. OA-6 Front Support Location ae {200m aT Be SUPPORT LOCATION: Rearver of aribossed: mark Fig. OA-7 Rear Support Location04-6 GENERAL INFORMATION ‘When using floor jack: 1 Front erotemember Fig. OA-B. Front Support Location crossmembor| rol rod Suspension arm Fig. OA-9. Rear Support LocationMAINTENANCE AND LUBRICATION 08-7 SECTION 0B MAINTENANCE AND LUBRICATION CONTENTS (RAINTENANCE SCHEDULE ........, ++ OB. 2 (AINTENANCE SERVICE + 0B. 5 Engine et 0B. 5 ‘gnition System - OB: 8 Fuel System oB- 9 Brake... 0+ 08-11 Chassis and Body 08-13 Final Inspection ........ 2 ees 08-15 QWNER INSPECTIONS AND SERVICES ......... 08-16 SECOMMENDED FLUIDS AND LUBRICANTS 08-1908-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE NOTE: © Chess 1: Austria, Denmark, Norway, Sweden and Switzerland © Class 2° Australia © Class 3: Others “This table Includes services as scheduled up to 80,000 km (48,000 miles) ‘20,000 km (48,000 miles), carry out the same services mileage. Beyond [Class 2 & 3) Interval: tthe samo intervals respectively Tarireitewinivedey lin iio 10 [9 [oo [a Te |e Te comes fist. Miles (x1000)| 6 | 12 | 18 | 24 | a0 | 36 | 4 | 48 Months 6 | 12 | 1 | 24 | a0 | 36 | 2 | 4 ENGINE 1-1, Water pump bet (tension, damage) | (Class 2& 3 Tes plat as oe class 1] = [eT rwitdlscot [oo 7-2, & 13, Engine oll and Engine oll filter RopeoR hPL LR 14, Cooling system, hoses and connections (leakage, damage) sicher ud’ slcsrs sh elacla saber! 15. Engine coolant = ees a = 8 16, Exhaust pipes and mountings Teast fo | 1-7. Wiring harness and connections Sele lets (= 2, IGNITION SYSTEM 2-1. Spark PlU85] wien unleaded fuel is used [Class 2 & 31 I Tas] gon ean eee (otass 1 an ee rece When leaded fuel is used i tion” schedule ~ 22, Distributor cap and rotor (erack, weer) le Sohal | 2. Ignition wiring (Class 2&3) Ss) an a ee {Class 1] =e ae 2-4. Ignition timing (Class 1) 5s Se es ee 25, Disributor advance [lcioss 11 =a (usa l Slemaleee | all 3. FUEL SYSTEM 3-1, Carburetor choke system lf equipped) T | 32, Air cleaner filter element | Pavedvoad R Dusty condition 33.Engine idle speed &idle mixture [ices 2eai| wm | 1 | - | 1 | = =a Le ‘ZA. Fuel tank, cap & lines (deterioration, leakage, damage) | - | — | - |! | - | - | - [1m 36. Fuel fiter = t= Si sen “4, EMISSION CONTROL SYSTEM | 4-1, PCV (Positive Crankcase Ventilation) valve [am 2aa (Gis 1 = fee eee od 7H. Chacon eats (teappedl_ fe eee es ges [ea [ 49: yer facta Ss espe ior een Taina meetin Simin [temasall =| — [oot pe Pea) ole iEMAINTENANCE AND LUBRICATION 083 “This table includes services as scheduled up to 80,000 km (48,000 miles) ‘mileage. Beyond 80,000 km (48,000 miles), carry out the same services Interval: at the same intervals respectively. This interval should be judged by see odometer reading or months, whichever | Km. (x1,000)| 10 | 20 | 90 | 40 | 60 | 60 | 70 | 60 ‘comes first. Mites (x 1000){ 6 | 12 | 18 | 24 | 30 | 36 | 42 | 48 Months 6 | 12 | 18 | 24 [ 30 | 36 [ 42 | 48 | 5. BRAKE ‘511. Brake discs and pads (thickness, wear, damage) Brake drums and shoes (wear, damage) ‘52. Brake hoses and pipes (leakage, damage, clamp) | 5. Brake fluid 5-4, Brake lover and cable (damage, stroke, operstion) 5.5, Brake pedal 6. CHASSIS AND BODY 6-1, Gluteh (For manual transmission) pedal free travel 62, Tices/wheel discs (wear, damage, rotation) 3. Drive shaft boots (breakage, damage) 64, Suspension system (tightness, damage, rattle, breakage! | 65, Steering system (tightness, damage, breakage, ratte) 68, Manual transmission oil (leakage, level) 67. Automatic transmission Fluid level Fluid change Fluid hose {638. Door hinges & Gear shift control lever/shaft NOTES: “R® ; Replace or change "1 Inspect and correct or replace if necessary Jt0m 33 Kem 34 item 35 1) fs applicable only to 10,000 kr. (Rh is applicable only to the fuel tank cap of Class 1. “A is recommended meintenance item.0B-4_ MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the car is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the below chart, Severe condition code ‘A— Repeated short trips B — Driving on rough and/or muddy roads © — Driving on dusty roads ing in extremely cold weather and/or salted roads E — Repeated short trips in extremely cold weather F — Leaded fuel use T ae intines Maintenance ae Maintenance Interval = = € DE ~| Engine oi! and oi filter R SO taal os, hated Every 10,000 km rere trea bars 2 (6,000 miles) or 6 months ; Every 2,500 kmn (1,500 miles) = = © — ==} Airctoaner filter element *1 5 Every 40,000 km (24,000 miles) oF 24 months = aipraaoan i Every 20,000 km e ELAS cop fen (12,000 miles) oF 12 months ABC — & | Brake discs and pads Every 10,000 km Brake drums and shoes {6,000 miles) or 6 months AB — DE ~|. Brake hoses and pipes \ ee AB ~~ & _| Automatic transmission = Every 20,000 km fluid change (12,000 miles) or 12 months Every 20,000 km pee eee) hoe eons ! | 12,000 mites) or 12 months “1 Inspect or replace more frequently if the car is used under dusty conditions. NOTES: “R“: Replace or change “I: Inspect and correct or replace if necessaryMAINTENANCE SERVICE ENGINE co Water Pump Belt Inspection WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Inspection) 1) Inspect 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 6B for its procedure. [Replacement] Replace belt. Refer to P, 68-12 of SECTION 6B for replacement procedure of pump belt. 12813 Engine Oil and Filter Change Before draining engine oil, check engine for oil leakage. If any evidence of leakage is found, make sure to correct defective part before pro- ceeding to following work. 1) Drain engine oil by removing drain plug. 2) After draining oil, wipe drain plug clean, Reinstall drain plug, and tighten it securely as specified in figure below, 5 Z iy = : Sy sere 2 Oil gain plug Fig. 8-7-2 MAINTENANCE AND LUBRICATION 085 3) Loosen oil filter by using oil filter wrench (Special tool}. Fig. 8-1-3 NOTE: Before fitting new oil filter, be sure to apply engine oil to its “0” ring, 4) Screw new filter on oil filter stand by hand until filter “O" ring contacts mounting surface, CAUTION: To tighten oil fil 5) Using oil filter wrench, tighten filter 3/4 turn from contact point described above, (0 fter tightening torave 1218 Nm 12-16 kom 1 a5 Tis Fig. O84—— =< - -eee-/- & &°&7&« an 08.6 MAINTENANCE AND LUBRICATION 6) Replenish oil until oil level is brought to FULL level mark on dipstick. (about 3.3 liters or 6.9/5.8 US/Imp pt.). Filler inlet is at the top of cylinder head cover. 7)Start engine and tun it for three minutes. Stop it and wait another 3 minutes before checking oi level. Add oil, as necessary, to Engine oil capacity about 3.1 liters (6.5/5.5 US/Imp pt.) about 0.2 liters (0.4/0.3 US/Imp pt.) ‘about 0.3 liters Oil pan capacity Oil filter capacity bring oil lovel to FULL level mark on dip oe (0.6/0.5 US/Imp pt.)_| stick. wal about 3.6 liters ae (7.5/6.3 US/Imp pt.) Not Loe level mark (bole), Full evel mark (hole Fig, OBS NOTE: Steps 1) —6) outlined above must be performed with ENGINE NOT RUNNING. For step 7), be sure to have adequate ventilation while engine is running. It is recommended to use engine oil of SE, SF or SF/CC class: Proper Engine Oil Viscosity Chart Toe OH i ow-30 asd) Fig, O8-1-5-1 Engine oil capacity is specified as above. However, note that amount of oil required when actually changing oil may somewhat differ from data in above table depending on various condt- tions (temperature, viscosity, ete.) Iter and drain plug for oil leakage, 8) Check oil 14 Cooling System, Hoses and Connections Inspection 1) Visually inspect cooling system hoses for any evidence of leakage end cracks. Exemine them ‘for damage, and check connection clamps for tightness. 4. Inlet Rose Fig, B-F6 2) Replace all hoses which show evidence of leakage, cracks or other damage. Replace all clamps which cannot maintain proper tight ness.MAINTENANCE AND LUBRICATION 08-7 3) Clean frontal area of radiator core. 4) Test system and radiator cap for proper pressure holding capacity, 0.9 kg/cm? (12.8 psi). If replacement cap is needed, use a cap desing- ed for cooling system of this car.. 5) Check coolant level and concentration, Add if necessary. Refer to COOLANT LEVEL of SECTION 68 for procedure of level check. 15 Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon. | 1) Remove radiator cap when engine is cool. 2) Loosen radiator drain plug to drain coolant, 3) Remove reservoir tank, and drain, 4) Tighten plug securely. Also reinstall reservoir tank: For A/T car For M/T ear Fig 8-17 1. Drain plug 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 throat of radiator. Reinstall radiator cap. 6) Add coolant to reservoir tank so that its level aligns with Full mark. Then, reinstall cep aligning arrow marks on tank and cap. Nore: ‘hon installing rasrvoir tank cap, marks on ark and exp. 4, Reservoir tank 2) FULL evel mack 3: 3. LOW ive! marke 4. Arrow mark Fig. 08-18 CAUTION: When changing engine coolant, use mixture of 50% water and 50% ETHYLENE GLY- COL BASE COOLANT (ANTIFREEZE/ ANTICORROSION COOLANT) for the market where ambient temperature falls lower than —16°C (3°F) in winter and mixture of 70% water and 30% ETHYLENE GLYCOL BASE | COOLANT (ANTI- FREEZE/ANTICORROSION COOLANT) for the market where ambient temperature doesn’t fall lower than 16°C (3°F). Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ETHYLENE GLYCOL BASE COOLANT (ANTIFREEZE/ANTICORRO- SION COOLANT) should be used for the purpose of corrosion protection and lubrication. Refer to SECTION 68 of this manual for COOLANT CAPACITY.08-8 MAINTENANCE AND LUBRICATION 16 Exhaust Pipes and Mountings Inspection WARNING: To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be | performed when it is cool. When carrying out periodic maintenance, or car is raised for other service, check exhaust system as follows: © Check rubber mountings for damage and deterioration. © Check muffler pipe for leakage, loose connections, dents, and damages. If bolts or nuts are loose, tighten them to specification. Refer to SECTION 6K (p. 6K-2) for torque specification of bolts and nuts. © Check nearby body areas for damaged, missing, or mispositioned parts, open seams, holes, loose connections or other defects which could permit exhaust fumes to seep into car. © Make sure that exhaust system components have enough clearance from underbody to avoid overheating and possible damage to floor carpet. ‘© Any defects should be fixed at once, WwW Wiring Harness and Connections Inspection. 1) Visually inspect all wires in engine compartment for evidence of breakage. Inspect condition of insulation (cracks). All clips and clamps should have solid connections to wires. 2) Replace any wires in a deteriorated or otherwise defective condition. IGNITION SYSTEM 24 ‘Spark Plugs Inspection and Replacement Replace spark plugs as follows: 1) Disconnect high tension cords at spark plugs. To avoid inside damage of cords, DO NOT pull on cords for disconnection. Pull on cap. Fig. O21 2) Dust off cylinder head around spark plugs. 3) Using a spark plug wrench, remove spark plugs. 4) Check plug gaps of spark plugs, and adjust ‘them to specification as necessary. 0.7-0.8mm . ind NOTE: When replacing plugs, make sure to use new plugs of specified heat range and size. Fig, 08-22PLUG SPECIFICATION Maker Heat range Standard type NGK BPGES (BPRGES) W20EP-U (W20EPR-U) Nippon Denso As can be seen in the above table, there are two types of spark plugs for this car, one without R included in its code and the other with R as in parenthesis, Which one is used depends on countries, Look at the label attached to the car. If originally equipped plug was with R included in its code, replacement plug should have R in its code, too, 5) Install new spark plugs. Tighten plugs to specification, 6) Connect high tension cords to spark plugs. DO NOT push cords for connection, Push cops. Tightening torque. |_Nm_| kom | bee for spark plug 25—30 25 — 30/180 215 22 Distributor Cap and Rotor Inspection 1) Inspect distributor cap and rubber caps for cracks. 2) Inspect center electrode and terminals for wear, 3) Inspect rotor for cracks, and its electrode for wear. 4) Repair or replace as necessary any component which is found to be in malcondition as described above. NOTE: Dust and stains found within distributor can be cleaned by using a dry, soft cloth. 23 Ignition Wiring (high-tension cord) Inspection and Replacement UInspection] 1) Inspect high-tension cords for cracks and check that their connections are secure. MAINTENANCE AND LUBRICATION 08.9 2) Measure resistance of high-tension cords by using a. circuit tester (special tool 09900: 25002). Refer to p..6F-4 ON CAR SERVICE of SECTION GF for resistance data and measuring procedure, 3) Replace high-tension cords that shown evidence of deterioration. NOTE: Check to make sure that each of the high- tension cord terminals and connections is secure and fully inserted into its mating component. Any burnt fitting must be replaced. [Replacement] 1) Disconnect high tension cords from spark plugs, ignition coil and distributor. 2) Connect new high tension cords and clamp them securely. DO NOT push cords for connection, Push boots. 7. 24 Ignition Timing Inspection Check to make sure that ignition timing is set properly. If out of specification, adjust it, Refer to p. 6F-7 of SECTION GF for inspection and adjustment procedure, 25 ributor Advance Inspection Check advancer for proper operation. Refer to p. BF-6 of SECTION GF for checking procedure. FUEL SYSTEM 34 Carburator Choke System Inspection 1) Remove air cleaner case, and lubricate rotating parts, 2)Check choke for proper operation, referring to ON CAR SERVICE of SECT'ON 6D. 32 Air Cleaner Element Replacement 1) Remove air cleaner cap. 2) Take cleaner element out of air cleaner case. 3) Install new cleaner element into cleaner case, 4) Install air cleaner cap securely.08-10 MAINTENANCE AND LUBRICATION NOTE: Replace more often under dusty conditicns. ‘Ask your dealer for proper replacement interval for your driving conditions. 1, Alrelsaner element 3. Recasion 2 Air cuaner lower ease Fig, 083-1 ‘Air Cleaner Element Inspection 1) Visually check that air cleaner element is not excessively dirty, damaged or oily. 2) Clean element with compressed air from inside of element. NoT! fear is Used in dusty ares, clean every 2,500 km Fig, 0832 33 Engine Idle Speed And Idle Mixture Inspection Check idle speed’ andidle mixture,’ and adjust them as necessary. Refer to'ON'CAR'SERVICE ‘of SECTION 6D for procedures to'check’and adjust idle speed/idle mixture 34 Fuel Tank, Cap Gasket and Fuel 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 fuel filler cap gasket for an even filler neck imprint or any damage. Replace any damaged or deteriorated parts: ‘There should be no’ sign of fuel leakage or moisture at any fuel connection. Fuel Filter Replacement WARNING: This work must be performed in a well ventilated area and away from any open flames (such os gas hot water heaters). “The entire filter unit is replaced at regular sched uled intervals,” The method of replacement is as follows: 4) Fuel filter is located at the front part of fuel tank, inside the leftthand side of chassis. Remove filter. 2) Position the new filter in place, and connect inlet and outlet hoses to it, NOTE: ‘The top connection is for the ‘outlet hose, the ower one for the inlet hose.EMISSION CONTROL SYSTEM a1 POV (Positive Crankcase Ventilation) Valve Sespection (Greck crankcase ventilation hoses and PCV fheses for leas, cracks or clog, and PCV valve for ‘Sick or slog. Refer to ON CAR SERVICE of SECTION GJ or 6J1 for PCV valve checking procedure, 2 ‘Ghercoal Canister Inspection Applicable to the car equipped with canister in ‘852 compartment ‘Check charcoal canister. Refer to ON CAR SER- WICE of SECTION 6J or 6J1 for procedures to Peck charcoal canister. “3 Fuel Cut System Inspection ‘Ger carburetor model) Check fuel cut system. Refer to ON Cai: SEF WICE of SECTION 6D and 6J for procedures te Peck fusl cut system. a Sereke Air Temperature Control System Sespection (for carburetor model) OTE: ‘Tas section is only applicable to the cars equip- ee with this system. ‘The system should be inspected for operation. Refer to p. 15 of SECTION 6) for inspection procedure, MAINTENANCE AND LUBRICATION 08-23 BRAKE 54 Brake Inspection Brake discs and pads 1) Remove wheel. and caliper but don’t disconnect brake hose from caliper. 2) Check front. disc brake pads and discs for excessive wear, damage and deflection. Replace parts as necessary. For the details, refer to SECTION 5. Be sure to torque caliper pin bolts to spi cation. 3, Pads, Brake Drums and Shoes Fig. OB-4-7 NOTE: If noise is heard from front brake when brake pedal is depressed, check brake pad lining for wear. If it is worn, both right and left brake pads should be replaced with new ones. CAUTION: After replacing any brake pipe or hose, be sure to carry out air purge operation. Brake drums and shoes 1) Remove wheel and brake drum. 2) Check rear brake drums and brake linings for excessive wear and damage, while wheels and drums are removed. At the same time, check ‘wheel cylinders for leakage. Replace as necessary. For the details, refer to SECTION 5.08-12 MAINTENANCE AND LUBRICATION Fig. B42 52 Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use @ mirror as necessary. ‘© Check brake hoses and pipes for proper hook- up, leaks, cracks, chafing, wear, corrosion bends, twists and other damage. Replace any of these parts as necessary. © Check all clamps for tightness and connections for leakage. ‘© Check that hoses and pipes are clear of sharp edges, moving parts. 63 Brake Fluid Inspection and Change Unspection] 1) Check around master cylinder and reservoir for fluid leaka If found leaky, correct. 2) Check fluid level If fluid level is lower than the minimum level of reservoir, refilling is necessary. Fill reservoir with specified brake fluid. Specification DOT3 or SAE J1703 Brake fluid For the details, refer to. ON-CAR SERVICE (page 5-48) of SECTION 5. CAUTION: ince brake system of this car is factory- filled with glycol-base brake fluid, do not use or mix different type of fluid when refilling; otherwise serious damage will occur. Do not use old or used brake fluid, or un- sealed container. [Change] Change brake fluid as follows. Drain existing fluid from brake system completely, fill system with above recommended fluid and carry out air purge operation. For air purging procedure, refer to p. 5:19 and 5-20 of SECTION 5. 54 Brake Lever and Cable Inspection Parking brake lever '* Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. © Check parking brake lever for proper operation and stroke, and adjust it if necessary. For checking and adjusting procedures, refer to PARKING BRAKE INSPECTION AND ADJUSTMENT (p. 5-18) of SECTION 5. Parking brake cable Inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorated cont 85 Brake Pedal Inspection Check brake pedal travel. For checking procedure, refer to PEDAL TRA- VEL CHECK of SECTION 5.‘CHASSIS AND BODY 61 ‘Gutch Pedal Free Travel Inspection ‘Check olutch pedal free travel. Refer to SECTION ‘FC for procedure to check and adjust it. 2 ‘Tee and Wheel Disc Inspection ‘Tie inspection} = Check tire for uneven or excessive wear, or Gamage. If defective, replace Check inflating pressure of each tire and adjust pressure to specification as necessary. MOTE: = Tire inflation pressure should be checked when tires are cool = Specified tire inflation pressure should be found on tire placard or in owner's manual which came with car. ‘Wheel dise inspection] ‘Sespect each wheel disc for dents, distortion and sacks. A disc in badly damaged condition must Be replaced. ire rotation] Rotate tires, Fer details of above steps, refer to SECTION Inspection] ‘Check. front wheel bearing for wear, damage, 2bnormal noise or rattles. For details, refer to FRONT SUSPENTION INSPECTION (p. 3D- 14) of SECTION 3D. *WCheck rear wheel bearing for wear, damage ‘bnormal noise or rattle, For details, refer to WHEEL BEARING INSPECTION (p. 3-15) of SECTION 3. MAINTENANCE AND LUBRICATION 08-13 63 Drive Axle Boot Inspection Check drive axle boots (wheel side and differential side) for leakage, detachment, tear or any other damage. Replace boot as necessary. 1, Drive axle shaft 2. Boot Fig, OB ET 64 ‘Suspension System Inspection © Inspect front & rear struts for evidence of oil leakage, dents or any other damage on sleeves; and inspect anchor ends for deterioration. Replace defective parts, if any. 1. tutes Fig. 08-5208-14 MAINTENANCE AND LUBRICATION ‘© Check front and rear suspension systems for damaged, loose or missing parts; also for parts showing signs of wear or lack of lubrication. Repair or replace defective parts, if any. © Check front suspension arm ball joint stud dust seals for leakage, detachment, tear, oF any other damage. Replace defective boot, if any. 1. Boll joint stud dost seal oot) 21 Suspension acm Fig, 085-3 65 ‘Steering System Inspection 1) Check steering wheel for play and-rattle, holding car straight on ground, ‘Steering wheel play on 0—30mm (0-1.2 in.) 2)Check steering linkage for, looseness: end damage. Repair or replace defective parts, if any. 3) Check boots of 'steering linkage and steering ‘gear case for damage (leaks, detachment, tear, etc.). If damage is found, replace defective boot with new on 4) Check universal joints of steering shaft for rattle and damage. If rattle or damage is found, replace defective part with @ new on« 4. Tierad end boot 2, Steering peer e288 boot 8. Universal joint Fig, OB 5S 66 Transmission (Manual) Oil Inspection and Change inspection] 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2)/Make suré that car is placed level for oll level check 3) Remove level plug of transmission. 4) Check oil level. il level can be checked roughly by means of filler/levet plug hole. That is, if oi! flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled. If oil is found insufficient, pour specified oil up to level hole, For specified oil, refer to description of oil change (p. 7:7) under ON-CAR SERVICE in section 7A.OE MAINTENANCE AND LUBRICAT‘ON 08-5 [Change] 4) Place the car level and drain oil by removing drain plug. 2)Apply. sealant, to. drain plug and_ tighten drain plug to specified torque. 3) Pour specified oil up to level hole. 4) Tighten filler plug to specified torque. For recommended oil, its amount and tightening torque data, refer to ON-CAR SERVICE (p. 78-7) of section 7A, 67 Automatic Transmission [Fluid level inspection] +) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2Make sure that car is placed level for. fluid level check. ‘Bi Check fluid level. | For fluid, level checking. procedure, refer to ON-CAR SERVICE in SECTION 78 and be sure to perform it under specified conditions. If fluid levet is low, replenish specified fluid. uid change] Perform steps 1) and 2) of above Fluid Level inspection. Change fluid. For its procedure, refer to ON- CAR SERVICE in SECTION 7B. \UTION: Use of specified fluid is absolutely neces- ay, ‘Fiuid cooler hose change] Peolace inlet and outlet hoses of cooler hose their clamps. For replacement procedure, to ON-CAR SERVICE in SECTION 78. Hinges; Gear Shift Control Lever and Lubrication. “Mice off dirt and apply a thin coat of engine oil. ‘Been and close door several times to insure that pas worked in effectively. etricate lever seat and shaft bushings with resistant chassis grease. FINAL INSPECTION BODY PARTS OPERATION Hood Latch ‘Check that hood opens and closes smoothly and properly. Also check that it locks securely when closed, Doors Check that each door opens and closes smoothly and locks securely when closed. Seats Check that seat slides smoothly and locks securely at any position. Also check that reclin= ing mechanism of front seat back’allows it to be locked at any angle ROAD TEST Carry out road test in safe place WARNIN | When carrying out following road tests, select a safe place where no man or no running car isseen so as to prevent any accident. Engine Start Check ‘engine start forireadiness. Clutch (For Manual transmission) Check for the following. © Clutch is completely released when depressing clutch pedal, © No slipping clutch occurs when releasing pedal ‘and accelerating, @ Clutch itself is ftée from: any abnormal condition Gearshift or Selector Lever (Transmission) Check gear shift or selector lever for smooth shift: ing to. all positions and for good performance of transmission in any position, With automatic transmission, equipped. car, also, check that shift indicator indicates properly according to which position selector ‘ever’ is shifted to. CAUTION: With, automatic transmission equipped.car, make sure that car is at complete stop when, shifting selector lever to “"P" range position.18-16 MAINTENANCE AND LUBRICATION Brake (Foot brake] Check the following when depressing brake pedal while drivin «that brake works properly, © that itis free from noise, ‘ and that braking force is applied equally on all wheels. [Parking brake] Check to ensure that parking brake is fully effective when the car is stopped on the slope and brake lever is pulled all the way. Steering © Check to ensure that steering wheel is free from instability, or abnormally heavy feeling while driving. © Check that the car does not wander or pull to one side. 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 Check that speedometer, odometer, fuel meter, ‘temperature gauge, etc. are operating accurately. Lights Check that all lights operate properly. Seat Belt Inspect belt system, including webbing, buckles, latch plates, retractors and anchors. is securely locked. For this test, select a safe place without any running car so as to prevent any accident, ‘And again make sure that no man or no ‘other car is seen in front or behind and use ‘great care to the surroundings when carry ing out the test. OWNER INSPECTIONS AND SERVICES Listed below are items which should be checked and serviced by either the owner himself or @ ‘qualified technician daily or periodically to help ensure safety and dependability of each car. ‘Should any problem occur, contact nearby dealer or a qualified technician for proper service advice. For the safety of the driver himself and others, be sure to inspect any safety-related parts that could 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, oil, or other fluid leakage by looking at surface beneath car after it has been parked for a while, Water dripping from air conditioning system after use is normal. If gasoline fume of fluid is noted at any time, inverstigate its cause and correct it at once. Door Operation Check that all doors including back door operate smoothly, and that all doors close and all latches lock securely. Tire, Wheel and Wheel Nut Inspection © Check pressure as shown on tire placard {including spare tire). Pressure should be checked when tires are “cold”. © Check tire for cuts, damage or excessive wear. ‘© Check wheel nuts for looseness of for missing nuts. If necessary, tighten them. [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 can be reclined smoothly and locked securely at any angle.‘ening Light, Buzzer and Tone Operation ‘Dheck ll warning lights, buzzers and interior ‘pcicator lights for operation. For details, refer ‘Owner's Manual. Sess, Mirror, Light and/or Reflector Condition Geese cach glass, mirror, light and reflector for ‘Seesisee, scratch, dirt or any other damage which ‘Seu reduce driver's view or visibility or cause ‘Shy. Replace, clean or repair promptly, if acessery ‘Fee View Mirror and Sun Visor Operation ‘Gheck that friction joints hold mirrors and sun as in place. ‘Dheck belt system including webbing, buckles, ‘=> plates, retractors, guide loops, and anchors | proper operation, damage and/or wear. ‘Geez Belts Condition and Operation isht Operation Deck license plate lights, headlights, small SSS. taillights, brake lights, turn signals, back- S@ Ghts, instrument panel lights and interior Se, hazard warning flashers and other fights. “Sees headlight aim checked at once if beams => improperly aimed. Pedal Free Travel Check = Deck free travel. “= Deck pedal for smooth operation. "Reselerator Podal Operation “Gheck that pedal operates smoothly without get- ‘Ses cought or interfered by any other part. ‘Exhaust System Check ‘Dreck for cracks or loose supports. ‘Beaks Pedal Check '® heck pedal for smooth operation. "® Check pedal travel (pedal-to-wall clearance). For checking procedure, see your Owner's Manual. (Greck brake booster function. ‘Parking Brake Lever Travel Check ‘that lever has proper travel. MAINTENANCE AND LUBRICATION. 08-17 Automatic Transmission Shift Indicator and Park Mechanism Operation ‘© Move selector lever and check that indicator points to exact gear as chosen, © Check the lock release button of the selector lever for proper and smooth operation, [UNDER HOOD] Engine Hood Latch Operation Check that hood closes firmly. Check for damaged, loose, or missing parts that might prevent tight latching. Make sure secondary latch keeps hood from opening all the way when primary latch is released. Engine Oil Level Check Check engine oil on the dipstick with the engine turned off and add if necessary. See your Owner's Manual. NOTE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Engine Coolant Level and Condition When engine is cool, check coolant level in reser voir tank and add if necessary. Inspect coolant and replace if dirty or rusty. ‘A normal coolant level should be between “FULL” and "LOW" marks on reservoir tank. ‘See Owner's Manual. NOTE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Windshield Washer Fluid Level Check: Check washer fluid level in tank and add if necessary. Brake Master Cylinder Fluid Level Check Check reservoir tank fluid level in accordance with Owner's Manual and keep at proper level. NOTE: A large loss in this system may indicate a pro- lem. Have it inspected and repaired at once.08-18 MAINTENANCE AND LUBRICATION. Battery Electrolyte Levél Check Check that the electrolyte level of all battery cells is between the upper and lower level lines onthe case, Engine Drive Belt(s) Inspection Inspect all belts for cracks, fraying and weer. Adjust or replace as needed. WHILE OPERATING YOUR CAR Horn Operation Check to make sure that horn works when its button is pushed at its any part. Windshield Wiper and Washer Operation Check wipers and washer for proper operation. Also check spray direction of washer fluid. Check wiper blades for wear or cracks whenever they fail to wipe 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 steering action. An inspection or servies is needed when: the steering wheel is harder to turn or has too much free play, or if there are strange sounds when tur 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 brakeiwarning light stays on or keeps flashing, there may be some trouble in brake system. Also, test parking brake by pulling parking brake lever. Exhaust System Operation Be alert for any changes in the sound of the ex- aust system or any smell of fumes, These are signs the system may be leaking or overheating. Have it check and/or repaired at once. Tire and Wheel Operation Be alert to vibration of the steering wheel or seat at normal highway speeds. This may mean a wheel balance is needed. Also, a pull right or left ona straight, level road may show the need for a tire pressure adjustment or wheel alignment.MAINTENANCE AND LUBRICATION 08-18 RECOMMENDED FLUIDS AND LUBRICANTS SD, SE or SF (Refer to Fig. 0B-1-5-1) ‘Engine coolant (long life coolant) Ethylene-glycol base coolant (“Antifreeze/Anticorrosion coolant” GOLDEN CRUISER 1200) @ fluid DOTS or SAE J1703 | transmission oil See oil chart on page 7A-7 matic transmission fluid Automatic transmission fluid DEXRON-I ‘Geer shift control lever and shaft Water resistance chassis grease (SUZUKI SUPER GREASE A 99000-25010) ‘Door hinges Engine oil latch assembly Engine oil ‘zy lock cylinder Spray lubricant wsHEATER AND VENTILATION 14 SECTION 1A HEATER AND VENTILATION igh figures in this section mainly show the left -spply to the right-hand steering car. ind steering car, the same work procedure and data CONTENTS RAL DESCRIPTION . 14 ON-CAR SERVICE .........0.00.0,. TAG Body Ventilation ....... 14 Heater Blower Motor 1A4 Hester... ax ea Heater Blower Motor Resistor AS "Hester Control Operation .. - 1A3 Heater Blower Motor Switch . 1A8 1S 5 2 1A Heater Control Cables... 1A7 Heater Unit -1A8 GENERAL DESCRIPTION VENTILATION ‘body ventilation system of this car is equipped with air conditioning that consists of a fresh air intake at the cowl top panel. Ventilating air is drawn into the interior from the intake grille and drawn the ventilator outlet provided at each side of the body outer panel.1A2 HEATER AND VENTILATION, HEATER ‘The heater and ventilation of this car consist of such main components as contral levers, blower motor, heater core and air ducts:-The blower motor runs on.electricity to send air inside; In the heater core, the cooling water warmed by the engine keeps circulating. Each control lever controls the blower moter speed, temperature and operation of the dampers in the air ducts so that the air is delivered where necessary. 1. Side venator outlet 2. Side deoster outlet 53. Canter vantlter outlet 4, Floor outot 5. Front derostr outlet 6. Haster unit 7. air duct 8, Blower motor unit 18. Conte! lever 101 Defromer nozzle 11, Sian cemister duct 42. Center vantistor duct 12. Side ventlator duct 44, Sige venitor joint 1s 16.HEATER AND VENTILATION 183 ‘TER CONTROL OPERATION ‘heater and ventilation provide temperature control, ventilation and defrosting functions. Their ope= is controlled by selecting the positions of the control levers on the instrument panel. Each lever ‘and function of heater and ventilation are as given below. A Lever B ster control lever. Fresh air contro! lever. venriuarion (Sf aaicuate) [a9] [eS | ecutarion Toa sieve (RJauourates’) [Ae] (CSeo | _rnesvae __[o2 wear (fisorston) a3] Tampemure i, — Canes Jes} [Eee fe + mom from front Lever D DEFROSTER. (Geet cae ) 5] Blower motor speed sole z Front detrostr ciate 5-2 lower motor Floor eutiet10:4 HEATER AND VENTILATION, DIAGNOSIS Trouble Possible cause Remedy Heater blower won't work even when its switch is ON. Blower fuse blown Blower register faulty Blower motor faulty Wiring or grounding faulty Replace fuse to check for short. Check continuity. Replace motor. Repair as necessary. Incorrect temperature output Control cables broken or binding ‘Air damper broken Air ducts clogged Heater radiator leaking or clogged Heater hoses leaking or clogged ON-CAR SERVICE HEATER BLOWER MOTOR NOTE: ‘Check cables. Repeir damper. Repair air ducts. Replace radiator. Replace hoses. Heater blower motor unit in left-hand steering car and that in right-hand steering care are symmetrical. Blower motor unit Blower moter resister Blower forHEATER AND VENTILATION 125 HEATER BLOWER MOTOR (AL Sonnect battery (-) leadwire. RESISTOR id REMOVAL connect blower motor and resister | eat couplers. 1) Remove blower motor unit. (Refer top. 1-4) snect fresh air control cable from motor 2) Remove heater blower motor resistor. blower motor unit after removing INSPECTION box upper panel and bolts as shown Check blower motor register for each terminal- to-terminal continuity. If there is no continuity, replace blower motor resistor. INSTALLATION Reverse removal procedure for installation, For lefchand steering car A a —— For righthand steering car TION ‘removal procedure for instal1A6_HEATER AND VENTILATION. TA HEATER AND VENTILATION HEATER BLOWER MOTOR SWITCH REMOVAL 1) Remove console box. 2).Remove ashtray and ashtray upper plate. 3) Remove cigaratte lighter. 4) Remove control lever knobs and control panel garnish. 5) Remave control panel 6) Disconnect leadwire from blower motor switch at coupler: 7) Disconnect control cables from blower motor unit and heater unit. 8) Remove control lever ass’y. 9) Remove blower motor switch. INSPECTION Heater blower motor switch is connected between battery and blower motor, through fuse and resistor as shown below. Check switch for each terminal-to-terminal continuity. If there is no continuity, replace blower motor switch, | I ; ; l 5 (fes| Sas wia/raon | wy : antareen murnvteh ‘pee re bon Fae ener ei Swe rear await Somer mete Prt Gren Pre Fig. 14-7 INSTALLATION Install in the reverse order of removal.‘TER CONTROL CABLES HEATER AND VENTILATION 1A: ‘For leftthand steering car 41, Hester uit 2, Heater blower motor unit 3, Fresh air contol cable | Heater contea ese 5, Aircontrotesble Cont! lever fe conslole box. fe ashtray and ashtray upper plate, Je cigaret fe control lever knobs. and control garnish, fe control panel. inect leadwire from blower motor ‘seitch at coupler. ‘Disconnect control cables from blower motor senit and heater unit. Remove control lever ass'y. ‘Disconnect control cables from control lever. FALLATION control cables by reversing removal noting the following point. installing control cables to control levers, control-levers to such position as to pull fully, then connect and clamp control tovheater_ unit and blower motor u 2s stowic, For laftchand steering car For right-hand) Fig. 14-9 NOTE: ‘After. installing contro! cables, be sure that control knobs move smoothly and stop at proper position,HEATER UNITREMOVAL 1) Disconnect battery (—-) leadwire, drain coolant and disconnect 2 water hoses from heater unit, 2) Remove console box. 3) Disconnect wires and cables from heater and blower ui 4) Remove steering wheel, steering column unit and steering joint upper bolt. (Refer to p. 3C-5) 5) Disconnect speedometer cable and remove speedometer ass'y. 6) Remove speaker garnish (R, L) and center cover. 7) Remove instrument panel member mounting bolts. 8) Remove instrument panel together with instru- ‘ment panel member. Fig TT 9) Remove heater unit, For left-hand steering car HEATER AND VENTILATION 14-3 10) Remove heater unit clips and screws to separate heater uni Fig 113, 11) Pull out heater core from unit. Fig. 114 INSTALLATION Install heater unit by reversing removal procedure, noting the following items. 1) Adjust control cables. (Refer to p. 1-7) 2) Fill coolant to radiator. NoTE: ‘© When installing each part, be careful not to catch any cable or wiring harness, ‘¢ When installing steering shaft to steering shaft joint, set front wheels (right and left) in the straight ahead state and check to make sure that steering wheel is also in that state ‘© When fastening steering column ass'y to car body, start with lower nuts on column and then upper nuts. Be sure to tighten them to specified torque. (Refer to p, 3C-6 for details.)BUMPERS AND SHEET METAL 27 SECTION 2 BUMPERS AND SHEET METAL CONTENTS BUMPERS, Cr HOOD . FRONT FENDER . 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 lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of these parts.BUMPERS AND SHEET METAL FRONT BUMPER Front uppar bumper rant lower bumper Front bumper member ‘Bumper member nut Bumper side attechment Bumpe side sider Bumper se holder ‘Surmper lower stay ‘Bumper bolt Fig. 27 REMOVAL INSTALLATION 1) Remove front fender lining. 1) Slide bumper onto’ bumper side attachments 2) Remove front turn signal lights. on both fenders, 3) Remove front bumper fitting bolts and nuts. 2) Use bolts and nuts to fix bumper in position. 4) Slide bumper (with bumper member) forward to remove it.REAR BUMPER BUMPERS AND SHEETMETAL 23 Fig. 22 Rear upper bu Rear lower bur Fea bumper stry Bumper member nut Bumper strachment ‘Bump slider Bumper sds holder Bumper bot REMOVAL 1) Remove rear combination light fitting screws. 2) Remove rear bumper fitting bolts and nuts. 3) Temporarily install, rear combination lights in position with screws. 4) Slide bumper (with bumper stays) backward to remove it. INSTALLATION 1) Slide. bumper onto side attachments on both fenders. 2) Use bolts and nuts to install bumper in position.2:4 BUMPERS AND SHEET METAL HOOD REMOVAL Remove four mounting bolts to detach hood. PSL As Fig. 24 Hood Adjustment Bolts (Right Side) ADJUSTMENT A Fore-and-aft and right-and-left adjustment Slacken four mounting bolts for adjustment, B. Vertical adjustment If only one side (right or left) of hood is not level with front fender, make it level by tightening or loosening hood cushion. 1. Hood cushion Fig. 26 Vertical Hood Adjustment 1. Hond Iaten Fig, 26 Hood Latch AdjustmentFRONT FENDER BUMPERS AND SHEET METAL 25 Fig 27 REMOVAL 1) Remove front bumper (Refer to p. 2:2). 2) Remove small light, 4. Small ght 2 serew Fig. 28 Removing Small Light 3) Remove front fender. INSTALLATION Reverse removal procedure for installation. NOTE: When replacing front fender, be sure to apply anti-corrosive treatment to replacement fender.NE DIAGNOSS 31 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS! .......6.05045 34 FRONT END ALIGNMENT ...............065 3A1 MANUAL RACK AND PINION A 384 STEERING COLUMN wR WA FRONT SUSPENSION. ...... 30-1 REAR SUSPENSION . 3E4 WHEELS AND TIRES . SFA CONTENTS GENERAL DIAGNOSIS denne Radial Tire Waddle . 36 TIRE DIAGNOSIS «0022. e cece 36 Badlalid gtd “ Irregular and/or Premature Wear .......3-6 VIBRATION DIAGNOSIS . 38 Wear Indicators... parts. 36 GENERAL DESCRIPTION Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the car first. Proceed with the following preliminary inspections and correct any defects which are found, 1) Inspect tires for proper pressure and uneven wear. 2) Raise car on a hoist and inspect front and rear suspension and rack and pinion for loose or damaged 3)Spin front wheels, Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough ‘wheel bearings. GENERAL DIAGNOSIS CHART A Condition Possible Cause Correction Car Pulls (Leads) geen |. Mismatched or uneven tires. . Tires not adequately inflated, 3. Broken or sagging springs. . Radial tire lateral force. 3. Disturbed front end alignment. Disturbed rear wheel alignment. Brake dragging in one road wheel Loose, bent or broken front or rear suspension parts, Replace tire. Adjust tire pressure. Replace spring. Replace tire, Check and adjust front end alignment. Check and adjust rear wheel alignment. Repair front brake. Tighten or replace suspension parts.3:2 DIAGNOSIS 3:2 DIAGNOSIS GENERAL DIAGNOSIS CHART B Condition. Possible cause Correction ‘Abnormal or Excessive Tire Wear 1. Sagging or broken spring, 2. Tire out of balance, 3, Disturbed front or rear end alignment. 4, Faulty shock absorber. 5. Herd driving. 6. Overloaded car. 7. Not rotating tire. 8, Worn or loose road wheel beating, 9, Wobbly wheel or tire. | 10. Tires not adequstely inflated. Replace spring. Adjust balance or replace tire. Check and adjust front end align ment, Replace strut. Replace tire. Replace tire. Replace or rotate tire. .) Replace wheel bearing. Replace wheel or tire. Adjust tire pressure. Wheel Tramp 1. Blister or bump on tire. 2. Improper shock absorber action. Replace tire. Replace shock absorber. Shimmy, Shake or 1, Tire or wheel out of balance. Balance wheels or replace tire Vibration and/or wheel 2, Loose wheel bearings Replace wheel bearing. 3, Worn tie rod ends. Replace tie rod end. 4, Worn lower ball joints. Replace front suspension arm. 5. Excessive wheel runout. Repair or replace wheel and/or tire, 6. Blister or bump on tire, Replace tire. 7: Excessively loaded radial runout | Replace tire or wheel. of tire/wheel assembly. 8, Disturbed front end alignment: | Check and adjust front end align= ment. 8. Loose or worn steering linkage. | Tighten or replace steering linkage. 10, Loose steering gear case bolts, | Tighten case bolts. Hard Steering 1. Bind in tie rod-end ball studs or | Replace tie rod end or front suspen | ower ball joints. | 2. Disturbed front end alignment. | 3, Rack and pinion adjustment 4, Tire not adequately inflated. 5. Bind in steering column. sion arm. ‘Check and adjust front end alignment. Check and adjust rack & pinion torque. Inflate tires to proper pressure. Repair or replace.Condition Possible Cause GENERAL DIAGNOSIS CHART C Correction Too Much Play In Steering 1. Wheel bearings worn. 2. Rack and pinion attachments loose. 3. Rack and pinion adjustments. 4, Worn steering shaft joints. 5. Worn tie rod ends or tie rod inside ball joints. 6. Worn lower ball joints. | Replace. | Tighten or repair. Check and adjust rack & pinion torque. | Replace joint. Replace tie rod end or tie rod, Replace front suspension control arm. Poor Returnability = Bind in tie rod end ball studs. Bind in ball joints. Bind in steering column, - Poorly lubricated rack and pinion. 6. Disturbed front end alignment. ReNe 6. Rack and pinion adjustment. 7. Tires not adequately inflated. Replace tie rodend. Replace, Repair or replace. Check, repair or lubricate rack & pinion, Check and adjust front end alignment. Check and adjust rack & pinion torque. ‘Adjust tire pressure. Rack and Pinion Noise (Rattle or Chuckle) 1. Rack and pinion attachments loose, 2. Worn rack bush. 3. Rack and pinion adjustment. Tighten steering gear case mounting bolts. Replace. Check and adjust rack & pinion torque. Abnormal Noise, Front End 1. Worn, sticky or loose tie rod ends, lower ball joints, tie rod inside ball joints or drive shaft joints. | 2. Damaged shock absorbers, struts | Repair or replace, or mountings. 3, Worn suspension arm bushings. | Replace. 4, Loose wheel nuts. Tighten wheel nuts, 5. Loose suspension bolts or nuts, | Tighten suspension bolts or nuts. 6. Broken or otherwise damaged | Replace. wheel bearings, . Broken suspension springs. 8. Poorly lubricated or worn strut, bearings. | Replace tie rod end, suspension | arm, tie rod or drive shaft joint, Replace. Lubricate or replace strut bearingee 244 DIAGNOSIS GENERAL DIAGNOSIS CHART D Condition Possible Cause Correction Wander Or Poor Steering Stability 1. Mismatched or uneven tires. 2. Loose ball jointsandtierod ends. 3. Faulty shock absorbers/struts or mounting. 4, Broken or sagging springs. 5. Rack and pinion adjustment. 6. Front end alignment. Replace or inflate tires to proper pressure, Replace suspension arm or tie rod end} Replace strut or repair mounting. Replace spring. Check and adjust rack and pinion torqu Check and adjust front end alignment. Erratic Steering When Braking 1, Worn wheel bearings. 2, Broken or sagging springs. 3.:Leaking wheel cylinder or caliper. 4, Werped brake discs. 5. Badly worn brake shoe linings. 6. Drum is out of round in some brakes. 7. Wheel tires are inflated unequally. 8, Defective wheel cylinders: 9. Disturbed front end alignment. Replace. Replace coil spring. Repair or replace wheel cylinder or caliper. Replace. Replace. Replace brake drum. Inflate tires to proper pressure. Repair or Replace wheel cylinder. Check and adjust front end alignment. Low Or Uneven Trim Height Right-to-left trim height (H) difference should be within 15 mm, (0.6 in) with curd weight, * Same with rear side. 1. Broken or sagging springs. 2. Over loaded. 3, Incorrect springs. Replace. Check loading, | Replace. Ride Too Soft 1, Faulty struts. Replace strut. Suspension Bottoms 1, Overloaded. 2, Faulty struts. 3. Incorrect broken or sagging sprints. Check loading. Replace strut. Replace.DIAGNOSIS 35 —!.. $s GENERAL DIAGNOSIS CHART E Condition Possible Cause Correction Body Leans Or Sways In | 1, Faulty struts or mounting. Replace strut or tighten Corners mounting. 2. Broken or sagging springs. Replace. 3. Overloaded. Check loading. Cupped Tires 1, Front Struts defective. Replace. 2. Worn wheel bearings. Replace. 3. Excessive tire or wheel run-out. | Replace tire or wheel disc. 4, Worn bail joints Replace front suspension arm. 5. Tire out of balance. Adjust tire balance.28 DIAGNOSIS TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR, Irregular and prematuré-wear has many causes. ‘Some of them ere: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, rotation is necessary 1, Front tire weer is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Front tire wear is unequal between the right and left. 4, Rear tire wear is unequal between the right and left. 5. There is cupping, flat spotting, etc. incorrect Whee! Alignment Fig. 31 Tire Wear Diagnosis ‘A wheel alignment check is necessary if following conditions are noted: 1. Front tire wear is unequal between the right and left. 2. Wear is uneven across the tread of any front tire. Front tire treads have scuffed appearance with “feather’” edges on one side of tread ribs or blocks, WEAR INDIGATORS (FIG. 32) Original equipment tires have built-in tread wear. indicators to show when theymeédiréblacement. These indicators will pear a8 12 mm {0.47 inch) 1.6 mm (0,063 inch). When the indicators appear in 3 or more grooves at 6 locations, tire replacement ig fécbitimended. | is i fetes i UP EN SNE VE Fig. 32 Tire Wear Indicator RADIAL TIRE WADDLE (FIG. 3-3) Waddle is side to side movement at the front and/or rear of the car. It is caused by the steel belt not being straight within the tire. It is most noticeable at a low speed, 5 to 30 mph. It is possible to locate the faulty tire by road testing the car, If it is on the rear, the rear end of the car shakes from side to side or “waddles”. To the driver in his seat, it feels as though some- ‘one is pushing on the side of the car. If the faulty tire is on the front, waddling is more visual, The front sheet metal appears to be moving back and forth and the driver feels as ‘though he is at the pivot point in the car. Waddle can be quickly diagnosed by using Tire Problem Detector (TPD) and following the equipment manufacturer's recommendations. If TPD is not available, an alternative method of substituting known good tire/wheel assemblies can be used as follows, although it takes a longer time. ahdl he Want! br 1. Ride car to Gekétinh scear wadiles: 5 2iinstalltires:ané. wheels that:are known tobe ‘egned {or simitaecar) iim place of those on waddling end of car. If waddling end:cannot be identified, substitute rear onesion 3. Road test again. If improvement: is noted, reinstall originals oneoat:/a:time till waddle causal tire is found. If no improvement is tee, THstdll ‘knowin’ good ‘tirés"in place OF all Foul “THEA “Fethstall tits Vi i sine © fer ds above, ¥ Fig, 43, Radial,Tire Waddle PRESSURE. ois y9pnol 6 sar 91 ANFLATESTIRES TO RECOMMENDED. | | ROAD TEST VEHICLE ON LEVEL UNCROWNED ROAD IN | BOTH DIRECTIONS ae "| -beqotsvab i } eT LEADS IN SAME LEAD CORRECTED [_ LEAD REVERSES DIRECTION IF ROUGHNESS RESULTS. DIRECTION REPLACE TIRES hee T ‘ [ PUT TIRES BACK IN INSTALL A KNOWN/GOOD TIRE ON ORIGINAL POSITION ONE FRONT SIDE AND CHECK ALIGNMENT 9 gf oN et LEAD GORREGTED | LEAD REMAINS REPLACE TIRE | INSTALL A KNOWN GOOD TIRE IN = PLACE OF OTHER FRONT TIRE LEAD CORRECTED. REPLACE TIRE 7 {READ REMAINS KNOWN GOOD TIRES ARE NOT GOOD Fig. 34 Lead Diagnosis,3:8 DIAGNOSIS. RADIAL TIRE LEAD “Lead” is the deviation of the car from a straight path on @ level road even with no pressure on the steering wheel. Lead is usually caused by: 41) Incorrect alignment 2) Uneven brake adjustment. 3) Tire construction. The way in which a tire is built can produce lead in a car. An exemple of this is placement of the belt. Off center belts on radial tires can cause the tire to develop @ side force while rolling straight down the road. If one side of the tire has a little larger diameter than the other, the tire will tend to roll to one side. This will develop a side force which can produce car lead. The procedure in Fig. 34 should be used to make sure that front alignment is not mistaken for tire lead. 1) Part of the lead diagnosis procedure is different from the proper tire rotation pattern cur rently in the owner and service manuals. If a medium to high mileage tire is moved to ‘the other side of the car, be sure to check that ride roughness has not developed. 2) Rear tires will not cause lead. VIBRATION DIAGNOSIS Wheel unbalance causes most of the highway’ speed vibration problems. If a vibration remains after dynamic balancing, its possible causes are) as follows, 1) Tire runout. 2) Wheel runout. 3) Tire stiffness 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). If TPD is not available, alternative method of substituting known good tire and wheel assemblies on the problem car can be} used, although it takes a longer time. Caused by (KG @ TIRE OUT SMOOTH ROAD SUSPENSION MOVEMENT (Loaded Runout) TIRE, RIM BENT STIFFNESS ‘oR VARIATION OUT oF ROUND Fig. $5 Vibration— ll CGGETEFE FRONT END ALIGNMENT 341 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS... . * a4 Preliminary Checks Prior to Adjusting GENERAL DESCRIPTION 3A-1 Front Alignment see BAD Toe Setting — Figure 34-1 34 Toe Adjustment Leki BA2 Camber —"Elgure SA-1, « BAT Camber and Caster Adjustment ...... 3A-2 Steering Angle 2 3A3 GENERAL DESCRIPTION CENTER LINE o Spee Alignment service data ~+2mm, ein 101 af " {0.079 ~ +0.078 in.) ‘Camber ot Body center ie caster Thee (16 mm 0.85 ind y Kingpin nner itv SRE 3 rete WHEEL TOEIN “8” CAMBER ANGLE CAMBER Torview Fig, GAT Toesin and Camber Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Generally, the only adjustment required for front alignment is ‘to8 setting, Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to’ the damage caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be determined first and damaged body should be repaired or damaged suspension should be replaced. TOE SETTING-FIGURE 3A-1 Toe is the turning in or out of the front wheels. The purpose of a toe specification is to ensure parallel rolling of the front wheels (Excessive toe-in or toe-out may increase tire wear). Amount of toe can be obtained by subtracting "A"" from "B" as shown in Fig. 3A-1 and therefore is given in mm (in.). CAMBER-FIGURE 3A-1 Camber is the tilting of the front wheels from the vertical, as viewed from the front of the car. When the wheels tilt outward at the top, the camber is positive, When the wheels tilt inward at the top, the camber is negative. The amount of tilt is measured in degrees.9:2) FRONT END:ALIGNMENT PRELIMINARY CHECKS PRIOR TO: ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are. notalways the result of improper alignment\/An/additional item to be checked is possibility of tire lead due to worn or improperly manufactured tires "Lead" is the deviation of the car from a straight path on a level road without hand pressure on the steering wheel, Section 3.of this manual.contains a procedure for determining presence:of @ tire lead problem, Before making.any. adjustment, affecting toe setting, following checks end inspactions should tbe made to insure correctness of alignment readings and alignment adjustments: 1) Check all tires for proper inflation pressures) and approximately the same tread wear. 2) Check ball joints for looseness. Check tie rod ends; if excessive looseness in noted, it must be corrected before adjusting. 3) Check wheels and tires for run-out. 4) Check car trim height. If it is out of limit and correction is necessary, it:must be made before adjusting toe (Refer to p. 3-4). 5) Check suspension arms for looseness, 6) Consideration must be given to excess loads, such as too! boxes. If this excess load is nor- ‘mally-carried~in-car,-it-should-remain there during alignment checks. 7) Consider the condition of the equipment being used to check alignment and follow its manufacturer's instr uetions> 8) Whatever equipment is used to check alignment, car must be placed on level surface. JOE ADJUSTMENT. Toe is adjusted by changing tie rod length. Loosen right and left, tie-rod end.Jock, nuts first ‘and then rotate right and left tie rods by the same améunt to align toe-in to /specification: In this “adjustment, fight’ and left’ tie rods should become equal in length (“A"" in'Fig/A°2). [Before rotating 'tie rods, apply ‘grease between tie’ rods’ ahd” rack” boots’s0 “that /boots won't bbe twisted. ‘Altar adjustment, tighten lock nuts to specified torque end make sure that rack boots are not ‘35-95 Nm ins 55 kam) (255-395 Df) Fig. 4-2 Too-Adjustment CAMBER AND CASTER, ADJUSTMENT, Should camber or castenbe foundiout of specifi: cations upon’ inspection; locate its cause firstolf itis inedamaged, ‘loose, bent;i;dented or-worn suspension parts, they'stiould be replaced:iIf tits in car-body, repairit sos toattain specifications. To prevent possible incorrect:reading of.camber or caster) car‘frontiend must be moved-up and down a few times before inspection.FRONT END ALIGNMENT 383 STEERING ANGLE eS ve inside 38° sering angle [outside zx When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length ("A"" in Fig. 34- 3. NOTE: If tie rod lengths were changed to adjust steering angle, reinspect toe-in. “Turning radios gauge Fig. 3A-3. Steering Angle Inspection Referrence information: SIDE SLIP: For inspecting front wheel side slip with side slip tester: Side slip limit: Less than 3 mm/m. (Less than 0.118 in/3 ft) If side slip exceeds above limit, toe-in or front wheel alignment may not be correct.MANUAL RACK AND PINION 35-1 SECTION 3B MANUAL RACK AND PINION NOTE: All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the seme 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 of these parts. CONTENTS BBAGNOSIS 0 ToT oss cs ences 34 6. Remove and install Steering GENERAL DESCRIPTION . i 3B-11 7. Remove an! Install Pinion ON-CAR SERVICE .. pal ae Lubrication ..... 2. Remove and Install Manual Rack and Pinion Assembly (Stesring Gear Case).........5.. 3B 5 3. Remove and Install Rack Boot/Tie odie sence act dNe nen 38-7 4, Remove and Install Steering Rack Plunger .. ++. 38-9 5, Remove and Install Steering NON. Se gE - 38-10 RACK AND PINION INSPECTION RECOMMENDED TORQUE SPECIFICATIONS . 8, Remove anc! Install Rack Bushing - 38-16 REQUIRED SERVICE MATERIAL ... 38-16 SPECIAL TOOLS.................. 3B738-2 MANUAL RACK AND PINION GENERAL DESCRIPTION The rack and pinion steering system consists of two main components, the rack and the pinion. When the steering wheel is turned, the motion is transmitted to the steering shaft, shaft jointand 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 to the steering knuckles which turn wheels, NOTE: Although the figure below show only the left-hand side steering car, the same work procedure and data apply to the right-hand side steering car. 4 | } | | | Va 3 Steering whee! Steering shaft Steering shaft joint Steering pinion ack and Pinion ~ Fig. 38-1. General Description of Steering System_————— eee ON-CAR SERVICE LUBRICATION When innner parts of the steering gear case were disassembled, they should be washed clean before reassembly. It is recommended to, use the grease as given at the right where grease applica tion is indicated in the text. "SUZUKI SUPER GREASE (E) 99000- 25050, or Lithium grease (applicable for 40°C ~ 130°C or —40°F ~ 26°F) 2 1 a Steering ger eate packing ‘Staering goar esse ol sel Pinion bering lug ‘Stuering pinion Steering pinion needle bearing Rack damper srew cap Rack domper screw ek plunger bring ing rack plunger Steering reek Rousing 8 gear case 11, Tiesod ond 21. Steering pinion side mount 12, Tierod end lock mut 22, Gear ent sta) 13, Rack boot eip 28. Snap tng 18, Boot 15, Wee 18. Storing tinvod 47, Therad lock washer 48. tering rock bushing 49, Steering feck side mount 20. Steering rack Fig, 38-2 Exploded View of Manual Rack and Pinion38-4 MANUAL RACK AN HON A 1. REMOVE AND INSTALL TIE ROD END REMOVAL 1) Hoist car and remove wheel. 2) Remove split pin and tie rod end castle nut from steering knuckle. “ie rod one Knuekle Castle nat Split pin INSTALLATION 1) Install tie rod end lock nut and tie rod end to tie rod. Align lock nut with mark on tie rod thread. 2) Connect tie rod end to knuckle. Tighten castle nut until holes for split pin are aligned, but only within specified torque. 3) Bend split pin as shown below. 4) Inspect for proper toe (Refer to FRONT END ALIGNMENT). 5) After confirming proper toe, tighten tie rod end lock nut to specified torque, 6) Tighten wheel to specified torque and lower hoist. Fig 383 3) Disconnect tie rod end from knuckle, using special too! (A). 4: Tia ro end emover losers 652101 Fig. 38-4 4) For ease of adjustment after installation, make marking of tie rod end lock nut position on tie rod thread. Then loosen lock nut and remove tie rod end from tie rod. Tiered Marking tobe made ‘Tie od end ack nut ‘Tierod end j Tecod teen mace teccree Tove end wenate Conte soit pin N 20-55 Nm 6 fo Sein) Gaoaeeh) 25-85 en eS ign) Gas —a98m%2. REMOVE AND INSTALL MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL 1) Slide driver's seat as far back as possible. 2)Pull off front part of floor mat on driver's side and remove steering shaft joint cover. 3) For ease of installation, loosen steering shaft upper joint bolt but don’t remove. 4) Remove steering shaft lower joint bolt and disconnect lower joint from pinion. 4, Steering 2. Stsoring Fa BT 5) Hoist car and remove both wheels, S)Remove split pins and tie rod from both knuckles, 4 Stoating kuekio 2 Cane nut 3, Splitpin Fin BB 7) Disconnect both tie rod ends from knuckles, using special tool (A). (A): Te cod end remover (ose13-¢5210) 1. Steoring knuckle 2. Tierod end Fig 89 8) Remove steering gear case mount bolts, gear case brackets and then gear case. 1, Gaor case mount bolt 2. Siaering ger ease Fig. 3B-T0,3B MANUAL RACK AN! INSTALLATION 1) Mount steering gear case to body and tighten ‘gear case mount bolts to specified torque. 3 20=30NNm (20-30 kom! (45 — 21.8 b-hd) 1. car body 4, Pinion side racket 2 Stasring goer case) Rack side bracket 13, Cese mount bolt Fig. 38-17 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 bend split pin as shown. ; 2 “Te od end Knuckle Geste sur | 7 2a (20-5 ig) (220 ~ 39.5 oie) Fig. 38-12 3) Be sure that steering wheel and brake discs (R & L) areall straightahead driving state and then insert steering lower joint into steering pinion shaft. 4) Tighten steering shaft joint bolts to specified torque (Lower side first and then upper side). Upper join bot Lower joint bolt 20-30 Nm 20-30 '¢m (4521s ie4 5) Reinstall! cover removed previously to steering shaft joint 1. doine cover Fig. 38-14 6) Put back floor mat as it was. 7) Install both wheels and tighten wheel nuts to specified torque. Nm kgem | 40-70 40-7.0 | 290-505 8) Lower hoist. 9) Check toe setting. Adjust as required (Refer FRONT END ALIGNMENT). }0) Tighten both tie rod end lock nuts to specified torque. 3585 s-S5i¢m) (25.5 — 39.5 Io)MANUAL RACK AND PINION 38:7 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 installation, ‘make marking of tie rod end lock nut position on tie rod thread. Make racking her. 4. Lock nut Fig. 38-16 3) Loosen tie rod end lock nut and remove tie rod end. 4) Remove boot wire and clip. Fig. 38-17 5) Remove boot from tie rod. 6) Unbend bent part of tie rod lock washer and remove tie rod from rack. 1. Lock washer 2. Tierod 4. saering rack Fig. 38-1838-8 MANUAL RACK AND PINION. INSTALLATION 1) Install tie rod lock washer and tie rod to rack. Align straight part “A’" of washer with flat part “B” of rack. 1, steering rack 2. Tierodlock washer rod Fig. 38-19 2)Tighten tie rod inside ball nut to specified torque. Nem kg-m’ Ib-ft 7o-100 | 70-100 | 510-720 3) Bend lock washer to tie rod side as shown below, Fig, 38-20 4) Position boot properly in grooves of gear and tie rod and clamp it with wire and clip. Wire should be new and should go around and be tightened with its both ends twisted together. The twisted ends should be bent in the circumferential direction. After this, check to ensure that boot is free from ‘twist and dent. 8 ‘Aoply grease here 1. Wire 3. clip 2 Reckidemount —&, Tievod Fig, 38-27 5) Install tie rod end lock nut and tie rod end to tie rod. Position lock nut to marking made inremoval. NOTE: When tie rod was replaced, measure length “A” on removed tie rod and use it on new replacement, tie rod so as to position lock nut properly. Ly Marking madi in cemoval Fig. 38-22 6) For installation procedures following the above, use Steps 1) — 10), INSTALLATION of STEERING GEAR CASE on p. 38-6.MANUAL RACK AND PINION 38.9 4. REMOVE AND INSTALL STEERING RACK PLUNGER REMOVAL 1) Remove parts as shown below. Rack damper srow cap Rack damper screwy Flack plunger spring Rack plunger Fin 38-23 INSTALLATION 1) Apply grease lightly to sliding part of plunger against rack, 2) Install parts as shown. 3) After tightening rack damper screw to the turn it back by 0 ~ 90° and check for rotation torque of pinion. tightest point, (@): Special r00! (Pinion torque checking socket (09044"182111 Fig. 98-24 Pinion torque: Also, check if rack asa whole moves smoothly. Nm kgm’ It 08-13 0.08 — 0.13 0.58 — 0.94 4) After adjustment, put rack damper screw cap as deeply as possible.—— 3B-10/ MANUAL RACK AND PINION. 5. REMOVE AND INSTALL STEERING PINION REMOVAL, INSTALLATION 11) Remove rack plunger as shown Item 4. 1) Apply grease to. all, around. pinion teeth. pinion needle bearing and gear case oil seal lip- 2) Remove gear case packing. 3) Remove bearing plug with special tool (C). 1 Gear eae ol 2a! 2. Greasing point 3, Pinion teeth 4 Fill isis of pinion bearing pa with ore B, Gane cose O ring 8. Apply LOCK CEMENT {99000-32050) to pinion 5 bearing plug thread. (cl: 43 mm Socket 09988-28710) Fig. 3-25 ES ig. 3B 4) Tap on position as shown with plastic hammer to separate pinion assembly from housing. 2) Install pinion assembly. 4 3) Tighten pinion bearing plug to specified) torque. Nm kg-m’ loft go-110 | 80-110 | 580-795 4. Pinion 2. Plastic harnner Fig, 38-26 '5) Remove pinion assembly. Fig, 38-29 4) Install gear case packing. 5) Install rack plunger as described in Item 4EE MANUAL RACK AND PINION S558 ‘& REMOVE AND INSTALL STEERING RACK REMOVAL 3) Remove boot wires and | Fie 38-30 2)Move both boots toward tie rod end. 3) Unbend bent part of tie rod lock washers and remove tie rods from right and left sides of steering rack. 4) Mark left and right tie rods accordingly. Fig, 38-37 5) Remove rack plunger and pinion assembly from gear case by performing Steps 1) — 5) in Item 5 STEERING PINION REMOVAL of this section, 6) Remove rack from gear case. Direction for rack removal is as shown below. Fig. 3-32 INSTALLATION 1) Apply grease to entire teeth’ surface of rack and its periphery. 2) Slide rack into steering gear case in the direction as shown below. CAUTION: Inside of steering rack bushing is coated with special coating. As it is damageable, be very careful not to cause damage to it wher ting rack into steering gear case. Fig. 833 3) Install pinion assembly to gear case by performing Steps 1) — 4) in Item 5 STEERING PINION INSTALLATION of this section. 4) Perform Steps 1) — 4) in Item 4 STEERING RACK PLUNGER INSTALLATION of this section. 5) Before installing boot to steering rack housing, make sure that rack side mount is positioned as shown below. Install tie rods to rack by performing Steps 1) — 6) in Item 3 RACK BOOT/TIE ROD INSTALLATION of this section, cohen, 1. Steering ack housing 2, Rack side mount 1.0 ~ 2.0 mm ‘0.04 — 0.08 in} Fig, 38-3438-12 MANUAL RACK AND PINION 7. REMOVE AND INSTALL PINION BEARING REMOVAL 1) Remove rack from steering 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 rollers of pinion bearing, 2)Pressfit pinion bearing into gear case with special tool (F) as shown, After press-fitting, make sure that bearing rollers are installed properly. (0): Bosring remover 09921-70200) {E): Stiding shart (09930-20102) 1. Pinion bessing (FI: Bearing instaliee 09043-88211), 1, Pinion besring Fig. B35 Fig. 38-36 3) Follow Steps 1) — 5) in Item 6 STEERING RACK INSTALLATION of this section to ‘complete insallation.MANUAL RACK AND PINION 38-23 8. REMOVE AND INSTALL RACK BUSHING REMOVAL 1) Remove rack from steering gedt case, 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 in a vise. Or housing (pipe) may come off gear case. For ‘this work, be sure to use the below specified special tool. 2) Remove snap ring, INSTALLATION 1) Apply grease lightly to entire inner surface of bushing, 2)Press-iit bushing as far into rack housing as shown below by using special tool (H). CAUTION. Inside of bushing is coated with spec coating. As it is damageable, be sure to use specail tool and special care not to cause damage to inside of bushing when pross- fitting it. 1. Rack housing 2. Shap rng } 3. Bushing Fig 38-37 3) Pull out bushing from rack housing with special tool (G) as shown. (og9se-a8210) Fig 28-8 (Bush instator (9945-78210) 1.0 2.0mm (0.08 ~ 0.08 in) Fig, 38-35 3) Install snap ring, 4) Follow Steps 1 — 5) in Item 6 STEERING RACK INSTALLATION of this section to complete installation,3B-16 MANUAL RACK AND PINION. RECOMMENDED TORQUE SPECIFICATIONS Tightening torque kgm Ibe Fastening parts . Steering shaft joint bolts 20-30 | 145-215 . Steering gear case bolts 20-30 | 145-215 . Tie-rod end castle nuts 30-55 22.0 - 39.5 |. Tie-rod end lack nuts 35-55 25.5 — 39.5 . Steering pinion bearing plug o8—11.0 | 580-795 [07-100 | 51.0-720 jerod I a}o]a}a|o|r| = [50-70 36.5 — 50.5 Fig, 38-49 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT A ® Sliding part of rack against steering housing (All around rack plunger, rack bushing and rack) « ‘Siding part against steering pinion Lithium Grease SUZUKI SUPER GREASE (E) | (Oil sal lip, needle bearing) (Should be applicable | (99000-25050) aks ion gaa Spon imanicay’ Steeringrackand pinion ger teeth ‘Filled into pinion bearing cap ‘© Contacting parts of tie-rod and rack side boots # Rack end ball jointMANUAL RACK AND PINION 38:17 SPECIAL TOOLS —_ | 09944-18211 09944-28210. © 02019-65010 Pinion torque checking | 43 mm Socket 09921-20200 Tie-rod end remover | socket (Pinion bearing plug remover) Pinion bearing remover ‘09930-30102 | 0943-88211 09944-48210 09943-78210 © Sliding shaft Pinion bearing installer ack bush remover Rack bush installer | = 38-50STEERING WHEEL AND COLUMN 303 SECTION 3C STEERING WHEEL AND COLUMN steering wheel and column fasteners are important parts in that they could affect the performance of 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 replacement becomes necessary. Do not use a replace- art of lesser quality of substitute design. Torque values must be used as specified during reassembly "sssure proper retention of this part. CONTENTS MOIS... ¢ perenne 34 ERAL DESCRIPTION ........... 3C-1 CAR SERVICE .. ao S63 4. Remove and Install Steering Wheel .. 36-3 2. Remove and Install Combination Switch ...... pases SOR 3. Remove and Install Steering Column .. 4. Remove and Install Steering Lock . 5, Remove and Install Steering Shaft Lower Joint ......... 6. Checking Steering Column for Accident Damage 7. Checking Tilt Steering Column. (if equipped) . : RECOMMENDED TORQUE SPECIFICATIONS . SPECIAL TOOL . GENERAL DESCRIPTION ‘There are two types of steering column for this =. They are double tube type and single ‘be type. Which type to be used varies with ‘countries. ‘Mestrations show double tube type only, but ‘Se same removal and installation procedures are ‘sd for single tube type. Both types of column may be easily removed ‘= installed. For installation, it is important ‘Set only the specified screws, bolts, and nuts be ‘sd as designated and that they are tightened to ‘Se specified torque. When removing the column assembly from the car, special care must be taken in handling it. Use of a steering wheel puller other than the steering wheel remover recommended in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly is prohibited. Any of such actions ‘could shear the plastic shear pins which maintain column length especially with the double tube type column,30-2. STEERING WHEEL AND COLUMN All the ears with the double tube type steering column are equip ed with the steering lock. ‘As for the cars with the single tube type steoring column, ‘whether equipped with the steering lock or not depends on the specifications, Steering whee pec Fig. 3C-1 Steering Whee! and ColumnSTEERING WHEEL AND COLUMN 303 ON CAR SERVICE 1. REMOVE AND INSTALL STEERING WHEEL NOTE: Removal and installation procedures of steering wheel may vary somewhat from description below depending on specifications. REMOVAL, 1) Disconnect negative battery cable. 2) Remove pad by pulling it upward. 3) Remove steering shaft nut, 4) Make alignment marks on steering wheel and shaft for a guide during reinstallation. 1. Make alignment marke Fig. 302 5) Remove steering wheel with special tool (A), a 7. Suzering whoo! (A): Steering wheel remover (3940-36070), Fig. 30-3 INSTALLATION 1) Install. steering wheel onto shaft, aligning alignment marks on them. 2) Torque steering shaft nut to spe given below. 3) Connect horn wire to steering wheel and then, install pad bumper and pad. cation as a 2540 Nm (25—40kgm) (185 —2B8i0% 1. Steering wheel pad 4, steering shaft nut 2. Stowring wheel bumper &, Stearing wes! 3. Bumper screw 6. Steering shaft Fig, 304 4) Connect negative battery cable,30-4 STEERING WHEEL AND COLUMN 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). Marked with * are standard “9 1. Upper cover serena. 2) Lower eover “The rst are capping saws. 3. Undercover Fig. 305 4) Disconnect lead wire from combination switch at coupler. 5) Loosen wire bands. 6) Remove combination switch assembly from steering column. INSTALLATION 1) Install combination switch. 2) Connect lead wire from this switch at coupler: 3) Tighten wire bands. 4) Install column lower cover and under cover. NOTE: gi When tightening lower cover and upper cover, be careful so that combination switch lead wire is hot caught between covers, 5) Install steering wheel. Refer to step 1) through 4) underSTEERING WHEEL INSTALLA- TION. 1. Combination switch Fig. 306NOTE: "Once the steering column is removed from’ the s@e,othe ‘column is extremely susceptible to damage. Dropping the column assembly on its eed could collapse the steering shaft or loosen | the plastic shear pins which maintain column ‘ength. Leaning on the column assembly could couse the jacket to bend or deform. Any of the above damage could impair the column’s col- lapsible design. If it is 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 length. REMOVAL 1) Disconnect 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, 4)Disconnect lead wires from ignition switch and ignition key warning switch {if equipped) at coupler: 5) Pull off floor mat at the foot of steering shaft and remove steering joint cover. 1. Joint cover Fig. 307, 6) Remove steering shaft joint upper side bolt. STEERING WHEELAND-COLUMN. 365 3. REMOVE AND INSTALL STEERING COLUMN Fig. 308. Fig. 30-9 8) Remove steering column assembly. NOTE: @ * Don’t separate double tube type steering col- ‘umn assembly into steering column and shaft. If column or shaft is defective replace as an assembly. ‘Single tube type steering column assembly can be separated into steering column and shaft. Double tube type (can’t be disassembled) Fig. 30-10 Steering Column Assembly30-6 STEERING WHEEL AND COLUMN. INSTALLATION 1) Align flat part ““A"' of lower joint shaft with bolt hole “B’ of upper side joint as shown. Then insert upper side joint into lower joint shaft. 2 1 ”" 3 fe 1. Lower joint 2. Upper joint Fig. 30-11 2) Install steering column assembly to lower and upper brackets, Torque steering column nuts to specifications as given below. @ Tighten nuts (a) first to specified torque. ‘® Then tighten nuts (b) to specified torque. 1-17 Nm # (1-17 om) (80120064 Fig, 3012 3) Install bolt to steering shaft upper joi tighten it to specified torque. NOTE: After tightening column nuts, bolt 1 should be ightoned. 20—30NNe 1 @o-30kgm (145-2151 Fig. 30-73 4) Install steering joint cover and put floor mat back as it was originally. 5) Connect lead wires from ignition switch and ignition key warning switch (if equipped) at coupler 6) Install combination switch. Refer to Steps 1 through 4 under COMBINATION SWITCH INSTALLATION. 7) Install steering wheel. Refer to Steps 1 through 4 under STEERING WHEEL IN- STALLATION.REMOVAL ‘Remove steering column. Refer to STEER- ING COLUMN REMOVAL. Fe 30-14 WUsing center punch as shown, loosen and remove steering lock mounting bolts. Use care ‘not to damage aluminum part of steering lock body with center punch, [Center punch (with herp point] ‘Scsering lock mounting bats ‘Turn ighition key to “ACC” or “ON” position ‘2nd remove st Wa column. STEERING WHEELAND COLUMN 307 -S SEEING WHEEL AND COLUMN 30-7 4. REMOVE AND INSTALL STEERING LOCK (Applicable to car equipped with steering lock.) INSTALLATION 1)Position oblong hole of steering shaft in the center of hole in column, 2 ) 1. Steering eotumn uring shaft Fig. 30-16 2) Turn ignition key to “ACC” or “ON” position and install steering lock assembly onto column. '3)Now turn ignition key to “LOCK” position and pull it out. 4) Align hub on lock with oblong hole of steering shaft and rotate shaft to assure that steering shaft is locked. Fig. 3-17 5) Tighten two new bolts until head of each bolt is broken off. ’ 7 Fig. 30-18 6) Turn ignition key to “ACC” or "ON" position and check to be sure that steering shaft rotates smoothly. Also check for lock operation. 7) Install steering column. Refer to Steps 1) through 7) under STEERING COLUMN IN- STALLATION.3C-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 bolts. INSTALLATION 1) Align flat part of lower joint s hole “of ‘upper joi shaft with’ bolt fas) shown. Then’ insert lower joint shaft into upper joint. Fig. 30-19 3) Remove steering shaft lower joint. If it’s hard to remove, loosen steering column mounting nuts little, 1 2 Fig, 30-20 2)Be sure that front wheels and are in straightforward state’ an joint into steering pinion shaft. Lower font Upper joint steering wheel 1d insert lower 3) If steering column nuts were loosened in removal, torque lower bracket specification first. nuts to below Nem kg-m ib-ft W417 We 80-120 tion, ‘And then torque upper bracket nuts to specifica pra: AT ee Jes Nem kg-m- E u-17 ii-17 [| 8. cation. 4) Torque steering shaft joint bolts to specifi: Nm kgm 2030) y [i 20-30 loft 145=215 5) Install steering shaft joint cover.STEERING WHEEL AND COLUMN 363 6. CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: ‘Cars involved in accidents resulting in body ‘emage or where the steering column has been impacted may also have a damaged or misaligned ‘steering column, fn such a case) following Step 1) through 4) should be performed for double tube type steer- jing column and 3) through §) for single tube ‘type steering column. CHECKING PROCEDURE 1) Check capsules on» steering column bracket; all should be contacting the bottom of slots. tf not, steering column assembly should be __replaced. Use thickness gauge for convenience. 1. Thickoei gun 2 capsules Clearance =O Izero) "Sich capa shouldbe contacting the bottom oF the slot Ino, eplacecoluma assembly. Fe 3021 Checking Steering Column 2) Take measurement “A” as shown. [fit is shorter than specified length, replace columa assembly with new one. A: 532.5 mm (20.96 In} Fig. 30-22 3) Check steering shaft joints and shaft for any damages such-as-crack, breakage; malfunction or excessive play. If anything is found fauity, replace as joint assembly. Fig. 30-28 4) Check steering shaft for smooth rota found defective, replace as column assembly... 5) Check steering shaft arid column for bend cracks or deformation. If found defective, replace,30-10, STEERING WHEEL AND COLUMN 7. CHECKING TILT STEERING COLUMUN (If equipped) Check to make sure the following: © Steering column moves smoothly when tilt lever is at lower position (i.e., steering column is unlocked). ‘ Steering column is fixed securely when tilt at higher position (ie., steering column is locked). 1. Seuering column 2 tock 3. Unlock Fig. 3-23-1 RECOMMENDED TORQUE SPECIFICATIONS A deen Tightening torque rt astening parts — ue. on 1, Steering shaft nut 25-40 25-40 18.5 — 28.5 2. Steering shaft joint bolts 20-30 2.0-3.0 14.5 — 21.5 3. Steering column nuts 1-17 T-17 80-120 7 2 oy PAG? exe BO) M4 ( Hil Fig. 30.24 SPECIAL TOOL 09944-36010 ‘Steering whee! remover Fig. 30-25FRONT SUSPENSION 30-1 SECTION 3D. FRONT SUSPENSION NOTE: * All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do notuse a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part. * Never attempt to heat, quench or straighten front suspension part, Replace it with a new part, or damage to the part may result. CONTENTS BENERAL DESCRIPTION weerer sabe dy. ccs ible cetiealiccas- ce no N ON CAR SERVICE 1. Remove and Install Strut Damper Assembly 2, Disassembly and Assembly Strut Damper . | 3, Remove and install Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race . 4. Remove and Install Suspension Arm/Bushing 5. Remove and Install Knuckle/Bearing ............. 6. Front Suspension Inspection ........ 002.05 RECOMMENDED TORQUE SPECIFICATIONS . ... REQUIRED SERVICE MATERIALS ....... SPECIAL TOOLS.........30:2 FRONT SUSPENSION GENERAL DECRIPTION The front suspension is the strut type independent suspension. The upper eng of a strut is anchored to the car body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the rubber mount. ‘The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached to the,strud.of a ball joint which is incorporated in a unit with 2 syspension contro! arm. And connacted to this steering knuckle is the tie-rod end, “Thus; movement Of the’steering wheel is transmitted to the tie-rodend and then to the knuckle, eventual- Iycausing ‘the wheel‘and-tire ‘to move. In this operation, with the movement of the knuckle,the strut also rotates by means of the strut bearing and ower ball joint, car body Svursstembly Steering Kruckle Suspension a (Lower arm) Bal sud Whe! beeing Front whee! hub Wee!FRONT: 1. nw 11> Baseing spacar 2 Washer 512) col spring up sat 3. Stopper 43. Collpring seat “2 4 nar sp0car 14. Strut eover = 5. Suppert comp. 18. Bump stopper 6. Bearing seat 16. Coil pring 7. Bearing upper washer 17. Stat 8 Beacing set 9. Bearing 10. Bearing tomar washer ‘Fig. 30-2 Front Suspension30-4 FRONT SUSPENSION ON-CAR SERVICE 1. REMOVE AND INSTALL STRUT DAMPER ASSEMBLY REMOVAL 1) Hoist car, allowing front suspension to hang free. 2) Remove wheel. 3) Remove E ring securing brake hose and take brake hose off strut bracket as shown below. 4) Remove strut bracket bolts. Fig. 3-4-2 5) Remove strut support nuts. Hold strut by hand so that it will not fall off. Fig. 30-13 6) Remove strut assembly. INSTALLATION 1) Install strut by reversing REMOVAL Steps 1) — 6). Insert bolts in such a direction as shown below. 2) Torque all fasteners to specification. 21-33Nm (24-33 kgm) (155238 bie) (70 -8.0 kgm) (505650108) Fig. 30-14 NOTE: Don’t twist brake hose when installing it. Install E ring as far as it fits to bracket as shown below. 3} ring Bracket ond surface Fig, 30-15SSEMBLY With special tool (A) placed to spring as ‘shown, turn special tool bolts alternately until ‘Srihg tension is released. Whether it is releas- ‘=J or not can be known by whether strut turns lightly while strut spring is held sta- ‘onary. W0): Spring compresor (ose40-71430) DWhile keeping spring compressed with special tool as shown above, remove strut nut and then disassemble parts. 9. Bearing ue 10. Beating tower washer Waser 11 Bearing spacer ‘Stopper 12, Coll spring upper seat liner specer 13, Coll pring soar Supper comp. 18. Strut cover ring seat 15. Bump stopper Bearing Upper wat 16. Coll spxing Bearing sal 17. Sin DISASSEMBLY AND ASSEMBLY STRUT DAMPER FRONT SUSPENSION 305 ASSEMBLY 1) Compress spring with special tool (A) until total length becomes about 230 mm (9.06 in) as shown, as OFM (OOS IA) ‘A: Upper side (small diam.) B: Lower sie large clam.) Fig. 30-23 2)Mate spring end with stepped part of lower seat as shown, 4. Stat lover seat Fig. 30-24 3) Install bump stopper onto strut rod, For i stalling direction, refer to the figure at the left. 4)Pull strut rod as far up as possible and use care not to allow it to retract into strut. 5) Install spring seat, bearing spacer and strut cover to spring upper seat and then install strut bracket its center aligned with ‘A”" mark on spring upper seat,3D.6 FRONT SUSPENSION 1. Spring upser seat 2. Strut bracket ‘A: Mark out) Fig. 30-25, 40 — 60 Nem 2 4 (40-6. emi (290-4300 1, Strut nut 10. Bearing lower washer 2) Lock wather ‘Leaving spacer 3. Strut topper 12, Coll spring upper se ‘4 Strut support comp. 13. Col spring saat 5. Inner sacer 14, Gump stopper 8. Gearing seat 46, Stut cover 7. Bearing upper washer” 16, Coil spring 8. Besring 17, Strut 8. Boating seal Fig, 30-26 6) Wash bearing lower washer and install it. 7) Wash strut bearing and apply grease., Insta it on bearing lower washer. 8) Wash bearing upper washer and install it. 9) Install bearing seal, bearing seat, stru support, inner spacer, washer and strut nu in this sequence Be careful for installing directions. Tighten strut nut to specified torque an then apply water-proof coating (paint 0 lacquer) all around nut and strut rod thread, 10) Loosen and remove special tool (A) com pressing coil spring. While loosening specie tool, recheck that stepped part of spring sea and spring end are in place to each other a described in foregoing Step 2). 11) Install. strut to car body. Refer to STRU’ DAMPER INSTALLATION of this section. Fig, 327FRONT SUSPENSION 30-7 3. REMOVE AND INSTALL WHEEL HUB, WHEEL STUD/WHEEL BEARING OUTSIDE INNER RACE REMOVAL +) Hoist car and remove wheel 2) Uncalk drive shaft nut ‘S)Depress foot brake pedal and hold it there. Remove drive shaft nut. 4) Remove caliper carrier bolts. 4, Drive safe nut Fig 33-4 5)Remove caliper with carrier. 5) Remove disc screws. 7) Pull brake disc off by using two 8 mm bolts. Fig. 3032 8) Pull out wheel hub with special tools (B) and to. (Brake drum remover tooes-17511) (ci: Siding hammer f09902-18510) © Fig. 30-33 9) Remove hub bolts. 1. Hammar 2 Hub bole Fig. 303-4 10} Remove whee! bearing inner race,30:8 FRONT/SUSPENSION INSTALLATION Install Hub Bolts Insert new stud in hub hole. Rotate stud slowly to assure serrations are aligned with those made by original bolt, 4. Oil hydraulic pres 2. Roa 3. Hub bolt Fig, 336 1) Install outside inner race to wheel hub using special tool (G). Installing direction is as shown, 1. Outside innar race 2 Wheel ub (G): Bearing instar logo40.sst11) Fig. 337 2) Apply grease to outside bearing, outside inner race and oil seal lip. ie at ‘utsce bearing Oitseat Outside inner race Fig. 3038 3) Install wheel! hub’ to knuckle’ by” tightenii drive shaft nut. Don’t tap wheel hub. Fig. 30-39 4) Install brake disc, 5) Install brake caliper/caliper cart 6) Tighten caliper carrier bolts to specifier torque. 7) Depress foot brake pedal and hold it there. Tighten drive shaft nut and brake disc screws to specified torque 8) Calk drive shaft nut as shown below. Calking drive shaft nut 15200 Nem (950 = 20.0 kgm) G—8Nm MOBS 1440 eth (06-03 kgm) 143 —6.51bH) 70-100 Nm (7.0 ~100 tam) (S10 7201) 1. caliper carer bo't 2. Brake oie era Fig, 30-3-10 9) Install wheel and lower hoist.FRONT SUSPENSION 30-9 4. REMOVE AND INSTALL SUSPENSION ARM/BUSHING REMOVAL +) Hoist car and remove wheel. 2) Remove ball stud bolt. 3) Remove suspension arm bracket nut. 4) Remove suspension arm bracket bolts. 5) Remove rear bracket and suspension arm. 6) Remove rear bushing with hydraulic press as shown. 1, Pres 2. Rea 3. Rear bushing Fig. 04-7 7) Cut off flange of front bushing as shwon in below figure “A” and then push out front bushing by using hydraulic press as shown in figure '8”. 1) Front bushing 2. Suspension arm 1. Prats 2) Front bushing 23. Suspension arm INSTALLATION 1) Install front bushing, Before installing bushing, apply soap water on its circumference to facilitate installation, 1, Press 2) Front Bushing 3. Suspansion atm When installed, bush should be equal on the right and left of arm as shown. fe a —| 1 eee 7 —|_- les 1, Front bushing 2. Suspension arm Fig. 3-46,30-10, FRONT SUSPENSION 2) Install rear bushing to susperision’ arm as follows. First, push in rear bushing in such direc- ttion and angle as shown in below figure “A"” and drive it into such position as shown in figure "8". ae 1. oar Bashing 2. Upper sie 5. Body canter side 4 Suspension arm Fig. 0-4-6 ‘5mm 1 fear busting 2 Suspension arm 3) Fit suspension arm bracket to suspension arm in such direction as shown in Fig. 3D-4-9 and hand-tighten bracket nut lightly and then install suspension arm bracket to car body. At this point, tighten bracket bolt only lightly by hand, 4) Install ball stud to knuckle, Align ball stud groove with knuckle bolt hole as shown in figure. Then drive in ball stud bolt from the direction as shown and install washer and nut. nO. ss 2 Ball stud Fig. 0-4-8 5) Install suspension arm rear bracket, 6) Tighten all bolts and nuts in figure to each specified torque. 7) Install wheel and lower hoist. 8) Check toe seating and adjust as required. FORWARD 4. Ball stud bolt a F 2 masse GG = + canoes a (ne + ee Tester ceed See ie sone IE Sheresesanaiont byREMOVAL, 1) Hoist car and remove wheel. 2) Remove wheel hub. Refer to Steps 2) — 8) in item 3 of WHEEL HUB REMOVAL of this section. 3) Disconnect tierod end from knuckle with special tool (H). FRONT SUSPENSION 30-11 5. REMOVE AND INSTALL KNUCKLE/BEARING INSTALLATION 1) Install knuckle to ball stud on suspension arm and strut bracket. Installing direction of each bolt is as shwon. Align knuckle bolt hole with ball stud groove as shown and install ball stud bolt, Tighten each nuts to specified torque. FORWARD 1. Knuekle 2 Ball sue 3. Suspension arm Fig. 305-1 4) Remove strut bracket bolts from strut bracket and then ball stud bolt. 1 Stewt 2. Bal stud 2 Knuckle {4 Stapension arm Remove knuckle. Fig. D3 2)Connect tie-rod end to knuckle and tighten tierod end castle nut to specified torque. Install split pin. N | \ Isa 4 Split pin, Fig. D4 3) For installation procedures following the ‘above, refer to Steps 1) — 9) in Item 3 WHEEL HUB INSTALLATION of this sec tion. For tightening torque, refer to next page.‘30-12 FRONT SUSPENSION (220-298 01) 2 0 . vette (70-90 tem! (S05 e800 Fig, 3055,REMOVE OIL SEALS, SNAP RING AND. ‘WHEEL BEARING ‘Orce bearing outer race is removed, bearing set seuter race, bearings and inner races) should be s=placed with new one, = Remove outside oil seal, snap ring outside bearing, inside oil seal and inside bearing in that order. (utsc o eal Shap ring Gutsce bearing Knuckle Inside bearing Tener rae (inside) Inside oi se BEE ™ Remove bearing outer race using special tool UW), and hydraulic press. (0 Bearing ietator f09913-755201 ALL OIL SEALS, SNAP RING AND. EL BEARING replacing bearing, inner race or outer race, ssure to replace them with new ones as a set. Fress-fit bearing outer race using special tools 1), (K) and (L). FRONT SUSPENSION 3D-13 Kerackle Bearing neal hance (03924-74810), Bearing & ol ea installer {osa44-6e2101 | Bearing installer support (oose4-78210), Fig. 30-58 ¢ After greasing (litchic grease) bearing outer race, bearings, inner race and oil seal lips, install them. Inside Oil Seal Drive in Oil seal until seal is flush with stopped surface of knuckle by using special tool (L). NTE: a Whan driving in il sea, be inside oil sel careful not to deform of 2 Knuckle 3. Ourside ol eat {itt oF otto caumdams (Susi al ge to rubber pert, Sera Fig. 3059 Outside Oil Seal Drive in oil seal until its end contacts snap ring using special tools W), (K) and (L). As for its installing direction, refer to Fig. 3D-5-10. 4. Outside oi es! (1: Bearing instlier hanale (09924-74510) (Bearing & ci sen Instr 09944-68210) (U): Bearing installer support (09844-76210) Fig. 305-1030-14 FRONT SUSPENSION 6. FRONT SUSPENSION INSPECTION STRUT DAMPER 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled. 2) Strut function check Check and adjust tire pressures as specified. Bounce car body three or four times continuously 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, note how many times cat 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 rebound on the right with those on the left. ‘And they must be eaual in both. With proper strut, car 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 damage or deformation. 4) Inspect bearing for wear, abnormal noise gripping. 5) Inspect for cracks or deformation in spri seat. 6) Inspect for deterioration of bump stopper. 7) Inspect rebound stopper and strut mount ‘wear, cracks or deformation. in Steps 2) Replace any parts found defe 7).FRONT SUSPENSION 30-15 SUSPENSION ARM/ARM BRACKET/ KNUCKLE ARM Inspect for cracks, deformation or damage. Fig. 3062 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 separat- a. ff there is any damage to either, control arm assembly must be replaced as a complete unit, cannot be separated Fig 3063 ‘SUSPENSION ARM BUSHING Inspect for damage, weer or deterioration. Fig. 306-4 WHEEL DISC, NUT & BEARING 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be relaced. 2) Check wheel nuts for tightness and, as necessary retighten them to specification Tighteningtoraue | Nm | kom | ibfe for wheel nuts [50-70 [50-7.0|36.5 608 3) Check wheel bearing for wear. When measuring thrust play, apply a dial gauge to wheel hub center after removing wheel center cap from wheel disc. Thrust play limit | 0.4 mm (0.016 in) When measurement exceeds limit, replace bearing 4) By rotating wheel actually, check wheel bearing for noise and smooth rotation. If defective, replace bearing, Fig. 30653D-16 FRONT SUSPENSION RECOMMENDED TORQUE SPECIFICATIONS Tightening torque Fastening parts iE, Nm kgm tbat 1. Strut bracket nut 70-90 7.0 =9.0 50.5 — 65.0 2, Strut nut 40-60 4.06.0 29.0 — 43.0 3. Strut support nut 21-33 21-33 | 155-235 4, Ball stud nut 50 —70 60-7.0 | 365-505 5, Suspension arm rear bracket bolt _30 55 30-55 22.0 -39.5 6. Suspension arm bracket bolt 100 @5-100 | 615-720 7. Bracket nut joo—150__| 100-150 | 725~-108.0 8, Drive shaft nut 150-200 | 150-200 | 1085-1440 9. Tie rod end castle nut 30 — 55 3.0 22.0 ~ 39.0 10, Wheel nut 50-70 36.5 — 50.5 Fig, DEE REQUIRED SERVICE MATERIALS RECOMMENDED AE SUZUKI PRODUCT USE SUZUKI SUPER GREASE Lithium grease (99000-25010) (A) | strut bearing Lithic wheel bearing grease (99000-25010) ‘SUZUKI SUPER GREASE (A) Wheel bearing, wheel bearing oil seal lipFRONT SUSPENSION 30-17 SPECIAL TOOLS 09940-71430 Spring compressor 09943-17911 Front wheel bub remover (Brake drum remover) 09924-74510 Bearing installer handle 09942.15510 Sliding hammer 09913.75520 Bearing installer | 09825-88210 Bearing puller attachment | 00913-65210 Tievrod end remover 0991361110 Bearing puller Oe | 09944-68210 | Bearing & oil seal installer 09944-78210 Bearing installer support 09900-06108 0994059111 Snap ring pliers Bearing installer (closing type) Fig. 0-67REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NoTE: ‘© All 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. 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 of this part. © Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage to the part may result. CONTENTS DIAGNOSIS... Br. ae Ge sessess Refer to SECTION 3 GENERAL DESCRIPTION .......0....0200008 ol eyoonl ee 3E- 2 ON-CAR SERVICE (Remove and Install) ......2--000e00eee ses ee este eeee este eeseee 3E- 3 Control Bods si... .seeeeenes sca eanta ite See Coil Spring and Suspension Arm Shins moe Seog Rear Strut Assembly 3E- § Rear Suspension Knuckle 3€-10 Wheel Bearing...... steer Pp ee, 3E13 REAR SUSPENSION INSPECTIO! -. 3E14 REAR WHEEL ALIGNMENT ...- coool es Matar - SE16 Toe Inspection and Adjustment ....--.6.es05 5 ‘ 3E-16 RECOMMENDED TORQUE SPECIFICATIONS . . .. . 36417 3E-18 REQUIRED SERVICE MATERIALS ......... 2... SPECIAL TOOLS...35-2) REAR SUSPENSION GENERAL DESCRIPTION The upper end of the strut is installed to the car body with @ rubber mount inbetween and its lower si to the rear knuckle, whose lower end is connected to the suspension arm through the rubber bush. Th is a coil spring between the suspension arm and car body. ‘Shown in the figure below are main components of the rear suspension. = strut Car body Coit sring Suspension arm rood ‘neko ‘Searing spacer Brake back pleteHoist car and remove wheel. Disconnect brake flexible hose from control 1. Control roa weEeira 3. Flexible nase © facilitate toe adjustment after reinstalla- ion, take following preparatory step before femoving control rod. Confirm which one of Snes stamped on washer is in the closest alignment with stamped line “A"" on car body ‘er putmatch marks. 1. Control rod 2. Gar body 3, Wither REAR SUSPENSION 3.3 c ON-CAR SERVICE (REMOVE AND INSTALL) 4) Remove control rod outside nut. §) Loosen Control rod inside nut (body center side). Hold inside bolt with another wrench to prevent it from turning as nut is turned. 6) Remove control rod inside bolt and control rod. Body comer side 4. Control rod = 2, Outside nut 3. Inside nut Fig. 36-4 INSTALLATION Install in reverse order of removal procedure, noting following items. 1)To determine installing direction of control rod, use installed position and shape of brake flexible hose mounting bracket welded on it, referring to Fig. 3E-5 which shows both control rods as installed. Leer aioe sive = FRONTSIDE > Sing REAR SIDE 1. Lae ile contol rod 2. Flight side control rod 3, Brake hose mounting bracket Fig. 653E.4 REAR SUSPENSION 2) Install control rod inside bolt with its cam “'B" faced down as shown below. Upper side t Fig. 366 3) Tighten control rod nuts (inside & outside) to such extent that they can be turned by hand, 4) Connect brake flexible hose to bracket securely. 1. Flexible hore 2. Exing 3, Control rod Fig. SET 5) Install wheel and tighten wheel nuts to specified torque (Refer to Fig. 3E-53). 6) Lower hoist. 7) Tighten control rod outside nut and inside nut to specified torque. It is the most desirable to have car off hoist ion when tightening NOTE: Tighten inside nut with line “A” stamped on body aligned with such line as confirmed befor removal or match marks aligned. 70~90.Nen (70-90 kam) (610-650 4) 70-90Nm (7.09.0 ko-m) (51.0 — 650 i0-4) 4. Contra! rod 2. Car body 3. Wlather 8) Check rear toe and ajust it as necessary. check and adjustment procedures, Refer to 3E-16.‘COIL SPRING AND SUSPENSION ARM REMOVAL ‘PP Hoist car and remove wheel. 2)To facilitate toe adjustment after reinstala- tion, confirm which one of lines stamped on washer is in the closest alignment with stamped line “A” on control rod inside mount part of car body or put match marks. Then remove control rod inside bolt (body center side). 1. Control rod 2) Inside nut | 3. Lock washer 4 Wether 5. Car body Fig 3E-9 3) Remove outside (wheel side) of contro! rod from rear knuckle stud bolt. 1, Knuekle stud bolt 2, Control rod Fig. E10, REAR SUSPENSION 3E5 4) Loosen rear mount nut of suspension arm. NOTE: But don’t remove bolt, 1. Suspension arm ‘ 2) Rear mount nut Fig, SEAT 5) Loosen front nut of suspension arm, Sy \ 2. Front nut Fig. E12 6) After loosening lower mount nut of knuckle, place jack under suspension arm to prevent it, from lowering suddenly and then remove lower mount nut of knuckle. 4. Kuekle 2. Lower mount nut Fig. 36-1336-6 REAR SUSPENSION 7) Raise jack placed under suspension arm a little and remove lower mount bolt of knuckle. 1. Lower mount bolt 2) Surpension arm 3, dace Fig. 3E-14 8) Move brake drum/brake 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 remove coil spring. 9) Remove suspension arm. To remove its front part, remove bracket bolts as shown in figure below. INSTALLATION 1) When installing front mount bush to suspension 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 regard to its vertical direction, referring to figure below. 3 Front bush Bracket Body outside Boay inside ‘Upper sige Lower sige“BP Fighten front mounting bracket bolts to spe- "sified torque. Tighten rear and front mount: mg nuts to such extent that they can be turn: ed by hand. Check to make sure that front mounting washer is installed in proper direc: tion referring to figure below. 25 55.Nm (38-65 kom) (25.5 — 39.5 ibe) 1. Front mounting bracket 2. Mounting 3. Wiethor 3) Place jack under suspension arm. 4) Install coil spring on spring seat of suspension arm and then raise suspension arm. _ NOTE: When seating coil spring, mate spring end with stepped part of suspension arm spring seat as shown. 1, Suspension arm 2. Stepped part 3 3. Spring and Fig, 3-19 REAR SUSPENSION 3E-7 5) Install lower mount bolt of knuckle and torque nut to specification. 1. Knuekle 2. Lower mount aut [3 Suspension arm 40-60 Nm '40—s04gm) 2 290 4301041 Fig. E20, 6) Remove jack from under suspension arm. 7} Install both inside and outside of control rod. When installing its inside bolt, refer to Control Rod INSTALLATION 2) on p. 3E-4, 8) Install wheel and tighten wheel nuts to specified torque. (Refer to Fig. 3E-53) 9) Lower hoist, 10) Tighten control rod outside nut and inside nut to specified torque. When tightening them, it is the most desirable to have car off hoist and in non-loaded state, Also, when tightening inside nut, align line “A” stamped on body with such stamped line ‘on washer as confirmed before removal or align match marks if marked, 1. conwal ied 2. Carbody 3 Washer Fig. SE-213E.8 REAR SUSPENSION { } 70—80.Nn (79-909) (61.0 - 65.0 lot) Fig. 3-22 11) Tighten suspension arm front nut and rear nut to specified torque. It is desirable to have car off hoist and in non-loaded state when tightening them. es) 1 40—80.Nm (49-60 kom) (29.9 — 430 fet) 50-70 Nem (S.0-7.0 kon) 4. Front ut (95 — 50.5 Ib) 2 Rear nut Fig. 36-23 12) After tightening suspension arm front nut, check to make sure that washer as shown below is not tilted. 1, Frontnut 2. Washer Fig. 3E-23-1 13) Check rear toe and adjust it as necessary. For check and adjustment procedures, refer to p. 3E-16, REAR STRUT ASSEMBLY REMOVAL 1) Hoist car and remove wheel. 2)Place jack under suspension arm so that it will be supported when it lowers. 3) Remove strut support nuts and push down strut fully as arrow shows in figure below. \ 1, Stat 2. Support nut 3, Path Fig. 3-28 4) Remove strut lower mount bolt. 4, srut 2. Knuckle 3. Mount bolt5)Remove strut from knuckle by pulling it up from upper side of knuckle, Make strut as short as possible for removal. If it is hart to remove it, open slit of knuckle 2 little by inserting a wedge as shown. CAUTION: Do not open slit wider than necessary. WARNING: Do not lower jack more than necessary for strut removal, for coil spring may come off, or so much as to make brake flexible hose stretch. 1. seut 2. Krk 5. wedge Fig. E26 e Fig. SED REAR SUSPENSION 369 INSTALLATION 1), Make strut short by pushing it. Fig. 36-28 2) Install strut to knuckle, Bring projection “A” on strut against slit of knuckle and push strut inte knuckle till upper end of knuckle contacts "“B’ on strut as shown in figure below. S) < snes 1, Strut ao es Fig. 3E-29 3) Tighten strut lower mount bolt to specified torque. SF 60 “FoNm 2 (50~7.0kgm) (365 —s05ib") 1, Strut 2) Lower mount bolt Fig. 3-306-10 REAR SUSPENSION 4) With strut extended fully, install upper part of strut to car body and tighten support nuts to specified torque. If upper part of strut does not reach car body, raise jack under suspension arm a little, (28-38 Kom) (208 27.0 Ib) Fig. 36-31 5) Remove jack from under suspension arm. 6) Tighten wheel nuts to specified torque (Refer to Fig. 3-53) 7) Lower hoist. REAR SUSPENSION KNUCKLE REMOVAL 1)Perform Steps 1) to 7) of brake drum RE- MOVAL on page 5-35. 2) Disconnect brake hose bracket from knuckle. 2) Brake hose bracket Fig. 36-32 3) Disconnect brake pipe from wheel cylinder and put wheel cylinder breather plug cap onto pipe to prevent fluid from spilling. 1. rake pipe 2, wheel cylinder 2. Beaather plug Fig, 3-33 4) Remove brake back plate from knuckle. 1. eck pate = 2, Plate bolt Fig. 3E-34 5) Place jack under suspension arm so as to pre: vent it from lowering. 6) 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 guide in reinstallation. Refer to SUSPENSION ARM REMOVAL 2) on p. 3E-5 for details. 7) Remove outside (wheel side) of control rod from rear knuckle stud bolt. Fig. 36-358) Remove strut lower mount bolt. Fe ES 9) Remove knuckle lower mount bolt. 1. Knuckle lowar mount bott 2. dock WDisconnect knuckle from suspension arm ‘and remove knuckle from strut, If it is hard to remove knuckle from strut, open slit of knuckle a little by inserting ‘wedge there as shown below. CAUTION: Don't open slit wider than necessary. |EAR SUSPENSION 3E- Fig, 3-38 INSTALLATION 1) Install knuckle to strut, Bring projection “A” on strut against slit of knuckle and push strut into knuckle till upper end of knuckle contacts "B’ on strut as shown in figure below, 2 Keke Fig, E39, 2) Install strut lower mount bolt. 3) Install lower mount part of knuckle to suspension arm. Ya Kwek 2, Suspension arm3E-12 REAR SUSPENSION 4) Tighten strut lower mount bolt to specified torque. For torque data, refer to Fig. 3E-41. 5) Remove jack from under suspension arm. 6) Torque lower mount nut of knuckle to specification. 2 50—70Nm (o-7.0%9) Py (365-505 ib) 40-60 ‘mount nut (40 -6.0 kom) 2. Strut loner (29.0 ~ 43.0 bt) mount aut Fig. 36-41 7) Apply water tight sealant to mating surfaces of brake back plate and rear knuckle. a> < Gi 5 Sif Zh ps d 1, Apply water tight slant (SEALING COMPOUND 9886), (99000-31090) (38-23 kom) (35-2004 Fig. 3-43 9) Install brake hose bracket to knuckle. 10) Tighten brake pipe flare nut to specif torque and. install breather plug cap tal off from pipe back to breather plug. (4-18 kp) (ios 120 4a — 1, Flore nut 2) Breather plug 2. Hore bracket 11) Install brake drum (Refer to Steps 1) to, of its INSTALLATION on p, 5-37 of manual), 12) Install control, rod, and control rod. inside & outside) and tighten them to extent that they can be turned by hand. 13) Fill reservoir with brake fluid and brake system, (For bleeding operation, p. 5-19.) 14) Upon completion of all jobs, depress bi pedal with about 30 kg (66 Ibs) load to five times so as to obtain proper drui shoe clearance.OO REAR SUSPENSION 36-33 5) Tighten parking brake lever cover screws. 16) Install wheel and tighten wheel nuts to specified torque. (Refer to Fig. 3E-53.) £7) Check to ensure that brake drum is free from dragging and proper braking is obtained, 78) Lower hoist. 39) Tighten outside and inside nuts of contro! rod to specified torque. When tightening inside nut, refer to CONTROL ROD IN- STALLATION 7) on p. 3E-4. Then check toe. 20) Perform brake test (foot brake and parking brake). 21) Check each installed part for fluid leakage. WHEEL BEARING REMOVAL 1) Perform Steps 1) to 7) of brake drum RE- MOVAL on p. 5-36. 2) Remove wheel bearing. Fis. 3-45 Removing INSTALLATION 1) Install bearing, When installing bearings: © Refer to Fig. 3E-46-1. for installing direction of spacer. © Direct both inner be ing sealed side outward. © Fill space indicated by “A” in figure with bearing grease as much as 40% of space capacity. ig and outer bear- 1. Specta too! {Geacng installer) (o981376010) Fig, 3-46 Fitting 1. Brake drum 2) Wheel bearing 3. Saad sce 4, Spacer 2) Install brake drum and wheel. (Refer to Steps 1) to 11) of BRAKE DRUM INSTALLA. TION on p. 5-37).3E-14 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 it can not be disassembled. SUSPENSION CONTROL ARM, COIL SPRING AND KNUCKLE ARI © Inspect for cracks, deformation or damage. © Inspect bushing for damage, wear or breakage. ee 2) Strut function check Check and adjust tire pressures as specified. Bounce car body three or four times continuously 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 rebound 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 or two small rebounds. If struts are suspected, ‘compare them with known good car or strut. 3) Inspect for damage or deformation. 4) Inspect for abnormal noise. 5) Inspect for cracks or deformation in spring seat. 6) Inspect for deterioration of bump stopper. 7) Inspect strut mount for wear, cracks or de formation. Replace any parts found defective in Steps 2) — 7. Fig. 36-47-1 Replace any defective part, CONTROL ROD Inspect for cracks, deformation or damage. '* Inspect bushings for wear and breakage. Fig, SEAPZ Replace any defective part,SUSPENSION FASTENERS Sch bolt and nut fastening suspension 4S tightness. Tighten loose one, if any, to torque, referring to Fig. 3E-53 of this L DISC, NUT & BEARING +t each wheel disc for dents, distortion ‘cracks. A disc in badly damaged condi. must be replaced. ‘Gheck wheel hub nuts for tightness and, as ‘Secessary, retighten to specification (Refer to Fis. 36-53). ‘wheel bearings for wear. When measur- ‘Pe thrust play, apply @ dial gauge to spindle ‘ep center. Treust play limit | Rear | 0.3 mm (0.012 in) measurement exceeds limit, replace bear- * By rotating wheel actually, check whee! bearing for noise and smooth rotation. If it is defective, replace bearing. Fig, 36-493E-16 REAR SUSPENSION ‘Among factors for rear wheel alignment, only ‘toe setting can be adjusted. Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision, whether ‘the damage is in body or 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 ""B" as shown in Fig. 3E-50 and therefore is given in mm (in.). FORWARD “A Reo. 8 WHEEL TOEIN TOP VIEW Fig. 3650 TOE INSPECTION AND ADJUSTMENT Preparation for toe inspection and adjustment © Place car in non-loaded state on level floor. ‘© Set steering wheel in straight state. © Check that inflation pressure of each tire is adjusted properly and disc wheel is free from deflection. © Check that each suspension part is free from bend, dent, wear or damage in any other form. ‘© Check that ground clearance at the right and left is just about the same. INSPECTION Measure toe with toe-in gauge. Toe should be within following speci REAR WHEEL ALIGNMENT 242mm (0.079+ 0.079 in, Toe-in Fig. £57 When checked with side slip tester, side-sii should satisfy following specification. 2+ 3mm/m (0.079 0.118 inv3 ft) Side slip If toe-in or side slip is out of above correspond ing specification, adjust toe properly. ADJUSTMENT 1) Loosen right and left control rod inside nuts. 2) Adjust toe to satisfy specification by tun right and left control rod inside bolts (car boits) by the same amount. 3) After adjustment, tighten right and left insid nuts to specified torque while holding care bolt with another wrench to prevent it fro turning. 70-90 Nm (7.0-9.0kem) ($1.0 ~ 65.0 Io) 4 1. Inside aut 2. Inside bot (eam bolt 3. Control rodRECOMMENDED TORQUE SPECIFICATIONS REAR SUSPENSION 36.37 Fastening parts Tightening torque Nam kgm tb-ft 70-90 70-90 | 510-650 jon arm mounting bracket bolt 35 55 35-55 | 255-395 ‘Suspension arm front nut 50-70 50-70 | 365-505 Tear nut peso er ese oe 4060 40-60 | 290-430 Kouckle arm lower mount nut p Strut support nut 28-38 28-38 | 206-270 ‘Swut upper nut 40-60 40-60 | 290-430 Strut lower mount bolt 50-70 60-70 | 365-605 Rear axle nut g0-120 | 60-120 | 580-865 Wheel nut -70 5.0-7.0 36.5 — 50.53E-18 REAR SUSPENSION REQUIRED SERVICE MATERIALS RECOMMENDED ties Bea SUZUKI PRODUCT il Brake fluid DOT 3 or SAE J1703 Brake reservoir tank Water tight sealant SEALING COMPOUND 366E (39000-31090) Joint seam of knuckle and brake back plate SPECIAL TOOLS 09943-17911 Brake drum remover SS 09942-15510 Sliding hammer 09913-76010 Rear wheel bearing installerWHEELS AND TIRES 36.1 SECTION 3F WHEELS AND TIRES e: wheel fasteners are important attaching parts in that they could affect the performance of vital parts system, and/or could result in major repair expense, They must be replacad with one of the same part ‘or with an equivalent part if replacement becomes necessary. Do not use a replacement part of quality or substitute design. Torque values must be used as specified during reassembly to assure retention of all parts. isto be no welding as it’ may resutt in extensive damage and weakening of the metal. ‘Ss ‘car is equipped with 155/70R13. tire is of tubeless type. The tire is design- % operate satisfactorily with loads up to full rated load capacity when inflated to recommended inflation pressures, t tire pressures and driving habits have an ant influence on tire life, Heavy corner- excessively rapid acceleration, and unneses: sharp braking increase tire wear. CONTENTS NOSIS... 6... We eT Tire Rotation: 80.6000 0. ceebeee ee SP ERAL DESCRIPTION ........... 3F-1 ON CAR SERVICE 2 eee Se eee AS . 2. FA Service Operations . " 3F4 Wheels 3F1 Metric lug nuts and wheel studs 3F-4 Replacement Tires ..... 3F1 Wheel Removal... 22... cee sees SFA Feplacement Wheels... 3F-2 Tire mounting and demounting .... 3F-5 TENANCE AND MINOR Tire repair Les svabes. OOBRS ISTMENTS ... 132 Balancing Wheels ......2... 0000.0. SE-B Wheel Maintenance................ 3-2 General balance procedures . 3F6 Wheel attaching studs. 0.0.20... 3F-2 Off-car balancing 3F-6 Matched tires and wheels . . a+ OF3. On-car balancing... + 3F-6 Inflation of tires... - 3F3 TORQUE SPECIFICATION , - FS Tire placard 3F3 GENERAL DESCRIPTION WHEELS Standard equipment wheel is the following steel wheel. 13 x ad 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 originally2-2 WHEELS AND TIRES on the car. Use of any other size or type tire may affect ride, handling, speedometer/odometer calibration, car ground clearance and tire or snow chain clearance to the body and chassi WARNING: Do not mix different types of tires on the same car such as radial, bias and bias-belted ‘tires except in emergencies, because handl- ay be seriously affected and may result in loss of control. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with the tire having the most tread, to equalize braking trac- tion. The metric term for tire inflation pressure is the kilopascal (kPa). Tire pressures is usually printed in both kPa and psi on the Tire Placard. Metric tire gages are available from tool suppliers. The chart in Fig. 3F-1 converts commonly used inflation pressures from kPa to psi kPa kgf/cm? psi 160 16 28 180 18 26 200 2.0 29 220 22 32 240 24 35 260 26 38 280 28 a 300 | 3.0 44 Fig. 3F-1. Tire Pressure Conversion Chort REPLACEMENT WHEELS Wheels must be replaced if they are ben! dented, have excessive lateral or radial runout ir leak through welds, have elongated b holes, if lug nuts won't stay tight, or if they ar heavily rusted. Wheels with greater runout th shown in Fig. 3F-2 may cause objectional vib tions. Replacement wheels must be equivalent to original equipment wheels in ,load capaci diameter, rim width, offset and mounting figuration. A wheel of improper size or ty may affect whee! and bearing life, brake cooli speedometer/odometer calibration, car grou clearance and tire clearance to body and chassis. Lint 1.40 mm [0.085 in) i) “TOTAL INDICATOR READING IGNORE INDICATOR "JUMPS" DUE TO WELD SEAMS, PAINT. RUNS, SCRATCHES, ETC, Fig. GF-2 Wheel Runout MAINTENANCE AND MINOR ADJUSTMENTS WHEEL MAINTENANCE Wheel repairs that use welding, heating, or pee ing are not approved. All| damaged wheels shou! be replaced. WHEEL ATTACHING STUDS / If a broken stud is found, see Section 3E (rear) ‘or Section 3D {front} for Note and Replacement procedure. /ED TIRES AND WHEELS. and wheels ate matchmounted at the fy plant. This means that the radially part of the tire, or “high spot”, is matched smallest radius or “low spot’‘of the wheel. is done to provide the smoothest possible high spot’ of the tire is originally marked peint dot on the outboard sidewall, This dot will eventually wash off the tire, “low spot” of the wheel is originally marked gaint dot on the wheel rim-flange. Properly led, the wheel rims’ paint dot should be with the tres’ paint dot as shown in 3F3. fer a tire is dismounted from its wheel, it |d be remounted so that the tire and wheel matched. If the tire’s paint dot cannot be a line should be scribed on the tire and before dismounting to assure that it is inted in the same position. © 3F-3 Matched Tires and Wheels INFLATION OF TIRES ‘The pressure recommended for any model is carefully calculated to give a satisfactory ride, bility, steering, tread: wear, tire life and resistance to bruises. WHEELS AND TIRES 35.3. Tire pressure, with tires cold, (after car has set for three hours or more, or driven less than one mile) should be checked monthly or before any extended trip, Set to the specifications on the @ placard located on the left door {right door for right-hand side steering car} lock pillar. It is normal for tire pressure to increase to 28 kPa (4 psi) when the tires become hot during driving, Do not bleed or reduce tire pressure after driving, Bleeding reduces the “Cold Inflation Pressure” Higher than recommended pressure can cause: 1, Hard ride 2, Tire bruising or carcass damage 3, Rapid tread wear at center of tire Lower than recommended pressure can cause: 1, Tire squeal on turns 2. Hard Steering 3, Rapid and uneven wear on the edges of the tread 4, Tire rim bruises and rupture 5, Tire cord breakage 6. High tire temperature 7. Reduced handling 8. High fuel consumption Unequal pressure on same axle can cause: 1. Uneven braking 2. Steering lead 3. Reduced handling 4, Swerve on acceleration Valve caps should be on the valves to keep dust and water out. TIRE PLACARD The tire placard is located on the left door (right door for right-hand side steering car) lock pillar and should be referred to for tire informa: tion. The placard lists the maximum load, tire size and cold tire pressure where applicable. NOTE: Whether rim size and/or maximum load are listed or not depends on regulations of each country.3F-4 WHEELS AND TIRES TIRE ROTATION To equalize wear, rotate tires according to Fig. 3F-4. Radial tires should be rotated at the first 10,000. km. (6,000 miles) and after that, tire rotation at least every 10,000 km is recommended. Set tire pressure, NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly in front positions. This makes regular rotation especially 1. Front tres necessary. 2, Roar res I Fig. 34 Tire Rotation ON-CAR SERVICE SERVICE OPERATIONS METRIC LUG NUTS AND WHEEL STUDS All models use metric lug nuts and wheel studs, Size:M12 x 1.25 oF Fig. 3F-5 Metric Stud and Nut WHEEL REMOVAL 1) Loosen. wheel nuts by approximately 1 {half a rotation), 2) Hoist car. 3) Remove wheel. 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 brake drum or disc, Fig, 3F-7. 50-70 Nn (60-70 kp) (36.5 ~ 505 tote) Fig. 3F-7 Wheel Nut Tightening Sequenceinstalling wheels, remove any build-up of jon on wheel mounting surface and brake or disc mounting surface by scraping and brushing. Installing wheels. without good to-metal contact at mounting surfaces can wheel nuts to loosen, which can later a wheel to come off while car is moving, TIRE MOUNTING AND DEMOUNTING ‘Ge attire changing machine to mount or demount ‘Sees. Follow equipement manufacturer's instruc: Sens. Do not use hand tools or tire irons alone % change tires as they may damage tire beads or shee! rim. im bead seats should be cleaned with a wire rush or coarse steel wool to remove lubricants, ‘ld rubber and light rust. Before mounting or emounting a tire, bead area should be well lubricated with approved tire lubricant. After mounting, inflate to specified pressure shown on tire pracard so that beads are completely seated. WARNING: | Do nat stand over tire when inflating. Bead | may break when bead snaps over rim’s safety hump and cause serious personal injury. Do not exceed specified pressure when inflating. If specified pressure will not seat beads, deflate, redubricate and reinflate. Over inflation may cause bead to break and cause serious personal injury. Install valve core and inflate to prager pressure. TIRE REPAIR There are many different materials and techni- ques on the market to repair tires. As not all of these work on all typesof tires, tire manufacturers have published detailed instructions on how and when to repair tires. These instructions can be ‘obtained from each tire manufacturer. WHEELS AND TIRES 36:5 BALANCING WHEELS There are two types of wheel and tire balance: static and dynamic. Static balance, Fig. 3F-8, is the equal distribution of weight around the Wheel. Wheels that’ are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear. Dynamic balance, Fig. 3F-9, is the equal distribution of weight on each side of the wheel centerline so that when the tire spins there is no tendency for the assembly to move from side to side. Wheels that are dynamically unbalanced may cause shimmy. » ADD BALANCE WEIGWTS HERE Lo OF SPINDLE heavY stor: WHEEL TRAMP CORRECTIVE WEIGHTS Fig. 3F-8 Static Unbalance Correction ‘ADO BALANCE WEIGHTS HERE ci OF SPINDLE HEAVY spoT. WHEEL SHIMMY CORRECTIVE WeIGHTs Fig. 3F-9 Dynamic Unbalance Correction3F-6 WHEELS AND TIRES GENERAL BALANCE PROCEDURES Deposits of mud, etc. must be cleaned from inside of rim. WARNING: Stones sholild be removed from the tread, in order to avoid operator injury during spin balancing and to obtain good balance. Eech tire should be ifspected for any damage, then balanced according to equipment manufacturer's recommendation. OFF-CAR BALANCING Most electronic off-car balancers are more accurate than the on-car spin balancers, They are easy to use and give a dynamic (two plane) balance, Although they do not correct for drum or disc unbalance as does on-car spin blanc: ing, this is overcome by their accuracy, usually to within 1/8 ounce. ON-CAR BALANCING On-car balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufacturer's instructions during balancing operation. WARNING: Wheel spin should be limited to 35 mph (55. km/h) as: indicated on speedometer. This limit is necessary because speedometer only indicates one-half of actual wheel speed when one drive wheel is spinning ‘and the other drive wheel is stopped. Unless care is taken in limiting drive wheel spin, spinning wheel can reach excessive speeds. This can result in possible tire disintegration or differential failure, which could cause serious personal injury or extensive car damage. RECOMMENDED TORQUE SPECIFICATIONS Wheel nuts: 60 — 70 N-m (5,0 ~7,0 kg-m, 36.5 — 50.5 lb-ft) Fig. 3F-10 :FRONT DRIVE SHAFT 41 SECTION 4 FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ...... 44 REMOVAL DISASSEMBLY .. REASSEMBLY .. INSTALLATION oe Kiya tne RECOMMNEDED TORQUE SPECIFICATIONS 45 REQUIRED SERVICE MATERIALS ........... GENERAL DESCRIPTION A. constant velocity ball joint is used on the drive shaft can slide through the tripod joint in wheel side of front drive shaft and a constant the extension/contraction direction. velocity tripod joint on the differential side. The 1. Snap ring 2. Differential side joint asembly (Constant velocity tripod int) 3. Cwrelip 4 Different sce boot band 9, Whee! sige boot 5, Different sie boot 10. Whee! sds boot band 8, Boot bene 111, Whee side joint assembly 7. Grease boot so {Constant velocity ball joint) (atl 90 ram 32.02) 12, Bearing ol scat 8, Grease inboot sot (Bleck 70 gram/2.5 02) Fig. #1 Front Drive Shaft Assambly (LH)4:2 FRONT DRIVE SHAFT REMOVAL ON FLOOR 1, Remove wheel cap. 2. Undo caulking and remove drive shaft nut and washer. IR: Uni caulking Fig. 42 Removing Drive Shaft Mut ON LIFT 1, Drain transmission oil. 2. By using large size screwdrivers, pull out drive shaft joint s0 as to release snap ring fitting of joint spline et differential side. 1) Drive shat joine (LHD 2. serendrver Fig. 43 Detaching Snap Ring trom Differential 3. Remove ball stud bolt and nut, and then separate suspension arm from knuckle. 1. Knwekle 2 Ball ud bol and aut 3. Suspension arm Fig. 44 Detaching Suspension Arm from Knuckle 4, To remove drive shaft assembly, pull out in board joint from differential side and then wheel side joint from steering knuckle, CAUTION: To prevent breakage of boots, be careful not to bring them into contact with other parts, when removing drive shaft assembly. DISASSEMBLY 1, Remove tripod joint boot band, then take out tripod joint housing 1) Tripod joint housing Fig. 48 Removing Tripod Joint Housing2 Remove grease from shaft and take off circlip by using special tool, then pull out spider from shaft. CAUTION: To prevent needle bearing of joint from being decreased, do not wash it, if itis to Bearing Grelip ‘Spacia to! (Soap ring pliers 0990006107), “€6 Removing Tripod Joint Spider Remove boot band, then pull out differential side boot from shaft. 4 Undo boot bands of wheel side joint boot, then pull out boot through shaft. CAUTION: * Disassembly of wheal side joint is not allowed. If noise or damage exists in it, replace it as assembly. * Do not disassemble tripod joint spider. If any malcondition is found in it, place it as differential side joint assembly. FRONT DRIVE SHAFT 43 REASSEMBLY Judging from abnormality noted before dis assembly and what is found through visual check ‘of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly and od joint housing are washed thoroughly and air dried, and boots are cleaned with cloth, if ‘they are to be reused. 1. Apply grease to wheel side joint. Use black grease in tube included in wheel side boot set. . Install wheel side boot on shaft. 3. Fill up boot inside with grease and then fasten boot with bands. 4. Install differential side boot on shaft. Apply grease to tripod joint. Use yellow grease in tube included in differential side boot set or differential side joint assembly of spare parts. 5, Install tripod joint spider on shaft, facing its chamfered spline inward (wheel side), then fasten it with circlip. 6.Fill up differential side boot inside with grease, then install housing and join it with boot. 7, Fasten boot with bands. CAUTION: © To prevent any problem caused by washing solution, do not wash joint boots and tripod joint except its housing, Degreasing of those parts with cloth is allowed. © To ensure full performance of joint as designed, be sure to distinguish between ‘two types of grease in repair set and apply specified volume is each tube to respective joint, i.e. black grease (80 g tube) to wheel side joint and yellow one (130 g tube) to tripod joint. © Bend each boot band against forward rotation. © Do not squeeze or distort boot when fastening it with bands, Distorted boot caused by squeezing air may reduce its durability.4-4 FRONT DRIVE SHAFT Whee! side joint assembly Hide boot bord fide boot Boot band Ditforantia side boot Differential side boot band ‘Tripod jint spider Grtip “rigod joint housira Snap ring Block grease (about 70 grm/28 02) Yalow great (about 80 qramn/3.2 02) homered spline Forward rotation lame band ehis wey ngoer Sepueasene Fig, 47 Assombling Front Drive Shatt INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. ‘© Clean front wheel, bearing oil seal and) then apply grease. Replace it if required. 1. Front whoo! beating of al {apply Svauk! super gress & 98000-28010), 2. Suspansion am Fig, 48 Lubricating Oil Seal with Grease © Install wheel side joint to steering knui first and then tripod joint to differen Apply sealant to drain plug for manual mission. Fill trans ission with oil as specified. NOTE: - For automatic transmission, carry out full of fluid level check procedure i.e. ROOM 7! PERATURE LEVEL CHECK first, and NORMAL OPERATING — TEMPERATI LEVEL CHECK, referring to page 7B-46. ‘CAUTION: @ To avoid excessive expansion of boot consequential disconnection of joint boot, do not pull tripod joint housing. # Protect oil seals and boots from a damage, preventing them from unnect sary contact while installing drive shaft. © Do not hit joint boot with hammer. In- serting joint only by hands is allowed. ‘@ Make sure that differential side joint is inserted fully and its snap ring is seated as it was.FRONT ORIVE SHAFT 45 RECOMMENDED TORQUE SPECIFICATIONS Fastening portion Tightening torque Nem kgm Ib-ft wt | 25-30 25-30 18.5 — 21.5 Oil drain plug am | 18-23 18-23 13.5 - 16.5 Ol filler and level plug [wr] 26-54 36-54 25.0 — 39.0 Bail joint stud bolt and nut 50-70 50-70 | 365-505 Drive shaft nut 150-200 | 150-200 | 1085-1445 REQUIRED SERVICE MATERIALS MATERIAL, RECOMMENDED SUZUKI PRODUCT USE Lithium grease ‘SUZUKI SUPER GREASE A (99000-25010) Oil seal lips Sealant ‘SUZUK! BOND NO. 1215 (99000-31110) Oil drain plug for manual transmissionBRAKES 6-1 SECTION 5 BRAKES NOTE: Alll brake fasteners are important attaching parts in that they could affect the performance of vital parts ad systems, and/or could result in major repair expense. They must be replaced with one of same part ‘sumber or with an equi nt part if replacement becomes necessary. Do not use a replacement part of ‘essor quality or substitute design. Torque values must be used as specified during reassembly to assure Proper retention of all parts. There is to be no welding as it may rasult in extensive damage and weakening ‘of the metal, CONTENTS GENERAL DESCRIPTION 52 DISC BRAKE R&! 5.28 Disc Brake Caliper Assembly 5-3 1. Remove and Install Pad Drum Brake Assembly gehen BOB, (Shoe & Lining) ..... 212528 Master Cylinder Assembly ............5: 8 2, Remove and install Caliper Assembly... 5-29 Booster Assembly . 5 5-10 3. Remove and Install Caliper Inner Parts... 5-30 4, Remove and Install Disc . 5:32 DIAGNOSIS ae 513 Rond Testing Brakes... IIIIlig13. DISC BRAKE INSPECTION 5:33 Brake Fluid Leaks ....... ++:+)5-13 DRUM AND COMPONENTS R&I . 5:35 Substandard or Contaminated Brake 1, Remove end Install Brake Drum . 5:35 Fluid 2. Remove end Install Brake Shoe . 5:39 Brake Diagnosis Chart A 3. Remove and Install Wheel Cylinder’... . 5-40 Brake Diagnosis Chart 8 5:15 4, Remove and Install Brake Back Plate... _ 5.41 ON CAR SERVICE +ss:.5:16 BRAKE DRUM AND COMPONENTS Brake Pedal Free Height Adjustment ....5-16 INSPECTION ; cee BMS 2 Stop Light Switch Adjustment .........516 MASTER CYLINDER REPAIR. 155 3. Excessive Pedal Travel Check 516 1, Remove and Install Master Cylinder 4. Rear Brake Shoe Inspection B17 Resear 5-45 5. Brake Pedal Play Inspection see 517 2. Remove and Install Master Cylinder 6. Rear Drum Brake Shoe Adjustment BAT NSABK Dag ag 7. Master Cylinder Inspection 517 3, Disassemble and Assemble Master 8. Disc Inspection 518 Cylinder. 5-47 9. Pad Lining Inspection . 518 Be racks Grke inepsttion ard” MASTER CYLINDER INSPECTION ...... 5.48 Adjustment BRAKE BOOSTER REPAIR .............6-49 31. Flushing Brake Hydraulic System 12. Bleeding Brakes coe 13. Brake Hose and Pipe Inspection .. +621 14. Brake Fluid Level Inspection 5.21 BRAKE HOSE/PIPE R & | 2 522 1. Remove and Install Front Brake Hose/Pipe 6.22 2. Remove and Instali Rear Hose/Pipe 5:23 PARKING BRAKE LEVER/CABLE FR &! 5.24 1. Remove and Install Parking Brake Lever... ov BO 2. Remove and Install Parking Brake Cable 5:26 1. Remove and Install Booster ...... 2. Disassemble and Assemble Booster . . BRAKE BOOSTER INSPECTION AND ADJUSTMENT 5-66 RECOMMENDED TORQUE SPECIFICATIONS 5-60 REQUIRED SERVICE MATERIALS ...... 5-61 SPECIAL TOOLS 5-62GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is/developed in the master cylinder to actue’ pistons (two in front and four in rear). ‘The master cylinder is a tandem master cylinder. Three brake pipes are connected to the master cylind: and they make two independent circuits. One connects front right & rear left brakesand the other connec front left & rear right brakes. ‘The proportioning valve (P valve) is included in these circuits between the master cylinder arid rear wheel In this brake system, the disc brake type is used for the front wheel brake and @ drum brake type (leadiny trailing shoes) for the rear whee! brake. The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cab ‘and mechanical linkage system. The same brake shoes are used for both parking and foot brakes. Righthend steering car igh side 1 Slee aah \ i \ prot 3 e bao ® 3 1. rake bios d Taide 2! Master oyiner 3 Secondary sie nd seating cat 4 mary te ant Sie iy ont? (properoning| valve Foon Ss 8. Away int 7. Parking broke ever 2 ett Side Fig 51BRAKE CALIPER ASSEMBLY ERAL DESCRIPTION ‘caliper has'a single bore. Hydraulic force, created by applying force to the brake pedal, is Converted ‘the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper to move the piston outward and to move (slide) the caliper inward, resulting in a'clamping action on disc. This clamping action forces the pads (linings) against the dise, creating friction to stop the car. details, refer to OPERATION in the next page. E: ite parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo- ‘may result. If any component is removed or line disconnected, bleed the brake system. Replace in axle sets only. The torque values specified are for dry, unlubricated fasteners. Caliper pin bot 7. ise brake inner pas Boot 8. Disc brake outer pad Dise brake calioer 9. Brake caliper cariar (Oise eke evlinderl 10. Pad spring - Piston ssl 11. Bleeder plop Disc brake piston 12. Bleeder pl exp Cylinder boot 13. Caliper pin Fig, 52 Front Caliver Assembly5-4 BRAKES Caliper OPERATION Single piston floating caliper type The single piston floating caliper type brake is employed in this model. One cylinder and one piston are usefl for this type. (The cylinder is constructed as a monoblock 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 cylinder pressure, as shown in below figure, which pulls pad (2) against the disc and so brakes the wheel. @ om Caliper boa Brake dee (rotor), Fig. 53 The dise brake has no servo assistance as in drum braking, and it is necessary to increase the working pressure of the piston and pad. For this purpose, the wheel cylinder has a large bore, Even only a little change in clearance between the disc and pad has therefore a large influence on the brake pedal stroke. It is necessary to keep the clearance adjusted to the minimum at all times, by means of the piston (rubber) seal. Piston sal Piston ss! (ovinger (rubber sell Orlindor (Rubber sea LA) N Prston Hyaraulicpresure Hydraulic pressure "OFF "ON Clearance correction When oil pressure is applied to. the piston, piston moves forward. The rubber seal, whic exerts considerable pressure against the pisto moves with the cylinder. However, as a part the rubber seal has been fixed into a groove the cylinder, the shape of the rubber seal is dis torted toward internal end of the cylinder, shown in-above figure. When pressure is take off from the foot brake pedal and fluid pressu is released from the piston, a restoring force ‘generated at the seal and pushes the piston bac! As the pads wear away and the clearance be tween the disc and pads becomes larger, ti piston moves a larger distance. The seal then could change in shape further but, since the e of the seal is fixed into the groove in the cylit der, the distortion is limited to the same amount as previously described. The piston moves furthe to cover the distance of clearance. The piston returns by the same distance and the rubber seal recovers its shape as described above and thus the clearance between the disc and pads is maintained in adjustment.iM BRAKE ASSEMBLY ERAL DESCRIPTION drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is ‘tained appropriate at all times. For details, refer to OPERATION in the next page, TE: components included in repair kits to service this drum brake. Lubricate parts as specified. WARNING: If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque walues specified are for dry, unlubricated fasteners. 1, Brake beck plate 8. Shoe hold down in 2. Brake shoe 10. Peeking 3, Parking brake shoe lever 11. Parking Laver eatenar 4 Brakestut 42, Whee! eylinder 5 Quadrant spring 12, Bleeder plug exp 14, Rubber plug 15, Rubber plug55 BRAKES naaaeecamaan Rear Brake OPERATION With the general drum brake type, when the brake pedal is depressed, two pistons in the wheel cylinder force the brake shoes outward, restraining the turn of the drum. ‘The more the brake shoes get worn, the longer distance the pistons must move. As a result, the brake pedal travel (pedal-to-wall clearance) increases. Then the shoe clearance must be adjusted by the shoe adjusting screws. Thus periodical adjustment is required for the drum brake type in general, This rear brake is provided with a self-adjusting system which automatically adjusts the shoe-to: drum clearence (pedal-to-wall clearance) caused by such brake shoe wear. Clearance correction In each rear wheel cylinder, pistons, piston-cups, and a piston spring (1) are installed. When the brake pedal is depressed, fluid pressure is applied to the inside of the chamber on the pistons (2) and (3). Being actuated by this pressure, the piston (2) moves to the left (piston (3) moves to the right) in the following figure and presses the brake shoe against the brake drum, thus producing brake force. Brake shoe io Whee eytinder Fig 56 At this time, the distance the brake shoe mov is "B", that is, the distance that “A” (the end ¢ the long hole made in the brake shoes wel moves till it contacts the lever (1) which is fitte in the long hole. Lever (1) Whee! eylinder Fig, 67 When the brake pedal is depressed, the pist and brake shoe move toward the brake dru side by the aforementioned distance “B” 2 "4\"" of the brake shoe web contacts the lever ( ‘As the brake shoe gets worn and the brake sh clearance becomes larger, the force applied. the lever (1) at the time of such a contact becon larger. When it exceeds 10 — 12 kg (22 — 26 Ib the “A” of the brake shoe web moves the le (1) as much as the amount of the brake sh lining wear toward the direction as shown. an arrow in the figure. Thus the shoe is for against the drum and the brake force is produtance the lever (1) moves corresponds to ount of wear. In accordance with the lever ent, the fan-shaped, ratchet (2) also for they are assembled as a unit. The (1), and ratchet (2) remain in the positions moved until the shoe-to-drum clearance es even larger en the brake pedel is released, the brake shoe lowed to move back by the amount of ¢"B” by means of the return spring. In way, the brake shoe-to-drum clearance is ‘tically adjusted constant every time the pedal is depressed. brake shoe-to-drum clearance “B’" corre ds to 0.36 — 0.54 mm (0.014 — 0.021 in.) terms of the brake drum diameter A —> A’. ‘the amount adjusted by one notch of the et corresponds to 0.18 mm (0.007 in.) ‘terms of the brake drum diameter A — A’. spring provided in the wheel cylinder press the piston from moving back more than the cified brake shoe-to-drum clearance.58 BRAKES MASTER CYLINDER ASSEMBLY GENERAL DESCRIPTION eestor cylinder has two pistons and three piston cups. fs hydraulle pressure is produced in primary ("2"” in the below figure) and secondary ("b") chambers, The hydraulic pressure produced in Primary chamber ("a") acts on the right front whee! brake and left rear wheel brake (For right-hand vag ear, it acts on the left front wheel brake and right rear wheel brake). ‘Ako, the hydraulic pressure produced in the secondary chamber ("b"?) sets on the left front wheel bi and right rear wheel brake (For right-hand steering car, it acts on the right front wheel brake and left wheel brake). NOTE: Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts lean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rubt Components may result. If any hydraulic component is removed oF brake line disconnected, bleed # brake system, The torque values specified are for dry, unlubricated fasteners, Pieton stopper ellp Piston stopper Gylinder cup Prmary piston Piston cup Secondary piston pressure eu Paton cue ‘Secondary piston Secondery piston return sri Secondary piston stopper bel ‘Master evlinder body Primary piston Seondery piston Fig. 59 Master Cylinder OPERATION Normal operation Depressing the brake pedal forces the primary piston “A” to move to the left in the below figure consequently the hydraulic pressure is produced in the chamber ‘a By means of this pressure and the return spring force, the secondary piston 1g" is also pushed to the ‘and thus the hydraulic pressure is produced in the chamber “*b’ Fig. 510BRAKES 5.9 jrcuit operation (Primary chamber “a” circuit failure) wressing the brake pedal forces the primary piston “A” to move as described previously, but since the circuit connected to the chamber ‘‘a’” cannot hold the pressure, no, pressure is produced in the fluid diately ahead of the piston “A”. The piston “A” keeps moving while compressing the spring and it reaches the retainer, the piston “B” Is pushed and begins to move. This causes the pressure to rise the chamber “b” and the pressure acts on the left front wheel brake and right rear wheel brake, (For it hand steering car, it acts on the right front wheel brake and left rear wheel brake). Fig 517 ‘One-circuit operation (Secondary chamber “b" circuit failure) Jn this case, the leftward movement of the piston “A” has but little effect in causing the fluid pressure to ‘ise in the chamber a’ in the beginning, because the initial rise of the fluid pressure causes the piston “B”” ‘0 promptly yield and move to the left. However, when the forward end of the piston “B" comes to the bead of the cylinder and stops there, the leftward movement of the piston “A” becomes effective. Thus ‘the fluid pressure is produced in the chamber “a” and it acts on the right front wheel brake and left rear wheel brake (For right-hand steering car, it acts on the left front wheel brake and right rear wheel brake). The below figure shows secondary piston “8” at halt.5:10 BRAKES BOOSTER ASSEMBLY GENERAL DESCRIPTION The booster is located between the master cylinder and the brake pedal. It is so designed that the forcé created when the brake pedal is depressed is mechanically increased combined with the engine vacuum. The booster has a diaphragm of ¢ 155 mm (6 in.) effective diameter. Its operation is described in the fol: lowing pages. NOTE: ‘© Use all components included in repair kits to service this booster. Lubricate rubber parts, where indicat ed, with silicone grease provided in kits. The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is removed or brake line disconnected, bleed the brake system, © Never lubricate any hydraulic component with silicone grease. 1. Sooner No. 1 body 11. No. 2body oil sat 2! Booster pision retun spring 12. Air eleoner separotor 3. Rod retainer 13. Aireleaner element 4. Pinton rod. 14. Body boot 5. Raection dsc 15. Nut 5. Booste piston 18. Bracket 7. valve stopper 17. Bin 8. Booster air valve assembly 18, Push rad clevis 9. Diaphragm 19. split pin 10. Booster No, 2 body Fig. 513BRAKES 517 Booster OPERATION Booster No.1 body Booster No. 2 body Valve operating rod Air leaner element ‘ir cleaner separetor ‘i valve return spring Control vlve spring retainer Conte vive spring Booster contra valve ster claphragm 16. Booster piston return spring 17. Booster piston roe 1B. Booster fod adjust aerew Fig. 5-14 Vacuum Booster Assembly When the brake pedal is depressed, the force is transmitted to the piston of the master cylinder through the valve operating rod, booster air valve, reaction disc and piston rod. At the same time, the force of the booster piston developed due to the pressure difference between the two chambers “A” and “B” in the ebove figure is added to it. The end of the booster control valve has 2 double function of a vacuum valve and air valve. That is, as shown in the figure, the booster control valve closes between the “A’” and “B” chambers as its outer end "C" contacts the booster piston seat and opens as "Cleaves the booster piston seat (vacuum valve function). Also it closes between the “'B" chamber and outside air as its inner end "D" contacts the air valve seat and opens as "” leaves the air valve seat (air 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 air valve is also enough to the right to contact the valve stopper key as shown. In this state, the vacuum valve (control valve “C”) is open and the air valve (control valve “D”) is closed. Thus the chambers “A” and “B"” conduct and share the same negative pressure (because of no pressure difference) which allows the return spring to push the booster piston to the right. Airvalve 4. Booster control valve 2. Boorer air valve 3. Boorter piston Fig. 5-185:12 BRAKES When foot brake pedal is depressed Being pushed by the operating rod, the booster air valve moves to the left as shown. Then the control valve is pushed against the booster piston seat closely by the valve spring force. Thus the vacuum valve (control valve “C”) is closed to cut, off between the chambers “A” and “B”, At this time the air valve (control valve “D”) is still closed. (Control valve 1, Booster control valve 2! Booster ar vale 3. Booster piston As the booster air valve moves further to the left, it leaves the control valve and the air valve (control valve “D"') opens to allow the air to flow into the chamber “B”. The entry of air causes a difference 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 stops the air flow into the chamber B’ and its pressure remains as it is, In this way, 2 small brake pedal depressing force is made into @ strong push to the master cylinder push rod to produce high hydraulic pressure. eeuum vaive “c [ar vive 1. Booster contra valve 2! Bootersirunve 3. Booster piston When foot brake pedal is released When the brake pedal is released, the booster valve returns to the right by the master cylit piston return force and the air valve re spring force as shown. Then the vacuum vé (control valve “C”) opens and causes negat pressure in the chamber 8”. The result is ti the master cylinder piston and booster pist return’ to their original positions. This is same state as described under “When foot pedal is not depressed”. 4. Booster air val 2. Air valve return spring 53 Boost piston 4: Booster cantal vale Fig. 5-18 ; Reference Should any of the vacuum related parts in the booster be faulty, the brake force is not incre ‘ed. Even then, however, the brake depressing force is transmitted to the valve operating rod, booster air valve, valve stopper key and booster piston in that order, to push the master cylinder push rod, Thus, the braking operation itself will not fail Fig. 619— BRAKES 5:13 races 5:13 DIAGNOSIS. SOAD TESTING BRAKES Bakes should be tested on dry, clean, smooth Be reasonably level roadway which is not crown. & Road test brakes by making brake applica- fers with both light and heavy pedal forces at Sous speeds to determine if the car stops evenly ms effectively, Sse drive car to see if it leads to one side or ®= other without brake application. If it does, Beck the tire pressure, front énd alignment and Set suspension attachments for looseness, Siagnosis chart for other causes. E FLUID LEAKS the master cylinder fluid levels. While @ drop in reservoir, level does result from | lining wear, an abnormally low level in- a leak in the system. In such acase, check entire brake system for leakage. If even a evidence of leakage is noted, the cause be corrected or defective parts should laced, SUBSTANDARD OR CONTAMINATED BRAKE FLUID Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate. If primary piston cups are swollen, then rubber arts have deteriorated. This deterioration may also, be evidenced by swollen wheel cylinder piston cups on the drum brake wheels. If deterioration of rubber is evident, disassemble all hydraulic parts and wash with alcohol. Dry these parts with compressed air before assembly to keep alcohol out of the system. Replace all Tubber parts in the system, including hoses. Also, when working on the brake mechanisms, check for fluid on the linings. If excessive fluid is found, replace the linings. If master: cylinder piston seals are satisfactory, check for leakage or excessive heat conditions. If condition is not found, drain fluid, flush with brake fluid, refill and bleed system. The system must be flushed if there is any doubt 88 to the grade of fluid in the system or if fluid has been used which contained parts that have been subjected to contaminated fluid.5:14 BRAKES BRAKE DIAGNOSIS CHART A Condition Possible Cause Correction Not enough braking force 1. Brake oil leakage from brake lines. 2. Brake disc or pads stained with oil. 3. Overheated brakes. 4, Poor contact of shoes on brake drum. 5, Brake shoes linings stained with oil or wet with water. 6. Badly worn brake shoe linings. 7. Defective wheel cylinders. 8. Malfunctioning caliper assembly. 9. Air in system. Locate leaking point and re Clean or replace. Determine cause and repair: Repair for proper contact. Replace. Replace. Repair or replace. Repair or replace. Bleed system, Brake pull (Brakes not working in unison) 1. Shoe linings are wet with water or stained with oil in some brakes, 2. Drum-to-shoe clearance out of adjust ment in some brakes. (Malfunctioning auto adjusting mechanism). 3. Drum is out of round in some brakes. 4, Whee! tires are inflated unequally. 5. Malfunctioning wheel cylinders. 6. Disturbed front end alignment. 7. Unmatched tires on same axle, 8. Restricted brake tubes or hoses. 9. Malfunctioning caliper assembly. 10, Loose suspension parts. 11. Loose calipers. Replace. Check for inoperative auto adjusting mechanism. Replace. Inflate equally. Repair or replace. Adjust as prescribed, Tires with approximately the same amount of tread should be used on the same axle. Check for soft hoses and damaged lines. Replace with new hoses and new double-walled stee! brake tubing, Check for stuck or sluggish pistons and proper lubrice- tion of caliper slide bush. Caliper should slide. Check all suspension mount ings. Check and torque bolts to specifications. Noise (high pitched squeak without brake applied) 1. Front lining worn out. Replace Tinings.BRAKES 6-15, BRAKE DIAGNOSIS. CHART B Condition Possible Cause Correction Excessive pedal travel (Pedal stroke too large) 1 2 Partial brake system failure. Insufficient fluid in master cylinder reservoirs. . Air in system. (pedal soft/spongy). |. Rear brake system not adjusted (malfunctioning auto adjusting mecha: nism) Bent brake shoes. 5. Worn rear brake shoes. Check brake systems and repair as necessary. Fill reservoirs with approved brake fluid. Check for leaks and air in brake systems. Check warning light. Bleed system if required. Bleed system. Repair auto adjusting mechanism. Adjust rear brakes. Replace brake shoes. Replace brake shoes, Dragging brakes (A very ‘ght drag is present in ‘ail disc brakes immedi ‘ely after pedal is released) - Master cylinder pistons not returning correctly. Restricted brake tubes or hoses. Incorrect parking brake adjustment on rear brakes. |. Weakened or broken return springs in the brake. Sluggish parking-brake cables or linkage, Wheel cylinder or caliper piston sticking. Repair master cylinder. Check for soft hoses or damag- ‘ed tubes and replace with new hoses and/or new double-walled steel brake tubing. Check and adjust to correct specifications. Replace. Repair or replace, Repair as necessary. Pedal pulsation (Pedal pulsates when depressed for braking.) Damaged or loose wheel bearings. Distorted steering knuckle or rear wheel spindle. . Excessive disc lateral runout. . Parallelism not within specifications. 5. Rear drums out of round. Replace wheel bearings. Replace knuckle or rear wheel spindle, Check per instructions. If not within specifications, replace or machine the disc. Check per instructions. If not within specifications, replace or machine the dise. Check runout. Repair or replace drum as necessary. Braking noise Glazed shoe linings, or foreign matters stuck to linings. ). Worn or distorted shoe linings. . Loose front wheel bearings. Distorted backing plates or loose mounting bolts, Repair or replace shoe lining. Replace shoe lining (or pad). Replace wheel bearing. Replace or retighten securing bolts.en oe oe ee en qa oe 5.16 BRAKES 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 clutch pedal. For left-hand steering vehicle: Height of brake pedal is normal if it is about 8 mm (0.3 in.} lower than clutéh pedal. 1) When booster push rod clevis has been reinstalled, it is important that measurement between booster mounting surface and center of clevis pin hole is adjusted within 114.5 — 116.5 mm (4.51 ~ 4.54 in.). See page 5-55. 2)When stop light switch has been removed, refer to the following STOP LIGHT SWITCH AD- JUSTMENT for proper installation, Services in above steps 1) and 2) may affect brake pedal height. 2. STOP LIGHT SWITCH ADJUSTMENT Adjustment should be made as follows when installing switch, Pull up brake pedal toward you and while holding it there, adjust switch position so that clearance between. end of thread and brake pedel return cushion (shown as “A” in figure) is within 0.6 — 1.0 mm (0.02 ~ 0.04 in.). Then tighten lock nut to specified torque. 10~15 Nem (10-15 kgen) 5-105 be) Fig. 6:20 3. EXCESSIVE PEDAL TRAVEL CHECK 1) Start engine, 2) Depress brake pedal a few times. 3) With brake pedal depressed with approxima ly 30 kg (66 Ibs) load, measure pedal arm wall clearance “B". It mustn't be less t 60 mm (2.36 in.) Fig, 521 4) If clearance “B” is less than 60 mm (2,36 i the most possible cause is either rear bral shoes are worn out beyond limit or air is lines. Should clearance “B" remain less than 60 (2.36 in.) even after replacement of bri shoes and bleeding of system, other possi but infrequent cause is malfunction of ri brake shoe adjusters or booster push length out of adjustment for the vehicle brake booster. © See page 5-43 for brake shoe inspection. © See page 5-19 for bleeding brake system, © Remove brake drums for adjuster inspecti (See page 5-35.). If defective, correct replace.4 REAR BRAKE SHOE INSPECTION Jespection should be carried out on following points after brake pedal travel “B” (pedal arm ‘® wall clearance) check as described in. Item 3 ‘en page 5-16 of this section, even when it ismore ‘en 60 mm (2.36 in.). Amount of brake shoe wear can be checked as follows. ‘}) Hoist car and remove wheel, 2) Remove rubber plug from brake back plate. 28y using mirror and light, visually check brake shoe lining for thickness. If lining thickness “A” is found less than below specified wear limit, replace with new brake shoes. -. 1. Robber plug 2. Obiong hole 3 Brake shoo 4% Brake shoe rim Wear ime Lom (0.039 in) Fig 6.22 5. BRAKE PEDAL PLAY INSPECTION Pedal play should be within below specification. 4 out of specification, check stop light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defec- tv BRAKES 5:17 Ped play: 1 = 8 mm [0.04 0.32 ing Fig. 523 6. REAR DRUM BRAKE SHOE ADJUSTMENT Rear brake has self-adjusting mechanism but it does require adjustment for proper drum to shoe clearance when brake shoe has been replaced or brake drum has been removed for some other service. Adjustment is automatically accomplished by depressing brake pedal 3 to 5 times with approximately 30 kg (66 Ibs) load after all parts are installed. ‘Then check brake drum for dragging and brake system for proper performance, After lowering car from hoist, brake test should be performed. 7. MASTER CYLINDER INSPECTION Check for a cracked master cylinder casting or brake fluid around the master cylinder. Leaks are indicated. only if there is at least a drop of fluid. A damp condition is not abnormal. Fig. 5285:18 BRAKES 8. DISC INSPECTION Refer to page 5-34 of this section for inspection point and procedure. 9. PAD LINING INSPECTION Inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end (or hole) of caliper and check lining thickness of outside and inside pads. If lining is worn and its thickness (“Cin figure) is less than 3 mm (0.12 in.}, all pads must be replaced at the same time. 1, Pad rien 2) Die 3, Uning Fig. 525 10. PARKING BRAKE INSPECTION AND ADJUSTMENT 4) Inspection Hold center of parking brake lever grip and pull it up with 20 to 25 kg (44 to 85 Ibs) force. 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 left rear wheels are locked firmly. To count number of notches easily, listen to click sounds that ratchet makes while pulling Parking brake lever without pressing its button. One elick sound corresponds to one notch. A" Barking brake lover travel: 4a Snotcher [With 20 kao 44 Jo, of pull presure) Fig 526 If number of notches is out of specification, ad just cable by referring to adjustment procedure described on the following step b) so as te obtain specified parking brake stroke. NOTE: Check 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 air is trapped in brake system. Brake pedal travel is prope ¢ Brake pedal has been depressed a few timer with about 30 kg (66 Ibs) load. ‘© Parking brake lever has been pulled up a few times with about 20 kg force. ‘© Rear brake shoes are not worn beyond limit and self adjusting mechanism operates proper- yy. After confirming that above 5 conditions are all satisfied, adjust parking brake lever stroke by loosening or tightening self locking nut (3 is figure below). - NOTE: . Check brake drum for dragging after adjustment . Parking brake stroke; when lever is oulled up at 20 kg (44 Ibs) Within 4-9 notches1. Parking brake lever 21 Brake ea 2, Setting nut |. FLUSHING BRAKE HYDRAULIC SYSTEM 's recommended that entire hydraulic system ‘be thoroughly flushed with clean brake fluid whenever new parts are installed in hydraulic system. Periodical change of brake fluid is also recom: mended. 2. BLEEDING BRAKES TE: @ fluid is extremely damaging to paint. If should accidentally touch painted surface, ately wipe fluid from paint and clean surface. ing operation is necessary to remove air | split system. When a brake pipe or hose disconnected at the wheel, bleeding opera- must be performed at both ends of the line removed pipe or hose. When any joint ‘of the master cylinder or other joint part nthe master cylinder and each brake was removed, the hydraulic brake system ‘be bled at all 4 wheel brakes. NOTE: Perform bleeding operation starting with wheel cylinder farthest from master cylinder and then at front caliper of the same brake line, Do the same on the other brake line, Lefe wheat evlinder Left brake caliper 1 @ REAR FRONT a 2 Right whee! evlincor Fight brake caliper Fig, 6:28 1) Fill master eylinder reservoir with brake fluid and keep at least one-half full of fluid during bleeding operation. 2) Remove bleeder plug cap. Attach a vinyl tube to bleeder plug of wheel cylinder, and insert the other end into eon- sainer. See-trough tube 1. Plug cap 3. Container 2. Vinyl tube Fig. 5:295:20 BRAKES 3) Depress brake pedal several times, and then 5) Repeat this operation until there arenomo while holding it depressed, loosen bleeder plug air bubbles in hydraulic line. ‘about one-third to one-half turn. 6)When bubbles stop, depress and hold bral pedal and tighten bleeder plug. (For tightening torque specification of bleeder plug, see page 5-60.) 7) Then attach bleeder plug cap. Depress brake pedal several times and with pedal depresad,oorenbleeder plug ato. Fig, 5:30 4)When fluid pressure in the cylinder is almost Fig, 5:32 depleted, retighten bleeder plug. } 8) After completing bleeding operation, apply fluid pressure to pipe line and check f leakage. | 9) Replenish fluid into reservoir up to specified level. ; ‘ith brake peda depeesied, retightenbleeder plug Fig. 531 Fig. 6:33 ‘ ; 10) Check brake pedal for “sponginess". If found. spongy, repeat entire procedure of bleeding.BRAKES 521 BRAKE HOSE AND PIPE 14, BRAKE FLUID LEVEL INSPECTION INSPECTION Be sure to use partioular brake fluid either as in- brake hose assembly should be checked for dicated on reservoir cap of that car or recom- hazard damage, for cracks and chafing of mended in owner’s manual which comes along outer cover, for leaks and blisters. A light with that car. mirror may be needed for an adequate in- Use of any other fluid is strictly prohibited. on. If any of the above conditions are ob- Fluid level should be between MIN and MAX on the brake hose, it is necessary to re lines marked on reservoir. When warning light lights sometimes during driving, replenish fluid to MAX line, When fluid decreases quickly, inspect brake sys tem for leakage. Correct leaky points and then refill to specified level. the tube for damage, cracks, dents and 3 CAUTION: Do not use shock absorber fluid or any other fluid which contains mineral oil. Do Not 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 brake fluid will lower fluid boiling point. Keep all fluid containers capped to prevent conta nation.5.22 BRAKES BRAKE HOSE/PIPE R & | 4. REMOVE AND INSTALL FRONT BRAKE HOSE/PIPE 41) Raise and suitably support car. Remove tire and wheel. This operation is not necessary when removing pipes connecting master cylinder and P valve, 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe 3) Reverse brake hose installation procedure. For installation, make sure that steering wheel is in straightforward position and hose has no twist kink. Check to make sure that hose doesn’t contact any part of suspension, both in extreme right ‘extreme left turn conditions. If it does at any point, remove and correct. Fill and maintain brake fi level in reservoir. Bleed brake system. Right-hand st Upper side RIGHT soe <> Left-hand steering car nase, EE es ism ra nen el tesco ee fk a ee Tiwi wet | gaa a 20-25 Nm (20-25 kgm) (145-180 fee) Fig. 637 Front Brake Hose/Pipe R & 1BRAKES 523 REMOVE AND INSTALL REAR BRAKE HOSE/PIPE Raise and suitably support car. Remove tire and wheel. Clean dirt and foreign material from both hose end or pipe end fittings, Remove brake hose or pipe. Reverse brake hose 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 properly referring to figure below and tighten bolts. ‘* When installing hose, make sure that it has no twist or kink. lamp “6 clamp "c" To Pvalve FRONT. => Side ‘To remove brake pipe as indicated in figure, disconnect its front side at P valve and rear side at 4-way joint. Then, remove it toge- ‘ther with clamps from car body. For removal and reinstallation procedures from and to car body, refer to SECTION 6C ENGINE FUEL on p. 6C-4 Uae eey Upside weer go q ici Soe : Esa Soe vie ve fait inter Upside clamp ¢ Clamp” kerr RIGHT sive <> > swe Tightening torque [_Net lem mm forbrake are nut [Ta— 18 | 14-18 [FOB - 180 Fig, 6:38 Rear Brake Hose/Pipe R&T5:24 BRAKES PARKING BRAKE LEVER/CABLE R & I 1, REMOVE AND INSTALL PARKING BRAKE LEVER REMOVAL 1) Remove parking brake lever cover. 2) Disconnect lead wire of parking brake switch ‘at coupler. 3) Remove parking brake cable locking nut, 4) Remove parking brake lever bolts and then remove parking brake lever assembly from equalizer. 5) Remove equalizer from parking brake cable, NOTE: Don’t disassemble parking brake lever switch, It must be removed and installed as a complete switch assembly. 10-18 Nm 110-18 kgm) W511 bR) INSTALLATION 1) Install in reverse order of REMOVAL p cedure, 2) After all parts are installed, parking brake le needs to be adjusted. Refer to PARKIN BRAKE, INSPECTION AND ADJUSTME} in this section (page 5-18). 3) Check brake drum for dragging and brake s tem for proper performance. 1. Parking brake cable 2. Brake cable locking nut 3. Spacer 4. Equalizer 5. Fin 1. Parking brake lever bolt 7. Parking brake lever assyBRAKES 5:25 ‘2. REMOVE AND. INSTALL PARKING BRAKE CABLE REMOVAL ‘Remove brake drum: (Refer to steps 1) to 7) ‘of BRAKE DRUM REMOVAL of this section, page 5-35.) 2Disconnect parking brake cable from brake shoe lever.(Refer to steps 2) & 3) of BRAKE SHOE REMOVAL of this section, page 5-39.) 3) Disconnect brake cable from brake back plate, (Refer to step 4) of BRAKE BACK PLATE REMOVAL section, page 5-41.) NOTE: When it is necessary to remove both right and Jeft parking brake cables, repeat above steps 1) 03) on right and left wheels. 4)Remove cable from parking brake lever. (Refer to steps 1), 2) & 3) of PARKING BRAKE LEVER REMOVAL of this section, page 5-24.) INSTALLATION Install parts in reverse order of removal procedure, noting the following. 1) Install brake cable stopper ring to brake back plate securely as shown in figure below. 1, Brake backplate 2. Cable stopper ring ‘Brake cable Fig. 540 2) Install. brake cable spring and nipple end to parking brake shoe lever securely as shown below, FRONT, SIDE ne 1. Barking brake shoe lever 2. Spring 3. Nipple ena Fig. 5416:25 BRAKES. 3)For brake shoe installation, refer to steps 1) and 2) of BRAKE SHOE INSTALLATION of this section, page 5-39, 4) For brake drum installation, refer to steps 1) and 7) of BRAKE, DRUM INSTALLATION of this section, page 5:37, 5)For proper routing and secure clamping parking brake cable, refer to figure below. 6) For installation of cable to parking brake le refer to PARKING BRAKE LEVER INST! LATION of this section, page 5-24. 7) Upon completion of installation, adjust cal (Refer to PARKING BRAKE INSPECTI AND ADJUSTMENT of this’ section, 5-18.) Then check brake drum for draggi and brake system “for proper performa’ After removing vehicle from hoist, brake should be performed. Parking brake lover Equalizer Brake cable king nut RIGHT SIDE t lamp tb) Grommet FRONT SIDE <3 4 LEFT SIDE 1), Parking bre lever 2) Parking brake cable (right ids) 23, Parking orake cable let sie) jamo (a) ww > reaR sive ee? camo to) Fig. 542/BRAKES 5.27 Boay Upper side ‘camp tb) lomo (ab ‘Viewed from arrow “B Lower side Fa. 5-43 Fig, 5-445.28 BRAKES DISC BRAKE R & I 4. REMOVE AND INSTALL PAD (SHOE & LINING) REMOVAL 1) Hoist car and'remove wheel. 2) Remove caliper pin bolts. 4. caper 2) Caliper pin bolt 3) Remove caliper from caliper carrier. NOTE: Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessively or being pulled. Don’t operate brake pedal with pads removed. 4, Caliper 2. Wire hook 2. Pe Fig. 546 4) Remove pads. INSTALLATION NOTE: ‘See NOTE at the beginning of this section. 1) Install pad clips and pads. clips 2 Peas Oise Caliper carrier 2) Install caliper and torque caliper pin bolts specification. = ‘Make sure that boots are ZV fino groove sce 1 Caliper pin bots Fig, 548 3) Torque front wheel nuts to specification. (Refer to Fig. 5-149) 4)Upon completion of installation, pero brake test.BRAKES 5.29 2. REMOVE AND INSTALL CALIPER ASSEMBLY REMOVAL, !) Hoist car and remove wheel. z Remove brake flexible hose mounting bolt from caliper. As this will allow fluid to flow ut of hose, have acontainer ready beforehand, 4. Wire hook 5. Container 1. Caliper 2) Flexible hose 2. Hose mounting bolt 5549 Remove caliper pin bolts. lemove caliper from carrier. INSTALLATION 1) Install caliper to caliper carrier, 2) Torque caliper pin bolts to specification. Nore: Make sure that boots are {itinto groove scarey 1 Caliper pin baits Fig. 551 3) Install brake flexible hose as shown and torque hose mounting bolt to specification, 20-25 Nm (20-25 kgm) (ia5—ie0inn) Fig. 652 4) Torque wheel nuts to specification. (Refer to Fig. 5-149) 5) After completing installation, fill reservoir with brake fluid and bleed brake system. Perform brake test and check each installed part for oil leakage,5:30 BRAKES 3. REMOVE AND INSTALL SEAL, PISTON, DUST BOOT AND BLEEDER SCREW REMOVAL Before disassembly, clean all eround caliper with brake fluid. 1) Blow 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 cylinder. It should be taken out gradually with moderately compressed air. Do not place your fingers in front of piston when using compressed Fig. 553 2) Remove piston seal using a thin blade like a thickness gauge, etc. NOTE: Be careful not to damage inside (bore side) of cylinder. Fig, 654 INSTALLATION Reassemble front brake in reverse order of d sembly, noting the following points. CAUTION: ‘¢ Wash each part cleanly before installatio in the same fluid as the one used in ma ter cylinder reservoir. ‘© ‘Never use other fluid or thinner. * Before installing piston and piston se to cylinder, apply fluid to them. © After reassembling brake lines, bleed a [__ trom them. Piston Seal Piston seal is used to seal piston and cylin and to adjust clearance between pad and d Replace with a new one at every overhaul. piston seal into groove in cylinder taking « not to twist it Piston and Boot 1) Before inserting piston into cylinder, ins boot onto piston as shown below. 1. Boot 2. Piston Fig. 655 2) Fit boot as it is in above figure into b groove in cylinder with fingers. Fig, 556BRAKES 5:31 3) Insert piston into cylinder by hand and fit boot in boot groove in piston. Fig. 657 4)To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder alittle but do not take it all out. Boots face “8 should be at the same love from evlinder's face "A all around. Fig. 558 5) Insert piston into cylinder by hand. Caliper Before installing caliper (cylinder body) to carrier, check to ensure that guide pin inserted in each caliper carrier hole can be moved smooth ly in thrust direction NOTE: Where temperature gets as low as 30°C in cold weather, use rubber grease whose viscosity varies very little even at 40°C (—40°F). Apply eubber grease Fig. 5595:32 BRAKES 4. REMOVE AND INSTALL DISC REMOVAL 1) Hoist car and remove wheel. 2) Remove caliper assembly by loosening carrier bolts (2 pes). CAUTION During removal, be careful not to damage brake flexible hose and not to depress brake pedal Fig. 560 3) Remove brake disc screws (2 pes). 4) Pull brake disc off by using 8 mm bolts (2 pe 1. 8mm ba Fig. 562 INSTALLATION NoTE: " ‘See NOTE at the beginning of this section. 1) Install disc to wheel hub. 2) Install caliper assembly to steering knuckle 3} Torque caliper carrier bolts to specification. 70100 Nim 17.0 — 10.0 kgm) (810720 1m) 4) Torque front wheel nuts to specification. (Refer to Fig. 5-149) 5)Upon completion of installation, perfor brake test.BRAKES 5.33 DISC BRAKE INSPECTION 1, INSPECT BRAKE PAD LINING 2, INSPECT BRAKE CALIPER ‘Check pad lining for wear. When wear exceeds INNER PARTS limit, replace with new one. Cylinder Slide Guide Pin ‘Check guide pin for smooth movement as shown. If it is found faulty, correct or replace. Apply rubber grease to guide pin outer surface. Rubber grease should be the one whose viscosity is less affected by such low temperature as —40°C {—40°F). Apply rubber presse Fig, 585 es CAUTION: Bush Dust Boot and Cylinder Boot Never polish pad lining with sandpaper. If Check boots for breakage, crack and damage, lining is polished with sandpaper, hard If defective, replace. Particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. 5 For Ventilated disc type Standard [Limit Pad thickness | Sameer’ | tim _| (lining + pad rim) | 160mm | 8.0mm (0.590 in.) | (0.315 in.) Fig. 556 For Solid disc type Standard ui Lip) Pad thickness as Excessive or uneven wear of pad lining may in- (lining + pad rim) dicate unsmooth return of the piston. In such a case, replace rubber seal 14.0 mm 8mm (0.551 in.) | (0.315 in.) NOTE: When pads are removed, visually inspect caliper for brake fluid leak, Correct leaky point, if any. Fig, 5675:34 BRAKES. 3. INSPECT BRAKE DISC Before this inspection, brake pads must be re moved (according to steps 1) to 4) on page 5-28). Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replacement are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc surface, replace it. When only one side is scratched, polish and correct that side. Fig. 588 For Ventilated disc type Standard [Limit Disc thickness 17mm 15mm (0.67 in.) _| (0.59 in.) For Solid dise type Standard | Limit Dise thickness [12mm | 10mm [10.47 in.) | (0.39 in) To measure deflection of disc, take measurement at 2 points on its periphery and center with dial gauge while rotating it Limit on disc deflection | 0.1 mm (0.004 in.) NOTE: Check front wheel bearing for looseness before ‘measurement. Fig. 569VAL ‘Hoist car and remove wheel. 570 Remove spindle cap as shown (by hammering fightly at 3 locations around it so as not to deform or cause damage to seating part of 1. spinal exo 2 Brake drum S71 3) Uncalk spindle nut and remove spindle nut and washer. BRAKES 5.35 DRUM AND COMPONENTS R & | REMOVE AND INSTALL BRAKE DRUM Spindle cap Spindle nut Vasher Brake cum Fig. 572 4) Release parking brake lever. 5) Remove parking brake lever cover screws and loosen parking brake cable locking nut. 1. Brake eable locking nut Fig. 573 6) Remove back plate plug attached to the back side of brake back plate so as to increase clearance between brake shoe and brake drum. Insert @ screwdriver into plug hole till its tip contacts shoe hold down spring and push driver in the arrow direction.ee 5:96 BRAKES With this push, hold down spring is pushed up and releases parking shoe lever from hold down spring, resulting in larger clearance. Fig, 574 7) Pull brake drum off by using special tools. eae Specia t0! (Sting hammer) (ovsa2.18510) ‘Space toa! {Brake drum remover] (09943-17911) 1. rake drum Fig. 576 8) Remove wheel stud bolt by using hydrau press. ‘ll hyarautie Fig. 676 9) Insert new stud in drum hole and rotate slowly to assure serrations are aligned wit those made by replaced bolt. Fig. 577BRAKES 5:37 INSTALLATION NOTE: See NOTE at the beginning of this section. ‘Before installing brake drum, to maximize brake shoe-to-drum clearance, put screwdriver between rod and ratchet and push down ratchet as shown in figure. 1. Rod 2 Ratehet 1. Rod 21 Ratenet [Above figure shows ratchet position where brake shoetodrum Fig 579 2) Put brake shoe hold down spring back to its original position as. shown. (Put shoe hold down spring in place by moving shoe lever so that shoe lever comes to the side of shoe hold down spring.) 1, Brake shoe 2. Shoe hale down 3. Parking brake s Fig. 580 3) Install brake ‘drum after making sure that in side of brake drum and brake shoes are free from dirt and oil. 4) Install washer and new spindle nut. 5) Tighten spindle nut to specified torque. NOTE: Removed spindle nut should be replaced with new one, (LL sm le (80-120) Brake drum5:38 BRAKES 6) Calk spindle nut as shown. 1. Spindle net 2. alk Fig. 582 7) Install spindle cap. NOTE: © When installing spindle cep, hammer lightly several locations on the coller of cap. until collar comes closely into contact with brake drum. © If fitting part of cap is deformed or damaged or if it is fitted loosely, replace with new one, 8) Upon completion of all jobs, depress brake pedal with about 30 kg (66 Ibs). load three to five times so as to obtain proper drum-to: shoe clearance. Adjust parking brake cable. (For adjustment, see page 6-18.) 9) Tighten parking brake lever cover screws. 10) Install wheel and tighten wheel nuts to spe- ied torque. (6.0~ 7.0 kom) (36.5 ~ 505 10s) 11) Check to ensure that brake drum is # from dragging and proper braking is ong ed. Then remove car from hoist and perf brake test (foot brake and parking brake).BRAKES 535 2. REMOVE AND INSTALL BRAKE SHOE REMOVAL Perform steps 1) to 7) of brake drum RE- MOVAL. 2)Remove shoe hold down springs by turning shoe hold down pins as shown. 1. Parkieg brake shoe lever 2. Parking brake cable ove strut and springs. ove parking brake shoe lever from shoe 1. Retainer 2) varking brake shoe lever INSTALLATION 1) Assemble parts as shown in reverse order of removal. Fig. 587 2) Install shoe hold down springs by pushing them down in place and turning hold down pins. 1. shoe hold down ple 2, Shoe held down spe | Fig. 588 3) For procedure hereafter, refer to steps 1) to 11) of BRAKE DRUM INSTALLATION on page 5-37.REMOVAL ‘Perform steps 1) to 7) of brake drum RE- MOVAL. 2)Perform steps 2) and 3) of brake shoe RE- MOVAL. 3) Loosen brake pipe flare nut but only within ‘the extent that fluid does not leak. ea) | Fig. 589 4) Remove wheel cylinder mounting bolts, Dis- connect brake pipe from wheel cylinder and put wheel cylinder breather plug cap onto Pipe to prevent fluid from spilling, 1. Breather plug cap Fig. £90 3. REMOVE AND INSTALL WHEEL CYLINDER INSTALLATION 1) Install. packing to wheel cylinder. Then, off breather plug cap from brake connect pipe to wheel cylinder just enough: prevent fluid from leaking, Fig. 591 2) Tighten wheel cylinder to brake back plate specified torque. 3) Torque flare nut of brake pipe which connected in step 1) to specification. 3. Brake pipe 4, Whee! eylindsr Ha 4) Install breather plug cap taken off from p back to breather plug."a oe — 5) Install brake shoes, referring to steps 1) and 2) of its INSTALLATION on page 5-39. 6) install brake drum. (Refer to steps 1) to 7) of its INSTALLATION on page 5-37 of this section. 7) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, see page 5-19.) 8) Upon completion of all jobs, depress brake pedal with about 30 kg (66 Ibs) load three to five times so as to obtain proper drum-to- shoe clearance. Adjust parking brake cable, (For adjustment, see page 5-18.) 9) Tighten parking brake lever cover screws. 10) Install wheel and tighten wheel nuts to specified torque. (refer to Fig. 5-148.) 11) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove car from hoist and perform brake test (foot brake and parking brake) 42) Check each installed part for oil leakage. 4. REMOVE AND INSTALL BRAKE BACK PLATE REMOVAL 4) Perform steps 1) to 7) of brake drum RE MOVAL on page 5-36 and 5-36, 2)Perform steps 2) and 3) of brake shoe RE MOVAL on page 5-39. 3) Perform steps 3) and 4) of wheel cylinder RE MOVAL on page 5°40. 4) Remove cable from brake back plate by squeezing parking brake cable stopper ring. 1. ake cable stoppee rine | rake back pie 2, Plate bolt Fig. 5945.42 BRAKES INSTALLATION 1) Apply water tight sealant to mating surfaces of brake back plate and rear knuckle. 1, Kwekle 2. Agply watertight salant {SEALING COMPOUND 356 99000-31090), Fig. 595 2) Install brake back plate and tighten back plate bolts to specified torque. 2am = 2.8 kom) 1135-20014) Fig. 5.96 3) Install parking brake cable to brake back plate, Brake back pla Cable xopper rng Brake cle Fig. 597 44) Install wheel cylinder, and. tighten. wt cylinder bolts and brake pipe flare nut to cified torque. (Refer to steps 1) to 4) of wi cylinder INSTALLATION on page 5-40 this section.) 5) For procedure hereafter, refer to steps 5) 12) of wheel cylinder INSTALLATION page 5-41.BRAKES 5.63 BRAKE DRUM AND COMPONENTS INSPECTION INSPECT BRAKE DRUM 2. INSPECT BRAKE SHOE & ‘t drum for cleanliness. Check wear of its LINING ing surface by measuring its inside diameter. Where lining is worn out beyond service limit, replace shoe. item Standard | Service limit - Brake lining | Standard | S° Brake drum ip} 180mm 182 mm dali (7.09 in.)_| (7.16 in.) Thickness &imm | 28mm (lining + shoe rim) | (0.24 in) | (0.11 in) snever brake drums are removed, they should thoroughly cleaned and inspected for cracks, ‘mores, deep grooves. If one of brake linings is worn to service limit, all linings must be replaced at the same time. ‘Gracked, Scored, or Grooved Drum Nori “A cracked drum is unsafe for further service and Never polish lining with sandpaper. If lining is ‘must be replaced. Do'not attempt to weld 2 polished with sandpaper, hard particles of sand- “wacked drum. paper will be deposited in lining and may damage Smooth up any slight scores. Heavy or extensive drum, When it is required to correct lining, re- ‘seoring will cause excessive brake lining wear place it with a new one, = it will probably be necessary to resurface ‘drum braking surface © brake linings are slightly worn and drum is sgooved, drum should be polished with fine ‘emery cloth but should not be turned. NOTE: in drum is removed, visually inspect wheel inder for brake fluid leakage, Correct leaky ‘point, if any.3. INSPECT WHEEL CYLINDER Inspect wheel cylinder disassembled parts for wear, cracks, corrosion or damage. NOTE: Clean wheel cylinder components with brake fluid. Fig. 6-100 4. INSPECT BRAKE STRUT Inspect ratchet of strut for wear or damage. Fig. 5-101 5. INSPECT SPRINGS Inspect for damage or weakening. Inspect each part with arrow for-cust. If foul defective, replace. Fig. 5-102 6. INSPECT PARKING SHOE LEVI Inspect brake shoe lever for free movemé against brake shoe web. If defective, correct, replace. Fig. 5108holding No. 2 body, use care so that dia- is not caught by projections at 12 loca- Tighten ght and lft muss equally, Specia 0! 18) (attachment) |o99si-16010) Spacial tool (A) (Booster overhaul toolset) {09880-88210), Turn special too! bolt counterclockwise until No. 1 body projecting part comes to mid- position of No. 2 body depressed parts as Specia to! bolt No.1 body projecting part Beko ass. No. 2 body depressed part Fig. 5136 13) Remove booster from special tool. 14) Install push rod clevis so. that dimension “A"" as shown below is within 114.5 — 115.6 mm (4,51 — 4.54 in) and torque nut to specification. NOTE: Dimension “A” dees not include thickness of gasket. 20 — 30.8) i2oL30Kg) 1145-1155m0) (451 — 454i) 1. Push od cevie Fig, 5137 NOTE: Whenever booster was disassembled, make sure to check clearance between piston rod and master cylinder piston after reassembly. (For details, refer to page 5-56.) 15) For installation of booster, see steps 1) to 10) of its INSTALLATION on page 5-49.556 BRAKES BRAKE BOOSTER INSPECTION AND ADJUSTMENT 1. INSPECT BOOSTER INNER PARTS NOTE: After disassembly, soak all metal parts in ethyl alcohol. Wipe rubber diaphragm and plastic parts with @ clean cloth. Use ethyl alcoho! damped cloth to wipe out heavy dirt. Application of much ethyl alcohol especially to rubber parts is prohibited. RUBBER PARTS Wipe fluid from rubber parts and carefully in spect each rubber part for cuts, nicks or other damage. These parts are key to air flow control. If there is any question as to serviceability. of rubber parts, REPLACE them. METAL PARTS BADLY DAMAGED ITEMS, OR THOSE WHICH WOULD TAKE EXTENSIVE WORK OR TIME TO REPAIR, SHOULD BE REPLACED. IN CASE OF DOUBT, INSTALL NEW PARTS. 2. INSPECT/ADJUST CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON The length of booster piston rod is adjusted to provide specified clearance between piston rod end and master cylinder piston. Tou Booster piston od Master evlinar. Fig, 5-138 © Before measuring clearance, push piston rod several times s0 as to make sure reaction disc isin place. © Keep inside of booster at atmospheric; for measurement. 1) Set special tool (E) on master cylinder push pin until contacts piston. 3 (eB Sa pom ‘od gauge (09950.96010) 1, Master 2. Piston 3, Pin nase Fig, 5129, 2) Turn special tool upside down and place. booster. Adjust booster piston rod length rod end contacts pin head. 3) Adjust clearance by turning adjusting ser piston rod, Spacial tg i Fig. 6-140Check Operation 1)With engine stopped, depress brake pedal several times with the same load and make sure that pedal travel doesn’t change. Check Air Tightness Under Load 1)With engine running, depress brake = Then stop engine while holding brake depressed, Fig. 5-144 2)Start engine while depressing brake pedal, If Pedal, travel increases a little, operation is satisfactory. But no change in pedal travel indicates malfunction. Fig, 5-148 2)Hold brake pedal depressed for 30 If pedal height does not change, cond is good. But it isn't if pedal rises. Fig. 6147TER INSPECTION TABLE Part Inspect For Corrective Action | ster piston | Cracks, distortion or damage. Replace. vied ‘Damaged or worn seal surfaces. Replace. {Control valve and spring) _ i sae Reaction disc Damage or wear. Replace, “4. Diaphragm, boot and rubber | Damage. Replace. Piston rod and retainer Damage, bend or cracks. Replace. - Booster No. 1 & No. 2 body 1. Scratches, scores, pits, dents, or other damage affecting rolling or sealing of diaphragm or other seals. 2. Cracks, damage at ears, damaged threads on studs. 3. Bent or nicked locking lugs. 4, Loose studs. Replace, unless easily repaired. Replace, unless easily repaired. Replace, unless easily | repaired. Replace. 7. Air iters and separator Dirt. | Replace, Fig. 6148560 BRAKES RECOMMENDED TORQUE SPECIFICATIONS Tightening torque Fastening parts Nm kg-m ib-ft 1. Brake caliper pin bolt 22-32 22-32 16.0 — 23: 2. Brake caliper carrier bolt 70100 70-100 | 61.0=7: 3, Front brake flexible hose bolt 20-25 145-11 4, Rear brake bolt (Brake back plate bolt) 18-28 13.5 — 200) 5. Master cylinder nut or booster nut 10=16 75 — 15 6. Brake pipe 4-way joint bol a as 7. Proportioning valve bolt 8. Brake pipe flare nut 14-18 10.5 — 13. 9. Brake pedal shaft nut ~ 18-28 13.5 — 20) | 10. Rear spindle nut 80 — 120 58.0865 (Front caliper) 11. Brake bleeder plug eres 7-10 55-75 12. Wheel nut 50-70 50-70 | 365-505 13. Front drive shaft nut 160—=200 | 15.0-20.0 | 108.5 — 144: Fig, 5-149REQUIRED SERVICE MATERIALS RECOMMENDED Ea SUZUKI PRODUCT ee , © To fill master cylinder reservoir. : eee CTR. ol To.clean antpppoly to Inver parts t rian yin fiuid | cap or described in owner's ere der caliper and wheel eylinder when they are disassembled. aes * To apply to brake booster inner parts where eee itrmaned in repale application is instructed in this manual. tight | SEALING COMPOUND 366E | © To apply to mating surfaces of brake back plate 99000-31090 and rear knuckle,SPECIAL TOOLS 09943-17911 Brake drum remover (Front whee! hub remover) (09942-15610 Sliding hammer (09960-96010 Booster piston rod gauge S Booster No. 2 bosiy (il seal remover & Installer No. 1, Nes 09950-88210, Booster overhaul tool set eet (09950-78210 Flare nut wrench (10 mm) 09951-16010 Booster overhaul ‘attachment, 09922-85811 Connector pin re 9 rf (09952-16010 Booster piston rod adjuster Fig. 5-150ENGINE S= SECTION 6 ENGINE CONTENTS JERAL INFORMATION . . a | ENGINE CRANKING SYSTEM. . 2 6G-1 INE DIAGNOSIS ..-..------- 64 ENGINE CHARGING SYSTEM... 6H-1 INE MECHANICAL ..........-+. GAT ENGINE EMISSION CONTROLS INE COOLING . . . 681 (for carburetor model) ....--.+++-022++ 614 ENGINE FUEL . ect ENGINE EMISSION CONTROLS SARBURETOR ... = 60-1 (for Electronic Fuel Injection model) ..... 61-1 =LECTRONIC FUEL INJECTION ENGINE EXHAUST ...... +++ 6K-1 SYSTEM... cc 6E-1 ENGINE IGNITION SYSTEM ert GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many echined, honed, polished and lapped surfaces ‘with tolerances that are measured in the thou- ‘ends of an millimeter (ten thousands of an inch) “Accordingly, when any internal engine parts are ‘eviced, care and cleanliness are important. “Throughout this section, it should be understood st proper cleaning and protection of machined ‘serfaces and friction areas is part of the repair ‘erocedure. This. is considered standard, shop ‘ractice even if not specifically stated. '* A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial | operation. = Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, "and crankshaft journal bearings are removed | for service, they should be retained in order. ‘At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. _* Battery cables should be disconnected before | ‘any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. ‘® Throughout this manual, the three cylinders of the engine are identified by numbers; No. 1, No. 2 and No, 3 counted from crankshaft pulley side to flywheel side as shown in Fi 1. No. evlinder 2, No. 2 evlingee 3. No. 3 eying Fig. 61 Cylinder NumbersGENERAL INFORMATION ON ENGINE SERVICE THE FOLLOWING INFORMATION ON EN- GINE SERVICE SHOULD BE NOTED CARE- FULLY, AS IT IS IMPORTANT IN PREVENT- ING DAMAGE, AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE. * When raising or supporting engine for any reason, do not use a jack under. oil pan. Due to small clearance between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer resulting in damaged oil pick-up unit. It should be kept in mind, while working on engine, that 12-volt electrical system is cape: ble of violent and damaging short circuits. When performing any work where electrical terminals could possibly be grounded, ground cable of the battery should be disconnected at battery. Any time the air cleaner, carburetor, throttle body or intake manifold is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material which coutd follow intake passage into cylinder and cause extensive damage when engine is started. @ When disconnecting couplers, don’t pull wire harness but make sure to hold coupler itself. With lock type coupler, be sure to unlock the lock before disconnection. With spring lock type coupler as shown in Fig. 6-2, push out spring before disconnection, but only within the extent that spring is not deformed. Attempt to disconnect. coupler without un- locking may result in damage to coupler. When connecting lock type coupler, insert it till clicking sound is heard'and connect it securely. ‘coupler Lock spring Serewsriver Pull Fig, 62 Disconnection of Spring Lock Type Cows (for Electronic Fuel Injection model) PRECAUTIONS ON FUEL LINE SERVICE © Work must be done with no’ smoking, well-ventilated area and away from any flames. © [For Electronic Fuel Injection model] AAs fuel feed line (between fuel pump and pressure regulator) is still under high fuel sure even after engine was stopped, loose or disconnecting fuel feed line directly cause dangerous spout of fuel to occur loosened or disconnected. Before loosening or disconnecting fuel line, make sure to relieve fuel pressure! acs ing to “FUEL PRESSURE RELIEF PR DURE”. © A small amount of fuel may be released ‘the fuel line is disconnected. In order to reduce the chance of personal jury, cover the fitting to be disconnected a shop cloth. Put that cloth in an app. container when disconnection is completed * Fuel or fuel vapor hose connection with each type of pipe, When reconnects fuel or fuel vapor hose, be sure to cor and clamp each hose correctly referring Fig, 6-3 Hose Connection. After connect make sure that it has no twist or kink.see short ipa Fit howe a fart rasches pipe joint Clamp securely ats postion 310 7mm (012 ~0.27 in.) from hare end seh following type pin, tt hose as far a ts peripheral ‘cama securely a «position f4—3 10 7 mm (0.12~0.27 in) trom hase end With bont pips, Fit hose afr as ite bent part a shown Sel pipe is about 20 to 30 mm (0.79 ~ 1.18 0.1 foto srs hore. |< clamp securely a e position 307 mm (0.12 0.27 In} rom hase en) ‘with sraight pipe it hor il pipe is about 20 10 30 nm [0.79 1.38 n.) into the hove. l—— 2010.30mm lamp (0.78-= 118m) } {camp securely at a postion 310 7 mm } (0,120.27 in.) from hose end. Fig. 63. Hose Connection FUEL PRESSURE RELIEF PROCEDURE {for Electronic Fuel Injection model) CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. ‘After making sure that engine is cold, relief fuel pressure as follows. (Shift selector lever to “P range for AIT model), set parking brake, and block cree wheels. 2. Remove main fuse box cover and engine cso! ing water reservoir from its bracket, 3, Detach main fuse box from body and i connect coupler from fuel pump relay. 1, Main fuse box 2, Fuel pumo relay 3 Coupler Fig, 64 Disconnecting Fue! Pump Relay Coupler 4, Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it. 5. Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2 ~ 3 times for about 3 seconds each time to dissipate fuel pressure in lines. Fuel connections are now safe for servicing 6. Upon completion of servicing, connect coupler to fuel pump relay and fix main fuse box. ABBREVIATIONS USED IN THIS SECTION AIC A/T: Automatic Transmission ATS: Air Temperature Sensor BVSV : Bimetal Vacuum Switching Valve ECM. : Electronic Control Module EGR; Exhaust Gas Recirculation ESA: Electronic Spark Advance Isc Idle Speed Control M/T Manual Transmission PCV: Positive Crankcase Ventilation TB: Throttle Body TPS: Throttle Position Sensor TS: Throttle Switch SV: Vacuum Switching Valve WTG : Water Temperature Gauge6-4 ENGINE ENGINE DIAGNOSIS Con ion Possible Cause Correction Hard Starting (Engine cranks OK) Ignition system out of order © Blown fuse Faulty spark plug © Leaky high-tension cord res high-tension cords or lead Maldjusted signal rotor air gap Improper ignition timing Faulty ignition coil Cracked rotor or cap in distributor Faulty noise suppressor Fuel system out of order * Lack of fuel in fuel tank © Dirty fuel filter ‘* Dirty or clogged fuel hose or pipe Malfunctioning fuel pump Air inhaling from intake manifold gasket, carburetor gasket or throttle body gasket * Carburetor choke will not work properly (for carburetor model) ‘¢ Improper adjustment of float level (for carburetor model) * Molfunctioning fuel cut solenoid valve (for carburetor model) * Carburetor out of adjustment (for carburetor model) Electronic Fuel Injection system out of order Low compression © Poor spark plug tightening or faulty gasket Compression leak from valve seat Sticky valve stem ‘Weak or damaged valve springs Compression leak at cylinder head gasket | © Sticking or damaged piston ring | © Worn piston, ring oF eylinder © Loose connection or disconnection of Faulty generator assembly in distributor Repair or replace Clean and adjust plug gap or replace Replace Repair or replace. Adjust Replace Adjust Replace Replace Replace Refill Replace Clean Replace Replace Check and adjust Adjust Check solenoid velve for operation. Replace if necessary. Adjust Refer to SECTION 6E Tighten to specified torque or replace gasket Remove cylinder head and lap valves Correct or replace valve and valve guide Replace Repair or replace Replace Replace ring and piston. Rebore or replace cylinderCondition Possible Cause Correction ] Starting Others ine cranks OK) | @ Broken valve timing belt Replace © Malfunctioning PCV valve Replace jne has no power | Ignition system out of order © Incorrect ignition timing Adjust © Faulty spark plug © Worn distributor terminals ‘© Leaks, loose connection or disconnection of high-tension cord © Malfunctioning ignition timing advancers Engine overheating Fuel system out of order ‘© Clogged fuel hose or pipe © Dirty or clogged fuel filter © Clogged air cleaner element @ Air inhaling from intake manifold gasket, carburetor gasket or throttle body gasket! © Malfunction of choke system (for carburetor model) © Fuel pump will not work properly © Clogged carburetor jets (for carburetor model) Electronic Fuel Injection system out of order Low compression Others ‘¢ Loose connection or disconnection of vacuum hoses Malfunctioning EGR valve (if equipped) © Dragging brakes ‘ Slipping clutch Adjust or replace Dress or replace. Also check rotor | Connect or replace as necessary Replace Refer to “Overheating” section Clean Replace Clean or replace Replace Adjust or replace Replace Clean Refer to SECTION 6E Previously outlined Connect securely Check and replace as necessary Repair or replace Adjust or replacePossible Cause Correction Ignition system out of order © Faulty spark plug ¢ Leaky or disconnected high tension cord © Worn distributor terminals © Improper ignition timing © Cracked cap in distributor with leakage inside © Malfunctioning ignition ti advancer Fuel system out of order © Shortage of fuel in fuel tank © Clogged air cleaner element © Leaky manifold, carburetor, throttle body, or cylinder head gasket © Clogged carburetor jets (for carburetor model) © Improper float level (for carburetor model) © Malfunctioning of choke system (for carburetor model) © Malfunctioning fuel cut solenoid valve (for carburetor model) Electronic Fuel Injection system out of order Engine overheating Low compression Others ¢ Loose connection or disconnection of vacuum hoses ‘© Malfunctioning EGR valve (if equipped) ‘© Malfunctioning PCV velve ‘Adjust or replace Connect or replace Replace Adjust Replace Replace Refill Clean or replace Replace Clean Adjust Adjust or replace Replace Refer to SECTION GE Refer to “Overheating” section Previously outlined Connect securely ‘Check and replace as necessary | Check and replace as necessary Engine hesitates (Momentary lack of response as accelerator is depressed. Can occur at all car speeds. Usually most severe when first trying to make car move, as from a stop sign.) Ignition system out of order ‘¢ Improper ignition timing Spark plug faulty or plug gap out of adjustment © Leaky high tension cord Adjust Replace or adjust gap ReplaceCondition i hesitates jentary lack of nse as accelera- 's depressed. occur at all car is. Usually most, when first try to make car move, rom a stop sign.) Possible Cause | Fuel system out of order ‘© Clogged air cleaner element © Clogged fuel filter, hose or pipe ‘© Leaky manifold or carburetor gaskets Improper adjustment of float level (for carburetor model) © Clogged carburetor jets (for carburetor model) © Loose manifold and carburetor bolts and nuts (for carburetor model) © Malfunctioning accelerator pump. (for carburetor model) Electronic Fuel Injection system out of order Engine overheating Low compression Others ¢. Malfunctioning EGR valve (if equipped) Correction. Clean or replace Clean or replace Replace | Adjust Clean Retighten Check and replace as necessary Refer to SECTION 6E Refer to “Overheating” section Previously outlined Check and replace as necessary gne power varia- under steady le or cruise. like car up and down ‘no change in tor pedal.) Ignition system out of order ©. Improper ignition timing © Malfunctioning ignition timing advancers © Leaky or loosely connected high- tension cord ‘© Faulty spark plug (excess carbon deposits, improper gap, and burned electrodes, etc.) © Cracked rotor or cap in distributor Fuel system out of order © Clogged fuel filter © Kinky or damaged fuel hose and lines © Leaky manifold or carburetor gaskets © Malfunctioning fuel pump. ©, Improper float level (for carburetor model) Electronic Fuel Injection system out of order Others ‘© Malfunctioning EGR valve (if equipped) © Leaky vacuum hoses Adjust Replace Check and repair or replace Check and clean, adjust or replace Replece Replace Check and replace as necessary Replace Check and replace as necessary Adjust Refer to SECTION 6& Check and replace as necessary Repair or replace6.8 ENGINE metallic knocks that change with throttle opening. ‘Sounds like pop corn popping.) Ignition system out of order © Faulty spark plug Improper ignition timing Loose connection of high tension cord Fuel system out of order ‘© Clogged fuel filter or fuel lines © Air inhaling from intake manifold, carburetor or throttle body gasket © Clogged carburetor jets (for carburetor model) © Improper adjustment of float level (for carburetor model) © Malfunctioning fuel pump Electronic Fuel Injection system out of order Others ‘© Loose connection or disconnection of vacuum hoses ‘© Excessive combustion chamber deposits ‘* Malfunctioning EGR valve (if equipped) Condition Possible Cause Correction Excessive detonation | Engine overheating Refer to “Overheating” (Engine makes sharp Replace Adjust Connect securely Replace or clean Replace Clean Adjust Replace Refer to SECTION 6E Connect securely Remove carbon Check and replace as neces: Overheating ‘© Insufficient coolant © Loose water pump belt Inoperative thermostat Poor water pump performance Improper ignition timing Clogged or leaky radiator Improper engine oil grade Clogged oil filter or oll strainer Not enough oi! Poor oil pump performance Oil leakage Dragging brakes Slipping clutch Blown cylinder head gasket Replenish Adjust. Replace Replace Adjust Flush, repair or replace Replace with proper grade oil Replace or clean (oil strainer) Replenish Repair or replace Repair Repair or repl Adjust or repair ReplaceCondition Possible Cause Correction “gesoline mileage Fuol system out of order © Fuel leakage from fuel tank, carburetor and lines © Clogged air cleaner element * Malfunctioning carburetor choke ‘system (for carburetor model) ‘Improper float level (for carburetor model) © Dirty or clogged carburetor jets {for carburetor model) Ignition system out of order Improper ignition timing '* Leaks or loose connection of high: tension cord | # Faulty spark plug (improper gap, heavy deposits, and burned electrodes, etc...) *, Malfunctioning mechanical and vacuum advancers in distributor Electronic Fuel Injection system out of order Low compression Others ‘© Poor valve seating © Dragging brakes Slipping clutch Thermostat out of order ‘© Improper tire pressure Malfunctioning EGR valve (If equipped) Repair or replace Clean or replace Repair or replace Adjust Clean Adjust Repair or replace Clean, adjust or replace Check and repair or replace Refer to SECTION 6E Previously outlined Repair or replace Repair or replace Adjust or replace Replace Adjust Check and replace as necessary8-10 ENGINE LS lll SS Oil entering combustion chamber © Sticky piston ring ‘© Worn piston and cylinder Condition Possible Cause Correction: Excessive engine oi | Oil leakage consumption © Loose oil drain plug Tighten © Loose oil pan bolts Tighten © Deteriorated or broken oil pan sealant | Replace sealant © Leaky crankshaft oil seals Replace © Leaky cylinder head cover gasket Replace © Improper tightening of oil filter Tighten © Loose oil pressure switch Tighten ‘Blown cylinder head gasket Repiace © Leaky camshaft oil seals Replace Remove carbon and replace r Replace or rebore cylinder, ané replace piston Excessive clearance in various sliding parts ‘© Worn piston ring groove and ring Replace piston and ring ‘¢ Improper location of piston ring gap _| Reposition ring gap © Worn or damaged valve stem seal Replace © Worn valve stem Replace Low oil pressure © Not enough oil Replenish © Improper oil viscosity Use oil of proper viscosity © Malfunctioning oil pressure switch Replace © Clogged oil strainer Clean © Functional deterioration of oil pump | Replace © Worn oil pump relief valve Replace Replace worn parts Engine noise Note: Before checking ‘mechanical noise, make sure that: © Ignition timing is properly adjusted. © Specified spark plug is used. © Specified fuel is used, Valve noise * Faulty hydraulic valve lash adjuster # Worn valve stem and guide * Weak or broken valve spring ‘© Warped or bent valve ‘© Loose camshaft housing bolts Piston, ring and cylinder noise ‘© Worn piston, ring and cylinder bore Replace Replace Replace Replace Tighten to specification Rebore or replace cylinder Replace piston and ringPossible Cause Connecting rod noise © Worn rod bearing | © Worn crank pin ‘© Loose connecting rod nuts © Low oil pressure Crankshaft noise © Low oil pressure © Worn bearing © Worn crankshaft journal Loose bearing cap bolts Excessive crankshaft thrust play Replace Repair by grinding or replace crankshaft Tighten to specification Previously outlined Previously outlined Replace Repair by grinding, or replace crankshaft Tighten to specification Replace thrust bearing Dieseling {Engine continues to un after ignition switch is turned off. ftruns unevenly and may make knocking noise.) ‘Malfunctioning fuel cut solenoid valve in carburetor Check the valve for proper ‘operation, and replace as necessary.ENGINE MECHANICAL 5-7 SECTION 6A ENGINE MECHANICAL CONTENTS RAL DESCRIPTION ..... Pressure Check . ir Cleaner Element .. Sr Cleaner Assembly... Dylinder Head Cover . (Cerburetor and Intake Mani Trrottle body and Intake Manifold (for Electronic Fuel Injection rode!) Exhaust Manifold . Timing Belt and Belt Tensioner. ‘Oil Pan and Oil Pump Strainer Oil Pump ... s CComshaft and Hydraulic Valve Lash Adjuster . Walves and Cylinder Head........+- Pistons, Piston Rings, Connecting Rods and Cylinders .. REPAIR OVERHAUL ... Engine Assembly Main Bearings, Crankshaft and Cylinder Block . IAL TOOLS... \UIRED SERVICE MATERIALS. . OMMENDED TORQUE SPECIFICATIONS ‘this section, the following system and parts appear in some description or illustrations, but whether ‘are installed in the particular car or not depends on specifications or models. Be sure to bear this in when performing inspection and service work. EGR system (EGR valve, EGR modulator, TVSV and vacuum hoses) Evaporative emission control system (charcoal canister and vacuum hoses) “= Pulse air control system (2nd air valve, pipe and hose) ‘For what each abbreviation stands for (i.e., full term), refer to SECTION 6,8A2 ENGINE MECHANICAL GENERAL DESCRIPTION ENGINE ‘The engine is a water -cooled, in line 3 cylinders, ‘The single overhead camshaft is mounted 4 stroke cycle gasoline unit equipped with a the cylinder head; it is driven from crank: direct acting type S.0.H.C. (Single Overhead through timing belt and opens and closes val Camshaft) valve mechanism, fe (IN & EX) via the hydraulic valve lash adjusters, a Fig. 64-1 Engine ConstructionLUBRICATION pump is of a trochoid type, and mounted Skshaft at crankshaft pulley side, awn up through oil pump strainer and shrough pump to oil filter, ed oil flows into two paths in cylinder path, oil reaches crankshaft journal crankshaft journal bearings is supplied jing rod bearings by means of inter- ‘passages drilled in crankshaft, and then from a small hole provided on big end ing rod to lubricate piston, rings, and wall. ENGINE MECHANICAL SAS In another path, oil goes up to cylinder head ena lubricates camshaft journals and hydraulic valve lash adjusters, etc., passing through oil gallery in cylinder head wall. There is a check valve in the path from cylinder block to cylinder head. It serves to keep oil gollery in cylinder head filled with oil even when engine is at a stop. An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over about 3.0 ka/em? (42.7 psi, 300 kPa). Relieved oil drains back to oil pan. 5A? Engine Lubrication6A.4 ENGINE MECHANICAL CYLINDER BLOCK The cylinder block is made of cast aluminum alloy and has 3.cylinders arranged “In-Line”. A cylindrical cast iron sieeve is installed in each cylinder. CRANKSHAFT AND MAIN BEARINGS A monoblock crankshaft made of forged steel is supported by 4 main bearings which are of precision insert type. Three crank pins on the crankshaft are positioned. 120° apart, PISTONS, RINGS, PISTON PINS AND CONNECTING RODS The piston is cast aluminum alloy, and has two ‘compression rings and one oil ring. ‘Among two compression rings (top and 2nd rings), the outer surface of the top ring is plated ‘with hard chromium for improvement in abrasion resi The oil ring consists of two rails and one spacer. The piston pin is offset 0.5 mm towards the major thrust side, This allows a gradual change in thrust pressure against the cylinder wall as the piston travels its path, Pins, made of chromium steel, have a floating fit in the pistons and press fit in the connecting rods. The connecting rods are made ‘of forged steel, and the rod bearings are of preci sion insert type. nce. CYLINDER HEAD, VALVE TRAIN AND HYDRAULIC VALVE LASH ADJUSTER The cylinder head is made of castaluminumalloy and has three combustion chambers arranged, indine, The single overhead camshaft driven by the crankshaft through the timing belt is mounted ‘on the cylinder head. It has six camsand operates the intake and exhaust valves via the hydraulic valve lash adjuster. OPERATION OF HYDRAULIC VALVE ADJUSTER, The hydraulic valve lash adjuster located be the camshaft and valve stem is direct acting) With the engine oil delivered into it from pump, the adjuster operates as follows so. adjust the valve lash (clearance) to matically at all time. 1.When the camshaft doesn’t push the body, the bucket body is pushed against cam, and the body against the, stem by plunger spring force. In this state, the lash is kept to “0”. (At “0" valve lash, pressure becomes equal, in the chambers, and ““B", and the check ball closes the between these two chambers.) 2.When the cam crest of the camshaft pushing the bucket body, the bucket and plunger are pushed downward and at same time the body is pushed upward by: counter force from the valve stem. Asa re the chamber “B" is compressed and the sure rises high. Then the oil in the chamber Jeaks through the slight clearance bet the body and plunger. However, as the pression time is very short, the volume changes and thus the bucket body, plu’ and body, substantially as one unit, down the valve stem to open the valve. 3,When pushing of the cam crest of the shaft against the bucket body is over, operation as described in above 1. starts a ‘As the oil pressure in the chamber “B™ lower than that in “A’" (for the oil in chamber “'B” under high pressure has lea gradually in above 2.), the oil pressure in chamber “A’” pushes the check ball open allow the oil to flow from the chamber “ to chamber “B” till the oil pressure bec ‘equal between the two chambers.3. Valve sem 4 Ollgalery 9. Chao bal oxing 5. Bucket body 10. Chack Ball cae ats { { 29 we “| a ° % 3 e 4 ° . Se Fig. 6A-3 Operation of Hydraulic Vaive Lash AdjusterON CAR SERVICEPRESSION CHECK compression pressure on all three cylinders follows: Warm up engine. ‘Stop engine after warming up. Remove all spark plugs and disconnect distri. butor wire harness at coupler. Remove 15A fuse for main relay shown in figure below (for Electronic Fuel Injection model). Fa GALT Removing 15A Fuse for Main Relay - (for Electronic Fuel Injection model) Install special tool (Compression gauge) into spark plug hole, @ o. @ Xa oy Disengage clutch (to lighten starting load on engine), for M/T. model, and depress accelerator pedal all the way to make throttle valve full-open. 7. Crank engine with fully charged battery, and sead the highest. pressure on compression Suge. ‘Compression pressure 14.0 kg/em? (199.0 psi, 1400 kPa}/400 r/min 11.0 kg/cm? (156.4 psi, 1100 kPa}/400 r/min Standard Limit Max. difference between any two cylinders 1.0 kg/em? (14.2 psi, 100 kPa)/400 r/min 8. Carry out steps 5 through 7 oneachecylniae to obtain three readings. 9. After checking, install 15A fuse (for Electro nic Fuel Injection model), connect coupler distributor and install spark plugs. ENGINE VACUUM CHECK The engine vacuum that develops inthe intake line is a good indicator of the condition of the engine. The vacuum checking procedure is 2s follows: 1. Warm up engine to normal operating tempers- ture. [For carburetor model] 2. Disconnect vacuuim hoses from VSV of idle up and connect the special tools (Vacuum gauge and. vacuum gauge hose joint) to, the hose disconnected. Special ool (Vacuum gauge 09816-67310), 2 Speci! ‘ool (Hose joint 08618-06210) SV vacuum hose _Gas filter 09 ints manifold Fig. 646 Installing Vacuum Gauge (for carburetor model) [For Electronic Fue! Injection model] 2, With engine stopped, disconnect vacuum hose from gas filter and connect 3-way joint, hoses and, special tool (vacumm gauge and joint) between gas filter and vacuum hose disconnected, 1, Gas iter 2. Say joint (SUZUKI GENUINE PARTS 00967-04002) 3. Hotes (SUZUKI GENUINE PARTS 09343-03087) 4. Spetial tool {Vacuum gouge 08915-97310) 6, Special tool (oss fon 09916-08710), Fig. 6-6-1 Installing Vacuum Gouge (for Electronic Poet Injection mode!)2. Run engine at specified idle speed (see section 6D or GE), and read vacuum gauge. Vacuum should be within following specification. 40 — 50 cmHg (15,7 — 19.7 in.Hg) at specified idling speed Vacuum, specification [For carburetor model] After checking, remove the hose joint and the vacuum gauge, and connect the vacuum hose to VSV securely. [for Electronic Fuel Injection model) 4, After checking, connect vacuum hose. OIL PRESSURE CHECK. NOTE: Prior to checking ’oil pressure, check the follow- ings. © Oil level in-oil pan. If ol level is low, add oil up to Full level hole on oil level gauge, © Oil quality. If oil is discolored, or deteriorated, change it. For particular oil to be used, refer to the table in Section OB. © Oilleaks. If leak is found, repair it. 1, Using special tool (Oil filter wrench), remove oil fitter. 2. After removing oil filter, remove oil pressure switch from cylinder block, 1 Ou (M Fig. 6-7 Oil Pressure Switch 3. Install special tool (Oil pressure gauge) to vacated threaded hole. time, be very careful not to exert force ‘to where oxygen sensor and its lead wire are connected (For Electronic Fuel Injection model). 4. Special too! (Oi presre gouge 09915-77310) 2) Special tool (Ol presaure gauge attachmont 09915-7 Fig, GAB Oil Pressure Gauge Instalati 4, Reinstall oil filter, 6, Start engine and warm it up to normal op ing temperature. 6. After warming up, raise engine speed to r/min and measure oil pressure. 3.0 — 3.8 kg/om* ye seeal 42.7 ~ 54.0 psi spe at 3,000 r/min (rp 7. After checking oil pressure, stop engine remove oil filter and oil pressure gauge. 8. Before reinstalling oil pressure switch, be to wrap its screw threads with sealing tz and tighten switch to specified torque. Teabening ore Twn | kgm] to for oll pressure swttch 12-18 |1.2-15] 9.0 - 105) NOTE: If sealing tape edge is bulged out from threads of switch, cut it off. 9. After oiling oil filter “O" ring (rubber gasket! screw oil filter on-oil filter stand by until filter “O" ring contacts mounti surface. CAUTION; To tighten oil filter properly, it is important to accurately ‘identify the position where filter “O” ring first contacts mount- 1g surface.Tighten filter 3/4 (270°) turn from the point of contact with mounting surface using an oil filter wrench. 1. Space oo! (OH er wrench 08915-47310) 2 oniter Fie 64-9 Tiahening Oil Filter CAUTION: ] To prevent oil leakage, make sure that oil | filter is tight, but do not overtighten it. | “1. After installing oil filter, start engine and check oil filter for oil leakage. AIR CLEANER ELEMENT “This air cleaner element is of dry type. Remember st it needs cleaning according to following jure. REMOVE OR DISCONNECT "Air cleaner upper case after removing case nut and 4 clamps. Fig. 6-10 Removing Upper Case 2. Air cleaner element. INSPECT Check air cleaner element for dirt. CLEAN Blow off dust by compressed air from air outlet side of element. Fig. 6A-11 Cleaning Air Cleaner Element INSTALL OR CONNECT 1. Air cleaner element to its lower case. Fit the lug of element to the recession of lower case as shown in below figure. 4 Ale cleaner efament 2 exe 3. Recession 4, Aig leaner lower Fig, 64-12 Installing Air Cleaner Element 2, Air cleaner upper case. Tighten case nut and clamps securely,S470 ENGINE MECHANICAL AIR CLEANER ASSEMBLY REMOVE OR DISCONNECT {For carburetor model] 1. Negative cable at battery. 2. EGR modulator (if equipped) 3. Air suction guide, warm air hose, PCV hose ‘and other hoses from leaner case. 4. Air cleaner assombly. 2. Air wetion guide 3. Air cloner assembly 6. PCV howe 4. Waem ir hose Fig. GA-13 Removing Air Cleaner Assembly [For Electronic Fuel Injection model] 1, Negative cable at battery, 2. Coupler from ATS, 3, ISC solenoid valve hose from air cleaner lower case, 4, PCV valve hose from air cleaner lower case. 5. Air cleaner assembly with air cleaner hose from throttle body. Remove air cleaner case nut and bolt, and disconnect air cleaner hose from its pipe. ats Nut ‘ie cleaner assembly Batt Ar eleanor pipe Fig. 6A-13-1 Removing Air Cleaner Assembly INSTALL OR CONNECT Reverse removal procedure for installation, noting following, © Before installing, make sure that air cleaner case seal is installed to air cleaner case securely. Fig. 6A-14 Air Cleaner Case Seal ‘© Clamp hose(s) securely. CYLINDER HEAD COVER REMOVE OR DISCONNECT 1. Negative cable at battery. 2. Air cleaner assembly as previously outlines 3, High-tension cord clamps from cylinder cover. 4. Cylinder “head” cover nuts and” then washers. 3. Cylinder mood cover Fig. 64-15 Removing Seal Weshers 5. Cylinder head cover from cylinder head. INSTALL OR CONNECT 1, Cylinder head cover gasket to head cover. Before installing gasket, check it for deterio ration or damage, and replace as necessary. 2. Cylinder head cover and seal washer. Before installing seal washers, check each one for deterioration or damage, and replace as necessary. ighten cover nuts to specified torque. Tightening torque [_Nm [kom [Ibe for cover nut [4-5 [04-06] 30-35 High+tension cord clamps to cylinder head cover. 4, Air cleaner assembly as previously outlined. 5. Negative cable at battery.‘TOR AND INTAKE MANIFOLD (for carburetor model) ENGINE MECHANICAL 6-764 Stud bolt Carburetor ay Gasket Intake manifole ket CCarouretor hose ‘Aceslestor cable (For MIT model) ‘Asealeratoreable (Fer A/T model) )VE OR DISCONNECT ive cable at battery. in cooling water. RNING: help avoid danger of being burned, do remove drain, plug and radiator cap ‘while engine and radiator are still hot. ding fluid and steam can be blown out jer pressure if plug and cap are taken off ‘t00 soon. Fig. 6A-16:2 Radiator Drain Plug 3. Air cleaner assembly as previously outlined.6A102 ENGINE MECHANICAL . Accelerator cable from carburetor. . Following electric lead wires: © Carburetor (auto choke, fuel cut solenoid valve and/or bowl vent valve wires). ‘© Throttle position sensor (for A/T) ‘© Water temperature gauge unit. © Radiator cooling fan switch. 6. Fuel feed and return hoses, Before disconnecting hose, remove fuel filler cap to release the pressure in fuel tank and oe reinstall it 7, Second air pipe (if equipped). 2. Camp 8. Following hoses: Fig. 64-153 Clamps © PCV hose from PCV valve. ‘© Water hoses from intake manifold and car- 3. PCV hose to PCV valve. buretor. 4, Vacuum hoses. ‘© Brake booster hose from brake booster. 5. Water hoses. ‘© VSV hose from gas filter and idle up ac- 6. Fuel return and feed hoses to pipes. tuator. 7. Electric lead wires. © Distributor vacuum advance hose from distributor, © Canister hose and purge hose from pipes (If equipped). 9. Other jointed parts from carburetor and intake manifold, if any. 10. Intake manifold with carburetor from eylinder head. INSTALL OR CONNECT 1. Intake manifold gasket to cylinder head. Use 1. Tocorburtor solenoid 3, To radiator fan motor a new gasket. 2. To water temp, gouge unit 4. To throttle position ; ; (For A/T mosel) 2. Intake manifold with carburetor to cylinder 5, Toda up vs, head. Fin GAT64 Connecting Couplers « Install clamps as shown in Fig. 6A-15-3, and tighten bolts and nuts to specification. TEL AARNE, caruiretors kom |b Adjust accelerator cable play to sp tion according to description in section 9. Air cleaner ‘assembly’ to ‘carburetor @s & viously outlined. 10. Check to ensure that all removed (pai back in place, Reinstall any necessary which have not been reinstalled. 11, Refill cooling system. 12. Negative cable at battery. 13, Upon completion of installation, start and check for fuel leaks and engine water leaks. Tightening torque |)_N-m forboltsand nuts | 48— 28 |1.8-2.8|13.5—200IROTTLE BODY AND INTAKE MANIFOLD (for Electronic Fuel Injection modell =] 2 Seal ‘3, Throttle body 4, Gasket 5 Intake manifold é 7 8 8 10. manifold ilst hose ogy outlet hase 11, Accelerator cable (Foe AIT mode!) 6A-16 Throttle Body and Intake Menifold REMOVE OR DISCONNECT 4 Relieve fuel pressure according to procedure described in P. 6-3, Negative cable at battery. Drain cooling water. WARNING: To help avoid danger of being burned, do while engine and radiator Scalding fluid and steam can be blown out 1. Redlator under pressure if plug and cap are taken off 2 Tedlte Sn t00 soon. Fig. 64-17 Radiator Drain Plug 4, Air cleaner assembly as previously outlined. 5. Following electric lead wires: '¢ VSV for EGR valve (if equipped) - ws ISC solenoid valve Ground wires from intake manifold Fuel injector TSor TPS WTGGA-12_ ENGINE MECHANICAL 6. Fuel return and feed, hoses from throttle body. 7. Water hoses from throttle body and intake |. Throtis body outlet hose 2, Hosta inlet nose 3. Intaks moni inlet bose Fig. 64-18 Water Hoses 8. Following vacuum hoses: © Distributor vacuum advancer hoses from advancer. © Canister purge hose from intake manifold. ‘© Canister hose from its pipe. © PS hose from intake manifold, © Brake booster hose from intake manifold, 9. PCV hose from cylinder head cover. 10, Accelerator cable from throttle body. 11. Other connected to throttle body and intake manifold, if any. 12, Intake manifold with throttle body from cylinder head, INSTALL OR CONNECT 1. Intake manifold gasket to cylinder head. Use a new gasket, 2. Intake manifold with throttle body to cylinder head. Install clamps as shown in tighten bolts and nuts to speci Tightening torque |_Nem | kgm | ibft forbolts and nuts _| 18 — 28 |[1.8—2.8| 136-200) Fig. GA-18. Clamps 3. PCV hose to cylinder head cover, 4, Vacuum hoses. Refer to Fig. GA-4 for routing and connecti 5. Water hoses, Refer to Fig. 6-18 for connection. 6. Fuel return and feed hoses to throttle body. 7, Electric lead wires, 1. Fuel feed hose 3. WTS 2. Fuel return ose Fig. 6A-20 Connecting Hoses and Coupler. 8. Accelerator cable to throttle body. Adjust accelerator cable play to specific tion according to description in section 6E: 9. Air cleaner assembly to throttle body previously outlined. 10. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled, 11, Refill cooling system. 12. Negative cable at battery. 13. Upon completion of installation, start engine ‘and check for fuel leaks and engine cocling water leaks.ENGINE MECHANICAL 5&7 EXHAUST MANIFOLD gOTE: Beygen sensor applicable to Electronic Fuel ejection model. To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system 1, Exhaust manifold 4. Oxygen sansor 2: Gasket 5, Pipe sal 3. cover 6. No. pipe GA-21 Exhaust Manifold, No. 1 Pipe, etc. MOVE OR DISCONNECT Negative cable at battery. Second air pipe (if equipped). Oxygen sensor coupler. jlease its wire from clamps. (4-22 Oxygen Sensor Coupler 4. Cover on exhaust manifold. 5. Exhaust No. 1 pipe from exhaust manifold. Fig. 6-23 Exhaust No. 1 Pipe 6, Exhaust manifold and its gasket from cylinder head. INSTALL OR CONNECT 1, Manifold gasket to cylinder head. Before installing gasket, check it for deterioration or damage, and replace as necessary. 2. Exhaust manifold. Tighten manifold bolts and nuts to specified torque. Tightening torque | Nem] komm [tte forboltsand nuts [78-28 [18-26 |135-200 Pipe seal and exhaust No. 1 pipe. Before installing pipe seal, chteck it for deterioration or damage, and replace as necessary. Tighten pipe bolts to specified torque. wm | kom | Jot for No. 1 pipe bolt [40—60 [406.0] 28.0 48.0 4, Cover to exhaust manifold. 5, Oxygen sensor coupler. Clamp its wire securely. 6. Second air pipe (if equipped). 7. Negative cable at battery. 8. Check exhasut system for exhaust gas leakeo=.6A-14 ENGINE MECHANICAL TIMING BELT AND BELT TENSIONER Timing bet Tansionee ‘Tansioner plas ‘Tensioner spring ‘Spring dame ‘Camshaft timing pulley Pia Pulley bote ‘Seal 3. aide cover sea Inside cower 2 Outs cover sat (Outside cover “Tensioner sts “Tensioner bolt ‘Tensioner spring serow BBRBSSS epsomeey> REMOVE OR DISCONNECT 1. Negative cable at battery. 2. Raise car. 3, Fender apron extension on right side. Remove clip after pushing center pin. o Fig. 64-24 Timing Bolt, Tensioner and Camshaft Timing Pulley, etc. 1, Rand apron extension 3 2. clin "o 3. Center pin of clip * N > bod A Fig. 64-25 Removing Fender Apron Extension 4. Water pump belt and its pulley. Loosen generator pivot bolts and its adjusting bolt and remove water pump belt. 5. Crankshaft pulley by removing 4 pulley bolts. It is not necessary to loosen crankshaft timing. belt pulley bolt at the center. 41. Crankshaft pully 2. Crankshaft pulley bolt Fig. 6A-26. Crankshaft Pulley and Pulley Boltsbelt outside cover. installation of timing belt, align 4 timing as shown: in. Fig, 64-27. by turning mark on cylinder Timing mark on camahefe timing belt pulley 9. Brow mark on oil ump case 1. Punch mark on crankehofe ting belt pulley (4.27 Aligning Timing Marks ‘Timing belt tensioner, tensioner plate, tension- spring, spring damper and timing belt. 4. Timingboit 4 Tensioner stud 12, Tonwoner plate 5. Sp:ing 3. Tensioner bolt 6. Spring damper CAUTION: After timing belt is removed, never tur | camshaft and crankshaft independently | more than such an extent as. shown below. If turned, interference may occur ‘among piston and valves, and parts related to piston and valves may be damaged. CCamshatt allowable turning range --~ By timing Irark, within 80° from "V" mark on head eover on both right and et. Crankshaft allowable turning range --- By punch rom arrow mark on ofl pump {uae Gn bath right and ef Fig, 6A-29 Allowable Turning Range Never bend timing bel INSPECT ‘© Timing belt for wear.or crack. Replace it as necessary. ‘© Tensioner for smooth rotation, INSTALL OR CONNECT 1, Tensioner plate to tensioner. Insert lug of tensioner plate into hole of tensioner. “Fis GA-28 Timing Belt Tensioner and Bolt |. Tensioner pate Tensioner Lg Hole Fig. 64-30 Lug and HoleGA16 ENGINE MECHANICAL . Tensioner and tensioner plate: Do not tighten tensioner bolt with wrench yet, Hand tighten only at this time. Check to ensure that plate movement inarrow direction as shown in Fig. 6A-31 causes tensioner tormove in the same direction. If no associated movement: between plate and tensioner occurs, remove tensioner and plate again and reinsert plate lug into tensioner hole. 1 Tensioner bolt 3. Tensioner plate 2. Tonsioner Fig. 64-31. Tensioner Installation 3. Check that timing mark on camshaft timing belt pulley is aligned with “V" mark on ylin- der head cover. If not, align two marks by turning camshaft but be careful not to turn it ‘more than its allowable turning range which is described on Fig. 6A-29. 1. Camshaft timing bet pulley 3. *V" mark 2 Timing mark 4. Cylinder head cover Fig. 64-32 Timing Marks |. Check that punch mark on crankshaft tit belt pulley is aligned with arrow mark om pump case,'If not, align two marks by tur crankshaft but be careful not to turn it than its allowable turning range which is cribed on Fig. 64-29. 1. Grant timing bait 3. Artow mack pulley bole 4: Grankchatt timing belt 2. Puneh mark pully Fig. 64-33 Timing Marks 5. Timing belt, tensioner spring and damper, With two sets of marks aligned and tensi plate pushed up, install timing belt on pulleys in such a way that drive side of is free from any slack. ‘And then install tensioner spring and spri damper as shown in Fig. 6A-34, and har tighten tensioner stud, NOTE: ‘© When installing timing belt, match arrow (=>) on timing belt with rotating dit of crankshaft. ¢ In this state, No. 1 piston is at top dead ‘of compression stroke. |. Drive side of ele “Tensioner spring Damper | Tonsoner stud Fig. 6A-34 Installing Timing Belt and Tensioner Springb take up’ slack of timing belt, turn crank- sft two rotations clockwise after installing After making sure that belt is free from k, tighten tensioner stud first and then sioner bolt to each specified torque. confirm again that two sets of marks aligned respectively: ening torque [Nm | kom Ibe tensioner stud” | 9-12 [o.9—n2| 7.0-85 24=90|24-20| 175-218 a eon ening torque tensioner bolt Fig, 64-36 Installing Crankshaft Pulley 9, Water pump pulley and water pump belt. ‘Adjust belt tension to specification, Refer to Section “6B” for procedure to adjust belt tension, 10, Fender apron extension of right side. 11, Negative cable at battery. OIL PAN AND OIL PUMP 41, Tengionar stud STRAINER 2. Tensioner bolt GAGE Tensioner Bolt and Stud i 3-2 Fiming belt outside cover. ® é 2 installing, make sure that, seal, is be- een water pump and oil pump case. ig torque | nm ]-kgem | bt Sover bolt & nut| 9 12 |o.9-1.2| 70-85 Crankshaft pulley. Seen 4, oltpan 2. Oil pump strainer keyway on pulley to the key on crankshaft aoa siming belt pulley, and tighten’ 4 bolts to 4) Din pg gasket ‘ssxcification. 5. Ora poy Fig, 6A-37 Oil Pan and Oj! Pump Strainer. cening torque |_Nm | kgm bh pulleybotts [9-12 foe—12| 70-85(SAcTS_ENGINE MECHANICAL REMOVE OR DISCONNECT 1. Hoist car. 2. Drain engine oil by removing drain plug. Fig, 64-38. Drain Plug 3, Clutch housing (torque converter housing for A/T) lower plate. 4. Oil pan from cylinder block, 5. Oil pump strainer. Tie sisbo Mabl:tas iodo fonholes 9412 [o9-12 Fig, 6A-40 Installing Séal and Strainer 2. Clean mating surfaces of oil pan and ci block, Remove oil, old sealant, and dusts mating surfaces. After cleaning, apply silicon type seal il pan mating surface continuously as in Fig. 6A-41 of oil pan and oil pump strainer screen. INSTALL OR CONNECT 1. Oil pump strainer. Install seal in such position as shown in Fig. 6A-40. Tighten strainer bolt first and then bracket bolt to specified torque. Fig. GA-41 Applying Sealant to Oil Pan 3. Oil pan to cylinder block. After fitting oll pan to block, rut in s bolts and start tightening at the center: wrench outward, tightening one bolt at at Tighten bolts to specified torque. nut 9-12 Jos—12 Tightening toraue | am | kgm {or oil pan bolt andGasket and drain plug to oil pan, Tighten drain plug to specified torque. iorraoaue [Ae] em [bn ‘drain plug 30 — 40 |3.0—4.0| 22.0—28.5 Clutch housing {torque converter Housing for A/T) lower plate. Refill engine with engine oil, referring to item “ENGINE OIL CHANGE" in Section 0B. PUMP |- Rotor plate Inner rotor Outer rotor Retainer ring jin engine oil. pump belt) pulley, generator:and. its et. inkshaft pulley, timing belt outside cover, 7..Crankshaft timing belt pulley and timing Belt guide. With crankshaft locked as shown in Fig. 64-43 or 64-44, remove crankshaft timing belt pulley bolt, |. Clutch housing Square hole Slottod teowrcriver Oil pan Exhaust No. ple Fig. 6A-43 Locking Crankshaft for M/T model 1. Drive pate 2) Slotted sxeudriver Fig, 64-44 Locking Crankshaft for A/T model 1. Crankshete timing belt puller 2! Pulley bolt 3, Timing bet guide Fig. 64-45 Crankshaft Timing Belt Pulley Bolt64-20 ENGINE MECHANICAL 8. Oil pan and oil pump strainer as previously outlined. 9. Oil pump assembly after removing 7 bolts Fig. 64-48 Rotor Pate 1, oil pump 21 Bolt 3. Outer rotor and inner rotor: Fig. 6A-46 Op Pump Assembly DISASSEMBLE 1, Oil level gauge quide from oil pump. After removing guide bolt, pull out guide from oil pump. 1. Oi pump. 2. Oi evel gauge guige 3. Guide bot 4. Guide seat 1. Outer rater 2. Inner rotor Fig, 84-49. Outer Rotor and Inner Rotor INSPECT. © Oil seal lip for fault or other damage. Rep as necessary. * Outer and inner rotors, rotor plate, and ump case for excessive wear or damage. Fig, 64-47 Oil Level Gauge Guide MEASURE © Radial clearance Check radial clearance between outer and case, using thickness gauge. If clearance exceeds: its limit, replace o rotor or case,Radial clearance ; Limit on radial clearance 0.310 mm (0.0122 in.) 1. Outer rotor 2. tne x0 GA.50 Meosuring Radial Clesrance de clearance ig straight edge and thickness gauge, ssure side clearance. ton side 0.15 mm ance (0.0059 in.) GA-51 Measuring Side Clearance ASSEMBLE 1. Wash, clean and then dry all disassembled parts. 2. Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, and inside surfaces of oil pump case and plate. 3. Outer and inner rotors to pump case. 4, Rotor plate. Tighten 5 screws securely. After installing plate, check to be sure that gears turn smoathly by hand. 5. Guide seal to pump case and then oil level gauge guide, Refer to Fig. 6A-47 for guide seal. INSTALL OR CONNECT 1; Two oil pump pins and oil pump gasket to cylinder block. Use a new gasket, To prevent oil seal lip from being damaged or upturned when installing off pump to crankshaft, fit special tool (Oil seal guide) to crankshaft, and apply engine oil to special rankahate Special too! (Ci set guide (Vinyl resin) (09026-18210) Fig. 6A-62 Special Too! (Oil Seal Guide) Installation68-22 ENGINE MECHANICAL 3. Oil pump to crankshaft and cylinder block: Amoung 7 oil pump bolts, 3 No. 1 bolts and one No, 3 bolt are shorter than 3 No, 2 bolts in length. The thread of new No. 3 bolt is coated with sealant, Apply sealant to the thread of No, 3 bolt only: when. reusing. Install No. 1, No. 2 and.No. 3 bolts in such arrangement. as. shown in’ Fig. 6A:53; and tighten them to specified torque. After installing oil pump, check tobe sure that oil seal lip is not upturned, and then remove special tool, ra Fig. 64-66 Cutting Edge of Gasker Tightening torque | Nm | kgm | Ibe ° ese) for oil pump bolts OMOEA FAC AALS 6. Timing belt guide, key, and cranks timing belt pulley. Refer to Fig. 6A-56 for proper install of these parts, Install timing belt guide in such a way its concave side faces oil pump. With crankshaft locked, tighten, cran! timing belt pulley bolt to specified torg Tightening torave | Nm | kgm | wi for timing belt pulley bolt 105—115|10.5-11.5| 76. 4. No. 1 bolts short) 2 No.2 bolts llonal 3. No. Sbalt (shor, apply sealant BOND No. 1215,98000-311 1 Fig. 64-53 ll Pump Bolts 4, Rubber seal between oil pump and water 4. Pulley bolt Fig, 64-56 Installing Guide, Key and Pulley 4. oi pump 7. Timing belt, tensioner, and other parts 2. uber seal 2. Woter pomp previously outlined. Fig, GA-6A Inataling Rubber Seal 8. Adjust water pump belt tension, 9. Refill engine oi 5. Edge of oil pump gasket might bulge out: if it 10. Negative cable at battery. does, cut bulge off with a sharp knife, making 11. After completing installation, check ‘edge smooth and flush with end faces of pump pressure by running engine. ‘case and cylinder block.ISHAFT AND HYDRAULIC VALVE LASH ADJUSTER 2: Cylinder head cover, 2 Gasket (yincer head © Camshaft housing Now 5. Camshaft houring No.2 © Camshaft housing No. 3 camshaft & Oileet 1S Valve lash adjuster 4.57 Camshaft, Camshaft Housing and Valve Lash Adjustor VE OR DISCONNECT itive cable at battery. ir cleaner assembly as previously outlined. linder head cover as previously outlined. stributor and then its case from cylinder inkshaft pulley, timing belt outside cover timing bett as previously outlined. removing timing belt, set key on crank sft in position as shown in Fig. 6A-58 by jing crankshaft. This is to, prevent inter- ince between valves and piston when stalling camshaft. 44. Crankshaft timing belt pulley 2 Key Fig. 64-58 Position of Crankshaft Key8A-24 ENGINE MECHANICAL 6. Camshaft timing belt pulley: Lock camshaft with a proper size rod inserted into hole (10 mm, 0,39 in) in itas shown below and then loosen camshaft. timing belt pulley bolt. NOTE: Mating surfaces of cylinder head end cover must not be damaged in this work. So, put clean shop cloth between rod and mating surfaces, and use care not to bump rod against mating surfaces hhard when loosening bolt. 1. Camshaft timing. Rod bat pulley 4, shop loth 2. Camshaft Fig. 6A-59 Loosening Pulley Bolt 7. Camshaft housings from cylinder head, 8. Camshaft from cylinder head. 9. Valve lash adjuster from cylinder head, Fig. 64-60 Removing Valve Lash Adjuster NOTE: fi © Never disassemble hydraulic valve lash adj. © Don't apply force to body of adjuster, in high pressure chamber in adjuster will Don't ppv force Fig, 64-61 Valve Lash Adjuster ‘¢ Immerse removed adjuster in clean engine and keep it there till reinstalling it so as prevent oil leakage. If it is left in air, pl with its bucket body facing down. place on its side or with bucket body up. 1. Engine ot 2) Adjuster Fig. 64-81-1 Storing Valve Lash Adjuster INSPECT Cam Wear Using @ micrometer, measure, height of car measure height is below its limit, replace shaft STANDARD uml Tea Vaeaig—aasreom [saan seoautcan | oat Za atte) | (noon Fig. 64-62 Measuring Cam HeightRunout ‘camshaft between two “V" blocks, and its runout by using a dial gauge. sured runout exceeds below specified replace camshaft. Runout limit 0.10 mm (0.0039 in.) GA-62 Measuring Camshaft Runout Journal Wear camshaft journals and camshaft housings iting, scratches, wear or damage. ‘sny malcondition is found, replace camshaft ‘eylinder head with housing. Never replace head without replacing housings. clearance by using gaging plastic. The ure is as follows. ‘Clear housings and camshaft journals. Make sure that all valve lash adjusters are semoved and install camshaft to cylinder peed Piace @ plece of gaging plastic the full width journal of camshaft (parallel to camshaft) jestall housings as outlined on p. 64-27 and evenly torque housing bolts to specified jue. Housings MUST be torqued to speci ‘cation in order to assure proper reading of camshaft journal clearance E: not rotate camshaft whil led. gaging plastic is ENGINE MECHAMNCAL SATS Remove housing, and using scale on seging plastic envelop, measure gaging plastic width at its widest point. Standard Limit Journal (0.020 0,062mm | 012mm clearance | {0.0008 ~ 0.0024 in.) | (0.0047 in.) ——— = ee 1, Gaping plastic 2, Seale Fig, 64-64 Measuring Carnshaft Journal Clearance If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater. Iter Standard 728,000 — 26.021 mm Camshaft journal (1.0236 — 1.0244 in.) bore dia, No. 2 &| 30,000 ~ 30.021 mm No.3 | (1.1811 — 1.1819 in.) 126,958 — 25.980 mm arnsheft curse (1.0220 ~ 1.0228 in.) oo. No, 2 &| 29.969 — 29.980 mm No. 3 | (1.1795 — 1.1803 in.)6A26 ENGINE MECHANICAL Fig. 6A-G6 Measuring Camshaft Journal Dia. Wear of Hydraulic Valve Lash Adjuster Check adjuster for pitting, scratches, or damage. If any malcondition is found, replace. Measure cylinder head bore and adjuster out diameter to determine cylinder head-to-adj clearance. If clearance exceeds limit, adjuster o cylinder head, hem Standard Limi Hydraulic valve 20,959 ~ 30.975 mm. lash adjuster a re L. be (1.2188 — 1.2194 in.) Gylinder head | 31.000 —~ 31.025 mm_ bore (1.2205 — 1.2214 in.) indeed | o.5—o086mm | 018 a shes {0.0070 — 0.0025 in.) | (0.0059 Fig. 6A-68 Measuring Valve Lash Adjuster Dia, Fig. 64-67 Checking Lash Adjuster Fig. GA-69 Measuring Cylinder Head Adjuster BoreLOR CONNECT installing valve lash adjuster to cylinder E fill oil passage of cylinder head with sre oil according to following procedure. engine oil through camshaft journal oil e¢ and check that oil comes out from oil es in sliding part of valve lash adjuster. ‘Walve lash adjuster to cylinder head ply engine oil around valve lash adjuster 41. Timing bee pulley pin bole Fig, GA-72. Installing Camshate 4, Camshaft housing to camshaft and cylinder head. © Apply engine oil to housing against camshaft journal. « Apply sealant to mating surface of No. 1 ‘and No. 3 housings which will mate with cylinder head. ing surface of each 1. Apply sesant (SUZUKI BOND No. 7218, 98000-31110) A-71 Installing Valve Lash Adjuster |. Camshaft to cylinder head. ‘After applying engine oil to. camshaft journal and all around. cam, set camshaft to cylinder head so that camshaft timing belt pulley pin hole in camshaft is at lower position. Fig. 6A-73 Applying Seatent ‘e Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housing as indicated by these marks. fe tndieates postion trom timing bet sd install in aumariest order starting == ‘ming belt indicates direction of housing. losalt = ‘that arrow ie directed towers Sing Se Oo, side.64-28 ENGINE MECHANICAL ‘* As camshaft housing No. 1 retains camshaft in proper position as to thrust direction, ‘make sure to first fit No. 1 housing to No. 1 journal of camshaft securely. 41. No.1 housing 2. No, 2 housing 3. No. Shousing Fig. GA-74 Position of Housings © After applying engine oil to housing bolts, tighten them temporarily first. Then tighten, them by following sequence as indicated in figure below. Tighten a little at a time and evenly among bolts and repeat tightening sequence three to four times before they are tightened to specified torque. Tishtaning toe [New| hemo forhousingbolt | 9-12 |o9-12| 70-85 Fig. GA-75 Tightening Sequence af Housing Bolts 15, Special tool (Deep socket 09918-1 Fig, 6A-76 Tightening Housing Bolt 5. Camshaft oil seal, After applying engine oil to oil seal lip, fit camshaft oil seal till oil seal surface comes flush with housing surface. 6. Camshaft timing belt pulley to ca after installing dwell pin to camshaft. With locking camshaft as shown in Fig. 6 tighten pulley bolt to specified torque. Tightening torque | Nm | kom |. bie for pulley bolt [56-64 |s6-64141.0— 1. Camshaft timing batt pulioy 2. Dual pin Fig. 6A-77 Installing Pulley 7. Cylinder head cover to cylinder head previously outlined. 8. Timing belt, timing belt outside co\ crankshaft pulley, water pump pulley 2: water pump belt as previously outlined, 9. Distributor case and distributor. Refer to section 6F for installation, 10. Air cleaner assembly as previously outlined. 11. Negative cable at battery. 12, Adjust ignition timing. Refer to section 6F for adjustment.Don’t turn camshaft or start engit valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshaft. As it takes time for valves to settle in place, in half an hour after their installation may cause interference to occur between valves and piston. If air is trapped in valve lash adjuster, valve may make tapping sound when engine is operated after valve lash adjuster is installed. In such a case, run engine for about half an hour at about 2,000 r/min., and then air will be purged and ‘tapping sound will cease. Should tapping shound not cease, it is possible that valve lash adjuster is defective. Replace it if defective, If defective adjuster can’t be located by hearing among 6 of them, check as follows. 1) Stop engine and remove cylinder head cover. 2)Push adjuster downward by hand (with less than 15 kg or 33 tbs force) when cam crest is not on adjuster to bbe checked and check if clearance exists between cam and adjuster. If it does, adjuster is defective and needs replacement.6A-30_ ENGINE MECHANICAL VALVES AND CYLINDER HEAD = Cylinder ead Cylinder head bole Valve euide Cylinder ad satket comehote Valve lash agjusar Valve cottrs ‘Vat spring retainer 10. Vatve spring 14 U1. VaWve ser sal 12, Valve epeing saat 18, Exhaust vale 14, Intake valve Fig, 6A-78 Cylinder Head, Valve, Vaive Spring, Valve Guide, etc. REMOVE OR DISCONNECT 1. Relieve fuel pressure according to procedure described in p. 6-3. (for Electronic Fuel Injec- tion model). 2, Negative cable at battery. 3. Drain cooling water. 4. Air cleaner assembly and distributor. 5. Electric wire harness end release above wire hamess from clamps. 6. [For carburetor model] Second air pipe (if equipped). 7, Water hoses. 8, Vacuum hoses. 9. Fuel return hose and fuel feed hose from carburetor (or throttle body). 10. Accelerator cable from carburetor (or thr body). 11. Check all around cylinder head for any ot arts required to be removed or disconr ed and remove or disconnect whatever ni sery. 12, Hoist car. 13, Water pump pulley, crankshaft pulley timing bett as previously outlined. 14. Exhaust No. 1 pipe from exhaust monifold. 15. Cylinder head cover. 16. Cylinder head bolts. Cylinder head with carburetor (or thro! body), intake manifold and exhaust manifstate, one of 6 valves is out toward com- ‘chamber (i.e. itis open). Be sure NOT to cylinder head on any flat surface with its surface with cylinder block facing down. calise damage to such open valve. EMBLY For ease in servicing cylinder head, remove Jetzke manifold with throttle body, exhaust ‘manifold and distributor from cylinder head. Remove camshaft and valve lash adjusters ‘from cylinder head. Using special too! (Valve lifter), compress salve springs and then remove valve cotters bby using special tool (Forceps). 4, Release special tool, and remove spriggie= tainer and valve spring. 5, Remove valve from combustion chamber side. 6. Remove valve stem seal from valve quide, and ‘then valve spring seat. NOTE: Do not reuse seal once disassembled. Be sure to use new seal when assembling. 41. Special to! (Vale lifter 09916-12510) 2) Special tal [Valve lifter attachment 09916-14910) 1. Speci! tool (Foreops 00016-84510) cot Fig. 6A-81. Removing Valve Stem Seal 7. Using’ special tool (Valve guide remover), drive valve guide out from combustion cham- bor side to.valve spring side. NOTE: Do not reuse valve guide once disassembled: Be sure to. use_new valve guide (Oversize) when assembling. 1. Spectal toot (Walve guide remover (09916-44910) Fig. 6-82 Ramaving Valve Guide 8.Place disassembled parts except valve stem seal and valve quide in order so that they can be installed in their original positions.GA32_ENGINE MECHANICAL INSPECT Valve Guides Using @ micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-quide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide. Te Sanied | [ue wy | Baa =880 0m vane (ove —o2ter nd Beer [eq | 5450 = 54850 {0.2146 — 0.2151 in.) Vere |ina 55008512 mm gue .o,| ex | (0266 —o2T70%m) 0.020 = 0.055 mm | 0.07 mm Stemto- |! | (0.0008 — 0.0021 in.) (0.0027 in.) guide Valve head thickness ‘Standard Umit i 1.0mm 0.6mm (0.039 in.) (0.023 in.) a 12mm 0.7 mm (0.047 in.) (0.027 in.) 0.035 0.062mm | 0.09 mm clearance | Ex (0.0014 ~ 0.0024 in.) | (0.0038 in.) Il carbon from valves. © Inspect each valve for wear, burn or distortion at its face and stem and, as necessary, replace it, ® Measure thickness of valve head. If measured thickness exceeds limit, replace valve. Fig. 64-84 Valve Head Thickness © Inspect valve stem end face for pitting wear. If pitting or wear is found there, val stem end may be resurfaced, but not so m: as to grind off its chamfer. When it is worn. much that its chamfer is gone, replace valve. Fig. 64-85 Valve Stem End Facek each valve for radial runout with a dial ge and “V" block. To check runout, rotate slowly. If measured runout exceeds ; replace valve. 0.08 mm (0.003 in.) 26 Measuring Radial Runout fing contact duce a contact pattern on each valve in Usual manner, that is, by giving auniform ‘of Red-lead paste to valve seat and by ingly tapping each seat with valve head. valve lapper (the tool used in valve lapping) st be used. pattern produced on seating face of each must be a continuous ring without any Sk, and width of pattern must be within 1.3- 1.5mm (0.0512 ~ 00690 in.) 1 a 1, Valve set contact width Fig, 68-87 Valve Seating Contact Width Valve seat repair: ‘A valve seat not producing a uniform contact with its valve or showing seating contact that is off the specified width must be repaired by regrinding or by cutting and regrinding and finished by lapping. ‘The valve seats for both the intake and exhaust valves are machined to two different angles. The seat contact surface is cut 45° and thearea above the contact surface (closest to the combustion chamber) is cut to 15°. 48 1, Vato sat Fig. 64-88 Valve Seat Angle6A34 ENGINE MECHANICAL Using 45° valve seat cutter, descale and clean up the seat with one or two turns. 2. Inspect seat by previously described seat width measurement procedure. If seat is pitted or burned, additional seat conditioning with 45° cutter is required. NOTE: Cut only the minimum amount necessary from the seat to prevent possibility of valve stem be- ‘coming too close to cam. 1. Valve sat cuter Fig, 64-89 Cutting Valve Seat If contact area is too wide, use a 15° valve seat cutter to make it narrower. If contact area is too narrow, use the 45° valve seat cutter to widen it. 1.3—1.6 mm Standard seating width 9.0512 — 0.0590 in.) 3. After desired seat width is achieved, on seat in two steps, first with a co lapping compound. applied to. its secondly with a fine-size_ compound, time using a valve lapper according usual lapping method. Cylinder Head © Removeall carbon from combustion cl carbon, Be careful not to scuff or nick the: surfaces when decarboning. The same valves and valve seats, too. ‘© Check cylinder heed for cracks in intak exhaust ports, combustion chambers, head surface. © Flatness of gasketed surface: Using a straightedge and thickness check surface at @ total of 6 locations. tortion limit, given below, is exceeded, gasketed surface with a surface plate abrasive paper of about # 400 (Wats silicon carbide abrasive paper): place on and over surface plate, and rub gas surface against paper to grind off high Should this fail to reduce thickness readings to within the limit, replace cy head, Leakage of combustion gases from keted joint is often due to a warped surface; such leakage results in reduced output. 1. Valve seat contact width Fig. 6A-90 Valve Seating Contact Width Limit of distortion | 0.05 mm (0.002 Fig, 6A-91 Locations for Measurement of Distor®54-92 Measuring Surface tion of manifold seating faces: seating faces of cylinder head for folds, using a straightedge and thickness in order to determine whether these 0.10 mm (0.004 in.) Fig, 64-94 Measuring Surface of Exhaust Manifold Seating Face Valve Springs ® Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure, GA-33 Measuring Surface of Intake Manifold ‘Seating Face trem | __ Standard Limit wei tres| 4073mm 39.5 mm sprinatee) (1.8035 in) (1.5861 in) Ea 16-249 aa at 32.6 mm 16.6 kg at 32.6 mm sprog | (at0~ 47216 | (986th 1.28 in) ee at 1.28 in.) Figs GA-95 Meesuring Free Length of Spring,GA-36 ENGINE MECHANICAL 2. Special too! (Remar henal 09915 Fig. 6A-96 Measuring Spring Prefoad © Spring squareness Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve spring and square. Valve 1s found to exhibit a larger clearance than limit given below must be replaced, 2.0 mm (0.079 in.) Fig. 64-97 Measuring Spring Squarenest ASSEMBLY 1, Before installing valve guide into cylinder head, ream guide hole with special tool (11: mm Teamer) to remove burrs and make it truly round. Fig, GA-98 Reaming Guide Hole 2. Valve guide to cylinder head. Heat eylinder head uniformly ata temp of 80 to 100°C (176 to 212°F) so that will not be distorted, and drive’ new guide into hole with special tools. Ri Fig. 64.99. Drive in new valve guide until special (Valve guide installer) contacts cylinder After installing, make sure that valve protrudes by 11.5 mm (0.45in.) from head (Fig, 6-99). NOTE: © Do not reuse valve guide once disasse Install new valve guide (Oversize! © Intake and exhaust valve guides are ider Valve guide 0.03 mm oversize (0.0012 in.) Valve guide protru- 11.5 mm. sion (In and Ex) (0.45 in.) guide installer attachment 0961656. 2. Special toot (Valve gue instlier hen 0916-58210) '3._Vavegulde protrusion (11.5 mm, 0.45 In.) Fig. 64-99 Installing Valve Guideam valve guide bore with special tool (5.5 reamer). r reaming, clean the bore. 4. Vat guide 2. Special tool (8.8 mm reamer 09916-24880) 3, Special tool (Reamer han '@4-100 Reaming Valve Guide Bore ive spring seat to cylinder head. ‘valve stem seal to valve guide applying engine oil to seal and spindle special tool (Valve guide installer handle), oil seal to spindle, and then install seal to guide by pushing special tool by hand. ier installing, check to be sure that seal is perly fixed to valve guide. rE: not reuse seal once disassembled. Be sure install new seal. en installing, never tap or hit special tool ‘a hammer or else. Install seal to guide ly by pushing special tool by hand. Tapping hitting special tool may cause damage to ‘Scio tool [Valve stom seal ‘aller 09917-98220) Special too! [Valve guide itgaller han) 4-101 Installing Vaive Stem Seal 6. Valve to valve guide. Before installing valve to valve guide: 2ppty engine oil to stem seal, valve guide bore, and valve stem, Fig. 6A-102 Installing Valve 7. Valve spring and spring retainer, Each valve spring has top end (large-pitch end) and bottom end (small-pitch end), Be sure to Position spring in place with its bottom end {small-pitch end) facing the bottom (valve spring seat side). Large-iteh Smal pRch 3. Valve ring resinor Fig. 6A-103 Installing Valve Spring68-38 ENGINE MECHANICAL 8. Using special tool (Valve lifter), compress valve spring and. fit two valve cotters into groove provided on the valve stem. 41. Special too! (Valve tte) 2, Speokal tool (Forcens) 3. Valve cotter Fig. 64-104 Installing Valve Cotters 9. Valve lash adjuster and camshaft as previously outlined. 10. Intake manifold with throttle body, exhaust manifold and distributor to cylinder head. INSTALL OR CONNECT 1. Cylinder head gasket. Install new head gasket as shown in Fig. GA- 105 in such a way that “TOP” mark provided ‘on the gasket comes on top side (toward cylinder head) and on crankshaft pulley side. 1. Oyindar head gosker After applying engne oil to cylinder bolts, tighten them gradually with a wrench, following sequence given in b figure. Finally tighten bolts to spec torque. Tightening torque en for cylinder head Fig. 64-106 Tightening Sequence of Cylinder Head 3. Rubber seal between water pump and cylis 2, Water pure 3. Rubber sat 21 Crankshaft pulley side Fig. 6A-105 Installing Cylinder Head Gasket Fig. 64-107 Installing Rubber Seal 4. Cylinder head cover.Timing belt as previously outlined. Distributor to cylinder head. See section 6F for installation, Reverse removal procedure for installation ‘of remainder. Adjust water pump belt. Refer to section 6B for adjusting procedure. Adjust accelerator cable play according to srocedure described in section 6E. Refill cooling system, referring to section 68. Negative cable at battery, ‘Adjust ignition timing. Refer to section GF for adjustment, Upon completion of installation, verify ‘that there is no fuel leakage, water leakage ‘or exhaust gas leakage at each connection. INS, PISTON RINGS, IECTING RODS AND INDERS VE OR DISCONNECT linder head from cylinder block as previous- ‘outlined, Drain engine oil. pan and oil pump strainer as previously ‘k cylinder number on all pistons, connect- rods and rod bearing caps, using silver il or quick drying paint, bearing caps. | guide hose over threads of rod bolts. This is to prevent damage to bearing journal ‘sed rod bolt threads when removing connect- 7. Decarbon top of cylinder bore before fenton ing piston from cylinder. 8. Push piston and connecting rod assembly out through the top of cylinder bore. DISASSEMBLY 1. Using piston ring expander, remove two com pression rings (Top and 2nd) and oil ring from piston, 2, Piston pin from connecting rod. Fit piston and connecting rod assembly to special tool (Piston pin remover and installer) as shown in Fig. 6A-109 and Fig. 6A-110, and then press piston pin out of connecting rod by using arbor press, 1. Piston 2 arrow mark and inealor 09010-38211) Fig, GA-108 Installing Piston to Special Tool Pratt Nore: Items 1,4, and 6 are In special fool. 1. Gulde hosse 4-108 Installing Guide Hoses Fig. 6A-110 Removing Piston Pin__—TTE—————————————————————— GA-40 ENGINE MECHANICAL CLEAN Clean carbon from piston head and ring grooves, using @ suitable tool. INSPECT Cylinders ‘© Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, oF ridged, rebore cylinder and use oversize piston. ‘© Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in Fig. 64-111. If any of following conditions is noted, rebore cylinder. 1. Cylinder bore dia. exceeds limit. 2. Difference of measurements at two posi- ions exceeds taper limit, 3, Difference between thrust and axial measurements exceeds out-of-round limit. Cylinder bore dia, 74.15 mm limit (2.9198 in.) Taper and outof- 0.10 mm round limit (0.0039 in.) NOTE: If any one of three cylinders has to be rebored, rebore the three to the same next oversize. This is necessary for the sake of uniformity and balance. E 1. 50 mm (1.96 ind 2. 98 mm (3.78 in} Fig. 64-111 Positions to be Measured, Fig. GA-T12 Measuring Cylinder Bore with Gylind Gauge Pistons ® Inspect piston for faults, cracks or © damaged. Damaged or faulty piston sho replaced. © Piston diameter: As indicated in Fig. 6A-113, piston diar should be measured at a position 16) (0.59 in) from piston, skirt end in the di tion perpendicular to piston pin. 7.970 — 78580 m= ees (2.9122 — 2.9129 i rrson | Owe | 74 200 — 74250 diameter | (2250 | (2aza0 292041 som | 74a76 74807 (0.01081) | «(201026922 m 1, 18mm or 0.69 In. Fig. 64-113 Measuring Piston Diameter with Micrometerclearance cylinder bore diameter and er to find their difference which is clearance. Piston clearance should be specification as given below. If it is specification, rebore cylinder and use ize piston. 0.02 — 0.04mm enclearance | (0,0008 — 0.0015 in.) bore diameters used here are measured st direction at two positions as shown in "g groove clearance: ore checking, piston grooves must be clean, Piston Pin ‘© Piston pin must be fitted into piston Bore ‘with an easy finger push at normal room te= ‘damage. If pin or piston bore is badly worn or damaged, replace pin or piston, or both. Piston Rings To measure end gap, insert piston ring into cylinder bore as shown in Fig. 64-115 and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring. NOTE: Decarbon and clean the top of cylinder bore before inserting piston ring. 4. Piston sna and free of carbon. new-piston ring into piston groove, and bent ae Line ssure clearance between ring and ring land pring | S00 00 HN sae Being thicknasd 3eUg2> asa (0.0079 —0.0118 in) | (0.0278 in.) clearance is out of specification, replace mg Vand ring | (9S sia aia S 0118 in) | (0.0278 in. es il ring 0.20 — 0.60 mm 1.8mm = a (0.0679 — 0.0286 in.) | (0.0708 in.) Boor (0.0012 — 0.0027 in) 2 (0.02 — 0.08 mm {0.0008 — 0.0029 in.) 2 Tinos gouge GATT4 Measiring Ring Groove Clearance 3 2 Footer gauge 3, Piston ring 44. 120 mm (4:72 in) Fig, 64-116 Measuring Piston Ring End Gap6A-42 ENGINE MECHANICAL Connecting Rod © Big-end side clearance: Check bigend of connecting rod. for side clearance, with rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod. tem Standard Limit Bigeend side 0:10-0.20mm | 036mm clearance | (0,0039 — 0.0078 in.) (0.0137 in.) Fig, 64-116 Measuring Side Clearance © Connecting rod alignment: Mount connecting rod on aligner to check it for bow and twist and, if limit is exceeded, replace it. Limit on bow imit on twist, 0.10 mm (0.0039 in.) 0.06 mm (0.0020 = Crank Pin and Connecting Rod Bearings Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin to undersize and use undersize bearing. Connecting in di rod bearing size _| _“renk Pin diameter 41.982 — 42.000 mm ae | (1.6529 — 1.6535 in.) (0.25 mm (0.0098 in.) | 41.732 — 41.750 mm undersize [1.6430 ~ 1.6437 in.) ‘Out-of-round and 0.01. mm... ‘taper limit (0.0004 in.) © Rod bearing: Inspect bearing shells for signs of fusio ting, burn or flaking and observe cs pattern, Bearing shells found in. det condition must be replaced. Two kinds of rod bearing are availab! ard size bearing and 0.25 mm undersize ing. To distinguish them, 0.25 mm und bearing has the stamped number (US 02% its backside as indicated. in Fig. 64-117, standard size one has no number. Fig, GA-117, 0.25 mm Undersize Bearing # Rod bearing clearance: 1. Before checking bearing clearance, ol bearing and crank pit 2. Install bearing in connecting rod and ing cap. 3. Place a piece of gaging plastic the width of crankpin as contacted by be (parallel to crankshaft), avoiding oil ho 4, Install rod bearing cep to connecting When installing cap, be sure to. point arrow mark on cap to crankshaft. p side, as shown in Fig. 6A-118, After ap ing engine oil to rod bolts, tighten cap 10 specified torque. DO NOT turnic shaft with gaging plastic installed. Tightening torque | Nm | kom | ibs for rod bearing §— |} — cap nuts 33-37 |33-3.7| 24.0-3, Crankshaft pulley side 4 Capnut 1, Rod bearing cap 2._ Arrow mark (S418 Insalling Bearing Cop Remove cap and using a scale on gaging plastic envelope, measure gaging plastic width at the widest point (clearance). if clearance exceeds its limit, use a new standard size bearing and remeasure clearance. ‘Standard Limit 0.020 0.050 mm | 0.080 mm {0.0008 - 0.0019 in} {0.0031 in3) tem | 41. Gaging plastic 2. Scale GA-119 Measuring Rod Bearing Clearance 6.f clearance can not be brought to within its limit even by using a new standard size bearing, regrind crankpin to undersize and use 0,25 mm undersize bearing. ASSEMBLE NOTE: Two sizes of piston are available as standard size spare part so as to ensure proper piston-to- cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. a) Each piston has stamped number 1 or 2 as shown, It represents outer diameter of piston. Fig. 6A-120 Piston Sie Number b) There are also stamped numbers of 1 and 2 on cylinder block as shown below. The first number represents inner diameter of No. 1 cylinder, the second number of No. 2 cylinder and the third number of No. 3 cylinder. ‘Nos ylindsr [Ne Cylinder [823 Onin lnder oct Fig, 4-121 Oylinder Bore NumberGAd4_ ENGINE MECHANICAL ©) Stamped number on piston and that. on cylinder block should correspond. That is, install 2 number 2 stamped piston to cylinder which is identified with number 2 and a number 1 piston to cylinder with number 1, Fig. GA-122 Piston-to-Cylinder Orientation Faon on nice domen | | gon eet 1 |aara-zsrom| 1 Jaaioe zoe] C50 Jeerae-zoraams], ER Also, @ letter A, B or C is stamped on piston head. but ordinarily it is not necessary to dis- criminate each piston by this letter. 1. Connecting rod to piston: After applying engine oil to piston pin holes in piston and connecting rod, fit cone rod to piston as shown in Fig. 6A-123. > canis pny side 1. Piston 21 erow mark 3. Connecting rx 4 Ollhole (Scat ve) Fig. 6A-123 Fitting Connecting Rod to Piston 2. Piston pin to piston and connecting rod: Place. piston onto special. tool (Pisto= remover and installer) as shown in Fi 124 and. 6A-125, and press piston pin piston and connecting rod. f Press piston pin until line marked ont handle is flush with flat surface of piston 6A-126). - snd ingaler) 4, Hole on base Spring gui Base cap Boe ‘Support Fig. 6A-126 Installing Piston PinDriver handle Line Piston Piston pi SS 64-126 Line Marked on Driver Handle : > ; . ; 2 3 4 = rings to piston: | As indicated in Fig. 6A-127, 1st and 2nd rings ave “R" or “*T" mark, When installing these viston rings to piston, direct marked side of ‘each ring toward top of piston. E: are 2 types of ‘1st ring, marked and un- ‘ed. When installing a new unmarked 1st it is not necessary to distinguish its top bottom (i.e., either side can face upward) when reinstalling a used one, be sure to guish its top from bottom as it was installed removal and direct topside upward. ‘4st ring differs from 2nd ring in thickness, ‘shape and color of surface contacting cylinder wall, Distinguish 1st ring from 2nd ring by referring ‘t Fig. 64-127. When installing oil ring, install spacer first ‘and then two rails. 4. string 2. 2nd ring 3. Ollring A127 Installing Piston Rings 4, After installing three rings (ist, 2nd: ame cit rings), distribute their end gaps 2s-shome i= Fig. 6A-128. ‘crow mark 1st ring end gop 2nd ring end gee Exhaust sie as" Oilringspecer 020 Fig. 6A-128 Piston Ring End Gaps Positions INSTALL OR CONNECT 1. Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. 2. Gude hoses over connecting rod bolts. These guide hoses protect crankpin and threads of rod bolt from damage during installation of connecting rod and piston assembly, Refer to Fig. 6A-108 for installation of guide hoses. 3,When installing piston and connecting rod assembly into cylinder bore, point arrow mark on piston head to crankshaft pulley side. 1. Crankshaft pulley side 2) Fiyhee side Fig, 6A-129 Direction of Arrow Mark on Pixon at6A-46 ENGINE MECHANICAL 4.Piston. and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connect: ing rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore, Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. 1. Special tol (Piston ring compressor 09916-77310) Fig. 64-130 Installing Piston to Cylinder 5, Bearing cap: When installing cap to rod, point arrow mark ‘on cap to crankshaft pulley side, Tighten cap nuts to specification. Tightening toraue | tum | kgm | ibe for rod bearing cap nuts 33 - 37 |33-3.7| 24.0-26.5 1. Bearing cap 3. Crankshaft pulley side 2 Arrow mark 4. Cap nat Fig. 64-131 Installing Bearing Cap 6, Reverse removal procedure for install of remainder, as previously outlined. 7. Adjust water pump belt tension. See 68 for adjustment, 8, Adjust accelerator cable play. See section for adjustment, 9. Refill engine with engine oil, referring item "ENGINE OIL CHANGE” in cooling system, referring to 11, Negative cable at battery. 12. Check ignition timing and adjust as nect 13, Upon completion of installation, verify there is no fuel leakage, water leakage exhaust gas leakage at each connection.UNIT REPAIR OVERHAUL INE ASSEMBLY JOVE OR DISCONNECT Relieve fuel pressure according to procedure described in p. 6-3 (for Electronic Fuel Injec- tion model) Engine hood after disconnecting front window washer hose. Battery cables at battery. For A/T model, remove battery and its tray. Drain cooling system. Ali cleaner assembly as previously outlined. Radiator with cooling fan. Refer to section 68 for removal. Following electric wire harness: ‘© High-tension cord from ignition coil * Distributor * Water temp. gauge * Radiator fan thermo switch '* VSV for EGR valve (if equipped) ‘* WTS (for Electronic Fuel Injection model) ISC solenoid vaive (for Electronic Fuel Injec- in model) Ground wire harness from intake manifold TSor TPS Fuel injector (for Electronic Fuel Injection model) '® Pressure sensor (for Electronic Fuel Injection model) © Oil pressure switch ‘Oxygen sensor (for Electronic Fuel Injection model) Generator Starter Back-up light switch (For M/T model) Battery negative cable from transmission Shift switch of A/T (For A/T model) Direct clutch and 2nd brake solenoids of AIT (For A/T model) ‘Speed sensor on A/T (For A/T model) release above wire harness from clamps. owing vacuum hoses: Brake booster hose from intake manifold. ‘Canister purge hose from intake manifold. Canister hose from its pipe. 9. Fuel return hose and fuel feed hose 10. Heater inlet and outlet hoses, 11, Following cabl @ Accelerator cabl Clutch cable from transmission. (For M/T model) ‘© Gear select cable and oil pressure control cable from transmission (For A/T model) Speedometer cable from transmission. 12. Hoist car. 13. Exhaust No. 1 pipe from exhaust manifold. 14. Gear shift control shaft and extension rod from transmission. (For M/T model) 15, Drain engine oil and transmission oil. 16. Drive shafts (R & L) from differential side gears of transmission. Refer to section 4 (DRIVE SHAFT) for procedure to disconnect drive shaft. For engine and. transaxle removal, it is not necessary to remove drive shaft from steering knuckle. 17. Engine rear torque rod bracket from transmission. (For A/T model) 18. Lower car. 19, Other attached parts from engine and transmission, if any. 20. Install lifting device. 21, Right side engine mounting from its bracket. Fig. 64-132 Removing Engine Mounting (Right Si)GA48 ENGINE MECHANICAL 22. Transmission rear mounting from body. (For M/T model) Transmission rear mounting nut. (For A/T model) 23. Transmission left side mounting bracket, 24, Engine with transmission from body. INSTALL OR CONNECT 1. Lower engine with transmission into engine compartment, but do not remove lifting device, 2. Transmission rear mounting to body. (For M/T model) ‘Transmission rear mounting nut. (For A/T model) 3. Transmission left side mounting bracket. 4, Right side engine mounting to its bracket, 5. Tighten bolts and nuts of all parts installed in above steps 2, 3 and 4 to specified torque. Tiotning rave ° 80 60 Nm @s0~ oka m —430ib 1. Rave mounting 5. 2 Rear mounting No.2 6. a bracket 3, Rear mounting No, 1 bracket 4. Left mounting body raeker Fight mounting bracket ign mourting Fig. 64-133 Engine Mounting (For M/T Model) sia eee eter agra +3, Right mounting bracket @s.0-60kam SRR EAT ou iro fi sateen re 8. Rear mounting bracket: Sir eRe ais eee 10. Rear mounting body No.1 ©)4.0- 5.0 kgm tse Fig. 64-134 Engine Mounting (For A/T Model) 6. Remove lifting device. 7. Reverse removal procedures for install of remainder. 8. Adjust clutch pedal free travel, referring: section 7C, (For M/T model) Adjust gear select cable and oil. p control cable, referring to section 7B. A/T model) 9. Adjust accelerator cable play, referring seotion 6E. 10, Refill transmission with gear oil, (A/T: for A/T model), referring to section 7A of 11. Refill engine with engine: oil, referring section OB. 12. Refill cooling system; referring to 6B. 13, Upon completion of installation, that there is no fuel leakage, water lea or exhaust gas leakage at each connection.. Timing pulley key 3 ao = a a 2 a > 6 2 2 < b < = a Zz Fa & 5 G g z = < a a6A-50 ENGINE MECHANICAL REMOVE OR DISCONNECT 1. Engine with transmission from body as pre~ viously outlined, 2. Transmission from engine, and then clutch and flywheel (drive plate for A/T). 3.Water pump belt, generator bracket, crank shaft pulley, timing belt, and crankshaft timing belt pulley, etc.. 4, Cylinder head assembly. 8. Oil pan and oil pump strainer. 6. Pistons and connecting rods. 7. Oil pump and oil seal housing. 8. Main bearing caps and crankshaft. INSPECT Crankshaft Crankshaft runout Using a dial guage, measure runout ot center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft, Limit on runout | 0.08 mm (0.0023 in.) Tightening torque or main bearing Nem [Keen 50-87 [5.0-67 |36. cap bolts Tom Standard Crankshaft | 0.11 —0.31mm thrustplay | (0.0044 ~0.0122 in.) | 0. 2 Thickness of Standard ©: crankshaft | 0.425 mm | 2 thrustbearing | Oversize: (50549 in) | (0. Fig. 64-137 Thrust Bearings Cd Fig. 64-136 Measuring Runout Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed. Tighten bearing cap bolts to specified torque. Use a dial gauge to read displacement in axial (thrust) direction of crankshaft. If its limit is exceedsd, replace thrust bearing with new standard one or oversize one to obtain standard thrust play. Fig. 64-138 Measu! ing Thrust Play of Crankshateround and taper (uneven wear) of Is unevenly worn crankshaft journal shows up ‘2 difference in diameter at a cross section or its length (or both). This difference, ifany, jined by taking micrometer readings. ‘sry one of journals is badly damaged or if unt’ of uneven wear in the sense explained ‘exceeds its limit, regrind or replace crank- Limit on out-of: dad and taper = | 0M (0.0004 in) ‘Service main bearings are available in standard- and 0,25 mm (0.0098 in.) undersize, and ‘zsch of them has 5 kinds of bearings differing ‘tolerance. ‘Upper half of bearing has oil groove as shown = Fig, 6A-140. Install this half with oil groove cylinder block. yng block 2. Upper hat f bering 3._Ollgroove A-140 Installing Upper Half of Bearing '* On each main bearing cap, afrow mare ane number are embossed as shown in Fig. GATT When installing each bearing cap to Cylincer block, point arrow mark toward cranksheft pulley side and install each cap from thet side to flywheel side in ascending order of numbers "1", “2”, "3" and "4". Tighten cap bolts to specified torque. Tiopaaioasrony Priya Pg] == HE for main bearing expt 60-67 [50-67 [205-410] 4, Crankshaft play side 2. Fyne side Fig. 6A-147 Bearing Caps Installation Inspect Check bearings for pitting, scratches, wear or damage. If any malcondition is found, replace both upper and lower halves. Never replace one half without replacing the other half. Main bearing clearance Check clearance by using gaging plastic according to following procedure. 1. Remove bearing caps 2. Clean bearings and main journals. 3. Place a piece of gaging plastic the full width of bearing (parallel to crankshaft) on journal, avoiding oil hol 4, Install bearing cap as previously outlined and evenly torque cap bolts to specified torque: Bearing cap MUST be torqued to specifics: tion in order to assure proper reading of clearance, NOTE: Do not otate crankshaft while gagin> plate is installed. f6A52_ENGINE MECHANICAL 5. Remove cap, and using scale on gaging plastic welop;, measure gaging plastic width, at its jdest point. If clearance exceeds its limit, replace. bearing. Always replace both. upper and, lower inserts as a unit. ‘A new standard bearing may produce proper clearance. If not, it will be necessary. to, regrind crankshaft journal for use of 0.25 mm undersize bearing. After selecting new bearing, recheck clearance. Standard Tinit (0.020 0.040 mm | 0.060mm (0.0008 — 0.0016 in.) |(0.0023 in.) Bearing clearance 1. Gaping plastic 2 Scale Fig, 6A-142 Measuring Main Bearing Clearance Selection of main bearings STANDARD BEARING: Mf bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to following procedure. and install it. 1. First check journal diameter, by ing procedure. ‘As shown in Fig. 64-143, crank webs of No. 1 cylinder have four stamped numerals The three kinds of numerals (""1!',"2" and "3/1 represent following journal diameters, follow: Numeral canes Journal diameter 44.994 — 45.000 mm (1.7714 —1,7716 in.) 44.988 — 44.994 mm (1.7712 - 1.7714 in) 44.982 — 44.988 mm (1.7710 = 1.7712 ind The first, second, third and fourth (left stamped numerals represent journal at bearing eps "1”", "2", "3!" and 4" vely. For example, in Fig. 64-143, the first (let ‘numeral "3" indicates that journal dia. ing cap,'"1'* is within 44.982 — 44.988 second, one ‘'I"" indicates that journal cap "72" is within 44.994 — 45,000 mm. ONE — AN al om ni) 1. rank wabe of No.1 2) Oil pump Fig. 6A-143 Stemped Numerals on Crank Webs of Cylinder 2. Next, check bearing cap bore diameter out bearing, On mating surface of cylinder block, fours phabets are stamped as shown in Fig. 6A- Three kinds of alphabets ("A”, "B" and represent following cap bore diameters, Alphabet | Bearing'cap bore dia stamped (without bearing) x 49.000 — 49.006 mi (1.9292 ~ 1.9294 in.) a 49.006 — 49.012 mm (1.9294 ~ 1.9296 in.) re 49.012 ~ 49.018 mm (1.9296 — 1.9298 in)first, second, third and fouth (left to right) it cap bore diameters "and "4", respecti- example, in Fig. 64-144, the first (leftmost) et_"B"" indicates that cap bore dia. of 4 cap "1" is within 49.006 — 49.012 mm, ‘thé fourth (rightmost) alphabet “A ind! = that cap bore dia. of cap “4” is within 6A-144 Stamped Alphabets on Cylinder Block There are five kinds of standard bearings Su oer fo 6. tone ee erate oe Lower body Airave Fuel aie Fig. 66 Throttle Body Cross-SectionLINJECTOR cctromagnetic type injection nozzle jects fuel in the throttle body bore 1g to the signal from ECM, on en the solenoid coil of the injector is energi2- by ECM, it becomes an electromagnet and the plunger. At the same time, the wie valve which is incorporated with the ‘opens and the injector which is under fuel pressure injects fuel in conic dispersion. lift stroke of the needle valve of the injec- Js set constant, the amount of fuel injected time is determined by the length of time 3 which the solenoid coil is energized ELECTRONIC FUEL INJECTION SYSTEM 6E-11 FUEL PRESSURE REGULATOR ‘The fuel pressure regulator is diaphragm-operated relief valve consisting of diaphragm, spring and valve. It keeps the fuel pressure applied to the injector 1.8 kg/m? (180'kPa, 25.6 psi) higher than that in the intake manifold at all times, ‘The pressure epplied to the chamber “A” of fuel pressure regulator is intake manifold pressure and that to the chamber “B” is fuel pressure, When the fuel pressure rises more than 1.8 kg/ em? (180 kPa, 25.6 psi) higher than the intake manifold pressure, the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank via the return line. ‘Chamber "A" 8. From fuel pump Chamber "8" 7. To uel ter 8. Inake menioia 1. xing lage) 4,’ Neadle valve 2. call 5. O-ring (eral) Preemie (cue) 3. Plunger 6. Fier B Fuel Injector Cross-Section Fig. 6E-8 Pressure Regulator Cross-SectionSYSTEM 6E-12 ELECTRONIC FUEL INJECTION. ‘As the engine is warmed up, the therme AIR VALVE The sir valve consists of thermo-wax, springs and expands gradually, then the piston pushes valve, the valve gradually, and the amountof air @ When the engine is cold, it sends the air into the through the air valve decreases and s0, do engine speed. When the engine cooling temperature reaches about 80°C (176°F) valve is fully closed and the engine speed is +o the normal idle speed. intake manifold without letting it pass through the throttle valve to increase the engine speed, and thus the engine is warmed up. Operation When the engine is cold (or engine cooling water is lower than about 80°C (176°F)), the thermo- wax contracts. In this state, the valve opens by the spring force, allowing the air to be drawn into the intake manifold. Thus the amountof intake air increases ‘even when the throttle valve is at the idle position and the engine speed rises to the fast idle state which is higher than the idle speed, 1. Piston 2. Vale 3 Theme we Fig. 6E-10 Closing Air Valve Pye 1, Throttlebody 4. Valve 2. Thermo wax’ 5. From inteke manifold 3. Springs 6. To inake pipe Fig. 6E-9 Opening Air Valve(Idle Speed Control) SOLENOID VALVE ISC solenoid valve opens and closes air by- passage according to the signal from ECM. sn it opens, the air is supplied to the intake fold, y Coit | Magnat yoke Core E101 ISC Solenoid Valve CrossSection ELECTRONIC FUEL INJECTION SYSTEM 6E-1366-14 ELECTRONIC FUEL INJECTION SYSTEM. ELECTRONIC CONTROL SYSTEM The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices. Fanctionally, it is divided into five sub systems: © Fuel injection control system ® ISC solenoid valve control system ‘© Fuel pump control system ‘© EGR: control system (For California model) © Shift-up indicator light control system M/T model only) Also, with A/T model ECM sends throttle: opening signal to A/T control module to. AIT. INFORMATION SENSORS CONTROLLED DEVICES Presse songor Fue injector TSor TPS ISC solenoid valve ats + Fuel pump relay wis EGRVSY Oxygen sensor "CHECK ENGINE" light ‘Speed sneor Shiftup indicator light AIT eontrot module {For A/T mse!) 3. Janetion Tue block {Disgnosie snitch terminal) Ignition cot oTHers eM in lay 2 EGR vale ee Ech l eoeEe P Canister + Monitor coupler Injector resistor Fig, 6E-11 Parts Locationonu09 mop ate sede sebaeneuxg = [ajuo epou (awe jopouy sumo jony/y “Wy 04) rd mm | roauoo yy we | onus uonsetur yang Teer duind jan TAuo epou Ly 403) ELECTRONIC FUEL INJECTION SYSTEM 6E-15 Hs route onenues (enc) 1109 a6 Axo ‘uioy aie Da ssneyxae| uyuado ‘dun jan Buyjooo ausbuze UsBAXO ainssaid SiV ASATWLV9 jorosinvay Jonosinv uanvano | eget ani = AYME ASNWHX3 oN sini aly =e 42 System Schematic! 6E-16 ELECTRONIC FUEL INJECTION SYSTEM - = 2] | & & 2 \¢ & a g-je Ls |e-——s— 8 ra | Taaea]aalaa|aslas] a7] aa aifea] ss [ea [os]oe] — SHEE a 1ZA1GAISATSAIGAT: /37} 68] 89 je10\811|51: Fig. 6E-13 System Wiring Diagram (M/T model)>PeIg/MOIIA ¢ MOI, : suryNyPed ELECTRONIC FUEL INJECTION SYSTEM 6E-17 moit@a/uaai6246) euymyuaes6iy6i9 ; so1tu6 Jeujwuier yous sisoU! x09 asny UIE * eujussay yous 350), woa 4ajdn09 4021U0WN * sossasddns aston Aojad We“ auumyAeg, 109 uo!uB} yous onaubew seers * hei: sosuas asnssaig youms yoni aap: {yous uado apim, ous Ure euyNyUModg | YOUMs app] “1+ Aseneg * umosg : \yoUMs apro.ys. ANIDNA X93HO,, peyvenig: sosuas “dwar 121294 1UBIL 4OeoIpUI ANasrYS + more A9218 sosues “duia) sty {jepous ‘gads eus0y!/e9 404) auumyeeta : 4osuas paads, ASA U9 * pouppela : 40SU95 U9BAXO * ‘nye p1oua}os OSI * uaai9/99e19 (seuorn:puoo-s1@ ym 489 404) s0081504 * anjge1g ASA J8U011pUOI-NY * soroafu jana yeea duind jong“ ‘Agia duind jan *ELECTRONIC FUEL INJECTION SYSTEM 6E-17 PRIG/MO}IOA > B/A, MOHIBA: A SUUMV PAY: M/E nj /NYM = 18/M onus M molreA ato: uaa ato: moji2A/uaes814617 : 4/89 auyyvu9e.6i yor :MV/57 Peay /uaasbrybr) 4/87 2y9e]g/u@8s51y619 : 2/69 aay]: 67 aUUM/Aeig >M/29 heg: 49 uaaig: 9 aUYNVUMOIg (MIE umoig: 4g peu/enia: Y/I8, MOHBA/HEIG: A/S aUYAV>eela : WE payors: ¥/8 uasp ela: O/8 anig/99e1g : 18/8 pela: a 40109 9119, sous, “6z og asny UleW “BZ WO "Lz. sossauddns asion “gz, [Woo uonyub} “gz. 40Su9s a1nssa4d “bz youms uado apim 2-67 LYOUMS OIP] “LEZ youms eprouyL “EZ. 4osuas “dussr J91e44 “ZZ, sosuas “dwar sy “Lz, 4osuas paads “OZ 40suas uaBAXO “GL (Jau0}n!pu09-4e pA 1e9 104) ASA J9U0}IPUOD-sIy “BL (,au0opypuos-s1e yum 489 40-4) wooly “Lb 46] UoReulNIT “gL youms Sunysry “SL Jeujuser youms sisouberq “Z-p) reujwusar Youms 1591 “L-PL 4ajdno9 1021U0WN “ph Aviad UIEW “EL youims oneuBeu 813215 ‘ZL yoRims YOINID “LL puns UIEW ‘OL Auaaeg 6 3y6ti ANIONS XO3HO,, ‘8 1YBIT 4oreo!pul dnaylus *Z {lepous “seds e1usoy1je5 104) ASA 493 9 anjea ploua}os QS} °g 20381524 “y sorsaful fang “e dwind jong °Z ‘eyo duund jan “18E:18 ELECTRONIC FUEL INJECTION SYSTEM [esse fat] 52] 3 [2 e722] 89 joigiariard az ale oT et 68 za Fig. GE-14 System Wiring Diagram (2/7 niodel)HORIE/MOIIOA : Molo, : aNUNVP AY: enjg/auum : ELECTRONIC FUEL INJECTION SYSTEM 6E-19 auiym/ue=s61y6"7 5yV/67 pay /vaeab1y6r7 yoeig/u99461467 vuaai6iybr]: 67 BUUNV ARID ‘AAD fein: 19 uaag: 9 Molla, /UMOUG : A/38 STIUM/UMOLE -NV28 Poy/umog 4/18 spelg/umoig: 8/48 48 406 wo3 sossaiddns aston uontub} Josuas aunssaig Lyoums aIp} Josues uon|sod ejsiouy, 4osu2s ‘duso} s91em * sosuss ‘dusay sy 4osuas paads 40su2s UaBAXQ (uauolnpuos-i1e yrim™ 429 404) ASA s2u0HIpUOD-sy xq asny UleW, Jeujwusor yoru s1soube1q 4 9% ‘az ve ee Lee @ Wz oz 6 ‘aL ub ‘OL SL eH 91 YORI 150), Ja}dn09 soo Aoyas u eubeu! series ‘ainpow jox,UOD 1 /y * ANION] XO3HO., * (lepow “vads erusoyyje9 404) ASA 493 ‘@njeA plousjos 9S) A ebb duund jang ‘Agju duind jan“ “bh vL el a ub on6E-20 ELECTRONIC FUEL INJECTION SYSTEM. Electronic Control Module (ECM) ECM is installed to the underside of the instrument panel at the driver's seat side. ECM js a precision unit consisting of micro: computer, A/D (Analog/Digital) converter, 1/0 (Input/Output) unit, etc.. It is an essential part of the electronic control system, for its functions include not only such a major function as to control fuel injector, ISC solenoid valve, fuel pump relay, etc. butalso self- diagnosis function and fail-safe function as described in the following section. 1 eM 2. hestrument panel steering whee! Fig. 6E-16 ECM Location Self-diagnosis function ECM diagnoses troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running, and indicates the result by turning on or flashing "CHECK ENGINE" light. ‘© Oxygen sensor ‘© Water temp. sensor Throttle switch (M/T model) or throttle position sensor (A/T model) Air temp. sensor Pressure sensor {nition signal Speed sensor EGR system (California spec. model only) CPU (Central Processing Unit) of ECM ECM and “CHECK ENGINE” light opera follows. © “CHECK ENGINE” light lights when the: tion switch is turned ON (but the eng stop) with the diagnosis switch terminal grounded regardless of the condition of system. This is only to check the ” ENGINE" light bulb and its circuit. © If the above areas of Electronic Fuel I ion system is free from any trouble after engine start (while engine is running), CK ENGINE” light turns OFF. © When ECM detects a trouble which has red in the above areas, it makes. ENGINE” light turn ON while the e running to warn the driver of such occus of trouble and at the same time it stores trouble area in ECM back-up memory. (The memory is kept as it is even if the was only temporary and disappeared i ately. And it is not erased unless the ECM is shut off for 60 seconds or longens ECM also indicates trouble area in m means of flashing of “CHECK ENGINE™ at the time of inspection (ive. when i switch terminal is grounded and i switch is turned ON). NOTE: © When a trouble occurs in the above ‘except EGR system and disappears soon ‘the diagnosis switch terminal is un and the engine is running, “CHECK E| light lights and remains ON as long a trouble exists but it turns OFF when normal condition is restored. When it is EGR system where 2 occurs, even if it is only a temporary disappears soon, “CHECK ENGINE” remains ON till the in switch is OFF.fe function when @ trouble has occurred in such area Electronic Fuel Injection system that the following parts and a failure signal ‘to ECM, control over the injector, ISC jd valve and others is maintained on the ‘of the standard. signals and/or back-up ym prestroed. in the ECM while ignoring failure signal and/or CPU. function is called “fail-safe function’ , with this function, a certain level of engine jance is available even when some failure in such area and disability in running is ater temp. sensor He switch (M/T model) or throttle posi- sensor (A/T model) sensor ‘temp. sensor6E-22 ELECTRONIC FUEL INJECTION SYSTEM. Pressure (intake manifold absolute pressure Sensor (PS) ‘This sensor senses pressure change in the intake manifold and converts it into voltage change. It consists of a semi-conductor type pressure converting element which converts a pressure change into an electrical change and an electronic circuit, which amplifies and corrects the electric change. The ECM sends a 5-volt reference voltage to the pressure sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, ECM knows the manifold pressure (intake air volume). Throttle Switch (M/T model only) The: throttle switch: consisting of 12 points (idle switch and) wide open swit connected to the throttle valve shaft throttle body, and detects the throttle opening. The throttle opening in the idle state is: by means of the idle switch which turns that state, The wide open. state is detected. by the ‘open switch which turns ON in that sta By monitoring thier ON/OFF signals, detects the throttle valve opening. z 5 fe 41. Output voltage 2, Reference voltage 3, Ground 4. Samiconduetor type aetre converting alam 5, Elecvonie ecu (tC) 6, Intake manioid pressure (Waewur Fig. 6E-18 Pressure Sensor on 3s ? i 3 3 8 8: i ac (Hah ecu)” take manttald yaaa) presse iment) Fig, 6&-19 Output Characteristic ECM uses the voltage signal from the pressure sensor as one of the signals to contro! fuel jector, ISC solenoid valve, shift-up indicator light and EGR VSV (if equipped). Le signal | To ECM (Ground! Wide open sans) Kale sich Wide open suites Idle siteh ON Wise opon switch Fully oper Fig. 6E-20 Throttle Switch ECM uses the ON/OFF signals from tl switch as one of the signals to control fuel i tor, ISC solenoid valve, shift up indicator and EGR VSV (if equipped).le Position Sensor (TPS) model only) throttle position sensor consisting of a ct point (idle switch) and a potentiometer nected to the throttle valve shaft on the le body, and detects the throttle valve ing. throttle opening in the idle state is detected -peans of the contact point which turns ON t state. beyond that the full opening is detected by ‘potentiometer as follows, It reference voltage is applied to the sensor ECM and as its brush moves over the print nce according to the throttle valve open- the output voltage varies accordingly, monitoring the ON/OFF signal and sensor it-voltage, ECM detects the throttle valve ing, Reterenca voltage Output voltage ON/OFF signal Ground Resistance Brush Rotor aay Salt ++ Large ‘Throttle valve opening (ares) =22. Output Characteristic ELECTRONIC FUEL INJECTION SYSTEM 6-23 ECM uses the signal from TPS as one of the signals to control fuel injector, ISC solenoid valve and EGR VSV {if equipped). Also, ECM ‘converts the voltage signal from TPS into ON/OFF signal and sends it to A/T control module, where it is used’as one of the signals to contro! the automatic transmission, Air Temperature Sensor (ATS) Located at the side of air cleaner case, this sensor constantly measures the temperature of ‘the air entering there and converts a change in the air temperature into that in resistance through its thermister. That is, as air temperature lowers, resistance increases and as it rises, resistance decreases. As air density of the intake air varies with variation in temperature, ECM, by monitoring the resistance, adjusts the amount of fuel injection according to the air temperature, Water Temperature Sensor (WTS) Located at the side of throttle body, this sensor ‘measures the temperature of the engine cooling water and converts its change into that in resi stance through the thermister like the air temperature sensor. That is, a8 cooling water temperature lowers, resistance increases and as it rises, resistance decreases, By monitoring the resistance of the water tem erature sensor, ECM detects the engine cooling water temperature and that affects most systems under the control of ECM. Fevietance tow High Temperaure~ Fig, 6-23 Alr/Water Temperature Sensor Characteristic6E-24 ELECTRONIC FUEL INJECTION SYSTEM Oxygen Sensor The oxygen sensor is located on the exhaust manifold to detect the concentration of oxygen in the exhaust gases. It consists of the zirconia element. (with thin platinum surface coating) which generates electromotive force, lead wire which draws out the electromotive force and cover and housing which protect the zirconic element from damage. The zirconia element, by its property, generates the electromotive force when a difference in oxygen concentration exists between its faces. As its temperature rises, the change of the electromotive force is amplified by catalytic reaction of the platinum. The oxygen sensor makes use of this property. As atmosphere is introduced into the oxygen sensor, the inside of the zirconia element is exposed to the atmosphere and outside to exhaust gases. Thus the difference in concentration between the inside and the outside of the zirconia element varies with the oxygen concentration in the exhaust gases, The large concentration difference results in about 1V of the electromotive force and small difference results in about OV. To put in other words, if the amount of oxygen in the exhaust gases is less (air-fuel mixture is richer than the stoichiometric mixture), about 1V of electromotive force is generated and if more (air-fuel mixture is leaner than the stoichiometric mixture), almost none is generated. In this way, the oxygen sensor detects whether ‘the oxygen concentration is high or low (or the mixture is leaner or richer than the stoichiometric mixture). ‘Stoichiomavrie ba Sir fun 1 1 s i B05 & , i A = Ai fuel ato ich Fig. 6E-24 Output Charactorstic Fig, 6:25 Oxygen Sensor ‘Speed Sensor The speed sensor consisting of the lead and magnet is built in the speedometer magnet turns with the speedometer magnetic force causes the lead switch ‘ON and OFF. Such ON/OFF frequency ® or decreases in proportion with the and is sent to ECM as pulse signals. ECM uses it as one of the signals to ISC solenoid valve and shift-up indicator Fig. 6E-26 Speed Sensorn Signal signal is sent from the ignition coil primary it, detects the engine speed through. this | and uses it as one of the factors for con- ing various devices. Start Signal Signal is sent from the engine starter circuit. ving it, ECM judges whether the engine is ng or not and uses it as one of the signals itrol the fuel injector and fuel pump relay. Bens 225,0r model only) signal is sent from A/T control module as @ ery voltage signal only when A/T is in “R”, 2" or “LY range. Thus, ECM judges er A/T is in one of the above ranges or ise (i.e. in “PY or “N" range) and uses it sone of the signals to control the fuel injector ISC solenoid valve, Range Signal ination Light Signal (M/T model only) signal is sent from the illumination light it, It is used to reduce intensity of the shift- indicator light when the illumination light is \ditioner Signal (Car with air-condi- only) signal is sent from the air-con detects whether the air-conditioner is ope- or not through the signal and uses it as of the signals for controlling ISC solenoid operation. y Voltage fuel injector is driven by its solenoid coil upon the ECM output signal. is some delay called as “Ineffective injec- time", which doesn’t provide fuel, between signal and valve action. the ineffective injection time depends on the y voltage, ECM takes voltage information ‘compensate it in fuel injection time. ELECTRONIC FUEL INJECTION SYSTEM 6E.25 Diagnosis Switch Terminal There are two diagnosis switch terminals; one included in the junction/fuse block and the other in the monitor coupler in the engine room. When either. diegnosis switch terminal is grounded, a diagnosis signal is fed to ECM which then out puts self-diagnosis code and at the same time fix the ON time of ISC solenoid valve constant, 4, dunetlonfussblock A: AIF duty check terminal 2 Diagnosis switch terminal B Diagnosis itch terminal 3. Monitor coupler (: Ground termi ax atch terminal Fig, 6E-28 Diagnosis and Test Switch Terminals Test Switch Terminal The test switch terminal is included in the monitor coupler. When both test switch terminal and diagnosis switch terminal are grounded, ECM outputs AJF duty through the A/F duty check terminal, At this time, “CHECK ENGINE” light may ‘turn ON regardless of EPI system self-diagnosis function.BE-26 ELECTRONIC FUEL INJECTION SYSTEM FUEL INJECTION CONTROL SYSTEM In this system, ECM controls the time (amount) ‘and timing of the fuel injection from the fuel injector into the throttle body according to the signals from the various sensors so that suitable air/fuel mixture is supplied to the engine in each driving condition. Injection Timing There are two types of injection timing. One is “synchronous injection” in which injection is synchronous with the ignition signal and the other is “asynchronous injection" in which injection takes place independently of the ignition signal. Synchronous injection Normally, the injector injects fuel at every ignition signal. But when the engine cooling water temperature is low immediately after its start, the injection time for one ignition cycle is divided into some and injection takes place accordingly. Injection piston No.3 piston No.2 GS. <1. Compression stroke Fig, 6E-29 Synchronous Injection © Asynchronous injection When the throttle valve is opened position, the injector injects fuel i= to synchronous injection ind the ignition signal. ees 3 No.1 piston noo HT pion US CS IPS. es | No.2 piston Fig. 6E-31 Asynchronous InjectionELECTRONIC FUEL INJECTION SYSTEM 6E-27 jon Time (amount of injection) ‘factors to determine the injection time are i¢ injection time which is calculated on basis of the ‘engine speed and the intake old pressure (amount of the intake air) and S compensations which’ are determined jing to the signals from various sensors detect the state of the engine and driving Engine speed cle Basie injection |p lection Taisetor Intoke manifold pressure | time pe Intake air temperature Engine cooling water temperature Engine start signal ulaGorssattion teu Throttle valve opening |Compensation Car speed Battery voltage mR QM pg “L""range signat ‘antral module ‘madel only) 32 Parameter Diagram for Fuel Injection Control System6E:28 ELECTRONIC FUEL INJECTION SYSTEM Intake air temperature compensation As the intake air volume varies with the temperature, it is compensated for its temperature. Enriching compensation while engine starting In order to improve starting performance, enriching compensation at start is carried out. Enriching compensation after engine start For a certain time after the engine is started, air/ fuel mixture enriching compensation is made so as to stabilize the engine speed. The amount of compensation varies depending on the engine cooling water temperature and it is the largest immediately after the engine start and after that, it reduces gradually, Enriching compensation while warming up When the engine is cold, enriching compensa. tion is made to ensure good driveability till the engine cooling water temperature reaches the specified level. The amount to enrich the air/fuel mixture is decreased as the temperature rises. Power enriching compensation To ensure smooth acceleration and good driveabi. lity under the high load driving condition, enriching compensation is carried out when the throttle valve opening is larger than specification. Enriching compensation when accelerating To ensure smooth acceleration, enriching compensation is carried out when the intake manifold pressure varies by more than a specified amount druring acceleration. The amount of compensation is determined according to the engine cooling water temperature and how much the intake manifold pressure varies. Leaning compensation when decelerating To obtain a proper air/fuel mixture ratio during deceleration, leaning compensation is carried out When the intake manifold pressure varies by more than a specified amount during deceleration, Battery voltage compensation ‘A power voltage drop delays. the m: operation of the injector. Then the actuali tion time becomes shorter for the time ctricity is supplied to the injector, To com this, the electricity supply time is made when the voltage is lower. Base air/fuel ratio compensation The air/fuel ratio may vary due to such as variation in each engine itself and compensate such variation, feed back tion is used and base air/fuel mixture adjusted to a proper level for feed back sation. Fuel cut Fuel injection stops (with operation of jector prevented) when decelerating (i.e. the throttle valve is at idle position engine speed is high], so that unburned not be exhausted and it starts again when: conditions are not met. The fuel injection also stops when the = speed exceeds 7,000 r/min to prevent Which affects the engine adversely and it again when the engine speed reduces to 6,800 r/min. Leaning compensation when EGR valve is ‘operating (For California spec. model) To. ensure proper air/fuel mixture ri while EGR valve is open, leaning com; is carried out when EGR VSV is ON.jel ratio feed back compensation necessary to keep the air/fuel mixture close theoretical air/fuel ratio (14.7) to obtain int performance of the Sway catalyst and clarification rate of CO, HC and NOx in exhaust gas. For thet purpose, ECM operates lows. It first compares the signal from the in sensor with a specified reference voltage if the signal is higher, it detects that the air/ ratio is richer than the theoretical air/fuel and reduces fuel. On the other hand, if the is lower, it detects that the air/fuel ratio is and increases fuel. By repeating these tions, it adjusts the air/fuel ratio closer to jeoretical air/fuel ratio, sn oxygen concentration in the exhaust is low, that is, when the air/fuel ratio is ler than the theoretical air/fuel ratio (fuel richer), electromotive force of the oxygen r increases. and a, rich signal is sent to M. 2} Upon receipt of the ri h signal, ECM decreases ‘the amount of fuel injection, which causes ‘oxygen concentration in the exhaust gas to increase and electromotive force of the oxygen sensor to decrease. Then a lean signal is sent to ECM. 3) As ECM increases the amount of fuel injection according to the lean signal, oxygen concentration in the exhaust gas decreases and the situation is back to above 1). This control process, however, will not take place under any of the following conditions. © At engine start and when fuel injection is increased after engine start ‘* When engine cooling water temperature is low ‘© When highly loaded and fuel injection is increased © At fuel cut ‘# When oxygen sensor is cold ‘* When engine is running at high speed (higher ‘than about 4000 r/min). Exhaust gos ‘Sense information E33. A/F Ratio Feed Back Compensation {Signal to decrease amount of es [— Signal 0 increse amount of | fut iejeetion| OXYGEN SENSOR T Al mixture oxveen | become ae oeGE-30 ELECTRONIC FUEL INJECTION SYSTEM FUEL PUMP CONTROL SYSTEM ECM controls ON/OFF operation of the fuel pump by turning it ON via the fuel pump relay under any af the following conditions. For 2 seconds after ignition switch ON, @ While cranking engine (while eng signal is inputted to ECM). ‘© While ignition signal is inputted to ECM. Fuel pump Ignition cot Noise suppressor ecw Starter 10. " caatery Clutch snitch (Fort model) 1 Nain awiteh Main relay Fuel pump relay Fig, 6-34 Fuel Pump CircuitLENOID VALVE CONTROL SYSTEM system controls the bypass air flow by of ECM and ISC solenoid valve for the ing three purposes. keep the engine idle speed as specified at times engine idle speed reasons. Load applied to engine (when electric load ‘is applied, automatic transmission is shifted to."R","D" "2" or “L” range, air-conditioner is turned ON, etc.) Variation in atmospheric pressure Change in engine itself with passage of time Other factors causing idle speed to change improve starting performance of engine ‘compensate air/fuel mixture ratio when lerating (Dash-pot effect) vary due to follow- n solenoid valve opens the bypass air passage it is tumed ON by ECM and closes it when OFF. detects the engine condition by using signals various sensors and switches and while ng ON and OFF cycle of ISC solenoid at a certain rate (12 times a second), it Is bypass air flow by increasing and de- its ON time within a cycle, the engine is cranking, ECM keeps ISC fd valve ON so as to obtain better start of jine. After the engine hes started, it re- ON time gradually to maintain the idle ‘specified, the accelerator pedal is depressed (throttle at other than idle position), ECM keeps joid valve ON. When decelerating, on hhand, it reduces its ON time gradually reducing the bypass air flow gradually) st air/fuel mixture to an optimum ratio stion. ‘the car is at a stop, the throttle valve is at position and the engine is running, ECM the bypass air flow by increasing or ing ON time of ISC solenoid valve so that ine speed is kept at @ specified idle speed. ELECTRONIC FUEL INJECTION SYSTEM 6E-31 With an air-conditioner equipped car, when the air-conditioner is ON, a certain amount of the bypass air is supplied by the air-conditioner VSV independently of this system. The bypass air supplied by this system is used for fine control to keep the idle speed as specified. NOTE: This system automatically adjusts the engine le speed to specification by means of ECM. If such specified idle speed is not available, it is necessary to adjust the basic idle speed with the idle speed adjusting screw as follows. With the diagnosis switch terminal grounded and ON time of ISC solenoid valve fixed constant, adjust the engine idle speed as specified. Engine idle speed specifications at engine normal operating temperature are as follows. (Unit: r/min) Aircondi- | Air-conditioner OFF | tioner ON MIT model 75050 | 900+50 eit 850250 | 850+60 an LIN range model | AER", oO", "2" ori" || 760:60"} 760+ 50 rangeGE-32 ELECTRONIC FUEL INJECTION SYSTEM. temperature Water tempeatine ecM PEt rey tery fag Engine 190d ignition ati) ‘Throttle valve opening Throttle aten = Engine cooling water Trowle Postion Pressure sensor Isc slenoid ON vane oFF <> Gueime Tevele (ecohatent) range signal A/T contol fore sara! ‘Airconditioner ON FOCAMT 4. Throttle body anal Aiccondttlori 2, 1SC solenoid valve ampli 3. Air eaaner ne t Diagnosis anal Diagnosis site termina! Fig, 6E-35 ISC Solenoid Valve Control System EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM (For California specification model) This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber through the intake manifold. The EGR valve is controlled by EGR modulator and VSV controlled by ECM according to signals from various sensors. The diaphragm mounted in the EGR modulator is operated by back pressure of the exhaust gas to open and close the valve. By this opening and closing action of the valve, the EGR modulator controls the vacuum transmitted to the EGR valve. Under a low load condition such as low speed driving, the exhaust pressure is low. In this state, the diaphragm in the EGR modulator is pushed down by the spring force and the modulator valve opens to allow the air into the vacuum passage from the outside. ‘As a result, the vacuum transmitted to valve becomes smaller and so does the of the EGR valve. Thus, less amount of exhaust gas is to the intake manifold, Under @ high load condition such as driving, on the other hand, the exhaust is high. By the high exhaust pressure: phragm in the modulator is pushed up: its valve. As the air does not enter passage in this state, the vacuum tra the EGR valve grows larger and so ‘opening of the EGR valve. Thus, larger amount of exhaust gasis to the intake manifold, Under any one of the following condi closes the vacuurh passage of VSV. In as the vacuum is not transmitted to valve, it remains closed.9 engine cooling water temperature is low. n throttle valve is at idle position. n engine is running under high load. intake manifold pressure is low. ELECTRONIC FUEL INJECTION SYSTEM 6E-33 Other than the above, EGR valve opens and closes in accordance with the EGR modulator operation. EGR valve EGR modulstor Modulat vev ecm Igoition coi 7, Noise suppressor 19, Prossure sone 2 Main awited 14, Exhaust gos 9. Battery 15. Air 10. Main relay 16. Vacuum 11. Tso TPS 12. WTS =36 EGR System (For California spec. model) -UP INDICATOR LIGHT CONTROL IM (For M/T model ony) system is intended for economical driving sing proper gear positions. When the follow- ‘conditions are all met, it turns ON the shift- Sedicator light included in the meter cluster, for 6 seconds at the longest, so as to urge sSriver to shift up the gear. speed Is higher than 5 km/h (3.1 mile/h) idle switch and wide open switch are OF F Jine speed is higher than a specified speed specified engine speed varies with the ke manifold pressure and engine cooling er temperature.) ensure better visibility of the shift-up indica- fight, its intensity is reduced when the meter ination light is turned ON. 2 ke ‘Sereed information Ship indicator tight ecw Main relay Ignition witch Battery Fig. 6-37 System CircuitGE-34 ELECTRONIC FUEL INJECTION SYSTEM THROTTLE VALVE OPENING SIGNAL OUTPUT FOR A/T Receiving the throttle valve opening signal from the throttle position sensor, ECM converts it into the three ON/OFF signals and sends their signals to A/T control module through A17, Ag, and A18 terminals. Then A/T control module uses them as the signals to control the automatic transmission, Fall open ON zone : & : 3 z | oFF zo °. rT) Terminal Fig. 6-38 ON/OFF Signal Diagram aa? 7 AIS AN7eh aa wr a9) FEL AtBee AIT comal module ecw 1s ain coay Ignition sate 5. Batery Fig. 6E-39 Signal Output Circuithhas a system self-diagnosis function as des- previously (p. 6E-20). figate where the trouble is by referring to ic Flow Chart" and “Diagnostic Code” section. \UTIONS IN DIAGNOSING TROUBLES "AUTIONS IN IDENTIFYING )STIC CODE} re identifying diagnostic code indicated ECK ENGINE” light, don’tdisconnect lers from ECM, battery cable from bat- . ECM ground wire harness from engine or sn fuse. isconnection will erase memorized le in ECM memory. ‘bhormality or malfunction ies in two or areas, “CHECK ENGINE” light indicates icable codes three times each. flashing of these codes is repeated as ‘as diagnosis switch terminal is grounded fuse is connected) and ignition switch id at ON position, @ note of diagnostic code indicated first. RMITTENT TROUBLES] are cases where “CHECK ENGINE” indicates a diagnostic code representing uble which occurred only temporarily hhas gone. In such case, it may occur that parts are replaced unnecessarily. To nt such an accident, be sure to follow ictions given below when checking by “Diagnostic Flow Chart”. ‘When trouble can be ident ‘Snot an intermittent on: k sensor (actuator), wires and each snnection and if they are all in good con- In, substitute a known-good ECM and week. A trouble can not be identified but “CHECK ENGINE” light in ied, that is, it DIAGNOSIS ELECTRONIC FUEL INJECTION SYSTEM 6E-35 Diagnose trouble by using that code No. and if sensor (actuator), wires and each connec- n are all in good condition, erase diagnostic code in ECM memory. Then conduct a ‘test run and check what “CHECK ENGINE” light indicates. Only when it indicates trouble code again, substitute @ known-good ECM and check aga If it indicates not trouble code but normal code No. 12, it means that an intermittent trouble did occur and has gone. In this case, check wires and connections carefully again. [NOTES ON SYSTEM CIRCUIT INSPECTION] ‘© Intermittent troubles Most intermittent problems are caused by faulty electrical connections or wiring. Perform careful check of suspect circuits for: = Poor mating of coupler halves, or terminals not fully seated in coupler body (backed out). — Improperly formed or damaged terminals. All coupler terminals in problem circuit should be carefully reformed to increase ‘contact tension, — Poor terminal to wire connection. ‘© Never connect any tester (voltmeter, ohmmeter, or whatever) to ECM when its coupler is disconnected. Attempt to do it may cause ‘damage to ECM. © Never connect an ohmmeter to ECM with its coupler connected to it. Attempt to do it may cause damage to ECM and sensors, © Be sure to use a voltmeter with high impedance (M&/V minimum) or a digital type voltmeter. Any other voltmeter should not be used because accurate measurements are not obtained.8E-36 ELECTRONIC FUEL INJECTION SYSTEM © When checking voltage at each terminal of the coupler which is connected to ECM, be sure to connect negative probe to body ground and using service wire, connect ECM case to body ground as shown in Fig. GE-43. Any other way is prohibited even by accident. Applying probes of voltmeter. improperly may cause the sensor or ECM to be shorted and damaged. © For ECM coupler terminal A2... to A18 and B1, B2 to Fig. 6E-44. positions to BI 2 Couplers 3. Body oround 4. Sarvca wire Fig. 6-43. Checking Voltage 1. Coulee Fig. 6E-44 Coupler Terminal Position (Viewed. Wire Horness Side) © When disconnecting and connecting make sure to turn ignition switch OFF: © When checking connection of check its male half for bend and fer for excessive opening and both for (looseness), corrosion, dust, etc. ‘© When connecting @ probe of ohmm: meter, etc, to coupler terminal, be connect it from wire harness side of . » Fig, 6-46 Connecting Meter Probe 10 cause 2, Probe 3. Wire!ELECTRONIC FUEL INJECTION SYSTEM 6E-37 When connecting meter probe from terminal de of coupler because it can't be connected from harness side, use extra care not to bend male terminal of coupler or force its female ‘terminal open for connection. Jn case of such coupler as shown below, con- ect probe as shown below to avoid opening female terminal. jever connect probe where male terminal is ‘supposed to fit. 2. Probe 3, Where mate termine! tes (BEA Connecting Meter Probe Before measuring voltage at each terminal, check to make sure that battery voltage is TIV or higher. Such terminal voltage check at low battery voltage will lead to erroneous dia- nosis. GEA? Checking Battery Voltage8E-38 ELECTRONIC FUEL INJECTION SYSTEM DIAGNOSTIC FLOW CHART Proceed to chart A-. (ECM! ower and ground i check.) svant Ton GREEK ENGINE Tp a =e aE an turn ON wien ignition switen L—=="] is'tumed ON (without start & ing engine)? (> G) No No = [Dow ngne sar | Conmact spe fue to dgre ji Se ont tia! etn A Ing'and. ctr “EHEC S| | bes ENGINE” ih Si Note: BS (tk If engine fails to start, rank it for 2 seconds LW 2 nd then while keeping eS K&R Proceed to chart A-2. ("CHE CK ENGINE” light circuie cheek.) t 1, Disconnect spare fuse from No ‘tum it OFF) connect spare 7. doncton/fure book fuse to diagnosis switch 2. Diagnose ste terminls terminal. on Proceed to chart A-3. (“CHE % CK ENGINE” light circa ¥ Flash check: Is diagnostic code No. 12 in dicated? Yes Are ‘engine basic parts des | yes || Proceed to “TROUBLE DIA [———= >| cribed in SECTION 6 “EN: GNOSIS" (p. 6E-56.) ¥No. GINE DIAGNOSIS" in good ‘Check and repair according to condition? flow chart corresponding to that code No. diagnosis switch terminal. jisconnect battery nega tive cable for 60 sec. t0 erase diagnostic code stor- ed in ECM memory and reconnect I. 3. Warm up engine to normal ‘operating temperature. 4. Connect spare fuse to diagnosis switch terminal. 5. Is diagnostic code No. 12 indicated then? Yves Disconnect spare fuse from diagnosis switch terminal y Is trouble corrected? Yves END Fig. 6E-48 Diagnostic Flow Chart for Electronic Fuel Injection System pair or replace, No. NoELECTRONIC FUEL INJECTION SYSTEM 639 DIAGNOSTIC CODE TABLE LE: THROTTLE SWITCH (THROTTLE POSITION SENSOR FOR A/T) FAILURE (CODE NO. 21) conn voce isons Speed ete 2 et tai a5 pa =, EMEGBONT DIAGNOSTIC AREA DIAGNOSIS Wont nontle ‘This code appears when none of the other codes Jt eer fun ome =u fLonion |" {N/T model only) Throttle position sensor (A/T model only) . Ee Diagnose trouble according to “DIAGNOSTIC FLOW CHART” corresponding to each code No, z Air temperature | ti ino. sensor a La P Pressure sensor Ignition signal kL L PC i EGR system (California spec. model) ECM ECM failure k Diagnostic Code TableGE-4) ELECTRONIC FUEL INJECTION SYSTEM A-1_ECM POWER AND GROUND CIRCUIT CHECK (“CHECK ENGINE” LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON AND ENGINE START THOUGH IT IS CRANKED UP.) |. Main fe nition Grout Fig, 6E-50 ECM Power and Ground Cireust Is operation of main relay heard at ignition switch ON? yrves 1s 15A main fuse in ‘Are_main and. circuit, good condition? fuses in good condition? yves Ne VYES. 1, Disconnect ECM cou- Repair and Is main relay in good ppler with ignition replace. condition? Ewitch OFF, (Check main ralay re- 2. Is battery voltage ap- ferring to p. 6E-90.) ied to Bt terminal at N Yves Ignition switch ON? ‘Poor relay-to-coupler ‘connection, B/W" wire open, "8" wire open or Poor "8" wire grounding 1. ECM coupler connected Z 2, Body ground ‘To be continuedELECTRONIC FUEL INJECTION SYSTEM 6E-41 Continued YES "81" or "BB" connection, "wW/R" wire open, "wire open or ‘®Poor relay-to-coupler connection or ““B/B\" wire grounding. 9""W/BI”" wire open ‘wire end connections are OK, substitute If wire and connection are OK, check main sEnown-good ECM and recheck relay referring to p. 6-80. 1 Diagnostic Flow Chart A-t for ECM Power and Ground Circuit “CHECK ENGINE” LIGHT CIRCUIT CHECK HECK ENGINE” LIGHT DOES NOT LIGHT BUT ENGINE STARTS.) Main fuse Ignition switch 3. Cree tose ‘CHECK ENGINE” light 3 Combination meter ecw $5.52 “CHECK ENGINE” Light Circuit With ignition switch turned | OFF, ‘disconnect coupler from ECM. Body-ground terninal "89" in couper disconnected. Does “CHECK ENGINE” light turn ON’ at ignition ms turn 1. ECM coupler disconnected 2. Body ground No Bulb burned out, “V" wire cireult open or “B/W” wire nected to ECM circuit open, 185-53 Disgnostic Flow Chart A-2 For “CHECK ENGINE” Light Circuit6E-42 ELECTRONIC FUEL INJECTION SYSTEM AS “CHECK ENGINE" LIGHT CIRCUIT CHECK ("CHECK ENGINE” LIGHT DOESN'T FLASH OR JUST REMAINS ON EVEN WITH SPai CONNECTED TO DIAGNOSIS SWITCH TERMINAL.) 2 1 1 & 2 80W. vs 89 i Fig. 6E-54 "CHECK ENGINE” Light Circuit fonnect ECM coupler "3" with gnition switch turned OFF. 2. Does “CHECK ENGINE” light turn ON at ignition switch ON? ves “V" wire circuit shorted. to p—___“§8 tre ‘round. Is coupler "B" (terminal ™B8") connected to ECM properly? [82+ Poor connection. yes 1. Using service wire, ground ‘terminal "88" with coupler connected to ECM, 2. Does “CHECK ENGINE” p—==~1 light flash ON? “a 2. Body ground 2 3. Service wire Spare fuse open, “"V/Y" wire circuit open or poor “B wire YN. rounding Substitute aknown-good ECM and recheck, Fig. 6E-55 Diagnostic Flow Chart A-3 For “CHECK ENGINE” Light Circuit1. Eom 2. ECM coupler 3. Oxygen sensor 4. Coupler =56 Oxygen Sensor Circuit Bemove ECM and connect couplers to ECM, Warm up engine to normal operating emperature. Connect voitmeter between “AG ter- ‘inal of ECM coupler and body ground. Maintain engine speed at 2000 r/min. After 60 seconds, check voltmeter. NO. 13 OXYGEN SENSOR CIRCUIT (SIGNAL VOLTAGE DOESN'T CHANGE) ELECTRONIC FUEL INJECTION SYSTEM_GE-43 NOTE: © Before diagnosing trouble according to flow chart given below, check to make sure that following system and Parts other than Electronic Fuel Injection system are in {004 condition, = Air cleaner (clogged) = Vacuum leaks (air inhaling) — Spark plugs (contamination, gap) = High-tension cords (crack, deterioration) = Distributor rotor or cap (wear, crack) = Ignition timing = Engine compression Any other system and parts which might affect A/F mixture or combustion. © If code No. 13 and another code No, are indicated toge- ‘ther, the latter has priority. Therefore, check and correct what is represented by that code No. first and then proceed to the following check. © Be sure to use a voltmeter with high impedance (MQ/V_ minimum) or digital type voltmeter for accurate measurement. as |. ECM 2. Body ground 3. Servics wire ‘After 60 sec., dis. ‘connection. ‘connect vacuum wire and con: hose from pressure on are OK, re- ‘and check ee oxygen san 2. Is voltage “and recheck. 0.48V or more? Remains unchanged emains_unchanged Daflecs” between at below 0:45 meabove 048V. above and’ below 0.450 repeated. Y 1 | t between sen- Maintain engine Poor AB connection ‘Oxygen sensor and- | nd ECM open ‘eed 2000 rin. onrich A/F mictre ity crit Vairvel no ves a 3 Poor AB connection pono cor lean A/F mixture, Check pressure sensor, WTS, ATS, fuel pressure ‘and injector. If all above are OK, check ECM and its circuit re- forring to p. BE-66. ‘@Check TS (TPS for ‘AIT model), clog: ‘ged pressure sensor ratio feed back sys tem) are in good condition, hose, pressure sen: Intermittent trouble sor, ATS, WTS, fuel or faulty ECM. pressure and injec: Recheck referring to tor. “intermittent — trou If ‘all above _are OK, check ECM and its circuit re ferring to P. 6E-66. ble’*on p, 6E-35. 57 Diagnostic Flow Chart For Code No. 13GE-44 ELECTRONIC FUEL INJECTION SYSTEM. CODE NO. 14 WTS (WATER TEMPERATURE SENSOR) CIRCUIT (LOW TEMPERATURE IN SIGNAL VOLTAGE HIGH) + “ ata rw teen 2. wis a at 3 3. WIS couple 4 cM coupler 5, Toother sensors 5 Note: When Code Nos. 14,28 and 32 are Fig. 6£-58 WTS Circuit together, it is posible that “La/8™ ‘open or A16 terminal connection is x 1. Disconnest WTS coupler with ignition s 3 switch OFF. = 2. With ignition switch ON, check voltage at ane "™Gr/W'" wire terminal of WTS coupler. @ Isit about 4 — BV? 3 1, WTS coupler disconnected 2, Rubber ssl 23, Engine ground VES yo 1. Using service wire, connect WTS coupler “GriW" wire open, poor A14 connection or terminals, " wire shortad to power circuit. 2. Check voitage at “Gr/W" wire terminal of If wire and connection are OK, substitute WTS coupler with ignition switch ON. ‘a known-good ECM and recheck. Is it below 0.18V?, 1. WTS coupler aisconnectes 2) Service wire 13, Engine ground yNO yyes “Lg/8" wire open or poor A16 connection. Poor WTSto0-WTS coupler connection or If wire and connection are OK, substitute & faulty WTS. known-good ECM and recheck. Hf connection and WTS are OK, intermittent trouble or faulty ECM, Recheck referring to "intermittent trouble” on p. 6-35, Fig. 6E-59 Diagnostic Flow Chart For Code No. 14ELECTRONIC FUEL INJECTION SYSTEM 6E-46 1E NO. 16 WTS (WATER TEMPERATURE SENSOR) CIRCUIT (HIGH TEMPERATURE INDICATED, SIGNAL VOLTAGE Low) a con Paci ars fe 7 2 NS : 4 Eeiebeoier 5 Tooter enor E60 WTS Circuit % Disconnect WTS coupler with ignition switch OFF. 2 With ignition switch ON, isvoltage applied to “Gr/W" wire terminal of WTS coupler 4V or mora? se eee ceeen el Sensor coupler ssconnected 2. Engine ground 3. Rubber ea! yes eu WTS referring to p. 6E-89. “GrAW” wire shorted to “Lg/B” wire or fin good condition’ ground circuit, it wire is OK, substitute a knowngood ECM and recheck, No ittent trouble or faulty ECM. sack referring to “Intermittent trouble"* 9. 6E-36. Faulty WTS. 61 Diagnostic Flow Chart For Code No. 158E-46 ELECTRONIC FUEL INJECTION SYSTEM. CODE NO, 21 TS (THROTTLE SWITCH) CIRCUIT (BOTH IDLE SWITCH AND WIDE OPEN FOR M/T MODEL ‘SWITCH ON) 1. Eom 7 5 2 ats 3. lal switen soir. 44 Wide open switch alter 5. EcMeovpler aishh z= Fig. 6E-62 TS Circuit 1, Disconnect TS. coupler switch OFF. 2. Check TS referring to p. 6E-84. Is it in good condition? yes peal “LglY" wire or “Lg” wire shorted 10 Faulty TS. “Lg/8" wire If wire is OK, intermittent trouble or faulty ECM. FRochock referring to “intermittent trouble” on p. 6E-35. ignition Fig. 6E-62 Diagnostic Flow Chart For Code No. 21 (M/T Model Only)ELECTRONIC FUEL INJECTION SYSTEM 6E-47 ‘21 TPS (THROTTLE POSITION SENSOR) CIRCUIT (SIGNAL VOLTAGE HIGH) FOR A/T MODEL 1. Eom 2) ECM coupler 3 TPs 4. TRS coupler 5. Tors 8. To other sensors NOTE: Be sure to turn OFF ignition switch for this cheek. TPS referring to p. GE-26, 0d condition? yyes Yo Faulty TPS. TPS ‘coupler disconnected, is there =" ty between ECM coupler termi- yNo Yves +t PS coupler. “Lg"* wire shorted ‘TPS coupler. to Lg/W" wire, ‘between ECM coupler termi- and A16 4.37 8.19 2? VYES {no connection. “Lg/B" wire open leconnected ion is OK, intermittent trouble or or poor TPS:t0- ECM. “Lg /B" wire referring to “intermittent trouble’ connection, 35, Diagnostic Flow Chart For Code No. 21 (A/T Model Only)E-48 ELECTRONIC FUEL INJECTION SYSTEM CODE NO. 22 TPS (THROTTLE POSITION SENSOR) CIRCUIT (SIGNAL VOLTAGE LOW) FOR A/T MODEL Eom ECM coupler TPs TPS coupler Tors To other sensors Fig. 6E-66 TPS Circuit 7, Disconnect TPS coupler with ‘ignition 7 eae Dre OFF: monmected 2. With nition switch ON, isvotage applied S| to "ig" wire terminal of TPS coupler about #— BV? YES ye ‘Check TPS refering top. OE 86. “Lg wire open, Lg wire shorted to ground Init in good condition? circuit or “gf” wie or poor Ad cannes tion. If wire ane eanneston are OK, substiute @ known-good ECM end recheck Fe eT veoh {ves “Lg” wire open, “Lg/W'" wire shorted to Faulty TPS. ground circuit, poor TPS0-TPS coupler ‘connection or poor A16 connection, If wire and connections are OK, intermittent trouble or faulty ECM. Recheck referring to “Intermittent trouble” on p. 6E-35. oe Fig. 6E-67 Diagnostic Flow Chart For Code No. 22 (A/T Model Only)S68 ATS Cireuit ELECTRONIC FUEL INJECTION SYSTEM 6E-49 NO. 23 ATS (AIR TEMPERATURE SENSOR) CIRCUIT (LOW TEMPERATURE INDICATED, SIGNAL VOLTAGE HIGH) eo 2. ECM coupler ats ‘ATS coupler ‘To thee sensors Disconnect ATS coupler with i -38°Gr" wire terminal of ATS coupler. Is itabout 4 — 6V? switch OFF. ‘With ignition switch ON, check voltage -——] 1. ATS coupler dlsconnectes 2. Rubber sal 3. Engine ground Yves re ‘Using service wire, connect ATS coupler ‘seminal. ‘Greck voltage at “Gr wire terminal of ATS coupler with ignition switch ON, Sit below 0.15V? "Gr" wire open, poor A13 connection or “"Gr" wire shorted to power circuit. If wire and connection are OK, substitute ‘8 known-good ECM and recheck. 1. ATS coupler 2 Service wie 1. Engine ground No yyes 1 ATS or poor ATS-10-ATS coupler ion. ‘nd connection are OK, intermittent or faulty ECM, Recheck referring to ittent trouble’ on p. 6E-35. ““Lg/B wire open or poor A16 connection. If wire and connection are OK, substitute @ known-good ECM and recheck. Diagnostic Flow Chart For Code No. 236E-50 ELECTRONIC FUEL INJECTION SYSTEM CODE NO. 25 ATS (AIR TEMPERATURE SENSOR) CIRCUIT (HIGH TEMPERATURE INDI ais $a Fig. 6E-70 ATS Circuit SIGNAL VOLTAGE LOW) ecu ECM coupler ATs ‘ATS coupter 1. Disconnect ATS coupler with ignition switch OFF. 2. With ignition. switch ON, is voltage applied to "Gr" wire terminal of ATS coupler 4V or more? 1. ATS coupler disconnected 2, Rubber sa! 3. Engine ground YES ne. Check ATS referring to p. 6-88, Is it in good condition? “Gr wire shorted to ground circuit, I wire is OK, substitute 2 known-good ECM and recheck yes ye Intermittent trouble or faulty ECM, Recheck referring to “Intermittent trouble on p. 6-35. Fig. 6E-71 Diagnostic Flow Chart For Code No. 25 Faulty ATS,ELECTRONIC FUEL INJECTION SYSTEM 6E51 1E INO. 24 SPEED SENSOR CIRCUIT (SPEED SENSOR SIGNAL NOT INPUTTED ALTHOUGH FUEL IS KEPT CUT AT LOWER THAN 4000 r/min FOR LONGER THAN 4 SECONDS) ecm OM coupler ‘Speed sensor ‘Speedometer (Coupler 2, NoTe: Be sure to turn OFF switch for this check. ‘Does speedometer indi icate car speed? yyes Ae 7. Disconnet FGM ouplar with Totan Sealer cae satan OFF Be Corned hroratic tetadhy “A19" tu. rina of EO caupie snd soayerounas | B Boor Guiveetir"iicttr defect whan rested bY hae 1, ECM coupler sisconnectes 2 Body ground tO. ee yNo 1 ‘Check speed sensor referring to p. 6-00. Poor ATT connection. If connection is OK, sit in good condition? intermittent trouble or faulty ECM. Recheck referring to, “Intermittent trouble” on p. 6-36. Wes No “YIG" wire open, "B/BI" wire open, poor Faulty speed sensor. -to-meter connection or poor "B/BI"" mire ground. 6E-73 Diagnostic Flow Chart For Code No. 246E52_ ELECTRONIC FUEL INJECTION SYSTEM, CODE NO. 31 PS (PRESSURE SENSOR) CIRCUIT (SIGNAL VOLTAGE LOW — LOW PRES: HIGH VACUUM) cou ECM coupler Ps PS coupler 5. To TPS (A/T mode! onty) To other sensors Fig. 66-74 PS Circuit 1. Disconnect PS coupler with ignition switch OFF. 2, With ignition switch ON, is voltage applied to “Lg” wire terminal of PS coupler Vv about 4— 8V? 1. PScoupler 2 2. Engine ground Yves ye Check PS referring to p, GE-83. “Lg wire open, “Lg” wire shorted to ground. Ist in good condition? circuit or poor Ad connection. If wire and connection are OK, substitute ‘8 known-good ECM and recheck. YES yn “LgIR” wire shorted to ground circuit, Faulty PS. poor PS-t0-PS coupler connection or poor ‘AB connection. I wire and connections are OK, intermittent ‘rouble or faulty ECM. Recheck referring to “Intarmittent trouble" on p. 6-36. Fig. 6E-75 Diagnostic Flow Chart For Code No. 31ELECTRONIC FUEL INJECTION SYSTEM 6E-53 NO. 32 PS (PRESSURE SENSOR) CIRCUIT (SIGNAL VOLTAGE HIGH — HIGH PRESSURE — LOW VACUUM) ecu ECM coupler Ps |. PS coupler 5. To TPS (A/T model ony) Te athec sears 1. Disconnect PS coupler with ignition switch OFF. 2. With ignition switch ON, isvoltage applied to “Lg” wire terminal of PS coupler about 4 — BV? 4, PS coupler 2. Engine groune {ves ha ‘Check PS referring top. 6E-83. {sit in good condition? cir: check. “Lg wire shorted to power If wire is OK, substitute a Knowngood ECM and re NOTE: When battery voltage is applied to "Lg" wire, itis possible ‘that PS is also faulty. ves ye "Lo" wire shorted to “Lg/R” wire, “Lg/B” Faulty PS. ‘wire open, poor A16 connection or poor P5:t0-"Lg/B” wire connectio Hf wires and connections are OK, inter: jttent trouble or faulty ECM, heck referring to “Intermittent trouble” ip. 6E-36. 8E-77 Diagnostic Flow Chart For Code No. 328E-54 ELECTRONIC FUEL INJECTION SYSTEM CODE NO. 41 IGNITION SIGNAL CIRCUIT (IGNITION SIGNAL NOT INPUTTED FOR 2'SEt AT ENGINE CRANKING) ecu ECM coupler Noise suppeessor (Coupler Ignition eo Coupler To disributor ) Ye “To ignition switch Fig, 6E-78 Ignition Signal Circuit Check ignition system referring to SECTION. 6F, Is it in good condition? Yves as 1. Disconnect ECM coupler with ignition Faulty ignition system. switch OFF, 2. Ie battery voltage applied to B2 terminal at ignition switch ON? iscannected 2. Bosy ground ves ye “Br” shorted to power circuit, poor B2 Faulty noise suppressor or open circuit connection. between ignition coil and B2 terminal. If wires and connection are OK, substitute ‘a known-good ECM and recheck, Fig. 6E-79 Diagnostic Flow Chart For Code No. 41ELECTRONIC FUEL INJECTION SYSTEM 6E.55 NO. 51 EGR SYSTEM FOR CALIFORNIA SPEC. MODEL (FAULTY EGR SYSTEM) EGR system referring to p. 6-93, ‘in good condition? No EGR vive EGR moduletor | vsv ecw Sensed information Main rely cmem et bee ck vacuum hose, EGR valve and EGR ator referring to p. BE-94, stay in good condition? Intermittent trouble or faulty ECM, Recheck referring to “Intermittent trouble’ on p. 6-35. YES ne ck VSV referring to p. 6E-98, in good condition? ‘* Vacuum hose misconnection, leakage, clog oF deterioration, ‘Faulty EGR valve or ulty EGR modulator. yes 8 wire open, wire shorted to ground, \VSV coupler connection or 83 connection, swice and connection are OK, substitute wn-good ECM and recheck. Faulty VSV. & Diagnostic Flow Chart For Code No. 51 (California Spee. Model Only)9E-56 ELECTRONIC FUEL INJECTION SYSTEM. TROUBLE DIAGNOSIS This section describes trouble diagnosis of Elect- When diagnostic code No. 12 is indicat ronic Fuel Injection system parts whose trouble self-diagnosis function and assuredly is not indicated by the self-diagnosis function. gine basic parts as described in DIAGNOSIS” are all in good condition. below Electronic Fuel Injection which may be a possible cause for each’ of the engine. SYMPTOM POSSIBLE CAUSE INSPECTI Hard or no starting Shortage of fuel in fuel tank 7 (Engine eranks OK) | « injector or its circuit faulty Diagnostic flow ‘© Faulty fuel pump or its circuit open Diagnostic flow c Fuel pressure out of specification Diagnostic flow chars © Faulty air valve See p. 6E-79 ‘© Engine start signal not to fed | Diagnostic flow c! # Poor performance of ATS, WTS or | See p. 6E-88, 6E-29 pressure sensor GE-83 | © Faulty ECM See p. 6E-66 NOTE: ‘© If engine doesn’t start at all, perform fuel injector and its circuit check first. (Advance to “Di Flow Chart B-1”.) © If engine is hard to start only when it is cold, check air valve first. Engine fails to idle | © Shortage of fuel in fuel tank ‘Faulty ISC solenoid valve control system | Diagnostic flow ‘© Maladjusted idle speed adjusting screw See p. 6E-72 © Faulty air valve See p. 6E-79 @ Faulty EGR system (For California spec. | See p. 66-93 model) © Fuel pressure out of specification Diagnostic flow chars © Faulty injector Check injector for and injection condi | (Refer to p. 6E-80) ‘© Poor performance of ATS, WTS or See p. 6E-88, 6E 82) pressure sensor 6E-83 © Faulty ECM See p. 6E-68 If engine fails to idle only when it is cold, check air valve,ELECTRONIC FUEL INJECTION SYSTEM SE57 SYMPTOM. POSSIBLE CAUSE INSPECTION per engine idle | © Maladjusted accelerator cable play See p. 6E-72 ‘© Clogged pressure sensor vacuum passage | Check vacuum hose and filter ‘Faulty ISC solenoid valve control system |. Diagnostic flow chart B-4 «Faulty air-conditioner VSV control system | See section 1B (if equipped) Faulty idle switch (in TS or TPS) See p. 6E-84 ‘*. Maladjusted idle speed adjusting screw See p. 6E-72 © Faulty air valve See p. GE-79 ‘© Fuel pressure out of specification Diagnostic flow chart 8-3 ‘© Poor performance of ATS, WTS or See p. 6E-88, 6E-89 or pressure sensor 6-83 © Faulty ECM See p. 6E-66 ‘With engine warmed up, if engine idle speed and ISC solenoid valve is not heard to operate, 4c accelerator cable play, idle switch and ISC solenoid valve control system in that order. if engine idle speed lowers below specification only when electric load is applied (e.g. headlight ON), check ISC solenoid valve control system first. ‘With A/T model, if engine idle speed lowers below specification only when shifted to “ 2° or “L" range, check if “R”, “D", “2” or “L'” signal is inputted to ECM first. thas no or poor | © Maladjusted accelerator cable play See p. 6-72 © Faulty TS (wide open switch) for M/T See p. BE-84 model ‘e Faulty EGR system (For California spec. | See p. 6E-93 model) ‘© Fuel pressure out of specification Diagnostic flow chart B-3 (Low fuel pressure) Poor performance of TPS (For A/T model),| See p. 6-86, 6E-88, 6E-89 ATS, WTS or pressure sensor or 6E-83 © Faulty ECM See p. GE-66 hesitates when | © Clogged pressure sensor vacuum passage | Check vacuum hose and filter ‘ng 'e Faulty EGR system (For California spec. | See p. 6E-93 model) ‘Fuel pressure out of specification Diagnostic flow chart 8-3 (Low fuel pressure) ‘* Poor performance of ATS, WTS or See p. 6E-88, GE-89 or pressure sensor 6E-83 © Faulty ECM See p. BE-66 ‘@ Variable fuel pressure (Clogged fuel filter, Diagnostic flow chart B-3 mn in car. faulty fuel pressure regulator, etc.) at ane ‘¢ Poor performance of pressure sensor, See p. 6E-83 ) @ Faulty ECM See p. 6E-66en 66-58 ELECTRONIC FUEL. INJECTION SYSTEM. ae SYMPTOM POSSIBLE CAUSE INSPECTION Poor gasoline mileage High idle speed Fuel pressure out of specification or fue! leakage Faulty TS (M/T model) or TPS (A/T model) Poor performance of ATS or WTS Faulty ECM Refer to item “i engine idle speed” outlined Diagnostic flow chars See p. 6E-84 or 6E: See p. GE-88 or ESS See p. 6E-66 Excessive hydrocarbon. (HC) emission Engine not at normal operating ‘temperature Clogged air cleaner Faulty ignition system Vacuum leaks Low compression Lead contamination of catalytic converter ‘© Fuel pressure out of specification A/F feed back compensation fails See section 6F See section 6 Check for absence of neck restrictor Diagnostic flow chart — Faulty TS (M/T model) or TPS (A/T See p, 6E-84 or 6E-B5- model) — Poor performance of WTS or pressure | See p. 6E-89 or GE: sensor © Poor performance of ATS See p. 6E-88 © Faulty injector See p. 6E-80 © Faulty ECM See p. 6E-66 Excessive carbon ‘¢. Engine not at normal operating temperature monoxide (CO) © Clogged air cleaner * Faulty ignition system See section 6F ‘* Low compression See section 6 ‘Lead contamination of catalytic conveter | Check for absence of © Fuel pressure out of specification A/F feed back compensation fails — Faulty TS (M/T model) or TPS (A/T. model —Poor performance of WTS or pressure sensor Poor performance of ATS Faulty injector Faulty ECM neck restrictor Diagnostic flow chart See p. 6E-84 or 6E-86 See p, 6E-89 or 6E-83 See p. GE-88 See p. 6E-80 ‘Seé p. BE-66EE Ee ELECTRONIC FUEL INJECTION SYSTEM 6E-59 SYMPTOM POSSIBLE CAUSE | INSPECTION model) sensor © Faulty injector © Faulty ECM © Improper ignition timing © Poor performance of ATS © Lead contamination of catalytic converter © Fuel pressure out of specification '* A/F feed back compensation fails — Faulty TS (M/T model) or TPS (A/T — Poor performance of WTS or pressure See section 6F Check for adsence of filler neck restrictor See p. 6€-93, Diagnostic flow chart B-3 See p. 6E-84 or 6E-86 See p. GE-89 or 6E-83 See p, 6E-88 See p. GE-80 See p. GE-66 2 wat rr 2m. Injector Circuit injected from injector tion switch ON {not ? Injected from injector cranking? 10 p, 6E-80 for check- To be continued EL INJECTOR AND ITS CIRCUIT CHECK (ENGINE NOT STARTING) ecw Injector es sin Main site Ech coupler Injector sub coupler 8. Injector coupler Weeheh= ves “Y/B" wire shorted to ground cr faulty injector, Mf wire and OK, check to make sure that resistance of resistor tor is as specified ively and then substitute _a_knowngood ECM and recheck.SE-60 ELECTRONIC FUEL INJECTION SYSTEM Continued . Nf WOT HoT Tar svn00 anaes To nouenimETnOS boa] wayyy Ma Using sound scope, eheak | Fuel injector, x 8©_l check injector for ea ct rte pr BESO tor Poses eer [stein god eonalson? Is it detected? im ves yNo Nace Injector and its circa pod Sndon Stee eee Check tuel_punp ond Tod Pores lees, 0 presse Pipers: tn Did ore Gnostic "Flow ‘CHART 2. Is resistance of injector 82 and 83), 0.5 — 1.5 & {at 20°C, 68°F)? ves ee 7. Biecreaeredearsaager Faly jal open wae with pnkion awish OFF or cer oe ae me 2 We Mttanee oh ea toe 1.9 — 2.1 Q (at 20°C, 68°F). fee ene 1. Conneat injector coupler Fabia tnd Yeo exuplor eh ignition sch OFE 2. Disconnect ECM coupler... 3. ie Dato volte eboled v to "ECM couple BE et le initio ch ON? het 2 a oor BE connection =" wire open, "VIB™ we i ifeonneion 6 OK, wit hai aaa rnor cau stitute a known-good ECM ‘connection or poor injector ane reheat couple sormectin Fig. 6-87 Diagnostic Flow Chart 8-1 For Injector and Its CircuitELECTRONIC FUEL INJECTION SYSTEM GE-61 FUEL PUMP AND ITS CIRCUIT CHECK 1. Eom 2. ECM coupler ‘Fuel pump relay 4 Fuel pump ‘5 Main vley ° 5E-88 Fuel Pump Circuit fuel pump hoard to operate for 2 sec. after, ition switch ON? 7S ves “Remove fuel pump relay from main fuse Fuel pump and its box. Circuit in good Using service wire, connect “PY and ———] condition. “W/BI" wire terminals, Is fuol pump heard to operate at ignition ‘switch ON? 1. Fuel pump 2. savicowire 10 Yves 1 fuel pump relay referring to p, GE-91. “P" wire open, poor fuel_pump coupler {in good condition? connection or faulty fuel pump. es. W felay coupler connection, “P/W” wire Faulty fuel pump relay. ‘or p90r B10 connection. ‘wire and connection are OK, substitute @ -good ECM and recheck. substituting 2 known-good ECM, ‘to make sure that resistance of coil in sas specified. 89 Diagnostic Flow Chart 8-2 For Fuel Pump and Its Circuit CheckE-62 ELECTRONIC FUEL INJECTION SYSTEM. B-3 FUEL PRESSURE CHECK 1. Fuel pump 1, Special too! (Ful 2. uel fter gauge & Say joe 2 Thr 7, Fuel feed tine > 4 4 Fuel injector B. Fuel return line 53, Fuel prssure reguitor 2 Fig. 6E-90 Fuel Pressure Check 1. Install_fuel pressure gauge referring to | No pressure p. 6E-73. mae me To (D on next) 2. Bperate ful pump for 10 see according ta procedure Gnebed on or GES He fuel pressure then 1.6 — 2.1 kg/em? gO Btosers, 227 £789 pl A, (80.0 lem? (9) Kh, 2 par het Prasie wing ‘el eat seg foe 1 hae te. For] A get ral fuel pump is stopped? 19 © on Pee Ves 1. Start engine and warm it up to normal ‘operating temperature, 2. Keep it to specified idle speed. Is fuel pressure then 0.9 — 1.4 kg/em? (80 ~ 140 kPa, 12.8 ~ 20.0 psi? PV etran ial wa aretiemoe | ye VYes Normal fuel pressure. ‘*Clogged vaccum passage for fuel pressure regulator or ‘Faulty fuel pressure regula: tor. Low pressure To (@)on next Fig. 6£-91 Diagnostic Flow Chart B-3 For Fuel Pressure (1)FUEL PRESSURE CHECK (continued) NO PRESSURE feo yp Faulty fuel pressure fer to "Diangostic Flow regulator 82), LOW PRESSURE ‘Operate fuel pump, With fuel return hose Blocked by pinching it, “check fuel pressure Isit 2.0 kg/em* (200 kP2, 4 psi) or more? Yes fuel filter, Faulty fuel ited fuel feed hose pressure pie, Fegulator uel pump o leakage from hose ction in fuel tank. 1 Diagnostic Flow Chart B-3 For Fuel Pressure (2) ELECTRONIC FUEL INJECTION SYSTEM 6E-63 @PRESSURE WITHIN SPEC. BUT NOT RETAINED. Y Is there fuel leakage from fuel feed line hose, pipe or their joint? a — | 1. Disconnect fuel return hose Fuel leakage | from throttle body and from hose, | connect new return hose pipe or jain. tolt rhew return hose in proved gasoline cont 3. Check again if specified pressure While doing 20, does fuel come out of return hose? 2p Balpart the ob dof | is retained. ROS! Ov she ores VES ‘Fuel leakage from injector, Faulty fuel ‘Fuel leakage from betwe pressure injector and throttle body, regulator. ‘Faulty fuel pump (faulty ‘check’ valve in fuel pump) ‘#Fuel leakage from fuel prossure regulator diaphragm. 3 @HiIGH PREssuRE 1. Disconnect fuel return hose from throttle body and connect new return hose toit. 2. Insert. the other end of nev return hose into approved gasoli 3. Operate fuel pump. Is specified fuel pressure obtained then? ‘container. {ie ee er Faulty fuel pressure regulator Restricted fuel return hose or pipe.GE-64 ELECTRONIC FUEL INJECTION SYSTEM B-4 ISC SOLENOID VALVE CONTROL SYSTEM CHECK SS 1s or mG zs Fig. GE-92 ISC Solenoid Valve Circutt 1. Connect spare fuse to diagnosis switch terminal (grounding). 2, Turn ignition switch ON. 43, Is diagnostic code No. 12 indicatod? ves. vo 1s operation of ISC solenoid vaive also heard then? Go back to “Diagnostic Flow Chart” on p. 6E-38. Yves No 1, Start engine and run it at idle speed. 2, Disconnect ISC solenoid valve hose from air cleaner case and check air flow. Is it drawn into it? Yes ye ‘System in good Clogged air Condition assage, Fig. 6£-99 Diagnostic Flow Chart B-4 For ISC Solenoid Valve Control System ‘Cheek 1SC solenoid valve referring to p. 6-92. Is it in good condition? yyes ‘RIW" wire open, RW" wire shorted to ‘ground circuit Poor ISC solenoid coupler connection or ‘*Poor 84 connection. If wire and connections are (OK, substitute a known-good ECM and recheck, NOTE: Before substituting a known- ‘good ECM, check to make sure that resistance of ISC solenoid valve is as speck CS eelELECTRONIC FUEL INJECTION SYSTEM 6E-65 ENGINE START SIGNAL CHECK 1. Eom 2) ECM coupler (BIR tor A/T 3. Clutch ewiten model oniv} (MrT model ont) 4. Main wit 6. To startar motor 65-93-1 Engine Start Signal Circult ‘YES [Engine start signal circuit is 1, EoM coupler | [—™] in good condition, isconnected 2. Body ground = With ignition switch OFF, disconnect “A” coupler (right side coupler) from ECM. a Is 6 ~12V voltage applied ‘eWire open, <0 A1 terminal of coupler INO | @Poor connection or ‘only when cranking engine ‘Faulty clutch switch (M/T > ‘model only). 'GE-93-2 Engine Start Signal Check “R","D","2" OR "L" RANGE SIGNAL CHECK (A/T MODEL ONLY) a ‘ F] 2 ecw cout moe ef 3. AMT contro module 93:3. "R", “D", "2" or “L” Range Signal Circuit ‘With ignition switch OFF, disconnect “AM coupler (right side coupler) from ECM. Turn ignition switch ON and check ee woltage at A2 terminal of coupler under 2. Body ground fesch condition given in below table. ‘Sélector lever in "Por YES | Signal circuit is in good =N" range position (as condition, ‘Selector lever in “F 9D", "2" or "L" range | 10-14 posi ‘© Wire open or LNO,.| ePoor connection If wire and connection are OK, check A/T control system raferring to section 7B. 93-4 “R", “D", “2” or “L Range Signal Check (A/T Mortal Only)SE-66 ELECTRONIC FUEL INJECTION SYSTEM INSPECTION OF ECM AND ITS CIRCUITS ECM and its circuits can be checked at ECM wiring couplers by measuring voltage and resistance. NOTE: ‘As each terminal voltage is affected Sy battery voltage, confirm that it is 11¥ when ignition switch is ON. CAUTIOI ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter ‘or ohmmeter to ECM with couplers dis- ‘connected from it. Voltage Check 1. Remove ECM from body referring to p. 6E- 82. 2. Connect ECM couplers to ECM. 3. Using service wire, ground ECM case, 4. Check voltage at each terminal’ of couplers connected. O Fig. 6E-94 Checking Voltage 1 coe 2. Body’ 3. Serve 1. eeu 2 ecw Fig. 6E-95 ECM Coupler TerminalsELECTRONIC FUEL INJECTION SYSTEM GE-67 NORMAL cIRCUIT WGIEAGE CONDITION Engine start switch 6 — 12V | While engine cranking (Engine start signal) OV _| Other than above Terao meals oy | [snition switch ON, Selector fever in “P"* or “N* (RY, DH, 12" on HL range position range signal} 10 14y | Ianition switch ON, Selector lever in “R "2" or “L"" range position ov | !srition switeh ON Idle switch Throttle valve at idle position {in TS or TPS) a sy | lanition switch ON = Throttle valve opens larger than idle position Power source of sensor : esandreek |4.75-6.26V | gnition switch ON Ignition switch ON Pressure sensor 85—41V | parometric pressure: 760 mmHg Indicator etlection repeated | While engine running at 2,000 r/min after warmed up ‘Oxygen sensor between i i disney rset) [and kept running at 2,000 r/min for 1 minute ‘under ousy Circuit ground OV | Ignition switch ON 1=2V_| Ignition switch ON Shiftup indicator light 10~14V | While engine running at idle speed 10—14V | Ignition switch ON, Throttle vaive at idle position ‘AIT control module Ignition switch ON, Voltage varies as specified at the (Throttle valve opening |0,2 — 0.4V | left while throttle valve is opened gradually. (Refer signal) {fo Fig. 6E-163 for relations between opening and. voltage) Air conditioner circuit HO S21 4¥" lonition awiteniON {if equipped) 0 — ov | While engnie running at idle speed Air-conditioner ON6E-68 ELECTRONIC FUEL INJECTION SYSTEM TER- NORMAL IN ian CIRCUIT OUEIGE CONDITIO Tadieator deflection vate maT" | Speed nr deflection | Ignition switch ON and front tires turned by between ov | slowly and 4—6V. 4—5V_| Ignition switch ON A12_| Test switch terminal OV _| Ignition switch ON, Test switch terminal grou Ignition switch ON Ai3_| ATS 2.0 —2.7V | Sensor ambient temp (Intake air temp.): 20°C (68°F) Ignition switch ON Ny O48-080V | eine cooling water temp.: 80°C (176°F) _ ignition switch ON (wrt | Wide open switch 4—5V_| Throttle valve at idle position pony | fin TS) iy Ignition switch ON Throttle valve at full open position Ignition switch ON als as [025-O88V | throttle valve at idle position oad 3.3 — 48 | [anition switch ON ‘SN | Throttle valve at full open position ‘16 _| Ground of sensors OV _| lgnition switch ON 10 ~14V | Ignition switch ON, Throttle vaive at idle posit AIT | A/T contro! module Tonition switch ON iM a rmode| | (Throttle valve opening | ay, | Voltage varies as specified at the left while th ‘only) | signal) Pr “| valve is opened gradually. (Refer to Fig. 6E-163° relations between opening and voltage.) 10 —14V_ | Ignition switch ON, Throttle valve at idle posi ie AST control module Ignition switch ON model | (Throttle vaive opening |) _ 9 4\, | Voltage varies as specified at the left while t only) | signal) valve is opened gradually. (Refer to Fig, 6E-163 relations between opening and voltage.)ELECTRONIC FUEL INJECTION SYSTEM 6E-69 TER: NORMAL Pa ciRCUIT eee CONDITION B1_| Power source 70 = 14V | lanition switch ON Ignition coil a 82 # i See lan 10 = 14V | Ignition switeh ON 83 en Sh | ecr vsv 10=14V | Ignition switch ON sees) Ignition switch ON y 0.8 ~1-8V | Diagnosis switch terminal ungrounded 84 | ISC solenoid valve Fo 1ay | lition switeh ON Diagnosis switch terminal grounded 85 _| Injector 70 —14V | Ignition switch ON 36_| Ground OV__| lanition switch ON 7 _| Power source for backup | 49 _ say | ignition switch ON and OFF 4—8V__| Ignition switch ON 88 mosis switch terminal [gy | lanition witch ON, Diagnosis switch terminal grounded Ignition switch ON 1.2~2.0V | diagnosis switch terminal ungrounded 89 | "CHECK ENGINE” light To ay | When engine running Diagnosis switch terminal ungrounded E f.2—1.8v | For 2 seconds after ignition switch ON 810. | Fuel pump relay 10 — 14V_| When over 2 seconds after ignition switch ONee 6E-70 ELECTRONIC FUEL INJECTION SYSTEM. Resistance Check 1, Disconnect ECM couplers from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itselt or connect voltmeter or ohmmeter. 2. Check resistance between each terminal of couplers disconnected. CAUTION: © Be sure to connect, ohmmeter probe from wire harness side of coup © Be sure to turn OFF ignition switch for this check, © Resistance in below table represents that when ambient temperature is 20°C (68°F). 1. ECM couple dis 2. Ohmmeter Fig, 6E-96 Checking Resistance TERMINALS | CIRCUIT |. preretaNcE CONDITION na — ate _| laleewiten O (zero) Throttle valve is at idle position Sor TPS) = (Infinity) | Throttle valve opens larger than idle posit AIT — Body | speed sensor Face Essien | While front tire turned slowly ground ape | A12— Body | Test switch 0 Test switch terminal ground ground | terminal = ‘Test switch terminal ungrounded A13—Até [ATS 2.21-2,69ka | Intake air temp. 20°C (68°F) Ata — Ate _ [WTS 290-364. | Engine cooling water temp, 80°C (176°F) ‘15 —At6 | Wide open = (infinity) | Throttle valve at idle position IM/T model oniy)| switch (in TS) [0 (Zero Throttle valve at full open position Ais — Al6 240-1140 _| Throttle valve at idle p |‘art model oniy)} TPS 3, 30kQ_| Throttle valve at full open positionELECTRONIC FUEL INJECTION SYSTEM 6E-71 CIRCUIT NORMAL RESISTANCE CONDITION EGR VSV 33-390 ISC solenoid valve 30-339 Injector and resistor 24-360 ECM ground 0 (Zero)6-72 ELECTRONIC FUEL INJECTION SYSTEM ON CAR SERVICE GENERAL When hoses have been disconnected and system's component removed for service, be sure to reinstall component properly, and route and connect hoses correctly after service. Refer to Fig, GA-4 for proper routing of hoses. ACCELERATOR CABLE ADJUSTMENT Check accelerator cable for play and adjust if necessary. Cable play should be within specification. If out of specification, loosen accelerator cable lock nut and adjust by turning adjusting nut. Be sure to tighten lock nut securely after adjustment. 3—5mm Accelerator cable play | 19.19 _ 0.201n.) Accalarator cable ‘Toroele valve loser 5. Agjusing nut Lock nat Coble pay 1 2 iz a 5 Fig, 6E-97 Accelerator Cable Play IDLE SPEED ADJUSTMENT (INCLUDING AIR-CONDITIONER VSV ADJUSTMENT) Before idle speed check and adjustment, make sure of the following. @ Lead wires and hoses of Electronic Fuel Injection and engine emission control systems are connected securely, © Accelerator cable has some play, that is, it is not tight. © Ignition timing is within specification. © All accessories (wipers, heater, are out of service. © Airconditioner is OFF, if equipped. © Air cleaner has been properly in: in good condition. After above items are all confirmed, spoed as follows. NOTE: Before starting engine, place tran: shift lever in “Neutral” (shift selector “B*" range for A/T model), and set and block drive wheels. 1. Warm up engine to normal operating: ture. 2, Set tachometer 3. Connect spare fuse to diagnosis minal in junction/fuse block, and air supplied by ISC solenoid valve wal constant. NOTE: At this time, “CHECK ENGINE” fi indicate diagnostic code NO. 12 and tion of ISC solenoid valve should be not, check and repair according to flow chart on p. 6E-38 and “Die chart 8-4" on p. 6E-64, Fig. 6E-98. Grounding Diagnosis Switch Te

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