SUZUKI
Camg for Customers
99500-83010-01 E
RELATED SERVICE MANUAL
SERVICE MANUAL RELATED TO THIS MANUAL 99500-83010 APPLICABILITY
-
SJ413 SUPPLEMENTARY SERVICE MANUAL 99501-83020-lBE Vehicles equipped with carburetor, oxygen
sensor and catalyst
--
SJ413 SUPPLEMENTARY SERVICE MANUAL 99501-83020-25E Vehicles equipped with catalyst
(but not oxygen sensor)
- - - - I- --
SJ413 SUPPLEMENTARY SERVICE MANUAL 99501-83310 Vehicles after body Nos. listed below.
For European Market & Australian Market
x JSAOSJ70000103001 :R: ~
S JSAOSJ70V00103001 S ~
S JSAOSJ50000190003 :R: ~
:R: JSAOSJ50V00150003 x ~
For Other Market
,___ -- - -
SJ50-1 38999
,- -
~
SJ413 SUPPLEMENTARY SERVICE MANUAL 99501-83321 Vehicles equipped with electronic fuel
injection system
-
SJ413 SUPPLEMENTARY SERVICE MANUAL 99501-83330 Vehicles after body Nos. listed below
I For European/ Australian Markets
x JSAOSJ70000400001 ~
:R:JSAOSJ70V00400001 S
For Other Markets
SJ70-400001 ~
For vehicles from the very beginning of the production up to body Nos. as listed in "FOR EWARD", refer
to SJ413 Service Manual 99500-83000.
I
SERVICE MANUAL RELATED TO S/M 99500-83000 APPLICABILITY
SJ413 SUPPLEMENTARY SERV IC E MANUAL 99501-83001 Vehicles equipped with oxygen sensor and
catilyst
-
SJ413 SUPPLEMENTARY SERVICE MANUAL 99501-83010 Vehicles equipped with catalyst
I
(but not oxygen sensor)
FOREWORD
This service manual is applicable to vehicle not equipped with catalytic converter.
This manual contains procedures for diagnosis, maintenance adjustments, service operations,
replacement of components (Service) and for disassembly and assembly of major compo-
nents.
The contents are classified into sections each of which is given a section number as indicated
in the Table of Contents on next page. And on the first page of each individual section is an
index of that section.
This manual should be kept in a handy place for ready reference of the service work. Strict
observance of the so specified 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, etc.) as specified in each
description.
All information, illustrations and specifications contained in this literature are based on the
latest product information available at the time of publication approval. The right is reserved
to make changes at any time without notice. And used as the main subject of description is
the vehicle of standard specifications among others. Therefore, note that illustrations and
photos may differ from the vehicle being actually serviced.
IMPORTANT:
It is important to note that, during any vehicle maintenance procedures, replacement
fasteners must have the same measurements as those removed.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possible
personal injury.
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 a replace-
ment that matches the original.
Additional information concerning this subject will be found in the section O (METRIC
INFORMATION).
This service manual is applicable to vehicles of and after the following body number.
Effective body No.:
For European Market For Other Market
x JSAOSJ70000102001 x SJS0 - 135001
x JSAOSJ70V00102001 °E SJS 1 - 110001
~ JSAOSJ710001.02001 R
x JSAOSJ50000170001 x
:R JSAOSJ50V00140001 ~
x JSAOSJ51000115001 x SUZUKI MOTOR CORPORATION
TECHNICAL DEPARTMENT
AUTOMOBILE SERVICE DIVISION
© COPYRIGHT SUZUKI MOTOR CORPORATION 1991
TABLE OF CONTENTS SECTIC
GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS
PERIODIC MAINTENANCE SERVICE
TROUBLE SHOOTING
ENGINE
FUEL SYSTEM (CARBURETOR, AIR CLEANER, FUEL PUMP AND FUEL FILTER)
EMISSION CONTROL SYSTEM
ENGINE COOLING SYSTEM
CAR HEATER
! IGNITION SYSTEM
I CRANKING SYSTEM
I CHARGING SYSTEM
I CLUTCH
I GEAR SHIFTING CONTROL
TRANSMISSION
TRANSFER GEAR BOX
PROPELLER SHAFTS
DIFFERENTIAL
SUSPENSION
STEERING SYSTEM
j BRAKES
I BODY SERVICE
I BODY ELECTRICAL EQUIPMENT
I SERVICE DATA
SECTION 0
GENERAL, SPECIAL TOOLS AND
SERVICE MATERIALS
CONTENTS
0-1. LOCATIONS OF BODY NUMBER AND ENGINE NUMBER ......... 0-1
0-2. STANDARD SHOP PRACTICES . .... . . ....... .. ........ . ...... 0-2
0-3. SPECIAL TOOLS . ..... . ... ... .. .... ....... ..... ..... ..... . . 0-s
0-4. REQUIRED SERVICE MATERIALS .. . .. . . . .... .... .. . .... . .. . 0-9
0-5. METRIC INFORMATION .. ..... . .. ...... . ... . ... . .......... 0-12
0-1. LOCATIONS OF BODY NUMBER
AND ENGINE NUMBER
The body number is punched on the chassis The engi ne number is punched on the rear
inside the tire housing on the right front side. portion of the left-hand skirt part of cylinder
block.
~'- ~
t
\ ~
I-----..;
~
Fig. 0-1 Location of Body No.
Exhaust manifold
Fig. 0-2 Location of Engine No.
0-1
0-2. STANDARD SHOP PRACTICES 4 . To perform service with either front or rear
car end jacked up, be sure to place safety
1. Protect painted surfaces of the body, and stands under chassis frame so that body is
avoid staining or tearing seats. When working securely supported. Refer to below figures
on fenders and seats, be sure to cover them for where to place safety stands. And then
up with sheets. check to ensure that chassis frame does not
2. Disconnect negative terminal connection of slide on safety stands and the car is held
the battery when working on any electrical stable for safety's sake.
part or component. This is necessary for
avoiding electrical shocks and short-circuit- WARNING:
ing, and is very simple to accomplish : merely Place chocks against both right and left
loosen wing nut on negative terminal and wheels on the ground from both front and
separate cable from terminal post. rear.
3. In raising front or rear car end off the floor
by jacking, be sure to put the jack against
differential portion of axle housing.
NOTE:
Don't get on the car, get under it or service it in
this state. 0
Chassis frame
□
Safety stand
07 I
Fig. 0-5 Front Side
Fig. 0-3 Front Side
Fig. 0-6 Rear Side
Fig. 0-4 Rear Side
0-2
5. Fig. 0 -7 and 0-8 show how to lift the car by 6. Orderliness is a key to successful overhauling.
using a hoist. Trays, pans and shelves are needed to set
aside disassembled parts in groups or sets
WARNING: in order to avoid confusion and misplace-
• When using frame contact hoist, apply ment. This is particularly important for
hoist as shown below (right and left at engine overhauling.
the same position). Lift up the car rill 4 7. Have on hand liquid packing-SUZUKI
tires are a I ittle off the ground and make BOND No. 1215 (99000-31110) - for
sure that the car will not fall off by try- ready use. This packing dope is an essential
ing to move car body in both ways. item to assure leak-free (water and oil) work-
Work can be started only after this manship.
confirmation. 8. Each bolt must be put back to where it was
• Before applying hoist to underbody, al- taken from or for which it is intended. Do
ways take car balance throughout serv- no1 depend on your hunch in tightening
ice into consideration. Car balance on bolts for which tightening torque values are
hoist may change depending of what specified: be sure to use torque wrenches on
part to be removed. those bolts.
• For suspention parts removal, follow 9. It is advisable to discard and scrap gaskets
previous steps 3 and 4. and "O" rings removed in disassembly. Use
• Make absolutely sure to lock hoist after new ones in reassembly, and try not to
car is hoisted up. economize gaskets and "O" rings.
10. Use of genuine SUZUKI parts is imperative.
When using frame contact hoist: Use of imitation parts is a big gamble on
safety and performance. Use genuine
SUZUKI parts and live up to the trust your
customer places on you.
11. Special tools save time and ensure good
workmanship: They are available from
SUZUKI. Use them where their use is
specified. Moreover, your own safety is
assured by the use of special tools in many
Chassis frame
of the disassembly and reassembly steps.
Fig. 0-7 Front Support Location
-----'~
Fig. 0-8 Rear Support Location
0-3
12. Refer to t he contents of this MANU A L as
oft en as pract ical, and do each job properly
as prescribed.
NOTE:
Engine cylinders are identified by numbers.
See Fig. 0-9. Counting from the front end, the
cylinders are referred to as No. 1, No. 2, No. 3
and No. 4 cylinders.
No. I No.2 No.3 No.4
Fig. 0-9 Engine Cylinder Numbers
0-4
0-3. SPECIAL TOOLS
Special tools assure three things: 1) improved workmanship; 2) speedy execution of jobs for which they
are meant; and 3) protection of parts and components against damage. Here are the special tools pres-
cribed for this Model:
1. 09927-18410
Universal puller 09926-48010
09900-06107 09900-06108 2. 09921-57810 Universal joint
Snap ring plier (opening type) Snap ring plier (closing type) Bearing remover assembler
a
II
09913-75510
09900-27311 09900-27301 09932-28211 Differential rear outer
Timing light (Ory cell type) Timing light (D .C. 12V) Carburetor float level gauge race installer
1. 09916-14510
Valve lifter
09913-6091 0 09918-38310 0991 5-47310 2. 09916-48210
Bearing puller Carburetor adjuster set Oil filter wrench Valve lifter attachment
0-5
09916-44511 09917-88210 09917-98210 09916-34520
Valve guide remover Valve guide installer Valve stem seal installer Reamer (7 mm)
09916-37310 09916-34541 09916-77310 09916-84510
Aeamer ( 12 mm) Reamer handle Piston ring compressor Forceps
3 09916-57321 09915-64510
Valve guide installer handle Compression gauge
6 5
09910-38210
Piston pin remover and installer
1. Base
2. Base cap
3. Driver handle
4. Piston pin guide for installation
5. Piston pin guide for removal
6. Spring 09915-77310 09915-67310
7. Spring guide Oil pressure gauge Vacuum gauge
0-6
09917-58010
09917-68210 09924-17810 09926-1 8210 Bearing remover
Camshaft lock holder Flywheel holder Oil seal guide (Vinyl resin) (for input shaft bearing)
09925-98210 09913-65135 09922-85811
09923-36330 Input shaft bearing Transmission and transfer Spring pin remover
Clutch center guide inst aller bearing and gear remover (4.5mm)
09925-18010 09925-4821 0
Transmission gear, bush Clutch release bush 09913-75810 09913-76010
and bearing installer remover Transfer bearing installer Tronsfer beuring installer
09922-75221
09930-40113 • Center brake drum lock
• Transfer flange lock holder holder 09926-58010
09913-84510 • Differential side bearing • Differential bearing Bearing puller attach-
Transfer bearing installer adjuster preload checking toot ment (transfer)
0-7
09913-85230 09926-78310 09940-53111
Differential side bearing Differential bevel pinion Differential side beari ng 09924-74510
remover jig mounting dummy installer Bearing installer attachment
09926-68310
Differenti al pinion bearing 09942-15510 09922-66010 09943-35511
installer Sliding hammer Rear axle shaft remover Brake drum remove~
09941-58010 09944-36010 09913-65210 09917-47910
50 mm socket wrench Steeri ng wheel remover T ie-rod end remover Vacuum pump gauge
No. 1
09951 -08210
No. 2
09951 -18210
Booster No. 2 body
09950-78210 09950-88210 09950-98210 Oil seal remover &
F lare nut wrench (10 mm) Booster overhaul tool set Booster piston rod gauge Installer No. 1, No. 2
0-8
