Suzuki GA413 Manual
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Suzuki GA413 Manual

Suzuki GA413 Manual

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IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
WARNING:
Indicates a potential hazard that could result in
death or injury.
CAUTION:
Indicates a potential hazard that could result in
vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for authorized
SUZUKI dealers and qualified service mechan-
ics only. Inexperienced mechanics or mechan-
ics without the proper tools and equipment may
not be able to properly perform the services de-
scribed in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.
WARNING:
For vehicles equipped with Supplemental Re-
straint (Air Bag) System:
D Service on or around the air bag system com-
ponents must be performed only by an autho-
rized SUZUKI dealer. Please observe all
WARNINGS, CAUTIONS and "Service Precau-
tions" under "On-Vehicle Service" in SEC-
TION 10B before performing service on or
around the air bag system components or wir-
ing. Failure to follow WARNINGS could result
in unintentional activation of the system or
could render the system inoperative. Either of
these two conditions may result in serve inju-
ry.
D If the air bag system and another vehicle sys-
tem both need repair, SUZUKI recommends
that the air bag system be repaired first, to
help avoid unintentional activation of the air
bag system.
D Do not modify the steering wheel, instrument
panel or any other air bag system component.
Modifications can adversely affect air bag
system performance and lead to injury.
D If the vehicle will be exposed to temperatures
over 93°C (200°F) (for example, during a paint
baking process), remove the air bag system
components (air bag (inflator) modules, SDM
and seat belt pretensioner (if equipped)) be-
forehand to avoid component damage or
unintended activation of the system.

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  • Page 1 D Service on or around the air bag system com- cial meanings. Pay special attention to the messages ponents must be performed only by an autho- highlighted by these signal words. rized SUZUKI dealer. Please observe all WARNINGS, CAUTIONS and “Service Precau- tions” under “On-Vehicle Service” in SEC- WARNING:...
  • Page 2 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 (lubricant, sealants, etc.) as specified in each description.
  • Page 3 AND DIFFERENTIAL Front Differential NOTE: This manual is for GA413 4WD model and contains only the different sections from GA413 Service Manual (99500-76A00-01E). Therefore, the section(s) not found in this manual, please refer to the related manual(s) described in FORE-...

  • Page 4: Table Of Contents

    GENERAL INFORMATION 0A1-1 SECTION 0A1 GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ............. 0A1- 2 PRECAUTIONS .

  • Page 5: How To Use This Manual

    0A1-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the first page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.

  • Page 6: Precautions

    D If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.

  • Page 7: Servicing And Handling

    0A1-4 GENERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY WARNING: FROM BODY. Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment.
  • Page 8 GENERAL INFORMATION 0A1-5 WARNING: During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rig- idly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued to ensure proper opera- tion of the air bag system.
  • Page 9 0A1-6 GENERAL INFORMATION CAUTION: D When using electric welding, be sure to temporarily dis- able air bag system. Refer to DISABLING AIR BAG SYS- TEM under SERVICE PRECAUTIONS in SECTION 10B. D Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames.

  • Page 10: General Precautions

    GENERAL INFORMATION 0A1-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under VEHICLE LIFTING POINTS on SECTION 0A.
  • Page 11 0A1-8 GENERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. 1.

  • Page 12: Precautions For Catalytic Converter

    GENERAL INFORMATION 0A1-9 D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D Never disconnect the fuel line between the fuel pump and in- jector without first releasing the fuel pressure, or fuel can be sprayed out under pressure.

  • Page 13: Precautions For Towing 4Wd Vehicles

    0A1-10 GENERAL INFORMATION PRECAUTIONS FOR TOWING 4WD VEHICLES When towing full-time 4WD vehicles, use one of the methods shown below. TOWING METHOD CONDITION 1 Flat Bed Truck Parking brake applied. 2 Wheel Lift Type Truck From Front Parking brake applied. From Rear CAUTION: D If vehicle has trouble in the chassis and drive train, use 1 flat...

  • Page 14: Precautions For Electrical Circuit Service

    GENERAL INFORMATION 0A1-11 PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch to OFF position, or electronic parts may get damaged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g.

  • Page 15: Electrical Circuit Inspection Procedure

    0A1-12 GENERAL INFORMATION D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage to check for electrical system, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.
  • Page 16 GENERAL INFORMATION 0A1-13 3) Using a test male terminal, check both terminals of the circuit be- ing checked for contact tension of its female terminal. Check contact tension by Check each terminal visually for poor contact (possibly caused inserting and removing just for once by dirt, corrosion, rust entry of foreign object, etc.).
  • Page 17 0A1-14 GENERAL INFORMATION If measurements were taken as shown in the figure and results were as listed below, it means that the circuit is open between termi- nals B-1 and A-1. Voltage Between: C-1 and body ground: Approx. 5V B-1 and body ground: Approx. 5V A-1 and body ground: 0V Also, if measured values were as listed below, it means that there is a resistance (abnormality) of such level that corresponds to the...

  • Page 18: Intermittent And Poor Connection

    GENERAL INFORMATION 0A1-15 INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).

  • Page 19: Precautions For Installing Mobile Communication Equipment

    0A1-16 GENERAL INFORMATION PRECAUTIONS FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Citi- zens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely affect electronic control system. D Keep the antenna as far away as possible from the vehicle’s elec- tronic control unit.

  • Page 20: Warning, Caution And Information Labels

    GENERAL INFORMATION 0A1-17 WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.

  • Page 21: Vehicle Lifting Points

    0A1-18 GENERAL INFORMATION 1. Air bag warning label on driver air bag (inflator) module 2. Air bag warning label on passenger air bag (inflator) module 3. Air bag warning label on contact coil and combination assembly 4. Air bag warning label on SDM 5.

  • Page 22: Wire Color Symbols In This Manual

    GENERAL INFORMATION 0A1-19 In raising front or rear vehicle end off the floor by jacking, be sure Front to put the jack against the center portion of the front lower cross- member or rear axle housing. WARNING: D Never apply jack against suspension parts (i.e., stabilizer, etc.) or vehicle floor, or it may get deformed.

  • Page 23: Abbreviations May Be Used In This Manual

    0A1-20 GENERAL INFORMATION There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “G”). The dual-colored wire uses two color symbols (i.e. “G/Y”). The first symbol represents the base color of the wire (“G”...
  • Page 24 GENERAL INFORMATION 0A1-21 IAC Valve : Idle Air Control Valve (Idle : Right Hand Speed Control Solenoid Valve, ISC Solenoid Valve) : Society of Automotive IAT Sensor : Intake Air Temperature Engineers Sensor (Air temperature : Sensing and Diagnostic Sensor, ATS) Module (Air bag controller, : Immobilizer Control Module Air bag control module)

  • Page 25: Metric Information

    0A1-22 GENERAL INFORMATION METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric. When replac- ing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 7T and radial line with the class identification embossed on the head of each bolt.
  • Page 26 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to AIR BAG SYSTEM COMPONENTS AND WIRING LOCATION VIEW of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.

  • Page 27: Maintenance Schedule Under Normal Driving Conditions

    0B1-2 MAINTENANCE AND LUBRICATION (4WD) MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS This table includes services as scheduled up to 90 000 k 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54 000 d 90 000 k (54 000 miles) carry out the same services at the same (54,000 miles), carry out the same services at the same Interval: Interval:...
  • Page 28 MAINTENANCE AND LUBRICATION (4WD) 0B1-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same Interval: intervals respectively. This interval should be judged by odometer reading This interval should be judged by odometer reading (x 1,000) or months, whichever comes first.

  • Page 29: Maintenance Recommended Under Severe Driving Conditions

    0B1-4 MAINTENANCE AND LUBRICATION (4WD) MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle 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 chart below.

  • Page 30: Maintenance Service

    MAINTENANCE AND LUBRICATION (4WD) 0B1-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt (V-rib belt) Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
  • Page 31 0B1-6 MAINTENANCE AND LUBRICATION (4WD) 3) Check belt (1) for tension. A/C compressor drive belt tension “b”: 8 – 9 mm (0.32 – 0.35 in.) deflection under 100 N (10 kg, 22 lb) pressure. 4) If belt tension is out of above specification, adjust it by adjusting compressor position.
  • Page 32 MAINTENANCE AND LUBRICATION (4WD) 0B1-7 ITEM 1-4 Engine Oil and Filter Change WARNING: New and used engine oil can be hazardous. Proper Engine Oil Viscosity Chart Be sure to read WARNING in GENERAL PRECAUTION in SECTION 0A and observe what in written there. Before draining engine oil, check engine for oil leakage.
  • Page 33 0B1-8 MAINTENANCE AND LUBRICATION (4WD) 5) Tighten oil filter (1) 3/4 turn from the point of contact with the mounting surface using an oil filter wrench. Special Tool (A): 09915-40611 Tightening Torque (b): 14 N m (1.4 kg-m, 10.5 lb-ft) 6) Replenish oil until oil level is brought to FULL level mark on dip- Proper Engine Oil Viscosity Chart stick.
  • Page 34 MAINTENANCE AND LUBRICATION (4WD) 0B1-9 ITEM 1-5 Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove radia- tor 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.
  • Page 35 0B1-10 MAINTENANCE AND LUBRICATION (4WD) 8) Add coolant to reservoir so that its level aligns with FULL mark (1). Then, reinstall cap aligning arrow marks (4) on reservoir and cap. NOTE: When installing reservoir cap, align arrow marks (4) on res- ervoir and cap.

  • Page 36: Ignition System

    MAINTENANCE AND LUBRICATION (4WD) 0B1-11 D Make sure that exhaust system components have enough clear- ance from the underbody to avoid overheating and possible dam- age to the floor carpet. D Any defects should be fixed at once. IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones.
  • Page 37 0B1-12 MAINTENANCE AND LUBRICATION (4WD) ITEM 3-2 Fuel tank Inspection After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check fuel pump assembly gaskets for leaks, visually inspect fuel tank for leaks and damage.

  • Page 38: Emission Control System

    MAINTENANCE AND LUBRICATION (4WD) 0B1-13 EMISSION CONTROL SYSTEM ITEM 4-1 Crankcase Ventilation Hoses and Connections Inspection Refer to following ITEM 4-2 PCV valve inspection. ITEM 4-2 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog.

  • Page 39: Chassis And Body

    0B1-14 MAINTENANCE AND LUBRICATION (4WD) CHASSIS AND BODY ITEM 6-1 Clutch Pedal inspection Check clutch pedal for height and free travel. Refer to CLUTCH PEDAL FREE TRAVEL in SECTION 7C. Adjust or correct if neces- sary. 1. Clutch pedal free travel ITEM 6-2 Brake Discs, Pads, Brake Drums and Shoes Inspection [Brake discs and pads (Front)]...
  • Page 40 MAINTENANCE AND LUBRICATION (4WD) 0B1-15 ITEM 6-4 Brake Fluid Inspection 1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct. 2) Check fluid level. If fluid level is lower than the minimum level of reservoir, refilling is necessary.
  • Page 41 0B1-16 MAINTENANCE AND LUBRICATION (4WD) Parking brake cable inspection Inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorated condition. ITEM 6-6 Tires Inspection and Rotation 1) Check tires for uneven or excessive wear, or damage. If defective, replace.
  • Page 42 MAINTENANCE AND LUBRICATION (4WD) 0B1-17 ITEM 6-8 Suspension System Inspection D Inspect front and rear shock absorber for evidence of oil leakage, dents or any other damage on sleeves; and inspect anchor ends for deterioration. Replace defective parts, if any. 1.
  • Page 43 0B1-18 MAINTENANCE AND LUBRICATION (4WD) Change Change transmission oil with new specified oil. Refer to MAINTE- NANCE SERVICE in SECTION 7A1. CAUTION: Specified gear oil must be used for differential. ITEM 6-10 Front differential Differential Oil Inspection 1) Check differential for evidence of oil leakage. Repair leaky point if any.
  • Page 44 MAINTENANCE AND LUBRICATION (4WD) 0B1-19 3) Check universal joints of steering shaft for rattle and damage. If rattle or damage is found, replace defective part with a new one. 4) Check steering linkage for looseness and damage. Repair or re- place defective parts, if any.
  • Page 45 0B1-20 MAINTENANCE AND LUBRICATION (4WD) Propeller Shaft(s) Inspection 1) Check universal joint, constant velocity joint (4WD) and spline of propeller shaft for rattle and damage. If rattle or damage is found, replace defective part with a new one. 2) Check propeller shaft joint bolts for tightness, and retighten them as necessary.

  • Page 46: Final Inspection

    MAINTENANCE AND LUBRICATION (4WD) 0B1-21 FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual Transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.

  • Page 47: Recommended Fluids And Lubricants

    (Refer to OIL CHANGE in SECTION 7E and SECTION 7F for detail.) Water resistance chassis grease Clutch linkage pivot points (SUZUKI SUPER GREASE A 99000-25010) Door hinges Engine oil or water resistance chassis grease Engine oil or water resistance chassis grease...
  • Page 48 FRONT SUSPENSION (4WD) 3D1-1 SECTION 3D1 FRONT SUSPENSION (4WD) NOTE: D 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.

  • Page 49: General Description

    3D1-2 FRONT SUSPENSION (4WD) GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehicle body by a strut support. The strut and strut support are isolated by a strut rubber support. A strut bearing is also installed a little lower to the strut rubber support.
  • Page 50 FRONT SUSPENSION (4WD) 3D1-3 STRUT ASSEMBLY : Tightening Torque 1. Strut support cap 3. Strut lock washer 8. Strut bearing 2. Strut nut: 4. Strut rebound stopper 9. Spring upper seat Apply water proof coating 5. Strut support 10. Spring seat (paint or lacquer) all around nut 6.

  • Page 51: Diagnosis

    3D1-4 FRONT SUSPENSION (4WD) DIAGNOSIS Refer to Section 3. CHECK AND ADJUSTMENT STABILIZER BAR AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing/Cushion Inspect for damage, wear or deterioration. If defective, replace. COMPRESSION ROD AND/OR BUSHING CHECK Inspect for damage or deformation.

  • Page 52: Strut Damper Check

    FRONT SUSPENSION (4WD) 3D1-5 STRUT DAMPER CHECK 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 on tire placard. Bounce vehicle body three or four times continuously by push- ing front end on the side with strut to be checked.

  • Page 53: Wheel Disc, Nut & Bearing Check

    3D1-6 FRONT SUSPENSION (4WD) WHEEL DISC, NUT & BEARING CHECK 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) Check wheel nuts for tightness and, as necessary retighten them to specification. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 3) Check wheel bearing for wear.

  • Page 54: On-Vehicle Service

    FRONT SUSPENSION (4WD) 3D1-7 ON-VEHICLE SERVICE STABILIZER BAR AND/OR BUSHINGS REMOVAL 1) Hoist vehicle and allow the front suspension control arms to hang free. 2) Remove stabilizer link nuts (9), washers (7) and cushions (8). When loosening link nut (9), hold stud with a wrench. 3) Remove stabilizer bar mount bushing bracket bolts (4).

  • Page 55: 1Compression Rod And/Or Bushings

    3D1-8 FRONT SUSPENSION (4WD) COMPRESSION ROD AND/OR BUSHINGS REMOVAL 1) Hoist vehicle, allow front suspension to hang free. 2) Remove stabilizer bar, refer to STABILIZER BAR AND/OR BUSHINGS REMOVAL. 3) Remove compression rod nuts (1, 2). 4) Remove compression rod (3). 1.

  • Page 56: Strut Damper Assembly

    FRONT SUSPENSION (4WD) 3D1-9 STRUT DAMPER ASSEMBLY REMOVAL 1) Disconnect negative cable at battery. 2) Hoist vehicle, allowing front suspension to hang free. 3) Remove wheel. 4) Remove E-ring securing brake flexible hose and take brake flex- ible hose off strut bracket as shown. 5) Remove wheel speed sensor harness clamp bolt from strut (if equipped with ABS).
  • Page 57 3D1-10 FRONT SUSPENSION (4WD) DISASSEMBLY 1) Remove strut support cap and loosen strut nut a little by using special tools. Special Tool (A): 09945-26010 (17 mm socket) (B): 09900-00411 (Socket) (C): 09900-00414 (6 mm) NOTE: When disassembling strut assembly, loosen strut nut a little before compressing strut spring.
  • Page 58 FRONT SUSPENSION (4WD) 3D1-11 ASSEMBLY For assembly, reverse disassembly procedure, observing the fol- lowing instruction. 1. Strut support cap 7. Strut bearing seat 2. Strut nut 8. Strut bearing 3. Strut lock washer 9. Spring upper seat 4. Strut rebound stopper 10.
  • Page 59 3D1-12 FRONT SUSPENSION (4WD) D Install bump stopper (11) onto strut rod. Refer to the left figure for installing direction. D Clean strut bearing (8) and install it on spring upper seat (9). Refer to figure at left for installing direction. D Wash bearing seat (7) and install it as shown.

  • Page 60: Steering Knuckle And Wheel Hub

    FRONT SUSPENSION (4WD) 3D1-13 STEERING KNUCKLE AND WHEEL HUB 1. Steering knuckle 2. Wheel hub 3. Snap ring 4. Wheel bearing 5. Brake dust cover 6. Drive shaft nut 7. Wheel hub bolt : Do not reuse : Tightening torque REMOVAL 1) Remove drive shaft nut.
  • Page 61 3D1-14 FRONT SUSPENSION (4WD) 7) Remove nut (1) and disconnect tie-rod end (2) from knuckle (3) with special tool. Special Tool (C): 09913-65210 8) Remove ball stud bolt (1) from knuckle. 9) Remove strut bracket bolts (1). 10) Remove knuckle (2). DISASSEMBLY Wheel Hub 1) Remove hub bolts.
  • Page 62 FRONT SUSPENSION (4WD) 3D1-15 Steering Knuckle 1) Using special tool, remove snap ring (1). Special Tool (A): 09900-06108 2) Remove bearing outer race/inner bearing using special tools and hydraulic press (1). Special Tool (B): 09924-84510 (C): 09913-75821 ASSEMBLY AND INSTALLATION 1) Install new wheel bearing (1) using special tool and hydraulic press (2).
  • Page 63 3D1-16 FRONT SUSPENSION (4WD) 4) Install wheel hub to knuckle (1) with special tool and hydraulic press (2). Special Tool (B): 09924-84510 (C): 09913-75821 (D): 09951-18210 5) Install knuckle (1) to knuckle (2) and tighten strut bracket bolts to specification. Tightening Torque (a): 95 N m (9.5 kg-m, 69.0 lb-ft)

  • Page 64: Suspension Control Arm/Bushing

    FRONT SUSPENSION (4WD) 3D1-17 SUSPENSION CONTROL ARM/BUSHING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove compression rod stud nuts (1) from suspension control arm. 3) Remove ball stud bolt (2) and nut (3). 4) Remove suspension control arm bolt (4) and nut (5). 5) Remove suspension control arm (6).
  • Page 65 3D1-18 FRONT SUSPENSION (4WD) 2) Install suspension control arm (1) to suspension frame, referring to left figure for proper installing direction of bolt and nut. NOTE: Nut should not be tightened. * : Forward 3) Install ball stud (1) to knuckle (2). Align ball stud groove with knuckle bolt hole as shown.

  • Page 66: Suspension Frame

    FRONT SUSPENSION (4WD) 3D1-19 SUSPENSION FRAME REMOVAL 1) Hoist vehicle and remove wheels. 2) Remove suspension control arms (right & left), refer to Steps 2) to 5) of SUSPENSION CONTROL ARM REMOVAL in this sec- tion. 3) Remove steering gear case mount bolts. 1.
  • Page 67 3D1-20 FRONT SUSPENSION (4WD) INSTALLATION 1) Install suspension frame and tighten suspension frame bolts to specified torque. Tightening Torque (a): 95 N m (9.5 kg-m, 69.0 lb-ft) 2) Install wheel speed sensor harness clamp bolts and clamps to suspension frame (if equipped with ABS). 3) Install front differential referring to SECTION 7E.

  • Page 68: Special Tools

    FRONT SUSPENSION (4WD) 3D1-21 SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 09943-17912 09943-77910 2. 09900-00414 09942-15511 Front wheel hub remover Front suspension lower arm Hexagon wrench bit 6 mm Sliding hammer (Brake drum remover) bush remover 09945-26010 09913-65210 09913-75520 09924-84510 Socket wrench 17 mm Tie-rod end remover Bearing installer...
  • Page 69 FRONT DRIVE SHAFT 4A-1 SECTION 4A FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ..............4A- 2 Component .

  • Page 70: General Description

    4A-2 FRONT DRIVE SHAFT GENERAL DESCRIPTION COMPONENT A constant velocity ball joint is used on the wheel side of front drive shaft and a constant velocity double offset joint (DOJ) on the differential side. The drive shaft can slide through the double offset joint in the extension/contrac- tion direction.

  • Page 71: Diagnosis

    FRONT DRIVE SHAFT 4A-3 DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction Abnormal Noise Worn or breakage drive shaft joint Replace. DRIVE SHAFT BOOT CHECK Inspect drive shaft boot (1) for tear. If even a small tear is noted, replace with new one.

  • Page 72: On-Vehicle Service

    4A-4 FRONT DRIVE SHAFT ON-VEHICLE SERVICE DRIVE SHAFT ASSEMBLY REMOVAL 1) Undo caulking and remove drive shaft nut (1) and washer. 2) Hoist vehicle and remove wheel. 3) Drain front differential oil. A: Undo caulking 4) Remove E-ring (1). 5) Remove brake caliper carrier (2), with caliper (3). NOTE: Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessive-...
  • Page 73 FRONT DRIVE SHAFT 4A-5 11) Using large size lever, pull out drive shaft joint (1) so as to re- lease snap ring fitting of joint spline at differential side. NOTE: Be careful not to damage differential oil seal. 2. Front differential 12) Remove drive shaft assembly.
  • Page 74 4A-6 FRONT DRIVE SHAFT DISASSEMBLY NOTE: Do not disassemble wheel side joint (outboard joint). If any malcondition is found in any joint, replace it as assembly. For DOJ type drive shaft (Differential side) 1) Remove boot band (1) of differential side joint. 2) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, then take shaft out of outer race (3).
  • Page 75 FRONT DRIVE SHAFT 4A-7 ASSEMBLY 1) Wash disassembled parts (except boots). After washing. dry parts completely by blowing air. 2) Clean boots with cloth. Do not wash boots in degreaser, such as gasoline or kerosene, etc. Washing in degreaser causes deterioration of boot. 3) Apply grease to wheel side joint.
  • Page 76 4A-8 FRONT DRIVE SHAFT 8) Apply grease to inside of outer race. 9) Insert cage into outer race and fit snap ring (1) into groove of outer race (2). CAUTION: Position opening of snap ring “c” so that it will not be lined up with a ball.
  • Page 77 FRONT DRIVE SHAFT 4A-9 INSTALLATION 2, “A”, (a) CAUTION: D To avoid excessive expansion of boot and consequential disconnection of joint in boot, do not pull differential side joint housing. D Protect oil seals and boots from any damage, preventing them from unnecessary contact while installing drive 1, “A”, (a) shaft.

  • Page 78: Required Service Materials

    4A-10 FRONT DRIVE SHAFT REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Oil seal lips Lithium grease (99000-25010) SUZUKI BOND NO. 1215 Oil drain and filler plug for manual Sealant (99000-31110) transmission SPECIAL TOOLS 09913-65210 09900-06107 Tie-rod end remover...
  • Page 79 PROPELLER SHAFT (4WD) 4B1-1 SECTION 4B1 PROPELLER SHAFT (4WD) CONTENTS GENERAL DESCRIPTION ..............4B1-2 DIAGNOSIS .

  • Page 80: General Description

    4B1-2 PROPELLER SHAFT (4WD) GENERAL DESCRIPTION The front propeller shaft has a constant velocity joint at its rear end and a universal joint at the other end. The rear propeller shaft is a three-part combination consisting of a shaft and two universal joints. It is connected to the differential pinion through flanged connection and to the transmission output (main) shaft through a sliding spline joint.

  • Page 81: Diagnosis

    PROPELLER SHAFT (4WD) 4B1-3 DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction D Loosen universal joint bolt. Abnormal noise Tighten universal joint bolt. D Spider bearing worn out or stuck. Replace propeller shaft. D Worn spider. Replace propeller shaft. D Deformed propeller shaft. Vibration Replace propeller shaft.

  • Page 82: On-Vehicle Service

    4B1-4 PROPELLER SHAFT (4WD) ON-VEHICLE SERVICE PROPELLER SHAFT REMOVAL 1) Hoist vehicle. 2) Drain transmission oil. 3) Before removing propeller shafts, give match marks (1) on each joint flange and propeller shaft as shown. 1. Match mark 2. Propeller shaft 3.

  • Page 83: Axc (Axial Plunger Pump Coupling) (If Equipped)

    PROPELLER SHAFT (4WD) 4B1-5 INSTALLATION Install propeller shaft reversing removal procedure noting following points: D When installing propeller shaft, align the match marks. Otherwise, vibration may occur during driving. D Use following specification to torque each joint flange. Tightening Torque (a): 23 N m (2.3 kg-m, 16.6 lb-ft) D Apply grease to spline part of propeller shaft and transmission...

  • Page 84: Required Service Material

    4B1-6 PROPELLER SHAFT (4WD) REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUPER GREASE C Lithium grease To apply to spline part of propeller shaft. (99000-25030)
  • Page 85 ............... . 7A1-16 NOTE: For the descriptions (items) not found in this section, refer to SECTION 7A of GA413 SERVICE MANUAL described in FOREWORD of this manual.

  • Page 86: General Description

    7A1-2 MANUAL TRANSMISSION (4WD) GENERAL DESCRIPTION There are two types of the manual transmission for full-time 4WD vehicles depending on the mounting location of the AXC (Axial Plunger Pump Coupling). One type is a built-in type which the AXC is built in transfer case, and the other type is an external type which the AXC is installed between the front differential and the front propeller shaft.
  • Page 87 7. Transfer sprocket spacer 23. Breather union 8. Transfer output rear bearing 24. Transfer rear case oil seal: 9. Circlip Apply SUZUKI SUPER GREASE A 10. Speedometer sensor rotor 99000-25010 to mating surface of oil seal lip. 11. Circlip 25. Engine hook 12.

  • Page 88: On-Vehicle Service

    7A1-4 MANUAL TRANSMISSION (4WD) ON-VEHICLE SERVICE MAINTENANCE SERVICE OIL CHANGE The transfer oil is used as manual transmission oil as well. 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage ex- ists, correct or repair it.

  • Page 89: Dismounting

    MANUAL TRANSMISSION (4WD) 7A1-5 DISMOUNTING 1) Disconnect negative (–) cable from battery terminals and hoist vehicle. 2) Disconnect back-up light switch lead wire at coupler. 3) Disconnect Black/Yellow lead wire and positive (+) cord from starting motor. Remove starting motor from transmission case. 4) Disconnect coupler from speed sensor and free its harness from transmissions.
  • Page 90 7A1-6 MANUAL TRANSMISSION (4WD) 12) Remove bolts and nuts fastening engine cylinder block and transmission case. NOTE: Before starting to remove transmission, check around once again to be sure that there is no connection left un- done. 13) Remove transmission rear mounting bolt & nut from chassis. 14) Separate transmission from engine and remove clutch housing upper and lower plates.

  • Page 91: Remounting

    MANUAL TRANSMISSION (4WD) 7A1-7 REMOUNTING For remounting, reverse dismounting procedure. Use specified torques as given below. Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 Ib-ft) (b): 25 N m (2.5 kg-m, 18.0 Ib-ft) NOTE: D To facilitate remounting, install rear mounting to transmis- sion after inserting input shaft into clutch disc.

  • Page 92: Unit Repair Overhaul

    7A1-8 MANUAL TRANSMISSION (4WD) UNIT REPAIR OVERHAUL TRANSFER CASE Disassembly 1) Remove engine rear mounting. 2) Remove speed sensor (1). 3) Remove bolts and separate transfer rear case (1) from transfer front case (2) using special tool. Special Tool (A): 09912-34510 4) Using special tool, remove circlip (1) and then speedometer sensor rotor (2).
  • Page 93 MANUAL TRANSMISSION (4WD) 7A1-9 6) For AXC built-in type: Uncaulk and remove output front shaft nut by using special tool. Special Tool (A): 09930-40113 7) For AXC built-in type: Remove output front shaft rear bearing (1), output front shaft spacer (2), and AXC (3). 8) Remove sprocket spacer (1), then push out and remove sprocket bush (2).
  • Page 94 7A1-10 MANUAL TRANSMISSION (4WD) 12) Remove gear shift guide bolt (1) and 3 bolts and disconnect gear shift and select shaft assembly (2). 13) Remove all bolts and separate transfer front case (1) from transmission case (2). When separating transfer front case from transmission case, make sure that reverse idler gear and shaft remain at their origi- nal position on transmission case side.

  • Page 95: Inspection

    MANUAL TRANSMISSION (4WD) 7A1-11 17) Remove output front shaft by using hydraulic press. 18) Remove transfer front case oil seal (1) by using special tool. Special Tool (A): 09913-50121 CAUTION: Be careful not to damage oil seal, if it remains in front case.

  • Page 96: Reassembly

    7A1-12 MANUAL TRANSMISSION (4WD) D For AXC built-in type: Check AXC for rotation. AXC can be rotated by hand but it is heavy. If it can be rotated lightly by hand, or can not be rotated, replace AXC. 1. AXC Reassembly Reverse disassembly procedure for reassembly, noting the follow- ing items.
  • Page 97 MANUAL TRANSMISSION (4WD) 7A1-13 D For AXC externally mounted type: Install output shaft rear bearing (1) by using hydraulic press and special tool. Special Tool (A): 09940-53111 D For AXC built-in type: Apply transmission oil to sprocket needle bearing, then install out- put sprocket bush (1), sprocket needle bearing (2) output front sprocket (3) and output front sprocket washer (4).
  • Page 98 7A1-14 MANUAL TRANSMISSION (4WD) D Apply sealant to gear shift guide case (1) and install it to transfer front case (2). Apply thread lock cement to gear shift guide bolt (3). Tighten bolts to specified torque. “A”: Sealant 99000-31110 “B”: Thread lock 99000-32020 Tightening Torque (a): 23 N m (2.3 kg-m, 16.5 lb-ft)

  • Page 99: Required Service Materials

    Special Tool (A): 09913-84510 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS SUZUKI SUPER GREASE A D Oil seal lips Lithium grease (99000-25010) D Oil drain and filler plug D Mating surface of transmission case D Mating surface of transfer front and rear cases SUZUKI BOND NO.1215...

  • Page 100: Special Tools

    7A1-16 MANUAL TRANSMISSION (4WD) SPECIAL TOOLS 09900-06107 Snap ring pliers 09924-84510 09912-34510 09913-50121 (Opening type) Bearing installer adapter Separator Oil seal remover 09913-65135 09913-84510 09913-75821 09913-80113 Bearing puller Bearing installer Install attachment Bearing installer 09940-53111 09930-40113 Differential side 09941-74910 Flange holder bearing installer Bearing installer...
  • Page 101 DIFFERENTIAL (FRONT) 7E-1 SECTION 7E DIFFERENTIAL (FRONT) CONTENTS GENERAL DESCRIPTION ..............7E- 2 DIAGNOSIS .

  • Page 102: General Description

    7E-2 DIFFERENTIAL (FRONT) GENERAL DESCRIPTION 1. Bevel pinion / gear set 17. Differential side bearing 2. Bevel pinion front bearing 18. Shim 3. Bevel pinion rear bearing 19. Differential side oil seal: 4. Bevel pinion spacer Apply grease 99000-25010 to oil seal lip. 5.

  • Page 103: Diagnosis

    DIFFERENTIAL (FRONT) 7E-3 DIAGNOSIS Condition Possible Cause Correction D Deteriorated or water mixed lubricant Gear noise Repair and replenish D Inadequate or insufficient lubricant Repair and replenish D Maladjusted backlash between bevel pinion and Adjust as prescribed gear D Improper tooth contact in the mesh between bevel Adjust or replace pinion and gear D Loose bevel gear securing bolts...

  • Page 104: On Vehicle Service

    7E-4 DIFFERENTIAL (FRONT) ON VEHICLE SERVICE MAINTENANCE SERVICE NOTE: D When having driven through water, check immediately if wa- ter has entered (if so, oil is cloudy). Water mixed oil must be changed at once. D Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breather hoses.

  • Page 105: Dismounting

    DIFFERENTIAL (FRONT) 7E-5 DISMOUNTING 1) Hoist vehicle and drain front differential oil. 2) Remove drive shafts referring to SECTION 4A. 3) Remove front propeller shaft referring to SECTION 4B1. 4) Support front differential (1) on jack (2). 5) Unclamp breather hose. 6) Remove front differential mounting bracket bolts (1) and then front differential assembly.

  • Page 106: Remounting

    7E-6 DIFFERENTIAL (FRONT) REMOUNTING Reverse dismounting procedure for installation. D Tighten bolts and nuts to specification as shown below. Apply thread lock cement “A”: Thread lock cement 99000-32020 Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) (b): 55 N m (5.5 kg-m, 40.0 lb-ft) (c): 65 N m (6.5 kg-m, 47.0 lb-ft)

  • Page 107: Unit Repair Overhaul

    DIFFERENTIAL (FRONT) 7E-7 UNIT REPAIR OVERHAUL DISASSEMBLY 1) Remove differential front cover (1) from differential front carrier (2). 2) Remove differential side output oil seal from differential front cover. 3) Remove differential case assembly (1) and shims (2). 4) Remove drive bevel gear (1). 5) Drive out differential pinion shaft pin from differential pinion shaft (1) by using special tool and hammer.
  • Page 108 7E-8 DIFFERENTIAL (FRONT) 6) Remove differential pinion shaft (1) from differential case (2) and then remove differential gears (3), differential pinions (4) and washers. 7) Remove differential side bearings (2) by using hydraulic press (1), bearing puller (3) and special tool. Special Tool (A): 09925-88210 8) Uncaulk drive bevel pinion nut and then remove it by using spe-...

  • Page 109: Inspection

    DIFFERENTIAL (FRONT) 7E-9 11) Remove drive bevel pinion rear bearing (1) by using hydraulic press (2) and bearing puller (3). 12) Drive out bevel pinion bearing outer races in differential carrier by hammering metal stick (1) applied to them. INSPECTION D Check companion flange for wear or damage.
  • Page 110 7E-10 DIFFERENTIAL (FRONT) DIFFERENTIAL CASE Left side Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean. 1) Assemble differential gear (1) and measure thrust play of differ- ential gear as follows.
  • Page 111 DIFFERENTIAL (FRONT) 7E-11 4) Put bevel gear (1) on differential case (2) and fasten them with 8 bolts (3) by tightening them to specified torque. Use thread lock cement for 8 bolts. CAUTION: Use of any other bolts than that specified is prohibited. “A”: Thread lock cement 99000-32020 Tightening Torque (a): 78 N...
  • Page 112 7E-12 DIFFERENTIAL (FRONT) 2) Install 2 bevel pinion bearing dummy (special tool (2)) to bevel pinion mounting dummy shaft (special tool (1)) becomes mea- surements “a” and “b” described below. Measurement “a”: 15 mm (0.59 in.) “b”: 20 mm (0.79 in.) 1.
  • Page 113 DIFFERENTIAL (FRONT) 7E-13 7) Install bevel pinion gauge block (special tool (7)) and then install 0 (zero) adjusted bevel pinion mounting dummy shaft assembly to differential front carrier. Then read dial gauge. NOTE: D Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurate- D When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
  • Page 114 7E-14 7DIFFERENTIAL (FRONT) 11) With new pinion spacer inserted as shown, install front bearing to differential carrier. NOTE: D Make sure to use new spacer for reinstallation. D Apply oil to bearings. 12) Drive in oil seal (1) into differential front carrier (2) till it becomes flush with carrier end by using special tool.
  • Page 115 DIFFERENTIAL (FRONT) 7E-15 ASSEMBLING UNIT 1) Measure width “a” of differential carrier and “b” of differential gear assembly. Then calculate shim thickness. Shim thickness = “a” – “b” 2) Select shim from below table and assemble differential gear as- sembly to front differential carrier. 2.45, 2.50, 2.55, 2.60, 2.65, 2.70, 2.75, 2.80 and 2.85 mm Available shim...
  • Page 116 7E-16 DIFFERENTIAL (FRONT) 5) Upon completion of gear tooth contact check in step 8), caulk flange nut (2) with caulking tool (1) and hammer. 6) Clean mating surface of both carrier and cover and apply sealant to differential front cover (2). Then tighten 8 bolts (1) to specified torque.
  • Page 117 DIFFERENTIAL (FRONT) 7E-17 TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY Outer end (Heel) Driven side Coast side NORMAL Inner end (Toe) HIGH CONTACT Gear Pinion is positioned too far from the center of driver bevel gear. 1. Increase thickness of pinion height adjusting shim and position pinion closer to gear center.

  • Page 118: Required Service Materials

    SUZUKI PRODUCT THREAD LOCK CEMENT Thread lock cement SUPER 1333B Bevel gear bolts (99000-32020) SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) D Front differential drain and filler plug SUZUKI BOND NO. 1215 D Mating surface of differential housing...

  • Page 119: Special Tools

    DIFFERENTIAL (FRONT) 7E-19 SPECIAL TOOLS 09900-20606 09900-20701 09913-50121 09913-60910 Dial gauge Magnetic stand Oil seal remover Bearing puller 09913-65135 09913-75520 09913-75821 Bearing puller Bearing installer Bearing installer 09922-76110 Differential adjuster set (1) 09922-76120 Bevel pinion mounting dummy shaft (2) 09922-76230 Bevel pinion bearing dummy (3) 09922-76140 Bevel pinion shaft...
  • Page 120 7E-20 DIFFERENTIAL (FRONT) 09944-66020 09951-16060 Bearing installer Lower arm bush remover...
  • Page 121 Prepared by Overseas Service Department 1st Ed. March, 2000 2nd Ed. March, 2001 Printed in Japan Printing: April, 2001...

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