Suzuki SN413 Manuals

Manuals and User Guides for Suzuki SN413. We have 1 Suzuki SN413 manual available for free PDF download: Service Manual

Suzuki SN413 Service Manual (687 pages)

Jimny Suzuki

Brand: Suzuki | Category: Automobile | Size: 16.42 MB

General Information

6
Maintenance and Lubrication

32
- Maintenance Schedule
  
  33
  - Maintenance Schedule under Normal Driving Conditions
    33
  - Maintenance Recommended under Severe Driving Conditions
    35
- Maintenance Service
  
  36
  - Engine
    36
    
    Drive Belt
    36
    
    Engine Oil and Filter
    37
    
    Valve Lash
    37
    
    Engine Coolant
    39
    
    Exhaust System
    39
  - Ignition System
    40
    
    Spark Plugs
    40
  - Fuel System
    40
    
    Air Cleaner Filter
    40
    
    Fuel Filter
    41
    
    Fuel Lines and Connections
    41
    
    Fuel Tank
    41
  - Emission Control System
    41
    
    Crankcase Ventilation Hoses and Connections
    41
    
    Fuel Evaporative Emission Control System
    42
    
    PCV (Positive Crankcase Ventilation) Valve
    42
  - Chassis and Body
    42
    
    Brake Discs and Pads
    42
    
    Clutch
    42
    
    Brake Drums and Shoes
    43
    
    Brake Fluid
    43
    
    Brake Hoses and Pipes
    43
    
    Parking Brake Lever and Cable
    44
    
    Tires/Wheels
    44
    
    Suspension System
    45
    
    Propeller Shafts
    46
    
    Automatic Transmission Fluid
    47
    
    Manual Transmission Oil
    47
    
    Transfer and Differential Oil
    48
    
    Steering Knuckle Seal
    49
    
    Steering System
    49
    
    All Hinges, Latches and Locks
    50
    
    Power Steering (P/S) System (if Equipped)
    50
- Final Inspection
  
  51
- Recommended Fluids and Lubricants
  
  53
Heater and Ventilation

54
- General Description
  
  55
- Diagnosis
  
  56
  - Diagnosis Table
    56
  - Wiring Circuit
    56
- On Vehicle Service
  
  57
  - Heater Blower Motor
    57
  - Heater Blower Resistor
    58
  - Heater Control Lever Assembly
    58
  - Heater Blower Fan Switch
    60
  - Heater Unit/Boost Ventilation
    60
Air Conditioning (Optional)

62
- General Description
  
  64
  - Major Components and Location
    64
  - Refrigerant Circulation
    65
  - Refrigerant Type
    65
- Diagnosis
  
  66
- Electronical Diagnosis
  
  77
  - Wiring Diagram
    77
  - A/C System Inspection of ECM and ITS Circuits
    78
- Refrigerant Recovery, Evacuating and Charging
  
  82
  - Operation Procedure for Refrigerant Charging
    82
  - Recovery
    83
  - Replenishing Compressor Oil
    83
  - Evacuating
    84
    
    Evacuating Procedure
    84
  - Charging
    86
    
    Charging Procedure
    86
  - Removing Manifold Gauge Set
    89
  - Leak Test
    89
- On-Vehicle Service
  
  90
  - Service Precaution
    90
    
    Refrigerant Line
    90
    
    Handling Refrigerant HFC-134A
    91
  - Condenser Assembly
    92
  - Receiver / Dryer
    93
  - Condenser Cooling Fan Assembly
    94
    
    Cooling Unit (Evaporator)
    95
    
    A/C Evaporator Thermistor (A/C Evaporator Temperature Sensor)
    98
    
    Expansion Valve
    98
    
    Dual Pressure Switch
    99
    
    A/C Switch
    100
    
    Compressor
    100
    
    Condenser Cooling Fan Motor Relay
    100
    
    Magnet Clutch
    102
    
    Lip Type Seal
    106
- Tightening Torque Specification
  
  107
- Special Tools
  
  108
- Required Service Materials
  
  108
Steering, Suspension, Wheels and Tires

110
- Diagnosis
  111
- General Diagnosis
  111
  - Wear Indicators
    114
  - Radial Tire Waddle
    114
- Tire Diagnosis
  114
  - Radial Tire Lead
    116
- Vibration Diagnosis
  116
And Linkage

122
- General Description
  
  123
- Diagnosis
  
  124
  - Diagnosis Table
    124
  - Steering Wheel Play Check
    124
  - Tie Rod and Drag Rod Check
    124
  - Steering Gear Box Oil Level Check
    125
  - Adjustment of Worm Shaft Starting Torque . 3B-4
    125
- On-Vehicle Service
  
  127
  - Steering Gear Box
    127
  - Tie Rod and Drag Rod
    129
- Required Service Material
  
  131
- Special Tools
  
  131
- Tightening Torque Specifications
  
  131
(If Equipped)

132
- General Description
  
  133
- Diagnosis
  
  134
  - Diagnosis Table
    134
  - Steering Wheel Play Check
    136
  - Steering Force Check
    136
  - Power Steering Belt Check
    137
  - Power Steering Belt Tension Adjustment
    137
  - Power Steering Fluid Level Check
    137
  - Idle-Up System Check
    138
  - Power Steering Fluid Leakage Check
    138
  - Air Bleeding Procedure
    139
  - Hydraulic Pressure in P/S Circuit Check
    141
- On-Vehicle Service
  
  143
  - Power Steering Belt
    143
  - Power Steering (P/S) Pump
    143
  - Power Steering (P/S) Gear Box
    149
- Tightening Torque Specifications
  
  152
- Special Tools
  
  152
- Required Service Materials
  
  152
Steering Wheel and Column

154
- General Description
  
  155
- On-Vehicle Service
  
  156
- Diagnosis
  
  156
  - Inspection and Repair Required after Accident
    156
- Checking Steering Column for Accident Damage
  
  171
- Special Tool
  
  172
- Required Service Material
  
  172
- Tightening Torque Specifications
  
  172
Front Suspension

174
- General Description
  
  175
  - 4WD Control System
    175
- Diagnosis
  
  181
  - Diagnosis Table
    181
  - 4WD Controller and ITS Circuit Check
    183
  - 4WD Control System Check
    184
  - Stabilizer Bar / Bushing Check
    186
  - Shock Absorber And/Or Coil Spring Check
    187
  - Leading Arm / Lateral Rod / Steering Knuckle Check
    187
  - Leading Arm Bushing / Lateral Rod Bushing Check
    188
  - Kingpin / Kingpin Bearing Check
    188
  - Barfield Joint Check
    188
  - Steering Knuckle Seal Check
    188
  - Wheel Disc, Nut and Bearing Check
    189
- On-Vehicle Service
  
  190
  - Stabilizer Bar / Bushings
    190
  - Front Shock Absorber
    192
  - Coil Spring
    192
  - Bump Stopper and Spring Upper Seat
    194
  - Wheel Hub / Bearing / Oil Seal
    194
  - Steering Knuckle / Wheel Spindle
    201
  - Front Axle Shaft / Oil Seal / Kingpin Bearing Outer Race
    205
  - Steering Knuckle Seal
    207
  - Lateral Rod
    208
  - Leading Arm / Bushing
    209
  - Front Axle Housing
    211
- Tightening Torque Specifications
  
  217
- Required Service Material
  
  217
- Special Tool
  
  218
Rear Suspension

220
- General Description
  
  221
- Diagnosis
  
  222
- On-Vehicle Service
  
  224
  - Rear Shock Absorber
    224
  - Coil Spring
    225
  - Bump Stopper
    228
  - Lateral Rod
    228
  - Trailing Arm / Bushing
    229
  - Rear Axle Shaft and Wheel Bearing
    231
  - Rear Axle Shaft Inner Oil Seal
    236
  - Rear Axle Housing
    237
- Tightening Torque Specifications
  
  241
- Required Service Materials
  
  241
- Special Tools
  
  242
Wheels and Tires

244
- General Description
  
  245
  - Tires
    245
  - Wheels
    245
  - Replacement Tires
    245
    
    How to Measure Wheel Runout
    246
    
    Metric Lug Nuts and Wheel Studs
    246
    
    Replacement Wheels
    246
- Diagnosis
  
  247
  - Diagnosis Table
    247
  - Balancing Wheels
    247
  - General Balance Procedure
    247
    
    Off-Vehicle Balancing
    247
    
    On-Vehicle Balancing
    247
- Maintenance and Minor Adjustments
  
  249
  - Wheel and Tire
    249
    
    Matched Tires and Wheels
    249
    
    Studs
    249
  - Inflation of Tires
    249
    
    Tire Placard
    250
    
    Tire Rotation
    250
- On-Vehicle Service
  
  251
  - Wheel
    251
  - Tire
    252
    
    Mounting and Demounting
    252
    
    Repair
    252
Propeller Shafts

254
- Diagnosis
  255
  - Diagnosis Table
    255
  - Propeller Shaft Joint Check
    255
- General Description
  255
  - Components
    255
- On-Vehicle Service
  256
  - Propeller Shafts
    256
  - Universal Joint
    258
- Required Service Material
  260
- Tightening Torque Specification
  260
- Special Tool
  261
Brakes

262
- Table of Contents
  262
- General Description
  
  264
- Diagnosis
  
  265
  - Road Testing Brakes
    265
  - Brake Fluid Leaks
    265
  - Substandard or Contaminated Brake Fluid
    265
  - Diagnosis Table
    266
  - Brake Pedal Free Height Adjustment
    269
  - Brake Pedal Play Check
    269
  - Stop Light Switch Adjustment
    269
  - Excessive Pedal Travel Check
    270
  - Front Brake Disc Check
    270
  - Front Brake Pad Check
    270
  - Rear Brake Shoe Check
    271
  - Master Cylinder and Brake Fluid Level Check
    271
  - Rear Drum Brake Shoe Adjustment
    272
  - Parking Brake Inspection and Adjustment
    272
  - Booster Operation Check
    273
  - Fluid Pressure Test (if Equipped with LSPV)
    276
- On-Vehicle Service
  
  278
  - Air Bleeding of Brake System
    278
  - Brake Hose and Pipe Inspection
    279
  - Front Disc Brake
    280
    
    Brake Pad
    281
    
    Caliper Assembly
    283
  - Brake Disc
    287
  - Rear Brake
    290
    
    Brake Drum
    290
    
    Brake Shoe
    292
  - Wheel Cylinder
    294
    
    Brake Back Plate
    295
- Master Cylinder
  
  297
  - Master Cylinder Reservoir
    297
  - Master Cylinder Assembly
    298
  - Master Cylinder
    299
  - Fill Reservoir
    301
- LSPV (Load Sensing Proportioning Valve) Assembly (if Equipped)
  
  303
  - LSPV Assembly
    304
- P (Proportioning) Valve
  
  305
- Brake Booster
  
  306
  - Inspection and Adjustment
    307
  - Brake Hose/Pipe
    309
    
    Front Brake Hose/Pipe
    309
  - Rear Brake Hose/Pipe
    312
  - Parking Brake Lever/Cable
    313
    
    Parking Brake Lever
    313
  - Parking Brake Cable
    314
- Required Service Material
  
  315
- Tightening Torque Specifications
  
  315
- Special Tool
  
  316
Antilock Brake System (Abs)

318
- General Description
  
  319
  - System Schematic
    320
  - ABS Component Parts Location
    321
  - ABS Control Module
    322
    
    Fail-Safe Function
    322
    
    Self-Diagnosis Function
    322
- Diagnosis
  
  323
- On-Vehicle Service
  
  346
  - Precaution
    346
  - ABS Hydraulic Unit Operation Check
    346
  - ABS Hydraulic Unit / Control Module Assembly
    347
  - Front Wheel Speed Sensor
    349
  - Front Wheel Sensor Ring
    352
  - Rear Wheel Speed Sensor
    353
  - Rear Wheel Sensor Ring
    355
  - G Sensor
    356
- Tightening Torque Specification
  
  357
- Special Tool
  
  357
Diagnosis

358
Engine Mechanical (M13 Engine)

482
- General Description
  
  483
  - Engine
    483
  - Engine Lubrication
    484
- Diagnosis
  
  485
  - Diagnosis Table
    485
  - Compression Check
    485
  - Engine Vacuum Check
    487
  - Oil Pressure Check
    488
  - Valve Lash (Clearance)
    490
- On-Vehicle Service
  
  494
  - Air Cleaner Element
    494
  - Air Cleaner Assembly
    495
  - Knock Sensor
    495
  - Cylinder Head Cover
    496
  - Throttle Body and Intake Manifold
    499
  - Exhaust Manifold
    502
  - Oil Pan and Oil Pump Strainer
    505
  - Timing Chain Cover
    509
  - Oil Pump
    514
  - Timing Chain and Chain Tensioner
    518
  - Camshaft, Tappet and Shim
    523
  - Valves and Cylinder Head
    529
  - Pistons, Piston Rings, Connecting Rods and Cylinders
    543
  - Engine Mountings
    553
- Unit Repair Overhaul
  
  554
  - Engine Assembly
    554
  - Main Bearings, Crankshaft and Cylinder Block
    560
- Tightening Torque Specification
  
  574
- Required Service Material
  
  574
- Special Tool
  
  575
Section 6B Engine Cooling

578
- Engine Cooling
  578
- General Description
  
  579
  - Cooling System Circulation
    579
  - Radiator Cap
    580
  - Coolant Reservoir
    580
  - Water Pump
    581
  - Thermostat
    581
  - Cooling Fan Clutch
    581
  - Coolant (Water) Temperature Gauge
    581
- Diagnosis
  
  582
- Maintenance
  
  583
  - Coolant
    583
  - Coolant Level
    584
  - Cooling System Service
    584
  - Cooling System Flush and Refill
    585
  - Water Pump Belt Tension
    586
- On-Vehicle Service
  
  587
  - Cooling System Component
    587
  - Coolant Draining
    588
  - Cooling Water Pipes or Hoses
    588
  - Thermostat
    588
  - Water Pump Belt and Cooling Fan
    590
  - Radiator
    591
  - Water Pump
    592
- Tightening Torque Specification
  
  594
- Required Service Material
  
  594
Engine Fuel

596
- General Description
  
  597
  - Fuel System
    597
  - Fuel Tank
    597
  - Fuel Pump Assembly
    598
  - Fuel Filler Cap
    598
- On-Vehicle Service
  
  599
  - Fuel Lines
    599
  - Fuel Filler Cap
    599
  - Fuel Tank
    599
  - Fuel Pump Assembly
    602
- Special Tool
  
  605
- Tightening Torque Specification
  
  605
Engine and Emission Control System

606
- General Description
  
  608
  - Air Intake System
    610
  - Fuel Delivery System
    611
    
    Fuel Pump
    611
  - Electronic Control System
    612
    
    Engine & Emission Control Input / Output Table
    613
- On-Vehicle Service
  
  620
  - Accelerator Cable Adjustment
    620
  - Idle Speed / Idle Air Control (IAC) Duty Inspection
    620
  - Idle Mixture Inspection / Adjustment (Vehicle Without Heated Oxygen Sensor)
    622
  - Air Intake System
    623
    
    Throttle Body
    623
    
    Idle Air Control Valve (IAC Valve)
    626
  - Fuel Delivery System
    627
    
    Fuel Pressure Inspection
    627
    
    Fuel Pump
    628
    
    Fuel Pressure Regulator
    629
    
    Fuel Injector
    630
  - Electronic Control System
    634
  - Engine Control Module (ECM)
    634
  - Manifold Absolute Pressure Sensor (MAP Sensor)
    634
  - Throttle Position Sensor (TP Sensor)
    635
  - Intake Air Temperature Sensor (IAT Sensor)
    636
  - Engine Coolant Temperature Sensor (ECT Sensor)
    637
  - Heated Oxygen Sensor (Sensor-1 and Sensor-2)
    638
  - Camshaft Position Sensor
    639
  - Crankshaft Position Sensor
    640
  - Vehicle Speed Sensor (VSS)
    641
  - Fuel Level Sensor (GAUGE)
    641
  - Knock Sensor
    641
  - Main Relay, Fuel Pump Relay and A/C Condenser Fan Control Relay
    641
  - Fuel Cut Operation
    642
  - A/C Condenser Fan Control System
    642
  - A/C Condenser Fan
    642
  - Output Signals of Throttle Valve Opening and Engine Coolant Temp
    643
  - (Vehicle with A/T Only)
    643
  - Emission Control System
    643
    
    General Description
    651
    
    Diagnosis
    652
    
    High-Tension Cords
    654
    
    Ignition Spark Test
    654
    
    On-Vehicle Service
    654
    
    Spark Plugs
    655
    
    Ignition Coil Assembly (Including Ignitor)
    656
    
    Crankshaft Position Sensor (CKP Sensor)
    657
    
    Ignition Timing
    657
    
    Special Tools
    659
    
    Tightening Torque Specification
    659
    
    Cranking Circuit
    661
    
    Diagnosis
    661
    
    Diagnosis Table
    661
    
    General Description
    661
    
    Performance Test
    663
    
    On-Vehicle Service
    664
    
    Starting Motor
    664
    
    Specifications
    666
Charging System

668
- General Description
  
  669
  - Battery
    669
  - Generator
    671
- Diagnosis
  
  673
  - Battery
    673
  - Generator
    674
- On-Vehicle Service
  
  676
  - Battery
    676
    
    Jump Starting in Case of Emergency
    676
    
    Dismounting
    678
    
    Handling
    678
    
    Remounting
    678
  - Generator
    678
    
    Generator Belt
    678
- Unit Repair Overhaul
  
  679
  - Generator
    679
    
    Dismounting
    679
    
    Disassembly and Reassembly
    680
    
    Remounting
    680
    
    Inspection
    681
- Specifications
  
  684
  - Battery
    684
  - Generator
    684
- Tightening Torque Specification
  
  684
  - Exhaust Pipe
    687

Suzuki Categories

Motorcycle Automobile Motorcycle Accessories Offroad Vehicle Musical Instrument

More Suzuki Manuals

Suzuki SN413 Manuals

Suzuki SN413 Service Manual (687 pages)

Table of Contents

General Information

How to Use this Manual

Precautions

Identification Information

Warning, Caution and Information Labels

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Fasteners Information

Maintenance and Lubrication

Maintenance Schedule

Maintenance Service

Final Inspection

Recommended Fluids and Lubricants

Heater and Ventilation

General Description

Diagnosis

On Vehicle Service

Air Conditioning (Optional)

General Description

Diagnosis

Electronical Diagnosis

Refrigerant Recovery, Evacuating and Charging

On-Vehicle Service

Tightening Torque Specification

Special Tools

Required Service Materials

Steering, Suspension, Wheels and Tires

And Linkage

General Description

Diagnosis

On-Vehicle Service

Required Service Material

Special Tools

Tightening Torque Specifications

(If Equipped)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Special Tools

Required Service Materials

Steering Wheel and Column

General Description

On-Vehicle Service

Diagnosis

Checking Steering Column for Accident Damage

Special Tool

Required Service Material

Tightening Torque Specifications

Front Suspension

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Required Service Material

Special Tool

Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Required Service Materials

Special Tools

Wheels and Tires

General Description

Diagnosis

Maintenance and Minor Adjustments

On-Vehicle Service

Propeller Shafts

Brakes

General Description

Diagnosis

On-Vehicle Service

Master Cylinder

LSPV (Load Sensing Proportioning Valve) Assembly (if Equipped)

P (Proportioning) Valve

Brake Booster