90-92 Samurai Supplementary Service Manual
Contents
1.2. For USA BRAKE OIL LEVEL Net for COMBINATION METER NOTE FUSIBLE LINK SWITCH ILLUMINATION Spec SAU ILLUMINATION m d FRONT SIDE MARKER lt r1 AMETE The parts with are provided LIGHT 8 ILLUMINATION not depending on specifications LI COUPL WIRE COLOR i BATTERY go g ane amp E Sud HEAD LIGHT t COUPLERST b de Blue zs ae j Brown Green FRONT TURN YW Sey SIGNAL LIGHT R Sky blue T i Light green AY SU SN POSITION Le H ROOM LIGHT White x Yellow f ig Pink Ow e vaca Violet HORN EU x WE Black with Blue tracer EWS DOOR Black with Green tracer OXYGEN Wim STOP TURN SWITCH Black with Red tracer SENSOR wi LIGHT SIGNAL 2 Black with White tracer em in E nd SWITCH RELAY searpett Black with Yellow tracer SWITCH Blue with Black tracer m FUSE Blue with Green tracer E 1 BOX Blue with Red tracer Bush White racer zw oH Blue with Yellow tracer
3. Shock absorber lock nut Spring bumper bolt 22 35 Nm 18 28 N m Either water or household type detergent 22 35 18 28 kgm Bush Bolt may be used to press fit the bush onto 16 0 25 0 lb ft 13 5 20 0 lb ft 5 5 spring But ail of any kind is strictly pro eae a S Ss hibited 8 insert both right and left bolts from the outside into the inside of body tn Steering knuckle oi seal Before installing oi seal apply SUZUKI SUPER GREASE H 99000 25120 to its lip portion Instali plates with their backs directed to each other When installing front axle housing position it in such way that vehicle manufacturing date stamp on it faces vehicle front Body center Front leaf spring shackle nins amp bush Insert both right and left pins from out Bush side into inside of body Tighten nuts to specified torque in unload ed state When pins are inserted make sure that the difference A B is within 0 3 40 3 mm 0 024 0 024 in Either water or household type detergent may be used to press fit bush onto spring But oil of any kind is strictly prohibited Body center Leaf spring center bolt amp nut Insert boit and nut securely into holes of axle housing seat and spring seat Front spring U bolt When securing U bolt tighten its front and rear nuts evenl
4. Sealant 14 15 15 PROPELLER SHAFTS NOTE This model uses only No 1 and No 3 of the propeller shafts used for the 4WD Model No 1 propeller shaft transmits drive from the transmission to the transfer gear box No 3 shaft extends from the transfer gear box to the rear axle Also dimensions and other details of these propeller shafts are the same as those of the 4WD Model Therefore for the removal and installation of propeller shafts and disassem HI bly and assembly of universal joint refer to the same section in GROUP 1 To transfer To rear differential From transmission To transfer 1 Propeller shaft No 1 2 Propeller shaft No 3 Tightening torque for propeller shaft Universal joint flange bolts and nuts 5 0 6 0 36 5 43 0 Fig 15 1 15 1 SECTION 16 DIFFERENTIAL NOTE This 2WD Model is equipped with the rear differential only and not the front differential For servicing procedures of the rear differential including its removal installation dis assembly assembly inspection and adjustment refer to the same section in GROUP 1 16 1 SECTION 17 SUSPENSION CONTENTS 17 1 FRONT SUSPENSION 00 ete n nn nn nn nnn 17 2 17 2 REAR SUSPENSION cece eet Rh rn 17 13 17 3 MAINTENANCE SERVICES ee n n n n nnn 17 14 17 4 RECOMMENDED TORQUE SPECIFICATIONS 17 19 a 175 REQU
5. POSITIVE CRANKCASE VENTILATION PCV 5 2 ON VEHICLE SERVICE 00 eee n nnn GENERAL iis vez ex aada sues o Bee teen te per eae PCV SYSTEM GENERAL DESCRIPTION VEHICLE EMISSION CONTROL INFORMATION LABEL The Vehicle Emission Control Information Label is located under hood The label contains important emission specifications and setting procedures as well as a vacuum hose schematic with emission components identified When servicing the engine or emission systems the Vehicle Emission Control Information Label should be checked for up to date information 1 Vehicle emission control information label 2 Hood Fig 5 1 Vehicle Emission Control Information Label POSITIVE CRANKCASE VENTILATION PCV SYSTEM The term blow by gas stands for the compres sed gas and exploded gas which blow through cy linder to piston clearance which contain a large amount of unburned gases such as CO and HC The PCV Positive Crankcase Ventilation sys tem is provided to prevent the blow by gas from being emitted into atmosphere and it operates as follows When the vacuum in the intake manifold is low throttle valve open the PCV valve is wide open due to its spring force Thus a large amount of the blow by gas is drawn into the intake mani fold On the other hand when the vacuum in the manifold is high the PCV valve opening is limited due to the high vacuum Th
6. Ili J 2 BRAKE Blue with Red eh T 4 t Wit Sacer wl Pim Blue with Yellow tracer EGRVSV HANT ELECTRONIC CONTROL r Brown with White tracer ey MODULE t Brown with Yellow tracer Groen with Red tracer REAR Green with White tracer E SIDE MARKER LIGHT IR Groon with Yellow pSTRIBUT Er gt ll Gray with Black tr amp 3i Gray with Green 134 1 Gray with White tracer neigh Wirt uis Gray with Red tracor j Gray with Yellow tracer SUPPRESSOR D ji TURN eIONAL with Black tracer 5 B3 ns an with White tracer I sss HORN SWITCH G W TAIL amp STOP with Yollow tracer LIGHT R E icri eye BACK UP Coupen 1111 piamen passing forr i LIGHT R Pink with Bluo tracer EE Tn gem Violet with Yellow tracer E Red with Black tracer amp i sis funy Red with Green tracer T LICENSE Red with White racor E LIGHT Red with Yellow tracor Har White with ez a white with 4 ul MAE T White with Yellow tracer E i D x IE TAIL amp STOP Yellow with Black tracer d ss g JL Yellow with Blue tracer EH 2 b REAR Yellow with Green tracer Yellow with Red nacer A TURN Yellow with White tracer PRESSURE IDLESPEED AIR ur SENSOR CONTROL TEMP TEMP Tahora UE E ENSOR CORNOID SENSOR S
7. 50 cece Kn n B 0 1 02 STANDARD SHOP PRACTICES 0 2 0 1 IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER The vehicle identification number is on the instrument panel left side Refer to below figure for detailed VIN cord information and its location 4533 D 3 1 CON 4 100001 uential Number Assembly Plant Model Year L 1990 1991 N 1992 Check Digit Body Type Design Sequence Engine Type Series Car Line World Manufacturer Identifier Fig 0 1 0 2 STANDARD SHOP PRACTICES When using the garage jack be sure to place it against the center of the axle housing to raise the front vehicle end and against the differential portion of the axle housing to raise the rear end NOTE Don t get on the vehicle get under it or service it in this state Fig 0 3 Rear Side SECTION 1 PERIODIC MAINTENANCE SERVICE NOTE For the items not found in this section refer to the same section in GROUP 1 CHASSIS AND BODY Refer to page 17 18 in SECTION 17 in GROUP 2 for replacement of the steering knuckle oil seal For servicing procedures such as inspection of the front wheel bearing disassembly and assembly of the front wheel hub refer to SECTION 17 in GROUP 2 SECTION 5 EMISSION CONTROL SYSTEM NOTE For the items not found in this section refer to the same section in GROUP 1 CONTENTS 5 1 GENERAL DESCRIPTION
8. te Grown wha White tracer ELECTRONIC CONTROL 1 ead um ety Green with Red tracer Green with White tracer I RS Green with Yellow tracer Gray with Black tracer DISTRIBU le Ri Gray with Green tracer i Gray with White tracer ony Gray with Red tracer nanio no NEN REEE r Dio norse 81 t Gray with Yellow tracer Suppressor FEAR Light green with Black tracer i THEE TURN SIGNAL Light green with White tracer on LIGHT R Light green with Yellow tracer i HORN SWITCH TAIL amp STOP Orange with Black tracer Orange with Beck tra coda i 1 Pink with Blue tracer fornia pec i DIMMER PASSING for T Dearie Violet with Yellow tracer im i Snc T T Red with Black tracer Red with Green tracer 1 T eiel heels e D H an Red with White tracer Red with Yellow tracer TEU LICENSE White with Black tracer d LIGHT White with Blus tracer ii i i i White with Green tracer t White with Red tracer White with Yellow tracer H Yellow with Black tracer HHn LIGHT U Yellow with Blue tracer i Ir STOP Yellow with Green tracer Hew LIGHT 0 Yellow with Red tracer Hct REAR Yellow with White tracer amp TURN SIGNAL g gan SENSOR cose SPEED Lig 9 wren E rLEFUEL LIGHT
9. size thickness 0 004 0 012 0 020 in Output shaft Just as with input shaft take measurements of A B and C as indicated in Fig 14 26 calculate shim thickness and install proper shim s between output shaft rear bearing and rear case when matching center case and rear case ie ud A oe 1 Shim for input shaft Fig 14 27 2 Shim for output shaft Rear Case 1 Install oil seal in rear case and apply grease to oil seal lip Fig 14 28 2 Install counter shaft thrust washer to rear case bringing its face without depressions against case and fit its bent portion securely into groove in case NOTE Apply ample amount of grease to both surfaces of washer so as to lubricate sliding surfaces and prevent washer from moving out of place or slipping off Fig 14 29 14 11 Center Case 4 Install the counter shaft thrust washer to center 1 Install input shaft front bearing circlip and oil case For installation apply ample amount of seal in center case grease to both faces of the washer so as to Snap ring pliers A 09900 06108 lubricate sliding surfaces and prevent it from moving out of place or slipping off and bring its face without depressions against center case and fit its bent portion into groove in case securely Fig 14 30 2 install input shaft to center case Fig 14 33 5 Install needle roller bearings spacer and cou
10. within specification 4 Upon completion of adjustment be sure to install wheel hub cap disc brake caliper amp holder and wheel Refer to INSTALLATION in this section King Pin Inspection and adjustment Where tapered roller bearings holding 2 kingpins at each front wheel are in good and properly preloaded tightened condition there will be no appreciable rattle of wheel To check kingpins and their tapered roller bearings jack up the front end and shake wheel to feel any rattle as shown in figure rattle is felt eliminate it by properly decreasing the shim thickness The shim is located between flanged part of kingpin and knuckle Fig 17 3 12 The above mentioned method of making a shim adjustment demands a high degree of skill on the part of the serviceman The alternative method is to adjust shim thickness by referring to the torque resistance which knuckle arm offers when pulled in the condition shown in figure For this method the reference torque value is established as indicated below and you are to increase or decrease shim thickness to produce this torque value NOTE After removing wheel and steering knuckle oil seal and disconnecting tie rod end this checking and adjustment should be carried out Spring balance Fig 17 3 13 Before giving a test pull to knuckle arm with a spring balance in the alternative method install a large amount of shims on each kingpin to lighten preload on
11. 16 Output shaft 23 Speedometer driven gear 3 Circlip 10 Counter shaft 17 Speedometer drive gear 24 Speedometer gear case 4 Bearing 11 Thrust washer 18 Bearing 25 Oil seal b Nut 12 Bearing 19 Shim 26 O ring 6 Input shaft 13 Spacer 20 Retainer 7 Bearing 14 Counter gear 21 Oil seal Fig 14 1 14 2 14 2 POWER FLOW OF TRANSFER The drive force is transmitted from the transmission through the input shaft of the transfer and the gear of the counter shaft to the output shaft Then from the output shaft it is transmitted through the pro peller shaft to the differential From transmission 190200 To rear wheel ii Fig 14 2 14 3 GEAR RATIO DATA Rear wheel drive 41 44 62 41 1 409 14 3 14 4 TRANSFER SERVICES NOT REQUIRING TRANSFER REMOVAL Foliowing parts or components do not require transfer removal to receive services replacement inspection Part or Component Nature of Service 1 Universal joint yoke flanges Replacement or inspection 2 Transfer output shaft front case Replacement 3 Transfer input shaft oil seal Replacement Replacement or inspection 4 Speedometer driven gear 14 4 14 5 REMOVAL 3 Disconnect speedometer drive cable from transfer gear box 1 Lift up vehicle and remove securing bolts from each universaljoint flange connection to sever 2 propeller shafts from transfer gear box Fig 14 5 Fig 14 3 4
12. 17 20 Thread lock SUZUKI LOCK CEMENT e Kingpin bolt cement 1342 09900 32050 Kingpin SUZUKI SEALING To matching surfaces of steering knuckle Sealing COMPOUND 366E brake caliper holder wheel spndie and compound 99000 31090 dust cover e Steering knuckle oil seal retainer e Wheel hub cap SECTION 18 STEERING SYSTEM NOTE The same description of steering system structure and operation as well as its service in formation applies to the 2WD Model as the 4WD Model except the shape of the differen tial housing of the front axle housing Therefore when servicing the steering system of the 2WD Model refer to the same section in GROUP 1 Steering wheel Steering upper shaft Steering lower shaft Tie rod Drag rod Steering damper Pitman arm Steering gear box Knuckle arm 00 10 01 i Fig 18 1 18 1 SECTION 22 SERVICE DATA NOTE For the items not found in this section refer to the same section in GROUP 1 CONTENTS 22 1 1 22 4 222 SERVICE DATA 22 22 1 SPECIFICATIONS Convertible Hard Top item POWER TRANSMISSION Clutch type Dry single disc Transmission type 5 forward all synchromesh 1 reverse Final reduction ratio Differential 3 727 B n 3 652 1 947 1 423 4th 1 000 5th 0 864 reverse
13. 4 Remove tie rod end castle nut and disconnect tie rod end from steering knuckle with special A Fig 17 1 18 Special Tool A Tie Rod End Remover 09913 65210 5 Remove joint seal bolts Then remove oil seal cover pad oil seal and retainer from knuckle Fig 17 1 19 6 Remove lower and upper kingpins NOTE Upper and lower kingpins when removed must be marked off one from the other e Also make sure to check the number of kingpin shims that were fitted on each side 1 Upper kingpins 2 Lower kingpins Fig 17 1 20 7 Pull off steering knuckle NOTE e When steering knuckle is pulled lower king pin bearing sometimes falls off So remove bearing while pulling off the knuckle gradually Upper and lower kingpin bearings must be also marked off one from the other T Steering knuckle 17 7 Fig 17 1 21 INSPECTION OF COMPONENT Stabilizer and its Bush Inspect stabilizer for damage or deformation If defective replace Inspect bushes for damage wear or deterioration tf defective replace Fig 17 1 22 Leaf Spring Bushes Inspect for wear and breakage If found defective replace Fig 17 1 23 Front Wheel Bearing Check front wheel bearing rollers for damage If anything is found wrong replace bearing with a new one Fig 17 1 24 17 8 Kingpins and Bearings Inspect each kingpin closely for dents signs of cracking distortion or any other damage Re
14. California spec ONTROI ROT model aniy SONO SENSOR SENSOR POSITION INJECTOR SENSOR POSITI LIGHT i uy REAR SIDE MARKER REAR DEFOGGER LIGHT D FRONT TURNI al SIGNAL LIGHT 0 EE Er HEAD LIGHT L exl H T 8 8 FRONTSIDEMARKERLIGHT l a WARNING BACK LIGHT SWITCH 4WD TH SWITCH CHECK DOOR SWITCH SWITCH for California spec model RELAY WARNING PUELLEVEL GAUGE fuel PUMP BUZZER For CANADA seen sereo at BRAKE LEVEL DAY TIME RUNNING COMBINATION METER ILLUMINATION FUSIBLE LINK LIGHT CONTROLLER 5 CONTROLLER cioci CIGARETTE lt 7 ranio LIGHTER FRONT SIDE MARKER Heer E n WIRE COLOR E RADIO 1 y T HEADLIGHTIR 25 uu FEES T coumi S be zg Bick AI eR i ff J Blue iid E Brown f i Green FRONT TURN Grey SIGNAL LIGHT RI Sky blue rM ul z Light green ROOM LIGHT Oranga POSITION LIGHT R T LLIT TET 1 4 ELE X GENERATOR 1 E Vite a aaa T sme m Black wit racer H za SENSOR BR 122 7 2292 LIGHT SIGNAL Black with Red WATER Temp 23 PRESSURE synon mey Black with White tracer GAUGE GAUGE SWITCH Black with Yellow tracer m ruse DERE B2B A BOX BH BEB PARKING
15. tapered roller bearing Keep on reading the torque each time decreasing shim thickness a little and continue this process until specified torque value is obtained This process protects kingpins because it ensure that no excessive pull will be applied to bearings at the onset If the process fails to produce specified torque that is if desired torque resistance does not occur even when shim thickness has been reduced to zero on each kingpin it means that bearings or king pins are excessively worn and need replacement NOTE e Read spring balance indication when knuckle arm begins to turn In other words you are to read starting torque e When checking knuckle arm starting torque be sure to have axle hub oil seal removed and tighten kingpin bolts to specified torque 1 0 1 8 kg 2 20 3 96 Ib without oil seal 0 1 0 5 mm 0 004 0 02 in Knuckle arm starting torque force Available sizes of shim fork kingpins Tightening torque for kingpin bolts 20 30 N m 2 0 3 0 kg m 14 5 21 5 tb ft Kingpin shim Fig 17 3 14 Upon completion of this check and or adjust ment be sure to connect tie rod end to steering knuckie and install oi seal retainer oil seal felt packing oi seal cover and wheel Refer to INSTALLATION in this section 17 17 Steering Knuckle Oil Seal The oil seal used at the spherical sliding joint between knuckle and inner case ac
16. 3 2 3 9 5 16 5 6 When installing speedometer driven gear and its gear case in rear case apply grease to O ring and oil seal lip and align bolt hoses in rear case and driven gear case Fig 14 39 7 Install propeller shaft flanges and tighten nuts to specified torque and calk the nuts b ft 80 108 0 14 13 Tightening torque for universal joint flange nuts 8 Upon completion of entire assembly work in stall transfer in chassis body in reverse sequence of removal Pour gear oil into transfer gear box Refer to information given in next oi and oil capacity for oil to be used and specified amount NOTE When installing oil filler and drain plugs to transfer case apply sealant SUZUK BOND No 1215 99000 31110 to theread part of plug 14 14 14 9 MAINTENANCE SERVICES Oil Level Oil level must be checked with vehicle held in horizontal position in both front to rear and side to side directions Oil level plug and oil filler plug are one and the same as shown in figure If oil flows out of filler plug hole or if oil level is found up to hole when plug is removed amount of oil is appropriate Replenish oil if noted as insufficient Oil and Oil Capacity Whenever vehicle is lifted up for any service in cluding oil change make sure to check around transfer gear box for oil leakage Correct defects if any and change or refill oil Transfer oil capacity 0 8 litre 1 7 1 4 US Im
17. 3 466 Transfer gear ratios 1 409 low 19 177 2nd 10 224 3rd 7 472 4th 5 251 Sth 4537 reverse 18 201 Transmission gear ratios Overall reduction ratios WHEEL AND SUSPENSION Tire size front and rear P195 75 R15 140 kPa 1 40 kg cm 20 psi 140 kPa 1 40 kg cm 20 psi unladen 180 kPa 1 80 kg cm 26 psi laden Tire pressure 22 1 22 2 SERVICE DATA SUSUPENSION Item Standard Service Limit vo 22 2 Front wheel bearing starting preload Rear wheel bearing thrust play Knuckle arm starting torque without seal 2 0 3 0 4 4 6 6165 0 8 mm 0 03 in 1 0 1 8 kg 2 20 3 96 Ibs WIRING DIAGRAM From the Samurai 1990 1991 and 1992 Supplementary Service Manual
18. 5 43 5 61 0 Leaf spring U bolt nut 60 80 Wheel nut 80 110 8 0 11 0 57 5 79 5 Front wheel hub cap 10 16 1 0 1 6 7 5 11 5 Kingpin upper amp lower bolts 20 30 2 0 3 0 14 5 21 5 Joint seal bolt 8 12 08 12 6 0 8 5 Front amp rear shock absorber lower nut 35 55 3 5 5 5 22 5 39 5 Front shock absorber upper lock nut 22 35 2 2 3 5 16 0 25 0 Front leaf spring bumper bolt 18 28 18 28 13 5 20 0 Stabilizer bolt 70 90 7 0 9 0 51 0 65 0 Stabilizer nut 22 35 2 2 3 5 16 0 25 0 Stabilizer mount bracket bolt 18 28 1 8 2 8 13 5 20 0 Front wheel bearing nut 10 15 10 1 5 7 5 10 5 Front wheel bearing lock nut 60 90 6 0 9 0 43 5 65 0 Rear differential oil drain plug 18 25 1 8 2 5 13 5 18 0 Rear differential oil filler amp level plug 25 5 36 0 Wheel center cap bolt 17 19 175 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE 99000 25010 Kingpin bearing Front wheel bearing Lip portion of front wheel bearing oil seal Lithium soap grease containing molybdenum disulfide SUZUKI SUPER GREASE 99000 25120 Steering knuckle Lip portion of steering knuckle oil seal
19. 6 7 8 9 0 Retainer Upper rubber bush Washer Shock absorber Lower rubber bush Shackle pin Shackle outer plate Shackle bush Shackle inner plate U bolt Fig 17 1 1 17 2 Leaf spring Spring seat Balt Spacer Spring bush Spring bumper Stabilizer Silencer Silencer Front axle housing Oil seal cover Pad Oil seal Qil seal retainer King pin King pin shim Steering knuckle Bearing Wheel spindle Caliper hoider BERORETBHS Dust cover seal Bearing Front wheel hub Washer Nut Lock washer Front hub cap Cap holder Wheel cap Y 1 Front brake disc 8 2 Wheel bearing 9 3 Wheel hub cap 10 4 Wheel hub 11 5 Dust cover 12 6 Oil seal 13 7 King pin 14 Fig 17 1 2 King pin bearing Steering knuckle Disc brake holder Disc brake caliper Shock absorber Spring bumper Leaf spring REMOVAL Shock Absorber The shock absorber is non adjustable non refillable and cannot be disassembled The only service the shock absorber requires is replacement when it has lost its resistance is damaged or leaking fluid 1 Hoist vehicle 2 Loosen lower and upper mounting nuts and remove shock absorber Nut Nut Retainer Upper rubber bush Washer Shock absorber Lower rubber bush Washer Nut 00 09050N2 Fig 17 1 3 Leaf Spring 1 Raise vehi
20. ENSOR POSITION i i VALVE SENSOR WINDSHIELD POSITION STARTER hen MASHER Sarre REAR SIDE MARKER LIGHT REAR DEFOGGER LIGHT L The parts with are provided or E x not depending on specifications FRONT TURN EE ns SIGNALLIGHT lU Lt T T Ser T SI i m HEAD LIGHT L 1 DEDE m H re 2 FRONT SIDE MARKER LIGHT IL k 2 E a DOOR EI WARNING BACKLIGHT SWITCH AWD 5 TH SWITCH SWITCH FUELLEVEL GAUGE yer PUMP YIE17 E28 Note the above diagrams are available separately in a larger format on the same webpage as this document at Ack s http www acksfaq com
21. GROUP 2 SUZUKI samurai SUPPLEMENTARY SERVICE MANUAL FOR 2WD MODEL FOREWORD This supplementary service manual has been pre pared for the 1991 and 1992 SAMURAI 2WD MODEL It describes different service information of 2WD MODEL as compared with 4WD MODEL Therefore whenever servicing 2WD MODEL consult GROUP 2 first And for any section item or description not found in GROUP 2 refer to GROUP 1 information illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval And used as the main subject of description is the vehicle of standard specifica tions among others Therefore note that illustra tions may differ from the vehicle being actually serviced The right is reserved to make changes at any time without notice SUZUKI MOTOR CORPORATION TECHNICAL DEPARTMENT AUTOMOBILE SERVICE DIVISION COPYRIGHT SUZUKI MOTOR CORPORATION 1991 TABLE OF CONTENTS SECTION GENERAL SPECIAL TOOLS AND SERVICE MATERIALS PERIODIC MAINTENANCE SERVICE EMISSION CONTROL SYSTEM TRANSFER GEAR BOX PROPELLER SHAFTS DIFFERENTIAL SUSPENSION STEERING SYSTEM SERVICE DATA SECTION 0 GENERAL SPECIAL TOOLS AND SERVICE MATERIALS NOTE For the items not found in this section refer to the same section in GROUP 1 CONTENTS 0 1 IDENTIFICATION NUMBER
22. IRED SERVICE MATERIALS 17 20 NOTE e 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 e Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may result e The leaf spring number or shape shown in this manual may differ from the vehicle be ing actually serviced depending on specification 17 1 17 1 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension consists of the double acting shock absorbers stabilizer bar semi elliptical leaf springs axle housing etc as shown below The end of the dead axle sleeve is in the shape of dish This dish is rotatably fitted into the knuckle structure to form a flexible connection the sliding clearance between the two being sealed with a felt packing against road dust and mud and also with an oil seal against the oil inside The upper and lower kingpins bolted to the knuckle extend into the knuckle and inside are held by the dish like inner case through tapered roller bearings 1 2 3 4 5
23. PCV Valve 1 Disconnect PCV hose from PCV valve 2 Run engine at idle 3 Place your finger over end of PCV valve to check for vacuum If there is no vacuum check for clogged valve Replace as necessary 1 New hose 2 Blow air Fig 5 3 Checking PCV Valve for Sticking 5 Connect PCV hose and clamp securely 1 PCV valve Fig 5 2 Checking Vacuum 14 14 14 14 14 14 10 14 11 14 12 wow Nom SECTION 14 TRANSFER GEAR BOX CONTENTS GENERAL DESCRIPTION POWER FLOW OF TRANSFER GEAR RATIO DATA TRANSFER SERVICES NOT REQUIRING TRANSFER REMOVAL REMOVAL 5 24 40 3 CUN SCC CERRO RODEO S DISASSEMBLY e E eek E RES eC eaten INSPECTION OF COMPONENTS HEASSEMBLY saci ka kk MAINTENANCE SERVICES TIGHTENING TORQUE SPECIAL TOOLS 6 03 bcs UE neh Ba wreaks REQUIRED SERVICE MATERIALS 14 1 14 1 GENERAL DESCRIPTION Shown in figure below are component parts included in the transfer gear box Main parts are 3 shafts and 3 gears Among those 3 gears the one on input and output shafts is incorporated with shafts as one unit C 1 Flange 8 Counter shaft lock plate 15 Bearing 22 Flange 2 Oil seal 9 O ring
24. Remove mounting nuts securing gear box to chassis and take down gear box 2 Drain out oil from gear box by loosening its Nu drain plug Fig 14 6 14 5 14 6 DISASSEMBLY Universal Joint Yoke Flanges There are 2 flanges to be removed one from input shaft and other from output shaft Lock flange so that it will not turn and loosen and remove nut holding flange to the shaft Draw off flange Special too 09922 66020 Fig 14 7 Speedometer Driven Gear Loosen speedometer driven gear case bolt and remove speedometer driven gear case with gear Transfter Center Case Remove bolts fastening center case output shaft front case and rear case together NOTE Do not loosen lock plate bolt at this point 14 6 1 Counter shaft lack plate bolt Fig 14 9 By tapping rear case and output shaft with a plastic hammer separate center and rear case Fig 14 10 Given below are procedures for disassembling component parts of center case as separated from rear case 1 Pull out counter gear bearings and spacer 2 Hammer output rear shaft with a plastic hammer to drive it out of center case Fig 3 Remove counter shaft from center case loosening counter shaft lock plate bolt Fig 14 12 4 Remove input shaft from center case by hammering thick part of case or input shaft center with a plastic hammer Fig 14 13 5 Remove output shaft rear bearing and retainer
25. cle In this operation garage jack or hoist must not be positioned against front suspension related parts When garage jack is used place safety stands under chassis to support raised body 2 Remove front wheel 3 Remove stabilizer bolt 4 Remove U bolt nuts 5 Remove shackle nuts and leaf spring nut NOTE Removal of leaf spring causes axle housing to hang Support it with safety stand to prevent it from damaging universal joint of propeller shaft and others 17 4 6 Pull out leaf spring bolt and remove leaf spring from shackle pin Leaf spring U bolt Spacer Spring bush Shackle pin Shackle bush Spring Stabilizer ONAT AWN Fig 17 14 Stabilizer 1 Hoist vehicle 2 Remove stabilizer bolts 3 After removing stabilizer mount bush bracket bolts remove stabilizer 2 AR e amp 3 1 Bolt 2 Stabilizer Fig 17 1 5 3 Bracket bolt Front Wheel Hub amp Bearing 1 Remove wheel center cap 2 Loosen the five nuts securing the wheel Raise the front end by jacking Rest the machine steady on safety stands 3 Remove the five nuts and take off the wheel Fig 17 1 6 4 Remove front wheel center cap holder and front wheel hub cap NOTE When loosening front wheel hub cap hold front wheel by depressing footbrake pedal This will facilitate the work 1 Center cap holder 2 Axle shaft cap Fig 17 1 7 5 Remove the caliper with carrier by loosening ca
26. complishes additional purposes of keeping out road dust and of acting as the damper for steering hand wheel As wear of this seal advances its damping effect decreases and thus makes front wheel develop a tendency to shimmy not only that road dust begins to creep into sliding clearance to promote wear of spherical sliding surfaces The oil seal is an expendable item and must be replaced at regular intervals Fig 17 3 15 How to replace oil seal 1 Remove 8 bolts securing joint seat and dis place oil seal cover and felt packing inward Fig 17 3 16 17 18 2 Cut oil seal in place with scissors or a knife and take it off 3 Cut replacement oi seal at one place with scissors or a knife as shown in figure below 4 Instal the seat in oil sea retainer bringing the cut portion to top side and locating it about 30 degrees off the matching face of oil seal retainer Fig 17 3 17 5 Apply grease to inside of oil seal Apply sealing compound to mating face all around this is for preventing entry of water SEALING COMPOUND CEMEDINE 366E 99000 31090 e SUZUKI SUPER GREASE H 99000 25120 Apply grease Apply sealer Oil seal gt SM Retainer Apply sealer Fig 17 3 18 6 Tighten joint seat securing bolts to specified torque 17 4 RECOMMENDED TORQUE SPECIFICATIONS Tightening torque Fastening parts N m Schackle pin nut 30 55 22 0 39 5 Leaf spring nut 60 8
27. h for wear cracking chipping and other malcondition Replace gear as necessary Fig 14 20 Bearings Check each bearing by spinning its outer race by hand to feel smoothness of rotation Replace bearing if noted to exhibit sticking resistance or abnormal noise when spun or rotated by hand Fig 14 21 14 8 REASSEMBLY NOTE All parts to be used in reassembly must be perfectly clean Oil or grease sliding and rubbing surfaces of transfer components just before using them in reassembly with gear oil and SUZUKI SUPER GREASE A 99000 25010 Oil seals rings gaskets and similar sealing members must be in perfect condition For these members use replacement parts in stock e Tightening torque is specified for important fasteners mainly bolts of transfer and other components Use torque wrenchs and constantly refer to specifed data given in 14 15 Input Shaft Press fit bearings onto both sides of input shaft by using bearing installer special tool Bearing installer A 09913 84510 b 1 Front bearing 2 Input shaft 3 Rear bearing Fig 14 22 Output Shaft Install following parts onto shaft in such order and directions as prescribed in the figure 1 Press fit speedometer drive gear by using bearing installer special tool Bearing installer A 09913 84510 1 Speedometer drive gear 2 Output shaft Fig 14 24 2 Press fit bearings and the retaine
28. he right and left leaf springs by means of spring seats and U bolts The two shock absorbers right amp left are installed with their lower ends attached to the spring seats and the upper ends to the chassis frame all through rubber bushes NOTE The structure of this rear suspension is the same as that of the 4WD Model except the spring rate of the rear leaf spring Also servicing procedures of the rear suspension such as removal installation and maintenance are the same as the 4WD Model Therefore refer to the same section in GROUP 1 1 2 3 4 5 6 7 8 Leaf spring Shackle plate inner Shackle plate outer Shackle bush U bolt Spring bumper Spring seat Spring bush Fig 17 2 1 Shock absorber Bush Axle housing Axle shaft Bearing Bearing retainer ring Oil seal Oil seal protector 17 13 17 3 MAINTENANCE SERVICES Shock Absorber 1 inspect for deformation or damage 2 Inspect bushings for wear or damage 3 Inspect for evidence of oil leakage Replace any defective part Fig 17 3 1 WARNING When handling rear shock absorber in which high pressure gas is sealed make sure to observe the following precautions 1 Don t disassemble it 2 Don t put it into the fire 3 Don t store it where it gets hot 4 Before disposing it be sure to drill a hole in it where shown by an arrow in the figure below and let gas and oil out Lay it do
29. ing knuckle Front wheel bearing oil seal Make sure to install oil seal in the correct direction as illustrated and drive it until the seal is flush with wheel hub end face Apply SUZUKI SUPER GREASE A 99000 25010 to lip portion of oil seal Grease Front wheel hub When installing hub cap apply SEALING COMPOUND 366 99000 31090 to mating surfaces of cap and front wheel hub Center cap 10 16N m 1 0 1 6 kg m 7 5 11 5 lb ft Front wheel bearing nut 1 for the details on tightening it Front wheel center Fro wi Refer to MAINTENANCE SERVICE in this section Install front wheel center cap by aligning rib on inside of cap with outside of center cap hoider Steering knuckle Apply SUZUKI SUPER GREASE H 99000 25120 within the knuckle Amount of grease to be applied within the knuckle is approximately 150 9 4 Front wheel bearing Before installing outer bearing apply about 159 of SUZUKI SUPER GREASE A 99000 25010 or wheel bearing grease between outer bearing and inner bearing Fig 17 1 28 17 10 Joint seal bolt 8 12 0 8 1 2 kg m 6 0 8 5 Ib ft Brake disc dust cover Apply SEALING COMPOUND 366E 99000 31090 to mating surfaces of dust cover and caliper holder Front leaf spring bush amp spring bolt
30. ise e Take the same measurement at 3 to 4 different positions and use their mean 14 10 1 Center case 4 Qutput shaft 7 Gasket thickness 2 Rear case 5 Bearing circlip 0 3 mm or 0 012 in 3 Input shaft 6 Gasket Fig 14 26 4 Using measurements obtained in steps 1 to 3 and equation described below calculate shim thickness which is necessary for proper thrust clearance Thrust clearance A Gasket thickness As the above equation holds for thrust clearance and gasket thickness is specified as 0 3 mm and thrust clearance as 0 05 to 0 15 mm shim thickness is calculated by the following equation Shim thickness A B 0 3 0 05 0 15 Example Supposing B and C are as follows A 81 35 mm 3 203 in B 35 70 mm 1 405 in C 117 05 mm 4 608 in Shim thickness 81 35 35 70 0 3 117 05 0 05 0 15 117 35 117 10 117 20 0 25 0 15 In this case use of 0 15 to 0 25 mm 0 006 to 0 009 in thick shim s will ensure specified thrust clearance which is 0 05 to 0 15 mm 0 002 to 0 006 in Therefore 2 pieces of 0 1 mm 0 004 in thick shim should be selected in avail able shims below to satisfy thickness 5 When shim thickness is determined select proper shim s from among the following shims and use it them between input shaft rear bearing and rear case when matching center case and rear case Available shim 0 1 0 3 0 5 mm
31. nter gear on counter shaft 1 Needle roller bearing 2 Spacer 3 Counter gear 1 Input shaft SS a Fig 14 31 3 After greasing O ring on counter shaft insert shaft into center case and secure shaft with Fig 14 34 lock plate and bolt 6 Install output shaft assembly to center case THe A S9 E SN Oo E Fig 14 32 228 Counter shaft lock kg m lb ft plate bolt 9 17 09 17 7 0 120 1 O tput sheft Fig 14 35 14 12 Center and Rear Cases 1 Check center case or rear case to ensure that it is provided with 2 dowel pins 1 Fig 14 36 1 Dowel pins NOTE e Matching must be made carefully so as not to move countershaft thrust washers out of place sure to install shims determined in previous item Shim Adjustment of Input and Output Shafts between input shaft rear bearing and rear case and between output shaft rear bearing and rear case 2 Put gasket on center case Bring rear case and center case into match and apply uniform force gradually all around rear case with a plastic hammer Fig 14 37 3 Put gasket on center case 4 Install front case to center case 5 Tighten center case and output shaft front case securing bolts to specified torque Length Pieces 85 mm 3 35 in 47 mm 1 85 in 35 mm 1 38 in Tightening torque for center case and retainer bolts 1
32. p pt Gear oil SAE 80W 90 75W 80 or 75W 90 Transfer oil specification it is highly recommended to use SAE 75W 90 gear oil For viscosity chart refer to 88 MODEL SERV ICE MANUAL at the page 1 20 SN E ROK AN 1 Drain plug 2 Oil level and oil filler plug Fig 14 40 14 10 TIGHTENING TORQUE 14 11 SPECIAL TOOLS Fastening parts Output shaft front case bolt Center case bolt Counter shaft lock plate bolt 09900 06108 Snap ring pliers 09922 66020 closing type Flange holder Universal joint flange 1 10 150 80 0 108 0 nut 11 0 15 0 Transfer mounting 18 28 bracket 18 28 25 35 Transfer mounting nut 18 5 25 0 2 5 3 5 50 60 Cross joint bolt amp nut 4 36 5 43 0 5 0 6 0 Oil filler and drain 18 28 plug 13 5 20 0 09926 58010 09913 75810 Bearing puller attach Transfer bearing installer ment transfer 13 5 20 0 09913 84510 Transfer bearing installer 14 12 REQUIRED SERVICE MATERIALS RECOMMENDED SUZUKI PRODUCT MATERIALS Sliding and rubbing surface of components SUZUKI SUPER GREASE A where application is instructed in this manual 99000 25010 Both surfaces of counter shaft thrust washer Oil seal lips SUZUKI BOND No 1215 Oil filler and drain plugs 99000 31110 Lithium grease
33. place the kingpins found in defective condition Fig 171 25 Check the kingpin bearings for damage If anyth ing is found wrong replace the bearing with new Steering Knuckle Oil Seal The oil seal used at the spherical sliding joint between the knuckle and the inner case accom plishes the additional purposes of keeping out road dust and of acting as the damper for the steering handwheel As the wear of this seal advances its damping effect decreases and thus make the front wheel develop a tendency to shimmy not only that road dust begins to creep into the sliding clearance to promote the wear of the spherical sliding surfaces Check the oil seal for wear or damage If defec tive replace with new one Fig 17 1 27 17 9 INSTALLATION Reverse removal procedure observing each precaution Kingpin bearing Kingpin bolt Kingpin Kingpin shim When installing kingpin bearing apply SUZUKI SU PER GREASE 99000 25010 to bearing roll before tightening it Apply SUZUKI LOCK CEMENT 1342 99000 32050 to bolt thread Refer to MAINTENANCE SERVICE in this section for details on shim Before fitting kingpin apply SEALING COM POUND 366 99000 31090 around it as shown ers all around Front wheel spindle by at the left SEALING COMPOUND 366 99000 31090 to mating surfaces of brake caliper holder and steer
34. r by using bearing installer special tool Bearing installer A 09913 84510 A 1 Output shaft rear bearing 2 Output shaft front bearing 3 Retainer Fig 14 25 3 Fit circlip securely into groove in out put shaft front bearing 14 9 Shim Adjustment of Input and Output Shaft Clearance in thrust direction of both input and output shafts is adjusted by putting shims between input shaft rear bearing and rear case for input shaft and between output shaft rear bearing and rear case for output shaft As thrust clearance is specified as follows determine shim thickness to meet specification according to the following procedures Thrust clearance 0 05 0 15 mm Specification 0 002 0 006 in Input shaft 1 Take measurement of rear case as shown in figure below by using depth gauge 2 Take measurement of center case with bearing circlip installed 3 Take measurement C between bearing inner races of input shaft with bearings installed by using micrometer NOTE e Before measuring make sure that each bearing is free from abnormal noise or resistance by spinning its outer race e Each measurement in above steps 1 to 3 must be taken accurately in careful manner If shim thickness is determined based on rough measurement clearance of each shaft in thrust direction will not satisfy specification And improper clearance may cause oil leakage broken bearing and abnormal no
35. rrier bolts 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 with caliper removed 1 1 Carrier bolts 2 Caliper Fig 17 1 9 6 Remove brake disc NOTE If brake disc can not be removed by hand use 8 mm bolts as shown below 1 8 bolt Fig 17 1 10 17 5 7 Straighten bent part of lock washer and 9 Pull front wheel hub off the front wheel remove wheel bearing lock nut with special spindle tool B Then remove lock washer Fig 17 1 14 Fig 17 1 11 10 Remove oil seal and outer race of inner bearing or outer bearing from wheel hub Fig 17 1 15 Fig 17 1 12 Special Tool B Front Wheel Bearing Nut Socket Wrench 09941 58010 Steering Knuckle 1 Remove front wheel hub referring to steps 1 8 After loosening front wheel bearing nut with to 9 of foregoing front whee hub and bearing the same special tool B take nut off the removal front wheel spindle 2 Loosen bolts securing kingpins upper amp lower At this point king pins mustn t be removed Fig 17 1 13 Fig 17 1 16 17 6 3 Remove disc dust cover caliper holder and wheel spindle NOTE Whee spindle can be removed by tapping it with a plastic hammer If it does not come off easily remove steering knuckle and then tap on inside of steering knuckle 1 Dust cover Fig 17 1 17
36. ted by an arrow in figure below to see if bearing rattles Fig 17 3 7 5 If bearing rattles check bearing preload with wheel and brake caliper amp holder removed as shown in figure below Fig 17 3 8 Wheel bearing starting 2 0 3 0 kg preload 4 4 6 6 Ib If preload is not within the above specifica tion adjust bearing preload according to following adjustment 17 15 Adjustment 1 After removing wheel bearing lock nut and lock washer tighten bearing nut to the torque of 80 Nm 80 57 5 lb ft while spinning hub by hand Next loosen the nut until the torque becomes N m 0 kg m 0 Ib ft and then tighten it again to tightening torque specified below In this way an appropriate bearing preload is obtained 10 0 15 0 N m 1 0 1 5 kg m 7 5 10 5 Ib ft Wheel bearing nut D tightening torque Fig 17 3 9 Special Tool A Front Wheel Bearing Nut Socket Wrench 09941 58010 1 Wheel bearing lock nut Fig 17 3 10 17 16 2 Be sure to insert lock washer after adjustment and tighten lock nut 2 to specified torque Then bend a part of lock washer toward bear ing nut body side and another part toward lock nut outside so that these 2 nuts are locked 60 90 N m 6 0 9 0 kg m 43 5 65 0 Ib ft Wheel bearing lock nut tightening torque Wheel bearing nut Wheei bearing lock nut Fig 17 3 71 3 Recheck that bearing starting preload 15
37. together by using bearing puller Retainer Bearing Output shaft Bearing puller 1 2 3 4 Fig 14 14 6 Remove speedometer drive gear by using bearing puller and press CAUTION When doing this work be careful not to damage speedometer drive gear 2 AE 1 Speedometer drive gear 2 Output shaft Fig 74 15 3 Press 7 Remove output shaft front bearing by using bearing puller and puller attachment special tool Puller attachment B 09926 58010 1 Bearing 2 Bearing puller Fig 14 16 2 8 When input shaft is removed or center case and rear case are separated input shaft bearings may come off In such a case bearings can be removed from shaft by using bearing puller 1 Bearing 2 Input shaft 3 Bearing puller Fig 14 17 14 7 9 When input shaft is removed front bearing may be left in case In this case after removing oil seal and circlip bearing can be taken out of case by using bearing installer special tool Bearing installer C 09913 75810 lt gt DNN Fig 14 18 Transfer Rear Case When center case and rear case are separated input shaft may be left in rear case In this case remove input shaft from rear case by hammering thick part of case with a plastic hammer 1 Input shaft Fig 14 19 14 7 INSPECTION OF COMPONENTS Gear Teeth Inspect gear teet
38. us the amount of the blow by gas drawn into the intake manifold is small For 91 92 model For 90 model a 8 lt 9 10 1 Intake manifold 7 PCV hose 2 Cylinder head cover 8 Blow by gas 3 PCV valve 9 Fresh air 4 Throttle body 10 Blow by gas and b Air intake case fresh air mixture 6 Breather hose Fig 5 2 PCV System Operation 5 2 ON VEHICLE SERVICE GENERAL 4 After checking vacuum stop engine and When the emission contro hoses are disconnect check PCV valve for sticking ed and the system s component is removed for With engine stopped connect a new hose to service reinstall the component properly and PCV valve route and connect hoses correctly after service Blow air into new hose and check that air Refer to Vehicle Emission Control Information flows with difficulty from cylinder head side Label for proper routing of hoses to intake manifold side If air flows without difficulty valve is stuck in Open position PCV SYSTEM Replace PCV valve NOTE WARNING Do not suck air through PCV valve Petrol eum substances inside the valve and fuel vapor inside the intake manifold are harm ful Be sure to check that there is no obstruction in PCV valve or its hoses before adjusting engine idle speed for obstructed PCV valve or hose hampers its accurate adjustment PCV Hose amp Breather Hose Check hoses for connection leakage clog and deterioration Replace as necessary
39. wn sideways for this work Drill hole with approx imately 3 mm 0 12 in diameter 14 gt Cut off Cover with a vinyl envelope as shown so that drill dust will not scatter around Fig 17 3 2 17 14 Leaf Spring and Bumper 1 Inspect leaf spring for crack wear and damage NOTE Special attention must be paid to that part as indicated by A in figure below where each end of the shorter leaf contacts 2 Inspect bumper for damage If found defective replace Fig 17 3 3 Rear Wheel Bearing 1 Check wheel bearings for wear When measur ing thrust play apply a dial gauge to drum center Thrust play Limit 0 8 mm 0 03 in Fig 17 3 4 When measurement exceeds limit replace bearing 2 By rotating wheel actually check wheel bear ing for noise and smooth rotation If it is defective replace bearing Front Wheel Bearing Inspection 1 To check wheel bearings jack up front end Spin wheel and check if it is spun smoothly and is free from abnormal noise If it isn t replace wheel bearing Fig 17 3 5 2 Upon completion of the check in above 1 check each joint of steering system for tightness each ball stud of the steering link as well as each kingpin for rattle Then check bearing as described below 3 Shake wheel in the direction indicated by an arrow in figure below to see if bearing rattles Fig 17 3 6 4 Shake wheel in the direction indica
40. y Shock absorber amp nut f t For correct installing direction of absorber washer refer to the figure 35 55 N m j 3 5 5 5 kg m When installing retainer apply SEALING COM 25 5 39 5 Ib ft POUND 366E 99000 31090 al around it NOTE Torque specifications of other bolts and nuts are given under RECOMMENDED TORQUE SPECIFICATIONS of this section Oil seal retainer 17 11 Stabilizer Stabilizer bolt amp lock washer Tighten to the following specified torque in unloaded condition 70 90 7 0 9 0 kg m 51 0 65 0 Ib ft install lock washer in body outer side ITA Stabilizer mount bracket bolt 18 28 Nm 1 8 2 8 kg m 13 5 20 0 Ib ft Stabilizer nut Tighten to the fallowing specified torque in unloaded condition 22 35 Nm 2 2 3 5 kg m 16 0 25 0 Ib ft Stabilizer mount bush install stabilizer mount bushes right amp left by aligning them with painted positions on stabilizer respectively Fig 17 1 29 17 12 17 2 REAR SUSPENSION GENERAL DESCRIPTION The rear suspension consists of leaf springs axle housing axle shafts and shock absorbers as shown below The leaf springs are attached to the chassis frame through rubber bushes located at their both ends as shown The axle housing is installed on t
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