SUZUKI ADDITIONAL SERVICE MANUAL eee 3 RT) USE THIS MANUAL IN ADDITION TO THOSE Ne aaa ag Cee} fav) lor aloIMPORTANT WARNING/CAUTION/NOTE Please read this manual and carefully follow the instruc- tions. The words WARNING, CAUTION and NOTE high- light important information and have very specific sig- nificance. Please pay great attention to the messages ‘emphasised by these headings. WARNING Indicates a potential danger which could result in personal injuries. CAUTION: Indicates potential danger which could damage the vehicle. NOTE: Provides special information to facilitate maintenance or clarify instructions.PREFACE This Manual is a supplement to the Vitara (SE- 416) Service Manual fet: 99500-60A10-015 and to Supplementary Service Manuals Ref.: 99501- {60A70-018, 99501-6110-015 and 00000801231, ‘This manual describes the differences between the Vitara 1.9 TD. model and the Vitara (SE-416) 3 and 5 doors. To look up information, initially consult the Vitara 1.9 TD. manual. Ifthe information cannot be found inthis Supplement, consult he Service Manual and, ‘Supplements previously mentioned When servicing, always use parts, special tools, and products recommended by Santana Motor SA ‘There may be some discrepancies between speci- fications, data, figures oto. that appear in this Manual (available at time of publication) and those. incorporated in vehicles currently manufacturod. RELATED SERVICE MANUALS: = SERVICE MANUAL (SE-416) (99500-60410-018) + SUPPLEMENTARY SERVICE MANUAL FOR 5D (89501-60A70-01S) MODEL + SUPPLEMENTARY SERVICE MANUAL, (99501-61410-01S) + SUPPLEMENTARY SERVICE MANUAL FOR AIR BAG AND 1.9 D. (00000401231) MODEL. GENERAL INFORMATION [0 General Information oA Maintenance and lubrication 08 STEERING, SUSPENSION, WHEELS AND TIRES Power assisted steering pump | 3B2 FRONT SUSPENSION Free-wheeling hubs 3D BRAKING SYSTEM Brakes 5 ENGINE General information and diagnosis 6 Engine repair 6A4 Cooling system 6B Emissions control 6E3 Starter system 6s Charging system 6H CLUTCH 7 ELECTRICAL SYSTEM Chassis electrical system 8 Vehicle Immobilizer coded 8B TECHNICAL INFORMATION 10 ty a I 10SECTION 0A GENERAL INFORMATION For those’sections not contained in this manual, you must consult Service Manual 99500-60A10-01S (VITARA SERVICE MANUAL), 99501-60A70-01S (5P SUPPLEMENTARY SERVICE MANUAL), 99501-61A10-01S (SUPPLEMENTARY SERVICE MANUAL) and 00000A01231 (1.9 D SUPPLEMENTARY SERVICE MANUAL). LIST OF CONTENTS. GENERAL INFORMATION Chassis number identification Engine number identiication OAT OAT GENERAL INFORMATION CHASSIS NUMBER IDENTIFICATION ‘The chassis number is engraved on the front right-hand side, as shown in the figure, IDENTIFICATION OF ENGINE NUMBER ‘The engine number is engraved on the plate indicated on the left hand side, as shown in the figure.MAINTENANCE AND LUBRICATION 0B. SECTION 0B E MAINTENANCE AND LUBRICATION NOTE For topics not covered in this section, please refer to the relevant section of the Vitara Service Manual outlir in the preface. TABLE OF CONTENTS MAINTENANCE PROGRAMME — oo 08-2 ‘Maintenance in narmal driving canditians soon OBZ Maintenance in severe driving conditions — 08-3 MAINTENANCE SERVICE oc 0B-4 Engine .0B-4 Ignition system . . nnn en OB-10 a feennnnininsn ns BAO Chassis and body OBZ Final Inspection ...-.. : 08-19 Recommended fluids and lubricants... 08-19MAINTENANCE AND LUBRICATION 08-2 MAINTENANCE PROGRAMME MAINTENANCE IN NORMAL DRIVING CONDITIONS Interval: . This interval must be measured by mileometer readings, or by months, This table includes programmed servicing up to 90,000 Km. (54,000 miles), subsequently at regular intervals ‘wichever come frst Km. (1000) is | 30 [ 4 | 60 | 75 | 90 Miles (1000) g | 18 [27 | 36 | 45 | 54 ‘Months 32_[ 24 {36 | a8 | 60 | 72 7. ENGINE 1-1. Drive belt Vee rTayTrytTayi ye Mutt Vee ~[-trp- tT. Tr 1:2. Camshaft timing bett Replace every 80,000 Km. (50,000 miles) 4-4, Engine oil and filer ‘CD, CE or CF-4 Replace every 10,000 Ki. (6,000 miles) ‘or 8 months 15. Coolant eros fener a [1-6. Exhaust ayatem (except catalyst) 1 tet 2.- IGNITION Glow plugs TEE TEE FUEL SYSTEM 341. Air filter element ‘Asphalt road -[at-Trf-|ar 3-2, Fuel typos and connections alla ie Le 3-3. Fuel filter Replace first after 10,000 Km (6,00 miles) and subsequently every 20,000 Kin (12,000 miles) 3-4, Purge lines fiter water Every 10,000 Km (6,000 miles) 3-5, Fuel Tank ces ee a 6.- CHASSIS AND BODY 6-1. Clutch 6-2 [Brake discs and pads (front) (Brake drums and shoes (rear) &-3. Brake hoses and lines: 6-4. Brake fluid 6-5. Hand brake lever and cable 6-6. Tyres 6-7. Wheels and free wheeling hubs (It fitted) 6-8. Sueponsion system j—|—|—|— fo [-L-|—| | 6-9. Propeller shafts 6-10. Transmision oil 6-12. Transfer case oll [ 6-13. Ditferential oil (to be changed only after first 15,000 Km) 6-14, Storing 6-15, Power assisted steering 6-76. All locks and hinges NOTES: “R": Replace or change “": Inspect and correct or lubricate It necessaryMAINTENANCE AND LUBRICATION 08-3 ee MAINTENANCE IN SEVERE DRIVING CONDITIONS Ifthe vehicle is driven in any of the severe conditions outlined below, itis recommended that servicing be performed atthe specific intervals indicated in the tables below. Code of severe conditions. ‘A= Shor frequent journeys G~ Use in towrvTowing a Tralle/Drving at high B~ Driving on muddy surfaces SpeewiAt tomporateres over 40°C © riving on dusty surfaces ow qualty lubricants or ue, D - Driving in extremely cold climates. H-— Trailer towing. E - Short frequent journey in extremely cold cllmates. Severe condone Wiantenance pon Waintonance ane Serdce interval Every 15,000 Km (9,000 miles) ' or 12 months: ZZMAINTENANCE AND LUBRICATION 06-9 IreM 1-6 Exhaust system (except catalyst). Inspection: WARNING: To avoid danger of burns, do not touch exhaust system when hot. In periodic maintenance work, always inspect exhaust system in following oder + Inspect rubber mounts for damage, wear or faulty positioning, + Inspect exhaust system for leaks, weak connections, dents and damage. If nuts and bolts are foose, tighten to specitied levels. * Inspect body exterior for broken or incorrectly situated parts, open seams, holes, loose connections or other defects which may cause exhaust fumes to enter vehicle interior. + Check that exhaust system components are not touching lower part of vehicle, thereby preventing over heating wel possible demage to floorpan lining and mats, + All defects must be repaired immediately Changing rubber mounts. Periodically change exhaust pipe rubber mounts.MAINTENANCE AND LUBRICATION 08-10 IGNITION SYSTEM ITEM 2-3 Glow plugs. Inspection 41) Visually check glow plug function by observing dashboard pa- ‘nel controls. 2) Observe engine running from a cold start. Any difficulty in starting from cold could be a result of problems with glow plug heating system. FUEL SYSTEM ITEM 3-1 Air filter Element. Inspection 1) Release air filter anchoring strap. 2) Release four clips securing upper housing and extract filter. 3) Remove dust by blowing compressed air onto outlet side of element. Replacement 1) Release air fiter anchoring strap. 2) Release four anchoring clips on upper housing and extract, finer. 9) Install new fitter in air filter housing. NOTE: Replace more frequently in dusty working conditions. Consult 08-3 for maintenance and correct replacement interval in severe driving conditions. ITEM 3-2 ‘Types of fuel and connections Inspection 1) Visually inspect fuel inlet and fuel return lines to ensure is there io distortion or friction liable to cause cracks. 2) Check that connections are not damaged and that hase clamps are securely fastened.MAINTENANCE AND LUBRICATION 08-11 ITEM 3-3 Fuel filter. Replacement WARNING: ‘This work must be carried out in a well ventilated place away from naked flames or heat. ‘ 1) Loosen the filter bott (A), remove case (0), etement (C) and gaskets (8) 2) Clean case with diesel oil and fit new filter and new seats. Tighten (A) as specttied, Filter bolt torque specifications: 15 Nm (1.5 kg:m, 111b.ft) NOTE: The fuel filter is located on the left-hand side of the engine compartment, attached to the bulkhead. ITEN 3-4 Fuel fitter bleed. Air bleed NOTE: This operation should be performedas frequently as indicated in the maintenance chart OB-2 and when the situation demands following an intake of air due to lack of diesel oil with the subsequent difficulties in starting. 1) Make sure there Is sulicient fuel in tank. 2) Slacken bleeder (B). Pump several times pressing button (C) Until air ceases to come out of the bleeder. Tigitten Lleeder (8) ‘when fuel with no air content comes out and when the button stiffens on pumping, water and residue bleed. 1) Slacken bleeder (A) and tighten it when water and residue cease to come oul, {TEM 3-5 Fuel tank. 1) Visually inspect fuel tank flier cap seal for damage, distortion or excessive stitfness. It damaged, change it for a new one. 2) Check fuel lines and hoses, making sure they are securely fastened and there are no leaks. Change noses or pipes damaged in any way.MAINTENANCE AND LUBRICATION 08-12 CHASSIS AND BODY ITEM 6-1 Clutch, 1) Inspect freeplay of clutch pedal. 2) Ineft-hand drive vehicles the clutch pedal should be S mm (0.2 ins.) higher than the brake pedal. On right-hand drive vehicles, the clutch pedal should be set level with the brake pedal Clutch pedal 15-25 mm freeplay (0.6-1.0 in) For more information, please refer to section 7C. ITEM 6-2 Brake discs and pads (frant) Brake drums and shoes (rear). Brake discs and pads 1) Remove wheel and brake caliper without disconnecting brake hose 2) Inspect brake pads and discs for excessive wear, damage or istortion. Replace any parts necessary. Tighten fastening elements as specified. For more information, please refer to section 5 of Service Manual 99500-60A10-01E, Brake drums and shoes. 1) Remove wheel and brake drum. 2) Check brake drums and brake shoe and damage. 3) Check wheel cylinders for leaks, condition of dust covers, etc. Replace parts in bad condition For more information, please refer to section 5 of Service Manual 99500-60A10-01E. ings for excessive wearMAINTENANCE AND LUBRICATION 08-13, —_—__— —————eomvOUhnywmwyamzmz—' ITEM 6-3 Brake lines and hocos 1) Check brake pipes and hoses for installation problems, leaks, cracks, splits and other damage. ‘CAUTION: After changing any pipe or hose, bleed areas in question. ITEM 6-4 Brake tluid Inspection 4) Inspect master cylinder and reservoir area for fuid leaks. Repair ‘or replace the parts causing any leak. 2) Inspect fluid level. I uid level is below reservoir minimum, fll to correct lavel using spacified brake fluid. ‘CAUTION: Use only glycol-based brake fluid matching the factory fill brake fluid. You could damage braking system if you use ‘or add other types of fluid. Do not use old or used brake {luld, oF tluta trom an unsealed container. ‘Changing Replace brake fluid by draining all braking system fluid and fil system with a recommended fluid before bleeding. For more information please refer to section § of Service Manual 99500- 60A10-01EMAINTENANCE AND LUBRICATION 08-14 Seratchet (torce of 20 go 44 pounds) 1. wast ingicator FRONT ul 4 whee! rotation (Radial tyres) ITEM 6-5 Handbrake lever and cable. Handbrake lever 1) Inspect points of ratchet teeth for any damage or wear. If damaged or worn, replace lever assembly. 2) Check that brake lever functions correctly and rises to correct, height. Adjust if necessary Handbrake cable Carefully inspect brake cable for damage Replace if damaged. For more information, please rofer to seotion § of Service Manual 99500-60A1-01 E. ITEM 6-6 Tyros 1) Inspect tyres for any uneven, excessive wear or damage. Replace if detective 2) Inspect air pressure in each tyre and adjust to specified pressure if necassary. 3) Rotate wheels in the manner shown. NOTE: + Inspect tyre pressure when cold, = Specific air pressure is indicated in Owner's manual. + Change tyres at recommended intervals. For more information, please refer to section 3F of Service Ma- nual 99500-60A10-01E. ITEM 6-7 Wheels and free wheeling hubs (if fitted ). Inspect each rim for dents, distortions or cracks. A rim with any of the above defects should be repiaced,MAINTENANCE AND LUBRICATION 08-15 ITEM 6-8 ‘Suspension system. + Inspect shock absorbers for cil leaks, dents or other. damage And inspects their mountings for weat. Change shock absorbers if necessary. + Inspect front rods for leaks. dents or other damage. + Inspect front control arms, balijoint dust covers for oilloss, loose or broken pars. Replace damaged or malfunctioning parts. + Inspect hal-shatt boot dust covers (wheel end and differential end) for cracks or other damage. ‘Change boots if necessary. “+ Inspect supension system for damaged, loose or missing parts. Repair or change detective parts or those that show signs of ‘wear of lack of lubrication. + Check torque of suspension nuts and bolts and tighten it necessary, Repair or change any defective parts. NOTE: For more informaticn on points to check, please refer to SPECIFICATIONS chart in Service Manual SECTIONS 3D and 3E 99500-60A10-01 . ITEM 6-9 Propeller shatts. 41) Inspect universal joint and axle shaft knurling for any looseness ‘or knocking when functioning. If any of the above anomalies are detected, change the defective part 2) Check tightness of propeller shaft nuts and bolts and retighten itnecessary. Propeller shaft nut torque specifications: ‘55 Nm (5.5 kg.m, 40 Ib.ft)MAINTENANCE AND LUBRICATION 08-16 SAE viscosity graph ‘Transmission and Transfer Casing Temperature ITEM 6-10 Transmission oll Inspection 1) Inspect transmission for possible oil leaks. 2) Park vehicle on horizontal ground before checking level. 3) Remove plug (2) to check oil level. The level is correct if a ‘small amount of oil seeps over tho of edge of the hole on removing plug. If no oil comes out, add a suitable quantity Oil change 1) With vehicle horizontal, drain oll rom transmission by removing drain plug (1) 2) Clean oil on plug and housing and apply sealer 99000-31110 to thread. Replace plug and tighten as specified, 3) Add oil to the level of filler plug (2) before replacing the plug and tightening to the specified torque. Torque specitications: Plug (1) 23 Nm (2.3 kg.m, 17 Ib.ft). Plug (2) 23 Nm (2.3 kg.m, 17 Ibf). Plug (3. and 4) 23 Nm (2.3 kg.m, 17 Ib.ft) Use of gear oll 75 W - 90, type API GL 4 Is strongly recommended Olt capacity Transmission: 1,5 litres (2.6 Imp. pints). Transfer case: 1.7 litres (3.0 Imp. pints). ITEM 6-12 Transfer case oll, Note: Proceed as for transmission (previous point), removing oil level (3) and drain, (4) plugs. ITEM 6-13 Differential oil. Inspection 1) Make sure vehicle is situated on horizontal ground, 2) Remove oil level and filler plug (2) If level is correct, a small amount of oll should seep out of the hole. Wo oil comes out, add a sultable quantity. oll change 1) With the vehicle situated horizontally, drain oil by removing plug (1). 2) Clean oil rom plug (1 ) and housing, apply sealer 99000-31110 to thread, tt plug to specitied torque. Pour in sutable quantity of oil to reach level and replace filler plug (2). applying sealer indicated as specitied.DIFFERENTIALS —— to 90 2 to 0 0 2 wo wo ee 74, se 8) 68 OB (1e Temperature MAINTENANCE AND LUBRICATION 08-17 Torque specifications: Front plug (1) Rear plug (1) Front plug (2) Rear plug (2) 23.Nm (2.3 kg.m, 17 Ib.ft). 22 Nm (2.2 kg.m, 16 Ib.ft). 40 Nm (4.0 kg-m, 29 Ib. 43 Nm (4.3 kg.m, 31Ib-ft). Use of hypoid gear oil 80 W - 90, type API GL 5 is strongly recommended. Oil capacity: Front axle: 1.0 litres (1.8 Imp. pints). Rear axle: 22 litres (3.9 Imp. pints). ITEM 6-14 Steering system. 1) Inspect steering wheel for play, noise or looseness while vehicle is maintained on the ground with wheels pointing torward Steering wheel free play: 10 - 30 mm (0.4 -1.1 ins.) at rim. 2) Inspect universal joints on steenng axis tor noise, looseness or damage. If any problem exists, replace defective part tor new one. 3) Check nuts ang bolts are correctly tightened and re-tighten it necessary. 4) Inspect steering gear mechanism for any ol! leaks. ifthere are, inspect oil level in gear mechanism. 5) Inspect steering linkage dust covers for damage (leaks, loose elements, breaks, etc). Replace any damaged dust covers, 6) Inspect wheel alignment.MAINTENANCE AND LUBRICATION 0B. ITEM 6-15 Power assisted steering. 1) Visually check power steering system for liquid leaks and ‘damaged hoses. Replace or change any defective parts. 2) Unscrew filler cap and check level marked by dipstick, which should be between MAX and MIN levels. If it is below MIN level, fll up to MAX level NOTE: ‘+ Ensure P/S, DEXRON-II or equivalent flui + Fluid level should be checked when cold. is used. 3) Visually inspect power steering pump belt for cracks or wear. 4) Check belt tension. For further information on this subject, please refer to section 3B3 of Power Steering System Service Manual 99500-60A10-01 S. Adjust or replace belt it necessary. ITEM 6-16 All locks and hinges. Lubricate door hinges and inspect locks for correct functioning lubricate as appropriate,MAINTENANCE AND LUBRICATION 08-19 FINAL INSPECTION Carry out a road test in a safe place. WARNING: When carrying out road tests, make sure they are In a safe place with no passing pedestrians or vehicles. This will reduce the possibility of accidents, 1) Starting engine. (Check that engine stans and runs without problem, 2) Clutch and clutch cable. Check the following points with engine running. * Test all six gears and ensure they all change without difficulty or soraping. ‘+ In 4” goar, engage the hand brake, accelerate a little and try to slowiy release the clutch pedal. The engine should stall and the vehicle remain stationary. This means the clutch does not slip. It fon releasing the cluich the engine ties to keep running, then the clutch is slipping. 3) Brakes. Check the following points when driving. + There are no abnormal noises when braking. = The same brake power is applied to all the wheels. + The vehicle does not tend to veer one way when brakes are applied firmly. + Wheels do not lock. + No one whee! locks up independently of the other wheels on the vehicle. 4) Hand brake Check hand brake functioning by stopping vehicle ‘on pronounced slope and fully engaging the hanalbrake, If vehicle moves, adjust the hanbrako, 5) Engine. + Check tnat It responds quickly in alt gears. * Check that engine does not produce abnormal noise or vibration, 6) Body, wheels and transmission system. Check body, wheels and transmission system for abnormal noise or vibration. 7) Meters and indicators Check speedometer, mileometer, fuel gauge, temperature gauge, ete. for correct functioning, 8) Oil pressure and charge lights. Check these lights go off when engine starts. If any come on, with the engine running, there is some problem with the engine lubrication system or the charging system 9) Safety belt. Inspect safety belt system, including belts, buckles, latch plates, retractors, anchoring, etc, 10) Body. Check the following points with the vehicle stationary: + Bonnet catch. * Door closure. + Scat sliding and rectining. + Battery electrolyte level, + Windseroon wipors. RECOMMENDED FLUIDS ENGINE OIL Multigrade 100/40 API CD or CE or CF-04 ENGINE COOLANT DINAMIC - DINAGEL - 9103 BRAKE FLUID DOT-3 or SAE J-1703 ‘TRANSMISSION API GL4 SAE 75W-90 TRANSFER CASE API.GL4 SAE 75W-90 DIFFERENTIALS APIGLS SAC 80W-90 POWER ASSISTED STEERING Equivalent to DEXRON+IPOWER ASSISTED STEERING PUMP 382-1 SECTION 3B2 POWER ASSISTED STEERING PUMP NOTE For topics not covered in this section, please refer to the relevant section of the Vitara Service Manual outlined in the pretace. TABLE OF CONTENTS PUMP REPLACEMENT sso penninnnncnnennnnnnnnennnninnnnennsney SBRRPOWER ASSISTED STEERING PUMP 382-2 PUMP REPLACEMENT Disassembly 1) Disconnect negative cablo from battery 2) Remove inner soundproof plate. 2) Slacken two bolts on the side and lower part of the alternator tensioner and remove belt 4) Remove attaching bolts and positive and altemator drive ca. bles. . '5) Remove lower and upper attaching bolt of the alternator to support. 6) Release inlot and outlet pump lines and collect liquid in a tray. 7) Turn power assisted steering pump pulley and slacken through hole one of the bolts on the side. Remove the other two attaching bolts. 8) Detach power assisted stearing pump. Assembly 1) Reverse order of the disassembly process. 2) Tighten attaching elements to their torque specification. Torque specification for pump attaching bolts to support: 20 Nm (2.0 ka.m, 15 Ib.ft). Torque specification for power assisted steering pump pressure lines: 50-70 Nm (5.0-7.0 kg.m, 36-51Ib.ft). 8) Tighten belt as indicated on page 08-4. 4) Add power assisted steering fluid in the reservoir, Start engine and turn the steering wheel several times in both directions, ‘adding fluid to the reservoir until the level is maximum. Power assisted steering fluid DEXRON-IIFRONT SUSPENSION 20-1 SECTION 3D FRONT SUSPENSION CONTENTS FREE WHEEL HUBS General description Manual free wheel performance 30-2 30-2 30-2 ‘Automatic tree whee! performance 30-2 Free wheel types description 30-3 Installation of "A" type manual free wheel . 305 Installation of "B” type manual free wheel.. 30-7 Installation of “A” type automatic free wheel 30-9 Installation of "8" type automatic free wheel 30-11 Replacement of “A’ type manual free wheel 30-13 Replacement of "B" type manual free whee! aD-14 Replacement of "A" type automatic free wheel ... 30-15 Replacement of "8" type automatic free wheel... 3D-16 RECOMMENDED TORQUES 30-17 SPECIAL TOOLS 3017FRONT SUSPENSION 30-2 FREE WHEEL HUB GENERAL DESCRIPTION ‘A free wheel hub disconnects the front wheel from its drive-shatt when two wheel drive is required yet allows reconnection when four wheel drive is used. This device is located at the end of each front drive shaft where it replaces the normal drive flange. Using a tree wheel hub reduces front tyre wear, and prevents the front wheels tron driving the drive-shatts, differential and front drive. This reduces noise and wear and aids fuel economy. ‘There are two types of free wheel device. A manual type Is operated by hand whilst the automatic types connect afd disconnect the drive wihout driver intervention whenever 4H or 4L are selected. MANUAL FREE WHEEL PERFORMANCE ‘The manual device is located at both ends of the front drive shatts and has a knob located at the center that can be rotated to either the FREE or LOCK positions. When the knob is set to its FREE position, the drive shaits and the wheel are disengaged and the front wheel rotation is free. When itis set to its LOCK position the axle and the wheel are engaged. Refer to the Owner's Manual, provided with the vehicle for further information AUTOMATIC FREE WHEEL PERFORMANCE This device is also located at the end of each front drive shaft. Whenever driving torque is trasmitted to the front drive shafts (when 4H or 4L is selected and the vehicle is driven) the internal mechanism automatically connects the drive- shafts with their respective driving wheels. The initial change from two to four wheel drive must be made with the vehicle stationary although sibsequart changes between 4H and 2H may be made on the move. The initial change takes place within 2 metres of vehicle movement fron stationary. To disengage the free wheel device set the transfer lover in 2H and the gear lever in reverse position. Approx. 2 metres later the locking device is disconected. To engage the free wheel in reverse, set the transfer lever in 4H or 4L and move backward a short distance. Now the unlocking will be produced by selecting 1* gear, the transfer lover in 2H and moving forward some metres.FRONT SUSPENSION 30-3 FREE WHEEL HUB TYPES DESCRIPTION ‘There are two types of free wheel hub, a manual driven one and an automatic one, and for each type there are two versions, so that, in total there aré four kinds of free wheels hub. ‘The installation of one or other type depends on the vehicle specification. The installation and maintenance method changes from one to another; make certain you are using the correct method by consulting the relevant section. CAUTION: * Make certain that the same type of free wheel hub is fitted to each side of the front axle, * Uf free wheel hubs are fitted, be suse that both are in the LOCK” or “FREE” position. * Never dismantle a free wheel hub as this may adversely affect its performance. This does not include the removal of the cover to lubricate the hubs splines. " Type manual fee wheel LOCKED position FREE postion whee! body oo clutch OFF ccluten ON o-ring altanle pub Type manual tree wheel 1. Knob 5. tntemnal driving gear 12. Retatner ring 19, Rear spring plate 2 ain spring 6. Cluteh ring 40. O-ing 44. Free wheel assy 3. Knob screw Return spring 11, Slotted nut 4 Knob nut Bearing 12. Antirotation springFRONT SUSPENSION 30-4 Type automatic tree whee!. ice i . 4 cs We f lL ”. oS 21 tom 1. cover 6. suaing gear 11. O-i0g 16, Driving washer 2.Cam 7. riving gear 12. internal brake 17. Elaatie ring 2. Retainer 8. Return spring 13. Retaining ring 18, Retaining plate 4. Screw 9. Change spring 14 External brake 48.0-ring 5. Bearing 10. Sustaining spring 15. Nedle bearing 20, Whee! hub "8" Type automate tree wheel wu Rie (esin) 1. Wavy return spring ‘5. Wavy spring box 2, mobile cam 15. check spring 2. Bearing 6. Cluten box ring 40. Fixcam 44. Plate Internal driving gear 7. Retaining ring 41 Oring $B Assy 4 clutch ring 8 Follower cam 12 Stotted nut NOTE: Some vehicles may incorporate the hub bearing retaining system consisting of nut (not slotted) and safety washer. This mechanism is compatible with “A” and “B” manual driven free wheels and with * type automatic ones. For “B” type automatic free wheel it is essential that a locking system ing of slotted nut, check spring and plate is used as shown above.FRONT SUSPENSION 30-5 =A" type manual foe wheel FREE position ong wether pes cover serow Serew ond srecher tock cover (1) lure (2) Se FREE INSTALLATION OF “A” TYPE MANUAL FREE WHEEL HUB Disassembly 1) Jack the vehicle and remove the wheel, it necessary. 2) Remove the crive-shaft and hub attaching flange. Assembly 4) Align the “O” mark on the free wheel hub knob with FREE: position. Detach from the hub body the free wheel hub cover assy, 2) Install the free wheel body assy on the wheel hub, Torque of attaching screws: 25 Nm (2.5 kg.m, 18 Ib.ft) 3) Chech that the gasket is aligned correctly and install the cover assy on the body assy, so that follower stopper pins of the driving roller are located in the arooves of the body assy. NOTE: Before installing the cover assy check the following points: + The “O” mark of the kno! FREE position. + The clutch (2) is located toward the cover side (1). + There are only two grooves to accomodate the follower stopper pins.FRONT SUSPENSION 30-6 Fate ond tock 4) Attach the cover assy on the body assy by means of cover screws. Torque of the cover attaching screws: 10 Nm (1.0 kg.m, 7 Ib.ft) 5) To check the performance of the free wheel, jack the front end of the vehicle and move the knob between FREE and LOCK positions, checking its free movement. Also check, by hand. turning, that the wheels remain attached to the halt-axie in the LOCK position and release in FREE position. MAINTENANCE SERVICE The vehicles provided with free wheel are subject to the following periodic checks. In order to check the performance of the free wheel hub, jack the front end of the vehicle, move the knob between FREE and LOCK positions, and check its free movement. Also check if the wheel operates correctly with the knob in FREE and LOCK positions by turning the wheel by hand. Mfnecessary, remove the tree wheel cover and grease each sliding surface using lithium grease or grease after cleaning each sliding part LITHIUM GREASE ‘SUZUKI SUPER GREASE A (99000-25010) If the performance does not improve after greasing, rework or replace the damaged part. ‘CAUTION. The hubs must not be packed with grease.INSTALLATION OF “B” TYPE MANUAL FREE WHEEL Disassembly 1) Jack the vehicle and remove the front wheels. 2) Undo the six bolts each sige and remove the front axle drive flanges. Assembly 1) Check that O-ring of the free wheel hub is not damaged and is correctly located. 2) Place the free wheel in FREE position by rotating the knob. 3) Clean the contact surfaces of the hub and the free wheel hub. 4) Intall the free wheel hub using the screws supplied witch must be tightered to the specified torque.” Torque of the free wheel hub bolts: 33 Nm (3.3 kg.m, 24 Ib.ft) 5) Check the following: + The knob actuates correctly and changes freely from FREE to LOCK position and vice-versa. + Tho wheel turns freely and it is not linked to the halt-axle when the knob is in its FREE position. + The free wheel assy is linked to the half-axle when the knob: is in its LOCK position.FRONT SUSPENSION 30.8 4) Replace the road wheels and torque the nuts to the specified value. Torque of wheel nuts: 95 Nm (9.5 kg.m, 69 Ib.ft) MAINTENANCE Jack the vehicle and check that the tree wheel operates in FREE and LOCK positions. by turing the wheel. It defective replace the tree wheel assy. CAUTION Hubs must not be grease packed.FRONT SUSPENSION 30-0 cuore 2. Free wheel brake aéty. INSTALLATION OF “A” TYPE AUTOMATIC FREE WHEEL Disassembly 1) Jack the vehicle and remove front wheels. 2) Remove drive-shatt and hub mounted drive flanges. Assembly 41) Check the O-ring of the free whee! hub for damage and correct location. 2) Install the free wheel hub aligning it with free wheel brake assy colter and with sleeve cotter. 3) Install the free whee! subassy matching the marks of the brake assy and subassy, CAUTION Make certain the marks mentioned above are aligned, if not, they may interfere with each other and cause damage. 4) Torque the free wheel hub bolts to the specified value. Torque of the bolls: 33 Nm (3.3 kg.m, 24 Ib-ft). 8) Install front road wheels, (if removed) and torque the attaching ‘nuts to the specified value. Torque of wheel nuts: 95 Nm (9.5 kg.m, 69 Ib-ft). 6) Lower the vehicle and perform the checks mentioned in the following paragraph.FRONT SUSPENSION 30-10 Performance checking Confirm the performance of the free wheel hub by means of the following tests: 1) Set the transfer box lever in 4H or 4L and slowly move the vehicle 2 metres or more forward. 2) Jack the vehicle front and check that the drive-shaft moves with the wheel when itis turned by hand in a clockwise direction (counterclockwise for the left wheel). 3) Lower the vehicle 4) Sot the transfer lever in 2H and slowly move the vehicle 2 metros or more backwards. 5) Jack the vehicle front and check that the drive-shatts do not move with the wheels when one are turned by hand in a clockwise (counterclockwise for the lett wheel) direction. 6) Repeat the steps 1) to 4) when revase gear in selceted in 4H or 4L. In this condition the hub should lock in the reverse direction and unlock when moving forward. Hf detective, replace the free whee! hub assy. MAINTENANCE Periodically check the performance of the free wheel hub following the steps above and replace them if required.1. interlocking. 2. Suewdsiver FRONT SUSPENSION 3D-11 INSTALLATION OF “B” TYPE AUTOMATIC FREE WHEEL Disassembly 1) Jack the vehicle and remove the wheel. 2) Remove the axle and hub attaching flange. 3) Remove the hub bearing interlocking piate by loosening the four screws. 4) Withdraw the hub bearing nut using a suitable tool 5) Witharaw the hub bearing safety washer Assembly 4) Install the spring washer (supplied with the free whee! hud assy), on the sieeve: aligning the tab in the groove. This washer may be instated in any positon, 2) Install the antirotation spring washer. (supplied with the free wheel Aub assy), on the sleave, The tab of the washer must be located in the groove and point outwards. 3) Install the slotted nut, supplied withthe free whee! hub assy, on the sleeve and tighten itby handFRONT SUSPENSION 30-12 4) Install the special too! (09943-0610) consisting of two parts attaching it to the hub by means of three bolts and matching the edges of the wrench with the slotted nut grooves. 5) Torque by hand the three tool attaching screws in the previous position, 6) While turning the wheel hub by hand, torque the slotted nut Using the special tool to the specified value. Torque specification for nut: 210 Nm (21.0 kg.m, 152 Ib.ft) 7) Check that the O-ring of the free wheel hub is not damaged and is correctly located ‘Check that the contact surfaces of the tree wheel hub and the hub are clean, 9) Install the free wheel hub matching its edges with the groove in of the slotted nut, already instaled on the hub. 10) Torque the screws supplied with the free whee! hub to the specified value, using a cross pattern. 8) Torque specification for the free wheel attaching screws: 33 Nm (33.0 kgm, 24 b.ft) 11) Install the wheels and torque the nuts to the specitied value. Torque specification for wheel attaching nuts: 95 Nm (9.5 kg.m, 69 Ib.ft) Performance Checking Use the same method as previously described for the “A" type automatic tree wheel.FRONT SUSPENSION 30-13 ca ape panel REPLACEMENT OF “A” TYPE MA- bahia NUAL FREE WHEEL HUB Disassembly 1) Jack the vehicle and remove the wheels if required. 2) Set the actuating knob of the free wheel hub to its FREE position, 3) Remove the 6 screws attaching the wheel to the hub. Assembly 1) Refer to steps 1) to 5) provided for the Installation of "A" type ‘manual free wheel hub, (Section 30-5)FRONT SUSPENSION 30-14 ————— SSS REPLACEMENT OF “B” TYPE MANUAL FREE WHEEL HUB Disassembly 1) Jack the vehicle and remove the wheels, 2) Set free wheel hub actuating knob to “FREE” position 3) Remove the 6 screws altaching the free wheel to the hub, Assembly 1) Perform the operations 1) to 5) provided for the installation of the “B" type manual free wheel (Section 30-7),FRONT SUSPENSION 30-15, 1. Free wheel subasey. 2. Free wheal broke sy 2. Brake spring 3. Deduiching plato REPLACEMENT OF “A” TYPE AUTOMATIC FREE WHEEL Disassembly 1) Set free wheels in free position (lransfer lever tw 2H position ‘and move the vehiole backwards 2 metres or more), 2) Jack ihe vehicle and, if necessary, remove the wheel 3) Remove the free wheel subassy and free wheel assy. Assembly 41) Refer to steps 1) to 6) of the installation of "A" type automatic tree wheel and performance checking. (Pages 3D-9 and 3D-10).FRONT SUSPENSION 30-16 REPLACEMENT OF “B” TYPE AUTOMATIC FREE WHEEL Disassembly Free wheel assy 1) Jack the vehicle and remove the wheel. 2) Remove the six screws attaching the free wheal to the hub and withdraw the free wheel. Bearing retaining system necessary remove the slotted nut, the antirotation spring washer and the spring washer following the steps below: 4) Install the plate and stotted wrench assy (tool ref.09943-06010) on the wheel hub, aligning the edges of the virench with the grooves in the slotted nut. 2) Torque the three plate attaching screws. ‘Torque specification for plate attaching bolts: 2.5 Nm (0.25 ka.m, 2 Ib-ft) 9) Tum the slotted nut counterclockwise 2 complete turns in order to loosen it from the antirotation spring washer. 4) Remove the special tool attached to the wheel hub, 5) Remove the slotted nut, the antirotation spring washer and the spring washer. Assembly 1) Perform the operations 1) to 6) indicated for the installation of the “B" type automatic free wheel (Page 3D-11) (Only if the spring washer, retaining spring washer and slotted nut assy has been replaced) 2) Install the free wheel assy as described in stops 7) to 11) of the installation of “B" lype automatic tree wheel (page 3D-12). 3) Undertake performance checks descrived on Page 30-10.FRONT SUSPENSION 30-17 SPECIFIED TORQUES TORQUE ELEMENT kgm | Nm. | tbat Hub attaching nuvolotted nut 21_| 210 | 152 Fixing late screws oz | 25 | 2 Attaching bots ofthe free wheel (B™ type manual and"A”and"8' types automatic) | 33 | 33 | 24 ‘Atteching bolis of the flange and “A” type manual tree wheo! 2s [2s | 1 HUB ATTACHING NUT. FIXING PLATE SCREWS REE WHEEL ATTACHING Beate VN @, %© "© rusnoe ArAcuna srs euorseonat SPECIAL TOOLS o fe Oj : oxo coses0si0 SLOTTED NUT TORQUE TOOLBRAKES 5. SECTION 5 BRAKES NOTE: For topics not covered in this section, please refer to the relevant section of the Vitara Service Manual sections outlined in the preface. LIST OF CONTENTS GENERAL OUTLINE 52 VACUUM CIRGUTT....... 53 CHECKING VACUUM PUMP... 5a REPLACING VACUUM PUW>P...... oaBRAKES 5-2 GENERAL OUTLINE 30 VEHICLE 5D VEHICLE Servo brake 5 way valve, LS.PV. valve. Rear axle Brake disc and drums,BRAKES 5.2 VACUUM PUMP CIRCUIT AIRFLTER TUBE YO TUREO ENGINE RESPIRATION. roturso..__[ COMPRESSOR ure SOUND, chamaer Beer teleletcr n 12, 13 14. 16, ‘SERVO BRAKE VACUUM LINE ‘SERVO BRAKE INTERCONNECTION LINE VACUUM PUMP EXHAUST LINE VACUUM PUMP INTAKE LINE VACUILIM LINE Not AIR ADMISSION DIVIDER ELECTRIC EGR VALVE LINE SOLENOID ELECTRIC VALVE ELECTRIC VALVE VACUUM TUBE LINE EGR VALVE EXHAUST MANIFOLD EGA VALVE TO DIVIDER LINE VACUUM LINE VACUUM PUMPBRAKES 5-4 To vacuum pump CHECKING VACUUM PUMP 1) Remove lower soundprooting plate of engine. 2) Make sure that belt is correctly tensioned. 3) lun the engine and check, that braking is sufficient. 4) If braking is unsatisfactory, remove suction lines connecting brake servo with vacuum pump and install a bypass vacuum gauge. 5) Rev engine to 1000 rpm and check that vacuum level is close 10.570 mm Hg. 6) Ifitis not, check for: = Possible leaks from suction lines. + Possible obstruction of pump outlet hose. REPLACING THE VACUUM PUMP Removal 1) Remove lowor eoundprooting plate of engine, 2) Remove suction and outet fines. 9) Slacken vacuum pump tension and mounting bolts. 4) Rock vacuum pump towards engine and remove belt. 8) Romove bolts and dismount vacuum pump. Installation 41) Install by reversing order of above operations, 2) Tension vacuum pump belt and tighten attaching bolts + Belt tension: 12-14 mm (0.5-0.55 in), with pressure of 100 N (10 kg, 22 Ib) + Idler pulley-depressor torque specifications: 18-23 Nm (1.8-2.3 kg.m, 13-17 Ib.tt) + Idler pulley-engine attachment bolt torque specifications: 18-23 Nm (1.8-2.3 kg.m, 13-17 Ib.ft).ENGINE 6-1 SECTION 6 ENGINE LIST OF CONTENTS GENERAL INFORMATION . ENGINE DIAGNOSIS 63 REPAIRING ENGINE = GAS COOLING SYSTEM 6B EMISSION CONTROL ... 6c STARTER SYSTEM 6G CHARGING SYSTEM 6HGENERAL REPORT 6-2 GENERAL INFORMATION CLEANING INSTRUCTIONS AND POINTS OF CAUTION ‘When repairing the engine please pay attention to the following points: + Order of injection in cylinders is 1,3,4,2. Cylinder no. 1 is situated at rear of engine and no. 4 at the front next to the radiator, + Before carrying out any general repair work, diagnose the engine (compression pressure measurement, leak check, tune up timing, pump setting and fitting, turbocompressor functioning, etc.), to help you isolate the problem, ‘Always disconnect negative battery cable, to prevent short circuits. + All operations related to fuel system must be carried out in well ventilated areas and adopting the appropriate safety measures. + During disassembly/assembly or when storing parts, protect cylinder heads. cylinder block, fuel distribution pump. turbocompressor, etc to prevent accidental entry of impurities and foreign material, * On removing engine components, please keep in order so thal they are placed in original position during stet reassembly. + Components like the turbocompressor are non-serviceable and the whole unit must be replaced. The injection pump must be serviced at an Official Lucas Service Centre. * During installation, use engine oil to lubricate surfaces exposed to friction, This will protect engine during initial functioning. + When removing electrical connectors do not pull on cables. Remove locking clamps first and pull at both ends. NOTE: - Unless otherwise stated, measurements are expressed in mm. and inches and degrees centi = Unless otherwise stated measurements are expressed in Nm, kg.m and Ib.ft.ENGINE nIAGNOSIS 62° ENGINE DIAGNOSIS. Valve stu omer + "Blocked exaust pipe + Broken ming bolt. Symptom Probable reason Correction Engine does not start Detective fuel system (engine turns over + Lack of fuel tank Add tuo correctly) + Diy fal titer Remove + Water or air in fuel lean + Diny or blooked tank and fv! lines Ropair Fuel aistibution pump Defective fue euot solenci. Replace + Dolectve fuel dstibution pump adjustment. Adjust 2 Aiitake Repair + Detective fuel dstibuton pump. Replace + Delectve ele ajusiment Agust 2 Matluncton in cols start mechanism ‘Adust ‘+ Manual stop contol locked Repair Low compression Incorrect valve clerence Adjust Loss of compression through valve seat Valve springs damaged or worn Los of compression through evlinder head gasket Piston rng stuck or damaged Piston, ng oF evtinaer worn Engine idles erratically | Detective tuel system + Lage of fue in tank + Diy Wet finer + water or an er Fue! distribution pump Injection tines = Cracked tue ines Injectors ozaie-helder + Needie nozzle leaks, Engine overheating otner + Low compression Detective et euotsolendi, Datecsive fue esibuton pump adjustment Detective fuel distibuton pump Iole speed baal adusted Detective thot cable ajustment Loose fel cstribuion pump clamps Residual flow (enistop) not property acjusted. Detective manual stop cont 1 Pressure measurement incorrect + Neadle stuck in one oF more nozzles + Incorest pasitoning of one or mare nozzles in 4 Injactr tock washers incorrectly fited, 2 Valve clearance incoreet ‘Grind valve seat Corrector replace Repiace pair or replace Hepace FRopiace piston ring or piston or recy cylinder Clean FRoplace and repair valves dd tet Clean o Remove Gwe place Adjust Repair Froplace Adjust ‘Adjust Tighten Repair Replace Respaie Adust Repiace Fopair place nozzle Repair ee Overhoating coction Adjust S09 previous pointENGINE DIAGNOSIS 6-4 ENGINE DIAGNOSIS {especialtes at ite) Blocked nozzles, lines oF connections. Engine overheating Symptom Probable reason Correction Excossive engine Detective fuel system movement + hic fiter elements blocked. Ciesn ot roplaco ean replace ‘Soe Overhasting section Fuel fter Water or arin titer, Repair + Blocked tor pl Fue! distribution tines + Cracks Replat 1 Loake through connections Repair Injectors +" lncotret pressure measurement Adjust + Needle tuck in nozzle. Replace nozzle + injector expping Replace + Lock washers incorrectly fie. Repair Fuel distribution pump + Loose pump clams. Tighten + Detective fuel cut solenove. Fepiace + Detective pump adjustment Adjust + Alciniake, Repaic + Detective tue dstbution pump. Replace + Idling speed incorecty adustes. Adjust 2 Throttle cab Incorectly adjusted. ‘ajust + ant-stalinconecty adjusted ‘Adjust + Defectve manual stop mechanism, Repae Low compression Previously described others + Incorrect vaive clearance. Adjust 1 EGR incortect perormartce Repair + Loose engine mounts. Tighten + Timing beltrottonae correctly ajuet Engine accelerates by | Lubrication ltsel from idle + Oillevel too high Correct Fuel distributton pump Detective ful distribution pump, Repiace Engine stalis when Fue! aistabution pump decelerating + idle speed incorrect adjusted. Ast + Amistait incorrect adjusted Adwust + Cota ie incorrect aajusted ‘gust + Gold ile thormastatic element Feplace and adjust ‘ralunetioning + Detective fuel disibution pump. ReplaceENGINE DIAGNOSIS 6-5 ENGINE DIAGNOSIS ‘Symptom Probable reason Correction Engine erawis. Detective fuel system Previously deserived Erratic running Fuel distribution pump + Inoortect adjustment of ie speed Adjust + Detective adjustment Adjust Dorectve tue astibuton pum. opiace Injectors + Injaction tines leaks, Correct + Detective injactors. Replace + tncorecty ted ook washers. Correct Low compression Praviously desert others + Valve clearance incoract gust Excessive oll consumption| Intake system + airfiter element blocked place + ir itake line blocked Repair Lubricating system + Exeeaave ol lave. Aas +. Crankease ventilation blocked, Repair Turoecompressor + Otdrain tines Dockes. Repair + Dofectiveturnocomprassor Replace otners + Plungers or guises wer, Replace + Valve guide retainers worn, replace + _Fiston. piston ring or evinders wom. Replace Excessive fuel Detective tus! system consumption + Fuel leaks in tank ones, Correct Fuster booked Replace Fuel distribution pump + Defective adjustment. Adjust + Ice speed 00 nigh, ‘Adhust Injectors + Incorrect pressure measurement, Adjust + Nozzle stuck Repiace ‘Incorrect nstalaton of nozzles tn holder. Repair ‘+ Fuol leak rom nozzte needle. Repiace Alr intake 2 Ai fifor blocked Replace Low compression Previously described others + inoortect valve seating Grind valves + Brakes onaing Hopair + Lom yee pressure. Adjust Clutch sips. Raplace ‘+ Dolectve performance of EGR system. Repair Blue fumes when hot, | Lubrieation Idling or decelerating Excessive lavel af engine oi eat ‘+ Grankease ventiaton system blocked. Repair Turbocompressor + Oldrain fines blocked Repair + Defective tursocomprossor RepiaceENGINE DIAGNOSIS 6-6 ENGINE DIAGNOSIS Symptom Probable reason Correction ‘Blue tumes wnen not, lang oF decelerating make system 1+ Air fiter element blocked. + Ririntake line blocked Fue! distribution pump + igcorcect tue eistiouton pump aalustment + Detective tue distribution pump. Injectors + Detective o¢ incorrect ited injector gasKews, + Detective injectors. Fuel circuit + Filter blocked Low compression Replace Repair ‘Ast Repiace Corcoct Replace Repiace Proviously described {no black fume) Fued distribution pump + Lack of travel in trotte cabte. adjusted, + Defective fu atsinbution purr. Fue! system + Diy ter + Aiclnvexcui Turbocompressor others 1+ Tncorrect distribution adjustment Acjust + tmrrect valve ceaiance, ‘Aciust Lack of powor Air intake system (Black fume) + Rictiter blocked. Replace 1 Intake flexible tine chocked. Replace Fue! system = Diy titer place + Ain circus. Repair Fue! distribution pump : + Detective fuel sistibution pump adjustment, ‘Adjust + Defective fuel eistibution pump. Replace Injesto 2 Detective injectors, Ropince + Crushed lines (connections over ighted}. Repiace Turbocompressor = Turbo to divider tine blocked. Ropar o piace + Airleak trom turbo eivder manila Repair or replace + Leaks from intake manifold gasket. Repair or replace + Gas leaks between exhaust manifol and turbo. | Repair + Gas leaks trom exhaust manifold Repiace + Gas leaks rom surbooomproceor. Ropiace + Mallunetioning f olat waste gate. Replace ol and titer. + Diy turbocompressor turbine. Replace turbocompresser + Detective turbocompressor Repiace Low compression Previously doceribed ‘otners + Incortect valve carance. Aust + Distibution incorrect adjustment. Aust + EGR elect valve noses Inverted. Repair + _ Exhaust pipe blocked, Repair or replace Lack of power Aust Adjust Replace Replace Repair ‘Spe lack of power (black fume) TurbocompressorENGINE DIAGNOSIS 6-7 —__— ENGINE DIAGNOSIS Symptom Probable reason Correction Low oil pressure Lubrication Inadequate ol vscosty Detective pressure swtch Insufficient oi (Ol pan pickup tubes blocked. Detective of pum, 7 Pressure coi! valve stuck Excessive moar in engiie pars Change viscosity Repair Replace defective parte Noises in engine Betore checking noises in engine, ensure that: “Injection pump is comecty | ‘ited + Inecter pressure + Conect ua is used + Conactalis uses Valve noises + Inadequate valve clearance. + Valve plungors and guides worn. ‘+ Valve spring woak or deteriorated. + Valve warped or bent Piston, piston ring and eylinder noises + Excessive wearin ston piston rngand ylndors. Connecting rods nolses + "Connecting rod bearings worn + Connecting red pins worn, 2 Connecting rod nuts lose. Adist Repair Replace Raft Roplace aftected parte Low ol pressure Prewausly described Crankshaft noises + Lowol pressure. Previously described 2 Engine main bearings worn. Repair + Crankshaft pins wor, opal 2 Engine bedpiate bolts loose. Repair + Exsessive cankshatt ond play Repair Noises in turbocompressor | Air intake system + ir intake blocked or losking Repair + Turbosompressor cvider noses blocked or Repair leaking + nlake mantel blocked ee teaking Repel Exhaust system 1 Exnaust eystom blocked. Pepa + Gas leek trom exhaust manifold Ropair ‘Turbocompressor + Gas lak (rom oxhaust and tubo manifold Repair + Gas leak tom exnaust mantra v0 Repair turbooompressor connection, + Datoctve timonompressot ReplaceENGINE DIAGNOSIS 6-8 ENGINE DIAGNOSIS + air titer blocked. Symptom Probabie reason Correction Overneating © + Front gil blocked. Eliminate obstacles + Detective ragiator thermo sensor. Replace + lagutfeient coolant Rott + Thermosiat not working or working incorrect, | Replace + Water pump voloctve, loco ‘+ Radiator blocked or leaking, ‘Clean, repair or replace Electrical system + Electric fan relays detective, Replace + Elects fan dct Replace Lubrication 2 Tnsutciont ongine ol Rott + Inadequate engine ol grade. Replace + Oiler Blocked, Ropiace + Oil pump detective, Roplaco otners + Brake diag Repair or repiaco 1 Delectve evinder head gasket. Replace lean or replaceENGINE REPAIR 6Ad-1 — SECTION 6A4 ENGINE REPAIR LIST OF CONTENTS IN THE VEHICLE, Ol level... Compression chock. Oil pressure check .. Turbocompressor and waste gato chocks \Valve clearance (checking) Valve clearance (adjusting) Timing Beit (replacement) Replacement ot fuel distribution pump... Replacement of cylinder head gasket... Oil sump, suction line and oil pump Air filer... Air intake system Turbocompressor (replacement) REMOVAL OF ENGINE BLOCK ENGINE BLOCK REPAIR Engine disassembly... Inspection of cylinder head Cylinder hoad. Repair... Cylinder block disassembly. Repair of cylinder block. Fitting cylinder block ... ‘SPECIAL TOOLS .. TORQUE SPECIFICATIONS .. oxENGINE REPAIR 604-2 Mini lva mor Mosinee mer ON VEHICLE CHECKS OIL LEVEL 1) Ensure that vehicle is on a horizental surface. 2) Start up engine and wait until it reaches a normal functioning temperature. Stop vehicle and wait 3 minutes. 3) Take out cipstick and check that oil is between maximum and ‘minimum levels. 4) Add any oil i necessary. NOTE: The difforance between maximum and minimum level ie 1.5 litres (2.6 Imp. pints) (approximately). COMPRESSION PRESSURE CHECK 1) Ensure that battery is fully charged. 2) Start up enginé and wait until it reaches a normal functioning temperature and then ewitch it off. NOTE: The compression check can be carried out from injector housing or heater housing, by using a comprossion gauge adaptor. ‘The compressor gauge must have a scale of at least 0-3923 K Pa (0-40 kg/cm’, 0-570 psi) 3) Disconnect all heaters, remove all injectors and attach compression gauge to first cylinder. 4) Disconnect the cut off solenoid from the jet pump. In vehicles with immobilizer, da not enter the code. 8) Activate ignition directly, without going through heater position and abserve compression levals on gauge 6) Repeat this operation in every cylinder. The correct level should be between the maximum and minimum indicated. Maximum compression 2941 K Pa (30 kg/m’, 427 psi) Minimum compression 2452 K Pa (25 kg/cm, 356 pei) Maximum difference between cylinders 490 K Pa (5 kg/em?, 71 psi) ” It compression in one or more cylinders is low, add 2 small Quantity of engine oil to the cylinder and repeat the test. 1) Ifthe compression level rises when ropeating the test, the piston, piston rings or the cylinders are defective, 2) If the compression level does not alter, the valve seats or valve clearances are defective. 3) Ifthe compression is low in adjoining cylinders, the cylinder head gasket might be defective, or the cylinder head distorted.ENGINE REPAIR 684-3 OIL PRESSURE CHECK NOTE: Betore checking oll pressure, examine the following: + Level of oil in oil pan, which should be between maximum ‘and minimum marks. © Olt quality. + Renew oil if discoloured or in deteriorated condition. ‘+, Repair if oil leaks observed. 1) Remove oil pressure switch trom cylinder block 2) Fit pressure gauge with a scale of at least 0-980 K Pa (0-10 kg/em, 142 psi) 2) Start up engine and heat up to normal functioning temperature. 4) Observe oll pressure fevel. ‘At 750 rpm 4196 K Pa (2.0 kg/em®, 28 psi) ‘At 2.000 rpm specification 343 K Pa (3.5 kg/em*, 50 psi) ‘At 4.000 rpm 441 K Pa (4.5 kg/em’, 64 psi) 5) After checking oil pressure, remove pressure gauge and fit pressure switch with new gasket tightened as specitied Pressure switch torque specifications: 30 Nm (3.0 kg.m, 22 Ib.ft) WARNING: Be careful working when engine is hot, high temperatures ean cause burns.ENGINE REPAIR GAS TURBOCOMPRESSOR CHECK Turbocompressor 1) Remove upper air filter cap and union between filter and turbocompressor. 2) Connect "T” bypass to pipes joining intercooler with relict valve, {as shown in figure, and attach pressure gauge 3) Fit air fitter and suction hose assembly 4) Set transmission in neutral and warm engine up to normal {functioning temperature . 5) Road test the vehicle and whilst ascending a slope check that pressure on gauge corresponds to specifield levels. At 1,000 r.p.m. 7 K Pa (0.07 kg/cm, 1.0 psi) AL 1,250 p.m. 11.5 K Pa (0.12 kg/cm, 1.7 psi) At 2,250 p.m. 30 K Pa (0.31 kg/om?, 4.35 psi) ‘At 4,600 p.m. 40 K Pa (0.41 kg/em?, 5.80 psi) 6) If pressure is below specified levels, check the following: = Leaks from connection between turbocompressor and exhaust manitold, + Air leaks from union between admission turbing and intercooler. RELIEF VALVE CHECK 4) Carry out operation (1) for checking turbocompressor. 2) Disconnect lines joining intercooler with reli valve and attach 2 too! to supply pressure as shown in igure. 8) Apply pressure up to maximum of 40 K Pa (0.41 kg/om?, 5.80 Psi). Obsorve that relief valve rod terminates travel when pressure is approximately 40 K Pa (0.41 kg/cm, §.80 psi). NOTE: Never exceed 40 K Pa (0.41 kg/em*, 5.80 psi) of pressure 4) Replace the turbocooler if the pressure is insufficient or if the relief valve functioning is incorrect.VALVE CLEARANCE (CHECKING) 1) Disassemble the following components ~ Negative battery cable, ‘Turbocompressor and intercooler union. Turbocompresor outlet line. Vacuum pump flexible line. Fuel floxible lines. EGR electric valve lines. Rocker arm cover. NOTE: ‘Valve olearanees should be checked with engine cold. Cylinder no. 1 is situated in the rear part of engine. 2) Turn engine in normal direction until valves of cylinder no. 4 are both open (cylinder no. 1 compressed). 3) Lock engine flywheel with tool (A) Ref. 00000V02008. In this position, check intake valve clearances on cylinders no. and 2 and exhaust valves for cylinders no. 1 and 3. 4) Potato crankshaft 360° (one completo turn ) and lock engine flywheel with a tool. Ret. 00000¥02008 At this moment cylinder no. 1 is crossed and no. 4 compressed Check intake valve clearances in cylinders no. 3 and 4, and exhaust valves for cylinders no. 2 and 4 CROSSED “es net Woet 4&4 CONTROL 2 es 3 Ez Valve clearance: Intake ' 0,15 mmm (0.006 in) Exhaust E 0,30 mm (0.011 in) Tolerance T 0,08 mm (0.003 in)ENGINE REPAIR 6A4-6 VALVE CLEARANCE ADJUSTMENT NoTE: Check valve clearances as indicated in 624-5. Disassembly 1) Remove negative cable from battery. 2) Remove electric fan connection next to engine 3) Remove the thermocontact connection. 4) Remove the dummy front engine mount. 5) Slacken the two upper fixing bolts of the radiator and move it backwards. 6). Slacken the four bolts of the electric an and take this out on the upper part. 7) Remove the left and right timing covers. 8) Rotate crankshaft until camshalt pulley and fuel distribution bump pulley with the timing bolt holes are aligned, fix stet with bolt M8 x 125 x 30. 9) Lock fue! distribution pump pulley using bolts TYPE M8 x 125'x 36. 10) Lock engine tiywheet with tool Ref. 00000V02008. 11) Remove lower soundproof plate. 42) Slacken tensioner and remove the vacuum pump belt. 13). Slacken the-tensioner and remove the alternator belt and ower steering pump. 44) Slacken the bolt and remove the crankshatt pulley and the lower timing cover. 15) Slacken nut (8) and bol (8) from the tensioner pulley mount- ing (10). NOTE: Before adjusting valve clearances, the actual clearances should be measured and recorded, 16) Insert a%/s" driver at point “a” and compress the bet tensioner spring to relax the belt tension, Lock it off with the batt (9)17) 18) 19) ENGINE REPAIR 6A4-7 Romove timing belt and detach camshatt pinion. Remove engine flywheel locking too! Ref. 00000V02008 and turn’ engine flywheel round until crankshaft keyway Is at 9 o'clock position. Remove of the following components and piace them in the ‘same order for assembly: = Camshaft bearing caps (1) = Oil seals?) = Camshatt (3) = Tappets (4) = Shims (5) Checking : 1) Taking account of the clearances obtained and after checking clearance and measuring thickness of each shim removed, determine the correct shim thickness by using the following example: EXAMPLE mn Clearance allowed 0,15 Clearance measured 0,25 Difference 0,10 Existing shim 2,425" Shim to be fitted 2,500 Play obtained 0,175 (7) 6ase stam, (vetve in rm) NOTE: 66 sizes of shim exist. The range of thickness varies from 1.650-4.000 mm (0.065-0.0158 in) 2) Fit shim and tappots proviously selected. NOTA: Apply MOLIKOTE G. PLUS RAPID to camshaft covers and recommended products for sealing the front and rear areas (a).ENGINE REPAIR 6A¢-8 cacedien-p-fs Assembly 1) Fit camshatt (3) with DIST label facing towards timing, and progrossivoly tighten camshatt bearing cap nuts (2) to torque specification, Torque specification for camshaft cap nuts: 18 Nm (1.8 kg.m, 13 Ib.ft) 2) Fit a new oilseal on the tool Ref. 00000V02007 locating it in the deeper recess. Instal the rear and front oilseais using the camshaft pulley bolt to press them into place, 3) Replace the woodruft key on the camshaft and fit the drive pulley with an M8 x 125 x 40 bolt, instal the pulley retaining bolt and tighten to the specified torque. Remove the locking bolt, Torque specification for camshaft pully bolt: 40 Nm (4.0 kgm, 29 Ib.ft) 4) Install belt and set timing (see timing Belt (Replacement) (6A4- 2) 5) Assemble the parts in the reverse order.ENGINE REPAIR 6A4-9 TIMING BELT (REPLACEMENT) Disassembly 1) Perform the operations: Op. Corresponding to valve clearance checking 6A4-5. Op.1t016 Corresponding to valve clearance adjust- ment 6A4-6. 2) Remove timing belt. Inspection 1) Ensure that tensioner pulley, fixed pulley and water pump pulley function correctly. (They should turn freely and without looseness). ‘Assembly 1) Ensure the engine flywheel, camshaft pulley and fuel distribution pump are locked in their position. 2) Assemble new timing belt, (14) in the following order: ~Crankshatt (12). ~ Fixed pulley (16). ~ Fue distribution pump pulley (7) ~ Camshatt pulley (6). = Tensioner pulley (10) = Water pump pulley (19). 3) Slacken bolt (9) and nut (8) ofthe tensioner pulley until it works freely and places pressure on the beit. 4) Pinch-tigaten tensioner pulley bott (8) anc nut (8). Timing adjustment 1) Remove tuel distribution pump and camshaft centering bolts, and flywheel locking tool. 2) Assemble bolt (1) and washer (2) at ihe end of crankshaft and rotate engine two complete tums (in normal engine rotation direction). Upon compietion of the second rotation, re-align the fluwheei mark and check the alignment of the camshaft {and tue! nolen distribution pump pulleys with their locking ott. 3) Place locking bolts in timing pinion, pump pinion and tool Ref. ‘00000V02008 of engine flywtiee! lock. NOTE: Engine must always be rotated in normal direction. If attaching points do not coincide (camshaft, fuel distribution pump and flywheel), repeat operation. 4) Release timing tensioner attaching bolt and nut and re-torque to thelr specttication. Tensioner pulley nut and bolt torque specifications: 18 Nm (1.8 kg.m, 13 Ib.ft)ENGINE REPAIR 644-10 5) Remove camshatt and {uel distribution pump pulley locking bolts. Remove bolt and washer from the crankshaft pulley, 6) Ascemble the three timing covers. 7) Clean and degrease the crankshaft pulley lock bolt and washer. 8) Apply LOCTITE FRENETACH to throad and friction area on the washer. Instal the pulley and reolace the pulley bolt and washer. Tighten to the specitied torque. Crankshatt pulley bolt torque: 40 Nm (4.0 kg.m, 29 lb-ft) PLUS 60? rotat 18) Remove engine flywheel retaining tool Continue assembly operations in reverse order to disassembly.ENGINE REPAIR 68-11 FUEL DISTRIBUTION PUMP REPLACEMENT Disassembly 41) Remove the following components: + Negative battery cable + Throttle and fast idle cable. + Fuel feed and overtiow lines. + Torque electric vaive connection. + Timing cover of (fuel distribution pump side). 2) Remove injection lines. . 3) Rotate crankshaft until position is fixed with too! 00000V02008 and itis possible to lock fuel distribution pump pulley with two bolts type MBx125x35. 4) Remove the bolts holding the pump fo the support, including ‘back bolt, and move the pump to maximum rear position (away from the engine), 5) Slacken lock bolt from the pump to the pinion. 6) Place tool Ref. 00000V02010 and fit it to the pump pinion with two bolts, slackening the bolt until it is completely moved. NOTE: For pump removal and replacement it is not necessary to time the engine. Assembly 1) Disassemble too! Ref. 00000V02010 2) Fit pump on the support and enter the drive shaft through the pulley placing the key in the keyway.ENGINE REPAIR 624-12 3) Fit nut to fix pinion to pump. Pinion to fuel distribution pump lock nut torque: 50 Nm (5.0 kg.m, 36 Ib.ft) 4) Fit ne three pump lock nuts to the pinion and tne back bolt using tool Ref. 0o000v02017. 5) Remove the two pinion lock nuts from the pump. 6) Perform pump tuning up, as indicated by points 1) to 10) of fuel distribution pump overnaul and 1) to 3) checking. Adjustment revision (pages 63-2 and 6E3-3) 7) Carry out assembly in reverse order to disassembly 8) Bleed system and start engine.ENGINE REPAIR 6A4-13, CYLINDER HEAD GASKET REPLACEMENT Disassembly 1) Carry out operations 1) to 9), indicated for Air Intake System, 6A4-16. 2) Carry out operations 2) to 14), indicated for Valve clearance adiusiment, 644-6 3) Disconnect, unclip and separate hoses and pipes connected to oylinder head, 4) Remove the collection bow! outlet of the first part of exhaust. 5) Remove the injection lines. 6) Slacken tensioner pulley (10) backplate bolt (8) and nut (9). 7) Insert a 6" drive into the recess in the tension pulley backing pate (10) at the point "a". Lever the plate against the tensioning soring (11) to relax the belt tension. 8) Re-fit the bol (9) to lock off the tension. 9) Remove the following elements: + Timing bet. + Camshatt pulley fastening bolt + Tensioner pulley (10), recovering the foliower (13) and spring «n. 10) Remove the tensioner spring lock upper bolt 11) Slacken the cylinder head bolts, progressively, following the ‘order shown opposite, 42) Remove the cylinder head and remove the gasket, using tools Ref. 00000V2015 and o0000V02016. Inspection 1) Please refer to engine assembly repair 6A4-25 and next section,ENGINE REPAIR 604-16 Oo OW 0. 9 a fe r\F\o 7\3 2) 6 / 19) 0.90% 0% 9 10, = O20" 07 OF Assembly 1) Turn crankshaft unti the pistons are midway up the cylinder bores and the crankshaft pinion key is at 9 o'clock position. 2) Once the inspection and repair is completed, fit new gasket and the cylinder head on the block. 3) Check tne lengths of each cylinder head bolts (as indicated in engine general repair section) and apply MOLICOTE G PLUS, RAPID on threads and washers (washers must always be ‘replaced with new parts) Fit the bolts. 4) Tighten head bolts using tools Ref. 00000V02015 and (0000002016. Apply as specified in sequence indicated. 20 Nm (2.0 kg.m, 14.5 Ib.ft) = Subsequent torque: 60 Nm (6.0 kg.m, 13.5 Ib.ft) ~ Angular: 180° 5) Continue assembly in reverse order to disassembly 6) Time the engine (pages 684-3)ENGINE REPAIR 6A4-15 OIL SUMP AND OIL PUMP Disassembly 4) Disconnect negative battery cable, 2) Lift the vehicle. 3) Remove lower engine soundpraot cover. 4) Drain the front diferential oil 5) Disconnect front axle assembly, and remove. 6) Loosen alternator tensioner and disassemble: = Belt, + Alternator. + Power steering pump, + Alternator mount and pump. 7) Remove plug and drain oil sump. 8) Loose bolts attaching sump to block and remove sump.ENGINE REPAIR 684-16 9) Laasen two attaching hoits and ramave the oil pick up. 10) Take out two oll pump attaching bolts (1), (2) and (3), noting, that bolt No.1 is different and serves to align the pump. 11) Remove oil pump. 12) Disassemble oil battle attaching bolts and extract if necessary. Assembly 1) Replace pump and chain. 2) Attach pump with batts NOTE: Bolt No.1 is different and aligns the pump. Torque specifications for off pump attaching bolts: 20 Ne (2.0 kg.m, 15.5 Ib.ft). 3) Continue assembly in reverse order to disassembly. applying sealing to oil sump and providing all elements with the corresponding torque specification. Torque specifications for oll sump attaching bolts: 20 Nm (2.0 kg.m, 15.5 tb.ft).ENGINE REPAIR 68-17 AIR FILTER Cleaning 1) Release air tiller attaching strap. 2) Disconnect four clips attaching upper body and extract filter. 3) Hemove cust by blowing compressed air onto oullet side of element Replacement 1) Release air filter attaching strap. 2) Disconnect four clips securing upper body and extract filter element 3) Install a new element in the air filter box.ENGINE REPAIR 604-18 OF AIR INTAKE SYSTEM Inspect 1) Disconnect battery 2) Remove air filter assembly and turbocompressor hose. 3) Remove the expanding cylinder, joining bolt and cooler gauge connector hoses. 4) Remove coolant expander reservoir 5) Disassemble turbocompressor and exhaust manifold. 6) Disassemble EGR eleciric valve and its hoses. 7) Slacken flexible hose clamps at the EGR side and the timing frame, 8) Disconnect turbocompressor oil drain line from its union with the block, and then remove the tuchocamprassor. 8) Slacken the 7 attaching bolts to intake manifold and remove this Inspection 1) Check cylinder head intake manifold mating surtaces tor flainess and evenness, replacing if necessary 2) If the inlet manifold is not being replaced, clean surfaces and apply Sealant before assembling to cylinder head, 3) Renew iniet manitold gaskets with new ones. Assembly 1) Assemble in reverse order to disassembly, following specitied torque specifications and following recommendations given, NOTE: Use jublllee clips for fixing EGR valve flexible hose. Torque specifications for intake manifold bolts: 25 Nm (2.5 kg.m, 18 Ib.tt). Torque specifications for exhaust manifold nuts: 15 Nm (1.5 kg.m, 11 bt. Torque specifications intake manifold flange nuts: 15 Nm (1.5 kg.m, 11 Ib.ft).ENGINE REPAIR 604-19 TURBOCOMPRESSOR REPLACEMENT Disassembly Perform the following operations: 1) Remove battery, coolant expander reservoir and air filter assembly and inlet ine. 2) Disconnect bolts (1) connecting EGR (2) to exhaust manifold. 3} Disconnect turbocompressor oil drain pipe at its union with engine block. 4) Disconnect turbocompressor flexible oil drain pipe. 5) Disconnect turbocompressor gas outlet elbow and plug its inlet and exhaust nozzles. 6) Slackon the six nuts attaching exhaust manifold to cylinder head. 7) Remove the fist exhaust section.ENGINE REPAIR 6A4-20 8) Disconnect the three bolts from the right side and the left side engine mount sitentblock. 9) Lift the engine with a crane towards the left, until the exhaust ‘manifold assembly and turbocompressor can be removed irom the right side. Inspection and replacement 1) Separate turbocompressor from the exhaust manifold by disconnecting the three joining bols, 2) Check the evenness of exhaust manifold, 3) Replace turbocompressor if itis defective. NOTE ‘Turbocompressor attaching nuts must always be replaced with new ones. Assembly 1) Carry out assembly in reverse order to disassembly, applying the torque specifications stated in the table al the end of this section, NOTE: When starting up engine, the following procedure is essential: + Disconnect the torque electric valve fuel at-off valve connection an the fuel distribution pump connection. + Switch on until engine oll pressure light goes off, - Connect again the torque electric valve fuel at-off valve connection an the fuel distribution pump connection. - Start the engine and let itturn at idle speed for 30 seconds, approximately. + Check the tightness of the different connectors.ENGINE REPAIR 614-21 REMOVAL OF ENGINE ASSEMBLY Disassembly Perform the following operations: 1) Remove battory. 2) Drain out cooling system. 3) Remove engine bonnet. 4) Remove section No.1 of the exhaust manifold 5) Remove flexible air pipe between titer and turbocompressor. 6) Remove fuel fier. 7} Remove cooling pipes, fuel, power steering lines and electrical connactions of the engine room. 8) Remove coolant header tank and air filter. 8) Remove throttle and clutch cables. 10) Slacken right side engine mount three attaching bolts to chassis and rubber silentblock attaching bolt. 11) Slacken left side engine mount three attaching bolts to chassis and rubber silentblock attaching bott. 12) Remove starter motor. 13) Remove the fasteners between the bell housing and the engine. 14) Take out engine with a crane, Assembly 1) Carry out assembly in reverse order to disassembly, applying the corresponding torque specications. Torque specification engine mount to chassis: 40-50 Nm (4.0-5.0 kg.m, 29-36 Ib.). ‘Torque specification silentblock to mount: 50-60 Nm (5.0-6.0 kg.m, 36-83 Ib ft)ENGINE REPAIR 684-22 ENGINE BLOCK REPAIR ENGINE DISASSEMBLY Exterlor components Remove the following components: 1). TOG pickup, 2) Vacuum pump belt. 3) Vacuum pump and pump mount. 4) Alternator. 5) Power steering pump. 6) Altemator and power steering pump brachets. 7) Turbocompressor oil feed and return lines (4) and (5). 8) Inlet and exhaust manifolds together with the turbocom- pressor (1), (2) and (3). Continue removing the following components: 1) Oilfiter (10), 2) Oil cooler (11) 3) Fast idle control (15). 4) Injectors lines (12). 5) Pre-heating plug lines. 8) Oil filler neck and blowby gas separator assy (19). 7) Oil pressure switch (14). 0), Dummy engine mount (16) 9) Thermostat housing (17) and (18). 10) Injectors using tool lef 00000V02001, (and recovering the fire cutotf and sealing washers (20) and (21)). 11) Glow plugs (2)ENGINE REPAIR €A4.23 Lock the flywheel using tool Ref. 0000002008. Remove the following components: 4) Pulley attaching bolt (1), 2) Clutch mechanism. 8) Granhshatt pulley. 4) Flywheel locking too! Ref. 00000V02008. 5) Right cam belt cover bolt (5) and nut (6). 6) Lett cam bett cover (2) bolts (7) and (8). 7) Lower cam belt cover (1) bolts (4). Timing belt disassembly. - 1) Fit bolt (1) and washer at crankshaft pinion. 2) Rotate engine until camshatt (6) and fuel distribution pump (7) pulleys align with the lock bolt tapping 8) Lock camshaft using bolt MB x 125 x 40 and the fuel distribution pump with two bolts M8 x 125 x 35. NOTE: Bolts should be tightened by hand.ENGINE REPAIR 6A6-24 4) Slackon nut (8) and bolt (9) of tensioner pulley mount (10). 5) Insert a 26" drive into the recess in the tensioner pulley ‘backing plate (10) atthe point “a”. Lever the tensioner against the spring (11) to relax the belt tension 6) Tighten the bolt (8) again 7) Remove timing belt 8) Tako out the camshatt (6), fuel alatribution pump (7) and crankshatt (12) pulleys and recover the keys, 8) Take out the tensioner pulley (10) and rocover the thruster (13) and spring (1). 10) Remove the dummy engine mount (16) and the fixed pulley (16). 11) Romove water pump (17) 12) Remove fuel distribution pump (19) and housing (20). Cylinder head disassembly 1) Ramave rocker arm caver 2) Slacken the cylinder head bolts progressively, following the ‘order shown apposite. 3) Dismount cylinder head and remove gasket. : 7 NOS ital, LastENGINE REPAIR 688-25 2 3) 4) 5) 6) 7) 8) 9) 10) 1) CYLINDER HEAD INSPECTION 1) Measurement of cylinder head height should be carried out with eamshatt in position and secured by two caps _(h) ‘measurement being taken of the oilseal diameter (the larger diameter) (h). Nominal: from 157.40 to 157.75mm (6.197 to 6.211 ins). The maximum distortion permitted for the camshaft is 0.07 ‘mm (0.003 in), (the camshatt should turn freely on cylinder head). ‘Maximum admitted rectification of cylinder head gasket face is (0.40 mm (0.016 in) with respect to nominal height measure (h) Rectified cylinder heads should be marked by stamping an Rin tho area (a). When the head gasket face of the cylinder head is rectified the following operations should be carried out: = Rectify valve seats to ensure they are correctly levelled. + Roplace turbulence chambers (pre-chambers) with ‘oversize chambers and level up correctly. + Fitcompensating washors of 0.4 mm (0.016 in) valve springs below Cylinder heads with under-size camshaft bearings (+0.5 mm) are markad with a (1) in the area indicated (a) Remove the following components trom cylinder head and place them in same order as that for assembly + Camshatt covers (1), = Oilseals (2) ‘+ Camshatt (3). += Tappets (4) ‘+ Shims (5). With the aid of a valve extractor, remove the following ‘components from cylinder head: + The 8 valves. ‘+ Turbulence chambers. Clean cylinder head using DECAPLOC 88. Check cylinder head distortion. Maximum distortion = 0.07 mm (0.003 in). Check condition as indicated in section on cylinder head repair: + Valve seats and guides. = Valves. + Valve springs. = Turbulonce canisters. + Camshatt. + Camehatt supports. + ThreadsENGINE REPAIR 6A4-26 CYLINDER HEAD REPAIR 1) It after checking the cylinder head gasket face level, rectifications have to be made, itis necessary ta check valve epih after rectitication and rectify seats to establish correct depth (6). Valve depth (dimension c) Intake 0.5. 1.05 mm (0.020-0.041 in). Exhaust 0.9. 1.45 mm (0.020-0.01 In). 2) Checking vaives. Intake Exhaust Lmin. 4125 ———< Ga +0 -0.015 8.005 7.985 Ob. +/-071 38.5 33 ‘Angle 30" ‘90° 9) Checking valve springs DIAMETER d: 29 i \ =| Pt: kgiN 18/180 et 42.4 P2: kg/N 45/450 2 33.3 4) Valve guides. ‘When valve guides are removed, and oversize guides are to 'be inserted, the vaive guide bores in the cylinder head must be machined to suit the oversize the guides according to the dimensions shown. og | ot | hb i_| or Tolerance |.0 | 0.032 | 025 | 05 o coo | o | -025 | -o5 | +02 14.02 | 13.981 Original value 14.13 [14.051] 52.00 | 365 | 5.02 a Repair | 14,29 | 14.211 2Repair | 14.59 | 14.511 NOTE: Value K is achieved once guides have been fitted in cylinder head.ENGINE REPAIR 6A 5) Valve seats. When valve seats are removed, the housing must be machined to accep! a new oversize seat. ‘The required measurements are shown in the tables below. : INTAKE Bb c a Tolerance 2 +1- 0.025 2 + 0.15 ~ 0.025 -0.01 Value | _40.161 40 6.25 8.267 original [40.361 | 402 6.45 8.467 ‘Repair | 40.401 | 40.3 6.45 3.467 2 Repair| 40.661 | 40.8 6.45 8.467 EXHAUST O:a :b c a Tolerance | —9_| +/-0.025 | _© + 0.15 3 = 0.025 +001 ~ Value | 34.137 34 6.05 8.15 original | sass7 | 342 6.25 835 vRepair| 34.437 | 343 6.25 8.35 2 Repair| 34637 | 345 625 835 6) Turbulence canisters. ‘When it is necessary to machine the cylinder head surface, itis Important to remove the pre-chambers first. To tit new ones, it necessary to machine the housing and then machine new canisters in areas (x) and (y) so that they remain level with the cylinder head surface. Machining of turbulence canister housing, O:4 9 h Tolerance 0.039 0.02 0.02 9 = 0.025 0.04 Value 32 4.00 3.90 original 32.2 44 40 4” Repair 32.4 42 at 2" Repair 32.6 43 42ENGINE REPAIR 684-28 Use dial gauge special tool 000002003 to check the level of the canisters to me tolerance below: Pro-chamber leve tolerance: from 0.00-0.03 mm (0.000-0.001 in) NOTE: ‘When major fissures (over2 mm.) are noted in pre-chamber window, this should be replaced. 7) Assembling cylinder head, Fit the valves, springs, new valve guide retainers (using too! Ref.00000¥02009), tappets, adjustment plates and camshaft to the cylinder head, ‘Adjust the valve clearances as described in sections 6A4-5 and 6A4-6 “Valve clearance checking and adjustment’.ENGINE REPAIR 6A4-29 ENGINE BLOCK DISASSEMBLY From the underside of engine remove the following components: 1) Oilpan, - 2) Two oil pump pickup bolts, removing the pick-up. 3) Oil pump (6) bolts (1), (2) and (3) and retainor holder (4). NoTE: Bolt no, 1 is special since it sorves to align the pump. 4) Remove the four battle attaching bolts, removing the baffle. 5) Price the pump (5) and remove with chain and crankshatt pinion (7), recovering the key. 6) Remave the following components * Connecting rod caps (8), marking them with a marker pen. ‘+ Main bearing caps (9), (welding mark). + Crankshatt shims installed in crankshaft support no. 2. Ollseal (10) and shims adjusting axial play (11). * Crankshatt, main bearing shells and connecting rod assemblies.ENGINE REPAIR 6AS-30 7) Untasten connecting rods by releasing circlips. 8) Remove oil gallery caps, (12). CYLINDER BLOCK REPAIR 1) Matching up cylinder and piston. Measure internal diameter of cylinders and extemal diameter of the pistons and determine the rectification that is necessary according to the following tablo. The piston diameter “b" must be measured at a distance “c” from the base. Distance (c) = 25.00 mm (1.00 in), ‘Senbe the relevant rectification mark (R1, R2 or A3) on the block in position (x). cyunpen | PISTON Mark (x) | Diameter(a}| Tolerance | Diameter (b} | Tolerance Value | wone | 93 02.93 original AY 83.03 | +0.018| 82.96 | + 0.009 Rt [e232 | -o | 69.13 |-0.000 R2 83.5 83.43 ra] 83.8 03.73 Diameter of piston pin: 28 mm.ENGINE REPAIR 6A6-31 2) Cranhshatt repairs Measure the main bearing and big-end journals. Machine to undersize if necessary. If machining is necessary (see the table below) use oversize shell bearings. These are marked with white paint on the side. The following dimension are in mm: Oia bo d — 0 0.003 oO 0.003 -0.016 | -0.003 | -o.019 | -0.003 Original 50 1.827 60 1.842 1 Repair | 49.7 1.997 50.7, 1.002 NOTE: Connecting rod and main bearing shells in first repair should be identified with a white paint marking on the edges. 3) Crankshatt thrust clearance adjystment. Crankshaft thrust play should be between 0.07-0.32 mm (0.003-0.012 in) It is secured by four crescent shims, two located on the block and two on the main bearing cap no.2. ‘They should be fitted with their copper side facing towards crankshaft The following dimension are in mm: Main bearing Axial shim No. 2 thickness e_|Tolerance| f _| Tolerance Value original| 26.6 2.305 1 Repair | 26.8 +005 | 2.405 | +0.025 2Repair.| 26.9 70 2.455 | - 0.025 3° Repai 27 2.505 4) Rear retainer seat. ‘Check diameter of crankshaft wrist pin and rectly it necessary. The following dimension are in mm: Dimension O=9 Tolerance Value original 90 +0 1“ Repair 99.60 - 0.087 5) Cleaning block and crankshaft. Clean wih degreasing producl, inserting @ suitable brush in internal holes of cylinder block and crankshatt.ENGINE REPAIR 64-32 CYLINDER BLOCK ASSEMBLY 1) Crankshaft assembly. * Replace oil gallery plugs using thread lock an their threads, + Replace the oil nozzles in the cylinder block. + Instal the shell bearings in the block main bearings and their caps, having applied lubricant to the shell face. + Instat the crankshaft and loosty install the main bearing caps on journals no. 3. 4. 5. ++ Fit two thrust bearing into no. 2 journal, applying lubricant to the thrust faces. * Insta! the main bearing cap no. 2 journal, ensuring that the thrust faces an lubricated.ENGINE REPAIR 6A0-33, * Fit two new lateral seals (3) to main bearing cap no.4 * Fix tool Ref. 00000V02002 equipped with metal centering plates A2 Ref. 0000002005, to main bearing cap no. 1 (4), by means of a bolt and washer (6). ‘= Adjust height (x) of metal centering plates. + Grease metal plates and housing. NOTE: So as not to elongate lateral seals, tit main bearing cap no. 1 as indicated below. . + Insert in housing at an inclination of 45°. ‘= Straighten up once inserted, * Slowly tower. + Tighten main bearing cap bolts as specified. Main bearing bolt torque specifications: 70 Nm (7.0 Kg-m. 50.5 Ib-ft). + Remove too! horizontally. + Cut lateral seals so they project out 2 mm.ENGINE REPAIR 6A4-34 2) Check crankshaft thrust clearance. Crankshaft thrust clearance: 0.07 to 0.32 mm. (0.003-0.012 in) It the clearance is out of specification adjust by reference to the section in 684-31, 3) Installation of connecting rods and pistons. + Assemble connecting rods and pistons aligning the connecting rod notches (a) towards the recesses (b) of the pistons. + Fit piston ring using expander, in the following order: (1) Oil control ring. (2) Tapered section compression ring. (3) Chrome/eonvex section compression ring. NOTE: The side marked (TOP) of the tapered ring should face the combustion chamber. + Align piston ring gaps at 120°, taking the clearance (¢) of oil conteal ring for ralerence * Lubricate piston and compress the piston rings with a compressor (4) + Remove connecting rod caps, install pistons in block, respecting the marks made during disassembly and pointing the recess (a) ofthe piston towards the oil fier. Fiteaps with ‘hair shel bearings and tighten to specified torque. Connecting rod caps torque specifications: 20 Nm (2.0 kg.m, 14.5 Ib.ft) PLUS 70? + 5? rotation NoT! lection of connecting rod shell bearing pleace to “ENGINE REPAIR”.ENGINE REPAIR 684.35, ‘+ Fit new oil seal on tool Ref.00000V02004. + Insert oll seal by hitting with a mallet until it its snug. jotate tool to remove + Check that oil seal lip is correctly positioned. + Fit sump baffle with 4 attaching bolts. ‘Tighten the bolts to the specified torque ‘Sump battle bolt torque specification, 4) Assembly of oil pump and pan. Install compurients in following order: + Woodruff key (6). = Pump assembly (7), chain and drive gear (8).ENGINE REPAIR 6A4-36 NOTE: Bolt no. 1 ie special and serves te align pump. + Tighton to specified torque pump bolts numbers (1), (2) and (3). ‘Torque specifications for bolts: 20 Nm (2.0 kg.m, 14.5 1b.ft) * Fit a new front oilseal on tool Ref.00000A02006 and insert in housing by knocking with @ mallet until itis snug. + Tighten attaching cover bolts as specified Torque epecifications for cover bolts: 15 Nm (1.5 kgm, 11 Ib.ft) * Install oil pickup tube and attach with two bolts to specified torque. Pickup tube bolts torque specifications: 20 Nem (2.0 kg.m, 14.5 Ib.ft) * Apply line of AUTO JOINT BLEU sealant to edges of boit housing in oil pan. * Fit oil pan on engine and tighten bolts to specified torque. ‘Torque epecitications for oil pan attaching bolts: 20 Nm (2.0 kg.m, 14.5 Ib.ft)ENGINE REPAIR 644-37 5) Clutch assembly installation = Fit engine flywheel and insert bolts smeared with LOCTITE, FRENETANCH. ‘+ Fitlocking tool Ref. 00000V02008 on the engine flywheel and tighten attaching bolts. Engine flywheel attaching bolts torque specifications: 50 Nm (5.0 kg.m, 36 Ib-ft) + Fit pressure disc and plate ang tighten attaching bolts. Torque specifications for pressure plate bolts: 25 Nm (2.5 kg.m, 18 Ib.ft) + Remove locking tool from engine flywheel 6) Cylinder head gasket assembly. Fit gial indicator on support Ref. 00000V02003 and set to zero on flat surface + Turn crankshaft until pistons no. 1 and 4 are at T.D.C. using detent too! Ref.00000V02008. ‘* Measure maximum projection of piston. + Repeat operation with pistons No.2 and 3. * With measurements obtained choose gasket thickness as in the table below. All dimension shun are in mm: enormusion | THCKNESS | Gu aasKeT 0.56-0.71 1.48 2 072-075 1.50 3 0.76 -0.78 1.54 4 0,80 - 0.83 1.58 5ENGINE REPAIR 6A6-38 7) Installing cylinder head, + Turn crankshatt until pistons are midway in their cylinder bores and the crankshaft woodrulf key (6) is at 9 o'clock position *+ Clean cylinder head fixing holes with M = 12 x 150 tap. * Fit dowel (7) on engine block. + Assemble cylinder head gasket (dry) ‘+ Place cylinder head on block. + Measure length (x) of cylinder head bolts from the underside of the bolt head flange to the tip of the threaded post. 1um length without tip 121.25 mm. Bolt maximum length with tip 124.5 mm. NOTE: ‘Screws longer than indicated measurement must not be used, ‘+ Clean sorew threads and replace washers with new ones, + Apply MOLIKOTE G RAPID PLUS to scrow threads and washer contact surfaces, + Tighten cylinder head Lolts in order indicated following tne steps below: Initial tightening: 20 Nm (2.0 kg.m, 14.5 Ib.ft) ‘Subsequent tightening: 60 Nm (6.0 kg.m, 43 Ib.ft) Final angular tightening: PLUS 180° rotation.ENGINE REPAIR 6A4-39 8) Timing belt assembly. + Fit fuel distribution pump bracket and pump. + Fit fuel distribution pump pulley (5). + Instal pulley timing bolts (7), (8) and (9), tightening by hand. * Tighten nut attaching pulley to fuel distribution pump to its torque specification. Torque specifications for nut attaching pulley to fuel distribution pump: 50 Nm (5.0 kg.m, 36 Ib.ft) + Rotate crankshaft in its normal rotation and lock flywheel at N° 1 TDC with tool Ref. 00000V02008. + Assemble the following components in the order indicated: = Water pump (10) with a new gasket. ‘Torque specitications for nut sealing to fuel distribution pump: 15 Nm (1.5 kg.m, 11 tb.ft) - Lower pulley (11). ‘Torque specification for lower pulley attaching bolts: 18 Nin (1.8 kg.m, 13 Ib.ft) - Woodruff key (12) and crankshaft pulley (13). = Dumtny engine mount (14) with screws with LOCTITE FRE- NETANCH and tightened to its torque specification. ‘Torque specification for crankshaft pulley bolt: 40 Nm (4.0 kg.m, 29 Ib.ft) = Spring (15), retainer (16) and tensioner pulley (17). ‘= Immobilise pulley (17) at tappet compressed position = Continue with operations (1} to (4) (assembly) (1) to (10) (¢iming adjustment) from "section 684-9 Timing Belt” (Repla- cemen) ‘Torque specification for tensioner bolts: 20 Nm (2.0 kg.m, 14.5 Ib.ft)ENGINE REPAIR 6As-10 SPECIAL TOOLING os / > MOUNT ATTACHING ELEMENT ‘0000v02001 ‘ono00va2002 o000v02003 INJECTOR EXTRACTOR MAIN BEARING DIAL INDICATOR WRENCH ‘CAP MOUNT SUPPORTS: ‘2000002008 ‘o0000v02008 ‘e0000v02008 RETAINER CcNTERING FRONT RETAINER ‘MOUNT PLATES MOUNT ‘ooo0ovaz007 o0cavez008, ‘0000v02008 CAMSHAFT RETAINER Toc. VALVE RETAINER INSTALLATION TUBE & om) om) & Q ‘o0009v02010 ‘0090v02015 ‘0000vo2016 INJECTION PUMP. ‘SOCKET HEXAGONAL, FLANGE, SOCKET ‘c0000v02017 SEMI CIRCLE WRENCH CO 9ENGINE REPAIR 604-81 a TORQUE SPECIFICATION SYSTEM ELEMENT a Nm. kgm Ib. Camshaft cover locknuts. 18 1.8 13.0 ‘Main bearing bolts 70 7.0 505 Gonneeting rod nuts 204.708 | 20+ 70° | 14.5 +70 Oil sump attaching bolts 20 2.0 14.5 Front retainer mount plate 15 1.8 11.0 Oil pump attaching bolt 20 2.0 14.5 Engine flywheel case attaching bolls 25 25 18.0 Clutch disc pressure plate bolts 50 50 36.0 Engine flywheel bolts 40 40) 23.0 Camshait pulley attaching bolts 50 5.0) 36.0 Fuel distribution pump/pulley locknut 20 2.0 14.5 ‘Spring tensioner suppor/cylinder head attaching bolts | 4s 45 32.5 Timing tensioner allaching nut and bor 18 18 73.0 Lower timing cover suppor fitings 15 13 11.0 ell timing cover attaching fitings 75 5 11.0 Right ming cover attaching bolt 10 1.0 7.0 Right timing cover locknut : s 05 35 ‘Crankshatt pulley attaching bol W162 | 44608 (29.04 60° Injectors 90 9.0 65.0 Glow plugs ~ 22 22 16.0 uw [Thermostat housing attaching holt 18 15 11.0 z Fuel fiter fitting 15 15 11.0 G — [Rockerarm cover ming 8 Te Tro 2 — [Oilpressure switch 30 3.0 25 i. ‘Alternator tensioner attaching bolts 22 2.2 16.0 Engine mounts attaching bolts 40-50 | 40-50 | 29.0360 Engine silentblock/support union 40-60 4.0-6.0 | 29.0-43.0 Oil pan drain plug bolt 30-95 | 9.0.35 | 21.5250 Fuel inesiiterfiting 30-40 | 30-40 | 21.5-28.0 Power steering pressure pump lines 50-70 | 50-7.0 | 36.0005 Engine/tranemission union 40-60 | 4.0-6.0 | 29.0-43.0 Power assisted steering pump and allemator to engine block | 18-28 | 1.8-28 | 13.0-20.0 ‘Vacuum pump mount fiting/engine block 30-40 | 3.0-40 | 21.5200 ‘Vacuum pump/mount attaching bolts 18-28 1.8-2.8 | 13.0-20.0 Vacuum pump tensioner 18-28 4.8-2.8 | 13.0-20.0 Vacuum pump tensioner (engine block sido) 78223 | 18-23 | 130-170 il pickup tube bolts 15 1.5 11.0 E.G, valve attaching bots 20 2.0 745 Exhaust collector tap halts 18 - 28 1.8-2.8 | 13.0-20.0 Intake manifold connections - frst section 18-28 | 18-28 | 13.0-20.0 Starter motor fing 20-80 | 20-30 | 145215 Intake manifold locknuts 25 25. 18.0 intake manifold attaching bolts 25 25 18.0 ‘Turbocompressor attaching bolts 30 3.0 215 Turbocompressor drain pipe attaching bolts 15, 15 11.0COOLING SYSTEM 6: SECTION 6B COOLING SYSTEM not covered in this section, please refer to the relevant section of the Vitara Service Manual outlined in the PREFACE. CONTENS GENERAL OUTLINE 6B-2 Coolina circuit. 6B-2 MAINTENANCE, 68-3 Coolant level 6B-3 Replacing coolant . 68-3 Inspection and cleaning 6B-4 IN THE VEHICLE. 6B-5 6B-5 ‘Checking and componentsENGINE COOLING SYSTEM 68-2 GENERAL OUTLINE ‘The cooling system comprises up of tne following components: radiator, degassing reservoir, coolant sensor, oil cooling, thermostat, heater, heat relay thermocontact and electric fan. Radiator Expansion reservoir Coolant level sensor Outlet hose-radiator Intake hose-radiator (no. 1) Thermo sensor Interconnecting hose Intake hose-radiator (no. 2) Intake hose-oil cooler 10. Oilcooler 11. Thermostat 12, Radiator expansion hose 13. Filler hose 14. Heater outtet hose (no. 2) 45. Heater outlet lines 16. Heater outlet hose (no. 1) 17. Heater intake hose 18, Engine expansion hose 19. Bypass hoseENGINE COOLING SYSTEM 68-3 MAINTENANCE COOLANT LEVEL Remove coolant expansion reservoir cap and check coolant is reaching upper part. =e 1. coolant draining plug WARNING: ‘To avoid the possible risk of burns do not remove cap whi engine and radiator are hot, pressurised vapour and boiling water could come out. It coolant level is low, fil with coolant to maximum level. NOTE: Ensure that filler cap is totally closed. COOLANT REPLACEMENT 1) Remove lower engine soundproofing plate. 2) With engine cold, unscrew expansion reservoir filler cap. 3) Open draining plug in lower part of radiator until all fluid has flown out, 4) Close draining plug. 5) Add coolant to expansion reservoir, unti it reaches upper part. 6) Tum on heater controls and start up engine. 7) Continue adding coolant as reservoir level reduces, until the engine is completely warmed up.ENGINE COOLING SYSTEM 68-6 7) Ensure that coolant stabilises at maximum lovel in expansion reservoir. 8) Fit cap on coolant expansion reservoir 9) Fit lower engine soundproofing plate. NOTE: Cooling system capacity is 8 litres. Use a mix of 50% DYNAMIC DYNAGEL 9103 antifreeze and 50% distilled or demineralized water. INSPECTION AND CLEANING Inepection. 1) Remove upper cover of coolant expansion reservolr. 2) Fit procoure gauge and create pressure of 197 K Pa (1.4 kg! cm?, 20 psi). 3) Check that pressure doos not fall from above lovel.Ift does, check for existence of leaks and correct if necessary. Cleaning. 1) Remove lower engine soundprooting plate. 2) Remove coolant expansion reservoir cap. 3) Start up engine and run until thermostat outlet hose is warm. 4) Turn off engine and remove radiator draining plug, thereby evacuating coolant. 5) Fit tila cap and wait far engine to cool down. 6) Add water to coolant expansion reservoir and wait again for engine to warm up until praceeding to drain. 7) Repeat this operation 3 or 4 times until water coming out of drain hola is almost transparent 8) Remove and eliminate interior dirt. 9) Fit once more and securely tighten radiator draining plug. 10) Fill system with mixture of water and antifreeze, as specied above,ENGINE COOLING SYSTEM 68-5 IN THE VEHICLE COMPONENT REPLACEMENT Radiator removal 1) Remove lower soundproot plate 2) Drain radiator by removing coolant expansion reservoir and ‘adiator draining plug. 3) Aer draining, be sure to replace and tighten radiator draining plug. 4) Disconnect radiator hases and the electric connections to the electric fan adjacent to the engine (rear). '5) Remove radiator support fitings to engine. 6) Remove rear electric fan from the radiator. NOTE: Be careful not to damage radiator tins. Radiator inspection Perform the following revisions, and repair or replace if necessary 1) Cracks or breaks. 2) Coating tins (straighten them with a sereweiiver) 3) Inlet and outlet radiator hoses (for distortion) Inspection of expansion reservoir cap 1) Clean expansion reservoir cap. 2) Install pressure testing tool and apply pressure of approximately 137 K Pa (1.4 kg/cm®, 20psi). This pressure should be maintained for at least 10 s. If not the cap should be replaced. Radiator assembly 1) Carry out disassembly operations in reverse ord 2) Fill and bleed system as outlined above. 3) Fit lower engine soundproofing plate.ENGINE COOLING SYSTEM 68-6 Coolant level mark 6 Car ¢ ‘cootaNT SENSOR Ground = eat + Contact Expend glass water & lovel control ight + Contest ThigeivisTOR AND THERMOCONTACT 118" Cootant tomperature concor 1) Ensure that coolant reaches upper part of coolant expansion 2) Check that the coolant level and temperature warning lamps light up when the starter motor is engaged. This shouldhappon before the engine starts. Once the engine has fired the lights should go out 3) It lights remain on after starting up, check: = Condition of diades on instrument panel, replacing if detective. = Connact voltmeter between coolant sensor terminal Br-Y ‘and ground. When engine is running the reading should be similarto battary voltage. Ifnot, check for possible grounding faultin the above circut. tno detectis found, replace sensor. = Connect volt mater hetween coolant sensor cable B-W and ground. When engaging starter motor the reading should be simiiarto battery voltage. If not, chack possible grounding fault of above cable. 4) I lights do not come on when engaging starter motor, check: = Condition of bulbs. = Condition of diodes. 5) Perform the following final inspections: = Disconnect the thermo probe sensor, start the engine and short-circuit the Br-Y cable to carth, The coolant level indicator must ight up. Ifthe contrary, check cable continuity, = Disconnect Lg-B cable from the termperature indicator thermo sensor and short-circuit it to earth. The indicator ‘must light up, if the contrary, check the cable continuity. Inspection of electric fans. 1) Turn ignition key in ON position. 2) Disconnect thermo sensor connector and link connector ends with a wire as shown in diagram (left). Check that both fans work. 3) If they do not, check electrical fitting, fuses, rolays and electric fans.ENGINE COOLING SYSTEM 68-7 Inspection of electric fans thermo sensor 1) Remove radiator thermo sensor. 2) Insert it in a container with water and a thermometer. 3) Apply heat to the water. 4) Check that on reaching a temperature of approximately 95° C there is continuity between the terminals at the ends. Check that when temperature drops to 86° C (approx.) no continui exists. Replace thermo sensor if necessary. Inspection of thermostat 41) Releaso hose attaching radiator to thermostat housing, 2) Remove rear thermostat cover and extract thermostat. 3) Place thermostat in a container with water and heat up, check that at beginning and end of aperture the following values show: Starting open: 86° C Fully opon: 95° C Movement: 7.5 mm (0.30 in) Replace tharmostat it does not perform to these values.ENGINE COOLING SYSTEM 68-8 Replacement of rear electric tan 4) Remove electric fan electric connection. 2) Remove the four bolts attaching the fan hood to radiator. 3) Detach electric tan cable from the circlips. 4) Remove nuts and separate electric fan trom hood. 5) For assembly perform, reverse order of disassembly. Replacement of front electric tan 1) Remove front grill 2) Remove electric fan connector, 3) Remove three bolts attaching hood to radiator support, 4) Remove three bolts attaching electric fan to hood and separate them. 5) For assembly, reverse order of disassembly.ENGINE AND EMISSIONS CONTROL 6E3-1 $$$ _____ an in EnISSIONS CONTROL GED-1 SECTION 6E3 ENGINE AND EMISSIONS ~~ ~ CONTROL SYSTEM LIST OF CONTENTS. IN THE VEHICLE... ee Fuel cistrioution pump overhaul. ‘Checking adjusiments.. ‘Adjusting fuel distribution pump Injectors replacement... : ENGINE AND EMISSIONS CONTROL... EGR system diagram EGR system (Components) EGR system functioning EGR system (Inspection) PCN, systom. on PRE HEATING SYSTEM, Functioning Inspection... SPECIAL TOOLS .ENGINE AND EMISSIONS CONTROL 6E3-2 ON THE VEHICLE NOTE: Internal adjustments and re must be carried out at an offi irs to fuel distribution pump Lucas Service Centre. FUEL DISTRIBUTION PUMP OVERHAUL (Lucas) Adjustment 1) Remove the tap from the pump port hole. 2) To ease engine rotation remove glow plugs. 3) Remove injection tines, loosen pump altachings and swing this, to the maximum retrieve position (away from the engine), 4) Set crankshaft to TDC of cylinder No. 1, setting engine flywheel with (oo! Ref. 00000V02008. 5) Install centering rod of too! Ref. 00000V02018 in its housing, 8 ovens 6) Ifthe engine is in injection position in cylinder No.1 rotate engine ‘a complete turn and set tlywneet with too! Ret. a000v02008, in this position cylinder No.4 willbe in injection. This position can be confirmed because the cylinder No.4 cams ae notin contact with tappets, or because the camshaft pulleys {and injection pump align with those of the cylinder block. 7) Set the dial indicator support Ref. 00000V02018 on the pump and to this attach a universal dial indicator provided with plain point (b). 8) From the TDC centering position turn the crankshaftin reverse movement to rotation until the dial indicator needle stops. In this position adjust the dial indicator to zero (0°).ENGINE AND EMISSIONS CONTROL 6E3-3, 9) Slowly turn erankshatt in normal rotating direction, until flywheel is locked by tool Ret. 00000V02008. Obsorve the dial indicator reading 10) Slowiy tum fue distribution purnpin advance direction towards engine), until dial indicator shows the (X) travel indicated on the plate on the throttle lover 0.04 mm (0.0016 in). NOTE: "Ifthe dimension is exceeded, turn the pump back until a reading less man (X) is obtained and adjust again. CHECKING ADJUSTMENT 1) Tum engine, from the previous position, a quarter turn in the opposite direction. 2) Turn engine in rotating direction and center engine flywheel with too! Ref. oo00v028008. At this position, dial indicator must show X 0.04 mm (0.0016 in). 8) Tighten pump attachings and remove dial indicator. Torque specifications for jet pump attaching bolts: 20 Nm (2.0 kg.m, 14.5 Ib.ft). ADJUSTING JET PUMP Throttle cable adjustment 1) Attach throttle cable to the lever. 2) Fit cable cover to mount with the retention clip, leaving 3-6 ‘mm (0-12-0.24 in) of slack. 3) Adjust throttle pedal height using stop bolt (0), in such a way that when pushing the pedal and stopping the bolt on the pe- dal there is 0.1-0.5 mm (0.004-0.020 in) betwoen the throttle lever (6) and the revolutions stop bolt (5). 4) Ensure that in idle position, throttle lever upper end (8) contacts the stop bolt (7). NOTE: Do not change maximum r.p.m. of the engine via the stop bolt.ENGINE AND EMISSIONS CONTROL 663-4 Adjusting fast idle cable 2 Sra 3 7, Al Ne ‘ Cold engine 1) Verity that when the lever (6) is pressed right, cable (6) is 4 A e a Ccomipltely tightened. not, ighten the cable using on he camp (10). x = 2) Aujusl cable lension with tensioner (8) P= r) Note Idle r.p.m. must be 950350. ivitgle VS Hot engine (thermostat open) ass i 37 1) Verity cable (8) is no tight. Sn Ee 2 2) Place the theimustalic probe on the thermostat housing and check engine temperature. NOTE Between cold engine and hot engine there must be a maximum cable movement of 6 mm (0.24 in) and the play (J) must be between 0.5-1.0 mm (0.020-0.040 in). Adjusting throttle lever 1) Ensure throttle fever idle is on the adjustment stop bolt (2). Adjusting rigging 1) Place a 3 mm (0.012 in) gauge (1) between throttle lever (3) and adjustable bolt (2). 2) Move the manual stop lever (4) to the left. 93) Place a 3. mm (0.012 in) drill (5) in the fast idle lever (6). 4) Adjust engine to 900250 r.p.m. by adjusting the screw (2). 5) Flemove gauge (1) and dril (5). Idle adjustment 1) Adjust idle by adjusting the idle screw (7). Fast idle r.p.m. (800%).1002 ENGINE AND EMISSIONS CONTROL 6E2-5 Engine deceleration control 4) Move throttle lever (5) until 3.000 rsp.m. ie obtained. Deceleration time must be about 310 4 sec. after throttle lever is released. 2) Adjust deceleration time by adjusting the dashpot bolt (1). E.G.R. system driving microswitch. 4) To check its performance use an ohmmotor and measure resistance between pump connector terminals A and B. From idle position, up to about, 30 mm (1.2 in) of throttle cable movement the ohmmeter must show continuity. Beyond that position, resistance must be infinite. NOTE Valve adjustment or replacement must be accomplished by a Lucas Service Centre. Manual stop control 1) With engine at idle, pull the lever (3) backwards. Engine must stop. Electric stop control 4) Measure resistance (between earth and output torminal) of the fuel shutoff electric valve (4). This must be about 82 p.m, sensor 4) Check resistance on the connector as shown at loft kup coil resistance: 100 2 (approx.)ENGINE AND EMISSIONS CONTROL 6E3-6 REPLACEMENT OF INJECTORS Disassembly 1) Disconnect injector and return lines. 2) Romove injectors using too! Ref.00000V02001. 3) Extract washers (2) and (3). NOTE: Injector checks and repairs should be performed by a Lucas Service Centre. Assembly 1) Insert new fire cutoff washer in housing (3) with convex area facing outwards. 2) Fit a new sealing washer (2). 3) Fit injectors and tighten to specified torque with tool Ref.o0000V02001. Torque specifications tor injector: 90 Nm (9.0 kg.m, 65 Ib-.ft). 4) Fit injection lines. 5) Check they are not blocked and fit injector retum lines.ENGINE AND EMISSIONS CONTROL 6E3-7 ENGINE AND EMISSIONS CONTROL EGR SYSTEM DIAGRAM EGR PNEUMATIC CIRCUIT. 1. EGR valve 2. Exhaust gases admision 3, Exhaust to intake gases output 4. EGR actuator 5. Vacuum pump vacuum tube 6. Solenoid valve 7. EGR vacuum tube 8 Electric connections 7 EGR ELECTRIC SYSTEM + INVERSOR RELAY VACUUM + eGR SOLENOID Ta) TEMPERATURE =a SWICH ‘THROTTLE LEVER MICRO.SWITCH vacuum con VALVEENGINE AND EMISSIONS CONTROL 63-8 ——[—==€=€=[—=————ee+— E.G.R. SYSTEM (COMPONENTS) The E.G.R. system is designed to reduce pollution levels. This is why it allows a certain amount of exhaust gases to enter the engine under certain operating conditions. it's made up of the following components, + Temperature switch This has two funcitons, one is to make EGR operative when coolant temperature is over 60° C and the other is to control the pertormance time of glow plugs. Its contact, is normally closed and itearths the circuit when temperature exceeds 60°C. ‘+ Throttle lever switch This control the system when the throttle lever is moved from rest position to a position between 25-30 mm (1.00- 1.20 tn). From that position the electrical circutt is interrupted and EGR system stops + EGR electric valve ‘When ki receives current, it allows a vacuum to pass trom vacuum pump to EGR valve. + EGR vaive This allows exhaust gases to pass into the inlet manitold when the valve is separated from its seat. This happens when vacuum is transmitted through EGR solenoid, + Relay This cuts current to electro valve when starting, even when coolant temperature exceeds 60° C and throttle lever movernent is under 25-30 mm (1.00-1.20 in), + Inversor relay This supplies current lo electric valve when the temperature switch is closed at 60? C. EGR SYSTEM FUNCTIONING When coolant temperature is under 60° C, temperature switch is open, not earthing the inversor relay and preventing EGR electric valve from functioning. When temperature is over 60° C, temperature switch is closed activating inversor relay, which will supply current to EGR electric valve, allowing vacuum to pass to EGR valve, this willbe lifted from ils seat allowing exhaust gases to flow into the intake manifold, When throttle lever is moved trom idle position to a driving of 25-30 mm (1.00-1.20 in), EGR system functions as previously described, but at that point 25-30 mm (1.00-1.20 in) micro-switch placed on fuel distribution pump is ‘opened and interupts the earth that activated the electric valve. In this way, vacuum to EGR valve is not present and exhaust gases are prevented from entering the engine's intace system.Fanconi ENGINE AND EMISSIONS CONTROL 6ES-9 EGR SYSTEM (INSPECTIONS) If the E.G.A. system does not work, the driver will not notice @ fault, but pollution levels will increase and could damage the exhaust catalyst It the E.G.R. system functions incorrectly or permanently. the level ‘of fumes will increase and engine performance will be affected. This is why the EGR system should be checked regularly in the following way: General inspection 41) With cold engine (temperature under 60 C) check that EGR membrane does ot move independently of the throttle lever position. 2) Ensure the engine temperature is over 60 C. Slowly move throttle lever and observe membrane which should return to rest position when throttle lever has moved between 25-30 mm (1.00-1.2 in) Electric cables 4) With engine running and hot, check one of the electric valve terminals for (+) and (-) earth in the other. 2) Check that when the thermocontact terminal is released, (+) disappears trom the electric valve. 3) Check that when moving throttle over the frst 25-30 mm (1.00- 1.2 in) earth (.) 1s cisconnected on the other side of the electric valve.ENGINE AND EMISSIONS CONTROL 6E2-10 i oS ZV Electric switch 4) Insert switch in a contalner of cold water and connect an ‘ohmmeter as shown. In this condition, ohmmeter must indicate ‘open circuit. 2) Raise temperature of the water and check at 60° C that ‘ohmmeter shows continuity. Throttle lever switch 1) Fit ohmmeter probes as indicated on the micro-switch connector, 2) Move throttie lever. in the first part from idle to 25-30 mm (1.00- 4.2 in). the ohmmeter must indicated continuity. Beyond that point, resistance must be infinite, NOTE Throttle lever switch can only be adjusted by a Lucas Service Centre. Electric valve 1) Blow through electric valve as shown and check that air co- mes out of the lower pipe. 2) Block lower exit and check no air comes out from the upper pipe. 3) Connect the electric valve to a 12v power surce and check no air comes pipe from the lower pipe and it only comes out from the upper. 4) Check electric valve lower resistance at 20° C, Electric valve resistance at 20°: 30 Q approx. NOTE The electric valve upper tube must be connected to the vacuum pump and the EGR valve to its horizontal pipe. Reversing these connections will cause engine and braking malfunctions.4, Fuses main box 2. EGR relays, Neatere and electric fan. ENGINE AND EMISSIONS CONTROL 6E9-11 EGR valve ‘Asuming EGR system works correctly, i the valve upper tube is removed when the engine is at idle, the sound of the engine will slightly change. If this does not occur, chek its functioning, by applying the following procedure: 41) Check the valve.is closed - 2) Apply vacuum as shown at feft, and check that the valve opens. 3) Maintain vacuum for 10 sec. with vacuum pump and ensure the reading does not drop. Relays 4) Remove the four relays placed next to the fuse main box, 2) Identity the EGR system relays and central heaters according to the line colours and the electrical diagram, 8) Separate relay from its connector and perform the following tests: ‘+ Use an ohmmeter to confirm an open circuit between AandC, * Chock, for a closed circuit between A and B. + Feed points D and E with a,.12v supply. # Check for continuity in this situation between A and Cand open circuit between A and B. + Replace those relays not performing as above.ENGINE AND EMISSIONS CONTROL 6E3-12 Air filter Intake collector Oil sump EGR valve Ai-resonator intake Regulator ‘Turbocompressor “Turbo line ~ intake collector Engine ventilation tine Vacuum pump auttlow lines Seomvogsena TURBO-DIESEL INTAKE SYSTEM POSITIVE CRANKCASE VENTILATION SYSTEM (PVC) Functioning 1) Gases generated in the oil sump rise through ventilation pipes, through the valve, and into the turbocompressor where they are sucked into the engine by the cylinders. Maintenance 1) Check and replace valve whenever the following are observed: * Bluish exhaust fumes. + Excess pressure in the crankcase which can cause oil loss through front and rear crankshatt retainer.ENGINE AND EMISSIONS CONTROL 6E3-13 ee GLOW PLUG CIRCUIT FUNCTIONING Pre-heating system supplies the necessary temperature to combustion pre-chamber which facilitates cold start. It consists of. + Four glow plugs, connected in parallel, which provides the proper temperature to combustion pre-chambers. = Pre-heating control which controls current feeding time to heaters for 9 seconds from initial start-up, when engine is cold, = Thetmocontact (the same as for EGR). Under 60° C it is kept open and its relay remains deactivated. Over 6D® C thermocontact closes and relay activates earthing the heater control, considerably reducing heaters feeding time, INSPECTIONS vl ‘@) US, ee 7 = {08-2 U4, AENGINE ANO EMISSIONS CONTROL 6E3-14 GENERAL TESTS NOTE: When using mu indicated po: jeter as ohmmeter, ensure there is no voltage In the circuit. Fit ignition key in the Abbreviations: LOCK = Key in rest position ACG = Accessones position ‘Giow plug indleator does oni ears 91 ght on with contact START = Start X = Disconnect battery Urs 12V Yes os 3 Cutoff contact indicator lamp yes [ Contact on: luo, Disconnect giow plug Cable continuity =>) -u2 = 12 v in glow plug [> plugs teeaing line of the Indicator (x) mass duration (ON) ‘low plug box (Looky. these controts ara Disconnect S-way : correct, replace pre- No[ Contact on: heating box (x) connector (LOCK) Ua 2 12v in glow plug uration (ON) ves ‘Check line continuity ro + [wz 2 Vion) Plugin shortcut after contact (x) Yes ‘Check: N Disconnect plugs: Mass ine continuity | “Fuss 12 VION 0,9 22R1 20,4200) Mass (x) vs v Ie Feeplace glow plug box (x) Replace plugte) in shortciccuit (x) CONTROLS WITH HOT ENGINE (TEMPERATURE OVER 60°) Periarm general tests Control cable and miero- Uae i2V(ON) PS R251 0H) |") contactisotation continuity &) ‘YES + YES Move throttle lever (x) Perform control in hot] < [~ R2~999KQ(M NS.[ Replace micro-contact (x) (See next test)ENGINE AND EMISSIONS CONTROL 6E3-15, CONTROLS WITH COLD ENGINE (TEMPERATURE UNDER 60°) Perform goneral tests S (Gos previous testo) End of test Ff Ud = 0 (ON) JNO.| ee the si Feeding cable (x) 2 Use12ViOn XY R2= 999 KATH I 3I Replace relay () £7 -0vion, Replace bese cra T 5 Rolease wator temperature probe (OFF) Us= 12 ViON) 2A Cable peween relay ana I probe (x) Ropiave probe (OFF)ENGINE AND EMISSIONS CONTROL 6E3-16. SPECIAL TOOLING 6 — ononoveen08 ceanavoc0 te eo000¥02019, To. FER FUEL DISTRIBUTION PUNP INieoToRS EXTRACTION Coubanaron suRPORT neni Q__# ed 0000v02017 SEMI-CIHGLE, WRENCH ol ‘20000v02001 INJECTORS EXIHACHION WRENCHSTARTER SYSTEM 66 ATER SYSTEM 6G SECTION 6G STARTER SYSTEM TABLE OF CONTENTS STARTER MOTOR REPLACEMENT ....ceornnnnnnnnnninnni menace 7 6G1STARTER MOTOR REPLACEMENT Characteristics Brand: BOSCH Voltage: 12 v Power: 1.7 Kw No. of teeth in pinion: 114 Disassembly 1) Disconnect the battery negative cable 2) Release positive cable and relay cable from the starter motor, 3) Slacken and remove the starter motor three altaching bos, Assembly 1) Perform assembly in reverse order as disassembly. 2) Tighten starter motor bolts according to its to specifications. ‘Torque specification for starter motor attaching bolts: 20-30 Nm (2.0-3.0 kg.m, 14.5-21.0 Ib.ft),(CHARGING SYSTEM GH $$$ AA tisins system crt SECTION 6H CHARGING SYSTEM LIST OF CONTENTS ALTERNATOR REPLACEMENT...(CHARGING SYSTEM 6H. ALTERNATOR REPLACEMENT Characteristics Brand: BOSCH Nominal voltage: 14 v Maximum outflow: 704 Polarity: Ground negative Vacuum speed: r.p.m. 1,200 Rogulated voltage: 14.5 40.3 ¥ Maximum speed allowed: r.p.m.18,000 Dicaccombly 1) Remove lower soundproof plate. 2) Remove negative cable trom battory. 3) Siacken vacuum pump tensioner and extract vacuum pump bolt. 4) Slacken two bolts at the sides and at the lower part of the alternator tonsioner and remove belt 5) Remove attaching nuts and remove altemator positive and dive cables. 6) Remove lower and upper alternator support bolts Assembly 1) Reverse the order of disassembly, tightening bolts to their torque specification ‘Torque specification for alternator tensioner bolts: 11-22 Nm (1.1-2.2 kg.m, 8.0-16.0 Ib.ft). Alternator belt tension: 10 mm (0.40 in) with 100 N (10 kg, 22 tb). Vacuum pump belt tension: 10 mm (0.40 in) with 100 N (10 kg, 22 tb).CLUTCH 7¢-1 SECTION 7C . CLUTCH section, please refer to the corresponding section of the Vitara Service Manual outlined in the PREFACE. LIST OF CONTENTS. IN THE VEHICLE... eo TOD ‘Adjustment of clutch cable TOR GENERAL REPAIRS OF THE ASSEMBLY 70-3 Clutch system. 70-3 Operation Shaft Disassembly... 70-3eLuTcH 762 a IN THE VEHICLE ADJUSTMENT OF CLUTCH CABLE 4) Lightly depress the clutch lever to remove the free play. 2) This required a force of 10 Nm (1.0 kg.m, 7.5 Ib.ft). 3) Adjust cable free-play to 0.5-0.10 mm (0.020-0.040 in) using the adjusting nut,CLUTCH 70-3, GENERAL REPAIR OF ASSEMBLY CLUTCH SYSTEM =< le, ages \ 1 taut shat berg 2. Flywhoe! 3 Clutch eee 4. Giuten cover 5.80!" 8. Thrust bearing 7. Shaft sealing 8 Buening 9. Gluten shat 40, Retum spring OPERATION SHAFT DISASSEMBLY Disassembly 41) Remove transmission and transfor case from vehicle. 2) Remove thrust bearing. 8) Disconnect return apring, aiding olutch shaft outwards. 4) Push downwards the bushing on the right side with special too! until the shaft and bushing are out of their housing. 8) Extract bushing on the right side and move clutch shaft upwards, until the lower end is disoonnocted from the bushing, and then exteact shaft of the clutch case. 16) Knock trom outside, to remove bushing on the loft sida, Inspection 4) Check clutch bearing turns smoothly.CLUTCH 70-4 ‘Assembly 1) Press the right-hand bush into the housing untilit stops. Apply grease to the inner surface. 2) Insert the clutch actuating shaft complete with spring into the housing having greased the right hand end. 3) Grease the inside of the left hand bush and its complementary surtace on the shaft 4) Press the left hand bush into position ensuring that the chamfered end is out board until the chamfer ridge ‘is level with the casing, 5) Position the spring ends, one on the casing and the other on the fork. CAUTION ‘Do not wash thrust bearing, this could cause grease to leak and consequently damage the bearing. Assembly 1) Fit clutch lever so that it aligns with center punch marks and tighten bolt and nut. Torque specification: from 10-16 Nm (1.0-1.6 kg.m, 7.0-11.5Ib.f). 2) Apply graphite grease inside the sliding surtace of the thrust bearing, assembly it and check it is properly fitted in the fork. 3) Assemble transmission and transter case on the vehicle. 4) Assemble clutch cable and perform adjustment as previously described.ELECTRICAL SvSTEt SECTION 8 ELECTRICAL SYSTEM NOTE For topies not covered in this section please refer to the corresponding section of the Vitara Service Manual in the PREFACE. LIST OF CONTENTS CHASSIS ELECTRICAL SYSTEM. vn BD Fuses aed INSTRUMENT DIALS BS Instrument panel e3ELECTRICAL SYSTEM 8.2 CHASSIS ELECTRICAL SYSTEM FUSES IGNITION Key ss Toe IF FIETTED iT | | | | | | rete | | | | | L MAIN p=) ONLY USE INDICATED FUSES Roa] O TOA | 10A | 10A | 15A | 15A | 15A | 20A ‘32|© Personne) ‘TSNe" jean) SNe a) SIs O54 aos | O| ORAENIO) 10A] 10A] 10A 20a 15A | 10A] 15A of ltteer me art, [ese me ne SUZUKIELECTRICAL SYSTEM 6.3 INSTRUMENTS AND DIALS INSTRUMENT PANEL 22 | | tf popeS eS cups PESPRRED BREnee He ala TADS Lele li eVeet) Uh debe lee 1. Turn signal ial let side) Q® Toalternator White/Red 2. Hazard light ® ignition Black/White 3. Turn signal (right side) @ To 4WD switch ‘Orange/Black 4, Temperature gauge ® Towater temperature sensor _Yellow/White 5. Parking light ® To pressure switch Yellow/Black 6. ABS light [if ited) @ lorp.m. sensor Brown/White 7. Broke wear warning light (OQ) To AIR BAG unit Yollow/Green 9. Heater light (0) Heoters relay Pink 10. “AIR BAG" light @® To ignition Violet/Red 11. Oil pressure gauge (3) To light key Black 12. Alternator charge gouge 6) To light relay Red/Yellow 13. 2WD light @) To headlamps Red 14, Road lamp Ga) lo fuse box White/Blue 15. lastrument ponel ght To ground Black 16, Coolont temperature warning To indicator light (left side) Green/Yellow 17, Seat belt warning lamp |i ited) to indicator ight (cight sida) Green/Red To Broke fluid level switch Red/Black To cooling level switch light Creen/Red To ABS control unit Red/Blue To parking brake switch Block/Red To fuel gauge Yellow/Red G8) To ground Black/Yellow @ To ignition Black/White G8) To seat belt switch Yellow/Red G9) To temperature switch White/BlackCODED VEHICLE IMMOBILIZER 88.1 ES SA SECTION 8B CODED VEHICLE IMMOBILIZER NOTE For topics not covered in this section, please refer to the corresponding section of the Vitara Serviee Manual ‘outlined in the PREFACE. LIST OF CONTENTS GENERAL OUTLINE sB2 Starting up engine... “83-2 Entering personal code for first time « “88-3 Modifying personal code... so BB-3 Securlty measures 88-3 Satting in service mode. 88-3 Locking system B35 System identification BBS DIAGNOSIS 83-4 tnteoduction. 88-4 Precautions in maifunetionmg diagnosis 20-4 Defect analysis, - 88-5 Testing wiring 88-7 “esting wiring feed: battery positive 83-9 Testing keypad ground... 88-10 Testing keypad feed: positive alter switching on “88-11 ‘Testing keypad connection to contro! module. 86-12 Testing eantral module feed (postive ater switching on} - “8B-13 Testing ignition information to keypad 8B-15 ‘Activating lock with engine running (on opening and closing ctiver's deen) 88-16 Non activation of lock (on opening and closing driver's door) .. S8BAT Activating lock (on apering and closina driver's don. 88-18 Wiring diagrams and identification symbols 8B19‘CODED VEHICLE IMMOBILIZER 88-2 — amo GENERAL OUTLINE The coded vehicle immobilizing system is a inechanism designed to lock the fuel injection system, as long as the access code established by the owner is not entered. It consists of the following components. + Engine control module (ECM) + Injection relay (IR) + Coded im ing keypad (CIK) It functions in the following way: STARTING THE ENGINE ‘When the ignition key is entered and tumed to ON position: ‘+ Ifthe green light on keypad comes on, the engine can be started directly. * It the red light on keypad comes on, the immobilizing system is activated and it is necessary to enter the personal access code. ‘To start up the engine with the red light on, itis necessary to key in your persona! four-digit number. The green light will ‘come on and the red light will go off (On leaving the Factory all vehicles have the code 1111 entered, which the customer may use if they do not wish to change it. U1 yoU Key n the wrong number, key inthe correct four-digit code again. Each time a key is pressed a “beep” is heard. {fan error is made on entering a code or in the process for changing a code, this is signalled by a two second warning sound. ‘With the ignition on, a “beep” sound is made if an attempt is made to start the engine up with the immobilizing system activated. This becomes permanent if the attempt to start continues. NOTE If the incorrect code is entered three times in succession, the keypad is rendered immobilized for thirty minutes. 2. Relay 3. Engine central module 4. Door switch 5. lgnition key 6, Ol preseus witehCODED VEHICLE IMMOBILIZER 68-3 ENTERING PERSONAL CODE FOR FIRST TIME ‘This should be effected In the following way: 4). Turn ignition key to ON position. 2). Enter code 1111. 9). Press key C. 4), Enter a personal four-digit code. 5). Press key C to validate operation. This operation is confirmed by four green flashes and four “beep” sounds. MODIFYING PERSONAL CODE This operation should be effected in the following way: 4). Tutm the ignition key to ON position. 2). Enter memorized code. 9). Pross key C. 4), Enter new four-digit code. 5). Press key C to validate operation. This operation is confirmed by four green flashes and four “beep” sounds. SECURITY MEASURES ‘The two codes (the old one preserved or new one validated) remain present until one of them is used, automatically anulling the other, It the code is not confirmed, take out the key, enter once more and repeat the operation Simultaneous flashing of red and green lights indicates an incorrect operation or a malfunction. If this occurs, wait for approximately 2 minute, switch off and then on again. If the problem persists, a diagnosis of the fault should be effected as indicated below. SETTING IN SERVICE MODE This process allows the customer to let a garage or another person use the vehicle without knowing their personal code. This mode allows the use of inmobilizer function with a variable code, regardless your own code (tour digits). This operation should be etfected in the following way: 1. Enter personal code and press S. 2. Enter service code (the cade 1111 is recommended) and press S. Six green flashes accompanied by six “beep” sounds contirm the operation. ‘Tho service code is automatically anulled when the personal code is entered again, it being unnecessary to go through the code modification process again. LOCKING SYSTEM Locking is effected automatically on switching off in the following cases. 1.Thirty seconds after opening and closing of driver's door. 2.Ten minutes after switching off NOTE: The oil pressure gauge switch is responsible for informing the engine control module, if the engine is off or running If the driver leaves the vehicle without turning off the engine, on opening the door the latter's switch sends a locking signal via the engine control module keypad. At the same time, the oil pressure gauge sends another signal to the running engine. This signal reaches the coded immobilizing module control so that the order received from door switch to lock doors Is not effected. IDENTIFICATION OF SYSTEM System locking can be checked after thiny seconds by observing the red keypad light. This light comes on for ten seconds after system locking and then flashes until the starter motor is engaged again. NOTE In the event of a malfunction or the battery current being cut off, the personal code remains in the memory. In the event of the personal code being lost, it Is necessary to replace the coded ignition engine control module.CODED VEHICLE IMMOBILIZER DIAGNOSIS INTRODUCTION To effect a correct diagnosis and repair of the coded immobilizing mechanism the following steps should be taken: 1) Talk to the with customer to know defective functioning symptoms of system and the conditions in which they have occurred. 2) Closely read the “General Outline” chapter in this section to gain thorough knowledge of the system. 3) Please refer to flow charts for each of the defects detected (see defect analysis). 4) Carry out repair to corresponding mechanism. 5) Perform test to confirm correct repair. PRECAUTIONS ON DIAGNOSING MALFUNCTIONS 1) Do not disconnect: Battery with the engine running. - £.C.M. relay or keypad after switching on. 2) Ensure that the battery is completely charged and that voltage is not lower than 12 v nor higher than 16 v. 3) The majority of intermittent problems are a result of: - Bad condition of cables or connections. + Incortect power supply of terminals, or loose connections. ~ Terminals badly conformed or damaged. + Oxidized terminals. - Faulty connection between terminal and cable. Ensure these faults are repaired before continuing with diagnosis. 4) Do not use a pilot lamp or go over an electric arc with a wire to check continuity of a circuit.CODED VEHICLE IMMOBILIZER 88-5 DEFECT ANALYSIS A-1 ENGINE DOES NOT START Te the customer code correct? Yes Have three successive incorrect codes been | YES| After switching on wait thirty entered? sinutos until system is unlocked NO Enter customer code YES J Check correct functioning of coded immobilizing system {the lights ill go ‘Swatch on m ee Gheck elecincal instalation ~—_—__- >| Red and green LEDS off, see following general vehicle pages 88-9 and 88-11 wiring dhagram. Reed and green LEDS on, seepage Keypad is off t——_——>| Besar Weorrect If none of these cases Red LED flashes, see page applies, carry outan overall aB-11 functions and wiring check, ‘see page 06-7 Red and green LEDS on, see pages 88-12 and 88-13 Keypads itCODED VEHICLE IMMOBILIZER 88-6 aTj__—_—_>rm A-2 ENGINE STARTS Sian up vehice Locking system s activated after 30 sec- ; ‘onds, with engine running on leaving ve- |_YES ee eenes cle? (avers coor opened and closed) OTHE ENGINE STOPS No Locking system isnot activated after 30 Secor, mh engine anmng on waving | YES__g} See page 88-17 wenile? {ortvore door epaned and cloced) a No Locking system is activated ater 30 sec- ‘S00 page 88-1 Conds with engine running on opening and |_YES. lee L Closing doors oer tha vers? No Nes Soe page 88-15 Keypad and green LED stay on? ae No Switch of ‘Switch on fed and green LEDS of See page 90.9 Keypad sof — Red and green LED on Sea page Af 10 Iroone ofthe above cases applies, any out an overall uneion and wnng check. GreentEDSon seepage | | Sueboqe 88-7 Keypad ights Redand green LEDS on, see —+| pageoaeria [Gheokolecticanstlaiontolow ing general vohiclo wing ca rareWIRING TEST PRIOR CONDITIONS: BATTERY VOLTAGE 12 - ENGINE CONTROL MODULE DISCONNECTED - KEYPAD CONNECTOR OIS- ‘CONNECTED Check keypad connector as follows: CODED VEHICLE IMMOBILIZER 88. U,=12V u, = 12 NO. ICheck keypad feed, see page 88:9 Check keypad ground, see page 88-10 ‘See folowing page(CODED VEHICLE IMMOBILIZER 88-8 Continued from previous page Yes ‘Switch on’ ves NO 12v | SS J check keypad feed + after switching on Seo page 88-11 YES NO (Chock ignition information to keypad. See Start up enaine U, | page 88-15 YES Switch off ZA R,s10 - ‘Check Keypad connection to engine Control module, coded ignition YES Seo page 88-13 R512 |__NO___J check Keypad connection 10 enaine oon- trol module, coded ignition, YES See page 88-12 ‘Switch on ]|__NO__ Check engine control module faad, coded ignition + after switching on, See page 88-13 Carry out tect with now keypadCODED VEHICLE IMMOBILIZER 88. KEYPAD POWER FEED BA TAC 1 PRIOR CONDITION BATTERY VOLTAGE = 12¥ Check keypad connector. KEYPAD DISCONNECTEO Try out with new keypadCODED VEHICLE IMMOBILIZER: 10 KEYPAD CONTROL EARTH FU Tac PRIOR CONDITION KEYPAD VOLTAGE SUPPLY (PREVIOUS TEST) Us 12 Check on keypad connector KEYPAD DISCONNECTED U,=12¥ YES Try out with new keypad ‘Check cable continuity of ground @ and ‘ground connection,CODED VEHICLE IMMOBILIZER KEYPAD POWER CONTROL: + AFTER CONTACT cA Tac PRIOR CONDITION BATTERY VOLTAGETE U = 12V (Check keypad connector KEYPAD DISCONNECTED “Test correct Switch on ves uj=12V |_ves ,. Switch off |_,| U,=0v NO I ee NO ‘Check continuity of cables U,= 12 [> i Wi, 0 an ts ves Check continuity of cabia A and ground connection