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SUZUKI VITARA SERVICE MANUAL

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Engine Identification
Table of Contents
Table of Contents
General Information
Abbreviations Used In This Manual
General Precautions
Body Number
Engine Identification Number
Transmission Identification Number
Identification Information
Metric fasteners fastener strength identification
Metric Information
Standard Tightening Torque
Vehicle Lifting Points
Front Support Location
Rear Support Location
Maintenance and Lubrication
Maintenance Schedule Under Normal Driving Conditions
Maintenance Recommended Under Severe Driving Conditions
Maintenance Service
Water Pump Belt Inspection and Replacement
A/C Compressor and/or Power Steering Pump Drive Belt
Camshaft Timing Belt Inspection
Engine Oil and Filter Change
Engine Bolts Tightening
Valve Lash Inspection
Cooling System Hoses and Connections Inspection
Engine Coolant Change
Engine oil capacity
Ignition System
Exhaust Pipes and Mountings Inspection
Ignition Wiring Replacement
Distributor Cap and Rotor Inspection
Spark plugs Replacement
Plug Specification
Fuel System
Ignition Timing Inspection
Distributor Advancer Inspection
Air Cleaner Element Replacement and Inspection
Emission Control System
Carburetor Choke System Lubrication and Inspection
Engine Idle Speed and Idle Mixture Inspection
Oxygen Sensor Replacement
Electrical
Crankcase Ventilation Hoses and Connections Inspection
PCV (Positive Crankcase Ventilation) Valve Inspection
Fuel Vapor Storage System Inspection
Chassis And Body
Clutch Pedal Inspection
Brake Discs, Pads, Brake Drums and Shoes Inspection
Brake Hoses and Pipes Inspection
Brake Lever and Cable Inspection
Tire Inspection and Rotation
Wheel Discs and Free Wheeling Hubs Inspection
Wheel Bearing Inspection
Suspension Inspection
Propeller Shafts Inspection
Transmission Oil Inspection and Change
Fluid Level Inspection
Transfer and Differential Oil Inspection and Change
Steering System inspection
Final Inspection
Power Steering System Inspection
Door Hinges Lubrication
Recommended Fluids and Lubricants
Heater and Ventilation
Heater General Description
Heater Control Operation
Forced Ventilation
Outside Air-Introduced Heating
Inside Air-Circulated Heating
Head-Cooled/Feet-Warmed Heating
Trouble Diagnosis
Servicing
Wiring Circuit
Heater Blower Motor Removal
Heater Blower Motor Installation
Heater Blower Resistor Removal
Heater Blower Resistor Inspection
Heater Blower Resistor Installation
Heater Blower Motor Switch Removal and Inspection
Heater Blower Motor Switch Installation
Control Cables
Air Control Cable Adjustment
Heater Control Cable Adjustment
Fresh Air Control Cable Adjustment
Heater Unit
Body Ventilation
Heater Unit Removal
Heater Unit Installation
Rear Duct Description
Rear Duct Removal
Rear Duct Installation
Bumpers and Sheet Metal
Front Bumper
Rear Bumper
Hood Adjustment
Hood Vertical Adjustment
Hood lock adjustment
Front Fender Removal
Front Fender Installation
Steering, Suspension, Wheels and Tires General Diagnosis
Tire Diagnosis
Irregular And/Or Premature Wear
Wear Indicator
Radial Tire Waddle
Vibration Diagnosis
Radial Tire Lead
Front End Alignment General Information
Toe Setting
Camber
Preliminary Checks Prior To Adjusting Front Alignment
Toe Adjustment
Camber And Caster Adjustment
Steering Angle
Steering Gear Box And Linkage
Steering Gear Box And Linkage General Description
Steering Gear Box Construction and Operation
Steering Gear Box Removal
Steering Gear Box Installation
Tie Rod End Removal
Tie Rod End Installation
Idler Arm Removal
Idler Arm Installation
Steering Wheel Inspection
Steering Gear Box Oil Level
Adjustment Of Worm Shaft Starting Torque
Torque Specifications
Special Tools
Power Steering (P/S) System
Power Steering (P/S) System General Description
Power Steering System Layout
Hydraulic Pressure Circuit
Operation with Steering Wheel in Straight-ahead Position
Operation with Steering Wheel Turned to Right
Valve Unit
Operation with Steering Wheel Turned to Left
Manual Steering
Spring Reaction Mechanism
Power Steering (P/S) Pump
Flow Contol Valve
Components of P/S Pump
Operation of Flow Control Valve (When Idling)
Relief Valve
Operation of Flow Control Valve (When Running at Low Speed)
Operation of Flow Control Valve (When Running at High Speed)
Power Steering System General Diagnosis
On Vehicle Service
Steering Wheel Play Inspection
Steering Force Inspection
Power Steering Belt Tension
Power Steering Belt Tension Adjustment
Power Steering Fluid Level
Idle Up System
Air Bleeding Procedure
Hydraulic Pressure In P/S Circuit
Power Steering (P/S) Gear Box Removal
Power Steering (P/S) Gear Box Installation
Removing Steering Lower Shaft
Removing Center Link End
Removing Steering Gear Box
Installing Steering Gear Box
Power Steering (P/S) Pump Removal
Installing Steering Lower Shaft
Power Steering (P/S) Pump Installation
Power Steering (P/S) Pump Disassembly
Removing P/S Pump Pulley
Removing Terminal Assembly and Discharge Connector
Removing P/S Pump Cover
Removing Cam Ring
Removing Rotor
Power Steering Pump Assembly
Installing Shaft
Installing Rotor
Installing Vane
Installing Cover
Installing Flow Control Valve
Installing Terminal
Installing Suction Connector
P/S Pump Body and Shaft Inspection
Cam Ring Inspection
Rotor Vane Inspection
Flow Control Valve Inspection
Steering Wheel, Column And Shaft Description
Steering Wheel Removal
Steering Wheel Installation
Turn Signal/Dimmer Switch Removal
Turn Signal/Dimmer Switch Installation
Steering Column Removal
Steering Column Installation
Steering Lock Removal
Steering Lock Installation
Steering Lower Shaft Removal
Steering Lower Shaft Installation
Checking Steering Column For Accident Damage
Checking Tilt Steering Column Torque Specifications
Checking Tilt Steering Column Special Tool
Front Suspension
Front Suspension General Description
Stabilizer Bar/Bushings Removal
Stabilizer Bar/Bushings Installation
Strut Damper Removal
Strut Damper Installation
Coil Spring/Bump Stopper/Spring Rubber Seat Removal
Coil Spring/Bump Stopper/Spring Rubber Seat Installation
Bump Stopper/Spring Rubber Seat Removal
Bump Stopper/Spring Rubber Seat Installation
Wheel Hub/Bearing/Oil Seal Removal
Wheel Hub/Bearing/Oil Seal Installation
Knuckle/Wheel Spindle Removal
Knuckle/Wheel Spindle Installation
Suspension Control Arm/Ball Stud/Bushings Removal
Suspension Control Arm/Ball Stud/Bushings Installation
Front Free Wheeling Hub (optional) General Description
Manual Free Wheeling Hub Operation
Manual Free Wheeling Hub Installation Instruction
Manual Free Wheeling Hub Maintenance Service
Automatic Free Wheeling Hub Operation
Automatic Free Wheeling Hub Installation Instruction
Automatic Free Wheeling Hub Maintenance Service
Post-assembly confirmation
Front Suspension Inspection
Bar
Bushing
Strut Damper And/Or Coil Spring
Required Service Materials
Front Suspension Special Tools
Rear Suspension
Rear Suspension General Description
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Coil Spring Removal
Coil Spring Installation
Trailing Rod And Bush Removal
Trailing Rod And Bush Installation
Rear Upper Arm Removal
Rear Upper Arm Installation
Rear Axle Shaft And Wheel Bearing Removal
Rear Axle Shaft And Wheel Bearing Installation
Rear Axle Shaft Inner Oil Seal Removal
Rear Axle Shaft Inner Oil Seal Installation
Rear Axle Housing Removal
Rear Axle Housing Installation
Rear Suspension Inspection
Trailing Rod, Upper Arm, Axle Housing And Coil Spring
Rear Suspension Fasteners
Upper Arm Ball Joint
Bearing Retainer And Axle Shaft Inner Oil Seal
Trailing Rod And Upper Arm Bush
Wheel Disc, Nut & Bearing
Recommended Torque Specifications
Wheels And Tires General Description
Replacement Tires
Wheels For Replacement
Wheel Maintenance
Wheel Attaching Studs
Inflation Of Tires
Wheels and Tires Service Operations
Metric Lug Nuts And Wheel Studs
Tire Placard
Tire Rotation
Balancing Wheels
Tire Mounting And Demounting
Tire Repair
Wheels and Tires Torque Specifications
General Balance Procedure
Off-Vehicle Balancing
On-Vehicle Balancing
Front Drive Axle/Axle Bearing, Oil Seal
Drive Axle General Description
Drive Axle Removal
Drive Axle Disassembly
Drive Axle Inspection
Drive Axle Cleaning
Drive Axle Assembly
Axle Bearing/Oil Seal Removal
Drive Axle Installation
Axle Bearing/Oil Seal Installation
Front Drive Axle/Axle Bearing/Oil Seal Torque Specifications
Front Drive Axle/Axle Bearing/Oil Seal Required Service Materials
Front Drive Axle/Axle Bearing/Oil Seal Special Tools
Propeller Shafts General Description
Propeller Shafts removal
Propeller Shafts Installation
Disassembly of Universal Joint
Universal Joint Noise
Disassembling On Flange Yoke Side
Reassembly Of Universal Joint
Propeller Shafts Required Service Material
Propeller Shafts Special Tools
Brake
Brake General Description
Disc Brake Caliper Assembly General Description
Front Caliper Assembly
Caliper Operation
Single piston floating caliper type
Clearance correction
Drum Brake Assembly General Description
Rear Brake Operation
Master Cylinder Assembly General Description
Master Cylinder Normal Operation
Master Cylinder One-circuit operation
Booster Assembly General Description
Booster Operation
Vacuum Booster Assembly
LSPV (Load Sensing Proportioning Valve) Assembly General
Description
LSPV (Load Sensing Proportioning Valve) Assembly Construction
LSPV (Load Sensing Proportioning Valve) Assembly Operation
Diagnosis
Road Testing Brakes
Brake Fluid Leaks
Substandard Or Contaminated Brake Fluid
Brake Diagnosis Chart
Brake Pedal Free Height Adjustment
Stop Light Switch Adjustment
Excessive Pedal Travel Check
Brake Pedal Play Inspection
Rear Drum Brake Shoe Adjustment
Master Cylinder Inspection
Disc Inspection
Parking Brake Inspection And Adjustment
Flushing Brake Hydraulic System
Bleeding Brakes
Bleeding Air From Master Cylinder
Brake Hose And Pipe Inspection
Brake Fluid Level Inspection
Remove And Install Front Brake Hose/Pipe
Remove And Install Rear Brake Hose/Pipe
Remove And Install Parking Brake Lever
Remove And Install Parking Brake Cable
Disc Brake Removal & Installation
Remove And Install Pad (Shoe & Lining)
Remove And Install Caliper Assembly
Remove And Install Seal, Piston, Dust Boot And Bleeder Screw
Remove And Install Disc
Disc Brake Inspection
Inspect Brake Pad Lining
Inspect Brake Caliper Inner Parts
Inspect Brake Disc
Remove And Install Brake Drum
Remove And Install Brake Shoe
Remove And Install Wheel Cylinder
Remove And Install Brake Back Plate
Inspect Brake Drum
Inspect Brake Shoe & Lining
Inspect Wheel Cylinder
Inspect Brake Strut
Inspect Springs
Inspect Parking Shoe Lever
Remove And Install Master Cylinder Reservoir
Remove And Install Master Cylinder Assembly
Disassemble And Assemble Master Cylinder
Inspect Master Cylinder
Fill Reservoir
Remove And Install LSPV
LSPV Inspection & Adjustment
Fluid Pressure Test
Remove And Install Brake Booster Repair
Disassemble And Assemble Booster
Inspect Booster Inner Parts
Inspect/Adjust Clearance Between Booster Piston Rod And Master
Cylinder Piston
Inspect Booster Operation
Booster Inspection Table
Brakes Recommended Torque Specifications
Brakes Required Service Materials
Brakes Special Tools
Engine General Information
Statement On Cleanliness And Care
Cylinder Numbers
General Information On Engine Service
Fuel Pressure Relief Procedure
Fuel Leakage Check Procedure
Engine Diagnosis
Engine Mechanical
Engine Mechanical General Description
Engine Construction
Engine Lubrication
Cylinder Head And Valve Train
Cylinder Block
Crankshaft And Main Bearings
Pistons, Rings, Piston Pins And Connecting Rods
Compression Check
Engine Vacuum Check
Oil Pressure Check
Valve Lash Specifications
Valve Lash Checking And Adjusting Procedures
Air Cleaner Element Remove
Air Cleaner Element Clean
Air Cleaner Element Inspect
Air Cleaner Element Install Or Connect
Air Intake Case Remove or Disconnect
Distributor Gear Case Remove Or Disconnect
Distributor Gear Case Install Or Connect
Throttle Body And Intake Manifold Remove Or Disconnect
Throttle Body And Intake Manifold Install Or Connect
Disconnecting Wire Harnesses
Intake Manifold Installation
Gasket Installation
Connecting Vacuum Hoses
Accelerator Cable and Kick-Down Cable
Exhaust Manifold Remove Or Disconnect
Exhaust Manifold Install Or Connect
Cylinder Head Cover Remove Or Disconnect
Cylinder Head Cover Install Or Connect
Timing Belt And Belt Tensioner Remove Or Disconnect
Timing Belt And Belt Tensioner Inspect
Timing Belt And Belt Tensioner Install Or Connect
Oil Pan And Oil Pump Strainer Remove Or Disconnect
Oil Pan And Oil Pump Strainer Clean
Oil Pan And Oil Pump Strainer Install Or Connect
Oil Pump Remove Or Disconnect
Oil Pump Disassemble
Oil Pump Inspect
Radial Clearance Measure
Side Clearance Measure
Oil Pump Assemble
Oil Pump Install Or Connect
Rocker Arms And Rocker Arm Shafts Remove Or Disconnect
Removing Front Grille
Rocker Arms And Rocker Arm Shafts Inspect
Adjusting Screw and Rocker Arm
Locking Camshaft
Valve Adjusting Screw and Lock Nut
Rocker Arms And Rocker Arm Shafts Install Or Connect
Rocker Arm Shaft Runout
Rocker Arm-To-Rocker Arm Shaft Clearance
Camshaft, Valves And Cylinder Head Remove Or Disconnect
Camshaft, Valves And Cylinder Head Disassemble
Camshaft Inspect
Valve Cotters Removal
Valve Stem Oil Seal Removal
Valve Guide Removal
Camshaft Runout Measurement
Camshaft Journal Dia. Measurement
Journal Bore Dia. Measurement
Valve Stem Dia. and Valve Guide I.D. Measurement
Valve Stem End Deflection Measurement
Valve Head Thickness
Radial Runout Measurement
Valve Seating Contact Width
Valve Seat Cutting
Valve Seat Angles for Exhaust and Intake Valves
Locations for Measurement of Distortion
Surface Measurement
Measuring Surface of Intake Manifold Seating Face
Valve Springs
Measuring Surface of Exhaust Manifold Seating Face
Measuring Free Length of Spring
Measuring Spring Preload
Reaming Guide Hole
Valve Guide Installation
Reaming Valve Guide Bore
Valve Stem Seal Installation
Valve Installation
Valve Spring Installation
Valve Cotter Installation
Camshaft Installation
Cylinder Head Gasket Installation
Tightening Sequence of Cylinder Head Bolts
Pistons, Piston rings, Connecting Rods And Cylinder Remove Or
Disconnect
Pistons, Piston rings, Connecting Rods Disassemble
Pistons, Piston rings, Connecting Rods Inspect
Removing Piston Pin
Position to be Measured
Measuring Cylinder Bore with Cylinder Gauge
Measuring Piston Diameter with Micrometer
Measuring Ring Groove Clearance
Measuring Small End Bore
Measuring Piston Ring End Gap
Measuring Side Clearance
Crank Pin and Connecting Rod Bearings
0.25mm Undersize Bearing
Installing Bearing Cap
Measuring Rod Bearing Clearance
Piston Identification
Cylinder Identification
Piston to Cylinder Orientation
Fitting Connecting Rod to Piston
Piston Rings Installation
Piston Ring End Gaps Positions
Direction of Arrow Mark on Piston Head
Installing Piston to Cylinder
Unit Repair Overhaul
Engine Assembly
Disconnecting Water Hoses
Exhaust Center Pipe
Clutch Cable
Removing Torque Converter Bolt
Hoisting Engine Assembly
Engine Assembly Install Or Connect
Engine Mounting
Main Bearings, Crankshaft And Cylinder Block
Main Bearings, Crankshaft And Cylinder Block Remove Or
Disconnect
Main Bearings, Crankshaft And Cylinder Block Inspect
Crankshaft Runout
Crankshaft thrust play
Out-of-round and taper (uneven wear) of journals
Main Bearings General Information
Main Bearings Inspect
Main bearing clearance
Selection of main bearings
Rear Oil Seal
Flywheel
Cylinder Block Distortion of gasketed surface
Honing or reboring cylinders
Main Bearings, Crankshaft And Cylinder Block Install Or Connect
Installing Main Bearing Caps
Cutting Off Edges of Gasket
Engine Mechanical Special Tools
Engine Mechanical Required Service Materials
Engine Mechanical Recommended Torque Specifications
Engine Cooling
Engine Cooling General Description
Cooling System Circulation
Radiator Cap
Water Reservoir Tank
Pressure Type Radiator Cap
Water Pump
Thermostat
Cooling Fan Clutch
Water Temp Gauge
Engine Cooling Diagnosis
Engine Cooling Maintenance
Coolant
Coolant Level
Coolant Capacity
Cooling System Service
Cooling System Flush And Refill
Water Pump Belt Tension
Coolant Draining
Cooling Water Pipes Or Hoses Removal
Cooling Water Pipes Or Hoses Installation
Thermostat Removal
Thermostat Inspection
Thermostat Installation
Water Pump Belt Removal
Water Pump Belt Installation
Water Pump Belt Tension Inspection
Cooling Fan, Fan Clutch And Water Pump Pulley Removal
Radiator Removal
Radiator Inspection
Radiator Installation
Water Pump Inspect
Water Pump Installation
Engine Cooling Required Service Materials
Engine Fuel General Description
Fuel System (Carburetor Model)
Fuel Tank
Fuel Pump
Fuel Filler Cap
Fuel Filter (Fuel Injection Model)
Fuel Filter (Carburetor Model)
Fuel Pump (Carburetor Model) Removal
Fuel Pump (Carburetor Model) Installation
Fuel Lines (Fuel Injection Model)
Fuel Lines (Fuel Injection Model) Inspect
Fuel Lines (Carburetor Model)
Fuel Tank Remove Or Disconnect
Fuel Tank Purging Procedure
Fuel Tank Inspect
Fuel Tank Install Or Connect
Fuel Filter Remove Or Disconnect
Fuel Filter Install Or Connect
Engine Fuel Recommended Torque Specifications
Fuel Filter Removal
Fuel Filter Installation
Carburetor
Carburetor General Description
Float System
Primary Slow System
Primary Main System
Secondary Slow System
Secondary Main System
Acceleration Pump System
Choke System
At Cold Engine Start
Immediately After Engine Start
Operation Of Unloader System
Choke Opening
Carburetor Removal
Carburetor Installation
Carburetor Unit Repair Overhaul
Carburetor Disassembly
Carburetor Cleaning
Carburetor Inspection
Carburetor Assembly
Primary And Secondary Main Jets
Float Chamber Cover
Accelerator Cable Play
Float Level Inspection
Float Level Adjustment
Idle Speed And Idle Mixture Inspection
Idle Speed And Idle Mixture Adjustment
Idle Up Inspection
TWSV (Three Way Solenoid Valve)
Idle Up Adjustment
Choke System Inspection
Fast Idle Inspection
Fast Idle Adjustment
Secondary Diaphragm Inspection
Unloader System Inspection
Manual Choke Type Carburetor Inspection
Manual Choke Type Carburetor Adjustment
Fuel Cut System Inspection
Accelerator Pump Inspection
Accelerator Pump Stroke
Carburetor Special Tool
Electronic Fuel Injection System
Electronic Fuel Injection System General Description
Air And Fuel Delivery System
Fuel Pump Cross-Section
Throttle Body Cross-section
Fuel Injector Cross-section
Fuel Pressure Regulator
Air Valve
ISC (Idle Speed Control) Solenoid Valve
Electronic Control System Component Parts Location
Electronic Control System Wiring Diagram
Electronic Control System Schematic
Electronic Control Module (ECM)
Self-diagnosis function
"CHECK ENGINE" Light Circuit
Fail-safe function
Back-up function
Pressure Sensor (PS)
Throttle Position Sensor (TPS)
Air Temperature Sensor
Water Temperature Sensor
Oxygen Sensor with Heater
Vehicle Speed Sensor (VSS)
Crank Angle Sensor (CAS)
Ignition Signal (Ignition fail safe signal)
Engine Start Signal
Power Steering Signal
Shift Switch (A/T only)
Fuel Injection Control System
Diagnosis Switch Terminal
Test Switch Terminal
Injection Timing
Injection Time (amount of injection)
Barometric pressure compensation
Intake air temperature compensation
Enriching compensation while warming up
Enriching compensation after engine start
Fuel feed back compensation (Air/fuel ratio compensation)
Oxygen Sensor Heater Control System
ISC Solenoid Valve Control System
Fuel Pump Control System
Throttle Opener Control System
Exhaust Gas Recirculation (EGR) Control System
ESA (Electronic Spark Advance) System
Ignition Timing Control at Engine Start
Ignition Timing Control After Engine Start
Electric Current Flow Time Control
Fuel Evaporative Emission Control System
Lock-Up Relay Control System (A/T vehicle only)
Precautions In Identifying Diagnostic Code
Intermittent Trouble
Notes On System Circuit Inspection
Checking Voltage and Terminal Position
Connecting Meter Probe
Checking Battery Voltage
Diagnostic Flow Chart For Electronic Fuel Injection System
Electronic Fuel Injection System Diagnostic Code Table
ECM Power And Ground Circuit Check
A-2 "Check Engine" Light Circuit Check
A-3 "Check Engine" Light Doesn't Flash Or Just Remains On Even
With Diagnosis Switch Terminal Grounded
Code No 13 Oxygen Sensor Circuit (Signal Voltage Doesn't
Change)
Code No. 14/WTS (Water Temperature Sensor) Circuit (Low
Temperature Indicated, Signal Voltage High)
Diagnostic Flow Chart For Code No. 14
Code No. 15 WTS (Water Temperature Sensor) Circuit (High
Temperature Indicated, Signal Voltage Low)
Code No. 15 TPS(Throttle Position Sensor) Circuit (Signal Voltage
High)
Code No. 22 TPS(Throttle Position Sensor) Circuit (Signal Voltage
Low)
Code No. 23 ATS (Air Temperature Sensor) Circuit (Low
Temperature Indicated, Signal Voltage High)
Code No. 23 ATS (Air Temperature Sensor) Circuit (High
Temperature Indicated, Signal Voltage Low)
Code No. 24 VSS(Vehicle Speed Sensor) Circuit
Vehicle Speed Lower Than 1.4km/h (0.9mile/h) Although Fuel Is
Kept Cut For Longer Than 3.5 Seconds
Code No. 31 PS(Pressure Sensor) Circuit (Signal Voltage High-High
Pressure-Low Vacuum)
Code No. 31 PS(Pressure Sensor) Circuit (Signal Voltage Low-Low
Pressure-High Vacuum)
Code No. 41 Ignition Signal Circuit (Ignition Fail Safe Signal Not
Inputted)
Code No. 42 CAS(Crank Angle Sensor) Circuit
Sensor Signal Not Inputted For 3 Seconds At Engine Cranking
Code No.44 Idle Switch Circuit
Circuit Open Or TPS Installation Angle Maladjusted
Code No. 45 Idle Switch Circuit
Circuit Short Or TPS Installation angle Maladjusted
Electronic Fuel Injection System Trouble Diagnosis
B-1 Fuel Injector And Its Circuit Check (Engine No Starting)
B-2 Fuel Pump Circuit Check
B-3 Fuel Pressure Check
B-4 Throttle Opener System Check
B-5 ISC Solenoid Valve Control System Check
B-6 EGR System Check
B-7 Fuel Evaporative Emission Control System Check
ECM And Its Circuit Check
Voltage Check
Resistance Check
Vacuum Hose Routing
Accelerator Cable Adjustment
Kick-Down Cable Adjustment
Idle Speed/ISC Duty Adjustment
Grounding Diagnosis Switch Terminal
Connecting Adapter Wire For Tachometer
Throttle Opener Adjustment
Engine Idle Speed And ISC Duty
Idle Speed Adjusting Screw
Checking and Adjusting Engine Speed For Opener
Fuel Pressure Inspection
Connecting Fuel Pressure Gauge
Checking Fuel Pump
Checking Fuel Pressure
Removing Fuel Pump
Fuel Pump Inspection
Fuel Pump Installation
Throttle Body Parts Identification
Checking Vacuum Passage
Air valve inspection
Throttle Body Removal
Throttle Body Disassembly
Throttle Body Cleaning
Throttle Body Assembly
Throttle Body Installation
Clamping Wire Harness
Checking Resistance of Fuel Injector
Checking Fuel Injection
Fuel Injector Removal
Fuel Injector Inspection
Fuel Injector Installation
Fuel Pressure Regulator Removal
Fuel Pressure Regulator Installation
Connecting Fuel Injector Wires
ISC Solenoid Valve Removal
ISC Solenoid Valve Installation
Electronic Control Module (ECM) Removal
Electronic Control Module Installation
Pressure Sensor Output Voltage Check
Pressure Sensor Individual Check
Throttle Position Sensor Inspection
Throttle Position Sensor Adjustment
Throttle Position Sensor Removal
Inserting Thickness Gauge
Adjusting Installation Angle of TPS
Removing Terminals
Throttle Position Sensor Installation
Air Temperature Sensor Removal
Air Temperature Sensor Inspection
Air Temperature Sensor Installation
Water Temperature Sensor Removal
Water Temperature Sensor Inspection
Water Temperature Sensor Installation
Oxygen Sensor Removal
Oxygen Sensor Installation
Vehicle Speed Sensor Inspection
Shift Switch Inspection
Shift Switch Adjustment
Shift Switch Removal and Installation
Adjusting Shift Switch Position
Installing Selector Cable
Main Relay Inspection
Main Relay and Fuel Pump Relay Circuits
Checking Main Relay Resistance
Checking Main Relay Operation
Fuel Pump Relay Inspection
Fuel Cut Operation Inspection
Throttle Opener System Inspection
Throttle Opener Vacuum Hoses Inspection
VSV(Vacuum Switching Valve) Inspection
Checking Throttle Opener
Checking Resistance
Checking Opener VSV
EGR System Inspection
EGR Vacuum Hose Inspection
EGR Valve Inspection
EGR Modulator Inspection
Canister Purge Inspection
Vacuum Passage Inspection
Vacuum Hose Inspection
VSV (Vacuum Switching Valve) Inspection
Charcoal Canister Inspection
2-Way Check Valve Inspection
Oxygen Sensor Heater Inspection
Canister Hoses
Lock-up Relay Control System Inspection
Lock-up Relay Control System Circuit
Lock-up Relay and Its Circuit
Brake Pedal Switch
Electronic Fuel Injection System Special Tools
Electronic Fuel Injection System Recommended Torque
Specifications
Ignition System General Description
Ignition Circuit Diagram
Ignition System Distributor
Ignition System Diagnosis
High Tension Cords
Spark Plugs
Rubber Boot
Ignition Coil
Signal Rotor Air Gap
Ignition Timing
Plug Gap
Ignition Timing Checking
Ignition Timing Adjusting
Checking Centrifugal Advancer
Checking Vacuum Advancer
Checking Generator Assembly
Checking Signal Rotor Position
Inserting Screw Driver
Distributor Remove or Disconnect
Distributor Disassemble
Distributor Inspect
Distributor Assemble
Distributor Install Or Connect
Distributor Driven Gear Inspect
Distributor Driven Gear Remove
Distributor Driven Gear Install
High Tension Cords Distribution
Ignition System Special Tools
Distributor Gear Case Remove
Distributor Gear Case Install
Cranking System (reduction type) General Description
Cranking Circuit
Starting Motor
Cranking System Diagnosis
Starting Motor Removal And Installation
Starting Motor Repair
Magnetic Switch Removal
Magnetic Switch Installation
Motor Brush Removal
Motor Brush Installation
Rear Bush (Bearing) Removal
Rear Bush (Bearing) Installation
Armature/Yoke Removal
Armature/Yoke Installation
Over-Running Clutch Removal
Over-Running Clutch Installation
Starting Motor Inspection
Inspect Plunger
Inspect Brush
Ground Test
Open Circuit Test
Inspect Brush Holder And Spring
Inspect Pinion And Over-Running Clutch
Inspect Armature Shaft Bushes
Inspect Magnetic Switch
Inspect Gears
Pull-In Coil Open Circuit Test
Hold In Coil Open Circuit Test
Performance Test
Pull-In Test
Hold-In Test
Check Plunger Return
Cranking System Specifications
Cranking System (No-Reduction Type)
Cranking System Lubrication
Cranking System Removal And Installation
Cranking System Disassembly
Inspect Commutator
Inspect Drive Lever
Inspect Pinion
Inspect Armature Shaft Bush
Charging System
Battery General Description
Care of Battery
Battery Remove and Replace
Battery Cables
Generator General Description
Generator Data And Specifications
Generator Diagnosis
Noise Generator
Faulty Indicator Lamp Operation
Undercharged Battery
Overcharged Battery
Generator Removal
Generator Installation
Generator Disassembly
Rotor Inspection
Stator Inspection
Brush And Brush Holder Inspection
Rectifier Inspection
Generator Assembly
Condenser Inspection
Emission Controls
Emission Controls General Description
Positive Crankcase Ventilation (PCV) System
Dash Pot System Operation
Thermostatically Controlled Air Cleaner (TCAC) System Operation
Charcoal Canister Storage System
Catalytic Converter
Bowl Vent Valve
Fuel Cut System
Exhaust Gas Recirculation (EGR) System
Exhaust Gas Recirculation (EGR) System Operation
Checking Positive Crankcase Ventilation (PCV) System
PCV Hoses
PCV Valve
VTV (Vacuum Transmitting Valve)
Dash Pot Adjustment
Exhaust System General Description
Exhaust System Maintenance
Exhaust System Recommended Torque Specification
Manual Transmission General Description
Manual Transmission Cutaway
Manual Transmission Exploded View
Manual Transmission Diagnosis
Manual Transmission And Transfer Maintenance Service
Oil Change
Transfer Oil Seals
Rear Case Oil Seal
Center Case Oil Seal (Front Side)
Shift Control Levers Removal
Shift Control Levers Inspection And Installation
Transfer 4WD Switch
Back-Up Light Switch
Inspection Of 4WD Switch And Back Up Light Switch
Speedometer Driven Gear Removal
Speedometer Driven Gear Installation
Engine Rear Mounting
Dismounting Of Trans. Unit
Gear Shift Control General Description
Gear Shift Lever Case Disassembly
Gear Shift Lever Case Inspection and Reassembly
Installing Return Inner Spring
Gear Shift Lever Case Plug
Assembling Select Return System
Transmission Unit Removal
Checking Gear Shift
Removing Rear Case
Removing Bearing Retainer
Removing Circlip
Removing Rear Bearing
Removing Reverse Idle Gear
Removing Bearing Plate
Inspection And Installation Of Counter Shaft
Removing Outside Circlip
Removing Counter Shaft
Removing Front Bearing
Press-Fitting Front Bearing
Press-Fitting Shaft with Bearing
Fitting Circlip
Installing Bearing Plate
Input Shaft-Main Shaft Assembly
Disassembly of Main Shaft
Press-Fitting Input Shaft Bearing
Removing High Speed Hub
Inspection of Main Shaft Inner Parts
Assembling Main Shaft
Upper Case And Shifter Disassembly
Upper Case And Shifter Inspection
Upper Case And Shifter Reassembly
Transmission Rear Case
Assembling Unit
Connection Of Transmission And Transfer
Manual Transmission Recommended Torque Specifications
Manual Transmission Required Service Materials
Manual Transmission Special Tools
Automatic Transmission
Automatic Transmission General Description
180-C Transmission Cutaway
Automatic Transmission Schematic
Automatic Transmission Component Operation Chart
Automatic Transmission Shift Point at Full Throttle
Line Pressure Test
Placing Wooden Block
Setting Oil Pressure Gauge
Transmission Oil Circuit - Park - T.C.C. Off
Transmission Oil Circuit - Drive 3 - T.C.C. On
Automatic Transmission Diagnosis
Preliminary Checking Procedure
T.C.C. Diagnosis (Fuel Injection Model Only) Electrical Check
Solenoid Valve Check
Checking Normal Function of Solenoid Valve
Automatic Transmission Maintenance Service
Fluid Change Intervals
Fluid Level And Capacity
Level Check At Normal Operating Temperature
Oil Cooler And Oil Hoses
Level Check At Room Temperature
Changing Fluid
Vacuum Modulator Diagnosis
Vacuum Modulator Removal
Vacuum Diaphragm Check
Vacuum Modulator Installation
Kick-Down Cable Removal and Installation
Select Cable Removal
Select Cable Installation And Adjustment
Selector Assembly Removal
Selector Assembly Installation
Manual Selector Components
Brake Interlock System
Unit Repair Overhaul General Service Procedures
Clutch Plate And Piston Spring Diagnosis
Dismounting Of Automatic Transmission With Transfer
Causes Of Burned Clutch Plates
Cooler Line Flushing
After Dismounting Of Automatic Transmission With Transfer
Supporting Transmission and Transfer
Holding Transmission and Transfer
Removing Torque Converter
Automatic Transmission Remounting
Torque Converter Construction and Operation
Torque Converter Stator Operation
Torque Converter Stator Assembly Remains Locked Up
Automatic Transmission Unit Removal
Removing Servo Piston
Removing Shift Switch
Removing Spring Pin
Removing Nut
Removing Adapter Case
Removing Vacuum Modulator
Removing Kick-down and Modulator Valves
Removing Governor Assembly
Removing Governor Housing Oil Seal
Removing Oil Pump
Removing Internal Parts
Sub Assembly Service
Adapter Case
Governor Hub
Governor Body
Automatic Transmission Case Assembly
Manual select shaft
Valve Body disassembly
Removing Retaining Clip
Valve Body Component Parts
Valve Body Inspection and Installation
Converter Housing, Oil Pump and Reverse Clutch Disassembly
Marking Oil Pump Gear
Removing Reverse Clutch Piston
Blowing Compressed Air
Second Clutch Assembly Disassembly
Aligning Converter Housing to Oil Pump
2nd Clutch Inner Parts
Second Clutch Assembly Inspection and Installation
Removing 2nd Clutch Piston
2nd Clutch Piston Seals
Installing 2nd Clutch Piston
Third Clutch Assembly Disassembly
2nd-to-3rd Clutch Thrust Washer
Removing One-way Clutch Assembly
Third Clutch Assembly Inspection and Installation
Installing 3rd clutch assembly into 2nd clutch assembly
Planetary Gear Carrier
Low Brake To Planetary Gear Carrier
2nd clutch-3rd Clutch Assembly To Reverse Clutch Plates
Choosing Selective Washer
Measuring Thrust Clearance
Reverse Clutch, Oil Pump and Converter Housing
Governor Assembly to Adapter Case
Servo Piston
Shift Switch and Oil Pan
Pipes and Brackets
Tightening Bolts and Nuts
Joining Transfer To Transmission
Torque Converter
Automatic Transmission Recommended Torque Specifications
Automatic Transmission Required Service Materials
Automatic Transmission Special Tools
Automatic Transmission Brake Interlock System General
Description
Automatic Transmission Brake Interlock System Operations
Shift Lock Solenoid
Manual Release
Automatic Transmission Brake Interlock System removal
Interlock System
Automatic Transmission Brake Interlock System Installation
Adjusting Interlock Cable
Adjusting Brake Light Switch
Automatic Transmission Brake Interlock System Inspection
Clutch General Description
Clutch Cutaway
Clutch Diagnosis
Clutch Maintenance Service
Clutch Pedal Height
Clutch Pedal Free Travel
Clutch Switch Adjustment
Clutch Switch Inspection
Clutch Cable Removal
Clutch Cable Inspection
Clutch Cable Installation
Clutch Unit Repair Overhaul
Clutch Cover, Clutch Disc And Flywheel Dismounting/Remounting
Clutch Cover, Clutch Disc And Flywheel Removal
Clutch Cover, Clutch Disc And Flywheel Inspection
Clutch Cover, Clutch Disc And Flywheel Installation
Clutch Release System Removal
Clutch Release System Inspection
Clutch Release System Installation
Clutch Recommended Torque Specifications
Clutch Required Service Material
Clutch Special Tools
Transfer General Description
Transfer Cutaway
Transfer Exploded View
Transfer Unit Repair Overhaul
Transfer Dismounting
Transfer Removal
Transfer Inspection
Transfer Assembling Unit
Connection Of Transfer And Transmission
Transfer Dismounting In Engine Room
Transfer Dismounting In Cabin
Transfer Dismounting On Lift
Transfer Remounting
Speedometer Cable Removal
Speedometer Cable Installation
Transfer Recommended Torque Specifications
Transfer Required Service Materials
Transfer Special Tools
Differential (Front and Rear) General Description
Front Differential Exploded View
Rear Differential Exploded View
Differential Maintenance Service
Front Differential Mounting
Changing Differential Oil
Removing Mounting Bracket R
Removing Mounting Bracket L
Removing Mounting Bush
Bush Alignment
Positioning Bushes
Differential Unit Repair Overhaul
Front Differential Dismounting
Removing Rear Mounting
Separating Propeller Shaft
Front Differential Remounting
Front Differential Disassembly
Disconnecting Rear Mounting
Separating Drive Shaft R
Disassembling Differential
Removing Bevel Pinion
Removing Side Bearing
Removing Bevel Gear
Front Differential Adjustment and Reassembly
Differential Carrier
Differential Case
Drive Bevel Pinion
Measuring Bevel Pinion Mounting Distance for Front Differential
Combination of Differential Preloads
Checking Gear Tooth Contact
Diagnosis and Remedy of Gear Mesh
Rear Differential Dismounting
Caulking nut
Rear Differential Remounting
Rear Differential Disassembly
Rear Differential Adjustment and Reassembly
Reassembly Of Differential Case
Differential Recommended Torque Specifications
Adjustment Of Bevel Pinion
Differential Required Service Materials
Differential Special Tools
Body Electrical System General Description
Wiring
Fuses System Circuit
Main Switch Inspection
Main Switch and Coupler
Continuity Check
Combination Switch Inspection
Combination Switch Continuity
Light Turn Signal/Dimmer Switch
Wiper/Mist & Washer Switch
Instruments And Gauges
Combination Meter Wiring
Body Electrical System Trouble Diagnosis
Fuel Meter/Fuel Gauge Unit Description of Circuit
Fuel Meter Inspection
Gauge Unit Inspection
Rheostat Fuel Gauge Circuit
Testing Fuel Gauge
Water Temp.Meter/Gauge Unit Description of Circuit
Water Temp.Meter Inspection
Water Temperature Gauge Circuit
Checking Temperature Gauge
Gauge Unit
Resistance-Temp.Relationship
Oil Pressure Light Description of Circuit
Oil Pressure Switch Inspection
Oil Pressure Switch Circuit
Brake Fluid Level Warning Light Description of Circuit
Brake Warning Circuit
Operation of Warning Light
Brake fluid level switch inspection
Seat Belt Warning Light/Buzzer Description of Circuit
Seat Belt Warning Light/Buzzer Inspection
Light Systems
Headlight Wiring Diagram
Headlight Trouble Diagnosis
Setting Headlight Beams
Headlight Inspection
Vertical beam alignment
Headlight Adjustment
Horizontal beam alignment
Daytime Running Light System Circuit
Dim-Dip System Circuit
Turn Signal And Hazard Warning Light Circuit
Turn Signal And Hazard Warning Light Trouble Diagnosis
Turn Signal And Hazard Warning Light Inspection
Back-up Lights Wiring Circuit
Back-up Lights Trouble Diagnosis
Stop Lights Wiring Circuit
Stop Lights Trouble Diagnosis
Small, Tail, And License Lights Wiring Circuit
Small, Tail, And License Lights Trouble Diagnosis
Interior Light Wiring Circuit
Interior Light Trouble Diagnosis
Cigar Lighter, Radio Wiring Circuit
Cigar Lighter, Radio Trouble Diagnosis
Light Warning Buzzer Description of Circuit
Light Warning Buzzer Inspection
Inspection Of Warning Controller
Windshield Wipers (Front Wiper)
Description Of Circuit (Windshield Wipers)
Intermittent Wiper Relay Circuit (Optional)
Mist Wiper Circuit
Windshield Wiper Wiring Diagram
Windshield Wiper Trouble Diagnosis
Wiper/Washer Switch Inspection
Wiper Motor Inspection
Washer Pump Inspection
Intermittent Wiper Relay Circuit
Checking Int. Relay Operation Sound
Wiper Motor, Linkage and Arms Installation
Rear Window Defogger Trouble Diagnosis
Rear Window Defogger Circuit
Defogger Switch Inspection
Defogger Wire Inspection
Defogger Circuit Repair
Rear Window Defogger Installation
Rear Window Wiper And Washer
Rear Wiper Circuit
Description Of Circuit And Trouble Diagnosis
Wiper and Washer Switches Inspection
Hole Drilling
Power Window Control System General Description
Component Parts Location and Wiring Diagram
Power Window Control System Operation
Rotation Direction of Motor and Circuit
Power Window Control System Circuit
Sub Switch System Circuit
Electric Power Mirror Control System General Description
Electric Power Mirror Control System Wiring Diagram
Electric Power Mirror Control System Circuit
Central Locking System Wiring Diagram
Central Locking System Circuit And Operation
Locking Operation
Unlocking Operation
Central Locking System Trouble Diagnosis
Headlight Beam Leveling System Operation
Headlight Beam Leveling System Circuit
Wiring Harness Routing
Right Side Inner Fender Wiring
Left Side Inner Fender Wiring
Floor Wiring
Engine Room Wiring No.1
Engine Room Wiring No.2
Cowl Upper Wiring
Instrument Panel Wiring
Manual Transmission Wiring
Automatic Transmission Wiring
Battery/Main Fuse Box
Back Door Wiring (Van Type)
Back Door Wiring (Canvas Top Type)
Rear Wiring
Front Door Wiring
Grounding Points
Body Electrical System Special Tool
Body Service
Front Door Glass Removal
Front Door Assembly
Front Door Glass Installation
Front Door Window Regulator Removal
Front Door Window Regulator Inspection
Front Door Window Regulator Installation
Front Door Lock Assembly Removal
Front Door Lock Assembly Installation
Front Door Assembly Removal
Front Door Assembly Installation
Back Door (Van Type) Removal
Back Door Assembly
Back Door (Van Type) Installation
Back Door Balancer Attaching Points
Wiring Harness Clamp Location
Sealing Cover Adhesive Application
Back Door Window Glass Removal and Installation
Outside Rear View Mirror Removal
Outside Rear View Mirror Installation
Door Sealing Cover
Windshield Removal
Windshield Installation
Quarter Window Adhesive Procedure
Front Seat Removal
Front Seat Installation
Front Seat Assembly
Rear Seat Assembly
Rear Seat Removal
Rear Seat Installation
Checking & Adjusting Seat Latch Engagement
Servicing Seat Belts
Front and Rear Seat Belt Set
Seat Belts Removal and Installation
Rear Seat Inspection
Head Lining Removal
Head Lining Installation
Anti-Corrosion Treatment
Metal Replacement Parts Finishing
Ander Body Sealing
Under Body Sealing
Under Coating/Anti-Corrosion Compound Application
Underbody
Underbody Dimensions
Body Dimensions
Removal Of Minor Scratches And Abrasions
Glass Polishing Procedure
Wiring Diagram
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