Suzuki SF413 - Checking Gear and Synchonizer Ring; Assembling High Speed Sleeve and Hub; Press-Fitting Input Shaft R Bearing; Air Checking Oil Holes

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Table of Contents2
Table of Contents: General Information4
Vehicle Identification4
Engine and Transmission Identification5
Metric Fasteners6
Fastener Strength Identification6
Bolt Strength Markings6
Standard Tightening Torque7
Vehicle Lifting Points8
Precaution against Tipping8
Front/Rear Support Locations8
Table of Contents: Maintenance and Lubrication10
Maintenance Schedule: Normal Condition11
Maintenance Recommended under Severe Driving Conditions13
Water Pump Belt Inspection and Replacement14
Engine Oil and Filter Change14
Engine Maintenance Service14
Engine Oil Capacity15
Cooling System, Hoses and Connections Inspection16
Engine Coolant Change16
Exhaust Pipes and Mountings Inspection17
Wiring Harness and Connections Inspection17
Ignition System Maintenance18
Spark Plugs Inspection and Replacement18
Plug Specification18
Distributor Cap and Rotor Inspection18
Ignition Wiring Inspection and Replacement19
Carburetor Choke System Inspection19
Air Cleaner Element Replacement19
Air Cleaner Element Inspection19
Engine Idle Speed and Idle Mixture Inspection20
Fuel Tank, Cap Gasket and Fuel Lines Inspection20
Fuel Filter Replacement20
Emission Control System Maintenance21
Brake Maintenance21
Brake Hoses and Pipes Inspection22
Brake Fluid Inspection and Change22
Brake Lever and Cable Inspection22
Brake Pedal Inspection22
Chassis and Body Maintenance23
Clutch Pedal Free Travel Inspection23
Tire and Wheel Disc Inspection23
Drive Axle Boot, Suspension System Inspection23
Steering System Inspection24
Transmission Oil Inspection and Change24
Automatic Transmission Inspection25
Door Hinges, Gear Shift Control Lever and Shaft Lubrication25
Final Inspection: Body Parts Operation25
Owner Inspections and Services: before Operating Your Car - Outside26
Owner Inspections and Services: before Operating Your Car - Inside26
Owner Inspections and Services: before Operating Your Car - under Hood27
Owner Inspections and Services: While Operating Your Car28
Recommended Fluids and Lubricants29
Table of Contents: Heater and Ventilation30
Heater Overview31
Heater Control Operation32
Heater Diagnosis33
On Car Service: Heater Blower Motor Overview33
On Car Service: Heater Blower Motor Removal, Installation34
On Car Service: Heater Blower Motor Resistor Removal, Inspection, Installation34
On Car Service: Heater Blower Motor Switch Removal, Inspection, Installation35
On Car Service: Heater Control Cables Removal, Installation36
On Car Service: Heater Unit Overview37
On Car Service: Heater Unit Removal, Installation38
Table of Contents: Bumpers and Sheet Metal39
Front Bumper Removal, Installation40
Rear Bumper Removal, Installation41
Hood Removal, Adjustment42
Front Fender Removal, Installation43
Removing Small Light43
Replacement Fender43
Steering, Suspension, Wheel and Tires: Table of Contents44
Steering, Suspension, Wheel and Tires: General Diagnosis45
Tire Diagnosis49
Irregular And/Or Premature Wear49
Wear Indicators49
Radial Tire Waddle49
Lead Diagnosis50
Radial Tire Lead51
Vibration Diagnosis51
Front End Alignment: Table of Contents52
Preliminary Checks Prior to Adjusting Front Alignment53
Toe Adjustment53
Camber and Caster Adjustment53
Steering Angle54
Manual Rack and Pinion: Table of Contents55
General Description of Steering System56
Exploded View of Manual Rack and Pinion57
On-Car Service: Lubrication57
Remove and Install Tie Rod End58
Remove and Install Manual Rack and Pinion Assembly (Steering Gear Case)59
Remove and Install Rack Boot/Tie Rod61
Remove and Install Steering Rack Plunger63
Remove and Install Steering Pinion64
Remove and Install Steering Rack65
Remove and Install Pinion Bearing66
Remove and Install Rack Bushing67
Rack and Pinion Inspection: Steering Rack Boots68
Rack and Pinion Inspection: Steering Shaft Joint68
Rack and Pinion Inspection: Tire Rod End/Boots68
Rack and Pinion Inspection: Rack Plunger68
Rack and Pinion Inspection: Steering Pinion/ Bearing69
Rack and Pinion Inspection: Steering Rack/Bushing69
Rack and Pinion Inspection: Steering Wheel69
Recommended Torque Specifications70
Required Service Materials70
Manual Rack and Pinion: Special Tools71
Steering Wheel and Column: Table of Contents72
Steering Wheel and Column Overview73
Remove and Install Sterring Wheel74
Remove and Install Combination Switch75
Remove and Install Steering Column76
Steering Column Assembly76
Remove and Install Steering Lock78
Remove and Install Steering Shaft Lower Joint79
Checking Steering Column for Accident Damage80
Checking Tilt Steering Column81
Recommended Torque Specifications: Tilt Steering Column81
Front Suspension: Table of Contents82
Front Suspension General Description and Overview83
Remove and Install Stabilizer Bar And/Or Bushings85
Remove and Install Strut Damper Assembly86
Disassembly and Assembly Strut Damper87
Remove and Install Wheel Hub, Wheel Stud/Wheel Bearing Outside Inner Race89
Remove and Install Suspension Arm/Bushing91
Remove and Install Knuckle/Bearing93
Remove Oil Seals, Snap Ring and Wheel Bearing95
Install Oil Seals, Snap Ring and Wheel Bearing95
Front Suspension Inspection: Stabilizer Bar And/Or Bushing96
Front Suspension Inspection: Strut Damper96
Front Suspension Inspection: Suspension Arm/Arm Bracket/Knuckle Arm97
Front Suspension Inspection: Suspension Arm Joint97
Front Suspension Inspection: Suspension Arm Bushing97
Front Suspension Inspection: Wheel Disc, Nut and Bearing97
Front Suspension Inspection: Recommended Torque Specifications98
Front Suspension Inspection: Required Service Materials98
Rear Suspension: Table of Contents100
Rear Suspension: General Description101
Remove and Install Control Rod102
Remove and Install Coil Spring and Suspension104
Rear Strut Assembly Remove and Install107
Rear Suspension Knuckle Remove and Install109
Wheel Bearing Remove and Install112
Rear Suspension Inspection113
Strut Damper113
Suspension Control Arm, Coil Spring and Knuckle Arm113
Control Rod113
Rear Suspension Fasteners114
Wheel Disc, Nut and Bearing114
Rear Wheel Alignment115
Toe Setting115
Toe Inspection and Adjustment115
Wheels and Tires: Table of Contents118
Wheels and Tires: General Description118
Wheel Maintenance119
Matched Tires and Wheels120
Inflation of Tires120
Tire Placard120
Tire Rotation121
Metric Lug Nuts and Wheel Studs121
Wheel Removal121
Tire Mounting and Demounting122
Tire Repair122
Balancing Wheels122
Static Unbalance/Dynamic Unbalance Correction122
General Balance Procedures123
Wheels and Tires Recommended Torque Specifications123
Front Drive Shaft: Table of Contents124
Front Drive Shaft: General Description124
Left Side Shaft Removal on Floor125
Left Side Shaft Removal on Lift125
Removing Drive Shaft Nut125
Detaching Suspension Arm from Knuckle/Snap Ring from Differential125
Right Side Shaft Removal on Floor126
Right Side Shaft Removal on Lift126
Drive Shaft Disassembly127
Drive Shaft Inspection128
Center Shaft and Center Bearing Support Disassembly128
Drive Shaft Reassembly128
Center Shaft and Center Bearing Support Reassembly131
Center Shaft and Center Bearing Support Installation132
Center Shaft and Center Recommended Torque Specifications132
Front Drive Shaft (Tripod Joint Type): Table of Contents134
Front Drive Shaft (Tripod Joint Type): General Description134
Front Drive Shaft (Tripod Joint Type): Removal135
Front Drive Shaft Disassembly135
Front Drive Shaft Inspection135
Brakes: Table of Contents138
Brakes: General Description139
Disc Brake Caliper Assembly140
Front Caliper Assembly140
Caliper Operation141
Clearance Correction141
Drum Brake Assembly: General Description142
Rear Brake Operation143
Rear Brake Clearance Correction143
Master Cylinder Assembly: General Description145
Master Cylinder Assembly: Operation145
Booster Assembly General Description and Overview147
Booster Operation148
Vacuum Booster Assembly148
When Foot Brake Pedal Is Not Depressed148
When Foot Brake Pedal Is Depressed149
When Foot Brake Pedal Is Released149
Diagnosis150
Road Testing Brakes150
Substandard or Contaminated Brake Fluid150
Break Fluid Leaks150
Brake Diagnosis Chart151
Break Pedal Free Height Adjustment153
Excessive Pedal Travel Check153
Stop Light Switch Adjustment153
Rear Brake Shoe Inspection154
Brake Pedal Play Inspection154
Rear Drum Brake Shoe Adjustment154
Master Cylinder Inspection154
Disc Inspection155
Pad Lining Inspection155
Parking Brake Inspection and Adjustment155
Flushing Brake Hydraulic System156
Bleeding Brakes156
Brake Hose and Pipe Inspection158
Brake Fluid Level Inspection158
Remove and Install Front Brake Hose/Pipe159
Remove and Install Rear Brake Hose/Pipe160
Precaution for Installation: Rear Brake Hose/Pipe160
Remove and Install Parking Brake Lever161
Remove and Install Parking Brake Cable162
Remove and Install Pad (Shoe and Lining)165
Remove and Install Caliper Assembly166
Remove and Install Seal, Piston, Dust Boot and Bleeder Screw167
Remove and Install Disc169
Disc Brake Inspection170
Inspect Brake Pad Lining170
Inspect Brake Caliper Inner Parts170
Inspect Brake Disc171
Remove and Install Brake Drum172
Remove and Install Brake Shoe176
Remove and Install Wheel Cylinder177
Remove and Install Brake Back Plate178
Brake Drum and Components Inspection180
Inspect Brake Drum180
Inspect Brake Shoe and Lining180
Inspect Wheel Cylinder181
Inspect Springs181
Inspect Brake Strut181
Inspect Parking Shoe Lever181
Master Cylinder Repair182
Remove and Install Master Cylinder Reservoir182
Remove and Install Master Cylinder Assembly183
Disassembly and Assembly of Master Cylinder184
Inspect Master Cylinder185
Master Cylinder: Fill Reservoir185
Remove and Install Booster186
Disassemble and Assemble Booster187
Brake Booster Inspection and Adjustment193
Inspect Booster Inner Parts193
Inspect/Adjust Clearance between Booster Piston Rod and Master Cylinder Piston193
Inspect Booster Operation194
Inspection Without Tester194
Check Operation195
Check Air Tightness under Load195
Booster Inspection Table196
Booster Recommended Torque Specifications197
Booster: Requires Service Materials198
Booster: Special Tools199
Engine: Table of Contents200
Engine: Statement on Cleanliness and Care200
General Information on Engine Service201
Engine: Hose Connection202
Engine Diagnosis203
Engine Mechanical: Table of Contents210
Engine Construction: General Description211
Engine Lubrication212
Cylinder Head and Valve Train213
Cylinder Block213
Crankshaft and Main Bearings213
Piston, Rings, Piston Pins and Connecting Rods213
Compression Check214
Engine Vacuum Check214
Oil Pressure Check215
Valve Lash Specifications216
Valve Lash Checking and Adjusting Procedures216
Air Cleaner Element217
Air Cleaner Assembly218
Cylinder Head Cover: Remove or Disconnect219
Cylinder Head Cover: Install or Connect219
Carburetor and Intake Manifold: Remove or Disconnect220
Carburetor and Intake Manifold: Install or Connect221
Exhaust Manifold Remove or Disconnect222
Exhaust Manifold Install or Connect222
Remove or Disconnect Timing Belt and Belt Tensioner223
Removing Fender Apron Extension223
Crankshaft Pulley and Pulley Bolts223
Timing Belt and Belt Tensioner Inspection, Installation, Connection224
Locking Crankshaft for M/T and A/T Models224
Removing the Timing Belt224
Loosening Timing Belt Pulley Bolt224
Tensioner Installation225
Valve Adjusting Screw and Lock Nut225
Timing Marks225
Installing Timing Belt226
Tensioner Bolt and Stud226
Tightening Pulley Bolt227
Oil Pan and Oil Pump Strainer: Remove and Disconnect227
Oil Pan and Oil Pump Strainer: Clean227
Oil Pan and Oil Pump Strainer: Install or Connect227
Applying Sealant to Oil Pan228
Oil Pump: Remove or Disconnect228
Oil Pump: Disassemble229
Oil Pump: Measure230
Oil Pump: Inspect230
Oil Pump: Install or Connect230
Oil Pump: Assemble230
Oil Seal Guide Installation231
Installing Rubber Seal231
Cutting Edge of Gasket231
Oil Pump Bolts231
Installing Guide, Key and Pulley232
Rocker Arms, Rocker Arm Shafts and Camshaft Overview233
Rocker Arms, Rocker Arm Shafts and Camshaft Remove and Disconnect233
Rocker Arm Shaft Screws Removal233
Adjusting Screw and Lock Nut233
Rocker Arm Shaft Removal234
Camshaft Removal234
Adjusting Screw and Rocker Arm234
Locking Camshaft234
Rocker Arm Shaft Runout235
Measuring Runout235
Measuring Cam Height235
Measuring Shaft Dia. and Arm I.D.235
Camshaft Runout236
Camshaft Runout Measurement236
Camshaft Journal Wear236
Camshaft Journal Dia. Measurement236
Journal Bore Dia. Measurement237
Pulley Pin, Slot and Pulley Bolt237
Camshaft Installation237
Rocker Arm Shafts Installation237
Rocker Arms, Springs, Rocker Arm Shafts and Screws Installation238
Valves and Cylinder Head: Remove or Disconnect239
Valve239
Special Tool (Valve Lifter) Installation240
Special Tool (Forceps) and Valve Cotters240
Valve Stem Oil Seal Removal240
Valve Guide Removal240
Valve Stem End Deflection Measurement241
Valve Head Thickness241
Radial Runout Measurement242
Valve Seating Contact Width242
Valve Seat Cutting243
Valve Seat Angles for Exhaust Valve243
Measuring Surface of Intake Manifold Seating Face244
Surface Measurement244
Measuring Surface of Exhaust Manifold Seating Face244
Valve Springs244
Measuring Free Length of Spring245
Measuring Spring Squareness245
Measuring Spring Preload245
Valve Guide Assembly245
Reaming Valve Guide Bore246
Valve Seal Installation246
Valve Installation246
Installing Valve Spring247
Valve Cotters Installation247
Cylinder Head Gasket Installation247
Tightening Sequence of Cylinder Head Bolts247
Pistons, Piston Rings, Connecting Rods and Cylinders: Remove or Disconnect248
Pistons, Piston Rings, Connecting Rods and Cylinders: Clean249
Pistons, Piston Rings, Connecting Rods and Cylinders: Disassembly249
Pistons, Piston Rings, Connecting Rods and Cylinders: Inspect249
Pistons to be Measured249
Measuring Cylinder Bore with Cylinder Gauge250
Measuring Piston Diameter with Micrometer250
Measuring Ring Groove Clearance250
Piston Pin, Piston Rings251
Connecting Rod251
Crank Pin and Connecting Rod Bearings251
Measuring Piston Ring End Gap251
Rod Bearing Clearance252
Piston, Piston Rings, Connecting Rods and Cylinders: Assembly253
Piston-To-Cylinder Orientation253
Fitting Connecting Rod to Piston253
Fitting Piston to Special Tool254
Installing Piston Pin254
Installing Piston Rings254
Line Marked on Driver Handle254
Piston Ring End Gaps Positions255
Piston, Piston Rings, Connecting Rods and Cylinders: Install or Connect255
Direction of Arrow Mark on Piston Head255
Installing Bearing Cap255
Unit Repair Overhaul257
Engine Assembly Dismounting257
Engine Assembly Remounting258
Main Bearings, Crankshaft and Cylinder Block Overview260
Main Bearings, Crankshaft and Cylinder Block Remove and Disconnect261
Inspecting Crankshaft Runout261
Out-Of-Round and Taper of Journals262
Main Bearings General Information262
Inspecting Main Bearing Clearance262
Selection of Main Bearings263
Stamped Alphabets on Cylinder Block264
Paint on Standard Bearing264
Paints on Undersize Bearing265
Rear Oil Seal266
Flywheel (M/T Model Only)266
Distortion of Gasket Surface266
Honing or Reboring Cylinders266
Installing Thrust Bearings267
Installing Main Bearing Caps268
Engine Cooling: Table of Contents273
Engine Cooling System Circulation274
Radiator Cap275
Water Reservoir Tank275
Water Pump276
Thermostat276
Cooling Fan277
Water Temp Gauge277
Thermo Switch277
Engine Cooling Diagnosis278
Engine Cooling Maintenance278
Coolant278
Anti-Freeze Proportioning Chart278
Coolant Capacity279
Coolant Level279
Cooling System Service280
Cooling System Flush and Refill280
Installation of Radiator Cap280
Radiator Drain Plug280
Water Pump Belt Tension281
Coolant Draining282
Cooling Water Pipes or Hoses Removal282
Thermostat Removal282
Cooling Water Pipes or Hoses Installation282
Air Bleed Valve of Thermostat283
Checking Thermostat Valve Operation283
Thermostat Installation283
Water Pump Belt Removal284
Water Pump Belt Installation284
Fan Thermo Switch Removal, Installation, Inspection284
Checking Fan Thermo Switch284
Radiator Removal, Clean285
Radiator Installation, Inspection285
Water Pump Inspection, Installation286
Engine Fuel: Table of Contents288
Fuel System Overview and General Description288
Fuel Tank and Fuel Pump289
Fuel Filter289
Fuel Filler Cap289
Fuel Filter Cap Cross-Section289
Fuel Lines Inspection290
Fuel Pipe Remove or Disconnect291
Fuel Pipe Install or Connect291
Installing, Removing Clamp291
Detaching Clamp with Pipes291
Fuel Filler Cap Removal and Replacement292
Fuel Filter: Remove or Disconnect292
Fuel Filter: Install or Connect292
Fuel Tank Remove or Disconnect293
Disconnecting Couplers293
Breather and Filler Hoses293
Disconnecting Hoses293
Fuel Tank Purging Procedure294
Fuel Tank Install or Connect294
Fuel Level Gauge Remove or Install294
Fuel Pump Remove or Install295
Carburetor: Table of Contents296
Carburetor: General Description297
Carburetor Scheme298
Float System299
Primary Slow System299
Primary Main System299
Secondary Main System300
Secondary Slow System300
Acceleration Pump System301
Choke System301
At Cold Engine Start302
Immediately after Engine Start303
Fast Idle Cam Opener Operation303
Release of Choke303
Summary of Choke System Operation304
Idle up System305
Accelerator Cable Play306
Float Level Inspection, Adjustment306
Idle Speed and Idle Mixture307
Idle up (for Manual Transmission) Inspection309
Idle up (for Manual Transmission) Adjustment309
Idle up (for Automatic Transmission) Inspection310
Idle up (for Automatic Transmission) Adjustment311
Choke System Inspection311
Fast Idle314
Secondary Diaphragm Inspection315
Unloader System Inspection315
Fuel Cut System Inspection315
Accelerator Pump Inspection316
Throttle Sensor (for Automatic Transmission) Inspection317
Throttle Sensor (for Automatic Transmission) Removal318
Throttle Sensor (for Automatic Transmission) Installation318
Carburetor Removal and Installation320
Carburetor Disassembly321
Carburetor Cleaning322
Carburetor Inspection323
Carburetor Assembly323
Float Chamber Cover323
Bimetal Case323
Ignition System: Table of Contents328
Ignition System: General Description328
Ignition Circuit Diagram329
Ignition Diagnosis329
Power Supply for Ignition Coil330
High Tension Cords330
Checking Power Supply to Distributor330
Measuring High Tension Cord Resistance330
Spark Plugs331
Ignition Coil331
Checking Spark Plug Gap331
Measuring Ignition Coil Resistance331
Distributor: Centrifugal Advancer332
Distributor: Vacuum Advancer332
Ignition Timing332
Distributor Components333
Distributor Removal334
Distributor Disassembly334
Distributor Inspection335
Checking Centrifugal Advancer335
Distributor Reassembly336
Distributor Installation336
Aligning Camshaft to TDC Compression336
Aligning Distributor Coupling337
Cranking System (0.8, 0.9, 1.0 Kw Type): Table of Contents338
Cranking System (0.8, 0.9, 1.0 Kw Type): Circuit338
Cranking System (0.8, 0.9, 1.0 Kw Type): Starting Motor338
Basic Cranking Circuit339
Cranking System Specifications339
Convertional Type Starting Motor340
Reduction Type Starting Motor341
Starting System Diagnosis342
Cranking System (0.8, 0.9, 1.0 Kw Type) Dismounting and Remounting343
Conventional Type Starting Motor344
Magnetic Switch Assembly344
Removing Magnetic Switch344
Installing Magnetic Switch344
Motor Assembly: Disassembly, Reassembly345
Installing Overrunning Clutch346
Installing Brush Holder346
Installing Armature346
Installing Commutator End Cap346
Reduction Type Starting Motor Overview347
Reduction System Disassembly Procedure347
Reduction System Reassembly348
Assembling Internal Gear348
Inspection and Correction of Armature348
Checking Coil Ground348
Checking Open Circuit349
Checking Commutator Diameter349
Checking Commutator Run-Out349
Checking Mica Depth349
Checking Yoke, Brush, Brush Holder350
Checking Overrunning Clutch, Shaft and Bush350
Cranking System (0.8, 0.9, 1.0 Kw Type) Performance Test351
Cranking System (1.2 Kw Type): Table of Contents352
Cranking System (1.2 Kw Type) General Description352
Cranking System (1.2 Kw Type) Diagnosis353
Starter Motor Overview353
Magnetic Switch Assembly: Removal and Installation354
Motor Brush Removal354
Armature Removal355
Over-Running Clutch Removal355
Armature Inspection and Correction358
Ground Inspection and Correction359
Plunger Inspection and Correction359
Open Circuit Inspection and Correction359
Brush Inspection and Correction359
Brush Holder and Spring Inspection and Correction360
Pinion and Over-Running Clutch Inspection and Correction360
Armature Shaft Bearing Inspection and Correction360
Magnetic Switch Inspection and Correction361
Gears Inspection and Correction361
Pull-In Coil Open Circuit Test361
Pull-In/Hold-In Tests362
Check Plunger Return362
Charging System: Table of Contents363
Battery General Description363
Electrolyte Freezing364
Carrier and Hold-Down364
Visual Inspection of Battery364
Care of the Battery364
Jump Starting in Case of Emergency366
Remove and Replace Battery367
Battery Cables367
Generator General Description and Overview368
Generator Schematic369
Generator Specifications369
Generator Diagnosis370
Faulty Indicator Lamp Operation370
Undercharged Battery370
Overcharged Battery371
Generator Exploded View372
Dismounting and Remounting Generator373
Generator Disassembly373
Removing Rectifier373
Removing Pulley Nut373
Generator Reassembly374
Inspection and Correction: Rotor, Fan, Bearing, Starter, Rotor375
Inspection and Correction: Rectifier376
Inspection and Correction: Brush376
Inspection and Correction: Condenser376
Emission Controls: Table of Contents377
Emission Controls: General Description377
Emission Controls for Vehicle with Manual Transmission: Scheme378
Emission Controls for Vehicle with Automatic Transmission: Scheme379
Positive Crankcase Ventilation PCV System380
Throttle Positioner System381
Intake Air Temperature Control System382
Exhaust Gas Recirculation (EGR with EGR Modulator) System383
Pulse Air Control System384
Fuel Cut System385
Evaporative Emission Control System386
Hot Idle Compensator (HIC)387
Catalyst387
Emission Controls Diagnosis388
PCV Hose Inspection389
Checking PCV Valve for Sticking389
Checking Throttle Positioner System390
Intake Air Temperature Control System Checking Procedure391
Checking Hot Idle Compensator (HIC)392
Checking Exhaust Gas Recirculation (EGR) System392
Thermal Vacuum Switching Valve (TVSV)393
Checking EGR Modulator394
Checking Pulse Air Control System395
Checking Fuel Cut System396
Checking Fuel Controller396
Checking Evaporative Emission Control System397
Exhaust System: Table of Contents399
Exhaust System: General Description399
Exhaust System: Maintenance400
Exhaust System: Recommended Torque Specifications400
Manual Transmission: Table of Contents401
Manual Transmission: Construction and Servicing401
Manual Transmission Cutaway402
Manual Transmission Exploded View403
Gear Shift Mechanism404
Gear Shifting Pattern404
Manual Transmission Diagnosis406
Oil Change407
Differential Side Oil Seal407
Detaching Snap Ring from Differential407
Gear Shift Control Components409
Gear Shift Control Removal410
Gear Shift Control Installation410
Installing Shift Control Lever411
Speedometer Driven Gear Removal411
Dismounting of Transmission under Hood412
Remounting of Transmission413
Disassembling Unit Fifth Gear414
Sub Assembly Service: Right Case418
Sub Assembly Service: Left Case419
Input Shaft Assembly420
Checking Gear and Synchonizer Ring421
Assembling High Speed Sleeve and Hub421
Press-Fitting Input Shaft R Bearing421
Air Checking Oil Holes421
Countershaft Assembly423
Gear Shifter426
Differential Assembly428
Measuring Gear Thrust Play429
Tightening Final Gear Bolts429
Press-Fitting Differential Side Bearing429
Assembling Unit: Differential to Left Case430
Assembling Unit: Fifth Gears431
Counter Shaft 5Th Gear433
Tightening Countershaft Nut433
Installing 5Th Speed Sleeve and Hub433
Gear Shift and Select Shaft Assembly434
Manual Transmission Recommended Torque Specifications436
Automatic Transmission: Table of Contents440
Automatic Transmission: General Description441
Automatic Transmission: Torque Converter441
Planetary Gear Units442
Direct Clutch Cross Section443
Forward Clutch Cross Section444
Second Brake445
First and Reverse Brake446
One-Way Clutch446
Power Flow447
Automatic Transmission Components Operation Chart452
Oil Pressure Control System Diagram453
Valve Body454
Oil Pump454
Manual Valve455
Throttle Valve455
Primary Regulator Valve455
Secondary Regulator Valve456
Cooler By-Pass Valve456
1-2 Shift Valve456
2-3 Shift Valve457
Direct Clutch and 2Nd Brake Solenoids457
Oil Circuit in "N" Range458
Oil Circuit in "D" or "2" Range459
Oil Circuit in "D" or "2" Range (2Nd Gear)460
Oil Circuit in "D" Range (3Nd Gear)461
Oil Circuit in "L" Range462
Oil Circuit in "R" Range463
Oil Cooling System463
Electric Shift Control System464
A/T Control Module (Controller)464
Gear Shift Control System464
Throttle Position Sensor (TPS)464
Shift Lever Switch465
Operation of Direct Clutch and 2Nd Brake Solenoids465
Speed Sensor466
Automatic Shift Diagram466
Transmission Unit: Systematic Troubleshooting467
Stall Test and Line Pressure Test468
Manual Road Test468
Line Pressure Test and Road Test469
Stall Test470
Line Pressure Test470
Road Test471
Engine Brake Test472
Shift Solenoid Check473
Electric Shift Control System Wiring Diagram474
Electric Shift Control System Self-Diagnosis475
Electric Shift Control Systematic Troubleshooting476
Shift Lever Switch Checking Procedure479
Speed Sensor Checking Procedure482
Shift Solenoid Checking Procedure483
Throttle Valve Opening Signal Checking Procedure484
Hot Level Check at Normal Operating Temperature485
Cold Level Check at Room Temperature about 25C486
Oil Cooler Hoses486
Oil Pan Gasket Removal, Installation487
Oil Strainer488
Shift Solenoids Removal, Installation488
Oil Pressure Control Cable Removal, Installation, Adjustment489
Select Cable Components490
Select Cable Components Removal491
Select Cable Components Installation491
Shift Lever Switch Removal and Installation491
Shift Lever Switch Joint492
Adjusting Shift Lever Switch Position492
Manual Selector Removal493
Manual Selector Installation493
Manual Selector Components494
Transmission Unit Repair Overhaul495
Automatic Transmission Construction495
Transmission Unit Dismounting496
Transmission Unit Remounting497
Cooler Line Flushing498
Torque Converter Diagnosis498
Transmission Unit Disassembly499
Removing Torque Converter499
Removing Solenoid Couplers499
Removing Oil Filler Tube499
Removing Oil Tubes500
Removing Oil Pressure Control Cable500
Removing Accumulator Pistons500
Removing Lower Valve Body500
Measuring Piston Rod Stroke501
Removing Second Brake Piston501
Removing Solenoid Wiring Harness502
Removing Transmission Case Housing502
Removing Second Brake Band Pin502
Removing Oil Pump502
Removing Direct Clutch and Input Shaft503
Removing Front Planetary Gear503
Removing Direct Clutch503
Removing Front Planetary Ring Gear and Bearing503
Removing One-Way Clutch Snap Ring504
Removing Rear Planetary Ring Gear504
Measuring 1St-Reverse Brake Clearance504
Removing One-Way Clutch504
Removing Snap Rings, Rear Cover505
Removing 1St-Reverse Brake505
Uncaulking Reduction Driven Gear Nut505
Removing Reduction Driven Gear506
Removing Output Shaft506
Removing Countershaft506
Removing Parking Lock Pawl506
Removing Parking Lock Pawl Sleeve507
Removing Snap Ring507
Removing 1St-Reverse Brake Piston507
Removing Return Spring Assembly507
Clutch and Brake Parts Diagnosis508
Sub Assembly Service508
Oil Pump Components509
Checking Gear-To-Body/Side/Tip Clearance510
Installing Pump Body Oil Seal511
Tightening Pump Cover Bolts511
Direct Clutch Components511
Measuring Direct Clutch Clearance512
Removing Direct Clutch Piston512
Removing Flange, Discs and Plates512
Checking Check Ball Leakage513
Installing Piston to Drum513
Installing Spring Seat513
Checking Piston for Movement514
Forward Clutch Exploded View515
Forward Clutch: Preliminary Check515
Forward Clutch: Removal515
Forward Clutch: Inspection516
Forward Clutch: Installation516
Installing Piston Return Springs516
Removing Clutch Piston516
Upper Valve Body Components517
Lower Valve Body Components518
Important Steps in Disassembly and Reassembly of Valve Bodies519
Installing Four Steel Balls519
Installing Upper Valve Body Bolts519
Countershaft and Output Shaft520
Countershaft Bearings Removal520
Countershaft Bearings Installation521
Output Shaft Bearings Removal521
Output Shaft Bearings Installation522
Differential Gear Components523
Differential Gear Disassembly524
Differential Gear Adjustment and Reassembly524
Differential Gear Assembly525
Thrust Bearings and Races526
Planetary Gears and Related Parts527
Second Brake Components528
Installing 2Nd Brake Piston and Piston Cover528
Manual Shift Shaft529
Installing Manual Shift Shaft and Manual Detent Spring529
Upper and Lower Nuts530
Installing Lock Pawl Shaft and Lock Pawl Spring530
Installing Parking Lock Pawl Sleeve530
Installing 1St-REV Brake Piston530
Installing Snap Ring, Output Shaft531
Tightening Driven Gear Nut531
Installing Countershaft531
Caulking Driven Gear Nut532
Searing Output Shaft in Rear Cover532
Installing Discs, Plates and Flange533
Installing Damper Plate533
Measuring 1St-Reverse Brake Clutch Clearance533
Checking 1St-Reverse Brake Piston Movement534
Installing Rear Planetary Ring Gear Bearing534
Checking Free Rotation of One-Way Clutch534
Installing Rear Planetary Ring Gear534
Installing Rear Planetary Thrust Washers535
Installing One-Way Clutch535
Checking Rear Planetary Gear Rotation535
Installing Rear Planetary Gear Assembly535
Installing One-Way Clutch Race Snap Ring536
Installing Sun Gear Assembly536
Installing Sun Gear Pin and Thrust Washer536
Installing Front Planetary Gear Bearing536
Installing Ring Gear Races and Bearing537
Installing Front Planetary Gear Assembly537
Installing Front Planetary Ring Gear Assembly537
Installing 2Nd Brake Band538
Installing Input Shaft Seal Rings538
Checking Output Shaft Seal Ring538
Installing Direct Clutch Washer538
Assembling Direct Clutch and Input Shaft539
Installing Input Shaft and Direct Clutch539
Installing Ring Gear Bearing539
Installing Gasket and Case Housing540
Measuring Distance between Case End Surface and Input Shaft Flange540
Installing Second Brake Band Pin540
Installing Case Housing Bolts540
Installing Another Input Shaft Bearing Race541
Measuring Thrust Play of Input Shaft542
Installing Solenoid Wiring Harness542
Checking Second Brake Band Alignment543
Installing Accumulator Pistons and Spring543
Installing Second Brake Cover543
Installing Valve Body544
Installing Oil Tubes544
Connecting Oil Pressure Control Cable544
Connecting Solenoid Wires544
Installing Oil Strainer545
Installing Oil Pan Bolts545
Installing Magnet in Oil Pan545
Installing Torque Converter546
Dimension Data547
Clutch: Table of Contents552
Clutch: General Description552
Clutch Cutaway553
Clutch Diagnosis554
Clutch Pedal Height555
Clutch Pedal Free Travel555
Clutch Switch Adjustment555
Clutch Cable Removal, Inspection, Installation556
Clutch Cover, Clutch Disc and Flywheel: Unit Repair Overhaul557
Clutch Cover, Clutch Disc and Flywheel Removal557
Clutch Cover, Clutch Disc and Flywheel Inspection558
Clutch Cover, Clutch Disc and Flywheel Installation558
Installing Flywheel558
Clutch Release System Removal559
Installing Clutch Disc and Cover559
Lubricating Input Shaft559
Clutch Release System Inspection560
Clutch Release System Installation560
Lubricating Release System and Input Shaft561
Installing Clutch Release Arm561
Body Electrical System: Table of Contents564
Body Electrical System General Description564
Body Electrical System Wiring564
Main Fuse Block Circuit565
Junction/Fuse Block Circuit and Fuse Block Designations565
Junction/Fuse Block Circuit and Color Codes566
Ignition Switch Inspection, Installation, Removal567
Ignition Switch: Checking Continuity between Terminals567
Combination Switch Inspection567
Combination Switch Couplers567
Illumination Controller Inspection568
Instruments and Gauges569
Combination Meter Wiring569
Body Electrical System Trouble Diagnosis570
Fuel Level Meter and Gauge Unit: Description of Circuit571
Fuel Level Meter and Gauge Unit: Inspection571
Gauge Unit Inspection572
Water Temperature Meter and Gauge Unit Circuit572
Checking Water Temperature Unit573
Oil Pressure Light: Description of Circuit574
Checking Oil Pressure Switch574
Brake Fluid Level Warning Light: Description of Circuit575
Brake Fluid Level Warning Light: Operation576
Brake Fluid Level Warning Light: Inspection of Brake Fluid Level Switch576
Seat Belt Warning Light/Buzzer: Description of Circuit576
Seat Belt Warning Light/Buzzer: Inspection576
Lighting Systems: Headlights Wiring Circuit577
Lighting Systems: Headlights Trouble Diagnosis577
Lighting Systems: Headlights Inspection578
Setting Headlight Beams578
Headlight Adjustment579
DIM-DIP System (for England Only)580
Turn Signal and Hazard Warning Light: Wiring Circuit580
Headlight Trouble Diagnosis581
Headlight Inspection581
Back-Up Lights Wiring Circuit582
Back-Up Lights Trouble Diagnosis582
Stop Lights: Wiring Circuit583
Stop Lights Trouble Diagnosis583
Small, Tail and License Light: Wiring Circuit584
Small, Tail and License Light: Trouble Diagnosis584
Cigar Lighter and Radio (Optional): Wiring Circuit585
Cigar Lighter and Radio (Optional): Trouble Diagnosis585
Interior (Dome) Light: Wiring Circuit585
Interior (Dome) Light: Trouble Diagnosis585
Front Window Wiper (Windshield Wipers) and Washer586
Windshield Wiper Circuit587
Intermittent Wiper Relay Circuit587
Wiper and Washer Wiring Circuit588
Wiper and Washer Trouble Diagnosis589
Wiper/Washer Switch Inspection589
Wiper Motor Inspection590
Washer Pump Inspection591
Intermittent Wiper Relay Inspection591
Rear Window Defogger (if Equipped): Wiring Diagram592
Rear Window Defogger (if Equipped): Trouble Diagnosis592
Defogger Switch Inspection593
Defogger Wire Inspection593
Defogger Circuit Repair594
Defogger Installation and Removal594
Rear Window Wiper and Washer (if Equipped) Circuit595
Rear Window Wiper and Washer (if Equipped) Inspection596
Wiring Harness Routing: Left Side Fender Apron Wiring598
Right Side Inner Fender Wiring599
Cowl Top Panel Wiring599
Engine Wiring600
Manual Transmission Wiring601
Automatic Transmission Wiring601
Cowl Upper Wiring602
Instrument Panel Wiring603
Floor Wiring604
Rear Body Wiring605
Back Door Wiring605
Back Door Wiring Protector606
Battery Wiring606
Grounding Poitns607
Body Service: Table of Contents608
Front Door Assembly609
Door Glass Removal609
Removing Door Trim609
Door Glass Installation610
Door Window Regulator Removal611
Door Window Regulator Inspection611
Door Window Regulator Installation611
Front Door Lock Assembly612
Front Door Lock Removal612
Front Door Lock Installation613
Front Door Assembly Removal614
Front Door Assembly Installation615
Rear Door Assembly616
Rear Door Glass Removal616
Rear Door Glass Installation617
Door Window Regulator Removal, Installation618
Rear Door Lock Assembly Removal/Installation619
Rear Quarter Window Assembly Removal, Installation620
Windshield626
Windshield Removal627
Windshield Installation628
Back Door Assembly Removal, Installation631
Back Door Balancer Removal, Installation633
Back Door Glass Removal634
Back Door Glass Installation635
Front Seat Removal, Installation637
Rear Seat Assembly637
Rear Seat Cushion Removal, Installation638
Rear Seatback Removal, Installation638
Seat Belts638
Front and Rear Seat Belt Assemblies639
Servicing Seat Belts639
Seatbelts Removal and Installation639
Seat Belts Inspection640
Front Floor Carpet Removal and Installation641
Luggage Floor Carpet Removal and Installation641
Head Lining Removal and Installation642
Headlining Wrinkle Removal643
Head Lining to Flange Overhang643
Head Lining Hem Cutting643
Anti-Corrosion Treatment644
Metal Replacement Parts Finishing645
Sealer Application Areas646
Undercoating Application Areas649
Application of Anti-Corrosion Compound and Chip Resistant Material650
Plastic Parts Finishing651
Underbody Dimensions652
Body Dimensions654
Side Molding Installation658
Key Coding659
Key Usage and Identification659
Junction/Fuse Block Circuit660
Automatic Transmission Brake Interlock System: General Description661
Automatic Transmission Brake Interlock System: Operations661
Shift Lock Solenoid662
Interlock Cable Removal and Installation663
Interlock Cable Adjustment663
Stop Light Switch Removal and Installation663
Interlock Cable System Inspection664

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