90-92 Samurai Supplementary Service Manual
Contents
1. Cooling system DIFFERENTIAL Bevel gear backlash 0 10 0 15 mm 0 004 0 006 in Side gear thrust play 0 12 0 37 mm 0 005 0 014 in Pinion bearing preload 1 8 3 4 kg 4 0 7 5 Ibs SUSPENSION Front wheel bearing starting preload 1 0 3 0 kg 2 2 6 6 Ibs k Rear wheel bearing thrust play 0 8 0 03 Axial play barfield joint 0 mm No play 1 5 mm 0 06 in Knackle arm starting torque 1 0 1 8 kg 2 20 3 96 Ibs without oil seal Suspension FUEL SYSTEM Engine idle speed 800 r min rpm Engine idle speed when turning A C ON 1 000 50 r min rpm STEERING SYSTEM Steering wheel piay 10 30mm 0 4 1 2 in o_o Steering angle outside BRAKE Front brake disc thickness 10 mm 0 394 in 8 5 mm 0 334 in Front brake disc deflection 0 15 mm 0 006 in Front brake pad thickness e lining ped rim 15 0 mm 0 590 in 6 0 mm 0 236 in Rear brake lining thickness Rear brake drum inside diameter 220 mm 8 66 in 222 mm 8 74 in Pedal to wall clearance 75mm When pedal is depressed at 30 kg 66 Ib 2 95 in minimum ELECTRICAL em Sea Tei E E Ignition coit Primary coil resistance E 20 C 68 F 0 9 1 1 ohms 8 3 c 5 t 5 Ignition c2. Tail Brake light 12V 3 32 cp Side marker light License plate light 12 4 cp 12V 32 cp 12V 1 4W 0 5 mm fusible link 10 10 15 15 15 20 15 15 10 15 15 20A Back up light Interior light Meter pilot light Main fuse Fuse box POWER TRANSMISSION Clutch type Dry single disc 5 forward all synchromesh 1 reverse 3 727 Transmission type Final reduction ratio Differential Transmission gear ratios Transfer gear ratios Overall reduction ratios reverse 3 466 low range 2 268 30 869 16 457 12 028 4th 8 452 7 303 29 297 Low range reverse low 2nd NON ah 22 2 Convertible Hard Top WHEEL AND SUSPENSION Tire size front and rear P205 70 R15 140 kPa 1 40 kg cm 20 psi Ti e ir 140 kPa 1 40 kg cm 20 psi unladen rear 180 kPa 1 80 kg cm 26 psi laden Suspension type STEERING Turning radius 5 1 m 16 7 ft BRAKE SYSTEM Type 4 wheel hydraulic front Disc brake floating caliper type rear Drum brake leading and trailing Mechanical actuated on rear wheels CAPACITIES 402 10 6 8 8 US Imp gal Transmission oil 1 39 2 7 2 3 US Imp pt m 2 08 4 2 3 5 US Imp pt 1 5 3 2 2 6 US Imp pt 0 8 1 7 1 4 US Imp pt Different
3. Piston diameter Piston ring groove width Piston ring thickness 2nd ring Piston ring 2nd ring 0 20 0 35mm 0 0079 0 0137 in 0 7mm 0 0275 in Oil ring 0 20 0 70mm 0 0079 0 0275 in 1 8mm 0 0708 in Crankshaft runout middle Po 00023 Piston ring end 16 968 16 979 mm 0 6680 0 6684 in 44 982 45 000 mm 1 7710 1 7716 in 0 020 0 040 mm 0 0008 0 0016 in Connecting rod small end bore 0 06 mm 0 0023 in 0 0004 in Crank shaft Crank journal diameter Crank pin diameter 41 982 42 000 mm 1 6529 1 6535 in Crank pin clearance in con rod 0 030 0 050 mm 0 0012 0 0019 in 0 08 mm 0 0031 in Bearing to journal clearance Crank pin out of round and taper 0 01 mm 22 5 Standard Service Limit 0 01 mm 0 0004 in 0 2 mm 0 0078 in 0 0149 in Crank journal out of round and taper Flywheel runout 0 11 0 31 mm 0 0044 0 0122 in 0 38 mm Crankshaft thrust play Connecting rod big end side clearance 0 10 0 20 mm 0 0039 0 0078 in 0 35 mm 0 0137 in Crankshaft 0 10 mm 0 0039 in M 0 05 mm 0 0020 in Connecting rod CLUTCH amp TRANSMISSI
4. Master cylinder OPERATION Normal operation Depressing the brake pedal forces the primary piston A to move to the left in the below figure and consequently the hydraulic pressure is produced in the chamber a By means of this pressure and the return spring force the secondary piston B is also pushed to the left and thus the hydraulic pressure is produced in the chamber b Fig 19 3 1 19 4 One circuit operation Primary chamber a circuit failure Depressing the brake forces the primary piston to move as described previously but since the brake circuit connected to the chamber a cannot hold the pressure no pressure is produced in the fluid immediately ahead of the piston The piston A keeps moving while compressing the spring and when it reaches the retainer the piston B is pushed and begins to move This causes the pressure to rise in the chamber and the pressure acts on front wheel brakes right amp left Retainer Fig 19 4 One circuit operation Secondary chamber b circuit failure In this case the leftward movement of the piston A has but little effect in causing the fluid pressure to rise in the chamber a in the beginning because the initial rise of the fluid pressure causes the piston B to promptly yield and move to the left However when the forward end of the piston B comes to the head of the cylinder and stops there the left
5. markings Fig 19 88 15 Turn special tool bolt counterclockwise until No 1 body projecting part comes to mid position of No 2 body depressed parts as shown No 2 body Special tool bolt No 1 body projecting part AR zum No 2 body depressed part Fig 19 89 16 Install push rod clevis so that below measure ment A is obtained and torque nut to specification 20 30 Nm 2 0 3 0 kg m 14 5 21 5 Ib ft 125 5 126 5 mm 4 94 4 98 in Fig 19 90 17 Remove booster from special tool NOTE Whenever booster was disassembled make sure to check clearance between piston rod and mas ter cylinder piston after reassembly For details refer to page 19 20 18 For installation of booster see steps 1 to 11 of its INSTALLATION on page 19 12 19 19 INSPECTION 1 INSPECT BOOSTER INNER PARTS NOTE After disassembly soak all metal parts in ethyl alcohol Wipe rubber diaphragm and plastic parts with a clean cloth Use ethyl alcohol damped cloth to wipe out heavy dirt Application of much ethyl alcohol especially to rubber parts is pro hibited RUBBER PARTS Wipe fluid from rubber parts and carefully in spect each rubber part for cuts nicks or other damage These parts are key to air flow control if there is any question as to serviceability of rubber parts REPLACE them METAL PARTS BADLY DAMAGED ITEMS OR THOSE WHICH WOULD TAKE EXTENSIVE WORK OR TIME
6. L system fails to stop Trouble Possible cause Correction D R L system remains operating D R L controller faulty Replace controller even after engine stop W R circuit faulty Repair D R L system remains operating Parking brake switch faulty Replace switch even after parking brake applied V G circuit faulty Repair D R L system remains operating Lighting switch faulty Repair or replace switch e after lighting switch turned Br Y circuit or its ground faulty Repair 21 5 SECTION 22 SERVICE DATA CONTENTS 22 1 1 1 22 1 22 2 SERVICE DATA IURE reueg REA ee Zw bran 22 4 22 1 SPECIFICATIONS Convertible Hard Top Four stroke cycle water cooled OHC Type Number of cylinders 4 Comprsssion ratio 9 5 1 Electronic Fuel Injection system Single point throttle body fuel injection system Air cleaner Polyester fiber element Dry type ELECTRICAL 8 B T D C at r min rpm NGK BPRSES or NIPPON DENSO W20EPR U Ignition timing Standard spark plug Starter Magnetic shift type Generator Alternator Headlight 12V 60 50W 12V 32 cp 12V 4 cp Turn signal light Clearance light 22 1 Models Convertible Hard Top
7. fit new oil seal to booster No 2 body by using special tools C and D Apply grease here C Oil seal remover amp installer No 1 09951 16020 D Oil seal remover amp installer No 2 09951 18210 1 Hammer 2 No 2 body 3 Oil seal Fig 19 76 2 Install retainer to diaphragm 1 Retainer 2 Piston diaphragm Fig 19 77 19 16 3 Install diaphragm to booster piston by hand 1 Piston 2 Retainer 3 Piston diaphragm Apply grease to entire mating surfaces of piston and diaphragm Fig 19 78 4 Install new diaphragm circular ring referring to figure below for its proper installing direc tion NOTE Be careful not to cause damage to piston when installing Piston Circular ring Retainer Diaphragm Fig 19 79 5 Install booster air valve assembly to booster piston Before installation apply grease as shown Sliding surface against piston sealed surface Fig 19 80 6 Compress air valve assembly and insert valve stopper key NOTE Don t compress air valve assembly forcibly 1 Valve assembly 2 Piston 3 Valve stopper key Fig 19 81 7 Install valve stopper key cushions NOTE Make sure that it is installed in proper direction and cushion is fitted to notch in key 2 Piston 4 Key cushion Fig 19 82 8 Install booster piston to booster No 2 body A Check all around booster N
8. the right to contact the valve stopper key as shown In this state the vacuum valve control valve C is open and the air valve contro valve 0 is closed Thus the chambers A and B conduct and share the same negative pressure because of no pressure difference which allows the return spring to push the booster piston to the right Vacuum valve C Air valve D 1 Booster control valve 2 Booster air valve 3 Booster piston Fig 19 13 2 Vacuum Booster Assembly 19 7 When foot brake pedal is depressed Being pushed by the operating rod the booster air valve moves to the left as shown Then the control valve is pushed against the booster piston seat closely by the valve spring force Thus the vacuum valve control valve E is closed to cut off between the chambers A and B At this time the air valve control valve D is still closed Vacuum valve CT Air valve Control 1 Booster control valve 2 Booster air valve 3 Booster piston Fig 19 14 1 As the booster air valve moves further to the left it leaves the control valve and the air valve control valve D opens to allow the air to flow into the chamber B The entry of air causes a difference in pressures between the chambers A and B When this pressure difference grows greater than the piston return spring force the booster piston moves to the left and the booster control valve also moves to the left The resu
9. AKES NOTE For the items not found in this section refer to the same section of 88 MODEL SERVICE MANUAL CONTENTS 19 1 GENERAL DESCRIPTION 0c cece reer n 19 2 19 4 MASTER CYLINDER 19 9 19 5 BRAKE BOOSTER e 19 12 19 7 BRAKE PIPES AND HOSES 19 24 19 10 SPECIAL TOOLS 2c cece eee m nnn 19 26 NOTE All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal WARNING When servicing wheel brake parts do not create dust by grinding sanding brake linings or by cleaning whee brake parts with a dry brush or with compressed air Many wheel brake parts contain asbestos fibers which can become airborned if dust is created dur ing servicing Breathing dust containing asbestos fibers may cause serious bodily harm A water dampened cloth or water based solution should be used to remove any dust on brake parts Equipment is commercially available to perform this washing function These wet methods will prevent asb
10. EALING COMPOUND 366E 99000 31090 to mating sur faces of both parts Brake backing plate A Apply sealing compound Brake pipe Screw Rear axle Rear axle Screw Brake pipe Brake pipe Screw Rear axle P amp B valve View from arrow 2 Up side d From 6 way joint Bolt To rear flexible hose 19 25 19 10 SPECIAL TOOLS Shown below are special tools necessary when servicing brake system of 90 MODEL The same ones are currently used for other models marked ones are used for SAMURAI 88 MODEL marked ones are used for SIDEKICK No 1 09951 16020 K 2 No 2 09951 18210 Booster No 2 body 09950 96010 Oil seal remover amp Booster piston rod gauge Installer No 1 No 2 09950 88210 09950 78210 Booster overhaul tool set Flare nut wrench 10 mm L 09952 16010 Booster piston rod adjuster 09943 35511 09922 85811 Brake drum remover Connector pin remover Front wheel hub remover RE 09951 16010 Booster overhaul attachment 09942 15510 Sliding hammer 19 26 SECTION 21 BODY ELECTRICAL EQUIPMENT NOTE For the items not found in this section refer to the same section of 88 MODEL SERVICE MANUAL CONTENTS 21 1 COMBINATION METER 21 2 21 16 WIRING DIAGRAM Wiring diagrams are attached
11. ON 1 0 14 mm 0 039 0 055 in 1 2 1 6 mm 0 047 0 063 in 0 5 mm 0 019 in 10 1 mm 0 397 in 10 4 mm 0 409 in 25 5 mm 1 004 in 21 0 mm 0 826 in 0 06 0 15 mm 0 0024 0 0059 in 0 3 mm 0 0118 in 1 2 mm 0 05 in Facing wear Rivet head depth Facing input shaft serration backlash Low amp high Key slot width of synchronizer ring Clearance between gears and rings Gear shift fork shaft spring free length Gear backlash Transmission LUBRICATION Item 0 310mm 0 0122 in Oil pump side clearance fiatness 0 15 mm 0 0058 in Oil relief valve spring Free length 45 mm 1 77 in O Set pressure of oil pressure switch 0 2 0 4 kg cm 2 84 5 68 psi Eege 3 0 4 2 kg cm 42 7 59 7 psi at ngine oil pressure 3 000 r min rpm Radial clearance between outer rotor and case Lubrication 22 6 COOLING SYSTEM Fan beit tension as deflection under 10 kg 22 b push applied to middie 6 9mm 0 23 0 35 in point between pulleys Thermostat start to open ES li 6 temperature 82 C 179 or 88 C 190 F Thermostat full open temperature 95 C 203 F or 100 C 212 F en I 031i oe There are two types of thermostat depending on specifications
12. Ones Valve spring squareness guide protrusion In amp Ex 14 mm 0 55 in Rocker shaft 15 973 15 988 mm 0 628 0 629 Standard Valve stern cam shaft Rocker arm shaft Valve valve spring amp E Rocker 1 0 16 000 16 018 mm 0 629 0 630 5 Shaft to arm Inlet 0 012 0 045 mm 0 0005 0 0017 0 09 mm 0 0035 in E clearance Exhaust 0 0127 0 045 mm 0 0005 0 0017 in 0 09 mm 0 0035 in Rocker shaft runout Flatness of gasketed surface 0 03 mm 0 0012 in 0 06 mm 0 0024 in Cylinder bore S T D 74 00 74 02mm 2 9134 2 9142 74 15 mm 2 9193 in Cylinder to piston clearance 0 02 0 04 mm 0 0008 0 0015 in Standard 73 970 73 990 mm 2 9122 2 9129 in Oversize 0 25 mm 74 220 74 230 mm 2 9220 2 9224 in 0 0098 in Over size 0 50 mm 74 470 74 480 mm 2 9319 2 9322 in 0 0196 in Top ring 1 22 1 24 mm 0 0480 0 0488 in 2nd ring 1 51 1 53 mm 0 0594 0 0602 in 2 81 2 83mm 0 1106 0 1114 in 16 995 17 000 mm 0 6691 0 6693 in Top ring 117 1 19 mm 0 0461 0 0468 in 147 149 mm 0 0578 0 0586 in Ringclearancein ring 0 03 0 07 mm 0 0012 0 0027 in 0 12 mm 0 0047 in Top ring 0 20 0 33mm 0 0079 0 0129 in Cylinder MM
13. SECTION 10 CHARGING SYSTEM NOTE For the items not found in this section refer to the same section of 88 MODEL SERVICE MANUAL CONTENTS 10 1 ALTERNATOR 10 1 GENERAL DESCRIPTION 10 1 DATA AND 10 2 10 1 ALTERNATOR GENERAL DESCRIPTION The maximum output of this alternator is 50A Its structure and operation are the same as the one used for the 88 model vehicle The component parts also remain the same except the rotor BEER zu ZC Rotor e Field coil Rotor coil B S sall 1 TA Stator ZA Regulator e Brush P 1 Pulley Battery terminal n 222 a Th Field terminal E E 3 SE e IS Fig 10 7 10 1 Generator pulley 1 2 Drive end frame 3 Drive and frame bearing 4 Rotor 5 Rear end frame bearing 6 Rear end frame 7 Regulator ass y 8 Brush 9 Rectifier 10 Rear end cover Fig 10 2 The graph given below shows the alternator frame temperature to output voltage relationship Nominal operating 12 volts Use it as reference when checking output of the voltage alternator DATA AND SPECIFICATION Max alternator output 50 Polarity No load alternator speed Regulated voltage 14 5 0 3V Clockwise as view ed from pulley side Direction of rotation Maximum pe
14. TO REPAIR SHOULD BE REPLACED IN CASE OF DOUBT INSTALL NEW PARTS 2 INSPECT ADJUST CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON The length of booster piston rod is adjusted to provide specified clearance between piston rod end and master cylinder piston Booster piston rod Master cylinder piston Fig 19 97 e Before measuring clearance push piston rod several times so as to make sure reaction disc is in place 19 20 e Take measurement with gasket installed to master cylinder e Keep inside of booster at atmospheric pressure for measurement 1 Set special tool E on master cylinder and push pin until contacts piston Gasket Master cylinder E Booster piston Piston rod gauge Pin head 09950 96010 Fig 19 92 2 Turn special tool upside down and place it on booster Adjust booster piston rod length until rod end contacts pin head 3 Adjust clearance by turning adjusting screw of piston rod 1 Booster body 2 Piston rod Special tool Clearance mm 0 in Between special tool and piston rod Fig 19 93 Special tool Booster piston rod adjuster 09952 16010 Fig 19 94 Reference When adjusted as above if negative pressure is applied to booster with engine at idle piston to piston rod clearance should become 0 25 0 5 mm 0 010 0 020 in 3 INSPECT BOOSTER OPERATION There are two ways to perform this inspection with and without a tes
15. at the end of this manual 21 17 DAYTIME RUNNING LIGHT 21 3 21 1 21 1 COMBINATION METER COMBINATION METER CIRCUIT The 90 mode combination meter includes a vehicle speed sensor VSS in addition to the same components as the 88 model combination NOTE Whether equipped with marked parts or not depends on vehicle specifications meter and parking brake switch 24 Ba 13 19 1 TIMER vss Gs Wl HOCGHOQOOOL L 224 2 D R emm e as mm Li KL Li L4 17 18 8 9 1012 2 16 11 14 20 EV 2 2 1 LI 1 Blank 10 To main switch 19 To lighting switch 2 To turn signal switch L 11 To DRL controller 20 To illumination controller 3 To ECM Canada spec vehicle only 21 To seat belt switch 4 To earth 12 To 4WD switch 22 Mileage sensor Federal spec 5 To ECM 13 To battery positive vehicle except California and Canada 6 To oil pressure switch 14 To dimmer amp passing switch 23 Cancel switch Federal spec 7 To ignition switch positive 18 To fuel level gauge vehicle except California and Canada 8 To generator 16 To turn signal switch 24 Combination meter 9 To brake fluid level switch 17 To water temp gauge To ignition coil negative Coupler Terminal Position of Meter Fig 21 1 Combinatio
16. estos fibers from becoming airborne 19 1 19 1 GENERAL DESCRIPTION When the foot brake pedal is depressed hydraulic pressure is developed in the master cylinder to actuate pistons two in front and four in rear The master cylinder is a tandem master cylinder Two brake pipes are connected to the master cylinder and they make two independent circuits One connects the front brakes right amp left and the other connects the rear brakes right amp left The proportioning and bypass valve P amp B valve is included within the brake circuit which connects the master cylinder and the re r wheel brake in this brake system the disc brake type is used for the front wheel brake and a drum brake type leading trailing shoes for the rear wheel brake The parking brake system is mechanical It applies brake force to only rear wheels by means of the cable and mechanical linkage system The same brake shoes are used for both parking and foot brakes Right side Left side 1 Brake booster P amp B Proportioning and bypass valve 2 Master cylinder Parking brake lever 3 Secondary side Differential 4 Primary side Rear axie housing 5 6 wey joint Fig 19 1 19 2 MASTER CYLINDER Fig 19 2 Brake master cylinder assembly Brake master cylinder piston set Piston stopper circlip Secondary piston stopper bolt Seal ring Piston stopper Cylinder cup Plate Master cy
17. eter In amp Ex 12 030 12 048 mm 45 0 4736 0 4743 in 0 15 mm 0 75 mm 0 0059 in 0 0295 in 0 050 0 091 mm 0 0020 0 0036 in 38 036 mm 1 4975 in 38 036 mm 1 4975 in 0 10 mm 0 0039 in 38 136 mm 1 5014 in 1 5014 in Exhaust Valve guide to valve Inlet 0 020 0 050 mm 0 0008 0 0019 in 0 07 mm 0 0027 in 0 035 0 065 mm 0 0014 0 0025 in Exhaust 6 965 6 980 mm 0 2742 0 2748 in 7 000 7 015 tnm 0 2756 0 2761 in 7 000 7 015 mm 0 2786 0 2761 in 0 09 mm 0 0035 in 0 6 mm 0 0236 in 0 039 in 1 0mm 0 039 in Exhaust 0 7 mm 0 0275 in 1 3 1 5 mm 0 0512 0 0590 in 1 3 1 5 mm 0 0512 0 0590 in Valve spring free length Valve spring preload 22 4 Iniet Exhaust Inlet Exhaust 48 1 mm 1 8937 in 48 1 mm 1 8937 in 24 8 29 2 kg 54 7 64 3 Ib for 22 8 kg 50 2 Ib for fitting fitting length 41 5 mm 1 63 in length 41 5 mm 1 63 in 24 8 29 2 kg 54 7 64 3 Ib for 22 8 kg 50 2 Ib for fitting fitting length 41 5 mm 1 63 in length 41 5 mm 1 63 in 49 3 mm 1 9409 in 1 9409 in Service Limit 0 14mm 0 005 end deflection Exhaust oo EE
18. ial gear box oil Transfer gear box oil 22 3 22 2 SERVICE DATA ENGINE Compression pressure cylinders Cold When cool ant temper ature is 15 25 C or 89 77 F Valve lash clearance Hot When cool 68 C or 140 154 F Flatness of manifold seat Difference between Exhaust Exhaust 14 0 kg cm 199 0 psi 12 0 kg cm 170 0 psi 1 0 kg cm 14 2 psi 0 137 0 18 mm 0 0051 0 0071 in 0 15 0 21mm 0 0059 0 0083 in 0 23 0 27 mm 0 009 0 011 in 0 26 0 30mm 0 0102 0 0118 in Flatness of gasketed surface Inlet Exhaust WEE RET 0 05 mm 0 002 in 0 1 mm 0 004 in OMM 0 1 mm 0 004 in Valve seat width Cylinder head over size Seating angle Camshaft Journal clearance Inlet 1 37 1 5 mm 1 3 1 5 mm 0 0512 0 0590 in 0 0512 0 0590 in Cam height Base circle lift Valve guide D stem clearance Thickness of valve head periphery Valve valve spring amp cam shaft Contact width of valve and valve seat Camshaft thrust clearance Camshaft runout Inlet Valve stem diameter 6 950 6 965 mm 0 2737 0 2742 in Valve guide hole diam
19. ing end surface is flush with or lower than bracket end surface instali the flexible hose so that it won t be kinked when the steering wheel is straightened After installing the flexible hose turn the steering wheel to the right fully and check that the clearance between the wheel tire and flexible hose is larger than 25 mm 0 984 in in that state and then chock likewise with the steering wheel turned to the full left position This is to ensure that more than 25 mm 0 984 in clearance is maintained even when bumping or rebounding fully 19 24 D 1 H RI eet ml be el Ee j d Clamp Brake pipe Clamp Bolt ei c p CX pe i Secondary Primary M side side na as TN _zW4w0Nwn gt gt n00 Up side Brake pipes Right side Install brake pipe to Up side wheel cylinder pro using care for To flexible its installing posi hose tion To left wheel cylinder Insert E ring in ar row direction into hose groove securely and clamp hose Brake pipe Left side Upper side Install brake pipe to t wheel cylinder pro Air bieeder perly using care for plug _ 1 its installing posi Brake pipe flexible hose tion Brake backing plate Right amp Left When installing backing plate onto axie housing apply S
20. ith anything abrasive is prohibited as damage to cylinder bore may occur Rinse cylinder in clean brake fluid ShaKe excess rinsing fluid from cylinder Do not use a cloth to dry cylinder as lint from cloth will remain on cylinder bore surface 19 10 Reservoir NOTE Do not use shock absorber fluid or any other fluid which contains mineral oil Do not use a container which has been used for mineral oil or container which is wet from water Mineral oil will cause swelling and distortion of rubber parts in the hydraulic brake system and water will mix with brake fluid lowering the fluid boiling point Keep ail fluid containers capped to prevent contamination Fluid to fill reservoir with is indicated on reservoir cap of the vehicle with embossed letters or in owner s manual supplied with the vehicle Add fluid up to MAX line Fig 19 60 ASSEMBLY NOTE Before assembling wash each part in fluid re commended to use for that vehicle 1 Assemble secondary piston as shown below 2 Install secondary piston assembly into cylin der 0 8 1 2 kg m 6 0 8 5 A 10 1 Piston stopper circlip 7 Piston cup 2 Piston stopper 8 Secondary piston 3 Cylinder cup and plate 9 Return spring secondary seat 4 Primary piston 10 Secondary piston return spring 5 Piston cup 11 Secondary piston stopper bolt 6 Secondary piston 12 Master cylinder body pressure cup 13 Sealing Fig 19 61 3 Install primary pisto
21. linder seal ring Pin Reservoir connector grommet Master cylinder reservoir Cylinder reservoir strainer Cylinder reservoir cap Master cylinder gasket Brake booster assembly Master cylinder mounting nut 19 3 MASTER CYLINDER ASSEMBLY GENERAL DESCRIPTION The master cylinder has two pistons and three piston cups Its hydraulic pressure is produced in the primary in the below figure and secondary b chambers The hydraulic pressure produced in the primary chamber a acts on the rear wheel brakes right amp left Also the hydraulic pressure produced in the secondary chamber b acts on the front wheel brakes right amp left NOTE Replace all components included in repair kits to service this master cylinder Lubricate rubber parts with clean fresh brake fluid to ease assembly Do not use lubricated shop air on brake parts as damage to rubber components may result If any hydraulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners Piston stopper circlip Piston stopper Cylinder cup Primary piston Piston cup Secondary piston pressure cup Piston cup Secondary piston Return spring secondary seat Secondary piston return spring Secondary piston stopper bolt Master cylinder body Plate 1 2 3 4 5 6 7 a 9 Primary piston Secondary piston Fig 19 3
22. lting air valve control valve p closure stops the air flow into the chamber B and its pressure remains as it is In this way a small brake pedal depressing force is made into a strong push to the master cylinder push rod to produce high hydraulic pressure Air valve pe Control valve 1 Booster control valve 2 Booster air valve 3 Booster piston Fig 19 14 2 19 8 When foot brake pedal is released When the brake pedal is released the booster air valve returns to the right by the master cylinder piston return force and the air valve return spring force as shown Then the vacuum valve control valve C opens and causes negative pressure in the chamber B The result is that the master cylinder piston and booster piston return to their original positions This is the same state as described under When foot brake pedal is not depressed E 1 Booster air valve B 2 Air valve return spring 3 Booster piston 4 Booster control valve Fig 19 14 3 Reference Should any of the vacuum related parts in the booster be faulty the brake force is not increas ed Even then however the brake depressing force is transmitted to the valve operating rod booster air valve valve stopper key and booster piston in that order to push the master cylinder push rod Thus the braking operation itself will not fail Fig 19 14 4 19 4 MASTER CYLINDER REMOVAL 1 Remove air cleaner case For right ha
23. n Meter Wiring 21 2 21 17 DAYTIME RUNNING LIGHT D R L SYSTEM If equipped GENERAL DESCRIPTION If equipped with this system the headlights light though dimmer than the low beam when the following three conditions are al met Also D R L indicator light in the combination meter comes ON at the same time Conditions for D R L system operation 1 The engine is running 2 The parking brake is not applied 3 The lighting switch is at either OFF or clearance light position Dimmer passing switch Lighting switch Headlights Main fuses Generator Battery Ignition switch RB R G Br Y Fuse box Beigl B LRAG R w w R WG Combination meter Brake fluid level switch Parking brake switch D R L resister D R L controller Terminal arrangement D R L controller side 2 1 feTs 8 7 213 000g Or 8 W G B Black B G Black Green B W Black White Br Y Brown Yellow O W Orange White Or B Orange Black R Red R B Red Black R BI Red Blue R G Red Green R W Red White W G White Green Sb Skyblue W R White Red V G Violet Green W Y White Yellow W BI White Blue Fig 21 2 D R L System Circuit NOTE e D R L controller is located at the backside of e D R L resister is located inside front fender glove box LH pane at fender apron panel D R L resister Front fender LH panel Fender apron LH panel Fro
24. n in cylinder 4 Depress and install circlip 1 Rod 2 Circlip Fig 19 62 5 Install piston stopper bolt with pistons pushed in all the way and tighten it to specified torque 6 For installation on vehicle refer to INSTAL LATION PRECAUTION OF INSTALLATION NOTE Adjust clearance between booster piston rod and primary piston with special too See page 19 20 1 Install master cylinder as shown and torque attaching nuts to specification 2 Connect 2 hydraulic lines and torque flare nuts to specification 3 When using new grommets lubricate them with the same fluid as the one to fill reser voir with Then press fit grommets to master cylinder Grommets must be seated in place 4 Install reservoir and drive in reservoir pin NOTE Drive in reservoir pin till both of its ends at the right and left of reservoir become the same fength 1 Reservoir Fig 19 63 ES Sp 5 Connect reservoir lead wire 6 Fill reservoir with specified fluid 7 Upon completion of installation check for fluid leakage 10 16 Nm 1 0 1 6 kg m 14 18 N m 1 Reservoir 1 4 1 8 kg rn 2 Cap 10 5 13 0 Ib ft Fig 19 64 19 11 19 5 BRAKE BOOSTER REMOVAL 4 Remove master cylinder assembly referring to steps 1 4 and 7 9 of its REMOVAL on page 19 9 2 Disconnect vacuum hose from booster 3 Disconnect push rod clevis from brake pedal arm 4 Remove attaching nuts a
25. nd steer ing vehicle 2 Disconnect reservoir lead wire at coupler 3 Clean outside of reservoir 4 Take out fluid with syringe or such Remove reservoir onnector by using spe cial tool E d Reservoir Master cylinder Special tool Connector pin remover 09922 85811 Fig 19 56 6 Remove reservoir 7 Disconnect two brake pipes from master cylinder NOTE Do not allow brake fluid to get on painted sur faces 8 Remove master cylinder mounting nuts 9 Remove master cylinder 1 Reservoir 2 Connector pin 3 Grommets Fig 19 56 1 DISASSEMBLY 1 Remove circlip 2 Remove primary piston 1 Circlip 2 Master cylinder Fig 19 57 3 Remove piston stopper bolt Then remove secondary piston by blowing compressed air into hole from which piston stopper bolt was removed Be cautious during removal as secondary pis ton jumps out 1 Stopper bolt 2 Compressed air Fig 19 58 19 9 INSPECTION OF COMPONENTS Master Cylinder Inner Parts Inspect all disassembled parts for wear or damage and replace parts if necessary NOTE e Wash disassembled parts with brake fluid e Do not reuse piston cups Fig 19 59 Inspect master cylinder bore for scoring or corrosion t is best to replace a corroded cylinder Corrosion can be identified as pits or excessive roughness NOTE Polishing bore of master cylinder with cast aluminum body w
26. nd then booster as shown 1 Vacuum hose B Master cylinder 2 Booster 9 Push rod bracket 3 Push rod clevis lock nut 10 Push rod clevis 4 Split pin 11 Clevis pin 5 Gasket 12 Attaching nut 6 Dash panel 7 Master cylinder mounting nut INSTALLATION NOTE e Adjust clearance between booster piston rod and master cylinder piston with special tool See page 19 20 e Check length of push rod clevis See page 19 19 1 Instal booster to dash panel as shown Then connect booster push rod clevis to pedal arm with clevis pin and split pin 2 Torque booster attaching nuts to specifi cation 3 Install master cylinder to booster and torque master cylinder mounting nuts to specifica tion 4 Connect two brake pipes and torque flare nuts to specification 5 Connect booster vacuum hose 6 Connect reservoir lead wire at coupler 7 Install air cleaner case 8 Fill reservoir with specified fluid 9 Bleed air from brake system 10 After installing check pedal height and play 11 Perform brake test and check each installed part for fluid leakage 20 30 Nm 2 0 3 0 kg m 14 5 2t 5 lb ft 3 10 16 Nm 1 0 1 6 kg m 7 5 11 5 lb ft 10 16 1 0 1 6 kg m 2 5 11 5 lb ft Fig 19 65 19 12 DISASSEMBLY 1 Booster No 1 body 2 Booster piston return spring Piston rod retainer Piston rod Reaction disc Bo
27. nt food panel eege SE 1 D R L controller Fig 21 3 TROUBLE DIAGNOSIS When a trouble has occurred in this system check it by using the following flow chart 1 or trouble diagnosis chart 2 depending on symptom 1 D R L system does not operate Apply parking brake and stop engine Turn on lighting switch and Headlights do not operate dimmer switch come on Headlights come on Check headlight bulbs and fuses If necessary replace it Check headlight circuit Turn OFF lighting switch Start engine Do not apply parking brake but apply foot brake Turn lighting switch at either OFF or Clearance light position Check D R L indicater light Indicater light comes on Indicater light does not come on With coupler connected to D R L controller check if voltage about 12V is applied to W R V G Br Y and B W lead wire terminals Apply and release parking brake and check if D R L controller makes a clicking sound each time Click heard No click heard Check resister and its Replace D R L control circuit ler No voltage is applied to one or more lead wire terminals Voltage applied to all lead wire terminals Check circuit of lead wire terminal where no voltage is applied W R V G Br Y or B W and its parts as well Check voltage at ground of D R L controller If it is OV replace D R L controller 21 4 2 D R
28. o 2 body to make sure that diaphragm is seated securely in its outer groove as shown in A 1 1 Booster No 2 body 2 Diaphragm 3 Booster piston Fig 19 83 9 Install air cleaner separator and then element to rod of air valve assembly 1O Install body boot to booster No 2 body Both ends of boot must be fitted securely as shown No 2 body Boot Red Booster piston Fig 19 84 19 17 11 Install reaction disc to booster piston rod after greasing its outer face NOTE Make sure that no air exists between piston rod and reaction disc Apply grease 1 Piston rod 2 Reaction disc Fig 19 85 12 Place No 1 body on special tool A Special too A 1 No 1 body Fig 19 86 13 Install piston rod rod retainer and piston return spring to booster piston as shown below Then install them to booster No 1 body 19 18 1 Piston 4 Piston return spring 2 Piston rod Booster No 1 body 3 Rod retainer 6 Booster No 2 body Fig 19 87 14 Put No 1 and No 2 bodies together by align ing markings made before disassembly Holding No 2 body with upper plate special tool as shown torque two nuts equally to specification NOTE When holding No 2 body use care so that dia phragm is not caught by projections at 16 loca tions around No 1 body Tighten right and left nuts equally Special tool A Booster overhaul tool set 09950 88210 Align match
29. oil Secondary coil resistance 10 2 13 8 kiloohms 20 C 68 F Spark plug gap 0 7 0 8 mm 0 027 0 031 in 22 8 Prepared by SUZUKI MOTOR CORPORATION Technical Department Automobile Service Division ist Ed May 1989 2nd Ed May 1991 Printed in Japan
30. oster piston Key cushion Valve stopper key Booster air valve assembly Diaphragm Diaphragm retainer Circular ring Booster No 2 body No 2 body oil seal Air Cleaner separator Air cleaner element Body boot Nut Bracket Push rod clevis Fig 19 66 1 Remove push rod clevis and nut A Booster overhaul tool set 09950 10 oa B Attachment 09951 16010 Tighten right and left nuts equally 1 Fig 19 67 3 5Nm Booster 0 3 0 5 kg m 22 3 6 tb ft 2 Attach booster to special tool A as shown and install special tool B to booster as shown NOTE e When attaching check to be sure that booster vacuum pipe is not in faulty contact with base of special tool A Be careful not to over tighten nuts or booster body will be deformed Fig 19 68 19 13 3 Turn special tool bolt clockwise until No 1 body projecting part and No 2 body depressed part fit each other Once they are matched make match marking on No 1 and No 2 bodies to facilitate their installation No 1 body projecting part 2 body depressed part Make match marking Fig 19 69 4 Detach booster from special tool and separate No 1 body and No 2 body Remove piston return spring WARNING When separating two bodies carefully hold both bodies to prevent either body from jumping off by spring force 5 From booster No 2 body remove piston rod boo
31. rmissible alternator speed 15 000 rpm r min Working temperature 30 90 C range 22 194 Full wave rectification Rectification 30 C 25 C 22 F 77 F Temperature Fig 10 3 SECTION 11 CLUTCH NOTE For the items not found in this section refer to the same section of 88 MODEL SERVICE MANUAL CONTENTS 11 5 MAINTENANCE SERVICES D age e See 11 1 11 5 MAINTENANCE SERVICES NOTE For the maintenance service procedure not found in this section refer to the same section of 88 MODEL SERVICE MANUAL Clutch Pedal Height Check to make sure that clutch peda height is within A range as illustrated Clutch pedal 148 154 mm height A 5 83 6 06 in Clutch peda free H clutch pedal height is out of above specifica position tion adjust it by turning pedal stopper bolt GE sure to tighten lock nut after adjustment Clutch pedal stopper boit Lock nut Clutch pedal height 11 1 SECTION 15 PROPELLER SHAFTS NOTE For the items not found in this section refer to the same section of 88 MODEL SERVICE MANUAL CONTENTS 15 5 TIGHTENING TORQUE eee n nnn 15 1 15 5 TIGHTENING TORQUE Bolts amp Nuts Check following bolts and nuts for tightness and retighten them as necessary Tightening torque for propeller shaft Universal joint flange bolts and nuts 15 1 SECTION 19 BR
32. s Fig 19 100 4 BOOSTER INSPECTION TABLE 1 Booster piston 2 Air valve ass y Control valve and spring Inspect For Corrective Action Cracks distortion or damage Replace Damaged or worn seal surfaces Replace 4 Diaphragm boot and rubber 6 Booster No 1 amp No 2 body 7 Air filters and separator Fig 19 101 Replace unless easily repaired 1 Scratches scores pits dents or other damage affecting rolling or sealing of diaphragm or other seals Replace unless easily repaired 2 Cracks damage at ears damaged threads on studs Replace unless easily repaired 3 Bent or nicked locking lugs 4 Loose studs Replace Replace 19 23 19 7 BRAKE PIPES AND HOSES NOTE For the service informations not found in this section refer to the same section of 88 MODEL SERVICE MANUAL REMOVAL AND INSTALLATION 6 way joint View from arrow 1 From master cylinder From master cylinder Secondary side i Primary side To front left flexible hose To P amp B valve To front right flexible hose Brake flexible hose and E ring Make sure that flexible hose is not twisted when it is i installed or connected to the pipe When installing flexible hose to bracket align 6 vertexes of metal fixture on hose with internal angles of bracket insert E ring till Er
33. t air cleaner element and air cleaner sepa rator in this order Piston rod Piston No 2 body Air cleaner separator Air cleaner element Boot Fig 19 70 19 14 6 Remove valve stopper key cushion from stop per key 1 Booster piston 2 Stopper key cushion Fig 19 71 7 While compressing air valve spring by moving rod up and down as shown remove valve stopper key Then remove booster air valve assembly from booster piston NOTE Booster air valve assembly can t be disassembled Valve stopper key Booster air valve assembly Fig 19 72 8 Remove diaphragm circular ring from booster piston 1 Booster piston 2 Circular ring Fig 19 72 1 9 Remove diaphragm from booster piston NOTE Don t use driver or other tool for removal Pull it off by hand carefully handling piston groove area where diaphragm is fitted Fig 19 73 10 Remove reaction disc from booster piston rod 1 Reaction disc 2 Piston rod Fig 19 74 11 Remove oil seal from booster No 2 body with special tools as shown NOTE Removed oil seal must not be reused Spacial tool 09951 16020 Special tool 09951 18210 1 Hammer lightly 2 No 2 body 3 Oil seal Fig 19 75 19 15 ASSEMBLY NOTE Be sure to use silicon grease wherever application of grease is instructed during assembly 1 Apply grease to new oil seal outer surface and oil seal lip as shown Press
34. ter Ordinarily it is possi ble to roughly determine its condition without using a tester NOTE For this check make sure that no air is in hy draulic line INSPECTION WITHOUT TESTER Check Air Tightness 1 Start engine 2 Stop engine after running for 1 to 2 minutes 3 Depress brake pedal several times with the same load as in ordinary braking and observe pedal travel If pedal goes down deep the first time but its travel decreases as it is depressed the second and more times air tightness is obtained Fig 19 95 4 If pedal travel doesn t change air tightness isn t obtained X N 1st 2nd 3rd NO GOOD Fig 19 96 NOTE If defective inspect vacuum lines and sealing parts and replace any faulty part When this has been done repeat the entire test 19 21 Check Operation 1 With engine stopped depress brake pedal several times with the same load and make sure that pedal travel doesn t change Fig 19 97 2 Start engine while depressing brake pedal If pedal travel increases a little operation is satisfactory But no change in pedal travel indicates malfunction Fig 19 98 19 22 Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed Fig 19 99 2 Hold brake pedal depressed for 30 seconds If pedal height does not change condition is good But it isn t if pedal rises 30 second
35. ward movement of the piston A becomes effective Thus the fluid pressure is produced in the chamber a and it acts on rear wheel brakes right amp left The below figure shows secondary piston B at halt Fig 19 4 1 19 5 BOOSTER ASSEMBLY GENERAL DESCRIPTION The booster is located between the master cylinder and the brake pedal it is so designed that the force created when the brake pedal is depressed is mechanically increased combined with the engine vacuum The booster has a diaphragm of 180 mm effective diameter Its operation is described in the following pages NOTE e Use all components included in repair kits to service this booster Lubricate rubber parts where indicat ed with silicone grease provided in kits The torque values specified are for dry unlu bricated fasteners if any hydraulic component is removed or brake line disconnected bleed the brake system e Never lubricate any hydraulic component with silicone grease Booster No 1 body Diaphragm retainer Booster piston return spring Diaphragm stopper ring Red retainer Booster No 2 body Piston rod Air cleaner separator Reaction disc Air cleaner element Booster piston Body boot Valve stopper key Nut Key cushion Bracket Booster air valve assembly Push rod c avis Diaphragm No 2 body oil seal 1 2 3 4 5 6 7 8 9 0 Fig 19 12 19 6 Booster OPERATION Booster No 1 bod
36. y Booster No 2 body Valve operating rod Air cleaner elernent Air cleaner separator Air valve spring retainer Air valve return spring Control valve spring retainer Control valve spring Booster control valve Booster air vaive Booster piston Valve stopper key Booster diaphragm Reaction disc Booster piston return spring Booster piston rod Booster rod adjust screw 3 Fig 19 13 1 Vacuum Booster Assembly When the brake pedal is depressed the force is transmitted to the piston of the master cylinder through the valve operating rod booster air valve reaction disc and piston rod At the same time the force of the booster piston developed due to the pressure difference between the two chambers A and B in the above figure is added to it The end of the booster contro valve has a double function of a vacuum valve and air valve That is as shown in the figure the booster control valve closes between the and B chambers as its outer end C contacts the booster piston seat and opens as C leaves the booster piston seat vacuum valve function Also it closes between the B chamber and outside air as its inner end D contacts the air valve seat and opens as D leaves the air valve seat air valve function When foot brake pedal is not depressed The valve operating rod is pushed to the right by the spring force as shown The air valve is also enough to
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