2000 SUZUKI SWIFT RG413 Service Workshop Manual

1B-40 AIR CONDITIONING (OPTIONAL)
7) Remove clutch pulley (2) with puller (1).
8) Remove clutch coil.
9) Remove circlip (1) by using special tool.
Special tool
(A) : 09900-06107
10) Remove clutch coil (2) from compressor (3).
INSTALLATION
1) Install clutch coil (2).
Protrusion on under side of clutch coil must match hole in
compressor (3) to prevent movement ant correctly locate
lead wire.
2) Using special tool, install new circlip (1) as shown.
Special tool
(A) : 09900-06107
3) Install clutch pulley (1).
a) Set clutch pulley (1) squarely over clutch pulley installation
boss.
b) Place special tool onto clutch coil bearing.
Ensure that edge rests only on inner race of bearing.
Special tool
(A) : 09991-06010
c) Install circlip. NOTE:
 Be careful not to damage pulley when tapping clutch
pulley.
 Be careful not to scratch bearing.
CAUTION:
Be careful not to scratch bearing seal.

AIR CONDITIONING (OPTIONAL) 1B-41
4) Adjust clearance, between clutch plate (1) and clutch pulley
(2) by putting shim on compressor shaft.
Clearance between clutch plate and clutch pulley
“a” : 0.3 – 0.6 mm (0.012 - 0.024 in.)
5) Tighten new clutch plate bolt (2) to specified torque as
shown.
Tightening torque
Clutch plate bolt (a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
Special tool
(A) : 09991-06020
LIP TYPE SEAL
REMOVAL
1) Remove magnet clutch referring to “MAGNET CLUTCH” in
this section.
2) Remove front head (1) mounting bolts (2).
3) Remove front head (1) by pushing cylinder shaft (2).
4) Remove O-ring (3).
1. Clutch plate
3. Washer
NOTE:
Be careful not to remove cylinder from front head.

1B-42 AIR CONDITIONING (OPTIONAL)
5) Remove lip type seal from front head (1) using special tool.
Special tool
(A) : 09923-73210
INSTALLATION
1) Press-fit new lip type seal (1) into front head (2) using spe-
cial tool.
Special tool
(A) : 09991-06050
2) Coat special tool surface with oil and place it on cylinder
shaft (1).
Special tool
(A) : 09991-06040
3) Install new O-ring (1) to case.
4) Apply compressor oil to lip type seal and O-ring (1).
5) Install front head (2).
Special tool
(A) : 09991-06040
CAUTION:
Do not reuse lip type seal (1) once removed from com-
pressor.
[A] : Obverse side
[B] : Back side

AIR CONDITIONING (OPTIONAL) 1B-43
6) Tighten new front head mounting bolts (a), (b).
Tightening torque
Front head bolt (a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
Front head bolt (b) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
REQUIRED SERVICE MATERIAL
NOTE:
 Be sure to use new front head mounting bolts.
 Tighten bolt (a) first, and next (b).
MaterialRecommended SUZUKI product
(Part Number)Use
Compressor oil
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088O-ring
Each component
Refrigerant REFRIGERANT DRUM (200 g)
95794-50G00Refrigerant charge
Sealant SUZUKI BOND No.1216B
99000-31160Cooling unit

1B-44 AIR CONDITIONING (OPTIONAL)
SPECIAL TOOL
09900-06107 09990-06010 09990 -86011
Snap ring pliers
(Opening type)Manifold gauge set
See NOTE below.Gas leak detector
09991-06010 09991-06020 09991-06030 09991-06040
Magnet clutch pulley
installerArmature plate spanner Armature plate remover Lip type seal protector
09991-06050 09923-73210
Lip type seal installer Bearing remover
NOTE:
This kit includes the following items.
1. Manifold gauge, 2. Changing hose, 3. Quick connector, 4. Refrigerant container tap valve,
5. Refrigerant container T joint, 6. Packing set

STEERING, SUSPENSION, WHEELS AND TIRES 3-1
6F1
6F2
6G
6H
6K
3
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FRONT END ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3A
MANUAL RACK AND PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B
ELECTRICAL POWER STEERING (P/S) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B1
STEERING WHEEL AND COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3C
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3D
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3E
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3F
CONTENTS
DIAGNOSIS ........................................................ 3-2
GENERAL DIAGNOSIS .................................. 3-2
DIAGNOSIS TABLE ........................................ 3-2
TIRE DIAGNOSIS ........................................... 3-5
IRREGULAR AND/OR PREMATURE
WEAR.......................................................... 3-5WEAR INDICATORS .................................. 3-5
RADIAL TIRE WADDLE.............................. 3-6
RADIAL TIRE LEAD.................................... 3-7
VIBRATION DIAGNOSIS................................ 3-7

3-2 STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid-
ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Pro-
ceed with the following preliminary inspection and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged
parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
DIAGNOSIS TABLE
Condition Possible Cause Correction
Vehicle Pulls (Leads)
Mismatched or uneven tires Replace tire.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging springs Replace spring.
Radial tire lateral force Replace tire.
Disturbed front end alignment Check and adjust front end align-
ment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear suspension
partsTighten or replace suspension
parts.
Abnormal or
Excessive Tire WearSagging or broken spring Replace spring.
Tire out of balance Adjust balance or replace tire.
Disturbed front end alignment Check and adjust front end align-
ment.
Faulty strut (shock absorber) Replace strut.
Hard driving Replace tire.
Overloaded vehicle Replace tire.
Not rotating tire Replace or rotate tire.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel Tramp
Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut.
Shimmy, Shake or
VibrationTire or wheel out of balance Balance wheels or replace tire and/
or wheel.
Loosen wheel bearings Replace wheel bearing.
Worn tie rod ends Replace tie rod end.
Worn lower ball joints Replace front suspension arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire/wheel
assemblyReplace tire or wheel.
Disturbed front end alignment Check and adjust front end align-
ment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten case bolts.

STEERING, SUSPENSION, WHEELS AND TIRES 3-3
Hard Steering
Tire not adequately inflated Inflate tires to proper pressure.
Malfunction of power steering system Check and correct.
Bind in tie rod end ball studs or lower ball joints Replace tie rod end or front sus-
pension arm.
Disturbed front end alignment Check and adjust front end align-
ment.
Rack and pinion adjustment Check and adjust rack and pinion
torque.
Bind in steering column Repair or replace.
Too Much Play in
SteeringWheel bearings worn Replace.
Loose steering gear case bolts Tighten.
Rack and pinion adjustments Check and adjust rack and pinion
torque.
Worn steering shaft joints Replace joint.
Worn tie rod ends or tie rod inside ball joints Replace tie rod end or tie rod.
Worn lower ball joints Replace front suspension control
arm.
Poor Returnability
Bind in tie rod end ball studs Replace tie rod end.
Bind in ball joints Replace.
Bind in steering column Repair or replace.
Poorly lubricated rack and pinion Check, repair or lubricate rack and
pinion.
Disturbed front end alignment Check and adjust front end align-
ment.
Rack and pinion adjustment Check and adjust rack and pinion
torque.
Tires not adequately inflated Adjust tire pressure.
Rack and Pinion Noise
(Rattle or Chuckle)Loose steering gear case bolts Tighten.
Worn rack bush Replace.
Rack and pinion adjustment Check and adjust rack and pinion
torque.
Abnormal Noise,
Front EndWorn, sticky or loose tie rod ends, lower ball
joints, tie rod inside ball joints or drive shaft
jointsReplace tie rod end, suspension
arm, tie rod or drive shaft joint.
Damaged struts or mountings Repair or replace.
Worn suspension arm bushings Replace.
Loose stabilizer bar Tighten bolts or nuts, replace
bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or otherwise damaged wheel bearings Replace.
Broken suspension springs Replace.
Poorly lubricated or worn strut bearings Replace strut bearing. Condition Possible Cause Correction