MARUTI SUZUKI Zen Manual

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SH410
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully.Toemphasizespecialinformation,thewords
WARNING,CAUTIONandNOTEhavespecialmean-
ings. Pay special attention to the messages high-
lighted by these signal words.
WARNING:
Indicatesapotentialhazardthatcouldresult
in death or injury.
CAUTION:
Indicatesapotentialhazardthatcouldresult
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for autho-
rized Maruti dealers and qualified service
mechanics only. Inexperienced mechanics
or mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle un-
safe for the driver and passengers.

0A
6A1
6B
6C
6E1
6F
6G
6H
6K
8A
8
0B
1B
3B1
6
3C
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SH410
NOTE:
The screen toned Section 8A WIRING DIAGRAM is not contained in this manual.
The Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in FOREWORD of this manual.
1B
0B
SECTION
0A
3B1
TABLE OF CONTENTS
GENERAL INFORMATION
General Information
Maintenance and Lubrication
HEATING AND AIR CONDI-
TIONING
Air Conditioning
(If Equipped)
STEERING, SUSPENSION,
WHEELS AND TIRES
Electrical Power Steering
(EPS) System
Steering Wheel and Column 3C
TABLE OF CONTENTS
ENGINE
Engine Diagnosis
Engine Mechanical
Engine Cooling
Engine Fuel
Engine and Emission Control
System
Ignition System
Cranking System
Charging System
Exhaust System
ELECTRICAL SYSTEM
Electrical System
Wiring Diagram
SECTION
8B
6A1
6B
6C
6E1
6F
6G
6H
6K
8
8A
6

0A
GENERAL INFORMATION 0A-1
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SECTION 0A
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL 0A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions 0A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Catalytic Converter 0A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Electrical Circuit Service 0A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Inspection Procedure 0A- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermittent and Poor Connection 0A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution for Installing Mobile Communication Equipment 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Identification Number 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Identification Number 0A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFTING POINTS 0A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METRIC INFORMATION 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fasteners 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners Strength Identification 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tightening Torque 0A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO USE THIS MANUAL
1) ThereisaTABLEOFCONTENTSFORTHEWHOLEMANUAL
onthethirdpageofthismanual,wherebyyoucaneasilyfindthe
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is indi-
cated at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TORQUE SPECIFICATION
are given as shown in figure below.
6) Install oil pump. Refer to “Oil pump”.
7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle).
Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts to specified torque.
Special Tool
(A): 09924-17810
Tightening Torque
(c): 78 N.m (7.8 kg-m, 56.0 lb-ft)
1. Flywheel bolts or drive plate bolts for A/T vehicle
4) A number of abbreviations are used in the text.
Fortheirfullexplanations,referto“ABBREVIATIONS MAY BE
USED IN THIS MANUAL” of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENING TORQUE SPECIFICATIONS that should be used for
the servicing work described in that section.
0A-2 GENGERAL INFORMATION
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PRECAUTIONS
GENERAL PRECAUTIONS
TheWARNINGandCAUTIONbelowdescribesomegeneralprecautionsthatyoushouldobservewhenservicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.
WARNING:
Wheneverraisinga vehicle forservice,be suretofollow the instructionsunder “VEHICLE LIFTING
POINTS” on SECTION 0A.
When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
Whenit is necessaryto runthe engine indoors,make surethat theexhaust gas isforced outdoors.
Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-
ant), make sure that the area you work in is well-ventilated.
To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new
or used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
Makesurethebonnetisfullyclosedandlatchedbeforedriving.Ifitisnot,itcanflyupunexpectedly
during driving, obstructing your view and resulting in an accident.
CAUTION:
Before starting any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained
during servicing. Also, be aware that what you wear (e.g,
buttons) may cause damage to the vehicle’s finish.
When performing service to electrical parts that does not
requireuse ofbattery power,disconnectthe negative cable
of the battery.
GENERAL INFORMATION 0A-3
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Whenremovingthebattery,besuretodisconnectthenega-
tivecablefirstandthenthepositivecable.Whenreconnect-
ing the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.
When removing parts that are to be reused, be sure to keep
them arranged in an orderly manner so that they may be re-
installed in the proper order and position.
Whenever you use oil seals, gaskets, packing, O-rings,
locking washers, split pins, self-locking nuts, and certain
other parts as specified, be sure to use new ones. Also, be-
foreinstallingnewgaskets,packing,etc.,besuretoremove
any residual material from the mating surfaces.
Make sure that all parts used in reassembly are perfectly
clean.
When use of a certain type of lubricant, bond or sealant is
specified, be sure to use the specified type.
“A”: Sealant 99000-31150
Be sure to use special tools when instructed.
Special Tool
(A): 09917-98221
(B): 09916-58210
0A-4 GENGERAL INFORMATION
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When disconnecting vacuum hoses, attach a tag describ-
ing the correct installation positions so that the hoses can
be reinstalled correctly.
After servicing fuel, oil, coolant, vacuum, exhaust or brake
systems, check all lines related to the system for leaks.
For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.
PRECAUTIONS FOR CATALYTIC CONVERT-
ER
For vehicles equipped with a catalytic converter, use only un-
leaded gasoline and be careful not to let a large amount of un-
burned gasoline enter the converter or it can be damaged.
– Conduct a spark jump test only when necessary, make it as
short as possible, and do not open the throttle.
– Conduct engine compression checks within the shortest
possible time.
– Avoid situations which can result in engine misfire (e.g.
starting the engine when the fuel tank is nearly empty.)
GENERAL INFORMATION 0A-5
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PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE
When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.
Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit like
as ECM, PCM, P/S controller, etc.). The static electricity
from your body can damage these parts.
Never connect any tester (voltmeter, ohmmeter, or whatev-
er) to electronic control unit when its coupler is discon-
nected. Attempt to do it may cause damage to it.
Never connect an ohmmeter to electronic control unit with
itscoupler connectedto it.Attempt todo itmay causedam-
age to electronic control unit and sensors.
Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained or personal
injurymayresult.Ifnotspecified,useavoltmeterwith high-
impedance (M/V minimum) or a digital type voltmeter.
When taking measurements at electrical connectors using
a tester probe (2), be sure to insert the probe from the wire
harness side (backside) of the connector (1).
Whenconnectingmeterprobe(2)fromterminalsideofcou-
pler (1) because it can’t be connected from harness side,
use extra care not to bend male terminal of coupler of force
its female terminal open for connection.
In case of such coupler as shown connect probe as shown
to avoid opening female terminal.
Never connect probe where (3) male terminal is supposed
to fit.
0A-6 GENGERAL INFORMATION
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Whencheckingconnectionofterminals,checkitsmalehalf
forbendandfemalehalfforexcessive opening andbothfor
locking (looseness), corrosion, dust, etc.
Before measuring voltage to check for electrical system,
check to make sure that battery voltage is 11V or higher.
Such terminal voltage check at low battery voltage will lead
to erroneous diagnosis.
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various electrical circuit inspection methods, de-
scribedhereisageneralmethodtocheckitsopenandshortcircuit
by using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK
Possible causes for the open circuit are as follows. As the cause
is in the connector or terminal in many cases, they need to be
checked particularly carefully.
Loose connection of connector
Poor contact of terminal (due to dirt, corrosion or rust on it, poor
contact tension, entry of foreign object etc.)
Wire harness being open
When checking system circuits including an electronic control unit
suchasECM,TCM,ABScontrolmodule,etc.,itisimportanttoper-
form careful check, starting with items which are easier to check.
1) Disconnect negative cable from battery.
2) Checkeachconnectoratbothendsofthecircuitbeingchecked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
1. Check for loose connection
Sensor ECM
GENERAL INFORMATION 0A-7
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3) Using a test male terminal, check both terminals of the circuit
being checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust, entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
Check contact tension by
inserting and removing just for
once
4) Usingcontinuitycheckorvoltagecheckproceduredescribedin
the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.
1. Looseness of crimping
2. Open
3. Thin wire (single strand of wire)
CONTINUITY CHECK
1) Measure resistance between connector terminals at both ends
ofthecircuitbeingchecked(betweenA-1andC-1inthefigure).
Ifnocontinuityisindicated(infinityoroverlimit),thatmeansthat
the circuit is open between terminals A-1 and C-1.
2) Disconnecttheconnectorincludedinthecircuit(connector-Bin
the figure) and measure resistance between terminals A-1 and
B-1.
If no continuity is indicated, that means that the circuit is open
between terminals A-1 and B-1. If continuity is indicated, there
is an open circuit between terminals B-1 and C-1 or an ab-
normality in connector-B.
VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
1) Withall connectorsconnectedand voltageappliedto the circuit
being checked, measure voltage between each terminal and
body ground.
0A-8 GENGERAL INFORMATION
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If measurements were taken as shown in the figure at the left and
results were as listed below, it means that the circuit is open be-
tween terminals B-1 and A-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V
Also, if measured values were as listed below, it means that there
is a resistance (abnormality) of such level that corresponds to the
voltage drop in the circuit between terminals A-1 and B-1.
Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V 2V voltage drop
A-1 and body ground: Approx. 3V
0V
SHORT CIRCUIT CHECK (wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnectconnectorsatbothendsofthecircuittobechecked.
NOTE:
If the circuit to be checked is connected to other parts, dis-
connect all connectors of those parts.
Otherwise, diagnosis will be misled.
3) Measure resistance between terminal at one end of circuit (A-1
terminal in figure) and body ground. If continuity is indicated, it
meansthatthereisashorttogroundbetweenterminalsA-1and
C-1 of the circuit.
1. Other parts
4) Disconnect the connector included in circuit (connector B) and
measure resistance between A-1 and body ground.
Ifcontinuityisindicated,itmeansthatthecircuitisshortedtothe
ground between terminals A-1 and B-1.
1. To other parts
GENERAL INFORMATION 0A-9
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INTERMITTENT AND POOR CONNECTION
Mostintermittentarecausedbyfaultyelectricalconnectionsorwir-
ing, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:
Poormating of connector halves,or terminals not fully seatedin
the connector body (backed out).
Dirt or corrosion on the terminals. The terminals must be clean
and free of any foreign material which could impede proper ter-
minalcontact.However,cleaningtheterminalwithasand paper
or the like is prohibited.
Damaged connector body, exposing the terminals to moisture
and dirt, as well as not maintaining proper terminal orientation
with the component or mating connector.
Improperly formed or damaged terminals.
Check each connector terminal in problem circuits carefully to
ensuregood contact tension byusingthecorresponding mating
terminal.
Ifcontacttensionisnotenough,reformittoincreasecontactten-
sion or replace.
1. Check contact tension by inserting and removing just once
2. Check each terminal for bend and proper alignment
Poor terminal-to-wire connection.
Checkeachwireharnessinproblemcircuitsforpoorconnection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.
Wireinsulationwhich is rubbed through, causing an intermittent
short as the bare area touches other wiring or parts of the ve-
hicle.
Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands
ofa multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.
0A-10 GENGERAL INFORMATION
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PRECAUTION FOR INSTALLING MOBILE
COMMUNICATION EQUIPMENT
WheninstallingmobilecommunicationequipmentsuchasCB(Cit-
izens-Band)-radioorcellular-telephone,besuretoobservethefol-
lowing precautions.
Failure to follow cautions may adversely affect electronic control
system.
Keep the antenna as far away as possible from the vehicle’s
electronic control unit.
Keep the antenna feeder more than 20 cm (7.9 in) away from
electronic control unit and its wire harnesses.
Do not run the antenna feeder parallel with other wire har-
nesses.
Confirm that the antenna and feeder are correctly adjusted.
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
Thenumberispunchedonthefrontdashpanelintheengineroom.
ENGINE IDENTIFICATION NUMBER
The number is punched on the cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The number is punched on the transmission case.
M/T A/T
GENERAL INFORMATION 0A-11
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VEHICLE LIFTING POINTS
WARNING:
Beforeapplyinghoisttounderbody,alwaystakevehiclebalancethroughoutserviceintoconsider-
ation. Vehicle balance on hoist may change depending of what part to be removed.
Beforelifting upthevehicle,checktobesurethatendofhoistarm isnotincontactwithbrakepipe,
fuel pipe, bracket or any other part.
When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
thevehicletill4tiresarealittleoffthegroundandmakesurethatthevehiclewillnotfalloffbytrying
to move vehicle body in both ways. Work can be started only after this confirmation.
Make absolutely sure to lock hoist after vehicle is hoisted up.
When using frame contact hoist:
1. Front right tire
2. Rear right tire
3. Front
4. Front fender right panel
5. Bolt
: Support position for frame contact hoist and safety stand.
: Floor jack position
0A-12 GENGERAL INFORMATION
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In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of front cross member (1)
or rear axle (2).
WARNING:
Never apply jack against suspension parts (i.e., stabi-
lizer, etc.) or vehicle floor, or it may get deformed.
If the vehicle to be jacked up only at the front or rear
end, be sure to block the wheels on ground in order to
ensure safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
the vehicle raised on jack alone.
When using floor jack:
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under body so that body is securely
supported. And then check to ensure that body does not slide on
safety stands and the vehicle is held stable for safety’s sake.
GENERAL INFORMATION 0A-13
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0A-14 GENGERAL INFORMATION
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AABS : Anti-lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A/T : Automatic Transmission
A/C : Air Conditioning
ABDC : After Bottom Dead Center
A/F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency
Locking Retractor
BB+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center
CCKT : Circuit
CMP Sensor : Camshaft Position Sensor
(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
CPU : Central Processing Unit
CRS : Child Restraint System
DDC : Direct Current
DLC : Data Link Connector
(Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
(Diagnostic Code)
EEBCM : Electronic Brake Control
Module, ABS Control
Module
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature
Sensor (Water Temp.
Sensor, WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor
(Recirculated Exhaust Gas
Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electronic Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Charcoal Canister)
F4WD : 4 Wheel Drive
GGEN : Generator
GND : Ground
HHC : Hydrocarbons
HO2S : Heated Oxygen Sensor
IIAC Valve : Idle Air Control Valve (Idle
Speed Control Solenoid
Valve, ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature
Sensor (Air temperature
Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
ABBREVIATIONS MAY BE USED IN THIS MANUAL

GENERAL INFORMATION 0A-15
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SH410
LLH : Left Hand
LSPV : Load Sensing Proportioning
Valve
MMAF Sensor : Mass Air Flow Sensor
(Air Flow Sensor, AFS, Air
Flow Meter, AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
M/T : Manual Transmission
NNOx : Nitrogen Oxides
OOBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O/D : Overdrive
OHC : Over Head Camshaft
PPNP : Park/Neutral Position
P/S : Power Steering
PSP Switch : Power Steering Pressure
Switch (P/S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
RRH : Right Hand
SSAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic
Module (Air bag controller,
Air bag control module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
TTBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A/T Controller, A/T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three Way Catalytic
Converter (Three Way
Catalyst)
2WD : 2 Wheel Drive
VVIN : Vehicle Identification
Number
VSS : Vehicle Speed Sensor
WWU-OC : Warm Up Oxidation
Catalytic Converter
WU-TWC : Warm Up Three Way
Catalytic Converter

METRIC INFORMATION
METRIC FASTENERS
Mostofthefastenersusedforthisvehiclearemetric.Whenreplac-
ing any fasteners, it is most important that replacement fasteners
be the correct diameter, thread pitch and strength.
FASTENER STRENGTH IDENTIFICATION
Mostcommonlyusedmetricfastenerstrengthpropertyclassesare
4T,7T andradial line with the classidentification embossed on the
head of each bolt. Some metric nuts will be marked with punch
mark strength identification on the nut face. Figure shows the dif-
ferent strength markings.
When replacing metric fasteners, be careful to use bolts and nuts
of the same strength or greater than the original fasteners (the
same number marking or higher). It is likewise important to select
replacement fasteners of the correct size. Correct replacement
bolts and nuts are available through the parts division.
METRIC BOLTS-IDENTIFICATION CLASS NUMBERS OR
MARKS CORRESPOND TO BOLT STRENGTH-INCREAS-
ING NUMBERS REPRESENT INCREASING STRENGTH.
STANDARD TIGHTENING TORQUE
Eachfastenershouldbetightenedtothetorquespecifiedineachsectionofthismanual.Ifnodescriptionorspecifi-
cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When
a fastener of greater strength than the original one is used, however, use the torque specified for the original fas-
tener.
NOTE:
For the flanged bolt and nut, add 10% to the tightening torque given in the chart below.
The chart below is applicable only where the fastened parts are made of steel or light alloy.
Conventional bolt “4T” bolt “7T” bolt
0A-16 GENGERAL INFORMATION

SH410
STRENGTH
THREAD
DIAMETER
(mm) N.m kg-m lb-ft N.m kg-m lb-ft
4 1.5 0.15 1.0 2.3 0.23 2.0
5 3.0 0.30 2.5 4.5 0.45 3.5
6 5.5 0.55 4.0 10 1.0 7.5
8 13 1.3 9.5 23 2.3 17.0
10 29 2.9 21.0 50 5.0 36.5
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 98.0
16 105 10.5 76.0 210 21 152.0
18 160 16 116.0 240 24 174.0

0B
MAINTENANCE AND LUBRICATION0B-1

SH410
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PERIODIC MAINTENANCESCHEDULE 0B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCESERVICE 0B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 0B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control System 0B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake 0B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis and Body 0B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Inspection 0B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDEDFLUIDS AND LUBRICANTS 0B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .