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MARUTI SUZUKI Zen Estilo 2018, Manual

The MARUTI SUZUKI Zen Estilo 2018 user manual is available for free download on our website. This comprehensive manual provides detailed instructions and guidance for operating and maintaining your vehicle. Explore its features and optimize your driving experience by accessing the manual from manualshive.com.

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5C-4  CLUTCH

On-Vehicle Service

Maintenance Service

Clutch Pedal

Clutch Pedal Height

Measure pedal height difference “a” using measure (3) and adjust
clutch pedal (1) height so that it becomes almost same as brake
pedal (2) height.

Height difference “a”: 0 mm (0 in.)

If clutch pedal height is not as specified above, adjust it by turning

pedal stopper bolt (4). Be sure to tighten lock nut (5) after adjustment.

Tightening Torque

(a): 5.5 N·m (0.6 kg-m, 4.5 lb-ft)

Clutch Pedal Free Travel

1) Depress clutch pedal (1), stop the moment clutch resistance

is felt, and measure distance (clutch pedal free travel). Free
travel should be within the following specification.

Pedal free travel “b”: 15 – 20 mm (0.6 – 0.8 in.)

2) If free travel is out of specification, adjust it with cable joint

nut (2).

Clutch Cable Adjustment

1) Fit joint pin (1) into slot “a” and tighten joint nut (2) securely

as shown in figure. Arm play should be within the following
specification.

Arm play “b”: 0-2 mm

2) Tighten joint lock nut (3) to specified torque, and then confirm

that clutch pedal height is in specified value referring to “Clutch
Pedal Height Inspection:”.

Tightening torque

Joint lock nut (c): 11 N.m (1.1 kgf-m, 8.0 lb-ft)

Summary of Contents for Zen Estilo 2018

Page 1: ...ft 3 i Front Drive Shaft 3A 1 Brakes 4 i Brakes 4 1 Brakes With ABS 4A 1 ABS 4B 1 Transmission 5 i Manual Transmission 5B 1 Clutch 5C 1 Volume 2 Precautions 00 i Precautions 00 1 Steering 6 i Steering General Diagnosis 6A 1 Steering Wheel and Column 6B 1 Electrical Power Steering System 6C 1 HVAC 7 i Precautions 7 1 Heater and Ventilation 7A 1 Air Conditioning System 7B 1 Restraint 8 i Seat Belts ...

Page 2: ...ler Refer to Air Bag System Components and Wiring Location View un der General Description in air bag system section in order to confirm whether you are perform ing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precautions under On Vehicle Service in air bag system section before perform ing service on or around the air bag system components or ...

Page 3: ...g page And on the first page of each individual section is an index of that section This manual should be kept in a handy place for ready reference of the service work Strict observance of the so specified items will enable one to obtain the full performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use MARUTI genuine parts tools and service materials a...

Page 4: ...ons 00 4 Precautions for Catalytic Converter 00 6 Precautions for Electrical Circuit Service 00 7 Electrical Circuit Inspections Procedure 00 8 Intermittent and Poor Connection Inspection 00 11 Air Bag Warning 00 13 Air Bag System Service Warning 00 13 Fastener Caution 00 13 Suspension Caution 00 13 Wheels and Tires Caution 00 14 Brake Caution 00 14 ...

Page 5: ......

Page 6: ...eering wheel dashboard or any other air bag system components Modifications can adversely affect air bag system performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove the air bag system components beforehand to avoid component damage or unintended air bag system activation Diagnosis When troubleshooting air bag...

Page 7: ...necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment Otherwise personal injury may result Never dispose of live undeployed air bag inflator modules driver and passenger If disposal is necessary be sure to deploy them according to deployment procedures described in Air Bag Inflator Module and Seat Belt Pretensioner Disposal in Sect...

Page 8: ...ght enough not to cause air bags to activate be sure to inspect system parts and other related parts according to instructions under Repair and Inspection Required after Accident in Section 8B When servicing parts other than air bag system if shocks may be applied to air bag system component parts remove those parts beforehand When handling the air bag inflator modules driver and passenger seat be...

Page 9: ...lammable materials such as gasoline and refrigerant 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 pet...

Page 10: ...n 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 before installing new gaskets packing etc be sure to remove any residual material form the mating surfaces Make sure that all parts used in reassembly are perfectly clean When use of a certain type of lubri...

Page 11: ...ector without first releasing the fuel pressure or fuel can be sprayed out under pressure Precautions For Catalytic Converter For vehicles equipped with a catalytic converter use only unleaded gasoline and be careful not to let a large amount of unburned 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 ...

Page 12: ...e to coupler When connecting lock type coupler insert it till clicking sound is heard and connect it securely Never connect any tester voltmeter ohmmeter or whatever to electronic control unit when its coupler is disconnected Attempt to do it may cause damage to it Never connect an ohmmeter to electronic control unit with its coupler connected to it Attempt to do it may cause damage to electronic ...

Page 13: ...efore measuring voltage at each terminal 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 Inspections Procedure While there are various electrical circuit inspection methods described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter Open Ci...

Page 14: ...al is locked in the connector fully 4 Using continuity check or voltage check procedure described in the following check the wire harness for open circuit and poor connection with its terminals Locate abnormality if any Continuity check 1 Measure resistance between connector terminals at both ends of the circuit being checked between A 1 and C 1 in the figure If no continuity is indicated i e reni...

Page 15: ... 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 Short Circuit CHECK Wire harness to ground 1 Disconnect negative cable from battery 2 Disconnect connectors at both ends of the circu...

Page 16: ...iring although a sticking relay or solenoid can occasionally be at fault When checking it for proper connection perform careful check of suspect circuits for Poor mating of connector halves or terminals not fully seated in 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 terminal contact However ...

Page 17: ...h wire harness in problem circuits for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace Wire insulation which is rubbed through causing an intermittent short as the bare area touches other wiring or parts of the vehicle Wiring broken inside the insulation This condition could cause continuity check to show a good circuit but if only 1 or 2 strands ...

Page 18: ...sult in unintended activation of the system or could render the system inoperative Either of these two conditions may result in severe injury The procedures in the air bag system section must be followed in the order listed to disable the air bag system temporarily and prevent false DTCs from setting Failure to follow procedures could result in possible activation of the air bag system personal in...

Page 19: ...oper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal Brake Caution Caution 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 beco...

Page 20: ...9 Air Cleaner Filter Replacement 0B 9 Fuel Lines Inspection 0B 9 Fuel Filter Replacement 0B 9 Fuel Tank Inspection 0B 10 PCV Valve Inspection 0B 10 Fuel Evaporative Emission Control System Inspection 0B 10 Brake Discs and Pads Front and Brake Drums and Shoes Rear Inspection 0B 10 Brake Hoses and Pipes Inspection 0B 11 Brake Fluid Replacement 0B 11 Brake Lever and Cable Inspection 0B 12 Clutch Peda...

Page 21: ......

Page 22: ...L Serial Data Link SDL DOHC Double Over Head Camshaft DOJ Double Offset Joint DRL Daytime Running Light DTC Diagnostic Trouble Code Diagnostic Code E EBCM 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...

Page 23: ...ressure Switch P S Pressure Switch PCM Powertrain Control Module PCV Positive Crankcase Ventilation R RH Right Hand S SAE Society of Automotive Engineers SDM Sensing and Diagnostic Module SFI Sequential Multiport Fuel Injection SOHC Single Over Head Camshaft T TBI Throttle Body Fuel Injection Single Point Fuel Injection SPI TCC Torque Converter Clutch TCM Transmission Control Module A T Controller...

Page 24: ...GENERAL INFORMATION 0A 3 ...

Page 25: ...7T 8 8 and radial line with the class identification embossed on the head of each bolt Some metric nuts will be marked with punch 6 or 8 mark strength identification on the nut face Figure shows the different 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...

Page 26: ...e 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 fastener Note For the flanged bolt flanged nut and self lock nut of 4T and 7T strength 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 a...

Page 27: ...heck to be sure that end of hoist arm is not in contact with brake pipe 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 the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to move vehicle body in both ways Work can be started only after this confirmation M...

Page 28: ...se it may get deformed Warning 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 To perform service with either front or rear vehicle end jacked up be sure to place safety stands 1 unde...

Page 29: ...ON Identification Information Vehicle Identification Number The vehicle identification number is located on the front dash panel in the engine room Engine Identification Number The number 1 is punched on the cylinder block ...

Page 30: ...d adjust the gap I R I R I R I R Fuel 1 Air cleaner Paved road Clean every 5 000 km Replace every 40 000 km Dusty Clean every 2 500 km or as required Replace every condition 40 000 km More frequent replacement if dust condition is severe 2 Accelerator cable and Throttle shafts I L I L I L I L I L I L I L I L I L 3 Fuel tank cap fuel lines connections leakage damage I I I 4 Fuel filter leakage I I ...

Page 31: ...eel bearings loose damage I I I I I I I I I 4 Rear wheel bearings loose damage I I I I I I I I I Front And Rear Suspension 1 Suspension strut oil leakage damage I I I I I I I I I I 2 Suspension arms and knuckle supports loose damage I I I I I I I I I 3 Rear spring damage I I I I I I I I I 4 Shock absorbers oil leakage damage I I I I I I I I I I 5 All bolts and nuts loose T T T T T T T T T 6 Suspen...

Page 32: ...eedometer I I I I I I I I I I 2 Body and Chassis noise I I I I I I I I I I Air Conditioner if equipped 1 Check belt tension I I I I I I I I I I 2 Tighten compressor mounting bolts T T T T T T T T T 3 Check all hose joints tighten if necessary I I I I I I I I I I 4 Check functioning of Recir flap I I I I I I I I I I 5 Clean condenser with low pressure water I C C C C C C C C C 6 Check belt for fray...

Page 33: ...ttery Water pump belt replacement Replace belt with new one referring to Water Pump Belt Removal and Installation in Section 1F A C compressor drive belt inspection If equipped 1 Disconnect negative cable from battery 2 Inspect belt for cracks cuts wear and deterioration Replace if any defect exists 3 Check belt for tension A C compressor drive belt tension b 5 7 mm 0 20 0 28 in deflection under 1...

Page 34: ...8 mm Exhaust 0 006 0 007 in 3 Install cylinder head cover and tighten bolts to specification Engine Oil and Filter Change Use engine oil of SE SF SG SH or SJ grade Select the appropriate oil viscosity according to the left chart Warning New and used engine oil can be hazardous Be sure to read WARNING in General Precaution in Section 0A and observe what in written there Use engine oil of SE SF SG S...

Page 35: ...h oil until oil level is brought to FULL level mark on dipstick oil pan and oil filter capacity Filler inlet is at the top of cylinder head cover 8 Start engine and run it for three minutes Stop it and wait another 5 minutes before checking oil level Add oil as necessary to bring oil level to FULL level mark on dipstick Note Engine oil capacity is specified as left table However note that amount o...

Page 36: ... ambient temperature falls lower than 16 C 3 F in winter and mixture of 70 water and 30 ethylene glycol base coolant for the market where ambient temperature doesn t fall lower than 16 C 3 F Even in a market where no freezing temperature is anticipated mixture of 70 water and 30 ethylene glycol base coolant should be used for the purpose of corrosion protection and lubrication Refer to Section 1F ...

Page 37: ...xhaust system when it is still hot Any service on exhaust system should be performed when it is cool When carrying out periodic maintenance or vehicle is raised for other service check exhaust system as follows Check rubber mountings for damage and deterioration Check exhaust system for leakage loose connections dents and damages If bolts or nuts are loose tighten them to specification Refer to Se...

Page 38: ...leaner Filter Replacement Replace air cleaner filter with new one according to procedure described in Section 1D Fuel System Fuel Lines Inspection Check fuel lines for loose connection deterioration or damage which could cause leakage Make sure all clamps are secure Replace any damaged or deteriorated parts There should be no sign of fuel leakage or moisture at any fuel connection Fuel Filter Repl...

Page 39: ...stick or clog Refer to Section 1B for PCV valve checking procedure Fuel Evaporative Emission Control System if equipped Check EVAP Evaporative Emission canister for damage clog and operation referring to Section 1B Brake Discs Pads Drums and Shoes Inspection Brake discs and pads 1 Remove wheel and caliper but don t disconnect brake hose from caliper 2 Check front disc brake pads and discs for exce...

Page 40: ...e any of these parts as necessary Check all clamps for tightness and connections for leakage Check that hoses and pipes are clear of sharp edges moving parts Caution After replacing any brake pipe or hose be sure to carry out air purge operation Brake Fluid Change Caution Since brake system of this vehicle is factory filled with brake fluid indicated on reservoir tank cap do not use or mix differe...

Page 41: ...ooth movement Replace cable if it is in deteriorated condition Clutch Pedal Free Travel Inspection Check clutch pedal 1 for height and free travel a referring to Section 5C Adjust or correct if necessary Tire and Wheel Disc Inspection Tire inspection 1 Check tire for uneven or excessive wear or damage If defective replace 2 Check inflating pressure of each tire and adjust pressure to specification...

Page 42: ...nspection Check drive shaft boots wheel side and differential side for leakage detachment tear or any other damage Replace boot as necessary Suspension System Inspection Inspect front strut and rear shock absorber for evidence of oil leakage dents or any other damage on sleeves and inspect anchor ends for deterioration Replace defective parts if any Check front and rear suspension systems for dama...

Page 43: ...case for damage leaks detachment tear etc If damage is found replace it with new one 5 Check universal joints 3 of steering shaft for rattle and damage If rattle or damage is found replace it with a new one 6 Check that steering wheel can be turned fully to the right and left Repair or replace defective parts if any 7 If equipped with power steering system check also in addition to above check ite...

Page 44: ...e Change 1 Place the vehicle level and drain oil by removing drain plug 2 2 Apply sealant to drain plug after cleaning it and tighten drain plug to specified torque 3 Pour specified oil up to level hole 4 Tighten filler plug to specified torque For recommended oil its amount and tightening torque data refer to On Vehicle Service of Section 5B All Latches Hinges and Locks Inspection Doors Check tha...

Page 45: ...ping clutch occurs when releasing pedal and accelerating Clutch itself is free from any abnormal condition Gearshift or Select Lever Transmission Check gear shift or select lever for smooth shifting to all positions and for good performance of transmission in any position Brake Foot brake Check the following that brake pedal has proper travel that brake works properly that it is free from noise th...

Page 46: ...cosity chart in item 1 4 Engine coolant Ethylene glycol base coolant Antifreeze Anticorrosion coolant Brake fluid GC 1500AA Sunstar CCI Manual transmission oil API GL 4 SAE75W 90 Refer to Section 5B for detail Door hinges Engine oil or water resistance chassis grease Hood latch assembly Key lock cylinder Spray lubricant ...

Page 47: ......

Page 48: ...Position CMP Sensor circuit 1A 37 DTC P0500 Vehicle Speed Sensor VSS Malfunction 1A 38 DTC P0112 0113 Intake Air Tempera ture Sensor Circuit 1A 39 DTC P0117 P0118 Engine Coolant Temperature Circuit 1A 40 Inspection of ECM and Its Circuits 1A 41 ECM Power and Ground Circuit Check 1A 45 Fuel Injector Circuit Check 1A 48 Fuel Pump and Its Circuit Check 1A 50 Fuel Pressure Check 1A 52 Idle Air Control...

Page 49: ...and Assembly 1D 33 Valves and Valve Guides Inspection 1D 36 Cylinder Head Inspection 1D 38 Valve Spring Inspection 1D 39 Pistons Piston Rings Connecting Rods and Cylinder Components 1D 40 Pistons Piston Rings Connecting Rods and Cylinder Removal and Installation 1D 40 Pistons Piston Rings Connecting Rods and Cylinder Disassembly and Assembly 1D 43 Cylinder Pistons and Piston Pins and connecting ro...

Page 50: ...nition System Wiring Circuit Diagram 1H 2 Component Location 1H 3 Ignition System Components Location 1H 3 Diagnostic Information and Procedures 1H 4 Ignition System Symptom Diagnosis 1H 4 Ignition Spark Test 1H 6 Repair Instructions 1H 6 High Tension Cord Removal Inspection and Installation 1H 6 Spark Plug Removal Inspection and Installation 1H 7 Ignition Coil Assembly Including ignitor Inspectio...

Page 51: ......

Page 52: ...re confirming diagnostic information DTC etc stored in ECM memory Such disconnection will erase memorized information in ECM memory Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool Before using scan tool read its Operator s Instruction Manual carefully to have good understanding as to what functions are available and how to use it Be sure to r...

Page 53: ...l system which are under control of ECM ECM has an On Board Diagnostic system which detects a malfunction in this system When diagnosing engine troubles be sure to have full understanding of the outline of On Board Diagnostic System Description and each item in Precautions in Diagnosing Trouble and execute diagnosis according to Engine and Emission Control System Check There is a close relationshi...

Page 54: ...e DTC can be checked either using SUZUKI scan tool 2 For details of the DTC checkingprocedure refer to Diagnostic Trouble Code DTC Check For details of clearing the DTC refer to Diagnostic Trouble Code DTC Clearance Warm Up Cycle A warm up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a minimumtemperature...

Page 55: ...vided into 4 major sub systems air intake system fuel delivery system electronic control system and emission control system Air intake system includes air cleaner throttle body IAC valve and intake manifold Fuel delivery system includes fuel pump delivery pipe etc Electronic control system includes ECM various sensors and controlled devices Emission control system includes EVAP and PCV system 2 B ...

Page 56: ...ke system are air cleaner air cleaner outlet hose throttle body IAC valve and intake manifold The air by the amount corresponding to the throttle valve opening and engine speed is filtered by the air cleaner passs through the throttle body is distributed by the intake manifold and finally drawn into each combustion chamber When the IAC valve is opened according to the signal from ECM PCM the air b...

Page 57: ...1A 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS ...

Page 58: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A 7 ...

Page 59: ...ECT sensor with gauge 26 1 ECT sensor 26 2 ECT gauge 27 IAT sensor 28 A C evaporator thermister if equipped 29 Oxygen sensor Heated 30 Stop light switch 31 Position light switch 32 Blank 33 Rear Detogger Switch 34 Heater Blower motor switch 35 Heater blower motor 36 A C dual pressure switch if equipped 37 A C switch if equipped 38 Blank 39 Data link connector Connector C50 Connector C50 TERMINAL W...

Page 60: ...EROXYGEN SENSOR 8 GREY BLACK POWER SUPPLY FOR SENSOR 9 GREY RED POWER SUPPLY FOR SENSOR 10 BLANK 11 LT GREEN RED IAT SENSOR 12 GREY BLUE TP SENSOR 13 RED S OXYGEN SENSOR 14 BLANK 15 LT GREEN ECT SENSOR 16 LT GREEN BLACK IAT SENSOR 17 BLANK 18 BLUE BLACK CANISTER PURGE VALVE TERMINAL WIRE COLOR CIRCUIT 19 BLANK 20 BLANK 21 BLANK 22 BLANK 23 BLANK 24 BLANK 25 BLANK 26 BLANK 27 BLANK 28 BLANK 29 ORAN...

Page 61: ...C EVAPORATOR TEMP SENSOR 9 BLANK 10 BLANK 11 RED YELLOW ELECTRIC LOAD 12 BLANK 13 BLANK 14 VIOLET VSS OUT 15 BROWN TACHO SIGNAL OUTPUT Terminal Arrangement of ECM PCM Coupler viewed from harness side TERMINAL WIRE COLOR CIRCUIT 16 VIOLET YELLOW DIAGNOSIS OUTPUT 17 VIOLET WHITE SERIAL DATA LINK 18 BLANK 19 BLANK 20 BLANK 21 BLANK 22 BLANK 23 BLANK 24 BLANK 25 BLANK 26 ORANGE SENSOR GROUND 27 BLANK ...

Page 62: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A 11 Schematic and Routing Diagram Engine and Emission Control System Diagram ...

Page 63: ...7 ECT sensor 18 Three way catalytic convertor 19 CMP sensor 20 Main relay 21 Ignition coil assembly For No 1 and No 4 spark plugs 22 Ignition coil assembly For No 2 and No 3 spark plugs 23 ECM PCM 24 Radiator fan 25 Radiator fan control relay 26 Speedometer in combination meter 27 A C compressor control relay 28 Malfunction indicator lamp in combination meter 29 Ignition switch 30 Starter magnetic...

Page 64: ...tion control system Radiator fan control system Evaporative emission control system A C control system if equipped INFORMATION SENSORS 1 MAP sensor 2 TP sensor 3 IAT sensor 4 ECT sensor 5 Heated Oxygen sensor 6 VSS 7 Battery 8 CMP sensor 9 A C evaporator temp sensor if equipped 10 A C dual pressure switch if equipped CONTROL DEVICES a Fuel injectors b EVAP canister purge valve c Fuel pump relay d ...

Page 65: ...or DTC referring to DTC Check in this section Is there any malfunction DTC s 8 Engine Basic Inspection and Engine Diagnosis Table 1 Check and repair according to Engine Basic Check and Engine Diagnosis Table in this section Are check and repair complete 9 Trouble shooting for DTC 1 Check and repair according to applicable DTC diag flow table in Section 6E Are check and repair complete 10 Check for...

Page 66: ...ormal idling speed Axal pedal is depressed High Low r min Accel pedal is released Unstable Load is applied Hunting r min to r min A C Electric load P S Other Other____________ Other____________ OTHERS VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Fair Cloudy Rain Snow Always Other Temperature Hot Warm Cool Cold F C Always Frequency Always Sometimes times day m...

Page 67: ...o DTC Clearance in this section DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now To check which case applies check the symptom in question according to Step 5 and recheck DTC according to Step 6 or 7 Attempt to diagnose a trouble based on DTC in this step only or failure to cl...

Page 68: ... Go to Step 5 Go to Step 7 5 Check engine idle speed IAC duty referring to Idle Go to Step 6 Go to ENGINE DIAGNOSIS Speed IAC Duty Inspection in this section TABLE in this section Is check result as specified 6 Check ignition timing referring to Ignition Timing Go to ENGINE Adjust ignition Inspection in section 1H DIAGNOSIS TABLE timing Is check result as specified in this section 7 Check fuel sup...

Page 69: ...write it down Refer to SUZUKI scan tool operator s manual for further details If communication between SUZUKI scan tool and ECM PCM is not possible check if SUZUKI scan tool is communi cable by connecting it to ECM PCM in another vehicle If communication is possible in this case SUZUKI scan tool is in good condition Then check data link connector and serial data line circuit in the vehicle with wh...

Page 70: ...heater circuit malfunction when heater is OFF P0032 Terminal Voltage is higher than specification P0134 HO2S malfunction Oxygen sensor malfunction P0340 Camshaft position sensor No signal for 2 sec during engine cranking circuit malfunction P0500 Vehicle speed sensor malfunction P0112 Intake Air Temp circuit Intake Air Temp circuit low input P0113 malfunction Intake air Temp circuit high input P01...

Page 71: ...iston ring Piston ring inspection in Section 1 Worn piston ring or cylinder Cylinders pistons and piston rings inspection in Section 1 Others Malfunctioning PCV valve PCV system inspection in Section 1 Engine has no power Engine overheating Refer to Overheating Section Ignition system out of order Defective spark plug Spark plugs in Section 1 Faulty ignition coil with ignitorIgnition coil in Secti...

Page 72: ...or is depressed Fuel system out of order Can occur at all Fuel pressure out of specification Diag Flow Table B 4 in Section 1 vehicle speeds Clogged fuel filter Usually most severe Faulty fuel pressure regulator when first trying to Clogged fuel filter hose or pipe Fuel pressure check in Section 1 make the vehicle move as from a Engine overheating Refer to Overheating Section stop sign Engine and ...

Page 73: ... check in Section 1 Dragging brakes Diagnosis in Section 4 Slipping clutch Diagnosis in Section 5C Blown cylinder head gasket Cylinder head inspection in Section 1 Poor gasoline Ignition system out of order mileage Faulty spark plug improper gap heavy Spark plugs in Section 1 deposits and burned electrodes etc Engine and emission control system out of order Fuel pressure out of specification Diag ...

Page 74: ...necting rod bearing inspection in Section 1 Loose connecting rod nuts Connecting rod installation in Section 1 Low oil pressure Previously outlined Crankshaft noise Low oil pressure Previously outlined Worn crankshaft journal bearing Crankshaft and bearing inspection in Section 1 Worn crankshaft journal Crankshaft and bearing inspection in Section 1 Loose lower crankcase Crankshaft installation in...

Page 75: ... system Check for absence of filler neck Lead contamination of three way catalytic restrictor converter if equipped Check oxygen sensor output voltage Closed loop system A F feed back referring to DTC P0130 P0134 P0135 compensation fails vehicle with HO2S Diag Flow Table in Section 1 Faulty TP sensor Faulty ECT sensor or MAP sensor Faulty O2 sensor Faulty injector Fuel injector Section 1 Faulty EC...

Page 76: ...ation meter 2 ECM Power and Ground Circuit Check Go to Step 3 Go to TABLE A 3 ECM Does engine start POWER AND GROUND CIRCUIT CHECK If engine is not cranked go to DIAGNOSIS in SECTION 1I 3 MIL Circuit Check Substitute a Bulb burned out or V Y wire 1 Turn ignition switch OFF and disconnect knowngood ECM circuit open connectors from ECM and recheck 2 Check for proper connection to ECM at terminal G01...

Page 77: ...cator Lamp Circuit Check Malfunction indicator lamp flashes at ignition switch ON Step Action Yes No 1 MIL Flashing Pattern Check Go to Step 2 Substitute a known good 1 Turn ignition switch ON ECM and recheck Does lamp flashing pattern indicate diagnostic trouble code ...

Page 78: ...o this fuse 3 Main Relay Check Go to Step 4 Replace main relay 1 Turn OFF ignition switch and remove main relay 2 Check for proper connection to main relay at terminal A and B 3 If OK check main relay for resistance and operation referring to MAIN RELAY INSPECTION in section 1C Is check result satisfactory 4 ECM Power Circuit Check Go to Step 5 Br W or B W 1 Turn OFF ignition switch disconnect con...

Page 79: ... terminal C50 15 and B O and B for open measure voltage between terminal C51 3 If OK then substitute a C51 2 and ground at ignition switch ON known good ECM Is it 10 14 V and recheck 6 Is operating sound of main relay heard in Step 1 Go to Step 7 B Y or B R wire Open 7 Main Relay Check 1 Check main relay according to procedure in Step 3 B Y or B R wire open Replace main Is main relay in good condi...

Page 80: ...on with ignition switch ON If wire and connection are OK Is voltage about 4 5 V substitute a known good ECM PCM and recheck 3 1 Connect Lg R and O wire terminals of Go to Step 4 O wire open MAP sensor coupler using service wire Poor C51 5 connection 2 Check voltage between Lg R wire terminal If wire and connection are OK of MAP sensor coupler and ground substitute a known good ECM Is voltage about...

Page 81: ...A 30 ENGINE GENERAL INFORMATION AND DIAGNOSIS Note Upon completion of inspection and repair work perform DTC Confirmation Procedure referring to page 1A 18 to confirm that the trouble has been corrected ...

Page 82: ...r BI wire open or short of TP sensor coupler and ground Poor C51 12 connection with ignition switch ON If wire and connection are OK Is voltage about 4 5 V substitute a known good ECM PCM and recheck 3 1 Connect Gr Bl and O wire terminals of Go to Step 4 O wire open TP sensor coupler using service wire Poor C51 5 connection 2 Check voltage between Br Bl wire terminal If wire and connection are OK ...

Page 83: ...A 32 ENGINE GENERAL INFORMATION AND DIAGNOSIS Note Upon completion of inspection and repair work perform DTC Confirmation Procedure referring to page 1A 18 to confirm that the trouble has been corrected ...

Page 84: ...over 10 V 3 HO2S heater power circuit check 1 Disconnect connectors from ECM with Go to Step 4 BLK WHT wire is high ignition switch turned OFF resistance circuit 2 Measure resistance between BLK WHT wire terminal of HO2S connector and C41 06 terminal of ECM connector Is resistance below 5 4 HO2S heater drive circuit check 1 Measure resistance between C51 07 Go to Step 5 YEL RED wire is terminal of...

Page 85: ...nnector and vehicle body ground with connector disconnected from ECM Is voltage over 10 V 7 HO2S heater check 1 Disconnect HO2S connector with ignition Go to Step 8 Replace HO2S switch turned OFF 2 Check HO2S heater resistance referring to Heated Oxygen Sensor Heater On Vehicle Inspection in Section 1C Is resistance within specified value range 8 HO2S heater power circuit check 1 Connect connector...

Page 86: ...ayed on scan tool go to Step 3 Is over 0 6 V and below 0 3 V indicated 3 HO2S ground check 1 Disconnect connector from HO2S with Go to Step 4 ORN wire is open or high ignition switch turned OFF resistance circuit Poor 2 Check for proper connection to HO2S C51 29 terminal at BLK WHT YEL RED RED and connection Faulty ECM ORN wire terminals ground 3 If wire and connection are OK measure If they are O...

Page 87: ...ng to DTC P0031 P0032 HO2S Heater Control Circuit Low High Is it in good condition 7 Exhaust system check 1 Check exhaust system for exhaust Go to Step 8 Repair leakage of gas leakage exhaust system Is it OK 8 Fuel pressure check 1 Check fuel pressure referring to Fuel Go to Step 9 Repair or replace Pressure Check Is check result satisfactory 9 Air intake system check 1 Check air intake system for...

Page 88: ...ation resistance 1 M or more Were measured resistance values in above 2 and 3 as specified 2 1 Check CMP sensor referring to Section 6F1 Poor C51 32 or C51 33 Faulty CMP sensor Is it in good condition terminal connection of ECM PCM coupler If connection is OK substitute a known good ECM PCM and recheck DTC P0340 CMP Sensor Circuit Sensor signal not inputted for 2 seconds at engine cranking Note If...

Page 89: ...and Go to Step 4 Go to Step 5 B O wire terminals of disconnected VSS coupler Is voltage more than 4 V 4 1 Remove VSS Faulty VSS signal rotor Poor connection of VSS 2 Visually inspect VSS signal rotor for coupler terminal damage If OK substitute a known Was any damage found good VSS and recheck 5 1 Turn ignition switch OFF Faulty speedometer V wire open or short 2 Disconnect combination meter coupl...

Page 90: ...switch ON Is voltage about 4 5 V 2 1 Connect IAT sensor coupler terminals using Go to Step 2 O wire open or poor C51 05 service wire connection 2 Check voltage between Lg B wire terminal If wire and connection are OK of IAT sensor coupler and ground with ignition substitute a known good ECM switch ON and recheck Is voltage 0 15 V or less 3 1 Perform IAT sensor inspection in this section Poor conne...

Page 91: ...wire terminal of ECT sensor coupler and ground with ignition switch ON Is voltage about 4 5 V 2 1 Connect ECT sensor coupler terminals using Go to Step 2 O wire open or poor C51 05 service wire connection 2 Check voltage between Lg wire terminal of If wire and connection are OK ECT sensor coupler and ground with ignition substitute a known good ECM switch ON and recheck Is voltage 0 15 V or less 3...

Page 92: ...ed to connect voltmeter or ohmmeter to ECM PCM with couplers disconnected from it Voltage Check 1 Remove ECM PCM from body with ignition switch OFF referring to ECM PCM REMOVAL 2 Connect ECM PCM couplers to ECM PCM 3 Check voltage at each terminal of couplers connected Note As each terminal voltage is affected by the battery voltage confirm that it is 11V or more when ignition switch is ON Termina...

Page 93: ...elay 1 V or less Ignition switch ON C50 16 Blank C50 17 Blank C50 18 Blank C50 19 Blank C50 20 Blank C50 21 Blank C50 22 Blank C50 23 Blank C50 24 Blank C50 25 Blank C50 26 Blank C50 27 Blank C50 28 Blank C50 29 Test Switch Terminal 10 14 V Ignition switch ON 1 V or less Ignition switch ON Test switch terminal grounded C50 30 Blank C50 31 Igniter 1 V or less Ignition switch ON C50 32 Igniter 1 V o...

Page 94: ...NAL CIRCUIT NORMAL VOLTAGE CONDITION C52 01 Blank to C52 35 Blank TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION G01 1 Blank G01 2 Electric load signal for blower fan 2 V or less Ignition switch ON Blower fan switch High Middle or Low position Motor 4 0 14 0 V Ignition switch ON Blower fan switch OFF position G01 3 Blank G01 4 Stop light switch 1 5 V or less Brake pedal relased switch OFF ignition swit...

Page 95: ...witch ON C51 01 C50 06 C50 07 Body ground Ground Continuity Resistance Check 1 Disconnect ECM PCM couplers from ECM PCM with ignition switch OFF Caution Never touch terminals of ECM PCM itself or connect voltmeter or ohmmeter 2 Check resistance between each pair of terminals of disconnected couplers as listed in following table Caution Be sure to connect ohmmeter probe from wire harness side of co...

Page 96: ...Map sensor 2 Ignition switch 6 ECM 10 RADIO fuse 14 A C refrigerant pressure sensor 3 Main relay 7 Relay box 11 DLC 4 Blank 8 IG ACC fuse 12 TP sensor Circuit Description When the ignition switch is turned ON the main relay turns ON the contact point closes and the main power is supplied to ECM For troubleshooting refer next page ...

Page 97: ... is open circuit connector and body ground Is voltage 10 14 V 3 Ignition signal check Go to Step 4 BLK WHT or GRN 1 Turn ignition switch to ON position wire is open circuit 2 Measure voltage between G01 05 terminal of ECM connector and body ground Is voltage 10 14 V 4 Main relay circuit check Go to Step 5 Go to Step 9 1 Turn ignition switch to OFF position 2 Check FI fuse 1 15 A in relay box for b...

Page 98: ... voltage between BLK YEL wire terminal of main relay connector and body ground Is voltage 10 14 V 10 Main relay check BRN WHT wire is Replace main relay 1 Check main relay referring to Main Relay Fuel Pump open or high Relay Starting Motor Control Relay and Throttle resistance circuit Actuator Control Relay Inspection in Section 1C Is main relay in good condition 11 Sensor power source circuit che...

Page 99: ...check Go to Step 3 Faulty fuel injector 1 Disconnect connectors from fuel injectors with ignition switch turned OFF 2 Check for proper connection to fuel injector at each terminals 3 If OK check all 4 fuel injectors for resistance ref erring to Fuel Injector Inspection in Section 1G Are all injectors in good condition 3 Fuel injector insulation resistance check Go to Step 4 Faulty fuel injector 1 ...

Page 100: ...LU YEL BLU ORN and or YEL GRN BLU ORN BRN WHT wire terminal BRN WHT wire s are of fuel injector connector and vehicle body ground shorted to power supply with ignition switch turned ON circuit Is voltage 0 V 7 Fuel injector drive signal check Check fuel injector BLU YEL YEL GRN 1 Connect connectors to each fuel injector and referring to Fuel BLU ORN and or ECM with ignition switch turned OFF Injec...

Page 101: ...ec after ignition is in good condition switch is turned ON 2 Fuel pump relay power supply check Go to Step 3 BLK WHT wire is open 1 Disconnect fuel pump relay from relay box with ignition or shorted to ground switch turned OFF circuit 2 Check for proper connection to fuel pump relay at each terminal 3 If OK turn ON ignition switch measure voltage between BLK WHT wire terminal of fuel pump relay co...

Page 102: ...fter ignition switch is ECM and recheck turned ON Is voltage 0 1 V 7 Wire circuit check Go to Step 8 PNK wire is shorted to 1 Turn OFF ignition switch ground 2 Detach fuel tank referring to Fuel Tank Removal and Installation in Section 1G 3 Disconnect connector from fuel pump 4 Measure resistance between PNK wire terminal of fuel pump connector and vehicle body ground Is resistance infinity 8 Fuel...

Page 103: ...ing Normal fuel Clogged vacuum temperature pressure passage for fuel 2 Keep it running at specified idle speed pressure regulator or Is fuel pressure then within 200 240 kPa faulty fuel pressure 2 0 2 4 kg cm2 28 4 34 1 psi regulator 4 Is there fuel leakage from fuel feed line hose pipe or Fuel leakage from Go to Step 10 their joint hose pipe or joint 5 Was fuel pressure higher than spec in step 1...

Page 104: ...ing it check regulator restricted fuel feed fuel pressure hose or pipe Faulty Is it 450 kPa 4 5 kg cm2 63 9 psi or more fuel pump or fuel leakage from hose connection in fuel tank 10 1 Disconnect fuel return hose from pressure Faulty fuel pressure Fuel leakage from regulator and connect new return hose to it regulator injector Fuel leakage 2 Insert the other end of new return hose into from betwee...

Page 105: ...d Go to Step 11 with headlight ON condition 4 Was idle speed higher than specification in step 1 Go to Step 5 Go to Step 8 5 Check A C input signal circuit referring to B 8 Go to Step 6 Repair or replace A C A C Signal Circuits Check if equipped signal circuit or A C Is it in good condition system 6 Check IAC system referring to step 11 of this table Go to Step 7 Go to Step 12 Is check result sati...

Page 106: ...ir passage used at high altitude higher than 2000 m Etc or 6560 ft 10 1 Remove IAC valve from throttle body referring Intermittent trouble or Go to Step 11 to IAC Valve in section 1C faulty ECM PCM 2 Check IAC valve for operation referring to IAC Recheck for referring to Valve in section 1C Intermittent Trouble Is check result satisfactory on SECTION 0A 11 1 Turn ignition switch OFF Replace IAC va...

Page 107: ...ignal is Bl R wire open or short condition given in table below in good condition Poor G01 02 terminal connection Ignition switch ON If wire and connection are A C switch OFF OK check dual pressure Blower fan switch OFF 10 14 V switch and A C switch Ignition switch ON referring to Section 7B A C switch ON 2 V or less Blower fan switch ON 2 Is check result satisfactory ...

Page 108: ... Check electric load signal under following conditions respectively Electric load signal Ignition switch turned ON blower speed selector turned OFF or 1st position OFF Ignition switch turned ON blower speed selector turned to 2nd position or more ON Is check result satisfactory 2 Electric load signal circuit check Electric load signal RED YEL wire is 1 Turn ON ignition switch circuit is in good op...

Page 109: ...condition 2 Check RFC relay referring to section 1F Go to Step 3 Faulty RFC relay Is it in good condition 3 Check wire harnesses and connections for open Poor performance of ECT Wire open or short or short sensor If ECT sensor is OK Poor connection or Are they in good condition substitute a known good Faulty radiator fan ECM PCM and recheck motor B 8 Radiator Fan Control System Check ...

Page 110: ...ithin specification All accessories wipers heater lights A C etc are out of service Air cleaner has been properly installed and is in good condition No abnormal air inhaling from air intake system ECM PCM does not detect any malfunction DTC After above items are all confirmed check idle speed and IAC duty as follows Note Before starting engine place transmission gear shift lever in Neutral and set...

Page 111: ...ATION AND DIAGNOSIS Special Tools TIGHTENING TORQUE SPECIFICATIONS FASTENING PARTS TIGHTENING TORQUE N m kg m Ib ft IAC value 3 5 0 35 2 5 TP sensor 2 5 0 25 2 0 ECT sensor 12 1 2 9 0 O2 sensor 45 4 5 32 5 MAP sensor 20 0 20 1 5 ...

Page 112: ...ing at idle speed 4 Also check that vacuum is felt when engine speed is increased to higher than about 3000 r min If check result is not satisfactory check vacuum passage hoses EVAP canister purge valve wire harness and ECM PCM Refer to Evaporative Emission Control System Check Vacuum Passage Inspection Start engine and run it at idle speed Disconnect vacuum hose from EVAP canister purge valve Wit...

Page 113: ...ifold Blow into hose A Air should not come out of nozzle B 6 Open EVAP canister purge valve using MISC TEST mode of SUZUKI scan tool with ignition switch ON In this state blow hose A Air should come out of nozzle B Warning Do not suck the air through valve Fuel vapor inside valve is harmful If check result is not as described check wire harnesses for open or short If it is in good condition replac...

Page 114: ...side valve is harmful If check result is not as described replace EVAP canister purge valve 6 Connect vacuum hoses 7 Connect EVAP canister purge valve coupler securely EVAP Canister Inspection Warning DO NOT SUCK nozzles on EVAP canister Fuel vapor inside EVAP canister is harmful 1 Disconnect vacuum hoses from EVAP canister 2 When air 4 is blown into tank pipe 1 there should be no restriction of f...

Page 115: ...ation Replace as necessary PCV Value Inspection 1 Disconnect PCV valve from cylinder head cover and install plug to head cover hole 2 Run engine at idle speed 3 Place your finger over end of PCV valve to check for vacuum If there is no vacuum check for clogged valve Replace as necessary 4 After checking vacuum stop engine and remove PCV valve Shake valve and listen for the rattle of check needle i...

Page 116: ... not change check IAC valve and wire harness Not Using SUZUKI Scan Tool 1 Warm up engine to normal operating temperature 2 Stop engine 3 Turn ignition switch to ON position 4 Disconnect IAC valve connector 5 Start engine 6 Connect IAC valve connector 7 Check that idle speed increases and or reduces when connector is connected to IAC valve If idle speed does not change check IAC valve and wire harn...

Page 117: ...ort If wire harness is in good condition replace IAC valve and recheck 4 Install IAC valve referring to Idle Air Control IAC Valve Removal and Installation IAC Value Removal and Installation Removal 1 Remove throttle body from intake manifold referring to Throttle Body Removal section 2 Remove IAC valve from throttle body Installation 1 Install new O ring to IAC valve 2 Install IAC valve to thrott...

Page 118: ...couplers to ECM PCM securely 3 Connect battery negative cable at battery MAP Sensor on Vehicle Inspection Output Voltage Check 1 Remove ECM PCM refering to ECM Remove in this section 2 Connect couplers to ECM PCM securely 3 With coupler connected to ECM PCM connect digital type voltmeter as shown and check that ECM PCM supply voltage 4 75 5 25 V is applied to coupler terminal C51 08 4 Check output...

Page 119: ...age is clogged Clean them Another possibility is that filter in MAP sensor is clogged from freezing If it is suspected leave it at room temperature 200 C 680 F for a while and recheck 5 Upon completion of checking install ECM PCM and connect ECM PCM couplers securely ALTITUDE BAROMETRIC OUTPUT Reference PRESSURE VOLTAGE ft m kPa mmHg V 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 0 305 610...

Page 120: ...hen check voltage between Vout and Ground Also check if voltage reduces when vacuum is applied up to 40 cmHg by using vacuum pump Output voltage Vin voltage 4 5 5 0 V ambient temp 20 300 C 68 860 F If check result is not satisfactory replace MAP sensor 3 Install MAP sensor referring to MAP sensor installation Removal 1 Disconnect battery negative cable at battery 2 Disconnect coupler from MAP sens...

Page 121: ... valve is at idle position and when it is fully open If check result is not satisfactory replace TP sensor 3 Connect TP sensor coupler securely 4 Connect negative cable to battery TP Sensor Removal and Installation Removal 1 Disconnect battery negative cable at battery 2 Disconnect coupler from TP sensor 3 Remove TP sensor from throttle body Installation 1 Install TP sensor to throttle body Fit TP...

Page 122: ...nd C51 05 terminal 3 Turn TP sensor clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified below is obtained TP sensor output voltage when throttle is fully close 0 805 0 025 V 4 Tighten TP sensor screw to specified torque TighteningTorque a 2 5 N m 0 25 kg m 2 0 lb ft 5 Check to make sure that TP sensor voltage is as shown below when throttle is fully o...

Page 123: ...hose Inspection Immerse temperature sensing part of IAT sensor in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in left figure replace IAT sensor Installation Reverse removal procedure noting the following Clean mating surfaces of IAT sensor and air cleaner outlet hose Connect IAT sensor c...

Page 124: ...it cap is taken off too soon Inspection Immerse temperature sensing part of ECT sensor in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in left figure replace ECT sensor Installation Reverse removal procedure noting the following Clean mating surfaces of ECT sensor and water outlet pipe Ch...

Page 125: ...r securely Heated Oxygen Sensor Removal and Installation Removal WARNING To avoid danger of being burned do not touch exhaust system when system is hot Oxygen sensor removal should be performed when system is cool 1 Disconnect negative cable at battery 2 Remove HO2S 1 as follows a Disconnect connector of HO2S and release its wire harness from clamps then remove exhaust manifold cover b Remove fron...

Page 126: ...t Position CMP Sensor Removal Inspection and Installation Removal 1 Disconnect nagative cable at battery 2 Removal air cleaner assemblty 1 3 Disconnect CMP sensor lead wire coupler 1 4 Remove flange bolt 1 and pull out CMP sensor assembly 2 ...

Page 127: ...recheck gap Note Check that CMP sensor tooth is free from any metal particles 4 Install distributor cap and rotor Installation Note Before installing CMP sensor assembly 2 check to make sure that its O ring 1 is in good condition If new O ring 1 is to be installed apply oil 1 Fit the dogs of CMP sensor assembly coupling into the slots of camshaft 3 when installing The dogs of CMP sensor assembly c...

Page 128: ...ith front left tire locked Voltmeter should indicate deflection between 0 1 V and 4 14 V a few times while tire is turned one revolution If check result is not satisfactory proceed to flow table of diagnostic trouble code NO 16 P0500 in this section Removal 1 Disconnect negative cable at battery 2 Disconnect VSS coupler 3 Remove VSS Installation 1 Check O ring and VSS surface for their flawlessnes...

Page 129: ...continuity between terminals A and B when battery is connected to terminals C and D If found defective replace Fuel Pump Relay Inspection 1 Disconnect negative cable at battery 2 Remove fuel pump relay from relay fuse box 3 Structure of fuel pump relay is the same as that of main relay Check its resistance and operation using the same procedure as that for main relay If found defective replace Fue...

Page 130: ... stops when throttle valve is closed instantly and it is heard again when engine speed is reduced to less than about 2 000 r min A C Compressor Control Relay if equipped Inspection 1 Disconnect negative cable at battery 2 Remove A C compressor control relay from relay fuse box 3 Structure of A C compressor control relay is the same as that of main relay Check its resistance and operation using the...

Page 131: ...ICAL DEVICES SPECIAL TOOLS TIGHTENING TORQUE SPECIFICATIONS FASTENING PARTS TIGHTENING TORQUE N m kg m Ib ft IAC value 3 5 0 35 2 5 TP sensor 2 5 0 25 2 0 ECT sensor 12 1 2 9 0 O2 sensor 45 4 5 32 5 MAP sensor 20 0 20 1 5 ...

Page 132: ...s 4 stroke cycle gasoline unit equipped with its S O H C Single Overhead Camshaft valve mechanism arranged for V type valve configuration and 16 valves IN 2 and EX 2 one cylinder The single overhead camshaft is mounted over the cylinder head it is driven from crankshaft through timing belt and opens and closes its valves via the rocker arms ...

Page 133: ...er to P range for A T model and set parking brake and block drive wheels 3 Disconnect fuel injector wire harness connector 4 Remove ignition coil assemblies and all spark plugs referring to section 6F 5 Install special tool Compression gauge into spark plug hole Special Tool A 09915M64510 001 B 09915M64510 002 C 09915M64530 D 09915M64550 6 Disengage clutch to lighten starting load on engine for M ...

Page 134: ...cylinders 1 0 kg cm2 14 2 psi 8 Carry out steps 5 through 7 on each cylinder to obtain four readings 9 After checking install spark plugs and ignition coil assemblies and connect injector wire harness connector securely Engine Vacuum Check The engine vacuum that develops in the intake line is a good indicator of the condition of the engine The vacuum checking procedure is as follows 1 Warm up engi...

Page 135: ...nnect vacuum hose to EVAP purge valve Valve Lash Clearance 1 Remove negative cable at battery 2 Remove cylinder head cover referring to item Cylinder Head cover 3 Using 17 mm socket turn crankshaft pulley clockwise until V mark in white paint on pulley aligns with O zero calibrated on timing belt cover 4 Check if the rocker arms of No 1 cylinder are off the respective cam lobes of camshaft if so v...

Page 136: ...g adjusting screw after loosening lock nut After adjustment tighten lock nut to specified torque while holding adjusting screw stationary and then make sure again that valve lash is within specification Special Tool A 09917M18210 Tightening Torque a 12 N m 1 2 kg m 9 0 lb ft 6 After checking and adjusting valve lashes at valves 1 2 5 and 7 or 3 4 6 and 8 rotate crankshaft exactly one full turn 360...

Page 137: ... 1 Disconnect negative cable at battery 2 Remove air cleaner case 3 Remove ignition coil assemblies with high tension cord 4 Disconnect PCV valve and breather hose from head cover 5 Remove cylinder head cover Installation 1 Install O rings 2 and cylinder head cover gasket 1 to cylinder head cover 3 Apply sealant to cylinder head cover gasket indicated part timing pulley side and CMP sensor side A ...

Page 138: ...pedal depressed fully check clearance between throttle lever and lever stopper throttle body wich should be within following specification Clearance b 0 5 2 0 mm 0 02 0 07 in With pedal depressed fully Note When installing cylinder head cover use care so that cylinder head cover gasket or O rings will not get out of place or fall off 3 Install ignition coil assemblies with high tension cord 4 Conn...

Page 139: ... moves smoothly Throttle Body Removal Disassembly Cleaning and Installation Removal 1 Disconnect negative cable at battery 2 Drain cooling system referring to Section 6B 3 Disconnect accelerator cable from throttle body 4 Remove air cleaner outlet hose Throttle Body Components ...

Page 140: ...throttle body bore and idle air passage by blowing compressed air Caution TP sensor IAC valve MAP sensor or other components containing rubber must not be placed in a solvent or cleaner bath A chemical reaction will cause these parts to swell harden or get distorted Do not blow compressed air through bypass air passage with IAC valve installed to throttle body This will cause IAC valve to malfunct...

Page 141: ...nstall throttle body to intake manifold 3 Connect engine coolant hoses and EVAP canister purge valve hose 4 Connect couplers to TP sensor MAP sensor and IAC valve securely 5 Install air cleaner outlet hose 6 Connect accelerator cable and adjust cable play to specification 7 Refill cooling system 8 Connect negative cable at battery ...

Page 142: ... Disconnect following electric lead wires Ground wires from intake manifold Engine coolant temperature sensor Injectors lead wires at the coupler EVAP canister purge valve Throttle position sensor Idle air control valve Ignition coils CMP sensor Throttle Body and Intake Manifold Components Removal 1 Relieve fuel pressure according to fuel pressure relief procedure described in section 6 2 Disconne...

Page 143: ...cations If distortion limit given below is exceeded correct gasketed surface or replace intake manifold Limit of distortion 0 05 mm 0 002 in Installation Reverse removal procedure for installation noting the followings Use new intake manifold gasket Tighten nuts to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft Adjust accelerator cable play referring to section 1D Check to ensure t...

Page 144: ...ENGINE MECHANICAL 1D 13 Engine Mounting Components RR RH LH 55 N m 5 5 kg m 55 N m 5 5 kg m 55 N m 5 5 kg m 23 N m 2 3 kg m 55 N m 5 5 kg m ...

Page 145: ...drive shafts Refer to Section 3A 7 Remove engine hood and front bumper Refer to Section 9J 8 Remove battery and its tray with EVAP canister 9 Remove air cleaner assembly 1 and their hoses as previously outlined 10 Release fuel pressure in fuel feed line Refer to Section 1G 11 Disconnect following Accelerator cable 1 from throttle body Clutch cable gear shift control rod 2 and extension rod 3 12 Di...

Page 146: ...ve generator belt and A C compressor drive belt 15 Remove A C compressor with hose still attached if equipped Note Suspend removed compressor at a place where no damage will be caused during removal and installation of engine assembly 16 Install lifting or sling device 17 Check to ensure all hoses electric wires and cables are disconnected from engine ...

Page 147: ...sion out of vehicle slowly and carefully Installation Reverse the removal procedure Tightening torque Engine left mounting bracket nut Engine right mounting brachet nut Sturting motor terminal nut Generator terminal nut RR RH LH 55 N m 5 5 kg m 55 N m 5 5 kg m 55 N m 5 5 kg m 23 N m 2 3 kg m 55 N m 5 5 kg m ...

Page 148: ...allation 1 Install transmission to engine refer Fig A 2 Install engine assembly together with transmission to vehicle refer Fig B Fig A Fig B RR RH LH 55 N m 5 5 kg m 55 N m 5 5 kg m 55 N m 5 5 kg m 23 N m 2 3 kg m 55 N m 5 5 kg m ...

Page 149: ...ion Removal 1 Disconnect negative cable at battery 2 Remove A C compressor belt if equipped 3 Remove water pump pulley and water pump drive belt 1 4 Remove crankshaft pulley 1 with crank shaft locked 5 Remove bumper and right side head light 6 Hold engine by using sling engine support device Attach engine hook to exhaust manifold ...

Page 150: ...e timing belt outside cover 10 For installation of timing belt align 4 timing marks 1 2 3 4 as shown in figure by turning crankshaft 11 Remove timing belt tensioner 1 and timing belt 2 Caution After timing belt is removed never turn camshaft and crankshaft independently more than such an extent as shown in figure If turned interference may occur among piston and valves and parts related to piston ...

Page 151: ...haft timing belt pulley 1 to crankshaft if removed 2 Install tensioner 2 Do not tighten tensioner bolt 1 with wrench yet Hand tighten only at this time 3 Check that timing mark 1 on camshaft timing belt pulley is aligned with mark 2 on timing belt inside cover If not align two marks by turning camshaft but be careful not to turn it more than its allowable turning range which is described on previo...

Page 152: ...h is described on previouspage 5 Check to ensure that valve clearance is adjusted correctly 6 Remove spark plugs 7 Install timing belt With two sets of marks 1 2 and 3 4 aligned install timing belt on two pulleys in such a way that drive side 5 of belt is free from any slack Note When installing timing belt match arrow mark on timing belt with rotating direction of crankshaft In this state No 4 pi...

Page 153: ... up slack of timing belt turn crankshaft two rotations clockwise Then confirm again that two sets of marks are aligned respectively And confirm belt tension again as previously outlined Note Perform steps a c repeatedly if belt tension is out of standards 9 Install spark plugs 10 Install timing belt outside cover Before installing make sure that seal is between water pump and oil pump case Tighten...

Page 154: ... m 61 0 lb ft 13 Adjust valve clearance as previously outlined 14 Install water pump pulley 1 and water pump drive belt 2 Adjust water pump drive belt tension referring to SECTION 6B 15 Install A C compressor bracket 3 A C compressor 4 and A C compressor belt 5 if equipped Tighten bolts as alphabetical order Adjust its belt tension referring to section 0B 16 Connect negative cable to battery ...

Page 155: ...viously outlined 3 Remove camshaft timing belt pulley by using special tool Special Tool A 09917M68221 4 Remove cylinder head cover as previously outlined 5 After loosening all valve adjusting screw lock nuts 2 turn adjusting screws 1 back all the way to allow all rocker arms to move freely 6 Remove rocker arm shaft bolts 1 Rocker Arms Rocker Shaft and Camshaft Components ...

Page 156: ...loosen them in such order as indicated in figure a little at a time Inspection Adjusting Screw and Rocker Arm If tip of adjusting screw 1 is badly worn replace it Rocker arm 2 must be replaced if its cam riding face 3 is badly worn Rocker Arm Shaft Runout Using V blocks and dial gauge check runout If runout exceeds its limit replace rocker arm shaft Runout limit 0 20 mm 0 008 in ...

Page 157: ...6 mm 0 0002 0 0016 in 0 0024 in Cam Wear Using a micrometer measured height of cam If measured height is below limit replace camshaft Cam height Standard Intake cam 30 478 30 494 mm 1 2000 1 2005 in Exhaust cam 29 438 29 454 mm 1 1590 1 1596 in Camshaft Runout Hold camshaft between two V blocks and measure runout by using a dial gauge If runout exceeds the limit replace camshaft Runout limit 0 10 ...

Page 158: ...Tightening Torque a 11 N m 1 1kg m 8 0 lb ft Note Do not rotate camshaft while gaging plastic is installed 6 Remove housing and using scale 1 on gaging plastic envelope measure gaging plastic width 2 at its widest point Standard Limit Journal 0 045 0 087 mm 0 12 mm Clearance 0 0018 0 0034 in 0 0047 in If measured camshaft journal clearance exceeds limit measure journal housing bore and outside dia...

Page 159: ...ing indicating position and direction for installation Install housing as indicated by these marks As camshaft housing No 1 retains camshaft in proper position as to thrust direction make sure to first fit No 1 housing to No 1 journal of camshaft securely After applying engine oil to housing bolts tighten them temporarily first Then tighten them by following sequence as indicated in figure Tighten...

Page 160: ...ghten pulley bolt to specified torque TighteningTorque a 55 N m 5 5 kg m 40 0 lb ft SpecialTool A 09917M68221 9 Install belt tensioner timing belt outside cover crankshaft pulley and water pump belt as previously outlined 10 Adjust valve clearance as previously outlined 11 Install cylinder head cover 12 Install radiator and refill cooling system referring to section 1F 13 Connect negative cable at...

Page 161: ...nd Installation Removal 1 Relieve fuel pressure according to fuel pressure relief procedure described in section 6 2 Disconnect negative cable at battery 3 Drain cooling system 4 Remove intake manifold as previously outlined Valves and Cylinder Head Components ...

Page 162: ...fold 8 Loosen cylinder head bolts in such order as indicated in figure and remove them 9 Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary 10 Remove cylinder head with intake manifold and exhaust manifold using lifting device Installation 1 Remove old gasket and oil on mating surfaces and install new head gasket as...

Page 163: ...que TighteningTorque a 62 N m 6 2 kg m 45 0 lb ft 4 Reverse removal procedure for installation 5 Adjust water pump drive belt tension referring to section 1F 6 Adjust A C compressor belt tension if equipped Refer to section 0B 7 Adjust intake and exhaust valve lashes as previously outlined 8 Adjust accelerator cable play Refer to section 1D 9 Check to ensure that all removed parts are back in plac...

Page 164: ...lve spring 4 Remove valve from combustion chamber side 5 Remove valve stem oil seal from valve guide and then valve spring seat Note Do not reuse oil seal once disassembled Be sure to use new oil seal when assembling 6 Using special tool Valve guide remover drive valve guide out from combustion chamber side to valve spring side SpecialTool A 09916M44910 Note Do not reuse valve guide once disassemb...

Page 165: ... into hole with special tools Drive in new valve guide until special tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrudes by 13 0 mm 0 51 in from cylinder head SpecialTool C 09916M57340 D 09916M58210 Note Do not reuse valve guide once disassembled Install new valve guide Oversize Intake and exhaust valve guides are identical Valve guide oversize 0...

Page 166: ...er or else Install seal to guide only by pushing special tool by hand Tapping or hitting special tool may cause damage to seal 6 Install valve to valve guide Before installing valve to valve guide apply engine oil to stem seal valve guide bore and valve stem 7 Install valve spring and spring retainer Each valve spring has top end large pitch end 1 and bottom end small pitch end 2 Be sure to positi...

Page 167: ...0 07 mm Stem to guide 0 0008 0 0018 in 0 0027 in clearance Ex 0 045 0 072 mm 0 09 mm 0 0018 0 0028 in 0 0035 in If caliper gauge is not available check end deflection of valve stem with a dial gauge instead Move stem end in directions 1 and 2 to measure end deflection If deflection exceeds its limit replace valve stem and valve guide Valve stem end deflection limit In 0 14 mm 0 005 in Ex 0 18 mm 0...

Page 168: ...idth Create contact pattern on each valve in the usual manner i e by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head Valve lapper tool used in valve lapping must be used Pattern produced on seating face of valve must be a continuous ring without any break and the width of pattern must be within specified range Standard seating width revealed In ...

Page 169: ...valve seat 1 1 1 3 mm 0 0433 0 0512 in 2 INTAKE VALVE SEAT Cutting sequence is the same as for exhaust valve seats Seat width for intake valve seat 1 1 1 3 mm 0 0433 0 0512 in 3 VALVE LAPPING Lap valve on seat in two steps first with coarse size lapping compound applied to face and the second with fine size compound each time using valve lapper according to usual lapping method Cylinder Head Inspe...

Page 170: ...educed power output Limit of distortion 0 05 mm 0 002 in Distortion of manifold seating faces Check seating faces of cylinder head for manifolds using a straightedge and thickness gauge in order to determine whether these faces should be corrected or cylinder head replaced Limit of distortion 0 10 mm 0 004 in Valve Spring Inspection Referring to data given below check to be sure that each spring i...

Page 171: ... Removal and Installation Removal 1 Remove cylinder head from cylinder block as previously outlined 2 Drain engine oil 3 Remove oil pan and oil pump strainer as previously outlined 4 Mark cylinder number on all pistons connecting rods and rod bearing caps using silver pencil or quick drying paint 5 Remove rod bearing caps 6 Install guide hose 1 over threads of rod bolts This is to prevent damage t...

Page 172: ... connecting rod assembly into cylinder bore point arrow mark 2 on piston head to crankshaft pulley side 1 4 Install piston and connecting rod assembly into cylinder bore Use special tool Piston ring compressor to compress rings Guide connecting rod into place on crankshaft Using a hammer handle tap piston head to install piston into bore Hold ring compressor firmly against cylinder block until all...

Page 173: ...cable play Refer to section 1D 11 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been reinstalled 12 Refill engine with engine oil referring to item ENGINE OIL CHANGE in section 0B 13 Refill cooling system referring to section 1F 14 Connect negative cable at battery 15 Verify that there is no fuel leakage coolant leakage oil leakage and exhaus...

Page 174: ...ze piston make sure to match piston with cylinder as follows a Each piston has stamped number 1 or 2 as shown It represents outer diameter of piston b There are paints on the cylinder block as shown The color red or blue of each paint represents cylinder bore diameter The first paint from crank pulley side represents inner diameter of No 1 cylinder the second paint of No 2 cylinder the third paint...

Page 175: ...1 respectively When installing these piston rings to piston direct marked side of each ring toward top of piston 1st ring differs from 2nd ring in thickness shape and color of surface contacting cylinder wall Distinguish 1st ring from 2nd ring by referring to figure When installing oil ring install spacer first and then two rails 3 After installing three rings 1st 2nd and oil rings distribute thei...

Page 176: ...rence between thrust and axial measurements exceeds out of round limit Cylinder bore dia limit 68 57 mm 2 6996 in Taper and out of round limit 0 10 mm 0 0039 in Note If any one of four cylinders has to be rebored rebore all four to the same next oversize This is necessary for the sake of uniformity and balance Pistons Inspect piston for faults cracks or other damaged Damaged or faulty piston shoul...

Page 177: ... using thickness gauge 2 If clearance is out of specification replace piston Ring groove clearance Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in Piston Pin Check piston pin connecting rod small end bore and piston bore for wear or damage paying particular attention to condition of small end bore bush If pin connecting rod small end bore or piston bore is badly worn or damaged...

Page 178: ... 2nd ring 0 12 0 26 mm 0 7 mm end gap 0 0047 0 0102 in 0 0275 in Oil ring 0 1 0 7 mm 1 8 mm 0 0039 0 0275 in 0 0709 in Connecting Rod Big end side clearance Check big end of connecting rod for side clearance with rod fitted and connected to its crank pin in the normal manner If measured clearance is found to exceed its limit replace connecting rod Item Standard Limit Big end side 0 10 0 25 mm 0 35...

Page 179: ...tion must be replaced General Information Two kinds of rod bearing are available standard size bearing and 0 25 mm undersize bearing To distinguish them 0 25 mm undersize bearing has the stamped number US025 on its backside as indicated in figure but standard size one has no number Rod bearing clearance 1 Before checking bearing clearance clean bearing and crank pin 2 Install bearing in connecting...

Page 180: ...ing a new standard size bearing replace crankshaft or regrind crankpin to undersize as follows Install 0 25 mm undersize bearing to connecting rod big end Measure bore diameter of connecting rod big end Regrind crankpin to following finished diameter Confirm that bearing clearance is within above standard value Finished crankpin dia Measured big end bore dia including undersize bearing 0 030 mm 0 ...

Page 181: ...1D 50 ENGINE MECHANICAL Main Bearings Crankshaft and Cylinder Block Components ...

Page 182: ...T vehicle SpecialTool A 09924 17810 3 Remove crankshaft pulley timing belt and crankshaft timing pulley 4 Remove cylinder head assembly 5 Remove oil pan and oil pump strainer 6 Remove oil pump 1 7 Remove oil seal housing 8 Remove connecting rod bearing caps 9 Loosen crankshaft bearing cap bolts in such order as indicated in figure a little at a time and remove bearing caps 10 Remove crankshaft fro...

Page 183: ...er half without oil groove to bearing cap Make sure that two halves are painted in the same color 2 Install thrust bearings 1 to cylinder block between No 2 and No 3 cylinders Face oil groove 2 sides to crank webs 3 Install crankshaft to cylinder block 4 Install bearing cap to cylinder block making sure to point arrow mark on each cap to crankshaft pulley side Fit them sequentially in ascending or...

Page 184: ...ock flywheel or drive plate and torque its bolts 1 to specification SpecialTool A 09924M17810 TighteningTorque a 42 N m 4 2 kg m 30 5 lb ft 8 Install pistons and connecting rods as previously outlined 9 Install oil pump strainer and oil pan as previously outlined 10 Install cylinder head assembly to cylinder block as previously outlined Note Tighten cylinder head bolts to specified torque as previ...

Page 185: ...aring with new standard one or oversize one to obtain standard thrust play Item Standard Limit Crankshaft 0 11 0 31 mm 0 35 mm thrust play 0 0044 0 0122 in 0 0138 in Thickness of crank Standard 2 500 mm shaft thrust bearing 0 0984 in Oversize 0 125 mm 2 563 mm 0 0049 in 0 1009 in Out of round and taper uneven wear of journals An unevenly worn crankshaft journal shows up as a difference in diameter...

Page 186: ... 4 and 5 Tighten cap bolts to specified torque Visual Inspection Check bearings for pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Never replace one half without replacing the other half Main bearing clearance Check clearance by using gaging plastic according to following procedure 1 Remove bearing caps 2 Clean bearings and main journals 3 Place a...

Page 187: ...arance is out of specification select a new standard bearing according to following procedure and install it 1 First check journal diameter by using following procedure As shown in figure crank webs of No 2 cylinder have five stamped numerals Three kinds of numerals 1 2 and 3 represent following journal diameters Numeral stamped Journal diameter 1 49 994 50 000 mm 1 9683 1 9685 in 2 49 988 49 994 ...

Page 188: ...aps 1 2 3 4 and 5 respectively For example in figure the first leftmost alphabet 2 indicates that cap bore dia of bearing cap 1 is within 54 006 54 012 mm and the fifth rightmost alphabet 1 indicates that cap bore dia of cap 5 is within 54 000 54 006 mm 3 There are five kinds of standard bearings differing in thickness To distinguish them they are painted in following colors at the position as ind...

Page 189: ...still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block due to any reason select new standard bearings to be installed by referring to numerals stamped on new crankshaft or alphabets stamped on mating surface of new cylinder block Undersize Bearing 0 25 mm 0 25 mm undersize bearing is available in five kinds varying in thickness To disti...

Page 190: ...580 1 9586 in 2 Using micrometer measure reground journal diameter Measurement should be taken in two directions perpendicular to each other in order to check for out of round 3 Using journal diameter measured above and alphabets stamped on mating surface of cylinder block select an undersize bearing by referring to table given below Check bearing clearance with newly selected undersize bearing Me...

Page 191: ...cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear Size Piston diameter O S 0 25 68 720 68 740 mm 2 7055 2 7062 in O S 0 50 68 970 68 990 mm 2 7154 2 7161 in 3 Using micrometer measure piston diameter 4 Calculate cylinder bore diameter to be rebored D A B C D Cylinder bore diameter to...

Page 192: ...ENGINE MECHANICAL 1D 61 REQUIRED SERVICE MATERIALS ...

Page 193: ...1D 62 ENGINE MECHANICAL ...

Page 194: ...orcing the oil through the oil filter The filtered oil flows into two paths inside the cylinder block In one path oil reaches the crankshaft journal bearings and big end bearings on crankpins Some of this oil goes to the connecting rod small ends and lubricates piston pins there and also the walls of cylinder bores In the other path oil goes up to the cylinder head and enters the oil gallery of ro...

Page 195: ...leaks If leak is found repair it 1 Hoist vehicle Remove oil pressure switch from cylinder block 2 Install special tool Oil pressure gauge to vacated threaded hole Then lower vehicle SpecialTool A 09915M77310 3 Start engine and warm it up to normal operating temperature Note Be sure to place transmission gear shift lever in Neutral and set parking brake and block drive wheels 4 After warming up rai...

Page 196: ...ith sealing tape and tighten switch to specified torque Note If sealing tape edge is bulged out from screw threads of switch cut it off TighteningTorque a 14 N m 1 4 kg m 10 5 lb ft 7 Start engine and check oil pressure switch for oil leakage 8 Stop engine and connect terminal to pressure switch terminal and cover pressure switch by boot with certainty ...

Page 197: ... Installation Removal 1 Drain engine oil by removing drain plug 1 2 Remove clutch housing torque converter housing for A T lower plate 1 3 Disconnect exhaust pipe from exhaust manifold 4 Remove oil pan 2 and then oil pump strainer 1 Oil Pan and Oil Pump Strainer Components ...

Page 198: ...inder block run in securing bolts and start tightening at the center move wrench outward tightening one bolt at a time Tighten bolts to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 3 Install new gasket and drain plug 1 to oil pan Tighten drain plug 1 to specified torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft 4 Install clutch torque converter housing lower plate 5 Connect ...

Page 199: ...ICATION SYSTEM Oil Pan and Oil Pump Stainer Cleaning Cleaning Clean mating surfaces of oil pan and cylinder block Remove oil old sealant and dusts from mating surfaces and oil pan inside Clean oil pump strainer screen ...

Page 200: ...llation Removal 1 Disconnect negative cable at battery 2 Remove timing belt as previously outlined 3 Remove generator and its bracket 4 Remove timing belt inside cover 5 Remove oil pan and oil pump strainer as previously outlined 6 Remove oil pump assembly 1 after removing bolts ...

Page 201: ...pump 5 Install timing belt tensioner oil pump strainer oil pan and other parts as previously outlined 6 Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been reinstalled 7 Adjust water pump drive belt tension referring to ENGINE COOLING section 8 Adjust power steering pump belt tension or A C compressor belt tension if equipped Refer to section ...

Page 202: ... press fit it till its end face is flush with oil pump case end face Check outer and inner rotors rotor plate and oil pump case for excessive wear or damage Mesurment Radial clearance Check radial clearance between outer rotor 1 and case 2 using thickness gauge If clearance exceeds its limit replace outer rotor or case Limit on radial clearance between outer rotor and case 0 310 mm 0 0122 in Side ...

Page 203: ...nner and outer rotors oil seal lip portion and inside surfaces of oil pump case and plate 3 Install outer and inner rotors to pump case 4 Install rotor plate Tighten screws securely After installing plate check to be sure that gears turn smoothly by hand 5 Apply engine oil to guide seal 1 and install new guide seal and guide 2 ...

Page 204: ...ecommended for use at any time there is also the possibility of causing a serious fire Check to make sure that engine coolant temperature is cold before removing any part of cooling system Also be sure to disconnect negative cable from battery terminal before removing any part The coolant recovery system is standard The coolant in the radiator expands with heat and the coolant is overflowed to the...

Page 205: ...system could occur Coolant must be mixed with demineralized water or distilled water Anti freeze proportioning table Freezing temperature C 16 36 F 3 33 Anti freeze Anticorrosion coolant concentration 30 50 Ratio of compound to cooling water ltr 1 32 3 08 2 20 2 20 Coolant capacity Engine radiator and heater 3 6 liters Reservoir 0 4 liters Total 4 0 liters ...

Page 206: ...ng System Circulation 1 While the engine is warmed up Thermostat closed coolant circulates as follows 2 When coolant is warmed up to normal temperature and the thermostat opens coolant passes through the radiator core to be cooled as well as the above flow circuit ...

Page 207: ...charge battery Check and replace as necessary Poor generation generator Check and repair ECT sensor faulty Check and replace as necessary Radiator cooling fan relay No 2 and or No 3 faulty Check and replace as necessary Radiator fan motor faulty Check and replace as necessary ECM faulty Check and replace as necessary Wiring or grounding faulty Repair as necessary Equipped with too much electric lo...

Page 208: ...oper coolant to tank to bring coolant level up to FULL mark 3 Then reinstall cap 4 and align match marks on tank and cap Note If proper quality antifreeze is used there is no need to add extra inhibitors or additives that claim to improve system They may be harmful to proper operation of system and are unnecessary expense When installing reservoir cap align arrow marks on reservoir and cap Engine ...

Page 209: ...in coolant 3 After draining cooloant be sure to tighten drain plug securely 4 Fill cooling system Refer to Item COONANT of MAINTENANCE Cooling System Flush and Refill 1 Remove radiator cap when engine is cool Turn cap counterclockwise slowly until it reaches a stop Do not press down while turning it Wait until pressure is relieved indicated by a hissing sound then press down on cap and continue to...

Page 210: ...d clean inside of tank with soap and water Flush it well with clean water and drain Reinstall tank 8 Add 50 50 mixture of good quality ethylene glycol antifreeze and water to radiator and tank Fill radiator to the base of radiator filler neck and reservoir tank to FULL level mark 3 Reinstall reservoir tank cap and align match marks 4 on tank and cap 9 Run engine with radiator cap removed until rad...

Page 211: ... parts in reverse order of removal procedure noting the following Tighten each clamp securely Refill cooling system with proper coolant referring to description on COOLANT of MAINTENANCE Thermostat Removal Inspecton and Installation Removal 1 Drain coolant and tighten drain plug 2 Remove air cleaner case together with air inlet hose 3 Remove thermostat cap 1 with air cleaner case bracket 4 Remove ...

Page 212: ...rature thermostat unit should be replaced with a new one Such a unit if reused will bring about overcooling or overheating tendency Thermostat functional spec 1 50 C 2 70 F Temp at which valve begins to open 820 C 1790 F Temp at which valve become fully open 950 C 2030 F Valve lift More than 8 mm at 950 C Installation 1 When positioning thermostat 1 on thermostat case 2 be sure to position it so t...

Page 213: ...ness ECT sensor ECM PCM coolant temp meter and sender gauge unit Refer to DIAGNOSTIC FLOW CHART in section 1A and COOLANT TEMP METER AND SENDER GAUGE INSPECTION of section 9C Radiator Fan Control Relay RFC Relay Inspection 1 Disconnect negative cable at battery 2 Remove RFC relay from relay fuse box 3 Structure of RFC relay is the same as that of main relay Check its resistance and operation using...

Page 214: ... connection Radiator Removal Inspection and Installation Removal 1 Disconnect negative cable at battery 2 Drain cooling system by loosening drain plug 1 of radiator 3 Disconnect coupler of cooling fan motor 4 Remove air cleaner case and air intake hose see section 1D 5 Remove A C condenser mounting bolts 3 if equipped and radiator bolts 1 6 Disconnect radiator inlet and outlet hoses and reservoir ...

Page 215: ...ore checking and djusting belt tension See WARNING described in COOLING SYSTEM SERVICE 1 Inspect belt for cracks cuts deformation wear and cleanliness If it is necessary to replace belt refer to section 1F for procedure 2 Check belt 4 for tension Belt is in proper tension when it deflects 12 15 mm 0 47 0 59 in under thumb pressure 1 about 10 kg or 22 Ib Belt tension a 3 4 mm 0 12 0 16 in as deflec...

Page 216: ...rive belt tension For Adjustment of compressor drive belt tension refer to SECTION 0B of this manual 3 Tighten water pump belt adjusting bolt and pivot bolts 4 Connect negative cable at battery Water Pump Removal and Installation 1 Disconnect negative cable at battery 2 Drain cooling system 3 Remove oil level gauge guide with oil level gauge 4 Remove timing belt and tensioner according to procedur...

Page 217: ...ng belt outside cover according to procedure described in item TIMING BELT AND TENSIONER of section 1D 5 With engine oil applied to O ring install oil level gauge guide 6 Adjust drive belt tension 7 Fill cooling system 8 After installation check each part for leakage REQUIRED SERVICE MATERIAL MATERIALS USE Ethylene glycol base coolant Additive to engine cooling system for improving cooling efficie...

Page 218: ...t system are hot Note that fuel hose connection varies with each type of pipe Be sure to connect and clamp each hose correctly referring to Fuel Hose Disconnecting and Reconnecting After connecting make sure that it has no twist or kink When installing injector or fuel feed pipe lubricate its O ring with gasoline General Description Fuel System Description Caution This engine requires the unleaded...

Page 219: ...type electric pump Incorporated in the pump assembly are a fuel level gauge 2 is attached Addition of the fuel pressure regulator makes it possible to maintain the fuel pressure at constant level and ECM controls compensation for variation in the intake manifold pressure ...

Page 220: ...rvice in order to reduce the risk or fire and personal injury 1 Relieve fuel pressure in fuel feed line referring to Fuel Pressure Relief Procedure 2 Disconnect fuel feed hose from fuel delivery pipe 3 Connect special tools and hose between fuel feed hose 1 and fuel delivery pipe as shown in the figure and clamp hoses securely in order to ensure that no leaks occur during checking Special tool A 0...

Page 221: ...heck in this section and check each possibly defective part Replace if found defective 8 After checking fuel pressure remove fuel pressure gauge Caution As fuel feed line is still under high fuel pressure make sure to release fuel pressure according to following procedures Place fuel container under joint Cover joint with rag and loosen joint nut slowly to release fuel pressure gradually 9 Removal...

Page 222: ...e engine speed to higher than 3 000 r min 3 Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is heard again when engine speed is reduced to approx 2 000 r min or less Repair Instructions Fuel System Components The main components of the fuel system are fuel tank fuel pump with fuel level gauge and fuel filter And there are three lines fuel fee...

Page 223: ...rojection as shown C With bent pipe fit hose as its bent part as shown or till depth b D With straight pipe fit hose till depth b E With red marked pipe fit hose end reaches red mark on pipe F For fuel tank filler hose insert it to spool or welding bead a Clamp securely at a position 3 7 mm 0 12 0 27 in from hose end b 20 30 mm 0 79 1 18 in c 0 5 mm 0 0 19 in d 5 12 mm 0 2 0 47 in e 40 mm 1 57 in ...

Page 224: ...for servicing 5 Upon completion of servicing install fuel pump relay to relay box Fuel Leakage Check Procedure After performing any service on fuel system check to make sure that there are no fuel leakages as follows 1 Turn the ignition switch ON position for 3 seconds to operate fuel pump and then turn it OFF position Repeat this ON and OFF 3 or 4 times and apply fuel pressure to fuel line till f...

Page 225: ...ury cover hose and pipe to be disconnected with a shop cloth Be sure to put that cloth in an approved container when disconnection is completed 6 Mark the location 1 of clamps 2 on fuel pipes so that the clamps can be reinstalled to where they were 7 Remove pipes 3 with clamp from vehicle 8 Remove clamp from pipes Installation 1 Install clamps to marked location on pipes If clamp is deformed or it...

Page 226: ...nect coupler to injector securely Fuel Injector Removal Inspection and Installation Removal 1 Relieve fuel pressure according to procedure described in Section 6 2 Disconnect battery negative cable at battery 3 Remove air cleaner outlet hose referring to Section 6A 4 Remove intake manifold stiffener 5 Disconnect fuel injector couplers 6 Remove fuel delivery pipe bolts 7 Remove fuel injector s Caut...

Page 227: ... fuel pressure to injector connect two terminals of relay box using service wire as shown in figure Caution Check to make sure that connections made between correct terminals Wrong connection can cause damage to ECM wire harness etc 8 Apply battery voltage to injector for 15 seconds and measure injected fuel volume with graduated cylinder Test each injector two or three times If not within specifi...

Page 228: ...te smoothly If not probable cause is incorrect installation of O ring Replace O ring with new one Tighten delivery pipe bolts and make sure that injectors rotate smoothly With engine OFF and ignition switch ON check for fuel leaks around fuel line connection Fuel Filler Cap Inspection Remove cap and check gasket for even filler neck imprint and deterioration or any damage If gasket is in malcondit...

Page 229: ...in fuel through it till fuel stops Caution Do not force hose of a hand operated pump into fuel tank Doing so can damage inlet valve 2 4 Disconnect filler hose 1 from fuel tank 2 and breather hose from fuel filler neck 5 Remove fuel tank inlet valve 3 Use care not to damage inlet valve when removing 6 Drain fuel tank by pumping fuel out through fuel tank filler Use hand operated pump device to drai...

Page 230: ...alconditioned parts Installation 1 If parts have been removed from fuel tank install them before installing fuel tank to vehicle 2 Connect fuel vapor hose 1 refer to 6C 2 for connection and pipe joints 2 to fuel pump assembly and clamp hoses securely Caution When connecting joint clean outside surfaces of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to e...

Page 231: ...l filter inlet and outlet hoses to fuel filter Tightening Torque a 23 N m 2 3 kg m 16 5 lb ft 8 Connect negative cable to battery 9 Upon completion of installation check fuel system for leakage 5 Connect fuel filler hose 1 to fuel tank 4 and breather hose 2 to fuel filler neck 3 and clamp hoses securely Tightening Torque a 1 5 N m 0 15 kg m 1 0 lb ft ...

Page 232: ... hose and pipe to be disconnected with a shop cloth Be sure to put that cloth in an approved container when disconnection is completed 2 Remove fuel pump assembly from fuel tank 3 Drain all remaining fuel from tank 4 Move tank to flushing area 5 Fill tank with warm water or tap water and agitate vigorously and drain Repeat this washing until inside of tank is clean Replace tank if its inside is ru...

Page 233: ...lt advance to DIAGOSTIC FLOW TABLE B 4 Removal 1 Remove fuel tank from body according to procedure described in section 1G and remove fuel pump form fuel tank Inspection Check fuel pump filter for evidence of dirt and contamination If present clean and check for presence of dirt in fuel tank Installation Install fuel pump to fuel tank and then install fuel tank to body according procedure describe...

Page 234: ...ose 1 and fuel vapor hose 2 from fuel pump assembly When disconnecting joint 3 of fuel feed line and return line from pipe unlock joint by inserting special tool between pipe and joint lock first Special Tool A 09919M47020 3 Remove fuel pump assembly 1 from fuel tank Installation 1 Clean mating surfaces of fuel pump assembly 1 and fuel tank 2 Install new gasket 2 and plate 3 to fuel pump assembly ...

Page 235: ...ation If present replace or clean and check for presence of dirt in fuel tank For inspection of fuel level gauge refer to Section 9C of this manual Disassembly Reassembly Caution While removing fuel level gauge do not contact resistor plate or deform arm It may cause fel level gauge to fail When removing grommet from bracket sub assembly be very careful not to cause damage to grommet installed sec...

Page 236: ...fuel may be released after fuel line is disconnected In order to reduce the chance of personal injury cover the fitting to be disconnected with a shop cloth Be sure to put that cloth in an approved container when disconnection is completed 5 Remove 2 nuts 3 and then fuel filter 4 with bracket from fuel tank Installation Reverse removal procedure noting the following Tighten fuel filter nuts 1 to s...

Page 237: ...se from fuel pressure regulator 7 Disconnect fuel return hose from fuel pressure regulator Caution A small amount of fuel may be released when hose is disconnected Cover hose to be disconnected with a shop cloth 8 Remove fuel pressure regulator from fuel delivery pipe Caution A small amount of fuel may be released when it is from delivery pipe Place a shop cloth under delivery pipe so that release...

Page 238: ...oltage is induced in the secondary coil High tension cords and spark plugs CMP sensor Camshaft position sensor Using signals from this sensor ECM identifies the specific cylinder whose piston is in the compression stroke and detects the crank angle TP sensor ECT sensor MAP sensor and other sensors switches Refer to section 6E for details Although this ignition system does not have a distributor it...

Page 239: ...1H 2 IGNITION SYSTEM Schematic and Routing Diagram Ignition System Wiring Circuit Diagram ...

Page 240: ...sor if equipped 10 A C dual pressure switch if equipped CONTROL DEVICES a Fuel injectors b EVAP canister purge valve c Fuel pump relay d Ignition coil assembly No 1 No 4 spark plugs e Ignition coil assembly No 2 No 3 spark plugs f Malfunction indicator lamp g Radiator fan control relay h IAC valve i A C compressor control relay if equipped j Main relay OTHERS A ECM PCM B PCV valve C EVAP canister ...

Page 241: ...tension cord s Faulty high tension cord s Replace Faulty spark plug s Adjust clean or replace Maladjusted signal rotor air gap Adjust Faulty ignition coil Replace ignition coil assembly Faulty CMP sensor Replace Faulty ignitor Replace ignition coil assembly Faulty ECM Replace Poor fuel economy or Incorrect ignition timing Adjust engine performance Faulty spark plug s or high tension Adjust clean o...

Page 242: ...ort Are circuits in good condition 7 Ignition Coil Assembly Check Go to Step 8 Replace ignition coil 1 Check ignition coil for resistance referring assembly to Ignition Coil Assembly section Is check result satisfactory 8 Camshaft Position CMP Sensor Check Go to Step 9 Adjust or replace 1 Check camshaft position sensor referring to Camshaft Position Sensor section Is check result satisfactory 9 Ig...

Page 243: ...sembly or high tension cord Ground spark plug 5 Crank engine and check if each spark plug sparks 6 If no spark is emitted inspect the related parts as described under Diagnosis earlier in section 1A 1B 1C Repair Instructions High Tension Cord Removal Inspection and Installation Removal 1 Remove air cleaner outlet hose and disconnect breather hose from cylinder head cover 2 Disconnect high tension ...

Page 244: ...nd disconnect breather hose from cylinder head cover 2 Pull out high tension cords by gripping their caps and then remove ignition coil assemblies referring to IGNITION COIL ASSEMBLY in this section 3 Remove spark plugs Inspection 1 Inspect them for Electrode wear Carbon deposits Insulator damage 2 If any abnormality is found adjust air gap clean with spark plug cleaner or replace them with specif...

Page 245: ...gh tension cord from ignition coil assembly 5 Remove ignition coil bolts and then pull out ignition coil assembly 6 Measure secondary coil for resistance Secondary coil resistance 11 1 14 9 kΩ Ω Ω Ω Ω at 200 C 680 F If resistance is out of specification replace ignition coil assembly 7 Install ignition coil assembly 8 Tighten ignition coil bolts and then connect ignition coil coupler 9 Install hig...

Page 246: ... to DLC with ignition switch OFF Special Tool A 99000M24120 426 SUZUKI Scan tool 2 Start engine and warm it up to normal operating temperature 3 Make sure that all of electrical loads except ignition are switched off 4 Check to be sure that idle speed is within specification refering to idle speed idea Air coutred IAC Duty inspection in section 1A 5 Fix ignition timing by using Fixed Spark of MISC...

Page 247: ...embly 2 while engine is running and then tighten bolt Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft 9 After tightening bolt recheck that ignition timing is within specification 10 After checking and or adjusting disconnect service wire from monitor connector or release fixed ignition timing and disconnect SUZUKI scan tool from DLC Caution Driving with test switch terminal grounded will cause damag...

Page 248: ...IGNITION SYSTEM 1H 11 Special Tools ...

Page 249: ......

Page 250: ...Routing Diagram Cranking System Circuit Diagram The cranking circuit consists of the battery starting motor ignition switch and related electrical wiring These componentsvare connected electrically Only the starting motor will be covered in this section ...

Page 251: ...ttery run down Recharge battery Battery voltage too low due to battery deterioration Replace battery Poor contact in battery terminal connection Retighten or replace Loose grounding cable connection Retighten Fuse set loose or blown off Tighten or replace Poor contacting action of ignition switch and magnetic Replace switch Lead wire coupler loose in place Retighten Open circuit between ignition s...

Page 252: ...utch slipping Replace over running clutch Worn teeth of pinion gear Replace flywheel Noise Abnormally worn bush Replace bush Worn pinion or worn teeth of pinion gear Replace pinion or flywheel Poor sliding of pinion failure in return movement Repair or replace Lack of oil in each part Lubricate Starting motor Fused contact points of magnetic switch Replace magnetic switch does not stop Short circu...

Page 253: ...y No Load Performance Test Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out Also check that ammeter indicates specified current Specified Current 50A at 11 5V Repair Instructions Starting Motor Dismounting and Remounting Dismounting and Remounting 1 Disconnect negative cable at battery 2 Disconnect magnetic switch lead wire 1 and battery cable...

Page 254: ...ote Do not disassemble magnetic switch Replace it as assembly when required A Pull up to disconnect hook 3 Remove housing bolts through bolts and then pull out commutator end housing 4 Remove insulator brush spring 1 and then brush holder 2 5 Remove yoke armature 1 and drive lever 2 from drive housing 3 6 Remove snap ring 2 by using snap ring pliers assisted with screwdriver then pull out pinion s...

Page 255: ...ing 3 Apply grease to drive lever 2 and combine it with armature 1 Then assemble them with drive housing 3 A Grease 99000 25010 4 Install yoke and brush holder 3 then set 4 brushes 1 with their springs 2 Install insulator Note When installing brushes make sure that brushes and commutator have been degreased thoroughly Check to confirm that brush parts do not have unnecessary contacts with others 5...

Page 256: ...netic switch assembly 1 with nuts 4 8 Connect lead wire 5 as it was and then check magnetic switch for operation Note Before installing nuts make sure that plunger hook is connected with drive lever without fail Face boot 2 breather down Upon completion of assembly carry out PERFORMANCETEST ...

Page 257: ...armature assembly over running clutch assembly magnetic switch assembly Iron housingm rear housing brush holder and drive lever The magnetic switch assembly ans parts in the starting motor are enclosed in teh housings so that they will be protected against possible dirt and water splash ...

Page 258: ...c switch S terminal 1 and M terminal 2 If no continuity exists coil is open and should be replaced Hold In Coil Open Circuit Test Check for continuity across magnetic switch S terminal 1 and coil case If no continuity exists coil is open and should be replaced Brush Measure length of brushes and replace them as necessary Brush length Limit 6 0 mm 0 236 in Brush Holder Check brush springs for rust ...

Page 259: ...must be replaced Check commutator for run out with armature 1 supported on V blocks 2 Correct it by using lathe if required Commutator out of round Limit maximum value 0 4 mm 0 015 in Check for wear and replace armature if diameter is below limit Commutator outside diameter Limit minimum value 27 mm 1 063 in Correct and clean surface by using 400 emery cloth Also check mica depth and correct it as...

Page 260: ...erminals Between A terminals Between B terminals Between B terminal and C bare metal part of yoke body Over Running Clutch Inspect pinion for wear damage or other abnormal conditions Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction Replace if necessary ...

Page 261: ...ic 11 5 V 50 A maximum 6 000 rpm minimum Around at Load characteristic 9 V 2 94 N m minimum 20O C 68O F 150 A 1 950 rpm minimum Locked rotor current 5 5 V 430 A maximum 6 4 N m 0 64 kg m 4 6 Ib ft minimum Magnetic switch operating voltage 8 volts maximum Required Service Material Material Recommended Use Suzuki Product Lithium grease SUZUKI SUPER GREASE A Armature shaft 99000 25010 Over running cl...

Page 262: ...ean and free from corrosion and make certain there are no parts in carrier To prevent the battery from shaking in its carrier the hold down bolts should be tight enough but not over tightened Electrolyte Freezing The freezing point of electrolyte depends on its specific gravity Since freezing may ruin a battery it should be protected against freezing by keeping it in a fully charged condition If a...

Page 263: ...e Recharge the battery twice a month to prevent it from discharging excessively This is especially important when ambient temperature is low The battery discharges even when it is not used while vehicles are being stored Battery electrolyte can freeze and battery case can crack at cold ambient condition if battery is not properly charged 2 Keep the battery cable connections clean The cable connect...

Page 264: ...h the brush holder assembly is attached to the rear housing The IC regulator uses integrated circuits and controls the voltage produced by the generator and the voltagesetting cannot be adjusted The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication Two brushes carry current through the two slip rings to the field coil mounted on the rotor and under norma...

Page 265: ...1J 4 CHARGING SYSTEM ...

Page 266: ...wing conditions 1 Faulty indicator lamp operation 2 Undercharged battery as evidenced by slow cranking or indicator dark 3 Overcharged battery as evidenced by excessive spewing of electrolyte from vents Noise from generator may be caused by a loose drive pulley loose mounting bolts worn or dirty bearings defective diode or defective stator Charging Indicator Lamp Operation Problem Possible Cause C...

Page 267: ...t wiring for defects Check all connections for tightness and cleanliness battery cable connections at battery starter and ignition ground cable 5 Connect voltmeter and ammeter as shown in figure Voltmeter Set between generator B terminal and ground Ammeter Set between generator B terminal and battery terminal Note Use fully charged battery 6 Measure current and voltage No load Check 1 Run engine f...

Page 268: ... standard value Generator itself has problem check the generator Load Check 1 Run engine at 2 000 rpm and turn on head light and heater motor 2 Measure current and if it is less than 20 A repair or replace generator Generator Test Overcharged Battery 1 To determine battery condition refer to Battery section in this DIAGNOSIS 2 If obvious overcharge condition exists as evidenced by excessive spewin...

Page 269: ...e a short circuit could occur 1 Set parking brake and place automatic transmission in PARK NEUTRAL on manual transmission Turn off ignition turn off lights and all other electrical loads 2 Check electrolyte level If it is below low level line add distilled water 3 Attach end of one jumper cable to positive terminal of booster battery and the other end of the same cable to positive terminal of disc...

Page 270: ...ove battery 4 Handling When handling battery following safety precautions should be followed Hydrogen gas is produced by battery A flame or spark near battery may cause the gas to ignite Battery fluid is highly acidic Avoid spilling on clothing or other fabric Any spilled electrolyte should be flushed with large quantity of water and cleaned immediately Installation 1 Reverse removal procedure 2 T...

Page 271: ... wire 3 and coupler 4 from generator 5 5 Remove bracket bolts 6 and remove generator with bracket Installation Reverse above procedure giving specified tension to drive belt Refer to Generator Water Pump Belt for belt tension Tightening Torque a 22 N m 2 2 kg m 16 0 lb ft b 50 N m 5 0 kg m 36 5 lb ft c 7 N m 0 7 kg m 5 0 lb ft Generator Removal and Installation ...

Page 272: ...CHARGING SYSTEM 1J 11 Generator Component ...

Page 273: ... Hold shaft by using hexagonal box wrench 1 and remove pulley nut and then pull out pulley 2 Caution To hold shaft use hexagonal box 3 Duodecimal box may cause slipping and consequential shaft or tool damage Do not attempt to hold pulley by using vise or pipe wrench so as not to distort it 9 Remove 4 rear end frame nuts 3 10 Drive out rear end frame 1 with rotor tapping shaft 2 lightly by using pl...

Page 274: ...drive end bearing 2 14 If required remove stud bolts and then pull out stator Note Heating drive end frame may facilitate removal of stator Assembly 1 If end housing bearing 1 is removed install it 2 Check end housing bearing turns smoothly 3 If stator 2 is removed install stator and tighten stud bolts 1 4 If drive end bearing 3 is removed install it 5 Check drive end bearing turns smoothly Tighte...

Page 275: ... 3 5 lb ft 9 Install pulley 1 and tighten pulley nut with holding shaft using hexagonal box wrench 2 to specified torque Tightening Torque a 113 N m 11 3 kg m 81 5 lb ft 10 Install rectifier holder 1 Caution When installing rectifier check to confirm that stator leads have enough clearance with cooling fan blades Tightening Torque a 3 9 N m 0 4 kg m 3 0 lb ft b 2 0 N m 0 2 kg m 1 5 lb ft 11 Instal...

Page 276: ...stall insulator 2 and tighten B terminal inner nut 3 to specified torque Tightening Torque b 3 6 N m 0 36 kg m 3 0 lb ft 16 Make sure that rotor turns smoothly Generator Inspection Rotor Open Circuit Using ohmmeter check for continuity between slip rings of rotor 1 If there is no continuity replace rotor Standard resistance About 2 9 Ground Using ohmmeter check that there is no continuity between ...

Page 277: ...tor Open Circuit Using ohmmeter check all leads for continuity If there is no continuity replace stator Ground Using ohmmeter check that there is no continuity between coil leads and stator core If there is continuity replace stator Brush Exposed Brush Length Check each brush for wear by measuring its length as shown If brush is found worn down to service limit replace brush Refer to Replace Brush...

Page 278: ...nd the other shows no continuity If there is continuity replace rectifier holder Negative Rectifier 1 Using ohmmeter connect one tester probe to each negative terminal E and the other to each rectifier terminal P1 P4 2 Reverse the polarity of tester probes and repeat step 1 3 Check that one shows continuity and the other shows no continuity If there is continuity replace rectifier holder Bearing D...

Page 279: ...ush 1 Unsolder and remove brush and spring 2 Run wire of new brush through the hole in the brush holder and insert spring and brush into brush holder 3 Solder brush wire to brush holder at specified exposed length Exposed length a 10 5 mm 0 413 in 4 Check that brush moves smoothly in brush holder 5 Cut off excess wire 6 Apply insulation paint to the soldered area ...

Page 280: ...ctrolyte S G 1 24 when fully charged at 200 C 680 F Generator Permissible ambient 30 to 900 C temperature 22 to 1940 F Nominal output 60 A at 13 5 V Permissible max speed 18 000 rpm Polarity Negative ground No load speed 1 150 rpm Rotation Clockwise viewed Setting voltage 14 2 to 14 8 V from pulley side Rated voltage 12 V ...

Page 281: ......

Page 282: ... hot Any service on the exhaust system should be performed when the system is cool At every interval of periodic maintenance service and when vehicle is raised for other service check exhaust system as follows Check rubber mountings for damage deterioration and out of position Check exhaust system for leakage loose connection dent and damage If bolts or nuts are loosened tighten them to specified ...

Page 283: ...Repair Instructions Exhaust System Components Warning To avoid the danger of being burned do not touch the exhaust system when the system is hot Any service on the exhaust system should be performed when the system is cool ...

Page 284: ...ioration or damage Replace them as necessary Exhaust Pipe For replacement of exhaust pipe be sure to hoist vehicle and observe WARNING under Maintenance and the following Caution Exhaust pipe have three way catalytic converter in it it should not be exposed to any impulse Be careful not to drop it or hit it against something Tighten bolts and nuts to specified torque when reassembling Refer to GEN...

Page 285: ...aust manifold cover of exhaust manifold 4 Remove exhaust pipe from exhaust manifold 5 Remove exhaust manifold and its gasket from cylinder head Installation 1 Install new gasket to cylinder head 2 Install exhaust manifold Tighten bolts and nuts to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 3 Install pipe gasket and install exhaust pipe to exhaust manifold Before installing pip...

Page 286: ...ning Torque b 50 N m 5 0 kg m 36 5 lb ft 4 Install upper cover to exhaust manifold 5 Connect oxygen sensor connector and fit connector to bracket 6 Connect negative cable at battery 7 Check exhaust system for exhaust gas leakage ...

Page 287: ......

Page 288: ... 4 Rear Suspension Fasteners 2C 4 Wheel Disc Nut and Bearing Check 2C 4 On Vehicle Service 2C 5 Lateral Rod 2C 6 Rear Shock Absorber 2C 7 Section 2 Suspension CONTENTS Coil Spring 2C 7 Bump Stopper 2C 9 Spring Upper Seat 2C 10 Trailing Arm 2C 10 Rear Axle 2C 13 Wheel Bearing and Wheel Stud 2C 17 Required Service Material 2C 19 Special Tools 2C 19 Wheel and Tires 2D 1 General Description 2D 1 Tires...

Page 289: ......

Page 290: ...Caution Refer to Wheels and Tires Caution in Section 00 General Precautions Refer to General Precautions in Section 00 Vehicle Lifting Points Refer to Vehicle Lifting Points in Section 0A Fastener Caution Refer to Fastener Caution in Section 00 Fastener Information Refer to Fasteners Information in Section 0A Brake Caution Refer to Brake Caution in Section 00 2A ...

Page 291: ... and adjust front end alignment Disturbed rear wheel alignment Check and adjust rear wheel alignment Brake dragging in one road wheel Repair front brake Loose bent or broken front or rear Tighten or replace suspension parts suspension parts Abnormal or Sagging or broken spring Replace spring Excessive Tire Wear Tire out of balance Adjust balance or replace tire Disturbed front or rear end alignmen...

Page 292: ...se suspension bolts or nuts Tighten suspension bolts or nuts Broken or otherwise damaged wheel Replace bearings Broken suspension springs Replace Poorly lubricated or worn strut Replace strut bearing bearings Low or Uneven Trim Broken or sagging springs Replace Height Over loaded Check loading Incorrect springs Replace Ride Too Soft Faulty struts shock absorber Replace strut Suspension Bottoms Ove...

Page 293: ...etermined If the body is damaged it should be repaired and if suspension is damaged it should be replaced Toe Setting Toe is the turning in or out of the front wheels The purpose of a toe specification is to ensure parallel rolling of the front wheels Excessive toe in or toe out may increase tire wear Amount of toe can be obtained by subtracting A from B as shown in above figure and therefore is g...

Page 294: ...deration must be given to excess loads such as tool boxes If this excess load is normally carried in vehicle it should remain in vehicle during alignment checks 8 Consider condition of equipment being used to check alignment and follow manufacturer s instructions 9 Regardless of equipment used to check alignment vehicle must be on a level surface both fore and aft and transversely Toe Adjustment T...

Page 295: ...k if right and left tie rods are equal in length A Note If tie rod lengths were changed to adjust steering angle reinspect toe in Steering angle inside 440 30 outside 370 30 Reference Information Side slip For inspecting front wheel side slip with side slip tester Side slip limit Less than 3 mm m 0 036 in ft If side slip exceeds above limit toe in or front wheel alignment may not be correct ...

Page 296: ...esult General Description The front suspension is the strut type independent suspension The upper end of a strut is anchored to the vehicle body by a strut support The strut and strut support are isolated by a rubber mount A strut bearing is also installed a little lower to the rubber mount The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is a...

Page 297: ...2B 2 FRONT SUSPENSION ...

Page 298: ...FRONT SUSPENSION 2B 3 ...

Page 299: ...nd note strut resistance both when pushed and rebounding Also note how many times vehicle body rebounces before coming to stop after hands are off Do the same for strut on the other side Compare strut resistance and number of rebounce on the right with those on the left And they must be equal in both With proper strut vehicle body should come to stop the moments hands are off or after only one or ...

Page 300: ...rm assembly must be replaced as a complete unit Wheel Disc Nut And Bearing Check 1 Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced 2 Check wheel nuts for tightness and as necessary retighten them to specification Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 3 By rotating wheel actually check wheel bearing for noise and smooth rotation If...

Page 301: ...icle Service Strut Assembly Removal Note When disassembling strut assembly loosen strut nut a little before removing strut assembly from vehicle This will make disassembly easier Note however nut must not be removed at this point ...

Page 302: ... that it will not fall off 7 Remove strut assembly Disassembly 1 Using a spring compressor compress the strut spring till its force pressing the spring seat is released Warning Use a commercially available spring compressor and follow the operation procedure described in the Instruction Manual supplied with that spring compressor 2 While keeping spring compressed with special tool as shown above r...

Page 303: ...o specified torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft Installation Reverse removal procedure for installation noting the following instructions Tighten all fasteners to specified torque Tightening Torque a 100 N m 10 0 kg m 72 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft Don t twist brake hose when installing it Install E ring 1 as far as it fits to bracket 2 as shown Tighten wheel nut to spec...

Page 304: ... cotter pin 1 stabilizer bar nut 2 and washer 3 2 Remove stabilizer bar mounting bracket bolts 1 3 Remove stabilizer bar 1 Note If it is hard to remove stabilizer bar set tires in contact with ground with suspension compressed Stablizer Bar ...

Page 305: ...3 Align the inside edge 3 of mount bushing with the outside edge of paint as shown in figure 4 Tighten stabilizer bar mounting bracket bolts 5 to specified torque Tightening Torque a 45 N m 4 5 kg m 32 5 lb ft 5 After tightening castle nut 1 to specified torque be sure to bend cotter pin 2 as shown Tightening Torque a 65 N m 6 5 kg m 47 0 lb ft Note Removed cotter pin should be replaced with new o...

Page 306: ... drive shaft nut 1 4 Remove caliper carrier bolts 5 Remove caliper 1 with carrier Note Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with pads removed 6 Pull brake disc 2 off by using two 8 mm bolts 3 Wheel Hub and Steer ing Knuckle ...

Page 307: ... 09942M15511 8 Disconnect tie rod end 1 from steering knuckle 2 with special tool Special Tool A 09913M65210 9 Loosen strut bracket nuts 1 10 Remove ball stud bolt 1 11 Remove strut bracket bolts from strut bracket and then remove steering knuckle 2 Disassembly 1 Uncaulk and remove dust cover 1 ...

Page 308: ...draulic press 1 and special tool remove wheel bearing Special Tool A 09913M75810 4 Remove wheel bearing inner race 1 Special Tool A 09913M61110 B 09925M88210 5 Remove hub bolts 1 Caution Never remove bolt unless replacement is necessary Because use a new bolt for replacement ...

Page 309: ... new wheel bearing 2 into steering knuckle 3 using special tools and hydraulic press 4 Special Tool A 09913M75520 B 09951M18210 2 Install circlip 1 to steering knuckle 2 3 Drive in dust cover so that dimensions a and b become equal as shown Caution When drive in dust cover be careful not to deform it 4 Caulk with a punch ...

Page 310: ...instruction Using special tools and hydraulic press 1 drive wheel hub 2 into steering knuckle 3 as shown Special Tool A 09913M75520 B 09944M66020 Install suspension arm ball stud bolt as shown and tighten suspension arm ball stud bolt 1 to specified torque Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft Install strut bracket bolt as shown and tighten strut bracket nuts 1 to specified torque Tighten...

Page 311: ...to specified torque Tightening Torque a 175 N m 17 5 kg m 127 0 lb ft Caulk drive shaft nut 3 as shown Caution Be careful while caulking nut so that no crack will occur in caulked part of nut Cracked nut must be replaced with new one Install wheel and tighten wheel nuts to specified torque Tightening Torque 85 N m 8 5 kg m 61 5 lb ft Suspension Control Arm Bushing Removal 1 Hoist vehicle and remov...

Page 312: ...nstallation 1 Install new bushing 1 with special tool and oil hydraulic press 2 as shown Special Tool A 09943M77910 Note Before installing bushing apply soap water on its circumference to facilitate installation When installed bush should be equal on the right and left of arm as shown 2 Install suspension control arm to vehicle body and tighten suspension control arm bolt 1 temporarily at this ste...

Page 313: ... tighten wheel nuts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 5 Lower hoist and bounce vehicle up and down several times to stabilize suspension Be sure that vehicle is in non loaded condition 6 Tighten control arm bolt 1 to specified torque Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft 7 Install stabilizer bar referring to STABILIZER BAR AND OR BUSHINGS INSTALLATION in t...

Page 314: ...FRONT SUSPENSION 2B 19 Required Service Material Material Recommended Use Suzuki Product Lithium wheel bearing grease SUZUKI SUPER GREASE A Wheel bearing 99000 25010 Special Tools ...

Page 315: ......

Page 316: ...e They must be replaced with one of the 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 this part Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may ...

Page 317: ...2C 2 REAR SUSPENSION General Description Rear suspension is Isolated Trailing Link l T L type which consists of coil springs rear axle shock absorbers lateral rod and trailing arms ...

Page 318: ...assemble it 2 Don t put it into the fire 3 Don t store it where it gets hot 4 Before disposing it be sure to drill a hole approximately 3 mm 0 12 in diameter in it where shown by an arrow in figure and let gas and oil out Lay it down sideways for this work 5 The gas itself is harmless but it may issue out of the hole together with chips generated by the drill Therefore be sure to wear goggle Trail...

Page 319: ...ut And Bearing Check Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced Check wheel nuts for tightness and as necessary retighten to specification Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft Check wheel bearings for wear When measuring thrust play apply a dial gauge to spindle cap center Thrust play limit a 0 1 mm 0 004 in When measurement...

Page 320: ...REAR SUSPENSION 2C 5 On Vehicle Service Note According to necessity apply works to right and left parts ...

Page 321: ...le body 3 referring to figure for proper installing direction of nuts 4 bolt 5 and washer 6 Tighten nuts temporarily at this step 2 Lower hoist and bounce vehicle up and down several times to stabilize suspension Be sure that vehicle in non loaded condition 3 Tighten lateral rod nuts 1 to specified torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft b 65 N m 6 5 kg m 47 0 lb ft ...

Page 322: ...ve floor jack from rear axle lower hoist and bounce vehicle up and down several times to stabilize suspension Be sure that vehicle in non loaded condition 3 Tighten nuts to specified torque Tightening Torque a 63 N m 6 3 kg m 46 0 lb ft b 25 N m 2 5 kg m 18 5 lb ft Coil Spring Removal 1 Hoist vehicle and remove rear wheel 2 Support rear axle 1 using floor jack 2 to prevent it from lowering 3 Remov...

Page 323: ... and parking brake cable 7 Remove coil spring Installation 1 Install coil spring 1 with its small pitch end facing up and large pitch end with paint marking down and make sure that spring end contact to stepped part 2 of spring seat 3 as shown 2 Install shock absorber lower end 1 to rear axle Tighten shock absorber lower nut 2 temporarily at this step 3 Remove floor jack from rear axle 4 Install b...

Page 324: ...veral times to stabilize suspension Be sure that vehicle in non loaded condition 9 Tighten absorber lower nut 1 and lateral rod body side nut 2 to specified torque Tightening Torque a 25 N m 2 5 kg m 18 5 lb ft b 65 N m 6 5 kg m 47 0 lb ft Bump Stopper Removal 1 Hoist vehicle and remove rear wheel 2 Remove bump stopper using flat end rod or the like Installation 1 Install bump stopper Note Before ...

Page 325: ...fer to figure 2 Install coil spring For details refer to COIL SPRING INSTALLATION in this section Trailing Arm Removal 1 Hoist vehicle and remove rear wheel 2 Support rear axle 1 using floor jack 2 Caution Never apply floor jack against lateral rod as it may get deformed 3 Remove lateral rod body side bolt 1 and nut 2 and then detach lateral rod 3 from vehicle body 4 Remove shock absorber lower nu...

Page 326: ...t 2 7 Remove trailing arm front bolt 1 and then remove trailing arm 2 Installation 1 Install trailing arm 1 to vehicle body and rear axle referring to figure for proper installing direction of bolts 2 Tighten front nut 3 center nut 4 and rear nut 5 temporarily at this step 2 Install parking brake cable clamp 1 to trailing arm 2 ...

Page 327: ...le 6 Install wheel and tighten wheel nuts to specified torque Tightening Torque 85 N m 8 5 kg m 61 5 lb ft 7 Lower hoist and bounce vehicle up and down several times to stabilize suspension Be sure that vehicle in non loaded condition 8 Tighten front center and rear trailing arm nuts 1 shock absorber lower nuts 2 and lateral rod vehicle side nut 3 to specified torque Tightening Torque a 90 N m 9 0...

Page 328: ...ove parking brake cable clamp 1 from trailing arm 5 Disconnect brake pipe flare nut 1 from wheel cylinder 2 and put bleeder plug cap 3 onto brake pipe 4 to prevent fluid from spilling Caution Do not allow brake fluid to get on painted surface 6 Remove back plate bolt 1 and then remove brake back plate 2 from rear axle and hang removed back plate with a wire hook ...

Page 329: ...ar down as where coil spring 1 can be removed Caution Be careful not to let rear axle down too much It may cause damage to brake flexible hose and parking brake cable 10 Remove coil spring 11 Loosen center trailing arm nut 1 and rear trailing arm nut 2 but don t remove bolts 12 While supporting rear axle at both ends remove center and rear trailing arm bolts and then remove rear axle from chassis ...

Page 330: ... rear nut 3 temporarily at this step 3 Install coil spring 1 with its small pitch end facing up and large pitch end with paint marking down and make sure that spring end contact to stepped part 2 of lower seat 3 as shown 4 Install shock absorber lower end 1 to rear axle Tighten shock absorber lower nut 2 temporarily at this step 5 Remove floor jack from rear axle 6 Clean mating surface of rear axl...

Page 331: ...tion Do not allow brake fluid to get on painted surface 9 Install parking brake cable clamp 1 to trailing arm 2 10 Connect brake flexible hose to brackets on rear axle and vehicle body and then fix it with E rings 1 Note For proper installing direction of E rings refer to figure 11 Fill reservoir with brake fluid and bleed brake system For bleeding operation see SECTION 5 in this manual 12 Install...

Page 332: ...ion 15 Tighten center and rear trailing arm nuts 1 shock absorber lower nut 2 and lateral rod axle side nut 3 to specified torque Tightening Torque a 80 N m 8 0 kg m 58 0 lb ft b 25 N m 2 5 kg m 18 5 lb ft c 50 N m 5 0 kg m 36 5 lb ft 16 Check to ensure that brake drum is free from dragging and proper braking is obtained 17 Perform brake test foot brake and parking brake Wheel Bearing And Wheel St...

Page 333: ...rum hole and rotate it slowly to assure serrations are aligned with those made by replaced bolt 2 Press fit wheel bearing 1 with it s seal side facing back plate side using special tools and hydraulic press Special Tool A 09951M76010 B 09924 84510 004 3 Install bearing circlip 1 using special tool Special Tool A 09900M06108 4 Install brake drum and wheel For details refer to REAR BRAKE DRUM INSTAL...

Page 334: ...2C 19 Required Service Materials Materials Recommended Use Suzuki Product Brake fluid DOT3 Brake reservoir tank Water tight sealant SEALING COMPOUND 366E 99000 31090 Join seam of rear axle and brake plate Special Tools ...

Page 335: ......

Page 336: ...65 R13 The tire is tube type The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures Correct tire pressures and driving habits have an important influence on tire life Heavy cornering excessively rapid acceleration and unnecessary sharp braking increase tire wear Wheels Standard equipment wheels are the follo...

Page 337: ...ed if they are bent dented have excessive lateral or radial runout air leak through welds have elongated bolt holes if lug nuts won t stay tight or if they are heavily rusted Wheels with greater runout than shown in figure below may cause objectional vibrations Replacement wheels must be equivalent to the original equipment wheels in load capacity diameter rim with offset and mounting configuratio...

Page 338: ... and wheels are matchmounted at the assembly plant This means that the radially stiffest part of the tire or high spot is matched to the smallest radius or low spot of the wheel This is done to provide the smoothest possible ride The high spot of the tire is originally marked by paint dot 1 on the outboard sidewall This paint dot will eventually wash off the tire The low spot of the wheel is origi...

Page 339: ...le can cause 1 Uneven braking 2 Steering lead 3 Reduced handling 4 Swerve on acceleration Lower than recommended pressure can cause 1 Tire squeal on turns 2 Hard Steering 3 Rapid and uneven wear on the edges of the tread 4 Tire rim bruises and rupture 5 Tire cord breakage 6 High tire temperature 7 Reduced handling 8 High fuel consumption Valve caps should be on the valves to keep dust and water ou...

Page 340: ...sion on wheel mounting surface and brake disc mounting surface by scraping and wire brushing Installing wheels without good metal to metal contact at mounting surfaces can cause wheel nuts to loosen which can later allow a wheel to come off while vehicle is moving Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft Tire Mounting And Demounting Use a tire changing machine to mount or demount tires Follo...

Page 341: ...ket to repair tires As not all of these work on all types of tires tire manufacturers have published detailed instructions on how and when to repair tires These instructions can be obtained from each tire manufacturer Balancing Wheels There are two types of wheel and tire balance static and dynamic Static balance as shown in left figure is the equal distribution of weight around the wheel Wheels t...

Page 342: ... disc unbalance as does on vehicle spin balancing this is overcome by their accuracy usually to within 1 8 ounce On Vehicle Balancing On vehicle balancing methods vary with equipment and tool manufacturers Be sure to follow each manufacturer s instructions during balancing operation Warning Wheel spin should be limited to 55 km h 35 mph as indicated on speedometer This limit is necessary because s...

Page 343: ... indicators will appear as 12 mm 0 47 in wide bands when the tire tread depth becomes 1 6 mm 0 063 in When the indicators appear in 3 or more grooves at 6 locations tire replacement is recommended RadialTireWaddle Waddle is side to side movement at the front and or rear of the vehicle It is caused by the steel belt not being straight within the tire It is most noticeable at a low speed 8 48 km h 5...

Page 344: ...r vehicle in place of those on waddling end of vehicle If waddling end cannot be identified substitute rear ones 3 Road test again If improvement is noted reinstall originals one at a time till waddle causal tire is found If no improvement is noted install known good tires in place of all four Then reinstall originals in the same manner as above ...

Page 345: ...hat front alignment is not mistaken for tire lead 1 Part of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner and service manuals If a medium to high mileage tire is moved to the other side of the vehicle be sure to check that ride roughness has not developped 2 Rear tires will not cause lead Vibration Diagnosis Wheel unbalance causes most of th...

Page 346: ...osis Table 3A 3 On Vehicle Service 3A 4 Drive Shaft Assembly 3A 4 Removal 3A 4 Section 3 Front Drive Shaft CONTENTS Disassembly Tripod Jopint Type 3A 5 Disassembly DOJ Type 3A 6 Inspection 3A 7 Reassembly Tripod Jopint Type 3A 7 Reassembly DOJ Type 3A 9 Installation 3A 11 Required Service Materials 3A 12 SpecialTool 3A 12 ...

Page 347: ......

Page 348: ...FRONT DRIVE SHAFT 3A 1 Front Drive Shaft General Description Removal Installation ...

Page 349: ...3A 2 FRONT DRIVE SHAFT Disassembly Reassembly ...

Page 350: ...ive Shaft Boot Check Inspect drive shaft boot for hear If even a small tear is found replace witha new one Diagnosis Diagnosis Table Condition Possible Cause Correction Abnormal Noise Worn or breakage drive shaft joint Replace ...

Page 351: ...l Tool A 09913M65210 6 Drain transmission fluid 7 Pull out right side drive shaft joint 1 by using large size lever 2 so as to release snap ring fitting of joint spline at differential side 8 Install appropriate metal band 1 to left side drive shaft joint 2 and then pull out left side drive shaft joint 2 by using large size lever 3 as shown 9 Disconnect front suspension control arm ball stud 1 fro...

Page 352: ...l tool and then pull out spider 2 from shaft Special Tool A 09900M06107 Caution To prevent needle bearing of joint from being degreased do not wash it if it is to be reused 3 Remove boot band then pull out differential side boot from shaft 4 Pull out dynamic damper through shaft 5 Undo boot bands of wheel side joint boot then pull out boot through shaft Caution Disassembly of wheel side joint is n...

Page 353: ...from shaft and remove circlip 1 used to fix cage by using special tool Special Tool A 09900M06107 4 Remove cage by hand and remove boot from shaft Note Do not disassemble wheel side joint outboard joint If any malfunction is found in any joint replace it as assembly Inspection Inspect boots for breakage or deterioration Replace them as necessary Inspect circlip snap ring and boot bands for breakag...

Page 354: ...volume to respective joint A Gray grease 60 80 g 2 1 2 8 oz B Green grease 90 110 g 3 2 3 9 oz Do not squeeze or distort boot 1 when fastening it with bands Distorted boot caused by squeezing air may reduce its durability 1 Wash disassembled parts except boots and tripod joint except its housing After washing dry parts completely by blowing air 2 Clean boots with cloth Do not wash boots in degreas...

Page 355: ...09900M06107 9 Apply grease to inside of outer race 1 then install housing joint it with boot and fit boot to outer race After fitting boot insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure 10 When fixing boot 1 to outer race 2 with boot band 3 adjust so that measurements become as indicated below Length...

Page 356: ...boot caused by squeezing air may reduce its durability 1 Wash disassembled parts except boots After washing dry parts completely by blowing air 2 Clean boots with cloth Do not wash boots in degreaser such as gasoline or kerosene etc Washing in degreaser causes deterioration of boot 3 Apply grease to wheel side joint Use Gray grease in tube included in wheel side boot set 4 Install wheel side boot ...

Page 357: ...hat it will not be lined up with a ball 9 Apply grease to inside of outer race and fit boot to outer race After fitting boot insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure 10 When fixing boot band 1 adjust so that measurements d become as specified Length d 144 5 191 0 mm 5 69 7 52 in M T vehicle 131...

Page 358: ...al side joint is inserted fully and its snap ring is seated as it was Reverse removal procedure for installation and then noting the following instruction Tighten each bolts and nuts to the specified torque Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft b 43 N m 4 3 kg m 31 5 lb ft c 175 N m 17 5 kg m 127 0 lb ft d 85 N m 8 5 kg m 61 5 lb ft e 21 N m 2 1 kg m 15 5 lb ft f 40 N m 4 0 kg m 29 0 lb f...

Page 359: ...3A 12 FRONT DRIVE SHAFT Required Service Materials Materials Recommended Suzuki Product Use Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain and filler plug for manual transmission Special Tools ...

Page 360: ...Brake Shoe 4 30 Wheel Cylinder 4 32 Brake Back Plate 4 35 Master Cylinder Assembly 4 37 Brake Booster 4 41 Required Service Materials 4 46 Special Tools 4 46 4 Section 4 Brakes CONTENTS Brakes with ABS 4A 1 General Description 4A 1 Diagnosis 4A 2 Road Testing Brakes 4A 2 Brake Fluid Leaks 4A 2 Substandard or Contaminated Brake Fluid 4A 2 Diagnosis Table 4A 3 On Vehicle Service 4A 6 Bleeding Brakes...

Page 361: ...ear Wheel Speed Sensor Circuit or Sensor Rotor 4B 18 DTC C1041 Right Front Inlet Solenoid Circuit 4B 20 DTC C1045 Left Front Inlet Solenoid Circuit 4B 20 DTC C1046 Left Front 4B 20 DTC C1051 Right Rear Inlet Solenoid Circuit 4B 20 DTC C1055 Left Rear Inlet Solenoid Circuit 4B 20 DTC C1042 Right Front Outlet Solenoid Circuit 4B 20 DTC C1052 Right Rear Outlet Solenoid Circuit 4B 20 DTC C1056 Left Re...

Page 362: ...ront right rear left brakes and the other connects front left rear right brakes The proportioning valve P valve is included in these circuits between the master cylinder and rear wheels In brake system of this model the disc brake type is used of 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...

Page 363: ...the bottom of the caliper bore to move the piston outward and to move slide the caliper inward resulting in a clamping action on the disc This clamping action forces the pads linings against the disc creating friction to stop the vehicle Note Lubricate parts as specified Do not use lubricated shop air on brake parts as damage to rubber components may result If any component is removed or line disc...

Page 364: ...that drum to shoe clearance is maintained appropriate at all times Caution Replace all components included in repair kits to service this drum brake Lubricate parts as specified If any hydraulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners ...

Page 365: ...rake Also the hydraulic pressure produced in the secondary chamber b acts on the right front wheel brake and left rear wheel brake Caution Replace all components included in repair kits to service this master cylinder Lubricate rubber parts with clean fresh brake fluid to ease assembly Do no use lubricated shop air on brake parts as damage to rubber components may result If any hydraulic component...

Page 366: ...ressed is mechanically increased combined with the engine vacuum Caution When and after removing booster never drop or deform it Warning Never disassemble brake booster assembly If it is found faulty replace it with new assembly Caution The torque values specified are for dry unlubricated fasteners If any hydraulic component is removed or brake line disconnected bleed the brake system ...

Page 367: ...cylinder and the wheel brakes It is installed on floor panel and controls the hydraulic pressure applied to the rear wheel brakes after predetermined pressure has been reached Caution Never disassemble proportioning valve Disassembly will spoil its original function If faulty condition is found replace it with new one ...

Page 368: ...illedwith brake fluid indicated on reservoir tank cap do not use or mix different type of fluid when refilling otherwise serious damage will occur Do not use old or used brake fluid or any fluid from a unsealed container Substandard or Contaminated Brake Fluid Improper brake fluid mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic system t...

Page 369: ...out of Check for inoperative auto adjustment in some brakes adjusting mechanism Malfunctioning auto adjusting mechanism Disc and or drum is out of round in some Replace brakes Wheel tires are inflated unequally Inflate equally Malfunctioning wheel cylinders Repair or replace Disturbed front end alignment Adjust as prescribed Unmatched tires on same axle Tires with approximately the same amount of ...

Page 370: ...ipes or hoses Check for soft hoses or damaged immediately after pipes and replace with new hoses pedal is released and or new brake pipes Incorrect parking brake adjustment on rear Check and adjust to correct brakes specifications Weakened or broken return springs in the Replace brake Sluggish parking brake cables Repair or replace Wheel cylinder or caliper piston sticking Repair as necessary Badl...

Page 371: ...parking brake and check turns on after engine that brake warning light turns off start Insufficient amount of brake fluid Add brake fluid Brake fluid leaking from brake line Investigate leaky point correct it and add brake fluid Brake warning light circuit faulty Repair circuit Brake warning light Brake fluid leaking from brake line Investigate leaky point correct it turns on when brake and add br...

Page 372: ...Adjustment should be made as follows when installing switch Pull up brake pedal toward you and while holding it there adjust switch position so that clearance between top of switch and stay is within specification Clearance b 0 5 1 5 mm 0 02 0 06 in Excessive Pedal Travel Check 1 Peel off carpet dash silencer and start engine 2 Depress brake pedal a few times 3 With brake pedal depressed with appr...

Page 373: ... than limit all pads must be replaced at the same time Thickness d Service limit 2 0 mm 0 08 in Rear Brake Shoe Inspection Inspection should be carried out on the following points after brake pedal travel pedal to wall clearance check even when pedal travel is normal Amount of brake shoe wear can be checked as follows 1 Hoist vehicle 2 Remove rubber plug 1 from brake back plate 3 Through hole of b...

Page 374: ...n brake shoe has been replaced or brake drum has been removed for some other service Adjustment is automatically accomplished by pulling parking brake lever 2 to 3 times with approximately 20kg 44 lbs load after all parts are installed Then check brake drum for dragging and brake system for proper performance After lowering vehicle from hoist brake test should be performed Parking Brake Inspection...

Page 375: ... with about 10 kg 22 lbs load Parking brake lever has been pulled up a few times with about 20 kg force Rear brake shoes are not worn beyond limit After confirming that above conditions are all satisfied adjust parking brake lever stroke by loosening or tightening adjusting nut 1 Note Check brake drum for dragging after adjustment Parking brake stroke when lever is Within 4 9 notches pulled up at ...

Page 376: ...each brake wheel was removed the hydraulic brake system must be bled at all 4 wheel brakes Note Perform bleeding operation starting with wheel cylinder farthest from master cylinder and then at front caliper of the same brake line Do the same on the other brake line 1 Fill master cylinder reservoir with brake fluid and keep at least one half full of fluid during bleeding operation 2 Remove bleeder...

Page 377: ... dents and corrosion If any defect is found replace it Brake Fluid Level Inspection Be sure to use particular brake fluid either as indicated on reservoir cap of that vehicle or recommended in owner s manual which comes along with that vehicle Use of any other fluid is strictly prohibited Fluid level should be between MIN and MAX lines marked on reservoir When warning light lights sometimes during...

Page 378: ...reversing removal procedure nothing the following points For installation make sure that steering wheel is in straightforward position and flexible hose has not twist or kink Check to make sure that flexible hose doesn t contact any part of suspension both in extreme right and extreme left turn conditions If it does at any point remove and correct Fill and maintain brake fluid level in reservoir B...

Page 379: ...brake flexible hose or pipe by reversing removal procedure nothing the following points Fill and maintain brake fluid level in reservoir Bleed brake system 2 Perform brake test and check each installed part for fluid leakage Precaution For Installation Never reuse protector nut once removed Be sure to use a new one Install clamps properly referring to figure below and tighten bolts When installing...

Page 380: ...ever assembly 2 with equalizer 3 7 Remove console box bracket 4 from parking brake lever assembly Note Don t disassemble parking brake lever switch It must be removed and installed as a complete switch assembly Installation 1 Install in reverse order of REMOVAL procedure Tightening Torque a 25 N m 2 5 kg m 18 0 lb ft 2 After all parts are installed parking brake lever needs to be adjusted Refer to...

Page 381: ...ke back plate Refer to step 4 of BRAKE BACK PLATE REMOVAL in this section Note When it is necessary to remove both right and left parking brake cables repeat above steps 1 to 3 on right and left wheels 4 Remove cable from equalizer Parking Brake Cable 1 Parking brake lever assembly 2 Equalizer 3 Adjusting nut 4 Parking cable bracket 5 Parking brake cable Apply water tight sealant 99000 31090 to pl...

Page 382: ...Install brake cable spring 1 and nipple end 2 to parking brake shoe lever 3 securely as shown in figure 4 For brake shoe installation refer to steps 1 to 3 of BRAKE SHOE INSTALLATION of this section 5 For brake drum installation refer to steps 2 to 7 of BRAKE DRUM INSTALLATION of this section 6 For proper routing and secure clamping of parking brake cable 7 Install cable to equalizer 8 Upon comple...

Page 383: ... If lining is polished with sandpaper hard particles of sandpaper will be deposited in lining and may damage disc When pad lining requires correction replace it with a new one Pad thickness lining pad rim Standard 14 65 mm 0 58 in Limit 7 mm 0 28 in Note When pads are removed visually inspect caliper for brake fluid leak Correct leaky point if any Cylinder Slide Guide Pin Check guide pin for smoot...

Page 384: ... gauge as shown To measure deflection of disc take measurement at 2 points on its periphery and center with dial gauge while rotating it Limit on disc deflection 0 15 mm 0 006 in Special Tool A 09900M20606 B 09900M20701 Note Check front wheel bearing for looseness before measurement Installation Note See Note at the beginning of this section 1 Install pad springs 1 and pads 2 2 Install caliper and...

Page 385: ...from carrier 2 Disassembly Before disassembly clean all around caliper with brake fluid 1 Blow compressed air into cylinder through bolt hole where flexible hose was fitted With this air pressure piston can be pushed out of cylinder Warning Do not apply too highly compressed air which will cause piston to jump out of cylinder It should be taken out gradually with moderately compressed air Do not p...

Page 386: ...Reassemble front brake in reverse order of disassembly noting the following points Caution Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir Never use other fluid or thinner Before installing piston and piston seal to cylinder apply fluid to them After reassembling brake lines bleed air from them Piston Seal Piston seal is used to seal piston...

Page 387: ...e in cylinder with fingers 3 Insert piston into cylinder by hand and fit boot in boot groove in piston 4 To confirm that boot is fitted in its groove in cylinder properly pull piston out of cylinder a little but do not take it all out Note Boot s face B should be at the same level from cylinder s face A all around 5 Insert piston into cylinder by hand ...

Page 388: ...pecified torque Note Make sure that boots are fit into groove securely Tightening Torque a 27 N m 2 7 kg m 19 5 lb ft 3 Tighten flexible hose bolt to specified torque Tightening Torque b 23 N m 2 3 kg m 16 5 lb ft Warning Make sure that flexible hose is not twisted when tightening hose bolt If it is twisted reconnect it using care not to twist it 4 Install E ring to strut securely 5 Lower hoist 6 ...

Page 389: ... Pull brake disc off by using 8 mm bolts 1 Inspection Refer to BRAKE PAD INSPECTION Installation Note See Note at the beginning of this section 1 Install disc to wheel hub 2 Install caliper assembly to steering knuckle 3 Tighten caliper carrier bolts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 4 Tighten front wheel nuts to specified torque Tightening Torque b 85 N m 8 5 kg m...

Page 390: ...indle nut remove spindle nut 1 4 Release parking brake lever 5 Remove brake drum If brake drum can not be removed easily increase clearance between brake shoes and drum as follows a Remove console box and loosen parking brake cable adjusting nut 1 b Pull brake drum 1 off by hand If it is hard to remove use special tools Special Tool A 09942M15510 B 09943M17912 6 Remove wheel stud bolt by using hyd...

Page 391: ...bably be necessary to resurface drum braking surface If brake linings are slightly worn and drum is grooved drum should be polished with fine emery cloth but should not be turned Note When drum is removed visually inspect wheel cylinder for brake fluid leakage Correct leaky point if any Brake Shoe Where lining 1 is worn out beyond service limit replace shoes Brake lining thickness lining shoe rim ...

Page 392: ...to specified torque Tightening Torque a 175 N m 17 5 kg m 126 5 lb ft 6 Calk spindle nut 1 7 Install spindle cap Note When installing spindle cap hammer lightly several locations on the collar of cap until collar comes closely into contact with brake drum If fitting part of cap is deformed or damaged or if it is fitted loosely replace with a new one 8 Upon completion of all jobs depress brake peda...

Page 393: ...ke and parking brake Brake Shoe Removal 1 Perform steps 1 to 5 of BRAKE DRUM REMOVAL 2 Remove shoe hold down springs 1 by turning shoe hold down pins 2 3 Remove return springs brake shoes and strut 4 Disconnect parking brake cable 1 from parking brake shoe lever 2 5 Remove push nut 1 6 Remove parking brake shoe lever 2 from shoe rim 3 Inspection Parking Shoe Lever Inspect brake shoe lever for smoo...

Page 394: ...ound defective replace Brake Shoe Refer to BRAKE DRUM INSPECTION in this section Installation 1 Clean brake back plate and apply thin coat of grease to eight surfaces on which shoe rims rest A Bentonite base brake grease Anti squeal agent 2 Assemble parts as shown in reverse order of REMOVAL 3 Install shoe hold down springs 2 by pushing them down in place and turning hold down pins 1 4 For procedu...

Page 395: ...g 5 For procedure hereafter refer to steps 1 to 4 of BRAKE SHOE Installation Note Be sure to bleed brake system Refer to BLEEDING BRAKES in this section Wheel Cylinder Removal 1 Perform steps 1 to 5 of BRAKE DRUM REMOVAL 2 Perform steps 2 to 4 of BRAKE SHOE REMOVAL 3 Loosen brake pipe flare nut but only within the extent that fluid does not leak 4 Remove wheel cylinder mounting bolts 1 Disconnect ...

Page 396: ...VAL in this section 4 Remove parking brake cable securing clip 3 and disconnect brake cable 2 from brake back plate 1 5 Remove brake back plate 1 from rear axle Installation 1 Apply water tight sealant to mating surfaces of brake back plate and rear axle A Sealant 366E 99000 31090 2 Install brake back plate and tighten back plate bolts to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 l...

Page 397: ...tion 7 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to BLEEDING BRAKES in this section 8 Install wheel and tighten wheel nuts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 9 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load three to five times so as to obtain proper drum to shoe clearance Adjust parking brake ca...

Page 398: ...e fluid to get on painted surfaces 4 Remove attaching nuts 5 5 Remove master cylinder Do not reuse 1 Master cylinder reservoir cap 2 Master cylinder reservoir 3 Grommet Apply brake fluid 4 Master cylinder body Apply brake fluid to inside of cylinder 5 Secondary piston return spring Apply brake fluid 6 Secondary piston Apply brake fluid 7 Primary piston return spring Apply brake fluid 8 Primary pis...

Page 399: ...wall and by tapping flange with a piece of wood or something soft Inspection Inspect all disassembled parts for wear or damage and replace parts if necessary Note Wash disassembled parts with specified brake fluid Do not reuse piston assembly Inspect master cylinder bore for scoring or corrosion It is best to replace corroded cylinder Corrosion can be identified as pits or excessive roughness Note...

Page 400: ...sert secondary piston 2 and next primary piston 1 into cylinder body Be sure to install piston cup in correct installation direction and straight into cylinder so that it is not caught 2 Install stopper cap 1 While holding piston with a new stopper cap push it in as far as groove in cylinder and check that claw of stopper cap is caught in cylinder groove securely Be sure to use a new stopper cap 3...

Page 401: ...ified torque Tightening Torque b 16 N m 1 6 kg m 12 0 lb ft 3 Connect reservoir lead wire at coupler 4 Fill reservoir with specified brake fluid to MAX line Caution Do not use shock absorber fluid or any other fluid which contains mineral oil Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and lowering fluid boiling point 5 After installing check brake peda...

Page 402: ...d gasket 6 as shown Caution Never disassemble brake booster Disassembly will spoil its original function If faulty condition is found replace it with a new one Inspection and Adjustment Booster Piston Rod and Master Cylinder Piston Clearance The length of booster piston rod is adjusted to provide specified clearance a between piston rod end and master cylinder piston Before measuring clearance pus...

Page 403: ...distance between piston rod and mating surface of booster to master cylinder Length of piston rod c 10 1 10 4 mm 0 40 0 41 in 2 If measurement is out of specified value adjust depth by turning adjusting screw of piston rod Special Tool A 09952M16030 ...

Page 404: ...b ft 5 Connect booster push rod clevis to pedal arm with clevis pin 5 and clip 6 6 Connect stop light switch coupler 7 7 Install master cylinder to booster and then connect brake pipes and tighten flare nuts to specified torque Refer to MASTER CYLINDER ASSEMBLY in this section 8 Connect booster vacuum hose 8 9 Connect reservoir lead wire at coupler 10 Fill reservoir with specified fluid 11 Bleed a...

Page 405: ...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 4 If pedal travel doesn t change air tightness isn t obtained Note If defective inspect vacuum lines and sealing parts and replace any faulty part When this has bee...

Page 406: ...isfactory But no change in pedal travel indicates malfunction Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed 2 Hold brake pedal depressed for 30 seconds If pedal height does not change condition is good But it isn t if pedal rises ...

Page 407: ...ts of master cylinder caliper and wheel cylinder when they are disassembled To apply to mating surfaces of brake back plate and SEALING COMPOUND 366E rear axle Water tight sealant 99000 31090 To apply to mating surfaces of brake back plate and parking brake cable Hydrocarbon base brake To coat thinly to surface on which shoe rims rest Anti squeal agent grease Special Tools ...

Page 408: ...One connects front right rear left brakes and the other connects front left rear right brakes The proportioning valve P valve is included in these circuits between the master cylinder and rear wheels In this brake system the disc brake type is used of 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 ...

Page 409: ...with brake fluid indicated on reservoir tank cap do not use or mix different type of fluid when refilling otherwise serious damage will occur Do not use old or used brake fluid or any fluid from a unsealed container Diagnosis Substandard or Contaminated Brake Fluid Improper brake fluid mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic sys...

Page 410: ...ined with oil in some brakes Drum to shoe clearance out of Check for inoperative auto adjustment in some brakes adjusting mechanism Malfunctioning auto adjusting mechanism Disc and or drum is out of round in some Replace brakes Wheel tires are inflated unequally Inflate equally Malfunctioning wheel cylinders epair or replace Disturbed front end alignment Adjust as prescribed Unmatched tires on sam...

Page 411: ...rag is correctly Check for soft hoses or damaged present in all Restricted brake pipes or hoses pipes and replace with new hoses brakes immediately and or new brake pipes after pedal is Incorrect parking brake adjustment on Check and adjust to correct released rear brakes specifications Weakened or broken return springs in the brake Replace Sluggish parking brake cables Repair or replace Wheel cyl...

Page 412: ...y Repair circuit Brake warning light Brake fluid leaking from brake line Investigate leaky point correct it turns on when and add brake fluid brake is applied Insufficient amount of brake fluid Add brake fluid Brake warning light Brake warning light circuit faulty Replace bulb or repair circuit fails to turn on even when parking brake is applied ABS warning lamp Malfunctioning ABS Check system ref...

Page 413: ...nd each brake wheel was removed the hydraulic brake system must be bled at all 4 wheel brakes Note Perform bleeding operation starting with wheel cylinder farthest from master cylinder and then at front caliper of the same brake line Do the same on the other brake line 1 Fill master cylinder reservoir with brake fluid and keep at least one half full of fluid during bleeding operation Brake Fluid G...

Page 414: ...racks dents and corrosion If any defect is found replace it Brake Fluid Level Inspection Be sure to use particular brake fluid either as indicated on eservoir cap of that vehicle or recommended in owner s manual which comes along with that vehicle Use of any other fluid is strictly prohibited Fluid level should be between MIN and MAX lines marked on reservoir When warning light lights sometimes du...

Page 415: ...utes 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 4 If pedal travel doesn t change air tightness isn t obtained Note If defective inspect vacuum lines and sealing parts and replace any faulty part When this ...

Page 416: ... satisfactory But no change in pedal travel indicates malfunction Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed 2 Hold brake pedal depressed for 30 seconds If pedal height does not change condition is good But it isn t if pedal rises ...

Page 417: ...lush it with water immediately if any fluid is spilled 4 Remove brake flexible hose or pipe Installation Reverse brake flexible hose installation procedure noting the followings Make sure that steering wheel is in straight forward position and flexible hose has not twist or kink Check to make sure that flexible hose doesn t contact any part of suspension both in extreme right and extreme left turn...

Page 418: ...BRAKES WITH ABS 4A 11 f a b c d e a b a b c e f d 1 2 6 5 4 7 8 3 ...

Page 419: ...aged by brake fluid flush it with water immediately if any fluid is spilled 4 Remove brake flexible hose or pipe Installation Reverse brake flexible hose installation procedure noting the followings Fill and maintain brake fluid level in reservoir Bleed brake system Refer to AIR BLEEDING OF BRAKE SYSTEM in this section Perform brake test and check each installed part for fluid leakage Install clam...

Page 420: ...BRAKES WITH ABS 4A 13 ...

Page 421: ...specified Do not use lubricated shop air on brake parts as damage to rubber components may result If any component is removed or line disconnected bleed the brake system Replace pads in axle sets only The torque values specified are for dry unlubricated fasteners ...

Page 422: ...dpaper If lining is polished with sandpaper hard particles of sandpaper will be deposited in lining and may damage disc When pad lining requires correction replace it with a new one Pad thickness lining pad rim Standard 14 65mm 0 58 in Limit 7 mm 0 28 in Note When pads are removed visually inspect caliper for brake fluid leak Correct leaky point if any Cylinder Slide Guide Pin Check guide pin for ...

Page 423: ...uge as shown To measure deflection of disc take measurement at 2 points on its periphery and center with dial gauge while rotating it Limit on disc deflection 0 15 mm 0 006 in max Special Tool A 09900M20606 B 09900M20701 NOte Check front wheel bearing for looseness before measurement Installation Caution Observe Caution at the beginning of this section 1 Install pad springs 1 and pads 2 2 Install ...

Page 424: ...iper from carrier 2 Disassembly Before disassembly clean all around caliper with brake fluid 1 Blow compressed air into cylinder through bolt hole where flexible hose was fitted With this air pressure piston can be pushed out of cylinder Warning Do not apply too highly compressed air which will cause piston to jump out of cylinder It should be taken out gradually with moderately compressed air Do ...

Page 425: ...e If defective replace Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth return of the piston In such a case replace rubber seal Caliper pin Before installing caliper cylinder body to carrier check to ensure that pin can be moved smoothly in thrust direction Note Where temperature gets as low as 30 C 22 F in cold weather use rubber grease whose viscosity varies very little e...

Page 426: ... fluid to them After reassembling brake lines bleed air from them Piston Seal Piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc Replace with a new one at ever overhaul Fit piston seal into groove in cylinder taking care not to twist it Piston and Boot 1 Before inserting piston 2 into cylinder install boot 1 onto piston as shown 2 Fit boot as it is in figu...

Page 427: ...ecified torque Note Make sure that boots are fit into groove securely Tightening Torque a 27 N m 2 7 kg m 19 5 lb ft 3 Tighten flexible hose bolt to specified torque Tightening Torque b 23 N m 2 3 kg m 16 5 lb ft Warning Make sure that flexible hose is not twisted when tightening hose bolt If it is twisted reconnect it using care not to twist it 4 Install E ring to strut securely 5 Lower hoist 6 T...

Page 428: ...AD in this section 3 Pull brake disc off by using 8 mm bolts 1 Inspection Refer to BRAKE PAD INSPECTION in this section Installation 1 Install disc to wheel hub 2 Install caliper assembly to steering knuckle 3 Tighten caliper carrier bolts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 4 Tighten front wheel nuts to specified torque Tightening Torque b 85 N m 8 5 kg m 61 5 Ib ft...

Page 429: ...s 1 Brake back plate Apply sealant 366E 99000 31090 to joint seam of brake back plate and rear axle 2 Brake shoe 3 Push nut 4 Shoe hold down spring 5 Shoe return spring 6 Shoe hold down pin 7 Brake strut 8 Wheel cylinder Apply brake fluid to piston cup 9 Bleeder plug 10 Bleeder plug cap 11 Parking lever spring 12 Parking brake shoe lever 13 Brake drum 14 Spindle nut Caulk spindle nut after tighten...

Page 430: ...lk spindle nut remove spindle nut 1 4 Release parking brake lever 5 Remove brake drum If brake drum can not be removed easily increase clearance between brake shoes and drum as follows a Remove console box and loosen parking brake cable adjusting nut 1 b Pull brake drum 1 off by hand If it is hard to remove use special tools Special Tool A 09942M15510 B 09943M17912 6 Remove wheel stud bolt by usin...

Page 431: ...le nut to specified torque Tightening Torque a 175 N m 17 5 kg m 126 5 lb ft 6 Calk spindle nut 1 7 Install spindle cap Note When installing spindle cap hammer lightly several locations on the collar of cap until collar comes closely into contact with brake drum If fitting part of cap is deformed or damaged or if it is fitted loosely replace with a new one 8 Upon completion of all jobs depress bra...

Page 432: ...l probably be necessary to resurface drum braking surface If brake linings are slightly worn and drum is grooved drum should be polished with fine emery cloth but should not be turned Note When drum is removed visually inspect wheel cylinder for brake fluid leakage Correct leaky point if any Brake Shoe Where lining 1 is worn out beyond service limit replace shoes Brake lining thickness lining shoe...

Page 433: ... parking brake Brake Shoe Removal 1 Remove brake drum referring to BRAKE DRUM REMOVAL in this section 2 Remove shoe hold down springs 1 by turning shoe hold down pins 2 3 Remove return springs brake shoes and strut 4 Disconnect parking brake cable 1 from parking brake shoe lever 2 5 Remove push nut 1 6 Remove parking brake shoe lever 2 from shoe rim 3 Inspection Parking Shoe Lever Inspect brake sh...

Page 434: ... arrow for rust If found defective replace Brake Shoe Refer to BRAKE DRUM INSPECTION in this section Installation 1 Clean brake back plate and apply thin coat of grease to eight surfaces on which shoe rims rest A Brake grease Anti squeal agent 2 Assemble parts as shown in reverse order of REMOVAL 3 Install shoe hold down springs 2 by pushing them down in place and turning hold down pins 1 4 Instal...

Page 435: ...el cylinder bleeder plug cap 2 onto pipe to prevent fluid from spilling Inspection Inspect wheel cylinder disassembled parts for wear cracks corrosion or damage Note Clean wheel cylinder components with brake fluid Installation 1 Take off bleeder plug cap from brake pipe and connect pipe for pipes to wheel cylinder just enough to prevent fluid from leaking 2 Tighten wheel cylinder 1 to brake back ...

Page 436: ...ve brake shoes referring to steps 2 to 4 of BRAKE SHOE REMOVAL in this section 3 Remove wheel cylinder referring to steps 3 to 4 of WHEEL CYLINDER REMOVAL in this section 4 Remove parking brake cable securing clip 3 and disconnect brake cable 2 from brake back plate 1 5 Remove brake back plate 1 from rear axle Installation 1 Apply water tight sealant to mating surfaces of brake back plate and rear...

Page 437: ... INSTALLATION in this section 7 Fill reservoir with brake fluid and bleed brake system referring to BLEEDING BRAKES in this section 8 Install wheel and tighten wheel nuts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 9 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load three to five times so as to obtain proper drum to shoe clearance Adjust parking br...

Page 438: ...ster 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 ...

Page 439: ...ng nuts 5 5 Remove master cylinder Disassembly 1 Remove reservoir pin 1 that fixes cylinder body and reservoir by using special tool Special Tool A 09922M89810 2 Remove reservoir and 2 grommets Remove secondary piston stopper pin 1 from master cylinder by pushing primary piston 3 Insert flat head rod or the like under each claw of stopper cap 1 straighten it and remove stopper cap As piston in mas...

Page 440: ...lace corroded cylinder Corrosion can be identified as pits or excessive roughness Note Polishing bore of master cylinder with cast aluminum body with 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 cannot be kept from cylinder bore surfaces Assembl...

Page 441: ...ole 4 in master cylinder body 5 and install piston stopper pin 1 with pistons pushed in all the way 2 Install stopper cap 1 While holding piston with a new stopper cap push it in as far as groove in cylinder and check that claw of stopper cap is caught in cylinder groove securely Be sure to use a new stopper cap 3 Apply thin coat of brake fluid to all around new grommets 2pcs and install them to c...

Page 442: ...d torque Tightening Torque b 16 N m 1 6 kg m 12 0 lb ft 3 Connect reservoir lead wire at coupler 4 Fill reservoir with specified brake fluid to MAX line Caution Do not use shock absorber fluid or any other fluid which contains mineral oil Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and lowering fluid boiling point 5 Check brake pedal play referring to B...

Page 443: ...h coupler c Remove brake pedal bracket 5 with brake pedal and stop light switch 4 d For ease of installation make marking 6 on clevis lock nut position of push rod thread e Remove push rod clevis 3 from push rod if clevis obstructs booster removal f Remove engine hook and A C hose clamp if necessary 4 Remove booster mounting nuts and then remove booster Inspection And Adjustment Booster Piston Rod...

Page 444: ...nut 3 and clevis 2 to push rod aligning lock nut end surface with marking made in removal 2 Check measurement between booster mounting surface 1 without packing and center 2 of clevis pin hole Measurement a 97 0 98 0 mm 3 82 3 86 in If it is out of specification loosen clevis lock nut 3 and adjust measurement to specification by turning clevis 3 Tighten clevis lock nut to specified torque with hol...

Page 445: ...uts to specified torque Tightening Torque b 13 N m 1 3 kg m 9 5 Ib ft f Connect booster push rod clevis to pedal arm with clevis pin 6 and clip 7 g Connect stop light switch coupler 2 Install master cylinder to booster referring to MASTER CYLINDER ASSEMBLY INSTALLATION in this section 3 Connect booster vacuum hose 8 4 Connect reservoir lead wire at coupler 5 Fill reservoir with specified fluid 6 F...

Page 446: ... apply to inner parts of master cylinder caliper and wheel cylinder when they are disassembled To apply to mating surfaces of brake SEALING COMPOUND 366E back plate and rear axle Water tight sealant 99000 31090 To apply to mating surfaces of brake back plate and parking brake cable Hydrocarbon base brake To coat thinly to surface on which Anti squeal agent grease shoe rims rest ...

Page 447: ......

Page 448: ...ere injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM Note All brake fastners are important attaching parts in that they could affect the performance of vital parts and syste...

Page 449: ... system Wheel speed sensor which senses revolution speed of each wheel and outputs its signal ABS warning lamp which lights to inform abnormality when system fails to operate properly ABS hydraulic unit control module assembly is incorporated ABS control module ABS hydraulic unit actuator assembly fail safe relay and pump motor relay ABS control module which sends operation signal to ABS hydraulic...

Page 450: ...ANTILOCK BRAKE SYSTEM 4B 3 System Schematic ...

Page 451: ...mp lights for 2 seconds to check its bulb and circuit 2 When no abnormality has been detected the system is in good condition ABS warning lamp turns OFF after 2 seconds 3 When an abnormality in the system is detected ABS warning lamp lights and the area where that abnormality lies is stored in the memory of EEPROM in ABS control module 4 For procedure to clear all DTC s refer to DIAGNOSTIC TROUBLE...

Page 452: ...ANTILOCK BRAKE SYSTEM 4B 5 System Circuit ...

Page 453: ...RN Black Orange LT GRN RED Light Green RED WHT BLK White Black BLK RED Black Red ORN Orange WHT BLU White Blue BLU Blue PNK Pink WHT GRN White Green BLU ORN Blue Orange PNK Orange Pink Green WHT RED White Red BRN Brown RED Red YEL Yellow GRN Green RED BLK Red Black VIO WHT Violet Green GRN WHT Green White RED WHT Red White GRN ORN Green Orange RED BLU Red Blue TERMINAL COLOR CIRCUIT 1 Blank 2 Y Ri...

Page 454: ...ing Wheel s was rotated while the vehicle was jacked up Be sure to read PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE in Section 0A before inspection and observe what is written there Be sure to use the trouble diagnosis procedure as described in the flow table Failure to follow the flow table may result in incorrect diagnosis Some other diagnosis trouble code may be stored by mistake in the memory o...

Page 455: ...n code 4 1 Inspect and repair referring to applicable Go to Step 7 End diagnostic trouble code table in this section 2 Perform FINAL CONFIRMATION TEST after cleared DTC Does trouble recur 5 1 Inspect and repair referring to DIAGNOSIS in BRAKES section 2 Perform FINAL CONFIRMATION TEST 6 1 Check intermittent troubles referring to Go to Step 7 End INTERMITTENT AND POOR CONNECTION in GENERAL INFORMAT...

Page 456: ...h other_______________ Vehicle at stop ignition switch ON When starting at initial start only at every start Other_____________ Vehicle speed while accelerating while decelerating at stop Conditons for while turning while running at constant speed Occurrence of Problem other_____________________ Road surface condition Paved road rough road snow covered road other__________________ Chain equipment ...

Page 457: ...necessary Proceed to Step 3 3 DIAGNOSTIC TROUBLE CODE CHECK Recheck diagnostic trouble code referring to DTC CHECK as shown in the following page 4 DIAGNOSTIC TROUBLE CODE FLOW TABLE According to Diagnostic flow table for the diagnostic trouble code confirmation in Step 3 locate the cause of the trouble namely in a sensor switch wire harness connector actuator assembly or other part and repair or ...

Page 458: ... SYSTEM 4B 11 ABS Warning Lamp Check 1 Turn ignition switch ON 2 Check that ABS warning lamp 1 comes ON for about 2 seconds and then goes off If any faulty condition is found advance to Diagnostic Flow Table A B or C ...

Page 459: ...module Also it is turned ON continuously by lamp driver module when the connector of ABS control module is disconnected Inspection Step Action Yes No 1 1 Turn ignition switch ON Go to Step 2 Go to Step 4 Do other warning lamp come ON 2 1 Disconnect ABS hydraulic unit control Substitute a known good Go to Step 3 module connector ABS hydraulic unit control Does ABS warning lamp light with ignition m...

Page 460: ...roper connection to ABS hydraulic unit control module connector at terminals E19 10 E19 20 E19 14 and E19 01 3 If OK then ignition switch ON and measure voltage at terminal E19 20 of connector Is it 10 14 V 4 1 With ABS hydraulic unit control module Go to Step 5 RED BLU circui connector disconnected turn ignition switch open If wire and ON and light ABS warning lamp connections are OK 2 Connect te...

Page 461: ...e Is it in good condition assembly and recheck Diagnostic Trouble Code DTC Check Using Suzuki Scan Tool 1 After setting cartridge for ABS to SUZUKI scan tool connect SUZUKI scan tool to data link connector 1 Special tool A SUZUKI scan tool 99000M24120 426 2 Turn ignition switch ON 3 Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down Refer to SUZUKI scan ...

Page 462: ...tor in the same manner as when making this connection for DTC check 2 Turn ignition switch to ON position 3 Erase DTC according to instructions displayed on scan tool Refer to scan tool operator s manual for further derails Note For DTC C 1021 C1022 C1025 C1026 C1031 C1032 C1035 C1036 and C1061 confirm that ABS warning lamp turns off after performing Step 2 of Test Driving under ABS Check and then...

Page 463: ... wheels Ignition switch ON Turn OFF air conditioner if equipped Apply no load to power steering if equipped Don t turn it Turn OFF all electric loads except ignition No DTC ABS is not operated Normal braking operation Scan Tool Standards Condition Data Battery 10 0 16 0 V Voltage Pump Motor 0 0 V Driver RF Wheel 0 km h 0 0 MPH Vehicle stop Speed LF Wheel 0 km h 0 0 MPH Vehicle stop Speed RR Wheel ...

Page 464: ...R C1022 RF C1026 LF Wheel speed sensor circuit C1032 RR or sensor rotor failure C1036 LR C1041 RF Inlet solenoid valve circuit C1042 RF Outlet solenoid valve circuit C1045 LF Inlet solenoid valve circuit C1046 LF Outlet solenoid valve circuit C1051 RR Inlet solenoid valve circuit C1052 RR Outlet solenoid valve circuit C1055 LR Inlet solenoid valve circuit C1056 LR Outlet solenoid valve circuit C10...

Page 465: ...pplicable DTC will be set Also when no sensor signal is inputted at starting or while running an applicable DTC will be set Note When the vehicle was operated in any of the following ways one of these DTCs may be set even when the sensor is in good condition If such possibility is suspected repair the trouble dragging of brake etc of the vehicle clear DTC once and then after performing the driving...

Page 466: ...ding sensor This check result should be the same as above Step 1 Either terminal of wheel speed sensor coupler and body ground This check result should be no continuity Are both check results OK 4 1 Remove applicable ABS wheel speed sensor Go to Step 5 Clean repair or 2 Check sensor for damage or foreign material replace attached Is it in good condition 5 Check front and or rear sensor rotor for t...

Page 467: ...n switch OFF Substitute a known WHT BLU or BLK 2 Disconnect ABS hydraulic unit control module good ABS hydraulic circuit open connector unit control module 3 Check for proper connection to ABS hydraulic assembly and unit control module connector at terminal recheck E19 13 4 If OK then measure voltage between terminal E19 13 of module connector and E19 14 or E19 01 Is it 10 14 V DTC C1041 Right Fro...

Page 468: ...p 2 terminal and body ground referring to CHARGING 2 Start the engine and measure the maximum SYSTEM section voltage when racing the engine Is it over 18V 2 1 Disconnect ABS hydraulic unit control module Check charging system Poor connection of connector referring to CHARGING terminal Terminal E19 20 2 Keep the engine idling measure the voltage SYSTEM section E19 14 or E19 01 between terminal E19 ...

Page 469: ...N CHECK and E19 26 connection in this section If connections OK Is it in good condition substitute a known good ABS hydraulic unit control module assembly and recheck 2 1 Ignition switch OFF Go to Step 3 WHT BLU circuit 2 Disconnect ABS hydraulic unit control module open connector 3 Check for proper connection to ABS hydraulic unit control module connector at terminal E19 26 4 If OK then measure v...

Page 470: ... switch turned ON this DTC will be set Installation Step Action Yes No 1 Check battery voltage Is it about 11 V or Go to Step 2 Check charging higher system referring to CHARGING SYSTEM section 2 Check ABS main fuse and connection Go to Step 3 Repair and or Is it in good condition replace fuse 3 1 Ignition switch OFF Substitute a known good GRN circuit 2 Disconnect ABS hydraulic unit control modul...

Page 471: ...ld be a temporary Is it DTC 71 malfunction of the ABS control module 2 1 Check proper connection of ABS hydraulic Replace ABS hydraulic Repair and recheck unit control module connector unit control module 2 If OK disconnect ABS hydraulic unit control assembly module connector and check the followings Voltage E19 13 terminal 10 14 V Resistance between E19 01 or E19 14 and body ground Continuity Are...

Page 472: ...tion switch OFF Special tool A SUZUKI scan tool 99000M24120 426 7 Turn ignition switch to ON position and select menu to HYDRAULIC CONTROL TEST under miscellaneous test MISC TEST mode of Suzuki scan tool 8 Perform the following checks with help of another person Brake pedal 1 should be depressed and then select testing wheel by SUZUKI scan tool and the wheel 2 should be turned by another person s ...

Page 473: ...se prohibited services will affect original performance of ABS hydraulic unit control module assembly Hydraulic Unit Inspection Check hydraulic unit for fluid leakage if any repair or replace Removal 1 Disconnect negative cable from battery 2 Disconnect ABC hydraulic unit control module assembly connector 1 by pulling up lock 2 16 N m 1 6kg m 16 N m 1 6kg m 4 1 1 9 N m 0 9kg m 9 N m 0 9kg m 3 2 ...

Page 474: ...erformance Installation 1 Install hydraulic unit control module assembly by reversing removal procedure Tightening torque Brake pipe flare nut a 16 N m 1 6 kg m 11 5 lb ft ABS hydraulic unit control module assembly bolt b 9 N m 0 9 kg m 6 5 lb ft ABS hydraulic unit control module assembly bracket bolt c 23 N m 2 3 kg m 16 5 lb ft 2 Bleed air from brake system referring to BRAKES section 3 Check ea...

Page 475: ...el speed sensor connector 4 Connect voltmeter between connector 1 terminals 5 While turning wheel by hand at a speed of approximately 1 2 to 1 rotation per second check AC voltage of sensor Output AC voltage at 1 2 to 1 rotation per second 106 mV or more 6 If measured voltage is not as specified check sensor rotor and their installation conditions ...

Page 476: ...heel 4 Remove harness clamp bolts 2 5 Remove front wheel speed sensor 3 from knuckle Caution Do not pull wire harness when removing front wheel speed sensor Do not cause damage to surface of front wheel speed sensor and do not allow dust etc to enter its installation hole Sensor Inspection Check sensor for damage Check sensor for resistance and continuity Between both terminals 1 of sensor 1 2 1 6...

Page 477: ... Front Wheel Speed Sensor Rotor Sensor Rotor Inspection Check rotor for being missing damaged or deformed Turn drive shaft and check if ring rotor is free from eccentricity and looseness Check that no foreign material is attached If any faulty is found repair or replace Refer to DRIVE SHAFT ASSEMBLY in SECTION 3A Note The front wheel sensor rotor can not be removed or replaced alone If front wheel...

Page 478: ...onnector of wheel speed sensor 6 Connect voltmeter between connector 1 terminals 7 While turning wheel at a speed of approximately 1 2 to 1 rotation per second check AC voltage of sensor Output AC voltage at 1 2 to 1 rotation per second 85 mV or more 8 If measured voltage is not as specified check sensor rotor and their installation conditions Rear Wheel Speed Sensor ...

Page 479: ...suspension frame 3 Note Do not detach clip of rear wheel speed sensor connector from vehicle body unless replacement is necessary 7 Remove rear wheel speed sensor 4 from rear axle housing Caution Do not pull wire harness when removing rear wheel speed sensor Do not cause damage to surface of rear wheel speed sensor and do not allow dust etc to enter its installation hole Sensor Inspection Check se...

Page 480: ... Be sure to install wheel speed sensor 2 and its bolt at the correct upper position as shown in figure Tighten sensor bolt to specified torque Tightening torque Sensor bolt a 11 N m 1 1 kg m 8 0 lb ft Caution Do not pull or twist wire harness more than necessary when installing rear wheel speed sensor Check that there is no clearance between sensor and rear axle shaft ...

Page 481: ... gradually and evenly Attempt to pull it out partially may cause it to be deformed Sensor Rotor Inspection Check rotor serration teeth for being missing damaged or deformed Turn wheel and check if rotor rotation is free from eccentricity and looseness Check that no foreign material is attached If any fault is found repair or replace Installation Note Do not reuse Reinstall removed sensor rotor 1 I...

Page 482: ...ANTILOCK BRAKE SYSTEM 4B 35 2 Install brake drum Refer to SECTION 5 3 Install rear wheel speed sensor 1 to rear axle housing Tightening torque Rear wheel speed sensor a 11 N m 1 1kg m 8 0 lb ft ...

Page 483: ...s the following items and substitutes for the Tech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case 12 Power supply ...

Page 484: ...ub Assembly Service 5B 17 Right case 5B 17 Left case 5B 18 Input shaft assembly 5B 18 Countershaft assembly 5B 21 Gear shifter 5B 24 5B Differential assembly 5B 26 Assembling Unit 5B 28 Differential to left case 5B 28 Fifth gear 5B 31 Gear shift select shaft assembly 5B 34 Required Service Materials 5B 35 SpecialTools 5B 36 Clutch 5C 1 General Description 5C 1 Diagnosis 5C 2 On Vehicle Service 5C ...

Page 485: ......

Page 486: ...iption The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shafts input shaft countershaft and reverse gear shaft All forward gears are in constant mesh and reverse uses a sliding idler gear arrangement ...

Page 487: ...2 5B MANUAL TRANSMISSION ...

Page 488: ...rectly shifted from 5th to reverse Gear Shift Mechanism Movement of gear shift control lever is transmitted to gear shift shaft through gear shift control shaft and gear shift select shaft through gear shift arm and gear shift yoke and then gear shift select lever to each gear shift yoke shaft and fork or arm Gear shift interlock plate is provided to prevent the gear from engaging double ...

Page 489: ...to neutral is available and further shift to reverse is interrupted However when shift select shaft 1 is moved to neutral of 3rd 4th position shift limit cam mechanism is canceled as shown in figure 3 Selected position in neutral of 5th REV is shown in figure While shift select shaft 1 moves up to allow shift select lever 5 to shift in 5th or reverse position shift cam 2 stays because of interfere...

Page 490: ...eve and gear Hard shifting Inadequate lubricant Replenish Improper clutch pedal free travel Adjust Distorted or broken clutch disc Replace Damaged clutch pressure plate Replace clutch cover Worn synchronizer ring Replace Worn chamfered tooth on sleeve or gear Replace sleeve or gear Worn gear shift control shaft joint bush Replace Distorted shift shaft Replace Noise Inadequate or insufficient lubri...

Page 491: ...9000 31110 TighteningTorque a 21 N m 2 1 kg m 15 5 lb ft 4 Fill new specified oil by specified amount up to level hole Note It is recommended to use API GL 4 75W 90 gear oil Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage Oil specification API GL 4 For SAE classification refer to viscosity chart at the left Oil capacity 2 1 liters 4 5 3 ...

Page 492: ...using flat end rods or the like pull out drive shaft joint so as to release snap ring fitting of joint spline at differential side Pushing knuckle portion outward detach drive shaft at differential side 7 Remove oil seal and install a new one until it becomes flush with case surface by using special tool and hammer Note When installing oil seal face its spring side inward SpecialTool A 09913M75810...

Page 493: ...h hammer or the like Nothing but hands is allowed to use when inserting joint 10 Connect ball stud with knuckle and fasten with bolt to specification refer to Section 2B 11 Connect tie rod end with knuckle and fasten castle nut to specified torque refer to Section 2B Install split pin and bend it 12 Install stabilizer mount brackets fasten bolts to specified torque referring to Section 2B 13 Fill ...

Page 494: ...MANUAL TRANSMISSION 5B 9 Gear Shift Control Lever and Rod ...

Page 495: ...ing or sliding portions 2 If knob has been removed from lever apply thread lock cement and then install knob to control lever Make sure that knob is aligned with lever 3 Install control lever assembly and related parts as they were Note Do not apply grease to extension rod bush of transmission end Apply grease to gear shift control shaft bushes Make sure that boots are installed correctly Note Che...

Page 496: ...e by using lifting device On Lift 7 Drain transmission oil referring to OIL CHANGE of ON VEHICLE SERVICE in this section 8 Remove left and right drive shaft referring to Section 3A 9 Remove engine left mounting 1 with bracket 2 10 Remove engine rear mounting No 1 bracket 3 with No 2 bracket 4 and then engine rear mounting 5 11 Remove clutch housing lower plate 12 Lower vehicle and support transmis...

Page 497: ...f dismounting procedure noting the following Push n drive shaft joints right left fully so as to snap ring of shaft engages with differential gear Set each clamp for wiring securely After connecting clutch cable be sure to adjust its play properly Refer to SECTION 5C Fill transmission with oil as specified Connect battery and check function of engine clutch and transmission Tighten bolts and nuts ...

Page 498: ...06107 Note Use of magnet would facilitate removal of guide ball 3 Drive out spring pin 1 by using special tool and hammer SpecialTool B 09922M85811 4 Remove gear shift fork 1 sleeve hub assembly 2 synchronizer ring spring synchronizer ring and 5th gear all together Caution Be careful not to pinch synchronizer ring spring when removing 5 Remove counter shaft nut 5 as follows a Tap the fork using a ...

Page 499: ...Countershaft 1 Remove 3 bolts from left case cap and then take off cap 2 Remove gear shift yoke bolt 1 3 Remove 3 gear shift fork shaft bolts 1 with washers then take out locating springs and steel balls 4 Remove 4 bolts from gear shift guide case 2 and then remove wiring harness clamp bracket and guide case 5 Remove gear shift interlock bolt 3 with washer 6 Remove back up light switch 4 Note Remo...

Page 500: ...ke off reverse idler gear 3 13 Remove gear shift locating bolts ball and spring 14 Pull out 5th REV gear shift guide shaft 4 together with 5th REV gear shift shaft 5 15 Remove differential assembly 16 Tapping input shaft 1 end with plastic hammer push it out as assembly from case a little then take out input shaft assembly counter shaft assembly 2 high speed gear shift shaft 3 and low speed gear s...

Page 501: ...o pull out countershaft R bearing cup 2 by using bearing remover 09941 64511 with sliding shaft 09930 30102 Note If input shaft R bearing has been left in right case pull it out by using bearing remover 09923M73210 with sliding shaft 09930M30102 5 Remove bolt 1 and then pull out gear shift arm 2 6 Remove gear shift shaft bolt 1 with washer 2 then take out spring 3 and steel ball 4 7 Remove gear sh...

Page 502: ... and install it up to bottom of the bore by using special tool and hammer B SUZUKI SUPER GREASE A 99000 25010 SpecialTool D 09925M58210 4 Install gear shift shaft 1 boot 2 steel ball spring and tighten bolt 3 with washer applied with sealant C SUZUKI BOND NO 1215 99000 31110 TighteningTorque a 13 N m 1 3 kg m 9 5 lb ft Note Bring breather of gear shift shaft boot downward 5 Install differential si...

Page 503: ...hread lock 1322 99000 32110 TighteningTorque a 10 N m 1 0 kg m 7 5 lb ft 2 Install differential side L oil seal 1 until it becomes flush with case surface by using special tool with hammer and then apply grease to its lip Note Face oil seal spring side inward B SUZUKI SUPER GREASE A 99000 25010 SpecialTool A 09913M75510 3 Install countershaft L bearing cup into case bore by tapping it with plastic...

Page 504: ...07 5 Drive out high speed synchronizer sleeve hub assembly 1 together with 3rd gear 2 by using puller 3 and press Caution Make sure to use flat side of puller to avoid causing damage to 3rd gear tooth 6 Take out 3rd gear needle bearing from shaft 7 Disassemble synchronizer sleeve hub assembly 1 Inspection and Reassembly 1 Clean all components thoroughly inspect them for any abnormality and replace...

Page 505: ...21 6 Install 3rd gear needle bearing apply oil to it then install 3rd gear 1 and synchronizer ring 2 7 Drive in high speed sleeve hub assembly 3 by using special tool and hammer Note While press fitting sleeve hub 3 make sure that synchronizer ring key slots are aligned with keys in sleeve hub assembly Check free rotation of 3rd gear 1 after press fitting sleeve hub assembly 3 Needle bearings and ...

Page 506: ...3 and press Caution Use puller and press that will bear at least 5 ton 11 000 lb safely To avoid tooth damage support 4th gear at flat side of puller 2 Apply puller 1 to 2nd gear 2 and drive out 3rd 4th gear spacer 3 together with 2nd gear 2 by using press Needle bearing would come out with 2nd gear 2 Caution If compression exceeds 5 ton 11 000 lb release compression once reset puller support and ...

Page 507: ...to be repaired check clearance a between ring 1 and gear 2 each chamfered tooth of gear ring and sleeve then determine parts replacement Clearance a Standard 1 0 1 4 mm 0 039 0 055 in Service limit 0 5 mm 0 019 in 3 To ensure lubrication air blow oil holes 1 and make sure that they are free from any obstruction 4 Fit low speed synchronizer sleeve 1 to hub 2 insert 3 keys 3 in it and then set sprin...

Page 508: ... identical 7 Drive in low speed sleeve hub assembly 1 by using special tool and hammer Note Support shaft with special tool as illustrated left so that retainer of bearing cone 4 will be free from compression Make sure that synchronizer ring key slots are aligned with keys while press fitting sleeve hub assembly Check free rotation of 1st gear 3 after press fitting sleeve hub assembly SpecialTools...

Page 509: ... illustrated SpecialTools A 09923M78210 E 09925M98221 Gear Shifter Gear Shift Select Shaft Assembly 1 To disassemble component parts use special tools and 2 8 3 0vmm 0 11 in pin remover in addition SpecialTools A 09922M85811 4 5 mm B 09925M78210 6 0 mm 2 Clean all parts thoroughly inspect them and replace with new ones as required 3 Assemble component parts by reversing removal procedure Note When...

Page 510: ...t shaft into case and check that it moves smoothly If it doesn t correct by using oilstone reamer or the like 5th REV Gear Shifter 1 Disassemble component parts by using special tool and hammer SpecialTool A 09922M85811 4 5 mm 2 Replace or correct parts as required and assemble shafts making sure that component parts are in proper order as shown left Note Distinguish reverse gear shift arm spring ...

Page 511: ...en disassemble component parts SpecialTool C 09922M85811 4 5 mm Adjustment and Reassembly Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly prepare replacing parts and proceed to reassembly Make sure that all parts are clean 1 Assemble differential gear and measure thrust play of differential gear as follows SpecialTools A...

Page 512: ... washer thickness 0 035 0 039 and 0 043 in 3 Install speed sensor rotor 1 using special tools and press Note Be sure to install in the direction as shown in figure SpecialTools C 09951M76010 D 09940M54910 4 Drive in spring pin 3 from right side till it is flush with differential case surface 5 Press fit L bearing by using special tool and copper hammer SpecialTools E 09913M76010 F 09951M16060 6 In...

Page 513: ...ase assembly into transmission turn final gear by hand slightly so that gear can mesh easily Never push or hit slit portion of case when inserting it Such attempt may cause case to break TighteningTorque a 5 5 N m 0 55 kg m 4 0 lb ft 3 Join input shaft 1 countershaft 2 low speed gear shift shaft 3 and high speed gear shift shaft 4 assemblies all together then install them into right case 5 Note In...

Page 514: ...been installed in shaft at above the gear Check to confirm that reverse gear shift lever 2 end has clearance a 1 mm 0 04 in to idler gear groove 7 Clean mating surfaces of both right and left cases coat mating surface of left case with sealant evenly then mate it with right case Sealant SUZUKI BOND No 1215 99000 31110 8 Tighten case bolts from outside to specified torque TighteningTorque a 19 N m ...

Page 515: ...vice Locating spring free length Standard Limit 5th REV 33 8 mm 32 7 mm Pink painted 1 331 in 1 287 in High speed Low speed 33 6 mm 32 5 mm Green painted 1 323 in 1 280 in 12 Install steel ball and locating spring for respective gear shift shaft and tighten with bolt TighteningTorque d 13 N m 1 3 kg m 9 5 lb ft ...

Page 516: ...able shim which adjusts clearance a to specification and put it on bearing cup Note Insert 0 1 mm 0 004 in feeler to know whether or not a shim fulfills specification quickly 0 40 0 45 0 50 0 55 0 6 0 65 0 7 0 75 0 8 0 85 0 9 0 95 1 0 1 05 1 1 and 1 15 mm Available shim 0 015 0 017 0 019 0 021 thickness 0 023 0 025 0 027 0 029 0 031 0 033 0 035 0 037 0 039 0 041 0 043 and 0 045 in 4 Place left cas...

Page 517: ...ine Inward 6 Install countershaft 5th gear 1 to counter shaft facing machined boss A inward 7 Apply oil to needle bearing and install it to input shaft 8 Install input shaft 5th gear to input shaft 9 Install counter shaft nut 1 as follows a Shift low speed gear shift shaft 2 to 1st gear position and high speed gear shift shaft 3 to 3rd gear position b Tighten nut with above double engagement and r...

Page 518: ...ith shaft mark B Note Long boss of hub faces inward gear side Caution Be careful not to pinch synchronizer ring spring by hub 13 Drive in spring pin facing its slit A outward 14 Fit hub plate 1 and fix it with circlip 15 Clean mating surface of both left case 1 and side cover 2 coat mating surface with sealant evenly mate it with left case and then tighten with 8 bolts B Sealant 99000 31110 Tighte...

Page 519: ... will go in smoothly 5 Tighten yoke and shaft with bolt 3 applied with thread lock cement B Thread lock 1322 99000 32110 TighteningTorque a 34 N m 3 4 kg m 24 5 lb ft 6 Install gear shift interlock bolt 5 with washer and tighten it to specification TighteningTorque b 23 N m 2 3 kg m 17 0 lb ft 7 Clean mating surface of left case and put gear shift guide case applied with sealant on it Sealant SUZU...

Page 520: ...UKI SUPER GREASE A Oil seal lips 99000 25010 Gear shift control lever Gear shift control shaft bushes Oil drain plug Sealant SUZUKI BOND NO 1215 Gear shift shaft bolt 99000 31110 Mating surface of transmission case Mating surface of side cover Mating surface of gear shift guide case Control lever knob Reverse gear shift lever bolts Thread lock cement THREAD LOCK 1322 Oil gutter bolt 99000 32110 Le...

Page 521: ...36 5B MANUAL TRANSMISSION Special Tools ...

Page 522: ...MANUAL TRANSMISSION 5B 37 ...

Page 523: ......

Page 524: ...he flow of drive from flywheel through clutch disc to transmission input shaft General Description The clutch is a diaphragm spring clutch of a dry single disc type The diaphragm spring is of a tapering finger type which is a solid ring in the outer diameter part with a series of tapered fingers pointing inward The disc carrying 4 torsional coil springs is positioned on the transmission input shaf...

Page 525: ...sc Clutch facings dirty with oil Replace disc Release bearing slides unsmoothly on input shaft Lubricate or replace input shaft bearing retainer bearing retainer Wobbly clutch disc or poor facing contact Replace disc Weakened torsion springs in clutch disc Replace disc Clutch disc rivets loose Replace disc Distorted pressure plate or flywheel surface Replace clutch cover or flywheel Weakened or lo...

Page 526: ...s clutch pedal 1 stop the moment clutch resistance is felt and measure distance clutch pedal free travel Free travel should be within the following specification Pedal free travel b 15 20 mm 0 6 0 8 in 2 If free travel is out of specification adjust it with cable joint nut 2 Clutch Cable Adjustment 1 Fit joint pin 1 into slot a and tighten joint nut 2 securely as shown in figure Arm play should be...

Page 527: ...sive cable friction Frayed cable Bent or kinked cable Broken boots Worn end Installation 1 Apply grease to cable end hook 1 and also joint pin 2 before installing cable A Grease Servo Gem 3 2 Hook cable end with pedal by using screwdriver or long nose pliers from cabin inside then join inner cable wire joint pin in release lever 3 Fasten cable with cable bolts 1 to dash panel 2 4 Screw in joint nu...

Page 528: ...stationary with special tool and remove clutch cover bolts 1 clutch cover 2 and clutch disc SpecialTool A 09924M17810 2 Pull out input shaft bearing 1 from flywheel 2 using special tool and wrench SpecialTool B 09917M58010 Unit Repair Overhaul Clutch Cover Clutch Disc And Flywheel ...

Page 529: ...have reached service limit at any of holes replace disc assembly Rivet head depth Standard 1 2 mm 0 05 in Service limit 0 5 mm 0 02 in Clutch Cover Check diaphragm spring 1 for abnormal wear or damage Inspect pressure plate 2 for wear or heat spots If abnormality is found replace it as assembly Do not disassemble it into diaphragm and pressure plate Flywheel Check surface contacting clutch disc fo...

Page 530: ...cial tool install clutch cover 1 and bolts Then tighten bolts to specification Note While tightening clutch cover bolts compress clutch disc with special tool by hand so that disc centered Caution Tighten cover bolts little by little evenly in diagonal order Special Tool A 09924M17810 C 09923M36330 Tightening Torque b 23 N m 2 3 kg m 16 5 lb ft 4 Slightly apply grease to input shaft 1 then joint t...

Page 531: ...ook return spring 1 using pliers 4 Drive out No 2 bush using special tool and hammer Release shaft seal will also be pushed out Special Tool A 09922M46010 5 Remove release shaft 2 and return spring 1 6 Install tap M14 1 5 1 to clutch release shaft No 1 bush 7 Pull No 1 bush out by using special tools Special Tool B 09923M46030 C 09930M30102 ...

Page 532: ...n 1 Drive in a new clutch release shaft No 1 bush 1 using special tools and then apply grease to bush inside SpecialTool A 09943M77910 B 09923M46030 A Grease 99000 25010 2 Install release shaft with return spring applied to it 3 Apply grease to clutch release shaft No 2 bush 1 inside and press fit it using the same special tool as in removal Grease 99000 25010 SpecialTool C 09922M46010 4 Apply gre...

Page 533: ...se bearing 2 inside and release shaft arm 3 then set bearing A Grease 99000M25010 8 Apply small amount of grease to input shaft spline 4 and front end as well B Grease 99000 25210 9 Set release arm 1 to release shaft aligning their punching marks 2 and tighten nut 3 TighteningTorque a 13 N m 1 3 kg m 9 5 lb ft ...

Page 534: ...ials Recommended Use Suzuki Product SUZUKI SUPER GREASE A Clutch cable hook and joint pin 99000 25010 Release shaft bushes and seal seal Release shaft arm Lithium grease SUZUKI SUPER GREASE I 99000 25210 Input shaft spline front end Special Tools ...

Page 535: ...DTC table 6C 7 DTC C1111 Torque sensor main sensor circuit failure 6C 8 DTC C1113 Torque sensor main and sub sensor circuit failure 6C 8 DTC C1115 Torque sensor sub sensor circuit failure 6C 8 DTC C1114 Torque sensor 5V power supply circuit failure 6C 9 DTC C1121 C1123 C1124 VSS circuit failure 6C 10 DTC C1122 Engine speed signal circuit failure 6C 11 DTC C1141 C1142 C1143 C1144 C1145 Motor circui...

Page 536: ...ii 6 TABLE OF CONTENTS ...

Page 537: ... steering shaft joints Replace joint Worn tie rod ends or tie rod inside ball Replace tie rod end or tie rod joints 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 Disturbe...

Page 538: ... tires to proper pressure Disturbed front end alignment Check and adjust front end alignment Brakes not working in unison Refer to Section 5 Leaking wheel cylinder or caliper Repair or replace wheel cylinder or caliper Warped discs Replace brake disc Badly worn brake linings Replace brake shoe lining Drum is out of round in some brakes Replace brake drum Defective wheel cylinders Replace or repair...

Page 539: ...rrect part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring threadlocking compound will be called out The correct torque value must be used when installing fasteners that require it If the above procedures are not followed parts or system damage c...

Page 540: ...the vehicle special care must be taken in handling it Use of a steering wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering shaft leaning on the assembly or dropping the assembly could shear the plastic shear pins which maintain column length and position Steering Wheel and Driver Air Bag Inflator Module The driver air bag inflator module is one of...

Page 541: ...the steering wheel and column refer to SECTION 6 For diagnosis of the air bag system refer to SECTION 8B Inspection And Repair Required After Accident After an accident be sure to perform checks inspections and repairs referring to CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE in this section On Vehicle Service ...

Page 542: ...CAUTIONS in SECTION 8B DISPOSAL For disposal refer to DISPOSAL under SERVICE PRECAUTIONS in SECTION 8B Driver Air Bag Inflator Module Warning When handling an air bag inflator module be sure to read SERVICE PRECAUTIONS in SECTION 8B and observe each instruction Failure to follow them could cause a damage to the air bag inflator module or result in personal injury Removal 1 Disconnect negative cabl...

Page 543: ...posed to strong impact dropped Installation 1 Check that horn wire is connected to horn connector 2 securely 2 Connect yellow connector 2 of driver air bag inflator module 1 securely till it is locked a click is heared 3 Install driver air bag inflator module to steering wheel taking care so that no part of wire harness is caught between them 4 Make sure that clearance between module and steering ...

Page 544: ...g wheel pad 1 from steering wheel 2 4 Remove steering shaft nut 1 5 Make alignment marks 2 on steering wheel and shaft 6 Remove steering wheel 1 using special tool Special Tool A 09944M36011 Caution Do not hammer the end of the shaft Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column Installation 1 Check that vehicle s f...

Page 545: ...turn signal lever for proper function 6 Install driver air bag inflator module to steering wheel Refer to DRIVER AIR BAG INFLATOR MODULE in this section Centering Contact Coil 1 Check that vehicle s wheels front tires are set at straightahead position 2 Check that ignition switch is at LOCK position 3 Turn contact coil 1 counterclockwise slowly with a light force till contact coil 1 will not turn ...

Page 546: ...el from steering column referring to STEERING WHEEL in this section 2 Remove dash side panel 1 right side 3 Remove steering column hole cover 1 4 Remove steering column cover screws 1 5 Separate upper cover 2 and lower cover 3 then remove them 6 Remove contact coil and combination switch assembly screws 1 ...

Page 547: ...Note New contact coil and combination switcg assemblty is supplied with contact coil set and held at its center position with a lock pin 1 and seal 2 Remove this lock pin after installing contact coil and combination switch assembly to steering column 2 Install contact coil and combination switch assembly 3 to steering column 3 Connect all connectors to combination switch assembly 1 4 Install stee...

Page 548: ...bly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length Leaning on the column assembly could cause it to bend or deform Any of the above damage could impair the column s collapsible design Removal 1 Disconnect negative cable at battery 2 Disable air bag system Refer to DISABLING AIR BAG SYSTEM Under SERVICE PRECAUTIONS in SECTION 8B 3 If it is...

Page 549: ...r column cover 2 and lower column cover 3 then remove them 8 Remove steering wheel contact coil and combination switch assembly 1 referring to STEERING WHEEL CONTACT COIL and COMBINATION SWITCH ASSEMBLY in this section if it is necessary 9 Disconnect connectors 2 from combination switch assembly 1 10 Disconnect ignition switch connectors 1 from ignition switch 2 ...

Page 550: ...lumn or shaft is defective replace as an assembly 15 Remove steering lower shaft Inspection Note Vehicles involved in accidents resulting in body damage where steering column has been impacted may have a damaged or misaligned steering column For checking procedure of steering column assembly refer to CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE in this section Installation...

Page 551: ...per and lower nuts refer to figure 5 If contact coil and combination switch assembly is removed install it Refer to CONTACT COIL AND COMBINATION SWITCH ASSEMBLY in this section 6 Connect all connectors disconnected in REMOVAL Ignition switch Combination switch Horn 7 Install combination switch referring to COMBINATION SWITCH ASSEMBLY in this section if combination switch assembly is removed 8 Inst...

Page 552: ...lumn side 5 to specified torque in the order 4 5 indicated in figure Tightening Torque b 27 5 N m 5 5 kg m 18 0 lb ft 11 Install steering joint cover 6 12 Install steering column hole cover 1 13 Enable air bag system Refer to ENABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in SECTION 8B 14 Install dash side panel 1 right side 15 Install steering wheel referring to STEERING WHEEL in this section ...

Page 553: ...tion 1 Position oblong hole 1 of steering shaft 2 in the center of hole in column 2 Turn ignition key to ACC or ON position and install steering lock assembly 3 onto column 3 Now turn ignition key to LOCK position and pull it out 4 Align hub on lock with oblong hole 1 of steering shaft 2 and rotate shaft to assure that steering shaft 2 is locked 5 Tighten new bolts 1 until head of each bolt is bro...

Page 554: ...les for any damages such as crack or breakage If anything is found faulty replace as steering column assembly 3 Take measurement a as shown If it is shorter than specified length replace column assembly 1 with new one Length a 518 521 mm 20 4 20 5 in 4 Check steering shaft joints and shaft for any damages such as crack breakage malfunction or excessive play If anything is found faulty replace as l...

Page 555: ...STEERING WHEEL AND COLUMN 6B 17 Required Service Material Material Recommended Suzuki Product Use Grease SUZUKI GREASE CE T Contact plate 99000 25290 SpecialTool ...

Page 556: ......

Page 557: ... a P S control module a torque sensor a motor assembly with clutch incorporated installed to the steering column In this system the P S control module determines the level and direction of the assist force for the steering wheel according to the signals from the torque sensor and the vehicle speed runs the motor so as to assist operation of the steering wheel 6C ...

Page 558: ...6C 2 ELECTRICAL POWER STERRING EPS SYSTEM ...

Page 559: ...is P S system is not equipped with malfunction indicator lamp which alert the driver to the occurrence of the trouble The trouble area is shown as Diagnostic Trouble Code DTC and it can be read using analog type voltmeter For detail refer to DTC CHECK in this Section Precautions In Diagnosing Troubles Take a note of DTC indicated first Be sure to read PRECAUTIONS FOR ELECTRONIC CIRCUIT SERVICE in ...

Page 560: ...to Step 4 right and left during test driving after see WARNING 1 Check if any trouble symptom exists 2 Inspect and repair basic parts referring to DIAGNOSIS CHART in Section 6 3 If the trouble cannot be repaired in Step 3 2 inspect and repair referring to TROUBLE DIAGNOSIS FOR TROUBLE NOT INDICATED BY ON BOARD DIAGNOSTIC SYSTEM in this section Does the trouble reoccur 4 Confirm that the problem sy...

Page 561: ... Frequency of Occurrence other________________ Vehicle at stop ignition is switch ON position When starting at initial start only at every start Other_______________ Vehicle speed while while accelerating while decelerating at stop Conditions for Occurrence of while turning while running at constant speed Problem other________________ Road surface condition Paved road rough road snow covered road ...

Page 562: ...ting the check turn ignition switch to OFF position and disconnect voltmeter probes from monitor coupler DTC Clearance 1 Remove glove box 2 Turn ignition switch to ON position 3 Using service wire short diagnosis output terminal 1 to ground terminal 2 of monitor coupler 3 4 After keeping them connected for more than 4 seconds disconnect one end of service wire open and within 2 seconds after that ...

Page 563: ...sis switch ter minal and ground terminal High Low This code appears when none of the other codes are identified Torque sensor VSS signal Engine speed signal Clutch 12 11 13 14 15 21 23 24 22 41 42 43 44 45 51 52 54 55 53 DTC VOLTMETER DEFLECTION PATTERN DIAGNOSTIC ITEM Diagnose trouble according to DIAGNOSTIC FLOW TABLE corresponding to each code number P S control module P S control module power ...

Page 564: ...ht torque sensor main 5 Check voltage between X02 5 W wire sensor X02 5 W terminal and X02 3 G wire terminal with X02 wire circuit and connector connected to P S control module recheck Is it about 2 5V 4 Check voltage between X02 4 B wire terminal Go to Step 5 Repair high resistance and X02 3 G wire terminal with X02 open or short to power connector connected to P S control module circuit or groun...

Page 565: ... or ground in 5V 3 If OK turn ignition switch to ON position power supply X02 2 4 Check voltage between X02 2 R wire terminal R wire circuit and and body ground with X02 connector connected recheck to P S control module Is it about 5 V 3 Check torque sensor referring to TORQUE SENSOR Substitute a known Replace steering Is torque sensor in good condition good P S control column assembly and module ...

Page 566: ...connector from P S control ferring to IN circuit referring to module TERMITTENT Section 1 4 Check Proper connection for 8 pin E10 connector TROUBLE in to P S control module Section 0A 5 If OK connect voltmeter between E10 7 V wire If OK substitute and body ground with E10 connector connected a known good 6 Hoist front left of vehicle and lock front right tire P S control 7 Turn front left tire qui...

Page 567: ...P S control module Substitute a known Repair poor connector and ECM at each Br wire terminal P S control good P S control or intermittent trouble module side E10 6 terminal ECM PCM side module and recheck Refer to in Section 1 then check intermittent trouble referring to INTERMITTENT TROUBLE in Section 0A 2 If they are OK check high resistance open or short to power circuit or ground in Br wire ci...

Page 568: ...l X01 1 B wire and body ground with X01 connector connected circuit to P S control module Are they 5 7 V with steering wheel held at position for vehicle to run straight 3 Check voltage between X01 2 R wire terminal Go to Step 4 Repair poor connec and body ground with X01 connector connected to tion high resistance P S control module open or short to power Are they 5 7 V with steering wheel held a...

Page 569: ...en X01 3 B wire X01 3 B wire terminal and body ground with X01 connector circuit connected to P S control module Is it 10 14 V with steering wheel held at position for vehicle to run straight 3 Check voltage between X01 4 B wire Go to Step 4 Repair poor connection terminal and body ground with X01 connector high resistance connected to P S control module open or short to power Is it 0 V circuit or...

Page 570: ... Check P S fuse and proper connection to P S trouble referring to tion or high resistance control module at E10 1 B R wire terminal INTERMITTENT in E10 1 B R wire 3 If OK check voltage between E10 1 B R wire TROUBLE in circuit terminal and body ground with E10 connector Section 0A connected to P S control module If OK substitute a Is it 10 14 V known good P S control module and recheck DTC C1152 C...

Page 571: ...It is strictly prohibited to connect voltmeter or ohmmeter to P S control module with coupler disconnected from it Voltage Check 1 Remove steering column hole cover with ignition switch to OFF position 2 Check voltage at each terminal with couplers 2 connected P S control module Each voltage should be as specified in the following page Note As each terminal voltage is affected by the battery volta...

Page 572: ... to run straight X01 2 Motor output 2 5 7V Engine idling Steering wheel held at position for vehicle to run straight X01 3 Clutch output 1 10 14V Engine idling X01 4 Clutch output 2 0V X02 1 8V power supply for torque About 8V Ignition switch is ON position sensor Check voltage between X02 1 and X02 3 terminals X02 2 5V power supply for torque About 5V Ignition switch is ON position sensor Check v...

Page 573: ...e Cause Inspection Steering wheel Steering wheel installed improperly Install steering wheel correctly feels heavy twisted Perform Poor performance of torque sensor Check torque sensor referring STEERING to TORQUE SENSOR in this section FORCE Poor performance of motor and clutch Check motor and clutch referring to INSPECTION on MOTOR ASSEMBLY WITH next page before INCORPORATED CLUTCH in this diagn...

Page 574: ...steering wheel play is not within specification inspect as follows and replace if found defective Tie rod end ball stud for wear Lower ball joint for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness Steering Force Inspection 1 Place vehicle on level road and set steering wheel 1 at straightahead position 2 Check that tire inflation pressu...

Page 575: ...y remove torque sensor or motor assembly with clutch incorporated Performing any of these prohibited services will affect original performance of EPS ystem P S Control Module Removal 1 Disconnect negative cable at battery 2 Remove steering column hole cover 3 Disconnect couplers 1 from P S control module 4 Remove P S control module 2 from steering column assembly Installation Reverse removal proce...

Page 576: ... 9 V X02 3 Sub sensor X02 4 About 3 9 V About 2 5 V About 1 1 V X02 3 Motor Assembly With Clutch Incorporated On Vehicle Inspection 1 Remove steering column hole cover 2 Disconnect motor and clutch coupler from P S control module when ignition switch is OFF position 3 Check resistance between terminals of motor assembly coupler 1 If check result is not as specified above replace steering column as...

Page 577: ...t between X01 1 and X01 2 using ammeter 2 as shown in left figure Standard current reference value About 0 65 A If check result is not satisfactory replace steering column assembly 6 Connect battery 1 between X01 3 and X01 4 then check that clutch operation sound is heard If check result is not satisfactory replace steering column assembly ...

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Page 579: ...ing reassembly to assure proper retention of these parts Although the figures in this section show only the left hand steering vehicle the same work procedure and data apply to the right hand steering vehicle General Description The rack and pinion steering system consists of two main components the rack and the pinion When the steering wheel is turned the motion is transmitted to the steering sha...

Page 580: ...uspension control arm joint for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness Steering Rack Boot Check Hoist vehicle Inspect each boot for tear A torn boot allows entry of dust and water which can cause wear to steering rack and pinion to produce noise as well as rust to result in malfunction of steering system If even a small tear is ...

Page 581: ...all joint Inspect for play in rack end ball joint In either case if found defective replace On Vehicle Service Note According to necessity apply works to right and left parts Lubrication When inner parts of the steering gear case were disassembled they should be washed clean before reassembly It is recommended to use the grease as given at the right where grease application is indicated in the tex...

Page 582: ...5050 to sliding part of plunger 9 Rack plunger spring Tightening Torque Do not reuse 21 Steering rack Apply SUZUKI SUPER GREASE E 99000 25050 to entire surface of rack 22 Tie rod lock washer 23 Steering tie rod Apply SUZUKI SUPER GREASE E 99000 25050 to rack end ball joint 24 Wire 25 Boot Apply SUZUKI SUPER GREASE E 99000 25050 to contacting part of tie rod and boot 26 Clamp 27 Tie rod end lock nu...

Page 583: ...allation and remove steering lower shaft lower bolt 2 3 Loosen steering lower shaft upper bolt 3 but don t remove 4 Remove steering shaft lower shaft 4 from steering pinion shaft 5 5 Hoist vehicle and remove front wheel 6 Disconnect tie rod end 1 from knuckle 2 using special tool Special Tool A 09913M65210 7 Remove steering gear case mount bolts 1 and then remove steering gear case mount brackets ...

Page 584: ...opper bracket bolts 2 11 Lower engine and then remove manual rack and pinion assembly Disassembly 1 For ease of adjustment after installation make marking 1 on tie rod end lock nut position of tie rod thread 2 Loosen tie rod end lock nut 2 and remove tie rod end 3 3 Remove boot wire 1 and clamp 2 4 Remove boot 3 from tie rod 4 ...

Page 585: ...k 3 6 Remove steering rack cap 4 7 Remove rack damper screw lock nut 1 rack damper screw 2 rack plunger spring 3 and rack plunger 4 8 Remove pinion bearing plug 1 using special tool Special Tool A 09944M26011 43 mm socket 9 Tap on position as shown using plastic hammer 1 to remove pinion assembly 2 from housing ...

Page 586: ...t is damageable be very careful not to cause damage to it when removing rack from steering gear case Do not use a wire brush when cleaning 11 Pull out pinion needle bearing 1 from gear case using special tools Special Tool A 09921M20200 B 09930M30104 12 Remove gear case oil seal 1 using special tool Special Tool A 09913M50121 13 Remove gear case O ring 2 ...

Page 587: ... of steering pinion 1 for wear or damage Inspect oil seal 2 for damage Inspect gear case O ring 3 for damage If found defective replace Steering Pinion Bearing Check rotation condition of bearing and inspect for wear If found defective replace Steering Rack Inspect for deflection teeth wear damage back surface wear or damage Limit of rack deflection 0 40 mm 0 02 in If deflection exceeds limit repl...

Page 588: ...nion needle bearing 1 into gear case 2 using special tool After press fitting make sure that bearing rollers are installed properly Special Tool A 09943M88211 Apply grease to entire teeth surface of steering rack 1 and its periphery A Grease 99000 25050 Slide steering rack 1 into steering gear case 2 in the direction as shown Caution Inside of steering rack bushing is coated with special coating A...

Page 589: ...tall rack plunger 1 rack plunger spring 2 and rack damper screw 3 and adjust rotation torque of pinion as follows i Tighten rack damper screw 3 to specified torque Tightening Torque a 12 N m 1 2 kg m 9 0 lb ft ii After tightening rack damper screw 3 to specified torque turn it back by 700 900 and check for rotation torque of pinion If it is not as specified below adjust so that it will be within s...

Page 590: ... it with wire 2 and clip 3 Wire should be new and should go around twice and be tightened with its both ends twisted together The twisted ends should be bent in the circumferential direction After this check to ensure that boot is free from twist and bent Apply grease to all around inner surface of hatched part A Grease 99000 25050 Install tie rod end lock nut and tie rod end to tie rod Position l...

Page 591: ... then tighten engine rear stopper bracket bolts 2 to specified torque Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft Install new exhaust pipe gasket and exhaust pipe 1 Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft Install tie rod end 1 to knuckle 2 Tighten castle nut 3 until holes for cotter pin 4 align but within specified torque and then bend new cotter pin 4 as shown Tightening Torque a 43 N m...

Page 592: ...ring pinion shaft 2 with matching mark 3 Tighten steering lower shaft lower bolt 4 and upper bolt 5 in that order Tightening Torque a 25 N m 2 5 kg m 18 0 lb ft Tighten wheel nuts 1 to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft After completion of installation check wheel alignment and toe setting referring to FRONT END ALIGNMENT in section 3A ...

Page 593: ...nd rack Lithium Grease Suzuki Super Greasee Sliding part against steering pinion Should be applicable 99000 25050 Oil seal lip needle bearing for 400 C 1300 C Steering rack and pinion gear teeth Filled into pinion bearing plug Contacting parts of tie rod and rack side boots Rack end ball joint Sealant Suzuki Bond No 1207C Thread part of rack damper screw 99000 31150 Special Tools ...

Page 594: ......

Page 595: ...em 7B 4 A C System Wiring Diagram 7B 5 Diagnostic Information and Procedures 7B 6 Section 7 HVAC CONTENTS A C System Symptom Diagnosis 7B 6 Abnormal Noise Symptom Diagnosis of A C System 7B 8 A C System Performance Inspection 7B 9 A C System Inspection at ECM 7B 15 Repair Instructions 7B 17 Operation Procedure for Refrigerant Charge 7B 17 Condenser Assembly On Vehicle Inspection 7B 23 Condenser As...

Page 596: ......

Page 597: ...Precautions on HVAC Air Bag Warning Refer to Air Bag Warning in Section 00 A C System Caution Refer to A C System Caution Manual Type in Section 7B Precautions on Servicing A C System Refer to Precautions on Servicing A C System Manual Type in Section 7B ...

Page 598: ...or 3 Defroster nozzle 8 Side defroster air 13 Blower motor 4 Heater core 9 Fresh air 5 Side ventilation air 10 Recirculation air Heater and Ventilation General Description Heater and Ventilation Construction Note The figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the opposite side ...

Page 599: ...n check for short operate with blower circuit to ground speed selector ON Blower motor relay faulty Check blower motor relay referring to Blower Motor Relay Inspection Blower motor resistor faulty Check blower motor resistor referring to Blower Motor Resistor Inspection Blower speed selector faulty Check blower speed selector referring to Blower Speed Selector Inspection Blower motor faulty Check ...

Page 600: ...osition even if air Air flow control door assembly broken Repair air flow control door assembly flow selector is Air ducts leaked or clogged Repair air ducts changed Air intake door does Air intake door broken Repair air intake door not change even if Air intake control actuator faulty Check air intake control actuator referring to air intake mode is Air Intake Control Actuator Inspection changed ...

Page 601: ...m in Section 8B 3 Disconnect connector 1 from blower motor 2 4 Remove blower motor from HVAC unit by removing screws 3 Installation Reverse removal procedure noting the following instruction Enable air bag system if equipped referring to Enabling Air Bag System in Section 8B Blower Motor Inspection Check for continuity between two terminals as shown If there is no continuity replace blower motor C...

Page 602: ...or Resistor Inspection Measure each terminal to terminal resistance If measured resistance is out of specification replace blower motor resistor Blower motor resistor resistance H MH Approximately 0 29 at 20 25 C 68 77 F MH ML Approximately 0 91 at 20 25 C 68 77 F ML L Approximately 2 48 at 20 25 C 68 77 F Blower Motor Relay Inspection 1 Disconnect blower motor relay 1 from Fuse Box 2 Check that t...

Page 603: ...erature 2 and fresh air flow control cable from HVAC unit 5 Disconnect blower fan switch and A C switch connectors from HVAC control unit 6 Remove HVAC control unit 1 from instrument panel by removing the screws 4nos Note Be careful not to damage HVAC control unit and instrument panel by using rag HVAC Control Unit Components 2 1 1 1 Heater control body assembly 4 Bulb 7 Air intake selector 2 Air ...

Page 604: ...ure control lever 1 air flow control plate 2 and air intake lever fully 3 to the arrow direction Note After installing control cables make sure that control lever and plate move smoothly and stop at proper position Enable air bag system referring to Enabling Air Bag System in Section 8B Make sure that air flow outlet changes correctly as air flow selector is changed 3 Fresh air link 6 Fresh air Co...

Page 605: ... HEATER AND VENTILATION Blower Speed Selector Inspection Check blower speed selector for each terminal to terminal continuity If check result does not meet the following conditions replace HVAC control unit ...

Page 606: ...ver side ventilation louver Removal 1 Disconnect negative cable from battery 2 Disable air bag system referring to Disabling Air Bag System in Section 8B 3 Remove steering column hole cover from instrument panel 4 Remove combination meter cluster panel from instrument panel and then disconnect connectors from front fog lamp switch illumination cancel switch and headlight leveling switch if equippe...

Page 607: ...ry 2 Disable air bag system referring to Disabling Air Bag System in Section 8B 3 Remove glove box from instrument panel 4 Separate passenger side ventilation louver 1 Installation Reverse removal procedure When installing passanger side ventilation louver to dash panel position the smallest clip to the top 1 ...

Page 608: ......

Page 609: ...em Warning Should refrigerant HFC 134a R 134a is exposed to your eye s consult a doctor immediately Do not use your hand to rub affected eye s Instead use fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point Obtain proper treatment as soon as possible from a doctor or eye specialist Should liquid refrigerant HFC 134a R 134a is exposed to...

Page 610: ...suction side referring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge Manual Type Refrigerant Recovery When discharging refrigerant out of A C system always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC 134a R 134a into atmosphere would cause adverse effect to environments Refrigerant Charge After performing compr...

Page 611: ...ed between those In the receiver dryer the refrigerant is separated into the vapor refrigerant and the liquid refrigerant Only the liquid refrigerant is delivered to the sub cooler part of the condenser The refrigerant is supercooled by the sub cooler part of the condenser A C Operation Description ECM controls the radiator fan relay and the compressor relay by following signals ON OFF signal of A...

Page 612: ...omponents of A C system 1 HVAC unit 5 Discharge hose 9 Side ventilation air 13 Side defroster air 2 Compressor 6 Suction hose 10 Center ventilation air 14 Fresh air 3 Condenser assembly 7 Liquid pipe 11 Foot air 15 Recirculation air 4 Intergrated Receiver dryer 8 Expension valve 12 Front defroster air 16 Evaporator ...

Page 613: ...AIR CONDITIONING SYSTEM 7B 5 A C System Wiring Diagram ...

Page 614: ...ened or Adjust or replace drive belt broken Compressor faulty Check compressor Compressor relay faulty Check compressor relay referring to Compressor Relay Inspection Manual Type No cool air comes Fuse blown Check related fuses and then check for short out radiator circuit to ground cooling fan motor Wiring or grounding faulty Repair as necessary does not operate Radiator cooling fan motor relay f...

Page 615: ...unit Blower motor faulty Check blower motor referring to Blower Motor Inspection in Section 7A Excessive compressor oil in A C system Drain excessive compressor oil from A C system circuit and compressor Cool air does not come Wiring connection faulty Repair as necessary out only intermittently Expansion valve faulty Check expansion valve referring to Expansion Valve Inspection Manual Type Excessi...

Page 616: ...ong time Abnormal Noise from Magnetic Clutch Condition Possible cause Correction Reference Item A rumbling noise Worn or damaged bearings Replace magnet clutch assembly is heard when compressor is not in operation A chattering noise is Faulty magnet clutch clearance Adjust magnet clutch clearance heard when compressor excessive clearance is in operation Worn magnet clutch friction surface Replace ...

Page 617: ...otation Fluttering noise or large Leaves or other debris introduced from Remove debris and make sure that the screen droning noise is heard fresh air inlet to blower motor at fresh air inlet is intact from blower motor A C System Performance Inspection 1 Confirm that vehicle and environmental conditions are as follows Vehicle is not exposed to direct sunlight Ambient temperature is within 25 400 C...

Page 618: ...or ten minutes to stabilize the A C operation 8 Open all windows doors and engine hood 9 With about 20 mm 0 8 in of dry bulb thermometer 1 put right in front of center ventilation louver and a wet and dry bulb thermometer 2 near air inlet of HVAC unit 10 Check for each pressure of low side and high side if it is within shaded range of graph If each gauge reading is out of specified pressure correc...

Page 619: ...auge HI 1780 2090 kPa 17 8 20 9 kg cm2 Pressure on low pressure gauge LO 310 440 kPa 3 1 4 4 kg cm2 1000 900 800 700 600 500 400 300 200 100 0 1000 900 800 700 600 500 400 300 200 100 0 25 30 35 40 Acceptable Range Ambient Temperature in C 0 3500 3000 2500 2000 1500 1000 3500 3000 2500 2000 1500 1000 40 35 30 25 A c c e p t a b l e R a n g e Ambient Temperature in C 0 ...

Page 620: ...ion valve Compressor malfunction Insufficient compression Check compressor Low pressure gauge Condition Possible cause Correction Pressure is higher than Expansion valve malfunction valve opens too wide Check expansion valve acceptable range C area Compressor malfunction Insufficient compression Check compressor Pressure is lower than Insufficient refrigerant Insufficient charge or leakage Check f...

Page 621: ... A C evaporator fins Clean or repair E area Air leakage from cooling heater unit or air duct Repair or replace Malfunctioning switch ov er function of door in Repair or replace cooling heater unit Compressor malfunction Check compressor Crossing point is lower Insufficient air volume from center duct Heater Check blower motor and fan than acceptable range blower malfunction F area Compressor malfu...

Page 622: ... refrigerant Using leak detector 0 5 1 5 7 10 pressure sides indicate in system check for leaks and 4 2 21 3 100 142 low readings Refrigerant leaking repair as necessary Output air is slightly cold Recharge refrigerant to a specified amount If the pressure reading is almost 0 when the manifold gauges are attached check for any leaks repair them and evacuate the system 0 4 0 6 Pressure on low press...

Page 623: ...d Installation in Section 1C 2 Connect special tool 2 between ECM and ECM connectors securely 3 Check voltage at each terminal NOTE As each terminal voltage is affected by the battery voltage confirm that the battery voltage is 11V or more when ignition switch is ON position Terminal arrangement of ECM coupler Viewed from harness side 01 51 50 ECM VOLTAGE VALUES TABLE FOR RELATION OF A C CONTROL T...

Page 624: ...ith engine running 10 14 volt Blower fan motor switch and A C switch OFF with Engine running G01 26 Or Sensor ground for Ground to 0 5 0 volt Engine running Evaporator ther body mistor Evaporator thermister temp at 2 0 2 3 volts approx 250 C 770 F with engine G01 08 W B Evaportor thermis Ground to 1800 2200Ω running tor temp input engine 3 5 3 6 vlots Evaporator thermister temp at 6300 7000Ω appro...

Page 625: ...ed eye s Instead use fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point Obtain proper treatment as soon as possible from a doctor or eye specialist Should the liquid refrigerant HFC 134a R 134a is exposed to your skin the affected area should be treated in the same manner as when skin is frostbitten or frozen Do not handle refriger...

Page 626: ...When handling recovery and recycling equipment be sure to follow the instruction manual for the equipment Replenishing Compressor Oil It is necessary to replenish specified amount of compressor oil to compressor from compressor suction side hole 1 before evacuating and charging refrigerant When charging refrigerant only When charging refrigerant without replacing any component replenish the same a...

Page 627: ...refrigerant in A C system Note Once air conditioning system circuit is opened exposed to atmospheric air system must be evacuated by using a vacuum pump The A C system should be attached with a manifold gauge set and should be evacuated for approximately 15 minutes 1 Connect high charging hose 1 and low charging hose 2 of manifold gauge set 3 respectively as follows High charging hose High pressur...

Page 628: ...auge reading has not changed Caution If the gauge reading moves closer to 0 there is a leak somewhere Inspect the tubing connections and make necessary corrections And then evacuate system once again and make sure that there are no leaks Charge Caution Because the sight glass is not used for this A C system do not perform an additional charge to the A C system To charge the proper amount of refrig...

Page 629: ...are routed properly after evacuating the system 2 Connect low charging hose 1 and high charging hose 2 of the manifold gauge set 3 in position Then open refrigerant container valve 4 to purge the charging line 3 Open the high pressure side valve 5 and charge refrigerant to system 4 After a while open the low pressure side valve 6 and close the high pressure side valve Warning Make sure that high p...

Page 630: ...e 1 and high pressure gauge 2 have indicated the following specified value close low pressure side valve 3 on manifold gauge set 4 Low side and high side pressure example Gauges should read as follows when ambient temperature is 300 C 860 F Pressure 1780 2090 kPa on high pressure gauge 17 8 20 9 kg cm2 Pressure 310 440 kPa on low pressure gauge 3 1 4 4 kg cm2 Removal of Manifold Gauge Set Warning ...

Page 631: ... not inhale this gas There are number of fittings and places throughout the A C system where a liquid leak detector solution may be used to pinpoint refrigerant leaks By merely applying the solution to the area in question with a swab such as attached to the cap of a vial bubbles will form within seconds if there is a leak For confined areas such as sections of the evaporator and condenser an elec...

Page 632: ...tery 2 Recover refrigerant from A C system referring to Operation Procedure for Refrigerant Charge Manual Type Note The amount of removed compressor oil must be measured for replenishing compressor oil 3 Remove front bumper referring to Front Bumper and Rear Bumper Components in Section 9K 4 Disconnect discharge hose 1 and liquid pipe 2 from condenser assembly 3 5 Remove condenser assembly mountin...

Page 633: ...llation Manual Type 2 Remove cap bolt 1 from receiver dryer tank 3 Remove desiccant bag 2 from receiver dryer tank Installation Reverse the removal procedure noting the following instructions Replenish specified amount of compressor oil to compressor suction side referring to in Operation Procedure for Refrigerant Charge Manual Type Do not remove desiccant from the plastic bag until just before in...

Page 634: ...ase 6 Foot duct 7 Air folw control door assembly 8 Temperature control door assembly 9 Blower motor case 10 Blower lower case 11 Blower motor 12 Heater unit lower case 13 Heater core 14 Temperature control lever 15 Air flow control lever 16 Evaporator 17 Blank 18 Expansion valve 19 Evaporator temperature sensor 20 Packing 21 Blank 22 Drain hose 23 Cable lock clamp Do not reuse ...

Page 635: ...or oil to compressor suction side referring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge Manual Type Install the padding 1 to the installation hole uniformly Evacuate and charge the A C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge Manual Type Adjust control cables referr ing to HVAC Control Unit Removal and Installation in ...

Page 636: ...pecified replace evaporator temperature sensor Evaporator temperature sensor resistance 00 C 320 F 5 15 8 15 k Ω Ω Ω Ω Ω 250 C 770 F 1 5 2 5 k Ω Ω Ω Ω Ω 1 Removal 1 Disconnect negative cable from battery 2 Remove HVAC unit from vehicle body referring to HVAC Unit Removal and In stallation Manual Type 3 Remove evaporator temperature sensor 1 from evaporator by disassembling HVAC unit 3 50 r 5 mm 2 ...

Page 637: ...on Procedure for Refrigerant Charge Manual Type ExpansionValve Inspection Refer to A C System Perf ormance Inspection Manual Type Expansion Valve Inspection Refer to Troubleshooting Procedure Using Manifold Gauge Set earlier in this Section Dual Pressure Switch Inspection 1 Check dual pressure switch 1 for continuity at normal tem perature approx 250 C 770 F when A C system has a proper charge of ...

Page 638: ...re is continuity between terminal 1 and terminal 2 when A C switch is at ON position Check that there is no continuity between terminal 1 and terminal 2 when A C switch is at OFF position If check result does not meet the above conditions replace HVAC control unit 1 2 ...

Page 639: ...pressor drive belt tension by measuring how much it deflects when pushed intermediate point between magnet clutch pulley 6 and crankshaft pulley 3 with about 100 N 10 kg force after rotating crankshaft pulley 3600 If belt tension is out of specification adjust belt tension referring to Adjustment Compressor drive belt tension a 5 7 mm 0 19 0 28 in Adjustment 1 Loosen tension pulley bolt 4 2 Adjust...

Page 640: ... magnet clutch lead wire coupler 1 8 Disconnect discharge hose 2 and suction hose 3 from compressor 4 Note Cap open fittings immediately to keep moisture out of the system 9 Remove compressor mounting bolts 1 and then remove compressor 2 from its bracket Installation Reverse removal procedure noting the following instructions If compressor is replaced pour new compressor oil referring to Replenish...

Page 641: ...ce at 200 C 680 F If the measured resistance does out of specification replace magnet clutch assembly Magnet clutch coil resistance Standard 3 5 4 1 at 200 C 680 F Magnet Clutch Removal and Installation Removal 1 Remove compressor from vehicle referring to Compressor Assembly Re moval and Installation Manual Type 2 Fix armature plate 1 with special tool and remove armature plate bolt 2 Special too...

Page 642: ...7 6 Remove magnet clutch pulley 2 Note If it is difficult to remove magnetic clutch pulley by hand use puller 1 Do not damage magnetic clutch pulley whileusing puller 7 Disconnect magnet clutch lead wire coupler 8 Remove circlip 1 using special tool Special tool B 09900M06107 9 Remove magnet clutch coil 2 from compressor 3 2 1 A B 1 1 2 1 B 2 3 ...

Page 643: ...agnet clutch pulley 6 Install new circlip 2 directing chamfer side 3 upward Special tool B 09900M06107 7 Tighten armature plate bolt to specified torque Tightening torque Armature plate bolt a 15 N m 1 5 kgf m 11 0 lb ft Special tool A 09991M06310 8 Adjust clearance between magnetic clutch plate 1 and magnet clutch pulley by putting shims s on compressor shaft To measure the clearance perform the ...

Page 644: ...ge by performing step d and e repeatedly Stroke of magnetic clutch plate is clearance between magnetic clutch plate and magnet clutch pulley If clearance is out of specification adjust clearance by changing number and or thickness of shim s Note Be sure to install the thickest shim in compressor shaft side Standard clearance between armature plate and magnet clutch pulley 0 3 0 6 mm 0 012 0 024 in...

Page 645: ... thermal switch to the specified torque Tightening torque Thermal switch a 12 N m 1 2 kgf m 9 0 lb ft Install connector bracket 3 noting the following instructions Note direction of connector 4 and lead wiring Fill a gap between tube 5 and connector 4 by moving tube 5 to protect lead wire from heat Relief Valve Inspection By using special tool check if there is refrigerant leakage If there is refr...

Page 646: ...emove compressor from compressor bracket assebly 3 Remove relief valve 1 from compressor 2 Installation Reverse removal procedure noting the following instructions Use new O ring Apply compressor oil to O ring Tighten relive valve to the specified torque Tightening torque Relief valve a 8 N m 0 8 kg m 6 0 lb ft Evacuate and charge the A C system referring to Evacuation and Charge in Operation Proc...

Page 647: ...g Compressor Assembly Components ManualType Reference For the tightening torque of fastener not specified in this section refer to Fasteners In formation in Section 0A Special Tools and Equipment Recommended Service Material Material MARUTI recommended product or Specification Compressor oil DHPS Note Required service material is also described in the following Precautions on Servicing A C System ...

Page 648: ......

Page 649: ...Resistance High 8B 18 DTC B1022 Driver Air Bag Initiator Circuit Resistance Low 8B 18 DTC B1024 Driver Air Bag Initiator8 Circuit Short To Ground 8B 18 DTC B1025 Driver Air Bag Initiator Circuit Short To Power Circuit 8B 18 DTC B1031 Power Source Voltage High 8B 25 DTC B1032 Power Source Voltage Low 8B 25 DTC B1051 Frontal Crash Detected System Activation Command Outputted 8B 28 DTC B1061 AIR BAG ...

Page 650: ......

Page 651: ...vice Precautions Service And Diagnosis Warning If replacing seat belt is necessary replace buckle and ELR or webbing together as a set This is for the reason of ensuring locking of tongue plate with buckle If these parts are replaced individually such a locking condition may become unreliable For this reason MARUTI will supply only the spare buckle and ELR or webbing in a set part Before servicing...

Page 652: ...2 8A SEAT BELTS Front Seat Belt Warning Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work Removal Remove front seat belts ...

Page 653: ...he front seat belt retractor assembly 1 should pass the above inspection and should lock webbing even when tilted approx 15o toward the fore and aft or right and left directions Anchor bolt Anchor bolts should be torqued to specification Belt latch It should be secure when latched Installation Install front seat belts in reverse order of removal noting the following Seat belt anchor bolts should h...

Page 654: ...on before starting to work and observe every precaution during work Removal Remove rear seat belts Inspection Check the rear seat belt in the same way as INSPECTION of FRONT SEAT BELT Installation Install the rear seat belt observing the same precautions as INSTALLATION of FRONT SEAT BELT ...

Page 655: ...stem temporarily and prevent false diagnostic trouble codes from setting Failure to follow procedures couid result in possible activation of the air bag system personal injury or otherwise unneeded air bag system repairs Caution When fasteners are removed always reinstall them at the same location from which they were removed If a fastener needs to be replaced use the correct part number fastener ...

Page 656: ...in occurrence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver seat belt 1 Driver side air bag The air bag system is designed to activate only in severe frontal collisions It is not designed to activate in rear impacts side impacts rollovers or minor frontal collisions since it would offer no protection in those types of accidents ...

Page 657: ...AIR BAG SYSTEM 8B 3 System Components and Wiring Location View and Connectors ...

Page 658: ...8B 4 AIR BAG SYSTEM System Wiring Diagram Terminal Arrangement of SDM Viewed From Harness Side ...

Page 659: ...agnostic trouble codes DTCs using SUZUKI scan tool Use of Special Tool Warning To avoid deployment when troubleshooting the air bag system do not use electrical test equipment such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equip ment other than that specified in this manual Do not use a non powered probe type tester Instructions in this manual must be foll...

Page 660: ...loyment The load tool has three connectors attached to its case which are electrically functional and serve as resistive load substitutions No more than two connectors are used at any time One of connectors STEERING WHEEL is used to substitute the load of followings Driver air bag inflator module when it is connected at the top of the column to the contact coil assembly Another connector BASE OF C...

Page 661: ...heck each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal included in the connector test adapter kit special tool If contact tension is not enough reform it to increase contact tension or replace Special tool A 09932M76010 ConnectorTest Adapter Kit Poor terminal to wire connection Check each wire harness in problem circuits...

Page 662: ...TABLE must be the starting point of any air bag system diagnosis The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE checks for proper AIR BAG warning lamp operation through AIR BAG warning lamp and whether air bag diagnostic trouble codes exist 2 Refer to the proper diagnostic table as directed by the AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOWTABLE will lead yo...

Page 663: ...h is ON FLASHES in this section 4 Does AIR BAG warning lamp Go to step 5 Go to step 8 turn OFF after flashing 6 times 5 Using SUZUKI scan tool Go to step 6 6 1 Check DTC using SUZUKI Air bag system is in good An intermittent trouble has scan tool Refer to DTC condition occurred at some place CHECK in this section Check the connector harness etc Is NO CODES displayed on related to the sensed DTC SU...

Page 664: ...ck turn ignition switch to OFF position and disconnect SUZUKI scan tool from data link connector DLC 1 Data link connector DLC DTC Clearance Using SUZUKI ScanTool 1 Turn ignition switch to OFF position 2 Connect SUZUKI scan tool to data link connector DLC in the same manner as when making this connection for DTC check Special tool 1 SUZUKI scan tool 99000M24120 426 3 Turn ignition switch to ON pos...

Page 665: ...ormal B1021 Resistance high B1022 Driver air Resistance low B1024 bag Circuit Short to ground B1025 Short to power circuit B1031 Power source To high Diagnose trouble according to B1032 voltage To Low diagnostic flow table corresponding to each code No B1051 SDM Frontal crash detected AIR BAG B1061 warning lamp Circuit failure circuit B1071 Internal fault Specifications different B1013 SDM between...

Page 666: ...uired in this table use a specified digital multimeter Refer to SPECIAL TOOL in this section along with a correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNECTIONS in this section If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness c...

Page 667: ...oltage between wire between ignition L 06 4 terminal of SDM connector switch and AIR BAG and body ground with ignition switch ON fuse open or short to Is it 8 V or more ground 3 1 Disconnect 16 pin connector from combina Substitute a known good YEL wire between tion meter Refer to COMBINATION METER SDM and recheck combination meter and in Section 9B SDM connector short to 2 Check resistance betwee...

Page 668: ...ition 3 1 Check proper connection to SDM at termi Substitute a known good Go to step 4 nal L06 2 SDM and recheck 2 If OK check voltage from L06 2 terminal of SDM connector to body ground with igni tion switch ON Is it 8 V or more 4 1 Turn ignition switch OFF Go to step 5 Replace bulb AIR BAG 2 Remove and inspect AIR BAG warning warning lamp bulb or lamp bulb and combination meter referring combina...

Page 669: ...ote Upon completion of inspection and repair work perform the following items Reconnect all air bag system components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected L L ...

Page 670: ...it in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly Tabletest Description STEP 1 An improper connection to the data link connector DLC will prevent communications from being established STEP 2 This test checks whether it is possible to communicate with other control module STEP 3 This test checks for an open in BLU OR...

Page 671: ...isconnect SDM Substitute a Repair high resistance or connector L06 and L02 connector known good open in VIO WHT wire 2 Check proper connection at L02 2 SDM and circuit in air bag harness VIO WHT wire terminal for DLC recheck 3 If OK then check resistance between L02 2 VIO WHT wire terminal and L06 14 VIO WHT wire terminal of SDM connector Is resistance 1Ω12 or less Special tool A 09932M76010 Note ...

Page 672: ...onnector and terminal as an assembly Wiring Diagram DTC Will set when DTC B1021 The combined resistance of the driver air bag inflator module contact coil assembly harness wiring and connector terminal contact is above a specified value for specified time DTC B1022 The combined resistance of the driver air bag inflator module contact coil assembly harness wiring and connector terminal contact is b...

Page 673: ...ol A 4 Measure resistance between L06 9 and L06 10 terminals with connected special tools B and C to L08 connector Is resistance 4 5 Ω or less 3 1 With ignition sw itch OFF disconnect special tools B Ignition switch OFF Ignition switch OFF and C from L08 connector then reconnect contact Replace contact coil Replace driver air coil connector L08 located nearthe base of the assembly Refer to bag inf...

Page 674: ... proper connection to SDM at terminals wire circuit or from GRN L06 9 and L06 10 or GRN RED wirecircuit 3 If OK release shorting bar in SDM connector tootherwirecircuit inserting release tool 1 included in special tool A 4 Measure resistance between L06 9 and L06 10 terminals with connected special tools B and C to L08 connector Is resistance 1 7 or more 3 1 With ignition switch OFF disconnect spe...

Page 675: ...pection and repair work perform the following items Reconnect all air bag system components ensure all componets are property mounted Repeat AIR BAG DIGONOSTIC SYSTEM CHECK to confirm that the trouble has been corrected Clear diagnostic trouble codes Refer to DTC CLEARENCE if any C L06 10 L06 9 L01 L08 ...

Page 676: ...3 Measure resistance between L06 9 terminal and body ground and between L06 10 terminal and body ground Are they 1 M Ωor more 3 1 With ignition switch OFF disconnect special tools Ignition switch OFF Ignition switch OFF B and C from L08 connector then reconnect Replace contact coil Replace driver air bag contact coil connector L08 located near the base assembly Refer to inflator module of the stee...

Page 677: ...wn good GRN or GRN RED SDM connector L06 from SDM respectively SDM and wire circuit to 2 Release shorting bar in SDM connector recheck power circuit inserting release tool 1 included in special tool A 3 Measure voltage from L06 9 terminal to body ground and from L06 10 terminal to body ground With ignition switch ON are they 1 V or less 3 1 With ignition switch OFF disconnect special Ignition swit...

Page 678: ...pection and repair work perform the following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected C L06 10 L06 9 L01 L08 ...

Page 679: ...TTENT AND POOR CONNECTIONS in this section If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will set When DTC B1031 The power source voltage to SDM is above specified value for specified time DTC B1032 The power source voltage is below specified value for specified time Table Test Descript...

Page 680: ...al tool A 09932M76010 Note Upon completion of inspection and repair work perform the following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1032 Power Source Voltage Low Step Action Yes No 1 1 Measure vol...

Page 681: ...nectoron instrument Charging System panel harness to body ground Referto DIAGNOSIS Is voltage 8 V or more in Section 1J 4 1 With ignition switch OFF reconnect SDM Substitute a known good Check Charging System connector SDM and recheck and repair as necessary With ignition switch ON is DTC B1032 Referto DIAGNOSIS in current Section 1J Special tool A 09932M76010 Note Upon completion of inspection an...

Page 682: ...form AIR BAG DIAGNOSTIC SYSTEM CHECK Step Action Yes No 1 1 Ignition switch OFF Replace components and Go to step 2 Has air bag inflator module deployed perform inspections as directed in REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT in this section 2 1 Inspect front of vehicle and under carriage Replace components and Substitute a known good for signs of impact perform inspections as SDM and...

Page 683: ...tor test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNECTIONS in this section If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set When The voltage at the AIR BAG warning lamp circuit terminal L06 2 does not match the commanded state of...

Page 684: ... components ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected DTC B1071 Internal SDM Fault DTC Will Set When An internal SDM fault is detected by SDM Caution Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to thefollowing diagnostic procedures Note DTC B1071 can never be cleared on...

Page 685: ...e correct table to diagnose any air bag malfunctions Bypassing these procedures may result in extended diagnostic time incorrect diagnosis and incorrect parts replacements Never use air bag component parts from another vehicle If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove the air bag system components beforehand to avoid component d...

Page 686: ...e With AIR BAG fuse removed and ignition switch ON AIR BAG warning lamp will be ON This is normal operation and does not indicate a air bag system malfunction Enabling Air Bag System 1 Turn ignition switch to LOCK position and remove key 2 Connect Yellow connector 1 of contact coil and combination switch assembly by pushing connector till click is heard from it 3 Install AIR BAG fuse to fuse box 4...

Page 687: ...EM CHECK when checking the SDM Never attempt disassembly of SDM When storing SDM select a place where neither high temperature nor high humidity is anticipated and oil water and dust are kept off If SDM has been dropped replace it with a new one If installation part of SDM was damaged repair that part completely before reinstallation All SDM and mounting bracket fasteners must be carefully torqued...

Page 688: ...al deployment Warning Never attempt to measure the resistance of the air bag inflator module It is very dangerous as the electric current from the tester may deploy theairbag Never attempt disassembly of the air bag inflator module If any abnormality is found be sure to replace it with new one as an assembly When an abnormality is noted as existing in the live undeployed air bag inflator module be...

Page 689: ...ning Failure to follow proper air bag inflator module disposal procedures can result in air bag deployment which could cause personal injury Undeployed air bag inflator module must not be disposed of through normal refuse channels The undeployed air bag inflator module contain substances that can cause severe illness or personal injury if the sealed container is damaged during disposal Deployed Ai...

Page 690: ...duction configuration Caution After detecting one time of such collision as to meet deployment conditions the SDM must not be used Refer to AIR BAG DIAGNOSTIC SYSTEM CHECK when checking the SDM Accident With Deployment Activation Component Replacement The following components must be replaced Driver air bag inflator module SDM Accident With or without Deployment Activation Component Inspection Cer...

Page 691: ...t cannot be fixed securely Check that connector or lead wire of SDM has a scorching meltingor damage Check that connector is connected securely or locked Check SDM connectorandterminalsfortightness Check SDM sets a diagnostic trouble code Refer to DTC CHECK in this section and the diagnostic table leads to a malfunctioning SDM If any faulty condition is found in above checks replace Instrument pan...

Page 692: ...lecting them may result in personal injury or inactivation of the air bag system when necessary Removal 1 Disconnect negative cable at battery 2 Disable air bag system Refer to DISABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS in this section 3 Remove center console boxes 1 by removing screws and clips 4 Disconnect SDM connector 2 from SDM 3 5 Remove SDM 3 with SDM plate 5 as an assembly from vehicl...

Page 693: ...tor 2 for damage cracks or lock mechanism Check SDM terminal for bent corrosion or rust If any faulty condition is found in above checks replace Installation For installation reverse removal procedure nothing following points Ensure that arrow 4 on the SDM 3 is pointing toward the front of the vehicle Tighten SDM bolts to specified torque Tightening torque SDM mounting bolt a 6 N m 0 6 kg m 4 5 Ib...

Page 694: ...air bag modules installed on vehicle Warning The following precautions must be observed for this work Failure to observe any of them may result in personal injury Procedure should be followed strictly as described here Be sure to read SERVICE PRECAUTIONS beforehand To avoid accidental deployment activation this work should be performed by no more than one person Since smoke is produced when air ba...

Page 695: ...ir bag inflator module s or seat belt pretensio ner s from vehicle referring to Section 3C 9 10 and or 10B Warning Deployment harness A shall remain shorted and not be connected to 12 volts vehicle battery till you are ready to deploy air bag module Warning For handing and storage of live air bag inflator module select place where ambient temperature below 65 C 150 F without high humidity and away...

Page 696: ...ength 10m 33 ft Special tool A 09932M75030 8 Place 12 volts vehicle battery 1 near shorted end of deployment harness A 9 Verify that area around air bag inflator module is clear of all people and loose or flammable objects 10 Connect adapter cable B as follows Special tool B 09932M78332 For driver air bag inflator module Verify that driver air bag inflator module is resting with its vinyl trim cov...

Page 697: ...bag inflator may contain powdery residue This powder consists primarily of cornstarch used to lubricate bag inflator as it inflates and byproducts of chemical reaction Warning Do not place deployed air bag inflator module near any flammable objects Do not apply water oil etc to deployed air bag inflator module Wait for about 30 minutes before touching any metal surface of air bag inflater module D...

Page 698: ... However they should be inspected for damage after deployment and replaced if necessary 21 Dispose of deployed air bag inflator module 1 through normal refuse channels after it has cooled for at least 30 minutes and tightly seal air bag inflator module 1 in strong vinyl bag Refer to Deployed Air Bag Inflator Module 22 Wash your hands with mild soap and water afterward Note Remaining steps are to b...

Page 699: ...t belt pretensioner connectors 4 4 Confirm that each air bag inflator module and or seat belt pretensioners is securely mounted 5 Check that there is no open short or damage in special tools deployment harness A and adapter cable B If any faulty condition is found do not use it and be sure to use new deployment harness A and or adapter cable B And connect adapter cable B to deployment harness A an...

Page 700: ...oner Note When air bag inflator module deploys rapid gas expansion will create substantial report Wear suitable ear protection Notify all people in immediate area that you intend to deploy air bag inflator module and suitable ear protection should be worn After air bag inflator module has been deployed surface of air bag may contain powdery residue This powder consists primarily of cornstarch used...

Page 701: ...vehicle and clean off any fragments or discard it entirely 20 Put on pair of shop gloves to protect your hands from possible irritation and heat when handling deployed air bag inflator module 21 Disconnect adapter cable special tool from air bag inflator module as soon as possible This will prevent adapter cable special tool from damage due to possible contact with hot air bag inflator module 22 C...

Page 702: ...t pretensioner can be disposed of through normal refuse channels just like any other parts For their disposal however following points should be noted The air bag inflator module and the seat belt pretensioner immediately after deployment activation is very hot Wait for 30 minutes to cool it off before handling it Never apply water oil etc to deployed air bag inflator module and the activated seat...

Page 703: ...en deployed activated inside the vehicle which is going to be scrapped leave them as installed to the vehicle Be sure to wash your hands with mild soap and water after handling it Tightening Torque Specification Tiqhteninq torque Fastening part N m kg m b ft SDM mounting bolt 11 1 1 8 0 09932M75010 09932M75030 09932M76010 09932M78332 09932M78340 ...

Page 704: ...stance measurement B This kit includes the following items and substitutes for theTech 1A kit 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector M Storage case 12 Power supply C Thissetincludesthefollowing items 1 Connector test adapter kit 09932 75020 2 Connector test adapt...

Page 705: ...9B 11 Headlight Leveling Actuator Inspection If Equipped 9B 11 Section 9 Body Cab and Accessories CONTENTS Instrumentation Driver Info Horn 9C 1 General Description 9C 1 Combination Meter Circuit Diagram 9C 1 Speedometer and VSS 9C 2 Engine Coolant Temperature ECT Meter 9C 2 Fuel Meter and Fuel Gauge 9C 2 Oil Pressure Light 9C 2 Brake and Parking Brake Warning Light 9C 2 Ignition Key Reminder Ligh...

Page 706: ... Door Lock Assembly Removal and Installation 9F 1 Front Door Lock Assembly Inspection 9F 2 Rear Door Lock Assembly Removal and Installation 9F 3 Back Door Lock Assembly Removal Installation and Inspection 9F 4 Key Coding 9F 5 Ignition Switch Lock Cylinder 9F 5 Electrical Diagnosis 9F 5 Seats 9G 1 Front Seat Removal and Installation 9G 1 Rear Seat Removal and Installation 9G 2 Interior Trim 9H 1 Fl...

Page 707: ...ightening Systems Component Location Lighting System Location 1 Headlight bulb 5 Head light assembly 2 Sochat Cover 6 Front tog lamp if equipred 3 Clearance light bulb 7 Rear combination light 4 Turn signal bulb 6 7 1 2 5 3 4 1 ...

Page 708: ...rn signal hazard warning relay faulty Replace relay Open circuit or high resistance Repair circuit existing between combination switch turn signal hazard warning switch and light on one side Wiring qr grounding faulty Repair circuit No flashing HORN HAZARD fuse blown Replace fuses to check for short Open circuit or high resistance existing Check bulb and check circuit between battery and switch Tu...

Page 709: ...sible Cause Correction Brake lights do not light up Buib s blown Replace bulb STOP fuse blown Replace fuse to check for short Brake light switch faulty Replace switch Wiring or grounding faulty Repair circuit Brake lights stay on Brake light switch faulty Check adjust or replace switch Repair Instructions Headlight RemovaL 1 Disconnect negative cable at battery 2 Remove headlight mounting bolts 1 ...

Page 710: ...st aiming Before adjustment make sure the following a Place vehicle on a flat surface in front of blank wall screen ahead of headlight surface Clearance a 10 m 32 8 ft b Adjust air pressure of all tires to a specified value respectively c Bounce vehicle body up and down by hand to stabilize suspen sion d Carry out with one driver aboard Driver s weight 75 kg 165 Ib Adjustment 1 Check to see if hot...

Page 711: ...dash side panel 1 right side 3 Remove steering column hole cover 1 4 Remove steering column cover screws 1 5 Separate upper cover 2 and lower cover 3 then remove them 6 Disconnect connectors 1 from combination switch assembly 2 7 Remove combination switch screws 3 8 Remove combination switch 2 from steering column ...

Page 712: ...ight ahead position and then ignition switch is at LOCK position 2 install combination switch assembly 1 to steering column 3 Connect all connectors 2 to combination switch assembly 1 4 Install steering column upper cover 1 and lower cover 2 and then tighten steering column cover screws 3 Caution When installing upper cover 1 and lower cover 2 be careful so that lead wire is not caught between cov...

Page 713: ... Disconnect negative cable at battery 2 Disconnect combination switch lead wire coupler 3 Check for continuity between terminals at each switch position shown below If check result is not as specified replace Removal And Installation Refer to COMBINATION SWITCH ASSEMBLY in section 6B ...

Page 714: ...heck for continuity between terminals at each switch position shown below Removal And Installation Refer to COMBINATION SWITCH ASSEMBLY in Section3c Turn Signal Hazard Relay The turn signal hazard relay 1 is located near the fuse box Inspection Connect battery and tester as shown left Unless a continued click sound is heard replace relay 1 T TURN HAZ TL TB TR B3 B1 F2 L OFF N ON R L R LNR ...

Page 715: ...arrow direction and then remove license lamp assembly 2 Installation Reverse removal procedure for installation Front Fog Light Assembly Removal and Installation Removal 1 Disconnect negative cable at battery 2 Remove front bumper Refer to Front Bumper and Rear Bumper Components in Section 9K 3 Disconnect couplers 1 from fog light 2 4 Remove fog light screws 3 and remove fiont fog light assembly 2...

Page 716: ... OFF automatically when headlight switch is turned to OFF position If front fog light switch holds ON position front fog lights turn ON automatically when headlight switch is tuned to HEADLIGHT position low or high beams or SMALL position again Check for continuity between terminals at each switch position If check result is not as specified replace switch Front Fog Light Relay Inspection 1 Check ...

Page 717: ...Inspection If Equipped 1 Make sure all headlight couplers and leveling actuator couplers are correctly connected 2 Turn the ignition switch to ON position 3 Check if the leveling actuator sounds slightly while the leveling switch is moved If no sound is heard with the movement of the leveling switch check headlight leveling switch and wiring If headlight leveling switch and wiring are OK replace h...

Page 718: ......

Page 719: ... 5 6 7 8 9 11 10 12 13 14 15 16 METER SIDE 1 2 3 4 5 6 7 8 9 11 10 12 13 CONNECTOR K 16P CONNECTOR L 13P 1 2 3 4 5 6 7 8 9 10 11 12 13 TURN L BEAM SPEED IN DOOR AJAR BEAM DOOR ILLUMINATION B ILLUMINATION IMMOVILITY CHECK ENGINE GND TURN L 1 2 3 4 5 6 7 8 9 10 11 12 13 KEY FUEL METER TEMP METER GND GAUGE FRONT FOG ABS IG TACHO REAR FOG BRAKE FLUID PARKING BRAKE CHARGE OIL PRESSURE 14 15 16 SEAT BEL...

Page 720: ...er Wiring or grounding Faulty Repair circuit Oil Pressure Light Trouble Possible Cause Correction Oil pressure warning light Bulb in combination meter blown Replace bulb does not light up when IG METER fuse blown Replace fuse to check for short ignition switch is on at en Printed plate in combination meter Replace printed piate gine off faulty Oil pressure switch faulty Replace oil pressure switch...

Page 721: ...RN HAZARD fuse blown Replace fuse to check for short Horn switch faulty Replace Wheel Horn faulty Replace horn Repair Instructions Ignition switch Removal and Installation Removal 1 Disconnect negative Cable from battery 2 Confirm that ignition key is removed 3 Deactivate air bag If equippod by refering to Air bag section in this manual 4 Remove steering wheel and combination switch assembly 1 ref...

Page 722: ...sult is not as specified replace switch Combination Meter Assembly Removal 1 Remove steering wheel from steering column referring to STEERING WHEEL in this section 2 Remove dash side panel 1 right side 3 Remove steering colun hole cover 1 4 Remove steering column cover screws 1 5 Separate upper cover 2 and lower cover 3 then remove them ...

Page 723: ...ct combination meter couplers Remove combination meter Installation 1 Check to make sure that vehicle s front tires are set at straightahead position and then ignition switch is at LOCK postion 2 Install combination switch assembly 1 to steering column 3 Connect all connectors to combination switch assembly 4 Install steering column upper cover 1 and lower cover 2 and then tighten steering column ...

Page 724: ...erminal 2 and cylinder biock 3 as shown During Engine Running No continuity At Engine Stop Continuity If check result is not as specified replace oil pressure switch 1 Removal And Installation Refer to OIL PRESSURE CHECK in Section 1E VSS Refer Section 1A for removal and installation ECT Refer Section 1 C for Inspection Brake And Parking Brake Warning Light Inspection BRAKE FLUID LEVEL SWITCH Chec...

Page 725: ...ner outlet hose Installation Reverse removal procedure noting the following Clean mating surfaces of IAT sensor and air cleaner outlet hose Connect IAT sensor coupler securely Inspection Immerse temperature sensing part of AT sensor in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in left ...

Page 726: ... and Driver Information Instrument Panel Removal 1 Disconnect Battary negative cable at 2 Remove steering column assembly 1 Refer to Section 3C 3 Remove glove box 1 and hood latch release lever 2 4 Remove both sides front pillar inner trim 1 and dash side trim 2 ...

Page 727: ...g bolts 1 8 Remove instrument panel 2 Installation 1 Install instrument panel by reversing removal procedure not ing the following items When installing each part be careful not to catch any cable or wiring harness When installing steering column assembly refer to Section 3C STEERING COLUMN INSTALLATION Tighten each parts to specified torque Tightening Torque a 23 N m 2 3 kg m 16 5 lb ft 2 Adjust ...

Page 728: ......

Page 729: ...tion switch wiper Check wiper switch referring to Windshield switch faulty Wiper and Washer Switch Inspection Wiring or grounding faulty Repair circuit Washer malfunctions Washer hose or nozzle clogged Clean or repair clogged hose or nozzle Circuit fuse blown Replace fuse and check for short circuit Washer motor faulty Check washer motor referring to Washer Pump Inspection Combination switch washe...

Page 730: ...pection 1 Disconnect negative cable at battery 2 Disconnect combination switch lead wire coupler 3 Check for continuity between erminals at each switch position as shown below Repair Instructions Wipers and Washers 1 Wiper Nozzile 2 Washer nose 1 1 2 ...

Page 731: ...e terminal to terminal LO 5 Connect voltmeter positive lead to terminal 1 and negative lead to terminal LO Check that the voltmeter indicates the battery voltage 10 14V 6 Connect terminal As and terminal B3 by a jumper wire Then move jumper wire end connected to terminal B3 to terminal HI Observe the voltmeter voltage drops to 0V right after connecting the jumper wire from terminal B3 to HI Then t...

Page 732: ...h lead wire coupler 3 Make sure that front wiper switch is at OFF position 4 Connect battery positive terminal to terminal B3 and battery negative terminal to terminal Lo 5 Connect voltmeter positive lead to terminal 1 and negative lead to terminal Lo 6 Push washer switch and check that voltage changes as shown in the table ...

Page 733: ...top c Connect terminal A and D with a jumper wire 3 and connect terminal C to battery terminal Observe the motor turns once again then stops at a given position d Repeat a thru c several times and inspect if the motor stops at the given position every time Front Washer Pump Removal 1 Disconnect negative cable at battery 2 Remove front Bumper Fender RH and Headlight Assembly RH 3 Remove inlet pipe ...

Page 734: ......

Page 735: ...e to read carefully the instruction and description given by the maker of the adhesive to be used and be sure to follow the procedure and observe each precaution throughout the work Should coated surface be scratched or otherwise damaged be sure to repair damaged part or corrosion may start from there Use an adhesive of above mentioned type which has the following property Shearing strength 40 kg ...

Page 736: ...ng sure that none of above parts is faulty Power Window Control System Symptom Diagnosis Condition Possible cause Correction Reference Item All power windows do Circuit fuse blown Replace fuse and check for short circuit not operate Power window main switch faulty Check power window main switch referring to Power Window Main Switch Inspection If Equipped Ignition switch faulty Check ignition switc...

Page 737: ...tch faulty Check power door mirror switch referring to Power Door Mirrior Switch Inspection If Equipped Wiring or grounding faulty Repair circuit One power mirror does Power door mirror switch faulty Check Power door mirror switch referring to not operate Power Door Mirror Switch Inspection If Equipped Power door mirror actuator faulty Check actuator referring to Power Door Mirror Actuator Inspect...

Page 738: ...Refer to HEAD LINING in this section 7 Remove or cut windshield molding until windshield edge comes out Remove or cut stopper 8 Drill hole with eyeletter 1 through adhesive and let piano string through it 9 Cut adhesive all around windshield with piano string 1 When using tool windshield knife 2 to cut adhesive be careful not to cause damage to windshield Use wire to cut adhesive along lower part ...

Page 739: ...rmine installing position of glass 1 to body 2 position glass against body so that clearance a between upper end of glass 1 and body 2 is about 5 mm 0 197 in and clearances a between each side end right left of glass 1 and body 2 are even Upper clearance can be adjusted by moving stoppers position Then mark mating marks 3 on glass and body as shown 4 Clean contact surfaces of old adhesive 1 paint ...

Page 740: ...f glass or molding a 30 50 mm 1 18 1 97 in 7 Install new spacer 1 to glass 2 as shown in figure 8 Using new brush apply sufficient amount of primer for glass along glass surface to be adhered to body Note Be sure to refer to maker s instruction for proper handling and drying time Do not apply primer on outside of ceramic coated surface Do not touch primer coated surface Width a 15 mm 0 59 in b 15 ...

Page 741: ...x 15 mm 0 59 in Distance c Approx 10 mm 0 39 in d Approx 17 mm 0 67 in Press glass against fittings surface of body quickly after adhesive is applied Use of rubber sucker grip is helpful to hold and carry glass after adhesive is applied Perform steps 9 to 10 within 10 min to ensure sufficient adhesion Be sure to refer to adhesive maker s instruction for proper handling and drying time 10 Holding r...

Page 742: ...n of installation note the following Sudden closing of door before adhesive is completely set may cause glass to become loose or to come off Therefore if door is opened or closed before adhesive is completely set make sure to open all door glasses and use proper care If molding is not securely in place hold it down with a tape until adhesive is completely set Each adhesive has its own setting time...

Page 743: ...1 7 1 Window regulator handle 2 Front door trim 3 Front door weatherstrip 4 Front door glass 5 Front door glass run 6 Front door glass sash 7 Front window regulator assembly Apply SUZUKI SUPER GREASE A 99000 25010 to sliding part 8 Glass attaching screw Front Door Glass ...

Page 744: ... With inside handle bezel 2 tilted as shown in figure turn door trim 1 90 counterclockwise to remove it And disconnect power window switch lead wire at coupler if equipped 6 Remove door sealing cover 1 7 Remove door outside weatherstrip 1 Lower window all the way down Then use a tape wrapped putty knife or screwdriver to pry off weatherstrip Caution Use a tape wrapped putty knife or screwdriver to...

Page 745: ...procedure to install door glass noting the following points Tighten glass attaching screws 1 to specified torque Tighten rear screw first then front screw TighteningTorque a 6 N m 0 6 kg m 4 3 lb ft Secure door sealing cover with adhesive 1 Install door window regulator handle 1 so that it has a 450 angle when glass is fully closed as shown in figure 1 ...

Page 746: ... through hole 2 as shown in figure Inspection 1 Check regulator sliding and rotating parts for greasing 2 Check rollers for wear and damage 3 Check wire for damage Installation Reverse removal procedure to install window regulator noting the following point Tighten door glass attaching screws to specified torque Refer to FRONT DOOR GLASS in this section Door mirror Removal and Installation When re...

Page 747: ...gulator handle 1 if equipped For its removal pull off snap by using a cloth 2 as shown in figure 1 2 3 4 5 6 7 8 7 1 Door glass 2 Window regulator Apply SUZUKI SUPER GREASE A 99000 25010 to sliding part 3 Glass run 4 Door trim 5 Door sealing cover 6 Window regulator handle 7 Door glass mounting screw 8 Side door trim handle 6 N m 0 6 kg m 6 N m 0 6 kg m ...

Page 748: ...y down Then use a tape wrapped putty knife or screwdriver to pry off weatherstrip Caution Using a tape wrapped putty knife or tape wrapped screwdriver pry off weatherstrip Use of an unwrapped tool will cause damage to painting 9 Remove door sash mounting bolts 1 10 Remove glass attaching screws 2 11 Remove glass run end section 4 12 Take out door glass 3 Installation Reverse removal procedure to i...

Page 749: ...R GLASS REMOVAL in this section 2 Remove regulator mounting nuts 1 and take out regulator through hole 2 as shown in figure Inspection 1 Check regulator sliding and rotating parts for greasing 2 Check rollers for wear and damage 3 Check wire for damage Installation Reverse removal procedure to install window regulator noting the following point Tighten door glass attaching screws to specified torq...

Page 750: ...ollowing Note Observe the following precautions when applying adhesive 4 along glass 2 edge Adhesive 4 should be applied evenly especially in height Be careful not to damage primer 3 Press glass against body quickly after adhesive 4 is applied Height b 15 mm 0 59 in Width c 7 mm 0 28 in Width d 16 mm 0 63 in Clearance e 13 mm 0 51 in 1 Fastener 2 Glass 3 Primer 4 Adhesive 2 1 ...

Page 751: ...Door Window Defogger Wire Inspection If Equipped Note When cleaning back door window glass use a dry cloth to wipe it along heat wire 1 direction When cleaning glass do not use detergent or abrasive containing glass cleaner When measuring wire voltage use a tester with positive probe 2 wrapped with a tin foil 3 which should be held down on wire by finger pressure Wire Damage Inspection 1 Start eng...

Page 752: ...ts negative terminal to terminal E of power window mainswitch 4 Check for continuity between terminals as shown below If check result is not as specified replace power window main switch 2 1 4 Touch voltmeter negative lead to defogger wire ground terminal end 1 5 Touch voltmeter positive lead with a foil strip to defogger wire power source terminal end 2 then move it along wire to defogger wire gr...

Page 753: ...Remove driver side door trim referring to step 1 to 4 of Front Door Glass Removal and Installation 2 Remove power window main switch from door trim 3 Check for continuity between terminals as shown below If check result is not as specified replace power window main switch ...

Page 754: ... trim refer to Step 1 to 4 of Front Door Glass Removal and Installation For rear door trim refer to Step 1 to 4 of Rear Door Glass Removal and Installation 2 Remove power window sub switch from door trim 3 Check for continuity between terminals at each switch condition If check result is not as specified replace switch ...

Page 755: ...LASS REMOVAL in this section 3 Remove door sash Security And Locks Front Door Lock Assembly 1 Out side door handle 2 Door lock cylinder 3 Inside door handle 4 Door latch assembly Apply SUZUKI SUPER GREASE A 99000 25010 to door latch sliding part 5 Door latch striker 6 Door latch assembly mounting screws 7 Door latch striker mounting screws ...

Page 756: ...lock TighteningTorque a 10 N m 1 0 kg m 7 5 lb ft b 6 N m 0 6 kg m 4 5 lb ft Move door latch striker 1 sideways to adjust door outer panel surface 2 flush with rear door outer panel or body outer panel surface 3 as shown In order to correctly obtain door latch 1 position in the fore andaft direction increase or decrease number of shims 4 inserted between body 3 and striker 1 to adjust it Note Appl...

Page 757: ...7 of REAR DOOR GLASS REMOVAL in this section 3 Disconnect door lock control rod 1 4 Disconnect door opening control rod 2 5 Remove door lock mounting screws 4 and door lock assem bly 3 Installation Reverse removal procedure to install rear door lock noting points mentioned in FRONT DOOR LOCK ASSEMBLY Rear Door Lock Assembly ...

Page 758: ... To install back door lock reverse removal procedure noting the following points Make sure that door latch striker 1 center aligns with the center of groove A in door lock 2 as shown in figure To adjust door lock 2 and door latch striker 1 each other insert proper number of shims 3 below the bottom of door latch striker 1 Inspection Check that door opens and closes smoothly and properly Also check...

Page 759: ...ners of key cut ting equipment from suppliers If key codes are not available from records or tags key code can be obtained from the right hand door lock cylinder if lock has not been replaced Lock cylinders supplied by the factory as service parts are unmarked If original key is available key code cutting combination can be determined by laying key Ignition Switch Lock Cylinder Removal Installatio...

Page 760: ......

Page 761: ...ms for installation When installing seat assembly to floor panel according to followings 1 Ensure that installing positioning pin for mounting parts to floor panel 2 Move to most backward seat slider for seat locking and check that making certain to locking 3 Tighten both side front seat adjuster bolt first and tighten both side rear seat adjuster bolt next by moving to most backward seat slider 4...

Page 762: ...9G 2 SEATS Removal and Installation Refer to above figure when removing and installing or disassembling and assembling rear seat Rear Seats 40 54 N m 40 54 N m 1 2 3 4 ...

Page 763: ...g brake lever cover console box 5 Remove front floor carpet Installation Reverse removal sequence to install front floor carpet noting the following point When tightening seat belt anchor bolt refer to Section 10 FRONT SEAT BELT for tightening torque 1 2 3 5 6 7 8 9 10 A 1 Floor carpet 2 Dash panel silencer 3 Floor upper pad if equipped 4 NIL 5 Luggage floor silencer and Spare tire cover 6 Tool as...

Page 764: ...sun visor 1 4 Remove assistant grip 1 5 Remove door opening trims 2 and quarter window trim 3 6 Remove centre pillar trim upper and front piller trim 7 Remove head lining clips 4 and head lining Note Adhesive is used to attach head lining Clear adhesive from headlining and roof after removing head lining 1 2 ...

Page 765: ...e removal procedure for installation noting the following items Attach adhesive tape 1 to head lining 2 as shown in figure Tighten sun visor screw 1 to specified torque Tightening Torque a 4 N m 0 4 kg m 2 8 lb ft Required Service Material ...

Page 766: ......

Page 767: ...ft of hood is not level with front fender make it level by tightening or loosening hood cushion 1 4 Hood lock position adjustment when installing hood lock 1 bring bolt at highest position and move it in vertical direction for adjustment free from loose to hood striker Tightening Torque a 10 N m 1 0 kg m 7 0 lb ft Inspection Check that hood opens and closes smoothly and properly ubricate if necess...

Page 768: ...or of side turn signal or side marker lamp 4 Remove wiper arms and garnish 5 Remove front fender 2 Installation Reverse removal procedure for installation Note If paint on fender bolt is peeled off be sure to apply paint again Adjust panel clearance referring to PANEL CLEARANCE in this section Front Fender ...

Page 769: ...pper 2 4 Support door panel 2 using a jack 3 with a piece of wood 1 placed between jack and panel as shown 1 2 3 4 5 2 1 2 3 4 5 2 1 Door panel 2 Door hinge Apply SUZUKI SUPER GREASE A 99000 25010 to hinge rotating part 3 Door open stopper Apply SUZUKI SUPER GREASE A 99000 25010 to stopper sliding part 4 Door open stopper pin 5 Door mounting bolts Front Door RearDoor ...

Page 770: ...referring to FRONT DOOR LOCK INSTALLATION section so that door is positioned correctly Adjust front door cushion so that door becomes flush with side body After installation open and close the door to check looseness Replace door open stopper pin when there is looseness When weatherstrip is hardened water leak may develop In such case replace it with a new one Rear Door Assembly Removal Installati...

Page 771: ...HOOD FENDERS DOORS 9J 5 Back Door Assembly 1 2 4 5 3 1 Removal 1 Remove back door trim 1 2 Remove wire harness connectors inside the back door ...

Page 772: ...ancer carefully Do not scar or scratch exposed surface of its piston rod and never allow any paint or oil to stick to its surface Do not turn piston rod with balancer fully extended 4 Remove door hinge bolts and remove back door assembly Installation Reverse removal procedure to install back door noting the following points Secure wiring harness 1 Adjust door latch striker position by referring to...

Page 773: ...BODY STRUCTURE 9K 1 Front Bumper Rear Bumper Body Structure ...

Page 774: ...9K 2 BODY STRUCTURE Body Dimensions Unit in mm ...

Page 775: ...BODY STRUCTURE 9K 3 Unit in mm Unit in mm ...

Page 776: ...9K 4 BODY STRUCTURE Unit in mm Unit in mm ...

Page 777: ...BODY STRUCTURE 9K 5 Unit in mm Under Body Dimensions ...

Page 778: ...9K 6 BODY STRUCTURE Unit in mm ...

Page 779: ... h i j k l m n o p q r s t u v i 3 9 1 0 j 7 8 1 0 k 5 1 1 0 l 5 5 1 0 m 5 2 1 0 n 5 6 1 0 o 4 6 1 0 b 4 2 2 0 0 0 c 5 1 1 0 e 6 5 1 0 f 6 5 1 0 g 6 5 1 0 h 10 3 1 0 a 1 6 1 0 p 3 2 1 0 q 3 2 1 0 s 4 5 1 0 r 7 8 1 5 t 4 2 2 0 0 0 u 6 3 1 0 v 8 9 1 0 ...

Page 780: ......

Page 781: ... is applied to the specific joints of a vehicle during production The sealer is intended to prevent dust from entering the vehicle and serves also as an anticorrosion barrier The sealer is applied to the door and hood hem areas and between panels Correct and reseal the originally sealed joints if damaged Reseal the attaching joints of a new replacement panel and reseal the hem area of a replacemen...

Page 782: ...aces of exterior body parts Also apply anti corrosive compound to inner surfaces of exterior body parts to be installed Scrape the accessible places If a standard putty knife or scraper does not fit to the elevant place consider to use a more flexible scraper to a place narrowly enclosed by sheet metals A jet of compressed air can remove most residues and is effective to limited areas However this...

Page 783: ...PAINT COATINGS 9L 3 Sealant Application Area ...

Page 784: ...9L 4 PAINT COATINGS ...

Page 785: ...PAINT COATINGS 9L 5 ...

Page 786: ...9L 6 PAINT COATINGS ...

Page 787: ...per drying temperature range is 60 to 70 C Reference Plastic parts employ not only ABS Acrylonitrile Butadiene Styrene plastic but also polypropylene vinyl or the like plastic Burning test method to identify ABS plastic is described below 1 Use a sharp blade to cut off a plastic sliver from the part at its hidden backside 2 Hold sliver with pincers and set it on fire 3 Carefully observe condition ...

Page 788: ......

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