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Suzuki 2006 SX4, Service Manual

The Suzuki 2006 SX4 Service Manual is available for free download at manualshive.com. This comprehensive manual provides detailed instructions and diagrams to help you maintain and repair your SX4. Get the manual today and keep your Suzuki running smoothly.

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1-iv Table of Contents

Oil Pump Components ........................................1E-8
Oil Pump Removal and Installation .....................1E-9
Oil Pump Disassembly and Reassembly ..........1E-10
Oil Pump Inspection ..........................................1E-10

Specifications.....................................................1E-11

Tightening Torque Specifications......................1E-11

Special Tools and Equipment ...........................1E-12

Recommended Service Material .......................1E-12
Special Tool ......................................................1E-12

Engine Cooling System ...........................1F-1

General Description ............................................. 1F-1

Cooling System ................................................... 1F-1
Coolant................................................................ 1F-1

Schematic and Routing Diagram........................ 1F-2

Coolant Circulation.............................................. 1F-2

Diagnostic Information and Procedures............ 1F-3

Engine Cooling Symptom Diagnosis................... 1F-3

Repair Instructions .............................................. 1F-4

Cooling System Components.............................. 1F-4
Coolant Level Check ........................................... 1F-5
Engine Cooling System Inspection and 

Cleaning............................................................ 1F-5

Cooling System Draining..................................... 1F-5
Cooling System Flush and Refill ......................... 1F-6
Cooling Water Pipes or Hoses Removal and 

Installation......................................................... 1F-6

Thermostat Removal and Installation.................. 1F-7
Thermostat Inspection......................................... 1F-7
Radiator Cooling Fan Assembly Inspection ........ 1F-8
Radiator Cooling Fan Relay Inspection............... 1F-8
Radiator Cooling Fan Assembly Removal and 

Installation......................................................... 1F-8

Radiator Cooling Fan Disassembly and 

Reassembly ...................................................... 1F-9

Radiator On-Vehicle Inspection and Cleaning .... 1F-9
Radiator Removal and Installation ...................... 1F-9
Water Pump Removal and Installation.............. 1F-10
Water Pump Inspection..................................... 1F-10

Specifications..................................................... 1F-10

Tightening Torque Specifications...................... 1F-10

Fuel System ............................................. 1G-1

Precautions.......................................................... 1G-1

Precautions on Fuel System Service ................. 1G-1

General Description ............................................ 1G-2

Fuel System ....................................................... 1G-2
Fuel Delivery System ......................................... 1G-2
Fuel Pump.......................................................... 1G-2

Schematic and Routing Diagram....................... 1G-3

Fuel Delivery System Diagram........................... 1G-3

Diagnostic Information and Procedures........... 1G-3

Fuel Pressure Inspection ................................... 1G-3
Fuel Cut Operation Inspection ........................... 1G-4

Repair Instructions ............................................. 1G-5

Fuel System Components.................................. 1G-5
Fuel Hose Disconnecting and Reconnecting ..... 1G-6
Fuel Pressure Relief Procedure ......................... 1G-8
Fuel Leakage Check Procedure......................... 1G-8

Fuel Tank, Cap Gasket and Fuel Line 

Inspection......................................................... 1G-8

Fuel Pipe Removal and Installation.................... 1G-9
Fuel Injector On-Vehicle Inspection ................... 1G-9
Fuel Injector Removal and Installation ............. 1G-10
Fuel Injector Inspection .................................... 1G-11
Fuel Filler Cap Inspection ................................ 1G-12
Fuel Tank Inlet Valve Removal and 

Installation ...................................................... 1G-13

Fuel Tank Inlet Valve Inspection ...................... 1G-13
Fuel Tank Removal and Installation................. 1G-13
Fuel Tank Inspection........................................ 1G-16
Fuel Tank Purging Procedure .......................... 1G-16
Fuel Pump On-Vehicle Inspection.................... 1G-16
Fuel Filter Replacement ................................... 1G-17
Fuel Pump Assembly Removal and 

Installation ...................................................... 1G-17

Main Fuel Level Sensor Removal and 

Installation ...................................................... 1G-18

Fuel Pump Inspection ...................................... 1G-18

Specifications .................................................... 1G-19

Tightening Torque Specifications..................... 1G-19

Special Tools and Equipment .......................... 1G-19

Special Tool ..................................................... 1G-19

Ignition System........................................ 1H-1

General Description .............................................1H-1

Ignition System Construction ..............................1H-1

Schematic and Routing Diagram ........................1H-2

Ignition System Wiring Circuit Diagram...............1H-2

Component Location ...........................................1H-3

Ignition System Components Location................1H-3

Diagnostic Information and Procedures ............1H-3

Ignition System Check ........................................1H-3
Ignition System Symptom Diagnosis...................1H-5
Reference Waveform of Ignition System.............1H-5
Ignition Spark Test ..............................................1H-5

Repair Instructions ..............................................1H-6

Spark Plug Removal and Installation ..................1H-6
Spark Plug Inspection .........................................1H-6
Ignition Coil Assembly (Including ignitor) 

Removal and Installation...................................1H-6

Ignition Coil Assembly (Including ignitor) 

Inspection..........................................................1H-6

Ignition Timing Inspection ...................................1H-7

Specifications .......................................................1H-8

Tightening Torque Specifications........................1H-8

Special Tools and Equipment .............................1H-8

Special Tool ........................................................1H-8

Starting System .........................................1I-1

Schematic and Routing Diagram ......................... 1I-1

Cranking System Circuit Diagram ........................ 1I-1

Diagnostic Information and Procedures ............. 1I-1

Cranking System Symptom Diagnosis................. 1I-1
Cranking System Test.......................................... 1I-3

Repair Instructions ............................................... 1I-4

Starting Motor Unit Components.......................... 1I-4
Starting Motor Dismounting and Remounting ...... 1I-4

Summary of Contents for 2006 SX4

Page 1: ...ed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing se...

Page 2: ......

Page 3: ...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 specif...

Page 4: ...old as SUZUKI authorized replacement parts and accessories Some genu ine SUZUKI parts and accessories are sold as re use parts and accessories These parts and accessories are non genuine Suzuki parts...

Page 5: ...kes 4B 1 Rear Brakes 4C 1 Parking Brake 4D 1 ABS 4E 1 Transmission Transaxle 5 i Precautions 5 1 Automatic Transmission Transaxle 5A 1 Manual Transmission Transaxle 5B 1 Clutch 5C 1 Volume 2 Precautio...

Page 6: ......

Page 7: ...icing 4WD Model 00 7 Precautions for Catalytic Converter 00 8 Precautions for Installing Mobile Communication Equipment 00 8 Precaution for CAN Communication System 00 8 Precautions for Electrical Cir...

Page 8: ...ures 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 troubles...

Page 9: ...ting bracket 3 It is also prohibited to place anything on top of the trim cover and stack air bag inflator modules This is necessary so that a free space is provided to allow the air bag to expand in...

Page 10: ...uired 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 inf...

Page 11: ...ly dispose of used oil and filters Be sure to observe following instructions when handling service materials such as fuel oil fluid coolant grease sealant thread lock cement etc Otherwise your health...

Page 12: ...n other parts as specified be sure to use new ones Also before installing new gaskets packing etc be sure to remove any residual material from the mating surfaces Make sure that all parts used in reas...

Page 13: ...he heat sensitive electrical part s beforehand Use care not to expose connectors and electrical parts to water which will be a cause of a trouble Always be careful not to handle electrical parts compu...

Page 14: ...erve the following instructions Otherwise drive train damage and personal injury may result Shift transaxle to N Neutral position Select 4WD system to 2WD mode Run engine at specified idle speed Rotat...

Page 15: ...be sure to observe the following precautions Failure to follow cautions may adversely affect electronic control system Keep the antenna as far away as possible from the vehicle s electronic control u...

Page 16: ...r lock first and then pull them apart by holding connectors themselves When connecting connectors also hold connectors and put them together until they lock securely a click is heard When installing t...

Page 17: ...igital type voltmeter When taking measurements at electrical connectors using a tester probe be sure to insert the probe 2 from the wire harness side backside of the connector 1 When connecting meter...

Page 18: ...are not followed parts or system damage could result Suspension Caution S6RW0C0000011 CAUTION All suspension fasteners are an important attaching part in that it could affect the performance of vital...

Page 19: ...e circuit being checked for contact tension of its female terminal Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time che...

Page 20: ...ls A 1 and B 1 Voltage between C 1 and body ground Approx 5 V B 1 and body ground Approx 5 V A 1 and body ground Approx 3 V Short Circuit Check Wire Harness to Ground 1 Disconnect negative cable at ba...

Page 21: ...formed or damaged terminals Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal If contact tension is not enough refor...

Page 22: ...00 15 Precautions...

Page 23: ...ines and Connections Inspection 0B 3 Fuel Filter Replacement 0B 3 Fuel Tank Inspection 0B 3 PCV Valve Inspection 0B 3 Fuel Evaporative Emission Control System Inspection 0B 4 Brake Discs and Pads Insp...

Page 24: ...lant Temperature Sensor Water Temp Sensor WTS EFE Heater Early Fuel Evaporation Heater Positive Temperature Coefficient PTC Heater EGR Exhaust Gas Recirculation EGRT Sensor EGR Temperature Sensor Reci...

Page 25: ...y Catalytic Converter Symbols S6RW0C0101002 Wire Color Symbols S6RW0C0101003 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO 1216B 99000 31230 Apply oil engine transmission...

Page 26: ...ad pitch for correct matching and then tighten it by hand temporarily If it is tight recheck the thread pitch JIS TO ISO Main Fasteners Comparison Table Fastener Strength Identification Most commonly...

Page 27: ...0 32 5 47 0 76 0 116 0 A equivalent of 6 8 strength fastener without flange N m 2 4 4 7 8 4 20 42 80 125 193 280 kgf m 0 24 0 47 0 84 2 0 4 2 8 0 12 5 19 3 28 lb ft 2 0 3 5 6 0 14 5 30 5 58 0 90 5 139...

Page 28: ...l not fall off by trying to move vehicle body in both ways Work can be started only after this confirmation Make absolutely sure to lock hoist after vehicle is hoisted up When Using Frame Contact Hois...

Page 29: ...cle body does not slide on safety stands 1 and the vehicle is held stable for safety s sake Vehicle Identification Number S6RW0C0101006 The number is punched on the front dash panel in engine room and...

Page 30: ...vehicle component parts When servicing and handling parts refer to WARNING CAUTION instructions printed on labels If any WARNING CAUTION label is found stained or damaged clean or replace it as neces...

Page 31: ...assembly 7 Pretensioner label on seat belt retractor 3 Air bag label on passenger air bag inflator module 8 Side Curtain air bag label on pillar both right and left sides if equipped 4 Air bag label o...

Page 32: ...R When unleaded fuel is used Nickel Plug R R When leaded fuel is used refer to Maintenance Recommended under Severe Driving Conditions Fuel system Air cleaner filter R I Paved road I I R I I R Dusty c...

Page 33: ...sfer oil 4WD leakage level I I I I Rear differential oil 4WD leakage level I R 1st 15 000 km only R or I I I All latches hinges and locks I I I I HVAC air filter if equipped I R I R I R Interval Km x...

Page 34: ...to Cooling System Flush and Refill in Section 1F Exhaust System Inspection S6RW0C0206006 Check exhaust system referring to Exhaust System Check in Section 1K Spark Plug Replacement S6RW0C0206007 Repla...

Page 35: ...eering system referring to Steering System Inspection in Section 6A Drive Shaft Axle Boots Inspection S6RW0C0206025 Check front and rear if equipped drive shaft boots referring to Front Drive Shaft As...

Page 36: ...ition promptly Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage On automatic transaxle vehicles try to start the engine in ea...

Page 37: ...froster outlet when operating heater or air conditioning Set mode control lever to defroster position and fan switch lever to highest position for this check Special Tools and Equipment Recommended Fl...

Page 38: ...0B 7 Maintenance and Lubrication...

Page 39: ...Lamp MIL Check 1A 28 DTC Check 1A 29 DTC Clearance 1A 29 Troubleshooting for Communication Error with Scan Tool Using CAN 1A 29 DTC Table 1A 34 Fail Safe Table 1A 40 Scan Tool Data 1A 42 Visual Inspe...

Page 40: ...Sensor Signal Stuck Lean Stuck Rich Sensor 1 Bank 1 1A 123 DTC P2227 P2228 P2229 Barometric Pressure Circuit Performance Low High 1A 124 DTC U0073 Control Module Communication Bus Off 1A 125 DTC U0101...

Page 41: ...linder Head Cover Removal and Installation 1D 12 Engine Mountings Components 1D 14 Engine Assembly Removal and Installation 1D 15 Timing Chain Cover Components 1D 19 Timing Chain Cover Removal and Ins...

Page 42: ...ing 1G 6 Fuel Pressure Relief Procedure 1G 8 Fuel Leakage Check Procedure 1G 8 Fuel Tank Cap Gasket and Fuel Line Inspection 1G 8 Fuel Pipe Removal and Installation 1G 9 Fuel Injector On Vehicle Inspe...

Page 43: ...ng in Case of Emergency 1J 6 Battery Dismounting and Remounting 1J 7 Water Pump and Generator Drive Belt On Vehicle Inspection 1J 8 Water Pump and Generator Drive Belt Removal and Installation 1J 8 Ge...

Page 44: ...of ECM Circuit Inspection in Section 1A Precautions on Fuel System Service Refer to Precautions on Fuel System Service in Section 1G Precaution for CAN Communication System Refer to Precaution for CAN...

Page 45: ...stic OBD System S6RW0C1100009 There are two types of On Board Diagnostic OBD system Euro OBD system and non Euro OBD system depending on the vehicle specification It is possible to identify each OBD s...

Page 46: ...Procedure after ECM Replacement in Section 10C Precautions for DTC Troubleshooting S6RW0C1100005 Before performed trouble shooting be sure to read the Precautions of ECM Circuit Inspection When measu...

Page 47: ...time than necessary 1 Checking connector related to CAN 2 Checking CAN line 3 Checking each control module sensor using DTC check or Bus Check 4 Checking power and ground connection of each control mo...

Page 48: ...nd TCM communicating with scan tool using CAN line General Description Statement on Cleanliness and Care S6RW0C1101001 An automobile engine is a combination of many machined honed polished and lapped...

Page 49: ...e effect to vehicle emission while the engine is running it makes MIL in the meter cluster of the instrument panel turn ON or flash flashing only when detecting a misfire which can cause damage to the...

Page 50: ...n the 2nd through the 4th frames the freeze frame data of each malfunction is stored in the order as the malfunction is detected These data are not updated Shown in the table below are examples of how...

Page 51: ...DTC Check and DTC Clearance For information about the following items refer to Euro OBD model Warm up cycle Driving cycle 2 driving cycle detection logic Pending DTC DLC Data Link Connector S6RW0C1101...

Page 52: ...system CAN communication system uses the serial communication in which data is transmitted at a high speed It uses a twisted pair of two communication lines for the high speed data transmission As one...

Page 53: ...MIL control signal Engine coolant temperature signal Fuel level signal Cruise control signal CRUSE and SET indication light control signal Vehicle speed signal Brake pedal switch signal A C compresso...

Page 54: ...drawn into each combustion chamber Electric throttle body is not equipped with IAC valve for idle speed control Idle speed control is done by the throttle actuator 7 which opens closes the throttle va...

Page 55: ...When there is no difference ECM controls the duty ratio of throttle actuator control to about 15 to maintain the throttle valve opening In this way the throttle valve 17 is opened and closed to achiev...

Page 56: ...ely closed throttle valve position If the engine is started during this registration process such symptom as longer cranking time or slow rise of revolution speed immediately after start up may occur...

Page 57: ...Electric Throttle Body Control System Fuel pump control system Radiator cooling fan control system Evaporative emission control system A F sensor heater control system HO2S heater control system A C c...

Page 58: ...ke light switch Air cleaner IAT sensor MAF sensor A C refrigerant pressure sensor TP sensor Throttle body assembly Throttle actuator IMT valve actuator A C condenser fan Three way catalyst DLC Cuise c...

Page 59: ...49 WHT RED 19 47 46 42 45 27 YEL YEL BLK C01 42 C01 43 E01 15 10 BLU YEL C01 28 56 GRN WHT 55 E01 20 24 8 C01 14 C01 12 RED BLU GRY RED E01 41 E01 36 WHT BLK ORN 9 44 23 IG2 BB BLU WHT BLU WHT E01 35...

Page 60: ...ompressor relay 73 Barometric pressure sensor 24 Blower speed selector Manual A C model 49 A C compressor 74 Engine ground 25 A C switch 50 A C fuse 75 Body ground E01 C01 3 4 18 19 5 6 7 10 11 17 20...

Page 61: ...tric load signal for heater blower motor 6 RED WHT Cruise control main switch signal 36 ORN Ground for sensor 7 LT GRN BLK Clutch pedal position switch signal cruise control model 37 8 GRN YEL Brake p...

Page 62: ...relay output Terminal Wire color Circuit Terminal Wire color Circuit Function Output Input Main relay control Main relay Ignition switch Fuel pump control Fuel pump relay CKP sensor Ignition switch St...

Page 63: ...switch A C switch Blower speed selector Barometric pressure sensor Ignition switch Starter switch Immobilizer control module in ECM Ignition control Ignition coil with igniter Ignition switch Starter...

Page 64: ...sor Immobilizer control module in ECM Throttle actuator power supply control Throttle actuator control relay Ignition switch TP sensor APP sensor IMT valve control IMT valve actuator Ignition switch E...

Page 65: ...A 21 A C condenser cooling fan control A C condenser cooling fan relay Wheel speed sensor VSS A C refrigerant pressure sensor A C evaporator outlet air temp sensor ECT sensor A C switch Blower fan swi...

Page 66: ...and Diagnosis Schematic and Routing Diagram Engine and Emission Control System Diagram S6RW0C1102001 23 29 14 13 15 16 17 11 12 10 1 2 19 20 21 39 42 41 40 38 36 28 3 30 31 37 26 27 32 4 5 22 24 35 34...

Page 67: ...control model 6 EVAP canister purge valve 20 CMP sensor 34 Brake switch cruise control model 7 EVAP canister 21 CKP sensor 35 APP sensor 8 Vapor control valve assembled into the fuel tank 22 TCM 36 Br...

Page 68: ...tor b EVAP canister purge valve B Combination meter 3 Brake light switch c Fuel pump relay C EVAP canister 4 ECT sensor d MIL D A C evaporator temperature sensor 5 A F sensor e Radiator cooling fan re...

Page 69: ...y faulty condition Repair or replace malfunction part and go to Step 11 Go to Step 8 5 Trouble symptom confirmation 1 Confirm trouble symptom referring to Trouble Symptom Confirmation Is trouble sympt...

Page 70: ...ation and Diagnosis 11 Final confirmation test 1 Clear DTC if any 2 Perform final confirmation test referring to Final Confirmation Test Is there any problem symptom DTC or abnormal condition Go to St...

Page 71: ...rred as described by the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis Customer problem inspec...

Page 72: ...check the parts of the system suspected as a possible cause referring to Engine Symptom Diagnosis and based on symptoms appearing on the vehicle symptoms obtained through steps of customer complaint...

Page 73: ...ool or SUZUKI scan tool to DLC 2 Turn ignition switch ON 3 Erase DTC and pending DTC according to instructions displayed on scan tool Freeze frame data is cleared with the DTC Refer to scan tool opera...

Page 74: ...14 29 55 57 5453 59 60 58 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 3938 44 45 43 41 33 12 13 23 8 E01 C01 1 2 3 10 11 12 16 17 18 15 14 13 19 20 21 25 24 23 22 26 5 4 6 7 8 9 F G26 6 5 15 16 1413...

Page 75: ...ool and ECM by DTC check in ECM Is it possible to check DTC in ECM Go to Step 2 Scan tool faulty Refer to its operator s manual 2 DLC power circuit check 1 Check for proper connection to all DLC 1 ter...

Page 76: ...short to other CAN line and high resistance Are CAN lines between DLC and BCM connector in good condition Go to Step 6 Repair CAN line 6 Control module connector check 1 Turn ignition switch to OFF p...

Page 77: ...ation meter connectors 3 Check communication between scan tool and ECM by DTC check in ECM Is it possible to check DTC in ECM A T model Go to Step 9 M T model Substitute a known good ECM and recheck G...

Page 78: ...though control duty ratio of HO2S heater is less than 75 with engine running Heater control duty pulse is not detected in its monitor signal 2 driving cycles 2 driving cycles P0038 HO2S Heater Control...

Page 79: ...nd HO2S max voltage minus HO2S min voltage is lower than 0 2 V 2 driving cycles 2 driving cycles P0140 O2 Sensor Circuit No Activity Detected Bank 1 Sensor 2 Output voltage of HO2S is higher than 4 5...

Page 80: ...cooling fan relay No 1 is OFF 1 driving cycle 1 driving cycle P0481 Fan 2 Control Circuit Monitor signal of A C condenser cooling fan relay is lower than specified voltage for 5 sec even though A C s...

Page 81: ...cycle 1 driving cycle P2123 Throttle Pedal Position Sensor Switch D Circuit High Input Output voltage of APP sensor main is higher than 4 8 V for 0 5 sec 1 driving cycle 1 driving cycle P2127 Throttl...

Page 82: ...cle equipped with keyless start system only Refer to DTC Table in Section 10C 1 driving cycle Not applicable P1616 Different registration ID codes vehicle equipped with keyless start system only Refer...

Page 83: ...erature Sensor A Circuit High P0717 Input Speed Sensor A Circuit No Signal P0722 Output Speed Sensor Circuit No Signal P0741 Torque Converter Clutch Circuit Performance or Stuck Off P0742 Torque Conve...

Page 84: ...M stops air fuel ratio feed back closed loop control ECM stops IAC feedback control ECM stops A C control P0118 Engine Coolant Temperature Circuit High P0122 Throttle Pedal Position Sensor Switch A Ma...

Page 85: ...its completely closed position default opening ECM controls fuel cut at specified engine speed P2102 Throttle Actuator Control Motor Circuit Low P2103 Throttle Actuator Control Motor Circuit High ECM...

Page 86: ...No Detected item Fail safe operation Scan tool data Vehicle condition Normal condition reference values COOLANT TEMP ENGINE COOLANT TEMP At specified idle speed after warming up 80 100 C 176 212 F IN...

Page 87: ...e under A C System Performance Inspection in Section 7B A C OFF A C is not operating at ambient temperature 30 C 86 F and engine coolant temperature 90 100 C 194 212 F 600 1000 kPa After longer than 1...

Page 88: ...E OPENING It idling with no load after warming up 5 55 THROTTLE MOTOR VOLT Ignition switch ON engine at stop 10 0 14 0 V CLOSED THROTTLE POS CLOSED THROTTLE POSITION Throttle valve at idle position ON...

Page 89: ...S installed on exhaust No 1 pipe post WU TWC It is used to detect catalyst deterioration SHORT FT B1 SHORT TERM FUEL TRIM Short term fuel trim value represents short term corrections to the air fuel m...

Page 90: ...ed position TARGET THROTTLE POSI TARGET THROTTLE VALVE POSITION Target Throttle Valve Position is ECM internal parameter which indicates the ECM requested throttle valve position IAC THROTTLE OPENING...

Page 91: ...ric wire harness Disconnection friction Fuses Burning Intermittent and Poor Connection Inspection in Section 00 Parts Installation deformation Bolt Looseness Other parts that can be checked visually A...

Page 92: ...t in good condition Go to Step 10 Immobilizer control system malfunction 10 Check fuel supply 1 Check to make sure that enough fuel is filled in fuel tank 2 Turn ON ignition switch for 2 sec and then...

Page 93: ...ction 1H Compression leak from valve seat Valves and Valve Guides Inspection in Section 1D Sticky valve stem Valves and Valve Guides Inspection in Section 1D Weak or damaged valve springs Valve Spring...

Page 94: ...el is used Low oil pressure Condition Low oil pressure Worn main bearing Main Bearings Crankshaft and Cylinder Block Inspection in Section 1D Worn crankshaft journal Main Bearings Crankshaft and Cylin...

Page 95: ...stion chamber Sticky piston ring Pistons Piston Rings Connecting Rods and Cylinders Inspection and Cleaning in Section 1D Worn piston and cylinder Pistons Piston Rings Connecting Rods and Cylinders In...

Page 96: ...ously sharp metallic knocks that change with throttle opening Sounds like pop corn popping Faulty spark plug Spark Plug Inspection in Section 1H Engine overheating Condition Engine overheating Clogged...

Page 97: ...idling or engine fails to idle Faulty spark plug Spark Plug Inspection in Section 1H Faulty ignition coil with ignitor Ignition Coil Assembly Including ignitor Inspection in Section 1H Fuel pressure...

Page 98: ...on APP Sensor Assembly Inspection in Section 1C Faulty injector s Fuel Injector Circuit Check Faulty ECM Inspection of ECM and Its Circuits Engine not at normal operating temperature Clogged air clean...

Page 99: ...2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31...

Page 100: ...referring to Step 5 to 10 under Troubleshooting for Communication Error with Scan Tool Using CAN Is circuit in good condition Go to Step 5 Repair or replace 5 METER fuse check 1 Turn ignition switch...

Page 101: ...detected MIL remains ON even when the engine is running Troubleshooting NOTE When measuring circuit voltage resistance and or pulse signal at ECM connector connect the special tool to ECM and or the E...

Page 102: ...2 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 1 2 BLK BLK 7 RED BLU C01 47 C01 11 C01 39 BLU WHT BRN BLK RED 3 8 4 6 2 A1 5 C...

Page 103: ...check that A F sensor circuit is as follows Insulation resistance of wire harness is infinity between Signal circuit of A F sensor terminal and each other terminal at A F sensor connector Wiring harne...

Page 104: ...d ON Is it good condition Go to Step 4 Repair or replace defective wiring harness connector 4 A F sensor heater circuit check 1 Disconnect connectors form ECM and check for proper terminal connection...

Page 105: ...though control duty ratio of HO2S heater is more than 25 with engine running Heater control duty pulse is not detected in its monitor signal 2 driving cycle detection logic HO2S heater and or its cir...

Page 106: ...n in Section 1C Is HO2S heater in good condition Substitute a known good ECM and recheck Replace HO2S Step Action Yes No E01 C01 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55...

Page 107: ...and throttle angle for 7 sec 2 driving cycle detection logic Air intake system Clog or leakage MAF sensor and or its circuit Exhaust system clogged WU TWC converter TP sensor and or its circuit ECM S...

Page 108: ...on 1C Is each value within specified range Substitute a known good ECM and recheck Replace MAF and IAT sensor Step Action Yes No DTC detecting condition Trouble area DTC P0102 Output voltage of MAF se...

Page 109: ...d ground circuit is less than 3 Insulation resistance between MAF sensor signal circuit and vehicle body ground is Infinity Insulation resistance of wire harness is infinity between MAF sensor signal...

Page 110: ...re than 37 mph 60 km h for 15 min 5 Stop vehicle and run engine at idle speed 6 Check DTC and pending DTC DTC Troubleshooting DTC P0112 P0113 Intake Air Temperature Sensor Circuit Low High Input S6RW0...

Page 111: ...IAT sensor and ECM connectors 4 If connections are OK check that IAT sensor circuit is as follows Wiring harness resistance of each IAT sensor signal and ground circuit is less than 3 Insulation resis...

Page 112: ...nd barometric pressure sensor 1 With ignition switch OFF connect scan tool 2 Turn ON ignition switch clear DTC 3 Drive vehicle more than 40 mph 65 km h for more than 12 minutes 4 Stop vehicle 5 Check...

Page 113: ...on in Section 1F Is thermostat in good condition Go to Step 5 Replace thermostat 5 ECT sensor circuit check 1 With ignition switch OFF connect scan tool to DLC and disconnect ECT sensor connector 1 2...

Page 114: ...Go to Step 2 Go to Engine and Emission Control System Check 2 Wire harness check 1 Turn ignition switch OFF position 2 Disconnect connectors from ECT sensor and ECM 3 Check for proper terminal connec...

Page 115: ...01 15 C01 29 C01 48 C01 58 BRN GRN GRY BLU YEL E01 16 E01 50 E01 17 C01 45 C01 44 2 3 4 6 7 8 10 11 9 13 12 E01 29 BLK WHT C01 30 RED GRN WHT BLK BLK C01 53 C01 54 C01 40 C01 41 C01 33 BLK RED BLK RED...

Page 116: ...area P0122 Output voltage of TP sensor main is lower than 0 3 V 1 driving cycle detection logic Electric throttle body assembly TP sensor main circuit ECM P0123 Output voltage of TP sensor main is hig...

Page 117: ...erminal at TP sensor connector Circuit voltage of each TP sensor main signal power supply and ground circuit is 0 1 V with ignition switch turned ON Are they in good condition Go to Step 4 Repair or r...

Page 118: ...ut current is lower than 5 mA for 5 sec with engine running 2 driving cycle detection logic DTC P0132 A F sensor terminal voltage is higher than 3 8 V or A F sensor output current is higher than 5 mA...

Page 119: ...F sensor between A F sensor connector and ECM connector is less than 2 Resistance between sensing circuit wires of A F sensor connector are infinity Resistance between each sensing circuit wire of A...

Page 120: ...ng scan tool 3 Start engine and warm up to normal operating temperature 4 Drive vehicle at 40 mph 65 km h or higher 5 Keep above vehicle speed for 6 min or more 6 Stop vehicle 7 Check whether O2 senso...

Page 121: ...ting DTC detecting condition Trouble area Impedance of A F sensor element is higher than 500 for 15 sec even though A F sensor heater is turned ON for specified time with engine running 2 driving cycl...

Page 122: ...icle speed to 60 80 km h 37 50 mile h at 5th gear or D range 5 Release accelerator pedal and with engine brake applied keep vehicle coasting with fuel cut for 12 sec or more then stop vehicle and run...

Page 123: ...ith ignition switch turned OFF 2 Check for proper connection of each HO2S circuit terminal to HO2S connector and to ECM connector 3 If connections are OK check HO2S circuit for the following Wiring ha...

Page 124: ...n Yes No DTC detecting condition Trouble area Output voltage of HO2S is higher than 4 5 V for 0 5 sec 2 driving cycle detection logic HO2S and or its circuit ECM Step Action Yes No 1 Was Engine and Em...

Page 125: ...metric pressure sensor and A F sensor 1 With ignition switch turned OFF connect scan tool 2 Turn ON ignition switch and print Freeze Frame Data or write them down using scan tool 3 Clear DTC using sca...

Page 126: ...F sensor and air intake system Objects which block measuring duct and resistor of MAF sensor Other air flow which does not pass MAF sensor Are they in good condition Go to Step 7 Repair or replace def...

Page 127: ...r circuit and or TP sensor ground circuit is open DTC detecting condition Trouble area DCT P0222 Output voltage of TP sensor sub is lower than 0 74 V 1 driving cycle detection logic TP sensor sub circ...

Page 128: ...TP sensor connector Circuit voltage of each TP sensor sub signal power supply and ground circuit is 0 1 V with ignition switch turned ON Are they in good condition Go to Step 4 Repair or replace defe...

Page 129: ...Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more The following DTCs are not detected DTCs related to MAF sensor ECT sensor IAT sensor barometric pressure sensor TP sensor CK...

Page 130: ...fuel pressure referring to Fuel Pressure Check Is check result satisfactory Go to Step 7 Repair or replace 7 Fuel injector inspection 1 Check fuel injector s referring to Fuel Injector Inspection in S...

Page 131: ...39 38 44 45 43 41 33 1 12 13 23 8 I7RW01110055 02 A1 Knock sensor signal circuit 1 Knock sensor 2 ECM DTC detecting condition Trouble area DTC P0327 Output voltage of knock sensor is lower than 1 23...

Page 132: ...56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 4...

Page 133: ...heck that CKP sensor circuit is as follows Wiring harness resistance of CKP sensor signal circuit is less than 3 Insulation resistance of each CKP sensor signal and ground circuit between CKP sensor c...

Page 134: ...6 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41...

Page 135: ...to ON position 4 Check that CMP sensor power supply voltage is battery voltage between CMP sensor connector and vehicle body ground Is it in good condition Go to Step 4 CMP sensor power supply circui...

Page 136: ...bstitute a known good ECM and recheck Replace CMP sensor and or sensor rotor Step Action Yes No C01 11 C01 38 C01 39 WHT BRN 1 3 2 4 5 V BLK RED BLU WHT BLU WHT C01 37 BLK 5 5 V E01 C01 3 4 18 19 5 6...

Page 137: ...perating temperature 4 Increase vehicle speed to 50 60 mph 80 100 km h 5 Keep above vehicle speed for 10 min or more 6 Stop vehicle 7 Check whether catalyst readiness monitoring test has completed or...

Page 138: ...48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39...

Page 139: ...pair or replace EVAP canister purge valve power supply circuit 3 Wire harness check 1 Disconnect connector from ECM with ignition switch turned OFF 2 Check that EVAP canister purge valve circuit is as...

Page 140: ...12 V 1 5 E01 24 YEL RED BLK ORN PNK BLK GRN WHT E01 15 BLK WHT BRN WHT BLK RED BLK RED BLK RED BLK RED WHT BLK YEL GRN 12V 5V 6 7 3 2 E01 1 E01 60 E01 16 BLK YEL BLK YEL 4 8 9 I6RW0C110023 01 1 Fuel p...

Page 141: ...el level sensor 3 Wire harness check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Check for proper terminal connection to fuel level sensor and ECM connectors 3 If connections ar...

Page 142: ...0 42 39 38 44 45 43 41 33 1 12 13 23 8 8 C01 15 C01 29 C01 48 C01 58 C01 30 BLK BLK BLK BLK ORN BLK ORN 12V 5V 2 1 11 7 3 4 6 5 10 E01 29 E01 1 E01 60 12 13 GRN BLK WHT WHT A2 A2 A2 A1 A1 A1 BLK RED B...

Page 143: ...again Go to Step 3 Intermittent trouble 3 Circuit fuse check 1 Check RDTR fuse 1 in fuse box No 2 with ignition switch turned OFF Is RDTR fuse in good condition Go to Step 4 Check for short in circuit...

Page 144: ...3 connector and vehicle body ground Is it in good condition Go to Step 6 Repair or replace power supply circuit of radiator cooling fan relay No 1 No 2 or No 3 6 Radiator cooling fan relay check 1 Che...

Page 145: ...6 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 7 C01 15 C01 29 C01 48 C01 58 C01 30 BLK BLK BLK BLK ORN BLK ORN 12V 5V 2 1 11 12 10 E01 29 E01 1 E01 60 8 9 GRN BLK WHT W...

Page 146: ...ck that A C condenser cooling fan relay control circuit voltage is battery voltage between ECM connector and vehicle body ground Is it in good condition Substitute a known good ECM and recheck Go to S...

Page 147: ...T model drive vehicle at more than 3 700 rpm for 10 sec 7 Check DTC and pending DTC E01 4 BLK WHT BLK WHT RED RED BLK 12V 12V E01 19 1 2 3 4 WHT BLK WHT RED WHT RED WHT E01 C01 3 4 18 19 5 6 7 10 11...

Page 148: ...nsor detected Go to applicable DTC diag Flow Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 If OK substitute a known good ECM and recheck E01 C01 3 4 18...

Page 149: ...signal ON are detected at a time Brake pedal switch signal OFF and brake light switch signal OFF are detected at a time 1 driving cycle detection logic but MIL does not light up Brake light switch an...

Page 150: ...ht switch Circuit voltage between Control circuit of brake pedal switch or Control circuit of brake light switch and vehicle body ground is 0 V with ignition switch turned ON Are they in good conditio...

Page 151: ...frigerant pressure sensor is lower than 0 2 V for 5 sec 1 driving cycle detection logic but MIL does not light up A C refrigerant pressure sensor and or its circuit ECM DTC P0533 Output voltage of A C...

Page 152: ...und circuit is in good condition referring to ECM Power and Ground Circuit Check Are checking results OK Substitute a known good ECM and recheck Repair ECM power or ground circuit E01 C01 3 4 18 19 5...

Page 153: ...d Emission Control System Check 2 Engine start signal check 1 Connect scan tool to DLC with ignition switch turned OFF 2 Turn ignition switch to ON position 3 Check engine start signal of STARTER SW u...

Page 154: ...47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25...

Page 155: ...nsulation resistance of wire harness is infinity between IMT valve control terminal and each other terminal at IMT valve connector Circuit voltage of IMT vacuum solenoid valve control circuit is 0 1 V...

Page 156: ...dal at fully depressed position for 2 sec 5 Repeat Step 3 and 4 for 3 times 6 Check DTC DTC detecting condition Trouble area Backup power voltage of internal circuit is lower than specified voltage fo...

Page 157: ...ectors 3 If connections are OK check that throttle actuator control circuit is as follows Wiring harness resistance of each throttle actuator control circuit and is less than 3 Insulation resistance b...

Page 158: ...on Control System Relay Inspection in Section 1C Is it in good condition Go to Step 4 Replace throttle actuator control relay 4 Wire harness check 1 Disconnect connectors from ECM with ignition switch...

Page 159: ...Trouble area Power supply voltage of throttle actuator control relay is higher than 5 V for 0 6 sec even though throttle actuator control relay is turned off 1 driving detection logic Throttle actuato...

Page 160: ...n in Section 1C Is it in good condition Substitute a known good ECM and recheck Repair or replace electric throttle body assembly DTC detecting condition Trouble area Difference between the measured a...

Page 161: ...en short or high resistance 4 Electric throttle body assembly check 1 Check electric throttle body for operation and condition referring to Electric Throttle Body Assembly On Vehicle Inspection in Sec...

Page 162: ...e detection logic Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 APP sensor assembly mounting check 1 Check t...

Page 163: ...nal at APP sensor connector Circuit voltage of each APP sensor main power supply signal and ground circuit is 0 1 V with ignition switch turned ON Are they in good condition Go to Step 5 Repair or rep...

Page 164: ...sor 2 Volt displayed on scan tool when accelerator pedal is idle position and fully depressed Is displayed APP sensor value as described voltage in Scan Tool Data Intermittent trouble Check for interm...

Page 165: ...icle Inspection in Section 1C Is it in good condition Substitute a known good ECM and recheck Replace APP sensor assembly Step Action Yes No DTC detecting condition Trouble area Difference between the...

Page 166: ...good ECM and recheck Repair or replace Step Action Yes No DTC detecting condition Trouble area Difference between the opening angle based on APP sensor main and the opening angle based on APP sensor...

Page 167: ...nsor and barometric pressure sensor 1 With ignition switch OFF connect scan tool 2 Turn ON ignition switch and clear DTC by using scan tool 3 Start engine and warm up to normal operating temperature 4...

Page 168: ...eck that A F sensor circuit is as follows Wiring harness resistance of each Signal circuit of A F sensor and Signal circuit of A F sensor is less than 1 Is it in good condition Replace A F sensor and...

Page 169: ...Also while performing Communication Bus Check do not perform any work other than instructed in this troubleshooting Or it may occur that display of control module sensor on SUZUKI SDT screen and or i...

Page 170: ...osition 2 Be sure to disconnect scan tool from DLC 3 Disconnect all the following control module connectors Control modules communicated by CAN ECM TCM ABS control module BCM Combination meter Keyless...

Page 171: ...Power and ground circuits check of BCM ECM ABS control module and combination meter 1 Check power and ground circuits the following control module ECM Refer to ECM Power and Ground Circuit Check BCM R...

Page 172: ...OFF position and battery negative cable is disconnected 2 Disconnect ABS control module connector 3 Measure resistance between the followings Between CAN high terminal on DLC and E08 2 terminal on ABS...

Page 173: ...ol module combination meter TCM and keyless start control module normally displayed Go to Step 14 Check power and ground circuits of keyless start control module referring to Keyless Start Control Mod...

Page 174: ...gnal using voltmeter 2 and oscilloscope 3 NOTE As each terminal voltage is affected by battery voltage confirm that it is 11 V or more when ignition switch is turned ON Voltage with asterisk cannot be...

Page 175: ...1 11 BRN Oxygen signal of HO2S 4 5 V IG switch ON Approx 0 7 V Reference waveform No 4 and Reference waveform No 5 Engine Idle speed after warming up C01 12 RED BLU A C refrigerant pressure sensor sig...

Page 176: ...ctive high pulse Pulse frequency varies depending on engine speed C01 19 GRN BLK Ignition coil No 3 0 0 6 V IG switch ON 0 0 6 V 4 6 V Reference waveform No 9 and Reference waveform No 11 Engine Idle...

Page 177: ...BLK Ground for A F sensor heater Below 0 3 V IG switch ON C01 32 RED Heater output of A F sensor 10 14 V IG switch ON 0 1 V 10 14 V Reference waveform No 15 Engine Idle speed after warming up Output...

Page 178: ...med up Accelerator pedal Released Output signal is duty pulse Duty ratio varies depending on throttle valve and accelerator pedal position 0 1 V 10 14 V Reference waveform No 19 and Reference waveform...

Page 179: ...quency varies depending on engine speed 30 36 6 pulses are generated par 1 crankshaft revolution C01 52 RED YEL CMP sensor signal 0 1 V or 4 5 V IG switch ON 0 0 6 V 4 5 V Reference waveform No 17 and...

Page 180: ...switch signal cruise control model 10 14 V IG switch ON Brake light OFF 0 1 V IG switch ON Brake light ON E01 9 E01 10 E01 11 E01 12 E01 13 YEL RED Clock signal for immobilizer coil antenna 10 14 V I...

Page 181: ...IG switch ON IG switch ST engine cranking E01 31 E01 32 E01 33 E01 34 E01 35 BLU WHT Electric load signal for heater blower motor 0 14 V IG switch ON Blower selector 3rd position Manual A C model IG...

Page 182: ...iator cooling fan relay No 2 and No 3 output 10 14 V IG switch ON ECT 102 C 216 F A C refrigerant pressure 1800 kPa 258 psi A C switch ON Engine Running 0 2 V IG switch ON ECT 102 C 216 F A C refriger...

Page 183: ...tor pedal Depressed fully E01 56 BRN Output for 5 V power source of APP sensor main 4 5 5 5 V IG switch ON E01 57 E01 58 E01 59 E01 60 BRN WHT Main power supply relay output 10 14 V IG switch OFF 0 2...

Page 184: ...CH2 C01 47 to C01 58 Oscilloscope setting CH1 500 mV DIV CH2 10 V DIV TIME 200 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 2 HO2S heate...

Page 185: ...58 CH2 C01 17 to C01 58 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder re...

Page 186: ...1 58 CH2 C01 20 to C01 58 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 2 Cylinder re...

Page 187: ...DIV CH2 10 V DIV TIME 200 ms DIV Measurement condition After warmed up to normal operating temperature Engine racing 1 IMT valve actuator signal 3 IMT valve open 2 IMT valve actuator signal I7RW01110...

Page 188: ...tuator drive signal C01 45 terminal 2 Throttle actuator drive signal C01 44 terminal 3 ON signal 4 OFF signal 5 One duty cycle I7RW01110025 01 Measurement terminal CH1 C01 45 to C01 58 CH2 C01 44 to C...

Page 189: ...easurement condition Ignition switch turned ON Signal pattern is depending on communication data 1 CAN communication line signal High 2 CAN communication line signal Low I4RS0B110073 01 I7RW01110028 0...

Page 190: ...IME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 3 720 crank angle I7RW01110089 01 Me...

Page 191: ...TION Be sure to connect ohmmeter probe from wire harness side of coupler Be sure to turn OFF ignition switch for this check Resistance in the following table represents that measured when parts temper...

Page 192: ...BLK WHT BLK RED BLK RED BLK RED BLK YEL BLK YEL GRN BRN WHT 12V 5V 2 1 3 10 11 1 12 1 12 2 11 2 4 6 E01 29 E01 1 E01 60 E01 16 9 WHT RED E01 2 E01 36 RED BLU ORN C01 12 E01 55 BLU YEL C01 45 C01 44 5...

Page 193: ...CM with ignition switch turned OFF 2 Check for proper connection to ECM connector at E01 2 E01 29 E01 60 E01 1 E01 16 C01 15 C01 30 C01 29 C01 48 and C01 58 terminals 3 If OK check DOME fuse and IG CO...

Page 194: ...n switch turned OFF 2 Using service wire ground E01 60 terminal of ECM connector and measure voltage between each E01 1 and E01 16 terminals of ECM connector and body ground Is voltage 10 14 V Go to S...

Page 195: ...E01 56 E01 53 and C01 53 terminal of ECM connector and vehicle body ground Is each resistance infinity Check internal short circuit of TP sensor A C refrigerant pressure sensor and or APP sensor GRY R...

Page 196: ...Measure voltage between each BLK RED wire terminal of fuel injector connector and engine ground with ignition switch turned ON Is voltage 10 14 V Go to Step 5 BLK RED wire is open or shorted to ground...

Page 197: ...9 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 4...

Page 198: ...turn ON ignition switch measure voltage between BLK WHT wire terminal of fuel pump relay connector and engine ground Is voltage 10 14 V Go to Step 3 BLK WHT wire is open or shorted to ground circuit 3...

Page 199: ...nal of fuel pump connector and vehicle body ground Is resistance infinity Go to Step 8 PNK wire is shorted to ground 8 Fuel pump circuit check 1 Connect service wire between E01 15 terminal of ECM con...

Page 200: ...nformation and Diagnosis Fuel Pressure Check S6RW0C1104090 System Diagram Special tool A 09912 58442 B 09912 58432 C 09912 58490 I7RW01110038 01 1 Injector 2 Delivery pipe 3 Fuel pump 4 Fuel filter 5...

Page 201: ...d at 4000 rpm Does fuel pressure show about the same value as Step 2 Go to Step 4 Go to Step 8 4 Fuel line check 1 Check fuel pipe fuel hose and joint for fuel leakage Are they in good condition Go to...

Page 202: ...5 WHT 6 7 BLK RED RED BLK BLK RED BLK RED BLK RED E01 16 E01 49 E01 48 BLU YEL BLU YEL BLU YEL GRY I6RW0C110020 01 1 Fuse box No 2 4 A C compressor relay 7 ECM 10 IG COIL fuse 2 Ignition switch 5 A C...

Page 203: ...engine ground and RED wire terminal of A C condenser fan connector Is resistance infinity Go to Step 8 RED wire shorted to ground circuit 8 Check A C condenser cooling fan control relay 1 Check A C c...

Page 204: ...17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 5...

Page 205: ...A C switch OFF OFF Engine running A C switch ON and blower speed selector turned 1st position or more ON Is check result satisfactory Go to Step 4 Check HVAC control module and its circuit 4 DTC chec...

Page 206: ...hicle body ground under the following conditions respectively Voltage between E01 49 terminal of ECM connector and ground While engine running and A C switch turned OFF 10 14 V While engine running A...

Page 207: ...WHT BRN WHT 12V 5V 12 E01 29 E01 1 E01 60 C01 15 C01 29 C01 48 C01 58 C01 30 BLK YEL BLK YEL BLK BLK BLK BLK ORN BLK ORN 10 1 BLK RED E01 16 2 3 BLU WHT BLU WHT E01 35 E01 35 11 WHT RED WHT RED WHT RE...

Page 208: ...elect Data List mode on scan tool 2 Check electric load signal under following conditions respectively Blower fan signal Manual A C model Blower speed selector turned 2nd position or less OFF Blower s...

Page 209: ...5 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 8 C01 15 C01 29 C01 48 C01 58 C01 30 BLK BLK BLK BLK ORN BLK ORN 12V 5V 2 1 11 7 3 4 6 5 10 E01 29 E01 1 E01 60 12 13 BLK YEL BLK W...

Page 210: ...witch turns OFF If engine coolant temp dose not rise check engine cooling system or ECT sensor Is radiator cooling fan started at low speed when engine coolant temp reached above temp Radiator cooling...

Page 211: ...Yes No 1 Low speed radiator cooling fan control circuit check 1 Check low speed radiator cooling fan control circuit referring to Radiator Cooling Fan Low Speed Control System Check Is it in good cond...

Page 212: ...ehicle and set parking brake and block drive wheels 1 Connect SUZUKI scan tool to DLC 1 with ignition switch turned OFF Special tool A SUZUKI scan tool SUZUKI SDT 2 Warm up engine to normal operating...

Page 213: ...e gauge This tool is included in fuel pressure gauge set 09912 58413 This tool is included in fuel pressure gauge set 09912 58413 09912 58490 09933 06320 3 way joint hose ECM check harness 120P SUZUKI...

Page 214: ...Disconnect purge hose 1 from purge valve chamber 5 Place finger against the end of disconnected purge hose 1 and check that vacuum is not felt there when engine is running at idle speed 6 Release par...

Page 215: ...isconnected hose and check that vacuum is not felt there when engine is cool and running at idle speed If check result is not satisfactory check EVAP canister purge valve wire harness and ECM I6RW0C12...

Page 216: ...to read the Precautions of ECM Circuit Inspection in Section 1A i Disconnect hoses from intake manifold and purge valve chamber ii Connect special tool between ECM and ECM connector referring to Insp...

Page 217: ...r purge valve 2 Remove EVAP canister purge valve from intake manifold 3 Check resistance between two terminals of EVAP canister purge valve If resistance is as specified proceed to next operation chec...

Page 218: ...of EVAP canister visually 2 Disconnect vacuum hoses from EVAP canister 3 Check that there is no restriction of flow through purge pipe 1 and air pipe 2 when air is blown 4 into tank pipe 3 If any faul...

Page 219: ...ir Cleaner Assembly Removal and Installation in Section 1D Specifications Tightening Torque Specifications S6RW0C1207001 NOTE The specified tightening torque is also described in the following EVAP Sy...

Page 220: ...ction 10C Removal 1 Disconnect negative cable at battery 2 Remove ECM cover 3 Disconnect connectors from ECM as follows a Push lock 1 to release locking of lock lever 2 b Turn lock lever to arrow dire...

Page 221: ...ttle valve actuator Throttle Valve Visual Check 1 Remove air cleaner outlet hose 2 Check that there isn t any foreign matter caught between throttle valve and throttle body housing If there is take it...

Page 222: ...r motor resistance 0 3 100 at 20 C 68 F Throttle Position TP Sensor Performance Check 1 Remove air cleaner outlet hose 2 Turn OFF ignition switch 3 Disconnect connector from electric throttle body ass...

Page 223: ...ing is not properly reinstall APP sensor assembly properly referring to Accelerator Pedal Position APP Sensor Assembly Removal and Installation 2 Connect scan tool to DLC with ignition switch turned O...

Page 224: ...torque Tightening torque APP sensor assembly nut a 6 N m 0 6 kgf m 4 5 lb ft Connect connector to APP sensor assembly securely Accelerator Pedal Position APP Sensor Assembly Inspection S6RW0C1306008...

Page 225: ...following Clean mating surfaces of ECT sensor and water outlet cap Check O ring for damage and replace if necessary Tighten ECT sensor 1 to specified torque Tightening torque ECT sensor a 12 5 N m 1...

Page 226: ...E Temperature of sensor affects resistance value largely Make sure that sensor heater is at correct temperature HO2S heater resistance 5 0 6 4 at 20 C 68 F Viewed from terminal side 3 Connect sensor c...

Page 227: ...emove metal particles on end face of CMP sensor if any 2 Arrange 12 V battery 1 and connect its positive terminal to Vin terminal 2 and negative terminal to Ground terminal 3 of sensor Then using ohmm...

Page 228: ...l Check Check that O ring is free from damage Check that end face of sensor and signal plate tooth are free from any metal particles and damage Resistance Check Measure resistance between 1 and 2 term...

Page 229: ...ct voltmeter to BLU RED wire terminal 2 of MAF and IAT sensor connector 1 disconnected and ground 3 Turn ON ignition switch and check that voltage is battery voltage If not check if wire harness is op...

Page 230: ...or screws to specified torque Tightening torque MAF and IAT sensor screw a 1 2 N m 0 12 kgf m 0 9 lb ft Connect MAF and IAT sensor connector securely Mass Air Flow MAF and Intake Air Temperature IAT S...

Page 231: ...ctuator Specifications Tightening Torque Specifications S6RW0C1307001 Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Rotativ...

Page 232: ...roke cycle gasoline unit with its DOHC Double over head camshaft valve mechanism arranged for V type valve configuration consisting of 16 valves 4 valves one cylinder The double overhead camshaft is m...

Page 233: ...effective intake pipe length is shorter Engine torque between middle and high engine speed ranges is improved whilst it drops between low and middle engine speed ranges When IMT valve is totally clos...

Page 234: ...T vehicle and depress accelerator pedal all the way to make throttle fully open 7 Crank engine with fully charged battery and read the highest pressure on compression gauge NOTE For measuring compress...

Page 235: ...ine at specified idle speed and read vacuum gauge Vacuum should be within specification Vacuum specification at sea level 59 73 kPa 45 55 cmHg 17 7 21 6 in Hg at specified idle speed 9 After checking...

Page 236: ...4 in Shim Replacement 1 Close the valve whose shim 2 is to be replaced by turning crankshaft then turn tappet 3 till its cut section 1 faces inside as shown in the figure 2 Lift down the valve by turn...

Page 237: ...ms No 7 Install new shim facing shim No side with tappet 8 Lift valve by turning crankshaft counterclockwise in opposite direction against above Step 4 and remove special tool Special tool A 09916 665...

Page 238: ...s 11 Check valve clearance again 12 After checking and adjusting all valves install cylinder head cover referring to Cylinder Head Cover Removal and Installation Repair Instructions Air Cleaner Compon...

Page 239: ...3 Install air cleaner inlet hose 2 and outlet hose Air Cleaner Filter Removal and Installation S6RW0C1406003 Removal 1 Open air cleaner case 1 by unhooking its clamps 2 2 Remove air cleaner filter Ins...

Page 240: ...05 a 4 2 2 2 1 3 I7RW01140021 03 1 Intake manifold Never disassemble intake manifold Disassembly will spoil its original performance If faulty condition is found replace it with new one 4 Electric thr...

Page 241: ...m intake manifold Installation 1 Clean mating surfaces and install new throttle body gasket to intake manifold 2 Install electric throttle body assembly 2 with stiffener 4 to intake manifold 3 Connect...

Page 242: ...e from intake manifold 6 Remove harness brackets 5 from intake manifold 7 Remove intake manifold and O ring from cylinder head Installation Reverse removal procedure for installation noting the follow...

Page 243: ...Ignition Coil Assembly Including ignitor Removal and Installation in Section 1H 3 Remove oil level gauge 1 4 Disconnect CMP sensor connector 2 and then remove CMP sensor 7 from cylinder head cover 5 D...

Page 244: ...hten cylinder head cover nuts in such order as indicated in the figure a little at a time till they are tightened to specified torque Use new seal washers Tightening torque Cylinder head cover nut a T...

Page 245: ...No 1 bracket 18 Mounting member nut Tighten order a b D A T model 9 Engine rear mounting No 2 bracket 19 Mounting member bolt Tighten order a b F Vehicle forward 10 Engine front mounting bracket 25 N...

Page 246: ...and installation of engine assembly 13 Remove condenser cooling fan from radiator referring to Condenser Cooling Fan Removal and Installation in Section 7B 14 Disconnect the following electric wires c...

Page 247: ...ler shaft from transfer referring to Propeller Shaft Assembly Removal and Installation in Section 3D 4WD model 20 Disconnect steering lower shaft from pinion shaft referring to Steering Lower Shaft Re...

Page 248: ...Flywheel Removal and Installation in Section 5C if necessary M T model 2 Connect transaxle to engine referring to Manual Transaxle Unit Dismounting and Remounting in Section 5B or Automatic Transaxle...

Page 249: ...condenser cooling fan to radiator referring to Condenser Cooling Fan Removal and Installation in Section 7B 15 Install A C compressor to its bracket if removed referring to Compressor Assembly Remova...

Page 250: ...der to fix crankshaft pulley by special tool Bolt size M8 P1 25 L 25 mm 0 98 in Strength 7T 2 9 d 6 b 3 5 1207B 4 1 a 7 8 10 c 1217G OIL I7RW01140039 01 1 Crankshaft pulley bolt 6 Timing chain cover b...

Page 251: ...e timing chain cover bolts 2 and nut 1 8 Remove timing chain cover 3 Installation 1 Clean sealing surfaces on timing chain cover cylinder block and cylinder head Remove oil old sealant and dust from s...

Page 252: ...o specified torque NOTE Before installing timing chain cover check that pin is securely fitted Tightening torque Timing chain cover bolt and nut a 11 N m 1 1 kgf m 8 0 lb ft 5 Install belt idler pulle...

Page 253: ...ng Chain Cover Cleaning and Inspection S6RW0C1406017 Clean Clean sealing surface on timing chain cover crank case cylinder block and cylinder head Remove oil old sealant and dust from sealing surface...

Page 254: ...points upward II Marks on cam sprockets match with marks on cylinder head III 3 Remove timing chain tensioner adjuster No 2 1 and gasket To remove them slacken 2nd timing chain by turning intake camsh...

Page 255: ...ll 2nd timing chain by aligning yellow plate 1 of 2nd timing chain and match marks on idler sprocket 5 Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain...

Page 256: ...own in figure At this time check timing marks 3 5 and 7 of sprockets are in match with timing marks 4 6 and 8 of cylinder head cylinder block and lower crank case 11 Apply oil to timing chains tension...

Page 257: ...k shoe 2 for wear or damage Camshaft Sprocket Check teeth of sprocket for wear or damage Timing Chain Check timing chain for wear or damage Tensioner Adjuster No 2 Check shoe 1 for wear or damage and...

Page 258: ...for removal 2 Remove timing chain guide No 1 1 3 Remove timing chain tensioner adjuster No 1 2 4 Remove timing chain tensioner 3 5 Remove idler sprocket 6 and 1st timing chain 5 6 Remove crankshaft t...

Page 259: ...ing surface of timing chain tensioner 1 and then install it as shown in figure Tighten tensioner nut to specified torque Tightening torque Timing chain tensioner nut a 25 N m 2 5 kgf m 18 0 lb ft 8 Wi...

Page 260: ...15 Install cylinder head cover Refer to Cylinder Head Cover Removal and Installation for installation 16 Install oil pan Refer to Oil Pan and Oil Pump Strainer Removal and Installation in Section 1E f...

Page 261: ...properly Camshafts Tappet and Shim Components S6RW0C1406024 I2RH01140094 01 I2RH01140077 01 I2RH01140095 01 I7RW01140059 01 1 Intake camshaft 5 Exhaust camshaft housing 9 Timing chain guide No 2 2 Ex...

Page 262: ...ms to cylinder head NOTE When installing shim make sure to direct shim No side toward tappet 2 Match match mark 1 on crank timing sprocket and mating surface of cylinder block 3 and lower crankcase 2...

Page 263: ...er to Cylinder Head Cover Removal and Installation for installation 11 Install oil pan Refer to Oil Pan and Oil Pump Strainer Removal and Installation in Section 1E for installation 12 Install engine...

Page 264: ...ue NOTE Do not rotate camshaft while gauging plastic is installed Tightening torque Camshaft housing bolt a Tighten 11 N m 1 1 kgf m 8 0 lb ft by the specified procedure 6 Remove housing and using sca...

Page 265: ...earance exceeds limit replace tappet or cylinder head Cylinder head bore and tappet outside diameter Oil Relief Valve Check oil relief valve for clogging and ball for being stuck Item Standard Limit T...

Page 266: ...hten cylinder head bolt M6 after securing cylinder head bolt M10 2 Cylinder head 8 Valve spring 14 Knock pin 3 Cylinder head gasket Identification number provided on gasket comes to crankshaft pully s...

Page 267: ...1 to cylinder block Identification number 6 provided on gasket comes to crankshaft pulley side 4 facing up toward cylinder head side 5 Install cylinder head to cylinder block Apply engine oil to cylin...

Page 268: ...ain and Chain Tensioner Removal and Installation for installation 9 Install timing chain cover Refer to Timing Chain Cover Removal and Installation for installation 10 Check intake and exhaust valve l...

Page 269: ...talling valve guide into cylinder head ream guide hole with special tool 11 mm reamer so as to remove burrs and make it truly round Special tool A 09916 34542 B 09916 38210 2 Install valve guide to cy...

Page 270: ...ay 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 E...

Page 271: ...lection If bore 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 replac...

Page 272: ...75 mm 0 057 0 069 in Limit 1 1 mm 0 04 in Valve head radial runout Check each valve for radial runout with a dial gauge and V block To check runout rotate valve slowly If runout exceeds its limit repl...

Page 273: ...ters 1 to make three cuts as illustrated in the figure Three cutters must be used the 1st for making 25 angle the 2nd for making 60 angle and 3rd for making 45 angle The 3rd cut 45 must be made to pro...

Page 274: ...on side Limit 0 03 mm 0 001 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 face...

Page 275: ...t plastic deformation tightening bolt for deformation when reuse it due to plastic deformation tightening referring to Connecting rod bolt under Pistons Piston Rings Connecting Rods and Cylinders Insp...

Page 276: ...to crankshaft pulley side 1 3 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 Usin...

Page 277: ...and Installation for installation 10 Install timing chain cover Refer to Timing Chain Cover Removal and Installation for installation 11 Check intake and exhaust valve lashes referring to Valve Lash...

Page 278: ...That is install number 2 stamped piston to cylinder which is identified with blue painted or 2 stamped and a number 1 piston to cylinder with red painted or 1 stamped Also a letter A or B is stamped...

Page 279: ...three rings 1st 2nd and oil rings distribute their end gaps as shown in figure Pistons Piston Rings Connecting Rods and Cylinders Inspection and Cleaning S6RW0C1406036 Inspection Cylinder Inspect cyl...

Page 280: ...f it is out of specification rebore cylinder and use oversize piston Piston clearance 0 02 0 04 mm 0 0008 0 0015 in NOTE Cylinder bore diameters used here are measured in thrust direction at two posit...

Page 281: ...e in piston Standard 0 006 0 017 mm 0 00024 0 00067 in Small end bore A 21 003 21 011 mm 0 8269 0 8272 in Piston pin diameter B 20 997 21 000 mm 0 8267 0 8268 in Piston bore 21 006 21 014 mm 0 8270 0...

Page 282: ...out of limit replace crankshaft or regrind crank pin Connecting rod bearing and crank pin Out of round A B Taper a b Out of round and taper limits 0 01 mm 0 0004 in Connecting rod bearing general info...

Page 283: ...plastic 1 width at the widest point clearance If clearance exceeds its limit select connecting rod bearing referring to Pistons Piston Rings Connecting Rods and Cylinders Inspection and Cleaning belo...

Page 284: ...iameter b Next check crank pin diameter On crank web of No 3 cylinder four alphabets are stamped as shown in the figure Three kinds of alphabet A B and C represent the following crank pin diameter res...

Page 285: ...earance still exceeds its limit use next thicker bearing and recheck clearance Connecting rod bolt Measure each thread diameter of connecting rod bolts 1 at A on 28 5 mm 1 12 in from bolt mounting sur...

Page 286: ...Water pump Tighten 26 N m 2 6 kgf m 19 0 lb ft by the specified procedure 3 Crankshaft 12 Heater outlet pipe 70 N m 7 0 kgf m 51 0 lb ft 4 O ring 13 CKP sensor 11 N m 1 1 kgf m 8 0 lb ft 5 Oil pump ch...

Page 287: ...lled must be perfectly clean Be sure to oil crankshaft journals journal bearings thrust bearings crankpins connecting rod bearings pistons piston rings and cylinder bores Journal bearings crankcase be...

Page 288: ...to lower crankcase 1 mating surface area as shown in figure A Water tight sealant 99000 31250 SUZUKI Bond No 1207F Sealant amount for lower crankcase Width a 3 mm 0 12 in Height b 2 mm 0 08 in 7 Insta...

Page 289: ...6 N m 2 6 kgf m 19 0 lb ft by the specified procedure NOTE After tightening crankcase bolts check to be sure that crankshaft rotates smoothly when turned by hand Use new crankcase bolt 10 mm thread di...

Page 290: ...tion 18 Check intake and exhaust valve lashes referring to Valve Lash Clearance Inspection 19 Install timing chain sprockets timing chains timing chain tensioner tensioner adjusters timing chain guide...

Page 291: ...etermined by taking micrometer readings If any one of journals is badly damaged or if amount of uneven wear in the sense exceeds its limit regrind or replace crankshaft Limit on out of round and taper...

Page 292: ...new standard bearing as followings and install it Bearing is in malcondition Bearing clearance is out of specification Crankshaft or cylinder block is replaced 1 First check journal diameter As shown...

Page 293: ...kcase side journal NOTE The meaning of Upper and Lower described in below table are the following Upper It is instruction of main bearing installed in cylinder block side journal Lower It is instructi...

Page 294: ...crometer measure reground journal diameter Measurement should be taken in two directions perpendicular to each other in order to check for out of round c Using journal diameter measured and alphabets...

Page 295: ...flywheel If the surface contacting clutch disc is damaged or excessively worn replace flywheel Check flywheel for face runout with a dial gauge If runout exceeds its limit replace flywheel Limit on ru...

Page 296: ...e piston clearance after honing Check Valve Check check valve for clogging and ball for being stuck Specifications Tightening Torque Specifications S6RW0C1407001 Size Piston diameter STD 83 970 83 990...

Page 297: ...adjuster No 2 bolt 11 1 1 8 0 Timing chain tensioner adjuster No 2 nut 45 4 5 33 0 Timing chain tensioner nut 25 2 5 18 0 Timing chain tensioner adjuster No 1 bolt 11 1 1 8 0 Timing chain guide No 1 b...

Page 298: ...nkshaft and Cylinder Block Components Special Tool S6RW0C1408002 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No 1217G P No 99000 31260 Thread lock cement Thread Lock...

Page 299: ...ller attachment 09916 57350 09916 66510 Valve guide installer handle 6 mm Tappet holder 09916 77310 09916 84511 Piston ring compressor 50 125 mm Forceps 09917 68221 09917 98221 Camshaft pulley holder...

Page 300: ...ths in cylinder block In one path oil reaches the crankshaft journal bearings Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages dril...

Page 301: ...to make special tool touch Exhaust manifold when installing because Exhaust manifold becomes very hot 4 Start engine and warm it up to normal operating temperature NOTE Be sure to place transmission...

Page 302: ...for ambient temperatures above 18 C 0 F Before draining engine oil check engine for oil leakage If any evidence of leakage is found make sure to correct defective part before proceeding to the followi...

Page 303: ...ller inlet is at the top of the cylinder head cover NOTE Engine oil capacity is specified as the following However note that the amount of oil required when actually changing oil may somewhat differ f...

Page 304: ...ten upper bolt first then tighten lower bolt 2 Oil pump strainer 11 Clutch housing plate lower bolt Tighten upper bolt first then tighten lower bolt 3 O ring 12 Clutch housing plate 4 Oil pump straine...

Page 305: ...ng to Transfer Dismounting and Remounting in Section 3C 4WD model 6 Remove clutch housing plate 1 7 Drain engine oil by removing drain plug 1 8 Cut sealant at hatched part shown in the figure using sp...

Page 306: ...l pan after applying engine oil Tighten drain plug to specified torque Tightening torque Oil drain plug c 35 N m 3 5 kgf m 25 5 lb ft 5 Install clutch housing plate 1 Tighten upper bolt first then tig...

Page 307: ...set 9 Oil pump chain guide 16 Oil pump sprocket cover 3 Baffle plate 10 Oil pump chain guide plate 17 Oil pump sprocket cover bolt 4 Pin No 1 11 Oil pump chain guide nut 25 N m 2 5 kgf m 18 0 lb ft 5...

Page 308: ...n installing oil pump be careful not to allow pins to fall off Tightening torque Oil pump mounting bolt M8 bolt a 25 N m 2 5 kgf m 18 0 lb ft Baffle plate bolt M6 bolt 11 N m 1 1 kgf m 8 0 lb ft 2 Ins...

Page 309: ...No 2 6 Assemble oil pump After assembling oil pump check to be sure that rotor turns smoothly by hand Tightening torque Oil pump case bolt a 12 N m 1 2 kgf m 9 0 lb ft Oil Pump Inspection S6RW0C150600...

Page 310: ...ts Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A 3 Inner rotor I2RH01150024 01 1 Oil pump case No 1 3 Inner rotor 2 Outer r...

Page 311: ...described in the following Oil Pan and Oil Pump Strainer Components Special Tool S6RW0C1508002 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No 1217G P No 99000 31260...

Page 312: ...expands with heat and the coolant is overflowed to the reservoir When the system cools down the coolant is drawn back into the radiator The cooling system has been filled with a quality coolant that i...

Page 313: ...emperature and the thermostat opens coolant passes through the radiator core to be cooled as follows 7 5 6 4 3 2 8 1 I5RW0C160001 02 1 Radiator inlet hose 3 Thermostat 5 Throttle body 7 Heater core 2...

Page 314: ...Slipping clutch Replace Poor charge battery Check and replace as necessary Poor generation generator Check and repair ECT sensor faulty Check and replace as necessary Radiator fan motor faulty Check a...

Page 315: ...bly refer to Radiator Cooling Fan Disassembly and Reassembly 2 Reservoir 10 O ring 18 To cylinder head 3 Radiator cap 11 Water pump 19 To throttle body 4 Drain plug 12 Thermostat 20 To heater core 5 R...

Page 316: ...are still hot Scalding fluid and steam can be blown out under pressure if cap is taken off too soon 1 Check cooling system for leakage or damage 2 Wash radiator cap and filler neck with clean water b...

Page 317: ...ny fluid scrub and clean inside of reservoir with soap and water Flush it well with clean water and drain Reinstall reservoir 9 Fill reservoir with coolant up to FULL level mark 3 10 Install reservoir...

Page 318: ...606008 Make sure that air bleed valve 1 of thermostat is clean Check to make sure that valve seat 2 is free from foreign matters which would prevent valve from seating tight Check thermostat seal 3 fo...

Page 319: ...relays as follows a Check that there is no continuity between terminals C and D If there is continuity replace relay b Connect battery positive terminal to terminal B of relay c Connect battery negat...

Page 320: ...S6RW0C1606014 Removal 1 Disconnect negative cable at battery 2 Drain coolant referring to Cooling System Draining 3 Remove front bumper referring to Front Bumper and Rear Bumper Components in Section...

Page 321: ...ring when installing Install water pump assembly to cylinder block and tighten bolts to specified torque Tightening torque Water pump bolt 25 N m 2 5 kgf m 18 0 lb ft Refill cooling system referring t...

Page 322: ...line make sure to relieve fuel pressure referring to Fuel Pressure Relief Procedure A small amount of fuel may be released when the fuel line is disconnected In order to reduce the risk of personal in...

Page 323: ...l pressure regulator delivery pipe injectors and fuel feed line The fuel in the fuel tank is pumped up by the fuel pump sent into delivery pipe and injected by the injectors As the fuel pump assembly...

Page 324: ...eed 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 fi...

Page 325: ...ing fuel pressure remove fuel pressure gauge WARNING As fuel feed line is still under high fuel pressure make sure to release fuel pressure according to the following procedures Place fuel container u...

Page 326: ...tank filler hose 12 Fuel tank protector 22 Fuel tank inlet valve 4 Fuel tank filler neck 13 Insulator 23 Fuel pump gasket 5 Fuel filler cap 14 To EVAP canister purge valve 24 Earth bracket 6 To EVAP...

Page 327: ...ry Connection Other Than Quick Joint Clamp around fuel tank NOTE Be sure to install hose to spool of pipe surely 8 Delivery pipe bolt 18 Cushion Do not reuse 9 Fuel tank bolt 19 Grommet I7RW01170005 0...

Page 328: ...ock securely a click is heard and confirm that quick joint is not disconnected by hand A With short pipe fit hose as far as it reaches pipe joint as shown B With the following type pipe fit hose as fa...

Page 329: ...ll relay fuse box cover Fuel Leakage Check Procedure S6RW0C1706004 After performing any service on fuel system check to make sure that there are no fuel leakages as follows 1 Turn ON ignition switch f...

Page 330: ...all clamps to marked location on pipes If clamp is deformed its claw is bent or broken replace it with new one 2 Install pipes with pipe clamps to vehicle 3 Connect fuel hoses and pipes to each pipe r...

Page 331: ...7 Remove fuel injector s 3 Installation Reverse removal procedure for installation noting the following Replace injector O ring 1 with new one using care not to damage it Check if cushion 2 is scored...

Page 332: ...B to injector c Install special tool C to special tool A d Connect fuel feed hose to special tool A 4 Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting...

Page 333: ...of fuel Before removing injector make sure to relieve fuel pressure as follows 1 Stop operation of fuel pump 2 Put graduated cylinder under injector 3 Apply battery voltage to injector until no fuel...

Page 334: ...ng the following procedure be sure to observe Precautions on Fuel System Service in order to reduce the risk or fire and personal injury Check fuel tank inlet valve for the following If any damage or...

Page 335: ...bsence of fuel tank drain plug drain fuel tank by pumping fuel out through fuel tank filler Use hand operated pump device to drain fuel tank CAUTION Do not force pump hose into fuel tank Never store f...

Page 336: ...ied torque Tightening torque Fuel tank bolt b 45 N m 4 5 kgf m 33 0 lb ft 4 Connect fuel filler hose 1 and breather hose 2 to filler neck 3 as shown in figure and clamp them securely Tightening torque...

Page 337: ...ng area 4 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 rusty 5 Completely flush out remaining...

Page 338: ...ssembly 2 referring to Fuel Hose Disconnecting and Reconnecting 3 Remove fuel pump assembly and earth bracket from fuel tank Installation CAUTION When connecting joint clean outside surface of pipe wh...

Page 339: ...Disconnect main fuel level sensor connector 3 3 With pressing snap fit part 2 remove main fuel level sensor 1 by sliding it in the arrow direction as shown in figure Installation Reverse removal proce...

Page 340: ...0 15 1 0 Fuel pump assembly bolt 11 1 1 8 0 09912 57610 09912 58421 Injector checking tool plate Checking tool set This kit includes the following items 1 Tool body and washer 2 Body plug 3 Body attac...

Page 341: ...nal from ECM When the current flow to the primary coil is turned OFF a high voltage is induced in the secondary coil One ignition coil is in charge of ignition of one cylinder only Spark plugs CMP sen...

Page 342: ...16 18 17 19 4 GRN YEL GRN WHT C01 21 C01 20 C01 19 GRN BLK GRN C01 18 BLK WHT E01 29 BRN WHT E01 60 E01 1 BLK RED E01 16 BLK RED C01 52 RED YEL C01 51 PNK C01 36 BLU BLK C01 58 BLK ORN BLK ORN BLK BLK...

Page 343: ...speed sensor VSS 14 Ignition coil assembly for No 4 5 MAF and IAT sensor 10 Fuse box No 2 15 ABS control module Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step...

Page 344: ...MP sensor or intake camshaft 9 Ignition trigger signal circuit check 1 Check ignition trigger signal wire for open short and poor connection Is circuit in good condition Go to Step 10 Repair or replac...

Page 345: ...gine and check if each spark plug sparks 6 If no spark is emitted inspect the related parts as described in Ignition System Symptom Diagnosis Condition Possible cause Correction Reference Item Engine...

Page 346: ...type NGK BKR6E 11 Nickel Ignition Coil Assembly Including ignitor Removal and Installation S6RW0C1806003 Removal 1 Disconnect negative cable at battery 2 Remove air cleaner case referring to Air Clea...

Page 347: ...nder and check that ignition timing is within specification Initial ignition timing Fixed with SUZUKI scan tool 2 8 BTDC at specified idle speed Ignition order 1 3 4 2 Special tool A 09930 76420 8 If...

Page 348: ...on in Section 0A Special Tools and Equipment Special Tool S6RW0C1808001 Fastening part Tightening torque Note N m kgf m lb ft Spark plug 25 2 5 18 0 Ignition coil bolt 6 5 0 65 5 0 09930 76420 SUZUKI...

Page 349: ...ttery wiring harness including starting motor switch starting motor or engine Do not remove motor just because starting motor does not run Check following items and narrow down scope of possible cause...

Page 350: ...poor contacting action of magnetic switch Replace magnetic switch Brushes are seating poorly or worn down Repair or replace Weakened brush spring Replace Burnt commutator Replace armature Layer short...

Page 351: ...inal M Check that plunger and pinion remain out If plunger and pinion return inward replace the magnetic switch Plunger and Pinion Return Test Disconnect negative lead from starting motor body Check t...

Page 352: ...nt bolt 3 and then starting motor 4 and bracket 5 Remounting Reverse dismounting procedure for remounting noting the following Tighten each bolts and nuts to specified torque Tightening torque Battery...

Page 353: ...2 Bush 8 Plunger 14 Planetary carrier shaft 20 Brush holder 3 Snap ring 9 Plate 15 Planetary gear 21 Rear bracket 4 Pinion stop ring 10 Seal rubber 16 Packing Apply grease 99000 25011 to sliding surf...

Page 354: ...across magnetic switch S terminal 1 and coil case If no continuity coil is open and should be replaced Rear Bracket Bush Inspect bush for wear or damage Replace if necessary Brush Check brushes for we...

Page 355: ...ature 1 supported on V blocks 2 If deflection of dial gauge 4 pointer exceeds limit repair or replace NOTE The following specification presupposes that the armature is free from bend Bent armature mus...

Page 356: ...r other abnormal conditions Replace if necessary Pinion and Over running Clutch Inspect the pinion for wear damage or other abnormal conditions Check that clutch locks up when turned in direction of d...

Page 357: ...the following Starting Motor Components Voltage 12 volts Output 1 4 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard 12 3 mm 0 48 in Limit 7 0 mm 0...

Page 358: ...specific gravity Since freezing may ruin a battery it should be protected against freezing by keeping it in a fully charged condition If a battery is frozen accidentally it should not be charged until...

Page 359: ...IC regulator incorporated The internal components are connected electrically as shown in the following figure The generator features are as follows Solid state regulator is mounted inside the generato...

Page 360: ...ator coil 8 Battery 13 IG fuse 4 Diode 9 ECM 14 METER fuse 5 Field coil rotor coil 10 BCM I5JB0A1A0004 01 1 Pulley 6 Field coil 11 Rear housing IG Ignition terminal 2 Pulley nut 7 Rectifier B Generato...

Page 361: ...ription To avoid damage always follow these precautions CAUTION Do not mistake polarities of IG terminal and L terminal Do not create a short circuit between IG and L terminals Always connect these te...

Page 362: ...B terminal and battery terminal NOTE Use fully charged battery 6 Measure current and voltage No Load Check 1 Run engine from idling up to 2000 rpm and read meters NOTE Turn off switches of all access...

Page 363: ...ery to open flame or electric spark Batteries generate gas which is flammable and explosive Remove rings watches and other jewelry Wear approved eye protection Do not allow battery fluid to contact ey...

Page 364: ...e 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 Dismounting 1 D...

Page 365: ...been installed indicator A should be within a of the figure If it isn t it means that belt is not installed properly Reinstall it properly Water Pump and Generator Drive Belt Removal and Installation...

Page 366: ...r belt make sure that tension indicator is within standard range referring to Water Pump and Generator Drive Belt On Vehicle Inspection Generator Unit Components S6RW0C1A06005 3 Tensioner pulley bolt...

Page 367: ...Intake Manifold Removal and Installation in Section 1D 5 Remove generator cover 1 6 Disconnect B terminal wire 2 and coupler 3 from generator 7 Remove generator mounting bolt 4 and generator pivot bol...

Page 368: ...t 6 Drive end bearing 11 Rear housing 16 B terminal nut 2 Pulley 7 Bearing retainer 12 Rectifier 118 N m 11 8 kgf m 85 5 lb ft 3 Front housing 8 Rotor 13 Regulator 4 5 N m 0 45 kgf m 3 5 lb ft 4 Stato...

Page 369: ...is no continuity replace rotor or regulator Using ohmmeter check for continuity between slip rings of rotor If there is no continuity replace rotor 1 Resistance between slip rings of rotor 1 7 2 0 Us...

Page 370: ...hat there is no continuity between coil leads 2 and stator core 1 If there is continuity replace stator Brush and brush holder Check each brush for wear by measuring its length If brush is found worn...

Page 371: ...robes of ohmmeter and there should be only one way continuity in each case If check result is not satisfactory replace rectifier 1 2 In the same manner as described in above Step 1 check that there is...

Page 372: ...ormation in Section 0A Battery type 55B24R Rated Capacity AH 5HR 12 Volts 42 5 Electrolyte L US Imp pt 2 8 5 92 4 93 Electrolyte S G 1 28 when fully charged at 20 C 68 F Type 80 A type Rated voltage 1...

Page 373: ...e exhaust system when the system is 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 o...

Page 374: ...ons Exhaust System Components S6RW0C1B06001 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 whe...

Page 375: ...ve exhaust manifold 1 engine hook 2 and gasket from cylinder head A View A 11 Exhaust No 2 pipe 23 Exhaust pipe No 1 stiffener bolt B View B 12 Exhaust center pipe 24 Catalyst heat insulator nut 1 Exh...

Page 376: ...eaner Assembly Removal and Installation in Section 1D 7 Install right and left side engine under covers 8 Install engine hood referring to Hood Removal and Installation in Section 9J 9 Connect negativ...

Page 377: ...ystem Components Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Fastening part Tightening torque Note N m kgf m lb ft Exhaus...

Page 378: ...1K 6 Exhaust System...

Page 379: ...Frame Stabilizer Bar and or Bushing Components 2B 16 Front Suspension Frame Stabilizer Bar and or Bushing Removal and Installation 2WD Model 2B 17 Front Suspension Frame Stabilizer Bar and or Bushing...

Page 380: ...ires Inspection 2D 5 Wheel Balance Inspection and Adjustment 2D 5 Tire Rotation 2D 5 Wheel with Tire Removal and Installation 2D 5 Tire Mounting and Dismounting 2D 6 Tire Repair 2D 6 Specifications 2D...

Page 381: ...res 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...

Page 382: ...tire and or wheel Loosen wheel bearings Replace wheel bearings Worn tie rod ends Replace tie rod ends Worn lower ball joints Replace suspension control arm Excessive wheel runout Repair or replace whe...

Page 383: ...ut shock absorber or mounting Replace strut shock absorber or tighten mounting Broken or sagging coil springs Replace coil springs Overloaded Check loading Cupped tires Front struts defective Replace...

Page 384: ...f wear or lack of lubrication Repair or replace defective parts if any Check front suspension arm ball joint stud dust seals for leakage detachment tear or any other damage Replace defective boot if a...

Page 385: ...D Front 16 1 Rear 1 1 Caster 2WD 3 40 2 4WD 3 34 2 Side Slip On one person 1 2WD 0 to IN 3 0 mm m 0 to IN 0 118 in 3 3 ft 4WD 0 to IN 3 0 mm m 0 to IN 0 118 in 3 3 ft Steering Angle Turning Angle 2WD...

Page 386: ...n frame 200 N m 20 0 kgf m 145 0 lb ft 2 Front drive shaft 9 Suspension control arm 23 N m 2 3 kgf m 17 0 lb ft 3 Steering knuckle 140 N m 14 0 kgf m 101 5 lb ft 95 N m 9 5 kgf m 69 0 lb ft 4 Front wh...

Page 387: ...ust be corrected before adjusting Check for run out of wheels and tires Check vehicle trim heights if it is out of limit and a correction is needed it must be done before adjusting toe Check for loose...

Page 388: ...oots are not twisted Steering Angle Check and Adjustment When tie rod or tie rod end was replaced check toe and then also steering angle with turning radius gauge 1 If steering angle is not correct ch...

Page 389: ...trut nut 50 N m 5 0 kgf m 36 5 lb ft 2 Coil spring 7 Strut bearing 12 Strut bracket bolt Insert from vehicle front side 55 N m 5 5 kgf m 40 0 lb ft 3 Bump stopper 8 Strut support 13 Strut bracket nut...

Page 390: ...ng joint nut hold stud with hexagon wrench 2 4 Remove brake hose mounting bolt 1 Remove brake hose 2 from bracket and wheel speed sensor harness 3 from strut bracket as shown in figure 5 Remove strut...

Page 391: ...n confirm front wheel alignment Front Strut Assembly Disassembly and Reassembly S6RW0C2206004 Disassembly 1 Attach special tool A to coil spring as shown Turn special tool bolts alternately until coil...

Page 392: ...ng 3 strut support 2 and strut support lower nut 1 in this sequence Tighten strut support lower nut 1 to specified torque When tightening strut support lower nut hold stud with hexagon wrench Tighteni...

Page 393: ...06006 Front Wheel Hub Steering Knuckle and Wheel Bearing Removal and Installation S6RW0C2206007 CAUTION When removing and installing steering knuckle assembly be careful not to damage dust boots of co...

Page 394: ...el hub 1 with special tools Special tool A 09943 17912 B 09942 15511 CAUTION When wheel hub is removed replace wheel bearing with new one 7 Disconnect tie rod end 1 from steering knuckle 2 with puller...

Page 395: ...ever remove bolt unless replacement is necessary Be sure to use a new bolt for replacement Installation For installation reverse removal procedure noting the following instructions 1 Face grooved rubb...

Page 396: ...ydraulic press press fit wheel hub 1 into wheel bearing 2 Face grooved rubber seal side to wheel hub Special tool A 09913 75510 7 Apply grease lightly to end face of inner ring 1 A Grease 99000 25121...

Page 397: ...rque Tie rod end nut a 45 N m 4 5 kgf m 32 5 lb ft 14 Install brake disk 2 and brake caliper 3 15 Tighten caliper carrier bolt to specified torque Tightening torque Caliper carrier bolt 85 N m 8 5 kgf...

Page 398: ...n figure Front wheel bearing thrust play Limit 0 1 mm 0 004 in Check wheel bearing noise and smooth wheel rotation by rotating wheel If defective replace bearing Suspension Control Arm Bushing Removal...

Page 399: ...que Wheel nut 85 N m 8 5 kgf m 61 5 lb ft 4 Lower hoist and vehicle in unloaded condition tighten new control arm bolts to specified torque Tightening torque Suspension control arm bolt a 95 N m 9 5 k...

Page 400: ...l Arm Steering Knuckle Check S6RW0C2206011 Inspect for cracks deformation or damage If defective replace Suspension Control Arm Bushing Check S6RW0C2206012 Inspect for damage wear or deterioration If...

Page 401: ...001 01 1 Stabilizer bar 4 Stabilizer bar mounting bracket bolt 7 Front suspension frame 95 N m 9 5 kgf m 36 5 lb ft 2 Stabilizer bushing 5 Suspension control arm 8 Front suspension frame mounting bolt...

Page 402: ...shaft referring to Steering Lower Shaft Removal and Installation in Section 6B 5 Hoist vehicle and remove front wheels 6 Remove exhaust No 1 No 2 and center pipes referring to Exhaust System Componen...

Page 403: ...2 Tighten stabilizer bar mounting bracket bolts to specified torque NOTE Tighten stabilizer bar mounting bracket rear bolt 5 after front bolt 6 Tightening torque Stabilizer bar mounting bracket bolt...

Page 404: ...n 1D 17 Install hood referring to Hood Removal and Installation in Section 9J 18 Lower hoist and vehicle in unloaded condition tighten suspension control arm bolts to specified torque Tightening torqu...

Page 405: ...fective replace Stabilizer Joint 1 Check for smooth rotation 2 Check damages of ball stud 3 Check damages of dust cover NOTE Stabilizer joint 1 cannot be disassembled If there is any damage to either...

Page 406: ...ction 0A Fastening part Tightening torque Note N m kgf m lb ft Tie rod end lock nut 45 4 5 32 5 Strut bracket nut 140 14 0 101 5 Brake hose mounting bolt 26 2 6 19 0 Stabilizer joint nut 50 5 0 36 5 S...

Page 407: ...e H P No 99000 25121 09913 65810 09913 75510 Crankshaft bearing puller Bearing installer 09913 75821 09913 85230 Bearing installer attachment Bearing remover tool 09925 14520 09942 15511 Bearing and o...

Page 408: ...sorber 17 Rear wheel hub assembly B 4WD model 9 Lower washer 73 N m 7 3 kgf m 53 0 lb ft 1 Coil spring 10 Lower nut 30 N m 3 0 kgf m 22 0 lb ft 2 Spring upper seat 11 Rear axle 175 N m 17 5 kgf m 127...

Page 409: ...2 Then remove shock absorber 3 upper washers 6 Remove absorber upper bushes Installation 1 Install absorber upper bushes 1 NOTE For proper installing direction of shock absorber bushes 1 refer to the...

Page 410: ...e Inspect bushings for wear or damage Inspect for evidence of oil leakage Replace any defective parts WARNING When handling rear shock absorber 1 in which high pressure gas is sealed make sure to obse...

Page 411: ...2 a little CAUTION Do not reuse rear axle bolt Otherwise bolt may loosen 4 Support both ends of rear axle 1 by using two floor jacks 2 5 Detach each lower end 2 of shock absorbers 1 right and left fro...

Page 412: ...al Dismounting and Remounting in Section 3B 6 Install wheel and tighten wheel nuts to specified torque Tightening torque Wheel nut 85 N m 8 5 kgf m 61 5 lb ft 7 Lower hoist and bounce vehicle up and d...

Page 413: ...hile supporting rear axle at both ends remove rear axle bolts and then remove rear axle from chassis by lowering floor jack gradually 8 Remove brake pipes from rear axle if necessary Installation CAUT...

Page 414: ...12 Perform brake test foot brake and parking brake 13 Check each installed parts for brake fluid leakage Rear Axle and Coil Spring Inspection S6RW0C2306009 Inspect for cracks deformation or damage Ins...

Page 415: ...6 If necessary remove wheel stud bolts 1 with copper hammer or hydraulic press CAUTION Never remove bolt unless replacement is necessary Be sure to use a new bolt for replacement Installation 1 Insert...

Page 416: ...completion of installation perform brake test Rear Suspension Fasteners Inspection S6RW0C2306014 Check each bolt and nut fastening suspension parts for tightness Tighten loose one if any to specified...

Page 417: ...uring driving Do not bleed or reduce tire pressure after driving Bleeding reduces the Cold Inflation Pressure Higher than recommended pressure can cause Hard ride Tire bruising or carcass damage Rapid...

Page 418: ...may cause objectional vibrations Replacement wheels must be equivalent to the original equipment wheels in load capacity diameter rim with offset and mounting configuration A wheel of improper size o...

Page 419: ...eel belt not being straight within the tire It is most noticeable at a low speed 8 to 48 kph 5 to 30 mph It is possible to locate the faulty tire by road testing the vehicle If it is on the rear the r...

Page 420: ...ng Wheels Description S6RW0C2401007 There are two types of wheel and tire balance static and dynamic Static balance as shown in figure is the equal distribution of weight around the wheel Wheels that...

Page 421: ...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 speedometer only indicat...

Page 422: ...ange tires as they may damage tire beads or wheel rim Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants old rubber and light rust Before mounting or dismount...

Page 423: ...fferential Oil Leakage 3B 1 Precautions in Diagnosing Trouble 3B 1 General Description 3B 2 Rear Differential Description 3B 2 Coupling Description 3B 2 4WD Control System Components 3B 3 4WD Control...

Page 424: ...ial Tools and Equipment 3B 47 Recommended Service Material 3B 47 Special Tool 3B 47 Transfer 3C 1 General Description 3C 1 Transfer Description 3C 1 Diagnostic Information and Procedures 3C 1 Transfer...

Page 425: ...1 Precaution for Rear Differential Oil Leakage Refer to Precaution for Rear Differential Oil Leakage in Section 3B Precautions in Diagnosing Trouble Refer to Precautions in Diagnosing Trouble in Secti...

Page 426: ...tripod joint in the extension contraction direction Component Location Front Drive Shaft Assembly Components Location S6RW0C3113001 I6RW0C311001 01 1 To transaxle 7 Wheel nut 200 N m 20 0 kgf m 145 0...

Page 427: ...on Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace Worn or breakage of the center bearing Replace 2 3 4 5 4 3 6 13 1 14 15 12 1 7 A 9 10 8 2 7 A 11 8 1 I6RW0C311002 01...

Page 428: ...seals and boots when installing drive shaft Do not hit joint boot with hammer Inserting joint only by hands is allowed Make sure that differential side joint is inserted fully and its snap ring is sea...

Page 429: ...sing For boot big band with joint Draw hooks of boot big band together and remove band 2 Wipe off grease from shaft and take off snap ring 1 using snap ring pliers 2 3 Remove tripod joint spider 1 usi...

Page 430: ...tion of the grease 1 Wash disassembled parts except boots After washing dry parts completely by blowing air 2 Clean boots with cloth 3 Apply grease to wheel side joint Use specified grease in tube in...

Page 431: ...gray Amount A 95 115 g 3 4 4 1 oz right side A 90 110 g 3 2 3 9 oz left side 12 Fit boot 1 to grooves of shaft and housing 2 adjust length to specification below 13 Insert screw driver into boot and...

Page 432: ...draw out center shaft 2 from center bearing 2 Remove oil seals from center bearing support 3 3 Remove bearing support circlip 1 using snap ring pliers 2 4 Remove center bearing from center bearing sup...

Page 433: ...icated in figure A Grease 99000 25011 SUZUKI Super Grease A Press fit center shaft 1 from left oil seal 2 side Specifications Tightening Torque Specifications S6RW0C3117001 NOTE The specified tighteni...

Page 434: ...rial is also described in the following Front Drive Shaft Components Special Tool S6RW0C3118002 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25011...

Page 435: ...nstant velocity DOJ Apply dark gray grease included in spare part to joint 6 Wheel side joint Constant velocity ball joint Apply black grease included in spare part to joint 11 Boot wheel side 2 Snap...

Page 436: ...s is allowed Tighten each nuts to specified torque referring to Rear Drive Shaft Components Rear Drive Shaft Disassembly and Reassembly S6RW0C3126003 Disassembly Refer to Front Drive Shaft Disassembly...

Page 437: ...ot becomes the same as atmospheric pressure Drive shaft boot fixing position distance between housing end and small boot band center Left side and right side drive shafts a 142 5 mm 5 61 in Fasten dif...

Page 438: ...nts Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S6RW0C3128001 NO...

Page 439: ...memorized information in 4WD control module memory Disconnection of coupler from 4WD control module Disconnection of battery cable from battery Disconnection of ground wire harness of 4WD control mod...

Page 440: ...situation and driving are judged with 4WD control module based on information from sensor and each control module and the distribution of driving force of the front and rear wheel has been changed by...

Page 441: ...3B 3 4WD Control System Components S6RW0C3201003 2 1 3 6 5 4 I5RW0A320002 04 1 4WD control module 3 4WD LOCK indicator 5 Coupling assembly 2 4WD AUTO indicator 4 2WD 4WD switch 6 Coupling air tempera...

Page 442: ...n Vehicle is at 4WD auto position 4WD control module detects DTC of 4WD control system Blinking at intervals of 2 seconds continuously 4WD control module detects the rotation difference of front wheel...

Page 443: ...temperature sensor 7 4WD control module 12 IG COIL fuse 3 Combination meter 8 2WD 4WD switch 13 4WD fuse 4 BCM 9 4WD switch 14 Main fuse box 5 ABS ESP control module 10 4WD lock switch 1 2 3 4 5 6 7 8...

Page 444: ...D AUTO indicator 1 and 4WD LOCK indicator 2 flash continuously or turn on and 4WD control module comes into fail safe mode For details of fail safe mode refer to Fail Safe Table 2WD 4WD switch Couplin...

Page 445: ...ock mode indication status 4WD diagnostic trouble codes control module 4WD clutch engagement percent ESP hydraulic unit control module if equipped 4WD clutch control request impossibility I7RW01320013...

Page 446: ...ol System Operation Inspection 2 Confirm trouble symptom Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and record of DTC 1 Recheck for DTC referring to DTC Check Is there any DT...

Page 447: ...step only or failure to clear the DTC in this step may result in an faulty diagnosis trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unnecessary Step 3 and 4...

Page 448: ...ON 4WD Control System Operation Inspection S6RW0C3204003 NOTE It automatically changes into 4WD auto position when the vehicle speed becomes specified speed or more at 4WD lock position It is 4WD auto...

Page 449: ...ignition switch OFF and disconnect SUZUKI scan tool from data link connector DLC DTC Clearance S6RW0C3204006 1 Turn ignition switch to OFF position 2 Connect SUZUKI scan tool to data link connector DL...

Page 450: ...of 4WD lock position and then vehicle is not changed for more than 5 seconds C1254 2WD 4WD switch malfunction Different switch combination from specification is detected more than 5 seconds U0073 Cont...

Page 451: ...Wheel speed diff Front rear wheel speed differential rpm This parameter indicates rotation difference between front wheel and rear wheel detected by 4WD control module 4WD duty This parameter indicat...

Page 452: ...f drive bevel pinion Replace referring to Rear Differential Inspection Noise while turning Damaged differential side bearing s or axle bearing s Replace referring to Rear Differential Inspection Oil l...

Page 453: ...RED WHT 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A I7RW01320004 01 A 4WD control module connector G26 viewed from harness side 4 Combination meter 1 Main fuse box 5 4WD...

Page 454: ...to Combination Meter Removal and Installation in Section 9C 2 Check proper connection to WHT RED and BLK wire terminal of combination meter connector 3 If OK then turn ignition switch to ON position a...

Page 455: ...WD control module power supply circuit 5V 5V G26 12 G26 11 G26 10 BLK WHT RED RED BLK 1 2 3 4 YEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A I7RW01320005 01 Step Action Yes...

Page 456: ...ule connector 3 If OK measure resistance between G26 10 terminal of 4WD control module connector and vehicle body ground If resistance 1 or less Substitute a known good 4WD control module and recheck...

Page 457: ...ule with ignition switch turned OFF 2 Measure resistance between ORN terminal of coupling air temperature sensor connector and G26 24 terminal of 4WD control module connector with ignition switch turn...

Page 458: ...erature sensor Coupling air temperature sensor circuit 4WD control module 2 G26 25 G26 24 ORN BRN 5V 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A I7RW01320006 01 Step Actio...

Page 459: ...pling assembly circuit check 1 Disconnect connector from 4WD control module with ignition switch turned OFF 2 Check for proper connection to G26 25 and G26 24 terminals of 4WD control module connector...

Page 460: ...ing assembly check 1 Check coupling assembly referring to Coupling Assembly Inspection Is it in good condition Substitute a known good 4WD control module and recheck Replace coupling assembly 5 Coupli...

Page 461: ...Trouble area 2WD 4WD switch is changed of 4WD lock position and then vehicle is not changed for more than 5 seconds Coupling assembly Coupling assembly circuit 4WD control module Step Action Yes No 1...

Page 462: ...te a known good 4WD control module and recheck 6 Coupling assembly circuit check 1 Disconnect connector from 4WD control module connector G26 with ignition switch turned OFF 2 Check for proper connect...

Page 463: ...minal or L174 5 terminal of 2WD 4WD switch connector and vehicle body ground Is it 10 14 V Go to Step 3 Go to Step 5 3 2WD 4WD switch ground circuit check 1 Measure resistance between L174 4 terminal...

Page 464: ...rol module and its circuits can be checked at coupler connected to 4WD control module by measuring voltage pulse signal CAUTION 4WD control module cannot be checked by itself It is strictly prohibited...

Page 465: ...G26 7 G26 8 G26 9 G26 10 BLK Ground 0 1 V G26 11 WHT RED Power source for internal memory 10 14 V G26 12 RED BLK Power source 10 14 V Ignition switch turned ON position G26 13 RED WHT 4WD switch 0 1 V...

Page 466: ...Voltage Condition Measurement terminal CH1 G26 3 to G26 2 Oscilloscope setting CH1 5 V DIV TIME 400 s DIV Measurement condition Run engine at idle speed and 2WD 4WD switch at 4WD lock position Selecto...

Page 467: ...hoisted for any other service work than oil change also be sure to check for oil leakage 3 Remove oil filler plug 2 4 Remove drain plug 1 and drain old oil 5 Apply sealant to thread of drain plug 1 a...

Page 468: ...ation Louver Removal and Installation in Section 7A 3 Disconnect connector 1 from 4WD control module 4 Remove 4WD control module 2 Installation Reverse removal procedure for installation Coupling Air...

Page 469: ...ured resistance does not show such characteristic as shown replace air temperature sensor Coupling Assembly Inspection S6RW0C3206008 Check coupling assembly for oil leakage If leakage exists replace i...

Page 470: ...differential 6 Front mounting to body bolt 11 Rear mounting bolt 50 N m 5 0 kgf m 36 0 lb ft 2 Front mounting arm 7 Front mounting to body nut 12 Damper Do not reuse 3 Mounting arm bolt 8 Rear mountin...

Page 471: ...09913 85210 B 09951 26020 Rear Differential Dismounting and Remounting S6RW0C3206012 Dismounting 1 Lift up vehicle and drain oil from rear differential 2 Remove propeller shaft referring to Propeller...

Page 472: ...im 28 Pinion shaft 5 Coupling case Apply sealant 99000 31260 to mating surface of carrier and coupling case 17 Bevel pinion 29 Pinion shaft pin 6 Coupling assembly Never disassemble 18 Shim 30 Couplin...

Page 473: ...pecial tool A 09930 40113 5 Remove companion flange 1 from pinion Use special tool if it is hard to remove Special tool A 09913 65135 6 Remove coupling assembly 1 by using hydraulic press CAUTION Do n...

Page 474: ...ar differential gears differential pinions and pinion shaft as follows a With aluminum plates 2 placed on vise first grip differential case with it and remove drive bevel gear hypoid gear 3 by removin...

Page 475: ...replacement becomes necessary When replacing taper roller bearing replace as inner race outer race assembly 1 Press fit bevel pinion bearing outer races to differential carrier 1 by using special tool...

Page 476: ...ghtening torque Bevel gear bolt a 73 N m 7 3 kgf m 52 0 lb ft 6 Press fit differential right side bearing 1 with special tools and hydraulic press Special tool A 09913 80113 B 09926 48010 7 Hold diffe...

Page 477: ...9922 76120 B 09922 76250 C 09922 76140 D 09922 76420 E 09922 76330 F 09922 76150 G 09922 76340 H 09922 76530 3 2 1 4 5 6 H B A C D E G F a c b d e I5RW0A320046 03 1 Front bearing a Pinion dummy height...

Page 478: ...e bevel pinion bearings install special tools with bearings to differential carrier as shown in figure Special tool A 09922 76140 B 09922 76420 C 09922 76330 D 09922 76340 E 09922 76150 F 09922 76530...

Page 479: ...e as far as top surface of pinion dummy accurately When dial gauge measuring tip extends from 0 zero position pointer turns counterclockwise 16 Necessary adjusting shim thickness is the same value as...

Page 480: ...m Write down measured value of bevel pinion bearing preload for differential side bearing shim adjustment Special tool A 09927 27910 Tightening torque Bevel pinion nut 230 340 N m 23 0 34 0 kgf m 166...

Page 481: ...ing brush 1 or sponge etc b Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact c Bring painted part up and check contact pat...

Page 482: ...pecial tool A 09913 75830 Low Contact Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion 2 height adjusting shim and position pinion farther from gear cent...

Page 483: ...Install companion flange to pinion and then hold companion flange with special tool and tighten flange nut Tightening torque Flange nut 110 N m 11 0 kgf m 79 5 lb ft Special tool A 09930 40113 31 Clea...

Page 484: ...er for cracks Check drive bevel pinion and bevel gear for wear or cracks Check side gears pinion gears and pinion shaft for wear or damage Check side gear spline for wear or damage Specifications Tigh...

Page 485: ...Grease SUZUKI Super Grease A P No 99000 25010 Sealant SUZUKI Bond No 1217G P No 99000 31260 09900 20607 09900 20701 Dial gauge Magnetic stand 09912 34510 09913 50121 Case separator Oil seal remover 0...

Page 486: ...evel pinion rear collar Bevel pinion rear collar 09922 76420 09922 76530 Bevel pinion front collar Bevel pinion gauge block 09922 85811 09925 18011 Spring pin remover 4 5 mm Transmission gear bush and...

Page 487: ...mover installer support This kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loop back adapter 7 Battery power cable 8 RS232 cable 9 RS232 a...

Page 488: ...h 90 degrees hypoid gears are provided Hypoid gears have an advantage of preventing gear noise at the same time they require accurate adjustment of tooth contact and backlash Diagnostic Information an...

Page 489: ...ct it NOTE Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage 3 Remove oil filler plug 2 4 Remove drain plug 1 and drain oil 5 Apply sealant t...

Page 490: ...nd Installation 2WD Model in Section 2B in order to lower transfer with front suspension frame 8 Remove front suspension frame front mounting bolt and loosen front suspension frame rear mounting bolt...

Page 491: ...pecified torque as follows Tightening torque Stiffener No 1 bolt and No 2 bolt a 55 N m 5 5 kgf m 40 0 lb ft Transfer to transaxle bolt b 98 N m 9 8 kgf m 71 0 lb ft Engine rear mounting upper nut c 2...

Page 492: ...ply grease 99000 25010 to oil seal lip 4 Pinion shaft rear taper roller bearing 18 Transfer case bolt 32 Left case oil seal No 2 Apply grease 99000 25010 to oil seal lip 5 Transfer output retainer bol...

Page 493: ...fer left case 6 by using special tool Special tool A 09912 34510 8 Remove reduction drive gear assembly 7 and reduction driven gear assembly 9 9 Remove shim 10 and bearing outer races 8 NOTE When it i...

Page 494: ...ive gear assembly 1 Reduction driven gear assembly 3 Bearing outer races 2 Reduction driven gear shims 5 Dowel pin 6 4 Tighten transfer case bolts 4 to specified torque Tightening torque Transfer case...

Page 495: ...925 15410 Intermediate output oil seal installing depth a 1 0 1 5 mm 0 04 0 06 in Reduction Drive Gear Assembly Disassembly and Reassembly S6RW0C3306006 Disassembly Remove bearings 1 from reduction dr...

Page 496: ...h a chisel 1 the thin ground bearing 2 and it can be removed Reassembly CAUTION Bevel gear and pinion must be replaced as a set when either replacement becomes necessary When replacing taper roller be...

Page 497: ...that oil seals in proper direction and position as shown in figure Apply grease to oil seal lip Special tool A 09925 15410 A Grease 99000 25010 SUZUKI Super Grease A Oil seals installing depth a 23 5...

Page 498: ...nion 1 from transfer output retainer by tapping it with plastic hammer 2 5 Drive out front taper roller bearing 1 from bevel pinion 3 by using bearing puller 2 and hydraulic press 6 Remove oil seal 1...

Page 499: ...aper roller bearing 2 and special tools to transfer output retainer 3 Special tool A 09922 76140 B 09922 76430 C 09922 76340 D 09922 76150 NOTE This installation requires no spacer or oil seal c Tight...

Page 500: ...ion shim thickness 0 30 1 85 1 88 1 91 1 94 1 97 2 00 2 03 2 06 2 09 2 12 and 2 15 mm 0 012 0 072 0 074 0 075 0 076 0 077 0 078 0 079 0 081 0 082 0 083 and 0 084 in 2 Press fit outer races front and r...

Page 501: ...mm 0 82 0 86 in 8 Install transfer output flange 1 by tapping with plastic hammer and tighten transfer output flange nut gradually so as rotational torque of bevel pinion to be in specified value NOTE...

Page 502: ...er assembly referring to Transfer Assembly Disassembly and Reassembly 3 Turn transfer output flange clockwise and counterclockwise repeatedly and remove transfer output retainer assembly and bevel gea...

Page 503: ...of reduction driven gear is too much or too little The remedy is to change the division of the bevel gear shim s These contact patterns located on toe or heel on both drive and coast sides mean that...

Page 504: ...ection 0A Fastening part Tightening torque Note N m kgf m lb ft Transfer oil level filler plug 23 2 3 17 0 Transfer oil drain plug 23 2 3 17 0 Stiffener No 1 bolt and No 2 bolt 55 5 5 40 0 Transfer to...

Page 505: ...ion Note Grease SUZUKI Super Grease A P No 99000 25010 Sealant SUZUKI Bond No 1217G P No 99000 31260 09900 20607 09900 20701 Dial gauge Magnetic stand 09912 34510 09913 50121 Case separator Oil seal r...

Page 506: ...andle Bearing installer attachment D 09925 15410 09925 16310 Oil seal installer Bearing installer 09925 18011 09925 98220 Transmission gear bush and bearing installer Bearing installer 09930 40113 099...

Page 507: ...pider rattles in yokes are worn down and replace defective propeller shaft assembly with new one Noise coming from universal joint and ball joint can be easily distinguished from other noises because...

Page 508: ...specification to torque each bolt and nut Tightening torque Propeller shaft bolt 23 N m 2 3 kgf m 17 0 lb ft Center support nut 55 N m 5 5 kgf m 40 0 lb ft Propeller Shaft Inspection S6RW0C3406003 1 C...

Page 509: ...4A 15 Booster Push Clevis Rod Adjustment 4A 16 Specifications 4A 16 Tightening Torque Specifications 4A 16 Special Tools and Equipment 4A 16 Recommended Service Material 4A 16 Special Tool 4A 16 Front...

Page 510: ...ensor or Encoder 4E 20 DTC C1033 Wheel Speed Sensor Deviation 4E 22 DTC C1041 C1042 C1045 C1046 C1051 C1052 C1055 C1056 Inlet Outlet Solenoid 4E 23 DTC C1057 Power Supply Voltage Too High Too Low 4E 2...

Page 511: ...Section 00 Brake Caution Refer to Brake Caution in Section 00 General Precautions Refer to General Precautions in Section 00 Vehicle Lifting Points Refer to Vehicle Lifting Points in Section 0A Fasten...

Page 512: ...connects front left rear right brakes In this brake system the disc brake is used for the front wheel brake and disc brake or drum brake leading trailing shoes for the rear brake The parking brake sy...

Page 513: ...ed toward the interior side In this case the brake pedal lever comes off from the brake pedal thereby preventing the brake pedal from moving rearward CAUTION Never disassemble brake pedal assembly Dis...

Page 514: ...ic unit control module assembly 18 N m 1 8 kgf m 13 0 lb ft 1 From master cylinder primary to ABS hydraulic unit 6 Master cylinder 16 N m 1 6 kgf m 12 0 lb ft 2 From master cylinder secondary to ABS h...

Page 515: ...e Pipe Construction S6RW0C4101003 I6RW0C410003 01 1 To left rear brake hose 5 Left rear brake hose to left brake 2 To right rear brake hose 6 Right rear brake hose to right brake 3 Left rear brake hos...

Page 516: ...erence Item Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair Brake disc or pad stained with oil Clean or replace Overheated brakes Determine cause and repair...

Page 517: ...r indicator to brake disc Replace brake pads Brake warning light lights after engine start Parking brake applied Release parking brake and check that brake warning light turns off Insufficient amount...

Page 518: ...owing specification If out of specification check brake light switch for proper installation position and adjust if necessary Also check pedal shaft bolt and booster clevis pin installation for loosen...

Page 519: ...em with specified fluid and carry out air purge operation For air purge procedure refer to Air Bleeding of Brake System Brake Light Switch Adjustment S6RW0C4106005 Adjustment should be made as follows...

Page 520: ...t Rear brake caliper bleeder plug 9 N m 0 9 kgf m 6 5 lb ft 7 Then attach bleeder plug cap 8 After completing bleeding operation apply fluid pressure to pipe line and check for leakage 9 Replenish flu...

Page 521: ...th water immediately if any fluid is spilled Removal 1 Raise and support vehicle properly Remove tire and wheel 2 Clean dirt and foreign material from both flexible hose end and pipe end fittings 3 Dr...

Page 522: ...ter immediately if any fluid is spilled Removal 1 Clean outside of reservoir and master cylinder 2 Disconnect fluid level switch coupler 1 and clamp 3 from reservoir 2 4 2 2 1 b 10 9 8 7 11 12 6 3 5 a...

Page 523: ...ill reservoir with specified brake fluid up to its MAX level 7 After completing the work bleed air from brake system referring to Air Bleeding of Brake System and bleed air from clutch system referrin...

Page 524: ...eservoir hose to reservoir and install reservoir hose clamp M T model 6 Connect fluid level switch connector and clamp 7 Fill reservoir with specified brake fluid up to its MAX level 8 After completin...

Page 525: ...d 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 526: ...N m 1 3 kgf m 9 5 lb ft 3 Connect vacuum hose to booster referring to Master Cylinder and Brake Booster Components 4 Install front brake pipe from master cylinder primary and secondary to ABS hydraul...

Page 527: ...Master Cylinder and Brake Booster Components Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Rec...

Page 528: ...ase included in brake pad spare parts to inside 26 N m 2 6 kgf m 19 0 lb ft 3 Boot 11 Brake disc 23 N m 2 3 kgf m 17 0 lb ft 4 Slide pin No 1 Apply rubber grease included in slide pin boot set 12 Brak...

Page 529: ...ace it on the right and left Removal 1 Hoist vehicle and remove front wheel 2 Remove caliper pin bolts 1 3 Remove caliper 1 from caliper carrier 2 NOTE Hang removed caliper 1 with a wire hook 4 or the...

Page 530: ...ne Front disc brake pad thickness lining thickness Standard 10 mm 0 39 in Limit 2 mm 0 08 in NOTE When pads are removed visually inspect caliper for brake fluid leak Correct leaky point if any Front D...

Page 531: ...ferring to Air Bleeding of Brake System in Section 4A 8 Check every installed part for fluid leakage 9 Perform brake test and check fluid leakage Front Disc Brake Caliper Disassembly and Assembly S6RW...

Page 532: ...check for its smooth movement in thrust direction Install piston seal boot and piston to caliper referring to the following instructions 1 Replace with a new piston seal 1 at every overhaul After appl...

Page 533: ...or uneven wear of pad lining may indicate unsmooth return of piston In such case replace rubber seal Front Brake Disc Removal and Installation S6RW0C4206008 CAUTION During removal be careful not to d...

Page 534: ...and Installation in Section 2D 4 Perform brake test Front Brake Disc Inspection S6RW0C4206009 Using magnetic stand and with dial gauge positioned at about 10 mm 0 39 in inward from periphery of disc...

Page 535: ...fer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S6RW0C4208001 NOTE Required service material is also described in the following Front Disc Brake Com...

Page 536: ...No 1 slide pin Apply rubber grease 14 Bleeder plug cap 24 Parking nut 5 Brake pad 15 Brake flexible hose 23 N m 2 3 kgf m 17 0 lb ft 6 Return spring 16 Flexible hose joint bolt 27 N m 2 7 kgf m 19 5...

Page 537: ...urn brake caliper piston clockwise to obtain clearance between brake disc and pads Special tool A 09945 16060 2 Clean and degrease pad spring installation face 3 of caliper carrier 1 3 Attach pad spri...

Page 538: ...sen brake pipe flare nut 1 using by flare nut wrench Then remove clip 2 5 Remove flexible hose joint bolt 3 and disconnect brake flexible hose 4 from brake caliper 6 Remove caliper pin bolts 7 Remove...

Page 539: ...ake pads and caliper referring to Rear Disc Brake Pad Removal and Installation 7 Connect flexible hose 4 with new washers 5 to caliper and brake pipe temporarily by hand Then install clip 2 8 Tighten...

Page 540: ...lining with sandpaper 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 Re...

Page 541: ...32110 Thread Lock Cement Super 1322 2 Apply grease to inside of new shaft cover 1 3 Install new shaft cover lever 2 washer 3 parking nut 4 and return spring 5 to caliper Tightening torque Parking nut...

Page 542: ...pply rubber grease to guide pin outer surface Rubber grease should be the one whose viscosity is less affected by such low temperature as 40 C 40 F Rear Brake Disc Removal and Installation S6RW0C43060...

Page 543: ...0 mm 0 004 in max Special tool A 09900 20607 B 09900 20701 Using micrometer measure thickness of brake disc If limit value is exceeded replace brake disc Rear brake disc thickness Standard 9 mm 0 354...

Page 544: ...material is also described in the following Rear Disc Brake Components Special Tool S6RW0C4308002 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super...

Page 545: ...eteriorated condition 9 a 2 a 5 3 1 3 4 4 6 F T T F F R A A a a 7 9 a a b 11 10 11 10 11 10 b 10 b 8 I6RW0C440001 01 T Top side 3 Equalizer 8 Parking brake cable left 26 N m 2 6 kgf m 19 0 lb ft F Fro...

Page 546: ...rake pedal has been depressed at least 3 times with about 300 N 30 kg 66 lbs load Parking brake lever has been pulled up a few times with about 200 N 20 kg 44 lbs load If parking brake cable is replac...

Page 547: ...ce Brake test should be performed Parking Brake Lever Removal and Installation S6RW0C4406003 Removal 1 Remove console box 2 Block vehicle wheels and release parking brake lever 3 Disconnect lead wire...

Page 548: ...tightening torque is also described in the following Parking Brake Cable Construction Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Se...

Page 549: ...what is written there Be sure to use the trouble diagnosis procedure as described in ABS Check Failure to follow it may result in incorrect diagnosis Some other diagnosis trouble code may be stored b...

Page 550: ...ol module assembly is incorporated ABS control module ABS hydraulic unit actuator assembly solenoid valve power supply driver transistor solenoid valve driver transistor pump motor driver transistor A...

Page 551: ...he system is in good condition ABS warning light turns OFF after 2 seconds When an abnormality in the system is detected ABS warning light lights and the area where that abnormality lies is stored in...

Page 552: ...tor LF inlet solenoid valve LF outlet solenoid valve LR inlet solenoid valve LR outlet solenoid valve RF inlet solenoid valve RF outlet solenoid valve RR inlet solenoid valve RR outlet solenoid valve...

Page 553: ...K WHT E08 22 E08 11 23 BLK WHT LT GRN BLK LT GRN 12V E08 10 E08 21 E08 23 E08 26 E08 1 E08 12 24 BLK WHT 12V YEL BRN E08 19 E08 20 27 1 2 E08 6 9 9 9 WHT RED 12V E08 25 M BLK BLK WHT BLU WHT RED WHT B...

Page 554: ...t rear wheel speed sensor Terminal Circuit E08 1 CAN communication line high for ECM 2 CAN communication line high for BCM 3 G sensor ground 4WD model only 4 5 6 G sensor signal 4WD mode only 7 Brake...

Page 555: ...4WD model Step Action Yes No 1 Malfunction analysis 1 Perform Customer complaint analysis 2 Perform Problem symptom confirmation 3 Perform DTC check record and clearance and recheck DTC Is there any m...

Page 556: ...ormation to the point required for proper analysis and diagnosis Customer questionnaire Example 6 Check for intermittent problem 1 Check intermittent troubles referring to Intermittent and Poor Connec...

Page 557: ...arness connector actuator assembly or other part and repair or replace faulty parts Step 5 Brakes Diagnosis Check the parts or system suspected as a possible cause referring to Brakes Symptom Diagnosi...

Page 558: ...r 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 manua...

Page 559: ...OFF This switch signal informs the ABS control module whether the brake is active or not G Sensor G 4WD model Vehicle acceleration is measured by G sensor and output to ABS control module as the linea...

Page 560: ...9 10 11 23 24 25 26 G241 B 1 3 2 4 5 6 7 8 9 10 11 12 13 14 1516 17 19 18 20 2122 23 2425 26 27 28 29 30 3132 WHT GRN 3 E08 2 E08 13 RED WHT 5 4 13 9 E08 23 BLK 6 7 BLK RED WHT G241 7 G241 10 G241 16...

Page 561: ...roper connection to RED BLK and BLK wire of combination meter connector 3 If OK then turn ON ignition switch and measure voltage at RED BLK wire of combination meter connector and vehicle body ground...

Page 562: ...ication line wire 4 If OK then check CAN communication line circuit between control modules for open short and high resistance Is each CAN communication line circuit in good condition Substitute a kno...

Page 563: ...or ABS hydraulic unit control module assembly and recheck Repair CAN communication line circuit Step Action Yes No 11 BB B G G1 12V 14 BLU RED WHT E08 A 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22...

Page 564: ...und 4 Data link connector ground circuit check 1 Turn ignition switch to OFF position and measure resistance between the following terminals Terminal G of data link connector and vehicle body ground T...

Page 565: ...viewed from terminal side 3 Ignition switch 6 ABS hydraulic unit control module assembly 1 Battery 4 Junction block assembly 2 Main fuse box 5 G sensor 4WD model DTC Detecting Condition Trouble Area...

Page 566: ...trol module terminals of E08 3 and E08 6 3 If OK then check G sensor referring to G Sensor Inspection 4WD Model Is it in good condition Go to Step 4 Replace G sensor 4 G sensor power source voltage ch...

Page 567: ...tage becomes 4 8 8 0 V for specified time Brake light circuit Brake light switch ABS control module Step Action Yes No 1 Was ABS Check performed Go to Step 2 Go to ABS Check 2 Brake light operation ch...

Page 568: ...The vehicle was stuck E08 A 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 23 24 25 26 WHT GRN GRN ORN 3 4 E08 9 9 12V 8 7 6 5 BLK WHT BLK WHT RED RED BLK LT GRN BLK LT GRN E08 22 E08 11 E08...

Page 569: ...eed sensor circuit in good condition Go to Step 4 Repair circuit and recheck 4 Wheel speed sensor check 1 Inspection applicable wheel speed sensor referring to Front and Rear Wheel Speed Sensor Inspec...

Page 570: ...r adjust tire pressure and recheck 4 Wheel speed sensor circuit check 1 Disconnect ABS hydraulic unit control module connector and all wheel speed sensor connectors with ignition switch turned OFF 2 C...

Page 571: ...driver 3 Solenoid valve DTC Detecting Condition Trouble Area DTC C1041 C1042 C1045 C1046 C1051 C1052 C1055 C1056 Solenoid valve circuit is opened shorted to power ground and or each valve in ABS hydr...

Page 572: ...t ABS control module Step Action Yes No 1 Was ABS Check performed Go to Step 2 Go to ABS Check 2 Check ABS hydraulic unit control module assembly power and ground circuit 1 Check that ABS hydraulic un...

Page 573: ...r supply voltage is too low Pump motor circuit in ABS control module is opened shorted to power or ground circuit Pump Motor and or Motor Driver power supply circuit ABS control module Step Action Yes...

Page 574: ...nd circuit in ABS control module Solenoid valve power supply voltage is too low Solenoid valve power supply driver is stuck to ON or OFF position Output circuit from control unit is opened or shorted...

Page 575: ...it control module assembly power and ground circuit 1 Check that ABS hydraulic unit control module assembly power supply circuit and ground circuit is in good condition referring to ABS Hydraulic Unit...

Page 576: ...t 1 Turn ignition switch to OFF position 2 Disconnect ABS control module connector 3 Check for proper connection to ABS control module connector at terminals E08 9 E08 23 E08 24 and E08 25 4 If OK the...

Page 577: ...tion is felt at brake pedal 9 Check for all 4 wheels condition respectively If a faulty condition is found replace ABS hydraulic unit control module assembly 10 After completing the check turn ignitio...

Page 578: ...onnect ABS hydraulic unit control module assembly connector 1 by pull up the lock 2 3 Using special tool loosen flare nuts 1 and disconnect brake pipes 2 from ABS hydraulic unit control module assembl...

Page 579: ...nd perform ABS Hydraulic Unit Operation Check NOTE For new ABS hydraulic unit control module assembly if ABS Hydraulic Unit Operation Check has not been performed ABS warning light may flash when igni...

Page 580: ...using oscilloscope for this check check if peak to peak voltage and waveform meet specification Peak to peak voltage at the resistance 115 with wheel rotation High voltage a 1360 to 1930 mV Low volta...

Page 581: ...el speed sensor included in rear wheel hub refer to Rear Wheel Hub Assembly Removal and Installation in Section 2C Rear Wheel Speed Sensor Removal and Installation 2WD Model S6RW0C4506009 CAUTION Do n...

Page 582: ...to Front Wheel Hub Steering Knuckle and Wheel Bearing Removal and Installation in Section 2B Rear Wheel Speed Sensor Encoder On Vehicle Inspection S6RW0C4506012 For 4WD model Refer to Rear Wheel Speed...

Page 583: ...Tightening torque G sensor bolt a 3 0 N m 0 3 kgf m 2 2 lb ft 2 Install center console box 3 Connect negative cable to battery G Sensor Inspection 4WD Model S6RW0C4506015 Connect positive cable of 12...

Page 584: ...kgf m lb ft Brake pipe flare nut 16 1 6 11 5 ABS hydraulic unit control module assembly bolt 9 0 9 6 5 ABS hydraulic unit control module assembly bracket bolt 26 2 6 19 0 Front wheel speed sensor bol...

Page 585: ...28 Stall Test 5A 29 Time Lag Test 5A 30 Line Pressure Test 5A 30 Engine Brake Test 5A 32 P Range Test 5A 32 A T Symptom Diagnosis 5A 33 Transmission Warning Light Circuit Check Light Does Not Come ON...

Page 586: ...onents 5A 83 Automatic Transaxle Unit Dismounting and Remounting 5A 83 Automatic Transaxle Assembly Components 5A 85 Automatic Transaxle Unit Disassembly 5A 88 Oil Pump 2nd Coast Brake and 2nd Brake C...

Page 587: ...Components 5B 28 Input Shaft Disassembly and Reassembly 5B 29 Countershaft Disassembly and Reassembly 5B 32 Gear Shift Shaft Components 5B 36 5th and Reverse Gear Shift Shafts Disassembly and Reassem...

Page 588: ...Refer to Air Bag Warning in Section 00 Precautions in Diagnosing Trouble Refer to Precautions in Diagnosing Trouble in Section 5A Precautions for Disassembly and Reassembly Refer to Precautions for D...

Page 589: ...CAN Communication System in Section 00 General Service Procedure Information S6RW0C5100002 When repairing automatic transaxle it is necessary to conduct the on vehicle test to investigate where the ca...

Page 590: ...place part Clogged fluid passage Clean with air or wire Flaw on installing surface residual gasket Remove with oil stone or replace part Crack Replace part Bearing Unsmooth rotation Replace Streak pit...

Page 591: ...converter 2 One way No 1 clutch 8 Rear planetary gear 14 One way No 3 clutch 20 Oil pump 3 2nd coast brake 9 Forward clutch 15 U D clutch 21 Drive plate mounting nut 4 2nd brake 10 Direct clutch 16 U...

Page 592: ...converter 2 One way No 1 clutch 8 Rear planetary gear 14 One way No 3 clutch 20 Oil pump 3 2nd coast brake 9 Forward clutch 15 U D clutch 21 Drive plate mounting nut 4 2nd brake 10 Direct clutch 16 U...

Page 593: ...2nd 3rd 4th automatic gear change 3 range Forward 1st 2nd 3rd 4th automatic gear change 2 range Forward 1st 2nd 3rd automatic gear change L range Forward 1st 2nd reduction and fixed at 1st gear Gear...

Page 594: ...r Direct clutch Meshes input shaft and front and rear planetary sun gears U D clutch Meshes underdrive planetary carrier and underdrive planetary sun gear 2nd coast brake Fixes front and rear planetar...

Page 595: ...osition unless ignition switch is turned to ACC or ON position Also ignition key cannot be pulled out of key slot unless select lever is in P range Shift Lock Solenoid Manual Release Remove plug cap o...

Page 596: ...TCM has following functions For Euro OBD model when the ignition switch is turned ON with the engine at a stop MIL 1 turns ON to check the bulb of the MIL For Euro OBD model when TCM detects a malfunc...

Page 597: ...ignal A T select lever position signal Transmission actual gear position signal Transmission oil temperature signal ECM Combination meter Transmit data of TCM Reception unit BCM 4WD control module if...

Page 598: ...Range N signal Range D signal Range 2 signal Range L signal Fail safe function Self diagnosis Warning function ECM Shift solenoid valve A Shift solenoid valve B TCC pressure control solenoid valve Pr...

Page 599: ...RED WHT 10 WHT RED 5 4 9 C06 7 C06 17 WHT RED RED WHT WHT RED 12V 12V WHT RED WHT RED RED WHT 31 32 I6RW0C510004 01 A Terminal arrangement of TCM connector viewed from harness side 11 Keyless start co...

Page 600: ...solenoid valve B No 2 Open Close TCC solenoid valve Close Open Throttle opening Shift Vehicle speed km h mph Remark UP shift Over 90 1st 2nd 56 62 35 39 2nd 3rd 111 117 69 73 3rd 4th 172 178 107 111 5...

Page 601: ...r acceleration so as to reduce frequent up shift and down shift operations while cruising Throttle opening Shift Vehicle speed km h mph Remark UP shift Over 90 1st 2nd 57 62 35 39 2nd 3rd 112 117 70 7...

Page 602: ...m in E mm in F mm in G mm in H mm in I mm in Front race Outer 58 2 3 54 2 1 74 2 9 41 1 6 Inner 43 8 1 7 39 1 5 53 2 1 13 5 0 53 Bearing Outer 62 0 2 4 88 7 3 5 57 2 2 65 2 6 43 4 1 7 41 7 1 6 70 4 2...

Page 603: ...10 8 15 16 17 14 18 13 2 9 12 11 3 4 19 5 I6RW0C510005 01 1 Engine 6 A T relay 11 Output shaft speed sensor 16 Pressure control solenoid 2 Transaxle 7 ECM 12 Input shaft speed sensor 17 TCC solenoid...

Page 604: ...trouble symptom Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and recording of DTC freeze frame data 1 Recheck for DTC and freeze frame data referring to DTC Check Is there any...

Page 605: ...ustomer For this purpose use of such an inspection form as shown in the following page as an example will facilitate collecting information to the point required for proper analysis and diagnosis Cust...

Page 606: ...arance Also reconfirm DTC according to DTC Confirmation Procedure described in each DTC Flow Step 6 and 7 Rechecking and Record of DTC Refer to DTC Check for checking procedure Step 8 A T Basic Check...

Page 607: ...evel leakage Engine Oil and Filter Change in Section 0B Engine coolant level leakage Engine Coolant Change in Section 0B Engine mountings play looseness damage Engine Assembly Removal and Installation...

Page 608: ...nge and less than 20 C 68 F while vehicle is running at 40 km h 25 mile h or more for 10 minutes or more 2 driving cycles 2 driving cycles P0712 Transmission Fluid Temperature Sensor A Circuit Low Tra...

Page 609: ...it Low Difference between command signal and monitor signal of shift solenoid valve B shift solenoid valve B circuit is shorted to ground 1 driving cycle 1 driving cycle P0977 Shift Solenoid B Control...

Page 610: ...mpleting the check turn ignition switch off and disconnect scan tool from DLC DTC Clearance S6RW0C5104006 WARNING When performing a driving test select a safe place where there is neither any traffic...

Page 611: ...ntrol Circuit Low P0963 Pressure Control Solenoid A Control Circuit High P0973 Shift Solenoid A Control Circuit Low P0974 Shift Solenoid A Control Circuit High P0976 Shift Solenoid B Control Circuit L...

Page 612: ...ning and 3rd gear 3 range 2300 RPM displayed in increments of 50 rpm Output shaft revolution At vehicle stop 0 RPM At 60 km h 37 5 mile h constant speed 20 or less throttle opening and 3rd gear 3 rang...

Page 613: ...gnal through CAN communication line fed from ECM Cruise control signal ON OFF ON Signal which inform that lock up inhibit signal from ECM is turned ON OFF Signal which inform that lock up inhibit sign...

Page 614: ...OFF Brake pedal released MIL request ON OFF ON Signal which TCM requires combination meter to turn on MIL OFF Signal which TCM does not require combination meter to turn on MIL A T Basic Check S6RW0C...

Page 615: ...ty valve body component Replace valve body assembly Faulty 2nd coast brake Inspect If NG replace Faulty 2nd brake Inspect If NG replace Faulty one way clutch No 1 Inspect If NG replace 2 3 upshift fai...

Page 616: ...ct lever shifted to each range L 2 3 and D drive vehicle at 1 000 rpm engine speed and then check vehicle speed by referring to Fixed gear position If vehicle speed is not as specified in Fixed gear p...

Page 617: ...way clutch of torque converter Replace torque converter Higher than standard level in D range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly...

Page 618: ...following conditions Automatic fluid is at normal operating temperature 70 80 C 158 176 F Fluid is filled to proper level between FULL and LOW on dipstick Air conditioner switch is turned OFF Conditi...

Page 619: ...9 6 2 kg cm2 84 88 psi At stall speed 10 5 13 5 kg cm2 149 192 psi 16 1 20 3 kg cm2 229 289 psi A I4RH01510010 01 Condition Possible cause Correction Reference Item Higher than standard level in each...

Page 620: ...ke 3 Then release brake pedal gradually and check that vehicle remains stationary 4 Depress brake pedal and shift select lever to N range 5 Then release brake pedal gradually and check that vehicle mo...

Page 621: ...for open short and intermittent If NG repair TCM Substitute a known good TCM and recheck ECM Substitute a known good ECM and recheck Poor 2 3 shift Transmission range sensor circuit faulty Inspect cir...

Page 622: ...Inspection in Section 1C If NG repair Brake light switch circuit faulty Inspect circuit for open short and intermittent If NG repair CAN communication circuit faulty Inspect circuit for open short an...

Page 623: ...4 shift excessive shock or slippage Engine abnormal condition Inspect and repair engine Malfunction of transmission range sensor Inspect If NG replace Malfunction of transmission fluid temperature sen...

Page 624: ...Non operate TCC lock up system Faulty torque converter Replace torque converter Excessive N D time lag Clogged oil strainer Replace Faulty oil pump Inspection If NG replace Slippery forward clutch Ins...

Page 625: ...rouble Code DTC Check 1 Check DTC referring to DTC Check Is there any DTC s Perform DTC Flow to repair and retry Substitute a known good TCM and recheck If OK substitute a known good combination meter...

Page 626: ...each range Taking terminal C07 19 as an example is battery voltage will be indicated only when select lever is shifted to 2 range and 0 V for other ranges as shown in table Check voltage at other ter...

Page 627: ...R N D 2 or L displayed on SUZUKI scan tool when shifting select lever to each range Is applicable range indicated Intermittent trouble Check for intermittent referring to Intermittent and Poor Connect...

Page 628: ...LK GRN RED GRN YEL or LT GRN BLK circuit open If wires and connections are OK substitute a known good TCM and recheck Replace Transmission range sensor Step Action Yes No Terminal C07 20 C07 1 C07 8 C...

Page 629: ...the following circuit for high resistance Between C06 11 terminal of TCM connector and LT GRN terminal of valve body harness connector Between C06 12 terminal of TCM connector and ORN terminal of valv...

Page 630: ...Is it in good condition Intermittent trouble or faulty TCM Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 If OK substitute a known good TCM and recheck R...

Page 631: ...nce referring to Transmission Fluid Temperature Sensor Inspection Is it in good condition Intermittent trouble or faulty TCM Check for intermittent referring to Intermittent and Poor Connection Inspec...

Page 632: ...nals 3 If OK check resistance of sensor circuit Resistance of input shaft speed sensor circuit Between terminals C07 6 and C07 16 of disconnected harness side TCM connector 344 516 at 20 C 68 F Betwee...

Page 633: ...70 km h 44 mile h or more vehicle speed at least for 30 seconds 4 Stop vehicle and check DTC 2 5V 6 5 16 15 14 13 12 11 4 3 24 23 21 22 10 9 8 7 2 1 19 20 18 17 C06 17 16 26 25 15 14 6 5 3 4 2 13 12 2...

Page 634: ...peed sensor for resistance referring to Output Shaft Speed Sensor Inspection Is it in good condition BLK or WHT wire open or short Replace output shaft speed sensor 4 Check visually output shaft speed...

Page 635: ...ful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Clear DTC 2 Start engine and it up to normal operating temp...

Page 636: ...o to Step 2 Go to A T System Check 2 Check shift solenoid valve A No 1 1 Check shift solenoid valve A No 1 for operation referring to Solenoid Valves Shift Solenoid Valves and TCC Solenoid Valve Inspe...

Page 637: ...ontrol solenoid valve or its circuit malfunction TCM Step Action Yes No 1 Was A T System Check performed Go to Step 2 Go to A T System Check 2 DTC check Is DTC P0962 or DTC P0963 detected Go to applic...

Page 638: ...to OFF position 2 Disconnect valve body harness connector 1 on transaxle 3 Check for proper connection to LT GRN and GRY terminals of valve body harness connector 4 Check resistance of pressure contro...

Page 639: ...nt of TCM connector viewed from harness side 2 Pressure control solenoid valve DTC detecting condition Trouble area Value of pressure control solenoid valve output current is too high for 12 5 seconds...

Page 640: ...onnector 3 3 3 7 at 20 C 68 F Between 3 terminal of valve body harness connector and vehicle body ground 2 Infinity Is check results satisfactory Intermittent trouble or faulty TCM Check for intermitt...

Page 641: ...ve A No 1 or its circuit malfunction P0973 Shift solenoid valve B No 2 or its circuit malfunction P0976 TCM Step Action Yes No 1 Was A T System Check performed Go to Step 2 Go to A T System Check 2 Ch...

Page 642: ...tent trouble or faulty TCM Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 If OK substitute a known good TCM and recheck Step Action Yes No DTC detecting...

Page 643: ...nal 2 and vehicle body ground 4 12 16 at 20 C 68 F Between shift solenoid valve B No 2 terminal 3 and vehicle body ground 4 11 15 at 20 C 68 F Is check result satisfactory Go to Step 4 Replace shift s...

Page 644: ...tecting condition Trouble area 3 position switch ON signal is inputted although transmission range sensor signal is inputted P R N or L range 1 driving cycle detection logic 3 position switch or its c...

Page 645: ...ed to ground If wire is OK replace 3 position switch Step Action Yes No 1 TCC solenoid valve 3 Terminal arrangement of TCM connector viewed from harness side 2 TCM DTC detecting condition Trouble area...

Page 646: ...d at vehicle speed of 80 km h 50 mile h or more 4 Decrease vehicle speed gradually and stop vehicle 5 Check DTC 3 Check TCC solenoid valve resistance 1 Turn ignition switch to OFF position 2 Disconnec...

Page 647: ...harness connector 4 Check resistance of TCC solenoid valve Resistance between terminal 2 of valve body harness connector and vehicle body ground 3 11 15 at 20 C 68 F Is check result satisfactory Go t...

Page 648: ...on 2 Connect TCM connectors 2 to TCM 3 Check voltage and or pulse signal at each terminal of connectors connected using voltmeter 3 and oscilloscope 4 NOTE As each terminal voltage is affected by batt...

Page 649: ...nal is pulse Pulse signal frequency varies depending on engine condition C06 8 C06 9 C06 10 C06 11 LT GRN Signal for transmission fluid temperature sensor 2 9 3 1 V Ignition switch is at ON position a...

Page 650: ...and select lever is at N range 0 1 V Ignition switch is at ON position and select lever is at other than N range C07 9 YEL 3 position switch 10 14 V Ignition switch is at ON position and select lever...

Page 651: ...engine Measurement terminal CH1 C06 5 to C06 1 Oscilloscope setting CH1 10 V DIV TIME 10 ms DIV Measurement condition Drive vehicle at 60 km h 37 mile h or higher after warmed up engine I7RW01510019 0...

Page 652: ...asurement condition Engine running at specified idle speed after warmed up engine I7RW01510023 01 5V 12V BB 6 5 16 15 14 13 12 11 4 3 24 23 21 22 10 9 8 7 2 1 19 20 18 17 C06 17 16 26 25 15 14 6 5 3 4...

Page 653: ...1 Turn ignition switch to OFF position 2 Remove A T relay 3 Check A T relay for operation referring to A T Relay Inspection Is it in good condition Go to Step 4 Replace A T relay 4 Check TCM power su...

Page 654: ...turned to ACC position push shift lock solenoid release plate 1 Then select lever can be shifted from P range position to any other range While ignition switch is at LOCK position even when shift loc...

Page 655: ...OT and LOW HOT If it is below LOW HOT add an equivalent of DEXRON III up to FULL HOT Automatic transaxle fluid An equivalent of DEXRON III NOTE Do not race engine while checking fluid level even after...

Page 656: ...lling select lever adjust select cable referring to Select Cable Adjustment Select Lever Knob Installation S6RW0C5106005 Screw select lever knob onto select lever by specified numbers of rotation belo...

Page 657: ...2 range Continuity Shift other above range No continuity Shift Lock Solenoid Inspection S6RW0C5106008 Check that shift lock solenoid rod 1 moves smoothly when battery voltage is conducted and it move...

Page 658: ...Adjust select cable referring to Select Cable Adjustment Select Cable Adjustment S6RW0C5106012 1 Remove adjuster cable end from select lever pin of select lever assembly 2 Shift manual shift lever 1 t...

Page 659: ...ey Interlock Cable Removal and Installation S6RW0C5106013 NOTE Don t bend interlock cable excessively when removing and installing it or system will not operate correctly Removal 1 If the vehicle is e...

Page 660: ...9 C A 7 1 2 3 4 5 6 7 8 2 B I5RW0C510073 01 A LH steering vehicle 2 Clamp 6 EPS control module B RH steering vehicle 3 Steering lock assembly Steering lock unit if equipped with keyless start system...

Page 661: ...knob button released ignition key can be turned from ACC position to LOCK position With knob button pressed ignition key cannot be turned from ACC position to LOCK position 10 Install knee protector t...

Page 662: ...s in N and P ranges but it doesn t start in D 3 2 L or R range Also check that back up light turn ON in R range Output Shaft Speed Sensor Removal and Installation S6RW0C5106015 Removal 1 Disconnect ne...

Page 663: ...and tighten bolt to specified torque Tightening torque Input shaft speed sensor bolt a 5 5 N m 0 55 kgf m 4 0 lb ft 3 Connect input shaft speed sensor connector 2 to input shaft speed sensor 1 4 Insta...

Page 664: ...rature Sensor Inspection S6RW0C5106020 1 Remove transmission temperature sensor referring to Transmission Fluid Temperature Sensor Removal and Installation 2 Immerse temperature sensing part of sensor...

Page 665: ...olenoid valve A No 1 1 shift solenoid valve B No 2 2 and TCC solenoid valve 3 Tightening torque Shift solenoid bolts a 7 0 N m 0 7 kgf m 5 0 lb ft 4 Install pressure control solenoid 1 Tightening torq...

Page 666: ...torque Tightening torque Transaxle side cover bolts a 13 N m 1 3 kgf m 9 40 lb ft 9 Pour A T fluid referring to A T Fluid Change 10 Verify that there is no A T fluid leakage Solenoid Valves Shift Sole...

Page 667: ...d then make sure that fluid comes out with vigor If check result is not as described replace shift solenoid valve TCC solenoid valve Check that solenoid valve 1 actuate with click sound when battery v...

Page 668: ...rent within 1 0 A 3 Check for gradual movement of valve 3 in the direction of arrow A as voltage is increased 4 Check movement of valve 3 in the direction of arrow B as voltage is decreased 5 Turn pow...

Page 669: ...System in Section 8B Differential Side Oil Seal Replacement S6RW0C5106025 1 Lift up vehicle and drain A T fluid 2 Remove drive shaft joints from differential gear of transaxle Refer to Front Drive Sh...

Page 670: ...rt hose as far as its limit mark to clamp clamps securely A T Relay Inspection S6RW0C5106027 1 Disconnect negative cable at battery 2 Remove A T relay 1 from fuse box 3 Check that there is no continui...

Page 671: ...3 and remove center bearing support 2 with center shaft 1 from differential side gear for 2WD vehicle 5 Remove clutch housing plate 1 6 Remove torque converter bolts To lock drive plate 1 engage a fl...

Page 672: ...n bolts through torque converter housing lower plate opening Lock drive plate 1 by engaging a flat head rod or the like 2 with drive plate gear Tightening torque Drive plate to torque converter bolts...

Page 673: ...m 3 4 5 13 14 15 10 9 12 11 8 7 5 5 N m 0 55 kg m 6 I7RW01510050 02 1 Torque converter 6 Input shaft speed sensor 11 O ring Tightening torque 2 Transaxle housing 7 Output shaft speed sensor 12 Underd...

Page 674: ...35 34 32 31 39 38 36 33 41 42 43 44 48 46 I4RH01510251 01 1 Transaxle rear cover 14 Planetary front gear 27 Thrust washer 40 Underdrive brake 2 Oil seal ring 15 Thrust bearing 28 One way No 1 clutch...

Page 675: ...ng 37 Thrust bearing Tightening torque 12 Thrust bearing 25 1st reverse brake piston 38 Snap ring Do not reuse 13 Bearing race 26 Reduction drive gear assembly 39 One way No 3 clutch 11 11 7 8 9 10 9...

Page 676: ...h straight as possible Leaning it may cause to damage oil seal lip 2 Remove fluid level gauge 1 fluid filler tube 2 output shaft speed sensor 3 and input shaft speed sensor 4 for speedometer 3 Disconn...

Page 677: ...ess 5 with O ring 9 Remove valve body assembly 1 by removing 9 bolts 4 and then disconnect manual valve connecting rod 2 from manual valve lever 3 CAUTION Be careful not to let manual valve fall off w...

Page 678: ...reservoir RH plate 1 by removing 3 bolts 16 Remove transaxle lubrication tube 2 by removing the bolt and prying up both ends of the tube 17 Remove countershaft front bearing 1 using bearing puller 18...

Page 679: ...orward and direct clutch assembly 1 thrust bearing 2 and bearing front race 3 of input shaft rear side 27 Remove planetary gear 1 and planetary sun gear 2 with the input shaft front thrust bearing 3 i...

Page 680: ...3 psi through oil hole section 2 NOTE If piston will not pop out it is recommended to use needle nose pliers for removal 34 Remove reduction drive gear 2 by removing retainer ring 1 35 Remove oil rese...

Page 681: ...ing and releasing compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole 4 42 Remove underdrive brake band anchor bolt 1 with O ring 2 using special tool Special tool A 09927 68010 43 Remov...

Page 682: ...ssed air 400 800 kPa 4 8 kg cm2 57 113 psi from oil hole 1 47 Remove snap ring 1 using flat end rod or the like 48 Remove one way No 3 clutch 2 49 Remove 2 oil seal rings 1 50 Remove differential side...

Page 683: ...ump body 9 2nd brake piston 16 2nd coast brake piston 23 Retaining plate 3 Oil pump driven gear 10 2nd brake piston return spring 17 O ring 24 Snap ring 4 Oil pump drive gear 11 Cushion plate 18 2nd c...

Page 684: ...specified valve disassemble and inspect inner parts Special tool A 09900 20607 B 09900 20701 2nd coast brake piston stroke Standard 0 82 1 66 mm 0 032 0 156 in Oil Pump 2nd Coast Brake and 2nd Brake D...

Page 685: ...pressed air 400 800 kPa 4 8 kg cm2 57 113 psi from through oil hole 2 NOTE If piston does not pop out it is recommended to use needle nose pliers for removal 7 Remove snap ring 1 using flat end rod or...

Page 686: ...drive gear 2 to oil pump body 3 aligning marks on the gears 3 Apply A T fluid to new O ring 4 and install it to oil pump body 4 Install oil pump plate 5 5 Install stator shaft 1 to oil pump body and t...

Page 687: ...E Do not twist or deviate O rings during installation 13 Install 2nd coast brake piston return spring 1 14 Using special tool and hydraulic press 2 compress 2nd coast brake piston return spring 1 unti...

Page 688: ...nap ring with lug of 2nd brake piston return spring at its retainer section 17 Measure 2nd brake piston stroke again using special tools If measured piston stroke exceeds specified value check for an...

Page 689: ...andard value replace oil pump assembly Clearance between drive gear and crescent Standard 0 004 0 248 mm 0 0001 0 010 in Limit 0 298 mm 0 0117 in 3 Check side clearance of both gears Using a straighte...

Page 690: ...worn or burnt If necessary replace NOTE If friction plate lining is exfoliated discolored or worn hardly replace all friction plates Before assembling new friction plates soak them in A T fluid for a...

Page 691: ...cks when turned clockwise B One Way No 1 Clutch Disassembly and Reassembly S6RW0C5106038 Disassembly 1 Remove one way No 1 clutch rear thrust washer 1 4 3 1 5 2 I4RH01510114 01 1 One way No 1 clutch i...

Page 692: ...her off when assembling 3 Install rear thrust washer 1 onto one way No 1 clutch outer race 2 4 Check that one way No 1 clutch 1 turns freely when turned counterclockwise A and looks when turned clockw...

Page 693: ...te 11 O ring 16 Input shaft rear thrust bearing front race 2 Retaining plate 7 Friction plate 12 Direct clutch piston 17 Input shaft rear thrust bearing 3 Friction plate 8 Separator plate 13 O ring 18...

Page 694: ...asured piston stroke exceeds specified value disassemble and inspect inner parts Special tool A 09900 20607 B 09900 20701 Direct clutch piston stroke Standard 1 52 1 89 mm 0 059 0 074 in Forward and D...

Page 695: ...rect clutch piston 3 with O rings by applying compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole 4 NOTE If piston does not pop out it is recommended to use needle nose pliers for remova...

Page 696: ...lling return spring be careful so that return spring will not fall or tilt Do not align opening in snap ring with lug of direct clutch piston return spring at its retainer section CAUTION Be careful w...

Page 697: ...ch retaining plate thickness 3 6 mm 0 141 in 3 8 mm 0 150 in 4 0 mm 0 158 in 13 Measure direct clutch piston stroke again using special tools If measured piston stroke exceeds specified value replace...

Page 698: ...plates soak them in A T fluid for at least two hours 2 Measure height of direct clutch piston return spring Forward clutch return spring height Standard 23 59 mm 0 93 in NOTE Do not apply excessive fo...

Page 699: ...r flange 2 1st reverse brake piston 7 Retaining plate 12 Snap ring 17 Snap ring 3 1st reverse brake piston return spring 8 Snap ring 13 One way No 2 clutch 18 Front planetary ring gear rear thrust bea...

Page 700: ...3 Remove one way No 2 clutch 2 and front planetary ring gear thrust washer 3 4 Remove snap ring 1 using pliers or the like 5 Remove front planetary ring gear flange 2 from front planetary ring gear 3...

Page 701: ...One Way No 2 Clutch Inspection S6RW0C5106047 1 Check that sliding surfaces of friction separator and retaining plates are not worn or burnt If necessary replace with a new one NOTE If friction plate l...

Page 702: ...13 I7RW01510055 01 1 Snap ring 5 Snap ring 9 Underdrive clutch drum 13 Cushion plate 2 Separator plate 6 Underdrive clutch piston return spring 10 Underdrive clutch thrust bearing Apply automatic tra...

Page 703: ...rd 1 22 1 69 mm 0 048 0 067 in Underdrive Clutch and One Way No 3 Clutch Operation Check S6RW0C5106050 1 Install one way No 3 clutch 1 to underdrive clutch drum 2 2 Check that one way No 3 clutch turn...

Page 704: ...spring 1 5 For removing underdrive clutch piston 1 install underdrive clutch drum to transaxle case 2 6 Remove underdrive clutch piston with O rings by applying compressed air 400 800 kPa 4 8 kg cm2...

Page 705: ...plates F and retaining plate R of coast clutch in the following order C S F S F S F R NOTE Make sure that A section of cushion plate faces toward piston side 5 Install snap ring 1 NOTE Make sure that...

Page 706: ...rive clutch piston return spring height Standard 20 1 mm 0 79 in NOTE Do not apply excessive force when measuring spring height or it is not measured accurately 3 Shake underdrive clutch piston lightl...

Page 707: ...y ring gear flange 9 Planetary sun gear 2 Front planetary carrier rear thrust bearing race 6 Snap ring 10 Input shaft front thrust bearing 3 Front planetary carrier rear thrust bearing 7 Rear planetar...

Page 708: ...on Inner surface of planetary ring gear Planetary Front Gear Measure inside diameter of planetary front gear 1 bushing using special tools If inside diameter exceeds limit replace planetary front gear...

Page 709: ...ton rod spring 3 Remove O ring 3 from underdrive brake piston NOTE Never reuse removed O rings 1 2 3 4 5 6 7 8 9 10 11 12 13 I4RH01510154 01 1 Underdrive brake band anchor bolt 6 Underdrive brake pist...

Page 710: ...free length underdrive brake piston return spring If necessary replace Underdrive brake piston return spring free length Standard 63 20 mm 2 49 in NOTE Do not apply excessive force when measuring spri...

Page 711: ...f underdrive gear If starting torque is out of specification replace underdrive gear assembly Starting torque of underdrive gear 0 55 1 35 N m 0 06 0 14 kgf m 0 40 1 01 lb ft 5 4 2 1 3 I4RH01510161 01...

Page 712: ...7 kg m 7 N m 0 7 kg m 7 N m 0 7 kg m 7 N m 0 7 kg m 12 10 1 9 4 3 2 5 8 11 6 7 7 7 13 I4RH01510176 01 1 Valve body assembly 5 Pressure control solenoid valve clamp 9 Shift solenoid valve B No 2 13 Suc...

Page 713: ...rings and install O rings to each solenoid valves 2 Install solenoid valves to valve body and tighten bolts to specified torque Tightening torque Shift solenoid bolts a 7 0 N m 0 7 kgf m 5 0 lb ft Pre...

Page 714: ...rting torque using special tool If starting torque exceeds specified value replace shim in the following so as starting torque to be in standard value Starting torque of differential assembly 0 7 1 2...

Page 715: ...emove 8 bolts and 4 final gear bolt lock plates NOTE Don t reuse lock plates 3 Remove final gear 2 Installation Bearing outer race 1 Install differential side right bearing race 1 and shim 2 to transa...

Page 716: ...ferential assembly starting torque using special tool If starting torque exceeds specified value replace shim in the following so as starting torque to be in standard value Special tool A 09928 06060...

Page 717: ...on 3 cover by removing 2 bolts 3 Remove O ring 4 from forward clutch accumulator piston 24 N m 2 4 kg m 24 N m 2 4 kg m 10 N m 1 0 kg m 10 N m 1 0 kg m 10 N m 1 0 kg m 1 2 3 6 5 4 7 I4RH01510190 02 1...

Page 718: ...sure that opening ends of oil seal rings are not lined up so as to prevent fluid leakage Transaxle Rear Cover Inspection S6RW0C5106069 Measure free length forward clutch accumulator spring If necessar...

Page 719: ...cumulator cover 2 into transaxle case NOTE Do not twist or deviate O rings during installation 8 Push underdrive brake accumulator cover and install underdrive brake accumulator bracket 1 spacer 2 and...

Page 720: ...roke while applying and releasing compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole 2 If measured piston stroke exceeds specified value replace underdrive brake piston rod in the follo...

Page 721: ...rust bearing race 3 and countershaft front thrust bearing 2 to counter driven gear 26 Install underdrive gear assembly 4 onto under drive clutch 5 27 Install parking lock pawl 1 Place torsion spring 2...

Page 722: ...race 3 onto counter driven gear 38 Apply petroleum jelly to front planetary ring gear front thrust bearing 1 and front planetary ring gear rear thrust bearing 2 39 Install front planetary ring gear f...

Page 723: ...nput shaft front thrust bearing 1 planetary sun gear 3 and rear planetary ring gear rear thrust bearing 2 to forward and direct clutch assembly 4 50 Apply petroleum jelly to rear planetary ring gear r...

Page 724: ...amount that its section is 1 5 mm 0 059 in in diameter A Sealant 99000 31230 SUZUKI Bond No 1216B 62 Install transaxle rear cover to transaxle case by a tightening bolts to specified torque NOTE Make...

Page 725: ...l reservoir RH plate bolt b 5 5 N m 0 55 kgf m 4 0 lb ft 69 Install oil reservoir LH plate 1 and tighten 2 bolts to specified torque Tightening torque Oil reservoir LH plate bolts a 5 5 N m 0 55 kgf m...

Page 726: ...straight edge 2 If distance is out of specification remove one way No 1 clutch assembly 3 and install them properly Distance between upper edge of one way No 1 clutch to oil pump plate a 51 1 51 7 mm...

Page 727: ...onnecting rod 1 to manual shift shaft 2 80 Install valve body assembly 3 by 9 tightening bolts to specified torque Tightening torque Valve body bolt 10 N m 1 0 kgf m 7 5 lb ft 81 Apply A T fluid to ne...

Page 728: ...shaft speed sensor 2 input shaft speed sensor 3 and fluid filler tube 4 88 Install input shaft speed sensor and output shaft speed sensor with new O rings installed by tightening bolts to specified t...

Page 729: ...mission range sensor bolt and nut to specified torque Tightening torque Transmission range sensor bolt c 25 N m 2 5 kgf m 18 0 lb ft Transmission range sensor nut d 7 5 N m 0 75 kgf m 5 5 lb ft 92 Ins...

Page 730: ...xle to engine bolts and nut 85 8 5 61 5 Drive plate to torque converter bolts 23 2 3 16 5 Clutch housing plate bolt M6 11 1 1 8 0 Clutch housing plate bolt M10 30 3 0 21 5 Oil pump cover bolts 6 5 0 6...

Page 731: ...ch Components Planetary Gear Components Underdrive Brake Components Underdrive Gear Assembly Components Valve Body Assembly Components Differential Components Transaxle Rear Cover Components Special T...

Page 732: ...hment D Oil pressure gauge 09926 95420 09926 98350 Clutch spring compressor Spring compressor No 4 09927 68010 09928 06060 Anchor Bolt Socket Adaptor Differential Preload 09940 51710 09941 51010 Beari...

Page 733: ...he cracking noise from the reverse gear when shifting transaxle gear into the reverse gear the reverse shift braking device is used The device utilizes the 5th synchromesh which is the lever synchro t...

Page 734: ...2 5th speed sleeve hub 7 Left case 12 Side cover 17 Low speed sleeve hub 3 Input shaft 5th gear 8 Reverse gear shaft 13 Countershaft 5th gear 18 Countershaft 1st gear 4 Input shaft 4th gear 9 Reverse...

Page 735: ...nput shaft 5th gear 10 Right case 17 Low speed sleeve hub 24 Transfer bevel pinion 4 Input shaft 4th gear 11 Countershaft 18 Countershaft 1st gear 25 Transfer right case 5 High speed sleeve hub 12 Sid...

Page 736: ...ar shift control cable 7 Reverse gear shift lever 13 Gear shift select lever 2 Gear select control cable 8 5th reverse gear shift guide shaft 14 Low speed gear shift shaft 3 Select cable lever 9 5th r...

Page 737: ...urn spring is contracted 3 When shift lever is shifted to 5th gear shift select shaft 1 turns clockwise letting shift cam 2 off from guide bolt and pushed up by return spring In this state movement of...

Page 738: ...ause Correction Reference Item Gears slipping out of mesh Worn shift fork shaft Replace Worn shift fork or synchronizer sleeve Replace Weak or damaged locating springs Replace Worn bearings on input s...

Page 739: ...ed torque A Sealant 99000 31260 SUZUKI Bond No 1217G Tightening torque Transaxle oil drain plug a 21 N m 2 1 kgf m 15 5 lb ft 6 Pour new specified oil until oil level reaches bottom of oil filler plug...

Page 740: ...Install oil seal horizontally to surface of case Special tool A 09913 75810 B 09913 75510 Distance between case and right oil seal for 2WD a 9 5 10 5 mm 0 37 0 41 in Distance between case and left oil...

Page 741: ...ssembly mounting nut 11 Shift cable seal 2 Cable bracket bolt 7 Gear shift control lever assembly 13 N m 1 3 kgf m 9 5 lb ft 3 Gear shift lever boot 8 Cable grommet bolt 10 N m 1 0 kgf m 7 5 lb ft 4 G...

Page 742: ...or panel Installation Reverse removal procedure for installation nothing the following Tighten each bolts and nuts to specified torque referring to Gear Shift Control Lever and Cable Components Adjust...

Page 743: ...Apply oil to new O ring 1 and tighten back up light switch 2 to specified torque Tightening torque Back up light switch a 23 N m 2 3 kgf m 17 0 lb ft 2 Connect back up light switch coupler 3 Install...

Page 744: ...4 6 5 2 A 1 a 7 7 a 9 b I7RW01520001 01 A Forward 4 Back up light switch connector 8 Transaxle to engine nut 1 Engine 5 Ground cable bolt 9 Stiffener bolt 2 Transaxle 6 Ground cable 85 N m 8 5 kgf m 6...

Page 745: ...g to Front Suspension Frame Stabilizer Bar and or Bushing Removal and Installation 2WD Model in Section 2B and Engine Mountings Components in Section 1D 16 For 4WD model remove transfer engine front m...

Page 746: ...thread 13 Oil seal Apply grease 99000 25011 to oil seal lip 2 5th reverse gear shift cam 8 Gear shift guide case bolt No 2 23 N m 2 3 kgf m 17 0 lb ft 3 Gear shift interlock plate 9 5th to reverse in...

Page 747: ...nd tighten them to specified torque Sealant 99000 31260 SUZUKI Bond No 1217G Tightening torque Guide case bolt No 1 23 N m 2 3 kgf m 17 0 lb ft Guide case bolt No 2 a 23 N m 2 3 kgf m 17 0 lb ft 3 Ins...

Page 748: ...pins prevent shaft from being bent by supporting it with wood block Assemble 5th reverse gear shift cam with its pit and spring pin aligned Make sure to select an appropriate spring by identifying th...

Page 749: ...mbly Apply sealant 99000 31260 to mating surface of guide case and left case 24 Needle bearing 4 Transaxle left case plate 25 Input shaft 5th gear 5 Transaxle side cover Apply sealant 99000 31260 to m...

Page 750: ...of countershaft 5th gear is tight 10 Oil drain plug Apply sealant 99000 31260 to all around thread part of plug 31 Reverse shaft bolt Apply sealant 99000 31260 to thread part of bolt 11 Oil gutter bo...

Page 751: ...lb ft 6 Assemble 5th speed synchronizer sleeve 1 hub 2 5th speed synchronizer levers 3 and synchronizer ring 4 as follows a Install hub 1 to 5th speed synchronizer sleeve 2 in specified direction as...

Page 752: ...ng pliers install new circlip 1 to input shaft 3 10 Clean mating surface of both left case and side cover 1 apply sealant to side cover as shown in figure by such amount that its section is 1 5 mm 0 0...

Page 753: ...r 5 10 Pull out 5th reverse gear shift guide shaft 6 together with 5th reverse gear shift shaft 7 NOTE When removing 5th reverse gear shift shaft 7 and guide shaft 6 push up high speed gear shift shaf...

Page 754: ...shift guide shaft 2 into right case 5 Reverse gear shift arm 4 has to be joined with reverse gear shift lever 3 at the same time 4 Make reverse idler gear 1 with reverse gear shift lever 2 insert rev...

Page 755: ...o 1217G Tightening torque Reverse shaft bolt b 21 N m 21 kgf m 15 5 lb ft 9 Check locating springs 2 4 and 5 for deterioration and replace with new ones as necessary Locating spring 10 Install steel b...

Page 756: ...se surface 5 and straight edge by using feeler gauge 6 Clearance between case surface and straight edge a 0 08 0 13 mm 0 0032 0 0050 in 15 By repeating step 14 select a suitable shim which adjusts cle...

Page 757: ...kgf m 17 0 lb ft Right Case Disassembly and Reassembly S6RW0C5206017 Disassembly 1 Remove differential side oil seal from right case referring to Differential Side Oil Seal Replacement if necessary 2...

Page 758: ...cial tool and hammer Special tool A 09924 74510 B 09925 14520 Left Case Disassembly and Reassembly S6RW0C5206018 Disassembly 1 Removal oil gutter 1 if necessary 2 Remove oil seal using flat end rod or...

Page 759: ...d Select shim 0 800 0 839 mm 0 0315 0 0330 in 1 00 mm 0 0394 in 0 840 0 879 mm 0 0331 0 0345 in 1 04 mm 0 0409 in 0 880 0 919 mm 0 0346 0 0362 in 1 08 mm 0 0425 in 0 920 0 959 mm 0 0362 0 0378 in 1 12...

Page 760: ...ershaft right bearing 26 Countershaft 2nd gear 5 Needle bearing 16 Countershaft 27 Countershaft 3rd gear 6 High speed synchronizer ring 17 Countershaft 1st gear 28 3rd 4th gear spacer 7 High speed syn...

Page 761: ...it from being compressed and then continue to remove bearing with gear 3 Take out 4th gear needle bearing and high speed synchronizer ring 4 Using snap ring pliers 2 remove circlip 1 NOTE For smooth r...

Page 762: ...mm 0 411 in 3 To ensure lubrication of input shaft 1 air blow oil holes 2 and make sure that they are free from any obstruction 4 Fit high speed synchronizer sleeve 4 to hub 3 insert 3 keys 2 in it an...

Page 763: ...d and 4th are identical Special tool B 09913 84510 8 Install circlip 1 and confirm that circlip is installed in groove securely Install needle bearing 2 of apply oil to it and then install synchronize...

Page 764: ...ON If compression exceeds 5 ton 11 000 lb release compression once reset bearing puller and then continue press work again To avoid gear tooth from being damaged support it at flat side of bearing pul...

Page 765: ...ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring and gear Standard 1 0 1 4 mm 0 040 0 055 in Service limit 0 5 mm 0 020 in Key slot width b Stand...

Page 766: ...6010 B 09924 07720 7 Install needle bearing 4 apply oil to it then install 1st gear and 1st gear synchronizer ring 2 8 Drive in low speed sleeve hub assembly 1 by using special tools and hammer NOTE S...

Page 767: ...hydraulic press NOTE It is recommended to press fit spacer and 3rd gear first and then 4th gear later separately so that countershaft will not be compressed excessively Special tool A 09923 78210 B 09...

Page 768: ...se parts if it exceeds limit of 1 0 mm 0 039 in NOTE For correct judgement of parts replacement carefully inspect contact portion of fork and sleeve Clearance a between fork and sleeve Service limit 1...

Page 769: ...tool remove right bearing 1 Special tool A 09913 65135 B 09913 85230 C 09940 54950 I5RW0A520043 02 1 Differential pinion washer 6 Differential case 90 N m 9 0 kgf m 65 0 lb ft 2 Differential pinion 7...

Page 770: ...09900 20701 C 09952 06010 a Differential side gear backlash Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to side gear as shown in figure Fixing differential p...

Page 771: ...bly Components Gear Shift Shaft Components Differential Components Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A 2 Differen...

Page 772: ...rential Components Special Tool S6RW0C5208002 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25011 Sealant SUZUKI Bond No 1217G P No 99000 31260 Thre...

Page 773: ...5 mm Bearing installer 09924 07710 09924 07720 Synchronizer hub installer Synchronizer hub installer 09924 74510 09924 84510 004 Bearing and oil seal handle Bearing installer attachment 09925 14520 09...

Page 774: ...ransmission Transaxle 09940 54950 09941 64511 Bearing installer attachment Bearing and oil seal remover 30 mm Min 09942 15511 09944 96011 Sliding hammer Bearing outer race remover 09952 06010 Dial gau...

Page 775: ...el with the disc in between when the clutch release bearing incorporated in clutch operating cylinder is held back This is the engaged condition of the clutch Depressing the clutch pedal causes the re...

Page 776: ...r or replace Clutch vibration Glazed glass like clutch facings Repair or replace disc Clutch facings dirty with oil Replace disc Release bearing slides unsmoothly Replace clutch operating cylinder ass...

Page 777: ...e and keep engine at idle with neutral gear position 3 Without clutch pedal 1 depressed slightly push the shift lever to reverse position until transaxle emits gear contact noise Do not shift the leve...

Page 778: ...e holding it depressed loosen bleeder plug about one third to one half turn 4 When fluid pressure in cylinder is almost depleted retighten bleeder plug 5 Repeat this operation until there are no more...

Page 779: ...adjust switch 2 position so that clearance between end of thread and clutch pedal arm is within specification and then tighten lock nut to specified torque Clearance between end of thread and clutch p...

Page 780: ...body or other parts Install each clamp securely After installation check clutch pedal free travel and bleed air from clutch system referring to Clutch Pedal Inspection and Air Bleeding of Clutch Syste...

Page 781: ...nual Transaxle Unit Dismounting and Remounting in Section 5B 3 Loosen clutch fluid pipe flare nut 1 of clutch operating cylinder assembly 2 4 Remove clutch pipe joint sleeve 3 from transaxle and then...

Page 782: ...linder Assembly Inspection S6RW0C5306014 Check clutch fluid leakage spring for damage and bearing for smooth rotation If malfunction is found replace clutch operating cylinder assembly Clutch Cover Cl...

Page 783: ...bearing 1 from flywheel 2 use the following special tool if necessary Special tool A 09921 26020 B 09930 30104 4 Remove flywheel 1 from crankshaft using special tool Special tool A 09924 17810 Instal...

Page 784: ...sc is centered Tighten cover bolts little by little evenly in diagonal order Special tool A 09924 17811 B 09923 36320 Tightening torque Clutch cover bolt a 23 N m 2 3 kgf m 17 0 lb ft 4 Slightly apply...

Page 785: ...r Do not disassemble it into diaphragm spring and pressure plate Specifications Tightening Torque Specifications S6RW0C5307001 NOTE The specified tightening torque is also described in the following C...

Page 786: ...mended product or Specification Note Grease SUZUKI Silicone Grease P No 99000 25100 SUZUKI Super Grease I P No 99000 25210 09921 26020 09923 36320 Bearing remover Clutch center guide 15 mm 09924 17810...

Page 787: ...6B 11 Power Assisted Steering System 6C 1 Precautions 6C 1 P S System Note 6C 1 Precautions in Diagnosing Troubles 6C 1 General Description 6C 2 P S System Description 6C 2 EPS Diagnosis General Descr...

Page 788: ...C 39 Tie Rod Rack Boot Removal and Installation 6C 39 Steering Rack Plunger Removal and Installation 6C 41 Steering Rack Plunger Inspection 6C 41 P S Control Module Removal and Installation 6C 42 Torq...

Page 789: ...fer to Air Bag Warning in Section 00 Precautions for Steering Diagnosis Refer to Precautions for Steering Diagnosis in Section 6A Service Precautions of Steering Wheel and Column Refer to Service Prec...

Page 790: ...ce steering gear case assembly Worn steering shaft joints Replace steering lower shaft assembly Worn tie rod ends or tie rod inside ball joints Replace tie rod end or tie rod Worn lower ball joints Re...

Page 791: ...der 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 whe...

Page 792: ...esigned to compress in a front end collision The ignition switch and lock are mounted conveniently on this column With the column mounted lock the ignition and steering operations can be locked to inh...

Page 793: ...ith new one Steering column length a 339 2 mm 13 3 0 08 in b 59 5 2 1 mm 2 4 0 08 in Steering lower shaft length c 348 1 mm 13 7 0 04 in Check that there is no axial looseness d and no axially vertica...

Page 794: ...2 tighten column mounting nut No 1 3 Contact coil cable assembly 11 Steering lower shaft assembly lower joint bolt 4 Steering column upper cover 12 Steering lower shaft assembly upper joint bolt After...

Page 795: ...if equipped 5 Remove steering shaft nut and then make alignment marks 1 on steering wheel and shaft for a guide during reinstallation 6 Remove steering wheel using special tool Special tool A 09944 36...

Page 796: ...t negative cable at battery 2 Disable air bag system referring to Disabling Air Bag System in Section 8B 3 Remove steering wheel from steering column referring to Steering Wheel Removal and Installati...

Page 797: ...any further it stopped turn it back clockwise about two and a half rotations and align center mark with alignment mark 1 Contact Coil Cable Assembly Inspection S6RW0C6206005 Refer to Contact Coil Cab...

Page 798: ...eering column from vehicle NOTE Do not move tilt lever until mounting bolts and nuts are tightened to specified torque Installation CAUTION After tightening steering column mounting nuts shaft joint b...

Page 799: ...y Removal and Installation Non Keyless Start Model S6RW0C6206010 Removal 1 Disconnect negative cable at battery 2 Disable air bag system referring to Disabling Air Bag System in Section 8B 3 Remove st...

Page 800: ...t 4 Align hub on lock with oblong hole 1 of steering shaft 2 and rotate shaft to assure that steering shaft is locked 5 Tighten new bolts 1 until head of each bolt is broken off 6 Turn ignition key to...

Page 801: ...haft 1 and pinion shaft 3 for a guide during reinstallation 5 Remove lower shaft upper and lower joint bolts 2 6 Remove steering lower shaft 1 Installation 1 Be sure that front wheels are in straight...

Page 802: ...specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Special Tool S6RW0C6208001 Fastening part Tightening torque Note N m kgf m lb ft Steering shaft nut...

Page 803: ...values must be used as specified during reassembly to assure proper retention of these parts Precautions in Diagnosing Troubles S6RW0C6300002 Take a note of DTC indicated on the SUZUKI scan tool Befo...

Page 804: ...ensor and the vehicle speed signal from BCM 9 The P S control module runs the motor so as to assist the operation of the steering wheel The P S control module diagnoses troubles which may occur in the...

Page 805: ...egardless of the condition of the P S control system This is only to check if the EPS warning light is operated properly If the areas monitored by the P S control module is free from any trouble after...

Page 806: ...E31 4 3V E31 1 L313 3 I6RW0C630001 02 A P S control module connector No 1 E11 viewed from harness side 5 Front left right wheel speed sensor 15 BCM B P S control module connector No 2 E13 viewed from...

Page 807: ...ngine speed signal E13 2 Ground for P S control module Step Action Yes No 1 Customer complaint analysis 1 Perform customer complaint analysis referring to Customer Complaint Analysis Was customer comp...

Page 808: ...heck and repair malfunction part s and go to Step 11 9 Troubleshooting for DTC 1 Check and repair according to applicable DTC diag flow Are check and repair complete Go to Step 11 Check and repair mal...

Page 809: ...ossible to know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been restored In order to know that check symptom in question according to Step 5 a...

Page 810: ...the DTC once perform DTC confirmation procedure and confirm that no DTC is indicated EPS Warning Light Check S6RW0C6304002 1 Turn ignition switch to ON position but without running engine and check i...

Page 811: ...ing torque sensor Main circuit voltage Circuit voltage of sensor main is more than 4 5 V or less than 0 5 V Torque sensor signal circuit Torque sensor P S control module 1 driving cycle 1 driving cycl...

Page 812: ...uit ECM P S control module 1 driving cycle 1 driving cycle C1123 No vehicle speed signal 30 seconds or more Vehicle speed signal is 0 km h with continuously more than 3 driving cycles even though engi...

Page 813: ...uty is more than 90 when target motor drive current is less than 8 A 1 driving cycle 1 driving cycle C1153 P S control module power supply circuit Power supply voltage of P S control module is less th...

Page 814: ...is diagnosed by comparing this parameter with Motor Control parameter described previously Vehicle Speed km h MPH Vehicle speed signal is fed from BCM P S control module determines the amount of power...

Page 815: ...rce Check before diagnosis Steering wheel installed improperly twisted Install steering wheel correctly Poor performance of P S motor Check P S motor referring to P S Motor and Its Circuit Inspection...

Page 816: ...r DLC 15 DLC power supply circuit C Combination meter connector G241 viewed from harness side 8 P S control module 16 DLC ground circuit 1 Main fuse box 9 BCM 17 IGN fuse 2 Ignition switch 10 To HVAC...

Page 817: ...ol Module Power Supply and Ground Circuit Check Is check result in good condition Substitute a known good P S control module and recheck Repair or replace defective circuit 6 DLC power and ground circ...

Page 818: ...vehicle Scan tool is in good condition check intermittent trouble referring to Intermittent and Poor Connection Inspection in Section 00 Recheck PCMCIA card and DLC cable for faulty condition If they...

Page 819: ...2 Check for proper connection to the combination meter at G241 31 terminal 3 If OK check voltage between G241 31 RED BLK wire terminal and body ground with ignition switch ON Is it 10 14 V Go to Step...

Page 820: ...on SUZUKI scan tool Go to applicable DTC diag flow Go to Step 2 2 EPS warning light circuit check 1 With ignition switch turned OFF disconnect P S control module connector 2 Check for proper connectio...

Page 821: ...13 viewed from harness side 4 Main fuse 9 IGN fuse C Torque sensor connector E31 viewed from harness side 5 P S control module 10 P S fuse 1 Main fuse box 6 Torque sensor 11 IG1 SIG fuse 2 Ignition sw...

Page 822: ...rque sensor signal circuit terminal and other terminal at torque sensor connector Wiring harness resistance of Torque sensor signal circuit is less than 1 Insulation resistance between Torque sensor s...

Page 823: ...005 02 A P S control module connector No 1 E11 viewed from harness side 3 Junction block assembly 8 Torque sensor power supply circuit B P S control module connector No 2 E13 viewed from harness side...

Page 824: ...ned OFF connect torque sensor connector 2 Check for voltage between E11 8 GRN wire terminal and body ground with ignition switch ON Is it approx 9 V Substitute a known good P S control module and rech...

Page 825: ...RN BLK E11 1 E11 14 E11 12 E01 44 E01 27 E13 1 GRN GRN WHT 8 3 10 12 13 11 4 1 2 12V E13 2 BLK 12V 12V 9 5 7 7 E11 11 G04 15 5V PPL E11 4 BLU WHT E04 9 6 14 I6RW0C630006 01 A P S control module connec...

Page 826: ...se of 5 min for engine start 3 driving cycle detection logic DTC C1124 Vehicle speed signal is less than 5 km h for more than 5 seconds continuously with more than specified deceleration speed 20 m s2...

Page 827: ...e speed signal circuit and ground circuit is 0 1 V with ignition switch turned ON Is it in good condition Replace P S control module Repair or replace defective circuit Step Action Yes No A 1 2 3 4 5...

Page 828: ...P S control module and ECM connectors 2 Check engine speed signal output referring to Inspection of ECM and Its Circuits in Section 1A Is it in good condition Substitute a known good P S control modul...

Page 829: ...de 4 Main fuse 9 P S fuse D Motor connector E61 viewed from harness side 5 P S control module 10 IG1 SIG fuse 1 Main fuse box 6 P S motor 11 Motor circuit DTC detecting condition Trouble area DTC C114...

Page 830: ...P S control module and P S motor Refer to Electrical Circuit Inspection Procedure in Section 00 Are they in good condition Go to Step 5 Repair motor circuit 5 P S motor check 1 Check P S motor referr...

Page 831: ...check result in good condition Substitute a known good P S control module and recheck Repair defective circuit DTC detecting condition Trouble area Internal memory EEPROM is data error In this case E...

Page 832: ...Step 3 GRN or WHT wire is open circuit 3 Ignition signal check 1 Turn ignition switch to ON position 2 Measure voltage between E11 1 terminal of P S control module connector and body ground Is voltage...

Page 833: ...tors disconnected from the P S control module Voltage Check 1 Remove console box 2 Check for voltage at each terminal with connectors connected to the P S control module NOTE As each terminal voltage...

Page 834: ...t voltage varies linearly depending on steering force About 2 5 V Steering wheel at free About 1 0 2 5 V Steering wheel with right turn Out put voltage varies linearly depending on steering force E11...

Page 835: ...heel at straight position Voltage between E12 1 and vehicle body ground E12 2 RED Motor output 2 0 1 V 10 14 V Reference waveform No 1 Reference waveform No 2 and Reference waveform No 3 Engine idling...

Page 836: ...turned to left or right at turning speed of 90 sec A Steering wheel is turned left at turning speed of 90 sec B Steering wheel is turned right at turning speed of 90 sec C 12 V ON D GND ON E 1 duty cy...

Page 837: ...wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness Steering wheel play a 0 30 mm 0 1 18 in Steering Force Check S6RW0C6304022 1 Place vehicle...

Page 838: ...ng to Steering Rack Plunger Removal and Installation 3 Tie rod 12 Steering gear case mounting bolt Refer to Steering Gear Case Assembly Removal and Installation 21 O ring 4 Wire 13 Steering gear case...

Page 839: ...2 using puller 3 4 For ease of adjustment after installation make marking 1 of tie rod end lock nut 2 position on tie rod end thread Then loosen lock nut and remove tie rod end 3 from tie rod 4 Insta...

Page 840: ...es in straight direction and remove ignition key from key cylinder before performing the following steps otherwise contact coil of air bag system may get damaged 1 Remove steering joint cover 2 Make a...

Page 841: ...ing lower shaft assembly upper joint bolt a 25 N m 2 5 kgf m 18 5 lb ft Steering lower shaft assembly lower joint bolt b 25 N m 2 5 kgf m 18 5 lb ft 7 Install steering joint cover Steering Rack Boot I...

Page 842: ...wice Pull its both ends together by screwdriver or such and make sure that the wire won t be crossed Then twist the ends 4 5 times the twisted ends should be bent in the circumferential direction NOTE...

Page 843: ...sealant 99000 31250 SUZUKI Bond No 1207F Tightening torque Rack damper screw a Tighten 25 N m 2 5 kgf m 18 0 lb ft and loosen 180 and then tighten 3 9 N m 0 39 kgf m 3 0 lb ft and turn it back by 10...

Page 844: ...ck that torque sensor circuit is in good condition referring to Step 2 to 3 of DTC C1111 C1113 C1115 Torque Sensor Circuit Failure If check result is not satisfactory repair torque sensor circuit 2 Re...

Page 845: ...ect motor connector from steering gear case assembly with ignition switch turned OFF 3 Check for resistance between terminals of motor connector If check result is not as specified check P S motor har...

Page 846: ...nd P S motor output referring to Inspection of P S Control Module and Its Circuits If they are OK replace steering gear case assembly NOTE When P S motor is cold condition that is armature coil of P S...

Page 847: ...nting bolt 70 7 0 51 0 Steering lower shaft assembly upper joint bolt 25 2 5 18 5 Steering lower shaft assembly lower joint bolt 25 2 5 18 5 Tie rod 75 7 5 54 5 Earth cable bolt 4 0 0 4 2 8 Rack dampe...

Page 848: ...6C 46 Power Assisted Steering System...

Page 849: ...cautions 7B 1 A C System Caution 7B 1 Precautions on Servicing A C System 7B 1 General Description 7B 2 Sub Cool A C System Description 7B 2 Manual A C Electronic Input Output Table 7B 3 A C Operation...

Page 850: ...tor and or Its Circuit Malfunction 7B 65 DTC B1514 Air Flow Control Actuator Motor and or Its Circuit Malfunction 7B 67 DTC B1520 B1521 B1522 Temperature Blower Speed Air Flow Selector Malfunction 7B...

Page 851: ...Refrigerant Pressure Sensor Removal and Installation 7B 87 Compressor Relay Inspection 7B 87 Compressor Drive Belt Inspection and Adjustment 7B 87 Compressor Drive Belt Removal and Installation 7B 87...

Page 852: ...em Caution Refer to A C System Caution in Section 7B or A C System Caution in Section 7B Precautions on Servicing A C System Refer to Precautions on Servicing A C System in Section 7B or Precautions o...

Page 853: ...eater and Ventilation General Description Heater and Ventilation Construction S6RW0C7101001 NOTE The figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at...

Page 854: ...HVAC unit 9 Fresh air 17 Engine 2 Ventilator duct 10 Recirculation air 18 Radiator 3 Defroster duct and demister duct 11 Center ventilation air 19 Reservoir 4 Heater core 12 Air intake door 20 Tempera...

Page 855: ...7 G154 8 G154 10 G154 13 G155 2 G155 3 G155 7 G155 6 G155 1 G154 9 G154 14 BLK WHT YEL BLU WHT RED RED BLK RED GRN GRN YEL RED YEL RED BLU BLK ORN 4 6 8 BLU YEL GRN WHT 13 15 14 A 21 BLK RED 12V BLK Y...

Page 856: ...tor faulty auto A C Check temperature control actuator referring to Temperature Control Actuator and Its Circuit Inspection in Section 7B HVAC control module faulty auto A C Check HVAC control module...

Page 857: ...ehicle body by removing nuts 2 Installation Reverse removal procedure noting the following instructions Be careful not to catch any cable and wiring harness in inappropriate position Adjust control ca...

Page 858: ...able from battery 2 Remove glove box from instrument panel 3 Remove passenger side foot duct 1 from HVAC unit by removing screw 2 4 Disconnect connector 1 from blower motor resistor 2 and then remove...

Page 859: ...place relay 6 Connect battery positive terminal to terminal B of relay Connect battery negative terminal A of relay Check continuity between terminal C and D If there is no continuity when relay is co...

Page 860: ...icle RH steering vehicle 6 Remove center garnish from instrument panel 7 Remove HVAC control unit from instrument panel 8 Disconnect connectors from HVAC control unit Installation Reverse removal proc...

Page 861: ...te 1 to DEF position c LH steering vehicle or VENT position d RH steering vehicle then fix air flow control inner cable 2 to pin of air flow control plate and fix outer cable 3 to cable lock clamp 4 L...

Page 862: ...ir intake selector is at REC position If check result does not meet the above conditions replace HVAC control unit Air Intake Control Actuator Removal and Installation S6RW0C7106012 Removal 1 Disconne...

Page 863: ...ector link operates smoothly and it stops at FRE position 1 2 Using service wire connect battery positive terminal to d terminal and battery negative terminal to terminal c And check if air intake sel...

Page 864: ...ouver and garnish Installation Reverse removal procedure Side Ventilation Louver Removal and Installation S6RW0C7106015 Removal 1 Remove instrument panel from vehicle body referring to Instrument Pane...

Page 865: ...C or manual A C or HVAC Control Module Removal and Installation in Section 7B auto A C if removed Install console box referring to Console Box Components in Section 9H Install front seats referring to...

Page 866: ...4a is exposed to your skin such affected part should be treated in the same manner as when skin is frostbitten or frozen Handling Refrigerant HFC 134a R 134a Always wear goggles to protect your eyes A...

Page 867: ...l A C System Description S6RW0C7211001 In the sub cool A C system condenser integrated with receiver dryer the inside of the condenser is divided into the condensation part and the sub cooler part and...

Page 868: ...t pressure is within specified range Evaporator temperature is within specified range Engine speed is within specified range Engine coolant temperature is lower than specified value Throttle opening i...

Page 869: ...ir flow 5 Discharge hose 11 Foot air 17 Air intake door B Refrigerant flow 6 Suction hose 12 Front defroster air 18 Temperature control door 1 HVAC unit 7 Liquid pipe 13 Side defroster air 19 Air flow...

Page 870: ...30 34 33 E01 4 E01 19 WHT RED C01 50 C01 49 WHT RED 32 LT GRN C01 57 C01 24 15 GRY BLU 5V I6RW0C721002 01 A Illumination control model 9 A C refrigerant pressure sensor 18 Condenser cooling fan relay...

Page 871: ...8 2 4 3 5 6 9 9 a a a b b c 1 I7RW01721004 03 1 HVAC unit 6 Discharge hose 25 N m 2 5 kgf m 18 0 lb ft 2 Compressor 7 Suction hose 3 5 N m 0 35 kgf m 2 51 lb ft 3 Condenser assembly 8 Liquid pipe Appl...

Page 872: ...7 15 16 4 2 3 I6RW0C721003 01 A Junction block assembly viewed from relay side 6 Blower motor relay 12 Air intake selector 1 A C refrigerant pressure sensor 7 Junction block assembly 13 Rear defogger...

Page 873: ...to low pressure service valve 6 4 Bleed the air in charging hoses 3 and 4 by loosening their nuts respectively utilizing the refrigerant pressure When a hissing sound is heard immediately tighten nut...

Page 874: ...mbient temperature E Acceptable range B Pressure of low pressure gauge D Humidity Condition Possible cause Correction Pressure is higher than acceptable range A area Refrigerant overcharged Recharge E...

Page 875: ...ressor malfunction Insufficient compression Check compressor Condition Possible cause Correction Pressure is higher than acceptable range C area Expansion valve malfunction valve opens too wide Check...

Page 876: ...ent air volume from center duct Heater blower malfunction Check blower motor and fan Compressor malfunction Check compressor Condition Possible cause Correction Manifold gauge MPa kgf cm2 psi Detail L...

Page 877: ...compressor Inspect compressor and repair or replace as necessary 0 40 0 45 4 0 4 5 57 64 2 0 2 5 20 25 285 355 High pressure reading on both low and high pressure sides Overcharged A C system Adjust...

Page 878: ...t Compressor faulty Check compressor Compressor relay faulty Check compressor relay referring to A C System Relay Inspection BCM faulty Check BCM referring to Inspection of BCM and Its Circuits in Sec...

Page 879: ...cessive compressor oil in A C system Drain excessive compressor oil from A C system circuit and compressor Cool air does not come out only intermittently Wiring connection faulty Repair as necessary E...

Page 880: ...ressor drive belt Adjust drive belt tension or replace drive belt Loose compressor mounting bolts Retighten mounting bolts A loud rattle is heard at low engine rpm Loose compressor clutch plate bolt R...

Page 881: ...e tension pulley Pulley cranks upon contact Cracked or loose bracket Replace or retighten bracket Condition Possible cause Correction Reference Item Whistling sound is heard from A C evaporator Depend...

Page 882: ...r as when skin is frostbitten or frozen Do not handle refrigerant near any place where welding or steam cleaning is performed Refrigerant should be kept in a cold and dark place It should never be sto...

Page 883: ...cm3 10 ml 0 34 US oz 0 35 Imp oz oil When replacing compressor CAUTION Be sure to use specified compressor oil or an equivalent compressor oil Compressor oil is sealed in each new compressor by the a...

Page 884: ...than 100 kPa 1 0 kgf cm2 760 mmHg 14 7 psi providing no leakage exists NOTE If the system does not show a vacuum below 100 kPa 1 0 kgf cm2 760 mmHg 14 7 psi close both valves stop vacuum pump and wat...

Page 885: ...causing troubles such as compression of liquid refrigerant and the like NOTE The air conditioning system contains HFC 134a R 134a Described here is a method to charge the air conditioning system with...

Page 886: ...needle is screwed into the new container to make a hole for refrigerant flow 8 After the system has been charged with specified amount of refrigerant or when low pressure gauge 1 and high pressure ga...

Page 887: ...s 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...

Page 888: ...ed air Condenser fins for leakage and breakage If any defects are found repair or replace condenser Condenser fittings for leakage If any defects are found repair or replace condenser Condenser Assemb...

Page 889: ...Assembly Removal and Installation 2 Remove circlip 4 using special tool Special tool 09900 06107 3 Remove the cap 1 from the receiver dryer tank 2 4 Remove desiccant 3 Installation Reverse the removal...

Page 890: ...Air intake control actuator 15 Evaporator 22 Temperature control door assembly 2 Blower lower case 9 Air intake control link 16 Evaporator temperature sensor 23 Drain hose 3 Heater unit upper case 10...

Page 891: ...hen disconnect heater hoses from HVAC unit 3 Remove cowl top cover from vehicle body referring to Cowl Top and Front Lower Crossmember Components in Section 9K 4 Remove instrument panel from vehicle b...

Page 892: ...und A C evaporator fins should be washed with water and then should be dried with compressed air A C evaporator fins for leakage and breakage If any defects are found repair or replace A C evaporator...

Page 893: ...eration Procedure for Refrigerant Charge 2 Loosen a bolt 1 and remove pipes from expansion valve 2 3 Loosen bolts 3 and remove expansion valve Installation Reverse removal procedure noting the followi...

Page 894: ...70 3 21 V A C Refrigerant Pressure Sensor Removal and Installation S6RW0C7216015 Removal 1 Recover refrigerant from the A C system with the recovery and recycling equipment referring to Recovery in O...

Page 895: ...Belt Removal and Installation S6RW0C7216019 Refer to Water Pump and Generator Drive Belt Removal and Installation in Section 1J Compressor Assembly Removal and Installation S6RW0C7216020 Removal 1 Ru...

Page 896: ...elt Inspection and Adjustment Compressor Assembly Components S6RW0C7216021 Magnet Clutch Inspection S6RW0C7216022 Check armature plate and magnet clutch pulley for wear and oil soak respectively Check...

Page 897: ...s from shaft 5 Remove circlip 1 using special tool Special tool B 09900 06107 6 Remove magnet clutch pulley 2 NOTE If it is difficult to remove magnet clutch pulley by hand use puller 1 Do not damage...

Page 898: ...a 16 N m 1 6 kgf m 11 5 lb ft Special tool A 09991 06310 7 Adjust clearance between armature plate 1 and magnet clutch pulley by putting shim s on compressor shaft To measure the clearance perform th...

Page 899: ...emoval 1 Remove compressor from engine referring to Compressor Assembly Removal and Installation 2 Disconnect thermal switch connector 3 Remove magnet clutch lead wire clamp 4 Remove thermal switch 1...

Page 900: ...equipment referring to Recovery in Operation Procedure for Refrigerant Charge 2 Remove right side engine under cover 3 Remove relief valve 1 from compressor 2 Installation Reverse removal procedure no...

Page 901: ...ghtening torque Note N m kgf m lb ft Expansion valve bolt 4 5 0 45 3 5 A C refrigerant pressure sensor 11 1 1 8 0 Compressor mounting bolt 25 2 5 18 0 Armature plate nut 16 1 6 11 5 Relief valve 8 0 8...

Page 902: ...re checking diagnostic information diagnostic trouble code read this manual and operator s manual for SUZUKI scan tool to know how to read diagnostic information diagnostic trouble code When trouble i...

Page 903: ...pectively by the inside air temperature sensor outside air temperature sensor sunload sensor and ECT sensor For the electronic control system components location refer to Electronic Control System Com...

Page 904: ...ntrol module determines the position of the air intake control door based on signals from the temperature selector inside air temperature sensor outside air temperature sensor and sunload sensor and s...

Page 905: ...speed selector of HVAC control module Back up power supply circuit of HAVC control module Serial communication line between BCM and HVAC control module Received data from BCM as follows Outside air te...

Page 906: ...G20 16 G20 28 G20 2 G20 1 5V G20 G20 26 G20 13 G20 23 BLK RED YEL RED YEL BLK YEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30 28 27 G20 9 G20 25 A G20 6 RED YEL 3...

Page 907: ...4 Outside air temperature sensor 26 Condenser cooling fan relay 38 Indicator light switch selector 3 CAN junction connector 15 Evaporator temperature sensor 27 Information display 39 FRE indicator lig...

Page 908: ...3 01 A Junction block assembly viewed from relay side 8 Junction block assembly 16 Blower motor controller 1 A C refrigerant pressure sensor 9 Sunload sensor 17 HVAC control module 2 Compressor relay...

Page 909: ...ndition Repair or replace malfunction part and go to Step 7 Go to Step 5 5 A C system performance inspection 1 Perform A C system performance inspection Is there any faulty condition Repair or replace...

Page 910: ...nsor wire harness connector actuator HVAC control module or other part and repair faulty parts Step 5 A C system performance inspection Inspect A C system suspected to be a possible cause referring to...

Page 911: ...sor relay faulty Check compressor relay referring to A C System Relay Inspection BCM faulty Check BCM referring to Inspection of BCM and Its Circuits in Section 10B No cool air comes out radiator cool...

Page 912: ...ck temperature control actuator referring to Temperature Control Actuator and Its Circuit Inspection Blower motor faulty Check blower motor referring to Blower Motor Inspection in Section 7A Excessive...

Page 913: ...rator clogged or frosted Check A C evaporator and evaporator temperature sensor referring to Evaporator Inspection and Evaporator Temperature Sensor Inspection Air leaking from HVAC unit or air duct R...

Page 914: ...part from about 100 mm 3 94 in NOTE If sunload sensor is not lighted over with an incandescent light DTC of sunload sensor is detected as current DTC even though there is not any malfunction 2 Set the...

Page 915: ...scan tool 5 After completing the clearance perform DTC Check and confirm if normal DTC No code is displayed 6 Turn ignition switch to OFF position and then disconnect SUZUKI scan tool from DLC Not Usi...

Page 916: ...wer than specification Flashed B1504 Sun load Sensor Circuit Malfunction 4 1 Signal voltage of sun load sensor is higher than specification Without sunlight 4 2 Signal voltage of sun load sensor is lo...

Page 917: ...serial communication circuit is lower than specification Flashed B1552 HVAC Control Module Check Sum Error 9 4 HVAC control module received unspecified data from BCM more than 8 times Flashed B1553 C...

Page 918: ...t the same time in specific pattern DTC No Detection item Detecting condition DTC will set when detecting MIL P0481 Fan 2 Control Circuit Refer to DTC Table in Section 1A P0532 A C Refrigerant Pressur...

Page 919: ...setting of blower speed selector is low 1st position B1522 Air flow selector malfunction HVAC control module maintains last normal value HVAC control module controls actuators assuming that setting o...

Page 920: ...lected position of temperature selector is displayed CABIN TEMPERATURE Ignition switch turned ON In car temperature is displayed OUTSIDE AIR TEMP Ignition switch turned ON Outside air temperature is d...

Page 921: ...s 1st position or more OFF Position of blower speed selector is OFF position AIR INTAKE MODE Air intake selector position AUTO FRE REC This parameter indicates the selected position of air intake sele...

Page 922: ...erminal Connectors of electric wire harness disconnection and friction Fuses burning Parts installation and damage Other parts that can be checked visually 5V G20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1...

Page 923: ...istance between inside air temperature sensor signal circuit and vehicle body ground is infinity Circuit voltage of each inside air temperature sensor signal circuit and ground circuit is 0 1 V with i...

Page 924: ...orator temperature sensor HVAC control module Step Action Yes No 1 Was Air Conditioning System Check performed Go to Step 2 Go to Air Conditioning System Check 2 Wire harness check 1 Turn ignition swi...

Page 925: ...good HVAC control module and recheck 4 Evaporator temperature sensor check 1 Check evaporator temperature sensor for performance referring to Evaporator Temperature Sensor Inspection Is it in good co...

Page 926: ...d ground circuit is 0 1 V with ignition switch turned ON Are they in good condition Go to Step 3 Sunload sensor power supply circuit and or signal circuit are open short or high resistance 3 Sunload s...

Page 927: ...temperature control actuator and HVAC control module connectors 4 If OK check that position sensor of temperature control actuator circuit is as follows Wiring harness resistance of each position sens...

Page 928: ...ion sensor ground terminal of temperature control actuator connector Position sensor signal terminal and position sensor ground terminal of temperature control actuator connector Is voltage 4 5 5 5 V...

Page 929: ...r supply signal and ground circuit is infinity between air flow control actuator connector and vehicle body ground Circuit voltage of each position sensor power supply signal and ground circuit is 0 1...

Page 930: ...sensor ground terminal of air flow control actuator connector Is voltage 4 5 5 5 V Check temperature control actuator and its circuit Substitute a known good HVAC control module and recheck Step Acti...

Page 931: ...minals of temperature control actuator and HVAC control module connectors 4 If OK check that actuator motor drive circuit of temperature control actuator is as follows Wiring harness resistance of eac...

Page 932: ...ck DTC Is DTC B1512 detected together Go to DTC B1512 Air flow Control Actuator Position Sensor and or Its Circuit Malfunction Go to Step 3 3 Visual Check Check if there is any obstruction in operatin...

Page 933: ...n good condition Substitute a known good HVAC control module and recheck Replace air flow control actuator Step Action Yes No DTC Detecting Condition Trouble Area When internal malfunction is detected...

Page 934: ...me Battery voltage supply circuit HVAC control module Step Action Yes No 1 Was Air Conditioning System Check performed Go to Step 2 Go to Air Conditioning System Check 2 DTC check 1 Turn ignition swit...

Page 935: ...ion switch turned OFF 2 Turn ignition switch to ON position and check DTC in BCM Is DTC B1141 or B1142 BCM detected Go to applicable DTC diag flow Go to Step 3 3 DTC check Check DTC in ECM Is DTC P053...

Page 936: ...tion circuit is as follows Wiring harness resistance of serial communication circuit is less than 3 Insulation resistance between serial communication circuit terminal and vehicle body ground is Infin...

Page 937: ...t Temp and Outside Air Temp displayed on scan tool Are values of A C refrigerant pressure sensor and outside air temperature within specified ranges indicated in Scan Tool Data Intermittent trouble Ch...

Page 938: ...System Check 2 DTC check 1 Connect scan tool to DLC with ignition switch turned OFF 2 Check DTC in ECM Is DTC P0500 detected Go to applicable DTC diag flow Substitute a known good HVAC control module...

Page 939: ...2 Go to Air Conditioning System Check 2 DTC check 1 Connect scan tool to DLC with ignition switch turned OFF 2 Check DTC in BCM Is DTC B1141 or B1142 detected Go to applicable DTC diag flow Substitute...

Page 940: ...check 1 Check ENGINE TYPE displayed on scan tool Is CAN Err displayed on scan tool data Check CAN communication circuit referring to Troubleshooting for CAN DTC in Section 1A Substitute a known good...

Page 941: ...module connector viewed from harness side Terminal Wire Color Circuit Normal Voltage Condition G20 1 GRY BLU Temperature control actuator COOL 10 14 V Ignition switch turned ON temperature control act...

Page 942: ...rol actuator FACE 10 14 V Ignition switch turned ON air flow control actuator is working in operation from DEF to FACE position 0 1 V Ignition switch turned ON except the above condition G20 16 BRN WH...

Page 943: ...F position G20 29 GRY Blower motor controller 0 1 V Ignition switch turned ON blower speed selector OFF position 2 3 5 V Ignition switch turned ON blower speed selector between 1st and 6th position Ap...

Page 944: ...Section 1A Measurement terminal Rear defogger switch CH1 G20 4 to G20 23 A C switch CH1 G20 21 to G20 23 Oscilloscope setting CH1 5 V DIV TIME 10 ms DIV Measurement condition Rear defogger switch Ign...

Page 945: ...r Refrigerant Charge HVAC Unit Components S6RW0C7226002 1 10 1 29 9 8 3 29 21 3 20 20 20 19 23 22 5 4 28 15 16 30 29 30 17 18 2 13 12 11 5 26 27 25 14 24 29 6 7 I6RW0C722008 01 1 Blower upper case 9 A...

Page 946: ...nd Its Circuit Inspection S6RW0C7226005 1 Remove temperature control actuator from HVAC unit referring to Temperature Control Actuator Removal and Installation 2 Connect connector to temperature contr...

Page 947: ...actuator 9 Measure resistance between terminal 1 and 2 Temperature control actuator resistance between terminal 1 and 2 MAX HOT position Reference value Approx 0 45 k at 25 C 77 F 10 Connect connecto...

Page 948: ...ctuator from HVAC unit referring to Air Flow Control Actuator Removal and Installation 2 Connect connector to air flow control actuator 3 Set air flow selector to BENT position with ignition switch tu...

Page 949: ...and 2 Air flow control actuator resistance between terminal 1 and 2 VENT position Reference value Approx 4 3 k at 25 C 77 F If measure resistance is out of specification replace the actuator with new...

Page 950: ...n series check that total voltage is 4 5 5 0 V and connect its positive terminal to 2 terminal of blower motor controller and negative terminal to 1 terminal of blower motor controller Then check that...

Page 951: ...Air Temperature Sensor Inspection S6RW0C7226017 Refer to Outside Air Temperature Sensor Inspection If Equipped in Section 9C Inside Air Temperature Sensor Removal and Installation S6RW0C7226018 Remov...

Page 952: ...lve Inspection A C Refrigerant Pressure Sensor and Its Circuit Inspection S6RW0C7226030 Refer to A C Refrigerant Pressure Sensor and Its Circuit Inspection A C Refrigerant Pressure Sensor Removal and...

Page 953: ...aterial is also described in the following HVAC Unit Components Special Tool S6RW0C7228002 SUZUKI scan tool This kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 C...

Page 954: ...7B 89 Air Conditioning System Automatic Type...

Page 955: ...Check 8B 12 Air Bag Diagnostic System Check Flow 8B 13 DTC Table 8B 14 DTC Check 8B 18 DTC Clearance 8B 18 Scan Tool Data 8B 19 AIR BAG Warning Light Comes ON Steady 8B 19 AIR BAG Warning Light Does N...

Page 956: ...8B 85 Contact Coil Cable and Its Circuit Check 8B 87 Inspection of Intermittent and Poor Connections 8B 89 Repair and Inspection Required after Accident 8B 90 Repair Instructions 8B 93 Disabling Air B...

Page 957: ...Service and Diagnosis of Seat Belt in Section 8A Precautions on Service and Diagnosis of Air Bag System Refer to Precautions on Service and Diagnosis of Air Bag System in Section 8B Precautions on Han...

Page 958: ...be normal relative to strap retractor and buckle portions Keep sharp edges and damaging objects away from belts Avoid bending or damaging any portion of belt buckle or latch plate Do not bleach or dye...

Page 959: ...5 7 A B I6RW0C810001 01 A A ELR rear center seat belt model 4 Buckle for front seat belt B Non A ELR rear center seat belt model 5 Buckle for rear seat belt 1 Front seat belt with ELR and pretensioner...

Page 960: ...is incorporated in retractor and controlled by SDM as one of air bag system components It will be activated at the same time as the driver and passenger air bag module when an impact at the front of...

Page 961: ...sult in personal injury or unactivation of the seat belt pretensioner when necessary I7RW01810002 01 1 Sash guide 10 Buckle mounting bolt 2 Anchor plate 11 Sash guide bolt Tighten sash guide bolt firs...

Page 962: ...ect connector 1 from retractor seat belt pretensioner 2 as following steps a Unlock lock button 3 by pulling it b After unlocked disconnect connector 5 Remove front seat belts from the vehicle Install...

Page 963: ...Pretensioner 1 Let the seat belt retract fully to confirm its easy retraction The retractor should lock webbing when pulled quickly The front seat belt retractor 1 should pass the inspection and shoul...

Page 964: ...r center seat belt model 10 Buckle bolt 1 Sash guide 11 Center retractor 2 Anchor plate 12 Center retractor mounting bolt Tighten lower bolt first then tighten upper bolt 3 Side retractor 13 Sash guid...

Page 965: ...ions on Service and Diagnosis of Seat Belt before starting to work and observe every precaution during work Check the rear seat belt in the same way as Front Seat Belt Inspection As to seat belts with...

Page 966: ...for example during a paint baking process remove the air bag system components beforehand to avoid component damage or unintended system activation When handling the air bag inflator modules driver mo...

Page 967: ...le or an object in front of the air bag inflator module to be thrown through the air in the unlikely event of an accidental deployment WARNING Never attempt to measure the resistance of the air bag in...

Page 968: ...hibited to place anything on top of the trim cover and stack air bag inflator modules This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of acciden...

Page 969: ...st 30 minutes to cool it off before proceeding the work Do not apply water oil etc to deployed air bag inflator module and to activate seat belt pretensioner After an air bag inflator module has been...

Page 970: ...ir bag system consists of the following component Driver and passenger air bag inflator modules Driver and passenger seat belt pretensioners Driver and passenger side air bag inflator modules Driver a...

Page 971: ...Impact Sensor Passenger Side Impact Sensor DC DC Converter Back Up Capacitor Safing Power Driver Mechanical Longitudinal G Sensor switch X Y G sensor Longitudinal Lateral Acceleration Driver Side Air...

Page 972: ...nal G sensor in SDM X Y G sensor longitudinal lateral acceleration in SDM OUTPUT deployment activation device INPUT sensor signal Driver Passenger air bag inflator modules Driver Passenger seat belt p...

Page 973: ...85 L04 12 L04 11 GRY RED GRY BLK BLU 27 PNK BLK ORN PNK BLK BLU RED YEL RED BLU RED YEL RED L377 G344 G259 24 L04 5 L04 6 GRN ORN GRN YEL BLU ORN BLU YEL L04 9 L04 7 L04 8 25 26 L283 L04 10 L285 L04 2...

Page 974: ...air bag inflator module 8 channel system 3 Fuse 17 Data link connector DLC 31 Safing power driver 4 Individual circuit fuse box No 1 18 Forward impact sensor 32 X Y G longitudinal lateral acceleratio...

Page 975: ...g deployment signal L04 12 Driver side air bag 8 channel system L04 38 L04 13 Passenger side air bag 8 channel system L04 39 L04 14 Passenger side air bag 8 channel system L04 40 L04 15 L04 41 L04 16...

Page 976: ...omponents Wiring and Connectors Location S6RW0C8203001 17 14 7 B 19 A 20 16 18 18 4 3 1 A 5 C 2 B 10 11 8 9 6 15 C 5 5 13 12 I6RW0C820004 01 A Combination meter 6 Side curtain air bag inflator module...

Page 977: ...r Bag Diagnostic System Check Flow The Air Bag Diagnostic System Check Flow must be the starting point of any air bag system diagnosis The Air Bag Diagnostic System Check Flow checks for proper AIR BA...

Page 978: ...light flash 6 times Go to Step 3 Go to Step 4 3 AIR BAG warning light check turning off check 1 In the state of Step 2 check that AIR BAG warning light turn OFF after flashing 6 times Does AIR BAG wa...

Page 979: ...ower supply voltage is more than 21 4 V for more than 16 sec Charging system SDM B1017 Power supply voltage too low Power supply voltage is less than 7 2 V for more than 16 sec Charging system SDM B10...

Page 980: ...nger air bag module SDM B1042 Passenger air bag circuit low resistance Passenger air bag circuit is less than 0 9 for more than 4 sec B1043 Passenger air bag circuit shorted to ground Passenger air ba...

Page 981: ...to power Passenger side air bag circuit has been shorted to power circuit for more than 4 sec B1071 Driver forward impact sensor communication data inconsistent Driver forward impact sensor has been c...

Page 982: ...Driver curtain air bag circuit high resistance Driver curtain air bag circuit is more than 3 8 for more than 4 sec Driver curtain air bag circuit Driver curtain air bag module SDM B1362 Driver curtai...

Page 983: ...ircuit and power supply and ground circuits of SDM are in good condition referring to SDM Power Supply and Ground Circuit Check and Serial Data Link Circuit Check 5 After completing the check turn ign...

Page 984: ...Sidebag Ini Res Passenger side air bag initiator resistance ohm This parameter indicates the resistance of the passenger side air bag initiator circuit Driv curtain Ini RES Driver side curtain air ba...

Page 985: ...G241 referring to Combination Meter Removal and Installation in Section 9C 2 Disconnect SDM connector L04 3 Check for proper connection to SDM connector at terminal L04 2 4 Check for proper connection...

Page 986: ...L04 and combination meter connector G241 2 With ignition switch turned ON measure voltage between G241 5 terminal and body ground Special tool A 09932 76010 Is measured voltage in 8 12 V Replace comb...

Page 987: ...parking brake 2 Note combination meter when ignition switch is turned ON Does the BRAKE indicator warning light come ON Go to Step 3 Check combination meter power and ground circuit referring to C 1...

Page 988: ...4 17 A A YEL L04 37 12V I6RW0C820006 01 A Junction block with BCM model 4 Individual circuit fuse box No 1 12 METER fuse B Junction block without BCM model That is TAIWAN spec model 5 IGN fuse 13 A B...

Page 989: ...Go to Step 4 Go to Step 6 4 Serial communication circuit check 1 With ignition switch turned OFF disconnect SDM connector L04 and check for proper connection at SDM connector terminal 2 If connections...

Page 990: ...fective circuit 8 Scan tool operation check 1 Check if communication is possible by making communication with other vehicles Is it possible to communicate with the other vehicle Scan tool is in good c...

Page 991: ...o power or opened for more than 4 sec AIR BAG warning light circuit Combination meter SDM Step Action Yes No 1 Was Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic...

Page 992: ...OFF disconnect SDM connector L04 2 Check for proper connection to SDM at L04 27 terminal 3 If OK run engine with more than 3000 rpm 4 In this state check voltage between L04 27 terminal on SDM connec...

Page 993: ...tch turned OFF reconnect SDM connector With ignition switch ON does DTC B1017 exist Substitute a known good SDM and recheck Intermittent trouble Check for intermittent trouble referring to Inspection...

Page 994: ...DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC B1024 Deployment of driver side air bag has been recorded in SDM DTC B1025 Deployment of passenger side air bag has be...

Page 995: ...of vehicle and undercarriage for signs of impact Are there any signs of impact Inspect and replace components according to Repair and Inspection Required after Accident Replace SDM DTC detecting condi...

Page 996: ...30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 1 2 L04 G347 1 2 L378 15 13 16 12V 5V 30V 30V 14 11 12 GRN RED GRN RED GRN GRN G347 S172 L378 G345 1 2 BLK WHT 3 4 5 I6RW0C820008 01 A...

Page 997: ...cated Go to Step 3 Go to Step 5 3 Driver air bag circuit check 1 Disconnect SDM connector L04 2 Check for proper connection to SDM connector at terminal L04 3 and L04 4 3 If OK release shorting bar in...

Page 998: ...ded in special tool A Special tool A 09932 76010 4 Measure resistance between L04 3 and L378 1 terminals 5 Measure resistance between L04 4 and L378 2 terminals Is each measured resistance 1 or less R...

Page 999: ...Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Driver air bag circuit check 1 With ignition switch turned OFF disconnect contact coil connect...

Page 1000: ...L378 connector located near the driver side front pillar lower trim 2 Check for proper connection to floor harness connector at terminal in L378 connector 3 If OK release shorting bar in SDM connector...

Page 1001: ...m Check Flow 2 Driver air bag circuit check 1 With ignition switch turned OFF disconnect contact coil connector G347 located under the steering column 2 Disconnect SDM connector L04 3 Check for proper...

Page 1002: ...nect contact coil connector G347 located under the steering column 2 Remove driver air bag inflator module from steering column referring to Driver Air Bag Inflator Module Removal and Installation 3 C...

Page 1003: ...c Driver air bag circuit SDM Step Action Yes No 1 Was Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Driver air bag circuit check 1 With ignit...

Page 1004: ...it check 1 Connect contact coil connector G347 located under the steering column 2 Remove driver air bag inflator module from steering column referring to Driver Air Bag Inflator Module Removal and In...

Page 1005: ...8 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 L04 14 12 15 12V 5V 30V 30V 13 11 BLU RED YEL RED L04 6 L04 5 L377 L04 G344 G259 BLU RED YEL RED 1...

Page 1006: ...Removal and Installation 2 Check for proper connection to passenger air bag inflator module at terminals in G259 connector 3 If OK then connect special tools A B and C to G259 connector Special tool...

Page 1007: ...e resistance between L04 6 and G259 2 terminals Is each measured resistance 1 or less Substitute a known good SDM and recheck Go to Step 4 4 Floor harness circuit check 1 Disconnect L377 connector loc...

Page 1008: ...to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Passenger air bag circuit check 1 Remove passenger air bag inflator module referring to Passenger Air Bag Inflator Module Removal and Installatio...

Page 1009: ...9932 76010 4 Measure resistance between G259 1 and G259 2 terminals Is measured resistance infinity Substitute a known good SDM and recheck Go to Step 4 4 Floor harness circuit check 1 Disconnect L377...

Page 1010: ...bag circuit check 1 Remove passenger air bag inflator module from steering column referring to Passenger Air Bag Inflator Module Removal and Installation 2 Disconnect SDM connector L04 3 Check for pro...

Page 1011: ...ed near the passenger side front pillar lower trim 2 Check for proper connection to floor harness connector at terminal in L377 connector 3 If OK release shorting bar in SDM connector inserting releas...

Page 1012: ...between L04 5 terminal and body ground and between L04 6 terminal and body ground Is each measured voltage 0 V Substitute a known good SDM and recheck Go to Step 3 3 Floor harness circuit check 1 Disc...

Page 1013: ...313 L04 27 9 10 15 13 16 12V 5V 30V 30V 14 1 2 BLK WHT 3 4 5 L04 GRN ORN GRN YEL BLU ORN BLU YEL L04 9 L04 7 L04 8 11 12 L283 L04 10 L285 I6RW0C820010 01 A Shorting bar 6 Ignition switch 12 Passenger...

Page 1014: ...nnector L283 or L285 2 Check for proper connection to applicable seat belt pretensioner at terminals in L283 or L285 connector 3 If OK then connect special tools A B and C to L283 or L285 connector di...

Page 1015: ...nect SDM connector L04 3 Check for proper connection to SDM at terminals L04 7 and L04 8 for DTC B1051 or terminals L04 9 and L04 10 for DTC B1055 4 If OK release shorting bar in SDM connector inserti...

Page 1016: ...lt pretensioner SDM Step Action Yes No 1 Was Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Seat belt pretensioner circuit check 1 With igniti...

Page 1017: ...sconnect special tools from applicable seat belt pretensioner connector 2 Disconnect SDM connector L04 3 Check for proper connection to SDM at terminals L04 7 and L04 8 for DTC B1052 or terminals L04...

Page 1018: ...ct applicable seat belt pretensioner connector L283 or L285 2 Disconnect SDM connector L04 3 Check for proper connection to applicable seat belt pretensioner at terminals in L283 or L285 4 Check for p...

Page 1019: ...river passenger seat belt pretensioner circuit SDM Step Action Yes No 1 Was Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Seat belt pretensio...

Page 1020: ...13 L04 14 12 Q104 Q133 L384 I6RW0C820011 01 A Shorting bar 5 Individual circuit fuse box No 1 10 SDM 1 Battery 6 Ignition switch 11 Driver side air bag inflator model 2 Fuse 7 A B fuse 12 Passenger s...

Page 1021: ...nstallation 2 Check for proper connection to applicable side air bag inflator module at terminal in connector Q104 or Q105 3 If OK then connect special tools A B and C to applicable side air bag infla...

Page 1022: ...4 If OK release shorting bar in SDM connector inserting release tool 1 included in special tool A Special tool A 09932 76010 5 Measure resistance between L04 12 and Q105 1 terminals between L04 11 and...

Page 1023: ...ng release tool 1 included in special tool A Special tool A 09932 76010 4 Measure resistance between L04 12 and L385 1 terminals between L04 11 and L385 2 terminals for DTC B1061 5 Measure resistance...

Page 1024: ...Yes No 1 Was Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Side air bag circuit check 1 Remove applicable driver passenger side air bag infla...

Page 1025: ...isconnect applicable L384 or L385 connector under front cushion 2 Check for proper connection to applicable floor harness connector at terminal in connector L384 or L385 3 If OK release shorting bar i...

Page 1026: ...Air Bag Circuit Shorted to Ground S6RW0C8204057 DTC B1063 Driver Side Air Bag Circuit Shorted to Ground DTC B1067 Passenger Side Air Bag Circuit Shorted to Ground Wiring Diagram Refer to DTC B1061 B1...

Page 1027: ...onnect SDM connector L04 4 Check for proper connection to SDM connector at terminal L04 11 and L04 12 for DTC B1063 or terminal L04 13 and L04 14 for DTC B1067 5 If OK release shorting bar in SDM conn...

Page 1028: ...e tool 1 included in special tool A Special tool A 09932 76010 4 Measure resistance between L04 11 terminal and body ground and between L04 12 terminal and body ground for DTC B1063 5 Measure resistan...

Page 1029: ...bag circuit check 1 Remove applicable driver passenger side air bag inflator module from seat back referring to Side Air Bag Inflator Module Removal and Installation 2 Disconnect SDM connector L04 3...

Page 1030: ...pecial tool A 09932 76010 4 With ignition switch turned ON measure voltage between L04 11 terminal and body ground and between L04 12 terminal and body ground for DTC B1064 5 Measure voltage between L...

Page 1031: ...Trouble area Forward impact sensor has been communicated with no response or inconsistent ID code for more than 4 sec Forward impact sensor Forward impact sensor circuit SDM Step Action Yes No 1 Was A...

Page 1032: ...block assembly 12 DC DC converter DTC detecting condition Trouble area Forward impact sensor circuit has been shorted to ground for more than 4 sec Forward impact sensor Forward impact sensor circuit...

Page 1033: ...Forward Impact Sensor Circuit Shorted to Ground DTC Detecting Condition and Trouble Area 3 Forward impact sensor circuit check 1 Measure resistance between L04 50 and L04 51 terminals Special tool A...

Page 1034: ...ion to SDM connector at terminals L04 50 and L04 51 4 Check for proper connection to forward impact sensor connector at terminals E40 1 and E40 2 5 Measure resistance between L04 50 and E40 2 terminal...

Page 1035: ...ion Trouble area DTC B1081 Driver side impact sensor has been communicated with no response for more than 4 sec DTC B1091 Passenger side impact sensor has been communicated with no response for more t...

Page 1036: ...ignition switch and check SDM for DTC Are there any DTC s B1083 B1084 B1085 for DTC B1082 or B1093 B1094 B1095 for DTC B1092 Go to applicable DTC diag flow Replace defective side impact sensor and rec...

Page 1037: ...for DTC B1093 4 Check for proper connection to applicable side impact sensor connector at terminals in connector L35 or L36 5 Measure resistance between L04 46 terminal and body ground for DTC B1083...

Page 1038: ...es No 1 Was Air Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Side impact sensor circuit check 1 Disconnect applicable side impact sensor connect...

Page 1039: ...DTC B1094 Special tool A 09932 76010 Is each measured voltage 0 V Replace side impact sensor and recheck If DTC still detected replace SDM Repair short to power supply circuit or other circuit in def...

Page 1040: ...YEL GRN YEL BLU BLK YEL BRN YEL YEL GRN YEL BLU BLK YEL BRN YEL L395 Q132 11 12 L04 Q102 Q103 L04 BLK L04 28 6 8 7 RED GRN L313 L04 27 9 1 2 BLK WHT 3 4 5 A 13 12V 5V 30V 14 I6RW0C820014 01 A Shorting...

Page 1041: ...le connector 2 Check for proper connection to applicable side curtain air bag inflator module at terminals in Q102 or Q103 connector 3 If OK then connect special tools A B and C to applicable side cur...

Page 1042: ...4 22 for DTC B1365 4 If OK release shorting bar in SDM connector inserting release tool 1 included in special tool A Special tool A 09932 76010 5 Measure resistance between L04 19 and Q103 2 terminals...

Page 1043: ...ool 1 included in special tool A Special tool A 09932 76010 4 Measure resistance between L04 19 and L395 4 terminals between L04 20 and L395 3 terminals for DTC B1361 5 Measure resistance between L04...

Page 1044: ...Bag Diagnostic System Check Flow performed Go to Step 2 Go to Air Bag Diagnostic System Check Flow 2 Driver passenger curtain air bag circuit check 1 With ignition switch turned OFF remove rear quart...

Page 1045: ...66 Is each measured resistance infinity Substitute a known good SDM and recheck Go to Step 4 4 Floor harness circuit check for wagon model 1 With ignition switch turned OFF remove rear inner trim of r...

Page 1046: ...in air bag circuit check 1 With ignition switch turned OFF remove rear quarter upper trim of applicable side and disconnect applicable side curtain air bag inflator module connector 2 Disconnect SDM c...

Page 1047: ...nnector inserting release tool 1 included in special tool A Special tool A 09932 76010 4 Measure resistance between L04 19 terminal and body ground and between L04 20 terminal and body ground for DTC...

Page 1048: ...curtain air bag circuit check 1 With ignition switch turned OFF remove rear quarter upper trim of applicable side and disconnect applicable side curtain air bag inflator module connector 2 Disconnect...

Page 1049: ...ease tool 1 included in special tool A Special tool A 09932 76010 4 With ignition switch turned ON measure voltage between L04 19 terminal and body ground and between L04 20 terminal and body ground f...

Page 1050: ...OME fuse 15 Ground for SDM Step Action Yes No 1 Battery voltage check 1 Measure voltage on battery Is voltage in 9 16 V Go to Step 2 Check charging system and repair as necessary referring to Generato...

Page 1051: ...cial tool A 09932 76010 Is voltage in 10 14 V Go to Step 5 Repair defective wire circuit 5 Ground circuit check 1 Turn ignition switch to OFF position 2 Check for proper connection to SDM terminal at...

Page 1052: ...4 terminals Is each measured resistance infinity Go to Step 2 Check defective wire harness If wire is OK replace contact coil 2 Contact coil circuit driver air bag circuit check 1 Remove contact coil...

Page 1053: ...Check for continuity between each terminal of horn switch terminals A and audio control switch terminals B if equipped as shown in figure Is each measured resistance 3 or less Go to Step 5 Replace con...

Page 1054: ...ited Damaged connector body exposing the terminals to moisture and dirt as well as not maintaining proper terminal orientation with the component or mating connector 4 Contact coil circuit horn audio...

Page 1055: ...resistance could be far too high Repair and Inspection Required after Accident S6RW0C8204048 CAUTION All air bag system components including the electrical harness component mounting points must be i...

Page 1056: ...ace faulty part Those components are Steering column 1 and shaft joints Check for length damage and bend according to Checking Steering Column for Accident Damage in Section 6B Steering column bracket...

Page 1057: ...ng or melting Seat belt pretensioner Check for dents cracks damage or fitness Check harness and connector for damage or tightness Seat belts and mounting points Refer to Front Seat Belt Components in...

Page 1058: ...bag inflator module under front seat cushion 1 a Release locking of lock slider 2 b After unlocked disconnect connector 8 Side curtain air bag inflator model Remove quarter inner trim and disconnect y...

Page 1059: ...iagnostic System Check SDM Removal and Installation S6RW0C8206003 WARNING During service procedures be very careful when handling a Sensing and Diagnostic Module SDM Be sure to read Precautions on Ser...

Page 1060: ...andling a Sensing and Diagnostic Module SDM Be sure to read Precautions on Service and Diagnosis of Air Bag System before starting to work and observe every precaution during work Neglecting them may...

Page 1061: ...ry may result Installation 1 Connect horn connector 1 securely if equipped 2 Connect driver air bag inflator module connector 2 to driver air bag inflator module 3 securely as shown in figure a Connec...

Page 1062: ...stem Precautions on Handling and Storage of Air Bag System Components and Precautions on Disposal of Air Bag and Seat Belt Pretensioner before starting to work and observe every precaution during work...

Page 1063: ...stem Components for handling and storing it Otherwise personal injury may result Installation 1 Install passenger air bag inflator module to its facing cover 2 CAUTION Confirm claw 1 of passenger air...

Page 1064: ...and if any one of them is found replace with a new one Air bag has deployed Wire harness or connector is damaged Air bag inflator module is damaged or a strong impact was applied to it Bend or deformi...

Page 1065: ...flator module by wires or connector on the side of the module In case of an accidental deployment the bag will then deploy with minimal chance of injury As the live side air bag inflator module must b...

Page 1066: ...ir bag inflator module If any abnormality is found be sure to replace it with new one as an assembly Be sure to read Precautions on Service and Diagnosis of Air Bag System before starting to work and...

Page 1067: ...in air bag inflator module WARNING When carrying a live air bag inflator module make sure the bag opening is pointed away from you Never carry air bag inflator module by wires or connector on the side...

Page 1068: ...precaution during work Neglecting them may result in personal injury or undeployment of the air bag when necessary CAUTION If air bag inflator module was dropped from a height of 90 cm 3 ft or more it...

Page 1069: ...r till click is heard from it 4 Install front bumper referring to Front Bumper and Rear Bumper Components in Section 9K 5 Enable air bag system referring to Enabling Air Bag System 6 Connect negative...

Page 1070: ...1 to side sill inner panel 2 and tighten side impact sensor bolt 3 to specified torque Tightening torque Side impact sensor bolt a 9 N m 0 9 kgf m 6 5 lb ft 3 Connect side impact sensor connector 4 b...

Page 1071: ...ator module of air bag harness included in instrument panel harness from floor harness located near the glove box 4 Cut off passenger air bag inflator module connector 1 and floor harness joint yellow...

Page 1072: ...utside of Vehicle When you intend to return the vehicle to service deploy the air bag inflator module s and or activate seat belt pretensioner s outside of the vehicle Deployment Activation Inside of...

Page 1073: ...ger Air Bag Inflator Module Removal and Installation Side Air Bag Inflator Module Removal and Installation Side Curtain Air Bag Inflator Module Removal and Installation or Front Seat Belt Removal and...

Page 1074: ...ent area b Place driver air bag inflator module 1 with its vinyl trim cover facing up 2 on ground in Step a For passenger air bag inflator module a Clear space 3 on ground about 185 cm 6 ft in diamete...

Page 1075: ...flator module a Cut off bag 1 of side curtain air bag inflator module b Tie side curtain air bag inflator 1 to tire 3 with wire harness 2 as shown Wire harness specifications Stripped wire harness sec...

Page 1076: ...5 on ground about 185 cm 6 ft in diameter where seat belt pretensioner 2 is to be activated Paved outdoor location where there is no activity is preferred If outdoor location is not available use spa...

Page 1077: ...curtain air bag inflator module b Pile 2 tires 2 and wheel installed tire 3 on top of tire with side curtain air bag inflator 4 and tie them with wire harness 5 as shown Wire harness specifications St...

Page 1078: ...or module or seat belt pretensioner 15 Disconnect deployment harness from 12 volts vehicle battery 2 and short two deployment harness leads together by fully seating one banana plug into the other 16...

Page 1079: ...te both side of seat belt pretensioners at the same time when using special tool C 1 Turn ignition switch to LOCK position remove key and put on safety glasses 2 Remove all loose objects from front se...

Page 1080: ...s For driver air bag inflator module A Connect adapter cable B in series with deployment harness A and push adapter cable B connector to air bag inflator module connector till click can be heard For p...

Page 1081: ...ensioners near any flammable objects Do not apply water oil etc to deployed air bag inflator module and activated seat belt pretensioners Wait for about 30 minutes before touching any metal surface of...

Page 1082: ...W0C8206019 WARNING Failure to follow proper air bag inflator module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal...

Page 1083: ...be familiar with the tools listed under the heading Special Tool You should be able to measure voltage and resistance You should be familiar with proper use of a scan tool such as Air Bag Driver Pass...

Page 1084: ...er seat belt pretensioners when it is connected to air bag harness connector in instrument panel harness for driver and passenger seat belt pretensioners Side air bag inflator module when it is connec...

Page 1085: ...75020 2 Connector test adapter shorting bar release tool 09932 76020 09932 76510 09932 77310 Deployment adapter cable Deployment adapter cable 4P 09932 78310 09932 78332 Adapter cable Deployment adap...

Page 1086: ...8B 121 Air Bag System...

Page 1087: ...9A 50 Junction Block Inner Circuit Detail Taiwan 9A 52 System Circuit Diagram 9A 57 System Circuit Diagram 9A 57 A 1 Cranking System Circuit Diagram 9A 58 A 2 Charging System Circuit Diagram 9A 59 A 3...

Page 1088: ...Connector 9A 149 L Connector 9A 150 O Connector 9A 152 Q Connector 8ch 9A 152 R Connector 9A 152 S Connector 9A 152 Lighting Systems 9B 1 Precautions 9B 1 Precautions for Discharge Headlight Service...

Page 1089: ...nication System Description 9C 1 Auto Volume Control System Description If Equipped 9C 3 Schematic and Routing Diagram 9C 4 Combination Meter Circuit Diagram 9C 4 Component Location 9C 5 Audio System...

Page 1090: ...uctions 9E 3 Windshield Components 9E 3 Windshield Removal and Installation 9E 4 Front Pillar Window Components 9E 8 Front Pillar Window Removal and Installation 9E 8 Rear Quarter Window Components 9E...

Page 1091: ...ghtening Torque Specifications 9G 3 Special Tools and Equipment 9G 3 Recommended Service Material 9G 3 Interior Trim 9H 1 Repair Instructions 9H 1 Floor Carpet Removal and Installation 9H 1 Head Linin...

Page 1092: ...Headlight Service If Equipped in Section 9B Precautions for Body Service S6RW0C9000002 WARNING For vehicles equipped with a Supplemental Restraint Air Bag System When servicing vehicle body if shock...

Page 1093: ...efer to Wire Color Symbols in Section 0A Abbreviation Full term Abbreviation Full term 2WD 2 wheel drive vehicles J B Junction block 4WD 4 wheel drive vehicles J C Joint connector A B Air bag KLS Keyl...

Page 1094: ...sed Open switch Closed switch I2RH01910910 01 IYSQ01910915 01 IYSQ01910916 01 IYSQ01910917 01 IYSQ01910918 01 IYSQ01910919 01 IYSQ01910920 01 IYSQ01910921 01 IYSQ01910922 01 IYSQ01910923 01 IYSQ019109...

Page 1095: ...bag R Side air bag L Side curtain air bag R Side curtain air bag L Glow plug I2RH01910912 01 I3JA01910902 01 I5RH01910901 01 I2RH01910915 01 I2RH01910916 01 I3JA01910904 01 I3JA01910905 01 I3JA019109...

Page 1096: ...ess J Side door wire Power window K Interior light harness Rear speaker wire Roof wire L Floor harness G sensor wire Fuel pump harness M Rear bumper harness O Rear end door harness Q Air bag Pretensio...

Page 1097: ...the illustration Refer to List of Connectors NOTE Molded terminal numbers that are different from the above can be found on some connectors in rare cases These molded numbers are not applied in this...

Page 1098: ...nstead of connecting them by welding or caulking one by one It is not an ordinary connector but a part of the continuous wire in the harness B15 B15 B14 B16 5 7 B14 B16 5 7 I5RW0A910995 03 BLK BLK A A...

Page 1099: ...A B 15A 2 6 5 13 J B Connector No Terminal No BCM IG1 MTR Power etc A B CONT K LINE K LINE A B SIGNAL A B SIGNAL A B SIG A B SIG IG Sig 10A EPS AT MTA 4 6 1 3 2 4 8 11 9 12 9 11 23 25 30 29 Example J...

Page 1100: ...STEM CIRCUIT DIAGRAM GROUND POINT CROSS REFERENCE Windoshield washer motor Individual circuit fuse box 20 15A Windoshield wiper motor E40 E09 E20 16 2 1 Off On Circuit breaker 60A B003 YEL BLU 1 20 5...

Page 1101: ...rcuit continues between the symbols C Circuit jumping point direction NOTE The circuit continues to the same symbol with opposite direction within the page You will find the other symbol in the direct...

Page 1102: ...itch BLU BLU GRN BLK GRN RED GRN BLK 1 2 GRN GRN C26 2 1 BLK 5 BLK 2 1 C40 GRN BLK XX Solenoid Fuse Fuse 3 15A Main relay ON OFF 1 15A 6 20A 1 Sensor 1 2 8 BRN RED E52 1 2 E52 1 BRN RED RED 2 BRN RED...

Page 1103: ...C48 C37 C123 C47 C32 C282 C283 C343 TO E371 C01 C34 C07 C06 C122 C46 C139 C44 C166 4 3 2 1 C A I6RW0C910901 01 No Color Connective position No Color Connective position C01 GRY ECM C101 GRY IG COIL 1...

Page 1104: ...4 No Color Connective position No Color Connective position C124 C32 C42 C102 C91 C192 C194 C43 C162 C141 C196 C195 C93 C94 C101 C39 C92 C31 C311 C313 C312 C36 C48 C37 C123 C47 C32 C282 C283 C343 TO...

Page 1105: ...x C92 GRY Injector 2 C311 Weld splice C93 GRY Injector 3 C312 Weld splice C94 GRY Injector 4 C313 Weld splice C101 GRY IG COIL 1 C343 N Main harness To E371 No Color Connective position No Color Conne...

Page 1106: ...5 BLK Starting motor C47 BLK MAF sensor C196 Starting motor C48 BLK Throttle position sensor C282 Main fuse box C91 GRY Injector 1 C283 Main fuse box C92 GRY Injector 2 C311 Weld splice C93 GRY Inject...

Page 1107: ...p light switch C45 BLK A T Output sensor C166 BLK A T Transaxle range sensor C46 GRY Current sensor C192 Generator C47 BLK MAF sensor C194 BLK Generator C48 BLK Throttle position sensor C195 BLK Start...

Page 1108: ...essure switch C44 BLK A T Input sensor C165 BLK M T Back up light switch C45 BLK A T Output sensor C166 BLK A T Transaxle range sensor C46 GRY Current sensor C192 Generator C47 BLK MAF sensor C194 BLK...

Page 1109: ...relay 3 E63 GRN Rear washer motor E225 BLK Starting motor relay E64 GRY Windshield wiper motor E226 BLK Throttle motor relay E65 BLK Radiator fan motor E227 BLK Fuel pump relay E68 GRY IF EQPD Headlig...

Page 1110: ...y 1 E36 BLK A C pressure sensor E223 BLK Except Taiwan Radiator fan relay 2 E37 BLK Ambient temperature sensor E224 BLK Except Taiwan Radiator fan relay 3 E40 YEL Forward sensor E225 BLK Starting moto...

Page 1111: ...L371 E04 E388 TO L372 E31 E61 E377 E378 E325 E323 E324 E381 TO G333 E382 TO G334 E191 E181 E192 10 Power steering wire E I6RW0C910908 04 No Color Connective position No Color Connective position E04...

Page 1112: ...BLU Except Taiwan BCM E325 N J B E13 BLK P S control module E377 BLU Power steering wire To E378 E181 N Brake light switch E381 GRY Instrument panel harness To G333 E191 BLK APP Acceleration pedal sen...

Page 1113: ...tion G04 BLU BCM G248 BLU Audio Navigation G14 N IF EQPD Auto leveling control module G251 N ACC socket G16 N IF EQPD KLS ECM G253 GRN Multi information display G17 BLK ICM G254 N IF EQPD Keyless rece...

Page 1114: ...Manual A C Heater fan switch G346 N or BLK Contact coil To S171 G211 BLK DLC G347 YEL Contact coil To S172 G241 GRY COMB meter G348 N Roof audio antenna wire To K153 G243 N IF EQPD Navigation No Colo...

Page 1115: ...position G04 N or BLU BCM G248 BLU Audio Navigation G05 N Taiwan BCM G251 N ACC socket G06 BLK Taiwan BCM G253 GRN Multi information display G16 N IF EQPD KLS ECM G254 N IF EQPD Keyless receiver G17 B...

Page 1116: ...G347 YEL Contact coil To S172 G214 N IF EQPD DRL controller G348 N Roof audio antenna wire To K153 G241 GRY COMB meter G349 YEL Taiwan Floor harness To L399 G243 N IF EQPD Navigation G352 N Taiwan Fl...

Page 1117: ...e position J21 BLK Front power window motor Driver side J87 N Mirror switch J27 N Mirror motor Driver side J141 N Front speaker R J31 N Front door lock motor Driver side J147 BLK Tweeter R J81 BLU Pow...

Page 1118: ...itch R J217 N Floor harness To L381 J84 N Rear power window sub switch L J218 N Floor harness To L382 No Color Connective position No Color Connective position K51 N Interior light K152 N Floor harnes...

Page 1119: ...J32 N Front door lock motor Passenger side J154 N IF EQPD Door antenna Passenger side J82 N Power window sub switch J216 GRY Floor harness To L380 J86 N IF EQPD Request switch Passenger side No Color...

Page 1120: ...No Color Connective position No Color Connective position L01 BLU BCM L313 YEL J B L04 PNK 4ch Air bag control module A B SDM L314 N J B L04 BRN 8ch Air bag control module A B SDM L315 N J B L31 GRY...

Page 1121: ...97 GRY IF EQPD Coupling harness To L408 L312 N J B No Color Connective position No Color Connective position No Color Connective position No Color Connective position L40 BLK IF EQPD Coupling air temp...

Page 1122: ...tive position L01 BLU Except Taiwan BCM L312 N J B L04 PNK 4ch Air bag control module A B SDM L313 YEL J B L04 BRN 8ch Air bag control module A B SDM L314 N J B L31 GRY Wheel speed sensor RR L315 N J...

Page 1123: ...Inside antenna L395 YEL 8ch Side curtain air bag wire To Q132 L296 N Rear ACC socket L399 YEL Taiwan Instrument panel harness To G349 L301 BLK Diode 2 L402 YEL Taiwan Instrument panel harness To G352...

Page 1124: ...or Connective position No Color Connective position O21 N Rear wiper motor O181 BLK Rear defogger O94 N License plate light 1 O182 BLK Rear defogger O95 N License plate light 2 O231 N Floor harness To...

Page 1125: ...und Point Ground earth Point S6RW0C910C001 Refer to Connector Layout Diagram 23 21 22 Left side Shown LH 19 20 RH 3 4 5 2 8 9 17 10 11 FWD FWD RH 12 13 LH 15 16 FWD 18 FWD 6 7 1 FWD 14 24 13 RH 11 LH...

Page 1126: ...U RED WHT WHT WHT RED 11 WHT GRN 14 WHT BLU 15 16 WHT RED GRN 12 30A 9 WHT BLU 9 30A 20A 30A 50A 40A 60A 20A 15A 15A BLK 2 E312 1 WHT BLU C282 C283 1 1 WHT BLK Main fuse box Starting motor A 1 Generat...

Page 1127: ...19 30A 15A 25 30A 35 10A 23 15A 24 15A 20 15A 21 10A 22 10A 26 10A 27 15A 28 10A relay Blower fan relay BCM 1 WHT E324 2 29 10A 30 15A 39 15A 36 10A 38 30A 31 20A 37 15A Flasher relay relay Tail ligh...

Page 1128: ...Protected Parts S6RW0C910D002 The chart below describes what parts each fuse protects Fuses in Main Fuse Box S6RW0C910D003 No Fuse Protected circuit 80 A All electric circuit Battery Generator 50 A J...

Page 1129: ...n the cover Protected circuit 15 A FI Main relay 15 A AT A T relay 15 A THR MOT Throttle motor relay 20 A A C A C compressor relay Condenser fan relay BLANK BLANK BLANK 30 A BLW J B 50 A IGN IG switch...

Page 1130: ...F sensor Current sensor ECM Fuel pump relay Generator Heated oxygen sensor 1 Heated oxygen sensor 2 VSS ICM IG coil 1 IG coil 2 IG coil 3 IG coil 4 10 A BACK Back up light switch Fresh Recircle actuat...

Page 1131: ...eat heater switch Driver side Seat heater switch Passenger side 10 A IG2 SIG Blower fan relay 15 A RR FOG COMB switch 15 A DOME Audio BCM COMB meter DLC ECM Interior light ICM TCM Rear interior light...

Page 1132: ...el pump relay Generator Heated oxygen sensor 1 Heated oxygen sensor 2 VSS ICM IG coil 1 IG coil 2 IG coil 3 IG coil 4 10 A BACK Back up light switch Fresh Recircle actuator Mode control switch Auto A...

Page 1133: ...CM COMB meter DLC ECM Interior light ICM TCM Rear interior light Luggage compartment light Main switch Key switch Multi information display KLS ECM 30 A RR DEF Rear defogger relay Mirror motor R Mirro...

Page 1134: ...15 5 9 8 7 17 6 16 19 18 20 10 6 5 4 3 2 8 1 7 10 9 12 11 3 4 6 5 2 1 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 G272 G271 G273 BCM J B side connector 3 4 1 2 5 15 14 1213 1011 9 8 6 7 18 17 2...

Page 1135: ...15 14 13 12 16 9 8 7 6 5 4 3 2 1 13 12 11 10 17 18 16 15 14 13 14 15 16 9 10 11 12 8 5 6 7 2 3 4 1 3 2 1 4 E323 L314 E324 L313 L315 E325 H Relay Relay Tail light relay 3 8 7 6 5 2 4 1 4 3 5 6 12 14 11...

Page 1136: ...CC 1 F WIP RLY R WASHER GND IP SIGNAL GND IP IG COIL EPS AT ABS CONT BACK STOP SW EPI BUL IN HORN FR TURN R FR TURN L POSI LP EPI STOP SW F WIP HTR FUSE ST RLY COIL 4 L314 15 L314 16 L314 5 L314 9 L31...

Page 1137: ...12 16 L313 L315 E325 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 IG COIL IG COIL IG1 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L315 IG COIL IG1 15A MTR...

Page 1138: ...8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L315 11 J B Flasher Relay 1 4 8 2 3 6 5 7 3 6 9 3 12 1 5 1 19 3 7 16 2 1 10 1 HORN S...

Page 1139: ...39 Continued Individual circuit fuse box No 2 In J B 4 3 1 2 RR FOG 15A 36 Connector No Terminal No BCM J B side connector 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11...

Page 1140: ...4 13 12 16 L313 L315 E325 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L315 9 J B 11 10 13 12 3 1 17 1 1 3 16 1...

Page 1141: ...3 L315 E325 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L315 J B 9 3 3 4 Continued GND IP POWER GND GND 22 GND...

Page 1142: ...0D007 Abbreviations Abbreviation Full term Abbreviation Full term AS Assistant Front passenger LP Lamp CTR Center O H Over head DR Driver R B Relay box F L Front L R L Rear L F R Front R R R Rear R FR...

Page 1143: ...ABS CONT BACK STOP SW EPI BUL IN HORN FR TURN R FR TURN L POSI LP EPI STOP SW F WIP HTR FUSE ST RLY COIL 4 L314 15 L314 16 L314 5 L314 9 L314 2 12 L314 13 L315 14 L315 7 L315 15 L315 14 L314 11 L314 6...

Page 1144: ...1 7 11 10 9 8 15 14 13 12 16 L313 L315 E325 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 IG COIL IG COIL IG1 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L...

Page 1145: ...18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L315 11 J B Flasher Relay 1 4 8 2 3 6 5 7 3 6 9 3 12 1 5 1 19 3 7 16 2 18 4 10 1 HORN SW HORN RE...

Page 1146: ...vidual circuit fuse box No 2 In J B 4 3 1 2 Connector No Terminal No BCM J B side connector 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12 9 10 3 4 6 5 2 1 G271 G273...

Page 1147: ...11 10 9 8 15 14 13 12 16 L313 L315 E325 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 E323 E325 E324 BCM G272 G271 G273 L312 L313 L314 L315 9 J B 11 13 12 3 1 4...

Page 1148: ...5 7 2 1 13 16 9 8 6 5 4 3 2 1 7 11 10 9 8 15 14 13 12 16 L313 L315 E325 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E323 L314 E324 E323 E325 E324 BCM G272 G271 G273 L312 L313...

Page 1149: ...er to B 9 Keyless Start System Circuit Diagram Refer to C 1 Combination Meter Circuit Diagram Meter Refer to C 2 Combination Meter Circuit Diagram Indicator Refer to C 3 Combination Meter Circuit Diag...

Page 1150: ...E371 C343 3 RED Individual circuit fuse box No 1 8 30A 33 10A WHT WHT J B E325 10 4 2 3 1 RED WHT ST ST SIG YEL GRN YEL GRN YG A 5 ECM GRN WHT G147 2 YEL GRN YEL GRN G273 4 B1 LOCK ACC ON ST ACC IG1 I...

Page 1151: ...0 E371 C343 20 G334 E382 BLK WHT BLK WHT BLK WHT 80A Main fuse box C192 J B 1 C283 IG COIL 43 15A 20 Generator IC regulator 1 E325 5 C194 2 4 WHT BLU WB BCM A 8 1 BLU YEL BY 3 BRN WHT BW ECM A 5 9 WHT...

Page 1152: ...cuit Diagram M15A engine M16A engine S6RW0C910E004 15A 20 E371 C343 2 C101 1 3 IG COIL 1 C102 BLK BLK WHT GRN YEL BLK WHT J B ECM GY GW 20 IG COIL BLK BLK IG COIL 2 E325 5 3 GRN WHT 1 3 2 C01 5 6 Weld...

Page 1153: ...20 E371 C343 2 C101 3 1 IG COIL 1 C102 BLK BLK WHT BLK WHT BLK WHT GRN YEL BLK WHT J B ECM GY GW 20 IG COIL BLK BLK BLK BLK BLK IG COIL 2 E325 5 3 GRN WHT 4 3 1 2 C01 20 21 Weld splice C312 BLK WHT GB...

Page 1154: ...Diagram M15A engine M16A engine S6RW0C910E005 E65 4 5 9 A 5 Lg BR BW Relay Motor E222 3 1 2 1 BLU RED LT GRN BRN WHT GRY BLK RED BLK YEL BLK YEL 30A RDTR 10 E221 1 2 15A FI 1 3 4 Main relay BLK ECM In...

Page 1155: ...g BR BB BW G BRN WHT BW BLK YEL BLK YEL Relay 1 Motor E222 3 1 2 4 3 1 BLU RED BLU RED BLU BLK BLK BLU RED BLU RED GRY GRY BLU WHT GRN GRN 30A RDTR 10 E221 1 2 15A FI 1 3 4 Main relay BLK BLK BLK RED...

Page 1156: ...A C Compressor relay E229 Relay BLU YEL BLU YEL Compressor C141 1 E325 5 E371 C343 20 E371 C343 4 BLK WHT C42 C40 Heated oxygen sensor RED BLU BRN A F sensor Condenser fan motor Condenser fan relay B...

Page 1157: ...N BLK RED BLK RED BLU BLK EVAP canister purge valve C123 ECT sensor GRY BLU GRY BLU BLK RED GRY BLU YEL BRN WHT A 4 Lg 30A RDTR 10 Relay motor A 1 Generator BLU RED LT GRN BRN GRN BR BY 46 E01 50 17 1...

Page 1158: ...GRN E323 4 E181 Brake light switch 1 2 ECM 2 CMP sensor C01 C01 BLK BLK BLK 3 4 6 3 15 29 30 31 1 C32 52 C01 E01 22 30 28 13 RED YEL BLK ORN BLK BLK BLK BLK BLK RED BLK RED 3 2 J B E325 1 2 YG YEL GR...

Page 1159: ...N RED YEL BLU E08 4 19 1 12 E191 1 6 C48 2 1 5 6 4 3 5 2 3 4 R W R W 33 41 40 54 53 45 44 53 52 51 56 55 54 E01 C01 CAN CAN WHT GRY GRN WHT GRN YEL BRN B P S Cont M F 3 RED BLU GW GY IG COIL 2 IG COIL...

Page 1160: ...WHT BW YR 4 20A A C Compressor relay E229 Relay BLU YEL BLU YEL Compressor C141 1 E325 5 E371 C343 20 E371 C343 4 BLK WHT C43 C42 Heated oxygen sensor 2 IF EQPD RED BLU BRN Heated oxygen sensor 1 Cond...

Page 1161: ...GRN BRN GRN BR BY 46 E01 45 32 1 1 2 29 17 16 2 1 24 25 28 26 27 2 1 4 3 5 BLK YEL 2 3 55 E371 C343 18 19 OCV 1 2 60 59 BLK RED BLK RED GRY GRY BLK RED BLK RED BLK RED BLK RED BLK RED BLK RED BLK RED...

Page 1162: ...2 CMP sensor C01 BLK 3 6 15 31 30 1or3 C32 20 C01 E01 48 30 28 13 RED YEL BLK ORN BLK ORN BLK ORN BLK BLK BLK C01 E01 58 BLK RED 3or2 2or1 J B E325 1 2 YG YEL GRN YEL BLK WHT RED WHT YEL RED Starting...

Page 1163: ...GRN RED YEL BLU E08 3 18 1 12 E191 1 6 C48 2 1 5 6 4 3 5 2 3 4 R W R W 41 42 40 54 43 45 44 34 36 51 35 37 52 50 E01 C01 CAN CAN BLK GRY GRN WHT GRN YEL BRN B P S Cont M F 3 RED BLU GW GY IG COIL 2 I...

Page 1164: ...A C Compressor relay E229 Relay BLU YEL BLU YEL Compressor C141 1 C31 2 1 3 E325 5 E371 C343 20 E371 C343 4 BLK WHT C42 C40 Heated oxygen sensor RED BLU BRN A F sensor CKP sensor Condenser fan motor...

Page 1165: ...BLK BLK LT GRN BRN GRN BR A 4 motor BB A 4 motor BW BY 46 47 E01 50 17 1 1 2 13 17 16 2 1 24 25 28 26 27 4 3 1 5 2 LT GRN BLK 2 57 E371 C343 18 19 C163 GRN 1 7 VIM motor 1 2 42 43 BLK RED BLK RED GRY...

Page 1166: ...L 1 2 S61 12 Steering switch Auto cruise switch Contact coil Contact coil 11 6 10 12 11 10 6 Cruise control IF EQPD ECM 2 CMP sensor C01 BLK 3 4 15 29 30 31 3 C32 52 C01 E01 22 30 28 13 RED YEL PNK BL...

Page 1167: ...9 1 12 E191 1 6 C48 1 2 5 6 4 3 5 2 3 4 R W R W 33 41 40 54 53 45 44 53 52 51 56 55 54 E01 C01 CAN CAN WHT BLK GRN WHT GRN YEL BRN B P S Cont M F 3 RED BLU GW GY IG COIL 2 IG COIL 1 BW Mode control sw...

Page 1168: ...371 C343 17 PNK BLK BLK BLK 6 3 BLK ORN 17 20 BLK 14 BLK BLK 7 9 L348 J C E387 L371 C343 E371 13 20 BCM BCM DLC G211 7 4 BLK BLK 11 J C G309 4 G334 E382 19 E371 C343 8 BLK ORN BLK ORN 5 23 9 GRN RED B...

Page 1169: ...5 C07 7 17 23 1 16 E01 2 J B 15A DOME 37 15A IG COIL 20 15A AT 2 6 3 WHT BLK LT GRN BLK Timing solenoid BLU BLK 14 WHT BLK 5 14 2 1 C45 Input sensor C07 WHT BLK 2 1 C44 Output sensor C06 E231 1 3 2 4...

Page 1170: ...COIL G272 6 J B 29 15A 20 BLK WHT 13 28 YEL BLK YB W YR E382 G334 19 G343 L376 15 C343 E371 8 BLK ORN BLK ORN BLK ORN BLK BCM G04 G05 G06 15 L312 5 16 WHT RED WHT WHT WHT E01 3 G17 1 6 4 BLK ORN WHT 2...

Page 1171: ...19 8 BLK ORN 5 4 J B J B 15A DOME 37 20A D L 31 G271 5 1 WHT RED WHT RED BLK ORN 7 16 B B J C G308 BLK ORN A A A J C IF EQPD G308 B B A A WHT RED WHT RED R W B A J C G311 F 2 B 9 C 1 C 2 C 3 B 2 Swit...

Page 1172: ...r B 5 Switch 6 14 16 17 12 5 RED BLU BRN YEL LT GRN BLK BRN GRY WHT GRY RED Parking brake switch Seat belt switch C 3 RB BY 11 5 RED BLK BB Oil pressure switch Brake fluid level switch G RB L01 L01 E0...

Page 1173: ...U YEL GRN Rear end 4 WHT RED Rear end door lock switch 3 D D F D 5 BLK YEL L01 Diode 2 BY GW GY WR G04 L315 15 PPL PPL P PPL P PPL P BY GR RB G G RB G RB G RB B 5 Audio J B G 1 Navigation G 4 Solenoid...

Page 1174: ...D WHT RED WHT RED WR WR 11 YEL Y GRY 8 G04 G G 2 Multi information display BCM Auto unit E 2 J B A 3 14 2 5 WHT W 7 2 L313 YEL Y 9 7 G272 RED YEL RY 16 E325 RED YEL RY 3 L314 RED YEL RED YEL RED YEL R...

Page 1175: ...15A IG COIL 20 G271 G271 5 G272 12 BLK RED 5 4 G272 6 WHT RED WHT RED BLK ORN 7 16 B B B J C G308 BLK ORN A A A J C G308 B B A A WHT RED WHT RED R W B A J C G311 F 2 B 9 C 1 C 2 C 3 B 2 Switch 7 G04 6...

Page 1176: ...26 RED BLU BRN YEL LT GRN BLK BRN GRY WHT GRY RED Parking brake switch Seat belt switch C 3 RB BY 9 7 RED BLK BB GR Oil pressure switch Brake fluid level switch Security option G RB G05 G06 17 PNK G04...

Page 1177: ...YEL BLU YEL GRN Rear end 30 WHT RED Rear end door lock switch 29 D D F D 5 BLK YEL BLK YEL G05 Diode 2 Relay BY GW GY WR G04 22 PPL PPL P PPL P BY GR RB G G RB G RB G RB B 5 Audio G 1 Solenoid Motor R...

Page 1178: ...h Auto unit D 6 Model control switch E 1 E 2 A T shift lever D 4 Switch D 3 Audio G 1 Y G04 34 G05 WHT W 14 BLK YEL BLK YEL BY C C J C G306 14 BLK YEL C C J C G308 YEL BLK BY A 2 Generator 10 WHT BLU...

Page 1179: ...BLK ORN YEL GRN YEL GRN WHT RED B B J C G309 B B J C G306 A A J C L348 24 7 BLU WHT BLU WHT 25 8 L408 L397 2 4 3 1 YEL BLK YEL BLK GRN YEL ORN BRN 22 23 RED WHT RED WHT BLU BLU BLK ORN BLK BLK 14 BLK...

Page 1180: ...T BLU WHT BLU RED BLU RED BLU YEL BLU YEL 4 WIP 30A 25 2 E62 1 G271 1 YEL GRN M YEL GRN BLU ORN 13 7 BLK OFF ON WF EW P T MIST OFF INT LO HI B 2 1 S INT1 INT2 B1 P T INT Unit YEL 5 E382 G334 BLU ORN G...

Page 1181: ...O231 2 O231 L391 20 M WASH OFF INT ON ON WASH WR EW 1R P T BLK BLK 2 E63 1 YEL YEL YEL M YEL BLK ORN ORN YEL 30A WIP J C G309 25 11 14 2 G334 E382 YEL BLK 1 3 2 4 Relay 21 13 R INT BLU BLK Switch moto...

Page 1182: ...72 9 B G141 9 G272 4 8 1 3 G04 L390 O231 2 O231 L391 5 20 M WASH OFF INT ON ON WASH WR EW 1R P T BLK BLK 2 E63 1 YEL YEL RED YEL M YEL BLK ORN ORN YEL 30A WIP J C G309 25 11 14 2 G334 E382 YEL BLK 1 3...

Page 1183: ...K RED O181 1 O182 1 23 21 4 3 2 1 30A RR DEF 38 Relay GRN YEL G04 17 G271 7 BLK RED BLK RED L314 8 REAR DEF Mode control switch BLK ORN 13 BLK ORN G309 J C A A BLK BLK BLK G154 G20 J B GY BR J B side...

Page 1184: ...BLK RED O181 1 O182 1 23 21 4 3 2 1 30A RR DEF 38 Relay GRN YEL BRN G04 20 G271 7 G272 14 BLK RED BLK RED L314 8 REAR DEF Mode control switch BLK ORN 13 BLK ORN G309 J C A G05 14 A BLK BLK BLK G154 G2...

Page 1185: ...BLU WHT BLU 1 2 3 4 5 6 RED WHT WHT BLU GRN WHT RED WHT GRN WHT RED WHT GRN WHT GRN YEL BLU YEL RED BLK M GRN J21 UNLOCK LOCK IG DRIVER SWITCH PASSENGER SWITCH REAR R SWITCH REAR L SWITCH E DRU DRD IG...

Page 1186: ...11 4 3 J215 L379 1 4 1 2 M GRN RED 1 4 1 2 GRN RED 1 2 3 4 5 6 UNLOCK UP OFF DOWN UP OFF DOWN LOCK IG E RLU RLD Rear L Sub switch Rear Motor L M UNLOCK UP OFF DOWN UP OFF DOWN LOCK IG E RRU RRD WHT BL...

Page 1187: ...RED GRY WHT 17 BLK 20 UP OFF DOWN LOCK UNLOCK E Receiver G254 G04 L01 LT GRN PNK 14 13 12 3 1 4 UP OFF DOWN LOCK UNLOCK E J215 L379 15 M BRN LT GRN BLK GRY RED GRY WHT GRN RED GRN RED BCM RED BLU RED...

Page 1188: ...26 M 24 L380 J216 2 O231 L390 GRN 3 YEL YEL RED BLU GRN 3 YEL YEL RED BLU GRN RED BLU YEL 1 YEL BLU YEL BCM 1 2 Switch 6 4 9 1 L315 10 O122 BLK BLK 23 21 BLU YEL WHT RED WHT RED BLK BLK RED BLU RED BL...

Page 1189: ...3 G352 L402 8 9 4 5 1 J81 GRY RED BLK BLK GRY WHT BRN LT GRN BLK GRY RED GRY WHT 17 BLK 20 UP OFF DOWN LOCK UNLOCK E Receiver G254 G05 G06 LT GRN PNK 19 18 20 3 1 4 UP OFF DOWN LOCK UNLOCK E J215 L379...

Page 1190: ...GRN RED BLU GRN GRN RED BLU 3 M B 9 2 3 J32 L347 G06 G05 4 G271 M 1 3 1 3 Rear motor L J36 M B E 25 26 M L380 J216 2 O231 L390 GRN RED BLU GRN RED BLU GRN RED BLU BLU YEL BLU YEL BCM 1 Switch 6 30 O12...

Page 1191: ...N 7 2 21 21 YEL RED YEL RED 8 1 22 32 PNK BLU PNK BLU YEL RED PNK BLU YEL RED PNK BLU BLK RED BLK RED BLK RED LT GRN BLU BLK RED BLU BLK RED BLU BLK RED BRN WHT GRN ORN BLK BLK BLK BLK BLK 20 BLK 21 B...

Page 1192: ...29 L380 J216 L379 J215 30 LT GRN BLK RED LT GRN GRN YEL BRN LT GRN 7 2 21 21 YEL RED YEL RED 8 1 22 32 PNK BLU PNK BLU YEL RED PNK BLU YEL RED PNK BLU BLK RED BLK RED BLK RED LT GRN BLU BLK RED BLU B...

Page 1193: ...rn Circuit Diagram S6RW0C910E017 3 3 J B 15A HORN HAZ 39 GRN BLU 1 1 Steering switch Horn switch Contact coil H 4 3 1 2 20 Relay H E281 S61 E325 G272 B G346 S171 1 J B side connector BCM Except Taiwan...

Page 1194: ...RN LT GRN RED YEL RED YEL RED YEL RED YEL BLU BLK L171 5 6 L281 3 4 4 1 2 L172 5 L282 3 4 BLK GRY BLK 4 1 2 BLK BLK BLK BLK BLK Switch FREE LOCK FREE LOCK Switch L314 15 15A S H 34 J B 6 J C L346 C A...

Page 1195: ...2 BLU BLU BLU 2 9 18 WHT BLK WHT BLK 6 Inside antenna 6 1 2 GRN GRN 5 16 LT GRN LT GRN 8 Luggage antenna 5 1 2 GRN WHT GRN WHT 7 15 BLK YEL BLK YEL BLK YEL 23 Door antenna 18 J216 L380 J154 L294 L293...

Page 1196: ...HT RED CAN G241 32 31 5 Stepper motor and LED output driver Voltage regulator Micro controller Interface circuit ILL Dial ILL Display ILL Pointer G271 6 RED BLK 16 B B BLK BLK BLK BLK J C G309 FUEL TE...

Page 1197: ...71 6 RED BLK D 1 BEAM 22 RED Dimmer Passing J B 16 B B BLK BLK J C G308 11 CAN Low High B B J C G308 R 25 GRY G G241 WHT RED WHT RED A 8 R W 10 7 D 10 YG BCM F 4 P S Cont M 26 21 1 D 6 TURN REAR FOG I...

Page 1198: ...B B J C G309 Seat belt switch Oil pressure switch J B 13 Y YEL D 4 ILL cancel switch E371 C343 7 G343 L376 9 3 G333 E381 5 6 GRY GRY 1 C162 RED BLK RED BLU BRN YEL GRY RED BLK E183 1 Brake fluid level...

Page 1199: ...g Systems 9A 107 GEAR ABS BELT DOOR CHARGE CHECK ENGINE AIRBAG OIL DRL D F LOCK 4WD AUTO SET CRUISE IMMOBI BRAKE FUEL DOME 15A 37 32 5 WHT RED WHT RED J B G271 G241 1 2 J C G308 B B IF EQPD I6RW0C9109...

Page 1200: ...WHT RED BLK 13 G144 15A 16 15A 15 H L R H L L 13 RED RED J B 10A TAIL 29 RED WHT RED WHT RED WHT 6 RED WHT E382 G334 RED RED RED WHT RED WHT RED WHT BEAM FLASH UP LOW T P ED EL UP LOW OFF TAIL HEAD B...

Page 1201: ...ED WHT RED GRN 3 RED YEL 5 20 E382 G334 30A WIP 25 DRL controller G214 10 WHT RED 8 BLU WHT 6 G271 1 4 9 GRY GRY BLK ORN BLK ORN 2 BLK BLK 1 C 3 1 4 2 3 G RY J B BCM D 4 11 14 13 A A J C J B With DRL...

Page 1202: ...RN BRN WHT WHT RED WHT RED 13 RED RED RED WHT RED RED RED BLK BLK RED WHT YEL 6 E382 G334 GRN WHT WHT RED BRN WHT GRN WHT WHT BLU GRN BLK BLK FLASH UP LOW T P ED EL UP LOW OFF TAIL HEAD B T T P H EL B...

Page 1203: ...9 7 23 20 BLK 21 WHT RED OFF TAIL HEAD B T T P Front position light RED YEL RED YEL RED YEL RED YEL RED YEL Tail light RY RY RY WR RY RY RED YEL RED YEL RED YEL RED YEL RED YEL RED YEL RED YEL RED YE...

Page 1204: ...162 BLK BLK BLK BLK BLK J B L314 3 E325 16 BLK BLK Licence plate light 2 Licence plate light 1 3 5 L133 BLK 13 9 7 23 20 BLK 21 BLU WHT RED YEL OFF TAIL HEAD B T T P Front position light RED YEL RED Y...

Page 1205: ...witch 3 E234 2 1 4 WHT GRN GRY RED LT GRN BLK BLK BLK LT GRN LT GRN 1 D D G334 E382 FREE IG LOAD E Il Ile TERMINAL POSITION PUSH 6 7 4 8 G306 G151 RED YEL RED YEL GRY RED RED YEL RED YEL 11 BLK BLK RE...

Page 1206: ...N RED YEL RED YEL LT GRN BLK BLK BLK LT GRN LT GRN 14 D D G333 E381 13 E381 G333 FREE IG LOAD E Il Ile TERMINAL POSITION PUSH 7 6 4 8 G306 G151 RED YEL RED YEL GRY RED RED YEL RED YEL 11 BLK YEL BLK Y...

Page 1207: ...F EQPD IF EQPD IF EQPD RY RED YEL Mode control switch E 1 Tail light L D 2 E 2 D 6 Switch B 8 Switch B 8 OFF TAIL HEAD B T T P 7 RY RED YEL Audio G 1 Navigation G 4 D D D D D RY RED YEL D RED YEL Mult...

Page 1208: ...06 RED YEL RY RED YEL Switch Auto unit RY RED YEL Mode control switch E 1 Tail light R D 2 E 2 D 6 OFF TAIL HEAD B T T P 18 7 RY RED YEL Audio G 1 D D D D D RY RED YEL D RED YEL Multi information disp...

Page 1209: ...BLK BLK WHT BLK WHT BLK BLK G272 9 L314 14 15 L01 7 3 WHT RED WHT RED WHT RED G309 J C B B 3 Luggage compartment light 2 1 L132 WHT RED BLK YEL BLU BLK YEL BLK BLU BLK RED 11 23 21 OFF ON O121 2 L390...

Page 1210: ...WHT BLK WHT WHT BLK BLK BLK G272 9 L314 14 38 G06 G05 15 1 39 29 WHT RED WHT RED WHT RED G309 J C B B 3 Luggage compartment light 2 1 L132 WHT RED BLK YEL BLK YEL BLU BLK YEL BLK BLU BLK RED 11 23 21...

Page 1211: ...Turn signal switch G144 10A MTR 22 RED BLU BLU RED J B L N R TURN T P TB TL TR J C 11 13 G272 1 RED BLU C C G306 J C ON OFF 3 B A B B G309 J C BLU YEL R 1 21 23 20 BLK 19 1 L314 10 IG 1 5 SW L SW R 6...

Page 1212: ...Turn R E165 12 G271 6 BLU YEL BLU YEL BLU YEL GRN RED BLU YEL C 2 GR BY Front turn signal light R Side turn signal light R E159 2 E166 Front turn signal light L Side turn signal light L BLK E323 5 BL...

Page 1213: ...RED YEL BLU WHT WHT WHT Turn signal switch 6 G144 7 5 10A MTR 22 RED BLU BLU RED J B L N R TURN T P TB TL TR J C 11 13 18 G272 12 1 BLK YEL C C G306 J C ON OFF 3 B A B B G309 J C BLU YEL R 1 21 23 20...

Page 1214: ...Turn R E165 12 G271 6 BLU YEL BLU YEL BLU YEL GRN RED BLU YEL C 2 GR BY Front turn signal light R Side turn signal light R E159 2 E166 Front turn signal light L Side turn signal light L BLK E323 5 BL...

Page 1215: ...HT GRN WHT GRN WHT GRN WHT 5 L315 E325 J B F 2 ABS Cont M GRN WHT 2 2 1 A 5 ECM 21 GW GW GRN YEL A 5 ECM GY GW 4 2 3 1 J B L133 2 5 2 1 GRN WHT A 6 GW O92 High mounted stop light 20 19 18 BLK BLK BLK...

Page 1216: ...Back up light Back up light R RED RED RED BLK RED BLK ON OFF J B 10A 21 BACK E371 C343 C165 2 1 L134 1 L133 1 RED RED RED L315 3 E325 11 J B E325 14 5 5 L R 14 13 L390 O231 2 A T M T P R N D 2 L Trans...

Page 1217: ...RW0C910E056 10A GRN GRN RED BLK GRN BLK BLK switch 21 BACK RED BLK RED BLK E69 G272 3 E68 3 2or1 8 E325 14 2or1 1or2 G152 E381 G333 4 3 5 1 G333 E381 2 1or2 BLK BLK Actuator L Actuator R Control circu...

Page 1218: ...og Light Circuit Diagram S6RW0C910E061 20 21 23 BLK BLK BLK L390 O231 2 15A RR FOG BLK YEL GRN YEL GRN YEL BLK OFF ON 5 4 C 1 YG YG G144 3 G272 10 4 J B G343 L376 4 36 L133 L134 B A A B Switch COMB sw...

Page 1219: ...1 4 GRN RED 9 G154 7 8 G306 J C 4 G272 BCM A 8 GW BCM B 3 GY GRN YEL 8 RED YEL RED YEL RED BLK RED BLK RED BLK 10 13 14 5 6 REAR DEF REO FRE A C HARF REO CIRCUIT Mode control switch 13 A A D D B B B...

Page 1220: ...G155 5 BRN J B BLK YEL 2 1 G61 11 G65 Fan driver 4 2 1 3 Blower fan motor G273 6 1 3 2 7 6 FAN Heater fan switch 4 2 5 1 3 30A BLW 6 10A 35 IG2 SIG Blower fan relay E323 7 G272 9 G309 J C 11 14 B B BL...

Page 1221: ...13 YEL A 8 Y B 3 BR 3 7 BLU WHT RED WHT RED BLU WHT RED BLK ORN BLK YEL 12V RED WHT 8 BLU WHT A 5 BW 4 GRN YEL B 3 GY J C A G308 A B B B J C J B 21 GRN WHT A 8 GW D 4 RY J B D G306 D 5 DOME 15A 37 J B...

Page 1222: ...r Mode selecting actuator Temperature control actuator 10A IG2 SIG 35 10A BACK 21 30A BLW 6 2 6 5 1 4 G63 M 2 6 5 1 4 2 G255 1 G62 G61 G273 1 2 6 G272 8 9 E323 7 1 5V 5V 5V 5V 12V 12V 11 G309 J C Indi...

Page 1223: ...37 50 51 2 A 8 L378 G345 ORN PNK BLK YEL YEL GRN RED GRN RED GRN GRN ORN GRN YEL BLU RED BLU RED BLU ORN BLU YEL L313 4 G272 13 J B J B C 3 YB YEL BLK YEL BLK J B side connector BCM Except M16A engine...

Page 1224: ...U PPL WHT PPL WHT J C IF EQPD G308 A A J C G309 B B DLC 16 WHT RED R W PW A 8 14 6 BCM CAN G211 4 BLK BLK BLK J B E Y A 8 D B 5 C D E J B side connector BCM Except M16A engine M T M16A engine M T Exce...

Page 1225: ...ard sensor Check terminal 1 2 2 50 51 ORN PNK BLK YEL BLK YEL BLK C 3 J B G272 L313 13 4 Q105 Q104 1 2 A B SDM 13 14 12 11 BRN WHT BRN 1 2 GRY RED GRY BLU BLK BLU BLK 1 2 1 2 L384 Q133 L385 Q134 L285...

Page 1226: ...LU GRN WHT 8 BLK R RED W WHT RED WHT RED WHT A 8 A 5 J B 10A ABS 28 E325 9 GRN ORN 9 L315 L33 8 3 2 GRN YEL GRN ORN 6 GW D 7 Brake light switch Individual circuit fuse box No 1 1 GRN BLK GRN YEL 3 G s...

Page 1227: ...heel speed sensor FL RED BLK 18 17 11 22 19 20 21 10 E08 1 2 1 2 1 2 1 2 16 DLC E382 G334 5 BLU BLU BLU WHT RED G211 B WHT RED R W BCM A 8 11 BLK BLK 14 BLK B B J C G309 4 E371 C343 8 E382 G334 12 BLK...

Page 1228: ...E378 Torque sensor BLK E13 10 GRN LT GRN BLK WHT 10 GRN 8 YEL 18 BLK 9 19 1 2 1 E11 PPL PPL 4 LT GRN BLK 1 E377 E378 4 PPL G333 E381 E31 E13 E11 E11 Individual circuit fuse box No 1 1 6 3 5 4 C 2 BCM...

Page 1229: ...B B J C Motor G309 BLU BLU E382 G334 19 E382 G334 12 E371 C343 8 BLK ORN 5 J B 15A DOME 37 G271 5 WHT RED BLK ORN 7 16 B B J C G308 BLK ORN 11 14 WHT RED BLK BLU B WHT RED R W A 8 14 6 BCM BLU A A J...

Page 1230: ...Rear R J C Rear L GRY RED GRY LT GRN BLK LT GRN GRY RED GRY LT GRN BLK LT GRN GRY RED GRY LT GRN BLK LT GRN Audio RED YEL 9 2 J146 C C G308 J C B B G306 J C D D P PPL 18 L381 J217 5 4 L382 J218 J145 G...

Page 1231: ...YEL RED YEL BLK YEL RED YEL BLK YEL RED YEL BLK YEL BLK YEL RED YEL RED S171 G346 S61 Roof audio antenna Contact coil Antenna amplifer 4 3 13 14 K153 G348 1 BLK BLK K154 G354 1 2 1 G343 L376 G341 L37...

Page 1232: ...1 4 3 WHT RED YEL RED YEL 7 G309 J C J B 5 G272 G271 12 L314 WHT BLK BLU WHT WHT BLK BLK BLK G251 ACC Socket 2 1 11 14 Rear ACC Socket BLK C C A A J C G308 B B C C G04 YEL RED YEL BLK YEL RED YEL BLK...

Page 1233: ...N GRY RED GRY LT GRN BLK LT GRN 1 Navigation RED YEL 9 2 J146 C C G308 J C B B G306 J C D D PPL PPL 18 G243 18 3 L381 J217 5 4 L382 J218 J145 G341 L374 G343 L376 1 2 Rear tweeter R GRY RED GRY J151 1...

Page 1234: ...audio antenna Antenna amplifer 4 3 13 14 K153 G348 1 BLK BLK K154 G354 1 1 G266 4 TV antenna TV antenna No 1 BLK BLK L409 G355 4 O240 L410 1 2 1 G343 L376 G341 L374 2 1 12 BLK YEL RED BLU RED BLU G309...

Page 1235: ...ne M16A engine J20A engine J20A engine 1 2 3 4 5 6 20 21 16 17 18 19 7 8 9 10 22 23 24 25 12 27 26 13 28 31 32 33 34 35 36 50 51 46 47 48 49 37 38 39 40 52 53 54 55 11 41 56 42 57 43 58 14 15 29 30 44...

Page 1236: ...66 01 1 2 3 MCONF030055 01 1 2 3 MCONF030103 02 1 2 3 MCONF030055 01 1 2 3 MCONF030103 02 1 2 3 MCONF030103 02 1 2 3 MCONF030103 02 1 2 3 4 5 6 MCONF060018 01 1 2 MCONF020042 01 1 2 MCONF020150 01 2 1...

Page 1237: ...260018 01 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 20 MCONF200029 01 1 2 MCONF020204 01 1 2 MCONF020185 01 3 2 1 6 5 4 MCONF060052 01 2 1 MCONM020033 01 2 1 MCONM020033 01 1 2 3 MCONF030062 01...

Page 1238: ...2 1 7 11 10 9 8 15 14 13 12 16 MCONF160034 01 3 4 7 2 6 8 9 10 12 13 14 17 16 1 5 11 15 18 19 20 MCONM200005 01 2 1 7 6 5 4 3 8 MCONM080012 01 4 1 8 3 5 6 7 2 MCONF080050 01 9 8 7 6 5 4 3 2 1 18 17 16...

Page 1239: ...CONF060093 01 4 5 6 3 1 2 MCONF060093 01 1 2 3 4 MCONF040009 01 2 1 4 3 MCONF040142 01 1 2 3 4 5 6 7 8 9 10 MCONF100038 01 7 10 5 6 1 2 3 4 8 9 11 12 13 MCONF130010 01 4 1 8 3 5 6 7 2 MCONF080050 01 3...

Page 1240: ...MCONF130019 01 A A B C C A A B C B B B C MCONF130019 01 A A A B B A A A B B B B B MCONF130021 01 A B A A B B B MCONF070023 01 A A A B B A A A B B B B B MCONF130021 01 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 1241: ...2 3 4 5 6 7 8 9 10 MCONF100054 01 1 2 9 10 11 3 4 12 13 14 15 5 6 7 8 16 17 18 MCONF180006 01 1 2 3 4 5 MCONF050001 01 1 2 3 4 5 MCONF050001 01 1 2 3 4 5 MCONF050001 01 2 1 MCONM020016 01 2 1 MCONM020...

Page 1242: ...123 01 1 2 MCONF020210 01 1 2 MCONF020210 01 3 2 1 MCONM030023 01 1 2 MCONF020042 01 1 2 3 4 5 6 MCONF060044 01 2 1 MCONM020058 01 1 2 MCONF020211 01 1 2 3 4 5 6 MCONF060044 01 1 2 3 4 5 6 MCONF060044...

Page 1243: ...10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 MCONF200021 01 2 1 8 3 9 7 6 5 13 12 11 18 19 4 10 14 20 17 16 15 MCONF200011 01 1 2 MCONF020212 01 1 2 MCONF020212 01 26 25 24 23 34 22 33 21 31 14...

Page 1244: ...auto cruise Without auto cruise 1 2 3 4 MCONF040012 01 2 1 MCONF020026 01 1 2 MCONF020013 01 1 2 MCONF020013 01 2 1 4 3 MCONF040093 01 1 2 4 3 MCONM040028 01 1 MCONF010021 01 1 MCONF010021 01 1 MCONF...

Page 1245: ...le electrical shock Do not set lighting switch to HEAD position with connector disconnected or any part removed to avoid possible electric shock Do not touch glass surface of headlight bulb Oil or gre...

Page 1246: ...high as about 20 000V to the tungsten electrode in the discharge headlight bulb After the discharge headlights light up the ballast supplies voltage to bulbs Discharge headlight bulb Discharge headlig...

Page 1247: ...ling control module 3 headlight leveling actuator 4 and headlight leveling warning light 5 With more passenger s or luggage in the vehicle the vehicle position differs from that in such vehicle state...

Page 1248: ...eadlight leveling control module makes the headlight leveling warning light in the combination meter light up to warn the driver of an abnormality in the system Fail safe function of headlight levelin...

Page 1249: ...o on headlight is controlled by auto on headlight controller 1 and works as follows Under such conditions as the ignition switch turned ON and the lighting switch 2 turned to the AUTO position when il...

Page 1250: ...ORN 5V G14 5 YEL G14 17 GRN G14 11 G14 24 ORN WHT 6 12V G14 18 LT GRN 7 8 G14 6 G14 9 RED WHT G14 10 11 12 13 16 17 18 19 20 5 6 9 21 22 23 24 A I6RW0C920007 01 A Headlight leveling control module co...

Page 1251: ...n S6RW0C9203001 NOTE Below figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the opposite side 10 11 9 D 25 30 21 27 26 29 31 20 1 3 4 2 4 A B 8 1 3 2...

Page 1252: ...BCM junction block without BCM type D Junction block viewed from relay side 12 Rear height sensor if equipped 24 Auto on headlight controller if equipped 1 Headlight bulb 13 Front height sensor if eq...

Page 1253: ...uit fuses blown Replace fuses and check for short circuit Headlight low beam relay faulty Check headlight relay referring to Tail Light Relay Headlight Relay Front Fog Light Relay Inspection If Equipp...

Page 1254: ...eplace fuse and check for short circuit Bulb blown Replace bulb Headlight high beam relay faulty if equipped Check headlight relay referring to Tail Light Relay Headlight Relay Front Fog Light Relay I...

Page 1255: ...nding faulty Repair circuit Condition Possible cause Correction Reference Item Headlight leveling warning light comes on steady Height sensor faulty Check height sensor referring to Height Sensor and...

Page 1256: ...ction Open circuit or high resistance existing either between turn signal switch and non lighting bulb or between hazard warning switch and non lighting bulb Repair circuit Wiring or grounding faulty...

Page 1257: ...n and Adjustment in Section 5A Wiring or grounding faulty Repair circuit Back up lights stay on Back up light switch M T model or transmission range sensor A T model faulty Check back up light switch...

Page 1258: ...do not light Circuit fuse blown Replace fuse and check for short circuit Bulb blown Replace bulb Rear fog light switch faulty Check rear fog light switch referring to Rear Fog Light Switch Inspection...

Page 1259: ...W0A920003 01 A DRL controller connector viewed from harness side Terminal Circuit Specification Condition 1 To clearance lamp 0 1 V Engine is at stop and lighting switch is at OFF position 10 14 V Eng...

Page 1260: ...ct connector to auto on headlight control module 5 Check that the voltage between the following terminals and vehicle body ground are specifications under each condition If measuring voltage is not wi...

Page 1261: ...V or more when ignition switch is ON Voltage with asterisk cannot be measured by voltmeter because it is pulse signal Check it with oscilloscope if necessary 2 Headlight control signal 0 V Lighting sw...

Page 1262: ...position 12 Power supply for rear height sensor About 5 V Ignition switch is at ON position 13 Power supply for front height sensor About 5 V Ignition switch is at ON position 14 15 16 Vehicle speed...

Page 1263: ...ulb light on at dirty condition Be sure to read Precautions for Discharge Headlight Service If Equipped before starting to service work Removal 1 Disconnect negative cable at battery 2 Remove front bu...

Page 1264: ...Equipped before starting to service work 1 Check to ensure that lighting switch is at OFF position 2 Disconnect negative cable at battery 3 Remove headlight housing referring to Headlight Housing Rem...

Page 1265: ...t aiming referring to Headlight Aiming Adjustment with Screen Igniter Removal and Installation Discharge Headlight Model S6RW0C9206024 WARNING Be sure to read Precautions for Discharge Headlight Servi...

Page 1266: ...d of headlight surface Distance a 10 m 32 8 ft Adjust air pressure of all tires to the specified value respectively Bounce vehicle body up and down by hand to stabilize suspension Carry out aiming wit...

Page 1267: ...ut headlight leveling actuator 4 Hot spot X X Horizontal center line of headlight bulbs F Headlight manual leveling model 5 Turning for up adjustment A A Vertical center line of left headlight bulb G...

Page 1268: ...oval procedure for installation Headlight Switch in Lighting Switch Inspection S6RW0C9206025 Check for continuity between terminals at each switch position If check result is not as specified replace...

Page 1269: ...between terminals at each switch position If check result is not as specified replace switch Brake Light Switch Inspection S6RW0C9206008 Check brake light switch for continuity between terminals at e...

Page 1270: ...tallation S6RW0C9206011 Removal 1 Disconnect negative cable at battery 2 Remove junction block assembly 1 referring to BCM Included in Junction Block Removal and Installation in Section 10B 3 Remove t...

Page 1271: ...nute 4 Check Hazard ON circuit Connect terminal 8 and battery negative terminal by a jumper wire Check all bulbs 1 for flashing cycle If check result is not as specified replace turn signal and hazard...

Page 1272: ...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...

Page 1273: ...to ON position only when headlight switch is turned to HEADLIGHT position low or high beams Rear fog light switch turns OFF automatically when headlight switch is turned to OFF position Check for cont...

Page 1274: ...3 to HEAD position 7 Check that optical axes of headlights reflected on blank wall screen change If not go to Headlight Auto Leveling System Symptom Diagnosis If Equipped Headlight manual leveling sys...

Page 1275: ...height sensor 2 with its bracket 4 from suspension frame 6 or rear floor center cross member 7 and lower arm 5 Installation For installation reverse removal procedure noting the following Check that b...

Page 1276: ...cable at battery 2 Remove glove box 3 Disconnect connector 1 from headlight leveling control module 2 4 Remove headlight leveling control module with its bracket from steering support member 3 Install...

Page 1277: ...urn lighting switch to OFF position b Repeat Step a 2 times 6 Confirm that headlight leveling warning light flashes 3 times and turns off which indicates that system initialization was completed prope...

Page 1278: ...terminal 2 of relay 4 Connect battery negative terminal to terminal A of relay 5 Check continuity between terminal 3 and 4 If there is no continuity when relay is connected to the battery replace rel...

Page 1279: ...fications S6RW0C9207001 Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Fastening part Tightening torque Note N m kgf m lb ft...

Page 1280: ...ped rear fog light indicator light if equipped high beam indicator light and turn signal indicator light Therefor check that no DTC is detected in each module before performing combination meter sympt...

Page 1281: ...rake warning light control signal Driver side seat belt buckle switch signal seat belt reminder light control signal Charging system warning light signal charge warning light control signal Engine oil...

Page 1282: ...o volume control system is to vary sound volume according to changes of vehicle speed How much sound volume varies depends on selected level Reference Correlation Chart of Vehicle Speed and Sound Volu...

Page 1283: ...8 19 G241 7 G241 10 10 10 I6RW0C930002 01 1 DOME fuse 8 ODO TRIP 15 Power supply 2 METER fuse 9 4WD control module if equipped 16 Interface circuit 3 Combination switch 10 CAN junction connector 17 CA...

Page 1284: ...To lighting switch high beam G241 7 CAN communication line Active High Signal G241 23 G241 8 G241 24 G241 9 CAN communication line Active Low Signal G241 25 To P S control module EPS warning light con...

Page 1285: ...ration or incorrect operation Circuit fuse blown Replace fuse and check for short circuit Wiring or grounding faulty Repair circuit Combination meter faulty Replace combination meter ECM faulty Replac...

Page 1286: ...place combination meter ECM faulty Replace after making sure that none of above parts is faulty Low fuel warning light comes ON steady Low fuel Refill fuel Fuel level sensor faulty Check fuel level se...

Page 1287: ...t Brake Warning Light Check in Section 4E Wiring or grounding faulty Repair circuit Combination meter faulty Replace combination meter BCM faulty Replace after making sure that none of above parts is...

Page 1288: ...se Correction Reference Item Main beam high beam indicator does not come ON Circuit fuse blown Replace fuse and check for short circuit Combination switch faulty Check combination switch referring to...

Page 1289: ...ndition Possible cause Correction Reference Item Horn does not operate Circuit fuse blown Replace fuse and check for short circuit Horn switch faulty Check horn switch Horn relay faulty Check horn rel...

Page 1290: ...ormation display unit faulty Replace unit BCM faulty Replace after making sure that none of above parts is faulty Display of fuel consumption does not change at l 100 km km l MPG Vehicle is not runnin...

Page 1291: ...g to after mentioned NOTE Wiring or grounding faulty Repair circuit Radio assembly faulty Replace radio assembly Radio does not operate and speaker does not sound Circuit fuse s blown Replace fuse s a...

Page 1292: ...skips or is noisy CD ROM faulty Driving vibration Water droplets form on internal lens Dry about 1 hour with power on Radio assembly installed incorrectly Install correctly Radio assembly faulty Repla...

Page 1293: ...al and Installation in Section 6B 6 Disconnect couplers 1 from ignition switch 2 7 Remove ignition switch 2 from key cylinder 3 Condition Possible cause Correction Reference Item Audio system is opera...

Page 1294: ...e trim 1 and steering column hole cover 2 3 Remove center ventilation louver referring to Step 1 and 2 of Information Display Clock Removal and Installation 4 Remove combination meter cluster panel 1...

Page 1295: ...ions Oil Pressure Switch Removal and Installation S6RW0C9306006 For removal and installation refer to Oil Pressure Check in Section 1E Oil Pressure Switch Inspection S6RW0C9306007 1 Disconnect oil pre...

Page 1296: ...ing brake released No continuity ON position parking brake lever pulled up Continuity Door Switch Front Rear Door Inspection S6RW0C9306011 Remove door switch from body and check switch for continuity...

Page 1297: ...temperature sensor Outside air temperature sensor resistance 1 61 k 1 79 k at 25 C 77 F Instrument Panel Removal and Installation S6RW0C9306015 WARNING Refer to Air Bag Warning in Section 00 before s...

Page 1298: ...en installing each part be careful not to catch any cable or wiring harness Tighten instrument panel mounting bolts to specified torque Tightening torque Instrument panel mounting bolt a 23 N m 2 3 kg...

Page 1299: ...Equipped S6RW0C9306018 Removal 1 Remove front door trim referring to Step 1 to 3 of Front Door Glass Removal and Installation in Section 9E 2 Remove 3 front speaker mounting screws 1 3 Remove front sp...

Page 1300: ...S6RW0C9306020 Removal 1 Disconnect negative cable at battery 2 Remove front bumper referring to Front Bumper and Rear Bumper Components in Section 9K 3 Disconnect horn connector 1 4 Remove horn 2 Inst...

Page 1301: ...nna base 2 from vehicle Installation Reverse removal procedure noting the following Tighten antenna base mounting bolt to specified torque Tightening torque Antenna base mounting bolt a 5 0 N m 0 5 kg...

Page 1302: ...pushing on ON 416 426 Switch 5 pushing on ON 743 759 Switch 6 pushing on ON 1555 1587 Vehicle Speed Signal Inspection For Audio Unit If Equipped S6RW0C9306026 Check vehicle speed pulse output signal...

Page 1303: ...e Correction Reference Item Wiper malfunctions NOTE Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or output side of BCM For checking procedure refer to...

Page 1304: ...11 8 16 9 16 I7RW01940001 03 1 Windshield wiper blade 8 Washer pump for rear washer 15 Windshield wiper bolt Tighten bolts in specified order 2 Windshield wiper arm 9 Washer tank 16 Washer tank bolt...

Page 1305: ...to pump and terminals respectively 2 Check windshield and rear washer pumps for operation If pump does not operate replace washer pump Windshield Wiper Removal and Installation S6RW0C9406004 Removal...

Page 1306: ...ll wiper pivot caps 2 to windshield wiper arm nuts 6 Connect negative cable to battery Windshield Wiper Motor Inspection S6RW0C9406005 NOTE Make sure that battery voltage is 12 V or more 1 Make a mark...

Page 1307: ...egative terminal to terminal 5 and let the motor turn b Disconnect terminal 1 from battery positive terminal and let the motor stop c Connect terminals 1 and 3 with a jumper wire and connect terminal...

Page 1308: ...unting bolt a 8 N m 0 8 kgf m 6 0 lb ft 2 Connect coupler to rear wiper motor 3 Install rear end door trim referring to Rear End Door Lock Assembly Removal and Installation in Section 9F 4 Install rea...

Page 1309: ...result is not as specified replace motor Specification 35 45 r min rpm For automatic stop operation a Connect battery positive terminal to terminal 1 and its negative terminal to terminal 2 and let t...

Page 1310: ...moval procedure Windshield Wiper and Washer Switch Inspection S6RW0C9406009 Windshield Wiper and Washer Switch Check for continuity between terminals at each switch position If check result is not as...

Page 1311: ...l 2 3 Connect voltmeter positive lead to terminal 4 and its negative lead to terminal 2 4 When front washer switch is ON check that voltage changes as shown in figure If check result is not satisfied...

Page 1312: ...terminals at each switch position If check result is not as specified replace switch Rear Wiper Relay Removal and Installation S6RW0C9406012 Removal 1 Disconnect negative cable at battery 2 Remove jun...

Page 1313: ...nnected to the battery replace relay Specifications Tightening Torque Specifications S6RW0C9407001 NOTE The specified tightening torque is also described in the following Wipers and Washers Components...

Page 1314: ...er Switch Inspection Rear end door window defogger relay faulty Check rear end door window defogger relay referring to Rear End Door Window Defogger Relay Inspection Defogger wire faulty Check defogge...

Page 1315: ...r door mirror switch faulty Check power door mirror switch referring to Power Door Mirror Switch Inspection Power door mirror actuator faulty Check actuator refraining to Power Door Mirror Actuator In...

Page 1316: ...E 3 Glass Windows Mirrors Repair Instructions Windshield Components S6RW0C9506001 3 3 1 2 4 4 4 I5RW0A950001 02 1 Windshield glass 3 Windshield glass stopper Do not reuse 2 Windshield molding 4 Spacer...

Page 1317: ...r otherwise damaged be sure to repair damaged part or corrosion may start from there Use the specific adhesive which has the following property Glass adhesive shearing strength 40 kg cm2 569 lb in2 or...

Page 1318: ...om it using care not to damage primer coated surface 2 Installation 1 Using cleaning solvent clean windshield edge where windshield glass is to be adhered Let it dry for more than 10 minutes 2 Install...

Page 1319: ...cleaning solvent is used let it dry for 10 minutes or more Cleaning Area for windshield distance from the edge of glass or molding 30 50 mm 1 19 1 96 in 7 Install new spacers 1 to windshield 2 8 Using...

Page 1320: ...pprox 15 mm 0 59 in Position c Approx 10 mm 0 39 in for right left and upper sections Position d Approx 50 mm 1 97 in for bottom section 11 Holding rubber sucker grips 1 place glass onto body by align...

Page 1321: ...d sufficient adhesion Front Pillar Window Components S6RW0C9506003 Front Pillar Window Removal and Installation S6RW0C9506004 Refer to Windshield Removal and Installation as preparation removal and in...

Page 1322: ...glass 2 edge Adhesive 1 should be applied evenly especially in height Be careful not to damage primer 3 Press glass against body quickly after adhesive 1 is applied Adhesive amount specifications and...

Page 1323: ...glass 2 on rear end door panel 5 noting the following With the position of fastener 4 properly aligned With the position of ceramic mark 6 aligned to the mark 7 of rear end door panel 5 Press glass ag...

Page 1324: ...r and tweeter if equipped 2 8 11 4 1 7 3 6 9 10 12 5 I7RW01950002 01 1 Door glass 5 Door sealing cover 9 Front door inner weather strip 2 Window regulator assembly Apply lithium grease 99000 25011 to...

Page 1325: ...ighten door glass front mounting screw 2 Secure door sealing cover 1 with adhesive 2 Install front door trim Front door trim attaching order 1 2 3 4 5 6 7 8 9 Front Door Window Regulator Removal and I...

Page 1326: ...06013 Rear Door Glass Removal and Installation S6RW0C9506014 Removal 1 Remove rear door inner garnish 1 2 Remove door trim mounting screws 2 2 8 12 4 6 3 13 10 11 9 7 5 1 I5RW0A950022 02 1 Door glass...

Page 1327: ...h 1 10 Remove door glass as shown Installation Reverse removal procedure noting the following instructions If there is deformity for glass run replace it with a new one Secure door sealing cover 1 wit...

Page 1328: ...amage Rear End Door Window Defogger Switch Inspection S6RW0C9506017 1 Check rear end door window defogger switch for operation as follows a Rear end door window defogger switch is built in HVAC contro...

Page 1329: ...loth 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...

Page 1330: ...e 2 to be repaired 3 Apply commercially available repair agent 3 with a fine tip brush 4 4 2 to 3 minutes later remove masking tapes 1 5 Leave repaired heat wire as it is for at least 24 hours before...

Page 1331: ...check result is not as specified replace power window main switch Power Window Sub Switch Inspection S6RW0C9506022 1 Remove front door trim from door panel refer to Step 1 to 3 of Front Door Glass Rem...

Page 1332: ...e door trim referring to step 1 to 3 of Front Door Glass Removal and Installation 2 Remove power window main switch from door trim 3 Check for continuity between terminals at each switch position If c...

Page 1333: ...ss Removal and Installation 2 Disconnect door mirror connector 1 3 Check for continuity between terminals a and b If no continuity replace outside mirror Door Mirror Heater Switch Inspection If Equipp...

Page 1334: ...consists of rear end door opener switch 1 rear end door opener relay in BCM rear end door lock assembly 2 and BCM 3 Rear end door opener system is activated by pushing rear end door opener switch aft...

Page 1335: ...nt Location If Equipped S6RW0C9603001 3 7 4 5 6 1 2 8 9 I6RW0C960002 01 1 Keyless entry receiver 4 Front door actuator 7 Door switch 2 Transmitter 5 Rear door actuator 8 BCM junction block with BCM ty...

Page 1336: ...erence Item All door can not be locked unlocked by all of switches Circuit fuse blown Replace fuse and check for short circuit Wiring or grounding faulty Repair circuit BCM faulty Replace after making...

Page 1337: ...warning relay faulty Check turn signal and hazard warning relay referring to Turn Signal and Hazard Warning Relay Inspection in Section 9B Wiring or grounding faulty Repair circuit BCM faulty Replace...

Page 1338: ...ch at the outside door handle Rear End Door Opener System Symptom Diagnosis If Equipped S6RW0C9604006 NOTE Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input sid...

Page 1339: ...ve door sash 1 4 Remove key cylinder mounting bolt 1 and then remove key cylinder 2 a b 5 3 6 1 4 2 I5RW0A960003 01 1 Front door latch assembly Apply lithium grease 99000 25011 to sliding and rotating...

Page 1340: ...que Door latch screw a 5 0 N m 0 5 kgf m 4 0 lb ft Move door latch striker 2 up or down so its center aligns with the center of groove A on the door lock assembly 1 as shown Striker should be moved ve...

Page 1341: ...r Lock Switch Inspection If Equipped S6RW0C9606004 Check for continuity between terminals at each switch position If check result is not as specified replace switch Door Key Cylinder Switch Inspection...

Page 1342: ...c d as shown in figure If it does not operate as specified in the following table replace door lock assembly For front door For rear door For rear end door A Without deadlock B With deadlock a b c d...

Page 1343: ...referring to Rear Door Glass Removal and Installation in Section 9E Rear Door Lock Assembly Inspection S6RW0C9606009 Check that door opens and closes smoothly and properly Check that door stops in the...

Page 1344: ...door is unlocked by pushing emergency lever with flat head driver if rear end door lock can not be released by door opener switch 10 N m 1 0 kgf m 7 5 lb ft 2 Rear end door opener switch 6 Rear end do...

Page 1345: ...olt a 10 N m 1 0 kgf m 7 5 lb ft Adjust door latch striker so that its center aligns with the center of groove in door latch base Tightening torque Rear end door striker screw a 23 N m 2 3 kgf m 17 0...

Page 1346: ...becomes unreliable replace transmitter battery as follows 1 Remove screw 1 and transmitter cover 2 2 Remove transmitter 3 from transmitter holder 4 CAUTION Use care not to allow grease or dirt to be a...

Page 1347: ...registration is completed 7 If an additional transmitter needs to be programed repeat the procedure of Step 1 Keyless Entry Answer Back Function Change over Procedure If Equipped S6RW0C9606018 Output...

Page 1348: ...own good keyless entry receiver b Record key code referring to Programming Transmitter Code for Keyless Entry System Other than Keyless Start Model c Recheck keyless entry receiver system 1 Keyless en...

Page 1349: ...fer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S6RW0C9608001 NOTE Required service material is also described in the following Front Door Lock Asse...

Page 1350: ...pped 2 Seat back Apply lithium grease 99000 25011 to sliding part of reclining 8 Side air bag harness if equipped 3 Headrest 23 N m 2 3 kgf m 17 0 lb ft 4 Cover 35 N m 3 5 kgf m 25 5 lb ft 5 Seat adju...

Page 1351: ...Seat Components Enable air bag system referring to Enabling Air Bag System in Section 8B Rear Seat Components S6RW0C9706003 3 5 4 4 4 7 4 2 6 b c a d a d b b b c A 7 A b 8 I6RW0C970002 01 1 Seat cush...

Page 1352: ...Seat Components Specifications Tightening Torque Specifications S6RW0C9707001 NOTE The specified tightening torque is also described in the following Front Seat Components Rear Seat Components Referen...

Page 1353: ...3 back panel trim 4 rear quarter lower trims 5 4 Remove console box referring to Console Box Components 5 Remove floor carpet Installation Reverse removal sequence to install front floor carpet noting...

Page 1354: ...and center 2 3 Remove front pillar upper trims 1 rear side sill scuffs 2 center pillar inner lower trims 3 center pillar inner upper trims 4 back panel trim 5 rear quarter lower trims 6 and rear quar...

Page 1355: ...osition and fix three clips 2 at rear end Tighten sun visor screw to specified torque Tightening torque Sun visor screw a 4 N m 0 4 kgf m 3 0 lb ft Console Box Components S6RW0C9806003 4 Clip 5 Flat h...

Page 1356: ...ng Torque Specifications S6RW0C9807001 Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Fastening part Tightening torque Note...

Page 1357: ...t hood stops in the secondary latched position properly preventing hood from opening freely and that hood closes completely in the fully latched position Adjust hood locks position if necessary Adjust...

Page 1358: ...ear Bumper Components in Section 9K 4 Remove headlight assembly referring to Headlight Housing Removal and Installation in Section 9B 5 Disconnect connector from side turn signal light if equipped 6 R...

Page 1359: ...3 and a piece of wood 4 placed between jack 2 and panel 1 as shown 2 2 4 4 5 3 1 6 a a c a b b b a b b b I6RW0B9A0002 01 1 Door panel 5 Door open stopper bolt 21 N m 2 1 kgf m 15 5 lb ft 2 Door hinge...

Page 1360: ...ase A Sealant 99000 31110 SUZUKI Bond No 1215 B Grease 99000 25011 SUZUKI Super Grease A Tighten front door hinge bolts and door open stopper bolt to specified torque referring to Front Door Assembly...

Page 1361: ...ear door hinge bolts and nuts to specified torque referring to Rear Door Assembly Components 2 2 4 5 4 3 1 6 a a b a a b a a a b a I6RW0B9A0005 01 1 Door panel 4 Rear door hinge nut 23 N m 2 3 kgf m 1...

Page 1362: ...er installation position 4 Rear end door balancer 8 Cap 1 Rear end door panel assembly 5 Rear end door trim 9 Clip 2 Rear end door window glass 6 Rear end door opening wether strip 23 N m 2 3 kgf m 17...

Page 1363: ...n rod and never allow any paint or oil to stick to its surface Do not turn piston rod with balancer fully extended Do not disassemble balancer 1 because its cylinder is filled with gas Discarding of r...

Page 1364: ...ck that hood opens and closes smoothly and properly and hood locks securely when closed If any malfunction is found lubricate hinge and latch or repair hood lock system Specifications Tightening Torqu...

Page 1365: ...ctions Front Bumper and Rear Bumper Components S6RW0C9B06001 1 2 4 5 6 3 7 8 9 10 I6RW0C9B0003 01 1 Front bumper 5 Front bumper lower member 9 Reflector 2 Radiator upper grill 6 Front bumper holder 10...

Page 1366: ...member Components S6RW0C9B06002 4 Front bumper upper member 8 Rear bumper I7RW019B0002 01 1 Cowl top garnish 3 Hood rear seal 5 Damper 55 N m 5 5 kgf m 40 0 lb ft 2 Cowl top panel 4 Front lower crossm...

Page 1367: ...installation upper front hole d d Headlight installation hole h h Front bumper lower member installation lower hole l Left side engine mounting installation upper front hole a d 623 mm 24 543 in b c 1...

Page 1368: ...installation left side hole b b Rear end door balancer lower hole d d Rear bumper installation hole f f Rear seat back striker installation rear hole a a 342 mm 13 465 in a e 906 mm 36 669 in d d 970...

Page 1369: ...cuff installation rear hole 7 mm e Curtain air bag module installation hole j Rear door lower hinge installation front hole o Parking brake cable bracket installation front hole a f 1 144 mm 45 039 in...

Page 1370: ...of windshield upper installation section c Parking brake cable bracket installation front hole b b Front end of windshield lower installation section a a 1 052 mm 41 417 in a b 1 428 mm 56 220 in b b...

Page 1371: ...14 in a b 1 066 mm 41 969 in c d 318 mm 12 520 in g i 1 274 mm 50 157 in a c 1 167 mm 45 945 in d e 850 mm 33 465 in g i 666 mm 26 220 in a d 1 386 mm 54 567 in d f 1 204 mm 47 402 in g j 1 579 mm 62...

Page 1372: ...h 325 mm 12 795 in b c 280 mm 11 024 in e f 565 mm 22 244 in g i 644 mm 25 354 in c d 316 mm 12 441 in f g 155 mm 6 102 in g j 1 145 mm 45 079 in a 31 mm 1 220 in e 91 mm 3 583 in i 112 mm 4 409 in b...

Page 1373: ...Front suspension control arm installation hole c Front suspension control arm installation hole a b 33 mm 1 299 in a d 313 mm 12 323 in a c 149 mm 5 866 in a e 350 mm 13 780 in a 0 mm 0 in c 43 mm 1 6...

Page 1374: ...1 mm 0 161 0 240 in c 3 6 5 6 mm 0 142 0 220 in o 0 1 0 mm 0 0 039 in d 1 0 3 0 mm 0 039 0 118 in For vehicle with splash guard p 5 2 7 2 mm 0 205 0 283 in e 4 8 6 8 mm 0 189 0 268 in q 2 0 mm 0 079...

Page 1375: ...seal the flanged joints overlap joints and seams The sealer must have flexible characteristics and paint ability after it s applied to repair areas For the sealer to fill open joints use caulking mat...

Page 1376: ...9L 2 Paint Coatings 5 Polypropylene must raise no readily distinguishable smoke while burning Component Location Sealant Application Areas S6RW0C9C03001 I7RW019C0007 01...

Page 1377: ...19C0002 01 A RH side B Wipe off excess sealant after application E Never fill up drain holes with sealant B LH side C Smooth out sealant with a brush F Fill gap hole with sealant A Apply sealant D Do...

Page 1378: ...9L 4 Paint Coatings I7RW019C0008 01 A Apply sealant D Do not apply sealant B Fill gap hole with sealant E Wipe off excess sealant after application C Smooth out sealant with a brush...

Page 1379: ...Paint Coatings 9L 5 I7RW019C0004 01 A Apply sealant C Never fill up drain holes a to f with sealant B Wipe off excess sealant after application D Apply sealant covering flange end...

Page 1380: ...Apply sealant D Smooth out sealant with a brush G Apply sealant covering flange end B Wipe off excess sealant application E Smooth out sealant with a brush Do not fill hole with sealant C Fill gap hol...

Page 1381: ...Paint Coatings 9L 7 I5RW0C9C0005 01 A Apply sealant 1 Hole...

Page 1382: ...9L 8 Paint Coatings I5RW0C9C0006 01 A Apply sealant covering flange end...

Page 1383: ...Paint Coatings 9L 9 Under Coating Application Areas S6RW0C9C03002 I6RW0C9C0005 02 A LH side C Do not apply undercoating B RH side D Apply under coating after panting black color...

Page 1384: ...apply undercoating and anti chip coat B Apply anti chip coat 300 m or more Except vehicle with splash guard I7RW019C0005 01 A 2WD vehicle B Apply undercoating PVC 600 m or more B 4WD vehicle C Do not...

Page 1385: ...1 Anti Corrosion Compound Application Area S6RW0C9C03003 I5RW0C9C0013 01 A Apply rust proof wax hot wax 50 m or more B Apply rust proof wax high viscosity wax 50 m or more C Never fill up drain holes...

Page 1386: ...9L 12 Paint Coatings I5RW0A9C0010 01 A Apply rust proof wax hot wax 50 m or more B Never fill up drain holes with rust proof wax...

Page 1387: ...Position roof molding with touching A to B 3 Roof rail nut if equipped B Roof molding clip installation position 4 Roof molding A Positioning rib 5 Roof molding clip Push in type Install roof molding...

Page 1388: ...tightening torque is also described in the following Roof Molding Removal and Installation Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information...

Page 1389: ...ctrical Control System Wiring Circuit Diagram 10B 2 Connector Layout Diagram of BCM and Junction Block 10B 5 Component Location 10B 6 BCM and Related System Component Location 10B 6 Diagnostic Informa...

Page 1390: ...Area of Remote Controller 10E 4 Alarm Function 10E 6 CAN Communication System Description 10E 6 Schematic and Routing Diagram 10E 7 Keyless Start System Electric Wiring Circuit Diagram 10E 7 Diagnosti...

Page 1391: ...Systems Precautions Precautions Precautions for Control Systems S6RW0CA000001 Air Bag Warning Refer to Air Bag Warning in Section 00 Precaution on CAN Troubleshooting Refer to Precaution on CAN Troub...

Page 1392: ...cancel cruise control CANCEL switch and resume the speed in memory automatically after cruise control is cancelled RES ACC switch The system mainly consists of electric throttle body assembly ECM crui...

Page 1393: ...ttle valve control is cancelled Wheel speed sensor vehicle speed signal ECM receives speed sensor signal from ABS control module through CAN communication and calculates vehicle speed using that signa...

Page 1394: ...er is shifted to P R or N range A T model CANCEL switch is turned ON NOTE When constant cruising is cancelled under any condition with asterisk vehicle speed before cancellation can be resumed by oper...

Page 1395: ...58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32...

Page 1396: ...ke light switch faulty Check brake light switch for function referring to Brake Light Switch Inspection CPP switch faulty M T model Check CPP switch for function referring to Clutch Pedal Position CPP...

Page 1397: ...AIN ON OFF switch is not pushed 10 14 V Ignition switch is at ON position and cruise control MAIN ON OFF switch is kept in push E01 7 ground CPP switch circuit 10 14 V Ignition switch is at ON positio...

Page 1398: ...satisfactory replace cruise control switch 2 Cruise MAIN ON OFF switch 3 specification B Switch button released Infinity Switch button pressed Continuity For SET COAST RES ACC and CANCEL Switch Check...

Page 1399: ...resistance When switch shaft is pushed A No continuity When switch shaft is free B Continuity Adjustment For adjustment refer to Installation under CPP Switch for Cruise Control Removal and Installati...

Page 1400: ...ncorporates relays and controllers which are used for the following systems and controls them Power door lock if equipped Keyless entry if equipped Door lock function of keyless start system if equipp...

Page 1401: ...Circuit Diagram S6RW0CA202001 NOTE This wiring diagram shows circuits related to only BCM not the entire circuits of BCM and junction block Refer to Power Supply Diagram in Section 9A for wiring circ...

Page 1402: ...41 44 44 43 42 46 47 45 48 49 52 BLK RED L314 8 50 51 53 54 55 56 57 IG1 BRN YEL 21 23 20 RED BLK 22 RED BLU IG1 26 GRN WHT 31 32 12V 12V LT GRN BLK BRN 12V L01 12 24 GRY WHT GRY RED IG1 27 GRN YEL 1...

Page 1403: ...window defogger switch 47 To turn signal light 8 Theft deterrent light 28 Rear wiper motor 48 Interior light 9 Oil pressure switch 29 Rear wiper relay 49 Rear end door window defogger relay 10 SDM 30...

Page 1404: ...M and Junction Block Connectors Viewed from Harness Side I6RW0CA20004 01 A Junction block viewed from BCM side 2 Junction block 5 Rear wiper relay B Junction block viewed from relay side 3 Blower moto...

Page 1405: ...s entry receiver or keyless start control module if equipped 21 Key reminder switch included in ignition switch 2 Brake fluid level switch 12 Parking brake switch 22 Junction block 3 ECM 13 Seat belt...

Page 1406: ...stem Key cylinder switch Manual door lock switch Each door lock actuator Keyless entry system Key reminder switch Keyless entry receiver Driver side door switch Each door lock actuator Turn signal and...

Page 1407: ...display or clock Control Input Output Step Action Yes No 1 Customer complaint analysis 1 Perform customer complaint analysis Was customer complaint analysis performed Go to Step 2 Perform customer com...

Page 1408: ...tom Diagnosis Check the parts or system suspected as a possible cause referring to symptom diagnosis of each system Check for Intermittent Problem Check parts where an intermittent trouble is easy to...

Page 1409: ...ion LOCK Key cylinder switch of driver side door not turned Neutral Key cylinder switch of driver side door at unlock position Unlock Door Lock Sw Lock side of manual door lock switch pressed LOCK Man...

Page 1410: ...out BCM type This parameter indicates the state of the front fog light switch Driv Seatbelt Sw Driver seat belt switch Fasten Unfasten This parameter indicates the state of the driver side seat belt b...

Page 1411: ...ecting condition NO DTC 0000 0000 No DTC detected B1133 1133 b1133 Battery voltage too high Battery voltage too high B1141 1141 b1141 Outside air temperature ambient temperature sensor circuit open Se...

Page 1412: ...Scan Tool 1 Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check 2 Turn ignition switch ON and engine stops 3 Erase DTC according to instruc...

Page 1413: ...s in good condition Go to Step 2 Replace fuse and check for short circuit to ground 2 Power supply circuit check 1 Disconnect connectors from junction block 2 Check for proper connection to junction b...

Page 1414: ...ck connector and vehicle body ground Between G272 9 terminal of junction block connector and vehicle body ground Between L314 4 terminal of junction block connector and vehicle body ground Is each res...

Page 1415: ...or malfunction BCM malfunction DTC B1142 DTC No 1142 Input signal from outside air temperature sensor is lower than 0 1 V Short in outside air temperature sensor circuit Outside air temperature sensor...

Page 1416: ...rt SDM malfunction BCM malfunction Step Action Yes No 1 Air bag communication circuit check 1 Turn ignition switch to OFF position 2 Disconnect connectors from junction block and SDM 3 Check for prope...

Page 1417: ...S6RW0CA204014 Refer to Troubleshooting for CAN DTC in Section 1A DTC U0101 No 0101 Lost Communication with TCM S6RW0CA204018 Refer to Troubleshooting for CAN DTC in Section 1A DTC U0155 No 0155 Lost C...

Page 1418: ...e measured by voltmeter because it is pulse signal Check it with oscilloscope if necessary BCM connector L01 1 2 1 2 I4RS0AA20030 01 Terminal Circuit Normal voltage Condition L01 1 Passenger side door...

Page 1419: ...position 0 V Driver side door key cylinder switch is at lock position L01 17 Driver side door key cylinder switch Unlock if equipped 10 14 V Driver side door key cylinder switch is at any position ot...

Page 1420: ...ch is at all positions G04 14 Signal for keyless entry receiver if equipped 0 1 V 4 6 V Refer to Reference waveform No 6 G04 15 Vehicle speed signal output 0 1 V 4 6V Refer to Reference waveform No 7...

Page 1421: ...t any position other than OFF position 0 V Lighting switch is at OFF position G272 9 Ground for BCM 0 V Ignition switch is at all positions G272 11 Hazard warning switch 10 14 V Hazard warning switch...

Page 1422: ...ition L315 9 Rear right and left door lock actuator control Unlock if equipped 10 14 V Unlock signal is output for rear door lock actuator 0 V Unlock signal is not output for rear door lock actuator L...

Page 1423: ...2 to G271 3 Oscilloscope setting CH2 1 V DIV CH3 1 V DIV TIME 40 s DIV Measurement condition Ignition switch is at ON position 1 CAN communication line signal High 2 CAN communication line signal Low...

Page 1424: ...ger switch Ignition switch is at ON position and rear end door window defogger switch is not pushed A C switch Ignition switch is at ON position A C switch or blower speed selector is at OFF position...

Page 1425: ...o Enabling Air Bag System in Section 8B With keyless entry system other than keyless start model if BCM is replaced register transmitter code into BCM referring to Programming Transmitter Code for Key...

Page 1426: ...A300002 If ECM is replaced with new or used one without Immobilizer control function the engine will not be started In case of the above check if the newly installed ECM has Immobilizer control functi...

Page 1427: ...h with the one registered with ECM ECM stops the operation of the fuel injection so as not to start up the engine and turns the immobilizer indicator light ON and OFF using CAN communication lines In...

Page 1428: ...29 G16 30 G146 3 G146 7 G146 8 WHT RED 5V 5V 9 G16 18 G16 19 E01 13 E01 28 BLU BLU RED WHT E08 12 E08 1 E01 19 E01 4 RED WHT E08 13 E08 2 E04 1 E04 2 WHT RED G04 1 G04 3 12V E04 9 G04 5 PPL WHT L313...

Page 1429: ...ected go to applicable DTC diag flow If not detected go to Immobilizer Indicator Light Does Not Come ON with Ignition Switch ON and Engine Stop 2 Immobilizer indicator light check Does immobilizer ind...

Page 1430: ...ble go to Troubleshooting for Communication Error with Scan Tool Using CAN in Section 1A 5 After completing the check turn ignition switch to OFF position and then disconnect SUZUKI scan tool from DLC...

Page 1431: ...e or ECM Flash P1616 Unregistered keyless start control module ECM detects different ID codes registered in ECM and keyless start control module Flash P1618 Keyless start control module CAN communicat...

Page 1432: ...Number of the Registered Immobilizer Key 0 4 keys The number of the transponder code in the transponder built in the ignition key that is registered with ECM NOTE A maximum of four transponder codes c...

Page 1433: ...TC check of BCM 1 Check BCM for DTC referring to DTC Check in Section 10B Is DTC U0073 U0100 U0101 U0155 and or U1144 detected Go to applicable DTC diag flow Substitute a known good combination meter...

Page 1434: ...good condition Substitute a known good combination meter and recheck If immobilizer indicator light still remains ON substitute a known good ECM and recheck Repair circuit Detecting Condition Trouble...

Page 1435: ...ode could not be registered in the keyless start control module or ECM Wire circuits between steering lock unit and keyless start control module CAN communication circuit Steering lock unit Keyless st...

Page 1436: ...unit power supply check 1 Connect keyless start control module connector 2 With ignition switch at ON position check power supply terminal voltage of steering lock unit connector Refer to Keyless Sta...

Page 1437: ...hen check for short circuit Go to Step 3 3 Voltage check at power and ground terminal 1 Check power and ground terminal voltage of ICM connector referring to Inspection of ICM and Its Circuit Is each...

Page 1438: ...ondition Trouble Area EEPROM in ECM is corrupted Internal failure EEPROM corruption of ECM Detecting Condition Trouble Area Transponder code in the transponder built in the ignition key is invalid Use...

Page 1439: ...tration of the immobilizer control system information in ECM is failed CAN communication circuit Keyless start control module if equipped Combination meter TCM A T model 4WD control module if equipped...

Page 1440: ...odule BCM ECM Step Action Yes No 1 Was Immobilizer Control System Check performed Go to Step 2 Go to Immobilizer Control System Check 2 DTC confirmation 1 Disconnect negative cable from battery for mo...

Page 1441: ...y voltage confirm that it is 11 V or more when the ignition switch is turned to ON position 6 CAN communication circuit check 1 Disconnect connectors from ECM BCM and ABS control module 2 Check CAN co...

Page 1442: ...pped 0 V Ignition key not inserted to the key cylinder Door opened 0 V 12 V Ignition key at OFF position From the time door is closed to the time interior light faded out completely As the interior li...

Page 1443: ...to be registered with ECM To register the transponder code with ECM perform Immobilizer Key Registration mode of SUZUKI scan tool referring to SUZUKI scan tool Operator s Manual NOTE A maximum of fou...

Page 1444: ...stem Special Tools and Equipment Special Tool S6RW0CA308001 SUZUKI scan tool SUZUKI SDT This kit includes following items 1 SUZUKI SDT 2 DLC3 cable 3 USB cable 4 AC DC power supply 5 Voltage meter pro...

Page 1445: ...de door passenger side door or rear end door while carrying the remote controller which has been registered in the keyless start control module doors can be locked or unlocked Keyless entry system fun...

Page 1446: ...gnal to remote controller Luggage room antenna Transmits request signal to remote controller Driver side door antenna Transmits request signal to remote controller Passenger side door antenna Transmit...

Page 1447: ...When ignition knob switch is at ACC or ON position engine not running and any door has been kept open for a certain time it may happen that engine fails to start In such a case turn ignition knob swit...

Page 1448: ...th ID codes match the keyless start control module outputs the lock or unlock request signal depending on the door lock switch 8 state then to BCM 9 When BCM receives such signal through CAN communica...

Page 1449: ...ission reception The remote controller is placed close to outside of the vehicle compartment such as on the instrument panel beside the front window shield glass on the rear parcel shelf or in a corne...

Page 1450: ...eturned alarm 2 times Flashing in red Remote controller is carried out of vehicle and doors are closed while ignition switch is at ON position remote controller carried out alarm 5 times Flashing in r...

Page 1451: ...15 G16 14 G16 37 G16 33 G16 16 G16 20 G16 29 G16 30 G16 36 G16 32 G16 10 G16 34 G16 11 BLU WHT WHT RED WHT RED PNK BLK GRY BLU BLU RED YEL PPL RED BLK 5V 5V 5V 5V 5V 5V 5V 12V 12V G16 2 G16 1 BLU ORN...

Page 1452: ...tects an abnormality in the system it saves the area where such abnormality has occurred as a DTC in its memory The DTC stored in memory of the keyless start control module is indicated by the key ind...

Page 1453: ...ction Yes No Customer s name Model VIN Date of issue Date Reg Date of problem Mileage Problem Symptoms Engine can not be started by turning Ignition knob switch All doors can not be locked unlocked by...

Page 1454: ...er side door window glass and door 3 Check to make sure that ignition key is not inserted in ignition key cylinder If it is remove it 4 Perform Key Indicator Light Check 5 Close driver side door and w...

Page 1455: ...k unit 12 Normal No malfunction DTC is detected 13 Release Signal Error from Steering Lock Unit Although lock release signal is output to steering lock unit it is not inputted from steering lock unit...

Page 1456: ...50011 02 Condition Possible cause Correction Reference Item All doors can not be locked unlocked by all of door request switches Circuit fuse s blown Replace fuse s and check for short circuit Remote...

Page 1457: ...rt System Check NOTE Pushing ignition knob switch for 5 seconds or longer causes function to protect steering lock releasing solenoid against heat to work Then steering lock unit stops energizing sole...

Page 1458: ...h request switch was pushed will be locked Inspection of Keyless Start Control Module and Its Circuits S6RW0CA504013 Keyless start control module and its circuits can be checked at keyless start contr...

Page 1459: ...all positions G16 11 Ignition switch ACC signal 10 12 V Ignition switch is at ACC or ON position 0 1 V Ignition switch is at any position other than ACC or ON position G16 12 G16 13 G16 14 Ignition s...

Page 1460: ...nition knob switch 10 12 V When pushing ignition knob switch of steering lock unit 0 1 V When releasing ignition knob switch of steering lock unit G16 35 G16 36 Passenger side door request switch 10 1...

Page 1461: ...V DIV TIME 20 ms DIV Measurement condition Ignition knob switch of steering lock unit is pushed Request switch of each door is pushed with remote controller carried Measurement terminal CH1 G16 8 to...

Page 1462: ...h CH2 G16 37 to G16 9 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 1 s DIV Measurement condition Press lock side of manual door lock switch 1 Unlock signal 2 Lock signal Measurement terminal Driv...

Page 1463: ...V Measurement condition Driver door is at unlock position and passenger side door is at lock position 1 Lock signal 2 Unlock signal I5JB0AA50030 03 BLK ORN G16 9 G16 15 G16 14 G16 16 G16 20 G16 29 G16...

Page 1464: ...rom ignition switch 3 Check key reminder switch for operation referring to Ignition Switch Inspection in Section 9C 4 If OK check for open short and high resistance in key reminder switch circuit Is i...

Page 1465: ...T WHT RED RED BLK I7RW01A50005 01 A Keyless start control module connector viewed from harness side 5 Steering lock solenoid 1 Keyless start control module 6 Key reminder switch 2 Combination meter 7...

Page 1466: ...start control module carried with you try to turn ignition knob switch Can it be turned to any position other than LOCK position Replace combination meter Substitute a known good keyless start control...

Page 1467: ...vehicle body ground with ignition switch is at ON position Is each terminal voltage is 10 14 V Go to Step 3 Repair defective power supply circuit 3 Ground circuit check 1 Check for proper connection...

Page 1468: ...t connector from keyless start control module 2 Check for proper connection to Steering lock unit power supply Steering lock unit signal and Steering lock unit ground terminals of keyless start contro...

Page 1469: ...Area DTC Confirmation Procedure 1 Clear DTC referring to DTC Clearance 2 Turn ignition knob switch pushing ignition knob switch 3 Push request switch of each door 4 Check DTC referring to DTC Check D...

Page 1470: ...witch DTC detecting condition Trouble area DTC No 51 Input signal from driver side door request switch remains ON unchanged for 10 minutes or longer DTC No 52 Input signal from passenger side door req...

Page 1471: ...each circuit in good condition Substitute a known good keyless start control module and recheck Repair circuit Step Action Yes No A B D C E 1 4 5 2 3 I5RW0AA50014 01 A Front door antenna and request s...

Page 1472: ...installation refer to Steering Lock Assembly Ignition Switch Removal and Installation in Section 6B Steering Lock Unit Inspection S6RW0CA506004 Check key reminder switch and ignition knob switch in st...

Page 1473: ...this check replace battery and then recheck If it doesn t light up even after battery replacement replace remote controller NOTE When remote controller transmits lock unlock or panic signal it makes...

Page 1474: ...t control module which was used in another vehicle has been installed register the ID code of the remote controller to the keyless start control module first and then the following code With immobiliz...

Page 1475: ...tional remote controller needs to be registered repeat the procedure of Step 6 within 30 seconds after Step 5 7 To end registration mode remove ignition key from ignition key cylinder or turn it to ON...

Page 1476: ...Prepared by 1st Ed Feb 2007...

Page 1477: ...31 0 mm 99500 80J00 01E SERVICE MANUAL VOL 1 OF 2 99500 80J00 01E SERVICE MANUAL VOLUME 1 OF 2 RW420...

Page 1478: ...28 0 mm 99500 80J00 01E SERVICE MANUAL VOL 2 OF 2 99500 80J00 01E SERVICE MANUAL VOLUME 2 OF 2 RW420...

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