Suzuki GA413 Service Manual Download Page 1

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99500-76A01-01E

-0

SERVISE MANUAL

Summary of Contents for GA413

Page 1: ...99500 76A01 01E 99500 76A01 01E SERVICE MANUAL SERVISE MANUAL...

Page 2: ...Bag System Service on or around the air bag system components must be performed only by an authorized SUZUKI dealer Please ob serve all WARNINGS CAUTIONS and Service Precautions under On Vehicle Serv...

Page 3: ...vehicle When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant sealants etc as specified in each description All inform...

Page 4: ...on Rear Suspension Wheel and Tires Propeller Shaft Brakes System Engine Mechanical Engine Cooling Engine Fuel Engine and Emission Control System Ignition System Cranking System Charging System Exhaust...

Page 5: ...t Service 0A 10 Electrical Circuit Inspection Procedure 0A 11 Intermittent and Poor Connection 0A 14 Precautions for Installing Mobile Communication Equipment 0A 15 IDENTIFICATION INFORMATION 0A 15 Bo...

Page 6: ...e or drive plate for A T vehicle Using special tool lock flywheel or drive plate and tighten flywheel or drive plate bolts to specified torque Special Tool A 09924 17810 Tightening Torque c 78 N m 7 8...

Page 7: ...s Modifications can adversely affect air bag system performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking pro cess remove the...

Page 8: ...vise to hold it securely at its lower mounting bracket This is necessary so that a free space is provided to allow the air bag to ex pand in the unlikely event of accidental deployment Otherwise pers...

Page 9: ...bag system component parts remove those parts beforehand When handling the air bag inflator modules driver and passenger or SDM be careful not to drop it or ap ply an impact to it If an excessive impa...

Page 10: ...10B Never expose air bag system component parts directly to hot air drying or baking the vehicle after painting or flames WARNING CAUTION labels are attached on each part of air bag system components...

Page 11: ...p away from hot metal parts such as the radiator exhaust manifold tailpipe muffler etc New and used engine oil can be hazardous Children and pets may be harmed by swallowing new or used oil Keep new a...

Page 12: ...rder and position Whenever you use oil seals gaskets packing O rings locking washers split pins self locking nuts and certain other parts as specified be sure to use new ones Also be fore installing n...

Page 13: ...r fuel can be sprayed out under pressure PRECAUTIONS FOR CATALYTIC CONVERT ER For vehicles equipped with a catalytic converter use only un leaded gasoline and be careful not to let a large amount of u...

Page 14: ...cted to it Attempt to do it may cause dam age to electronic control unit and sensors Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained or personal injur...

Page 15: ...CK Possible causes for the open circuit are as follows As the cause is in the connector or terminal in many cases they need to be checked particularly carefully Loose connection of connector Poor cont...

Page 16: ...1 Measure resistance between connector terminals at both ends of the circuit being checked between A 1 and C 1 in the figure If no continuity is indicated infinity or over limit that means that the ci...

Page 17: ...rcuit check wire harness to ground 1 Disconnect negative cable at battery 2 Disconnect connectors at both ends of the circuit to be checked NOTE If the circuit to be checked is connected to other part...

Page 18: ...d 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 reform it...

Page 19: ...ntrol unit Keep the antenna feeder more than 20 cm 7 9 in away from electronic control unit and its wire harnesses Do not run the antenna feeder parallel with other wire har nesses Confirm that the an...

Page 20: ...ined or damaged clean or replace it as necessary NOTE Air bag CAUTION WARNING labels are attached on the vehicle equipped with air bag system only For van type For truck type Attached on the other sid...

Page 21: ...t part to be removed Before lifting up the vehicle check to be sure that end of hoist arm is not in contact with brake pipe fuel pipe bracket or any other part When using frame contact hoist apply hoi...

Page 22: ...rform service with either front or rear vehicle end jacked up be sure to place safety stands under chassis frame for front side and rear axle housing for rear side so that body is securely sup ported...

Page 23: ...Circuit CMP Sensor Camshaft Position Sensor Crank Angle Sensor CAS CO Carbon Monoxide CPP Switch Clutch Pedal Position Switch Clutch Switch Clutch Start Switch CPU Central Processing Unit CRS Child Re...

Page 24: ...C Over Head Camshaft P PNP Park Neutral Position P S Power Steering PSP Switch Power Steering Pressure Switch P S Pressure Switch PCM Powertrain Control Module PCV Positive Crankcase Ventilation R RH...

Page 25: ...IC BOLTS IDENTIFICATION CLASS NUMBERS OR MARKS CORRESPOND TO BOLT STRENGTH INCREAS ING NUMBERS REPRESENT INCREASING STRENGTH STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque...

Page 26: ...ag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in se...

Page 27: ...ngine oil and oil filter Vehicle with HO2S SE SF Vehicle without HO2S Replace every 10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R 1 6 Exhaust pipes and mountings except catalyst I I I IGNIT...

Page 28: ...ASSIS AND BODY 6 1 Clutch I I I 6 2 Brake discs and pads front I I I I I I Brake drums and shoes rear I I I 6 3 Brake hoses and pipes I I I 6 4 Brake fluid R R R 6 5 Parking brake lever and cable I 6...

Page 29: ...Every 15 000 km 9 000 miles or 12 months B C D Drive belt V rib belt R Every 45 000 km 27 000 miles or 36 months A C D E F H Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months A B C E...

Page 30: ...on to 5 7 mm 0 20 0 27 in 3 If belt is too tight or too loose adjust it to specification by adjust ing generator position 4 Tighten bolt adjusting bolt and pivot bolt to specified torque Tightening To...

Page 31: ...TENSION ER in SECTION 6A ITEM 1 3 Valve Lash Inspection 1 Remove cylinder head cover 2 Inspect intake and exhaust valve lash and adjust as necessary Refer to VALVE LASH CLEARANCE in SECTION 6A for va...

Page 32: ...ning oil wipe drain plug clean Reinstall drain plug and tighten it securely as specified torque Tightening Torque a 35 N m 3 5 kg m 25 5 lb ft 1 Oil pan 2 Oil drain plug 3 Loosen oil filter by using o...

Page 33: ...ified However note that the amount of oil required when actually changing oil may somewhat differ from the data in the table depending on various conditions temperature viscosity etc 7 Check oil filte...

Page 34: ...stat cap must not be removed 1 Radiator 2 Radiator drain plug 5 Fill radiator with specified amount of coolant bleed air from cooling system by disconnecting heater breather hose and loosening thermos...

Page 35: ...used for the purpose of corrosion protection and lu brication 1 Full level mark 2 Low level mark 3 Tank cap 4 Match marks ITEM 1 6 Exhaust Pipes and Mountings Inspection When carrying out periodic mai...

Page 36: ...rk plugs with new ones Refer to SPARK PLUG in SECTION 6F FUEL SYSTEM ITEM 3 1 Air Cleaner Filter Element Inspection 1 Remove air cleaner case clamps 2 Take cleaner element out of air cleaner case 3 Ch...

Page 37: ...Repair leaky joints if any Replace hoses that are suspected of being cracked 2 Visually inspect gasket of fuel tank cap If it is damaged or dete riorated replace it with new one ITEM 3 4 Fuel Filter R...

Page 38: ...M 4 3 Fuel Evaporative Emission Control System Inspection 1 Visually inspect hoses for cracks damage or excessive bends Inspect all clamps for damage and proper position 2 Check evaporative emission c...

Page 39: ...fer to CHECK AND ADJUSTMENT in SECTION 5 Be sure to torque caliper pin bolts to specification Brake drums and shoes Rear 1 Remove wheel and brake drum 2 Check rear brake drums and brake linings for e...

Page 40: ......

Page 41: ...flating pressure of each tire and adjust pressure to specification as necessary NOTE Tire inflation pressure should be checked when tires are cool Specified tire inflation pressure should be found on...

Page 42: ...s and retighten them as necessary Repair or replace defective parts if any 1 Ball joint stud dust seal boot 2 Suspension arm ITEM 6 9 Manual Transmission Oil Inspection 1 Inspect transmission case for...

Page 43: ......

Page 44: ...t NOTE For the details of wheel alignment refer to GENERAL DE SCRIPTION in SECTION 3A 1 Tie rod end boot 2 Steering gear case boot 3 Universal joint ITEM 6 12 All Hinges Latches and Locks Doors Check...

Page 45: ...hift or selector lever for smooth shifting to all positions and for good performance of transmis sion in any position With automatic transmission equipped vehicle also check that shift indicator indic...

Page 46: ...roster outlet when operating heater or air conditioning Set fan switch lever to HI position for this check MAINTENANCE AND LUBRICATION 0B 21 RECOMMENDED FLUIDS AND LUBRICANTS Engine oil SE SF SG SH or...

Page 47: ...fore per forming service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative...

Page 48: ...LATION GENERAL DESCRIPTION HEATER The heater and ventilation of this vehicle consist of such main components as control levers blower motor heater core and air ducts The blower motor runs on electrici...

Page 49: ...essary Incorrect temperature output Control cables broken or binding Air damper broken Air ducts clogged Heater core leaking or clogged Heater hoses leaking or clogged Check cables Repair damper Repai...

Page 50: ...1A 4 HEATER AND VENTILATION HEATER UNIT 1 Heater unit assembly 2 Blower fan 3 Fan motor 4 Resistor 5 Mode lever 6 Air mix link 7 Heater core...

Page 51: ...disconnect heater hoses from heater unit For vehicle with air conditioner recover refrigerant 3 If equipped with air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B...

Page 52: ...m enable air bag system Refer to ENABLING AIR BAG SYSTEM in Section 10B 1 Heater unit 2 Nut 3 Heater duct 4 Air inlet box HEATER BLOWER RESISTOR REMOVAL 1 Disconnect battery cable at battery 2 Disconn...

Page 53: ...continuity If there is no continuity replace control lever assembly B Black P Pink P B Pink Black P Bl Pink Blue P G Pink Green INSTALLATION Reverse removal procedure for installation B H M L P G P Bl...

Page 54: ...ully as shown in left figure and fix cable there 1 Temperature control cable 2 Link Fresh air control cable 1 Set control lever to FRESH AIR position 2 Pull lever in arrow direction fully as shown in...

Page 55: ...RVICE in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or coul...

Page 56: ...ompressor 2 Magnet clutch 3 Condenser 4 Receiver dryer 5 Dual pressure switch 6 Expansion valve 7 Evaporator 8 Blower motor 9 Heater core 10 Ventilation 11 Foot 12 Defroster 13 Demister 1B 2 AIR CONDI...

Page 57: ...ressure switch 4 Receiver Dryer 5 Evaporator inlet pipe 6 Condenser 7 Expansion valve 8 Compressor 9 High pressure service valve 10 Low pressure service valve 11 Heater unit 12 Cooling unit 13 A C con...

Page 58: ...tor relay 12 Condenser fan motor 13 Compressor 14 Dual pressure switch 15 Evaporator thermistor 16 ECM 17 Heater motor B Black B BI Black Blue B R Black Red Br B Brown Black Bl Y Blue Yellow G B Green...

Page 59: ...efer to AIR CONDITIONING BASIC MANUAL 99520 02130 A High pressure service valve B Low pressure service valve 1 Manifold gauge set 2 Low pressure gauge 3 High pressure gauge 4 Recovery equipment or vac...

Page 60: ...ve Condenser cooling fan relay faulty Wiring or grounding faulty A C condenser fan relay signal from ECM faulty Condenser cooling fan motor faulty Check condenser cooling fan relay Repair as necessary...

Page 61: ...l protector faulty Excessive charge of refrigerant Repair as necessary Check expansion valve Replace receiver dryer and evacua tion and charging Check A C controller Check magnetic clutch Check compre...

Page 62: ...ed by itself It is strictly prohibited to connect voltmeter or ohmmeter to A C controller with couplers disconnected from it 1 A C controller 1B 8 AIR CONDITIONING TERMINAL CIRCUIT NORMAL VOLTAGE COND...

Page 63: ...NING 1B 9 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION A11 A12 A13 ECM A C signal Refer to INSPECTION OF ECM AND ITS CIR CUIT in ENGINE AND EMISSION CONTROL SYSTEM Section A14 A15 A16 Compressor relay 0...

Page 64: ...nut 8 mm pipe 13 N m 1 3 kg m 9 5 lb ft 14 5mm pipe 32 N m 3 2 kg m 23 0 lb ft A C CONDENSER ASSEMBLY INSPECTION Check the following Condenser fins for leakage blockage and damage Condenser fittings f...

Page 65: ...l procedure 2 Attach pipes to evaporator expansion valve and tighten bolt to specified Connect coupler of wire harness as they were 3 Evacuate and charge system according to previously described proce...

Page 66: ...a proper charge of refriger ant and when A C system compressor is under operation In each of these cases switches should show proper continuity 2 When pressure is following specified pressure switch...

Page 67: ...ts 1 Blower fan and A C switch A C COMPRESSOR RELAY AND CONDENS ER COOLING FAN RELAY INSPECTION 1 Disconnect negative cable at battery 2 Remove condenser cooling fan relay from vehicle 3 Connect batte...

Page 68: ...pulley 8 Circlip 9 Circlip 10 Armature plate Tightening torque a 23 N m 2 3 kg m 16 5 lb ft b 50 N m 5 0 kg m 36 0 lb ft c 10 N m 1 0 kg m 7 5 lb ft INSPECTION Check pressure plate and rotor for wear...

Page 69: ...Armature plate 4 Remove lead wire clamp 5 Remove felt ring and shims from shaft 6 Using special tool C remove circlip Special Tool C 09900 06107 7 Remove magnet clutch lead wire clamp screw and disco...

Page 70: ...puller ASSEMBLY 1 Press fit lip seal into front head using special tool D Special Tool D 09991 06050 CAUTION Do not reuse mechanical seal once removed from compressor 1 Lip type seal 2 Front head 2 C...

Page 71: ...stall snap ring as shown Special Tool C 09990 06107 9 Clamp covering portion of lead wire 1 Snap ring 2 Clutch coil 3 Compressor assembly 10 Install magnet clutch 1 Set magnet clutch squarely over clu...

Page 72: ...r some other reason replenish 100cc oil When replenishing gas only oil replen ishment is not necessary When replacing compressor Compressor oil is sealed in each new compressor by the amount required...

Page 73: ...hrometer dry and wet bulb thermometer close to inlet of cooling unit 6 The high pressure gauge reading should be within specified pressure range High pressure gauge reading 1 4 1 6 Mpa 14 16 kg cm2 20...

Page 74: ...midity curve at their intersection Example If dry bulb temperature is 90 F and wet bulb temperature is 78 F the relative humidity is 60 RELATIVE HUMIDITY TEMPERATURE DIFFERENCE BETWEEN INLET AND OUTLE...

Page 75: ...ring pliers Opening type 09991 06010 Magnet clutch pulley installer 09991 06030 Armature plate remover 09991 06040 Lip type seal protector 09991 06050 Lip type seal installer 09991 06060 Armature plat...

Page 76: ...ilure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service work...

Page 77: ...uately inflated Broken or sagging springs Radial tire lateral force Disturbed front end alignment Disturbed rear wheel alignment Brake dragging in one road wheel Loose bent or broken front or rear sus...

Page 78: ...pinion adjustment Bind in steering column Inflate tires to proper pressure Perform Diagnosis in Electrical power steering system section Replace tie rod end or front suspension control arm Check front...

Page 79: ...spring Lubricate or replace strut bearing Wander or Poor Steering Stability Mismatched or uneven tires Loosen ball joints and tie rod ends Faulty struts or mounting Loose stabilizer bar Broken or sagg...

Page 80: ...struts shock absorber Incorrect broken or sagging springs Check loading Replace shock absorber Replace spring Body Leans or Sways in Corners Loose stabilizer bar Faulty struts shock absorbers or mount...

Page 81: ...en they need replacement These indicators will appear as 12 mm 0 47 in wide bands when the tire tread depth becomes 1 6 mm 0 063 in When the indicators appear in 3 or more grooves at 6 locations tire...

Page 82: ...install known good tires in place of all four Then reinstall originals in the same manner as above INFLATE TIRES TO RECOMMENDED PRESSURE SWITCH FRONT TIRES SIDE TO SIDE AND ROAD TEST AGAIN INSTALL A K...

Page 83: ...art of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner and service manuals If a medium to high mileage tire is moved to the other side of the veh...

Page 84: ...ined If the body is damaged it should be repaired and if suspension is damaged it should be replaced TOE SETTING Toe is the turning in or out of the front wheels The purpose of a toe specification is...

Page 85: ...m to be checked is the possibility of tire lead due to worn or improperly manufactured tires Lead is the deviation of the vehicle from a straight path on a level road without hand pressure on the stee...

Page 86: ...al in length A in left figure NOTE If tie rod lengths were changed to adjust steering angle rein spect toe in Steering angle inside 39 outside 35 Reference Information Side slip For inspecting front w...

Page 87: ...AGNOSIS 3B 2 Diagnosis Table 3B 2 Steering Wheel Play Check 3B 2 Steering Rack Boot 3B 2 Tie Rod End Boot 3B 2 Steering Shaft Joint 3B 2 Tie Rod End 3B 3 ON VEHICLE SERVICE 3B 3 Lubrication 3B 3 Steer...

Page 88: ...eakage Each part for looseness STEERING RACK BOOT Inspect each boot for tear A torn boot allows entry of dust and wa ter which can cause wear to steering rack and pinion to produce noise as well as ru...

Page 89: ...s shown below GREASE SUZUKI SUPER GREASE E 99000 25050 or Lithium grease applicable for 40 C 130 C 104 F 266 F 1 Steering rack 2 Tie rod lock washer 3 Steering tie rod 4 Tie rod end 5 Boot 6 Steering...

Page 90: ...e tie rod end nut 5 Disconnect both tie rod ends from knuckles by using puller 1 Puller 2 Knuckle 3 Tie rod end 6 Remove steering gear case 1 Steering gear case 2 Mounting bolt DISASSEMBLY 1 Remove st...

Page 91: ...mper screw 2 Rack plunger spring 3 Rack plunger 4 Rack plunger lock nut 7 Remove steering gear case cover 8 Remove pinion bearing plug with special tool Special Tool 43 mm socket A 09944 26011 9 Tap o...

Page 92: ...eterioration In either case if found defective replace 1 Rack damper screw 2 Rack plunger spring 3 Rack plunger 4 Rack plunger lock nut Steering Pinion Inspect pinion teeth surface for wear or damage...

Page 93: ...Pinion bearing plug 3 Apply grease to entire teeth surface of rack and its periphery A Grease 99000 25050 4 Slide rack into steering gear case in the direction as shown CAUTION Inside of steering rac...

Page 94: ...que a 12 N m 1 2 kg m 9 0 Ib ft 1 Rack damper screw 2 Rack plunger spring 3 Rack plunger 4 Rack damper screw lock nut 10 After tightening rack damper screw to above specified torque turn it back by 40...

Page 95: ...ecified torque Tightening Torque a 85 N m 8 5 kg m 61 5 Ib ft 1 Steering rack 2 Tie rod lock washer 3 Tie rod 4 Rack side 15 Bend lock washer to tie rod side as shown 16 Before installing boot to stee...

Page 96: ...side G of boot 1 New wire 2 Rack side mount 3 Clip 4 Tie rod 19 Install tie rod end lock nut and tie rod end to tie rod Position lock nut to marking made in removal NOTE When tie rod was replaced mea...

Page 97: ...hten tie rod end nut to speci fied torque Tightening Torque c 43 N m 4 3 kg m 31 5 Ib ft Tighten tie rod end lock nut to specified torque Tightening Torque d 45 N m 4 5 kg m 32 5 Ib ft 1 Tie rod end 2...

Page 98: ...ug 95 9 5 69 0 Tie rod inside ball nut 85 8 5 61 5 Wheel nut 85 8 5 61 5 Rack damper screw lock nut 40 4 0 29 0 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease should...

Page 99: ...omponents 3B1 2 Wiring diagram 3B1 3 DIAGNOSIS 3B1 4 On board diagnosis system 3B1 4 Precautions in diagnosing troubles 3B1 4 System check flow table 3B1 5 DTC check 3B1 7 DTC clearance 3B1 8 DTC tabl...

Page 100: ...cle speed runs the motor so as to assist operation of the steering wheel P S control module diagnoses troubles which may occur in the area including the following parts when the ignition switch is ON...

Page 101: ...meter 8 To vehicle speed sensor VSS 9 ECM 10 Data link connector DLC 11 Monitor coupler 12 Diagnosis switch terminal for P S system 13 Ground terminal 14 To ABS control module if equipped 15 P S cont...

Page 102: ...le engine is running MIL EPS light turns OFF When P S control module detects a trouble which has occurred in the areas it makes MIL EPS light turn ON while the engine is running to warn the driver of...

Page 103: ...t service wire from monitor coupler 3 Apply chocks to wheels set shift lever to neutral position and pull parking brake fully 4 Check MIL EPS light comes ON when igni tion switch is turned ON position...

Page 104: ...nd history DTC can be identified by lighting and flashing of EPS light as follows Current DTC is set Abnormality exists at present History DTC is set only Faulty condition occurred once in the past bu...

Page 105: ...1 Data link connector DLC NOT USING SUZUKI SCAN TOOL 1 Check that MIL EPS light comes ON when ignition switch is turned to ON position If it does not come ON proceed to Table A MIL CIRCUIT CHECK MIL D...

Page 106: ...eting the check turn ignition switch to OFF position and disconnect SUZUKI scan tool from data link connector DLC 1 Data link connector DLC NOT USING SUZUKI SCAN TOOL 1 Turn ignition switch to ON posi...

Page 107: ...M DIAGNOSIS 12 Normal This code appears when none of the other codes are identified C1111 11 C1113 13 C1114 14 Torque sensor C1115 15 C1116 16 C1121 21 C1123 23 VSS signal C1124 24 C1122 22 Engine spe...

Page 108: ...y ground 15 Connector A 15 CAUTION Be sure to perform SYSTEM CHECK FLOW TABLE before starting diagnosis according to flow table TABLE TEST DESCRIPTION Table A STEP 1 Check fuses STEP 2 Check power sup...

Page 109: ...en in B W wire circuit 4 1 Ignition switch OFF 2 Remove combination meter 3 Remove and check EPS bulb 4 Is EPS bulb in good condition Go to STEP 5 Replace bulb 5 1 Check voltage between A6 terminal an...

Page 110: ...STEERING P S SYSTEM Fig for Step 2 Fig for Step 3 Fig for Step 5 Fig for Step 6 Fig for Step 7 NOTE Upon completion of inspection and repair work repeat SYSTEM CHECK FLOW TABLE to confirm that the tro...

Page 111: ...ch OFF disconnect 8 pin A connector from P S control module 2 Measure resistance between A7 terminal of A connector and body ground 3 Is resistance 1 or less Substitute a known good P S control mod ul...

Page 112: ...between A7 terminal and V W wire terminal on monitor coupler 6 Is resistance 1 or less Go to STEP 3 Repair high resistance or open in V W wire circuit 3 1 Check proper connection to P S control module...

Page 113: ...eter 7 Combination meter 8 To VSS 9 Data link connector DLC 10 To ECM SDM if equipped and ABS control module if equipped 11 P S control module 12 Connector A 12 CAUTION Be sure to perform SYSTEM CHECK...

Page 114: ...n com mon section of serial data circuit V G wire circuit used by all con trollers or short to ground or power circuit which has occurred somewhere in serial data circuit V G wire circuit 3 1 With ign...

Page 115: ...tarting diagnosis according to flow table of each DTC STEP ACTION YES NO 1 Is DTC C1114 or C1116 indicated too Go to flow table corre sponding to each DTC No Go to STEP 2 2 1 Check proper connection f...

Page 116: ...or to P S control module 3 If OK ignition switch ON 4 Check voltage between C4 BI wire terminal of 5 pin C connector and body ground with C connector connected to P S control module 5 Is it about 5 V...

Page 117: ...tor to P S control module 3 If OK ignition switch ON 4 Check voltage between C5 R wire terminal of 5 pin C connector and body ground with C connector connected to P S control module 5 Is it about 8 V...

Page 118: ...from P S control mod ule 4 Check proper connection to P S control module at termi nal A4 Y wire 5 If OK connect voltmeter between A4 Y wire terminal and body ground with A connector connected 6 Hoist...

Page 119: ...proper connection to P S control module and ECM at each Br wire terminal P S control module side A5 terminal ECM side Refer to WIRING DIAGRAM in SECTION 6E then check intermittent trouble Refer to INT...

Page 120: ...ule 3 If OK start engine 4 Check voltage between B1 terminal and body ground and B2 terminal and body ground with B connector connected to P S control module 5 Are they 5 7 V with steering wheel held...

Page 121: ...control module 5 Is it 0 V Go to STEP 2 Repair poor connec tion high resistance open or short to pow er circuit or ground in B3 circuit 2 1 Check voltage between B4 terminal and body ground with B con...

Page 122: ...n to P S control module at A2 BI R wire terminal 3 If OK check voltage between A2 terminal and body ground with A connector connected to P S control module 4 Is it 10 14 V Check intermittent trouble R...

Page 123: ...module with coupler disconnected from it Voltage Check 1 Remove steering column lower cover with ignition switch OFF 2 Check voltage at each terminal of couplers connected NOTE As each terminal volta...

Page 124: ...e idling and steering wheel held at position for vehicle to run straight B2 Motor output 1 5 7V Engine idling and steering wheel held at position for vehicle to run straight B3 Clutch output 2 0V B4 C...

Page 125: ...YSTEM 3B1 27 SYMPTOM POSSIBLE CAUSE INSPECTION Steering wheel feels heavy Steering wheel installed improperly twisted Poor performance of torque sensor Poor performance of motor and clutch Faulty stee...

Page 126: ...llows and replace if found defective Tie rod end ball stud for wear Lower ball joint for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness IN...

Page 127: ...INSPECTION 1 Remove steering column lower cover 2 Turn ignition switch to ON position 3 Check voltage between terminals of torque sensor connector with connecting it to P S control module and not runn...

Page 128: ...lt is not satisfactory replace steering column as sembly 4 Check continuity between terminal of motor and clutch coupler and body ground If check result is not satisfactory replace steering column as...

Page 129: ...r needs to be replaced use the correct part number fastener for that ap plication If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fas...

Page 130: ...s manual or a sharp blow on the end of the steering shaft lean ing on the assembly or dropping the assembly could shear the plastic shear pins which maintain column length and position The driver air...

Page 131: ...in this section as well as REPAIRS AND INSPECTIONS REQUIRED AFTER ACCIDENT in SECTION 10B ON VEHICLE SERVICE SERVICE PRECAUTIONS FOR VEHICLE WITH AIR BAG SYSTEM Refer to SERVICE PRECAUTIONS in SECTION...

Page 132: ...in this section 3 Remove driver air bag inflator module mounting bolts at right and left side of steering wheel 1 Steering wheel 2 Mounting bolt 3 Driver air bag inflator module 4 Remove driver air ba...

Page 133: ...r air bag inflator module and horn connector in order i iv shown in the figure securely 1 Driver air bag inflator module connector 2 Horn connector 3 Driver air bag inflator module 4 Connector clamp 3...

Page 134: ...hicle without air bag system 1 Steering wheel 2 Steering wheel pad Type A Type B For vehicle with air bag system Remove driver air bag inflator module from steering wheel Refer to REMOVAL of DRIVER AI...

Page 135: ...wheel onto shaft aligning them by matching marks For vehicle with air bag system Install steering wheel to steering shaft with 2 lugs on contact coil fitted in two grooves in the back of steering whee...

Page 136: ...clockwise 4 From the position where contact coil became unable to turn any further it stopped turn it back clockwise about two and a half rotations and align center mark with alignment mark 1 Align ma...

Page 137: ...embly 1 Contact coil and combination switch assembly 2 To horn and driver air bag inflator module 3 To air bag wire harness INSTALLATION 1 Check to make sure that vehicle s front tires are set at stra...

Page 138: ...SSEMBLY CAUTION Once the steering column is removed from the vehicle the column is extremely susceptible to damage Dropping the column assembly on its end could col lapse the steering shaft or loosen...

Page 139: ...lt column side 6 Move upper joint assembly to lower shaft side in arrow direc tion in the figure 1 Upper joint assembly 2 Upper joint bolt column side 3 Upper joint bolt lower shaft side 4 Marks 7 Loo...

Page 140: ...steering column assembly 1 Capsules 3 Take measurement b as shown If it is shorter than specified length replace column assembly Length b 430 2 432 2 mm 16 94 17 02 in for left hand steering vehicle 4...

Page 141: ...it to marks made before removal 5 Tighten upper joint bolt column side to specified torque then tighten upper joint bolt lower shaft side to specified torque Tighten Torque b 25 N m 2 5 kg m 18 0 lb...

Page 142: ...ion oblong hole of steering shaft in the center of hole in col umn 2 Turn ignition key to ACC or ON position and install steering lock assembly onto column 3 Now turn ignition key to LOCK position and...

Page 143: ...inion shaft B for a guide during reinstallation 5 Loosen upper joint bolt lower shaft side then remove upper joint bolt column side 6 Move upper joint assembly to lower shaft side in arrow direc tion...

Page 144: ...bracket Clearance a 0 0 mm 0 0 in 2 Check capsule for crack If found defective replace steering column assembly 1 Capsule 3 Take measurement b as shown If it is shorter than specified length replace...

Page 145: ...er air bag inflator module if equipped 9 0 9 6 5 Steering shaft nut 33 3 3 24 0 Steering shaft joint bolt 25 2 5 18 0 Steering column mounting bolt 15 1 5 11 0 P S control module if equipped 3 0 3 2 0...

Page 146: ...quench or straighten any front suspension part Replace it with a new part or damage to the part may result CONTENTS GENERAL DESCRIPTION 3D 2 DIAGNOSIS 3D 4 CHECK AND ADJUSTMENT 3D 4 Stabilizer Bar an...

Page 147: ...er end of knuckle is attached to the stud of a ball joint which is incorporated in a unit with a suspension control arm And connected to this steering knuckle is the tie rod end Thus movement of the s...

Page 148: ...ut support cap 2 Strut nut 3 Strut lock washer 4 Strut rebound stopper 5 Strut support 6 Strut rubber support 7 Strut bearing seat 8 Strut bearing 9 Spring upper seat 10 Spring seat 11 Bump stopper 12...

Page 149: ...age or deformation If defective replace Bushing Cushion Inspect for damage wear or deterioration If defective replace COMPRESSION ROD AND OR BUSHING CHECK Rod Inspect for damage or deformation If defe...

Page 150: ...ds are off or after only one or two small rebounds If struts are sus pected compare them with known good vehicle or strut 3 Inspect for damage or deformation 4 Inspect bearing for wear abnormal noise...

Page 151: ...ing Torque a 85 N m 8 5 kg m 61 5 lb ft 3 Check wheel bearing for wear When measuring thrust play ap ply a dial gauge to wheel hub center after removing wheel cen ter cap from wheel disc Thrust play l...

Page 152: ...ssion rod Forward INSTALLATION Install in reverse order of removal procedure noting the following points When installing stabilizer loosely assemble all components while insuring that stabilizer is ce...

Page 153: ...ON Install in reverse order of removal procedure noting the following points For correct installation of compression rod bushings and com pression rod washers refer to the left figure Use new compress...

Page 154: ...4 Remove E ring securing brake flexible hose and take brake flexible hose off strut bracket as shown 5 Remove wheel speed sensor harness clamp bolt from strut if equipped with ABS 6 Remove strut brac...

Page 155: ...ly easier Note however nut must not be removed at this point 2 Using a spring compressor compress strut spring till its force pressing the spring seat is released CAUTION Use a commercially available...

Page 156: ...t 7 Strut bearing seat 8 Strut bearing 9 Spring upper seat 10 Spring seat 11 Bump stopper 12 Coil spring 13 Strut assembly Mate spring end with stepped part of lower seat as shown 1 Strut lower seat W...

Page 157: ...ecurely Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft Recheck that stepped part of spring seat and spring end are in place to each other as described 1 Strut support cap 2 Strut nut 3 Strut lock wash...

Page 158: ...s 6 Remove caliper with carrier NOTE Hang removed caliper with a wire hook of the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with...

Page 159: ...ning Torque a 175 N m 17 5 kg m 126 5 lb ft 3 Install brake disc 4 Install brake caliper caliper carrier Tighten caliper carrier bolts to specified torque Tightening Torque b 95 N m 9 5 kg m 69 0 lb f...

Page 160: ...bolt 3 Ball stud lock nut 4 Control arm bolt 5 Control arm nut 6 Suspension control arm 6 Remove bushing Pull out bushing with special tool and hydraulic press as shown Special Tool F 09943 77910 1 Hy...

Page 161: ...n of bolt and nut NOTE Nut should not be tightened 1 Suspension arm Forward 4 Tighten compression rod stud nuts to specified torque Tightening Torque b 95 N m 9 5 kg m 69 0 lb ft 1 Compression rod 2 C...

Page 162: ...f each bolt is as shown Align knuckle bolt hole with ball stud groove as shown and install ball stud bolt Tighten each bolt and nuts to specified torque Use new ball stud nut Tightening Torque a 95 N...

Page 163: ...sor harness clamp 3 Suspension frame bolts Wheel side INSTALLATION 1 Install suspension frame and tighten suspension frame bolts to specified torque Tightening Torque a 95 N m 9 5 kg m 69 0 lb ft 2 In...

Page 164: ...Stabilizer bar mount bracket bolt 25 2 5 18 0 Stabilizer link nut 23 2 3 17 0 Stabilizer joint nut 50 5 0 36 5 Spindle nut 175 17 5 126 5 Brake caliper carrier bolt 95 9 5 69 0 Tie rod end nut 43 4 3...

Page 165: ...ENTS GENERAL DESCRIPTION 3E 2 DIAGNOSIS 3E 4 CHECK AND ADJUSTMENT 3E 4 Rear Shock Absorber Check 3E 4 Trailing Arm Lateral Rod Rear Axle and Coil Spring Check 3E 4 Leaf Spring and Spring Bumper Check...

Page 166: ...ed with the axle are installed to the body by using a bush so that axle moves up and down with the bush as its supporting point The shock absorber is installed between the body and axle to absorb up a...

Page 167: ...SUSPENSION 3E 3 1 Rear spring assy 2 Rear spring bumper 3 Spring shackle 4 Shock absorber 5 Spring shackle No 1 bushing 6 Spring shackle No 2 bushing 7 Spring U bolt 8 U bolt guide plate LEAF SPRING...

Page 168: ...XLE AND COIL SPRING CHECK Inspect for cracks deformation or damage Inspect bushing for damage wear or breakage Replace any defective part NOTE Bushing can not be replaced Replace lateral rod or traili...

Page 169: ...specified torque by referring to TIGHT ENING TORQUE SPECIFICATIONS of this section WHEEL DISC NUT BEARING CHECK Inspect each wheel disc for dents distortion and cracks A disc in badly damaged conditi...

Page 170: ...t 3 Tighten bolt and nuts to specified torque NOTE Tighten bolt and nuts with vehicle off hoist and in non loaded condition Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft b 80 N m 8 0 kg m 58 0 lb ft...

Page 171: ...ION Be careful not to let rear axle down too much It may cause damage to brake flexible hose 1 Coil spring 8 Remove coil spring INSTALLATION 1 Install coil spring with its closed end facing up and ope...

Page 172: ...ightening Torque a 80 N m 8 0 kg m 58 0 lb ft 1 Shock absorber 2 Lateral rod BUMP STOPPER AND SPRING UPPER SEAT COIL SPRING TYPE REMOVAL 1 Removal coil spring For details refer to steps 1 to 8 of COIL...

Page 173: ...pring center bolt in the hole of rear axle hous ing and spring bumper as shown in figure Tighten new spring U bolt nuts to specified torque NOTE Insert U bolt guide plate between rear axle housing and...

Page 174: ...from vehicle body and leaf spring 1 Spring shackle nuts 2 Spring shackle outer plate 3 Spring shackle 4 Vehicle body 5 Leaf spring 5 Remove spring shackle bushings 1 Spring shackle No 1 bushings 2 Spr...

Page 175: ...nd rear axle housing refer ring to figure for proper installing direction of bolts NOTE Nut and bolts should not be tightened 2 Install wheel speed sensor lead wire clamp if equipped 3 Connect parking...

Page 176: ...specification Tightening Torque a 25 N m 2 5 kg m 18 0 lb ft 2 Install lateral rod to vehicle body and rear axle housing refer ring to figure for proper installing direction NOTE Nut should not be tig...

Page 177: ...ent fluid from spilling 1 Wheel speed sensor 2 Brake pipe 3 Bleeder plug 6 Remove brake back plate bolts 1 Brake back plate bolts 7 Using special tools indicated draw out axle shaft with brake back pl...

Page 178: ...e move brake back plate Special Tool C 09927 18411 D 09921 57810 12 Remove stud bolts by using hydraulic press 1 Stud bolt 2 Hydraulic press INSTALLATION 1 Aligning serrations between new stud bolt s...

Page 179: ...s 4 Apply grease to axle shaft oil seal lip as shown A Grease 99000 25010 5 Apply sealant to mating surface of axle housing with brake back plate NOTE Make sure to remove old sealant before applying i...

Page 180: ...ke drum is free from dragging and proper braking is obtained 15 Perform brake test foot brake and parking brake For brake test see Section 5 16 Check each installed part for oil leakage REAR AXLE SHAF...

Page 181: ...support rear axle housing by using floor jack under axle housing 1 Jack 2 Axle housing 9 Remove lateral rod Coil spring type 1 Lateral rod 2 Left side mounting bolt and nut 3 Right side mounting nut 1...

Page 182: ...easurement a in figure is the same Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft 2 Install coil springs right left on spring seat of rear axle as shown in figure and then raise rear axle Coil spring...

Page 183: ...PV stay to axle housing for vehicle with LSPV 13 Lower hoist 14 Tighten trailing arm front and rear nuts coil spring type shock absorber lower nut to specified torque Tighten lateral rod nuts to speci...

Page 184: ...ut 16 1 6 12 0 Wheel nut 85 8 5 61 5 Spring front bolt 80 8 0 58 0 Spring shackle nut 55 5 5 40 0 Spring U bolt nut 60 6 0 43 5 Axle housing oil level plug 55 5 5 40 0 Axle housing oil drain plug 50 5...

Page 185: ...ng hammer 09943 17912 Brake drum remover 09913 75520 Bearing installer 09941 66010 Bump stopper wrench 1 09927 18411 Universal puller 2 09921 57810 Bearing remover 1 09944 96010 Bearing outer race rem...

Page 186: ...IFICATIONS 3F 7 GENERAL DESCRIPTION TIRES This vehicle is equipped with 155 R13C 6PR The tires are of tubeless type The tires are designed to operate satisfactorily with loads up to the full rated loa...

Page 187: ...l of improper size or type may af fect wheel and bearing life brake cooling speedometer odometer calibration ground clearance to the body and chassis To measure the wheel runout it is necessary to use...

Page 188: ...n D Corrective weights 1 Heavy spot wheel shimmy 2 Balance weights addition point 3 C L of spindle WHEELS AND TIRES 3F 3 GENERAL BALANCE PROCEDURE Deposits of mud etc must be cleaned from inside of ri...

Page 189: ...e replaced STUDS If a broken stud is found see Section 3E rear or Section 3D front for Note and Replacement procedure INFLATION OF TIRES The pressure recommended for any model is carefully calculated...

Page 190: ...should be referred to for tire information The placard lists the maxi mum load tire size and cold tire pressure where applicable TIRE ROTATION To equalize wear rotate tires periodically as shown in f...

Page 191: ...d in sequence and to proper torque to avoid bending wheel or brake drum or disc as in figure NOTE Before installing wheels remove any build up of corrosion on wheel mounting surface and brake drum or...

Page 192: ...e and inflate to proper pressure WARNING Do not stand over tire when inflating Bead may break when bead snaps over rim s safety hump and cause seri ous personal injury Do not exceed 350 kPa 50 psi pre...

Page 193: ...erential pinion through flanged connection and to the transmission output main shaft through a sliding spline joint The yoke of the front universal joint has its shank internally splined The splined e...

Page 194: ...ses because rhythm of chattering or rattling is in step with cruising speed Noise is pronounced particularly on standing start or in coasting condition when braking effect of engine is showing in the...

Page 195: ...t runout exceeds its limit replace Runout limit 0 7 mm 0 028 in INSTALLATION Install propeller shaft reversing removal procedure noting following points When installing propeller shaft align the match...

Page 196: ...4B 4 PROPELLER SHAFT REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUPER GREASE C 99000 25030 To apply to spline part of propeller shaft...

Page 197: ...ts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part...

Page 198: ...ble 5 28 Brake Pad 5 31 Caliper Assembly 5 33 Brake Disc 5 37 Brake Drum 5 38 Brake Shoe 5 40 Wheel Cylinder 5 41 Brake Back Plate 5 43 Master Cylinder Reservoir 5 45 Master Cylinder Assembly 5 46 Bra...

Page 199: ...r cylinder and rear wheels In brake system of this model the disc brake type is used of the front wheel brake and a drum brake type leading trailing shoes for the rear wheel brake The parking brake sy...

Page 200: ...action on the disc This clamping action forces the pads linings against the disc creating friction to stop the vehicle NOTE Lubricate parts as specified Do not use lubricated shop air on brake parts a...

Page 201: ...its to service this drum brake Lubricate parts as specified WARNING If any hydraulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlu...

Page 202: ...ts to service this master cylinder Lubricate rubber parts with clean fresh brake fluid to ease assembly Do no use lubricated shop air on brake parts as dam age to rubber components may result If any h...

Page 203: ...CAUTION The torque values specified are for dry unlubricated fasteners If any hydraulic component is re moved or brake line disconnected bleed the brake system A Brake pedal B Master cylinder 1 Boost...

Page 204: ...ar wheel brakes after prede termined pressure has been reached A in figure below And also it stops control of the rear brake pressure at the other predetermined pressure B in figure CAUTION Never disa...

Page 205: ...V assembly 3 From master cylinder Secondary 4 To rear wheel brakes Right and Left 5 From master cylinder Primary 6 Loaded 7 Empty CONSTRUCTION The LSPV components are grounded into 3 sections as follo...

Page 206: ...mble all hydraulic parts and wash with alcohol Dry these parts with compressed air before assembly to keep alcohol out of the system Replace all rubber parts in the sys tem including hoses Also when w...

Page 207: ...flate equally Repair or replace Adjust as prescribed Tires with approximately the same amount of tread should be used on the same axle Check for soft hoses and damaged lines Replace with new hoses and...

Page 208: ...springs in the brake Sluggish parking brake cables or linkage Wheel cylinder or caliper piston sticking Badly worn piston seal in the caliper Malfunctioning ABS Anti lock Brake Sys tem Maladjusted br...

Page 209: ...shorted to ground Release parking brake and check that brake warning light turns off Add brake fluid Investigate leaky point correct it and add brake fluid Repair circuit Brake warning light fails to...

Page 210: ...e between end of thread and brake pedal is specified Then tighten lock nut to specified torque Clearance a 1 5 2 0 mm 0 06 0 08 in Tightening Torque a 7 5 N m 0 75 kg m 5 5 lb ft EXCESSIVE PEDAL TRAVE...

Page 211: ...be replaced at the same time Thickness d Service limit 1 5 mm 0 06 in 1 Pad rim 2 Disc 3 Lining REAR BRAKE SHOE CHECK Inspection should be carried out on following points after brake pedal travel ped...

Page 212: ...eplaced or brake drum has been removed for some other service Adjustment is automatically accomplished by depressing brake pedal about 30 times with approximately 30kg 66 lbs load after all parts are...

Page 213: ...ver has been pulled up a few times with about 20 kg force Rear brake shoes are not worn beyond limit After confirming that above 5 conditions are all satisfied adjust parking brake lever stroke by loo...

Page 214: ...should accidentally touch painted surface immediately wipe fluid from paint and clean painted surface 1 Master cylinder 2 4 way joint 3 4 way cross joint 4 ABS actuator 5 LSPV 6 Blend proportion ing v...

Page 215: ...e cracks dents and corrosion If any de fect is found replace it BRAKE FLUID LEVEL CHECK Be sure to use particular brake fluid either as indicated on reservoir cap of that vehicle or recommended in own...

Page 216: ...veral times with the same load as in or dinary braking and observe pedal travel If pedal goes down deep at the first time but its travel decreases as it is depressed the second and more times air tigh...

Page 217: ...no change in pedal travel indicates malfunction Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed 2 Hold brake pedal depres...

Page 218: ...ol A without changing its attachment 1 Air bleeder plug 2 Weight 3 Attachment 2 Place weight about 90 130 kg 200 285 Ib slowly on rear floor axle housing center so that rear axle weight is measured as...

Page 219: ...lever 2 LSPV spring 3 LSPV stay 4 Disconnect brake pipe connecting between master cylinder and 4 way cross joint from master cylinder Attach plug special tool to master cylinder as shown in left fig u...

Page 220: ...rn conditions If it does at any point remove and correct Fill and maintain brake fluid level in reser voir Bleed brake system 4 Perform brake test and check installed part for fluid leakage 1 4 way jo...

Page 221: ...brake Right 10 To front brake Left 11 From B P valve to ABS actuator Primary 12 From B P valve to ABS actuator Secondary 13 To rear brake or LSPV 14 From 4 way cross joint to LSPV 15 E ring 16 Flexib...

Page 222: ...ever reuse protector nut once removed Be sure to use a new one Install clamps properly referring to figure below and tighten bolts When installing hose make sure that it has no twist or kink 1 Flexibl...

Page 223: ...actuator 10 From master cylinder Primary 11 From master cylinder Secondary 12 To wheel cylinder 13 Bleeder plug 14 Rear axle 15 Up side 16 Front side 17 Left side A For vehicle without ABS B For vehi...

Page 224: ...erformance 4 Install console box 1 Parking brake cable 2 Parking cable locking nut 3 Parking cable adjusting nut 4 Parking brake lever bolt 5 Parking brake lever assembly 6 Center member PARKING BRAKE...

Page 225: ...5 Cable stopper ring Insert cable to center mem ber until cable stopper ring fit certainly B 1 Clamp B 2 Stud blot insert direction B 3 Cable C 1 Cable end cover D 1 Equalizer F 1 Parking brake shoe...

Page 226: ...1 of PARK ING BRAKE LEVER INSTALLATION of this section Don t make lever adjustment at this point yet NOTE Above steps 1 to 3 must be performed on both right and left wheels 5 Clamp cable securely by r...

Page 227: ...mm 0 59 in Limit 6 5 mm 0 26 in NOTE When pads are removed visually inspect caliper for brake fluid leak Correct leaky point if any CAUTION Never polish pad lining with sandpaper If lining is pol ishe...

Page 228: ...center with dial gauge while rotating it Limit on disc deflection 0 15 mm 0 006 in Special Tool A 09900 20606 B 09900 20701 NOTE Check front wheel bearing for looseness before measure ment INSTALLATIO...

Page 229: ...ow out of flexible hose have a con tainer ready beforehand 1 Caliper 2 Caliper pin bolt 3 Disc DISASSEMBLY Before disassembly clean all around caliper with brake fluid 1 Blow compressed air into cylin...

Page 230: ...case replace rubber seal ASSEMBLY Reassemble front brake in reverse order of disassembly noting the following points Piston Seal 1 Replace with a new one at every overhaul Fit piston seal into groove...

Page 231: ...s Check to make sure that boot is fitted into boot groove in cylin der completely in its circumference 4 Insert piston into cylinder by hand and fit boot in boot groove in piston 5 To confirm that boo...

Page 232: ...e NOTE Make sure that boots are fit into groove securely Tightening Torque a 27 N m 2 7 kg m 19 5 lb ft 1 Caliper 2 Caliper pin bolt 3 Disc 3 Tighten union bolt to specified torque Tightening Torque b...

Page 233: ...off by using 8 mm bolts 2 pcs 1 8 mm bolt INSPECTION Refer to BRAKE PAD INSPECTION INSTALLATION NOTE See NOTE at the beginning of this section 1 Install disc to wheel hub 2 Install caliper assembly to...

Page 234: ...uring its inside diameter Brake drum ID Standard 220 mm 8 66 in Service limit 222 mm 8 74 in Whenever brake drums are removed they should be thoroughly cleaned and inspected for cracks scores deep gro...

Page 235: ...Before installing brake drum check outer diameter of brake shoes If it is not within value as specified below adjust it to specification by turning adjuster Outer diameter of brake shoes a 219 4 219...

Page 236: ...rning shoe hold down pins 3 Remove brake shoes 4 Disconnect parking brake shoe lever from parking brake cable 1 Shoe hold down pins 2 Shoe hold down springs 3 Shoe return lower spring 4 Shoe return up...

Page 237: ...wn in figure 1 Apply rubber grease 2 Install shoe hold down springs by pushing them down in place and turning hold down pins 3 Install shoe return spring adjuster lever and adjuster spring 4 For proce...

Page 238: ...cylinder Then take off bleeder plug cap from brake pipe and connect pipe to wheel cylinder just enough to prevent fluid from leaking A Sealant 99000 31090 2 Tighten wheel cylinder to brake back plate...

Page 239: ...gging and proper braking is obtained Then remove vehicle from hoist and perform brake test foot brake and parking brake 12 Check each installed part for oil leakage BRAKE BACK PLATE REMOVAL 1 Perform...

Page 240: ...0 Install brake drum Refer to steps 1 to 2 of BRAKE DRUM INSTALLATION 11 Refill differential housing with new specified gear oil Refer to MAINTENANCE SERVICE in Section 7F for refill 12 Fill reservoir...

Page 241: ...reservoir 5 Remove reservoir bracket nuts 6 Remove reservoir with reservoir bracket INSTALLATION 1 Install reservoir and tighten nuts to specified torque Tightening Torque a 11N m 1 1 kg m 8 0 Ib ft 2...

Page 242: ...per bolt 11 Master cylinder body 12 O ring A with ABS B without ABS REMOVAL 1 Clean around reservoir cap and take out fluid with syringe or such 2 Disconnect fuse box from steering support member 3 Di...

Page 243: ...grommets 1 Connector 2 Pin 3 Grommets 3 Remove circlip 1 Circlip 2 Master cylinder 4 Remove primary piston Remove piston stopper bolt Then remove secondary piston by blowing compressed air into hole f...

Page 244: ...LY CAUTION Never use any mineral oil such as kerosene oil and gasoline when washing and assembling parts Check inside of cylinder wall pistons and cup seals are free from any foreign objects such as d...

Page 245: ...iston rod length with special tool Refer to BRAKE BOOSTER INSPECTION AND ADJUSTMENT 1 Install master cylinder as shown and torque attaching nuts to specification Tightening Torque a 13 N m 1 3 kg m 9...

Page 246: ...m clutch pedal arm 1 Stop light switch coupler 2 4 way joint 3 Brake pipes 4 Vacuum hose No 1 5 Steering lower shaft 6 Vacuum pipe 7 Remove steering lower shaft refer to Section 3C 8 Remove pedal brac...

Page 247: ...earance a between piston rod end and master cylinder piston 1 Booster piston rod 2 Master cylinder piston Before measuring clearance push piston rod several times so as to make sure reaction disc is i...

Page 248: ...ed torque Tightening Torque b 25 N m 2 5 kg m 18 5 lb ft 4 Connect clutch cable to clutch pedal arm refer to CLUTCH CABLE INSTALLATION of Section 7C 5 Install vacuum pipe with vacuum hose No 1 and con...

Page 249: ...ervoir cap and take out fluid with syringe or such 2 Hoist vehicle 3 Disconnect brake pipes from LSPV 4 Remove LSPV assembly with LSPV stay 5 Remove spring from LSPV lever CAUTION Nuts of LSPV assembl...

Page 250: ...75 kg m 5 5 lb ft 3 Upon completion of installation fill reservoir tank with specified fluid and bleed air from brake system NOTE Make sure to bleed air from LSPV bleeder without fail 4 After bleeding...

Page 251: ...3 Spring length L should be as specified below Spring length L 299 mm 11 77 in Van 291 mm 11 46 in Track NOTE Don t depress brake pedal when measuring spring length If it isn t adjust it to specificat...

Page 252: ...mble B P valve assembly If it is found faulty replace it with new one 1 A C hoses if equipped 2 B P valve INSTALLATION 1 Install B P valve Tightening Torque a 16 N m 1 6 kg m 12 0 lb ft 2 Tighten flar...

Page 253: ...8 0 Brake bleeder lug Rear cylinder LSPV 7 5 0 75 5 5 Wheel nut 85 8 5 61 5 Wheel cylinder bolt 9 0 9 6 5 Parking brake lever bolt 23 2 3 17 0 LSPV bolt 23 2 3 17 0 LSPV nut 23 2 3 17 0 REQUIRED SERVI...

Page 254: ...1 Pin remover 09956 02210 Brake circuit plug 09950 78210 Flare nut wrench 10 mm 09956 02310 Fluid pressure gauge 09952 16010 Booster piston rod adjuster 09900 20606 Dial gauge 09900 20701 Magnetic sta...

Page 255: ...use a re placement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may re...

Page 256: ...ponent ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to each wheel cylinder based on signal from each wheel speed sensor so as to prevent whee...

Page 257: ...ING For LH Steering Vehicle For RH Steering Vehicle 1 Brake master cylinder 2 Proportioning valve 3 Front disk brake 4 ABS hydraulic unit control module assembly 5 Rear drum brake ANTILOCK BRAKE SYSTE...

Page 258: ...ABS pump motor relay 11 ABS fail safe relay Solenoid valve relay 12 ABS hydraulic unit 13 ABS warning lamp 14 ABS warning circuit lamp driver module 15 Proportioning valve Wheel speed sensor RF Wheel...

Page 259: ...t that means nothing abnormal 4 When an abnormality in the system is detected ABS warning lamp lights and the area where that abnormality lies is stored in the memory in ABS control module 5 When Diag...

Page 260: ...vehicle was driven with brake dragging The vehicle was stuck in mud sand etc Wheel spin occurred while driving Wheel s was rotated while vehicle was jacked up Be sure to read Precautions for Electroni...

Page 261: ...diagnostic trouble code table in this section Then perform fi nal confirmation test after cleared diagnostic trouble code Does trouble recur Go to Step 7 END 5 Inspect and repair referring to DIAGNOSI...

Page 262: ...noise while vehicle is running from motor from valve other Wheel is locked at braking Pump motor does not stop running Braking does not work Other Frequency of occurrence Continuous Intermittent time...

Page 263: ...symptom such as abnormal lighting of ABS warning light exists If the malfunction DTC is confirmed again at ignition switch ON driving test as described in above is not neces sary Proceed to Step 3 3...

Page 264: ...t diag switch terminal of diagnosis connector to ground 2 Turn ignition switch ON 3 Read flashing of ABS warning lamp which represents DTC as shown in example below and write it down When more than 2...

Page 265: ...ire connect diag switch terminal of diag con nector to diag ground terminal 3 With connection described in above step 2 maintained turn ignition switch ON 4 Repeat on off operation of service wire at...

Page 266: ...Left front 26 Left front Wheel speed sensor circuit and rotor 31 Right rear Wheel speed sensor circuit and rotor 32 Right rear 35 Left rear 36 Left rear 41 Right 42 g front 45 Left Solenoid in hydrau...

Page 267: ...SYSTEM CIRCUIT ANTILOCK BRAKE SYSTEM ABS OPTIONAL 5E 13...

Page 268: ...ar wheel speed sensor 8 Left rear wheel speed sensor 9 Right front wheel speed sensor 10 Left front wheel speed sensor 11 Data link connector 12 Diagnosis connector 13 Stop lamp 14 Stop lamp switch 15...

Page 269: ...condition ABS control module turns ABS warning lamp ON at the ignition switch ON keeps it ON for 2 seconds only and then turns it OFF If an abnormality in the system is detected the lamp is turned ON...

Page 270: ...er connection to ABS hydraulic unit control module connector at terminals A17 A25 and A10 3 If OK then ignition switch ON and measure voltage at terminal A25 of connector Is it 10 14 V Go to step 4 B...

Page 271: ...point although a history malfunction DTC is stored in memory NOTE If ABS hydraulic unit control module assembly has been replaced by a new one ABS warning lamp may flash when ignition switch is turne...

Page 272: ...terminal by service wire properly Go to step 2 Connect service wire securely 2 1 Disconnect service wire 2 Disconnect ABS hydraulic unit control module connector See Fig 1 3 Measure resistance betwee...

Page 273: ...t fuse for ABS 4 Left front wheel speed sensor rotor 5 Right front wheel speed sensor rotor 6 Left rear wheel speed sensor rotor 7 Right rear wheel speed sensor rotor 8 ABS hydraulic unit control modu...

Page 274: ...n repair or replace 3 1 Install each speed sensor to each knuckle and or axle housing 2 Tighten each sensor bolt to specified torque Is there any clearance between sensor and knuckle or axle housing S...

Page 275: ...ion switch is ON When the voltage is not within the specified range applicable DTC will be set Also when no sensor signal is inputted at starting or while running applicable DTC will be set NOTE When...

Page 276: ...n sensor positive terminal and negative terminal of module connector between positive terminal and body ground Are measured resistance values within each specified range described in above step 1 Go t...

Page 277: ...ANTILOCK BRAKE SYSTEM ABS OPTIONAL 5E 23 Fig 1 Fig 2 Fig 3 Fig 5 Fig 4 1 ABS hydraulic unit control module connector...

Page 278: ...e with solenoid turned OFF INSPECTION STEP ACTION YES NO 1 1 Check solenoid operation referring to item ABS HYDRAULIC UNIT OPERATION CHECK in this section Is it in good condition Check terminals A11 a...

Page 279: ...as the voltage rises to the specified level the set DTC will be cleared INSPECTION STEP ACTION YES NO 1 Check battery voltage Is it about 11 V or higher Go to step 2 Check charging system referring t...

Page 280: ...o item ABS HYDRAULIC UNIT OPERATION CHECK in this section Is it in good condition Check terminals A11 and A27 connection If connections OK substitute a known good ABS hydraulic unit control module ass...

Page 281: ...tage at all solenoid circuit terminals is low with ignition switch turned ON and ABS not operated this DTC will be set INSPECTION STEP ACTION YES NO 1 Check battery voltage Is it about 11 V or higher...

Page 282: ...l fault is detected in ABS control module INSPECTION STEP ACTION YES NO 1 1 Ignition switch OFF 2 Disconnect connectors from ABS control module 3 Check for proper connection to ABS control module at a...

Page 283: ...onnector DLC ABS HYDRAULIC UNIT OPERATION CHECK NOT USING SUZUKI SCAN TOOL 1 Check that basic brake system other than ABS is in good condition 2 Check that battery voltage is 11V or higher 3 With ABS...

Page 284: ...all 4 wheels are checked If a faulty condition is found in Steps 9 and 10 replace hy draulic unit control module assembly 11 Turn ignition switch OFF and remove service wire from diag nosis connector...

Page 285: ...et CAUTION Do not give an impact to hydraulic unit Use care not to allow dust to enter hydraulic unit Do not place hydraulic unit on its side or upside down Handling it in inappropriate way will affec...

Page 286: ...r second 100 mV or more If measured voltage is not as specified check sensor rotor and their installation conditions 1 Wheel speed sensor connector 2 Rotate by hand Reference When using oscilloscope f...

Page 287: ...sor coupler SENSOR INSPECTION Check sensor for damage Check sensor for resistance and continuity Between both terminals of sensor 1 2 1 6 k at 205C 685F Between sensor terminal and sensor body No cont...

Page 288: ...ck sensor ring for being deformed warped Check that no foreign material is attached If any malcondition is found repair or replace 1 Sensor ring INSTALLATION NOTE Do not reuse reinstall removed sensor...

Page 289: ...C voltage at 1 to 1 1 3 rotation per second 100 mV or more If measured voltage is not as specified check sensor rotor and their installation conditions 1 Wheel speed sensor connector 2 Rotate by hand...

Page 290: ...NSOR INSPECTION Check sensor for damage Check sensor for resistance and continuity Between both terminals of sensor 1 4 1 8 k at 205C 685F Between sensor terminal and sensor body No continuity If the...

Page 291: ...ION Check ring serration teeth for being missing damaged or de formed Check sensor ring for being deformed warped Check that no foreign material is attached If any malcondition is found repair or repl...

Page 292: ...olt 11 1 1 8 0 Rear wheel speed sensor bolt 10 1 0 7 2 Rear wheel speed sensor harness clamp bolt 2 5 0 25 1 8 SPECIAL TOOLS 09913 61510 Bearing puller 09913 85230 Differential gear side bearing remov...

Page 293: ...ponents or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in severe injury T...

Page 294: ...to friction areas during assembly to protect and lubricate the surfaces on initial operation Whenever valve train components pistons piston rings con necting rods rod bearings and crankshaft journal...

Page 295: ...hen disconnecting couplers don t pull wire harness but make sure to hold coupler itself With lock type coupler be sure to un lock before disconnection Attempt to disconnect coupler with out unlocking...

Page 296: ...iagnostic System in Section 6E PRECAUTION IN DIAGNOSING TROUBLES Be sure to read Precaution in Diagnosing Troubles in Section 6E and observe what is written there 6 4 ENGINE ENGINE DIAGNOSIS This vehi...

Page 297: ...ction Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Record of DTC 1 Recheck for DTC Refer to DTC Check in Section 6E Is there any DTC s Go to Step 9 Go to Step 8 7 Recheckin...

Page 298: ...Other j Other j OTHERS VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Temperature Frequency Road j Fair j Cloudy j Rain j Snow j Always j Other j Hot j Warm j Coo...

Page 299: ...engine INSPECTION ITEM REFERRING Section Engine oil level leakage Engine coolant level leakage Fuel level leakage Air cleaner element dirt clogging Battery fluid level corrosion of terminal Water pum...

Page 300: ...engine start Go to Step 5 Go to Step 7 5 Check engine idle speed IAC duty Refer to Idle Speed IAC Duty Inspection in Section 6E Is check result as specified Go to Step 6 Go to DIAG Flow Table B 4 in...

Page 301: ...lty ECT sensor TP sensor CKP sensor CMP sensor or MAP sensor Faulty EGR system Fuel pressure out of specification Faulty fuel injector Faulty ECM Malfunctioning PCV system Low compression Improper val...

Page 302: ...d Diagnosis in Section 5 Diagnosis in Section 7C Improper engine idling or engine fails to idle Ignition system out of order Faulty ignition coil or high tension cord Engine overheating Engine and emi...

Page 303: ...ignition coil or high tension cord Engine and emission control system out of order D Variable fuel pressure D Faulty EGR system if equipped D Faulty MAP sensor D Faulty injector D Faulty ECM Diagnosis...

Page 304: ...n 5 Diagnosis in Section 7C Cylinder head inspection in Section 6A Poor gasoline mileage Ignition system out of order Faulty ignition coil or high tension cord Engine and emission control system out o...

Page 305: ...mechanical noise make sure that Ignition timing is properly adjusted Specified spark plug is used Specified fuel is used Valve noise Improper valve lash Worn valve stem and guide Weak or broken valve...

Page 306: ...ol system check in Section 6E Check oxygen sensor output voltage Refer to DTC No 14 Heated Oxygen Sensor Circuit in Section 6E Idle mixture adjustment in Section 6E Fuel injector injection volume insp...

Page 307: ...must be started at least 90 seconds after the ignition switch is turned to the LOCK position and negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy...

Page 308: ...amshaft valve mechanism ar ranged for V type valve configuration and 16 valves IN 2 and EX 2 one cylinder The single overhead camshaft is mounted over the cylinder head it is driven from crankshaft th...

Page 309: ...y means of intersecting pas sages drilled in crankshaft and then injected from a small hole provided on big end of connecting rod to lu bricate piston rings and cylinder wall In another path oil goes...

Page 310: ...et parking brake and block drive wheels 3 Disconnect fuel injector wire harness connector 4 Remove ignition coil assemblies and all spark plugs referring to section 6F 5 Install special tool Compressi...

Page 311: ...eutral shift selector lever to P range for A T model and set parking brake and block drive wheels 2 With engine stopped disconnect fuel pressure regulator vacu um hose from intake manifold and connect...

Page 312: ...il pressure switch from cylinder block 2 Install special tool Oil pressure gauge to vacated threaded hole Special Tool A 09915 77310 B 09915 78211 3 Set engine tachometer 4 Start engine and warm it up...

Page 313: ...gnition timing inspection plug from clutch housing of transmission case 4 Turn crankshaft clockwise viewing from crankshaft pulley side to the extent that line below T mark punched on flywheel is alig...

Page 314: ...ter checking and adjusting valve lashes at valves 1 2 5 and 7 or 3 4 6 and 8 rotate crankshaft exactly one full turn 360_ and check the same at valves 3 4 6 and 8 or 1 2 5 and 7 Adjust them as necessa...

Page 315: ...ive battery cables at bat tery terminal and remove battery 2 Remove ignition coil assemblies with high tension cord 3 Disconnect PCV valve and breather hose from head cover 4 Remove cylinder head cove...

Page 316: ...8 0 lb ft NOTE When installing cylinder head cover use care so that cylin der head cover gasket or O rings will not get out of place or fall off 3 Install ignition coil assemblies with high tension co...

Page 317: ...ble at battery and remove engine room center member with shift control and parking brake lever WARNING To help avoid danger of being burned do not remove drain plug and radiator cap while engine and r...

Page 318: ...se wire harness from clamp 6 Disconnect accelerator cable from throttle body 7 Disconnect following hoses Brake booster hose from intake manifold Canister purge hose from EVAP canister purge valve Hea...

Page 319: ...TROL INSTALLATION in Section 7A Connect parking brake cable to parking brake lever and perform parking brake adjustment by referring PARKING BRAKE IN SPECTION AND ADJUSTMENT in Section 5 Adjust accele...

Page 320: ...3 Exhaust pipe INSTALLATION 1 Install new gasket to cylinder head 2 Install exhaust manifold Tighten bolts and nuts to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 3 Install pipe g...

Page 321: ...ect negative cable at battery 2 Drain engine coolant and remove water hoses and brake boost er hose from water hose bracket 3 Remove generator belt and A C compressor belt if equipped 1 Drive belt 2 C...

Page 322: ...Spring 1 Camshaft allowable turning range By timing mark within 90_ from V mark on head cover on both right and left 2 Crankshaft allowable turning range By punch mark within 90_ from arrow mark on oi...

Page 323: ...late again and reinsert plate lug into tensioner hole 1 Tensioner bolt 2 Tensioner 3 Tensioner plate 3 Check that timing mark on camshaft timing belt pulley is aligned with V mark on cylinder head cov...

Page 324: ...t turn crankshaft two rotations clockwise after installing it After making sure that belt is free from slack tighten tensioner stud first and then tensioner bolt to each specified torque Then confirm...

Page 325: ...its belt tension referring to Section 1B 11 Connect brake booster hose and water hoses to intake man ifold thermostat cap and water floor pipe clamp them secure ly 12 Refill cooling system and bleed a...

Page 326: ...oil pan 1 Drain engine oil by removing drain plug 2 Remove lower oil pan 1 Lower oil pan 2 Drain plug 3 Upper oil pan 3 Remove engine and transmission stiffener 1 Stiffener 2 Upper oil pan 3 Clutch ca...

Page 327: ...ces and oil pan inside Clean oil pump strainer screen INSTALLATION 1 Install oil pump strainer Install seal in such position as shown in figure Tighten strainer bolt first and then bracket bolt to spe...

Page 328: ...run in securing bolts and start tightening at the center move wrench outward tightening one bolt at a time Install oil level gauge guide if it was removed Tighten bolts and nuts to specified torque T...

Page 329: ...egative cable at battery 2 Remove timing belt as previously outlined 3 Remove crankshaft timing belt pulley 1 Pulley bolt 2 Crank timing belt pulley 4 Remove oil pan and oil pump strainer as previousl...

Page 330: ...ss gauge If clearance exceeds its limit replace outer rotor or case Limit on radial clearance between outer rotor and case 0 310 mm 0 0122 in 1 Outer rotor 2 Inner rotor Side clearance Using straight...

Page 331: ...mp bolts refer to figure for their cor rect use and tighten them to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 1 No 1 bolts short 2 No 2 bolts long 4 Install rubber seal between oi...

Page 332: ...ing to BELT TENSION INSPECTION in Section 6H 9 Adjust A C compressor belt tension if equipped Refer to Sec tion 0B 10 Refill engine with engine oil referring to item ENGINE OIL CHANGE in Section 0B 11...

Page 333: ...ove battery 2 Drain coolant 3 Remove water hoses and timing belt as previously outlined 4 Remove camshaft timing belt pulley by using special tool Special Tool A 09917 68221 5 Remove cylinder head cov...

Page 334: ...ug 2 Timing belt inside cover 10 Remove intake rocker arm with clip from rocker arm shaft NOTE Do not bend clip when removing intake rocker arm 1 Rocker arm IN 2 Clip 3 Rocker arm shaft 11 Remove rock...

Page 335: ...nd dial gauge check runout If runout exceeds its limit replace rocker arm shaft Runout limit 0 20 mm 0 008 in Rocker Arm to Rocker Arm Shaft Clearance Using a micrometer and a bore gauge measure rocke...

Page 336: ...housing Check clearance by using gaging plastic The procedure is as follows 1 Clean housing and camshaft journals 2 Install camshaft to cylinder head 3 Place a piece of gaging plastic the full width o...

Page 337: ...ON 1 Apply engine oil to rocker arm shaft and rocker arms 2 Install rocker arm shaft rocker arm exhaust side and rocker arm spring 1 Rocker arm spring 2 Rocker arm EX No 1 3 Rocker arm EX No 2 3 Insta...

Page 338: ...ten them to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 7 Fill small amount of engine oil into arm pivot holding part of rock er arm shaft Install rocker arm intake side with clips...

Page 339: ...e as in dicated in figure Tighten a little at a time and evenly among bolts and repeat tightening sequence three to four times before they are tightened to specified torque Tightening Torque a 11 N m...

Page 340: ...ust valve clearance as previously outlined 15 Install cylinder head cover 16 Refill cooling system and bleed air from system referring to Section 6B 17 Adjust generator belt tension referring to BELT...

Page 341: ...cording to fuel pressure relief proce dure described in section 6 2 Disconnect cables at battery and remove battery 3 Release front seat lock handle and raise front seats then re move engine room cent...

Page 342: ...witch MAP sensor and then release wire harnesses from clamps 7 Disconnect following hoses Canister purge hose from EVAP canister purge valve Radiator inlet hose and reservoir hose from thermostat cap...

Page 343: ...Remove exhaust manifold as previously outlined 13 Loosen cylinder head bolts in such order as indicated in figure and remove them 14 Check all around cylinder head for any other parts required to be...

Page 344: ...e from combustion chamber side 1 Valve cotters 5 Remove valve stem oil seal from valve guide and then valve spring seat NOTE Do not reuse oil seal once disassembled Be sure to use new oil seal when as...

Page 345: ...ves D Inspect each valve for wear burn or distortion at its face and stem and as necessary replace it D Measure thickness of valve head If measured thickness ex ceeds limit replace valve 1 Valve head...

Page 346: ...ern on each valve in the usual manner i e by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head Valve lapper tool used in valve lapping must be used P...

Page 347: ...1 Valve seat cutter 2 INTAKE VALVE SEAT Cutting sequence is the same as for exhaust valve seats Seat width for intake valve seat 1 1 1 3 mm 0 0433 0 0512 in 3 VALVE LAPPING Lap valve on seat in two s...

Page 348: ...off high spots Should this fail to reduce thickness gauge readings to within limit replace cylinder head Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface s...

Page 349: ...essure Spring squareness Use a square and surface plate to check each spring for square ness in terms of clearance between end of valve spring and square Valve springs found to exhibit a larger cleara...

Page 350: ...ial tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrudes by 11 5 mm 0 45 in from cylinder head Special Tool C 09916 56011 D 09916 58210 NOTE Do not r...

Page 351: ...by hand Tapping or hitting special tool may cause damage to seal 1 Valve stem seal 6 Install valve to valve guide Before installing valve to valve guide apply engine oil to stem seal valve guide bore...

Page 352: ...that oil jet venturi plug is installed and if it is that it is not clogged When installing it be sure to tighten to specified torque Tightening Torque a 5 N m 0 5 kg m 4 0 lb ft 3 Apply engine oil to...

Page 353: ...reinstalled 10 Refill cooling system and bleed air from system referring to Section 6B 11 Install battery and connect cables at battery 12 Verify that there is no fuel leakage coolant leakage and ex h...

Page 354: ...oil pump strainer as previously outlined 4 Mark cylinder number on all pistons connecting rods and rod bearing caps using silver pencil or quick drying paint 5 Remove rod bearing caps 6 Install guide...

Page 355: ...rings Top and 2nd and oil ring from piston 2 Remove piston pin from connecting rod Ease out piston pin circlips as shown 1 Piston pin circlip Force piston pin out CLEANING Clean carbon from piston hea...

Page 356: ...Cylinder bore dia limit 74 15 mm 2 9196 in Taper and out of round limit 0 10 mm 0 0039 in NOTE If any one of four cylinders has to be rebored rebore all four to the same next oversize This is necessar...

Page 357: ...is out of specification replace piston Ring groove clearance Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in 1 Piston ring 2 Thickness gauge Piston Pin Check piston pin connecting...

Page 358: ...ted to its crank pin in the normal manner If measured clearance is found to exceed its limit replace con necting rod Connecting rod alignment Mount connecting rod on aligner to check it for bow and tw...

Page 359: ...ated in figure but standard size one has no number Rod bearing clearance 1 Before checking bearing clearance clean bearing and crank pin 2 Install bearing in connecting rod and bearing cap 3 Place a p...

Page 360: ...hin above standard value Finished crankpin dia Measured big end bore dia including undersize bearing 0 035 mm 0 0014 in ASSEMBLY NOTE Two sizes of piston are available as standard size spare part so a...

Page 361: ...piston As indicated in figure at the left 1st and 2nd rings have RN T or R mark respectively When installing these piston rings to piston direct marked side of each ring toward top of piston 1st ring...

Page 362: ...r on piston head to crank shaft pulley side 1 Crankshaft pulley side 2 Flywheel side 4 Install piston and connecting rod assembly into cylinder bore Use special tool Piston ring compressor to compress...

Page 363: ...k to ensure that all removed parts are back in place Rein stall any necessary parts which have not been reinstalled 12 Refill engine with engine oil referring to item ENGINE OIL CHANGE in Section 0B 1...

Page 364: ...e air intake hose 7 Disconnect following electric wires Ground wires from intake manifold exhaust manifold and transmission Camshaft position sensor EGR valve if equipped EVAP canister purge valve Eng...

Page 365: ...h hose is con nected 10 Disconnect accelerator cable from throttle body and each clamp 11 Remove generator 12 With hose connected detach A C compressor and bracket from cylinder block if equipped NOTE...

Page 366: ...ansmission recheck to make sure all hoses electric wires and cables are disconnected from engine and transmission 21 Remove engine with transmission from body 22 Remove transmission stiffener and sepa...

Page 367: ...t parking brake cable to parking brake lever Perform parking brake adjustment refer to PARKING BRAKE IN SPECTION AND ADJUSTMENT in Section 5 10 Adjust accelerator cable play Refer to Section 6E 11 Che...

Page 368: ...Cap bolt 6 Timing pulley key 7 Crankshaft 8 Thrust bearing 9 Rear oil seal 10 Pin 11 Oil seal housing gasket 12 Oil seal housing 13 Housing bolt 14 Input shaft bearing 15 Flywheel 16 Flywheel bolt 6A...

Page 369: ...y timing belt and crankshaft timing pulley 4 Remove cylinder head assembly 5 Remove upper oil pan with lower oil pan and oil pump strainer 6 Remove oil pump 1 Oil pump 2 Bolt 7 Remove oil seal housing...

Page 370: ...ndard one or oversize one to obtain standard thrust play Out of round and taper uneven wear of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or a...

Page 371: ...ghten cap bolts to specified torque Inspection Check bearings for pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Never replace one half without repla...

Page 372: ...k journal diameter by using following procedure As shown in figure crank webs of No 2 and No 3 cylinders have five stamped numerals Three kinds of numerals 1 2 and 3 represent following journal diamet...

Page 373: ...tes that cap bore dia of cap 5 is within 49 000 49 006 mm 3 There are five kinds fo standard bearings differing in thickness To distinguish them they are painted in following colors at the position as...

Page 374: ...ected standard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block due to any reason select new standard bearings...

Page 375: ...referring to table given below Check bearing clearance with newly selected undersize bearing Green Red Black Red Red only Black Red Red only Yellow Red Red only Yellow Red Blue Red A B C Measured jou...

Page 376: ...g or reboring cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear 3 Using micrometer m...

Page 377: ...connecting rods rod bear ings rod bearing caps pistons and piston rings are in com bination sets Do not disturb such combination and make sure that each part goes back to where it came from when insta...

Page 378: ...8 lb ft torque or below 5 Install new gasket and oil seal housing Do not reuse gasket removed in disassembly Apply engine oil to oil seal lip before installation Tighten housing bolts to specifi cati...

Page 379: ...lined and loosen them once till tightening torque becomes zero And then torque them to specifi cation again 11 Install camshaft crankshaft timing belt pulley timing belt crankshaft pulley water pump p...

Page 380: ...1 8 0 Oil pan bolts and nuts 11 1 1 8 0 Oil pan drain plug 35 3 5 25 5 Oil pump rotor plate screws 11 1 1 8 0 Oil pump case bolts 11 1 1 8 0 Crankshaft timing belt pulley bolt 130 13 0 94 0 Camshaft...

Page 381: ...attachment 1 09916 14510 Valve lifter 2 09916 14910 Valve lifter attachment 09916 34542 Reamer handle 09916 34550 Reamer 5 5 mm 09916 38210 Reamer 11 mm 09916 44910 Valve guide remover 09916 56011 Val...

Page 382: ...Vinyl resin REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND NO 1207C 99000 31150 Mating surfaces of cylinder block and oil pan Sealant SUZUKI BOND NO 1215 99000...

Page 383: ...6B 3 MAINTENANCE 6B 4 Coolant 6B 4 Coolant Level 6B 5 Cooling System Service 6B 5 Cooling System Flush and Refill 6B 6 Water Pump Belt Tension 6B 7 ON VEHICLE SERVICE 6B 8 Cooling System Draining 6B 8...

Page 384: ...closed coolant circulates as follows Water pump Cylinder block Cylinder head Intake manifold Radiator outlet way Throttle body Heater 2 When coolant is warmed up to normal temperature and the thermost...

Page 385: ...emp gauge is located at intake manifold This gauge acti vates a water temp meter in the instrument cluster 1 ECT sensor 2 Generator 3 Intake manifold ENGINE COOLING 6B 3 DIAGNOSIS Condition Possible C...

Page 386: ...because of coolant loss or to provide added protection against freezing at temperature lower than 36 C 33 F NOTE Alcohol or methanol base coolant or plain water alone should not be used in cooling sys...

Page 387: ...oir cap align arrow marks on reser voir and cap WARNING To help avoid danger of being burned do not remove reservoir tank cap while coolant is boiling and do not remove radiator cap while engine and r...

Page 388: ...YSTEM FLUSH AND REFILL 1 Remove radiator cap when engine is cool Turn cap counterclockwise slowly until it reaches a stop Do not press down while turning it Wait until pressure is relieved indicated b...

Page 389: ...at the ear of cap lines is parallel to radiator Add coolant to reservoir when engine cold 13 Repeat step 8 to 12 accordingly when air is still in cooling sys tem 1 Thermostat cap bleeder bolt 2 Thermo...

Page 390: ...m Refer to Item COOLANT of MAINTE NANCE 1 Radiator 2 Radiator drain plug COOLING WATER PIPES OR HOSES 1 Intake manifold 2 Thermostat 3 Heater core 4 Reservoir tank 5 Radiator 6 To throttle body REMOVA...

Page 391: ...ee from foreign matters which would prevent valve from seating tight 3 Check thermostat seal for breakage deterioration or any other damage 1 Air bleed valve 2 Thermostat seal 4 Check thermostatic mov...

Page 392: ...generator adjusting arm reinforcement 4 Install engine room center member 5 Fill cooling system refer to page 6B 6 6B 7 6 After installation check each part for leakage WATER PUMP BELT For removal ins...

Page 393: ...e Section 9 1 Radiator 2 Radiator drain plug 1 Bolt 2 Radiator upper bracket 5 Disconnect radiator inlet and outlet hoses and reservoir tank hose from radiator 6 Remove radiator upper bracket bolts 7...

Page 394: ...y and pump drive belt When servicing vehicle equipped with A C remove compressor drive belt before removing water pump drive belt 6 Remove timing belt and tensioner according to procedure de scribed i...

Page 395: ...e equipped with A C adjust A C drive belt referring to Section 0B 7 Connect negative cable at battery 8 Fill cooling system 9 Install engine room center member then perform parking brake adjustment re...

Page 396: ...w WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in severe injury Technical service work must be star...

Page 397: ...never servicing fuel pump as sembly fuel tank must be removed from vehicle 1 Fuel tank 2 Fuel pump assembly 6C 2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM Main components of fuel system are fuel tan...

Page 398: ...pressure of fuel tank constant to prevent fuel from blowing out and fuel tank from being deformed Relief valve is provided to prevent discharged pressure in fuel tank from rising excessively and 2 wa...

Page 399: ...ped loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected Before loosening or disconnecting fuel feed line make sure to relieve f...

Page 400: ...t battery 3 Remove ABS hydraulic unit if equipped with ABS 4 Remove air cleaner case 5 Disconnect fuel pipe joint and fuel hose from fuel pipe at the front and rear of each fuel pipe For quick joint d...

Page 401: ...are connected securely or fuel leak may oc cur When connecting hoses to rear end of pipes se cure them with clamps referring to 6C 4 And for hoses to front end of pipes refer to Engine sec tion 4 Inst...

Page 402: ...er 2 Fuel tank 6 Disconnect fuel filler hose from filler neck breather hose from tank 1 Fuel filler hose 2 Breather hose 3 Fuel filler neck 4 Fuel tank 5 Due to absence of fuel tank drain plug drain f...

Page 403: ...ressed air 8 Support fuel tank with jack and remove 4 bolts 9 Remove fuel tank from vehicle 1 Fuel tank 2 Jack 10 Disconnect fuel tank filler hose from fuel tank and drain fuel from fuel tank as follo...

Page 404: ...s and pipes connected to fuel tank for leaks loose connections deterioration or damage Also check fuel pump assembly gaskets for leaks visually inspect fuel tank for leaks and damage Replace any damag...

Page 405: ...securely or fuel leak may occur 3 Install fuel tank to vehicle Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 1 Joint 2 Fuel return hose 3 Fuel feed hose 4 Fuel vapor hose 5 Fuel tank 6 Bolt 4 Connec...

Page 406: ...this section REMOVAL 1 Remove fuel tank from vehicle Refer to FUEL TANK RE MOVAL in this section 2 Remove fuel pump assembly from fuel tank 1 Fuel pump assembly INSPECTION Check fuel pump assembly for...

Page 407: ...liding it in the arrow direction CAUTION While removing fuel level gauge do not contact resis tor plate or deform arm It may cause fuel level gauge to fail 1 Snap fit part 2 Float arm 3 Remove bracket...

Page 408: ...ening its snap fit parts REASSEMBLY NOTE Use of new parts is recommended for all parts other than fuel pump and fuel level gauge Also be sure to use new grommets or oil leakage may occur 1 Install lea...

Page 409: ...et sub assembly 2 Lug 3 Housing 7 Install fuel level gauge to housing Fit protrusion of fuel level gauge in groove in housing and slide it up till lug fits in window securely 8 Connect fuel level gaug...

Page 410: ...INSTALLATION in this section 09919 47020 Quick joint remover ENGINE FUEL 6C 15 TIGHTENING TORQUE SPECIFICATION Fastening parts Tightening torque Fastening arts N m kg m lb ft Fuel pump assembly bolt 1...

Page 411: ...to bear this in mind when performing service work Ignition timing adjusting resistor EGR valve Heated oxygen sensor or CO adjusting resistor Three way catalytic converter CONTENTS GENERAL DESCRIPTION...

Page 412: ...emoval Installation 6E 68 MAP Sensor Removal Installation and Inspection 6E 68 IAT Sensor Removal Installation and Inspection 6E 69 ECT Sensor Removal Installation and Inspection 6E 69 TP Sensor Inspe...

Page 413: ...control system and emission control sys tem Air intake system includes air cleaner throttle body idle air control valve and intake manifold Fuel delivery system includes fuel pump delivery pipe fuel p...

Page 414: ...6E 4 ENGINE AND EMISSION CONTROL SYSTEM...

Page 415: ...r if equipped 16 PCV valve 17 Fuel injector 18 Engine coolant temp sensor 19 EGR valve if equipped 20 Three way catalytic converter if equipped 21 Crankshaft position sensor 22 Vehicle speed sensor 23...

Page 416: ...ose 10 PCV hose 11 PCV valve 12 EGR valve if equipped FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank fuel pump fuel filter fuel pressure regulator delivery pipe and fuel injec...

Page 417: ...on control system EGR system if equipped Heated oxygen sensor heater control system if equipped 1 CO adjusting resistor if equipped 2 CMP sensor 3 HO2S if equipped 4 VSS 5 CKP sensor 6 ECT sensor 7 MA...

Page 418: ...6E 8 ENGINE AND EMISSION CONTROL SYSTEM ECM CONNECTORS TERMINAL ARRANGEMENT VIEWED FROM TERMINAL SIDE...

Page 419: ...top lamp switch A11 R Y Lighting switch A12 P G Heater blower switch A13 B W Ignition switch A14 Y G CO adjusting resistor if equipped A15 Bl W Diagnosis switch terminal A16 Y Vehicle speed sensor A17...

Page 420: ...CO ADJUSTING RESISTOR W O HO2S HO2S IF EQUIPPED IAT SENSOR ECT SENSOR TP SENSOR MAP SENSOR CMP SENSOR CKP SENSOR 6E 10 ENGINE AND EMISSION CONTROL SYSTEM SIGNAL FROM SENSOR SWITCH AND CONTROL MODULE...

Page 421: ...the engine start while engine is running malfunction indicator lamp CHECK ENGINE light turns OFF When ECM detects a trouble which has occurred in the areas it makes malfunction indicator lamp CHECK EN...

Page 422: ...ection In case of such connector as shown connect probe as shown to avoid opening female terminal Never connect probe where male terminal is supposed to fit 1 Connector 2 Probe 3 Where male terminal f...

Page 423: ...nnect it to data link connector DLC located on underside of instrument panel at driver s seat side Special Tool A 09931 76011 SUZUKI scan tool B Mass storage cartridge C 09931 76030 16 14 pin DLC cabl...

Page 424: ......

Page 425: ...OXYGEN SENSOR CIRCUIT in this section P0340 15 Camshaft position sensor Go to DTC No 15 CAMSHAFT POSI TION SENSOR CIRCUIT in this section P0500 16 Vehicle speed sensor Go to DTC No 16 VEHICLE SPEED S...

Page 426: ......

Page 427: ......

Page 428: ......

Page 429: ...from A1 terminal of ECM connector to ground and from A2 terminal of ECM connector to ground Is each voltage within 10 14V Go to Step 7 B R wire open 7 ECM ground circuit check 1 Check for continuity...

Page 430: ...ition leaving engine OFF 3 Measure voltage from terminal c of MAP sen sor connector to ground Is voltage within 4 5V Go to Step 3 Lg R wire open or short Poor connection of ECM connector terminal If O...

Page 431: ...o to Step 6 6 1 Perform MAP sensor inspection in this section Is voltage within specified value Poor connection of MAP sensor connector termi nal If OK substitute a known good ECM and recheck Faulty M...

Page 432: ...NOSTIC FLOW TABLE 2 1 With ignition switch OFF position disconnect TP sensor electrical connector 2 Turn ignition switch ON position leaving en gine OFF 3 Measure voltage from terminal b of TP sen sor...

Page 433: ...f ECM connector terminal If OK substitute a known good ECM and recheck 5 1 Perform TP sensor inspection in this sec tion Is resistance within specified value Poor connection of TP sensor connector ter...

Page 434: ...her system and parts which might affect A F mixture or combustion If code No 14 and another code No are indicated together the latter has priority Therefore check and correct what is represented by th...

Page 435: ...sor electrical connector 3 Install SUZUKI scan tool 4 Start engine 5 Run engine to normal operating temperature 6 Maintain engine speed at 2000RPM for 60 se conds 7 Using data list function of SUZUKI...

Page 436: ...W TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC FLOW TABLE 2 1 With ignition switch OFF position disconnect CMP sensor electrical connector 2 Turn ignition switch ON position leaving en gin...

Page 437: ...1 Install a known good CMP sensor Refer to CMP Sensor Installation in this section 2 Start engine and run it for 5 seconds 3 Stop engine and check for DTC Is DTC NO 15 detected Poor connection of CMP...

Page 438: ...you perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC FLOW TABLE 2 Does speedometer indicate vehicle speed Y wire open or short Poor connection of ECM connector...

Page 439: ...buzzer electrical connectors if equipped 4 Disconnect P S control module connector if equipped 5 Turn ignition switch ON position leaving engine OFF 6 Measure voltage from terminal c of VSS con necto...

Page 440: ...4 5V Go to Step 3 Lg B wire open or short Poor connection of ECM connector terminal If OK substitute a known good ECM and recheck 3 1 Connect jumper wire from terminal a to b of IAT sensor connector 2...

Page 441: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 31 Fig for Step 2 Fig for Step 3...

Page 442: ...age within 4 5V Go to Step 3 Lg W wire open or short Poor connection of ECM connector terminal If OK substitute a known good ECM and recheck 3 1 Connect jumper wire from terminal a to c of ECT sensor...

Page 443: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 33 Fig for Step 2 Fig for Step 3...

Page 444: ...tion disconnect ABS control module electrical connector 2 Turn ignition switch ON position leaving en gine OFF 3 Measure voltage from terminal a of ABS con trol module connector to ground Is voltage w...

Page 445: ...connectors 2 Measure resistance from terminal a to b of ECM connector Is resistance within 360 460 at 20 C 68 F Go to Step 3 W Bl or R Bl wire open or short Poor connection of CKP sensor connector ter...

Page 446: ...6E 36 ENGINE AND EMISSION CONTROL SYSTEM Fig for Step 2...

Page 447: ...engine 4 Run engine to normal operating temperature 5 Maintain engine speed at 2000RPM for 60 seconds 6 Using SUZUKI scan tool monitor oxygen sensor output voltage with engine running at 2000RPM 7 Con...

Page 448: ...position while start engine signal is inputted while engine is running INSPECTION STEP ACTION YES NO 1 Did you perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC F...

Page 449: ......

Page 450: ...EP ACTION YES NO 1 Did you perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC FLOW TABLE 2 Fuel injector operation sound check 1 Perform Injector On vehicle Inspec...

Page 451: ...Poor connection of con nector If OK substitute a known good ECM and recheck 5 Fuel injector circuit check 1 With ignition switch OFF position disconnect ECM connectors 2 Check B R Br B Br Br W Br Y w...

Page 452: ...FLOW TABLE 2 1 Install fuel pressure gauge Refer to Fuel Pres sure Inspection in this section 2 Turn ignition switch ON position leaving engine OFF After 3 seconds turn ignition switch OFF position R...

Page 453: ...Connect new fuel hose to fuel pressure regula tor 3 Turn ignition switch ON position leaving engine OFF Is fuel pressure indicated within 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi Restricted fuel retu...

Page 454: ...YES NO 1 Did you perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC FLOW TABLE 2 1 Perform IAC Valve Inspection in this section Is IAC valve in good condition Go t...

Page 455: ...k engine idle speed Go to Step 5 5 1 Perform TP Sensor Inspection in this section Is resistance within specified value Faulty Gr Y Lg R or Bl Y wire Poor connector connec tion If OK substitute a known...

Page 456: ...IAG NOSTIC FLOW TABLE 2 1 Perform the following inspections EVAP System Hose and Pipes EVAP Canister Purge Valve EVAP Canister Are they in good condition Go to Step 3 Repair or replace 3 1 Disconnect...

Page 457: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 47 Fig for Step 2 Fig for Step 3 Fig for Step 4 1 EVAP hose...

Page 458: ...the exhaust gas flow from the exhaust manifold to the intake manifold INSPECTION STEP ACTION YES NO 1 Did you perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC F...

Page 459: ...ou perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC FLOW TABLE 2 1 With ignition switch OFF position install SUZU KI scan tool 2 Start engine and run it at idle...

Page 460: ...known good ECM and recheck 5 1 Run engine at idle 2 Monitor A C ON signal A C MAGNET CLUT parameter on SUZUKI scan tool 3 Turn A C switch ON and blower speed selector switch to any position except OFF...

Page 461: ...FF position install SUZU KI scan tool 2 Start engine and run it at idle 3 Observe engine coolant temperature on scan tool Does cooling fan turn ON when engine coolant temperature reaches above 90 C 19...

Page 462: ...r to ground Is each voltage within 10 14V Go to Step 6 Faulty Bl W B R wire 6 1 Turn ignition switch OFF position 2 Connect jumper wire between a and b of radiator fan relay connector Does cooling fan...

Page 463: ......

Page 464: ......

Page 465: ...EM 6E 55 ON VEHICLE SERVICE 1 Air cleaner case 2 EVAP canister 3 EVAP canister purge hose 4 Fuel feed hose 5 EVAP canister purge valve 6 Breather hose 7 PCV valve 8 PCV hose 9 Fuel pressure regulator...

Page 466: ...ication Clearance b 0 5 2 0 mm 0 02 0 07 in With pedal depressed fully If measured value is out of specification adjust it to specification by changing height of pedal stopper bolt 1 Lever stopper 2 T...

Page 467: ...Not using SUZUKI scan tool 1 Disconnect scan tool from DLC if connected 2 Using service wire ground diagnosis switch terminal in monitor connector 3 Connect duty meter between duty output terminal and...

Page 468: ...ctory setting However if during diagnosis check indicates idle mixture to be cause of a driver performance complaint or emission failure idle mixture can be adjusted using the following proce dures NO...

Page 469: ...reaction will cause these parts to swell hard en or get distorted 1 Throttle body 2 Accelerator cable bracket 3 MAP sensor 4 TP sensor 5 IAC valve 6 Coolant hoses 7 Gasket INSTALLATION 1 Clean mating...

Page 470: ...on check 3 times or more continuously If rotary valve of IAC valve does not operate at all check wire harness for open and short If wire harness are in good condition replace IAC valve and recheck The...

Page 471: ...gative cable at battery 2 Disconnect connector from CMP sensor 3 Remove CMP sensor from sensor case INSTALLATION 1 Check that O ring is free from damage 2 Check that CMP sensor and signal rotor tooth...

Page 472: ...fuel pressure at idling 6 Stop engine wait for 1 minute and then measure fuel pressure If measured pressure doesn t satisfy specification go to B 3 Fuel Pressure Check in this section At specified id...

Page 473: ...conds and stop Be sure to reinstall fuel filler cap after checking If above check result is not satisfactory advance to B 1 Fuel Pump Circuit Check in this section 2 Fuel pressure should be felt at f...

Page 474: ...pressure regulator from fuel delivery pipe 8 Disconnect fuel return hose from fuel pressure regulator WARNING A small amount of fuel may be released when it is from delivery pipe Place a shop cloth u...

Page 475: ...pressure in fuel feed line Refer to Fuel Pressure Relief Procedure in Section 6 2 Disconnect battery negative cable at battery 3 Disconnect connector from each injector 4 Remove fuel delivery pipe bo...

Page 476: ...n correct terminals Wrong connection can cause dam age to ECM wire harness etc 1 Main relay 2 Service wire 1 Injector 2 Battery 3 Vinyl tube 4 Graduated cylinder 1 Injector 2 Battery 3 Vinyl tube 4 Gr...

Page 477: ...that injectors rotate smoothly If not probable cause is incorrect installation of O ring Replace O ring with new one 4 Tighten delivery pipe bolts and make sure that injectors rotate smoothly Tighten...

Page 478: ...nector 3 Remove MAP sensor from throttle body Reverse above procedure in case of installation NOTE Replace O ring with new one 1 MAP sensor 2 O ring INSPECTION 1 Arrange 3 new 1 5V batteries in series...

Page 479: ...ance doesn t show such characteristic as shown in figure replace IAT sensor 0 322 ENGINE COOLANT TEMPERATURE SENSOR ECT SENSOR REMOVAL INSTALLATION 1 Disconnect negative cable at battery 2 Drain cooli...

Page 480: ...tance between terminals under each condition given in table below NOTE There should be more than 1 5 k resistance difference be tween when throttle valve is at idle position and when it is fully open...

Page 481: ...crew hole 4 Turn TP sensor after fitting and align holes HEATED OXYGEN SENSOR HO2S IF EQUIPPED ON VEHICLE INSPECTION Inspect oxygen sensor and its circuit Refer to DTC No 14 Heated Oxygen Sensor Circu...

Page 482: ...ng oxygen sensor start engine and check that no ex haust gas leakage exists WARNING To avoid danger of being burned do not touch exhaust system when system is hot Oxygen sensor removal should be perfo...

Page 483: ...t connector from CKP sensor 3 Remove CKP sensor from oil pan INSTALLATION 1 Check that CKP sensor is free from any metal particles 2 Install CKP sensor to oil pan Tightening Torque a 10 N m 1 0 kg m 3...

Page 484: ...ON INSPECTION NOTE Before inspection check to make sure that gear shift lever is in Neutral position and that parking brake lever is pulled all the way up 1 Warm up engine to normal operating temperat...

Page 485: ...OFF position Special tool A 09931 76011 SUZUKI scan tool B Mass storage cartridge C 09931 76030 16 14 pin DLC cable NOTE For operation procedure of cartridge refer to its cartridge operator s manual 2...

Page 486: ...the following D Clean mating surface of valve and intake manifold D Use new gasket INSPECTION 1 Remove carbon from EGR valve gas passage NOTE Do not use any sharp edged tool to remove carbon Be carefu...

Page 487: ...lve 30 34 at 20_C 68_F If resistance is as specified proceed to next operation check If not replace 3 Disconnect hoses from intake manifold and its pipe 4 With connector disconnected blow into pipe A...

Page 488: ......

Page 489: ...head cover hole 1 Breather hose 2 PCV valve 3 PCV hose A Cylinder head B Cleaner outlet hose C Intake manifold 3 Run engine at idle 4 Place your finger over end of PCV valve to check for vacuum If th...

Page 490: ...2 SPECIAL TOOLS 1 Pressure gauge 09912 58441 2 Pressure hose 09912 58431 3 Attachment 09919 46010 4 Checking tool set 09912 58421 4 1 Tool body washer 4 2 Body plug 4 3 Body attachment 4 4 Holder 4 5...

Page 491: ...result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in severe injury Technical service work must be started at least 90...

Page 492: ...is induced in the secondary coil High tension cords and spark plugs CMP sensor Camshaft position sensor and CKP sensor Crankshaft position sensor Using signals from these sensors ECM identifies the sp...

Page 493: ...for No 2 and No 3 spark plugs 5 CMP sensor 6 CKP sensor 7 No 1 spark plug 8 No 2 spark plug 9 No 3 spark plug 10 No 4 spark plug 11 ECM 12 Sensed information MAP sensor ECT sensor IAT sensor TP senso...

Page 494: ...ey Adjust clean or replace Replace Clean tighten or replace Replace DIAGNOSTIC FLOW TABLE STEP ACTION YES NO 1 Was ENGINE DIAG FLOW CHART performed Go to Step 2 Go to ENGINE DIAG FLOW CHART in SECTION...

Page 495: ...9 CMP Sensor Check 1 Check CMP sensor and signal rotor referring to DTC NO 15 CMP SENSOR CIRCUIT in SEC TION 6E Is check result satisfactory Go to Step 10 Tighten CMP sensor bolt replace CMP sensor 10...

Page 496: ...on coils 7 Connect injector couplers 1 Ignition coil assembly 2 High tension cord WARNING If the injector couplers are not disconnected com bustible gas will come out of the spark plug holes dur ing t...

Page 497: ...WRONG INSPECTION Measure resistance of high tension cord by using ohmmeter High tension cord resistance 4 10 k m 1 2 3 0 k ft If resistance exceeds specification replace high tension cord s 1 High te...

Page 498: ...6E for removal inspection and installation IGNITION TIMING NOTE For vehicle without ignition timing adjusting resister con nector ignition timing is not adjustable If ignition timing is out of specifi...

Page 499: ...2 Fuse box 6 Open the engine service hole cover behind the front seats and remove the inspection hole cap on the transmission case to ob serve ignition timing 7 If equipped with ignition timing adjus...

Page 500: ...nal ungrounded throttle opening at closed position and car stopped check that igni tion timing fluctuates between 6 18 BTDC Constant varia tion within a few degrees from 6 18 indicates no abnormality...

Page 501: ...er 1 or 1 as your purpose Check if the result if satisfactory If not replace the register with next larger degree change register step by step until satisfactory result is obtained 1 Ignition timing a...

Page 502: ...f test adapter 09931 76011 Tech 1A kit 09930 76420 Timing light Dry cell type 09931 76030 16 14 pin DLC cable Mass storage cartridge 09900 27301 Timing light DC 12V 6F 12 IGNITION SYSTEM TIGHTENING TO...

Page 503: ...2 Starting Motor 6G 3 DIAGNOSIS 6G 4 UNIT REPAIR OVERHAUL 6G 6 Dismounting and Remounting 6G 6 Disassembly 6G 6 Reassembly 6G 7 Inspection 6G 8 Performance Test 6G 11 Pull in test 6G 11 Hold in test 6...

Page 504: ...STARTING MOTOR CIRCUIT The magnetic switch coils are magnetized when the ignition switch is closed The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel...

Page 505: ...s so that they will be protected against possible dirt and water splash NOTE Make sure to apply grease before assembly where so indicated A in the figure below 1 Drive housing assembly 2 Washer 3 Snap...

Page 506: ...rioration Poor contact in battery terminal connection Loose grounding cable connection Fuse set loose or blown off Poor contacting action of ignition switch and magnetic switch Lead wire coupler loose...

Page 507: ...e bush Starting motor running but not cranking engine Worn pinion tip Poor sliding of over running clutch Over running clutch slipping Worn teeth of pinion gear Replace over running clutch Repair Repl...

Page 508: ...m drive lever NOTE Do not disassemble magnetic switch Replace it as assem bly when required 1 Lead wire 2 Nut 3 Magnetic switch 4 Nut A Pull up to disconnect hook 3 Remove housing bolts through bolts...

Page 509: ...ture 2 Drive lever 3 Drive housing A Apply grease 4 Install yoke and brush holder then set 4 brushes with their springs Install insulator NOTE When installing brushes make sure that brushes and commut...

Page 510: ...Boot Face breather down 3 Plunger hook Upon completion of assembly carry out PERFORMANCE TEST Refer to page 6G 11 INSPECTION PLUNGER Inspect plunger for wear Replace if necessary MAGNETIC SWITCH Push...

Page 511: ...Limit 6 0 mm 0 236 in BRUSH HOLDER Check brush springs for rust or breakage Also check brush holder for rust and insulation Replace it as assembly if required ARMATURE Ground Test Between commutator s...

Page 512: ...cloth Also check mica depth and correct it as required Commutator insulator depth a Limit minimum value 0 2 mm 0 008 in 1 Mica insulator 2 Commutator segment YOKE Check field coil for continuity There...

Page 513: ...ing disconnect field coil lead from terminal M CAUTION Each test must be performed within 3 5 seconds to avoid coil from burning 1 Terminal S 2 Terminal M 3 Lead wire Switch to motor HOLD IN TEST Whil...

Page 514: ...heck to make sure that pinion returns inward quickly NO LOAD PERFORMANCE TEST Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out Also check that am...

Page 515: ...Condition Guarantee No load characteristic 11 5 V 50 A maximum 6 000 rpm minimum Around at 20 C Load characteristic 9 V 150 A 2 94 N m minimum 1 950 rpm minimum 68 F Locked rotor current 5 5 V 430 A m...

Page 516: ...r could render the system inop erative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the...

Page 517: ...carrier the hold down bolts should be tight enough but not over tightened ELECTROLYTE FREEZING The freezing point of electrolyte depends on its specific gravity Since freezing may ruin a battery it s...

Page 518: ...ions clean The cable connections particularly at the positive terminal post tend to become corroded The product of corrosion or rust on the mating faces of conductors resists the flow of cur rent Clea...

Page 519: ...s integrated circuits and controls the voltage produced by the generator and the voltage setting cannot be adjusted The generator rotor bearings contain enough grease to eliminate the need for periodi...

Page 520: ...Stator coil 5 Stator core 6 Field coil 7 Regulator 8 Brush 9 Rear end frame 10 Drive end frame B Generator output Battery terminal D Dummy terminal E Ground F Field coil terminal IG Ignition terminal...

Page 521: ...eezing As the S G varies with the temperature if battery temperature is not at 20_C 68_F you have to correct your S G reading taken with your hydrometer to the value at 20_C 68_F and apply the correct...

Page 522: ...E When connecting a charger or a booster battery to ve hicle battery refer to this section describing battery charging B Generator output Battery terminal D Dummy terminal E Ground F Field coil termi...

Page 523: ...ion ground cable 5 Connect voltmeter and ammeter as shown in left figure Voltmeter Set between generator B terminal and ground Ammeter Set between generator B terminal and battery terminal NOTE Use fu...

Page 524: ...ue Generator itself has problem check the generator Load Check 1 Run engine at 2 000 rpm and turn on head light and heater mo tor 2 Measure current and if it is less than 20 A repair or replace gen er...

Page 525: ...ery and the other end to a solid engine ground such as exhaust manifold at least 45 cm 18 in away from battery of vehicle being started 5 Start engine of vehicle with booster battery and turn off elec...

Page 526: ...ions should be fol lowed Hydrogen gas is produced by battery A flame or spark near bat tery may cause the gas to ignite Battery fluid is highly acidic Avoid spilling on clothing or other fabric Any sp...

Page 527: ...vot bolt 5 Remove generator together with generator adjusting arm and remove generator adjusting arm from generator INSTALLATION Reverse above procedure giving specified tension to drive belt Refer to...

Page 528: ...N m 5 0 kg m 36 5 lb ft 5 Connect negative cable at battery terminal 1 Adjusting bolt 2 Pivot bolt 3 Belt adjusting bolt 4 10 kg 22 lbs REMOVAL 1 Disconnect negative cable at battery 2 Loosen generato...

Page 529: ...lley nut 2 Pulley 3 Space collar 4 Drive end frame 5 Stator 6 Stud bolt 7 Drive end bearing 8 Bearing retainer 9 Rotor 10 End housing bearing 11 Bearing cover 12 Rear end frame 13 Rectifier 14 Insulat...

Page 530: ...exagonal box wrench and remove pulley nut and then pull out pulley CAUTION To hold shaft use hexagonal box Duodecimal box may cause slipping and consequential shaft or tool damage Do not attempt to ho...

Page 531: ...e applying puller 1 End housing bearing 2 Bearing puller 3 Bearing cover 12 If required remove 4 screws retainer plate and then drive out drive end bearing 1 Stud bolt 2 Retaining plate 3 Drive end be...

Page 532: ...Check slip rings for roughness or scoring If rough or scored re place rotor Using a vernier caliper measure slip ring diameter Standard diameter 14 4 mm 0 567 in Minimum diameter 14 0 mm 0 551 in If...

Page 533: ...of tester probes and repeat step 1 3 Check that one shows continuity and the other shows no conti nuity If there is continuity replace rectifier holder B Positive terminal E Negative terminal P1 P4 R...

Page 534: ...Unsolder and remove brush and spring 2 Run wire of new brush through the hole in the brush holder and insert spring and brush into brush holder 3 Solder brush wire to brush holder at specified exposed...

Page 535: ...e a 8 8 N m 0 88 kg m 6 5 lb ft b 2 6 N m 0 26 kg m 2 0 lb ft 1 Stud bolt 2 Retaining plate 3 Drive end bearing 4 Stator 6 Place space collar and drive end frame on pulley and then install rotor to dr...

Page 536: ...brush holder horizontally on rear end frame 13 Install 5 screws until there is a clearance of approx 1 mm 0 04 in between brush holder and connector Tightening Torque 2 0 N m 0 2 kg m 1 5 lb ft 1 IC r...

Page 537: ...ion Clockwise viewed Setting voltage 14 2 to 14 8 V Rotation from pulley side TIGHTENING TORQUE SPECIFICATIONS Fastening Tightening torque Fastening N m kg m lb ft Body ground bolt 8 0 8 6 0 Generator...

Page 538: ...ter equipped vehicle Use of LEADED FUEL will affect performance of the catalytic converter adversely to a great ex tent 1 Exhaust manifold 2 Exhaust pipe without TWC 3 Exhaust pipe with TWC 4 Muffler...

Page 539: ...Any defect should be fixed at once ON VEHICLE SERVICE Refer to Section 6A for removal and installation pro cedures of exhaust manifold For replacement of exhaust pipe muffler or any part used to moun...

Page 540: ...smission case 7A 9 Countershaft 7A 10 Input shaft and main shaft 7A 11 Shift shafts and forks 7A 14 Inspection 7A 15 Assembling Unit 7A 18 Main shaft and input shaft 7A 18 Countershaft and reverse idl...

Page 541: ...eed synchronizer hub 11 5th speed synchronizer hub 12 Reverse gear shaft 13 Reverse idle gear 14 Countershaft reverse gear 15 Main shaft reverse gear 16 Upper case 17 Lower case 18 Extension case 19 I...

Page 542: ...lip 24 Circlip 25 Countershaft 26 Countershaft 5th gear 27 Front bearing 28 Circlip 29 Center bearing 30 Rear bearing 31 Low speed synchronizer hub assembly 32 Low speed synchronizer ring 33 Low speed...

Page 543: ...own below by specified amount roughly up to level hole NOTE It is highly recommended to use SAE 75W 90 gear oil Whenever vehicle is hoisted for any service work other than oil change also be sure to c...

Page 544: ...control cable grommet plate 5 Remove gear shift select control cables from gear shift control lever assembly 6 Loosen 4 bolts and take out gear shift control lever assembly INSTALLATION 1 Apply greas...

Page 545: ...negative cable from battery terminals and hoist vehicle 2 Disconnect back up light switch lead wire at coupler 3 Disconnect Black Yellow lead wire and positive cord from starting motor Remove starting...

Page 546: ...With transmission supported on jack remove stiffner 1 12 Remove bolts and nuts fastening engine cylinder block and transmission case NOTE Before starting to remove transmission check around once agai...

Page 547: ...rear mounting to transmis sion after inserting input shaft into clutch disc For tightening torque of starting motor bolts refer to sec tion 6G Refill specified amount of gear oil as previously outlin...

Page 548: ...hift cam by winding cam guide return spring and then drive in spring pin Locate low speed select spring Green and reverse se lect spring Yellow correctly 1 Shift cable lever 2 Shift cable lever outer...

Page 549: ...faces or faces may get damaged 1 Pry point COUNTERSHAFT 1 Remove reverse idle gear shaft 1 with gear 2 Remove outside circlip of countershaft front bearing 2 3 Using plastic hammer drive countershaft...

Page 550: ...NPUT SHAFT AND MAIN SHAFT 1 Take out input shaft 1 by hand taking care not to let high speed synchronizer ring 3 fall off 2 Main shaft 4 Bearing 5 3rd gear 2 Remove circlip of input shaft 1 and pull o...

Page 551: ...h reverse gear 2 by using puller 3 and hydraulic press 4 In the case of loose fitting hub Remove 5th speed synchronizer sleeve and hub assembly 1 and reverse gear 8 Take out reverse gear needle bearin...

Page 552: ...d hub assembly 1 together with 2nd gear 2 and low speed synchronizer ring by using puller 3 and hydraulic press 4 In the case of loose fitting hub Remove low speed synchronizer sleeve and hub assembly...

Page 553: ...nd hub assembly 1 high speed synchronizer ring and 3rd gear 2 16 Take out 3rd gear needle bearing from main shaft CAUTION Make sure to use flat side of puller to avoid causing damage to reverse gear t...

Page 554: ...ure not to drive it out so far as to contact case Or it will cause damage to case 3 Transmission case 3 Drive spring pin out of low speed gear shift fork 1 as in above step 2 and pull out shift shaft...

Page 555: ...f found defective Synchronizer Hubs Sleeves and Keys Check each part for wear or damage Replace if found defective Shift Forks and Sleeves Check contact surfaces for wear or damage Measure clearance b...

Page 556: ...ce a Standard 1 0 1 4 mm 0 039 0 055 in Service limit 0 5 mm 0 019 in Slot width b Standard 10 1 mm 0 397 in Service limit 10 4 mm 0 409 in Inspect external cone of gear and internal cone of ring for...

Page 557: ...e last page of this section MAIN SHAFT AND INPUT SHAFT Install each parts by reversing respective removal procedures Be careful for installing direction of each washer gear synchronizer hub and sleeve...

Page 558: ...ear 3 and 2nd synchronizer ring to main shaft 3 In the case of press fitting hub Using special tool puller and hydraulic press drive in low speed synchronizer sleeve and hub assembly 1 with punch mark...

Page 559: ...needle bearing synchronizer ring low gear ball and washer onto main shaft Fit ball into hole in shaft and install washer so that its slot 1 comes over ball 3 To direct washer correctly bring its circu...

Page 560: ...and keys 3 a Slide hub in sleeve so that punch marked side of hub and groove machined side of sleeve face the same forward direction b Insert keys in hub slots with depression side of keys face center...

Page 561: ...ng sleeve and hub assembly Special Tool A 09924 07720 B 09924 07710 In the case of loose fitting hub Install 5th speed synchronizer sleeve and hub assembly 2 with punch marked side of hub directed for...

Page 562: ...a Slide hub in sleeve so that punch marked side 6 of hub and groove machined side of sleeve face opposite direc tion b Insert keys in hub slots with depression side of keys face center of hub c Insta...

Page 563: ...hub Install high speed synchronizer sleeve and hub assembly 2 with punch marked side of hub directed to forward input shaft side CAUTION Make sure synchronizer ring key slots 3 must be aligned with ke...

Page 564: ...synchronizer ring 3 needle bearing 4 and input shaft 1 2 Main shaft 5 3rd gear COUNTERSHAFT AND REVERSE IDLE GEAR 1 Press fit front bearing 1 and fit circlip Special Tool A 09925 18011 2 Countershaft...

Page 565: ...irclip securely NOTE When press fitting hold countershaft with its front end set on wood blocks Special Tool A 09913 80113 5 Install reverse idle gear 3 and washer onto reverse gear shaft and pin 1 in...

Page 566: ...n hole 1 Locating ball 2 Interlock ball 3 Locating ball 4 Interlock roller 5 Interlock ball 6 Locating ball 7 Reverse gear shift shaft 8 High speed gear shift shaft 9 Low speed gear shift shaft 10 Loc...

Page 567: ...in sert reverse gear shift shaft into upper case as described in 2 and 3 TRANSMISSION LOWER CASE AND UPPER CASE 1 With countershaft assembly reverse idle gear and reverse gear shaft installed in lowe...

Page 568: ...Back up light switch EXTENSION CASE 1 Check to ensure that knock pins 1 are fitted 2 Install extension case seal 2 so that end surface of oil seal be comes flush with that case Apply grease to extens...

Page 569: ...hten retainer bolts to specification Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 4 Check transmission input shaft for easy rotation by hand 5 Check each select and shift shaft for operation 1 Input...

Page 570: ...ly 2 Tighten 3 bolts 4 to specification Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 3 Install gear shift stop bolt 5 applied with thread lock cement B Thread lock 1322 99000 32110 Tightening Torque...

Page 571: ...nsmission bolt bracket bolt 25 2 5 18 0 Transmission to engine bolt and nut 61 6 1 44 5 Transmission stiffener bolt 55 5 5 40 0 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCTS USE Lit...

Page 572: ...09925 18011 Bearing installer 09913 60910 Bearing puller 09913 80113 Bearing installer 09940 51710 Bearing installer 09924 74510 Oil seal installer handle 09941 34513 004 Oil seal installer 09913 8521...

Page 573: ...AGNOSIS 7C 3 ON VEHICLE SERVICE 7C 4 Clutch Pedal Free Travel 7C 4 Cable Routing 7C 5 UNIT REPAIR 7C 6 Clutch Cover Clutch Disc and Flywheel 7C 6 Clutch Release Fork 7C 9 TIGHTENING TORQUE SPECIFICATI...

Page 574: ...pushes on the pressure plate against the flywheel with the disc in between when the clutch release bearing is held back This is the engaged condition of the clutch Depressing the clutch pedal causes t...

Page 575: ...bearing slides unsmoothly on input shaft bearing retainer Wobbly clutch disc or poor facing contact Weakened torsion springs in clutch disc Clutch disc rivets loose Distorted pressure plate or flywhee...

Page 576: ...ee travel Free travel should be within following specification Pedal free travel a 10 15 mm 0 4 0 6 in 1 Clutch pedal 2 If free travel is out of specification adjust it by turning cable ad justing nut...

Page 577: ...ase cap 9 Oil level gauge guide RH vehicle LH vehicle When installing clutch pedal shaft arm to clutch pedal shaft align punch marks as shown in figure Apply grease to pin clevis and arm before instal...

Page 578: ...MISSION section for dismounting re mounting of manual transmission CLUTCH COVER CLUTCH DISC AND FLY WHEEL REMOVAL 1 Hold flywheel stationary with special tool A and remove clutch cover bolts clutch co...

Page 579: ...at any of holes replace disc assembly Rivet head depth Standard 1 2 mm 0 05 in Service limit 0 5 mm 0 02 in Clutch Cover 1 Check diaphragm spring for abnormal wear or damage 2 Inspect pressure plate f...

Page 580: ...bolts Then tighten bolts to specification NOTE While tightening clutch cover bolts compress clutch disc with special tool C by hand so that disc centered Tighten cover bolts little by little evenly in...

Page 581: ...Clutch release bearing Check clutch release bearing for smooth rotation and its clip for deflection or damage If abnormality is found replace it CAUTION Do not wash release bearing Washing may cause...

Page 582: ...s Apply grease as shown in figure A Grease 99000 25010 B Grease 99000 25210 Install release bearing return spring and clips to release fork as shown in figure 1 Release fork 2 Release bearing 3 Bearin...

Page 583: ...QUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE SUZUKI SUPER GREASE A Clutch pedal shaft arm Lithium grease 99000 25010 Clutch release fork Lithium grease SUZUKI SUPER GREASE I 99000...

Page 584: ...SCRIPTION 7F 2 DIAGNOSIS 7F 3 ON VEHICLE SERVICE 7F 4 OIL CHANGE 7F 4 REMOVAL 7F 4 INSTALLATION 7F 5 UNIT REPAIR 7F 6 DISASSEMBLY 7F 6 ADJUSTMENT AND REASSEMBLY 7F 7 TIGHTENING TORQUE SPECIFICATIONS 7...

Page 585: ...to permit the car body to be lowered in design and that some wiping or sliding action occurs in tooth meshing between pinion and gear Here lies the reason why use of hypoid gear oil is specified for...

Page 586: ...gear s or pinion s Repair and replenish Repair and replenish Adjust Adjust or replace Replace or retighten Replace Bearing noise Constant noise Deteriorated or water mixed lubricant Constant noise In...

Page 587: ...3 US Imp pt NOTE Hypoid gear oil must be used for differential It is highly recommended to use SAE 80W 90 viscosity 4 Install level filler plug and torque it to specification Tightening Torque b 50 N...

Page 588: ...torque A Sealant 99000 31110 Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft For installation of rear suspension refer to Rear axle shaft installation in REAR SUSPENSION section of this manual Fill gea...

Page 589: ...fied and so handled at the time of reassembly A Match mark 3 Remove the two bearing caps right and left and lift the differen tial case assembly off the carrier case after loosening lock plate bolts a...

Page 590: ...erly by using adjusting shim as described on following pages Shown in following page are rela tive positions of bevel pinion differential carrier and mounting dummy 1 Install bevel pinion dummy with b...

Page 591: ...osition and extended dial gauge measuring tip The value of b is unknown and is to be determined now for cal culating the required thickness of shims The value of a c is 85 mm 3 35 in NOTE Repeat turni...

Page 592: ...erential carrier NOTE Make sure to use new spacer for reinstallation Apply oil to bearings 1 Bevel pinion 2 Rear bearing 3 Spacer 4 Differential carrier 5 Front bearing 7 Using special tool and plasti...

Page 593: ...g torque preload by loosening pinion nut will not do Pinion bearing preload 5 0 13 0 kg cm 4 4 11 2 Ib in Spring balance reading 1 0 2 6 kg 2 3 5 7 Ib Special Tool A 09922 75222 G 09922 66020 1 Power...

Page 594: ...ed 4 Drive in spring pin for differential side pinion shaft till it comes at the position with differential case surface as shown in figure Special Tool C 09922 85811 Spring pin depth a 9 mm 0 35 in 1...

Page 595: ...gear to differential case When mounting gear on case be sure to apply thread lock ce ment to these bolts before running them in A Cement 99000 32020 Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 7F...

Page 596: ...l Tightening Torque a 15 N m 1 5 kg m 11 0 lb ft 1 Match mark 5 Tighten both bearing adjusters so as to obtain specified gear backlash and at the same time obtain preload of side bearing Special Tool...

Page 597: ...ndard preload is within the range given in graph be low which should be read as follows Example When preload of bevel pinion is 2 6 kg 5 73 Ib acceptable composite preload of both pinion bearings and...

Page 598: ...g its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact 3 Bring painted part up and check contact pattern referring to following chart next page If cont...

Page 599: ...erns indicate that the offset of differential carrier is too much or too little The remedy is to replace the carrier with a new one These contact patterns located on toe or heel on both drive and coas...

Page 600: ...BLANK DIFFERENTIAL 7F 17...

Page 601: ...lts 50 5 0 36 5 Lock plate bolts 11 5 1 15 8 5 Rear differential carrier bolts 23 2 3 17 0 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCTS USE Thread lock cement THREAD LOCK CEMENT SU...

Page 602: ...aller attachment 09913 85230 Bearing removing jig 09930 40120 Attachment 09940 51710 Bearing installer 09930 40113 Rotor holder 09924 36320 For Front Diff Bevel pinion mounting dummy 09922 75222 Prelo...

Page 603: ...work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and negative cable is disconnected from the battery Otherwise the system may be activated by reserve e...

Page 604: ...m 8 18 Turn Signal and Hazard Warning Light 8 19 Ignition Switch 8 20 Rear Fog Light If Equipped 8 21 Combination Meter 8 22 Vehicle Speed Sensor 8 22 Fuel Meter Fuel Gauge Unit 8 23 Engine Coolant Te...

Page 605: ...ecting cables from the battery be sure to discon nect the one from the negative terminal first and then the oth er from the positive terminal Reverse the above order when connecting the cables to the...

Page 606: ...to the harness protect its part which may con tact against a part forming a sharp angle by winding tape or the like around it When replacing a fuse make sure to use a fuse of the specified capacity Us...

Page 607: ...or measuring volt age be sure to insert the tester probe from the wire harness side When connecting JOINT CONNECTORS make sure to tighten its bolt to the specified torque indicated on the housing of J...

Page 608: ...st symbol represents the base color of the wire G in the figure and the second symbol represents the color of the stripe Y in the fig ure Symbol G Green G Y Green Yellow POWER SUPPLY CIRCUIT AND RELAY...

Page 609: ...gauge Y R 3 To ECT sensor Y W 4 To ground B Y 5 Blank 6 To ABS controller if equipped R Bl 7 To fuse box B W 8 Blank 9 To generator B G 10 To brake fluid level switch Bl 11 To parking brake switch R...

Page 610: ...PER AND WASHER 1 Wiper blade 2 Wiper arm 3 Wiper link 4 Wiper motor 5 Washer nozzle 6 Washer hose 7 Washer pump 8 Washer tank POWER WINDOW SYSTEM 1 Power window switch 2 Window actuator 8 8 BODY ELECT...

Page 611: ...POWER DOOR LOCK SYSTEM 1 Power door lock controller 2 Front door lock actuator 3 Joint connector 4 Rear door lock actuator 5 Back door lock actuator BODY ELECTRICAL SYSTEM 8 9...

Page 612: ...M IF EQUIPPED Trouble Possible Cause Correction Both headlights do not move Fuse blown Leveling switch faulty Supply voltage too low Wiring or grounding faulty Check circuit and replace fuse If replac...

Page 613: ...cuit to ground Check circuit Check relay Check switch Repair circuit Flash rate low Supply voltage low Turn signal hazard relay faulty Check charging system Check relay CLEARANCE TAIL AND LICENSE PLAT...

Page 614: ...short circuit to ground Check VSS Check printed plate Repair Check signal rotor Replace speedometer FUEL METER AND FUEL GAUGE UNIT Trouble Possible Cause Correction Fuel meter shows no op eration or i...

Page 615: ...k parking brake switch Repair circuit Brake warning light does not light up when cranking when turned ignition switch to ST position Ignition switch faulty Printed plate in combination meter faulty Wi...

Page 616: ...lty Check fuse and replace as necessary Check ignition main switch Check power window main switch Check window actuator Repair circuit Only one power window does not operate Wiring and or coupler faul...

Page 617: ...ircuit to ground Check switch Check switch Repair One of interior light does not light up Bulb blown Interior light switch faulty Door switch faulty Wiring or grounding Replace Check switch Check swit...

Page 618: ...uity is not obtained replace combination switch Terminal Wire Switch Position Color LH steering vehicle shown HE HU HL RF B2 M B R R W G B R G R Y passing passing passing Low Beam High Beam OFF 1 Comb...

Page 619: ...10 m 32 8 ft b Adjust air pressure of all tires to a specified value respectively c Bounce vehicle body up and down by hand to stabilize suspen sion d Carry out with one driver aboard Driver s weight...

Page 620: ...on switch to the ON position and check the voltage on the voltmeter 1 Leveling switch Lg Y Left side leveling Lg R Right side leveling Approx 6 2 V Approx 6 2 V Approx 9 0 V Approx 9 0 V 0 4 Wire Swit...

Page 621: ...INSPECTION Use an ohmmeter to check the continuity at each switch position shown below Terminal WireColor Turn SignalSW Hazard SW LH steering vehicle shown 1 Combination switch assembly HAZARD RELAY...

Page 622: ...teering column upper and lower cover 3 Disconnect wiring main harness coupler from ignition switch 4 Use an ohmmeter to check the continuity at each switch posi tion If any continuity is not obtained...

Page 623: ...ight switch to ON 4 Check that the voltmeter indicates at the battery voltage and check light the indicator lamp If not replace switch 5 Push the OFF button of rear fog switch to off 6 Check that the...

Page 624: ...ter cluster 4 Disconnect couplers from combination meter Remove combination meter INSTALLATION Reverse removal procedure for installation 1 Combination meter 2 Cluster panel LH steering vehicle shown...

Page 625: ...el pump assembly referring to Section 6C of this manu al Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position If the measured value is out of specifica...

Page 626: ...Drain coolant 2 Remove ECT sensor WARNING Make sure that engine coolant temperature is cold be fore removing any part of cooling system Also be sure to disconnect negative cable from battery terminal...

Page 627: ...Refer to Section 6A OIL PRESSURE CHECK in this manual BRAKE AND PARKING BRAKE WARNING LIGHT BRAKE FLUID LEVEL SWITCH INSPECTION Use an ohmmeter to check switch for continuity If found defective replac...

Page 628: ...brassive containing glass cleaner When measuring wire voltage use a tester with negative probe wrapped with a tin foil which should be held down on wire by finger pressure 1 Heat wire 2 Tin foil 3 Tes...

Page 629: ...cate 12V at heat wire positive terminal end and its indication should decrease gradually toward zero at the other termi nal ground DEFOGGER CIRCUIT REPAIR 1 Clean glass with white gasoline 2 Apply mas...

Page 630: ...mbination switch assembly WIPER MOTOR Inspection 1 As illustrated left have a 12V battery and connect its termi nal to terminal A and its terminal to bracket wiper ground If motor rotates at a low rev...

Page 631: ...and inspect if the motor stops at the given position every time 1 Battery 2 Wiper motor 3 Red lead 4 Black lead 5 Jumper WASHER PUMP Removal 1 Disconnect battery cable 2 Remove washer tank fitting sc...

Page 632: ...Power window main switch 2 Power window lock switch 3 Driver side window switch 4 Passenger side window switch Power Window Sub Switch Inspect switch continuity between terminal Switch Position Termin...

Page 633: ...negative battery terminal and check the voltage indicated on the voltmeter at the moment of connection Also disconnect it and check the voltage at the mo ment of disconnection The voltage values shou...

Page 634: ...sitive and negative terminals to the door lock actuator terminals shown below If it does not follow the table s operation replace the faulty door lock actuator Front Door Operation Terminal Back Door...

Page 635: ...h 4 Close rear door 5 As shown in the figure check that there is continuity between terminals of the same wire color If not replace junction switch STOP LAMP SWITCH INSPECTION Use an ohmmeter to check...

Page 636: ...Disconnect door switch coupler and check switch for continuity If found defective replace switch 8 34 BODY ELECTRICAL SYSTEM ON position door switch released OFF Continuity OFF position door switch p...

Page 637: ...ther of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and negative cable is disco...

Page 638: ...10 Window regulator assembly 11 Bottom channel 12 Channel rubber 13 Window regulator handle 14 Door hinge 15 Door inside handle assembly 16 Door outside handle assembly 17 Door latch assembly 18 Door...

Page 639: ...6 Remove inside lock knob door handle or armrest fitting screw if necessary 8 Remove door sealing cover 9 Remove glass run rear part 10 Remove glass bottom channel attaching screws 11 Take out door g...

Page 640: ...ttom channel Tighten channel attaching screw in alphabetical order as shown in the figure 1 Sash 2 Glass run 3 Window regulator 4 Door glass When installing glass check that the top part of the glass...

Page 641: ...ach joint of control link and connector of door lock actuator remove door outside handle and door latch ass y 1 Door latch 2 Outside handle 3 Retainer 4 Key cylinder BODY SERVICE 9 5 FRONT DOOR LOCK 1...

Page 642: ...que by referring to the figure on previous page Move door latch striker sideways to adjust to 0 mm 0 in the door surface to body surface difference with door closed 1 Body 2 Door 3 Door latch striker...

Page 643: ...ax for proper anticorrosion treatment Refer to RUST PROOF TREATMENT AREA in this section Apply rust proof sealant to hinge installation face shown in the figure and grease to rotating part When weathe...

Page 644: ...oor front sash 14 Door rear sash 15 Door front glass run 16 Door rear grass run 17 Channel rubber 18 Bottom channel 19 Door glass 20 Window regulator assembly 21 window regulator handle 22 Door stoppe...

Page 645: ...rip if equipped 6 Remove door sealing cover 1 Cloth 2 Regulator handle 7 Remove door sash 8 Remove glass run 9 Remove glass attaching screws 10 Take out door glass NOTE Be careful not to damage to the...

Page 646: ...ng glass check that the top part of the glass con tacts the glass run evenly and that the glass moves up and down smoothly If the glass is tilted with respect to the glass run make a fine ad justment...

Page 647: ...y INSTALLATION Reverse removal procedure to install rear door lock Adjust door latch striker refer to FRONT DOOR LOCK INSTAL LATION When install door link ass y set cable as shown in the figure and ma...

Page 648: ...EA in this section When weatherstrip is hardened water leak may develop In this case replace it if possible After installing adjust door fitting and door latch striker position as described below and...

Page 649: ...toppers and tighten the screws Insert or adjust the number of spacer between stopper and body if necessary 1 Slide hinge 2 Door stopper 3 Screw Door latch striker position adjustment Adjust striker po...

Page 650: ...Door lock key cylinder 14 retainer 15 Door lock actuator if equipped A Without power door lock B With power door lock REMOVAL 1 Remove back door trim and sealing cover 2 Disconnect wire harness conne...

Page 651: ...n rod with balancer fully extended INSTALLATION Reverse removal procedure to install back door by note the follow ing procedure NOTE When replacing back door coat replacement door inside with wax for...

Page 652: ...ion When using primer and adhesive made by other manufacturers be sure to refer to handling instructions supplied with them Negligence in following such procedure or mis use of the adhesive in any way...

Page 653: ...Clean both inside and outside of glass and around it 2 Remove wiper arms 3 Remove garnish and stoppers 4 Using tape cover body surface around glass to prevent any damage 5 Remove instrument panel and...

Page 654: ...3 Tape 4 Adhesive 11 Using knife smooth adhesive remaining on body side so that it is 1 2 mm 0 04 to 0 08 in thick all around NOTE Before using knife clean it with alcohol or the like to re move oil...

Page 655: ......

Page 656: ...to figure at the left NOTE Start from bottom side of glass Be careful not to damage primer Apply specified amount of adhesive as given Width e Approx 8 mm 0 31 in Height f Approx 14 mm 0 55 in Cleara...

Page 657: ...amp or the like for drying CAUTION Upon completion of installation note the following Sudden closing of door before adhesive is completely set may cause glass to become loose or to come off Therefore...

Page 658: ...tring through outer groove of weatherstrip groove where panel fits in so that weatherstrip can be installed with ease 3 Apply soap water to outer edge of back door panel or side panel and install glas...

Page 659: ...emove speedome ter assembly 7 Remove front hood opener 8 Disconnect couplers which need to be disconnected for re moval for instrument panel refer to the left figure and pull wire harness out of dash...

Page 660: ...vertical direction for adjustment by refer ring PANEL CLEARANCE Tightening Torque a 8 0 N m 0 80 kg m 6 0 lb ft 1 Hood latch 2 Hood latch bolts Vertical adjustment If only one side right or left of ho...

Page 661: ...lip REMOVAL 1 Remove radiator grille 2 Remove front bumper 3 Disconnect connector of side turn signal lamp 4 Remove front fender lining 5 Remove front fender INSTALLATION Reverse removal procedure to...

Page 662: ...t be replaced with one of the same part num ber or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be u...

Page 663: ...esive of head lining will be attached 2 Apply adhesive on recess of head lining and install it to body 3 Install assistant grips and clips from front side of vehicle to rear side 1 Recess for adhesive...

Page 664: ...ht front seat inside adjuster 6 Right front seat outside adjuster 7 Left front seat inside adjuster 8 Left front seat outside adjuster 9 Right front seat riser panel 10 Left front seat riser panel 11...

Page 665: ...TRUCK model 1 Seat cushion 2 Seat back 3 Seat back frame 4 Bracket Tightening torque b 23 N m 2 3 kg m 17 0 lb ft c 5 5 N m 0 55 kg m 4 0 lb ft NOTE Insert seat back frame into bracket surely BODY SE...

Page 666: ...SEAT for vehicle equipped with third seat 2ND SEAT for vehicle without third seat 3RD SEAT REMOVAL 1 Remove seat rail mounting bolts Then remove seat ass y with seat rail front seats 2 Disassemble an...

Page 667: ...r panel 4 6 6 6 mm 0 18 0 26 in 9 Front door Rear door 4 6 6 6 mm 0 18 0 26 in 10 Rear door Side body outer panel 4 6 6 6 mm 0 18 0 26 in 11 Back door Side body outer panel 4 6 6 6 mm 0 18 0 26 in 12...

Page 668: ...barrier The sealer is applied to the door and hood hem areas and between panels Correct and re seal the originally sealed joints if damaged Reseal the attaching joints of a new replacement panel and r...

Page 669: ...al conditioner to the bare metal exposed to open air As for method of use of the metal conditioner follow directions on the con tainer 4 Apply primer surfacer to the part completely dry before startin...

Page 670: ...9 34 BODY SERVICE SEALANT APPLICATION AREA Van model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...

Page 671: ...BODY SERVICE 9 35 Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...

Page 672: ...9 36 BODY SERVICE...

Page 673: ...BODY SERVICE 9 37 Truck model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...

Page 674: ...9 38 BODY SERVICE...

Page 675: ...BODY SERVICE 9 39 RUST PROOF TREATMENT AREA...

Page 676: ...9 40 BODY SERVICE...

Page 677: ...re range is 60 to 70 C Reference Plastic parts employ not only ABS Acrylonitrile Butadiene Sty rene plastic but also polypropylene vinyl or the like plastic Burn ing test method to identify ABS plasti...

Page 678: ...nstallation hole g g Front bumper installation hole h Front lower crossmember jig hole Measurement Dimension Measurement Position Length mm in Measurement Position Length mm in a c 729 5 28 72 c c 122...

Page 679: ...de c Garnish installation clip hole Measurement Dimension Van Truck Measurement Position Length mm in Measurement Position Length mm in a a 1099 9 43 30 a a 1082 4 42 61 a b 610 1 24 02 a b 624 0 24 5...

Page 680: ...lower stopper installation hole lower side n Rear door lower cushion installation hole o Body outer panel jig hole p Body outer panel dent section q Body outer panel dent section Measurement Dimension...

Page 681: ...Rear door striker installation hole upper side j Rear door rear upper stopper installation hole k Front suspension strut installation hole front side l Engine room front panel air bag controller lowe...

Page 682: ...hed part v v Pillar outer panel jig hole Measurement Dimension The mark shows the low roof model Measurement Position Length mm in r t 1196 1 47 09 r t 1112 2 43 79 r v 1394 2 54 89 r v 1298 6 51 13 s...

Page 683: ...od bracket inside d d Installation hole of engine mount bracket outside j15 e e Drain hole of floor center frame f Engine mount installation hole on rear crossmember g g Trailing arm installation hole...

Page 684: ...0 17 32 i 2891 5 113 84 325 7 12 82 400 1 15 75 j 2963 5 116 67 83 0 3 27 k 3196 5 125 85 312 0 12 28 487 0 19 17 Measurement Dimension Measurement Position Length mm in Measurement Position Length mm...

Page 685: ...t inside d d Installation hole of engine mount bracket outside e Cabin back lower member hole square hole f Engine mount installation hole on rear crossmember left side g g Deck mounting hole h h Drai...

Page 686: ...19 37 i 2353 8 92 67 0 0 458 5 18 05 j 2481 5 97 70 250 4 9 84 576 7 22 70 k 2681 5 105 57 208 5 8 21 392 3 15 44 l 3306 5 130 18 137 5 5 41 530 5 20 89 Measurement Dimension Measurement Position Leng...

Page 687: ...after the ignition switch is turned to the LOCK position and negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Modul...

Page 688: ...SEAT IF EQUIPPED 1 Driver side air bag if equipped 2 Passenger side air bag if equipped 3 Lap shoulder seat belt with Emergency Locking Retractor ELR 4 Lap seat belt 5 Energy Management Loop EML if eq...

Page 689: ...currence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts SEAT BELT ON VEHICLE SERVICE SERVICE PRECAUTI...

Page 690: ...re starting to work and observe every precaution during work REMOVAL Remove front seat belts 1 Upper anchor 2 Lower anchor 3 Retractor assembly 4 Buckle 5 Front seat belt Truck Van Tightening Torque a...

Page 691: ...be torqued to specification Belt latch It should be secure when latched INSTALLATION Install in reverse order of removal noting the following Seat belt anchor bolts should have an unified fine thread...

Page 692: ...NSTALLATION Install the 2nd seat belt observing the same precautions as when installing front seat belt Refer to INSTALLATION of FRONT SEAT BELT in this section Be sure to tighten seat belt anchor bol...

Page 693: ...t type INSPECTION Check the 3rd seat belt in the same way as when inspecting front seat belt Refer to INSPECTION of FRONT SEAT BELT in this section INSTALLATION Install the 3rd seat belt observing the...

Page 694: ...NING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fastening arts N m kg m lb ft Upper and lower anchor bolt 35 3 5 25 5 Retractor assembly bolt 35 3 5 25 5 Retractor assembly screw 5 5 0 55...

Page 695: ...out The correct torque value must be used when installing fasteners that require it If the above conditions are not followed parts or system damage could result CONTENTS 10B GENERAL DESCRIPTION 10B 3...

Page 696: ...nspections 10B 35 ON VEHICLE SERVICE 10B 38 Service Precautions 10B 38 Service and diagnosis 10B 38 Disabling air bag system 10B 39 Enabling air bag system 10B 39 Handling and storage 10B 40 Disposal...

Page 697: ...offered by the driver and front passenger if equipped seat belts 1 Driver side air bag 2 Passenger side air bag if equipped The air bag system is designed to activate only in severe frontal collision...

Page 698: ...AND WIRING LOCATION VIEW AND CONNECTORS 1 Air bag harness 2 Fuse box 3 AIR BAG monitor coupler 4 DLC 5 Contact coil assembly 6 Driver air bag inflator module 7 Passenger air bag inflator module if equ...

Page 699: ...flator module if equipped 13 AIR BAG monitor coupler 14 Ground for air bag system WIRE HARNESS COLOR B Black B W Black White B Bl Black Blue G Green G R Green Red Or Orange V Violet V G Violet Green Y...

Page 700: ...e voltage and resistance You should be familiar with proper use of a scan tool such as Air Bag Driver Passenger Load Tool Connector Test Adapter Kit and the Digital Multimeter WARNING To avoid deploym...

Page 701: ...s connector for passenger air bag inflator mod ule Another connector BASE OF COLUMN is used to substitute the load of the driver air bag inflator module and the contact coil as sembly when it is conne...

Page 702: ...rminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal included in the connector test adapter kit special tool If contact tension is not enough...

Page 703: ...tarting point of any air bag system diagnosis The AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE checks for proper AIR BAG warning lamp op eration through AIR BAG warning lamp and whether air bag diagnost...

Page 704: ...NO CODES displayed NOTE See NOTE2 described below Air bag system is in good condition NOTE See NOTE3 described below An intermittent trouble has oc curred at some place Check the connector harness et...

Page 705: ...UKI scan tool from data link connector DLC 1 Data link connector DLC Not using SUZUKI scan tool 1 Check that malfunction indicator lamp AIR BAG warning lamp comes ON when ignition switch is turned to...

Page 706: ...6 Perform DTC CHECK and confirm that normal DTC NO CODES is displayed and not malfunction DTC NOTE If DTC B1051 or DTC B1071 is stored in SDM it is not pos sible to clear DTC 1 Data link connector DL...

Page 707: ...ated the lowest numbered code will appear first If a code not listed on the table is displayed then the SDM is faulty Current DTC and history DTC can be identified by lighting and flashing of AIR BAG...

Page 708: ...is table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in...

Page 709: ...wire between ignition switch and AIR BAG fuse open or short to ground 3 1 Disconnect 16 pin connector from com bination meter Refer to COMBINATION METER in SECTION 8 2 Check resistance between A2 term...

Page 710: ...n good SDM and recheck Go to step 4 4 1 Remove combination meter Refer to COM BINATION METER in SECTION 8 2 Check proper connection to combination me ter at Or terminal for AIR BAG warning lamp and to...

Page 711: ...e terminal Special Tool A 09932 76010 NOTE Upon completion of inspection and repair work perform following items 1 Reconnect all air bag system components ensure all components are properly mounted 2...

Page 712: ...easure resistance between A15 terminal of SDM connector and body ground 3 Is resistance 1 or more Substitute a known good SDM and recheck Repair short from V wire circuit to ground Fig for STEP 2 Spec...

Page 713: ...e A15 terminal of SDM connector and terminal on AIR BAG monitor coupler terminals 3 If OK then measure resistance between V wire circuit terminals 4 Is resistance 1 or more Check V wire terminals If O...

Page 714: ...en measurement of resistance or voltage is required in this table use a tester along with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is...

Page 715: ...ers or short to ground or power circuit which has occurred some where in serial data circuit V G wire circuit 3 1 With ignition switch OFF disconnect SDM and E connector 2 Check proper connection at V...

Page 716: ...air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN DTC B1015 The combined resistance of the passenger air bag...

Page 717: ...G INFLATOR MOD ULE in this section 2 1 With ignition switch OFF disconnect SDM 2 Check proper connection to SDM at termi nals A7 and A8 3 If OK then measure resistance between A7 and A8 terminals with...

Page 718: ...1 With ignition switch OFF disconnect SDM 2 Check proper connection to SDM at ter minals A7 and A8 3 If OK then measure resistance between A7 and A8 terminals with connected Special Tool B 4 Is resist...

Page 719: ...switch OFF disconnect Special Tool B and SDM 2 Measure resistance between A7 termi nals and body ground 3 Is resistance 10 or more Go to step 3 Repair short from Y R wire circuit to ground 3 1 Measur...

Page 720: ...t Special Tool B and SDM 2 Measure voltage from A7 terminal to body ground 3 With ignition switch ON is voltage 1 V or less Go to step 3 Repair short from Y R wire circuit to power circuit 3 1 Measure...

Page 721: ...ness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC WILL SET WHEN DTC B1021 The combined resistance of the driver air bag inflator module con...

Page 722: ...or located near the base of the steering column 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper connection to driver a...

Page 723: ...t coil connector located near the base of the steering column 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper connecti...

Page 724: ...teering column 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper connection to driver air bag inflator module at termina...

Page 725: ...se of the steering column 2 Remove driver air bag inflator module from steering wheel Refer to DRIVER AIR BAG IN FLATOR MODULE in SECTION 3C 3 Check proper connection to driver air bag infla tor modul...

Page 726: ...with a cor rect terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to INTERMITTENT AND POOR CONNEC TIONS in this section If there is ope...

Page 727: ...8 V or more Repair poor connec tion high resistance in Y B or B Bl cir cuit of air bag har ness or AIR BAG fuse Possibly faulty points are as follows Check each of them and repair as neces sary Circu...

Page 728: ...ents and perform inspections as di rected in REPAIRS AND IN SPECTIONS REQUIRED AF TER AN ACCIDENT in this section Substitute a known good SDM and recheck NOTE Upon completion of inspection and repair...

Page 729: ...ed SDM Contact coil and combination switch assembly Air bag wire harness Proper operation of the sensors and air bag system requires that any repairs to the vehicle struc ture return it to its origina...

Page 730: ...c Check that SDM cannot be installed properly due to a cause in itself There is a gap between SDM and SDM plate or it cannot be fixed securely Check that connector or lead wire of SDM has a scorching...

Page 731: ...Check for damages deformities or poor connections Refer to INTERMITTENTS AND POOR CONNECTIONS in this section Check wire harness clamps for tightness If any faulty condition is found correct or repla...

Page 732: ...CHECK will verify proper AIR BAG warning lamp operation and will lead you to the correct chart to diagnose any air bag malfunctions Bypassing these procedures may result in extended diag nostic time...

Page 733: ...ever ii After unlocked disconnect connector NOTE With AIR BAG fuse removed and ignition switch ON AIR BAG warning lamp will be ON This is normal operation and does not indicate a air bag system malfun...

Page 734: ...when SDM is not rigidly attached to the vehicle Otherwise personal injury may result CAUTION After detecting one time of such collision as to meet de ployment conditions the SDM must not be used Refe...

Page 735: ...fimmediately with a dry cloth If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be replaced with a new one as an assem bly WARNING Never attempt to measure the resis...

Page 736: ...M COVER AIR BAG OPENING UP AWAY FROM LOOSE OBJECTS 1 Slit on workbench 2 Workbench vise 3 Lower mounting bracket DEPLOYED AIR BAG INFLATOR MODULES WARNING The air bag inflator module immediately after...

Page 737: ...t Poor grounding can cause intermittent problems that are difficult to diagnose 1 Air bag wire harness 2 Ground 3 SDM case ground DISPOSAL Do not dispose of the live undeployed air bag inflator module...

Page 738: ...TE Do not separate SDM and SDM plate INSPECTION CAUTION Do not connect a tester whatever type it may be Never repair or disassemble SDM If SDM was dropped from a height of 90 cm 3 ft or more it should...

Page 739: ...sult CAUTION If air bag Inflator module was dropped from a height or 90 cm 3 ft or more it should be replaced Check air bag inflator module appearance visually for following symptoms and if any one of...

Page 740: ...bag system Refer to ENABLING AIR BAG SYSTEM of SERVICE PRECAUTIONS in this section 1 Passenger air bag inflator module 2 Instrument panel 3 Glove box 4 Glove box clip 5 Harness cover DRIVER AIR BAG I...

Page 741: ...work Failure to observe any of them may result in personal injury To avoid an accidental deployment this work should be performed by no more than one person The procedure should be followed strictly...

Page 742: ...over away from you When storing a live air bag inflator module or when leaving a live air bag inflator module unat tended on a bench or other surface always face the bag and trim cover up and away fro...

Page 743: ...re there is no activity is preferred If an outdoor location is not available a space on the shop floor where there is no activity and sufficient ventilation is recom mended Ensure that no loose or fla...

Page 744: ...onnector with lock lever 11 Notify all people in the immediate area that you intend to deploy the air bag inflator module NOTE When the air bag deploys the rapid gas expansion will create a substantia...

Page 745: ...rness leads together by fully seating one banana plug into the other 15 In the unlikely event that the air bag inflator module did not deploy after following these procedures proceed immediately with...

Page 746: ...the air bag inflator module did not deploy after following these procedures 20 Ensure that the deployment harness has been disconnected from the power source and that its two banana plugs have been s...

Page 747: ...r module if equipped Remove glove box from instrument panel and disconnect pas senger air bag inflator module connector Yellow connector 4 Confirm that each air bag inflator module is securely mounted...

Page 748: ...ate area that you in tend to deploy the air bag inflator module and suitable ear protection should be worn After the air bag inflator module has been deployed the surface of the air bag may contain a...

Page 749: ...y air bag inflator mod ules which has not been deployed if any 21 In the unlikely event that the air bag inflator module proceed immediately with Steps 23 through 25 If the air bag inflator module did...

Page 750: ...t is very hot Wait for 30 minutes to cool it off before handling it Never apply water oil etc to deployed air bag inflator module to cool it off and be careful so that water oil etc does not get on th...

Page 751: ...the specified digital multimeter Otherwise air bag deployment or personal injury may result Digital multimeter for which the maximum test current is 10 mA or less at the minimum range of resistance m...

Page 752: ...Prepared by Overseas Service Department 1st Ed February 1999 2nd Ed October 2001 Printed in Japan Printing 762...

Page 753: ......

Page 754: ...Bag System Service on or around the air bag system components must be performed only by an authorized SUZUKI dealer Please ob serve all WARNINGS CAUTIONS and Service Precautions under On Vehicle Serv...

Page 755: ...lt this supplement first And for any section item or description not found in this supplement refer to the related manuals mentioned in the next page When replacing parts or servicing by disassembling...

Page 756: ...ERVICE MANUAL FOR 4WD MODEL 99501 76A00 XXX 4WD vehicle before the vehicle identifica tion number mentioned in FOREWORD of this supplementary service manual GA413 WIRING DIAGRAM MANUAL 99512 76A10 015...

Page 757: ...ngine and Emission Control System Ignition System Cranking System Charging System Exhaust System Manual Transmission 2WD Clutch Differential Rear HEATING AND AIR CONDITIONING STEERING SUSPENSION WHEEL...

Page 758: ...ul to use bolts and nuts of the same strength or greater than the original fasteners the same number marking or higher It is likewise important to select replacement fasteners of the correct diameter...

Page 759: ...0 116 0 N m 2 4 4 7 8 4 20 42 80 125 193 280 kg 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 5 202 5 N m 2 4 4 9 8 8 21 44 84 133 203 298 kg m 0 24 0 49 0 88 2 1...

Page 760: ...ure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in severe injury Technical service work...

Page 761: ...grade oil Vehicle without HO2S Replace every 10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R 1 6 Exhaust system I I I IGNITION SYSTEM 2 1 Spark plugs When unleaded fuel is used Vehicle withou...

Page 762: ...Brake discs and pads front I I I I I I Brake drums and shoes rear I I I 6 3 Brake hoses and pipes I I I 6 4 Brake fluid R R R 6 5 Parking brake lever and cable Inspect at first 15 000 km 9 000 miles o...

Page 763: ...belt I Every 15 000 km 9 000 miles or 12 months B C D Drive belt V rib belt R Every 45 000 km 27 000 miles or 36 months A C D E F H Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months A...

Page 764: ...the ve hicle Make sure that exhaust system components have enough clearance from the underbody to avoid overheating and pos sible damage to the floor carpet Any defects should be fixed at once WARNING...

Page 765: ...nt if any 2 Make sure that vehicle is placed level for oil level check 3 Remove level plug of transmission 4 Check oil level Oil level can be checked roughly by means of level plug hole That is if oil...

Page 766: ...l 4 Tighten level plug to specified torque Refer to OIL CHANGE in SECTION 7E and or 7F Change Change differential oil with new specified oil Refer to OIL CHANGE in SECTION 7E and or 7F A B A Front dif...

Page 767: ...E for detail Brake fluid DOT 3 Manual transmission oil API GL 4 Refer to MAINTENANCE SERVICE in SECTION 7A or 7A1 for detail Differential oil Hypoid gear oil API GL 5 Refer to OIL CHANGE in SECTION 7E...

Page 768: ...d or could result in major repair expense They must be re placed with one of the same part number or with an equivalent part if replacement becomes nec essary Do not use a replacement part of lesser q...

Page 769: ...to the stud of a ball joint which is incorporated in a unit with a suspension control arm And connected to this steering knuckle is the tie rod end Thus movement of the steering wheel is transmitted t...

Page 770: ...stalling directions Tighten strut nut to specified torque and then apply water proof coating paint or lacquer all around nut and strut rod screw part NOTE As shown at the left have sections A and B of...

Page 771: ...must be used as specified during reassembly to assure proper retention of this part Never attempt to heat quench or straighten any suspension part Replace it with a new part or dam age to the part ma...

Page 772: ...7 Lateral rod outer washer 8 Rear axle 9 Bearing 10 Rear shaft oil seal 11 Brake drum 12 Bearing retainer ring 13 Rear axle shaft 14 Wheel bearing spacer Tightening Torque a 80 N m 8 0 kg m 58 0 lb ft...

Page 773: ...after the ignition switch is turned to the LOCK position and negative cable is disconnected from the battery Otherwise the sys tem may be activated by reserve energy in the Sensing and Diagnostic Mod...

Page 774: ...disc brake type is used of the front wheel brake and a drum brake type leading trailing shoes for the rear wheel brake The parking brake system is mechanical It applies brake force to only rear wheels...

Page 775: ...to make sure that flexible hose doesn t contact any part of suspension both in extreme right and extreme left turn conditions If it does at any point remove and correct Fill and maintain brake fluid l...

Page 776: ...ng one brake pad with wear gauge install the pad with wear gauge to body center side of right caliper carrier 1 Clips 2 Pads 3 Wear gauge 4 Caliper carrier BRAKE STOP LAMP REMOVAL 1 Disconnect negativ...

Page 777: ...Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be...

Page 778: ...Activity Detected Sensor 1 6 54 DTC P0135 HO2S Heater Circuit Malfunction Sensor 1 6 55 DTC P0136 HO2S Circuit Malfunction Sensor 2 6 57 DTC P0141 HO2S Heater Circuit Malfunction Sensor 2 6 60 DTC P01...

Page 779: ...e to disconnect cables may result in damage to wire har ness or other electrical parts Throughout this manual the four cylinders of the engine are identified by numbers No 1 1 No 2 2 No 3 3 and No 4 4...

Page 780: ...onnecting fuel or fuel vapor hose be sure to connect and clamp each hose correctly referring to left figure Hose Con nection After connecting make sure that it has no twist or kink When installing inj...

Page 781: ...el pressure in lines Fuel connections are now safe for servicing 6 Upon completion of servicing connect fuel pump relay 1 to its connector CAUTION This work must not be done when engine is hot If done...

Page 782: ...with the engine at a stop malfunction indicator lamp MIL 1 turns ON to check the bulb of the malfunction indicator lamp 1 When ECM detects a malfunction which gives an adverse effect to vehicle emiss...

Page 783: ...Also ECM has a function to store each freeze frame data for three different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunc...

Page 784: ...al data line is used for SUZUKI scan tool Tech 1 to communicate with immobilizer control module B Body ground ECM ground Serial data line K line of ISO 9141 SUZUKI serial data line 6 8 ENGINE GENERAL...

Page 785: ...ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the trouble area in ECM back up memory The memory is kept as it is even if the trouble w...

Page 786: ...diagnostic trouble codes according to the following priorities 1 Diagnostic trouble codes DTCs other than DTC P0171 P0172 Fuel system too lean too rich DTC P0300 P0301 P0302 P0303 P0304 Misfire detect...

Page 787: ...l Never connect probe where male terminal is supposed to fit 1 Connector 2 Probe 3 Where male terminal fits In case of such connector as shown connect connector test adopter and probe Special tool A 0...

Page 788: ...tion 1 Confirm trouble symptom referring to the next page Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame da...

Page 789: ...MATION Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC freeze frame data check confirm trouble symptoms Also reconfirm DTC according to DTC Confirmation Procedure de...

Page 790: ...nvironmental Condition Weather Temperature Frequency Road jFair jCloudy jRain jSnow jAlways jOther jHot jWarm jCool jCold _F _C jAlways jAlways jSometimes times day month jOnly once jUnder certain con...

Page 791: ...d print it or write it down Refer to scan tool operator s manual for further details If communication between scan tool and ECM is not possible check if scan tool is communicable by connecting it to E...

Page 792: ...operator s manual for fur ther details 4 After completing the clearance turn ignition switch off and dis connect scan tool from data link connector NOTE DTC and freeze frame data stored in ECM memory...

Page 793: ...133 HO2S circuit slow response Sensor 1 Response time of HO2S 1 output voltage between rich and lean is longer than specification 2 driving cycles Not applicable P0134 No 14 HO2S circuit no activity d...

Page 794: ...HO2S 1 to that of HO2S 2 is shorter than specifica tion 2 driving cycles Not applicable P0443 Purge control valve circuit malfunction Purge control valve circuit is open or shorted to ground 2 driving...

Page 795: ...Refer to Section 8G P1622 No 82 Faulty in ECM Refer to Section 8G P1623 No 81 ECU code not matched Note D For marked No in DTC column it is used for vehicle without EGR valve D DTC No 12 appears when...

Page 796: ...ure is 20_C 68_F D ECM PCM stops EGR and idle air control P0115 No 19 Engine coolant temp sensor circuit mal function D ECM PCM controls actuators assuming that en gine coolant temperature is 80_C 176...

Page 797: ...tion bend Connectors of electric wire harness disconnection friction Fuses burning Parts installation bolt looseness Parts deformation Other parts that can be checked visually Also check following ite...

Page 798: ...ound See Fig 2 When using SUZUKI scan tool select MISC mode on SUZUKI scan tool and fix ignition timing to initial one See Fig 3 2 Open the engine service hole cover behind the front seats and remove...

Page 799: ...ration as follows 1 Install spark plugs and connect injector connectors 2 Using sound scope 1 check operating sound of each injector 2 when cranking engine See Fig 6 Was injector operating sound heard...

Page 800: ...ve timing Compression leak from valve seat Sticky valve stem Weak or damaged valve springs Compression leak at cylinder head gasket Sticking or damaged piston ring Worn piston ring or cylinder Faulty...

Page 801: ...in Section 6E Accelerator cable play in Section 6E Previously outlined Diagnosis in Section 5 Diagnosis in Section 7C Improper engine idling or engine fails to idle Ignition system out of order Fault...

Page 802: ...edal Ignition system out of order D Faulty ignition coil or high tension cord Engine and emission control system out of order D Variable fuel pressure D Faulty MAP sensor if equipped D Faulty injector...

Page 803: ...Section 5 Diagnosis in Section 7C Valves and cylinder head inspection in Section 6A Poor gasoline mileage Ignition system out of order Faulty ignition coil or high tension cord Engine and emission co...

Page 804: ...n 6A Refer to Section 6A Engine noise Note Before check ing the mechanical noise make sure that Ignition timing is properly adjusted Specified spark plug is used Specified fuel is used Valve noise Imp...

Page 805: ...e B 3 Maintenance in Section 6K PCV hose and PCV valve in Section 6E EVAP control system check in Section 6E Check oxygen sensor output voltage Refer to DTC P0130 Table in this section Diagnostic Flow...

Page 806: ...sary switches SCAN TOOL DATA CONDITION REFERENCE VALUES FUEL SYSTEM B1 FUEL SYSTEM STATUS At specified idle speed after warming up CLOSED closed loop CALC LOAD CALCULATED LOAD At specified idle speed...

Page 807: ...at fuel cut condition ON FUEL CUT Other than fuel cut condition OFF RADIATOR FAN RADIATOR FAN Ignition switch Engine coolant temp 85 5C 1855F or lower OFF RADIATOR FAN CONTROL RELAY g ON Engine coola...

Page 808: ...e air temp sensor and used to determine the amount of air passing into the intake manifold as air density varies with temperature MAF MASS AIR FLOW RATE gm s lb min It represents total mass of air ent...

Page 809: ...light heater fan or rear window defogger ON signal inputted OFF Above electric loads all turned OFF A C SWITCH ON OFF ON Command for A C operation being output from ECM to A C amplifier OFF Command fo...

Page 810: ...Connector 2 Probe 6 34 ENGINE GENERAL INFORMATION AND DIAGNOSIS GA413 supple TERMINALS CIRCUIT STANDARD RESISTANCE C23 6 to L20 2 3 HO2S 1 heater if equipped 5 6 4 W L20 1 to L20 17 HO2S 2 heater if e...

Page 811: ...nsor 10 TP sensor A ECM B A C control module if equipped C DLC D ABS hydraulic unit if equipped E EVAP canister a MIL b IAC valve c EVAP canister purge valve d Fuel injector e Ignitor coil f EGR valve...

Page 812: ...MIL Power Supply Check 1 Turn ignition switch ON Do other indicator warning lights in com bination meter comes ON Go to Step 2 Main fuse blown ignition switch malfunction BLK WHT circuit between IG C...

Page 813: ...t shorted to ground Substitute a known good ECM and recheck TABLE A 3 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK MIL FLASHES AT IGNITION SWITCH ON VEHICLE WITH MONITOR CONNECTOR WIRING DIAGRAM CIRCUIT D...

Page 814: ...t jumper wire from monitor connector b terminal to monitor connector d terminal See Fig 1 3 Check for continuity from L20 21 terminal of ECM connector to ground Is there continuity Go to Step 2 BLU WH...

Page 815: ...remove main relay 1 2 Check for proper connection to main relay 1 at terminal 3 and 4 3 Check resistance between each two terminals See Fig 1 and 2 Between terminals A and B Infinity Between terminals...

Page 816: ...14 V Check ground circuits BLK and BLK BLU for open If OK then substitute a known good ECM and recheck Go to Step 6 6 Is operating sound of main relay heard in Step 1 Go to Step 7 BLK RED or BLK BLU w...

Page 817: ...signal is 4 49 V or higher High pressure Low vacuums High voltage BLU YEL circuit open LT GRN RED circuit open or shorted to ground LT GRN YEL circuit open or shorted to ground MAP sensor malfunction...

Page 818: ...ls 3 If OK then with ignition switch ON check voltage at each of LT GRN RED and LT GRN YEL wire terminals and body ground See Fig 1 Is voltage about 4 6 V at each terminal Go to Step 4 LT GRN RED wire...

Page 819: ...tage Low resistance LT GRN BLK circuit open or shorted to power BLU YEL circuit open IAT sensor malfunction ECM malfunction NOTE When DTC P0105 No 11 P0110 No 18 P0115 No 19 and P0120 No 13 are indica...

Page 820: ...tch ON is voltage applied to LT GRN BLK wire terminal about 4 6 V See Fig 1 Go to Step 5 LT GRN BLK wire open or shorted to pow er or poor C23 23 con nection If wire and connection are OK substitute a...

Page 821: ...T GRN WHT circuit open or shorted to power BLU YEL circuit open ECT sensor malfunction ECM malfunction NOTE When DTC P0105 No 11 P0110 No 18 P0115 No 19 and P0120 No 13 are indicated together it is po...

Page 822: ...titute a known good ECM and recheck 4 Does scan tool indicate 40 C 40 F at Step 2 Go to Step 6 Go to Step 5 5 Check Wire Harness 1 Disconnect ECT sensor connector with ignition switch OFF 2 Check for...

Page 823: ...BLU YEL circuit open GRY YEL circuit open or shorted to ground LT GRN RED circuit open or shorted to power or ground TP sensor malfunction ECM malfunction NOTE When DTC P0105 No 11 P0110 No 18 P0115 N...

Page 824: ...YEL and BLU YEL wire terminal 3 If OK then with ignition switch ON check voltage at each of LT GRN RED and GRY YEL wire terminals and body ground See Fig 1 Is voltage about 4 6 V at each terminal Go t...

Page 825: ...10_C 14_F or higher Intake air temp 70_C 158_F or lower Engine coolant temp 705C 1585F or higher 2 Warm up engine to normal operating temperature 3 Increase vehicle speed to 30 40 mph 50 60 km h in 3...

Page 826: ...6 50 ENGINE GENERAL INFORMATION AND DIAGNOSIS GA413 supple Fig 1 for Step 2 Fig 2 for Step 3 Closed condition A Fully open Throttle Opening...

Page 827: ...TION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful during testing to avoid occurrence of an accident...

Page 828: ...operating tempera ture and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal to enrich and enlean A F m...

Page 829: ...rom lean to rich or from rich to lean of HO2S 1 output voltage is about 1 sec at minimum or average time of 1 cycle is 5 sec at minimum See Fig 1 2 driving cycle detection logic Monitoring once 1 driv...

Page 830: ...to DTC P0130 section INSPECTION STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Is there DTC s other than Fuel system DTC P0171 P0172 and HO2S 1 D...

Page 831: ...cle detection logic Continuous monitoring HO2S 1 heater circuit open or shorted to ground ECM malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is n...

Page 832: ...to Intermit Go to Step 3 2 Check BLK RED and BLU wires for open or short Are BLK RED and BLU wires in good condition tent and Poor Connec tion in Section 0A 3 Check Heater of Sensor 1 1 Disconnect HO...

Page 833: ...CUIT DESCRIPTION 1 Heated oxygen sensor 2 HO2S 2 DTC DETECTING CONDITION POSSIBLE CAUSE Engine is warmed up and HO2S 2 voltage is 4 5 V or more circuit open 2 driving cycle detection logic monitoring...

Page 834: ...d to higher than 20 mph 32 km h and then stop vehicle 6 Repeat above steps 5 4 times 7 Increase vehicle speed to about 50 mph 80 km h in 3rd gear 8 Release accelerator pedal and with engine brake appl...

Page 835: ...3 Check HO2S 2 and Its Circuit Was HO2S 2 output voltage indicated on scan tool in step 3 of DTC confirmation test less than 1 275 V Go to Step 4 BLU or RED circuit open or HO2S 2 malfunction 4 Check...

Page 836: ...fied time after engine start or while engine running at high load B High voltage at terminal L20 1 while engine running under other than above condition 2 driving cycle detection logic continuous moni...

Page 837: ...hort Are BLK WHT and BLU wires in good condition Intermittent trouble Check for intermittent referring to Intermit tent and Poor Connec tion in Section 0A Go to Step 3 3 Check Heater or Sensor 2 1 Dis...

Page 838: ...ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Start engine and keep it at idle for 5 sec or more 4 Check DTC by using scan tool INSPECTION STEP ACTION YES NO 1...

Page 839: ...G CONDITION POSSIBLE CAUSE When following condition occurs while engine running under closed loop condition Air fuel ratio too lean Total fuel trim short and long terms added is more than 30 or Air fu...

Page 840: ...ith ignition switch ON 3 Check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C...

Page 841: ...s and Circuit 1 Using sound scope 1 or such check operating sound of each injector 2 when engine is running Cycle of operating sound should vary according to engine speed See Fig 2 If no sound or an u...

Page 842: ...ood condition Go to Step 10 Replace intake air temp sensor 10 Check throttle position sensor for performance See step 4 of DTC P0121 Diag Flow Table Is it in good condition Go to Step 11 Replace throt...

Page 843: ...r Then it calculates the change in the crankshaft revolution speed and from how many times such change occurred in every 200 or 1000 engine revolutions it detects occurrence of misfire When ECM detect...

Page 844: ...misfire occurs at cylinders 1 and 4 or cylinders 3 and 2 simulta neously it may not possible to reconfirm DTC by using the following DTC confirmation procedure When diagnosing the trouble of DTC P0300...

Page 845: ...uel pump operating and engine at stop 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi At specified idle speed 210 260 kPa 2 1 2 6 kg cm2 29 8 37 0 psi Is measured value as specified Go to Step 5 Go to Diag F...

Page 846: ...See step 4 DTC P0105 Diag Flow Table Is it in good condition Go to Step 9 Repair or replace 9 Check engine coolant temp sensor for performance See Section 6E Is it in good condition Go to Step 10 Rep...

Page 847: ...ctor 4 Shield wire 5 ECM connector C23 6 ECM DTC DETECTING CONDITION POSSIBLE CAUSE NO CKP sensor signal for 2 seconds at engine crank ing CKP sensor circuit open or short Signal teeth damaged CKP sen...

Page 848: ...Then check for proper connection to CKP sensor at RED BLU and WHT BLU wire terminals 3 If OK measure sensor resistance between termi nals See Fig 1 CKP sensor resistance 360 460 at 20 C 68 F 4 Measure...

Page 849: ...e number of CMP sensor signal pulses is incorrect during 6 revolution of crankshaft CMP sensor circuit open or short Signal rotor teeth damaged CMP sensor malfunction foreign material being attached o...

Page 850: ...check result satisfactory Go to Step 5 Go to Step 4 4 Was terminal Vout voltage out of specification in Step 3 check BRN RED wire open short or poor connec tion If wire and connection are OK substitu...

Page 851: ...vehicle speed after engine warm up During deceleration engine speed high with closed throttle position ON in which fuel cut is involved difference in intake manifold absolute pressure between when EGR...

Page 852: ...for 5 min 3 Increase vehicle speed to 50 55 mph 80 88 km h in 5th gear 4 Hold throttle valve at that opening position for 2 min or longer 5 Increase engine speed to 4000 r min in 3rd gear 6 Release a...

Page 853: ...tch OFF disconnect EGR valve coupler 2 With ignition switch ON check voltage between a and ground b and ground Is each voltage 10 14 V Go to Step 5 Faulty BLK RED wire 5 EGR Valve Stepper Motor Coil C...

Page 854: ...n concentration is slower than that of HO2S 1 output voltage because of the amount of oxygen in the exhaust gas which has been stored in the catalyst Reference Oscilloscope Waveforms Engine running at...

Page 855: ...lyst Monitoring TEST COMPLETED is displayed in READINESS TESTS mode and DTC is not displayed in DTC mode confirmation test is completed If TEST NOT COMPLTD is still being displayed continue test drivi...

Page 856: ...p 3 of DTC confirmation test Go to Step 3 Check fuel system Go to DTC P0171 P0172 Diag Flow Table 3 Check HO2S 2 for Output Voltage Perform steps 1 through 9 of DTC confirmation procedure for DTC P013...

Page 857: ...DTC and pending DTC by using scan tool INSPECTION STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check EVAP canister purge system for operation...

Page 858: ...engine coolant temp is below 85 C 185 F 2 driving cycle detection logic continuous monitoring D RED GRN or BLK RED circuit open or short D Radiator fan motor relay malfunction D ECM malfunction DTC C...

Page 859: ...ain Relay Fuel Pump Relay Radiator Fan Relay Inspec tion in Section 6E Is radiator fan relay functioning normally Go to Step 4 Faulty radiator fan relay 4 1 Turn ignition switch ON position leaving en...

Page 860: ...alfunction D Speedometer malfunction DTC CONFIRMATION PROCEDURE WARNING D When performing a road test select a place where there is no traffic or possibility of a traffic acci dent and be very careful...

Page 861: ...OFF position disconnect VSS connector 2 Turn ignition switch to ON position without running engine 3 Measure voltage from terminal a to b of VSS connector Is voltage within 10 14 V Go to Step 5 BLK RE...

Page 862: ...NG CONDITION POSSIBLE CAUSE D No closed signal to IAC valve is detected after engine start 2 driving cycle detection logic continuous monitoring D BLK RED ORN or BLK BLU circuit open or short D IAC va...

Page 863: ...UZUKI scan tool 1 Remove IAC valve from throttle boy referring to IAC Valve Removal in Section 6E 2 Check IAC valve for operation referring to IAC Valve Inspection in Section 6E See Fig 1 Is check res...

Page 864: ...n logic monitoring once 1 driving D ECM barometric pressure sensor malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Turn ignition switch ON for 2...

Page 865: ...supple STEP ACTION YES NO 3 Check MAP Sensor 1 Remove MAP sensor from intake manifold and connect vacuum pump gauge to MAP sensor See Fig 1 2 Connect scan tool to DLC and turn ignition switch ON 3 Ch...

Page 866: ...tion switch OFF 2 Clear DTC with ignition switch ON crank engine and run it at idle for 3 min 3 Check pending DTC in PENDING DTC mode and DTC in DTC mode INSPECTION STEP ACTION YES NO 1 Was ENGINE DIA...

Page 867: ...g engine WHT circuit open ECM malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and run it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION STEP ACTION YES NO 1...

Page 868: ...or operating sound at engine cranking Do all 4 injector make operating sound Fuel injector circuit is in good condition Go to Step 3 3 Dose none of 4 injectors make operating sound at Step 2 Go to Ste...

Page 869: ...Pump for Operation 1 Remove fuel pump relay from relay box with ignition switch OFF 2 Check for proper connection to relay at each terminals 3 If OK using service wire connect terminals A and B of re...

Page 870: ...6 94 ENGINE GENERAL INFORMATION AND DIAGNOSIS GA413 supple Fig 1 for Step 2 Fig 2 for Step 3 Fig 3 for Step 4...

Page 871: ...then 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi Go to Step 2 Go to Step 4 2 Is 200 kPa 2 0 kg cm2 28 4 psi or higher fuel pressure retained for 1 minute after fuel pump is stopped at Step 1 Normal fuel...

Page 872: ...er purge control system Clog of IAC air passage Accessory engine load Closed throttle position TP sensor Stuck of PCV valve 3 Is engine idle speed kept specified speed even with headlight ON System is...

Page 873: ...system Check TP sensor closed throttle position and ECT sensor for perfor mance If sensors are OK substitute a known good ECM 8 Check IAC system referring to Step 2 of DTC P0505 Diag Flow Table Is che...

Page 874: ...Then A C is operated INSPECTION STEP ACTION YES NO 1 Did you perform ENGINE DIAGNOSTIC FLOW TABLE in Section 6 Go to Step 2 Go to ENGINE DIAG NOSTIC FLOW TABLE 2 Check A C signal circuit 1 Disconnect...

Page 875: ...n switch OFF 2 Start engine and select DATA LIST mode on scan tool 3 Check electric load signal under following each condition Ignition switch ON Small light and rear defogger all turned OFF OFF Ignit...

Page 876: ...diator Fan Relay and Its Circuit 1 Check DTC and pending DTC with scan tool Is DTC P0480 displayed Go to DTC P0480 Diag Flow Table Go to Step 3 3 Check radiator Fan Relay 1 Turn ignition switch OFF an...

Page 877: ...NERAL INFORMATION AND DIAGNOSIS 6 101 GA413 supple Fig 1 for Step 3 Fig 2 for Step 4 1 Radiator cooling fan 2 Radiator cooling fan connector 1 Main fuse box 2 Fuel pump relay 3 Main relay 4 Radiator f...

Page 878: ...r s manual 3 Tech 1 A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor 1 Pressure gauge 09912 58441 2 Pressure hose 09912 58431 3 3 way...

Page 879: ...Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in severe injury Technical service w...

Page 880: ...ing 117 Valve spring retainer 118 Valve cotter 119 Valve spring seat 120 Valve stem seal INSPECTION Rocker Arm to Rocker Arm Shaft Clearance Using a micrometer and a bore gauge measure rocker shaft di...

Page 881: ...s R L and rear mount ing nut as shown in the figure above 3 Reverse removal procedure for installation Install generator bracket A C compressor and generator re ferring to Section 1B and 6H Tighten bo...

Page 882: ...STMENT in Section 5 10 Adjust accelerator cable play Refer to Section 6E 11 Check to ensure that all removed parts are back in place Rein stall any necessary parts which have not been reinstalled 12 R...

Page 883: ...lt 6 Timing pulley key 7 Crankshaft 8 Thrust bearing 9 Rear oil seal 10 Pin 11 Oil seal housing gasket 12 Oil seal housing 13 Housing bolt 14 Input shaft bearing 15 Flywheel 16 Flywheel bolt ENGINE ME...

Page 884: ...or oversize one to obtain standard thrust play Out of round and taper uneven wear of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its...

Page 885: ...cap bolts to specified torque Inspection Check bearings for pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Never replace one half without replacing t...

Page 886: ...nal diameter by using following procedure As shown in figure crank webs of No 2 and No 3 cylinders have five stamped numerals Three kinds of numerals 1 2 and 3 represent following journal diameters Th...

Page 887: ...at cap bore dia of cap 5 is within 49 000 49 006 mm 3 There are five kinds fo standard bearings differing in thickness To distinguish them they are painted in following colors at the position as indic...

Page 888: ...tandard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block due to any reason select new standard bearings to be i...

Page 889: ...ring to table given below Check bearing clearance with newly selected undersize bearing Green Red Black Red Red only Black Red Red only Yellow Red Red only Yellow Red Blue Red A B C Measured journal d...

Page 890: ...boring cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear 3 Using micrometer measure...

Page 891: ...to calculated dimension NOTE Before reboring install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores 6 Measure piston clearance after honing ENGINE MEC...

Page 892: ...or this vehicle NOTE After installing radiator cap to radiator make sure that the ear of cap lines is parallel to radiator 5 Tighten hose clamps and inspect all hoses Replace hoses whenever cracked sw...

Page 893: ...the Sensing and Diagnostic Module SDM NOTE This section covers vehicle equipped with HO2S 2 rear heated oxygen sensor or immobilizer system For other than the vehicle refer to the same section of the...

Page 894: ...es fuel pump delivery pipe fuel pressure regulator etc Electronic control system includes ECM various sensors and controlled devices Emission control system includes EGR EVAP and PCV system Vehicle Sp...

Page 895: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 3 GA413 supple...

Page 896: ...6E 4 ENGINE AND EMISSION CONTROL SYSTEM GA413 supple...

Page 897: ...17 PCV valve 18 Fuel injector 19 ECT sensor 20 EGR valve if equipped 21 Three way catalytic convertor if equipped 22 CKP sensor 23 VSS 24 Heater blower fan switch 25 A C control module if equipped 26...

Page 898: ...ve 6 opening and engine speed is filtered by the air cleaner 1 passes through the throttle body 3 is distributed by the intake manifold 5 and finally drawn into each combustion chamber When the idle a...

Page 899: ...ain amount higher than the pressure in the intake manifold by the fuel pressure regulator the fuel is injected into the intake port of the cylinder head when the injector open according to the injecti...

Page 900: ...rol system Oxygen sensor heater control system Ignition control system 1 CO adjusting resistor if equipped 2 CMP sensor 3 HO2S 1 if equipped 3 1 HO2S 2 if equipped 4 VSS 5 CKP sensor 6 ECT sensor 7 MA...

Page 901: ...L VEHICLE WITHOUT EGR VALVE f BAROMETRIC PRESSURE SENSOR VEHICLE WITH EGR VALVE f f f STOP LAMP SWITCH f STARTER SWITCH f f f f IGNITION SWITCH f f f f f f f f f LIGHTING SWITCH f REAR DEFOGGER SWITCH...

Page 902: ...6E 10 ENGINE AND EMISSION CONTROL SYSTEM GA413 supple...

Page 903: ...gauge Diagnosis switch terminal vehicle without EGR valve 22 YEL VSS 23 24 RED WHT Rear defogger switch if equipped Duty output terminal vehicle without EGR valve 26 27 BLU YEL Ground for sensor Test...

Page 904: ...ight of pedal stopper bolt 3 IDLE SPEED IDLE AIR CONTROL IAC DUTY INSPECTION Before idle speed IAC duty check make sure of the following Lead wires and hoses of Electronic Fuel Injection and engine em...

Page 905: ...itor connector 1 and connect duty meter between Duty output terminal 4 and Ground terminal 5 of moni tor connector 1 If duty and or idle speed is out of specifications inspect idle air control system...

Page 906: ...inspection and adjustment exhaust gas tester CO meter and engine tachometer are necessary 1 CO adjusting resistor 1 Check idle speed according to Idle Speed Inspection section 2 Using exhaust gas test...

Page 907: ...Do not reuse ON VEHICLE INSPECTION Check that throttle valve lever 1 moves smoothly REMOVAL 1 Disconnect negative cable at battery 2 Drain cooling system Refer to Section 6B 3 Disconnect accelerator c...

Page 908: ...ing compressed air NOTE TP sensor MAP sensor idle air control valve or other compo nents containing rubber must not be placed in a solvent or cleaner bath A chemical reaction will cause these parts to...

Page 909: ...onnectors to TP sensor 1 MAP sensor 3 and IAC valve 2 securely 5 Install air cleaner outlet hose 1 and pipe 6 Connect accelerator cable and adjust cable play to specifica tion Refer to Accelerator Cab...

Page 910: ...tch while the other checks valve operation As valve operation is momentary it may be overlooked To prevent this perform this operation check 3 times or more continuously If rotary valve of lAC valve d...

Page 911: ...2 7 3 1 kg cm2 38 4 44 0 psi At specified idle speed With 1 min after engine fuel pump stop Pressure re duces as time passes over 250 kPa 2 5 kg cm2 35 6 psi CONDITION FUEL PRESSURE With fuel pump op...

Page 912: ...sure to reinstall fuel filler cap after checking If above check result is not satisfactory advance to Diagnostic Flow Table B 2 in Section 6 2 Turn OFF ignition switch and leave over 10 minutes as it...

Page 913: ...ection 6 2 Disconnect battery negative cable from battery 3 Disconnect fuel injector connectors from injectors 4 Disconnect vacuum hose from fuel pressure regulator 5 Remove fuel delivery pipe from in...

Page 914: ...L INJECTOR ON VEHICLE INSPECTION 1 Using sound scope 1 or such check operating sound of injec tor 2 when engine is running or cranking Cycle of operating sound should vary according to engine speed If...

Page 915: ...shop cloth INSPECTION WARNING As fuel is injected in this inspection perform in a well ventilated area and away from open flames Use special care to prevent sparking when connecting and disconnecting...

Page 916: ...of relay connector using service wire 1 as shown in figure c Turn ignition switch ON 7 Apply battery voltage 3 to injector 2 for 15 seconds and mea sure injected fuel volume with graduated cylinder T...

Page 917: ...injectors 4 into delivery pipe 5 and intake manifold Make sure that injectors 4 rotate smoothly If not probable cause is incorrect installation of O ring 1 Replace O ring 1 with new one Tighten delive...

Page 918: ...onnect MAP sensor connector 3 Remove MAP sensor 1 from throttle body INSPECTION 1 Arrange 3 new 1 5V batteries 2 in series check that total volt age is 4 5 5 0V and connect its positive terminal to Vi...

Page 919: ...iven in table below NOTE There should be more than 1 5 k resistance difference be tween when throttle valve is at idle position and when it is fully open If check result is not satisfactory replace TP...

Page 920: ...ector to TP sensor securely 3 Connect battery negative cable to battery 4 Turn TP sensor after fitting and align holes INTAKE AIR TEMPERATURE SENSOR IAT SENSOR REMOVAL 1 Disconnect battery negative ca...

Page 921: ...ect connector from ECT sensor 5 Remove ECT sensor 1 from intake manifold WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scaldingfluid a...

Page 922: ...nsor connector 2 Using ohmmeter measure resistance between terminals VB and GND of sensor connector NOTE Temperature of sensor affects resistance value largely Make sure that sensor heater is at corre...

Page 923: ...oxygen sensor 2 start engine and check that no exhaust gas leakage exists Sensor 1 Sensor 2 CAMSHAFT POSITION SENSOR CMP SENSOR INSPECTION Check CMP sensor referring to DTC P0340 No 15 Diag Flow Table...

Page 924: ...7 2 lb ft 3 Connect connector to it securely 4 Connect negative cable to battery CAUTION Be sure to tighten to specified torque CKP sensor will be deformed if overtightened and correct CKP sensor sign...

Page 925: ...y replace relay FUEL CUT OPERATION INSPECTION NOTE Before inspection check to make sure that gear shift lever is in neutral position A C is OFF and that parking brake lever is pulled all the way up 1...

Page 926: ...me on whether or not the engine is running The fan can start automatically in response to the ECM and ECT sensor with the ignition switch in the ON posi tion RADIATOR FAN INSPECTION 1 Check continuity...

Page 927: ...ration check If not replace 3 Disconnect hoses from intake manifold and fuel pressure regu lator 4 Blow into pipe A Air should come out of pipe B and not out of filter 5 Connect 12 V battery to fuel p...

Page 928: ...edal open EGR valve by using STEP EGR mode in MISC TEST menu In this state according as EGR valve opening increases engine idle speed drops If not possible cause is clogged EGR gas passage stuck or fa...

Page 929: ...on Be careful not to damage or bend EGR valve valve seat and rod 3 Inspect valve 2 valve seat 3 and rod for fault cracks bend or other damage If found faulty replace EGR valve assembly INSTALLATION Re...

Page 930: ...is felt when engine is running at 3000 r min NOTE ECM detects a change in the purge fuel vapor concentra tion and sometimes stops purging for several seconds but this is nothing abnormal 8 If vacuum...

Page 931: ...ore checking IAC duty for obstructed PCV valve or hose hampers its accurate adjustment PCV HOSE INSPECTION Check hoses for connection leakage clog and deterioration Replace as necessary 1 Breather hos...

Page 932: ...r 4 5 Return hose clamp 4 6 Body attachment 2 washer 4 7 Hose attachment 1 4 8 Hose attachment 2 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Powe...

Page 933: ...bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in...

Page 934: ...he secondary coil High tension cords and spark plugs CMP sensor Camshaft position sensor and CKP sensor Crankshaft position sensor Using signals from these sensors ECM identifies the specific cylinder...

Page 935: ...No 3 spark plugs 5 CMP sensor 6 CKP sensor 7 No 1 spark plug 8 No 2 spark plug 9 No 3 spark plug 10 No 4 spark plug 11 ECM 12 Sensed information MAP sensor ECT sensor IAT sensor TP sensor VSS Electri...

Page 936: ...g belt pulley Adjust clean or replace Replace Clean tighten or replace Replace DIAGNOSTIC FLOW TABLE STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE...

Page 937: ...belt pulley 9 CMP Sensor Check 1 Check CMP sensor referring to Step 3 and 4 of DTC P0340 No 15 Diag Flow Table in Section 6 Is check result satisfactory Go to Step 10 Tighten CMP sensor bolt replace...

Page 938: ...s 7 Connect injector couplers 1 Ignition coil assembly 2 High tension cord WARNING If the injector couplers are not disconnected com bustible gas will come out of the spark plug holes dur ing this tes...

Page 939: ...INSPECTION Measure resistance of high tension cord by using ohmmeter High tension cord resistance 4 10 k m 1 2 3 0 k ft If resistance exceeds specification replace high tension cord s 1 High tension...

Page 940: ...SOR Refer to Section 6E for removal inspection and installation IGNITION TIMING NOTE Basically ignition timing is not adjustable If ignition timing is out of specification check system related parts B...

Page 941: ...ignition timing is fixed on initial one D Ground terminal E Test switch terminal 1 Monitor connector 2 Fuse box 6 Open the engine service hole cover behind the front seats and remove the inspection ho...

Page 942: ...ng initial ignition timing not fixed throttle open ing at closed position and car stopped check that ignition tim ing fluctuates between 6 16 BTDC Constant variation within a few degrees from 6 16 ind...

Page 943: ...931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter 09931 76011 SUZUKI scan tool Tech 1A kit 09931 76030 16 14 pin DLC cable IGNITION SYSTEM 6F 11 GA413 supple TIG...

Page 944: ...ag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions may result in se...

Page 945: ...CRIPTION GENERATOR 1 Pulley 2 Pulley nut 3 Rotor fan 4 Stator coil 5 Stator core 6 Field coil 7 Regulator 8 Brush 9 Front housing 10 Rear housing B Generator output Battery terminal D Dummy terminal E...

Page 946: ...starting motor and ignition ground cable 5 Connect voltmeter and ammeter as shown in left figure Voltmeter Set between generator B terminal and ground Ammeter Set between generator B terminal and batt...

Page 947: ...ir or replace generator Volt Temperature OVERCHARGED BATTERY 1 To determine battery condition refer to Battery section 2 If obvious overcharge condition exists as evidenced by exces sive spewing of el...

Page 948: ...ing instruction Push brushes into brush holder then support brushes by insert ing appropriate wire from hole of rear housing NOTE After installing rotor remove wire Check to make sure that match marks...

Page 949: ...If rough or scored re place rotor 1 Rotor Stator 1 Using ohmmeter check all leads for continuity If there is no continuity replace stator 1 Stator 2 Using ohmmeter check that there is no continuity be...

Page 950: ...In the same manner as described in above step 1 check that there is only one way continuity between both leads of diode trio 1 Rectifier 2 Diode lead CHARGING SYSTEM 6H 7 GA413 supple SPECIFICATIONS...

Page 951: ...model 6 Muffler Truck model 7 Seal ring 8 Gasket 9 Spring 10 Mounting 11 O2 sensor 12 Muffler connecting nut 13 Exhaust pipe connecting bolt Do not reuse Tightening Torque EXHAUST SYSTEM 6K 1 GA413 su...

Page 952: ...rative Ei ther of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative...

Page 953: ...BLY in Section 3C INSPECTION Use an ohmmeter to check the continuity at each switch position shown below If any continuity is not obtained replace combination switch 1 Terminal Switch Position HE HU H...

Page 954: ...BINATION SWITCH ASSEMBLY in Section 3C INSPECTION Use an ohmmeter to check the continuity at each switch position shown below If any continuity is not obtained replace combination switch 1 Terminal Tu...

Page 955: ...Wiper link 4 Wiper motor 5 Front washer nozzle 6 Front washer hose 7 Rear washer hose if equipped 8 Front washer pump 9 Rear washer pump if equipped 10 Washer tank REAR WIPER IF EQUIPPED 1 Wiper blad...

Page 956: ...tester to check the continuity at each switch position as shown below If any continuity is not obtain replace combination switch 1 Wiper SW Terminal Terminal B3 W Washer SW OFF ON I II I Without INT...

Page 957: ...connec tion the jumper wire from terminal B3 to HE Then the voltage rises to battery voltage 10 14 V within the time shown below Voltage 10 14 V 0 V 3 8 1 sec A LH steering vehicle B RH steering vehi...

Page 958: ...ly to check pumping rate Check for washer pump Reference pumping Rate more than 1 0 l min 2 1 US pt min 1 76 Imp pt min INSTALLATION Reverse removal procedure for installation REAR WIPER AND WASHER SW...

Page 959: ...B and wiper bracket wiper ground respectively Then motor should rotate at 35 to 45 rpm Automatic Stop Operation 1 First connect battery terminal to terminal B and battery terminal to wiper bracket wi...

Page 960: ...RAL DESCRIPTION 8G 2 DIAGNOSIS 8G 6 Precautions in Diagnosing Troubles 8G 6 Diagnostic Flow Table 8G 7 Diagnostic Trouble Code Check Immobilizer Control Module 8G 8 Diagnostic Trouble Code Check ECM 8...

Page 961: ...at registered in Immobilizer Control Module and checks if they match 3 When it is confirmed that two Transponder codes match each other as described above Immobilizer Control Module and ECM check if E...

Page 962: ...e ignition key for the immobilizer control system has a built in transponder Each transponder in the key has an each transmitting code Transponder code The code will transmitted from the key via the c...

Page 963: ...nction in this section 1 Immobilizer Control Module 2 Coil antenna ECM As main functions ECM not only checks matching of ECM Immobi lizer Control Module code but also has an on board diagnostic sys te...

Page 964: ...e immobilizer control system While the diagnosis is being made the malfunction indicator lamp stays ON and if the diag nosis result is abnormal it immediately changes to flashing but if the result if...

Page 965: ...wire harness from engine Such disconnection will clear trouble codes stored in memory of immobilizer control module Take a note of diagnostic trouble code indicated first INTERMITTENT TROUBLES There...

Page 966: ...CHECK in Section 6 3 Does malfunction indicator lamp flash as Fig 4 Go to Step 4 Go to MALFUNCTION INDI CATOR LAMP CHECK in Section 6 4 1 Check DTC stored in immobilizer control mod ule referring to...

Page 967: ...n For details of DTC refer to Immobilizer Control Module side in Diagnostic Trouble Code Table If voltmeter indicator does not deflect go to Diagnostic Flow Table A NOTE If abnormality or malfunction...

Page 968: ...ction lies in two or more areas mal function indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diagno sis terminal is grounded and ignition...

Page 969: ...ode from the communication mode menu dis played on Suzuki scan tool If ECM detects a trouble in both engine and emission control system and immobilizer control system Suzuki scan tool indicates troubl...

Page 970: ...odule code sponding to each code No 22 Ignition switch circuit 23 Serial data link circuit ECM To learn how to read diagnostic trouble code DTC from flashing of malfunction indicator lamp refer to Sec...

Page 971: ...diagnostic output terminal of im mobilizer diagnostic coupler short If wire and connections are OK sub stitute a known good Immobilizer Control Module and recheck NOTE After replacing with a known go...

Page 972: ...izer Control Module this DTC is set INSPECTION Register ignition key with built in transponder by using SUZUKI scan tool and performing following steps 1 Register Transponder code in Immobilizer Contr...

Page 973: ...isconnect coil antenna coupler with ignition switch turned OFF 2 Is there continuity between coil antenna coupler termi nals A and B See Fig 2 Go to Step 3 Coil antenna open 3 Measure resistance betwe...

Page 974: ...uilt in transponder for that vehicle used Substitute a known good Immobilizer Con trol Module and recheck NOTE After replacing with a known good Im mobilizer Control Module register ECM Immobilizer Co...

Page 975: ...when ignition switch is ON If they do not this DTC is set DTC84 P1620 ECM checks if code transmitted from Immobilizer Control Module and that registered in ECM match when igni tion switch is ON If th...

Page 976: ...lizer Control Module coupler terminal E64 1 and body ground with ignition switch turned ON See Fig 1 Is it 10 14V Poor E64 1 terminal connection If connection is OK substitute a known good Immobilizer...

Page 977: ...o Step 2 Bl R wire short 2 1 Disconnect ECM coupler with ignition switch turned OFF 2 Is there continuity be tween Immobilizer Control Module coupler terminal E64 7 and serial data link terminal L20 9...

Page 978: ...YSTEM IF EQUIPPED 8G 19 GA413 supple Fig 1 for step 1 1 Immobilizer Control Module Fig 2 for step 2 Connect to serial data link terminal L20 9 of ECM coupler disconnected 1 Immobilizer Control Module...

Page 979: ...is affected by the battery voltage confirm that it is 11V or more when ignition switch is ON 1 Immobilizer Control Module 2 Immobilizer Control Module coupler 3 Body ground 8G 20 IMMOBILIZER CONTROL S...

Page 980: ...le itself or connect voltmeter or ohmmeter CAUTION Be sure to connect ohmmeter probe from wire har ness side of coupler Be sure to turn OFF ignition switch for this check Resistance in table below rep...

Page 981: ...ith any type of metal wound around its grip or in contact with it Or the system may detect abnormal condition and prevent engine from start ing Do not leave ignition key where high temperature is anti...

Page 982: ...Control Module and ECM Immobilizer Control Module code in ECM by performing procedure de scribed in Procedure After Immobilizer Control Module Re placement 1 Immobilizer Control Module 2 Data link con...

Page 983: ...using it 4 Number of Transponder codes for ignition key with a built in transponder that can be registered in Immobilizer Control Mod ule is limited to 4 If needed clear all Transponder codes for ign...

Page 984: ...ON 7 If any other Transponder code for ignition key with a built in transponder needs to be registered repeat above steps 3 5 and 6 NOTE Up to 4 Transponder codes for ignition key with a built in tra...

Page 985: ...the immo bilizer indicator lamp ON it remains ON even after execu tion of that command is over It will start flashing when the ignitionswitch is turned OFF once and then turned ON after some seconds...

Page 986: ...described in How To Register Ignition Key And then turn ignition switch ON 2 Using SUZUKI scan tool register ECM Immobilizer Control Module code in ECM by executing RECORD ECU RECORD ECM lCM command i...

Page 987: ...2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor 09931 76011 SUZUKI scan tool Tech 1A kit Immobilizer cartridge of version 1 1...

Page 988: ...ound the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inop erative Either of these two conditions ma...

Page 989: ...A413 supple METAL REPLACE PARTS FINISHING SEALANT APPLICATION AREA Van model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating Apply sealan...

Page 990: ...BODY SERVICE 9 3 GA413 supple Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...

Page 991: ...9 4 BODY SERVICE GA413 supple...

Page 992: ...BODY SERVICE 9 5 GA413 supple Truck model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating Apply sealant to reverse side...

Page 993: ...9 6 BODY SERVICE GA413 supple...

Page 994: ...BODY SERVICE 9 7 GA413 supple RUST PROOF TREATMENT AREA...

Page 995: ...9 8 BODY SERVICE GA413 supple...

Page 996: ...nt mat clip installation hole A Left side B Right side A B Measurement Dimension a b 1032 mm 40 63 in a b 1160 mm 45 67 in c c 1274 mm 50 16 in a c 1086 mm 42 76 in a c 1208 mm 47 56 in d d 1193 mm 46...

Page 997: ...t side B Right side A B Measurement Dimension a b 965 mm 37 99 in a b 1094 mm 43 07 in b b 1210 mm 47 64 in a c 1127 mm 44 37 in a c 1232 mm 48 50 in c c 1124 mm 44 25 in a d 1338 mm 52 68 in a d 1428...

Page 998: ...BODY SERVICE 9 11 GA413 supple UNDERBODY DIMENSIONS For van model...

Page 999: ...811 mm 31 93 in h j 846 mm 33 31 in k o 1315 mm 51 77 in e h 1239 mm 48 78 in k l 402 mm 15 83 in k p 1091 mm 42 95 in f h 713 mm 28 07 in k m 1072 mm 42 20 in k q 1291 mm 50 83 in f h 617 mm 24 29 in...

Page 1000: ...BODY SERVICE 9 13 GA413 supple For truck model...

Page 1001: ...31 93 in h i 787 mm 30 98 in l o 1082 mm 42 60 in e h 1239 mm 48 78 in h j 858 mm 33 78 in l p 809 mm 31 85 in f h 713 mm 28 07 in h k 814 mm 32 05 in l q 1611 mm 63 43 in f h 617 mm 24 29 in l m 325...

Page 1002: ...ll them at the same location from which they were re moved If a fastener needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not avail...

Page 1003: ...N VIEW AND CONNECTORS 1 Air bag harness 2 Fuse box 3 AIR BAG monitor coupler 4 DLC 5 Contact coil assembly 6 Driver air bag inflator module 7 Passenger air bag inflator module if equipped 8 SDM 9 Grou...

Page 1004: ...t not be used Refer to AIR BAG DIAGNOSTIC SYSTEM CHECK in this section when checking the SDM ACCIDENT WITH DEPLOYMENT ACTIVATION COMPONENT REPLACEMENT Certain air bag system components must be replace...

Page 1005: ...k that SDM cannot be installed properly due to a cause in itself There is a gap between SDM and SDM plate or it cannot be fixed securely Check that connector or lead wire of SDM has a scorching meltin...

Page 1006: ...for damages deformities or poor connections Refer to INTERMITTENTS AND POOR CONNECTIONS in this section Check wire harness clamps for tightness If any faulty condition is found correct or replace 1 A...

Page 1007: ...SYSTEM CHECK will verify proper AIR BAG warning lamp operation and will lead you to the correct chart to diagnose any air bag malfunctions Bypassing these procedures may result in extended diag nostic...

Page 1008: ...s found replace wire harness connectors and terminals as an assembly When installing it be careful so that the air bag wire harness is not caught or does not interfere with other parts Make sure all a...

Page 1009: ...not separate SDM and SDM plate INSPECTION CAUTION Do not connect a tester whatever type it may be Never repair or disassemble SDM If SDM was dropped from a height of 90 cm 3 ft or more it should be re...

Page 1010: ...Prepared by Overseas Service Department 1st Ed October 2000 Printed in Japan Printing October 2000 262...

Page 1011: ...ag System D Service on or around the air bag system com ponents must be performed only by an autho rized SUZUKI dealer Please observe all WARNINGS CAUTIONS and Service Precau tions under On Vehicle Se...

Page 1012: ...iterature are based on the latest product information available at the time of publication approval and used as the main subject of description is the vehicle of standard specifications among others T...

Page 1013: ...4WD Maintenance and Lubrication 4WD Front Suspension 4WD Front Drive Shaft Propeller Shaft 4WD Manual Transmission 4WD Front Differential NOTE This manual is for GA413 4WD model and contains only the...

Page 1014: ...for Electrical Circuit Service 0A1 11 Electrical Circuit Inspection Procedure 0A1 12 Intermittent and Poor Connection 0A1 15 Precautions for Installing Mobile Communication Equipment 0A1 16 IDENTIFIC...

Page 1015: ...Also there is a CONTENTS on the first page of EACH SECTION where the main items in that section are listed 2 Each section of this manual has its own pagination It is indicated at the top of each page...

Page 1016: ...stem be repaired first to help avoid unintended air bag system activation D Do not modify the steering wheel dashboard or any other air bag system components Modifications can adversely affect air bag...

Page 1017: ...he module When placing a live air bag inflator module on a bench or other surface always face the bag up away from the surface As the live passenger air bag inflator module must be placed with its bag...

Page 1018: ...e applied to air bag system component parts re move those parts beforehand D When handling the air bag inflator modules driver and passenger or SDM be careful not to drop it or apply an im pact to it...

Page 1019: ...E PRECAUTIONS in SECTION 10B D Never expose air bag system component parts directly to hot air drying or baking the vehicle after painting or flames D WARNING CAUTION labels are attached on each part...

Page 1020: ...well ventilated D To avoid getting burned keep away from hot metal parts such as the radiator exhaust manifold tail pipe muffler etc D New and used engine oil can be hazardous Children and pets may b...

Page 1021: ...stalled in the proper order and position D Whenever you use oil seals gaskets packing O rings lock ing washers split pins self locking nuts and certain other parts as specified be sure to use new one...

Page 1022: ...releasing the fuel pressure or fuel can be sprayed out under pressure PRECAUTIONS FOR CATALYTIC CONVERTER For vehicles equipped with a catalytic converter use only un leaded gasoline and be careful no...

Page 1023: ...n above For example the towing methods shown below are dangerous or damage vehicle so do not use them D If this towing method is used either from the front or rear there is a danger of the drivetrain...

Page 1024: ...damage to it D Never connect an ohmmeter to electronic control unit with its coupler connected to it Attempt to do it may cause dam age to electronic control unit and sensors D Be sure to use a specif...

Page 1025: ...d short circuit by using an ohmmeter and a voltmeter OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows As the cause is in the connector or terminal in many cases they need to be c...

Page 1026: ...ty if any Continuity check 1 Measure resistance between connector terminals at both ends of the circuit being checked between A 1 and C 1 in the figure If no continuity is indicated infinity or over l...

Page 1027: ...5V 2V voltage drop A 1 and body ground Approx 3V Short circuit check wire harness to ground 1 Disconnect negative cable at battery 2 Disconnect connectors at both ends of the circuit to be checked NO...

Page 1028: ...terminals to moisture and dirt as well as not maintaining proper terminal orientation with the component or mating connector D Improperly formed or damaged terminals Check each connector terminal in...

Page 1029: ...l system D Keep the antenna as far away as possible from the vehicle s elec tronic control unit D Keep the antenna feeder more than 20 cm 7 9 in away from electronic control unit and its wire harnesse...

Page 1030: ...placard 4 ID plate 5 LSPV label if equipped 6 Cooling fan label 7 Coolant warning label 8 Emission control label if equipped GENERAL INFORMATION 0A1 17 WARNING CAUTION AND INFORMATION LABELS The figur...

Page 1031: ...e balance throughout service into consideration Vehicle balance on hoist may change depending on what part to be removed D Before lifting up the vehicle check to be sure that end of hoist arm is not i...

Page 1032: ...ear end be sure to block the wheels on ground in order to ensure safety After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on the vehicle raised on...

Page 1033: ...ng Light DTC Diagnostic Trouble Code Diagnostic Code E EBCM Electronic Brake Control Module ABS Control Module ECM Engine Control Module ECT Sensor Engine Coolant Temperature Sensor Water Temp Sensor...

Page 1034: ...C Over Head Camshaft P PNP Park Neutral Position P S Power Steering PSP Switch Power Steering Pressure Switch P S Pressure Switch PCM Powertrain Control Module PCV Positive Crankcase Ventilation R RH...

Page 1035: ...the original fasteners the same number marking or higher It is likewise important to select replacement fasteners of the correct size Correct replacement bolts and nuts are available through the part...

Page 1036: ...r bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in...

Page 1037: ...O2S Replace every 10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R 1 6 Exhaust pipes and mountings except catalyst I I I IGNITION SYSTEM 2 1 Spark plugs When unleaded fuel is used Vehicle with...

Page 1038: ...SIS AND BODY 6 1 Clutch I I I 6 2 Brake discs and pads front I I I I I I Brake drums and shoes rear I I I 6 3 Brake hoses and pipes I I I 6 4 Brake fluid R R R 6 5 Parking brake lever and cable I 6 6...

Page 1039: ...ry 15 000 km 9 000 miles or 12 months B C D Drive belt V rib belt R Every 45 000 km 27 000 miles or 36 months A C D E F H Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months A B C E F H...

Page 1040: ...belt with a new one adjust belt tension to 5 7 mm 0 20 0 27 in 3 If belt is too tight or too loose adjust it to specification by displac ing generator position For adjustment tighten or loosen belt ad...

Page 1041: ...belt Refer to TIMING BELT AND BELT TENSION ER in SECTION 6A ITEM 1 3 Valve Lash Inspection 1 Remove cylinder head cover 2 Inspect intake and exhaust valve lash and adjust as necessary Refer to VALVE...

Page 1042: ...lowing work 1 Drain engine oil by removing drain plug 2 2 After draining oil wipe drain plug clean Reinstall drain plug and tighten it securely as specified torque Tightening Torque a 35 N m 3 5 kg m...

Page 1043: ...ed to use SAE 10W 30 oil Engine oil capacity Oil pan capacity About 4 0 liters 8 5 7 0 US Imp pt Oil filter capacity About 0 2 liters 0 4 0 35 US Imp pt Others About 0 8 liters 1 7 1 4 US Imp pt Total...

Page 1044: ...or cap when engine is cool 2 Loosen radiator drain plug 2 to drain coolant 3 Remove reservoir which is on the side of radiator and drain 4 Tighten plug securely Also reinstall reservoir 5 Fill radiato...

Page 1045: ...temperature is antici pated mixture of 70 water and 30 ANTIFREEZE AN TICORROSION COOLANT should be used for the pur pose of corrosion protection and lubrication ITEM 1 6 Exhaust Pipes and Mountings I...

Page 1046: ...nes Refer to SPARK PLUG in SEC TION 6F FUEL SYSTEM ITEM 3 1 Air Cleaner Filter Element Inspection 1 Remove air cleaner case clamps 2 2 Take cleaner element out of air cleaner case 3 Check air cleaner...

Page 1047: ...Connections Inspection 1 Visually inspect fuel lines and connections for evidence of fuel leakage hose cracking and damage Make sure all clamps are secure Repair leaky joints if any Replace hoses tha...

Page 1048: ...heck crankcase ventilation hose and PCV hose for leaks cracks or clog and PCV valve for stick or clog Refer to PCV SYSTEM in SECTION 6E for PCV valve checking procedure ITEM 4 3 Fuel Evaporative Emiss...

Page 1049: ...ce parts as necessary For details re fer to CHECK AND ADJUSTMENT in SECTION 5 Be sure to torque caliper pin bolts to specification Brake drums and shoes Rear 1 Remove wheel and brake drum 2 Check rear...

Page 1050: ...en refilling system otherwise serious damage willoccur Do not use old or used brake fluid or one taken from unsealed container Change Change brake fluid as follows Drain existing fluid from brake syst...

Page 1051: ...E DIAGNOSIS in SECTION 3 2 Check inflating pressure of each tire and adjust pressure to specification as necessary NOTE D Tire inflation pressure should be checked when tires are cool D Specified tire...

Page 1052: ...r leak age detachment tear or any other damage Replace defective boot if any D Check suspension bolts and nuts for tightness and retighten them as necessary Repair or replace defective parts if any IT...

Page 1053: ...l plug hole That is if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed oil is properly filled If oil is found insufficient pour specified amount of spec...

Page 1054: ...boot with new one 7 Check wheel alignment NOTE For the details of wheel alignment refer to GENERAL DE SCRIPTION in SECTION 3A ITEM 6 12 All Hinges Latches and Locks Doors Check that each door of front...

Page 1055: ...joint constant velocity joint 4WD and spline of propeller shaft for rattle and damage If rattle or damage is found replace defective part with a new one 2 Check propeller shaft joint bolts for tightn...

Page 1056: ...select lever position The starting mo tor should crank only in P Park or N Neutral On manual transmission vehicles place the shift le ver in Neutral depress clutch pedal fully and try to start Exhaus...

Page 1057: ...heck that air comes out from defroster outlet when operating heater or air conditioning Set fan switch lever to HI position for this check RECOMMENDED FLUIDS AND LUBRICANTS Engine oil SE SF SG SH or S...

Page 1058: ...Never attempt to heat quench or straighten any front suspension part Replace it with a new part or dam age to the part may result CONTENTS GENERAL DESCRIPTION 3D1 2 DIAGNOSIS 3D1 4 CHECK AND ADJUSTMEN...

Page 1059: ...olated by a strut rubber support A strut bearing is also installed a little lower to the strut rubber support The lower end of the strut is connected to the upper end of a steering knuckle and lower e...

Page 1060: ...g 1 Strut support cap 2 Strut nut Apply water proof coating paint or lacquer all around nut and strut rod screw part 3 Strut lock washer 4 Strut rebound stopper 5 Strut support 6 Strut rubber support...

Page 1061: ...HECK Bar Inspect for damage or deformation If defective replace Bushing Cushion Inspect for damage wear or deterioration If defective replace COMPRESSION ROD AND OR BUSHING CHECK Rod Inspect for damag...

Page 1062: ...uld come to stop the moment hands are off or after only one or two small rebounds If struts are sus pected compare them with known good vehicle or strut 3 Inspect for damage or deformation 4 Inspect b...

Page 1063: ...to specification Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 3 Check wheel bearing for wear When measuring thrust play ap ply a dial gauge to wheel hub center after removing wheel center cap from...

Page 1064: ...lizer bar 1 and its joints 5 Remove stabilizer joints 5 from stabilizer bar 1 When loosening joint nut 6 hold stud with a wrench INSTALLATION Install in reverse order of removal procedure noting the f...

Page 1065: ...S REMOVAL 1 Hoist vehicle allow front suspension to hang free 2 Remove stabilizer bar refer to STABILIZER BAR AND OR BUSHINGS REMOVAL 3 Remove compression rod nuts 1 2 4 Remove compression rod 3 5 Rem...

Page 1066: ...on to hang free 3 Remove wheel 4 Remove E ring securing brake flexible hose and take brake flex ible hose off strut bracket as shown 5 Remove wheel speed sensor harness clamp bolt from strut if equipp...

Page 1067: ...ut a little before compressing strut spring This will make disas sembly easier Note however nut must not be removed at this point 2 Using a spring compressor compress strut spring till its force press...

Page 1068: ...at 11 Bump stopper 12 Coil spring 13 Strut assembly FRONT SUSPENSION 4WD 3D1 11 ASSEMBLY For assembly reverse disassembly procedure observing the fol lowing instruction D Mate spring end with stepped...

Page 1069: ...stopper 4 strut support 5 and rubber support 6 in this sequence Refer to the figure for instal ling directions Tighten strut nut 2 to specified torque and then apply water proof coating paint or lacqu...

Page 1070: ...t vehicle and remove wheel Remove wheel speed sensor for ABS if equipped 3 Remove caliper carrier bolts 4 Remove caliper with carrier NOTE Hang removed caliper with a wire hook of the like so as to pr...

Page 1071: ...10 8 Remove ball stud bolt 1 from knuckle 9 Remove strut bracket bolts 1 10 Remove knuckle 2 DISASSEMBLY Wheel Hub 1 Remove hub bolts CAUTION Never remove bolt unless replacement is necessary Be sure...

Page 1072: ...cial Tool B 09924 84510 C 09913 75821 ASSEMBLY AND INSTALLATION 1 Install new wheel bearing 1 using special tool and hydraulic press 2 Special Tool A 09913 75520 NOTE D Do not reuse wheel bearing D No...

Page 1073: ...t Tightening Torque b 55 N m 5 5 kg m 40 0 lb ft 7 Connect tie rod end to knuckle and tighten new tie rod end nut to specified torque Tightening Torque a 43 N m 4 3 kg m 31 5 lb ft CAUTION Removed tie...

Page 1074: ...pension control arm bolt 4 and nut 5 5 Remove suspension control arm 6 6 Remove bushing Pull out bushing with special tool and hydraulic press 1 as shown Special Tool A 09943 77910 INSTALLATION 1 Inst...

Page 1075: ...with knuckle bolt hole as shown Then drive in ball stud bolt from the direction as shown Tighten new ball stud nut to specified torque Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft 4 Tighten compres...

Page 1076: ...nd remove wheels 2 Remove suspension control arms right left refer to Steps 2 to 5 of SUSPENSION CONTROL ARM REMOVAL in this sec tion 3 Remove steering gear case mount bolts 4 Remove front differentia...

Page 1077: ...eed sensor harness clamp bolts and clamps to suspension frame if equipped with ABS 3 Install front differential referring to SECTION 7E 4 Install steering gear case mount bolts and tighten bolts to sp...

Page 1078: ...ront suspension lower arm bush remover 09945 26010 Socket wrench 17 mm 09913 65210 Tie rod end remover 09913 75520 Bearing installer 09924 84510 Bearing installer 09913 75821 Bearing installer attachm...

Page 1079: ...4A 1 SECTION 4A FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION 4A 2 Component 4A 2 DIAGNOSIS 4A 3 Diagnosis table 4A 3 ON VEHICLE SERVICE 4A 4 Drive shaft assembly 4A 4 REQUIRED SERVICE MATERIALS 4A 1...

Page 1080: ...2218 label tube in spare part 60 80g 8 Boot 9 Band 4A 2 FRONT DRIVE SHAFT GENERAL DESCRIPTION COMPONENT A constant velocity ball joint is used on the wheel side of front drive shaft and a constant vel...

Page 1081: ...GNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction Abnormal Noise Worn or breakage drive shaft joint Replace DRIVE SHAFT BOOT CHECK Inspect drive shaft boot 1 for tear If even a small tear is...

Page 1082: ...2 with caliper 3 NOTE Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessive ly or being pulled Don t operate brake pedal with pads removed 6...

Page 1083: ...int 1 so as to re lease snap ring fitting of joint spline at differential side NOTE Be careful not to damage differential oil seal 12 Remove drive shaft assembly CAUTION To prevent breakage of boots b...

Page 1084: ...the center of shaft and remove snap ring 2 from outer race then take shaft out of outer race 3 3 Wipe off grease and remove circlip 1 used to fix cage by using special tool A Special Tool A 09900 061...

Page 1085: ...t set 4 Install wheel side boot 1 on shaft fill up boot inside with grease and then fasten boot 2 with band 5 Drive in the cage 1 by using a pipe 2 whose inner diameter is 23 mm 0 906 in or more and o...

Page 1086: ...ow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure 11 When fixing boot band note the direction of band and adjust the boot position so that measurements d becom...

Page 1087: ...snap ring is seated as it was Install drive shaft assembly by reversing removal procedure and noting following points D Clean front wheel bearing oil seal and then apply grease Replace it if required...

Page 1088: ...07 Snap ring pliers Open type REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110...

Page 1089: ...ER SHAFT 4WD CONTENTS GENERAL DESCRIPTION 4B1 2 DIAGNOSIS 4B1 3 Diagnosis Table 4B1 3 Propeller Shaft Joint Check 4B1 3 ON VEHICLE SERVICE 4B1 4 Propeller Shaft 4B1 4 AXC Axial Plunger Pump Coupling i...

Page 1090: ...velocity joint at its rear end and a universal joint at the other end The rear propeller shaft is a three part combination consisting of a shaft and two universal joints It is connected to the differ...

Page 1091: ...If universal joints or constant velocity joint are suspected of produc ing chattering or rattling noise inspect them for wear or breakage of boot Check to see if cross spider rattles in yokes or if sp...

Page 1092: ...propeller shafts give match marks 1 on each joint flange and propeller shaft as shown 4 Loosen propeller shaft bolts 1 5 Remove propeller shafts INSPECTION Inspect propeller shaft and flange yoke for...

Page 1093: ...output shaft NOTE If transmission oil was drained for propeller shaft removal pour specified gear oil into transmission case to specified level AXC Axial Plunger Pump Coupling if equipped REMOVAL 1 Ho...

Page 1094: ...4B1 6 PROPELLER SHAFT 4WD REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUPER GREASE C 99000 25030 To apply to spline part of propeller shaft...

Page 1095: ...RVICE 7A1 4 Maintenance Service 7A1 4 Dismounting 7A1 5 Remounting 7A1 7 UNIT REPAIR OVERHAUL 7A1 8 Transfer Case 7A1 8 Disassembly 7A1 8 Inspection 7A1 11 Reassembly 7A1 12 REQUIRED SERVICE MATERIALS...

Page 1096: ...p Coupling One type is a built in type which the AXC is built in transfer case and the other type is an external type which the AXC is installed between the front differential and the front propeller...

Page 1097: ...Transfer output shaft front bearing 16 Transfer output front sprocket 17 Transfer output shaft rear bearing 18 Transfer output front shaft nut After tightening to specified torque caulk nut securely 1...

Page 1098: ...sealant to their thread A Sealant 99000 31110 Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 4 Fill new specified oil as shown below by specified amount roughly up to level hole NOTE D It is highly re...

Page 1099: ...wire and positive cord from starting motor Remove starting motor from transmission case 4 Disconnect coupler from speed sensor and free its harness from transmissions 5 Remove drain plugs to drain oil...

Page 1100: ...ion case NOTE Before starting to remove transmission check around once again to be sure that there is no connection left un done 13 Remove transmission rear mounting bolt nut from chassis 14 Separate...

Page 1101: ...facilitate remounting install rear mounting to transmis sion after inserting input shaft into clutch disc D For tightening torque of starting motor bolts refer to Section 6G D Refill specified amount...

Page 1102: ...1 3 Remove bolts and separate transfer rear case 1 from transfer front case 2 using special tool Special Tool A 09912 34510 4 Using special tool remove circlip 1 and then speedometer sensor rotor 2 S...

Page 1103: ...shaft rear bearing 1 output front shaft spacer 2 and AXC 3 8 Remove sprocket spacer 1 then push out and remove sprocket bush 2 9 Remove drive chain 3 and front drive sprocket 4 10 For AXC built in typ...

Page 1104: ...e make sure that reverse idler gear and shaft remain at their origi nal position on transmission case side 14 For AXC externally mounted type Uncaulk and remove output front shaft nut by using special...

Page 1105: ...tput shaft front bearing 1 by using hydraulic press 2 and special tool Special Tool A 09913 84510 Inspection D Check each ball bearing for smooth rotation If found abnormal replace D Check drive chain...

Page 1106: ...grease to front case oil seal 1 and install it by using special tools A Grease 99000 25010 Special Tool A 09924 84510 B 09913 75821 D Install output shaft front bearing 1 to output front shaft 2 be co...

Page 1107: ...and output front sprocket washer 4 D Tighten new output front shaft nut by using special tool Tightening Torque a 125 N m 12 5 kg m 90 5 lb ft Special Tool A 09930 40113 D After cleaning mating surfac...

Page 1108: ...them set the 3 parts at the position as shown in figure and drive in sprocket bush lightly by using special tool Special Tool A 09941 74910 D Install sprocket spacer D Using special tool and hammer i...

Page 1109: ...MATERIALS RECOMMENDED SUZUKI PRODUCTS USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 D Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110 D Oil drain and filler plug D Mating surface of tran...

Page 1110: ...or 09913 50121 Oil seal remover 09913 65135 Bearing puller 09913 84510 Bearing installer 09913 75821 Install attachment 09913 80113 Bearing installer 09930 40113 Flange holder 09940 53111 Differential...

Page 1111: ...GENERAL DESCRIPTION 7E 2 DIAGNOSIS 7E 3 ON VEHICLE SERVICE 7E 4 Maintenance Service 7E 4 Dismounting 7E 5 Remounting 7E 6 UNIT REPAIR OVERHAUL 7E 7 Disassembly 7E 7 Inspection 7E 9 Adjustment and Rea...

Page 1112: ...el gear bolt Apply thread lock cement 99000 32020 to thread of bolt Tightening Torque 17 Differential side bearing 18 Shim 19 Differential side oil seal Apply grease 99000 25010 to oil seal lip 20 Dif...

Page 1113: ...lenish Repair and replenish Adjust as prescribed Adjust or replace Replace or retighten Replace Bearing noise D Constant noise Deteriorated or water mixed lubricant D Constant noise Inadequate or insu...

Page 1114: ...e SAE 80W 90 viscosity 1 Before oil change or inspection be sure to stop engine and lift up vehicle horizontally 2 Check oil level and existence of leakage If leakage is found cor rect its cause 3 Dra...

Page 1115: ...ferential oil 2 Remove drive shafts referring to SECTION 4A 3 Remove front propeller shaft referring to SECTION 4B1 4 Support front differential 1 on jack 2 5 Unclamp breather hose 6 Remove front diff...

Page 1116: ...own below Apply thread lock cement A Thread lock cement 99000 32020 Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft b 55 N m 5 5 kg m 40 0 lb ft c 65 N m 6 5 kg m 47 0 lb ft D Clamp breather hose secur...

Page 1117: ...tial front carrier 2 2 Remove differential side output oil seal from differential front cover 3 Remove differential case assembly 1 and shims 2 4 Remove drive bevel gear 1 5 Drive out differential pin...

Page 1118: ...d special tool Special Tool A 09925 88210 8 Uncaulk drive bevel pinion nut and then remove it by using spe cial tool Special Tool A 09930 40113 9 Remove companion flange 1 by using special tools Speci...

Page 1119: ...side gear spline for wear or damage ADJUSTMENT AND REASSEMBLY Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc after disasse...

Page 1120: ...uge to top surface of gear D Using 2 screwdrivers 2 move gear up and down and read movement of dial gauge pointer Right Side D Using similar procedure to above mentioned procedure set dial gauge tip t...

Page 1121: ...on the other side NOTE Be sure to use bearing holder for the purpose of protecting lower bearing Special Tool B 09944 66020 C 09951 16060 DRIVE BEVEL PINION To engage bevel pinion and gear correctly...

Page 1122: ...bevel pinion front special tool 6 and rear special tool 5 to bevel pinion shaft special tool 3 5 Install drive bevel pinion bearing after apply gear oil to bearing and then assemble them to different...

Page 1123: ...D When dial gauge measuring tip extends from 0 zero position pointer turns counterclockwise D Measured value may exceed 1 mm Therefore it is also necessary to know reading of short pointer 8 Obtain a...

Page 1124: ...pecial tool and pow er wrench set preload of pinion to specification Special Tool A 09930 40113 NOTE D Before taking measurement with torque wrench check for smooth rotation by hand D Bearing preload...

Page 1125: ...10 0 20 mm 0 0039 0 0078 in NOTE D Be sure to apply measuring tip of dial gauge at right angles to convex side drive side of tooth D Measure at least 4 points on drive bevel gear periphery 4 As final...

Page 1126: ...ng tool 1 and hammer 6 Clean mating surface of both carrier and cover and apply sealant to differential front cover 2 Then tighten 8 bolts 1 to specified torque A Sealant 99000 31110 Tightening Torque...

Page 1127: ...r backlash to specification LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height adjusting shim and position pinion farther from gear cent...

Page 1128: ...USE Thread lock cement THREAD LOCK CEMENT SUPER 1333B 99000 32020 Bevel gear bolts Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110 D Front differ...

Page 1129: ...76120 Bevel pinion mounting dummy shaft 2 09922 76230 Bevel pinion bearing dummy 3 09922 76140 Bevel pinion shaft 4 09922 76150 Bevel pinion nut 5 09922 76350 Bevel pinion rear collar 6 09922 76430 Be...

Page 1130: ...7E 20 DIFFERENTIAL FRONT 09944 66020 Bearing installer 09951 16060 Lower arm bush remover...

Page 1131: ...Prepared by Overseas Service Department 1st Ed March 2000 2nd Ed March 2001 Printed in Japan Printing April 2001 122...

Page 1132: ...SUPPLEMENTARY SERVICE MANUAL FOR 4WD MODEL SUPPLEMENTARY SERVICE MANUAL 99501 76A01 01E 99501 76A01 01E I 20mm...

Page 1133: ...99512 76A20 015 WIRING DIAGRAM MANUAL 99512 76A20 015 HAMDBUCH F R VERKABELUNG MANUAL DES SCHEMAS DE CABLAGE MANUAL DE DIAGRAMA DE CONEXIONES WIRING DIAGRAM MANUAL C...

Page 1134: ...ications Therefore please note that the actual vehicle being serviced may differ from the man ual SUZUKI MOTOR CORPORATION reserves the right to make changes at any time without notice Please note tha...

Page 1135: ...den tats chlichen Gegebenheiten des zu wartenden Fahrzeugs ab SUZUKI MOTOR CORPORATION beh lt sich das Recht zu Ver nderungen ohne Ank ndigung vor Wir bitten zu beachten da diese Anleitung auch Infor...

Page 1136: ...t noter que le v hi cule soumis entretien peut tre diff rent du manuel SUZUKI MOTOR CORPORATION se r serve le droit de proc der sans pr avis et tout moment des changements Noter que ce manuel contient...

Page 1137: ...aciones no correspondan con el veh culo sometido a servicio SUZUKI MOTOR CORPORATION se reserva el derecho de efectuar cambios en cualquier momento y sin previo aviso Noter que ce manuel contient des...

Page 1138: ...6 1 A 1 Cranking system 8A 6 1 A 2 Charging system 8A 6 2 A 3 Ignition system 8A 6 3 A 4 Cooling system 8A 6 4 A 5 Engine control System With heated oxygen sensor 2 GCC with heated oxygen sensor 1 8A...

Page 1139: ...mm 8A 6 1 A 1 Kurbelsystem 8A 6 1 A 2 Ladesystem 8A 6 2 A 3 Z ndanlage 8A 6 3 A 4 K hlsystem 8A 6 4 A 5 Motorsteuersystem Mit geheizter lambdasonde 2 8A 6 6 A 5 Motorsteuersystem Ohne geheizter lambda...

Page 1140: ...8A 5 1 Sch ma du circuit d alimentation 8A 5 1 Fusibles et pi ces prot g es 8A 5 3 Bo te fusibles principale 8A 5 3 Bo te fusibles principale 8A 5 4 Sch ma des circuits lectriques 8A 6 1 A 1 Syst ne...

Page 1141: ...Tables des mati res K Connecteur 8A 7 4 L Connecteur 8A 7 5 O Connecteur 8A 7 6 Q Connecteur 8A 7 6 Glossaire 8A 8 1...

Page 1142: ...de fusibles del circuito 8A 5 4 Diagrama del circuito el ctrico 8A 6 1 A 1 Sistema de arranque 8A 6 1 A 2 Sistema de carga 8A 6 2 A 3 Sistema de encendido 8A 6 3 A 4 Sistema de refrigeracion 8A 6 4 A...

Page 1143: ...ndice MEMO Notizen Note Notas...

Page 1144: ...rts computer relay etc roughly or drop them Do not expose electrical electronic parts to high temperature Approximately 80 C 176 F or higher or water For open back connectors be sure to insert the tes...

Page 1145: ...lt werden nicht fallen lassen Elektrische und elektronische Komponenten d rfen keinen hohen Temperaturen ber 80 oder Wasser ausgesetzt werden Im Falle von Steckverbindungen mit offener R ckseite mu be...

Page 1146: ...tomber Ne pas exposer les pi ces lectriques lectroniques des temp ratures excessives environ 80 C ou plus ou l eau Pour le contr le des connecteurs dos ouvert ins rer la pointe du testeur dans le dos...

Page 1147: ...imadamente 80 C 176 F o superior ni al agua Para la inspecci n aseg rese de insertar la sonda de prueba sobre el lado del cableado preformado del conector En cuanto a los conectores abiertos atr s ase...

Page 1148: ...baum Faisceau de c bles du pan neau des instruments Cableado preformado del tablero de instrumentos J Side door wire Power window Seitent r Kabelbaum elektri sche Fensterheber C ble de porti re lat ra...

Page 1149: ...de terminales Connector type Steckertyp Type de connecteur Tipo de conector A40 View Z Ansicht Z Vue Z Vista Z View Z Ansicht Z Vue Z Vista Z View Z Ansicht Z Vue Z Vista Z 1 1 2 3 4 5 6 7 8 2 3 4 5 6...

Page 1150: ...one It is not an ordinary connector but a part of the continuous wire in the harness ZUR BEACHTUNG Der Verbindungsstecker J C bringt verschiedene Leitungsdr hte derselben Farbe an einer Stelle zusamme...

Page 1151: ...LOCS RACCORD DE C BLAGE emplacement du connecteur Secci ne 8A 3 DIAGRAMA DE LA DISPOSICION DE CONECTORES ubicaci n del conector C Abschnitt 8A 7 Steckverbindungsli ste Stekkerform und Klemmenanord nun...

Page 1152: ...gskastem Bo tier fusibles Caja de fusibles Fuse number Sicherungsnummer N de fusible No de fusible 1 Battery 80A 23 15A 24 15A 7 15A 7 15A 33 25A A 50A 30A 60A BLK YEL BLK PNK BLK LT GRN YEL GRN YEL B...

Page 1153: ...lectrique vers le bas masse terre comme le ferait un coulement d eau El diagrama de circuito ha sido dise ado de manera que la corriente circule desde la parte superior del diagrama fuente de ali men...

Page 1154: ...r zur durch Anzahl von Pfeilen bezeichneten Seite Zum Beispiel Zwei Pfeile nach links weisend bedeutet Weiter zur vorvorigen Seite Auf der jeweiligen Bezugsseite finden Sie dann dasselbe Symbol mit de...

Page 1155: ...d switch Zungen Schalter Resistance Widerstand Commutateur tiges Interruptor de l minas R sistance Resistencia Variable resistance Variabler Widerstand Transistor Transistor R sistance variable Resist...

Page 1156: ...mp Kraftstoffpumpen Ventilateur de radia teur Ventilador del radia dor Pompe carburant Bomba de combusti ble Injector Einspritzd se XX control module XX Steuermodul Injecteur Inyector Module de com ma...

Page 1157: ...de commande du moteur M dulo de control del motor ECT Engine coolant tempera ture Motork hlmitteltemperatur Temp rature de r frig rant du moteur Temperatura del refrige rante del motor EGR Exhaust ga...

Page 1158: ...converter clutch Drehmomentwandlerkupp lung Accouplement du conver tisseur de couple Embrague del convertidor de par TCM Transmission control mod ule Getriebe steuermodul Modulle de commande de trans...

Page 1159: ...8A 1 12 MEMO Notizen Note Notas...

Page 1160: ...8A 3 1 8A Connector layout diagram Stecker layout diagramm Sch ma de dispositiondes blocs raccord de c blage Diagrama de disposici n de conectores...

Page 1161: ...m harness IF EQPD A C fahrgastzellenkabelbaum Faisceauz de plafonnier A C Cableado de interior del veh culo A C A C engine harness IF EQPD A C motorkabelbaum Faisceau du moteur A C Cableado del motor...

Page 1162: ...L56 Bodenwannen kabel baum ZUR L56 Faisceau de fils lectri ques de plancher AU L56 Mazo de cables del piso AL L56 B09 N LHD Floor harness To L57 Bodenwannen kabel baum ZUR L57 Faisceau de fils lectri...

Page 1163: ...lectriques principal E Mazo de cables principal RHD LHD E11 E08 E65 E13 E63 Van only E12 Truck Van E55 E56 E60 E66 E58 E57 E61 E10 E06 E07 Van only E 5 7 6 E11 E08 E65 E13 E63 Van only E56 Van E55 E1...

Page 1164: ...L Eclairage de clignotant G Luz de la se al de giro lateral IZQ E55 N Side turn signal light R Seitenblinkleuchte R Eclairage de clignotant D Luz de la se al de giro lateral DER E56 GRY Brake fluid l...

Page 1165: ...moteur Compartimento del motor C Engine harness C Motorkabelbaum C Faisceau de fils lectriques de moteur C Mazo de cables del motor C12 C02 C03 C19 C22 TO L21 C05 TO L19 C23 C10 C18 C26 C13 C24 C01 C...

Page 1166: ...nister purge valve EVAP sp lluft ventil Clapet de pur ge cartou che d EVAP V lvula de purga del reci piente EVAP C14 BLK MAP sensor MAP sensor D tecteur MAP Sensor de MAP C15 N Throttle position senso...

Page 1167: ...32 E26 E41 E39 E40 E04 TO K03 E05 TO J05 E72 TO B06 E14 E83 E16 E22 E23 E24 E29 E71 E30 E27 E28 E44 E47 E35 E43 E37 E34 E81 E76 E36 E48 E64 E67 E51 E52 E42 E01 TO L01 E84 TO K20 E 8 E54 TO J01 E02 E39...

Page 1168: ...rruptor de combina ci n bocina E29 N Heater resistor Heizungswiderstand Resistance de chauffage Resistor del calefactor E30 N Heater fan motor Heizgebl semotor Moteur de ventilateur de chauffage Motor...

Page 1169: ...A C AU B06 Cableado de interior del vehiculo A C AL B06 E73 GRY ICM E74 N Coil antenna Antennenspule Antenne de bobine Antena de bobina E75 N Immobilizer output diag nosis coupler Wegfahrsperreausgang...

Page 1170: ...lectri ques de sac gonflable Mazo de cables del col che n de aire Q01 YEL Main harness To E19 Hauptkabelbaum ZUR E19 Faisceau de fils lectri ques principal AU E19 Mazo de cables principal AL E19 Q03...

Page 1171: ...K06 K03 TO E04 K20 TO E84 J07 J13 J05 TO E05 J01 TO E54 J03 J02 J04 J10 K09 J11 K12 K05 K14 K13 K02 K25 K10 K26 K04 K07 K27 K01 J14 J J K K11 K01 K03 TO E04 Truck Van J12 K19 J09 K18 No Color Connect...

Page 1172: ...hebermotor Moteur de vitre lectrique Motor para ventanilla motriz J14 Power window sub switch RL Nebenschalter f r auto matischen fensterheber Interrupteur secondaire de l ve vitres Interruptor secund...

Page 1173: ...le de bomba del combustible No Color Connective position Anschlussposition Position de connexion Posici n de conexi n Oil pressure switch wire ldruckschalterkabel Fil du commutateur de pression d huil...

Page 1174: ...de pompe essence AU L47 Cable de bomba del com bustible AL L47 L40 N Rear combination light R Heckkombinations leuchte R Feu combin arri rE D Luz de combinaci n tra sera DER L42 N Van GND J C L43 BLU...

Page 1175: ...ussposition Position de connexion Posici n de conexi n Oil pressure switch wire ldruckschalterkabel Fil du commutateur de pression d huile Cable conmutador de presi n de aceite D01 Oil pressure switch...

Page 1176: ...N Rear combination light L Heckkombinations leuchte L Feu combin arri rE G Luz de combinaci n tra sera IZQ L52 BLK Back up light switch R ckfahrleu chtenschal ter Interrupteur de feux de marche arri r...

Page 1177: ...e lectrique de desembueur de lunette arri re O Cableado preformado del port n trasero Cable del desempa ador trasero O10 TO L44 O01 O08 O09 TO L43 O05 O07 O06 O03 O11 Rear defogger Heckscheiben heizun...

Page 1178: ...on D Luz de la matr cula DER O08 N Rear wiper motor Heckscheibe nwischer motor Moteur d essuie glace arri re Motor del limpiador tra sero O09 BLU Floor harness To L43 Bodenwannen Kabel baum ZUM L43 Fa...

Page 1179: ...8A 3 20 Memo Notizen Note Notas...

Page 1180: ...s de masa Engine compartment Instrument panel Motorraum Armaturenbrett Compartiment moteur Panneau d instruments Compartimento del motor Tablero de instrumentos 5 7 10 6 9 3 2 4 12 11 Van only Van onl...

Page 1181: ...8A 4 2 Memo Notizen Note Notas...

Page 1182: ...Diagrama de alimentaci n el ctrica RED GRN GRN RED BLK RED WHT BLK 20A 30A 15A 10A 15A 10A 10A A BLK LT GRN BLK 70A 30A 15A Starting motor Main fuse 20A 60A 1 2 3 Generator WHT GRN WHT GRN WHT YEL WHT...

Page 1183: ...WHT YEL BLK LT GRN 15A 30A 20A BLU RED YEL GRN 15A WHT BLK Starting motor WHT GRN Fuse box 2 5 1 4 6 53 3 3 E01 L01 E34 ST ON Key reminder SW Out Key Position Treminal K1 K2 In ACC Lock ST IG2 IG1 AC...

Page 1184: ...arburant Rel de la bomba de combustible Radiator fan control relay K hlergebl se steuerrelais Relais de commande de ventilateur de radiateur Rel de control del rel del radiador No Nr No N Amperage Amp...

Page 1185: ...de venti lateur de con dendeur Radiatrurrel de control del rel del radiaor Compressor relay Compresseur rel del Kompressorre laiserelais de Compresor 15A REAR DEFG Rear defogger switch Schalter f r he...

Page 1186: ...er Arnsummer Vibreur d aver tissement Zumbador de aviso P S controller Servolenkung steuereinheit Commande P S Controlador de la servodirec ci n 15A TURN BACK DRL controller DRL regler Regulateur de D...

Page 1187: ...rette nan z nder Allume cigars Encendedorde cigarrillos 15A HORN HAZARD Horn relay Hupenrelais Relais d avertis seur sensor Rel de bocina Combination switch Kombinations schalter Commutateur combine I...

Page 1188: ...l circuito el ctrico A 1 Cranking system A 1 Kurbelsystem A 1 Syst ne de d marrage A 1 Sistema de arranque E34 1 1 L30 3 L31 ST On Key reminder sw Out Key Position Terminal K1 K2 In ACC Lock ST IG2 IG...

Page 1189: ...a C10 L21 C22 1 4 E01 L01 13 12 1 70A 10 E40 Charge 5 15A IG METER C11 2 1 BLK WHT WHT RED 3 YEL GRN BLK WHT WHT GRN WHT GRN WHT RED BLK WHT WHT RED 1 L19 C05 1 16 Generator Main fuse Van Truck Hong K...

Page 1190: ...danlage A 3 Syst me d allumage A 3 Sistema de encendido 15A IG METER 1 L21 C22 E01 L01 2 C01 1 3 2 C02 1 3 WHT RED BLK WHT BLK WHT BLK BLK WHT BLK WHT 16 4 IG coil 1 4 IG coil 2 3 Fuse box 16 56 Van T...

Page 1191: ...issement A 4 Sistema de refrigeracion L08 M 1 2 L14 3 1 4 2 L21 C22 5 BLK RED GRN RED GRN BLU RED 30A L16 3 1 4 2 BLK YEL BLK RED BLK GRN BLU WHT 15A J C L42 6 4 10 RED GRN Main relay Relay Main fuse...

Page 1192: ...8A 6 5 Memo Notizen Note Notas...

Page 1193: ...10 14 8 PNK BLK WHT BLK WHT BLK WHT BLU RED RED GRN PNK BLK PPL YEL PNK BLK BLU WHT BLU BLU WHT PNK WHT WHT BLK WHT RED PPL YEL L48 P 3 4 16 56 E01 L01 BLK RED BLU WHT L01 E01 8 IF EQPD L21 C22 L20 BL...

Page 1194: ...2 2 3 L57 B09 4 5 Starting motor controller Fuse box BLK BLK YEL BLK YEL Data link connector Controller A C amplifier Brake light switch Heater blower motor switch A B 42 1 A B 50 30 6 2 A B 32 31 A B...

Page 1195: ...2 C04 1 3 BLK BRN RED C23 L20 22 12 BLK YEL BLK YEL BLK RED 52 20 E01 L01 14 6 BLK RED E01 L01 C21 22 1 2 GRN C25 L21 C22 8 L21 C22 3 L21 C22 YEL 3 2 1 L35 BLK YEL 4 15 Vehicle speed sensor CMP sensor...

Page 1196: ...E01 L01 41 L01 E01 7 L21 C22 C23 18 19 28 27 C19 3 1 4 6 2 5 RED BLK RED RED YEL RED BLU 4 C24 1 2 BLK RED ORN BLK LT GRN RED GRY YEL LT GRN RED LT GRN RED LT GRN RED Throttle position sensor CO adju...

Page 1197: ...YEL RED BLU YEL YEL RED RED 1 BLU IF EQPD IF EQPD 2 4 L53 2 L37 L47 3 L47 L37 BLK BLK BLU YEL BLU YEL BLK WHT J C L42 10 9 10 9 BLK Fuel pump gauge Van only A B P BLK BLK Heated oxygen sensor 2 Rear V...

Page 1198: ...8A 6 11 Memo Notizen Note Notas...

Page 1199: ...4 BLK BLK YEL 2 8 PNK BLK WHT BLU RED RED GRN RED GRN PNK BLK PPL YEL PNK WHT BLU BLU WHT PNK WHT WHT BLK WHT RED PPL YEL 16 56 E01 L01 BLK RED BLU WHT L01 E01 5 L21 C22 8 IF EQPD L21 C22 L20 BLK YEL...

Page 1200: ...tor A C controller Fuse box BLK BLK BLK Data link connector Heater blower motor switch 48 8 A B 42 1 A B 50 30 A B 49 19 Q01 E19 2 A A B A E C D B 56 47 A B L01 E01 29 40 37 A B 32 31 A B Brake light...

Page 1201: ...YEL 5 C13 1 2 GRN YEL 16 2 C04 1 3 BLK BRN RED C23 L20 16 BLK YEL BLK YEL BLK RED YEL E01 L01 6 BLK RED E01 L01 C21 22 1 2 BLU YEL GRN C25 9 L21 C22 8 L21 C22 3 L21 C22 YEL 3 2 1 L35 BLK YEL 4 Vehicl...

Page 1202: ...2 1 3 2 14 RED BLU WHT BLU YEL GRN BLU YEL BLU YEL YEL GRN BLU YEL RED WHT 24 E01 L01 L01 E01 E01 L01 6 7 L21 C22 18 19 28 27 C19 3 1 4 6 2 5 RED BLK RED RED YEL RED BLU BLK RED GRY YEL LT GRN RED LT...

Page 1203: ...CHECK ENGINE BLK RED BLK RED BLK GRN GRN BLK BLK GRN BLU RED BLU RED WHT BLU RED BLK PPL YEL BLK WHT BLK GRN WHT 15A PPL YEL 12 16 6 8 5 4 IG METER RADIO DOME L16 1 E64 E74 L20 E40 E39 2 8 3 4 2 1 E75...

Page 1204: ...avador del parabrisas E06 M 2 1 YEL BLU 15A WIPER WASHER E35 3 2 4 BLK BLU BLU BLU RED BLU WHT YEL BLU H L M E12 4 3 1 2 D 12V OFF INT LO Hi B3 2 1 INT1 INT2 E37 BLK W S E41 18 7 A B 5 1 A B 4 2 A B 1...

Page 1205: ...E52 M O08 E07 4 2 3 2 IF EQPD 4 5 1 6 20 E01 L01 18 19 3 Not used L44 O10 1 2 YEL BLU ORN YEL BLU ORN BLK GRN BLK YEL BLU ORN BLU GRN 15A WIPER WASHER 3 M 2 1 J C E63 BLK BLK BLK BLK O09 L43 1 18 9 11...

Page 1206: ...E01 L01 19 L44 O10 2 YEL BLU 15A WIPER WASHER 18 E07 3 4 BLK GRN M M 2 1 J C E63 E41 8 6 O08 2 4 3 BLK 7 8 9 11 BLK 5 BLK YEL BLU ORN BLK YEL BLU BLK ORN ORN ORN O09 L43 1 BLK Fuse box Motor Switch WA...

Page 1207: ...arri re B 3 Desempa ador trasero O12 O13 1 1 YEL GRN RED WHT RED WHT RED WHT BLK 3 L43 O09 1 O03 O11 24 E01 L01 15A REAR DEFG E51 5 6 4 1 2 BLK BLK BLK W S E41 8 12 8 8 5 Switch Switch position Free...

Page 1208: ...8A 6 21 Memo Notizen Note Notas...

Page 1209: ...ER WINDOW Main switch IF EQPD IF EQPD Window lock switch Auto circuit up RY2 down down Auto switch Motor Front Motor J C Front Sub switch 1 2 RED BLK RED BLK RED BLK 3 GRN BLK GRN BLK GRN BLK 4 RED YE...

Page 1210: ...T GRN WHT GRN WHT WHT RED BLK WHT RED RED BLK WHT RED GRN BLK RED YEL WHT BLU GRN YEL BLK BLU RED BLU GRN BLU BRN BLU RED Diode RL D 5 Diode RR D 5 M UP M UP Sub switch L Rear Sub switch R Rear J11 3...

Page 1211: ...LK BLU BLK BLU BLK BLU 6 E04 K03 3 M BLU BLK BLU E01 L01 M BLU BLK BLU PNK BLU BLU J08 BLU BLU BLK BLU BLU BLK BLU BLU BLK K10 1 2 K09 1 J C switch PS J C switch DR 2 L43 O09 W S E41 5 8 BLK 5 8 10 4...

Page 1212: ...1 L01 M BLU BLK BLU PNK BLU BLU J08 2 RH 1 LH BLU BLU BLK BLU BLU BLK BLU BLU BLK K10 1 2 K09 1 J C switch PS J C switch DR 2 L43 O09 W S E41 5 8 BLK 5 8 10 4 B 4 A 3 B 2 A 1 B 2 A 1 B 1 A 2 B 1 A 2 B...

Page 1213: ...48 1 Without horn relay With horn relay 3 2 5 WHT GRN E35 6 LH RH WITH AIR BAG Without air bag J C BLK BLU GRN BLK BLU GRN WHT GRN 21 5 7 E63 E28 1 RH LH E35 6 E28 1 BLU GRN BLU GRN E61 2 1 WHT GRN Co...

Page 1214: ...C22 L37 L47 2 4 YEL RED YEL RED YEL WHT BRN BLK YEL L35 1 3 2 E82 BLK YEL L48 1 2 W S E41 16 12 8 4 8 5 Vehicle speed sensor Not used Van only Main relay Fuse box Speedmeter BLK BLK Fuel pump gauge B...

Page 1215: ...Indicator C 2 Compteur mixte Indicator C 2 Medidor de combinaci n Indicator Beam Turn R Turn L 13 E39 1 2 12 9 WHT BLU GRN YEL GRN RED RED 10A H L L BLK BLK W S E41 22 8 5 BLK 6 Van Truck RHD Truck LH...

Page 1216: ...8A 6 29 Memo Notizen Note Notas...

Page 1217: ...BLU E01 L01 RED BLK WHT RED WHT RED WHT RED BLK GRN GRY BLK 15A IG METER BLK WHT GRY BLK YEL BLK 1 L24 D01 PPL YEL E01 L01 1 33 E01 L01 4 L21 C22 RED BLK 1 YEL BLK 1 L13 D02 L23 1 2 J C L42 16 7 10 J...

Page 1218: ...E19 Q01 13 12 E01 L01 BLK RED BLU GRN WHT BLK RED E04 K03 E01 L01 4 1 2 4 L21 C22 1 Van only L62 K05 Door switch Controller Generator 15A RADIO DOME 12 E33 1 2 Fuse box IG switch Engine switch Van Tr...

Page 1219: ...E01 L01 1 L13 D02 42 1 E01 L01 W S E41 D10 8 5 17 10A H L R 23 14 22 9 E37 1 6 8 3 7 1 4 7 10 BLK BLK BLK BLK BLK BLK Headlight L Headlight R Combination meter E57 3 2 1 RED RED WHT RED WHT RED RED G...

Page 1220: ...R 10A TAIL E39 Beam 12 9 RED YEL 4 E37 RED YEL RED YEL BLK GRN BLK E01 L01 W S E41 BLK BLK BLK 8 5 14 23 22 A 1 B E F 5 A 10 B E F 8 A 7 B E F 6 A 9 B E F 9 A 6 B E F 7 A 8 B E F 42 C 1 D BLK Headligh...

Page 1221: ...AIL OFF HEAD 7 E37 1 2 BLK BLK E60 1 2 RED YEL 1 2 L60 O07 1 2 BLK BLK RED YEL RED YEL RED YEL 42 1 E01 L01 RED YEL RED YEL 6 L43 O09 1 BLK BLK J C E63 J C 14 7 5 BLK 7 8 BLK 5 5 8 11 9 10 A 8 B 6 A 9...

Page 1222: ...K Fuse box OFF TAIL HEAD GRN BLK BLK 15A FOG 9 9 10 8 5 6 8 5 J C W S L42 E41 J C E86 E67 4 L46 E37 E01 L01 43 6 1 2 4 1 3 6 1 BLK 2 5 A B 9 E 6 F A B 10 E 5 2 1 9 F A B 7 E 8 F A L40 B L58 D C C D A...

Page 1223: ...B 1 E 42 D A B D 8 E78 E80 1 E79 E77 6 L43 O09 E01 L01 Radio ILL Heater blower motor switch C RED YEL RED YEL RED YEL ORN ORN DRL controller Switch Fuse box RHD LHD With DRL LHD Without DRL Van Truck...

Page 1224: ...IO DOME BLK RED BLK WHT DOOR OFF ON 1 2 K07 1 E04 K03 3 K03 E04 BLK RED BRN 12 5 8 Interior light Front Interior light Rear Door switch Fuse box BLK Warning buzzer Van Truck A B A B A A B B A A B 2 BL...

Page 1225: ...15A HORN HAZARD 15A TURN BACK 4 GRN RED L40 4 L46 4 GRN YEL GRN RED GRN YEL GRN YEL GRN RED GRN YEL GRN RED GRN RED BLK BLK BLK BLK BLK BLK J C E63 44 26 E01 L01 W S E41 8 5 7 5 9 10 21 17 A 3 B 5 A 2...

Page 1226: ...8A 6 39 Memo Notizen Note Notas...

Page 1227: ...Fuse box RHD LHD A B ECM A 5 GW For E44 L54 See the wire colors to identify the terminals There are some kinds of connector and terminal layout F r E32 Die Klemmen sind farblich gekennzeichnet Es gibt...

Page 1228: ...light BLK Fuse box RHD LHD A B ECM A 5 GW For E44 L54 See the wire colors to identify the terminals There are some kinds of connector and terminal layout F r E32 Die Klemmen sind farblich gekennzeich...

Page 1229: ...E01 L01 BRN YEL BRN YEL RED RED 15A TURN BACK L46 5 4 5 4 L40 BLK BLK 17 L52 1 2 10 9 9 10 J C L42 BLK Back up light switch Back up light L R Van Truck For dealer option A C With factory equipped A C...

Page 1230: ...de nivelci n del haz de luz de los faros YEL BLU LT GRN YEL LT GRN RED BLK BLK Actuator L Fuse box BRN YEL 15A WIPER WASHER 18 15A TURN BACK 17 7 8 5 5 5 8 8 5 E65 E66 1 1 2 2 E73 3 4 6 5 3 3 BLK BLK...

Page 1231: ...BLK LT GRN B13 E17 16 56 47 L01 E01 46 52 E01 L01 1 E72 B06 BLK 10 RED YEL GRN BLK 1 6 2 2 3 2 1 5 E20 4 3 1 ILL 1 LT GRN 7 17 8 6 5 BLK PNK GRN PNK GRN Heater resistor Heater blower motor switch Back...

Page 1232: ...7 10 9 5 6 5 BLK BLK 9 10 BLK Condenser fan motor Main fuse Dual pressure switch amplifier Thermistor Compressor relay Condenser fan relay Van Truck For dealer option A C RHD LHD With factory equipped...

Page 1233: ...RN PPL GRN BLK YEL BLK YEL BLK YEL 3 E19 Q01 1 2 15A IG METER 2 10 9 WHT 15 14 17 3 Q05 15A AIR BAG 15A RADIO DOME E40 10 2 Air bag BLK WHT ORN ORN BLK GRN RED GRN 2 1 PPL GRN 15 E01 L01 8 L21 C22 YEL...

Page 1234: ...7 11 12 16 With heated oxygen sensor 2 Without heated oxygen sensor 2 Van Truck A 5 B 5 A B EPS Controller BLK 7 BLK 8 BLK 5 BLK BLK BLK 8 5 4 BLK E01 L01 BLK 5 6 5 6 Fuse box Diagnosis connector 1 D...

Page 1235: ...Zumbador de aviso E33 L62 K05 E39 E40 8 1 CLOSE OPEN 16 10 7 2 2 1 BLK ORN BLK RED WHT BLU GRN BLK WHT RED YEL 15A IG METER RADIO DOME 15A BLK BLK 4 2 E04 K03 E01 L01 W S E41 8 5 16 19 BLK Fuse box W...

Page 1236: ...DOME WHT RED YEL WHT BLK RED 1 BLK RED BLK BLU BLU BLK 20 12 Radio Front speaker R Front speaker L 8 5 BLK Antenna Van Truck A B A 8 B BLK Fuse box D 4 BLK BLK E24 E23 1 1 W S E41 8 BLK 5 Cigar lighte...

Page 1237: ...8A 6 50 Memo Notizen Note Notas...

Page 1238: ...O B10 B06 TO E72 Van B07 TO L55 B08 TO L56 B09 TO L57 B10 TO B05 B11 TO B12 B12 TO B11 B13 B14 B15 B16 B17 2 1 1 2 3 4 1 2 3 4 1 2 3 2 1 6 5 4 3 2 1 1 1 2 3 2 1 1 2 3 4 5 6 3 2 1 6 4 5 1 2 3 4 6 5 1 2...

Page 1239: ...9 1 2 1 2 1 D01 D02 1 1 E01 TO L01 E02 E04 TO K03 E05 TO J05 Van Truck Van E06 E07 E08 E10 Van E11 E12 E13 E14 E16 E17 E19 TO Q01 E20 E22 2 1 9 8 11 12 10 43 52 53 42 45 46 44 19 18 20 25 24 26 31 30...

Page 1240: ...1 2 3 1 1 2 1 2 3 4 6 5 2 1 3 2 1 6 5 4 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 5 6 7 9 10 11 13 14 15 4 8 12...

Page 1241: ...TO E05 Van 4 terminal 6 terminal J06 J07 J08 J09 TO K18 J10 J11 J12 TO K19 J13 J14 1 2 3 8 4 6 7 5 1 2 3 8 4 6 7 5 1 2 1 2 3 4 1 2 4 5 3 6 1 2 3 4 5 6 1 2 3 4 5 1 2 1 2 3 4 1 2 3 4 6 5 1 2 1 4 2 5 3...

Page 1242: ...ith heated oxy gen sensor 2 6 7 16 17 14 13 15 50 56 55 51 48 47 49 22 23 21 28 29 27 34 35 33 40 41 39 1 2 10 11 12 8 9 44 52 53 54 5 3 4 45 46 42 43 19 20 18 25 26 24 31 32 30 37 38 36 1 2 3 4 5 6 1...

Page 1243: ...09 M T L58 L59 L60 L61 L62 Truck Truck Truck Truck Truck 1 2 3 4 1 2 3 4 1 2 1 2 1 2 3 1 1 2 1 2 1 2 1 2 1 or 1 O01 O03 TO O11 O05 O06 O07 O08 O09 TO L43 O10 TO L44 O11 TO O03 O12 O13 Van Van 2 1 1 2...

Page 1244: ...de cesto de EVAP EVAP canister vent valve EVAP Entl ftungsventil Clapet d event de cartouche d EVAP V lvula de ventilaci n del cesto EVAP Exhaust gas recirculation Abgasr ckf hrung Re circulation des...

Page 1245: ...tch Reed Schalter Contacteur lame Interruptor de l mina Reference zener diode Bezugsdiode Zenerdiode Diode de Zener de r f rence Diodo de referencia Zener Seat belt switch Sicherheitsgurtschalter Cont...

Page 1246: ...Prepared by 1st Ed July 2002 Printed in Japan 114...

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