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YH4

GRAND

VITARA

7F

DIFFERENTIAL (REAR)

7F-1

The differential assembly is decisive in that the drive
power is concentrated there. Therefore, use of genu-
ine parts and specified torque is compulsory. Further,
because of sliding tooth meshing with high pressure
between bevel pinion and gear, it is mandatory to lu-
bricate them by hypoid gear oil.

SECTION 7F

DIFFERENTIAL (REAR)

CONTENTS

GENERAL DESCRIPTION

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ON-VEHICLE SERVICE

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Maintenance Service

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UNIT REPAIR

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TIGHTENING TORQUE SPECIFICATIONS

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REQUIRED SERVICE MATERIALS

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GENERAL DESCRIPTION

The differential assembly using a hypoid bevel pinion
and gear is installed to the rear axle. It is set in the con-
ventional type axle housing.

The reduction ratio and differential case vary depend-
ing on transmission or engine type.

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Summary of Contents for Grand Vitara 1998

Page 1: ...SUZUKI SQ 416 420 625 M Y 1998 2005 SERVICE MANUAL VOLUME 1 CHASSIS SECTIONS ELECTRICAL BODY SECTIONS ...

Page 2: ...d Differentials Front and Rear of SQ series SQ416 SQ420 SQ625 Wiring Diagram Manual 99512 65D10 015 Applicable model mentioned in FOREWORD of this manual SQ416 SQ420 SQ625 Service Manual 99500 65D00 xxx Vehicles before the vehicle identification number mentioned in FOREWORD of this manual SQ416 SQ420 SQ625 Wiring Diagram Manual 99512 65D01 015 ...

Page 3: ...Lighting System Instrumentation Driver Information Windows Mirrors Security and Lock Immobilizer Control System BODY SERVICE RESTRAINT SYSTEM Seat Belt Air Bag System GENERAL INFORMATION General Information Maintenance and Lubrication TABLE OF CONTENTS TABLE OF CONTENTS SECTION SECTION 0B HEATING AND AIR CONDITIONING Heater and Ventilation Air Conditioning STEERING SUSPENSION WHEELS AND TIRES Fron...

Page 4: ...rical Circuit Service 0A 10 Electrical Circuit Inspection Procedure 0A 12 Intermittent and Poor Connection 0A 15 Precaution for Installing Mobile Communication Equipment 0A 16 IDENTIFICATION INFORMATION 0A 17 Body Number 0A 17 Engine Identification Number 0A 17 Transmission Identification Number 0A 17 WARNING CAUTION AND INFORMATION LABELS 0A 18 VEHICLE LIFTING POINTS 0A 19 ABBREVIATIONS MAY BE US...

Page 5: ...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 along with the Section name 3 The SPECIAL TOOL usage and TORQUE SPECIFICATION are given as shown in figure below 4 A number of abbreviations are used in the text For their full explanations refer to ABBREV...

Page 6: ... first to help avoid unintended air bag system activation Do not modify the steering wheel dashboard or any other air bag system components Modifications can adversely affect air bag system performance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process re move the air bag system components beforehand to avoid component damage...

Page 7: ...rside of the 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 trim cover facing up place it on the workbench with a slit or use the workbench vise to hold it securely at its lower mounting bracket This is necessary so that a free space is provided to ...

Page 8: ...nt temperature below 65 C 150 F without high humidity and away from electric noise Never carry seat belt pretensioner by wire or connector of pretensioner When placing a live seat belt pretensioner on the workbench or some place like that be sure not to lay it with its exhaust hole provided side facing down It is also prohibited to put something on its face with an ex haust hole or to put a seat b...

Page 9: ...senger wipe off im mediately with a dry cloth Air bag wire harness can be identified easily as it is cov ered with a yellow protection tube Be very careful when handling it When an open in air bag wire harness damaged wire har ness connector or terminal is found replace wire har ness connectors and terminals as an assembly Do not apply power to the air bag system unless all com ponents are connect...

Page 10: ...in is well ventilated To avoid getting burned keep away from hot metal parts such as the radiator exhaust manifold tail pipe muffler etc New and used engine oil can be hazardous Children and pets may be harmed by swallowing new or used oil Keep new and used oil and used engine oil filters away from children and pets Continuous contact with used engine oil has been found to cause skin cancer in lab...

Page 11: ...n stalled in the proper order and position 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 ones Also before installing new gaskets packing etc be sure to remove any residual material from the mating surfaces Make sure that all parts used in reassembly are perfectly clean When use of a certain t...

Page 12: ...p and injector without first releasing the fuel pressure or fuel can be sprayed out under pressure PRECAUTIONS FOR CATALYTIC CONVERTER For vehicles equipped with a catalytic converter use only un leaded gasoline and be careful not to let a large amount of un burned gasoline enter the converter or it can be damaged Conduct a spark jump test only when necessary make it as short as possible and do no...

Page 13: ...use damage to it 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 Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained or personal in jury may result When taking measurements at electrical connectors using a tester probe be sure to insert the p...

Page 14: ... male half for bend and female half for excessive opening and both for locking looseness corrosion dust etc Before measuring voltage at each terminal check to make sure that battery voltage is 11V or higher Such terminal volt age check at low battery voltage will lead to erroneous diag nosis ...

Page 15: ...t etc Wire harness being open When checking system circuits including an electronic control unit such as ECM TCM ABS control module etc it is important to per form careful check starting with items which are easier to check 1 Disconnect negative cable from battery 2 Check each connector at both ends of the circuit being checked for loose connection Also check lock condition of connector if equippe...

Page 16: ...r an ab normality in connector B Voltage Check If voltage is supplied to the circuit being checked voltage check can be used as circuit check 1 With all connectors connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the left and results were as listed below it means that the circuit is...

Page 17: ...connect all connectors of those parts Otherwise diagnosis will be misled 3 Measure resistance between terminal at one end of circuit A 1 terminal in figure and body ground If continuity is indicated it means that there is a short to ground between terminals A 1 and C 1 of the circuit 4 Disconnect the connector included in circuit connector B and measure resistance between A 1 and body ground If co...

Page 18: ...eated in the connector body backed out Dirt or corrosion on the terminals The terminals must be clean and free of any foreign material which could impede proper termi nal contact However cleaning the terminal with a sand paper or the like is prohibited Damaged connector body exposing the terminals to moisture and dirt as well as not maintaining proper terminal orientation with the component or mat...

Page 19: ...strand type wire are intact resistance could be far too high If any abnormality is found repair or replace PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB Citi zens Band radio or cellular telephone be sure to observe the fol lowing precautions Failure to follow cautions may adversely affect electronic control system Keep the antenn...

Page 20: ...ed on the chassis inside the tire housing on the right front side It is possible to identify the country of origin the production plant of the vehicle by the first three digits of the body number as shown below JSAxxx Japan Iwata produced 2S2xxx Canada CAMI produced ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block TRANSMISSION IDENTIFICATION NUMBER The number is located on ...

Page 21: ...l Australia only Air bag label on sun visor Transfer label 0A 18 GENERAL INFORMATION WARNING CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts When servicing and handling parts refer to WARNING CAUTION instructions printed on labels If any WARNING CAUTION label is found stained or damaged clean or replace it as necessary ...

Page 22: ...ke sure that the vehicle will not fall off by trying to move vehicle body in both ways Work can be started only after this confirmation Before applying hoist to underbody always take vehicle balance throughout service into consider ation Vehicle balance on hoist may change depending of what part to be removed Make absolutely sure to lock hoist after vehicle is hoisted up Before lifting up the vehi...

Page 23: ...vehicle floor or it may get deformed If the vehicle to be jacked up only at the front or rear end be sure to block the wheels on ground in order to ensure safety After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on the vehicle raised on jack alone To perform service with either front or rear vehicle end jacked up be sure to place safety stands ...

Page 24: ... DOJ Double Offset Joint DRL Daytime Running Light DTC Diagnostic Trouble Code Diagnostic Code E EBCM Electronic Brake Control Module ABS Control Module EBD Electric Brake force Distribution ECM Engine Control Module ECT Sensor Engine Coolant Temperature Sensor Water Temp Sensor WTS EGR Exhaust Gas Recirculation EGRT Sensor EGR Temperature Sensor Recirculated Exhaust Gas Temp Sensor REGTS EFE Heat...

Page 25: ...rain Control Module PCV Positive Crankcase Ventilation R RH Right Hand S SAE Society of Automotive Engineers SDM Sensing and Diagnostic Module Air bag controller Air bag control module SFI Sequential Multiport Fuel Injection SOHC Single Over Head Camshaft T TBI Throttle Body Fuel Injection Single Point Fuel Injection SPI TCC Torque Converter Clutch TCM Transmission Control Module A T Controller A ...

Page 26: ...IDENTIFICATION Most commonly used metric fastener strength property classes are 4T 6 8 7T 8 8 and radial line with the class identification embossed on the head of each bolt Some metric nuts will be marked with punch 6 or 8 mark strength identification on the nut face Figure shows the different strength markings When replacing metric fasteners be careful to use bolts and nuts of the same strength ...

Page 27: ...0 5 5 13 29 45 65 105 160 kg m 0 15 0 30 0 55 1 3 2 9 4 5 6 5 10 5 16 lb ft 1 0 2 5 4 0 9 5 21 0 32 5 47 0 76 0 116 0 A equivalent of 6 8 strength fastener without flange N m 2 4 4 7 8 4 20 42 80 125 193 280 g 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 A equivalent of 6 8 strength fastener with flange N m 2 4 4 9 8 8 21 44 84 133 203 298 g kg m 0...

Page 28: ...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 inoperative 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 LOCK position and the negative cable is disconnected from the battery Oth...

Page 29: ...cle without HO2S Nickel plug R R R When unleaded HO2S Iridium plug R unleaded fuel is Vehicle with HO2S Nickel plug R R fuel is used HO2S Iridium plug Replace every 105 000 km or 63 000 miles When leaded fuel is used refer to Severe Driving Condition schedule FUEL SYSTEM 3 1 Air cleaner filter I I R I I R 3 2 Fuel lines and connections I I I 3 3 Fuel filter Replace every 105 000 km or 63 000 miles...

Page 30: ...ke fluid R R R 6 5 Brake lever and cable damage stroke operation Inspect at first 15 000 km 9 000 miles only 6 6 Tires wear damage rotation I I I I I I 6 7 Wheel discs damage I I I I I I 6 8 Suspension system tighteness damage rattle breakage I I I 6 9 Propeller shafts and drive shafts I I 6 10 Manual transmission oil leakage level I 1st 15 000 km only I R R 6 11 Automatic transmission Fluid level...

Page 31: ...iles or 12 months C ITEM 3 1 I Every 2 500 km 1 500 miles C Air cleaner filter 1 R Every 30 000 km 18 000 miles or 24 months A B C E F H ITEM 2 1 Nickel plug R Every 10 000 km 6 000 miles or 8 months A B C E F H Spark plugs Iridium plug R Every 30 000 km 18 000 miles or 24 months B D E H ITEM 6 9 Propeller shafts and drive shafts I Every 15 000 km 9 000 miles or 12 months B E H ITEM 6 10 6 12 6 13...

Page 32: ...mation wear and cleanliness If any defect exists replace Check belt for tension Water pump and generator belt tension a 6 8 mm 0 24 0 32 in deflection for G16 9 11 mm 0 35 0 43 in deflection for H25 under 100 N 10 kg or 22 lb pressure NOTE When replacing belt with a new one adjust belt tension to 5 6 mm 0 20 0 24 in for G16 7 9 mm 0 28 0 35 in for H25 3 If belt is too tight or too loose adjust it ...

Page 33: ...eplacement Replace belt referring to Section 6H for replacement procedure of generator drive belt Engine cooling fan drive belt J20 engine Inspection 1 Disconnect negative cable at battery 2 Inspect belt for cracks cuts deformation wear and cleanliness If any defect exists replace Check belt for tension Cooling fan belt tension a 5 7 mm 0 20 0 27 in deflection under 100 N 10 kg or 22 lb pressure N...

Page 34: ...ative cable at battery 2 Inspect belt for cracks cuts deformation wear and cleanliness If any defect exists replace Check belt for tension Power steering pump and or A C compressor drive belt tension a 6 9 mm 0 24 0 35 in deflection under 100 N 10 kg or 22 lb pressure b 4 7 mm 0 16 0 28 in deflection under 100 N 10 kg or 22 lb pressure If belt tension is out of above specification adjust it referr...

Page 35: ... 0 005 0 007 in 0 17 0 21 mm 0 007 0 008 in tion Exhaust 0 23 0 27 mm 0 009 0 011 in 0 28 0 32 mm 0 011 0 013 in 3 Install cylinder head cover and tighten bolts to specification ITEM 1 4 Engine Oil and Filter Change WARNING New and used engine oil can be hazardous Be sure to read WARNING in General Precaution in Sec tion 0A and observe what in written there Before draining engine oil check engine ...

Page 36: ...e using an oil filter wrench Tightening Torque Reference b 14 N m 1 4 kg m 10 5 lb ft 6 Replenish oil until oil level is brought to FULL level mark on dip stick oil pan and oil filter capacity The filler inlet is at the top of the cylinder head cover It is recommended to use engine oil of SG SH or SJ grade NOTE For temperature between 20_C 4_F and 30_C 86_F it is highly recommended to use SAE 10W ...

Page 37: ...OT RUNNING For step 8 be sure to have adequate ven tilation while engine is running ITEM 1 5 Engine Coolant Change WARNING To help avoid danger of being burned do not remove radia tor cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if cap is taken off too soon 1 Remove radiator cap when engine is cool 2 Loosen radiator drain plug to drain coolan...

Page 38: ...ICORROSION COOLANT should be used for the pur pose of corrosion protection and lubrication ITEM 1 6 Exhaust System Inspection WARING To avoid danger of being burned do not touch exhaust sys tem when it is still hot Any service on exhaust system should be performed when it is cool When carrying out periodic maintenance or the vehicle is raised for other service check exhaust system as follows D Che...

Page 39: ...Replace excessively dirty filter 4 Blow off dust by compressed air from air outlet side of filter 5 Install air cleaner filter into case 6 Install air cleaner case cap and clamp it securely Replacement Replace air cleaner filter with new one according to above steps 1 2 and 5 6 ITEM 3 2 Fuel Lines and Connections Inspection 1 Visually inspect fuel lines and connections for evidence of fuel leakage...

Page 40: ...flames such as gas hot water heaters Fuel filter is located at the front part of fuel tank inside the right hand side of chassis Replace fuel filter with new one periodically referring to Section 6C for proper procedure ITEM 3 4 Fuel Tank Inspection Check fuel tank for damage cracks fuel leakage corrosion and tank bolts looseness If a problem is found repair or replace ...

Page 41: ...lation Valve Inspection Check crankcase ventilation hose and PCV hose for leaks cracks or clog and PCV valve for stick or clog Refer to On vehicle service of Section 6E1 6E2 for PCV valve checking procedure ITEM 4 3 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 EVAP canister for...

Page 42: ... filled with glycol base brake fluid do not use or mix different type of fluid when refilling system otherwise serious damage willoccur Do not use old or used brake fluid or one taken from unsealed container ITEM 6 2 Brake Discs Pads Brake Drums and Shoes Inspection Brake discs and pads 1 Remove wheel and caliper but don t disconnect brake hose from caliper 2 Check front disc brake pads and discs ...

Page 43: ...s Drain existing fluid from brake system completely fill system with specified fluid and carry out air purge operation For air purging procedure refer to Section 5 ITEM 6 5 Parking Brake Lever and Cable Inspection Parking brake lever 1 Check tooth tip of each notch for damage or wear If any damage or wear is found replace parking lever 2 Check parking brake lever for proper operation and stroke an...

Page 44: ...hould be checked when tires are cool Specified tire inflation pressure should be found on tire placard or in owner s manual which came with the vehicle 3 Rotate tires For details refer to Section 3F ITEM 6 7 Wheel Discs Inspection Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced Wheel Bearing Inspection 1 Check front wheel bearing for wear ...

Page 45: ...damage deformation oil leakage and opera tion If strut is found faulty replace it as an assembly unit be cause it can not be disassembled Refer to strut check Section 3D for operation check 4 Inspect strut boot for damage or crack 5 Inspect for cracks or deformation in spring seat 6 Inspect for deterioration of bump stopper 7 Inspect strut mount for wear cracks or deformation 8 Check ball joint st...

Page 46: ...signs of wear or lack of lubrication Replace any parts found defective in steps 1 to 13 ITEM 6 9 Propeller Shafts and Drive Shafts Inspection 1 Check universal joint and spline of propeller shaft for rattle If rattle is found replace defective part with a new one 2 Check propeller shaft front rear flange yoke bolts for tight ness and retighten them as necessary Refer to Section 4B for tightening t...

Page 47: ...e 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 specified oil 5 Tighten level plug to specified torque Refer to Section 7A or 7A1 for installation and tightening torque Change Change transmission oil with new specified oil referring to Section 7A or 7A1 ITEM 6 1...

Page 48: ...on and Change Inspection 1 Check transfer case and differential for evidence of oil leakage Repair leaky point if any 2 Make sure that vehicle is placed level for oil level check 3 Remove level plug of transfer or differentials front and rear and check oil level Oil level can be checked roughly by means of level plug hole That is if oil flows out of level plug hole or if oil level is found up to h...

Page 49: ...3B or 3B1 and 3C or 3C1 for particular check points 5 Check boots of steering linkage for damage leaks detachment tear dent etc If damage is found replace it with new one If any dent is found on steering rack boots correct it to original shape by turning steering wheel to the right or left as far as it stops and holding it for a few seconds 6 Check wheel alignment NOTE For details of wheel alignme...

Page 50: ...perates properly check that second ary latch keeps hood from opening all the way even when pulling hood release handle inside vehicle Also check that hood opens and closes smoothly and properly and hood locks securely when closed If any malfunction is found lubricate hinge and latch or repair hood lock system ITEM 6 17 Air Conditioning Filter if equipped Inspection 1 Remove air conditioning filter...

Page 51: ...earshift or Select Lever Transmission Check gear shift or select 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 indicates properly according to which position select lever is shifted to With automatic transmission equipped vehicle make sure that vehicle is at complete ...

Page 52: ...ccurately Lights Check that all lights operate properly Windshield Defroster Periodically check 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 SG SH or SJ Refer to engine oil viscosity chart in item 1 4 Engine coolant Ethylene glycol base coolant Antifreeze Anticorros...

Page 53: ...RNINGS could result in unintentional activation of the system or could render the system inoperative Either or 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 cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensi...

Page 54: ...SCRIPTION The heater an in and out air selectable type hot water heater is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides right and left of the instrument panel the hot air outlet at a place close to the feet of front passengers and the defroster air outlets at places right and left along the w...

Page 55: ...Blower resistor faulty Blower motor faulty Wiring or grounding faulty Replace fuse to check for short Check resistor Replace motor Repair as necessary Incorrect temperature output Control cables broken or binding Air damper broken Air ducts clogged Heater radiator leaking or clogged Heater hoses leaking or clogged Check cables Repair damper Repair air ducts Replace radiator Replace hoses When mode...

Page 56: ...ight relay 5 To A C controller 6 Blower motor relay 7 Blower motor switch 8 Blower resistor 9 Blower motor 10 To ECM 11 To illumination controller if equipped or body ground 12 Mode control actuator 13 Mode control switch 14 From main fuse 15 TAIL fuse 15 A 16 IG METER fuse 20 A 17 HEATER fuse 30 A 18 REAR DEFG fuse 15 A 19 Drive circuit WIRING CIRCUIT ...

Page 57: ... ON VEHICLE SERVICE BLOWER UNIT REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove passenger lower member 1 4 Remove ECM 1 with bracket 2 from blower motor unit 4 5 Disconnect blower motor 1 blower motor relay 2 and resistor lead wires 3 at couplers ...

Page 58: ...move blower motor unit 1 by removing its fastening nuts 2 9 Disconnect blower motor lead wire 2 at coupler from blower unit 1 10 Remove blower motor 3 by removing its mounting screws 4 INSTALLATION 1 Reverse removal procedure for installation 2 Connect fresh air control cable refer to HEATER CONTROL CABLES INSTALLATION 3 Enable air bag system if equipped Refer to ENABLING AIR BAG SYSTEM in Section...

Page 59: ... unit 6 Disconnect blower motor lead wire at coupler 2 7 Remove blower motor 3 from blower unit 1 INSPECTION Check continuity between terminal to terminal as shown in left fig ure If check results are continuity proceed to next operation check If not replace Connect battery to blower motor as shown then check that the blower motor operates smoothly and specified current Specified current Max 25 A ...

Page 60: ...ove glove box 5 Disconnect relay coupler 6 Remove blower motor relay 1 by removing its fastening screw 2 INSPECTION 1 Check that there is no continuity between terminal c and d If there is continuity replace relay 2 Connect battery positive terminal to terminal b of relay Connect battery negative terminal a of relay Check continuity between terminal c and d If there is no continuity when relay is ...

Page 61: ...emove glove box 5 Disconnect blower motor resistor 1 at coupler 6 Remove heater blower resistor 1 by removing its fastening screw 2 INSPECTION Measure each terminal to terminal resistance on resistor Resistance H LO Approx 2 0 H M1 Approx 1 0 H M2 Approx 0 4 If measured resistance is incorrect replace heater blower resistor INSTALLATION 1 Install heater blower resistor with screws 2 Enable air bag...

Page 62: ...h air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove meter cluster hood 1 by removing its mounting screws 2 4 Remove ashtray center garnish 1 and instrument glove box compartment 5 Remove radio 1 if equipped or clock or accessory case 6 Disconnect control cables 3 from blower motor unit 2 and heater unit 1 ...

Page 63: ...m heater control lever assembly 1 11 Remove heater control panel from mode control switch INSPECTION Mode Control Switch Check if continuity exists between each pair of terminals listed be low when mode control button is pressed Mode Mode control switch terminals VENT F M BI LEVEL F N HEAT F E DEF HEAT F B DEF F C With battery voltage connected to terminal I and to termi nal F press each mode cont...

Page 64: ...lamp in position as shown in left figure 3 Push blower lever fully in arrow direction and fix cable with clamp in position as shown in left figure NOTE After installing control cables be sure that control levers move smoothly and stop at proper position 3 If equipped with air bag enable air bag system Refer to ENAB LING AIR BAG SYSTEM in Section 10B HEATER MODE CONTROL ACTUATOR REMOVAL 1 Disconnec...

Page 65: ... heater unit by re moving its mounting screw 3 INSPECTION 1 Connect battery voltage to terminal b and to terminal a 2 Connect each terminal listed below to terminal a negative terminal of battery and check if lever rotation angle is as speci fied in figure MODE TERMINAL VENT c BI LEVEL d HEAT e DEF HEAT f DEF g INSTALLATION 1 Install in reverse order of removal procedure 2 If equipped with air bag...

Page 66: ...equipped with air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove mode control switch Refer to item HEATER MODE CONTROL SWITCH in this section INSPECTION Check heater blower motor switch for each terminal to terminal continuity For the detail refer to WIRING CIRCUIT earlier in this section E F L ML MH H LOW M1 M2 HIGH ...

Page 67: ... CABLES REMOVAL 1 Remove heater control lever assembly Refer to HEATER CONTROL LEVER ASSEMBLY in this sec tion 2 Remove control cables 2 from control lever assembly 1 INSTALLATION 1 Install in reverse order of removal procedure Refer to HEATER MODE CONTROL SWITCH in this section 2 If equipped with air bag enable air bag system Refer to ENABLING AIR BAG SYSTEM in Section 10B ...

Page 68: ...YH4 GRAND VITARA 1A 16 HEATER AND VENTILATION 1 Heater unit 2 Heater core 3 Damper 4 Heater mode control actuator 5 Heater mode control switch 6 Heater control lever assembly HEATER UNIT ...

Page 69: ...ver attempt disas sembly or repair but replace it with a new one When grease cleaning agent Oil water etc has got onto air bag inflator modules driver and passenger wipe off immediately with a dry cloth 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Drain engine coolant and disconnect heater hose 1 from heater unit 4 R...

Page 70: ...part be careful not to catch any cable or wiring harness When installing steering column assembly refer to STEER ING COLUMN INSTALLATION in Section 3C or 3C1 2 Install control cables Refer to HEATER CONTROL CABLES in this section 3 Fill engine coolant to radiator 4 Enable air bag system if equipped Refer to ENABLING AIR BAG SYSTEM in Section 10B 5 Evacuate and charge system Refer to items EVACUATI...

Page 71: ...er unit 2 Rear duct 3 SDM REAR DUCT REMOVAL 1 Disconnect negative cable at battery 2 Remove front seat 3 Remove console box 4 Take off carpet till rear duct is totally exposed 5 Remove rear duct INSTALLATION Reverse removal sequence to install rear duct ...

Page 72: ...and Service Precau tions under On Vehicle Service 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 could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after ...

Page 73: ...perature Sensor 1B 43 Refrigerant Pipes and Hoses 1B 44 A C Switch 1B 45 A C Controller 1B 46 Dual Pressure Switch 1B 47 A C Compressor Relay and A C Condenser Cooling Fan Relay 1B 48 Compressor Assembly 1B 49 Magnet Clutch Assembly For Denso Compressor 1B 53 Magnet Clutch Assembly For Seiko Seiki Compressor 1B 56 Lip Type Seal For Seiko Seiki 1B 59 REQUIRED SERVICE MATERIAL 1B 61 SPECIAL TOOLS 1B...

Page 74: ...o IDENTIFICATION INFORMATION of Section 0A in this manual The compressor used of Japan IWATA produced vehicle is made of SEIKO SEIKI and the compressor used of Canada CAMI produced vehicle is made of DENSO IDENTIFICATION OF REFRIGERATING SYSTEM Whether the A C equipped with the vehicle being serviced uses re frigerant R 134a or R 12 is indicated on the LABEL installed the compressor Also it can be...

Page 75: ...mpressor 2 Magnet clutch 3 Condenser assembly 4 Receiver dryer 5 Dual pressure switch 6 Expansion valve 7 Evaporator Liquid Vapor Superheated vapor 1B 4 AIR CONDITIONING OPTIONAL REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM ...

Page 76: ...ion valve 10 Ventilation air 11 Foot air 12 Defroster air 13 Demister air 14 Fresh air 15 Recirculation air 16 Heater unit 17 Air inlet box 18 Dual pressure switch 19 Low pressure charge valve 20 High pressure charge valve 21 Suction pipe 22 Sight glass CAMI PRODUCTION VEHICLE IWATA PRODUCTION VEHICLE AIR CONDITIONING OPTIONAL 1B 5 MAJOR COMPONENTS AND LOCATION ...

Page 77: ...gnal Check A C controller Cool air won t come out A C condenser cooling fan motor won t operative Condenser cooling fan relay faulty Wiring or grounding faulty A C condenser cooling fan relay signal in ECM faulty Condenser cooling fan motor faulty Check condenser cooling fan relay Repair as necessary Check A C condenser cooling fan relay signal Check condenser cooling fan motor Cool air won t come...

Page 78: ...ontroller faulty Magnetic clutch faulty Excessive charge of refrigerant Repair as necessary Check expansion valve Replace condenser dryer and evacuation and charging Check A C controller Check magnetic clutch Check charge of refrigerant Cool air comes out only at high speeds Condenser clogged Insufficient charge of refrigerant Air in A C system Drive belt slipping Compressor faulty Check condenser...

Page 79: ...s condition for a long time ABNORMAL NOISE FROM MAGNETIC CLUTCH Condition Possible Cause Correction A rumbling noise is heard when compressor is not operating Worn or damaged bearings Replace bearings A chattering noise is heard when compressor is engaged Faulty clutch gap excessive Worn clutch friction surface Compressor oil leaked from shaft seal contaminating the friction surface Adjust clutch ...

Page 80: ...sound is heard from evaporator Depending on the combination of the interior exterior temperatures engine rpm and refrigerant pressure the refrigerant flowing out of the expansion valve may under certain conditions make a whistling sound At times slightly decreasing refrigerant volume may stop this noise Inspect expansion valve and replace if faulty ABNORMAL NOISE FROM BLOWER MOTOR Condition Possib...

Page 81: ...for leaks with a leak tester No bubbles observed in sight glass No charge or proper or too much charge of refrigerant in system Refer to the following item No temperature difference between compressor inlet and outlet Empty or nearly empty system Recovery evacuate and charge system and then check it for leaks with a leak tester Noticeable temperature difference between compressor inlet and outlet ...

Page 82: ...ld be replaced only when a large amount of compressor oil is leaking out or when gas leakage is discovered by using gas tester In regard to noise and insufficient pressure repairs should be made only after diagnosing the trouble properly CONDITION POSSIBLE CAUSES CORRECTION Noise from compressor Defective bearing Defective cylinder and or shaft Replace Replace Noise from magnetic clutch Defective ...

Page 83: ...rchange high and low pressure charging hoses by mistake 5 Warm up engine to normal operating temperature engine cool ant temperature at 80 90_C 176 194_F and keep it at spe cified idle speed Radiator cooling fan should not be working when checking pressure and temperature 6 Turn A C switch ON and set blower switch at HI 4th position temperature control knob at COOL air outlet control knob at FACE ...

Page 84: ...g cm2 Pressure on high pressure gauge LO 230 350 kPa 2 3 3 5 kg cm2 NOTE Pressure registered on gauge varies with ambient temper ature Therefore use left graphs when determining if pres sures are normal or not 10 Check inlet port temperature to outlet port temperature rela tionship using graph For example if evaporator inlet port temperature is 25 C 77 F and center duct air outlet temperature is 8...

Page 85: ...on valve malfunction Valve opens too wide D Compressor malfunction Insufficient compression D Check expansion valve D Check compressor Pressure low B area of low side graph D Insufficient refrigerant Insufficient charge or leakage D Expansion valve malfunction Valve opens too narrow D Clogged refrigerant passage Crashed pipe D Check for leakage repair if necessary and recharge D Check expansion va...

Page 86: ...ubbles are visible through sight glass D Output air is slightly cold D Insufficient refrigerant in system Refrigerant leaking D Using a gas leak detector check for leaks and repair as necessary D Recharge refrigerant to a specified amount If the pressure reading is almost 0 when the manifold gauges are attached check for any leaks repair them and evacuate the system 0 4 0 6 4 6 56 9 85 3 D Pressur...

Page 87: ...y 11 Compressor 12 Condenser cooling fan relay 13 Condenser cooling fan 14 Fuse box 15 A C fuse 25 A 16 Ignition switch 17 Main fuse box 18 Battery main fuse 80 A 19 Battery 20 Generator 21 Ignition main fuse 60 A 22 Heater A C main fuse 60 A 23 Ignition meter fuse 20 A 24 Rear defogger fuse 15 A 25 Heater fuse 30 A 26 Compressor thermal switch only IWATA production vehicle FOR LH VEHICLE 1B 16 AI...

Page 88: ...rant pressure switch FOR RH VEHICLE 10 Compressor relay 11 Compressor 12 Condenser cooling fan relay 13 Condenser cooling fan 14 Fuse box 15 A C fuse 25 A 16 Ignition switch 17 Main fuse box 18 Battery main fuse 80 A 19 Battery 20 Generator 21 Ignition main fuse 60 A 22 Heater A C main fuse 60 A 23 Ignition meter fuse 20 A 24 Rear defogger fuse 15 A 25 Heater fuse 30 A 26 Compressor thermal switch...

Page 89: ...C controller and ECM with couplers disconnected from it A C controller 1 and its circuits can be checked at A C controller wiring couplers by measuring voltage Voltage Check 1 Remove A C controller 1 from vehicle refer to A C CON TROLLER REMOVAL in this section 2 Remove ECM 2 from vehicle 3 Connect A C controller couplers to A C controller and connect ECM couplers to ECM 4 Check each terminal volt...

Page 90: ...h 8 A C thermistor evaporator temperature sensor 9 Compressor relay 10 Compressor 11 Condenser fan motor relay 12 Condenser fan motor 13 A C controller 14 ECM 15 Compressor thermal switch only IWATA production vehicle TERMINAL ARRANGEMENT OF A C CONTROLLER TERMINAL ARRANGEMENT OF ECM FOR G16 J20 ENGINE TERMINAL ARRANGEMENT OF ECM FOR H25 ENGINE H25 engine E61 27 G16 J20 engines E61 8 H25 engine E6...

Page 91: ... G B position switch input see NOTE engine Fig B 0 1 5 volts Blower fan motor switch or A C or defroster position switch see NOTE OFF with engine running AC1 9 Gr W Signal input from ECM A C ON Ground to 10 14 volts Approve of A C ON AC1 9 Gr W permission signal engine Fig B 0 1 volt A C ON forbid AC1 13 Y B Signal output to ECM A C ON request signal Ground to engine Fig B 0 1 5 volts Blower fan m...

Page 92: ... with normal condition refer to INSPECTION OF ECM AND ITS CIRCUIT in Section 6E G16 J20 engines E61 8 permission signal Fig C 0 1 volt Except the above mentioned with engine running In this case compressor should be stop H25 engine E61 28 Y B Signal input from A C controller Ground to engine 0 1 5 volts Require A C ON G16 J20 engines E61 17 Y B A C ON request signal g Fig C 10 14 volts Turn off th...

Page 93: ...engine 1 Generator belt 2 Compressor drive belt 3 Compressor pulley 4 Crankshaft pulley 1B 22 AIR CONDITIONING OPTIONAL DRIVE BELT INSPECTION For G16 and H25 engines Refer to Section 3B1 for details For J20 engine Refer to Section 6H for details ...

Page 94: ...TEAD use quantities of fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point Obtain proper treatment as soon as possible from a doctor or eye specialist D Should the HFC 134a R 134a liquid come into contact with your skin the affected area should be treated in the same manner as when skin is frostbitten or frozen D Refrigerant must no...

Page 95: ...ERY NOTE When discharging refrigerant out of A C system always re cover it by using refrigerant recovery and recycling equip ment 1 Discharging it into atmosphere would cause ad verse effect to environments When handling recovery and recycling equipment be sure to follow the instruction manual for the equipment ...

Page 96: ...t 4 Approx 10 minutes later low pressure gauge 11 should show a vacuum lower than 760 mmHg providing no leakage exists NOTE If the system does not show a vacuum below 760 mmHg close both valves stop vacuum pump and watch move ment of low pressure gauge Increase in the gauge reading suggests existence of leak age In this case repair the system before continuing its evacuation If the gauge shows a s...

Page 97: ...ins HFC 134a R 134a Described here is a method to charge the air conditioning system with refrigerant from the refrigerant ser vice container When charging refrigerant recovered by using the refrigerant and recycling equipment when recycling refrigerant follow the procedure described in the equipment manufacturer s instruction manual The initial charging of the A C system is performed from the hig...

Page 98: ...nstall previously removed refrigerant container tap valve 4 to a new refrigerant container 3 c Purge any air existing in center charging hose When using refrigerant container tap valve use following procedure to purge air i Once fully tighten refrigerant container tap valve and then loosen open plate nut slightly ii Open low pressure valve of manifold gauge set a little iii As soon as refrigerant ...

Page 99: ...sure side vale 3 of manifold gauge set 4 If equipped with sight glass in this time look into the sight glass 6 of condenser outlet pipe 5 and check that there are no bubbles 7 in it which means that the system is fully charged Low pressure gauge when charged with specified amount About 200 300 kPa 2 3 kg cm2 29 43 psi At A C inlet temperature 30 35_C 86 95_F High pressure gauge when charged with s...

Page 100: ...s been performed which may result in disturbing lines or connections it is advisable to test for leaks Common sense should be used in performing any refrigerant leak test since the need and extent of any such test will in general de pend upon the nature of a complaint and the type of a service per formed on the system LIQUID LEAK DETECTORS There are a number of fittings and places throughout the a...

Page 101: ...tween two types of A C one using CFC 12 R 12 and the other using HFC 134a R 134a For identification between these two types refer to page 1B 2 When replenishing or changing refrigerant and compressor oil and when replacing parts make sure that the material or the part to be used is appropriate to the A C installed in the vehicle being serviced Use of incorrect one will result in leakage of refrige...

Page 102: ...ls Refrigerant combined with moisture is corrosive and will tarnish surfaces of bright metals including chrome D After recovering refrigerant from system the amount of compressor oil removed must be measured and the same amount added to the system REFRIGERANT RECOVERY When discharging refrigerant out of A C system always recover it by using refrigerant recovery and recycling equipment Discharging ...

Page 103: ...ea son replenish 20 cc oil When replenishing gas only oil replenish ment it not necessary When replacing compressor Compressor oil is sealed in each new compressor by the amount required for air conditioner cycle Therefore when using a new compressor for replacement drain oil from it by the amount calcu lated as follows C A B C Amount of oil to be drained A Amount of oil sealed in a new compressor...

Page 104: ... pair of pliers If any leakage is found from fitting or tube repair or replace condenser REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant by using recovery and recycling equipment Be sure to follow the instruction manual for the equipment The amount of compressor oil removed must be measured and the same amount added to the system 3 Remove front bumper assembly and remove lower...

Page 105: ...emove condenser with fan NOTE Be careful not to damage fins of condenser and radiator 9 Remove A C condenser cooling fan assembly from condenser INSTALLATION Reverse removal sequence to install condenser noting following point 1 When replacing condenser add 20 to 30 cc of refrigerating oil from compressor suction side 2 Evacuate and charge system according to previously described procedure ...

Page 106: ...ONDENSER AS SEMBLY REMOVAL in this section Check continuity between terminal to terminal as shown If check results are continuity proceed to next operation check If not replace Connect battery to condenser fan motor as shown then check that the condenser fan motor operates smoothly and specified current Specified current Maximum 12 A at 12 V ...

Page 107: ...a plier 2 INSTALLATION Reverse removal sequence to install condenser dryer according to instruction manual with supply parts NOTE When replacing condenser dryer add 40 cc of refrigerating oil the same as compressor oil Do not remove the dryer from the plastic bag until just before inserting it into the receiver Install the condenser dryer 1 with its double layer portion facing the bottom of the re...

Page 108: ...ILTER ELEMENT REMOVAL 1 Disconnect negative cable at battery 2 For vehicle with air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Pull down glove box 1 by pushing the shown part a 4 Remove filter cover 1 5 Pull out filter element 1 Pull out upper filter first then the lower one ...

Page 109: ...ed air from air outlet side of the filter ele ment INSTALLATION Reverse removal procedure for installation noting the followings Install filter into cooling unit directing arrow mark on its end face to heater unit Enable air bag system after installation Refer to ENABLING AIR BAG SYSTEM in Section 10B ...

Page 110: ...mount added to the system 4 For G16 and J20 engine Disconnect suction pipe 1 and liquid pipe 2 from evaporator cooling unit CAUTION As soon as above hose and pipe are disconnected cap opened fittings so that moisture and dust may not enter cooling unit 5 Remove blower motor unit Refer to Section 1A HEATER AND VENTILATION 6 Disconnect thermistor wire coupler 7 Remove cooling unit evaporator DISASSE...

Page 111: ...porator temperature sensor 4 DISASSEMBLY FOR IWATA PRODUCTION VEHICLE 1 Remove filter 2 from cooling unit 3 assembly by removing fil ter cover 1 2 Detach clamps 1 to separate evaporator upper and lower cases from each other 3 Remove upper case 1 and remove evaporator 2 from lower case 3 4 Remove following components from evaporator Expansion valve 5 Thermistor evaporator temperature sensor 4 ...

Page 112: ...scratch Repair them as required REASSEMBLY and INSTALLATION 1 Reverse removal and disassembly sequence to install cooling unit noting the following points Install uniformly the evaporator packing to dash panel hole for expansion valve Adjust fresh air control cable refer to HEATER CONTROL LEVER ASSEMBLY in Section 1A 2 Enable air bag system Refer to Enabling Air Bag System in Section 10B 3 Evacuat...

Page 113: ...t added to the system 2 Remove front grill 3 Disconnect suction pipe 1 and liquid pipe 2 from evaporator Cooling unit CAUTION As soon as above hose and pipe are disconnected cap opened fittings so that moisture and dust may not enter cooling unit 4 Disconnect suction pipe and liquid pipe from suction hose 1 and condenser outlet pipe 2 5 Remove pipe clamp then remove suction pipe and liquid pipe 6 ...

Page 114: ...ure amplifier makes magnet clutch turn off to prevent evaporator from frosting INSPECTION Check resistance between A C evaporator thermistor 1 termi nals If check results are as not specified replace thermistor Sensor Temperature Resistance 0_C 32_F 7 0 7 7 k 25_C 77_F 2 1 2 4 k REMOVAL Refer to COOLING UNIT EVAPORATOR in this section INSTALLATION 1 Reverse removal sequence to install thermistor 2...

Page 115: ...the equipment The amount of compressor oil removed must be measured and the same amount must be added to the system when reinstal ling 2 Replace defective hose or pipe CAUTION As soon as the above hose or pipe is disconnected cap its opened fitting to prevent moisture and dust from en tering INSTALLATION 1 Reverse removal procedure to install refrigerant line 2 Evacuate and charge system Refer to ...

Page 116: ... Section 10B 3 Remove mode control switch Refer to MODE CONTROL SWITCH in Section 1A INSPECTION A C Switch Press A C button and check if there is continuity between termi nals D and G With battery voltage connected to terminal K and to termi nal D press A C button and check if indicator lamp lights INSTALLATION 1 Install in reverse order of removal procedure 2 If equipped with air bag system enabl...

Page 117: ...love box then remove screw 4 Remove glove box 5 Disconnect A C controller coupler 2 evaporator thermistor coupler 3 6 Remove A C controller 1 from heater unit 4 INSPECTION Refer to INSPECTION OF A C CONTROLLER AND ITS CIR CUIT in this section INSTALLATION 1 Install in reverse order of removal procedure 2 If equipped with air bag system enable air bag system Refer to ENABLING AIR BAG SYSTEM in Sect...

Page 118: ...nt and when A C system com pressor is under operation In each of these cases switch should show proper continuity 2 Using a manifold gauge set check switch for operation at speci fied pressure as shown refer to PERFORMANCE DIAGNO SIS in this section Switch ON above C and below D Switch OFF below A or above B A Approx 200 kPa 2 0 kg cm2 B Approx 3200 kPa 32 kg cm2 C Approx 230 kPa 2 3 kg cm2 D Appr...

Page 119: ...emove condenser cooling fan motor relay 2 and or compres sor relay 1 from vehicle 3 Check that there is no continuity between terminal c and d If there is continuity replace relay 4 Connect battery positive terminal to terminal b of relay Connect battery negative terminal a of relay Check continuity between terminal c and d If there is no continuity when relay is connected to the battery replace r...

Page 120: ...ide of the compressor should be cleaned before any On vehicle repair or before removal of the compressor The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichloroethane naphtha kerosene or equivalent solvent and dried with dry air Use only lint free cloths to wipe parts The operations described are based on bench overhaul with compressor removed fro...

Page 121: ... 4 Disconnect thermal protector lead wire 5 Disconnect suction and discharge hoses from compressor as sembly NOTE Cap open fitting immediately to keep moisture out of sys tem 6 For G16 engine Remove compressor drive belt by loosening compressor as sembly mounting bolts For J20 engine Remove generator belt Refer to Section 6H For H25 engine Remove compressor drive belt by loosening tension pulley b...

Page 122: ...ompressor assembly to its bracket Tighten bolts a first then b Tightening Torque a b 23 N m 2 3 kg m 17 0 lb ft 3 Connect suction and discharge hoses to compressor assembly 4 For G16 engine Tension compressor drive belt 2 by tightening compressor as sembly mounting bolts Refer to Section 3B1 for drive belt ten sion Tighten bolt a first then b Tightening Torque a b 23 N m 2 3 kg m 17 0 lb ft For J2...

Page 123: ...pressor drive belt 2 For J20 engine Install compressor assembly to its bracket Tighten bolts a Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 3 Connect suction and discharge hoses to compressor assembly 4 For G16 engine Tension compressor drive belt 2 by tightening compressor as sembly mounting bolts Refer to Section 3B1 for drive belt ten sion Tighten bolt a first then b Tightening Torque a 23 N ...

Page 124: ...n ohmmeter measure resistance of clutch coil between clutch lead wire 1 and compressor body 2 If measured resistance is not within tolerance replace magnet clutch assembly Standard resistance 3 5 5 0 at 20_C 68_F REMOVAL 1 Remove compressor assembly from vehicle Refer to COM PRESSOR ASSEMBLY in this section 2 Fix clutch plate 1 with special tool A and remove clutch plate bolt Special Tool A 09991 ...

Page 125: ...ulley with puller 1 from compressor 2 NOTE Be careful not to damage pulley when tapping magnet clutch assembly 8 Remove clutch coil Special tool C 09900 06107 INSTALLATION 1 Install clutch coil 2 Protrusion on under side of coil ring must match hole in com pressor 3 to prevent movement ant correctly locate lead wire 2 Using special tool C install snap ring 1 as shown Special Tool C 09990 06107 3 I...

Page 126: ... that edge rests only on inner race of bearing 3 Install snap ring Special Tool D 09991 06010 CAUTION Be careful not to scratch bearing seal 5 Adjust clearance between clutch plate 1 and clutch pulley by putting shim on compressor shaft Standard clearance a 0 3 0 5 mm 0 012 0 02 in 6 Tighten new clutch plate bolt as specified below Tightening Torque a 14 N m 1 4 kg m 10 5 lb ft Special Tool A 0999...

Page 127: ...ns of oil D Check clutch pulley bearings for noise and grease leakage D Using and ohmmeter measure resistance of clutch coil between clutch coil lead wire 1 and compressor body If measured resistance is not within tolerance replace coil Standard resistance 2 5 4 5 at 20_C 68_F COMPRESSOR THERMAL SWITCH Use an ohmmeter to check thermal switch for continuity If there is no continuity replace it REMO...

Page 128: ...Special Tool C 09900 06107 7 Remove clutch coil lead wire clamp screw 8 Remove clutch pulley with puller 1 from compressor 2 NOTE Be careful not to damage pulley when tapping magnet clutch 9 Remove clutch coil INSTALLATION 1 Install clutch coil 2 Protrusion on under side of clutch coil must match hole in com pressor 3 to prevent movement ant correctly locate lead wire 2 Using special tool C instal...

Page 129: ...sure that edge rests only on inner race of bearing 3 Install snap ring Special Tool D 09991 06010 CAUTION Be careful not to scratch bearing seal 5 Adjust clearance between clutch plate and clutch pulley 2 by putting shim on compressor shaft Standard clearance a 0 3 0 6 mm 0 012 0 024 in 6 Tighten new clutch plate 1 bolt 2 as specified below Tightening Torque a 14 N m 1 4 kg m 10 5 lb ft Special To...

Page 130: ...section 2 Remove compressor front head 1 mounting bolt 10 pcs 3 Remove compressor front head 1 by pushing cylinder shaft 2 NOTE Be careful not to remove cylinder from case 4 Remove O ring 5 Remove lip seal from compressor front head 1 INSTALLATION 1 Press fit lip seal 1 into compressor front head 2 using special tool E Special Tool E 09991 06050 CAUTION Do not reuse mechanical seal once removed fr...

Page 131: ...ial Tool F 09991 06040 3 Install O ring 2 to case 4 Apply compressor refringent oil to lip seal and O ring 5 Install compressor front head 1 6 Tighten compressor front head bolt Tightening Torque a 14 N m 1 4 kg m 10 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft NOTE Be sure to use new front head bolt washer Tighten bolt a first and next b ...

Page 132: ...protector 09991 06050 Lip type seal installer REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Compressor oil for DENSO compressor Refrigerant oil COMPRESSOR OIL ND OIL 8 250 cc 99000 27080 O ring Each component Compressor oil for SEIKO SEIKI compressor Refrigerant oil COMPRESSOR OIL RS20 150 cc 99000 99088 00D O ring Each component Refrigerant REFRIGERANT DRUM 200 g 95794 50G00 R...

Page 133: ...he vehicle first Proceed with the following preliminary inspections and correct any defects which are found 1 Inspect tires for proper pressure and uneven wear 2 Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts 3 Spin front wheel Inspect for out of round tires out of balance tires bent rims loose and or rough wheel bear ings DIAGNOSIS TA...

Page 134: ... ball joints Excessive wheel runout Blister or bump on tire Excessively loaded radial runout of tire wheel assembly Disturbed front end alignment Loose or worn tie rod end Loose steering gear case bolts Balance wheels or replace tire and or wheel Replace wheel bearing Replace tie rod end Replace front suspension control arm Repair or replace wheel and or tire Replace tire Replace tire or wheel Che...

Page 135: ...joint Repair or replace Check repair or lubricate rack and pinion Check and adjust front end alignment Check and adjust rack and pinion torque Adjust pressure Steering Noise Rattle or Chuckle Loose bolts and nuts Broken or otherwise damaged wheel bearings Worn or sticky tie rod ends Rack and pinion not properly adjusted if equipped with manual steering gear case Retighten Replace Replace Check and...

Page 136: ...en or sagging springs Leaking wheel cylinder or caliper Warped discs Badly worn brake linings Drum is out of round in some brakes Wheel tires are inflated unequally Defective wheel cylinders Disturbed front end alignment Replace wheel bearing Replace spring Repair or replace wheel cylinder or caliper Replace brake disc Replace brake shoe lining Replace brake drum Inflate tires to proper pressure R...

Page 137: ...r sagging springs Overloaded Tighten stabilizer bar bolts or replace bushes Replace shock absorber strut or tighten mounting Replace spring Check loading Cupped Tires Front struts defective Worn wheel bearings Excessive tire or wheel run out Worn ball joints Tire out of balance Replace strut Replace wheel bearing Replace tire or wheel disc Replace front suspension control arm Adjust tire balance ...

Page 138: ... indicators to show when tires 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 replacement is recommended RADIAL TIRE WADDLE Waddle is side to side movement at the front and or rear of the ve hicle It is caused by the steel belt not being straight within t...

Page 139: ...ACE OF OTHER FRONT TIRE LEAD CORRECTED REPLACE TIRE LEAD REMAINS KNOWN GOOD TIRES ARE NOT GOOD STEERING SUSPENSION WHEELS AND TIRES 3 7 1 Ride vehicle to determine if the waddle is coming from the front or rear 2 Install tires and wheels that are known to be good on similar ve hicle in place of those on the offending end of the vehicle If the waddle cannot be isolated to front or rear substitute t...

Page 140: ... be used to make sure that front alignment is not mistaken for tire lead 1 Part of the lead diagnosis procedure is different from the tire rotation pattern currently in the owner s and service manuals If a medium to high mileage tire is moved to the other side of the vehicle be sure to check that ride roughness has not developed 2 Rear tires will not cause lead VIBRATION DIAGNOSIS Wheel unbalance ...

Page 141: ...YH4 GRAND VITARA STEERING SUSPENSION WHEELS AND TIRES 3 9 Caused by SMOOTH ROAD SUSPENSION MOVEMENT Loaded Runout TIRE OUT OF ROUND TIRE STIFFNESS VARIATION RIM BENT OR OUT OF ROUND ...

Page 142: ...nt wheels the front suspension attaching parts and the ground Generally the only adjustment required for front alignment is toe setting Camber and caster can t be adjusted Therefore should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision whether the damage is in body or in suspension should be deter mined If the body is damaged it should b...

Page 143: ...heels and tires 4 Check vehicle trim heights if out of limits and a correction is to be made it must be made before adjusting toe 5 Check for loose control arms 6 Check for loose or missing stabilizer bar attachments 7 Consideration must be given to excess loads such as tool boxes If this excess load is normally carried in ve hicle it should remain in vehicle during alignment checks 8 Consider con...

Page 144: ...if right and left tie rods are equal in length A in left figure Steering angle inside 35 3 outside 33 3 NOTE If tie rod lengths were changed to adjust steering angle rein spect toe in Reference Information Side slip For inspecting front wheel side slip with side slip tester Side slip limit Less than 3 mm m Less than 0 118 in 3 ft If side slip exceeds above limit toe in or front wheel alignment may...

Page 145: ... bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service 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 could ...

Page 146: ...GENERAL DESCRIPTION POWER STEERING SYSTEM The power steering P S system in this vehicle reduces the driver s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering P S pump which is driven by the engine It is an integral type with the rack and pinion gears and the control valve unit hydraulic pressure cylinder unit all built in the steering ...

Page 147: ... stub shaft The sleeve is linked with the pinion through a pin and the valve and stub shaft are integrated into one unit Then the pinion and the stub shaft are linked to each other by means of the torsion bar Thus when the stub shaft moves the valve changes its position thereby switching the hydraulic passage from the pump to the cylin der to help steering operation When turning the steering wheel...

Page 148: ...2 995 psi J20 Type engine 7350 kPa 73 5 kg cm2 1045 psi H25 Type engine Control Flow control valve device Relief valve Power steering pressure switch Switch turns on closes when the pressure is higher than 2500 3500 kPa 25 35 kg cm2 356 498 psi ECM uses this signal for idle speed control Capacity 0 70 0 75 1 48 1 23 1 58 1 32 US Imp pt Specified fluid DEXRON II DEXRON III A T fluid or equivalent F...

Page 149: ... Replace gear box Steering wheel feels heavy momentarily when turning it to the left or right D Air drawn in due to insufficient amount of fluid D Slipping P S belt D P S pump hydraulic pressure fails to increase D P S pump hydraulic pressure increases but slowly D Steering gear box malfunction Add fluid and purge air Adjust belt tension or replace belt as necessary Check pressure and repair or re...

Page 150: ...is in Section 3 Fluid leakage Loose joints of hydraulic pressure pipes and hoses Deformed or damaged pipes or hoses Retighten Replace defective part Abnormal noise Air drawn in due to insufficient amount of fluid Air mixed into fluid from pipes or hoses Slipping loose P S belt Worn P S belt Loose gear box fastening bolt Loose linkage or joints Pipes or hoses in contact with part of vehicle body Va...

Page 151: ...or wear or breakage D Each part for looseness STEERING FORCE CHECK 1 Place vehicle on level road and set steering wheel at straight ahead position 2 Check that tire inflation pressure is as specified Refer to tire placard 3 Start engine and keep it running till power steering fluid is warmed to 50 to 60_C 122 to 140_F 4 With engine idling measure steering force by pulling spring ba lancer hooked o...

Page 152: ...g 22 lb force Deflection of P S belt 6 9 mm 0 24 0 35 in G16 Type engine 4 7 mm 0 16 0 28 in H25 Type engine BELT TENSION ADJUSTMENT For G16 Type engine a To adjust P S pump drive belt tension use adjusting bolt of com pressor for A C equipped vehicles and that of P S pump for ve hicles without A C b Adjust belt tension to above specification c Then tighten adjusting and mounting bolts to specifie...

Page 153: ...tely If power steering pressure switch connector is connected check the same with that connector disconnected Momentary drop of engine idle speed should be less when it is connected than when disconnected FLUID FLUID LEAKAGE CHECK Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided Then visually check gear box P S pump and P S fluid reser...

Page 154: ...ten each flare nut to specified torque CAUTION Take care not to cause damage to A C condenser during service operation if equipped Special Tool A 09915 77410 Oil pressure gauge B 09915 77420 2 Check each connection for fluid leakage and bleed air Refer to AIR BLEEDING PROCEDURE in this section 3 With engine idling turn steering wheel and warm up engine till temperature of fluid in P S fluid reserv...

Page 155: ...g CAUTION Be sure not to close gauge valve for longer than 10 se conds Next open gauge valve fully and increase engine speed to about 1 500 r min rpm Then turn steering wheel to the left or right fully and take reading of relief pressure Relief pressure 6200 7000 kPa 62 70 kg cm2 882 995 psi G16 Type engine 6700 7500 kPa 67 75 kg cm2 953 1067 psi J20 Type engine 7050 7850 kPa 70 5 78 5 kg cm2 1003...

Page 156: ... mod el and set parking brake 3 After running engine at idling speed for 3 to 5 seconds stop it and add fluid to satisfy specification 4 With engine stopped turn steering wheel to the right and left as far as it stops repeat it a few times and fill fluid to specified level 5 With engine running at idling speed repeat stop to stop turn of steering wheel till all foams in P S fluid reservoir are gon...

Page 157: ...by using puller 4 To facilitate adjustment after installation put a mark on tie rod thread indicating position of tie rod end lock nut Then loosen lock nut and remove tie rod end from tie rod INSPECTION Tie rod End Ball Joint Inspect for play in tie rod end ball joint If found defective replace INSTALLATION 1 Install tie rod end lock nut and tie rod end to tie rod Tighten lock nut to mark on tie r...

Page 158: ...a 65 N m 6 5 kg m 47 0 lb ft POWER STEERING GEAR BOX ASSEMBLY REMOVAL 1 Take out fluid in P S fluid reservoir with syringe or such 2 Disconnect high pressure pipe from steering gear box by remov ing union bolt NOTE As fluid flows out of disconnected joints put a receptacle under joints or a plug to pipe 3 Disconnect low pressure hose from steering gear box NOTE As fluid flows out of disconnected j...

Page 159: ...y Next with tie rod end installed to knuckle set rack in position close to neutral Then obtain the neu tral state by aligning match marks on pinion shaft and steering gear case and insert steering lower joint into pinion shaft CAUTION Be sure to confirm that steering wheel and front tires wheels are in straight position when inserting steering lower joint into steering pinion shaft If a plug was p...

Page 160: ... end thread 3 Loosen tie rod end lock nut and remove tie rod end 4 Remove boot wire and clip 5 Remove boot from tie rod INSTALLATION 1 Visually inspect that rack and rack end ball joint are free from dirt or foreign matters Clean thoroughly with cloth or such Position boot properly in grooves of gear case and tie rod and clamp it with wire and clip Wire should be new and should go around twice Pul...

Page 161: ...RING GEAR BOX ASSEMBLY INSTALLATION in this section After installation fill specified P S fluid and bleed air from sys tem Then check toe setting and adjust as required RACK BOOT AND TIE ROD FOR CANVAS TOP LH MODEL REMOVAL 1 Remove steering gear case refer to POWER STEERING GEAR BOX ASSEMBLY REMOVAL in this section 2 For ease of adjustment after installation make marking of tie rod end lock nut po...

Page 162: ...in figure 5 Position boot properly in grooves of gear case and tie rod Check to ensure that boot is free from twist and dent 6 Fasten boot with new clamp and clip securely Special Tool A 09943 55010 7 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 measure length A on re moved tie rod and use it on new replacement ...

Page 163: ...t d 11 N m 1 1 kg m 8 0 lb ft e 35 N m 3 5 kg m 25 5 lb ft f 40 N m 4 0 kg m 29 0 lb ft g 45 N m 4 5 kg m 33 0 lb ft 1 Power steering pump assembly 2 Bracket 3 P S fluid reservoir 4 High pressure hose pipe 5 Suction hose 6 Low pressure return hose 7 Oil tank bracket 8 To P S gear box G16 ENGINE MODEL J20 ENGINE MODEL H25 ENGINE MODEL POWER STEERING PUMP ...

Page 164: ...eceptacle under joints or a plug to pipe 4 Disconnect pressure switch lead wire at switch terminal 5 Loosen related bolts and remove power steering drive belt 6 Remove P S pump mounting bolt s 7 Remove P S pump NOTE Plug each port of removed pump to prevent dust or any oth er foreign matter from entering DISASSEMBLY 1 Clean its exterior thoroughly 2 With aluminum plates placed on vise first grip p...

Page 165: ...amage If any defect is found replace pump assembly Rotor and Vane Check sliding surfaces of rotor and vane for wear and damage Check clearance between rotor and vane Clearance Standard 0 015 mm 0 0006 in Limit 0 027 mm 0 0011 in Replace pump assembly if any defect is found in above checks Relief Valve Flow Control Valve and Its Spring Check fluid passage of relief valve and orifice of connector fo...

Page 166: ...al lip and apply power steering fluid to slid ing surface of the shaft then insert pulley s shaft from oil seal side of the pump body A Grease 99000 25010 2 Apply power steering fluid to O rings and fit them to pump body 3 Install side plate to pump body NOTE Carefully align the dowel pins on the side plate at bolt hole as shown in figure 4 Apply power steering fluid to sliding surface of rotor 5 ...

Page 167: ...m ring to pump body The tapered end of cam ring should face the side plate 9 Apply power steering fluid to each vane 10 Install vanes 10 pieces to rotor 11 Apply power steering fluid to O ring 12 Install O ring to pump body 13 Apply power steering fluid to sliding surface of pump cover and rotor 14 Match the dowel pins to the holes of the cover plate as shown and install pump cover to pump body ...

Page 168: ...y Tightening Torque a 28 N m 2 8 kg m 20 0 lb ft 18 Apply power steering fluid to relief valve flow control valve 19 Install relief valve flow control valve to pump body 20 Install flow control spring 21 Apply power steering fluid to O rings of plug 22 Install O rings to plug 23 Tighten plug to specified torque Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft 24 Apply power steering fluid to O ring ...

Page 169: ... For tightening torques refer to structural diagram on previous page Adjust power steering pump drive belt by referring to BELT TEN SION ADJUSTMENT under POWER STEERING PUMP DRIVE BELT in this section Fill specified power steering fluid after installation and bleed air without failure Refer to AIR BLEEDING PROCEDURE in this section ...

Page 170: ...olt J20 Type engine 25 2 5 18 5 H25 Type engine 45 4 5 32 5 Pump union bolt 60 6 0 43 5 Oil pump mount bolts 25 2 5 18 5 Pipe clamp bolt Reservoir bracket bolt 11 1 1 8 0 Steering shaft joint bolt 25 2 5 18 0 High pressure flare nuts 40 4 0 29 0 Pump cover bolts 23 2 3 17 0 Plug 60 6 0 43 5 Pressure switch Terminal 28 2 8 20 Suction connector bolt 10 1 0 7 5 Tie rod end nut 48 4 8 35 0 Tie rod for...

Page 171: ...Checking steering column for accident damage 3C 13 Adjustable steering column release lever 3C 14 TIGHTENING TORQUE SPECIFICATIONS 3C 14 SPECIAL TOOL 3C 14 GENERAL DESCRIPTION This double tube type steering column has the following three important features in addition to the steering function The column is energy absorbing designed to compress in a front end collision The ignition switch and lock ...

Page 172: ...ering shaft joint 12 Steering lower shaft assembly 13 Adjustable steering column release lever 14 Steering column lower seal If equipped 3C 2 STEERING WHEEL AND COLUMN DIAGNOSIS For diagnosis of the steering wheel steering column and steering shaft lower assembly refer to Section 3 INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT After an accident be sure to perform checks inspections and repairs des...

Page 173: ...ion 6 Remove steering wheel with special tool Special Tool A 09944 36011 CAUTION Do not hammer the end of the shaft Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column INSTALLATION 1 Install steering wheel to steering shaft with 2 lugs on combina tion switch fitted in two grooves in the back of steering wheel and also ali...

Page 174: ... from steering column Refer to STEERING WHEEL in this section 3 Remove steering column hole cover 4 Remove steering column cover screws 3 pieces 5 Separate upper cover and lower cover then remove them 6 Disconnect all connectors for combination switch 7 Remove combination switch from steering column INSPECTION Check combination switch wire harness for any signs of scorching melting or other damage...

Page 175: ...remely susceptible to damage Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length Leaning on the column assembly could cause it to bend or deform Any of the above damage could impair the column s col lapsible design When loosening steering column mounting bolts make sure that steering column assembly and steering sh...

Page 176: ...f not removing steering wheel and or combination switch i Turn steering wheel so that vehicle s front tires are at straight ahead position ii Turn ignition switch to LOCK position and remove key 3 Remove steering column hole cover 4 Disconnect all connectors for the following parts Combination switch Ignition switch Immobilizer control system parts if equipped 5 Make alignment marks on shaft joint...

Page 177: ...s involved in accidents resulting in body damage where steering column has been impacted or air bag deployed may have a damaged or misaligned steering col umn CHECKING PROCEDURE 1 Check that two capsules are attached to steering column brack et securely Check clearance between capsules and steering column bracket Clearance should be 0 mm 0 in on both sides If found loose or clearance replace steer...

Page 178: ...umn for bend cracks or deforma tion If found defective replace as column assembly INSTALLATION CAUTION After tightening steering column mounting bolts steering shaft joint bolts should be tightened After tightening steering column lower bolts steering col umn upper bolts should be tightened 1 Be sure that front wheels and steering wheel are in straight ahead position 2 If equipped with shift key i...

Page 179: ...olumn side to steering shaft joint Tighten shaft joint bolt column side to specified torque first and then shaft joint bolt lower shaft assembly side to specified torque Tightening Torque b 25 N m 2 5 kg m 18 0 lb ft 6 If combination switch is removed install combination switch Refer to COMBINATION SWITCH in this section 7 Connect all connectors that have been removed in removal 8 Install steering...

Page 180: ... ACC or ON position and remove steering lock assembly from steering column INSTALLATION 1 Position 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 pull it out 4 Align hub on lock with oblong hole of steering shaft and rotate shaft to assure that steer...

Page 181: ...ad position 2 Turn ignition switch to LOCK position and remove key 3 Make alignment marks on shaft joint and shaft column side for a guide during reinstallation 4 After removing bolt on column side of shaft joint and loosening bolt on its lower shaft assembly side move shaft joint to lower shaft assembly side in arrow direction in figure 5 Make alignment marks on lower shaft assembly lower joint a...

Page 182: ...shaft as sembly 3 Install shaft joint bolt lower shaft assembly side to shaft joint Then tighten it by hand 4 Insert pinion shaft into lower shaft assembly lower joint by matching it to marks made before removal And then install low er shaft assembly lower joint bolt to lower shaft assembly lower joint Tighten it to specified torque Tightening Torque a 25 N m 2 5 kg m 18 0 lb ft 5 Install steering...

Page 183: ...teering column assembly 2 Check two plates for any damages such as crack or breakage If anything is found faulty replace as steering column assembly 3 Take measurement a as shown If it is shorter than specified length replace column assembly with new one Length a 895 0 8 mm 35 24 0 03 in 4 Check steering column lower seal for breakage or deformation If found defective replace 5 Check steering shaf...

Page 184: ...ase lever is at lower position i e steering column is not locked Steering column is fixed securely when adjustable steering col umn release lever is at higher position i e steering column is locked TIGHTENING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fastening arts N m kg m lb ft Steering shaft nut 33 3 3 23 5 Steering column mounting bolt 23 2 3 17 0 Steering shaft joint bolt 25 2 5...

Page 185: ...ervice in air bag system section before performing service on or around the air bag system compo nents 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 severe injury The procedures in this section must be followed in the order listed to disable the air bag system tem porar...

Page 186: ...he ignition and steering operations can be locked to inhibit theft of the vehicle To insure the energy absorbing action it is important that only the specified screws bolts and nuts be used as designated and that they are tightened to the specified torque When the column assembly is removed from the vehicle special care must be taken in handling it Use of a steering wheel puller other than the one...

Page 187: ... VEHICLE SERVICE SERVICE PRECAUTIONS For service precautions refer to SERVICE PRECAUTIONS un der ON VEHICLE SERVICE in Section 10B DIAGNOSIS AND SERVICING For diagnosis and servicing refer to DIAGNOSIS AND SERVIC ING under SERVICE PRECAUTIONS in Section 10B DISABLING AIR BAG SYSTEM For disabling air bag system refer to DISABLING AIR BAG SYS TEM under SERVICE PRECAUTIONS in Section 10B ENABLING AIR...

Page 188: ...ystem Refer to DISABLING AIR BAG SYS TEM under SERVICE PRECAUTIONS in Section 10B 3 Loosen 2 bolts mounting driver air bag inflator module till it turns freely pull them out and fix them to bolt clamps 4 Remove air bag inflator module from steering wheel 5 Remove driver air bag inflator module yellow connector and horn connector from steering wheel 6 Disconnect driver air bag inflator module yello...

Page 189: ...g inflator module being damaged or having been exposed to strong impact dropped INSTALLATION 1 Connect horn connector securely 2 Connect yellow connector of driver air bag inflator module con nector as shown in the figure securely ii Connect connector ii Lock connector with lock lever 3 Install horn connector and driver air bag inflator module con nector 4 Install driver air bag inflator module to...

Page 190: ...g wheel and shaft for a guide during reinstallation 4 Remove steering wheel with special tool Special Tool A 09944 36011 CAUTION Do not hammer the end of the shaft Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column CENTERING CONTACT COIL 1 Check that vehicle s wheels front tires are set at straight ahead position 2 Check...

Page 191: ... in the back of steering wheel and also align ing marks on steering wheel and steering shaft 3 Tighten steering shaft nut to specified torque Tightening Torque a 33 N m 3 3 kg m 23 5 lb ft 4 Install driver air bag inflator module to steering wheel Refer to DRIVER AIR BAG INFLATOR MODULE in this section CONTACT COIL AND COMBINATION SWITCH ASSEMBLY CAUTION Do not turn contact coil on combination swi...

Page 192: ...teering column INSPECTION Check contact coil and combination switch wire harness for any signs of scorching melting or other damage If it is damaged re place INSTALLATION 1 Check to make sure that vehicle s front tires are set at straight ahead position and then ignition switch is at LOCK position 2 Install contact coil and combination switch assembly to steering column NOTE New contact coil and c...

Page 193: ...olumn is removed from the vehicle the column is extremely susceptible to damage Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length leaning on the column assembly could cause it to bend or deform Any of the above damage could impair the column s col lapsible design When loosening steering column mounting bolts make...

Page 194: ...move steering wheel and contact coil and combination switch assembly if necessary Refer to STEERING WHEEL and CONTACT COIL AND COMBINATION SWITCH ASSEMBLY in this section Perform the following procedure if not removing steering wheel and or combination switch ii Turn steering wheel so that vehicle s front tires are at straight ahead position ii Turn ignition switch to LOCK position and remove key ...

Page 195: ...hicles involved in accidents resulting in body damage where steering column has been impacted or air bag deployed may have a damaged or misaligned steering col umn CHECKING PROCEDURE 1 Check that two capsules are attached to steering column brack et securely Check clearance between capsules and steering column bracket Clearance should be 0 mm 0 in on both sides If found loose or clearance replace ...

Page 196: ...column assembly 7 Check steering shaft and column for bend cracks or deforma tion If found defective replace as column assembly INSTALLATION CAUTION After tightening steering column mounting bolts steering shaft joint bolts should be tightened 1 Be sure that front wheels and steering wheel are in straight ahead position 2 If equipped with shift key interlock cable install shift key inter lock cabl...

Page 197: ...and then shaft joint bolt lower shaft assembly side to specified torque Tightening Torque c 25 N m 2 5 kg m 18 0 lb ft 6 If contact coil and combination switch assembly is removed install it referring to CONTACT COIL AND COMBINATION SWITCH ASSEMBLY in this section 7 Connect all connectors that have been removed in removal 8 Install steering column hole cover 9 If steering wheel is removed install ...

Page 198: ... key to ACC or ON position and remove steering lock assembly from steering column INSTALLATION 1 Position 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 pull it out 4 Align hub on lock with oblong hole of steering shaft and rotate shaft to assure tha...

Page 199: ...ombina tion switch have got out of its centered position it needs to be centered again Also turning steering wheel more than about two and a half turns will break contact coil REMOVAL 1 Turn steering wheel so that vehicle s front tires are at straight ahead position 2 Turn ignition switch to LOCK position and remove key 3 After removing bolt on column side of shaft joint and loosening bolt on its ...

Page 200: ...n Then insert shaft joint into lower shaft as sembly 3 Install shaft joint bolt lower shaft assembly side to shaft joint Then tighten it by hand 4 Insert pinion shaft into lower shaft assembly lower joint with slit of lower joint marks on pinion shaft and gear case aligned And then install lower shaft assembly lower joint bolt to lower shaft assembly lower joint Tighten it to specified torque Tigh...

Page 201: ...ance replace steering column assembly 2 Check two plates for any damages such as crack or breakage If anything is found faulty replace as steering column assembly 3 Take measurement a as shown If it is shorter than specified length replace column assembly with new one Length a 895 0 8 mm 35 24 0 03 in 4 Check steering column lower seal for breakage or deformation If found defective replace 5 Check...

Page 202: ...ing column is not locked Steering column is fixed securely when adjustable steering col umn release lever is at upper position i e steering column is locked TIGHTENING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fastening arts N m kg m lb ft Driver air bag inflator module bolt 9 0 9 6 5 Steering shaft nut 33 3 3 23 5 Steering column mounting bolt 23 2 3 17 0 Steering shaft joint bolt 2...

Page 203: ...rol Arm Bushings 3D 21 TIGHTENING TORQUE SPECIFICATIONS 3D 23 REQUIRED SERVICE MATERIALS 3D 24 SPECIAL TOOLS 3D 25 SECTION 3D FRONT SUSPENSION CAUTION All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalen...

Page 204: ...chored to the body by a strut support The strut and strut support are isolated by a rubber mount The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached to the stud of a ball joint which is incorporated in a unit with a suspension control arm And this steering knuckle is connected to the tie rod end Thus movement of the steering wheel is ...

Page 205: ... and note strut resistance both when pushed and rebounding Also note how many times vehicle body rebounds before com ing to stop after hands are off Do the same for strut on the other side Compare strut resistance and number of rebound on the right with those on the left And they must be equal in both With proper strut body should come to stop the moment hands are off or after only one or two smal...

Page 206: ...disc for dents distortion and cracks Disc in badly damaged condition must be replaced 2 Check wheel nuts for tightness and retighten them to specifica tion as necessary Tightening Torque a 100 N m 10 0 kg m 72 5 lb ft 3 Check wheel bearing for wear After retightening lock nut to spe cified torque apply dial gauge to wheel hub center and measure thrust play Thrust play limit 0 05 mm 0 002 in When m...

Page 207: ...t installation of stabilizer bar side to side be sure that color paint on stabilizer bar aligns with mount bush both right and left as shown 1 Connect stabilizer ball joints and stabilizer bar 2 Install stabilizer ball joints to control arms NOTE Do not tighten stabilizer ball joint nuts completely 3 Install stabilizer bar mount bush brackets 4 When installing stabilizer loosely assemble all compo...

Page 208: ...trut tower bar if equipped 2 Hoist vehicle allowing front suspension to hang free 3 Remove wheel 4 Remove E ring securing brake hose and take brake hose off strut bracket as shown 5 If equipped with ABS remove front wheel speed sensor harness clamp bolt 6 Remove strut bracket bolts then support lower arm with jack 7 Remove strut support nuts Hold strut by hand so that it will not fall off 8 Remove...

Page 209: ...al steps 1 8 Insert bolts in such a direction as shown 2 Torque all fasteners to specifications Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft b 95 N m 9 5 kg m 69 0 lb ft c 50 N m 5 0 kg m 36 5 lb ft NOTE Brake hose installation Don t twist hose when installing it Install E ring as far as bracket end surface as shown ...

Page 210: ...h a wire hook CAUTION Hang removed caliper with a wire hook so as to prevent brake hose from bending and twisting excessively or be ing pulled Don t operate brake pedal with pads removed 6 If equipped with ABS remove harness clamp bolt and remove front wheel speed sensor from knuckle CAUTION Do not pull wire harness when removing front wheel speed sensor Do not cause damage to surface of front whe...

Page 211: ...BAR BUSHINGS REMOVAL in this section 9 Disconnect tie rod end from knuckle by using puller 10 Support lower arm using jack as shown 11 Remove strut bracket bolts 12 Remove ball stud castle nut 13 Using puller disconnect knuckle from ball stud 14 Remove knuckle and wheel hub comp while lowering jack 15 Remove coil spring ...

Page 212: ...t be sure to insert split pin and bend it after tight ening it Tighten tie rod end nut with pushing ball stud to upper side so as not ball stud to be rotated For 4WD vehicle Apply lithium grease to front drive shaft washer and front wheel spindle outer A Grease 99000 25010 For 4WD vehicle When installing circlip to drive shaft utilize screw hole in drive shaft to pull it out and bring large diamet...

Page 213: ... front wheel speed sensor Fit harness grommet to inner fender securely Check that there is no clearance between sensor and knuckle BUMP STOPPER SPRING RUBBER SEAT REMOVAL 1 Remove coil spring Refer to steps 1 to 15 of item COIL SPRING REMOVAL in this section 2 Remove spring rubber seat 3 Remove bump stopper using special tool Special Tool A 09941 66010 INSTALLATION 1 Tighten bump stopper to specif...

Page 214: ...e caliper bolt and suspend caliper CAUTION Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal with pads removed 5 Remove brake disc NOTE If brake disc can not be removed by hand use 8 mm bolts as shown 6 Remove front wheel bearing lock washer by loosening 4 screws 7 Remove front wheel bearing...

Page 215: ...ION If wheel bearing inner race remains on wheel spindle when removing wheel hub which means break of wheel bearing replace wheel hub component included wheel bearing 10 Remove sensor rotor from wheel hub as shown if equipped with ABS CAUTION Pull out sensor rotor from wheel hub gradually and evenly Do not reuse sensor rotor once removed Be sure to new sensor rotor when installing 11 Remove hub bo...

Page 216: ...as shown CAUTION Don t tap wheel hub component by hammer or the like Otherwise it will be broken NOTE When it is impossible to install wheel hub component by hand which means the inner race is out of alignment re move wheel hub component once and reinstall it 4 Install wheel bearing washer and the install wheel bearing lock nut 5 Tighten wheel bearing lock nut to specified torque while turning whe...

Page 217: ...e diameter of circlip at right as shown 9 For vehicle with ABS check that no foreign material is attached to sensor and rotor Install wheel speed sensor and its harness clamp Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft CAUTION Do not pull wire harness or twist more than necessary when installing front wheel speed sensor Fit harness grommet to inner fender securely Ch...

Page 218: ...ighten flange bolt to speci fied torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft A Sealant 99000 31090 For 2WD vehicle Remove grease old sealant and dusts from mating surfaces of hub cap and hub to clean apply water tight sealant A to cap mating surface evenly and install cap to hub A Sealant 99000 31090 12 Install wheel Tightening Torque a 100 N m 10 0 kg m 72 5 lb ft 13 For vehicle equippe...

Page 219: ...2 Remove front drive shaft circlip and front spindle thrust washer for 4WD vehicle or front hub cap for 2WD vehicle 3 Disconnect tie rod end from knuckle 4 Remove stabilizer bar Refer to STABILIZER BAR BUSH INGS in this section 5 Remove ball stud nut 6 Support lower arm with jack 7 Remove strut bracket bolts from strut bracket 8 By using puller disconnect knuckle from ball stud 9 While lowering ja...

Page 220: ...l knuckle wheel spindle oil seal and drive shaft bearing noting following points For 4WD vehicle Install drive shaft bearing by using special tool Special Tool A 09913 76010 Type A drive shaft thrust washer A 09913 80112 Type B drive shaft thrust washer Dimension a 0 1 mm 0 0 04 in Dimension a Type A drive shaft thrust washer Dimension a 1 75 2 50 mm 0 069 0 098 in Dimension a Type B drive shaft t...

Page 221: ...to its hollow to fill more than 60 of its vacant space Apply lithium grease A to drive shaft A Grease 99000 25010 Press fit front drive shaft thrust washer to drive shaft if it is re moved for Type B drive shaft thrust washer Apply lithium grease A to drive shaft thrust washer A Grease 99000 25010 Apply lithium grease A and install front drive shaft thrust wash er with its chamfered side facing to...

Page 222: ...hub A Sealant 99000 31090 For 4WD vehicle When installing axle shaft drive flange to wheel hub apply sealant to mating surface of axle shaft drive flange A Sealant 99000 31090 Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft For installation procedures of wheel hub component refer to WHEEL HUB INCLUDED WHEEL BEARING in this section Connect tie rod end to knuckle and tighten new tie rod end nut Tight...

Page 223: ...236 in 4 Place control arm and special tool on hydraulic press Set con trol arm cutting flange to welded part 1 of the special tool and control arm joint side to the stepped part 2 of special tool CAUTION Use special care in driving out control arm bush to press it vertically Or it may cause personally injury Special tool A 09951 46020 5 Remove front bushing by using hydraulic press and special to...

Page 224: ...ear bushing until its flange contacts housing edge of control arm use special tools as shown Special Tool E 09925 58210 F 09913 85210 NOTE When press fitting bushing compounding oil or soap water applied to inside of control arm housing will facilitate work 3 Install control arm to chassis Tighten suspension arm nut to specified torque after lowering hoist and vehicle in non loaded condition Tight...

Page 225: ...YH4 GRAND VITARA FRONT SUSPENSION 3D 23 TIGHTENING TORQUE SPECIFICATIONS ...

Page 226: ...haft oil seal Recess of wheel spindles Spindle outer washer Spindle part of drive shaft Spindle bush inside and flange part Spindle inner washer a b c d e f Sealant SUZUKI BOND NO 1215 99000 31110 Mating surfaces of wheel spindle and knuckle 1 Sealing compound SUZUKI SEALING COM POUND 366E 99000 31090 Front axle cap Mating surfaces of wheel hub and drive flange Knuckle cap Hub cap A B C D ...

Page 227: ... 09943 35512 Brake drum remover 09944 68210 Bearing oil seal installer 09944 66010 Wheel hub knuckle oil seal installer 09951 16050 Wheel bearing tightening tool 09951 46020 Control arm remover support 09951 16060 Control arm bush remover front 09913 80112 Bearing installer 09925 58210 Oil seal installer 09913 85210 Oil seal installer 09952 86510 Front sensor rotor installer SPECIAL TOOLS ...

Page 228: ...GHTENING TORQUE SPECIFICATIONS 3E 23 REQUIRED SERVICE MATERIALS 3E 23 SPECIAL TOOLS 3E 24 SECTION 3E REAR SUSPENSION NOTE All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes neces...

Page 229: ... and then apply sealant SUZUKI BOND No 1215 99000 31110 to the portion 8 3E 2 REAR SUSPENSION GENERAL DESCRIPTION Rear suspension is 5 link type of rigid axle which consists of coil springs rear axle shock absorbers upper rods lower rods and lateral rod The lower rod and upper rod are connected with the axle and body by using bushes so that axle moves up and down with bushes as their supporting po...

Page 230: ...the fire 3 Don t store it where it gets hot 4 Before disposing it be sure to drill a hole in it where shown by an arrow in the figure and let gas and oil out Lay it down sideways for this work 5 The gas itself is harmless but it may issue out of the hole together with chips generated by the drill Therefore be sure to wear goggle LOWER ROD UPPER ROD LATERAL ROD CHECK Inspect for cracks deformation ...

Page 231: ...il seal during disassembly check its lip for wear If oil leakage or worn lip is found replace defective oil seal WHEEL DISC NUT BEARING CHECK Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced Check wheel hub nuts for tightness and retighten to specification as necessary Tightening Torque a 100 N m 10 0 kg m 72 5 lb ft Check wheel bearings fo...

Page 232: ...lacement when it has lost its resistance is damaged or leaking fluid REMOVAL 1 Hoist vehicle and remove rear wheel 2 Support rear axle housing by using floor jack to prevent it from lowering 3 Remove lock nut if equipped and absorber nut 4 Remove lower mounting bolt 5 Remove shock absorber INSTALLATION 1 Install shock absorber Refer to figure for proper installing direc tion of lower mounting bolt...

Page 233: ... housing by using floor jack 3 Disconnect parking brake cable hanger from chassis frame and clamp from cross member 4 Remove shock absorber lower mounting bolt 5 Remove wheel speed sensor clamps from upper rod and axle housing if equipped with ABS For right side remove E ring for fixing brake pipe from cross member and disconnect breather hose from axle housing 6 Lower rear axle housing gradually ...

Page 234: ...shock absorber lower bolt For its proper installing direc tion refer to figure Nut should not be tightened 3 Install wheel speed sensor clamp if equipped and E ring and connect breather hose to axle housing 4 Connect cable hanger to chassis frame and clamp to cross member Remove floor jack from axle housing 5 Install wheel and tighten wheel nuts to specified torque Tightening Torque a 100 N m 10 0...

Page 235: ...emove lower rod front mount bolt 4 Remove lower rod rear mount bolt INSTALLATION 1 Install lower rod to chassis frame and axle housing referring to figure for proper installing direction of bolts Nuts should not be tightened 2 Remove floor jack from rear axle housing 3 Install wheel and tighten wheel nuts to specified torque Tightening Torque for wheel nuts 100 N m 10 0 kg m 72 5 lb ft 4 Lower hoi...

Page 236: ...rness clamp from left upper rod 3 Remove upper rod INSTALLATION 1 Install upper rod to chassis frame and axle housing referring to figure for installing direction of bolts Nuts should not be tightened 2 See figure for distinction of installing direction of left side upper rod for vehicle equipped with ABS 3 Connect wheel speed sensor harness clamp to upper rod if equipped with ABS 4 Lower hoist an...

Page 237: ...al rod to rear axle and vehicle body 2 Lower hoist 3 Tighten lateral rod mounting bolts to specified torque Tightening Torque a 90 N m 9 0 kg m 65 0 lb ft REAR AXLE SHAFT AND WHEEL BEARING REMOVAL 1 Remove rear brake drum For details refer to REAR BRAKE DRUM REMOVAL in SECTION 5C 2 Drain gear oil from rear axle housing by loosening drain plug 3 Remove rear wheel bearing retainer nuts from axle hou...

Page 238: ...rear wheel bearing retainer and parking brake shoe lever If no clearance is found loosen cable locking nut further to obtain clearance 6 Using special tools B C indicated below draw out axle shaft NOTE Use care not to pull brake back plate along with shaft CAUTION Pull out axle shaft using care so that upper and lower brake struts and parking cable are not caught Special Tool C 09943 35512 B 09942...

Page 239: ...moved if equipped with ABS 10 In order to remove the retainer ring from the shaft grind with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin CAUTION Be careful not to grind too far not to damage the shaft 11 Break with a chisel the thin ground retainer ring and it can be removed 12 Remove bearing from shaft by using hydraulic press 13 Remove bearing retainer 14...

Page 240: ...ing the following 1 Apply grease to oil seal lip as shown and install it to axle shaft NOTE Amount of grease applied to hollow in oil seal should be more than 60 of its vacant space A Grease 99000 25010 2 Aligning serrations between new stud bolt s and flange install new stud bolt s by tightening nut as shown 3 Install bearing retainer to shaft 4 Press fit wheel bearing and retainer ring as shown ...

Page 241: ...alant before applying it anew B Sealant 99000 31110 8 Install rear axle shaft to rear axle housing and tighten bearing retainer nuts to specified torque NOTE When installing rear axle shaft be careful not to cause damage to oil seal lip in axle housing Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 9 Tighten wheel speed sensor bolt to specified torque if equipped with ABS Tightening Torque b 21 N ...

Page 242: ...the hole for bear ing retainer mounting 3 Remove rear axle shaft inner oil seal NOTE Take care not to bend the brake pipe INSTALLATION 1 Using special tool drive in oil seal until it contacts oil seal protec tor in axle housing NOTE Make sure that oil seal is free from inclination as it is installed Refer to figure so that oil seal is installed in proper direc tion Special Tool A 09913 75510 A Gre...

Page 243: ...t left wheel and its related parts are used in illustrations in this section 2 Remove rear brake drum Refer to steps 1 to 5 of BRAKE DRUM REMOVAL 3 Disconnect brake pipe from wheel cylinder With right side wheel cylinder disconnect 2 brake pipes 4 For vehicle with ABS disconnect wheel speed sensor coupler and remove wheel speed sensor with its harness 5 Remove rear wheel bearing retainer nuts from...

Page 244: ...ousing before drawing out axle shaft NOTE Use care not to pull brake back plate along with shaft Special Tool C 09943 35512 B 09942 15510 8 For vehicle without ABS remove LSPV stay from axle housing 9 Remove brake back plate from rear axle housing 10 Disconnect brake pipe from flexible hose and remove E ring front side 11 Remove brake pipe clamps and pipes from axle housing and disconnect breather...

Page 245: ...er axle housing 14 Remove differential carrier assembly 15 Loosen rear mount nut of upper rod but don t remove bolt 16 Loosen rear mount nut of lower rod but don t remove bolt 17 Remove rear axle side lateral rod mount bolt 18 Remove shock absorber lower mount bolt 19 Lower floor jack until tension of suspension coil spring be comes a little loose and remove rear mount bolt of upper lower and late...

Page 246: ...2 Install coil spring right left on spring seat of axle housing and raise axle housing NOTE When seating coil spring mate spring end with stepped part of rear axle spring seat as shown 3 Install lateral rod to rear axle housing 4 Install lower part of shock absorber to right and left sides of axle housing and install bolts in proper direction as shown in figure At this time mount nuts but don t ti...

Page 247: ...TION 5A of this manual 11 Connect brake flexible hose to bracket on axle housing and se cure it with E ring 12 Install LSPV stay to axle housing tighten LSPV stay bolt to specified torque And adjust LSPV referring to LSPV ASSEMBLY INSPEC TION AND ADJUSTMENT in SECTION 5A Tightening Torque c 23 N m 2 3 kg m 17 0 lb ft 13 Connect brake pipe to brake flexible hose and tighten brake pipe flare nut to ...

Page 248: ...ip in axle housing Tightening Torque e 23 N m 2 3 kg m 17 0 lb ft 18 For vehicle with ABS tighten wheel speed sensor bolt to speci fied torque Tightening Torque f 21 N m 2 1 kg m 15 5 lb ft 19 Connect brake pipes to wheel cylinders right left and tighten brake pipe flare nuts to specified torque Tightening Torque g 16 N m 1 6 kg m 11 5 lb ft 20 Install brake drum right left For details refer to SE...

Page 249: ...N 5C of this manual 25 Tighten parking brake lever cover screws 26 Lower hoist 27 Tighten right and left lower upper rod nuts lateral rod mount bolt and shock absorber nuts to specified torque NOTE When tightening these nuts be sure that vehicle is off hoist and in non loaded condition Tightening Torque i 90 N m 9 0 kg m 65 0 lb ft j 85 N m 8 5 kg m 61 5 lb ft 28 Check to ensure that brake drum is...

Page 250: ...3 2 3 17 0 Differentiation gear oil Filler plug 50 5 0 36 5 g filler drain plug Drain plug 27 2 7 16 0 Wheel nut 100 10 0 72 5 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lip Brake fluid DOT 3 Brake reservoir tank Sealant SUZUKI BOND NO 1215 99000 31110 Joint seam of axle and brake back plate Joint seam of bearing re...

Page 251: ...H4 GRAND VITARA 3E 24 REAR SUSPENSION 09924 74510 Bush remover handle 09926 88310 Oil seal installer 09942 15510 Sliding hammer 09943 35512 Brake drum remover 09913 75510 Oil seal installer SPECIAL TOOLS ...

Page 252: ...60 R16 The tires are of tubeless type The tires are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressure Correct tire pressures and driving habits have an important influence on tire life Heavy cornering excessively rapid acceleration and unnecessary sharp braking increase tire wear WHEELS Standard equipment wheels are...

Page 253: ...lly equipped wheels in load capacity diameter rim width off set and mounting configuration A wheel of improper size or type may affect wheel and bearing life brake cooling speedometer odometer cal ibration ground clearance to the body and chassis To measure the wheel runout it is necessary to use accurate dial indicator The tire may be on or off the wheel The wheel should be installed to the wheel...

Page 254: ...ire spins there is no tendency for the assembly to move from side to side Wheels that are dynamically unbalanced may cause shimmy GENERAL BALANCE PROCEDURE Deposits of mud etc must be cleaned from inside of rim WARNING Stones should be removed from tread in order to avoid operator injury during spin balancing and to obtain good balance Tire should be inspected for any damage then balanced accordin...

Page 255: ... radius or low spot of the wheel This is done to provide the smoothest possible ride The high spot of the tire is originally marked by paint dot on the outboard sidewall This paint dot will eventually wash off the tire The low spot of the wheel is originally marked by paint dot on the wheel rim flange Properly assembled the wheel rims paint dot should be aligned with the tires paint dot as shown i...

Page 256: ...re placard is located on the driver s side door lock pillar and 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 figure ...

Page 257: ...ION Wheel nuts must be tightened 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 disc mounting sur face by scraping and wire brushing Installing wheels without good metal to metal contact at mounting surfaces can cause wheel nuts to loosen which can ...

Page 258: ...etely seated Then adjust pressure to specified shown an tire placard WARNING Do not stand over tire when inflating Bead may break when bead snaps over rim s safety hump and cause serious per sonal injury Do not exceed 240 kPa 35 psi pressure when inflating If 240 kPa 35 psi pressure will not seat beads deflate re lu bricate and reinflate Over inflation may cause bead to break and cause serious per...

Page 259: ...YH4 GRAND VITARA 3F 8 WHEELS AND TIRES TIGHTENING TORQUE SPECIFICATIONS Tightening Torque for wheel nut a 100 N m 10 0 kg m 72 5 lb ft ...

Page 260: ...ICLE SERVICE 4A2 3 Drive Shaft 4A2 3 Shaft Bearing Oil Seal 4A2 9 TIGHTENING TORQUE SPECIFICATIONS 4A2 11 REQUIRED SERVICE MATERIALS 4A2 11 SPECIAL TOOLS 4A2 11 GENERAL DESCRIPTION The drive shaft joint is a constant velocity joint C V joint which slides in the axial direction The joint is composed of an outer race cage inner race and balls In the turning direction the joint rotates in the same wa...

Page 261: ...nt boot and apply grease Replace drive shaft joint When running Abnormal Noise Broken drive shaft joint Poorly lubricated or worn drive shaft joint Loose drive shaft flange bolts Deformed drive shaft oil seal Replace drive shaft joint Lubricate or replace joint Tighten drive shaft flange bolts Replace Vibration Worn drive shaft joint Deformed drive shaft oil seal Deformed drive shaft Replace drive...

Page 262: ...clip and front spindle thrust washer 4 Remove drive shaft flange bolts and nuts 5 Remove drive shaft assembly to differential side as shown in left figure CAUTION To prevent breakage of boots wheel side and differential side be careful not to bring them into contact with other parts when removing drive shaft assembly 6 Remove drive shaft thrust washer vehicle with G16 or J20 en gine from drive sha...

Page 263: ...r to steps 5 to 7 and 9 to 14 of item COIL SPRING REMOVAL in Section 3D 6 Remove drive shaft assembly To detach snap ring fitted on the spline of differential side joint inboard joint from differential side gear pull inboard joint by us ing a tire lever CAUTION To prevent breakage of boots wheel side and differential side be careful not to bring them into contact with other parts when removing dri...

Page 264: ...nt If any malcondition is found in joint replace it as assem bly Do not disassemble ball joint of differential side joint If any malcondition is found in ball joint replace differ ential side joint assembly INSPECTION Check boots for breakage or deterioration Replace them as nec essary Check circlip snap ring and boot bands for breakage or deforma tion Replace as necessary CLEANING Wash disassembl...

Page 265: ...t forward rotation Do not squeeze or distort boot when fastening it with bands Distorted boot caused by squeezing air may reduce its du rability 1 Fully apply joint grease to wheel side joint Use joint grease in the tube included in spare part 2 Fit wheel side boot on shaft Fill up inside of boot with joint grease of about 90 gram Before fixing boot band insert screwdriver into boot on joint side ...

Page 266: ... of outer race and fit boot to outer race Fill up inside of boot with joint grease A Joint Grease 99000 25120 about 90 95g 3 2 3 4 oz 10 Fitting boot to outer race adjust so that measurements b and c become as indicated in figure Length b 203 2 213 2 mm 8 00 8 40 in 196 8 206 8 mm 7 75 8 14 in M T vehicle with H25 engine c 125 5 135 5 mm 4 94 5 33 in 127 5 137 5 mm 5 02 5 41 in M T vehicle with H2...

Page 267: ...e Diameter b 80 mm 3 150 in or less Drive in drive shaft thrust washer Vehicle with G16 or J20 en gine RH Side Push differential side joint by hand until it is positioned by snap ring fitted to its spline LH Side Connect drive shaft flange bolts and nuts Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft Apply grease to front spindle thrust washer and front spindle part of drive shaft A Grease 99000 2...

Page 268: ... to item DRIVE SHAFT REMOVAL LEFT and RIGHT in this section For right side shaft bearing oil seal removal drain differential gear oil 2 Remove left drive shaft by using tire lever 3 Remove left side strut Refer to steps 1 and 4 to 8 of item STRUT DAMPER REMOVAL in Section 3D 4 Remove oil seal using plain screw driver 5 Remove circlip 6 Remove bearing using special tools A and B Special Tool A 0994...

Page 269: ...stall circlip 4 Drive in oil seal with special tools B and C Special Tool B 09951 16090 C 09924 74510 NOTE As depth to which oil seal should be driven into axle hous ing is different between the left and right be sure to check stamped marks on special tool B and drive each oil seal to corresponding mark 5 Install left drive shaft 6 Install left side strut Refer to steps 1 to 2 of item STRUT DUMPER...

Page 270: ...6 5 Oil level plug 23 2 3 17 0 Drain plug 23 2 3 17 0 Axle shaft drive flange bolt 48 4 8 35 0 NOTE Refer to standard tightening torque specifications if no description or specification is provided REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Joint grease Molybdenum grease SUZUKI SUPER GREASE H 99000 25120 Drive axle joint Lithium grease SUZUKI SUPER GREASE A 99000 25010 Driv...

Page 271: ...specified during reas sembly to assure proper retention of this part Never attempt to heat quench or straighten any propeller shaft part Replace it with a new part or dam age to the part may result CONTENTS GENERAL DESCRIPTION 4B 1 DIAGNOSIS 4B 2 Diagnosis Table 4B 2 Propeller Shaft Joint Check 4B 2 ON VEHICLE SERVICE 4B 3 Propeller Shaft 4B 3 TIGHTENING TORQUE SPECIFICATION 4B 6 REQUIRED SERVICE ...

Page 272: ...CHECK If universal joints are suspected of producing chattering or rattling noise inspect them for wear Check to see if cross spider rattles in yokes or if splines are worn down and replace defective propeller shaft with new one Noise coming from universal joint can be easily distinguished from other noises because rhythm of chattering or rattling is in step with cruising speed Noise is pronounced...

Page 273: ... Remove propeller shaft DISASSEMBLY 1 Using special tool A remove 2 circlips Special Tool A 09900 06108 2 Using special tool B push spider bearing race out 3 4 mm 0 12 0 16 in from shaft yoke race NOTE Before pushing it out apply penetrate lubricant between bearing race and yoke race Special Tool B 09926 48010 Length a 3 4 mm 0 12 0 16 in 3 Tapping yoke with a hammer completely remove bearing race...

Page 274: ...emoved bearings temporarily in spider so that they can be reinstalled in their original positions INSPECTION Inspect propeller shaft and flange yoke for damage and propeller shaft for runout If damage is found or shaft runout exceeds its limit replace Runout limit 0 8 mm 0 031 in ASSEMBLY NOTE Make sure that rollers inside spider bearing race are all in place Make sure to apply grease to spider be...

Page 275: ...bove 4 Place a metal plate on bearing races when tapping them in to avoid damaging yoke 5 Securely fit 4 circlips to shaft and flange yoke NOTE After assembly check to ensure that both shaft yoke and flange yoke move smoothly Make sure that each circlip is fitted in groove securely INSTALLATION Reverse removal procedure to install propeller shaft Use following specification to torque universal joi...

Page 276: ...disassembling tool set TIGHTENING TORQUE SPECIFICATION Fastener Tightening torque Fastener N m kg m lb ft Propeller shaft nut Center support bolt 50 5 0 36 5 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUPER GREASE C 99000 25030 To apply to spider bearing race SPECIAL TOOLS ...

Page 277: ...rve all WARNINGS and Service Precau tions under On Vehicle Service 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 could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least ...

Page 278: ...connected to the master cylinder and they make two independent circuits One connects front brakes right and left and the other connects rear brakes right and left The load sensing proportioning valve LSPV is included in these circuits between the master cylinder and the rear brake for the vehicle without ABS In this brake system the disc brake type is used for the front wheel brake and a drum brak...

Page 279: ...id DIAGNOSIS ROAD TESTING BRAKES Brakes should be tested on dry clean smooth and reasonably level roadway which is not crowned Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to de termine if the vehicle stops evenly and effectively Also drive vehicle to see if it leads to one side or the other without brake application If it does check the ti...

Page 280: ...of adjustment in some brakes Malfunctioning auto adjusting mechanism Drum is out of round in some brakes Wheel tires are inflated unequally Malfunctioning wheel cylinders Disturbed front end alignment Unmatched tires on same axle Restricted brake pipes or hoses Malfunctioning caliper assembly Loose suspension parts Loose calipers Replace Check for inoperative auto adjusting mechanism Replace Infla...

Page 281: ...ge Wheel cylinder or caliper piston sticking Malfunctioning ABS if equipped with ABS Replace master cylinder Check for soft hoses or damaged pipes and replace with new hoses and or new brake pipes Check and adjust to correct specifi cations Replace Repair or replace Repair as necessary Check system and replace as necessary Pedal pulsation Pedal pulsates when depressed for braking Damaged or loose ...

Page 282: ...s on when brake is applied Brake fluid leaking from brake line Insufficient amount of brake fluid Investigate leaky point correct it and add brake fluid Add brake fluid Brake warning light fails to turn on even when parking brake is applied Bulb burnt out Brake warning light circuit open Replace bulb Repair circuit ABS warning light does not turn on for 2 sec after ignition switch has turned ON Bu...

Page 283: ...o bleed air of brake system according to following proce dure when its oil hydraulic circuit has been disconnected Hydraulic lines of brake system consists of two separate lines one for front wheel brakes and the other for rear wheel brakes Air bleeding is necessary at right and left front wheel brakes left rear wheel brake and LSPV if equipped without ABS i e 4 places 3 places for vehicle with AB...

Page 284: ...old brake pedal and tighten bleeder plug For tightening torque specification of air bleeder plug re fer to TIGHTENING TORQUE SPECIFICATION in this section 7 Then attach bleeder plug cap 8 After completing bleeding operation apply fluid pressure to pipe line and check for leakage 9 Replenish fluid into reservoir up to specified level 10 Check brake pedal for sponginess If found spongy repeat entire...

Page 285: ...le holding it there adjust switch position so that clearance between end of thread and brake pedal return cushion shown as b in figure Then tighten lock nut to specified torque Clearance b 1 5 2 0 mm 0 06 0 08 in Tightening Torque b 7 5 N m 0 75 kg m 5 5 lb ft EXCESSIVE PEDAL TRAVEL CHECK 1 Remove foot rest and displace carpet and dash silencer s 2 Start engine 3 Depress brake pedal a few times 4 ...

Page 286: ...to specified level CAUTION Do not use shock absorber fluid or any other fluid which contains mineral oil Do not use a container which has been used for mineral oil or a container which is wet from water Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and water mixed into brake fluid will lower fluid boiling point Keep all fluid containers capped to prevent ...

Page 287: ...Limit 2 0 mm 0 08 in If one of brake pad is worn to service limit all linings must be re placed at the same time BRAKE SHOE CHECK Inspection should be carried out on following points after brake ped al travel c pedal to asphalt sheet clearance check as described on previous page of this section even when it is more than 115 mm 4 53 in Amount of brake shoe wear can be checked as follows 1 Hoist veh...

Page 288: ...stroke NOTE Check tooth tip of each notch for damage or wear If any dam age or wear is found replace parking brake lever ADJUSTMENT NOTE Make sure for following conditions before cable adjustment No air is trapped in brake system Brake pedal travel is proper Brake pedal has been depressed a few times with about 30 kg 66 lbs load Parking brake lever has been pulled up a few times with about 20 kg 4...

Page 289: ...le weight L 800 kg 1764 lb 2 Install special tool to front and rear brake NOTE Special tool should be connected to breather of front driv er s side brake and rear brakes Special Tool Front brake A 09956 02310 B 09952 46510 Attachment for vehicle with SUMITOMO ELECTRIC brake caliper C 55473 82030 Air bleeder plug supplied as a spare part Rear brake A 09956 02310 B 09952 36310 Attachment for thread ...

Page 290: ...138 psi 100 kg cm2 1 422 psi 5 Door 5 000 8 000 kPa 50 80 kg cm2 711 1 138 psi 4 If rear brake pressure is not within specification adjust it by changing stay A position as follows Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft If rear brake pressure is higher than specification move stay A to direction a and if it is lower to direction b Repeat steps 3 and 4 until rear brake pressure is within sp...

Page 291: ...ydraulic line INSPECTION WITHOUT TESTER Check Air Tightness 1 Start engine 2 Stop engine after running for 1 to 2 minutes 3 Depress brake pedal several times with the same load as in ordi nary braking and observe pedal travel If pedal goes down deep the first time but its travel decreases as it is depressed the se cond and more times air tightness is obtained 4 If pedal travel doesn t change air t...

Page 292: ...le depressing brake pedal If pedal travel in creases a little operation is satisfactory But no change in pedal travel indicates malfunction Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed 2 Hold brake pedal depressed for 30 seconds If pedal height does not change condition is good But it isn t if pedal rises ...

Page 293: ... 6 5 Brake bleeder lug Wheel cylinder 7 5 0 75 5 5 LSPV 7 5 0 75 5 5 LSPV mounting bolt LSPV stay bolt 23 2 3 17 0 LSPV spring nut Wheel nut 100 10 0 72 5 Stop light switch lock nut 7 5 0 75 5 5 REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED SUZUKI PRODUCT USE Brake fluid Indicated on reservoir cap or described in owner s manual of vehicle To fill master cylinder reservoir To clean and apply to i...

Page 294: ...VITARA 5 18 BRAKES 09950 78220 Flare nut wrench 10 mm 09900 20205 Micrometer 0 25 mm 09956 02310 Fluid pressure gauge 09956 02210 Brake circuit plug 09952 36310 09952 46510 Pressure gauge attachment SPECIAL TOOLS ...

Page 295: ...K position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equiva...

Page 296: ...condary chamber b acts on the rear for vehicle without ABS front wheel brakes NOTE Replace all components included in repair kits to service this master cylinder Lubricate rubber parts with clean fresh brake fluid to ease assembly Do not use lubricated shop air on brake parts as damage to rub ber components may result If any hydraulic component is removed or brake line disconnected bleed the brake...

Page 297: ... control over the hydraulic pressure applied to the rear wheel brake should any failure occur in the hydraulic circuit of the front wheel brake so that the hydraulic pressure produced in the mas ter cylinder is applied to the rear wheel brake directly to operate it CONSTITUTION The LSPV components are grouped into three sections as follows A Sensor section The main parts in this section are a leve...

Page 298: ...material from both hose end or pipe end fittings Remove brake hose or pipe INSTALLATION 1 Reverse removal procedure for brake hose and pipe installation procedure For installation make sure that steering wheel is in straightforward position and hose has no twist or kink Check to make sure that hose doesn t contact any part of suspension both in extreme right and extreme left turn condi tions If it...

Page 299: ...hose 3 Hose washer 4 Hose bolt 5 Brake caliper 6 2 way joint NOTE Insert E ring till its end surface is flush with or lower than bracket end surface Tightening Torque a 16 N m 1 6 kg m 11 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft c 10 N m 1 0 kg m 7 5 lb ft b 21 N m 2 1 kg m 15 5 lb ft A View A B View B C View C a Clamp a b Clamp b c Clamp c d Clamp d C t Top side f Front side A B ...

Page 300: ...ce Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft C Vehicle without ABS for right hand steering vehicle D Vehicle without ABS for left hand steering vehicle 1 E ring 2 Flexible hose 3 Hose washer 4 Hose bolt 5 Brake caliper 6 4way joint C D D View D a Clamp a b Clamp b c Clamp c d Clamp d t Top side f Front side ...

Page 301: ...rial from both hose end or pipe end fittings Remove brake hose or pipe INSTALLATION 1 Reverse removal procedure for brake hose or pipe installation procedure Be sure to obtain more than 3 mm 0 118 in clearance between axle housing and brake pipe Install clamps properly referring to figure below and tighten bolts When installing hose make sure that it has no twist or kink 2 Fill and maintain brake ...

Page 302: ... 3 Grommets MASTER CYLINDER RESERVOIR REMOVAL 1 Disconnect reservoir lead wire at coupler 2 Clean outside of reservoir 3 Take out fluid with syringe or such 4 Remove reservoir connector pin by using special tool Special Tool A 09922 85811 5 Remove reservoir NOTE Do not allow brake fluid to get on painted surfaces ...

Page 303: ...same fluid as the one to fill reservoir with Then press fit grommets to mas ter cylinder Grommets must be seated in place 2 Install reservoir and drive in reservoir pin NOTE Drive in reservoir pin till both of its ends at the right and left or reservoir becomes the same length 3 Connect reservoir lead wire 4 Fill reservoir with specified fluid 5 Upon completion of installation check for fluid leak...

Page 304: ...R MASTER CYLINDER ASSEMBLY REMOVAL NOTE Do not allow brake fluid to get on painted surfaces 1 Disconnect reservoir lead wire at coupler 2 Clean around reservoir cap and take out fluid with syringe or such 3 Remove master cylinder with reservoir from brake booster For vehicle with ABS a Loosen flare nuts for master cylinder and ABS hydraulic unit as shown b For LH steering vehicle disconnect ABS co...

Page 305: ...embly straight so as not to cause any damage to inside of cylinder wall Pull out secondary piston assembly straight so as not to cause any damage to inside of cylinder wall and by tapping flange with a piece of wood or something soft 3 For vehicle without ABS Remove piston stopper bolt Then remove secondary piston by blowing compressed air into hole from which piston stopper bolt was removed Be ca...

Page 306: ...t aluminum body with anything abrasive is prohibited as damage to cylinder bore may occur Rinse cylinder in clean brake fluid Shake excess rinsing fluid from cylinder Do not use a cloth to dry cylinder as lint from cloth cannot be kept from cylinder bore surfaces ASSEMBLY NOTE See NOTE at the beginning of this section Before assembling wash each part in fluid recommended to use for that vehicle 1 ...

Page 307: ...on 1 Install master cylinder to brake booster 2 Tighten master cylinder attaching nuts to specification Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft 3 Connect brake pipes to master cylinder For vehicle with ABS a Connect brake pipes between master cylinder and ABS hy draulic unit b For LH steering vehicle connect ABS control module con nector c For RH steering vehicle install ABS hydraulic unit b...

Page 308: ...OSTER REMOVAL NOTE Do not allow brake fluid to get on painted surfaces 1 For vehicle equipped with ABS disconnect brake pipes from ABS hydraulic unit 2 Remove master cylinder assembly referring to MASTER CYL INDER ASSEMBLY REMOVAL in this section 3 Disconnect brake vacuum hose from brake booster 4 Disconnect push rod clevis from brake pedal arm 5 Remove attaching nuts and then booster as shown CAU...

Page 309: ...disc is in place Keep inside of booster at atmospheric pressure for measure ment 1 Set special tool A on master cylinder and push pin until con tacts piston Special Tool A 09950 96010 2 Turn special tool upside down and place it on booster Adjust booster piston rod length until rod end contacts pin head Special Tool A 09950 96010 Clearance b 0 mm 0 in NOTE Take measurement with booster set vertica...

Page 310: ...ton rod Refer to CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON ADJUSTMENT of this sec tion Apply silicone grease to master cylinder piston 1 Install booster to dash panel as shown Then connect booster push rod clevis to pedal arm with clevis pin and clip 2 Tighten booster attaching nuts to the specified torque Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft 3 Connect brake vacuum h...

Page 311: ...yringe or such 2 Hoist vehicle 3 Disconnect brake pipes from LSPV 4 Remove LSPV assembly with spring from vehicle body 5 Remove spring from lever CAUTION LSPV assembly must not be disassembled Replace with new one if defective Stopper bolt should not be loosened or tightened if equipped INSTALLATION CAUTION Refer to above CAUTION Install by reversing removal procedure noting the following 1 Apply ...

Page 312: ...JUSTMENT Confirm the following before inspection and adjustment Fuel tank is filled with fuel fully Vehicle is equipped with spare tire tools jack and jack handle Vehicle is free from any other load With vehicle in above conditions 1 Place it on level floor 2 Push up for 5 door model or push down for 3 door model LSPV lever with finger till it stops and measure length L of coil spring as it is pul...

Page 313: ...18 2 way or 4 way joint mounting bolt 10 1 0 7 5 Brake pipe flare nut 16 1 6 11 5 Front caliper M8 8 0 0 8 6 0 Brake bleeder plug Front cali er M10 8 5 0 85 6 5 Brake bleeder lug Wheel cylinder 7 5 0 75 5 5 LSPV 8 0 0 8 6 0 LSPV mounting bolt LSPV stay bolt 23 2 3 17 0 LSPV spring nut Wheel nut 100 10 0 72 5 REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED SUZUKI PRODUCT USE Brake fluid Indicated o...

Page 314: ...becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal CONTENTS GENERAL DESCRIPTION 5B 2 DIAGNOSIS 5B 3 CHECK AND ADJUSTMENT 5B 3 ON VEHICLE SERVICE 5B 3 Front Disc Brake Pad 5B 3 ...

Page 315: ...Hydraulic force created by applying force to the brake pedal is converted by the caliper to friction The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move slide the caliper inward resulting in a clamping action on the disc This clamping action forces the pads linings against the disc creating friction to stop the vehicle NOTE ...

Page 316: ...operate brake pedal with pads re moved 4 Remove pads INSPECTION Brake Pad Check pad lining for wear When wear exceeds limit replace with new one CAUTION Never polish pad lining with sandpaper If lining is polished with sandpaper hard particles of sandpaper will be depos ited in lining and may damage disc When pad lining re quires correction replace it with a new one Pad thickness lining rim a Stan...

Page 317: ...in For TOKICO brake caliper Service limit 20 mm 0 787 in For SUMITOMO ELECTRIC brake caliper 15 mm 0 590 in For TOKICO brake caliper Use wheel nuts and suitable plain washers to hold the disc securely against the hub then mount a dial indicator as shown and measure the runout at 25 mm 0 98 in from the outer edge of the disc Limit on disc deflection 0 15 mm 0 006 in NOTE Check front wheel bearing f...

Page 318: ...sensor to body center side of caliper 2 Install caliper and torque caliper pin bolts to specification Tightening Torque a b 27 N m 2 7 kg m 20 0 lb ft For TOKICO brake caliper a 50 N m 5 0 kg m 36 5 lb ft For SUMITOMO b 85 N m 8 5 kg m 61 5 lb ft NOTE Make sure that boots are fit into groove securely 3 Torque front wheel nuts to specification Tightening Torque b 100 N m 10 0 kg m 72 5 lb ft 4 Upon...

Page 319: ...e caliper pin bolts 4 Remove caliper DISASSEMBLY Before disassembly clean all around caliper with brake fluid 1 Remove anti noise shim if equipped and blow compressed air into cylinder through bolt hole where flexible hose was fitted With this air pressure piston can be pushed out of cylinder WARNING Do not apply too highly compressed air which will cause piston to jump out of cylinder It should b...

Page 320: ...l ASSEMBLY Reassemble front brake in reverse order of disassembly noting the following points CAUTION Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir Never use other fluid or thinner Before installing piston and piston seal to cylinder apply fluid to them After reassembling brake lines bleed air from them Piston Seal Piston seal is used to ...

Page 321: ...nder with fingers Check to make sure that boot is fitted into boot groove in cylinder completely in its circumference 3 Insert piston into cylinder by hand and fit boot in boot groove in piston 4 To confirm that boot is fitted in its groove in cylinder properly pull piston out of cylinder a little but do not take it all out 5 Insert piston into cylinder by hand 6 Install anti noise shim if equippe...

Page 322: ...r pin bolts to specifications Tightening Torque a b 27 N m 2 7 kg m 20 0 lb ft For TOKICO brake caliper a 50 N m 5 0 kg m 36 5 lb ft For SUMITOMO b 85 N m 8 5 kg m 61 5 lb ft ELECTRIC brake 85 N m 8 5 kg m 61 5 lb ft caliper NOTE Make sure that boots are fit into groove securely 3 Install brake flexible hose as shown and torque hose mounting bolt to specification Tightening Torque b 23 N m 2 3 kg ...

Page 323: ... Remove disc by using 8 mm bolts 2 pcs INSPECTION Refer to FRONT DISC BRAKE PAD INSPECTION INSTALLATION NOTE See NOTE at the beginning of this section 1 Install disc to wheel hub 2 Install caliper assembly to steering knuckle 3 Torque caliper carrier bolts to specification Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 4 Torque front wheel nuts to specifications Tightening Torque b 100 N m 10 0 kg...

Page 324: ... 7 20 0 Caliper pin bolt M10 For SUMITOMO ELECTRIC brake caliper 50 5 0 36 5 Caliper pin bolt M12 For SUMITOMO ELECTRIC brake caliper 85 8 5 61 5 Flexible hose bolt 23 2 3 17 0 Brake carrier bolt 85 8 5 61 5 Wheel nut 100 10 0 72 5 REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED SUZUKI PRODUCT USE Brake fluid Indicated on reservoir cap or described in owner s manual of vehicle To fill master cylin...

Page 325: ...st 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They mus...

Page 326: ...tem so that drum to shoe clearance is main tained appropriate at all times Rear brake is a drum type It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudinal direction of vehicle NOTE Replace all components included in repair ki...

Page 327: ...NG BRAKE LEVER REMOVAL 1 Disconnect negative cable at battery 2 Block vehicle wheels and release parking brake lever 3 Remove rear center console box 4 Disconnect lead wire of parking brake switch at coupler 5 Remove parking brake cable locking nut 6 Remove parking brake lever bolts and then remove parking brake lever assembly from equalizer 7 Remove equalizer from parking brake cable NOTE Don t d...

Page 328: ...Install in reverse order of REMOVAL procedure Check equalizer inclined angle Angle a within 15 degrees Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 2 After all parts are installed parking brake lever needs to be ad justed Refer to PARKING BRAKE INSPECTION AND AD JUSTMENT in Section 5 3 Check brake drum for dragging and brake system for proper per formance ...

Page 329: ... to steps 1 to 5 of BRAKE DRUM REMOVAL of this section 2 Check the color of ring or tape for reinstallation NOTE Color ring on brake cable is for the purpose of identifica tion 3 Disconnect parking brake cable from brake shoe lever Refer to steps 2 to 5 of BRAKE SHOE REMOVAL of this section 4 Disconnect brake cable from brake back plate Refer to step 4 of BRAKE BACK PLATE REMOVAL NOTE When it is n...

Page 330: ...e end to parking brake shoe lever securely as shown in figure 3 For brake shoe installation refer to steps 1 and 4 of BRAKE SHOE INSTALLATION of this section 4 For brake drum installation refer to steps 1 and 3 of BRAKE DRUM INSTALLATION of this section 5 For proper routing and secure clamping of parking brake cable 6 For installation of cable to parking brake lever refer to PARKING BRAKE LEVER IN...

Page 331: ...sole box screws and with rear part of rear center console box lifted a little loosen parking brake cable locking nut 5 Remove brake drum by using 8 mm bolts 2 pcs INSPECTION Brake Drum Inspect drum for cleanliness Check wear of its braking surface by measuring its inside diameter Inside diameter a Standard 220 mm 8 66 in Service Limit 222 mm 8 74 in Whenever brake drums are removed they should be ...

Page 332: ...rake fluid leakage Correct leaky point if any Brake Shoe Where lining is worn out beyond service limit replace shoe Thickness a Standard 6 5 mm 0 24 in Service limit 3 0 mm 0 12 in If one of brake linings is to service limit all linings must be replaced at the same time CAUTION Never polish lining with sandpaper If lining is polished with sandpaper hard particles of sandpaper will be deposited in ...

Page 333: ...ghten rear center console box screws 5 Install wheel and tighten wheel nuts to specified torque Tightening Torque b 100 N m 10 0 kg m 72 5 lb ft 6 Check to ensure that brake drum is free from dragging and prop er braking is obtained Then remove vehicle from hoist and per form brake test foot brake and parking brake BRAKE SHOE REMOVAL 1 Perform steps 1 to 5 of BRAKE DRUM REMOVAL WARNING Use special...

Page 334: ...N Parking Shoe Lever Inspect brake shoe lever for free movement against brake shoe web If defective correct or replace Strut Adjuster Check thread or ratchet of strut and adjuster for wear sticking and corrosion Springs Inspect for damage or weakening Inspect each part with arrow for rust If found defective replace Brake Shoe Refer to BRAKE DRUM INSPECTION ...

Page 335: ...n spring 2 Lower strut PARKING AND REAR BRAKE 5C 11 INSTALLATION 1 Assemble parts as shown in reverse order of removal 2 Install shoe hold down springs by pushing them down in place and turning hold down pins 3 Install adjuster and upper shoe return spring 4 Install adjuster lever adjuster spring and strut spring 5 For procedure hereafter refer to steps 1 to 6 of BRAKE DRUM INSTALLATION ...

Page 336: ...cylinder and put wheel cylinder bleeder plug cap onto pipe to prevent fluid from spilling INSPECTION Inspect wheel cylinder disassembled parts for wear cracks corro sion or damage NOTE Clean wheel cylinder components with brake fluid INSTALLATION For non sealed type 1 Take off bleeder plug cap from brake pipe and connect pipe or pipes to wheel cylinder just enough to prevent fluid from leak ing 2 ...

Page 337: ... plate Then take off bleeder plug cap from brake pipe and con nect pipe or pipes to wheel cylinder just enough to prevent fluid from leaking NOTE Be sure to check gasket for deterioration or any damage be fore installation and replace if found defective 2 Tighten wheel cylinder to brake back plate to specified torque 3 Torque flare nut or nuts of brake pipe which was connected in step 1 to specifi...

Page 338: ...KE DRUM REMOVAL 2 Perform steps 2 to 4 of BRAKE SHOE REMOVAL 3 Perform steps 3 and 4 of WHEEL CYLINDER REMOVAL 4 Remove cable from brake back plate by squeezing parking brake cable cap 5 Drain rear differential gear oil 6 Remove wheel bearing retainer nuts from rear axle housing 7 Using special tools draw out rear axle shaft with brake back plate Special Tool A 09943 35512 B 09942 15510 8 Remove b...

Page 339: ...A Sealant 99000 31110 NOTE Make sure to remove old sealant before applying it anew 2 Install brake back plate to rear axle shaft 3 Apply sealant to joint seam of rear axle housing and brake back plate A Sealant 99000 31110 NOTE Make sure to remove old sealant before applying it anew 4 Install rear axle shaft to rear axle housing 5 Tighten brake back plate nuts to specified torque Tightening Torque...

Page 340: ...ANCE SERVICE in Section 7E for refill 11 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to BLEEDING BRAKES in Section 5 12 Install wheel and tighten wheel nuts to specified torque Tightening Torque b 100 N m 10 0 kg m 72 5 lb ft 13 Upon completion of all jobs depress brake pedal with about 30 kg 66 lbs load three to ten times so as to obtain proper drum to shoe...

Page 341: ...te nut 23 2 3 17 0 Wheel nut 100 10 0 72 5 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Brake fluid Indicated on reservoir cap or described in owner s manual of vehicle To fill master cylinder reservoir To clean and apply to inner parts of master cylinder caliper and wheel cylinder when they are disassembled Water tight sealant SEALING COMPOUND 366E 99000 31090 To apply to m...

Page 342: ... or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service 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 could render the system inoperative Either of these two conditions may result in severe injury Technical service work mus...

Page 343: ...CK BRAKE SYSTEM ABS OPTIONAL GENERAL DESCRIPTION The ABS Antilock Brake System controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied This ABS is a 4 wheel type which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel from getting lock...

Page 344: ...r drum brake 3 ABS hydraulic unit control module assembly with ABS pump motor relay and fail safe relay 4 Brake master cylinder Reservoir LH steering vehicle RH steering vehicle ANTILOCK BRAKE SYSTEM ABS OPTIONAL 5E1 3 BRAKE HOSE PIPE ROUTING ...

Page 345: ...sembly with ABS pump motor fail safe relays 17 EBD warning lamp Brake warning lamp Wheel speed sensor LR Wheel speed sensor LF Wheel speed sensor RF Wheel speed sensor RR Stop lamp switch G sensor For 4WD model only Diag switch terminal Battery Voltage 4WD switch For 4WD model only Pump motor relay Pump motor LF inlet solenoid LF outlet solenoid LR inlet solenoid LR outlet solenoid Rear inlet sole...

Page 346: ...connector Black connector 9 Wheel speed sensor Left front 10 ABS hydraulic unit control module assembly with ABS pump motor relay and fail safe relay 11 G sensor For 4WD model only 12 Wheel speed sensor rotor ring 13 4WD switch For 4WD model only 14 EBD warning lamp Brake warning lamp LH steering vehicle RH steering vehicle ANTILOCK BRAKE SYSTEM ABS OPTIONAL 5E1 5 ABS COMPONENT PARTS LOCATION ...

Page 347: ...ng 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 of EEPROM in ABS control module 5 When Diag switch terminal of diagnosis connector monitor connector is grounded the abnormal area is output as DTC It is indicated by flashing of ABS warning lamp Refer to the table below ABS WARNING LAMP SYSTEM CONDIT...

Page 348: ...vehicle was driven with parking brake pulled The vehicle was driven with brake dragging The vehicle was stuck in mud sand etc Wheel spin occurred while driving Wheel s was rotated while the vehicle was jacked up Be sure to read Precautions for Electronic Circuit Service in GENERAL INFORMATION section before inspection and ob serve what is written there Be sure to use the trouble diagnosis procedur...

Page 349: ...o applicable diagnostic trouble code table in this section Then perform final confirmation test after clearing diagnostic trouble code Is trouble recur Go to step 7 END 5 Inspect and repair referring to DIAGNOSIS in BRAKES section Then perform final confirmation test after clearing diagnostic trouble code Is trouble recur Go to step 7 END 6 Check for intermittent problems referring to INTERMITTENT...

Page 350: ...______________ D Wheel is locked at braking D Pump motor does not stop running D Braking does not work D Other Frequency of occurrence D Continuous Intermittent times a day a month other______________ Conditions for Occurrence of Problem D Vehicle at stop ignition switch ON D When starting at initial start only at every start Other______________ D Vehicle speed while accelerating while deceleratin...

Page 351: ...eck if any trouble symptom such as abnormal lighting of ABS warning lamp 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 DIAGNOSTIC TROUBLE CODE CHECK Recheck diagnostic trouble code referring to item DTC CHECK as shown below 4 DIAGNOSTIC TROUBLE CODE FLOW CHART According to Diagnostic flow table for th...

Page 352: ...that EBD warning lamp brake warning lamp goes off If it doesn t go off go to TABLE E in this section ABS WARNING LAMP CHECK 1 Turn ON the ignition switch 2 Check that ABS warning lamp lights for about 2 seconds and then goes OFF If anything faulty is found advance to Diagnostic table A B or C DIAGNOSTIC TROUBLE CODE DTC CHECK USING ABS WARNING LAMP 1 Using service wire connect diag switch terminal...

Page 353: ...TC s DTC 12 which means that no malfunction DTC is stored and his tory DTC which indicates history trouble area When there is a current trouble ABS warning lamp remains ON and therefore DTC is not indicated 4 After completing the check turn ignition switch off and discon nect service wire from DIAG connector ...

Page 354: ... performing a driving test select a safe place where there is neither any traffic nor any traffic accident possibil ity and be very careful during testing to avoid occurrence of an accident After repair or replace malfunction part s clear all DTC s by per forming the following procedure 1 Turn ignition switch OFF 2 Using service wire connect diag switch terminal of diag con nector to diag ground t...

Page 355: ...t 35 C1035 rear Wheel speed sensor circuit and rotor 22 C1022 Right Wheel speed sensor circuit and rotor 22 C1022 g front 26 C1026 Left 26 C1026 front 32 C1032 Right 32 C1032 g rear 36 C1036 Left 36 C1036 rear 41 C1041 Right Inlet solenoid circuit 41 C1042 g front Outlet solenoid circuit 45 C1045 Left Inlet solenoid circuit 45 C1046 front Outlet solenoid circuit 56 C1055 Rear Inlet solenoid circui...

Page 356: ...ire color B Black B Bl Black Blue B O Black Orange B W Black White Bl Blue Bl B Blue Black Bl O Blue Orange Br Brown G Green G B Green Black G W Green White Lg Lightgreen Lg B Lightgreen Black O B Orange Black O G Orange Green O W Orange White P Pink P B Pink Black V G Violet Green W BI White Blue W G White Green W Y White Yellow Y Yellow Y B Yellow Black SYSTEM CIRCUIT TERMINAL CIRCUIT A1 Right r...

Page 357: ...ule If the Antilock brake system is in good condition the ABS control module turns the 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 by ABS control module Also it is turned ON by ABS lamp driver module when the connector of the ABS control module was disconnected INSPECTION STEP A...

Page 358: ... unit control module connector See Fig 1 2 Check for proper connection to ABS hydraulic unit control module connector at terminals A17 A25 and A10 3 If OK turn ignition switch ON and measure voltage at terminal A25 of connector Is it 10 14 V Go to step 4 B W circuit open 4 1 With ABS control module connector disconnected turn ignition switch ON and light ABS warning lamp 2 Connect terminal A17 of ...

Page 359: ... is detected in the ABS A history malfunction DTC is indicated by flashing of the lamp if a current malfunction DTC is not detected at that point although a history malfunction DTC is stored in memory INSPECTION STEP ACTION YES NO 1 Is diag switch terminal connected to ground via service wire Go to step 3 Go to step 2 2 1 Ignition switch ON 2 Measure voltage between diag switch terminal and ground...

Page 360: ...YES NO 1 Is it shorted diag switch terminal and ground 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 between diag switch terminal and connector terminal A8 Is it infinite P circuit open Go to step 3 3 1 Measure resistance between ground terminal of moni...

Page 361: ...the minimum level Are the check results OK and or replenish brake fluid 2 Does ABS warning lamp come on Perform TABLE B previously outlined Go to step 3 3 1 Disconnect ABS hydraulic unit control module connector 2 Check for proper connection to ABS hydraulic unit control module connector at terminals A26 3 If OK apply chocks to wheels and select gear in neutral position P range for A T 4 Keep brak...

Page 362: ...R 4WD MODEL ONLY DESCRIPTION While a vehicle is at stop or running if the potential difference between the sensor signal terminal A14 and the sensor ground terminal A4 is not within the specified voltage value or if the signal voltage while at a stop does not vary from that while running this DTC is set Therefore this DTC may be set when a vehicle is lifted up and its wheel s is turned In such cas...

Page 363: ...t control module assembly See Fig 1 and G sensor 2 Check for proper connection to ABS control module at terminals A14 and A4 3 If OK then turn ignition switch ON and measure voltage between B W terminal of sensor connector and body ground Is it 10 14 V Go to step 4 B W circuit open 4 Measure voltage between O W terminal of sensor connector and body ground Is it 0 V Go to step 5 O W circuit shorted...

Page 364: ...age at the positive terminal of each sensor while the ignition switch is ON When the voltage is not within the specified range an applicable DTC will be set Also when no sensor signal is inputted at starting or while running an applicable DTC will be set NOTE When the vehicle was operated in any of the following ways one of these DTC s may be set even when the sensor is in good condition If such p...

Page 365: ...esistance between 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 to step 4 Circuit open or shorted to ground 4 1 Remove wheel speed sensor 2 Check sensor for damage or foreign material being attached Is it in good condition See Fig 3 Go to step 5 Cle...

Page 366: ...YH4 GRAND VITARA ANTILOCK BRAKE SYSTEM ABS OPTIONAL 5E1 25 1 ABS hydraulic unit control module connector Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 ...

Page 367: ...noid or the voltage difference between solenoid circuit terminals exceeds the specified value with the solenoid turned OFF INSPECTION STEP ACTION YES NO 1 1 Check solenoid referring to 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 assembly and recheck...

Page 368: ...e while the pump motor is operating this DTC will be set As soon 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 to CHARGING SYSTEM section 2 Check ABS main fuse and connection Is it in good condition Go to step 3 Repair and or replace fuse 3 1 Ignit...

Page 369: ...se commands INSPECTION STEP ACTION YES NO 1 1 Check pump motor referring to 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 assembly and recheck Go to step 2 2 1 Ignition switch OFF 2 Disconnect ABS hydraulic unit control module connector See Fig 1 3 Ch...

Page 370: ... Low High If anything faulty is found in the initial check and when the voltage at all solenoid circuit terminals is low with the 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 Go to step 2 Check charging system referring to CHARGING SYSTEM section 2 Check ABS main fuse and connection Is it in goo...

Page 371: ...hen an internal fault is detected in the 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 all terminals Are they in good condition Substitute a known good ABS control module and recheck Repair or replace ...

Page 372: ...ake 6 Turn each wheel gradually by hand to check if brake dragging occurs If it does correct 7 With diag switch terminal of diagnosis connector connected to ground by using service wire turn ignition switch ON and check if ABS warning lamp indicates DTC 12 8 Turn ignition switch OFF 9 Perform following checks with help of another person Brake pedal should be depressed and then ignition switch turn...

Page 373: ...any of these prohibited services will affect original performance of ABS hydraulic unit control module assembly HYDRAULIC UNIT INSPECTION Check hydraulic unit for fluid leakage If any repair or replace REMOVAL 1 Disconnect negative cable at battery 2 Using special tool disconnect brake pipes from ABS hydraulic unit control module assembly and loosen flare nuts as shown figure Special Tool A 09950 ...

Page 374: ...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 affect its original performance INSTALLATION 1 Install hydraulic unit by reversing removal procedure Tightening Torque a 16 N m 1 6 kg m 12 0 lb ft b 21 N m 2 1 kg m 15 5 lb ft c 10 N m 1 0 kg m 7 5 lb ft 2 Bleed air from brake system Refer to BLEEDIN...

Page 375: ... Connect voltmeter between connector terminals 5 While turning wheel at a speed of approximately 2 3 to 1 full rotation per second check AC voltage of sensor Output AC voltage at 2 3 to one rotation per second 35 53 Hz 106 mV or more If measured voltage is not as specified check sensor rotor and their installation conditions Reference When using oscilloscope for this check check if peak to peak vo...

Page 376: ... D Do not cause damage to surface of front wheel speed sensor and do not allow dust etc to enter its installa tion hole SENSOR INSPECTION D Check sensor for damage D Check sensor for resistance Resistance between terminals 1 2 1 6 k at 20_C 68_F Resistance between terminal and sensor body 1 M or more If any faulty is found replace SENSOR ROTOR INSPECTION D Check rotor for being missing damaged or ...

Page 377: ...nt wheel speed sensor Fit harness grommet to inner fender securely Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft 3 Check that there is no clearance between sensor and knuckle FRONT SENSOR ROTOR REMOVAL Remove front sensor rotor referring to WHEEL HUB REMOVAL in Section 3D INSTALLATION CAUTION Don t reuse front sensor rotor removed from front wheel hub because of it for...

Page 378: ...d 25 38 Hz 106 mV or more Reference When using oscilloscope peak to peak voltage at 2 3 to one rotation per second 25 38 Hz 150 mV or more REMOVAL 1 Disconnect negative cable at battery 2 Hoist vehicle 3 Disconnect rear wheel speed sensor connector and detach wire harness from vehicle body and rear axle 4 Remove harness clamps and remove rear wheel speed sensor from rear axle CAUTION Do not pull w...

Page 379: ...serration teeth for being missing damaged or de formed D Turn wheel and check if rotor rotation is free from eccentricity and looseness D Check that no foreign material is attached If any faulty is found repair or replace INSTALLATION 1 Check that no foreign material is attached to sensor and rotor 2 Install it by reversing removal procedure Tightening Torque a 21 N m 2 1 kg m 15 0 lb ft CAUTION D...

Page 380: ...g grind with a grinder one part of the sensor rotor as illustrated till it becomes thin CAUTION Cover vinyl sheet or the like over wheel bearing so that fine grains from grinding will not enter there Be careful not to go so far as to grind the retainer ring 3 Break with a chisel the thin ground sensor rotor and it can be re moved INSTALLATION 1 Press fit sensor rotor as shown NOTE Use care not to ...

Page 381: ... It will lead to erro neous assembly Sensor must not be dropped or shocked It will affect its original performance INSPECTION 1 Check sensor bracket for bend 2 Connect positive cable of 12 volt battery to A terminal of sensor and ground cable to C terminal Then using voltmeter check voltage between B terminal and C terminal When placed horizontally 2 3 V When placed upright with arrow upward 3 4 V...

Page 382: ...Section 7A TIGHTENING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fastening arts N m kg m lb ft Brake pipe flare nut a 16 1 6 11 5 ABS hydraulic unit nut b 21 2 1 15 5 ABS hydraulic unit bracket bolt c 10 1 0 7 5 Wheel speed sensor bolt Front d 23 2 3 17 0 Wheel s eed sensor bolt Rear e 21 2 1 15 5 Parking lever assy mounting bolt f 23 2 3 17 0 ...

Page 383: ...0 Flare nut wrench 10 mm 09931 76011 SUZUKI scan tool Tech 1A kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter Mass storage cartridge 09931 76030 16 14 pin DLC cable SPECIAL TOOLS ...

Page 384: ...e description under ON VEHICLE SERVICE in this section covers a part of the TYPE 2 manual transmis sion and the transfer The transfer is next to the trans mission as well but their gear boxes are independent and each of them has its own drain and level filler plugs for the oil change or the level check For the repair procedure of the transfer unit refer to Section 7D SECTION 7A MANUAL TRANSMISSION...

Page 385: ...rs refusing to disengage Weakened or broken synchronizer spring Distorted shift shaft or shift fork Replace Replace Hard shifting Improper clutch pedal free travel Distorted or broken clutch disc Damaged clutch pressure plate Worn synchronizer ring Worn chamfered tooth on sleeve or gear Distorted shift shaft Adjust Replace Replace clutch cover Replace Replace sleeve and gear Replace Noise Inadequa...

Page 386: ...ver vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage and status of breather hoses If water or rust is mixed in drained oil be sure to check breather hose and boot of transmission and transfer Gear Oil Specification Oil grade API GL 4 Viscosity SAE 75W 85 75W 90 or 80W 90 Oil Capacity Transmission 1 5 liters 3 2 2 6 US Imp pt Transfer 1 7 liters 3 ...

Page 387: ...om transmis sion shift lever case 4 With gear shift control case cover pushed down with fingers turn it to counter clockwise and take out shift control lever 5 Take out transfer shift control lever in similar manner as de scribed above INSPECTION AND INSTALLATION 1 Check shift control lever lower portion and control lever locating sheet for excessive wear and boot for damage Correct or re place if...

Page 388: ...all transmission boot No 1 from inside of cabin and clamp it with a new clamp securely 6 Install transfer boot No 1 securely on lift and clamp it by using a new clamp 7 Tighten transmission boot No 2 with boot cover and console box bracket Tightening Torque a 6 N m 0 6 kg m 4 0 lb ft 8 Install console box NOTE Be sure that flare end of transmission boot No 3 is engaged with console box ...

Page 389: ...h shift transfer shift control lever to 4WD position and check that indicator lights Turn OFF switch after checking NOTE When removing and reinstalling switch use care not to let dust enter transfer box inside Make sure to reset clamp for wiring which is located where invisible directly It is recommended to work on transfer shift control lever boot No 1 from underside of vehicle on lift Identify t...

Page 390: ... its function INSPECTION OF 4WD SWITCH AND BACK UP LIGHT SWITCH 1 Undo clamp and disconnect coupler of back up light switch and or 4WD switch 2 Function of back up light switch can be checked as shown in fig ure There should be conduction at these terminals only when shift lever is shifted to reverse position 3 Function of transfer 4WD switch can be checked in the same manner as back up light swit...

Page 391: ... Mounting bracket 3 Engine rear mounting FRONT SIDE REAR SIDE 7A 8 MANUAL TRANSMISSION TYPE 1 ENGINE REAR MOUNTING When replacement of mounting parts are necessary torque bolts and nut as specified below Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft ...

Page 392: ...G OF TRANS UNIT IN CABIN Remove transmission shift control lever refer to page 7A 4 and transfer shift control lever knob IN ENGINE ROOM 1 Disconnect negative cable of battery 2 Remove breather hose from clamp at the rear end of cylinder head 3 Remove starting motor fixing bolts and nut and then remove starter 4 Remove transmission fastening bolts ...

Page 393: ...sion It is not necessary to disconnect clutch hose from operating cylinder NOTE It is not necessary to drain transmission oil when dis mounting transmission and transfer for clutch mainte nance only Work without draining transfer oil is possible if front pro peller shaft is dismounted together with transmission and transfer 6 Remove clutch housing lower plate 7 Disconnect couplers from 4WD switch ...

Page 394: ...sembly 3 Wiring harness 4 Breather hose 5 Gear shift lever case 6 Bolt 7 Bolt MANUAL TRANSMISSION TYPE 1 7A 11 10 Remove wiring harness and breather hose 11 Separate gear shift lever case and transfer assembly or exten sion case 2WD model from transmission ...

Page 395: ...ghtening torque of transmission stiffener bolt refer to ENGINE MECHANICAL section Set each clamp for wiring hose and cable securely Set clamp for shift control lever boots securely After installing clutch operating cylinder check clutch pedal free travel Refer to SECTION 7C1 CLUTCH Fill gear oil to transmission and transfer as specified Connect battery and check function of engine clutch and trans...

Page 396: ... 17 0 lb ft After installing check to make sure that each pin moves smooth ly 3 Install speedometer driven gear case assembly to extension case EXTENSION CASE OIL SEAL 2WD MODEL REMOVAL AND INSTALLATION 1 Remove propeller shaft referring to SECTION 4B 2 Using screwdriver remove oil seal 3 Using special tool A and plastic hammer press fit new oil seal into extension case till oil seal contacts step...

Page 397: ...ntrol lever locating bolts 17 1 7 12 5 Transmission to engine bolts and nuts 85 8 5 61 5 Engine rear mounting bolts and nut 50 5 0 36 5 Exhaust center pipe to manifold nuts 50 5 0 36 5 Muffler to exhaust center pipe bolts 50 5 0 36 5 Universal joint flange bolts 50 5 0 36 5 Select return spring bolts 23 2 3 17 0 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZU...

Page 398: ...ubs are assembled The gear shift lever case is located at the upper be hind the transmission case and has a cam which pre vents direct gear shift from the 5th speed gear to the reverse gear As the aluminum and castings cases are sealed with liquid type gasket it is necessary to use genuine seal ant or its equivalent on its mating surfaces when reas sembling them Also the case fastening bolts must ...

Page 399: ...rs refusing to disengage Weakened or broken synchronizer spring Distorted shift shaft or shift fork Replace Replace Hard shifting Improper clutch pedal free travel Distorted or broken clutch disc Damaged clutch pressure plate Worn synchronizer ring Worn chamfered tooth on sleeve or gear Distorted shift shaft Adjust Replace Replace clutch cover Replace Replace sleeve and gear Replace Noise Inadequa...

Page 400: ... oil Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage and status of breather hoses If water or rust is mixed in drained oil be sure to check breather hose and boot of transmission and transfer Gear Oil Specification Oil grade API GL 4 Viscosity SAE 75W 85 75W 90 or 80W 90 Oil Capacity Transmission 2 6 liters 5 5 4 6 US Imp pt Transfer 1 7...

Page 401: ...UNTING Refer to SECTION 7A in this manual DISMOUNTING REMOUNTING OF TRANS UNIT Refer to the same item in SECTION 7A MANUAL TRANSMIS SION For tightening torque of filler and level drain plug refer to Gear Oil Inspection and Change of ON VEHICLE SERVICE in this sec tion UNIT REPAIR Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual ...

Page 402: ... switch 45 4 5 32 5 Control lever locating bolts 17 1 7 12 5 Transmission to engine bolts and nuts 85 8 5 61 5 Engine rear mounting bolts 50 5 0 36 5 Muffler to exhaust No 2 pipe nuts 50 5 0 36 5 Universal joint flange bolts 50 5 0 36 5 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Shift control lever Thread lock cement THREAD L...

Page 403: ... Malfunction 7B1 42 DTC P0720 Output Speed Sensor Circuit Malfunction 7B1 44 DTC P0741 TCC Solenoid Valve Performance or Stuck Off 7B1 46 DTC P0743 TCC Solenoid Electrical 7B1 47 DTC P0751 Shift Solenoid Valve A 1 Performance or Stuck Off 7B1 49 DTC P0756 Shift Solenoid Valve B 2 Performance or Stuck Off 7B1 49 SECTION 7B1 AUTOMATIC TRANSMISSION 4 A T WARNING For vehicles equipped with Supplementa...

Page 404: ...THROTTLE CABLE 7B1 61 MANUAL SELECTOR ASSEMBLY 7B1 62 SELECT CABLE 7B1 63 TRANSMISSION RANGE SWITCH 7B1 64 A T OUTPUT SPEED SENSOR 7B1 64 O D CUT SWITCH 7B1 64 SOLENOID VALVES 7B1 64 THROTTLE POSITION SENSOR 7B1 66 POWER NORMAL CHANGE SWITCH 7B1 66 OIL COOLER PIPES 7B1 67 BRAKE INTERLOCK SYSTEM 7B1 68 Shift Lock Solenoid Control 7B1 68 Shift Lock Solenoid Control Operations 7B1 68 Shift Lock Solen...

Page 405: ...orque converter is a 3 element 1 step and 2 phase type and is equipped with an electronically controlled lock up mechanism The gear shift device consists of 3 sets of planetary gear units 3 disc type clutches 4 disc type brakes and 3 one way clutches The gear shift is done by selecting one of 6 positions P R N D 2 and L by means of the select lever installed on the floor On the shift knob there is...

Page 406: ...de Forward 1st 2nd 3rd automatic gear change Power mode Forward 2nd 3rd automatic gear change and fixed at 2nd gear L range Forward 1st 2nd 3rd reduction and fixed at 1st gear Gear Engine type G16 engine J20 H25 engines change device 1st low gear 2 826 2 826 device 2nd second gear 1 493 1 493 Gear 3rd top gear 1 000 1 000 Gear ratio 4th overdrive 4th gear 0 730 0 689 Reverse reverse Reverse gear 2...

Page 407: ...h Meshes overdrive carrier and overdrive sun gear only when driven by engine Forward clutch Meshes input shaft and intermediate shaft Direct clutch Meshes input shaft with front sun gear and rear sun gear Second coast brake Fixes front sun gear and rear sun gear Second brake Fixes outer race of one way clutch No 1 to prevent front sun gear and rear sun gear from turning counterclockwise reverse di...

Page 408: ... D clutch Forward clutch Inner piston Outer piston O D brake coast brake Second brake Inner piston Outer piston one way clutch y clutch No 1 y clutch No 2 P f X f f R f X f f f f f f N f X f f 1st gear f X f f f f D 2nd gear f f f f f f f D 3rd gear X f f f f f f O D X X f f f f 1st gear f X f f f f 2 2nd gear f f f f f f f 2 3rd gear Fail safe X f f f f f f 1st gear f X f f f f f L 2nd gear Fail ...

Page 409: ...OWER lamp MIL Transmission range switch O D cut switch P N change switch Transfer 4L switch if equipped CMP sensor Powertrain engine control module Power transmission Fluid pressure circuit Electric signal Input speed sensor Brake pedal switch Output speed sensor AUTOMATIC TRANSMISSION 4 A T 7B1 7 ELECTRONIC SHIFT CONTROL SYSTEM The gear ratio change in D or 2 range and torque converter clutch ope...

Page 410: ...Transmission range switch 9 Shift solenoid A 10 Shift solenoid B 11 TCC solenoid 12 Data link connector 13 Cruise control module 14 POWER lamp 15 O D OFF lamp 16 MIL 17 O D cut switch 18 P N change switch 19 4WD low switch 20 Main relay 21 Ignition switch 22 Battery 23 PCM ECM connector terminal viewed from harness side Bl Y Bl G W Or C51 1 11 C51 1 10 C51 1 23 C51 1 22 12V ...

Page 411: ...sensor 9 Transmission range switch 10 Shift solenoid A 11 Shift solenoid B 12 TCC solenoid 13 Data link connector 14 Cruise control module 15 POWER lamp 16 O D OFF lamp 17 MIL 18 O D cut switch 19 P N change switch 20 4WD low switch 21 Main relay 22 Ignition switch 23 Battery 24 PCM ECM connector terminal viewed from harness side Bl Y Bl G W Or C51 1 16 C51 1 8 C51 1 10 C51 1 9 12V ...

Page 412: ...ion Condition Shift position Normal Shift solenoid valve A 1 abnormal Shift solenoid valve B 2 abnormal Shift solenoid valves A B 1 and 2 abnormal 1st 1st D 2nd 3rd O D D 3rd O D O D O D O D 1st 1st 2 2nd 3rd 3rd 3rd 3rd 3rd L 1st 1st 1st 1st L 2nd 2nd 1st 1st Change Mechanism The same select pattern shift lever is used as the floor type and fre quently used N and D ranges are made selectable free...

Page 413: ... for G16 engine 45 km h or 28 mile h for J20 engine 55 km h or 34 mile h for H25 engine 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that No up shift is available in L The same as the select lever is shifted to 2 at a higher than 102 km h 64 mile h speed for G16 J20 engines 105 km h or 65 mile h for H25 engine 3rd gear is operated and then down shifts to 2nd at a s...

Page 414: ...ng Vehicle speed Throttle valve opening TCC ON TCC OFF 4th gear 3rd gear km h km h 7B1 12 AUTOMATIC TRANSMISSION 4 A T Normal Mode For G16 Engine Unit km h mile h Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle 45 28 94 58 136 85 124 77 74 46 39 24 Closed throttle 14 9 32 20 45 28 35 22 29 18 7 4 ...

Page 415: ...shift Throttle valve opening Vehicle speed 3rd gear 4th gear TCC ON TCC OFF km h km h AUTOMATIC TRANSMISSION 4 A T 7B1 13 Power Mode For J20 Engine Unit km h mile h Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle 50 31 98 61 135 84 84 52 46 29 Closed throttle 18 11 33 21 50 31 44 27 26 16 8 5 ...

Page 416: ...ed Throttle valve opening 3rd gear 4th gear TCC ON TCC OFF Vehicle speed km h km h 7B1 14 AUTOMATIC TRANSMISSION 4 A T Normal Mode For J20 Engine Unit km h mile h Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle 50 31 98 61 147 91 135 84 84 52 42 26 Closed throttle 11 7 27 17 40 25 37 23 24 15 8 5 ...

Page 417: ...ft Throttle valve opening Vehicle speed TCC ON TCC OFF 3rd gear 4th gear km h km h AUTOMATIC TRANSMISSION 4 A T 7B1 15 Power Mode For H25 Engine Unit km h mile h Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle 48 30 99 62 160 99 150 93 90 56 41 25 Closed throttle 16 10 30 19 45 28 38 24 24 15 7 4 ...

Page 418: ...pening Vehicle speed Throttle valve opening Vehicle speed Upshift Downshift TCC ON TCC OFF 3rd gear 4th gear km h km h Normal Mode For H25 Engine Unit km h mile h Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle 48 30 99 62 160 99 150 93 90 56 41 25 Closed throttle 11 7 27 17 40 25 35 22 21 13 7 4 ...

Page 419: ...lity of those parts that influence the engine exhaust emission When diagnosing a trouble in transmission including this system be sure to have full understanding of the outline of On board Diagnostic System and each item in Precaution in Diagnosing Trouble and execute diagnosis ac cording to AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE given below to obtain correct result smoothly NOTE There are t...

Page 420: ...erse effect to vehicle emission while the engine is running it makes the malfunction indicator lamp in the meter cluster of the instrument panel turn ON and stores the malfunction area in its memory If it detects that contin uously 3 driving cycles are normal after detecting a malfunction however it makes MIL turn OFF although DTC stored in its memory will remain It is possible to communicate thro...

Page 421: ...cts a trouble in electronic shift control system it stores its trouble code in back up memory in itself The memory is kept as it is even if the trouble was only temporary and disap peared immediately And it is not erased unless the power to PCM is shut off for 30 seconds or longer It is possible to communicate through DLC by using not only SU ZUKI scan tool Tech 1 but also generic scan tool Diagno...

Page 422: ...wo or more diagnostic trouble codes DTCs are stored proceed to the flow table of the DTC which was de tected earliest in the order and follow the instruction in that table If no instructions are given troubleshoot diagnostic trouble codes according to the following priorities 1 Diagnostic trouble codes DTCs other than DTC P0171 P0172 Fuel system too lean too rich and DTC P0400 EGR flow malfunction...

Page 423: ...nfirmation 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 data referring to DTC Check in this section Is there any DTC s Go to Step 9 Go to Step 8 7 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame data referring to DTC C...

Page 424: ...ed in Step 1 CUSTOMER COMPLAINT ANALYSIS and Step 2 DTC FREEZE FRAME DATA CHECK Also recheck DTC according to DTC Confirmation Procedure described in each DTC FLOW TABLE 6 and 7 RECHECKING AND RECORD OF DTC FREEZE FRAME DATA Refer to DTC Check section for checking procedure 8 A T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE Perform A T basic check according to the A T Basic Check Flow Table first When ...

Page 425: ...Sometimes j times day month jOnly Once jUrban jSuburb jHighway jMountainous uphill downhill jPaved road jGravel jOther Vehicle Condition Engine Brake O D cut switch P N change switch j P R N D 2 L range j range jCold jWarming up phase jWarmed up jAt stop jDuring driving constant speed accelerating decelerating right hand corner left hand corner jOther jSpeed km h mile h jSpeed r min jThrottle open...

Page 426: ...ange sensor circuit Multiple signals inputted simulta neously or no signal inputted while 2 driving cycles Not applicable sensor circuit malfunction neously or no signal in utted while running at 60 km h or more cycles a licable P0715 76 Input Turbine speed sensor circuit malfunction Input shaft revolution speed is lower than specified value while vehicle is running with D range and specified engi...

Page 427: ... safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that DTC NO Using scan tool Not using scan tool TROUBLE AREA FAIL SAFE OPERATION P0177 P0118 14 15 ECT SENSOR D Each control except 4 A T is permitted on the basis of 30 1_C engine coolant temp D 4 A T control is performed assuming 31_C engine warmed up or higher after 15 min from...

Page 428: ... fluid level corrosion of terminal Connectors of electric wire harness disconnection friction Fuses burning Parts installation damage Bolt looseness Other parts that can be checked visually Also check following items at engine start if possible O D OFF lamp POWER lamp Malfunction indicator lamp Charge warning lamp Engine oil pressure warning lamp Engine coolant temp meter Other parts that can be c...

Page 429: ...ep 3 Go to Step 4 3 Proceed to TROUBLE DIAGNOSIS TABLE 1 in this section Is trouble identified Repair or replace defective parts Go to Step 5 4 Perform stall test time rag test line pressure test engine brake test and P range test referring to STALL TEST LINE PRESSURE TEST ENGINE BRAKE TEST and P RANGE TEST in this section Are the test results satisfactory Go to Step 5 Proceed to TROUBLE DIAGNO SI...

Page 430: ...NOSIS TABLE 2 Condition Possible Cause Correction Low fluid pressure Clogged oil pump strainer Malfunction of pressure regulator valve Wash strainer Overhaul valve body High fluid pressure Pressure regulator valve Overhaul valve body Unable to run in all range Regulator valve stick Replace Clogged oil strainer Wash strainer Seized or broken planetary gear Repair or replace Faulty manual valve Repl...

Page 431: ...ve sticking Replace 2 3 shift Faulty accumulator direct clutch piston Replace Excessive shock on 3 4 shift Regulator valve sticking Replace Non operate lock TCC Lock up control valve sticking Replace up system Solenoid valve No 2 TCC solenoid valve sticking Replace TROUBLE DIAGNOSIS TABLE 3 Condition Possible Cause Correction Low fluid pressure Leakage from oil pressure circuit Overhaul Unable to ...

Page 432: ...cond brake piston Replace Faulty second coast brake in 2 range Replace Poor 2 3 shift ex cessive slippage Fluid pressure leakage to overdrive clutch due to wear or breakage of O D case seal ring Replace Worn direct clutch bushing Replace Direct clutch slipping Replace Foreign material caught in direct clutch pis ton check ball Replace Poor start or surging in D range Fluid pressure leakage of forw...

Page 433: ...2 ECT check 1 Warm up engine to normal operating temperature 2 Check ECT using scan tool Is ECT more than 30_C 86_F Go to Step 3 Faulty ECT sensor its circuit or engine cooling system If OK substitute a known good PCM and recheck 3 Perform running test under the following conditions and check voltage between C51 1 8 G16 J20 engines or C51 1 2 H25 engine terminal of PCM coupler and ground D Normal ...

Page 434: ...s specified Go to Step 7 Faulty 4WD LOW switch or its circuit If OK substitute a known good PCM and recheck 7 Is vehicle equipped with cruise control system Go to Step 8 Substitute a known good PCM and recheck 8 Cruise control signal inspection 1 With ignition switch ON check voltage between E61 35 G16 J20 engines or E61 3 H25 engine terminal of PCM coupler and ground Is it battery voltage Substit...

Page 435: ...ating temperature 2 Check ECT using scan tool Is ECT more than 30_C 86_F Go to Step 3 Faulty ECT sensor its circuit or engine cooling system If OK substitute a known good PCM and recheck 3 Perform running test under the following conditions and check voltage between C51 1 2 G16 J20 engines or C51 1 6 H25 engine terminal of PCM coupler and ground C51 1 1 terminal of PCM coupler and ground D O D cut...

Page 436: ...s specified Go to Step 6 Faulty 4WD LOW switch or its circuit If OK substitute a known good PCM and recheck 6 Is vehicle equipped with cruise control system Go to Step 7 Substitute a known good PCM and recheck 7 Cruise control signal inspection 1 With ignition switch ON check voltage between E61 35 G16 J20 engines or E61 3 H25 engine terminal of PCM coupler and ground Is it battery voltage Substit...

Page 437: ...N SWITCH ON BUT ENGINE STARTS UP WIRING DIAGRAM TROUBLESHOOTING STEP ACTION YES NO 1 O D OFF light circuit check 1 With ignition switch OFF disconnect couplers from PCM 2 Using service wire connect E61 20 G16 J20 engines or E61 7 H25 engine terminal of disconnected PCM coupler and ground Does O D OFF light turn ON at ignition switch ON Poor E61 20 G16 J20 engines or E61 7 H25 engine terminal conne...

Page 438: ...ch ON Does O D OFF lamp come ON steadily W B circuit shorted to ground Go to Step 3 3 Check O D cut Switch Circuit 1 Check resistance between terminal E61 33 G16 J20 engines or E61 14 H25 engine of disconnected PCM connector and body ground with O D cut switch OFF Is continuity indicated Go to Step 4 Check PCM ground circuit for open If ground circuit is OK substitute a known good PCM and recheck ...

Page 439: ...SWITCH ON BUT ENGINE STARTS UP WIRING DIAGRAM TROUBLESHOOTING STEP ACTION YES NO 1 POWER light circuit check 1 With ignition switch OFF disconnect couplers from PCM 2 Using service wire connect E61 21 G16 J20 engines or E61 10 H25 engine terminal of disconnected PCM coupler and ground Does POWER light turn ON at ignition switch ON Poor E61 21 G16 J20 engines or E61 10 H25 engine terminal connectio...

Page 440: ... Bl circuit shorted to ground Go to Step 3 3 Check Power Normal Change Switch Circuit 1 Check resistance between terminal E61 31 G16 J20 engines or E61 9 H25 engine of disconnected PCM connector and body ground with P N change switch OFF Is continuity indicated Go to Step 4 Check PCM ground circuit for open If ground circuit is OK substitute a known good PCM and recheck 4 Check Power Normal Change...

Page 441: ...ISSION 4 A T 7B1 39 G16 J20 Engines H25 Engine 1 PCM 2 J B 3 Transmission range sensor switch 1 PCM 2 Fuse 3 J C 4 Transmission range sensor switch DTC P0705 DTC NO 72 TRANSMISSION RANGE SENSOR SWITCH CIRCUIT MALFUNCTION WIRING DIAGRAM ...

Page 442: ...ON PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC and start engine 3 Shift A T selector lev...

Page 443: ...y with select lever shifted to each range Taking terminal C51 1 28 for G16 J20 C51 1 20 for H25 as an example is battery voltage indicated only when select lever is shifted to 2 range and 0 V for other ranges as shown in figure Check voltage at other terminals likewise referring to figure Are check results satisfactory Intermittent trouble Check for intermittent referring to Intermit tent and Poor...

Page 444: ...cles detection logic Input speed sensor and its circuit PCM DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition swi...

Page 445: ... 1 16 for H25 and ground 1 M or more Are check results satisfactory Go to Step 4 Go to Step 3 3 Input speed sensor check 1 With ignition switch OFF disconnect input speed sensor connector 2 Check for proper connection to input speed sensor at each terminals 3 If OK then check resistance of input speed sensor Are measured values as specified in Step 2 Bl G or Bl Y wire open or shorted to ground Rep...

Page 446: ...n specified engine speed with D range 2 driving cycles detection logic A T output speed sensor or its circuit PCM DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a l...

Page 447: ...1 1 10 for H25 and ground 1 M or more Are check results satisfactory Go to Step 4 Go to Step 3 3 Output speed sensor check 1 With ignition switch OFF disconnect output speed sensor connector 2 Check for proper connection to output speed sensor at each terminals 3 If OK then check resistance of output speed sensor Are measured values as specified in Step 2 Or or W wire open or shorted to ground Rep...

Page 448: ...ame data in PCM memory by using scan tool and check fuel level meter indication is 1 4 or more 3 Start engine warm it up to normal operating temperature and shift transfer lever to 2H or 4H range 4 Increase vehicle speed with D range and check that gear position changes from 1st to 2nd and keep driving about 20 mph 30 km h in 2nd of D range for 10 seconds Throttle valve should be not at idle posit...

Page 449: ...ON PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF if available 2 Clear DTC 3 Start engine warm it up to normal opera...

Page 450: ...are OK replace malfunction shift solenoid 5 Check TCC Solenoid Circuit for Short 1 Turn ignition switch ON 2 Measure voltage between terminal C51 1 8 for G16 J20 C51 1 2 for H25 of disconnected PCM connector and ground Is it about 0 V Intermittent trouble or faulty PCM Check for Intermittent and Poor Connection in Section 0A G Y circuit shorted to power circuit 6 Check TCC Solenoid Circuit for Sho...

Page 451: ...of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF 2 Clear DTC pending DTC and freeze frame data in PCM memory by using scan tool and check fuel level meter indication is 1 4 or more 3 Start engine warm it up to normal ope...

Page 452: ...AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P0753 Voltage detected at C51 1 2 for G16 J20 C51 1 6 for H25 terminal is specified voltage or lower when shift solenoid valve A is ON or specified voltage or higher when it is OFF Shift solenoid valve A Shift solenoid valve A circuit PCM DTC P0758 Voltage detected at C51 1 1 terminal is specified volt age or lower when shift solenoid valve...

Page 453: ...enoid Circuit for Open or Short 1 Turn ignition switch OFF and disconnect PCM connectors 2 Check for proper connection to PCM at terminals C51 1 2 for G16 J20 C51 1 6 for H25 or C51 1 1 3 If OK then measure resistance between terminal C51 1 2 for G16 J20 C51 1 6 for H25 or C51 1 1 of disconnected PCM connector and ground Is it 11 15 at 20_C 68_F Go to Step 5 G or G R circuit open or shorted to gro...

Page 454: ...n performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to DLC with ignition switch OFF 2 Clear DTC pending DTC and freeze frame data in PCM memory by using scan tool 3 Start eng...

Page 455: ... position 4H or 2H position 10 14 V 4L position 0 1 V Is voltage as specified Check for poor con nection at the termi nal of PCM if voltme ter is used in Step 2 If connection is OK intermittent trouble or faulty PCM Check for intermittent referring to Intermit tent and Poor Connection in Section 0A Go to Step 3 3 4WD low switch check 1 Check 4WD low switch for operation referring to 4WD Low Switch...

Page 456: ...ing oil pressure gauge check that not fluid leakage exists 3 Depress foot brake fully run engine at idle and stall and then check fluid pressure in D or R range CAUTION Do not continue running engine at stall speed longer than 5 seconds G16 Engine Engine running Line pressure g g mode D range R range At idle speed 3 9 4 4 kg cm2 55 63 psi 5 1 5 7 kg cm2 73 81 psi At stall speed 11 7 13 2 kg cm2 16...

Page 457: ...rque of transmission case plug 17 N m 1 7 kg m 12 0 lb ft STALL TEST This test is to check overall performance of automatic transmission and engine by measuring stall speed at D and R ranges Be sure to perform this test only when transmission fluid is at normal operat ing temperature and its level is between FULL and LOW marks CAUTION Do not run engine at stall more than 5 seconds continu ously fo...

Page 458: ...h ROAD TEST This test is to check if upshift and downshift take place at specified speed while actually driving vehicle on a level road WARNING Carry out test in very little traffic area to prevent an acci dent Test requires 2 persons a driver and a tester 1 Warm up engine 2 With engine running at idle shift select lever D 3 Accelerate vehicle speed by depressing accelerator pedal grad ually 4 Whi...

Page 459: ...e checks stop vehicle then engine and connect shift solenoids coupler with ignition switch OFF WARNING To avoid the danger of being burned do not touch the hot exhaust system when connecting shift solenoid valves coupler 7 Clear DTC with scan tool TIME LAG TEST This test is to check conditions of clutch reverse brake and fluid pressure Time lag means time elapsed since select lever is shifted with...

Page 460: ...hich is sus pected to be the cause Condition Possible cause Fails to operate when shifted down to 2 range Second coast brake defec tive Fails to operate when shifted down to L range Reverse brake defective P RANGE TEST 1 Stop vehicle on a slope shift select lever to P range and at the same time apply parking brake 2 After stopping engine depress brake pedal and release parking brake 3 Then release...

Page 461: ...nd back to P position 6 With engine idling pull out dipstick wipe it off with a clean cloth and put it back into place 7 Pull out dipstick again and check fluid level indicated on it Fluid level should be between FULL HOT and LOW HOT If it is below LOW HOT add an equivalent of DEXRONr III up to FULL HOT Fluid specification An equivalent of DEXRONr III NOTE D DO NOT RACE ENGINE while checking fluid...

Page 462: ...d when the fluid temperature has reached the normal operating temperature check fluid level again and adjust it as necessary FLUID CHANGE 1 Lift up vehicle 2 With engine is cool remove drain plug from oil pan and drain A T fluid 3 Install drain plug Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 4 Lower vehicle and fill proper amount of an equivalent of DEX RONr III 5 Check fluid level according t...

Page 463: ...USTMENT 1 Pull inner cable by force of 2 N 0 2 kg 0 45 lb or less to be no slack of inner cable with A T throttle cable curved as shown in the figure 2 Fix stopper to inner cable with clearance c Clearance c 0 8 1 5 mm 0 03 0 06 in 3 For G16 J20 engines a Check clearance c If it is out of specifications adjust it by turning cable adjusting nut Clearance c 0 8 1 5 mm 0 03 0 06 in b Tighten lock nut...

Page 464: ... REMOVAL 1 Disconnect negative cable at battery 2 Remove console box 3 Disconnect connector for illumination lamp shift lock solenoid and overdrive OFF switch 4 Disconnect interlock cable from interlock cam of selector as sembly 5 Remove selector assembly mounting bolts 6 Disconnect select cable from lever of selector assembly INSTALLATION NOTE New selector assembly of Type 1 is supplied with held...

Page 465: ...ut movement and position indicator for correct indication For operation of select lever refer to left figure SELECT CABLE ADJUSTMENT 1 Before tightening cable end nut shift select lever to N 2 Also shift manual shift lever to N NOTE Make sure that nut and cable joint have clearance under above conditions If select cable has been moved push it in arrow C direc tion as shown in figure at the left ti...

Page 466: ...iscon nect transmission range switch coupler and check that continu ity exists as shown by moving select lever Terminal No 5 4 9 8 2 3 10 7 6 5 4 9 8 2 3 10 7 6 P R N D 2 L A T OUTPUT SPEED SENSOR INSPECTION Check A T output speed sensor for resistance between terminals of sensor or PCM coupler A T output speed sensor resistance value 387 473 at 20_C 68_F O D CUT SWITCH INSPECTION Check O D cut sw...

Page 467: ...differential if equipped 5 Remove oil pan bolts 6 Remove oil pan 7 Remove oil tubes 8 Remove solenoid valve No 1 shift solenoid valve A and B or so lenoid valve No 2 TCC solenoid valve OPERATION CHECK Whenever shift solenoid valves and TCC lock up solenoid valve are removed from transmission verify their valve function physical ly before they are reinstalled 1 Apply oiler to solenoid valve and giv...

Page 468: ...n refer to Unit Repair section Use new oil pan gasket Tighten universal joint flange bolts nuts and exhaust pipe brack et bolts to specified torque Fill A T fluid and check fluid level according to procedure de scribed in CHANGING FLUID previously Check for fluid leakage after warming up A T THROTTLE POSITION SENSOR INSPECTION Refer to SECTION 6E1 6E2 for inspection POWER NORMAL CHANGE SWITCH INSP...

Page 469: ...hoses NOTE To avoid fluid leakage plug open ends of oil outlet unions and hoses right after they are disconnected INSTALLATION 1 Use new union gaskets and connect oil cooler pipes to oil outlet unions 2 Connect hoses to pipes and clamp them securely 3 Tighten union bolts to specified torque with oil outlet union locked Tightening Torque a 35 N m 3 5 kg m 25 5 lb ft 4 Tighten pipe bolt securely 5 C...

Page 470: ... Also the ignition key cannot be pulled out of the key slot unless the selector lever is in P range SHIFT LOCK SOLENOID CONTROL OPERATIONS When the select lever is in P range the ignition key position is ON and depressing the brake pedal cause the electric current to flow to the solenoid As the shift lock solenoid rod or the lock plate is drawn toward the solenoid in this state it frees the interl...

Page 471: ...se plate toward rear side of vehicle by using screw driver or the like 3 In this state select lever can be moved to any range or position SYSTEM INSPECTION 1 Check to make sure that select lever cannot be moved to any other range from P range position when ignition switch key is at ACC position at LOCK position or it is removed from key hole of ignition switch or brake pedal is not depressed 2 Shi...

Page 472: ...range position to any other range With shift lock solenoid rod or manual release plate moved in arrow direction and ignition key turned to LOCK position select lever can not be shifted from P range position to any other range When ignition switch is turned ON and brake pedal is de pressed select lever can be shifted from P range position to any other range 3 With select lever shifted to any positi...

Page 473: ...rom battery 2 If equipped with air bag system disable air bag system Refer to Disabling Air bag System in Section 10B 3 Remove steering column hole cover 4 Tilt steering column if steering column is adjustable If no adjustable loosen steering column bolts 5 Remove steering column cover 6 Remove interlock cable clamp screw located at ignition switch assembly 7 Disconnect interlock cable inner end I...

Page 474: ...o holes of cam and lever plate 6 Install cable end to interlock cam and stud bolt and after making sure that cable outer is pushed in arrow direction B by leaf spring tighten mounting nut to specified torque Remove pin Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft 7 Turn ignition key to ACC position and shift select lever to N range and check for the followings a When select lever is shifted at P ...

Page 475: ...rrow direction B by leaf spring tighten mounting nut to speci fied torque Remove special tool Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft 8 Turn ignition key to ACC position and shift select lever to N range and check for the followings a When select lever is shifted at P range with knob button depressed ignition key can not be turned from ACC to LOCK position b When knob button is released igni...

Page 476: ...emove console box NOTE To remove clip push in its center pin first 2 Remove boot cover and boot No 2 if equipped 3 Remove boot clamp and then remove boot No 1 from transfer gear shift lever case if equipped 4 With transfer shift control case cover pushed down with fingers turn it to counterclockwise and take out shift control lever if equipped IN ENGINE ROOM 1 Remove battery dipstick and oil fille...

Page 477: ... figure 3 Remove universal joint flange bolts and take out rear propeller shaft 4 Likewise take out front propeller shaft if equipped 5 Remove nut from the end of select cable and bracket to set cable free 6 Remove select cable bracket by removing its 2 bolts 7 Remove exhaust No 1 and No 2 pipe 8 Remove transmission stiffener right side if equipped 9 Unclamp and disconnect oil cooler hoses from pi...

Page 478: ... and transfer if equipped assembly held up on jack move them to the rear and lower them including torque converter WARNING Transmission and transfer if equipped assembly may tilt rearward on jack It is recommended to use an auxil iary arm of jack for the purpose of safety AFTER DISMOUNTING WARNING Be sure to keep transmission and transfer if equipped as sembly horizontal throughout the work Should...

Page 479: ... may allow converter to fall off Where by an injury may result For remounting reverse dismounting procedure Use specified torque as given below and left Tightening torque N m kg m lb ft Exhaust No 1 pipe to manifold bolts or nuts 50 5 0 36 5 Muffler to exhaust No 2 pipe nuts 60 6 0 43 5 Universal joint flange bolts and nuts 50 5 0 36 5 Oil filler tube bolts Select cable bracket bolts 23 2 3 17 0 C...

Page 480: ... 9 5 Manual select cable nut 7 0 7 5 5 Manual selector assembly bolts 18 1 8 13 5 Transmission to engine bolts and nuts 85 8 5 61 5 Engine rear mounting bolts Engine rear mounting member bolts Transmission case right stiffener bolts 50 5 0 36 5 Universal joint flange bolts and nuts 50 5 0 36 5 Torque converter mounting bolts 65 6 5 47 0 Adapter case or extension case bolts G16 engine 35 3 5 25 5 A...

Page 481: ...ator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter Mass storage cartridge REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE A T fluid An equivalent of DEXRONr III D Automatic transmission D Parts lubrication when installing Lithium grease SUZUKI SUPER GREASE A 99000 25010 D Cable ends Sealant SUZUKI BOND NO 1215 99000...

Page 482: ... Clutch Fluid Pipe and Hose 7C1 4 Clutch Master Cylinder 7C1 5 Fluid Inspection 7C1 6 Disassembly and Assembly Clutch Master Cylinder 7C1 7 Clutch Operating Cylinder 7C1 8 UNIT REPAIR 7C1 10 Clutch Cover Clutch Disc and Flywheel 7C1 10 TIGHTENING TORQUE SPECIFICATIONS 7C1 14 REQUIRED SERVICE MATERIALS 7C1 14 SPECIAL TOOLS 7C1 14 SECTION 7C1 CLUTCH CONTENTS ...

Page 483: ...he transmission input shaft with an involute spline fit The clutch cover is secured to the flywheel and car ries the diaphragm spring in such a way that the pe ripheral edge part of the spring pushes on the pres sure plate against the flywheel with the disc in be tween when the clutch release bearing is held back This is the engaged condition of the clutch Depressing the clutch pedal causes the re...

Page 484: ...ibration Glazed glass like clutch facings Clutch facings dirty with oil Release 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 flywheel surface Weakened or loosened engine mounting bolt or nut Repair or replace disc Replace disc Lubricate or replace inpu...

Page 485: ...ecified torque Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft CLUTCH PEDAL FREE TRAVEL Depress clutch pedal stop the moment clutch resistance is felt and measure distance clutch pedal free travel Free travel should be within following specification Pedal free travel a 15 25 mm 0 6 1 1 in CLUTCH FLUID PIPE AND HOSE REMOVAL NOTE Do not allow fluid to get on painted surface 1 Remove dust and dirt from...

Page 486: ...of removal and installation of master cylin der assembly and air bleeding refer to CLUTCH MASTER CYLINDER section Do not allow fluid to get on painted surface Do not allow pipe and hose to contact hard against vehicle or other parts Install each clamp securely Install E ring securely as shown After installation check clutch pedal free travel and bleed air from system Check fluid leakage Add fluid ...

Page 487: ...rake fluid and check fluid leakage 7 After installation bleed air from system and check clutch pedal free travel Refer to BRAKE section for air bleeding procedure FLUID INSPECTION Fluid level should be always between MIN and MAX lines on reser voir If fluid decreases quickly check for leakage repair leaky point if any and add fluid up to MAX level NOTE Brake fluid damages painted surface badly Sho...

Page 488: ...ssary NOTE Wash disassembled parts with brake fluid Do not reuse piston assembly and circlip Inspect cylinder bore for scoring or corrosion It is best to replace corroded cylinder Corrosion can be identified as pits or excessive roughness NOTE Polishing bore of cylinder with anything abrasive is prohib ited as damage to cylinder bore may occur Rinse cylinder in clean brake fluid Shake excess rinsi...

Page 489: ...t fluid with syringe or such 2 Disconnect fluid hose from operating cylinder 3 Remove operating cylinder attaching bolts and operating cylin der INSTALLATION 1 For air bleeding of master cylinder alone it must be removed from vehicle For procedures of removal and installation of master cylinder as sembly and air bleeding refer to CLUTCH MASTER CYLINDER section 2 Apply small amount of grease to rod...

Page 490: ...RAND VITARA CLUTCH 7C1 9 5 Fill reservoir with specified brake fluid and check for fluid leak age 6 Bleed air from system and check clutch pedal free travel Refer to BRAKE section for air bleeding procedure ...

Page 491: ...REPAIR CLUTCH COVER CLUTCH DISC AND FLYWHEEL DISMOUNTING REMOUNTING Refer to SECTION 7A Dismounting Remounting of Trans Unit REMOVAL 1 Hold flywheel stationary with special tool A and remove clutch cover bolts clutch cover and clutch disc Special Tool A 09924 17810 2 Pull out input shaft bearing by using special tool B and wrench Special Tool B 09917 58010 G16 engine B 09923 73210 J20 and H25 engi...

Page 492: ...s found to have reached service limit at any of holes replace disc assembly Rivet head depth Standard 1 6 mm 0 06 in Service limit 0 5 mm 0 02 in Clutch Cover 1 Check diaphragm spring for abnormal wear or damage 2 Inspect pressure plate for wear or heat spots 3 If abnormality is found replace it as assembly Do not disas semble it into diaphragm and pressure plate Flywheel Check surface contacting ...

Page 493: ... lb ft G16 engine a 70 N m 7 0 kg m 50 5 lb ft J20 and H25 engines 2 Using special tool B install input shaft bearing to flywheel Special Tool B 09925 98210 3 Aligning clutch disc to flywheel center by using special tool C install clutch cover and bolts Then tighten bolts to specification NOTE While tightening clutch cover bolts compress clutch disc with special tool C by hand so that disc centere...

Page 494: ...25010 Then install release fork and release bearing as shown in figure 5 Slightly apply grease to input shaft and install clutch disc Then join transmission transfer assembly with engine Refer to SEC TION 7A B Grease 99000 25210 NOTE Turn crankshaft with wrench from front while inserting transmission input shaft to clutch disc until splines mesh ...

Page 495: ...lywheel bolts G16 engine 78 7 8 56 5 Flywheel bolts J20 and H25 engines 70 7 0 50 5 Clutch cover bolts 23 2 3 16 5 Operating cylinder bolt 50 5 0 36 5 Clutch hose union bolt 23 2 3 16 5 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Clutch master cylinder clevis pin Release fork Push rod tip of operating cylinder SUZUKI SUPER GRE...

Page 496: ...e center of the output rear shaft Also with a synchronizer installed to the front drive clutch it is possible to change the drive mode between 2WD high speed only and 4WD high speed only even while running The front drive shift fork has an auxiliary spring to make a smooth shift from 4H to 2H possible The case has an oil gutter and a plate at synchronizer to provide proper lubrication even under t...

Page 497: ...nosis table Condition Possible Cause Correction Gear slipping out of mesh Worn shift fork shaft Worn shift fork or synchronizer sleeve Weak or damaged locating spring Worn bearings on output rear shaft Worn chamfered tooth on sleeve or gear Missing or disengagement of circlip s Replace Replace Replace Replace Replace sleeve and gear Install Gears refusing to disengage Weakened or broken synchroniz...

Page 498: ...al lip A Grease 99000 25010 Special Tool A 09940 53111 6 Clean and inspect sliding portion of propeller shaft front end where oil seal contacts before installation and if even small dent or scratch exists correct and clean it again Then apply grease inside splines of propeller shaft B Grease 99000 25010 7 Install propeller shaft and torque universal joint flange bolts to specification CAUTION Be s...

Page 499: ...nsor from transfer INSTALLATION 1 Make sure that O ring and speed sensor have not been dam aged 2 Inspect speedometer driven gear for abnormal wear of gear teeth or bend of shaft portion and replace it if necessary 3 Make sure its smooth rotation 4 Install speed sensor assembly to transfer and connect coupler as it was Tightening Torque a 6 N m 0 6 kg m 4 5 lb ft ENGINE REAR MOUNTING Refer to ON V...

Page 500: ...tween engine and dash panel so that it serves as stopper when engine transmission and transfer unit hangs down as rear mounting member is removed CAUTION Make sure to use wood block to prevent contact which may occur between dash panel and CMP sensor case G16 CMP sensor J20 or intake manifold H25 and fan and shroud IN CABIN 1 Remove console box 2 Remove shift lever of transmission and transfer ON ...

Page 501: ...n jack to transfer to support it 3 Remove couplers for 4WD 4WD LOW switches lead 4 Remove transfer front case bolts 5 With transfer assembly supported with transmission jack slide it rearward and when it is apart from transmission lower it REMOUNTING For remounting reverse dismounting procedure described above noting following Be sure to use specified torque for tightening Clamp wiring and breathe...

Page 502: ...ing torque Fastening ortion N m kg m lb ft Oil filler level and drain plugs 23 2 3 17 0 Engine rear mounting bolts 50 5 0 36 5 Universal joint flange bolts 50 5 0 36 5 Speed sensor bolt 6 0 6 4 5 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips and O rings Splines of propeller shaft Select return system Shift control ...

Page 503: ...ure between bevel pinion and gear it is mandatory to lu bricate them by hypoid gear oil SECTION 7E DIFFERENTIAL FRONT CONTENTS GENERAL DESCRIPTION 7E 1 4WD CONTROL SYSTEM 7E 2 DIAGNOSIS 7E 5 DIAGNOSIS TABLE 7E 5 Differential Assembly 7E 5 4WD Control System Diagnostic Flow Table 7E 5 4WD CONTROL CIRCUIT INSPECTION 7E 7 ON VEHICLE SERVICE 7E 9 MAINTENANCE SERVICE 7E 9 Gear Oil Change 7E 9 INSPECTIO...

Page 504: ...dels or 4WD controller H25 engine model actuates energizes the air pump assembly Then positive pressure is sent from the air pump assembly to the actuator installed to the differential case and causes the axle lock clutch and the free axle hub in the differential case to be engaged resulting in the 4WD mode Only when running in the 4WD mode front axles are joined to differential case and they beco...

Page 505: ...Release valve 5 Pressure switch 6 Transfer 7 Front differential 8 Air hose and pipe 9 4WD indicator lamp 10 To ignition switch 11 ECM or PCM Operation refer to Components and Functions Power supply from ECM or PCM DIFFERENTIAL FRONT 7E 3 System Circuit and Operation ...

Page 506: ... to 4H or 4L so that the positive pressure is applied to the actuator and opens when N or 2H to release the pressure to the atmosphere Pressure switch Turns ON and OFF depending on the pressure level in the pump assembly whether higher or lower than the set pressure level ECM or PCM detects the pressure level through this switch Differential case assembly Free axle hub Axle lock clutch Actuator Th...

Page 507: ... Repair and replenish Repair and replenish Replace Replace Oil leakage Worn or damaged oil seal Excessive oil Loose differential carrier bolts Replace Adjust oil level Replace or retighten 2WD 4WD switching error Defective actuator Abnormality in 4WD control system Replace Inspect referring to 4WD CONTROL SYSTEM DIAG NOSTIC FLOW TABLE 4WD Control System Diagnostic Flow Table Before performing the ...

Page 508: ...transfer shift lever is in 4L or 4H 10 14 V Is the check result satisfactory Go to step 4 Check R circuit If it is OK substitute a known good ECM PCM and recheck 4 Check air pump assembly circuit 1 Check for proper connection to air pump assembly at all terminals 2 Turn ignition switch ON 3 Check voltage between C51 2 27 and C51 3 17 ground for G16 J20 C51 1 18 and C51 3 26 ground for H25 The chec...

Page 509: ...ift lever 2H or N E61 19 4WD Indicator lamp Or B 0 1 V 4 seconds after transfer shift lever shifted to 4H or 4L C51 2 Air pump assembly 0 1 V Transfer shift lever 2H or N C51 2 7 Pump motor and release valve R 10 14 V 1 seconds after transfer shift lever shifted to 4H or 4L C51 2 4WD switch B Or 10 14 V Transfer shift lever 2H or N 18 4WD switch B Or 0 1 V Transfer shift lever 4H or 4L C51 3 17 Gr...

Page 510: ...ed to 4H or 4L C51 1 Air pump assembly 0 1 V Transfer shift lever 2H or N C51 1 15 Pump motor and release valve R 10 14 V 1 seconds after transfer shift lever shifted to 4H or 4L C51 1 4WD switch B Or 10 14 V Transfer shift lever 2H or N 11 4WD switch B Or 0 1 V Transfer shift lever 4H or 4L C51 3 26 Ground B Bl 0 1 V C51 1 Air pump assembly 0 1 V Transfer shift lever 2H or N C51 1 18 Air um assem...

Page 511: ...rential It is highly recommended to use 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 Drain old oil and pour proper amount of gear oil as specified be low roughly up to level hole 4 Apply sealant to thread of drain plug b and torque plugs to specifica...

Page 512: ... lever from 2H to 4H range 3 Check that motor starts running a sound can be heard within 1 second and it stops when gauge of special tool indicates speci fied pressure value Check also for air leakage Pressure specification 30 0 45 0 kPa 0 30 0 45 kg cm2 4 25 6 40 psi 4 Check that pressure value indicated on gauge of special tool drops as soon as transfer lever is shifted to 2H position 5 Start mo...

Page 513: ...eding 200 kPa 2 0 kg cm2 28 4 psi which may cause damage to diaphragm 3 With the vehicle lifted so that both of the front wheels are off the ground turn one of the front wheels by hand and check the other wheel which should act as described below When the pressure from compressor is applied to actuator The other front wheel should turn in the direction opposite to the wheel being turned by hand Wh...

Page 514: ...sting screw of special tool as far as it stops and close its air check side opening by using fuel hose as blind plug Special Tool A 09918 18110 3 Check that motor starts to run a sound can be heard when bat tery is connected and it stops when specified pressure is ob tained Check also for air leakage Specified pressure 30 0 45 0 kPa 0 30 0 45 kg cm2 4 25 6 40 psi 4 Check that value indicated on vo...

Page 515: ...rential Mountings 1 Lift up vehicle and turn steering wheel all way to the right 2 Separate mounting bracket R from differential housing by re moving bolts from its lower part 3 Remove mounting bracket R by removing mounting front bolt from its upper part 4 Remove mounting bracket L by removing upper and lower fas tening bolts 5 Check conditions of each bush If it is damaged or deteriorated drive ...

Page 516: ...wing torque for reinstallation Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft b 50 N m 5 0 kg m 36 5 lb ft REAR MOUNTING For front differential carrier 1 Lift up vehicle and remove mounting assembly by removing 2 bolts and nuts from differential carrier side and 2 bolts from cross member side 2 Check mounting rubber for damage or deterioration and replace as necessary 3 Use following torque for re...

Page 517: ...tch marks on joint flange and propeller shaft as shown 4 Remove propeller shaft flange by removing its 4 bolts and sus pend it with cord or the like NOTE If pull out propeller shaft transfer oil must be drained be fore pulling out 5 Remove 3 bolts for left mounting bracket and 3 bolts for drive shaft flange to set left side of differential free 6 Remove 2 bolts from cross member to set differentia...

Page 518: ...int from differential and dismount housing assembly from vehicle CAUTION During above work use care not to cause damage to drive shaft boot REMOUNTING For remounting reverse dismounting procedure and use following tightening torque Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft After tightening all fasteners properly fill hypoid gear oil as speci fied and check tightening of plugs with specificati...

Page 519: ...portion Tightening torque Fastening ortion N m Kg m lb ft Differential oil filler level plug 23 2 3 17 0 Differential oil drain plug 23 2 3 17 0 Differential mounting front bolts 85 8 5 61 5 Differential mounting bracket bolts 50 5 0 36 5 Front drive shaft flange bolts 50 5 0 36 5 Propeller shaft flange bolts 50 5 0 36 5 Pump assembly bolts 13 1 3 9 5 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED...

Page 520: ...m by hypoid gear oil SECTION 7F DIFFERENTIAL REAR CONTENTS GENERAL DESCRIPTION 7F 1 DIAGNOSIS 7F 2 ON VEHICLE SERVICE 7F 3 Maintenance Service 7F 3 Dismounting 7F 4 Remounting 7F 5 UNIT REPAIR 7F 5 TIGHTENING TORQUE SPECIFICATIONS 7F 6 REQUIRED SERVICE MATERIALS 7F 6 GENERAL DESCRIPTION The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle It is set in the co...

Page 521: ...gear s or side pinion s Repair and replenish Repair and replenish Adjust as prescribed Adjust or replace Replace or retighten Replace Bearing noise Constant noise Deteriorated or water mixed lubricant Constant noise Inadequate or insufficient lubricant Noise while coasting Damaged bearing s of bevel pinion Noise while turning Damaged diff side bearing s or axle bearing s Repair and replenish Repai...

Page 522: ...poid gear oil must be used for differential It is highly recommended to use 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 Drain old oil and pour proper amount of gear oil as specified roughly up to level hole 4 Torque drain and level filler plugs to s...

Page 523: ...l housing 2 Remove rear brake drums and pull out right and left rear axle shafts Refer to rear axle shaft removal of SECTION 3E 3 Before removing propeller shaft give match marks on joint flange and propeller shaft as shown 4 Remove propeller shaft by removing its 4 flange bolts and nuts 5 Remove differential assembly by removing its 8 fastening nuts ...

Page 524: ...ng Torque a 55 N m 5 5 kg m 40 0 lb ft 3 Install propeller shaft to joint flange aligning match marks and torque flange bolts to specification Tightening Torque a 50 N m 5 0 kg m 36 5 lb ft 4 Install right and left rear axle shafts and drums Refer to rear axle installation of SECTION 3E and rear brake drum installation of SECTION 5 5 Install wheels 6 Fill hypoid gear oil as specified and tighten p...

Page 525: ...ller level plug 50 5 0 36 5 Differential oil drain plug 28 2 8 20 5 Propeller shaft flange bolts 50 5 0 36 5 Differential carrier nuts 55 5 5 40 0 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND NO 1215 99000 31110 Rear differential oil drain plug Mating surface of differential housing Mating surface of rear axle housing ...

Page 526: ...llow 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 must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in th...

Page 527: ...tery terminals for inspection or service works on the electric systems always confirm first that the ignition switch and all the other switches have been turned OFF Other wise the semi conductor part may be damaged When disconnecting cables from the battery be sure to discon nect the one from the negative terminal first and then the other from the positive terminal Reverse the above order when con...

Page 528: ...t by any other part To avoid damage 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 Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire Always be careful not to handle electrical parts computer relay etc in a r...

Page 529: ...e the heat sensitive electrical part s beforehand D Use care not to expose connectors and electrical parts to water which will be a cause of a trouble D When using a tester for checking continuity or measuring voltage be sure to insert the tester probe from the wire harness side SYMBOLS AND MARKS Refer to Section 8A ABBREVIATIONS Refer to Section 8A ...

Page 530: ...olored striped wire The single colored wire uses only one color symbol i e G The dual colored wire uses two color symbols i e G Y The first 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 JOINT CONNECTOR J C Wiring of this vehicle employs joint connector J C which divide one wire into several different wires or ...

Page 531: ...YH4 GRAND VITARA 8 6 BODY ELECTRICAL SYSTEM POWER SUPPLY DIAGRAM Refer to Section 8A ...

Page 532: ...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 cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CONTENTS GENERAL DESCRIPTION 8B 2 Cautions in Servicing 8B 2 Symbols and Marks 8B 2 Wiri...

Page 533: ...ket 7 Position light bulb socket 8B 2 LIGHTING SYSTEM GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8 SYMBOLS AND MARKS Refer to Section 8 WIRING COLOR SYMBOLS Refer to Section 8 ABBREVIATIONS Refer to Section 8 JOINT CONNECTOR Refer to Section 8 FUSE BOX AND RELAY Refer to Section 8 POWER SUPPLY DIAGRAM Refer to Section 8 HEADLIGHTS ...

Page 534: ...ling switch 2 Headlight leveling unit actuator 3 Headlight 4 Headlight leveling unit shaft Switch Position Headlight beam down angle 0 1 0 624_ 2 1 243_ 3 1 867_ 4 2 479_ LIGHTING SYSTEM 8B 3 HEADLIGHT WITH LEVELING SYSTEM IF EQUIPPED ...

Page 535: ...e or replace battery One of headlights either Right or Left does not move Socket wiring or grounding faulty Actuator faulty Vehicle body around headlight deformed Headlight ass y itself deformed Repair Replace actuator Repair body Replace headlight ass y TURN SIGNAL AND HAZARD WARNING LIGHTS Trouble Possible cause Correction Flash rate high or one side only flashes Incorrect bulb One of light bulb...

Page 536: ... Model Bulb s blown Brake light switch faulty Wiring or grounding faulty Replace fuse to check for short Replace bulb s Adjust or replace switch Repair Brake lights stay on Brake light switch faulty Adjust or replace switch Only one light does not light Bulb blown Wiring or grounding faulty Replace bulb Repair REAR FOG LIGHT IF EQUIPPED Trouble Possible cause Correction Rear fog light does not com...

Page 537: ...ch EL T H W G R OFF SMALL HEAD Dimmer Passing Switch ED HL HU HF W B R W R R B Passing PASS Low Beam High Beam HI REMOVAL AND INSTALLATION For vehicle without air bag system refer to Section 3C COMBINA TION SWITCH and for vehicle with air bag system refer to Section 3C1 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY REMOVAL 1 Disconnect negative cable at battery 2 Remove front grille 3 Disconnect ha...

Page 538: ...herwise obligated by local regulations adjust headlight aiming according to following procedure After replacing headlight be sure to perform its aiming When inspecting and adjusting headlight with leveling sys tem make sure to set the leveling switch to 0 position with IG switch ON Before adjustment make sure the following a Place vehicle on a flat surface in front of blank wall as below ahead of ...

Page 539: ...btained it means the switch is defective Replace it with a new one LEVELING ACTUATOR INSPECTION All headlight system couples connected including leveling actuator and switch and at Ignition switch ON listen to the leveling actuator sound on both actuators according to the movement of the leveling switch If no sound is heard with the movement of the leveling switch replace headlight assembly ...

Page 540: ...heck result is not as specified replace switch TL TB TR G R G G Y L N R REMOVAL AND INSTALLATION Refer to Section 3C COMBINATION SWITCH for vehicle without air bag system and Section 3C1 CONTACT COIL AND COMBINA TION SWITCH ASSEMBLY for vehicle with air bag system HAZARD SWITCH REMOVAL 1 Remove meter cluster 2 Pull hazard switch out of instrument panel 3 Disconnect coupler from hazard switch 4 Rem...

Page 541: ...AND VITARA 8B 10 LIGHTING SYSTEM 1 Hazard relay 2 Junction box 3 Fuse box Type A Type B 3 3 2 HAZARD RELAY INSPECTION Connect battery and tester as shown Unless a continued click sound is heard replace relay ...

Page 542: ...ity between terminals at each switch position shown below Hold the switch button ON or OFF pushed in during checking switch NOTE Rear fog light lights up only when headlights low or high beams or front fog lights if equipped are ON Rear fog lights turns OFF automatically when headlights or front lights are turned OFF ...

Page 543: ...Door Switch 8C 13 Seat Belt Warning Light If Equipped 8C 13 SECTION 8C INSTRUMENTATION DRIVER INFORMATION WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system...

Page 544: ...ped 14 High beam light 15 Oil pressure warning light 16 Charge warning light 17 Brake and parking brake warning light 18 POWER indicator light A T vehicle only 19 Shift position indicator A T vehicle if equipped or CHECK ENGINE or ABS 8C 2 INSTRUMENTATION DRIVER INFORMATION GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8 SYMBOLS AND MARKS Refer to Section 8 WIRING COLOR SYMBOLS Refer ...

Page 545: ... B Coupler C Coupler A Coupler B Coupler C 1 Blank 2 Blank 3 To ignition switch B W 4 Blank 5 To ABS control module Bl O if equipped 6 To PCM A T vehicle only Gr Bl 7 To ABS control module Br if equipped 8 To VSS Bl Y 9 To combination switch G R 10 To SDM if equipped Y G or Bl 11 To main fuse W Bl 12 To fuse box W 13 To combination switch R 14 To ECM PCM for A T vehicle V if equipped 15 To ECM PCM...

Page 546: ...er faulty Fuel meter faulty Wiring or grounding faulty Replace fuse to check for short Replace fuel gauge unit Replace printed plate Replace fuel meter Repair ENGINE COOLANT TEMP ECT METER AND SENSOR Trouble Possible Cause Correction Engine coolant temp meter shows no operation IG METER fuse blown Hard Top Model IG fuse blown Canvas Top Model ECT meter faulty Printed plate in combination meter fau...

Page 547: ...rrection Seat belt warning light does not light up Bulb in combination meter blown IG METER fuse blown Hard Top Model IG fuse blown Canvas Top Model Seat belt switch faulty Wiring or grounding faulty Replace bulb Replace fuse to check for short Replace seat belt switch Repair IGNITION KEY REMAINDER WARNING BUZZER IF EQUIPPED Trouble Possible Cause Correction Ignition key remainder warning buzzer s...

Page 548: ... IG1 2 IG2 ST L1 L2 K1 K2 W Y Bl B W B W Y B B Y B B G G OUT LOCK LOCK ACC IN ON START REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B of this manual 3 Remove steering column referring to Section 3C1 of this manu al Then remove steering lock ignition main switch from steer ing column INSTALLATION 1 Install steering lock ignit...

Page 549: ... 10B of this manual 3 Remove column hole cover 4 Remove instrument cluster panel 5 Remove screws fastening combination meter 6 Disconnect couplers from combination meter 7 Remove combination meter from instrument panel INSTALLATION Reverse removal procedure for installation noting the following If the vehicle is equipped with air bag system be sure to enable air bag system after installation Refer...

Page 550: ...N DRIVER INFORMATION SPEEDOMETER AND VSS VEHICLE SPEED SENSOR VSS REMOVAL 1 Hoist vehicle 2 Disconnect coupler from VSS 1 3 Remove VSS INSTALLATION Reverse removal procedure for installation Tightening Torque a 5 5 N m 0 55 kg m 4 0 lb ft ...

Page 551: ...tion switch ON and check that bulb light up and pointer 5 moves to F side 8 If fuel meter shows no operation repair or replace defective parts FUEL SENDER GAUGE INSPECTION 1 Remove fuel pump assembly 1 referring to FUEL PUMP RE MOVAL in Section 6C 2 Check resistance between terminals A and B under each float position Float Position Fuel Resistance 56 model 66 model Meter Resistance a 88 3 mm 3 48 ...

Page 552: ...at ECT meter indicates COOL 3 Turn ignition switch OFF 4 Ground Y W lead wire through a 3 4 W test bulb 1 as illustrated 5 Turn ignition switch ON and check that bulb light up and pointer 2 moves to hot side 6 If ECT meter shows no operation repair or replace defective parts ENGINE COOLANT TEMPERATURE ECT SENSOR REMOVAL AND INSTALLATION Refer to ECT SENSOR in ON VEHICLE SERVICE in Section 6E1 for ...

Page 553: ...sult is not as specified replace sen sor Temperature Resistance 50_C 122_F 136 216 OIL PRESSURE LIGHT OIL PRESSURE SWITCH REMOVAL AND INSTALLATION Refer to OIL PRESSURE CHECK in Section 6A1 for G16 Section 6A2 for H25 and Section 6A4 for J20 of this manual for details INSPECTION 1 Disconnect oil pressure switch 1 lead wire 2 Check for continuity between oil pressure switch terminal 2 and cylinder ...

Page 554: ... Continuity PARKING BRAKE SWITCH INSPECTION Check switch 1 for continuity If check result is not as specified replace switch OFF position parking brake lever released No continuity ON position parking brake lever pulled up Continuity IGNITION KEY REMAINDER IF EQUIPPED LIGHT REMAINDER WARNING BUZZER REMOVAL 1 Remove combination meter 1 Refer to COMBINATION ME TER in this section 2 Remove buzzer uni...

Page 555: ...osition Door closed No continuity ON position Door open Continuity SEAT BELT WARNING LIGHT IF EQUIPPED SEAT BELT BUCKLE SWITCH INSPECTION Check for continuity between seat belt buckle switch terminal A and B at following condition Buckle out seat belt not fastened Continuity Buckle in seat belt fastened No Continuity If seat belt buckle switch does not follow the above condition re place seat belt...

Page 556: ...ed 8D 20 Power Door Lock and Keyless Entry System If Keyless Entry is Equipped 8D 23 Power Door Mirror Control System 8D 30 Door Mirror Heater If Equipped 8D 31 Power Sliding Roof If Equipped 8D 32 Front Seat Heater If Equipped 8D 33 SECTION 8D WINDOWS MIRRORS SECURITY AND LOCKS WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system compon...

Page 557: ...SCRIPTION CAUTIONS IN SERVICING Refer to Section 8 SYMBOLS AND MARKS Refer to Section 8 WIRING COLOR SYMBOLS Refer to Section 8 ABBREVIATIONS Refer to Section 8 JOINT CONNECTOR Refer to Section 8 FUSE BOX AND RELAY Refer to Section 8 POWER SUPPLY DIAGRAM Refer to Section 8 WINDSHIELD WIPER AND WASHER FRONT WIPER AND WASHER ...

Page 558: ...YH4 GRAND VITARA Rear Wiper Switch Rear Wiper Intermittent Relay Rear Wiper Assembly WINDOWS MIRRORS SECURITY AND LOCKS 8D 3 REAR WIPER AND WASHER IF EQUIPPED ...

Page 559: ...r Lock Switch Back Door Actuator except Canvas Top Model Rear Door Actuator Front Door Actuator Fuse box Power Door Lock and Keyless Entry if equipped Controller Hard Top Model Keyless Entry Transmitter If keyless entry is equipped The illustration shows LH steering vehicle And RH steering vehicle is symmetrical POWER DOOR LOCK AND KEYLESS ENTRY IF EQUIPPED SYSTEM ...

Page 560: ...er switch faulty Wiring faulty Clean or repair clogged hose or nozzle Replace fuse to check for short Replace motor Replace switch Repair REAR WINDOW DEFOGGER IF EQUIPPED Trouble Possible cause Correction Defogger does not work REAR DEFG fuse blown Defogger switch faulty Defogger heat wire faulty Wiring or grounding faulty Replace fuse to check for short Replace switch Repair heat wire Repair POWE...

Page 561: ...troller faulty Wiring or grounding faulty Replace fuse to check for short Replace controller Repair All power doors are not locked unlocked by only power door lock switch Power door lock switch faulty Wiring or grounding faulty Replace switch Repair All power doors are not locked unlocked by only driver side door key switch Driver side door key switch faulty Wiring or grounding faulty Replace swit...

Page 562: ...itch faulty Wiring or grounding faulty Replace switch Repair All power doors are not locked unlocked by only driver side door key switch Driver side door key switch faulty Wiring or grounding faulty Replace switch Repair All power doors are not locked unlocked by only keyless entry transmitter Code registration error Transmitter battery dead Transmitter faulty Power door lock and keyless entry sys...

Page 563: ...conflicts Install correctly Sliding roof does not operate sliding roof motor does not run SUN ROOF fuse blown Sliding roof switch faulty Sliding roof motor ass y faulty Wiring or grounding faulty Replace fuse to check for short Replace switch Replace motor Repair FRONT SEAT HEATER IF EQUIPPED Trouble Possible cause Correction Both seat back and cushion do not become hot although seat heater switch...

Page 564: ...ch B3 2 1 As B3 2 1 As OFF B3 W INT B3 W LO OFF HI ON REMOVAL AND INSTALLATION For vehicle without air bag system refer to Section 3C COMBINA TION SWITCH and for vehicle with air bag system refer to Section 3C1 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY Wiper Motor 1 As illustrated use a 12 V battery to connect its terminal to ter minal A and its terminal to Black lead wire 2 Type A B or termina...

Page 565: ...let the motor stop c Connect terminal A and D with a jumper wire 3 and con nect terminal C to battery terminal Observe the motor turns once again then stops at a given position d Repeat a thru c several times and inspect if the motor stops at the given position every time Washer Pump Connect battery and terminals to pump and terminals respectively to check pumping rate Check for both front 3 and r...

Page 566: ...minal to terminal B3 and battery negative terminal to terminal E 6 Connect voltmeter positive lead to terminal 1 and negative lead to terminal E Check that the voltmeter indicates the battery voltage 10 14 V 7 Connect terminal As and terminal B3 by a jumper wire Then move jumper wire end connected to terminal B3 to terminal E Observe the voltmeter voltage drops to 0 V right after connecting the ju...

Page 567: ... 2 Disconnect combination switch lead wire coupler 3 Make sure that front wiper switch is at OFF position 4 Connect battery positive terminal to terminal B3 and battery negative terminal to terminal E 5 Connect voltmeter positive lead to terminal 1 and negative lead to terminal E 6 Pull washer switch and check that voltage changes as shown in the table Washer switch Voltmeter ...

Page 568: ...re coupler 3 Check for continuity between terminals at each switch position as shown below If check result is not as specified replace switch Rear Wiper Switch BR INT IR BR INT IR OFF INT ON Rear Washer Switch BR WR BR WR OFF ON Washer Pump Refer to FRONT WIPER AND WASHER INSPECTION in this sec tion Wiper Motor 1 TESTING WIPER MOTOR As shown left use a 12 V battery to connect its and termi nals to...

Page 569: ...of relay If measured voltage is battery voltage relay is in good condition If not replace relay 2 Connect positive terminal of battery to terminal 2 of relay then disconnect positive terminal from terminal 4 of relay and check voltage between terminals 6 and 5 of relay If measured voltage is battery voltage relay is in good condition If not replace relay 3 Disconnect positive terminal from termina...

Page 570: ...terminal to terminal 3 of relay checking voltage between terminals 6 and 5 of relay If measured voltage changes from about 0 V to battery voltage when connecting positive terminal to terminal 3 relay is in good condition If not replace relay 2 Connect positive terminal of battery to terminal 2 of relay then disconnect positive terminal from terminal 2 of relay checking voltage between terminals 6 ...

Page 571: ...ong wire direction When cleaning glass do not use detergent or abrasive con taining 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 Checking wire damage a Turn main switch ON b Turn defogger switch ON c Use a voltmeter to check voltage at the center of each heat wire as shown Voltage Criteria ...

Page 572: ...es from zero to several volts is where there is damage NOTE If heat wire is free from damage voltmeter should indicate 12 V at heat wire positive terminal end and its indication should decrease gradually toward zero at the other terminal ground REPAIR DEFOGGER CIRCUIT 1 Use white gasoline for cleaning 2 Apply masking tape at both upper and lower sides of heat wire to be repaired 3 Apply commercial...

Page 573: ...ow Driver Side Passenger Side Window Lock Window Switch 2 g Window Switch 3 Lock Switch 1 C H G A C E B A A F UP UP OFF OFF OFF OFF DOWN DOWN UP UP ON OFF ON OFF DOWN DOWN Type 2 LH steering vehicle Window Lock Switch 1 Driver Side Window Switch 2 Passenger Side Window Switch 3 Rear RH Window Switch 4 Rear LH Window Switch 5 Switch 1 K C A B K C E F K C I J K C G H K C A B K C E F K C I J K C G H ...

Page 574: ... 1 Driver Side Window Switch 2 Passenger Side Window Switch 3 Rear RH Window Switch 4 Rear LH Window Switch 5 Switch 1 K C E F K C A B K C I J K C G H K C E F K C A B K C I J K C G H UP UP OFF OFF OFF OFF DOWN DOWN UP UP ON OFF ON OFF DOWN DOWN POWER WINDOW SUB SWITCH Check switch for continuity between terminals as shown below C B E A D C B E A D UP UP OFF OFF DOWN DOWN ...

Page 575: ... operation is heard every time it means that controller is operating POWER DOOR LOCK CONTROLLER HARD TOP MODEL 1 With the driver side door key turned LOCK check all power doors are locked 2 With the driver side door key turned UNLOCK check only the driver side power door is unlocked Turn the driver side door key to UNLOCK again within 5 se conds check all power doors are unlocked If check result o...

Page 576: ...driver side door key switch is OFF position No continuity ground When driver side door key switch is LOCK position Continuity E02 9 and When driver side door key switch is OFF position No continuity ground When driver side door key switch is UNLOCK position Continuity If check result is not satisfactory repair circuit and recheck If check result is satisfactory replace controller KEY CYLINDER SWIT...

Page 577: ...8D 22 WINDOWS MIRRORS SECURITY AND LOCKS POWER DOOR LOCK ACTUATOR 1 Disconnect power door lock actuator coupler 2 Connect 12 V battery positive and negative terminals to the door lock actuator terminals shown below and check operation If it does not operate as specified in table below replace door lock actuator UNLOCK LOCK 2 3 ...

Page 578: ...IAGRAM MANUAL and recheck And go to Step 4 6 Check ignition switch and door switch circuit referring to its INSPECTION in this section Is this circuit OK Replace controller and recheck And go to Step 4 Repair circuit referring to WIRING DIAGRAM MANUAL and recheck And go to Step 4 7 Check power door lock actuator circuit referring to its INSPECTION in this section Is this circuit OK Go to Step 8 Re...

Page 579: ...ors are unlocked If check result of Step 1 and Step 2 is satisfactory this operation is OK KEYLESS ENTRY OPERATION INSPECTION 1 With the IG switch OFF and all doors closed push LOCK button on transmitter Check all power doors are locked 2 Push UNLOCK button on transmitter Check only driver side power door is unlocked 3 Push UNLOCK button on transmitter again within 5 seconds Check all power doors ...

Page 580: ...nd resistance between following termi nals are specifications Terminals Condition Specification E02 7 and ground Anytime 10 14 V E02 14 and ground Anytime Continuity If check result is satisfactory this circuit is OK DOOR LOCK KEY AND POWER DOOR LOCK SWITCH CIRCUIT INSPECTION 1 Disconnect negative cable at battery 2 Disconnect coupler of power door lock and keyless entry con troller 3 Check for co...

Page 581: ...When all doors are closed No continuity E02 10 and ground When any one door is opened Continuity If check result is satisfactory this circuit is OK DOOR KNOB SWITCH AND TURN SIGNAL RELAY CIRCUIT INSPECTION 1 Disconnect negative cable at battery 2 Disconnect coupler of power door lock and keyless entry con troller and connect negative cable at battery 3 Check that the voltage and resistance between...

Page 582: ...LESS ENTRY IS NOT EQUIPPED in this section KEY CYLINDER SWITCH DRIVER SIDE INSPECTION Refer to KEY CYLINDER SWITCH DRIVER SIDE INSPECTION of POWER DOOR LOCK SYSTEM IF KEYLESS ENTRY IS NOT EQUIPPED in this section POWER DOOR LOCK ACTUATOR INSPECTION Refer to POWER DOOR LOCK ACTUATOR INSPECTION of POWER DOOR LOCK SYSTEM IF KEYLESS ENTRY IS NOT EQUIPPED in this section ...

Page 583: ...Replace the battery lithium disc type CR2032 or equivalent so its terminal faces the mark of the transmitter CAUTION Use care not to allow grease or dirt to be attached on the printed circuit board and the battery 3 Close the transmitter firmly 4 Make sure the door locks can be operated with the transmitter NOTE To prevent theft be sure to break the transmitter before discarding it Dispose of the ...

Page 584: ...ch is turned to OFF position 5 Within 10 seconds after the door switch is turned to ON turn the IG switch to ON position and then OFF position 6 Push and hold the LOCK and UNLOCK buttons on transmitter at the same time within 20 seconds after IG switch is turned to OFF position Hold the buttons for at least 5 seconds During this time the driver side door should lock and unlock once 7 Push LOCK or ...

Page 585: ...s not as specified replace mirror switch DOOR MIRROR ACTUATOR 1 Remove garnish from door 2 Disconnect door mirror coupler 3 Check that door mirror operates properly when battery voltage is applied to connector terminals Connect battery positive and negative terminal to the door mirror terminal shown below and check operation If it does not operate as specified in table below replace door mirror as...

Page 586: ...ater switch from instrument panel 2 Check for continuity between terminals at each switch position as shown below If check result is not as specified replace switch MIRROR HEATER IF EQUIPPED 1 Remove garnish from door 2 Disconnect door mirror coupler 3 Check for continuity between terminals a and b If not continuity replace outside mirror ...

Page 587: ...ead lining Refer to Section 9 for detail 2 Remove sliding roof motor assembly 1 3 Connect known good sliding roof switch 2 to sliding roof motor assembly 4 Connect 12 V battery positive terminal to terminal A of motor assembly 1 and battery negative terminal to terminal B of mo tor assembly 1 5 Check that the sliding roof motor 1 runs according to the move ment of the sliding roof switch 2 Sliding...

Page 588: ...result is not as specified replace SEAT HEATER WIRE INSPECTION 1 Confirm that seat heater switch is OFF position 2 Disconnect two couplers of seat heater under the seat cushion If seat under tray is equipped pull out coupler between tray and seat cushion 3 Check for continuity between terminals as shown below If not continuity replace faulty seat heater Hard Top Model Seat heater circuit in seat b...

Page 589: ...ECM Immobilizer Control Module Code Transmitted from Immobilizer Control Module or DLC Circuit Opened Shorted 8G 22 DTC82 P1622 Fault in ECM PCM 8G 23 Inspection of ECM PCM Immobilizer Control Module and Its Circuit 8G 24 Voltage Check 8G 24 Resistance Check 8G 25 ON VEHICLE SERVICE 8G 26 Precautions in Handling Immobilizer Control System 8G 26 Immobilizer Control Module 8G 27 Coil Antenna 8G 27 H...

Page 590: ...ed in memory When the ignition switch is turned ON Immobilizer Control Module tries to read the Transponder code through the coil antenna installed to the steering lock assembly 2 Immobilizer Control Module compares the Transponder code read in 1 and that registered in Immobilizer Con trol Module and checks if they match 3 When it is confirmed that two Transponder codes match each other as describ...

Page 591: ...al arrangement of Immobilizer Control Module coupler Viewed from harness side B R BI BI B B W V Y BI B B W B V W V W BI R SbI B V G V B R Y WIRE SYMBOL WIRE COLOR a b c d e f g h i j k l m n 1 Ignition key with built in transponder 1 1 Coil antenna o p q r IGNITION KEY The ignition key for the immobilizer control system has a built in transponder Each transponder in the key has an each transmittin...

Page 592: ...nosis func tion which is described in On Board Diagnostic System Self Diagnosis Function in this section ECM PCM As main functions ECM PCM not only checks matching of ECM Immobilizer Control Module code but also has an on board diag nostic system self diagnosis function as described in On Board Diagnostic System Self Diagnosis Function in this section For installation position of ECM PCM refer to ...

Page 593: ...g but if the result is normal it remains ON Diagnosis takes about 3 seconds at maximum Vehicle not equipped with monitor coupler With the ignition switch turned ON but the engine at stop regard less of the condition of the electronic fuel injection system ECM PCM indicates whether a trouble has occurred in the immobi lizer control system or not by causing the immobilizer indicator lamp to flash or...

Page 594: ... lies in two or more areas malfunc tion indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diagnosis ter minal is grounded and ignition switch is held at ON position When ECM PCM detects a trouble in both electronic fuel injec tion system and immobilizer control system malfunction indicator lamp indicates trouble codes of both systems alte...

Page 595: ...te not trouble code but normal code it means that an intermittent trouble did occur and has gone In this case check wires and connections carefully again Vehicle not equipped with monitor coupler There are cases where output of diagnostic output terminal and or Suzuki scan tool indicates a diagnostic trouble code represent ing a trouble which occurred only temporarily and has gone In such case it ...

Page 596: ...procedure described in Proce dure after ECM PCM Replacement on p 8G 27 If it is not regis tered the engine would not start and accurate trouble diagnosis would not be assured When Immobilizer Control Module was replaced including when replaced because rechecking by using a known good Immobiliz er Control Module was necessary during trouble diagnosis the Transponder code and ECM Immobilizer Control...

Page 597: ...in Section 6 2 1 Using service wire ground diagnosis switch terminal in monitor coupler See Fig 3 Dose malfunction indicator lamp flash Immobilizer control system is in good condition Go to MALFUNCTION INDICATOR LAMP CHECK in Section 6 3 Dose malfunction indicator lamp flash as Fig 4 Go to Step 4 Go to MALFUNCTION INDICATOR LAMP CHECK in Section 6 4 1 Check DTC stored in immobilizer control module...

Page 598: ...tion Is there any DTC s Go to IMMOBILIZER INDICATOR LAMP CHECK in this section Immobilizer control system is in good condition 3 1 Check DTC stored in immobilizer control module referring to DIAGNOSTIC TROUBLE CODE CHECK IMMOBILIZER CONTROL MODULE in this section Is there any DTC s Go to flow table for DTC No Go to Step 4 4 1 Check DTC stored in ECM PCM referring to DIAGNOSTIC TROUBLE CODE CHECK E...

Page 599: ...trol Module side in Diagnostic Trouble Code Table If voltmeter indicator dose not deflect go to Diagnostic Flow Table A NOTE If abnormality or malfunction lies in two or more areas volt meter indicates applicable codes three times each DIAGNOSTIC TROUBLE CODE DTC CHECK ECM PCM Not using SUZUKI scan tool Vehicle equipped with monitor coupler 1 Using service wire ground diagnostic switch terminal in...

Page 600: ...t or write it down Refer to Suzuki scan tool opera tor s manual for further details NOTE When reading DTC stored in ECM PCM using Suzuki scan tool select ECM from the applications menu and SU ZUKI mode from the communication mode menu dis played on Suzuki scan tool If ECM PCM detects a trouble in both electric fuel injec tion system and immobilizer control system Suzuki scan tool indicates trouble...

Page 601: ... according to DIAGNOSTIC FLOW TABLE corresponding to each code No 21 ECM Immobilizer Control Module code corres onding to each code No 22 Ignition switch circuit 23 Serial data link wire ECM PCM side DTC indicated on Suzuki scan tool DTC indicated by MIL Malfunction Indicator lamp MIL flashing pattern DIAGNOSTIC AREA DIAGNOSIS NO DTC 12 Normal This code appears when it is confirmed that none of ot...

Page 602: ...tic output terminal of immobi lizer diagnostic coupler short If wire and connections are OK substi tute a known good Immobilizer Control Module and recheck NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM PCM and Transponder code and ECM Immobilizer Control Module code in Immobilizer Control Module by performing procedure describ...

Page 603: ...ion meter come ON Go to Step 2 IG fuse blown main fuse blown ignition switch malfunction B W circuit between IG fuse and combination meter or poor coupler connection at combination meter 2 1 Turn ignition switch OFF and disconnect connectors from ECM PCM 2 Check for proper connection to ECM PCM at terminal E61 5 for G16 J20 engine or E61 23 for H25 engine 3 If OK then using service wire ground ter...

Page 604: ...G16 J20 engine For H25 engine G16 J20 Engine H25 Engine TABLE C IMMOBILIZER INDICATOR LAMP CHECK IMMOBILIZER INDICATOR LAMP REMAINS ON AFTER ENGINE STARTS STEP ACTION YES NO 1 1 With ignition switch OFF disconnect couplers from ECM PCM Does immobilizer indicator lamp turn ON at ignition switch ON p wire shorted to ground circuit Substitute a known good ECM PCM and recheck ...

Page 605: ...izer Control Module this DTC is set INSPECTION Register ignition key with built in transponder by using Suzuki scan tool TECH1 cartridge for immobilizer control system and TECH 1A kit and performing following steps 1 Register Transponder code in Immobilizer Control Module by performing procedure described in How to regis ter ignition key section 2 Turn ignition switch OFF then turn it ON and check...

Page 606: ...ntinuity between coil antenna cou pler terminals A and B See Fig 2 Go to Step 3 Coil antenna open 3 Measure resistance between terminals of coil an tenna coupler and body ground See Fig 3 Is it infinity Go to Step 4 Coil antenna shorted to ground 4 1 With coil antenna coupler disconnected dis connect Immobilizer Control Module coupler 2 Measure resistance between coil antenna ter minals of Immobil...

Page 607: ... Module and recheck NOTE After replacing with a known good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM PCM and Transponder code and ECM Immobilizer Control Module code in Immobilizer Control Module by performing procedure described in Procedure after Immobilizer Control Module Replacement section Faulty ignition key 1 Coil antenna coupler 1 1 Coil antenna coupler...

Page 608: ...ed in Immobilizer Control Module match when ignition switch is ON If they do not this DTC is set DTC81 P1623 ECM PCM checks if ECM Immobilizer Control Module code transmitted from Immobilizer Control Module and that registered in ECM PCM match when ignition switch is ON If they do not this DTC is set DTC84 P1620 ECM PCM checks if code transmitted from Immobilizer Control Module and that registered...

Page 609: ...Immobilizer Control Module coupler terminal A4 and body ground with ignition switch turned ON See Fig 1 Is it 10 14V Poor A4 terminal connection If connection is OK substitute a known good Immobilizer Control Module and recheck NOTE After replacing with a know good Immobilizer Control Module register ECM Immobilizer Control Module code in ECM PCM and Transponder code and ECM Immobilizer Control Mo...

Page 610: ...ch turned OFF 2 Is there continuity be tween Immobilizer Control Module cou pler terminal A8 and Data link connector terminal of ECM PCM coupler For posi tions of Data link con nector terminal of ECM PCM coupler refer to Section 6E1 or 6E2 Poor A8 connection Immobilizer Control Module or Poor Data link connector terminal connection ECM PCM If connections are OK substitute a known good ECM PCM or I...

Page 611: ...NO 1 1 Ignition switch OFF 2 Disconnect connectors from ECM PCM 3 Check for proper connection to ECM PCM at all terminals Are they in good condition Substitute a known good ECM PCM and recheck NOTE After replacing with a known good ECM PCM register ECM Immobilizer Control Module code in ECM PCM by performing procedure described in Procedure after ECM PCM Replacement section Repair or replace ...

Page 612: ...ition switch OFF referring to p 8G 24 2 Connect Immobilizer Control Module coupler to Immobilizer Control Module 3 Check voltage at each terminal of coupler connected NOTE As each terminal voltage is affected by the battery voltage confirm that it is 11 V or more when ignition switch is ON TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION A1 Coil antenna 1 0 V A2 Coil antenna 2 0 V Ignition switch ON A3 P...

Page 613: ...CAUTION Never touch terminals of Immobilizer Control Module it self or connect voltmeter or ohmmeter 2 Check resistance between each terminal of coupler discon nected CAUTION D Be sure to connect ohmmeter probe from wire harness side of coupler D Be sure to turn OFF ignition switch for this check D Resistance in table below represents that when parts temperature is 20_C 68_F TERMINAL CIRCUIT NORMA...

Page 614: ...tarting Do not turn ON ignition switch by using ignition key with any type of metal wound around its grip or in contact with it Or the system may detect abnormal condition and prevent engine from starting Do not leave ignition key where high temperature is anticipated High temperature will cause transponder in ignition key to be ab normal or damaged Do not turn ON ignition switch with a radio ante...

Page 615: ...edure for installation NOTE After replacing Immobilizer Control Module be sure to register Transponder code and ECM Immobilizer Control Module code in Immobilizer Control Module and ECM Immobilizer Control Module code in ECM PCM by performing procedure described in Procedure after Immobilizer Control Module Replacement section COIL ANTENNA Removal 1 Disconnect negative cable at battery 2 Remove st...

Page 616: ...d ule is limited to 4 If needed clear all Transponder codes for igni tion key with a built in transponder that have been registered in Immobilizer Control Module by executing the CLR TRANS COD CLEAR TP CODE command in the SELECT MODE menu by using Suzuki scan tool NOTE When CLR TRANS COD CLEAR TP CODE command is executed with the malfunction indicator lamp the lamp for vehicles equipped with the m...

Page 617: ...RANS COD CLEAR TP CODE command is executed with the malfunction indicator lamp the lamp for vehicles equipped with the monitor coupler ON or the im mobilizer indicator lamp the lamp for vehicles not equipped with the monitor coupler ON it remains ON even after execution of that command is over It will start flashing when the ignition switch is turned OFF once and then turned ON after some seconds ...

Page 618: ...ed including when replaced because rechecking by using a known good ECM PCM was necessary dur ing trouble diagnosis register ECM Immobilizer Control Module code in ECM PCM by performing following procedure 1 Perform Steps 1 and 2 described in How to register ignition key section And then turn ignition switch ON 2 Using TECH1 register ECM Immobilizer Control Module code in ECM PCM by executing RECO...

Page 619: ... be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service ...

Page 620: ...7 Door hinge 8 Door open stop 9 Door sealing cover 10 Window regulator handle if equipped 1 Door glass 2 Weatherstrip 3 Opening weatherstrip 4 Window regulator 5 Glass run 9 2 BODY SERVICE GLASS WINDOWS AND MIRROR FRONT DOOR GLASS ...

Page 621: ...ow 4 Remove door trim With inside handle bezel tilted as shown in figure turn door trim 90_ counterclockwise to remove it And disconnect power window switch lead wire at coupler if equipped 5 Remove door inside pull handle bracket 6 Remove door sealing cover 7 Remove door outside weatherstrip Lower window all the way down Then use a tape wrapped putty knife or screwdriver to pry off weatherstrip C...

Page 622: ...g points Tighten glass attaching screws to specified torque Tighten front screw first then rear screw Tightening Torque a 2 5 N m 0 25 kg m 1 8 lb ft When window becomes hard to raise and lower adjust screws to correct tilted glass as shown in figure Adjust equalizer of window regulator so that measurement A and B are equal Secure door sealing cover with adhesive ...

Page 623: ...ON 1 Check regulator sliding and rotating parts for greasing 2 Check rollers for wear and damage 3 Check wire for damage INSTALLATION Reverse removal procedure to install window regulator noting the following point Tighten bolts and nuts according to the order a b c 1 2 3 4 shown in left figure When installing glass check that the top part of the glass contacts the glass run evenly and that the gl...

Page 624: ...e of the adhesive in any way hinders its inherent adhesive property Therefore before the work make sure to read carefully the instruction and description given by the maker of the adhesive to be used and be sure to follow the procedure and observe each precaution throughout the work Should coated surface be scratched or otherwise damaged be sure to repair damaged part or corro sion may start from ...

Page 625: ...s section 6 If necessary remove head lining Refer to HEAD LINING in this section 7 If necessary remove roof trim Refer to ROOF TRIM in this section 8 Remove or cut windshield molding all around until windshield edge comes out 9 Drill hole with eyeletter through adhesive and let piano string through it 10 Cut adhesive all around windshield with piano string When using tool to cut adhesive be carefu...

Page 626: ... SERVICE 11 Using knife smoothen adhesive remaining on body side so that it is 1 to 2 mm thick all around NOTE Before using knife clean it with alcohol or the like to re move oil from it 12 When reusing windshield remove the adhesive from it using care not to damage primer coated surface ...

Page 627: ...en each side end right left of glass and body are even Place glass so that lug of fastener is matched with cut in body and fit fastener Then mark mating marks on glass and body as shown Upper clearance can be adjusted by moving stoppers position 4 Clean contact surfaces of old adhesive paint or bare metal thor oughly If surfaces of paint or bare metal come out apply primer for body with caution no...

Page 628: ...n figure 9 Apply adhesive referring to figure at the left NOTE Start from bottom side of glass Be careful not to damage primer Height of adhesive applied to lower side should be high er than that of other three sides Upper right and left sides Width e Approx 11 mm 0 43 in Height f Approx 17 mm 0 67 in g Approx 25 mm 0 98 in Distance h Approx 16 mm 0 63 in Press glass against body quickly after adh...

Page 629: ... use infrared lamp or like for drying Sudden closing of door before adhesive is completely set may cause glass to become loose or to come off Therefore if door is opened or closed before adhesive is completely set make sure to open all door glasses and use proper care If molding is not securely in place hold it down with a tape until adhesive is completely set Each adhesive has its own setting tim...

Page 630: ...im 9 12 BODY SERVICE REAR DOOR GLASS REMOVAL 1 Remove inside handle bezel 2 Remove inside lock knob and door inside pull handle case fit ting screw 2 1 Window regulator handle if equipped To remove regulator handle pull off snap ring by using a cloth as shown below 3 Remove door trim with inside weatherstrip With inside handle bezel tilted as shown in figure turn door trim 90_ counterclockwise to ...

Page 631: ...ed tool will cause damage to painting 6 Remove glass fitting screws Then down door glass 7 Detach rear part of glass run from center sash 8 Remove door center sash by removing two screws with door glass lowered all the way down 9 When remove partition glass slide to front to remove it 10 Take out glass INSTALLATION Reverse removal sequence to install door glass However be careful of following poin...

Page 632: ...uence to install door window regulator noting following points Tighten regulator base nuts according to the order a b c shown in figure Adjust door window regulator according to following procedure a Loosen three nuts two screws and two bolts b Raise window fully c Tighten three regulator rail nuts according to the order d e f shown in figure and two center sash bolts A d Lower window e Tighten tw...

Page 633: ...ever note the fol lowing NOTE Before applying primer to glass edge install molding ac cording to installing position shown in figure Observe following precautions when applying adhesive along glass edge Adhesive should be applied evenly especially in height Be careful not to damage primer Press glass against body quickly after adhesive is applied Height b 12 mm 0 47 in Width d 16 mm 0 63 in c 8 mm...

Page 634: ...ng precautions when applying adhesive along glass edge Adhesive should be applied evenly especially in height Be careful not to damage primer Press glass against body quickly after adhesive is applied Height b 15 mm 0 59 in Width c 8 mm 0 31 in Width d 16 mm 0 63 in Clearance e 1 mm 0 04 in When replacing back door coat replacement door inside with wax for proper anticorrosive treatment Refer to U...

Page 635: ...al procedure to install door assembly noting follow ing point NOTE When replacing door coat replacement door inside with wax for proper anticorrosion treatment Refer to UNDERCOATING ANTI CORROSION COMPOUND APPLICATION AREA in this section Tighten door hinge bolts and nut to specified torque Tightening torque a 27 N m 2 7 kg m 19 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft Adjust door latch striker positi...

Page 636: ...YH4 GRAND VITARA 9 18 BODY SERVICE REAR DOOR ASSEMBLY REMOVAL INSTALLATION Follow procedures for Front Door removal installation in this sec tion ...

Page 637: ... at its body side as shown WARNING Handling of Back Door Rear Gate Balancer Damper Do not disassemble balancer because its cylinder is filled with gas The gas itself is harmless but it may issue out of the hole together with chips generated by the drill Therefore be sure to wear goggle When discarding removed back door rear gate balanc er damper use a 2 to 3 mm 0 08 to 0 12 in drill to make a hole...

Page 638: ...re wiring harness Secure back door rear gate sealing cover NOTE Use adhesive to seal sealing cover to back door rear gate Adjust back door rear gate latch striker position by referring BACK DOOR LOCK ASSEMBLY INSTALLATION so that back door rear gate is positioned correctly Adjust back door rear gate cushion so that back door rear gate contacts body when closed ...

Page 639: ...adjustment if neces sary Tightening Torque a 10 N m 1 0 kg m 7 5 lb ft Vertical adjustment If only one side right or left of hood is not level with front fender make it level by tightening or loosening hood cushion INSTALLATION Reverse removal procedure to install hood INSPECTION Check that secondary latch operates properly check that second ary latch keeps hood from opening all the way even when ...

Page 640: ...emove fender splush guard H25 engine 3 Remove front fender lining 4 Remove front fender INSTALLATION 1 Remove pad from side body and or fender using care not to damage painted surface 2 Attach new pad cutting appropriately size temporarily and adjust height with a knife so that fender becomes flush with side body 3 Reverse removal procedure for installation NOTE If paint on fender bolt is peeled o...

Page 641: ...tems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as spe cified during reassembly to assure proper retention of these parts Before removing front bumper remove fender lining and disconnect c...

Page 642: ...YH4 GRAND VITARA 9 24 BODY SERVICE 1 Rear bumper 2 Rear bumper screws 3 Rear bumper member REAR BUMPER ...

Page 643: ... c g 1105 mm 43 50 in d g 1319 mm 51 93 in d f 874 mm 34 41 in e g 525 mm 20 67 in e g 857 mm 33 74 in f g 927 mm 36 50 in h i 178 mm 7 01 in h j 133 mm 5 24 in h k 325 mm 12 80 in h l 674 mm 26 54 in h m 803 mm 31 61 in h n 1161 mm 45 71 in h o 1184 mm 46 61 in h p 1190 mm 46 85 in i q 999 mm 39 33 in j q 997 mm 39 25 in k q 824 mm 32 44 in l q 1130 mm 44 49 in m q 1258 mm 49 53 in n q 1483 mm 58...

Page 644: ...1 in h j 677 mm 26 65 in h k 927 mm 36 50 in i i 1344 mm 52 91 in i j 391 mm 15 39 in i k 760 mm 29 92 in j j 1348 mm 53 07 in j k 676 mm 26 61 in l j 961 mm 37 83 in l k 1018 mm 40 08 in a Front bumper installation clip hole b b Front bumper installation hole c c Headlight installation hole d d Headlight installation resin nut hole e e Headlight installation hole f f Front fender installation hol...

Page 645: ...m 42 72 in g o 1099 mm 43 27 in a Garnish installation clip hole b b Front end of front windshield lower installation section c c Front end of front windshield upper installation section d Hole in F door lower hinge at rear e Trim installation clip hole f f Scuff installation hole at rearmost end g g Trim installation hole h h Hole in R door upper hinge in upper part i i Hole in R door lower hinge...

Page 646: ...ower part h Assistant grip installation hole i Trim installation hole j Door striker lower section installation hole k F seat belt installation hole Hole to hole distance a d 1155 mm 45 47 in a g 1090 mm 42 91 in a f 1046 mm 41 18 in b f 1120 mm 44 09 in b g 1140 mm 44 88 in c k 1245 mm 49 02 in d e 1174 mm 46 22 in f j 839 mm 33 03 in g j 918 mm 36 14 in h j 941 mm 37 04 in h k 1189 mm 46 81 in i...

Page 647: ...0 55 in f g 512 mm 20 16 in g h 808 mm 31 79 in g g 1544 mm 60 79 in a Clip hole in the center of head lining rear installation section b b Innermost end of roof panel installation section c Installation hole in upper part of back door striker d Installation hole in uppermost part of upper hinge e Installation hole in uppermost part of lower hinge f f Innermost end of rear floor tail member instal...

Page 648: ...37 64 in a Garnish installation clip hole b b Front end of front windshield lower installation section c c Front end of front windshield upper installation section d Hole in F door lower hinge at rear e Trim installation clip hole f f Scuff installation hole at rearmost end g g Trim installation hole h h 11 jig hole i Installation hole for F seat front inside j Installation hole for F seat rear in...

Page 649: ...m 44 96 in c g 1246 mm 49 06 in d e 1146 mm 45 12 in a Hole in door upper hinge at rear b Hole in door lower hinge at rear c Trim installation clip hole d 7 jig hole e Scuff installation hole rearmost end f Door striker lower section installation hole g F seat belt installation hole BODY SERVICE 9 31 2 door model ...

Page 650: ...f 1029 mm 40 51 in a a Trim installation clip hole b Installation hole in uppermost part of upper hinge c Installation hole in outside part of lower hinge d Installation hole in uppermost part of rear gate striker e e Installation hole in outer upper section of R COMB R L lamp f f Innermost end of rear floor tail member installation section g g Garnish installation clip hole 9 32 BODY SERVICE 2 do...

Page 651: ...and air bag ground terminal for air bag 8 Remove engine hood opener 9 Disconnect couplers which need to be disconnected for removal for instrument panel 10 Remove instrument panel mounting screws 11 Remove instrument panel mounting bolt 12 Remove instrument panel CAUTION For vehicle with Air Bag instrument panel could not be re moved with SDM coupler connected and ground terminal installed Use car...

Page 652: ... m 3 5 kg m 25 5 lb ft b 23 N m 2 3 kg m 17 0 lb ft 1 Cover 2 Coupler b 9 34 BODY SERVICE SEAT FRONT SEAT REMOVAL 1 Disconnect lead wire s at coupler if equipped Remove four mounting bolts fixing front seat to seat rail to remove front seat 2 Disassemble and repair seat as necessary INSTALLATION Reverse removal procedure to install front seat Torque to specifications as shown Tightening Torque a 3...

Page 653: ...DY SERVICE 9 35 REAR SEAT REMOVAL 1 Remove four mounting bolt to remove seat cushion 2 Remove four mounting bolts to remove seat back 3 Disassemble and repair seat as necessary INSTALLATION Reverse removal procedure to install rear seat Torque to specifications as shown Tightening Torque a 35 N m 3 5 kg m 25 5 lb ft ...

Page 654: ...y sealer all joints sealed originally 4 Apply color in areas where color is required such as hem flanges exposed joints and under body components 5 Apply anticorrosion compound penetrative wax 6 Apply undercoating rust proof material PAINT AND COATINGS ANTI CORROSION TREATMENT WARNING Standard shop practices particularly eye protection should be followed during the per formance of the below itemiz...

Page 655: ...e 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 starting sand paper polishing As for drying time follow directions advised on the primer sur facer container 5 Use a wet or dry sand paper No 400 and water to polish the panel lightly 6 Wash the part again 7 Apply color coating to t...

Page 656: ...ar panel 3 Rear wheel housing panel 4 Rear floor panel 5 Tail lower member 6 Center floor panel 7 Front floor panel 8 Center floor member 9 Side sill inner panel 10 Side outer panel A Apply sealant B Brush treatment 9 38 BODY SERVICE SEALANT APPLICATION AREA 4 door model ...

Page 657: ...YH4 GRAND VITARA 1 Cowl top panel 2 Dash panel 3 Cowl front panel 4 Front floor panel 5 Front pillar inner lower panel A Apply sealant B Brush treatment BODY SERVICE 9 39 ...

Page 658: ...VICE 1 Side body inner panel 2 Side body outer panel 3 Back pillar outer panel 4 Front pillar inner panel 5 Roof panel 6 Front pillar upper reinforcement 7 Rear wheel housing panel 8 Fuel inlet box A Apply sealant B Brush treatment ...

Page 659: ...YH4 GRAND VITARA BODY SERVICE 9 41 1 Side body outer panel A Apply sealant B Brush treatment ...

Page 660: ...GRAND VITARA 9 42 BODY SERVICE Sealant width W more than 5 mm between a and b A Apply sealant B Brush treatment C Wipe sealant away 1 Sealant application area 2 Outside of body 2 A Vehicle produced in IWATA ...

Page 661: ... VITARA A Apply sealant B Brush treatment C Wipe sealant away D Role sealant between d and e Sealant width W more than 5 mm between c and d 1 Sealant application area Vehicle produced in IWATA BODY SERVICE 9 43 ...

Page 662: ...YH4 GRAND VITARA A Apply sealant Sealant width W more than 5 mm between c and d Vehicle produced in IWATA 9 44 BODY SERVICE ...

Page 663: ...ITARA Sealant width W more than 5 mm between a and b A Apply sealant 1 Sealant application area 2 Outside of body Be free from protrude of sealant outside from this line Vehicle produced in CAMI BODY SERVICE 9 45 ...

Page 664: ...YH4 GRAND VITARA 9 46 BODY SERVICE Sealant width W more than 5 mm between a and b between c and d A Apply sealant 1 Sealant application area Vehicle produced in CAMI ...

Page 665: ... Side body inner panel 2 Rear wheel housing panel 3 Rear floor panel 4 Center floor panel 5 Front floor panel 6 Center floor member 7 Side sill inner panel A Apply sealant B Brush treatment BODY SERVICE 9 47 2 DOOR MODEL ...

Page 666: ...YH4 GRAND VITARA 9 48 BODY SERVICE 1 Cowl top panel 2 Dash panel 3 Cowl front panel 4 Front floor panel 5 Front pillar inner lower panel A Apply sealant B Brush treatment ...

Page 667: ...ont pillar inner panel 4 Front pillar upper reinforcement 5 Rear wheel housing panel 6 Fuel inlet box 7 Center pillar reinforcement 8 Center pillar joint outer panel 9 Center pillar joint inner panel 10 Tail upper member 11 Back pillar outer panel A Apply sealant B Brush treatment C Wipe ...

Page 668: ...YH4 GRAND VITARA 9 50 BODY SERVICE Sealant width W more than 5 mm Be free from protrude of sealant outside from this line A Apply sealant ...

Page 669: ...ax hot wax 50 mm or more B Apply rust proof wax high viscosity wax 50 mm or more 1 Side body outer 2 Side sill inner 3 Frame 4 Main floor 5 Rear fender 6 Rear wheel housing 7 Center floor BODY SERVICE 9 51 UNDERCOATING ANTI CORROSION COMPOUND APPLICATION AREA 4 door model ...

Page 670: ...applying of under coating B for 5 door vehicle without splush guard C Apply PVC chip resistant material 200 m or more 1 Side body outer 2 Side sill inner 3 Main floor 4 Front fender 5 Front wheel housing 6 Frame 7 Dash panel 8 Center floor 9 Rear floor Vehicle produced in IWATA VIEW Z 9 52 BODY SERVICE ...

Page 671: ... applying of under coating B for 5 door vehicle without splush guard C Apply PVC chip resistant material 200 m or more 1 Side body outer 2 Side sill inner 3 Main floor 4 Front fender 5 Front wheel housing 6 Frame 7 Dash panel 8 Center floor 9 Rear floor Vehicle produced in CAMI VIEW Z BODY SERVICE 9 53 ...

Page 672: ...YH4 GRAND VITARA 9 54 BODY SERVICE a 240 mm 9 45 in b 20 mm 0 79 in c 40 mm 1 57 in d 134 mm 5 28 in e 177 mm 6 97 in A Black paint A e Vehicle produced in CAMI ...

Page 673: ...YH4 GRAND VITARA BODY SERVICE 9 55 B B C C 2 DOOR MODEL ...

Page 674: ... 400 mm or more B Additional applying of under coating B for 5 door vehicle without splush guard C Apply PVC chip resistant material 200 mm or more 1 Side body outer 2 Side sill inner 3 Main floor 4 Front fender 5 Front wheel housing 6 Frame 7 Dash panel 8 Center floor 9 Rear floor B B A A C C VIEW Z ...

Page 675: ...YH4 GRAND VITARA BODY SERVICE 9 57 a 240 mm 9 45 in b 20 mm 0 79 in c 40 mm 1 57 in d 134 mm 5 28 in e 177 mm 6 97 in A Black paint VIEW A VIEW B VIEW C VIEW D ...

Page 676: ...ime Proper dry ing temperature range is 60 to 70_C Reference Plastic parts employ not only ABS Acrylonitrile Butadiene Styrene plastic but also polypropylene vinyl or the like plastic Burning test method to identify ABS plastic is described below 1 Use a sharp blade to cut off a plastic sliver from the part at its hidden backside 2 Hold sliver with pincers and set it on fire 3 Carefully observe co...

Page 677: ...d 3 SECURITY AND LOCKS FRONT DOOR LOCK ASSEMBLY REMOVAL 1 Raise window all the way up 2 Remove door trim and door sealing cover refer to steps 1 to 6 of FRONT DOOR GLASS REMOVAL in this section 3 Remove door opening control rods Unlock door lock rod pin retainer and disconnect control rod 4 Remove door lock control rod 5 Disconnect door lock motor lead wire if equipped 6 Remove lock assembly ...

Page 678: ...the door as shown NOTE Striker should be moved vertically and placed level Do not adjust door lock Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft Move door latch striker sideways to adjust door surface flush with body surface as shown In order to correctly obtain door latch striker position in the fore and aft direction increase or decrease number of shims inserted between body and striker to adjus...

Page 679: ...ontrol rod REAR DOOR LOCK ASSEMBLY REMOVAL 1 Remove door trim and door sealing cover refer to steps 1 to 4 of REAR DOOR GLASS REMOVAL in this section 2 Remove door opening control rod and door lock control rod 3 Remove lock assembly INSTALLATION Reverse removal sequence to install rear door lock noting points mentioned in FRONT DOOR LOCK ASSEMBLY ...

Page 680: ...retainer and disconnect control rod 6 Disconnect back door lock motor lead wire if equipped 7 Remove lock assembly INSTALLATION Reverse removal procedure to install back door rear gate lock as sembly noting following points D Back door Rear gate latch striker Adjust back door rear gate latch striker so that its center aligns with the center of groove in back door rear gate latch base To adjust bac...

Page 681: ...wners of key cut ting equipment from suppliers If key codes are not available from records or tags key code can be obtained from the right hand door lock cylinder if lock has not been replaced Lock cylinders supplied by the factory as service parts are unmarked If original key is available key code cutting combination can be de termined by laying key IGNITION SWITCH LOCK CYLINDER Removal Installat...

Page 682: ... 1 Open sunshade fully and tilt up sliding roof 2 Disconnect battery negative cable at battery 3 Remove sliding roof glass by removing bolts torx INSTALLATION For installation reverse removal procedure noting following points 1 Tighten glass fixing bolts temporarily 2 Position sliding roof glass by closing sliding roof glass complete ly 3 Tighten glass fixing bolts ...

Page 683: ...sliding roof weather strip 2 Position sunroof glass by such dimensions with respect to roof panel surface as specified below Dimension a 0 mm 0 0 in 3 After installing all parts and adjusting properly check sunroof for proper operation open close and up SLIDING ROOF DEFLECTOR REMOVAL 1 Open sliding roof 2 Disconnect negative cable at battery 3 Remove screws and disconnect deflector from deflector ...

Page 684: ... ROOF MOTOR RELAY REMOVAL 1 Remove head lining refer to HEAD LINING REMOVAL in this section 2 Disconnect coupler and remove sliding roof motor assembly by removing 3 screws CAUTION After removing sliding motor assembly do not move guide and link INSTALLATION For installation reverse removal procedure noting following point Before installing connect coupler and push the CLOSE side of the slide swit...

Page 685: ...mbly SLIDING ROOF ASSEMBLY REMOVAL 1 Remove roof lining Refer to HEAD LINING REMOVAL in this section 2 Remove sliding roof glass Refer to SLIDING ROOF GLASS REMOVAL 3 Disconnect drain hoses connected to sliding roof assembly at 4 locations 4 Disconnect sliding roof motor at coupler 5 Remove 6 nuts and then remove sliding roof assembly ...

Page 686: ...8 Drip rail 9 Drip link 1 Rear drip 2 Screw 3 Clip LH only 1 Drip rail 2 Drip link 3 Screw DISASSEMBLY Before disassembling be sure that sliding roof is CLOSE state 1 Remove rear drip 2 Pull out sunshade by sliding it 3 Remove drip rail 4 Remove sliding motor assy 5 Move cable fully to the direction shown in figure ...

Page 687: ...MBLY Reverse disassembly procedure for assembly observing following instructions CAUTION Match protrusion of guide and dent in cable for completely closed position of sliding roof drive cable and match marks holes for completely closed position of sliding roof motor assembly and then install sliding roof motor assembly Press the CLOSE side switch to match marks of sliding roof motor assembly Apply...

Page 688: ... side for installation Connect drain hoses to sliding roof assembly at 4 locations Pass front drain hose between roof panel and inner panel and through front pillar down to sill side Pass rear drain hose into baring hole in rear quarter inner panel and through C pillar down to jig hole in rear side bumper NOTE After reinstalling sliding roof assembly be sure to make glass adjustment Refer to SLIDI...

Page 689: ...w front frame CANVAS TOP AND TOPBOW FRAMES Removal 1 Open canvas to referring to Owner s Manual 2 Remove fording top and rear canvas top 3 Remove topbow bracket cover 4 Remove topbow center frame 5 Remove topbow front frame Installation Install in reverse order of removal procedure ...

Page 690: ...r pillar inner lower rims 4 door model rear side sill scuffs 4 door model side sill scuffs 2 door model and rear quarter lower trim 4 Remove parking brake lever cover console box and console box front extension 5 Remove front floor carpet INSTALLATION Reverse removal sequence to install front floor carpet noting fol lowing point When tightening seat belt anchor bolt refer to Section 10A FRONT SEAT...

Page 691: ...er trims covering head lining and door opening trim 6 Remove rear speaker cover if equipped 7 Disconnect rear washer hose and roof harness from body 8 Remove head lining NOTE Adhesive double coated tape is used to attach rear part of head lining Detach head lining from roof after removing all above parts INSTALLATION 1 Set roof harness and washer hose to head lining with tape 2 Clean roof where ad...

Page 692: ... 2 Head lining Set Set 4 Assistant grip 5 Rear room light 6 Inner trim 1 Room light 2 Sunshade assembly 3 Spot light IWATA CAMI 5 Install door opening trim 6 Install spot light sunshade assembly speaker cover room light and inner trims covering head lining ...

Page 693: ...MOVAL 1 Remove canvas top 2 Remove rear topbow 3 Remove side body garnishes 4 Remove luggage mat end garnish 5 Remove assistant grips 6 Remove sunshade assemblies 7 Remove sunshade hooks 8 Remove front topbow locks 9 Remove canvas top snaps 10 Remove front seat belts 11 Remove front pillar trims 12 Remove rear side inner lower trims 13 Remove rear side inner upper trims 14 Disconnect room light co...

Page 694: ...t lens 4 Clip 5 Screw 6 Room light harness 7 Marking tape 1 Seat belt INSTALLATION 1 Set room light and clip to roof trim 2 Set room light harness to roof trim with marking tape 3 Reverse removal sequence to install roof trim Tightening Torque a 35 N m 3 5 kg m 25 3 lb ft ...

Page 695: ... SIDE MOLDINGS IF EQUIPPED INSTALLATION 1 Bonding surfaces should be cleaned thoroughly 2 Install molding by aligning it to clip holes and pulling it to the rear so that fender or door will not interfere with it when door is opened 3 If adequate adhesive force is not available use urethane adhe sive ...

Page 696: ...YH4 GRAND VITARA 9 78 BODY SERVICE 1 Fender splash guard 2 Front door splash guard 3 Rear door splash guard 4 Rear splash guard 5 Side sill splash guard 6 Rear door guard holder SPLASH GUARD IF EQUIPPED ...

Page 697: ...roof rail front and rear caps as shown in figure 2 Remove nuts 3 Remove roof rail assembly Installation Reverse removal procedure for installation Confirm that each roof rail fixing nut is tightened securely ROOF MOLDING REMOVAL AND INSTALLATION If roof rail is equipped remove it in advance refer to ROOF RAIL section When reusing roof molding be careful not to make roof molding warped ...

Page 698: ...ber LUGGAGE UNDER BOX WARNING Do not remove member in the center of luggage under box If member had to be removed temporarily for repair or for some oth er reason be sure to reinstall it by using specified new bolts until head of bolt is broken off ...

Page 699: ...cau tions under On Vehicle Service 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 could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition sw...

Page 700: ... with A ELR The automatic and emergency locking retractor A ELR works as an Emergency Locking Retractor ELR till its webbing is pulled all the way out and then on as an Automatic Locking Retractor ALR till it is retracted fully ALR Automatically locks when the webbing is pulled out from the retractor and allowed to retract even a little Then the webbing can not be pulled out any further unless it ...

Page 701: ... injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CAUTION When fasteners are removed always reinstall them at the same location from which they were re moved If a fastener n...

Page 702: ...le portions Keep sharp edges and damaging objects away from belts Avoid bending or damaging any portion of belt buckle latch plate and ELR Do not bleach or dye belt webbing Use only mild soap and lukewarm water to clean it When installing a seat belt anchor bolt start bolt by hand to prevent cross threading Use only the correct seat belt anchor bolts and screws and tighten to the correct torque va...

Page 703: ...r anchor 3 Retractor assembly 4 Buckle SEAT BELT 10A 3 FRONT SEAT BELT WARNING Be sure to read Service Precautions before starting to work and observe every precaution during work REMOVAL Refer to the figure below to remove front seat belts ...

Page 704: ... secure and torqued to specification Belt latch D Belt latch should be secure when latched D Inspect the seat belt buckle ensuring that it locks and unlocks easily D After buckling the seat belt tug sharply on the belt checking that the buckle remains locked Warning system Check driver side seat belt strap switch for continuity by using ohm meter Without inserted buckle tongue to buckle catch Term...

Page 705: ...rse order of removal noting the following Seat belt anchor bolts should have an unified fine thread 7 16 20 UNF Under no circumstances should any different sized or metric screw threads be used Be sure to tighten seat belt anchor bolts to specified torque Tightening torque a 35 N m 3 5 kg m 25 5 lb ft b 5 5 N m 0 55 kg m 4 0 lb ft ...

Page 706: ...heck the rear seat belt in the same way as when inspecting front seat belt Refer to page 10A 4 INSTALLATION Install the rear seat belt observing the same precautions as when installing front seat belt Refer to page 10A 5 Tightening Torque a 35 N m 3 5 kg m 25 5 lb ft TIGHTENING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fastening arts N m kg m lb ft Upper and lower anchor bolt 35 3 5 ...

Page 707: ...ircuit resistance high 10B 44 Code 45 Passenger pretensioner initiator circuit resistance high 10B 44 Code 42 Driver pretensioner initiator circuit resistance low 10B 46 SECTION 10B AIR BAG SYSTEM WARNING Service on or around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Please observe all WARNINGS and Service Precautions under On Vehicle Service in...

Page 708: ...bling air bag system 10B 56 Enabling air bag system 10B 56 Handling and storage 10B 57 Disposal 10B 62 Repairs and Inspections Required after an Accident 10B 63 Accident with deployment component replacement 10B 63 Accident with or without deployment component inspections 10B 64 Driver Air Bag Inflator Module 10B 66 Contact Coil and Combination Switch Assembly 10B 66 Seat Belt Pretensioner 10B 66 ...

Page 709: ... well as the seat belt pretensioners if equipped the sag of the seat belt is taken up the driver air bag in flator module is deployed from the center of the steering column and the passenger air bag inflator module from the top of the instrument panel in front of the front passenger seat in occurrence of a front collision with an impact larger than a certain set value to supplement protection offe...

Page 710: ...river air bag inflator module 7 Passenger air bag inflator module 8 SDM 9 Seat belt pretensioner retractor assembly if equipped 10 Pretensioner harness if equipped 11 Ground for air bag system CONNECTOR A CONNECTOR C D CONNECTOR B CONNECTOR E CONNECTOR H CONNECTOR F CONNECTOR G SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS ...

Page 711: ...sembly 12 Driver air bag inflator module 13 Driver seat belt pretensioner if equipped 14 Passenger air bag inflator module 15 Passenger seat belt pretensioner if equipped 16 Pretensioner harness if equipped 17 Ground for air bag system TERMINAL A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A13 A11 A12 A14 A15 A16 Passenger air bag inflator module Low High CIRCUIT Data link connector DLC Low High Low High Low Hig...

Page 712: ...AL TOOLS WARNING To avoid deployment when troubleshooting the air bag system do not use electrical test equipment such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equipment other than that specified in this manual Do not use a non powered probe type tester Instructions in this manual must be followed carefully otherwise personal injury may result You should ...

Page 713: ...e column to the air bag wire harness Another connector B STEERING WHEEL is used to substitute the load of followings Driver air bag inflator module when it is connected at the top of the column to the contact coil assembly Passenger air bag inflator module when it is connected to the air bag harness connector for passenger air bag inflator module Driver and passenger seat belt pretensioner when it...

Page 714: ...osing the terminals to moisture and dirt as well as not maintaining proper terminal orientation with the component or mating connector Improperly formed or damaged terminals If any abnormality is found repair or replace as a wire harness as sembly Check each connector terminal in problem circuits carefully to en sure good contact tension by using the corresponding mating termi nal included in the ...

Page 715: ...a touches other wiring or parts of the vehicle Wiring broken inside the insulation This condition could cause a continuity check to show a good circuit but if only 1 or 2 strands of a multi strand type wire are intact resistance could be far too high If any abnormality is found repair or replace as a wire harness as sembly ...

Page 716: ...ables and follow the sequence listed below A PERFORM THE AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE The Air Bag Diagnostic System Check Flow Table must be the starting point of any air bag system diagnostics The Air Bag Diagnostic System Check Flow Table checks for proper AIR BAG warning lamp operation the ability of the SDM to communicate through AIR BAG warning lamp and whether air bag diagnosti...

Page 717: ... data circuit proceed to Table D on p 10B 22 Not using SUZUKI scan tool Is DTC 12 indicated Air bag system is in good condition NOTE As execution of the Diag nostic Trouble Code DTC Clearance will clear all DTCs be sure to record all DTCs before servicing An intermittent trouble has occurred at some place Check the connector harness etc related to the sensed DTC Refer to Intermittent and Poor Conn...

Page 718: ...Tool A 09931 76011 Tech 1 B Mass storage cartridge C 09931 76030 3 Turn ignition switch ON 4 Read DTC according to instructions displayed on Tech 1 and print it or write it down Refer to Tech 1 operator s manual for fur ther details 5 After completing the check turn ignition switch OFF and discon nect Tech 1 from data link connector DLC Not using SUZUKI scan tool 1 Check that malfunction indicator...

Page 719: ...layed on Tech 1 Refer to Tech 1 operator s manual for further details 5 After completing the check turn ignition switch OFF and discon nect Tech 1 from data link connector DLC 6 Perform Diagnosis Trouble Code DTC Check and confirm that normal DTC NO CODES is displayed and not malfunction DTC NOTE If DTC 51 or DTC 71 is stored in SDM it is not possible to clear DTC Not using SUZUKI scan tool 1 Turn...

Page 720: ...o 21 Code No 21 Time sec DIAGNOSTIC TROUBLE CODE DIAGNOSIS NO MODE DIAGNOSIS 12 Normal 15 Resistance high 16 Passenger air bag Resistance low 18 air bag circuit Short to ground 19 Short to power circuit 21 Resistance high Diagnose trouble according to Diagnos tic Flow Table corre 22 Driver air bag Resistance low tic Flow Table corre sponding to each code No 24 g circuit Short to ground 25 Short to...

Page 721: ...ar 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 warning lamp as follows Current DTC is set Abnormality exists at present History DTC is set only Faulty condi tion occurred once in the past but nor mal condition is restored at present AIR BAG warning lamp after ignition switch ON Remains...

Page 722: ...r terminal is found replace wire harness connectors and terminals as an assembly STEP ACTION YES NO 1 1 Ignition switch OFF 2 Remove and inspect AIR BAG fuse 3 Is fuse good Go to step 2 BI R wire short to ground After repair replace AIR BAG fuse 2 1 Disconnect SDM 2 Check proper connection to SDM at terminal A16 3 If OK then check voltage between A16 terminal of SDM connector and body ground with ...

Page 723: ...ig for STEP 3 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 Repeat Air Bag Diagnostic System Check Flow Table referring to p 10B 11 to confirm that the trouble has been corrected ...

Page 724: ...s damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly STEP ACTION YES NO 1 1 Set parking brake 2 Note combination meter as ignition switch is turned ON 3 Does the BRAKE indicator warning lamp come ON Go to step 2 B W wire IG COIL METER fuse or J B between ignition switch and combination meter open or short to ground 2 1 With ignition swi...

Page 725: ...en in BI or Y G wire circuit between combination meter and SDM 5 1 Measure voltage from A5 terminal of SDM connector to body ground with ignition switch ON 2 Is it 9 V or more Repair short from BI or Y G wire circuit between combination meter and SDM to power circuit Go to step 6 6 1 Remove and inspect AIR BAG bulb 2 Is bulb good Substitute a known good combination meter and recheck Replace bulb F...

Page 726: ... tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly STEP ACTION YES NO 1 1 Check AIR BAG monitor coupler 2 Is it connected diagnosis switch terminal and ground te...

Page 727: ...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 Repeat Air Bag Diagnostic System Check Flow Table referring to p 10B 11 to confirm that the trouble has been corrected ...

Page 728: ...tal multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly STEP ACTION YES NO 1 1 Make sure that scan tool Tech ...

Page 729: ...ircuit 3 1 With ignition switch OFF disconnect SDM and Lamp DLC and Monitor Coupler Ground E connector 2 Check proper connection at W B wire terminal for DLC in E connector 3 If OK then check resistance between W B wire terminal in E connector and A4 terminal of SDM connector 4 Is resistance 1 or less Substitute a known good SDM and recheck Repair high resistance or open in W B wire circuit in air...

Page 730: ...nal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The combined resistance of the passenger air bag inflator module har...

Page 731: ...tor module 2 1 With ignition switch OFF disconnect SDM 2 Check proper connection to SDM at terminals A2 and A3 3 Release shorting bar in SDM connector by inserting a piece of paper referring to the figure below 4 If OK then measure resistance between A2 and A3 terminals with connected Special Tool B 5 Is resistance 2 9 or less Substitute a known good SDM and recheck Repair high resistance or open ...

Page 732: ...nal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The combined resistance of the passenger air bag inflator module har...

Page 733: ...ion switch OFF disconnect SDM 2 Check proper connection to SDM at terminals A2 and A3 3 Release shorting bar in SDM connector by inserting a piece of paper referring to the figure below 4 If OK then measure resistance between A2 and A3 terminals with connected Special Tool B 5 Is resistance 1 7 or more Substitute a known good SDM and recheck Repair short from Y wire circuit to Y R wire circuit or ...

Page 734: ...timeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The voltage measured at passenger air bag ...

Page 735: ...ON is DTC 18 current Go to step 2 1 Ignition switch OFF 2 Replace passenger air bag inflator module 2 1 With ignition switch OFF disconnect Special Tool B and SDM 2 Measure resistance between A2 and A10 terminals 3 Is resistance 1 k or more Substitute a known good SDM and recheck Repair short from Y or Y R wire circuit to ground Fig for STEP 1 and 2 Fig for STEP 2 Special Tool A 09932 76010 B 0993...

Page 736: ... chart use specified digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The voltag...

Page 737: ...9 current Go to step 2 1 Ignition switch OFF 2 Replace passenger air bag inflator module 2 1 With ignition switch OFF disconnect Special Tool B and SDM 2 Measure voltage from A3 terminal to body ground 3 With ignition switch ON is voltage 1 V or less Substitute a known good SDM and recheck Repair short from Y or Y R wire circuit to power circuit Fig for STEP 1 and 2 Fig for STEP 2 Special Tool A 0...

Page 738: ...iring and connec tor terminal contact is above a specified value for specified time NOTE Before executing items in this table be sure to perform Air Bag Diagnostic Check Flow Table STEP ACTION YES NO 1 1 With ignition switch OFF disconnect contact coil connector located near the base of the steering column 2 Check proper connection to contact coil at terminals in C connector 3 If OK then connect S...

Page 739: ...iver air bag inflator module disconnected at step 2 5 With ignition switch ON is DTC 21 current 1 Ignition switch OFF 2 Replace contact coil assembly Refer to SECTION 3C1 1 Ignition switch OFF 2 Replace driver air bag inflator module Refer to SECTION 3C1 Fig for STEP 1 and 2 Fig for STEP 2 Fig for STEP 3 Special Tool A 09932 76010 B 09932 75010 NOTE Upon completion of inspection and repair work pe...

Page 740: ...nal contact is below a specified value for specified time NOTE Before executing items in this table be sure to perform Air Bag Diagnostic Check Flow Table STEP ACTION YES NO 1 1 With ignition switch OFF disconnect contact coil connector located near the base of the steering column 2 Check proper connection to contact coil at terminals in C connector 3 If OK then connect Special Tool B to contact c...

Page 741: ...iver air bag inflator module disconnected at step 2 5 With ignition switch ON is DTC 22 current 1 Ignition switch OFF 2 Replace contact coil assembly Refer to SECTION 3C1 1 Ignition switch OFF 2 Replace driver air bag inflator module Refer to SECTION 3C1 Fig for STEP 1 and 2 Fig for STEP 2 Fig for STEP 3 Special Tool A 09932 76010 B 09932 75010 NOTE Upon completion of inspection and repair work pe...

Page 742: ...y DTC WILL SET WHEN The voltage measured at driver air bag initiator circuit is below a specified value for specified time NOTE Before executing items in this table be sure to perform Air Bag Diagnostic Check Flow Table STEP ACTION YES NO 1 1 With ignition switch OFF disconnect contact coil connector located near the base of the steering column 2 Check proper connection to contact coil at terminal...

Page 743: ...er air bag inflator module disconnected at step 2 5 With ignition switch ON is DTC 24 current 1 Ignition switch OFF 2 Replace contact coil assembly Refer to SECTION 3C1 1 Ignition switch OFF 2 Replace driver air bag inflator module Refer to SECTION 3C1 Fig for STEP 1 and 2 Fig for STEP 2 Fig for STEP 3 Special Tool A 09932 76010 B 09932 75010 NOTE Upon completion of inspection and repair work perf...

Page 744: ...nals as an assembly DTC WILL SET WHEN The voltage measured at driver air bag initiator circuit is above a specified value for specified time NOTE Before executing items in this table be sure to perform Air Bag Diagnostic Check Flow Table STEP ACTION YES NO 1 1 With ignition switch OFF disconnect contact coil connector located near the base of the steering column 2 Check proper connection to contac...

Page 745: ...river air bag inflator module disconnected at step 2 5 With ignition switch ON is DTC 25 current 1 Ignition switch OFF 2 Replace contact coil assembly Refer to SECTION 3C1 1 Ignition switch OFF 2 Replace driver air bag inflator module Refer to SECTION 3C1 Fig for STEP 1 and 2 Fig for STEP 2 Fig for STEP 3 Special Tool A 09932 76010 B 09932 75010 NOTE Upon completion of inspection and repair work p...

Page 746: ... digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The power source voltage to SD...

Page 747: ... repair as necessary Refer to SECTION 6H Changing System 2 1 With ignition switch OFF reconnect SDM 2 With ignition switch ON is DTC 31 current Substitute a known good SDM and recheck Check Charging System and repair as necessary Refer to SECTION 6H Changing System Fig for STEP 1 Special Tool A 09932 76010 NOTE Upon completion of inspection and repair work perform following items 1 Reconnect all a...

Page 748: ...fied digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The power source voltage i...

Page 749: ... then check voltage from terminal in F connector on main harness to body ground 4 Is voltage 8 V or more Repair poor connec tion high resistance in BI R or BI B circuit of air bag harness or AIR BAG fuse Possibly faulty points are as follows Check each of them and repair as necessary Circuit from battery to F connector Charging System Refer to SECTION 6H Changing System 4 1 With ignition switch OF...

Page 750: ...in this chart use specified digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The...

Page 751: ...rrent Go to step 2 1 Ignition switch OFF 2 Replace seat belt preten sioner Refer to SECTION 10A 2 1 With ignition switch OFF disconnect SDM 2 Check proper connection to SDM at terminals A13 and A14 or A11 and A12 3 If OK then measure resistance between A13 and A14 terminals or A11 and A12 terminals with connected Special Tool B 4 Is resistance 2 9 or less Substitute a known good SDM and recheck DT...

Page 752: ...n this chart use specified digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The ...

Page 753: ...e seat belt preten sioner Refer to SECTION 10A 2 1 With ignition switch OFF disconnect SDM 2 Check proper connection to SDM at terminals A13 and A14 or A11 and A12 3 If OK then measure resistance between A13 and A14 terminals or A11 and A12 terminals with connected Special Tool B 4 Is resistance 1 7 or more Substitute a known good SDM and recheck DTC42 Repair short from P wire circuit to W wire ci...

Page 754: ...this chart use specified digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an assembly DTC WILL SET WHEN The vo...

Page 755: ...t the step 1 4 With ignition switch ON is DTC 43 or 47 still current Go to step 2 1 Ignition switch OFF 2 Replace seat belt preten sioner Refer to SECTION 10A 2 1 With ignition switch OFF disconnect Special Tool B and SDM 2 Measure resistance between A13 or A11 and A10 terminals 3 Is resistance 1 k or more Substitute a known good SDM and recheck DTC43 Repair short P or W wire circuit to ground DTC...

Page 756: ... When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as ...

Page 757: ... 4 With ignition switch ON is DTC 44 or 48 still current Go to step 2 1 Ignition switch OFF 2 Replace seat belt pretensioner Refer to SECTION 10A 2 1 With ignition switch OFF disconnect Special Tool B and SDM 2 Measure voltage from A14 or A12 terminal to body ground 3 With ignition switch ON is voltage 1 V or less Substitute a known good SDM and recheck DTC44 Repair short P or W wire circuit to po...

Page 758: ...ted in Repairs and Inspections Required after an Accident in this section Go to step 2 2 1 Inspect front of vehicle and undercarriage for signs of impact 2 Are there signs of impact Replace components and perform inspections as directed in Repairs and Inspections Required after an Accident in this section Substitute a known good SDM and recheck NOTE CODE 51 can never be cleared once it has been se...

Page 759: ... measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is requested refer to Intermittent and Poor Connections in this section When an open in air bag wire harness damaged wire harness connector or terminal is found replace wire harness connectors and terminals as an as...

Page 760: ...ion Go to step 2 Repair AIR BAG warning lamp circuit 2 1 Clear diagnostic trouble codes 2 Is DTC 61 set Substitute a known good SDM and recheck Recheck air bag system referring to Air Bag Diagnostic System Check Flow Table 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 Repeat Air Bag ...

Page 761: ...roper 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 diagnostic time incor rect diagnosis and incorrect parts replacements Never use air bag component parts from another vehicle If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove ...

Page 762: ...ellow connector of contact coil and combination switch assembly ii Release locking of lock lever ii After unlocked disconnect to connector 5 Pull out glove box while pushing its stopper from both right and left sides and disconnect Yellow connector of passenger air bag inflator module ii Release locking of lock lever ii After unlocked disconnect to connector NOTE With AIR BAG fuse removed and igni...

Page 763: ...air bag system when SDM is not rigidly at tached to the vehicle Otherwise personal injury may result CAUTION After detecting one time of such collision as to meet deploy ment conditions the SDM must not be used Refer to Diagnosis when checking the SDM Never attempt disassembly of SDM When storing SDM select a place where neither high tempera ture nor high humidity is anticipated and oil water and ...

Page 764: ...ity is found be sure to replace it with new one as an assembly When an abnormality is noted as existing in the live undeployed air bag inflator module be sure to deploy it before discarding it When grease cleaning agent oil water etc got on the air bag inflator modules driver and passenger wipe it off immediately with a dry cloth If air bag inflator module was dropped from a height of 90 cm 3 ft o...

Page 765: ...acket It is also prohibited to place anything on top of the trim cov er and stack air bag inflator modules This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental de ployment Otherwise personal injury may result LIVE INACTIVATED SEAT BELT PRETENSIONERS Special care is necessary when handling and storing a live inacti vated seat belt pre...

Page 766: ...ioner was dropped from a height of 30 cm 1 ft or more it should be replaced with a new one as an assembly WARNING For handling and storage of a live seat belt pretensioner select a place where the ambient temperature below 65 C 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wires or con nector on the underside of the pretensioner When placing...

Page 767: ...ures gloves and safety glasses should be worn Wash your hands with mild soap and water after complet ing the work Refer to the procedure described under Deployed Air Bag Inflator Modules Disposal in this section ACTIVATED SEAT BELT PRETENSIONERS WARNING The seat belt pretensioner immediately after activation is very hot Wait for at least 30 minutes to cool it off before proceeding the work Do not ...

Page 768: ...o diagnose DISPOSAL Do not dispose of the live undeployed air bag inflator modules and the live inactivated seat belt pretensioners When disposal is necessary be sure to deploy the air bag according to deployment procedure described under Air Bag Inflator Modules Disposal and to activate the pretensioner according to activation procedure described under Seat Belt Pretensioners Disposal WARNING Fai...

Page 769: ...retensioner 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 structure return it to its original production configuration CAUTION After detecting one time of such collision as to meet deployment conditions the SDM must not be used Refer to Diagnosis when checking the SDM ACCIDENT WITH D...

Page 770: ... is found in above checks replace faulty part Steering wheel and driver air bag inflator module Check for damage or air bag inflator module fitness Check trim cover pad surface for cracks Check wire harness and connector for damage or tightness If any faulty condition is found in above checks replace faulty part Contact coil and combination switch assembly Check wire harness and connectors for dam...

Page 771: ...led properly due to a cause in it self There is a gap between SDM and SDM plate or it cannot be fixed securely Check whether connector or lead wire of SDM has a scorching melting or damage Check whether connector can be connected securely or locked Check SDM connector and terminals for tightness Check SDM sets a diagnostic trouble code and the diagnostic table leads to a malfunctioning SDM If any ...

Page 772: ...ts Refer to SECTION 10A AIR BAG warning lamp air bag system After vehicle is completely repaired perform Air Bag Diagnos tic System Check under Diagnosis in this section DRIVER AIR BAG INFLATOR MODULE Refer to SECTION 3C1 for removal inspection and installation CONTACT COIL AND COMBINATION SWITCH ASSEMBLY Refer to SECTION 3C1 for removal inspection and installation SEAT BELT PRETENSIONER Refer to ...

Page 773: ...tem Refer to Disabling Air Bag System ear lier in this section 3 Remove rear and front center console box by removing screw and clips 4 Remove center garnish panel 5 Remove ashtray and tuner assembly clock assembly tuner pocket radio hole cover etc 6 Disconnect SDM connector from SDM 7 Remove SDM with SDM plate as an assembly from vehicle NOTE Do not separate SDM and SDM plate INSPECTION CAUTION D...

Page 774: ... vehicle body mounted on SDM 2 Install SDM with SDM plate to vehicle CAUTION Ensure that arrow on the SDM is pointing toward the front of the vehicle 3 Tighten SDM bolts to specified torque Tightening Torque a 6 0 N m 0 6 kg m 4 5 lb ft 4 Connect SDM connector to SDM securely 5 Install tuner assembly clock assembly tuner pocket radio hole cover etc and ashtray 6 Install center garnish panel 7 Inst...

Page 775: ...from instrument panel 4 Remove glove box from instrument panel 5 Remove passenger air bag inflator module attaching bolts and screws and passenger air bag inflator module from vehicle WARNING When carrying a live air bag inflator module make sure the bag opening is pointed away from you Never carry air bag inflator module by wires or con nector on the side of the module In case of an acciden tal d...

Page 776: ...mptoms and if any one of them is applicable replace with a new one Air bag has deployed There is a crack in trim cover pad surface Wire harness or connector is damaged Air bag inflator module is damaged or a strong impact e g dropping was applied to it INSTALLATION 1 Install passenger air bag inflator module to vehicle 2 Tighten passenger air bag inflator module attaching bolts and screws to speci...

Page 777: ...precautions must be observed for this 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 as described here Be sure to read Service Precautions in this section for the air bag inflater module beforehand Never connect deployment harness to any power sour...

Page 778: ... the air bag is to be deployed Special Tool A 09932 75030 4 Remove driver or passenger air bag inflator module from ve hicle referring to SECTION 3C1 or 10B WARNING Always carry live air bag inflator module with trim cov er away from you When storing a live air bag inflator module or when leaving a live air bag inflator module unattended on a bench or other surface always face the bag and trim cov...

Page 779: ...ure special tool with attached air bag inflator module is to be placed for deployment A paved outdoor loca tion where there is no activity is preferred If an outdoor loca tion is not available a space on the shop floor where there is no activity and sufficient ventilation is recommended Ensure that no loose or flammable objects are within the deployment area iii Place special tool passenger air ba...

Page 780: ...that the passenger air bag inflator module is firmly and properly secured in passenger air bag inflator module deploy ment fixture special tool 11 Connect the driver or passenger air bag inflator module to the deployment harness connector and lock connector with lock le ver 12 Notify all people in the immediate area that you intend to deploy the air bag inflator module NOTE When the air bag deploy...

Page 781: ... must be moved before it is cool wear gloves and handle it by using nonmetal material such as the air bag and vinyl trim Failure to follow procedures may result in fire or per sonal injury 13 Separate the two banana plugs on the deployment harness 14 Connect the deployment harness to the power source 12V ve hicle battery to immediately deploy the driver or passenger air bag 15 Disconnect the deplo...

Page 782: ...ess are designed to be reused They should however be inspected for damage after each deployment and replaced if necessary 19 Dispose of the deployed air bag inflator module through nor mal refuse channels after it has cooled for at least 30 minutes and tightly seal the air bag inflator module in a strong vinyl bag Refer to Deployed Air Bag Inflator Modules Disposal in detail 20 Wash your hands wit...

Page 783: ... always face the bag and trim cover up and away from the surface As the live pas senger air bag inflator module must be placed with its bag trim cover facing up place it or the work bench with a slit or use the workbench 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 expand in the unlikely event of ac cidental deplo...

Page 784: ...ess to the air bag inflator module Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed The air bag inflator module will immediately deploy the air bag when a power source is connected to it Wear safety glasses throughout this entire deployment and disposal procedure Wear suitable ear protection when deploying air bag Also advise those ...

Page 785: ... is found do not use it and be sure to use new deployment harness Special Tool A 09932 75030 6 Short the two deployment harness leads together by fully seat ing one banana plug into the other WARNING Deployment wires shall remain shorted and not be con nected to a power source until the air bag is to be deployed Special Tool A 09932 75030 7 Connect deployment harness connector to air bag inflator ...

Page 786: ...rea that you intend to deploy the air bag inflator module NOTE When the air bag deploys the rapid gas expansion will create a substantial report Wear suitable ear protection Notify all people in the immediate area that you intend 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 contai...

Page 787: ...e banana plug into the other 17 Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling the deployed air bag inflator module NOTE As a precaution gloves and safety glasses are recom mended to prevent any possible irritation of the skin or eyes 18 Disconnect the deployment harness from the air bag inflator module as soon after deployment as possible This w...

Page 788: ...from the vehicle For driver air bag inflator module refer to SECTION 3C1 for passenger air bag inflator module refer to On Ve hicle Service in this section WARNING Always carry a live air bag inflator module with trim cover away from you When storing a live air bag inflator module or when leaving a live air bag inflator module unattended on a bench or other surface always face the bag up away from...

Page 789: ...used again only the seat belt pretensioner s are disposed of WARNING Following precautions must be observed for this work Failure to observe any of them may result in personal injury To avoid an accidental activation this work should be performed by no more than one person The procedure should be followed strictly as described here Be sure to read Service Precautions in this section for the seat b...

Page 790: ... or passenger seat belt pretensioner s and seat belt pretensioner harness s from vehicle referring to SECTION 10A WARNING For handling and storage of a live seat belt pretension er select a place where the ambient temperature below 65 C 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wires or connector on the underside of the pretensioner When...

Page 791: ... paved outdoor location where there is no activity is preferred If an out door location is not available a space on the shop floor where there is no activity and sufficient ventilation is recommended Ensure no loose or flammable objects are within the activation area 8 Place the seat belt pretensioner as shown in the figure on the ground in the space just cleared 9 Stretch the deployment harness f...

Page 792: ...nside the pretensioner WARNING Safety precautions must be observed when handling an activated seat belt pretensioner After activation the metal surfaces of the seat belt pretensioner will be very hot Do not touch the metal areas of the seat belt pretensioner for about 30 min utes after activation Do not place the activated seat belt pretensioner near any flammable objects Do not apply water oil et...

Page 793: ...ended to prevent any possible irritation of the skin or eyes 20 Disconnect the deployment harness from the seat belt preten sioner as soon after activation as possible This will prevent damage to the deployment harness due to possible contact with the hot seat belt pretensioner canister The deployment harness are designed to be reused They should however be inspected for damage after each activati...

Page 794: ...he ambient temperature below 65 C 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wires or con nector on the underside of the pretensioner When placing a live seat belt pretensioner on the work bench or some place like that be sure not to lay it with its exhaust hole provided side facing down It is also prohib ited to put something on its face...

Page 795: ...ons for the seat belt pretensioner beforehand Never connect deployment harness to any power source before connecting deployment harness to the seat belt pretensioner Deployment harness shall remain shorted and not be connected to a power source until the pretensioner is to be activated The seat belt pretensioner will immediately activate the pretensioner when a power source is con nected to it Wea...

Page 796: ...A 09932 75030 7 Connect the deployment harness connector to the seat belt pretensioner harness and lock the connector with lock lever Special Tool A 09932 75030 8 Route deployment harness out the vehicle 9 Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable ob jects 10 Stretch the deployment harness to its full length 10 m 33 ft...

Page 797: ... when handling an activated seat belt pretensioner After activation the metal surfaces of the seat belt pretensioner will be very hot Do not touch the metal areas of the seat belt pretensioner for about 30 min utes after activation Do not apply water oil etc to activated seat belt pre tensioner If the activated seat belt pretensioner must be moved before it is cool wear gloves and handle by using ...

Page 798: ... pretensioner which has not been activated if any 21 In the unlikely event that either or both of the seat belt preten sioners proceed immediately with steps 23 through 25 If the seat belt pretensioner did activate proceed with step 22 22 With pretensioners activated the vehicle may be scrapped in the same manner as a non air bag system equipped vehicle 23 Remove the inactivated seat belt pretensi...

Page 799: ...mal refuse channels just like any other parts For their disposal however following points should be noted The air bag inflator module immediately after deployment 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 the deployed air bag inflator module Afte...

Page 800: ...ust like any other parts For their disposal however following points should be noted The seat belt pretensioner immediately after activation is very hot Wait for 30 minutes to cool it off before handling it Never apply water oil etc to activated seat belt pretensioner to cool it off and be careful so that water oil etc does not get on the activated seat belt pretensioner With many service procedur...

Page 801: ...r air bag inflator module deployment fixture Digital multimeter for which the maximum test current is 10 mA or less at the minimum range of resistance measurement WARNING Be sure to use the specified digital multimeter Otherwise air bag deploy ment or personal injury may result TIGHTENING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fastening arts N m kg m lb ft SDM bolt 6 0 6 4 5 Passe...

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