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Suzuki GRAND VITARA JB416, Service Manual

The Suzuki Grand Vitara JB416 is a versatile SUV known for its reliable performance and rugged design. Whether you need routine maintenance or more extensive repairs, our Service Manual is available for free download at manualshive.com. Keep your vehicle in top condition with our comprehensive manual.

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Table of Contents 4- i

4

Section 4

CONTENTS

Brakes

Precautions .................................................4-1

Precautions............................................................. 4-1

Precautions for Brakes.......................................... 4-1

Brake Control System and Diagnosis ... 4A-1

General Description .............................................4A-1

Brakes Construction............................................ 4A-1
Front Brake Hose / Pipe Construction................. 4A-2

Rear Brake Hose / Pipe Construction ..................4A-*
Master Cylinder Assembly Construction ..............4A-*
Booster Assembly Construction ...........................4A-*

Diagnostic Information and Procedures............4A-3

Brake Diagnosis Note ..........................................4A-*

Brakes Symptom Diagnosis ................................ 4A-3

Repair Instructions ..............................................4A-5

Excessive Pedal Travel Check.............................4A-*
Brake Pedal Play Check ......................................4A-*
Brake Fluid Level Check ......................................4A-*
Air Bleeding of Brake System ..............................4A-*
Brake Pedal Free Height Adjustment...................4A-*
Brake Light Switch Adjustment ............................4A-*
Brake Flexible Hose and Pipe Check...................4A-*
Master Cylinder Check.........................................4A-*
Flushing Brake Hydraulic System ........................4A-*
Booster Operation Check.....................................4A-*

Front Brake Hose / Pipe Removal and 

Installation ......................................................... 4A-5

Rear Brake Hose / Pipe Removal and 

Installation ......................................................... 4A-5

Master Cylinder Components...............................4A-*

Master Cylinder Reservoir Removal and 

Installation ......................................................... 4A-5

Master Cylinder Assembly Removal and 

Installation ......................................................... 4A-6

Master Cylinder Assembly Inspection ................. 4A-8
Brake Booster Components ................................ 4A-9
Brake Booster Removal and Installation ........... 4A-10

Booster Push Rod Clevis Adjustment ..................4A-*

Specifications....................................................... 4A-*

Specifications.....................................................4A-11

Tightening Torque Specifications...................... 4A-11

Special Tools and Equipment ...........................4A-11

Special Tool ...................................................... 4A-11

Front Brakes ............................................ 4B-1

General Description ............................................. 4B-*

Front Disc Brake Caliper Assembly 

Construction ...................................................... 4B-*

Repair Instructions ..............................................4B-1

Front Disc Brake Components ............................ 4B-*
Front Disc Brake Pad On-Vehicle Check ............ 4B-*

Front Disc Brake Pad Removal and 

Installation .........................................................4B-1

Front Brake Disc and Pad Inspection.................. 4B-*

Front Disc Brake Caliper Removal and 

Installation .........................................................4B-2

Front Disc Brake Caliper Disassembly and 

Assembly........................................................... 4B-*

Front Disc Brake Caliper Inspection.................... 4B-*

Front Brake Disc Removal and Installation .........4B-2

Front Brake Disc Inspection ................................ 4B-*

Specifications .......................................................4B-3

Tightening Torque Specifications........................4B-3

Rear Brakes...............................................4C-*

General Description ............................................. 4C-*

Rear Drum Brake Assembly Construction .......... 4C-*

Repair Instructions .............................................. 4C-*

Rear Drum Brake Assembly Components .......... 4C-*
Rear Brake Drum Removal and Installation........ 4C-*
Rear Brake Drum and Shoe Inspection .............. 4C-*
Rear Brake Shoe On-Vehicle Check................... 4C-*
Rear Brake Shoe Removal and Installation ........ 4C-*
Rear Brake Shoe Inspection ............................... 4C-*
Wheel Cylinder Removal and Installation ........... 4C-*
Wheel Cylinder Inspection .................................. 4C-*
Rear Brake Back Plate Removal and 

Installation ......................................................... 4C-*

Specifications ....................................................... 4C-*

Tightening Torque Specifications........................ 4C-*

Special Tools and Equipment ............................. 4C-*

Recommended Service Material ......................... 4C-*

Parking Brake ...........................................4D-*

Component Location ........................................... 4D-*

Parking Brake Cable Location............................. 4D-*

Repair Instructions .............................................. 4D-*

Parking Brake Check and Adjustment ................ 4D-*

NOTE

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual 
mentioned in the “FOREWORD” of this manual.

Summary of Contents for GRAND VITARA JB416

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

Page 2: ......

Page 3: ...efer to the related manual below When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials as specified in each description All infor...

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

Page 5: ...ansaxle 5 i Precautions 5 Automatic Transmission Transaxle 5A 1 Manual Transmission Transaxle 5B Clutch 5C Steering 6 i Precautions 6 Steering General Diagnosis 6A Steering Wheel and Column 6B 1 Power...

Page 6: ......

Page 7: ...stem 00 Precautions for Electrical Circuit Service 00 Precautions for Installing Mobile Communication Equipment 00 Air Bag Warning 00 Discharge Headlight Warning 00 A C System Caution 00 Fastener Caut...

Page 8: ...done calibrate steering angle sensor G sensor and master cylinder pressure sensor in ESP control module referring to Sensor Calibration in Section 4F When battery or dome fuse is removed When steerin...

Page 9: ...without A F Sensor 0B PCV Valve Inspection 0B Fuel Evaporative Emission Control System Inspection 0B Brake Discs and Pads Inspection 0B Brake Drums and Shoes Inspection 0B Brake Hoses and Pipes Inspe...

Page 10: ...Gas Recirculation EGRT Sensor EGR Temperature Sensor Recirculated Exhaust Gas Temp Sensor REGTS ELR Emergency Locking Retractor EPS Electronic Power Steering ESP Electronic Stability Program EVAP Evap...

Page 11: ...Module TPMS Tire Pressure Monitoring System TP Sensor Throttle Position Sensor TVV Thermal Vacuum Valve Thermal Vacuum Switching Valve TVSV Bimetal Vacuum Switching Valve BVSV TWC Three Way Catalytic...

Page 12: ...0A 3 General Information...

Page 13: ...n Tool Data 1A Visual Inspection 1A Engine Basic Inspection 1A Engine Symptom Diagnosis 1A Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop but Engine Can Be Started...

Page 14: ...6 Starter Relay Circuit Low 1A DTC P0617 Starter Relay Circuit High 1A DTC P0620 Generator Control Circuit 1A DTC P0625 P0626 Generator Field Terminal Circuit Low High 1A DTC P0660 Intake Manifold Tun...

Page 15: ...spection 1C Knock Sensor Removal and Installation 1C Control Relay Inspection 1C Mass Air Flow MAF and Intake Air Temperature IAT Sensor On Vehicle Inspection 1C Mass Air Flow MAF and Intake Air Tempe...

Page 16: ...er Head Cover Removal and Installation 1D Engine Mountings Components 1D Engine Assembly Removal and Installation 1D Timing Chain Cover Components 1D Timing Chain Cover Removal and Installation 1D Tim...

Page 17: ...1F Radiator Cooling Fan Assembly Removal and Installation 1F Radiator On Vehicle Inspection and Cleaning 1F Radiator Removal and Installation 1F Water Pump Removal and Installation For M16 Engine Mode...

Page 18: ...otor Specifications 1I Tightening Torque Specifications 1I Special Tools and Equipment 1I Recommended Service Material 1I Charging System 1J General Description 1J Battery Description 1J Generator Des...

Page 19: ...DTCs according to the following priorities a DTCs other than DTC P0171 P0172 Fuel system too lean too rich DTC P0300 P0301 P0302 P0303 P0304 Misfire detected and DTC P0401 P0402 EGR flow malfunction b...

Page 20: ...some areas in the system being monitored by ECM and turning ON the malfunction indicator lamp 1 due to that malfunction 2 driving cycle detection logic is adopted to prevent erroneous detection When...

Page 21: ...e power to ECM is shut off for specified time or it is cleared by SUZUKI scan tool 2 In addition DTC can be read by not only using SUZUKI scan tool but also displayed on odometer 5 of the combination...

Page 22: ...n stored the freeze frame data 2 will be updated by the freeze frame data 1 In the 2nd through the 4th frames the freeze frame data of each malfunction is stored in the order as each malfunction is de...

Page 23: ...intake system includes air cleaner throttle body and intake manifold Fuel delivery system includes fuel pump delivery pipe etc Electronic control system includes ECM various sensors and controlled dev...

Page 24: ...e if equipped Combination meter keyless start control module if equipped and 4WD control module if equipped does not transmit data to ECM Engine torque signal Accelerator pedal position Engine speed T...

Page 25: ...ommunication system Especially ECM Engine Control Module BCM Body electrical Control Module combination meter TCM Transmission Control Module For A T model ABS ESP control module 4WD control module if...

Page 26: ...TUATOR OIL CONTROL VALVE FOR M16 ENGINE ACCELERATOR PEDAL POSITION APP SENSOR A C COMPRESSOR CLUTCH IF EQUIPPED WITH A C HEATER CONTROL GENERATOR IMMOBILIZER COIL ANTENNA IF EQUIPPED KEYLESS START CON...

Page 27: ...ED C37 25 52 PNK E23 49 53 58 63 67 69 71 C37 12 16 WHT 2 C37 56 BRN 54 C37 21 55 BRN BLK C37 20 32 BLU ORN GRN C37 53 C37 54 C37 40 C37 41 C37 45 C37 44 WHT BLK RED BLU RED BLU YEL E23 17 E23 50 WHT...

Page 28: ...fuse 38 Fuel injector No 2 64 Ignition switch 13 HO2S heater relay 39 Fuel injector No 3 65 IGN fuse 14 HO2S 2 40 Fuel injector No 4 66 STR MOT fuse 15 A F sensor 41 EVAP canister purge valve 67 ST SI...

Page 29: ...C37 26 C37 27 C37 14 C37 10 C37 55 C37 24 C37 57 RED C37 25 47 PNK E23 49 48 16 55 59 17 C37 12 15 WHT 2 C37 56 BRN 49 C37 21 50 BRN BLK C37 20 27 BLU ORN GRN C37 53 C37 54 C37 40 C37 41 C37 45 C37 44...

Page 30: ...ule 41 Radiator cooling fan relay No 1 64 Engine ground 19 BCM 42 Radiator cooling fan relay No 2 65 Body ground 20 Combination meter 43 Radiator cooling fan relay No 3 66 Main fuel level sensor 21 St...

Page 31: ...M16 engine 50 Ignition coil No 2 for J20 engine 21 BRN Ignition coil No 1 and No 4 for M16 engine 51 WHT BLU CKP sensor signal for M16 engine Ignition coil No 1 for J20 engine BLU Crankshaft position...

Page 32: ...ignal to ABS ESP control module 49 PNK A C compressor relay output if equipped with A C 20 GRN WHT Stop lamp switch signal 50 BLU ORN Throttle actuator control relay output 21 BLK YEL Cruise control c...

Page 33: ...IAT SENSOR ECT SENSOR POWER STEERING PRESSURE SWITCH TP SENSOR THROTTLE ACTUATOR FUEL PUMP RELAY FUEL INJECT IMT VACUUM SOLENOID VALVE for J20 engine GENERATOR CONTROL THROTTLE ACTUATOR CONTROL RELAY...

Page 34: ...is Schematic and Routing Diagram Engine and Emission Control System Diagram S5JB0E1102001 48 37 25 42 35 33 34 24 43 18 26 10 9 7 8 14 13 23 11 15 12 2 6 1 3 30 29 38 16 17 36 31 22 21 40 27 41 32 4 2...

Page 35: ...control relay 7 EGR valve 24 DLC 41 A C refrigerant pressure sensor if equipped with A C 8 EVAP canister 25 Electric load 42 Accelerator pedal position APP sensor 9 Tank pressure control valve built...

Page 36: ...dule if equipped 7 Battery g IMT vacuum solenoid valve G TCM for A T model 8 CMP sensor h Ignition coil assembly with ignitor H BCM 9 MAP sensor i Main relay I Immobilizer coil antenna if equipped 10...

Page 37: ...il antenna if equipped 10 CKP sensor j Oil control valve J Fuse box No 2 11 Main fuel level sensor k Radiator cooling fan relay No 2 K A C refrigerant pressure sensor if equipped with A C 11 1 Sub fue...

Page 38: ...nge performance Engine coolant temperature is less than specified temperature for specified time from engine start 2 driving cycles P0117 Engine coolant temperature circuit low Circuit voltage of ECT...

Page 39: ...U P0402 Exhaust gas recirculation flow detected as excessive Difference in intake manifold absolute pressure between opened EGR valve and closed EGR valve is more than specification 2 driving cycles...

Page 40: ...speed control engine power control and so on by TCM this DTC is detected by ECM 1 driving cycle P1674 CAN communication bus off error Transmission error that is inconsistent between transmission data...

Page 41: ...it range performance Difference of barometric pressure value and intake manifold pressure value is more than specification at engine start 2 driving cycles U P2228 Barometric pressure circuit low Baro...

Page 42: ...tuck off P0752 Shift solenoid A No 1 stuck on P0756 Shift solenoid B No 2 performance or stuck off P0757 Shift solenoid B No 2 stuck on P0962 Pressure control solenoid control circuit low P0963 Pressu...

Page 43: ...ED WHT BLU E23 29 E23 4 E23 1 E23 60 E23 19 E23 16 10 12 11 A E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37...

Page 44: ...le DTC diag flow Substitute a known good combination meter and recheck If MIL still remains OFF substitute a known good ECM and recheck 5 CAN communication line circuit check 1 Check CAN communication...

Page 45: ...onnector connect the special tool to ECM and or the ECM connectors referring to Inspection of ECM and Its Circuits 8 Combination meter circuit check 1 Turn ignition switch to OFF position 2 Measure re...

Page 46: ...A T model drive vehicle at more than 3700 rpm for 10 sec 7 Check pending DTC and DTC E23 4 E23 19 WHT RED WHT BLU WHT RED WHT BLU E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 2...

Page 47: ...Poor Connection Inspection in Section 00 in related manual Go to Step 3 3 DTC check in ABS ESP control module 1 Connect scan tool to DLC with ignition switch turned OFF 2 Check ABS ESP control module...

Page 48: ...signal due to malfunctions of sensor circuits used for gear shift control DTC Troubleshooting NOTE Before this trouble shooting is performed read the precautions for DTC troubleshooting referring to...

Page 49: ...15 16 D 8 7 6 5 4 3 2 1 9 10 11 12 13 14 15 16 16 1 15 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 J G45 10 9 3 2 1 WHT...

Page 50: ...ol module if equipped ABS or ESP control module 4WD control module if equipped Combination meter CAN communication line circuit Steering angle sensor for vehicle with ESP Step Action Yes No 1 Was Engi...

Page 51: ...d and BCM Is there DTC s P1774 in TCM for A T model U1073 in BCM ABS ESP control module and 4WD control module if equipped and or DTC No 33 in keyless start control module if equipped Go to Step 6 Go...

Page 52: ...tion switch turned OFF 2 Check ECM for DTC Is there DTC P1674 Go to Step 12 CAN communication circuit wire between 4WD control module and CAN circuit junction connector is open or high resistance If w...

Page 53: ...s resistance of CAN communication circuit is less than 1 between each control module Insulation resistance between CAN communication circuit wires is infinity at each control module connector Insulati...

Page 54: ...r Connection Inspection in Section 00 in related manual 5 ECM power and ground circuit check 1 Check ECM power and ground circuits referring to ECM Power and Ground Circuit Check in related manual Are...

Page 55: ...eck keyless start control module power and ground circuits If circuits are OK substitute a known good keyless start control module and recheck 11 DTC check 1 Disconnect connector from combination mete...

Page 56: ...art control module if equipped combination meter steering angle sensor vehicle with ESP with ignition switch turned OFF 2 Check that CAN communication circuit is as follows All wire harness resistance...

Page 57: ...4 CAN Communication Bus Off Error Go to Step 4 4 ECM ABS ESP control module and BCM connector check 1 Check for proper connection at each ECM ABS ESP control module and BCM connector terminals with ig...

Page 58: ...ires are OK check TCM power and ground circuits If circuits are OK substitute a known good TCM for A T model and recheck 10 DTC check 1 Disconnect connector from keyless start control module if equipp...

Page 59: ...nnect connectors from all control modules ECM TCM if equipped BCM ABS or ESP control module 4WD control module if equipped keyless start control module if equipped combination meter steering angle sen...

Page 60: ...k Step Action Yes No DTC detecting condition Trouble area Reception error of communication data for ABS or ESP control module is detected for longer than specified time continuously 1 driving detectio...

Page 61: ...dule Communication Bus Off in Section 4F Go to Step 7 7 CAN communication circuit check 1 Disconnect connectors from ABS or ESP control module and ECM 2 Check that CAN communication circuit is as foll...

Page 62: ...ground circuits If circuits are OK substitute a known good TCM for A T model and recheck 11 DTC check in ECM 1 Disconnect connector from keyless start control module if equipped with ignition switch...

Page 63: ...ation circuit check 1 Disconnect connectors from all control modules ECM TCM if equipped BCM ABS or ESP control module 4WD control module if equipped keyless start control module if equipped combinati...

Page 64: ...gnal using voltmeter 2 and oscilloscope 3 NOTE As each terminal voltage is affected by battery voltage confirm that it is 11 V or more when ignition switch is turned ON Voltage with asterisk cannot be...

Page 65: ...Reference waveform No 4 Ignition switch is turned to ST cranking position Output signal is active low duty pulse Number of pulse generated times varies depending on vehicle condition C37 5 YEL BLK EG...

Page 66: ...ition A C refrigerant pressure 800 kPa 116 psi 2 15 2 38 V Engine running A C switch ON and blower selector at 1st position or more A C refrigerant pressure 1400 kPa 203 psi 2 67 2 95 V Engine running...

Page 67: ...0 engine 0 0 6 V Ignition switch turned ON 0 0 6 V 3 5 V Reference waveform No 12 and Reference waveform No 14 Engine running at idle after warmed up engine Output signal is active high pulse Pulse fr...

Page 68: ...CM Below 0 3 V Ignition switch turned ON C37 30 BLK ORN Ground for ECM Below 0 3 V Ignition switch turned ON C37 31 BLK YEL Ground for A F sensor heater Below 0 3 V Ignition switch turned ON C37 32 PN...

Page 69: ...d accelerator pedal position 0 1 V 10 14 V Reference waveform No 22 and Reference waveform No 23 Ignition switch turned ON and accelerator pedal at full depressed position after warmed up engine C37 4...

Page 70: ...eed 6 pulses are generated per 1 camshaft revolution C37 53 WHT Output for 5 V power source of throttle position sensor 4 5 5 5 V Ignition switch turned ON C37 54 BLK Throttle position sensor main sig...

Page 71: ...regular frequency which varies depending on engine condition E23 5 PPL WHT Serial communication line of data link connector 12 V 8 14 V Ignition switch turned ON E23 6 BLK WHT Cruise control main swi...

Page 72: ...condition E23 20 GRN WHT Stop lamp switch signal 0 1 V Ignition switch turned ON stop lamp not lit up 10 14 V Ignition switch turned ON stop lamp lit up E23 21 BLK YEL Cruise control command switch gr...

Page 73: ...while engine is running 0 2 V Ignition switch turned ON engine coolant temp 102 5 C 216 5 F or higher or A C refrigerant pressure 1600 kPa 232 psi or higher with A C switch turned on while engine is...

Page 74: ...rator pedal position APP sensor sub 4 5 5 5 V Ignition switch turned ON E23 54 ORN Ground for accelerator pedal position APP sensor main Below 0 3 V Ignition switch turned ON E23 55 WHT BLU Accelerato...

Page 75: ...normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 3 720 crank angle I5JB0A110074 01 I5JB0A110075 01 Measurement terminal CH1 C37 52 to C37 5...

Page 76: ...58 CH2 C37 28 to C37 58 Oscilloscope setting CH1 5 V DIV CH2 5 V DIV TIME 20 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed For a few sec...

Page 77: ...N signal 2 OFF signal 3 One duty cycle 4 10 14 V Measurement terminal CH1 C37 52 to C37 58 CH2 C37 16 to C37 58 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DIV Measurement condition After...

Page 78: ...ngine B For M16 engine 1 4 6 V 3 Ignition coil pulse width I5JB0A110083 02 Measurement terminal CH1 C37 52 to C37 58 CH2 C37 18 to C37 58 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 40 ms DIV Me...

Page 79: ...58 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed A For J20 engine B For M16 engine 3...

Page 80: ...ignal 3 Racing 4 Idle Measurement terminal CH1 C37 38 to C37 58 CH2 C37 37 to C37 58 CH3 C37 32 to C37 31 Oscilloscope setting CH1 500 mV DIV CH2 500 mV DIV CH3 10 V DIV TIME 100 ms DIV Measurement co...

Page 81: ...ied idle speed A For J20 engine B For M16 engine 1 Cylinder reference signal CMP reference signal 2 CKP signal 3 360 crank angle 4 4 5 V 5 36 6 30 CKP pulse I5JB0A110091 01 Measurement terminal CH1 C3...

Page 82: ...45 terminal 2 Throttle actuator drive signal C37 44 terminal 3 ON signal 4 OFF signal 5 One duty cycle I4RS0B110081 02 Measurement terminal CH1 C37 45 to C37 58 CH2 C37 44 to C37 58 Oscilloscope setti...

Page 83: ...mal operating temperature Engine racing 2 Throttle position sensor main signal 3 Racing 4 Idle Measurement terminal CH1 C37 56 to C37 58 Oscilloscope setting CH1 1 V DIV TIME 10 ms DIV Measurement con...

Page 84: ...ontrol valve signal 4 ON signal 5 OFF signal Measurement terminal CH1 E23 4 to C37 58 CH2 E23 19 to C37 58 Oscilloscope setting CH1 1 V DIV CH2 1 V DIV TIME 40 s DIV Measurement condition Ignition swi...

Page 85: ...ured when parts temperature is 20 C 68 F 1 2 I4RS0A110086 02 Terminals Circuit Standard resistance Condition E23 60 to E23 29 Main relay 160 240 Battery disconnected and ignition switch turned ON E23...

Page 86: ...9 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 2...

Page 87: ...g Go to Step 11 Go to Step 6 6 Radiator cooling fan control circuit check 1 Check DTC with scan tool Is DTC P0480 displayed Go to DTC P0480 Fan 1 Radiator Cooling Fan Control Circuit in related manual...

Page 88: ...Step 13 Go to Step 14 13 A C compressor relay check 1 Check A C compressor relay referring to A C Compressor Relay Inspection in Section 7B in related manual Is it in good condition A C compressor dr...

Page 89: ...60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48...

Page 90: ...r more ON Blower fan signal Engine running blower speed selector OFF OFF Engine running blower speed selector 5th position or more ON PSP signal Engine running steering wheel to neutral position OFF E...

Page 91: ...ilizer Bar and or Bushings Removal and Installation 2B 16 Front Suspension Frame Check 2B 20 Front Stabilizer Bar Bushing and or Joint Check 2B 20 Front Suspension Fasteners Check 2B 21 Specifications...

Page 92: ...steners Check 2C Specifications 2C Tightening Torque Specifications 2C Special Tools and Equipment 2C Recommended Service Material 2C Special Tool 2C Wheels and Tires 2D General Description 2D Tires D...

Page 93: ...t assembly 7 Tie rod 200 N m 20 0 kgf m 145 0 lb ft 2 Stabilizer bar 8 Stabilizer bar joint 65 N m 6 5 kgf m 47 0 lb ft 3 Steering knuckle 135 N m 13 5 kgf m 98 0 lb ft 43 N m 4 3 kgf m 31 0 lb ft 4 S...

Page 94: ...is noted it must be corrected before adjusting Check for run out of wheels and tires Check vehicle trim heights if it is out of limit and a correction is needed it must be done before adjusting toe Ch...

Page 95: ...Make sure that rack boots are not twisted Steering Angle Check and Adjustment When tie rod or tie rod end was replaced check toe and then also steering angle with turning radius gauge 1 If steering an...

Page 96: ...cover 3 Bump stopper 9 Strut nut 50 N m 5 0 kgf m 36 5 lb ft 4 Coil spring seat 10 Strut bracket bolt Insert from vehicle front side If reuse bolt apply engine oil to thread bearing and trunk surface...

Page 97: ...oint nut hold stud with hexagon wrench 3 Remove brake hose mounting bolt 1 and remove brake hose 2 from bracket 4 Disconnect front height sensor if equipped from suspension control arm for left side r...

Page 98: ...in unloaded condition tighten strut support nuts b to specified torque Tightening torque Strut support nut b 50 N m 5 0 kgf m 36 5 lb ft CAUTION If reuse strut bracket bolt and nut apply engine oil to...

Page 99: ...as shown Special tool A 09900 00411 B 09900 00414 C 09941 56510 3 Disassemble strut assembly Assembly For assembly reverse disassembly procedure noting the following instructions 1 Compress coil sprin...

Page 100: ...s found replace strut as an assembly unit because it can not be disassembled Inspect strut function referring to the following procedures 1 Check and adjust tire pressures as specified 2 Bounce vehicl...

Page 101: ...Never disassemble front wheel hub assembly Disassembly will spoil its original function If faulty condition is found replace it with new one Removal 1 Hoist vehicle and remove wheel 2 Uncaulk drive sh...

Page 102: ...ssary Be sure to use a new bolt for replacement Installation 1 Insert new hub bolt 1 in hub hole Rotate hub bolt slowly to assure that serrations are aligned with those made by original bolt 2 Apply g...

Page 103: ...0 N m 10 0 kgf m 72 5 lb ft Steering Knuckle Removal and Installation S5JB0E2206008 Removal 1 Hoist vehicle and remove wheel 2 Remove Front wheel hub assembly referring to Front Wheel Hub Assembly Rem...

Page 104: ...bolt 3 Tightening torque Front wheel speed sensor bolt b 10 N m 1 0 kgf m 7 5 lb ft 6 Connect front height sensor if equipped to suspension control arm for left side referring to Height Sensor Remova...

Page 105: ...l Arm Removal and Installation S5JB0E2206010 Removal 1 Remove steering knuckle from suspension control arm referring to Steering Knuckle Removal and Installation 2 Remove suspension control arm bolts...

Page 106: ...press 2 and special tools Special tool A 09945 55410 B 09913 75821 Assembly CAUTION Apply grease included in the repair kit to ball joint and inside of ball stud boot when the ball stud boot is replac...

Page 107: ...nts S5JB0E2206015 I4RS0B220023 01 10 7 3 2 5 1 8 8 7 a 4 6 b 9 b 9 11 b F c d 12 I5JB0A220040 02 F Forward 6 Stabilizer joint nut 12 Stabilizer mount 1 Stabilizer bar 7 Suspension control arm 50 N m 5...

Page 108: ...e stabilizer joints 1 When loosening joint nut hold stud with hexagon wrench 6 Disconnect front fender lining clip 1 if equipped with head light auto leveling system 7 Disconnect front height sensor c...

Page 109: ...on in Section 9J in related manual b Support engine assemble by using chain hoist 14 Support suspension frame at the specified positions 1 indicated in figure WARNING When removing suspension frame be...

Page 110: ...bly 1 and front differential assembly 2 referring to P S Gear Case Assembly Removal and Installation in Section 6C in related manual and Front Differential Dismounting and Remounting Front in Section...

Page 111: ...referring to Propeller Shaft Removal and Installation in Section 3D in related manual 10 Tighten pipe bracket 1 bolts to specified torque and then insert low pressure return hose 2 to low pressure ret...

Page 112: ...engine under cover 19 Install wheels right left and lower hoist 20 After installation be sure to fill specified power steering fluid and bleed air referring to P S System Air Bleeding Procedure in Sec...

Page 113: ...Bar and or Bushings Components Reference For the tightening torque of fastener not specified in this section refer to Fastener Information in Section 0A in related manual 1 I4RH01220007 01 Fastening p...

Page 114: ...JB0E2208002 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25010 09900 00411 09900 00414 Hexagon bit socket Hexagon bit 6 mm 09913 75821 09941 56510...

Page 115: ...tions 3B Front Differential Oil Change 3B Front Differential Unit Components 3B Front Differential Dismounting and Remounting 3B Front Differential Components 3B Front Differential Assembly Disassembl...

Page 116: ...mmunication with ECM 3C 50 DTC U1101 Lost Communication with TCM 3C 51 DTC U1121 Lost Communication with ABS Electronic Stability Program Hydraulic Unit Control Module 3C 52 Inspection of 4WD Control...

Page 117: ...n and Procedures 3D Propeller Shaft Symptom Diagnosis 3D Repair Instructions 3D Propeller Shaft Joint Check 3D Propeller Shaft Removal and Installation 3D Propeller Shaft Disassembly and Assembly 3D P...

Page 118: ...er to 4H lock position as follows Non shift type Transfer without shift actuator Remove lever bolt 1 on transfer push down lever to 4H lock position 2 and fix lever with bolt Motor shift type Transfer...

Page 119: ...in the center differential the effect of LSD works when a rotation difference between front and rear wheels is occurring The transfer has such a selective mechanism as to enable the shift actuator to...

Page 120: ...tor Transfer Shift Control System Components S5JB0E3311002 6 7 5 1 8 2 3 4 I5JB0A332001 01 1 Transfer switch 4 N indicator 7 Center differential lock switch 2 Differential lock indicator 5 4WD control...

Page 121: ...ects the transfer actual shift position 4H 4H lock N or 4L lock by the signals from the 4L N switch and center differential lock switch as follows Relationship of transfer shift position and switches...

Page 122: ...sfer is at 4L lock position Flashes at 0 25 seconds for 3 times at intervals of 20 seconds Sounds at 1 second at intervals of 20 seconds The transfer shift position is different for transfer switch Fl...

Page 123: ...N position or not 4L indicator Indicates transfer is at 4L lock position or not Differential lock indicator Indicates transfer is at 4H lock 4L lock or not Transmission range sensor N position for A T...

Page 124: ...force from the center LSD is transmitted to the front drive shaft through front drive sprocket Then the front drive sprocket rotates the front output shaft via the drive chain A B 1 2 5 4 4 3 5 9 8 6...

Page 125: ...from the transfer input gear to the rear output shaft as in the case of 4H position Also as the front drive shaft and front drive sprocket bush are engaged via differential lock clutch sleeve the dri...

Page 126: ...h sleeve also moves in the arrow direction C The driving force from the transmission is transmitted to the transfer input gear However as the reduction shift sleeve is not engaged with the transfer in...

Page 127: ...gear and transfer counter gear with the speed reduced At this time as the center LSD case and transfer low gear are engaged via reduction shift sleeve the driving force is transmitted to the rear out...

Page 128: ...WHT RED WHT BLU 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 17 18 19 20 21 23 22 16 E91 8 PNK I5JB0A332007 03 1 Transfer actuator 9 ABS hydraulic unit control module 17 DLC 2 Transfer actuator position switc...

Page 129: ...Transfer switch 2 E91 3 Transfer actuator motor 2 E91 20 Transfer switch 3 E91 7 CPP switch E91 21 Data link connector DLC E91 8 Diagnosis connector E91 22 CAN communication line High E91 10 Ground E9...

Page 130: ...details of fail safe mode refer to Fail Safe Table Motor Shift Type Transfer with Shift Actuator Transfer switch Transfer shift actuator motor Transfer shift actuator motor position switch 4L N switc...

Page 131: ...n gear selector position Wheel speed pulse front right Wheel speed pulse front left Wheel speed pulse rear right Wheel speed pulse rear left Antilock brake system active ABS hydraulic unit control mod...

Page 132: ...frame data 1 Recheck for DTC referring to DTC Check Motor Shift Type Transfer with Shift Actuator Is there any DTC s Go to Step 9 Go to Step 10 8 4WD control symptom diagnosis 1 Check and repair acco...

Page 133: ...d In order to know that check symptom in question according to Step 5 and then recheck DTC according to Step 6 Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in th...

Page 134: ...that transfer position indicators turn on for about 2 seconds and then turns off If any faulty condition is found proceed to Transfer Position Indicator Does Not Come ON at Ignition Switch ON but Engi...

Page 135: ...ahead c Confirm that vehicle is under following conditions Transfer shift position is 4H Transmission shift lever is at N position for A T model Clutch pedal is depressed fully for M T model Brake ped...

Page 136: ...tool is in good condition Then check data link connector and serial data line circuit in the vehicle with which communication was not possible 5 After completing the check turn ignition switch OFF an...

Page 137: ...When the same malfunction DTC is not detected again during 40 engine warm up cycles Using Diagnosis Connector 1 Turn ignition switch to ON position 2 Using service wire short diagnosis switch termina...

Page 138: ...WD control module power supply circuit malfunction Battery voltage is lower than lower limit voltage for 4WD control module diagnosis C1243 Internal circuit malfunction of 4WD control module EEPROM er...

Page 139: ...Scan Tool Data Vehicle Condition Normal Condition Reference Value Vehicle speed At vehicle stop 0 km h 0 mph Actuator Pos Sen Transfer shifted to 4H position 4H Transfer being shifted between 4H lock...

Page 140: ...nsmission Range Sensor Inspection and Adjustment in Section 5A in related manual CPP switch faulty for M T model Check CPP switch referring to Clutch Pedal Position CPP Switch Inspection and Adjustmen...

Page 141: ...referring to Transfer Assembly Inspection Motor Shift Type Transfer with Shift Actuator Worn chamfered tooth on sleeve or gear Check sleeve and gear referring to Transfer Assembly Inspection Motor Shi...

Page 142: ...d then turned to OFF position If an abnormality is detected in the system transfer position indicator remains lighting E91 22 E91 23 RED WHT RED WHT G28 10 G28 8 1 2 G28 13 PPL RED BLK WHT GRN BLK YEL...

Page 143: ...pair or replace 4 METER fuse check 1 Turn ignition switch to OFF position 2 Check for fuse blown to METER fuse in junction block assembly Is METER fuse in good condition Go to Step 5 Replace METER fus...

Page 144: ...18 19 20 21 22 23 24 25 26 A I5JB0A332015 03 A 4WD control module connector E91 viewed from harness side 4 4L indicator B Combination meter connector viewed from harness side 5 N indicator 1 4WD contr...

Page 145: ...e 1 4WD control module B Transfer switch connector G59 viewed from harness side 2 Transfer switch DTC detecting condition Trouble area Transfer switch combination different from specification is detec...

Page 146: ...9 2 terminal of transfer switch connector and E91 18 terminal of 4WD control module connector Between G59 3 terminal of transfer switch connector and E91 19 terminal of 4WD control module connector Be...

Page 147: ...ls of transfer switch connector 3 If connection is OK measure voltage between G59 2 G59 3 or G59 4 terminal of transfer switch connector and vehicle body ground with ignition switch ON Is it 10 14 V G...

Page 148: ...EL RED BLK BLU M E91 3 E91 25 E91 26 RED E91 24 BLK YEL 1 2 3 C54 1 C54 4 C54 2 C54 3 C54 5 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A 1 2 3 4 5 6 B I5JB0A332017 01 A 4WD...

Page 149: ...switch check 1 Check transfer shift actuator position switch referring to Transfer Assembly Inspection Motor Shift Type Transfer with Shift Actuator Is actuator in good condition Substitute a known go...

Page 150: ...YEL RED BLK BLU M E91 3 E91 25 E91 26 RED E91 24 BLK YEL 1 2 3 C54 1 C54 4 C54 2 C54 3 C54 5 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A 1 2 3 4 5 6 B I5JB0A332017 01 A 4W...

Page 151: ...tion switch check 1 Check transfer shift actuator position switch referring to Transfer Assembly Inspection Motor Shift Type Transfer with Shift Actuator Is actuator in good condition Substitute a kno...

Page 152: ...trol module 4 Center differential lock switch 2 TCM DTC detecting condition Trouble area Though transfer shift actuator motor position switch is 4L lock position the ON signal is not input from the 4L...

Page 153: ...tion switch OFF 2 Check for proper connection to E91 13 terminal of 4WD control module connector 3 If OK measure resistance between PNK WHT terminal of 4L N switch connector and E91 13 terminal of 4WD...

Page 154: ...itch ON Is it 10 14 V Go to Step 3 Go to Step 4 3 4L N switch check 1 Check 4L N switch referring to Transfer Assembly Inspection Motor Shift Type Transfer with Shift Actuator Is switch in good condit...

Page 155: ...K YEL 1 2 3 C54 1 C54 4 C54 2 C54 3 C54 5 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A 1 2 3 4 5 6 B I5JB0A332017 01 A 4WD control module connector E91 viewed from harness...

Page 156: ...ep 3 Go to Step 4 3 Transfer shift actuator check 1 Check transfer shift actuator referring to Transfer Assembly Inspection Motor Shift Type Transfer with Shift Actuator Is actuator in good condition...

Page 157: ...E91 13 E91 14 RED GRN PNK WHT 2 3 4 12V 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A I5JB0A332018 01 A 4WD control module connector E91 viewed from harness side 3 4L N swit...

Page 158: ...switch ON Is it 10 14 V Go to Step 3 Go to Step 4 3 Center differential lock switch check 1 Check center differential lock switch referring to Transfer Assembly Inspection Motor Shift Type Transfer wi...

Page 159: ...14 15 16 17 18 19 20 21 22 23 24 25 26 A I5JB0A332018 01 A 4WD control module connector E91 viewed from harness side 3 4L N switch 1 4WD control module 4 Center differential lock switch 2 TCM DTC dete...

Page 160: ...ferential lock switch connector and vehicle body ground with ignition switch ON Is it 10 14 V Go to Step 3 Go to Step 4 3 Center differential lock switch check 1 Check center differential lock switch...

Page 161: ...C 5V BB E91 12 E91 11 E91 10 E91 1 BLK BLK WHT BLK WHT 2 4 6 3 5 7 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A BLK I5JB0A332019 01 A 4WD control module connector E91 viewe...

Page 162: ...ct 4WD control module connector with ignition switch OFF 2 Check for proper connection to E91 terminal of 4WD control module connector 3 If connection is OK measure voltage between E91 11 terminal of...

Page 163: ...per connection to terminal of CPP switch connector 3 If connection is OK measure voltage between BLK ORN terminal of CPP switch connector and vehicle body ground with ignition switch ON Is it 10 14 V...

Page 164: ...55 57 5453 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 3938 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 4746 49 50 51 21 22 52 16 25 9 24 14 29 55 57 5453 59 60 58 26 27 28 15...

Page 165: ...rol module if equipped E Combination meter connector viewed from harness side 5 ECM F 4WD control module connector viewed from harness side 6 ABS hydraulic unit control module if equipped G BCM connec...

Page 166: ...tion switch to OFF position 2 Disconnect connectors of all control modules communicating by means of CAN 3 Check CAN communication circuit between control modules for open short and high resistance Is...

Page 167: ...ntrol module Is DTC U1100 and DTC U1073 detected together Go to DTC U1073 Control Module Communication Bus Off Motor Shift Type Transfer with Shift Actuator Go to Step 3 3 DTC check 1 Check DTC in ECM...

Page 168: ...DTC U1100 and DTC U1073 detected together Go to DTC U1073 Control Module Communication Bus Off Motor Shift Type Transfer with Shift Actuator Go to Step 3 3 DTC check 1 Check DTC in TCM Is DTC P1774 de...

Page 169: ...e Is DTC U1100 and DTC U1073 detected together Go to DTC U1073 Control Module Communication Bus Off Motor Shift Type Transfer with Shift Actuator Go to Step 3 3 DTC check 1 Check DTC in ABS or ESP hyd...

Page 170: ...voltage is affected by the battery voltage confirm that it is 11 V or more when ignition switch is turned ON Pulse signal cannot be measured by voltmeter It can be measured by oscilloscope Item with a...

Page 171: ...ition E91 15 E91 16 E91 17 E91 18 LT GRN Transfer switch 1 10 14 V Ignition switch turned to ON position and transfer switch at 4H N or 4L lock position 0 1 V Ignition switch turned to ON position and...

Page 172: ...or oil leakage 3 Remove oil filler plug 2 4 Remove drain plug 1 and drain oil 5 Apply sealant to thread of drain plug 1 and tighten it to specified torque A Sealant 99000 31260 SUZUKI Bond No 1217G Ti...

Page 173: ...ler plug b 23 N m 2 3 kgf m 17 0 lb ft Transfer Oil Seal Removal and Installation S5JB0E3316003 Removal 1 Lift up vehicle and drain transfer oil 2 Remove front propeller shaft and or rear propeller sh...

Page 174: ...anual and then remove transfer switch 1 from center cluster 2 Installation Reverse removal procedure Transfer Switch Inspection S5JB0E3316005 Check continuity between following terminals when transfer...

Page 175: ...connector 5 4L N switch connector 6 8 Support engine rear mounting member 1 with transmission jack 2 9 Remove engine rear mounting bolts 3 and then slant the transmission with transfer 10 Remove gear...

Page 176: ...5JB0E3316008 11 16 44 45 42 43 41 40 9 c a 39 38 b 37 a 37 35 a a 1217G 10 1217G 33 32 30 31 1217G 34 1217G 48 A OIL 9 28 27 OIL 9 OIL OIL 9 OIL 9 OIL 19 29 19 47 A 26 25 24 23 22 4 5 7 6 21 20 OIL 9...

Page 177: ...ansfer to transmission bolt 9 Needle bearing 28 Front drive sprocket bush 47 Front oil seal No 2 Apply grease 99000 25010 to oil seal lip 10 Center case Apply sealant 99000 31260 to mating surface of...

Page 178: ...dle bearings 1 from center case 2 using special tools if necessary Special tool A 09913 76010 B 09925 98210 10 Remove needle bearing 1 snap ring 2 washer 3 and shim s 4 from rear output shaft 5 11 Rem...

Page 179: ...ear case 5 all at once 16 Remove snap ring 1 and then remove rear output shaft assembly 2 from rear case 3 17 Remove rear oil seal 1 from rear case 2 using flat end rod or the like if necessary 18 Rem...

Page 180: ...pecial tool and then apply grease to oil seal lip Grease 99000 25010 SUZUKI Super Grease A Special tool A 09913 85210 2 Install counter gear assembly 1 to front case 2 and then install input gear asse...

Page 181: ...177 in Special tool A 09913 70123 6 Install rear output shaft assembly 1 to rear case 2 and then install snap ring 3 7 Install front drive sprocket 1 front output shaft assembly 2 drive chain 3 and ne...

Page 182: ...14 Install needle bearings 1 to center case 2 using special tools as shown in figure Distance between case and needle bearing a 0 0 5 mm 0 0 008 in Special tool A 09913 76010 B 09925 98210 15 Install...

Page 183: ...both center case 1 and front case apply sealant to center case as shown in figure by such amount that its section is 1 2 mm 0 047 in in diameter mate front case 3 with center case and then tighten bo...

Page 184: ...ove of the sleeve mate control cover with center case and then tighten control cover bolts 3 to which thread lock cement has been applied and control cover dowel bolts 4 to specified torque A Sealant...

Page 185: ...e groove width 6 9 7 1 mm 0 272 0 280 in Assemble front drive shaft 1 front drive sprocket 2 and differential lock clutch sleeve 3 check whether differential lock clutch sleeve moves smoothly and repl...

Page 186: ...voltage while transfer actuator removed from transfer control cover assembly 1 Do not apply voltage of the battery in the direction of rotation limit at rotation limit position of transfer actuator Op...

Page 187: ...Assembly Disassembly and Reassembly S5JB0E3316012 Disassembly 1 Remove snap ring 1 from input gear and then remove bearing 2 2 Remove snap rings 1 4 3 2 5 6 7 OIL 2 OIL 2 OIL 2 OIL 2 OIL 1 1 1 1 2 OI...

Page 188: ...ler 3 and press 4 NOTE Assemble bearing so that seal side 5 may come to the front side Special tool A 09913 85210 3 Install snap rings 1 to input gear 2 4 Install bearing 1 and snap ring 2 Counter Gea...

Page 189: ...output shaft 2 using special tool bearing puller 3 and press 4 Special tool A 09925 98221 2 Remove bearing 1 from front output shaft 2 using bearing puller 3 and press 4 Reassembly 1 Clean all compone...

Page 190: ...ll components thoroughly inspect them for any abnormality and replace with new ones as necessary 2 To ensure lubrication of rear output shaft 1 air blow oil holes 2 and make sure that they are free fr...

Page 191: ...Assembly and Rear Output Shaft Assembly Components Motor Shift Type Transfer with Shift Actuator Special Tool S5JB0E3318002 Fastening part Tightening torque Note N m kgf m lb ft Transfer oil level fi...

Page 192: ...g installer Bearing installer 09928 36510 09940 54910 Transfer cap Front fork oil seal install driver SUZUKI scan tool This kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19...

Page 193: ...d in the transfer With the torque induction type LSD used in the center differential the effect of LSD works when a rotation difference between front and rear wheels The differential lock lever is ins...

Page 194: ...with Shift Actuator Weak or damaged control cover shift shaft spring Replace referring to Transfer Assembly Inspection Motor Shift Type Transfer with Shift Actuator Worn bearings on input gear or cou...

Page 195: ...nsfer oil capacity Reference 1 6 liters 3 4 2 8 US lmp pt Transfer Oil Level Check S5JB0E3326002 Refer to Transfer Oil Level Check Motor Shift Type Transfer with Shift Actuator Transfer Oil Seal Remov...

Page 196: ...sfer Assembly Components S5JB0E3326005 37 36 9 38 c 32 a 25 20 a a 40 a 27 b a A OIL 28 29 31 33 1217G 30 26 10 10 19 9 OIL 9 OIL 23 1217G 24 1217G 22 21 35 A 9 OIL 9 OIL 16 OIL 18 17 15 14 13 12 11 9...

Page 197: ...ft assembly 37 Damper 6 Input gear assembly 22 Drive chain 38 Damper bolt 7 Center case Apply sealant 99000 31260 to mating surface of front case differential lock shift lever case and center case 23...

Page 198: ...ol if necessary Special tool A 09913 76010 8 Remove needle bearing 1 snap ring 2 washer 3 and shim s 4 from rear output shaft 5 9 Remove reduction shift sleeve 1 and center differential 3 from rear ou...

Page 199: ...needle bearing 1 from rear case 2 using special tool if necessary Special tool A 09913 76010 17 Remove input gear plate 1 and then remove input gear assembly 3 from front case 2 18 Remove front oil s...

Page 200: ...rear case 2 using special tool as shown in figure and then apply grease to oil seal lip Distance between case and oil seal a 3 5 4 5 mm 0 138 0 177 in A Grease 99000 25010 SUZUKI Super Grease A Speci...

Page 201: ...heck clearance between shim and washer c If clearance is out of specified value select shim from the following table so that clearance becomes specified value Clearance between shim and washer 0 1 0 3...

Page 202: ...nter case and rear case 1 apply sealant to rear case as shown in figure by such amount that its section is 1 2 mm 0 047 in in diameter mate center case with rear case and then tighten bolts 2 to speci...

Page 203: ...e as shown in figure by such amount that its section is 1 2 mm 0 047 in in diameter confirm the each fork of lever case is in groove of the sleeve mate differential lock shift lever case with center c...

Page 204: ...Fastener Information in Section 0A in related manual Special Tools and Equipment Recommended Service Material S5JB0E3328001 NOTE Required service material is also described in the following Transfer...

Page 205: ...pecial Tools and Equipment 4A 11 Special Tool 4A 11 Front Brakes 4B 1 General Description 4B Front Disc Brake Caliper Assembly Construction 4B Repair Instructions 4B 1 Front Disc Brake Components 4B F...

Page 206: ...Module Communication Bus Off 4E 30 DTC U1100 Lost Communication with ECM Reception Error 4E 32 Repair Instructions 4E 33 Hydraulic Unit Operation Check 4E 33 ABS ESP Hydraulic Unit Control Module Asse...

Page 207: ...Communication With Yaw Rate G Sensor Assembly 4F 36 DTC C1075 1076 1077 1078 Steering Angle Sensor Master Cylinder Pressure Sensor Longitudinal G Sensor Lateral G Sensor in Yaw Rate G Sensor Assembly...

Page 208: ...4 iv Table of Contents Specifications 4F 52 Tightening Torque Specifications 4F 52 Special Tools and Equipment 4F 52 Special Tool 4F 52...

Page 209: ...Section 00 in related manual Brake Caution Refer to Brakes Caution and Note in Section 00 General Precautions Refer to General Precautions in Section 00 in related manual Vehicle Lifting Points Refer...

Page 210: ...ight brakes In this brake system the disc brake type is used for the front wheel brake and a drum brake type leading trailing shoes for the rear brake The parking brake system is mechanical It applies...

Page 211: ...ng vehicle 5 ABS ESP hydraulic unit control module assembly 10 Brake joint bolt 1 From master cylinder primary to ABS hydraulic unit 6 Master cylinder 11 4 way joint 2 From master cylinder secondary t...

Page 212: ...ith new hoses and new brake piping Malfunctioning caliper assembly Check for stuck or sluggish pistons and proper lubrication of caliper slide bush Loose suspension parts Caliper should slide Check al...

Page 213: ...te leaky point correct it and add brake fluid Brake warning light circuit faulty Repair circuit Malfunctioning EBD system if equipped with ABS ESP Check system referring to EBD Warning Lamp Brake Warn...

Page 214: ...f Brake System in related manual Perform brake test and check installed part for fluid leakage Rear Brake Hose Pipe Removal and Installation S5JB0E4106012 CAUTION Do not allow brake fluid to get on pa...

Page 215: ...M T vehicle 4 Connect reservoir lead wire at coupler 5 Fill reservoir with specified fluid 6 After installing bleed air from brake system referring to Air Bleeding of Brake System in related manual a...

Page 216: ...er cylinder 1 6 Loosen master cylinder fixing nuts 1 and then remove master cylinder 2 with reservoir 3 from brake booster 4 Installation 1 Install new master cylinder O ring 1 to master cylinder 2 In...

Page 217: ...id 8 After installing bleed air from brake system referring to Air Bleeding of Brake System in related manual and at the same time bleed air from clutch system referring to Air Bleeding of Clutch Syst...

Page 218: ...location of vacuum hose 1 2 3 4 5 6 7 8 10 a b c 9 11 I5JB0D410001 01 1 Brake master cylinder assembly 5 Clevis pin lock nut 9 Brake vacuum hose 13 N m 1 3 kgf m 9 5 lb ft 2 Brake booster assembly 6...

Page 219: ...ter push rod clevis 2 to pedal arm 3 with clevis pin inserting from left 4 and clip 5 2 Tighten booster attaching nuts 6 to the specified torque Tightening torque Booster attaching nut a 13 N m 1 3 kg...

Page 220: ...ference For the tightening torque of fastener not specified in this section refer to Fastener Information in Section 0A in related manual Special Tools and Equipment Special Tool S5JB0E4108001 Fasteni...

Page 221: ...y or being pulled Don t operate brake pedal with pads removed 4 Remove pads 3 Installation 1 Install pad spring 1 and pads 2 NOTE Install brake pad with wear indicator 5 to vehicle center side on righ...

Page 222: ...it into groove securely Tightening torque Caliper pin bolt 36 N m 3 6 kgf m 26 0 lb ft 3 Install brake flexible hose as shown and tighten flexible hose joint bolt 1 to specified torque Tightening torq...

Page 223: ...d torque Tightening torque Wheel nut 100 N m 10 0 kgf m 72 5 lb ft 6 Upon completion of installation perform brake test Specifications Tightening Torque Specifications S5JB0E4207001 Reference For the...

Page 224: ...k lever 2 until it locks When disconnecting ESP hydraulic unit control module connector 1 pull up lock lever 2 of connector When connecting set the connector on ESP hydraulic unit control module assem...

Page 225: ...ch wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking ABS ESP hydraulic unit which operates according to signal from ABS ESP control module to control flui...

Page 226: ...ollows ABS Transmission Data ABS Reception Data Torque up request Wheel speed signal front right Wheel speed signal front left Wheel speed signal rear right Wheel speed signal rear left ABS active ABS...

Page 227: ...amp EBD warning lamp Data link connector ABS ESP hydraulic unit control module assembly Wheel speed sensor RR Stop lamp switch 3 7 2 6 4 5 8 12 13 ECM Longitudinal G sensor for 4WD vehicle only Yaw ra...

Page 228: ...5 16 17 PPL WHT 18 19 BB PPL RED WHT BLK WHT BLK WHT BLU BLK GRN BLK BLU GRN YEL BLK YEL LT GRN LT GRN BLK E03 21 E03 22 E03 19 E03 18 E03 15 E03 16 E03 25 E03 24 E03 7 E03 13 E03 26 BLK BLK E03 5 E03...

Page 229: ...unit Terminal Wire color Circuit E03 1 WHT BLU ABS pump motor driver Transistor 2 3 4 5 PPL WHT Data link connector 6 WHT CAN communication line low for combination meter 7 GRN ORN Ignition switch 8...

Page 230: ...k connector stop lamp switch and the brake master cylinder assembly only changes 6 2 1 7 4 5 6 2 3 2 6 6 2 8 9 I6JB01450004 01 1 ABS ESP hydraulic unit control module assembly 6 Wheel encoder included...

Page 231: ...there any malfunction DTC Go to Step 4 Go to Step 2 2 Driving test 1 Perform Step 2 Driving Test Is trouble symptom identified Go to Step 3 Go to Step 6 3 DTC check 1 Perform DTC Check Is it malfuncti...

Page 232: ...referring to DTC Check When DTC which is recorded at DTC check procedure is detected again after performing DTC clearance go to Step 4 ABS Check to proceed the diagnosis When DTC which is recorded at...

Page 233: ...o 3 Step 7 Final Confirmation Test Confirm that the problem symptom has gone and the ABS is free from any abnormal conditions If what has been repaired is related to the malfunction DTC clear the DTC...

Page 234: ...SUZUKI scan tool Diagnostic Items NO DTC Normal C1015 G sensor circuit failure for 4WD vehicle C1021 RF Wheel speed sensor circuit C1025 LF C1031 RR C1035 LR C1022 RF Wheel speed sensor or encoder fai...

Page 235: ...and block wheels Ignition switch ON Turn OFF air conditioner if equipped Apply no load to power steering if equipped Don t turn it Turn OFF all electric loads except ignition No DTC ABS is not operat...

Page 236: ...T RED WHT BLU BLK BLK BLK RED WHT RED WHT E53 13 E53 44 11 10 5 7 8 6 9 E53 16 1 15 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 4...

Page 237: ...ck DTC Is there DTC U1073 Go to DTC U1073 Control Module Communication Bus Off Substitute a known good combination meter and recheck If ABS warning lamp remains OFF substitute a known good ABS ESP hyd...

Page 238: ...on to ABS ESP control module connector at terminals E03 1 and E03 14 or E53 1 and E53 32 3 If OK then turn ignition switch to ON position and measure voltage between each terminal of E03 1 E03 14 or E...

Page 239: ...2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 E03 13 E03 26 12V 12V E03 1 E03 14 E03 7 GRN ORN WHT RED WHT BLU BLK BLK RED...

Page 240: ...known good combination meter and recheck If ABS warning lamp remains ON substitute a known good ABS ESP hydraulic unit control module assembly and recheck Repair or replace 3 4 2 1 12V 12V E03 1 E03...

Page 241: ...ck for proper connection to ABS hydraulic unit control module connector at terminals E03 13 and E03 26 3 If OK measure resistance between each terminal of E03 13 E03 26 and vehicle body ground Are res...

Page 242: ...nd check again DTC Troubleshooting 1 Ignition switch OFF 2 Check for proper connection from harness to control module 3 If OK substitute an ABS hydraulic unit control module assembly with correct part...

Page 243: ...urred while driving Wheel s was turned while the vehicle was jacked up The vehicle was stuck 1 2 12V E53 35 GRN ORN BLK YEL 7 D E03 3 4 5 6 BLK WHT BLK WHT BLU BLK GRN BLK BLU GRN YEL BLK YEL LT GRN L...

Page 244: ...check result should be no continuity Between applicable sensor terminal of module connector and corresponding terminal of wheel speed sensor connector 2 in main harness for front sensor or floor harn...

Page 245: ...ion and or Rear Wheel Speed Sensor On Vehicle Inspection check output voltage or waveform Is specified voltage and or waveform obtained Substitute a known good ABS ESP hydraulic unit control module as...

Page 246: ...t Rear Left Rear Outlet Solenoid Circuit Failure DTC C1043 C1044 Master Cylinder Cut Solenoid Circuit No 1 No 2 Failure DTC C1053 C1054 Low Pressure Solenoid Circuit No 1 No 2 Failure NOTE The DTC C10...

Page 247: ...switch to OFF position 2 Disconnect ABS ESP control module connector 3 Check for proper connection to ABS ESP control module connector at terminal E03 14 4 If OK then measure voltage between terminal...

Page 248: ...Go to Step 3 3 1 Turn ignition switch to OFF position 2 Check for proper connection to ABS ESP control module connector at terminals E03 13 and E03 26 or E53 16 and E53 47 3 If OK then turn ignition...

Page 249: ...attery 5 ESP hydraulic unit control module assembly B Without ESP 2 Main fuse box 6 ABS hydraulic unit control module assembly C ESP control module connector viewed from terminal side 3 Pump motor dri...

Page 250: ...03 15 16 17 18 19 20 21 22 23 24 25 2 3 4 5 6 7 8 9 10 11 12 1 13 14 26 C E53 16 1 15 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44...

Page 251: ...ound Is it 10 14 V Substitute a known good ABS ESP hydraulic unit control module assembly and recheck WHT BLU circuit imperfect short to ground Step Action Yes No 1 2 WHT BLU 12V M 3 4 E53 32 E53 1 BL...

Page 252: ...ABS ESP control module connector 2 If OK disconnect ABS ESP control module connector and check the following Voltage E03 1 or E53 32 terminal 10 14 V Voltage E03 14 or E53 1 terminal 10 14 V Resistan...

Page 253: ...21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 A K G45 10 9 3 2 1 A B 2 1 E23 3 4 18 19 5 6 7 10 11 17 20 4746 49 50 51 21 22 52 16 25 9 24 14 29 55 57 5453 59 60 58...

Page 254: ...unication circuit between control modules for open short and high resistance Is each CAN communication circuit in good condition Go to Step 4 Repair insulation of CAN communication line circuit referr...

Page 255: ...SP control module and ECM communicating by means of CAN 3 Check CAN communication circuit between ABS ESP control module and ECM for open short and high resistance Is CAN communication circuit in good...

Page 256: ...ool and the wheel 2 should be turned by another person s hand At this time check whether the wheel rotates freely due to brake depressurization Pressurization check Step off brake pedal 1 and then sel...

Page 257: ...6 6 8 8 9 10 I5JB0B450006 01 A With ESP 5 ABS control module connector 16 N m 1 6 kgf m 11 5 lb ft B Without ESP 6 Brake pipe flare nut for M10 19 N m 1 9 kgf m 14 0 lb ft 1 ABS hydraulic unit contro...

Page 258: ...using flat end rod or the like 2 CAUTION Do not give an impact to hydraulic unit Use care not to allow dust to enter hydraulic unit Do not place hydraulic unit on its side or upside down Handling it i...

Page 259: ...On Vehicle Inspection S5JB0E4506005 Output Voltage Inspection 1 Disconnect negative cable from battery 2 Hoist vehicle a little 3 Disconnect wheel speed sensor connector 4 Disconnect wheel speed gromm...

Page 260: ...nect negative cable from battery 2 Disconnect front wheel speed sensor coupler 1 3 Hoist vehicle and remove wheel 4 Remove harness clamp clamp bolts 2 and grommet 3 5 Remove front wheel speed sensor 4...

Page 261: ...knuckle CAUTION Do not pull wire harness when removing rear wheel speed sensor Do not cause damage to surface of rear wheel speed sensor and do not allow dust etc to enter its installation hole Instal...

Page 262: ...b Assembly Removal and Installation in Section 2B Front Wheel Encoder Removal and Installation S5JB0E4506012 CAUTION Front wheel encoder is included in front wheel hub assembly If front wheel encoder...

Page 263: ...related manual Special Tools and Equipment Special Tool S5JB0E4508001 Fastening part Tightening torque Note N m kgf m lb ft Brake pipe flare nut for M10 16 1 6 11 5 Brake pipe flare nut for M12 19 1 9...

Page 264: ...le during inspection When disconnecting ESP control module connector 1 pull up lock lever 2 of connector When connecting set the connector on ESP hydraulic unit control module assembly and pull down t...

Page 265: ...varied with referring each wheel slip condition EBD function is that front and rear wheel braking forces are varied with referring loading distribution of the vehicle ABS improves the vehicle stabilit...

Page 266: ...nd indicator lamp in instrument cluster which are controlled by ESP control module They give warning indication to driver by changing the modes light ON blinking light OFF The followings are the condi...

Page 267: ...ESP OFF lamp light up ESP OFF lamp light up to indicate that brake control of traction control function is controlled not to act if brake pad temperature is over 350 C 662 F and any of wheel is in wh...

Page 268: ...ion system is independent from other control modules ESP communicates control data with yaw rate G sensor assembly as follows ESP Transmission Data to Yaw Rate G Sensor Assembly Longitudinal G neutral...

Page 269: ...hydraulic unit control module assembly Wheel speed sensor RR Stop lamp switch Engine torque Accelerator pedal position Engine speed Cruise control if equipped Master cylinder cut solenoid valve No 1...

Page 270: ...RED E53 29 E53 25 E53 31 L39 5 BLK WHT L39 2 L39 1 12V PNK GRN E53 16 E53 47 BLK BLK 5V BLU WHT BLK 12V E53 7 12V E53 10 RED YEL A WHT 4 5 6 6 8 10 11 12 14 17 6 19 18 6 22 23 24 25 26 27 29 28 30 31...

Page 271: ...ow for yaw rate G sensor assembly E53 2 Right front wheel speed sensor E53 26 E53 3 Right front wheel speed sensor E53 27 E53 4 E53 28 E53 5 Left rear wheel speed sensor E53 29 CAN communication line...

Page 272: ...g lamp 7 ESP OFF switch 13 Yaw rate G sensor assembly 2 EBD warning lamp brake warning lamp 8 Rear wheel speed sensor 14 Data link connector 3 ABS warning lamp 9 Rear wheel encoder 15 Back up light sw...

Page 273: ...rance and recheck DTC Is there any malfunction DTC Go to Step 4 Go to Step 2 2 Driving test 1 Perform Step 2 Driving Test Is trouble symptom identified Go to Step 3 Go to Step 6 3 DTC check 1 Perform...

Page 274: ...tion 4E and ESP Warning lamp Check DTC check record and clearance Perform DTC Check procedure record it and then clear it referring to DTC Clearance Recheck DTC referring to DTC Check When DTC which i...

Page 275: ...ntermittent trouble is easy to occur e g wire harness connector etc referring to Intermittent and Poor Connection Inspection in Section 00 in related manual and related circuit of trouble code recorde...

Page 276: ...tch failure Vehicle behavior and stop lamp switch signal is disagreed for specified time C1017 Lateral G sensor in yaw rate G sensor assembly failure Lateral G sensor signal is out of specified range...

Page 277: ...ilure Mismatching solenoid output and solenoid monitor is detected C1042 Outlet solenoid valve circuit failure C1045 LF Inlet solenoid valve circuit failure C1046 Outlet solenoid valve circuit failure...

Page 278: ...nal to ESP control module C1092 TCM data in CAN line failure TCM sent invalid signal to ESP control module for A T model C1093 4WD control module data in CAN line failure 4WD control module sent inval...

Page 279: ...ow DTC Clearance S5JB0E4604006 WARNING When performing a driving test select a safe place where there is neither any traffic nor any traffic accident possibility and be very careful during testing to...

Page 280: ...m as normal after ignition switch turned OFF to ON C1016 C1017 X When ESP control module detects the system as normal after ignition switch turned OFF to ON C1018 X C1020 X C1021 X 1 X When estimated...

Page 281: ...to ON C1057 X 4 X C1061 X X When estimated vehicle speed exceeds 10 km h 6 5 mile h and detects system as normal C1063 X X X When ESP control module detects the system as normal after ignition switch...

Page 282: ...ABS warning lamp and ESP warning lamp are lit and ABS and TCS stability control are deactivated For 2WD vehicle ESP warning lamp is lit and TCS stability control is deactivated 3 ESP OFF mode is cance...

Page 283: ...Yaw rate sensor is measured by yaw rate G sensor assembly and output to ESP control module by pulse signal Steering angle Sen Steering wheel rotation angle is measured by steering angle sensor and ou...

Page 284: ...ol module connector viewed from terminal side 4 Junction block assembly 8 CAN driver 1 Battery 5 Combination meter 9 Junction connector 2 Main fuse box 6 ESP warning lamp 10 To TCM BCM 4WD control mod...

Page 285: ...meter connector and vehicle body ground Is resistance less than 2 Replace combination meter BLK circuit open or high resistance Step Action Yes No Step Action Yes No 1 1 Perform diagnostic trouble co...

Page 286: ...46 47 8 8 I6JB01460014 01 A ESP control module connector viewed from terminal side 5 Combination meter 10 To ECM TCM BCM SDM and 4WD control module 1 Battery 6 ESP warning lamp 11 Junction connector 2...

Page 287: ...t PPL WHT wire circuit used by all controllers or short to ground or power circuit which has occurred somewhere in serial data circuit PPL WHT wire circuit 7 1 Turn ignition switch to ON position 2 Me...

Page 288: ...and check DTC for ESP Are DTC C1034 and or C1073 detected Go to applicable DTC diag flow Go to Step 3 3 Check sensor calibration 1 Calibrate yaw rate G sensor assembly referring to Sensor Calibration...

Page 289: ...on Go to Step 4 Replace stop lamp switch 4 Check stop lamp switch circuit 1 Disconnect connector from stop lamp switch connector with ignition switch turned OFF 2 Check for proper connection to switch...

Page 290: ...el is too low Input voltage of brake fluid level switch to BCM is low Brake fluid level Brake fluid level switch circuit Brake fluid level switch BCM ESP control module Step Action Yes No 1 Was Electr...

Page 291: ...ody ground Is resistance infinity Go to Step 6 BLKL RED wire circuit is shorted to ground 6 Check BCM 1 Connect brake fluid level switch connector and BCM connector 2 Check voltage at G31 7 terminal o...

Page 292: ...ssembly and recheck Replace steering angle sensor Step Action Yes No A E53 16 1 15 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45...

Page 293: ...ESP hydraulic unit control module assembly and recheck BLU WHT wire circuit is shorted to ground Step Action Yes No DTC Detecting Condition Trouble Area Input signal voltage from master cylinder press...

Page 294: ...tion Trouble Area Power supply voltage of yaw rate G sensor assembly is too high when ignition switch OFF Power supply voltage of yaw rate G sensor assembly is too low when ignition switch ON Yaw rate...

Page 295: ...terminal L39 3 of sensor terminal Between terminal E53 31 of module connector and terminal L39 5 of sensor terminal Are resistance less than 2 Substitute a known good ESP hydraulic unit control module...

Page 296: ...ween connector terminal E45 1 and vehicle body ground with ignition switch turned ON Is it 10 14 V Go to Step 5 GRN ORN wire circuit open 5 Check steering angle sensor power supply circuit 1 Turn igni...

Page 297: ...ignition switch turned OFF 2 Turn ignition switch ON and check DTC Are DTC C1034 and or C1073 detected Go to applicable DTC diag flow Go to Step 3 3 Check sensor calibration 1 Calibrate yaw rate G se...

Page 298: ...37 Wiring Diagram DTC Detecting Condition and Trouble Area DTC Troubleshooting A E53 16 1 15 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 4...

Page 299: ...r proper connection to ESP control module connector terminal at E53 10 4 If OK then measure voltage between connector terminal E53 10 and vehicle body ground Is it 0 V Go to Step 4 RED wire circuit is...

Page 300: ...ntermittent and Poor Connection Inspection in Section 00 in related manual 4 CAN communication circuit check 1 Turn ignition switch to OFF position 2 Disconnect connectors of ESP control module and ya...

Page 301: ...e all sensors referring to Sensor Calibration 2 Clear all DTC s and check DTC for ESP Is DTC C1075 C1076 C1077 and or C1078 still detected DTC C1075 Replace steering angle sensor DTC C1076 Replace ESP...

Page 302: ...1091 ECM sent invalid signal to ESP control module Engine control system ECM ESP control module C1092 TCM sent invalid signal to ESP control module for A T model A T system TCM ESP control module C109...

Page 303: ...26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 H G45 10 9 3 2 1 1 2 3 4 9 5 7 6 8 G31 2 G31 4 10 B 2 1 E23 3 4 18 19 5 6 7 10 11 17 20 4746 49 50 51 21 22 52 16 25 9 24 14 29 55 57...

Page 304: ...manual 5 CAN communication circuit check 1 Turn ignition switch to OFF position 2 Disconnect connectors of ESP control module and TCM communicating by means of CAN Is each CAN communication circuit be...

Page 305: ...munication circuit check 1 Turn ignition switch to OFF position 2 Disconnect connectors of ESP control module and steering angle sensor communicating by means of CAN Is each CAN communication circuit...

Page 306: ...ommunication Bus Off Motor Shift Type Transfer with Shift Actuator in Section 3C for troubleshooting Go to Step 4 4 Check each control module connectors 1 Check connection of connectors of all control...

Page 307: ...t 4WD control module ESP control module Step Action Yes No 1 Was Electronic Stability Program Check performed Go to Step 2 Go to Electronic Stability Program Check 2 DTC check for ESP 1 Check DTC for...

Page 308: ...gnition switch OFF Special tool A SUZUKI scan tool 6 CAN communication circuit check 1 Disconnect connectors of all control modules communicating by means of CAN Is each CAN communication circuit betw...

Page 309: ...C first 3 Drive vehicle straight on level ground at 15 km h 9 5 mph or above for few seconds without spinning wheels And confirm that SLIP indicator lamp is OFF ESP Hydraulic Unit Control Module Assem...

Page 310: ...connector DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool 4 Turn ignition switch to ON position and select menu DATA LIST mode of SUZUKI scan tool Refer to scan tool operator s manual...

Page 311: ...SUZUKI scan tool in the following vehicle conditions Level condition Front up condition Rear up condition If Longitudinal G condition is out of specification replace yaw rate G sensor assembly Longitu...

Page 312: ...tool A SUZUKI scan tool 4 Turn ignition switch to ON position and select menu DATA LIST mode of SUZUKI scan tool Refer to scan tool operator s manual for further derails 5 Check Yaw rate sensor under...

Page 313: ...mpact to it If an excessive impact was applied never attempt disassembly or repair but replace it with a new one Removal 1 Disconnect negative cable at battery 2 Remove console rear panel referring to...

Page 314: ...n and select menu DATA LIST mode of SUZUKI scan tool Refer to scan tool operator s manual for further derails 3 Check Steering angle Sen under DATA LIST of SUZUKI scan tool in the following steering w...

Page 315: ...ch switch position If check result is not as specified replace ESP OFF switch Specifications Tightening Torque Specifications S5JB0E4607001 Reference For the tightening torque of fastener not specifie...

Page 316: ...4F 53 Electronic Stability Program...

Page 317: ...Test 5A Time Lag Test 5A Line Pressure Test 5A Engine Brake Test 5A P Range Test 5A A T Symptom Diagnosis 5A No Gear Shift to 4th Gear 5A 20 No Lock Up Occurs 5A 21 Transmission Warning Light Circuit...

Page 318: ...Pressure Control Solenoid and Pressure Control Solenoid Removal and Installation 5A Solenoid Valves Shift Solenoid A Shift Solenoid B TCC Pressure Control Solenoid and Pressure Control Solenoid Inspec...

Page 319: ...spection 5B Output Shaft Disassembly and Assembly 5B Output Shaft Inspection 5B Manual Transmission Front Case Disassembly and Assembly 5B Manual Transmission Adapter Case Disassembly and Assembly 5B...

Page 320: ...have good understanding of its functions and usage Not using scan tool if equipped with AT monitor connector the DTC stored in TCM memory also can be checked and cleared DTC stored in the TCM memory i...

Page 321: ...e of 7 positions P R N D 3 2 and L by means of the select lever installed on the floor Also by using the P N mode switch located on the console box it is possible to select the gear change timing of 2...

Page 322: ...fer 4L 4WD model only Forward 1st 2nd 3rd gear change 3 range Forward 1st 2nd 3rd automatic gear change 2 range Normal mode Forward 1st 2nd 3rd automatic gear change 2 range Power mode Forward 2nd 3rd...

Page 323: ...Torque reduction request Slip control signal Transmission emissions related malfunction active Transmission malfunction indication ON Transmission gear selector position Transmission diagnostic troubl...

Page 324: ...ear inhibit control Slope shift control Cruise shift control if equipped with cruise control system Lock up control Slip control 1 Torque control Line pressure control Overrun control Reverse control...

Page 325: ...cruise control system P N mode switch 3 position switch Input shaft speed sensor ATF temperature sensor Output shaft speed sensor 4L N switch if equipped Torque reduction request Shift switch Lock up...

Page 326: ...RED WHT RED 2 5V WHT ORN 1 2 E93 5 E93 14 2 5V BLU PNK E93 6 E93 16 15 6 9 BLK WHT 3 6 4 5 7 8 10 22 I5JB0A510009 03 A TCM connector viewed from harness side 9 P N mode switch 18 Shift solenoid valve...

Page 327: ...4th 3rd 148 153 92 95 3rd 2nd 84 89 52 55 2nd 1st 41 46 25 29 50 4th 3rd 68 73 42 45 75 80 47 50 with cruise set condition 3rd 2nd 42 47 26 29 2nd 1st 23 28 14 17 14 19 9 12 with cruise set condition...

Page 328: ...55 2nd 1st 45 50 28 31 50 4th 3rd 82 87 51 54 3rd 2nd 53 58 33 36 2nd 1st 24 29 15 18 0 4th 3rd 35 40 14 17 With applying brake pedal cost down condition 3rd 2nd 18 23 11 14 2nd 1st 16 21 10 13 Lock...

Page 329: ...ope is executed by changing the gear change point to the high speed side so as to reduce frequent up shift and down shift operations When the AT controller makes down shift judgment Slope Shift Contro...

Page 330: ...5A 11 Automatic Transmission Transaxle Component Location Electronic Shift Control System Components Location S5JB0E5103001 7 6 5 4 3 20 1 2 9 8 10 11 12 13 14 15 16 17 18 19 I5JB0A510014 02...

Page 331: ...ith engine diagnosis connector 12 Pressure control solenoid valve 17 Valve body assembly 3 BCM 8 Input shaft speed sensor 13 TCC pressure control solenoid valve 18 Transmission range sensor 4 Selector...

Page 332: ...iving cycle P072 2 Output Speed Sensor Circuit No Signal No sensor signal is inputted although input speed sensor signal is inputted 1driving cycle 1driving cycle P074 1 Torque Converter Clutch Circui...

Page 333: ...ation Bus OFF Transmitting error detected to TCM for specified time continuously 1driving cycle 1driving cycle P177 7 TCM Lost Communication with ECM Reception Error Receiving error from ECM detected...

Page 334: ...inhibited to operate Torque reducing request to ECM torque reduction control is inhibited Line pressure control at gear shifting is inhibited P07 42 Torque Converter Clutch Circuit Stuck On When vehi...

Page 335: ...umed to be 100 Throttle opening used for gear shifting control is assumed to be 0 Engine revolution is assumed to be maximum revolution Engine torque is assumed to be maximum torque Engine coolant tem...

Page 336: ...mile h constant speed 20 or less throttle opening and 3rd gear 3 range 2300 RPM displayed in increments of 50 rpm At 60 km h 37 5 mile h constant speed 20 or less throttle opening and 4th gear D range...

Page 337: ...osition R Select lever is in N position N Select lever is in D position D Select lever is in 3 position D Select lever is in 2 position 2 Select lever is in L position L Shift Sol A Con At vehicle sto...

Page 338: ...transmission range switch signal Shift Sol A Con MON ON OFF COM ON ON command being outputted to shift solenoid A COM OFF OFF command not being outputted to shift solenoid A MON ON Electricity being...

Page 339: ...ating temperature 2 Check ECT monitored by TCM using scan tool Is ECT indicated 40 C 40 F Go to Step 4 Faulty ECT sensor its circuit or engine cooling system If OK substitute a known good TCM and rech...

Page 340: ...763 or P2764 detected Perform DTC Flow to repair and retry Go to Step 3 3 ECT check 1 Warm up engine to normal operating temperature 2 Check ECT using scan tool Is ECT more than 60 C 140 F For vehicle...

Page 341: ...8 39 40 41 42 43 44 45 46 47 J G45 10 9 3 2 1 WHT RED G45 9 G45 10 E23 B 2 1 3 4 18 19 5 6 7 10 11 17 20 4746 49 50 51 21 22 52 16 25 9 24 14 29 55 57 5453 59 60 58 26 27 28 15 30 56 48 32 31 34 35 36...

Page 342: ...module Steering angle sensor if equipped 4WD control module if equipped Keyless start control module if equipped CAN communication line circuit Step Action Yes No 1 Was A T System Check performed Go...

Page 343: ...Disconnect connectors of control modules other than the one whose connector is disconnected in Step 3 one by one and check that DTC P1774 is detected by TCM each time connector is disconnected When DT...

Page 344: ...ted manual 3 DTC check in ABS ESP control module 1 Check DTC in ABS ESP control module Is there DTC U1100 Go to Step 4 Go to Step 5 4 DTC check 1 Check DTC in ECM referring to DTC Check in Section 1A...

Page 345: ...10 9 21 20 19 8 7 18 1 E93 I5JB0A510026 01 1 4L N switch 3 4WD control module 2 TCM 4 Terminal arrangement of TCM connector viewed from harness side DTC Detecting Condition Trouble Area Actual transf...

Page 346: ...or intermittent trouble referring to Intermittent and Poor Connection Inspection in Section 00 in related manual If OK substitute a known good TCM and recheck Go to Step 6 5 4L N switch and its circui...

Page 347: ...s 4H position OFF 4L position ON Is OFF ON displayed as described above Intermittent trouble or faulty TCM Check for intermittent trouble referring to Intermittent and Poor Connection Inspection in Se...

Page 348: ...anual 2 Connect TCM connectors 2 to TCM 3 Check voltage and or pulse signal at each terminal of connectors connected using voltmeter 3 and oscilloscope 4 NOTE As each terminal voltage is affected by b...

Page 349: ...er warming up CAN communication signal is pulse Pulse signal frequency varies depending on engine condition 8 9 10 YEL BLK 3 position switch 0 1 V Ignition switch ON 11 YEL BLK Transmission fluid temp...

Page 350: ...t shaft revolution 7 GRN Transmission range sensor D range 8 14 V Ignition switch ON selector lever at D range 0 1 V Ignition switch ON selector lever at other than D range 8 GRN ORN Transmission rang...

Page 351: ...ture Engine at specified idle speed with P range Measurement terminal CH1 E92 5 to E92 1 Oscilloscope setting CH1 5 V DIV Time 2 ms DIV Measurement condition After warmed up to normal operating temper...

Page 352: ...Input shaft speed sensor signal at engine speed 3000 rpm Measurement terminal CH1 E93 6 to E92 1 Oscilloscope setting CH1 2 V DIV TIME 10 ms DIV Measurement condition After warmed up to normal operati...

Page 353: ...ng bolt No 2 9 Engine to transmission bolt 17 Oil filler tube 65 N m 6 5 kgf m 47 0 lb ft 2 Torque converter mounting bolt No 2 10 Exhaust pipe No 2 bracket 18 Input shaft speed sensor 10 N m 1 0 kgf...

Page 354: ...f reverse brake piston return spring Standard free length of reverse brake piston return spring 16 84 mm 0 663 in 4 Install reverse brake piston assembly and brake piston return spring to transmission...

Page 355: ...ate and lugs of transmission case If measured value is less than standard range it is possible that something is installed improperly or dust or fluid is on reverse brake disc etc If it exceeds standa...

Page 356: ...e in grooves securely hold retaining ring 1 of planetary sun gear install center support assembly by aligning bolt holes 2 in center support and transmission case NOTE Unless retaining ring of planeta...

Page 357: ...nstalled to forward clutch hub fall off 18 When clutch disc and plate have been replaced check height difference between forward clutch input shaft and transmission case 1 by measuring as shown in the...

Page 358: ...id to new housing O ring and install it to O D case Then install converter housing 1 and tighten housing bolt to specified torque Tightening torque Torque converter housing bolt a 35 N m 3 5 kgf m 25...

Page 359: ...p seal and drive in oil lip seal with special tool till it contacts transmission case Special tool A 09923 46020 31 Install a new spacer 1 to manual shift lever 2 32 Install manual shift shaft 3 to tr...

Page 360: ...o accumulator piston and install accumulator piston to transmission case Accumulator spring specification 39 After confirming that accumulator piston is pushed all the way down match pin of manual shi...

Page 361: ...noid And install new gasket and brake applying cover Tightening torque Transmission wire connector bolt a 16 N m 1 6 kgf m 11 5 lb ft 43 Connect solenoid coupler to each solenoid 44 Install oil strain...

Page 362: ...hten nut After tightening it bend claws of lock washer Tightening torque Manual shift shaft nut a 12 5 N m 1 25 kgf m 9 0 lb ft 50 With neutral reference line 1 and cut groove 2 in switch aligned tigh...

Page 363: ...Fastening part Tightening torque Note N m kgf m lb ft Center support bolt 26 2 6 19 0 Torque converter housing bolt 35 3 5 25 5 Torque converter housing bolt 58 5 8 42 0 Oil pump bolt 22 2 2 16 0 Park...

Page 364: ...5A 45 Automatic Transmission Transaxle...

Page 365: ...llation without Keyless Start System 6B Steering Lock Assembly Ignition Switch Removal and Installation 6B Adjustable Steering Column Release Lever Inspection 6B Steering Angle Sensor Inspection 6B 4...

Page 366: ...End Ball Joint Inspection 6C P S Gear Case Assembly Components 6C P S Gear Case Assembly Removal and Installation 6C Steering Gear Case Mount Bushing Removal and Installation 6C Steering Gear Case Mou...

Page 367: ...y the specified screws bolts and nuts be used as designated and that they are tightened to the specified torque When the column assembly 6 is removed from the vehicle special care must be taken in han...

Page 368: ...ing column assembly mounting bolt 33 N m 3 3 kgf m 24 0 lb ft 4 Steering column upper cover 12 Steering column assembly mounting nut After tightening column mounting nut tighten column mounting bolt 2...

Page 369: ...m 5 Disconnect all connectors for contact coil cable assembly 6 Remove contact coil cable assembly 1 with steering angle sensor if equipped from steering column 7 Separate steering angle sensor from c...

Page 370: ...ering Wheel Removal and Installation in related manual and Contact Coil Cable Assembly Removal and Installation 2 Remove steering angle sensor 2 from contact coil cable assembly 3 while opening fittin...

Page 371: ...ations S5JB0E6207001 NOTE The specified tightening torque is also described in the following Steering Wheel and Column Construction Reference For the tightening torque of fastener not specified in thi...

Page 372: ...6B 6 Steering Wheel and Column...

Page 373: ...val and Installation 7A HVAC Control Module and Its Circuits Inspection for Vehicle without A C 7A Air Flow Control Actuator Removal and Installation 7A Air Flow Control Actuator Inspection 7A Tempera...

Page 374: ...Circuit Malfunction 7B DTC B1562 Outside Air Temperature Sensor and or Its Circuit Malfunction 7B DTC B1563 A C Refrigerant Pressure Sensor and or Its Circuit Malfunction 7B HVAC Control Module and It...

Page 375: ...el 7B Magnet Clutch Removal and Installation for J20 Engine Model 7B Thermal Switch On Vehicle Inspection for M16 Engine Model 7B Thermal Switch Removal and Installation for M16 Engine Model 7B Relief...

Page 376: ...7A 1 Heater and Ventilation Heater and Ventilation Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S5JB0E7102001 Refer to A C System Wiring Circuit Diagram in Section 7B...

Page 377: ...r Temperature selector MODE air flow selector Blower speed selector Air intake selector AUTO switch A C switch Compressor relay Blower motor controller Temperature control actuator Air flow control ac...

Page 378: ...WHT BLU BLK RED PNK YEL PPL WHT BLK BLK RED RED BLK PPL GRN G52 10 G52 11 G52 6 G52 5 YEL RED PNK GRN PNK BLK RED GRN WHT BLK GRY GRN GRY RED GRY BLK M M RED YEL RED RED BLK BLU WHT BLK WHT RED BLK R...

Page 379: ...To rear defogger relay 12 Air intake control actuator 28 Radiator fan No 2 44 To combination switch 13 Air flow control actuator 29 ECM 45 AUTO ON head light system vehicle 14 Sunload sensor 30 Outsi...

Page 380: ...code from BCM continuously CMP sensor circuit CMP sensor HVAC control module Step Action Yes No 1 DTC check 1 Connect scan tool to DLC with ignition switch turned OFF 2 Check ECM for DTC Is there DTC...

Page 381: ...skin is frostbitten or frozen Do not handle refrigerant near any place where welding or steam cleaning is performed Refrigerant should be kept in a cold and dark place It should never be stored in any...

Page 382: ...high charging hose 1 and low charging hose 2 of manifold gauge set 3 respectively as follows High charging hose 1 High pressure charging valve 4 on discharge hose Low charging hose 2 Low pressure cha...

Page 383: ...of A C system at after the initial charging is performed from the high pressure side with the engine stopped Never charge to high pressure side of A C system with engine running Do not charge while co...

Page 384: ...de valve 6 WARNING Make sure that high pressure side valve is closed securely 5 Start engine and keep engine speed at 1 500 rpm Then operate A C system 6 Charge A C system with refrigerant in vapor st...

Page 385: ...ifold gauge set The high pressure side valve is closed continuously during the process of charging 2 Close refrigerant container valve 3 Stop engine 4 Using shop rag remove charging hoses from service...

Page 386: ...86012 Relief Valve On Vehicle Inspection for M16 Engine Model S5JB0E7206044 Using special tool check is there is refrigerant leakage If there is refrigerant leakage replace relief valve 1 Special too...

Page 387: ...f wire LHD 5dr 9A J Front and rear door wire K Roof wire RHD 3dr 9A J Front and rear door wire K Roof wire LHD 3dr 9A Floor 9A L Floor harness Rear height sensor wire R Fuel pump wire RHD 5dr 9A L Flo...

Page 388: ...9A Q Connector 9A R Connector 9A Lighting Systems 9B 1 Precautions 9B Precautions for Discharge Headlight Service If Equipped 9B Precautions in Diagnosing Troubles Vehicle Equipped with Auto Leveling...

Page 389: ...Location 9C Audio System Component Location 9C Diagnostic Information and Procedures 9C 4 Speedometer Symptom Diagnosis 9C 4 Tachometer Symptom Diagnosis 9C 4 Engine Coolant Temperature ECT Meter Sym...

Page 390: ...eral Description 9E Rear End Door Window Defogger System Description 9E Windshield Construction 9E Rear Quarter Window Construction 9E Diagnostic Information and Procedures 9E Rear End door Window Def...

Page 391: ...ns 9H Floor Carpet Removal and Installation 9H Head Lining Removal and Installation 9H Console Box Components 9H Sun Roof T Top Convertible Top 9I General Description 9I Power Sliding Sun Roof System...

Page 392: ...f Contents Exterior Trim 9M Repair Instructions 9M Roof Drip Molding Removal and Installation If Equipped 9M Roof Rail Removal and Installation If Equipped 9M Splash Guard Removal and Installation If...

Page 393: ...adlight Service Refer to Precautions for Discharge Headlight Service If Equipped in Section 9B in related manual Precautions for Body Service S5JB0E9000002 WARNING For vehicles equipped with a Supplem...

Page 394: ...3 BLU BLK RED BLU 5V G51 5 PNK G51 17 RED G51 11 G51 24 YEL GRN GRN BLK 6 12V G51 18 GRN 7 8 G51 6 G51 9 BLU WHT G51 10 11 12 13 16 17 18 19 20 3 1 5 6 9 21 22 23 24 A I5JB0D920001 01 A Headlight leve...

Page 395: ...flashing NOTE Use of SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or output side of BCM For checking procedure refer to Diagnosis Using Output Test Function...

Page 396: ...it Bulbs blown Replace bulbs Front fog light switch faulty Check front fog light switch referring to Front Fog Light Switch Inspection If Equipped in related manual Front fog light relay faulty Check...

Page 397: ...t as specified replace switch Without rear fog light switch and auto on headlight switch With rear fog light switch A LH steering vehicle B RH steering vehicle C Terminal D Shaft condition C D 5 3 1 2...

Page 398: ...3 and 4 If there is continuity replace relay 4 Connect battery positive terminal to terminal 2 of relay and battery negative terminal to terminal 1 of relay 5 Check continuity between terminal 3 and 4...

Page 399: ...S5JB0E9206028 Check for continuity between terminals at each switch position If check result is not as specified replace switch A Other than RH steering vehicle without rear fog light B RH steering ve...

Page 400: ...Info Horn General Description CAN Communication System Description S5JB0E9301001 Refer to CAN Communication System Description in Section 1A for CAN communication system description Combination meter...

Page 401: ...trol signal Charging system warning light signal charge warning light control signal Engine oil pressure switch signal oil pressure warning light control signal Parking brake switch signal brake warni...

Page 402: ...nfo Horn Schematic and Routing Diagram Combination Meter Circuit Diagram S5JB0E9302001 7 6 5 4 17 G28 8 G28 10 9 9 G28 22 16 G28 16 1 2 10 G28 13 G28 14 8 11 12 13 14 15 G28 19 3 G28 20 3 G28 11 3 G28...

Page 403: ...ipped G28 22 To illumination cancel switch if equipped 17 16 11 1 22 10 21 9 20 8 19 7 18 6 15 5 14 4 13 3 12 2 I5JB0A930002 01 Condition Possible cause Correction Reference Item Speedometer shows no...

Page 404: ...s faulty Low fuel warning light comes ON steady Low fuel Refill fuel Data information can not be received by CAN communication Check ECM for DTC referring to DTC Check in Section 1A in related manual...

Page 405: ...ondition Possible cause Correction Reference Item Warning buzzer shows no sounding Circuit fuse blown Replace fuse and check for short circuit Driver side door switch faulty Check driver side door swi...

Page 406: ...ay does not change at 30 C Outside air temperature is 30 C 22 F or less Outside air temperature sensor faulty Check outside air temperature sensor referring to Outside Air Temperature Sensor Inspectio...

Page 407: ...terminals a and b at each float position in the following If the measured value is out of specification replace fuel pump and or sub fuel level sensor Main fuel level sensor A specifications Sub fuel...

Page 408: ...b terminals under each condition below If check result is not satisfactory replace remote audio control switch Remote audio control switch resistance All switches released OFF 4700 5600 ENTER switch 1...

Page 409: ...negative terminal to terminal 2 3 Connect voltmeter positive lead to terminal 4 and its negative lead to terminal 2 4 Check that the voltmeter indicates the battery voltage 10 14 V 5 Connect terminal...

Page 410: ...to terminal 4 and its negative lead to terminal 2 4 When front washer switch is ON check that voltage changes as shown in figure If check result is not satisfied replace switch A RH steering vehicle w...

Page 411: ...eck for continuity between terminals at each switch position If check result is not as specified replace switch A RH steering vehicle without rear fog light B Other than RH steering vehicle without re...

Page 412: ...9D 4 Wipers Washers...

Page 413: ...Component Location 10B BCM and Related System Component Location 10B Diagnostic Information and Procedures 10B 4 BCM Self Diagnosis Function 10B Body Electrical Control System Check 10B 4 Scan Tool Da...

Page 414: ...Lock Function of Keyless Start System 10E Operation Area of Remote Controller 10E 1 Alarm Function 10E CAN Communication System Description 10E 2 Schematic and Routing Diagram 10E 3 Keyless Start Sys...

Page 415: ...he speed in memory automatically after cruise control is cancelled RES ACC switch The system mainly consists of electric throttle body assembly ECM cruise control switch MAIN ON OFF switch SET COAST s...

Page 416: ...SP control module through CAN communication and calculates vehicle speed using that signal Brake light switch Brake light switch has 2 contact points One contact point closes when brake pedal is depre...

Page 417: ...shifted to P R or N range CANCEL switch is turned ON ESP is operating if equipped NOTE When constant cruising is cancelled under any condition with asterisk vehicle speed before cancellation can be re...

Page 418: ...0 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 1...

Page 419: ...related manual Wiring or grounding faulty Repair Combination meter faulty Replace ECM faulty Replace after making sure that none of above parts is faulty Vehicle speed can not be set MAIN ON OFF swit...

Page 420: ...n CPP Switch for Cruise Control Inspection and Adjustment in related manual Wiring or grounding faulty Repair ECM faulty Replace after making sure that none of above parts is faulty Cruise control at...

Page 421: ...tion for CAN Communication System in Section 00 in related manual before inspection and handle CAN communication line General Description BCM General Description S5JB0EA201001 The BCM incorporates rel...

Page 422: ...e fluid level switch signal Parking brake switch signal Seat belt buckle switch signal Charging system signal Engine oil pressure switch signal Illumination ON signal Diagnostic trouble code DTC Door...

Page 423: ...G32 3 BLU RED B B B G32 7 BLU WHT B ORN BLU G31 2 G31 4 LT GRN RED G31 17 YEL BLK PNK GRN BB PNK BLU GRN YEL G31 8 G31 7 G31 40 G31 27 G31 26 G31 24 G31 9 G31 39 G31 38 G31 18 G31 19 G31 20 G30 9 G30...

Page 424: ...Turn signal and hazard warning relay HI High beam position 17 Brake fluid level switch 38 Hazard warning switch A Auto position 18 Parking brake switch 39 Interior light C Clearance position 19 Door k...

Page 425: ...r not any fault exists Troubleshooting for DTC Based on the DTC indicated in Step 3 and referring to applicable DTC flow locate the cause of the trouble namely in a sensor wire harness connector BCM o...

Page 426: ...t pressed Neutral Unlock side of manual door lock switch pressed Unlock Driv Door Sw Driver side door open Open Driver side door closed Close Pass Door Sw Doors other than driver side door open Open D...

Page 427: ...tate of the lighting switch Driv Seat belt Sw Driver seat belt switch Fasten Unfasten This parameter indicates the state of the driver side seat belt buckle switch Charge Light ON OFF This parameter i...

Page 428: ...B1150 1150 b1150 Air bag communication circuit malfunction Air bag communication circuit open or short to ground B1157 1157 b1157 Air bag deployment signal input Air bag deployment signal inputted B11...

Page 429: ...9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 G31 WHT BLK BLK RED 5V G31 24 G31 21 1 2 2 3 1 I5JB0AA20007 01 1 Outside air temperature sensor 3 Outside...

Page 430: ...Sensor Inspection If Equipped in Section 9C in related manual Is it in good condition Go to Step 2 Replace outside air temperature sensor 2 Outside air temperature sensor circuit check 1 Disconnect c...

Page 431: ...2 23 24 25 2 3 4 5 6 7 8 9 10 11 12 1 13 14 26 8 7 6 5 4 3 2 1 9 10 11 12 13 14 15 16 G31 2 WHT 1 2 3 4 9 5 6 7 8 11 WHT RED G45 9 G45 10 10 L K E03 12 E03 10 E03 6 E03 8 J E53 16 1 15 2 3 4 5 6 7 8 9...

Page 432: ...or ESP control module TCM A T model Keyless start control module if equipped ECM Steering angle sensor if equipped Step Action Yes No 1 Control module connector check 1 Check connection of connectors...

Page 433: ...n DTC U1073 is not detected by BCM while checking in this way go to description under NO below If DTC U1073 is detected by BCM even when connectors of all control modules that use CAN communication wi...

Page 434: ...istance Is each CAN communication circuit in good condition Go to Step 8 Repair circuit 8 CAN communication circuit check 1 Disconnect connectors of all control modules communicating by means of CAN 2...

Page 435: ...3 3 Control module connector check 1 Check connection of connectors of all control modules communicating by means of CAN 2 Recheck BCM for DTC Is DTC U1101 No 1101 detected Go to Step 4 Intermittent t...

Page 436: ...and check that DTC U1101 is detected by BCM each time connector is disconnected When DTC U1101 is not detected by BCM while checking in this way go to description under NO below If DTC U1101 is detect...

Page 437: ...ion of connectors of all control modules communicating by means of CAN 2 Recheck BCM for DTC Is DTC U1144 No 1144 detected Go to Step 4 Intermittent trouble Check for intermittent referring to Intermi...

Page 438: ...1144 is detected by BCM each time connector is disconnected When DTC U1144 is not detected by BCM while checking in this way go to description under NO below If DTC U1144 is detected by BCM even when...

Page 439: ...or s manual carefully to know how to use it and what functions are available Be sure to read Precautions for Electrical Circuit Service in Section 00 in related manual before inspection Communication...

Page 440: ...10 G42 19 G42 18 G42 20 G42 29 G42 30 5V ORN BRN YEL BLK YEL G22 3 G22 7 G22 8 G28 13 PPL RED 1 2 2 2 2 2 3 4 2 5 6 7 15 9 10 11 12 13 14 BLK BLK RED G24 5 G24 6 14 E03 8 E03 10 E03 12 E03 6 8 19 1 2...

Page 441: ...module or ECM Flash P1616 Unregistered keyless start control module for vehicle with keyless start system ECM detects different ID codes registered in ECM and keyless start system Flash P1618 Keyless...

Page 442: ...ble Code DTC Check in related manual Is any DTC other than P1614 is detected Perform troubleshooting referring to the corresponding flowchart in this section and then go to Step 3 Go to Step 3 3 Regis...

Page 443: ...the Ignition Key in related manual Detecting Condition and Trouble Area 5 Immobilizer control module ICM check 1 Check immobilizer control module ICM referring to Inspection of Immobilizer Control Mo...

Page 444: ...hooting referring to the corresponding flowchart Go to Step 5 5 Steering lock unit check 1 Turn on the engine start knob of the keyless start system Is the engine start knob at ON position Replace the...

Page 445: ...icle body ground Between G42 30 terminal of keyless start control module connector and vehicle body ground Is each resistance infinity Go to Step 10 Repair short to ground wire circuit in malfunctiona...

Page 446: ...Step Action Yes No 1 Diagnostic Trouble Code DTC confirmation 1 Clear DTC s referring to Diagnostic Trouble Code DTC Clearance in related manual 2 Turn the ignition switch to OFF position 3 Check if a...

Page 447: ...ulty Step Action Yes No 1 Diagnostic Trouble Code DTC confirmation 1 Clear DTC s referring to Diagnostic Trouble Code DTC Clearance in related manual 2 Turn the ignition switch to OFF position 3 Check...

Page 448: ...wire circuits between ABS ESP control module and keyless start control module 1 Disconnect connector G31 from BCM connector 2 Disconnect connector G28 from combination meter 3 Measure resistance at th...

Page 449: ...t to power supply wire circuit in CAN communication wire circuits 8 Check of keyless start control module power and ground wire circuits 1 Check keyless start control module power and ground wire circ...

Page 450: ...13 and E23 28 wire terminals are normal Is each wire connection normal Go to Step 5 Repair poor connection s 5 Check for open in power supply wire circuit 1 Connect immobilizer control module ICM conn...

Page 451: ...wire terminal at ECM connector Is resistance infinite Repair open in communication wire circuit Go to Step 11 11 Check for short to ground wire circuit in communication wire circuit 1 With immobilize...

Page 452: ...ual Is immobilizer control module ICM normal Replace ECM with new one referring to Engine Control Module ECM Removal and Installation in Section 1C in related manual and then perform Procedure after E...

Page 453: ...in related manual Replace immobilizer control module ICM with new one referring to Immobilizer Control Module ICM Removal and Installation in related manual Step Action Yes No Detecting Condition Trou...

Page 454: ...o Step 2 The troubleshooting is completed 2 Diagnostic Trouble Code DTC check in ECM Is any DTC other than P1636 detected in Step 1 Perform the troubleshooting referring to the corresponding flowchart...

Page 455: ...cted referring to Diagnostic Trouble Code DTC Check in related manual Is DTC P1638 still detected Go to Step 2 The troubleshooting is completed 2 Diagnostic Trouble Code DTC confirmation 1 Disconnect...

Page 456: ...ed Go to Step 6 The troubleshooting is completed 7 Replacement of ECM 1 Replace ECM with new one referring to Engine Control Module ECM Removal and Installation in Section 1C in related manual 2 Check...

Page 457: ...in some metallic container which disturb radio wave transmission reception One of doors is open The ignition key is inserted in the ignition key cylinder The function of the keyless start system to pr...

Page 458: ...ggage room CAN Communication System Description S5JB0EA501007 Refer to CAN Communication System Description in Section 1A for CAN communication system description Keyless start control module communic...

Page 459: ...1 2 3 4 5 6 7 8 9 10 11 14 15 16 36 34 33 32 30 29 24 23 37 18 19 20 WHT WHT BLU WHT BLU WHT RED WHT RED WHT RED WHT RED 6 7 8 9 10 11 12 13 14 15 1 18 21 2 3 5 4 19 20 16 17 I5JB0DA50002 01 A Keyles...

Page 460: ...ne with care referring to Precaution for CAN Communication System in Section 00 in related manual Replacement of the keyless start control module When keyless start control module is replaced with new...

Page 461: ...increasing order NOTE Go to No DTC Detection After Performing DTC Check in related manual in case that any DTC is detected after performing the procedure mentioned above 7 After completing the check...

Page 462: ...isconnect negative cable at battery 2 Remove keyless start control module from vehicle body referring to Keyless Start Control Module Removal and Installation in related manual 3 Connect connector to...

Page 463: ...witch of driver side door is released 0 1 V Request switch of driver side door is pushed G44 17 G44 18 CAN communication line low 1 6 2 5 V Refer to Reference waveform No 4 G44 19 CAN communication li...

Page 464: ...e door antenna CH1 G44 2 to G44 9 CH2 G44 1 to G44 9 Passenger side door antenna CH1 G44 24 to G44 9 CH2 G44 23 to G44 9 Rear end door antenna CH1 G44 4 to G44 9 CH2 G44 3 to G44 9 Oscilloscope settin...

Page 465: ...Measurement terminal CH1 G44 8 to G44 9 CH2 G44 7 to G44 9 Oscilloscope setting CH1 10 V DIV CH2 10 V DIV TIME 20 ms DIV Measurement condition Request switch of each door is pushed with remote contro...

Page 466: ...terminal Driver side door lock switch CH1 G42 33 to G42 9 Passenger side door lock switch CH2 G42 37 to G42 9 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 1 s DIV Measurement condition Press lock...

Page 467: ...lock switch CH2 G42 37 to G42 9 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 400 ms DIV Measurement condition Driver door is at unlock position and passenger side door is at lock position 1 Lock...

Page 468: ...13 14 26 8 7 6 5 4 3 2 1 9 10 11 12 13 14 15 16 G31 2 WHT 1 2 3 4 9 5 6 7 8 11 WHT RED G45 9 G45 10 10 L K E03 12 E03 10 E03 6 E03 8 J E53 16 1 15 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 2...

Page 469: ...0 or DTC U1101 detected Go to applicable DTC diag flow Go to Step 4 4 CAN communication circuit check 1 Check connection of connectors of all control modules communicating by means of CAN 2 Disconnect...

Page 470: ...d disconnect connectors of control module other than keyless start control module one by one to check if DTC No 31 is detected If DTC No 31 is detected even through connector of control module other t...

Page 471: ...del ECM Steering angle sensor if equipped Step Action Yes No 1 Was Keyless Start System Check performed Go to Step 2 Go to Keyless Start System Check in related manual 2 Control module connector check...

Page 472: ...DTC No 33 detected Using same method disconnect connectors of control module other than keyless start control module and combination meter one by one to check if DTC No 33 is detected If DTC No 33 is...

Page 473: ...Prepared by 1st Ed Jan 2006...

Page 474: ...19 mm 19 mm 99501 64J00 01E SUPPLEMENTARY SERVICE MANUAL 99501 64J00 01E 99501 64J00 01E SUPPLEMENTARY SERVICE MANUAL FOR ESP MODEL...

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