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6C

ENGINE FUEL

6C-1

1. Fuel tank
2. Fuel level gauge
3. Fuel pump
4. Fuel filler cap
5. Breather hose
6. Fuel feed line (to feed pipe)
7. Fuel return line (from return pipe)
8. 2-way check valve
9. Fuel tank protector

10. Belt
11. Fuel tank bolt
12. Fuel tank protector bolt
13. Fuel level gauge bolt

: Tightening Torque

GENERAL DESCRIPTION

6C -1

. . . . . . . . . . . . . .

Fuel System

6C -1

. . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE

6C -2

. . . . . . . . . . . . . . . .

Water Draining of Fuel System

6C -2

. . . . . . . . .

Air Bleeding of Fuel System

6C -2

. . . . . . . . . . . .

Fuel Filter Element

6C-2

. . . . . . . . . . . . . . . . . . .

Fuel Pump

6C-4

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Pump

6C -4

. . . . . . . . . . . . . . . . . . . . . . .

2-way Check Valve

6C -5

. . . . . . . . . . . . . . . . . . .

Fuel Tank

6C -5

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Level Gauge

6C-7

. . . . . . . . . . . . . . . . . . . .

Fuel Heater

6C-7

. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6C

ENGINE FUEL

CAUTION:
Be sure to read “Precaution” in Section 6E before disconnecting fuel line or removing fuel system part(s).
Failure to follow “Precaution” could result unneeded fuel system repairs.

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION

FUEL SYSTEM

The main components of the fuel system are fuel tank, fuel pump, high pressure fuel pump, fuel filter and fuel level
gauge and it includes three lines and fuel feed line, fuel return line.

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Summary of Contents for GRAND VITARA XL-7

Page 1: ...em compo nents or wiring Modifications can adverse ly affect air bag system performance and lead to injury D If the vehicle will be exposed to tempera tures over 93_C 200_F for example during a paint...

Page 2: ...etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product information available at the time of publication app...

Page 3: ...ND AIR CONDITIONING Heater and Ventilation Air Conditioning BODY ELECTRICAL SYSTEM Instrumentation Driver Information Immobilizer Control System TABLE OF CONTENTS SECTION GENERAL INFORMATION General I...

Page 4: ...of the Service Manual men tioned in FOREWORD of this manual CONTENTS PRECAUTIONS 0A 2 General Precautions 0A 2 IDENTIFICATION INFORMATION 0A 5 Vehicle Identification Number 0A 5 Engine Identification...

Page 5: ...that the area you work in is well ventilated D To avoid getting burned keep away from hot metal parts such as the radiator exhaust manifold tail pipe muffler etc D New and used engine oil can be hazar...

Page 6: ...the proper order and position D Whenever you use oil seals gaskets packing O rings lock ing washers split pins self locking nuts and certain other parts as specified be sure to use new ones Also befo...

Page 7: ...an be re installed correctly D After servicing fuel oil coolant vacuum exhaust or brake systems check all lines related to the system for leaks D For vehicles equipped with fuel injection systems neve...

Page 8: ...EHICLE IDENTIFICATION NUMBER The number is punched on the chassis inside the tire housing on the right front side ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block TRANSMISSION...

Page 9: ...pretensioner label on retractor 10 Air bag label on SDM 11 Air bag label on driver air bag inflator module 12 Air bag label on combination switch and contact coil assembly 13 Air bag label on steerin...

Page 10: ...rect diameter thread pitch and strength CAUTION Note that both ISO and JIS type bolts and nuts are used for the engine assembly and related parts Even when the diam eter of the thread is the same its...

Page 11: ...g Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury D Technical servic...

Page 12: ...5 60 75 90 whichever comes first Miles x 1 000 9 18 27 36 45 54 Months 12 24 36 48 60 72 1 ENGINE 1 1 Accessory drive belt I R 1 2 Camshaft timing belt Replace every 150 000 km 90 000 miles 1 3 Engine...

Page 13: ...damage I I I I I I 6 8 Suspension system tightness damage rattle breakage I I I 6 9 Propeller shafts and drive shafts I I 6 10 Manual transmission oil leakage level I 1st 15 000 km only I R R 6 11 Aut...

Page 14: ...2 000 miles A C D E F G H ITEM 1 3 Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months B ITEM 1 5 Exhaust pipe mountings I Every 15 000 km 9 000 miles or 12 months C ITEM 3 1 I Every 2...

Page 15: ...t belt for cracks cuts deformation wear and cleanliness using mirror under enough lighting If any defect exists replace 3 Check that belt wear check mark 1 tension indicator is within range a using mi...

Page 16: ...oils 5W 30 API CF except CF 2 or ACEA B3 98 15W 40 API SG CF except CF 2 or ACEA B2 96 Select the appropriate oil viscosity according to the left chart Before draining engine oil check engine for oil...

Page 17: ...ish oil until oil level is brought to FULL level mark on dip stick about 4 75 liters or 10 0 8 4 US Imp pt NOTE Note that amount of oil required when actually changing oil may somewhat differ from thi...

Page 18: ...r than 16_C 3_F Even in a market where no freezing temperature is antici pated mixture of 70 water and 30 ethylene glycol base coolant should be used for the purpose of corrosion protec tion and lubri...

Page 19: ...r to SECTION 6K for torque specification of bolts and nuts D Check nearby body areas for damaged missing or mispositioned parts open seams holes loose connections or other defects which could permit e...

Page 20: ...ure all clamps are secure Repair leaky joints if any Replace hoses that are suspected of being cracked ITEM 3 3 Fuel Filter Replacement WARNING This work must be performed in a well ventilated area an...

Page 21: ...d If oil is found insufficient pour specified amount of specified oil 5 Tighten level plug to specified torque Refer to Section 7A2 for installation and tightening torque Change Change transmission oi...

Page 22: ...tem for fluid leakage and hose for damage and deterioration Repair or replace defective parts if any 2 With engine stopped check fluid level indicated on fluid tank which should be between MAX and MIN...

Page 23: ...ylene glycol base coolant Antifreeze Anticorrosion coolant Brake fluid DOT 3 Manual transmission oil Refer to Section 7A or 7A2 Transfer oil Refer to Section 7A or 7A2 Differential oil front rear Refe...

Page 24: ...GS could result in unintentional activation of the system or could render the system inoperative Either or these two conditions may result in severe injury D Technical service work must be started at...

Page 25: ...use Inspection correction Supplementary heater won t operate with its switch ON D Fuses blown D Supplementary heater switch faulty D Supplementary heater relay faulty D Radiator fan signal relay fault...

Page 26: ...fan motor 23 A C controller 24 ECM 25 Supplementary heater 26 Supplementary heater relay 27 Supplementary heater switch 28 Radiator fan signal relay HEATER AND VENTILATION 1A 3 WIRING CIRCUIT SUPPLEM...

Page 27: ...ssary INSTALLATION Reverse removal procedure for installation nothing the following D When installing supplementary ceramic heater be careful not to keep in contact with wiring harness or other parts...

Page 28: ...elay 4 Check that there is no continuity between terminal c and d when a 12 V battery is connected to terminals a and b If malfunction is found replace it with a new one SUPPLEMENTARY HEATER SWITCH RE...

Page 29: ...1A 6 HEATER AND VENTILATION INSPECTION D Check for switch and lamps by tester If there is continuity between terminal as shown in table supple mentary heater switch 1 functions good INSTALLATION Rever...

Page 30: ...must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve en...

Page 31: ...Ventilation air 11 Foot air 12 Defroster air 13 Demister air 14 Fresh air 15 Recirculation air 16 Heater unit 17 Air inlet box 18 Dual Refrigerant pressure switch 19 Low pressure charge valve 20 High...

Page 32: ...heck A C controller Cool air won t come out A C condenser fan motor won t operative D Condenser fan motor relay faulty D Wiring or grounding faulty D A C condenser fan relay signal in ECM faulty D Con...

Page 33: ...faulty D Excessive charge of refrigerant Repair as necessary Check expansion valve Replace condenser dryer and evacuation and charging Check A C controller Check magnetic clutch Check charge of refrig...

Page 34: ...or fan relay 3 low 11 Radiator fan motor No 2 12 Blower motor relay 13 Blower motor 14 Blower motor resistor 15 Blower motor switch 16 A C switch and mode controller 17 Compressor relay 18 Compressor...

Page 35: ...relay 3 low 11 Radiator fan motor No 2 12 Blower motor relay 13 Blower motor 14 Blower motor resistor 15 Blower motor switch 16 A C switch and mode controller 17 Compressor relay 18 Compressor 19 A C...

Page 36: ...checked at A C controller 1 and ECM wiring couplers by measuring voltage Voltage Check NOTE For ECM terminal voltage check refer to INSPECTION OF ECM PCM AND ITS CIRCUITS in Section 6 1 Remove A C co...

Page 37: ...roller 6 Defroster position switch LH model only 7 Defroster Foot position switch LH model only 8 A C switch 9 Compressor relay 10 Compressor 11 A C evaporator thermistor A C evaporator temperature se...

Page 38: ...bid AC1 10 G B A C switch and or defroster switch ON signal input Ground to engine Fig B 0 3 0 3 V Fulfill all the following conditions DBlower fan motor switch ON DFulfill either the following condit...

Page 39: ...12 15 V Except the above mentioned condition with engine running C51 47 Y B A C ON signal input ECM ground 12 15 V A C ON E227 29 Y B g from A C controller g terminal 0 3 0 3 V A C OFF A C ON signal i...

Page 40: ...If belt tension is without specification adjust belt tension referring to below procedures Compressor drive belt tension a 9 mm 0 35 in ADJUSTMENT 1 Loosen tension pulley nut 4 2 Adjust belt tension...

Page 41: ...move condenser cooling fan motor relay 1 compressor relay 2 condenser cooling fan control relay 4 and or A C sig nal relay 5 from vehicle 3 Check that there is no continuity between terminal c and d I...

Page 42: ...of compressor oil at removed must be mea sured and the same amount must be poured when installing the compressor 5 Disconnect thermal protector lead wire 6 Disconnect suction hose 1 and discharge hose...

Page 43: ...to engine bracket 2 3 Connect suction hose 3 and discharge hose 4 to compressor 1 4 Install compressor drive belt 5 referring to DRIVE BELT in this section 5 Connect thermal protector lead wire 6 Inst...

Page 44: ...m may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE D For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in F...

Page 45: ...of relieved pressure shown below Relieved pressure 7850 kPa 78 5 kg cm2 1116 psi DIAGNOSIS POWER STEERING PUMP DRIVE BELT INSPECTION For the details refer to INSPECTION of GENERATOR BELT in Section 6H...

Page 46: ...en each flare nut to specified torque CAUTION Take care not to cause damage to A C condenser during service operation if equipped Special Tool A 09915 77410 Oil pressure gauge B 09915 77420 2 Check ea...

Page 47: ...is malfunction of relief valve D When it is lower than specified values possible cause is ei ther failure of P S pump or settling of relief valve spring CAUTION Be sure not to close gauge valve for l...

Page 48: ...8 5 lb ft 1 Power steering pump assembly 2 P S fluid reservoir 3 High pressure hose pipe 4 Suction pipe 5 Low pressure return pipe 6 Steering gear case LH For left hand steering vehicle RH For right h...

Page 49: ...ive belt 5 Remove P S pump mounting bolt s 6 Remove P S pump NOTE Plug each port of removed pump to prevent dust or any oth er foreign matter from entering DISASSEMBLY AND ASSEMBLY For the disassembly...

Page 50: ...47 0 Pump bracket bolt 25 2 5 18 5 Pump union bolt 60 6 0 43 5 Oil pump mount bolts 25 2 5 18 5 Pipe clamp bolt Reservoir bracket bolt 11 1 1 8 0 Steering shaft joint bolt 25 2 5 18 0 High pressure fl...

Page 51: ...ajor repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replace ment part of lesser quality or substitute de...

Page 52: ...housing side A Sealant 99000 31110 D Install differential carrier assembly to axle housing and tighten carrier bolts to specified torque Tightening torque Differential carrier bolt a 55 N m 5 5 kg m...

Page 53: ...iller drain plug drain plug 27 2 7 16 0 Wheel nut 100 10 0 72 5 Wheel speed sensor bolt 21 2 1 15 5 REQUIRED SERVICE MATERIAL Material Recommended SUZUKI product Part Number Use Lithium grease SUZUKI...

Page 54: ...09942 15510 Sliding hammer 09943 35512 Brake drum remover 09944 88210 Bearing installer 3E 4 REAR SUSPENSION SPECIAL TOOL...

Page 55: ...DRIVE SHAFT SHAFT BEARING OIL SEAL NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in the FOREWORD of this manual CONTENTS ON VEHI...

Page 56: ...oint grease in the tube included in spare part 2 Fit wheel side boot on shaft Fill up inside of boot with remainder of joint grease of about 90 gram Before fixing boot band insert screwdriver into boo...

Page 57: ...uter race and fit boot to outer race Fill up inside of boot with joint grease A Joint Grease about 90 100 g 3 2 3 5 oz 10 Fitting boot to outer race adjust so that measurements b and c become as indic...

Page 58: ...RED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Drive shaft oil seal Wheel spindle part of differential side drive shaft RH Sealant SEALIN...

Page 59: ...SHAFTS NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in the FOREWORD of this manual CONTENTS ON VEHICLE SERVICE 4B 2 Propeller Sh...

Page 60: ...lb ft Rear propeller shaft flange bolts a 60 N m 6 0 kg m 43 5 lb ft D When installing propeller shaft align the match marks Otherwise vibration may occur during driving NOTE If transfer oil was drain...

Page 61: ...P0180 Fuel Temp Sensor Circuit Malfunction 6 39 DTC P0190 P0190 Fuel Rail Pressure Sensor Circuit Malfunction 6 40 DTC P0191 P0230 Fuel Rail Pressure Sensor Pressure Regulator Consistency Function 6...

Page 62: ...TC P0603 P0606 G P1171 P1617 ECM Function 6 55 DTC P1169 P0170 Condenser Voltage Function 1 6 55 DTC P1170 P0170 Condenser Voltage Function 2 6 55 DTC P1101 P0105 Barometric Pressure Sensor Circuit Ma...

Page 63: ...before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts D Throughout this manual the four cylinders of the engine a...

Page 64: ...engine and exhaust system are hot D Fuel or fuel vapor hose connection varies with each type of pipe When reconnecting fuel or fuel vapor hose be sure to connect and clamp each hose correctly referri...

Page 65: ...e till fuel pressure is felt by hand placed on fuel return hose 2 In this state check to see that there are no fuel leakages from any part of low pressure fuel system between fuel pump and in jection...

Page 66: ...ble even when the malfunction indicator lamp MIL doesn t turn ON it should be diagnosed according to this flow table ON BOARD DIAGNOSTIC SYSTEM ECM PCM in this vehicle has the following functions D Wh...

Page 67: ...eze Frame Data NOTE Freeze frame data can be read using generic scan tool or Euro mode of Suzuki scan tool ECM PCM stores the engine and driving conditions in the form of data as shown at the left at...

Page 68: ...e as clearance of diagnostic trouble code DTC Data Link Connector DLC DLC in compliance with SAE J1962 in its installation position the shape of connector and pin assignment K and L lines of ISO 9141...

Page 69: ...an tool 2 Diagnostic trouble codes other than listed below DTC indicated by generic scan tool or Euro mode of Suzuki scan tool DTC indicated by Suzuki mode of Suzuki scan tool P0100 P0120 P0170 P0190...

Page 70: ...o the Trouble Symptom Confirmation in this section Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame data refe...

Page 71: ...of the items that support proper function of the engine referring to Visual Inspection section 5 TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 Customer complaint analysis and S...

Page 72: ...tal Condition Weather Temperature Frequency Road VFair VCloudy VRain VSnow VAlways VOther ______________ _F _C VHot VWarm VCool VCold VAlways VAlways VSometimes times day month VOnly once VUnder certa...

Page 73: ...further details If communication between scan tool and ECM PCM is not pos sible check if scan tool is communicable by connecting it to ECM PCM in another car If communication is possible in this case...

Page 74: ...uel temp sensor Each control is performed based on 90_C P0110 Intake air temp sensor in mass air flow Each control is performed based on 50_C P0235 P0235 Intake air pressure sensor Each control is per...

Page 75: ...ing cycle l P0201 P0200 Injector circuit malfunction cyl 1 Monitor signal of fuel injection 1 is different from command signal circuit open or short or Poor performance of Fuel Injector 1 1 driving cy...

Page 76: ...ent detected Insufficient EGR flow 1 driving cycle 1 driving cycle P0402 P0903 EGR solenoid valve flow excessive detected Excessive EGR flow 1 driving cycle 2 driving cycles P0500 P0500 VSS circuit ma...

Page 77: ...function Monitor signal of pre post heating relay is different from command signal 1 driving cycle 2 driving cycles P1511 Ignition switch circuit malfunction Ignition signal is not memorized in ECM 1...

Page 78: ...ioration bend D Connectors of electric wire harness disconnection friction D Fuses burning D Parts installation bolt looseness D Parts deformation D Other parts that can be checked visually Also add f...

Page 79: ...D Go to DIAGNOSIS in Section 8G if Suzuki scan tool is not available Go to Step 8 7 Check immobilizer system malfunction as follows 1 Execute Data List mode of Suzuki mode using ECM application of Su...

Page 80: ...el pressure regulator D Faulty fuel injector D Faulty ECT sensor Glow system out of order D Faulty glow plug D Faulty pre post heating relay Low compression D Compression leak from valve seat D Sticky...

Page 81: ...re regulator Faulty fuel pressure sensor Faulty TP sensor accelerator stroke sensor D Faulty VSS D Faulty CKP sensor D Faulty ECT sensor Glow system out of order D Faulty glow plug D Faulty pre post h...

Page 82: ...clogged Water mixed in D Dirty or clogged fuel hose or pipe D Fuel injection pipe Cracks Fuel leakage from joints D Clogged fuel injector Engine overheating Engine and emission control system out of...

Page 83: ...an sealant D Leaky crankshaft oil seal D Leaky cylinder head cover gasket D Improper tightening of oil filter D Loose oil pressure switch D Blown cylinder head gasket D Leaky crankshaft pulley oil sea...

Page 84: ...ed air cleaner element D EGR throttle valve Engine and emission control system out of order D Faulty ECM D Faulty fuel injection pump Pump internal damage Fuel injector D Faulty intake air pressure se...

Page 85: ...1 Disconnect ECM from bracket referring to ENGINE CONTROL MODULE in this section 2 Remove harness cover 2 from ECM connector assembly 3 by removing clamp 4 3 Remove ECM cover 1 from ECM connector afte...

Page 86: ...tor assembly 3 by fas tening clamp 4 and then lock ECM connector using lock lever 6 NOTE When clamp replacement is necessary be sure to use a clamp with width and thickness as specified below or less...

Page 87: ...esistance in table represents that when parts temper ature is 20_C 68_F TERMINAL CIRCUIT STANDARD RESISTANCE CONDITION C51 2 to C51 30 Fuel injector No 1 Max 0 6 C51 5 to C51 6 Fuel injector No 2 Max...

Page 88: ...unning INSPECTION STEP ACTION YES NO 1 MIL Power Supply Check 1 Turn ignition switch ON Do other indicator warning lights in combination meter comes ON Go to Step 2 IG fuse blown main fuse blown Ignit...

Page 89: ...LOW TABLE in this section Go to Step 2 2 MIL circuit Check 1 With ignition switch OFF disconnect couplers from ECM PCM Does MIL turn ON at ignition switch ON PPL YEL wire shorted to ground circuit Sub...

Page 90: ...switch disconnect connectors from ECM PCM and install main relay 2 Check for proper connection to ECM PCM at terminals C51 69 C51 86 C51 29 and C51 1 3 If OK then measure voltage between terminal C51...

Page 91: ...at the following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE D Intake air temp 8_C 18_F or higher D Engine coolant temp 8 110_C 18 230_F D Altitude barometric pressure 2400 m...

Page 92: ...AF sensor output voltage Check 1 With ignition switch OFF connect MAF sensor coupler 2 Remove ECM PCM cover 3 Start engine and check voltage between C51 13 and C51 33 terminal at idle speed Is voltage...

Page 93: ...ed for 10 sec or more 3 Then run engine over 3000 rpm for 10 sec or more 4 Check DTC and pending DTC TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE...

Page 94: ...E AIR TEMP IAT CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame da...

Page 95: ...e applied to PPL GRN wire terminal of harness side about 5 V Go to Step 4 PPL GRN wire open or shorted to power or poor C51 11 connection If wire and connection are OK substitute a known good ECM and...

Page 96: ...Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness 1 Remove intercooler referring to INTERCOOLER in Section 6E3 2 Disconnect ECT sensor connector with ignition switch OFF 3 Check for proper con...

Page 97: ...NGE PERFORMANCE PROBLEM DTC P0604 P0120 THROTTLE POSITION SENSOR MONITORING SYSTEM MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON i...

Page 98: ...then with ignition switch ON check voltage between LT GRN wire and BRN wire terminals at connector of TP sensor Is voltage about 5 V Go to Step 4 LT GRN wire open BRN wire open poor C51 44 connection...

Page 99: ...NGINE DIAG FLOW TABLE 2 1 Remove intercooler referring to INTERCOOLER in Section 6E3 2 Disconnect fuel temp sensor connector with ignition switch OFF 3 Check for proper connection to fuel temp sensor...

Page 100: ...ESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze flame dat...

Page 101: ...sensor at each terminals 3 If OK then with ignition switch ON check voltage between LT GRN wire and GRY wire terminals at connector of fuel pressure sensor Is voltage about 5 V Go to Step 4 LT GRN wir...

Page 102: ...ATOR CONSISTENCY FUNCTION DTC P1112 P0230 FUEL PRESSURE MONITORING CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition...

Page 103: ...r Output Voltage 1 Remove ECM cover referring to Voltage Check in the Section 2 Connect fuel pressure sensor connector 3 Start engine and check voltage between C51 74 and C51 33 terminal at idle speed...

Page 104: ...OR CIRCUIT MALFUNCTION CYLINDER 2 DTC P0203 P0200 INJECTOR CIRCUIT MALFUNCTION CYLINDER 3 DTC P0204 P0200 INJECTOR CIRCUIT MALFUNCTION CYLINDER 4 WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect sc...

Page 105: ...ween terminals of all fuel injectors infinity Go to Step 3 Short circuit between PNK wire and RED wire PNK BLK wire and RED BLK wire PNK GRN wire and RED GRN wire or PNK BLU wire and RED BLU wire 3 Ch...

Page 106: ...itch ON for 5 sec and then OFF Is click of double relay heard from double relay at 2 sec after ignition switch OFF Substitute a known good ECM and recheck Go to Step 3 3 1 Remove ECM cover referring t...

Page 107: ...TEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Is operating sound heard from fuel pump Substitute a known good ECM and recheck Go to Step 3 3 Chec...

Page 108: ...NE WITH SINGLE CONNECTOR ECM DTC P0243 P0243 TURBO PRESSURE SOLENOID VALVE CIRCUIT RANGE PERFORMANCE PROBLEM WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch O...

Page 109: ...tor disconnected and ground Within 5 sec after ignition switch ON about 12 V Over 5 sec after ignition switch ON 0 V Is check result as specified Go to Step 4 BLU WHT wire open shorted to power ground...

Page 110: ...essure regulator solenoid valve for resistance referring to BOOST PRESSURE REGULATOR SOLENOID VALVE in Section 6E3 Is resistance as specified Substitute a known good ECM and recheck See NOTE Replace b...

Page 111: ...to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness 1 Remove ECM cover from ECM referring to CHECK VOLTAGE in this section 2 Check voltage between C51 88 C51 69 and ground with ignition switch...

Page 112: ...p 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness Not Using Suzuki Scan Tool 1 Disconnect connector at ECM with ignition switch OFF 2 Supply battery power 12 V to C51 56 using service wire Dose gl...

Page 113: ...pm for 10 or more 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check EGR vacuum...

Page 114: ...Is operating sound heard from fuel pump Go to Step 3 Proceed to DTC P0230 Diag Flow table 3 Check Wire Harness 1 Disconnect EGR solenoid valve connector with ignition switch turned OFF 2 With ignitio...

Page 115: ...RING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze flame data by using scan tool 3 Run engine at...

Page 116: ...and freeze flame data by using scan tool 3 Start engine and warm up completely 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed...

Page 117: ...warm up completely 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harne...

Page 118: ...tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness 1 Remove ECM cover from ECM referring to Voltage Check in...

Page 119: ...to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Is operating sound heard from fuel pump Go to Step 3 Proceed to DTC P0230 Diag Flow table 3 Check Wire Harness 1 Disconnect injection pump solenoid valve conn...

Page 120: ...DIAG FLOW TABLE 2 Check Wire Harness 1 Disconnect connector at fuel pressure regulator 2 Check voltage between YEL terminal of regula tor connector and ground with ignition switch ON D Ignition switch...

Page 121: ...DIAG FLOW TABLE 2 Is operating sound heard from fuel pump Go to Step 3 Proceed to DTC P0230 Diag Flow table 3 Check Wire Harness 1 Disconnect EGR throttle solenoid valve connector with ignition switc...

Page 122: ...can tool 3 Turn off ignition switch and then on 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG...

Page 123: ...GINE DIAGNOSIS RHZ ENGINE WITH SINGLE CONNECTOR ECM 6 63 DTC P1519 RADIATOR FAN CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P1108 P1109 TROUBLESHOOTING Proceed to DTC P1108 and P1109 TROUBLESHOOTI...

Page 124: ...switch and then on 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 MIL Circuit Chec...

Page 125: ...witch and then on 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Engine Coolant Wa...

Page 126: ...NE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 LT GRN Circuit Check 1 Disconnect connector at intake air pressure sensor 2 Check voltage between LT GRN wire terminal of conne...

Page 127: ...e of Suzuki Scan tool P0560 Go to DTC P1614 P0560 Diag Flow Table Go to Step 3 3 Check Wire Harness 1 Disconnect connector from TP sensor with ignition switch OFF 2 Check for proper connection to TP s...

Page 128: ...0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC an...

Page 129: ...eck 1 With ignition switch OFF disconnect CKP sensor coupler and remove CKP sensor 2 Check resistance between terminals of CKP sensor See Fig Were measured resistance values as specified in Step 2 Fau...

Page 130: ...G FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Sensor Power Supply Circuit 1 Connect scan tool to DLC with ignition switch OFF and then turn ignition switch ON 2 Dose scan to...

Page 131: ...erminals of sensor connector disconnected Is voltage about 5 V Go to Step 8 BRN YEL wire open short or poor connection If wire and connection are OK substitute a known good ECM and recheck See NOTE 8...

Page 132: ...f a traffic accident and be very careful during testing to avoid occurrence of an accident D Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool to...

Page 133: ...hort 4 VSS Signal Harness Check 1 With ignition switch ON leaving engine OFF check voltage between BLU YEL wire terminal and BLK wire terminal of VSS coupler Is voltage 4 V or more Go to Step 5 Go to...

Page 134: ...oad test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE D In...

Page 135: ...Remove ECM cover referring to Voltage Check in this section 2 Check voltage C51 71 and ground with ignition switch ON Is it between 1 and 5 V Intermittent trouble or faulty ECM Check for intermittent...

Page 136: ...00 STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 1 Remove ECM cover referring to Voltage Check in this section 2 While engine running check volt...

Page 137: ...l Pump Circuit Check 1 With ignition switch OFF remove double relay from connector 2 Check for proper connection to relay at each terminal 3 If OK using service wire connect terminals 8 and 5 of relay...

Page 138: ...ation even if fuel pump and line are in good condition STEP ACTION YES NO 1 1 Install fuel pressure gauge referring to Low Pressure Fuel Supply System Inspection in Section 6E3 2 Operate fuel pump Is...

Page 139: ...ee NOTE B below 09931 76011 Tech 1A kit SUZUKI scan tool See NOTE A below 09931 76030 16 14 pin DLC cable SPECIAL TOOLS NOTE D A This kit includes the following items and substitutes for the Tech 2 ki...

Page 140: ...on 6 1 16 DTC P0180 Fuel Temp Sensor Circuit Malfunction 6 1 18 DTC P0190 P0190 Fuel Rail Pressure Sensor Circuit Malfunction 6 1 19 DTC P0191 P0230 Fuel Rail Pressure Sensor Pressure Regulator Consis...

Page 141: ...P1171 P1617 ECM Function 6 1 34 DTC P1169 P0170 Condenser Voltage Function 1 6 1 34 DTC P1170 P0170 Condenser Voltage Function 2 6 1 34 DTC P1101 P0105 Barometric Pressure Sensor Circuit Malfunction 6...

Page 142: ...6 in this manual CUSTOMER PROBLEM INSPECTION FORM Refer to SECTION 6 in this manual MALFUNCTION INDICATOR LAMP MIL CHECK Refer to SECTION 6 in this manual DIAGNOSTIC TROUBLE CODE DTC CHECK Refer to SE...

Page 143: ...ferring to ENGINE CON TROL MODULE ECM in Section 6E3 2 Remove harness clamps 1 from ECM harness connector as semblies 2 3 Remove connector covers 3 from ECM harness connector as semblies loosing conne...

Page 144: ...9 Connect ECM connector assemblies to ECM using connector lock lever securely NOTE When clamp replacement is necessary be sure to use a clamp with width and thickness as specified below or less If a l...

Page 145: ...this check D Resistance in table represents that when parts temper ature is 20_C 68_F TERMINAL CIRCUIT STANDARD RESISTANCE CONDITION E229 2 to E229 9 Fuel injector No 1 Max 0 6 E229 25 to E229 17 Fue...

Page 146: ...unning INSPECTION STEP ACTION YES NO 1 MIL Power Supply Check 1 Turn ignition switch ON Do other indicator warning lights in combination meter comes ON Go to Step 2 IG fuse blown main fuse blown Ignit...

Page 147: ...LOW TABLE in this section Go to Step 2 2 MIL circuit Check 1 With ignition switch OFF disconnect couplers from ECM PCM Does MIL turn ON at ignition switch ON PPL YEL wire shorted to ground circuit Sub...

Page 148: ...tch disconnect connectors from ECM PCM and install main relay 2 Check for proper connection to ECM PCM at terminals E227 11 E228 24 E228 1 and E228 2 3 If OK then measure voltage between terminal E227...

Page 149: ...the following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE D Intake air temp 8_C 18_F or higher D Engine coolant temp 8 110_C 18 230_F D Altitude barometric pressure 2400 m 80...

Page 150: ...WHT BLK wire 3 MAF sensor output voltage Check 1 With ignition switch OFF connect MAF sensor coupler 2 Remove ECM PCM cover 3 Start engine and check voltage between E228 29 and E228 30 terminal at idl...

Page 151: ...ed for 10 sec or more 3 Then run engine over 3000 rpm for 10 sec or more 4 Check DTC and pending DTC TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE...

Page 152: ...KE AIR TEMP IAT CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame d...

Page 153: ...applied to PPL RED wire terminal of harness side about 5 V Go to Step 4 PPL RED wire open or shorted to power or poor E228 28 connection If wire and connection are OK substitute a known good ECM and r...

Page 154: ...o Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness 1 Remove intercooler referring to INTERCOOLER in Section 6E3 2 Disconnect ECT sensor connector with ignition switch OFF 3 Check for proper co...

Page 155: ...ANGE PERFORMANCE PROBLEM DTC P0604 P0120 THROTTLE POSITION SENSOR MONITORING SYSTEM MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON...

Page 156: ...then with ignition switch ON check voltage between LT GRN wire and BRN wire terminals at connector of TP sensor Is voltage about 5 V Go to Step 4 LT GRN wire open BRN wire open poor E227 23 connection...

Page 157: ...NGINE DIAG FLOW TABLE 2 1 Remove intercooler referring to INTERCOOLER in Section 6E3 2 Disconnect fuel temp sensor connector with ignition switch OFF 3 Check for proper connection to fuel temp sensor...

Page 158: ...RESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame da...

Page 159: ...at each terminals 3 If OK then with ignition switch ON check voltage between LT GRN BLK wire and GRY wire terminals at connector of fuel pressure sensor Is voltage about 5 V Go to Step 4 LT GRN BLK w...

Page 160: ...TOR CONSISTENCY FUNCTION DTC P1112 P0230 FUEL PRESSURE MONITORING CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition s...

Page 161: ...sor Output Voltage 1 Remove ECM cover referring to Voltage Check in the Section 2 Connect fuel pressure sensor connector 3 Start engine and check voltage between E228 6 and E227 32 terminal at idle sp...

Page 162: ...TOR CIRCUIT MALFUNCTION CYLINDER 2 DTC P0203 P0200 INJECTOR CIRCUIT MALFUNCTION CYLINDER 3 DTC P0204 P0200 INJECTOR CIRCUIT MALFUNCTION CYLINDER 4 WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect s...

Page 163: ...tween terminals of all fuel injectors infinity Go to Step 3 Short circuit between PNK wire and RED wire PNK BLK wire and RED BLK wire PNK GRN wire and RED GRN wire or PNK BLU wire and RED BLU wire 3 C...

Page 164: ...witch ON for 5 sec and then OFF Is click of double relay heard from double relay at 2 sec after ignition switch OFF Substitute a known good ECM and recheck Go to Step 3 3 1 Remove ECM cover referring...

Page 165: ...TEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Is operating sound heard from fuel pump Substitute a known good ECM and recheck Go to Step 3 3 Chec...

Page 166: ...H TRIPLE CONNECTOR ECM 6 1 27 DTC P0243 P0243 TURBO PRESSURE SOLENOID VALVE CIRCUIT RANGE PERFORMANCE PROBLEM WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch...

Page 167: ...ctor disconnected and ground Within 5 sec after ignition switch ON about 12 V Over 5 sec after ignition switch ON 0 V Is check result as specified Go to Step 4 BLU WHT wire open shorted to power groun...

Page 168: ...ressure regulator solenoid valve for resistance referring to BOOST PRESSURE REGULATOR SOLENOID VALVE in Section 6E3 Is resistance as specified Substitute a known good ECM and recheck See NOTE Replace...

Page 169: ...to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness 1 Remove ECM cover from ECM referring to CHECK VOLTAGE in this section 2 Check voltage between E229 7 E227 11 and ground with ignition swit...

Page 170: ...p 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness Not Using Suzuki Scan Tool 1 Disconnect connector at ECM with ignition switch OFF 2 Supply battery power 12 V to E227 14 using service wire Dose g...

Page 171: ...rpm for 10 or more 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check EGR vacuum...

Page 172: ...2 Is operating sound heard from fuel pump Go to Step 3 Proceed to DTC P0230 Diag Flow table 3 Check Wire Harness 1 Disconnect EGR solenoid valve connector with ignition switch turned OFF 2 With igniti...

Page 173: ...IRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC and freeze frame data by using scan tool 3 Run engine a...

Page 174: ...and freeze frame data by using scan tool 3 Start engine and warm up completely 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed...

Page 175: ...warm up completely 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harn...

Page 176: ...tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Wire Harness 1 Remove ECM cover from ECM referring to Voltage Check in...

Page 177: ...p 2 Go to ENGINE DIAG FLOW TABLE 2 Is operating sound heard from fuel pump Go to Step 3 Proceed to DTC P0230 Diag Flow table 3 Check Wire Harness 1 Disconnect injection pump solenoid valve connector w...

Page 178: ...DIAG FLOW TABLE 2 Check Wire Harness 1 Disconnect connector at fuel pressure regulator 2 Check voltage between YEL terminal of regula tor connector and ground with ignition switch ON D Ignition switc...

Page 179: ...DIAG FLOW TABLE 2 Is operating sound heard from fuel pump Go to Step 3 Proceed to DTC P0230 Diag Flow table 3 Check Wire Harness 1 Disconnect EGR throttle solenoid valve connector with ignition switc...

Page 180: ...can tool 3 Turn off ignition switch and then on 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG...

Page 181: ...42 ENGINE DIAGNOSIS RHZ ENGINE WITH TRIPLE CONNECTOR ECM DTC P1519 RADIATOR FAN CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P1108 P1109 TROUBLESHOOTING Proceed to DTC P1108 and P1109 TROUBLESHOOT...

Page 182: ...switch and then on 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 MIL Circuit Chec...

Page 183: ...witch and then on 4 Check DTC and pending DTC by using scan tool TROUBLESHOOTING STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Engine Coolant Wa...

Page 184: ...FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check TP Sensor Circuit 1 Disconnect connector from TP sensor with ignition switch turned OFF 2 Turn ON ignition switch 3 Check voltage...

Page 185: ...sure sensor harness connector and vehicle body ground Is voltage about 5 1 V to 4 88 V Go to Step 7 LT GRN wire shorted to other circuits If wire are OK substitute a known good ECM and recheck 7 Check...

Page 186: ...e of Suzuki Scan tool P0560 Go to DTC P1614 P0560 Diag Flow Table Go to Step 3 3 Check Wire Harness 1 Disconnect connector from TP sensor with ignition switch OFF 2 Check for proper connection to TP s...

Page 187: ...P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ON ignition switch and clear DTC pending DTC a...

Page 188: ...heck 1 With ignition switch OFF disconnect CKP sensor coupler and remove CKP sensor 2 Check resistance between terminals of CKP sensor See Fig Were measured resistance values as specified in Step 2 Fa...

Page 189: ...AG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 Check Sensor Power Supply Circuit 1 Connect scan tool to DLC with ignition switch OFF and then turn ignition switch ON 2 Dose scan t...

Page 190: ...terminals of sensor connector disconnected Is voltage about 5 V Go to Step 8 BRN YEL wire open short or poor connection If wire and connection are OK substitute a known good ECM and recheck See NOTE 8...

Page 191: ...of a traffic accident and be very careful during testing to avoid occurrence of an accident D Road test should be carried out with 2 persons a driver and a tester on a level road 1 Connect scan tool t...

Page 192: ...short 4 VSS Signal Harness Check 1 With ignition switch ON leaving engine OFF check voltage between BLU YEL wire terminal and BLK wire terminal of VSS coupler Is voltage 4 V or more Go to Step 5 Go t...

Page 193: ...Road test should be carried out with 2 persons a driver and a tester on a level road NOTE Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO CEDURE D I...

Page 194: ...1 Remove ECM cover referring to Voltage Check in this section 2 Check voltage E228 45 and ground with ignition switch ON Is it between 1 and 5 V Intermittent trouble or faulty ECM Check for intermitte...

Page 195: ...00 STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 Go to ENGINE DIAG FLOW TABLE 2 1 Remove ECM cover referring to Voltage Check in this section 2 While engine running check volt...

Page 196: ...el Pump Circuit Check 1 With ignition switch OFF remove double relay from connector 2 Check for proper connection to relay at each terminal 3 If OK using service wire connect terminals 8 and 5 of rela...

Page 197: ...cation even if fuel pump and line are in good condition STEP ACTION YES NO 1 1 Install fuel pressure gauge referring to Low Pressure Fuel Supply System Inspection in Section 6E3 2 Operate fuel pump Is...

Page 198: ...r Tech 1A Tech 2 kit SUZUKI scan tool See NOTE B Mass storage cartridge for Tech 1A SPECIAL TOOLS NOTE D A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Ope...

Page 199: ...gative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CAUTION Be sure to read Precaution in Section 6E before d...

Page 200: ...g load on engine for M T vehicle 8 Crank engine and inspect compression pressure Compression pressure specification at cranking engine engine speed is 250 rpm or more Minimum 2 5 MPa 25 kg cm2 356 psi...

Page 201: ...nect ECM connector to ECM 14 Connect negative cable at battery AIR CLEANER ELEMENT REMOVAL 1 Remove air cleaner case clamps 2 Remove air cleaner element from case INSPECTION Check air cleaner element...

Page 202: ...let hose referring to IN TERCOOLER in Section 6E3 5 Remove intercooler bracket 1 heater outlet pipe 2 heater inlet pipe 3 vacuum pipe 4 and bracket 5 6 Remove upper timing belt cover 7 Disconnect brea...

Page 203: ...gasket will not get out of place or fall off 4 Connect breather hose 1 and PCV hose 2 to cylinder head cover Special Tool A 09919 46510 OUT0000110 5 Install CMP sensor if removed 6 Check CMP sensor ai...

Page 204: ...Remove exhaust manifold with turbocharger referring to TURBOCHARGER in Section 6E3 2 Remove throttle valve assembly referring to THROTTLE VALVE ASSEMBLY in Section 6E3 3 Remove heater inlet pipe 1 va...

Page 205: ...ake manifold gasket D Check to ensure that all removed parts are back in place Rein stall any necessary parts which have not been reinstalled D Install exhaust manifold with turbocharger referring to...

Page 206: ...bolt 11 Timing belt tensioner bolt 12 Roller bolt Tightening Torque TIMING BELT AND BELT TENSIONER ENGINE WITH CAMSHAFT HUB REMOVAL 1 Disconnect negative cable at battery 2 Remove A C compressor belt...

Page 207: ...haft hub 1 inserting special tool A into cylin der head hole 2 as shown in figure Special Tool A 09910 26540 OUT0000151 11 Lock flywheel MT or drive plate AT inserting special tool B into holes in bot...

Page 208: ...at this time Tightening Torque Roller bolt a 45 N m 4 5 kg m 32 5 lb ft 2 Check that camshaft hub 5 is locked inserting special tool A into cylinder head hole 6 as shown in figure Special Tool A 0991...

Page 209: ...specified torque Special Tool B 09919 56550 OUT0000141 Tightening Torque Timing belt tensioner bolt a 25 N m 2 5 kg m 18 0 lb ft 8 By removing camshaft timing belt pulley bolt 1 check to make sure tha...

Page 210: ...ool B 09919 56550 OUT0000141 Tightening Torque Timing belt tensioner bolt a 25 N m 2 5 kg m 18 0 lb ft 15 Tighten camshaft timing belt pulley bolts to specified torque Tightening Torque Camshaft timin...

Page 211: ...5 N m 19 5 kg m 141 lb ft by turning it to about 50_ Tightening Torque Crankshaft pulley bolt a 195 N m 19 5 kg m 141 lb ft Sealant A LOCTITE 273 22 Install bracket 1 23 Install radiator referring to...

Page 212: ...haft timing belt pulley bolt 11 Timing belt tensioner bolt TIMING BELT AND BELT TENSIONER ENGINE WITHOUT CAMSHAFT HUB REMOVAL 1 Disconnect negative cable at battery 2 Remove A C compressor belt if equ...

Page 213: ...as shown in figure Special tool A 09910 26540 OUT0000151 10 Remove fuel filter assembly 11 Lock flywheel MT or drive plate AT inserting special tool B into holes in both cylinder block and flywheel M...

Page 214: ...26530 OUT0000160 3 Install timing belt tensioner 1 and roller 2 Do not tighten timing belt tensioner bolt with wrench yet Tighten by hand only at this time Tightening torque Roller bolt a 45 N m 4 5...

Page 215: ...and then lock camshaft timing belt pulley 1 inserting special tool C into cylinder head hole as shown in figure Special tool C 09910 26540 OUT0000151 13 Lock flywheel MT or drive plate AT inserting s...

Page 216: ...rankshaft pulley bolt 5 22 Install crankshaft pulley bolt 5 with crankshaft locked by using flat end rod 4 or the like apply sealant to crankshaft pulley bolt 5 and tighten it gradually as follows a T...

Page 217: ...n in figure Special tool A 09910 26540 OUT0000151 b Flywheel MT or drive plate AT is locked inserting special tool B into holes in both cylinder block and flywheel MT or drive plate AT Special tool B...

Page 218: ...ctor 4 Install degassing tank to its bracket 5 Start engine and check for oil leakage OIL COOLER REMOVAL 1 Drain engine coolant 2 Detach degassing tank from its bracket 3 Remove oil filter 1 4 Disconn...

Page 219: ...Remove oil level gauge 2 Raise vehicle and remove both front wheels 3 Remove steering gear box 1 from vehicle referring to Section 3B1 4 Remove front differential housing 2 with differential from chas...

Page 220: ...stening bolts 1 9 Remove oil pan bolts Bolt 1 at the rear of power steering pump bracket 2 should be loosened only It is not possible to remove it due to interfer ence with bracket 10 Remove oil pan 1...

Page 221: ...block Remove oil old sealant and dust from mating surfaces and in side of oil pan INSTALLATION 1 Apply sealant to oil pan mating surface continuously as shown in figure A Sealant 99000 31150 2 Using n...

Page 222: ...ing one bolt at a time Tighten bolts to specified torque Tightening Torque a 16 N m 1 6 kg m 11 5 lb ft 5 Install new gasket and drain plug 3 to oil pan Tighten drain plug to specified torque Tighten...

Page 223: ...ction 7E 10 Install steering gear box to vehicle referring to Section 3B1 11 Install oil level gauge 12 Refill engine with engine oil referring to item ENGINE OIL CHANGE in Section 0B 13 Refill power...

Page 224: ...to oil seal lip Do not reuse OIL PUMP REMOVAL 1 Disconnect negative cable at battery 2 Remove timing belt referring to TIMING BELT AND BELT TEN SIONER in this section 3 Remove oil pan and oil pump st...

Page 225: ...mp sprocket and or oil pump rotor shaft might be damaged INSPECTION D Check rotor 3 and oil pump cases 1 2 for excessive wear or damage D Check relief valve 4 for excessive wear or damage D Check teet...

Page 226: ...SSEMBLY 1 Wash clean and then dry all disassembled parts 2 Apply thin coat of engine oil to rotors and inside surface of each oil pump case 3 Assemble oil pump After assembling oil pump check to be su...

Page 227: ...sealant to mating surface of gasket holder plate A Sealant 99000 31150 4 Install gasket holder plate 1 to cylinder block 5 Install crankshaft timing belt pulley 2 6 Install oil pump strainer and oil p...

Page 228: ...ey engine without camshaft hub Tightening Torque Do not reuse Apply engine oil to sliding surface of each part 45 N m 4 5 kg m 32 5 lb ft 25 N m 2 5 kg m 18 0 lb ft 10 N m 1 0 kg m 7 5 lb ft 52 N m 5...

Page 229: ...g bolts in such order as indicated in figure and remove them 8 Remove camshaft housing 9 Remove camshaft and camshaft oil seal 10 Remove valve rocker 1 with ball valve rocker 2 NOTE D Never disassembl...

Page 230: ...ump side 11 Knock pin Tightening Torque Do not reuse Apply engine oil to sliding surface of each part 60 N m 6 0 kg m 43 5 lb ft and retighten 220_ 8 VALVES AND CYLINDER HEAD REMOVAL 1 Disconnect nega...

Page 231: ...water hose 4 radiator outlet hose No 1 5 and inlet fuel hoses 6 from water outlet box 12 Remove oil level gauge upper guide bolt 13 Disconnect fuel pressure sensor connector ECT sensor con nector and...

Page 232: ...bocharger water outlet box injectors and common rail using lifting device DISASSEMBLY 1 For ease in servicing cylinder head remove intake manifold ex haust manifold with turbocharger water outlet box...

Page 233: ...fter compress valve springs and then remove valve cotters 1 by using special tool Forceps as shown Special Tool A 09916 14510 B 09916 14910 C 09916 84511 5 Release special tool and remove spring retai...

Page 234: ...urnals on camshaft 1 and set camshaft to camshaft housing 2 Fit camshaft housing with camshaft to cylinder head 4 After applying oil to housing bolts tighten them temporarily first Then tighten them b...

Page 235: ...40 OUT0000151 Tightening torque Camshaft timing pulley bolt b 52 N m 5 2 kg m 37 5 lb ft 7 Install camshaft timing belt pulley and tighten bolts by hand 8 Install vacuum pump to cylinder head referrin...

Page 236: ...ses from this gasketed joint is often due to warped gasketed surface such leakage results in reduced power output Limit of distortion 0 05 mm 0 002 in ASSEMBLY 1 Install valve to valve guide Before in...

Page 237: ...ecial tool and dial gauge measure projection b at two points A and B and take an average Repeat this procedure with each piston Special Tool A 09910 26510 OUT 0000005 b Using the largest value among a...

Page 238: ...ten them gradual ly as follows a Tighten all bolts to 20 N m 2 0 kg m 14 5 lb ft according to numerical order in figure b In the same manner as in Step a tighten them to 60 N m 6 0 kg m 43 5 lb ft c R...

Page 239: ...m 4 5 kg m 32 5 lb ft Engine bracket bolt No 2 b 20 N m 2 0 kg m 14 5 lb ft D Adjust generator belt tension referring to Section 6H D Adjust A C compressor belt tension if equipped referring to Sectio...

Page 240: ...l pump strainer referring to OIL PAN AND OIL PUMP STRAINER in this section 4 Remove oil pump referring to OIL PUMP in this section 5 Remove cylinder head referring to VALVES AND CYLINDER HEAD in this...

Page 241: ...ring expander remove two compression rings Top and 2nd and oil ring from piston 2 Remove piston pin from connecting rod D Ease out piston pin circlips 1 as shown D Force piston pin out CLEANING Clean...

Page 242: ...necting rod fit connecting rod to piston so that bear ing lock tab 3 and arrow mark 4 come on the same side and insert piston pin to piston and connecting rod and install piston pin circlips 2 Install...

Page 243: ...kshaft pulley side 1 4 Install piston and connecting rod assembly into cylinder bore Use special tool Piston ring compressor to compress rings Guide connecting rod into place on crankshaft Using a ham...

Page 244: ...removed parts are back in place Rein stall any necessary parts which have not been reinstalled 11 Refill engine with engine oil referring to ENGINE OIL CHANGE in Section 0B 12 Refill cooling system r...

Page 245: ...ENGINE COOLING section 6 Remove air cleaner outlet hose 7 Remove intercooler 8 Remove transmission assembly referring to Section 7A or 7B 9 Disconnect following electric wires D Intake air pressure se...

Page 246: ...fluid hose clamp from bracket 11 With hose connected detach A C compressor and power steering pump from bracket if equipped 12 Drain engine oil if necessary 13 Install lifting device 14 Remove engine...

Page 247: ...may become detached and cause turbo system failure D Install transmission assembly referring to Section 7A or 7B D Adjust generator belt tension referring to Section 6H D Adjust A C compressor belt t...

Page 248: ...ain bearing cap bolt No 2 Follow tightening procedure referring to Installation 15 Input shaft bearing 16 Flywheel 17 Flywheel bolt 18 Bearing cap seal 19 O ring Tightening Torque Do not reuse 1 Cylin...

Page 249: ...nkshaft timing belt pulley D Oil pump oil pump drive sprocket and gasket holder plate D Cylinder head assembly D Piston and connecting rod 3 Remove clutch cover clutch disc and flywheel drive plate an...

Page 250: ...der block point bearing lock tab toward oil filter side 1 and install each cap from that side to crankshaft pulley side in ascending order of numbers 1F 2F 3F 4F and 5F Tighten cap bolts to specified...

Page 251: ...ation sets Do not disturb such combination and make sure that each part goes back to where it came from when installing 1 Install main bearings 1 to cylinder block One of two halves of main bearing ha...

Page 252: ...ial Tool A 09911 16510 OUT0000002 B 09913 96510 OUT0000012 10 Apply oil to shims and their contact surface on block 11 Install main bearing cap No 1 according to the following proce dure a Engage cap...

Page 253: ...and gasket holder plate Timing belt belt tensioner roller and crankshaft timing sprocket Timing belt cover Cylinder head cover Intake manifold and exhaust manifold Oil pan and oil pump strainer 20 Ins...

Page 254: ...lb ft 22 Install engine assembly to vehicle as previously outlined 19 Install following parts to engine as previously outlined Piston and connecting rod Cylinder head assembly Oil pump oil pump drive...

Page 255: ...ft TDC positioner 09919 56560 OUT0000138 Tension measuring equipment 09913 56510 OUT0000152 Oil seal installer 09910 26510 OUT0000005 Dial gauge support 1 09916 14510 Valve lifter 2 09916 14910 Valve...

Page 256: ...MENDED SUZUKI PRODUCT USE Sealant 1207C 99000 31150 D To apply to mating surfaces of cylinder block and oil pan D To apply to mating surfaces of cylinder block and gasket holder plate Sealant 1207B 99...

Page 257: ...g about 50 a Tighten 20 N m b Turn 70 a Tighten 25 N m b Turn 60 a Tighten 2 0 kg m b Turn 70 a Tighten 2 5 kg m b Turn 60 a Tighten 14 5 lb ft b Turn 70 a Tighten 24 5 lb ft b Turn 60 a Tighten 4 0 k...

Page 258: ...e system or could render the system inoperative Either of these two conditions may result in severe injury D Technical service work must be started at least 90 seconds after the ignition switch is tur...

Page 259: ...oil cooler 4 Engine 5 Degassing tank 6 Degassing tank cap Radiator cap 7 Water pump 8 Heater 6B 2 ENGINE COOLING GENERAL DESCRIPTION The cooling system consists of the degassing tank cap radiator deg...

Page 260: ...ter pump 1 is driven by timing belt 2 The water pump can not be disassembled THERMOSTAT A wax pellet type thermostat is used in the coolant outlet passage to control the flow of engine coolant to prov...

Page 261: ...ylene glycol antifreeze This 50 50 mixture coolant solution provides freezing protection to 36_C 33_F D Maintain cooling system freeze protection at 36_C 33_F to ensure protection against corrosion an...

Page 262: ...leakage on cooling system D Defective cooling fan motor D Faulty fan motor control circuit D Plugged radiator D Faulty degassing tank cap D Dragging brakes D Slipping clutch Check coolant level and a...

Page 263: ...nk cap and add proper coolant to tank to bring coolant level up to FULL mark Then install degassing cap making sure that the ear of cap lines up with degassing tank pipe 5 NOTE If proper quality antif...

Page 264: ...COOLING SYSTEM FLUSH AND REFILL 1 Remove degassing tank cap when engine is cool Turn cap slowly to the left until it reaches a stop Do not press down while turning it Wait until pressure is relieved...

Page 265: ...nk and pour out any fluid Scrub and clean inside of de gassing tank with soap and water Flush it well with clean water and drain Reinstall degassing tank and hose 11 Add 50 50 mixture of good quality...

Page 266: ...lant be sure to tighten drain plug securely 4 Fill cooling system Refer to COOLANT and steps 8 to 10 of COOLING SYSTEM FLUSH AND REFILL in this section COOLING WATER PIPES OR HOSES REMOVAL 1 Drain coo...

Page 267: ...ve seat is free from foreign matters which would prevent valve from seating tight 2 Check thermostat seal 1 for breakage deterioration or any oth er damage 3 Check thermostatic movement of wax pellet...

Page 268: ...onnect A T fluid hoses 2 3 from radiator 5 Detach water outlet pipe 1 from engine mounting bracket and disconnect radiator outlet hose 2 from radiator 6 Disconnect radiator inlet hose 1 and degassing...

Page 269: ...val procedures noting the followings D Refill cooling system with proper coolant referring to COOLANT and steps 8 to 10 of COOLING SYSTEM FLUSH AND REFILL in this section D After installation check ea...

Page 270: ...ON D Rotate water pump by hand to check for smooth operation If pump does not rotate smoothly or makes abnormal noise replace it D Inspect water pump impeller for damage Replace as necessary INSTALLAT...

Page 271: ...GINE COOLING REQUIRED SERVICE MATERIALS MATERIALS USE Ethylene glycol base coolant Anti freeze Anti corrosion coolant Engine cooling system for improving cooling efficiency and for protection against...

Page 272: ...4 Injection Pump 6C 4 2 way Check Valve 6C 5 Fuel Tank 6C 5 Fuel Level Gauge 6C 7 Fuel Heater 6C 7 SECTION 6C ENGINE FUEL CAUTION Be sure to read Precaution in Section 6E before disconnecting fuel li...

Page 273: ...eding must be carried out when fuel system has been disas sembled or when vehicle ran out of fuel Turn ignition switch ON to operate fuel pump and after about 5 se conds turn it OFF Repeat this 6 time...

Page 274: ...1 to bracket 2 2 Set fuel filter element 3 and position it correctly 3 Set corrugated washer 4 on fuel filter 4 Set cover 1 so that arrow 2 on it is directed toward dash pan el 5 Tighten cover 1 a qu...

Page 275: ...el pump resistance About 2 1 INSTALLATION 1 Install fuel pump 1 with its bracket 2 to chassis frame 2 Connect inlet hose 3 and outlet hose 4 3 Connect PNK BLK wire terminal 5 and BLK wire terminal 6 t...

Page 276: ...hard blow is re quired in step 2 replace 2 way check valve WARNING DO NOT SUCK air through 2 way check valve Fuel vapor inside the valve is harmful FUEL TANK REMOVAL CAUTION This work must not be done...

Page 277: ...2 from pipes 8 Remove fuel tank protector if equipped from vehicle 9 Lower fuel tank gradually while holding it horizontally and pull out coupler 3 at fuel level gauge 4 INSTALLATION For installation...

Page 278: ...Reverse removal procedure for installation noting the followings D Use new gasket 2 D Tighten fuel level gauge bolts to specified torque Tightening Torque Fuel level gauge bolt a 5 0 N m 0 5 kg m 3 5...

Page 279: ...sor 6E3 40 Crankshaft Position Sensor Engine Speed Sensor 6E3 41 Intake Air Pressure Sensor Manifold Absolute Pressure Sensor 6E3 42 Radiator Fan Control System 6E3 43 Double Relay 6E3 46 Pre Post Hea...

Page 280: ...6E3 2 ENGINE AND EMISSION CONTROL SYSTEM RHZ ENGINE EGR System 6E3 48 Vacuum Hose 6E3 48 EGR Valve 6E3 48 EGR Solenoid Valve 6E3 49 TIGHTENING TORQUE SPECIFICATIONS 6E3 50 SPECIAL TOOLS 6E3 51...

Page 281: ...4 Fuel temperature sensor 15 Fuel pressure sensor 16 Vacuum pump 17 EGR throttle solenoid valve 18 EGR solenoid valve 19 EGR valve 20 Boost Turbo pressure regulator solenoid valve 21 Injection pump 22...

Page 282: ...ensor 3 Air cleaner outlet hose 4 Turbocharger 5 Intercooler inlet hose 6 Intercooler 7 Intake air pressure sensor 8 Intercooler outlet hose 9 Throttle valve assembly 10 Elbow air divider 11 Intake ma...

Page 283: ...YSTEM RHZ ENGINE 6E3 5 1 Fuel tank 2 Fuel pump 3 Fuel filter 4 Fuel temperature sensor 5 Injection pump 6 Common rail High pressure fuel injection rail 7 Injector 8 Fuel heater Fuel feed line Fuel ret...

Page 284: ...njector b Radiator fan relay 1 High Low c Radiator fan relay 2 High d Radiator fan relay 3 Low e Engine coolant temperature warning lamp f Malfunction indicator lamp g Glow indicator lamp h Fuel press...

Page 285: ...ENGINE AND EMISSION CONTROL SYSTEM RHZ ENGINE 6E3 7 SYSTEM WIRING DIAGRAM For Vehicle Equipped with Single Connector ECM...

Page 286: ...e position signal A T C51 5 Fuel injector No 2 C51 35 C51 65 Engine torque signal A T C51 6 Fuel injector No 2 C51 36 Immobilizer control module signal C51 66 Immobilizer control module wake up signal...

Page 287: ...ENGINE AND EMISSION CONTROL SYSTEM RHZ ENGINE 6E3 9 For Vehicle Equipped with Triple Connector ECM...

Page 288: ...5 11 Engine torque signal A T 1 Fuel injector No 4 6 12 2 Fuel injector No 1 7 Engine speed signal Combination meter 13 3 Pre post heating diagnostic 8 14 Fuel pressure regulator 4 9 15 Vehicle speed...

Page 289: ...y If measured value is out of specification adjust it to specification by changing height of pedal stopper bolt IDLE SPEED INSPECTION 1 Shift transmission into Neutral for M T or P range for A T 2 Sta...

Page 290: ...pump 2 Throttle valve assembly 3 Intake air pressure sensor 4 EGR valve 5 EGR throttle solenoid valve 6 EGR solenoid valve 7 Boost Turbo pressure regulator solenoid valve 8 Waste gate actuator Turboch...

Page 291: ...SYSTEM RHZ ENGINE 6E3 13 1 Intercooler 2 Clamp 3 Intercooler outlet hose 4 Intercooler inlet hose INTERCOOLER REMOVAL 1 Loosen intercooler hose clamps 2 Remove intercooler INSTALLATION For installatio...

Page 292: ...tarting vacuum 0 About 10 7 kPa 80 mmHg Valve operation completion vacuum About 50 6 kPa 380 mmHg REMOVAL 1 Remove intercooler and intercooler outlet hose 2 Disconnect vacuum hose 1 from throttle valv...

Page 293: ...ttle solenoid valve Throttle solenoid valve resistance 15 20 INSTALLATION For installation reverse removal procedure VACUUM PUMP REMOVAL 1 Remove throttle valve assembly referring to THROTTLE VALVE AS...

Page 294: ...Turbocharger nut 17 Turbocharger outlet pipe nut 18 Turbocharger outlet pipe bolt Tightening Torque Do not reuse 14 6 25 N m 2 5 kg m 18 0 lb ft 25 N m 2 5 kg m 18 0 lb ft 30 N m 3 0 kg m 22 0 lb ft...

Page 295: ...turbocharger with exhaust manifold and manifold gasket 3 13 Remove turbocharger from exhaust manifold INSPECTION Rotate turbine shaft 1 by hand and verify that it turns smoothly without any abnormal...

Page 296: ...egulator solenoid valve 1 4 Disconnect vacuum hoses from boost pressure regulator sole noid valve 5 Remove boost pressure regulator solenoid valve from bracket INSPECTION Measure resistance between ea...

Page 297: ...ds remain engaged then loosen and remove by hand 1 Disconnect negative cable at battery 2 Remove intercooler and intercooler bracket 1 3 Disconnect each coupler and install wire harness protector 2 4...

Page 298: ...ries or death and damage D Fuel can also irritate skin and eyes To prevent this always complete following Precautions PRECAUTIONS D When disconnecting a fuel hose or pipe wrap rag around it to protect...

Page 299: ...ail High pressure fuel injection rail 12 High pressure supply pipe 13 Injection pump 14 Stud bolt 15 Bolt 16 Fuel feed hose 17 Fuel return hose 18 Fuel heater 19 Inlet fuel hose 20 Fuel filter assembl...

Page 300: ...lace that cloth in an approved container 2 Connect special tools and hose 2 between fuel feed hose and fuel feed pipe as shown in figure and clamp hose securely to en sure no leaks occur during checki...

Page 301: ...o Diagnostic Flow Table B 1 in Section 6 2 Check that fuel pressure is felt at fuel feed hose 1 for about 5 seconds after ignition switch ON If fuel pressure is not felt advance to Diagnostic Flow Tab...

Page 302: ...nd of injector when engine is running or cranking Cycle of operating sound should vary according to engine speed If no sound or an unusual sound is heard check injector circuit wire or coupler or inje...

Page 303: ...h pressure pipe hold union nut of injector with wrench as shown Special Tool A 09950 76510 OUT0000148 7 Remove nut 1 and washer 2 then remove injector 3 with its clamp 4 NOTE If the injector cannot be...

Page 304: ...tighten nut 7 to specified torque Tightening Torque Fuel injector nut b 30 N m 3 0 kg m 22 0 lb ft 5 Install new high pressure pipe When tightening union nuts of high pressure pipe hold union nut of i...

Page 305: ...N RAIL REMOVAL 1 Disconnect negative cable at battery 2 Remove intercooler referring to INTERCOOLER in this sec tion 3 Remove fuel temperature sensor referring to FUEL TEMPERA TURE SENSOR in this sect...

Page 306: ...re sensor to specified torque referring to FUEL PRESSURE SENSOR in this section 2 Install common rail 1 and tighten bolts 3 temporarily by hand 3 Connect connector to fuel pressure sensor 4 Install hi...

Page 307: ...OUT0000148 Tightening Torque High pressure supply pipe union nut a 20 N m 2 0 kg m 14 5 lb ft High pressure pipe union nut b 20 N m 2 0 kg m 14 5 lb ft 7 Install PCV hose 2 and bracket 1 8 Install fue...

Page 308: ...TIMING BELT AND BELT TEN SIONER in Section 6A3 4 Loosen injection pump pulley nut 1 with pulley locked by using special tool Special Tool A 09919 56570 OUT0000157 5 Remove injection pump pulley 2 by u...

Page 309: ...hold union nut of injection pump with wrench Special Tool A 09950 76510 OUT0000148 D Tighten each bolt and nut to specified torque Tightening Torque Injection pump bracket bolt a 20 N m 2 0 kg m 14 5...

Page 310: ...f equipped referring to Disabling the Air Bag System in Air Bag System section 3 Remove ECM cover clips and then remove ECM cover from bracket by pulling off the cover to the seat side 4 Disconnect EC...

Page 311: ...section 3 Remove ECM cover clips and then remove ECM cover from bracket by pulling off the cover to the seat side 4 Remove ECM 1 from bracket 5 Disconnect ECM connector from ECM by pulling off lock 1...

Page 312: ...voltage at MAF sensor output terminal C51 13 or E228 29 referring to VOLTAGE CHECK in following section D For vehicle equipped with single connector ECM Section 6 D For vehicle equipped with triple c...

Page 313: ...sor coupler securely 5 Connect battery negative cable to battery THROTTLE POSITION SENSOR TP SENSOR ACCELERATOR STROKE SENSOR INSPECTION Refer to DTCs P0121 P0221 and P0604 in following section D For...

Page 314: ...NTERCOOLER in this sec tion 3 Remove intercooler bracket 1 4 Disconnect fuel temperature sensor connector injector connec tor CMP sensor connector and injection pump solenoid valve connector Then deta...

Page 315: ...a thermometer in water Heat water gradually and verify that resistance between fuel temperature sensor ter minals at following temperatures is as specified If not as specified replace fuel temperatur...

Page 316: ...rring to Section 6C 3 Disconnect connector from fuel pressure sensor 1 4 Remove fuel pressure sensor from common rail 2 INSPECTION Measure resistance between sensor terminals 1 and 2 If resistance is...

Page 317: ...erse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals 1 and 2 while heating water gradually If measured resistance doesn t shown such characteristic as s...

Page 318: ...R ON VEHICLE INSPECTION Check CMP sensor and its circuits referring to flow table of diagnos tic trouble code P0340 in following section D For vehicle equipped with single connector ECM Section 6 D Fo...

Page 319: ...f CKP sensor is within specification Resistance 315 405 If not as specified replace CKP sensor D Check to make sure that crankshaft position sensor 1 and sen sor rotor tooth 2 is free from any metal p...

Page 320: ...ly sure to con nect properly as shown in left figure Output voltage When sensor input voltage is 4 5 5 5 V ambient temp 20 30_C 68 86_F ALTITUDE BAROMETRIC OUTPUT Reference PRESSURE VOLTAGE ft m mmHg...

Page 321: ...position Check system for operation referring to DTCs P1108 P1109 and P1519 Diag Flow Table in following section D For vehicle equipped with single connector ECM Section 6 D For vehicle equipped with...

Page 322: ...is no continuity when relay is connected to the battery replace relay RADIATOR FAN RELAY 2 High Inspection 1 Disconnect negative cable at battery 2 Remove radiator fan relay 2 1 from bracket 3 Check t...

Page 323: ...between terminal c and d If there is continuity replace relay 4 Connect battery positive terminal to terminal b of relay Connect battery negative terminal a of relay Check continuity between terminal...

Page 324: ...double relay 2 Remove FUEL PUMP fuse from fuse box 3 Disconnect ECM connector 4 Connect negative cable at battery 5 Check voltage between each terminal and ground If not as specified replace double r...

Page 325: ...REMOVAL 1 Disconnect negative cable at battery 2 Remove pre post heating control unit 1 from bracket 3 Disconnect connector from pre post heating control unit by pushing lock 1 4 Disconnect WHT wire t...

Page 326: ...nsor 2 Remove EGR pipe clamps 1 by using special tool Special Tool A 09919 46510 OUT0000110 3 Remove EGR pipe 1 from EGR valve 2 and intake manifold 4 Remove EGR valve from exhaust manifold 3 INSPECTI...

Page 327: ...R pipe clamps by using special tool Special Tool A 09919 46510 OUT0000110 EGR SOLENOID VALVE REMOVAL 1 Disconnect negative cable at battery 2 Remove air cleaner outlet hose 3 Disconnect connector from...

Page 328: ...olt and nut 30 3 0 22 0 Lubrication pipe union bolt 20 2 0 14 5 Glow plug 10 1 0 7 5 Fuel injector clamp stud bolt 7 5 0 8 5 5 Fuel injector clamp nut 30 3 0 22 0 High pressure pipe union nut 20 2 0 1...

Page 329: ...50010 Fuel system plug set 09917 47910 Vacuum pump gauge 09919 46510 OUT0000110 Clamp pliers 09919 56570 OUT0000157 Injection pump pulley lock 09919 56580 OUT0000158 Injection pump pulley remover 1 09...

Page 330: ...ERAL DESCRIPTION 6G 2 Cranking Circuit 6G 2 Starting Motor Circuit 6G 2 Starting Motor 6G 3 DIAGNOSIS 6G 4 UNIT REPAIR OVERHAUL 6G 5 Dismounting and Remounting 6G 5 Disassembly and Reassembly 6G 5 Ins...

Page 331: ...switch and related electrical wiring These com ponents are connected electrically Only the starting motor will be covered in this section STARTING MOTOR CIRCUIT D The magnetic switch coils are magnet...

Page 332: ...Front housing 12 Rear bracket 13 Brush holder 14 Brush spring 15 Brush 16 Bearing 17 Armature 18 Yoke CRANKING SYSTEM 6G 3 STARTING MOTOR The starting motor consists of parts shown in below The magnet...

Page 333: ...of armature D Crankshaft rotation obstructed Recharge battery Replace battery Retighten Replace magnetic switch Repair or replace Replace Replace armature Repair Replace Repair Starting motor running...

Page 334: ...attery 2 Disconnect magnetic switch lead wire S terminal and battery cable from starting motor terminal B terminal 3 Remove strut tower bar 4 Drain coolant 5 Hoist vehicle 6 Remove water outlet pipe m...

Page 335: ...brush springs for wear damage or other abnormal conditions Replace if necessary Brush spring tension Standard 3 1 kg 6 8 lb Limit 1 5 kg 3 3 lb 3 BRUSH HOLDER D Check movement of brush in brush holder...

Page 336: ...ial gauge pointer exceeds limit repair or replace NOTE Below specification presupposes that armature is free from bend Bent armature must be replaced Commutator out of round Standard 0 05 mm 0 002 in...

Page 337: ...for continuity between segments If there is no continuity at any test point there is an open circuit and armature must be replaced 5 FIELD COIL D Check for continuity between brushes 1 and between co...

Page 338: ...connect nega tive lead from terminal M Check that plunger and pinion remain out If plunger and pinion return inward replace magnetic switch 3 Plunger and Pinion Return Test Disconnect negative lead fr...

Page 339: ...rpm minimum 68 _F Locked characteristic 3 0 V 1000 A maximum 29 4 N m 2 94 kg m 21 3 lb ft minimum Magnetic switch operating voltage 8 volts maximum REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZ...

Page 340: ...em section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in uninten tional activation of the system or could render the system...

Page 341: ...urface and damage on pulley D Inspect belt for cracks cuts deformation wear and cleanliness using mirror under enough lighting If any defect exists replace D Check that belt wear check mark 1 tension...

Page 342: ...oner insert special tool B into them Special tool B 09919 56590 OUT0000142 3 Loosen roller tensioner bolt 1 using special tool C Special tool C 09919 56620 4 Remove generator belt INSTALLATION 1 Using...

Page 343: ...cial tool B 09919 56590 OUT0000142 C 09919 56620 Tightening torque a 50 N m 5 0 kg m 36 5 lb ft 4 Remove special tool B and C turn crankshaft pulley 4 revolu tions 5 Using special tool B check that dy...

Page 344: ...n figure below and note the following D For reassembly reverse disassembly procedure D When removing stator lead wire from rectifier carry out soldering quickly CAUTION Overheating can damage semicond...

Page 345: ...remover attachment 09919 56610 OUT0000143 Belt tension lever 09919 56590 OUT0000142 Belt tensioner pin 09919 56620 Belt tension adjuster wrench SPECIFICATIONS GENERATOR Type 150 A type Rated voltage...

Page 346: ...not reuse 12 11 11 11 EXHAUST SYSTEM 6K 1 SECTION 6K EXHAUST SYSTEM CONTENTS GENERAL DESCRIPTION 6K 1 MAINTENANCE 6K 2 ON VEHICLE SERVICE 6K 3 GENERAL DESCRIPTION The exhaust system consists of an exh...

Page 347: ...erioration and out of position D Check exhaust system for leakage loose connection dent and damage If bolts or nuts are loosened tighten them to specified torque Refer to GENERAL DESCRIPTION in this s...

Page 348: ...tion procedures Before installation check gasket and seal for de terioration or damage Replace them as necessary MUFFLER CAUTION As exhaust No 2 pipe has catalytic converter in it it should not be exp...

Page 349: ...VER CASE ASSEMBLY 7A2 17 TRANSMISSION UNIT 7A2 17 INPUT SHAFT ASSEMBLY 7A2 26 MAIN SHAFT ASSEMBLY 7A2 26 COUNTER SHAFT ASSEMBLY 7A2 27 5TH AND REVERSE SYNCHRONIZER RING 7A2 28 INPUT SHAFT BEARING RETA...

Page 350: ...ng noise when shifting gear into the reverse gear The double cone synchronizer mechanism is provided to the 2nd and 3rd gear synchromesh devices for high performance of shifting into the 2nd and 3rd g...

Page 351: ...gear 6 Main shaft 2nd gear 7 Main shaft low gear 8 Front case 9 Main shaft reverse gear 10 Gear shift inner shaft 11 Main shaft 5th gear 12 Gear shift lever case 13 Gear shift shaft 14 Main shaft 15 R...

Page 352: ...fusing to Weakened or broken synchronizer spring Replace disengage Distorted shift shaft or shift fork Replace Hard shifting Improper clutch pedal free travel Adjust Distorted or broken clutch disc Re...

Page 353: ...1 7 liters 3 6 3 0 US Imp pt NOTE D It is highly recommended to use SAE 75W 90 gear oil D Whenever vehicle is hoisted for any other service work than oil change also be sure to check for oil leakage...

Page 354: ...Remove boot clamp and then remove boot No 1 9 from trans mission shift lever case 7 5 With gear shift control case cover 8 pushed down with fingers turn it to counter clockwise and take out shift cont...

Page 355: ...portions and seat then install shift control lever A Grease 99000 25010 5 Install transmission boot No 1 1 from inside of cabin and clamp it with a new clamp 2 securely 6 Install transfer boot No 1 1...

Page 356: ...d check that indicator lights Turn OFF switch after checking NOTE D When removing and reinstalling switch use care not to let dust enter transfer box inside D Make sure to reset clamp for wiring which...

Page 357: ...p light switch and or 4WD switch 2 Function of back up light switch 2 can be checked by using Ohmmeter 1 as shown in the figure There should be conduction at these terminals only when shift lever is s...

Page 358: ...ar mounting member bolts b 50 N m 5 0 kg m 36 5 lb ft DISMOUNTING OF TRANSMISSION UNIT IN CABIN Remove transmission shift control lever Refer to SHIFT CON TROL LEVERS in this section and transfer shif...

Page 359: ...Remove clutch operating cylinder from transmission It is not necessary to disconnect clutch hose from operating cylinder NOTE D It is not necessary to drain transmission oil when dis mounting transmi...

Page 360: ...sensor assembly and release their harness from clamps 14 Remove engine to transmission bolts and nuts 15 With transmission assembly held up on jack move them to rear and lower them WARNING Transmissi...

Page 361: ...e to muffler nuts d 60 N m 6 0 kg m 43 5 lb ft Front propeller shaft universal joint flange bolts e 50 N m 5 0 kg m 36 5 lb ft Rear propeller shaft universal joint flauge bolts f 60 N m 6 0 kg m 43 5...

Page 362: ...rface to transmission front and rear case 12 Main and counter shaft bearing retainer 13 Main and counter shaft bearing retainer screw Apply thread lock 99000 32110 to all around thread part of screw 1...

Page 363: ...ynchronizer outer ring 22 Low speed hub 23 Low speed sleeve 24 Low gear synchronizer ring 25 Low gear 26 Needle bush 27 Main shaft bearing 28 Reverse gear 29 5th gear 30 Output bearing 31 Output beari...

Page 364: ...ner shaft 18 Gear shift shaft inner lever 19 Gear shift shaft inner lever bolt Apply thread lock 99000 32110 to all around thread part of bolt 20 Plug Apply thread lock 99000 32110 to all around threa...

Page 365: ...igure CAUTION When driving spring pin 2 use care not to damage gear shift lever case 1 Special tool A 09922 85811 4 Likewise drive spring pin 2 into gear shift lever 3 as far as the position shown in...

Page 366: ...back up light switch 1 3 Remove return spring low bolt 1 and return spring reverse bolt 2 4 Remove gear shift shaft inner bolt 1 and plug 2 5 Using bolt hole pull gear shift inner shaft 2 and then re...

Page 367: ...aring retainer 1 8 Remove C ring 1 of input shaft bearing and C ring 2 of count er shaft front bearing Special tool A 09900 06107 9 Tapping transmission front case 1 flanges with plastic hammer remove...

Page 368: ...rk bolt 1 13 Remove low gear shift shaft 2 and low speed gear shift fork 1 14 Remove interlock pin 1 and straight pin 2 by using magnet 3 NOTE When straight pin 2 can t be removed push 5th reverse gea...

Page 369: ...peed gear shift shaft 2 and high speed gear shift fork 1 18 Remove interlock pin 1 by using magnet 2 19 After removing straight plug screw 1 remove compression spring 2 and ball 3 by using magnet from...

Page 370: ...3 dropping from reverse gear shift link comp 4 22 Remove circlip 1 from 5th gear shift shaft 2 as shown in the figure 23 Remove spring pin from 5th gear shift fork 1 Special tool A 09922 85811 24 Rem...

Page 371: ...counter shaft Special tool A 09900 06107 28 Remove bearing 1 spacer 2 counter shaft 5th gear 3 and counter shaft 5th gear needle bearing by using puller 4 29 Pull off 5th reverse synchronizer ring ass...

Page 372: ...in shaft 2 as shown in the figure 33 Remove output bearing 1 and 5th gear 2 by using special tool Special tool A 09926 36510 001 B 09926 36510 002 C 09926 36510 003 34 Remove circlip 1 and then remove...

Page 373: ...he figure NOTE When input shaft assembly 1 main shaft assembly 2 and counter shaft assembly 3 can t be pulled off by hand from intermediate case 4 pull off them by tapping lightly both the rear of mai...

Page 374: ...d MAIN SHAFT ASSEMBLY 1 Pull out needle bush 1 needle bearing 2 main shaft bearing 3 and low gear 4 together by using puller 5 and press 6 2 Remove low gear synchronizer ring 2 and ball 1 3 Pull out 2...

Page 375: ...speed syn chronizer hub and then remove keys 1 and springs from high speed synchronizer hub by using slotted screwdriver or the like as shown in the figure 6 Remove low speed synchronizer sleeve hub...

Page 376: ...from reverse brake ring 1 and then remove keys 2 and springs from reverse brake ring by using slotted screw driver or the like as shown in the figure INPUT SHAFT BEARING RETAINER AND OIL SEAL Remove o...

Page 377: ...key slot width c in high speed synchronizer hub and each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Clearance a between synchronizer ring...

Page 378: ...m 0 020 in 3rd Standard 0 7 1 2 mm 0 028 0 047 in Service limit 0 5 mm 0 020 in Width of index protrusion b Main shaft 1st Standard 4 2 4 6 mm 0 165 0 181 in Service limit 4 0 mm 0 157 in 2nd Standard...

Page 379: ...0 2402 in F 4 78 4 91 mm 0 1882 0 1933 in D Using V blocks 1 and dial gauge 2 check runout If runout exceeds limit below replace main shaft 3 Main shaft runout limit 0 06 mm 0 0023 in D Using cylinde...

Page 380: ...ured valve is out of specification replace it Counter shaft diameter standard a 26 975 26 991 mm 1 0620 1 0626 in b 29 95 29 97 mm 1 1791 1 1799 in D Measure width of 5th reverse gear shift fork end a...

Page 381: ...shaft 1 by measuring inside diameter of gear and diameter of shaft and calculate its clearance If clearance exceeds limit replace gear and shaft Oil clearance between reverse idle gear and shaft Stand...

Page 382: ...ce downward when shift shaft 1 is installed D Shift lever 2 should be installed at the same time 3 Drive in new spring pins 2 for gear shift lever 5 and shift arm 7 NOTE When driving in spring pins po...

Page 383: ...Cement 99000 32110 Tightening torque Control lever locating bolts a 17 N m 1 7 kg m 12 5 lb ft INPUT SHAFT ASSEMBLY 1 Bring bearing 1 so that its groove for circlip is in the front of input shaft 2 an...

Page 384: ...ing to the following procedure a Install compression springs 1 and shifting keys 2 to high speed synchronizer hub 3 as shown in the figure b Slide hub 3 in sleeve 4 so that chamfered side of sleeve 4...

Page 385: ...d synchronizer sleeve and hub assembly 3 which was assembled in step a through c to main shaft 1 using special tool Special tool A 09940 53111 4 Select circlip 1 that will make thrust clearance of clu...

Page 386: ...Slide low speed synchronizer hub 3 in sleeve 4 so that chamfered side of sleeve 4 and dent side of hub 3 face op posite as shown in the figure also aligning hub slots with key location teeth of sleev...

Page 387: ...sembly with special tool and press 3 Special tool A 09940 53111 10 Check 2nd gear thrust clearance referring to MAIN SHAFT ASSEMBLY in this section 11 Apply grease to ball 1 and set it to main shaft 3...

Page 388: ...ring bring it so that its groove for circlip is in the front Special tool A 09940 54950 3 Select circlip that will make its thrust clearance 0 1 mm 0 0039 in or less and install it Circlip thickness s...

Page 389: ...o oil seal lip Grease 99000 25010 Special tool A 09913 75821 B 09924 84510 004 TRANSIMISSION REAR CASE 1 Check that interlock cam component 1 moves smoothly in both turning direction and sliding direc...

Page 390: ...oil seal to rear case so that end surface of oil seal be comes flush with that case Apply grease to oil seal lip Grease 99000 25010 Special tool A 09913 75520 TRANSMISSION INTERMEDIATE CASE AND FRONT...

Page 391: ...s 1 Set intermediate case 1 to vise 3 Clean mating surfaces of intermediate case both sides if inter mediate case is reused 2 Install main shaft assembly 1 to intermediate case NOTE When fitting of in...

Page 392: ...TE D When installing bearing bring it so that its C ring side is at rear side of intermediate case as shown in the figure D When fitting of intermediate case and bearing is tight tap outer race of bea...

Page 393: ...13 2 40 2 45 mm 0 0944 0 0964 in 14 2 45 2 50 mm 0 0964 0 0984 in 15 2 50 2 55 mm 0 0984 0 1003 in 16 2 55 2 60 mm 0 1003 0 1023 in 17 2 61 2 66 mm 0 1024 0 1047 in 18 2 67 2 72 mm 0 1048 0 1070 in 19...

Page 394: ...0999 in 12 2 55 2 60 mm 0 1000 0 1023 in 13 2 61 2 66 mm 0 1024 0 1047 in 14 2 68 2 73 mm 0 1055 0 1074 in 15 2 74 2 79 mm 0 1075 0 1098 in 12 Press fit 5th reverse synchronizer hub 1 to counter shaft...

Page 395: ...reak ring fitting key of the reverse break ring 1 into groove of 5th gear synchronizer outer ring 2 as the figure shows c Install 5th gear synchronizer cone ring to 5th gear synchro nizer outer ring s...

Page 396: ...as figure shows 15 Attach 5th gear synchronizer ring assembly 3 to 5th reverse synchronizer sleeve 4 so that spline teeth of 5th gear syn chronizer ring assembly 1 which was assembled in step a throu...

Page 397: ...ce 0 1 mm 0 0039 in or less and install it Circlip thickness specification ID mark Circlip thickness 1 1 90 1 95 mm 0 0748 0 0767 in 2 1 96 2 01 mm 0 0768 0 0791 in 3 2 02 2 07 mm 0 0792 0 0814 in 4 2...

Page 398: ...erse idler shaft 2 into reverse idler gear 1 and inter mediate case 24 Insert 5th gear shift shaft 3 into 5th gear shift fork 2 reverse gear shift link comp 1 and intermediate case 25 Fix new circlip...

Page 399: ...topper 1 to intermediate case A Cement 99000 32110 Tightening torque Stopper mounting bolt a 25 N m 2 5 kg m 18 0 lb ft 30 Install ball 1 compression spring 2 and straight plug 3 A Cement 99000 32110...

Page 400: ...bolt and tighten bolt to specification A Cement 99000 32110 Tightening torque High speed gear shift fork bolt a 20 N m 2 0 kg m 14 5 lb ft 35 Install new circlip 1 to high gear shift shaft 2 by using...

Page 401: ...torque Locating spring screws a 25 N m 2 5 kg m 18 0 lb ft 40 Place intermediate case assembly upright as shown in the fig ure by using workbench or the like 41 Apply sealant evenly to front case side...

Page 402: ...5 kg m 18 0 lb ft 45 Clean mating surface of rear case and apply sealant evenly to rear case side of intermediate case in the same manner as Step 41 Sealant 99000 31110 46 Install rear case to interme...

Page 403: ...lb ft 49 Tighten return spring low bolt Yellow 2 and return spring re verse bolt Black 1 A Sealant 99000 31110 Tightening torque Return spring low bolt Yellow a 28 N m 2 8 kg m 20 5 lb ft Return spri...

Page 404: ...ting member bolts 50 5 0 36 5 Exhaust No 1 pipe to manifold nuts 60 6 0 43 5 Exhaust No 1 pipe to exhaust No 2 pipe bolts 50 5 0 36 5 Exhaust No 2 pipe to muffler nuts 60 6 0 43 5 Front propeller shaf...

Page 405: ...p ring pliers opening type 09925 18011 Installer attachment 09926 36510 Bearing remover See NOTE 09926 36510 001 Bearing remover plate No 1 09926 36510 002 Bearing remover plate No 2 09926 36510 004 B...

Page 406: ...B1 35 INSPECTION OF TCM AND ITS CIRCUITS 7B1 36 WIRE HARNESS AND CONNECTORS 7B1 36 DTC P0705 TRANSMISSION RANGE SENSOR SWITCH CIRCUIT MALFUNCTION 7B1 37 DTC P0710 TRANSMISSION FLUID TEMPERATURE SENSOR...

Page 407: ...RANGE SWITCH 7B1 65 INPUT SHAFT SPEED SENSOR 7B1 66 OUTPUT SHAFT SPEED SENSOR 7B1 66 O D OFF SWITCH 7B1 66 SOLENOID VALVES SHIFT SOLENOID VALVES TCC SOLENOID VALVE AND PRESSURE CONTROL SOLENOID VALVE...

Page 408: ...s a 3 element 1 step and 2 phase type and is equipped with an electronically controlled lock up mechanism The gear shift device consists of 3 sets of planetary gear units 3 disc type clutches 4 disc t...

Page 409: ...tic gear change D range Forward 1st 2nd 3rd O D OFF automatic gear change 2 range Forward 1st 2nd z 3rd automatic gear change L range Forward 1st z 2nd z 3rd reduction and fixed at 1st gear Gear ratio...

Page 410: ...shes overdrive carrier and overdrive sun gear only when driven by engine Forward clutch Meshes forward clutch input shaft and intermediate shaft Direct clutch Meshes forward clutch input shaft with fr...

Page 411: ...valve A No 1 valve B No 1 clutch clutch clutch brake coast brake brake Inner piston Outer piston way clutch clutch No 1 clutch No 2 P f X f f R f X f f f f f N f X f f 1st gear f X f f f f D 2nd gear...

Page 412: ...5 Output shaft speed sensor 6 Transmission range sensor 7 O D off switch 8 Transmission fluid temperature sensor 9 O D OFF lamp 10 Monitor connector 11 Acceleration stroke sensor 12 Engine speed sens...

Page 413: ...r connector 14 Data link connector DLC 15 A T 16 Shift solenoid A Shift solenoid No 1 17 Shift solenoid B Shift solenoid No 2 18 TCC Lock up solenoid 19 Pressure control solenoid 20 Transmission fluid...

Page 414: ...e quently used N and D ranges are made selectable freely OPERATION OF SHIFT SOLENOIDS AND TCC SOLENOID RANGE D 2 L P N R GEAR 1st 2nd 3rd 4th O D 1st 2nd 1st Shift solenoid A NO 1 f f X X f f f f Shif...

Page 415: ...40 km h or 25 mile h speed 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that No up shift is available in L The same as the select lever is shifted to 2 at a higher th...

Page 416: ...BLE to obtain correct result smoothly ON BOARD DIAGNOSTIC SYSTEM For automatic transmission control system TCM has following functions D When TCM detects a malfunction in A T control system while the...

Page 417: ...rmation stored in TCM memory can be checked and cleared as well Before its use be sure to read Operator s Instruction Manual supplied with it carefully to have good understanding of its functions and...

Page 418: ...e Is there any faulty condition Go to Step 8 5 Trouble Symptom Confirmation 1 Confirm trouble symptom referring to the next page Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking an...

Page 419: ...ircuit or difficulty in troubleshooting which is otherwise unneces sary STEP 3 and STEP 4 VISUAL INSPECTION As a preliminary step be sure to perform visual check of the items that support proper funct...

Page 420: ...stops j Transmission does not shift j 1st 2nd 3rd 4th Rev gear j Automatic shift does not occur j Transmission slipping in j 1st 2nd 3rd 4th Rev gear j Other VEHICLE ENVIRONMENTAL CONDITION WHEN PROB...

Page 421: ...CHECK Check DTC using SUZUKI scan tool 1 Turn ignition switch OFF 2 After setting cartridge connect SUZUKI scan tool to data link connector DLC 1 located in underside of instrument panel at driver s...

Page 422: ...is OFF in combination meter with O D off switch OFF 2 Turn ignition switch OFF 3 Remove steering column hole cover 4 4 Using service wire ground diagnosis switch terminal 2 of mon itor connector 1 5...

Page 423: ...N 4 Erase DTC according to instructions displayed on SUZUKI scan tool Refer to SUZUKI scan tool operator s manual for further de tails 5 After completing the erasing turn ignition switch OFF and dis c...

Page 424: ...verter clutch lock up system P0743 26 electrical P0720 31 Output speed sensor circuit malfunction P1700 32 Acceleration stroke signal input malfunction P1700 33 Acceleration stroke signal in ut malfun...

Page 425: ...less than 10 km h 6 mile h gear position is fixed in 1st gear for prevention of engine stall P0705 34 Transmission range sensor or its circuit D In case of circuit open selected range is set as D ran...

Page 426: ...r troubleshooting when TCM has detected no DTC and no abnormality has been noted in visual inspection Follow flow table carefully Step Action Yes No 1 Was AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE...

Page 427: ...nd P0221 in this section If NG replace Shift solenoid A or B valve circuit faulty Inspect circuit for open short and intermittent Output shaft speed sensor circuit faulty Ins ect circuit for o en shor...

Page 428: ...ace valve body assembly Poor 2 3 shift excessive shock or Defective shift solenoid A valve Inspect If NG replace slippage Defective valve body component Replace valve body assembly Poor 3 O D shift ex...

Page 429: ...Defective transmission range sensor Inspect If NG replace Non operate TCC lock up system Defect in torque converter Replace valve body assembly Defective forward clutch Replace Excessive N D time lag...

Page 430: ...alve body assembly Malfunction of output shaft speed sensor Inspect If NG replace 3 O D upshift fails to occur Malfunction of acceleration stroke sensor Inspect referring to Section 6E3 If NG replace...

Page 431: ...te that 1st gear is be ing used 4 At 20 km h 12 5 mile h shift select lever to 2 range and ac celerate to 40 km h 25 mile h Check in this state that 3rd gear is being used 5 At 40 km h 25 mile h shift...

Page 432: ...heck overall performance of automatic transmission and engine by measuring stall speed at D and R ranges Be sure to perform this test only when transmission fluid is at normal operating temperature an...

Page 433: ...ective pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Higher than standard level in Defective primary regulator valve Low line pressure Replace valve body...

Page 434: ...test TROUBLESHOOTING Condition Possible cause Correction Defective pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Defective primary regulator valve Low lin...

Page 435: ...re gauge to fluid pressure check hole 1 in transmission case Special tool A 09925 37810 CAUTION After attaching oil pressure gauge check that not fluid leakage exists 3 Depress foot brake fully run en...

Page 436: ...erhaul or replace valve body assembly Lower than standard level only in D range Leakage from D range fluid pressure circuit Overhaul or replace valve body assembly Lower than standard level only in R...

Page 437: ...tween terminal E203 4 of TCM connector and ground terminal E203 3 of TCM connector and ground D O D off switch is OFF D Selector lever is in D range D Transfer lever is in 2H position D Drive vehicle...

Page 438: ...is section 2 Check DTC Is DTC P0710 P0715 P0720 P0743 P0748 P0753 P0758 or P1700 detected Perform TROUBLE DIAGNOSIS TABLE to repair and retry Go to Step 3 3 Perform running test under the following co...

Page 439: ...ION SWITCH ON WIRING DIAGRAM TROUBLESHOOTING Step Action Yes No 1 O D OFF lamp circuit check 1 With ignition switch OFF disconnect couplers from TCM 2 Using service wire connect E202 10 terminal of di...

Page 440: ...ed to ground Go to Step 3 3 Check O D off switch circuit 1 Check resistance between terminal E202 3 of disconnected TCM harness side connector and body ground with O D off switch button 1 released Is...

Page 441: ...hibited to connect voltmeter or ohmmeter to TCM with connector dis connected from it INSPECTION 1 Remove TCM from vehicle referring to TRANSMISSION CON TROL MODULE in this section 2 Connect TCM connec...

Page 442: ...ion range sensor switch or its circuit malfunction D TCM DTC CONFIRMATION PROCEDURE WARNING D When performing a road test select a place where there is no traffic or possibility of a traffic accident...

Page 443: ...9 E202 20 and E202 21 respec tively with select lever shifted to each range Taking terminal E202 21 as an example is battery voltage indicated only when select lever is shifted to 2 range and 0 V for...

Page 444: ...or Step 3 Terminal E202 2 E202 1 E202 9 E202 8 E202 21 E202 20 Select lever position P B V 0 V 0 V 0 V 0 V 0 V R 0 V B V 0 V 0 V 0 V 0 V N 0 V 0 V B V 0 V 0 V 0 V D 0 V 0 V 0 V B V 0 V 0 V 2 0 V 0 V 0...

Page 445: ...temperature sensor output volt age is too low or too high D Transmission fluid temperature sensor D Transmission fluid temperature sensor circuit D TCM DTC CONFIRMATION PROCEDURE WARNING D When perfor...

Page 446: ...ion fluid temperature sensor Reference 231 263 at 110_C 230_F 105 117 at 145_C 293_F Intermittent trouble or faulty TCM Check for intermittent referring to INTERMITTENT AND POOR CONNECTION in Section...

Page 447: ...CTING CONDITION TROUBLE AREA The following condition is detected for one minute continuously in the period between ignition switch ON and OFF D No pulse signal out of input shaft speed sensor is input...

Page 448: ...ctors 2 Check for proper connection to input shaft speed sensor at E202 5 and E202 17 terminals 3 If OK check resistance of sensor circuit Input shaft speed sensor resistance Resistance between E202 5...

Page 449: ...C TRANSMISSION 4 A T A Oscilloscope waveforms at specified idle speed in p range REFERENCE Connect oscilloscope between E202 5 and E202 17 of TCM connector connected to TCM and check input shaft speed...

Page 450: ...period between ignition switch ON and OFF D No pulse signal out of output shaft speed sensor is inputted although 20 pulses out of input shaft speed sensor are inputted and D Transmission range senso...

Page 451: ...ve TCM cover 2 With ignition switch OFF disconnect TCM connectors 3 Check for proper connection to output shaft speed sensor at E202 4 and E202 16 terminals 4 If OK check resistance of sensor circuit...

Page 452: ...RANSMISSION 4 A T 7B1 47 A Oscilloscope waveforms at about 40 km h 25 mile h REFERENCE Connect oscilloscope between E202 4 and E202 16 of TCM connector connected to TCM and check output shaft speed se...

Page 453: ...or signals indicate 2000 rpm or more D Engine speed input circuit D TCM D ECM DTC CONFIRMATION PROCEDURE WARNING D When performing a road test select a place where there is no traffic or possibility o...

Page 454: ...equipped with triple connector ECM terminal E227 7 of disconnected harness side ECM connector Is it about 0 Go to Step 3 BRN circuit open 3 Check engine speed input circuit Measure between terminal E...

Page 455: ...TEM ELECTRICAL WIRING DIAGRAM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA The following condition is detected 8 times of gear change continuously D Voltage at termina...

Page 456: ...sing scan tool TROUBLESHOOTING Step Action Yes No 1 Was A T DIAGNOSTIC FLOW TABLE in this section performed Go to Step 2 Go to A T DIAGNOSTIC FLOW TABLE in this section 2 Check TCC solenoid circuit fo...

Page 457: ...ontrol solenoid valve D Pressure control solenoid valve circuit D TCM DTC CONFIRMATION PROCEDURE WARNING D When performing a road test select a place where there is no traffic or possibility of a traf...

Page 458: ...to Step 3 BLU ORN or BLU RED circuit shorted to power circuit 3 Check pressure control solenoid circuit for short Measure resistance between terminal E203 11 or disconnected harness side TCM connector...

Page 459: ...following condition is detected 8 times of gear change continuously D Voltage at terminal E203 4 of TCM is too high while shift solenoid OFF is commanded or too low while shift solenoid ON is commande...

Page 460: ...Was A T DIAGNOSTIC FLOW TABLE in this section performed Go to Step 2 Go to A T DIAGNOSTIC FLOW TABLE in this section 2 Check shift solenoid circuit for short 1 Turn ignition switch OFF and disconnect...

Page 461: ...INPUT MALFUNCTION WIRING DIAGRAM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Continuous time of low voltage acceleration stroke signal is too long or D Continuous...

Page 462: ...input circuit for short Measure between terminal E202 6 of disconnected harness side TCM connector and ground Is it infinity Go to Step 4 BLU WHT circuit shorted to ground 4 Check acceleration stroke...

Page 463: ...with pre stored checking data in TCM D TCM DTC CONFIRMATION PROCEDURE 1 Connect scan tool to DLC with ignition switch OFF 2 Clear DTC in TCM memory by using scan tool 3 Turn ignition switch ON and OF...

Page 464: ...GNAL CIRCUIT MALFUNCTION WIRING DIAGRAM DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Continuous time of low voltage engine torque signal is too long or D Continuous...

Page 465: ...ircuit for short Measure between terminal E202 23 of disconnected harness side TCM connector and ground Is it infinity Go to Step 4 WHT circuit shorted to ground 4 Check engine torque signal circuit f...

Page 466: ...cated around 1 unit above C point 5 Keep engine idling and shift selector slowly to L and back to P position 6 With engine idling pull out dipstick 1 wipe it off with a clean cloth and put it back int...

Page 467: ...s between FULL COLD and LOW COLD proceed to test drive And when the fluid temperature has reached the normal operating temperature check fluid level again and adjust it as necessary FLUID CHANGE 1 Lif...

Page 468: ...OSES When replacing them be sure to note the followings D to replace clamps at the same time D to insert hose as far as bulge of pipe D to clamp hose securely MANUAL SELECTOR ASSEMBLY Tightening torqu...

Page 469: ...le joint 14 Bush 15 Washer 16 E ring 17 Transmission range sensor assembly 18 Bolt INSTALLATION Reverse removal procedure to install INSPECTION Check select lever for smooth and clear cut movement and...

Page 470: ...4 After select cable 1 was installed check for the following D Push vehicle with select lever shifted to P Vehicle should not move D Vehicle can not be driven in N D Vehicle can be driven in D 2 and L...

Page 471: ...nsor resistance 560 680 at 20_C 68_F OUTPUT SHAFT SPEED SENSOR INSPECTION Check output shaft speed sensor 1 for resistance between termi nals of sensor or TCM connector Output shaft speed sensor resis...

Page 472: ...torque A T fluid drain plug a 20 N m 2 0 kg m 14 5 lb ft 9 Remove A T oil pan 7 10 Disconnect shift solenoid A valve shift solenoid B valve TCC solenoid valve and pressure control solenoid valve conn...

Page 473: ...hown in the figure D When TCC solenoid valve 1 is connected to battery 2 confirm that shift solenoid valve is close condition by blowing air 50 200 kpa 0 5 2 0 kg cm2 7 28 5 psi into solenoid valve as...

Page 474: ...solenoid valve 1 to battery 4 setting the 8 10 W bulb 5 on the way as shown in the figure 2 Check for movement of valve 3 in the direction of arrow A 3 Disconnect pressure control solenoid valve 1 fr...

Page 475: ...ble at battery 2 If vehicle is equipped with air bag system disable air bag sys tem Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove steering column hole cover 3 4 Disconnect couplers 2 from...

Page 476: ...ed and remove oil cooler pipes 1 from oil outlet unions and hoses NOTE To avoid fluid leakage plug open ends of oil outlet unions and hoses right after they are disconnected INSTALLATION 1 Use new uni...

Page 477: ...nsole box NOTE To remove clip push in its center pin first 2 Remove boot cover 1 and boot No 2 2 3 Remove boot clamp 1 and then remove boot No 1 2 from transfer gear shift lever case 4 With transfer s...

Page 478: ...ge and propeller shaft as shown in the figure 4 Remove universal joint flange bolts and take out rear propeller shaft 5 Likewise take out front propeller shaft 6 Remove nut from the end of select cabl...

Page 479: ...input shaft speed sensor transmission range sensor shift TCC solenoid valves and other electrical parts and release their wire harness from clamps 18 Remove breather hose and harness clamp mounting bo...

Page 480: ...eather hose 2 Remove transfer by removing its bolts REMOUNTING WARNING When moving transmission assembly with torque convert er equipped in it be sure to keep it horizontal Tilting it with its front f...

Page 481: ...b ft Muffler to exhaust No 2 pipe nuts 60 N m 6 0 kg m 43 5 lb ft Front propeller shaft universal joint flange bolts 50 N m 5 0 kg m 36 5 lb ft Rear propeller shaft universal joint flange bolts 60 N m...

Page 482: ...parts are allowed to disassemble or not referring to VALVE BODY ASSEMBLY in this section D Make sure to wash dirt off from the transmission so that no such dirt will enter the transmission during dism...

Page 483: ...ear burning Replace Oil seal gasket Flawed or hardened seal ring Replace Worn seal ring on its periphery or side Replace Piston seal ring oil seal gasket etc Replace Gear Flaw burr Replace Worn gear t...

Page 484: ...case fixing bolts and then remove adaptor case 2 NOTE Use care not to cause damage to oil seal 4 Remove gasket 5 Remove transmission range sensor 1 6 Remove C ring 1 and then remove speed sensor roto...

Page 485: ...il pan from entering valve body D If iron powder is found it is possible that bearing gear or clutch plate is worn 15 Remove oil strainer 1 16 Remove wire harness 2 from wire harness clamp 3 17 Discon...

Page 486: ...acting surface with stand by using shop cloth or the like D A stand of such size as shown in the figure will facilitate work 23 Check top surface level of forward clutch 2 against case 1 for reassembl...

Page 487: ...aining ring 1 planetary gear assembly and leaf spring NOTE D Use care not to cause damage to case when removing re taining ring D Confirm direction of bearing and bearing race for reas sembly 30 Remov...

Page 488: ...by using moderate stick 2 and move sleeve cover 33 Using a punch drive out manual shift lever pin pull out manual shift shaft 2 and remove manual shift lever 1 Then remove sleeve cover from manual sh...

Page 489: ...ssion fluid 1 Sealing 2 Bearing 3 Bearing race 4 O D case 5 Planetary ring gear 6 O ring 7 Brake piston 8 Return spring 9 Retainer 10 Retaining ring 11 Cushion plate 12 Brake backing plate 13 Brake di...

Page 490: ...able plate thickness 2 0 2 3 mm 0 079 0 091 in 2 Remove retaining ring 1 brake backing plate 2 brake disc 3 brake plate 4 cushion brake plate 5 in that order Then remove planetary ring gear thrust bea...

Page 491: ...e D Apply A T fluid to O ring disc etc before installing them D Opening of retaining brake front ring 2 and projection 1 of O D case should be matched D When installing each component refer to the fir...

Page 492: ...87 1 Input shaft 2 Piston 3 Return spring 4 O ring 5 Retaining ring 6 Bearing race 7 Bearing 8 Clutch plate 9 Clutch disc 10 Froward clutch hub 11 Direct clutch input hub Do not reuse Apply automatic...

Page 493: ...ll forward clutch 2 to O D case 1 Apply 4 8 kg cm2 air pressure into fluid hole at the right of cut in O D case and mea sure movement of forward clutch piston If measured value is not within standard...

Page 494: ...turn spring to deform 8 Remove forward clutch piston return spring 9 Install forward clutch to O D case Blow low pressure air into fluid hole at the right of cut in O D case to remove forward clutch p...

Page 495: ...that return spring 2 will not fall or tilt D Do not align opening in retaining ring 1 with lug of for ward clutch piston return spring 2 at its retainer section CAUTION Be careful when applying pressu...

Page 496: ...CLUTCH DISASSEMBLY 1 Install direct clutch assembly 1 to center support 2 and with 4 8 kg cm2 air pressure applied to second fluid hole from the left measure stroke of direct clutch piston as shown in...

Page 497: ...irect clutch piston return spring 3 and remove retaining return spring ring 2 Special tool A 09926 98310 CAUTION Be careful when applying pressure for overpressure will cause plate section of piston r...

Page 498: ...ure and noting the following points D Always use new O ring and apply A T fluid before installation D Do not align opening in retaining ring 2 with lug of direct clutch piston return spring at retaine...

Page 499: ...pring 5 Snap ring 6 Second coast brake plate 7 Second coast brake disc 8 Clutch backing plate 9 Retaining ring 10 Seal ring 11 Second brake piston 12 Second brake plate 13 Second brake disc 14 Planeta...

Page 500: ...into fluid hole at the extreme left and measure movement of second coast brake piston If measured value is not within standard range replace second coast brake plate or second coast brake disc Standar...

Page 501: ...e at the extreme left and remove second coast brake piston as shown in the figure Then remove piston inner O ring and piston outer O ring from second coast brake piston 9 Remove 3 seal rear rings 1 NO...

Page 502: ...l when applying pressure for overpressure will cause plate section of piston return spring to de form Special tool A 09926 98310 13 Remove brake piston return spring 14 Blow air into the second air ho...

Page 503: ...o not open sun gear seal ring more than necessary D Always use new O ring and apply A T fluid before installation D When installing O ring make sure that it is not kinked or caught D Push in brake pis...

Page 504: ...ove ment of brake piston again If it is not within standard range it is possible that ring is not installed properly Then disassemble and reassemble again Standard movement of second coast brake pisto...

Page 505: ...t planetary gear 8 Reverse brake plate 9 Reverse brake disc 10 Reverse brake backing plate 11 Washer 12 Front planetary ring gear 13 Retaining ring 14 Rear planetary gear 15 Blank 16 Bearing 17 Rear p...

Page 506: ...as sembly 2 2 Remove rear planetary thrust washer 1 reverse brake backing plate 2 reverse brake disc 3 and reverse brake plate 4 from front planetary gear assembly 3 Remove reverse brake reaction pla...

Page 507: ...removing retaining ring 2 from inner shaft 1 remove rear planetary ring gear 3 and thrust bearing assembly ASSEMBLY Assemble components by reversing disassembly procedure and noting following points D...

Page 508: ...Install one way clutch as shown in the figure D Install reverse brake reaction plate 2 to front planetary gear 1 With reverse brake reaction plate 2 fixed stationary turn front planetary gear 1 clockw...

Page 509: ...e 6 O ring 7 TCC lock up solenoid valve 8 Pressure control solenoid valve 9 Clamp 10 Shift solenoid A No 1 valve Apply automatic transmission fluid Tightening torque Do not reuse 9 VALVE BODY ASSEMBLY...

Page 510: ...alve 4 and Pressure control solenoid valve 5 ASSEMBLY Reverse disassembling procedure noting the following points D Use new O ring for shift solenoid valves and TCC solenoid valve D Tighten solenoid b...

Page 511: ...nap ring 1 will not align with any of 3 lugs of spring seat D Do not compress spring more than necessary and do not allow it fall or tilt 3 Prepare a stand as shown in the figure It is necessary becau...

Page 512: ...that aligned lugs fit in groove in transmis sion case 7 Measure clearance between reverse brake plate and lugs of transmission case If measured value is less than standard range it is possible that s...

Page 513: ...ts off center support and that will make it impossible to align fluid holes with bolt holes 11 Tighten center support bolts by certain amount at a time till spe cified tightening torque is obtained Ti...

Page 514: ...ifference a About 2 0 mm 0 079 in NOTE If measured value is less than standard value remove for ward clutch assembly and install it again 16 Apply grease to thrust forward clutch bearing and install i...

Page 515: ...e cified torque Tightening torque Torque converter housing No 1 bolts a 35 N m 3 5 kg m 25 5 lb ft Torque converter housing No 2 bolts b 58 N m 5 8 kg m 42 0 lb ft 21 Apply grease to thrust front race...

Page 516: ...on by applying dial gauge 1 to output shaft as shown in the figure Standard clearance in shaft direction 0 3 0 9 mm 0 012 0 035 in 25 Check that inner shaft runs smoothly 26 Install parking lock pawl...

Page 517: ...curely with pin punch 1 Then check that manual shift shaft turns smoothly 31 With parking lock rod 1 installed to manual shift lever place parking lock rod 1 on parking lock pawl 2 as shown in the fig...

Page 518: ...h accumulator 1 1 252 1 254 in Lower spring Second brake accumulator 3 34 80 34 85 mm Upper spring 56 4 mm 2 220 in Green Second brake accumulator 3 1 370 1 372 in Lower spring 18 5 mm 0 728 in Light...

Page 519: ...D Pressure control solenoid connector 8 Black 39 Install oil strainer 9 Tightening torque Oil strainer bolts a 10 N m 0 1 kg m 7 5 lb ft 40 Confirm two oil pan magnet 1 are in its place 41 Install tr...

Page 520: ...ll transmission range sensor lock washer and set nut and tighten set nut After tight ening it bend claws of lock washer Tightening torque Manual shift shaft set nut a 4 N m 0 4 kg m 3 0 lb ft 46 With...

Page 521: ...7B1 116 AUTOMATIC TRANSMISSION 4 A T BEARING AND RACE INSTALLATION DIAGRAM...

Page 522: ...ar mounting member bolts 50 5 0 36 5 Exhaust No 1 pipe to manifold nuts 50 5 0 36 5 Exhaust No 2 pipe to No 1 pipe bolts 50 5 0 36 5 Muffler to exhaust No 2 pipe nuts 60 6 0 43 5 Front propeller shaft...

Page 523: ...g compressor 09900 20606 Dial gauge 09900 20701 Magnetic stand REQUIRED SERVICE MATERIAL Material Recommended SUZUKI product Part Number Use A T fluid Refer to Section 0B D Automatic transmission D Pa...

Page 524: ...B below NOTE D A This kit includes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable a...

Page 525: ...section refer to the same section of the Service Manual men tioned in the FOREWORD of this manual CONTENTS GENERAL DESCRIPTION 7C1 2 UNIT REPAIR 7C1 3 CLUTCH COVER CLUTCH DISC AND FLYWHEEL 7C1 3 TIGH...

Page 526: ...which is peculiar to the diesel engine This performance of the silent type clutch disc is attained from the character istics which can vary torsional torque as two step depending on its torsional ang...

Page 527: ...m 5 0 kg m 36 5 lb ft UNIT REPAIR CLUTCH COVER CLUTCH DISC AND FLYWHEEL DISMOUNTING REMOUNTING Refer to SECTION 7A2 DISMOUNTING REMOUNTING OF TRANSMISSION REMOVAL 1 Hold flywheel stationary with speci...

Page 528: ...have reached service limit at any of holes replace disc assembly Rivet head depth Standard 1 6 mm 0 06 in Service limit 0 5 mm 0 02 in Clutch Cover 1 Check diaphragm spring for abnormal wear or damag...

Page 529: ...bearing to flywheel Special Tool B 09925 98210 3 Aligning clutch disc to flywheel center by using special tool install clutch cover and bolts Then tighten bolts to specification NOTE CAUTION Do not r...

Page 530: ...ork 1 and release bearing as shown in fig ure 5 Slightly apply grease to input shaft 3 and install clutch disc Then join transmission transfer assembly with engine Refer to Section 7A2 B Grease 99000...

Page 531: ...1 0 7 5 Flywheel bolts 50 5 0 36 5 Clutch cover bolts 23 2 3 16 5 Clutch operating cylinder bolt 50 5 0 36 5 Clutch hose union bolt 23 2 3 16 5 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI P...

Page 532: ...ndatory to lu bricate them by hypoid gear oil SECTION 7E DIFFERENTIAL FRONT NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in the...

Page 533: ...er actuates energizes the air pump assembly Then positive pressure is sent from the air pump assembly to the actuator installed to the differen tial case and causes the axle lock clutch and the free a...

Page 534: ...Pressure switch 6 Transfer 7 Front differential 8 Air hose and pipe 9 4WD indicator lamp 10 To ignition switch 11 4WD controller Operation refer to Components and Functions Power supply from 4WD cont...

Page 535: ...4L so that the positive pressure is applied to the actuator and opens when N or 2H to release the pressure to the atmosphere Pressure switch Turns ON and OFF depending on the pressure level in the pu...

Page 536: ...Adjust or replace Replace or retighten Replace Bearing noise D Constant noise Deteriorated or water mixed lubricant D Constant noise Inadequate or insufficient lubricant D Noise while coasting Damaged...

Page 537: ...air leakage from air hoses If OK inspect differential assembly referring to Section 7E in UNIT REPAIR MANUAL 3 Inspect air pump assembly for air leakage and operation referring to AIR PUMP ASSEMBLY o...

Page 538: ...heck voltage between terminal E23 7 and ground Transfer lever is in N or 2H 0 1 V Transfer lever is in 4L or 4H 10 14 V 4 seconds after transfer lever is shifted to 4H or 4L Go to Step 9 Substitute a...

Page 539: ...icator lamp ORN BLK 0 1 V 4 seconds after transfer shift lever shifted to 4H or 4L E23 2 Ignition switch BLK WHT 10 14 V Ignition switch ON Air pump assembly 0 1 V Transfer shift lever 2H or N E23 3 P...

Page 540: ...lever from 2H to 4H range 3 Check that motor starts running a sound can be heard within 1 second and it stops when gauge of special tool indicates speci fied pressure value Check also for air leakage...

Page 541: ...Pa 2 0 kg cm2 28 4 psi which may cause damage to diaphragm 3 With the vehicle lifted so that both of the front wheels are off the ground turn one of the front wheels by hand and check the other wheel...

Page 542: ...w of special tool as far as it stops and close its air check side opening by using fuel hose as blind plug Special Tool A 09918 18111 3 Check that motor starts to run a sound can be heard when bat ter...

Page 543: ...ial housing 3 by removing bolts 1 from its lower part 3 Remove mounting bracket R 2 by removing mounting front bolt 4 from its upper part 4 Remove mounting bracket L 3 from differential housing 1 by r...

Page 544: ...m 36 5 lb ft REAR MOUNTING For front differential carrier 1 Lift up vehicle and remove rear mounting bracket 3 by remov ing rear mounting bolt 1 and rear mounting bracket bolts 2 2 Check mounting rub...

Page 545: ...y removing its 4 bolts and sus pend it with cord or the like NOTE If pull out propeller shaft transfer oil must be drained be fore pulling out 5 Remove bolts 1 for left mounting bracket and bolts and...

Page 546: ...and use following tightening torque Tightening torque Propeller shaft flange bolts a 50 N m 5 0 kg m 36 5 lb ft Front drive shaft flange bolts b 50 N m 5 0 kg m 36 5 lb ft Front mounting bracket bolts...

Page 547: ...t N m kg m lb ft Differential oil level filler plug 23 2 3 17 0 Differential oil drain plug 23 2 3 17 0 Front mounting bolts 85 8 5 61 5 Front mounting bracket bolts 50 5 0 36 5 Front drive shaft flan...

Page 548: ...BLY 7F 5 DISMOUNTING 7F 5 REMOUNTING 7F 5 UNIT REPAIR 7F 6 DISASSEMBLING UNIT 7F 6 COMPONENT INSPECTION 7F 9 SUB ASSEMBLY ADJUSTMENT AND REASSEMBLY 7F 9 DIFFERENTIAL CARRIER 7F 9 DIFFERENTIAL CASE 7F...

Page 549: ...ant Repair and replenish Inadequate or insufficient lubricant Repair and replenish Maladjusted backlash between drive bevel pinion and gear Adjust as prescribed Improper tooth contact in the mesh betw...

Page 550: ...ion 11 Differential gear 12 Pinion shaft No 1 13 Differential left case 14 Differential right case Do not reuse Tightening torque Apply differential oil 15 Thrust washer 16 Differential side bearing 1...

Page 551: ...D It is highly recommended to use SAE 80W 90 viscosity 1 Before oil change or inspection be sure to stop engine and lift up vehicle horizontally 2 Check oil level and existence of leakage If leakage i...

Page 552: ...match marks 1 on joint flange and propeller shaft as shown 4 Remove propeller shaft by removing its flange bolts 5 Remove differential assembly by removing its 8 fastening bolts 1 REMOUNTING 1 Clean m...

Page 553: ...of Section 5 5 Install wheels 6 Fill hypoid gear oil as specified and tighten plug to specification 7 Lower lift UNIT REPAIR DISASSEMBLING UNIT 1 Hold differential assembly securely and put identifica...

Page 554: ...ers differen tial pinions spring washers thrust washers 4 Using special tools pull out differential side bearings 1 Special tool C 09913 85230 D 09913 61510 5 Remove drive bevel pinion hypoid gear ass...

Page 555: ...bevel pinion 2 by using rod 4 approx 22 mm 0 866 in in diameter and press 5 then remove drive bevel pinion 2 and companion flange 3 CAUTION Do not drop drive bevel pinion by holding its gear part by h...

Page 556: ...or damage SUB ASSEMBLY ADJUSTMENT AND REASSEMBLY Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc after disassembly prepare...

Page 557: ...r 2 and spring washer 1 refer to the figure 2 When installing pinion shaft No 2 2 shorter into differential case and pinion insert its a side into pinion joint 1 NOTE a is longer than b a b 3 Check di...

Page 558: ...d fasten them with bolts 2 by tightening them to specified torque Use thread lock cement for bolts 2 CAUTION Use of any other bolts than that specified is prohibited A Cement 99000 32110 Tightening to...

Page 559: ...g 1 with special tool and press Special tool A 09944 66020 2 Hold bearing press fitted in Step 1 with holder and press fit side bearing on the other side NOTE Be sure to use bearing holder for the pur...

Page 560: ...on mounting distance 110 00 mm 4 3307 in a e Shim size for mounting distance adjustment c DIFFERENTIAL REAR 7F 13 DRIVE BEVEL PINION To engage drive bevel pinion and gear correctly it is pre required...

Page 561: ...that specified bearing preload is ob tained NOTE D Before taking measurement with spring balance 2 or torque wrench 3 check for rotation by hand and apply small amount of differential oil to bearings...

Page 562: ...hen long one is at 0 zero Special tool A 09900 20606 B 09926 78320 4 Place zero adjusted mounting dummy and dial gauge set on pinion mounting dummy and take measurement between zero position and exten...

Page 563: ...ble shim thickness 1 12 1 15 1 18 1 21 1 24 1 27 1 30 and 0 3 mm 0 044 0 045 0 046 0 047 0 048 0 049 0 050 and 0 012 in 7 With new pinion spacer 3 inserted as shown in the figure install front bearing...

Page 564: ...ch 4 check for smooth rotation by hand D On measuring preload rotate the drive bevel pinion about 1 rotation per 2 seconds D Be sure to tighten gradually and carefully till specified starting torque i...

Page 565: ...5 Tighten cap bolts provisional torque Tightening torque Bearing cap bolt Provisional torque a 15 N m 1 5 kg m 11 0 lb ft 6 Tighten both bearing adjusters 2 so as to obtain specified gear backlash and...

Page 566: ...3 55 kg 4 30 7 83 lb Special tool D 09922 75222 8 Torque bearing cap bolts 2 to specification and install bearing lock plates Tightening torque Lock plate bolt b 12 N m 1 2 kg m 9 0 lb ft Bearing cap...

Page 567: ...ONTACT Pinion is positioned too close to the center of drive bevel gear 1 Decrease thickness of pinion height adjusting shim and position pinion farther from gear center 2 Adjust drive bevel gear back...

Page 568: ...5 40 0 Bevel gear bolts 95 9 5 68 5 Bearing cap bolts 85 8 5 61 5 Lock plate bolts 12 1 2 9 0 Differential case screws 9 0 9 6 5 REQUIRED SERVICE MATERIAL Material Recommended SUZUKI product Part Num...

Page 569: ...66021 Flange holder 09922 75222 Preload checking tool 09924 74510 Installer attachment 09925 18011 Bearing installer 09926 68310 Bearing installer 09926 78311 002 Pinion mounting dummy See NOTE 09926...

Page 570: ...4 66020 Bearing installer 09951 16060 Lower arm bush remover 09951 18210 Oil seal remover installer No 2 09951 46010 Drive shaft oil seal installer DIFFERENTIAL REAR 7F 23 NOTE This tool is constituen...

Page 571: ...the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may res...

Page 572: ...To transmission range switch R A T vehicle only R 8 To ground B 9 To PCM A T vehicle only W B 10 To ECT sensor Y W 11 To fuel level gauge Bl W 12 To ground B 13 To combination switch G Y NOTE Terminal...

Page 573: ...oat position Float Position Fuel Meter Resistance a 51 7 mm 2 04 in F 6 8 b 139 6 mm 5 50 in 1 2 29 5 35 5 c 254 9 mm 10 0 in E 94 96 If measured valve is out of specification replace fuel sender gaug...

Page 574: ...19 HOW TO REGISTER IGNITION KEY 8G 20 PROCEDURE AFTER IMMOBILIZER CONTROL MODULE REPLACEMENT 8G 21 PROCEDURE AFTER ECM REPLACEMENT 8G 22 SPECIAL TOOLS 8G 23 SECTION 8G IMMOBILIZER CONTROL SYSTEM IF EQ...

Page 575: ...wn Transponder code stored in memory When the ignition switch is turned ON Immo bilizer Control Module tries to read the Transponder code through the coil antenna installed to the steering lock assemb...

Page 576: ...6 PNK Serial data line between ECM and immobilizer control module 7 GRN Power control of ECM 8 BLK WHT Ignition signal 1 Coil antenna 2 Immobilizer control module 3 ECM 4 DOME fuse 5 Ignition switch...

Page 577: ...key to Immobilizer Control Module IMMOBILIZER CONTROL MODULE Immobilizer Control Module is installed to the underside of the instrument panel at the driver s seat side As main functions Immobilizer C...

Page 578: ...ode or ECU code D ECM ECU code Immobilizer Control Module IMMOBILIZER CONTROL SYSTEM IF EQUIPPED 8G 5 ON BOARD DIAGNOSTIC SYSTEM SELF DIAGNOSIS FUNCTION Immobilizer Control Module and ECM diagnoses tr...

Page 579: ...eplacing ECM or Immobilizer Control Module D When ECM was replaced the ECM codes must be registered in ECM and Immobilizer Control Module by performing procedure described in Procedure after ECM Repla...

Page 580: ...obilizer control module referring to DIAGNOSTIC TROUBLE CODE CHECK Are there DTC Nos 13 and or 14 Go to flow table for DTC No Go to Step 3 3 Is there DTC No 12 Go to flow table for DTC No Go to Step 4...

Page 581: ...within 10 seconds DTC41 is stored in the immobilizer con trol module 4 Read DTC stored in immobilizer control module according to instructions displayed on Suzuki scan tool and print it or write it do...

Page 582: ...de transmitted from ignition key Diagnose trouble according to DIAGNOSTIC FLOW TABLE di t h d 14 Coil antenna circuit malfunction FLOW TABLE corresponding to each code No 41 ECM not registered 43 ECU...

Page 583: ...10 14 V Go to Step 2 D BLK WHT wire open D IG METER fuse broken 2 Check voltage between G09 3 terminal and body ground Is it 10 14 V Go to Step 3 D WHT wire open D DOME fuse broken 3 Is there continu...

Page 584: ...ignition key in immobilizer control module according to the procedure described in How to Register Ignition Key And then go to Step 3 Replace ignition key 3 Read DTC according to Diagnostic Trouble Co...

Page 585: ...ized DTC 13 and 14 are set INSPECTION STEP ACTION YES NO 1 Was Immobilizer Diag Flow Table performed Go to Step 2 Go to Immobilizer Diag Flow Table 2 1 Disconnect coil antenna coupler with ignition sw...

Page 586: ...ECM coupler 2 Disconnect coupler at immobilizer control module 3 Is there continuity between G09 7 of immobilizer control module coupler and C51 66 in coupler of ECM equipped with single connector or...

Page 587: ...ON STEP ACTION YES NO 1 Was Immobilizer Diag Flow Table performed Go to Step 2 Go to Immobilizer Diag Flow Table 2 1 Disconnect coupler at immobilizer control module 2 Check for proper connection to i...

Page 588: ...l Module sets DTC 43 INSPECTION STEP ACTION YES NO 1 Was Immobilizer Diag Flow Table performed Go to Step 2 Go to Immobilizer Diag Flow Table 2 1 Register ECU code in immobilizer control module accord...

Page 589: ...izer Control Module cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to Immobilizer Control Module with coupler disconnected from it Voltage Check 1 Remove Immobi...

Page 590: ...tch OFF G09 8 Ignition signal 10 14 V Ignition switch ON NOTE When measuring voltage at G08 1 and G08 3 terminals with ignition switch turned ON be sure to turn igni tion switch ON before connecting p...

Page 591: ...not turn ON ignition switch by using ignition key with any type of metal wound around its grip or in contact with it Or the system may detect abnormal condition and prevent engine from starting D Do...

Page 592: ...verse removal procedure for installation NOTE After replacing Immobilizer Control Module be sure to register Transponder code and ECU code in Immobilizer Control Mod ule by performing procedure descri...

Page 593: ...onder that can be registered in Immobilizer Control Mod ule is limited to 4 If needed clear all Transponder codes for igni tion key with a built in transponder that have been registered in Immobilizer...

Page 594: ...ith a built in transponder And then turn ignition switch ON by using it 3 Using Suzuki scan tool clear all transponder codes registered in Immobilizer Control Module by executing CLR TRANS COD Clear t...

Page 595: ...dy registered in Immobilizer Control Module PROCEDURE AFTER ECM REPLACEMENT CAUTION After replacing the ECM with a new one whose ECU code has not been registered be sure to register it according to th...

Page 596: ...uzuki scan tool D It takes 1 minute max until registration of ECU code to the ECM is completed 3 Make sure that no DTC is displayed on Suzuki scan tool after ignition switch is turned OFF for 10 secon...

Page 597: ...Prepared by 1st Ed Feb 2002 Printed in Japan Printing 600...

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