Suzuki Liana RH413 Service Manual Download Page 546

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5-ii Table of Contents

Select Cable Removal and Installation .............5A-82
Selector Cable Adjustment................................5A-82
Transmission Range Sensor (Shift Switch)

Inspection and Adjustment..............................5A-83

Output Shaft Speed Sensor / VSS Removal

and Installation ................................................5A-84

Output Shaft Speed Sensor / VSS Inspection...5A-84
Input Shaft Speed Sensor Removal and

Installation.......................................................5A-85

Input Shaft Speed Sensor Inspection................5A-85
Transmission Fluid Temperature Sensor

Removal and Installation.................................5A-85

Transmission Fluid Temperature Sensor

Inspection........................................................5A-86

“O/D OFF” Switch Inspection ............................5A-86
Solenoid Valves (Shift Solenoid Valves, TCC

Solenoid Valve and Timing Solenoid Valve)
Removal and Installation.................................5A-87

Solenoid Valves (Shift Solenoid Valves, TCC

Solenoid Valve and Timing Solenoid Valve)
Inspection........................................................5A-88

Pressure Control Solenoid Valve Removal

and Installation ................................................5A-90

Pressure Control Solenoid Valve Inspection.....5A-90
Transmission Control Module (TCM)

Removal and Installation.................................5A-91

Learning Control Initialization............................5A-92
Brief Learning....................................................5A-92
Differential Side Oil Seal Replacement .............5A-93
Shift Lock Solenoid Replacement .....................5A-94
Key Interlock Cable Removal and Installation...5A-94
A/T Fluid Cooler Hoses Replacement...............5A-95
Automatic Transaxle Unit Components.............5A-96
Automatic Transaxle Unit Dismounting and

Remounting.....................................................5A-97

Automatic Transaxle Assembly Components .5A-100
Automatic Transaxle Unit Disassembly...........5A-101
Oil Pump Components ....................................5A-113
Oil Pump Disassembly and Reassembly ........5A-113
Oil Pump Inspection ........................................5A-114
Direct Clutch Components ..............................5A-116
Direct Clutch Preliminary Check .....................5A-116
Direct Clutch Disassembly and Reassembly ..5A-117
Direct Clutch Inspection ..................................5A-119
Forward and Reverse Clutch Assembly

Components..................................................5A-120

Forward and Reverse Clutch Assembly

Preliminary Check .........................................5A-120

Forward and Reverse Clutch Assembly

Disassembly and Reassembly ......................5A-121

Forward and Reverse Clutch Assembly

Inspection......................................................5A-124

2nd Brake Piston Assembly Components.......5A-125
2nd Brake Piston Assembly Disassembly and

Reassembly ..................................................5A-125

Transaxle Rear Cover and O/D and 2nd

Coast Brake Piston Assembly Components .5A-126

Transaxle Rear Cover and O/D and 2nd

Coast Brake Piston Assembly Disassembly
and Reassembly ...........................................5A-127

Transaxle Rear Cover and O/D and 2nd

Coast Brake Piston Assembly Inspection .....5A-128

Countershaft Assembly Components..............5A-129
Countershaft Assembly Disassembly and

Reassembly ..................................................5A-129

Valve Body Assembly Components ................5A-130
Valve Body Assembly Disassembly and

Reassembly ..................................................5A-131

Differential Assembly Components .................5A-132
Differential Assembly Disassembly and

Reassembly ..................................................5A-133

Differential Assembly Inspection .....................5A-134
Torque Converter Housing Disassembly and

Reassembly ..................................................5A-135

Transaxle Case Disassembly and

Reassembly ..................................................5A-137

Automatic Transaxle Unit Inspection and

Adjustment ....................................................5A-138

Automatic Transaxle Unit Assembly ...............5A-140

Specifications ...................................................5A-157

Tightening Torque Specifications....................5A-157

Special Tools and Equipment .........................5A-159

Recommended Service Material .....................5A-159
Special Tool ....................................................5A-159

Manual Transmission/Transaxle ............ 5B-1

General Description .............................................5B-1

Manual Transaxle Construction ..........................5B-1

Diagnostic Information and Procedures ............5B-6

Manual Transaxle Symptom Diagnosis...............5B-6

Repair Instructions ..............................................5B-6

Manual Transaxle Oil Change.............................5B-6
Differential Side Oil Seal Replacement ...............5B-7
Gear Shift Control Lever and Cable

Components......................................................5B-8

Gear Shift Control Lever and Cable Removal

and Installation ..................................................5B-9

Vehicle Speed Sensor (VSS) Removal and

Installation .........................................................5B-9

Back Up Lamp Switch Removal and

Installation .......................................................5B-10

Back Up Lamp Switch Inspection......................5B-10
Manual Transaxle Unit Components.................5B-11
Manual Transaxle Unit Dismounting and

Remounting.....................................................5B-12

Gear Shift and Select Shaft Components .........5B-13
Gear Shift and Select Shaft Removal and

Installation .......................................................5B-14

Gear Shift and Select Shaft Disassembly and

Assembly.........................................................5B-15

Manual Transaxle Assembly Components........5B-16
Fifth Gear Disassembly and Assembly .............5B-17
Manual Transaxle Assembly Disassembly

and Assembly..................................................5B-19

Right Case Disassembly and Assembly ...........5B-25
Left Case Disassembly and Assembly..............5B-25
Input Shaft and Countershaft Components.......5B-26
Input Shaft Disassembly and Assembly............5B-27
Countershaft Disassembly and Assembly.........5B-29

Summary of Contents for Liana RH413

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

Page 2: ......

Page 3: ...f the service work Strict observance of the so specified items will enable one to obtain the full performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use...

Page 4: ......

Page 5: ...ke Control System and Diagnosis 4A 1 Front Brakes 4B 1 Rear Brakes 4C 1 Parking Brake 4D 1 ABS 4E 1 Volume 2 Precautions 00 i Precautions 00 1 Transmission Transaxle 5 i Precautions 5 1 Automatic Tran...

Page 6: ......

Page 7: ...trical Circuit Service 00 7 Precautions for Installing Mobile Communication Equipment 00 9 Precautions for Vehicle Tie Down Hooks 00 9 Precautions in Servicing Full Time 4WD Vehicle 00 10 Air Bag Warn...

Page 8: ...erformance and lead to injury If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove the air bag system components beforehand to avoid componen...

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

Page 10: ...where the ambient temperature below 65 C 150 F without high humidity and away from electric noise Never carry seat belt pretensioner by wire or connector of pretensioner When placing a live seat belt...

Page 11: ...fter vehicle is completely repaired perform Air Bag Diagnostic System Check in Section 8B General Precautions S3RH0A0000002 The WARNING and CAUTION describe some general precautions that you should ob...

Page 12: ...le and replace the terminal cover When removing parts that are to be reused be sure to keep them arranged in an orderly manner so that they may be reinstalled in the proper order and position Whenever...

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

Page 14: ...ector lock first and then pull them apart by holding connectors themselves When connecting connectors also hold connectors and put them together until they lock securely a click is heard When installi...

Page 15: ...gital type voltmeter When taking measurements at electrical connectors using a tester probe be sure to insert the probe 2 from the wire harness side backside of the connector 1 When connecting meter p...

Page 16: ...control unit Keep the antenna feeder more than 20 cm 7 9 in away from electronic control unit and its wire harnesses Do not run the antenna feeder parallel with other wire harnesses Confirm that the a...

Page 17: ...as front wheel drive by removing rear propeller shaft When using On vehicle type wheel balancing equipment 1 be sure to jack up all four wheels off the ground completely and support vehicle with safe...

Page 18: ...TCs from setting Failure to follow procedures could result in possible air bag system activation personal injury or otherwise unneeded air bag system repairs Fastener Caution S3RH0A0000009 CAUTION Whe...

Page 19: ...ection of connector Poor contact of terminal due to dirt corrosion or rust on it poor contact tension entry of foreign object etc Wire harness being open When checking system circuits including an ele...

Page 20: ...ge is supplied to the circuit being checked voltage check can be used as circuit check 1 With all connectors connected and voltage applied to the circuit being checked measure voltage between each ter...

Page 21: ...although a sticking relay or solenoid can occasionally be at fault When checking it for proper connection perform careful check of suspect circuits for Poor mating of connector halves or terminals no...

Page 22: ...sulation which is rubbed through causing an intermittent short as the bare area touches other wiring or parts of the vehicle Wiring broken inside the insulation This condition could cause continuity c...

Page 23: ...6 Fuel Tank Inspection 0B 7 PCV Valve Inspection 0B 7 Fuel Evaporative Emission Control System Inspection 0B 7 Brake Discs and Pads Front Inspection 0B 7 Brake Drums and Shoes Rear Inspection 0B 7 Bra...

Page 24: ...Sensor Recirculated Exhaust Gas Temp Sensor REGTS EFE Heater Early Fuel Evaporation Heater Positive Temperature Coefficient PTC Heater ELR Emergency Locking Retractor EPS Electronic Power Steering EV...

Page 25: ...ay Catalytic Converter Symbols S3RH0A0101003 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO 1216B 99000 31230 Apply oil engine transmission transfer differential Apply SILI...

Page 26: ...are 4T 6 8 7T 8 8 and radial line with the class identification embossed on the head of each bolt Some metric nuts will be marked with punch 6 or 8 mark strength identification on the nut face Figure...

Page 27: ...0 2 5 4 0 9 5 21 0 32 5 47 0 76 0 116 0 A equivalent of 6 8 strength fastener without flange N m 2 4 4 7 8 4 20 42 80 125 193 280 kgf m 0 24 0 47 0 84 2 0 4 2 8 0 12 5 19 3 28 lb ft 2 0 3 5 6 0 14 5 3...

Page 28: ...g frame contact hoist apply hoist as shown right and left at the same position Lift up the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying t...

Page 29: ...ck against suspension parts i e stabilizer etc or vehicle floor or it may get deformed For 2WD vehicle In raising front or rear vehicle end off the floor by jacking be sure to put the jack against the...

Page 30: ...n number is attached on the left front top of the instrument panel and punched on the front dash panel in engine room Refer to figure for detail VIN cord information and its location Engine Identifica...

Page 31: ...rts When servicing and handling parts refer to WARNING CAUTION instructions printed on labels If any WARNING CAUTION label is found stained or damaged clean or replace it as necessary I3RH0A010002 01...

Page 32: ...el on seat belt retractor 2 Air bag label on combination switch and contact coil assembly 6 Child seat label if equipped 3 Air bag label on passenger air bag inflator module 7 Air bag label on side ai...

Page 33: ...ed fuel is used Vehicle without HO2S Nickel plug R R R Iridium plug R Vehicle with HO2S Nickel plug R R Iridium plug Replace every 105 000 km 63 000 miles or 84 months When leaded fuel is used refer t...

Page 34: ...amage breakage rattle I I I I Drive shaft axle boots Propeller shafts 4WD I I I Manual transaxle oil leakage level I 1st 15 000 km only R I I R R Automatic transaxle fluid Fluid level I I I I Fluid ch...

Page 35: ...found adjust or replace A C Compressor and or Power Steering Pump Drive Belt Inspect belt for cracks cuts deformation wear cleanliness and tension referring to P S Pump Drive Belt On Vehicle Inspecti...

Page 36: ...nd used engine oil can be hazardous Be sure to read WARNING in General Precautions in Section 00 and observe what is written there Step 1 7 outlined below must be performed with ENGINE NOT RUNNING For...

Page 37: ...t for three minutes Stop it and wait another 5 minutes before checking oil level Add oil as necessary to bring oil level to FULL level mark on dipstick Engine Coolant Change S3RH0A0206004 WARNING To a...

Page 38: ...filter more often under dusty conditions Ask your dealer for proper replacement interval for your driving conditions Replace air cleaner filter with new one according to steps 1 2 3 5 and 6 of inspect...

Page 39: ...e parts as necessary Be sure to torque caliper pin bolts to specification Brake Drums and Shoes Rear Inspection S3RH0A0206014 Check rear brake drums and brake linings for excessive wear and damage whi...

Page 40: ...defective replace Refer to Irregular and or Premature Wear Description in Section 2D and Wear Indicators Description in Section 2D for details 2 Check inflating pressure of each tire and adjust pressu...

Page 41: ...epair or replace defective parts if any 4 Check boots of steering linkage and steering gear case for damage leak detachment tear etc If damage is found replace defective boot with new one If any dent...

Page 42: ...n S3RH0A0206027 1 Inspect transaxle case for evidence of oil leakage Repair leaky point if any 2 Make sure that vehicle is placed level for oil level check 3 Remove oil filler level plug 1 of transaxl...

Page 43: ...for evidence of fluid leakage Repair leaky point if any 2 Make sure that vehicle is placed level 3 Change fluid For its procedure refer to A T Fluid Change in Section 5A Automatic Transaxle Fluid Coo...

Page 44: ...t rear and back doors opens and closes smoothly and locks securely when closed If any malfunction is found lubricate hinge and latch or repair door lock system Engine Hood Check that secondary latch o...

Page 45: ...ual transaxle vehicles place the shift lever in Neutral depress clutch pedal fully and try to start Exhaust System Check Check for leakage cracks or loose supports Clutch for Manual Transaxle Check fo...

Page 46: ...cial Tools and Equipment Recommended Fluids and Lubricants S3RH0A0208002 Special Tool S3RH0A0208003 Fastening part Tightening torque Note N m kgf m lb ft Engine oil drain plug 50 5 0 36 5 Oil filter 1...

Page 47: ...MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Terminal Vehicle without Immobilizer Indicator Lamp 1A 43 MIL Does Not Light at Ignition Switch ON and Engine Does Not Start...

Page 48: ...4 Vacuum Hose Inspection 1B 4 EGR Valve Removal and Installation 1B 4 EGR Valve Inspection 1B 4 PCV Hose Inspection 1B 4 PCV Valve Inspection 1B 5 Special Tools and Equipment 1B 5 Special Tool 1B 5 E...

Page 49: ...1D 57 Recommended Service Material 1D 57 Special Tool 1D 57 Engine Lubrication System 1E 1 General Description 1E 1 Engine Lubrication Description 1E 1 Diagnostic Information and Procedures 1E 2 Oil P...

Page 50: ...ion Spark Test 1H 5 Repair Instructions 1H 6 High Tension Cord Removal and Installation 1H 6 High Tension Cord Inspection 1H 6 Spark Plug Removal and Installation 1H 7 Spark Plug Inspection 1H 7 Ignit...

Page 51: ...er to Air Bag Warning in Section 00 Precautions on Engine Service Refer to Precautions on Engine Service in Section 1A Precautions in Diagnosing Trouble Refer to Precautions in Diagnosing Trouble in S...

Page 52: ...ow which has detected earliest in the order it can be identified by referring freeze frame data and follow the instruction in that flow If no instructions are given troubleshoot DTCs according to the...

Page 53: ...lfunction which gives an adverse effect to vehicle emission while the engine is running it makes the malfunction indicator lamp 1 in the meter cluster of the instrument panel turn ON or flash flashing...

Page 54: ...e upper square 1 is detected while the freeze frame data in the lower square 2 has been stored the freeze frame data 2 will be updated by the freeze frame data 1 In the 2nd through the 4th frames the...

Page 55: ...Malfunction indicator lamp 1 lights when the ignition switch is turned ON but the engine at stop with the diagnosis switch terminal ungrounded regardless of the condition of Engine and Emission contro...

Page 56: ...ECM TCM ABS control module and Air bag SDM SUZUKI serial data line 6 is used for SUZUKI scan tool to communicate with immobilizer control module Engine and Emission Control System Description S3RH0A11...

Page 57: ...nifold Electronic Control System Description S3RH0A1101018 The electronic control system consists of 1 various sensors which detect the state of engine and driving conditions 2 ECM which controls vari...

Page 58: ...1A 7 Engine General Information and Diagnosis Engine and Emission Control System Flow Diagram I2RH0B110006 01...

Page 59: ...BLK GRY RED GRY BLU LT GRN RED LT GRN LT GRN BLK ORN RED WHT PNK BLK WHT PNK BLU B YEL WHT ORN BLU BLK WHT G04 17 BB 50 YEL BLK 51 48 49 G03 8 YEL BLK RED GRY GRY WHT BRN WHT 55 28 56 56 WHT ORN 12V...

Page 60: ...zer indicator lamp if equipped 16 ABS control module 38 Radiator fan relay No 1 60 Engine ground 17 CO adjusting resistor vehicle without EGR valve 39 Radiator fan motor 61 Body ground 18 Blower fan m...

Page 61: ...ure switch 19 PNK Immobilizer indicator lamp if equipped 8 GRY BLK Engine coolant temp signal for TCM A T 20 9 BLU YEL A C condenser fan relay if equipped 21 10 BRN WHT Main relay 22 11 YEL WHT A C ev...

Page 62: ...HEATED OXYGEN SENSOR 1 VEHICLE WITH EGR VALVE HEATED OXYGEN SENSOR 2 VEHICLE WITH IMMOBILIZER INDICATOR LAMP For detecting deterioration of three way catalytic converter IAT SENSOR ECT SENSOR TP SENSO...

Page 63: ...hematic and Routing Diagram Engine and Emission Control System Diagram S3RH0A1102001 12 11 10 7 8 18 15 16 13 19 14 2 6 5 1 3 29 30 24 31 45 37 36 20 21 22 46 38 28 27 25 17 35 26 34 33 1 33 2 33 3 33...

Page 64: ...ressure regulator 26 Park Neutral position switch A T 40 A C compressor clutch if equipped 10 Tank pressure control valve built in fuel pump 27 Ignition switch 41 A C condenser fan motor if equipped 1...

Page 65: ...ygen sensor 2 vehicle with immobilizer indicator lamp f Ignition coil assembly F A C EVAP inlet air temp sensor if equipped 6 VSS g Radiator fan control relay No 1 G A C EVAP outlet air temp sensor if...

Page 66: ...T sensor 22 Knock sensor vehicle with EGR valve 5 A C compressor relay 14 Ignition coil with igniter 23 CMP sensor 6 A C condenser fan relay 15 HO2S 1 vehicle with EGR valve 24 EGR valve vehicle with...

Page 67: ...any faulty condition Repair or replace malfunction part and go to Step 11 Go to Step 8 5 Trouble symptom confirmation 1 Confirm trouble symptom referring to the Trouble Symptom Confirmation Is trouble...

Page 68: ...the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis 11 Final confirmation test 1 Clear DTC if a...

Page 69: ...General Information and Diagnosis 1A 18 Customer problem inspection form example NOTE The form is a standard sample It should be modified according to conditions characteristic of each market I2RH0111...

Page 70: ...erform basic engine check according to the Engine Basic Inspection first When the end of the flow has been reached check the parts of the system suspected as a possible cause referring to Engine Sympt...

Page 71: ...l if connected and using service wire 4 connect diagnosis switch terminal 1 to ground terminal 2 in diagnosis connector 3 3 With the ignition switch ON position and leaving engine OFF read DTC from fl...

Page 72: ...nput 1 driving cycle 1 driving cycle P0120 No 13 Throttle position circuit malfunction Throttle position circuit low input Throttle position circuit high input 1 driving cycle 1 driving cycle P0121 Th...

Page 73: ...celerating 2 driving cycles 1 driving cycle P0505 Idle control system malfunction No closed signal to IAC valve is detected 2 driving cycles Not applicable P0601 No 71 Internal control module memory c...

Page 74: ...iagnosis in Section 5A and DTC Table in Section 5A P0758 Shift solenoid B No 2 electrical Refer to A T Symptom Diagnosis in Section 5A and DTC Table in Section 5A P0785 Timing solenoid Refer to A T Sy...

Page 75: ...s 20 Rough or incorrect idle excessive fuel consumption hesitation poor acceleration P0130 No 14 P0134 HEATED OXYGEN SENOR 1 Hard starting rough or incorrect idle excessive fuel consumption hesitation...

Page 76: ...other necessary switches Scan tool data Vehicle condition Normal condition reference values FUEL SYSTEM B1 FUEL SYSTEM STATUS At specified idle speed after warming up CLOSED closed loop CALC LOAD CAL...

Page 77: ...THROTTLE POSITION Throttle valve at idle position ON Throttle valve opens larger than idle position OFF FUEL CUT When engine is at fuel cut condition ON Other than fuel cut condition OFF RADIATOR FAN...

Page 78: ...eference pulses from the crankshaft position sensor VEHICLE SPEED km h MPH It is computed based on pulse signals from vehicle speed sensor IGNITION ADVANCE IGNITION TIMING ADVANCE FOR NO 1 CYLINDER Ig...

Page 79: ...y open valve CLOSED THROT POS CLOSED THROTTLE POSITION ON OFF This parameter will read ON when throttle valve is fully closed or OFF when the throttle is not fully closed FUEL CUT ON OFF ON Fuel being...

Page 80: ...1J Water pump belt tension damage Drive Belt Inspection in Section 0B Throttle cable play installation Accelerator Cable Adjustment in Section 1D Vacuum hoses of air intake system disconnection loosen...

Page 81: ...min for A T vehicle Go to Step 6 Go to Engine Symptom Diagnosis 6 Do you have SUZUKI scan tool Go to Step 8 Go to Step 7 7 Check ignition timing as follows 1 Connect test switch terminal of diagnosis...

Page 82: ...mmobilizer indicator lamp or MIL malfunction indicator lamp for flashing Is it flashing when ignition switch is turned to ON position Go to DTC Table in Section 10C Go to Step 11 11 Check fuel supply...

Page 83: ...sparks Is it in good condition Go to Step 14 Go to Ignition System Symptom Diagnosis in Section 1H 14 Check fuel injector for operation as follows 1 Install spark plugs and connect injector connectors...

Page 84: ...1H Compression leak from valve seat Valves and Valve Guides Inspection in Section 1D Sticky valve stem Valves and Valve Guides Inspection in Section 1D Weak or damaged valve springs Valve Spring Inspe...

Page 85: ...per oil viscosity Engine Oil and Filter Change in Section 0B Malfunctioning oil pressure Oil Pressure Check in Section 1E Clogged oil strainer Oil Pan and Oil Pump Strainer Cleaning in Section 1E Func...

Page 86: ...ogged or leaky radiator Radiator On Vehicle Inspection and Cleaning in Section 1F Improper engine oil grade Engine Oil and Filter Change in Section 0B Clogged oil filter or oil strainer Oil Pressure C...

Page 87: ...r head gasket Replace Low engine compression Compression Check in Section 1D Surge Engine power variation under steady throttle or cruise Feels like vehicle speeds up and down with no change in accele...

Page 88: ...Clogged oil filter or oil strainer Oil Pressure Check in Section 1E Poor oil pump performance Oil Pressure Check in Section 1E Faulty radiator fan control system Radiator Fan Control System Check Drag...

Page 89: ...1F Improper engine oil grade Engine Oil and Filter Change in Section 0B Clogged oil filter or oil strainer Oil Pressure Check in Section 1E Poor oil pump performance Oil Pressure Check in Section 1E F...

Page 90: ...ecification Fuel Pressure Check Closed loop system A F feed back compensation fails Faulty TP sensor Poor performance of ECT sensor or MAP sensor Throttle Position TP Sensor On Vehicle Inspection in S...

Page 91: ...ector G03 2 Check for proper connection to ECM connector at G03 7 terminal 3 If OK measure voltage between G03 7 terminal of ECM connector and vehicle body ground with ignition switch turned ON Is vol...

Page 92: ...G03 7 PPL YEL 5 6 9 IG1 PNK BLK BLK RED BLK YEL 8 7 GRN GRN I3RH0A110012 01 1 BATT fuse 6 MIL 2 Main fuse box 7 To ignition switch 3 IG fuse 8 Main relay 4 To battery 9 METER fuse 5 Monitor connector...

Page 93: ...3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 BLK DN TS GND...

Page 94: ...1 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 BLK DN TS GND MON PPL WHT C41 27 G04 15 PNK GRN G03 17 7 4 G03 7 PPL YEL 5 6 9 IG1 PNK BLK BL...

Page 95: ...K RED BLK RED C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15...

Page 96: ...urned OFF 2 Check for proper connection to ECM connector at G04 23 G04 10 G04 6 G04 5 C41 1 C41 2 and C41 3 wire terminals 3 Turn ignition switch to ON position 4 Measure voltage between G04 23 wire t...

Page 97: ...04 5 and G04 6 wire terminals of ECM connector and body ground Is voltage 10 14 V Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 If...

Page 98: ...ntrol System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 Check MAP sensor and its circuit 1 Connect scan tool to DLC with ignition switch OFF 2 Turn ignition switch O...

Page 99: ...ck MAP sensor referring to Manifold Absolute Pressure MAP Sensor Inspection in Section 1C Is it in good condition GRY RED wire shorted to ORN wire LT GRN RED wire open poor C41 10 connection If wire a...

Page 100: ...ls 3 If OK then with ignition switch ON Is voltage applied to LT GRN BLK wire terminal about 4 6 V Go to Step 5 LT GRN BLK wire open or shorted to power or poor C41 15 connection If wire and connectio...

Page 101: ...er it is possible that ORN circuit be open DTC Confirmation Procedure 1 Clear DTC start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC C41 14 5V ECM LT GRN ORN C41 1...

Page 102: ...shorted to ground If wire is OK substitute a known good ECM and recheck 4 Does scan tool indicate 40 C 40 F at Step 2 Go to Step 6 Go to Step 5 5 Check wire harness 1 Disconnect ECT sensor connector...

Page 103: ...min 2 Select DTC mode on scan tool and check DTC DTC Troubleshooting C41 10 C41 22 C41 16 5V 5V ECM GRY RED GRY BLU ORN C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2...

Page 104: ...ction to TP sensor at GRY RED GRY BLU and ORN wire terminals 3 If OK then with ignition switch ON check voltage between each of GRY RED or GRY BLU wire terminals and body ground Is voltage about 4 6 V...

Page 105: ...3 Increase vehicle speed to 50 60 km h 30 40 mph in 3rd gear or D range and hold throttle valve at that opening position for 1 min 4 Stop vehicle 5 Check DTC and pending DTC C41 10 C41 22 C41 16 5V 5...

Page 106: ...output voltage when throttle valve is at idle position and fully opened Does voltage vary within specified value linearly as shown in the figure Substitute a known good ECM and recheck Go to Step 5 4...

Page 107: ...sor resistance Between 1 and 2 4 0 6 0 k Between 1 and 3 0 02 6 0 k varying according to throttle valve opening Are measured values as specified High resistance in GRY RED GRY BLU or ORN circuit If wi...

Page 108: ...at idle speed after engine warmed up and running at specified vehicle speed HO2S 1 output voltage does not go below 0 3 V or order 0 6 V 2 driving cycle detection logic Monitoring once 1 driving Heat...

Page 109: ...400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower ECM WHT BLU WHT ORN C41 10 1 C41 13 C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 1...

Page 110: ...barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower Step Action Yes No 1 Was Engine and Emission Control System Che...

Page 111: ...p it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal to enrich A F mixture Does HO2S 1 output voltage deflect...

Page 112: ...m Check 2 Check heater for operation 1 Check voltage at terminal C41 7 2 Warm up engine to normal operating temperature 3 Stop engine 4 Turn ignition switch ON and check voltage at terminal C41 7 Volt...

Page 113: ...6 Repeat above steps 5 4 times 7 Increase vehicle speed to about 80 km h 50 mph in 3rd gear or 2 range 8 Release accelerator pedal and with engine brake applied keep vehicle coasting fuel cut conditi...

Page 114: ...System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 Check exhaust system for leakage loose connection and damage Is it in good condition Go to Step 3 Repair or replac...

Page 115: ...28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 ECM BLK WHT PNK BLU G04 4 IG1 BLK BLK I3RH0A110018 01 DTC detecting condition Po...

Page 116: ...check result as specified Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 Go to Step 3 3 Check heater of sensor 2 1 Disconnect HO2S...

Page 117: ...Oxygen concentration increases 4 Sensed information d Low voltage 5 ECM e A F mixture becomes richer DTC detecting condition Possible cause When one of the following conditions is met while engine ru...

Page 118: ...it Malfunction Sensor 2 for 5 min or longer and until engine is warmed up to normal operating temperature 4 Keep vehicle speed at 50 60 km h 30 40 mph in 5th gear or D range for 5 min or more 5 Stop v...

Page 119: ...uel pressure gauge 3 Check fuel pressure Fuel pressure specification With fuel pump operating and engine at stop 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi At specified idle speed 270 310 kPa 2 7 3 1 kg...

Page 120: ...oupler or injector 2 Turn ignition switch OFF and disconnect a fuel injector connector 3 Check for proper connection to fuel injector at each terminal 4 If OK then check injector resistance Fuel injec...

Page 121: ...n control system Go to Step 7 7 Check MAP sensor for performance 1 See Manifold Absolute Pressure MAP Sensor Inspection in Section 1C Is it in good condition Go to Step 8 Replace MAP sensor 8 Check EC...

Page 122: ...it makes the malfunction indicator lamp MIL flash as long as misfire occurs at that rate After that however when the misfire rate drops MIL remains ON until it is judged as normal 3 times under the sa...

Page 123: ...2 min or more 4 Check DTC and pending DTC 5 If DTC is not detected at idle consult usual driving based on information obtained in Customer Complaint Analysis and Freeze Frame Data Check DTC Troublesh...

Page 124: ...Crank engine and check that each spark plug sparks Are above check results satisfactory Go to Step 4 Check ignition system parts 4 Check fuel pressure 1 Release fuel pressure from fuel feed line 2 Ins...

Page 125: ...or or injector 2 Turn ignition switch OFF and disconnect a fuel injector connector 3 Check for proper connection to fuel injector at each terminal 4 If OK then check injector resistance Fuel injector...

Page 126: ...losing 1 Disconnect purge hose from EVAP canister purge valve 2 Place finger against the end of EVAP canister purge valve 3 Check that vacuum is not felt there when engine is cool and running at idle...

Page 127: ...Tappet and shim Inspection in Section 1D Valve timing Refer to Timing Chain and Chain Tensioner Removal and Installation in Section 1D Are they in good condition Check wire harness and connection of E...

Page 128: ...ulty ECM Recheck referring to Intermittent and Poor Connection Inspection in Section 00 Go to Step 3 3 Check knock sensor output 1 Stop engine 2 With ignition switch at OFF position disconnect knock s...

Page 129: ...DTC Confirmation Procedure 1 Clear DTC and crank engine for 2 sec 2 Select DTC mode on scan tool and check DTC I2RH0B110046 01 DTC detecting condition Possible cause No CKP sensor signal for 2 sec at...

Page 130: ...ignition switch ON and check for voltage at each terminal of sensor connector disconnected CKP sensor voltage Terminal B 10 14 V Terminal Vout 4 5 V Terminal GND 0 1 V Is check result satisfactory Go...

Page 131: ...ic substance iron 1 while keeping approximately 1 mm 0 03 in gap with respect to end face of CKP sensor Does voltage vary from low 0 1 V to high 4 5 V or from high to low Go to Step 7 Replace CKP sens...

Page 132: ...an tool and check DTC ECM 5V B BLK RED BLU BLK ORN C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14...

Page 133: ...rn ignition switch and check for voltage at each terminal of sensor connector disconnected CMP sensor voltage Terminal B 10 14 V Terminal Vout 4 5 V Terminal GND 0 1 V Is check result satisfactory Go...

Page 134: ...etic substance iron 1 while keeping approximately 1 mm 0 03 in gap with respect to end face of CMP sensor Does voltage vary from low 0 1 V to high 4 5 V or from high to low Go to Step 7 Replace CMP se...

Page 135: ...nd run it at idle for 5 min 3 Increase vehicle speed to 80 88 km h 50 55 mph in 5th gear or in D range 4 Hold throttle valve at that opening position for 2 min or longer 5 Increase engine speed to 400...

Page 136: ...eted No DTC is detected Confirmation test is completed Repeat DTC confirmation procedure Step Action Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emiss...

Page 137: ...and disconnect ECM couplers 2 Check resistance between G04 5 and C41 18 C41 29 C41 17 C41 28 Is each resistance 20 24 at 20 C 68 F Go to Step 7 Faulty GRY GRY WHT GRY YEL BRN WHT wire or EGR valve 7 M...

Page 138: ...t of HO2S 1 output voltage because of the amount of oxygen in the exhaust gas which has been stored in warm up three way catalytic converter and three way catalytic converter Reference Oscilloscope wa...

Page 139: ...m h 35 45 mph for 8 min or longer While this driving if Catalyst Monitoring TEST COMPLETED is displayed in READINESS TESTS mode and DTC is not displayed in DTC mode confirmation test is completed If T...

Page 140: ...performed Go to Step 2 Go to Engine and Emission Control System Check 2 Short term fuel trim check Did short term fuel trim vary within 20 20 range in Step 3 of DTC Confirmation Procedure Go to Step 3...

Page 141: ...Section 1B Is it as specified BLU BLK circuit open or short BLK RED circuit open or short Replace EVAP canister purge valve BATT 80A 30A 60A BLK ECM BLK ORN BLK C41 1 C41 3 L L H H BRN C41 31P G04 24P...

Page 142: ...fan relay No 3 Is voltage 10 14 V Go to Step 3 BLK WHT and or BLU WHT wire open circuit 3 Check wire circuit 1 Connect radiator fan control relay No 1 to relay box with ignition switch turned OFF 2 T...

Page 143: ...ck radiator fan control 1 Disconnect radiator fan control relay No 2 2 and No 3 3 from relay box with ignition switch turned OFF 2 Run engine at ECT is over 97 C 207 F 3 Measure voltage between vehicl...

Page 144: ...in good condition GRN RED wire open circuit Replace relay 14 Check radiator fan control No 2 and No 3 1 Connect connectors to ECM with ignition switch turned OFF 2 Run engine at ECT is over 107 C 225...

Page 145: ...n logic continuous monitoring BLK ORN circuit open PPL or BLK RED circuit open or short VSS malfunction ECM malfunction Speedometer malfunction TCM malfunction Step Action Yes No 1 Was Engine and Emis...

Page 146: ...age from b to c of VSS connector Is voltage within 10 14 V Go to Step 7 BLK RED or BLK ORN wire open or short 7 Check VSS signal circuit 1 Measure voltage from terminal a of VSS connector to ground Is...

Page 147: ...wn good ECM and recheck 10 Does speedometer indicate vehicle speed Go to Step 11 Go to Step 12 11 Check vehicle speed signal 1 Turn ignition switch to OFF position 2 Disconnect combination meter conne...

Page 148: ...circuit for short 1 Turn ignition switch OFF position 2 Disconnect connector from combination meter 3 Turn ignition switch ON position without engine running 4 Measure voltage from terminal PPL wire...

Page 149: ...mittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 Go to Step 5 4 Check idle air control system 1 Remove IAC valve from throttl...

Page 150: ...th ignition switch ON 3 Turn ignition switch ON for 2 sec crank engine for 2 sec and run it at idle for 1 min 4 Check pending DTC and DTC DTC Troubleshooting DTC P1450 DTC detecting condition Possible...

Page 151: ...lute pressure Is it barometric pressure approx 100 kPa 760 mmHg at sea level Go to Step 3 Substitute a known good ECM and recheck 3 MAP sensor check 1 Remove MAP sensor from intake manifold and connec...

Page 152: ...cranking engine or High voltage at terminal C41 30 after starting engine 2 driving cycle detection logic continuous monitoring BLK YEL circuit open ECM malfunction Step Action Yes No 1 Was Engine and...

Page 153: ...2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 ECM G03 11 I2RH0B110069 01 DTC detecting condition Possible cause Low voltage at terminal G03 11 afte...

Page 154: ...Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Start engine and run it at idle for 1 min 4 Select DTC mode on scan tool and check DTC ECM TCM GRN YEL 12V G08 7 G03 17 C41 31P G04 24P...

Page 155: ...age 8 12 V Go to Step 7 Go to Step 4 4 Signal circuit check 1 Disconnect connectors from TCM with ignition switch turned OFF 2 Turn ON ignition switch 3 Measure voltage between G03 17 terminal and veh...

Page 156: ...ep 9 GRN YEL wire shorted to ground or other circuits 9 Signal circuit check 1 Connect connectors to TCM with ignition switch turned OFF 2 Turn ON ignition switch 3 Measure voltage between G03 17 and...

Page 157: ...se D range signal not inputted Park Neutral position signal inputted to ECM while vehicle running 2 driving cycle detection logic continuous monitoring GRY RED circuit open Transmission range switch m...

Page 158: ...smission range sensor and circuits referring to Transmission Range Sensor Shift Switch Inspection and Adjustment in Section 5A Go to Step 6 6 Check PNP signal circuit 1 Turn ignition switch OFF 2 Disc...

Page 159: ...lse signal Check it with oscilloscope if necessary Viewed from harness side I3RH0A110026 01 C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 27 29 30 31...

Page 160: ...th after warming up Pulse frequency varies depending on engine speed 6 pulses are generated par 1 camshaft revolution C41 12 Generator control signal Min 4 8 V Ignition switch ON C41 13 Heated oxygen...

Page 161: ...pending on engine speed 30 pulses are generated par 1 crankshaft revolution C41 24 Fuel pump relay 0 1 V For 2 seconds after ignition switch ON 10 14 V After the time shown above C41 25 Knock sensor v...

Page 162: ...2 23 psi or more G04 8 Engine coolant temp signal for TCM A T 10 14 V Ignition switch ON 0 1 V 8 14 V Engine running at idling Output signal is active low duty pulse Duty ratio varies depending on ECT...

Page 163: ...Terminal No Circuit Normal Voltage Condition Terminal No Circuit Normal Voltage Condition G03 1 Tachometer 0 1 V Ignition switch ON 0 1 V 8 14 V Reference waveform No 19 and No 20 While engine runnin...

Page 164: ...le opening 0 0 78 ms ON duty Throttle opening 100 6 24 ms ON duty G03 15 Fuel level sensor gauge vehicle with heated oxygen sensor 2 0 2 V Ignition ON and fuel tank fully filled 4 5 7 5 V Ignition ON...

Page 165: ...4 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed I3RH0A110029 01 I3RH0A110030 01 Measurement terminal CH1 C41 18 to C41 1 CH2 C41 29 to C4...

Page 166: ...CH1 5 V DIV CH2 20 V DIV TIME 4 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 Fuel inj...

Page 167: ...ignal CMP reference signal 2 No 2 fuel injector signal Measurement terminal CH1 C41 11 to C41 1 CH2 C41 9 to C41 1 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DIV Measurement condition Af...

Page 168: ...Measurement terminal CH1 C41 26 to C41 10 CH2 C41 16 to C41 10 Oscilloscope setting CH1 2 V DIV CH2 1 V DIV TIME 200 ms DIV Measurement condition After warmed up to normal operating temperature Igniti...

Page 169: ...1 C41 11 to C41 1 CH2 G03 1 to C41 1 Oscilloscope setting CH1 5 V DIV CH2 5 V DIV TIME 10 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1...

Page 170: ...00 ms DIV Measurement condition After warmed up to normal operating temperature Engine at cranking 1 Ignition coil No 1 and No 4 signal 2 No 1 fuel injector signal 3 Cylinder reference signal CMP refe...

Page 171: ...12 0 17 C41 9 to G04 5 6 No 1 injector 11 3 17 C41 21 to G04 5 6 No 2 injector 11 3 17 C41 31 to G04 5 6 No 3 injector 11 3 17 C41 8 to G04 5 6 No 4 injector 11 3 17 C41 18 to G04 5 6 EGR valve steppe...

Page 172: ...No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 Check injector for operating sound 1 Using sound scope check each injector fo...

Page 173: ...8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 1 2 I2RH0B110079 01 1 Fue...

Page 174: ...K BLK or BLK RED circuit open or fuel pump malfunction 4 Check fuel pump relay for operation 1 Check resistance between each two terminals of fuel pump relay Fuel pump relay resistance Between termina...

Page 175: ...nformation and Diagnosis 1A 124 Fuel Pressure Check S3RH0A1104068 System Diagram Special tool A 09912 58442 B 09912 58432 C 09912 58490 I2RH0B110082 01 1 Injector 3 Fuel pressure regulator 2 Delivery...

Page 176: ...eturn hose to it 2 Put the other end of new return hose into approved gasoline container 3 Operate fuel pump Is specified fuel pressure obtained then Restricted fuel return hose or pipe Faulty fuel pr...

Page 177: ...ir control duty referring to Idle Speed Idle Air Control IAC Duty Inspection Is idle speed within specification Go to Step 2 Go to Step 4 2 Is IAC duty within specification in Step 1 Go to Step 3 Chec...

Page 178: ...Repair or replace A C signal circuit or A C system 7 1 Check IAC system referring to Step 3 or Step 4 of DTC P0505 Idle Control System Malfunction Is check result satisfactory Go to Step 8 Go to Step...

Page 179: ...ck voltage at terminal G03 6 of ECM connector connected PNP signal P and N range 10 14 V R D 2 and L range 0 1 V Is check result satisfactory Go to Step 12 Repair or replace 12 1 Check IAC system refe...

Page 180: ...16 G04 7 G04 9 C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 27 29 30 31 5 6 1 2 3 4 5 6 7 11 12 9 10 11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 1...

Page 181: ...1st speed position or more 0 1 V Is check result satisfactory Go to Step 3 GRN BLK wire open or short Poor G04 16 terminal connection If wire and connection are OK faulty A C pressure switch A C contr...

Page 182: ...n control relay 6 Check A C condenser fan 1 Turn ignition switch OFF 2 Disconnect A C condenser fan motor connector 1 3 Check for proper connection to motor at RED BLU and BLK terminals 4 If OK connec...

Page 183: ...Turn ignition switch OFF and remove A C compressor control relay 1 2 Check for proper connection to relay at terminals c and d 3 If OK check that there is continuity between c and d when battery is co...

Page 184: ...lamp 6 A C control module Step Action Yes No 1 Do you have SUZUKI scan tool Go to Step 2 Go to Step 3 2 Check electric load signal circuit 1 Connect SUZUKI scan tool to DLC with ignition switch OFF 2...

Page 185: ...position or more all turned ON 0 V Is each voltage as specified Electric load signal circuit is in good condition YEL BLK and or BLU BLK circuit open or short electric load diodes malfunction or each...

Page 186: ...tep 13 in DTC P0480 diag flow If OK Go to Step 4 4 Check radiator fan control No 2 and No 3 1 Connect connectors to ECM with ignition switch turn OFF 2 Run engine until ECT is over 102 C 216 F 3 Measu...

Page 187: ...th ignition switch turn OFF 2 Run engine until ECT is over 97 C 207 F 3 Measure voltage between vehicle body ground and BLU RED wire terminal in radiator fan harness connector Is voltage 10 14 V Go to...

Page 188: ...it check 1 Turn ignition switch ON 2 Check for voltage at terminal C41 5 of ECM connector connected Power steering pressure switch specification Engine running and steering wheel at straight ahead pos...

Page 189: ...13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 C C41 12 1 GEN I2RH0B110090 01 1 Generator Step Action Yes No 1 Check generator control signal circuit 1 Check voltage at termi...

Page 190: ...ange for A T vehicle and set parking brake and block drive wheels 1 Connect SUZUKI scan tool to DLC 1 with ignition switch OFF if it is available Special tool A SUZUKI scan tool 2 Warm up engine to no...

Page 191: ...engine tachometer are necessary 1 Check idle speed according to Idle Speed Idle Air Control IAC Duty Inspection 2 Using exhaust gas tester check that idle mixture CO is within above specification If i...

Page 192: ...ed in fuel pressure gauge set 09912 58413 This tool is included in fuel pressure gauge set 09912 58413 09912 58490 SUZUKI scan tool 3 way joint hose This kit includes following items 1 Tech 2 2 PCMCIA...

Page 193: ...in ECM memory Repair Instructions EVAP Canister Inspection S3RH0A1206002 WARNING DO NOT SUCK nozzles on EVAP canister Fuel vapor inside EVAP canister is harmful 1 Check outside of EVAP canister visua...

Page 194: ...s a When using SUZUKI scan tool i Connect SUZUKI scan tool to DLC with ignition switch OFF and disconnect purge valve vacuum hoses from pipes ii Turn ON ignition switch clear DTC and select MISC TEST...

Page 195: ...nals 30 34 at 20 C 68 F Between terminal and body 1 M or higher 3 Disconnect vacuum hoses 4 Apply vacuum 53 kPa 7 69 psi to 67 kPa 9 72 psi to hose 1 using a special tool Check that vacuum can not be...

Page 196: ...ng Clean mating surface of valve and cylinder head Use new gaskets EGR Valve Inspection S3RH0A1206014 1 Check resistance between the following terminals of EGR valve 1 in each pair If found faulty rep...

Page 197: ...ck for clogged valve Replace as necessary 4 After checking vacuum stop engine and remove PCV valve 1 Shake valve and listen for the rattle of check needle inside the valve If valve does not the rattle...

Page 198: ...erring to Throttle Body Removal and Installation in Section 1D Idle Air Control IAC Valve Inspection S3RH0A1306004 1 Connect each connector to IAC valve 1 TP sensor and IAT sensor 2 Check that rotary...

Page 199: ...or wiring harness Manifold Absolute Pressure MAP Sensor Inspection S3RH0A1306007 1 Disconnect connector from MAP sensor 2 Remove MAP sensor 3 Arrange 3 new 1 5 V batteries 2 in series check that tota...

Page 200: ...TP Sensor Removal and Installation S3RH0A1306009 Removal 1 Disconnect battery negative cable at battery 2 Remove throttle body from intake manifold referring to Throttle Body Removal and Installation...

Page 201: ...onnect negative cable from battery 2 Drain coolant referring to Cooling System Flush and Refill in Section 1F WARNING To help avoid danger of being burned do not remove radiator cap while engine and r...

Page 202: ...nect connector of heated oxygen sensor and release its wire harness from clamp 3 For HO2S 2 a Remove parking lever garnish and center console box 2 b Remove left front seat assembly and turn over floo...

Page 203: ...cuit Inspection S3RH0A1306019 1 Confirm that terminal voltages and ground circuit continuity at CMP sensor connector terminals are in good condition referring to Step 3 and 5 of DTC P0340 No 15 Camsha...

Page 204: ...eferring to Output Shaft Speed Sensor VSS Inspection in Section 5A 2 For M T vehicle confirm that terminal voltages at VSS connector terminals are in good condition referring to Step 6 and 7 of DTC P0...

Page 205: ...n terminal C and D If there is no continuity when relay is connected to the battery replace relay Specifications Tightening Torque Specifications S3RH0A1307001 Reference For the tightening torque of f...

Page 206: ...rs 4 stroke cycle gasoline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration consisting of 16 valves 4 valves one cylinder The double overhead camshaf...

Page 207: ...d on engine for M T vehicle and depress accelerator pedal 2 all the way to make throttle fully open 10 Crank engine with fully charged battery and read the highest pressure on compression gauge NOTE F...

Page 208: ...m specification at sea level 59 73 kPa 45 55 cmHg 17 7 21 6 in Hg at specified idle speed 6 After checking disconnect special tool Vacuum gauge from intake manifold 7 Install cap to intake manifold Va...

Page 209: ...ial tool selection table c Hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt 1 tighten housing bolts to specified torque Special tool...

Page 210: ...thickness of new shim 2 65 mm 0 104 in 6 Select new shim No 1 with a thickness as close as possible to calculated value Available new shims No 7 Install new shim facing shim No side with tappet 1 Spec...

Page 211: ...Cylinder Head Cover Removal and Installation Repair Instructions Air Cleaner Element Removal and Installation S3RH0A1406002 Removal 1 Disconnect air cleaner outlet No 1 hose 1 from air cleaner case 2...

Page 212: ...ve lever 1 moves smoothly Throttle Body Removal and Installation S3RH0A1406008 Removal 1 Disconnect negative cable at battery 2 Drain cooling system referring to Cooling System Flush and Refill in Sec...

Page 213: ...0A1406042 Disassembly Remove TP sensor and IAC valve from throttle body NOTE While disassembling and assembling throttle body use special care not to deform levers on throttle valve shaft or cause dam...

Page 214: ...ill in Section 1F 4 Remove air cleaner outlet No 1 and No 2 hoses I3RH0A140004 01 1 Intake manifold 7 EVAP canister purge valve 13 Intake manifold mounting bolt short 19 Cushion 2 Intake manifold gask...

Page 215: ...tle body and thermostat case Fuel pressure regulator vacuum hose from intake manifold Fuel feed hose and return hose from each pipe 8 Remove fuel delivery pipe with fuel injectors from cylinder head 9...

Page 216: ...cable at battery 2 Remove engine cover 1 3 Disconnect ignition coil couplers 1 4 Remove ignition coil assemblies 2 with high tension cord 3 5 Remove oil level gauge 1 6 Disconnect PCV hose 2 from PCV...

Page 217: ...little at a time till they are tightened to specified torque Tightening torque Cylinder head cover bolt a Tighten 8 N m 0 8 kgf m 6 0 lb ft by the specified procedure 5 Connect PCV hose 2 to PCV valv...

Page 218: ...ove engine hood after disconnecting windshield washer hose 4 Remove right and left side engine under covers 5 Remove A C compressor and or P S belt if equipped I2RH0B140040 01 A 4WD model 3 Engine lef...

Page 219: ...onnect the following cables Accelerator cable Gear select control cable For M T vehicle Gear shift control cable For M T vehicle Gear select cable 15 For A T vehicle TP sensor 1 Generator 8 MAP sensor...

Page 220: ...1 and engine right mounting bracket nuts 2 23 Before removing engine with transaxle from body recheck to make sure all hoses electric wires and cables are disconnected from engine and transaxle 24 Low...

Page 221: ...t No 1 and No 2 pipes referring to Exhaust Pipe Removal and Installation in Section 1K 11 Install suspension frame 1 with stabilizer bar and suspension control arms referring to Front Suspension Frame...

Page 222: ...se special tools as shown in the figure Special tool A 09944 36011 B 09926 58010 I3RH0A140005 01 A Sealant application amount 2 Crankshaft pulley 6 Timing chain cover mounting bolts a 3 mm 0 12 in 3 O...

Page 223: ...al tool A 09913 75810 Oil seal installation depth a 1 5 mm 0 06 in 2 Apply sealant A to mating surface between cylinder and cylinder head and apply sealant B to mating surface of timing chain cover as...

Page 224: ...nd Installation Timing Chain Cover Cleaning and Inspection S3RH0A1406021 Clean Clean sealing surface on timing chain cover cylinder block and cylinder head Remove oil old sealant and dust from sealing...

Page 225: ...ton and valves and valves themselves and parts related to piston and valves may be damaged Installation CAUTION After timing chain is removed never turn crankshaft and camshafts independently more tha...

Page 226: ...torque Tightening torque Timing chain No 1 guide bolt a 9 N m 0 9 kgf m 6 5 lb ft 6 Apply engine oil to sliding surface of chain tensioner 1 and install chain tensioner and spacer Tighten tensioner b...

Page 227: ...upside of crankshaft as shown in the figure If each mark of timing chain and each match mark are no matches adjust each sprocket and timing chain 11 Install timing chain cover referring to Timing Chai...

Page 228: ...n referring to Timing Chain and Chain Tensioner Removal and Installation 3 Loosen camshaft housing bolts in such order as indicated in the figure and remove them 4 Remove camshaft housings 5 Remove in...

Page 229: ...the figure 4 Check position of camshaft housings Embossed marks are provided on each camshaft housing indicating position and direction for installation Install housings as indicated by these marks 5...

Page 230: ...shaft housings for pitting scratches wear or damage If any malcondition is found replace camshaft or cylinder head with housing Never replace cylinder head without replacing housings Check clearance b...

Page 231: ...hes or damage If any malcondition is found replace Measure cylinder head bore and tappet outside diameter to determine cylinder head to tappet clearance If clearance exceeds limit replace tappet or cy...

Page 232: ...r M10 Make sure of cylinder head bolt M10 diameter when reusing it due to plastic deformation tightening referring to Valves and Cylinder Head Removal and Installation Tighten 20 N m 2 0 kgf m 14 5 lb...

Page 233: ...ure by using a 12 corner socket wrenches and remove them NOTE Don t forget to remove bolt M8 1 as shown in the figure 9 Check all around cylinder head for any other parts required to be removed or dis...

Page 234: ...ew ones if thread diameter difference exceeds limit Measure each thread diameter of cylinder head bolt 1 at A on 83 5 mm 2 81 in from seat side of flange bolt and B on 115 mm 4 53 in from seat side of...

Page 235: ...nd valve spring 4 Remove valve from combustion chamber side 5 Remove valve stem seal 1 from valve guide and then valve spring seat 2 NOTE Do not reuse seal once disassembled Be sure to use new oil sea...

Page 236: ...ersize Intake and exhaust valve guides are identical Valve guide protrusion a In and Ex 11 3 mm 0 44 in 3 Ream valve guide bore with special tool 5 5 mm reamer After reaming clean bore Special tool A...

Page 237: ...ides Inspection S3RH0A1406034 Valve Guides Using a micrometer and bore gauge take diameter readings on valve stems and guides to check stem to guide clearance Be sure to take reading at more than one...

Page 238: ...chamber is gone replace valve Check each valve for radial runout with a dial gauge and V block To check runout rotate valve slowly If runout exceeds its limit replace valve Limit on valve head radial...

Page 239: ...o face and the second with fine size compound each time using valve lapper according to usual lapping method Cylinder Head Inspection S3RH0A1406044 Remove all carbon deposits from combustion chambers...

Page 240: ...ber weakened valve springs can cause chatter not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure Valve spring free length Standard 36 83 mm 1 45...

Page 241: ...d bolt Refer to Piston Pins and Connecting Rods Inspection 1 Apply engine oil to pistons rings cylinder walls connecting rod bearings and crankpins NOTE Do not apply oil between connecting rod and bea...

Page 242: ...ing rod bearing cap nut to specified procedure as follows i Tighten all cap nuts to 15 N m 1 5 kgf m 11 0 lb ft ii Retighten them to 45 iii Repeat Step ii once again Tightening torque Connecting rod b...

Page 243: ...oil ring 3 install spacer first and then two rails 4 After installing three rings 1st 2nd and oil rings distribute their end gaps as shown in the figure Cylinders Pistons and Piston Rings Inspection S...

Page 244: ...pecification rebore cylinder and use oversize piston Piston clearance Standard 0 032 0 061 mm 0 0013 0 0024 in Standard piston with coating new one 0 016 0 045 mm 0 0006 0 0018 in Limit 0 161 mm 0 006...

Page 245: ...e in small end Connecting rod small end 0 003 0 014 mm 0 0001 0 0006 in Piston 0 006 0 017 mm 0 00024 0 00067 in Small end bore 20 003 20 011 mm 0 7875 0 7878 in Piston pin diameter 19 997 20 000 mm 0...

Page 246: ...by using a micrometer 3 Calculate difference in diameters A B If it is exceeds limit replace connected rod Connecting rod bolt measurement points a 32 mm 1 25 in b 40 mm 1 57 in Connecting rod bolt d...

Page 247: ...b Retighten them to 45 c Repeat Step b once again Tightening torque Connecting rod bearing cap nut a Tighten 15 N m 1 5 kgf m 11 0 lb ft 45 and 45 by the specified procedure 5 Remove cap and measure g...

Page 248: ...od big end inside diameter 2 Next check crankshaft pin diameter On crank web No 3 four alphabets are stamped as shown in figure Three kinds of alphabet A B and C represent the following crankshaft pin...

Page 249: ...bearing painted in Black to its connecting rod big end inside Specification of new standard connecting rod bearing size 5 Using scale 1 on gaging plastic 2 check bearing clearance with newly selected...

Page 250: ...r Block Components S3RH0A1406039 I3RH0A140012 01 A Sealant application amount 6 Sensor plate 14 Main bearing cap a 3 mm 0 12 in 7 Crankshaft timing sprocket key 15 Flywheel mounting bolt See C b 2 mm...

Page 251: ...emove cylinder head assembly referring to Valves and Cylinder Head Removal and Installation 10 Remove pistons and connecting rods referring to Pistons Piston Rings and Connecting Rods Removal and Inst...

Page 252: ...half without oil groove to bearing cap Make sure that two halves are painted in the same color 3 Install thrust bearings 1 to cylinder block between No 2 and No 3 cylinders Face oil groove 2 sides to...

Page 253: ...nstall cylinder head assembly to cylinder Refer to Valves and Cylinder Head Removal and Installation 12 Install camshafts tappets and shims referring to Camshaft Tappet and Shim Removal and installati...

Page 254: ...m to 50 N m 5 0 kgf m 36 5 lb ft 3 In the same manner as in Step 1 retighten them to 60 4 Tighten bolts 11 20 to 22 N m 2 2 kgf m 16 0 lb ft according to numerical order in the figure Tightening torqu...

Page 255: ...e If any malcondition is found replace both upper and lower halves Never replace either half without replacing the other half Main Bearing Clearance Check clearance by using gauging plastic according...

Page 256: ...ain Bearings Standard bearing If bearing is in malcondition or bearing clearance is out of specification select a new standard bearing according to the following procedure and install it 1 First check...

Page 257: ...llowing thickness at the center of bearing Standard size of crankshaft main bearing thickness Engine model Stamped alphabet Bearing cap bore diameter without bearing M13 engine A 49 0000 49 0060 mm 1...

Page 258: ...five kinds varying in thickness To distinguish them each bearing is painted in the following colors at such position as indicated in the figure Each color represents the following thickness at the cen...

Page 259: ...ate difference in diameters A B If it exceeds limit replace with new one Bearing cap No 1 bolt diameter measurement points a 60 mm 2 36 in b 90 mm 3 54 in Bearing cap No 1 bolt diameter difference Lim...

Page 260: ...stortion and if flatness exceeds its limit correct It Cylinder block flatness Limit 0 05 mm 0 0020 in Honing or Reboring Cylinders 1 When any cylinder needs reboring all other cylinders must also be r...

Page 261: ...olt Tighten 8 N m 0 8 kgf m 6 0 lb ft by the specified procedure Engine left mounting bolt 55 5 5 40 0 Engine right mounting bracket nut 75 7 5 54 5 Timing chain cover bolt 23 2 3 17 0 Crankshaft pull...

Page 262: ...ylinder Block Components Special Tool S3RH0A1408002 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No 1215 P No 99000 31110 SUZUKI Bond No 1207B P No 99000 31140 Water t...

Page 263: ...0 Valve guide installer attachment protrusion 11 5 mm Valve guide installer handle 09916 67020 09916 67021 Tappet holder Overseas Tappet holder 09916 77310 09916 84511 Piston ring compressor 50 125 mm...

Page 264: ...shaft journal bearings Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft and then injected from the big en...

Page 265: ...hole Special tool A 09915 77311 B 09915 78211 CAUTION Be careful not to make special tool touch Exhaust manifold when installing because Exhaust manifold becomes very hot 5 Start engine and warm it up...

Page 266: ...0A1506002 Removal 1 Remove oil level gauge 2 Remove exhaust No 1 pipe and exhaust manifold stiffener referring to Exhaust Pipe Removal and Installation in Section 1K 3 Drain engine oil by removing dra...

Page 267: ...e careful not to damage stud bolt 3 between oil pan and cylinder block when cutting sealant 9 Remove oil pan 2 from cylinder block 10 Remove oil pump strainer 1 from cylinder block Installation 1 Appl...

Page 268: ...l exhaust manifold stiffener and exhaust No 1 pipe referring to Exhaust Pipe Removal and Installation in Section 1K 9 Install oil level gauge 10 Refill engine with engine oil referring to Engine Oil a...

Page 269: ...dry all disassembled parts 2 Apply thin coat of engine oil to inner and outer rotors oil seal lip portion and inside surfaces of oil pump case 3 Install outer 1 and inner rotors 2 to oil pump case 4 I...

Page 270: ...e and operates smoothly Radial Clearance Check radial clearance between outer rotor 1 and case 2 using thickness gauge 3 If clearance exceeds its limit replace outer rotor or case Limit on radial clea...

Page 271: ...ed service material is also described in the following Oil Pan and Oil Pump Strainer Components Oil Pump Components Special Tool S3RH0A1508002 Fastening part Tightening torque Note N m kgf m lb ft Oil...

Page 272: ...m battery terminal before removing any part The coolant recovery system is standard The coolant in the radiator expands with heat and the overflow is collected in the reservoir When the system cools d...

Page 273: ...hermostat opens coolant passes through the radiator core to be cooled as well as the flow circuit Water pump Cylinder block Thermostat closed Cylinder head Water intake pipe Throttle body Heater unit...

Page 274: ...eck A C condenser cooling fan relay Refer to Generator Control Signal Circuit Check in Section 1A A C condenser cooling fan motor faulty Check A C condenser cooling fan motor Refer to Generator Contro...

Page 275: ...valve if equipped Install noting its direction as shown 5 Radiator outlet hose 18 Water outlet cap 31 Throttle body water inlet valve 6 Radiator inlet hose 19 Heater inlet hose 32 Throttle body water...

Page 276: ...ful to proper operation of system and are unnecessary expense When installing reservoir cap align arrow marks on reservoir and cap Engine Cooling System Inspection and Cleaning S3RH0A1606003 WARNING T...

Page 277: ...nd pour out any fluid scrub and clean inside of tank with soap and water Flush it well with clean water and drain Reinstall tank 8 Add coolant that is a mixture of good quality ethylene glycol antifre...

Page 278: ...the figure Use new O rings when installing Adjust water pump belt tension referring to Water Pump Generator Drive Belt Tension Inspection and Adjustment Adjust A C compressor belt tension if equipped...

Page 279: ...t each connection Water Valve If Equipped Inspection S3RH0A1606017 Check water valve operation as follows 1 Connect water valve 1 to vacuum pump gauge A discharge side as shown and then check that air...

Page 280: ...there is continuity replace relay 4 Connect battery positive terminal to terminal b of relay Connect battery negative terminal a of relay Check continuity between terminal c and d If there is no conti...

Page 281: ...ystem with proper coolant referring to Cooling System Flush and Refill After installation check each joint for leakage Water Pump Generator Drive Belt Tension Inspection and Adjustment S3RH0A1606018 W...

Page 282: ...belt 1 to water pump pulley 2 crankshaft pulley 3 and generator pulley 4 When servicing car equipped with A C install compressor drive belt too 2 Adjust belt tension by referring to Water Pump Generat...

Page 283: ...tening torque Water pump bolt and nut a 22 N m 2 2 kgf m 16 0 lb ft 3 Install water pump pulley 4 Install water pump generator drive belt referring to Water Pump Generator Drive Belt Removal and Insta...

Page 284: ...section refer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S3RH0A1608001 Special Tool S3RH0A1608002 Fastening part Tightening torque Note N m kgf m...

Page 285: ...is disconnected In order to reduce the chance of personal injury cover the fitting to be disconnected with a shop cloth Be sure to put that cloth in an approved container when disconnection is comple...

Page 286: ...ied to the injector the fuel pressure in the fuel feed line is always kept a certain amount higher than the pressure in the intake manifold by the fuel pressure regulator the fuel is injected into the...

Page 287: ...sconnect fuel feed hose from fuel delivery pipe 3 Connect special tools and hose between fuel feed hose 1 and fuel delivery pipe as shown in the figure and clamp hoses securely to ensure to no leaks o...

Page 288: ...der joint Cover joint with rag and loosen joint nut slowly to release fuel pressure gradually 9 Remove special tools from fuel delivery pipe 10 Connect fuel feed hose to fuel delivery pipe and clamp i...

Page 289: ...mbly 8 To EVAP canister 14 Tank protector 20 Fuel pump 3 Breather hose 9 To Delivery pipe 15 Fuel cut valve 21 Fuel filter assembly 4 Fuel filler cap 10 Fuel vapor separator 16 2 way check valve 22 Fu...

Page 290: ...ate fuel pump and then turn it OFF Repeat this ON and OFF 3 or 4 times and apply fuel pressure to fuel line till fuel pressure is felt by hand placed on fuel return hose 2 In this state check to see t...

Page 291: ...icks and check to ensure that pipes are connected securely or fuel leak may occur 4 With engine OFF turn ignition switch to ON position and check for fuel leaks Fuel Injector On Vehicle Inspection S3R...

Page 292: ...e Apply thin coat of fuel to O rings 1 and then install injectors 3 into delivery pipe 4 and intake manifold Make sure that injectors rotate smoothly 6 If not probable cause is incorrect installation...

Page 293: ...uel pump ON by using SUZUKI scan tool Special tool A SUZUKI scan tool b When not using SUZUKI scan tool CAUTION Check to make sure that connection is made between correct terminals Wrong connection ca...

Page 294: ...uel pressure regulator 2 4 Remove fuel pressure regulator from fuel delivery pipe 5 Disconnect fuel return hose 3 from pressure regulator Installation For installation reverse removal procedure and no...

Page 295: ...Installation in Section 3D if equipped 8 Remove EVAP canister with its bracket 1 from vehicle 9 Disconnect fuel filler hose 1 and breather hose 2 from filler neck 3 CAUTION Never disconnect fuel fille...

Page 296: ...connector and ground wire harness and clamp wire harness 3 Install fuel tank to vehicle Tightening torque Fuel tank bolt a 50 N m 5 0 kgf m 36 5 lb ft 4 Connect fuel filler hose 1 and breather hose 2...

Page 297: ...k 1 After removing fuel tank remove all hoses pipes fuel pump assembly from fuel tank 2 Drain all remaining fuel from tank 3 Move tank to flushing area 4 Fill tank with warm water or tap water and agi...

Page 298: ...l filler 1 for about 2 seconds and stop Be sure to install fuel fill cap after checking If the check result is not satisfactory advance to Fuel Pump and Its Circuit Check in Section 1A 2 Turn ignition...

Page 299: ...surfaces of fuel pump assembly 1 and fuel tank 2 Put plate 2 on fuel pump assembly 1 by matching the protrusion of fuel pump assembly 3 to plate hole 4 as shown 3 Install new gasket 2 and fuel pump as...

Page 300: ...ection S3RH0A1706025 Check fuel pump assembly for damage Check fuel suction filter 1 for evidence of dirt and contamination If present replace or clean and check for presence of dirt in fuel tank For...

Page 301: ...ing torque Note N m kgf m lb ft Fuel delivery pipe bolt 28 2 8 20 5 Fuel pressure regulator bolt 10 1 0 7 5 Fuel tank bolt 50 5 0 36 5 Fuel filler hose clamp 1 5 0 15 1 0 Fuel pump assembly bolt 10 1...

Page 302: ...njector test lead This kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loop back adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter...

Page 303: ...e is induced in the secondary coil High tension cords and spark plugs CMP sensor Camshaft Position Sensor and CKP sensor Crankshaft position sensor Using signals from these sensors ECM identifies the...

Page 304: ...11 13 12 14 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 BLK WHT 7 3 4 8 9 10 GRN YEL GRN WHT C41 20 C41 19 5V 5V 12 11 I3RH0A180001 01 1 Ignition switch 7 No 1 spark plug 2 Main r...

Page 305: ...002 01 1 ECM 6 MAP sensor 11 Transmission range switch A T 2 Ignition coil assembly for No 1 and No 4 spark plugs 7 ECT sensor 12 High tension cords 3 Ignition coil assembly for No 2 and No 3 spark pl...

Page 306: ...ission Control System Check in Section 1A 2 Ignition spark test 1 Check all spark plugs for condition and type referring to Spark Plug Inspection 2 If OK perform ignition spark test referring to Ignit...

Page 307: ...mbly and high tension cord referring to Ignition Coil Assembly Including Igniter Removal and Installation 10 Connect injector harness coupler and ignition coil harness coupler 11 Install engine cover...

Page 308: ...sistive conductor For the same reason pull out each connection by gripping cap portion Installation 1 Install No 1 cylinder high tension cord 2 and No 3 high tension cord 3 to spark plugs and ignition...

Page 309: ...p for the iridium platinum spark plugs Electrode wear Carbon deposits Insulator damage If any abnormality is found for nickel spark plugs adjust air gap clean with spark plug cleaner or replace them w...

Page 310: ...Start engine and warm it up to normal operating temperature 3 Make sure that all of electrical loads except ignition are switched off 4 Check to be sure that idle speed is within specification referri...

Page 311: ...peration of electronic timing control system Also check that increasing engine speed advances ignition timing If the check results are not satisfactory check CKP sensor test switch terminal circuit an...

Page 312: ...e lies in battery wiring harness including starting motor switch starting motor or engine Do not remove motor just because starting motor does not run Check the following items and narrow down scope o...

Page 313: ...rly or worn down Repair or replace Weakened brush spring Replace Burnt commutator Replace armature Layer short circuit of armature Replace Crankshaft rotation obstructed Repair Starting motor running...

Page 314: ...inal M Check that plunger and pinion remain out If plunger and pinion return inward replace the magnetic switch Plunger and Pinion Return Test Disconnect negative lead from starting motor body Check t...

Page 315: ...lead wire 1 and battery cable 2 from starting motor terminals 3 Remove starting motor mount bolt 3 and nut 4 4 Remove starting motor 5 Remounting Reverse the dismounting procedure Tightening torque S...

Page 316: ...Seal rubber 14 Center bearing with shock absorber 20 Starting motor battery cable nut 3 Snap ring 9 Magnetic switch 15 Yoke Tightening torque 4 Pinion stop ring 10 Internal gear 16 Armature Do not reu...

Page 317: ...3 Starting motor battery cable nut 3 Snap ring 10 Seal rubber 17 Yoke Tightening torque 4 Pinion stop ring 11 Magnetic switch 18 Armature Do not reuse 5 Pinion gear 12 Ball 19 Brush Apply grease 99000...

Page 318: ...across magnetic switch S terminal 1 and coil case If no continuity coil is open and should be replaced Rear Bracket Bush Inspect bush for wear or damage Replace if necessary Brush Check brushes for we...

Page 319: ...The following specification presupposes that the armature is free from bend Bent armature must be replaced Commutator out of round Inspect the commutator for wear If diameter is below limit replace t...

Page 320: ...ver Running Clutch Inspect the pinion for wear damage or other abnormal conditions Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction Replace if nec...

Page 321: ...ut 1 2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard 12 3 mm 0 48 in Limit 7 0 mm 0 28 in Number of pinion teeth 8 Performance Condition Guarant...

Page 322: ...specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S3RH0A1908001 NOTE Required service material is also described in the fo...

Page 323: ...revived by very slow charging and may be restored to usable condition but its capacity is lower than before Built In Indicator If Equipped The battery has a built in temperature compensated indicator...

Page 324: ...the battery The simplest way to tell the state of charge is to carry out a hydrometer test The hydrometer is an instrument for measuring the specific gravity S G of the battery electrolyte The S G of...

Page 325: ...F you have to correct your S G reading taken with your hydrometer to the value at 20 C 68 F and apply the corrected S G value to the three point guide stated value For the manner of correction refer...

Page 326: ...eter Make sure that undercharged condition has not been caused by accessories left on for extended period of time Check drive belt for proper tension If battery defect is suspected refer to Battery De...

Page 327: ...or If the generator is in good condition check generator control signal Refer to Generator Control Signal Circuit Check in Section 1A Load Check 1 Run engine at 2 000 rpm and turn on head light and he...

Page 328: ...l If it is below low level line add distilled water 3 Attach end of one jumper cable to positive terminal of booster battery and the other end of the same cable to positive terminal of discharged batt...

Page 329: ...sconnect negative cable at battery 2 Remove exhaust No 2 pipe referring to Exhaust System Components in Section 1K 3 Dismount in numerical order as shown in the figure 4 Reverse dismounting procedure...

Page 330: ...oughness or scoring If rough or scored replace the rotor Using a vernier caliper measure the slip ring diameter If the diameter is less than minimum replace the rotor Slip ring diameter Standard 14 2...

Page 331: ...tifier 1 Using an ohmmeter connect one tester probe to the B terminal 1 and the other to each rectifier terminal 2 2 Reverse the polarity of the tester probes and repeat Step 1 3 Check that one shows...

Page 332: ...asteners Information in Section 0A Battery type 38B20L 55B24L 75D23L Rated capacity AH 5HR 12 Volts 28 38 54 Electrolyte L US lmp pt 2 1 4 44 3 70 2 8 5 92 4 93 3 9 8 24 6 86 Electrolyte S G 1 28 when...

Page 333: ...ce on the exhaust system should be performed when the system is cool 14 16 15 14 10 6 6 3 2 1 4 12 11 A 17 18 a b View A 9 9 8 9 16 5 7 9 7 13 45 N m 4 5 kg m 45 N m 4 5 kg m 43 N m 4 3 kg m 43 N m 4...

Page 334: ...d 6 Remove exhaust manifold 1 and its gasket from cylinder head Installation 1 Install new gasket to cylinder head Then install exhaust manifold Tighten manifold bolts and nuts to specified torque I3R...

Page 335: ...nd observe WARNING under Exhaust System Components and the following CAUTION Exhaust pipe have three way catalytic converter in it it should not be exposed to any impulse Be careful not to drop it or...

Page 336: ...1K 4 Exhaust System...

Page 337: ...sion Control Arm Steering Knuckle Check 2B 17 Suspension Control Arm Bushing Check 2B 17 Suspension Control Arm Joint Check 2B 18 Front Suspension Frame Components 2B 18 Front Suspension Frame Removal...

Page 338: ...Torque Specifications 2C 24 Special Tools and Equipment 2C 24 Recommended Service Material 2C 24 Special Tool 2C 25 Wheels and Tires 2D 1 General Description 2D 1 Tires Description 2D 1 Wheels Descrip...

Page 339: ...H0A2000001 Suspension Caution Refer to Wheels and Tires Note in Section 00 Wheels and Tires Note Refer to Brake Note in Section 00 Precautions for Steering Suspension Wheels and Tires Diagnosis Refer...

Page 340: ...hock absorber action Replace strut Shimmy shake or vibration Tire or wheel out of balance Balance wheels or replace tire and or wheel Loosen wheel bearings Replace wheel bearing Worn tie rod ends Repl...

Page 341: ...ce Body leans or sways in corners Loose stabilizer bar Tighten stabilizer bar bolts or nuts or replace bushes Faulty struts shock absorbers or mountings Replace strut or tighten mounting Broken or sag...

Page 342: ...079 in IN 6 2 2 mm 0 244 0 079 in Camber C Non adjustable for reference only 0 10 1 1 15 1 Caster Non adjustable for reference only 2 11 2 Kingpin Inclination 12 52 3 Side Slip Limit mm m in 3 3 ft I...

Page 343: ...euse this nut to prevent it from loosening Be sure to replace nut with a new one whenever loosening once Be sure to use a bolt and nut in the right combination which is specified I3RH0A220010 03 1 Str...

Page 344: ...adjusting Check for run out of wheels and tires Check vehicle trim heights if out of limits and a correction is to be made it must be made before adjusting toe Check for loose of suspension arms Chec...

Page 345: ...Make sure that rack boots are not twisted Steering Angle Check and Adjustment When tie rod or tie rod end was replaced check toe and then also steering angle with turning radius gauge 1 If steering a...

Page 346: ...ted mark 1 on stabilizer bar and end face of mount bushing 2 aligned tighten mount bracket bolts to specified torque NOTE If painted mark has gone align the vehicle center and the center of stabilizer...

Page 347: ...damage wear or deterioration If defective replace Stabilizer Joint 1 Check for smooth rotation 2 Inspect ball stud for damage 3 Inspect dust cover for damage NOTE Stabilizer joint 1 cannot be disasse...

Page 348: ...one whenever loosening once Be sure to use a bolt and nut in the right combination which is specified I3RH0A220011 02 1 Strut assembly 6 Strut bearing 11 Strut bracket nut Do not reuse 2 Coil spring...

Page 349: ...e removed at this point 1 Hoist vehicle allowing front suspension to hang free 2 Remove wheel and disconnect stabilizer joint 1 from strut bracket 3 Remove brake hose mounting bolt 1 and take off brak...

Page 350: ...36 5 lb ft NOTE Don t twist brake hose and ABS wheel speed sensor harness if equipped when installing it Install ABS wheel speed sensor harness if equipped to strut bracket as shown in figure Strut br...

Page 351: ...ith that spring compressor 2 While keeping spring compressed with special tool as shown remove strut nut Special tool B 09900 00411 socket C 09900 00414 6 mm 3 Disassemble strut assembly Assembly For...

Page 352: ...st tire pressures as specified 2 Bounce vehicle body 3 or 4 times continuously by pushing front end on the side with strut to be checked 3 Apply the same amount of force at each push and note strut re...

Page 353: ...carrier bolts 5 Remove caliper 1 with carrier NOTE Hang removed caliper with a wire hook or the like 3 so as to prevent brake hose 4 from bending and twisting excessively or being pulled Don t operat...

Page 354: ...d then steering knuckle 2 Installation For installation reverse removal procedure noting the following instructions Using special tool drive wheel hub 1 into steering knuckle 2 and then install steeri...

Page 355: ...2 Tighten castle nut 3 until holes for split pin 4 are aligned but only within specified torque Tightening torque Tie rod end castle nut a 45 N m 4 5 kgf m 32 5 lb ft Install new split pin 4 Install...

Page 356: ...eel bearing outside inner race 1 Special tool C 09913 65810 D 09913 85230 5 Remove hub bolts 1 with copper hammer or hydraulic press CAUTION Never remove bolt unless replacement is necessary Be sure t...

Page 357: ...t Front Wheel Disc Nut and Bearing Check S3RH0A2206012 Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced Check wheel nuts for tightness and as...

Page 358: ...t to steering knuckle Align ball stud groove with steering knuckle bolt hole Then install ball joint bolt 1 from the direction as shown in figure Tighten suspension arm ball joint nut 2 to specified t...

Page 359: ...raulic press 2 Special tool A 09913 75821 Assembly 1 Press fit front bushing 1 by using special tool C and press 2 Special tool C 09913 75810 CAUTION Be sure to use new bushing NOTE Before installing...

Page 360: ...e is any damage to either control arm assembly must be replaced as a complete unit Front Suspension Frame Components S3RH0A2206018 I2RH01220007 01 I4RH01220018 01 A For 4WD vehicle 3 Suspension arm Ri...

Page 361: ...port transmission to prevent joint parts from being applied excessive force at removal of suspension frame 1 5 Remove suspension frame from body Installation 1 Install suspension frame 1 to body and t...

Page 362: ...bar mounting bracket bolt e 23 N m 2 3 kgf m 17 0 lb ft 6 Install wheels right left and lower hoist 7 Confirm front wheel alignment referring to Front Wheel Alignment Inspection and Adjustment Front...

Page 363: ...orque Note N m kgf m lb ft Tie rod end lock nut 45 4 5 32 5 Stabilizer bar mounting bracket bolt 23 2 3 17 0 Stabilizer joint nut 50 5 0 36 5 Strut bracket nut For 8 8 strength bolt 105 10 5 76 0 Stru...

Page 364: ...mm 09913 65210 09913 65810 Tie rod end remover Crankshaft bearing puller 09913 75510 09913 75520 Bearing installer Bearing installer 09913 75810 09913 75821 Bearing installer Bearing installer attachm...

Page 365: ...pension Construction S3RH0A2301001 2WD Vehicle I3RH0A230008 03 1 Vehicle body 4 Suspension frame 7 Brake drum Do not reuse 2 Strut assembly 5 Control rod 8 Wheel Bearing A 8 8 strength bolt nut 3 Rear...

Page 366: ...lass Never reuse this nut to prevent it from loosening Be sure to replace nut with a new one whenever loosening once Be sure to use a bolt and nut in the right combination which is specified 4WD Vehic...

Page 367: ...d be repaired or damaged suspension should be replaced Toe Inspection and Adjustment Preparation for toe inspection and adjustment Place vehicle in non loaded state on level floor Set steering wheel i...

Page 368: ...IN 7 0 IN 10 0 mm m IN 0 276 IN 0 393 in 3 3 ft If side slip exceeds the limit toe or wheel alignment may not be correct Rear Stabilizer Bar and or Bushings Components S3RH0A2306002 3 Control rod I2RH...

Page 369: ...ings 1 aligned tighten stabilizer bar bracket bolts temporarily by hand at this step NOTE If painted mark has faded out align the vehicle center and the center of stabilizer bar 3 Lower hoist 4 Tighte...

Page 370: ...the strength class Never reuse this nut to prevent it from loosening Be sure to replace nut with a new one whenever loosening once Be sure to use a bolt and nut in the right combination which is speci...

Page 371: ...rut by hand so that it will not fall off 7 Remove strut assembly Installation 1 Install strut by reversing Removal procedure Insert bracket bolts in such a direction as shown in figure 2 Torque all fa...

Page 372: ...l tool A 09940 71431 2 While keeping spring compressed with special tool as shown remove strut nut Special tool A 09945 26010 17 mm B 09900 00411 C 09900 00414 6 mm 3 Disassemble strut assembly Assemb...

Page 373: ...spring upper seat 1 and the center of strut bracket 2 aligned place upper spring seat together with spring rubber seat on coil spring 8 Put strut support 2 on spring upper seat 3 Tighten strut nut 1 t...

Page 374: ...n the left And they must be equal in both With proper strut vehicle body should come to stop the moment hands are off or after only one or two small rebounds If struts are suspected compare them with...

Page 375: ...l rod No 2 2 a Install control rod No 2 2 setting it so that its welded nut 8 comes toward the front b Insert control rod No 2 bolt 9 from the vehicle front and outer bolt 3 from the rear c Install wa...

Page 376: ...06011 Inspect for cracks deformation or damage Inspect bushing for wear and breakage If any faulty condition is found replace Trailing Rod Removal and Installation S3RH0A2306012 Removal 1 Hoist vehicl...

Page 377: ...I4RH01230012 01 1 Suspension frame 5 Control rod No 2 rear side F Forward 2 Suspension frame cap 6 Joint Tightening torque 3 Suspension frame bolt 7 Stabilizer bar 4 Control rod No 1 front side 8 Pad...

Page 378: ...move suspension frame bolts 2 and suspension frame 1 9 Remove suspension frame bushings 1 by using a pipe 2 whose outer diameter a is 37 mm 1 46 in and inner diameter b is 27 mm 1 06 in or more an app...

Page 379: ...ts in Section 0A Removal WARNING To avoid the risk of being burned start your work after the exhaust system has cooled down 1 Hoist vehicle and remove wheels right and left 2 Drain differential oil 3...

Page 380: ...djustment in Section 4A if equipped with LSPV 7 Install stabilizer bar Refer to Front Stabilizer Bar and or Bushings Removal and Installation in Section 2B 8 Install muffler Refer to Exhaust Manifold...

Page 381: ...part of nut Cracked nut must be replaced with new one 5 Install new spindle cap NOTE When installing spindle cap hammer lightly several locations on the collar of cap until collar comes closely into...

Page 382: ...lation 1 Install hub bolts Refer to Front Wheel Hub and Steering Knuckle Disassembly and Assembly in Section 2B 2 Install outside inner race 1 to wheel hub 2 using special tool Installing direction is...

Page 383: ...Wheel bearing 2 and wheel hub 1 form a solid unit for 2WD model When wheel bearing is found defective and its replacement is necessary replace hub assembly for 2WD model Rear Wheel Disc Nut and Bearin...

Page 384: ...isconnect brake pipe 1 from wheel cylinder 2 and put wheel cylinder bleeder plug cap 3 onto pipe to prevent fluid from spilling 4 Remove ABS wheel speed sensor from knuckle if equipped 5 Remove brake...

Page 385: ...ghten back plate bolts to specified torque Tightening torque Back plate bolt b 50 N m 5 0 kgf m 36 0 lb ft 5 For ABS equipped vehicle check to make sure that ABS wheel speed sensor tooth is free from...

Page 386: ...uid leakage Rear Knuckle Wheel Bearing Oil Seal Removal and Installation 4WD Model S3RH0A2306023 Removal CAUTION Once bearing outer race is removed bearing set outer race bearings and inner races shou...

Page 387: ...6 Install knuckle Refer to Rear Knuckle Removal and Installation 2WD Model 7 Install wheel hub Refer to Wheel Hub Wheel Stud Wheel Bearing Outside Inner Race Removal and Installation 4WD Model Rear Su...

Page 388: ...ear side inner nut 90 9 0 65 0 Stabilizer bar bracket bolt 23 2 3 17 0 Stabilizer joint nut 50 5 0 36 5 Strut support nut 28 2 8 20 5 Strut bracket nut 90 9 0 65 0 Strut upper nut 70 7 0 50 5 Control...

Page 389: ...24 84510 004 09925 88210 Bearing installer attachment Bearing puller attachment 09940 53111 09940 71431 Differential side bearing installer Suspension spring compressor 09942 15511 09943 17912 Sliding...

Page 390: ...ving Do not bleed or reduce tire pressure after driving Bleeding reduces the Cold Inflation Pressure Higher than recommended pressure can cause Hard ride Tire bruising or carcass damage Rapid tread we...

Page 391: ...wn in the following may cause objectional vibrations Replacement wheels must be equivalent to the original equipment wheels in load capacity diameter rim with offset and mounting configuration A wheel...

Page 392: ...the steel belt not being straight within the tire It is most noticeable at a low speed 8 to 48 kph 5 to 30 mph It is possible to locate the faulty tire by road testing the vehicle If it is on the rea...

Page 393: ...ng Wheels Description S3RH0A2401007 There are two types of wheel and tire balance static and dynamic Static balance as shown in figure is the equal distribution of weight around the wheel Wheels that...

Page 394: ...n speedometer This limit is necessary because speedometer only indicates one half of actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped Unless care is taken in li...

Page 395: ...w equipment manufacturer s instructions Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim Rim bead seats should be cleaned with a wire brush or coars...

Page 396: ...m 61 5 lb ft NOTE Tire inflation pressure should be checked when tires are cool Specified tire inflation pressure should be found on tire placard or in owner s manual which came with the vehicle Tigh...

Page 397: ...Rear Differential Symptom Diagnosis 3B 2 Repair Instructions 3B 2 Rear Differential Oil Change 3B 2 Rear Differential Front Mounting Removal and Installation 3B 3 Rear Differential Rear Mounting Remov...

Page 398: ...ropeller Shaft Description 3D 1 Repair Instructions 3D 1 Propeller Shaft Components 3D 1 Propeller Shaft Removal and Installation 3D 2 Propeller Shaft Inspection 3D 3 Specifications 3D 3 Tightening To...

Page 399: ...tions 3 1 Driveline Axle Precautions Precautions Precautions on Driveline Axle S3RH0A3000001 Precaution for Rear Differential Oil Leakage Refer to Precaution for Rear Differential Oil Leakage in Secti...

Page 400: ...al side and transfer side For M T vehicle a double offset type constant velocity joint DOJ is used on the differential or center shaft side The drive shaft can slide through the tripod joint or the do...

Page 401: ...to joint 1 Differential side joint A T model Apply orange grease included in spare part to joint 14 Center bearing support 2 Boot Differential transfer or center shaft side 15 Center bearing 3 Circlip...

Page 402: ...from steering knuckle 4 by using special tool Special tool A 09913 65210 9 Pull out drive shaft joint 2 as follows For vehicle without center shaft Using tire lever 1 pull out drive shaft joint 2 so a...

Page 403: ...ot damage oil seal when installing and removing center shaft Install drive shaft assembly by reversing removal procedure and noting the following points Do not reuse drive shaft nut 2 Do not reuse spl...

Page 404: ...o boot bands of wheel side joint boot then pull out boot through shaft CAUTION Disassembly of wheel side joint is not allowed If any noise or damage exists in it replace it as assembly Do not disassem...

Page 405: ...y noted before disassembly and what is found through visual check of component parts after disassembly prepare replacing parts and proceed to reassembly Make sure that wheel side joint assembly 1 and...

Page 406: ...rive shaft for 2WD model 369 375 mm 14 5 14 8 in Left side drive shaft for 2WD model and 4WD model 189 5 195 5 mm 7 5 7 7 in 7 Set new differential side small band and new differential side boot 1 on...

Page 407: ...from abnormality noted before disassembly and what is found though visual check of component parts after disassembly prepare replacing parts and proceed to reassembly Make sure that wheel side joint...

Page 408: ...1 on left drive shaft according to dimension specified as follows Drive shaft damper installing position distance a between reference position and damper Left side drive shaft for 2WD model 187 193 mm...

Page 409: ...ts become as indicated in the following CAUTION Bend each boot band against forward rotation A Do not squeeze or distort boot when fastening it with bands Distorted boot caused by squeezing air may re...

Page 410: ...ecommended Service Material S3RH0A3118001 NOTE Required service material is also described in the following Front Drive Shaft Components Special Tool S3RH0A3118002 Fastening part Tightening torque Not...

Page 411: ...il Change in Section 3B 3 Hoist vehicle 4 Remove parking brake wire mounting bolt 1 rear control rod outer bolts 2 and rear trailing rod rear bolt 3 5 Install used clamp 2 to differential side joint 1...

Page 412: ...ry contact while installing drive shaft Do not hit joint boot with hammer Inserting joint only by hands is allowed Make sure that differential side joint is inserted fully and its snap ring is seated...

Page 413: ...ols and Equipment Recommended Service Material S3RH0A3128001 NOTE Required service material is also described in the following Rear Drive Shaft Components Fastening part Tightening torque Note N m kgf...

Page 414: ...inion and gear The differential assembly is decisive in that the drive power is concentrated there Therefore use of genuine parts and specified torque is compulsory Further because of sliding tooth me...

Page 415: ...g torque Oil level filler plug a 21 N m 2 1 kgf m 15 5 lb ft Specified gear oil Hypoid gear oil API GL 5 SAE 75W 85 or 80W 90 For oil viscosity refer to the chart Oil capacity 0 7 liters 1 5 1 2 US lm...

Page 416: ...differential front mounting 1 and tighten mounting bracket bolts 2 and mounting nut 3 to specified torque Tightening torque Differential front mounting bracket bolts a 50 N m 5 0 kgf m 36 5 lb ft Diff...

Page 417: ...2 Install differential rear mounting 4 and tighten mounting bracket bolts 5 and mounting bolts 6 to specified torque Tightening torque Differential rear mounting bracket bolt a 50 N m 5 0 kgf m 36 5 l...

Page 418: ...unting bracket bolts 5 10 Lower jack 4 with rear differential assembly Remounting Reverse dismounting procedure for remounting noting the following points Install propeller shaft 1 to companion flange...

Page 419: ...e bevel gear set 27 Differential pinion washer 4 Front case Apply sealant 99000 31260 to mating surface with differential carrier 16 Breather cover 28 Front case bolt 5 Drive bevel pinion washer 17 Di...

Page 420: ...bevel gear 2 7 Remove differential side bearings 3 8 Drive out differential side pinion shaft pin with special tool and hammer Special tool B 09922 85811 9 Disassemble differential side gears 2 pinio...

Page 421: ...d what is found through visual check of bearing and gear tooth etc after disassembly prepare replacing parts and proceed to reassembly according to procedures as described in the following CAUTION Bev...

Page 422: ...with differential case and drive in differential pinion shaft pin till they are flush with end surface of case Special tool A 09922 85811 4 Apply thread lock cement to thread of bevel gear bolts 1 5 P...

Page 423: ...ol A 09951 16060 B 09924 74510 C 09923 78210 Differential unit 1 Install side oil seal to bearing outer race 1 Then apply grease to oil seal lip Grease 99000 25010 Special tool A 09913 75520 2 Place b...

Page 424: ...ners inward lightly Tighten both retainers further by one notch at a time Measure at least 4 points on drive bevel gear periphery Special tool C 09900 20606 09923 58520 09900 20701 Drive bevel gear ba...

Page 425: ...ttern is not normal readjust or replace as necessary according to instruction in chart NOTE Apply red lead paste all around bevel gear but not so much as to become sticky Be careful not to turn bevel...

Page 426: ...defective Poor squareness of differential carrier Differential carrier surface where gear is installed is defective Replace defective part as an assembly 1 Check seating of bevel gear or differential...

Page 427: ...ock cement 99000 32110 Tightening torque Breather cover bolt b 6 0 N m 0 6 kgf m 4 5 lb ft Differential cover bolts 23 N m 2 3 kgf m 17 0 lb ft 12 Caulk bevel pinion nut 2 with caulking tool 1 and ham...

Page 428: ...re relative positions of bevel pinion differential carrier and mounting dummy Special tool A 09900 20606 B 09922 77280 C 09922 75222 I3RH01322051 01 a Pinion dummy height 1 36 mm nut Spare parts No 09...

Page 429: ...s or more to ensure its good fitting Pinion bearing preload Pinion dummy rotational torque 5 0 13 0 kg cm 4 4 11 2 lb in Rotational force with special tool and spring balance 1 0 2 6 kg 2 2 5 7 lb 5 S...

Page 430: ...3 NOTE Apply differential oil to front and rear bearings 11 Install washer 5 to bevel pinion 1 12 After applying sealant to mating surface of front case 6 install it to differential carrier 3 A Seala...

Page 431: ...1 Fastening part Tightening torque Note N m kgf m lb ft Oil drain plug 21 2 1 15 5 Oil level filler plug 21 2 1 15 5 Differential front mounting bracket bolts 50 5 0 36 5 Differential front mounting n...

Page 432: ...UZUKI Bond No 1217G P No 99000 31260 Thread lock cement Thread Lock Cement Super 1322 P No 99000 32110 09900 20606 09900 20701 Dial gauge 1 100 mm Magnetic stand 09913 65135 09913 75520 Bearing puller...

Page 433: ...18011 09930 40113 Transmission gear bush and bearing installer Flywheel rotor holder 09951 16060 09951 16080 Control arm bush remover Bearing installer 09951 16090 09951 26020 Oil seal installer Bush...

Page 434: ...ear reduction driven gear and bevel gear of transfer As bevel gears which change the direction of driving torque axis to the direction of the angle with 90 degrees hypoid gears are provided Hypoid gea...

Page 435: ...r to the chart Oil capacity 0 55 liters 1 16 0 97 US lmp pt Transfer Dismounting and Remounting S3RH0A3306002 Dismounting 1 Disconnect negative cable at battery 2 Remove transfer breather hose from cl...

Page 436: ...transfer to transaxle stiffener 1 by removing its 5 bolts 2 17 Remove transfer to engine stiffener 1 by removing its 6 bolts 18 Remove transfer mounting bolts 1 19 Separate transfer assembly 1 from t...

Page 437: ...0 kgf m 36 5 lb ft Transfer to transaxle stiffener bolts d 50 N m 5 0 kgf m 36 5 lb ft Propeller shaft No 1 bolts e 23 N m 2 3 kgf m 17 0 lb ft Exhaust No 2 pipe to muffler bolts f 43 N m 4 3 kgf m 31...

Page 438: ...Oil seal Apply grease 99000 25010 to oil seal lip 33 Transfer right case Apply sealant 99000 31260 to mating surface with right case 4 Pinion shaft RR taper roller bearing 19 Reduction drive gear LH...

Page 439: ...se 5 10 Remove reduction idler gear taper roller bearing outer race 10 reduction driven gear LH taper roller bearing outer race 13 from transfer left case 6 NOTE When it is difficult to remove taper r...

Page 440: ...gear i e preload of reduction idler gear taper roller bearings by using special tool and torque wrench 1 Special tool A 09928 36010 Starting torque a of reduction drive gear 0 5 1 4 N m 5 14 kg cm 0 3...

Page 441: ...wall of bevel gear adjuster 3 as shown in the figure to prevent bevel gear adjusters 3 from loosing Tightening torque Adjuster plate bolt a 12 N m 1 2 kgf m 9 0 lb ft 8 Inspect tooth contact according...

Page 442: ...ng taper roller bearing replace as inner race outer race assembly 1 Drive in reduction drive gear bearings right and left to reduction drive gear by using bearing puller and hydraulic press 2 Drive in...

Page 443: ...seals 1 2 to right case 3 by using special tool CAUTION Use care the installation direction and depth of oil seals for correct installation Special tool 09913 75520 Transfer reduction drive gear oil...

Page 444: ...51 in b 2 5 3 5 mm 0 098 0 138 in 8 Screw bevel gear adjuster 1 in left case 2 until side face of bevel gear adjuster 1 come to flush position with side face of left case 2 by using special tool Speci...

Page 445: ...omes necessary When replacing taper roller bearing replace as inner race outer race assembly 1 To mesh bevel gears correctly it is prerequired to install bevel pinion to transfer output retainer prope...

Page 446: ...84 and 0 87 mm 0 012 0 024 0 025 0 026 0 027 0 028 0 030 0 031 0 032 0 033 and 0 034 in 2 Press fit pinion shaft taper roller bearing outer races front and rear by using special tools and hydraulic pr...

Page 447: ...08 in 8 Install transfer output flange 1 by tapping with plastic hammer and tighten transfer output flange nut gradually so as rotational torque of bevel pinion shaft to be in specified value NOTE If...

Page 448: ...ut retainer assembly referring to Transfer Assembly Disassembly and Assembly 3 Turn transfer output flange clockwise and counterclockwise repeatedly and remove transfer output retainer assembly and be...

Page 449: ...fset of reduction driven gear is too much or too little The remedy is to change the division of the bevel gear shim s These contact patterns located on toe or heel on both drive and coast sides mean t...

Page 450: ...bolts 23 2 3 17 0 Exhaust No 2 pipe to muffler bolts 43 4 3 31 5 Suspension frame bolts 90 9 0 65 0 Engine rear mounting nuts 45 4 5 32 5 Ball stud lock nuts 60 6 0 43 5 Exhaust No 2 pipe to No 1 pip...

Page 451: ...0 Sealant SUZUKI Bond No 1217G P No 99000 31260 Thread lock cement Thread Lock Cement Super 1322 P No 99000 32110 09912 34510 09913 50121 Case separator Oil seal remover 09913 75520 09913 75810 Bearin...

Page 452: ...r Bearing puller attachment 09928 36010 09930 40113 Reduction drive holder Flywheel rotor holder 09940 14940 09941 54911 Swing arm adjuster lock nut wrench Bearing outer race remover 09941 74910 09944...

Page 453: ...unit Handle it carefully so that balance can be maintained A viscous coupling is used for the coupling system which distributes an optimum driving force to the front and rear wheels according to the d...

Page 454: ...No 1 No 2 shaft are removed in one without separation Use care not to drop it Installation Reverse removal procedure to install propeller shaft noting the following point When installing propeller sh...

Page 455: ...ce Specifications Tightening Torque Specifications S3RH0A3407001 NOTE The specified tightening torque is also described in the following Propeller Shaft Components Reference For the tightening torque...

Page 456: ...3D 4 Propeller Shafts...

Page 457: ...Sensing Proportioning Valve Removal and Installation 4A 23 LSPV Load Sensing Proportioning Valve Inspection and Adjustment 4A 24 Specifications 4A 25 Tightening Torque Specifications 4A 25 Special Too...

Page 458: ...DTC C1021 C1022 C1025 C1026 C1031 C1032 C1035 C1036 No 21 22 25 26 31 32 35 36 Wheel Speed Sensor Circuit or Sensor Ring 4E 24 DTC C1041 C1045 C1051 C1055 DTC C1042 C1046 C1052 C1056 No 41 45 51 55 No...

Page 459: ...m master cylinder Brake pipes are connected to the master cylinder and they make two independent circuits One connects front right rear left brakes and the other connects front left rear right brakes...

Page 460: ...icle without ABS 3 Secondary side 7 P Proportioning valve or 5 way joint B For vehicle with ABS 4 Primary side 8 LSPV Load Sensing Proportioning Valve if equipped 1 Brake booster 5 4 way joint A Forwa...

Page 461: ...joint T Top side 3 From ABS hydraulic unit to left front brake 10 From ABS hydraulic unit to ABS 4 way joint F Front side 4 From ABS hydraulic unit to right front brake 11 From ABS 4 way joint to 4 wa...

Page 462: ...ic unit to left front brake 10 From ABS hydraulic unit to ABS 4 way joint F Front side 4 From ABS hydraulic unit to right front brake 11 From ABS 4 way joint to 4 way joint rear side R Right side 5 AB...

Page 463: ...eering vehicle X View X 4 Front brake hose B For RH steering vehicle Y View Y 5 5 way joint or P valve T Top side 1 From master cylinder primary to left front brake a h Clamp F Front side 2 From maste...

Page 464: ...iagnosis Rear Brake Hose Pipe Construction S3RH0A4101003 I3RH0A410003 01 A with ABS or P valve F Front side 1 4 way joint a f Clamp B with LSPV R Right side 2 LSPV assembly Tightening torque T Top sid...

Page 465: ...rake wheels If deterioration of rubber is evident disassemble all hydraulic parts and wash with alcohol Dry these parts with compressed air before assembly to keep alcohol out of the system Replace al...

Page 466: ...djust Malfunction LSPV assembly if equipped Replace assembly Excessive pedal travel Pedal stroke too large Partial brake system failure Check brake systems and repair as necessary Insufficient fluid i...

Page 467: ...acking plates or loose mounting bolts Replace or retighten securing bolts Contact wear indicator to brake disc Replace pads Brake warning lamp lights after engine start Parking brake applied Release p...

Page 468: ...k that rear brake pressure then is within specification as given below 5 If rear brake pressure is not within specification adjust it by changing bolt A tightening position as follows Tightening torqu...

Page 469: ...adjust if necessary Also check pedal shaft bolt and booster clevis pin installation for looseness and replace if defective Brake pedal play a 1 8 mm 0 04 0 31 in Excessive Pedal Travel Inspection S3R...

Page 470: ...hydraulic brake system and water mixed into brake fluid will lower fluid boiling point Keep all fluid containers capped to prevent contamination Stop Light Switch Adjustment S3RH0A4106005 Adjustment s...

Page 471: ...is operation until there are no more air bubbles in hydraulic line 6 When bubbles stop depress and hold brake pedal and tighten bleeder plug Tightening torque Front brake caliper bleeder plug 8 5 N m...

Page 472: ...rake Hose Pipe Removal and Installation S3RH0A4106008 Removal 1 Raise and support vehicle properly Remove tire and wheel 2 Clean dirt and foreign material from both flexible hose end and pipe end fitt...

Page 473: ...t on painted surfaces I2RH01410020 01 A For vehicle without ABS For RH steering vehicle with ABS 5 Piston cup Apply brake fluid Confirm installing direction 11 Secondary piston stopper bolt for LH ste...

Page 474: ...2 Drain brake fluid in reservoir 3 Disconnect fluid level switch coupler 1 on reservoir 4 Disconnect brake pipes 2 connected to master cylinder CAUTION Do not allow brake fluid to get on painted surfa...

Page 475: ...piston Then remove secondary piston by blowing compressed air 2 into hole Be cautious during removal as secondary piston jumps out WARNING Do not apply too highly compressed air which will cause pisto...

Page 476: ...5 Install circlip 1 Master Cylinder Assembly Inspection S3RH0A4106014 Inspect all disassembled parts for wear or damage and replace parts if necessary NOTE Wash disassembled parts with brake fluid Do...

Page 477: ...ster NOTE For this check make sure that no air is in hydraulic line Check Air Tightness 1 Start engine 2 Stop engine after running for 1 to 2 minutes 3 Depress brake pedal several times with the same...

Page 478: ...tion Check Air Tightness Under Load 1 With engine running depress brake pedal Then stop engine while holding brake pedal depressed 2 Hold brake pedal depressed for 30 seconds If pedal height does not...

Page 479: ...to pedal arm with clevis pin 2 and clip 6 4 Tighten booster mounting nuts 3 to specified torque Tightening torque Booster mounting nut a 13 N m 1 3 kgf m 9 5 lb ft 5 For LH steering vehicle with ABS I...

Page 480: ...H steering vehicle Clevis lock nut a 19 N m 1 9 kgf m 14 0 lb ft RH steering vehicle Clearance Between Booster Piston Rod and Master Cylinder Piston For left hand steering vehicle 1 Set special tool A...

Page 481: ...1 Clean around reservoir cap and take out fluid with syringe or such 2 Hoist vehicle 3 Disconnect brake pipes from LSPV assembly 4 Remove mounting bolts 3 and adjusting nut 2 5 Remove LSPV assembly 1...

Page 482: ...the following before inspection and adjustment Fuel tank is filled with fuel fully Vehicle is equipped with spare tire tools jack and jack handle Vehicle is free from any other load Vehicle is placed...

Page 483: ...in Section 0A Fastening part Tightening torque Note N m kgf m lb ft LSPV adjust nut 23 2 3 17 0 Front brake caliper bleeder plug 8 5 0 85 6 5 for NISSIN made caliper Front brake caliper bleeder plug...

Page 484: ...8002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 3 DOT 3 09161 10009 09360 10040 Washer Union bolt Spare part Spare part 09922 85811 09950 96010 Spring pin remover 4 5 mm...

Page 485: ...ISSIN made caliper 7 Brake pad 14 Slide pin Apply grease included in spare parts 1 Brake caliper carrier 8 Bleeder plug 15 Retaining ring 2 Boot 9 Bleeder plug cap Tightening torque 3 Caliper 10 Pad s...

Page 486: ...ove caliper 1 from caliper carrier 2 NOTE Hang removed caliper 1 with a wire hook 4 or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pe...

Page 487: ...orrect leaky point if any Front Disc Brake Caliper Removal and Installation S3RH0A4206005 Removal 1 Hoist vehicle and remove wheel 2 Loosen flexible hose joint bolt 1 a little at caliper CAUTION Be ca...

Page 488: ...ion fill reservoir with brake fluid and bleed air from brake system Perform brake test and check each installed part for oil leakage Front Disc Brake Caliper Disassembly and Assembly S3RH0A4206006 Dis...

Page 489: ...ot twisted Before installing caliper to carrier install slide pin with grease applied into caliper carrier hole and check for its smooth movement in thrust direction After reassembling brake lines ble...

Page 490: ...fective replace Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth return of piston In such case replace rubber seal Front Brake Disc Removal and Installation S3RH0A4206008 Remov...

Page 491: ...n of installation perform brake test Front Brake Disc Inspection S3RH0A4206009 Using magnetic stand and with dial gauge positioned at about 10 mm 0 39 in inward from periphery of disc measure deflecti...

Page 492: ...l S3RH0A4208001 NOTE Required service material is also described in the following Front Disc Brake Components Special Tool S3RH0A4208002 Fastening part Tightening torque Note N m kgf m lb ft Caliper p...

Page 493: ...ble locking nut 1 I2RH01430001 01 1 Brake back plate Apply water tight sealant 99000 31090 to mating surfaces of brake back plate and rear axle 9 Shoe hold down pin 2 Brake shoe 10 Blank 3 Parking bra...

Page 494: ...ull brake drum off by using 8 mm bolts 1 2 pieces Installation 1 Before installing brake drum to maximize brake shoe to drum clearance put screwdriver between rod 1 and ratchet 2 and push down ratchet...

Page 495: ...ace drum Drum inner diameter a Standard 200 mm 7 87 in Limit 202 mm 7 95 in Cracked Scored or Grooved Drum A cracked drum is unsafe for further service and must be replaced Do not attempt to weld a cr...

Page 496: ...3 Installation Install parts in reverse order of removal noting the following Install shoe hold down springs 2 by pushing them down in place and turning hold down pins 1 For procedure hereafter refer...

Page 497: ...lare nut b 16 N m 1 6 kgf m 11 5 lb ft 4 Install bleeder plug cap taken off from pipe back to bleeder plug 5 Install brake shoes Refer to Rear Brake Shoe Removal and Installation 6 Install brake drum...

Page 498: ...e stopper ring 1 5 Remove wheel hub referring to Wheel Hub with Wheel Bearing and Wheel Stud Removal and Installation 2WD Model in Section 2C or Wheel Hub Wheel Stud Wheel Bearing Outside Inner Race R...

Page 499: ...S3RH0A4307001 NOTE The specified tightening torque is also described in the following Rear Drum Brake Components Reference For the tightening torque of fastener not specified in this section refer to...

Page 500: ...uction S3RH0A4401001 I3RH0A440001 01 T Top side 3 Inner cable end 8 Equalizer E View E F Front side 4 Spring A View A F View F R Rear side 5 Adjusting nut B View B Tightening torque 1 Backing plate 6...

Page 501: ...Parking brake lever 1 has been pulled up a few times with about 200 N 20 kg 44 lbs load If parking brake cable is replaced with new one pull up parking brake lever a few times with about 500 N m 50 kg...

Page 502: ...able Refer to Parking Brake Inspection and Adjustment Check brake drum for dragging and brake system for proper performance After removing vehicle from hoist brake test should be performed Specificati...

Page 503: ...disconnecting ABS hydraulic unit control module connector 1 pull down lock lever 2 of connector When connecting set the connector on ABS hydraulic unit control module assembly and pull up the lock lev...

Page 504: ...applied to wheel cylinder of each 4 wheels Fail safe relay transistor which supplies power to solenoid valve in ABS hydraulic unit Pump motor relay transistor which supplies power to pump motor in ABS...

Page 505: ...g Lamp Operation DTC Indicated by ABS Warning Lamp In good condition at present No trouble in the past OFF DTC 12 Trouble occurred in the past OFF History DTC Abnormal ity exists at present No trouble...

Page 506: ...t 2 ABS control module 8 EBD warning lamp Brake warning lamp 14 Wheel speed sensor Left front 3 ABS hydraulic unit 9 Lamp driver module 15 Wheel speed sensor Right rear 4 Fail safe relay transistor 10...

Page 507: ...ent of ABS hydraulic unit control module assembly 9 ABS hydraulic unit control module assembly 19 To ECM TCM SDM and A C control module if equipped a Upside 10 ABS fail safe relay transistor 20 Stop l...

Page 508: ...tor 15 LT GRN RED Left rear wheel speed sensor 16 LT GRN BLK Left rear wheel speed sensor 17 RED WHT ABS warning lamp 18 WHT BLK Right front wheel speed sensor 19 WHT Right front wheel speed sensor 20...

Page 509: ...of the combination meter monitor connector data link connector stop lamp switch and the brake master cylinder assembly only changes 2 5 4 3 1 6 2 2 2 7 I4RH01450004 01 1 ABS hydraulic unit control mod...

Page 510: ...1 1 Left front wheel speed sensor 3 Grommet 5 Sensor ring 2 Clamp bolt No 1 4 Connector 6 Clamp bolt No 2 5 6 2 3 2 1 4 5 2 3 2 1 4 A B 6 23 N m 2 3 kg m 10 N m 1 0 kg m 10 N m 1 0 kg m 23 N m 2 3 kg...

Page 511: ...to Step 5 4 ABS check 1 Inspect and repair referring to applicable DTC flow 2 Perform Step 2 Driving Test Does trouble recur Go to Step 5 Go to Step 7 5 Brakes diagnosis 1 Inspect and repair referring...

Page 512: ...This step should be shared with the customer if possible Check warning lamps related to brake system referring to EBD Warning Lamp Brake Warning Lamp Check and ABS Warning Lamp Check DTC check record...

Page 513: ...to Intermittent and Poor Connection Inspection in Section 00 and related circuit of trouble code recorded in Step 1 to 3 Step 7 Final Confirmation Test Confirm that the problem symptom has gone and t...

Page 514: ...mallest DTC number in increasing order For details of DTC refer to DTC Table If DTC is not indicated at ABS warning lamp go to Code DTC Is Not Outputted Even with Diagnosis Switch Terminal Connected t...

Page 515: ...mal C1015 15 G sensor circuit C1021 21 RF Wheel speed sensor circuit C1025 25 LF C1031 31 RR C1035 35 LR C1022 22 RF Wheel speed sensor circuit or sensor ring C1026 26 LF C1032 32 RR C1036 36 LR C1041...

Page 516: ...aking this connection for DTC check 2 Turn ignition switch to ON position 3 Erase DTC according to instructions displayed on scan tool Refer to scan tool operator s manual for further derails 4 After...

Page 517: ...through lamp driver module in combination meter If the antilock brake system is in good condition ABS control module turns ABS warning lamp ON at the ignition switch ON keeps it ON for 2 seconds and...

Page 518: ...tep 5 Replace fuse and check for short circuit to ground 5 1 Remove combination meter with ignition switch turned OFF 2 Check for proper connection to BLK RED wire of combination meter connector 3 If...

Page 519: ...ydraulic unit control module connector at terminals E15 7 E15 17 and E15 13 4 If OK then turn ignition switch to ON position and measure voltage between terminal E15 7 and vehicle body ground Is it 10...

Page 520: ...unit control module connector E15 5 Combination meter 9 1 Diagnosis switch terminal 1 Battery 6 ABS warning lamp 9 2 Diagnosis ground terminal 2 Main fuse box 7 Lamp driver module 10 ABS fuse 10A 3 Ig...

Page 521: ...cuit fuse box 9 Monitor connector Step Action Yes No 1 Is it shorted diagnosis switch terminal and ground terminal by service wire properly Go to Step 2 Connect service wire securely 2 1 Disconnect se...

Page 522: ...n Yes No I3RH0A450004 01 A ABS hydraulic unit control module connector E15 5 Combination meter 10 Parking brake switch 1 Battery 6 EBD warning lamp Brake warning lamp 11 ABS hydraulic unit control mod...

Page 523: ...ulic unit control module connector E15 1 Battery 4 Circuit fuse box 7 Lamp driver module 10 ABS hydraulic unit control module assembly 2 Main fuse box 5 Combination meter 8 Data link connector DLC 11...

Page 524: ...if communication is possible by trying communication with other controller ECM TCM or SDM Is it possible to communicate with other controller Go to Step 7 Repair open in common section of serial data...

Page 525: ...S hydraulic unit control module assembly 3 If OK substitute an ABS hydraulic unit control module assembly with correct part number 4 Recheck system 9 1 Turn ignition switch to OFF position 2 Check pro...

Page 526: ...sor signal is inputted at running an applicable DTC will be set NOTE When the vehicle was operated in any of the following ways one of these DTCs may be set even when the sensor is in good condition I...

Page 527: ...nding sensor This check result should be the same as Step 2 Either terminal of wheel speed sensor coupler and body ground This check result should be no continuity Are both check results OK Go to Step...

Page 528: ...Front Left Front Outlet Solenoid Circuit DTC C1052 C1056 No 52 56 Right Rear Left Rear Outlet Solenoid Circuit Wiring Diagram DTC Detecting Condition The ABS control module monitors the output from t...

Page 529: ...1 Check solenoid operation referring to item ABS Hydraulic Unit Operation Check Is it in good condition Check terminal E15 14 connection If connection is OK substitute a known good ABS hydraulic unit...

Page 530: ...gnition switch to ON and measure resistance between each terminal of E15 13 and E15 26 and vehicle body ground Is resistance less than 2 Go to Step 4 BLK wire circuit in open or high resistance 4 1 Me...

Page 531: ...formed Go to Step 2 Go to ABS Check 2 1 Check pump motor referring to ABS Hydraulic Unit Operation Check Is it in good condition Check terminals E15 1 E15 13 and E15 26 connection If connections OK su...

Page 532: ...0 A fuse 2 Main fuse box 6 ABS hydraulic unit control module assembly 3 Ignition switch 7 To solenoid valve Step Action Yes No 1 Was ABS Check performed Go to Step 2 Go to ABS Check 2 Check battery vo...

Page 533: ...Action Yes No 1 Was ABS Check performed Go to Step 2 Go to ABS Check 2 Clear all DTCs and check DTC Is it DTC C1071 No 71 Go to Step 3 Could be a temporary malfunction of the ABS control module 3 1 Ch...

Page 534: ...AULIC CONTROL TEST under miscellaneous test MISC TEST mode of SUZUKI scan tool 8 Perform the following checks with help of another person Brake pedal 1 should be depressed and then select testing whee...

Page 535: ...If malfunction DTC is indicated repair it first 8 Turn ignition switch OFF 9 Perform the following checks with help of another person Brake pedal 1 should be depressed and then ignition switch 2 turne...

Page 536: ...blind plug or remove motor Performing any of these prohibited services will affect original performance of ABS hydraulic unit control module assembly 9 N m 0 9 kg m 1 1 4 3 m 0 9 kg m 9 N 23 N m 2 3...

Page 537: ...lic Unit Control Module Assembly On Vehicle Inspection 1 Disconnect negative cable from battery 2 Disconnect ABS hydraulic unit control module assembly connector 1 by pull down the lock 2 3 Using spec...

Page 538: ...3 kgf m 17 0 lb ft 2 Bleed air from brake system referring to Air Bleeding of Brake System in Section 4A 3 Check each installed part for fluid leakage and perform ABS Hydraulic Unit Operation Check NO...

Page 539: ...tage 1 meets specification and waveform is complete Peak to peak voltage at 3 4 to 1 1 4 rotation per second 150 mV or more at 32 53 Hz Front Wheel Speed Sensor Removal and Installation S3RH0A4506006...

Page 540: ...and any malcondition is found replace Rear Wheel Speed Sensor On Vehicle Inspection S3RH0A4506008 Output Voltage Inspection 1 Disconnect negative cable from battery 2 Remove quarter inner trim 1 3 Tu...

Page 541: ...arter inner trim 1 3 Turn over floor carpet 4 Hoist vehicle 5 Disconnect rear wheel speed sensor coupler 1 6 Detach ABS wheel sensor wire harness 2 NOTE Do not detach clip of rear wheel speed sensor c...

Page 542: ...Speed Sensor Inspection S3RH0A4506010 Check sensor for damage Measure resistance of sensor Between both terminals 1 of sensor 1 2 1 6 k at 20 C 68 F Between sensor terminal 1 and sensor body 2 Infinit...

Page 543: ...if ring rotation is free from eccentricity and looseness Check that no foreign material is attached If any faulty is found repair or replace Rear Wheel Speed Sensor Ring Removal and Installation S3RH0...

Page 544: ...ng part Tightening torque Note N m kgf m lb ft Brake pipe flare nut 16 1 6 11 5 ABS hydraulic unit control module assembly bolt 9 0 9 6 5 ABS hydraulic unit control module assembly bracket bolt 23 2 3...

Page 545: ...D 5A 44 No Lock Up Occurs 5A 45 DTC P0705 No 34 Transmission Range Sensor Circuit Malfunction 5A 46 DTC P0710 No 36 or 38 Transmission Fluid Temperature Sensor Circuit Malfunction 5A 48 DTC P0715 No...

Page 546: ...eassembly 5A 125 Transaxle Rear Cover and O D and 2nd Coast Brake Piston Assembly Components 5A 126 Transaxle Rear Cover and O D and 2nd Coast Brake Piston Assembly Disassembly and Reassembly 5A 127 T...

Page 547: ...spection 5C 4 Clutch Fluid Pipe and Hose Components 5C 4 Clutch Fluid Pipe and Hose Removal and Installation 5C 5 Clutch Fluid Pipe and Hose Inspection 5C 5 Clutch Master Cylinder Removal and Installa...

Page 548: ...ssion Transaxle S3RH0A5000001 Air Bag Warning Refer to Air Bag Warning in Section 00 Precautions in Diagnosing Trouble Refer to Precautions in Diagnosing Trouble in Section 5A Precautions for Disassem...

Page 549: ...and actuators have resistance of specified value MAP sensor and TP sensor are in good condition Also the power circuit of these sensors is not shorted to the ground When replacing TCM with used one a...

Page 550: ...ace oil seals that are removed and apply grease to their lips Before installing be sure to apply automatic transaxle fluid to sliding rolling and thrusting surface of all component part Also after ins...

Page 551: ...hifting from 3rd gear to 4th gear to adjust the drain hydraulic pressure at releasing the forward clutch a timing solenoid valve is used to switch a hydraulic passage with an orifice to another during...

Page 552: ...nion 23 Short planet pinion 4 Input shaft 14 One way clutch No 2 24 Countershaft 5 Oil pump 15 Second brake 25 Reduction driven gear 6 Direct clutch drum which doubles as sensor rotor for input shaft...

Page 553: ...Automatic Transmission Transaxle 5A 5 4WD I3RH0A510002 01 1 Transfer...

Page 554: ...range Forward 1st 2nd 3rd automatic gear change L range Forward 1st 2nd 3rd reduction and fixed at 1st gear Gear ratio 1st 2 875 Number of teeth Front sun gear 24 2nd 1 568 Rear sun gear 30 3rd 1 000...

Page 555: ...ast brake Fixes rear sun gear 2nd brake Fixes rear sun gear 1st and reverse brake Fixes planet carrier One way clutch No 1 Prevents rear sun gear from turning counterclockwise One way clutch No 2 Prev...

Page 556: ...s General Description S3RH0A5101005 This vehicle is equipped with an electronic transaxle control system which controls the automatic shift up and shift down timing TCC operation etc suitably to vehic...

Page 557: ...nction for 3 driving cycles continuously it turns MIL off although DTC stored in ECM memory will also remain It is possible to communicate with ECM and or TCM through data link connector DLC 3 by usin...

Page 558: ...switch is turned ON and then goes OFF for bulb check If O D off switch is ON at this time however O D OFF lamp remains ON to let driver known that gear is not shifted to overdrive gear When TCM detect...

Page 559: ...G07 3 5 PPL YEL 12V G08 6 G08 16 G07 12 G07 18 G03 6 G04 8 G03 14 G03 5 G03 4 G03 1 G03 12 G07 7 G07 6 G07 23 G07 14 G07 15 G07 28 G07 2 G07 1 G07 9 G07 8 G07 21 G07 20 BLU ORN GRN ORN GRN YEL BLU WH...

Page 560: ...R Reverse When vehicle is traveling forwards in less than 11 km h 7 mile h vehicle speed When vehicle is traveling forwards in 11 km h 7 mile h or more vehicle speed When fail safe function is operat...

Page 561: ...igher than 97 km h 60 5 mile h speed 3rd gear is operated and then down shifts to 2nd at a speed lower than that Gear shift diagram A and TCC lock up diagram B Shift Throttle opening 1 2 2 3 3 4 4 3 3...

Page 562: ...le h speed 3rd gear is operated and then down shifts to 2nd at a speed lower than that Gear shift diagram A and TCC lock up diagram B Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle km h...

Page 563: ...ation Electronic Shift Control System Components Location S3RH0A5103001 17 16 15 12 13 14 11 18 10 9 7 8 6 5 4 19 1 20 2 3 I3RH0A510017 02 1 Engine 8 Brake light switch 15 Timing solenoid valve 2 Tran...

Page 564: ...ft solenoid valves TCC solenoid valve and Timing solenoid valve Pressure control solenoid valve Final gear reduction unit Engine control module ECM A Throttle opening signal B Engine speed signal Tran...

Page 565: ...nfirm trouble symptom Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and record of DTC freeze frame data 1 Recheck for DTC and freeze frame data referring to DTC Check Is there a...

Page 566: ...rred as described by the customer For this purpose use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis Customer problem inspec...

Page 567: ...ed through steps of customer complaint analysis trouble symptom confirmation and or A T basic check and repair or replace faulty parts if any Step 9 Troubleshooting for DTC Based on the DTC indicated...

Page 568: ...ouble is detected and DTC is stored in TCM for vehicle with immobilizer lamp 3 O D OFF lamp does not flash although DTC is detected and stored for vehicle without immobilizer lamp 4 If short circuit i...

Page 569: ...ommanding TCC solenoid to turn ON or Difference in revolution between engine and input shaft is too small although TCM is commanding TCC solenoid to turn OFF 2 driving cycles Not applicable P0743 25 T...

Page 570: ...f TCM Calculation of current data stored in TCM is not correct comparing with pre stored checking data in TCM 1 driving cycle 1 driving cycle P1705 51 Engine coolant temperature signal circuit malfunc...

Page 571: ...CM is not possible check if scan tool is communicable by connecting it to TCM in another vehicle If communication is possible in this case scan tool is in good condition Then check data link connector...

Page 572: ...KI scan tool to data link connector DLC 1 located In underside of instrument panel at driver s seat side Special tool A SUZUKI scan tool 3 Turn ignition switch ON 4 Clear DTC according to instructions...

Page 573: ...l is inhibited P0720 31 Output shaft speed sensor or its circuit Vehicle speed which is calculated by input shaft speed sensor signal is used for gear shifting control instead of vehicle speed calcula...

Page 574: ...lant temperature is assumed to be normal operating temperature and controls of overdrive and lock up is released from inhibition P1730 64 Engine torque signal circuit Engine torque is assumed to be th...

Page 575: ...switch ON closed throttle and 1st gear OFF At 100 km h 62 5 mile h constant speed O D off switch OFF 20 or less throttle opening and 4th gear ON PRESS CONT SOL At vehicle stop closed throttle engine...

Page 576: ...utputted to timing solenoid valve OFF ON command not being outputted to timing solenoid valve SHIFT TIMING SOL MON ON Electricity being passed to timing solenoid valve OFF Electricity not being passed...

Page 577: ...pedal gradually 4 While driving in D range check if gear shift and lock up occur properly as shown in Automatic Gear Shift Diagram Step Action Yes No 1 Was A T System Check preformed Go to Step 2 Go...

Page 578: ...lenoid valve A Inspect If NG replace Malfunction of output shaft speed sensor VSS Inspect If NG replace Malfunction of throttle position sensor Inspect If NG replace Malfunction of transmission range...

Page 579: ...Inspect If NG replace 2 1 downshift fails to occur Malfunction of shift solenoid valve B Inspect If NG replace Malfunction of output shaft speed sensor VSS Inspect If NG replace Malfunction of throttl...

Page 580: ...icle in 3rd gear of D range shift select lever down to 2 range and check if engine brake operates 2 In the same way as in Step 1 check engine brake for operation when select lever is shifted down to L...

Page 581: ...ion Reference Item Lower than standard level in both D and R range Engine output torque failure Inspect and repair engine Faulty one way clutch of torque converter Replace torque converter Malfunction...

Page 582: ...ition Possible cause Correction Reference Item N D time lag exceeds specification Malfunction of transmission fluid temperature sensor Inspect If NG replace Malfunction of pressure control solenoid va...

Page 583: ...ure to leave engine running at idle for longer than one minute before performing another line pressure test Automatic transaxle line pressure Troubleshooting D range R range At idle speed 3 7 4 1 kg c...

Page 584: ...n N D or 3 O D shifting Inspect circuit for open short and intermittent If NG repair Output shaft speed sensor VSS circuit faulty Inspect circuit for open short and intermittent If NG repair Input sha...

Page 585: ...nt If NG repair Throttle position sensor circuit faulty Inspect circuit for open short and intermittent referring to DTC P0120 No 13 Throttle Position Circuit Malfunction in Section 1A If NG repair TC...

Page 586: ...t faulty Inspect circuit for open short and intermittent referring to DTC P0115 No 19 Engine Coolant Temp ECT Circuit Malfunction in Section 1A If NG repair Crankshaft position sensor circuit faulty I...

Page 587: ...repair Throttle position signal circuit faulty Inspect circuit for open short and intermittent If NG repair Throttle position sensor circuit faulty Inspect circuit for open short and intermittent ref...

Page 588: ...tion in Section 1A If NG repair Engine coolant temperature sensor circuit faulty Inspect circuit for open short and intermittent referring to DTC P0115 No 19 Engine Coolant Temp ECT Circuit Malfunctio...

Page 589: ...ensor Inspect referring to Throttle Position TP Sensor On Vehicle Inspection in Section 1C If NG replace Faulty valve body component Replace valve body assembly Poor 2 3 shift Malfunction of shift sol...

Page 590: ...rmal condition Inspect and repair engine Malfunction of output shaft speed sensor VSS Inspect If NG replace Malfunction of throttle position sensor Inspect referring to Throttle Position TP Sensor On...

Page 591: ...D shift excessive shock or slippage Faulty forward clutch Inspect If NG replace Faulty O D and 2nd coast brake Inspect If NG replace Poor 3 2 shift excessive shock or slippage Faulty direct clutch Ins...

Page 592: ...test under the following conditions and measure voltage between terminal G08 4 of TCM connector and ground terminal G08 3 of TCM connector and ground O D off switch is turned OFF Engine coolant temper...

Page 593: ...0720 P0725 P0743 P0748 P0753 P0758 P0785 P1700 or P1702 detected Perform DTC flow to repair and retry Go to Step 3 3 1 Perform running test under the following conditions and check voltage between ter...

Page 594: ...37 5 mile h or faster in D range 5 Keep driving above vehicle speed for 40 seconds 6 Release accelerator pedal decrease vehicle speed and stop vehicle 7 Check DTC pending DTC and freeze frame data if...

Page 595: ...range and 0 V for other ranges as shown in the following table Check voltage at other terminals likewise referring to the following table Are check results satisfactory Intermittent trouble Check for...

Page 596: ...M and ECM memories by using scan tool and start engine 3 Shift selector lever to D range and drive vehicle for 20 minutes 4 Stop vehicle and check DTC pending DTC and freeze frame data if available 5...

Page 597: ...ound Go to Step 4 4 Check transmission fluid temperature circuit for IG short 1 Cool down A T fluid temperature under ambient temperature 2 Connect TCM connectors to TCM with ignition switch OFF 3 Tur...

Page 598: ...in TCM and ECM memories by using scan tool and start engine 3 Shift selector lever to D range and drive vehicle at 50 km h 31 mile h or more with 3rd gear at least for 5 minutes 4 Stop vehicle and ch...

Page 599: ...7 17 and ground No continuity Are check result satisfactory Go to Step 4 Go to Step 3 3 Inspect input shaft speed sensor 1 Inspect input shaft speed sensor referring to Input Shaft Speed Sensor Inspec...

Page 600: ...can tool and start engine 3 Shift selector lever to D range and drive vehicle at 50 km h 31 mile h or more vehicle speed at least for 3 minutes 4 Stop vehicle and check DTC pending DTC and freeze fram...

Page 601: ...put shaft speed sensor harness side connector and ground Is continuity indicated PPL RED wire shorted to ground Go to Step 5 5 Check output shaft speed sensor VSS signal circuit for open 1 Check conti...

Page 602: ...Keep engine speed of 2500 rpm for 10 seconds 5 Release accelerator pedal and check DTC pending DTC and freeze frame data if available 4 C41 G04 G03 1 15 G08 G07 12V 12V 3 LT GRN BLK G03 1 G07 15 1 2 I...

Page 603: ...onnected harness side TCM connector and ground Is continuity indicated LT GRN BLK circuit shorted to ground Go to Step 4 4 Check TCM terminal voltage 1 Connect TCM connectors to TCM with ignition swit...

Page 604: ...nge Confirm O D OFF lamp lights 8 Drive vehicle with 3rd gear in D range more than 10 throttle opening and at vehicle speed of 30 40 km h 19 25 mile h for 10 seconds or longer 9 Stop vehicle and turn...

Page 605: ...in D range and repeat lock up ON and OFF operations 2 times each referring to Automatic Gear Shift Diagram In brief 75 km h 47 mile h with 4th gear repeat accelerator pedal depressing so as throttle o...

Page 606: ...o solenoid at BLU WHT circuit 4 Check resistance of solenoid TCC solenoid valve resistance Between terminal 2 of transaxle side valve body harness connector and transaxle 3 11 15 at 20 C 68 F Is check...

Page 607: ...n TrouBle Area Too much electric flow is detected on pressure control solenoid valve circuit No electric flow is detected on pressure control solenoid valve circuit Pressure control solenoid valve cir...

Page 608: ...ure control solenoid valve or lead wire 4 Check pressure control solenoid valve circuit for ground short 1 Connect valve body harness connector 2 Check continuity between terminal G08 11 of disconnect...

Page 609: ...the following condition is detected while driving at 15 km h 10 mile h or more in D range after engine being warmed up Transaxle gear ratio is detected as same as that of 2nd gear although TCM command...

Page 610: ...G07 12V 12V 5 GRY G08 4 G08 3 GRN ORN 2 3 4 1 I2RH0B510026 01 1 TCM 4 A T 2 Shift solenoid valve A No 1 5 Terminal arrangement of TCM connector viewed from harness side 3 Shift solenoid valve B No 2 D...

Page 611: ...C 68 F Is check result satisfactory Go to Step 4 Replace shift solenoid valve or lead wire 4 Check shift solenoid circuit for ground short or open 1 Connect valve body harness connector 2 Measure resi...

Page 612: ...ement of TCM connector viewed from harness side DTC detecting condition Trouble area Voltage of timing solenoid valve TCM terminal is low although TCM is commanding timing solenoid valve to turn ON or...

Page 613: ...Is check result satisfactory Go to Step 4 Replace timing solenoid valve or lead wire 4 Check timing solenoid valve circuit for ground short 1 Connect valve body harness connector 2 Disconnect TCM conn...

Page 614: ...nd keep it for 10 seconds 6 Check DTC pending DTC and freeze frame data if available 4 C41 G04 G03 14 6 G08 G07 PPL WHT 12V 3 G03 14 G07 6 2 1 I2RH0B510030 01 1 TCM 3 Terminal arrangement of TCM conne...

Page 615: ...and ground Is it 10 14 V PPL WHT circuit shorted to power circuit Go to Step 4 4 Check throttle position signal circuit for open 1 Turn ignition switch OFF 2 Check continuity between terminal G07 6 o...

Page 616: ...7 G08 G07 GRY BLK 12V 3 G04 8 G07 7 2 1 I2RH0B510031 01 1 TCM 3 Terminal arrangement of TCM connector viewed from harness side 2 ECM 4 Terminal arrangement of ECM connector viewed from harness side DT...

Page 617: ...circuit for open 1 Turn ignition switch OFF 2 Check continuity between terminal G07 7 of disconnected harness side TCM connector and terminal G04 8 of disconnected harness side ECM connector Is contin...

Page 618: ...ngement of ECM connector viewed from harness side DTC detecting condition Trouble area Too short low signal of pulse signal from ECM to TCM continues out of specification Too long low signal of pulse...

Page 619: ...4 BLU RED circuit open 4 Check engine torque signal circuit for ground short 1 Check continuity between terminal G07 23 od disconnected harness side TCM connector and ground Is continuity indicated B...

Page 620: ...signal circuit for open 1 Turn ignition switch OFF 2 Disconnect TCM and ECM connectors from TCM and ECM 3 Check continuity between terminal G07 18 of disconnected harness side TCM connector and termin...

Page 621: ...pulse Duty ratio varies depending on engine coolant temperature Duty On time 850 ms at 20 C 68 F 1450 ms at 80 C 176 F 8 YEL RED Transmission range sensor D range 8 14 V Ignition switch ON selector le...

Page 622: ...ver at P range 5 BLU ORN Transmission fluid temperature sensor 4 5 4 9 V Ignition switch ON fluid temperature is 30 C 22 F 3 3 3 7 V Ignition switch ON fluid temperature is 10 C 50 F 0 3 0 5 V Ignitio...

Page 623: ...M power circuit 1 Disconnect TCM connector with ignition switch OFF 2 Check for proper connection to TCM at G08 20 terminal 3 If OK turn ignition switch ON and check voltage at terminal G08 20 of disc...

Page 624: ...and combination meter break down open or shot O D OFF lamp blinks only for 10 seconds Troubleshooting 10 3 G08 G07 4 GRN BLK 12V 5 G07 10 G07 3 RED YEL 2 3 5V 1 I2RH0B510035 01 1 TCM 3 To ignition swi...

Page 625: ...turning ignition switch ON Faulty combination meter or TCM Inspect combination meter referring to O D OFF Indicator Lamp A T Vehicle Only Symptom Diagnosis in Section 9C If OK substitute a know good T...

Page 626: ...With shift lock solenoid release button 1 pushed and ignition key turned to LOCK position selector lever can not be shifted from P range position to any other range When ignition switch is turned ON a...

Page 627: ...loth and put it back into place 7 Pull out fluid level gauge 1 again and check fluid level indicated on it The lowest fluid level should be between FULL HOT 2 and LOW HOT 3 If it is below LOW HOT add...

Page 628: ...l check under normal operating condition Failure to perform fluid level check under normal operating temperature may result in damage to transaxle A T Fluid Change S3RH0A5106002 1 Lift up vehicle 2 Wh...

Page 629: ...or smooth and clear cut movement and position indicator for correct indication For operation of select lever refer to the figure 3 N m 0 3 kg m 3 5 N m 0 35 kg m 2 5 N m 0 25 kg m 1 2 3 4 5 I3RH0A5100...

Page 630: ...ows Apply grease to pin and cable joint Tighten bolts to specified torque Adjusting procedure is as follows Refer to Selector Cable Adjustment Selector Cable Adjustment S3RH0A5106007 1 Shift manual sh...

Page 631: ...ge Vehicle should not move Vehicle can not be driven in N range Vehicle can be driven in D 2 and L ranges Vehicle can be backed in R range Transmission Range Sensor Shift Switch Inspection and Adjustm...

Page 632: ...t to specified torque Tightening torque Output shaft speed sensor VSS bolt a 13N m 1 3 kgf m 9 5 lb ft 3 Connect output shaft speed sensor connector 2 to output shaft speed sensor VSS 1 4 Connect nega...

Page 633: ...Disconnect input shaft speed sensor connector 2 3 Check resistance between input shaft speed sensor 1 terminals Input shaft speed sensor resistance Standard 560 680 at 20 C 68 F Transmission Fluid Te...

Page 634: ...dure described in A T Fluid Change Check for fluid leakage after warning up A T Transmission Fluid Temperature Sensor Inspection S3RH0A5106013 Warm up transmission fluid temperature sensor 2 Check res...

Page 635: ...r 1 from sensor clamp 9 Disconnect solenoid connectors 2 10 Remove TCC solenoid valve 1 shift solenoid valve A No 1 2 and shift solenoid valve B No 2 3 and timing solenoid valve by removing bolts Inst...

Page 636: ...ve resistance Shift solenoid valves timing solenoid valve and TCC solenoid valve resistance Standard 11 15 at 20 C 68 F Operation Check Shift solenoid valve A No 1 B No 2 and TCC solenoid valve CAUTIO...

Page 637: ...oid valve If not the strainer will be damaged Check that solenoid valve 1 actuate with click sound when battery voltage is conducted When timing solenoid valve 1 is connected to battery 2 confirm that...

Page 638: ...nit Assembly For detail of installing wire harness for solenoid valves and sensor refer to Automatic Transaxle Unit Assembly Use new O rings For detail of A T oil pan and oil strainer assembly install...

Page 639: ...ransmission Control Module TCM Removal and Installation S3RH0A5106018 CAUTION TCM consists of highly precise parts therefore when handling it be careful not to expose to excessive shock Removal 1 Disc...

Page 640: ...tion which is suitable for automatic transaxle is necessary immediately For example at the time when shift shock at downshifting 4th gear to 3rd gear or any upshifting become worse than shift shock be...

Page 641: ...ve drive shafts from steering knuckle NOTE For 4WD model transaxle is not equipped with differential right side oil seal 3 Remove differential side oil seal s by using screwdriver or the like 4 Apply...

Page 642: ...e correctly Removal 1 If the vehicle is equipped with air bag system disconnect negative cable at battery and disable air bag system referring to Disabling Air Bag System in Section 8B 2 Remove steeri...

Page 643: ...tion and then check for the following conditions With knob button released ignition key can be turned from ACC position to LOCK position With knob button pressed ignition key cannot be turned from ACC...

Page 644: ...0 N m 1 0 kg m 9 50 N m 5 0 kg m 5 25 N m 2 5 kg m 7 69 N m 6 9 kg m 6 4 1 8 8 B A I3RH0A510024 01 1 Transaxle housing lower plate 5 Drive plate to torque converter bolt 9 Lower stiffener bolt 2 Trans...

Page 645: ...d sensor and output shaft speed sensor VSS 3 Undo wiring harness clamps 4 Disconnect select cable from transaxle 5 Remove water intake pipe bolts 6 Remove transaxle and engine fastening bolts 7 Remove...

Page 646: ...as to release snap ring fitting of joint spline at intermediate shaft of transfer 3 20 Remove ball stud bolts and lock nuts from both knuckles and detach suspension arms and then pull out both drive...

Page 647: ...No 2 bracket M10 bolt j 55 N m 5 5 kgf m 40 0 lb ft Engine rear mounting No 2 bracket M8 bolt k 25 N m 2 5 kgf m 18 0 lb ft Engine LH mounting No 1 bolt l 55 N m 5 5 kgf m 40 0 lb ft Engine LH mounti...

Page 648: ...5A 100 Automatic Transmission Transaxle Automatic Transaxle Assembly Components S3RH0A5106025 I3RH0A510027 01...

Page 649: ...se 99000 25030 to oil seal lip 47 Fluid outlet union 80 O D and 2nd coast brake retaining plate snap ring 15 Torque converter housing plug 48 Reduction drive gear nut After tightening nut so as rotati...

Page 650: ...nge sensor 1 6 Remove output shaft speed sensor VSS 2 and input shaft speed sensor 1 7 Remove select cable clamp 3 8 Remove select cable bracket 1 9 Remove fluid cooler pipes 1 and fluid cooler pipe u...

Page 651: ...e like 12 Remove oil strainer assembly 1 13 Disconnect connectors from solenoid valves and transmission fluid temperature sensor 14 Remove valve body assembly bolts CAUTION Be careful not to let manua...

Page 652: ...accumulator pistons and springs To remove C2 1 C1 2 and B1 3 accumulator pistons and springs position rag on pistons to catch each piston To remove pistons force low pressure compressed air 1 kg cm2...

Page 653: ...ion select input shaft front thrust bearing with proper thickness from among the list below and replace it Special tool A 09900 20607 B 09900 20701 Input shaft thrust play 0 3 0 9 mm 0 012 0 035 in Av...

Page 654: ...th direct clutch assembly 30 Remove direct clutch hub 1 31 Remove differential assembly 1 and countershaft assembly 2 32 Remove governor apply No 2 gasket 1 33 Remove fluid reservoir LH plate 1 34 Tur...

Page 655: ...nd b Piston stroke a b O D and 2nd coast brake piston stroke Standard 0 65 1 05 mm 0 026 0 041 in CAUTION When brake disc retaining plate separator plate and or rear plate of O D and 2nd coast brake h...

Page 656: ...hrust bearing race 1 44 Remove rear planetary sun gear subassembly 1 and one way clutch No 1 assembly 2 45 Remove planetary gear thrust bearing 1 NOTE If planetary gear thrust bearing is not found on...

Page 657: ...ke have been replaced all learned contents which have been stored in TCM memory by executing learning control should be initialized referring to Learning Control Initialization Neglecting this initial...

Page 658: ...ates both ways or does not rotate either way one way clutch No 2 assembly will need to be replaced with new one way clutch No 2 assembly 59 Remove one way clutch No 2 assembly 1 60 Remove planetary ge...

Page 659: ...aining plate discs and separator plates 64 Remove 1st and reverse brake return spring subassembly 1 65 Turn over transaxle and uncaulk reduction drive gear nut 1 66 Secure reduction drive gear 1 with...

Page 660: ...d air from oil hole of oil pump remove 1st and reverse brake piston 1 71 Remove parking lock pawl bracket 1 72 With slotted screw driver cut and unfold manual valve lever spacer 1 and proceed to remov...

Page 661: ...bly 1 Remove O ring from pump body 2 Remove 8 oil pump subassembly bolts 1 and stator shaft assembly 2 I2RH0B510146 01 I2RH0B510147 01 I2RH0B510148 01 1 Oil seal Apply grease 99000 25030 to oil seal l...

Page 662: ...driver 2 5 Check drive gear for smooth rotation by using slotted screwdriver Oil Pump Inspection S3RH0A5106029 1 Check body clearance of driven gear 1 Push driven gear to one side of oil pump body 2 U...

Page 663: ...0 mm 0 7254 0 7264 in 5 Install direct clutch assembly 1 to stator shaft assembly 2 then ensure that direct clutch assembly turns smoothly If unsmooth rotation or noise are found in oil pump assembly...

Page 664: ...t clutch If piston stroke exceeds specified value disassemble inspect and replace inner parts Special tool A 09900 20607 B 09900 20701 Direct clutch piston stroke 0 4 0 7 mm 0 016 0 027 in I2RH0B51016...

Page 665: ...plates 2 Using special tool and hydraulic press remove shaft snap ring 1 Special tool A 09926 98310 CAUTION Do not press direct clutch return spring subassembly in over 0 4 mm 0 016 in Excessive compr...

Page 666: ...separator plates 4 discs 3 retaining plate 2 and snap ring 1 to input shaft subassembly Install plate snap ring so that its both ends would be positioned in correct locations as shown in the figure Af...

Page 667: ...Direct Clutch Return Spring Subassembly Measure free length of direct clutch return spring Direct clutch return spring free length a 36 04 mm 1 419 in NOTE Do not apply excessive force when measuring...

Page 668: ...le inspect and replace inner parts Special tool A 09900 20607 B 09900 20701 Reverse clutch piston stroke 1 2 1 6 mm 0 047 0 063 in I3RH0A510029 01 1 Forward clutch balancer 8 Inter mediate shaft seal...

Page 669: ...n stored in TCM memory by executing learning control should be initialized referring to Learning Control Initialization Neglecting this initialization may cause excessive shift shock Disassembly 1 Rem...

Page 670: ...ssembly 2 9 Remove forward clutch drum O ring 1 from forward clutch drum 2 10 Remove intermediate shaft seal ring 1 from intermediate shaft subassembly 2 Reassembly Reverse disassembly procedure for a...

Page 671: ...00 20607 B 09900 20701 C 09952 06020 Forward clutch piston stroke 1 30 1 50 mm 0 051 0 059 in Available forward clutch retaining plate thickness Apply A T fluid to reverse clutch separator plate 1 dis...

Page 672: ...Check that sliding surfaces of discs separator plates and retaining plate are not worn hard or burnt If necessary replace NOTE If disc lining is exfoliated or discolored replace all discs Before asse...

Page 673: ...g If necessary replace 2nd Brake Piston Assembly Components S3RH0A5106038 2nd Brake Piston Assembly Disassembly and Reassembly S3RH0A5106040 Disassembly 1 Apply compressed air 400 800 kPa 4 8 kg cm2 5...

Page 674: ...mage O ring when installing 2nd brake piston Transaxle Rear Cover and O D and 2nd Coast Brake Piston Assembly Components S3RH0A5106042 I2RH0B510198 01 I2RH0B510199 01 I2RH0B510200 01 1 Snap ring 5 O D...

Page 675: ...nd or piston 1 Remove snap ring by using special tools and hydraulic press Special tool A 09926 96030 B 09946 06710 2 Remove O D and 2nd coast brake return spring assembly 3 Apply compressed air 400 8...

Page 676: ...26 96030 B 09946 06710 Transaxle Rear Cover and O D and 2nd Coast Brake Piston Assembly Inspection S3RH0A5106045 O D and 2nd Coast Brake Return Spring Subassembly Measure free length of O D and 2nd co...

Page 677: ...1510 B 09926 58010 Reassembly 1 Install new countershaft RH bearing 1 by using special tool and hydraulic press Special tool A 09913 84510 NOTE Replace countershaft RH bearing together with bearing cu...

Page 678: ...sembly Components S3RH0A5106050 I2RH0B510214 01 I2RH0B510215 01 1 Pressure control solenoid valve 6 Temperature sensor clamp Apply automatic transaxle fluid 2 Shift solenoid valve A No 1 7 Valve body...

Page 679: ...ssure control solenoid independently may cause excessive shift shock Disassembly 1 Pull out manual valve 1 2 Remove pressure control solenoid valve 1 3 Remove TCC solenoid valve 1 4 Remove shift solen...

Page 680: ...rque Tightening torque Solenoid valve bolt a 11 N m 1 1 kgf m 8 0 lb ft Solenoid valve bolt specification Differential Assembly Components S3RH0A5106052 Bolt Length a Pieces A 1 49 mm 1 93 in 5 B 2 20...

Page 681: ...ARNING When taking warmed final driven gear out of vessel use tongs or the like Taking out it with bare hand will cause severe burn While installing warmed final driven gear use oven glove such as lea...

Page 682: ...tial side RH bearing together with bearing cup as a set Special tool A 09913 70123 6 Install new differential side LH bearing 1 by using special tool and hydraulic press NOTE Replace differential side...

Page 683: ...E Do not bend lubrication tube with excessive force 3 Remove differential side oil seal 1 4 Remove countershaft RH bearing cup by using special tools Special tool A 09944 96011 B 09942 15511 5 Remove...

Page 684: ...l tool A 09913 75520 4 Using special tools install new differential side oil seal to torque converter housing Special tool A 09924 74510 B 09944 88220 Differential side oil seal installing depth a 2 6...

Page 685: ...tools assemble shim and differential side LH bearing cup NOTE Use shim with same thickness as the removed one Special tool A 09924 74510 B 09944 68210 2 Using special tools assemble shim and countersh...

Page 686: ...ration or surface scuffing is indicated plate must be replaced Brake return spring subassembly Measure brake return springs Evidence of extreme heat or burning in the area of clutch may have caused sp...

Page 687: ...preload within specification Available shim thickness NOTE Record measured value a because it is necessary to adjust counter shaft bearing preload 5 Remove differential assembly Counter shaft bearing...

Page 688: ...tomatic transaxle fluid Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before assembly Use Suzuki Super Grease C to retain parts in place Be sure to install thrust bearin...

Page 689: ...r pin 2 by using spring pin remover with 3 mm 0 12 in in diameter 5 and hammer turn spacer to set the position as shown in the figure Then calk spacer with a punch 6 Install parking lock pawl bracket...

Page 690: ...l 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations as shown in the figure 13 Using special tools measure 1st and reverse brake piston stroke when co...

Page 691: ...work to press fit planetary ring gear subassembly Do not give load more than 20 kN 2000 kg 4410 Ib with hydraulic press Otherwise it may result in damaging reduction drive gear bearing Special tool A...

Page 692: ...out of specification remove planetary gear assembly and reinstall it properly Distance between planetary gear assembly and mating surface of transaxle case a More than 49 9 mm 1 965 in 21 Apply A T fl...

Page 693: ...iscs by pressing in 2nd brake assembly passing through its original installing position over 0 4 mm 0 016 in Special tool A 09926 96050 28 Check 2nd brake piston stroke by measuring clearance between...

Page 694: ...ke retaining plate snap ring correctly in groove of transaxle case 32 After applying grease to slide contact face of planetary carrier thrust washer 1 install it to planetary gear assembly A Grease 99...

Page 695: ...mbly 1 Install forward and reverse clutch assembly while rotating clockwise and counter clockwise frequently to fit clutch discs to mating hubs NOTE Before installation align teeth of forward and reve...

Page 696: ...1 05 mm 0 026 0 041 in When piston stroke is out of specification select O D and 2nd coast brake rear plate with proper thickness from among the list below and replace it CAUTION When brake disc reta...

Page 697: ...bly on transaxle case 49 Tighten rear cover bolts 1 Tightening torque Rear cover bolt a 25 N m 2 5 kgf m 18 0 lb ft 50 Install transaxle hook 2 to location shown in figure and tighten nut 3 Tightening...

Page 698: ...e rotating clockwise and counter clockwise frequently to fit clutch discs to mating hub NOTE Before installation align teeth of direct clutch discs to facilitate installation 58 Check for correct inst...

Page 699: ...f and clean mating surface between transaxle case 1 and torque converter housing 65 Apply sealant to torque converter housing 1 by using a nozzle 2 as shown in the figure by such amount that its secti...

Page 700: ...ccumulator O ring 2 Large C1 accumulator O ring 2 Large C2 accumulator O ring 2 Above three O rings are same 29 4 mm 1 16 in 2 6 mm 0 10 in Small B1 accumulator O ring 4 19 7 mm 0 78 in 2 6 mm 0 10 in...

Page 701: ...amage transmission fluid temperature sensor 2 at narrow entrance of case Careless sensor treatment might cause sensor malfunction Tightening torque Valve body harness connector bolt a 5 5 N m 0 55 kgf...

Page 702: ...Install new oil pan gasket 1 between transaxle case and oil pan 2 Tightening torque Oil pan bolt a 7 0 N m 0 7 kgf m 5 0 lb ft 80 After applying A T fluid to new O rings fit it to fluid cooler pipe un...

Page 703: ...ft 84 Apply A T fluid to O rings of each sensor and install input shaft speed sensor 1 and output shaft speed sensor VSS 2 Tightening torque Input shaft speed sensor bolt a 5 5 N m 0 55 kgf m 4 0 lb...

Page 704: ...5 N m 0 55 kgf m 4 0 lb ft 93 Bend dents of lock washer 1 in order to prevent displacement of lock washer 94 Install manual select lever 1 Tightening torque Manual select lever nut a 13 N m 1 3 kgf m...

Page 705: ...ion range sensor bolt 5 5 0 55 4 0 Output shaft speed sensor VSS bolt 13 1 3 9 5 Input shaft speed sensor bolt 5 5 0 55 4 0 Valve body harness connector bolt 5 5 0 55 4 0 Shift solenoid bolt 11 1 1 8...

Page 706: ...bolt 78 7 8 56 5 Torque converter housing plug 7 5 0 75 5 5 Lubrication tube clamp bolt 5 5 0 55 4 0 Fluid reservoir RH plate bolt 5 5 0 55 4 0 Torque converter housing bolt 33 3 3 24 0 Manual detent...

Page 707: ...and O D and 2nd Coast Brake Piston Assembly Components Countershaft Assembly Components Valve Body Assembly Components Differential Assembly Components Special Tool S3RH0A5108002 Material SUZUKI reco...

Page 708: ...ng installer blue Oil pressure gauge 09925 88210 09925 98210 Bearing puller attachment Input shaft bearing installer 09925 98221 09926 37610 Bearing installer Bearing remover 09926 37610 001 09926 376...

Page 709: ...09944 88220 Bearing installer support Oil seal installer 09944 96011 09946 06710 Bearing outer race remover Transfer bearing dummy 09951 18210 09952 06020 Oil seal remover installer No 2 Dial gauge pl...

Page 710: ...er synchro type to apply the brake on the input shaft rotation The double cone synchronizing mechanism is provided to 2nd gear synchromesh device for high performance of shifting to 2nd gear The count...

Page 711: ...b 8 Reverse gear shaft 14 Countershaft 4th gear 20 Differential case 3 Input shaft 5th gear 9 Reverse idler gear 15 Countershaft 3rd gear 21 Sensor rotor 4 Input shaft 4th gear 10 Right case 16 Counte...

Page 712: ...t 2nd gear 23 Transfer output shaft 3 Input shaft 5th gear 10 Right case 17 Low speed sleeve hub 24 Transfer output case 4 Input shaft 4th gear 11 Countershaft 18 Countershaft 1st gear 25 Transfer out...

Page 713: ...RH01520025 01 1 Gear shift control cable 5 5th reverse gear shift cam 9 5th reverse gear shift shaft 13 Gear shift interlock bolt 2 Gear select control cable 6 5th gear shift fork 10 Gear shift select...

Page 714: ...urn spring is contracted 3 When shift lever is shifted to 5th gear shift select shaft 1 turns clockwise letting shift cam 2 off from guide bolt and pushed up by return spring In this state movement of...

Page 715: ...for 2WD 2 0 liters 4 2 3 5 US lmp pt Transaxle oil capacity for 4WD 4 1 liters 8 7 7 2 US lmp pt Condition Possible cause Correction Reference Item Gears slipping out of mesh Worn shift fork shaft Re...

Page 716: ...tool A 09913 75810 for 4WD A 09913 75520 for 2WD Distance between case and oil seal for 4WD a 1 0 1 5 mm 0 04 0 06 in Distance between case and oil seal for 2WD a 0 0 5 mm 0 0 02 in 5 Apply grease to...

Page 717: ...EASE A 99000 25010 to connecting portion of gear shift control cable 9 Cable bracket bolt 2 Lever boot collar 6 Gear shift control cable guide nut 10 Cable grommet 3 Gear shift lever boot 7 Gear shift...

Page 718: ...ody Installation Reverse removal procedure for installation and note as follows Tighten each bolts and nuts to specified torque referring to Gear Shift Control Lever and Cable Components Apply grease...

Page 719: ...1 and tighten back up lamp switch 2 to specified torque Tightening torque Back up lamp switch a 23 N m 2 3 kgf m 17 0 lb ft 2 Connect back up lamp switch coupler 3 Connect negative cable at battery Ba...

Page 720: ...0 1 Engine 13 Lower stiffener for 2WD model 25 Engine rear mounting for 2WD model 2 Transaxle 14 Lower stiffener bolts 26 Engine rear mounting to member nuts 3 Lower stiffener for 4WD model 15 Clutch...

Page 721: ...ts and nut 20 Lower vehicle and support transaxle 2 with transmission jack 21 Remove engine left mounting with bracket 1 22 Remove other attached parts from transaxle if any 23 Pull transaxle out so a...

Page 722: ...ernal diameter 2 5th reverse gear shift cam 8 Select lever bracket bolt Tightening torque 3 Gear shift interlock plate 9 5th to reverse interlock guide bolt Apply thread lock cement 99000 32110 to bol...

Page 723: ...bolt 5 with select lever bracket Tightening torque Select lever bracket bolt c 23 N m 2 3 kgf m 17 0 lb ft 5 Install washer and gear shift interlock bolt 3 to which thread lock cement has been applie...

Page 724: ...g bent by supporting it with wood block Assemble 5th reverse gear shift cam with its pit and spring pin aligned Make sure to select an appropriate spring by identifying the painted colors to keep gear...

Page 725: ...nd thread part of bolt 3 Gear shift and select shaft assembly Apply sealant 99000 31260 to mating surface of gear shift guide case and left case 25 5th gear shift fork 4 Transaxle left case plate 26 N...

Page 726: ...ing of countershaft 5th gear is tight 9 Oil level filler plug Apply sealant 99000 31260 to all around thread part of plug 31 Washer 10 Oil drain plug Apply sealant 99000 31260 to all around thread par...

Page 727: ...lb ft 6 Assemble 5th speed synchronizer sleeve 1 hub 2 5th speed synchronizer levers 3 and synchronizer ring 4 as follows a Install hub 1 to 5th speed synchronizer sleeve 2 in specified direction as s...

Page 728: ...specified direction as shown in figure Special tool 09900 06107 10 Clean mating surface of both left case 2 and side cover 1 apply sealant to side cover as shown in figure by such amount that its sect...

Page 729: ...her with 5th reverse gear shift shaft 7 NOTE When removing 5th reverse gear shift shaft 7 and guide shaft 6 push up high speed gear shift shaft and shift it to 4th to facilitate removal of 5th reverse...

Page 730: ...gear shift lever 3 at the same time 3 Make reverse idler gear 1 with reverse gear shift lever 2 insert reverse gear shaft 3 into right case 4 through idler gear and then align A in shaft with B in ca...

Page 731: ...0 b Select a shim of differential side bearing as follows i Measure depth a from left case end face 1 to side bearing outer race 2 using depth gauge ii Measure height b of side bearing retainer with d...

Page 732: ...all new snap ring 1 using special tool Special tool A 09900 06107 0 996 1 025 mm 0 0392 0 0403 in 1 11 mm 0 044 in 1 026 1 055 mm 0 0404 0 0415 in 1 14 mm 0 045 in 1 056 1 085 mm 0 0416 0 0427 in 1 17...

Page 733: ...race NOTE Insert 0 1 mm 0 004 in feeler to know whether or not a shim fulfills specification quickly Available countershaft 5th gear shim thickness 17 Place left case plate 2 inserting its end in groo...

Page 734: ...ls if necessary Special tool A 09930 30104 C 09941 64511 Assembly 1 Install input shaft oil seal 1 facing its spring side upward Use special tool and hammer for installation and apply grease to oil se...

Page 735: ...Circlip 24 2nd gear synchronizer inner ring 3 Input shaft right bearing 14 5th gear spacer 25 Circlip 4 Input shaft 3rd gear 15 Countershaft right bearing 26 Countershaft 2nd gear 5 Needle bearing re...

Page 736: ...be flat Special tool A 09900 06107 5 Drive out high speed synchronizer sleeve hub assembly 2 together with 3rd gear 3 by using puller 4 and hydraulic press CAUTION To avoid gear tooth from being dama...

Page 737: ...allation position A B 5 Drive in right bering 1 to input shaft 2 using special tool and hammer Special tool A 09913 80113 6 Install 3rd gear needle bearing apply oil to it then install 3rd gear 2 and...

Page 738: ...cone 2 with 4th gear 3 by using puller 4 and hydraulic press CAUTION Use puller and hydraulic press that will bear at least 5 ton 11 000 lb safely To avoid tooth damage support 4th gear 3 at flat sid...

Page 739: ...red check clearance a between ring 2 and gear 1 each chamfered tooth of gear ring and sleeve then determine parts replacement Clearance a between synchronizer ring and gear Standard 1 0 1 4 mm 0 039 0...

Page 740: ...al tool A 09923 78210 7 Install needle bearing of resin cage type apply oil to it then install 1st gear and 1st gear synchronizer ring 8 Drive in low speed sleeve hub assembly 1 by using special tools...

Page 741: ...ools and hydraulic press NOTE It is recommended to press fit spacer and 3rd gear first and then 4th gear later separately so that countershaft will not be compressed excessively Special tool A 09923 7...

Page 742: ...ance a between fork and sleeve Service limit 1 0 mm 0 039 in 2 Insert each gear shift shaft into case and check that it moves smoothly If it doesn t correct by using oilstone reamer or the like 5th an...

Page 743: ...H0A5206023 2 Spring 7 5th reverse gear shift guide shaft 5 5th reverse gear shift shaft 8 5th gear side 6 5th reverse gear shift yoke A Face pin slit toward 5th gear side I4RH01520038 01 I3RH0A520025...

Page 744: ...t play of differential gear as follows Special tool A 09900 20607 B 09900 20701 Differential gear thrust play 0 05 0 33 mm 0 002 0 013 in Left side Hold differential assembly with soft jawed vise and...

Page 745: ...t right bearing 1 by using special tools and copper hammer Special tool A 09924 74510 B 09951 16060 C 09913 85230 7 Hold differential assembly with soft jawed vise 3 install final gear 2 and bevel gea...

Page 746: ...aring 18 Final gear 3 Transfer output flange oil seal Apply grease 99000 25010 to oil seal lip 11 Pinion spacer 19 Final gear bolt for 4WD Apply thread lock 99000 32110 to all around thread part of bo...

Page 747: ...ase 3 6 Using special tool hold drive gear 2 securely and loosen bevel pinion nut Special tool A 09927 76030 7 Drive out bevel pinion 1 with plastic hammer 2 At this time drive gear bearing 3 drive ge...

Page 748: ...l lip A Grease 99000 25010 Special tool A 09913 75810 Clearance a 1 0 1 5 mm 0 04 0 06 in 2 Install output flange 1 washer and new nut 3 Tighten nut to specified torque by using special tool and then...

Page 749: ...ial tool A 09915 24550 NOTE Apply thin coat of gear oil to bearing before measurement Also before measuring preload turn taper bearing a few times to ensure its good fitting c Place bevel pinion adjus...

Page 750: ...Shim to use Measured level difference Dimension b 0 586 0 615 0 616 0 645 0 646 0 675 0 676 0 705 0 706 0 735 0 736 0 765 0 766 0 795 0 796 0 825 0 826 0 855 0 976 1 005 1 006 1 035 1 036 1 065 1 066...

Page 751: ...ied torque while holding drive gear with special tool Tightening torque Bevel pinion nut a 120 N m 12 0 kgf m 87 0 lb ft Special tool A 09927 76030 f Using torque wrench 1 and special tool measure bea...

Page 752: ...cm 0 217 0 361 lb ft 7 Inspect tooth contact according to Gear Tooth Surface Contact Inspection 8 Clean mating surface to both rear case 1 and output case coat mating surface of rear case with sealan...

Page 753: ...im s from pinion shaft Assembly 1 Select pinion bearing shim No 1 as follows a Measure length A of drive pinion spacer 1 b Using special tool measure level difference B between other outer race 1 plus...

Page 754: ...005 1 006 1 035 1 036 1 065 1 066 1 095 1 096 1 125 1 126 1 155 1 156 1 185 1 186 1 215 1 216 1 245 1 246 1 275 1 276 1 305 1 306 1 335 1 336 1 365 1 366 1 395 1 396 1 425 1 426 1 455 1 456 1 485 1 48...

Page 755: ...nd hydraulic press 2 Drive out No 2 bearing 1 by using puller 2 and hydraulic press 3 3 Drive out No 1 bearing 1 by using puller 2 and hydraulic press 3 Assembly 1 Drive in No 1 bearing 1 by using spe...

Page 756: ...t with drive bevel pinion Adjust if check result is not satisfactory NOTE Apply red lead paste all around bevel gear but not so much as to become sticky A 1 I3RH0A520046 01 Tooth surface contact Possi...

Page 757: ...is defective Correction Replace defective part as an assembly When tooth contacts occur as shown at the left gear itself is defective Correction Replace drive bevel gear and drive bevel pinion as a se...

Page 758: ...21 2 1 15 5 VSS bolt 5 5 0 55 4 0 Back up lamp switch 23 2 3 17 0 Gear shift guide case bolt 23 2 3 17 0 Select lever bracket bolt 23 2 3 17 0 Gear shift interlock bolt 23 2 3 17 0 5th to reverse inte...

Page 759: ...fer Components Special Tool S3RH0A5208002 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25010 Sealant SUZUKI Bond No 1217G P No 99000 31260 Thread l...

Page 760: ...socket 1 2 x 1 4 Dial depth gauge 09922 77270 09922 85811 Bevel pinion dummy set Spring pin remover 4 5 mm 09923 74510 09923 78210 Bearing puller 20 35 mm Bearing installer 09924 74510 09924 84510 004...

Page 761: ...9930 30104 09930 40113 Sliding shaft Flywheel rotor holder 09940 54910 09941 64511 Front fork oil seal install driver Bearing and oil seal remover 30 mm Min 09944 78210 09951 16060 Bearing installer s...

Page 762: ...that the peripheral edge of the spring pushes on the pressure plate against the flywheel with the disc in between when the clutch release bearing is held back This is the engaged condition of the clut...

Page 763: ...Fluid leakage Repair or replace Clutch vibration Glazed glass like clutch facings Repair or replace disc Clutch facings dirty with oil Replace disc Release bearing slides unsmoothly on input shaft bea...

Page 764: ...Push rod play B Max 3 mm 0 12 in 2 If B is not within specification replace clevis pin 4 or pedal arm 2 Clutch Release Margin C 1 Pull up parking brake fully and block wheels 2 Start engine and keep...

Page 765: ...or which is wet from water Mineral oil will cause swelling and distortion of rubber parts in hydraulic clutch system and water will mix with brake fluid lowering fluid boiling point Keep all fluid co...

Page 766: ...r parts For air bleeding of master cylinder alone it must be removed from vehicle body For procedures of removal and installation of master cylinder and air bleeding refer to Clutch Master Cylinder Re...

Page 767: ...2 Install master cylinder assembly 1 and new gasket 2 to body attaching nuts 3 NOTE Do not reuse gasket 3 Tighten attaching nuts 3 to specified torque Tightening torque Clutch master cylinder attachi...

Page 768: ...or damage and replace parts if necessary CAUTION Polishing bore of cylinder with cast aluminum body with anything abrasive is prohibited as damage to cylinder bore may occur NOTE Wash disassembled pa...

Page 769: ...nstallation 1 Apply small amount of grease to rod tip NOTE Don t allow any grease to be on boot A Grease 99000 25010 2 Install clutch operating cylinder assembly 1 and tighten attaching bolts 2 to spe...

Page 770: ...14 Inspect all disassembled parts for wear or damage and replace parts if necessary NOTE Wash disassembled parts with brake fluid Do not reuse piston assembly Inspect cylinder bore for scoring or corr...

Page 771: ...30104 Installation NOTE Before assembling make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly 8 23 N m 2 3 kg m 11 23 N m 2 3 kg m 5 4 2 1 3 9 7 6 10 12...

Page 772: ...cover bolts compress clutch disc with special tool clutch center guide by hand so that disc is centered Tighten cover bolts little by little evenly in diagonal order Special tool A 09924 17811 B 0992...

Page 773: ...assembly Do not disassemble it into diaphragm and pressure plate Flywheel Check surface contacting clutch disc for abnormal wear or heat spots Replace or repair as required Clutch Release System Remov...

Page 774: ...r and release shaft arm 2 then set release bearing 1 A Grease 99000 25010 8 Apply small amount of grease to input shaft 3 spline and front end as well B Grease 99000 25210 9 Set release arm to release...

Page 775: ...Required service material is also described in the following Clutch Master Cylinder Components Clutch Operating Cylinder Components Clutch Cover Clutch Disc Flywheel and Clutch Release System Compone...

Page 776: ...aller Bearing remover 09922 46010 09923 36320 Clutch bush remover Clutch center guide 15 mm 09923 46020 09924 17811 Joint pipe Flywheel holder 09925 46010 09925 98221 Clutch release bush remover Beari...

Page 777: ...ion 6B 11 Specifications 6B 12 Tightening Torque Specifications 6B 12 Special Tools and Equipment 6B 12 Special Tool 6B 12 Power Assisted Steering System 6C 1 Precautions 6C 1 P S System Note 6C 1 Gen...

Page 778: ...er to Air Bag System Service Warning in Section 00 Precautions for Steering Suspension Wheels and Tires Diagnosis Refer to Precautions for Steering Suspension Wheels and Tires Diagnosis in Section 6A...

Page 779: ...d Worn lower ball joints Replace front suspension control arm Malfunction of power steering system Check and correct Poor returnability Bind in tie rod end ball studs Replace tie rod end Bind in ball...

Page 780: ...ion switch and lock are mounted conveniently on this column With the column mounted lock the ignition and the steering operations can be locked to inhibit theft of the vehicle To insure the energy abs...

Page 781: ...ssembly for Accident Damage S3RH0A6204003 NOTE Vehicles involved in accidents resulting in body damage where steering column has been impacted or air bag deployed may have a damaged or misaligned stee...

Page 782: ...06001 CAUTION Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil on the combination switch more than allowable number of turns about two and a quarte...

Page 783: ...rew a 0 85 N m 0 085 kgf m 0 6 lb ft b Install audio control switch 1 to steering wheel 2 2 Check that vehicle s front tires are at straight ahead position and contact coil is centered Refer to Center...

Page 784: ...tion S3RH0A6206002 CAUTION Do not turn contact coil on combination switch more than allowable number of turns about two and a quarter turns from the center position clockwise or counterclockwise respe...

Page 785: ...nd combination switch lead wire is not caught between covers 4 Install steering column hole cover 1 5 Install steering wheel to steering column Refer to Steering Wheel Removal and Installation Centeri...

Page 786: ...n assembly on the steering wheel with the air bag inflator module face down and column vertical Otherwise personal injury may result 1 Disconnect negative cable at battery 2 Disable air bag system Ref...

Page 787: ...17 If it is necessary to remove steering lock assembly ignition switch remove it referring to Steering Lock Assembly Ignition Switch Removal and Installation Installation CAUTION After tightening ste...

Page 788: ...n switch assembly is removed install it Refer to Contact Coil and Combination Switch Assembly Removal and Installation 9 Connect the following connectors disconnected in Removal Ignition switch Combin...

Page 789: ...part of steering lock body with center punch 3 Turn ignition key to ACC or ON position and remove steering lock assembly from steering column Installation 1 Position oblong hole 1 of steering shaft 2...

Page 790: ...lower shaft 1 and shaft joint of steering column 2 and lower shaft 1 and pinion shaft 3 for a guide during reinstallation 5 Remove lower shaft joint bolts 6 6 Remove steering lower shaft 1 Installati...

Page 791: ...For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Special Tool S3RH0A6208001 Fastening part Tightening torque...

Page 792: ...ld affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement become...

Page 793: ...he power steering P S pump which is driven by the engine It is an integral type with the rack and pinion gears and the control valve unit hydraulic pressure cylinder unit all built in the steering gea...

Page 794: ...rt P S pump hydraulic pressure increases but slowly Check pressure and repair or replace defective part Steering gear box malfunction Replace gear box Poor recovery from turns NOTE To check steering w...

Page 795: ...in tangential direction Steering force Less than 40 N 4 0 kg 8 8 lb Idle Up System Check S3RH0A6304004 1 Warm up engine to normal operating temperature 2 Turn A C switch OFF if equipped 3 Turn steerin...

Page 796: ...asuring hydraulic pressure with engine idling and hands off steering wheel When back pressure is higher than specified values check control valve and piping for clogging Back pressure Lower than 1000...

Page 797: ...han specified values possible cause is failure in steering gear box 5 Replace gear box CAUTION Be sure not to hold steering wheel at fully turned position for longer than 10 seconds Relief pressure 82...

Page 798: ...o the right and left so that maximum hydraulic pressure is provided Then visually check gear box P S pump P S fluid reservoir and each joint of pipes for leakage CAUTION Never keep steering wheel turn...

Page 799: ...ness If any defect is found replace power steering belt Refer to P S Pump Drive Belt Removal and Installation 3 Check belt tension by measuring how much it deflects Push the belt intermediate point be...

Page 800: ...ion by referring to P S Pump Drive Belt Tension Adjustment P S Pump Drive Belt Inspection S3RH0A6306019 Check power steering belt for wear and cracks and replace as required Tie Rod End Boot On Vehicl...

Page 801: ...a 45 N m 4 5 kgf m 32 5 lb ft 3 Bend new split pin 7 as shown in the figure 4 After installing wheels lower vehicle and tighten wheel nuts to specified torque Tightening torque Wheel nut a 85 N m 8 5...

Page 802: ...ed I3RH0A630001 01 1 Steering rack side mount 5 High pressure pipe 9 Rack side boot 13 Steering tie rod end 17 Split pin 2 Gasket 6 Low pressure return hose 10 Pinion side boot wire 14 Boot Tightening...

Page 803: ...nion and lower joint 4 Hoist vehicle and remove both right and left front wheels 5 Remove split pin 3 and then remove tie rod castle nut 2 from steering knuckle 1 6 Using special tool remove tie rod e...

Page 804: ...nder joints or a plug to pipe 10 Remove steering gear box mounting bolts and then remove steering gear box from vehicle Installation Reverse removal procedure for installation of steering gear box not...

Page 805: ...od end 4 Remove boot wire and clip 5 Remove boot 3 from tie rod 1 6 Unbend three bent portions 1 of tie rod lock washer and then remove tie rod 2 from rack 3 Model Part Section 2WD Exhaust pipe No 2 E...

Page 806: ...d be tightened with its both ends twisted together The twisted ends should be bent in the circumferential direction After this check to ensure that boot is free from twist and dent A Grease 99000 2505...

Page 807: ...tension pulley nut B Tighten bolt with pipe stopper contacted to projection of P S pump 6 Low pressure return pipe 12 Power steering belt 1 Power steering pump assembly 7 Low pressure return hose pip...

Page 808: ...r foreign matter from interfusion Installation Reverse removal procedure NOTE Fill specified power steering fluid after installation and bleed air without failure For tightening torques refer to P S P...

Page 809: ...lt hole 2 as shown in the figure 4 Apply power steering fluid to sliding surface of rotor 1 5 Install rotor to shaft directing dot 3 marked side of rotor facing up 6 Install new snap ring 2 to shaft t...

Page 810: ...pump cover 1 check that shaft can be turned by hand Tightening torque Pump cover bolt a 28 N m 2 8 kgf m 20 0 lb ft 16 Apply power steering fluid to O ring of terminal switch 17 Install pressure swit...

Page 811: ...ied torque Tightening torque Suction connector bolt d 12 N m 1 2 kgf m 8 5 lb ft P S Pump Inspection S3RH0A6306017 Pump Body Cover Side Plate and Shaft Check sliding surfaces of each part for wear and...

Page 812: ...1630044 01 I2RH01630045 01 Item Specification Hydraulic pressure Control Relieved pressure 8 200 8 900 kPa 82 89 kg cm2 or 1 166 1 265 psi Control device Flow control valve Relief valve Power steering...

Page 813: ...out 100 N 10 kg 22lb For vehicle without A C system 4 9 mm 0 16 0 35 in deflection for new and used belts The push force should be about 100 N 10 kg 22 lb Item Specification Fastening part Tightening...

Page 814: ...ial SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25010 SUZUKI Super Grease E P No 99000 25050 Sealant Silicone Sealant P No 99000 31120 for resin 09913 6521...

Page 815: ...Installation 7A 14 Blower Motor Inspection 7A 14 Blower Motor Controller Removal and Installation 7A 14 Blower Motor Controller Inspection 7A 15 Blower Motor Relay Inspection 7A 15 Heater Unit Compon...

Page 816: ...nstallation 7B 33 Compressor Drive Belt Inspection 7B 33 Compressor Removal and Installation 7B 34 Compressor Inspection 7B 34 Magnet Clutch Components 7B 35 Magnet Clutch Removal and Installation 7B...

Page 817: ...val and Installation 7B 74 Condenser Assembly Inspection 7B 74 Desiccant Removal and Installation 7B 74 Condenser Cooling Fan Removal and Installation 7B 74 Condenser Cooling Fan Inspection 7B 74 A C...

Page 818: ...Section 00 Heater and Ventilation Note Refer to Precautions in Diagnosing Trouble in Section 7A A C System Caution Refer to A C System Caution in Section 7B Precaution for Charging Refer to Precautio...

Page 819: ...rmation diagnostic trouble code read this manual and operator s manual for SUZUKI scan tool to know how to read diagnostic information diagnostic trouble code When checking diagnostic information diag...

Page 820: ...module detects malfunction the diagnostic information as diagnostic trouble code DTC is stored in the memory of the module By performing the DTC check procedure the diagnostic information can be known...

Page 821: ...77 26 G77 20 G77 19 G77 12 G77 18 G77 17 G77 22 G77 21 G77 3 G77 6 G77 5 G77 14 G77 13 BLU WHT RED WHT BLU LT GRN BLU YEL LT GRN G77 7 G77 25 BLK ORN BLU G77 15 G77 16 12V BLU BLK G77 2 1 3 2 4 5 6 7...

Page 822: ...Temperature control actuator faulty Check temperature control actuator referring to Temperature Control Actuator Inspection Temperature selector faulty Check HVAC control module and its circuit refer...

Page 823: ...ir indicator 2 operate properly 2 Set the following selectors to the specified positions respectively Temperature selector 3 Maximum cool position Air flow selector 4 Ventilation position Blower speed...

Page 824: ...ions related to temperature selector blower speed selector and or air flow selector on HVAC control module the following procedure can not be used However SUZUKI scan tool can be used to perform DTC c...

Page 825: ...ion Short to 5 V electrical power 2 4 Short to ground B1513 13 3 5 Temperature control actuator and or its circuit malfunction Lock B1514 14 3 6 Air flow control actuator and or its circuit malfunctio...

Page 826: ...e 1 5 seconds B DTC No 22 Recirculation indicator lamp flashing pattern F Normal b Indicator OFF f 2 seconds C Fresh air indicator lamp flashing pattern No 1 c 0 5 seconds g 3 seconds D Fresh air ind...

Page 827: ...it DEF position Scan Tool Data Condition Normal Condition Reference Value TEMP CONT SWITCH Each reference value is relative to the position of temperature selector of HVAC control module Max Cool P1 P...

Page 828: ...07 Refer to DTC B1511 No 11 Temperature Control Actuator Position Sensor and or its Circuit Malfunction in Section 7B DTC B1512 No 12 Air Flow Control Actuator Position Sensor and or its Circuit malfu...

Page 829: ...for blower motor 10 0 14 0V Ignition switch ON Blower speed selector OFF 1st or 2nd position about 2 0V Ignition switch ON Blower speed selector between 3rd and HIGH position G77 3 PPL WHT Rear defog...

Page 830: ...0 V Ignition switch ON except the above condition G77 19 GRY BLU Temperature control actuator COOL 10 0 14 0 V Ignition switch ON Temperature control actuator is working in operation from HOT to COOL...

Page 831: ...5 Disconnect main harness connector 1 and clamp air intake control actuator connector 2 and blower motor connector 3 6 Remove blower motor relay 4 from blower unit 7 Remove blower unit 1 from vehicle...

Page 832: ...1 Fix blower motor assembly 1 using soft jawed vise 2 Connect battery to blower motor assembly 1 as shown 3 Check if blower motor operates smoothly and doesn t make abnormal noise 4 Check if ammeter...

Page 833: ...nce between c and d terminals of blower motor controller If measured resistance is incorrect replace blower motor controller Blower motor controller resistance c d approximately 1 5 k Blower Motor Rel...

Page 834: ...vehicle body 7 Remove heater unit 3 from vehicle body Installation Reverse removal procedure to install heater unit noting the following instructions When installing each part be careful not to catch...

Page 835: ...instrument panel center garnish 7 Remove audio system 1 from instrument panel center garnish 8 Remove screws and HVAC control module 2 from instrument panel center garnish Installation Reverse removal...

Page 836: ...ach temperature control actuator rod 2 from linkage 3 4 Remove temperature control actuator 4 from heater unit Installation Reverse removal procedure to install temperature control actuator Temperatur...

Page 837: ...n 2 Disconnect negative cable at battery 3 Disconnect connector 2 4 Remove air flow control actuator 1 from heater unit and then detach air flow actuator rod from clip on linkage 3 Installation 1 Inst...

Page 838: ...tance between terminal 1 and 3 Air flow control actuator resistance between terminal 1 and 3 VENT position Approximately 1 0 k If check result is not satisfactory replace the actuator with new one Act...

Page 839: ...ation louver body Installation Reverse removal procedure to install side ventilation louver Special Tools and Equipment Special Tool S3RH0A7108001 2 Rag 1 2 I3RH0A710018 01 2 Rag 1 I3RH0A710019 01 SUZ...

Page 840: ...e A C system installed in the vehicle being serviced Use of incorrect one will result in leakage of refrigerant damage in parts or other faulty condition Precaution for Charging S3RH0A7210003 The refr...

Page 841: ...Always wear goggles to protect your eyes Avoid you direct contact to liquid refrigerant Do not heat refrigerant container higher than 40 C 104 F Do not discharge refrigerant into atmosphere Do not all...

Page 842: ...ressor oil to compressor suction side by referring to Operation Procedure for Refrigerant Charging General Description A C Evaporator Inlet Air Temperature Sensor and A C Evaporator Outlet Air Tempera...

Page 843: ...or refrigerant and the liquid refrigerant Only the liquid refrigerant is delivered to the sub cooler part of the condenser The refrigerant is supercooled by the sub cooler part of the condenser On Boa...

Page 844: ...on hose 11 Windscreen demister air 16 A C refrigerant pressure switch 2 Compressor 7 Liquid pipe 12 Side demister air 17 Low pressure charge valve 3 Condenser assembly 8 Expansion valve 13 Fresh air 1...

Page 845: ...G77 5 G77 14 G77 13 BLU WHT RED WHT BLU LT GRN BLU YEL LT GRN G77 7 G77 25 BLK ORN BLU RED LT GRN WHT BLU YEL BRN YEL RED BLU G77 15 G77 16 GRN BLK BLU ORN 12V G77 4 YEL WHT WHT BLK ORN ORN BLU BLK G...

Page 846: ...ssure switch referring to A C Refrigerant Pressure Switch Inspection Wiring or grounding faulty Check wiring and grounding ECT sensor faulty Check ECT sensor referring to Engine Coolant Temperature EC...

Page 847: ...nd Outlet Air Temperature Sensors Inspection A C evaporator inlet and or outlet air temperature sensor faulty Check A C evaporator inlet and or outlet temperature sensor referring to A C Evaporator In...

Page 848: ...let and Outlet Air Temperature Sensors Inspection Air leaking from cooling unit or air duct Repair as necessary Blower motor faulty Check blower motor referring to Blower Motor Inspection in Section 7...

Page 849: ...se Correction Reference Item Crankshaft Pulley A large rattling noise is heard at idle or sudden acceleration Loosen crankshaft pulley bolt Retighten bolt Condition Possible cause Correction Reference...

Page 850: ...fogger indicator lamp Scan Tool Data Condition Normal Condition Reference Value TEMP CONT SWITCH Each reference value is relative to the position of temperature selector of HVAC control module Max Coo...

Page 851: ...2 Air Flow Selector and or its Circuit Malfunction S3RH0A7214016 Refer to DTC B1522 No 22 Air Flow Selector and or its Circuit Malfunction Air Conditioning System Check S3RH0A7214017 Step Action Yes N...

Page 852: ...namely in a sensor wire harness connector actuator HVAC control module or other part and repair faulty parts Step 5 A C system symptom diagnosis Check any part or system suspected to be a possible cau...

Page 853: ...C compressor drive belt looseness and damage Refer to Compressor Drive Belt Inspection Battery fluid level and corrosion of terminal Connectors of electric wire harness disconnection and friction Fuse...

Page 854: ...G77 16 RED BLK Electric power source 10 0 14 0 V Ignition switch ON G77 17 GRY RED Air flow control actuator DEF 10 0 14 0 V Ignition switch ON Air flow control actuator is working in operation from...

Page 855: ...g temperature 6 Set A C switch to ON position blower speed selector at maximum speed position temperature selector at maximum cool position air flow selector at vent position and air intake selector a...

Page 856: ...fan malfunction Insufficient cooling of condenser Check radiator or condenser cooling fan Dirty or bent condenser fins Insufficient cooling of condenser Clean or repair Compressor malfunction Insuffic...

Page 857: ...e Dirty or bent A C evaporator fins Clean or repair Air leakage from cooling heater unit or air duct Repair or replace Malfunctioning switch over function of door in cooling heater unit Repair or repl...

Page 858: ...5 3 Pressure on low pressure side is high Pressure on high pressure side is low Both pressure becoming equal right after A C is turned OFF Internal leak in compressor Inspect compressor and repair or...

Page 859: ...that the battery voltage is 11 V or more when ignition switch is ON position Terminal arrangement of ECM coupler Viewed from harness side ECM Voltage Values Table for Relation of A C Control I3RH0A721...

Page 860: ...h OFF G04 9 BLU YEL Condenser cooling fan relay output Ground to engine Fig B 0 1 V Fulfill all the following conditions Blower speed selector ON A C or defroster switch ON Engine running Engine coola...

Page 861: ...G03 10 BLU BLK Blower speed input Ground to engine Fig B 10 14 V Ignition switch ON Blower speed selector OFF 1st or 2nd position about 2 0 V Ignition switch ON Blower speed selector between 3rd and H...

Page 862: ...de vehicle including trunk room Avoid breathing fumes produced when HFC 134a R 134a is burned Such fumes may be hazardous to health Recovery When evacuating A C system always recover refrigerant by us...

Page 863: ...mount of compressor oil Evaporator 25 cm3 25 cc Condenser 15 cm3 15 cc Desiccant 20 cm3 20 cc Hoses 10 cm3 10 cc each Pipes 10 cm3 10 cc each Evacuating of A C System CAUTION Do not evacuate before re...

Page 864: ...ng tap valve to refrigerant container to make a hole carefully follow directions given by manufacturer A pressure gauge should always be used before and during charging The refrigerant container shoul...

Page 865: ...frigerant When using refrigerant container tap valve 2 use the following procedure for replacement a Retract needle 3 and remove refrigerant container tap valve 2 by loosening its plate nut 4 b Instal...

Page 866: ...leak detector is more practical for determining leaks Special tool A 09990 86011 Heater and Cooling Unit Components S3RH0A7216003 I2RH01720020 01 10 22 5 1 3 20 6 17 7 7 21 9 16 11 14 6 2 4 15 8 19 14...

Page 867: ...wer unit 1 referring to Blower Unit Removal and Installation in Section 7A 9 Disconnect couplers from the following parts Temperature control actuator Air flow control actuator A C evaporator inlet ai...

Page 868: ...ction S3RH0A7216009 Check the following Clog of condenser fins If any clogs are found condenser fins should be washed with water and should be dried with compressed air Condenser fins for leakage and...

Page 869: ...nt straighten it by using flat head screwdriver or pair of pliers Removal 1 Disconnect negative cable at battery 2 Recover refrigerant from A C system by referring to Operation Procedure for Refrigera...

Page 870: ...S3RH0A7216014 Check the following Clog of A C evaporator fins If any clogs are found A C evaporator fins should be washed with water and should be dried with compressed air Leakage and breakage of A C...

Page 871: ...Charging Evacuate and charge refrigerant by referring to Operation Procedure for Refrigerant Charging Sufficiently apply compressor oil to fitting surface of O ring and pipe Expansion Valve Inspectio...

Page 872: ...00 kPa 32 kg cm2 455 psi E Approx 1100 kPa 11 kg cm2 156 psi F Approx 1500 kPa 15 kg cm2 213 psi Compressor Relay and Condenser Cooling Fan Relay Inspection S3RH0A7216021 1 Disconnect negative cable a...

Page 873: ...NOTE Cap all of the refrigerant line opening immediately to keep moisture out of the system 10 Remove compressor mounting bolts 1 and then remove compressor 2 from its bracket Installation Reverse rem...

Page 874: ...essor body assembly Disassembly will affect original performance of A C system 2 3 4 3 6 7 5 8 1 18 N m 1 8 kg m I2RH01720042 01 1 Armature plate bolt 5 Shim Tightening torque 2 Armature plate 6 Magne...

Page 875: ...armature plate bolt 3 Remove armature plate 1 4 Remove shims from shaft 5 Using special tool remove circlip Special tool A 09900 06107 6 Remove magnet clutch lead wire clamp screw and then remove mag...

Page 876: ...clutch pulley bearing Ensure that edge rests only on inner race of bearing Special tool A 09991 06010 c Install new circlip CAUTION Be careful not to scratch bearing seal 5 Adjust clearance between a...

Page 877: ...mended Service Material S3RH0A7218001 NOTE Required service material is also described in the following Precautions on Servicing A C System Special Tool S3RH0A7218002 Fastening part Tightening torque...

Page 878: ...ervicing A C System General Description A C System Introduction S3RH0A7221001 Automatic air conditioning system is that controller in HVAC control module 1 automatically controls in car temperature fa...

Page 879: ...or Outside air temperature sensor A C evapoator outlet air temperature A C refrigerant pressure switch Temperature selector Air flow selector Blower speed selector Air intake switch A C switch Compres...

Page 880: ...actuator of heater unit Air flow control actuator of heater unit Temperature selector of HVAC control module Blower speed selector of HVAC control module Air flow selector of HVAC control module When...

Page 881: ...N WHT GRY RED GRY BLK BLU BLK GRY BLU GRY PNK YEL RED BLK G77 2 G77 1 G77 24 G77 9 G77 28 G77 26 G77 20 G77 19 G77 12 G77 18 G77 17 G77 22 G77 21 G77 27 G77 10 G77 30 G77 29 G77 11 G77 3 G77 6 G77 5 G...

Page 882: ...ounding ECT sensor faulty Check ECT sensor referring to Engine Coolant Temperature ECT Sensor Inspection in Section 1C ECM and or its circuit faulty Check ECM and or its circuit referring to A C Syste...

Page 883: ...to A C Evaporator Outlet Air Temperature Sensor Inspection Expansion valve faulty Check expansion valve referring to Expansion Valve Inspection Desiccant clogged Check desiccant Compressor drive belt...

Page 884: ...Condenser Assembly Inspection Insufficient charge of refrigerant Check amount of refrigerant charged Air in A C system Replace desiccant and perform evacuation and charging Compressor drive belt loose...

Page 885: ...the following selectors to the specified positions respectively Temperature selector 3 Maximum cool position Air flow selector 4 AUTO position Blower speed selector 5 OFF position 4 Keep air intake s...

Page 886: ...f malfunctions related to temperature selector blower speed selector and or air flow selector on HVAC control module the following procedure can not be used However SUZUKI scan tool can be used to per...

Page 887: ...511 11 1 10 Temperature control actuator position sensor and or its circuit malfunction Short to 5 V electrical power 2 11 Short to ground B1512 12 1 12 Air flow control actuator position sensor and o...

Page 888: ...circulation indicator lamp flashing pattern F Fresh air indicator lamp flashing pattern No 4 d 1 second B DTC No 22 Recirculation indicator lamp flashing pattern G Normal e 1 5 seconds C Fresh air ind...

Page 889: ...175 W m2 B1510 Water temperature sensor and or its circuit 80 C 176 F B1511 Temperature control actuator position sensor and or its circuit The operation of actuator stops B1512 Air flow control actu...

Page 890: ...INDICATOR LAMP ON or OFF State of A C indicator lamp REC INDICATOR LAMP ON or OFF State of recirculation air REC indicator lamp FRE INDICATOR LAMP ON or OFF State of fresh air indicator lamp REAR DEF...

Page 891: ...de Go to Step 4 Go to Step 5 4 Troubleshooting malfunction 1 Perform Troubleshooting malfunction Is there any faulty condition Repair or replace malfunctional part Go to Step 7 Go to Step 5 5 Perform...

Page 892: ...ontrol module or other part and repair faulty parts Step 5 A C system symptom diagnosis Check any part or system suspected to be a possible cause referring to A C System Symptom Diagnosis Step 6 Check...

Page 893: ...mperature is less than 44 C 111 F Outside air temperature signal is more than the specified 3 3 V Outside air temperature is more than 155 C 311 F YEL BLK and or BLK RED wire faulty Outside air temper...

Page 894: ...air temperature is less than 15 C 5 F Inside air temperature signal is more than the specified 3 3 V Inside air temperature is more than 74 C 165 2 F ORN BLK and or BLK RED wire faulty Inside air tem...

Page 895: ...n Trouble Area Signal from A C evaporator temperature sensor is less than the specified 0 7 V A C evaporator temperature is less than 70 C 94 F Signal from A C evaporator temperature sensor is more th...

Page 896: ...10 2 1 3 10 27 I3RH0A722010 01 1 HVAC control module 2 Sunload sensor 3 HVAC control module connector G77 viewed from harness side DTC Detecting Condition Trouble Area Signal from sunload sensor is l...

Page 897: ...re than 1 M Poor connection of YEL wire terminal at HVAC control module connector and or HVAC control module faulty YEL wire shorted to ground 6 1 Check resistance between PNK wire terminal and YEL wi...

Page 898: ...scope Is waveform as shown in figure above Poor connection of YEL GRN wire terminal at HVAC control module connector and or HVAC control module faulty Go to Step 3 3 1 Disconnect HVAC control module c...

Page 899: ...and body ground Is voltage about 5 V Go to Step 4 Go to Step 2 2 1 Turn ignition switch OFF and then disconnect HVAC control module connector referring to HVAC Control Module Removal and Installation...

Page 900: ...actuator faulty Step Action Yes No 5V 5V RED WHT WHT BLU BLK RED G77 9 G77 12 G77 26 2 1 3 9 12 26 I3RH0A722014 01 1 HVAC control module 2 Air flow control actuator 3 HVAC control module connector G77...

Page 901: ...to Step 8 Go to Step 6 6 1 Turn ignition switch OFF disconnect HVAC control module connector referring to HVAC Control Module Removal and Installation in Section 7A 2 Check resistance between WHT BLU...

Page 902: ...ernal fault of heater and cooling unit Go to Step 2 2 1 Turn ignition switch OFF and then disconnect temperature control actuator connector referring to Temperature Control Actuator Removal and Instal...

Page 903: ...ector Is resistance less than 1 M Go to Step 3 RED WHT wire open or high resistance poor connection of RED WHT wire terminal at HVAC control module connector and or HVAC control module faulty 3 1 With...

Page 904: ...ED WHT WHT BLU and or BLK RED wire faulty Linkage faulty Heater and cooling unit faulty Air flow control actuator faulty HVAC control module faulty Step Action Yes No 1 1 Check if there is any obstruc...

Page 905: ...r connector and body ground Is voltage about 5 V Go to Step 3 Go to Step 2 2 1 Turn ignition switch OFF and then disconnect HVAC control module connector referring to HVAC Control Module Removal and I...

Page 906: ...stallation in Section 7A Inspection of HVAC Control Module and its Circuit S3RH0A7224023 HVAC control module and its circuits can be checked at HVAC control module wiring couplers by measuring voltage...

Page 907: ...ic power source for sunload sensor about 5 0 V Ignition switch ON G77 11 ORN BLK Inside air temperature sensor about 2 5 V Room temperature 25 C 77 F about 2 0 V Room temperature 10 C 50 F G77 12 WHT...

Page 908: ...tor and Temperature control actuator about 5 0 V Ignition switch ON G77 27 YEL Sunload sensor G77 28 WHT Temperature control actuator position sensor about 4 0 V Ignition switch ON Temperature selecto...

Page 909: ...age is affected by the battery voltage confirm that the battery voltage is 11 V or more when ignition switch is ON position Terminal arrangement of ECM coupler Viewed from harness side ECM Voltage Val...

Page 910: ...ndenser fan control pressure switch input Ground to engine Fig B 0 5 0 5 V Radiator cooling fan control pressure of A C refrigerant pressure switch ON 12 15 V Radiator cooling fan control pressure of...

Page 911: ...g tab and pushing sensor upward from underneath 3 Disconnect sunload sensor connector 2 Installation Reverse removal procedure for installation 18 5 1 3 20 6 17 9 10 16 14 6 2 4 15 8 19 14 6 12 13 7 1...

Page 912: ...installation Outside Air Temperature Sensor Inspection S3RH0A7226014 Use an ohmmeter to check resistance of outside air temperature sensor If check result is not satisfactory replace outside air tempe...

Page 913: ...and Installation Condenser Cooling Fan Inspection S3RH0A7226026 Refer to Condenser Cooling Fan Inspection A C Evaporator Removal and Installation S3RH0A7226027 Refer to A C Evaporator Removal and Inst...

Page 914: ...ve Belt Removal and Installation S3RH0A7226036 Refer to Compressor Drive Belt Removal and Installation Compressor Drive Belt Inspection S3RH0A7226037 Refer to Compressor Drive Belt Inspection Compress...

Page 915: ...c System Check 8B 12 Air Bag Diagnostic System Check Flow 8B 13 DTCs Description 8B 14 DTC Table 8B 14 DTC Check 8B 17 DTC Clearance 8B 18 Scan Tool Data 8B 19 Scan Tool Data Definition 8B 19 AIR BAG...

Page 916: ...3 B1087 Side Air Bag Driver Passenger Side Initiator Circuit Short to Ground 8B 89 DTC B1084 B1088 Side Air Bag Driver Passenger Side Initiator Circuit Short to Power Circuit 8B 93 Repair Instructions...

Page 917: ...autions on Service and Diagnosis of Seat Belt in Section 8A Precautions on Service and Diagnosis of Air Bag System Refer to Precautions on Service and Diagnosis of Air Bag System in Section 8B Precaut...

Page 918: ...uld be normal relative to strap retractor and buckle portions Keep sharp edges and damaging objects away from belts Avoid bending or damaging any portion of belt buckle or latch plate Do not bleach or...

Page 919: ...ont seat belt 8 Buckle for rear seat belt B For wagon model with 3 point rear center seat belt 4 Label for seat belt pretensioner 9 Rear center seat belt C For all model with 2 point rear center seat...

Page 920: ...pact at the front of vehicle exceeds the specified value When servicing seat belt retractor assembly with pretensioner be sure to observe all WARNINGS and CAUTIONS and Precautions on Service and Diagn...

Page 921: ...of Seat Belt before starting to work and observe every precaution during work Neglecting them may result in personal injury or unactivation of the seat belt pretensioner when necessary I3RH01810002 01...

Page 922: ...oner securely If seat belt pretensioner is equipped a Connect connector b Lock connector with lock slider 2 Enable air bag system Refer to Enabling Air Bag System in Section 8B If seat belt pretension...

Page 923: ...sembly 1 with seat belt pretensioner appearance visually for following symptoms and if any one of them is applicable replace it with a new one as an assembly If seat belt pretensioner is equipped Pret...

Page 924: ...5 N m 3 5 kg m 35 N m 3 5 kg m 35 N m 3 5 kg m 35 N m 3 5 kg m 5 5 N m 0 55 kg m 35 N m 3 5 kg m 35 N m 3 5 kg m 2 5 3 4 1 7 10 8 7 8 10 9 6 8 I3RH0A810002 01 A For sedan model E For wagon model equip...

Page 925: ...pull it It should not be pulled out that is it should be locked where retracted Let seat belt retract to its original state Next pull it half way out let it retract a little and try to pull it again...

Page 926: ...arning lamp operation and will lead you to the correct table to diagnose any air bag malfunctions Bypassing these procedures may result in extended diagnostic time incorrect diagnosis and incorrect pa...

Page 927: ...s necessary when handling and storing a live undeployed air bag inflator modules The rapid gas generation produced during deployment of the air bag could cause the air bag inflator module or an object...

Page 928: ...le Otherwise personal injury may result WARNING When placing a live air bag inflator module on bench or other surface always face the bag up away from the surface As the live passenger air bag inflato...

Page 929: ...e ambient temperature below 65 C 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wire or connector of the pretensioner When placing a live seat b...

Page 930: ...en disposal is necessary be sure to deploy activate the air bag and seat belt pretensioner according to deployment activation procedure described in Air Bag Inflator Module and Seat Belt Pretensioner...

Page 931: ...ssenger seat in occurrence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts Side air bag 3 inflator mod...

Page 932: ...0 18 DS DS L73 15 RED BLK RED YEL L70 20 L70 21 PS PS L74 16 11 10 9 L70 G20 20 SP SP 12V 12V 12V 12V 12V G21 L28 L81 8 PPL L79 I3RH0A820008 01 A Shorting bar 7 Data link connector DLC 14 Passenger se...

Page 933: ...25 L70 7 L70 26 Driver air bag inflator module Low L70 8 Diagnosis switch L70 27 High L70 9 L70 28 Data link connector DLC L70 10 L70 29 L70 11 L70 30 AIR BAG warning lamp L70 12 L70 31 Ground L70 13...

Page 934: ...TOR L70 CONECTOR L72 G28 CONECTOR L35 11 CONECTOR L83 G46 CONECTOR L80 G14 12 I3RH0A820010 01 1 Air bag harness in floor harness 5 Driver air bag inflator module 9 Ground for air bag system 2 Air bag...

Page 935: ...Activation Component Replacement When driver and passenger air bags are deployed the following components must be replaced Driver and passenger air bag inflator modules Driver and passenger seat belt...

Page 936: ...k connector for damage or tightness Seat belts and mounting points Refer to Front Seat Belt Components in Section 8A AIR BAG warning lamp After vehicle is completely repaired perform Air Bag Diagnosti...

Page 937: ...t such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equipment other than that specified in this manual Do not use a non powered probe type tester Instructions in...

Page 938: ...to AIR BAG Warning Lamp Does Not Come ON 2 Does AIR BAG warning lamp come ON steady Proceed to AIR BAG Warning Lamp Comes ON Steady Go to Step 3 3 Does AIR BAG warning lamp keep flashing indicating D...

Page 939: ...isplayed on SUZUKI scan tool Substitute a known good SDM and recheck Check and repair according to flow corresponding to that DTC 10 1 Check DTC using monitor coupler referring to DTC Check Is flashin...

Page 940: ...B1058 58 Frontal crash detected pretensioner activation command outputted B1061 61 AIR BAG warning lamp circuit Circuit failure B1063 63 Side sensor circuit driver side Short to ground B1064 64 Short...

Page 941: ...r passenger side Internal fault B1075 75 Side sensor circuit passenger side Correspondence abnormality B1081 81 Side air bag circuit driver side Resistance high B1082 82 Resistance low B1083 83 Short...

Page 942: ...t 5 After completing the check turn ignition switch to OFF position and disconnect SUZUKI scan tool from data link connector DLC 1 Not using SUZUKI Scan Tool 1 Check that malfunction indicator lamp AI...

Page 943: ...Perform DTC Check and confirm that normal DTC NO CODES is displayed and not malfunction DTC NOTE If DTC B1051 B1058 or B1071 is stored in SDM it is not possible to clear it Not using SUZUKI scan tool...

Page 944: ...it Driv Preten Ini Res OHMS This parameter indicates the resistance of the driver s seat belt pretensioner initiator circuit Pass Preten Ini Res OHMS This parameter indicates the resistance of the pas...

Page 945: ...ector and SDM Step 4 Check for power supply circuit Step 5 Check for short circuit between AIR BAG warning lamp circuit and ground Troubleshooting Step Action Yes No 1 1 Ignition switch turn to OFF po...

Page 946: ...Measure resistance between L70 30 terminal and body ground Special tool A 09932 76010 Is resistance infinity Substitute a known good SDM and recheck Clear up short circuit between YEL RED wire and gro...

Page 947: ...amp blown Step 3 Check for open circuit in AIR BAG warning lamp circuit Step 4 Check for short circuit between AIR BAG warning lamp circuit and power supply circuit Troubleshooting Step Action Yes No...

Page 948: ...terminal inserting release tool A 4 Check continuity between G21 14 and L70 30 terminals Special tool A 09932 76010 Is there any continuity Go to Step 4 Clear up open circuit in YEL RED wire 4 1 With...

Page 949: ...low Test Description Step 1 Check for connection between diagnosis switch terminal and ground terminal by service wire Step 2 Check for short circuit between diagnosis switch circuit and ground Troubl...

Page 950: ...1 and body ground Special tool A 09932 76010 Is resistance infinity Substitute a known good SDM and recheck Repair short from PPL wire circuit to ground Step Action Yes No A L70 8 1 I2RH01820018 01 1...

Page 951: ...bleshooting NOTE Upon completion of inspection and repair work perform the following items Reconnect all air bag system components ensure all components are properly mounted Repeat Air Bag Diagnostic...

Page 952: ...found damaged replace the wire harness connector and terminal as an assembly Flow Test Description Step 1 An improper connection to the data link connector DLC will prevent communications from being e...

Page 953: ...control module Go to Step 3 Repair open in common section of serial data circuit BLU wire circuit used by all controllers or short to ground or power circuit which has occurred some where in serial da...

Page 954: ...kit When a check for proper connection is required refer to Inspection of Intermittents and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damage...

Page 955: ...onnector L35 3 If OK then connect Special Tool A B and C to passenger air bag inflator module connector L35 disconnected at the step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78340 With ignit...

Page 956: ...has been corrected 2 1 With ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at L70 24 and L70 23 terminals 3 If OK then measure resistance between L70 24 and L70 23 termi...

Page 957: ...en circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The combined resistance of the passenger...

Page 958: ...connector L35 3 If OK then connect Special Tool A B and C to passenger air bag inflator module connector disconnected at the Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78340 With ignitio...

Page 959: ...ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at L70 24 and L70 23 terminals 3 If OK then measure resistance between L70 24 and L70 23 terminals with connected Special...

Page 960: ...d terminal as an assembly NOTE If vehicle is equipped with driver or passenger side air bag ON OFF switch perform Air Bag Diagnostic System Check Flow with disconnecting air bag ON OFF switch from air...

Page 961: ...inals in connector L35 3 If OK then connect Special Tool A B and C to passenger air bag inflator module connector L35 disconnected at the Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78340...

Page 962: ...04017 Wiring Diagram 2 1 With ignition switch OFF disconnect Special Tool A B C and SDM connector L70 2 Measure resistance between L70 24 terminal and body ground and between L70 23 terminal and body...

Page 963: ...s in passenger air bag inflator module Step 2 Check passenger air bag inflator module initiator circuit in air bag harness Step 3 Check passenger air bag inflator module initiator circuit in air bag h...

Page 964: ...is voltage 0 1 V Go to Step 3 Repair short from YEL GRN wire circuit to power circuit 3 1 Measure voltage from L70 23 terminal to body ground Special tool A 09932 76010 With ignition switch ON is vol...

Page 965: ...red refer to Inspection of Intermittents and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and termina...

Page 966: ...se of the steering column 2 Check proper connection to contact coil at terminals in connector L28 3 If OK then connect Special Tool B and C to contact coil connector L28 disconnected at Step 1 Special...

Page 967: ...K then measure resistance between L70 27 and L70 26 terminals with connected Special Tool B and C Special tool A 09932 76010 B 09932 75010 C 09932 78340 Is resistance 3 4 or less Substitute a known go...

Page 968: ...d Installation 3 Check proper connection to driver air bag inflator module at terminals in connector L81 4 If OK then connect Special Tool A B and C to connector L81 Special tool A 09932 76010 B 09932...

Page 969: ...ontact coil assembly harness wiring and connector terminal contact is below a specified value for specified time Flow Test Description Step 1 Check whether malfunction is in contact coil and driver ai...

Page 970: ...etween L70 27 and L70 26 terminals with connected Special Tool B and C Special tool A 09932 76010 B 09932 75010 C 09932 78340 Is resistance 2 0 or more Substitute a known good SDM and recheck Repair s...

Page 971: ...and Installation 3 Check proper connection to driver air bag inflator module at terminals in connector L81 4 If OK then connect Special Tool B and C to connector L81 Special tool A 09932 76010 B 09932...

Page 972: ...ver air bag initiator circuit is below a specified value for specified time Flow Test Description Step 1 Check whether malfunction is in contact coil and driver air bag inflator module or the others S...

Page 973: ...between L70 27 terminal and body ground and between L70 26 terminal and body ground Special tool A 09932 76010 B 09932 75010 C 09932 78340 Are they infinity Substitute a known good SDM and recheck Rep...

Page 974: ...al and Installation 3 Check proper connection to driver air bag inflator module at terminals in connector L81 4 If OK then connect Special Tool B and C to connector L81 Special tool A 09932 76010 B 09...

Page 975: ...ver air bag initiator circuit is above a specified value for specified time Flow Test Description Step 1 Check whether malfunction is in contact coil and driver air bag inflator module or the others S...

Page 976: ...to body ground and from L70 26 terminal to body ground Special tool A 09932 76010 B 09932 75010 C 09932 78340 With ignition switch ON are they 0 1 V Substitute a known good SDM and recheck Repair shor...

Page 977: ...ng to Driver Air Bag Inflator Module Removal and Installation 3 Check proper connection to driver air bag inflator module at terminals in connector L81 4 If OK then connect Special Tool B and C to con...

Page 978: ...C Troubleshooting NOTE Upon completion of inspection and repair work perform the following items Reconnect all air bag system components ensure all components are properly mounted Clear diagnostic tro...

Page 979: ...ound damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The power source voltage is below an approx 8 V for specified time Flow Test Description Step 1 Check if v...

Page 980: ...r G14 1 in instrument panel harness 2 Check proper connection at G14 3 RED wire terminal 3 If OK then ignition switch ON and then check voltage from G14 3 RED wire terminal to body ground Special tool...

Page 981: ...pen circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The resistance of driver or passenger se...

Page 982: ...t terminals in connector L75 or L76 3 If OK then connect Special Tool A B and C to seat belt pretensioner connector disconnected at the Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78310 Wi...

Page 983: ...a DTC B1041 between L70 33 and L70 34 terminals Special tool A 09932 76010 b DTC B1045 between L70 36 and L70 35 terminals Special tool A 09932 76010 Is resistance 2 5 or less Substitute a known good...

Page 984: ...special tool Connector test adapter kit When a check for proper connection is required refer to Inspection of Intermittents and Poor Connections If there is open circuit in the air bag wire harness c...

Page 985: ...t terminals in connector L75 or L76 3 If OK then connect Special Tool A B and C to seat belt pretensioner connector disconnected at the Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78310 Wi...

Page 986: ...erminals 3 If OK then measure resistance with connected Special Tool B Special tool A 09932 76010 B 09932 75010 C 09932 78310 a DTC B1042 between L70 33 and L70 34 terminals b DTC B1046 between L70 36...

Page 987: ...open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at driver or pass...

Page 988: ...t terminals in connector L75 or L76 3 If OK then connect Special Tool A B and C to seat belt pretensioner connector disconnected at the Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78310 Wi...

Page 989: ...round Special tool A 09932 76010 b DTC B1047 between L70 36 terminal and body ground and between L70 35 terminal and body ground Special tool A 09932 76010 Is resistance infinity Substitute a known go...

Page 990: ...m special tool Connector test adapter kit When a check for proper connection is required refer to Inspection of Intermittents and Poor Connections If there is open circuit in the air bag wire harness...

Page 991: ...tensioner at terminals in connector L75 or L76 3 If OK then connect Special Tool A B and C to seat belt pretensioner connector disconnected at the Step 1 Special tool A 09932 76010 B 09932 75010 C 099...

Page 992: ...A 09932 76010 b DTC B1048 between L70 36 terminal and body ground and between L70 35 terminal and body ground Special tool A 09932 76010 With ignition switch ON is voltage 0 1 V Substitute a known go...

Page 993: ...s ensure all components are properly mounted Repeat Air Bag Diagnostic System Check to confirm that the trouble has been corrected DTC B1056 B1057 Sideward Crash Driver Passenger Side Detected Side Ai...

Page 994: ...ir work perform the following items Reconnect all air bag system components ensure all components are properly mounted Repeat Air Bag Diagnostic System Check to confirm that the trouble has been corre...

Page 995: ...ep 1 This test rechecks AIR BAG warning lamp operation Step 2 This test rechecks whether an abnormality is in SDM DTC Troubleshooting 1 2 3 4 GRN GRN BLK RED YEL RED YEL RED RED RED BLU BLU 5 8 9 PPL...

Page 996: ...al Tool along with a correct terminal adapter from special tool Connector test adapter kit When a check for proper connection is required refer to Inspection of Intermittents and Poor Connections If t...

Page 997: ...r connector 2 Disconnect SDM connector L70 3 Check proper connection to applicable side sensor at terminals in L77 or L78 connector 4 If OK measure resistance a DTC B1063 between L70 17 terminal and b...

Page 998: ...onnections If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage meas...

Page 999: ...ector 4 If OK measure resistance a DTC B1064 between L77 1 and L70 17 terminals and between L77 2 and L70 6 terminals Special tool A 09932 76010 b DTC B1066 between L78 1 and L70 16 terminals and betw...

Page 1000: ...64 between L70 17 terminal and body ground and between L70 6 terminal and body ground Special tool A 09932 76010 b DTC B1066 between L70 16 terminal and body ground and between L70 5 terminal and body...

Page 1001: ...sor Driver Passenger Side Correspondence Abnormality S3RH0A8204038 Wiring Diagram CAUTION Be sure to perform Air Bag Diagnostic System Check before starting diagnosis according to flow table When meas...

Page 1002: ...terminals in L77 or L78 connector 3 If OK measure resistance a DTC B1073 between L77 1 and L70 17 terminals and between L77 2 and L70 6 terminals Special tool A 09932 76010 b DTC B1075 between L78 1 a...

Page 1003: ...1075 Measure resistance between L70 16 and L70 5 terminals Special tool A 09932 76010 Is resistance infinity Go to Step 3 DTC B1073 Repair short from GRN WHT wire to GRN BLK wire DTC B1075 Repair sho...

Page 1004: ...ure resistance between L70 16 terminal and body ground and between L70 5 terminal and body ground Special tool A 09932 76010 Is resistance infinity Go to Step 4 DTC B1073 Repair short from GRN WHT or...

Page 1005: ...rected 4 DTC B1073 Measure voltage from L70 17 and L70 6 terminals to body ground Special tool A 09932 76010 DTC B1075 Measure voltage from L70 16 and L70 5 terminals to body ground Special tool A 099...

Page 1006: ...e harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The combined resistance of the side air bag inflator module driver or...

Page 1007: ...eck proper connection to applicable side air bag inflator module at terminals in L73 or L74 connector 3 If OK then connect Special tool B and C to side air bag inflator module connector disconnected a...

Page 1008: ...B1081 between L70 19 and L70 18 terminals Special tool A 09932 76010 b DTC B1085 between L70 20 and L70 21 terminals Special tool A 09932 76010 Is resistance 2 8 or less Substitute a known good SDM a...

Page 1009: ...tor module connector 1 from side air bag inflator module 3 Check proper connection to side air bag inflator module at terminal in connector 4 If OK then connect Special Tool A B and C to connector Spe...

Page 1010: ...e harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The combined resistance of the side air bag inflator module driver or...

Page 1011: ...eck proper connection to applicable side air bag inflator module at terminals in L73 or L74 connector 3 If OK then connect Special tool B and C to side air bag inflator module connector disconnected a...

Page 1012: ...9932 76010 b DTC B1086 between L70 20 and L70 21 terminals Special tool A 09932 76010 Is resistance 1 8 or more Substitute a known good SDM and recheck DTC B1082 Repair short from WHT RED wire circuit...

Page 1013: ...Check proper connection to side air bag inflator module at terminal in connector 4 If OK then connect Special Tool A B and C to connector Special tool A 09932 76010 B 09932 75010 C 09932 78310 With ig...

Page 1014: ...circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at side air bag driver...

Page 1015: ...eck proper connection to applicable side air bag inflator module at terminals in L73 or L74 connector 3 If OK then connect Special tool B and C to side air bag inflator module connector disconnected a...

Page 1016: ...cial tool A 09932 76010 b DTC B1087 between L70 20 terminal and body ground and between L70 21 terminal and body ground Special tool A 09932 76010 Is resistance infinity Substitute a known good SDM an...

Page 1017: ...ect side air bag inflator module connector 1 from side air bag inflator module 3 Check proper connection to side air bag inflator module at terminal in connector 4 If OK then connect Special Tool A B...

Page 1018: ...en circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at side air bag driv...

Page 1019: ...eck proper connection to applicable side air bag inflator module at terminals in L73 or L74 connector 3 If OK then connect Special tool B and C to side air bag inflator module connector disconnected a...

Page 1020: ...6010 b DTC B1088 between L70 20 terminal and body ground and between L70 21 terminal and body ground Special tool A 09932 76010 With ignition switch ON is voltage 0 1 V Substitute a known good SDM and...

Page 1021: ...r module pull out glove box while pushing its stopper from both right and left sides and disconnect yellow connector 4 of passenger air bag inflator module as follows a Release locking of lock slider...

Page 1022: ...d does not indicate air bag system malfunction Enabling Air Bag System S3RH0A8206002 1 Confirm that battery negative cable is disconnected 2 Turn ignition switch to LOCK position and remove key 3 Conn...

Page 1023: ...SDM Removal and Installation S3RH0A8206003 WARNING During service procedures be very careful when handling a Sensing and Diagnostic Module SDM Be sure to read Precautions on Service and Diagnosis of...

Page 1024: ...handling a Sensing and Diagnostic Module SDM Be sure to read Precautions on Service and Diagnosis of Air Bag System before starting to work and observe every precaution during work Neglecting them may...

Page 1025: ...and side sensor 2 from under body 3 6 Disconnect side sensor connector sliding connector outer 1 as shown Installation CAUTION Proper operation of side sensor requires sensor be rigidly attached to sp...

Page 1026: ...n personal injury or undeployment of the air bag when necessary Removal 1 Disconnect negative battery cable at battery terminal 2 Disable air bag system Refer to Disabling Air Bag System 3 Loosen driv...

Page 1027: ...pair the driver air bag inflator module If any abnormality is found be sure to replace it with new one as an assembly Be sure to read Precautions on Service and Diagnosis of Air Bag System before star...

Page 1028: ...val and Installation in Section 7A 3 Disconnect passenger air bag inflator module connector 1 as shown in the figure a Unlock lock button 2 b With lock button unlocked disconnect connector 4 Remove pa...

Page 1029: ...any abnormality is found be sure to replace it with new one as an assembly Be sure to read Precautions on Service and Diagnosis of Air Bag System before starting to work and observe every precaution...

Page 1030: ...w 1 of side air bag inflator module on installation hole 2 b Tighten side air bag inflator module mounting bolt to specified torque c Install side air bag inflator module cover Tightening torque Side...

Page 1031: ...hicle will be destroyed or salvaged for component parts deploy the air bag modules and or activate seat belt pretensioners installed on vehicle WARNING The following precautions must be observed for t...

Page 1032: ...lation Side Air Bag Inflator Module Removal and Installation or Front Seat Belt Removal and Installation in Section 8A WARNING For handing and storage of live air bag inflator module select place wher...

Page 1033: ...are within deployment area ii Place driver air bag inflator module 1 with its vinyl trim cover facing up 2 on ground in step i b For passenger air bag inflator module i Clear space 3 on ground about 1...

Page 1034: ...bolt nut 2 NOTE Make sure that deploying direction faces as shown in figure against mounting attachment CAUTION Be sure to use M8 size and 7T strength bolt and nut for fixing side air bag inflator mod...

Page 1035: ...ver air bag inflator module is resting with its vinyl trim cover facing up and connect adapter cable B to driver air bag inflator module b For passenger air bag inflator module Verify that passenger a...

Page 1036: ...of cornstarch used to lubricate bag inflator as it inflates and by products of chemical reaction WARNING Do not place deployed air bag inflator module and activated seat belt pretensioner near any fla...

Page 1037: ...Remaining steps are to be followed in the unlikely event that air bag inflator module did not deploy or seat belt pretensioner did not activate 22 Ensure that deployment harness has been disconnected...

Page 1038: ...r by fully seating one banana plug into the other WARNING Deployment harness A shall remain shorted and not be connected to 12 volts vehicle battery until you are ready to deploy air bag inflator modu...

Page 1039: ...e or activate seat belt pretensioner NOTE When air bag inflator module deploys or seat belt pretensioner activates rapid gas expansion will create substantial report Wear suitable ear protection Notif...

Page 1040: ...designed to be reused However it should be inspected for damage after deployment and replaced if necessary 23 With air bag inflator modules deployed and seat belt pretensioners activated vehicle may...

Page 1041: ...after handling it Specifications Tightening Torque Specifications S3RH0A8207001 Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section...

Page 1042: ...inflator module when it is connected to the air bag harness connector in floor harness for passenger air bag inflator module Each of driver and passenger seat belt pretensioners when it is connected...

Page 1043: ...et Deployment adapter cable This set includes the following items 1 Connector test adapter kit 09932 75020 2 Connector test adapter shorting bar release tool 09932 76020 09932 78310 09932 78332 Adapte...

Page 1044: ...8B 119 Air Bag System...

Page 1045: ...ircuit Diagram 9A 42 System Circuit Diagram 9A 42 A 1 Cranking System Circuit Diagram 9A 43 A 2 Charging System Circuit Diagram 9A 44 A 3 Ignition System Circuit Diagram 9A 45 A 4 Cooling System Circu...

Page 1046: ...6 Headlight Aiming Adjustment with Screen 9B 6 Headlight Switch in Lighting Switch Removal and Installation 9B 7 Headlight Switch in Lighting Switch Inspection 9B 8 Headlight Leveling Switch If Equip...

Page 1047: ...pection 9D 7 Rear Wiper Intermittent Relay Removal and Installation 9D 7 Rear Wiper Intermittent Relay Inspection 9D 7 Glass Windows Mirrors 9E 1 General Description 9E 1 Windshield Construction 9E 1...

Page 1048: ...t Removal and Installation 9G 4 Seat Heater Switch Driver and Passenger Side Inspection 9G 5 Seat Heater Wire Inspection 9G 5 Specifications 9G 6 Tightening Torque Specifications 9G 6 Interior Trim 9H...

Page 1049: ...Table of Contents 9 v Roof Molding Components 9M 1 Splash Guard If Equipped Components 9M 2...

Page 1050: ...stem in Section 9A Precautions for Body Service S3RH0A9000002 WARNING For vehicles equipped with a Supplemental Restraint Air Bag System When servicing vehicle body if shock may be applied to air bag...

Page 1051: ...n switch and all other switches 2 disconnect the negative terminal wire and then 3 disconnect the positive terminal wire Connect the wires in the reverse order of disconnecting When disconnecting the...

Page 1052: ...ehicles IND Indicator A B Air bag INT Intermittent A C Air conditioning ISC Idle speed control A T Automatic transaxle J B Junction fuse block ACC Accessory J C Joint connector BCM Body control module...

Page 1053: ...r Motor Pump Horn Speaker Buzzer Chime Condenser Thermistor Reed switch Resistance Variable resistance Transistor NPN PNP Abbreviation Full term Abbreviation Full term GRN Base color GRN Base color YE...

Page 1054: ...nger side Driver side Seat heater A C Power steering Side air bag R IYSQ01910939 01 IYSQ01910940 01 IYSQ01910941 01 IYSQ01910942 01 IYSQ01910943 01 IYSQ01910944 01 IYSQ01910945 01 IYSQ01910946 01 IYSQ...

Page 1055: ...indow K Interior light harness Rear speaker wire Roof wire L Floor harness G sensor wire Fuel pump harness M Rear bumper harness O Rearend door harness Q Air bag Pretensioner harness R Fuel pump wire...

Page 1056: ...or shape and terminal layout shown in this manual are those when viewed from Z in the illustration Refer to List of Connector 2 Connector type A40 View Z View Z 1 1 2 3 4 5 6 7 8 2 3 4 5 6 7 8 D18 5 D...

Page 1057: ...at one place instead of connecting them by welding or caulking one by one It is not an ordinary connector but a part of the continuous wire in the harness 5 Connector location shape and terminal No Re...

Page 1058: ...onnector shape and terminal position C02 C02 C02 C02 C02 C02 I2RH01910906 01 Left side shown 10 11 12 SYSTEM CIRCUIT DIAGRAM GROUND POINT CROSS REFERENCE Windoshield washer motor Individual circuit fu...

Page 1059: ...th opposite direction within the page You will find the other symbol in the direction of the arrow D Terminals in one connector mark E Wire color F Shield wire G Ground point H From or To With ID lett...

Page 1060: ...Rear for Connector Layout Diagram Switch BLU BLU GRN BLK GRN RED GRN BLK 1 2 GRN GRN C26 2 1 BLK 5 BLK 2 1 C40 GRN BLK XX Solenoid Fuse Fuse 3 15A Main relay ON OFF 1 15A 6 20A 1 Sensor 1 2 8 BRN RED...

Page 1061: ...1 C21 C26 C25 C24 C37 C30 C22 C17 C40 C36 C35 C27 C39 C34 C29 4 2 1 3 C38 C28 C20 C23 C32 C44 C11 C18 C19 C31 C16 C05 C03 C02 C01 C41 C07 I3RH0A910956 01 5 3 4 2 1 C10 TO E07 C43 TO G02 C42 TO G01 C09...

Page 1062: ...Y A T Output shaft speed sensor C34 Generator C13 BLK A T Input sensor C35 GRY IAC valve C14 GRY A T Shift solenoid C36 BLK Generator C15 GRY A T Transmission range sensor C37 GRY Knock sensor C16 N P...

Page 1063: ...pump relay C30 N Oil pressure switch C09 BLK Condenser fan relay C31 BLK Compressor C10 GRY Main harness To E07 C32 N Heated oxygen sensor 1 C11 BLK M T Back up light switch C34 Generator C12 GRY A T...

Page 1064: ...motor E39 N Side turn signal light R E05 BLK Rear washer motor E40 N Wheel speed sensor FR E06 GRY or BLK Radiator fan motor E41 GRY Condenser fan motor E07 GRY Engine harness To C10 E42 BLK Horn E08...

Page 1065: ...gnal light L E38 GRY Brake fluid level switch E03 N Front position light L E39 N Side turn signal light R E04 N Windshield Screen washer motor E40 N Wheel speed sensor FR E05 BLK Rear washer motor E41...

Page 1066: ...G27 E32 E69 E25 E26 E24 E23 E68 E29 E28 E27 E72 E70 E65 TO G76 E67 E66 TO G75 I3RH0A910962 01 No Color Connective position No Color Connective position E23 YEL Mode actuator E35 BLU Instrument panel h...

Page 1067: ...fan motor E36 N Instrument panel harness To G27 E25 BLK Blower motor relay E37 N Instrument panel harness To G28 E26 BLK Blower motor relay HI E65 N Instrument panel harness To G76 E27 N Thermistor IN...

Page 1068: ...ECM G39 BLK Combination switch G04 N ECM G40 N Combination switch G05 BLU Diagnosis connector 2 G43 GRY or BRN EU Front fog light switch G06 N Diagnosis connector 1 G44 GRY or BLK Headlight leveling...

Page 1069: ...G26 BLU Main harness To E35 G82 N 5 dr type 4 4 dr type 3 Cigar lighter harness To G81 G27 N Main harness To E36 G83 N 5 dr type 4 Cigar lighter G28 N Main harness To E37 G84 N 5 dr type 4 4 dr type...

Page 1070: ...3 N ECM G44 GRY or BLK Headlight leveling switch G04 N ECM G45 N ICM G05 BLU Diagnosis connector 2 G46 YEL Floor harness To L83 G06 N Diagnosis connector 1 G47 N Rear fog light controller G07 GRY A T...

Page 1071: ...G28 N Main harness To E37 G82 N 5 dr type 4 4 dr type 3 Cigar lighter harness To G81 G29 BLK Power window fuse G83 N 5 dr type 4 4 dr type 3 Cigar lighter G32 BLK Head Tail light relay G84 N 5 dr type...

Page 1072: ...ck motor Driver side J06 N Power window main switch J29 BLK 5 dr type 4 4 dr type 3 Power mirror switch No Color Connective position No Color Connective position J10 N Floor harness To L36 J14 N Front...

Page 1073: ...main switch J29 BLK 5 dr type 4 4 dr type 3 Power mirror switch No Color Connective position No Color Connective position J02 N Front speaker R J14 N Front power window sub switch J10 N Floor harness...

Page 1074: ...peaker L L02 BLU Main harness To E33 L45 BLK Rear combination light L L05 N Instrument panel harness To G49 L70 YEL A B SDM L06 N or GRN Heated oxygen sensor 2 L71 YEL Resister wire To L37 L07 N Instr...

Page 1075: ...6 N Front door wire To J10 L101 N 5 dr type 4 4 dr type 3 Front door switch Driver side L40 N 5 dr type 1 3 4 dr type 1 2 Front door switch Passenger side L102 N 5 dr type 4 4 dr type 3 Rear door swit...

Page 1076: ...L Side air bag inflator Passenger side L06 N or GRN Heated oxygen sensor 2 L75 YEL Pretensioner Driver side L07 N Instrument panel harness To G33 L76 YEL Pretensioner Passenger side L08 GRY Instrument...

Page 1077: ...dr type 3 Front door switch Driver side L44 BLK Rear speaker L L102 N 5 dr type 4 4 dr type 3 Rear door switch R L45 BLK or N Rear combination light L L103 N 5 dr type 4 4 dr type 3 Front door switch...

Page 1078: ...ire To J01 L41 N Rear door wire To J21 L02 BLU Main harness To E33 L42 N Wheel speed sensor RL L05 N Instrument panel harness To G49 L43 N 5 dr type 1 3 4 dr type 1 2 Rear door switch L L06 N or GRN H...

Page 1079: ...r harness To O13 L30 YEL Seat heater switch R L98 N 5 dr type 4 4 dr type 3 Woofer L31 GRN Seat heater switch L L100 N 5 dr type 4 4 dr type 3 Accessories socket L32 N Parking brake switch L101 N 5 dr...

Page 1080: ...air bag inflator Driver side L06 N or GRN Heated oxygen sensor 2 L74 YEL Side air bag inflator Passenger side L07 N Instrument panel harness To G33 L75 YEL Pretensioner Driver side L08 GRY Instrument...

Page 1081: ...ccessories socket L42 N Wheel speed sensor RL L101 N 5 dr type 4 4 dr type 3 Front door switch Driver side L43 N 5 dr type 1 3 4 dr type 1 2 Rear door switch L L102 N 5 dr type 4 4 dr type 3 Rear door...

Page 1082: ...e 3 A A I3RH0A910972 02 No Color Connective position No Color Connective position O01 BLU Floor harness To L21 O07 N Rear defogger O02 N Floor harness To L22 O08 N Rearend door lock motor lock switch...

Page 1083: ...ss M06 M04 M03 M02 M05 M01 TO L91 I3RH0A910973 01 No Color Connective position No Color Connective position M01 N Floor harness To L91 M04 N High mounted stop light 2 M02 N License plate light 1 M05 N...

Page 1084: ...4 Wiring Systems Ground Point Ground earth Point S3RH0A910C001 Refer to Connector Layout Diagram 3 4 5 11 12 15 16 17 22 20 18 19 A T R L Right side shown LHD shown 4door Fuel tank 1 FWD R I3RH0A91097...

Page 1085: ...Wiring Systems 9A 35 8 9 17 18 21 FWD R 5door 4door 5door 23 FWD L 6 7 7 2 FWD L Left side shown 13 10 14 L R I3RH0A910975 01...

Page 1086: ...er to Power Supply Diagram 5 Door Type 1 3 4 Door Type 1 2 Refer to Power Supply Diagram 5 Door Type 4 4 Door Type 3 Refer to Fuses and the Protected Parts Refer to Fuses in Main Fuse Box Refer to Ind...

Page 1087: ...28 1 9 G26 E35 2 E07 C10 1 RED WHT BLU Supple mentary fuse box No 2 15A GRN 60A E19 1 BLU YEL BLK 10A RED BLK WHT RED WHT RED WHT RED WHT RED WHT RED YEL BLK YEL BLK Fuse box 28 28 22 23 24 25 26 27 1...

Page 1088: ...YEL WHT BLU WHT RED BLK BLK 2 E37 G28 1 9 G26 E35 2 E07 C10 1 RED WHT BLU Supple mentary fuse box No 2 15A GRN 60A E19 1 BLU YEL BLK 10A RED BLK WHT RED WHT RED WHT RED WHT RED YEL BLK YEL BLK Fuse b...

Page 1089: ...5 1 80A ALT I4RH01910955 01 No Fuse Protected circuit 80 A Battery Generator All electric circuit 60 A Ignition switch 60 A Individual circuit fuse box Supplementary fuse box 60 A ABS actuator unit c...

Page 1090: ...I 15 A SEAT HEATER Seat heater switch L Seat heater switch R 20 A REAR DEFG Rear defogger switch 5 dr type 1 Rear defogger relay 5 dr type 2 4 dr 15 A RADIO DOME ECM Data link connector Combination me...

Page 1091: ...Warning buzzer controller Clock 15 A CIGAR Power mirror switch Radio Antenna amplifier 5 dr type 1 Cigar lighter Woofer Accessories socket relay Clock 15 A ACC Accessories socket relay 15 A FRONT FOG...

Page 1092: ...fer to C 2 Combination Meter Circuit Diagram Indicator 5 Door Type 1 3 4 Door Type 1 2 Refer to C 2 Combination Meter Circuit Diagram Indicator 5 Door Type 4 4 Door Type 3 Refer to C 3 Combination Met...

Page 1093: ...M T A T P R N D 2 L G37 1 1 C38 Starting motor Transaxle range sensor 2 G37 2 C39 LOCK B ACC ACC IG1 IG2 ST R ON START 2 E07 C10 M BLK YEL C15 6or9 5or6 BLK YEL BLK YEL BLK YEL BLK BLK 9 G26 E35 9 G2...

Page 1094: ...10 1 C02 1 Main fuse box 80A BLK WHT BLK WHT WHT BLU RED BLU BLK RED BLK WHT WHT BLU BLK G21 G21 CHARGE CHARGE 15A IG 10A METER Individual circuit fuse box C36 2 1 3 23 1 27 A 5 RB 5 dr type 1 3 4 dr...

Page 1095: ...nition System Circuit Diagram S3RH0A910E004 15A IG Individual circuit fuse box 10 G25 E34 1 E07 C10 2 C18 1 3 IG COIL 1 IG COIL 2 2 C19 1 3 BLK WHT BLK WHT BLK WHT GRN YEL BLK GRN WHT 23 4 A 5 A 5 GY...

Page 1096: ...E06 M 2 1 3 4 Main fuse box 30A 13 E36 G27 Individual circuit fuse box 15A IG BLK WHT BLU WHT BLK WHT BRN Relay 1 E08 3 2 E20 1 4 1 E09 4 2 3 1 E11 4 1 3 2 14 E36 G27 BRN BLU RED BLU BLK BLU GRN RED...

Page 1097: ...OCV Solenoid ADR M18 3 4 YEL YEL YEL RED 4 1 3 G33 L07 L50 1 2 L13 L49 5 C42 G01 14 G01 C42 11 20 G04 C41 13 4 GRN YEL BLK WHT BLK WHT BLK WHT BRN WHT BLK RED BLK RED BRN WHT BLK YEL 30A BLK BLU BLK...

Page 1098: ...10 1 G01 C42 2 G03 GRN WHT GRN WHT Brake light switch Diode 1 19 G04 PNK C41 12 RED BLU 5 YEL 5 BLK WHT BLK WHT 10 G25 E34 13 C42 G01 YEL BLK Power steerring pump pressure switch Auto A C Manual A C...

Page 1099: ...K 15 20 1 IAT sensor C17 2 10 7 ORN WHT BLK 11 Thermistor In 5 YEL WHT YEL WHT LT GRN Knock sensor CO adjusting resistor C37 1 BLK ORN 8 4 C26 2 1 C28 EVAP canister purge valve 2 1 BLU GRN BLU BLK WHT...

Page 1100: ...GRN YEL 1 15 LT GRN BLK C42 G01 4 3 G01 C42 5 C10 E07 10 C42 G01 Compressor E41 M Condenser fan motor 1 2 BLK RED BLU 1 C31 WHT 9 10 18 9 29 17 28 20A Main fuse box Individual circuit fuse box 10A HEA...

Page 1101: ...T RED BLU G01 C42 1 BLK Shift lock solenoid 1 4 L27 3 6 O D OFF 13 1 BLK WHT BLK WHT BLK C43 G02 7 20 GRN YEL E32 A T shift lever Brake light switch 4 G26 E35 GRN BLK GRN YEL GRN BLK Back up light LHD...

Page 1102: ...solenoid 1 12 11 GRY RED 15A IG Individual circuit fuse box BLK WHT BLK BLK 16 4 RED GRN RED GRN 17 5 C12 C13 1 2 Output shaft speed sensor 1 2 Input sensor GRY GRN ORN BLU WHT LT GRN GRY BLK BLU ORN...

Page 1103: ...RADIO DOME CHECK ENGINE IMMOBI Main relay 4 3 BLK 1 G01 C42 3 E35 G26 Individual circuit fuse box Main fuse box 23 10A METER 27 10 15 1 C03 2 BLK YEL BLK WHT WHT RED BRN WHT BLK RED BLK RED BRN WHT P...

Page 1104: ...11 17 BLU ORN BLU BLU RED BLU ORN BLU BLU RED BLU WHT YEL RED BLK BLK On Off Limit switch H L M E22 2 BLU WHT Relay 12V Washer switch Circult OFF INT LO HI B3 2 1 1 INT1 INT2 BLK 25 RHD without rear f...

Page 1105: ...2 3 1 4 L22 O02 6 5 BLU BLU ORN YEL RED ORN GRN GRN 15A WIPER WASHER Individual circuit fuse box 3 M 2 1 BLK BLK BLK BLK G26 E35 8 G33 L07 1 2 O02 L22 2 L13 L49 3 BLK Wash Switch Off On Wash YEL RED L...

Page 1106: ...x 3 M 2 1 G33 L07 1 G26 E35 8 L96 O13 1 L22 O02 6 L22 O02 5 11 2 12 L13 L49 3 Wash Switch Off INT On Wash L20 11 17 G39 YEL RED YEL RED BLU YEL BLU GRN GRN YEL RED BLU YEL BLU GRN 25 RHD without rear...

Page 1107: ...L86 1 G58 G60 8 G59 G57 20A REAR DEFG Individual circuit fuse box G16 Switch 4 5 2 3 1 1 BLK RED WHT RED YEL 1 3 2 C06 Diode 1 YEL BLK YEL BLK H T RED YEL RED YEL RED YEL RED BLU 14 YEL OFF ON 21 11...

Page 1108: ...RED WHT RED YEL 1 3 2 G64 Diode 1 Wagon Sedan Wagon YEL BLK H T relay RED YEL RED YEL RED YEL RED BLU 14 10A HEATER 12 BLK YEL LT GRN OFF ON 21 11 13 RED BLU C 1 D 4 A 5 E 2 Relay Auto A C unit With...

Page 1109: ...LK BLK RED WHT GRN WHT WHT RED WHT GRN RED YEL WHT RED WHT GRN WHT WHT RED WHT GRN RED YEL WHT 7 11 3 GRN RED Front J03 1 2 M UP G33 L07 8 L01 J01 22 33 Unlock Lock Off Up Off Up Down Down 16 A C B D...

Page 1110: ...M J12 Front Front Sub switch Up 1 2 M J18 Rear R Up 1 2 M J22 Up 1 2 RED WHT GRN WHT WHT BLU WHT RED WHT GRN RED GRN RED GRN RED GRN RED YEL WHT RED WHT GRN WHT WHT BLU WHT BLU WHT RED WHT BLU WHT GR...

Page 1111: ...door key switch 1 BRN WHT BLK BRN WHT BLK 3 L13 L49 20 10A TURN 24 14 RED BLK RED BLK Rear turn signal light RHD LHD EU NON EU NON Taiwan Taiwan 5 dr type 1 5 dr type 2 4 5 dr type 1 3 4 dr type 1 2...

Page 1112: ...ode 2 Interior light G38 1 2 15 10A HAZARD 17 BLK RED 18 21 Rear R EU only 2 M 1 2 M 1 1 RED BLU RED BLU GRN GRN RED BLU GRN D 5 D 5 Diode 4 5door GCC L84 Rear L 2 3 15 14 G34 L08 BR C 2 D 6 GR GR BY...

Page 1113: ...BLK 17 3 G34 L08 4 BLK GRY BLU LT GRN BLK LT GRN BLK LT GRN BLK GRY RED GRY LT GRN RED GRY BLU GRY LT GRN BLK GRY RED GRY GRY RED GRY RED GRY GRY BLK 3 L13 L49 BLK BLK 3 L13 L49 28 12 RHD LHD 5 dr ty...

Page 1114: ...A910E017 15A HORN Supplementary fuse box No 2 9 E42 2 1 H GRN WHT E36 G27 Combination switch Horn With air bag Without air bag G24 1 E12 Horn relay 2 4 1 3 BLK BRN YEL GRN BRN YEL BRN YEL BRN YEL A B...

Page 1115: ...0E018 Individual circuit fuse box 15A SEAT HEATER LT GRN RED LT GRN RED 15 G33 L07 3 L13 L49 L30 4 3 5 6 Hi Hi Lo Lo N Hi L31 Switch R 4 3 5 6 Hi Hi Lo Lo N Hi L34 L 3 2 1 RED BLK BLK L25 3 2 1 BLK RE...

Page 1116: ...RN BLK ORN LT GRN BLK BLK PPL Individual circuit fuse box WHT RED G20 G21 PPL RED YEL 1 2 L13 L49 L49 L13 10 L50 1 2 With meter ILL YEL RED Vehicle speed sensor C20 2 1or3 3or1 Main relay Clock BLK RE...

Page 1117: ...L07 10A METER 15A RADIO DOME YEL GRN BLK ORN BLK PPL Individual circuit fuse box WHT RED G20 PPL RED YEL 1 2 L13 L49 L49 L13 10 L50 1 2 With meter ILL YEL Vehicle speed sensor C20 2 1or3 3or1 Main rel...

Page 1118: ...pe 1 3 4 Door Type 1 2 S3RH0A910E021 Dimmer passing Warning buzzer controller LCD BEAM TURN R TURN L Turn signal switch E16 13 G20 G21 14 20 17 10 15 WHT RED WHT RED BLU YEL GRN RED BLK RED RED YEL 4...

Page 1119: ...6 20 G20 11 18 9 14 11 21 WHT RED WHT RED BLU YEL GRN RED BLK RED RED YEL 4 E36 G27 15A Individual circuit fuse box 2 6 11 13 D 6 A 6 D 1 TCM GR BY R RY LT GRN BLK A 5 A 6 TCM LB ECM L 2 D N R P O D O...

Page 1120: ...0A METER RADIO DOME Individual circuit fuse box BLK RED BLU RED WHT PNK GRN PPL YEL RED WHT PNK GRN 10 C30 Front door switch Front door switch 1 L10 1 L40 Rear door switch L 1 L43 Rear door switch R 1...

Page 1121: ...L13 L49 12 G01 C42 1 L83 G46 3 E36 G27 1 G01 C42 7 SEAT BELT SW 12 G21 1 CHARGE 16 G19 7 Data link connector WHT RED 9 5 BLK ORN 4 BLK 15A RADIO DOME Individual circuit fuse box BLK ORN IF EQPD 15 13...

Page 1122: ...K RED BLU RED WHT PNK GRN RED WHT PNK GRN 10 C30 Front door switch Front door switch 1 L101 1 L103 Rear door switch L 1 L104 Rear door switch R 1 L102 6 G01 C42 G27 E36 L21 O01 5 G33 L07 14 11 2 1 BLK...

Page 1123: ...20 G20 G21 16 G19 7 Data link connector WHT RED 9 5 BLK ORN 4 BLK 15A RADIO DOME Individual circuit fuse box BLK ORN IF EQPD 15 13 3 11 15 20 17 YEL A 5 A 5 A 7 A 2 F 1 A B SDM F 1 A B SDM F 2 ABS Co...

Page 1124: ...E16 E29 G32 E01 E43 G40 Main fuse box 10 E35 G26 9 G57 G59 5 5 E36 G27 11 15A 15A RED BLU RED BLU RED 7 6 13 11 H T light relay Tail light G57 For optional DRL controller RHD without rear fog light L...

Page 1125: ...1 IF EQPD IF EQPD IF EQPD License plate light RED YEL RED YEL RED YEL 6 H T light relay Tail light G57 G58 For optional DRL controller G32 RED GRN PNK BLU RED YEL 10 15 14 G40 H T light relay Head li...

Page 1126: ...ry fuse box No 2 11 13 6 8 H T light relay Tail light EU Except EU With meter ILL control Without meter ILL control 5 dr type 1 3 4 dr type 1 2 5 dr type 4 4 dr type 3 A B C D E E F A B 4 6 A B 3 5 RE...

Page 1127: ...ED GRN PNK BLU RED YEL 10 15 14 G40 H T light relay Head light A B A B 19 A RED BLU RED YEL RED YEL E B 14 13 A E B 1 8 A E B RED BLU 11 13 1 G12 1 2 Ashtray ILL G16 3 1 Switch G36 6 5 2 Mirror heater...

Page 1128: ...LK BLK Rearend door switch BLK WHT BLK YEL Off On Trunk room light 2 L94 BLK WHT WHT RED BLK RED 3 1 L21 O01 1 Diode 2 L18 2 Spot light K02 1 2 WHT RED BLK RED BLK RED BLK BLK 3 L13 L49 Rear door swit...

Page 1129: ...N BACK HAZARD 10A 7 2 L19 4 2 L45 4 2 L R Rear turn signal light BLK BLU YEL BLU YEL GRN RED BLK 4 5 RED BLK H T relay Individual circuit fuse box RED YEL ILL 4 BLK BLK BLK BLK 3 L13 L49 A E B 6 1 A E...

Page 1130: ...15A Main fuse box BLK L85 1 High mounted stop light 5door 10 9 E33 L02 1 L91 M01 2 6 E36 G27 2 BLK 3 L13 L49 11 GRN YEL GRN YEL 15 17 20 A 6 F 2 A 6 A 5 ABS Cont M A 6 TCM ECM TCM BLK BLK GRN WHT GRN...

Page 1131: ...01 C42 20 C42 G01 7 G33 L07 3or6 3 L21 O01 2 O02 L22 BLK BLK BLK RED BLK RED BLK RED RED RED RED RED RED 10A TURN BACK Individual circuit fuse box O09 1 2 Back up light L IF EQPD O12 1 2 1 2 C11 RED T...

Page 1132: ...uit Diagram S3RH0A910E033 GRN GRN BLK GRN BLK BLK Individual circuit fuse box Actuator L Switch YEL RED YEL RED YEL RED 15A WIPER WASHER 25 6 E48 E49 1 1 3 3 G44 3 4 6 5 2 2 1 G26 E35 1 E34 G25 GRN BL...

Page 1133: ...EAR FOG 16 21 13 11 5 4 G52 3 6 Controller 5door G47 4 2 6 5 1 1 3 G33 L07 BRN BRN YEL L21 O01 2 O02 L22 BRN YEL PNK BLU BRN YEL BLK BLK RHD LHD A B RED YEL H T relay H T relay Off On O10 2 1 D 4 D 1...

Page 1134: ...H0A910E035 LT GRN RED 10A REAR FOG 16 21 11 Relay 5door 3 G33 L07 BRN YEL BLK BRN YEL BRN L21 O01 2 O02 L22 BRN YEL BLK RHD LHD A B OFF ON O10 2 1 D 10 18 13 BLK 18 4door L91 M01 2 BRN YEL BLK M06 2 1...

Page 1135: ...Thermistor 11 E30 G10 10 30A Main fuse box Triple pressure switch E21 3 2 GRN BLK 1 4 BLU ORN GRN BLK BLU ORN 1 2 1 5 Blower motor relay E25 E19 3 1 2 5 Blower motor relay HI E26 3 BLU LT GRN LT GRN...

Page 1136: ...use box Auto A C unit ILL Auto A C panel Sunlight sensor Data link connector H T relay Relay Room temperature sensor Mode actuator For optional DRL controller 10A HEATER TURN BACK 12 10A 24 1 11 13 10...

Page 1137: ...BLU WHT BLU RED BLU LT GRN GRN BLK BLU ORN GRN BLK GRN WHT GRN WHT BLK BLU YEL BLU RED BLU RED BLU WHT BLK BLK 2 2 Individual circuit fuse box Main fuse box Blower fan main relay Fan driver A C Diode...

Page 1138: ...D RED WHT RED YEL RED YEL RED BLK IF EQPD IF EQPD PNK YEL GRN YEL YEL RED YEL GRN RED GRN BRN LT GRN 1 2 L75 L28 L71 L37 Not used BLU 1 G01 C42 L83 G46 3 E36 G27 1 L80 G14 Individual circuit fuse box...

Page 1139: ...bag inflator Side air bag sensor Side air bag sensor IF EQPD 19 18 17 6 Side air bag inflator 20 21 16 5 GRN WHT GRN BLK RED BLK RED YEL WHT RED WHT GRN GRN YEL GRN ORN 2 1 L77 L70 2 1 L78 1 2 L74 1...

Page 1140: ...RN BLK ORN 10 G27 E36 RED WHT RED WHT 11 PNK GRN PNK GRN 10A ABS Individual circuit fuse box 1 G27 E36 13 E33 L02 WHT BLU 1 Main fuse box 60A GRN ORN GRN ORN E15 3 GRN ORN M 1 L33 26 4 C 3 D 7 ABS Con...

Page 1141: ...1 L02 E33 2 4 5 4 6 G05 Diagnosis connector 2 5 BLU 4 7 9 16 G19 Data link connector 5 2 E36 G27 3 BLU BLK ORN BLK BLK ORN WHT RED 1 YEL 1 G01 C42 Individual circuit fuse box RADIO DOME 15A WHT RED 15...

Page 1142: ...fuse box WHT BLK GRY RED LT GRN BLK 1 BLK LT GRN RED LT GRN BLK LT GRN RED GRY BLK L01 J01 L36 J10 L36 J10 L01 J01 10 2 10 2 L22 O02 4 1 YEL BLK YEL GRN BLU BLK BLU RED YEL GRN YEL BLK BLU RED BLU BLK...

Page 1143: ...LT GRN RED GRY BLK L01 J01 L36 J10 L36 J10 L01 J01 10 2 10 2 L22 O02 4 1 YEL BLK YEL GRN BLU BLK BLU RED G86 L R Tweeter G85 1 2 1 2 YEL GRN YEL BLK BLU RED BLU BLK GRY RED LT GRN BLK BLK BLK LT GRN R...

Page 1144: ...LT GRN BLK BLK BLK BLK BLK BLK LT GRN RED IF EQPD 28 29 RHD LHD 5 dr type 1 3 4 dr type 1 2 5 dr type 4 4 dr type 3 NON Taiwan Taiwan A B C D E F 15 20 17 Cigar lighter Accessory socket relay 1 2 Pus...

Page 1145: ...G27 17 G01 C42 28 15 11 13 C 1 D 4 E62 Ambient temperature sensor 2 1 P RY Clock with OUT TEMP indication 5 dr type 3 4 dr type 2 Clock without OUT TEMP indication 5 dr type 1 2 4 dr type 1 Clock with...

Page 1146: ...NF040005 01 1 2 3 4 MCONF040005 01 1 2 3 4 5 6 MCONF060030 01 1 2 MCONF020049 01 1 2 MCONF020155 01 1 2 MCONF020064 01 1 2 3 4 5 6 7 8 MCONF080007 01 1 2 5 6 7 10 3 8 4 9 MCONF100048 01 1 5 6 2 3 4 7...

Page 1147: ...01 1 2 MCONF020008 01 1 2 MCONF020008 01 1 2 3 4 MCONM040009 01 3 2 1 6 5 4 MCONM060018 01 1 2 3 4 MCONF040043 01 1 2 3 4 MCONF040043 01 1 2 3 4 MCONF040043 01 1 2 3 4 MCONF040043 01 1 2 3 4 MCONF040...

Page 1148: ...20144 01 1 MCONM010021 01 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 MCONM220003 01 1 2 MCONF020008 01 1 2 3 4 5 6 7 MCONF070011 01 1 2 3 4 5 6 7 MCONF070011 01 1 2 MCONF020149 01 1 2 MC...

Page 1149: ...9 8 7 6 5 2 1 MCONM110001 01 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 MCONM180001 01 1 2 MCONM020026 01 1 3 2 4 MCONF040047 01 3 5 1 2 6 4 7 8 10 9 MCONF100028 01 3 4 7 2 6 8 9 10 12 13 14 17 16...

Page 1150: ...01 1 2 MCONF020158 01 1 2 MCONF020116 01 2 1 MCONF020159 01 2 1 MCONF020159 01 1 2 3 4 6 5 MCONM060012 01 3 5 1 2 6 4 7 8 10 9 MCONF100028 01 3 5 1 2 6 4 7 8 10 9 MCONF100028 01 1 2 3 4 MCONF040016 0...

Page 1151: ...2 3 4 MCONF040022 01 1 2 3 4 MCONF040022 01 2 1 8 3 9 4 10 5 11 6 12 7 MCONF120026 01 1 2 3 MCONF030036 01 1 2 MCONF020016 01 1 2 3 MCONF030015 01 14 13 12 11 4 3 22 21 20 19 28 27 26 25 24 23 18 17 1...

Page 1152: ...1 2 3 MCONF030036 01 1 2 MCONF020160 01 1 2 MCONF020121 01 14 13 12 11 4 3 22 21 20 19 28 27 26 25 24 23 18 17 10 9 16 15 8 7 2 1 6 5 MCONF280006 01 1 2 MCONM020004 01 1 2 MCONM020004 01 1 MCONF01003...

Page 1153: ...10021 01 1 2 3 MCONF030036 01 1 MCONM010022 01 1 2 3 4 6 5 MCONM060012 01 1 MCONF010061 01 1 MCONM010017 01 1 2 MCONF020012 01 1 MCONF010061 01 1 MCONM010021 01 1 MCONM010017 01 1 2 MCONF020105 01 2 5...

Page 1154: ...urn signal light bulb socket 11 Front fog light 16 Headlight leveling switch 2 Socket cover 7 Clearance light relay 12 Front fog light switch 17 Rear turn signal light 3 Clearance light bulb 8 Headlig...

Page 1155: ...g Light Relays Inspection Lighting or dimmer switch faulty Check headlight switch referring to Headlight Switch in Lighting Switch Inspection Headlight R and L fuses blown Replace fuse and check for s...

Page 1156: ...ning switch and non lighting bulb Repair circuit Wiring or grounding faulty Repair circuit No flashing Circuit fuse s blown Replace fuse s and check for short circuit Open circuit or high resistance e...

Page 1157: ...fuse and check for short circuit Stop brake lamp switch faulty Check stop brake lamp switch referring to Stop Brake Lamp Switch Inspection Wiring or grounding faulty Repair circuit Stop brake lamp sta...

Page 1158: ...tion Possible cause Correction Reference Item Dome light does not light up Bulb blown Replace bulb Circuit fuse blown Replace fuse and check for short circuit Dome light switch faulty Check dome light...

Page 1159: ...ess otherwise obligated by local regulations adjust headlight aiming according to the following procedure After replacing headlight assembly be sure to adjust aiming 1 Make sure the following items Pl...

Page 1160: ...steering column cover screws 3 4 Remove lighting switch 1 from combination switch assembly 2 and disconnect its coupler 3 Installation Reverse removal procedure for installation I3RH0A920003 01 A The...

Page 1161: ...minals at each switch position as shown If check result is not as specified replace switch Headlight Diode Removal and Installation S3RH0A9206006 Removal 1 Disconnect negative cable at battery 2 Remov...

Page 1162: ...B of relay 3 Connect battery negative terminal to terminal A of relay 4 Check continuity between terminal C and D If there is no continuity when relay is connected to the battery replace relay Hazard...

Page 1163: ...wheel to remove steering column cover screws 3 4 Remove lighting switch 1 from combination switch 2 and disconnect its coupler 3 Installation Reverse removal procedure Turn Signal Light Switch in Ligh...

Page 1164: ...2 and licence lamp socket cover 3 3 Using flat head screw driver or the like 1 push locking part of licence lamp socket 2 And then remove licence lamp socket 2 as shown CAUTION To prevent vehicle bod...

Page 1165: ...s or SMALL position Front fog lights turn OFF automatically when headlight switch is turned to OFF position If front fog light switch holds ON position front fog lights turn ON automatically when head...

Page 1166: ...module 19 Oil pressure switch 25 Key remainder switch 2 METER fuse 8 ODO TRIP 14 Fuel level gauge 20 Headlight relay 1 Serial communication 3 Combination switch 9 Back light 15 ECM 21 Driver side doo...

Page 1167: ...o ECM tachometer signal G20 12 G21 12 PPL To VSS M T vehicle or TCM A T vehicle G20 13 G21 13 YEL GRN To ECM ECT meter signal G20 14 G21 14 RED YEL To TCM O D OFF A T shift position indicator control...

Page 1168: ...8 9 5 8 4 2 2 1 5 3 3 6 A B I4RH01930001 01 A For wagon model 2 Front speaker 5 Antenna feeder 8 Glass antenna B For sedan model 3 Rear speaker for wagon 6 Antenna 9 Antenna amplifier 1 Radio assembl...

Page 1169: ...ty Replace combination meter Condition Possible cause Correction Reference Item Low fuel warning light does not come ON when fuel level is lower than specification Combination meter faulty Replace com...

Page 1170: ...n meter Condition Possible cause Correction Reference Item Seat belt warning light does not light up Combination meter faulty Replace combination meter Seat belt switch faulty Check seat belt switch r...

Page 1171: ...Section 5A O D OFF indicator lamp keep flashing Wiring harness between combination meter and TCM is open or short to ground Replace circuit O D OFF switch faulty Check O D OFF switch referring to O D...

Page 1172: ...ary Information display unit faulty Replace unit Incorrect thermometer display Outside air temperature sensor faulty Check outside air temperature sensor referring to Outside Air Temperature Sensor If...

Page 1173: ...sembly Radio is operative but all speakers does not sound Wiring and or grounding faulty Repair as necessary Radio assembly faulty Replace radio assembly Individual speaker is noisy or inoperative Spe...

Page 1174: ...circuit Extraneous material come to be mixed in tape player Clear extraneous material form tape player or replace radio assembly Wiring and or grounding faulty Repair as necessary Radio assembly fault...

Page 1175: ...ering wheel to remove steering column cover screws 3 5 Disconnect couplers from ignition switch 1 6 Remove ignition switch 1 from key cylinder 2 Installation Reverse removal procedure Ignition Switch...

Page 1176: ...between terminals a and b of fuel level sensor changes with change of float position Check resistance between terminals a and b at each float position in the following If the measured value is out of...

Page 1177: ...emoval and Installation in Section 5B VSS Inspection S3RH0A9306009 Refer to Vehicle Speed Sensor VSS and Its Circuit Inspection in Section 1C Engine Coolant Temperature ECT Sensor Inspection S3RH0A930...

Page 1178: ...ollowing If check result is not as specified replace switch Rearend door switch for 5 door model specification Rearend door closed No continuity Rearend door opened Continuity Trunk Lid Switch Inspect...

Page 1179: ...rring to Disabling Air Bag System in Section 8B 3 Remove steering column hole cover 4 Detach steering lower shaft referring to Steering Column Assembly Removal and Installation in Section 6B 5 Remove...

Page 1180: ...m in Section 8B Information Display or Clock Removal and Installation S3RH0A9306017 Removal 1 Remove information display or clock garnish 1 from instrument panel 2 pulling it arrow direction as shown...

Page 1181: ...an Model Removal and Installation S3RH0A9306020 Removal 1 Fold rear seat back forward 2 Remove high mounted stop light 3 Remove tether anchorage if equipped 1 and center seat belt cover 4 Remove parti...

Page 1182: ...ion 9H 2 Remove antenna 1 from antenna base 2 3 Disconnect antenna feeder from antenna base 2 4 Remove antenna base 2 from vehicle Installation Reverse removal procedure noting the following Tighten a...

Page 1183: ...110 k MODE switch pushing on ON 300 360 switch pushing on ON 900 1100 switch pushing on ON 2900 3500 Specifications Tightening Torque Specifications S3RH0A9307001 Reference For the tightening torque...

Page 1184: ...switch washer switch faulty Check washer switch referring to Windshield Wiper and Washer Switch Inspection Wiring or grounding faulty Repair circuit Condition Possible cause Correction Reference Item...

Page 1185: ...shield wiper blade 4 Windshield wiper link 7 Rear wiper motor if equipped 10 Washer tank 2 Windshield wiper arm 5 Rear wiper blade if equipped 8 Washer pump for windshield washer 11 Washer hose 3 Wind...

Page 1186: ...6004 NOTE Make sure that battery voltage is 12 V or more Motor Operation in Low Speed 1 Connect battery positive terminal to terminal L and its negative terminal to terminal E 2 Check if motor revolut...

Page 1187: ...let the motor turn 2 Disconnect terminal L from battery positive terminal and let the motor stop 3 Connect terminal B to battery positive terminal Observe the motor turns once again then stops at a s...

Page 1188: ...to terminal EW 3 Connect voltmeter positive lead to terminal L and its negative lead to terminal EW 4 Check that the voltmeter indicates the battery voltage 10 14 V 5 Connect terminal AS and terminal...

Page 1189: ...t voltage changes as shown in figure If check result is not satisfied replace switch Rear Wiper and Washer Switch Removal and Installation S3RH0A9406008 Refer to Windshield Wiper and Washer Switch Rem...

Page 1190: ...nner trim 3 3 Remove rear wiper intermittent relay 1 from vehicle Installation Reverse removal procedure Rear Wiper Intermittent Relay Inspection S3RH0A9406011 1 Check INT circuit as follows a Connect...

Page 1191: ...tisfied replace relay c Check that voltage between b terminal and e terminal changes as below figure when disconnecting battery positive terminal from d If check result is not satisfied replace relay...

Page 1192: ...sive to be used with primer in combination When using primer and adhesive made by other manufacturers be sure to refer to handling instructions supplied with them Negligence in following such procedur...

Page 1193: ...r one sheet of windshield Adhesive 470 g 15 7 oz Primer for glass 30 g 1 0 oz Primer for body 30 g 1 0 oz Primer for molding 30 g 1 0 oz Eyeleteer Piano string Windshield knife Brush for primer applic...

Page 1194: ...or coupler faulty Check wiring and or coupler Power window main switch faulty Check power window main switch referring to Power Window Main Switch Inspection Power window sub switch faulty Check powe...

Page 1195: ...stallation in Section 9H 7 Remove or cut windshield molding 8 Drill hole with eyeleteer 1 through adhesive and let piano string through it 9 Cut adhesive all around windshield 1 with piano string 2 Wh...

Page 1196: ...by moving glass stoppers position Windshield clearance a approx 5 mm 0 197 in 4 Clean contact surfaces of old adhesive 4 paint or bare metal thoroughly If surfaces of paint or bare metal come out app...

Page 1197: ...grip is helpful to hold and carry glass after adhesive 1 is applied Perform steps 8 to 9 within 10 min to ensure sufficient adhesion Be sure to refer to adhesive maker s instruction for proper handlin...

Page 1198: ...ape until adhesive is completely set Each adhesive has its own setting time Be sure to refer to its maker s instruction check setting time of adhesive to be used and observe precautions to be taken be...

Page 1199: ...ad wire at coupler 10 6 5 1 3 11 1 5 N m 0 15 kg m 9 8 9 2 7 4 I4RH01950006 01 1 Door glass 5 Door sealing cover 9 Front door window regulator mounting bolt Tighten referring to Front Door Window Regu...

Page 1200: ...en tighten door glass front mounting screw 2 Secure door sealing cover 1 with adhesive 2 Tighten front door outer weather strip mounting screw to specified torque Tightening torque Front door outer we...

Page 1201: ...er Front door window regulator bolt tightening order a b c Front Door Window Regulator Inspection S3RH0A9506006 Check the following parts for wear damage smooth operation and lubrication Check regulat...

Page 1202: ...t of glass run from sash 4 and remove sash by removing 2 screws 5 and bolt 6 9 Remove door glass 2 1 Door glass 6 Inner sash 11 Door grip cover 2 Window regulator assembly Apply lithium grease 99000 2...

Page 1203: ...ling cover 1 with adhesive 2 Tighten rear door outer weather strip mounting screw to specified torque Tightening torque Rear door outer weather strip mounting screw a 1 5 N m 0 15 kgf m 1 0 lb ft Rear...

Page 1204: ...ly the same However note the following Observe the following precautions when applying adhesive 1 along glass 2 edge Adhesive 1 should be applied evenly especially in height Be careful not to damage p...

Page 1205: ...uld be applied evenly especially in height Be careful not to damage primer 3 With the position of fastener 4 properly aligned install glass 2 on rearend door panel 5 Press glass against body quickly a...

Page 1206: ...lying adhesive 1 along glass 2 edge Adhesive 1 should be applied evenly especially in height Be careful not to damage primer 3 Press glass against body quickly after adhesive 1 is applied Adhesive amo...

Page 1207: ...ed replace HVAC control module assembly Rearend Door Window Back Window Defogger Wire Inspection S3RH0A9506017 NOTE When cleaning rear window glass use a dry cloth to wipe it along heat wire 1 directi...

Page 1208: ...s where there is open If found defective repair defogger wire referring to Rearend Door Window Back Window Defogger Wire Repair Measuring position Voltage Circuit a 10 12 V Defogger wire open between...

Page 1209: ...ed 3 Apply commercially available repair agent 3 with a fine tip brush 4 4 2 to 3 minutes later remove masking tapes 1 5 Leave repaired heat wire as it is for at least 24 hours before operating the de...

Page 1210: ...tch condition If check result is not as specified replace switch Door Mirror Components S3RH0A9506021 Door Mirror Removal and Installation S3RH0A9506022 When removing or installing door mirror refer t...

Page 1211: ...ce door mirror switch Power Door Mirror Actuator Inspection S3RH0A9506024 1 Remove door trim referring to Front Door Glass Removal and Installation 2 Disconnect door mirror coupler 1 3 Check that door...

Page 1212: ...minals at each switch position as shown If check result is not as specified replace switch Door Mirror Heater If Equipped Inspection S3RH0A9506026 1 Remove door trim referring to Front Door Glass Remo...

Page 1213: ...ection 0A Special Tools and Equipment Recommended Service Material S3RH0A9508001 NOTE Required service material is also described in the following Front Door Window Components Rear Door Window Compone...

Page 1214: ...wners of key cutting equipment from suppliers If key codes are not available from records or tags key code can be obtained from the right hand door lock cylinder if lock has not been replaced Lock cyl...

Page 1215: ...o power door lock switch faulty Repair Power door lock controller faulty Check system referring to Power Door Lock System Circuit Inspection Wiring or grounding faulty Check system referring to Power...

Page 1216: ...all doors are unlocked Connect battery positive and negative terminals to door lock controller coupler terminals and check door lock and unlock operation as follows If it does not operate as specified...

Page 1217: ...960004 01 1 Power door lock controller coupler L82 viewed from terminal side Circuit Terminal Wire Specification Condition Power door lock switch circuit L82 5 BLU BLK Continuity Power door lock switc...

Page 1218: ...re not locked unlocked by only keyless entry transmitter Transmitter battery dead Replace battery Door switch faulty Check door switch referring to Door Switch Front Rear Door Inspection in Section 9C...

Page 1219: ...tter twice within 3 seconds Hazard warning signal circuit left side L82 8 GRN RED Figure A Push LOCK button on transmitter once Figure B Push UNLOCK button on transmitter once Figure C Push LOCK butto...

Page 1220: ...ck 1 Front door latch assembly Apply lithium grease 99000 25010 to sliding and rotating parts and spring if any 4 Latch striker 7 Key cylinder protector B Without power door lock 2 Outside handle Appl...

Page 1221: ...key cylinder as follows a Install key cylinder plate 1 b Tighten lower outside handle screw 2 c Install key cylinder 3 and then rotate it to arrow mark 4 direction as shown d Tighten upper outside han...

Page 1222: ...ch Door Key Cylinder Switch Driver and Passenger Side Inspection S3RH0A9606005 Check for continuity between terminals at each switch position If check result is not as specified replace key cylinder D...

Page 1223: ...a b as shown If it does not operate as specified in the following table replace door lock actuator Type 1 Without dead lock system Type 2 With dead lock system a b UNLOCK LOCK LOCK UNLOCK Operation T...

Page 1224: ...striker position if necessary Rear Door Lock Assembly Components S3RH0A9606009 9 8 4 5 2 1 3 3 6 7 B A I4RH01960003 02 A With power door lock 1 Outside handle Apply lithium grease 99000 25010 to slidi...

Page 1225: ...everse removal procedure to install rear door lock assembly referring to the following instruction and Front Door Lock Assembly Removal and Installation Tighten out side rear handle mounting bolt firs...

Page 1226: ...or Lock Assembly for Wagon Model Components S3RH0A9606012 1 1 3 4 A B 5 2 I4RH01960004 01 A With power door lock 1 Rearend door latch assembly 3 Latch striker 5 Door handle B Without power door lock 2...

Page 1227: ...Reverse removal procedure to install rearend door lock assembly noting the following instruction Adjust door latch striker so that its center aligns with the center of groove in door latch base Rearen...

Page 1228: ...llation S3RH0A9606016 Removal 1 Disconnect trunk lid lock control rod 1 2 Remove trunk lid lock cylinder 2 3 Loosen trunk lid latch bolts 1 and remove trunk lid latch assembly 2 4 Disconnect trunk lid...

Page 1229: ...ed battery properly according to applicable rules or regulations Do not dispose of lithium batteries with ordinary household trash Programming Transmitter Code S3RH0A9606019 NOTE Three transmitter cod...

Page 1230: ...vice Material S3RH0A9608001 NOTE Required service material is also described in the following Front Door Lock Assembly Components Rear Door Lock Assembly Components Material SUZUKI recommended product...

Page 1231: ...nt back and or heater front cushion referring to Seat Heater Wire Inspection Only seat back does not become hot although seat heater switch is HI position Wiring faulty Repair Seat heater switch fault...

Page 1232: ...3 kg m 8 5 23 N m 2 3 kg m 6 10 35 N m 3 5 kg m 6 35 N m 3 5 kg m 7 35 N m 3 5 kg m 9 9 4 4 2 3 1 10 10 10 I4RH01971001 01 1 Seat cushion 4 Cover 7 Reclining bolt 10 Cover 2 Seat back 5 Seat adjuster...

Page 1233: ...r if equipped 4 Remove 4 mounting bolts to remove seat assembly 5 Disassemble and repair seat as necessary Installation Reverse removal procedure to install front seat Torque to specifications as show...

Page 1234: ...cushion hook with seat back bracket Wagon Removal 1 Remove 2 seat cushion nuts to remove seat cushion 2 Remove 4 seat back bolts to remove seat back 3 Disassemble and repair seat as necessary Installa...

Page 1235: ...sult is not as specified replace switch Seat Heater Wire Inspection S3RH0A9706006 1 Confirm that seat heater switch is OFF position 2 Disconnect two couplers of seat heater under the seat cushion 3 Ch...

Page 1236: ...ons S3RH0A9707001 NOTE The specified tightening torque is also described in the following Front Seat Components Rear Seat Components Reference For the tightening torque of fastener not specified in th...

Page 1237: ...Belt Components in Section 8A For tightening torque of front seat adjuster bolt refer to Front Seat Components in Section 9G Head Lining Removal and Installation S3RH0A9806002 Removal 1 Remove spot li...

Page 1238: ...edure noting the following Tighten sun visor screw to specified torque Tightening torque Sun visor screw a 4 N m 0 4 kgf m 3 0 lb ft Tighten rear center seat belt upper anchor bolt to specified torque...

Page 1239: ...ue of fastener not specified in this section refer to Fasteners Information in Section 0A A A A A A A A A A 1 2 3 4 5 I3RH0A980002 01 1 Front console box 4 Ashtray 2 Rear console box 5 Cup holder 3 Pa...

Page 1240: ...ary Check that hood stops in the secondary latched position properly preventing hood from opening freely and that hood closes completely in the fully latched position Adjust hood locks position if nec...

Page 1241: ...9M 2 Remove front fender lining 3 Remove front bumper referring to Front Bumper and Rear Bumper Components in Section 9K 4 Disconnect connector from side turn signal lamp 5 Remove front fender Install...

Page 1242: ...r panel 1 using a jack 2 with rags 3 and a piece of wood 4 placed between jack 2 and panel 1 as shown 6 Remove door assembly 1 by loosening hinge mounting bolts 2 1 3 2 4 23 N m 2 3 kg m 5 28 N m 2 8...

Page 1243: ...per 1 is installed be careful make sure punch mark 2 comes to the top Door open stopper installing direction Left side door L punch mark is upward Right side door R punch mark is upward Tighten door o...

Page 1244: ...r to the figure in Rear Door Assembly Components for grease and sealant 2 2 1 3 5 28 N m 2 8 kg m 4 23 N m 2 3 kg m 4 23 N m 2 3 kg m 6 I4RH019A0003 01 1 Door panel 3 Door stopper 5 For open stopper b...

Page 1245: ...l assembly 4 Rearend door balancer 7 Back up lamp 2 Rearend door window glass 5 Rearend door trim 8 Rearend door license garnish 3 Rearend door hinge Apply lithium grease 99000 25010 to door hinge mov...

Page 1246: ...is filled with gas Discarding of Rearend Door Balancer Damper The gas itself in balancer is harmless but it may issue out of the hole together with chips generated by the drill 2 Therefore be sure to...

Page 1247: ...room harness from trunk lid panel 1 2 Remove trunk lid attaching bolts 2 and trunk lid NOTE Handle removed trunk lid carefully Dropping it can cause damage to itself and vehicle body A A A 4 3 2 5 1...

Page 1248: ...ting the following Install torsion bars as following a Open trunk lid and hold it b Distinguish torsion bar A from B by end shape 1 c Insert end 1 into hole of partition side panel 3 and fit end 2 to...

Page 1249: ...ference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S3RH0A9A08001 NOTE Req...

Page 1250: ...3 d c 1 2 5 7 d e e c 8 9 10 11 A A A 6 12 A I3RH0A9B0003 01 A Type A model 4 License plate retainer 8 Rear bumper 12 Rear bumper cap 1 Front bumper 5 Front bumper cap 9 Rear bumper reinforcement 2 Fr...

Page 1251: ...r side garnish 8 Plastic nut 12 Rear bumper absorber If equipped 1 Front bumper 5 Front bumper cap 9 Bumper holder 13 Rear bumper side bracket 2 Radiator upper grill 6 Front bumper absorber If equippe...

Page 1252: ...gine Room b c d g h b c l k d e f g a j j h i I2RH019B0002 01 a Datum point e Jig hole i Hood lock brace installation lower left side hole b b Front fender installation hole f Hood cushion installatio...

Page 1253: ...mm 27 57 in d d 894 0 mm 35 20 in j j 950 2 mm 37 41 in b b 1354 0 mm 53 30 in d i 650 9 mm 25 63 in k l 950 7 mm 37 43 in a a b f c d e f c d b I2RH019B0003 01 a a Rearend door hinge installation ho...

Page 1254: ...f panel Side body outer panel and partition panel f f Rear bumper installation hole c High mount stop lamp installation hole g Rear luggage end garnish installation hole d d Weather strip mounting cli...

Page 1255: ...r upper hinge installation upper hole n Side sill scuff installation rear hole e Jig hole 10 mm 0 39 in j Rear door lower hinge installation lower hole o Jig hole 10 mm 0 39 in a f 1112 mm 43 78 in f...

Page 1256: ...ower installation section f Quarter window trim mounting clip installation hole c Datum point g Jig hole 10 mm 0 39 in d Quarter window trim mounting clip installation hole a a 1078 mm 42 44 in a g 11...

Page 1257: ...per hinge installation upper hole n Side sill scuff installation rear hole e Jig hole 10 mm 0 39 in j Rear door lower hinge installation lower hole o Jig hole 10 mm 0 39 in a f 1112 mm 43 78 in f h 10...

Page 1258: ...hole b b Front end of windshield lower installation section e Quarter window trim mounting clip installation hole c Datum point f Quarter window trim mounting clip installation hole a a 1078 mm 42 44...

Page 1259: ...railing rod inside installation hole b b Jig hole 20 mm 0 78 in f f Front suspension frame installation hole k k Rear suspension frame installation hole c c Front fender panel installation hole g g Fr...

Page 1260: ...in i n 1593 mm 62 72 in e h 994 mm 39 13 in i j 1039 mm 40 91 in b b 660 mm 25 98 in g g 600 mm 23 62 in k k 978 mm 38 50 in c c 1532 mm 60 31 in h h 632 mm 24 87 in l l 906 mm 35 65 in e e 950 mm 37...

Page 1261: ...ed Reseal the attaching joints of a new replacement panel and reseal the hem area of a replacement door or hood Use a quality sealer to seal the flanged joints overlap joints and seams The sealer must...

Page 1262: ...back smoke while burning with its residue suspended in air temporarily 5 Polypropylene must raise no readily distinguishable smoke while burning Component Location Sealant Application Areas S3RH0A9C1...

Page 1263: ...edan 9L 3 NOTE VIEW SS TT VV Refer to the next figure VIEW A B C D E H Refer to Sealant Application Areas I2RH019C0008 01 A Apply sealant C Smooth out sealant with a brush B Wipe off excess sealant af...

Page 1264: ...DETAIL X Refer to Sealant Application Areas Under Coating Application Areas S3RH0A9C13002 I4RH019C1002 02 A Apply undercoating PCV 400 m or more C Apply anti chip coat 300 m or more B Apply anti chip...

Page 1265: ...Paint Coatings Sedan 9L 5 I4RH019C1003 01 A Apply undercoating PCV 400 m or more C Do not apply undercoating B Apply undercoating PCV 600 m or more D Do not apply undercoating 4WD model only...

Page 1266: ...9L 6 Paint Coatings Sedan Anti Corrosion Compound Application Area S3RH0A9C13003 I3RH0A9C1002 01 A Apply rust proof wax hot wax 50 m or more B Apply rust proof wax high viscosity wax 50 m or more...

Page 1267: ...ngs Wagon 9L 7 Wagon General Description Anti Corrosion Treatment Construction S3RH0A9C21001 Refer to Anti Corrosion Treatment Construction Plastic Parts Finishing S3RH0A9C21002 Refer to Plastic Parts...

Page 1268: ...agon Component Location Sealant Application Areas S3RH0A9C23001 I4RH019C2001 01 A Apply sealant C Do not apply sealant E Apply sealant on hole B Wipe off excess sealant after application D Smooth out...

Page 1269: ...DETAIL VIEW and SECT which are not shown in this figure refer to the following figure I4RH019C2002 03 A Apply sealant C Smooth out sealant with a brush E Wipe off swell sealant B Apply sealant coverin...

Page 1270: ...9L 10 Paint Coatings Wagon I4RH019C2003 01 A Apply sealant C Smooth out sealant with a brush B Wipe off excess sealant after application...

Page 1271: ...Paint Coatings Wagon 9L 11 I2RH019C0004 01 A Apply sealant D Wipe off sealant so as not to over flow from this surface B Wipe off swell sealant E Do not apply sealant C Never fill up drain holes...

Page 1272: ...9L 12 Paint Coatings Wagon I2RH019C0005 01 A Apply sealant D Do not apply sealant B Wipe off swell sealant E Wipe off sealant so as not to over flow from this surface C Smooth out sealant with brush...

Page 1273: ...Paint Coatings Wagon 9L 13 I3RH0A9C2001 01 A Apply sealant B Smooth out sealant with a brush C Wipe off excess sealant after application...

Page 1274: ...9L 14 Paint Coatings Wagon Under Coating Application Areas S3RH0A9C23002 Refer to Under Coating Application Areas...

Page 1275: ...Paint Coatings Wagon 9L 15 Anti Corrosion Compound Application Area S3RH0A9C23003 I3RH0A9C2002 01 A Apply rust proof wax hot wax 50 m or more B Apply rust proof wax high viscosity wax 50 m or more...

Page 1276: ...nents S3RH0A9D06001 NOTE For Sedan model there are 6 place roof molding clips and not equipped with roof molding cap A A 2 1 4 3 I2RH01980006 01 1 Roof molding 3 Roof molding clip Locate between punch...

Page 1277: ...06002 A A A B A 5 4 7 7 3 2 1 B A 5 6 7 2 1 A B A A A A I3RH0A980004 01 A For wagon model 1 Front fender splash guard 4 Rear door splash guard 7 Adhesive tape B For sedan model 2 Side sill splash guar...

Page 1278: ...9M 3 Exterior Trim...

Page 1279: ...ped with Immobilizer Indicator Lamp 10C 11 DTC Is Not Output from Immobilizer Control Module 10C 12 DTC 11 32 Transponder Code Not Matched 10C 13 DTC 31 Transponder Code Not Registered 10C 13 DTC 12 F...

Page 1280: ...rness from engine Such disconnection clears DTCs for engine and emission control system and immobilizer control system stored in memory of ECM Take a note of DTC indicated first Immobilizer Control Mo...

Page 1281: ...ch by using ignition key with any type of metal 1 wound around its grip or in contact with it Or the system may detect abnormal condition and prevent engine from starting Do not leave ignition key whe...

Page 1282: ...teering lock assembly 2 Immobilizer Control Module compares the Transponder code read in Step 1 and that registered in Immobilizer Control Module and then checks if they match If they do not match ECM...

Page 1283: ...During diagnosis the malfunction indicator lamp stays ON If the diagnosis result is abnormal it immediately starts flashing ON and OFF However if the result is normal it remains ON Diagnosis takes ab...

Page 1284: ...G07 11 WHT RED PNK BLK RED PPL YEL BLK RED 11 27 a a WHT RED 1 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 I3RH0AA30008 01 1 Battery 5 RADIO DOME fuse 15 A 9 Immobilizer indicator lamp if equipped 13 Dat...

Page 1285: ...ains ON go to Step 2 If malfunction indicator lamp remains OFF go to Malfunction Indicator Lamp MIL Check in Section 1A 2 1 Using service wire 1 ground diagnostic switch terminal 2 to ground terminal...

Page 1286: ...ition switch is ON but without starting engine Does immobilizer indicator lamp flash Go to Step 3 If immobilizer indicator lamp remains ON go to Step 2 If immobilizer indicator lamp remains OFF go to...

Page 1287: ...I scan tool in detail refer to the operator s manual for SUZUKI scan tool 1 Turn ignition switch OFF 2 After setting program card to SUZUKI scan tool connect it to data link connector DLC 1 located on...

Page 1288: ...peated as long as diagnosis terminal is grounded and ignition switch is at ON position 3 After completing the check turn ignition switch OFF and disconnect service wire from diagnosis connector DTC Ta...

Page 1289: ...Immobilizer Control Module ECU code Start troubleshooting referring to applicable troubleshooting procedure P1620 84 P1622 82 ECM P1621 83 Serial data link circuit MCODE00012 0 01 MCODE00081 0 01 MCO...

Page 1290: ...ire ground terminal G04 19 in connector disconnected Does immobilizer indicator lamp light on at ignition switch ON Substitute a known good ECM and recheck Immobilizer indicator lamp faulty or PNK wir...

Page 1291: ...ol Module 4 Main relay 8 To data link connector 9th pin Step Action Yes No 1 Check voltage between G45 3 terminal and body ground with ignition switch turned ON Is it 10 14 V Go to Step 2 BLK RED wire...

Page 1292: ...om ignition key and that registered in Immobilizer Control Module match when ignition switch is ON If there is no Transponder code registered in Immobilizer Control Module this DTC is set DTC Troubles...

Page 1293: ...zer Control Module ECU code in ECM and Transponder code and ECM Immobilizer Control Module ECU code in Immobilizer Control Module by performing procedure described in Procedure after Immobilizer Contr...

Page 1294: ...procedure described in Procedure after ECM Replacement DTC 82 P1622 Fault in ECM S3RH0AA304012 Description This DTC is set when an internal fault is detected in ECM DTC Troubleshooting NOTE After repl...

Page 1295: ...ECU code If ECM Immobilizer Control Module ECU code is not transmitted from ECM Immobilizer Control Module sets this DTC DTC 83 P1621 When the ignition switch is turned to ON position ECM requests Imm...

Page 1296: ...e between Immobilizer Control Module 1 coupler terminal G45 1 and body ground with ignition switch turned ON Is it 4 5 V Go to Step 2 YEL wire short 2 1 Disconnect ECM coupler with ignition switch tur...

Page 1297: ...Control Module with coupler disconnected from it Voltage Check 1 Remove Immobilizer Control Module 1 from steering lock assembly with ignition switch OFF referring to Immobilizer Control Module Remov...

Page 1298: ...ith center punch 6 Disconnect coupler at Immobilizer Control Module 7 Remove Immobilizer Control Module 1 from steering lock assembly 2 Installation 1 Install Immobilizer Control Module 1 on steering...

Page 1299: ...Immobilizer Control Module code in Immobilizer Control Module and ECM Immobilizer Control Module code in ECM by performing the following procedure Perform Record ECU IMMOBI ECM and Register New Ig Ke...

Page 1300: ...Prepared by 1st Ed Nov 2003 2nd Ed Feb 2007...

Page 1301: ...19 mm 99500 54G10 01E 99500 54G10 01E SERVICE MANUAL VOLUME 1 OF 2 SERVICE MANUAL VOL 1 OF 2...

Page 1302: ...27 mm 99500 54G10 01E 99500 54G10 01E SERVICE MANUAL VOLUME 2 OF 2 SERVICE MANUAL VOL 2 OF 2...

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Suzuki Liana RH413, Service Manual

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