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Suzuki Liana RH418, Supplementary Service Manual

The Suzuki Liana RH418 Supplementary Service Manual is a comprehensive and essential resource for all Liana vehicle owners. This manual provides detailed instructions, diagrams, and procedures for maintenance, repair, and troubleshooting. Downloadable for free from manualshive.com, it ensures that you can conveniently access the information you need.

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5-ii Table of Contents

Input Shaft Speed Sensor Removal and 

Installation.......................................................5A-70

Input Shaft Speed Sensor Inspection................5A-70
Transmission Fluid Temperature Sensor 

Inspection........................................................5A-70

“O/D OFF” Switch Inspection ............................5A-72
Solenoid Valves (Shift Solenoid Valves, TCC 

Solenoid Valve and Pressure Control 
Solenoid Valve) Removal and Installation ......5A-72

Solenoid Valves (Shift Solenoid Valves and 

TCC Solenoid Valve) Inspection .....................5A-74

Pressure Control Solenoid Valve Inspection.....5A-75
Transmission Control Module (TCM) 

Removal and Installation.................................5A-76

Differential Side Oil Seal Replacement .............5A-77
A/T Fluid Cooler Hoses Replacement...............5A-77
Automatic Transaxle Unit Components.............5A-78
Automatic Transaxle Unit Dismounting and 

Remounting.....................................................5A-79

Automatic Transaxle Assembly Components ...5A-81
Automatic Transaxle Unit Disassembly.............5A-82
Oil Pump Components ......................................5A-89
Oil Pump Disassembly and Reassembly ..........5A-90
Oil Pump Inspection ..........................................5A-91
Forward Clutch Components ............................5A-92
Forward Clutch Preliminary Check....................5A-92
Forward Clutch Disassembly and 

Reassembly ....................................................5A-93

Forward Clutch Inspection ................................5A-95
Overdrive Clutch and Coast Clutch 

Components....................................................5A-96

Overdrive Clutch and Coast Clutch 

Preliminary Check ...........................................5A-96

Overdrive Clutch and Coast Clutch 

Disassembly and Reassembly ........................5A-97

Overdrive Clutch and Coast Clutch Inspection 5A-100
Planetary Gear Components...........................5A-101
Planetary Gear Operation Check ....................5A-102
Planetary Gear Disassembly and 

Reassembly ..................................................5A-102

Planetary Gear Inspection...............................5A-106
Reverse Clutch Components ..........................5A-106
Reverse Clutch Preliminary Inspection ...........5A-107
Reverse Clutch Disassembly and 

Reassembly ..................................................5A-108

Reverse Clutch Inspection ..............................5A-110
Counter Drive Gear Components....................5A-111
Counter Drive Gear Disassembly and 

Reassembly ..................................................5A-111

Counter Driven Gear Components..................5A-113
Counter Driven Gear Disassembly and 

Reassembly ..................................................5A-114

Valve Body Assembly Components ................5A-116
Valve Body Assembly Disassembly and 

Reassembly ..................................................5A-117

Differential Components..................................5A-118
Differential Removal and Installation...............5A-118
Differential Inspection......................................5A-120
Transaxle housing Removal and Installation ..5A-120
Transaxle Housing Inspection.........................5A-122

Transaxle Case Removal and Installation.......5A-122
Automatic Transaxle Unit Assembly ...............5A-122

Specifications ...................................................5A-132

Tightening Torque Specifications....................5A-132

Special Tools and Equipment .........................5A-133

Recommended Service Material .....................5A-133
Special Tool ....................................................5A-133

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

General Description ............................................. 5B-*

Manual Transaxle Construction .......................... 5B-*

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

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

Repair Instructions .............................................. 5B-*

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

Components...................................................... 5B-*

Gear Shift Control Lever and Cable Removal 

and Installation .................................................. 5B-*

Vehicle Speed Sensor (VSS) Removal and 

Installation ......................................................... 5B-*

Back Up Lamp Switch Removal and 

Installation ......................................................... 5B-*

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

Remounting....................................................... 5B-*

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

Installation ......................................................... 5B-*

Gear Shift and Select Shaft Disassembly and 

Assembly........................................................... 5B-*

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

and Assembly.................................................... 5B-*

Right Case Disassembly and Assembly ............. 5B-*
Left Case Disassembly and Assembly................ 5B-*
Input Shaft and Countershaft Components......... 5B-*
Input Shaft Disassembly and Assembly.............. 5B-*
Countershaft Disassembly and Assembly........... 5B-*
Gear Shift Shaft Components ............................. 5B-*
Gear Shift Shaft Disassembly and Assembly...... 5B-*
Differential Components...................................... 5B-*
Differential Disassembly and Assembly .............. 5B-*
Transfer Components ......................................... 5B-*
Transfer Assembly Disassembly and 

Assembly........................................................... 5B-*

Pinion Shaft Disassembly and Assembly............ 5B-*
Output Shaft Disassembly and Assembly ........... 5B-*
Transfer Assembly Inspection............................. 5B-*
Gear Tooth Surface Contact Inspection.............. 5B-*

Specifications ....................................................... 5B-*

Tightening Torque Specifications........................ 5B-*

Special Tools and Equipment ............................. 5B-*

Recommended Service Material ......................... 5B-*
Special Tool ........................................................ 5B-*

Summary of Contents for Liana RH418

Page 1: ...med 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 ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or aroun...

Page 2: ...lated manual below When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials as specified in each description All information illustrations and specifications contained in this literature are based on the latest product infor mation available at the time of publication approval And used as the main subject of description is the veh...

Page 3: ...ABS 4E Transmission Transaxle 5 i Precautions 5 1 Automatic Transmission Transaxle 5A 1 Manual Transmission Transaxle 5B Clutch 5C Steering 6 Precautions 6 Steering General Diagnosis 6A Steering Wheel and Column 6B Power Assisted Steering System 6C HVAC 7 Precautions 7 Heater and Ventilation 7A Air Conditioning System 7B Restraint 8 Precautions 8 Seat Belts 8A Air Bag System 8B Body Cab and Access...

Page 4: ......

Page 5: ...rative Emission Control System Inspection 0B Brake Discs and Pads Front Inspection 0B Brake Drums and Shoes Rear Inspection 0B Brake Hoses and Pipes Inspection 0B Brake Fluid Replacement 0B Brake Lever and Cable Inspection 0B Clutch Fluid Inspection 0B Tires Wheels Inspection 0B Wheel Discs Inspection 0B Wheel Bearing Inspection 0B Suspension System Inspection 0B Steering System Inspection 0B Driv...

Page 6: ... General Information General Information General Description Transmission Identification Number S3RH0B0101008 The automatic transmission identification number is located on transmission case I3RH01010004 01 ...

Page 7: ...ecified conditions If fluid level is low replenish specified fluid Automatic Transaxle Fluid Replacement S3RH0B0206031 1 Inspect transaxle case 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 Cooler Hose Inspection S3RH0B0206032 Check automatic transax...

Page 8: ...check 3 Remove level plug of transfer or differential and check oil level Oil level can be checked roughly by means of level plug hole That is if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed oil is properly filled If oil is found insufficient pour specified amount of specified oil 4 Tighten level plug to specified torque A Transfer 1 Oil level fil...

Page 9: ... Light at Ignition Switch ON and Engine Does Not Start Through It Is Cranked Up 1A 41 DTC P0011 No 32 P0012 No 32 Camshaft Position Timing Over Advanced or System Performance Timing Over Retarded 1A 44 DTC P0105 No 11 Manifold Absolute Pressure MAP Circuit Malfunction 1A 46 DTC P0110 No 18 Intake Air Temp IAT Circuit Malfunction 1A 48 DTC P0115 No 19 Engine Coolant Temp ECT Circuit Malfunction 1A ...

Page 10: ...nstallation 1C Crankshaft Position CKP Sensor and Its Circuit Inspection 1C Vehicle Speed Sensor VSS and Its Circuit Inspection 1C Main Relay Fuel Pump Relay A C Compressor Relay and A C Condenser Fan Relay Inspection 1C Radiator Fan Relay No 1 No 2 and No 3 Inspection 1C Specifications 1C 3 Tightening Torque Specifications 1C 3 Engine Mechanical 1D 1 General Description 1D 1 Engine Construction D...

Page 11: ...mptom Diagnosis 1F Repair Instructions 1F Cooling System Components 1F Coolant Level Check 1F Engine Cooling System Inspection and Cleaning 1F Cooling System Flush and Refill 1F Cooling Water Pipes or Hoses Removal and Installation 1F Thermostat Removal and Installation 1F Thermostat Inspection 1F Water Valve If Equipped Removal and Installation 1F Water Valve If Equipped Inspection 1F Radiator Co...

Page 12: ...t 1H Special Tool 1H Starting System 1I Schematic and Routing Diagram 1I Cranking System Circuit Diagram 1I Diagnostic Information and Procedures 1I Cranking System Symptom Diagnosis 1I Cranking System Test 1I Repair Instructions 1I Starting Motor Dismounting and Remounting 1I Starting Motor Components 1I Starting Motor Inspection 1I Specifications 1I Cranking System Specifications 1I Tightening T...

Page 13: ...g in Section 00 in related manual Precautions on Engine Service Refer to Precautions on Engine Service in Section 1A Precautions in Diagnosing Trouble Refer to Precautions in Diagnosing Trouble in Section 1A Precautions on Fuel System Service Refer to Precautions on Fuel System Service in Section 1G in related manual ...

Page 14: ...idental entrance of foreign material which could follow intake passage into cylinder and cause extensive damage when engine is started Precautions in Diagnosing Trouble S3RH0B1100002 Don t disconnect couplers from ECM battery cable from battery ECM ground wire harness from engine or main fuse before confirming diagnostic information DTC etc stored in ECM memory Such disconnection will erase memori...

Page 15: ...ing to Engine and Emission Control System Check There is a close relationship between the engine mechanical engine cooling system ignition system exhaust system etc and the engine and emission control system in their structure and operation In case of an engine trouble even when the malfunction indicator lamp MIL doesn t turn ON it should be diagnosed according to this flow table On Board Diagnost...

Page 16: ...t 1 driving cycle of the DTC which is detected in the 2 driving cycle detection logic Data link connector DLC DLC 1 is in compliance with SAE J1962 in the shape of connector and pin assignment Serial data line K line of ISO 9141 3 is used for SUZUKI scan tool to communicate with ECM TCM ABS control module and Air bag SDM SUZUKI serial data line 6 is used for SUZUKI scan tool to communicate with im...

Page 17: ...the intake manifold Electronic Control System Description S3RH0B1101006 The electronic control system consists of 1 various sensors which detect the state of engine and driving conditions 2 ECM which controls various devices according to the signals from the sensors and 3 various controlled devices Functionally it is divided into the following sub systems Fuel injection control system Ignition con...

Page 18: ...ER CHECK VALVE FUEL INJECTOR ECT SENSOR TACHO METER SPEED METER VSS STOP LAMP SWITCH ELECTRIC LOAD RADIATOR FAN TCM HEATER CONTROL BAROMETRIC PRESSURE SENSOR HO2S 1 IMMOBILIZER CONTROL MODULE MIL A C EVAPRATOR INLET AIR TEMP SENSOR A C EVAPRATOR OUTLET AIR TEMP SENSOR A C SWITCH SIGNAL THROTTLE SIGNAL WATER TEMP SIGNAL A C COMPRESSOR CLUTCH AND CONDENSER FAN RELAY D RANGE SIGNAL TRANSMISSION RANGE...

Page 19: ...T RED BRN WHT BLK RED BLK RED BLK YEL BLK ORN BLK YEL BLK GRY RED GRY BLU LT GRN RED LT GRN LT GRN BLK ORN RED WHT PNK BLK YEL WHT BLU BLK WHT G04 17 BB 47 YEL BLK 48 45 46 G03 8 YEL BLK RED 52 53 53 WHT ORN 12V 5V BLU WHT BLK YEL BLK RED BLK ORN G04 1 8 11 G04 11 G04 9 BLU YEL 19 21 20 22 RED BLU BRN YEL BLK WHT YEL 23 C41 5 BLK RED BLU C41 12 24 WHT BLK 55 17 G03 12 12 PLL G03 1 G03 6 G03 14 G04...

Page 20: ...let air temp sensor 30 Injector No 4 50 Main relay 11 A C evaporator inlet air temp sensor 31 IAC valve 51 Transmission range switch A T 12 TCM A T 32 EVAP canister purge valve 52 Starting motor 13 Park neutral position switch A T 33 Fuel pump relay 53 Shield wire 14 ABS control module 34 Fuel pump 54 Main fuse 15 Blower fan motor 35 Radiator fan relay No 1 55 Barometric pressure sensor 16 A C con...

Page 21: ... color Circuit 1 BRN YEL A C compressor relay if equipped 13 2 GRN WHT Stop lamp switch 14 WHT BLK A C evaporator outlet air temp sensor 3 GRN RED Radiator fan relay 2 15 PNK BLK Test switch terminal 4 16 GRN BLK A C input signal if equipped 5 BLK RED Power source 17 YEL BLK Electric load signal 6 BLK RED Power source 18 BRN Radiator fan relay 1 7 BLU ORN A C pressure switch 19 8 GRY BLK Engine co...

Page 22: ...D A C EVAP INLET OUTLET AIR TEMP SENSORS IF EQUIPPED VSS HEATED OXYGEN SENSOR IAT SENSOR ECT SENSOR TP SENSOR MAP SENSOR CMP SENSOR CKP SENSOR TEST SWITCH TERMINAL KNOCK SENSOR FUEL PUMP RELAY FUEL INJECTOR HO2S HEATER IAC VALVE IGNITION COIL WITH IGNITER EVAP CANISTER PURGE VALVE A C COMPRESSOR RELAY RADIATOR FAN RELAY MIL MAIN RELAY TRANSMISSION CONTROL MODULE SIGNAL FROM SENSOR SWITCH AND CONTR...

Page 23: ...l System Diagram S3RH0B1102001 10 9 7 14 13 11 15 12 2 6 5 1 3 25 42 26 20 27 40 33 32 16 17 18 41 34 24 23 21 31 22 30 29 1 29 2 29 3 33 28 39 38 36 4 35 37 19 8 GEN I3RH0B110003 01 1 Air cleaner 16 CMP sensor 29 2 Test switch terminal 2 EVAP canister purge valve 17 CKP sensor 29 3 Duty output terminal ...

Page 24: ... switch 35 A C compressor clutch if equipped 9 Tank pressure control valve built in fuel pump 24 Starter magnetic switch 36 A C condenser fan motor if equipped 10 Fuel pump 25 TCM 37 A C switch if equipped 11 Ignition coil assembly 26 Generator 38 A C evaporator inlet air temperature sensor if equipped 12 Fuel injector 27 DLC 39 A C evaporator outlet air temperature sensor if equipped 13 Heated ox...

Page 25: ... connector 5 Heated oxygen sensor e Malfunction indicator lamp E Data link connector 6 VSS f Ignition coil assembly F A C EVAP inlet air temp sensor if equipped 7 Transmission range switch A T g Radiator fan control relay No 1 G A C EVAP outlet air temp sensor if equipped 8 Battery h Radiator fan control relay No 2 H A C compressor relay 9 CMP sensor i Radiator fan control relay No 3 I A C condens...

Page 26: ...8 5 Trouble symptom confirmation 1 Confirm trouble symptom referring to the Trouble Symptom Confirmation Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and record of DTC 1 Recheck for DTC referring to DTC Check Is there any DTC s Go to Step 9 Go to Step 8 7 Rechecking and record of DTC 1 Recheck for DTC referring to DTC Check Is there any DTC s Go to Step 9 Go to Step 10 8 En...

Page 27: ...urred 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 inspection form example NOTE The form is a standard sample It should be modified according to conditions characteristic of each market I2RH01110010 02 ...

Page 28: ...has been reached check the parts of the system suspected as a possible cause referring to Engine Symptom Diagnosis and based on symptoms appearing on the vehicle symptoms obtained through steps of customer complaint analysis trouble symptom confirmation and or basic engine check and repair or replace faulty parts if any Step 9 Troubleshooting for DTC See each DTC Diag Flow Based on the DTC indicat...

Page 29: ...ON Even with Grounding Diagnosis Switch Terminal NOTE If abnormality or malfunction lies in two or more areas malfunction indicator lamp indicates applicable codes three times each And flashing of these codes is repeated as long as diagnosis terminal is grounded and ignition switch is held at ON position Take a note of diagnostic trouble code indicated first 4 After completing the check turn the i...

Page 30: ...ion when driving with high engine load after engine warmed up 2 driving cycles P0135 No 14 HO2S heater circuit malfunction Sensor 1 Terminal voltage is lower than specification at heater OFF or it is higher at heater ON 1 driving cycle P0325 No 17 Knock sensor circuit malfunction Knock sensor circuit low input Knock sensor circuit high input 1 driving cycle P0335 No 23 Crankshaft position sensor c...

Page 31: ...ECT SENSOR ECM controls actuators assuming that engine coolant temperature is 80 C Radiator fan motor ON Hard starting rough or incorrect idle excessive fuel consumption hesitation poor acceleration detonation or spark knock P0120 No 13 TP SENSOR ECM controls actuators assuming that throttle opening is 20 Rough or incorrect idle excessive fuel consumption hesitation poor acceleration P0130 No 14 P...

Page 32: ...SED closed loop CALC LOAD CALCULATED LOAD VALUE At specified idle speed with no load after warming up 3 9 At 2500 r min with no load after warming up 12 17 COOLANT TEMP ENGINE COOLANT TEMP At specified idle speed after warming up 80 100 C 176 212 F SHORT FT B1 SHORT TERM FUEL TRIM At specified idle speed after warming up 20 20 LONG FT B1 LONG TERM FUEL TRIM At specified idle speed after warming up...

Page 33: ...ondition OFF RADIATOR FAN RADIATOR FAN CONTROL RELAY Ignition switch ON Engine coolant temp Lower than 95 C 203 F OFF Engine coolant temp 97 5 C 208 F or higher ON ELECTRIC LOAD Ignition switch ON Headlight small light and rear window defogger all turned OFF OFF Ignition switch ON Headlight small light or rear window defogger turned ON ON A C SWITCH Ignition switch turned ON A C switch and blower ...

Page 34: ...EED km h MPH It is computed based on pulse signals from vehicle speed sensor IGNITION ADVANCE IGNITION TIMING ADVANCE FOR NO 1 CYLINDER Ignition timing of No 1 cylinder is commanded by ECM The actual ignition timing should be checked by using the timing light INTAKE AIR TEMP C F It is detected by intake air temp sensor and used to determine the amount of air passing into the intake manifold as air...

Page 35: ...he throttle is not fully closed FUEL CUT ON OFF ON Fuel being cut output signal to injector is stopped OFF Fuel not being cut RADIATOR FAN RADIATOR FAN CONTROL RELAY ON OFF ON Command for radiator fan control relay operation being output OFF Command for relay operation not being output ELECTRIC LOAD ON OFF ON Headlight small light or rear window defogger ON signal inputted OFF Above electric loads...

Page 36: ... of air intake system disconnection looseness deterioration bend Connectors of electric wire harness disconnection friction Fuses burning Parts installation bolt looseness Parts deformation Other parts that can be checked visually Check the following items at engine start if possible Malfunction indicator lamp Operation Malfunction Indicator Lamp MIL Check Charge warning lamp Operation Generator S...

Page 37: ... 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 connector to ground 2 Using timing light check initial ignition timing Is it 5 3 BTDC at specified idle speed Go to Engine Symptom Diagnosis Check ignition control related parts referring to Ignition Timing ...

Page 38: ...ollows 1 Check MIL malfunction indicator lamp for flashing Is it flashing when ignition switch is turned to ON position Go to DTC Table in Section 10C in related manual Go to Step 11 11 Check fuel supply as follows 1 Check to make sure that enough fuel is filled in fuel tank 2 Turn ON ignition switch for 2 seconds and then OFF Is fuel pressure felt from fuel feed hose when ignition switch is turne...

Page 39: ...s it in good condition Go to Step 14 Go to Ignition System Symptom Diagnosis in Section 1H in related manual 14 Check fuel injector for operation as follows 1 Install spark plugs and connect injector connectors 2 Using sound scope 1 check operating sound of each injector 2 when cranking engine Was injector operating sound heard from all injectors Go to Engine Symptom Diagnosis Go to Fuel Injector ...

Page 40: ...n related manual Faulty ECM Low compression Compression Check in Section 1D Poor spark plug tightening or faulty gasket Spark Plug Inspection in Section 1H in related manual 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 Inspection in Section 1D Compressi...

Page 41: ... in Section 0B in related manual Malfunctioning oil pressure Oil Pressure Check in Section 1E in related manual Clogged oil strainer Oil Pan and Oil Pump Strainer Cleaning in Section 1E in related manual Functional deterioration of oil pump Oil Pump Inspection in Section 1E in related manual Worn oil pump relief valve Oil Pump Inspection in Section 1E in related manual Excessive clearance in vario...

Page 42: ...al Clogged oil filter or oil strainer Engine Oil and Filter Change in Section 0B in related manual or Oil Pan and Oil Pump Strainer Cleaning in Section 1E in related manual Poor oil pump performance Oil Pressure Check in Section 1E in related manual Faulty radiator fan control system Radiator Fan Control System Check Dragging brakes Condition Dragging brakes in Brakes Symptom Diagnosis in Section ...

Page 43: ...in related manual Inoperative thermostat Thermostat Inspection in Section 1F in related manual Poor water pump performance Water Pump Inspection in Section 1F in related manual Clogged or leaky radiator Radiator On Vehicle Inspection and Cleaning in Section 1F in related manual Improper engine oil grade Engine Oil and Filter Change in Section 0B in related manual Clogged oil filter or oil strainer...

Page 44: ...anual Engine Coolant Temperature ECT Sensor Inspection in Section 1C in related manual or Manifold Absolute Pressure MAP Sensor Inspection in Section 1C in related manual Fuel injector Fuel Injector Inspection in Section 1G Faulty ECM Inoperative thermostat Thermostat Inspection in Section 1F in related manual Poor water pump performance Water Pump Inspection in Section 1F in related manual Clogge...

Page 45: ...n 1G Faulty ECM Excessive detonation Engine makes continuously sharp metallic knocks that change with throttle opening Sounds like pop corn popping Faulty spark plug Spark Plug Inspection in Section 1H in related manual Loose connection of high tension cord High Tension Cord Inspection in Section 1H in related manual Clogged fuel filter faulty fuel pump or fuel lines Fuel Pressure Check Air inhali...

Page 46: ...il and Filter Change in Section 0B in related manual or Oil Pan and Oil Pump Strainer Cleaning in Section 1E in related manual Poor oil pump performance Oil Pressure Check in Section 1E in related manual Faulty radiator fan control system Radiator Fan Control System Check Dragging brakes Condition Dragging brakes in Brakes Symptom Diagnosis in Section 4A in related manual Slipping clutch Condition...

Page 47: ...y ECM Loose connection or disconnection of vacuum hoses Malfunctioning PCV valve PCV Valve Inspection in Section 1B in related manual Inoperative thermostat Thermostat Inspection in Section 1F in related manual Poor water pump performance Water Pump Inspection in Section 1F in related manual Clogged or leaky radiator Radiator On Vehicle Inspection and Cleaning in Section 1F in related manual Impro...

Page 48: ...ture ECT Sensor Inspection in Section 1C in related manual or Manifold Absolute Pressure MAP Sensor Inspection in Section 1C in related manual Faulty injector s Fuel Injector Inspection in Section 1G Faulty ECM Engine not at normal operating temperature Clogged air cleaner Vacuum leaks Excessive nitrogen oxides NOx emission Improper ignition timing Ignition Timing Inspection in Section 1H in relat...

Page 49: ...s OFF but if a malfunction was or is detected MIL remains ON even when the engine is running 1 G04 10 G04 23 12V 5V ECM 2 3 G04 6 B G04 5 B D A C BLK WHT BRN WHT BLK 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 17 18 8 19 20 21 22 23 24 BLK DN TS...

Page 50: ...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 voltage 10 14 V Go to Step 6 Go to Step 5 5 MIL power supply check 1 Turn ignition switch to OFF position 2 Remove combination meter referring to Combination Meter Removal and Installation in Section 9C ...

Page 51: ...RN G03 17 7 4 G03 7 PPL YEL 5 6 9 IG1 PNK BLK BLK RED BLK YEL 8 7 GRN GRN I3RH0A110012 01 1 BATT fuse 4 To battery 7 To ignition switch 2 Main fuse box 5 Diagnosis connector 8 Main relay 3 IG fuse 6 MIL 9 METER fuse Step Action Yes No 1 DTC check 1 Check DTC referring to DTC Check Is there any DTC s Go to Step 2 of Engine and Emission Control System Check Go to Step 2 2 DTC check 1 Start engine an...

Page 52: ... 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 MON PPL WHT C41 27 G04 15 PNK GRN G03 17 7 4 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...

Page 53: ...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 BLK RED BLK YEL 8 7 GRN GRN I3RH0A110012 01 1 BATT fuse 4 To battery 7 To ignition switch 2 Main fuse box 5 Diagnosis connector 8 Main relay 3 IG fuse 6 MIL 9 METER fuse Step Action Yes No 1 MIL circuit...

Page 54: ...wer is supplied to ECM 1 G04 10 G04 23 12V 5V ECM 2 7 3 G04 6 B G04 5 B D A C BLK WHT BRN WHT BLK 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 17 18 8 19 20 21 22 23 24 5 4 C41 3 C41 2 C41 1 BLK BLK IG1 BLK YEL 6 GRN BLK ORN I3RH0A110013 01 1 BAT...

Page 55: ...body ground Is voltage 10 14 V Go to Step 3 Open wire in BLK YEL circuit 3 Main relay check 1 Check for main relay referring to Main Relay Fuel Pump Relay A C Compressor Relay and A C Condenser Fan Relay Inspection in Section 1C in related manual Is main relay in good condition Go to Step 4 Replace main relay 4 Ignition signal check 1 Disconnect connectors from ECM with ignition switch turned OFF ...

Page 56: ... resistance 1 Ω or less Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 in related manual If OK substitute a known good ECM and recheck Open or high resistance wire in BLK ORN or BLK circuit 8 Main relay circuit check 1 Using service wire ground G04 10 wire terminal of ECM connector 2 Turn ignition switch to ON position 3 Measure v...

Page 57: ...1 3 7 1 A 4 5 6 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 17 18 8 19 20 21 22 23 24 I3RH0B110005 01 A Oil flow 2 ECM 4 Oil filter 6 Oil pan 1 Oil control valve 3 Camshaft position actuator 5 Oil pump 7 Intake camshaft DTC detecting condition Trouble area ...

Page 58: ...that the VVT GAP displayed on SUZUKI scan tool is 0 5 Is it OK Go to Step 4 Check valve timing referring to Timing Chain and Chain Tensioner Removal and Installation in Section 1D If OK go to Step 5 4 Camshaft position control signal check 1 Drive vehicle the following condition Vehicle speed at 80 km h 50 mile h Gear position at 5th or D range 2 Check that the VVT GAP displayed on SUZUKI scan too...

Page 59: ...g to Oil Control Valve Inspection in Section 1C Is it in good condition Replace camshaft timing sprocket Replace oil control valve Step Action Yes No ECM GRY RED ORN C41 22 5V 1 2 AMP C41 26 5V C41 10 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 17 18 8 19 2...

Page 60: ...heck wire harness 1 Disconnect connector from MAP sensor with ignition switch tuned OFF 2 Check for proper connection of MAP sensor at GRY RED and LT GRN RED wire terminals 3 If OK then with ignition switch ON check voltage between each of GRY RED or LT GRN RED wire terminals and body ground Is voltage about 4 6 V at each terminal Go to Step 4 GRY RED wire open or shorted to ground circuit or shor...

Page 61: ... start engine and keep it at idle for 1 min 2 Select DTC mode on scan tool and check DTC C41 10 C41 15 5V ECM LT GRN BLK ORN 1 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 17 18 8 19 20 21 22 23 24 I2RH0B110024 01 1 From other sensors DTC detecting condition...

Page 62: ...re terminals 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 connection are 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 Check intake air temp displayed on scan tool w...

Page 63: ...together 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 10 1 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 17 ...

Page 64: ...T GRN wire 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 with ignition switch OFF 2 Check for proper connection to ECT sensor at ORN and LT GRN wire terminals 3 If OK then with ignition switch ON Is voltage applied to LT GRN wire terminal about 4 ...

Page 65: ... for 1 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 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 I2RH0B110026 01 1 To MAP sensor and CO adjust resistor i...

Page 66: ...er connection 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 at each terminal Go to Step 4 GRY RED wire open GRY RED wire shorted to ground or power circuit or GRY BLU wire ORN wire open or shorted to ground circuit or poor C41 22 or C41 16 connection ...

Page 67: ...8 F or lower 1 Turn ignition switch OFF Clear DTC with ignition switch ON 2 Warm up engine to normal operating temperature 3 Drive vehicle at 70 100 km h 45 60 mph engine speed 1500 4000 r min for 6 min or more 4 Stop vehicle and run engine at idle for 2 min 5 Check DTC and pending DTC 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 12 13 14 15 16 17 18 19 20 21...

Page 68: ...up engine to normal operating temperature and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal to enrich and enlean A F mixture Does HO2S 1 output voltage deflect between 0 3 V and over 0 6 V repeatedly Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspectio...

Page 69: ...witch ON start engine and keep it at idle for 1 min 3 Start vehicle and depress accelerator pedal fully for 5 sec or longer 4 Stop vehicle 5 Check DTC ECM BLK WHT BLK BLK PNK BLK C41 7 IG1 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 17 18 8 19 20 21 22 23 2...

Page 70: ...check voltage at the same terminal Voltage should be below 1 9 V Are check results specified ones Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 in related manual Go to Step 3 3 Check heater of sensor 1 1 Disconnect HO2S 1 coupler with ignition switch OFF 2 Check for proper connection to HO2S 1 at BLK BLK WHT and PNK BLK wire term...

Page 71: ...n scan tool and check DTC ECM C41 25 5V 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 17 18 8 19 20 21 22 23 24 I3RH0A110019 01 DTC detecting condition Possible cause Knock sensor voltage is 3 91 V or more or Knock sensor voltage is 1 23 V or less RED cir...

Page 72: ... Recheck referring to Intermittent and Poor Connection Inspection in Section 00 in related manual Go to Step 3 3 Check knock sensor output 1 Stop engine 2 With ignition switch at OFF position disconnect knock sensor connector 3 With ignition switch at ON position check voltage from RED terminal of knock sensor connector to body ground Is it 4 5 V Faulty knock sensor Substitute a known good knock s...

Page 73: ...l 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 engine cranking CKP sensor circuit open or short Crankshaft timing belt pulley teeth damaged CKP sensor malfunction foreign material being attached or improper installation ECM malfunction I2RH0B110...

Page 74: ... 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 to Step 5 Go to Step 4 4 Was terminal Vout voltage out of specification in Step 3 check YEL BLK wire open short or poor connection If wire and connection are OK substitute a known good ECM and rechec...

Page 75: ...ance 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 sensor 7 Check signal rotor for the following Damage No foreign material attached Is it in good condition Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection In...

Page 76: ...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 15 16 16 17 1 2 7 8 13 14 3 4 9 10 15 17 18 8 19 20 21 22 23 24 C41 11 I2RH0B110051 01 DTC detecting condition Possible cause No CMP sensor signal during engine running CKP sensor signal is inputted CMP senso...

Page 77: ...urn 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 to Step 5 Go to Step 4 4 Was terminal Vout voltage out of specification in Step 3 check BLU wire open short or poor connection If wire and connection are OK substitute a known good ECM and recheck BL...

Page 78: ...stance 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 sensor 7 Check signal rotor for the following Damage No foreign material attached Is it in good condition Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection ...

Page 79: ...ator pedal and with engine brake applied keep vehicle coasting fuel cut condition for 4 sec or more 4 Check DTC 5V B BLK RED BLK ORN PPL 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 17 18 8 19 20 21 22 23 24 G04 24 1 4 c a b 2 3 7 5V G04 24 PPL BLK RED BLK O...

Page 80: ... Inspection in Section 00 in related manual Go to Step 5 5 Check VSS signal circuit 1 With turn OFF ignition switch disconnect connector from VSS 2 Disconnect combination meter connectors 3 Turn ON ignition switch without running engine 4 Measure voltage from terminal a of VSS connector to ground Is voltage within 4 5 V Faulty speedometer PPL wire open or short Poor connection of ECM connector ter...

Page 81: ...or connection of VSS connector terminal If OK substitute a known good VSS and recheck 9 Check VSS signal rotor 1 Turn OFF ignition switch 2 Visually inspect VSS signal rotor for damage Was any damage found Faulty VSS signal rotor Substitute a known 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...

Page 82: ... voltage from terminal PPL wire of TCM connector to ground Is voltage 0 V Go to Step 14 PPL wire shorted to power supply 14 Check VSS and its circuit 1 Check VSS and its circuit referring to Vehicle Speed Sensor VSS and Its Circuit Inspection in Section 1C in related manual Is it result satisfactory Go to Step 15 Repair or replace for VSS and its circuit 15 Check vehicle speed signal circuit for s...

Page 83: ...nsor Circuit Malfunction S3RH0B1104039 System Description Barometric pressure sensor is installed in ECM DTC Detecting Condition and Possible Cause DTC Confirmation Procedure 1 Turn ignition switch OFF 2 Clear DTC with 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 DTC DTC Troubleshooting DTC detecting condition Possible cause Dat...

Page 84: ...r 10 seconds 3 Check DTC Refer to DTC Check C41 1 C41 2 BLK ORN BLK BLK C41 3 YEL GRN BLK YEL RED G04 12 G04 21 3 2 1 3 7 1 A 4 5 6 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 17 18 8 19 20 21 22 23 24 I3RH0B110007 01 A Oil flow 2 ECM 4 Oil filter 6 Oil pan...

Page 85: ...to Step 3 Go to Step 5 3 Check oil control valve circuit Was resistance more than 6 5 Ω in Step 2 Go to Step 4 Go to Step 6 4 Check oil control valve circuit for power short 1 Turn on ignition switch 2 Measure voltage between G04 12 terminal of ECM connector and vehicle body ground Is voltage less than 1 V Go to Step 6 RED or GRN wire is shorted to power supply circuit 5 Check oil control valve ci...

Page 86: ...ch terminal voltage is affected by the battery voltage confirm that it is 11 V or more when ignition switch is turned ON Voltage with asterisk cannot be measured by voltmeter because it is pulse 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 5 6 1 2 3...

Page 87: ...8 No 9 and No 24 Engine running Output signal is active low pulse Pulse frequency varies depending on engine speed C41 9 Fuel injector No 1 10 14 V Ignition switch ON 0 0 6 V 10 14 V Reference waveform No 8 No 12 No 23 and No 24 Engine running Output signal is active low pulse Pulse frequency varies depending on engine speed C41 10 Sensor ground Below 0 3 V Ignition switch turned ON C41 11 Camshaf...

Page 88: ...k sensor 2 3 V Reference waveform No 13 and No 14 Ignition switch turned ON Run engine a 4 000 r min with after warning up C41 26 Manifold absolute pressure sensor 3 3 4 0 V Reference waveform No 16 Ignition switch turned ON with barometric pressure at 100 kPa 760 mmHg while engine is stopped 0 4 1 8 V Reference waveform No 17 While specified idle speed after warming up with barometric pressure at...

Page 89: ...y ratio varies depending on vehicle condition G04 13 Blank G04 14 A C evaporator outlet temperature sensor if equipped 3 3 3 8 V Ignition switch turned ON at A C evaporator outlet temperature 0 C 32 F 2 5 2 9 V Ignition switch turned ON at A C evaporator outlet temperature 15 C 59 F 1 9 2 3 V Ignition switch turned ON at A C evaporator outlet temperature 25 C 77 F G04 15 Test switch terminal 4 6 V...

Page 90: ...I serial data line 4 6 V Ignition switch ON G03 9 Engine coolant temp signal for meter 0 1 V 10 14 V Reference waveform No 21 Ignition switch turned ON Output signal is active low duty pulse Duty ratio varies depending on ECT 40 C 10 ON duty 120 C 90 ON duty G03 10 Electric load signal 4 14 V Ignition switch turned ON and blower motor switch turned to 1st speed position or OFF 0 2 V Ignition switc...

Page 91: ...med up to normal operating temperature Drive vehicle at 20 km h 12 mil h and depress accelerator pedal fully A Accelerator pedal depress fully B Accelerator pedal depress partially 1 Oil control valve signal I3RH0B110008 01 I3RH0B110009 01 Measurement terminal CH1 C41 13 to C41 10 CH2 C41 7 to C41 1 Oscilloscope setting CH1 500 mV DIV CH2 20 V DIV TIME 1 s DIV Measurement condition After warmed up...

Page 92: ...rmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 No 2 and No 3 ignition signal I3RH0A110030 01 I3RH0B110010 01 Measurement terminal CH1 C41 11 to C41 1 CH2 C41 20 to C41 1 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle ...

Page 93: ...loscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 No 3 fuel injector signal I3RH0B110013 01 I3RH0B110014 01 Measurement terminal CH1 C41 11 to C41 1 CH2 C41 21 to C41 1 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DIV Measurement ...

Page 94: ...cilloscope setting CH1 1 V DIV TIME 200 μs DIV Measurement condition After warmed up to normal operating temperature Run engine at 4000 r min I3RH0A110039 01 I3RH0A110040 01 Measurement terminal CH1 C41 11 to C41 1 CH2 C41 23 to C41 1 Oscilloscope setting CH1 2 V DIV CH2 2 V DIV TIME 20 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cy...

Page 95: ...rement terminal CH1 G04 24 to C41 1 Oscilloscope setting CH1 5 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Drive vehicle at 30 km h 19 mil h I3RH0A110043 01 I3RH0A110044 01 Measurement terminal CH1 C41 11 to C41 1 CH2 G03 1 to C41 1 Oscilloscope setting CH1 5 V DIV CH2 5 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating te...

Page 96: ...g CH1 5 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Drive vehicle at 40 km h 25 mil h or more I3RH0A110047 01 I3RH0A110048 01 Measurement terminal CH1 C41 20 to C41 1 CH2 C41 9 to C41 1 CH3 C41 11 to C41 1 CH4 C41 30 to C41 1 Oscilloscope setting CH1 5 V DIV CH2 50 V DIV CH3 5 V DIV CH4 10 V DIV TIME 100 ms DIV Measurement condition After warmed up to...

Page 97: ...113009 01 Terminals CIrcuit Standard resistance C41 7 to G04 23 HO2S 1 heater 5 0 10 Ω C41 9 to G04 5 6 No 1 injector 11 3 17 Ω C41 21 to G04 5 6 No 2 injector 11 3 17 Ω C41 31 to G04 5 6 No 3 injector 11 3 17 Ω C41 8 to G04 5 6 No 4 injector 11 3 17 Ω C41 4 to G04 5 6 EVAP canister purge valve 30 37 Ω C41 24 to G04 23 Fuel pump relay 56 151 Ω G04 1 to G04 23 A C compressor relay 56 151 Ω G04 9 to...

Page 98: ... 3 injector 2 No 2 injector 4 No 4 injector Step Action Yes No 1 Check injector for operating sound 1 Using sound scope check each injector for operating sound at engine cranking Do all 4 injector make operating sound Furl injector circuit is in good condition Go to Step 2 2 Does none of 4 injectors make operating sound at Step 1 Go to Step 3 Check coupler connection and wire harness of injector n...

Page 99: ...D BLK RED C41 24 ECM 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 17 18 8 19 20 21 22 23 24 1 2 I2RH0B110079 01 1 Fuel pump relay 2 Fuel pump Step Action Yes No 1 Check fuel pump control system for operation Is fuel pump heard to operate for 2 sec after igni...

Page 100: ...K BLK or BLK RED circuit open or fuel pump malfunction 3 Check fuel pump relay for operation 1 Check resistance between each two terminals of fuel pump relay Fuel pump relay resistance Between terminals c and d Infinity Between terminals a and b 56 146 Ω 2 Check that there is continuity between terminals c and d when battery is connected to terminals a and b Is fuel pump relay in good condition BR...

Page 101: ...l pressure regulator for operation 1 Start engine and warm it up to normal operating temperature 2 Keep it running at specified idle speed Is fuel pressure then within 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi Normal fuel pressure Clogged vacuum passage for fuel pressure regulator or faulty fuel pressure regulator 4 Is there fuel leakage from fuel feed line hose pipe or their joint Fuel leakage fro...

Page 102: ...ct fuel return hose from pressure regulator and connect new return hose to it 2 Insert the other end of new return hose into approved gasoline container 3 Check again if specified pressure is obtained While doing so does fuel come out of return hose Faulty fuel pressure regulator Fuel leakage from injector fuel leakage from between injector and delivery pipe faulty fuel pump faulty check valve in ...

Page 103: ...h steering wheel turned to the right or left as far as it stops vehicle with power steering system System is in good condition Check power steering pressure switch signal circuit referring to Power Steering Pressure PSP Switch Signal Circuit Check If check result is OK go to Step 5 5 Was idle speed higher than specification in Step 1 Go to Step 6 Go to Step 9 6 1 Check A C input signal circuit ref...

Page 104: ...nition switch ON 2 Check 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 referring to Step 3 or Step 4 of Idle Air Control Circuit Check Is check result satisfactory Go to Step 13 Go to Step 4 of Idle Air Control Circuit Check 13 Was IAC duty more than ab...

Page 105: ...ontrol system 1 Connect SUZUKI scan tool to DLC with ignition switch OFF set parking brake and block drive wheels 2 Warm up engine to normal operating temperature 3 Clear DTC and select MISC TEST mode on SUZUKI scan tool Is it possible to control increase and reduce engine idle speed by using SUZUKI scan tool Circuit is in good condition Go to Step 4 3 Check idle air control system 1 Remove IAC va...

Page 106: ... C41 6 terminal 6 If OK check BLK RED GRN RED and BLK circuit for open and short Are they in good condition Replace IAC valve and recheck Repair or replace Step Action Yes No 6 IG2 M ECM BLU BLK GRN BLK BLU ORN G03 10 12 V 12 V 12 V G04 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...

Page 107: ...Evaporator temp sensor resistance At 0 C 6 3 6 9 kΩ At 25 C 1 8 2 2 kΩ Is it within specification Go to Step 2 Faulty A C evaporator temp sensor or its circuit 2 Check A C switch signal 1 Check voltage at terminal G04 16 under each condition given as follows Voltage at terminal G04 16 Ignition switch ON A C switch OFF 10 14 V Ignition switch ON A C switch ON and blower motor switch 1st speed posit...

Page 108: ...to Step 5 BLU YEL wire open or short Poor G04 9 terminal connection If wire and connection are OK substitute a known good ECM and recheck Then go to Step 5 5 Check A C condenser fan control relay 1 Turn ignition switch OFF and remove A C condenser fan 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 c...

Page 109: ...rned ON while engine running A C control system is in good condition Go to Step 8 8 Check A C compressor signal 1 Check voltage at G04 1 terminal under each condition given as follows Voltage at G04 1 terminal While engine running A C switch OFF 10 14 V While engine running A C switch ON 0 V NOTE When A C evaporator thermistor temp is below 2 5 C 36 5 F A C remains OFF G04 1 terminal voltage becom...

Page 110: ...lay 10 Check A C compressor circuit 1 Disconnect connector from A C compressor with ignition switch at OFF position 2 Check voltage at A C compressor harness under each condition given as follows Voltage at A C compressor harness While engine running A C switch OFF 0 V While engine running A C switch ON 10 14 V Is check result satisfactory Check A C compressor referring to Compressor Inspection Ma...

Page 111: ... 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 Start engine and select DATA LIST mode on scan tool 3 Check electric load signal under the following each condition Electric load signal Clearance light rear defogger and blower motor all turned OFF ...

Page 112: ...d 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 electric load circuit malfunction Step Action Yes No I2RH0B110086 01 BATT 80A 30A 60A BLK ECM BLK ORN BLK C41 1 C41 3 L L H H BRN C41 31P G04 24P G03 17P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 113: ...Fan Control Circuit Check 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 Measure voltage between vehicle body ground and G04 3 terminal wire Is voltage lower 1 5 V Go to Step 5 Faulty ECM 5 Check radiator fan No 2 wire circuit 1 Disconnect connector from radiator fan with ignition ...

Page 114: ...iator fan harness connector Is voltage 10 14 V Go to Step 11 BLU RED wire open circuit 11 Check radiator cooling fan 1 Check radiator cooling fan referring to Radiator Cooling Fan On Vehicle Inspection in Section 1F in related manual Is it good condition BLK wire in radiator fan harness connector open circuit Faulty radiator cooling fan Step Action Yes No BATT 80A 30A 60A BLK ECM BLK ORN BLK C41 1...

Page 115: ...y box with ignition switch turned OFF 2 Turn ON ignition switch measure voltage between vehicle body ground and G04 18 terminal wire Is voltage 10 14 V Go to Step 6 Go to Step 3 3 Check wire circuit 1 Disconnect connector from ECM with ignition switch turned OFF 2 Disconnect radiator fan control relay No 1 from relay box 3 Measure resistance between G04 18 terminal wire and vehicle ground Is resis...

Page 116: ... ground and each BLU RED wire terminal 1 Radiator fan relay No 1 Is voltage lower 10 14 V Go to Step 8 BLU RED wire open circuit 8 Check wire circuit 1 Disconnect connector from ECM with ignition switch turned OFF 2 Connect radiator fan control relay No 2 to relay box 3 Turn ON ignition switch measure voltage between vehicle body ground and G04 3 terminal wire Is voltage 10 14 V Go to Step 9 Go to...

Page 117: ... 1C in related manual Is result in good condition GRN RED wire open circuit Replace relay 13 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 102 C 216 F 3 Measure voltage between vehicle body ground and G04 3 terminal wire Is voltage lower 1 5 V Radiator cooling fan control circuit is in good condition Faulty ECM Step...

Page 118: ...uit 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 position 10 14 V Engine running and steering wheel turned to the right or left as far as it stops 0 1 V Is each voltage as specified Signal circuit is in good condition Go to Step 4 4 Check wire harness...

Page 119: ... 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 terminal C41 12 under each condition given as follows vehicle at stop Voltage at terminal C41 12 While engine running 10 14 V While engine running at 2000 rpm or less and throttle valve is not totally clo...

Page 120: ...ntenance schedule All accessories wipers heater lights A C etc are out of service Air cleaner has been properly installed and is in good condition Ignition timing is within specification No abnormal air inhaling from air intake system After the items are all confirmed check idle speed and IAC duty as follows NOTE Before starting engine place transmission gear shift lever in Neutral shift selector ...

Page 121: ...emove service wire from diagnosis connector 6 Check that specified engine idle speed is obtained with A C ON if vehicle is equipped with A C If not check A C control circuits and idle air control system referring to A C Control System Check Vehicle with A C and Idle Air Control System Check Engine idle speed and IAC duty NOTE Above duty values are ON duty low voltage rate meter indications A T M T...

Page 122: ...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 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 10 RS232 loop back connector 11 Storage case 12 Power supply ...

Page 123: ...e speed Disconnect vacuum hose 1 from EVAP canister purge valve 2 With finger placed against hose disconnected check that vacuum is applied If it is not applied clean vacuum passage by blowing compressed air Vacuum Hose Inspection S3RH0B1206006 Check hoses for connection leakage clog and deterioration Replace as necessary I2RH0B120003 01 I2RH0B120004 01 ...

Page 124: ...to Throttle Body Removal and Installation in Section 1D Idle Air Control IAC Valve Inspection S3RH0B1306002 1 Connect each connector to IAC valve 1 TP sensor and IAT sensor 2 Check that rotary valve 2 of lAC valve opens and closes once and then stops in about 60 ms as soon as ignition switch is turned ON NOTE This check should be performed by two people one person turns ignition switch ON while th...

Page 125: ...trol valve Replace oil control valve if its mating surface is damaged 2 Check resistance between terminals of oil control valve Resistance of oil control valve 6 7 7 7 Ω at 20 C 68 F Heated Oxygen Sensor HO2S Removal and Installation S3RH0B1306011 Removal WARNING To avoid danger of being burned do not touch exhaust system when system is hot Oxygen sensor removal should be performed when system is ...

Page 126: ...der head Installation 1 Check that O ring is free from damage 2 Check that CMP sensor and signal rotor teeth are free from any metal particles and damage 3 Install CMP sensor 1 to cylinder head Tightening torque Camshaft position sensor bolt a 10 N m 1 0 kgf m 7 5 lb ft 4 Connect connector to it securely 5 Connect negative cable to battery Specifications Tightening Torque Specifications S3RH0B1307...

Page 127: ... 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 camshaft is mounted over the cylinder head it is driven from crankshaft through timing chain and no push rods are provided in the valve train system I3RH0B140001 01 ...

Page 128: ...em operation the intake valve timing is varied by the cam timing sprocket 1 which varies the rotational phase between the intake camshaft 3 and sprocket The rotor 2 in the cam timing sprocket is actuated by switching or adjusting the hydraulic pressure applied to the chambers for the timing advancing 7 and or retarding 6 To switch or adjust the hydraulic pressure appropriately ECM operates the oil...

Page 129: ...efore the actuation of the rotor makes the phase difference between the sprocket and intake camshaft Timing advancing When the duty ratio of the signal output from the ECM is heavy the spool valve 4 of the oil control valve moves to the left opposite direction against the coil 5 By this spool valve movement the pressurized oil 1 is led into the chambers for timing advancing and the oil in the cham...

Page 130: ...n Light engine load range To the retarded side To shorten the valve opening overlap in order to prevent the exhaust gas counter flow to intake manifold Keeping of the engine stability Low or average engine speed range with heavy engine load To the advanced side To advance the closing timing of the intake valve in order to improve the volumetric efficiency Improvement of generating the engine torqu...

Page 131: ...ole Special tool A 09915 64512 B 09915 64530 C 09915 67010 9 Disengage clutch 1 to lighten starting load 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 For measuring compression pressure crank engine at least 250 r min by using fully charged battery ...

Page 132: ...ng procedure is as follows 1 Warm up engine to normal operating temperature NOTE After warming up engine be sure to place transaxle gear shift lever in Neutral shift selector lever to P range for A T model and set parking brake and block drive wheels 2 Stop engine and turn off the all electric switches 3 Remove engine cover 1 4 Remove PCV hose 1 from PCV valve 2 5 Connect special tool Vacuum gauge...

Page 133: ...camshafts by 90 by turning crankshaft with wrench c Make sure that cam lobes are perpendicular to shim faces at valves to be checked in this case 3 and 8 if not adjust it by turning crankshaft Check valve lashes d In the same manner as b c check valve lashes at valves 4 and 6 e In the same manner as b c again check valve lashes at valves 2 and 5 If valve lash is out of specification record valve l...

Page 134: ...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 A 09916 67021 or 09916 67020 Tightening torque Camshaft housing bolt a 8 N m 0 8 kgf m 6 0 lb ft for tightening of special tool 4 Turn camshaft by approximately 90 clockwise and remove shim 3 WARNING Never put in the hand between camshaft an...

Page 135: ...nd remove special tool Special tool A 09916 67021 or 09916 67020 9 Install camshaft housing 1 and tighten bolts to specified torque Tightening torque Camshaft housing bolt a 11 N m 1 1 kgf m 8 0 lb ft 10 Check valve clearance again after adjusting it 11 After checking and adjusting all valves 12 Install cylinder head cover referring to Cylinder Head Cover Removal and Installation Thickness mm in S...

Page 136: ...ck air cleaner element for dirt Replace excessive dirty element Cleaning Blow off dust by compressed air from air outlet side of element Accelerator Cable Adjustment S3RH0B1406003 With accelerator pedal depressed fully check clearance between throttle lever 1 and lever stopper 2 throttle body which should be within the following specification If measured value is out of specification adjust it to ...

Page 137: ... 1F in related manual 3 Disconnect accelerator cable 1 from throttle valve lever 4 Disconnect IAT sensor connector and remove air cleaner assembly with air cleaner outlet hose 5 Disconnect electric connector from TP sensor 1 and IAC valve 2 6 Remove throttle body from intake manifold 7 Disconnect engine coolant hoses from throttle body 1 Throttle body 4 Gasket 7 TP sensor screws 2 Gasket 5 Idle ai...

Page 138: ...H0B1406007 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 damage to any other parts Assembly 1 Install IAC valve to throttle body referring to Idle Air Control IAC Valve Removal and Installation in Section 1C 2 Install TP sensor to throttle body referring to T...

Page 139: ...t 19 Cushion 2 Intake manifold gasket 8 TP sensor 14 Intake manifold mounting bolt long 20 Fuel delivery pipe mounting bolt 3 Throttle body 9 IAC valve 15 EGR pipe gasket if equipped Tightening torque 4 Gasket 10 Fuel delivery pipe 16 O ring Do not reuse 5 EGR pipe if equipped 11 Intake manifold stiffener 17 Grommet 6 MAP sensor 12 Intake manifold mounting nut 18 Injector assembly ...

Page 140: ...fold Each wire harness clamps 6 Disconnect accelerator cable from throttle body and remove its bracket from intake manifold 7 Disconnect the following hoses Brake booster hose 1 from intake manifold PCV hose 2 from PCV valve Canister purge hose 3 from EVAP canister purge valve Water hoses 4 from throttle body and thermostat case Fuel pressure regulator vacuum hose from intake manifold Fuel feed ho...

Page 141: ...nstallation turn ignition switch ON but engine OFF and check for fuel leaks Finally start engine and check for engine coolant leaks Cylinder Head Cover Removal and Installation S3RH0B1406011 Removal 1 Disconnect negative 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...

Page 142: ... 4 Tightening bolts in such order as indicated in the figure a 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 valve 3 6 Connect breather hose 4 7 Install oil level gauge 1 8 Install power steering hose bracket to cylinder head cover if removed 9 Instal...

Page 143: ...1 A A T model 3 Engine left mounting 7 Engine front torque bush B M T model 4 Engine left mounting bracket No 1 8 Mounting member 1 Engine right mounting 5 Engine left mounting bracket No 2 9 Suspension frame 2 Engine right mounting bracket 6 Engine rear mounting Tightening torque ...

Page 144: ... S pump at a place where no damage will be caused during removal and installation of engine assembly 11 Disconnect the following electric wires 12 Remove fuse box from its bracket 13 Disconnect 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 2 Starting m...

Page 145: ...s 1 and engine right mounting bracket nuts 2 22 Before removing engine with transaxle from body recheck to make sure all hoses electric wires and cables are disconnected from engine and transaxle 23 Lower engine with transaxle 1 from body NOTE Before lowering engine to avoid damage to P S pump and or A C compressor raise it through clearance made on engine crankshaft pulley side At this time use c...

Page 146: ...Connect drive shaft joints referring to Front Drive Shaft Assembly Removal and Installation in Section 3A 9 Install exhaust No 1 and No 2 pipes referring to Exhaust Pipe Removal and Installation in Section 1K in related manual 10 Install suspension frame 1 with stabilizer bar and suspension control arms referring to Front Suspension Frame Removal and Installation in Section 2B in related manual 11...

Page 147: ... ring a 3 mm 0 12 in 9 Oil pan mounting nut 19 Oil control valve b 2 mm 0 08 in 10 Cylinder head cover See C 20 Oil control valve mounting nut 1 Crankshaft pulley bolt 11 Oil gallery pipe No 1 21 O ring 2 Crankshaft pulley 12 Copper washer 22 Cap 3 Oil seal Apply engine oil to oil seal lip 13 Oil gallery pipe No 1 bolt 23 O ring 4 Timing chain cover See A See B 14 Oil gallery pipe No 2 24 Cap bolt...

Page 148: ...ial tool A 09917 68221 3 Remove crankshaft pulley 1 If it is hard to remove use special tools as shown in the figure Special tool A 09944 36011 B 09926 58010 4 Remove cylinder head cover and oil pan referring to Cylinder Head Cover Removal and Installation and Oil Pan and Oil Pump Strainer Removal and Installation in Section 1E 5 Remove P S pump bracket if equipped 6 Remove water pump pulley 7 Rem...

Page 149: ...cation Tightening torque Oil gallery pipe No 1 bolt b 30 N m 3 0 kgf m 21 5 lb ft 5 Apply sealant A to mating surface between cylinder and cylinder head and apply sealant B to mating surface of timing chain cover as shown in the figure A Sealant 99000 31140 B Water tight sealant 99000 31250 Sealant amount for timing chain cover Width a 3 mm 0 12 in Height b 2 mm 0 08 in 6 Apply engine oil to oil s...

Page 150: ... 1 Tighten bolt 2 to specified torque To lock crankshaft pulley use special tool with it as shown in the figure Special tool A 09917 68221 Tightening torque Crankshaft pulley bolt a 150 N m 15 0 kgf m 108 5 lb ft 16 Install engine assembly to vehicle referring to Engine Assembly Removal and Installation Timing Chain Cover Cleaning and Inspection S3RH0B1406016 Clean Clean sealing surface on timing ...

Page 151: ...in and Chain Tensioner Components S3RH0B1406017 1 2 I3RH0B140029 01 1 3 2 I3RH0B140030 01 I3RH0B140031 01 1 Crankshaft timing sprocket 4 Timing chain tensioner Apply engine oil to sliding surface 7 Chain tensioner mounting bolt 2 Timing chain Apply engine oil 5 Timing chain tensioner adjuster assembly 8 Chain guide mounting bolt 3 Timing chain No 1 guide Apply engine oil to sliding surface 6 Chain...

Page 152: ...ay occur between piston 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 than such an extent a b as shown in the figure If turned interference may occur between piston and valves and valves themselves and parts related to piston and valves may be damaged 1...

Page 153: ... bolts to specified 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 bolt to specified torque Tightening torque Timing chain tensioner bolt a 25 N m 2 5 kgf m 18 0 lb ft 7 Check that match marks 1 on intake and exhaust camshaft timing sprockets are in...

Page 154: ... ft 10 Apply engine oil to timing chain and then turn crankshaft clockwise by 2 revolutions and check that match marks 1 on intake and exhaust camshaft timing sprockets are in match with notches 2 on cylinder head and key 3 is in match with notch 4 on cylinder block 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 Insta...

Page 155: ...e Timing Chain Tensioner Check shoe 1 for wear or damage Crankshaft Timing Sprocket Check teeth of sprocket for wear or damage Timing Chain Check timing chain for wear or damage Timing Chain Tensioner Adjuster Check that tooth surface 1 are free from damage I2RH0B140068 01 I2RH0B140069 01 I2RH0B140070 01 I2RH01140077 01 I2RH0B140071 01 ...

Page 156: ...move timing chain referring to Timing Chain and Chain Tensioner Removal and Installation 3 With hexagonal section 1 of intake camshaft 2 held stationary with spanner or the like loosen mounting bolt of intake cam timing sprocket assembly 3 and remove it I3RH0B140037 01 1 Intake camshaft 5 Shim Shim No on it faces tappet side 9 Camshaft bearing Install a bearing half with some holes to upper side o...

Page 157: ...ake sure to direct shim No side toward tappet 2 Install camshaft bearing 1 to cylinder head CAUTION Do not apply engine oil to camshaft bearing back Only a upper half bearing of intake camshaft bearing No 1 has some holes Other bearings 3 Install intake camshaft 1 and exhaust camshaft 2 Align knock pin 3 and match mark 4 with notches 5 as shown in the figure NOTE Before installing camshafts turn c...

Page 158: ... N m 1 1 kgf m 8 0 lb ft by the specified procedure 8 With hexagonal section 1 of intake camshaft 2 held stationary with spanner or the like tighten bolt of intake cam timing sprocket assembly 3 to specification Tightening torque Intake cam timing sprocket bolt a 60 N m 6 0 kgf m 43 5 lb ft 9 Install timing chain with crankshaft sprocket referring to Timing Chain and Chain Tensioner Removal and In...

Page 159: ...haft Camshaft runout limit 0 10 mm 0 0039 in Camshaft Journal Wear Check camshaft journals and camshaft 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 by using gauging plastic Checking procedure is as follows 1 Clean housings and camshaft journals 2 Remo...

Page 160: ...eter of camshaft journal Replace camshaft or cylinder head assembly whichever the difference from specification is greater Camshaft journal specification Item Standard Limit Intake side No 1 housing 0 020 0 072 mm 0 0008 0 0028 in 0 10 mm 0 0039 in Others 0 045 0 087 mm 0 0018 0 0034 in 0 12 mm 0 0047 in 10 9 2 1 a 6 5 14 13 20 17 19 18 21 12 11 4 3 8 7 16 15 I3RH0B140041 01 I2RH0B140083 01 Item S...

Page 161: ... diameter to determine cylinder head to tappet clearance If clearance exceeds limit replace tappet or cylinder head Cylinder head to tappet clearance Standard 0 025 0 066 mm 0 0010 0 025 in Limit 0 15 mm 0 0059 in Tappet outside diameter A Standard 30 959 30 975 mm 1 2189 1 2194 in Cylinder head tappet bore B Standard 31 000 31 025 mm 1 2205 1 2214 in I2RH0B140085 01 I2RH0B140086 01 ...

Page 162: ...t for M10 Make sure cylinder head bolt M10 diameter when reuse 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 ft 40 N m 4 0 kgf m 29 0 lb ft 60 and 60 by the specified procedure Do not reuse 4 Valve stem seal 10 Cylinder head Apply engine oil to sliding surface of each part 5 Valve spring seat 11 Cylinder hea...

Page 163: ...ing 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 disconnected and remove or disconnect whatever necessary 10 Remove exhaust manifold if necessary referring to Exhaust Manifold Removal and Installation in Section 1K in related manual 11 Remove cylinder head with...

Page 164: ...ew ones if thread diameter difference exceeds limit Measure each thread diameter of cylinder head bolt 1 at A on 83 5 mm 3 29 in from seat side of flange bolt and B on 115 mm 4 53 in from seat side of flange bolt by using a micrometer 2 Then calculate difference in diameters A B If it exceeds limit replace with new one Cylinder head bolt diameter measurement points a 83 5 mm 3 29 in b 115 mm 4 53 ...

Page 165: ...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 valve stem seal 1 once disassembled Be sure to use new valve stem seal when assembling 6 Using special tool Valve guide remover drive valve guide out from combustion chamber side to valve spring side Special tool A 09916 44910 NOTE Do not reuse valve guide o...

Page 166: ...versize 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 09916 34542 B 09916 34550 4 Install valve spring seat to cylinder head 5 Install new valve stem seal 1 to valve guide After applying engine oil to seal and spindle of special tool Valve guide install...

Page 167: ...4910 C 09916 84511 9 Install intake manifold injectors and exhaust manifold to cylinder head Valves and Valve Guides Inspection S3RH0B1406026 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 place along the length of each stem and guide If clearance exceeds limit replace valve a...

Page 168: ...ure thickness a of valve head If measured thickness exceeds limit replace valve Valve head thickness In and Ex Standard 1 25 1 55 mm 0 050 0 061 in Limit 0 9 mm 0 035 in Inspect valve stem end face for pitting and wear If pitting or wear is found there valve stem end may be resurfaced but not so much as to grind off its chamber When it is worn out too much that its chamber is gone replace valve Ch...

Page 169: ...ed the first for making 22 angle and the second for making 45 angle The second cut must be made to produce desired seat width Seat width for exhaust valve seat a 1 0 1 4 mm 0 0389 0 0551 in b Intake valve seat Use valve seat cutters 1 to make four cuts as illustrated in figure Four cutters must be used the 1st for making 75 angle the 2nd for making 22 angle the 3rd for making 60 angle and the 4th ...

Page 170: ...nder head surface on piston side 0 03 mm 0 001 in Distortion of manifold seating faces Check seating faces of cylinder head for manifolds using a straightedge and thickness gauge in order to determine whether these faces should be corrected or cylinder head replaced Limit of distortion for cylinder head surface on intake and exhaust manifold 0 05 mm 0 002 in Valve Spring Inspection S3RH0B1406028 R...

Page 171: ...ing 3 Oil ring 4 Piston 5 Connecting rod See A 6 Connecting rod bearing cap See B 7 Connecting rod bearing 8 Piston pin 9 Piston pin circlip 10 Bearing cap nut Tighten 15 N m 1 5 kgf m 11 0 lb ft 45 and 45 by the specified procedure Tightening torque Apply engine oil to sliding surface of each part Do not reuse A Apply engine oil to sliding surface except inner surface of big end and rod bolts Mak...

Page 172: ...efer 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 bearing or between bearing cap and bearing 2 Install guide hoses 1 over connecting rod bolts These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and pist...

Page 173: ...Rods and Cylinders Disassembly and Assembly S3RH0B1406031 Disassembly 1 Using piston ring expander remove two compression rings Top and 2nd and oil ring from piston 2 Remove piston pin from connecting rod Ease out piston pin circlips 1 as shown Force piston pin out Assembly 1 Install piston pin to piston 1 and connecting rod 2 a After applying engine oil to piston pin and piston pin holes in pisto...

Page 174: ...or deeply scratched or ridged rebore cylinder and use oversize piston Using a cylinder gauge 1 measure cylinder bore in thrust and axial directions at two positions a and b as shown in the figure If any of the following conditions is noted rebore cylinder 1 Cylinder bore dia exceeds limit 2 Difference of measurements at two positions exceeds taper limit 3 Difference between thrust and axial measur...

Page 175: ...follows If it is out of specification rebore cylinder and use oversize piston Piston clearance Standard 0 016 0 045 mm 0 0007 0 0017 in Limit 0 161 mm 0 0065 in NOTE Cylinder bore diameters used here are measured in thrust direction at two positions Ring groove clearance Before checking piston grooves must be clean dry and free of carbon deposits Fit new piston ring 1 into piston groove and measur...

Page 176: ...ton if its small end is badly worn or damaged or if measured clearance exceeds limit Piston pin clearance in small end Connecting rod small end 0 003 0 014 mm 0 00012 0 00055 in Piston 0 006 0 017 mm 0 00024 0 00066 in Small end bore 20 003 20 011 mm 0 7876 0 7878 in Piston pin diameter 19 997 20 000 mm 0 7873 0 7874 in Piston bore 20 006 20 014 mm 0 7877 0 7879 in Connecting Rod Big end side clea...

Page 177: ... use undersize bearing Connecting rod bearing and crank pin Out of round A B Taper a b Out of round and taper limits 0 01 mm 0 0004 in Connecting Rod Bolt Connecting rod bolt deformation Plastic deformation tightening bolt Measure each thread diameter of connecting rod 1 bolt 2 at A and B by using a micrometer 3 Calculate difference in diameters A B If it is exceeds limit replace connected rod Con...

Page 178: ...ure to point arrow mark 2 on cap to crankshaft pulley side as shown in the figure After applying engine oil to rod bolts tighten cap nuts 3 gradually as follows a Tighten all cap nuts to 15 N m 1 5 kgf m 11 0 lb ft 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 ca...

Page 179: ...rod 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 diameter respectively For example stamped A indicates that corresponding crankshaft pin diameter is 41 994 42 000 mm 1 6533 1 6535 in Crankshaft pin outer diameter Stamped numbers Connecting rod big...

Page 180: ... 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 standard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance Color painted Bearing thickness Blue 1 4991 1 5020 mm 0 05902 0 05913 in Yellow 1 4961 1 4990 mm 0...

Page 181: ... Components S3RH0B1406035 I3RH0B140048 01 A Sealant application amount 7 Crankshaft timing sprocket key 16 Rear oil seal housing mounting bolt a 3 mm 0 12 in 8 Crankshaft 17 Main bearing mounting No 2 bolt Tighten 25 N m 2 5 kgf m 18 0 lb ft by the specified procedure ...

Page 182: ...move 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 Installation 11 Remove rear oil seal housing 1 12 Loosen bearing cap No 1 and No 2 bolts in such order as indicated in the figure and remove them 13 Remove crankshaft from cylinder block b 2 mm 0 08 in 9 T...

Page 183: ...ensor plate bolt a 11 N m 1 1 kgf m 8 0 lb ft 2 Install main bearings to cylinder block Upper half of bearing 1 has an oil groove 2 Install it to cylinder block 3 and the other 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 crank webs 4 Confirm th...

Page 184: ...ply sealant to mating surface of rear oil seal housing 1 A Water tight sealant 99000 31250 Sealant amount for rear oil seal housing Width a 3 mm 0 12 in Height b 2 mm 0 08 in 8 Install rear oil seal housing 1 and tighten bolts to specified torque by using special tool Special tool A 09911 97720 Tightening torque Rear oil seal housing bolt 11 N m 1 1 kgf m 8 0 lb ft 9 Install flywheel drive plate f...

Page 185: ...lation in Section 5C in related manual 18 Install engine assembly to vehicle Refer to Engine Assembly Removal and Installation Crankshaft Inspection S3RH0B1406037 Runout Using a dial gauge measure runout at center journal Rotate crankshaft slowly If runout exceeds its limit replace crankshaft Crankshaft runout Limit 0 02 mm 0 0008 in Thrust Play Measure this play with crankshaft set in cylinder bl...

Page 186: ...nd or replace crankshaft Limit on out of round and taper 0 01 mm 0 0004 in Out of round A B Taper a b Main Bearings Inspection S3RH0B1406038 General Information Service main bearings are available in standard size and 0 25 mm 0 0098 in undersize and each of them has 5 kinds of bearings differing in tolerance Upper half of bearing 1 has oil groove 2 as shown in the figure Install this half with oil...

Page 187: ...ghten 25 N m 2 5 kgf m 18 0 lb ft by the specified procedure NOTE Do not rotate crankshaft while gauging plastic is installed 5 Remove bearing caps and measure gauging plastic 2 width at its widest point using scale 1 on gauging plastic envelop If clearance exceeds its limit replace bearing Always replace both upper and lower inserts as a unit A new standard bearing may produce proper clearance If...

Page 188: ...aring cap bore diameter without bearing On mating surface of cylinder block five alphabets are stamped as shown in the figure Three kinds of alphabets A B and C or numbers 1 2 and 3 represent the following cap bore diameters Stamped alphabets on cylinder block represent bearing cap bore diameter marked with an arrow in the figure respectively For example stamped A or 1 indicates that corresponding...

Page 189: ...installed by referring to number stamped on new crankshaft or alphabets stamped on new cylinder block Undersize bearing 0 25 mm 0 25 mm 0 0098 in undersize bearing is available in 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 center of bearing Under...

Page 190: ...ification Bearing Cap Bolt Measure each thread diameter bearing cap No 1 bolts 1 at A and B by using a micrometer 2 Calculate 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 Limit A B 0 2 mm 0 008 in Sensor Plate Inspection S3RH0B1406039 Check sensor plat...

Page 191: ...stortion and if flatness exceeds its limit correct It Cylinder block flatness Limit 0 03 mm 0 0012 in Honing or Reboring Cylinders 1 When any cylinder needs reboring all other cylinders must also be rebored at the same time 2 Select oversized piston according to amount of cylinder wear Oversize piston specification 3 Using micrometer measure piston diameter Measurement position for piston diameter...

Page 192: ...l valve mounting nut 11 1 1 8 0 Oil gallery pipe No 1 bolt 30 3 0 21 5 Timing chain cover bolt 25 2 5 18 0 Timing chain cover nut 25 2 5 18 0 Cap bolt 25 2 5 18 0 Oil gallery pipe No 2 and No 3 bolt 11 1 1 8 0 Crankshaft pulley bolt 150 15 0 108 5 Timing chain No 1 guide bolt 9 0 9 6 5 Timing chain tensioner bolt 25 2 5 18 0 Timing chain tensioner adjuster bolt 11 1 1 8 0 Camshaft housing bolt Tig...

Page 193: ...lves and Cylinder Head Components Pistons Piston Rings and Connecting Rods Components Main Bearings Crankshaft and Cylinder Block Components Special Tool S3RH0B1408002 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 tight sealant SUZUKI Bond No 1207F P No 99000 31250 09911 97720 09911 97820 Oil seal ...

Page 194: ...1 Valve guide installer remover Valve guide installer attachment protrusion 11 5 mm 09916 58210 09916 67021 Valve guide installer handle Tappet holder 09916 77310 09916 84511 Piston ring compressor 50 125 mm Forceps 09917 68221 09917 98221 Camshaft pulley holder Valve guide stem attachment 09924 17811 09926 58010 Flywheel holder Bearing remover attachment 09944 36011 Steering wheel remover ...

Page 195: ...aft 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 end of connecting rod to lubricate piston rings and cylinder wall In the other path oil goes up to the cylinder head and lubricates valves and camshafts etc after passing through the internal oilway of ca...

Page 196: ...c Transaxle Unit Dismounting and Remounting in Section 5A 5 Remove oil pan bolts and nuts 6 Cut sealant at hatched part shown in figure using special tool and hammer 1 Special tool A 09921 96510 NOTE Be careful not to damage stud bolt 3 between oil pan and cylinder block when cutting sealant 7 Remove oil pan 2 from cylinder block I3RH0B150002 01 A Sealant application amount 3 O ring 8 Oil pan nut ...

Page 197: ...uts to specified torque by numerical order as shown in figure Tightening torque Oil pan bolt and nut a Tighten 11 N m 1 1 kgf m 8 0 lb ft by the specified procedure 4 Install new gasket and drain plug to oil pan Tighten drain plug to specified torque Tightening torque Oil pan drain plug bolt b 50 N m 5 0 kgf m 36 5 lb ft 5 Install transaxle lower stiffener referring to Manual Transaxle Unit Compon...

Page 198: ...e 1 spring 2 and retainer 3 by removing circlip 4 I3RH0B150004 01 1 Rotor plate 6 Rotor plate bolt Tightening torque 2 O ring 7 Relief valve Do not reuse 3 Outer rotor 8 Spring Apply thin coat of engine oil to sliding surface of each parts 4 Inner rotor 9 Retainer 5 Timing chain cover For detail of timing chain cover components refer to Timing Chain Cover Components in Section 1D 10 Circlip I2RH0B...

Page 199: ...2 to oil pump case 4 Apply engine oil to relief valve 1 and spring 2 and install them with retainer 3 and new circlip 4 to rotor plate 5 5 Install rotor plate and tighten all bolts to specified torque After installing plate check to be sure that rotors turn smoothly by hand 0 3 N m 0 03 kgf m 0 25 lb ft torque or below Tightening torque Oil pump rotor plate bolt a 11 N m 1 1 kgf m 8 0 lb ft I2RH0B...

Page 200: ...ce Material S3RH0B1508001 NOTE Required service material is also described in the following Oil Pan and Oil Pump Strainer Components Oil Pump Components Special Tool S3RH0B1508002 Fastening part Tightening torque Note N m kgf m lb ft Oil pump strainer bolt 11 1 1 8 0 Oil pump strainer bracket bolt 11 1 1 8 0 Oil pan bolt and nut Tighten 11 N m 1 1 kgf m 8 0 lb ft by the specified procedure Oil pan...

Page 201: ...een pipe and joint Special tool A 09919 47020 c Disconnect joint 2 from pipe 1 4 Disconnect brake pipe from pipe joint 5 Mark the location of clamps 1 on fuel pipes 2 so that the clamps can be reinstalled to where they were 6 Remove pipes 2 with clamp 1 from vehicle 7 Remove clamp 1 from pipes 2 Installation 1 Install clamps to marked location on pipes If clamp is deformed or its claw is bent or b...

Page 202: ...l injector s 3 Installation Reverse removal procedure for installation noting the following Replace injector O ring 1 with new one using care not to damage it Check if insulator 2 is scored or damaged If it is replace with new one 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 cau...

Page 203: ...C 09930 88530 4 Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting 5 Put graduated cylinder under injector as shown 6 Operate fuel pump and apply fuel pressure to injector as follows a When using SUZUKI scan tool i Connect SUZUKI scan tool to DLC 5 with ignition switch OFF ii Turn ignition switch ON clear DTC and select MISC TEST mode on SUZUKI scan ...

Page 204: ...age Less than 1 drop min Fuel Pressure Regulator Removal and Installation S3RH0B1706010 WARNING Before servicing fuel system be sure to observe Precautions on Fuel System Service in related manual Removal 1 Relieve fuel pressure according to Fuel Pressure Relief Procedure in related manual 2 Disconnect battery negative cable from battery 3 Disconnect vacuum hose 1 from fuel pressure regulator 2 4 ...

Page 205: ...l system be sure to observe Precautions on Fuel System Service in related manual Removal 1 Relieve fuel pressure in fuel feed line according to Fuel Pressure Relief Procedure in related manual 2 Disconnect negative cable at battery 3 Remove fuel filler cap 4 Insert hose of a hand operated pump into fuel filler hose 1 and drain fuel in space A in the figure CAUTION Do not force pump hose into fuel ...

Page 206: ...m fuel pipes For quick joint disconnect it as follows a Remove mud dust and or foreign material between pipe and joint by blowing compressed air b Unlock joint 1 lock by inserting special tool between pipe 2 and joint 1 Special tool A 09919 47020 c Disconnect joint from pipe WARNING A small amount of fuel may be released after the fuel hose is disconnected In order to reduce the chance of personal...

Page 207: ... pipe 1 fuel return pipe 3 and purge pipe 2 to each pipe as shown in the figure and clamp them securely CAUTION When connecting joint clean outside surfaces of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely or fuel leak may occur Never let the fuel hoses touch the ABS sensor harness if equipped 6 Install EVAP can...

Page 208: ...lated manual Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A in related manual Fastening part Tightening torque Note N m kgf m lb ft Fuel delivery pipe bolt 25 2 5 18 0 Fuel pressure regulator bolt 11 1 1 8 0 Fuel tank bolt 50 5 0 36 5 Fuel filler hose clamp 1 5 0 15 1 0 Fuel pump assembly bolt 10 1 0 7 5 ...

Page 209: ...aft Components 3A 1 Drive Shaft Boot On Vehicle Inspection 3A Front Drive Shaft Assembly Removal and Installation 3A 2 Front Drive Shaft Disassembly and Assembly 3A 4 Specifications 3A 12 Tightening Torque Specifications 3A 12 Special Tools and Equipment 3A 12 Recommended Service Material 3A 12 Special Tool 3A 12 NOTE For the items with asterisk in the CONTENTS below refer to the same section of t...

Page 210: ...3A 1 Drive Shaft Axle Drive Shaft Axle Repair Instructions Front Drive Shaft Components S3RH0B3106001 I3RH0B311009 02 A Tripod joint type 10 Damper ...

Page 211: ... center shaft B DOJ type 11 Center shaft side joint RH of M T model Apply light black grease included in spare part to joint C Center shaft M T model 12 Wheel side joint Apply black grease included in spare part to joint D Center shaft A T model 13 Center bearing support 1 Differential side joint LH of A T model Apply light green grease included in spare part to joint 14 Center bearing 2 Boot Diff...

Page 212: ...with hammer Inserting joint only by hands is allowed Make sure that differential side joint is inserted fully and its snap ring is seated as it was Do not 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 split pin 1 Tighten each bolt and nut to the specif...

Page 213: ... 4 Remove differential side boot small band and then pull out differential side boot from shaft 5 Remove damper band and then pull out damper through shaft 6 Remove wheel side boot big band 1 using flat end rod or the like 7 Remove wheel side boot small band 2 and then pull out wheel side boot from shaft CAUTION Disassembly of wheel side joint is not allowed If any noise or damage exists in it rep...

Page 214: ... small band and then pull out differential side boot from shaft 6 Remove damper band and then pull out damper through shaft 7 Remove wheel side boot big band 1 using flat end rod or the like 8 Remove wheel side boot small band 2 and then pull out wheel side boot from shaft CAUTION Do not disassemble wheel side joint If any malcondition is found replace it as assembly For center shaft 1 Using hydra...

Page 215: ...sh boots in degreaser such as gasoline or kerosene etc Washing in degreaser causes deterioration of boot To ensure full performance of joint as designed be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint referring to the followings for identification of the grease Grease color A Black B Light green Amount A 70 90 g 2 5 3 2 oz B 90 110 g ...

Page 216: ...ig band 1 securely using special tool Special tool A 09943 57010 9 Install damper 1 on drive shaft according to dimension specified as follows Drive shaft damper installing position distance a between reference position and damper Right side drive shaft 154 3 160 3 mm 6 08 6 31 in Left side drive shaft 187 0 193 0 mm 7 37 7 58 in 10 Set new differential side small band and new differential side bo...

Page 217: ...d against forward rotation Do not squeeze or distort boot when fastening it with bands Distorted boot caused by squeezing air may reduce its durability For DOJ type Judging 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 assembly 1 and DOJ housing 2...

Page 218: ...0 mm 7 37 7 59 in Right side drive shaft 154 3 160 3 mm 6 08 6 31 in 3 Set new differential side small band and new differential side boot on shaft temporarily 4 Drive in the cage 1 using a pipe 2 CAUTION Install cage directing smaller outside diameter side to wheel side Drive shaft joint cage installing pipe diameter a 23 0 mm 0 906 in or more b 32 0 mm 1 260 in or less 5 Install circlip 1 using ...

Page 219: ... air to enter boot so that air pressure in boot becomes the same as atmospheric pressure 9 When fixing boot 1 to joint housing 2 with differential side big band 3 adjust so that measurements 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 reduce its dur...

Page 220: ...del When installing circlip 1 make sure that if fits in circlip groove in center bearing support 2 securely as shown Install oil seals 1 2 to center bearing support 4 in proper direction and specified position as shown using special tool Special tool A 09925 15410 Distance a 0 1 mm 0 0 04 in b 4 5 mm 0 16 0 19 in Fill the space between oil seals and center shaft support bearing 3 with grease A Gre...

Page 221: ... also described in the following Front Drive Shaft Components Special Tool S3RH0B3108002 Fastening part Tightening torque Note N m kgf m lb ft Ball stud bolt 60 6 0 43 5 Tie rod end castle nut 45 4 5 32 5 Drive shaft nut 175 17 5 127 0 Wheel nut 85 8 5 61 5 Center bearing support bolt 55 5 5 40 0 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 2501...

Page 222: ...3A 13 Drive Shaft Axle ...

Page 223: ...uid Temperature Sensor Circuit Malfunction 5A 37 DTC P0715 No 37 Input Turbine Speed Sensor Circuit Malfunction 5A 39 DTC P0720 No 31 Output Shaft Speed Sensor Circuit Malfunction 5A 41 DTC P0725 No 35 Engine Speed Input Circuit Malfunction 5A 43 DTC P0743 No 25 No 26 Torque Converter Clutch Circuit Electrical 5A 45 DTC P0748 No 41 No 42 Pressure Control Solenoid A Electrical 5A 47 DTC P0753 P0758...

Page 224: ... Reassembly 5A 117 Differential Components 5A 118 Differential Removal and Installation 5A 118 Differential Inspection 5A 120 Transaxle housing Removal and Installation 5A 120 Transaxle Housing Inspection 5A 122 Transaxle Case Removal and Installation 5A 122 Automatic Transaxle Unit Assembly 5A 122 Specifications 5A 132 Tightening Torque Specifications 5A 132 Special Tools and Equipment 5A 133 Rec...

Page 225: ...ylinder Disassembly and Reassembly 5C Clutch Master Cylinder Inspection 5C Clutch Operating Cylinder Removal and Installation 5C Clutch Operating Cylinder Components 5C Clutch Operating Cylinder Disassembly and Reassembly 5C Clutch Operating Cylinder Inspection 5C Clutch Cover Clutch Disc Flywheel and Clutch Release System Components 5C Clutch Cover Clutch Disc and Flywheel Removal and Installatio...

Page 226: ...H0B5000001 Air Bag Warning Refer to Air Bag Warning in Section 00 in related manual Precautions in Diagnosing Trouble Refer to Precautions in Diagnosing Trouble in Section 5A Precautions for Disassembly and Reassembly Refer to Precautions for Disassembly and Reassembly in Section 5A ...

Page 227: ...lace a rubber mat on the work bench to protect parts from damage Work gloves or shop cloth should not be used Use a nylon cloth or a paper towel When separating the case joint do not pry with a screwdriver or such but tap with a plastic hammer lightly Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during disassembly and reassembly Wash the disassembled ...

Page 228: ...ipped with an electronically controlled lock up mechanism The gear shift device consists of 2 sets of planetary gear units 4 disc type clutches a disc type brake a band type brake and 2 one way clutches The gear shift is done by selecting one of 6 positions P R N D 2 and L by means of the select lever installed on the floor On the shift knob there is an overdrive O D off switch which prevents shif...

Page 229: ...ven gear Reduction gear 3 Reverse clutch 11 Coast clutch 19 Oil pump 4 One way clutch No 1 12 Overdrive clutch 20 Torque converter 5 1st and reverse brake 13 Planetary sun gear 21 Drive plate 6 Front large planetary pinion 14 Front small planetary pinion 22 Input shaft 7 Rear planetary pinion 15 Front planetary ring gear 8 Rear planetary ring gear 16 Counter drive gear Reduction gear ...

Page 230: ...gear change L range Forward 1st 2nd reduction and fixed at 1st gear Gear ratio 1st 2 807 Number of teeth Front sun gear 26 2nd 1 479 Rear sun gear 35 3rd 1 000 Front large pinion gear 28 4th overdrive gear 0 734 Front small pinion gear 19 Rear pinion gear 19 Reverse reverse gear 2 769 Front internal gear 98 Rear internal gear 73 Control elements Wet type multi disc clutch 4 sets Band type brake 1 ...

Page 231: ...ing gear and input shaft only when forward clutch is at work One way clutch No 0 Prevents rear planetary ring gear from turning counterclockwise reverse direction of engine input rotation direction only when forward clutch is at work Coast clutch Meshes rear planetary ring gear and input shaft only when forward clutch is at work Forward clutch Meshes rear planetary and front planetary ring gear on...

Page 232: ...alfunction in A T control system is detected O D OFF lamp 1 lights for about 2 seconds after ignition 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 detects a malfunction in A T control system it flashes O D OFF lamp 1 and stores malfunction DTC in its ...

Page 233: ... 4 15 14 26 25 24 13 12 11 23 22 10 9 8 21 20 3 2 1 G08 G07 21 LT GRN BLK 5V BB 12V 5V 10 11 IG11 5V G08 6 G08 7 G08 12 G08 8 G08 5 G08 14 G07 10 G08 20 G08 13 G08 15 G08 19 PPL YEL BLU GRY GRN ORN BLU WHT GRY RED GRY BLK BLU ORN LT GRN RED YEL BLK WHT WHT RED BLK BLK 12 13 14 16 19 17 20 18 15 12V 12V G08 4 G08 3 12V 12V G08 11 12V 12V G07 14 WHT GRN G03 4 12V 12V G03 5 BRN YEL G07 23 I3RH0B51000...

Page 234: ...N only when lock up function operates Gear is neutral position regardless of solenoid status RANGE D 2 L N R P GEAR 1st 2nd 3rd 4th O D 1st 2nd 1st Neutral Rev 7 km h Rev 7 km h SOLENOIDS Shift solenoid valve A NO 1 U U Shift solenoid valve B NO 2 TCC solenoid valve Valve status Turn power ON Turn power OFF Shift solenoid valve A No 1 Close Open Shift solenoid valve B No 2 Close Open TCC solenoid ...

Page 235: ... 110 km h 68 mile h speed 3rd gear is operated and then down shifts to 2nd at a speed lower than that No up shift is available in 2 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 mile h 55 34 110 68 163 101 144 89 96 60 48 30 Closed throttle km h mile h 13 8 27 17 45 28 20 12 10 6 10 6 100 50 0 0 50 100 150 100 km h mile h 50 0 Thro...

Page 236: ...eter O D OFF lamp and shift indicator in combination meter M D range signal Transmission range sensor signal except P and N range 7 Engine coolant temperature sensor 21 Data link connector N Engine coolant temperature signal 8 Transmission range sensor shift switch A Output shaft speed O Throttle opening signal 9 Output shaft speed sensor B Input shaft speed P Engine speed signal 10 Monitor connec...

Page 237: ...nfirmation 1 Perform confirm trouble symptom Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and record of DTC 1 Recheck for DTC referring to DTC Check Is there any DTC s Go to Step 9 Go to Step 8 7 Rechecking and record of DTC 1 Recheck for DTC referring to DTC Check Is there any DTC s Go to Step 9 Go to Step 10 8 A T basic check and A T symptom diagnosis 1 Check and repair a...

Page 238: ...ails of the problem failure complaint and how it occurred 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 inspection form Example I2RH01510008 01 ...

Page 239: ... and Clearance Also reconfirm DTC according to DTC Confirmation Procedure described in each DTC Flow Step 6 and 7 Rechecking and Record of DTC Refer to DTC Check for checking procedure Step 8 A T Basic Check and A T Symptom Diagnosis Perform basic check of A T according to A T Basic Check first When the end of the flow has been reached check the parts of the system suspected as a possible cause re...

Page 240: ...nual Engine coolant level leakage Engine Coolant Change in Section 0B in related manual Engine mountings play looseness damage Engine Assembly Removal and Installation in Section 1D Suspension play looseness Suspension Wheels and Tires Symptom Diagnosis in Section 2A in related manual Drive shafts damage Front Drive Shaft Assembly Removal and Installation in Section 3A Battery indicator condition ...

Page 241: ... A electrical No electric flow is detected on solenoid circuit 1 driving cycle 42 Too much electric flow is detected on pressure control solenoid circuit P0753 21 Shift solenoid A No 1 electrical Voltage of shift solenoid terminal is high although TCM is commanding shift solenoid to turn OFF 1 driving cycle 22 Voltage of shift solenoid terminal is low although TCM is commanding shift solenoid to t...

Page 242: ...mmunication is possible in this case scan tool is in good condition Then check data link connector and serial data line circuit in the vehicle with which communication was not possible 5 After completing the check turn ignition switch OFF and disconnect SUZUKI scan tool from data link connector DLC 1 Displaying DTC on Odometer 1 Turn ignition switch OFF 2 Remove glove box 1 from instrument panel 3...

Page 243: ...ol Refer to SUZUKI scan tool operator s manual for further details 5 After completing the clearance turn ignition switch OFF and disconnect SUZUKI scan tool from data link connector DLC 1 DTC Clearance Using Monitor Connector 1 Remove glove box 1 from instrument panel 2 Turn ignition switch ON 3 After 6 seconds or more repeat connecting and disconnecting diagnosis switch terminal 3 and ground term...

Page 244: ...et as D range In case of circuit short In case that 2 or more sensor signals are inputted selected range is set in priority order shown below N R L 2 D P P0710 36 38 Transmission fluid temperature sensor or its circuit Line pressure raising control at low fluid temperature is inhibited P0715 37 Input shaft speed sensor or its circuit Power supply to shift solenoid valve and TCC solenoid valve is c...

Page 245: ...ine idle speed is displayed in increments of 50 rpm At 60 km h 37 5 mile h constant speed O D off switch ON 20 or less throttle opening and 3rd gear D range 2150 RPM displayed in increments of 50 rpm OUTPUT SHAFT REV At vehicle stop 0 RPM At 60 km h 37 5 mile h constant speed O D off switch ON 20 or less throttle opening and 3rd gear 2150 RPM displayed in increments of 50 rpm BATTERY VOLT Ignition...

Page 246: ...o 2 COM OFF ON command not being outputted to shift solenoid B No 2 MON ON Electricity being passed to shift solenoid B No 2 MON OFF Electricity not being passed to shift solenoid B No 2 TCC SOL COM MON TCC SOLENOID COMMAND MONITOR ON OFF COM ON ON command being outputted to shift solenoid B No 2 COM OFF ON command not being outputted to shift solenoid B No 2 MON ON Electricity being passed to shi...

Page 247: ...d by duty signal from ECM A C SWITCH ON Signal which inform that air conditioner compressor is turned ON OFF Signal which inform that air conditioner compressor is not turned ON ENGINE TORQUE N m Engine torque computed by duty pulse signal outputted from ECM A T Basic Check S3RH0B5104010 This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in v...

Page 248: ...sor Inspect If NG replace Malfunction of transmission range sensor Inspect If NG replace Faulty valve body component Replace valve body assembly Faulty 2nd 4th brake Inspect If NG replace Faulty one way clutch No 1 Inspect If NG replace 2 3 upshift fails to occur Malfunction of shift solenoid valve A Inspect If NG replace Malfunction of throttle position sensor Inspect If NG replace Malfunction of...

Page 249: ...ut shaft speed sensor Inspect If NG replace Malfunction of throttle position sensor Inspect If NG replace TCC lock up function does not operate Malfunction of TCC solenoid valve Inspect If NG replace Malfunction of brake light switch Inspect If NG replace Malfunction of engine coolant temperature sensor Inspect If NG replace Malfunction of throttle position sensor Inspect If NG replace Malfunction...

Page 250: ... torque failure Inspect and repair engine Faulty one way clutch of torque converter Replace torque converter Higher than standard level in D range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Malfunction of primary regulator valve Low line pressure Replace valve body assembly Slippery forward clutch Inspect If NG replace Faulty one way ...

Page 251: ...lag data Troubleshooting Condition Possible cause Correction Reference Item N D time lag exceeds specification Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Malfunction of primary regulator valve Low line pressure Replace valve body assembly Clogged oil strainer Replace Faulty oil pump Inspect If NG replace Faulty forward clutch Inspect ...

Page 252: ...ch oil pressure gauge to fluid pressure check hole in transaxle case Special tool A 09925 37811 001 CAUTION After attaching oil pressure gauge check that no fluid leakage exists 4 Depress foot brake fully run engine at idle and stall then check fluid pressure in D or R range CAUTION Do not continue running engine at stall speed longer than 5 seconds After performing line pressure test be sure to l...

Page 253: ...than standard level in each range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Malfunction of primary regulator valve Low line pressure Replace valve body assembly Lower than standard level in each range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Malfunction of primary regu...

Page 254: ...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 TCM Substitute a known good TCM and recheck ECM Substitute a known good ECM and recheck Poor 3 O D shift Shift solenoid valve B circuit faulty Inspect circuit for open short and intermittent If NG repai...

Page 255: ...and intermittent If NG repair Engine coolant temperature sensor 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 referring to DTC P0120 No 13 Throttle Position Circuit Malfunction in Section 1A If NG repair Engine coolant temperature sensor circuit faulty Inspect circuit for op...

Page 256: ...itch Inspection in Section 9B in related manual If NG replace Malfunction of pressure control solenoid valve Inspect If NG replace valve body assembly Faulty valve body component Replace valve body assembly Poor 2 3 shift excessive shock or slippage Engine abnormal condition Inspect and repair engine Malfunction of shift solenoid valve A Inspect If NG replace Malfunction of input shaft speed senso...

Page 257: ... component Replace valve body assembly Incorrect shift point Engine abnormal condition Inspect and repair engine Malfunction of output shaft speed sensor Inspect If NG replace Malfunction of throttle position sensor Inspect If NG replace Non operate TCC lock up system Malfunction of TCC solenoid valve Inspect If NG replace Malfunction of output shaft speed sensor Inspect If NG replace Malfunction ...

Page 258: ...NG replace Faulty 2nd 4th brake Inspection If NG replace Faulty one way clutch No 0 Inspection If NG replace Non operate TCC lock up system Faulty valve body component Replace valve body assembly Excessive N D time lag Clogged oil strainer Replace Faulty oil pump Inspection If NG replace Faulty forward clutch Inspection If NG replace Faulty one way clutch No 0 and or No 1 Inspection If NG replace ...

Page 259: ... retry Go to Step 3 3 1 Perform running test under the following conditions and check voltage between terminal G08 4 of TCM connector and ground terminal G08 3 of TCM connector and ground O D off switch is OFF O D OFF lamp OFF Selector lever is in D range Engine coolant temperature is normal operating temperature Cruise control switch is turned OFF Drive vehicle with 4th gear condition referring t...

Page 260: ...t with 2 persons a driver and tester on a level road Step Action Yes No 1 Was A T System Check performed Go to Step 2 Go to A T System Check 2 Check DTC Is DTC P0715 P0720 P0743 P0748 P0753 P0758 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 terminal G08 12 of TCM connector and ground Sele...

Page 261: ...riving the vehicle speed for 30 seconds 5 Release accelerator pedal decrease vehicle speed and stop vehicle 6 Turn ignition switch OFF 7 Repeat Step 3 to 6 one time 8 Check DTC 9 8 21 20 2 1 G08 G07 7 P R N D 2 L 3 WHT BLK RED WHT RED YEL RED YEL RED BLU G07 2 G07 1 G07 9 G07 8 G07 21 G07 20 RED BLK 5 4 2 6 1 I2RH01510020 01 1 TCM 4 Brake light switch 7 Terminal arrangement of TCM connector viewed...

Page 262: ...nge and 0 V for other ranges as shown in table Check voltage at other terminals likewise referring to table Are check results satisfactory Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 in related manual Go to Step 5 5 Check select cable for adjustment 1 Check select cable for adjustment referring to Selector Cable Adjustment Is i...

Page 263: ...level road 1 Clear DTCs in TCM memory and start engine 2 Shift selector lever to D range and drive vehicle for 20 minutes or more 3 Stop vehicle 4 Check DTC I3RH01510272 01 1 TCM 3 Terminal arrangement of TCM connector viewed from harness side 2 Transmission fluid temperature sensor 4 Valve body connector DTC detecting condition Trouble area Transmission temperature sensor terminal voltage is less...

Page 264: ...onnector and ground Is continuity indicated BLU ORN circuit shorted to ground Go to Step 4 4 Check transmission fluid temperature sensor 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 Turn ignition switch ON 4 Measure voltage between terminal G08 5 of TCM connector and ground Is it 4 6 V or more BLU ORN ci...

Page 265: ...icle at least for 60 seconds 3 Stop vehicle 4 Check DTC 17 5 G08 G07 3 1 2 GRN RED G07 5 G07 17 2 5V I2RH01510022 01 1 TCM 2 Input shaft speed sensor 3 Terminal arrangement of TCM connector viewed from harness side DTC detecting condition Trouble area No input shaft speed sensor signal is detected although output shaft speed sensor signals are detected under vehicle condition shown in the followin...

Page 266: ...7 of disconnected harness side TCM connector 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 Inspection Is result satisfactory RED or GRN circuit open or short Replace input shaft speed sensor 4 Check visually input shaft speed sensor and forward clutch drum ...

Page 267: ...mal operating temperature 3 Shift selector lever to D range and drive vehicle at 30 km h 19 mile h or more vehicle speed at least for 60 seconds 4 Stop vehicle 5 Check DTC 16 4 G08 G07 3 1 2 2 5V BLK WHT G07 4 G07 16 I2RH01510024 01 1 TCM 2 Output shaft speed sensor 3 Terminal arrangement of TCM connector viewed from harness side DTC detecting condition Trouble area No output shaft speed sensor si...

Page 268: ...nnected harness side TCM connector and ground No continuity Are check results satisfactory Go to Step 4 Go to Step 3 3 Inspect output shaft speed sensor 1 Inspect output shaft speed sensor referring to Output Shaft Speed Sensor Inspection Is result satisfactory BLK or WHT wire open or short Replace output shaft speed sensor 4 Check visually output shaft speed sensor and sensor rotor using mirror f...

Page 269: ...3 Check DTC 15 G08 G07 4 1 5 12V 12V LT GRN BLK G07 15 G04 2 2 3 C46 G04 C45 2 I2RH01510025 01 1 TCM 3 To tachometer 5 Terminal arrangement of ECM connector viewed from harness side 2 ECM 4 Terminal arrangement of TCM connector viewed from harness side DTC detecting condition Trouble area No engine speed signal is inputted although engine is running and engine coolant temperature sensor signal is ...

Page 270: ...arness 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 switch OFF 2 Turn ignition switch ON 3 Measure voltage between terminal G07 15 of connected harness side TCM connector and ground Is it 10 14 V Go to Step 5 Substitute a known good TCM and recheck 5 Check ECM termi...

Page 271: ...FF lamp does not light 4 Drive vehicle with 3rd or 4th gear in D range and lock up ON for 10 seconds or longer referring to Automatic Gear Shift Diagram Reference less than 20 throttle opening and at vehicle speed of 80 km h 50 mile h or more 5 Decrease vehicle speed gradually and stop vehicle 6 Check DTC 12 G08 G07 3 12V G08 12 BLU WHT 1 2 I3RH0B510005 01 1 TCC solenoid valve 2 TCM 3 Terminal arr...

Page 272: ...to 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 11 15 Ω at 20 C 68 F Is check result satisfactory Go to Step 4 Replace shift solenoid valve or lead wire 4 Check TCC solenoid circuit for ground short 1 Connect valve body harness connector 2 Measure resistance between terminal ...

Page 273: ...tected on pressure control solenoid circuit No electric flow is detected on pressure control solenoid circuit Pressure control solenoid circuit shorted to power circuit Pressure control solenoid circuit open or shorted to ground Pressure control solenoid malfunction TCM Step Action Yes No 1 Was A T System Check performed Go to Step 2 Go to A T System Check 2 Check pressure control solenoid valve c...

Page 274: ...re control solenoid valve circuit for ground short 1 Connect valve body harness connector 2 Disconnect TCM connectors 3 Check for proper connection to TCM at terminal G08 11 and G08 8 4 If connection is OK check continuity between terminal G08 11 of disconnected harness side TCM connector and ground Is continuity indicated GRY RED or GRY BLK circuit shorted to ground Go to Step 5 5 Check pressure ...

Page 275: ...nge 3 Start vehicle and increase vehicle speed to 80 km h 50 mile h in D range 4 Keep on driving in the speed for 10 seconds and decrease vehicle speed gradually 5 Stop vehicle 6 Check DTC 4 3 G08 G07 4 1 2 3 GRN ORN 12V 12V G08 4 G08 3 GRY I3RH01510279 01 1 Shift solenoid valve A No 1 3 TCM 2 Shift solenoid valve B No 2 4 Terminal arrangement of TCM connector viewed from harness side DTC detectin...

Page 276: ...A No 1 terminal 2 and transaxle 12 16 Ω at 20 C 68 F Between shift solenoid valve B No 2 terminal 3 and transaxle 12 16 Ω at 20 C 68 F Is check result satisfactory Go to Step 4 Replace shift solenoid valve or lead wire 4 Check shift solenoid circuit for open 1 Connect valve body harness connector 2 Measure resistance between terminal G08 4 or G08 3 of disconnected harness side TCM connector and gr...

Page 277: ... idle for 20 seconds 6 Check DTC 6 G08 G07 3 1 12V PPL WHT G07 6 G03 14 2 4 C41 G04 G03 14 I3RH0B510018 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 DTC detecting condition Trouble area Too short low signal of pulse signal from ECM to TCM continues out of specification or Too long low signal of puls...

Page 278: ... 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 of disconnected harness side TCM connector and terminal G03 14 of disconnected harness side ECM connector Is continuity indicated Go to Step 5 PPL WHT circuit open 5 Check throttle position signal circuit for ground short 1 Check ...

Page 279: ...angement of TCM connector viewed from harness side 2 ECM 4 Terminal arrangement of ECM connector viewed from harness side DTC detecting condition Trouble area After 15 minutes or more from starting to run engine in 600 rpm or more 0 V of engine coolant temperature TCM terminal voltage continues out of specification While engine is running in 600 rpm or more 12 V of engine coolant temperature TCM t...

Page 280: ...ground Is it 10 14 V GRY BLK circuit shorted to power circuit Go to Step 4 4 Check engine coolant temperature signal 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 continuity indicated Go to Step 5 GRY BLK circuit open 5 Check engine coolant temperature...

Page 281: ...3 G08 G07 3 1 2 12V G07 23 12V G04 35 RED WHT 4 C41 G04 G03 5 I3RH0B510020 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 DTC detecting condition Trouble area Too long low signal of pulse signal from ECM to TCM continues out of specification or Too short low signal of pulse signal from ECM to TCM cont...

Page 282: ...ignition switch OFF 2 Check continuity between terminal G07 23 of disconnected harness side TCM connector and terminal G03 5 of disconnected harness side ECM connector Is continuity indicated Go to Step 4 BRN YEL circuit open 4 Check engine torque signal circuit for ground short 1 Check continuity between terminal G07 23 of disconnected harness side TCM connector and ground Is continuity indicated...

Page 283: ... 3 Check continuity between terminal G07 18 of disconnected harness side TCM connector and terminal G03 12 of disconnected harness side ECM connector Is continuity indicated Go to Step 3 LT GRN RED circuit open 3 Check torque reduction signal circuit for ground short 1 Check continuity between terminal G07 18 of disconnected harness side TCM connector and ground Is continuity indicated LT GRN RED ...

Page 284: ... TCM 1 from vehicle referring to Transmission Control Module TCM Removal and Installation 2 Connect TCM connectors 2 to TCM 3 Check voltage at each terminal of connectors connected NOTE As each terminal voltage is affected by battery voltage confirm that it is 11 V or more when ignition switch is ON Terminal arrangement of TCM coupler Viewed from harness side 3 Body ground 1 2 3 I2RH01510036 01 4 ...

Page 285: ...on range sensor N range 8 14 V Ignition switch ON selector lever at N range 0 1 V Ignition switch ON selector lever at other than N range 10 Serial data line to Speedometer 0 2 V 4 6 V Ignition switch ON 11 12 13 14 Air conditioner compressor signal 0 1 V Ignition switch ON A C compressor turned ON 8 14 V Ignition switch ON A C compressor turned OFF 15 Engine speed signal 0 1 V Ignition switch ON ...

Page 286: ... ON 8 Pressure control solenoid valve ground 0 6 1 0 V Ignition switch ON 9 10 11 Pressure control solenoid valve 0 1 V 9 14 V Ignition switch ON Output signal is duty pulse Duty ratio varies as throttle valve opening 12 TCC solenoid valve 0 1 V Ignition switch ON 13 Power source for back up 10 14 V Constantly 14 Transmission fluid temperature sensor ground 0 1 V Ignition switch ON 15 Ground 0 1 V...

Page 287: ...CM 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 disconnected TCM connector Is it 10 14 V Go to Step 2 BLK WHT circuit open 2 Check TCM ground circuit 1 Turn ignition switch OFF 2 With TCM connectors disconnected check for proper connection to TCM at G08 15 terminal 3 If OK check re...

Page 288: ...on switch is turned ON and malfunction is not detected TCM turns O D OFF lamp ON only for 2 seconds to check bulb and terns it OFF When communication circuit between TCM and combination meter break down open or shot O D OFF lamp blinks only for 10 seconds 12V 5V GRN BLK G07 3 G07 10 RED YEL 3 2 1 10 3 G08 G07 4 I2RH01510016 01 1 TCM 3 O D off switch 2 Combination meter 4 Terminal arrangement of TC...

Page 289: ...l If OK substitute a know good TCM and recheck 3 Check O D off switch 2 for operation 1 Disconnect O D off switch coupler 1 2 Check continuity between switch terminals under each condition O D off switch specification O D off switch under being released 2 No continuity O D off switch under being pressed 3 Continuity Is check result satisfactory GRN BLK circuit shorted to ground Replace O D off swi...

Page 290: ...Section 9C in related manual If OK substitute a know good TCM and recheck Go to Step 6 6 Is O D OFF lamp blinking steady for over 10 seconds Go to Step 7 System is OK 7 Check DTC 1 Check DTC referring to DTC Check Are there any DTC s Proceed to A T Diagnostic Flow Faulty combination meter or TCM Inspect combination meter referring to O D OFF Indicator Lamp A T Vehicle Only Symptom Diagnosis in Sec...

Page 291: ... should be between FULL HOT 2 and LOW HOT 3 If it is below LOW HOT add an equivalent of DEXRON III up to FULL HOT Automatic transaxle fluid An equivalent of DEXRON III NOTE Do not race engine while checking fluid level even after the engine start Do not overfill Overfilling can cause foaming and loss of fluid through breather Then slippage and transaxle failure can result Bringing the level from L...

Page 292: ...rom manual shift 5 Remove select cable retainer from dash panel Installation Install select cable by reversing removal procedure The important steps in installation are as follows Apply grease to pin and cable joint Tighten bolts in upper figure to specified torque Adjusting procedure is as follows Selector Lever Components S3RH0B5106004 Selector Lever Inspection S3RH0B5106005 Check select lever f...

Page 293: ... of cable end holder 2 4 Push cable end holder 1 out from eye end 2 using an appropriate tool 3 to disengage cable I3RH0B510008 01 1 Selector lever assembly 6 Clip 2 Select cable 7 Select cable retainer bolt 3 Select cable retainer 8 Manual shift lever pin Apply lithium grease 99000 25010 to all around pin 0 15 g 4 Cable bracket 9 Selector lever pin Apply lithium grease 99000 25010 to all around p...

Page 294: ...ansmission Range Sensor Shift Switch Inspection and Adjustment S3RH0B5106008 Inspection 1 Disconnect transmission range sensor connector 1 2 Check that continuity exists at terminals shown in the following figure by moving selector lever Adjustment 1 Shift manual shift lever 1 to N range 2 Connect ohmmeter between 7 and 9 terminals of disconnected transmission range sensor connector 3 3 Turn trans...

Page 295: ... O ring 2 Install output shaft speed sensor 1 to A T case and tighten bolt to specified torque Tightening torque Output shaft speed sensor bolt a 5 5 N m 0 55 kgf m 4 0 lb ft 3 Connect output shaft speed sensor connector 2 to output shaft speed sensor 1 4 Connect negative cable to battery Output Shaft Speed Sensor Inspection S3RH0B5106010 1 Disconnect negative cable at battery 2 Disconnect output ...

Page 296: ...ut shaft speed sensor 1 4 Connect negative cable to battery Input Shaft Speed Sensor Inspection S3RH0B5106012 1 Disconnect negative cable at battery 2 Disconnect input shaft speed sensor connector 2 3 Check resistance between input shaft speed sensor 1 terminals Input shaft speed sensor resistance Standard 387 473 Ω at 20 C 68 F Transmission Fluid Temperature Sensor Inspection S3RH0B5106013 1 Lift...

Page 297: ...r and A T case by using a nozzle referring to Automatic Transaxle Unit Assembly Sealant 99000 31230 10 Install transaxle side cover 1 NOTE Apply sealant to 2 bolts 2 A Sealant 99000 31230 Tightening torque Transaxle side cover bolt a 24 N m 2 4 kgf m 17 5 lb ft 11 Install A T fluid cooler pipe 1 Tightening torque A T fluid pipe union bolt color green a 27 N m 2 7 kgf m 19 5 lb ft A T fluid pipe un...

Page 298: ...rol Solenoid Valve Removal and Installation S3RH0B5106015 Removal 1 Disconnect negative cable at battery 2 Drain A T fluid 3 Remove A T fluid cooler pipe 1 and hose 2 4 Remove A T side cover 3 5 Remove transmission fluid temperature sensor 1 and sensor harness from clamp 6 Disconnect solenoid connectors 2 7 Remove pressure control solenoid valve 1 by removing bolt 2 and clamp 3 8 Remove TCC soleno...

Page 299: ...ve 1 Pink Brown Shift solenoid valve A No 1 2 White Shift solenoid valve B No 2 3 Black TCC solenoid valve 4 Yellow 4 Install transmission fluid sensor 5 and sensor wire to clamp 5 Clean mating surface of A T side cover and A T case 6 Apply sealant to mating surface of A T side cover and A T case by using a nozzle 1 as shown in figure by such amount that its section is 1 5 mm 0 059 in in diameter ...

Page 300: ...3RH0B5106016 Resistance Check Shift solenoid valve A No 1 B No 2 and TCC solenoid valve Shift solenoid valves and TCC solenoid valve resistance Standard 11 15 Ω at 20 C 68 F Operation Check Shift solenoid valve A No 1 and B No 2 Check that solenoid valve 1 actuate with click sound when battery voltage is conducted Apply oiler 2 to solenoid valve 1 and give compression by hands and then check to be...

Page 301: ...essure control solenoid valve 1 terminals Pressure control solenoid valve resistance Standard 3 3 3 7 Ω at 20 C 68 F Operation Check Check pressure control solenoid valve operation in the either manner of the following Using regulated DC power supply 1 Connect pressure control solenoid valve 1 with regulated DC power supply 2 as shown in the figure 2 Turn regulated DC power supply switch ON and in...

Page 302: ...nsists of highly precise parts therefore when handling it be careful not to expose to excessive shock Removal 1 Disconnect negative cable at battery 2 If the vehicle is equipped with air bag system disable air bag system Refer to Disabling Air Bag System in Section 8B in related manual 3 Remove parking brake cover console box 1 and console covers 2 4 Disconnect connectors 3 from TCM 4 5 Remove TCM...

Page 303: ... 25030 5 Install new differential side oil seal 1 by using special tool NOTE For oil seal installation press fit oil seal so that transaxle case end face 2 is flush with oil seal end face Special tool A 09944 66020 6 Install drive shaft referring to Front Drive Shaft Assembly Removal and Installation in Section 3A 7 Pour A T fluid referring to A T Fluid Change A T Fluid Cooler Hoses Replacement S3...

Page 304: ... kg m 7 70 N m 7 0 kg m 5 25 N m 2 5 kg m 8 50 N m 5 0 kg m 3 85 N m 8 5 kg m 3 85 N m 8 5 kg m 1 6 4 I3RH0B510012 01 1 Lower stiffener 4 Torque converter 7 Drive plate bolt 2 Transaxle to engine nut 5 Drive plate to torque converter bolt 8 Lower stiffener bolt 3 Transaxle to engine bolt 6 Drive plate Tightening torque ...

Page 305: ...emove lower stiffener 5 Remove drive plate bolts To lock drive plate 1 engage a flat head rod or the like 2 with drive plate gear 6 Remove starting motor 7 Remove bolts and nut fastening engine and transaxle then detach transaxle from engine NOTE When detaching transaxle from engine move it in parallel with crankshaft and use care so as not to apply excessive force to drive plate and torque conver...

Page 306: ...housing lower plate opening Lock drive plate 1 by engaging a flat head rod or the like 2 with drive plate gear Tightening torque Drive plate to torque converter bolt a 25 N m 2 5 kgf m 18 0 lb ft 4 Install lower stiffener Tightening torque Lower stiffener bolt 50 N m 5 0 kgf m 36 5 lb ft 5 Install starter motor Tightening torque Starter motor bolt 23 N m 2 3 kgf m 16 5 lb ft 6 Install center shaft...

Page 307: ...s S3RH0B5106025 I3RH0B510036 01 1 Torque converter 22 Gasket 43 Manual valve lever 2 A T fluid drain plug 23 1st reverse brake piston 44 Spacer 3 Transaxle housing 24 O ring 45 Output shaft speed sensor 4 A T fluid outlet pipe 25 1st reverse brake return spring 46 Cable bracket ...

Page 308: ...8 Oil strainer Replace oil strainer when overhauling 29 Oil reservoir plate 50 Valve body connector 9 Snap ring 30 Transaxle lubrication tube 51 Fluid filler tube 10 2nd 4th brake cover 31 Counter shaft RH thrust roller bearing 52 Fluid level gauge 11 O ring 32 Counter shaft RH cylindrical roller bearing 53 1st reverse brake separator plate 12 Brake inner cover 33 Cylindrical roller bearing retain...

Page 309: ...k washer 4 c Remove lock nut 3 d Remove lock washer 4 and rubber plate e Remove 2 bolts 5 NOTE Never reuse lock washer after removal 5 Remove fluid level gauge 1 fluid filler tube 2 output shaft speed sensor 3 input shaft speed sensor 4 and vehicle speed sensor 5 for speedometer 6 Remove transaxle housing by removing 15 bolts as shown I3RH0B510014 01 I2RH01510099 01 5 I3RH0B510030 01 I2RH01510101 ...

Page 310: ... as shown in figure 11 Remove oil reserve plate 1 by removing 2 bolts 12 Remove oil strainer 2 13 Remove manual detent spring 1 by removing 2 bolts 14 Remove transaxle side cover 1 by removing bolts 15 Remove transmission fluid temperature sensor 1 from clamp 16 Remove sensor harness from clamp 2 17 Disconnect pressure control solenoid shift solenoid A shift solenoid B and TCC solenoid connectors ...

Page 311: ...c stand special tools Special tool A 09900 20607 B 09900 20701 b Plug oil hole 1 c Measure piston rod stroke while applying and releasing compressed air 400 800 kPa 4 8 kg cm2 57 113 psi from oil hole 2 2nd and 4th brake piston rod stroke Standard 1 78 2 22 mm 0 070 0 087 in NOTE If piston rod stroke exceeds the specification adjust piston rod or inspect band assembly of 2nd and 4th brake for dama...

Page 312: ...in figure of step 23 b 30 Remove spring 3 31 Disassemble 2nd and 4th brake piston assembly a Remove brake inner cover 1 and O rings 2 NOTE Never reuse removed O ring b Remove E ring 1 brake piston 2 spring 3 and rod washer 4 32 Loosen six bolts of transaxle rear cover 1 33 Lightly and uniformly tap two rib sections of transaxle rear cover 1 using plastic hammer 34 Remove ten bolts and engine mount...

Page 313: ...everse brake piston stroke a Set special tools dial gauge and magnetic stand Special tool A 09900 20607 B 09900 20701 b Measure piston stroke while applying and releasing compressed air 400 800 kPa 4 8 kg cm2 57 113 psi from oil hole 1 1st and reverse brake piston stroke Standard 1 73 2 57 mm 0 068 0 101 in NOTE If piston stroke exceeds the specification inspect or replace plates 40 Remove snap ri...

Page 314: ...6 Remove parking lock pawl 1 by pulling out pawl shaft 4 with torsion spring installed 47 Pullout counter driven gear assembly 5 towards you 48 Remove countershaft thrust roller bearing 1 with race Countershaft thrust roller bearing dimension Outside diameter 66 0 mm 2 60 in Inside diameter 51 0 mm 2 01 in Thickness 2 7 mm 0 11 in 49 Remove transaxle lubrication tube 2 50 Measure torque bearing pr...

Page 315: ...3 54 Remove manual valve lever shaft subassembly 1 manual valve lever 4 and oil seal NOTE Never reuse removed oil seal Oil Pump Components S3RH0B5106027 I2RH01510126 01 I2RH01510127 01 I2RH01510128 01 1 O ring 6 Knock pin Apply automatic transaxle fluid 2 Oil pump body oil seal Apply grease 99000 25030 to oil seal lip 7 Oil pump cover Tightening torque 3 Driven gear 8 Seal ring Do not reuse 4 Driv...

Page 316: ...2 Install driven gear and drive gear to oil pump body after applying fluid to gears 3 Install oil pump cover 1 to oil pump body 2 and tighten eight torx bolts 3 to specification Tightening torque Oil pump cover bolt a 10 N m 1 0 kgf m 7 5 lb ft NOTE Be sure to tighten bolts alternately and uniformly The figure indicates a typical example of the tightening sequence 4 Install two new seal rings 1 NO...

Page 317: ...115 in 3 Check side clearance of both gears Using a straightedge 1 and a feeler gauge measure side clearance between gears and pump body If clearance exceeds standard value replace gears Side clearance between gears and oil pump body Standard 0 02 0 05 mm 0 0008 0 0019 in Drive gear and driven gear have some kinds of thickness as listed Drive gear and driven gear thickness If side clearance of the...

Page 318: ...ard clutch piston stroke Standard 0 84 1 06 mm 0 033 0 042 in If measured piston stroke exceeds specified value disassemble and inspect inner parts I2RH01510137 01 1 Race 7 Clutch drum thrust washer 13 Forward clutch roller thrust bearing 2 Clutch drum oil seal ring 8 Snap ring 14 Rear cover oil seal ring 3 Snap ring 9 Forward clutch return spring subassembly 15 Transaxle rear cover 4 Retaining pl...

Page 319: ...ssure will cause plate section of forward clutch return spring subassembly to deform 5 Remove forward clutch return spring subassembly 3 6 Install forward clutch piston subassembly 1 to transaxle rear cover 2 7 Remove forward clutch piston subassembly 3 with O rings installed through oil hole 4 compressed air 400 800 kPa 4 8 kg cm2 57 113 psi NOTE If piston does not pop out it is recommended to us...

Page 320: ...ool A 09926 98330 NOTE When installing return spring be careful so that return spring will not fall or tilt Do not align opening in snap ring with lug of forward clutch return spring subassembly at its retainer section CAUTION Be careful when applying pressure for overpressure will cause plate section of forward clutch return spring subassembly to deform 8 Select and measure correct thickness of f...

Page 321: ... Forward Clutch Inspection S3RH0B5106033 1 Check that sliding surfaces of friction separator and retaining plates are not worn or burnt If necessary replace NOTE If friction plate lining is exfoliated discolored or worn hardly replace all friction plates Before assembling new friction plates soak them in A T fluid for at least two hours 2 Measure height of forward clutch return spring Forward clut...

Page 322: ...through oil hole 3 by using special tools Special tool A 09900 20607 B 09900 20701 Overdrive clutch piston stroke Standard 1 04 1 36 mm 0 041 0 054 in If piston stroke exceeds specified value disassemble and inspect inner parts I2RH01510150 01 1 Overdrive and coast clutch assembly 7 Retaining plate 13 Coast clutch piston 2 Snap ring 8 Friction plate 14 Overdrive clutch piston 3 Retaining plate 9 S...

Page 323: ...rdrive Clutch and Coast Clutch Disassembly and Reassembly S3RH0B5106036 Disassembly 1 Remove snap ring 1 2 Remove retaining plates R friction plates F and separator plates S in the following order R F S F S F R NOTE Measure thickness of retaining plate and record for reference of piston stroke confirmation 3 Remove snap ring 1 4 Remove retaining plates R friction plates F and separator plate S in ...

Page 324: ...psi through oil hole 2 9 Remove O rings from coast clutch piston NOTE Never reuse O rings after removal 10 Remove coast clutch piston 1 with O rings using compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole 2 11 Remove O rings from overdrive clutch piston NOTE Never reuse O rings after removal Reassembly 1 Apply A T fluid to new O rings 2 Install new O rings to pistons 3 Set coast cl...

Page 325: ...oast clutch in the following order R F S F R NOTE Be sure to confirm that flat section of retaining plate faces toward piston side and also that of separate plate faces toward upper side 8 Install snap ring 1 NOTE Make sure that opening end of ring is not aligned with groove section of drum 9 Select and measure correct thickness of overdrive clutch retaining plate Available overdrive clutch retain...

Page 326: ... sliding surfaces of friction separator and retaining plates are not worn or burnt If necessary replace NOTE If friction plate lining is exfoliated discolored or worn hardly replace all friction plates Before assembling new friction plates soak them in A T fluid for at least two hours 2 Measure height of overdrive clutch return spring Overdrive clutch return spring height Standard 18 9 mm 0 74 in ...

Page 327: ...ne way clutch No 0 outer race 5 Thrust washer 16 Snap ring 27 One way clutch No 0 retainer 6 O ring 17 Planetary sun gear assembly 28 Snap ring 7 Front ring gear thrust washer 18 Sun gear thrust roller bearing 29 Rear ring gear thrust roller bearing 8 Front ring gear thrust roller bearing race 19 Sun gear thrust roller bearing race 30 Rear ring gear thrust roller bearing race 9 Front ring gear thr...

Page 328: ...o 1 turns freely when turned counterclockwise A and locks when turned clockwise B Planetary Gear Disassembly and Reassembly S3RH0B5106040 Disassembly Planetary gear assembly 1 Remove the following parts by removing snap ring 1 Overdrive clutch hub 2 Planetary pinion gear assembly 3 Two thrust bearing races 4 2 Pull out carrier front thrust roller bearing 1 Carrier front thrust roller bearing dimen...

Page 329: ...de diameter 64 5 mm 2 54 in Thickness 2 7 mm 0 11 in 7 Remove thrust washer 2 8 Remove front ring gear flange 1 by removing snap ring 2 9 Remove O ring 1 NOTE Never reuse O ring 1 after removal Rear planetary ring gear assembly 1 Remove sun gear thrust roller bearing race 1 Sun gear thrust roller bearing race dimension Outside diameter 29 6 mm 1 17 in Inside diameter 19 2 mm 0 76 in Thickness 0 8 ...

Page 330: ...th snap ring 2 4 Coat thrust washer 2 with A T fluid 5 Install thrust washer 2 6 Install front ring gear thrust roller bearing 1 7 Apply A T fluid to front ring gear thrust roller bearing race 1 and install it 8 Apply A T fluid to front ring gear thrust washer 1 and install it 9 Set one way clutch No 1 and one way clutch No 1 inner race NOTE Make sure that A section shorter than rear of inner race...

Page 331: ...lanetary ring gear assembly 1 Set one way clutch No 0 to one way clutch No 0 outer race and rear planetary ring gear NOTE Make sure that thinner section A of one way clutch faces toward front side 2 Install one way clutch No 0 retainer 1 and rear ring gear thrust roller bearing 2 3 Install snap ring 3 4 Install rear ring gear flange 3 with snap ring 4 5 Coat sun gear thrust roller bearing race 1 a...

Page 332: ...mponents S3RH0B5106044 I2RH01510182 01 I2RH01510183 01 1 Reverse clutch drum with bearing 8 Friction plate 15 Sun gear input flange 2 O ring 9 Snap ring 16 Thrust washer 3 Reverse clutch piston 10 Input shaft front thrust roller bearing 17 Retainer ring 4 Reverse clutch return spring 11 Input shaft 18 Input shaft front thrust roller bearing race 5 Snap ring 12 Input shaft rear thrust roller bearin...

Page 333: ... clutch drum with bearing to oil pump body 1 6 Measure piston stroke with compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole section 2 using special tools Special tool A 09900 20607 B 09900 20701 Reverse clutch piston stroke Standard 1 54 1 86 mm 0 061 0 073 in NOTE To prevent air leakage from oil hole section 2 during piston stroke measurement with air nozzle gun it is recommended ...

Page 334: ... 09926 96010 NOTE To prevent deformation of spring seat it is recommended to compress spring seat until claw section of snap ring is free 5 Mount reverse clutch drum with bearing 2 to oil pump body 3 6 Remove reverse clutch piston 1 by blowing compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole section 4 7 Remove two O rings from piston NOTE Never reuse removed O rings Reassembly 1 A...

Page 335: ... retainer ring 2 9 Measure piston stroke referring to Reverse Clutch Preliminary Inspection 10 Remove reverse clutch from oil pump body 11 Remove sun gear input flange by removing retainer ring 12 Install snap ring 2 to reverse clutch drum with bearing 1 13 Apply A T fluid to input shaft rear thrust roller bearing 1 14 Install input shaft rear thrust roller bearing 1 to input shaft 3 Input shaft r...

Page 336: ...nt thrust roller bearing race dimension Outside diameter 34 4 mm 1 35 in Inside diameter 21 5 mm 0 85 in Thickness 0 8 mm 0 03 in Reverse Clutch Inspection S3RH0B5106047 1 Check that sliding surfaces of friction separator and cushion plates are not worn or burnt If necessary replace NOTE If friction plate lining is exfoliated discolored or worn hardly replace all friction plates Before assembling ...

Page 337: ...er Drive Gear Disassembly and Reassembly S3RH0B5106049 Disassembly 1 Clamp special tool in vise 1 and place counter drive gear onto the special tool Special tool A 09927 76040 2 Unstake lock section of lock nut and remove lock nut using special tool Special tool A 09927 26010 1 Counter drive gear 2 Angular ball bearing 3 Locknut After tightening nut so as starting rotational torque of counter driv...

Page 338: ...ool B 09927 76040 4 Tighten new lock nut using special tool until starting rotation torque bearing preload will be in specified value shown in the following Special tool A 09927 26010 Counter drive gear bearing preload Starting torque 0 05 0 25 N m 0 005 0 025 kgf m 0 037 0 180 lb ft Rotational torque 0 05 0 15 N m 0 005 0 015 kgf m 0 037 0 108 lb ft 5 Stake new lock nut using standard punch in co...

Page 339: ...t driven gear lock nut for output shaft speed sensor After tightening nut to specified tightening torque stake nut securely Apply automatic transaxle fluid 2 Differential drive pinion 6 Counter shaft LH thrust roller bearing race Tightening torque 3 Counter driven gear 7 Counter shaft LH thrust roller bearing Do not reuse 4 Cylindrical roller bearing inner race ...

Page 340: ... bearing inner race 1 by pressing differential drive pinion 2 using hydraulic press 3 Reassembly 1 Press differential drive pinion 2 to counter driven gear 1 using hydraulic press 3 2 Apply A T fluid to inner surface of cylindrical roller bearing inner race 3 Press cylindrical roller bearing inner race 1 using special tool and hydraulic press 2 Special tool A 09951 16060 4 Tighten new counter shaf...

Page 341: ...the figure Poor staking may cause abnormal noise 6 Apply A T fluid to counter shaft LH thrust roller bearing 1 and race Counter shaft LH thrust roller bearing dimension Outside diameter 66 0 mm 2 60 in Inside diameter 50 0 mm 1 97 in Thickness 2 7 mm 0 11 in 7 Place counter shaft LH thrust roller bearing 1 and race to transaxle case 8 Apply A T fluid to counter shaft RH roller bearing race 9 Insta...

Page 342: ...9 10 5 7 N m 0 7 kg m 7 N m 0 7 kg m 7 N m 0 7 kg m 7 N m 0 7 kg m 7 N m 0 7 kg m 11 I2RH01510214 01 1 Valve body assembly 6 Pressure control solenoid valve 11 Transmission fluid temperature sensor clamp 2 Manual valve 7 O ring Apply automatic transaxle fluid 3 Manual valve rod 8 Shift solenoid valve A No 1 Tightening torque 4 E ring 9 Shift solenoid valve B No 2 Do not reuse 5 Pressure control so...

Page 343: ... torque Tightening torque Shift solenoid bolt a 7 0 N m 0 7 kgf m 5 0 lb ft Pressure control solenoid bolt b 7 0 N m 0 7 kgf m 5 0 lb ft NOTE Don t reuse solenoid valve O rings Shift solenoid valve A No 1 and shift solenoid valve B No 2 are interchangeable with each other 2 Install manual shift valve to valve body 1 Pressure control solenoid valve 3 Shift solenoid valve B No 2 2 Shift solenoid val...

Page 344: ...ential side oil seal NOTE Don t reuse removed side oil seal 2 Drive out taper roller bearing outer race and shim from transaxle case by using special tools or like Special tool A 09924 74510 B 09924 74590 C 09924 84510 005 I2RH01510217 01 1 Differential gear assembly 5 Differential side bearing outer race Tightening torque 2 Bolt 6 Differential side bearing shim Do not reuse 3 Final gear 7 Oil sea...

Page 345: ...ential assembly starting torque by using special tool Special tool A 09928 06050 Starting torque of differential assembly 0 8 1 4 N m 0 08 0 14 kgf m 0 58 1 01 lb ft NOTE If starting torque exceeds specified value reselect shim on both transaxle case and housing Starting torque changes about 0 3 0 4 N m 0 03 0 04 kgf m 0 22 0 29 lb ft with each shim thickness Available differential side bearing sh...

Page 346: ...tial gear thrust washer thickness 0 95 mm 0 037 in 1 00 mm 0 039 in 1 05 mm 0 041 in 1 075 mm 0 042 in 1 10 mm 0 043 in 1 15 mm 0 045 in 1 20 mm 0 047 in Transaxle housing Removal and Installation S3RH0B5106057 Removal 1 Remove oil seal 4 NOTE Never reuse removed oil seal 2 Remove oil reservoir plate 1 with three magnets 2 by removing bolts 3 Remove cylindrical roller bearing retainer 3 by removin...

Page 347: ...drical roller bearing using special tools Special tool A 09924 74510 B 09944 88210 5 Tighten cylindrical roller bearing retainer 2 with bolt Tightening torque Cylindrical roller bearing retainer bolt a 13 N m 1 3 kgf m 9 5 lb ft 6 Install transaxle lubrication tube 3 and clamp 7 Tighten them with bolt Tightening torque Lubrication tube clamp bolt b 5 5 N m 0 55 kgf m 4 0 lb ft 8 Tighten oil reserv...

Page 348: ...ing 1 using special tools Special tool A 09942 15511 B 09941 54911 C 09921 26010 NOTE Never reuse removed cylindrical roller bearing Installation 1 Apply A T fluid to outer surface of cylindrical roller bearing 2 Tap cylindrical roller bearing using special tools Special tool A 09924 74510 B 09944 88210 Automatic Transaxle Unit Assembly S3RH0B5106060 1 Apply lithium grease to new oil seal lip Grea...

Page 349: ...led NOTE Be careful not to damage O rings during piston installation 12 Mount 1st and reverse brake piston return spring 2 13 Install retainer ring 1 by compressing brake piston return spring with flat end rod or the like 14 Install separator plates S friction plates F and retaining plates R in the following order R F S F S F S F S F R 15 Install snap ring 1 NOTE Make sure that opening end of snap...

Page 350: ...ings 2 20 Put 2nd and 4th brake piston spring in transaxle case and insert piston assembly and brake inner cover into case 21 Apply valve lifter as shown figure and push piston cover Special tool A 09916 14510 B 09916 48210 22 Install snap ring by using snap ring pliers special tool and re move special tools A and B Special tool C 09900 06108 23 Check 2nd and 4th brake piston stroke For detail ref...

Page 351: ...se Pin Dimension 27 Apply A T fluid to transaxle lubrication tube 1 28 Install transaxle lubrication tube 1 29 Tighten clamp with bolt Tightening torque Lubrication tube clamp bolt a 5 5 N m 0 55 kgf m 4 0 lb ft 30 Install 2nd and 4th brake band 1 31 Install 1st and reverse clutch assembly 2 32 Temporarily tighten bolts of oil pump body 1 1 2 3 Outer diameter 8 0 mm 0 31 in 10 0 mm 0 39 in 12 0 mm...

Page 352: ...ly 1 while rotating counterclockwise and clockwise NOTE Make sure that overdrive coast clutch assembly locks when turned counterclockwise A and moves freely when turned clockwise B 40 Install forward clutch assembly while rotating 41 Check for correct installation of each component parts as follows Measure the distance a by using vernier 1 and straightedge 2 If out of specification remove forward ...

Page 353: ...ounter shaft LH thrust roller bearing dimension Outside diameter 66 0 mm 2 60 in Inside diameter 50 0 mm 1 97 in Thickness 2 7 mm 0 11 in 50 Install counter driven gear 51 Install parking lock rod 2 with parking lock paw 1 parking lock pawl bracket 3 and torsion spring 5 52 With spacer and torsion spring 6 placed install bolt and tighten parking lock pawl bracket 3 Tightening torque Parking lock p...

Page 354: ...etween spring detent and lever manual valve and then tighten bolts 58 Install oil strainer 1 NOTE When overhauling automatic transaxle replace oil strainer 59 Tighten oil reservoir plate 2 with bolts Tightening torque Oil reservoir plate bolt a 5 5 N m 0 55 kgf m 4 0 lb ft 60 Install three new gaskets 1 61 Install differential gear assembly 2 62 Tighten oil pump body 3 with six bolts Tightening to...

Page 355: ...wing table Bolt Length L 1 20 mm 2 50 mm 3 55 mm 4 75 mm Tightening torque Valve body bolt a 10 N m 1 0 kgf m 7 5 lb ft 71 Clamp wiring harness 1 of solenoids and transmission fluid temperature sensor 72 Connect couplers of solenoids by identifying wire color shown in the following table and install transmission fluid temperature sensor 6 to its clamp 7 NOTE There is an interchangeability between ...

Page 356: ...saxle side cover bolt a 24 N m 2 4 kgf m 17 5 lb ft 77 Install the following parts with new O rings installed with bolts Valve body connector 1 Output shaft speed sensor 2 Input shaft speed sensor 3 Fluid filler tube 4 Tightening torque Input shaft speed sensor bolt a 5 5 N m 0 55 kgf m 4 0 lb ft Valve body connector bolt b 7 0 N m 0 7 kgf m 5 0 lb ft Output shaft speed sensor bolt c 5 5 N m 0 55 ...

Page 357: ... 19 5 lb ft A T fluid pipe union bolt color silver a 35 N m 3 5 kgf m 25 5 lb ft A T fluid pipe b 35 N m 3 5 kgf m 25 5 lb ft A T fluid pipe nut c 18 N m 1 8 kgf m 13 0 lb ft NOTE Make sure to use new gaskets 2 82 Install torque converter 1 to input shaft a Install torque converter 1 using care not to damage oil seal of oil pump b After installing torque converter 1 check that distance a is within...

Page 358: ...ipe union bolt color silver 35 3 5 25 5 A T fluid pipe nut 18 1 8 13 0 Shift solenoid bolt 7 0 0 7 5 0 Valve body bolt 10 1 0 7 5 Pressure control solenoid bolt 7 0 0 7 5 0 Transaxle to engine bolts and nut 85 8 5 61 5 Drive plate to torque converter bolt 25 2 5 18 0 Lower stiffener bolt 50 5 0 36 5 Starter motor bolt 23 2 3 16 5 Center bearing support bolt 55 5 5 40 0 Oil pump cover bolt 10 1 0 7...

Page 359: ...rive Gear Components Counter Driven Gear Components Valve Body Assembly Components Differential Components Special Tool S3RH0B5108002 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25010 SUZUKI Super Grease C P No 99000 25030 Sealant SUZUKI Bond No 1216B P No 99000 31230 09900 06108 09900 20607 Snap ring pliers closing type Dial gauge 09900 20701 ...

Page 360: ...earing puller attachment Differential bevel pinion bearing installer 09926 96010 09926 98310 Clutch spring compressor Clutch spring compressor 09926 98330 09927 26010 Spring compressor No 2 Counter drive gear socket 09927 76040 09927 76050 Counter drive gear holder Counter driven gear socket 09928 06050 09941 54911 Differential preload adapter Bearing outer race remover 09942 15511 09944 66020 Sli...

Page 361: ... 09951 46010 Control arm bush remover Drive shaft oil seal installer SUZUKI scan tool 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 10 RS232 loop back connector 11 Storage case 12 Power supply ...

Page 362: ...5A 136 Automatic Transmission Transaxle ...

Page 363: ...1 Cranking System Circuit Diagram 9A A 2 Charging System Circuit Diagram 9A A 3 Ignition System Circuit Diagram 9A A 4 Cooling System Circuit Diagram 9A A 5 Engine and A C Control System Circuit Diagram 9A A 6 4 A T Control System Circuit Diagram 9A A 7 Immobilizer Control System Circuit Diagram 9A B 1 Windshield Wiper and Washer Circuit Diagram 9A B 2 Rear Wiper and Washer Circuit Diagram Instrum...

Page 364: ...t Switch in Lighting Switch Inspection 9B Headlight Diode Removal and Installation 9B Headlight Diode Inspection 9B Headlight Clearance Light Front Rear Fog Light Relays Inspection 9B Hazard Switch Inspection 9B Stop Brake Lamp Switch Inspection 9B Turn Signal Light Switch in Lighting Switch Removal and Installation 9B Turn Signal Light Switch in Lighting Switch Inspection 9B Turn Signal and Hazar...

Page 365: ...d Installation 9E Front Pillar Window Removal and Installation 9E Front Door Window Components 9E Front Door Glass Removal and Installation 9E Front Door Window Regulator Removal and Installation 9E Front Door Window Regulator Inspection 9E Rear Door Window Components 9E Rear Door Glass Removal and Installation 9E Rear Door Window Regulator Removal and Installation 9E Rear Door Window Regulator In...

Page 366: ...epair Instructions 9J Hood Removal and Installation 9J Hood Inspection and Adjustment 9J Front Fender Components 9J Front Fender Removal and Installation 9J Front Door Assembly Components 9J Front Door Assembly Removal and Installation 9J Rear Door Assembly Components 9J Rear Door Assembly Removal and Installation 9J Rearend Door Assembly for Wagon Model Components 9J Rearend Door Assembly for Wag...

Page 367: ... G21 12 21 G21 17 4 4 3 5 6 7 8 9 10 13 I3RH0B930001 01 1 RADIO DOME fuse 7 Fuel meter 13 VSS or TCM 19 Generator 25 TCM 2 METER fuse 8 ECT meter 14 ABS control module 20 Oil pressure switch 26 Key remainder switch 3 Main fuse 9 ODO TRIP 15 Fuel level gauge 21 Headlight relay 1 Serial communication 4 Combination switch 10 Back light 16 ECM 22 Driver side door switch 5 Tacho meter 11 Brake fluid le...

Page 368: ...le EBD warning indicator control signal G21 10 G20 11 BLU YEL To combination switch turn R G21 11 LTGRN BLK To 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 signal G20 15 BLU ORN To key remainder switch G21 15 BLK RED To METER fuse G20 16 PPL YEL T...

Page 369: ...tch Inspection S3RH0B9506019 Check for continuity between terminals at each switch position If check result is not as specified replace switch I3RH0B950001 01 1 Power window lock switch 4 Rear LH window switch 2 Driver side window switch 5 Rear RH window switch 3 Passenger side window switch ...

Page 370: ...Prepared by 1st Ed Feb 2004 2nd Ed Jul 2006 367 ...

Page 371: ...14 mm 99501 54G30 24E 99501 54G30 24E SUPPLEMENTARY SERVICE MANUAL SUPPLEMENTARY SERVICE MANUAL ...

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