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Suzuki SWIFT RS415 2017, Service Manual

The Suzuki Swift RS415 2017 Service Manual is available for free download on manualshive.com. This comprehensive manual includes detailed instructions and diagrams for vehicle maintenance and repairs. Get your hands on this essential manual to ensure your Suzuki Swift stays in top condition. Download it now!

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Table of Contents 5-iii

Vehicle Speed Sensor (VSS) Removal 

and Installation.................................................. 5B-7

Back Up Lamp Switch Removal and 

Installation......................................................... 5B-7

Back Up Lamp Switch Inspection ....................... 5B-8
Manual Transaxle Unit Components................... 5B-8
Manual Transaxle Unit Dismounting and 

Remounting....................................................... 5B-9

Gear Shift and Select Shaft Assembly 

Components.................................................... 5B-11

Gear Shift and Select Shaft Assembly 

Removal and Installation................................. 5B-11

Gear Shift and Select Shaft Disassembly 

and Assembly ................................................. 5B-12

Manual Transaxle Assembly Components........ 5B-13
Fifth Gear Disassembly and Assembly .............5B-14
Manual Transaxle Assembly Disassembly 

and Reassembly .............................................5B-17

Transaxle Right Case Disassembly and 

Assembly ........................................................ 5B-22

Transaxle Left Case Disassembly and 

Assembly ........................................................ 5B-23

Input Shaft and Countershaft Components....... 5B-24
Input Shaft Assembly Disassembly and 

Reassembly .................................................... 5B-25

Countershaft Assembly Disassembly 

and Reassembly .............................................5B-27

Synchronizer Parts Inspection ..........................5B-30
Gear Shift Shaft Components ........................... 5B-30
5th and Reverse Gear Shift Shafts 

Disassembly and Assembly ............................5B-31

Gear Shift Shaft and Fork Inspection ................5B-31
Differential Components ...................................5B-32
Differential Disassembly and Assembly ............5B-32

Specifications.....................................................5B-34

Tightening Torque Specifications......................5B-34

Special Tools and Equipment ...........................5B-35

Recommended Service Material .......................5B-35
Special Tool ......................................................5B-35

Clutch ....................................................... 5C-1

General Description .............................................5C-1

Clutch Construction.............................................5C-1

Diagnostic Information and Procedures............5C-2

Clutch System Symptom Diagnosis ....................5C-2

Repair Instructions ..............................................5C-3

Clutch Pedal Inspection ......................................5C-3
Clutch Fluid Level Inspection ..............................5C-4
Air Bleeding of Clutch System.............................5C-4
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-5
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and 

Installation .........................................................5C-6

Clutch Operating Cylinder Removal and 

Installation .........................................................5C-6

Clutch Pedal and Clutch Pedal Bracket 

Components......................................................5C-7

Clutch Cover, Clutch Disc and Flywheel 

Components......................................................5C-8

Clutch Cover, Clutch Disc and Flywheel 

Removal and Installation...................................5C-8

Clutch Cover, Clutch Disc and Flywheel 

Inspection........................................................5C-10

Clutch Release System Removal and 

Installation .......................................................5C-10

Clutch Release System Inspection ...................5C-12

Specifications.....................................................5C-12

Tightening Torque Specifications......................5C-12

Special Tools and Equipment ...........................5C-13

Recommended Service Material .......................5C-13
Special Tool ......................................................5C-13

Summary of Contents for SWIFT RS415 2017

Page 1: ...performed 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 perfor...

Page 2: ......

Page 3: ...llowing page And on the first page of each individual section is an index of that section This manual should be kept in a handy place for ready reference of the service work Strict observance of the s...

Page 4: ......

Page 5: ...rakes 4B 1 Rear Brakes 4C 1 Parking Brake 4D 1 ABS 4E 1 Volume 2 Precautions 00 i Precautions 00 1 Transmission Transaxle 5 i Precautions 5 1 Automatic Transmission 5A 1 Manual Transmission 5B 1 Clutc...

Page 6: ......

Page 7: ...00 6 Precautions for Installing Mobile Communication Equipment 00 6 Precaution for CAN Communication System 00 7 Precautions for Electrical Circuit Service 00 7 Air Bag Warning 00 9 Air Bag System Se...

Page 8: ...ratures over 93 qC 200 qF for example during a paint baking process remove the air bag system components beforehand to avoid component damage or unintended air bag system activation Diagnosis When tro...

Page 9: ...mounting bracket 3 It is also prohibited to place anything on top of the trim cover and stack air bag inflator modules This is necessary so that a free space is provided to allow the air bag to expand...

Page 10: ...equired after Accident in Section 8B When servicing parts other than air bag system if shocks may be applied to air bag system component parts remove those parts beforehand When handling the air bag i...

Page 11: ...as dish washing gloves when changing engine oil If engine oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil recycle or properly dispose of used o...

Page 12: ...ing nuts and certain other parts as specified be sure to use new ones Also before installing new gaskets packing etc be sure to remove any residual material from the mating surfaces Make sure that all...

Page 13: ...ul not to let a large amount of unburned gasoline enter the converter or it can be damaged Conduct a spark jump test only when necessary make it as short as possible and do not open the throttle Condu...

Page 14: ...g a fuse make sure to use a fuse of the specified capacity Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire When disconnecting and connecting coupler make su...

Page 15: ...may not be obtained or personal injury may result If not specified use a voltmeter with high impedance M V minimum or a digital type voltmeter When taking measurements at electrical connectors using...

Page 16: ...m setting Failure to follow procedures could result in possible activation of the air bag system personal injury or otherwise unneeded air bag system repairs Fastener Caution S4RS0A0000010 CAUTION Whe...

Page 17: ...re harness being open When checking system circuits including an electronic control unit such as ECM TCM ABS control module etc it is important to perform careful check starting with items which are e...

Page 18: ...1 and A 1 Voltage between C 1 and body ground Approx 5 V B 1 and body ground Approx 5 V A 1 and body ground 0 V b Also if measured values were as listed in the following it means that there is a resis...

Page 19: ...t Dirt or corrosion on the terminals The terminals must be clean and free of any foreign material which could impede proper terminal contact However cleaning the terminal with a sand paper or the like...

Page 20: ...insulation which is rubbed through causing an intermittent short as the bare area touches other wiring or parts of the vehicle Wiring broken inside the insulation This condition could cause continuit...

Page 21: ...Filter Replacement 0B 6 Fuel Lines and Connections Inspection 0B 6 Fuel Filter Replacement 0B 7 Fuel Tank Inspection 0B 7 PCV Valve Inspection 0B 7 Fuel Evaporative Emission Control System Inspection...

Page 22: ...t Gas Temp Sensor REGTS EFE Heater Early Fuel Evaporation Heater Positive Temperature Coefficient PTC Heater EPS Electronic Power Steering EVAP Evaporative Emission EVAP Canister Evaporative Emission...

Page 23: ...re GRN in the figure and the second symbol represents the color of the stripe YEL in the figure Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO 1216B 99000 31230 Apply oil e...

Page 24: ...lable through the parts division Metric bolts Identification class numbers or marks correspond to bolt strength increasing numbers represent increasing strength Standard Tightening Torque Each fastene...

Page 25: ...4 7 8 4 20 42 80 125 193 280 kg m 0 24 0 47 0 84 2 0 4 2 8 0 12 5 19 3 28 lb ft 2 0 3 5 6 0 14 5 30 5 58 0 90 5 139 5 202 5 A equivalent of 6 8 strength fastener with flange Self lock nut N m 2 4 4 9...

Page 26: ...oor or it may get deformed When jacking up the front end be sure to use an air type floor jack with the following specified height or a manual type floor jack of the following size Otherwise the jack...

Page 27: ...fety s sake Engine Supporting Points S4RS0A0101008 WARNING When using engine supporting device 1 be sure to observe the followings Otherwise not only deformation of vehicle body but also personal inju...

Page 28: ...009 The automatic transmission identification number is located on transmission case Component Location Warning Caution and Information Labels Location S4RS0A0103001 The figure shows main labels among...

Page 29: ...S0A010009 1 Air bag label on driver air bag inflator module 5 Air bag label on curtain air bag inflator module 2 Air bag label on combination switch and contact coil assembly 6 Air bag label on SDM 3...

Page 30: ...HO2S Nickel plug R R R Iridium plug R Vehicle with HO2S Nickel plug R R Iridium plug Highly recommended Replace every 105 000 km 63 000 miles or 84 months When leaded fuel is used refer to Maintenanc...

Page 31: ...amage breakage rattle I I I I Drive shaft axle boots I I I Manual transaxle oil leakage level I 1st 15 000 km only R I R R Automatic transaxle fluid Fluid level I I I I Fluid change R Replace every 16...

Page 32: ...ust it to specification by adjusting alternator position 4 Tighten alternator adjusting bolts and pivot bolt 5 Connect negative cable to battery A C Compressor Drive Belt If Equipped 1 Disconnect nega...

Page 33: ...ction and adjustment procedure Engine Oil and Filter Change S4RS0A0206004 WARNING New and used engine oil can be hazardous Be sure to read WARNING in General Precautions in Section 00 and observe what...

Page 34: ...ewhat differ from the data depending on various conditions temperature viscosity etc Engine oil specification Oil pan capacity About 3 7 liters 7 8 6 5 US lmp pt Oil filter capacity About 0 2 liter 0...

Page 35: ...g and possible damage to floor carpet Any defects should be fixed at once Spark Plugs Replacement S4RS0A0206007 Replace spark plugs with new ones referring to Spark Plug Removal and Installation in Se...

Page 36: ...cracks damage or excessive bends Inspect all clamps for damage and proper position 2 Check EVAP canister for operation and clog referring to EVAP Canister Inspection in Section 1B If a malfunction is...

Page 37: ...ion 4A Brake Lever and Cable Inspection S4RS0A0206019 1 Inspect brake cable for damage and smooth movement Replace cable if it is in deteriorated condition 2 Check tooth tip of each notch for damage o...

Page 38: ...2B 2 Check rear wheel bearing for wear damage abnormal noise or rattles For details refer to Rear Wheel Disc Nut and Bearing Inspection in Section 2C Suspension System Inspection S4RS0A0206024 Inspec...

Page 39: ...boots wheel side and differential side for leaks detachment tear or other damage Replace defective parts as necessary Manual Transaxle Oil Inspection S4RS0A0206028 1 Inspect transaxle case for evidenc...

Page 40: ...ic Transaxle Fluid Cooler Hose Inspection S4RS0A0206041 Check automatic transaxle fluid cooler hose for fluid leakage cracks damage and deterioration Replace hose and or clamp if any faulty condition...

Page 41: ...hat pedal operates smoothly without getting caught or interfered by any other part Engine Start Check engine start for readiness WARNING Before performing the following check be sure to have enough ro...

Page 42: ...lights operate properly Windshield Defroster Periodically check that air comes out from defroster outlet when operating heater or air conditioning Set mode control lever to defroster position and fan...

Page 43: ...A 40 DTC P0010 Camshaft Position Actuator Circuit 1A 42 DTC P0011 P0012 Camshaft Position Timing Over Advanced or System Performance Retarded 1A 44 DTC P0031 P0032 HO2S Heater Control Circuit Low High...

Page 44: ...Circuit Check 1A 180 Fuel Pump and Its Circuit Check 1A 182 Fuel Pressure Check 1A 185 Idle Air Control System Check 1A 186 A C System Circuits Check 1A 188 Electric Load Signal Circuit Check 1A 192 R...

Page 45: ...on 1D 25 Timing Chain and Chain Tensioner Inspection 1D 27 Camshaft Tappet and Shim Components 1D 28 Camshaft Tappet and Shim Removal and Installation 1D 29 Camshaft Tappet and Shim Inspection 1D 31 V...

Page 46: ...ocedure 1G 8 Fuel Lines On Vehicle Inspection 1G 8 Fuel Pipe Removal and Installation 1G 8 Fuel Injector On Vehicle Inspection 1G 9 Fuel Injector Removal and Installation 1G 9 Fuel Injector Inspection...

Page 47: ...ck 1J 5 Repair Instructions 1J 6 Jump Starting in Case of Emergency 1J 6 Battery Dismounting and Remounting 1J 6 Generator Dismounting and Remounting 1J 7 Generator Components 1J 7 Generator Inspectio...

Page 48: ...1A Precautions of ECM Circuit Inspection Refer to Precautions of ECM Circuit Inspection in Section 1A Precautions on Fuel System Service Refer to Precautions on Fuel System Service in Section 1G Prec...

Page 49: ...an tool used SUZUKI scan tool displays DTC detected by ECM OBD II generic scan tool displays DTC detected by each of ECM and TCM simultaneously Priorities for diagnosing troubles If two or more DTCs a...

Page 50: ...agnosis General Description S4RS0A1101002 This vehicle is equipped with an engine and emission control system which are under control of ECM The engine and emission control system in this vehicle are...

Page 51: ...f same malfunction also in the next driving cycle Pending DTC Pending DTC means a DTC detected and stored temporarily at 1 driving cycle of the DTC which is detected in the 2 driving cycle detection l...

Page 52: ...r SUZUKI scan tool or OBD generic scan tool to communicate with ECM Air bag SDM immobilizer control module in ECM BCM Body electrical Control Module TCM Transmission Control Module and ABS control mod...

Page 53: ...uses the serial communication in which data is transmitted at a high speed It uses a twisted pair of two communication lines for the high speed data transmission As one of its characteristics multiple...

Page 54: ...ning and engine speed is filtered by the air cleaner passes through the throttle body distributed by the intake manifold and finally drawn into each combustion chamber When the idle air control valve...

Page 55: ...tems Fuel injection control system Ignition control system Idle speed control system Fuel pump control system Radiator cooling fan control system Evaporative emission control system EGR system Oxygen...

Page 56: ...PURGE VALVE CHECK VALVE FUEL INJECTOR ECT SENSOR ELECTRIC LOAD RADIATOR FAN TCM A T ECM HEATER CONTROL BAROMETRIC PRESSURE SENSOR HO2S 1 HO2S 2 ENGINE CMP SENSOR CKP SENSOR KNOCK SENSOR IGNITION COIL...

Page 57: ...LT GRN GRY GRN E23 60 E23 30 C37 48 YEL BLK YEL GRN YEL RED WHT BLK ORN BLK BLK YEL BLK YEL RED C37 21 C37 20 IG1 9 8 WHT BRN RED BLU BLK WHT 46 46 C37 10 C37 47 C37 11 YEL BLK RED C37 57 C37 46 YEL...

Page 58: ...erant pressure sensor 41 Transmission range switch A T 63 Combination meter 20 Immobilizer coil antenna 42 Ignition switch 64 IG ACC fuse 21 Data link connector 43 Main relay 65 Only for M T vehicle 2...

Page 59: ...L Ground for sensors 28 58 BLK ORN Ground for ECM 29 BLU BLK EVAP canister purge valve output 59 YEL GRN Oil control valve ground 30 BLK Ground for ECM 60 YEL RED Oil control valve output Terminal Wir...

Page 60: ...RED A C refrigerant pressure sensor signal 26 RED BLU EPS signal 56 27 57 WHT BLK A C evaporator outlet air temp sensor signal 28 YEL BLK Serial communication line for immobilizer coil antenna 58 29...

Page 61: ...LOWER SWITCH A C SWITCH A C EVAP OUTLET AIR TEMP SENSOR VSS HEATED OXYGEN SENSOR 1 HEATED OXYGEN SENSOR 2 IAT SENSOR MAF SENSOR ECT SENSOR TP SENSOR MAP SENSOR CMP SENSOR CKP SENSOR KNOCK SENSOR ABS C...

Page 62: ...and Diagnosis Schematic and Routing Diagram Engine and Emission Control System Diagram S4RS0A1102001 26 10 9 7 8 14 13 23 11 15 12 2 6 5 1 3 18 24 39 42 35 30 29 38 16 17 37 36 31 22 21 40 27 25 41 3...

Page 63: ...10 Fuel pump with pressure regulator 24 DLC 38 Oil control valve 11 Ignition coil assembly 25 Electric load 39 TCM A T 12 Fuel injector 26 Fuel level sensor 40 Starting motor control relay 13 Heated o...

Page 64: ...wn and clear them by referring to DTC Clearance and go to Step 3 Go to Step 4 3 Visual inspection 1 Perform visual inspection referring to Visual Inspection Is there any faulty condition Repair or rep...

Page 65: ...o the point required for proper analysis and diagnosis 10 Intermittent problems check 1 Check for intermittent problems referring to Intermittent Problems Check Is there any faulty condition Repair or...

Page 66: ...Engine General Information 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 I2RH011...

Page 67: ...s if any Step 9 Troubleshooting for DTC See each DTC Diag Flow Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag flow locate the cause of the trouble namely in a senso...

Page 68: ...k connector NOTE DTC and freeze frame data stored in ECM memory are also cleared in the following cases Be careful not to clear them before keeping their record When power to ECM is cut off by disconn...

Page 69: ...ification 1 driving cycle P0118 Engine coolant temperature circuit high Circuit voltage of ECT sensor is more than specification 1 driving cycle P0121 Throttle position sensor circuit range performanc...

Page 70: ...purge valve is different from command signal circuit open or shorted to ground 2 driving cycles P0462 Fuel level sensor circuit low Circuit voltage of fuel level sensor is less than specification P04...

Page 71: ...Trouble Code DTC Table in Section 10C 1 driving cycle P1623 Unregistered transponder Refer to Diagnostic Trouble Code DTC Table in Section 10C 1 driving cycle P1625 Immobilizer antenna error Refer to...

Page 72: ...opening closed throttle position or not ECM stops EGR control P0103 Mass air flow circuit high input P0112 Intake air temperature sensor circuit low ECM controls actuators assuming that intake air te...

Page 73: ...with no load after warming up 4 0 12 0 g s 0 53 1 58 Ib min CALC LOAD CALCULATED LOAD VALUE At specified idle speed with no load after warming up 0 10 At 2500 r min with no load after warming up 0 10...

Page 74: ...ON engine at stop 10 14 V FUEL PUMP Within 3 seconds after ignition switch ON or engine running ON Engine at stop with ignition switch ON OFF ELECTRIC LOAD Ignition switch ON Headlight small light all...

Page 75: ...e indicates how much correction is necessary to keep the air fuel mixture stoichiometrical MAF MASS AIR FLOW RATE g s lb min It represents total mass of air entering intake manifold which is measured...

Page 76: ...e state of the A C switch VEHICLE SPEED km h It is computed based on pulse signals from vehicle speed sensor VVT GAP TARGET ACTUAL POSITION q It is calculated using the formula target valve timing adv...

Page 77: ...Yes No 1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 Check battery voltage Is it 11 V or more Go to Step 3 Charge or replace ba...

Page 78: ...nition Timing Inspection in Section 1H 7 Check immobilizer system malfunction 1 Check immobilizer indicator lamp for flashing Is it flashing when ignition switch is turned to ON position Go to Diagnos...

Page 79: ...nect them to high tension cords or ignition coil assembly 3 Ground spark plugs 4 Crank engine and check if each spark plug sparks Is it in good condition Go to Step 11 Go to Ignition Spark Test in Sec...

Page 80: ...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 Compression leak at cyl...

Page 81: ...ion Low oil pressure Worn bearing Main Bearings Inspection in Section 1D Worn crankshaft journal Crankshaft Inspection in Section 1D Loose bearing cap bolts Main Bearings Crankshaft and Cylinder Block...

Page 82: ...ction 1D Excessive engine oil consumption Oil entering combustion chamber Sticky piston ring Cylinders Pistons and Piston Rings Inspection in Section 1D Worn piston and cylinder Cylinders Pistons and...

Page 83: ...corn popping Faulty spark plug Spark Plug Inspection in Section 1H Loose connection of high tension cord High Tension Cord Removal and Installation in Section 1H Engine overheating Condition Engine ov...

Page 84: ...sion Compression Check in Section 1D Camshaft position control VVT system out of order Oil Control Valve Inspection in Section 1D Improper engine idling or engine fails to idle Faulty spark plug Spark...

Page 85: ...Section 1C Faulty injector s Fuel Injector Circuit Check Faulty ECM Engine not at normal operating temperature Clogged air cleaner Air Cleaner Element Inspection and Cleaning in Section 1D Vacuum leak...

Page 86: ...BLK YEL BLK YEL RED BLK BLK YEL GRN BRN WHT 12V 5V 2 1 3 8 6 5 7 RED WHT RED WHT RED WHT RED WHT E23 29 E23 3 E23 1 E23 60 E23 18 C37 58 C37 15 C37 30 E23 16 BLK ORN BLK ORN BLK BLK 4 9 10 12 11 G28...

Page 87: ...ng to Step 9 to 14 of DTC P1674 CAN Communication Bus Off Error Is circuit in good condition Go to Step 4 Repair or replace 4 METER fuse check 1 Turn ignition switch to OFF position 2 Check for fuse b...

Page 88: ...15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37...

Page 89: ...trouble shooting be sure to read the Precautions of ECM Circuit Inspection When measuring circuit voltage resistance and or pulse signal at ECM connector connect the special tool to ECM and or the ECM...

Page 90: ...LK BLK ORN RED YEL YEL RED YEL GRN C37 60 C37 59 3 2 1 E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42...

Page 91: ...ectrical circuit check Was resistance more than 6 5 in Step 2 Go to Step 4 Go to Step 7 4 Oil control valve electrical circuit for power short check 1 Turn ON ignition switch 2 Measure voltage between...

Page 92: ...cle speed up to 80 km h 50 mile h 6 Keep vehicle speed at 80 km h 50 mile h for 1 minute or longer at 5th gear position or D range 7 Decrease vehicle speed gradually 8 Stop vehicle and turn OFF igniti...

Page 93: ...f OK go to Step 5 4 Camshaft position control check 1 Drive vehicle under following conditions Vehicle speed at 80 km h 50 mile h Gear position at 5th or D range 2 Check that VVT GAP displayed on SUZU...

Page 94: ...4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47...

Page 95: ...ch turned ON Is voltage over 10 V Go to Step 3 BLK WHT wire is open circuit or shorted to ground circuit 3 HO2S 1 heater power circuit check 1 Disconnect connectors from ECM with ignition switch turne...

Page 96: ...and or GLY wire is high resistance circuit Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37...

Page 97: ...inals 3 If wire and connection are OK measure voltage between BLK WHT wire terminal of HO2S 2 connector and engine ground with ignition switch turned ON Is voltage over 10 V Go to Step 3 BLK WHT wire...

Page 98: ...30 HO2S 2 heater circuit is OK Substitute a known good ECM and recheck RED BLU wire is high resistance circuit Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 2...

Page 99: ...2500 rpm for 1 min 5 Increase vehicle speed to 80 km h 45 mile h at 5th gear or D range 6 Release accelerator pedal to decrease vehicle speed to 40 km h 25 mile h 7 Stop vehicle and run it idle for 1...

Page 100: ...eck 1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM connectors connected 3 Measure voltage between C37 26 and C37 27 terminals of ECM connector referring to Mass Air Flow MAF and Int...

Page 101: ...o Step 9 GRN BLK wire is shorted to others circuit 9 MAF sensor signal circuit check 1 Turn OFF ignition switch measure resistance between GRN BLK wire terminal of MAF and IAT sensor connector and eng...

Page 102: ...6 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 BLK WHT BLK RED BLK RED WHT 80A BLK YEL BLK YEL BLK YEL GRN B...

Page 103: ...n ON ignition switch measure voltage between engine ground and BLK RED wire terminal of MAF and IAT sensor connector Is voltage 10 14 V Go to Step 4 BLK RED wire is open circuit 4 MAF sensor ground ci...

Page 104: ...ehicle Inspection in Section 1C Is each value within specified range Substitute a known good ECM and recheck Faulty MAF and IAT sensor Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 5...

Page 105: ...stem Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 MAF sensor and its circuit check 1 Connect scan tool to DLC with ignition switch turned OFF 2 Start engine and check...

Page 106: ...No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 1...

Page 107: ...pection of ECM and Its Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected Step Action Yes No 1 Was Engine and Emi...

Page 108: ...form DTC Confirmation Procedure and confirm that the trouble has been corrected E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48...

Page 109: ...power supply circuit check 1 Disconnect connectors from TP sensor and A C refrigerant pressure sensor with ignition switch turned OFF 2 Turn ON ignition switch measure voltage between engine ground a...

Page 110: ...4 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 3...

Page 111: ...eck for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 3 MAP sensor power supply voltage check 1 Disconnect connector from MAP sensor with ignition switch turned O...

Page 112: ...istance between RED BLK wire terminal of MAP sensor connector and C37 53 terminal of ECM connector Is resistance below 2 RED BLK wire is shorted to power supply circuit RED BLK wire is open or high re...

Page 113: ...Inspection When measuring circuit voltage resistance and or pulse signal at ECM connector connect the special tool to ECM and or the ECM connectors referring to Inspection of ECM and Its Circuits Upo...

Page 114: ...terminal BLK YEL wire is open circuit If wire and connection are OK go to Step 5 Go to Step 5 5 Wire circuit check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Measure resistanc...

Page 115: ...istance circuit Poor C37 55 connection Faulty ECM ground circuit If circuit is OK substitute a known good ECM and recheck 10 IAT sensor check 1 Check IAT sensor according to Mass Air Flow MAF and Inta...

Page 116: ...firmation Procedure and confirm that the trouble has been corrected DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for 0 5 seconds continuously Engi...

Page 117: ...terminal of MAF and IAT sensor connector and vehicle body ground Is resistance infinity Go to Step 5 BLK YEL wire is shorted to ground circuit If wire is OK substitute a known good ECM and recheck 5...

Page 118: ...Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16...

Page 119: ...ion switch measure voltage between BLK YEL wire terminal of MAF and IAT sensor connector 1 and vehicle body ground Is voltage about 4 6 V Go to Step 7 Go to Step 4 4 ECM voltage check 1 Turn OFF ignit...

Page 120: ...rned OFF Is resistance below 5 Go to Step 9 Go to Step 8 8 Ground circuit check 1 Remove ECM from its bracket with ECM connectors connected 2 Measure resistance between C37 55 terminal of ECM connecto...

Page 121: ...re 1 With ignition switch turned OFF connect scan tool 2 Turn ON ignition switch clear DTC 3 Start engine 4 Drive vehicle at 40 mph 60 km h or higher for 20 min or more 5 Stop vehicle 6 Check DTC and...

Page 122: ...1 Turn ON ignition switch and check engine coolant temp displayed on scan tool 2 Warm up engine to normal operating temp and check engine coolant temp displayed on scan tool Does engine coolant temp v...

Page 123: ...een C37 24 terminal of ECM connector and LT GRN wire terminal of ECT sensor connector with ignition switch turned OFF Is resistance below 5 Go to Step 9 LT GRN wire is high resistance circuit 9 Ground...

Page 124: ...16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53...

Page 125: ...sconnect connector from ECT sensor with ignition switch turned OFF 2 Check for proper connection to ECT sensor at LT GRN and ORN wire terminals 3 If OK then turn ON ignition switch measure voltage bet...

Page 126: ...g to Inspection of ECM and Its Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected C37 55 ORN ORN 3 1 2 5V C37 24...

Page 127: ...6 Go to Step 4 4 ECM voltage check 1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM connectors connected 3 Check for proper connection of ECM connector at C37 24 terminal 4 If OK then...

Page 128: ...aulty ECM ground circuit If circuit is OK substitute a known good ECM and recheck 9 ECT sensor for performance check 1 Check ECT sensor according to Engine Coolant Temperature ECT Sensor Inspection in...

Page 129: ...tric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 With ignition switch turned OFF connect scan tool 2 Turn ON ignition switch and clear DTC using scan tool 3 Start engine and warm up to n...

Page 130: ...gnition switch and connect SUZUKI scan tool to DLC 2 Turn ON ignition switch and check TP sensor output voltage when throttle valve is at idle position and fully opened Does voltage vary within specif...

Page 131: ...age check 1 Turn ignition switch to OFF position 2 Check for proper connection of ECM connector at C37 54 terminal 3 Turn ignition switch to ON position 4 Measure voltage between C37 54 terminal of EC...

Page 132: ...e circuit Poor C37 55 connection Faulty ECM ground circuit If circuit is OK substitute a known good ECM and recheck 13 TP sensor check 1 Measure resistance between terminals of TP sensor referring to...

Page 133: ...6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 5...

Page 134: ...on switch turned OFF and then turn ON ignition switch 2 Check throttle valve opening percentage displayed on scan tool 3 Check throttle valve opening percentage displayed on scan tool while opening th...

Page 135: ...minal 4 Turn ignition switch to ON position 5 Measure voltage between C37 14 terminal of ECM connector and vehicle body ground Is terminal voltage about 4 6 V GRY RED wire is open or high resistance c...

Page 136: ...referring to Inspection of ECM and Its Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected GRY RED GRY BLU GRY RED...

Page 137: ...ith ignition switch turned OFF 2 Check for proper connection to TP sensor at GRY RED GRY BLU and ORN wire terminals 3 If OK then with ignition switch turned ON check following terminal voltages Betwee...

Page 138: ...re is open or high resistance circuit 8 Ground circuit check 1 Connect connectors to ECM with ignition switch turned OFF 2 Measure resistance between ORN wire terminal of TP sensor connector and vehic...

Page 139: ...42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12...

Page 140: ...ts Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected Step Action Yes No 1 Was Engine and Emission Control System Check pe...

Page 141: ...S 1 signal circuit check 1 Measure voltage between WHT wire terminal of HO2S 1 connector and vehicle body ground Is voltage 0 V Go to Step 8 WHT wire is shorted to other circuits 8 HO2S 1 heater circu...

Page 142: ...h and clear DTC using scan tool 3 Start engine and warm up to normal operating temperature 4 Drive vehicle at 40 mph 60 km h or higher engine speed 2500 3000 r min E23 C37 3 4 18 19 5 6 7 10 11 17 20...

Page 143: ...completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected DTC P0134 O2 Sensor HO2S Circuit No Activity Detected Sensor 1 S4RS0A110402...

Page 144: ...s kept constant in this step 6 Release accelerator pedal and with engine brake applied keep vehicle coasting with fuel cut for 3 sec or more and then stop vehicle 7 Check if DTC and pending DTC exist...

Page 145: ...d Is resistance less than 5 Go to Step 4 YEL wire is open or high resistance circuit Poor C37 57 terminal connection Faulty ECM ground If they are OK substitute a known good ECM and recheck 4 Wire cir...

Page 146: ...5 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 BLK WHT WHT 80A 11 GRN 3 9 E23 29 BRN YEL BLK WHT GRY C37 47 C37 11 C37 57 6 2 7 10 GRY BLU WHT RED BLU 1 4 5 8 5 V 12 I4RS0A110030 1 Battery fuse box 4...

Page 147: ...6 Repeat Step 4 7 Keep above vehicle speed for 8 min or more Throttle valve opening is kept constant in this step 8 Repeat Step 5 9 Check DTC and pending DTC DTC Troubleshooting NOTE Before performed...

Page 148: ...eck 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Measure resistance between BRN wire terminal of HO2S 2 connector and vehicle body ground Is resistance infinity Go to Step 7 BRN...

Page 149: ...h fuel cut for 4 sec or more then stop vehicle and run engine at idle speed for 60 sec or more 6 Check DTC and pending DTC E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29...

Page 150: ...7 57 terminal connection Faulty ECM ground If they are OK substitute a known good ECM and recheck 3 Wire circuit check 1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM connectors conn...

Page 151: ...itude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more 1 With ignition switch turned OFF connect scan tool 2 Turn ON ignition switch and print freeze frame data or write them down us...

Page 152: ...part 5 Fuel injectors and its circuit check 1 Check fuel injectors referring to Fuel Injector Inspection in Section 1G Is check result satisfactory Go to Step 6 Faulty injector s or its circuit 6 Vis...

Page 153: ...gher Engine coolant temp 10 qC 14 qF or higher Altitude barometric pressure 2500 m 8200 ft or less 540 mmHg 72 kPa or more 1 With ignition switch turned OFF connect scan tool 2 Turn ON ignition switch...

Page 154: ...und Go to Step 5 Check coupler connection and wire harness of injector not making operating sound and injector itself If OK substitute a known good ECM and recheck 5 Fuel pressure check 1 Check fuel p...

Page 155: ...59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56...

Page 156: ...ion in Section 00 If OK substitute a known good ECM and recheck Go to Step 3 3 Knock sensor circuit for open check 1 Disconnect connector from knock sensor with ignition switch turned OFF 2 Turn ON ig...

Page 157: ...9 38 44 45 43 41 33 1 12 13 23 8 12V 5V BLK RED BLK RED 80A BLK YEL BLK YEL BLK YEL BRN WHT 5 9 4 13 3 E23 29 E23 1 E23 60 C37 58 C37 15 C37 30 BLK ORN BLK BLK 10 BLK RED BLK RED E23 16 BLK ORN 1 15 C...

Page 158: ...ission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 CKP sensor and connector for proper installation check Is CKP sensor installed properly and connecto...

Page 159: ...8 Repair or replace 8 CKP sensor check 1 Check CKP sensor and sensor plate tooth referring to Crankshaft Position CKP Sensor Inspection in Section 1C Is check result satisfactory Substitute a known go...

Page 160: ...g be sure to read the Precautions of ECM Circuit Inspection When measuring circuit voltage resistance and or pulse signal at ECM connector connect the special tool to ECM and or the ECM connectors ref...

Page 161: ...d power supply circuit If wire and connection are OK substitute a known good ECM and recheck 5 Ground circuit check 1 Turn ignition switch to OFF position 2 Measure resistance between BLK ORN wire ter...

Page 162: ...ulation Flow Insufficient Detected Excessive Detected S4RS0A1104037 System and Wiring Diagram I4RS0A110035 1 EGR valve 4 Sensed information 7 IG COIL fuse 10 Main relay 2 Intake manifold 5 Fresh air 8...

Page 163: ...gnition switch and clear DTC using scan tool 3 Start engine and warm up to normal operating temperature 4 Run engine at idle for 10 min 5 Drive vehicle and increase engine speed 3000 rpm in 3rd gear 6...

Page 164: ...Section 1B Is it in good condition Go to Step 4 Go to Step 5 4 MAP sensor check 1 Check MAP sensor for performance referring to Manifold Absolute Pressure MAP Sensor Inspection in Section 1C Is check...

Page 165: ...his step 6 Stop vehicle and check DTC and pending DTC E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 3...

Page 166: ...e terminals of EGR valve connector Is each voltage 0 V Go to Step 4 Faulty wire s are shorted to other circuit If wires are OK substitute a known good ECM and recheck 4 Wire circuit check 1 With ignit...

Page 167: ...stored in warm up three way catalytic converter Reference Oscilloscope waveforms DTC Detecting Condition and Trouble Area C37 11 C37 10 C37 57 WHT BRN 1 3 2 4 5 V YEL YEL BLU WHT BLU WHT 5 I4RS0A1100...

Page 168: ...not completed check vehicle condition environmental and repeat Step 3 through 5 DTC Troubleshooting NOTE Before performed trouble shooting be sure to read the Precautions of ECM Circuit Inspection Whe...

Page 169: ...d pending DTC E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18...

Page 170: ...3 BLK RED wire is open circuit 3 Wire circuit check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Measure resistance between C37 29 terminal of ECM connector and vehicle body grou...

Page 171: ...54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15...

Page 172: ...n 00 4 Fuel level sensor output signal check 1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM connector connected 3 Turn ON ignition switch and measure voltage between E23 24 terminal...

Page 173: ...11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 2...

Page 174: ...d vehicle body ground Is resistance below 280 Go to Step 7 Go to Step 8 7 Short circuit check for fuel level sensor output signal circuit 1 Turn ON ignition switch and measure voltage between E23 24 t...

Page 175: ...2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31...

Page 176: ...2 Go to Engine and Emission Control System Check 2 Circuit fuse check 1 Check RDTR FAN fuse 1 in relay box with ignition switch turned OFF Is RDTR FAN fuse in good condition Go to Step 3 Check for sh...

Page 177: ...of ECM connector and vehicle ground Is resistance infinity Go to Step 6 LT GRN wire is shorted to ground circuit 6 Wire circuit check 1 Turn ON ignition switch 2 Measure voltage between E23 46 termina...

Page 178: ...E23 48 terminal of ECM connector Is voltage 10 14 V Go to Step 11 Go to Step 12 11 Wire circuit check 1 Disconnect radiator cooling fan relay No 2 and then connect radiator cooling fan relay No 3 to...

Page 179: ...vehicle body ground and E23 48 terminal of ECM connector Is voltage lower than 1 5 V Intermittent trouble Check for intermittent refer to Intermittent and Poor Connection Inspection in Section 00 If O...

Page 180: ...special tool to ECM and or the ECM connectors referring to Inspection of ECM and Its Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the tro...

Page 181: ...d PPL wire terminal of VSS connector Is measured voltage 4 5 V Go to Step 11 Go to Step 8 8 ECM voltage check 1 Turn OFF ignition switch 2 Remove ECM form its bracket with ECM connectors connected 3 T...

Page 182: ...4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47...

Page 183: ...eferring to Intermittent and Poor Connection Inspection in Section 00 If OK substitute a known good ECM and recheck Go to Step 4 4 Idle air control valve circuit check 1 Disconnect connector from idle...

Page 184: ...ntrol valve circuit check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Using service wire ground E23 60 terminal of ECM connector because of main relay turned ON 3 Measure voltag...

Page 185: ...1 Was Engine and Emission Control System Check performed Go to Step 2 Go to Engine and Emission Control System Check 2 A C refrigerant pressure sensor power supply circuit check 1 Disconnect connecto...

Page 186: ...Pressure Sensor and Its Circuit Inspection in Section 7B Is it in good condition Substitute a known good ECM and recheck Faulty A C refrigerant pressure sensor Step Action Yes No E23 C37 3 4 18 19 5...

Page 187: ...wire terminal of A C refrigerant pressure sensor connector Is voltage 4 6 V Go to Step 4 Go to Step 3 3 A C refrigerant pressure sensor power supply circuit check 1 Disconnect connectors from TP sens...

Page 188: ...C refrigerant pressure sensor check 1 Check A C refrigerant pressure sensor referring to A C Refrigerant Pressure Sensor and Its Circuit Inspection in Section 7B Is it good condition Substitute a know...

Page 189: ...51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29...

Page 190: ...connections are OK substitute a known good ECM and recheck YEL GRN wire is open or high resistance circuit Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14...

Page 191: ...n switch turned OFF 2 Check for proper connection to starting motor control relay at RED WHT RED WHT YEL A T vehicle and YEL GRN M T vehicle wire terminals 3 Disconnect connectors from starting motor...

Page 192: ...r the ECM connectors referring to Inspection of ECM and Its Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected E2...

Page 193: ...repair work perform DTC Confirmation Procedure and confirm that the trouble has been corrected 2 Battery voltage supply circuit check 1 Turn OFF ignition switch 2 Remove ECM from its bracket with ECM...

Page 194: ...32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 3...

Page 195: ...nection at each ECM TCM equipped with A T BCM and combination meter connector terminals with ignition switch turned OFF 2 If connections are OK recheck ECM for DTC with engine running Is there DTC P16...

Page 196: ...ction 00 11 CAN communication line circuit insulation check equipped with A T 1 Measure resistance between C37 13 and C37 12 terminals of ECM connector Is resistance infinity Go to Step 12 Repair insu...

Page 197: ...ication System in Section 00 14 Check for short circuit of CAN communication line to power circuit 1 Measure voltage at following connector terminals with ignition switch turned ON Between E23 3 termi...

Page 198: ...4 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 A B G37 E46 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 12 13 14 15 16 17 18...

Page 199: ...Go to DTC P1674 CAN Communication Bus Off Error Go to Step 4 4 CAN communication error check for BCM and TCM equipped with A T 1 Check BCM and TCM equipped with A T for DTC s Are there DTC U1073 in B...

Page 200: ...terminal of combination meter connector Is each resistance below 1 Go to Step 11 Repair open or high resistance of CAN communication line circuit referring to Precaution for CAN Communication System i...

Page 201: ...Action Yes No RED WHT E23 3 E23 18 RED WHT C37 13 C37 12 RED WHT RED WHT RED WHT RED WHT E46 1 G37 4 G28 8 G28 10 G37 2 C34 7 E46 2 C34 17 1 2 3 4 C E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51...

Page 202: ...stem Check 2 DTC check 1 Connect scan tool to DLC with ignition switch turned OFF 2 Check ECM TCM and BCM for DTC Is there any DTC s other than DTC P1674 P1675 P1676 P1678 in ECM DTC P1774 P1775 P1777...

Page 203: ...Between C37 13 terminal of ECM connector and vehicle body ground Between C37 12 terminal of ECM connector and vehicle body ground Is each resistance infinity Go to Step 11 Repair short to ground of CA...

Page 204: ...54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15...

Page 205: ...ck DTC U1073 in BCM Is it indicated Go to DTC U1073 No 1073 Control Module Communication Bus Off in Section 10B Go to Step 7 7 CAN communication line circuit continuity check 1 Disconnect connectors f...

Page 206: ...ndicated Go to Step 13 Substitute a known good ECM and recheck 13 ECM circuit check 1 Disconnect connectors from BCM and TCM equipped with A T with ignition switch turned OFF 2 Measure resistance at f...

Page 207: ...tool to ECM and or the ECM connectors referring to Inspection of ECM and Its Circuits Upon completion of inspection and repair work perform DTC Confirmation Procedure and confirm that the trouble has...

Page 208: ...g voltmeter 2 and oscilloscope 3 NOTE As each terminal voltage is affected by battery voltage confirm that it is 11 V or more when ignition switch is turned ON Voltage with asterisk cannot be measured...

Page 209: ...ehicle condition C37 4 GRN RED EGR valve stepper motor coil 1 output 10 14 V Ignition switch turned ON 0 1 V np 10 14 V Reference waveform No 4 Ignition switch is turned to ST cranking position Output...

Page 210: ...urned ON C37 15 BLK Ground for ECM Below 0 3 V Ignition switch turned ON C37 16 BLU RED Fuel injector No 3 output 10 14 V Ignition switch turned ON 0 0 6 V np 10 14 V Reference waveform No 1 and Refer...

Page 211: ...53 V Ignition switch turned ON ECT at 100 qC 212 qF C37 25 BLK YEL Intake air temp IAT sensor signal 3 18 3 67 V Ignition switch turned ON IAT at 0 qC 32 qF 1 32 1 65 V Ignition switch turned ON IAT a...

Page 212: ...ECM for shield wire Below 0 3 V Ignition switch turned ON C37 51 Ground of ECM for shield wire Below 0 3 V Ignition switch turned ON C37 52 Ground of ECM for shield wire Below 0 3 V Ignition switch t...

Page 213: ...N communication line signal is pulse Pulse signal displayed with a regular frequency with varies depending on engine condition E23 4 BRN Engine revolution signal output for EPS control module 0 0 8 V...

Page 214: ...itch turned ON Voltage varies depends on fuel level E23 25 PPL Vehicle speed signal output for EPS control module 0 1 V np 10 14 V Reference waveform No 8 Vehicle running Sensor signal is pulse Pulse...

Page 215: ...ine running A C switch OFF and blower selector at OFF position 0 1 V Engine running A C switch ON and blower selector at 1st position or more E23 48 GRN Radiator cooling fan relay No 2 and No 3 output...

Page 216: ...WHT BLK A C evaporator outlet air temp sensor signal 3 4 3 7 V Ignition switch turned ON at A C evaporator outlet temperature 0 qC 32 qF 2 5 2 8 V Ignition switch turned ON at A C evaporator outlet t...

Page 217: ...easurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 3 720q crank angle I4RS0A110088 I4RS0A110089 Measur...

Page 218: ...loscope setting CH1 2 V DIV CH2 2 V DIV TIME 40 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference si...

Page 219: ...C37 58 Oscilloscope setting CH1 500 mV DIV CH2 10 V DIV TIME 2 s DIV Measurement condition After warmed up to normal operating temperature Drive vehicle at 60 km h 37 mph for 10 min Engine at specifie...

Page 220: ...CH2 2 V DIV TIME 20 ms DIV Measurement condition After warmed up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 CKP signal 3 360q cra...

Page 221: ...rement terminal CH1 C37 49 to C37 58 Oscilloscope setting CH1 5 V DIV TIME 2 ms DIV Measurement condition After warmed up to normal operating temperature Ignition switch turned ON 1 ON signal 2 OFF si...

Page 222: ...ed up to normal operating temperature Engine racing 2 Throttle position sensor signal 3 Racing 4 Idle Measurement terminal CH1 C37 56 to C37 58 Oscilloscope setting CH1 1 V DIV TIME 10 ms DIV Measurem...

Page 223: ...signal Measurement terminal CH1 E23 3 to C37 58 CH2 E23 18 to C37 58 Oscilloscope setting CH1 1 V DIV CH2 1 V DIV TIME 40 Ps DIV Measurement condition Ignition switch turned ON Signal pattern is depen...

Page 224: ...istance in the following table represents that measured when parts temperature is 20 qC 68 qF Measurement terminal CH1 C37 20 to C37 58 CH2 C37 6 to C37 58 CH3 C37 1 to C37 58 CH4 C37 48 to C37 58 Osc...

Page 225: ...45 to E23 1 16 Throttle actuator control relay for AMT model 160 240 Terminals Circuit Standard resistance Condition E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57...

Page 226: ...r short in circuits connected to fuse s 2 Power supply circuit check 1 Measure voltage between E23 2 terminal of ECM connector and body ground Is voltage 10 14 V Go to Step 3 WHT RED or WHT wire is op...

Page 227: ...ain relay 1 from relay box 2 Check for proper connection to main relay connector at BLK YEL and BLK RED wire terminals 3 If OK measure resistance between each E23 1 and E23 16 wire terminals of ECM co...

Page 228: ...ty Check internal short circuit of TP sensor MAP sensor and or A C refrigerant pressure sensor GRY RED wire is shorted to ground circuit Step Action Yes No BLK WHT BLK RED BLK RED WHT 80A BLK YEL BLK...

Page 229: ...re voltage between each BLK RED wire terminal of fuel injector connector and engine ground with ignition switch turned ON Is voltage 10 14 V Go to Step 5 BLK RED wire is open or shorted to ground circ...

Page 230: ...D BLK RED BLK YEL BLK YEL BLK RED BLK RED 80A E23 29 BLK WHT GRN WHT BLK WHT BLK WHT PNK BLK WHT GRN C37 58 C37 15 C37 30 BLK ORN BLK BLK 1 7 8 9 6 4 3 2 5 E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49...

Page 231: ...measure voltage between BLK RED wire terminal of fuel pump relay connector and engine ground Is voltage 10 14 V Go to Step 4 BLK RED wire is open circuit 4 Fuel pump relay check 1 Check fuel pump rela...

Page 232: ...horted to ground 8 Fuel pump circuit check 1 Turn OFF ignition switch 2 Connect service wire between E23 15 terminal of ECM connector and vehicle body ground 3 Turn ON ignition switch measure voltage...

Page 233: ...I3RM0A110081 1 Injector 2 Delivery pipe 3 Fuel filter and fuel pump Step Action Yes No 1 Fuel pressure check 1 Check fuel pressure referring to Fuel Pressure Inspection in Section 1G Is check result...

Page 234: ...1 Check fuel pipe fuel hose and joint for damage or deform Are they in good condition Clogged fuel filter faulty fuel pump faulty fuel pressure regulator or fuel leakage from hose connection in fuel...

Page 235: ...kept at specified speed even with headlight turned ON System is in good condition Go to Step 7 4 Was idle speed higher than specification in Step 1 Go to Step 5 Go to Step 7 5 A C system circuit chec...

Page 236: ...4 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45...

Page 237: ...o 1 Reception data check from BCM 1 Connect scan tool to DLC with ignition switch turned OFF 2 Turn ON ignition switch 3 Check DTC for reception data from BCM Is there DTC P1678 Go to applicable DTC d...

Page 238: ...Is there DTC P0532 or DTC P0533 Go to applicable DTC diag flow Go to Step 8 8 A C refrigerant pressure sensor voltage check 1 Check A C refrigerant pressure sensor voltage referring to Inspection of...

Page 239: ...ry Go to Step 12 Go to Step 13 12 A C compressor relay check 1 Check A C compressor relay referring to Compressor Relay Inspection in Section 7B Is it in good condition A C compressor drive circuit ma...

Page 240: ...50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 I4RS0A110081 1 Blower fan motor 3 ECM 2 Blower fan switch 4 To blo...

Page 241: ...Step Action Yes No E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3...

Page 242: ...itch turns OFF If engine coolant temp dose not rise check engine cooling system or ECT sensor Is radiator cooling fan started at low speed when engine coolant temp reached above temp Radiator cooling...

Page 243: ...ing to Inspection of ECM and Its Circuits E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 4...

Page 244: ...g fan control system is in good condition Perform from Step 9 to Step 14 in DTC P0480 diag flow If OK Go to Step 4 4 Radiator cooling fan control No 2 and No 3 check 1 Run engine when ECT is over 102...

Page 245: ...LK wire terminal of disconnected radiator cooling fan control relay No 3 connector in relay box Is resistance below 1 Go to Step 11 BLK wire is open or high resistance circuit 11 Radiator cooling fan...

Page 246: ...AC duty as follows NOTE Before starting engine place transmission gear shift lever in Neutral shift selector lever to P range for A T vehicle and set parking brake and block drive wheels 1 Connect SUZ...

Page 247: ...gauge set 09912 58413 This tool is included in fuel pressure gauge set 09912 58413 09912 58490 09930 76420 3 way joint hose Timing light dry cell type SUZUKI scan tool This kit includes following item...

Page 248: ...l position with A T model selector lever in P range and that parking brake lever is pulled all the way up 1 Disconnect purge hose 1 from EVAP canister 2 2 Place finger against the end of disconnected...

Page 249: ...l circuit of special tool valve ON B and unground it valve OFF A 2 Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wi...

Page 250: ...ly vacuum 60 kPa 8 7 psi to pipe 1 If vacuum can be applied go to next step If vacuum can not be applied replace EVAP canister purge valve 5 In this state connect 12 V battery to EVAP canister purge v...

Page 251: ...ction S4RS0A1206009 NOTE Be sure to check that there is no obstruction in PCV valve or its hoses before checking IAC duty for obstructed PCV valve or hose hampers its accurate adjustment Check hoses f...

Page 252: ...09917 47011 SUZUKI scan tool Vacuum pump gauge This kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8...

Page 253: ...ses and or reduces when connector is connected to IAC valve If idle speed does not change check IAC valve and wire harness Idle Air Control IAC Valve On Vehicle Inspection S4RS0A1306002 1 Remove IAC v...

Page 254: ...precision parts be careful not to expose it to excessive shock Removal 1 Disconnect negative cable at battery 2 Remove ECM 1 from its bracket by removing its mounting bolts 2 3 Disconnect connectors f...

Page 255: ...or On Vehicle Inspection S4RS0A1306006 1 Disconnect negative cable at battery 2 Disconnect TP sensor connector 3 Using ohmmeter check resistance between terminals under each condition If check result...

Page 256: ...ion S4RS0A1306008 Removal 1 Disconnect negative cable at battery 2 Drain coolant referring to Cooling System Draining in Section 1F WARNING To avoid danger of being burned do not remove radiator cap w...

Page 257: ...t temperature Resistance of oxygen sensor heater HO2S 1 5 0 6 4 at 20 qC 68 qF HO2S 2 11 7 14 5 at 20 qC 68 qF Viewed from terminal side 3 Connect sensor connector securely Heated Oxygen Sensor HO2S 1...

Page 258: ...10 N m 1 0 kg m 7 5 lb ft 2 Connect connector to CMP sensor securely 3 Connect negative cable to battery Camshaft Position CMP Sensor Inspection S4RS0A1306014 Visual check Check that O ring is free fr...

Page 259: ...cylinder block Tighten CKP sensor bolt to specified torque Tightening torque CKP sensor bolt a 10 N m 1 0 kg m 7 5 lb ft 2 Connect connector to CKP sensor securely 3 Adjust generator drive belt tensio...

Page 260: ...check 1 Remove metal particles on end face of VSS if any 2 Arrange 12 V battery 1 and connect its positive terminal to Vin terminal 2 and negative terminal to Ground terminal 3 of sensor Then using oh...

Page 261: ...n ON ignition switch position and check that voltage is battery voltage If not check if wire harness is open or connection is poor 5 Turn OFF ignition switch position and connect connector to MAF and...

Page 262: ...ning torque MAF and IAT sensor screw a 1 5 N m 0 15 kg m 1 1 lb ft Connect MAF and IAT sensor connector securely Mass Air Flow MAF and Intake Air Temperature IAT Sensor Inspection S4RS0A1306022 CAUTIO...

Page 263: ...ft IAC valve screw 3 5 0 35 2 5 ECM mounting bolt 8 0 8 6 0 TP sensor screw 2 5 0 25 1 8 ECT sensor 15 1 5 11 0 Heated oxygen sensor 45 4 5 32 5 CMP sensor bolt 10 1 0 7 5 CKP sensor bolt 10 1 0 7 5 K...

Page 264: ...e timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high In the area o...

Page 265: ...valve timing is varied continuously Signals output from the ECM are the duty pulse of about 240 Hz 1 4 5 13 10 8 9 2 7 6 12 11 3 14 60 variable angle Most retarded timing Most advanced timing Exhaust...

Page 266: ...rates no oil pressure changes in both chambers the rotor is fixed at a target position Timing Retarding When the duty ratio of the signal output from the ECM is light the spool valve of the oil contro...

Page 267: ...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...

Page 268: ...that develops in the intake line is a good indicator of the condition of the engine The vacuum checking procedure is as follows 1 Warm up engine to normal operating temperature NOTE After warming up e...

Page 269: ...ar 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 m...

Page 270: ...between camshaft and tappet 5 Using a micrometer 2 measure the thickness of the removed shim 1 and determine replacement shim by calculating the thickness of new shim with the following formula and ta...

Page 271: ...oval and Installation S4RS0A1406001 Removal 1 Open air cleaner case 1 by unhooking its clamps 2 2 Remove air cleaner element from case Installation Reverse removal procedure for installation Thickness...

Page 272: ...cover 5 6 Disconnect ignition coil couplers 1 7 Remove ignition coil assemblies 2 with high tension cord 3 8 Remove wire harness clamp 4 from cylinder head cover 9 Remove oil level gauge 1 10 Disconn...

Page 273: ...or spark plug hole gaskets will not get out of place or fall off 4 Tightening bolts in such order as indicated in the figure a little at a time till they are tightened to specified torque Tightening...

Page 274: ...lerator cable locking nut to specified torque Tightening torque Accelerator cable locking nut a 12 N m 1 2 kg m 9 0 lb ft Accelerator cable adjustment clearance with pedal depressed fully a 0 5 2 0 mm...

Page 275: ...vers on throttle valve shaft or cause damage to any other parts Installation 1 Install IAC valve to throttle body referring to Idle Air Control IAC Valve Removal and Installation in Section 1C 2 Insta...

Page 276: ...ody bore 1 and idle air passage 2 by blowing compressed air NOTE TP sensor idle air control valve or other components containing rubber must not be placed in a solvent or cleaner both A chemical react...

Page 277: ...nifold O ring 8 O ring 14 EVAP canister purge valve hose 20 To cylinder head cover 3 Throttle body 9 Gasket 15 Brake booster hose 21 To brake booster 4 TP sensor 10 MAP sensor 16 EVAP canister purge v...

Page 278: ...fold O ring Use new EGR pipe gasket and O ring Tighten EVAP canister purge valve bracket bolt to specified torque Tightening torque EVAP canister purge valve bracket bolt 5 N m 0 5 kg m 4 0 lb ft Inst...

Page 279: ...mounting No 1 bracket 14 Engine left mounting No 2 bracket bolt long 25 Engine rear mounting stiffener 4 Engine left mounting 15 Engine left mounting bracket nut 26 Engine rear mounting stiffener bol...

Page 280: ...TP sensor 1 MAP sensor 2 ECT sensor 3 EGR valve 4 CMP sensor 5 IAC valve 6 Ignition coil assembly 7 Injectors 8 Heated oxygen sensor 9 Oil control valve 10 Engine oil pressure switch 11 CKP sensor 12...

Page 281: ...n Section 0A 23 Remove suspension frame referring to Front Suspension Frame Stabilizer Bar and or Bushings Removal and Installation in Section 2B 24 Remove engine rear mounting from engine rear mounti...

Page 282: ...Tightening torque Engine left mounting bracket nut a 55 N m 5 5 kg m 40 0 lb ft Engine right mounting nut b 65 N m 6 5 kg m 47 0 lb ft 5 Support engine assemble by using supporting device referring to...

Page 283: ...fuel leakage coolant leakage oil leakage and exhaust gas leakage at each connection Timing Chain Cover Components S4RS0A1406014 I4RS0A140011 1 Crankshaft pulley bolt 9 Oil gallery pipe No 1 17 Oil co...

Page 284: ...6011 B 09926 58010 5 Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation 6 Remove oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation in Sectio...

Page 285: ...m 2 5 kg m 18 0 lb ft Timing chain cover nut b 25 N m 2 5 kg m 18 0 lb ft 6 Apply engine oil to new O rings 2 and install them to cap 3 7 Install cap 3 to timing chain cover 1 Tighten bolts to specifi...

Page 286: ...passage for driving intake cam timing sprocket assembly VVT actuator If clog or foreign matter exists clean strainer Oil Control Valve Removal and Installation S4RS0A1406043 Removal Remove oil galler...

Page 287: ...e 6 7 7 7 at 20 qC 68 qF Oil Gallery Pipe Inspect oil gallery pipes No 1 No 2 2 and No 3 3 Replace if crack deformation or clog exists Timing Chain and Chain Tensioner Components S4RS0A1406017 1 2 I3R...

Page 288: ...chain tensioner 6 5 Remove timing chain No 1 guide 7 6 Remove timing chain 8 with crankshaft timing sprocket 9 Installation CAUTION After timing chain is removed never turn crankshaft and camshafts in...

Page 289: ...guide bolts to specified torque Tightening torque Timing chain No 1 guide bolt a 11 N m 1 1 kg m 8 0 lb ft 6 Apply engine oil to sliding surface of chain tensioner 1 and install chain tensioner and s...

Page 290: ...at 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 black as shown in the figure If each markin...

Page 291: ...1406020 I2RH0B140070 I2RH01140077 I2RH0B140071 I4RS0A140013 1 Intake camshaft 5 Shim Shim No on it faces tappet side 9 Upper camshaft bearing Install a bearing half with some holes to upper side of in...

Page 292: ...cket assembly held stationary Failure to follow this could result in damage to lock pin Do not loosen bolt a because intake cam timing sprocket assembly is not serviceable 4 Loosen camshaft housing bo...

Page 293: ...hten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque Tightening torque Camshaft housing bolt a 11 N m 1 1 kg m...

Page 294: ...measured runout exceeds limit replace camshaft 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 m...

Page 295: ...whichever the difference from specification is greater Camshaft journal diameter A Camshaft journal bearing bore B Wear of Tappet and Shim Check tappet and shim for pitting scratches or damage If any...

Page 296: ...earance If clearance exceeds limit replace tappet or cylinder head Cylinder head to tappet clearance Standard 0 025 0 066 mm 0 0010 0 026 in Limit 0 15 mm 0 0059 in Tappet outside diameter A Standard...

Page 297: ...4 0 kg m 29 0 lb ft 60q and 60q by the specified procedure 3 Valve spring 9 Cylinder head bolt M10 Never reuse cylinder head bolts once disassembled it due to plastic deformation tightening Be sure t...

Page 298: ...ny other parts required to be removed or disconnected and remove or disconnect whatever necessary 9 Remove exhaust manifold if necessary referring to Exhaust Manifold Removal and Installation in Secti...

Page 299: ...3 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...

Page 300: ...m valve guide and valve spring seat 2 NOTE Do not reuse valve stem seal once disassembled Be sure to use new seal when assembling 6 Using special tool Valve guide remover drive valve guide out from co...

Page 301: ...er 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 s...

Page 302: ...in Section 1G 11 Install exhaust manifold referring to Exhaust Manifold Removal and Installation in Section 1K Valves and Valve Guides Inspection S4RS0A1406026 Valve Guide Valve stem to guide clearan...

Page 303: ...from valves Inspect each valve for wear burn or distortion at its face and stem end as necessary replace it Inspect valve stem end face for pitting and wear If pitting or wear is found there valve st...

Page 304: ...ng width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping 1 Exhaust valve seat Use valve seat cutters 1 to make two...

Page 305: ...limit replace cylinder head Leakage of combustion gases from this gasketed joint is often due to warped gasketed surface such leakage results in reduced power output Distortion for cylinder head surfa...

Page 306: ...s S4RS0A1406029 I2RH01140143 I2RH01140144 A 1 Tighten all nuts to 15 N m 1 5 kg m 2 Then retighten all nuts by turning through 45q 3 Repeat Step 2 again 7 Connecting rod bearing 1 Top ring 8 Piston pi...

Page 307: ...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 conn...

Page 308: ...grooves using a suitable tool 2 Install piston pin to piston 1 and connecting rod 2 a After applying engine oil to piston pin and piston pin holes in piston and connecting rod b Fit connecting rod as...

Page 309: ...Cylinder bore diameter Standard 78 00 78 014 mm 3 0709 3 0714 in Limit 78 050 mm 3 073 in Cylinder taper and out of round Limit 0 10 mm 0 004 in NOTE If any one of four cylinders has to be rebored reb...

Page 310: ...easure clearance between ring and ring land by using thickness gauge 2 If clearance is out of specification replace piston Ring groove clearance Piston Ring Piston ring end gap To measure end gap inse...

Page 311: ...in Limit 0 05 mm 0 00020 in Piston pin clearance in piston Standard 0 006 0 017 mm 0 00024 0 00067 in Limit 0 05 mm 0 0020 in Small end bore 20 003 20 011 mm 0 7875 0 7878 in Piston pin dia 19 997 20...

Page 312: ...r difference Limit A B 0 1 mm 0 004 in Crank Pin and Connecting Rod Bearings Inspection S4RS0A1406034 Crank Pin Diameter Inspect crank pin for uneven wear or damage Measure crank pin for out of round...

Page 313: ...stall rod bearing cap 1 to connecting rod When installing cap be sure 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 n...

Page 314: ...responding crankshaft pin diameter is 41 994 42 000 mm 1 6533 1 6534 in Crankshaft pin outer diameter 3 There are five kinds of standard bearings differing in thickness To distinguish them they are pa...

Page 315: ...its cap is 1 and alphabet stamped on crank web No 3 is B install a new standard bearing painted in Black to its connecting rod big end inside Specification of new standard connecting rod bearing size...

Page 316: ...1D 53 Engine Mechanical Main Bearings Crankshaft and Cylinder Block Components S4RS0A1406035 I4RS0A140016...

Page 317: ...n and make sure that each part goes back to where it came from when installing 1 CKP sensor if equipped See A 11 Rear oil seal 21 Oil filter adapter bolt 2 Knock sensor 12 Input shaft bearing 22 Sprin...

Page 318: ...ley side After applying engine oil to main bearing cap No 1 bolts 1 10 and main bearing cap No 2 bolts 11 20 tighten them gradually as follows a Tighten bolts 1 10 to 30 N m 3 0 kg m 22 0 lb ft accord...

Page 319: ...ywheel bolts to specified torque NOTE Use new flywheel bolts Special tool A 09924 17810 Tightening torque Flywheel bolt a 70 N m 7 0 kg m 51 0 lb ft 11 Install piston and connecting rod referring to P...

Page 320: ...etighten by turning through 60q Main bearing cap No 2 bolt 11 20 25 N m 2 5 kg m 18 0 lb ft 3 Use a dial gauge to read displacement in axial thrust direction of crankshaft If its limit is exceeded rep...

Page 321: ...No 1 bolts 1 10 and main bearing cap No 2 bolts 11 20 gradually as follows a Tighten bolts 1 10 to 30 N m 3 0 kg m 22 0 lb ft according to numerical order in the figure b In the same manner as in Ste...

Page 322: ...represent bearing cap bore diameter marked with an arrow in the figure respectively For example stamped A or 1 indicates that corresponding bearing cap bore diameter is 56 0000 56 0060 mm 2 2048 2 20...

Page 323: ...ng painted in Brown to its journal New standard size crankshaft main bearing specification 5 Using scale 1 on gauging plastic 2 check bearing clearance with newly selected standard bearing If clearanc...

Page 324: ...undersize bearing to use with it as follows a Regrind journal to the following finished diameter Finished journal diameter 51 732 51 750 mm 2 0367 2 0374 in b Using micrometer measure regrind journal...

Page 325: ...t replace with new one Main bearing cap No 1 bolt diameter measurement points a 60 mm 2 36 in b 90 mm 3 54 in Main bearing cap No 1 bolt diameter difference Limit A B 0 2 mm 0 008 in Measured journal...

Page 326: ...uge check gasketed surface for distortion 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 a...

Page 327: ...5 40 0 Engine right mounting nut 65 6 5 47 0 Engine rear mounting bush bolt 55 5 5 40 0 Starting motor terminal nut 11 1 1 8 0 Generator terminal nut 6 0 6 4 5 Timing chain cover bolt 25 2 5 18 0 Timi...

Page 328: ...kshaft and Cylinder Block Components Special Tool S4RS0A1408002 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No 1207B P No 99000 31140 SUZUKI Bond No 1217G P No 99000...

Page 329: ...protrusion 11 5 mm 09916 58210 09916 67020 Valve guide installer handle Tappet holder Overseas 09916 67021 09916 77310 Tappet holder Piston ring compressor 50 125 mm 09916 84511 09917 68221 Forceps Ca...

Page 330: ...crankshaft 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 b...

Page 331: ...Engine Lubrication System 1E 2 I3RH0B150001...

Page 332: ...engine front cover 1 3 Disconnect oil pressure switch coupler 1 4 Remove oil pressure switch 2 from cylinder block 5 Install special tools oil pressure gauge to vacated threaded hole of oil pressure...

Page 333: ...re switch for oil leakage If oil leakage is found repair it 11 Connect oil pressure switch coupler 1 Repair Instructions Oil Pan and Oil Pump Strainer Components S4RS0A1506001 I2RH0B150005 I2RH0B15000...

Page 334: ...1 from cylinder block Installation 1 Install new O rings 2 in the position as shown in the figure and install oil pump strainer 1 Tighten strainer bolt 3 first and then bracket bolt 4 to specified to...

Page 335: ...l pan drain plug b 35 N m 3 5 kg m 25 5 lb ft 8 Tighten transaxle stiffener bolts to specified torque Tightening torque Transaxle stiffener bolt d 55 N m 5 5 kg m 40 0 lb ft 9 Install exhaust manifold...

Page 336: ...sembly S4RS0A1506006 Disassembly 1 Remove rotor plate 1 by removing its mounting bolts 2 Remove outer rotor 1 and inner rotor 2 3 Remove relief valve 1 spring 2 and retainer 3 by removing circlip 4 I4...

Page 337: ...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 kg m 0 25 lb ft torque or below Tightening torque Oil pump rotor...

Page 338: ...earance If side clearance exceeds its limit replace oil pump assembly Side clearance for oil pump inner rotor Limit 0 15 mm 0 0059 in Relief valve spring free length and load Check relief valve spring...

Page 339: ...s also described in the following Oil Pan and Oil Pump Strainer Components Oil Pump Components Special Tool S4RS0A1508002 Fastening part Tightening torque Note N m kg m lb ft Oil pressure switch 13 1...

Page 340: ...s with heat and the coolant is overflowed to the reservoir When the system cools down the coolant is drawn back into the radiator The cooling system has been filled with a quality coolant that is a 50...

Page 341: ...6 5 2 12 1 I3RM0A160001 1 Radiator inlet hose 5 Thermostat 9 Heater core inlet hose 2 Radiator outlet hose 6 Water pump 10 Heater core outlet hose 3 Throttle body inlet hose 7 Throttle body 11 Heater...

Page 342: ...Poor charge battery Check and replace as necessary Poor generation generator Check and repair ECT sensor faulty Check and replace as necessary Radiator cooling fan relay No 2 and or No 3 faulty Check...

Page 343: ...o timing chain cover 5 Radiator outlet hose 17 Water inlet No 1 pipe 29 To cylinder head 6 Radiator inlet hose 18 Water inlet hose 30 To water pump 7 Water outlet cap 19 Water inlet No 2 pipe 31 To he...

Page 344: ...6003 WARNING To help avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if cap is taken off too so...

Page 345: ...ervoir with soap and water Flush it well with clean water and drain Reinstall reservoir 9 Fill reservoir with coolant up to Full level mark 3 10 Install reservoir cap 2 on reservoir 11 Loosen air vent...

Page 346: ...in Section 1J 4 Disconnect water hose 1 and heater hose 2 from each pipe 5 Remove thermostat case 3 with thermostat cap 4 and water inlet pipe 5 6 Remove water inlet pipe with thermostat cap from the...

Page 347: ...below or above specific temperature thermostat unit should be replaced with a new one Such a unit if reused will bring about overcooling or overheating tendency Radiator Cooling Fan Motor On Vehicle I...

Page 348: ...f cooling fan motor 3 Drain coolant 4 Remove front bumper front bumper upper absorber and upper member referring to Front Bumper and Rear Bumper Components in Section 9K 5 Remove radiator inlet hose a...

Page 349: ...lp avoid danger of being burned do not remove radiator cap while engine and radiator are still hot Scalding fluid and steam can be blown out under pressure if cap is taken off too soon 1 Inspect belt...

Page 350: ...with A C install compressor drive belt 5 referring to Compressor Drive Belt Removal and Installation in Section 7B 4 Connect negative cable at battery Water Pump Removal and Installation S4RS0A160601...

Page 351: ...nd to check for smooth operation If pump does not rotate smoothly or makes abnormal noise replace it Specifications Tightening Torque Specifications S4RS0A1607001 NOTE The specified tightening torque...

Page 352: ...varies with each type of pipe Be sure to connect and clamp each hose correctly referring to Fuel Hose Disconnecting and Reconnecting After connecting make sure that it has no twist or kink When insta...

Page 353: ...outing Diagram Fuel Delivery System Diagram S4RS0A1702001 Diagnostic Information and Procedures Fuel Pressure Inspection S4RS0A1704001 WARNING Before starting the following procedure be sure to observ...

Page 354: ...min after engine fuel pump stop Pressure reduces as time passes Over 250 kPa 2 5 kg cm2 35 6 psi 6 After checking fuel pressure remove fuel pressure gauge WARNING As fuel feed line is still under hig...

Page 355: ...l delivery pipe insulator 2 Fuel pump assembly 11 Fuel pump gasket 20 Wire harness for fuel pump 3 Breather hose 12 Fuel tank bolt 21 To canister 4 Fuel tank filler hose 13 Fuel pump bolt 22 Fuel tank...

Page 356: ...uce the risk or fire and personal injury Be sure to connect and clamp each hose correctly as shown in figure For Normal Clamp Fuel tank system NOTE Be sure to install hose to spool of pipe surely 7 Fu...

Page 357: ...mm 0 12 0 28 in e 38 mm 1 50 in 3 Clamp b 5 12 mm 0 20 0 48 in 2 N m 0 2 kg m 1 5 lb ft 4 Fuel filler hose clamp screw c 33 mm 1 30 in I3RM0A170001 A With short pipe fit hose as far as it reaches pipe...

Page 358: ...econds to operate fuel pump and then turn it OFF Repeat this ON and OFF 3 or 4 times and apply fuel pressure to fuel line until fuel pressure is felt by hand placed on fuel feed hose 2 In this state c...

Page 359: ...njector 2 Disconnect connector 1 from injector connect ohmmeter between terminals of injector and check resistance If resistance is out of specification replace Resistance of fuel injector 11 3 13 8 a...

Page 360: ...que Fuel delivery pipe bolt a 25 N m 2 5 kg m 18 0 lb ft After installation with engine OFF and ignition switch ON check for fuel leaks around fuel line connection Fuel Injector Inspection S4RS0A17060...

Page 361: ...aduated cylinder Test each injector two or three times If not within specification replace injector Injected fuel volume 43 47 cc 15 sec 1 45 1 51 1 58 1 65 US lmp oz 15 sec 8 Check fuel leakage from...

Page 362: ...fuel tank or pump hose may damage to fuel tank inlet valve 2 3 Hoist vehicle and remove clamp 2 and fuel filler hose 1 from fuel tank 4 Remove fuel tank inlet valve 1 using flat head rod 2 or the lik...

Page 363: ...ect negative cable at battery 3 Hoist vehicle 4 Remove exhaust center pipe 5 Disconnect fuel filler hose and breather hose from filler neck referring to Fuel Tank Inlet Valve Removal and Installation...

Page 364: ...and check for fuel leaks Fuel Tank Inspection S4RS0A1706013 After removing fuel tank check hoses and pipes connected to fuel tank for leaks loose connections deterioration or damage Also check fuel p...

Page 365: ...N If fuel pressure is not felt go to Fuel Pressure Check in Section 1A Fuel Pump Assembly Removal and Installation S4RS0A1706019 WARNING Before starting the following procedure be sure to observe Prec...

Page 366: ...ay cause fuel level sensor to fail Be very careful not to cause damage to fuel tube installed section sealed section in bore If it be damaged replace it with new one or fuel will leak from the part Re...

Page 367: ...Sensor Inspection in Section 9C Specifications Tightening Torque Specifications S4RS0A1707001 NOTE The specified tightening torque is also described in the following Fuel System Components Fuel Hose...

Page 368: ...2 09912 58432 09912 58442 Fuel pressure gauge hose Fuel pressure gauge This tool included in fuel pressure gauge set 09912 58413 This tool included in fuel pressure gauge set 09912 58413 09912 58490 0...

Page 369: ...ion cords and spark plugs CMP sensor Camshaft position sensor and CKP sensor Crankshaft position sensor Using signals from these sensors ECM identifies the specific cylinder whose piston is in the com...

Page 370: ...37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33...

Page 371: ...A180002 1 ECM 7 ECT sensor 13 Data link connector 2 Ignition coil assembly for No 1 and No 4 spark plugs 8 MAF and IAT sensor 14 Main relay box 3 Ignition coil assembly for No 2 and No 3 spark plugs 9...

Page 372: ...en or replace Faulty CMP sensor or sensor rotor tooth of camshaft Clean tighten or replace Faulty ECM Replace Poor fuel economy or engine performance Incorrect ignition timing Check related sensors an...

Page 373: ...it check 1 Check ignition coil assembly power supply and ground circuits for open and short Are circuits in good condition Go to Step 7 Repair or replace 7 Ignition coil assembly check 1 Check ignitio...

Page 374: ...spect the related parts as described in Ignition System Symptom Diagnosis 12 Knock sensor check 1 Confirm that knock sensor circuit is in good condition referring to DTC P0327 P0328 Knock Sensor Circu...

Page 375: ...ductor For the same reason pull out each connection by gripping cap portion Installation 1 Install No 1 cylinder 2 and No 3 cylinder 3 high tension cords to spark plugs and ignition coil assemblies 1...

Page 376: ...nsulator damage If any abnormality is found adjust air gap clean with spark plug cleaner or replace them with new plugs Spark plug air gap a 1 0 1 1 mm 0 040 0 043 in Spark plug type NGK BKR6E 11 DENS...

Page 377: ...ection in Section 1A 5 Fix ignition timing by using Fixed Spark of Misc Test mode on scan tool 6 Set timing light 1 to high tension cord for No 1 cylinder and check that ignition timing is within spec...

Page 378: ...t Special Tool S4RS0A1808001 Fastening part Tightening torque Note N m kg m lb ft Spark plug 25 2 5 18 0 Ignition coil bolt 10 1 0 7 5 09930 76420 SUZUKI scan tool Timing light dry cell type This kit...

Page 379: ...iring harness including starting motor switch starting motor or engine Do not remove motor just because starting motor does not run Check the following items and narrow down scope of possible causes 1...

Page 380: ...too low due to battery deterioration Replace battery Loose battery cable connections Retighten Burnt main contact point or poor contacting action of magnetic switch Replace magnetic switch Brushes ar...

Page 381: ...connect negative lead from starting motor body Check that plunger and pinion return inward If plunger and pinion don t return replace the magnetic switch No Load Performance Test Connect battery and a...

Page 382: ...2 from starting motor terminals 3 Detach shift select control cable bracket from transaxle M T model only 4 Remove starting motor mount bolt 3 and nut 4 5 Remove starting motor 5 Remounting Reverse th...

Page 383: ...tic switch 16 Armature Apply grease 99000 25010 to sliding surface of each part 3 Pinion stop ring 10 Ball 17 Brush assembly 4 Over running clutch 11 Internal gear 18 Rear bracket 5 Lever 12 Planetary...

Page 384: ...ntinuity across magnetic switch S terminal 1 and coil case If no continuity coil is open and should be replaced Rear Bracket Bush Inspect bush for wear or damage Replace if necessary Brush Check brush...

Page 385: ...ear with armature 1 supported on V blocks 2 If deflection of dial gauge 4 pointer exceeds limit repair or replace NOTE The following specification presupposes that the armature is free from bend Bent...

Page 386: ...damage or other abnormal conditions Replace if necessary Pinion and Over Running Clutch Inspect the pinion for wear damage or other abnormal conditions Check that clutch locks up when turned in direc...

Page 387: ...ial is also described in the following Starting Motor Components Voltage 12 volts Output 1 2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard 12 3...

Page 388: ...lt In Indicator If Equipped The battery has a built in temperature compensated indicator in the top of the battery This indicator is to be used with the following diagnostic procedure When checking th...

Page 389: ...t a hydrometer test The hydrometer is an instrument for measuring the specific gravity S G of the battery electrolyte The S G of the electrolyte is indicative of the state of charge Refer to Battery I...

Page 390: ...p Starting in Case of Emergency Trouble in charging system will show up as one or more of the following conditions 1 Faulty indicator lamp operation 2 An undercharged battery as evidenced by slow cran...

Page 391: ...is lower than standard value proceed to the following check Specification for undercharged battery No load check Current 10 A Voltage 14 2 14 8 V at Hi H at 25 qC 77 qF Voltage 12 5 13 1 V at Lo L at...

Page 392: ...n 20 A repair or replace generator Generator Test Overcharged Battery Check S4RS0A1A04004 1 To determine battery condition refer to Battery Description 2 If obvious overcharged condition exists as evi...

Page 393: ...of booster battery and the other end of the same cable to positive terminal of discharged battery Use 12 volt battery only to jump start engine 4 Attach one end of the remaining negative cable to neg...

Page 394: ...aft Assembly Removal and Installation in Section 3A 3 Dismount in numerical order as shown in the figure 4 Reverse dismounting procedure for remounting I4RS0A1A0003 1 B terminal nut 4 Generator adjust...

Page 395: ...fier 20 Rear end cover 2 0 N m 0 2 kg m 1 5 lb ft 3 Drive end frame 9 End housing bearing 15 Insulator 21 Terminal plate 4 5 N m 0 45 kg m 3 5 lb ft 4 Stator 10 Bearing cover 16 Regulator 111 N m 11 1...

Page 396: ...e slip ring diameter If the diameter is less than minimum replace the rotor Slip ring diameter Standard 14 2 14 4 mm 0 560 0 566 in Limit 12 8 mm 0 503 in Stator 1 Using an ohmmeter check all leads fo...

Page 397: ...ne shows continuity and the other shows no continuity If there is continuity replace the rectifier 4 Using an ohmmeter connect one tester probe to each negative terminal 1 and the other to each rectif...

Page 398: ...not specified in this section refer to Fasteners Information in Section 0A Battery type 46B24R Rated capacity AH 5HR 12 Volts 36 Electrolyte L US lmp pt 3 2 6 76 5 63 Type 70 A type Rated voltage 12 V...

Page 399: ...stem is hot Any service on the exhaust system should be performed when the system is cool At every interval of periodic maintenance service and when vehicle is raised for other service check exhaust s...

Page 400: ...nting 24 Heated oxygen sensor No 2 connector color gray 3 Exhaust manifold stiffener 14 Exhaust manifold bolt 25 Heat insulator 4 Heated oxygen sensor No 1 connector color green 15 Exhaust manifold nu...

Page 401: ...sors 3 from exhaust manifold and exhaust No 1 pipe if necessary 8 Disconnect exhaust No 1 pipe 2 from exhaust manifold 9 Remove exhaust manifold 1 and its gasket from cylinder head Installation 1 Inst...

Page 402: ...to Radiator Removal and Installation in Section 1F for equipped with A C 9 Install front bumper with front grille by referring to Front Bumper and Rear Bumper Components in Section 9K 10 Connect nega...

Page 403: ...Components Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Fastening part Tightening torque Note N m kg m lb ft Exhaust mani...

Page 404: ...1K 6 Exhaust System...

Page 405: ...Stabilizer Bar Bushing and or Joint Check 2B 19 Front Suspension Fasteners Check 2B 19 Specifications 2B 19 Tightening Torque Specifications 2B 19 Special Tools and Equipment 2B 20 Special Tool 2B 20...

Page 406: ...f Contents Tire Rotation 2D 5 Wheel Removal and Installation 2D 6 Tire Mounting and Dismounting 2D 6 Tire Repair 2D 6 Specifications 2D 7 Wheels and Tires Specifications 2D 7 Tightening Torque Specifi...

Page 407: ...ution Refer to Wheels and Tires Caution in Section 00 General Precautions Refer to General Precautions in Section 00 Vehicle Lifting Points Refer to Vehicle Lifting Points in Section 0A Fastener Cauti...

Page 408: ...l bearings Replace wheel bearing Worn tie rod ends Replace tie rod end Worn lower ball joints Replace front suspension arm Excessive wheel runout Repair or replace wheel and or tire Blister or bump on...

Page 409: ...or replace bushes Faulty struts shock absorbers or mountings Replace strut or tighten mounting Broken or sagging springs Replace Overloaded Check loading Cupped tires Front struts defective Replace Wo...

Page 410: ...e for reference only IN 0 1 0 0 5 mm IN 0 0 0394 0 0197 in IN 5 2 r 5 2 mm 0 205 r 0 205 in Camber C Non adjustable for reference only 0 q 00 r 1 q 1 q 00 r 1q Caster Non adjustable for reference only...

Page 411: ...m 2 3 kg m 17 0 lb ft 2 Stabilizer bar 8 Tie rod 105 N m 10 5 kg m 76 0 lb ft 85 N m 8 5 kg m 61 5 lb ft 3 Steering knuckle 9 Brake disc 175 N m 17 5 kg m 126 5 lb ft Do not reuse 4 Wheel 10 Stabilize...

Page 412: ...or loose of suspension arms Check for loose or missing stabilizer bar attachments Consideration must be given to excess loads such as tool boxes If this excess load is normally carried in vehicle it s...

Page 413: ...turning radius gauge 1 If steering angle is not correct check if right and left tie rods are equal in length NOTE If tie rod lengths were changed to adjust steering angle reinspect toe in Steering an...

Page 414: ...from vehicle I4RS0A220002 1 Strut assembly 6 Strut bearing 11 Strut bracket nut 105 N m 10 5 kg m 76 0 lb ft 2 Coil spring 7 Strut support 12 Stabilizer joint nut 50 N m 5 0 kg m 36 5 lb ft 3 Bump st...

Page 415: ...od cap 7 Remove strut nut 1 and remove rebound stopper 2 NOTE Hold strut by hand so that it will not fall off 8 Remove strut assembly Installation Install strut assembly by reversing removal procedure...

Page 416: ...al tool A 09940 71431 WARNING Use a commercially available spring compressor and follow the operation procedure described in the Instruction Manual supplied with that spring compressor 2 While keeping...

Page 417: ...ue When tightening strut support lower nut hold stud with special tools Special tool A 09900 00411 socket B 09900 00414 6 mm Tightening torque Strut support lower nut a 50 N m 5 0 kg m 36 5 lb ft Fron...

Page 418: ...or deformation If defective replace Front Wheel Hub and Steering Knuckle Components S4RS0A2206009 Front Wheel Hub Steering Knuckle and Wheel Bearing Removal and Installation S4RS0A2206010 Removal 1 Ho...

Page 419: ...wheel speed sensor 1 from knuckle if equipped with ABS 10 Loosen strut bracket nuts 1 11 Remove ball joint bolt 3 and nut 4 12 Remove strut bracket bolts from strut bracket and then steering knuckle...

Page 420: ...eal side 1 of new wheel bearing 2 upward as shown in figure and press fit it into knuckle using special tool Special tool A 09913 75510 CAUTION When installing wheel bearing replace it with new one 2...

Page 421: ...hten new nut 3 to specified torque Tightening torque Tie rod end nut a 45 N m 4 5 kg m 32 5 lb ft 10 Install brake disk 2 and brake caliper 3 11 Tighten caliper carrier bolt to specified torque Tighte...

Page 422: ...oose replace both bolt and wheel hub with new ones Tightening torque Wheel nut a 85 N m 8 5 kg m 61 5 lb ft Check wheel bearing for wear When measuring thrust play apply a dial gauge to wheel hub Thru...

Page 423: ...que Tightening torque Control arm mounting bolt a 170 N m 17 0 kg m 123 0 lb ft 4 Confirm front wheel alignment referring to Front Wheel Alignment Inspection and Adjustment Suspension Control Arm Bush...

Page 424: ...defective replace Suspension Control Arm Bushing Check S4RS0A2206016 Inspect for damage wear or deterioration If defective replace Suspension Control Arm Joint Check S4RS0A2206017 Check for smooth ro...

Page 425: ...ecial tool A 09900 00411 socket B 09900 00413 5 mm 4 Support engine assemble by using supporting device referring to Engine Supporting Points in Section 0A 5 Remove steering gear case No 1 bolts 1 and...

Page 426: ...under it at well balanced position in the center section so as to prevent suspension frame dropping 9 Remove suspension frame mounting bolts 1 and then lower mission jack and remove suspension frame...

Page 427: ...re to apply some supporting equipment such as jack under it at well balanced position in the center section so as to prevent suspension frame dropping 5 Align lugs 1 right and left of suspension frame...

Page 428: ...torque When tightening hold stud with special tools Special tool A 09900 00411 socket B 09900 00413 5 mm Tightening torque Stabilizer joint nut a 50 N m 5 0 kg m 36 5 lb ft 13 Install suspension cont...

Page 429: ...ring to Front Suspension Construction Specifications Tightening Torque Specifications S4RS0A2207001 I4RS0A220052 I4RS0A220056 1 I4RH01220007 Fastening part Tightening torque Note N m kg m lb ft Tie ro...

Page 430: ...r not specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Special Tool S4RS0A2208001 09900 00411 09900 00413 Hexagon bit socket Hexagon bit 5 mm 09900 00...

Page 431: ...1 2 4 I4RS0A230001 1 Rear coil spring 6 Wheel bearing 11 Rear shock absorber lower nut 16 Rear spindle 2 Rear spring lower seat 7 Brake drum 12 Rear spindle bolt 17 Washer 3 Rear spring upper seat 8...

Page 432: ...0 lb ft 3 Rear spring upper seat 10 Rear shock absorber upper nut 17 Washer 85 N m 8 5 kg m 61 5 lb ft 4 Rear shock absorber 11 Rear shock absorber lower nut F Front side 175 N m 17 5 kg m 126 5 lb f...

Page 433: ...ion 1 Install shock absorber 1 Tighten new rear shock absorber upper nut and lower nut temporarily at this step CAUTION Never reuse the removed rear shock absorber upper nut 2 Remove floor jack 2 from...

Page 434: ...wn by an arrow in the figure and let gas and oil out Lay it down sideways for this work The gas itself is harmless but it may issue out of the hole together with chips generated by the drill Therefore...

Page 435: ...where coil spring 2 can be removed CAUTION Be careful not to let rear axle down too much It may cause damage to brake flexible hose wheel speed sensor lead wire and parking brake cable 5 Remove coil s...

Page 436: ...pring Lower Seat Inspection S4RS0A2306032 Inspect for cracks deformation or damage Replace any defective part Spring Upper Seat and Lower Seat Removal and Installation S4RS0A2306033 Removal 1 Remove c...

Page 437: ...surfaces 4 Disconnect brake pipe flare nuts 1 from wheel cylinders 3 right left and put bleeder plug cap 4 onto pipe 2 to prevent fluid from spilling CAUTION Do not allow brake fluid to get on painte...

Page 438: ...ing floor jack gradually 13 Remove brake pipes 2 from rear axle 1 if necessary Installation 1 Install brake pipes to rear axle 2 Place rear axle on floor jacks Then install trailing arm and new traili...

Page 439: ...N m 1 6 kg m 11 5 lb ft 9 Connect brake flexible hoses 1 to bracket on rear axle with E rings 3 right left and tighten brake pipe flare nuts a to specified torque Tightening torque Brake pipe flare nu...

Page 440: ...fied torque NOTE When tightening these nuts and bolts be sure that vehicle is off hoist and in non loaded condition Tightening torque Rear shock absorber lower nut a 90 N m 9 0 kg m 65 0 lb ft Rear tr...

Page 441: ...ve play 4 Remove wheel stud bolts 1 using hydraulic press 2 and general rod 3 Installation 1 Install new wheel bearing 1 by using special tool and hydraulic press NOTE Seal side of bearing comes brake...

Page 442: ...When measurement exceeds limit replace bearing Thrust play limit a 0 1 mm 0 004 in By rotating wheel actually check wheel bearing for noise and smooth rotation If it is defective replace bearing Spind...

Page 443: ...rque Tightening torque Wheel nut a 85 N m 8 5 kg m 61 5 lb ft 7 Upon completion of all jobs depress brake pedal with about 300 N 30 kg 66 lbs load three to five times so as to obtain proper drum to sh...

Page 444: ...Section 0A Special Tools and Equipment Special Tool S4RS0A2308001 Fastening part Tightening torque Note N m kg m lb ft Rear shock absorber upper nut 25 2 5 18 0 Rear shock absorber lower nut 90 9 0 65...

Page 445: ...ng Swerve on acceleration Lower than recommended pressure can cause Tire squeal on turns Hard Steering Rapid and uneven wear on the edges of the tread Tire rim bruises and rupture Tire cord breakage H...

Page 446: ...nd outside of the rim flange With the dial indicator set in place securely turn the wheel one full revolution slowly and record every reading of the indicator When the measured runout exceeds the spec...

Page 447: ...on the side of vehicle If the faulty tire is on the front waddling is more visual The front sheet metal appears to be moving back and forth and the driver feels as though he is at the pivot point in v...

Page 448: ...lancing Wheels Description S4RS0A2401007 There are two types of wheel and tire balance static and dynamic Static balance as shown in figure is the equal distribution of weight around the wheel Wheels...

Page 449: ...on speedometer This limit is necessary because speedometer only indicates one half of actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped Unless care is taken in...

Page 450: ...llow equipment manufacturer s instructions Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim Rim bead seats should be cleaned with a wire brush or co...

Page 451: ...Tire inflation pressure should be checked when tires are cool Specified tire inflation pressure should be found on tire placard or in owner s manual which came with the vehicle Tightening Torque Spec...

Page 452: ...2D 8 Wheels and Tires...

Page 453: ...m Diagnosis 3A 2 Repair Instructions 3A 2 Front Drive Shaft Components 3A 2 Front Drive Shaft Assembly On Vehicle Inspection 3A 3 Front Drive Shaft Assembly Removal and Installation 3A 3 Front Drive S...

Page 454: ...nts Location S4RS0A3103001 I4RS0A310001 1 Transaxle 10 Ball stud bolt 50 N m 5 0 kg m 36 5 lb ft 2 Drive shaft assembly 11 Drive shaft nut 21 N m 2 1 kg m 15 5 lb ft 3 Tie rod end 12 Wheel nut 45 N m...

Page 455: ...ft joint Replace Worn or breakage of the center bearing Replace I4RS0A310002 A Right side drive shaft assembly 9 Center shaft side joint Constant velocity tripod joint Apply dark gray grease included...

Page 456: ...rol arm ball joint bolt 1 8 Disconnect front suspension control arm ball joint stud from steering knuckle 9 Pull out drive shaft joint 2 as follows For left side shaft Using tire lever 1 pull out driv...

Page 457: ...l and Installation in Section 2B Tighten brake hose mounting bolt to specified torque Tightening torque Brake hose mounting bolt 25 N m 2 5 kg m 18 0 lb ft Fill transaxle with oil as specified referri...

Page 458: ...thoroughly and air dried Replace boot s 3 with new one s CAUTION Do not wash boots in degreaser such as gasoline or kerosene etc Washing in degreaser causes deterioration of boot To ensure full perfo...

Page 459: ...6107 B 09925 98220 10 Apply grease in the supplied parts to inside of tripod joint housing 1 joint it with tripod joint and fit boot 2 to tripod joint housing Grease color A Dark gray Amount A 70 90 g...

Page 460: ...clip 1 using special tool Special tool A 09900 06108 4 Remove center bearing from center bearing support Assembly Install center shaft by reversing removal procedure and noting the following points Wh...

Page 461: ...rom center bearing support Assembly 1 Install center bearing 1 to center bearing support 2 and then install circlip 3 into groove of bearing support as shown in figure 2 Install left oil seal 1 to cen...

Page 462: ...ning ring and snap ring for breakage or deformation Replace as necessary Check boots for breakage or deterioration Specifications Tightening Torque Specifications S4RS0A3107001 NOTE The specified tigh...

Page 463: ...cation Front Drive Shaft Components Special Tool S4RS0A3108002 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P No 99000 25010 09900 06107 09900 06108 Snap ring...

Page 464: ...3A 11 Drive Shaft Axle...

Page 465: ...ended Service Material 4A 16 Front Brakes 4B 1 Repair Instructions 4B 1 Front Disc Brake Components 4B 1 Front Disc Brake Pad On Vehicle Inspection 4B 2 Front Disc Brake Pad Removal and Installation 4...

Page 466: ...C1045 C1051 C1055 DTC C1042 C1046 C1052 C1056 Right Front Left Front Right Rear Left Rear Inlet Solenoid Circuit Right Front Left Front Right Rear Left Rear Outlet Solenoid Circuit 4E 20 DTC C1057 Po...

Page 467: ...tion Refer to Wheels and Tires Caution in Section 00 Brake Caution Refer to Brake Caution in Section 00 General Precautions Refer to General Precautions in Section 00 Vehicle Lifting Points Refer to V...

Page 468: ...e master cylinder and they make two independent circuits One connects front right rear left brakes and the other connects front left rear right brakes In this brake system the disc brake type is used...

Page 469: ...inder primary to ABS hydraulic unit 6 Master cylinder 11 4 way joint to right rear brake hose 2 From master cylinder secondary to ABS hydraulic unit 7 From ABS hydraulic unit to 4 way joint 12 Master...

Page 470: ...luid Improper brake fluid mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate If primary piston cups are swollen then ru...

Page 471: ...rbed front wheel alignment Adjust as prescribed Unmatched tires on same axle Tires with approximately the same amount of tread should be used on the same axle Restricted brake pipes or hoses Check for...

Page 472: ...bearings Replace wheel bearings Distorted backing plates or loose mounting bolts Replace or retighten securing bolts Contact wear indicator to brake disc Replace pads Brake warning lamp lights after...

Page 473: ...d adjust if necessary Also check pedal shaft bolt and booster clevis pin installation for looseness and replace if defective Brake pedal play a 1 8 mm 0 04 0 31 in Excessive Pedal Travel Inspection S4...

Page 474: ...Adjustment should be made as follows Pull up brake pedal toward you and while holding it there adjust switch position so that clearance between end of thread and brake pedal is as specified Then lock...

Page 475: ...reservoir up to specified level 10 Check brake pedal for sponginess If found spongy repeat entire procedure of bleeding Front Brake Hose Pipe Removal and Installation S4RS0A4106007 Removal 1 Raise and...

Page 476: ...ystem Perform brake test and check each installed part for fluid leakage Never reuse protector nut once removed Be sure to use a new one Install clamps properly referring to the figure and tighten bol...

Page 477: ...nnect fluid level switch coupler on reservoir 4 Connect clutch reservoir hose 1 to reservoir 2 for MT vehicle 5 Install clutch reservoir hose clamp 3 for MT model 6 Fill reservoir with special fluid 7...

Page 478: ...cted to master cylinder 6 Remove master cylinder fixing nuts 1 7 Remove master cylinder and master cylinder seal Installation 1 Install new master cylinder seal 2 Install master cylinder to booster an...

Page 479: ...to prevent piston from damage It should be taken out gradually with moderately compressed air Do not place your fingers in front of piston when using compressed air Assembly CAUTION Never use any min...

Page 480: ...orrosion can be identified as pits or excessive roughness NOTE Polishing bore of master cylinder with cast aluminium body with anything abrasive is prohibited as damage to cylinder bore may occur Rins...

Page 481: ...l travel doesn t change air tightness isn t obtained NOTE If defective inspect vacuum lines and sealing parts and replace any faulty part When this has been done repeat the entire test Check Operation...

Page 482: ...tment 3 Install booster 4 to dash panel Then connect push rod clevis 5 to pedal arm with clevis pin 2 and clip 6 4 Tighten booster mounting nuts a to specified torque Tightening torque Booster mountin...

Page 483: ...the following Front Brake Hose Pipe Construction Master Cylinder Components Brake Booster Components Reference For the tightening torque of fastener not specified in this section refer to Fasteners In...

Page 484: ...k 3 Boot 11 Brake caliper carrier 26 N m 2 6 kg m 19 0 lb ft 4 Slide pin Apply rubber grease included in repair kit 12 Caliper carrier bolt 85 N m 8 5 kg m 61 5 lb ft 5 Brake pad 13 Front caliper blee...

Page 485: ...emoval 1 Loosen wheel nuts and with vehicle lifted up remove wheels 2 Remove caliper pin bolts 1 3 Remove caliper 1 from caliper carrier 2 NOTE Hang removed caliper 1 with a wire hook 4 or the like so...

Page 486: ...th sandpaper If lining is polished with sandpaper hard particles of sandpaper will be deposited in lining and may damage disc When pad lining requires correction replace it with a new one Brake pad th...

Page 487: ...que Bleeder plug c 8 0 N m 0 8 kg m 6 0 lb ft 6 Lower hoist 7 Torque wheel nuts to specifications Tightening torque Wheel nut 85 N m 8 5 kg m 61 5 lb ft 8 After completing installation fill reservoir...

Page 488: ...ll slide pin with grease applied into caliper carrier hole and check for its smooth movement in thrust direction After reassembling brake lines bleed air from them Install piston seal boot and piston...

Page 489: ...ston Seal Excessive or uneven wear of pad lining may indicate unsmooth return of piston In such case replace rubber seal Front Brake Disc Removal and Installation S4RS0A4206008 Removal 1 Hoist vehicle...

Page 490: ...61 5 lb ft 5 Upon completion of installation perform brake test Front Brake Disc Inspection S4RS0A4206009 Install wheel nuts to hub bolts and fasten to fix the brake disc Using magnetic stand and with...

Page 491: ...ners Information in Section 0A Special Tools and Equipment Recommended Service Material S4RS0A4208001 NOTE Required service material is also described in the following Front Disc Brake Components Spec...

Page 492: ...rake lever 5 Pull rear brake drum 1 off by using special tools Special tool A 09943 17912 B 09942 15511 I4RS0A430001 1 Rear brake drum 9 Quadrant spring 17 Brake back plate 2 Spindle 10 Shoe return sp...

Page 493: ...fter making sure that inside of brake drum and brake shoes are free from dirt and oil 4 Install new spindle nut a 5 Tighten spindle nut a to specified torque Tightening torque Spindle nut a 175 N m 17...

Page 494: ...worn and drum is grooved drum should be polished with fine emery cloth but should not be turned NOTE When drum is removed visually inspect wheel cylinder for brake fluid leakage Correct leaky point if...

Page 495: ...g missing damaged or deformed Check sensor ring 1 for being deformed warped Check that no foreign material is attached If any malfunction is found repair or replace Rear Brake Shoe Removal and Install...

Page 496: ...006 Removal 1 Remove brake drum referring to Rear Brake Drum Removal and Installation 2 Remove brake shoe referring to Rear Brake Shoe Removal and Installation 3 Loosen brake pipe flare nut 1 but only...

Page 497: ...e from dragging and proper braking is obtained Then remove vehicle from hoist and perform brake test foot brake and parking brake 11 Check each installed part for fluid leakage Wheel Cylinder Inspecti...

Page 498: ...Removal and Installation 6 Install brake shoe referring to Rear Brake Shoe Removal and Installation 7 Install brake drum referring to step 2 to 7 of Rear Brake Drum Removal and Installation 8 Fill re...

Page 499: ...1 NOTE Required service material is also described in the following Rear Drum Brake Components Special Tool S4RS0A4308002 Fastening part Tightening torque Note N m kg m lb ft Spindle nut 175 17 5 126...

Page 500: ...w D F Front side 5 Parking cable bracket bolt 11 Rear wheel speed sensor bolt E View E R Right side 6 Grommet 12 Vehicle body F View F 1 Parking brake lever assembly 7 Parking cable cap nut A View A 2...

Page 501: ...notch for damage or wear If any damage or wear is found replace parking brake lever Adjustment NOTE Make sure for the following conditions before cable adjustment No air is trapped in brake system Bra...

Page 502: ...s to specified torque referring to Parking Brake Cable Construction Tightening torque Parking brake lever bolt 25 N m 2 5 kg m 18 0 lb ft Parking cable clamp bolt 11 N m 1 1 kg m 8 0 lb ft Parking cab...

Page 503: ...or proper performance After removing vehicle from hoist brake test should be performed Specifications Tightening Torque Specifications S4RS0A4407001 NOTE The specified tightening torque is also descri...

Page 504: ...ection and observe what is written there Be sure to use the trouble diagnosis procedure as described in ABS Check Failure to follow it may result in incorrect diagnosis Some other diagnosis trouble co...

Page 505: ...applied to wheel cylinder of each 4 wheels Solenoid valve power supply driver transistor which supplies power to solenoid valve in ABS hydraulic unit Solenoid valve driver transistor which controls ea...

Page 506: ...valve driver transistor Hydraulic unit Pump motor LF inlet solenoid valve LF outlet solenoid valve LR inlet solenoid valve LR outlet solenoid valve RF inlet solenoid valve RF outlet solenoid valve RR...

Page 507: ...HT WHT BLK 16 RED BLK WHT BLK WHT BLK WHT BLK WHT RED BLK 17 A 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 26 5V 5V 5V 5V E03 23 E03 12V 12V PPL WHT 18 E03 5 19 12V 5V 12V 23 24...

Page 508: ...wheel speed sensor 17 RED BLU ABS warning lamp 18 WHT BLK Right front wheel speed sensor 19 WHT Right front wheel speed sensor 20 21 RED Left front wheel speed sensor 22 RED BLK Left front wheel spee...

Page 509: ...S4RS0A4503003 A B 1 1 2 3 4 1 a b I4RS0A450005 A OK 1 Front wheel speed sensor 3 Connector 25 N m 2 5 kg m 18 0 lb ft B NG 2 Grommet 4 Sensor ring 11 N m 1 1 kg m 8 0 lb ft 1 2 3 4 5 A B 1 1 a a I4RS0...

Page 510: ...DTC Is there any malfunction DTC Go to Step 4 Go to Step 2 2 Driving test 1 Perform Step 2 Driving Test Is trouble symptom identified Go to Step 3 Go to Step 6 3 DTC check 1 Perform DTC Check Is it ma...

Page 511: ...DTC referring to DTC Check When DTC which is recorded at DTC check procedure is detected again after performing DTC clearance go to Step 4 ABS Check to proceed the diagnosis When DTC which is recorded...

Page 512: ...C Clearance and perform test driving and confirm that no DTC is indicated ABS Warning Lamp Check S4RS0A4504002 1 Turn ignition switch ON 2 Check that ABS warning lamp 1 comes ON for about 2 seconds an...

Page 513: ...ed on scan tool Scan Tool Data S4RS0A4504007 The parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions When taking measureme...

Page 514: ...r module in combination meter If the antilock brake system is in good condition ABS control module turns ABS warning lamp ON at the ignition switch ON keeps it ON for 2 seconds and then turns it OFF I...

Page 515: ...Is it infinite f Go to Step 6 RED BLU circuit shorted to ground 4 Is Circuit fuse for combination meter in good condition Go to Step 5 Replace fuse and check for short circuit to ground 5 1 Remove com...

Page 516: ...oper connection to ABS hydraulic unit control module connector at terminals E03 1 and E03 14 3 If OK then turn ignition switch to ON position and measure voltage between each terminal of E03 1 E03 14...

Page 517: ...ning lamp 2 Main fuse box 7 EBD warning lamp brake warning lamp 3 Ignition switch 8 Lamp driver module 4 Circuit fuse box 9 ABS hydraulic unit control module assembly Step Action Yes No 1 1 Check for...

Page 518: ...minimum level Are the check results OK Go to Step 2 Release parking brake completely and or replenish brake fluid 2 1 Turn ignition switch to ON position Does ABS warning lamp come on steady Perform...

Page 519: ...d ABS solenoid in good condition Go to Step 3 Replace fuse and check for short 3 1 Disconnect ABS hydraulic unit control module connector 2 Check for proper connection to ABS hydraulic unit control mo...

Page 520: ...tion switch to ON position 2 Measure voltage between terminal B of data link connector and vehicle body ground Is voltage 10 12 V Go to step 8 Terminal B circuit open or shorted to ground 8 1 Turn ign...

Page 521: ...ibed in Step 2 of ABS Check check whether or not any abnormality exists The vehicle was driven with parking brake pulled Wheel spin occurred while driving Wheel s was turned while the vehicle was jack...

Page 522: ...to ground 5 1 Remove applicable ABS wheel speed sensor 2 Check sensor for damage or foreign material attached Is it in good condition Go to Step 6 Clean repair or replace 6 Check front and or rear sen...

Page 523: ...module assembly connector E03 3 ABS power control module 6 Solenoid valve power supply driver transistor 1 Battery 4 Solenoid valve 7 Solenoid valve driver transistor 2 Main fuse box 5 ABS hydraulic...

Page 524: ...module connector with ignition switch turned OFF 2 Check for proper connection to ABS hydraulic unit control module connector at terminals E03 14 and E03 13 3 If OK then turn ignition switch to ON po...

Page 525: ...nerator Test Overcharged Battery Check in Section 1J Step Action Yes No I4RS0A450017 A ABS hydraulic unit control module connector E03 2 Main fuse box 4 ABS pump motor 1 Battery 3 Pump motor driver tr...

Page 526: ...t control module assembly 2 Main fuse box 7 To solenoid valve 3 Ignition switch 8 ABS power control module 4 Circuit fuse box Step Action Yes No 1 Was ABS Check performed Go to Step 2 Go to ABS Check...

Page 527: ...ep 2 Go to ABS Check 2 Clear all DTCs and check DTC Is it DTC C1071 Go to Step 3 Could be a temporary malfunction of the ABS control module 3 1 Check for proper connection of ABS hydraulic unit contro...

Page 528: ...ld be depressed and then select testing wheel by SUZUKI scan tool and the wheel 2 should be turned by another person s hand At this time check that Operation sound of solenoid is heard and the wheel t...

Page 529: ...S0A4506004 CAUTION Never disassemble ABS hydraulic unit control module assembly loosen blind plug or remove motor Performing any of these prohibited services will affect original performance of ABS hy...

Page 530: ...1 from bracket 3 using flat end rod or the like 2 CAUTION Do not give an impact to hydraulic unit Use care not to allow dust to enter hydraulic unit Do not place hydraulic unit on its side or upside d...

Page 531: ...d at a speed of approximately 3 4 rotation to 1 1 4 rotation per second check AC voltage of sensor Output AC voltage at 3 4 to 1 1 4 rotation per second 53 mV or more 7 If measured voltage is not as s...

Page 532: ...f sensor 1 2 1 6 k at 20 qC 68 qF Between sensor terminal 1 and sensor body 2 Infinity f If the check result is not as specified and any malcondition is found replace Rear Wheel Speed Sensor On Vehicl...

Page 533: ...heel speed sensor coupler 1 5 Hoist vehicle 6 Detach ABS wheel sensor wire harness 1 NOTE Do not detach clip of rear wheel speed sensor connector from vehicle body unless replacement is necessary 7 Re...

Page 534: ...eed Sensor Inspection S4RS0A4506010 Check sensor for damage Measure resistance of sensor Between both terminals 1 of sensor 1 2 1 6 k at 20 qC 68 qF Between sensor terminal 1 and sensor body 2 Infinit...

Page 535: ...4 For removal and installation of rear wheel speed sensor ring refer to ABS Sensor Ring Removal and Installation If Equipped in Section 4C Specifications Tightening Torque Specifications S4RS0A4507001...

Page 536: ...UKI scan tool Flare nut wrench 10 mm This kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cab...

Page 537: ...sion Range Sensor Circuit Low 5A 45 DTC P0712 Transmission Fluid Temperature Sensor Circuit Low 5A 47 DTC P0713 Transmission Fluid Temperature Sensor Circuit High 5A 48 DTC P0717 Input Turbine Speed S...

Page 538: ...Components 5A 123 Oil Pump Assembly Disassembly and Reassembly 5A 124 Oil Pump Assembly Inspection 5A 124 Direct Clutch Assembly Components 5A 126 Direct Clutch Assembly Preliminary Check 5A 126 Direc...

Page 539: ...ection 5B 31 Differential Components 5B 32 Differential Disassembly and Assembly 5B 32 Specifications 5B 34 Tightening Torque Specifications 5B 34 Special Tools and Equipment 5B 35 Recommended Service...

Page 540: ...5 1 Precautions Precautions Precautions Precautions on Transmission Transaxle S4RS0A5000001 Air Bag Warning Refer to Air Bag System Service Warning in Section 00...

Page 541: ...s first Then whether overhaul should be done or not is determined If the transaxle is disassembled without such preliminary procedure not only the cause of the trouble would be unknown but also a seco...

Page 542: ...llation make sure to check each part for proper operation Always use torque wrench when tightening bolts A new discs should be soaked in ATF at least 2 hours before use Part Inspection and Correction...

Page 543: ...uring shifting When upshifting from 3rd gear to 4th gear with engine throttle opened to optimize the line pressure applied to the forward clutch at releasing the forward clutch the learning control is...

Page 544: ...n 23 Short planet pinion 4 Input shaft 14 One way No 2 clutch 24 Countershaft 5 Oil pump 15 2nd brake 25 Reduction driven gear 6 Direct clutch drum double as sensor rotor for input shaft speed sensor...

Page 545: ...e 3 range Forward 1st l 2nd l 3rd m 4th automatic gear change 2 range Forward 1st l 2nd m 3rd automatic gear change L range Forward 1st m 2nd m 3rd reduction and fixed at 1st gear Gear ratio 1st 2 875...

Page 546: ...Long planet pinion 13 Forward clutch 7 1st and reverse brake 14 Ring gear Part name Function Forward clutch Meshes intermediate shaft and front sun gear Direct clutch Meshes input shaft and planet car...

Page 547: ...nction in A T control system TCM desire turning on malfunction indicator lamp MIL 1 and stores malfunction DTC in TCM memory It is possible to communicate with TCM through data link connector DLC 2 by...

Page 548: ...iple control modules can communicate simultaneously In addition it has a functionality to detect a communication error automatically Each module reads necessary data from the received data and transmi...

Page 549: ...RN GRN ORN PNK BLK GRN YEL LT GRN BLK C35 6 C35 16 C35 23 C35 25 C35 20 C35 1 C35 8 C35 7 C35 19 C35 18 C34 17 C34 7 4 IG11 12V 23 PPL WHT LT GRN I4RS0A510005 1 TCM 12 Backup lamp 23 Starter motor rel...

Page 550: ...h 6 mile h or more vehicle speed Reverse u u u u When fail safe function is operating N Neutral u u D Neutral o 1st Timing solenoid is turned ON for about 0 5 sec while on gear shifting 1st u u 2nd u...

Page 551: ...37 142 85 88 3rd o 2nd 76 81 47 50 2nd o 1st 33 38 21 24 50 4th o 3rd 64 69 40 43 3rd o 2nd 31 36 19 22 2nd o 1st 8 13 5 8 0 4th o 3rd 28 33 17 21 3rd o 2nd 17 22 11 14 2nd o 1st 8 13 5 8 Lock up clut...

Page 552: ...id valve 15 ECM 2 Transaxle 9 Transmission fluid temperature sensor 16 TCM 3 MIL 10 Timing solenoid valve 17 AT relay 4 Shift position indicator lamp 11 Pressure control solenoid valve 18 3 position s...

Page 553: ...st C 4th gear inhibit D Torque converter clutch control inhibit E Lock up slip control inhibit signal F Throttle position G Engine coolant temperature H Brake pedal switch active P 3 position switch T...

Page 554: ...pection Is there any faulty condition Repair or replace malfunction part Go to Step 11 Go to Step 8 5 Trouble symptom confirmation 1 Confirm trouble symptom Is trouble symptom identified Go to Step 6...

Page 555: ...Automatic Transmission 5A 15 Customer problem inspection form Example NOTE The form is a standard sample It should be modified according to conditions characteristic of each market I2RH01510008...

Page 556: ...onfirm DTC according to DTC Confirmation Procedure described in each DTC flow Step 6 and 7 Rechecking and Record of DTC and Freeze Frame Data Refer to DTC Check for checking procedure Step 8 A T Basic...

Page 557: ...dition corrosion of terminal Battery Inspection in Section 1J Connectors of electric wire harness disconnection friction Electronic Shift Control System Components Location Fuses burning Parts install...

Page 558: ...solenoid circuit 1 driving cycle P0973 Shift solenoid A No 1 control circuit low Voltage of shift solenoid terminal is low although TCM is commanding shift solenoid to turn ON 1 driving cycle P0974 S...

Page 559: ...nication was not possible 5 After completing the check turn ignition switch off and disconnect scan tool from data link connector DTC Clearance S4RS0A5104007 WARNING When performing a driving test sel...

Page 560: ...to ECM torque reduction control is inhibited Garage shift control is inhibited Learning control is inhibited P0722 Output speed sensor circuit no signal Vehicle speed which is calculated by input sha...

Page 561: ...ue reducing request to ECM torque reduction control is inhibited Garage shift control is inhibited Learning control is inhibited In case of engine torque signal malfunction Line pressure control at ge...

Page 562: ...hift control is inhibited Learning control is inhibited P1878 Torque converter clutch shudder Slip controlled lock up function is inhibited to operate P2763 Torque converter clutch pressure control so...

Page 563: ...le stop closed throttle engine idle speed and 1st gear 0 VEHICLE SPEED At vehicle stop 0 km h 0 MPH O D OFF SWITCH Ignition switch ON Shift selector lever to 3 or 2 range ON Shift selector lever to ot...

Page 564: ...utted to timing solenoid valve OFF ON command not being outputted to timing solenoid valve TIMING SOLENOID MONITOR ON Electricity being passed to timing solenoid valve OFF Electricity not being passed...

Page 565: ...nform that fuel cut is not operating A T Basic Check S4RS0A5104010 This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in Visual Inspection Follo...

Page 566: ...reverse brake Inspect If NG replace Damaged drive plate Inspect If NG replace Faulty torque converter Replace No gear shift as 3rd gear Malfunction of shift solenoid valve A and or B Inspect If NG rep...

Page 567: ...noid valve Inspect If NG replace valve body assembly O D o 3 downshift fails to occur Malfunction of shift solenoid valve A Inspect If NG replace Malfunction of 3 position switch Inspect If NG replace...

Page 568: ...TC TCC lock up function pressure control does not operate Malfunction of TCC pressure control solenoid valve Inspect If NG replace Malfunction of shift solenoid valve A and or B Inspect If NG replace...

Page 569: ...1 minute before another stall test 1 Apply parking brake and block wheels 2 Install tachometer 3 Start engine with select lever shifted to P range 4 Depress brake pedal fully 5 Shift select lever to D...

Page 570: ...uit Overhaul or replace valve body assembly Higher than standard level in R range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Faulty valv...

Page 571: ...rrection Reference Item N o D time lag exceeds specification Malfunction of transmission fluid temperature sensor Inspect If NG replace Malfunction of pressure control solenoid valve Low line pressure...

Page 572: ...le for longer than one minute before performing another line pressure test Automatic transaxle line pressure Troubleshooting D range R range At idle speed 3 6 4 0 kg cm2 51 57 psi 5 8 6 7 kg cm2 82 95...

Page 573: ...ing Inspect circuit for open short and intermittent If NG repair Output shaft speed sensor VSS circuit faulty Inspect circuit for open short and intermittent If NG repair Input shaft speed sensor circ...

Page 574: ...TCM Substitute a known good TCM and recheck ECM Substitute a known good ECM and recheck Poor 2 o 3 shift Shift solenoid valve A circuit faulty Inspect circuit for open short and intermittent If NG re...

Page 575: ...or DTC P0118 Engine Coolant Temperature Circuit High in Section 1A If NG repair Crankshaft position sensor circuit faulty Inspect circuit for open short and intermittent referring to DTC P0335 Cranksh...

Page 576: ...uit 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 P0122 Throttle Position...

Page 577: ...Sensor Circuit Low in Section 1A and or DTC P0123 Throttle Position Sensor Circuit High in Section 1A If NG repair Engine coolant temperature sensor circuit faulty Inspect circuit for open short and i...

Page 578: ...place Malfunction of crankshaft position sensor Inspect referring to Camshaft Position CMP Sensor Inspection in Section 1C If NG replace Malfunction of throttle position sensor Inspect referring to Th...

Page 579: ...t If NG replace Malfunction of 3 position off switch Inspect If NG replace Malfunction of throttle position sensor Inspect referring to Throttle Position TP Sensor On Vehicle Inspection in Section 1C...

Page 580: ...ssure control solenoid valve circuit faulty Inspect If NG replace valve body assembly Clogged oil strainer Replace Faulty valve body component Replace valve body assembly Condition Possible cause Corr...

Page 581: ...ay No 2 clutch Inspect If NG replace Non operate TCC lock up system Faulty torque converter Replace Excessive N o D time lag Faulty oil pump Inspect If NG replace Faulty forward clutch Inspect If NG r...

Page 582: ...Select lever is in D range Drive vehicle with 4th gear condition referring to Automatic Gear Shift Table Voltage between TCM connector and ground Between terminal C39 16 of TCM connector and ground 0...

Page 583: ...depressed 8 14 V Is result as specified Substitute a known good TCM and recheck Mis adjusted brake light switch faulty brake light switch If OK substitute a known good TCM and recheck Step Action Yes...

Page 584: ...o the following table Are check results satisfactory Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 Go to Step 5 5 1 Check select ca...

Page 585: ...op vehicle and turn ignition switch OFF 6 Repeat Step 3 to 4 one time 7 Stop vehicle and check DTC DTC Troubleshooting 1 TCM 3 Backup lamp 2 Transmission range sensor A Terminal arrangement of TCM con...

Page 586: ...referring to the following table Are check results satisfactory Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 Go to Step 5 5 1 Chec...

Page 587: ...ent of TCM connector viewed from harness side DTC detecting condition Trouble area Transmission temperature sensor terminal voltage is less than specified value for 5 minutes or more after turning ign...

Page 588: ...C35 A 1 I4RS0A510011 1 TCM 3 A T 2 Transmission fluid temperature sensor A Terminal arrangement of TCM connector viewed from harness side DTC detecting condition Trouble area Transmission fluid tempe...

Page 589: ...4 Inspect transmission fluid temperature sensor 1 Inspect transmission fluid temperature sensor referring to Transmission Fluid Temperature Sensor Inspection Is result satisfactory Intermittent troub...

Page 590: ...s with ignition switch OFF 2 Check for proper connection to input shaft speed sensor at C35 6 and C35 16 terminals 3 If OK check resistance of sensor circuit Input shaft speed sensor specification Bet...

Page 591: ...t speed sensor VSS A Terminal arrangement of TCM connector viewed from harness side DTC detecting condition Trouble area No output shaft speed sensor signal is detected although input shaft speed sens...

Page 592: ...connected output shaft speed sensor harness side connector and terminal C35 25 of disconnected harness side TCM connector Is continuity indicated Go to Step 6 PPL wire open 6 Inspect output shaft spee...

Page 593: ...itch OFF 9 Repeat Step 3 to 7 one time 10 Stop vehicle and check DTC DTC Troubleshooting DTC detecting condition Trouble area When driving vehicle with 3rd or 4th gear in D range difference in revolut...

Page 594: ...of valve body assembly Fluid passage clogged or leaking Mechanical malfunction of automatic transaxle clutch brake or gear etc DTC detecting condition Trouble area 2nd gear ratio is detected although...

Page 595: ...ect lever from N range to D range and vice versa for 3 times 5 Check DTC Step Action Yes No 1 Was A T System Check performed Go to Step 2 Go to A T System Check 2 1 Check shift solenoid valve A No 1 o...

Page 596: ...e body harness connector and transaxle 11 15 at 20 qC 68 qF Is check result satisfactory Go to Step 3 Replace timing solenoid valve or lead wire 3 Check timing solenoid valve circuit for ground short...

Page 597: ...ve to turn OFF Timing solenoid valve circuit open or shorted to power circuit Timing solenoid valve malfunction TCM 12V C34 14 BLU BLK 3 1 2 14 C34 C35 A I4RS0A510014 Step Action Yes No 1 Was A T Syst...

Page 598: ...per connection to solenoid valve at BLU BLK circuit 4 Check resistance of solenoid valve Timing solenoid valve resistance Between terminal of transaxle side valve body harness connector and transaxle...

Page 599: ...ine running at idle speed for 30 seconds or more 5 Stop vehicle and check DTC 1 TCM 3 A T 2 Pressure control solenoid valve A Terminal arrangement of TCM connector viewed from harness side DTC detecti...

Page 600: ...ide valve body harness connector 5 0 5 6 at 20 qC 68 qF Between terminals of transaxle side valve body harness connector and Transaxle Infinity Is check results satisfactory Go to Step 3 Replace press...

Page 601: ...nected harness side TCM connector Is it infinite GRY or LT GRN BLK circuit open Intermittent trouble or faulty TCM Check for intermittent referring to Intermittent and Poor Connection Inspection in Se...

Page 602: ...rol solenoid valve resistance 1 Turn ignition switch OFF 2 Disconnect valve body harness connector 1 2 on automatic transaxle 3 Check for proper connection to solenoid at GRY and LT GRN BLK circuit 4...

Page 603: ...ct scan tool to DLC with ignition switch OFF if available 2 Clear DTC in TCM memory 3 Start engine shift select lever to D range 4 Start vehicle and increase vehicle speed until gear position reaches...

Page 604: ...at 20 qC 68 qF Is check results satisfactory Go to Step 3 Replace applicable shift solenoid valve or valve body harness 3 Check shift solenoid valve circuit for ground short 1 Disconnect TCM connector...

Page 605: ...th ignition switch OFF if available 2 Clear DTC in TCM memory 3 Start engine and shift select lever to D range 4 Start vehicle and increase vehicle speed until gear position reaches 3rd or 4th gear 5...

Page 606: ...circuit DTC P0977 BLK YEL circuit shorted to power circuit 3 Check shift solenoid valve resistance 1 Turn ignition switch OFF 2 Disconnect valve body harness connector 1 2 on automatic transaxle 3 Che...

Page 607: ...trol signal from ECM is detected by TCM TCM sets DTC P1703 DTC Troubleshooting DTC detecting condition Trouble area Calculation of current data stored in TCM is not correct comparing with pre stored c...

Page 608: ...connector viewed from harness side 2 ECM 4 3 position switch B TCM connector viewed from harness side DTC detecting condition Trouble area 3 position switch ON signal is inputed although transmission...

Page 609: ...20 47 46 49 50 51 21 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 21 22 52 16...

Page 610: ...on in Section 00 4 Check TCM power and ground circuit 1 Check for TCM power and ground circuit referring to TCM Power and Ground Circuit Check Is it in good condition Go to Step 5 Repair TCM power and...

Page 611: ...rminal of ECM connector and C34 7 terminal of TCM connector Between G37 4 terminal of BCM connector and G28 8 terminal of combination meter connector Between G37 2 terminal of BCM connector and G28 10...

Page 612: ...ction Yes No RED WHT E23 3 E23 18 RED WHT C37 13 C37 12 RED WHT RED WHT RED WHT RED WHT E46 1 G37 4 G28 8 G28 10 G37 2 C34 7 E46 2 C34 17 1 2 3 4 C E23 C37 3 4 18 19 5 6 7 10 11 17 20 47 46 49 50 51 2...

Page 613: ...Go to Step 4 4 Check ECM and TCM connectors 1 Check for proper connection at each ECM and TCM connector terminals with ignition switch turned OFF 2 If connections are OK recheck TCM for DTC with engin...

Page 614: ...ion for CAN Communication System in Section 00 10 Check CAN communication line circuit power supply short 1 Measure voltage at the following connector terminals with ignition switch turned ON Between...

Page 615: ...1 22 52 16 25 9 24 14 29 55 57 54 53 59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 A B G37 E46 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 12 1...

Page 616: ...k DTC for ECM 1 Check DTC P1674 in ECM Is it indicated Go to DTC P1674 CAN Communication Bus Off Error in Section 1A Go to Step 7 7 Check CAN communication line circuit continuity 1 Disconnect connect...

Page 617: ...Precaution for CAN Communication System in Section 00 11 Check DTC in BCM 1 Connect connectors to ECM and TCM with ignition switch turned OFF 2 Check DTC U1100 in BCM Is it indicated Substitute a kno...

Page 618: ...9 10 11 12 13 14 12 13 14 15 16 17 18 19 20 21 22 D 6 5 16 15 14 13 12 11 4 3 24 23 21 22 10 9 8 7 2 1 19 20 18 17 C34 17 16 26 25 15 14 6 5 3 4 2 13 12 23 22 24 11 10 9 21 20 19 8 7 18 1 C35 G28 1 2...

Page 619: ...switch turned OFF 2 Measure resistance at the following connector terminals Between C34 17 terminal of TCM connector and E46 1 terminal of BCM connector Between C34 7 terminal of TCM connector and E46...

Page 620: ...unication line circuit power supply short 1 Measure voltage at the following connector terminals with ignition switch turned ON Between E23 3 terminal of ECM connector and vehicle body ground Between...

Page 621: ...controlled lock up ON for 20 seconds or longer referring to Automatic Gear Shift Table 5 Stop vehicle 6 Check DTC pending DTC and freeze frame data DTC Troubleshooting DTC detecting condition Trouble...

Page 622: ...e 2 Clear DTC in TCM memory 3 Start engine 4 Keep engine running at idle speed in P range for 10 seconds or more 5 Check DTC DTC Troubleshooting 1 TCC lock up pressure control solenoid valve 3 A T 2 T...

Page 623: ...ignition switch OFF 2 Disconnect valve body harness connector 1 2 on automatic transaxle 3 Check for proper connection to solenoid at WHT BLU and WHT BLK circuits 4 Check resistance of TCC lock up pr...

Page 624: ...available 2 Clear DTC in TCM memory 3 Start engine 4 Keep engine running at idle speed in P range for 20 seconds or more 5 Check DTC DTC Troubleshooting 1 TCC pressure control solenoid valve 3 A T 2 T...

Page 625: ...s check results satisfactory Go to Step 3 Replace TCC lock up pressure control solenoid valve or lead wire 3 Check TCC lock up pressure control solenoid valve circuit for ground short 1 Disconnect TCM...

Page 626: ...11 V or more when ignition switch is ON Voltage with asterisk cannot be measured by voltmeter because it is pulse signal check it with oscilloscope if necessary Terminal arrangement of TCM coupler Vi...

Page 627: ...ON 15 BLK YEL Shift solenoid valve B No 2 9 14 V Ignition switch ON select lever in P range 16 BRN Shift solenoid valve A No 1 9 14 V Ignition switch ON select lever in P range 17 RED CAN communicatio...

Page 628: ...Transmission range sensor 2 range 8 14 V Ignition switch ON selector lever at 2 range 0 1 V Ignition switch ON selector lever at other than 2 range 20 PNK BLK Transmission range sensor P range 8 14 V...

Page 629: ...re Engine at specified idle speed with P range Measurement terminal CH1 C34 7 to C34 1 CH2 C34 17 to C34 1 Oscilloscope setting CH1 1 V DIV TIME 100 Ps DIV Measurement condition After warmed up to nor...

Page 630: ...connection to TCM at C34 24 terminal 3 If OK check voltage at terminal C34 24 of disconnected TCM connector Is it 10 14 V Go to Step 2 WHT RED circuit open or shorted to ground 2 Check TCM power circu...

Page 631: ...e button 1 pushed and ignition key turned to LOCK position selector lever can not be shifted from P range position to any other range When ignition switch is turned ON and brake pedal is depressed sel...

Page 632: ...UZUKI ATF 3317 or Mobil ATF 3309 up to FULL HOT Automatic transaxle fluid SUZUKI ATF 3317 or Mobil ATF 3309 NOTE Do not race engine while checking fluid level even after the engine start Do not overfi...

Page 633: ...d pour proper amount of SUZUKI ATF 3317 or Mobil ATF 3309 5 Check fluid level referring to A T Fluid Level Check Automatic transaxle fluid SUZUKI ATF 3317 or Mobil ATF 3309 Automatic transaxle fluid c...

Page 634: ...ect lever by specified numbers of rotation below Rotation numbers for select lever knob Installation a 11 12 rotations CAUTION When installing select lever knob do not turn more than specified numbers...

Page 635: ...1 out from eye end 2 using an appropriate tool 3 to disengage cable 5 Shift selector lever to N position 6 Apply grease to selector lever pin and install adjuster cable end to it Grease 99000 25010 7...

Page 636: ...nsmission range sensor connector and check that continuity exists as shown by moving manual select lever Output Shaft Speed Sensor VSS Removal and Installation S4RS0A5106009 Removal 1 Disconnect negat...

Page 637: ...Disconnect negative cable at battery 2 Disconnect input shaft speed sensor connector 2 3 Remove input shaft speed sensor 1 by removing its bolt Installation 1 Apply A T fluid to input shaft speed sens...

Page 638: ...assembly noting the following points For details of valve body assembly and their connectors installation refer to Automatic Transaxle Unit Assembly For details of A T oil pan installation refer to A...

Page 639: ...g Solenoid Valve Removal and Installation S4RS0A5106015 Removal 1 Disconnect negative cable at battery 2 Lift up vehicle 3 Remove drain plug and drain A T fluid 4 Install drain plug Tightening torque...

Page 640: ...ighten oil pan bolts to specified torque diagonally and little by little Tightening torque Oil pan bolt b 7 0 N m 0 7 kg m 5 0 lb ft Solenoid Valves Shift Solenoid Valves and Timing Solenoid Valve Ins...

Page 641: ...th air to prevent mistaken checking because return spring for valve is not installed into solenoid valve Timing solenoid valve CAUTION Do not insert air gun against strainer installed on inlet of sole...

Page 642: ...tallation refer to Valve Body Assembly Disassembly and Reassembly For detail of valve body assembly installation refer to Automatic Transaxle Unit Assembly For detail of installing wire harness for so...

Page 643: ...for movement of valve 3 in the direction of arrow A 3 Disconnect pressure control solenoid valve 1 from battery 2 and check movement of valve 3 in the direction of arrow B as shown in figure CAUTION S...

Page 644: ...f A T relay If continuity does not indicated replace A T relay Differential Side Oil Seal Replacement S4RS0A5106019 1 Lift up vehicle and drain automatic transaxle fluid 2 Remove drive shaft joints fr...

Page 645: ...Lock Solenoid Inspection S4RS0A5106064 Check that shift lock solenoid 1 actuate when battery voltage is conducted Shift Lock Solenoid Replacement S4RS0A5106065 1 Remove console box referring to Consol...

Page 646: ...pressing checkhook 8 Remove interlock cable Installation 1 Lay interlock cable to its original cabling route 2 Turn ignition switch to ACC position 3 Insert cable casing cap 1 into key cylinder cover...

Page 647: ...be sure to note the following to replace clamps at the same time to insert hose as far as its limit mark to clamp clamps securely Automatic Transaxle Unit Components S4RS0A5106023 1 Inlet hose Outlet...

Page 648: ...hroughout the work Should it be tilted with torque converter down converter may fall off and cause personal injury NOTE When detaching transaxle from engine move it in parallel with crankshaft and use...

Page 649: ...e to torque converter bolt a 25 N m 2 5 kg m 18 0 lb ft 4 Tighten transaxle stiffener bolts to specified torque 5 Install transaxle housing lower plates 1 Tightening torque Transaxle stiffener bolt a...

Page 650: ...5A 110 Automatic Transmission Automatic Transaxle Assembly Components S4RS0A5106025 I3RM0B510053...

Page 651: ...ut After tightening nut so as rotational torque of reduction drive gear to be in specified value caulk nut securely 80 O D and 2nd coast brake retaining plate snap ring 17 Lubrication RH tube 49 Reduc...

Page 652: ...ove torque converter as much straight as possible Leaning it may cause to damage oil seal lip 2 Remove engine mounting LH bracket 1 3 Remove manual select lever 1 4 Uncaulk lock washer 1 then remove l...

Page 653: ...e 11 Remove oil strainer assembly 1 12 Disconnect connectors 2 from solenoid valves and transmission fluid temperature sensor 1 13 Remove valve body assembly bolts CAUTION Be careful not to let manual...

Page 654: ...spring 2 18 Remove accumulator pistons and springs To remove C2 1 C1 2 and B1 3 accumulator pistons and springs position rag on pistons to catch each piston To remove pistons force low pressure compr...

Page 655: ...specification select input shaft front thrust bearing with proper thickness from among the list below and replace it Special tool A 09900 20607 B 09900 20701 Input shaft thrust play 0 3 0 9 mm 0 012...

Page 656: ...emove differential assembly 1 and countershaft assembly 2 31 Remove governor apply No 2 gasket 1 32 Remove fluid reservoir LH plate 1 33 Turn over transaxle and remove rear cover assembly 1 34 Remove...

Page 657: ...caliper Calculate piston stroke from measured value of dimensions a and b Piston stroke a b O D and 2nd coast brake piston stroke Standard 0 65 1 05 mm 0 026 0 041 in 37 Remove forward and reverse cl...

Page 658: ...planetary sun gear subassembly 1 and one way clutch No 1 assembly 2 44 Remove planetary gear thrust bearing 1 NOTE If planetary gear thrust bearing is not found on one way clutch No 1 assembly it may...

Page 659: ...d brake piston assembly in over 0 4 mm 0 016 in Excessive compression may cause damage to piston assembly return spring plates and or discs Special tool A 09926 96050 51 Remove 2nd brake piston assemb...

Page 660: ...ied value disassemble inspect and replace discs and plates Using special tool measure 1st and reserve brake piston stroke when compressed air 400 800 kPa 4 8 kg cm2 57 113 psi is blown through oil hol...

Page 661: ...s recommended that this operation should be carried out on rubber mat to prevent damaging transaxle case Never reuse removed nut 65 Using special tools and hydraulic press remove planetary ring gear s...

Page 662: ...t and reverse brake piston 2 69 Remove parking lock pawl bracket 1 70 With slotted screwdriver cut and unfold manual valve lever spacer 1 and proceed to remove manual valve lever spacer 71 Using sprin...

Page 663: ...nts S4RS0A5106027 I2RH0B510146 I2RH0B510147 I2RH0B510148 1 Oil seal Apply grease 99000 25030 to oil seal lip 5 Oil pump drive gear Apply automatic transaxle fluid 2 O ring 6 Stator shaft assembly Tigh...

Page 664: ...oil pump body and tighten 8 pump subassembly bolts 1 to specification Tightening torque Oil pump subassembly bolt a 10 N m 1 0 kg m 7 5 lb ft 4 After applying A T fluid to new O ring install it to oi...

Page 665: ...shaft bush bore is out of specifications replace oil pump assembly with new one Special tool A 09900 20605 Stator shaft bush bore Standard 18 424 18 450 mm 0 7254 0 7264 in 5 Install direct clutch as...

Page 666: ...f direct clutch If piston stroke exceeds specified value disassemble inspect and replace inner parts Special tool A 09900 20607 B 09900 20701 Direct clutch piston stroke 0 4 0 7 mm 0 016 0 027 in I2RH...

Page 667: ...bassembly in over 0 7 mm 0 027 in Excessive compression may cause damage to direct clutch return spring subassembly and or piston 3 Remove direct clutch return spring assembly 2 4 Using a finger to bl...

Page 668: ...plate 2 and snap ring 1 to input shaft subassembly Install plate snap ring so that its both ends would be positioned in correct locations as shown in figure After assembly measure direct clutch pisto...

Page 669: ...them in A T fluid for at least two hours Direct Clutch Return Spring Subassembly Measure free length of direct clutch return spring Direct clutch return spring free length a 36 04 mm 1 419 in NOTE Do...

Page 670: ...and replace inner parts Special tool A 09900 20607 B 09900 20701 Reverse clutch piston stroke 1 20 1 60 mm 0 047 0 063 in I3RM0B510061 1 Forward clutch balancer 8 Intermediate shaft seal ring 15 Forw...

Page 671: ...ssembly S4RS0A5106036 Disassembly 1 Remove reverse clutch plate snap ring 1 and take out reverse clutch retaining plate discs separator plates and clutch cushion plate from intermediate shaft subassem...

Page 672: ...mbly 2 9 Remove forward clutch drum O ring 1 from forward clutch drum 2 10 Remove intermediate shaft seal ring 1 from intermediate shaft subassembly 2 Reassembly Reverse disassembly procedure for asse...

Page 673: ...g table and replace it Special tool A 09900 20607 B 09900 20701 C 09952 06020 Forward clutch piston stroke 1 30 1 50 mm 0 051 0 059 in Available forward clutch retaining plate thickness Install revers...

Page 674: ...and Retaining Plate Check that sliding surfaces of discs separator plates and retaining plate are not worn hard or burnt If necessary replace NOTE If disc lining is exfoliated or discolored replace a...

Page 675: ...106038 2nd Brake Piston Assembly Disassembly and Reassembly S4RS0A5106040 Disassembly 1 Apply compressed air 400 800 kPa 4 8 kg cm2 57 113 psi to oil hole 1 of 2nd brake cylinder 3 to remove 2nd brake...

Page 676: ...amage O ring when installing 2nd brake piston Transaxle Rear Cover O D and 2nd Coast Brake Piston Assembly Components S4RS0A5106042 I2RH0B510198 I2RH0B510199 I2RH0B510200 1 Snap ring 5 O D and 2nd coa...

Page 677: ...Pa 4 8 kg cm2 57 113 psi to oil hole 2 of transaxle rear cover 1 to remove O D and 2nd coast brake piston 4 Remove O D and 2nd coast brake piston front O ring 1 and rear O ring 2 5 Remove rear cover s...

Page 678: ...ake return spring Free length of O D and 2nd coast brake return spring a 18 99 mm 0 748 in NOTE Do not apply excessive force when measuring spring free length Perform measurement at several points Tra...

Page 679: ...61510 B 09926 58010 Reassembly 1 Install new countershaft RH bearing 1 by using special tool and hydraulic press Special tool A 09913 84510 NOTE Replace countershaft RH bearing together with bearing...

Page 680: ...Components S4RS0A5106050 I2RH0B510214 I4RS0A510044 1 Pressure control solenoid valve 6 Temperature sensor clamp Apply automatic transaxle fluid 2 Shift solenoid valve A No 1 7 Valve body assembly Tigh...

Page 681: ...ontrol solenoid valve and or TCC pressure control solenoid valve independently may cause excessive shift shock Disassembly 1 Pull out manual valve 1 2 Remove pressure control solenoid valve 1 3 Remove...

Page 682: ...torque Solenoid valve bolt a 11 N m 1 1 kg m 8 0 lb ft Solenoid valve bolt specification Differential Assembly Components S4RS0A5106052 Bolt Length a Pieces A 1 49 mm 1 93 in 5 B 2 20 mm 0 79 in 1 C...

Page 683: ...WARNING When taking warmed final driven gear out of vessel use tongs or the like Taking out it with bare hand will cause severe burn While installing warmed final driven gear use oven glove such as l...

Page 684: ...rential side RH bearing together with bearing cup as a set Special tool A 09913 70123 6 Install new differential side LH bearing 1 by using special tool and hydraulic press NOTE Replace differential s...

Page 685: ...NOTE Do not bend lubrication tube with excessive force 3 Remove differential side oil seal 1 4 Remove countershaft RH bearing cup by using special tools Special tool A 09944 96011 B 09942 15511 5 Rem...

Page 686: ...A 09924 74510 B 09944 88220 4 Using special tools install new differential side oil seal to torque converter housing Special tool A 09924 74510 B 09944 88220 Differential side oil seal installing dept...

Page 687: ...tools assemble shim and differential side LH bearing cup NOTE Use shim with same thickness as the removed one Special tool A 09924 74510 B 09944 88220 2 Using special tools assemble shim and counters...

Page 688: ...oloration or surface scuffing is indicated plate must be replaced Brake return spring subassembly Measure brake return springs Evidence of extreme heat or burning in the area of clutch may have caused...

Page 689: ...within specification Available shim thickness NOTE Record measured differential side bearing because it is necessary to adjust countershaft bearing preload 5 Remove differential assembly Countershaft...

Page 690: ...n sliding or rotating surfaces of the parts before assembly Use Suzuki Super Grease C to retain parts in place Be sure to install thrust bearings and races in correct direction and position Make sure...

Page 691: ...2 in in diameter 5 and hammer turn spacer to set the position as shown in figure Then caulk spacer with a punch 6 Install parking lock pawl bracket 1 to transaxle case Tightening torque Parking lock p...

Page 692: ...nstall 1st and reverse brake plate snap ring so that its both ends would be positioned in correct locations as shown in figure 13 Using special tools measure 1st and reverse brake piston stroke when c...

Page 693: ...dwork to press fit planetary ring gear subassembly Do not give load more than 20 kN 2000 kg 4410 lb with hydraulic press Otherwise it may result in damaging reduction drive gear bearing Special tool A...

Page 694: ...is out of specification remove planetary gear assembly and reinstall it properly Distance between planetary gear assembly and mating surface of transaxle case a More than 49 9 m 1 965 in 21 Apply A T...

Page 695: ...case then put together 27 Install 2nd brake piston snap ring 1 by using special tool and hydraulic press CAUTION Do not damage 2nd brake piston assembly return spring subassembly plates and discs by p...

Page 696: ...ring 1 then install it to one way clutch No 1 assembly 3 34 After applying A T fluid to rear planetary sun gear subassembly and one way clutch No 1 assembly 1 install them in transaxle case 2 35 After...

Page 697: ...1 29 4 mm 1 067 1 157 in 41 After applying A T fluid to O D and 2nd coast brake retaining plate 4 separator plate 3 discs 2 and rear plate 1 install them to transaxle case 5 42 Measure O D and 2nd co...

Page 698: ...mount that its section is 1 2 mm 0 047 in in diameter A Sealant 99000 31230 47 Install transaxle rear cover assembly on transaxle case 48 Install hook 2 to location shown in figure 49 Tighten rear cov...

Page 699: ...thrust bearing race 2 install them into direct clutch hub 3 55 After applying A T fluid to input shaft front thrust bearing 1 install it to direct clutch assembly 2 56 Apply A T fluid to direct clutch...

Page 700: ...t shaft thrust play Apply dial gauge onto input shaft end 1 and measure thrust play of input shaft Special tool A 09900 20607 B 09900 20701 Input shaft thrust play 0 3 0 9 mm 0 012 0 035 in When input...

Page 701: ...ch accumulator piston and apply A T fluid to them Accumulator O ring dimension NOTE Make sure that O rings are not twisted or caught when installing 68 Install B1 C1 C2 accumulator pistons and springs...

Page 702: ...o transaxle case take care not to damage transmission fluid temperature sensor 2 at narrow entrance of case Careless sensor treatment might cause sensor malfunction Tightening torque Valve body harnes...

Page 703: ...to specified torque diagonally and little by little Tightening torque Oil pan bolt a 7 0 N m 0 7 kg m 5 0 lb ft 79 After applying A T fluid to new O rings fit it to fluid inlet union 1 Then install fl...

Page 704: ...torque Harness bracket bolt c 23 N m 2 3 kg m 17 0 lb ft Select cable clamp bolt d 10 N m 1 0 kg m 7 5 lb ft 84 Install transmission range sensor to transaxle case tighten bolts temporarily at this s...

Page 705: ...h may cause oil seal to leak Be very careful not to drop converter on oil pump gear Damage in gear should it occur may cause a critical trouble Install torque converter aligning grooves 1 of torque co...

Page 706: ...l pan bolt 7 0 0 7 5 0 Transaxle and engine fastening bolt and nut 85 8 5 61 5 Drive plate to torque converter bolt 25 2 5 18 0 Transaxle stiffener bolt 55 5 5 40 Starter motor bolt and nut 50 5 0 36...

Page 707: ...e Rear Cover O D and 2nd Coast Brake Piston Assembly Components Countershaft Assembly Components Valve Body Assembly Components Differential Assembly Components Special Tool S4RS0A5108002 Material SUZ...

Page 708: ...t shaft bearing installer Bearing installer 09926 37610 001 09926 37610 002 Bearing puller Bearing puller attachment 09926 37610 003 09926 37610 Bearing remover attachment Bearing remover 09926 58010...

Page 709: ...0 Bearing outer race remover Transfer bearing dummy 09951 18210 09952 06020 Oil seal remover installer No 2 Dial gauge plate No 2 SUZUKI scan tool This kit includes following items 1 Tech 2 2 PCMCIA c...

Page 710: ...into the reverse gear the reverse shift braking device is used The device utilizes the 5th synchromesh which is the lever synchro type to apply the brake on the input shaft rotation The double cone s...

Page 711: ...rshaft 2nd gear 3 Input shaft 4th gear 10 Right case 17 Low speed synchronizer sleeve hub 4 High speed synchronizer sleeve hub 11 Side cover 18 Countershaft 1st gear 5 Input shaft 3rd gear 12 Counters...

Page 712: ...2 liters 4 8 3 9 US Imp pt 7 Apply sealant to thread of level filler plug and then tighten it to specified torque A Sealant 99000 31260 Tightening torque Transaxle oil level filler plug b 21 N m 2 1 k...

Page 713: ...its spring side inward Use special tool and hammer for installation Special tool A 09913 85210 5 Apply grease to oil seal lip and at the same time check drive shaft where oil seal contacts and make s...

Page 714: ...trol lever assembly mounting nut 10 N m 1 0 kg m 7 5 lb ft 2 Cable bracket bolt 7 Gear shift control lever assembly 55 N m 5 5 kg m 40 0 lb ft 3 Gear shift lever boot 8 Cable grommet bolt Do not reuse...

Page 715: ...nothing the following Tighten each bolts and nuts to specified torque referring to Gear Shift Control Lever and Cable Components Adjust gear select control cable referring to Gear Select Control Cabl...

Page 716: ...m 4 0 lb ft 2 Connect VSS coupler 1 3 Install cable bracket 2 to transaxle Tightening torque Cable bracket bolt a 55 N m 5 5 kg m 40 0 lb ft 4 Connect gear shift and select control cables 1 to transa...

Page 717: ...8 Check back up lamp switch for function using ohmmeter Back up lamp switch specification Switch ON Push Continuity Switch OFF Release No continuity Manual Transaxle Unit Components S4RS0A5206009 1 2...

Page 718: ...ove transaxle to engine bolts 1 of upper side 12 Support engine using supporting device 1 CAUTION Do not apply supporting device to projection part A If do so it may be deformed 13 Remove front drive...

Page 719: ...ratch oil seal lip with drive shaft while raising transaxle Do not hit drive shaft joint with hammer when installing it into differential gear Reverse dismounting procedure for remounting noting the f...

Page 720: ...de case bolt a 23 N m 2 3 kg m 17 0 lb ft 3 Tighten select lever bracket bolt with select lever bracket to specified torque Tightening torque Select lever bracket bolt 23 N m 2 3 kg m 17 0 lb ft I4RS0...

Page 721: ...ion or damage If any detect is found replace detective part with new one NOTE Set new gear shift select lever inner pin 8 and outer pin 9 facing each gap a b in the opposite direction as shown in figu...

Page 722: ...5B 13 Manual Transmission Manual Transaxle Assembly Components S4RS0A5206028 I4RS0A520013...

Page 723: ...ad lock 99000 32110 to all around thread part of bolt 6 Back up lamp switch 30 Reverse gear shaft 7 O ring 31 Washer 8 Differential assembly 32 Reverse idler gear 9 Oil level filler plug Apply sealant...

Page 724: ...ion A of 5th speed synchronizer levers 1 with groove of hub 2 c Install synchronizer ring 1 to hub 2 as shown in the figure 2 Install 5th gear 1 to countershaft facing machined boss A inward 3 Install...

Page 725: ...kg m 7 5 lb ft 7 Using special tool install new circlip 1 to input shaft 3 in specified direction as shown in the figure Special tool 09900 06107 8 Clean mating surface of both left case 2 and side c...

Page 726: ...er bolts from clutch housing side 9 Tapping left case flanges with plastic hammer remove left case 3 10 Pull out reverse gear shaft 1 with washer 2 then take off reverse idler gear 3 11 Remove reverse...

Page 727: ...rom right case 2 Installation 1 Install differential assembly 1 into right case 2 2 Join input shaft assembly 5 countershaft assembly 4 low speed gear shift shaft 2 and high speed gear shift shaft 3 a...

Page 728: ...0 mm 0 02 0 04 in 6 Clean mating surfaces of both right and left cases apply sealant to right case 2 as shown in the figure by such amount that its section is 1 5 mm 0 059 in in diameter then mate it...

Page 729: ...4 in 0 786 0 815 mm 0 0310 0 0320 in 0 90 mm 0 035 in 0 816 0 845 mm 0 0321 0 0332 in 0 93 mm 0 037 in 0 846 0 875 mm 0 0333 0 0344 in 0 96 mm 0 038 in 0 876 0 905 mm 0 0345 0 0356 in 0 99 mm 0 039 in...

Page 730: ...ocating bolt a 13 N m 1 3 kg m 9 5 lb ft 12 Install new snap ring 1 using special tool Special tool A 09900 06107 13 To seat countershaft left bearing outer race 1 to bearing cone and tap countershaft...

Page 731: ...t shaft assembly referring to Gear Shift and Select Shaft Assembly Removal and Installation 19 Install back up lamp switch referring to Back Up Lamp Switch Removal and Installation 20 Check input shaf...

Page 732: ...with its spring side facing upward Use special tool and hammer for installation and apply grease to oil seal lip B Grease 99000 25010 Special tool A 09913 84510 3 If countershaft right bearing outer...

Page 733: ...S4RS0A5206030 I3RM0A520048 I3RM0B521010 1 Input shaft 12 Input shaft left bearing 23 2nd gear synchronizer center cone 2 Oil seal Apply grease 99000 25010 to oil seal lip 13 Circlip 24 2nd gear synch...

Page 734: ...sing bearing puller 4 and hydraulic press CAUTION Make sure to use flat side of bearing puller to avoid causing damage to 3rd gear tooth 6 Take out 3rd gear needle bearing of resin cage type from shaf...

Page 735: ...onizer ring 2 6 Drive in high speed synchronizer sleeve hub assembly 3 using special tool and hammer facing long flange side of hub to 3rd gear NOTE While press fitting sleeve hub make sure that synch...

Page 736: ...ng puller 5 to 2nd gear 4 and drive out 3rd 4th gear spacer 2 and 3rd gear 3 together with 2nd gear from countershaft 1 using hydraulic press Take out needle bearing of resin cage type from countersha...

Page 737: ...ert 3 keys 2 in it and then set springs 1 as shown in the figure NOTE No specific direction is assigned to each key but it is assigned as sleeve hub assembly Size of low speed synchronizer keys and sp...

Page 738: ...il to bearing With synchronizer outer ring 3 center cone 4 and inner ring 5 put together and installed to 2nd gear 6 as shown in the figure 8 Press fit 3rd gear 2 and spacer 1 using special tools and...

Page 739: ...each chamfered tooth of gear and synchronizer ring and replace with new one if necessary Also check gear tooth Difference b between synchronizer outer ring and inner ring Standard 1 0 1 4 mm 0 039 0...

Page 740: ...reverse gear shift arm facing slit A toward 5th gear side Gear Shift Shaft and Fork Inspection S4RS0A5206037 Using feeler gauge check clearance between fork 1 and sleeve 2 and replace those parts if...

Page 741: ...gear 4 Using special tool and hammer drive out differential pinion shaft pin and then disassemble component parts Special tool C 09922 85811 1 Differential pinion washer 8 Final gear 2 Differential si...

Page 742: ...e gear up and down by hand and read dial gauge 2 If thrust play is out of specification select suitable thrust washer from among the following available size install it and check again that specified...

Page 743: ...ain plug 21 2 1 15 5 Transaxle oil level filler plug 21 2 1 15 5 VSS bolt 5 0 5 4 0 Cable bracket bolt 55 5 5 40 0 Back up lamp switch 23 2 3 17 0 Gear shift guide case bolt 23 2 3 17 0 Select lever b...

Page 744: ...d service material is also described in the following Gear Shift Control Lever and Cable Components Gear Shift and Select Shaft Assembly Components Manual Transaxle Assembly Components Input Shaft and...

Page 745: ...5 mm Bearing puller 20 35 mm 09923 78210 09924 07710 Bearing installer Synchronizer hub installer 09924 07730 09924 74510 Bearing installer Bearing and oil seal handle 09924 84510 004 09925 15410 Bear...

Page 746: ...60 09930 30104 Gear holder Sliding shaft 09940 51710 09940 54910 Bearing installer Front fork oil seal install driver 09941 64511 09951 16060 Bearing and oil seal remover 30 mm Min Control arm bush re...

Page 747: ...t the peripheral edge part of the spring pushes on the pressure plate against the flywheel with the disc in between when the clutch release bearing is held back This is the engaged condition of the cl...

Page 748: ...r replace Clutch vibration Glazed glass like clutch facings Repair or replace disc Clutch facings dirty with oil Replace disc Release bearing slides unsmoothly on input shaft bearing retainer Lubricat...

Page 749: ...play B Max 3 mm 0 12 in 2 If B is not within specification replace master cylinder 3 or pedal arm 2 Clutch Release Margin C 1 Pull up parking brake fully and block wheels 2 Start engine and keep engi...

Page 750: ...rating cylinder 3 Attach a vinyl tube 1 to bleeder plug 4 and insert the other end into container 2 3 Depress clutch pedal several times and then while holding it depressed push snap ring 2 and pull p...

Page 751: ...der reservoir cap 2 Take out fluid with syringe or such from brake master cylinder reservoir 3 Pull clamp 1 of master cylinder and push clamp 5 of operating cylinder and then disconnect clutch fluid p...

Page 752: ...take out fluid with syringe or such from brake master cylinder reservoir 2 Disconnect clutch fluid pipe from clutch master cylinder 1 referring to Clutch Fluid Pipe Removal and Installation 3 Disconne...

Page 753: ...Pedal Bracket Components S4RS0A5306007 A I4RS0A530011 1 7 2 10 5 b 8 9 a 3 a A A 5 A 6 4 11 I4RS0A530012 1 Clutch pedal bracket 8 Clutch pedal Apply grease 99000 25010 to outside surf of pin 2 Pedal b...

Page 754: ...4 a b b A A A 12 11 5 6 A 3 A 4 7 10 2 9 8 1 I4RS0A530013 1 Flywheel 9 Clutch disc 2 Flywheel bolt 10 Clutch cover bolt 3 Clutch release shaft seal Apply grease 99000 25010 to seal lip 0 3 g 0 01 oz 1...

Page 755: ...10 3 Aligning clutch disc to flywheel center using special tool install clutch cover 1 and bolts 2 Then tighten bolts 2 to specification NOTE While tightening clutch cover bolts compress clutch disc w...

Page 756: ...9 in Limit 0 5 mm 0 02 in Clutch Cover 1 Check diaphragm spring 1 for abnormal wear or damage 2 Inspect pressure plate 2 for wear or heat spots 3 If abnormality is found replace clutch cover Do not di...

Page 757: ...pecial tool as in removal A Grease 99000 25010 Special tool A 09922 46010 4 Coat grease to release shaft seal 2 lip and then install it till it is flush with case surface Use special tool for this ins...

Page 758: ...ease shaft and its pin for deflection or damage If abnormality is found replace it Specifications Tightening Torque Specifications S4RS0A5307001 NOTE The specified tightening torque is also described...

Page 759: ...ial SUZUKI recommended product or Specification Note Brake fluid DOT 3 DOT 3 Grease SUZUKI Super Grease A P No 99000 25010 SUZUKI Silicone Grease P No 99000 25100 SUZUKI Super Grease I P No 99000 2521...

Page 760: ...5C 14 Clutch...

Page 761: ...ing Lamp Check 6C 5 DTC Check 6C 6 DTC Clearance 6C 6 DTC Table 6C 6 Scan Tool Data 6C 8 P S System Symptom Diagnosis 6C 9 Serial Data Link Circuit Check 6C 9 EPS Warning Lamp Does Not Come ON at Igni...

Page 762: ...6 ii Table of Contents Special Tool 6C 38...

Page 763: ...m Service Warning Refer to Air Bag System Service Warning in Section 00 Precautions for Steering Diagnosis Refer to Precautions for Steering Diagnosis in Section 6A Service Precautions of Steering Whe...

Page 764: ...complaint To avoid using the wrong symptom always road test the vehicle first Proceed with the following preliminary inspection and correct any defects which are found 1 Inspect tires for proper pres...

Page 765: ...ar case assembly Tires not adequately inflated Adjust tire pressure Rack and pinion adjustment Check and adjustment rack and pinion torque Rack and pinion noise Rattle or chuckle Loose steering gear c...

Page 766: ...al of Air Bag and Seat Belt Pretensioner in Section 8B Diagnostic Information and Procedures Checking Steering Column for Accident Damage S4RS0A6204003 NOTE Vehicles involved in accidents resulting in...

Page 767: ...ngth and impair the collapsible design of the column 1 Disconnect negative battery cable at battery terminal 2 Disable air bag system referring to Disabling Air Bag System in Section 8B 2 1 2 3 4 7 5...

Page 768: ...coil fitted in 2 lugs 2 in the back of steering wheel and also aligning marks 3 on steering wheel and steering shaft 3 Tighten steering shaft nut 4 to specified torque Tightening torque Steering shaft...

Page 769: ...and lower cover 2 4 Install steering wheel to steering column Refer to Steering Wheel Removal and Installation 5 Connect battery negative cable 6 Enable air bag system referring to Enabling Air Bag Sy...

Page 770: ...ring column simply to gain access to instrument panel components leave steering wheel installed on steering column Removal WARNING Never rest a steering column assembly on the steering wheel with the...

Page 771: ...en joint bolt steering column side 5 to specified torque CAUTION After tightening column nuts tighten steering shaft upper joint bolt Otherwise shaft joint bearing is damaged Tightening torque Steerin...

Page 772: ...to LOCK position and remove key 3 Remove steering joint cover 4 Make alignment marks 4 on lower shaft 1 and shaft joint of steering column 2 and lower shaft 1 and pinion shaft 3 for a guide during rei...

Page 773: ...olumn Construction Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Special Tools and Equipment Special Tool S4RS0A6208002 Fas...

Page 774: ...is at ON position and engine is not running but it means there is nothing abnormal if indication changes to a normal one when engine is started As DTC is stored in memory of the P S control module be...

Page 775: ...tem This is only to check if the EPS warning lamp is operated properly If the areas monitored by the P S control module is free from any trouble after the engine start while engine is running the EPS...

Page 776: ...5 E52 11 E52 14 E52 12 E51 1 E51 2 E52 18 E52 6 E52 8 E52 20 E52 9 E52 16 E52 19 E49 2 E49 1 BLK GRN 5V 1 2 B 1 2 C 12V PPL GRY PPL WHT 12V GRN BLK G28 25 G28 31 RED BLK 10 9 8 7 6 5 4 3 2 1 16 15 14...

Page 777: ...omer if possible 3 Check for operation of the EPS warning lamp referring to EPS Warning Lamp Check 4 Check for DTC referring to DTC Check and then record DTC s 5 Clear DTC if any DTC exists referring...

Page 778: ...Turn ignition switch to ON position but without running engine and check if the EPS warning lamp 1 lights up If the lamp dose not light up go to EPS Warning Lamp Does Not Come ON at Ignition Switch ON...

Page 779: ...tions displayed on SUZUKI scan tool For further details refer to operator s manual for SUZUKI scan tool 5 After completing the clearance turn ignition switch to OFF position and disconnect SUZUKI scan...

Page 780: ...ore than 4000 rpm engine speed before a lapse of 5 minutes from the engine start 2 More than 30 seconds pass at more than 2500 rpm engine speed after a lapse of 5 minutes from the engine start 3 drivi...

Page 781: ...or that assist amount This parameter indicates that control value MOTOR MON This parameter indicates the actually measured value of the current flowing to the motor The motor circuit condition is diag...

Page 782: ...orque Sensor Inspection Poor performance of motor Check motor referring to Motor Assembly Inspection Steering gear case assembly faulty Replace Poor performance of VSS Check VSS referring to DTC P0500...

Page 783: ...embly if equipped or SDM or other vehicles Is it possible to communicate with the other controllers Go to Step 4 Repair open in common section of serial data circuit PPL WHT wire circuit used by all c...

Page 784: ...4 23 22 21 20 19 18 17 32 31 30 29 28 27 C 7 3 2 5 6 4 4 4 4 1 4 I4RS0B630005 A Connector E52 viewed from harness side 2 Ignition switch 6 EPS warning lamp B Connector E49 viewed from harness side 3 J...

Page 785: ...ignition switch turned OFF 2 Check for proper connection to the combination meter at G28 31 terminal 3 If OK check voltage between G28 31 RED BLK wire terminal and body ground with ignition switch ON...

Page 786: ...3 2 5 6 4 4 4 4 1 4 I4RS0B630005 A Connector E52 viewed from harness side 2 Ignition switch 6 EPS warning lamp B Connector E49 viewed from harness side 3 Junction block assembly 7 P S control module...

Page 787: ...S control module B Connector E49 viewed from harness side 3 Junction block assembly 6 Torque sensor 1 Main fuse 4 Fuse 7 Torque sensor amplifier DTC detecting condition Trouble area DTC C1113 Differe...

Page 788: ...sensor Is check result in good condition Go to Step 4 Repair WHT BLU and or YEL wire circuit for P S control module to torque sensor 4 1 Check torque sensor and its circuit referring to Torque Sensor...

Page 789: ...re and or DTC C1155 P S Control Module Failure Go to Step 3 3 1 Remove console box 2 Check P S control module connector E52 for proper connection 3 If OK turn ignition switch ON 4 Check for voltage be...

Page 790: ...ide 2 Ignition switch 5 P S control module B Connector E49 viewed from harness side 3 Junction block assembly 6 Torque sensor 1 Main fuse 4 Fuse 7 Torque sensor amplifier DTC detecting condition Troub...

Page 791: ...e P S control module Is it about 12 V Go to Step 4 Repair high resistance open or short to power circuit or ground in 12 V power supply GRN wire circuit 4 1 Check torque sensor and its circuit referri...

Page 792: ...1 E52 5 E52 4 E49 2 E49 1 BLK GRN GRN BLK G28 25 G28 31 RED BLK 1 2 B A 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 26 25 24 23 22 21 20 19 18 17 32 31 30...

Page 793: ...hicle speed is inputted to P S control module as having decelerated by more than specified deceleration and lower than 5 km h vehicle speed continued for 5 seconds after deceleration 1 driving cycle d...

Page 794: ...tem Check performed Go to Step 2 Go to EPS System Check 2 1 Clear DTC s referring to DTC Clearance 2 Turn the ignition switch to OFF position 3 Check if any DTC is detected referring to DTC Check Is D...

Page 795: ...harness side 2 Ignition switch 5 P S control module C Connector E51 viewed from harness side 3 Junction block assembly 6 P S motor DTC detecting condition Trouble area DTC C1141 Voltage at E51 1 termi...

Page 796: ...nnector E51 connected to the P S control module Are they 5 7 V with steering wheel at straight position Go to Step 4 Repair poor connection high resistance open or short to power circuit or ground in...

Page 797: ...Section 1J 3 1 With ignition switch OFF disconnect P S control module connector E49 2 Check for proper connection to the P S control module at E49 2 BLK wire terminal 3 If OK then check for high resi...

Page 798: ...16 17 18 19 20 5 3 4 4 4 4 1 2 I4RS0B630010 A Connector E52 viewed from harness side 2 Ignition switch 5 P S control module B Connector E49 viewed from harness side 3 Junction block assembly 1 Main f...

Page 799: ...harness side C Connector E49 viewed from harness side Terminal Wire color Circuit Normal voltage Condition E49 1 GRN P S control module power supply from battery 10 14 V E49 2 BLK Ground E51 1 BLK Mo...

Page 800: ...a link connector E52 12 BRN Engine speed signal Indicator deflection repeated 0 1 V and 6 10 V Engine idling E52 13 E52 14 RED BLU P S signal About 5 V Ignition switch ON Engine idling and turning ste...

Page 801: ...for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness Steering wheel play a 0 30 mm 0 1 18 in Steering Force Check S4RS0A6304003 1 Place vehi...

Page 802: ...45 N m 4 5 kg m 32 5 lb ft 4 Band 13 Steering gear case mounting bracket 55 N m 5 5 kg m 40 0 lb ft 5 Boot 14 Steering rack plunger Apply grease 99000 25010 to rack plunger 40 N m 4 0 kg m 29 0 lb ft...

Page 803: ...er 3 4 For ease of adjustment after installation make marking 1 of tie rod end lock nut 2 position on tie rod end thread Then loosen lock nut and remove tie rod end 3 from tie rod 4 Installation 1 Ins...

Page 804: ...emoval and Installation S4RS0A6306013 Removal CAUTION Be sure to set front wheels tires in straight direction and remove ignition key from key cylinder before performing the following steps otherwise...

Page 805: ...torque Steering gear case mounting No 1 bolt a 55 N m 5 5 kg m 40 0 lb ft Steering gear case mounting No 3 bolt b 40 N m 4 0 kg m 29 0 lb ft 2 Install front suspension frame with steering gear case as...

Page 806: ...steering rack and pinion to produce noise as well as rust to result in malfunction of steering system If even a small tear is noted replace with new one Also check each boot for dent If there is a den...

Page 807: ...ar case or rack side mount and tie rod After this check to ensure that boot is free from twist and dent A Sealant 99000 31120 5 Fasten boot with new band and clip securely Special tool A 09943 55010 6...

Page 808: ...back by 10q or less by the specified procedure 4 Pinion rotation torque should be checked with rack position centered Also check if rack as a whole moves smoothly Special tool A 09944 18310 Tightening...

Page 809: ...en terminal of motor connector E51 and body ground If check result is not as specified replace steering gear case assembly Motor circuit resistance 5 Connect battery 1 between E51 1 and E51 2 Check if...

Page 810: ...ft Tie rod end nut 45 4 5 32 5 Tie rod end lock nut 45 4 5 32 5 Wheel bolt 85 8 5 61 5 Steering gear case mounting No 1 bolt 55 5 5 40 0 Steering gear case mounting No 3 bolt 40 4 0 29 0 Engine rear m...

Page 811: ...n Note Grease SUZUKI Super Grease E P No 99000 25050 Sealant Silicone Sealant P No 99000 31120 Thread lock cement Thread Lock Cement Super 1322 P No 99000 32110 09943 55010 09944 18310 Boot clamp plie...

Page 812: ...6C 39 Power Assisted Steering System...

Page 813: ...7B 5 Major Components of A C System 7B 5 A C System Wiring Diagram 7B 6 Diagnostic Information and Procedures 7B 7 A C System Symptom Diagnosis 7B 7 Abnormal Noise Symptom Diagnosis of A C System 7B 9...

Page 814: ...ecautions on HVAC S4RS0A7000001 Air Bag Warning Refer to Air Bag Warning in Section 00 A C System Caution Refer to A C System Caution in Section 7B Precautions on Servicing A C System Refer to Precaut...

Page 815: ...Construction S4RS0A7101001 I4RS0A710001 1 HVAC unit 6 Foot air 11 Center ventilation air 2 Ventilator duct 7 Front defroster air 12 Air intake door 3 Defroster nozzle 8 Side defroster air 13 Blower mo...

Page 816: ...3 G18 4 G18 7 G18 8 G18 10 G18 13 G19 2 G19 3 G19 7 G19 6 G19 1 G18 9 G18 14 BLK WHT YEL BLU WHT RED RED BLK RED GRN BRN BLK RED RED YEL BLK BLK YEL BLK ORN 10A 10A 4 6 10 8 9 M I4RS0A710002 1 Igniti...

Page 817: ...rol door assembly broken Repair temperature control door assembly Air ducts clogged Repair air ducts Heater core leaked or clogged Replace heater core Heater hoses leaked or clogged Replace heater hos...

Page 818: ...t 6 Foot duct 11 Blower motor 16 Drain hose 2 Blower upper case 7 Airflow control door assembly 12 Heater unit lower case 17 Packing 3 Air intake control actuator 8 Temperature control door assembly 1...

Page 819: ...stem referring to Enabling Air Bag System in Section 8B Blower Motor Removal and Installation S4RS0A7106003 Removal 1 Disconnect negative cable from battery 2 Disable air bag system referring to Disab...

Page 820: ...ew 2 7 Remove connector 1 from blower motor resistor 2 and then remove blower motor resistor from HVAC unit by removing screws 3 Installation Reverse removal procedure noting the following instruction...

Page 821: ...sembly Removal and Installation in Section 9C 5 Remove foot duct 1 from HVAC unit by removing screw 2 6 Disconnect temperature control cable 1 and airflow control cable 2 from HVAC unit 7 Remove two c...

Page 822: ...ble 2 to pin of airflow control plate and then fix each outer cable 3 to each cable lock clamp NOTE After installing control cables make sure that control lever and plate move smoothly and stop at pro...

Page 823: ...air intake control actuator 2 from HVAC unit Installation Reverse removal procedure noting the following instruction Be sure to insert the linkage pin 1 into the groove 2 of air intake control actuato...

Page 824: ...ilation Louver Removal and Installation S4RS0A7106015 Right side ventilation louver Removal 1 Disconnect negative cable from battery 2 Disable air bag system referring to Disabling Air Bag System in S...

Page 825: ...e smallest clip to the top Air Filter Removal and Installation S4RS0A7106023 Removal 1 Remove glove box from instrument panel 2 Remove air filter cover 1 from HVAC unit 3 Pull out air filter from HVAC...

Page 826: ...e in parts or other faulty condition Precautions on Servicing A C System S4RS0A7200004 WARNING Should refrigerant HFC 134a R 134a is exposed to your eye s consult a doctor immediately Do not use your...

Page 827: ...rring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge Refrigerant Recovery When discharging refrigerant out of A C system always recover it by using refrigerant recovery a...

Page 828: ...201004 In the sub cool A C system condenser integrated with receiver dryer the inside of the condenser is divided into the condensation part and the sub cooler part and the receiver dryer is located b...

Page 829: ...720051 A Liquid 2 Magnet clutch 6 Expansion valve 10 Desiccant B Vapor 3 Condenser 7 A C evaporator 11 Filter C Superheated vapor 4 Receiver dryer 8 Condensation part 12 Vapor refrigerant 1 Compressor...

Page 830: ...ts of A C system I4RS0A720003 7 2 3 4 1 8 6 5 I4RS0A720004 1 HVAC 5 Discharge hose 9 Side ventilation air 13 Side defroster air 2 Compressor 6 Suction hose 10 Center ventilation air 14 Fresh air 3 Con...

Page 831: ...G18 4 G18 7 G18 8 G18 10 G18 13 G18 5 G18 6 G19 5 G19 2 G19 3 G19 7 G19 6 G19 1 G18 9 G18 14 BLK WHT YEL BLU WHT RED BRN WHT GRN WHT RED BLK RED GRN BRN BLK RED RED YEL BLK BLK YEL BLK ORN 10A 10A 4 6...

Page 832: ...erring to Magnet Clutch Inspection Compressor drive belt loosened or broken Adjust or replace drive belt Compressor faulty Check compressor Compressor relay faulty Check compressor relay referring to...

Page 833: ...motor referring to Blower Motor Inspection in Section 7A Excessive compressor oil in A C system Drain excessive compressor oil from A C system circuit and compressor Cool air does not come out only i...

Page 834: ...le is heard at low engine rpm Loose compressor clutch plate bolt Retighten clutch plate bolt Replace compressor if it was operated in this condition for a long time Condition Possible cause Correction...

Page 835: ...ed 6 Turn A C switch ON set blower speed selector at maximum speed position temperature selector at maximum cold position airflow selector at face position and air intake switch at recirculation posit...

Page 836: ...ining if pressures are normal or not Low side and high side pressure example Gauges should read as follows when ambient temperature is 30 qC 86 qF Pressure on high pressure gauge HI 1240 1520 kPa 12 4...

Page 837: ...ooling fan Dirty or bent condenser fins Insufficient cooling of condenser Clean or repair Compressor malfunction Insufficient oil etc Check compressor Engine overheat Check engine cooling system refer...

Page 838: ...eck compressor Temp at Air Outlet of Center Ventilation Louver 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 46 4 48 2 50 0 51 8 53 6 55 4 57 2 59 0 60 8 62 6 64 4 66 2 68 0 69 8 71 6 7...

Page 839: ...cuate the system 0 4 0 6 4 6 56 9 85 3 Pressure on low pressure side is high Pressure on high pressure side is low Both pressure becoming equal right after A C is turned OFF Internal leak in compresso...

Page 840: ...ected from ECM 1 Remove ECM from its bracket referring to Engine Control Module ECM Removal and Installation in Section 1C 2 Connect ECM couplers to ECM 3 Check voltage at each terminal NOTE As each t...

Page 841: ...N blower fan selector at 2nd speed position or more E23 47 GRY A C compressor relay output 10 14 V Engine running A C request signal high input 0 1 V Engine running A C request signal low input E23 54...

Page 842: ...s possible from a doctor or eye specialist Should the liquid refrigerant HFC 134a R 134a is exposed to your skin the affected area should be treated in the same manner as when skin is frostbitten or f...

Page 843: ...replacing any component replenish the same amount of measured oil when recovering refrigerant if not measure replenish 30 cm3 30 cc oil When replacing compressor CAUTION Be sure to use P N 99000 9901...

Page 844: ...0 kPa 1 0 kg cm2 760 mmHg 14 7 psi providing no leakage exists NOTE If the system does not show a vacuum below 100 kPa 1 0 kg cm2 760 mmHg 14 7 psi close both valves stop vacuum pump and watch movemen...

Page 845: ...The air conditioning system contains HFC 134a R 134a Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container When charging refrigerant...

Page 846: ...a hole for refrigerant flow 8 After the system has been charged with specified amount 370 r 20 g of refrigerant or when low pressure gauge 1 and high pressure gauge 2 have indicated the following spe...

Page 847: ...ch as sections of the evaporator and condenser an electronic refrigerant leak detector is more practical for determining leaks Special tool A 09990 86011 Condenser Assembly On Vehicle Inspection S4RS0...

Page 848: ...and Installation 2 Remove cap 1 from receiver dryer tank 3 Remove desiccant 2 from receiver dryer tank Installation Reverse the removal procedure noting the following instructions Replenish specified...

Page 849: ...assembly 13 Heater core 19 Evaporator thermistor evaporator temperature sensor 2 Blower upper case 8 Temperature control door assembly 14 Temperature control lever 20 Packing 3 Air intake control act...

Page 850: ...1 to the installation hole uniformly Evacuate and charge the A C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge Adjust control cables referring to HVAC Control...

Page 851: ...porator themistor resistance 0 qC 32 qF 6 6 6 9 k 25 qC 77 qF 1 9 2 3 k Expansion Valve Removal and Installation S4RS0A7206015 Removal 1 Recover refrigerant from the A C system with recovery and recyc...

Page 852: ...ssure measured by manifold gauge 0 8 MPa 8 0 kg cm2 116 psi 1 46 1 71 V 1 4 MPa 14 kg cm2 203 psi 2 28 2 53 V 1 6 MPa 16 kg cm2 232 psi 2 55 2 80 V 1 8 MPa 18 kg cm2 261 psi 2 82 3 03 V A C Refrigeran...

Page 853: ...If any defect is found replace the belt with new one referring to Compressor Drive Belt Removal and Installation Check compressor drive belt tension by measuring how much it deflects when pushed inter...

Page 854: ...dure for Refrigerant Charge 5 Remove compressor drive belt referring to Compressor Drive Belt Removal and Installation 6 Remove right side engine under cover 7 Disconnect magnet clutch lead wire coupl...

Page 855: ...t clutch coil resistance Standard 3 5 4 0 Magnet Clutch Removal and Installation S4RS0A7206025 Removal 1 Remove compressor from vehicle referring to Compressor Assembly Removal and Installation 2 Fix...

Page 856: ...tion 1 Install magnet clutch coil 2 fitting protrusion 4 of magnet clutch coil onto hole 5 of compressor 3 2 Install new circlip 1 directing chamfer side 6 downward Special tool B 09900 06107 3 Apply...

Page 857: ...net clutch pulley are not in contact f Read stroke of magnet clutch plate from dial gauge by performing step d and e repeatedly Stroke of magnet clutch plate is clearance between magnet clutch plate a...

Page 858: ...ge in Operation Procedure for Refrigerant Charge Specifications Tightening Torque Specifications S4RS0A7207001 NOTE The specified tightening torque is also described in the following Compressor Assemb...

Page 859: ...also described in the following Precautions on Servicing A C System Special Tool S4RS0A7208002 Material SUZUKI recommended product or Specification Note Compressor oil Compressor oil MATSUSHITADENKI D...

Page 860: ...7B 35 Air Conditioning System...

Page 861: ...13 AIR BAG Warning Lamp Does Not Come ON 8B 15 AIR BAG Warning Lamp Flashes 8B 17 DTC B1013 SDM fault 8B 18 DTC B1014 AIR BAG Warning Lamp Circuit Failure 8B 18 DTC B1016 Power Source Voltage High 8B...

Page 862: ...Circuit 8B 99 Inspection of Intermittent and Poor Connections 8B 101 Repair and Inspection Required after Accident 8B 102 Repair Instructions 8B 105 Disabling Air Bag System 8B 105 Enabling Air Bag S...

Page 863: ...utions on Service and Diagnosis of Seat Belt in Section 8A Precautions on Service and Diagnosis of Air Bag System Refer to Precautions on Service and Diagnosis of Air Bag System in Section 8B Precauti...

Page 864: ...te Do not bleach or dye belt webbing Use only mild soap and lukewarm water to clean it When installing a seat belt anchor bolt it should be tightened by hand at first to prevent cross threading and th...

Page 865: ...er The seat belt with ELR and a pretensioner has a pretensioner mechanism which operates in linkage with the air bag in addition to the described ELR The pretensioner is incorporated in retractor asse...

Page 866: ...e sure to read Precautions on Service and Diagnosis of Seat Belt before starting to work and observe every precaution during work Neglecting them may result in personal injury or unactivation of the s...

Page 867: ...retractor assembly If any abnormality is found be sure to replace it with new one as an assembly Be sure to read Precautions on Service and Diagnosis of Seat Belt before starting to work and observe e...

Page 868: ...ollowing symptoms and if any one of them is applicable replace it with a new one as an assembly Pretensioner has activated There is a crack in seat belt pretensioner retractor assembly Seat belt prete...

Page 869: ...t Belt before starting to work and observe every precaution during work b a a a a a 3 4 3 6 5 2 1 7 I4RS0A810003 1 Upper anchor 4 Rear center seat belt 7 Rear seat belt 2 Lower anchor 5 Buckle for rea...

Page 870: ...utions on Service and Diagnosis of Seat Belt before starting to work and observe every precaution during work Check the rear seat belt in the same way as Front Seat Belt Inspection As to seat belts wi...

Page 871: ...omponents beforehand to avoid component damage or unintended system activation When handling the air bag inflator modules driver passenger side of both sides and curtain of both sides seat belt preten...

Page 872: ...unlikely event of an accidental deployment WARNING Never attempt to measure the resistance of the air bag inflator modules driver passenger and side of both sides and curtain of both sides It is very...

Page 873: ...e must be placed with its bag trim cover facing up place it on the workbench with a slit 1 or use the workbench vise 2 to hold it securely at its lower mounting bracket 3 It is also prohibited to plac...

Page 874: ...sult Deployed Air Bag Inflator Module and Activated Seat Belt Pretensioner WARNING The air bag inflator module and seat belt pretensioner immediately after deployment activation is very hot Wait for a...

Page 875: ...n substances that can cause severe illness or personal injury if the sealed container is damaged during disposal General Description Air Bag System Construction S4RS0A8201001 With the air bag system w...

Page 876: ...o protection in those types of accidents Air Bag System Input Output Table S4RS0A8201002 I2RH0B820007 INPUT Sensor in SDM and forward sensor Driver side air bag and Driver side curtain air bag Passeng...

Page 877: ...0 L29 21 PC PC L41 23 16 15 14 L29 SP SP G26 L32 L03 E44 E13 12 GRY RED GRY GRY RED GRY L29 49 L29 50 FD FD 3 4 BLU ORN BLU ORN GRN RED BLK I4RS0A820006 A Shorting bar 8 BCM 17 Passenger air bag infla...

Page 878: ...9 7 DP Driver seat belt pretensioner L29 32 L29 8 PP Passenger seat belt pretensioner L29 33 L29 9 PP Passenger seat belt pretensioner L29 34 L29 10 DS Driver side air bag If equipped L29 35 L29 11 DS...

Page 879: ...r Bag System 8B 9 Component Location Air Bag System Components Wiring and Connectors Location S4RS0A8203001 5 2 10 a b b b b c d 1 1 2 3 4 5 6 7 8 8 8 9 10 11 11 12 12 11 12 13 13 13 15 14 I4RS0A82000...

Page 880: ...Check Flow after any repair or diagnostic procedures have been performed Performing the Air Bag Diagnostic System Check Flow after all repair or diagnostic procedures will ensure that the repair has...

Page 881: ...B1021 SDM Front air bag module exploded B1024 Driver side air bag module exploded B1025 Passenger side air bag module exploded B1026 Pretensioner activated B1027 Reusable number exceeded B1031 Driver...

Page 882: ...connector DLC 1 in the same manner as when making this connection for DTC check Special tool A SUZUKI scan tool 3 Turn ignition switch to ON position 4 Erase DTC according to instructions displayed on...

Page 883: ...cates the resistance of the driver side air bag initiator circuit Pass Sidebag Ini Res Passenger side air bag initiator resistance ohm This parameter indicates the resistance of the Passenger side air...

Page 884: ...cuit between AIR BAG warning lamp circuit and ground Troubleshooting Step Action Yes No 1 1 Turn ignition switch OFF 2 Remove and inspect AIR BAG fuse Is fuse good Go to Step 2 RED wire short to groun...

Page 885: ...nal L29 1 3 If OK then check resistance between BLU ORN wire terminal of combination meter connector G28 and L29 1 terminal of SDM connector Special tool A 09932 76010 Is resistance 1 or less Substitu...

Page 886: ...ning lamp circuit Troubleshooting NOTE Upon completion of inspection and repair work perform the following items Reconnect all air bag system components and ensure all components are properly mounted...

Page 887: ...diagnosis switch circuit and ground Troubleshooting NOTE Upon completion of inspection and repair work perform the following items Reconnect all air bag system components and ensure all components ar...

Page 888: ...r connection is required refer to Inspection of Intermittent and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness c...

Page 889: ...mittent and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly Step Action Yes...

Page 890: ...orrected Step Action Yes No 1 1 With ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at L29 26 terminal 3 If OK turn ignition switch ON and then check voltage between L29...

Page 891: ...onnector and terminal as an assembly DTC Will Set when The power source voltage is below an approx 8 V for specified time Flow Test Description Step 1 Check if voltage on battery is within normal rang...

Page 892: ...d body ground Special tool A 09932 76010 Is voltage 8 V or more Go to Step 4 Go to step 3 3 1 With ignition switch OFF disconnect on connector L04 junction block assembly 2 Check proper connection at...

Page 893: ...Clearance in Section 10B DTC B1024 B1025 Side Air Bag Driver Passenger Deployed S4RS0A8204069 DTC Will Set when The SDM detects a sideward crash driver or passenger side of sufficient force to warrant...

Page 894: ...g items Reconnect all air bag system components and ensure all components are properly mounted Repeat Air Bag Diagnostic System Check to confirm that the trouble has been corrected Clear DTCs of BCM r...

Page 895: ...it in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The combined resistance of the driver air bag inf...

Page 896: ...the steering column 2 Check proper connection to contact coil at terminal in G26 connector 3 If OK then connect special tools B and C to G26 connector disconnected in Step 1 Special tool B 09932 75010...

Page 897: ...n connect special tools B and D to L32 connector Special tool B 09932 75010 D 09932 77320 4 Check SDM DTC NOTE At this time DTC B1041 may be output but it is not related to this check With ignition sw...

Page 898: ...e tool 1 included in special tool A 4 Measure resistance between L29 2 and L29 3 terminals with connected special tools B and D Special tool A 09932 76010 B 09932 75010 D 09932 77320 Is resistance 3 8...

Page 899: ...r module from steering wheel referring to Driver Air Bag Inflator Module Removal and Installation 3 Check proper connection to driver air bag inflator module connector 4 If OK then connect special too...

Page 900: ...ined resistance of the driver air bag inflator module contact coil assembly harness wiring and connector terminal contact is below a specified value for specified time Flow Test Description Step 1 Che...

Page 901: ...the steering column 2 Check proper connection to contact coil at terminal in G26 connector 3 If OK then connect special tools B and C to G26 connector disconnected in Step 1 Special tool B 09932 75010...

Page 902: ...tools B and D to L32 connector Special tool B 09932 75010 D 09932 77320 4 Check SDM DTC NOTE At this time DTC B1041 may be output but it is not related to this check With ignition switch ON is DTC B10...

Page 903: ...in special tool A 4 Measure resistance between L29 2 and L29 3 terminals with connected special tool B and D Special tool A 09932 76010 B 09932 75010 D 09932 77320 Is resistance 2 1 or more Substitut...

Page 904: ...odule from steering column referring to Driver Air Bag Inflator Module Removal and Installation 3 Check proper connection to driver air bag inflator module connector 4 If OK then connect special tools...

Page 905: ...n assembly DTC Will Set when The voltage measured at driver air bag initiator circuit is below a specified value for specified time Flow Test Description Step 1 Check whether malfunction is in contact...

Page 906: ...the steering column 2 Check proper connection to contact coil at terminal in G26 connector 3 If OK then connect special tools B and C to G26 connector disconnected in Step 1 Special tool B 09932 75010...

Page 907: ...then connect special tools B and D to L32 connector Special tool B 09932 75010 D 09932 77320 4 Check SDM DTC NOTE At this time DTC B1041 may be output but it is not related to this check With ignition...

Page 908: ...tool 1 included in special tool A 3 Measure resistance between L29 2 terminal and body ground and between L29 3 terminal and body ground Special tool A 09932 76010 B 09932 75010 D 09932 78340 Are resi...

Page 909: ...odule from steering column referring to Driver Air Bag Inflator Module Removal and Installation 3 Check proper connection to driver air bag inflator module connector 4 If OK then connect special tools...

Page 910: ...d damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at driver air bag initiator circuit is above a specified value for specified time Flow T...

Page 911: ...the steering column 2 Check proper connection to contact coil at terminal in G26 connector 3 If OK then connect special tools B and C to G26 connector disconnected in Step 1 Special tool B 09932 75010...

Page 912: ...nnect special tools B and D to L32 connector Special tool B 09932 75010 D 09932 77320 4 Check SDM DTC NOTE At this time DTC B1041 may be output but it is not related to this check With ignition switch...

Page 913: ...ded in special tool A 3 Measure voltage from L29 2 terminal to body ground and between L29 3 terminal to body ground Special tool A 09932 76010 B 09932 75010 D 09932 77320 With ignition switch ON is e...

Page 914: ...tor module from steering column referring to Driver Air Bag Inflator Module Removal and Installation 3 Check proper connection to driver air bag inflator module connector 4 If OK then connect special...

Page 915: ...wire harness connector and terminal as an assembly DTC Will Set when The combined resistance of the passenger air bag inflator module harness wiring and connector terminal contact is above a specified...

Page 916: ...ule at terminals in G10 connector 3 If OK then connect special tools A B and D to G10 connector Special tool A 09932 76010 B 09932 75010 D 09932 78310 4 Check SDM DTC With ignition switch ON is DTC B1...

Page 917: ...ial tools B and C to L32 connector disconnected in Step 1 Special tool B 09932 75010 C 09932 77320 4 Check SDM DTC NOTE At this time DTC B1031 may be output but it is not related to this check With ig...

Page 918: ...ct SDM connector L29 2 Check proper connection to SDM at terminals L29 4 and L29 5 3 If OK release shorting bar in SDM connector inserting release too 1 included in special tool A 4 Measure resistance...

Page 919: ...ire harness connector and terminal as an assembly DTC Will Set when The combined resistance of the passenger air bag inflator module harness wiring and connector terminal contact is below a specified...

Page 920: ...ule at terminals in G10 connector 3 If OK then connect special tools A B and D to G10 connector Special tool A 09932 76010 B 09932 75010 D 09932 78310 4 Check SDM DTC With ignition switch ON is DTC B1...

Page 921: ...connector disconnected in Step 1 Special tool B 09932 75010 C 09932 77320 4 Check SDM DTC NOTE At this time DTC B1031 may be output but it is not related to this check With ignition switch ON is DTC...

Page 922: ...Check proper connection to SDM at terminals L29 4 and L29 5 3 If OK release shorting bar in SDM connector inserting release tool 1 included in special tool A 4 Measure resistance between L29 4 and L2...

Page 923: ...ound damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at passenger air bag initiator circuit is below a specified value for specified time...

Page 924: ...ule at terminals in G10 connector 3 If OK then connect special tools A B and D to G10 connector Special tool A 09932 76010 B 09932 75010 D 09932 78310 4 Check SDM DTC With ignition switch ON is DTC B1...

Page 925: ...special tools B and C to L32 connector disconnected in Step 1 Special tool B 09932 75010 C 09932 77320 4 Check SDM DTC NOTE At this time DTC B1031 may be output but it is not related to this check Wi...

Page 926: ...nnect special tools B and C from L32 connector and SDM connector L29 from SDM respectively 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure resista...

Page 927: ...is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at passenger air bag initiator circuit is above a specified value for specified t...

Page 928: ...ule at terminals in G10 connector 3 If OK then connect special tools A B and D to G10 connector Special tool A 09932 76010 B 09932 75010 D 09932 78310 4 Check SDM DTC With ignition switch ON is DTC B1...

Page 929: ...l tools B and C to L32 connector disconnected in Step 1 Special tool B 09932 75010 C 09932 77320 4 Check SDM DTC NOTE At this time DTC B1031 may be output but it is not related to this check With igni...

Page 930: ...tools B and C from L32 connector and SDM connector L29 from SDM respectively 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure voltage from L29 4 t...

Page 931: ...air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The resistance of driver or passenger seat belt pretension...

Page 932: ...etensioner at terminals in L10 or L36 connector 3 If OK then connect special tools A B and C to L10 or L36 connector disconnected in Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78310 4 Che...

Page 933: ...L29 7 for DTC B1051 or L29 8 and L29 9 for DTC B1055 3 If OK release shorting bar in SDM connector inserting release tool 1 included in special tool A 4 Measure resistance between L29 6 and L29 7 term...

Page 934: ...air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The resistance of driver or passenger seat belt pretensione...

Page 935: ...etensioner at terminals in L10 or L36 connector 3 If OK then connect special tools A B and C to L10 or L36 connector disconnected in Step 1 Special tool A 09932 76010 B 09932 75010 C 09932 78310 4 Che...

Page 936: ...DTC B1056 3 If OK release shorting bar in SDM connector inserting release tool 1 included in special tool A 4 If OK then measure resistance between L29 6 and L29 7 terminals for DTC B1052 or L29 8 an...

Page 937: ...r bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at driver or passenger seat belt pretens...

Page 938: ...ace seat belt pretensioner referring to Front Seat Belt Removal and Installation in Section 8A 2 1 With ignition switch OFF disconnect special tools A B and C and SDM connector 2 Release shorting bar...

Page 939: ...t adapter kit When a check for proper connection is required refer to Inspection of Intermittent and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is foun...

Page 940: ...oner referring to Front Seat Belt Removal and Installation in Section 8A 2 1 With ignition switch OFF disconnect special tools A B and C and SDM connector 2 Release shorting bar in SDM connector inser...

Page 941: ...n of Intermittent and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Wi...

Page 942: ...n to driver or passenger side air bag inflator module at terminals in L25 or L30 connector 3 If OK then connect special tools B and C to side air bag inflator module connector disconnected at the Step...

Page 943: ...1 terminals for DTC B1061 or L29 12 and L29 13 terminals for DTC B1065 with connected special tool B and C Special tool A 09932 76010 B 09932 75010 C 09932 78340 Is resistance 2 62 or less Substitute...

Page 944: ...air bag inflator module 3 Check proper connection to side air bag inflator module at terminal in connector 4 If OK then connect special tools A B and C to side air bag inflator connector Special tool...

Page 945: ...arness connector and terminal as an assembly DTC Will Set when The combined resistance of the side air bag inflator module driver or passenger harness wiring and connector terminal contact is below a...

Page 946: ...n to driver or passenger side air bag inflator module at terminals in L25 or L30 connector 3 If OK then connect special tools B and C to side air bag inflator module connector disconnected at the Step...

Page 947: ...DTC B1066 with connected special tools B and C Special tool A 09932 76010 B 09932 75010 C 09932 78340 Is resistance 1 8 or more Substitute a known good SDM and recheck DTC B1062 Repair short from WHT...

Page 948: ...ir bag inflator module at terminal in connector 4 If OK then connect special tools A B and C to side air bag inflator connector Special tool A 09932 76010 B 09932 75010 C 09932 78310 5 Check SDM DTC W...

Page 949: ...damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The voltage measured at side air bag driver or passenger initiator circuit is below a specified value for speci...

Page 950: ...n to driver or passenger side air bag inflator module at terminals in L25 or L30 connector 3 If OK then connect special tools B and C to side air bag inflator module connector disconnected at the Step...

Page 951: ...s 3 1 With ignition switch OFF disconnect special tools B and C then reconnect connector L25 or L30 2 Disconnect side air bag inflator module connector 1 from side air bag inflator module 3 Check prop...

Page 952: ...required refer to Inspection of Intermittent and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damaged replace the wire harness connector and ter...

Page 953: ...n to driver or passenger side air bag inflator module at terminals in L25 or L30 connector 3 If OK then connect special tools B and C to side air bag inflator module connector disconnected at the Step...

Page 954: ...oor harness 3 1 With ignition switch OFF disconnect special tools B and C then reconnect connector L25 or L30 2 Disconnect side air bag inflator module connector 1 from side air bag inflator module 3...

Page 955: ...or S4RS0A8204045 DTC Will Set when Forward sensor abnormal signal is detected by SDM DTC Troubleshooting 1 Turn ignition switch OFF 2 Replace forward sensor referring to Forward Sensor Removal and Ins...

Page 956: ...Step 1 Check for short circuit between forward sensor circuit and ground Step 2 Check if malfunction is in forward sensor DTC Troubleshooting Step Action Yes No 1 1 Disconnect forward sensor connecto...

Page 957: ...kit When a check for proper connection is required refer to Inspection of Intermittent and Poor Connections If there is open circuit in the air bag wire harness connector or terminal is found damaged...

Page 958: ...sured resistance 1 or less Go to Step 2 High resistance or open wire in GRY RED circuit or GRY circuit 2 1 Disconnect service wire from E13 connector 2 Measure voltage between L29 49 terminal and body...

Page 959: ...er or passenger side sensor referring to Side Sensor Removal and Installation 3 Repeat Air Bag Diagnostic System Check DTC B1083 B1093 Driver Passenger Side Sensor Circuit Short to Ground S4RS0A820408...

Page 960: ...sconnect side sensor connector L11 or L35 2 Disconnect SDM connector L29 3 Check proper connection to SDM connector at terminals L29 45 and L29 46 or terminals L29 43 and L29 44 4 Measure resistance b...

Page 961: ...connector or terminal is found damaged replace the wire harness connector and terminal as an assembly DTC Will Set when The resistance measured between side sensor circuit and power source circuit is...

Page 962: ...or open wire in GRN WHT circuit or GRN BLK circuit DTC B1094 High resistance or open wire in GRN YEL circuit or GRN ORN circuit 2 1 Disconnect service wire from L11 or L35 connector 2 Measure voltage...

Page 963: ...System Check to confirm that the trouble has been corrected DTC B1361 B1365 Driver Passenger Side Curtain Air Bag Initiator Circuit Resistance High S4RS0A8204083 Wiring Diagram CAUTION Be sure to per...

Page 964: ...ch OFF remove rear side upper trim of driver or passenger side and disconnect side curtain air bag inflator module connector 2 Check proper connection to side curtain air bag inflator module at termin...

Page 965: ...istance between L29 18 and L29 19 terminals for DTC B1361 or L29 20 and L29 21 terminals for DTC B1365 with connected special tools A B and C Special tool A 09932 76010 B 09932 75010 C 09932 78310 Is...

Page 966: ...tact is below a specified value for specified time Flow Test Description Step 1 Check whether malfunction is in side curtain air bag inflator module Step 2 Check side curtain air bag initiator circuit...

Page 967: ...or L29 20 and L29 21 terminals for DTC B1366 with connected special tools A B and C Special tool A 09932 76010 B 09932 75010 C 09932 78310 Is resistance 1 8 or more Substitute a known good SDM and rec...

Page 968: ...fied value for specified time Flow Test Description Step 1 Check whether malfunction is in side curtain air bag inflator module Step 2 Check side curtain air bag initiator circuit DTC Troubleshooting...

Page 969: ...ody ground for DTC B1363 or L29 20 and body ground and between L29 21 and body ground for DTC B1367 with connected special tools A B and C Special tool A 09932 76010 B 09932 75010 C 09932 78310 Is res...

Page 970: ...value for specified time Flow Test Description Step 1 Check whether malfunction is in side curtain air bag inflator module Step 2 Check side curtain air bag initiator circuit DTC Troubleshooting Step...

Page 971: ...well as not maintaining proper terminal orientation with the component or mating connector Improperly formed or damaged terminals Check each connector terminal in problem circuits carefully to ensure...

Page 972: ...attempt to service the parts below Service of these parts is by replacement only Driver Passenger air bag inflator modules Driver Passenger side air bag inflator modules Driver Passenger side curtain...

Page 973: ...onnector for damage or tightness Contact coil and combination switch assembly Check wire harness and connectors for damage or tightness Check contact coil case for damage Instrument panel member and r...

Page 974: ...ge or fitness Check harness and connector for damage or tightness Seat belts and mounting points Refer to Front Seat Belt Components in Section 8A AIR BAG warning lamp After vehicle is completely repa...

Page 975: ...side air bag inflator module under front seat cushion 3 a Release locking of lock slider b After unlocked disconnect connector 7 If equipped with side curtain air bag inflator module remove quarter in...

Page 976: ...as described perform Air Bag Diagnostic System Check SDM Removal and Installation S4RS0A8206003 WARNING During service procedures be very careful when handling a Sensing and Diagnostic Module SDM Be s...

Page 977: ...nnect a tester whatever type it may be Never repair or disassemble SDM If SDM has been dropped it should be replaced If any faulty condition is found in the following checks replace Check SDM and SDM...

Page 978: ...o specified torque first and then driver air bag inflator module mounting bolt right side 4 to specified torque Tightening torque Driver air bag inflator module mounting bolt a 9 N m 0 9 kg m 6 5 lb f...

Page 979: ...module attaching bolts 1 4 Remove passenger air bag inflator module with air bag hole cover 1 from instrument panel as shown 5 Remove passenger air bag inflator module 1 from air bag hole cover 2 WARN...

Page 980: ...system Refer to Enabling Air Bag System Passenger Air Bag Inflator Module Inspection S4RS0A8206008 WARNING Never measure resistance of passenger air bag inflator module or disassemble it Otherwise per...

Page 981: ...t of the air bag when necessary Removal 1 Disable air bag system Refer to Disabling Air Bag System 2 Roll up the seat surface of the seat back 3 Remove sleeve lock nut 1 from seat back 2 4 Remove side...

Page 982: ...repair the side air bag inflator module If any abnormality is found be sure to replace it with new one as an assembly Be sure to read Precautions on Service and Diagnosis of Air Bag System before star...

Page 983: ...bag inflator module make sure the bag opening is pointed away from you Never carry air bag inflator module by wires or connector on the side of the module In case of an accidental deployment the bag...

Page 984: ...glecting them may result in personal injury or undeployment of the air bag when necessary CAUTION If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be replaced Check...

Page 985: ...er strike or jar a sensor A sensor and mounting bracket bolts must be carefully torqued to assure proper operation Under loose connection it could cause improper operation of the air bag system CAUTIO...

Page 986: ...9 N m 0 9 kg m 6 5 lb ft 3 Connect side sensor connector pushing connector inner 1 as shown 4 Connect negative cable at battery 5 Enable air bag system Refer to Enabling Air Bag System Side Sensor Ins...

Page 987: ...isable air bag system Refer to Disabling Air Bag System 2 Disconnect L32 connector from floor harness located near the glove box 3 Cut off passenger air bag inflator module harness 1 included in instr...

Page 988: ...parts deploy the air bag module s and or activate seat belt pretensioner s installed on vehicle WARNING The following precautions must be observed for this work Failure to observe any of them may resu...

Page 989: ...iver Air Bag Inflator Module Removal and Installation Passenger Air Bag Inflator Module Removal and Installation or Front Seat Belt Removal and Installation in Section 8A WARNING For handing and stora...

Page 990: ...ere there is no activity and sufficient ventilation is provided Ensure no loose or flammable object exists within deployment area b Place driver air bag inflator module 1 with its vinyl trim cover fac...

Page 991: ...lastic reservoir in deployment fixture A with water or sand This is necessary to provide sufficient stabilization of fixture during deployment e Attach side air bag inflator module 1 in deployment fix...

Page 992: ...least 3 times e Clear space 5 on ground about 185 cm 6 ft in diameter where seat belt pretensioner 2 is to be activated Paved outdoor location where there is no activity is preferred If outdoor locati...

Page 993: ...e harness 5 as shown Wire harness specifications Stripped wire harness section 1 25 mm2 0 0019 in 2 or more Stripped wire harness diameter 1 25 mm 0 05 in or more NOTE Wind wire harness 5 around at le...

Page 994: ...lator module or seat belt pretensioner 15 Disconnect deployment harness from 12 volts vehicle battery 2 and short two deployment harness leads together by fully seating one banana plug into the other...

Page 995: ...alled on vehicle NOTE If equipped with the seat belt pretensioners activate both side of seat belt pretensioners at the same time when using special tool C 1 Turn ignition switch to LOCK position remo...

Page 996: ...or module A Connect adapter cable B in series with deployment harness A and push adapter cable B connector to air bag inflator module connector till click can be heard For side air bag inflator module...

Page 997: ...nt harness 2 to 12 volts vehicle battery 3 This will immediately deploy or activate air bag inflator module or seat belt pretensioners 16 Disconnect deployment harness 2 from 12 volts vehicle battery...

Page 998: ...nsioner contains substances that can cause severe illness or personal injury if the sealed container is damaged during disposal Deployed air bag inflator module and the activated seat belt pretensione...

Page 999: ...r with proper use of a scan tool such as Air Bag Driver Passenger Load Tool Connector Test Adapter Kit and the Digital Multimeter Special tool A 09932 76010 Connector Test Adapter Kit This must be use...

Page 1000: ...for side air bag inflator module Side curtain air bag inflator module when it is connected to the floor harness connector for side curtain air bag inflator module Another connector BASE OF COLUMN is...

Page 1001: ...ture Connector test adapter set This set includes the following items 1 Connector test adapter kit 09932 75020 2 Connector test adapter shorting bar release tool 09932 76020 09932 76510 09932 77310 De...

Page 1002: ...is kit includes following items 1 Tech 2 2 PCMCIA card 3 DLC cable 4 SAE 16 19 adapter 5 Cigarette cable 6 DLC loopback adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loop back c...

Page 1003: ...verview 9A 27 Junction Block Inner Circuit Detail 9A 28 System Circuit Diagram 9A 33 System Circuit Diagram 9A 33 A 1 Cranking System Circuit Diagram 9A 34 A 2 Charging System Circuit Diagram 9A 35 A...

Page 1004: ...iagram 9C 2 Component Location 9C 3 Audio System Component Location 9C 3 Diagnostic Information and Procedures 9C 4 Speedometer and VSS Symptom Diagnosis 9C 4 Tacho meter Symptom Diagnosis 9C 4 Engine...

Page 1005: ...tion 9E 9 Rear Door Window Regulator Removal and Installation 9E 10 Rear Door Window Regulator Inspection 9E 11 Rear End Door Window Components 9E 11 Rear End Door Glass Removal and Installation 9E 11...

Page 1006: ...ion 9J 1 Hood Inspection and Adjustment 9J 1 Front Fender Components 9J 2 Front Fender Removal and Installation 9J 2 Front Door Assembly Components 9J 3 Front Door Assembly Removal and Installation 9J...

Page 1007: ...ion 9A Precautions for Body Service S4RS0A9000002 WARNING For vehicles equipped with a Supplemental Restraint Air Bag System When servicing vehicle body if shock may be applied to air bag system compo...

Page 1008: ...ll other switches 2 disconnect the negative terminal wire and then 3 disconnect the positive terminal wire Connect the wires in the reverse order of disconnecting When disconnecting the connectors be...

Page 1009: ...position LHD Left hand drive vehicle COMB Combination LO Low DLC Data link connector MAP Manifold absolute pressure DRL Daytime running light M T Manual transaxle DSL Diesel engine O D Over drive ECM...

Page 1010: ...lighter Motor Pump Horn Speaker Buzzer Chime Condenser Thermistor Reed switch Resistance Variable resistance Transistor NPN PNP GRN Base color GRN Base color YEL Stripe color GRN YEL I2RH01910941 I2R...

Page 1011: ...nger side Driver side Seat heater A C Power steering Side air bag R IYSQ01910939 01 IYSQ01910940 01 IYSQ01910941 01 IYSQ01910942 01 IYSQ01910943 01 IYSQ01910944 01 IYSQ01910945 01 IYSQ01910946 01 IYSQ...

Page 1012: ...window K Interior light harness Rear speaker wire Roof wire L Floor harness G sensor wire Fuel pump harness M Rear bumper harness O Rear end door harness Q Air bag Pretensioner harness R Fuel pump wir...

Page 1013: ...s manual are those when viewed from Z in the illustration Refer to List of Connectors 2 Connector type 3 Terminals in one connector Broken line B15 Terminals in different connectors B14 B16 A40 View Z...

Page 1014: ...YEL Weld ORN WHT BLK J C Weld splice BLK BLK RED YEL RED YEL WHT BLK WHT BLK WHT BLK WHT BLK WHT BLK WHT BLK C C C C C C Weld splice in Connector list J C ORN ORN ORN ORN ORN ORN Weld splice Example I...

Page 1015: ...CTOR LAYOUT DIAGRAM Connector location CROSS REFERENCE CONNECTOR LIST Connector shape and terminal position C02 C02 C02 C02 C02 C02 I2RH01910906 Left side shown 10 11 12 SYSTEM CIRCUIT DIAGRAM GROUND...

Page 1016: ...ith opposite direction within the page You will find the other symbol in the direction of the arrow D Terminals in one connector mark E Wire color F Shield wire G Ground point H From or To With ID let...

Page 1017: ...elay ON OFF 1 15A 6 20A 1 Sensor 1 2 8 BRN RED E52 1 2 E52 1 BRN RED RED 2 BRN RED BRN RED Motor M M 6 5 5 A B A B 5 6 1 2 5 6 4 6 4 4 DOOR 2 DOOR 2 C71 E03 E34 O06 C31 E19 A B C F G H D I K L E33 7 5...

Page 1018: ...1 C33 C29 A T C28 A T C27 A T C30 M T C25 A T C24 C25 M T C26 C07 C06 C05 C04 C22 C21 C20 C23 C13 C12 C14 C08 C01 C C40 C41 C39 C38 C11 I4RS0A910964 No Color Connective position No Color Connective po...

Page 1019: ...eld splice C20 GRY CKP sensor C41 Weld splice No Color Connective position No Color Connective position 5 6 E06 E12 E E03 E07 E09 E08 E13 E10 E11 E05 E04 E01 E02 E19 7 E34 E31 E32 E24 TO C36 E33 E36 E...

Page 1020: ...ht relay E17 BLK Radiator fan motor E35 N Fuel pump relay E18 BLK IF EQPD Front fog light L E36 N A C compressor relay E19 N Side turn signal light L E55 Weld splice No Color Connective position No Co...

Page 1021: ...Connective position G01 YEL Fresh Recircle actuator G20 BLK Data link connector G02 N Keyless receiver G21 N IG switch G03 N Floor harness To L33 G22 N Main switch Key switch G04 YEL Floor harness To...

Page 1022: ...ver side J07 N Power mirror switch Driver side J04 N Front speaker Driver side J08 BLK Power window main switch No Color Connective position No Color Connective position J09 N Floor harness To L03 J13...

Page 1023: ...tion K01 N J B K02 GRY Interior light L48 14 L43 L42 TO O01 L40 L41 L33 TO G03 L32 TO G04 L46 ACC socket wire L02 TO E45 L03 TO E44 L01 L04 L05 L06 L07 TO J01 L08 L09 15 16 L23 A T 17 18 L31 TO J09 L2...

Page 1024: ...r side L34 N Front door switch Passenger side L13 N Rear door wire R To J16 L35 N Side air bag sensor Passenger side L14 N Wheel speed sensor RR L36 BLK Pretentioner Passenger side L15 GRY Fuel pump w...

Page 1025: ...ogger wire O01 TO L42 O02 O03 19 O04 O05 O06 20 I4RS0A910970 No Color Connective position No Color Connective position O01 N Floor harness To L42 O04 N Rear end door lock solenoid O02 BLK Rear defogge...

Page 1026: ...19 Wiring Systems Ground Point Ground earth Point S4RS0A910C001 Refer to Connector Layout Diagram 20 19 13 LHD Shown LH 14 RH 7 3 4 1 2 FWD 5 6 17 8 9 10 FWD FWD RH 11 12 LH 15 16 FWD 18 FWD I4RS0A910...

Page 1027: ...s and the Protected Parts Refer to Fuses in Main Fuse Box Refer to Individual Circuit Fuse Box No 1 Refer to Individual Circuit Fuse Box No 2 In J B Refer to Junction Block J B Connector Fuse Layout R...

Page 1028: ...WHT GRY 14 WHT GRN 19 WHT BLU 20 21 WHT RED WHT BLU 16 15A 15A 30A 50A 30A 30A 30A 30A 15A 15A 15A BLK 2 E26 1 WHT BLU C31 C33 1 1 WHT BLK Main fuse box Starting motor A 1 Generator A 2 Battery 80A 5...

Page 1029: ...ED FUSES AND RELAYS ONLY Relay 1 A 4 E28 Relay 2 A 4 E29 Relay 3 A 4 E30 A 5 E35 Relay Relay D 3 E34 Compressor Relay E 1 E36 A T relay A 6 E33 Main relay A 5 E32 Starting motor relay A 1 E31 IF EQPD...

Page 1030: ...2 28 23 29 37 24 30 38 25 31 39 26 32 40 27 33 41 34 42 35 43 36 44 45 USE THE DESINGNATED FUSES AND RELAYS ONLY I4RS0A910907 No Fuse Description on the cover Protected circuit BLANK BLANK BLANK 15 A...

Page 1031: ...10 A ST SIG Starting motor relay 15 A SEAT HTR BLANK 10 A IG2 SIG Heater relay 15 A RR FOG BLANK 15 A RADIO Audio BCM COMB meter DLC ECM Interior light Luggage compartment light Main switch Key switc...

Page 1032: ...13 15 5 9 8 7 17 6 16 19 18 20 10 6 5 4 3 2 8 1 7 10 9 12 11 3 4 6 5 2 1 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 20 G34 G33 G32 BCM J B side connector 3 4 1 2 5 15 14 1213 1011 9 8 6 7 17 16...

Page 1033: ...5 6 12 14 11 10 15 7 2 1 13 16 9 8 1 2 3 4 5 6 7 8 9 10 4 3 2 1 10 9 8 7 6 5 6 5 4 3 2 1 7 11 10 9 8 15 14 13 12 16 9 8 7 6 5 4 3 2 1 13 12 11 10 17 18 16 15 14 13 14 15 16 9 10 11 12 8 5 6 7 2 3 4 1...

Page 1034: ...P A C PANEL MTR Power etc IMMOBI IG A C PANEL RADIO CLOCK A B SIG COMB SW GND IP SIGNAL GND IP IG Coil etc EPS AT ABS CONT BACK SHIFT STOP SW ABS CONT EPI BUL IN HORN FR TURN R FR TURN L POSI LP EPI F...

Page 1035: ...16 L04 L06 E41 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E39 L05 E40 IMMOBI IG IG1 IG Coil etc E39 E41 E40 BCM G34 G33 G32 K01 L04 L05 L06 IG COIL IG1 15A METER 10A A BAG 1...

Page 1036: ...9 10 E39 L05 E40 E39 E41 E40 BCM G34 G33 G32 K01 L04 L05 L06 11 J B Flasher Relay 7 8 2 5 1 4 6 3 6 12 3 6 9 3 12 1 5 1 19 14 3 18 7 16 2 15 1 10 1 Serial OUT Serial INF DISP HORN SW HORN RELAY GND SW...

Page 1037: ...43 40 42 35 Continued Individual circuit fuse box No 2 In J B 1 2 3 4 Connector No Terminal No BCM J B side connector 3 4 1 2 5 15 14 12 13 10 11 9 8 6 7 17 16 18 21 22 19 20 23 1 2 3 4 5 7 8 11 6 12...

Page 1038: ...8 15 14 13 12 16 L04 L06 E41 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E39 L05 E40 E39 E41 E40 BCM G34 G33 G32 K01 L04 L05 L06 9 J B 10 11 13 12 3 1 16 1 9 1 3 16 15 5 ACC...

Page 1039: ...16 L04 L06 E41 2 1 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 1 2 3 4 5 6 7 8 9 10 E39 L05 E40 E39 E41 E40 BCM G34 G33 G32 K01 L04 L05 L06 J B 9 3 3 20 3 4 Continued GND IP POWER GND BCM SIG GND GND...

Page 1040: ...7 Horn Circuit Diagram Refer to C 1 Combination Meter Circuit Diagram Meter Refer to C 2 Combination Meter Circuit Diagram Indicator Refer to C 3 Combination Meter Circuit Diagram Warning Light Refer...

Page 1041: ...C28 1 4 E31 C23 1 C24 1 Starting motor M OFF ON BLK 1 BLK GRY C31 1 Battery E24 C36 1 RED Individual circuit fuse box No 1 10 30A 36 10A WHT WHT M T E24 C36 1 J B A T E41 10 1 3 2 4 RED WHT 2 ST MOT...

Page 1042: ...rging System Circuit Diagram S4RS0A910E003 4 E24 C36 BLK WHT BLK WHT BLK WHT 80A Main fuse box C22 J B 1 C33 IG COIL 1 15A 23 Generator IC regulator 1 E41 5 C21 2 1 WHT BLU WB BCM A 8 16 WHT BLU BLK W...

Page 1043: ...nition System Circuit Diagram S4RS0A910E004 15A 4 E24 C36 2 C02 1 3 IG COIL 1 C03 BLK BLK WHT GRN YEL BLK WHT J B ECM GY GW 23 IG COIL BLK BLK IG COIL 2 E41 5 3 GRN WHT 1 3 2 C37 5 6 Weld splice C39 B...

Page 1044: ...5 Lg BRN WHT BW BLK YEL BLK YEL BR Relay 1 E28 3 5 BLU RED Relay 2 E29 3 2 1 Relay 3 E30 5 3 1 2 2 4 GRY GRN BLU RED BLU WHT BLU RED BLU RED BLU BLK GRN GRY 30A RDTR FAN 14 E32 4 3 15A FI 5 2 1 5 Main...

Page 1045: ...Weld splice E55 GRN WHT IG COIL J B 5 15A FI BLK YEL E32 4 3 2 1 15A 23 BRN WHT BW 6 10A A C COMP Compressor relay E36 Relay BLU YEL Compressor C17 1 E41 5 E24 C36 3 E24 C36 11 BLK WHT C15 C16 Heated...

Page 1046: ...tle position sensor Weld splice C41 ORN ORN ORN LT GRN GRY 2 1 A 4 3 5 Lg 30A RDTR FAN 14 Relay 1 BLU RED BR 46 1 2 1 29 17 16 2 1 24 25 26 27 4 3 2 1 5 BLK RED 1 2 3 1 3 2 2 3 54 55 RED BLK GRY RED G...

Page 1047: ...5 CKP sensor CMP sensor Vehicle speed sensor BLK ORN BLK ORN TCM C37 BLK 3 15 58 30 C25 2 1 3 3 1 3 2 1 1 2 3 C08 C20 C37 18 19 4 3 20 21 9 PNK RED YEL E23 54 55 C36 E24 10 1 2 3 19 4 RED WHT 49 BLK...

Page 1048: ...A A D E A A PPL WHT PPL WHT PPL WHT PPL WHT YEL GRN WHT RED BLK 9 A PPL E42 PPL J C ECM E39 4 J B 15A RADIO 40 E23 E23 YEL BLK YEL RED RED BLU 13 28 26 20 BLK 2 C37 M T A T 48 GY GW IG COIL 1 IG COIL...

Page 1049: ...Wiring Systems 9A 42 ECM WHT WHT W Starting motor relay A 1 GRN BCM Relay 2 Relay 3 G A 4 E23 48 RED E46 3 18 30 TCM WHT RED 12 13 C34 C37 E23 1 2 7 17 R W E23 I4RS0A910923...

Page 1050: ...BLK BLK 6 3 BLK ORN 18 L24 J C E45 L02 4 J C E43 J C G16 BCM DLC G20 7 G37 5 E46 9 4 BLK BLK 11 BLK J C G15 3 G36 E38 14 E24 C36 15 BLK ORN BLK ORN 5 23 GRN RED BLK 7 E24 C36 19 E41 14 RED BLK PNK 15A...

Page 1051: ...ure control solenoid LT GRN BLK 3 8 Shift solenoid LT GRN BLU BLK 5 ECM WHT RED WHT RED WHT RED E24 C36 18 C37 BLK BLK BLK E39 4 WHT RED 24 C34 7 17 23 1 16 12 13 E23 2 J B 15A RADIO 40 15A AT ETM 7 6...

Page 1052: ...13 28 YEL BLK YB YR E38 G36 14 C36 E24 15 BLK ORN BLK ORN BLK ORN BLK J C E43 J C G16 BCM G37 5 E46 9 16 WHT RED E23 3 G24 1 4 BLK ORN 2 E38 G36 5 15 G33 5 15A RADIO 40 E41 5 YEL RED YEL BLK WHT RED B...

Page 1053: ...12 Receiver 5 PPL WHT PPL WHT A A J C G16 A 5 F 2 F 3 9 E46 PPL WHT ECM E D J C E D E43 PPL WHT PPL WHT P S Cont M ABS Cont M E42 R W PW PPL WHT PW PW PW A 6 TCM E38 G36 14 E24 C36 15 BLK ORN 5 3 J B...

Page 1054: ...temperature sensor B 5 Switch 6 L01 14 16 17 12 5 RED BLK BRN YEL LT GRN BLK BRN GRY WHT GRY Parking brake switch Seat belt switch C 3 RB BY 8 LT GRN A T shift lever A T shift lever 11 5 RED BLK D 4 L...

Page 1055: ...ar J B GRN GRN RED BLU B L09 RED BLU GRN RED BLU GRN RED BLU B 1 10 B E GRN RED RED BLU BLU YEL Rear end L01 4 WHT Rear end door lock switch 3 D 5 BLK YEL L01 Luggage compartment light 7 6 K01 Interio...

Page 1056: ...LK ORN 16 BLK ORN F 1 YEL PPL WHT A B SDM 14 3 16 E41 7 G34 Front position light D 2 D 2 J B RED YEL RED YEL J C L08 L09 C A C Tail light L Licence plate light D 2 Y PW A 2 Generator E46 4 WHT BLU WB...

Page 1057: ...01 3 4 6 BLK E39 3 9 G23 8 Switch 1 13 BLU WHT BLU WHT 5 3 2 BLU RED BLU RED BLU YEL BLU YEL BLU YEL 3 2 4 6 WIPER 15A 28 2 E11 1 G33 1 YEL M M YEL BLU ORN 10 5 BLK OFF ON WF EW P T MIST OFF INT LO HI...

Page 1058: ...4 9 A G23 9 8 1 8 G37 L42 O01 6 E39 9 M WASH OFF INT ON ON WASH WR EW 1R P T BLK BLK BLK 2 E10 1 YEL YEL M YEL RED ORN ORN YEL 20A WIPER J C G15 28 11 12 E37 G35 YEL RED 4 2 3 1 Relay R INT 10 9 BLU B...

Page 1059: ...agram S4RS0A910E012 L42 O01 3 BLK RED O02 1 O06 1 20 1 2 4 3 20A RR DEF 41 Relay 17 BRN G37 17 G33 7 BLK RED BLK RED L05 8 REAR DEF Mode control switch BLK ORN 10 BLK ORN G15 9 J C B B BLK G18 7 8 J B...

Page 1060: ...5 L05 J B 18 BLK BLK 2 13 WHT BLU WHT BLU 1 2 3 4 5 6 RED WHT WHT BLU GRN WHT RED WHT GRN WHT RED WHT GRN WHT GRN YEL BLU YEL RED BLK M GRN J05 UNLOCK LOCK IG DRIVER SWITCH PASSENGER SWITCH REAR R SWI...

Page 1061: ...U WHT GRN 4 12 11 J C L08 L09 J01 L07 1 4 2 1 M GRN RED 1 4 2 1 GRN RED 1 2 3 4 5 6 UNLOCK UP OFF DOWN UP OFF DOWN LOCK IG E RLU RLD Rear L Sub switch M UNLOCK UP OFF DOWN UP OFF DOWN LOCK IG E RRU RR...

Page 1062: ...LT GRN BLK Main switch L01 34 14 9 5 12 22 21 J08 GRY BLK BLK GRY WHT BRN LT GRN BLK GRY GRY WHT 18 UP OFF DOWN LOCK UNLOCK E Receiver G02 G37 LT GRN PNK 14 13 12 3 1 4 UP OFF DOWN LOCK UNLOCK E J01...

Page 1063: ...J20 RED BLU GRN RED BLU GRN RED BLU D L 20A 34 3 M 4 2 B 1 J13 L09 L01 M 1 3 Rear L J25 M B E 25 L31 J09 23 M GRN RED BLU GRN RED BLU GRN RED BLU BLU YEL BLU YEL BCM 1 Switch 6 4 O05 BLK 19 WHT WHT B...

Page 1064: ...1 L07 BLK BLK 18 Switch Motor M M DOWN UP 5 R L 6 Motor M M DOWN UP BLU WHT BLU WHT 1 J B ACC 1 15A 26 31 30 27 31 30 27 L31 J09 LT GRN ORN LT GRN BLK LT GRN LT GRN LT GRN GRN ORN BRN WHT GRN ORN BRN...

Page 1065: ...n Circuit Diagram S4RS0A910E016 BCM 14 A 8 3 B 7 IG 3 3 Flasher relay 10A METER J B 25 GRN BLU 1 1 Combination switch Horn H 9 A A BLK J C 1 2 4 3 Relay H E15 G27 G15 E41 G34 9 A 11 BLK BLK J B side c...

Page 1066: ...RADIO J B 15A 40 METER 10A 25 WHT RED G28 32 31 5 Stepper motor and LED output driver Voltage regulator Micro controller ILL Dial ILL Display ILL Pointer G33 6 RED BLK 16 B B BLK ORN BLK ORN J C G15 F...

Page 1067: ...oltage regulator Micro controller SMART KEY G33 6 RED BLK D 1 BEAM 22 A T RED Dimmer Passing J B L 2 3 D N R P 16 B B BLK ORN BLK ORN J C G15 10 CAN Hight Low R G28 WHT RED A 8 R W 10 8 BCM 26 1 D 6 T...

Page 1068: ...6 RED BLK 14 5 25 PNK BLK GRY GRY RED BLU PNK BLK RED BLU P S Cont M F 3 RB PB YB YEL BLK A B SDM F 1 ABS Cont M F 2 G CAN Hight Low WHT RED R W 10 8 6 L01 14 RED BLK BRN YEL L27 1 Parking brake switc...

Page 1069: ...Wiring Systems 9A 62 GEAR ABS BELT DOOR CHARGE IMMOBI BRAKE FUEL RADIO 15A 40 32 5 WHT RED J B G33 G28 1 2 I4RS0A910943...

Page 1070: ...B C B C 3 3 15 1 22 G28 E08 G34 E21 G33 6 31 RED BLK WHT RED 10A 25 METER WHT RED 7 10 9 BLK 11 G25 15A 21 15A 20 H L R H L L 5 8 RED WHT RED 10 RED RED J B 10A TAIL 32 RED WHT 5 RED WHT E37 G35 E42...

Page 1071: ...G34 7 BLK G25 5 10A TAIL 32 1 2 E07 1 C C A 2 E D E E22 BLK BLK RED YEL J B L05 3 E41 16 BLK BLK E43 J C Licence plate light 1 3 5 L20 BLK BCM 14 11 5 13 WHT RED OFF TAIL HEAD B T T P H EL A Front po...

Page 1072: ...E34 3 4 1 WHT GRN GRY RED GRY RED LT GRN BLK BLK BLK BLK LT GRN LT GRN 7 D D E37 G35 FREE IG LOAD E Il Ile TERMINAL POSITION PUSH 6 7 4 8 G15 G31 G29 RED YEL RED YEL 11 A A A BLK BLK 5 J C 7 5 J C J...

Page 1073: ...11 17 A T B B J C L24 RED YEL RED YEL RED YEL J C L08 C A L05 3 D 3 IF EQPD RY Switch J C G31 RED YEL RY RED YEL Switch RY RED YEL Mode control switch E 1 D 6 OFF TAIL HEAD B T T P H EL RED YEL 7 RY...

Page 1074: ...D BLK OFF ON OFF ON L16 L34 1 L40 1 Rear door switch Front door switch BLK RED BLK BLK BLK L05 14 WHT RED G15 J C A A 5 7 G34 K01 J B L01 Luggage compartment light 2 1 3 L19 WHT RED BLK YEL WHT 11 19...

Page 1075: ...LP L LP R Flasher relay G34 RED YEL RED YEL Turn signal switch 12 G25 13 11 10A METER 25 RED BLU BLU RED J B L N R TURN T P TB TL TR J C 11 10 7 G34 14 A BCM 12 1 BLK C C G31 J C ON OFF 3 A B A A G15...

Page 1076: ...GRN RED 9 Turn L Turn R E06 12 G33 6 BLU YEL GRN RED BLU YEL C 2 GR BY FR turn signal light R Side turn signal light R E09 2 E19 FR turn signal light L Side turn signal light L BLK 5 E39 5 BLK BLK BLK...

Page 1077: ...L 15A 8 STOP LAMP E47 L43 GRN WHT GRN WHT GRN WHT 5 4 1 L06 2 8 E41 1 J B F 2 ABS Cont M GRN WHT 2 A 5 ECM 13 GW GW GW TCM PB PNK BLK A 6 GRN YEL A T shift lever GY A 6 2 3 A T 18 Individual circuit f...

Page 1078: ...D L28 Back up light switch Back up light R RED RED RED BLK RED BLK ON OFF J B 10A 24 BACK E24 C36 19 C30 2 1 20 L43 1 L20 1 RED RED RED A T M T L06 3 E41 11 J B P R N D 2 L Transaxle range sensor RED...

Page 1079: ...ORN BLK ORN G15 J C G01 Fresh Recircle actuator 3 7 1 GRN RED 9 G18 7 8 G31 J C 4 G34 BCM A 8 GW BCM B 3 B BRN 8 RED YEL RED YEL RED BLK RED BLK RED BLK 10 13 14 5 6 REAR DEF REO FRE A C HARF REO CIR...

Page 1080: ...J B BLK WHT BLK YEW 1 2 G05 12 BLK G06 Heater resister 1 3 4 2 Blower fan G32 6 1 7 2 3 6 FAN ECM A 5 BW Heater fan switch 1 2 5 3 30A HTR FAN 4 10A 38 IG2 SIG Heater relay E39 7 G34 9 G15 J C 11 A A...

Page 1081: ...BAG 30 RED L04 BCM 15 BLK 1 E44 L03 1 PNK BLK E13 Forward sensor R 1 2 Contact coil G26 1 2 L32 G04 2 1 L10 2 1 YEL RED GRN RED G10 1 2 4 3 YEL RED L36 1 2 3 4 7 8 5 6 9 10 28 27 37 32 50 51 A 8 L32 G...

Page 1082: ...L11 L35 1 2 1 2 12 11 13 14 20 19 21 22 46 47 45 44 IF EQPD sensor sensor LT GRN BLK YEL GRN BLK YEL BRN YEL Side curtain Side curtain L04 4 G34 13 J B C 3 YB 2 YEL BLK YEL BLK WHT RED WHT GRN LT GRN...

Page 1083: ...13 26 14 1 3 23 17 E03 ABS Cont M BLK 30A ABS SOL 16 30A ABS MOT 9 WHT RED WHT BLU GRN WHT 6 BLK PNK BLK PB PNK BLK RB RED BLU RED BLU 14 9 G35 E37 C 3 J B 10A ABS 31 E41 9 GRN ORN 7 GW D 7 Brake ligh...

Page 1084: ...nsor FR WHT RED E25 Wheel speed sensor FL RED BLK 18 19 22 21 25 24 16 15 E03 2 1 2 1 2 1 2 1 5 DLC PPL WHT PPL WHT A A E38 G36 5 E42 D J C G16 PPL WHT E 5 9 E46 BCM PPL WHT WHT RED G20 G37 PW E03 WHT...

Page 1085: ...031 P S Cont M 50A EPS 12 E41 12 J B 10A IG1 SIG 29 RED 6 20 E48 E50 E50 E48 Torque sensor BLK E49 8 GRN LT GRN BLK YEL 1 16 GRN 2 8 BRN 4 9 WHT 5 18 BLU 7 6 19 1 2 1 LT GRN BLK 3 E53 E49 E52 E52 RB 5...

Page 1086: ...PL 2 P 4 PPL WHT PPL WHT EPS METER 10A 25 G28 31 G33 6 RED BLK 25 PPL G20 DLC 4 BLK A A J C G15 5 PPL WHT PPL WHT A A J C G16 9 E46 E38 G36 14 E24 C36 15 BLK ORN 5 3 J B 15A RADIO 40 G33 5 WHT RED BLK...

Page 1087: ...C G31 BCM A 8 Antenna amplifier WHT GRN L39 L33 G03 18 WHT GRN BLU WHT BLU WHT 15A ACC 2 27 BLK 10 Tweeter Front PNK BLU J12 J10 Tweeter Front J04 J02 YEL BLK YEL RED Rear R Rear L LT GRN LT GRN BLK...

Page 1088: ...7 L28 L44 Y G Multi information display J B BCM J B G34 7 14 RED YEL 10 BLK ORN 2 BLK ORN 15A RADIO 40 G33 5 WHT RED G14 1 3 J C YEL YEL G16 4 5 7 G15 J C 12 L05 WHT BLK L46 ACC Socket 2 1 18 WHT BLK...

Page 1089: ...MCONF020065 01 1 2 MCONF020065 01 2 3 1 MCONF030016 01 1 2 MCONF020057 01 1 2 3 4 5 6 MCONF060018 01 1 2 3 MCONF030062 01 1 2 3 MCONF030084 01 1 4 3 2 5 MCONF050025 01 1 2 MCONF020156 01 1 2 3 4 MCONF...

Page 1090: ...3 4 5 6 MCONF060062 01 1 2 MCONF020195 01 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 MCONF260011 01 1 2 3 MCONF030062 01 2 1 MCONM020043 01 2 1 MCONF020196 01 1 2 MCONF020013...

Page 1091: ...3 12 11 8 MCONM200008 01 1 2 3 4 5 6 7 8 9 10 MCONF100003 01 2 1 MCONF020202 01 6 5 4 3 2 1 7 11 10 9 8 15 14 13 12 16 MCONF160034 01 C C A A B B D E D D E E MCONF120027 01 C C A A B B D E D D E E MCO...

Page 1092: ...14 15 16 MCONF160023 01 3 2 1 6 5 4 MCONF060063 01 2 5 1 4 7 6 8 3 MCONF080014 01 1 2 3 4 5 6 7 8 9 10 MCONF100038 01 2 1 8 3 9 4 10 5 11 6 12 7 MCONF120026 01 7 10 5 6 1 2 3 4 8 9 11 12 13 MCONF13001...

Page 1093: ...6 8 9 10 11 13 2 4 7 12 MCONF130011 01 1 2 3 4 9 10 11 5 6 7 8 12131415 161718 MCONF180011 01 31 32 34 33 30 29 24 28 23 27 22 26 21 25 16 20 19 15 12 11 10 14 18 13 17 8 7 6 2 4 1 3 5 9 MCONM340002...

Page 1094: ...022 01 2 3 4 1 MCONF040033 01 1 2 3 4 5 6 7 8 9 15 16 17 18 11 10 12 13 14 MCONF180013 01 4 3 5 6 12 14 11 10 15 7 2 1 13 16 9 8 MCONF160014 01 31 32 34 33 30 29 24 28 23 27 22 26 21 25 13 20 19 14 9...

Page 1095: ...19 20 21 22 23 24 25 26 1 MCONF510002 01 1 2 MCONF020212 01 31 32 34 33 30 29 24 28 23 27 22 26 21 25 13 20 19 14 9 10 11 15 18 16 17 7 1 3 2 4 5 6 8 12 MCONF340005 01 4 3 2 1 MCONF040099 01 2 3 4 1 5...

Page 1096: ...ing relay 2 Socket cover 8 Lighting switch 14 Rear combination light 3 Clearance light bulb 9 Front fog light if equipped 15 Junction block assembly BCM cannot be removed from junction block 4 Clearan...

Page 1097: ...er switch faulty Check headlight switch referring to Headlight Switch in Lighting Switch Inspection Headlight R and L fuses blown Replace fuse and check for short circuit Wiring or grounding faulty Re...

Page 1098: ...fuse s and check for short circuit Hazard warning switch faulty Check hazard warning switch referring to Hazard Warning Switch Inspection Turn signal light switch faulty Check turn signal light switch...

Page 1099: ...ion Range Sensor Shift Switch Inspection and Adjustment in Section 5A Condition Possible cause Correction Reference Item Stop brake lamp do not light up Bulb s blown Replace bulb s Circuit fuse blown...

Page 1100: ...val procedure noting the following Install headlight mounting bolts and then tighten headlight mounting bolts 1 3 according to numerical order as shown in figure After installation be sure to inspect...

Page 1101: ...regulations adjust headlight aiming according to the following procedure After replacing headlight housing be sure to adjust aiming 1 Make sure the following items Place vehicle on a flat surface in f...

Page 1102: ...ation switch assembly 2 and disconnect its coupler 3 Installation Reverse removal procedure for installation I4RS0A920006 2 Headlight bulb 7 Turning for down adjustment X X Horizontal center line of h...

Page 1103: ...and Installation in Section 7A 3 Disconnect coupler and then remove hazard warning switch 2 from center ventilation louver 1 while releasing the locks 3 Installation Reverse removal procedure for inst...

Page 1104: ...tive cable at battery 2 Remove junction block assembly referring to BCM Included in Junction Block Assembly Removal and Installation in Section 10B 3 Remove turn signal and hazard warning relay Instal...

Page 1105: ...Remove rear bumper Refer to Front Bumper and Rear Bumper Components in Section 9K 3 Disconnect coupler 1 from license lamp assembly 2 4 Push locking part to arrow direction and then remove license la...

Page 1106: ...lly when headlight switch is turned to OFF position If front fog light switch holds ON position front fog lights turn ON automatically when headlight switch is tuned to HEADLIGHT position low or high...

Page 1107: ...he specified value respectively Bounce vehicle body up and down by hand to stabilize suspension Carry out aiming with a driver aboard Driver s weight 75 kg 165 lb 2 Check to see if hot spot high inten...

Page 1108: ...e following information from each control module Data which combination meter receives from ECM Engine revolution speed signal Engine coolant temperature signal Vehicle speed signal Malfunction indica...

Page 1109: ...19 3 3 12 14 15 16 17 G28 16 3 L 2 D N R P 18 G28 31 G28 26 G28 25 I4RS0A930002 1 Main fuse 6 Fuel meter 11 SDM 16 Interface circuit 2 METER fuse 7 ECT meter 12 Combination switch high beam 17 CAN dr...

Page 1110: ...G28 21 G28 6 G28 22 To lighting switch high beam G28 7 G28 23 G28 8 CAN communication line Active High Signal G28 24 G28 9 G28 25 To EPS control module EPS indicator control signal G28 10 CAN communic...

Page 1111: ...fuse blown Replace fuse and check for short circuit VSS faulty M T vehicle Check VSS referring to Vehicle Speed Sensor VSS Inspection M T model in Section 1C Output shaft speed sensor VSS faulty A T...

Page 1112: ...Reference Item Low fuel warning light does not come ON when fuel level is lower than specification Circuit fuse blown Replace fuse and check for short circuit Fuel level sensor faulty Check fuel leve...

Page 1113: ...g to Parking Brake Switch Inspection ABS system faulty Refer to ABS Check in Section 4E Wiring or ground faulty Repair circuit Combination meter faulty Replace combination meter Brake warning light st...

Page 1114: ...ome ON Circuit fuse blown Replace fuse and check for short circuit Combination switch faulty Check combination switch referring to Headlight Switch in Lighting Switch Inspection in Section 9B Wiring o...

Page 1115: ...or short circuit Wiring and or grounding faulty Repair as necessary Information display unit faulty Replace unit Incorrect thermometer display Outside air temperature sensor faulty Check outside air t...

Page 1116: ...sembly Radio is operative but all speakers does not sound Wiring and or grounding faulty Repair as necessary Radio assembly faulty Replace radio assembly Individual speaker is noisy or inoperative Wir...

Page 1117: ...layer is operative but all speakers does not sound Wiring and or grounding faulty Repair as necessary Radio assembly faulty Replace radio assembly Individual speaker is noisy or inoperative Wiring and...

Page 1118: ...and Installation S4RS0A9306004 Removal Remove fuel pump assembly referring to Fuel Pump Assembly Removal and Installation in Section 1G Installation Install fuel pump assembly referring to Fuel Pump A...

Page 1119: ...al and Installation in Section 5B or Output Shaft Speed Sensor VSS Removal and Installation in Section 5A VSS Inspection S4RS0A9306009 Refer to Vehicle Speed Sensor VSS Inspection M T model in Section...

Page 1120: ...ion Door open Continuity Rear End Door Switch Inspection S4RS0A9306014 Check for continuity between terminal a and b shown in the following If check result is not as specified replace switch Rear end...

Page 1121: ...k Removal 1 Disconnect negative cable at battery 2 Disable air bag system referring to Disabling Air Bag System in Section 8B 3 Remove steering column hole cover 1 4 Turn steering wheel to remove stee...

Page 1122: ...installing each part be careful not to catch any cable or wiring harness Tighten instrument panel mounting bolts to specified torque Tightening torque Instrument panel mounting bolt a 23 N m 2 3 kg m...

Page 1123: ...er 2 from front door 3 4 Disconnect front speaker coupler from front speaker 2 Installation Reverse removal procedure Rear Speaker Removal and Installation S4RS0A9306022 Removal 1 Remove door trim ref...

Page 1124: ...S4RS0A9306025 NOTE Antenna amplifier incorporated with antenna base Removal 1 Remove head lining referring to Head Lining Removal and Installation in Section 9H 2 Remove antenna 1 from antenna base 2...

Page 1125: ...N 680 820 switch 6 pushing on ON 1400 1700 Specifications Tightening Torque Specifications S4RS0A9307001 NOTE The specified tightening torque is also described in the following Audio System Component...

Page 1126: ...n Reference Item Wiper malfunctions NOTE Use SUZUKI scan tool makes it easy to check whether a faulty condition is on the input side or output side of BCM For checking procedure refer to Diagnosis Usi...

Page 1127: ...Wipers Washers 9D 2 Repair Instructions Wipers and Washers Components S4RS0A9406001 11 5 6 b b c 12 13 14 14 14 A d 7 9 10 10 10 11 11 8 a a b b 3 1 2 1 4 b 2 I4RS0A940001...

Page 1128: ...r tank bolt a 4 N m 0 4 kg m 3 0 lb ft Washer Pump Inspection S4RS0A9406003 1 Connect battery positive and negative terminals to pump and terminals respectively 2 Check front and rear washer pumps for...

Page 1129: ...m nut a 16 N m 1 6 kg m 11 5 lb ft 5 Install wiper pivot caps 2 to windshield wiper arm nuts 6 Connect negative cable to battery Windshield Wiper Motor Inspection S4RS0A9406004 NOTE Make sure that bat...

Page 1130: ...turns once again then stops at a specified position as shown d Repeat Step 1 to 3 several times and check that the motor stops at the specified position every time If check result is not satisfied rep...

Page 1131: ...on as shown in figure 7 Tighten rear wiper arm nut to specified torque and then install arm cover 1 Tightening torque Rear wiper arm nut a 8 N m 0 8 kg m 6 0 lb ft 8 Connect negative cable to battery...

Page 1132: ...9406006 Removal 1 Disconnect negative cable at battery 2 Remove steering column hole cover 1 3 Remove steering column covers 2 Turn steering wheel to access steering column cover rear end screws 3 4 R...

Page 1133: ...ges as shown If check result is not satisfied replace switch Washer Linked Circuit 1 Make sure that front wiper switch is at OFF position 2 Connect battery positive terminal to terminal 5 and its nega...

Page 1134: ...ive terminal to terminal 2 of relay 3 Connect battery negative terminal to terminal 1 of relay 4 Check continuity between terminal 3 and 4 If there is no continuity when relay is connected to the batt...

Page 1135: ...tions supplied with them Negligence in following such procedure or misuse of the adhesive in any way hinders its inherent adhesive property Therefore before the work make sure to read carefully the in...

Page 1136: ...lay faulty Check rear end door window defogger relay referring to Rear End Door Window Defogger Relay Inspection Defogger wire faulty Check defogger wire referring to Rear End Door Window Defogger Wir...

Page 1137: ...h piano string 2 When using tool windshield knife 3 to cut adhesive be careful not to cause damage to windshield Use wire to cut adhesive along lower part of windshield NOTE Use piano string 2 as clos...

Page 1138: ...2 as shown Upper clearance can be adjusted by moving glass stoppers position Windshield clearance a approx 5 mm 0 197 in 4 Clean contact surfaces of old adhesive 4 paint or bare metal thoroughly If su...

Page 1139: ...s instruction for proper handling and drying time Start from bottom side of glass 2 Be careful not to damage primer Adhesive amount specifications and position for windshield Width a Approx 7 mm 0 27...

Page 1140: ...hesive has its own setting time Be sure to refer to its maker s instruction check setting time of adhesive to be used and observe precautions to be taken before adhesive is set Refrain from driving ti...

Page 1141: ...rews 1 7 Remove door glass 2 while tilting it as shown Installation Reverse removal procedure noting the following instructions If there is deformity for glass run replace it with a new one Tighten do...

Page 1142: ...Installation Reverse removal procedure noting the following instruction Apply grease to sliding portions of window regulator Grease 99000 25010 Tighten front door window regulator attaching screws Fro...

Page 1143: ...c 12 5 2 8 4 a 1 I4RS0A950015 1 Door glass 6 Door sash 11 Rear door inner garnish 2 Window regulator assembly Apply lithium grease 99000 25010 to sliding part 7 Door panel 12 Door trim bracket 3 Glas...

Page 1144: ...er a o b o c Secure door sealing cover 1 with adhesive 2 Install rear door trim Rear door trim attaching order 1 o 2 o 3 o 4 o 5 o 6 Rear Door Window Regulator Removal and Installation S4RS0A9506009 R...

Page 1145: ...d Installation as removal and installation procedures are basically the same However note the following Observe the following precautions when applying adhesive 1 along glass 2 edge Adhesive 1 should...

Page 1146: ...F position If check result does not meet the above conditions replace HVAC control unit Rear End Door Window Defogger Relay Inspection S4RS0A9506027 1 Disconnect negative cable from battery 2 Remove j...

Page 1147: ...positive lead with a foil strip to defogger wire power source terminal end 2 then move it along wire to defogger wire ground terminal end 1 The place where voltmeter fluctuates from 10 12 V to 0 1 V i...

Page 1148: ...tch and its negative terminal to terminal E of power window main switch 4 Check for continuity between terminals as shown below If check result is not as specified replace power window main switch Swi...

Page 1149: ...door trim refer to Step 1 to 3 of Rear Door Glass Removal and Installation 2 Remove power window sub switch from door trim 3 Check for continuity between terminals at each switch condition If check re...

Page 1150: ...step 1 to 3 of Front Door Glass Removal and Installation 2 Disconnect door mirror coupler 1 3 Check that door mirror operates properly when battery voltage is applied to connector terminals 4 Connect...

Page 1151: ...re unmarked If original key is available key code cutting combination can be determined by laying key Rear End Door Opener System Description S4RS0A9601002 Rear end door opener system consists of rear...

Page 1152: ...and Keyless Entry System Component Location S4RS0A9603001 I4RS0A960001 1 Keyless entry receiver 3 Power door lock switch 5 Rear door actuator 7 Door switch 2 Transmitter 4 Front door actuator 6 Rear e...

Page 1153: ...Wiring or grounding faulty Repair circuit BCM faulty Replace after making sure that none of above parts is faulty All door can not be locked unlocked by only power door lock switch Circuit fuse blown...

Page 1154: ...9C Key remainder switch in ignition switch faulty Check ignition switch referring to Ignition Switch Inspection in Section 9C Wiring or grounding faulty Repair circuit Transmitter faulty Replace tran...

Page 1155: ...ructions Front Door Lock Assembly Components S4RS0A9606001 Condition Possible cause Correction Reference Item Rear end door can not be opened Circuit fuse blown Replace fuse and check for short circui...

Page 1156: ...en remove key cylinder 2 9 Disconnect door opening control rod 1 from outside handle 10 Disconnect door lock motor lead wire at coupler 11 Remove door latch screws 2 and remove door lock assembly 3 In...

Page 1157: ...ock operation increase or decrease number of shims inserted between body and striker 1 to adjust it Front Door Lock Assembly Inspection S4RS0A9606019 Check that door open and closes smoothly and prope...

Page 1158: ...ear Door Glass Removal and Installation in Section 9E For rear end door refer to Step 1 of Rear End Door Assembly Removal and Installation in Section 9J 2 Disconnect power door lock actuator coupler 3...

Page 1159: ...que Door latch screw a 5 0 N m 0 5 kg m 4 0 lb ft Rear Door Lock Assembly Inspection S4RS0A9606009 Check that door opens and closes smoothly and properly Check that door stops in the secondary latched...

Page 1160: ...1 and remove door latch assembly 2 1 3 4 5 2 a b 6 I4RS0A960015 1 Rear end door latch assembly including in rear end door switch 3 Latch striker 5 Door handle 10 N m 1 0 kg m 7 5 lb ft 2 Rear end doo...

Page 1161: ...Disconnect rear end door switch coupler 3 Check that there is continuity between terminals when rear end door opener switch 1 is pushed 4 Check that there is no continuity between terminals when rear...

Page 1162: ...onds after that 4 Push and release driver side door switch 1 at 3 times by hand within 20 seconds after removing ignition key from ignition key cylinder 5 Turn ignition switch to ON position and then...

Page 1163: ...a known good keyless entry receiver b Record key code referring to Programming Transmitter Code c Recheck keyless entry receiver system 1 Keyless entry receiver 2 Keyless entry receiver connector view...

Page 1164: ...fer to Fasteners Information in Section 0A Special Tools and Equipment Recommended Service Material S4RS0A9608001 NOTE Required service material is also described in the following Front Door Lock Asse...

Page 1165: ...ove seat assembly 4 Disassemble and repair seat as necessary Installation Reverse removal procedure to install front seat Torque to specifications as shown in Front Seat Components Enable air bag syst...

Page 1166: ...Torque Specifications S4RS0A9707001 NOTE The specified tightening torque is also described in the following Front Seat Components Rear Seat Components Reference For the tightening torque of fastener...

Page 1167: ...nts in Section 9G For tightening torque of front seat mounting bolt refer to Front Seat Components in Section 9G Head Lining Removal and Installation S4RS0A9806002 WARNING Refer to Air Bag Warning in...

Page 1168: ...s shown in the figure and then install head lining 2 Tighten sun visor screw to specified torque Tightening torque Sun visor screw a 4 N m 0 4 kg m 3 0 lb ft Console Box Components S4RS0A9806003 4 Cli...

Page 1169: ...nts S4RS0A9806004 Splash Guard If Equipped Components S4RS0A9806005 4 2 3 2 1 I4RS0A980009 1 Roof molding 3 Roof molding clip Push in type 2 Roof side weather strip 4 Windshield side garnish A A A A 1...

Page 1170: ...ing Torque Specifications S4RS0A9807001 Reference For the tightening torque of fastener not specified in this section refer to Fasteners Information in Section 0A Fastening part Tightening torque Note...

Page 1171: ...he secondary latched position properly preventing hood from opening freely and that hood closes completely in the fully latched position Adjust hood locks position if necessary Adjustment Adjust the f...

Page 1172: ...ts in Section 9K 4 Remove headlight assembly referring to Headlight Housing Removal and Installation in Section 9B 5 Disconnect connector from side turn signal lamp 6 Remove front fender cover 7 Remov...

Page 1173: ...5 Remove door assembly 1 by loosening hinge mounting bolts 2 Installation Reverse removal procedure to install door assembly noting the following instructions 2 2 1 a 4 a 4 3 b 7 b 7 c 5 6 I4RS0A9A000...

Page 1174: ...side door L punch mark is upward Right side door R punch mark is upward Tighten door open stopper bolt 3 to specified torque Tightening torque Door open stopper bolt a 21 N m 2 1 kg m 15 5 lb ft Adju...

Page 1175: ...10 Removal 1 Remove rear end door trim 1 2 Remove related section of head lining and rear trim 3 Disconnect rear end door harness couplers 2 and washer hose 3 4 Remove rear end door balancers 4 5 Remo...

Page 1176: ...hen drilling Using a 2 to 3 mm 0 08 to 0 12 in drill 2 make a hole to remove gas inside as shown before discarding Installation Reverse removal procedure noting the following Tighten rear end door bal...

Page 1177: ...Recommended Service Material S4RS0A9A08001 NOTE Required service material is also described in the following Front Door Assembly Components Rear Door Assembly Components Rear End Door Assembly Compon...

Page 1178: ...d Rear Bumper Components S4RS0A9B06001 1 2 11 3 4 5 6 7 8 9 10 12 14 13 15 I4RS0A9B0001 1 Front bumper 5 Front fog lamp cap 9 Front bumper lower member 13 Rear bumper holder 2 Radiator upper grill 6 F...

Page 1179: ...wer grill 7 Front bumper lower absorber 11 License plate nut 15 Plastic nut 4 Front air dam skirt 8 Front bumper upper member 12 Rear bumper 1 Cowl top cover 3 Cowl top side garnish 5 Hood rear seal 2...

Page 1180: ...le g g Front fender installation hole k k Jig hole I 7 mm d d Hood lock member installation hole when hood lock member removed h h Engine mounting installation front hole a d 675 mm 26 57 in b c 343 m...

Page 1181: ...ole c c Back panel bolt installation hole b b Jig hole d Rear end door striker installation left side hole a a 759 mm 29 88 in a b 1037 mm 40 83 in b c 985 mm 38 78 in a c 762 mm 30 00 in a d 904 mm 3...

Page 1182: ...eeding hole h h Curtain air bag clip installation hole Body right side a d 1055 mm 41 54 in c e 1021 mm 40 20 in f j 835 mm 32 87 in a f 747 mm 29 41 in c f 1123 mm 44 21 in h i 601 mm 23 66 in a g 37...

Page 1183: ...nce I4RS0A9B0006 a a Jig hole I 6 5 mm b b Panel cross point c Parking brake cable bracket installation front hole a b 638 mm 25 12 in a b 1194 mm 47 01 in a c 1293 mm 50 91 in b c 1422 mm 55 98 in a...

Page 1184: ...mm 32 91 in g h 1135 mm 44 69 in a b 1018 mm 40 08 in c d 288 mm 11 34 in g i 1229 mm 48 39 in a c 1163 mm 45 79 in d e 911 mm 35 87 in g i 612 mm 24 09 in a d 1391 mm 54 76 in d f 1205 mm 47 44 in g...

Page 1185: ...488 mm 19 21 in g h 293 mm 11 54 in b c 260 mm 10 24 in e f 440 mm 17 32 in g i 597 mm 23 50 in c d 288 mm 11 34 in f g 138 mm 5 43 in g j 956 mm 37 64 in a 73 mm 2 87 in e 10 mm 0 39 in i 181 mm 7 1...

Page 1186: ...frame installation hole b Front suspension frame installation hole e Front suspension control arm installation hole c Front suspension control arm installation hole a b 10 mm 0 39 in a d 270 mm 10 63...

Page 1187: ...40 0 319 in c 3 1 5 1 mm 0 122 0 201 in j 15 4 18 4 mm 0 606 0 724 in q 2 3 mm 0 091 in d 1 1 3 1 mm 0 043 0 122 in k 3 0 5 0 mm 0 118 0 197 in r 7 2 8 7 mm 0 283 0 343 in e 4 7 6 7 mm 0 185 0 263 in...

Page 1188: ...nts and seams The sealer must have flexible characteristics and paint ability after it s applied to repair areas For the sealer to fill open joints use caulking material Select a sealer in conformance...

Page 1189: ...raise no readily distinguishable smoke while burning Component Location Sealant Application Areas S4RS0A9C03001 I4RS0A9C0001 A Apply sealant C Smooth out sealant with a brush B Wipe off excess sealant...

Page 1190: ...9L 3 Paint Coatings I4RS0A9C0002 A Apply sealant C Smooth out sealant with a brush B Fill gap hole with sealant D Do not apply sealant...

Page 1191: ...aint Coatings 9L 4 I4RS0A9C0003 A Apply sealant C Smooth out sealant with a brush E Apply sealant covering flange end between c and d B Wipe off excess sealant after application D Do not apply sealant...

Page 1192: ...9L 5 Paint Coatings I4RS0A9C0004 A Apply sealant...

Page 1193: ...Paint Coatings 9L 6 I4RS0A9C0005 A Apply sealant C Apply sealant covering flange end B Wipe off excess sealant after application D Do not apply sealant...

Page 1194: ...der Coating Application Areas S4RS0A9C03002 I4RS0A9C0006 A Apply undercoating PVC 400 Pm or more C Do not apply undercoating B Apply anti chip coat 300 Pm or more D Apply undercoating PVC 400 Pm or mo...

Page 1195: ...Paint Coatings 9L 8 I4RS0A9C0007 A Apply undercoating PVC 400 Pm or more C Do not apply undercoating B Apply undercoating PVC 600 Pm or more...

Page 1196: ...s Anti Corrosion Compound Application Area S4RS0A9C03003 I4RS0A9C0008 A Apply rust proof wax hot wax 50 Pm or more B Apply rust proof wax high viscosity wax 50 Pm or more C Never fill up drain holes w...

Page 1197: ...or Trim 9M 1 Exterior Trim Repair Instructions Roof Molding Components S4RS0A9D06005 4 2 3 2 1 I4RS0A980009 1 Roof molding 3 Roof molding clip Push in type 2 Roof side weather strip 4 Windshield side...

Page 1198: ...9M 2 Exterior Trim Splash Guard If Equipped Components S4RS0A9D06006 A A A A 1 I4RS0A980010 1 Side sill splash guard...

Page 1199: ...U1101 No 1101 Lost communication with TCM 10B 29 Inspection of BCM and its Circuits 10B 30 Repair Instructions 10B 39 BCM Included in Junction Block Assembly Removal and Installation 10B 39 Outside A...

Page 1200: ...10 1 Precautions Precautions Precautions Precautions for Control Systems S4RS0AA000001 Air Bag Warning Refer to Air Bag Warning in Section 00...

Page 1201: ...cation System in Section 00 General Description BCM General Description S4RS0AA201001 The Body electrical Control Module BCM is incorporated in junction block assembly Do not attempt removal of BCM fr...

Page 1202: ...1 transmits to ECM 2 Air conditioning switch signal Electric load Rear end door window defogger switch signal Ignition switch signal B Data which BCM receives from ECM Vehicle speed signal Engine cool...

Page 1203: ...again Also to check DTCs stored in BCM without using a SUZUKI scan tool when diagnosing troubles it is possible to identify them by flashing patters of the alarm indicator lamp Schematic and Routing...

Page 1204: ...ED L05 8 G33 7 ON DOOR OFF B B IG1 WHT K01 5 5V 5V 5V 5V 5V 5V L04 2 YEL L01 6 E46 5 RED BLK L01 14 BRN YEL L01 4 WHT G37 18 GRN WHT G37 17 BRN L01 16 LT GRN BLK L01 17 BRN L01 12 GRN WHT L01 5 GRY 12...

Page 1205: ...r 7 Ignition key switch 25 Rear end door opener relay 43 Rear window defogger indicator lamp 8 Alarm indicator light 26 Rear end door opener actuator 44 Horn relay 9 Oil pressure switch 27 TCM 45 Horn...

Page 1206: ...ction block assembly connectors viewed from harness side I4RS0AA20004 A Junction block assembly viewed from BCM side 4 Horn relay B Junction block assembly viewed from relay side 5 Rear wiper relay 1...

Page 1207: ...6 27 28 22 23 22 1 2 8 9 10 I4RS0AA20005 1 Generator 11 Keyless entry receiver 21 3 position switch 2 Brake fluid level switch 12 Parking brake switch 22 Junction block switch 3 ECM 13 Seat belt buckl...

Page 1208: ...er switch 16 A C switch 26 Rear wiper relay 7 Door switch 17 Hazard warning switch 27 Rear end door window defogger relay 8 Interior light 18 Rear wiper switch 28 Turn signal and hazard warning relay...

Page 1209: ...witch Rear end door opener relay Alarm indicator lamp Key reminder switch Alarm indicator lamp located in information display Control Input Output Step Action Yes No 1 Customer complaint analysis 1 Pe...

Page 1210: ...that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now To check which case applies clear DTC once and check...

Page 1211: ...ver side door at lock position LOCK Key cylinder switch of driver side door not turned Neutral Key cylinder switch of driver side door at unlock position Unlock Door Lock Sw Lock side of manual door l...

Page 1212: ...lever is released Rear Defogger Sw Rear end door window defogger switch ON OFF This parameter indicates the state of the rear end door window defogger switch Driv Seatbelt Sw Driver seat belt switch F...

Page 1213: ...ature ambient temperature sensor circuit short to ground Sensor output voltage too low B1143 1143 b1143 Outside air temperature ambient temperature sensor malfunction Sensor output voltage out of spec...

Page 1214: ...ition switch is turned ON and engine stops a Turn headlight switch to SMALL position b Turn headlight switch to OFF position c Repeat Steps a and b 2 times d Press and release driver side door switch...

Page 1215: ...turn ignition switch off and disconnect scan tool from data link connector Without Using SUZUKI Scan Tool 1 Turn ignition switch to OFF position 2 Perform following Steps a to d within 10 seconds aft...

Page 1216: ...and G32 5 2 If OK turn ignition switch ON 3 Measure voltage between following terminals Between G32 2 terminal of junction block assembly connector and vehicle body ground Between G32 5 terminal of j...

Page 1217: ...rness side 3 Ignition switch 1 BCM 4 Battery 2 Junction block assembly DTC detecting condition Possible cause Power voltage supplied from battery to BCM is higher than 16V Charging system malfunction...

Page 1218: ...bly 1 Outside air temperature sensor 4 Outside air temperature sensor connector 2 BCM DTC detecting condition Possible cause DTC B1141 DTC No 1141 Input signal from outside air temperature sensor is h...

Page 1219: ...to ON position 2 Measure voltage between E14 2 terminal of outside air temperature sensor connector and vehicle body ground Is voltage 4 6 V Go to Step 3 Open or short in YEL RED circuit If OK substi...

Page 1220: ...g communication circuit Step 2 Check air bag communication circuit Step 3 Check air bag communication circuit I4RS0AA20011 A Junction block assembly connector viewed from harness side 2 BCM 1 SDM 3 Ju...

Page 1221: ...munication circuit 2 Check air bag communication circuit 1 Turn ignition switch to OFF position 2 Connect connectors to junction block assembly 3 Turn ignition switch to ON position 4 Measure voltage...

Page 1222: ...witch OFF 2 Replace BCM 3 Repeat BCM Check Flow Table I4RS0AA20012 A Junction block assembly connector viewed from harness side 2 BCM 1 SDM 3 Junction block assembly DTC detecting condition Possible c...

Page 1223: ...it for 1 min or more 4 Check DTC I4RS0AA20014 A BCM connector viewed from harness side D TCM connector viewed from harness side 3 ECM B ECM connector viewed from harness side 1 BCM 4 TCM equipped wit...

Page 1224: ...es communicating by means of CAN 3 Check CAN communication circuit between control modules for open short and high resistance Is each CAN communication circuit in good condition Go to Step 4 Repair ci...

Page 1225: ...nd pending DTC I4RS0AA20014 A BCM connector viewed from harness side D TCM connector equipped with A T viewed from harness side 3 ECM B ECM connector viewed from harness side 1 BCM 4 TCM equipped with...

Page 1226: ...CM NOTE If vehicle equipped with M T go to Step 4 1 Turn ignition switch to OFF position 2 Connect connectors to combination meter BCM and ECM 3 Recheck BCM for DTC Is DTC U1073 detected Go to Step 4...

Page 1227: ...run it for 1 min or more 4 Check DTC I4RS0AA20014 A BCM connector viewed from harness side D TCM connector equipped with A T viewed from harness side 3 ECM B ECM connector viewed from harness side 1...

Page 1228: ...etected Go to Step 4 Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 00 4 CAN communication circuit check 1 Turn ignition switch to OFF...

Page 1229: ...run it for 1 min or more 4 Check DTC I4RS0AA20014 A BCM connector viewed from harness side D TCM connector equipped with A T viewed from harness side 3 ECM B ECM connector viewed from harness side 1...

Page 1230: ...le Communication Bus Off Go to Step 2 2 Check DTC in TCM 1 Check TCM for DTC Is DTC P1774 detected Go to DTC P1774 Control Module Communication Bus Off in Section 5A Go to Step 3 3 Check each control...

Page 1231: ...s not pushed 0 V Rear end door switch is pushed L01 5 GRY Manual door lock switch Unlock 4 6 V Manual door lock switch is at any position other than unlock position 0 V Manual door lock switch is at u...

Page 1232: ...e door key cylinder switch Unlock 10 14 V Driver side door key cylinder switch is at any position other than unlock position 0 V Driver side door key cylinder switch is at unlock position L01 18 Termi...

Page 1233: ...0 14 V Ignition switch is at ON position G37 6 G37 7 G37 8 GRY Alarm indicator light 10 14 V Alarm indicator light is not lit up 0 V Alarm indicator light is lit up G37 9 G37 10 G37 11 YEL Serial comm...

Page 1234: ...Ignition switch is at all positions Terminal Wire color Circuit Normal voltage Condition E41 3 GRN Horn 10 14 V Horn switch is at ON position 0 V Horn switch is at OFF position Terminal Wire color Ci...

Page 1235: ...5 5 YEL Power supply for rear wiper motor 10 14 V Ignition switch is at ON position and rear wiper motor is not in operation 0 V Ignition switch is at ON position and rear wiper motor is in operation...

Page 1236: ...itch Ignition switch is at ON position brake fluid lever is in normal Measurement terminal CH2 L01 8 to G33 3 Oscilloscope setting CH2 5 V DIV TIME 400 ms DIV Measurement condition Ignition switch is...

Page 1237: ...rminal CH2 G37 1 to G33 3 CH3 G37 3 to G33 3 Oscilloscope setting CH2 1 V DIV CH3 1 V DIV TIME 40 Ps DIV Measurement condition Ignition switch is at ON position 1 CAN communication line signal High 2...

Page 1238: ...l CH2 G37 18 to G33 3 Oscilloscope setting CH2 5 V DIV TIME 10 ms DIV Measurement condition Ignition switch is at ON position and A C switch is at ON position I4RS0AA20022 I4RS0AA20023 Measurement ter...

Page 1239: ...n block assembly Installation Reverse removal procedure for installation noting following points Connect connectors securely Enable air bag system referring to Enabling Air Bag System in Section 8B If...

Page 1240: ...ol S4RS0AA208001 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 loopback adapter 7 Battery power cable 8 RS232 cable...

Page 1241: ...e the transponder code in the transponder built in the ignition key has to be registered with ECM Or the engine cannot be started up For the registration procedure refer to Procedure after ECM Replace...

Page 1242: ...CM Basically when the ignition switch is turned ON ECM reads the code by the coil antenna Then if the code in transponder in the ignition key does not match with the one registered with ECM ECM stops...

Page 1243: ...ECM indicates whether there is any trouble with the immobilizer control system or not by either lighting ON or flashing ON and OFF the immobilizer indicator lamp Immobilizer indicator lamp lights ON N...

Page 1244: ...59 60 58 2 26 27 28 15 30 56 48 32 31 34 35 36 37 40 42 39 38 44 45 43 41 33 1 12 13 23 8 1 2 3 4 G24 E46 G28 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 27 28 29 30 31 32 G3...

Page 1245: ...s manual 1 Turn the ignition switch to OFF position 2 Connect SUZUKI scan tool to data link connector DLC 1 located under instrument panel at driver s seat side Special tool A SUZUKI scan tool 1 Turn...

Page 1246: ...r in which the transponder code in the transponder built in the ignition key is registered with ECM INPUT MONTH 1 12 The month in which the transponder code in the transponder built in the ignition ke...

Page 1247: ...cted Perform troubleshooting referring to the corresponding flowchart in this section and then go to Step 3 Go to Step 3 3 Registration of the new ignition key with ECM and Diagnostic Trouble Code DTC...

Page 1248: ...till detected Go to Step 2 The troubleshooting is completed 2 Fuse check 1 Check if any related fuse is blown Is any fuse blown Replace blown fuse s with new one s Go to Step 3 3 Check for poor connec...

Page 1249: ...bilizer control module connector G24 and ECM connector E23 disconnected turn the ignition switch to ON position 2 Check voltage between G24 3 wire terminal at immobilizer control module connector and...

Page 1250: ...ion of Immobilizer Control Module and Its Circuit Is immobilizer control module normal Replace ECM with new one referring to Engine Control Module ECM Removal and Installation in Section 1C and then p...

Page 1251: ...lacement Replace immobilizer control module with new one referring to Immobilizer Control Module Removal and Installation Step Action Yes No Possible Cause Trouble Area Temporary error Immobilizer con...

Page 1252: ...d Installation 2 Connect immobilizer control module wiring connector 2 to immobilizer control module 3 Check voltage at each terminal NOTE As each terminal voltage is affected by the battery voltage c...

Page 1253: ...ponder code successfully at the second try A The transponder code read successfully at the first try B The transponder code read successfully at the second try 1 Serial communication line 2 Clock line...

Page 1254: ...erform Register Ig Key mode of SUZUKI scan tool referring to SUZUKI Tech 2 Operator s Manual NOTE A maximum of four transponder codes can be registered with ECM At an early part of the registration pr...

Page 1255: ...Prepared by 1st Ed Dec 2004...

Page 1256: ...21 mm 99500 63J00 24E 99500 63J00 24E SERVICE MANUAL VOLUME 1 OF 2 SERVICE MANUAL VOL 1 OF 2...

Page 1257: ...29 mm 99500 63J00 24E 99500 63J00 24E SERVICE MANUAL VOLUME 2 OF 2 SERVICE MANUAL VOL 2 OF 2...

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