Suzuki Wagon R Plus RB310 Service Manual Download Page 796

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TRANSFER 7D-7

Required Service Material

Material

Recommended SUZUKI products

(Part Number)

Use

Lithium grease

SUZUKI SUPER GREASE A
(99000-25010)

• Oil seal lips
• O-ring

Sealant

SUZUKI BOND NO. 1217G
(99000-31260)

• Oil drain plug
• Oil level plug
• Mating surface of transfer case

Summary of Contents for Wagon R Plus RB310

Page 1: ...he air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system sec...

Page 2: ...in each description All information illustrations and specifications contained in this literature are based on the latest product infor mation available at the time of publication approval And used a...

Page 3: ......

Page 4: ...G10 Engine 7A 4A 7F Wheels and Tires 3F Manual Transaxle M13 Engine 7A2 4B DRIVE SHAFT AND PROPELLER SHAFT Automatic Transaxle M13 Engine 7B1 8 Front Drive Shaft G10 M13 Engines 4A Clutch G10 M13 Eng...

Page 5: ......

Page 6: ...rvice 0A 12 Electrical Circuit Inspection Procedure 0A 15 Open circuit check 0A 15 Continuity check 0A 16 Voltage check 0A 16 Short circuit check wire harness to ground 0A 17 Intermittent and Poor Con...

Page 7: ...th the Sec tion name 3 The special tool usage and torque specification are given as shown in the figure 4 A number of abbreviations and symbols are used in the text For their full explanations refer t...

Page 8: ...SUZUKI recommends that the air bag sys tem be repaired first to help avoid unintended air bag system activation Do not modify the steering wheel dashboard or any other air bag system components Modifi...

Page 9: ...diagnosis and incorrect parts replacement Never use electrical test equipment other than that specified in this manual WARNING Never attempt to measure the resistance of the air bag inflator modules...

Page 10: ...air bag inflator module must be placed with its frontal seat cover facing up It is also prohibited to place anything on top of the trim cover and stack air bag inflator modules This is necessary so t...

Page 11: ...nd pre tensioner connectors from air bag wire harness respectively Never expose air bag system component parts directly to hot air drying or baking the vehicle after painting or flames WARNING SDM For...

Page 12: ...et fully and the transmission is in Neutral for manual transmission vehicles or Park for auto matic transmission vehicles Keep hands hair clothing tools etc away from the fan and belts when the engine...

Page 13: ...the proper order and position Whenever you use oil seals gaskets packing O rings locking washers split pins self locking nuts and cer tain other parts as specified be sure to use new ones Also before...

Page 14: ...systems never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure or fuel can be sprayed out under pressure When performing a work that produces a he...

Page 15: ...atalytic converter use only unleaded gasoline and be careful 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...

Page 16: ...wheels which are jacked up C Towing under the condition where either front or rear wheels can not rotate When testing with 2 wheel chassis dynamometer speedometer tester or brake tester be sure to ma...

Page 17: ...electrical parts and a fire When disconnecting and connecting coupler make sure to turn ignition switch OFF or electronic parts may get damaged When disconnecting connectors never pull the wiring harn...

Page 18: ...tronic control unit like as ECM PCM P S controller etc The static elec tricity from your body can damage these parts Never connect any tester voltmeter ohmmeter or what ever to electronic control unit...

Page 19: ...ler of force its female terminal open for connection In case of such coupler as shown connect probe as shown to avoid opening female terminal Never connect probe where male terminal is supposed to fit...

Page 20: ...nt to perform careful check starting with items which are easier to check 1 Disconnect negative cable from battery 2 Check each connector at both ends of the circuit being checked for loose connection...

Page 21: ...in connector B Voltage check If voltage is supplied to the circuit being checked voltage check can be used as circuit check 1 With all connectors connected and voltage applied to the cir cuit being c...

Page 22: ...intermittent are caused by faulty electrical connections or wiring although a sticking relay or solenoid can occasionally be at fault When checking it for proper connection perform careful check of su...

Page 23: ...by shaking it by hand lightly If any abnormal condi tion is found repair or replace Wire insulation which is rubbed through causing an intermit tent short as the bare area touches other wiring or par...

Page 24: ...in engine room and it is also on the left side of instrument panel depending on the vehi cle specification Engine Identification Number The number is punched on cylinder block Transmission Identificat...

Page 25: ...ace it as necessary 1 Air bag caution label on back side of engine hood 6 Air bag caution label on combination switch and contact coil assembly 2 Air bag caution label on sun visor for vehicle with ai...

Page 26: ...tact with brake pipe fuel pipe bracket or any other part When using frame contact hoist apply hoist as shown right and left at the same position Lift up the vehicle till 4 tires are a little off the g...

Page 27: ...afety stands 1 under vehicle body so that vehi cle body is securely supported And then check to ensure that vehicle body does not slide on safety stands 1 and the vehicle is held stable for safety s s...

Page 28: ...Camshaft Position Sensor IG Ignition CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator CPP switch Clutch Pedal Position Switch Clutch Switch Clutch Start Switch L LH Left Hand LSPV Load Sen...

Page 29: ...mshaft T TBI Throttle Body Fuel Injection Sin gle Point Fuel Injection SPI TCC Torque Converter Clutch TCM Transmission Control Module A T Controller A T Control Module TP Sensor Throttle Position Sen...

Page 30: ...il engine transmission trans fer differential Apply SILICONE SEALANT 99000 31120 Apply fluid brake power steering or automatic transmission fluid Apply SEALING COMPOUND 366E 99000 31090 Apply GREASE A...

Page 31: ...1 of thread is the same the thread pitch 2 or the width across flats 3 may vary between ISO and JIS Refer to JIS TO ISO Main Fasteners Comparison Table below for the difference Installing a mismatche...

Page 32: ...acement bolts and nuts are available through the parts divi sion Metric bolts Identification class numbers or marks correspond to bolt strength increasing numbers represent increasing strength Standar...

Page 33: ...ener with flange N m 2 4 4 9 8 8 21 44 84 133 203 298 kg m 0 24 0 49 0 88 2 1 4 4 8 4 13 3 20 3 29 8 lb ft 2 0 3 5 6 5 15 5 32 0 61 0 96 5 147 0 215 5 A equivalent of 7T strength fastener N m 2 3 4 5...

Page 34: ...n 0B 14 Brake Fluid Replacement 0B 14 Brake Lever and Cable Inspection 0B 14 Clutch Inspection 0B 15 Tires Inspection 0B 15 Wheel Discs Inspection 0B 16 Wheel Bearing Inspection 0B 16 Suspension Syste...

Page 35: ...l Oil 4WD Inspection 0B 19 Transfer Oil 4WD and Rear Differential Oil 4WD Replacement 0B 20 All Latches Hinges and Locks Inspection 0B 20 Doors 0B 20 Engine hood 0B 20 Ventilator Air Filter If Equippe...

Page 36: ...lugs When unleaded fuel is used M13 engine Iridium plug Replace every 105 000 km 63 000 miles or 84 months G10 engine R R When leaded fuel is used refer to Maintenance Recommended Under Severe Driving...

Page 37: ...Tires wear damage rotation wheels damage I I I I I I Suspension system tightness damage rattle breakage I I I Steering system tightness damage breakage rattle I I I Drive shaft axle boots Propeller sh...

Page 38: ...r cleaner filter 1 I Every 2 500 km 1 500 miles R Every 30 000 km 18 000 miles or 24 months A B C E F H Spark plugs Iridium spark plug of M13 engine R Every 30 000 km 18 000 miles or 24 months G10 eng...

Page 39: ...pect belt for cracks cuts deformation wear and cleanli ness If any defect exists replace Check belt for tension If belt tension is out of specification adjust it referring to A C Compressor Driver Bel...

Page 40: ...er pump belt tension a 7 9 mm 0 27 0 35 in deflection under 100 N 10 kg or 22 lb pressure Drive Belt Replacement G10 Engine A C compressor drive belt replacement 1 Disconnect negative cable from batte...

Page 41: ...Valve Lash Clearance Inspection M13 Engine 1 Inspect intake and exhaust valve lash and adjust as neces sary Refer to Valve Lash Clearance Inspection in Section 6A2 for valve lash inspection and adjust...

Page 42: ...g oil filter wrench special tool Special tool A 09915 47330 4 Screw new filter on oil filter stand by hand until the filter O ring contacts the mounting surface WARNING New and used engine oil can be...

Page 43: ...7 Check oil filter and drain plug for oil leakage 8 Start engine and run it for 3 minutes Stop it and wait 5 min utes before checking oil level Add oil as necessary to bring oil level to FULL level m...

Page 44: ...eep into the vehicle Make sure that exhaust system components have enough clearance from the underbody to avoid overheating and pos sible damage to the floor carpet Any defects should be fixed at once...

Page 45: ...ase clamps 2 Take air cleaner filter out of case 3 Check that filter is not excessively dirty damaged or oily clean filter with compressed air from air outlet side of filter 4 Install air cleaner filt...

Page 46: ...isually inspect hoses for 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 under EVAP Control...

Page 47: ...s for proper hookup leaks cracks chafing and other damage Check that hoses and pipes are clear of sharp edges and moving parts Repair or replace any of these parts as necessary Brake Fluid Replacement...

Page 48: ...or height and free travel 1 referring to Clutch Pedal Height Check and Clutch Pedal Free Travel Check in Section 7C Adjust or correct if necessary Tires Inspection 1 Check tires for uneven or excessiv...

Page 49: ...r shock absorbers for evidence of oil leakage dents or any other damage on sleeves and inspect anchor ends for deterioration Replace defective parts if any Check front and rear suspension systems for...

Page 50: ...defective parts if any 7 If equipped with power steering system check also in addi tion to above check items that steering wheel can be turned fully to the right and left more lightly when engine is r...

Page 51: ...al Transmission Oil Replacement 1 Place the vehicle level and drain oil by removing drain plug 2 2 Apply sealant to drain plug after cleaning it and tighten drain plug to specified torque 3 Pour speci...

Page 52: ...case or differential for evidence of oil leakage Repair leaky point if any 2 Make sure that vehicle is placed level for oil level check 3 Remove level plug of transfer or differential and check oil le...

Page 53: ...secondary latch operates properly check that sec ondary latch keeps hood from opening all the way even when pulling hood release handle inside vehicle Also check that hood opens and closes smoothly a...

Page 54: ...art EXHAUST SYSTEM CHECK Check for leakage cracks or loose supports CLUTCH FOR MANUAL TRANSMISSION Check for the following Clutch is completely released when depressing clutch pedal No slipping clutch...

Page 55: ...Check that engine is free from abnormal noise and abnormal vibration BODY WHEELS AND POWER TRANSMITTING SYSTEM Check that body wheels and power transmitting system are free from abnormal noise and abn...

Page 56: ...nt Brake fluid DOT 4 or SAE J1704 Manual transmission oil Refer to Manual transaxle Oil Change in Section 7A or 7A2 Automatic transmission fluid An equivalent of DEXRON III Transfer oil 4WD Refer to T...

Page 57: ...0B 24 MAINTENANCE AND LUBRICATION...

Page 58: ...erative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative...

Page 59: ...r 2 Main relay 8 Dual pressure switch 14 ECT sensor 3 Radiator and condenser cooling fan motor relay 9 Blower fan motor relay 15 Compressor relay 4 Radiator and condenser cooling fan motor 10 Blower f...

Page 60: ...nal of couplers connected Refer to next page and Inspection of ECM and Its Circuits in Sec tion 6 2 CAUTION ECM cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter t...

Page 61: ...23 01 BLK YEL ECM ground for power cir cuit Ground to body Fig A 0 3 0 3 V Ignition switch ON E21 06 BLK RED Power supply for engine con trol Ground to engine Fig B 10 14 V Ignition switch ON E21 4 BL...

Page 62: ...sion Replacement 1 Loosen tension pulley nut 3 2 Loosen belt tension by loosen tension pulley adjusting bolt 4 3 Remove compressor drive belt 6 E21 30 LT GRN RED A C switch input Ground to engine Fig...

Page 63: ...h should show proper continuity 2 Check switch for continuity at specified pressure as shown A Approx 200 KPa 2 0 kg cm2 B Approx 3200 KPa 32 kg cm2 C Approx 260 KPa 2 6 kg cm2 D Approx 2600 KPa 26 kg...

Page 64: ...igerant from refrigeration system by using recov ery and recycling equipment 4 Remove front bumper 5 Remove engine front cover 6 Disconnect magnet clutch lead wire and disengage lead wire clamp 7 Remo...

Page 65: ...1B 8 AIR CONDITIONING OPTIONAL...

Page 66: ...all of the wheel bolts at once because all the wheels of this vehicle are mounted by the wheel bolts Leave a bolt at least not to drop the wheel Support the wheel and or tire and then remove the bolt...

Page 67: ...refore should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision whether the damage is in body or in suspension should be determined If the bod...

Page 68: ...o conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from...

Page 69: ...en new tie rod end nut 1 to specified torque Tightening torque Tie rod end nut a 40 N m 4 0 kg m 29 0 lb ft 3 Inspect for proper toe Refer to Front Wheel Alignment 4 After confirming proper toe tighte...

Page 70: ...torque Tightening torque Engine rear mounting bolt a 55 N m 5 5 kg m 40 lb ft 3 Remove transmission jack 4 Install tie rod ends to knuckles right left Tighten each new tie rod end nut 1 to specified t...

Page 71: ...just as required refer to Front Wheel Alignment in Section 3A 12 Tighten both tie rod end lock nuts to specified torque Tightening torque Tie rod end lock nut a 45 N m 4 5 kg m 32 5 lb ft Tightening T...

Page 72: ...re performing service on or near the air bag system components or wiring Please observe all WARNINGs and Service Precau tions under On Vehicle Service in Section 10B performing service on or around th...

Page 73: ...ning lamp 16 Torque sensor 3 Ignition switch 10 To vehicle speed sensor VSS for G10 engine model To ECM PCM for M13 engine model 17 P S control module body ground 4 Circuit fuse box 11 Noise suppresso...

Page 74: ...p as ignition switch is turned to ON position Does EPS warning lamp come ON when igni tion switch is turned to ON position Go to Step 2 Proceed to Table A EPS Warning Lamp Does Not Light 2 Check that...

Page 75: ...ctor from P S control module 2 Measure resistance between G14 5 termi nal of A connector and body ground Is resistance 1 or less Go to step 3 Substitute a known good P S control module and recheck 3 1...

Page 76: ...and then remove the bolt s left with the wheel NOTE All front suspension fasteners are an important attaching part in that it could affect the perfor mance of vital parts and systems and or could resu...

Page 77: ...lower end of knuckle is attached to the stud of a ball joint which is incorporated in a unit with a suspension control arm And connected to this steering knuckle is the tie rod end Thus movement of th...

Page 78: ...tion as necessary Tightening torque Wheel bolt a 95 N m 9 5 kg m 69 0 lb ft 3 By rotating wheel actually check wheel bearing for noise and smooth rotation If defective replace bearing 4 Check wheel be...

Page 79: ...1 so that paint mark 2 on it comes to the right side of vehicle Align the outside edge 1 of mount bushing with the inside edge 2 of paint as shown in figure 1 Split pin 4 Stabilizer bar bushing 7 Mou...

Page 80: ...ghtening torque Castle nut a 50 150 N m 5 0 15 0 kg m 36 5 108 5 lb ft Install wheels and tighten wheel bolts to specified torque Tightening torque Wheel bolt a 95 N m 9 5 kg m 69 0 lb ft Strut Assemb...

Page 81: ...ring Components 1 Wheel hub 5 Dust cover 9 Tie rod end nut 13 Brake disk screw 2 Circlip 6 Tie rod end 10 Control arm ball stud bolt 14 Brake disc 3 Wheel bearing Face grooved rubber seal side to whee...

Page 82: ...er bolts 5 Remove caliper with carrier 6 Remove brake disk screws 7 Pull brake disc 1 off by using two 8 mm bolts 2 8 Pull out wheel hub 1 with special tools Special tool A 09943 17912 B 09942 15511 N...

Page 83: ...h puller 10 Remove wheel speed sensor 1 from knuckle if equipped 11 Remove strut bracket bolts 1 from strut bracket and then control arm ball stud bolt 2 12 Remove knuckle 3 Disassembly 1 Uncaulk and...

Page 84: ...locations around it so as not to cause damage to seating part 2 of wheel hub Special tool C 09913 61110 D 09925 88210 Assembly 1 Face grooved rubber seal side 1 of new wheel bearing upward as shown a...

Page 85: ...in dust cover 1 so that dimensions a and b become equal as shown 4 Caulk with a punch Installation 1 Using special tools and hydraulic press 1 drive wheel hub 2 into wheel bearing 3 as shown Special t...

Page 86: ...ve and install con trol arm ball stud bolt 5 Tighten each bolt and nuts to spec ified torque Tightening torque Strut bracket bolt a 115 N m 11 5 kg m 83 5 lb ft Control arm ball stud bolt b 60 N m 6 0...

Page 87: ...t Suspension Control Arm Bushing Removal 1 Hoist vehicle and remove wheel referring to Wheel Removal in Section 3F 2 Remove split pin 12 stabilizer bar nut 10 washer 9 and bushing 8 3 Remove stabilize...

Page 88: ...rol arm onto flat surface side of spe cial tool and install new bushing with special tool and oil hydraulic press as shown Special tool A 09943 77910 2 Install suspension control arm to vehicle body a...

Page 89: ...tion tighten con trol arm mounting bolt 1 to specified torque Tightening torque Control arm mounting bolt a 60 N m 6 0 kg m 43 5 lb ft Install stabilizer bar referring to Stabilizer Bar Installation i...

Page 90: ...2 15511 09900 06108 09913 75810 Front wheel hub remover Sliding hammer Snap ring pliers closing type Bearing installer for gasoline engine model 09913 85210 09913 61110 09925 88210 09913 75510 for die...

Page 91: ...3D 16 FRONT SUSPENSION...

Page 92: ...Leave a bolt at least not to drop the wheel Support the wheel and or tire and then remove the bolt s left with the wheel NOTE All suspension fasteners are an important attaching part in that it could...

Page 93: ...irclip 2 Rear bump stopper 5 Lateral rod 8 Wheel bearing Tightening torque 3 Rear spring upper seat 6 Trailing arm 9 Brake drum 6 7 5 2 1 3 4 90 N m 9 0 kg m 63 N m 6 3 kg m 63 N m 6 3 kg m 95 N m 9 5...

Page 94: ...ainer ring or rear wheel sensor ring if equipped with ABS B Without ABS 5 Lateral rod 10 Rear axle shaft 15 Spacer 1 Rear coil spring 6 Trailing arm 11 Breather cap Tightening torque 2 Rear bump stopp...

Page 95: ...ness and as necessary retighten to specification Tightening torque Wheel bolt a 95 N m 9 5 kg m 69 0 lb ft Check wheel bearings for wear When measuring thrust play apply a dial gauge to spindle cap ce...

Page 96: ...ear bump stopper Apply soap water when installing 9 Bearing Seal side of bearing comes brake back plate side 16 Lateral rod axle side nut Tightening torque 3 Rear spring upper seat 10 Brake drum 17 La...

Page 97: ...r 4 Rear shock absorber 15 Brake back plate 26 Lateral rod dumper nut 5 Lateral rod 16 Lateral rod axle housing side nut 27 Lateral rod dumper 6 Trailing arm 17 Lateral rod body side bolt Insert from...

Page 98: ...ve vehicle off hoist and in non loaded condi tion when tightening them Tightening torque Lateral rod nut axle side a 50 N m 5 0 kg m 36 5 lb ft Lateral rod nut body side b 100 N m 10 0 kg m 72 5 lb ft...

Page 99: ...per installing direction of bolt 2 Tighten nut 3 temporarily by hand at this step 4 Remove floor jack from rear axle or axle housing 5 Install brake flexible hose E ring 6 Install LSPV spring to rear...

Page 100: ...portioning Valve Inspection and Adjustment in Section 5A and Brake Fluid Pressure Test if equipped with LSPV in Section 5 Bump Stopper Installation 1 Install bumper stopper 2 Install wheel and tighten...

Page 101: ...ar axle 7 Install wheel and tighten wheel bolts to specified torque Tightening torque Wheel bolt a 95 N m 9 5 kg m 69 0 lb ft 8 Lower hoist and vehicle in non loaded condition tighten trail ing arm fr...

Page 102: ...2 temporarily by hand 3 Install coil springs 1 right left on spring seat 2 of rear axle as shown in figure and then raise rear axle 4 Tighten shock absorber lower bolts 1 right left tempo rarily by ha...

Page 103: ...left and tighten brake pipe flare nuts 2 to specified torque Tightening torque Brake pipe flare nut b 16 N m 1 6 kg m 11 5 lb ft 10 Connect brake flexible hoses 1 right left to bracket on rear axle an...

Page 104: ...stall console box 17 Lower hoist and bounce vehicle up and down several times to stabilize suspension 18 Tighten right and left trailing arm rear nuts shock absorber lower bolts and lateral rod rear a...

Page 105: ...llation 1 Install new wheel bearing 1 by using special tool and hydraulic press Special tool A 09913 75810 2 Install circlip 1 Special tool A 09900 06108 3 Install brake drum and wheel referring to Br...

Page 106: ...rake shoe referring to Brake Shoe in Section 5C 5 Remove parking brake cable from brake back plate 6 Disconnect brake pipe 1 from wheel cylinder and put wheel cylinder bleeder plug cap 2 onto pipe to...

Page 107: ...retainer ring as illustrated till it becomes thin 11 Break with a chisel the thin ground retainer ring and it can be removed 12 Using special tools remove bearing 1 from shaft and then remove brake ba...

Page 108: ...ng an hydraulic press 4 3 Inspect axle shaft length Rear axle shaft length a Right side 657 5 mm 25 9 in Left side 785 5 mm 30 9 in 4 Apply grease to axle shaft oil seal 1 lip as shown A Grease 99000...

Page 109: ...on in Section 5C 11 Install wheel speed sensor if equipped with ABS 12 Install brake drum right left after marking sure that inside of brake drum and brake shoes are free from dirt and oil Then tighte...

Page 110: ...and remove E rings 3 4 Remove brake pipes from wheel cylinders right left 5 Remove wheel speed sensors right left and release clamps from axle housing if equipped with ABS 6 Remove LSPV adjust nut an...

Page 111: ...but don t remove bolts 12 Remove shock absorber lower mounting bolts 1 13 Lower floor jack until tension of suspension coil spring becomes a little loose and remove trailing arm rear mounting bolts 2...

Page 112: ...ring seat 2 of axle housing 1 and raise axle housing 3 Install shock absorber 1 right left to axle housing 2 and install bolts in proper direction as shown Then tighten bolts 3 right left temporarily...

Page 113: ...spring to rear axle Tighten LSPV adjust nut temporarily at this step if equipped with LSPV 9 Install wheel speed sensor and clamp wire securely right left if equipped with ABS 10 Remove floor jack fr...

Page 114: ...e Shoe in Section 5C 20 Install brake drums 1 right left after making sure that inside of brake drum and brake shoes are free from dirt and oil Then tighten brake drum screw 2 21 Fill reservoir with b...

Page 115: ...ipped with LSPV check and adjust LSPV spring refer ring to LSPV Inspection and Adjustment in Section 5A and perform Fluid Pressure Test in Section 5 30 Check each installed part for oil leakage Tighte...

Page 116: ...rier and axle housing Differential carrier bolt Gear oil For gear oil information refer to Section 7F for 4WD Model Differential gear Rear axle housing Water tight sealant SUZUKI SEALING COMPOUND 366E...

Page 117: ...earing installer for 2WD Model Universal puller for 4WD Model Snap ring pliers for 2WD Model 09942 15511 09943 17912 09921 57810 09913 50121 Sliding hammer Brake drum remover Bearing remover for 4WD M...

Page 118: ...rmance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not...

Page 119: ...nnecessary sharp braking increase tire wear Maintenance And Minor Adjustments Wheel Maintenance Wheel repairs that use welding heating or peening are not approved All damaged wheels should be replaced...

Page 120: ...d to proper torque to avoid bending wheel or brake disc left figure WARNING Do not removal all of the wheel bolts at once because all the wheels of this vehicle are mounted by the wheel bolts Leave a...

Page 121: ...WHEELS AND TIRES Tightening order A B C D Tightening torque Wheel bolt a 95 N m 9 5 kg m 69 0 lb ft Tightening Torque Specifications Fastening part Tightening torque N m kg m lb ft Wheel bolt 95 9 5...

Page 122: ...n 4A 18 Required Service Material 4A 19 Special Tools 4A 19 General Description A constant velocity double offset joint DOJ and tripod joint are used on the differential side of drive shaft as the fol...

Page 123: ...thread 13 Drive shaft washer 2 Drive shaft assembly 8 Oil drain plug Apply sealant 99000 31260 to plug thread 14 Center bearing support 3 Tie rod end 9 Tie rod end nut 15 Center shaft 4 Suspension con...

Page 124: ...nual mentioned in the FOREWORD of this manual For M T model with M13 engine Refer to Transaxle Oil Change in Section 7A2 For A T model Refer to Fluid Change in Section 7B1 6 Drain transfer oil referri...

Page 125: ...ine Using plastic hammer drive out drive shaft joint 2 so as to release snap ring fitting of joint spline at transfer side 10 Remove two stabilizer mount brackets from vehicle body 11 Disconnect front...

Page 126: ...Change in Section 7A2 For A T model Refer to Fluid Change in Section 7B1 Fill transfer oil referring to Oil Change in Section 7D of the Service Manual mentioned in the FOREWORD of this man ual Check...

Page 127: ...ack grease included in spare part to joint 9 Differential side joint LH of all models Apply Black grease included in spare part to joint 17 Circlip 2 Boot Differential transfer or center shaft side 10...

Page 128: ...ig band with joint Draw hooks of boot big band together and remove band 2 Remove DOJ from shaft as follows a Fold over boot and remove old grease so that retaining ring 1 is accessible b Clamp drive s...

Page 129: ...saw or a nipper with care not to damage wheel side joint housing For boot big band with joint Draw hooks of boot big band together and remove band 6 Remove wheel side small band and then pull out whee...

Page 130: ...t Draw hooks of boot big band together and remove band 2 Take out tripod joint housing 2 3 Wipe off grease from shaft and take off snap ring 1 by using special tool Special tool A 09900 06107 4 Remove...

Page 131: ...and differential side joint 2 are washed thoroughly and air dried and boots 3 are cleaned with cloth if they are to be reused 1 Wash disassembled parts except boots and then dry parts completely by bl...

Page 132: ...el side boot big band onto boot putting band outer end 1 against forward rotation 2 as shown in figure 7 Fasten wheel side boot big band 1 by drawing hooks 2 with plier 3 and engage hooks 4 in slot an...

Page 133: ...model with M13 engine a 157 163 mm 6 18 6 42 in 11 Install retaining ring 2 to cage 1 12 Set new differential side small band 2 and differential side boot 1 on shaft temporarily 13 Apply grease in th...

Page 134: ...allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure Length a 181 4 mm 7 26 in b 147 1 mm 5 88 in 16 Install and fasten new big and small bands at the position...

Page 135: ...ase color For 2WD model Dark brown For 4WD model Black Grease amount Approx 70 g 2 5 oz 4 Install wheel side boot on shaft fill up boot inside with grease and then fasten boot big band 1 by drawing ho...

Page 136: ...t side drive shaft according to dimension specified below if equipped Damper installing position a 347 353 mm 13 66 13 90 in 9 Set new differential side small band and differential side boot 1 on shaf...

Page 137: ...1 to joint housing 2 with differential side big band 3 adjust so that measured dimensions become as indicated below Length a 152 7 mm 6 11 in for right side of G10 engine model b 188 2 mm 7 53 in for...

Page 138: ...ss 1 draw out center shaft 2 from cen ter shaft support bearing 3 Remove oil seals from center bearing support bracket 3 4 Remove bearing support circlip s 1 by using special tool Special tool A 09900...

Page 139: ...0 35 in b 2 3 mm 0 08 0 12 in For A T model a 0 mm 0 in b 0 mm 0 in Be sure to apply grease to oil seal lip and bearing side space indicated in figure A Grease 99000 25010 Press fit center shaft 1 fr...

Page 140: ...eal lip Sealant SUZUKI BOND NO 1217G 99000 31260 Oil drain and filler level plugs for manual transmission 09900 06107 09900 06108 09913 76010 09925 15410 Snap ring plier Open type Snap ring plier Clos...

Page 141: ...4A 20 FRONT DRIVE SHAFT G10 M13 ENGINES...

Page 142: ...4B PROPELLER SHAFTS CONTENTS On Vehicle Service 4B 2 Tightening Torque Specification 4B 6 NOTE For the descriptions items not found in this section refer to the same section of the Service Manual ment...

Page 143: ...t is found replace Check propeller shaft center support for biting of foreign mat ter crack abnormal noise and damage If any defect is found replace A Forward 4 Propeller shaft No 2 bolt Apply thread...

Page 144: ...o give match marks 1 on propeller shaft No 2 yoke 5 dynamic damper 3 viscous coupling with center support 6 yoke 7 of propeller shaft No 1 with center support 8 and transfer output flange 9 3 Loosen p...

Page 145: ...ler shaft No 1 with center support 2 propeller shaft No 2 3 dynamic damper 5 and viscous coupling with center sup port 4 all together 6 Disconnect propeller shaft No 1 with center support and pro pell...

Page 146: ...ion may occur during driving Apply thread lock cement to thread of propeller shaft No 2 bolts A Cement 99000 32110 Use following specification to torque bolts Tightening torque Propeller shaft bolt a...

Page 147: ...S Tightening Torque Specification Fastening portion Tightening torque N m kg m lb ft Propeller shaft bolt 23 2 3 17 0 Propeller shaft No 2 bolt 23 2 3 17 0 Center support bolt 55 5 5 40 0 Viscous coup...

Page 148: ...he ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module S...

Page 149: ...the vehicle without ABS In this brake system the disc brake type is used for the front wheel brake and a drum brake type leading trail ing shoes for the rear brake The parking brake system is mechani...

Page 150: ...keep at least one half full of fluid during bleeding operation 2 Remove bleeder plug cap 1 Attach a vinyl tube 2 to bleeder plug of wheel cylinder and insert the other end into container 3 CAUTION Br...

Page 151: ...line 6 When bubbles stop with depressing brake pedal tighten bleeder plug Tightening torque Brake bleeder plug b 8 5 N m 0 85 kg m 6 5 lb ft for rear brake Brake bleeder plug b 6 5 N m 0 65 kg m 5 0 l...

Page 152: ...e 2 Remove rubber cover plug 1 from brake back plate 3 Through hole of back plate visually check for thickness of brake shoe lining 2 If lining thickness f is found less than below specified wear limi...

Page 153: ...5 6 BRAKES...

Page 154: ...started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in...

Page 155: ...g to figure below When installing hose make sure that it has no twist or kink 2 Fill and maintain brake fluid level in reservoir Bleed brake system 3 Perform brake test and check each installed part f...

Page 156: ...out ABS vehi cle 2WD 2 LSPV assembly 5 Out side Tightening torque a g Clamp 3 E ring Insert delection 6 Front side A B View A a Detail B View C b c d e f g 3 1 C 3 2 2 3 1 3 6 4 4 4 4 4 6 4 6 4 7 4 7...

Page 157: ...r brake hose 7 From master cylinder Secondary 11 Front side a g Clamp 4 To left rear wheel cylinder 8 Top side 12 E ring Insert delection 1 E ring 5 To right rear wheel cylinder 9 Left side Tightening...

Page 158: ...steners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part numbe...

Page 159: ...result If any component is removed or line disconnected bleed the brake system Replace pads in axle sets only The torque values specified are for dry unlubricated fasteners 1 Wheel bolt Tightening to...

Page 160: ...rake Caliper Installation 1 Install caliper 1 to caliper carrier 2 2 Torque caliper pin bolts 3 to specifications Tightening torque Caliper pin bolt a 30 N m 3 0 kg m 22 0 lb ft 3 Install brake flexib...

Page 161: ...Brake Disc Removal 1 Hoist vehicle and remove wheel 2 Remove caliper assembly by loosening carrier bolts 1 3 Remove brake disc screws 4 Remove disc by using M8 x 1 25 bolts 1 2 pcs Installation 1 Ins...

Page 162: ...pecifications Tightening torque Wheel bolt b 95 N m 9 5 kg m 69 0 lb ft 5 Upon completion of installation perform brake test Tightening Torque Specification Fastening part Tightening torque N m kg m l...

Page 163: ...5B 6 FRONT BRAKE...

Page 164: ...uld render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK...

Page 165: ...drum brake Lubricate parts as speci fied If any hydraulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners A 2WD Mo...

Page 166: ...h ABS 3 Retractor spring 11 Sensor ring if equipped with ABS 19 Adjuster cover 4 Brake adjuster strut Apply Bentonite base brake grease between actuator and shoe rim and at actuator pivot points 12 Ci...

Page 167: ...ocation 1 Parking brake lever assembly 4 Parking cable bracket 7 Parking brake cable bolt 2 Equalizer 5 Parking brake cable Apply water tight sealant 99000 31090 to plate and cable contact 8 Parking b...

Page 168: ...parking brake lever 5 Remove brake drum If brake drum can not be removed easily increase clearance between brake shoes and drum as follows a Remove console box cap and loosen parking brake cable adju...

Page 169: ...09926 68310 2 Before installing brake drum check outer diameter a of brake shoes If it is not within value as specified below adjust it to specification by turning adjuster NOTE When drum is removed v...

Page 170: ...adjustment refer to Parking Brake Inspection and Adjustment in Section 5 9 Install console box cap if removed 10 Install wheel and tighten wheel bolts to specified torque Tightening torque Wheel bolt...

Page 171: ...rake drum and brake shoes are free from dirt and oil 3 Tighten screw 1 to specified torque Tightening torque Brake dram screw a 9 N m 0 9 kg m 6 5 lb ft 4 Upon completion of all jobs depress brake ped...

Page 172: ...rake test foot brake and parking brake Brake Back Plate for 2WD Model Removal 1 Remove brake drum referring to step 1 to 5 of Brake Drum Removal in this section 2 Remove brake shoe referring to step 2...

Page 173: ...ure it with clip 3 A Sealant 366E 99000 31090 4 Install wheel cylinder and tighten wheel cylinder bolts and brake pipe flare nut to specified torque Refer to steps 1 to 4 of Wheel Cylinder Installatio...

Page 174: ...ee from dragging and proper braking is obtained Then remove vehicle from hoist and perform brake test foot brake and parking brake 12 Check each installed part for oil leakage Brake Back Plate for 4WD...

Page 175: ...12 09913 75520 Sliding hammer Brake drum remover Front wheel hub remover Bearing installer for 2WD model Snap on Part NO B3404B or equivalent 09913 65135 09926 68310 09950 78230 Bearing puller for 2WD...

Page 176: ...nd Engine Doesn t Start Though It Is Cranked Up 6 2 58 DTC P0010 Camshaft Position Actuator Circuit 6 2 61 DTC P0011 Camshaft Position Timing Over Advanced or System Performance 6 2 64 DTC P0012 Camsh...

Page 177: ...High 6 2 110 DTC P0335 Crankshaft Position CKP Sensor Circuit 6 2 112 DTC P0340 Camshaft Position Sensor Circuit 6 2 116 DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected 6 2 120 DTC P04...

Page 178: ...lly stated A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation Whenever valve train components pistons piston...

Page 179: ...e opening should be covered This will protect against accidental entrance of foreign material which could follow intake passage into cylinder and cause exten sive damage when engine is started Precaut...

Page 180: ...block drive wheels 2 Remove relay box cover A With short pipe fit hose as far as it reaches pipe joint as shown B With following type pipe fit hose as far as its peripheral projection as shown C With...

Page 181: ...re now safe for servicing 6 Upon completion of servicing connect fuel pump relay 1 to relay box 2 and install relay box cover Fuel leakage check procedure After performing any service on fuel system c...

Page 182: ...MIL 1 turns ON to check the circuit of the malfunction indicator lamp 1 When ECM detects a malfunction which gives an adverse effect to vehicle emission while the engine is running it makes the malfun...

Page 183: ...s detected by checking the freeze frame data Also ECM has a function to store each freeze frame data for three different malfunctions in the order as the malfunction is detected Utilizing this functio...

Page 184: ...ol to communicate with ECM Air bag SDM immobilizer control module and ABS control module FRAME FRAME 1 FRAME 2 FRAME 3 FRAME 4 FREEZEFRAME DATA to be updated 1st FREEZE FRAME DATA 2nd FREEZE FRAME DAT...

Page 185: ...Priorities for diagnosing troubles If two or more diagnostic trouble codes DTCs are stored proceed to the flow table of the DTC which has detected ear liest in the order and follow the instruction in...

Page 186: ...Visual Inspection in followings Is there any faulty condition Go to Step 8 5 Trouble Symptom Confirmation 1 Confirm trouble symptom referring to the Trouble Symptom Confirmation in followings Is troub...

Page 187: ...C Confirmation Procedure described in each DTC Diagnosis Flow Table 6 and 7 RECHECKING AND RECORD OF DTC FREEZE FRAME DATA Refer to DTC check in this section for checking procedure 8 ENGINE BASIC INSP...

Page 188: ...ENERAL INFORMATION AND DIAGNOSIS M13 ENGINE 6 2 13 Customer Problem Inspection Form Example NOTE The above form is a standard sample It should be modified according to conditions characteristic of eac...

Page 189: ...ata according to instructions displayed on scan tool and print it or write it down Refer to scan tool operator s manual for further details If communication between scan tool and ECM is not possi ble...

Page 190: ...wing cases Be careful not to clear them before keeping their record When power to ECM is cut off by disconnecting bat tery cable removing fuse or disconnecting ECM con nectors When the same malfunctio...

Page 191: ...voltage P0107 Manifold absolute pressure low input Low voltage or manifold absolute pressure sensor circuit open or shorted to ground 1 driving cycle P0108 Manifold absolute pressure high input High v...

Page 192: ...shaft position sensor circuit No reference signal during engine cranking or pulse number of position signal is out of specification P0401 Exhaust gas recirculation flow insufficient detected Insuffici...

Page 193: ...arometric pressure circuit low Barometric pressure sensor circuit shorted to ground 1 driving cycle P2229 Barometric pressure circuit high Barometric pressure sensor circuit open 1 driving cycle P1610...

Page 194: ...ure sensor circuit high P0117 Engine coolant temperature circuit low ECM controls actuators assuming that engine cool ant temperature is 80 C 176 F ECM operates radiator fan P0118 Engine coolant tempe...

Page 195: ...rative Emission Control System Inspection in Section 6E2 Connectors of electric wire harness disconnection friction Fuses burning Parts installation bolt looseness Parts deformation Other parts that c...

Page 196: ...s 1 Using SUZUKI scan tool select MISC mode on SUZUKI scan tool and fix ignition timing to initial one See Fig 2 2 Using timing light 1 check initial ignition timing See Fig 3 Is it 5 3 BTDC at specif...

Page 197: ...Go to Ignition Spark Test in Section 6F2 12 Check fuel injector for operation as follows 1 Install spark plugs and connect injector connectors 2 Using sound scope 1 check operating sound of each injec...

Page 198: ...body gasket Faulty idle air control system Table B 4 Idle Air Control System Check in this section Faulty ECT sensor or MAF sensor ECT Sensor Inspection or Mass Air Flow MAF and Intake Air Temperature...

Page 199: ...d Inspection in Section 6A2 Warped or bent valve Valves and Cylinder Head Inspection in Section 6A2 Worn piston ring and cylinder bore Pistons Piston rings Connecting Rods and Cylinders Inspection in...

Page 200: ...gh tension Cords Inspection in Sec tion 6F2 Faulty spark plug improper gap heavy deposits and burned electrodes etc Spark Plugs Inspection in Section 6F2 Malfunctioning EGR valve EGR Valve Inspection...

Page 201: ...ylinder Head Inspection in Section 6A2 Engine hesitates Momentary lack of response as accel erator is depressed Can occur at all vehicle speeds Usually most severe when first trying to make vehicle mo...

Page 202: ...ith throttle opening Sounds like pop corn pop ping Faulty spark plug Spark Plugs Inspection in Section 6F2 Loose connection of high tension cord High tension Cords Removal and Installation in Section...

Page 203: ...this section Air inhaling from intake manifold gasket or throttle body gasket Engine overheating Overheating in this table Malfunctioning EGR valve EGR Valve Inspection in Section 6E2 Maladjusted acc...

Page 204: ...Control System Check in this section Faulty evaporative emission control system Evaporative Emission Control System Inspection in Section 6E2 Faulty EGR system EGR Valve Inspection in Section 6E2 Fau...

Page 205: ...Flow MAF and Intake Air Temperature IAT Sensor Inspection in Section 6E2 Faulty injector s Table B 1 Fuel Injector Circuit Check in this section Faulty ECM Engine not at normal operating temperature C...

Page 206: ...ll electric loads P S and all the other necessary switches SCAN TOOL DATA VEHICLE CONDITION NORMAL CONDITION REFERENCE VALUES COOLANT TEMP ENGINE COOLANT TEMP At specified idle speed after warming up...

Page 207: ...ESSURE At specified idle speed with no load after warm ing up 24 38 kPa 180 285 mmHg BAROMETRIC PRES Display the barometric pres sure STEP EGR FLOW DUTY At specified idle speed after warming up 0 FUEL...

Page 208: ...indicates the ECM requested idle If the engine is not running this number is not valid IAC FLOW DUTY IDLE AIR SPEED CONTROL DUTY This parameter indicates current flow time rate within a certain set c...

Page 209: ...st catalyst It is used to detect catalyst dete rioration FUEL SYSTEM FUEL SYSTEM STATUS Air fuel ratio feedback loop status displayed as one of the followings OPEN Open loop has not yet satisfied cond...

Page 210: ...ht ON signal inputted OFF Above electric loads all turned OFF BRAKE SW ON OFF This parameter indicates the state of the brake switch RADIATOR FAN RADIATOR FAN CONTROL RELAY ON OFF ON Command for radia...

Page 211: ...y prohibited to connect voltmeter or ohmmeter to ECM with coupler disconnected from it NOTE As each terminal voltage is affected by the battery volt age confirm that it is 11 V or more when ignition s...

Page 212: ...tch turned ON 0 2 V 8 14 V Reference wave form No 4 Engine running at idling with after warm ing up Output signal is active low duty pulse Pulse generated times depending on vehicle condition E23 9 E2...

Page 213: ...2 E23 23 E23 24 E23 25 E23 26 E23 27 E23 28 E23 29 E23 30 E23 31 RED BLU Ignition coil No 2 and No 3 output 0 0 6 V Ignition switch turned ON 0 0 6 V 2 5 V Reference wave form No 6 Engine running Outp...

Page 214: ...eference wave form No 10 and No 11 Engine running Output signal is active low pulse Pulse frequency varies depending on engine speed E22 5 BLU RED Fuel injector No 3 out put 10 14 V Ignition switch tu...

Page 215: ...gine running at specified idle speed after warming up E22 15 LT GRN RED Manifold absolute pressure MAP sensor signal About 4 V Reference wave form No 19 Ignition switch turned ON with baromet ric pres...

Page 216: ...19 ml h E22 34 GRY Throttle position TP sensor signal 0 5 1 0 V Ignition switch turned ON and throttle valve at idle position with warmed engine 3 4 4 7 V Ignition switch turned ON and throttle valve...

Page 217: ...n switch turned ON blower fan selector selected at OFF 0 1 V Ignition switch turned ON blower fan selector selected at 2nd speed position or more E21 14 YEL RED Fuel level sensor sig nal 0 6 V Ignitio...

Page 218: ...ometer 0 1 V 10 14 V Reference wave form No 21 Vehicle running Sensor signal is pulse Pulse frequency varies depending on vehicle speed 8190 pulses sec are generated par 60 km h 37 5 ml h E21 32 WHT G...

Page 219: ...37 mil h for 10 min Engine at specified idle speed 1 Heated oxygen sensor 2 signal 2 Heated oxygen sensor 2 heater signal Measurement terminal CH1 E22 11 to E23 1 CH2 E23 4 to E23 1 Oscilloscope setti...

Page 220: ...23 1 CH3 E23 16 to E23 1 CH4 E23 33 to E23 1 Oscilloscope setting CH1 20 V DIV CH2 20 V DIV CH3 20 V DIV CH4 20 V DIV TIME 40 ms DIV Measurement condition At the moment of the ignition switch in turne...

Page 221: ...up to normal operating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 No 1 and No 4 ignition signal Measurement terminal CH1 E22 3 to E23 1 Oscilloscope...

Page 222: ...le speed 1 Cylinder reference signal CMP reference signal 2 Fuel injector signal Measurement terminal CH1 E22 10 to E23 1 CH2 E22 4 to E23 1 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV TIME 40 ms DI...

Page 223: ...fied idle speed 1 Cylinder reference signal CMP reference signal 2 No 2 fuel injector signal Measurement terminal CH1 E22 10 to E23 1 CH2 E22 7 to E23 1 Oscilloscope setting CH1 5 V DIV CH2 20 V DIV T...

Page 224: ...emperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 CKP signal Measurement terminal CH1 E22 14 to E22 28 CH2 E22 34 to E22 28 Oscilloscope setting CH1 1 V DIV...

Page 225: ...ng temperature Engine racing 1 Manifold absolute pressure sensor signal 2 Throttle position sensor signal Measurement terminal CH1 E21 31 to E23 1 CH2 E22 19 to E23 1 Oscilloscope setting CH1 5 V DIV...

Page 226: ...perating temperature Engine at specified idle speed 1 Cylinder reference signal CMP reference signal 2 Ignition pulse signal Measurement terminal CH1 E22 16 to E22 28 CH2 E21 32 to E23 1 Oscilloscope...

Page 227: ...tor fan relay 160 240 E23 15 to E21 28 Main relay 160 240 Battery discon nected and ignition switch ON E23 14 to E21 28 Fuel pump relay 160 240 E23 5 to E21 5 6 A C condenser fan relay No 2 if equippe...

Page 228: ...gen sensor 1 e Malfunction indicator lamp E Data link connector 5 1 Heated oxygen sensor 2 f Radiator fan control relay F A C compressor relay if equipped 6 VSS g IAC valve G TCM A T 7 Battery h Ignit...

Page 229: ...fuse 8 Circuit fuse box 3 Main relay 6 METER fuse E23 15 E21 28 12V 5V E21 6 E21 5 BLK WHT BLK RED BLK RED BLK RED WHT BLU 80A 60A 20A B BLK YEL BLK YEL BLK YEL BLU BLK BLU BLK PPL WHT E21 1 BLK RED B...

Page 230: ...ire terminals 5 If OK then turn ignition switch to ON posi tion and measure voltage between combi nation meter connector at BLK RED wire terminal and body ground Is it 10 14 V Go to Step 5 BLK RED wir...

Page 231: ...ombination meter 7 ECM 2 Ignition switch 5 IG COIL fuse 8 Circuit fuse box 3 Main relay 6 METER fuse E23 15 E21 28 12V 5V E21 6 E21 5 BLK WHT BLK RED BLK RED BLK RED WHT BLU 80A 60A 20A B BLK YEL BLK...

Page 232: ...tion8 3 Disconnect connectors from ECM 4 Measure resistance between PPL WHT wire terminal of combination meter connector and body ground Is resistance infinity Go to Step 3 PPL WHT wire cir cuit short...

Page 233: ...D C A E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20...

Page 234: ...check BLK YEL or BLK wire open circuit or high resistance circuit 6 Main Relay Circuit Check 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Using service wire ground E23 15 wire te...

Page 235: ...inity C and D 160 240 at 20 C 68 F 2 Check that there is continuity between terminals A and B when battery is connected to terminals C and D See Fig 4 Is main relay in good condition BLU BLK wire open...

Page 236: ...ake camshaft 2 ECM 5 Oil pump E22 1 E23 2 BLK BLK YEL BLK YEL E23 1 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16...

Page 237: ...vehicle body ground Is voltage 0 1 V Go to Step 4 BLK YEL wire shorted to power supply circuit 4 Check wire circuit 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Check for proper...

Page 238: ...l of ECM con nector and BLK YEL wire terminal of oil control valve con nector Is resistance 1 or less Go to Step 9 BLK YEL wire open or high resis tance circuit 9 Check wire circuit 1 Measure resistan...

Page 239: ...radually 8 Stop vehicle and ignition switch OFF 9 Repeat step 4 to 7 one time 10 Stop vehicle Check DTC Refer to DTC Check in this section Troubleshooting DTC Detecting Condition Trouble Area Actual v...

Page 240: ...ove oil control valve referring to Oil Control Valve Removal and Installation in Section 6A1 2 Remove oil gallery pipe referring to Oil Gallery Pipe Removal and Installation in Section 6A1 3 Check oil...

Page 241: ...YEL BLU BLK BLU BLK E22 1 E23 2 BLK YEL BLK YEL BLK E23 1 BLK RED WHT E22 14 E22 32 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11...

Page 242: ...low 5 Go to Step 6 Go to Step 5 5 Check ground circuit 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Remove ECM from vehicle body and connect connec tors to ECM 3 Measure resistan...

Page 243: ...ith ignition switch turned OFF 2 Check voltage between E22 14 and E22 32 under the following condition Voltage between E22 14 and E22 32 of ECM con nector at ignition switch ON leaving engine stop 0 5...

Page 244: ...YEL BLU BLK BLU BLK E22 1 E23 2 BLK YEL BLK YEL BLK E23 1 BLK RED WHT E22 14 E22 32 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11...

Page 245: ...ector and engine ground Is resistance below 5 Go to Step 6 Go to Step 5 5 Check ground circuit 1 Disconnect connectors from ECM with ignition switch turned OFF 2 Remove ECM from vehicle body and conne...

Page 246: ...2 32 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20...

Page 247: ...nal of IAT sensor connector and vehicle body ground See Fig 1 Is voltage about 4 6 V Go to Step 6 Go to Step 4 4 Check IAT circuit insulation 1 Disconnect connectors from ECM with igni tion switch tur...

Page 248: ...12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30...

Page 249: ...s from ECM with igni tion switch turned OFF 2 Remove ECM from vehicle body and con nect connectors to ECM 3 Check for proper connection of ECM con nector at E22 17 terminal 4 If OK then turn ON igniti...

Page 250: ...esistance between E22 28 ter minal of ECM connector and body ground Is resistance below 5 BRN WHT wire open cir cuit or high resistance cir cuit Poor E22 28 connection Faulty ECM ground cir cuit If ci...

Page 251: ...28 29 30 28 29 30 31 31 33 33 32 33 34 34 35 34 35 E22 28 BRN WHT BRN WHT 3 1 2 E22 16 YEL GRN DTC Detecting Condition Trouble Area DTC will be set when all of the following conditions are detected f...

Page 252: ...stance between YEL GRN wire terminal of ECT sensor connector and body ground Is resistance infinity Got to Step 5 YEL GRN wire shorted to ground circuit If wire are OK substitute a known good ECM and...

Page 253: ...4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26...

Page 254: ...V Go to Step 6 Go to Step 4 4 Check ECM voltage 1 Disconnect connectors from ECM with igni tion switch turned OFF 2 Remove ECM from vehicle body and con nect connectors to ECM 3 Check for proper conne...

Page 255: ...Step 8 8 Check ECT sensor ground circuit 1 Measure resistance between E22 28 ter minal of ECM connector and vehicle body ground Is resistance below 5 BRN WHT wire open cir cuit or high resistance cir...

Page 256: ...Area Difference between actual throttle opening detected from TP sensor and opening calculated by ECM obtained on the basis of engine speed and intake manifold pressure is larger than specified value...

Page 257: ...own in figure Go to Step 11 Go to Step 3 3 Check TP sensor voltage 1 Disconnect connector from TP sensor with ignition switch turned OFF 2 Check for proper connection to TP sensor connector at WHT GRN...

Page 258: ...ignition switch turned OFF Is resistance below 5 Go to Step 8 GRY wire in high resistance circuit 8 Check ground circuit 1 Connect connectors to ECM 2 Check for proper connection of MAP sensor connec...

Page 259: ...ace it 12 Is DTC P0506 or P0507 detected Go to applicable DTC diag flow table Go to Step 13 13 Check idle air control IAC valve 1 Check idle air control valve referring to Idle Air Con trol IAC Valve...

Page 260: ...0 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 2...

Page 261: ...GRY terminal of TP sensor con nector and body ground See Fig 1 Is each terminal voltage about 4 6 V Go to Step 5 Go to Step 4 4 Check ECM voltage 1 Check for proper connection of ECM con nector at E22...

Page 262: ...k resistance between terminals of TP sensor See Fig 2 TP sensor resistance Between 1 and 3 4 0 6 0 k Between 1 and 2 0 1 6 5 k Are measured values within specifications Substitute a known good ECM and...

Page 263: ...sor 4 ECM E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 2...

Page 264: ...HT GRN terminal of TP sensor connector and body ground Between GRY terminal of TP sensor con nector and body ground See Fig 1 Is each terminal voltage about 4 6 V Go to Step 6 Go to Step 4 4 Check ECM...

Page 265: ...AP sensor connector and body ground Is resistance below 5 Go to Step 9 Go to Step 8 8 Check ground circuit 1 Measure resistance between E22 28 wire terminal of ECM connector and body ground Is resista...

Page 266: ...N WHT BRN WHT BLK WHT BLK WHT E21 28 E23 4 E22 11 E22 28 9 6 2 7 5 4 1 3 8 10 DTC Detecting Condition Trouble Area DTC P0131 HO2S voltage is higher than 4 5 V even after engine run ning for specified...

Page 267: ...stem Check in this section 2 Is there DTC s other than HO2S 1 Go to applicable DTC diag flow table Go to Step 3 3 Check HO2S 1 signal 1 Connect scan tool to DLC with ignition switch turned OFF 2 Warm...

Page 268: ...connector from ECM with igni tion switch turn OFF 2 Measure resistance between RED wire terminal of HO2S 1 sensor connector and body ground Is resistance infinity Go to Step 8 RED wire shorted to grou...

Page 269: ...2 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30 3...

Page 270: ...gine and Emission Control System Check performed Go to Step 2 Go to Engine and Emis sion Control System Check in this section 2 Is there DTC s other than HO2S 1 DTC P0133 Go to applicable DTC diag flo...

Page 271: ...uously to enrich A F mixture and take foot off from pedal to enlean and check HO2S output voltage displayed on scan tool Is over 0 5 V and below 0 3 V indicated Go to Step 4 Go to Step 3 3 Check HO2S...

Page 272: ...ED wire terminal of HO2S 1 sensor connector and body ground Is resistance infinity Go to Step 7 RED wire shorted to ground circuit 7 Check HO2S 1 heater circuit 1 Check HO2S 1 heater circuit referring...

Page 273: ...r sensor 2 Shield wire 5 IG COIL fuse 8 To HO2S 2 heater 3 Ignition switch 6 HO2S 1 9 ECM E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9...

Page 274: ...and E21 28 terminal wire of ECM connector Is resistance below 5 Go to Step 4 BLK WHT wire high resistance circuit 4 Check HO2S 1 heater drive circuit 1 Measure resistance between E23 4 wire terminal o...

Page 275: ...n switch turned OFF 2 Connect connector to HO2S 1 with ignition switch turned OFF 3 Measure resistance between E23 4 wire and E21 28 wire terminals of ECM con nector It resistance below 12 HO2S 1 heat...

Page 276: ...TC Detecting Condition Trouble Area DTC will set when one of the following conditions is detected Maximum output voltage of HO2S 2 is lower than specified value or minimum output voltage is higher tha...

Page 277: ...arm up engine to normal operating tem perature and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal to...

Page 278: ...Step 8 BLU wire shorted to ground circuit 8 Check HO2S 2 signal circuit 1 Measure voltage between BLU wire termi nal of HO2S 2 sensor connector and vehi cle body ground Is voltage 0 V Go to Step 9 BL...

Page 279: ...6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 2...

Page 280: ...sor connector and E21 28 terminal wire of ECM connec tor Is resistance below 5 Go to Step 4 BLK WHT wire high resistance circuit 4 Check HO2S 2 heater drive circuit 1 Measure resistance between BLU RE...

Page 281: ...S 2 heater circuit are OK Substitute a known good ECM and recheck BLU RED wire high resistance circuit Step Action Yes No DTC Detecting Condition Trouble Area P0171 Total fuel trim is higher than 35 P...

Page 282: ...heck MAF sensor and air intake system for 1 Objects which block measuring duct and resistor of MAF sensor 2 Other air flow which does not pass the MAF sensor Are there in good condition Go to Step 7 R...

Page 283: ...ffects exhaust emission adversely during 1000 engine revolution is detected at 2 or more cylinders 2 driving cycle detection logic Ignition system Fuel injector and its circuit Fuel pressure EGR syste...

Page 284: ...plug or other system parts 4 Fuel injector circuit check 1 Using sound scope check each injector operating sound at engine cranking or idling Do all injectors make operating sound Go to Step 5 Check...

Page 285: ...ness and connection of ECM ground ignition system and fuel injec tor for intermittent open and short Repair or replace Step Action Yes No 1 Knock sensor 2 ECM E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2...

Page 286: ...ect connector from knock sensor with ignition switch turned OFF 2 Turn ON ignition switch measure voltage between WHT wire of knock sensor con nector and engine ground See Fig 1 Is voltage 4 6 V Go to...

Page 287: ...0 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30 31 31 33 33 32 33 34 34 35 34 35 E23 15 E21 28 12V 5V 5V E21 6 E21 5 BLK WHT BLK RED BLK RED BLK RED WHT BLU 80A 60A...

Page 288: ...or voltage at BLK RED PNK and BLK wire terminals of disconnected CKP sensor con nector See fig 1 Terminal B 10 14 V Terminal Vout 4 5 V Terminal GRD 0 V Is check result satisfactory Go to Step 5 Go to...

Page 289: ...ctor and engine ground by pass ing magnetic substance iron 1 while keep ing approx 1 mm 0 03 in gap with respect to end face of CKP sensor See fig 2 Does voltage vary from low 0 1 V to high 4 5 V or f...

Page 290: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS M13 ENGINE 6 2 115 A Fig 1 for Step 3 B Fig 3 for Step 8 C Fig 2 for Step 7...

Page 291: ...g Condition and Trouble Area 1 CMP sensor 3 ECM 5 Ignition switch 2 Signal rotor 4 Main relay 6 Starting motor E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10...

Page 292: ...ck for volt age at BLK RED ORN and BLK wire termi nals of disconnected CMP sensor connector See fig 1 Terminal B 10 14 V Terminal Vout 4 5 V Terminal GRD 0 V Is check result satisfactory Go to Step 5...

Page 293: ...or and engine ground by passing magnetic substance iron 1 while keeping approx 1 mm 0 03 in gap with respect to end face of CMP sen sor See fig 2 Does voltage vary from low 0 1 V to high 4 5 V or from...

Page 294: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS M13 ENGINE 6 2 119 A Fig 1 for Step 3 B Fig 3 for Step 8 C Fig 2 for Step 7...

Page 295: ...aust Gas Recirculation Flow Insufficient Detected DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected System Wiring Diagram 1 EGR value 4 Sensed information 7 IG COIL fuse 10 Main relay 2 Inta...

Page 296: ...ake manifold absolute pressure between opened EGR valve and closed EGR valve is larger than specified value 2 driving cycle detection logic monitoring once 1 driving EGR valve EGR passage MAP sensor E...

Page 297: ...ng between engine ground and each GRN YEL GRN BLK BLK RED and GRN ORN wire terminal of EGR valve connector Are there insulating Go to Step 8 Some wire shorted to ground circuit If wires are OK substit...

Page 298: ...way catalytic converter by HO2S 2 2 When the catalyst is functioning properly the variation cycle of HO2S 2 2 output voltage oxygen concentra tion is slower than that of HO2S 1 1 output voltage becau...

Page 299: ...s leak Three way catalytic converter malfunction HO2S 2 malfunction HO2S 1 malfunction WARNING When performing a road test select a place where there is no traffic or possibility of a traffic acci den...

Page 300: ...22 1 E23 2 BLK YEL BLK YEL BLK E23 1 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 2...

Page 301: ...finity Go to Step 4 RED BLK wire shorted to ground circuit 4 Check wire circuit 1 Measure voltage between E23 13 terminal of ECM connector and vehicle body ground Is voltage 0 V Go to Step 5 RED BLK w...

Page 302: ...in DTC mode 1 Relay box 3 Radiator fan relay 5 ECT sensor 2 Main relay 4 Radiator fan motor 6 ECM E23 15 12V 5V E21 6 E21 5 BLK RED BLK RED BLK RED 80A BLK YEL BLK YEL BLK YEL BLU BLK E22 1 E23 2 BLK...

Page 303: ...Step 4 Go to Step 6 4 Check Relay Circuit 1 Turn ignition switch to OFF position 2 Disconnect connectors from ECM 3 Remove radiator fan relay from relay box 4 Measure voltage between E21 4 wire ter m...

Page 304: ...sistance 1 or less Go to Step 8 BLU wire in open or high resistance circuit 8 Check Relay Circuit 1 Measure resistance between E21 4 wire terminal of ECM connector and vehicle body ground Is it infini...

Page 305: ...f equipped DTC Detecting Condition Trouble Area Vehicle speed signal is not input while fuel cut at deceleration for 4 seconds continu ously BRN circuit open YEL or BLK RED circuit open or short VSS m...

Page 306: ...Measure resistance between engine body ground and BRN wire terminal with ignition switch turn OFF Is resistance below 5 Go to Step 5 BRN wire open or high resistance circuit 5 Check wire circuit 1 Tur...

Page 307: ...voltage between E22 19 terminal of ECM connector and engine ground by pass ing magnetic substance iron 1 while keeping approx 1 mm 0 03 in gap with respect to end face of VSS Does voltage vary from lo...

Page 308: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS M13 ENGINE 6 2 133 A Fig 1 for Step 5 B Fig 2 for Step 9...

Page 309: ...BLU 80A 60A 20A BLK YEL BLK YEL BLK YEL BLU BLK BLU BLK E22 1 E23 2 BLK YEL BLK YEL BLK E23 1 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16...

Page 310: ...nals of idle air control valve connector and engine ground Is voltage 10 14 V Go to Step 5 BLK RED wire in open or high resistance circuit 5 Idle Air Control Valve Check 1 Check idle air control valve...

Page 311: ...smission range sensor shift switch E22 35 WHT BLU 80A 60A BLK YEL BLK YEL 1 2 3 5 4 C64 C63 G91 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11...

Page 312: ...itch turned OFF 2 Remove ECM from vehicle body and then connect connectors to ECM 3 Check for voltage at terminal E22 35 under the following condition While engine cranking 6 14 V After starting engin...

Page 313: ...17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30 31 31 33 33 32...

Page 314: ...igni tion switch turned OFF 2 Remove ECM from vehicle body and then connect connectors to ECM 3 Turn ON ignition switch measure voltage between vehicle body ground and E22 8 terminal Is voltage 4 5 V...

Page 315: ...re resistance between LT GRN RED wire terminal in MAP sensor harness connector and E22 15 terminal in ECM connector Is resistance below 5 Go to Step 12 LT GRN RED wire in open or high resistance circu...

Page 316: ...18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30 31 31 33 33 32 33 34 34 35 34 35 WHT GRN WHT GRN LT GRN RED E22 28 E22 15 E22 8 4 2 1...

Page 317: ...g 1 Is voltage 4 5 V Go to Step 5 Go to Step 4 4 Check MAP sensor power supply voltage 1 Disconnect connectors from ECM with igni tion switch turned OFF 2 Remove ECM from vehicle body and then connect...

Page 318: ...sing scan tool Troubleshooting Substitute a known good ECM and recheck 7 Check MAP sensor signal circuit 1 Disconnect connectors from ECM with igni tion switch turn OFF 2 Turn ON ignition switch 3 Mea...

Page 319: ...N ignition switch and clear DTC using scan tool and run engine at idle speed for 1 min 3 Check DTC and pending DTC 1 ECM 2 DOME RADIO fuse 3 Relay box E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6...

Page 320: ...tors from ECM with igni tion switch turned OFF 2 Remove ECM from vehicle body and then connect connectors to ECM 3 While engine running check voltage between E21 16 and ground Is voltage 10 14 V Poor...

Page 321: ...5 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30 31 31 33 33 32 33 34 34 35 34 35 2 1 D...

Page 322: ...WHT wire in shorted to ground circuit 6 Circuit Check 1 Check for proper connection to E21 8 ter minal of ECM connector and E13 17 ter minal of TCM connector 2 If OK measure resistance between E21 8...

Page 323: ...ECM sets DTC P1603 TCM outputs the trouble code to ECM when TCM can not compute the engine control signal due to malfunctions of sensor circuits used for gear shift control DTC Troubleshooting Step A...

Page 324: ...5 sec or more Keep fuel cut condition for 5 sec or more If fuel cut condition is not kept for 5 sec or more coast down a slope in engine speed 1000 3000 rpm for 5 sec or more 5 Stop vehicle and run e...

Page 325: ...d recheck MAP sensor or its circuit malfunction 1 Relay box 4 No 1 injector 7 No 4 injector 2 Main relay 5 No 2 injector 8 IG COIL fuse 3 ECM 6 No 3 injector 9 Ignition switch E23 15 E21 28 12V 5V E21...

Page 326: ...tion switch turned ON Is voltage 10 14 V Go to Step 5 BLK RED wire in open circuit or shorted to ground circuit If it is in good condition go to diag flow table A 3 5 Check wire circuit 1 Turn OFF ign...

Page 327: ...BLK WHT wire terminal and engine ground Is voltage 10 14 V Go to Step 3 BLK WHT wire open or shorted to ground circuit 3 Check fuel pump relay power supply 1 Turn ON ignition switch measure voltage be...

Page 328: ...titute a known good ECM and recheck 7 Check wire circuit 1 Turn OFF ignition switch 2 Detach fuel tank referring to Fuel Tank Removal and Installation in Section 6C 3 Disconnect connector from fuel pu...

Page 329: ...d line are in good con dition Step Action Yes No 1 Fuel Pressure Check 1 Check fuel pressure referring to Fuel Pressure Inspection under Fuel Delivery System in Sec tion 6E2 Are they satisfied each co...

Page 330: ...e fuel hose and joint for damage or deform Are they in good condition Faulty fuel pressure reg ulator Repair or replace 7 Fuel Pump Operating Sound Check 1 Remove fuel filler cap and then turn ON igni...

Page 331: ...25 26 27 26 27 28 29 30 31 32 32 28 29 30 28 29 30 31 31 33 33 32 33 34 34 35 34 35 E23 8 BLK RED BLK RED BLK GRN YEL 6 5 4 3 1 2 Step Action Yes No 1 Check engine idle speed and IAC duty referring t...

Page 332: ...ve Inspection in Section 6E2 See Fig 1 Is check result satisfactory Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection Inspection in Section 0A Go...

Page 333: ...BLU YEL RED 60A 60A 20A 30A E21 13 E21 15 E22 28 E23 E22 E21 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17...

Page 334: ...o ECM with ignition switch turned OFF 2 Measure voltage between E21 30 wire ter minal of ECM connector and vehicle body ground under the following condition With ignition switch ON and A C switch OFF...

Page 335: ...n Replace A C compressor relay 10 Check A C Compressor Relay Circuit 1 Remove A C compressor relay with ignition switch turned OFF 2 Turn ON ignition switch check voltage between BLU YEL wire terminal...

Page 336: ...l to DLC with ignition switch OFF 2 Start engine and select DATA LIST mode on scan tool 3 Check electric load signal under following each condition See Table 1 Is check result satisfactory Electric lo...

Page 337: ...N BRN WHT E22 28 BLK RED 1 2 6 3 4 5 Step Action Yes No 1 DTC Check Is there DTC s ETC sensor circuit DTC P0117 P0118 and or radiator fan circuit DTC P0480 displayed Go to corresponding DTC diag flow...

Page 338: ...wire circuit open or poor connection 7 Radiator Fan Control Circuit Check 1 Measure resistance between BLU RED wire terminal of radiator fan motor connec tor and vehicle body ground Is it infinite Go...

Page 339: ...t SUZUKI scan tool See NOTE C NOTE C This kit includes the 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...

Page 340: ...nts 6A2 34 Timing Chain Cover Removal and Installation 6A2 35 Timing Chain Cover Inspection 6A2 38 Oil seal 6A2 38 Timing chain cover 6A2 38 Oil control valve 6A2 39 Oil gallery pipe 6A2 39 Oil Pump C...

Page 341: ...Valves and Cylinder Head Inspection 6A2 63 Valve guides 6A2 63 Valves 6A2 63 Cylinder head 6A2 65 Valve springs 6A2 66 Pistons Piston Rings Connecting Rods and Cylinders Components 6A2 67 Pistons Pis...

Page 342: ...rs 4 stroke cycle gasoline unit with its DOHC Double overhead camshaft valve mechanism arranged for V type valve configuration and 16 valves 4 valves one cylinder The double overhead camshaft is mount...

Page 343: ...Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersecting passages drilled in the crankshaft and then injected from the big end of connecting rod to...

Page 344: ...f of the system operation the intake valve timing is varied by the cam timing sprocket 1 which var ies the rotational phase between the intake camshaft 3 and sprocket The rotor 2 in the cam timing spr...

Page 345: ...camshaft by fastening the bolts Therefore the actuation of the rotor makes the phase difference between the sprocket and intake camshaft Timing advancing When the duty ratio of the signal output from...

Page 346: ...ight engine load range To the retarded side To shorten the valve opening overlap in order to prevent the exhaust gas counterflow to intake manifold Keeping of the engine stability Low or average engin...

Page 347: ...ll spark plugs 6 Disconnect fuel injector wires 4 at the coupler 7 Install special tools compression gauge into spark plug hole Special tool A 09915 64512 B 09915 64530 C 09915 67010 8 Disengage clutc...

Page 348: ...ng temperature 2 Stop engine and turn off the all electric switches NOTE For measuring compression pressure crank engine at least 250 rpm by using fully charged battery If measured compression pressur...

Page 349: ...ing tape 3 or the like 7 Install air cleaner case and resonator 8 Run engine at specified idle speed and read vacuum gauge Vacuum should be within specification Vacuum specification at sea level 59 73...

Page 350: ...itch coupler 1 2 Remove exhaust manifold cover if necessary 3 Remove oil pressure switch 2 from cylinder block 4 Install special tools Oil pressure gauge to threaded hole of oil pressure switch Specia...

Page 351: ...ent 8 Before reinstalling oil pressure switch 2 be sure to wrap its screw threads with sealing tape 1 and tighten switch to specified torque Tightening torque Oil pressure switch a 14 N m 1 4 kg m 10...

Page 352: ...d 8 if not adjust it by turning crankshaft Check valve lashes d In the same manner as b c check valve lashes at valves 4 and 6 e In the same manner as b c again check valve lashes at valves 2 and 5 If...

Page 353: ...ts to specified torque Special tool A 09916 67020 or 09916 67021 Tightening torque Camshaft housing bolt for tightening of special tool a 11 N m 1 1 kg m 8 0 lb ft 4 Turn camshaft by approximately 90...

Page 354: ...him 2 650 mm 0 1043 in 6 Select new shim No 1 with a thickness as close as possi ble to calculated value Available new shims No 7 Install new shim facing shim No side with tappet Thickness mm in Shim...

Page 355: ...ighten 11 N m 1 1 kg m 8 0 lb ft by the specified procedure 10 Check valve clearance again after adjusting it 11 After checking and adjusting all valves 12 Install cylinder head cover referring to Cyl...

Page 356: ...Knock Sensor Removal and Installation in Section 6E2 Cylinder Head Cover Removal and Installa tion Removal 1 Disconnect negative cable at battery 2 Disconnect MAF sensor coupler 1 3 Remove EVAP canist...

Page 357: ...Remove cylinder head cover 1 with cylinder head cover gasket 2 and spark plug hole gasket 3 Installation 1 Install new spark plug hole gaskets 1 and new cylinder head cover gasket 2 to cylinder head c...

Page 358: ...0 75 kg m 5 5 lb ft by the specified procedure 5 Connect PCV hose 2 to PCV valve 1 6 Connect breather hose 4 7 Install oil level gauge 3 8 Install wire harness clamp to cylinder head cover 9 Install i...

Page 359: ...nsor bolt 27 To heater union 4 TP sensor 12 Breather hose 20 MAF sensor Tightening torque 5 IAC valve 13 EVAP canister purge valve 21 VSV bracket bolt Do not reuse 6 O Ring 14 EVAP canister purge valv...

Page 360: ...5 12 Remove throttle body 7 from intake manifold Installation Reverse removal procedure for installation noting the followings Use new throttle body O ring Check to ensure that all removed parts are...

Page 361: ...e for installation noting the followings Use new intake manifold O ring Use new EGR pipe gasket and O ring Tighten bolts 1 and nuts 2 to specified torque Tightening torque Intake manifold bolt and nut...

Page 362: ...ld stiffener 12 Exhaust pipe No 2 bolt 3 Exhaust oxygen sensor 8 Engine hook 13 Caution plate 4 Exhaust pipe gasket 9 Exhaust manifold mounting bolt and nut Tightening torque 5 Seal ring No 1 10 Exhau...

Page 363: ...ion 6B2 for equipped with A C 4 With hose connected detach A C condenser from vehicle body for equipped with A C 5 Disconnect heated oxygen sensor coupler 1 and detach it from its stay 6 Remove exhaus...

Page 364: ...e Exhaust manifold stiffener bolt b 50 N m 5 0 kg m 36 5 lb ft 4 Install new seal ring and connect exhaust No 1 pipe 1 to exhaust No 2 pipe Tighten pipe fasteners to specified torque Tightening torque...

Page 365: ...clutch housing lower plate 3 4 For 2WD vehicle remove engine rear mounting bracket 5 For 4WD vehicle remove transfer referring to Transfer Dis mounting and Mounting in Section 7D A Sealant applicatio...

Page 366: ...ion 1 Clean oil pump strainer screen 1 2 Clean sealing surface on oil pan and cylinder block Remove oil old sealant and dust from sealing surface 3 Apply sealant continuously to oil pan mating surface...

Page 367: ...ghtening torque Oil pan drain plug bolt b 50 N m 5 0 kg m 36 5 lb ft 7 For 2WD vehicle install Engine rear mounting bracket 8 For 4WD vehicle install transfer referring to Transfer Dis mounting and Mo...

Page 368: ...ng B M T model 8 Engine rear mounting No 2 bracket 16 Engine left mounting nut 1 Engine right mounting 9 Engine rear mounting bracket stiffener 17 Engine rear mounting bolt short 2 Engine right engine...

Page 369: ...Manual Transaxle Oil Change in Section 7A2 8 Drain transfer oil referring to Transfer Oil Change in Section 7D for 4WD vehicle 9 Drain coolant by referring to Cooling System Flush and Refill in Sectio...

Page 370: ...ng cables Accelerator cable 20 Gear select control cable 21 Gear shift control cable 22 Clutch cable 23 17 Disconnect the following hoses Brake booster hose 24 from intake manifold Radiator inlet and...

Page 371: ...nit Dismounting and Remounting in Section 7A2 26 Remove clutch cover and clutch disk referring to Clutch Cover Clutch Disc and Flywheel Removal and Installation in Section 7C2 Installation 1 Install c...

Page 372: ...wires for connection 10 Install air cleaner case and resonator 11 Install A C compressor to its bracket if equipped 12 Adjust A C compressor belt tension if equipped referring to Compressor Drive Belt...

Page 373: ...11 Copper washer 21 Water outlet cap 2 Crankshaft pulley 12 Oil gallery pipe No 1 bolt 22 O ring 3 Oil seal Apply engine oil to oil seal lip 13 Oil gallery pipe No 2 23 Water outlet cap bolt 4 Timing...

Page 374: ...hard to remove use special tools as shown in figure Special tool A 09944 36011 B 09926 58010 4 Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation in this section 5 Re...

Page 375: ...linder head Remove oil old sealant and dust from sealing surface 2 Install new O ring 1 to oil control valve 2 3 Install oil control valve to timing chain cover 3 Tighten nuts to specification Tighten...

Page 376: ...5 kg m 18 0 lb ft Timing chain cover mounting nut b 25 N m 2 5 kg m 18 0 lb ft 7 Apply engine oil to new O rings 2 and install them to cap 3 8 Install water outlet cap 3 to timing chain cover 1 Tighte...

Page 377: ...tening torque Crankshaft pulley bolt a 150 N m 15 0 kg m 108 5 lb ft 15 Install engine assembly to vehicle referring to Engine Assembly Removal and Installation in this section Timing Chain Cover Insp...

Page 378: ...control valve Inspect strainer 1 and mating surface 2 of oil control valve Clean oil control valve Oil gallery pipe Inspect oil gallery pipes No 1 1 No 2 2 and No 3 3 Replace if crack deformation or c...

Page 379: ...uter rotor 1 and inner rotor 2 A Sealant application amount 4 Inner rotor 10 Circlip a 3 mm 0 12 in 5 Timing chain cover Apply sealant 99000 31140 to the mating surface of cylinder and cylinder head A...

Page 380: ...es of oil pump case and plate 3 Install outer 1 and inner rotors 2 to oil pump case 4 Apply engine oil to relief valve 1 and spring 2 and install them with retainer 3 and new circlip 4 to rotor plate...

Page 381: ...09913 75810 Drive in dimension a 1 5 mm 0 06 in Oil pump assembly Check outer 1 and inner rotors 2 rotor plate and oil pump case for excessive wear or damage Check relief valve 1 for excessive wear o...

Page 382: ...ht edge 1 and thickness gauge 2 measure side clearance If clearance exceeds its limit replace oil pump assembly Limit on side clearance for oil pump inner rotor 0 15 mm 0 0059 in Relief valve spring f...

Page 383: ...ce 7 Timing chain tensioner bolt 2 Timing chain Apply engine oil 5 Timing chain tensioner adjuster assembly 8 Timing chain guide bolt 3 Timing chain No 1 guide Apply engine oil to sliding surface 6 Te...

Page 384: ...e in match with notches 2 on cylinder head as shown in figure 2 Set key 3 and turn crankshaft to position key on upside of crankshaft 3 4 1 1 2 5 6 7 8 9 CAUTION After timing chain is removed never tu...

Page 385: ...ft timing sprocket fitted with chain to crankshaft 5 Apply engine oil to sliding surface of timing chain No 1 guide 1 and install it as shown in figure Tighten guide bolts to specified torque Tighteni...

Page 386: ...ing chain 4 8 Screw in plunger 1 by turning body 2 in arrow direction and install a retainer 3 wire to hold plunger in place 9 Install timing chain tensioner adjuster assembly 1 with a retainer 2 Tigh...

Page 387: ...igure If each marking chain and each match mark are no matches adjust each sprockets and timing chain 11 Install timing chain cover referring to Timing Chain Cover Removal and Installation in this sec...

Page 388: ...ENGINE 6A2 49 Timing chain Check timing chain for wear or damage Timing chain tensioner adjuster Check that tooth surface 1 are free from damage Timing chain No 1 guide Check timing chain No 1 guide...

Page 389: ...tappet side 9 Upper camshaft bearing Install a bearing half with some holes to upper side of intake camshaft No 1 bearing 2 Intake camshaft sprocket assembly 6 Tappet Tightening torque 3 Intake camsh...

Page 390: ...in figure and remove them 5 Remove camshaft housings 6 Remove intake and exhaust camshafts 7 Remove camshaft bearing 1 8 Remove tappets 2 with shims 1 CAUTION Never attempt to loosen mounting bolt wit...

Page 391: ...ure 4 Apply engine oil to sliding surface of each camshaft and camshaft journal then install them as shown in figure 5 Install camshaft housing pins 1 as shown in figure NOTE When installing shim make...

Page 392: ...y 3 to specification Tightening torque Intake cam timing sprocket bolt a 60 N m 6 0 kg m 43 lb ft 9 Install timing chain with crankshaft sprocket referring to Tim ing Chain and Chain Tensioner Removal...

Page 393: ...eck clearance by using gaging plastic Checking procedure is as follows 1 Clean housings and camshaft journals 2 Remove all tappets with shims 3 Install camshafts to cylinder head 4 Place a piece of ga...

Page 394: ...ameter A Camshaft journal bearing bore B Wear of tappet and shim Check tappet and shim for pitting scratches or damage If any malcondition is found replace Standard Limit Intake side No 1 housing 0 02...

Page 395: ...ce If clearance exceeds limit replace tappet or cylinder head Cylinder head to tappet clearance Standard 0 025 0 066 mm 0 0010 0 0025 in Limit 0 15 mm 0 0059 in Tappet outside diameter A Standard 30 9...

Page 396: ...be removed or disconnected and remove or disconnect whatever necessary 9 Remove exhaust manifold if necessary referring to Exhaust Manifold Removal and Installation in this section 10 Remove cylinder...

Page 397: ...5 Install cylinder head to cylinder block Apply engine oil to new cylinder head bolts and tighten them gradually as follows a Tighten cylinder head bolts 1 10 to 20 N m 2 0 kg m 14 5 lb ft according t...

Page 398: ...ation in this section 9 Install cylinder head cover referring to Cylinder Head Cover Removal and Installation in this section 10 Install oil pan referring to Oil Pan and Oil Pump Strainer Removal and...

Page 399: ...ve spring retainer and valve spring 4 Remove valve from combustion chamber side 5 Remove valve stem seal 1 from valve guide and valve spring seat 2 6 Using special tool valve guide remover drive valve...

Page 400: ...ools Drive in new valve guide until special tool Valve guide installer con tacts cylinder head After installing make sure that valve guide protrudes by specified dimension a from cylinder head Special...

Page 401: ...spring has top end large pitch end 1 and bot tom end small pitch end 2 Be sure to position spring in place with its bottom end small pitch end facing the bottom valve spring seat side 8 Using special...

Page 402: ...it replace valve and valve guide Valve stem to guide clearance Valve stem diameter A standard In 5 465 5 480 mm 0 2152 0 2157 in Ex 5 440 5 455 mm 0 2142 0 2147 in Valve guide bore B standard In and E...

Page 403: ...t Check each valve for radial runout with a dial gauge and V block To check runout rotate valve slowly If runout exceeds its limit replace valve Limit on valve head radial runout 0 08 mm 0 003 in Seat...

Page 404: ...TAKE VALVE SEAT Use valve seat cutters 1 to make three cuts as illustrated in figure Three cutters must be used the 1st for making 15 angle the 2nd for making 60 angle and 3rd for making 45 angle The...

Page 405: ...t of distortion for cylinder head surface on piston side 0 03 mm 0 001 in Distortion of manifold seating faces Check seating faces of cylinder head for manifolds using a straightedge and thickness gau...

Page 406: ...nents 1 Top ring 8 Piston pin 2 2nd ring 9 Piston pin circlip 3 Oil ring 10 Bearing cap nut Tighten 15 N m 1 5 kg m 11 0 lb ft 45 and 45 by the specified procedure 4 Piston Tightening torque 5 Connect...

Page 407: ...and rod bolt threads when removing connecting rod 6 Decarbonize top of cylinder bore before removing piston from cylinder 7 Push piston and connecting rod assembly out through the top of cylinder bore...

Page 408: ...ts to 15 N m 1 5 kg m 11 0 lb ft b Retighten them to 45 c Repeat Step b once again Tightening torque Bearing cap nut a Tighten 15 N m 1 5 kg m 11 0 lb ft 45 and 45 by the specified procedure 6 Install...

Page 409: ...n installing these piston rings to piston direct marked side of each ring toward top of piston b 1st ring 1 differs from 2nd ring 2 in thickness shape and color of surface contacting cylinder wall Dis...

Page 410: ...rence between thrust and axial measurements exceeds out of round limit 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...

Page 411: ...ween ring and ring land by using thickness gauge 2 If clear ance is out of limit replace piston Ring groove clearance Top ring Standard 0 03 0 07 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring S...

Page 412: ...in Small end bore 20 003 20 011 mm 0 7876 0 7878 in Piston pin dia 19 997 20 000 mm 0 7873 0 7874 in Piston bore 20 006 20 014 mm 0 7877 0 7879 in Piston rings Piston ring end gap To measure end gap...

Page 413: ...for bow and twist If the measured value exceeds the limit replace it Connecting rod alignment Limit on bow 0 05 mm 0 0020 in Limit on twist 0 10 mm 0 0039 in Connecting rod bolt deformation Plastic de...

Page 414: ...ffering in tolerance For identification of undersize bearing it is painted red at the position as indicated in figure undersize bearing thickness is 1 605 1 615 mm 0 0632 0 0635 in at the center of it...

Page 415: ...selecting new bearing recheck clearance Connecting rod bearing clearance Standard 0 029 0 047 mm 0 0011 0 0018 in Limit 0 065 mm 0 0026 in 6 If clearance can not be brought to its limit even by using...

Page 416: ...pin diameter respectively For example stamped A indicates that corresponding crankshaft pin diameter is 41 9940 42 0000 mm 1 6534 1 6535 in Crankshaft pin outer diameter Stamped numbers connecting ro...

Page 417: ...nstall a new standard bearing painted in Black to its con necting rod big end inside Specification of new standard connecting rod bearing size 5 Using scale 1 on gaging plastic 2 check bearing clear a...

Page 418: ...ENGINE MECHANICAL M13 ENGINE 6A2 79 Main Bearings Crankshaft and Cylinder Block Components...

Page 419: ...reuse 7 Crankshaft timing sprocket key 17 Main bearing cap No 2 bolt Tighten 25 N m 2 5 kg m 18 0 lb ft by the specified procedure Apply engine oil to inside sliding surface 8 Crankshaft 18 Main bear...

Page 420: ...e sure that two halves are painted in the same color CAUTION Use new bearing cap No 1 bolts They are deformed once they are used because they are plastic deforma tion tightening bolts All parts to be...

Page 421: ...order as shown by using a 12 cor ner socket wrenches b In the same manner as in Step a tighten them to 50 N m 5 0 kg m 36 5 lb ft c In the same manner as in Step a retighten them to 60 d Tighten bolts...

Page 422: ...lb ft 10 Install flywheel for M T or drive plate for A T Using special tool lock flywheel or drive plate and tighten flywheel or drive plate bolts to specified torque Special tool A 09924 17810 Tighte...

Page 423: ...eter measurement points a 60mm 2 36in b 90mm 3 54in Main bearing cap No 1 bolt diameter difference Limit A B 0 2mm 0 008in Crankshaft Crankshaft runout Using a dial gauge measure runout at center jour...

Page 424: ...eeded replace thrust bearing with new stan dard one or oversize one to obtain standard thrust play Crankshaft thrust play Standard 0 11 0 31 mm 0 0043 0 0122 in Limit 0 35 mm 0 0138 in Out of round an...

Page 425: ...ll width of bearing parallel to crankshaft on journal avoiding oil hole 4 Tighten main bearing cap No 1 bolts 1 10 and main bearing No 2 cap bolts 11 20 gradually as follows a Tighten bolts 1 10 to 30...

Page 426: ...ion of main bearings Standard bearing If bearing is in malcondition or bearing clearance is out of specifi cation select a new standard bearing according to the following procedure and install it 1 Fi...

Page 427: ...as indicated in figure Each color indicated the following thickness at the center of bearing Standard size of crankshaft main bearing thickness 4 From number stamped on crank web No 2 and alphabets st...

Page 428: ...ing colors at such position as indicated in figure Each color represents the following thickness at the center of bearing Undersize of crankshaft main bearing thickness If necessary regrind crankshaft...

Page 429: ...or damage If its lip is worn or damaged replace it Flywheel Visual inspection If ring gear is damaged cracked or worn replace flywheel If the surface contacting clutch disc is damaged or exces sively...

Page 430: ...rebored at the same time 2 Select oversized piston according to amount of cylinder wear Oversize piston diameter 3 Using micrometer measure piston diameter Measurement position for piston diameter a 1...

Page 431: ...Camshaft housing bolt Tighten 11 N m 1 1 kg m 8 0 lb ft by the specified procedure Cylinder head cover bolt Tighten 5 0 N m 0 5 kg m 3 5 lb ft 7 5 N m 0 75 kg m 5 5 lb ft by the specified procedure I...

Page 432: ...5 0 kg m 36 5 lb ft and 60 by the specified procedure Main bearing cap No 2 bolt Tighten 25 N m 2 5 kg m 18 0 lb ft by the specified procedure Sensor plate bolt 11 1 1 8 0 Rear oil seal housing bolt 1...

Page 433: ...ssion gauge 09915 64530 09915 67010 09915 67311 09915 77310 Hose Attachment Vacuum gauge Oil pressure gauge 09915 78211 09916 14510 09916 14521 09916 34542 Oil pressure gauge attach ment Valve lifer V...

Page 434: ...ppet holder See NOTE below Tappet holder Piston ring compressor 09916 84511 09917 68221 09917 98221 09924 17810 Forceps Camshaft lock holder Valve stem seal installer Flywheel holder 09926 58010 09944...

Page 435: ...6A2 96 ENGINE MECHANICAL M13 ENGINE...

Page 436: ...0 Cooling System Refill 6B2 10 Cooling Water Pipes or Hoses 6B2 10 Thermostat Removal and Installation 6B2 11 Thermostat Inspection 6B2 11 Radiator Removal and Installation 6B2 12 Radiator Inspection...

Page 437: ...ens coolant passes through the radi ator core to be cooled as follows 1 Radiator inlet hose 5 Thermostat 9 Heater core inlet hose 2 Radiator outlet hose 6 Water pump 10 Heater core outlet hose 3 Throt...

Page 438: ...ant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than 36 C 33 F Anti freeze proportioning table Coolant capacity NOTE Alcohol or methano...

Page 439: ...lace Improper ignition timing Adjust Dragging brakes Adjust brake Slipping clutch Adjust or replace Poor charge battery Check and replace as necessary Poor generation generator Check and repair Wiring...

Page 440: ...an be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil Removal of the radiator cap while engine is hot and pressure is high will ca...

Page 441: ...oling System Flush and Refill 1 Remove radiator cap when engine is cool as follows a Turn cap counterclockwise slowly until it reaches a stop Do not press down while turning it b Wait until pressure i...

Page 442: ...olant up to spilling coolant from air ventila tion bolt 5 13 Tighten air ventilation bolt 5 to specified torque Tightening torque Air ventilation bolt a 4 5 N m 0 45 kg m 3 5 lb ft 14 Fill radiator wi...

Page 443: ...kg 22 lbs 3 If belt is too tight or too loose adjust it to proper tension by displacing generator position 4 Tighten generator adjusting bolt 1 and pivot bolts 2 as specified torque Tightening torque...

Page 444: ...cap 15 Thermostat case 27 Radiator cooling fan assembly 4 Drain plug 16 Thermostat 28 To timing chain cover 5 Radiator outlet hose 17 Thermostat cap 29 To cylinder head 6 Radiator inlet hose 18 Water...

Page 445: ...tem Flush and Refill in this section Cooling Water Pipes or Hoses Removal 1 Drain coolant referring to Cooling System Draining in this section 2 To remove these pipes or hoses loosen clamp on each hos...

Page 446: ...on thermostat case 2 be sure to position it so that jiggle valve 3 comes at position as shown in figure Use new O rings when installing Adjust water pump belt tension referring to Water Pump Generator...

Page 447: ...hould be replaced with a new one Such a unit if reused will bring about overcooling or overheating tendency Radiator Removal and Installation Removal 1 Disconnect negative cable at battery 2 Drain coo...

Page 448: ...ect negative cable at battery 2 Drain coolant referring to Cooling System Draining in this section 3 Remove air cleaner suction pipe 1 and reservoir 2 4 Disconnect cooling fan motor connector 3 5 Remo...

Page 449: ...te smoothly replace motor Radiator cooling fan motor specified current at 12 V 10 0 A maximum For A T vehicle 1 Check continuity between terminals If there is no continuity replace radiator fan motor...

Page 450: ...belt adjusting bolt 2 and generator pivot bolt 3 4 Slacken belt by displacing generator and then remove it Installation 1 Install belt 1 to water pump pulley 2 crankshaft pulley 3 and generator pulle...

Page 451: ...g surface of water pump Width a 3mm 0 12 in Height b 2mm 0 08 in 2 Install water pump assembly 1 to cylinder block and tighten bolts and nut to specified torque Tightening torque Water pump bolt and n...

Page 452: ...Coolant Temperature Sensor ECT Sensor Inspection Refer to Engine Coolant Temperature Sensor ECT Sensor in Section 6E2 Required Service Material CAUTION Do not disassemble water pump If any repair is r...

Page 453: ...ning part Tightening torque N m kg m lb ft ETC sensor 15 1 5 11 0 Air ventilation bolt 4 5 0 45 3 5 Thermostat cap bolt 11 1 1 8 0 Thermostat case bolt 25 2 5 18 0 Generator adjusting bolt 23 2 3 17 0...

Page 454: ...8 Manifold absolute pressure sensor MAP sensor inspection 6E2 29 Throttle position sensor TP sensor on vehicle inspection 6E2 30 Throttle position sensor TP sensor removal and installation 6E2 30 Engi...

Page 455: ...on 6E2 36 Knock sensor removal and installation 6E2 36 Main relay fuel pump relay and radiator fan relay inspection 6E2 37 Fuel cut operation inspection 6E2 37 Radiator fan control system inspection 6...

Page 456: ...sub systems air intake system fuel delivery system electronic control system and emission control system Air intake system includes air cleaner throttle body IAC valve and intake manifold Fuel delive...

Page 457: ...6E2 4 ENGINE AND EMISSION CONTROL SYSTEM M13 ENGINE Engine and Emission Control System Flow Diagram...

Page 458: ...NGINE AND EMISSION CONTROL SYSTEM M13 ENGINE 6E2 5 Engine and Emission Control System Diagram 26 10 9 7 8 14 13 23 11 15 12 2 6 5 1 3 18 24 39 35 30 29 38 16 17 37 36 31 22 21 19 20 27 25 34 32 4 33 2...

Page 459: ...ir Cleaner 14 Knock sensor 27 Stop lamp 2 EVAP canister purge valve 15 ECT sensor 28 Stop lamp switch 3 MAF and IAT sensor 16 CMP sensor 29 ECM 4 TP sensor 17 CKP sensor 30 Barometric pressure sensor...

Page 460: ...canister 12 Fuel Delivery System Diagram Fuel Pump An in tank type electric pump has been adopted for the fuel pump 1 Incorporated in the pump assembly are Tank pressure control valve 2 which keeps t...

Page 461: ...ious controlled devices Functionally it is divided into nine sub systems Fuel injection control system Idle speed control system Fuel pump control system A C control system if equipped Radiator fan co...

Page 462: ...d 5 Heated oxygen sensor 1 e Malfunction indicator lamp E Data link connector 5 1 Heated oxygen sensor 2 f Radiator fan relay F A C compressor relay if equipped 6 VSS g IAC valve G TCM A T 7 Battery h...

Page 463: ...TCH A C SWITCH A C EVAP OUTLET AIR TEMP SENSOR VSS HEATED OXYGEN SENSOR 1 HEATED OXYGEN SENSOR 2 IAT SENSOR MAF SENSOR For detecting deterioration of three way catalytic converter ECT SENSOR TP SENSOR...

Page 464: ...WHT RED BLK ORN B 32 26 GRN ORN BLK YEL BRN YEL BLK YEL BLU RED BLK RED GRN YEL BLU YEL ORN 40 59 41 15 16 18 19 21 20 49 30 31 14 17 36 37 33 44 11 34 RED BLU PPL WHT GRY RED GRN BLK LT GRN IG1 E22...

Page 465: ...or 1 28 Fuel pump relay 47 Main fuse 10 A C evaporator outlet air temp sensor 29 Fuel pump 48 Barometric pressure sensor 11 Battery 30 Radiator fan relay 49 Oil control valve 12 Combination meter 31 R...

Page 466: ...ial communication line of data link con nector 12 V 28 29 12 BRN YEL Engine revolution signal output for tachom eter 30 31 RED BLU Ignition coil No 2 and No 3 output 13 PNK BLU Electric load signal fo...

Page 467: ...6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18 19 18 19 17 18 19 20 21 22 23 24 25 26 27 20 21 22 23 20 21 22 23 24 25 24 25 26 27 26 27 28 29 30 31 32 32 2...

Page 468: ...peed IAC duty check make sure of the following Lead wires and hoses of Electronic Fuel Injection and engine emission control systems are connected securely Accelerator cable has some play that is it i...

Page 469: ...and or idle speed is out of specifications inspect idle air control system referring to Diagnostic Flow Table B 4 Idle Air Control System Check in Section 6 2 Engine idle speed and IAC duty 5 Check t...

Page 470: ...Disconnect negative cable at battery 2 Drain coolant referring to Cooling System Draining in Sec tion 6B2 3 Disconnect accelerator cable 1 from throttle body 4 Detach purge valve chamber and remove ai...

Page 471: ...nsor Removal and Installation in this section 3 Clean mating surfaces and install new throttle body gasket 1 to intake manifold 4 Install throttle body 1 to intake manifold 5 Connect connectors to TP...

Page 472: ...and wire har ness Not Using SUZUKI Scan Tool 1 Warm up engine to normal operating temperature 2 Stop engine 3 Turn ignition switch to ON position 4 Disconnect IAC valve connector 5 Start engine 6 Con...

Page 473: ...ch connector to IAC valve 1 and TP sensor 3 Check that rotary valve 2 of lAC valve opens and closes once and then stops in about 60 ms as soon as ignition switch is turned ON 4 Install IAC valve refer...

Page 474: ...m 8 0 lb ft 3 Install oil gallery pipe No 1 with new copper washers 5 to timing chain cover Tighten bolts to specification Tightening torque Oil gallery pipe No 1 bolts b 30 N m 3 0 kg m 21 5 lb ft Oi...

Page 475: ...6 Start engine and warm it up to normal operating tempera ture 7 Measure fuel pressure at idling If measured pressure does not satisfy specification refer to Diagnostic Flow Table B 3 in Section 6 2...

Page 476: ...Flow Table B 2 in Section 6 2 2 Turn OFF ignition switch and leave over 10 minutes as it is 3 Fuel pressure should be felt at fuel feed hose 1 for about 2 seconds after ignition switch ON If fuel pres...

Page 477: ...re regulator inspection Check fuel pump filter for evidence of dirt and contamination If present clean and check for presence of dirt in fuel tank Fuel injector on vehicle inspection 1 Using sound sco...

Page 478: ...val procedure and note following precautions Replace injector O ring 1 with new one using care not to damage it Check if cushion 2 is scored or damaged If it is replace with new one Apply thin coat of...

Page 479: ...pe 1 of vehicle 3 Connect special tool test lead to injector Special tool C 09930 88530 4 Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting 5 Put gradu...

Page 480: ...h ON 7 Apply battery voltage 3 to injector 2 for 15 seconds and measure injected fuel volume with graduated cylinder Test each injector two or three times If not within specification replace injector...

Page 481: ...r bag system refer to Disabling Air Bag System in Section 10B if equipped 3 Remove glove box 4 Disconnect ECM 1 and TCM 2 if equipped couplers 5 Loosen 2 nuts 3 and remove ECM and TCM if equipped Inst...

Page 482: ...lso check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump 3 Output voltage When input voltage is 4 5 5 5 V ambient temp 20 30 C 68 86 F If check result is not satisfactor...

Page 483: ...remove air cleaner outlet hose 3 Disconnect TP sensor connector and remove TP sensor from throttle body Installation 1 Install TP sensor 1 to throttle body Fit TP sensor to throttle body in such way...

Page 484: ...Reverse removal procedure noting the following Clean mating surfaces of ECT sensor 1 and water outlet cap Check O ring for damage and replace if necessary Tighten ECT sensor 1 to specified torque Tigh...

Page 485: ...raph replace ECT sensor 1 Heated oxygen sensor HO2S 1 and HO2S 2 heater on vehicle inspection 1 Disconnect sensor connector 2 Using ohmmeter measure resistance between terminals VB and GND of sensor c...

Page 486: ...or of heated oxygen sensor 1 and clamp wire harness securely After installing heated oxygen sensor 1 start engine and check that no exhaust gas leakage exists Camshaft position sensor CMP sensor and i...

Page 487: ...ghtening torque Camshaft position sensor bolt a 10 N m 1 0 kg m 7 5 lb ft 4 Connect connector to it securely 5 Connect negative cable to battery Crankshaft position sensor CKP sensor and its cir cuit...

Page 488: ...ation 1 Check to make sure that crankshaft position sensor and pul ley teeth are free from any metal particles and damage 2 Install crankshaft position sensor to cylinder block 3 Connect connector to...

Page 489: ...cified voltage referring to Step 9 of DTC P0500 Diag Flow in Section 6 2 If signal voltage varies as specified VSS is in good condi tion If not replace VSS Vehicle speed sensor VSS removal and install...

Page 490: ...there is no continuity when relay is connected to the bat tery replace relay Fuel cut operation inspection 1 Warm up engine to normal operating temperature 2 While listening to sound of injector 1 by...

Page 491: ...oor 5 Turn ignition switch OFF and connect coupler to MAF and IAT sensor 6 Turn ignition switch ON and check MAF signal voltage between E22 14 terminal and E22 32 terminal of ECM coupler MAF signal vo...

Page 492: ...oting the followings Tighten MAF and IAT sensor screws to specified torque Tightening torque MAF sensor screw a 2 5 N m 0 25 kg m 1 8 lb ft Connect MAF and IAT sensor coupler securely CAUTION Do not d...

Page 493: ...n sensor terminals while heating air gradually If measured resistance does not show such characteristic as shown replace MAF and IAT sensor Intake air temperature sensor resistance CAUTION Do not heat...

Page 494: ...ode in MISC TEST menu In this state according as EGR valve opening increases engine idle speed drops If not possible cause is clogged EGR gas passage stuck or faulty EGR valve EGR valve removal and in...

Page 495: ...Purge Valve and Its Circuit 1 Prepare to operate EVAP canister purge valve as follows a When using SUZUKI scan tool i Connect SUZUKI scan tool to DLC with ignition switch OFF and disconnect purge val...

Page 496: ...eck vacuum hoses EVAP canister purge valve wire harness and connections EVAP canister purge valve specification A Valve OFF When vacuum is applied to hose 1 vacuum can be applied B Valve ON When vacuu...

Page 497: ...fied replace EVAP canister resistance 30 34 at 20 C 68 F 4 With coupler disconnected apply vacuum to pipe 1 If vacuum can be appied go to next step If vacuum can not be applied replace EVAP canister p...

Page 498: ...nd deterioration Replace as necessary PCV Valve 1 Detach air cleaner assembly 2 Disconnect PCV valve from cylinder head cover and install plug to head cover hole 3 Install air cleaner assembly tempora...

Page 499: ...ter checking vacuum stop engine and remove PCV valve Shake valve and listen for the rattle of check needle inside the valve If valve does not the rattle replace valve 7 After checking remove plug and...

Page 500: ...Tech 2 kit SUZUKI scan tool See NOTE B NOTE A This kit includes the following items 1 Tool body washer 2 Body plug 3 Body attachment 1 4 Holder 5 Return hose clamp 6 Body attachment 2 washer 7 Hose a...

Page 501: ...screw 2 5 0 25 1 8 IAC valve screw 3 5 0 35 2 5 ECT sensor 15 1 5 11 5 Heated oxygen sensor 45 4 5 32 5 Camshaft position sensor 10 1 0 7 5 Knock sensor 22 2 2 16 0 Oil control valve mounting nut 11 1...

Page 502: ...l 6F2 12 WARNING For vehicles equipped with a Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer...

Page 503: ...ng automatically TP sensor ECT sensor MAP sensor MAF sensor IAT sensor and other sensors switches Refer to Electronic Control System in Section 6E2 for details Although this ignition system does not h...

Page 504: ...gnal Engine start signal 6 CKP sensor E23 15 E21 28 12V 5V 5V E21 6 E21 5 BLK WHT BLK RED BLK RED BLK RED E23 E22 E21 1 1 1 2 3 4 5 6 7 2 3 4 5 6 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12...

Page 505: ...ion coil Replace ignition coil assembly Faulty CKP sensor or CKP sensor plate Clean tighten or replace Faulty CMP sensor or sensor rotor tooth of camshaft Clean tighten or replace Faulty ECM Replace P...

Page 506: ...H1 2 V DIV CH2 2 V DIV TIME 10 ms DIV Measurement condition After warmed up engine to normal oper ating temperature Engine at specified idle speed A Oscilloscope waveforms at specified idle speed B De...

Page 507: ...on coil assembly 8 Crankshaft Position CKP Sensor Check 1 Check crankshaft position sensor referring to Crank Position Sensor CKP Sensor Inspection in Section 6E2 Is check result satisfactory Go to St...

Page 508: ...escribed under Ignition System Symptom Diagnosis in this section High Tension Cords Removal and Installation Removal 1 Remove air cleaner assembly with air intake pipe and cylin der head upper cover 2...

Page 509: ...move air cleaner assembly with air intake pipe and cylin der head upper cover 2 Pull out high tension cords by gripping their caps and then remove ignition coil assemblies referring to Ignition Coil A...

Page 510: ...Ignitor Removal and Installation in this section 3 Install high tension cords securely by gripping their caps 4 Install cylinder head upper cover and air cleaner assembly with air intake pipe Spark Pl...

Page 511: ...llation 1 Install ignition coil assembly 2 2 Tighten ignition coil bolts 1 to specified torque and then connect ignition coil coupler Tightening torque Ignition coil bolt a 10 N m 1 0 kg m 7 5 lb ft 3...

Page 512: ...Control IAC Duty Inspection in Section 6E2 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 ignitio...

Page 513: ...increasing engine speed advances ignition timing If above check results are not satisfactory check CKP sen sor and ECM Tightening Torque Specification Special Tool Fastening part Tightening torque N...

Page 514: ...ations 6G 2 NOTE Starting motor vary depending on specifications etc Therefore be sure to check model and specification of the vehicle being serviced before replacing parts For the descriptions items...

Page 515: ...ength 12 3 mm 0 44 in Number of pinion teeth 8 Performance Condition Guarantee Around at 20 C 68 F No load characteristic 11 0 V 90 A maximum 2 800 rpm minimum Load characteristic 8 V 4 8 N m 0 48 kg...

Page 516: ...Generator 6H 2 Diagnosis 6H 2 Undercharged battery 6H 2 Unit Repair Overhaul 6H 3 Removal and installation 6H 3 Specifications 6H 3 Generator 6H 3 NOTE For the descriptions items not found in this se...

Page 517: ...le No load Check 1 Connect voltmeter and ammeter as shown in the figure 2 Run engine from idling up to 2 000 rpm and read meters If voltage is higher than standard value check ground of brushes If bru...

Page 518: ...ervice Manual mentioned in FOREWORD of this manual For M13 Engine Specifications Generator 1 B terminal wire 3 Generator bolt 5 Splash cover Tightening torque 2 B terminal nut 4 Generator belt 6 Gener...

Page 519: ...6H 4 CHARGING SYSTEM G10 M13 ENGINES...

Page 520: ...CONTENTS General Description 6K2 2 Maintenance 6K2 2 On Vehicle Service 6K2 3 Exhaust System Components 6K2 3 Exhaust Manifold Removal and Installation 6K2 4 Exhaust Manifold Inspection 6K2 4 Exhaust...

Page 521: ...ntings 1 for damage deterioration and out of position Check exhaust system for leakage loose connection dent and damage If bolts or nuts are loosened tighten them to specified torque referring to Exha...

Page 522: ...d when the system is cool 1 Gasket 8 Exhaust No 1 pipe 15 Exhaust manifold stiffener bolt 2 Exhaust manifold 9 Exhaust No 2 pipe 16 Exhaust No 2 pipe bolt 3 Exhaust manifold stiffener 10 Muffler 17 Ca...

Page 523: ...on and the following Tighten bolts and nuts to specified torque when reassembling referring to Exhaust System Components in this section After installation start engine and check each joint of exhaust...

Page 524: ...d Assembly 7A2 31 Counter Shaft Disassembly and Assembly 7A2 34 Gear Shift Shaft Components 7A2 38 High Speed and Low Speed Gear Shift Shafts Inspection 7A2 39 5th Reverse Gear Shift Shafts Disassembl...

Page 525: ...echanism is provided to 2nd gear synchromesh device for high performance of shifting to 2nd gear The countershaft turns the final gear and differential assembly thereby turning the front drive shafts...

Page 526: ...ar 9 Input shaft 16 Countershaft 2nd gear 3 Input shaft 4th gear 10 Right case 17 Low speed sleeve hub 4 High speed sleeve hub 11 Side cover 18 Countershaft 1st gear 5 Input shaft 3rd gear 12 Counters...

Page 527: ...h gear 8 Reverse idler gear 14 Countershaft 20 Differential case 3 Input shaft 4th gear 9 Input shaft 15 Countershaft 3rd gear 21 Vehicle speed sensor 4 High speed sleeve hub 10 Right case 16 Counters...

Page 528: ...ables Adjust Inadequate or insufficient lubricant Replenish Improper clutch pedal free travel Adjust Distorted or broken clutch disc Replace Damaged clutch pressure plate Replace clutch cover Worn syn...

Page 529: ...4 For SAE classification refer to viscosity chart A in the figure Transaxle oil capacity 2 2 liters 4 6 3 9 US lmp pt Differential Side Oil Seal Replacement Replacement 1 Lift up vehicle and drain tr...

Page 530: ...emounting in Section 7D 7 Insert front drive shafts referring to Drive Shaft Assembly Removal and Installation in Section 4A 8 Install ball stud and stabilizer mount brackets referring to Wheel Hub an...

Page 531: ...trol cable 9 Cable mounting bolt 2 Lever boot holder 6 Gear shift control lever assembly mounting nut 10 Cable bracket bolt 3 Gear shift lever boot 7 Gear shift control lever assembly Apply grease 990...

Page 532: ...n 6 3 Remove gear shift control lever assembly mounting nuts 3 and gear shift lever assembly 2 from body 4 Disconnect shift and select cables 1 from transmission in the same manner as step 2 5 Remove...

Page 533: ...adjustment tighten cable lock nut 4 to specified torque Tightening torque Cable lock nut a 5 5 N m 0 55 kg m 4 0 lb ft c Make sure that boots are installed correctly Adjustment of select cable a With...

Page 534: ...VSS Removal and Installation Removal 1 Disconnect negative cable at battery 2 Disconnect VSS coupler 1 3 Remove VSS 2 Installation 1 Apply oil to new O ring 1 and then install VSS to transaxle 2 Conn...

Page 535: ...ly oil to new O ring 1 and tighten back up lamp switch 2 to specified torque Tightening torque Back up lamp switch a 23 N m 2 3 kg m 17 0 lb ft 2 Connect back up lamp switch coupler 3 Connect negative...

Page 536: ...ts 3 Engine rear mounting No 1 bracket 11 Transaxle to engine bolts 19 Transaxle to engine rear mounting No 2 bracket bolt 4 Engine rear mounting No 2 bracket 12 Engine left mounting bracket bolts 20...

Page 537: ...lifting device On lift 10 Drain transaxle oil referring to Manual Transaxle Oil Change in this section 11 Remove front drive shafts referring to Front Drive Shaft Assembly Removal and Installation in...

Page 538: ...ach clamp for wiring securely Install starting motor referring to Starting Motor Dismounting and Remounting in Section 6G After connecting clutch cable be sure to adjust its play prop erly Refer to Cl...

Page 539: ...7A2 16 MANUAL TRANSAXLE M13 ENGINE Transaxle Case Components...

Page 540: ...ntial assembly Tightening torque 9 Oil level filler plug Apply sealant 99000 31260 to all around thread part of plug Do not reuse 10 Oil drain plug Apply sealant 99000 31260 to all around thread part...

Page 541: ...Tighten gear shift guide case bolts 1 to specified torque at the position that clearance a is within 1 1 5 mm 0 04 0 06 in B Sealant 99000 31260 Tightening torque Gear shift guide case bolt a 23 N m...

Page 542: ...ent shaft from being bent by supporting it with wood block Assemble 5th reverse gear shift cam with its pit and spring pin aligned Make sure to select an appropriate spring by identify ing the painted...

Page 543: ...ynchronizer ring and 5th gear all together Use gear puller 1 for removal if spline fitting of hub is tight 5 Install input shaft 5th gear 1 and special tool to stop rota tion of shafts and remove coun...

Page 544: ...nd straight edge using feeler gauge 5 Clearance between case surface and straight edge a 0 13 0 17 mm 0 0051 0 0067 in Shim protrusion 3 By repeating above step select a suitable shim which adjusts cl...

Page 545: ...ynchronizer key installation position A B 7 Install 5th gear 1 to counter shaft facing machined boss A inward CAUTION Do not reuse left case plate screw 1 and bolts 7 Be sure to use new adhesive pre c...

Page 546: ...nut b 70 N m 7 0 kg m 51 0 lb ft 10 Remove special tool then caulk countershaft nut 4 at C with caulking tool and hammer 11 Install synchronizer ring 2 12 Fit 5th gear shift fork 1 to sleeve hub asse...

Page 547: ...m 2 3 kg m 17 0 lb ft Gear Shift Shaft Input Shaft and Counter Shaft Removal and Installation Removal 1 Remove gear shift and select shaft assembly referring to Gear Shift and Select Shaft Assembly R...

Page 548: ...lever bolts 4 and reverse gear shift lever 5 11 Pull out 5th reverse gear shift guide shaft 6 together with 5th reverse gear shift shaft 7 12 Tapping input shaft end with plastic hammer push it out a...

Page 549: ...se idler gear 1 with reverse gear shift lever 2 insert reverse gear shaft 3 into case through idler gear and then align A in shaft with B in case CAUTION Take care not to damage oil seal lip by input...

Page 550: ...another case bolts from clutch housing side and tighten them to specification Tightening torque Transaxle case bolt 19 N m 1 9 kg m 14 0 lb ft 11 Install new snap ring 1 using special tool Special too...

Page 551: ...witch in reverse position using ohmmeter Transaxle Case Disassembly and Assembly Disassembly 1 Remove input shaft oil seal 1 using special tools if neces sary Special tool A 09930 30104 B 09923 74510...

Page 552: ...been removed install it using special tools and hammer Special tool B 09924 74510 C 09925 68210 3 If input oil gutter 1 has been removed install it with bolt to which thread lock cement have been appl...

Page 553: ...7A2 30 MANUAL TRANSAXLE M13 ENGINE Input Counter Shaft Components...

Page 554: ...haft left bearing 7 High speed synchronizer spring 24 Reverse idler gear 41 Bearing set shim 8 High speed sleeve hub 25 Reverse shaft washer 42 Countershaft 5th gear 9 High speed synchronizer key 26 C...

Page 555: ...thoroughly inspect them for any abnormality and replace with new ones as necessary 2 If synchronizer parts need to be repaired check clearance a between ring 2 and gear 1 each chamfered tooth of gear...

Page 556: ...special tool and hammer facing long flange side of hub to 3rd gear Special tool B 09913 84510 NOTE No specific direction is assigned to each key but it is assigned as sleeve hub assembly Size of high...

Page 557: ...to 2nd gear 4 and drive out 3rd 4th gear spacer 2 and 3rd gear 3 together with 2nd gear 4 from counter shaft 1 using press Take out needle bearing of separated steel cage type from counter shaft 3 Tak...

Page 558: ...ght bearing cone 2 using puller 3 metal stick 1 and press Assembly 1 Clean all components thoroughly inspect them for any abnormality and replace with new ones as necessary 2 If synchronizer parts nee...

Page 559: ...1 and make sure that they are free from any obstruction 5 Fit low speed synchronizer sleeve 4 to hub 3 insert 3 keys 2 in it and then set springs 1 as shown in figure Synchronizer key installation po...

Page 560: ...lled to 2nd gear 6 as shown in fig ure 10 Press fit 3rd gear 2 and spacer 1 using special tools and press Special tool A 09923 78210 D 09913 80112 NOTE Support shaft with special tool as shown in figu...

Page 561: ...ng cone 3 always support shaft with special tool as illustrated 1 Low speed gear shift shaft 5 5th reverse gear shift guide shaft 9 Reverse gear shift lever bolt Apply thread lock 99000 32110 to all a...

Page 562: ...using special tool and hammer Special tool A 09922 85811 Assembly Replace or correct parts as required and assemble shafts making sure that component parts are in proper order as shown in figure NOTE...

Page 563: ...ly thread lock 99000 32110 to all around thread part of bolt 3 Differential side gear 11 Differential pinion shaft 4 Side gear washer 12 Differential pinion shaft pin 5 Differential side oil seal Appl...

Page 564: ...omponent parts Special tool C 09922 85811 Assembly 1 Drive in new differential pinion shaft pin 2 till the depth from differential case 3 surface is about 1 mm 0 04 in 2 Press fit new sensor rotor 1 w...

Page 565: ...isassembly prepare replacing parts and proceed to reassembly Make sure that all parts are clean 1 Assemble differential gear and measure thrust play of differ ential gear as follows Differential gear...

Page 566: ...and read dial gauge Special tool A 09900 20606 B 09900 20701 2 If thrust play is out of specification select suitable thrust washer from among the following available size install it and check again...

Page 567: ...lt 23 2 3 17 0 Gear shift guide case bolt 23 2 3 17 0 Gear shift interlock bolt 23 2 3 17 0 5th to reverse interlock guide bolt 23 2 3 17 0 Back up lamp switch 23 2 3 17 0 Gear shift control lever ass...

Page 568: ...lt Mating surface of transaxle case Mating surface of side cover Gear shift interlock bolt 5th to reverse interlock guide bolt Guide case bolt Thread lock cement THREAD LOCK 1322 99000 32110 Reverse g...

Page 569: ...09925 78210 09925 88210 09925 98221 Bearing outer race installer Spring pin remover 6 mm 0 24 in Bearing puller attachment Bearing installer 09927 76010 09930 30104 09940 53111 09940 54910 Gear holder...

Page 570: ...7B1 44 Diagnostic Flow Table A 3 O D OFF Lamp Circuit Check O D OFF Lamp Lights Steadily 7B1 45 Diagnostic Flow Table A 4 O D OFF Lamp Circuit Check O D OFF Lamp Does Not Light Anytime 7B1 47 Diagnost...

Page 571: ...hot temperature Hot check 7B1 91 Fluid level check at room cold temperature Cold check 7B1 92 Fluid change 7B1 92 A T fluid cooler hoses 7B1 93 Selector Lever 7B1 94 Select Cable 7B1 95 Transmission R...

Page 572: ...3rd gear to 4th gear to adjust the drain hydraulic pressure at releasing the forward clutch a timing solenoid valve is used to switch a hydraulic passage with an orifice to another during shift ing W...

Page 573: ...5 Oil pump 15 2nd brake 25 Reduction driven gear 6 Direct clutch drum double as sensor rotor for input shaft speed sensor 16 One way No 1 clutch 26 Differential case assembly 7 Direct clutch 17 O D a...

Page 574: ...automatic gear change D range O D OFF Forward 1st 2nd 3rd 4th automatic gear change 2 range Forward 1st 2nd 3rd automatic gear change L range Forward 1st 2nd 3rd reduction and fixed at 1st gear Gear...

Page 575: ...ard clutch F2 One way No 2 clutch 6 Final drive gear C2 Direct clutch 7 Final driven gear C3 Reverse clutch PART NAME FUNCTION Forward clutch Meshes intermediate shaft and front sun gear Direct clutch...

Page 576: ...AUTOMATIC TRANSAXLE M13 ENGINE 7B1 7 Table of Component Operation...

Page 577: ...7B1 8 AUTOMATIC TRANSAXLE M13 ENGINE Electronic Shift Control System 14 13 12 9 10 11 8 21 1 2 5 6 7 15 16 17 18 19 20 22 23 4 3...

Page 578: ...lves in valve body Planetary gear unit Clutches and brakes Control valves in valve body Shift solenoid valves TCC solenoid valve and Timing solenoid valve Pressure control solenoid valve Final gear re...

Page 579: ...valve A Terminal arrangement of TCM connector viewed from harness IG1 5 6 P R N D 2 L 7 BLU RED E12 6 12V 2 5V 12V 5V 12V 5V 12V 12V 12V 12V IG11 IG1 12V WHT BLK BRN BLK BLK BLK WHT RED YEL ORN RED G...

Page 580: ...of shift solenoid valves timing solenoid valve and TCC solenoid valve Valve status Turn power ON Turn power OFF Shift solenoid valve A No 1 Close Open Shift solenoid valve B No 2 Close Open Timing sol...

Page 581: ...n 88 km h 55 mile h speed 3rd gear is oper ated and then down shifts to 2nd at a speed lower than that Gear Shift Diagram A and TCC Lock up Diagram B Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Ful...

Page 582: ...to vehicle driving conditions TCM has an On Board Diagnosis System which detects a malfunction in this system When diagnosing a trouble in transaxle including this system be sure to have full understa...

Page 583: ...ked and erased by using scan tool Warm up Cycle A warm up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a...

Page 584: ...to read Operator s instruction Manual supplied with it carefully to have good under standing of its functions and usage Be sure to read Precautions for Electrical Circuit Service in Section 0A before...

Page 585: ...tion part 2 Go to Step 11 Go to Step 8 5 Trouble Symptom Confirmation 1 Confirm trouble symptom referring to the fol lowings Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Re...

Page 586: ...e Symptom Confirmation Check trouble symptoms based on information obtained in Step 1 Customer Complaint Analysis and Step 2 DTC Check Also reconfirm DTC according to DTC Confirmation Procedure descri...

Page 587: ...onfirmation Test Confirm that the problem symptom has gone and the vehicle is free from any abnormal conditions If what has been repaired is related to the malfunction DTC clear the DTC once and check...

Page 588: ...AUTOMATIC TRANSAXLE M13 ENGINE 7B1 19 Customer Problem Inspection Form Example NOTE The above form is a standard sample It should be modified according to conditions characteristic of each market...

Page 589: ...1 lights for about 2 sec and then goes OFF If anything faulty is found advance to Diagnostic Flow Table A 3 or Diagnostic Flow Table A 4 Malfunction Indicator Lamp MIL Check Refer to the same item in...

Page 590: ...ON 3 Erase DTC and pending DTC according to instructions dis played on scan tool Refer to scan tool operator s manual for further details 4 After completing the clearance turn ignition switch off and...

Page 591: ...Solenoid A Performance or Stuck Off Actual gear position is 3rd gear although TCM command is for 2nd gear 2 driving cycles P0752 Shift Solenoid A Stuck On Actual gear position is 2nd gear although TCM...

Page 592: ...pre stored check ing data in TCM 1driving cycle P1703 CAN Invalid Data TCM TCM receives malfunction signal of throttle position engine coolant temperature engine revolution and engine torque from ECM...

Page 593: ...D is inhibited Lock up function is inhibited to operate Line pressure control at gear shifting is inhibited Torque reducing request to ECM torque reduction control is inhibited Garage shift control i...

Page 594: ...sure control is assumed to be 100 Throttle opening used for gear shifting control is assumed to be 0 Upshifting to O D is inhibited Lock up function is inhibited to operate Garage shift control is inh...

Page 595: ...ness damage Section 6A2 Suspension play looseness Section 3 Drive shafts damage Section 4A Battery indicator condition corrosion of terminal Connectors of electric wire harness disconnection friction...

Page 596: ...hooting in Manual Road Test 4 Perform Engine Brake Test in this section Is it OK Go to Step 5 Proceed to Trouble shooting in Engine Brake Test 5 Perform Stall Test in this section Is it OK Go to Step...

Page 597: ...Inspect circuit for open short and intermit tent If NG repair Pressure control solenoid valve circuit faulty Timing solenoid valve circuit faulty TCM Substitute a known good TCM and recheck Poor 1 2 s...

Page 598: ...peed sensor VSS circuit faulty Input shaft speed sensor circuit faulty CAN communication circuit faulty Throttle position sensor circuit faulty Inspect circuit for open short and intermit tent referri...

Page 599: ...smission fluid temperature sensor circuit faulty CAN communication circuit faulty Brake light switch circuit faulty Refer to Diagnostic Flow Table A 2 in this section Throttle position sensor circuit...

Page 600: ...tion of shift solenoid valve B Inspect If NG replace Malfunction of output shaft speed sensor VSS Malfunction of transmission range sensor Malfunction of throttle position sensor Inspect referring to...

Page 601: ...mbly Incorrect shift point Engine abnormal condition Inspect and repair engine Malfunction of output shaft speed sensor VSS Inspect If NG replace Malfunction of throttle position sensor Inspect referr...

Page 602: ...e shock or slippage Faulty forward clutch Inspect If NG replace Faulty O D and 2nd coast brake Poor 3 2 shift excessive shock or slippage Faulty direct clutch Inspect If NG replace Faulty one way No 1...

Page 603: ...y gear Faulty one way No 2 clutch Faulty forward clutch Faulty reverse clutch Faulty 1st and reverse brake Damaged drive plate Faulty torque converter Replace No gear shift as 3rd gear Malfunction of...

Page 604: ...throttle position sensor Malfunction of timing solenoid valve Malfunction of pressure control solenoid valve Inspect If NG replace valve body assembly Faulty valve body component Replace valve body as...

Page 605: ...erature sen sor Malfunction of output shaft speed sensor VSS Malfunction of input shaft speed sensor Malfunction of throttle position sensor Malfunction of transmission range sensor Malfunction of tra...

Page 606: ...vehicle is running shift select lever to 2 range and check that 3rd gear is being used 5 While vehicle is running shift select lever to D range and check that 3rd gear is being used 6 After above che...

Page 607: ...ke should operate in above test Troubleshooting WARNING Before test make sure that there is no vehicle behind so as to prevent rear end collision Condition Possible Cause Correction Failure to operate...

Page 608: ...e Cause Correction Lower than standard level in both D and R range Engine output torque failure Inspect and repair engine Faulty one way clutch of torque converter Replace torque converter Higher than...

Page 609: ...or final time lag data Condition Possible Cause Correction N D time lag exceeds specification Malfunction of transmission fluid temperature sensor Inspect If NG replace Malfunction of pressure control...

Page 610: ...bolt 3 Attach oil pressure gauge to fluid pressure check hole in transaxle case Special tool A 09925 37811 001 4 Depress foot brake fully run engine at idle and stall then check fluid pressure in D o...

Page 611: ...ody assembly Lower than standard level in each range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Faulty valve body component Replace valv...

Page 612: ...repair and retry Go to Step 3 3 Perform running test under the following conditions and measure voltage between terminal E13 16 of TCM connector and ground terminal E13 15 of TCM connector and ground...

Page 613: ...P0722 P0785 P0962 P0963 P0973 P0974 P0976 P0977 P1701 P1702 P1703 P2769 and or P2770 detected Perform DTC flow table to repair and retry Go to Step 3 3 Perform running test under the following condi...

Page 614: ...gement of TCM connector viewed from harness side 3 To ignition switch 4 BLU RED 12V E12 11 E12 9 BLU YEL 1 E13 11 9 E12 A 2 3 Step Action Yes No 1 Check O D off switch status Press O D off switch butt...

Page 615: ...pler 2 Check continuity between terminals under each condition below See fig O D off switch under being released No conti nuity O D off switch under being pressed Continuity Is check result satisfacto...

Page 616: ...to check bulb and turn it OFF Troubleshooting 1 TCM 4 O D off switch 2 O D OFF lamp A Terminal arrangement of TCM connector viewed from harness side 3 To ignition switch 4 BLU RED 12V E12 11 E12 9 BL...

Page 617: ...nection to TCM at E13 24 terminal 3 If OK check voltage at terminal E13 24 of disconnected TCM connector Is it 10 14 V Go to Step 2 WHT BLU circuit open or shorted to ground 2 Check TCM Power Circuit...

Page 618: ...ctors disconnected check for proper connection to TCM at E13 1 E13 23 terminal 3 If OK check resistance between E13 1 E13 23 terminal of disconnected TCM connector and body ground Is continuity indica...

Page 619: ...ing at idle speed for 25 seconds or more 5 Stop vehicle and check DTC 1 TCM 3 Backup lamp 2 Transmission range sensor A Terminal arrangement of TCM connector viewed from harness side DTC DETECTING CON...

Page 620: ...12 20 respectively with select lever shifted to each range Taking terminal E12 19 as an example is battery voltage indicated only when select lever is shifted to 2 range and 0 V for other ranges as sh...

Page 621: ...tep 4 Terminal E12 20 E12 1 E12 8 E12 7 E12 19 E12 18 Select lever position P 8 14 V 0 V 0 V 0 V 0 V 0 V R 0 V 8 14 V 0 V 0 V 0 V 0 V N 0 V 0 V 8 14 V 0 V 0 V 0 V D 0 V 0 V 0 V 8 14 V 0 V 0 V 2 0 V 0...

Page 622: ...nt of TCM connector viewed from harness side DTC DETECTING CONDITION TROUBLE AREA Transmission range switch signal P R N D 2 or L is not inputted for more than 32 seconds when vehicle speed is faster...

Page 623: ...E12 19 and E12 20 respec tively with select lever shifted to each range Taking terminal E12 19 as an example is bat tery voltage indicated only when select lever is shifted to 2 range and 0 V for othe...

Page 624: ...tep 4 Terminal E12 20 E12 1 E12 8 E12 7 E12 19 E12 18 Select lever position P 8 14 V 0 V 0 V 0 V 0 V 0 V R 0 V 8 14 V 0 V 0 V 0 V 0 V N 0 V 0 V 8 14 V 0 V 0 V 0 V D 0 V 0 V 0 V 8 14 V 0 V 0 V 2 0 V 0...

Page 625: ...sensor A Terminal arrangement of TCM connector viewed from harness side DTC DETECTING CONDITION TROUBLE AREA Transmission temperature sensor terminal voltage is less than 0 05 V for 5 minutes or more...

Page 626: ...tors to TCM with igni tion switch OFF 3 Turn ignition switch ON 4 Measure voltage between terminal E13 11 of TCM connector and ground Is it 4 6 V or more GRN circuit shorted to power circuit If circui...

Page 627: ...ector viewed from harness side 2 Transmission fluid temperature sensor 4 Valve body connector DTC DETECTING CONDITION TROUBLE AREA Transmission temperature sensor terminal voltage is more than 4 6 V a...

Page 628: ...hort 1 Cool down A T fluid temperature under ambient temperature 2 Connect TCM connectors to TCM with igni tion switch OFF 3 Turn ignition switch ON 4 Measure voltage between terminal E13 11 of TCM co...

Page 629: ...angement of TCM connector viewed from harness side DTC DETECTING CONDITION TROUBLE AREA No input shaft speed sensor signal is detected although output shaft speed sensor signals are detected Input sha...

Page 630: ...een terminal E12 6 E12 16 of disconnected harness side TCM connec tor and ground No continuity Are check result satisfactory Go to Step 4 Go to Step 3 3 Inspect Input Shaft Speed Sensor Inspect input...

Page 631: ...viewed from harness side DTC DETECTING CONDITION TROUBLE AREA No output shaft speed sensor signal is detected although input shaft speed sensor signals are detected while vehi cle is running at 5 km...

Page 632: ...nected output shaft speed sensor harness side connector and ground Is continuity indicated Go to Step 4 BRN wire open 4 Check Output Shaft Speed Sensor VSS Sig nal Circuit for short 1 Disconnect TCM c...

Page 633: ...drive gear on differential case No damage in driven gear in output shaft speed sensor Is result satisfactory Intermittent trouble or Faulty TCM Check for intermittent referring to Intermittent and Po...

Page 634: ...though TCM commanded TCC solenoid to turn ON Mechanical malfunction of TCC solenoid valve Malfunction of valve body assembly Fluid passage clogged or leaking Torque converter clutch malfunction DTC DE...

Page 635: ...ion of valve body assembly Fluid passage clogged or leaking Mechanical malfunction of automatic transaxle clutch brake or gear etc DTC DETECTING CONDITION TROUBLE AREA 3rd gear ratio is detected altho...

Page 636: ...vehicle and turn ignition switch OFF 7 Repeat Step 3 to 5 one time 8 Stop vehicle and check DTC DTC Troubleshooting Step Action Yes No 1 Was Automatic Transaxle Diagnostic Flow Table performed Go to...

Page 637: ...es 5 Check DTC 1 TCM 3 A T 2 Timing solenoid valve A Terminal arrangement of TCM connector viewed from harness side DTC DETECTING CONDITION TROUBLE AREA Voltage of timing solenoid valve TCM terminal i...

Page 638: ...Check resistance of solenoid valve See Fig Resistance between terminal of transaxle side valve body harness connector and transaxle 11 15 at 20 C 68 F Is check result satisfactory Go to Step 4 Replace...

Page 639: ...ubleshooting 1 TCM 3 A T 2 Pressure control solenoid valve A Terminal arrangement of TCM connector Viewed from harness side DTC DETECTING CONDITION TROUBLE AREA Pressure control solenoid valve output...

Page 640: ...heck pressure control solenoid valve circuit for ground short 1 Connect valve body harness connector 2 Disconnect TCM connectors 3 Check for proper connection to TCM at termi nals E13 2 and E13 4 If c...

Page 641: ...oo high comparing with TCM command value Pressure control solenoid valve circuit shorted to power circuit Pressure control solenoid valve malfunction TCM 12V E13 4 E13 2 BRN YEL LT GRN RED 3 1 2 4 2 E...

Page 642: ...side valve body harness connector 5 0 5 6 at 20 C 68 F Resistance between pressure control solenoid valve terminals of transmission side valve body harness connector and transmission body Infinity Is...

Page 643: ...tor Viewed from harness side 2 Shift solenoid valve A No 1 4 A T DTC DETECTING CONDITION TROUBLE AREA Voltage of shift solenoid valve TCM terminal is high although TCM is commanding shift solenoid to...

Page 644: ...2 Disconnect valve body harness connector on automatic transmission 3 Check for proper connection to solenoid at BRN for shift solenoid valve A No 1 or BLK YEL for shift solenoid valve B No 2 circuit...

Page 645: ...Terminal arrangement of TCM connector Viewed from harness side 2 TCM B Terminal arrangement of ECM connector Viewed from harness side DTC DETECTING CONDITION TROUBLE AREA Transmission or reception er...

Page 646: ...ground Is it infinite Go to Step 5 RED wire circuit shorted to ground 5 Check CAN communication circuit for open 1 Turn ignition switch to OFF position 2 Disconnect connectors from ECM and TCM 3 Check...

Page 647: ...sets DTC P1703 DTC Troubleshooting DTC DETECTING CONDITION TROUBLE AREA Calculation of current data stored in TCM is not correct comparing with pre stored checking data in TCM TCM Step Action Yes No...

Page 648: ...T A Terminal arrangement of TCM connector Viewed from harness side 12V E13 5 WHT BLU 3 2 5 E13 E12 A 1 DTC DETECTING CONDITION TROUBLE AREA Voltage of TCC solenoid valve TCM terminal is low although T...

Page 649: ...n TCC solenoid valve terminals of transmission side valve body harness connector and transmission body Infinity Is check results satisfactory Go to Step 3 Replace TCC solenoid valve or lead wire 3 Che...

Page 650: ...A Terminal arrangement of TCM connector Viewed from harness side 12V E13 5 WHT BLU 3 2 5 C39 C38 A 1 DTC DETECTING CONDITION TROUBLE AREA Voltage of TCC solenoid valve TCM terminal is high although T...

Page 651: ...alve resistance 1 Turn ignition switch OFF 2 Disconnect valve body harness connector on automatic transmission 3 Check for proper connection to solenoid at WHT BLU circuit 4 Check resistance of soleno...

Page 652: ...INPUT SHAFT REVOLUTION Ignition switch ON and engine stop 0 RPM At 60 km h 37 5 mile h constant speed O D off switch ON 20 or less throttle opening and 3rd gear D range 2 600 RPM displayed in increme...

Page 653: ...n P position P Selector lever is in R position R Selector lever is in N position N Selector lever is in D position D Selector lever is in 2 position 2 Selector lever is in L position L D RANGE SIGNAL...

Page 654: ...ity not being passed to shift solenoid valve A No 1 SHIFT SOLENOID B COMMAND ON On command being outputted to shift solenoid valve B No 2 OFF ON command not being outputted to shift solenoid valve B N...

Page 655: ...from ECM BRAKE SWITCH Inputted signal from brake light switch on pedal bracket ON Brake pedal depressed OFF Brake pedal released TORQUE REDUCTION SIGNAL ON Signal which TCM require ECM to reduce outp...

Page 656: ...checked by itself it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it NOTE As each terminal voltage is affected by battery voltage confirm that it is...

Page 657: ...h ON lamp turned ON 8 14 V Ignition switch ON lamp turned OFF 12 13 14 15 16 BLK Input shaft speed sensor 2 3 V Ignition switch ON engine at stop 17 18 GRN BLK Transmission range sen sor L range 8 14...

Page 658: ...s pulse Pulse signal frequency varies depending on engine condition 8 9 10 11 GRN Transmission fluid temper ature sensor 2 9 3 1 V Ignition switch ON fluid temperature is 20 C 68 F 0 3 0 5 V Ignition...

Page 659: ...p to normal operating tem perature Engine at specified idle speed with P range Measurement terminal CH1 E12 25 to E13 1 Oscilloscope setting CH1 5 V DIV TIME 2 ms DIV Measurement condition After warme...

Page 660: ...t fluid level gauge 1 again and check fluid level indi cated on it The lowest fluid level should be between FULL HOT and LOW HOT If it is below LOW HOT add an equiva lent of DEXRON III up to FULL HOT...

Page 661: ...luid temperature has reached normal operating hot tempera ture check fluid level again and adjust it as necessary Fluid change 1 Lift up vehicle 2 When engine is cool remove drain plug 1 from transaxl...

Page 662: ...plug hole 3 3 liters 6 97 5 81 US Imp pt When overhauling 5 6 liters 11 83 9 86 US Imp pt A T fluid cooler hoses The rubber hoses for the A T fluid cooler should be replaced at specified interval When...

Page 663: ...osition indicator for correct indication For operation of select lever refer to the figure 1 Selector lever assembly 4 Indicator assembly 2 Knob assembly 5 Illumination lamp assembly 3 Screw 6 Connect...

Page 664: ...t cable by reversing removal procedure The important steps in installation are as follows Apply grease to pin and cable joint Tighten bolts in upper figure to specified torque Adjusting procedure is a...

Page 665: ...selector lever to N position 6 Apply grease to selector lever pin and install adjuster cable end to it Grease 99000 25010 7 With both selector lever and transmission range sensor kept each N position...

Page 666: ...sor are aligned If not loosen sensor bolts 3 and align them 3 Check that engine starts in N and P ranges but it does not start in D 2 L or R range Also check that back up lamp lights in R range Tighte...

Page 667: ...of alternating 0 1 V and 10 14 V 2 Check output shaft speed sensor VSS driven gear 1 for wear Replace if necessary Removal 1 Disconnect negative cable at battery 2 Disconnect output shaft speed sensor...

Page 668: ...d sensor connector 2 3 Remove input shaft speed sensor 1 by removing its bolt Installation 1 Apply A T fluid to input shaft speed sensor O ring 2 Install input shaft speed sensor 1 to A T case and tig...

Page 669: ...referring to Engine Coolant Temperature Sensor in Section 6E1 O D Off Switch Inspection 1 Remove console box 2 Disconnect O D off switch connector 1 3 Check continuity between O D off switch terminals...

Page 670: ...tive cable at battery 2 Lift up vehicle 3 Remove drain plug and drain A T fluid 4 Install drain plug Tightening torque A T fluid drain plug 17 N m 1 7 kg m 12 5 lb ft 5 Remove A T oil pan 1 and oil pa...

Page 671: ...enoid valve 1 shift solenoid valve A No 1 2 shift solenoid valve B No 2 3 and timing sole noid valve 4 by removing bolts Inspection Resistance Check Shift solenoid valves Timing solenoid valve and TCC...

Page 672: ...si into solenoid valve as shown in the figure When solenoid valve 1 is not connected to battery 2 con firm that solenoid valve is open condition by blowing air 50 200 kPa 0 5 2 0 kg cm2 7 28 5 psi int...

Page 673: ...shown in the figure When timing solenoid valve 1 is not connected to battery 2 confirm that timing solenoid valve is close condition by blowing air 50 200 kPa 0 5 2 0 kg cm2 7 28 5 psi into solenoid v...

Page 674: ...g their installing posi tions by wire color 3 Install transmission fluid temperature sensor 5 to sensor clamp 4 Install oil strainer assembly 1 Tightening torque Oil strainer bolt a 10 N m 1 0 kg m 7...

Page 675: ...ing torque A T fluid drain plug 17 N m 1 7 kg m 12 5 lb ft 5 Remove A T oil pan 1 and oil pan gasket 2 6 Remove oil strainer assembly 3 7 Remove transmission fluid temperature sensor 1 from sen sor cl...

Page 676: ...egulated DC power supply 1 Connect pressure control solenoid valve 1 to regulated DC power supply 2 as shown in the figure 2 Turn regulated DC power supply switch ON increase voltage of power supply k...

Page 677: ...y noting the following points For detail of pressure control solenoid valve installation refer to Valve Body Assembly in this section For detail of valve body assembly installation refer to Unit Assem...

Page 678: ...Reverse removal procedure noting the following Connect TCM connectors securely If the vehicle is equipped with air bag system be sure to enable air bag system after TCM is back in place Refer to Enabl...

Page 679: ...el wire harness 4 Check that there is no continuity between terminal C and D If continuity is indicated replace A T relay 5 Connect battery positive terminal to terminal A of A T relay and battery neg...

Page 680: ...n this section 8 Remove solenoid wire harness 1 9 Warm up transmission fluid temperature sensor 2 Check resistance between terminals of valve body harness connec tor 1 Thus make sure its resistance de...

Page 681: ...refer to Unit Assembly in this section For details of A T oil pan installation refer to Unit Assembly in this section Use new oil pan gasket Tighten valve body harness connector bolt to specified torq...

Page 682: ...ifferential gear of transaxle Refer to Drive Shaft Assembly in Section 4A for procedure to disconnect drive shaft joints For differential side oil seal removal it is not necessary to remove drive shaf...

Page 683: ...ial tool C 09944 88220 D 09924 74510 Differential side oil seal installing depth Right side a 2 6 3 6 mm 0 10 0 14 in Left side b 3 8 4 8 mm 0 15 0 19 in 6 Install drive shaft referring to Drive Shaft...

Page 684: ...Assembly Components 1 Drive plate 5 Lower stiffener 2 Drive plate bolt Apply sealant 99000 31230 to thread 6 Transaxle and engine fastening bolt 3 Drive plate to torque converter bolt 7 Transaxle and...

Page 685: ...te ring gear 4 Remove starting motor 5 Remove bolts and nut fastening engine and transaxle then detach transaxle from engine 1 WARNING Be sure to keep transaxle with torque converter horizon tal or fa...

Page 686: ...plate gear Tightening torque Drive plate to torque converter bolt a 19 N m 1 9 kg m 14 0 lb ft 4 Install lower stiffener 1 Tighten lower stiffener bolts a first and next b with speci fied torque Tight...

Page 687: ...ody Assembly in this section Make sure to wash dirt off from the transaxle so that no such dirt will enter the transaxle during dismounting and remounting Select a clean place free from dust and dirt...

Page 688: ...wear burning Replace Oil seal gasket Flawed or hardened seal ring Replace Worn seal ring on its periphery or side Replace Piston seal ring oil seal gasket etc Replace Gear Flaw burr Replace Worn gear...

Page 689: ...o as not to damage them Do not expose removed parts to dust Keep them always clean NOTE Oil pump assembly direct clutch assembly forward and reverse clutch assembly 2nd brake piston assembly O D and 2...

Page 690: ...AUTOMATIC TRANSAXLE M13 ENGINE 7B1 121...

Page 691: ...ear nut After tightening nut so as rota tional 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...

Page 692: ...rque converter 1 2 Remove engine mounting LH bracket 1 3 Remove manual select lever 1 4 Uncaulk lock washer 1 then remove lock nut 2 and lock washer 1 CAUTION Remove torque converter as much straight...

Page 693: ...Remove fluid cooler pipes 1 and pipe union 2 9 Remove fluid level gauge 3 and fluid filler tube 4 10 Remove oil pan 1 and oil pan gasket 2 1 2 4 3 NOTE For removal of oil pan do not turn transaxle ov...

Page 694: ...ure sensor 1 13 Remove valve body assembly bolts 14 Remove manual valve rod 1 from manual valve lever 2 then remove valve body assembly 3 CAUTION Be careful not to let manual valve fall off when remov...

Page 695: ...overnor apply No 1 gasket 1 17 Remove cooler check valve 1 and spring 2 CAUTION When pulling valve body harness 1 out of transaxle case take care not to damage transmission fluid temper ature sensor 2...

Page 696: ...kg cm2 15 psi 100 kPa max into hole 4 as shown in figure and pop each piston into rag 19 Remove transaxle case plug 1 20 Remove torque converter housing bolts 21 Remove torque converter housing 1 whi...

Page 697: ...shaft When input shaft thrust play is out of 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 207...

Page 698: ...ce 2 29 Remove direct clutch hub 1 30 Remove differential assembly 1 and counter shaft assem bly 2 31 Remove governor apply No 2 gasket 1 NOTE If input shaft front thrust bearing is not found it may h...

Page 699: ...ervoir LH plate 1 33 Turn over transaxle and remove rear cover assembly 1 34 Remove reverse clutch drum thrust bearing 1 35 Remove 2nd brake gasket 1 NOTE If reverse clutch drum thrust bearing is not...

Page 700: ...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 If piston stroke exceeds specification ab...

Page 701: ...40 Remove forward clutch hub 1 41 Remove rear sun gear thrust bearing 1 from forward clutch hub 2 42 Remove rear sun gear thrust bearing race 1 43 Remove rear planetary sun gear subassembly 1 and one...

Page 702: ...subassembly 3 46 Remove planetary carrier thrust washer 1 47 Remove O D and 2nd coast brake retaining plate snap ring 1 48 Remove front planetary sun gear 1 49 Remove front sun gear thrust bearing rac...

Page 703: ...replace brake discs and plates with new ones 2nd brake piston stroke a 0 40 1 25 mm 0 016 0 049 in 51 Using special tool and hydraulic press remove 2nd brake piston snap ring 1 Special tool A 09926 96...

Page 704: ...r race retainer 1 57 Check one way clutch No 2 as follows Ensure planetary carrier 1 rotates only in counterclockwise direction A never in clockwise direction B If the planetary carrier rotates both w...

Page 705: ...31 0 059 in If piston stroke exceeds specified value disassemble inspect and replace discs and plates 61 Remove snap ring while the 1st and reverse brake piston return springs are compressed using spe...

Page 706: ...press remove planetary ring gear subassembly 1 Special tool A 09913 84510 B 09923 78210 67 Remove parking lock pawl shaft then spring 2 and parking lock pawl 1 CAUTION It is recommended that this oper...

Page 707: ...move 1st and reverse brake piston 1 70 Remove parking lock pawl bracket 1 71 With slotted screw driver cut and unfold manual valve lever spacer 1 and proceed to remove manual valve lever spacer Bolt L...

Page 708: ...g pin remover with 3 mm 0 12 in in diameter and hammer drive out manual valve lever pin 1 73 Remove manual shift shaft 2 74 Remove parking lock pawl rod 2 from manual valve lever 1 75 Remove manual de...

Page 709: ...spot discoloration or surface scuffing is indicated plate must be replaced Brake Return Spring Subassembly Measure brake return springs Free length of 1st reverse brake return spring a 21 71 mm 0 855...

Page 710: ...rags to clean or dry parts All oil passages should be blown out and checked to make sure that they are not obstructed Keep face and eyes away from solvent spray while air blowing parts Check mating su...

Page 711: ...emove 8 oil pump subassembly bolts 1 and stator shaft assembly 2 1 Oil seal Apply grease 99000 25030 to oil seal lip 7 Oil pump subassembly bolts 2 O ring Apply automatic transaxle fluid 3 Oil pump bo...

Page 712: ...drive and driven gear Using a feeler gauge measure clearance between drive and driven gear tips If clearance exceeds its standard value replace oil pump assembly Tip clearance between oil pump drive g...

Page 713: ...also be done to input shaft assembly and replace input shaft assembly if necessary 6 Using special tool measure oil pump body bush bore Special tool A 09900 20605 Oil pump body bush bore Standard 38...

Page 714: ...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 oil pump body 5 Check drive gear for smooth rotation by...

Page 715: ...snap ring 2 Input shaft seal ring 9 Direct clutch separator plate 3 Input shaft subassembly 10 Direct clutch disc 4 Inner O ring 11 Direct clutch retaining plate 5 Direct clutch piston 12 Plate snap r...

Page 716: ...d value disassemble inspect and replace inner parts Disassembly 1 Remove plate snap ring 1 then remove direct clutch retain ing plate discs and separator plates 2 Using special tool and hydraulic pres...

Page 717: ...cs Plates and Retaining Plate Check that sliding surfaces of discs separator plates and retain ing plate are not worn hard or burnt If necessary replace 2 Direct clutch piston 1 Input shaft subassembl...

Page 718: ...dure for assembly noting the following points Use new seal ring and O ring Apply A T fluid before installa tion Do not damage direct clutch return spring subassembly 1 and piston by pressing in direct...

Page 719: ...00 20701 Direct clutch piston stroke 0 4 0 7 mm 0 016 0 027 in When piston strike is out of specification select direct clutch retaining plate with suitable thickness from among the list below and rep...

Page 720: ...erse clutch cushion plate 4 Forward clutch piston O ring 14 Forward clutch plate snap ring 5 Forward clutch drum 15 Forward clutch retaining plate 6 Forward clutch drum O ring 16 Forward clutch disc 7...

Page 721: ...w compressed air 400 800 kPa 4 8 kg cm2 57 113 psi through oil hole 1 of transaxle rear cover with the spe cial tool attached on the upper surface of forward clutch retaining plate and measure forward...

Page 722: ...xle rear cover 2 Apply compressed air 400 800 kPa 4 8 kg cm2 57 113 psi to oil hole 3 of transaxle rear cover to remove forward clutch piston 4 7 Apply compressed air 400 800 kPa 4 8 kg cm2 57 113 psi...

Page 723: ...intermediate shaft seal ring 1 from intermediate shaft subassembly 2 Inspection Clutch Discs Separator Plates and Retaining Plate Check that sliding surfaces of discs separator plates and retain ing p...

Page 724: ...for wear deformation cut and or hardening If necessary replace Forward Clutch Drum Lip Check each lip for wear deformation cut and or hardening If necessary replace Assembly Reverse disassembly proce...

Page 725: ...ling position over 1 5 mm 0 059 in Special tool A 09926 97610 Apply A T fluid to forward clutch separator plates 1 discs 2 and retaining plate 3 Install forward clutch separator plates 1 discs 2 and r...

Page 726: ...place it Available forward clutch retaining plate thickness Install reverse clutch cushion plate 1 in correct direction as shown in figure Apply A T fluid to reverse clutch cushion plate 1 reverse clu...

Page 727: ...ary Check Special tool A 09900 20607 B 09900 20701 Reverse clutch piston stroke 1 20 1 60 mm 0 047 0 063 in When piston stroke is out of specification select reverse clutch retaining plate with proper...

Page 728: ...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 piston 2 2 Remove inner O ring 1 and outer O ring 2 1 2nd brake cylinder 4 Outer O ring...

Page 729: ...ssembly procedure for assembly noting the following points Use new O rings Apply A T fluid to the O rings before installation Install 2nd brake piston 1 to which A T fluid is applied to 2nd brake cyli...

Page 730: ...d coast brake return spring subassembly 8 Rear cover plug 3 O D and 2nd coast brake piston front O ring 9 Rear cover plug O ring 4 O D and 2nd coast brake piston rear O ring Apply automatic transaxle...

Page 731: ...ed air 400 800 kPa 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 Rem...

Page 732: ...h new one In replacement intermediate shaft subassembly also needs to be checked Replace intermediate shaft subassembly if necessary Assembly Reverse disassembly procedure for assembly noting the foll...

Page 733: ...ginal installing position over 1 0 mm 0 039 in Special tool A 09926 96030 B 09946 06710 Differential Assembly 1 Transaxle rear cover 1 Differential side RH bearing 7 Side bearing cup 2 Output shaft sp...

Page 734: ...ring by using special tools Special tool A 09926 37610 B 09926 37610 001 C 09926 37610 003 D 09926 47610 002 3 Remove output shaft speed sensor VSS drive gear 1 4 Remove differential side LH bearing b...

Page 735: ...ls then remove moisture 2 As shown in figure facing groove 2 side upward install final driven gear 1 to differential case WARNING When taking warmed final driven gear out of vessel use tongs or the li...

Page 736: ...tall new differential side RH bearing 1 by using special tool and hydraulic press Special tool A 09913 70123 6 Install new differential side LH bearing 1 by using special tool and hydraulic press Spec...

Page 737: ...y using special tool and hydraulic press Special tool A 09925 98221 2 Remove countershaft RH bearing 1 by using special tools Special tool A 09913 61510 B 09926 58010 1 Countershaft RH bearing 5 Beari...

Page 738: ...Special tool A 09913 84510 2 Install reduction driven gear 1 with special tools and hydraulic press Special tool A 09913 84510 B 09925 88210 3 Install countershaft LH bearing 1 with special tools and...

Page 739: ...noid valve B No 2 10 O ring 4 TCC Lock up solenoid valve Apply automatic transaxle fluid 5 Timing solenoid valve Tightening torque 6 Temperature sensor clamp Do not reuse 7 Valve body assembly CAUTION...

Page 740: ...13 ENGINE 7B1 171 2 Remove pressure control solenoid valve 1 3 Remove TCC Lock up solenoid valve 1 4 Remove shift solenoid valve A 1 5 Remove shift solenoid valve B 1 6 Remove timing solenoid valve 1...

Page 741: ...al After applying A T fluid to new O rings fit them to solenoid valves then install solenoid valves to valve body Tighten solenoid valve bolts to specified torque Tightening torque Solenoid valve bolt...

Page 742: ...oil seal 1 4 Remove countershaft RH bearing cup by using special tools Special tool A 09944 96011 B 09942 15511 5 Remove differential side RH bearing cup by using special tools Special tool A 09944 96...

Page 743: ...special tools assemble differential side RH bearing cup Special tool A 09924 74510 B 09944 88220 3 Using special tool install countershaft RH bearing cup Special tool A 09924 74510 B 09944 88220 a Usi...

Page 744: ...rication tube clamp 2 Tightening torque Lubrication tube clamp bolt a 5 5 N m 0 55 kg m 4 0 lb ft Fluid reservoir RH plate bolt b 5 5 N m 0 55 kg m 4 0 lb ft Transaxle case Disassembly 1 Remove differ...

Page 745: ...220 2 Using special tools assemble shim and countershaft LH bearing cup Special tool A 09924 74510 B 09944 88220 3 Install new differential side oil seal to transaxle case by using special tools Speci...

Page 746: ...er housing bolt a 33 N m 3 3 kg m 24 0 lb ft 3 Measure bearing preload a by using a special tool Special tool A 09928 06050 Differential side bearing preload starting torque In the case of new bearing...

Page 747: ...ickness Identification mark 1 80 mm 0 070 in A 1 85 mm 0 072 in B 1 90 mm 0 074 in C 1 95 mm 0 076 in D 2 00 mm 0 078 in E 2 05 mm 0 080 in F 2 08 mm 0 081 in G 2 11 mm 0 083 in H 2 14 mm 0 084 in J 2...

Page 748: ...suitable thickness from among the list below and replace it Then adjust countershaft bearing preload within specifica tion Available shim thickness 5 Remove differential assembly and counter shaft as...

Page 749: ...flaw in small part may cause oil leak age or decrease in function check each part carefully before installation Clean all parts with compressed air Never use wiping cloths or rags Before assembling n...

Page 750: ...hammer turn spacer to set the position as shown in the figure Then calk spacer with a punch 6 Install parking lock pawl bracket 1 to transaxle case Tightening torque Parking lock pawl bracket bolt a 7...

Page 751: ...ate 1 then install them to tran saxle case 11 Compress 1st and reverse brake return spring using special tool and hydraulic press then attach snap ring Special tool A 09926 97620 CAUTION Do not damage...

Page 752: ...se brake piston stroke Standard 0 791 1 489 mm 0 0311 0 0586 in 14 Install reduction drive gear 1 to transaxle case 3 by using special tools and hydraulic press Special tool A 09951 18210 B 09944 7821...

Page 753: ...N m 10 0 kg m 72 5 lb ft Reduction drive gear bearing preload turning torque Standard 0 05 0 35 N m 0 5 3 5 kg cm 0 036 0 253 lb ft CAUTION Do not reuse planetary ring gear subassembly Other wise it m...

Page 754: ...y 20 Check for correct installation of planetary gear assembly as follows Measure the distance a by using micrometer caliper 1 and straightedge 2 If measured value is out of specifica tion remove plan...

Page 755: ...ly in counterclockwise direction A not in clockwise direction B 22 Install one way clutch outer race retainer 1 23 Apply A T fluid to new brake drum gasket 1 then install it to transaxle case 24 Apply...

Page 756: ...g clearance between 2nd brake separator plate 1 and piston 2 with feeler gauge 3 If clearance piston stroke is out of specification replace clutch discs and plates with new ones 2nd brake piston strok...

Page 757: ...ly A Grease 99000 25030 33 Apply A T fluid to one way clutch No 1 assembly 3 and install one way clutch No 1 assembly 3 to rear planetary sun gear subassembly 2 34 Apply A T fluid to planetary gear th...

Page 758: ...ermediate shaft thrust bearing rear race 3 thrust bearing 2 and front race 1 install them to forward and reverse clutch assembly 4 Bearing race dimension 40 Apply A T fluid to forward and reverse clut...

Page 759: ...ward and reverse clutch assembly forward clutch hub rear planetary sun gear subassembly and one way clutch No 1 assembly and reinstall them properly Distance between forward and reverse clutch assembl...

Page 760: ...ston stroke a b O D and 2nd coast brake piston stroke standard 0 65 1 05 mm 0 026 0 041 in When piston stroke is out of specification select O D and 2nd coast brake rear plate with proper thickness fr...

Page 761: ...transaxle rear cover assembly on transaxle case 49 Install hook 2 to location shown in figure Tightening torque Rear cover bolt a 25 N m 2 5 kg m 18 0 lb ft 50 Tighten rear cover bolts 1 51 Install f...

Page 762: ...ng race 2 install them into direct clutch hub 3 56 After applying A T fluid to input shaft front thrust bearing 1 install it to direct clutch assembly 2 57 Apply A T fluid to direct clutch assembly 1...

Page 763: ...f out of specification remove direct clutch assembly direct clutch hub and reinstall them properly Distance between direct clutch assembly and mating sur face of transaxle case a 10 5 11 3 mm 0 413 0...

Page 764: ...Install breather hose 1 64 Wipe off and clean mating surface between transaxle case 1 and torque converter housing 65 Apply sealant to torque converter housing 1 by using a noz zle 2 as shown in figu...

Page 765: ...iameter B1 accumulator O ring Large 2 C1 accumulator O ring Large 2 C2 accumulator O ring Large 2 Above three O rings are same 29 4 mm 1 16 in 2 6 mm 0 10 in B1 accumulator O ring Small 4 19 7 mm 0 78...

Page 766: ...valve body har ness connector 3 then install valve body harness to tran saxle case Tightening torque Valve body harness connector bolt a 5 5 N m 0 55 kg m 4 0 lb ft 73 Install manual valve rod 1 to ma...

Page 767: ...o its clamp 76 Install oil strainer assembly 1 Tightening torque Oil strainer bolt a 10 N m 1 0 kg m 7 5 lb ft Bolt Length a Pieces A 20 mm 0 79 in 6 B 28 mm 1 10 in 5 C 49 mm 1 93 in 1 D 36 mm 1 42 i...

Page 768: ...ghtening torque Fluid outlet union a 25 N m 2 5 kg m 18 0 lb ft 80 Install new gasket 2 and then install fluid cooler pipes Tightening torque Fluid cooler pipe bolt b 22 N m 2 2 kg m 16 0 lb ft Fluid...

Page 769: ...axle case tighten bolts temporarily at this step 85 Install lock washer 1 and tighten lock nut 2 to specified torque Tightening torque Transmission range sensor lock nut a 7 N m 0 7 kg m 5 0 lb ft 86...

Page 770: ...order to prevent displace ment of lock washer 92 Install manual select lever 1 Tightening torque Manual select lever nut a 13 N m 1 3 kg m 9 5 lb ft 93 Install engine mounting LH bracket 1 Tightening...

Page 771: ...converter installing position a More than 19 9 mm 0 783 in Check torque converter for smooth rotation Apply grease around cup at the center of torque converter C Grease 99000 25010 CAUTION Before ins...

Page 772: ...olt 25 2 5 18 0 Fluid reservoir LH plate bolt 10 1 0 7 5 Manual detent spring bolt 10 1 0 7 5 Parking lock pawl bracket bolt 7 5 0 75 5 5 Oil pump assembly bolt 25 2 5 18 0 Torque converter housing bo...

Page 773: ...70123 09913 84510 09913 85210 Bearing puller Bearing installer Bearing installer Bearing installer 09923 78210 09924 74510 09925 37811 001 09925 88210 Bearing installer Bearing installer handle Oil pr...

Page 774: ...pressor 09926 96050 09926 97610 09926 97620 09926 98310 Brake piston compressor Spring compressor Spring compressor Clutch spring compressor 09928 06050 09942 15511 09944 78210 09944 88220 Differentia...

Page 775: ...al Recommended SUZUKI product Part Number Use Automatic transmission fluid An equivalent of DEXRON III Automatic transaxle Parts lubrication when installing O rings Sealant SUZUKI BOND No 1216B 99000...

Page 776: ...hether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before per...

Page 777: ...LH vehicle 6 Clutch release lever bolt 12 Clutch cable outer bolt 1 Clutch cable 7 Clutch pedal 13 Clamp bolt 2 Clutch release lever 8 Clutch cable hook Apply grease 99000 25010 to cable hook Tighteni...

Page 778: ...2 from clutch release lever 3 4 Remove clutch cable outer bolts 1 from dash panel 2 in engine room 5 Disconnect cable hook from clutch pedal then take off cable INSPECTION Inspect clutch cable and re...

Page 779: ...river or long nose pliers from cabin inside then join inner cable joint pin in release lever 3 Fasten cable with clutch cable outer bolts 1 to dash panel 2 Tightening torque Clutch cable outer bolt a...

Page 780: ...edal bracket bolt 10 Packing in cabin 3 Pedal bracket nut 11 Pedal return cushion 4 Pedal shaft 12 Clutch pedal 5 Pedal bush 13 Pedal pad 6 Pedal spring Apply grease 99000 25010 to inside surface of s...

Page 781: ...se 99000 25010 to bush inside 0 3 g 0 01 oz B G10 engine 8 Release bearing Apply grease 99000 25010 to joint of bearing and release shaft and also bearing inside 0 3 g 0 01 oz 1 Flywheel 9 Clutch cove...

Page 782: ...ywheel from crank shaft INSPECTION Input shaft bearing Check bearing 1 for smooth rotation and replace it if abnormality is found Clutch disc Measure depth of rivet head depression i e distance betwee...

Page 783: ...bnormal wear or heat spots Replace or repair as required INSTALLATION 1 Install flywheel 1 to crankshaft and tighten bolts 2 to spec ified torque Special tool A 09924 17810 Tightening torque Flywheel...

Page 784: ...xle Unit Dismounting and Remounting in Section 7A2 A Grease 99000 25210 Clutch Release Bearing Shaft Bush Lever REMOVAL 1 Remove release lever by loosening its bolt 2 Take out release bearing by turni...

Page 785: ...46020 C 09930 30104 INSPECTION Clutch release bearing Check clutch release bearing for smooth rotation If abnormality is found replace it Clutch release shaft Check clutch release shaft and its pin f...

Page 786: ...pecial tool A 09922 46010 4 Coat grease to shaft seal 2 lip and then install it till it is flush with case surface Use special tool for this installation and face seal lip downward inside A Grease 990...

Page 787: ...lutch cover bolt 23 2 3 16 5 Clutch release lever nut 23 2 3 16 5 Pedal bracket bolt 13 1 3 9 5 Pedal bracket nut 13 1 3 9 5 Clutch cable clamp bolt 50 5 0 36 5 Lock nut 6 0 0 6 4 5 Clutch cable outer...

Page 788: ...9923 36320 Bearing remover Bearing remover Bush remover Clutch center guide 09923 36330 09923 46020 09923 46030 09924 17810 Clutch center guide Joint pipe Joint pipe Flywheel holder 09925 98210 09925...

Page 789: ...7C 14 CLUTCH G10 M13 ENGINES...

Page 790: ...he Service Man ual mentioned in FOREWORD of this manual The sealant SUZUKI BOND NO 1215B 99000 31110 is changed to SUZUKI BOND NO 1217G 99000 31260 In the service manual mentioned in FOREWORD of this...

Page 791: ...o engine stiffener 11 Transfer rear mounting bracket bolts 2 Transfer rear mounting bracket 7 Transfer to engine stiffener No 1 bolts 12 Transfer rear mounting 3 Transfer mounting bolt 8 Transfer to e...

Page 792: ...ly sealant 99000 31260 to all around thread part of drain plug 16 Pinion shaft spacer 26 Transfer case bolt 7 Transfer oil level Filler plug Apply sealant 99000 31260 to all around thread part of leve...

Page 793: ...o 1 pipe 1 6 Remove propeller shaft referring to Propeller Shaft Removal and Installation in Section 4B 7 Remove right side drive shaft referring to Front Drive Shaft Assembly Removal and Installation...

Page 794: ...m 5 5 kg m 40 0 lb ft 2 Tighten transfer rear mounting bracket No 2 bolts 1 and transfer rear mounting bracket nuts 2 to specified torque Tightening torque Transfer rear mounting bracket No 2 bolt a...

Page 795: ...ansfer with transfer oil referring to Oil Change in Sec tion 7D of the Service Manual mentioned in the FORE WORD of this manual Fill transaxle with transaxle oil referring to Manual Transaxle Oil Chan...

Page 796: ...terial Material Recommended SUZUKI products Part Number Use Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips O ring Sealant SUZUKI BOND NO 1217G 99000 31260 Oil drain plug Oil level plug...

Page 797: ...7D 8 TRANSFER...

Page 798: ...el pinion bearing outer race 7F 9 Differential case assembly 7F 9 Differential carrier and drive bevel pinion 7F 11 Tightening Torque Specification 7F 18 Required Service Material 7F 18 Special Tool 7...

Page 799: ...bevel pinion and gear it is mandatory to lubricate them by hypoid gear oil The hypoid gears have an advantage of preventing gear noise at the same time they require accurate adjust ment of tooth contr...

Page 800: ...Removal and Installation in Section 5C 4 Remove axle shafts referring to Rear Axle Shaft and Wheel Bearing Remove and Installation for 4WD Model in Sec tion 3E 5 Before removing propeller shaft give...

Page 801: ...atch marks 3 and tighten propeller shaft bolts 4 to specified torque Tightening torque Propeller shaft bolt b 23 N m 2 3 kg m 17 0 lb ft For installation of rear axle shaft refer to Rear Axle Shaft an...

Page 802: ...Differential side gear 4 Drive bevel pinion front taper roller bearing 13 Drive bevel gear hypoid gear 22 Differential pinion shaft 5 Differential carrier bolt Apply sealant 99000 31260 to thread part...

Page 803: ...with it and remove drive bevel gear by removing its bolts 4 Using special tools pull out differential side bearings Special tool A 09913 60910 B 09925 88210 5 Drive out differential pinion shaft pin w...

Page 804: ...al tool if it is hard to remove Special tool B 09913 65135 11 Remove drive bevel pinion with rear bearing and spacer from differential carrier 12 Remove drive bevel pinion rear bearing 2 by using bear...

Page 805: ...for wear or damage Check side gear spline for wear or damage ADJUSTMENT AND ASSEMBLY Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear...

Page 806: ...al tools as shown Special tool A 09925 98210 B 09941 34513 004 C 09924 74510 D 09951 16090 Differential case assembly 1 Assemble differential case assembly noting installing posi tion and direction of...

Page 807: ...g the following available size install it and check again that specified gear thrust play is obtained Available side washer thickness 0 10 0 30 0 50 and 0 70 mm 0 0039 0 0118 0 0196 and 0 0275 in 4 Dr...

Page 808: ...ar A Dummy height of pinion form dummy 40 mm 1 575 in F Shim thickness for mounting distance adjustment D 6 Front bearing B Radius of bearing form dummy with dummy shaft 36 mm 1 417 in 1 Pinion form d...

Page 809: ...dummy using special tools Special tool A 09922 76140 B 09922 76410 4 Apply gear oil to drive bevel pinion rear bearing install rear bearing to pinion form dummy and then install pinion form dummy to...

Page 810: ...ge in the following equation NOTE Before taking measurement check for rotation by hand more than 15 revolutions NOTE When setting dial gauge to bearing form dummy with dummy shaft tighten screw lightl...

Page 811: ...043 0 044 0 045 0 046 0 048 0 049 0 050 and 0 051 in 12 With new pinion spacer 3 inserted as shown install front bearing to differential carrier 13 Install new oil seal 1 into differential carrier 2...

Page 812: ...hims closest to measured value Available shim thickness 0 1 0 3 0 5 and 0 7 mm 0 0039 0 0117 0 0197 and 0 0276 in NOTE Before taking measurement check for smooth rotation by hand Drive bevel pinion be...

Page 813: ...with gear marking compound evenly by using brush or sponge etc b Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact c Bring painte...

Page 814: ...ion height adjusting shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to specification LOW CONTACT Pinion is positioned too close to the center of drive bevel gear 1 D...

Page 815: ...nd if the seat is defective so is transfer case Tooth Contact Pattern Diagnosis and Remedy Fastening part Tightening torque N m kg m lb ft Rear differential oil drain plug 55 5 5 40 0 Rear differentia...

Page 816: ...ler 09913 65135 09913 75810 09922 76120 09922 76140 Bearing puller Bearing installer Dummy shaft Bevel pinion shaft 09922 76150 09922 76230 09922 76320 09922 76340 Bevel pinion nut Bevel gear dummy Re...

Page 817: ...25 98210 09930 40113 09940 51710 Bearing puller attachment Bearing installer Flange holder Bearing installer 09941 34513 004 09951 16060 09951 16090 09951 76010 Bearing installer Lower arm bush remove...

Page 818: ...Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow...

Page 819: ...ding faulty Repair as necessary Bulb burnt out Replace Rear fog light controller faulty Replace controller If front fog lights are equipped Rear fog light does not come on when only headlights come on...

Page 820: ...cifications If check result is not satisfactory repair A The illustration shows LH steering vehicle And RH steering vehicle is symmetrical 2 Fuse box Terminals Condition Specification G53 2 and ground...

Page 821: ...8B 4 LIGHTING SYSTEM...

Page 822: ...ther you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before perfo...

Page 823: ...rminal at battery WHT BLU A2 To ignition switch BLK RED A18 To tail light relay RED YEL A3 To ground BLK A19 To ground BRN A4 To SDM BLU A20 To fuel level gauge YEL RED A5 A21 To ECM WHT GRN A6 To oil...

Page 824: ...aulty Check combination meter circuit referring to Combination Meter in this section ECM faulty Check ECM referring to Inspection of ECM and Its Circuits in Section 6 3 Low engine oil level warning li...

Page 825: ...out 2 Remove fuel pump assembly referring to Fuel Pump Assembly With Fuel Filter Fuel Level Gauge Fuel Pressure Regulator and Fuel Cut Valve in Section 6C 3 Check fuel sender gauge referring to Fuel S...

Page 826: ...w fuel warning light operation for Z13DT engine Engine Oil Level Switch for Z13DT Engine Inspection Check engine oil level switch referring to Engine Oil Level Switch in Section 6E3 Float position Low...

Page 827: ...8C 6 INSTRUMENTATION DRIVER INFORMATION...

Page 828: ...stem components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in Section 10B in order to confirm...

Page 829: ...ed algorithm On the other hand transponder also calculates received variable with SKC stored in memory by means of same algo rithm and sends back to ECM 4 Only when ECM transponder calculated values m...

Page 830: ...switch turned ON but the engine at stop regard less of the condition of the engine and emission control system ECM indicates whether a trouble has occurred in the immobilizer control system or not by...

Page 831: ...tep 4 Go to step 5 4 Check repair and or perform necessary regis tration procedure according to flow table corre sponding to DTC s Is there other DTC s Repeat step 4 until no DTC is indicated Go to st...

Page 832: ...ion Then check data link connector and serial data line circuit in the vehicle with which communication can not be established 4 After completing the check turn ignition switch to OFF posi tion and di...

Page 833: ...ts each terminal voltage confirm that it is 11 V or more when ignition switch is turned to ON position Connec tor Terminal Circuit Nornal Voltage Condition G17 1 Not used 2 PPL WHT MIL 0 1 V MIL light...

Page 834: ...ndition Go to step 2 Repair or replace 2 1 Ignition switch at OFF position 2 Disconnect connector from immobilizer con trol module 3 Check for proper connection to immobilizer control module at G17 7...

Page 835: ...on switch at OFF position 2 Disconnect connector from ECM 3 Check for proper connection to ECM at E21 11 terminal Is it in good condition Go to step 2 Repair or replace 2 1 Connect connector to ECM 2...

Page 836: ...ch at OFF position 2 Disconnect connector from ECM 3 Check for proper connection to ECM at E21 11 Is it in good condition Go to step 2 Repair or replace 2 1 Connect connector to ECM 2 Measure voltage...

Page 837: ...tion for more than 5 seconds then turn ignition switch to ON II position Recheck DTC Is DTC B3059 current Go to step 2 Communication between ECM and immobilizer control module was not finished correct...

Page 838: ...case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter B This kit includes the following items and substitutes for the Tech 1A k...

Page 839: ...8G 12 IMMOBILIZER CONTROL SYSTEM G10 M13 ENGINES...

Page 840: ...render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK pos...

Page 841: ...connector of side turn signal lamp 3 Remove front fender lining 1 4 Remove front fender 2 Installation Reverse removal procedure for installation Adjust panel clearance referring to Panel Clearance i...

Page 842: ...n major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute...

Page 843: ...r and Interior Trim Back Door Emblem Back door emblem dimension Position Dimension Position Dimension mm in mm in a 568 22 36 g 40 1 57 b 76 2 99 h 2 0 08 c 69 2 72 i 9 0 35 d 574 22 6 j 9 0 35 e 74 5...

Page 844: ...5 7 0 197 0 276 l 4 8 7 8 0 189 0 307 c 5 7 0 197 0 276 m 2 5 4 5 0 098 0 177 d 5 7 0 197 0 276 n 4 2 6 2 0 165 0 244 e 3 6 5 6 0 142 0 22 o 3 7 5 7 0 146 0 224 f 4 2 6 2 0 165 0 244 p 5 2 7 2 0 204 0...

Page 845: ...9 6 BODY SERVICE...

Page 846: ...Prepared by 1st Ed August 2003 Printed in Japan 844...

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Suzuki Wagon R Plus RB310, Service Manual

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