Suzuki Wagon R RB310 Supplementary Service Manual Download Page 49 | Manualshive

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5E-32 ANTILOCK BRAKE SYSTEM (ABS)

ABS Hydraulic Unit/Control Module Assembly

HYDRAULIC UNIT INSPECTION

Check hydraulic unit for fluid leakage.
If any, repair or replace.

REMOVAL

1) Disconnect negative cable from battery.
2) For LH vehicle, remove air cleaner outlet pipe (1) referring to

“Engine Mechanical” section.

CAUTION:

Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor.
Performing any of these prohibited services will affect original performance of ABS hydraulic unit/
control module assembly.

1. Brake pipe

3. Bracket

2. ABS hydraulic unit/control module assembly

4. Connector

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Summary of Contents for Wagon R RB310

Page 1: ...ler Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag syste...

Page 2: ...rts tools and service materials lubricant sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product in...

Page 3: ......

Page 4: ...ystem 6E 6E Ignition System Electronic Ignition System 6F1 6F1 TRANSMISSION AND DIFFERENTIAL Automatic Transmission 4 A T 7B 7B 8C ELECTRICAL SYSTEM Instrumentation Driver Information 8C 8D Windows Mi...

Page 5: ......

Page 6: ...2 Precaution for Vehicles Equipped with a Supplemental Restraint Air Bag System 0A 2 Diagnosis 0A 2 Servicing and handling 0A 3 Warning Caution and Information Labels 0A 6 NOTE For descriptions items...

Page 7: ...epair 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...

Page 8: ...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 th...

Page 9: ...iver and Passenger Seat Belt Pretensioners For handling and storage of a live seat belt pretensioner select a place where the ambient tempera ture below 65 C 150 F without high humidity and away from...

Page 10: ...ir bag wire harness is included in instrument panel wire harness Air bag wire harness branched off from instrument panel wire harness can be identified easily as it is covered with a yellow protec tio...

Page 11: ...sembly 2 Air bag caution label on sun visor for vehicle with air bag system 7 Air bag caution label on passenger air bag inflator module 3 Pretensioner label on seat belt retractor 8 Air bag caution l...

Page 12: ...or wiring 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 Failur...

Page 13: ...ib belt I Every 15 000 km 9 000 miles or 12 months R Every 45 000 km 27 000 miles or 36 months A C D E F H Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months C Air cleaner filter 1 I E...

Page 14: ...LUBRICATION 0B 3 NOTE R Replace or change I Inspect and correct or replace if necessary 1 Inspect or replace more frequently if necessary 2 Clean or replace more frequently if the air from the ventil...

Page 15: ...0B 4 MAINTENANCE AND LUBRICATION...

Page 16: ...around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions m...

Page 17: ...3B1 2 ELECTRICAL POWER STEERING EPS SYSTEM IF EQUIPPED...

Page 18: ...upplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer Refer to Air Bag System Components and Wiring L...

Page 19: ...Solenoid Circuit 5E 26 DTC C1056 Left Rear Outlet Solenoid Circuit 5E 26 DTC C1057 Power Source Circuit 5E 27 DTC C1061 ABS Pump Motor Circuit 5E 28 DTC C1063 ABS Fail Safe Relay Circuit 5E 29 DTC C1...

Page 20: ...motor relay ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure applied to each wheel cylinder based on signal from each wheel speed sensor so as to preven...

Page 21: ...motor relay 11 Data link connector 17 G sensor For 4WD model only 6 Stop lamp switch 12 Blank INPUT OUTPUT ABS control module Wheel speed sensor LF Wheel speed sensor LR Wheel speed sensor RF Wheel sp...

Page 22: ...When ignition switch is turned ON ABS warning lamp lights for 2 seconds to check its bulb and circuit 2 When no abnormality has been detected the system is in good condition ABS warning lamp turns OF...

Page 23: ...5E 6 ANTILOCK BRAKE SYSTEM ABS System Circuit...

Page 24: ...nsor For 4WD model only Wire color B Black Br Brown R Red B R Black Red G Green V W Violet White B W Black White G R Green Red W B White Black Bl B Blue Black G W Green White W Bl White Blue Bl R Blue...

Page 25: ...d etc Wheel spin occurred while driving Wheel s was rotated while the vehicle was jacked up Be sure to read PRECAUTIONS FOR ELECTRONIC CIR CUIT SERVICE in Section 0A before inspection and observe what...

Page 26: ...to Step 5 4 1 Inspect and repair referring to applicable diagnostic trouble code table in this section 2 Perform FINAL CONFIRMATION TEST after cleared DTC Does trouble recur Go to Step 7 End 5 1 Insp...

Page 27: ...ion to the point required for proper analysis and diagnosis CUSTOMER QUESTIONNAIRE EXAMPLE b Problem Symptom Confirmation Check if what the customer claimed in CUSTOMER QUESTIONNAIRE is actually found...

Page 28: ...is not nec essary Proceed to Step 3 3 DIAGNOSTIC TROUBLE CODE CHECK Recheck diagnostic trouble code referring to DTC CHECK as shown in the following page 4 DIAGNOSTIC TROUBLE CODE FLOW TABLE According...

Page 29: ...ance to Diagnostic Flow Table A B or C EBD Warning Lamp Brake Warning Lamp Check 1 Turn ignition switch ON with parking brake applied 2 Check that EBD warning lamp brake warning lamp 1 is turned ON 3...

Page 30: ...N 1 Main fuse 5 ABS warning lamp 9 Brake fluid level switch 2 Ignition switch 6 Brake warning lamp 10 ABS hydraulic unit control module assembly 3 Circuit fuse 7 Lamp driver module 11 ABS hydraulic un...

Page 31: ...c unit control module connector at termi nals E20 14 E20 18 and E20 24 3 If OK then ignition switch ON and measure voltage at terminal E20 18 of connector Is it 10 14 V Go to Step 4 W B circuit open 4...

Page 32: ...bination meter 3 ABS hydraulic unit control module connector 2 ABS hydraulic unit control module assembly Step Action Yes No 1 1 Check for proper connection to ABS control module at ABS hydraulic unit...

Page 33: ...2 Release parking brake completely and or replen ish brake fluid 2 Does ABS warning lamp come on Perform TABLE B pre viously outlined Go to Step 3 3 1 Disconnect ABS hydraulic unit control mod ule con...

Page 34: ...replace malfunction part s clear all DTCs by per forming the following procedure 1 Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check 2 Tu...

Page 35: ...SYSTEM CHECK FLOW TABLE before starting diagnosis according to flow table 1 ABS warning lamp in combination meter 3 Data link connector DLC 5 To ECM TCM P S control module and SDM 2 ABS hydraulic unit...

Page 36: ...r SDM Is it possible to communicate with other control ler Go to Step 4 Repair open in common section of serial data cir cuit W R wire circuit used by all controllers or short to ground or power circu...

Page 37: ...1031 RR C1035 LR C1022 RF Wheel speed sensor circuit or sensor ring C1026 LF C1032 RR C1036 LR C1041 RF Inlet solenoid valve circuit C1042 Outlet solenoid valve circuit C1045 LF Inlet solenoid valve c...

Page 38: ...oltage value or if the signal voltage while at a stop does not vary from that while running this DTC is set Therefore this DTC may be set when a vehicle is lifted up and its wheel s is turned In such...

Page 39: ...sensor 2 Check for proper connection to ABS control module at terminals E20 11 and E20 13 3 If OK then turn ignition switch ON and mea sure voltage between W B terminal of sen sor connector and body g...

Page 40: ...IPTION The ABS control module monitors the voltage at the terminal of each sensor while the ignition switch is ON When the voltage is not within the specified range an applicable DTC will be set Also...

Page 41: ...BS hydraulic unit control module connec tor 3 Check for proper connection to ABS control module at each sensor terminal 4 If OK then turn ignition switch ON and measure voltage between sensor terminal...

Page 42: ...uckle Is it OK Go to Step 7 Replace ABS wheel speed sensor 7 Referring to Reference of FRONT WHEEL SPEED SEN SOR and or Reference of REAR WHEEL SPEED SEN SOR in this section check output voltage or wa...

Page 43: ...t control module assembly 3 ABS control module 5 Fail safe relay 2 ABS hydraulic unit control module assembly connector 4 Signal Step Action Yes No 1 1 Check solenoid operation referring to item ABS H...

Page 44: ...tmeter between battery posi tive terminal and body ground 2 Start the engine and measure the maximum voltage when racing the engine Is it over 18 V Check charging system referring to CHARGING SYSTEM s...

Page 45: ...eferring to ABS HYDRAULIC UNIT OPERATION CHECK in this section Is it in good condition Check terminals E20 25 and E20 23 connection If connections OK substi tute a known good ABS hydraulic unit contro...

Page 46: ...module connector 5 To pump motor relay 2 ABS hydraulic unit control module assembly 4 To solenoid valves 6 Fail safe relay Step Action Yes No 1 Check battery voltage Is it about 11 V or higher Go to...

Page 47: ...ail safe relay Step Action Yes No 1 Clear all DTCs and check DTC Is it DTC C1071 Go to Step 2 Could be a temporary malfunction of the ABS control module 2 1 Check proper connection of ABS hydraulic un...

Page 48: ...connector DLC 1 with ignition switch OFF Special tool A SUZUKI scan tool 8 Turn ignition switch to ON position and select menu to HYDRAULIC CONTROL TEST under miscellaneous test MISC TEST mode of SUZ...

Page 49: ...m battery 2 For LH vehicle remove air cleaner outlet pipe 1 referring to Engine Mechanical section CAUTION Never disassemble ABS hydraulic unit control module assembly loosen blind plug or remove moto...

Page 50: ...6 5 lb ft d 26 N m 2 6 kg m 18 0 lb ft 2 Bleed air from brake system referring to BRAKE section 3 Check each installed part for fluid leakage and perform ABS Hydraulic Unit Operation Check in this se...

Page 51: ...body 5 Connect voltmeter between connector 1 terminals 6 While turning wheel by hand at a speed of approximately 1 full rotation to 1 1 3 rotation per second check AC voltage of sensor Output AC volt...

Page 52: ...wheel 4 Remove harness clamp bolts 2 and grommet 3 5 Remove front wheel speed sensor 4 from knuckle SENSOR INSPECTION Check sensor for damage Check sensor for resistance and continuity Between both te...

Page 53: ...is no clearance between sensor and knuckle Front Wheel Speed Sensor Ring For removal and installation of wheel side joint assembly of drive shaft refer to FRONT DRIVE SHAFT section CAUTION Do not pull...

Page 54: ...connector 1 terminals 7 While turning wheel at a speed of approximately 1 2 rotation to 1 rotation per second check AC voltage of sensor Output AC voltage at 1 to 1 1 3 rotation per second 100 mV or...

Page 55: ...heel speed sensor connector from vehicle body unless replacement is necessary 5 Remove rear wheel speed sensor 4 from rear axle housing SENSOR INSPECTION Check sensor for damage Check sensor for resis...

Page 56: ...on of rear wheel sensor ring refer to BRAKE DRUM in Section 5C Rear Wheel Speed Sensor Ring For 4WD vehicle INSPECTION Check rotor serration teeth for being missing damaged or deformed Turn wheel and...

Page 57: ...n placed horizontally 2 3 V When placed upright with arrow upward 3 4 V When placed upright with arrow downward 1 2 V If measured voltage is not as specified replace sensor INSTALLATION 1 Connect conn...

Page 58: ...ludes the following items and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor B T...

Page 59: ...5E 42 ANTILOCK BRAKE SYSTEM ABS...

Page 60: ...ure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service work m...

Page 61: ...6 2 ENGINE...

Page 62: ...tem components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe in...

Page 63: ...6E 2 ENGINE AND EMISSION CONTROL SYSTEM...

Page 64: ...ents and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please obse...

Page 65: ...nals from these sensors ECM identifies the specific cylinder whose piston is in the compression stroke and detects the crank angle TP sensor ECT sensor MAP sensor and other sensors switches Refer to s...

Page 66: ...s but will not start or hard to start No spark Blown fuse for ignition coil Replace Loose connection or disconnection of lead wire or high tension cord s Connect securely Faulty high tension cord s Re...

Page 67: ...round circuits for open and short Are circuits in good condition Go to Step 7 Repair or replace 7 Ignition Coil Assembly Check 1 Check ignition coil for resistance referring to Ignition Coil Assembly...

Page 68: ...his section High tension cords 1 Disconnect high tension cords 2 from ignition coil assem blies 1 while gripping each cap 2 Pull out high tension cords from spark plugs while gripping each cap 3 Measu...

Page 69: ...normality is found adjust air gap clean with spark plug cleaner or replace them with specified new plugs Spark plug air gap a 1 0 1 1 mm 0 040 0 043 in Spark plug type NGK BKR6E 11 DENSO K20PR U11 5 I...

Page 70: ...f specification replace ignition coil assembly 7 Install ignition coil assembly 8 Tighten ignition coil bolts and then connect ignition coil cou pler 9 Install high tension cord to ignition coil assem...

Page 71: ...n specification Initial ignition timing fixed with SUZUKI scan tool 5 3 BTDC at idle speed Ignition order 1 3 4 2 8 If ignition timing is out of specification check the followings CKP sensor Crankshaf...

Page 72: ...s and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor B Thi...

Page 73: ...6F1 10 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM...

Page 74: ...or switch circuit malfunction 7B 39 DTC P0725 Engine speed input circuit malfunction 7B 41 DTC P0710 Transmission fluid temperature sensor circuit malfunction 7B 43 DTC P0763 Shift solenoid C No 3 ele...

Page 75: ...nction of TCM 7B 48 Inspection of TCM and ITS circuits 7B 49 On Vehicle Service 7B 51 Maintenance Service 7B 51 Fluid level at normal operating temperature 7B 51 Fluid level at room temperature 7B 52...

Page 76: ...P R N D 2 and L by means of the select lever installed on the floor On the shift knob there is an overdrive O D cut switch which allows shift up to the overdrive mode and shift down from the overdriv...

Page 77: ...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 reduction and fixed at 1st gear Gear ratio 1st 2 962 2nd 1 515 Number of...

Page 78: ...ch Meshes input shaft and front internal gear and rear carrier Overdrive brake Fixes rear sun gear 1st 2nd brake Fixes front sun gear Reverse brake Fixes front internal gear and rear carrier Direct cl...

Page 79: ...olenoid 21 Ignition switch K Serial communication with Suzuki scan tool 8 Shift solenoid A Shift solenoid No 1 22 Battery L Power supply 9 Shift solenoid B Shift solenoid No 2 23 A T relay M Throttle...

Page 80: ...2 21 A T relay 6 Barometric pressure sensor 14 Shift solenoid valve C No 3 22 Ignition switch 7 To A C compressor 15 Shift solenoid valve D No 4 23 Data link connector DLC 8 Transmission range sensor...

Page 81: ...ge 1st Output shaft speed sensor circuit DTC P0720 Output shaft speed sensor signal voltage is too high or too low Shift solenoid DTC P0753 DTC P0758 DTC P0763 DTC P0768 DTC P0773 Solenoid output volt...

Page 82: ...ehicle stop and lock up function is turned OFF When vehicle is at stop after or during detecting the trouble gear is fixed as the followings and lock up function is turned OFF When 2 adjoining gear po...

Page 83: ...oid power sup ply relay output volt age is too high although TCM orders relay to turn off or relay output voltage is too low although TCM orders relay to turn on When relay shorted the gear is fixed a...

Page 84: ...gear shift diagram Automatic shift schedule as a result of shift control is shown below Gear Shift Diagram TCC Lock up Diagram Shift Throttle opening 1 2 2 3 3 4 4 3 3 2 2 1 Full throttle km h 44 98 1...

Page 85: ...Diagnostic Trouble Code DTC Check Record and Clearance 1 Check for DTC referring to the following page Is there any DTC s 1 Print DTC or write it down and clear it by referring to DTC CLEARANCE in th...

Page 86: ...or DTC 1 Check and repair according to applicable DTC Diagnostic Flow Table Are check and repair complete 10 Check for Intermittent Problems 1 Check for intermittent problems referring to the followin...

Page 87: ...described by the customer For this purpose use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis CUSTOMER QUES...

Page 88: ...f what the customer claimed in CUSTOMER COMPLAINT ANALYSIS is actually found in the vehicle and if that symptom is found whether it is identified as a failure This step should be shared with the custo...

Page 89: ...E PRESSURE TEST in this section 5 ROAD TEST Perform road test to understand correctly the trouble area 6 Electrical Harness and Coupler Check Check the connection of the harness coupler Check for the...

Page 90: ...3rd 2nd 2nd 1st Shift solenoid C No 3 4th 3rd D No 4 2nd 1st A No 1 3rd 2nd B No 2 4th 3rd E No 5 3rd 2nd or its circuit faulty Repair or replace Throttle position sensor or its circuit faulty Inspec...

Page 91: ...or replace Vehicle does not move at 1st 2nd 3rd and reverse gear Rear clutch faulty Repair or replace Reverse gear Reverse brake faulty Repair or replace 2nd 3rd and 4th gear Front clutch faulty Repai...

Page 92: ...y after stall speed is checked 7 In the same way check stall speed in R range 8 Stall speed should be within following specification Stall speed 2 700 3 100 r min CAUTION Do not run engine at stall mo...

Page 93: ...that moment till shock is felt 4 Similarly measure time lag by shifting select lever from N to R range Specification for time lag N D Less than 1 0 sec N R Less than 1 2 sec NOTE Make sure that selec...

Page 94: ...er attaching oil pressure gauge check that no fluid leakage exists A CAUTION Do not continue running engine at stall speed longer than 5 seconds D range R range At idle speed 7 6 9 2 kg cm2 108 1 130...

Page 95: ...ake pedal gradually and check that vehicle remains stationary 4 Depress brake pedal and shift select lever to N range 5 Then release brake pedal gradually and check that vehicle moves WARNING Before t...

Page 96: ...although TCM detects malfunction of automatic transmission system Using SUZUKI scan tool 3 diagnostic trouble code DTC stored in TCM memory can be checked and cleared as well Before its use be sure to...

Page 97: ...ual for further details 5 After completing the check turn ignition switch OFF and dis connect SUZUKI scan tool from data link connector DLC 1 DTC clearance 1 Turn ignition switch OFF 2 Connect it to d...

Page 98: ...Not applicable P0743 Torque converter clutch lock up system electrical 1 driving cycle Not applicable P0741 Torque converter clutch lock up solenoid perfor mance or stuck off 2 driving cycles Not app...

Page 99: ...tch OFF 2 Check for proper connection to TCM at E13 2 terminal 3 If OK turn ignition switch ON and check voltage at terminal E13 2 of disconnected TCM coupler Is it 10 14 V Go to Step 2 P Bl wire open...

Page 100: ...ected sensor side coupler Is it 160 200 See figure Go to Step 3 Replace input shaft speed sensor 3 1 Connect output shaft speed sensor input shaft speed sensor coupler then disconnect TCM couplers 2 M...

Page 101: ...7B 28 AUTOMATIC TRANSMISSION 4 A T Figure for Step 2 Figure for Step 4 1 Output shaft speed sensor Input shaft speed sensor coupler 2 Input shaft speed sensor terminal...

Page 102: ...1 Turn ignition switch OFF and discon nect TCM couplers 2 Measure resistance between terminal E12 13 of the disconnected harness side coupler and body ground Is it about 0 See figure Short in between...

Page 103: ...7B 30 AUTOMATIC TRANSMISSION 4 A T Figure for Step 2 Figure for Step 3 1 Output shaft speed sensor 2 Input shaft speed sensor...

Page 104: ...ect solenoid coupler 2 Measure the resistance between each sole noid terminal of the solenoid side coupler and transmission ground Is it 11 15 See figure Go to Step 2 Solenoid lead wire open or shorte...

Page 105: ...titute a known good TCM and recheck B R B O or Br wire or shift solenoid lead wire shorted to power source circuit Step Action Yes No Solenoid TCM Terminal Number Lead Wire Color between TCM and solen...

Page 106: ...valve body for fluid passage clog or lock up control valve secondary regulator valve or signal valve stuck referring to TRANSMIS SION UNIT REPAIR OVERHAUL in this sec tion Are they in good condition...

Page 107: ...n switch OFF and disconnect output shaft speed sensor input shaft speed sensor coupler See figure 2 Measure the resistance between terminals of disconnected sensor side coupler Is it 160 200 See figur...

Page 108: ...al E12 6 of disconnected harness side coupler and body ground then terminal E12 14 of disconnected harness side coupler and body ground Is it about 0 See figure W or B wire shorted to ground Go to Ste...

Page 109: ...7B 36 AUTOMATIC TRANSMISSION 4 A T Figure for Step 2 5 Figure for Step 4 1 E12 14 terminal 2 E12 6 terminal 3 E12 13 terminal 4 TCM couplers 1 E12 14 terminal 2 E12 6 terminal 3 TCM couplers...

Page 110: ...GNOSIS referring to Section 6 Is there DTC related to throttle position sensor detected Inspect and repair refer ring to DTC flow table of ENGINE DIAGNOSIS in Section 6 Go to Step 2 2 1 Check for prop...

Page 111: ...nnect TCM couplers 2 Turn ignition switch ON 3 Measure voltage between terminal E12 8 of connected harness side TCM coupler and ground Is it 10 14 V Intermittent trouble or faulty ECM Check for interm...

Page 112: ...ess side TCM coupler Is it 10 14 V at P range and 0 V at the other range Go to Step 2 Go to Step 7 2 While ignition switch ON check voltage between terminal E12 2 and E13 15 of dis connected harness s...

Page 113: ...minal E12 11 and E13 15 of dis connected harness side TCM coupler Is it 10 14 V at L range and 0 V at the other range Intermittent trouble or faulty TCM Check for intermittent trouble referring to INT...

Page 114: ...to Section 6 Is there DTC related to engine speed sensor Inspect and repair refer ring to DTC flow table of ENGINE DIAGNOSIS in Section 6 Go to Step 2 2 1 Turn ignition switch OFF and disconnect ECM...

Page 115: ...inal E12 5 of discon nected harness side TCM coupler and body ground Is it 10 14 V Intermittent trouble or faulty ECM or TCM Check for intermittent referring to INTERMIT TENT AND POOR CON NECTION in S...

Page 116: ...ler 2 Measure resistance between Bl wire and G wire terminal of sensor side coupler Is it infinity or 0 Faulty transmission fluid temperature sensor Replace transmission temperature sensor Go to Step...

Page 117: ...harness side coupler and engine ground See figure Is it 4 6 V Intermittent trouble or faulty TCM Check for intermittent referring to INTERMIT TENT AND POOR CON NECTION in Section 0A If no trouble fou...

Page 118: ...r 2 Measure resistance between terminal of sole noid coupler and transmission ground See figure Is it 2 0 4 0 Go to Step 2 Solenoid lead wire open or shorted to ground Malfunction of solenoid valve 2...

Page 119: ...ITTENT AND POOR CONNECTION in Sec tion 0A If no trouble found substitute a known good TCM and recheck Solenoid TCM terminal No Solenoid coupler lead wire color body side C No 3 E13 11 R W D No 4 E13 1...

Page 120: ...Is any DTC detected Inspect and repair refer ring to DTC flow table in Section 6 Go to Step 2 2 1 Turn ignition switch OFF and disconnect TCM and ECM couplers 2 Check continuity between terminal E13...

Page 121: ...hough TCM orders the relay to turn OFF or relay output voltage too low although TCM orders the relay to turn on Incorrect calculations of checking TCM programmed data indicated Step Action Yes No 1 1...

Page 122: ...or lever at P range 0 1 V IG switch ON selector lever other than P range 2 Transmission range R switch 10 14 V IG switch ON selector lever at R range 0 1 V IG switch ON selector lever other than R ran...

Page 123: ...resistor 10 14 V IG switch ON select lever at P range 13 Shift solenoid E Dropping resistor 0 1 V IG switch ON select lever at P range 15 Ground 16 Transmission temperature sen sor ground 17 O D off s...

Page 124: ...a clean cloth and put it back into place 7 Pull out dipstick 1 again and check fluid level indicated on it Fluid level should be between FULL HOT and LOW HOT If it is below LOW HOT add an equivalent o...

Page 125: ...described previously If the fluid level is between FULL COLD and LOW COLD proceed to test drive And when the fluid temperature has reached the normal operating temperature check fluid again and adjus...

Page 126: ...n Control Module TCM REMOVAL 1 Disconnect negative cable at battery 2 If the vehicle is equipped with air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove gl...

Page 127: ...d remove TCM from vehicle INSTALLATION Reverse removal procedure noting the following Connect ECM and TCM couplers securely If the vehicle is equipped with air bag system be sure to enable air bag sys...

Page 128: ...ire 1 connect terminal E12 4 of con nected TCM harness side coupler with body ground 3 3 Shift selector lever from D range to 2 range 3 times repeatedly within 10 seconds with terminal E12 4 kept on c...

Page 129: ...bolts 10 1 0 7 5 Valve body bolts 5 5 0 55 4 0 Final gear bolts 90 9 0 65 0 Counter drive gear installing bolts 5 5 0 55 4 0 Rear cover bolts 19 1 9 14 0 Control shift lever nuts 30 3 0 22 0 Detent s...

Page 130: ...09913 85210 09922 85811 09923 74510 Bearing installer Bearing installer Spring pin remover 6 mm Bearing remover 09924 74510 09925 37811 001 09925 88210 09926 26030 Installer handle Oil pressure gauge...

Page 131: ...n DLC cable for Tech 1A 09931 76011 09941 64511 09944 68510 09951 16060 Tech 1A kit SUZUKI scan tool See NOTE A Bearing remover Bearing installer Bush remover 09952 06010 09952 06020 09926 26050 Dial...

Page 132: ...ack adapter 7 Battery power cable 8 RS232 cable 9 RS232 adapter 10 RS232 loopback connector 11 Storage case 12 Power supply Material Recommended SUZUKI product Part Number Use Automatic transmission f...

Page 133: ...7B 60 AUTOMATIC TRANSMISSION 4 A T...

Page 134: ...near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section before performing service on or around the air bag...

Page 135: ...ch Y B 17 To positive terminal at battery W BI 28 To ignition switch ACC Y B 7 To ABS control module O 18 To lighting switch R Y 29 To positive terminal at battery W BI 8 To EPS control module Gr 19 T...

Page 136: ...HICLE SERVICE in this Section Condition Possible Cause Correction Low fuel warning light does not come ON after ignition switch turns to ON position Bulb blown Check bulb IG METER fuse blown Check fus...

Page 137: ...heck for low fuel warning lamp operation under the following each float position 1 of fuel pump 2 If faulty condition is found replace combination meter Low fuel warning light operation Float position...

Page 138: ...ized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near th...

Page 139: ...er switch Wiring harness connected to driver side door key cylinder switch faulty Repair Power door lock controller faulty Check system referring to POWER DOOR LOCK SYSTEM CIRCUIT INSPECTION in this s...

Page 140: ...turned UNLOCK twice check all doors unlock Interior light does not turn ON when doors are unlocked by keyless entry transmitter Power door lock controller faulty Check system referring to KEY LESS ENT...

Page 141: ...operate as specified repair applicable circuit or check actuator If it operates as specified go to next step Power door lock operation for vehicle with dead lock system Power door lock operation for...

Page 142: ...tion G02 9 WHT GRN Main power supply 10 14 V G02 11 YEL BLK Key remainder circuit 10 14 V Ignition key is in ignition switch 0 1 V Ignition key is not in ignition G02 12 YEL Ignition switch circuit 10...

Page 143: ...cle equipped dead lock system When pushing LOCK button 1 on transmitter 2 twice within 2 seconds check all doors lock and not pulled up all door lock knobs by hand If check result is not satisfied go...

Page 144: ...s G02 8 GRN RED Hazard waning signal circuit left side Figure A Push LOCK button on transmitter once Figure B Push UNLOCK button on transmit ter once Figure C Push LOCK button on transmitter twice wit...

Page 145: ...ON position and then drawn ignition key from ignition key cylinder within 10 seconds after that 4 Push and release driver side door switch 1 at 3 times by hand within 20 seconds after removing igniti...

Page 146: ...AUTIONS under ON VEHICLE SERVICE in air bag system section before per forming service on or around the air bag system components or wiring Failure to follow WARN INGS could result in unintentional act...

Page 147: ...Select vehicle immobilizer and Registration at each menu screen 5 Select Register New Ig Key Fix code to register fix code from ignition key into immobilizer control module and register secret key cod...

Page 148: ...ister ignition key fix code into immobilizer control mod ule by performing Register New Ig Key Fix Code at Immo bilizer Registration Menu Procedure after ECM replacement When using Tech 1A For the pro...

Page 149: ...stitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor B This kit inc...

Page 150: ...wo 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 fro...

Page 151: ...an assembly Be sure to read SERVICE PRECAUTIONS in Section 10B before starting to work and observe every precaution during work Neglecting them may result in personal injury or undeployment of the ai...

Page 152: ...in Section 10B 2 Disconnect side air bag coupler 1 if equipped 3 Remove center console box 1 4 Remove 4 mounting bolts to remove front seat from vehicle floor INSTALLATION Reverse removal procedure t...

Page 153: ...9 4 BODY SERVICE Rear Seat REMOVAL INSTALLATION For removal and Installation of rear seat refer to above figure 1 Seat cushion 4 Seat cushion bolt 2 Seat back 5 Folding bolt 3 Seat back bolt...

Page 154: ...rcuit Resistance High 10B 36 DTC B1042 Driver Pretensioner Initiator Circuit Resistance Low 10B 36 DTC B1043 Driver Pretensioner Initiator Circuit Short to Ground 10B 36 WARNING Service on or around t...

Page 155: ...B 53 DTC B1081 Side Air Bag Driver Side Intiator Circuit Resistance High 10B 57 DTC B1082 Side Air Bag Driver Side Intiator Circuit Resistance Low 10B 57 DTC B1083 Side Air Bag Driver Side Intiator Ci...

Page 156: ...in occurrence of a front colli sion with an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts Side air bag inflator module is deploye...

Page 157: ...R X01 CONNECTOR X02 X03 10 8 11 10 8 7 11 9 1 5 3 2 6 4 1 Air bag harness in instrument panel harness 5 Driver air bag inflator module 9 Ground for air bag system 2 AIR BAG fuse in circuit fuse box 6...

Page 158: ...AIR BAG fuse 13 Driver seat belt pretensioner 6 To ECM and ABS control module if equipped 14 Passenger seat belt pretensioner 7 Data link connector DLC 15 Side air bag inflator module at driver side i...

Page 159: ...26 Driver air bag inflator module Low G66 8 G66 27 High G66 9 G66 28 Data link connector DLC G66 10 G66 29 G66 11 G66 30 AIR BAG warning lamp G66 12 G66 31 Ground G66 13 G66 32 Ignition switch power...

Page 160: ...e to the terminal will occur from the multimeter probe such as spreading or bending An SDM short bar release tool is included in the connector test adapter kit Inserting it into the SDM connector will...

Page 161: ...ector for side air bag inflator module Each of driver and passenger seat belt pretensioners when it is connected to instrument panel harness connector for driver and passenger seat belt pretensioners...

Page 162: ...or damaged terminals Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal included in the connector test adapter kit s...

Page 163: ...FLOW TABLE after any repair or diagnostic proce dures have been performed Performing the AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE after all repair or diagnostic proce dures will ensure that the rep...

Page 164: ...AG warning lamp circuit is good condition Go to step 4 AIR BAG warning lamp circuit is good condition Go to step 5 4 1 Check DTC using SUZUKI scan tool Refer to DTC CHECK in this section Is NO CODES d...

Page 165: ...ition switch to OFF posi tion and disconnect SUZUKI scan tool from data link connec tor DLC DTC Clearance 1 Turn ignition switch to OFF position 2 Connect SUZUKI scan tool to data link connector DLC i...

Page 166: ...r cuit Resistance high B1046 Resistance low B1047 Short to ground B1048 Short to power circuit B1051 SDM Frontal crash detected B1056 Sideward crash driver side detected B1057 Sideward crash passenger...

Page 167: ...corre sponding to each code No B1082 Resistance low B1083 Short to ground B1084 Short to power circuit B1085 Side air bag circuit passenger side Resistance high B1086 Resistance low B1087 Short to gro...

Page 168: ...3 5 4 9 7 8 10 6 1 CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table When measurement of resistance or voltage is required in this table use...

Page 169: ...n ignition switch to OFF position 2 Remove and inspect AIR BAG fuse Is fuse good Go to step 2 Clear up short circuit between BLU RED wire and ground After clearing up replace AIR BAG fuse 2 1 Check fo...

Page 170: ...RED or GRN wire Short circuit between BLK RED or GRN and ground METER fuse blown 2 1 Turn ignition switch to OFF position 2 Remove combination meter Refer to COM BINATION METER in Section 8 3 Remove a...

Page 171: ...ts ensure all components are properly mounted Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected Step Action Yes No 1 1 Check G66 8 terminal of SDM Is it shorted to...

Page 172: ...ED BLK G66 G66 30 G66 32 G66 28 G66 31 BLK BRN WHT BLU G25 G25 1 2 3 5 4 9 6 1 7 8 10 11 CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table Wh...

Page 173: ...epair open in serial data power circuit BLU WHT wire circuit 4 1 Check resistance the following serial data ground cir cuits Between DLC terminal G09 4 BLK wire terminal and body ground Between DLC te...

Page 174: ...connector G66 D Fig for Step 5 A A G66 28 G09 7 G09 05 G09 04 A A B C D 1 3 1 A G09 16 1 NOTE Upon completion of inspection and repair work perform following items Reconnect all air bag system compon...

Page 175: ...function is in passenger air bag inflator module STEP 2 Check passenger air bag inflator module initiator circuit in air bag harness in instrument panel har ness STEP 3 Check passenger air bag inflato...

Page 176: ...ignition switch OFF disconnect SDM connector G66 2 Check proper connection to SDM connector G66 at terminals G66 24 and G66 23 3 If OK release shorting bar in SDM connector insert ing release tool 1...

Page 177: ...connector G66 2 Check proper connection to SDM at terminals G66 24 and G66 23 3 If OK release shorting bar in SDM connector inserting release tool 1 included in special tool A 4 Measure resistance be...

Page 178: ...from G74 connector and SDM connector G66 from SDM respectively 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure resistance between G66 24 terminal...

Page 179: ...74 connector and SDM connector G66 from SDM respectively 2 Release shorting bar in SDM connector inserting release tool 1 included in special tool A 3 Measure voltage from G66 24 terminal to body grou...

Page 180: ...STEP 1 Check whether malfunction is in contact coil and driver air bag inflator module or the others STEP 2 Check driver air bag inflator module initiator circuit in instrument panel harness STEP 3 Ch...

Page 181: ...nd C to G65 connector Is resistance 5 1 or less Substitute a known good SDM and recheck Repair high resis tance or open in GRN RED or GRN wire circuit 3 1 With ignition switch OFF disconnect Special T...

Page 182: ...se shorting bar in SDM connec tor inserting release tool 1 included in spe cial tool A 4 Measure resistance between G66 27 and G66 26 terminals with connected Special Tools B and C to G65 connector Is...

Page 183: ...has been corrected Step Action Yes No 1 1 With ignition switch OFF disconnect contact coil connector G65 behind steering wheel 2 Check proper connection to contact coil at terminals in G65 connector...

Page 184: ...F Replace driver air bag inflator module Refer to DRIVER AIR BAG INFLATOR MODULE in Section 3 A Fig for STEP 1 and 2 1 Release tool B Fig for STEP 2 2 SDM connector G66 C Fig for STEP 3 3 Contact coil...

Page 185: ...in Section 3C 3 Check proper connection to driver air bag inflator module at terminals in Q08 con nector 4 If OK then connect Special Tools B and C to Q08 connector With ignition switch ON is DTC B102...

Page 186: ...2 still exists 1 From main fuse 3 AIR BAG fuse 5 Ground for air bag system 2 Ignition switch 4 SDM 1 2 GRN BLU RED 3 5 BLK G66 G66 32 G66 31 4 30V 5V CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYST...

Page 187: ...ion switch OFF disconnect SDM connector G66 With ignition switch ON is DTC B1031 current Substitute a known good SDM and recheck Check Charging System and repair as necessary Refer to DIAGNOSIS in Sec...

Page 188: ...H 3 1 With ignition switch OFF reconnect SDM connector G66 With ignition switch ON is DTC B1032 current Substitute a known good SDM and recheck Check Charging System and repair as necessary Refer to D...

Page 189: ...rom main fuse 4 SDM 7 Ground for air bag system 2 Ignition switch 5 Driver seat belt pretensioner GRN PNK WHT BLU RED G67 BLK G66 BRN LT GRN G72 G66 12V 12V G66 32 G66 31 G66 33 G66 34 G66 36 G66 35 A...

Page 190: ...1043 B1044 B1045 B1046 B1047 or B1048 STEP 1 Check whether malfunction is in seat belt pretensioner STEP 2 Check seat belt pretensioner initiator circuit in instrument panel harness DIAGNOSTIC FLOW TA...

Page 191: ...66 35 terminals Is resistance 4 1 or less Substitute a known good SDM and recheck DTC B1041 Repair high resistance or open in PNK or WHT wire circuit DTC B1045 Repair high resistance or open in BRN or...

Page 192: ...isconnect SDM connector G66 2 Check proper connection to SDM at termi nals G66 33 and G66 34 or G66 36 and G66 35 3 If OK release shorting bar in SDM connec tor inserting release tool 1 included in sp...

Page 193: ...nsioner at terminals in G67 or G72 connector 3 If OK then connect Special Tools A B and C to seat belt pretensioner connector disconnected at the step 1 With ignition switch ON is DTC B1043 or B1047 s...

Page 194: ...ensure all components are properly mounted Clear diagnostic trouble codes Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected Step Actio...

Page 195: ...ignition switch ON is voltage 0 1 V Substitute a known good SDM and recheck DTC B1044 Repair short PNK or WHT wire circuit to power circuit DTC B1048 Repair short from BRN or LT GRN wire circuit to p...

Page 196: ...tion switch OFF Has driver air bag inflator module deployed Replace components and perform inspections as directed in REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT in this sec tion Go to step 2 2...

Page 197: ...1057 Sideward Crash Passenger Side Detected Side Air Bag System Activation Command Outputted CAUTION Before starting diagnosis according to flow table Air Bag Diagnostic System Check Step Action Yes N...

Page 198: ...1 Ignition switch OFF Has air bag inflator module deployed Replace components and perform inspections as directed in REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT in this sec tion Go to step 2 2...

Page 199: ...engine block GRN GRN BLK RED BLU BLU RED 30V 5V WHT RED BLK G66 G66 30 G66 32 G66 28 G66 31 BLK BRN WHT BLU G25 G25 1 1 2 3 5 4 9 6 7 10 8 CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK b...

Page 200: ...lear DTC Refer to DTC CLEARANCE in this section 2 Check DTC Refer to DTC CHECK in this section Is DTC B1061 set Substitute a known good SDM and recheck Recheck air bag system Refer to AIR BAG DIAG NOS...

Page 201: ...system 2 Ignition switch 5 Side sensor driver side 3 AIR BAG fuse 6 Side sensor passenger side GRN BLU RED G68 G71 GRN WHT GRN BLK GRN YEL GRN ORN BLK G66 G66 32 G66 17 G66 6 G66 16 G66 5 G66 31 1 2 3...

Page 202: ...on nector 4 If OK measure resistance with connected special tool A DTC B1063 between G66 17 terminal and body ground and between G66 6 terminal and body ground DTC B1065 between G66 16 terminal and bo...

Page 203: ...71 1 and G66 16 terminals and between G71 2 and G66 5 terminals Is resistance 0 1 Got to Step 2 DTC B1064 Repair open in GRN WHT or GRN BLK wire circuit DTC B1066 Repair open in GRN YEL or GRN ORN wir...

Page 204: ...17 B G66 5 G66 16 A A 1 1 NOTE Upon completion of inspection and repair work perform the following items Reconnect all air bag system components ensure all components are properly mounted Clear diagn...

Page 205: ...fault signal from side sensor CAUTION Be sure to perform Air Bag Diagnostic System Check before starting diagnosis according to flow table NOTE DTC B1071 can never be cleared once it has been set 1 I...

Page 206: ...WHT GRN BLK GRN YEL GRN ORN BLK G66 G66 32 G66 17 G66 6 G66 16 G66 5 G66 31 1 2 3 5 6 7 4 CAUTION Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table...

Page 207: ...stance between G68 1 and G66 17 terminals and between G68 2 and G66 6 terminals with connected special tool A Is resistance 0 1 DTC B1075 If OK then measure resistance between G71 1 and G66 16 termina...

Page 208: ...ort from GRN YEL or GRN ORN wire to body ground 4 1 DTC B1073 Measure voltage from G66 17 and G66 6 terminals to body ground with connected special tool A With ignition switch ON is voltage 0 1V DTC B...

Page 209: ...17 G66 5 G66 16 A A E D F 1 1 C E G66 6 G66 17 F G66 5 G66 16 A A 1 1 NOTE Upon completion of inspection and repair work perform the following items Reconnect all air bag system components ensure all...

Page 210: ...ator module 1 From main fuse 3 AIR BAG fuse 5 Side air bag driver side inflator module 7 Ground for air bag system GRN BLU RED BLK G66 G66 12V 12V G66 32 G66 31 G66 19 G66 18 G66 20 G66 21 A 3 7 WHT R...

Page 211: ...time TABLE TEST DESCRIPTION DTC B1081 B1082 B1083 B1084 B1085 B1086 B1087 or B1088 STEP 1 Check whether malfunction is in side air bag inflator module STEP 2 Check side air bag initiator circuit in i...

Page 212: ...sistance 2 6 or less Substitute a known good SDM and recheck DTC B1081 Repair high resistance or open in WHT RED or WHT GRN wire circuit DTC B1085 Repair high resistance or open in RED BLK or RED YEL...

Page 213: ...DM connector G66 2 Check proper connection to SDM at termi nals G66 19 and G66 18 or G66 20 and G66 21 3 If OK release shorting bar in SDM connec tor inserting release tool 1 included in spe cial tool...

Page 214: ...ctor 3 If OK then connect Special Tools B and C to side air bag inflator module connec tor G69 or G70 disconnected at the step 1 With ignition switch ON is DTC B1083 or B1087 still current Go to step...

Page 215: ...system components ensure all components are properly mounted Clear diagnostic trouble code Refer to DTC CLEARANCE if any Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been co...

Page 216: ...d With ignition switch ON is voltage 0 1V Substitute a known good SDM and recheck DTC B1084 Repair short from WHT RED or WHT GRN wire circuit to ground DTC B1088 Repair short from RED BLK or RED YEL w...

Page 217: ...SDM be careful not to drop it or apply an impact to it If an excessive impact was applied e g side sensors are dropped SDM is dropped air bag inflator mod ule is dropped from a height of 90 cm 3 ft or...

Page 218: ...g of lock lever 2 b After unlocked disconnect connector 6 If equipped with passenger air bag inflator module remove glove box and disconnect Yellow connector 3 of passenger air bag inflator module a R...

Page 219: ...Yellow connector 1 of passenger air bag inflator module by pushing connector till click is heard from it 5 Install glove box 6 If equipped with side air bag inflator module connect Yel low connector...

Page 220: ...at part completely before reinstallation All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointed toward the front of the vehicle to ensure proper operation of th...

Page 221: ...inflator modules driver passenger and side of driver and passenger wipe it off immediately with a dry cloth If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be repl...

Page 222: ...carry live air bag inflator module with trim cover away from you When storing live air bag inflator module or when leaving live air bag inflator module unattended on bench or other surface always fac...

Page 223: ...ioner was dropped from a height of 30 cm 1 ft or more it should be replaced with a new one as an assembly WARNING Never attempt to measure the resistance of the seat belt pretensioners It is very dang...

Page 224: ...for at least 30 minutes to cool it off before pro ceeding the work Do not apply water oil etc to deployed air bag infla tor module and to activate seat belt pretensioner After an air bag inflator modu...

Page 225: ...n cause intermittent problems that are difficult to diagnose Disposal Do not dispose of the live undeployed air bag inflator modules and the live inactivated seat belt pretensioners When disposal is n...

Page 226: ...ION 3C If any faulty condition is found in above checks replace faulty part Steering column bracket 2 and capsules 3 Check for damage and bent If any faulty condition is found in above checks replace...

Page 227: ...ue to a cause in itself Check that connector or lead wire of SDM has a scorching melting or damage Check that connector is connected securely or locked Check SDM connector and terminals for tightness...

Page 228: ...heck for dents cracks damage or fitness Check harness and connector for damage or tightness If any faulty condition is found in above checks replace Seat belts and mounting points Refer to FRONT SEAT...

Page 229: ...age cracks or lock mech anism Check SDM terminal for bent corrosion or rust If any faulty condition is found in above checks replace WARNING During service procedures be very careful when han dling a...

Page 230: ...SDM connector 2 to SDM 3 securely Enable air bag system Refer to ENABLING AIR BAG SYS TEM in this section Side Sensor if equipped REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag syste...

Page 231: ...ensor connector sensor side and harness side lock mechanism or sensor lead wire for damage crack scorching or melting Check connector terminals for bent corrosion or rust If any faulty condition is fo...

Page 232: ...orque Tightening torque Side sensor bolt a 9 N m 0 9 kg m 6 5 lb ft 3 Push connector inner 1 until side sensor is connected as shown 4 Connect negative cable at battery 5 Enable air bag system Refer t...

Page 233: ...r bag has deployed There is a crack in trim cover pad surface Wire harness or connector is damaged Air bag inflator module is damaged or a strong impact was applied to it WARNING Never attempt to disa...

Page 234: ...ator module attaching bolts 3 to specified torque Tightening torque Passenger air bag inflator module mounting bolt a 23 N m 2 3 kg m 16 5 lb ft 3 Set glove box 4 to original position of instrument pa...

Page 235: ...ATION SWITCH ASSEMBLY in Section 3C for removal inspection and installa tion Seat Belt Pretensioner Refer to FRONT SEAT BELT WITH PRETENSIONER in Section 10 for removal inspection and installation WAR...

Page 236: ...ed air bag inflator module and inactivated seat belt pretensioner contain substances that can cause severe illness or personal injury if sealed container is damaged during disposal WARNING The followi...

Page 237: ...steering wheel referring to Driver Air Bag inflator Module in Section 3C For passenger air bag inflator module Remove passenger air bag inflator module from instrument panel referring to Passenger Ai...

Page 238: ...ent temperature below 65 C 150 F without high humidity and away from electric noise Always carry live air bag inflator module with trim cover away from you When storing live air bag inflator module or...

Page 239: ...flator module 2 in deploy ment fixture A using mounting attachment 3 hold down bolts nuts 4 and M8 bolts nuts 5 For side air bag inflator module a Clear space 3 on ground about 185 cm 6 ft in diameter...

Page 240: ...re harness diameter 1 25 mm 0 05 in or more e Clear space 4 on ground about 185 cm 6 ft in diameter where seat belt pretensioner 1 is to be activated Paved outdoor location where there is no activity...

Page 241: ...nt fixture special tool For side air bag inflator module To turn over seat back trim 6 and disconnect side air bag inflator module connector 7 then connect adapter cable B to side air bag inflator mod...

Page 242: ...deploys and seat belt pretensioner activates rapid gas expansion will create substantial report Wear suitable ear protection Notify all people in immediate area that you intend to deploy air bag infla...

Page 243: ...it has cooled for at least 30 minutes and tightly seal air bag inflator module 1 or seat belt pretensioner 2 in strong vinyl bag Refer to Deployed Air Bag Inflator Mod ule and Activated Seat Belt Pret...

Page 244: ...nnect contact coil connector 1 located behind steering wheel b For passenger air bag inflator module Remove glove box from instrument panel and disconnect passenger air bag inflator module connector 2...

Page 245: ...ial tool A 09932 75030 B 09932 78320 6 Short two deployment harness leads 1 together by fully seating one banana plug into the other NOTE If faulty of seat belt pretensioner connector 1 of adapter cab...

Page 246: ...odule Connect deployment harness A to passenger air bag infla tor module connector 2 till click can be heard For seat belt pretensioner Connect adapter cable B to deployment harness A and lock connect...

Page 247: ...hort two deployment harness leads together by fully seating one banana plug into the other 1 2 3 NOTE When air bag inflator module deploys or seat belt pre tensioner activates rapid gas expansion will...

Page 248: ...bag inflator module Air bag inflator module connector of adapter cable special tool are designed to be reused However they should be inspected for damage after deployment Replace it with new deployme...

Page 249: ...bag side air bag inflator module from front seat referring to Front Seat and Rear Seat in Section 9 For seat belt pretensioner Remove seat belt pretensioner from vehicle referring to Front Seat Belt w...

Page 250: ...h used to lubricate air bag infla tor module as it inflates and by products of chemical reaction As with many service procedures you should wear gloves and safety glasses When disposing of deployed ai...

Page 251: ...31 Air bag load tool Connector test adapter set See NOTE E Air bag deployment har ness Digital multimeter See NOTE A and WARNING 09932 75041 09932 78310 09932 78320 09931 76011 Passenger air bag infla...

Page 252: ...and substitutes for the Tech 2 kit 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter D These connector are spare...

Page 253: ...Prepared by Service Department 1st Ed November 2001 Printed in Hungary 252...

Page 254: ...Prepared by Service Department 1st Ed November 2001 Printed in Hungary 252...

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