Suzuki WagonR+ RB310 Service Manual Download Page 967

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7B1-2 AUTOMATIC TRANSAXLE (M13 ENGINE MODEL)

DTC P0713 Transmission Fluid

Temperature Sensor Circuit High ............. 7B1-58

DTC P0717 Input/Turbine Speed

Sensor Circuit Malfunction ........................ 7B1-60

DTC P0722 Output Speed Sensor

(VSS) Circuit No Signal............................. 7B1-62

DTC P0741/P0742 TCC Circuit

Performance or Stuck OFF/TCC Circuit

Stuck ON................................................... 7B1-65

DTC P0751/P0752/P0756/P0757

Shift Solenoid-A (No.1) Performance

or Stuck OFF/Shift Solenoid-A (No.1)

Stuck ON/Shift Solenoid-B (No.2)

Performance or Stuck OFF/Shift

Solenoid-B (No.2) Stuck ON..................... 7B1-66

DTC P0785 Timing Solenoid .................... 7B1-68

DTC P0962 Pressure Control

Solenoid Control Circuit Low..................... 7B1-70

DTC P0963 Pressure Control

Solenoid Control Circuit High.................... 7B1-72

DTC P0974/P0977 Shift Solenoid-A

(No.1) Control Circuit High/Shift

Solenoid-B (No.2) Control Circuit High ..... 7B1-74

DTC P1701 CAN Communication

Error .......................................................... 7B1-76

DTC P1702 Internal Control Module

Memory Check Sum Error ........................ 7B1-78

DTC P1703 CAN Invalid Data-TCM.......... 7B1-78

DTC P2769 Torque Converter Clutch

(TCC) Circuit Low ..................................... 7B1-79

DTC P2770 Torque Converter Clutch

(TCC) Circuit High..................................... 7B1-81

Scan Tool Data ......................................... 7B1-83

Inspection of TCM and Its Circuits ............ 7B1-87

On-Vehicle Service .....................................7B1-91

Maintenance Service ................................ 7B1-91

Fluid level check at normal

operating (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 Range Sensor

(Shift Switch)............................................. 7B1-97

Output Shaft Speed Sensor (VSS) ........... 7B1-98

Input Shaft Speed Sensor......................... 7B1-99

Throttle Position Sensor ........................... 7B1-99

Engine Coolant Temperature Sensor ..... 7B1-100

O/D Off Switch........................................ 7B1-100

Solenoid Valves (Shift Solenoid

Valves, TCC Solenoid Valve and

Timing Solenoid Valve)........................... 7B1-101

Pressure Control Solenoid Valve............ 7B1-106

Transmission Control Module

(TCM)...................................................... 7B1-109

A/T Relay................................................ 7B1-110

Transmission Fluid Temperature

Sensor .................................................... 7B1-111

Differential Side Oil Seal......................... 7B1-113

Automatic Transaxle Assembly .............. 7B1-115

Unit Repair ................................................ 7B1-118

Precautions............................................. 7B1-118

Part Inspection and Correction Table ..... 7B1-119

Unit Disassembly.................................... 7B1-120

Components ....................................... 7B1-120

Disassembly/Assembly of

Subassembly .......................................... 7B1-141

Oil pump assembly ............................. 7B1-142

Direct clutch assembly........................ 7B1-146

Forward and reverse clutch

assembly............................................. 7B1-151

2nd brake piston assembly ................. 7B1-159

Transaxle rear cover assembly

(O/D and 2nd coast brake piston)....... 7B1-161

Differential Assembly.............................. 7B1-164

Countershaft assembly ....................... 7B1-168

Valve body assembly.......................... 7B1-170

Torque converter housing................... 7B1-172

Transaxle case.................................... 7B1-175

Adjustment before unit assembly........ 7B1-177

Unit Assembly......................................... 7B1-180

Tightening Torque Specification............. 7B1-203
Special Tool .............................................. 7B1-204
Required Service Material........................ 7B1-206

Summary of Contents for WagonR+ RB310

Page 1: ...SERVICE MANUAL SUPPLEMENTARY SERVICE MANUAL WIRING DIAGRAM MANUAL SERVICE MANUAL SUPPLEMENTARY SERVICE MANUAL WIRING DIAGRAM MANUAL...

Page 2: ...within the range shown in the table are categorized as model E TSMMMA93S00210001 TSMMMA93S00280000 TSMMMB53S00210001 TSMMMA53S00210001 TSMMMA53S30210001 Model F The VIN within the range shown in the t...

Page 3: ...Part Number Manual Part Name RB413 Service Manual RB413 Supplementary Service Manual 4WD RB310 Service Manual RB310 413 Supplementary Service Manual RB310 413 413D Supplementary Service Manual E G F D...

Page 4: ...erse order of manual group number Applicable Manual Group NO 1 8 Model Category Language Service Manual Wiring Diagram Manual Model A 2000 2001 WagonR RB413 Model D 2002 1 WagonR RB310 RB413 Model E 2...

Page 5: ...nual MAGYAR SUZUKI CORPORATION reserves the right to make changes at any time without notice Please note that this manual contains references to equipment that may not be marketed in all countries For...

Page 6: ...Foreword...

Page 7: ...h lt sich das Recht zu Ver nderungen ohne Ank ndigung vor Wir bitten zu beachten da diese Anleitung auch Informationen zu Ausr stungen enth lt die eventuell nicht in allen L ndern zur Fahrzeugausstatt...

Page 8: ...Vorwort...

Page 9: ...ATION se r serve le droit de proc der sans pr avis et tout moment des changements Noter que ce manuel contient des r f rences des quipements qui ne sont pas n cessairement commerciali s s dans tous le...

Page 10: ...Avant propos...

Page 11: ...onder voorafgaande kennisgeving te allen tijde wijzigingen aan te bren gen Gelieve er rekening mee te houden dat dit handboek verwijzingen bevat naar uitrusting die mogelijk niet in alle landen op de...

Page 12: ...Voorwoord...

Page 13: ...iagram G10 M13A 8A 5 1 Power supply diagram DSL 8A 5 2 Fuses and the protected parts 8A 5 3 Main fuse box 8A 5 3 Individual circuit fuse box 8A 5 5 Supplementary fuse box DSL 8A 5 8 System circuit dia...

Page 14: ...3A 8A 6 54 E 1 Heater and air conditioner DSL 8A 6 55 F 1 Anti lock brake system 8A 6 56 F 2 Air bag control system 8A 6 58 F 3 Power steering 8A 6 60 G 1 Radio 8A 6 62 G 2 Cigarette lighter 8A 6 63 G...

Page 15: ...A 5 1 Stromversorgungsdiagramm G10 M13A 8A 5 1 Stromversorgungsdiagramm iDSL 8A 5 2 Sicherungen und gesch tzte teile 8A 5 3 Hauptsicherungskasten 8A 5 3 Einzelschaltkreissicherungskasten 8A 5 5 Zusatz...

Page 16: ...M13A 8A 6 54 E 1 Heizung und klimaanlage DSL 8A 6 55 F 1 Antiblockiersystem 8A 6 56 F 2 Airbag steuersystem 8A 6 58 F 3 Servolenkung 8A 6 60 G 1 Radio 8A 6 62 G 2 Zigarettenanz nder 8A 6 63 G 3 Uhr 8A...

Page 17: ...u circuit d alimentation 8A 5 1 Sch ma du circuit d alimentation G10 M13A 8A 5 1 Sch ma du circuit d alimentation DSL 8A 5 2 Fusibles et pi ces prot g es 8A 5 3 Bo te fusibles principale 8A 5 3 Bo te...

Page 18: ...0 M13A 8A 6 54 E 1 Chauffage et climatisation DSL 8A 6 55 F 1 Syst me d antiblocage des freins 8A 6 56 F 2 Syst me de commande des airbags 8A 6 58 F 3 Direction assist e 8A 6 60 G 1 Radio 8A 6 62 G 2...

Page 19: ...ma 8A 5 1 Voedingsschema G10 M13A 8A 5 1 Voedingsschema DSL 8A 5 2 Zekeringen en beschermde onderdelen 8A 5 3 Hoofdzekeringenkast 8A 5 3 Individuele circuitzekeringenkast 8A 5 5 Hulpzekeringenkast DSL...

Page 20: ...E 1 Verwarming en airconditioning DSL 8A 6 55 F 1 Antiblokkeersysteem 8A 6 56 F 2 Airbagregelsysteem 8A 6 58 F 3 Stuurbekrachtiging 8A 6 60 G 1 Radio 8A 6 62 G 2 Sigarettenaansteker 8A 6 63 G 3 Klok 8...

Page 21: ...arts computer relay etc roughly or drop them Do not expose electrical electronic parts to high temperature Approximately 80 C 176 F or higher or water For open back connectors be sure to insert the te...

Page 22: ...he Komponenten d rfen keinen hohen Temperaturen ber 80 oder Wasser ausgesetzt werden Im Falle von Steckverbindungen mit offener R ckseite mu bei der berpr fung die Pr fspitze unbedingt von der R cksei...

Page 23: ...e tomber Ne pas exposer les pi ces lectriques lectroniques des temp ratures excessives environ 80 C ou plus ou l eau Pour le contr le des connecteurs dos ouvert ins rer la pointe du testeur dans le do...

Page 24: ...derdelen computer relais enz niet met geweld en laat ze niet val len Stel elektrische elektronische onderdelen niet bloot aan hoge temperatuur ongeveer 80 C of hoger of water Bij stekkers met een open...

Page 25: ...ntafel Kabelbaum Faisceau de c bles du pan neau des instruments Instrumentenpaneelbedra dingsbundel J Side door wire Power window Seitent r Kabelbaum elektri sche Fensterheber C ble de porti re lat ra...

Page 26: ...tor type Steckertyp Type de connecteur Stekkertype A40 View Z Ansicht Z Vue Z Aanzicht Z View Z Ansicht Z Vue Z Aanzicht Z View Z Ansicht Z Vue Z Aanzicht Z 1 1 2 3 4 5 6 7 8 2 3 4 5 6 7 8 D18 5 D18 A...

Page 27: ...ne It is not an ordinary connector but a part of the continuous wire in the harness ZUR BEACHTUNG Der Verbindungsstecker J C bringt verschiedene Leitungsdr hte derselben Farbe an einer Stelle zusammen...

Page 28: ...S BLOCS RACCORD DE C BLAGE emplacement du connecteur Hoofdstuk 8A 3 STEKKERSCHEMA Plaats van stekker C Abschnitt 8A 7 Steckverbindungsli ste Stekkerform und Klemmenanord nung Section 8A 7 Liste des co...

Page 29: ...YEL GRN YEL BLU BLK WHT WHT BLK WHT GRN RED GRN WHT WHT BLU WHT BLU BLU WHT YEL WHT GRN WHT GRN WHT GRN WHT RED BLU RED RED YEL BLU RED Individual circuit fuse box Einzelschaltkreissicherungskasten Bo...

Page 30: ...sch ma source d alimentation lectrique vers le bas masse terre comme le ferait un coulement d eau In een elektrisch schema loopt de elektrische stroom vanaf de bovenkant van het schema stroombron naa...

Page 31: ...spiel Zwei Pfeile nach links weisend bedeutet Weiter zur vorvorigen Seite Auf der jeweiligen Bezugsseite finden Sie dann dasselbe Symbol mit den Pfeilen in der umgekehrten Richtung Der Schaltkreis wir...

Page 32: ...d Commutateur tiges Reed schakelaar R sistance Weerstand Variable resistance Variabler Widerstand Transistor Transistor R sistance variable Variabele weerstand Transistor Transistor Diode Diode Piezoe...

Page 33: ...ector Einspritzd se XX control module XX Steuermodul Injecteur Verstuiver Module de com mande XX XX regelapparaat Windshield wiper Windschutzscheiben wischer Windshield washer Windschutzscheiben Wasch...

Page 34: ...L Daytime running light Tagesfahrlicht falls vor handen Feux diurnes Daglichtlampen DSL Diesel engine Dieselmotor Moteur diesel Dieselmotor ECM Engine control module Motorsteuermodul Module de command...

Page 35: ...sist e Stuurbekrachtigingsdruk R Right Rechts Droite Rechts RHD Right hand drive vehicle Fahrzeug mit Rechtslen kung V hicule conduite gau che Voertuig met rechts stuur SDM Sensing and diagnostic modu...

Page 36: ...uin GRN Green Gr n Vert Groen GRY Gray Grau Gris Grijs LT BLU Light blue Hellblau Bleu clair Lichtblauw LT GRN Light green Hellgr n Vert clair Lichtgroen ORN Orange Orange Orange Oranje RED Red Rot Ro...

Page 37: ...kerschema Engine compartment Motorraum Compartiment moteur Motorruimte A Battery harness A Batterie KabelbFaum A Faisceau de c bles de la batterie A Accubedradingsbundel C Engine harness C Motor Kabel...

Page 38: ...ition de connexion Aansluitpositie Engine harness Motor Kabelbaum Faisceau de c bles du moteur Motorbedradingsbundel C01 N Main fuse Hauptsicherung Fusible principal Hoofdzekering C02 N Main fuse Haup...

Page 39: ...programme variable VVT soleno de C18 N M13A Oil pressure switch ldruckschalter Interrupteur de pression d huile Oliedrukschakelaar C19 GRY M13A Heated oxygen sensor 1 Reheizte lambdas onde 1 Capteur...

Page 40: ...bundel G Instrument panel harness G Instrumententafel Kabelbaum G Faisceau de c bles du panneau des instruments G Instrumentenpaneelbedradingsbundel RHD G10 M13A LHD G10 M13A B01 TO E02 G39 G41 TO E47...

Page 41: ...ce de parebrise Ruitenwissermotor G41 GRY Main harness To E47 Haupt Kabelbaum ZUM E47 Faisceau de c bles prin cipal AU E47 Hoofdbedradingsbundel naar E47 G42 N Main harness To E46 Haupt Kabelbaum ZUM...

Page 42: ...ntil Clapet de purge cartou che d EVAP Afzuigklep van EVAP koolstoffilter D06 BLK MAP sensor MAP sensor D tecteur MAP MAP sensor D08 BLK ECT sensor ECT sensor D tecteur ECT ECT sensor D10 BLK Injector...

Page 43: ...Brandstofdrukregelaar D31 EGR valve EGR ventil Soupape EGR EGR klep D32 Compressor Kompressor Compresseur Compressor D33 CMP sensor CMP sensor D tecteur CMP CMP sensor D34 Glow plug 1 Gl hkerze 1 Boug...

Page 44: ...38 E55 E57 E52 E54 E43 E60 E59 E42 E08 E02 TO B01 E47 TO G41 E53 E49 E58 E50 E48 E56 E25 E63 E62 2 E62 1 E51 E20 E04 E46 TO G42 E41 TO D01 E40 TO D02 E 8 7 9 10 11 E09 E02 TO B01 E03 E06 E05 E07 E04 E...

Page 45: ...am leveling actuator L Scheinwerferstrahlnivel lierstellglied L Commande de reglage du faisceau de phare G Actuator van koplamp hoogteverstelling L E35 BLK Headlight L Scheinwerf erlicht L Phare G Kop...

Page 46: ...leuchten relais Relais d antibroillard avant Voormistlichtrelais E58 BLK Noise suppressor St rfunkenunterdr cker Suppresseur de bruit Storingsonderdrukker E59 BLK IG COIL E60 GRY Igniter Z ndgeber Ign...

Page 47: ...les principal M13A E Hoofdbedradingsbundel M13A RHD E09 E03 E05 E06 E07 E01 E44 E27 E36 E32 E35 E34 E37 E38 E55 E57 E52 E54 E43 E42 E08 E47 TO G41 E53 E49 E50 E48 E56 E25 E51 E20 E04 E46 TO G42 E26 TO...

Page 48: ...sensor R Capteur de vitesse de la roue D Voorwieltoerentalsensor R E09 N Side turn signal light R Seitenblinkleuchte R Eclairage de clignotant D Richtingaanwijzer zijkant R E10 BLK LHD Windshield wipe...

Page 49: ...ett kabel baum ZUM G42 Faisceau de fils lectri ques de planche de bord AU G42 Instrumentenpaneelbe dradingsbundel naar G42 E47 GRY Instrument panel harness To G41 Armaturenbrett kabel baum ZUM G41 Fai...

Page 50: ...lglied R Commande de reglage du faisceau de phare D Actuator van koplamp hoogteverstelling R E07 N Front fog light R Vordere nebelleuchten R Feu de d antibroillard D Voormistlicht R E08 N Front wheel...

Page 51: ...ichtingaanwijzer zijkant L E52 BLK Fuel pump relay Kraftstoff pumpenrelais Relais de pompe car burant Brandstofpomprelais E53 BLK Radiator fan control relay 1 K hlergebl sesteuerre lais 1 Relais de co...

Page 52: ...n harness E Haupt Kabelbaum E Faisceau de c bles principal E Hoofdbedradingsbundel RHD G10 M13A LHD G10 M13A E21 E16 TO G56 E18 TO L23 E17 TO G57 E13 A T E12 A T E23 E22 E E61 G10 E78 M13A E79 M13A E1...

Page 53: ...BRN Instrument panel harness To G57 Armaturenbrett kabel baum ZUM G57 Faisceau de fils lectri ques de planche de bord AU G57 Instrumentenpaneelbe dradingsbundel naar G57 E18 BLK Floor harness To L23...

Page 54: ...32 G37 G33 G29 G30 G22 G65 G25 G34 G11 G18 G10 G13 G53 G04 G02 G01 1 G01 2 G05 TO J01 G63 G06 TO J02 G09 G12 G08 TO L31 G78 G G52 1 M13A G52 2 A T 14 15 12 13 16 17 G34 G11 G04 G02 G01 2 G53 G05 TO J0...

Page 55: ...de feux arri re Achterlichtrelais G02 N Door lock controller Steuereinheit f r t rver riegelung Commande de ver rouillage des portes Portierslotregeleenheid G04 BLK Turn signal relay Blinkerrelais Rel...

Page 56: ...parleur avant G Voorluidspreker L G36 N Heater resistor Heizungswiderstand Resistance de chauffage Verwarmingsweerstand G37 N Blower fan motor Gebl semotor Moteur de ventilateur soufflant Aanjagermoto...

Page 57: ...generator Beifahrer seite Gazog ne c t passager Opblaaseenheid passa giersairbag G74 GRY DSL IF EQPD Diode Diode Diode Diodo G78 ORN J C 2 G82 BLK DSL Acceleration pedal sen sor Fahrpedalsensor Capteu...

Page 58: ...3 O08 O05 O10 O11 K O R Rear defogger wire Rear wiper wire High mounted stop lamp wire R01 TO L13 21 24 22 K No Color Connective position Anschlussposition Position de connexion Aansluitpositie Roof w...

Page 59: ...v e Draad van hooggemon teerd remlicht O08 N Rearend door harness To O03 Heckt r Kabelbaum ZUM O03 Faisceau de c bles de hayon arri re AU O03 Kofferdekselbedradings bundel naar O03 O09 N High mounted...

Page 60: ...raad RHD LHD J01 TO G05 J02 TO G06 J10 TO G55 J09 TO G54 J15 TO L20 J11 J14 J13 J16 J08 J19 J03 J17 TO L15 J18 J07 J06 J05 J12 A B A B With power window Without power window J J J J J10 TO G55 J09 TO...

Page 61: ...Frontt raabel Beifahrer seite Fil de porti r avant C t conducteur Voorportierdraad passa giersszijde J09 N Instrument panel harness To G54 Armaturenbrett kabel baum ZUM G54 Faisceau de fils lectri que...

Page 62: ...7 L17 L25 TO K01 L13 TO R01 L21 L23 TO E18 L20 TO J15 L18 L19 L12 L06 L02 TO O02 L01 L10 L03 TO O01 L08 L16 L27 L30 TO K03 L32 L11 L28 L14 L22 A T L31 TO G08 19 18 20 L15 TO J17 L23 TO E18 L17 L14 L22...

Page 63: ...J17 Fil de porti re arri re AU J17 Achterportierdraad naar J17 L16 N Front door switch R Vorderer T rschalter R Commutateur de porte avant D Voorportierschakelaar R L17 N Parking brake switch Handbrem...

Page 64: ...baum G Faisceau de c bles du panneau des instruments G Instrumentenpaneelbedradingsbundel Q Pretensioner wire Q Gurtstrafferkabel Q Fil de pr tendeur Q Gordelvoorspannerdraad RHD LHD G66 G70 G71 G67 G...

Page 65: ...r side Seiten Airbag gasgene rator Beifahrerseite Gonfleur d airbag lat ral C t passager Zij airbagopblaaseen heid passagierszijde G70 YEL Side air bag inflator Driver side Seiten Airbag gasgene rator...

Page 66: ...8A 3 30 Memo Notizen Note Memo...

Page 67: ...th point G10 M13A Massepunkt G10 M13A Points de masse G10 M13A Massapunt G10 M13A 2 R LHD shown Right side shown FWD 21 22 24 23 20 8 7 9 11 10 15 14 13 12 Driver side 17 16 Passenger side 18 19 1 M13...

Page 68: ...round earth point DSL Massepunkt DSL Points de masse DSL Massapunt DSL 21 22 24 23 20 8 7 9 11 10 15 14 13 12 Driver side 17 16 Passenger side 18 19 R 1 26 25 27 LHD shown Right side shown FWD FWD 4 3...

Page 69: ...1 RED 1 E43 RHD LHD WHT BLU WHT BLU WHT BLU YEL 25A BLK RED WHT GRN 20A 15A WHT BLU 30A BLU BLK 15A YEL BLK YEL BLU RED GRN 10A BLK RED 10A 5 G24 WHT 4 2 1 3 10A BLU WHT 10A BLU BLU BLK YEL Starting m...

Page 70: ...15A WHT BLU 30A BLU BLK 15A YEL BLK YEL BLU RED GRN 10A BLK RED 10A 5 G24 WHT 4 2 1 3 10A BLU WHT 10A BLU BLU BLK YEL BLK BLK Starting motor A 1 4 5 6 A 1 WHT G57 E17 2 26 7 8 9 10 11 12 33 13 14 15 1...

Page 71: ...1 A 3 E53 A 5 E52 Relay A 5 E55 H relay B 7 E54 ISC relay ISC relais Relais d ISC ISC relais 20A G10 M13A DSL No Nr No Nr Fuse Sicherung Fusible Zekering Protected circuit Schutzschaltung Circuit prot...

Page 72: ...ontrol relay 1 DSL K hlergebl sesteuerre lais 1 DSL Relais de commande de ventilateur de radiateur 1 DSL Stuurrelais 1 van radia teurventilator DSL Radiator fan control relay 2 DSL K hlergebl sesteuer...

Page 73: ...ADIO Clock Uhr Horloge Klok Combination meter Kombination mterr Commodo Combinatiemeter DLC Interior light front Inneraumleuchte Vorde rer Plafonnier Avant Interieurverlichting voor Interior light Rea...

Page 74: ...rstofsen sor 1 Heated oxygen sensor 2 Reheizte lambdasonde 2 Capteur d oxyg ne chauff 2 Verwarmde zuurstofsen sor 2 IG COIL 1 IG COIL 2 Igniter Z ndgeber Igniteur Ontsteker Imb CM Noise suppressor St...

Page 75: ...essuie glace et du lave glace Wisser en sproeierscha kelaar 10A ABS ABS control module ABS steuermodul Module de commande de l ABS ABS regelapparaat 25A HEATER Blower fan motor Gebl semotor Moteur de...

Page 76: ...gsrelais Relais de chauffage du carburant Brandstofverwarmingsre lais 80A Glow controller Flammw chter R gulateur de pr chauf fage Voorgloeiregeleenheid 30A Option PTC heater relay 1 PTC Heizungsrelai...

Page 77: ...A 1 Syst ne de d marrage A 1 Startsysteem B LOCK ACC ON ST ACC IG1 IG2 ST OUT IN M T A T P R N D 2 L BLK BLK YEL BLK BLK YEL Transaxle range sensor BLK G57 E17 RHD LHD G57 E17 2 3 BLK RED BLK YEL 3 E...

Page 78: ...LK WHT WHT RED BLK WHT RED WHT RED 80A 15A CHARGE BLK WHT 3 BLK WHT Main fuse box 6 1 C07 Individual circuit fuse box 1 C08 13 G41 E47 2 5 15 G25 1 C02 26 IG COIL BATT 1 16 BLK RED 10A METER 34 E26 C0...

Page 79: ...froidissement G10 M13A A 3 Koelsysteem G10 M13A BLU YEL M BLK control relay 1 E53 4 3 E44 2 1 1 BLK RED Main relay 2 E56 3 4 2 1 Main fuse box 30A 2 E42 BLU BLK 20A BLK YEL BLK YEL FI RDTR A 5 BB B BL...

Page 80: ...3 2 Main fuse box 2 E42 30A FI RDTR 29 30A 5 10 1 2 3 1 4 3 1 3 1 M A 5 Lg ECM A 5 B ECM BLK E44 Control relay 3 Control relay 1 E69 E53 Control relay 2 BLK BLK LT GRN LT GRN LT GRN BLK YEL BLK YEL BL...

Page 81: ...10 15A IG COIL BLK WHT G41 E47 E59 E60 13 1 D23 1 2 1 3 2 4 BLK WHT BLK WHT YEL BLU BRN E58 4 2 3 1 BLK YEL BLK YEL E40 D02 2 BLK WHT BLK WHT RED BLU RED BLU RED BLU WHT BLK Noise suppressor Igniter D...

Page 82: ...M13A A 4 Ontstekingssysteem M13A 15A IG COIL BLK WHT BLK WHT RED BLU BLK WHT YEL BLU BLK YEL BLK YEL IG COIL 1 IG COIL 2 E41 C13 G41 E47 13 C28 1 C29 1 RED BLU 15 16 14 YEL BLU 3 3 2 2 BLK WHT YB RB...

Page 83: ...8A 6 7 Memo Notizen Note Memo...

Page 84: ...L RED YEL RED YEL RED 3 G07 L26 7 YEL RED E40 D02 13 G41 E47 13 2 22 12 15 E56 4 E63 1 2 2 1 3 FI Main fuse box L13 R01 4 E52 4 2 1 3 E21 21 7 11 D05 2 1 D10 1 2 E22 20 BLK WHT BLK RED BLK RED E18 L23...

Page 85: ...2 Heated oxygen sensor 1 15A DOME RADIO 14 16 G56 E16 WHT BLU WHT BLU Distributor 20 BLU 15 16 13 4 5 E41 D01 1 6 7 14 BLK WHT BLK WHT BLU RED BLU RED BLU BLU RED RED PTC heater relay PTC heater 25 12...

Page 86: ...BLK YEL BLK YEL BLK YEL BLK YEL WHT GRN 4 3 D15 Throttle position sensor 1 GRY GRY 3 D24 15 1 6 4 5 14 16 E55 GRN RED GRN RED GRN GRN YEL RED YEL RED BLK YEL WHT GRN 26 BLK RED IAC VSV IAT sensor 14 L...

Page 87: ...E22 PPL WHT 17 Tacho Check engine C 1 BY PW Compressor relay E 1 O Brake light switch D 7 ECM WB ImbCM A 7 WHT BLK 7 ECT sensor E23 YEL GRN C 1 YG 10 YEL BLU Igniter A 4 YB E22 GW GRN WHT C 3 Blower f...

Page 88: ...RED BRN BLK WHT BLK RED BLK RED EVAP canister purge valve 13 RED BLK C13 E41 10 C24 2 1 BLK RED RED BLK 2 7 5 L23 E18 E26 C03 Fuel level sensor C 1 15A IG COIL 16 20A 29 3 4 Relay BLK RED BLK BLK 4 R0...

Page 89: ...sor 1 3 2 Throttle position sensor 2 GRY E41 C13 7 1 E40 C14 WHT GRN WHT GRN GRY WHT GRN WHT GRN C25 C23 3 1 ECT sensor YEL GRN C30 EVAP thermistor 1 2 2 1 6 E41 C13 8 E46 G42 5 G50 GRN RED GRN RED YE...

Page 90: ...9 ECM E21 A 4 E23 32 YEL BLU YB IG COIL 1 31 RED BLU RB IG COIL 2 WG WHT GRN G41 E47 9 WHT GRN 32 4 A 3 Control relay 1 B BLU 2 Vehicle speed sensor YEL 19 C03 E26 9 YEL A 6 Y 9 TCM C04 YEL BRN 3 A B...

Page 91: ...tch RED YEL 10 RED YEL Tail light relay RY D 3 C 3 PPL WHT PW E21 16 33 1 30 E 1 G42 E46 1 PPL WHT Speed PPL G41 E47 10 P P S Cont M F 3 PPL 31 P PPL PPL PPL C 1 Check engine L23 E18 GW Brake light sw...

Page 92: ...K YEL BLU BLK 4 E47 G41 14 GRN 3 2 4 1 E75 Main relay BLK RED BLK RED BLK RED 80 4 6 5 E46 G42 5 BLU BLK BLK RED 3 LT GRN RED BRN WHT 87 10 S 2 A C pressure sensor GRN RED 37 1 5 15 1 5 EGR valve D31...

Page 93: ...15A DOME RADIO 9 WHT BLU G57 E17 6 BLU WHT BLK WHT 79 E17 G57 7 YEL GRN BLU ORN 4 Fuel temperature sensor Compressor 13 61 Compressor relay 4 2 1 3 2 4 1 5 Fuel heating relay 76 G88 Diesel engine cont...

Page 94: ...T 15 RED BLK WHT E71 D46 2 E72 D26 23 G88 70 74 GRN WHT Diesel engine control circuit 4 1 1 1 1 D34 D35 D36 D37 1 2 3 4 G42 E46 9 11 1 3 8 7 5 4 6 Individual circuit fuse box 30 GRN WHT BLK WHT BLRK W...

Page 95: ...F 1 P PPL E16 G56 12 PPL ABS Cont M 89 C 1 P PPL PPL Speed G88 GRN YEL GRY RED 52 77 C 3 GY GLOW C 3 GR Control relay 2 Control relay 3 CKP sensor CMP sensor 43 59 25 56 21 D45 D33 1 2 2 1 3 3 45 D26...

Page 96: ...E18 E31 7 9 8 5 3 6 2 G41 E47 6 YEL TURN BACK E12 9 GRN GRN RED 17 Back up light 4 RED D 8 R Transaxle range sensor TCM L22 4 O D switch A T shift lever BLK 19 OFF ON 20 BLU BLK BLU BLK E18 L23 3 1 RE...

Page 97: ...16 DLC G09 7 4 16 Timing solenoid GRN WHT RED WHT BLU Pressure control solenoid LT GRN RED BRN YEL BLU RED 3 8 G78 J C 2 WHT RED WHT RED E16 G56 14 WHT RED 12 16 15A DOME RADIO 9 WHT BLU G56 E16 16 1...

Page 98: ...BLK DLC G17 7 G41 E47 8 WHT BLK 9 5 6 7 5 G09 16 4 BLK PPL WHT 2 4 IG COIL E16 G56 20 E26 C03 5 BRN BRN BRN 15A GRN RED STOP 15A DOME RADIO CHECK ENGINE G25 23 15 ECM A 5 16 8 9 4 12 WB ImbCM BLK 16 B...

Page 99: ...ORN 6 G51 2 G40 E10 4 RHD LHD 6 7 4 BLU RED BLU BLU WHT YEL BLU BLU RED BLU BLU WHT YEL BLU 2 3 1 3 G56 E16 7 BLK ORN E38 1 G41 E47 15 BLU BLK BLU BLK 4 8 5 5 BLU WHT YEL BLU YEL BLU G16 2 9 1 8 BLU O...

Page 100: ...hterruitwisser en sproeier 15A ORN ORN ORN L03 O01 4 O11 1 2 3 1 19 20 G07 L26 G16 6 9 YEL BLU M G56 E16 7 E38 G41 E47 15 BLK ORN BLK ORN 3 7 4 G30 BLK BLK YEL BLU YEL BLU BLU BLK BLU BLK M YEL BLU WI...

Page 101: ...3 Achterruitverwarming BLK BLK 25A G32 3 BRN BLK YEL BLK YEL Relay G01 1 5 3 1 BLK RED 2 15A BLU YEL G07 L26 3 L03 O01 3 BLK O04 1 O12 1 5 6 Push Pull REAR DEFG HEATER BLK YEL BLK YEL 10 24 Blower fa...

Page 102: ...A UP ON OFF DOWN UP Main switch Front J08 G05 J01 1 WHT BLU GRN BLK RED BLU RED M UP GRN Sub switch UP OFF DOWN WHT BLU G54 J09 4 RED BLU 1 2 GRN BLK RED BLU RHD LHD 8 7 J05 2 1 4 1 J02 G06 4 BLK 5 6...

Page 103: ...8A 6 27 Memo Notizen Note Memo...

Page 104: ...1 BR G55 J10 WHT Lock OFF Un lock WHT BLK WHT BLK BLK main switch 6 J19 J08 J03 4 WHT RED 6 4 G05 J01 5 WHT BLK WHT BLK WHT RED 14 13 6 4 J02 G06 OFF Push Lock OFF Un lock RED WHT BLK 1 J11 RED YEL 3...

Page 105: ...BLU 2 J18 4 6 5 RED BLK RED BLK GRN 3 O06 3 4 GRN BLU GRN RED BLK BLU 3 10 2 1 RED BLK GRN RED BLK GRN Front Front 8 7 6 2 J03 3 1 BLU 3 2 M Unlock BLU RED BLK GRN BLU BLU RED BLK GRN BLU Lock dead l...

Page 106: ...Y BLU GRY BLU LT GRN RED LT GRN BLK J07 7 YEL BLK G06 J02 5 RHD LHD 3 J02 G06 6 2 1 J06 3 2 1 J13 3 2 1 G54 J09 3 2 4 6 1 2 5 ACC RH DOWN R L LH RH U P D O W N L E F T R I G H T 4 8 J02 G06 BLK BLK M1...

Page 107: ...B 7 Claxon Horn switch In driver inflator 15A BLU ORN BLK GRN WHT GRN WHT Horn relay Horn Main fuse box E54 2 4 GRN WHT E01 1 2 3 1 WHT BLK BLK E47 G41 2 HORN BLK WHT G65 8 BLK 7 G78 J C 2 31 8 12 16...

Page 108: ...32 PPL G41 E47 10 PPL C04 1 BRN 2 E26 C03 1 PPL ECM A 5 P BRN BRN WHT GRN YEL RED YEL RED YEL RED BRN Fuel level sensor G56 E16 20 E26 C03 5 E22 1 10 G07 L26 7 L13 R01 2 R02 1 2 1 BRN L23 E18 7 BRN G...

Page 109: ...gulator 10A METER 34 DOME RADIO 15A 9 ILL 14 BLK 16 J C 2 G78 16 BLK BLK Warning buzzer WHT BLU 32 RED YEL RED YEL 31 G30 J C 1 D 3 RY Tail light relay 2 1 1 BRN BRN BRN 7 YEL RED YEL RED BRN 2 7 5 L2...

Page 110: ...Compteur mixte T moin indicateur C 2 Combinatiemeter indicator GRN YEL BEAM TURN R TURN L 15A G25 22 20 E47 G41 1 WHT BLU Main fuse box 6 GRN RED H L L Turn signal switch In turn dimmer switch D 6 GR...

Page 111: ...8A 6 35 Memo Notizen Note Memo...

Page 112: ...YEL 24 GRY 9 A 6 TCM P S Cont M BY G G25 F 3 YEL BLK 11 7 YEL BLK OFF ON Oil pressure switch E41 D01 9 D20 1 A YEL BLK BLU C18 B 1 E40 C14 12 G41 E47 Oil pressure switch D43 6 G87 D27 YEL BLK DSL C E...

Page 113: ...1 Front door switch L 1 L16 OFF ON Front door switch R BLK ORN 1 Diode 3 2 L32 Parking brake switch OFF ON L17 1 YEL GRN G07 L26 4 YEL GRN 7 IF EQPD F 1 1 2 ABS Warning buzzer Brake fluid level switch...

Page 114: ...WHT RED 15A BEAM WHT BLU 15A BLK WHT BLU RED RED RED Headlight R Headlight L Main fuse box G25 20 E35 3 2 1 E05 3 2 1 E16 G56 2 3 E47 G41 1 10 G22 8 WHT BLU 4 BLK BLK 7 6 BLK RED BLU Pass LO HI 9 RED...

Page 115: ...8A 6 39 Memo Notizen Note Memo...

Page 116: ...WHT RED RED BEAM WHT BLU BLK WHT BLU RED RED Pass LO HI Dimmer passing switch Headlight R Headlight L Main fuse box G25 20 E35 3 2 1 E05 3 2 1 E16 G56 2 3 E47 G41 1 10 G22 8 WHT BLU 4 9 BLK BLK 7 BLK...

Page 117: ...controller Main fuse box 1 7 4 5 WHT RED G61 9 RED WHT HEATER 8 1 2 24 17 1 G62 RED BLU 3 Tail light relay 3 G01 2 5 1 GRN RED RED GRN RED GRN RED GRN BLU YEL 4 G61 10A TAIL 33 RED YEL RY 3 Tail lamp...

Page 118: ...Front position light R BLK BLK License plate light L License plate light R Rear combination light R Rear combination light L 2 G56 E16 L10 1 L11 1 2 2 L01 3 L12 3 5 5 RED YEL RED YEL RED YEL E18 L23 1...

Page 119: ...8A 6 43 Memo Notizen Note Memo...

Page 120: ...1 16 12 1 BLK 2 BLK RED WHT RED WHT RED WHT BLK BLK BLK BLK BLK BLK RED YEL RED YEL RED YEL RED WHT 2 6 5 2 5 2 1 2 5 YEL 4 5 10A TAIL GRN RED RED YEL 33 10A TURN BACK 17 RED GRN RED YEL G30 8 BLK 2...

Page 121: ...BLK G56 E16 10 RED YEL 2 5 E18 L23 10 RED YEL RED YEL A 5 D 9 RED YEL GRN RED Switch BLK A T shift ILL L22 2 5 BLK BLK G08 L31 5 RED WHT RED WHT 19 20 BLK RED YEL RED YEL RY Clock G 3 BLK BLK RED YEL...

Page 122: ...witch OFF ON BLK ORN Rear door switch L Rear door switch R OFF ON OFF ON OFF ON BLK RED BLK RED Interior light Rear Interior light Front Diode 3 K01 L25 1 L25 K01 2 L30 K03 1 K02 2 BRN WHT 1 K06 K07 1...

Page 123: ...BLK Interior light Rear Interior light Front Diode 3 1 K01 L25 L25 K01 2 L30 K03 1 K02 2 BRN WHT BRN WHT BRN WHT BRN WHT 1 K06 K07 1 3 K03 L30 5 1 L32 2 Diode 5 1 L27 2 1 L21 8 G07 L26 WHT BLU 12 G07...

Page 124: ...ares D 5 Koplamphoogteverstellingssysteem Actuator R Switch 10A Actuator L YEL GRN BLK GRN BLK BLK GRN BLK BLK BLK E06 E34 2 2 E47 G41 3 G41 E47 6 YEL YEL YEL 3 2 6 YEL G11 7 TURN BACK P3 R4 P2 R3 P1...

Page 125: ...23 1 L01 5 2 E03 1 2 E09 1 13 E18 L23 1 L12 5 HAZARD 10A TURN BACK Turn L Turn R 12 17 C 2 8 Side turn signal light R GR GY Rear turn signal light L Rear turn signal light R 5 G56 E16 6 GRN YEL GRN RE...

Page 126: ...ight G15 1 3 G07 L26 6 L01 6 5 L12 6 5 L03 O01 2 O03 O09 1 2 L23 E18 16 O03 O08 1 O08 O03 2 BLK BLK STOP Brake light L BLK High mounted stop light door mounted High mounted stop light spoiler built in...

Page 127: ...8 Achteruitrijlicht E27 2 1 E18 L23 4 OFF ON 10A RED BLK RED YEL YEL Back up light switch Back up light In rear combination light G41 E47 6 L12 L01 2 5 P R N D 2 L RED Transaxle range sensor E31 7 1...

Page 128: ...T GRN RED BLK RED WHT LT GRN 15A Main fuse box FOG 30 16 12 G12 2 4 3 5 Switch R E07 2 1 D 3 Tail light relay L 2 1 E32 7 BLK Relay 2 4 E57 1 3 LT GRN LT GRN BLK BLK RED YEL RY D 10 RW Controller PW P...

Page 129: ...witch RED BLU D 1 RB Dimmer passing switch Switch G13 2 4 1 3 5 Controller 5 6 2 G53 8 7 14 18 BLK BRN YEL BRN YEL BLK 4 L01 L12 5 A B 4 WHT RW RED WHT BRN YEL BRN 10A REAR FOG 7 WHT 1 1 D 3 Tail ligh...

Page 130: ...RN RED LR ECM A 5 PB G78 J C 2 Switch BLK WHT 1 3 2 5 1 OFF 2 3 4 Blower fan switch 7 10 9 8 PNK 16 12 BLK 2 BLU WHT BLU WHT 3 BLU YEL 1 5 M BLU YEL BLU YEL G42 E46 BLU YEL E62 2 PNK RHD G10 LHD G10 A...

Page 131: ...r B7 B6 B3 B4 B2 B3 B4 B5 B6 B7 B8 B10 B11 B12 B13 B14 B15 B16 B1 B9 Supplementary fuse box 30A 40 30A 41 30A 42 PTC heater relay 3 BLU YEL BLU YEL Diode BLK GRN ORN GRN ORN HEATER 25A 24 Blower fan m...

Page 132: ...6 14 WHT BLU DOME RADIO 4 ABS BLK BLK BLK 9 19 ABS Cont M 16 12 WHT BLK 14 1 1 E42 Main fuse box 60A ABS WHT BLK WHT BLK 6 E20 GRN WHT 3 Brake light switch GW D 7 17 ABS EBD circuit 7 G56 E16 1 G25 15...

Page 133: ...5 5 6 11 12 Front wheel speed sensor L Front wheel speed sensor R Rear wheel speed sensor L Rear wheel speed sensor R RED L23 E18 GRN BLK RED ABS Cont M 22 21 1 2 1 2 2 1 2 1 E20 PPL WHT 20 Diagnosis...

Page 134: ...s F 2 Airbagregelsysteem 1 2 BLU RED YEL RED Contact coil G65 G66 32 GRN RED 1 27 GRN 2 26 G67 WHT 34 1 24 23 G73 YEL 2 1 G72 LT GRN 1 35 BRN 2 36 BLK 15A A B Q08 28 DLC 7 G09 4 WHT RED 15A 16 WHT BLU...

Page 135: ...nection detection pin G25 15 20 21 19 18 1 2 WHT RED WHT GRN G70 1 2 17 6 1 2 1 2 16 5 G66 G66 31 30 13 GRN YEL 23 sensor sensor A B BLK RED 10A METER 34 AIR BAG A B SDM IF EQPD Individual circuit fus...

Page 136: ...RADIO 5 EPS 9 G25 15 GRY P S 4 15A IG COIL 16 9 A B E17 G57 BLK RED A B P S Cont M RHD LHD M13A G10 A B C D BLK RED 10A METER 34 WHT BLU G78 2 13 BLK 12 16 BLK WHT RED DLC G09 7 J C 2 WHT RED BLK BLK...

Page 137: ...ch M 9V Torque sensor Main 3 3V Sub GND C1 C2 C3 C4 C5 C1 C2 C5 C4 C3 B1B2 B3 B4 B2 B1 B3 A B4 B B4 B3 A B BRN YEL E16 G56 BRN YEL C A 5 ECM BY G14 D D C BRN YEL BRN Noise suppressor A 4 Br 6 19 G14 6...

Page 138: ...2 K04 1 2 K05 G07 L26 L30 K03 1 2 BLK WHT BLK RED 5 4 6 BLK 1 2 2 7 1 1 3 8 6 ACC Front L Front R Rear L Rear R LT GRN LT GRN BLK GRY RED GRY BLU LT GRN LT GRN BLK GRY RED GRY BLU LT GRN LT GRN BLK G...

Page 139: ...aansteker OFF ON 15A Cigarette lighter G49 1 G48 1 J C 1 BLK BLK G30 15A CIGAR ACC Ashtray ILL YEL BLK G47 2 1 14 13 BLU BLK 16 12 G07 L26 15 L06 2 1 BLK Accessory socket YEL BLK 19 20 RED YEL RED YEL...

Page 140: ...ck G 3 Uhr G 3 Horloge G 3 Klok 15A 15A J C 1 RED YEL YEL BLK RED YEL WHT BLU Clock G29 3 G30 1 4 2 DOME RADIO ACC BLK 9 14 D 3 RY Tail light relay G30 J C 1 12 16 BLK Without DRL Individual circuit f...

Page 141: ...G10 DSL M13A A T M T C05 C05 C06 C06 C07 C07 G10 M13A DSL G10 M13A DSL G10 DSL M13A C08 C09 C10 C11 C12 C13 TO E41 C14 TO E40 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 1 1 5 4 6 2 1 3 5 4 6 2 1 3 8 7 9...

Page 142: ...8 D29 D30 D31 D32 1 2 3 4 13 14 15 16 5 6 7 8 9 10 11 12 4 3 2 1 16 15 14 13 8 7 6 5 12 11 10 9 2 1 1 2 3 1 2 3 1 2 1 2 3 4 1 2 1 2 1 1 2 3 4 1 2 3 4 2 1 3 1 2 3 4 1 2 31 34 35 36 37 38 39 40 41 32 33...

Page 143: ...1 E02 TO B01 E02 TO B01 E03 E04 E05 RHD LHD E06 E07 E08 E09 E10 LHD E12 E13 E16 TO G56 A T A T 1 2 1 2 1 2 3 4 1 2 1 2 1 2 3 1 2 2 3 1 2 2 1 1 2 1 2 3 4 18 19 21 20 22 23 24 7 8 10 9 11 12 13 14 15 25...

Page 144: ...9 13 14 15 16 1 10 11 12 17 18 19 20 21 22 23 24 31 32 33 34 28 29 30 2 3 4 5 25 26 27 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 20 23 24 25 26 28 29 30 33 31 32 34 8 11 12 13 1...

Page 145: ...E75 E76 E77 E78 E79 3 1 4 2 2 1 1 2 3 4 1 2 3 4 5 6 5 6 4 2 3 1 11 10 8 9 7 1 2 3 4 13 14 15 16 5 6 7 8 9 10 11 12 1 2 1 1 2 1 2 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3 1 1 2 1 2 3 4 3...

Page 146: ...6 17 18 19 20 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 4 5 6 7 8 1 2 3 4 3 1 5 2 4 3 1 5 2 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 7 8 9 5 6 9 8 7 6 5 4 3 2...

Page 147: ...7 2 1 1 1 1 2 1 2 3 4 5 6 7 8 9 3 4 5 2 1 3 4 5 2 1 1 2 3 5 4 3 1 9 7 2 5 6 8 4 1 2 3 4 6 5 6 5 4 3 2 1 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 10 1 2 3 4 7 3 2 1 6 5 4 1 2 1 2 1 7 5 6 4 3 8 9 1 1 1 2...

Page 148: ...69 89 92 93 94 90 91 2 1 4 3 6 5 7 29 51 73 3 4 2 1 5 3 4 2 1 5 1 2 3 1 2 3 4 5 6 7 8 11 12 13 14 15 16 9 10 17 18 19 20 1 2 1 2 3 4 3 4 2 1 5 J01 TO G05 J02 TO G06 J03 J05 J06 J07 J08 IF EQPD J09 TO...

Page 149: ...A T L23 TO E18 L25 TO K01 L26 TO G07 L27 L28 L30 TO K03 L31 TO G08 L32 3 2 1 6 4 5 3 2 1 1 2 3 4 6 5 2 1 1 1 2 1 2 3 2 1 6 4 5 2 1 4 3 1 2 1 2 3 1 1 1 2 1 1 2 3 1 3 2 1 6 4 5 4 3 2 1 10 9 8 7 6 5 14...

Page 150: ...8A 7 10 O Q R O01 TO L03 O02 TO L02 O03 TO O08 O04 O05 TO O10 O06 O08 TO O03 O09 O10 TO O05 O11 O12 3 2 1 6 4 5 1 2 3 2 1 1 1 2 3 1 2 3 4 1 2 1 2 1 2 3 3 2 1 1 Q08 1 2 R01 TO L13 R02 1 2 3 4 2 1 3 4...

Page 151: ...Clutch pedal position switch Kupplungspedal Positions schalter Contacteur de position de p dale d embrayage Koppelingspedaalstandscha kelaar Clutch switch Kupplungsschalter Contacteur d embrayage Kop...

Page 152: ...r Illumination controller Beleuchtungsregler R gulateur d clairage Verlichtingsregeleenheid Input sensor Eingabesensor Capteur d entree Ingangssensor Interior dome light Innenbeleuchtung Dachhim melle...

Page 153: ...Opblaaseenheid van zij airbag Slide switch Schiebeschalter Contacteur de toit ouvrant Schuifschakelaar Sliding roof Schiebedach Toit ouvrant Schuifdak Solenoid valve Magnetventil Electrovanne Soleno d...

Page 154: ...8A 8 4 Memo Notizen Note Memo...

Page 155: ...Prepared by 1st Ed January 2004 146F...

Page 156: ...on the latest prod uct information available at the time of publication approval And used as the main subject of descrip tion is the vehicle of standard specifications among others Therefore note that...

Page 157: ...basieren auf den neuesten Daten wie sie zum Zeitpunkt der Drucklegung zur Verf gung standen Die Angaben beziehen sich gr tenteils auf Fahrzeuge mit Standardspezifikationen Sie weichen daher zuweilen v...

Page 158: ...for mations produit les plus r centes la mise sous presse Les descriptions principales concernent les v hicules aux sp cifications standards Veuillez donc noter que les illustrations peuvent pr senter...

Page 159: ...ductinformatie beschikbaar ten tijde van de goedkeuring voor deze uitgave In de beschrijvingen wordt het voertuigmodel met de standaard specificaties gebruikt Daarom kunnen sommige afbeeldingen afwijk...

Page 160: ...Connector Layout Diagram SECTION 8A 3 8A 1 8 Indication of Connectors and How to Read them 8A 1 9 How to Read Installation Positions of Single Unit Parts SECTION 8A 4 8A 1 11 How to Read Ground Point...

Page 161: ...is shown The circuit diagram is designed so as to show the electric flow from the top to the bottom in it Shapes of connectors used in this vehicle and arrangements of their pins are shown Positions w...

Page 162: ...he other switches have been turned OFF Otherwise the semi conductor part may be damaged When disconnecting cables from the battery be sure to dis connect the one from the negative terminal first and t...

Page 163: ...rt To avoid damage to the harness protect its part which may contact against a part forming a sharp angle by winding tape or the like around it When replacing a fuse make sure to use a fuse of the spe...

Page 164: ...G This vehicle is equipped with Supplemental Inflatable Restraint Air Bag System Service on or around Air Bag System Components or Wiring must be performed only by an autho rized Suzuki dealer Please...

Page 165: ...use Slow blow fuse Circuit breaker Coil Solenoid Heater Bulb Cigarette lighter Motor Pump Horn Speaker Buzzer Chime Condenser Thermistor Reed switch Resistance Variable resistance Transistor Photo tra...

Page 166: ...ission control module Vacuum switching valve Weld splice Full term 2WD 4WD A C A T ACC CKP CMP DLC DRL ECT EGR HI IAC IAT IG ILL Listed below are the abbreviations as used in this manual and their ful...

Page 167: ...UND POINT section This indicates the connector code The connector code in the parentheses has the same meaning as the above intermediate connec tor and at the same time it indicates that there is a ha...

Page 168: ...the equipment is shown by the shape of the connector on the harness side The connectors described in this manual are always harness side connectors which are viewed from the direction as shown at the...

Page 169: ...YSTEM CIRCUIT DIAGRAM section to consult the connector code and pin No of the questioned connector Then refer to LIST OF CONNECTORS section as shown at the right in the figure below and look for the d...

Page 170: ...PRINCIPAL HOOFDRELAIS A T RELAY E55 AUTOMATIKGERTRIEBE RELAIS RELAYS D VITESSES AUTOMATICUE A T RELAYS MAIN FUSE C01 C02 E42 E43 E49 E50 HAUPTSICHERUNG FUSIBLE PRINCIPAL HOOFDZEKERING ABS CONTROL MODU...

Page 171: ...d to some part of the vehicle To locate the ground point installation position refer to GROUND POINT section 8A 1 12 HOW TO USE THIS MANUAL How to locate ground point Look in GROUND POINT section for...

Page 172: ...of each fuse is indicated Since every SYSTEM CIRCUIT DIAGRAM is drawn from the circuit down the fuse cross refer to POWER SUPPLY DIAGRAM for the continuity of the upper circuit referring to Fuse No su...

Page 173: ...5 2 6 1 2 3 15A This indicates the ground No Refer to GROUND POINT section for the location GROUND POINT This indicates the variations by the specifications This indicates the wire color Refer to item...

Page 174: ...re used for better legibility For more information refer to item SYMBOLS AND MARKS in HOW TO USE THIS SECTION Symbol mark This indicates the reference code to CONNECTOR LAY OUT DIAGRAM or LIST OF CONN...

Page 175: ...s and some connectors in the list may discrepant to the actual ones depending on the specifications How to Use List of Connectors It is easily possible to find the shape of the connector in question a...

Page 176: ...r Layout Diagramm zu Lesen ist ABSCHNITT 8A 3 8A 1 24 Anschlu markierungen und Identifizierung 8A 1 25 Erkl rung der Einbaupositionen von Einzeleinheit s teilen ABSCHNITT 8A 4 8A 1 27 Erkl rung eines...

Page 177: ...abelb umen unter Verwendung von Symbolen in den Abbildungen dargestellt Der Plan zeigt den Stromflu vom positiven Batteriepol bis zur Hauptsicherung und weiter zu jeder einzelnen Sicherung im Sicherun...

Page 178: ...ung auszuschalten und alle sonstigen Schalter auf OFF zu stellen da andernfalls der Halbleiter besch digt werden kann Vor dem Trennen der Batteriekabel stets darauf achten zuerst das Kabel am Minuspol...

Page 179: ...ung des Kabels zu vermeiden sind hervorstehende Kabelabschnitte die eventuell andere Teile ber hren durch Umwickeln mit Klebeband zu sch tzen BeimAustauschen von Sicherungen stets darauf achten eine n...

Page 180: ...zlichen Airbag R ckhaltesystem ausger stet Wartungen an den und rund um die Komponenten des Airbagsystems oder an der Verdrahtung d rfen nur von einem autorisierten SUZUKI Vertragsh ndler ausgef hrt w...

Page 181: ...rstand Transistor Fototransistor Diode Referenzdiode Z Diode LED Fotodiode Piezoelektrisches Bauelement Kabelstrang Relais Schalter Stecker O Typ Terminal 8A 1 22 VERWENDUNG DIESER ANLEITUNG SYMBOLE U...

Page 182: ...t Allradantrieb Klimaanlage Automatikgetriebe Zubeh r Kurbelwellenposition Nockenwellenposition Datenverbindungsstecker Tagesfahrlicht falls vorhanden Motork hlmitteltemperatur Abgasr ckf hrung Hoch E...

Page 183: ...UNKT Zeigt den Steckercode an Der in Klammern aufgef hrte Steckercode weist die gleiche Bedeutung wie der obige Zwischenstecker auf und zeigt gleichzeitig an da ein Kabelbaum zwischen den Seiten oder...

Page 184: ...lemmen als auch als Buchsenklemmen dargestellt wobei jedoch der direkt an das Ger t anzuschlie ende Stecker durch die kabelbaumseitige Steckerform dargestellt ist Bei den in dieser Anleitung beschrieb...

Page 185: ...ckercode und die Stift Nr des fraglichen Steckers zu entnehmen Danach sehen Sie in dem in der unteren Abbildung rechts dargestellten Abschnitt LISTE DER STECKER nach um den gew nschten Steckercode auf...

Page 186: ...Y E57 NEBELLEUCHTEN RELAIS RELAIS D ANTIBROILLARD VOORMISTLAMP RELAIS MAIN RELAY E56 HAUPT RELAIS RELAIS PRINCIPAL HOOFDRELAIS A T RELAY E55 AUTOMATIKGERTRIEBE RELAIS RELAYS D VITESSES AUTOMATICUE A T...

Page 187: ...it einem derartigen schwarzen Kreis an einem Teil des Fahrzeugs geerdet ist Um den Massenpunkt Einbauposition festzustellen siehe Abschnitt MASSEPUNKT Auffinden des Massepunkts Im Abschnitt MASSEPUNKT...

Page 188: ...im Sicherungskasten und zeigt wo jede Sicherung angeschlossen ist alle Namen der Systemschaltungen Au erdem wird die elektrische Last jeder Sicherung angezeigt Da jedes SYSTEMSCHALTDIAGRAMM f r den Sc...

Page 189: ...R REED FUSE BOX 15A 15A 20A MAIN RELAY M M 1 5 2 6 1 2 1 2 Zeigt die Massepunkt Nr an F r den Einbauort siehe den Abschnitt MASSEPUNKT MASSEPUNKT STEUEREINHEIT 1 4 DOOR 2 2 DOOR Dieser Code kennzeichn...

Page 190: ...rbe Zeigt die Stift Nr an F r die Stiftposition in dem Stecker siehe LISTE DER STECKER Stift Nr Zeigt an da der Zwischenstecker identisch ist Gleiche Markierung Diese Markierung kennzeichnet eine je n...

Page 191: ...undlegenden Konfiguration der Stecker erstellt wurde so da manche Stecker in der Liste in Abh ngigkeit von den Spezifikationen davon abweichen k nnen Verwendung der Liste der Stecker Durch Auffinden d...

Page 192: ...s blocs raccord de c blage SECTION 8A 3 8A 1 40 Indication et l gende des connecteurs 8A 1 41 L gende des Positions D installation des Pi ces Individuelles SECTION 8A 4 8A 1 43 L gende des Points Mass...

Page 193: ...rt aux faisceaux de fils lectriques en se servant de symboles dans les illustrations Indique le passage du courant lectrique de la borne positive de la batterie au fusible principal et chaque fusible...

Page 194: ...tacteur d allumage et tous les autres interrupteurs ont t mis surArr t sinon les semi conducteurs risquent d tre endommag s Toujours d brancher en premier le c ble reli la borne n gative de la batteri...

Page 195: ...pi ce Pour viter que le faisceau lectrique ne s ab me prot ger les parties touchant un angle aigu avec du ruban isolant ou autre Toujours remplacer un fusible par un fusible de m me capacit L utilisat...

Page 196: ...utifs du syst me sac gonflable ou du c blage doivent tre ex cut s par un concessionnaire Suzuki autoris Veuillez vous conformer toutes les mises en garde d crites dans la rubrique intitul e Section en...

Page 197: ...ateur tiges R sistance R sistance variable Transistor Phototransistor Diode Diode de r f rence Zener Diode luminescente Photodiode El ment pi zo lectrique Faisceau Relais Interrupteur Connecteur Borne...

Page 198: ...atisation Bo te vitesses automatique Accessoire Position du vilebrequin Position de I arbre cames Connecteur de transmission de donn es Feux diurnes si quip Temp rature de r frig rant du moteur Recyca...

Page 199: ...ls lectriques se r f rer au tableau ci dessous Symbole de faisceau de fils lectriques et appellation correspondante de faisceau de fils lectriques Ceci indique le code de bloc raccord de c blage Le co...

Page 200: ...RD DE C BLAGE pour conna tre la position des broches en r f rence ce code D18 5 Borne m le Borne femelle 4 4 3 3 2 2 1 1 8 8 7 7 6 6 5 5 2 Il existe trois types de connecteurs d apr s la fa on dont il...

Page 201: ...t le num ro de broche du bloc raccord de c blage en question Ensuite se r f rer la liste intitul e LISTE DES BLOCS RACCORD DE C BLAGE comme repr sent e droite de la figure ci dessous puis chercher le...

Page 202: ...RELAIS D ANTIBROILLARD VOORMISTLAMP RELAIS MAIN RELAY E56 HAUPT RELAIS RELAIS PRINCIPAL HOOFDRELAIS A T RELAY E55 AUTOMATIKGERTRIEBE RELAIS RELAYS D VITESSES AUTOMATICUE A T RELAYS MAIN FUSE C01 C02...

Page 203: ...marqu par un cercle noir est mis quelque part la masse sur le v hicule Pour localiser le point de mise la masse position d installation se r f rer la section intitul e POINT DE MASSE Section POINT MA...

Page 204: ...la charge lectrique de chaque fusible est indiqu e tant donn que chaque SCH MA DE CIRCUIT DE SYST ME est trac partir du circuit plac sous le fusible proc der une r f rence crois e avec le SCH MA DU CI...

Page 205: ...4 3 E08 2 1 B R O G R Br E52 1 2 E52 Br Br A 1 SENSOR COMBINATION METER REED FUSE BOX MAIN RELAY M M 1 5 2 6 1 2 1 2 FUSE BO 3 15A 6 15A 1 20A Ceci indique les variations suivant les sp cifications In...

Page 206: ...OMMENT UTILISER CETTE SECTION Symbole rep re Indique la couleur du c ble Code de couleur Ceci indique que le bloc raccord de c blage interm diaire est identique Marques identiques Ceci indique le num...

Page 207: ...blocs raccord de c blage mentionn s dans la liste risquent de pr senter une certaine diff rence par rapport aux blocs raccord de c blage r els suivant les sp cifications Comment se servir de la Liste...

Page 208: ...worden DEEL 8A 3 8A 1 56 Hoe stekkers worden aangegeven en hoe deze gelezen moeten worden 8A 1 57 Hoe installatieposities van eenheidsonderdelen gelezen moeten worden DEEL 8A 4 8A 1 59 Hoe de aarding...

Page 209: ...dingsbundel door middel van symbolen in de afbeelding Elektrische stroom van de positieve pool van de accu naar de hoofdzekering en afzonderlijke zekeringen in de zekeringbox en de namen van de hoofds...

Page 210: ...ntact en alle andere schakelaars UIT staan Is dat niet het geval dan kunnen half geleider onderdelen beschadigd raken Wanneer u de kabels loskoppelt van de accu moet u er op letten dat u de negative k...

Page 211: ...bedradingsbundel te voorkomen dient u delen daarvan die tegen scherpe hoeken liggen te beschermen door er isolatieband of iets dergelijks omheen te wikkelen Wanneer u een zekering vervangt moet u een...

Page 212: ...ken NEE NEE WAARSCHUWING Dit voertung is uitgerust met een Supplemental Inflatable Restraint Air Bag System Onderhoud aan of bij onderdelen of beadrading van het Airbag systeem mag alleen worden uitge...

Page 213: ...Transistor Foto transistor Diode Referentie zener diode Licht emitterend Foto diode Pi zo elektrisch element Bedradingsbundel Relais Schakelaar Aansluitingen O type aansluiting 8A 1 54 GEBRUIK VAN DE...

Page 214: ...cessoire Krukaspositie Nokkenaspositie Data verbindingsaansluiting Dagverlichting indien aanwezig Motorkoelvloe stoftemperatuur Uitlaatgas hercirculatie Hoog Stationair luchtregeling Inlaatluchttemper...

Page 215: ...kercode aan De stekkercode tussen haakjes heeft dezelfde betekenis als de tussenstekker erboven en tegelijkertijd geeft dit aan dat er continu teit is wat betreft de bedradingsbundel tussen de bladzij...

Page 216: ...l een stekker die direct op de appartuur moet worden aangesloten alleen wordt afgebeeld met de vorm van de stekken die aan de bedradingsbundel zit De stekkers en aansluitingen die in deze handleiding...

Page 217: ...s de LIJST VANAANSLUITINGEN zoals u hieronder aan de rechterkant van de afbeelding kunt zien en zoek de gewenste stekkercode op waaronder de vorm van die stekker staat afgebeeld Dit is een makkelijke...

Page 218: ...LEUCHTEN RELAIS RELAIS D ANTIBROILLARD VOORMISTLAMP RELAIS MAIN RELAY E56 HAUPT RELAIS RELAIS PRINCIPAL HOOFDRELAIS A T RELAY E55 AUTOMATIKGERTRIEBE RELAIS RELAYS D VITESSES AUTOMATICUE A T RELAYS MAI...

Page 219: ...ingsbundel met een dergelijk zwart cirkeltje ergens aan een onderdeel van het voertuig geaard is Om het aardingspunt terug te vinden installatiepositie dient u de sectie AARDEPUNT te raadplegen Terugv...

Page 220: ...astingswaarde van elke zekering aangegeven Aangezien elk SYSTEEMCIRCUIT DIAGRAM getekend is voor de schakeling vanaf de zekering dient u het SPANNINGSTOEVOERDIAGRAM hiermee te vergelijken aan de hand...

Page 221: ...ode nummer van het aardingspunt en zekeringsnummer zijn de referentiecodes voor de vergelijking BEDIENINGSEENHEID 1 4 DOOR 2 2 DOOR Dit geeft aan dat de stekker idenitiek is Stekkerteken Dit geeft de...

Page 222: ...teren Raadpleeg het onderdeel SYMBOLEN EN TEKENS onder GEBRUIK VAN DEZE HANDLEIDING voor meer informatie Symboolteken Dit geeft de kleur van de draad aan Draadkleur Dit geeft aan dat de tussen stekker...

Page 223: ...an de stekkers te symboliseren en dat sommige stekkers uit de lijst kunnen afwijken van de daadwerkelijk aangetroffen stekkers afhankelijk van de specificaties Hoe u de LIJST VAN AANSLUITINGEN dient t...

Page 224: ...T ARRI RE 8A 3 26 PORTE 8A 3 28 PLANCHER 8A 3 30 MOTORBAK 8A 3 2 INSTRUMENTENPANEEL 8A 3 16 INSTRUMENTENPANEEL VLOER TIPO 1 TIPO 2 TIPO 3 8A 3 22 DAK ACHTERKANT 8A 3 26 PORTIER 8A 3 28 VLOER 8A 3 30 8...

Page 225: ...e le num ro de connecteur correspondant OPMERKING Het stekkernummer tussen haakjes geeft het nummer van de bijbehorende stekker aan ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK A BATTERY CABLE C...

Page 226: ...PRINCIPAL HOOFDZEKERING MAIN FUSE HAUPTSICHERUNG FUSIBLE PRINCIPAL HOOFDZEKERING MAIN HARNESS E26 HAUPTKABELBAUM E26 FAISCEAU PRINCIPAL E26 HOOFDBEDRADINGSBUNDEL E26 VEHICLE SPEED SENSOR FAHRZEUGGESC...

Page 227: ...GINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK B A C HARNESS G INSTRUMENT PANEL HARNESS B KLIMAANLAGEN KABELBAUM G INSTRUMENTENTAFEL KABELBAUM B FAISCEAU C A G FAISCEAU DE TABLEAU DE BORD B BEDRADIN...

Page 228: ...UDIGE DRUKSCHAKELAAR BRAKE FLUID LEVEL SWITCH BREMSFL SSIGKEITSSTANDSCHALTER CONTACTEUR DE NIVEAU DE LIQUIDE DE FREINS REMVLOEISTOFNIVEAUSCHAKELAAR FRONT WIPER MOTOR FRONTSCHEIBENWISCHERMOTOR MOTEUR D...

Page 229: ...Het stekkernummer tussen haakjes geeft het nummer van de bijbehorende stekker aan ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK D INJECTOR HARNESS D EINSPRITZVORRICHTUNG KABELBAUM D FAISCEAU DE F...

Page 230: ...INSPRITZD SE 4 INJECTEUR 4 VERSTUIVER 4 INJECTOR 3 EINSPRITZD SE 3 INJECTEUR 3 VERSTUIVER 3 INJECTOR 2 EINSPRITZD SE 2 INJECTEUR 2 VERSTUIVER 2 INJECTOR 1 EINSPRITZD SE 1 INJECTEUR 1 VERSTUIVER 1 IAC...

Page 231: ...ARTIMENT MOTEUR 1 0L MOTORBAK 1 0L E MAIN HARNESS E HAUPTKABELBAUM E FAISCEAU PRINCIPAL E HOOFDBEDRADINGSBUNDEL RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS E4...

Page 232: ...SENSOR L ENGINE HARNESS C03 MOTORKABELBAUM C03 FAISCEAU DE MOTEUR C03 BEDRADINGSBUNDEL MOTOR C03 BACK UP LIGHT SWITCH R CKFAHRLEU CHTENSCHALTER INTERRUPTEUR DE FEUX DE MARCHE ARRI RE ACHTERUITRIJLICHT...

Page 233: ...AISCEAU PRINCIPAL E HOOFDBEDRADINGSBUNDEL RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS ENGINE ROOM 1 0L MOTORRAUM 1 0L COMPARTIMENT MOTEUR 1 0L MOTORBAK 1 0L E...

Page 234: ...ELAAR FUEL PUMP RELAY KRAFTSTOFFPUMPENRELAIS RELAIS DE POMPE CARBURANT BRANDSTOFPOMPRELAIS RADIATOR FAN CONTROL RELAY K HLERGEBL STE STEUERRELAIS RELAIS DE COMMANDE DE VENTILATEUR DE RADIATEUR STUURRE...

Page 235: ...RTIMENT MOTEUR 1 3L MOTORBAK 1 3L E MAIN HARNESS E HAUPTKABELBAUM E FAISCEAU PRINCIPAL E HOOFDBEDRADINGSBUNDEL RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS E39...

Page 236: ...SS C03 MOTORKABELBAUM C03 FAISCEAU DE MOTEUR C03 BEDRADINGSBUNDEL MOTOR C03 BACK UP LIGHT SWITCH R CKFAHRLEU CHTENSCHALTER INTERRUPTEUR DE FEUX DE MARCHE ARRI RE ACHTERUITRIJLICHTSCHAKELAAR DROPPING R...

Page 237: ...SCEAU PRINCIPAL E HOOFDBEDRADINGSBUNDEL RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS ENGINE ROOM 1 3L MOTORRAUM 1 3L COMPARTIMENT MOTEUR 1 3L MOTORBAK 1 3L E39...

Page 238: ...GSBUNDEL INSTRUMENTENPANEEL G42 INSTRUMENT PANEL HARNESS G41 INSTRUMENTENTAFEL KABELBAUM G41 FAISCEAU DE TABLEAU DE BORD G41 BEDRADINGSBUNDEL INSTRUMENTENPANEEL G41 SIDE TURN SIGNAL LIGHT L SEITENBLIN...

Page 239: ...rrespondant OPMERKING Het stekkernummer tussen haakjes geeft het nummer van de bijbehorende stekker aan INSTRUMENT PANEL INSTRUMENTENTAFEL TABLEAU DE BORD INSTRUMENTENPANEEL E MAIN HARNESS E HAUPTKABE...

Page 240: ...DE BORD G56 BEDRADINGSBUNDEL INSTRUMENTENPANEEL G56 INSTRUMENT PANEL HARNESS G57 INSTRUMENTENTAFEL KABELBAUM G57 FAISCEAU DE TABLEAU DE BORD G57 BEDRADINGSBUNDEL INSTRUMENTENPANEEL G57 FLOOR HARNESS L...

Page 241: ...OITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS G34 G11 G13 G04 G02 G01 2 G01 1 G53 G05 J01 G06 J02 G07 L26 G09 G14 G17 G16 G15 G36 G49 G48 G47 G24 G22 G25 G65 G26 G27 G30 G31 G29 G33...

Page 242: ...TERSCHAKELAAR P S CONTROL MODULE SERVOLENKUNGS STEUERMODUL MODULE DE CONTR LE P S STUURBEKRACHTIGING REGELAPPARAAT BRAKE LIGHT SWITCH BREMSLICHT SCHALTER INTERRUPTEUR DE FEUX STOP REMLICHTSCHAKELAAR W...

Page 243: ...OITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS G34 G11 G13 G04 G02 G01 2 G01 1 G53 G05 J01 G06 J02 G07 L26 G09 G14 G17 G16 G15 G36 G49 G48 G47 G24 G22 G25 G65 G26 G27 G30 G31 G29 G33...

Page 244: ...R LIGHTER ZIGARETTE NANZ NDER ALLUME CIGARES SIGARETTEAANSTEKER THERMISTOR THERMISTOR THERMISTANCE TERMISTOR INTERMITTENT TIMER INTERVALLTIMER MINUTERIE INTERMITTENTE TIJDKLOK INTERVALWISSER BLOWER FA...

Page 245: ...NG Het stekkernummer tussen haakjes geeft het nummer van de bijbehorende stekker aan INSTRUMENT PANEL FLOOR TYPE 1 INSTRUMENTENTAFEL BODEN TYP 1 TABLEAU DE BORD PLANCHER TYPE 1 INSTRUMENTENPANEEL VLOE...

Page 246: ...ARNESS G43 INSTRUMENTENTAFEL KABELBAUM G43 FAISCEAU DE TABLEAU DE BORD G43 HOOFDBEDRADINGSBUNDEL G43 DIAGNOSIS CONNECTOR 2 DIAGNOSESTECKER 2 CONNECTEUR DE DIAGNOSTIC 2 DIAGNOSESTEKKER 2 PRETENSIONER P...

Page 247: ...stekker aan 8A 3 24 INSTRUMENT PANEL FLOOR TYPE 2 3 INSTRUMENTENTAFEL BODEN TYP 2 3 TABLEAU DE BORD PLANCHER TYPE 2 3 INSTRUMENTENPANEEL VLOER TIPO 2 3 Q AIR BAG HARNESS Q AIRBAG KABELBAUM Q FAISCEAU...

Page 248: ...G INFLATOR DRIVER SIDE SEITEN AIRBAG GASGENERATOR FAHRERSEITE GONFLEUR D AIRBAG LAT RAL C T CONDUCTEUR INFLADOR DE LA BOLSA DE AIRE LATERAL BESTUURDERSZIJDE SIDE AIR BAG INFLATOR PASSENGER SIDE SEITEN...

Page 249: ...TTE BREMSLEUCHTE O FAISCEAU DE PORTEARRI RE C BLE D ESSUIE GLACE ARRI RE C BLE DE FEUX STOP SUR LEV S O BEDRADINGSBUNDEL ACHTERKLEP KABEL ACHTERRUITENWISSER KABEL HOOGGEPLAATST REMLICHT R FUEL PUMP HA...

Page 250: ...PARLEUR ARRIERE G ACHTERLUIDSPREKER L INTERIOR LIGHT REAR INNENLEUCHTE HINTEREN PLAFONNIER ARRIERE INTERIEURVERLICHTING ACHTER INTERIOR LIGHT REAR INNENLEUCHTE HINTEREN PLAFONNIER ARRIERE INTERIEURVER...

Page 251: ...OR HARNESS L HINTERT R KABELBAUM L FAISCEAU DE FILS LECTRIQUES DES PORTES AVANT G BEDRADINGSBUNDEL VOOR L REAR DOOR HARNESS L HINTERT R KABELBAUM L FAISCEAU DE FILS LECTRIQUES DES PORTES AVANT G BEDRA...

Page 252: ...ELEKTRISCH BEDIENDE RUIT DOOR LOCK MAIN SWITCH HAUPTSCHALTER DER T RVERRIEGELUNG COMMUTATEUR PRINCIPAL DE VERROUILLAGE DES PORTES PORTIERSLOTSCHAKELAAR INSTRUMENT PANEL HARNESS G54 INSTRUMENTENTAFEL K...

Page 253: ...van de bijbehorende stekker aan FLOOR BODEN PLANCHER VLOER L FLOOR HARNESS L BODENKABELBAUM L FAISCEAU DE PLANCHER L BEDRADINGSBUNDEL VLOER RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUI...

Page 254: ...ANT R01 BEDRADINGSBUNDEL BRANDSTOFPOMP R01 REAR WHEEL SENSOR R HINTERRADSENSOR R DETECTEUR DE ROUE ARRIERE D ACHTERWIELSENSOR R REAR DOOR HARNESS J17 HINTERT R KABELBAUM J17 FAISCEAU DE FILS LECTRIQUE...

Page 255: ...TEERING VEHICLE 8A 4 6 INSTRUMENT PANEL LEFT HAND STEERING VEHICLE 8A 4 7 FLOOR 8A 4 8 MOTORRAUM FAHRZEUG MIT RECHTSLENKUNG 8A 4 2 MOTORRAUM FAHRZEUG MIT LINKSLENKUNG 8A 4 3 MOTORRAUM 1 0L 8A 4 4 INST...

Page 256: ...Y E56 HAUPT RELAIS RELAIS PRINCIPAL HOOFDRELAIS ISC RELAY E55 ISC RELAIS RELAYS D ISC RELAIS ISC MAIN FUSE C01 C02 E42 E43 E49 E50 HAUPTSICHERUNG FUSIBLE PRINCIPAL HOOFDZEKERING ABS CONTROL MODULE E20...

Page 257: ...E56 HAUPT RELAIS RELAIS PRINCIPAL HOOFDRELAIS ISC RELAY E55 ISC RELAIS RELAYS D ISC RELAIS ISC MAIN FUSE C01 C02 E42 E43 E49 E50 HAUPTSICHERUNG FUSIBLE PRINCIPAL HOOFDZEKERING ABS CONTROL MODULE E20 A...

Page 258: ...E ONDERDELEN 8A 4 4 ENGINE ROOM 1 0L MOTORRAUM 1 0L COMPARTIMENT MOTEUR 1 0L MOTORBAK 1 0L NOISE SUPPRESSOR G58 ST RFUNKEN UNITERDR CKER SUPPRESSEUR DE BRUIT SUPRESOR DE RUIDO EFE HEATER RELAY 1 E62 1...

Page 259: ...TALLATION POSITIONS OF SINGLE UNIT PARTS EINBAUPOSITIONEN VON EINZELEINHRIT TEILEN PASITIONS D INSTALLATION DES PIECES INDIVIDUELLES INSTALLATIEPOSITIE VAN ENKELE ONDERDELEN 8A 4 5 MEMO NOTIZEN NOTE M...

Page 260: ...BEKRACHTIGING REGELAPPARAAT BRAKE LIGHT SWITCH G15 BREMSLICHT SCHALTER INTERRUPTEUR DE FEUX STOP REMLICHTSCHAKELAAR TURN SIGNAL RELAY G04 BLINKERRELAIS RELAIS DE CLIGNOTANT RICHTINGAANWI JZERRELAIS RE...

Page 261: ...IMER G51 INTERVALLTIMER MINUTERIE INTERMITTENTE TIJDKLOK INTERVALWISSER DATA LINK CONNECTOR G09 DATENVERBINDUNGSSTECKER CONNECTEUR DE TRANS MISSION DE DONN ES DATA LINK STEKKER BRAKE LIGHT SWITCH G15...

Page 262: ...ROL MODULE Q06 AIRBAG STEUERMODUL MODULE DE COMMANDE DES COUSSINS D AIR AIRBAG REGELMODULE RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR LINKS FLOOR BODEN PLANCHER VL...

Page 263: ...SE AARDEPUNT CONTENTS INHALT TABLE DES MATI RES INHOUD ENGINE ROOM 8A 5 2 INSTRUMENT PANEL 8A 5 3 FLOOR 8A 5 4 REAR 8A 5 5 MOTORRAUM 8A 5 2 INSTRUMENTENTAFEL 8A 5 3 BODEN 8A 5 4 T R 8A 5 5 COMPARTIMEN...

Page 264: ...ROUND POINT MASSEPUNKT POINTS DE MASSE AARDEPUNT 8A 5 2 ENGINE ROOM MOTORRAUM COMPARTIMENT MOTEUR MOTORBAK 1 3L ONLY NUR 1 3L 1 3L UNIQUEMENT ALLEEN 1 3L 1 0L ONLY NUR 1 0L 1 0L UNIQUEMENT ALLEEN 1 0L...

Page 265: ...POINT MASSEPUNKT POINTS DE MASSE AARDEPUNT 8A 5 3 INSTRUMENT PANEL INSTRUMENTENTAFEL TABLEAU DE BORD INSTRUMENTENPANEEL RHD RECHTS CONDUITE DROITE MET STUUR RECHTS LHD LINKS CONDUITE GAUCHE MET STUUR...

Page 266: ...GROUND POINT MASSEPUNKT POINTS DE MASSE AARDEPUNT 8A 5 4 FLOOR BODEN PLANCHER VLOER...

Page 267: ...GROUND POINT MASSEPUNKT POINTS DE MASSE AARDEPUNT 8A 5 5 REAR T R PORTE ACHTERKANT...

Page 268: ...TION TYPE 3 8A 6 4 FUSIBLE PRINCIPAL FUSIBLE RELAIS 8A 6 6 FUSIBLE TYPE 1 2 8A 6 6 FUSIBLE TYPE 3 8A 6 7 SPANNINGSTOEVOER DIAGRAM TIPO 1 2 8A 6 2 SPANNINGSTOEVOER DIAGRAM TIPO 3 8A 6 4 HOOFDZEKERING Z...

Page 269: ...1 RED 1 E43 1 5 6 RHD RECHTS CONDUITE A DROITE MET STUUR RECHTS LHD LINKS CONDUITE A GAUCHE MET STUUR LINKS WHT BLU WHT BLU WHT RED BLK BLU YEL 25A 10A 10 9 12 11 BLK RED WHT GRN 20A 15A WHT BLU 30A...

Page 270: ...30 LT GRN RED 30 31 RED MAIN FUSE FUSE RELAY BOX HAUPTSICHERUNG SICHERUNG RELAISKASTEN FUSIBLE PRINCIPAL FUSIBLE BO TIER DE RELAIS HOOFDZEKERING ZEKERING RELAIS 3 OFF TAIL HEAD 7 G10 8 LIGHTING SWITC...

Page 271: ...ZEKERING E17 G57 3 1 E50 G59 4 4 1 3 2 6 5 1 C01 1 C02 2 1 E49 G60 2 E42 1 RED 1 E43 1 5 6 RHD RECHTS CONDUITE A DROITE MET STUUR RECHTS LHD LINKS CONDUITE A GAUCHE MET STUUR LINKS WHT BLU WHT BLU WHT...

Page 272: ...8 29 15A WHT BLU BLK YEL 15A 27 20A WHT RED 27 28 29 1 31 15A GRN WHT 15A 30 LT GRN RED 30 31 RED MAIN FUSE FUSE RELAY BOX HAUPTSICHERUNG SICHERUNG RELAISKASTEN FUSIBLE PRINCIPAL FUSIBLE BO TIER DE RE...

Page 273: ...agram 8A 7 E53 RADIATOR FAN CONTROL RELAY K HLERGEBL SE STEUERRELAIS RELAIS DE COMMANDE DE VENTILATEUR DE RADIATEUR STUURRELAIS RADIATEURVENTILATOR E52 FUEL PUMP RELAY KRAFTSTOFFPUMPENRELAIS RELAIS DE...

Page 274: ...Circuit Diagram 8A 7 HINWEIS Die Nummer jeder Sicherung entspricht der jeweiligen Nummer auf dem Stromversorgungsdiagramm 8A 6 2 3 oder Systemschaltdiagramm 8A 7 REMARQUE Le num ro de chaque fusible...

Page 275: ...B 4 B 5 B 6 B 7 C 1 D 1 D 2 D 3 D 4 D 5 D 6 D 7 D 8 D 9 D 10 D 11 F 1 F 2 F 3 F 4 F 5 F 6 G 1 G 2 A 1 CRANKING SYSTEM 8A 7 5 A 2 CHARGING SYSTEM 8A 7 6 A 3 COOLING SYSTEM 8A 7 7 A 4 IGNITION SYSTEM 8...

Page 276: ...4 B 5 B 6 B 7 C 1 D 1 D 2 D 3 D 4 D 5 D 6 D 7 D 8 D 9 D 10 D 11 F 1 F 2 F 3 F 4 F 5 F 6 G 1 G 2 A 1 KURBELSYSTEM 8A 7 5 A 2 LADESYSTEM 8A 7 6 A 3 K HLSYSTEM 8A 7 7 A 4 Z NDSYSTEM 8A 7 8 A 5 MOTORSTEUR...

Page 277: ...B 6 B 7 C 1 D 1 D 2 D 3 D 4 D 5 D 6 D 7 D 8 D 9 D 10 D 11 F 1 F 2 F 3 F 4 F 5 F 6 G 1 G 2 A 1 SYST ME DE D MARRAGE 8A 7 5 A 2 SISTEMA DE CARGA 8A 7 6 A 3 SYSTEME DE REFROIDISSEMENT 8A 7 7 A 4 SYSTEME...

Page 278: ...5 B 6 B 7 C 1 D 1 D 2 D 3 D 4 D 5 D 6 D 7 D 8 D 9 D 10 D 11 F 1 F 2 F 3 F 4 F 5 F 6 G 1 G 2 A 1 STARTSYSTEEM 8A 7 5 A 2 LAADSTROOMSYSTEEM 8A 7 6 A 3 KOELSYSTEEM 8A 7 7 A 4 ONTSTEKINGSSYSTEEM 8A 7 8 A...

Page 279: ...RANSMISSIE BEREIKSENSOR MAIN SWITCH HAUPTSCHALTER COMMUTATEUR PRINCIPAL HOOFDSCHAKELAAR BLK G57 E17 RHD LHD G57 E17 2 3 BLK RED BLK YEL G24 3 E31 6 9 E26 C03 2 C06 1 C05 1 5 MAIN FUSE HAUPTSICHERUNG F...

Page 280: ...NSTRUMENT COMPTEUR MIXTE COMBINATIEMETER COMBINATION METER KOMBINATIONS INSTRUMENT COMPTEUR MIXTE COMBINATIEMETER 80A 15A CHARGE BLK WHT GENERATOR LICHTMASCHINE G N RATEUR DYNAMO 3 BLK WHT BLK WHT MAI...

Page 281: ...OL RELAY K HLERGEBL SE STEUERRELAIS RELAIS DE COMMANDE DE VENTILATEUR DE RADIATEUR STUURRELAIS RADIATEURVENTILATOR E53 4 3 CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING E44 2 1...

Page 282: ...DKERZE BOUGIE BOUGIE NOISE SUPPRESSOR ST RFUNKEN UNITERDR CKER SUPPRESSEUR DE BRUIT SUPRESOR DE RUIDO DISTRIBUTER VERTEILER DISTRIBUTEUR DISTRIBUIDOR IGNITION COIL Z NDSPULE BOBINE D ALL UMAGE BOBINE...

Page 283: ...BLK YEL IGNITION COIL 1 Z NDSPULE 1 BOBINE D ALL UMAGE 1 BOBINE 1 IGNITION COIL 2 Z NDSPULE 2 BOBINE D ALL UMAGE 2 BOBINE 2 SPARK PLUG Z NDKERZE BOUGIE BOUGIE SPARK PLUG Z NDKERZE BOUGIE BOUGIE 16 E4...

Page 284: ...EISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING PNK 8 L13 R01 4 E52 4 2 1 3 E21 21 7 11 D05 2 1 D10 1 2 E22 20 BLK WHT BLK WHT BLK RED BLK RED E18 L23 2 PPL 1 E26 C03 PPL VEHICLE SPEED SENSOR FAHRZEUG...

Page 285: ...lgende bladzijde 15A DOME RADIO 9 CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 14 10 16 G56 E16 WHT BLU WHT BLU YEL BLU 1 2 BLK RED BLK RED 1 DISTRIBUTER SEE A 4 VERTEILER SIEH...

Page 286: ...e Ga naar de vorige bladzijde RED WHT REAR WINDOW DEFOGGER SEE B 3 HECKSCHEIBENHEIZUNG SIEHE B 3 D SEMBUEUR DE LUNETTE ARRI RE VOIR B 3 ACHTERRUITVERWARMING ZIE B 3 18 L23 E18 17 RED WHT DIODE 4 DIODE...

Page 287: ...FEUX STOP VOIR D 7 REMLICHTSCHAKELAAR ZIE D 7 GRN WHT GRN WHT E22 12 PPL WHT 17 COMBINATION METER SEE C 1 KOMBINATIONSINSTRUMENT SIEHE C 1 COMPTEUR MIXTE VOIR C 1 COMBINATIEMETER ZIE C 1 TACHO CHECK...

Page 288: ...11 D05 2 1 BLK RED D03 E39 2 1 4 3 2 9 8 17 GRN YEL GRN BLK GRN RED GRN ORN GRN YEL GRN BLK GRN RED GRN ORN D09 2 3 5 4 1 6 E23 6 BLK RED BLK RED BLK RED BLK RED 2 E23 PPL 1 E26 C03 PPL VEHICLE SPEED...

Page 289: ...R ECT VOIR C 1 ECT SENSOR ZIE C 1 E21 14 YEL GRN PPL WHT 1 COMBINATION METER SEE C 1 KOMBINATIONSINSTRUMENT SIEHE C 1 COMPTEUR MIXTE VOIR C 1 COMBINATIEMETER ZIE C 1 15 RED RED BLK WHT YEL 3 BRN WHT B...

Page 290: ...HALTER SIEHE F 1 COUTATEUR DE VENTILATEUR DE CHAUFFAGE ET DE D SEMBUEUR DE D SEMBUEUR DE LUNETTE ARRI RE VOIR F 1 AANJAGERVENTILATOR EN ACHTERRUITVERWARMINGSSCHAKELAAR ZIE F 1 GRN RED GRY GRY LT GRN R...

Page 291: ...WHT BRAKE LIGHT SWITCH SEE D 7 BREMSLICHT SCHALTER SIEHE D 7 INTERRUPTEUR DE FEUX STOP VOIR D 7 REMLICHTSCHAKELAAR ZIE D 7 GRN WHT REAR COMBINATION LIGHT SEE D 7 HECK KOMBINATIOS LEUCHTE SIEHE D 7 FEU...

Page 292: ...KELAAR 15A CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 8 E13 E13 4 17 STOP L23 E18 GRN WHT ABS CONTROL MODULE SEE G 1 ABS STEUERMODUL SIEHE G 1 MODULE DE COMMANDE DE L ABS VOI...

Page 293: ...URSENSOR 25A PNK BLU BLK YEL A C COMPRESSOR KLIMAANLAGEN KOMPRESSOR COMPRESSEUR A C A C COMPRESSOR BLK YEL CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING E13 26 32 AT SHIFT SOLEN...

Page 294: ...N ES DATA LINK STEKKER CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING G17 7 G41 E47 8 WHT BLK WHT BLK 9 5 16 6 7 5 G09 16 4 BLK BLK PPL WHT PPL WHT G25 23 2 G42 E46 1 15 4 G30 IG...

Page 295: ...DE LAVE GLACE AVANT ET ARRI RE VOOR EN ACHTERSPROEIERMOTOR 15A M WIPER WASHER SWITCH WISCHER U WASCHERSCHALTER CONTACTEUR DE L ESSUIE GLACE ET LAVE GLACE WISSER EN SPROEIERSCHAKELAAR BLK ORN 6 CIRCUI...

Page 296: ...SSER FRONT REAR WASHER MOTOR FRONT HECKSCHEIBEN WASCHPUMPENMOTOR MOTEUR DE LAVE GLACE AVANT ET ARRI RE VOOR EN ACHTERSPROEIERMOTOR L03 O01 4 O11 1 2 CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUI...

Page 297: ...21 CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING G32 3 BRN BLK YEL BLK YEL BLK YEL REAR WINDOW DEFOGGER RELAY HECKSCHEIBENHEIZUNGSRELAIS RELAIS DE D SEMBUEUR DE LUNETTE ARRI RE...

Page 298: ...EUR MOTOR RUITBEDIENING VOOR BESTUURDERSZIJDE CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING J08 25 G05 J01 1 WHT BLU GRN BLK RED BLU RED M UP GRN POWER WINDOW SUB SWITCH PASSENG...

Page 299: ...SYSTEM CIRCUIT DIAGRAM SYSTEM SCHALTDIAGRAMM SCH MA DES CIRCUITS LECTRIQUES SYSTEEMCIRCUITDIAGRAM 8A 7 25 MEMO NOTIZEN NOTE MEMO...

Page 300: ...OWER WINDOW LINKSLENLUNG MIT FENSTERHEBER CONDUITE GAUCHE AVEC L VE GLACE LECTRIQUES LINKS STUUR MET ELEKTRISCH BEDIENDE RUITEN VEHICLE WITHOUT POWER WINDOW FAHRZEUG OHNE FENSTERHEBER VOERTUIG ZONDER...

Page 301: ...LK BLU RED BLK BLU BLU 2 2 BLU BLU 2 2 RED BLK M UNLOCK LOCK DEAD LOCK RED BLK GRN M UNLOCK LOCK DEAD LOCK 3 O06 3 4 GRN RED BLK BLU GRN RED BLK BLU DOOR LOCK CONTROLLER STEUEREINHEIT F R T RVERRIEGEL...

Page 302: ...BLK LH UP WHT GRN WHT GRN WHT GRN WHT GRN GRY RED GRY RED GRY RED GRY BLU GRY BLU GRY BLU LT GRN RED LT GRN RED LT GRN RED LT GRN BLK LT GRN BLK LT GRN BLK 14 J07 7 YEL BLK G06 J02 5 CIRCUIT FUSE SCH...

Page 303: ...SONORE DANS LE GONFLEUR DE CONDUCTEUR CLAXONSCHAKELAAR IN OPBLAASMECHANISME BESTUURDER H 15A WHT BLU ORN BLK GRN WHT GRN WHT HORN RELAY HUPENRELAIS RELAIS D AVERTISSEUR SONORE CLAXIONRELAIS HORN HUPE...

Page 304: ...IAGRAMM SCH MA DES CIRCUITS LECTRIQUES SYSTEEMCIRCUITDIAGRAM 8A 7 30 B 8 POWER DOOR LOCK SYSTEM TYPE 2 3 B 8 ZENTRALVERRIEGELUNG TYP 2 3 B 8 SYST ME DE VERROUILLAGE DE PORTI RE MOTORIS TYPE 2 3 B 8 CE...

Page 305: ...K LOCK DEAD LOCK 3 O06 3 4 GRN BLU GRN RED BLK BLU 3 10 2 1 L L G L RED BLK GRN PASSENGER SIDE BEIFAHRERSEITE C T PASSAGER PASSAGIERSZIJDE RED BLK GRN FRONT DOOR LOCK MOTOR VORDERT R SPERRMOTOR MOTEUR...

Page 306: ...2 G41 E47 10 PPL BLK WHT 13 C04 1 3 BLK WHT BRN 2 WHT BLU 32 15A 16 E22 G25 1 10 18 29 G07 L26 7 L13 R01 2 R02 1 2 1 BRN L23 E18 7 BRN 28 DOME RADIO E26 C03 1 4 15A 9 IG COIL G56 E16 G41 E47 19 9 WHT...

Page 307: ...LARMKNIPPERLICHTSCHAKELAAR ZIE D 5 G42 E46 1 PPL WHT G41 E47 7 YEL BLK E41 D01 9 OFF ON YEL BLK OIL PRESSURE SWITCH LDRUCKSCHALTER INTERRUPTEUR DE PRESSION D HUILE OLIEDRUKSCHAKELAAR D20 1 ABS EBD CIR...

Page 308: ...G41 E47 10 PPL BLK WHT 13 C04 1 3 BLK WHT BRN 2 WHT BLU 32 15A 16 E23 G25 16 E22 22 18 29 G07 L26 7 L13 R01 2 R02 1 2 1 BRN L23 E18 7 BRN 28 DOME RADIO E26 C03 1 4 15A 9 IG COIL G41 E47 11 9 WHT GRN...

Page 309: ...3 G43 Q03 1 BLU AIR BAG CONTROL MODULE SEE G 2 AIRBAG STEUERMODUL SIEHE G 2 MODULE DE COMMANDE DES COUSSINS D AIR VOIR G 2 AIRBAG REGELMODULE ZIE G 2 CHECK ENGINE PPL WHT 23 BLU BLK 7 G56 E16 1 BLU BL...

Page 310: ...CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 14 ACC GRY EPS 9 YEL GRN OFF ON BLK ORN BLK ORN 19 G07 L26 9 L21 1 BLK RED FRONT DOOR SWITCH L VORDERERT R SCHALTER L COMMUTATEUR...

Page 311: ...HT EN INHAALLICHTSCHAKELAAR HEADLIGHT R SCHEINWERF ERLICHT R PHARE D KOPLAMP R HEADLIGHT L SCHEINWE RFERLICHT L PHARE G KOPLAMP L CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 2...

Page 312: ...HTSCHAKELAAR HEADLIGHT R SCHEINWERF ERLICHT R PHARE D KOPLAMP R HEADLIGHT L SCHEINWE RFERLICHT L PHARE G KOPLAMP L CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 28 G25 20 E35 3...

Page 313: ...ALTER INTERRUPTEUR DE PRESSION D HUILE OLIEDRUKSCHAKELAAR DRL CONTROLLER DRL REGLER REGULATEUR DE DRL DRL REGELAAR CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 1 7 2 G41 E47 7...

Page 314: ...G SWITCH LICHTSCHALTER COMMUTATEUR DE FEU LICHTSCHAKELAAR BLK TAIL LIGHT RELAY HECKLEUCHTENRELAIS RELAIS DE FEUX ARRI RE ACHTELICHTRELAIS GRN RED 3 G01 2 4 5 1 OFF TAIL HEAD 7 G10 8 LIGHTING SWITCH LI...

Page 315: ...MEMO NOTIZEN NOTE MEMO SYSTEM CIRCUIT DIAGRAM SYSTEMSCHALTDIAGRAMM SCH MA DES CIRCUITS LECTRIQUES SYSTEEMCIRCUITDIAGRAM 8A 7 41...

Page 316: ...IL HEAD 7 G10 8 LIGHTING SWITCH LICHTSCHALTER COMMUTATEUR DE FEU LICHTSCHAKELAAR BLK 10A 33 TAIL RED GRN RED GRN FRONT POSITION LIGHT VORDERE PARKLEUC HTE FEU DE POSITION AVANT PARKEERLICHT VOOR R R D...

Page 317: ...06 K07 1 3 K03 L30 5 1 L27 2 1 L21 8 G07 L26 WHT BLU 12 G07 L26 10A 3 G10 21 2 INTERIOR LIGHT SWITCH IN LIGHTING SWITCH INNENLEUCHTENSCHALTER IM LICHTSCHALTER CONTACTEUR DE PLAFONNIER DANS LE CONTACTE...

Page 318: ...1 K06 K07 1 3 K03 L30 5 1 L27 2 DIODE 3 DIODE 3 DIODE 3 DIODE 3 1 L32 2 1 L21 8 G07 L26 WHT BLU 12 G07 L26 10A 3 G10 21 2 INTERIOR LIGHT SWITCH IN LIGHTING SWITCH INNENLEUCHTENSCHALTER IM LICHTSCHALTE...

Page 319: ...N SIGNAL LIGHT R SEITENBLINKLEU CHTE R CLIGNOTANT LAT RAL D RICHTINGAANWIJZER ZIJKANT R FRONT TURN SIGNAL LIGHT FRONTBLINK LEUCHTE CLIGNOTANT AVANT SEITLICHE BLINKLEUCHTE 12 CIRCUIT FUSE SCHALTKREISSI...

Page 320: ...OL MODULE SEE G 1 ABS STEUERMODUL SIEHE G 1 MODULE DE COMMANDE DE L ABS VOIR G 1 ABS REGELAPPARAAT ZIE G 1 REAR COMBINATION LIGHT L HECK KOMBINATIONS LEUCHTE L FEU COMBINE ARRIERE G COMBI LICHT ACHTER...

Page 321: ...UX DE MARCHE ARRI RE ACHTERUITRIJLICHT SCHAKELAAR BACK UP LIGHT IN REAR COMBINATION LIGHT R CKFAHRSCHEINWERFER IN KOMBIR CKLEUCHTE FEU DE RECUL DANS LE FEU COMBIN ARRI RE ACHTERUITRIJLICHT IN COMBINAT...

Page 322: ...MANDE DE REGLAGE DU FAISCEAU DE PHARE G KOPLICHTHOOGTE STELMOTOR L YEL GRN BLK GRN BLK BLK GRN BLK BLK BLK E06 17 21 21 21 21 E34 2 2 E47 G41 3 G41 E47 6 YEL YEL YEL 3 2 6 YEL G11 7 CIRCUIT FUSE SCHAL...

Page 323: ...NTIBROUILLARD AVANT MISTVOORLICHTSCHAKELAAR CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 30 G12 1 FRONT FOG RELAY NEBELSCHEINWERFERRELAIS RELAIS D ANTIBROUILLARD AVANT VOORMIST...

Page 324: ...12 5 WHT WHT RED BLU 5 OFF TAIL HEAD 6 G10 8 LIGHTING SWITCH LICHTSCHALTER COMMUTATEUR DE FEU LICHTSCHAKELAAR G30 BLK BLK 1 3 REAR FOG 4 21 33 ILLUMI TAIL YEL RED RED WHT RED YEL RED GRN 3 PPL FRONT F...

Page 325: ...SYSTEM CIRCUIT DIAGRAM SYSTEM SCHALTDIAGRAMM SCH MA DES CIRCUITS LECTRIQUES SYSTEEMCIRCUITDIAGRAM 8A 7 51 MEMO NOTIZEN NOTE MEMO...

Page 326: ...SISTOR HEIZUNGSWIDERSTAND R SISTANCE DE CHAUFFAGE VERWARMING WEERSTAND BLOWER MOTOR GEBL SEMOTOR MOTEUR DE SOUFFLERIE AANJAGERMOTOR BLOWER FAN REAR WINDOW DEFOGGER SWITCH GEBL SE HECKSCHEIBENHEIZUNGSS...

Page 327: ...COMMANDE DE VENTILATEUR DE RADIATEUR VOIR A 3 STUURRELAIS RADIATEURVENTILATOR ZIE A 3 BLU 20 IG COIL 10A 26 A C BLK G30 3 15 E23 PNK BLU E16 G56 11 PNK BLU 4 5 BLK GRN ORN GRN ORN BLK BLK BLK BLK J C...

Page 328: ...ER MOTOR GEBL SEMOTOR MOTEUR DE SOUFFLERIE AANJAGERMOTOR BLOWER FAN REAR WINDOW DEFOGGER SWITCH GEBL SE HECKSCHEIBENHEIZUNGSSCHALTER CONTACTEUR DE D SEMBUEUR DE LUNETTE ARRI RE ET VENTILATEUR DE SOUFF...

Page 329: ...E22 B01 E02 1 LT GRN RED LT GRN RED G42 E46 4 GRN ORN CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 2 E46 G42 5 6 BRN WHT GRN RED E23 E21 14 10 E02 B01 3 RADIATOR FAN CONTROL RE...

Page 330: ...K03 1 2 BLK WHT BLK RED 5 4 6 BLK 1 2 2 7 1 1 3 8 6 SEE F 6 SIEHE F 6 VOIR F 6 ZIE F 6 RADIO DOME ACC FRONT SPEAKER L VORDERER LAUTSPRECHER L HAUT PARLEUR AVANT G VOORLUIDSPREKER L FRONT SPEAKER R VO...

Page 331: ...15A CIGAR LIGHTER ZIGARETTE NANZ NDER ALLUME CIGARES SIGARETTEAANSTEKER CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING 13 G49 1 G48 1 J C 1 BLK BLK BLK G30 G07 L26 15 L06 2 1 BLK...

Page 332: ...D SENSOR FAHRZEUGGESCH WINDIGKEITSSENSOR CAPTEUR DE VITESSE DU V HICULE RIJSNELHEIDSSENSOR PPL G41 E47 10 PPL C04 1 7 E26 C03 1 PPL BRN YEL BLU RED BLK 5 EPS 9 COMBINATION METER KOMBINATIONS INSTRUMEN...

Page 333: ...A 15A J C 1 RED YEL YEL BLK RED YEL WHT BLU CLOCK UHR HORLOGE KLOK CIRCUIT FUSE SCHALTKREISSICHERUNG FUSIBLE DE CIRCUIT CIRCUITZEKERING G29 3 9 G30 14 1 4 BLK 2 SEE F 6 SIEHE F 6 VOIR F 6 ZIE F 6 DOME...

Page 334: ...F 2 RADIO VOIR F 2 RADIO ZIE F 2 RED YEL RED YEL CLOCK SEE F 5 UHR SIEHE F 5 HORLOGE VOIR F 5 KLOCK ZIE F 5 REAR FOG LIGHT SWITCH SEE D 10 NEBELSCHLUSSLEUCHTENSCHALTER SIEHE D 10 COMMUTATEUR D ANTIBR...

Page 335: ...REAR FOG LIGHT SWITCH SEE D 10 NEBELSCHLUSSLEUCHTENSCHALTER SIEHE D 10 COMMUTATEUR D ANTIBROUILLARD ARRI RE VOIR D 10 MISTACHTERSCHAKELAAR ZIE D 10 HEADLIGHT BEAM LEVELING SWITCH SEE D 9 SCHEINWERFER...

Page 336: ...TECTEUR DE ROUE AVANT D VOORWIEL SENSOR R FRONT WHEEL SENSOR L VORDERRAD SENSOR L DETECTEUR DE ROUE AVANT G VOORWIEL SENSOR L REAR WHEEL SENSOR R HINTERRAD SENSOR R DETECTEUR DE ROUE ARRIERE D ACHTERW...

Page 337: ...T BROCHE DE D TECTION DE CONNEXION VERBINDINGSDETECTIEPEN CONTACT COIL KONTAKTSPULE BOBINE DE CONTACT CONTACTSPOEL DRIVER INFLATOR GASGENERATOR FAHRERSEITE GAZOG NE C T CONDUCTEUR BESTUURDER AIRBAG PA...

Page 338: ...UCTEUR BESTUURDER AIRBAG PASSENGER INFLATOR BEIFAHRER INFLATOR GAZOGENE PASSAGER OPBLAASMECHANISME PASSAGER AIRBAG AIR BAG CONTROL MODULE AIRBAG STEUERMODUL MODULE DE COMMANDE DES COUSSINS D AIR AIRBA...

Page 339: ...G68 1 2 G71 1 2 16 5 G66 G66 31 30 13 IG COIL 16 SIDE AIR BAG INFLATOR DRIVER SIDE SEITEN AIRBAG GASGENERATOR FAHRERSEITE GONFLEUR D AIRBAG LAT RAL C T CONDUCTEUR INFLADOR DE LA BOLSA DE AIRE LATERAL...

Page 340: ...08 2 2 L18 1 2 L14 1 5 6 11 12 14 1 1 E42 MAIN FUSE HAUPTSICHERUNG PUSIBLE PRINCIPAL HOOFDZEKERING FRONT WHEEL SENSOR R VORDERRAD SENSOR R DETECTEUR DE ROUE AVANT D VOORWIEL SENSOR R FRONT WHEEL SENSO...

Page 341: ...BLE DES MATI RES INHOUD B B01 B03 8A 8 2 C C01 C08 8A 8 2 D D01 D25 8A 8 2 E E01 E19 8A 8 2 E E20 E63 8A 8 3 G G01 G07 8A 8 3 G G08 G73 8A 8 4 J J01 J20 8A 8 5 K K01 K07 8A 8 5 L L01 L33 8A 8 5 N N01...

Page 342: ...s van de bijbehorende stekkers LIST OF CONNECTORS LISTE DER STECKVERBINDER LISTE DES CONNECTEURS LIJST VAN AANSLUITINGEN 8A 8 2 C01 D01 E41 D11 D21 E01 E10 C02 D02 E40 D12 D22 E02 B01 E12 B02 C03 E26...

Page 343: ...60 E61 E62 1 E62 2 9 1 2 3 4 5 6 7 8 10 11 20 21 12 13 14 15 16 17 18 19 22 23 30 31 24 25 26 27 28 29 2 1 2 1 1 2 5 4 8 6 3 7 6 9 1 2 3 4 5 7 8 1 2 3 1 2 1 2 1 2 3 4 13 14 15 16 5 6 7 8 9 10 11 12 4...

Page 344: ...8 9 10 4 5 6 7 8 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 7 8 9 5 6 G25 9 8 7 6 5 4 3 2 1 1 2 4 5 3 2 6 1 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 4 3 1 5...

Page 345: ...le No des connecteurs correspondants OPMERKING De stekkernummers tussen haakjes zijn de nummers van de bijbehorende stekkers J J11 J12 J13 J14 J15 L20 J16 J17 L15 J18 J19 J20 K01 L25 K02 K L 5 4 3 2...

Page 346: ...EURS LIJST VAN AANSLUITINGEN NOTE Connector Nos in indicate mating connector Nos HINWEIS Die in angegebenen Nummern kennzeichnen die passenden Steckverbinder REMARQUE Les Nos de connecteurs entre pare...

Page 347: ...the 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 se...

Page 348: ...re are based on the latest product infor mation available at the time of publication approval And used as the main subject of description is the vehicle of standard specifications among others Therefo...

Page 349: ......

Page 350: ...Engine Model 7A2 5B 7F BRAKES 5 Manual Transaxle Z13DT Engine Model 7A3 5C Brakes Pipe Hose Master Cylinder 5A Automatic Transaxle M13 Engine Model 7B1 5E1 8 Front Brake 5B Clutch G10 M13 Engine Mode...

Page 351: ......

Page 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ...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 359: ...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 360: ...ithout first releasing the fuel pressure or fuel can be sprayed out under pressure Refer to Fuel Pressure Relief Procedure in section 6 for fuel pressure releasing For vehicles equipped with diesel en...

Page 361: ...s installed using wheel bolts When removing any of these wheels never remove all wheel bolts at the same time Leave at least 1 bolt for each wheel as it is to prevent wheel from dropping When removing...

Page 362: ...tion in servicing Otherwise front wheels drive rear wheels or vise versa and vehicle accidents drivetrain damage and personal injury may result Never perform any of the following types of service work...

Page 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...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 369: ...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 370: ...ne 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 Identification Num...

Page 371: ...equipped 6 Air bag label on combination switch and contact coil assembly 2 Air bag label on sun visor for vehicle with air bag system 7 Air bag label on passenger air bag inflator module 3 Pretension...

Page 372: ...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 373: ...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 374: ...ition 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 Sensing Proporti...

Page 375: ...tart of Injection 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 P...

Page 376: ...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 377: ...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 378: ...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 379: ...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 380: ...Engine 0B 16 Air Cleaner Filter Inspection G10 M13 Engines 0B 16 Air Cleaner Filter Replacement G10 M13 Engines 0B 16 Air Cleaner Filter Inspection Z13DT Engine 0B 16 Air Cleaner Filter Replacement Z1...

Page 381: ...ropeller Shafts 4WD Inspection 0B 23 Manual Transmission Oil Inspection G10 M13 Engines 0B 23 Manual Transmission Oil Replacement 0B 23 Automatic Transmission Fluid Level Inspection 0B 24 Automatic Tr...

Page 382: ...I IGNITION SYSTEM Spark plugs 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 Recomme...

Page 383: ...every 10 000 km 6 000 miles or 8 months Engine coolant R R Exhaust system I I I FUEL SYSTEM Air cleaner filter Replace every 50 000 km 30 000 miles or 40 months Fuel lines and connections I I I Fuel f...

Page 384: ...I I I 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 Prope...

Page 385: ...A C D E F H Engine oil and oil filter G10 M13 engines R Every 5 000 km 3 000 miles or 4 months A C D E H Z13DT engine Every 10 000 km 6 000 miles or 8 months C Air cleaner filter 1 I Every 2 500 km 1...

Page 386: ...N 0B 7 NOTE I Inspect and correct or replace if necessary R Replace or change 1 Inspect more frequently if the vehicle is used under dusty conditions 2 Clean or replace more frequently if the air from...

Page 387: ...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 388: ...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 389: ...referring to Water Pump Generator Drive Belt Removal and Installation in Section 6B3 Camshaft Timing Belt Replacement G10 Engine Replace belt with new one Refer to Section 6A for replacement procedure...

Page 390: ...r by using 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 oi...

Page 391: ...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 392: ...ut oil filter element 2 from cover 2 Drain engine oil by removing drain plug 1 3 After draining oil wipe drain plug clean and replace seal ring with a new one Reinstall drain plug and tighten it secur...

Page 393: ...by the engine oil filter Use specified engine oil Select the appropriate oil viscosity according to the proper engine oil viscosity chart A 6 Check oil filter and drain plug for oil leakage 7 Start en...

Page 394: ...umes to seep 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 fixe...

Page 395: ...Cleaner Filter Inspection G10 M13 Engines 1 Unclamp air cleaner case clamps 2 Take air cleaner filter out of case 3 Check that filter is not excessively dirty damaged or oily clean filter with compre...

Page 396: ...ally inspect fuel lines and connections for evidence of fuel leakage hose cracking and damage Make sure all clamps are secure Repair leaky joints if any Replace hoses that are suspected of being crack...

Page 397: ...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 398: ...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 399: ...otches with 20 kg 44 lbs of pull pressure Clutch Inspection G10 M13 engine models Check clutch pedal for height and free travel 1 referring to Clutch Pedal Height Check and Clutch Pedal Free Travel Ch...

Page 400: ...r wheel bearing for wear damage abnormal noise or rattles For details refer to Wheel Disc Nut and Bearing Check in Section 3E Suspension System Inspection Inspect front struts rear shock absorbers for...

Page 401: ...mage is found replace defective boot with new one If any dent is found on steering gear case boots correct it to original shape by turning steering wheel to the right or left as far as it stops and ho...

Page 402: ...ines 1 Inspect transmission case for evidence of oil leakage Repair leaky point if any 2 Make sure that vehicle is placed level for oil level check 3 Remove oil filler level plug 1 of transmission 4 C...

Page 403: ...rform it under specified con ditions If fluid level is low replenish specified fluid Automatic Transmission Fluid Replacement 1 Inspect transmission case for evidence of fluid leakage Repair leaky poi...

Page 404: ...up to hole when level plug is removed oil is properly filled If oil is found insufficient pour specified amount of specified oil referring to Transfer Oil Change in Section 7D or Rear Differential Oi...

Page 405: ...pulling hood release handle inside vehicle Also check that hood opens and closes smoothly and properly and hood locks securely when closed If any malfunction is found lubricate hinge and latch or repa...

Page 406: ...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 407: ...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 408: ...olant Ethylene glycol base coolant Antifreeze Anticorrosion coolant Brake fluid DOT 4 or SAE J1704 Manual transmission oil Refer to Manual transaxle Oil Change in Section 7A G10 engine 7A2 M13 engine...

Page 409: ...0B 30 MAINTENANCE AND LUBRICATION...

Page 410: ...stem Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring...

Page 411: ...HEATER AND VENTILATION General Description Major Components and Location NOTE For M13 and G10 engine models refer to the same section of the Service Manual mentioned in the FOREWORD of this service ma...

Page 412: ...otor 20 Supplementary heater if equipped 3 Ventilator duct 9 Side defroster air 15 Heater core 21 Supplementary heater controller if equipped 4 Defroster nozzle 10 Fresh air 16 Temperature control doo...

Page 413: ...cts some malfunction the diagnostic information as diagnostic trouble code DTC is stored in the memory of the controller By performing the DTC check procedure the diagnostic information can be known F...

Page 414: ...roken Repair damper Air ducts clogged Repair air ducts Heater radiator leaking or clogged Replace radiator Heater hoses leaking or clogged Replace hoses Thermostat faulty Check thermostat Fuse blown C...

Page 415: ...ature and heater relay 6 Blower fan motor resistor 13 Supplementary heater relay No 2 c To speedometer 7 Rear defogger relay 14 Supplementary heater relay No 3 RED GRN BLK 15A 60A 15A 60A c a b c a 25...

Page 416: ...lementary heater controller 2 NOTE This checking procedure is available only for Z13DT engine model with the supplementary heater system If more than two DTCs are detected only DTC which has the highe...

Page 417: ...wire at G92A 5 terminal open BLK wire at G92A 6 terminal open 3 2 3 2 7 BLK wire at G92A 5 terminal short BLK wire at G92A 6 terminal short 4 3 4 3 8 BLU YEL wire at G92 3 terminal open BLU YEL wire a...

Page 418: ...HEATER AND VENTILATION 1A 9 Example DTC No 2 2 of LED Flashing Pattern A First figure 1 LED ON a 0 3 seconds c 2 0 seconds B Second figure 2 LED OFF b 1 0 seconds A 1 2 a a a b a a a c B...

Page 419: ...Manual mentioned in the FOREWORD of this service manual 11 10 9 1 Heater core 4 Temperature control door assembly 7 Temperature control lever 10 Full hot switch if equipped 2 Blower motor assembly 5 M...

Page 420: ...ounting nut 3 7 Remove bolts 4 nuts 5 and screws 6 8 Remove heater unit 7 M13 and G10 Engine Models Refer to the same section of the Service Manual mentioned in the FOREWORD of this service manual Ins...

Page 421: ...y other damage Replace if needed Supplementary Heater Controller if equipped Z13DT Engine Removal 1 Remove air inlet box referring to Air Inlet Box in this sec tion 2 Remove supplementary heater contr...

Page 422: ...of the Service Manual mentioned in the FOREWORD of this service manual NOTE For M13 and G10 engine models refer to the same section of the Service Manual mentioned in the FOREWORD of this service man...

Page 423: ...1A 14 HEATER AND VENTILATION...

Page 424: ...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 WARNINGs could result in unintenti...

Page 425: ...IR CONDITIONING OPTIONAL General Description Major Components and Location NOTE For M13 and G10 engine models refer to the same section of the Service Manual mentioned in the FOREWORD of this service...

Page 426: ...e defroster air 17 Supplementary heater 2 Compressor 6 Suction hose 10 Center ventilation air 14 Fresh air 3 Condenser assembly 7 Liquid pipe 11 Foot air 15 Recirculation air 4 Receiver dryer 8 Expans...

Page 427: ...Magnet clutch faulty Check magnet clutch Drive belt loose or broken Adjust or replace drive belt Compressor faulty Check compressor ECM faulty Check ECM Radiator and condenser cooling fan motor inope...

Page 428: ...system cir cuit and replace compressor Cool air does not comes out only inter mittently Wiring connection faulty Repair as necessary Expansion valve faulty Check expansion valve Excessive moisture in...

Page 429: ...Main fuse box 7 A C switch 13 A C evaporator thermistor 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...

Page 430: ...EL BLU RED BLU BLK BLU YEL YEL WHT BLU BRN G88 1 G88 2 G88 3 BRN BRN 15 8 7 5 6 9 10 1 22 4 3 14 11 12 13 30A 30A 30A G92 5 G92 8 G92A 2 G92A 3 G92A 5 G92A 6 21 18 17 2 19 20 16 BLK BLK BRN YEL WHT RE...

Page 431: ...0 41 42 31 32 33 34 35 36 43 44 45 52 53 54 55 56 57 46 47 48 49 50 51 58 59 60 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90...

Page 432: ...nected Refer to next page and Inspection of ECM and Its Circuits in Sec tion 6 2 NOTE For G10 engine model refer to the same section of the Service Manual mentioned in the FOREWORD of this service man...

Page 433: ...ermistor 12 Radiator and condenser cooling fan motor relay c To IG COIL fuse 15A in circuit fuse box 3 Blower fan motor relay 8 ECT sensor 13 Radiator and condenser cooling fan motor d To FI fuse 20A...

Page 434: ...itch ON E21 15 GRN RED Evaporator thermistor temp input Ground to engine Fig B 2 0 2 3 V 1800 2200 Evaporator thermistor temp at Approx 25 C 77 F with ignition switch ON 3 5 3 6 V 6300 7000 Evaporator...

Page 435: ...ngine Model Refer to Water Pump Generator Drive Belt Removal and Instal lation in Section 6B3 Adjustment M13 Engine Model 1 Loosen tension pulley nut 3 2 Adjust belt tension by tighten or loosen tensi...

Page 436: ...g Operation Procedure for Charging A C with Refrigerant Z13DT Engine Model NOTE For M13 and G10 engine models refer to the same section of the Service Manual mentioned in the FOREWORD of this service...

Page 437: ...em install a blinding plug or cap to fitting of such line immediately When connecting hoses and pipes to each other respectively previously apply a few drops of compressor oil refrigerating oil to O r...

Page 438: ...eferring to Front Bumper and Rear Bumper in Section 9 4 Disconnect discharge hose 1 and liquid pipe 2 from con denser assembly 3 5 Remove condenser bracket bolts 4 6 Remove condenser assembly 3 M13 an...

Page 439: ...the FOREWORD of this service manual Inspection Z13DT Engine Model Check the following Condenser fins for leakage blockage and damage Condenser fittings for leakage Clogged condenser fins should be was...

Page 440: ...ection of the Service Manual mentioned in the FOREWORD of this service manual Installation Z13DT Engine Model Reverse removal sequence to install receiver dryer noting the following points If receiver...

Page 441: ...equipment referring to Operation Proce dure for Refrigerant Charge in this section 4 Remove heater control cable main harness clamp 5 Remove 20 pin connector from supplementary heater con troller and...

Page 442: ...cc of refrig erating oil to compressor suction side Install uniformly the padding 1 to installation hole Evacuate and charge system according to previously described procedure Adjust heater control ca...

Page 443: ...ses switch 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...

Page 444: ...e pressure sensor A C Relay Z13DT Engine Inspection 1 Disconnect negative cable at battery 2 Remove steering column hole cover 3 Remove A C relay 1 4 Check that there is no continuity between terminal...

Page 445: ...y is connected to terminals C and D If found defective replace Compressor Removal M13 Engine 1 Run engine at idle speed with air conditioning ON for 10 min utes After that stop the engine 2 Disconnect...

Page 446: ...DT Engine Model 1 Run engine at idle speed with air conditioning ON for 10 min utes After that stop the engine 2 Disconnect negative cable at battery 3 Remove front bumper by referring to Front Bumper...

Page 447: ...s section Adjust drive belt tension by referring to Compressor Drive Belt in this section Replenishing Compressor Oil Z13DT Engine Model It is necessary to replenish specified amount of compressor oil...

Page 448: ...e Service Manual mentioned in the FOREWORD of this service manual Magnet Clutch Inspection Z13DT Engine Model Check armature plate and magnet clutch pulley for wear and oil soaked conditions respectiv...

Page 449: ...ef Valve Z13DT Engine Model Inspection By using special tool check if there is refrigerant leakage If there is refrigerant leakage replace the compressor assembly Special tool A 09990 86011 Required S...

Page 450: ...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 451: ...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 452: ...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 453: ...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 454: ...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 455: ...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 456: ...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 457: ...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 458: ...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 459: ...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 460: ...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 461: ...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 462: ...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 463: ...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 464: ...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 465: ...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 466: ...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 467: ...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 468: ...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 469: ...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 470: ...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 471: ...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 472: ...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 473: ...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 474: ...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 475: ...3D 16 FRONT SUSPENSION...

Page 476: ...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 affect the perf...

Page 477: ...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 478: ...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 479: ...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 480: ...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 481: ...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 482: ...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 483: ...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 484: ...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 485: ...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 486: ...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 487: ...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 488: ...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 489: ...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 490: ...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 491: ...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 492: ...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 493: ...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 494: ...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 495: ...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 496: ...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 497: ...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 498: ...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 499: ...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 500: ...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 501: ...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 502: ...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 503: ...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 504: ...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 505: ...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 506: ...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 following...

Page 507: ...ug 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...

Page 508: ...Manual 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 refe...

Page 509: ...engine 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 fr...

Page 510: ...Oil 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 Che...

Page 511: ...Black 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...

Page 512: ...t big 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 driv...

Page 513: ...on 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 w...

Page 514: ...oint 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 Rem...

Page 515: ...1 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...

Page 516: ...wheel 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...

Page 517: ...A T 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...

Page 518: ...nd 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 posit...

Page 519: ...Grease 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...

Page 520: ...ight 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 s...

Page 521: ...oot 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...

Page 522: ...press 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 09...

Page 523: ...31 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...

Page 524: ...l seal 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 C...

Page 525: ...4A 20 FRONT DRIVE SHAFT G10 M13 ENGINE MODELS...

Page 526: ...4A3 12 Tightening Torque Specification 4A3 12 Special Tools 4A3 12 General Description A constant velocity cross groove joint is used on the differential side of the left side drive shaft assembly A...

Page 527: ...ive Shaft Assembly Construction 1 Transaxle 6 Stabilizer mount bracket bolt 11 Drive shaft washer 2 Drive shaft assembly 7 Tie rod end nut Do not reuse 3 Tie rod end 8 Ball stud bolt Tightening torque...

Page 528: ...od end 1 from steering knuckle 2 by using puller 3 8 Using tire lever 1 pull out drive shaft joint 2 so as to release snap ring fitting of joint spline at differential side 9 Remove two stabilizer mou...

Page 529: ...o Manual Transaxle Oil Change in Section 7A3 Check toe setting and adjust referring to Toe Setting and Toe Adjustment in Section 3 Front Drive Shaft Assembly Inspection Inspection Check boots for brea...

Page 530: ...joint boot 14 Circlip 1 Wheel side joint housing constant velocity ball joint Apply dark brown grease included in spare parts 8 Cross groove joint boot 15 Differential side joint housing Tripod joint...

Page 531: ...e out tripod joint housing 2 3 Remove grease from shaft and then take off snap ring 1 by using special tool Special tool A 09900 06107 4 Remove tripod joint 1 by using 3 arms puller 2 5 Remove differe...

Page 532: ...e 8 Remove wheel side boot small band then pull out wheel side boot from shaft For Cross groove joint type left side 1 Remove differential side boot big band 1 by using flat end rod or the like 2 Remo...

Page 533: ...band without joint a Cut boot big band using a iron saw or a nipper with care not to damage wheel side joint housing For boot big band with joint a Remove boot big band by using flat end rod or the li...

Page 534: ...ward rotation 2 as shown in figure 7 Confirm that wheel side boot is not stretched or contracted and then fasten boot big band 1 securely using special tool Special tool A 09943 55010 or 09943 57010 8...

Page 535: ...are parts Grease color Black Amount Approximately 160 g 5 6 oz 14 Fit boot to grooves of shaft and housing and adjust boot length to specification below Insert screwdriver into boot and allow air to e...

Page 536: ...ne of drive shaft and drive onto drive shaft by using plastic hammer until circlip engages 6 Fit boot to grooves of shaft and housing and adjust length a to specification below Insert screwdriver into...

Page 537: ...orma tion Replace as necessary Tightening Torque Specification Special Tools Fastening part Tightening torque N m kg m lb ft Ball stud bolt 60 6 0 43 5 Tie rod end nut 40 4 0 29 0 Drive shaft nut 175...

Page 538: ...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 539: ...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 540: ...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 541: ...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 542: ...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 543: ...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 544: ...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 545: ...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 546: ...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 547: ...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 548: ...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 549: ...5 6 BRAKES...

Page 550: ...k must be 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...

Page 551: ...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 552: ...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 553: ...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 554: ...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 555: ...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 556: ...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 557: ...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 558: ...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 559: ...5B 6 FRONT BRAKE...

Page 560: ...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 561: ...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 562: ...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 563: ...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 564: ...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 565: ...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 566: ...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 567: ...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 568: ...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 569: ...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 570: ...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 571: ...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 572: ...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 573: ...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 574: ...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 575: ...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 576: ...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 577: ...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 578: ...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 579: ...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 580: ...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 581: ...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 582: ...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 583: ...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 584: ...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 585: ...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 586: ...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 587: ...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 588: ...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 589: ...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 590: ...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 591: ...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 592: ...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 593: ...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 594: ...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 595: ...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 596: ...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 597: ...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 598: ...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 599: ...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 600: ...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 601: ...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 602: ...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 603: ...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 604: ...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 605: ...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 606: ...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 607: ...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 608: ...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 609: ...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 610: ...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 611: ...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 612: ...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 613: ...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 614: ...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 615: ...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 616: ...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 617: ...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 618: ...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 619: ...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 620: ...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 621: ...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 622: ...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 623: ...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 624: ...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 625: ...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 626: ...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 627: ...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 628: ...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 629: ...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 630: ...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 631: ...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 632: ...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 633: ...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 634: ...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 635: ...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 636: ...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 637: ...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 638: ...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 639: ...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 640: ...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 641: ...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 642: ...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 643: ...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 644: ...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 645: ...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 646: ...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 647: ...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 648: ...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 649: ...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 650: ...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 651: ...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 652: ...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 653: ...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 654: ...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 655: ...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 656: ...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 657: ...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 658: ...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 659: ...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 660: ...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 661: ...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 662: ...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 663: ...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 664: ...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 665: ...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 666: ...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 667: ...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 668: ...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 669: ...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 670: ...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 671: ...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 672: ...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 673: ...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 674: ...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 675: ...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 676: ...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 677: ...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 678: ...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 679: ...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 680: ...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 681: ...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 682: ...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 683: ...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 684: ...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 685: ...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 686: ...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 687: ...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 688: ...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 689: ...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 690: ...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 691: ...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 692: ...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 693: ...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 694: ...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 695: ...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 696: ...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 697: ...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 698: ...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 699: ...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 700: ...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 701: ...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 702: ...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 703: ...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 704: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS M13 ENGINE 6 2 133 A Fig 1 for Step 5 B Fig 2 for Step 9...

Page 705: ...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 706: ...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 707: ...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 708: ...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 709: ...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 710: ...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 711: ...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 712: ...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 713: ...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 714: ...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 715: ...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 716: ...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 717: ...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 718: ...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 719: ...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 720: ...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 721: ...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 722: ...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 723: ...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 724: ...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 725: ...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 726: ...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 727: ...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 728: ...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 729: ...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 730: ...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 731: ...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 732: ...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 733: ...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 734: ...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 735: ...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 736: ...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 737: ...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 738: ...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 739: ...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 740: ...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 741: ...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 742: ...Light 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 engi...

Page 743: ...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 744: ...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 745: ...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 746: ...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 747: ...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 748: ...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 749: ...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 750: ...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 751: ...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 752: ...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 753: ...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 754: ...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 755: ...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 756: ...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 757: ...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 758: ...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 759: ...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 760: ...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 761: ...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 762: ...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 763: ...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 764: ...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 765: ...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 766: ...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 767: ...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 768: ...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 769: ...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 770: ...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 771: ...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 772: ...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 773: ...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 774: ...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 775: ...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 776: ...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 777: ...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 778: ...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 779: ...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 780: ...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 781: ...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 782: ...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 783: ...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 784: ...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 785: ...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 786: ...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 787: ...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 788: ...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 789: ...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 790: ...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 791: ...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 792: ...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 793: ...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 794: ...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 795: ...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 796: ...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 797: ...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 798: ...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 799: ...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 800: ...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 801: ...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 802: ...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 803: ...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 804: ...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 805: ...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 806: ...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 807: ...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 808: ...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 809: ...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 810: ...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 811: ...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 812: ...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 813: ...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 814: ...ENGINE MECHANICAL M13 ENGINE 6A2 79 Main Bearings Crankshaft and Cylinder Block Components...

Page 815: ...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 816: ...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 817: ...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 818: ...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 819: ...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 820: ...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 821: ...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 822: ...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 823: ...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 824: ...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 825: ...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 826: ...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 827: ...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 828: ...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 829: ...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 830: ...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 831: ...6A2 96 ENGINE MECHANICAL M13 ENGINE...

Page 832: ...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 833: ...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 834: ...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 835: ...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 836: ...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 837: ...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 838: ...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 839: ...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 840: ...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 841: ...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 842: ...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 843: ...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 844: ...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 845: ...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 846: ...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 847: ...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 848: ...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 849: ...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 850: ...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 851: ...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 852: ...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 853: ...6E2 4 ENGINE AND EMISSION CONTROL SYSTEM M13 ENGINE Engine and Emission Control System Flow Diagram...

Page 854: ...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 855: ...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 856: ...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 857: ...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 858: ...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 859: ...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 860: ...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 861: ...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 862: ...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 863: ...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 864: ...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 865: ...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 866: ...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 867: ...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 868: ...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 869: ...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 870: ...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 871: ...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 872: ...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 873: ...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 874: ...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 875: ...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 876: ...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 877: ...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 878: ...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 879: ...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 880: ...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 881: ...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 882: ...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 883: ...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 884: ...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 885: ...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 886: ...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 887: ...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 888: ...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 889: ...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 890: ...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 891: ...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 892: ...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 893: ...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 894: ...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 895: ...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 896: ...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 897: ...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 898: ...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 899: ...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 900: ...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 901: ...on 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 Po...

Page 902: ...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 903: ...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 904: ...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 905: ...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 906: ...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 907: ...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 908: ...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 909: ...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 910: ...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 911: ...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 912: ...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 913: ...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 914: ...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 915: ...6H 4 CHARGING SYSTEM G10 M13 ENGINES...

Page 916: ...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 917: ...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 918: ...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 919: ...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 920: ...bly and 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 Disa...

Page 921: ...g mechanism 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 shaf...

Page 922: ...gear 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 Count...

Page 923: ...5th 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 Count...

Page 924: ...l cables 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...

Page 925: ...GL 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...

Page 926: ...d Remounting 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...

Page 927: ...control 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...

Page 928: ...pin 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 Remo...

Page 929: ...le 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 Wi...

Page 930: ...sor 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 C...

Page 931: ...Apply 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 negat...

Page 932: ...bolts 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...

Page 933: ...ing 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...

Page 934: ...t each 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...

Page 935: ...7A2 16 MANUAL TRANSAXLE M13 ENGINE MODEL Transaxle Case Components...

Page 936: ...erential 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 pa...

Page 937: ...s 1 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...

Page 938: ...revent 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 pain...

Page 939: ...g synchronizer 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 c...

Page 940: ...4 and 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...

Page 941: ...1 Synchronizer 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 pr...

Page 942: ...aft 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 a...

Page 943: ...3 N 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 Assembl...

Page 944: ...ift 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 ou...

Page 945: ...verse 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 inp...

Page 946: ...ll 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...

Page 947: ...p switch 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 745...

Page 948: ...as 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 a...

Page 949: ...7A2 30 MANUAL TRANSAXLE M13 ENGINE MODEL Input Counter Shaft Components...

Page 950: ...ershaft 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 2...

Page 951: ...nts 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 g...

Page 952: ...ing 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 h...

Page 953: ...5 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...

Page 954: ...right 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...

Page 955: ...les 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...

Page 956: ...stalled 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 f...

Page 957: ...aring 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 al...

Page 958: ...rts 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 N...

Page 959: ...Apply 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 A...

Page 960: ...e component 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...

Page 961: ...r disassembly 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 ge...

Page 962: ...and 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 aga...

Page 963: ...bolt 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...

Page 964: ...bolt 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 Revers...

Page 965: ...10 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 hol...

Page 966: ...Table A 2 No Lock Up Occurs 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...

Page 967: ...ng 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 Transmissio...

Page 968: ...rom 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 in...

Page 969: ...aft 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...

Page 970: ...O D 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 Ge...

Page 971: ...orward 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 clu...

Page 972: ...AUTOMATIC TRANSAXLE M13 ENGINE MODEL 7B1 7 Table of Component Operation...

Page 973: ...7B1 8 AUTOMATIC TRANSAXLE M13 ENGINE MODEL 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 974: ...valves 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...

Page 975: ...oid 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 RE...

Page 976: ...on 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...

Page 977: ...than 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...

Page 978: ...ly 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 under...

Page 979: ...hecked 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...

Page 980: ...ure 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 bef...

Page 981: ...unction 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...

Page 982: ...uble 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 des...

Page 983: ...l Confirmation 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 ch...

Page 984: ...UTOMATIC TRANSAXLE M13 ENGINE MODEL 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 985: ...amp 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...

Page 986: ...ch 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 a...

Page 987: ...ft 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...

Page 988: ...th 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 E...

Page 989: ...o O 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 contro...

Page 990: ...ressure 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...

Page 991: ...oseness 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 fricti...

Page 992: ...e shooting 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 St...

Page 993: ...ty 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...

Page 994: ...t speed 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 refe...

Page 995: ...ransmission 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 circu...

Page 996: ...unction 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...

Page 997: ...ssembly 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 ref...

Page 998: ...sive 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 N...

Page 999: ...tary 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...

Page 1000: ...of 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...

Page 1001: ...emperature 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...

Page 1002: ...ile 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...

Page 1003: ...brake 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 oper...

Page 1004: ...ible 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 t...

Page 1005: ...a for 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 cont...

Page 1006: ...lug 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...

Page 1007: ...e body assembly Lower than standard level in each range Malfunction of pressure control solenoid valve Low line pressure Inspect If NG replace valve body assembly Faulty valve body component Replace v...

Page 1008: ...to 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 gro...

Page 1009: ...717 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 con...

Page 1010: ...rangement 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 b...

Page 1011: ...coupler 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 satisfa...

Page 1012: ...nds 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...

Page 1013: ...connection 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 Circu...

Page 1014: ...nnectors 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 ind...

Page 1015: ...unning 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...

Page 1016: ...d E12 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...

Page 1017: ...r Step 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...

Page 1018: ...ement 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 fast...

Page 1019: ...18 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 o...

Page 1020: ...r Step 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...

Page 1021: ...re 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 mo...

Page 1022: ...nectors 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 cir...

Page 1023: ...onnector 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...

Page 1024: ...G Short 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...

Page 1025: ...arrangement of TCM connector viewed from harness side DTC DETECTING CONDITION TROUBLE AREA No input shaft speed sensor signal is detected although output shaft speed sensor signals are detected Input...

Page 1026: ...etween 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 inp...

Page 1027: ...tor 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...

Page 1028: ...connected 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 TC...

Page 1029: ...in 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...

Page 1030: ...although 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...

Page 1031: ...nction 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 al...

Page 1032: ...top 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...

Page 1033: ...times 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 termina...

Page 1034: ...4 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 Repl...

Page 1035: ...Troubleshooting 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 outp...

Page 1036: ...3 Check 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 I...

Page 1037: ...s too 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...

Page 1038: ...ion 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...

Page 1039: ...nector 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...

Page 1040: ...FF 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 circu...

Page 1041: ...M A 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...

Page 1042: ...dy 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 Ch...

Page 1043: ...TCM sets DTC P1703 DTC Troubleshooting DTC DETECTING CONDITION TROUBLE AREA Calculation of current data stored in TCM is not correct comparing with pre stored checking data in TCM TCM Step Action Yes...

Page 1044: ...A 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 althoug...

Page 1045: ...ween 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...

Page 1046: ...A T 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 althoug...

Page 1047: ...d valve 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 sol...

Page 1048: ...yed 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 incr...

Page 1049: ...s in 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 SIGN...

Page 1050: ...ricity 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...

Page 1051: ...nal 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 o...

Page 1052: ...be 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...

Page 1053: ...itch 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...

Page 1054: ...l is 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 Igniti...

Page 1055: ...d up 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 wa...

Page 1056: ...out 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 H...

Page 1057: ...n fluid 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 trans...

Page 1058: ...in 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 W...

Page 1059: ...d position 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 Conn...

Page 1060: ...lect 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 i...

Page 1061: ...ift 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 posit...

Page 1062: ...sensor 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 Tig...

Page 1063: ...al 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 sen...

Page 1064: ...peed 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...

Page 1065: ...or 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 termin...

Page 1066: ...egative 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...

Page 1067: ...solenoid 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...

Page 1068: ...5 psi 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...

Page 1069: ...as 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 solenoi...

Page 1070: ...ying 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...

Page 1071: ...tening 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...

Page 1072: ...g regulated 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 suppl...

Page 1073: ...mbly 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 As...

Page 1074: ...on 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 En...

Page 1075: ...panel 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...

Page 1076: ...y in 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...

Page 1077: ...on 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 t...

Page 1078: ...m differential 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 s...

Page 1079: ...pecial 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 Sh...

Page 1080: ...xle 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...

Page 1081: ...plate 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...

Page 1082: ...ve 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 Ti...

Page 1083: ...e Body 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 di...

Page 1084: ...rr 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 ge...

Page 1085: ...s so 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 an...

Page 1086: ...AUTOMATIC TRANSAXLE M13 ENGINE MODEL 7B1 121...

Page 1087: ...e gear 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...

Page 1088: ...torque 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 straig...

Page 1089: ...4 8 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...

Page 1090: ...rature 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 re...

Page 1091: ...e governor 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 senso...

Page 1092: ...r 1 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...

Page 1093: ...ut 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...

Page 1094: ...race 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 ma...

Page 1095: ...reservoir 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 n...

Page 1096: ...er 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...

Page 1097: ...4 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 o...

Page 1098: ...ar 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...

Page 1099: ...on 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...

Page 1100: ...uter 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 bot...

Page 1101: ...0 031 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...

Page 1102: ...ic 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 o...

Page 1103: ...remove 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 Bol...

Page 1104: ...ring 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...

Page 1105: ...eat 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...

Page 1106: ...or 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...

Page 1107: ...2 Remove 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...

Page 1108: ...en 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 driv...

Page 1109: ...uld 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...

Page 1110: ...1 to specification Tightening torque Oil pump subassembly bolt a 10 N m 1 0 kg m 7 5 lb ft 4 After applying A T fluid to new O ring install it to oil pump body 5 Check drive gear for smooth rotation...

Page 1111: ...ft 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 sna...

Page 1112: ...fied 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 p...

Page 1113: ...Discs 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 subasse...

Page 1114: ...ocedure 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 dir...

Page 1115: ...09900 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...

Page 1116: ...Reverse 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 dis...

Page 1117: ...Blow 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 forw...

Page 1118: ...nsaxle 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...

Page 1119: ...ve 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 in...

Page 1120: ...lip 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 pr...

Page 1121: ...talling 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 an...

Page 1122: ...replace 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...

Page 1123: ...minary 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 pro...

Page 1124: ...1 Apply compressed air 400 800 kPa 4 8 kg cm2 57 113 psi to oil hole 1 of 2nd brake cylinder 3 to remove 2nd brake piston 2 2 Remove inner O ring 1 and outer O ring 2 1 2nd brake cylinder 4 Outer O r...

Page 1125: ...isassembly 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 c...

Page 1126: ...2nd 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 transax...

Page 1127: ...essed 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...

Page 1128: ...with 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 f...

Page 1129: ...original 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...

Page 1130: ...bearing 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 bearin...

Page 1131: ...boils 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...

Page 1132: ...Install 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 S...

Page 1133: ...e by 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 Be...

Page 1134: ...ess 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...

Page 1135: ...olenoid 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 CAUT...

Page 1136: ...ENGINE MODEL 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...

Page 1137: ...tical 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 b...

Page 1138: ...de 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...

Page 1139: ...ng 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...

Page 1140: ...lubrication 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 dif...

Page 1141: ...88220 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 Sp...

Page 1142: ...erter 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 bear...

Page 1143: ...Thickness 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...

Page 1144: ...ith 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...

Page 1145: ...ven 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 assemblin...

Page 1146: ...nd 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...

Page 1147: ...plate 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 dam...

Page 1148: ...verse 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 7...

Page 1149: ...00 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 i...

Page 1150: ...mbly 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 p...

Page 1151: ...only 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 Ap...

Page 1152: ...ring 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 st...

Page 1153: ...embly 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...

Page 1154: ...intermediate 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 c...

Page 1155: ...forward 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 asse...

Page 1156: ...Piston 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...

Page 1157: ...all 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 Instal...

Page 1158: ...aring 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...

Page 1159: ...2 If 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...

Page 1160: ...63 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 f...

Page 1161: ...n diameter 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...

Page 1162: ...to 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...

Page 1163: ...r to 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 4...

Page 1164: ...Tightening 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 Flu...

Page 1165: ...ansaxle 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...

Page 1166: ...in 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 Tighteni...

Page 1167: ...que 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...

Page 1168: ...r bolt 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...

Page 1169: ...13 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...

Page 1170: ...compressor 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 Differen...

Page 1171: ...erial 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 990...

Page 1172: ...firm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section befo...

Page 1173: ...or 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 Tight...

Page 1174: ...pin 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...

Page 1175: ...ewdriver 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...

Page 1176: ...2 Pedal 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 o...

Page 1177: ...rease 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 c...

Page 1178: ...flywheel 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 bet...

Page 1179: ...r abnormal 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 Flywhe...

Page 1180: ...nsaxle 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 tu...

Page 1181: ...923 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 pi...

Page 1182: ...0 Special 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...

Page 1183: ...5 Clutch 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 ou...

Page 1184: ...0 09923 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 099...

Page 1185: ...7C 14 CLUTCH G10 M13 ENGINE MODELS...

Page 1186: ...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 1187: ...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 1188: ...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 1189: ...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 1190: ...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 1191: ...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 1192: ...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 1193: ...7D 8 TRANSFER...

Page 1194: ...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 1195: ...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 1196: ...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 1197: ...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 1198: ...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 1199: ...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 1200: ...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 1201: ...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 1202: ...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 1203: ...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 1204: ...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 1205: ...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 1206: ...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 1207: ...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 1208: ...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 1209: ...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 1210: ...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 1211: ...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 1212: ...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 1213: ...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 1214: ...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 1215: ...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 1216: ...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 1217: ...8B 4 LIGHTING SYSTEM...

Page 1218: ...confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system section...

Page 1219: ...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 1220: ...se to circuit for short Wiring or grounding faulty Repair circuit Engine oil level switch faulty Check engine oil level switch refer ring to Engine Oil Level Switch in Section 6E3 Combination meter fa...

Page 1221: ...ition and goes 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 refe...

Page 1222: ...warning light operation for Z13DT engine Engine Oil Level Switch for Z13DT Engine If Equipped Inspection Check engine oil level switch referring to Engine Oil Level Switch in Section 6E3 Float positi...

Page 1223: ...8C 6 INSTRUMENTATION DRIVER INFORMATION...

Page 1224: ...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 Section 10B in order to c...

Page 1225: ...ified 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 value...

Page 1226: ...on 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...

Page 1227: ...o step 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...

Page 1228: ...dition 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...

Page 1229: ...fects 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 li...

Page 1230: ...condition 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...

Page 1231: ...ition 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...

Page 1232: ...witch 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 volta...

Page 1233: ...osition 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 corr...

Page 1234: ...age 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 1...

Page 1235: ...8G 12 IMMOBILIZER CONTROL SYSTEM G10 M13 ENGINE MODELS...

Page 1236: ...es 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 Refer to Air Bag System Com...

Page 1237: ...ing to specified algorithm On the other hand transponder also calculates received variable with SKC stored in its memory by means of same algorithm and sends back to ECM 4 Only when ECM transponder ca...

Page 1238: ...ON but the engine at stop regardless of the condition of the engine and emission control system ECM indicates whether some trouble has occurred in the immobilizer control system or not by turning ON...

Page 1239: ...ked by using SUZUKI scan tool Before using scan tool read its Operator s Instruction Manual Carefully to have good understanding as to what functions are available and how to use it Be sure to read Pr...

Page 1240: ...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 1241: ...condition 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...

Page 1242: ...ct transponder detected Unregistered transponder is detected B3061 Transponder communication fail Incorrect signal or no response from transpon der B3077 Read only transponder detected Transponder not...

Page 1243: ...ked at wiring connectors by measuring voltage CAUTION Immobilizer Control Module can not be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to Immobilizer Control Module w...

Page 1244: ...ion switch signal 10 14 V Ignition switch at ON position 0 1 V Ignition switch at OFF position 6 WHT RED Data link connector Serial data line 10 14 V SUZUKI scan tool connected 0 1 V SUZUKI scan tool...

Page 1245: ...in good condition Go to Step 2 Repair or replace 2 1 Ignition switch at OFF position 2 Disconnect connector from Immobilizer Control Module 3 Check for proper connection to Immobilizer Control Module...

Page 1246: ...OFF position 2 Disconnect connector from ECM 3 Check for proper connection to ECM at G88 88 terminal Is it in good condition Go to Step 2 Repair or replace 2 1 Connect connector to ECM 2 Measure volt...

Page 1247: ...connect connector from ECM 3 Check for proper connection to ECM at E88 88 terminal Is it in good condition Go to Step 2 Repair or replace 2 1 Connect connector to ECM 2 Measure voltage between G17 7 t...

Page 1248: ...or position 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...

Page 1249: ...sary during trouble diagno sis register FIX CODE FC and SECRET KEY CODE SKC to Immobilizer Control Module by performing the following proce dure Perform IMM Cont Register Secret Key Code and Register...

Page 1250: ...ZUKI scan tool See NOTE below NOTE 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 c...

Page 1251: ...8G3 16 IMMOBILIZER CONTROL SYSTEM Z13DT ENGINE MODEL...

Page 1252: ...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 1253: ...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 1254: ...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 1255: ...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 1256: ...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 1257: ...9 6 BODY SERVICE...

Page 1258: ...Prepared by 1st Ed August 2003 Printed in Belgium Printed January 2004 910...

Page 1259: ...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 1260: ...ricant sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product infor mation available at the time of...

Page 1261: ......

Page 1262: ...ystem 10B 3C 10A Power Steering System 3B1 3D 10B Steering Wheel and Column 3C 3E Front Suspension 3D 3F Rear Suspension 3E Wheels and Tires 3F 4 DRIVE SHAFT AND PROPELLER SHAFT Front Drive Shaft 4 5A...

Page 1263: ......

Page 1264: ...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 use a replacement part of lesser quality...

Page 1265: ...e 4 Rear shock absorber 13 Oil seal protector 22 Brake back plate bolt 5 Lateral rod 14 LSPV bracket only vehicle with LSPV 23 Bearing retainer ring without ABS 6 Trailing arm 15 Brake back plate 24 B...

Page 1266: ...INSTALLATION 1 Using special tool drive in new oil seal 1 until it contacts oil seal protector 2 in axle housing Special tool A 09944 67010 B 09924 74510 A Grease 99000 25010 2 For procedure hereafte...

Page 1267: ...ial Tool 09927 18411 09913 50121 09942 15511 09943 17912 Universal puller Oil seal remover Sliding hammer Brake drum remover 09921 57810 09944 67010 09924 74510 Bearing remover Oil seal installer Bear...

Page 1268: ...em section before performing service on or 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 i...

Page 1269: ...treme right and extreme left turn conditions If it does at any point remove and correct Fill and maintain brake fluid level in reservoir Bleed brake system 2 Perform brake test and check installed par...

Page 1270: ...om master cylinder secondary to ABS hydraulic unit 6 To rear brakes B For right hand steering vehicle 3 From ABS hydraulic unit to left front brake Tightening Torque a n Clamp 4 From ABS hydraulic uni...

Page 1271: ...or vehicle without ABS A For left hand steering vehicle 2 From master cylinder secondary to left front brake B For right hand steering vehicle 3 To rear brakes a g Clamp Tightening Torque 1 From maste...

Page 1272: ...rformance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not u...

Page 1273: ...que values specified are for dry unlubricated fasteners 1 Guiding pin 6 Piston boot 13 Caliper pin bolt 1 1 Locking pin Apply specified rubber grease to guiding and locking pins surfaces for smooth mo...

Page 1274: ...in Service limit 8 2 mm 0 32 in NOTE Hang removed caliper with a wire hook 2 or the like so as to prevent brake hose from bending and twisting excessively or being pulled Don t operate brake pedal wit...

Page 1275: ...unt a dial indicator as shown and measure the runout at 20 mm 0 79 in from the outer edge of the disc Limit on disc deflection 0 15 mm 0 006 in Cylinder Slide Guiding and Locking Pins Check guiding pi...

Page 1276: ...letion of installation perform brake test CAUTION Observe CAUTION at the beginning of ON VEHICLE SER VICE NOTE Install pad with sensor 2 to vehicle center side Note the direction of each pad as shown...

Page 1277: ...l Recommended SUZUKI product Part Number Use Brake fluid DOT4 To fill master cylinder reservoir To clean and apply to inner parts of caliper and wheel cylinder when they are disassembled Rubber grease...

Page 1278: ...mponents 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 injury T...

Page 1279: ...ied are for dry unlubricated fasteners 1 Brake back plate Clean back plate and apply thin coat of Bentonite base brake grease anti squeal agent to six surfaces on which shoe rims rest 7 Adjuster sprin...

Page 1280: ...ease 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 and loosen parking brake cable adju...

Page 1281: ...2 using special tool if equipped with ABS Special tool A 09913 75520 B 09913 65135 INSPECTION Sensor Ring Check ring serration teeth for being missing damaged or deformed Check sensor ring for being...

Page 1282: ...ill probably be neces sary to resurface drum braking surface If brake linings are slightly worn and drum is grooved drum should be polished with fine emery cloth but should no be turned Brake Shoe Whe...

Page 1283: ...ameter a of brake shoes If it is not within value as specified below adjust it to specification by turning adjuster 4 Install brake drum after making sure that inside of brake drum and brake shoes are...

Page 1284: ...wheel and tighten wheel nuts so specified torque Tightening torque b 85 N m 8 5 kg m 61 5 lb ft 12 Check to ensure that brake drum is free from dragging and proper braking is obtained Then remove veh...

Page 1285: ...oe lever for smooth movement along shoe rim If defective correct or replace Brake Adjuster Strut and Adjuster Actuator Check ratchet 1 of adjuster and adjuster actuator 2 for opera tion wear or damage...

Page 1286: ...on which shoe rims rest A Bentonite base brake grease Anti squeal agent 2 Apply thinly grease between actuator and shoe rim and at actuator pivot point A Bentonite base brake grease Anti squeal agent...

Page 1287: ...or damage INSTALLATION 1 Take off bleeder plug cap from brake pipe and connect pipe for pipes to wheel cylinder just enough to prevent fluid from leaking 2 Tighten wheel cylinder 1 to brake back plate...

Page 1288: ...cable securing clip 1 and discon nect brake cable 2 from brake back plate 3 5 Remove brake back plate 1 from rear axle INSTALLATION 1 Apply water tight sealant to mating surfaces of brake back plate...

Page 1289: ...ith brake fluid and bleed brake system For bleeding operation see BLEEDING BRAKES in SECTION 5 8 Install wheel and tighten wheel nuts to specified torque Tightening torque a 85 N m 8 5 kg m 61 5 lb ft...

Page 1290: ...and rear wheel cylinder To apply to contact position of parking brake cable and back plate To apply to mating surfaces of brake back plate and rear axle Bentonite base brake grease Anti squeal agent...

Page 1291: ...5C 14 PARKING AND REAR BRAKE...

Page 1292: ...Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components...

Page 1293: ...C C1052 Right Rear Outlet Solenoid Circuit 5E 19 DTC C1056 Left Rear Outlet Solenoid Circuit 5E 19 DTC C1057 Power Source Circuit 5E 20 DTC C1061 ABS Pump Motor Circuit 5E 21 DTC C1063 ABS Fail Safe F...

Page 1294: ...l 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 prevent wheel from locking AB...

Page 1295: ...5E 4 ANTILOCK BRAKE SYSTEM ABS System Schematic...

Page 1296: ...dule 8 Brake warning lamp 14 Wheel speed sensor Left front 3 ABS hydraulic unit 9 Lamp driver module 15 Wheel speed sensor Right rear 4 Fail safe relay 10 ECM Combination meter and P S control module...

Page 1297: ...5E 6 ANTILOCK BRAKE SYSTEM ABS System Circuit...

Page 1298: ...27 To main fuse box Wire color B Black Br Brown R Y Red Yellow B G Black Green G Green V Violet B R Black Red G R Green Red V Y Violet Yellow B W Black White G W Green White W White B Y Black Yellow...

Page 1299: ...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 is w...

Page 1300: ...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 1301: ...ic unit control module connector at termi nals E99 4 E99 20 and E99 26 3 If OK then ignition switch ON and measure voltage at terminal E99 20 of connector Is it 10 14 V Go to Step 4 W B circuit open 4...

Page 1302: ...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 1303: ...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 1304: ...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 1305: ...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 circuit C1046...

Page 1306: ...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 case clear the DTC and check again INSPECTION 1 Ignition switch OFF 2 Check for prop...

Page 1307: ...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 1308: ...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 1309: ...nuckle Is it OK Go to Step 7 Replace ABSwheel 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 1310: ...nit 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...

Page 1311: ...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 1312: ...unit control module connector Step Action Yes No 1 1 Check pump motor referring to ABS HYDRAULIC UNIT OPERATION CHECK in this section Is it in good condition Check terminal E99 14 connection If connec...

Page 1313: ...unit control module connector 5 Fail safe FET 2 ABS hydraulic unit control module assembly 4 To solenoid valves Step Action Yes No 1 Check battery voltage Is it about 11 V or higher Go to Step 2 Check...

Page 1314: ...ail safe FET 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 unit...

Page 1315: ...STEM ABS On Vehicle Service Precautions When connector is connected to ABS hydraulic unit control mod ule assembly do not disconnect connectors of sensors with igni tion switch ON Then DTC will be set...

Page 1316: ...g 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 p...

Page 1317: ...move one screw and disconnect take out ABS hydraulic unit control module assembly 1 from bracket using screw driver 2 2 1 NOTE Put bleeder plug cap onto pipe to prevent fluid from spill ing Do not all...

Page 1318: ...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 sec tion A RH B LH 3 3 A B b c b b a a...

Page 1319: ...5E 28 ANTILOCK BRAKE SYSTEM ABS...

Page 1320: ...rder to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service in air bag system s...

Page 1321: ...bly 2 5 Remove ignition coil bolts 1 and then pull out ignition coil assembly 6 Measure secondary coil for resistance Secondary coil resistance 7 1 9 5 k at 20 C 68 F If resistance is out of specifica...

Page 1322: ...Power door lock system operation inspection Power door lock system circuit inspection Power door lock system circuit check Key cylinder switch 8D 3 Power door lock actuator 8D 3 Keyless Entry System...

Page 1323: ...ND LOCKS Keyless entry system operation inspection Keyless entry system circuit inspection Keyless entry system circuit check Transmitter Power Door Mirror Control System If Equipped Mirror switch Doo...

Page 1324: ...minals to the door lock actuator terminals shown below If it does not operate as specified in table below replace door lock actuator For Front Rear Door For Back Door A Lock B Neutral C Lock A B C a b...

Page 1325: ...8D 4 WINDOWS MIRRORS SECURITY AND LOCKS...

Page 1326: ...r 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 system comp...

Page 1327: ...9 Reclining bolt 2 Seat back 6 Tray bracket 10 Bracket bolt 3 Head rest 7 Tray 11 Reclining bolt 4 Cover 8 Seat adjuster bolt Tightening Torque 3 2 9 35 N m 3 5 kg m 9 35 N m 3 5 kg m 11 16 N m 1 6 kg...

Page 1328: ...Seat back bolt 12 Rear seat striker bracket bolt 3 Head restraint 8 Seat back bolt Tightening Torque 4 Rear seat striker bracket 9 Folding bolt 5 rear seat striker 10 Folding bolt 1 2 3 4 5 6 8 7 7 7...

Page 1329: ...d 2 from outside handle 6 Disconnect door lock control rod 3 7 Disconnect door lock motor lead wire if equipped 8 Remove door lock nob 4 9 Loosen door lock mounting screw 5 door lock mounting bolt 6 v...

Page 1330: ...outer panel or body outer panel surface 3 as shown In order to correctly obtain door lock operates increase or decrease number of shims inserted between body and striker 1 to adjust it INSPECTION Chec...

Page 1331: ...d 1 and door lock con trol rod 2 3 Loosen door lock mounting screw 3 door lock actuator screw 5 if equipped power door lock and remove door lock assembly 4 INSTALLATION Reverse removal sequence to ins...

Page 1332: ...tem inoperative Either of these two conditions may result in severe injury The procedures in this section must be followed in the order listed to temporarily disable the air bag system and prevent fal...

Page 1333: ...ract even a little Then the webbing can not be pulled out any further unless it is wound all the way back into the retractor which releases the lock and allows the webbing to be pulled out Seat belt w...

Page 1334: ...the system inoperative Either of these two conditions may result in severe injury The procedures in this section must be followed in the order listed to disable the air bag system temporarily and prev...

Page 1335: ...work 1 Upper anchor 4 Rear seat belt with A ELR 7 Buckle for rear center seat belt 2 Lower anchor 5 Buckle for rear seat belt 8 Connector for rear center seat belt 3 Retractor assembly 6 Rear center s...

Page 1336: ...et it retract a little and try to pull it again It should be pulled out smoothly that is it should not be locked at this time INSTALLATION Install in reverse order of removal noting the following Seat...

Page 1337: ...10A 4 SEAT BELT...

Page 1338: ...Prepared by Service Department 1st Ed June 2002 Printed in Hungary Printing August 2002 80...

Page 1339: ...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 1340: ...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 1341: ......

Page 1342: ...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 1343: ......

Page 1344: ...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 1345: ...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 1346: ...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 1347: ...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 1348: ...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 1349: ...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 1350: ...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 1351: ...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 1352: ...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 1353: ...0B 4 MAINTENANCE AND LUBRICATION...

Page 1354: ...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 1355: ...3B1 2 ELECTRICAL POWER STEERING EPS SYSTEM IF EQUIPPED...

Page 1356: ...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 1357: ...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 1358: ...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 1359: ...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 1360: ...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 1361: ...5E 6 ANTILOCK BRAKE SYSTEM ABS System Circuit...

Page 1362: ...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 1363: ...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 1364: ...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 1365: ...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 1366: ...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 1367: ...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 1368: ...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 1369: ...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 1370: ...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 1371: ...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 1372: ...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 1373: ...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 1374: ...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 1375: ...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 1376: ...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 1377: ...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 1378: ...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 1379: ...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 1380: ...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 1381: ...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 1382: ...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 1383: ...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 1384: ...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 1385: ...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 1386: ...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 1387: ...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 1388: ...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 1389: ...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 1390: ...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 1391: ...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 1392: ...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 1393: ...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 1394: ...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 1395: ...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 1396: ...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 1397: ...5E 42 ANTILOCK BRAKE SYSTEM ABS...

Page 1398: ...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 1399: ...6 2 ENGINE...

Page 1400: ...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 1401: ...6E 2 ENGINE AND EMISSION CONTROL SYSTEM...

Page 1402: ...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 1403: ...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 1404: ...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 1405: ...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 1406: ...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 1407: ...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 1408: ...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 1409: ...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 1410: ...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 1411: ...6F1 10 IGNITION SYSTEM ELECTRONIC IGNITION SYSTEM...

Page 1412: ...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 1413: ...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 1414: ...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 1415: ...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 1416: ...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 1417: ...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 1418: ...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 1419: ...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 1420: ...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 1421: ...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 1422: ...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 1423: ...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 1424: ...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 1425: ...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 1426: ...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 1427: ...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 1428: ...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 1429: ...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 1430: ...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 1431: ...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 1432: ...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 1433: ...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 1434: ...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 1435: ...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 1436: ...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 1437: ...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 1438: ...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 1439: ...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 1440: ...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 1441: ...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 1442: ...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 1443: ...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 1444: ...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 1445: ...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 1446: ...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 1447: ...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 1448: ...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 1449: ...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 1450: ...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 1451: ...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 1452: ...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 1453: ...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 1454: ...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 1455: ...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 1456: ...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 1457: ...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 1458: ...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 1459: ...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 1460: ...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 1461: ...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 1462: ...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 1463: ...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 1464: ...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 1465: ...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 1466: ...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 1467: ...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 1468: ...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 1469: ...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 1470: ...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 1471: ...7B 60 AUTOMATIC TRANSMISSION 4 A T...

Page 1472: ...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 1473: ...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 1474: ...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 1475: ...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 1476: ...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 1477: ...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 1478: ...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 1479: ...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 1480: ...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 1481: ...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 1482: ...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 1483: ...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 1484: ...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 1485: ...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 1486: ...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 1487: ...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 1488: ...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 1489: ...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 1490: ...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 1491: ...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 1492: ...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 1493: ...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 1494: ...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 1495: ...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 1496: ...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 1497: ...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 1498: ...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 1499: ...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 1500: ...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 1501: ...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 1502: ...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 1503: ...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 1504: ...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 1505: ...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 1506: ...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 1507: ...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 1508: ...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 1509: ...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 1510: ...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 1511: ...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 1512: ...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 1513: ...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 1514: ...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 1515: ...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 1516: ...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 1517: ...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 1518: ...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 1519: ...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 1520: ...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 1521: ...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 1522: ...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 1523: ...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 1524: ...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 1525: ...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 1526: ...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 1527: ...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 1528: ...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 1529: ...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 1530: ...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 1531: ...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 1532: ...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 1533: ...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 1534: ...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 1535: ...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 1536: ...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 1537: ...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 1538: ...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 1539: ...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 1540: ...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 1541: ...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 1542: ...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 1543: ...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 1544: ...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 1545: ...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 1546: ...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 1547: ...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 1548: ...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 1549: ...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 1550: ...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 1551: ...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 1552: ...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 1553: ...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 1554: ...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 1555: ...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 1556: ...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 1557: ...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 1558: ...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 1559: ...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 1560: ...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 1561: ...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 1562: ...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 1563: ...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 1564: ...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 1565: ...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 1566: ...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 1567: ...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 1568: ...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 1569: ...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 1570: ...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 1571: ...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 1572: ...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 1573: ...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 1574: ...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 1575: ...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 1576: ...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 1577: ...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 1578: ...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 1579: ...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 1580: ...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 1581: ...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 1582: ...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 1583: ...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 1584: ...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 1585: ...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 1586: ...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 1587: ...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 1588: ...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 1589: ...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 1590: ...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 1591: ...Prepared by Service Department 1st Ed November 2001 Printed in Hungary 252...

Page 1592: ...Prepared by Service Department 1st Ed November 2001 Printed in Hungary 252...

Page 1593: ...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 1594: ...embling it is recommended to use SUZUKI genuine parts tools and service materials lubricant sealants etc as specified in each description All information illustrations and specifications contained in...

Page 1595: ......

Page 1596: ...ock 8D 3D 8G Immobilizer Control System 8G 3E Steering Wheel and Column 3C BODY SERVICE 9 3F 9 Front Suspension 3D RESTRAINT SYSTEM 10 Rear Suspension 3E Seat Belt 10A 4 10 Wheels and Tires 3F Air Bag...

Page 1597: ......

Page 1598: ...GENERAL INFORMATION CONTENTS Precautions 0A 2 Precaution in Servicing Full Time 4WD Vehicle 0A 2 Vehicle Lifting Points 0A 3 NOTE For descriptions items not found in this section refer to the same sec...

Page 1599: ...nt 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...

Page 1600: ...nd of hoist arm is not in contact 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...

Page 1601: ...ands 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 and the vehicle is held stable for safety s sake WARNIN...

Page 1602: ...system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vice Precautions under On Vehicle Service...

Page 1603: ...R R R R R R Engine oil filter When SE or SF grade oil is used Replace every 10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R R 1 6 Exhaust system leakage damage tightness I I I 2 IGNITION SYST...

Page 1604: ...6 4 Suspension system tightness damage rattle break age I I I 6 5 Steering system tightness damage breakage rattle I I I 6 6 Manual transmission oil leakage level I 1st 15 000 km only I R R 6 7 Autom...

Page 1605: ...4 Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months A B C E H ITEM 2 1 Spark plugs R Every 10 000 km 6 000 miles or 8 months C ITEM 3 1 Air cleaner filter 1 I Every 2 500 km 1 500 mi...

Page 1606: ...eaks detachment tear or other damage Replace boot as necessary PROPELLER SHAFTS 4WD INSPECTION 1 Check propeller shaft connecting bolts for looseness If looseness is found tighten to specified torque...

Page 1607: ...ied torque referring to TRANS FER OIL CHANGE in Section 7D or CHANGING DIFFER ENTIAL OIL in Section 7F REPLACEMENT Change transfer oil and differential oil with new specified oil refer ring to TRANSFE...

Page 1608: ...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 use a replacement part of lesser...

Page 1609: ...e 4 Rear shock absorber 13 Oil seal protector 22 Brake back plate bolt 5 Lateral rod 14 LSPV bracket only vehicle with LSPV 23 Bearing retainer ring without ABS 6 Trailing arm 15 Brake back plate 24 B...

Page 1610: ...ng by loosening drain plug 1 4 Disconnect parking brake cable from parking brake shoe lever 2 and remove parking brake cable 1 from brake back plate 5 Disconnect brake pipe 1 from wheel cylinder and p...

Page 1611: ...43 17912 9 In order to remove the retainer ring 1 from the axle shaft 2 grind 3 with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin 10 Break with a chisel the thi...

Page 1612: ...aft and then remove brake back plate 2 Special tool D 09927 18411 E 09921 57810 12 Remove stud bolts 1 by using hydraulic press 2 INSTALLATION 1 Aligning serrations between new stud bolts 1 and flange...

Page 1613: ...ate bolts to specified torque Tightening torque Brake back plate bolts a 23 N m 2 3 kg m 17 0 lb ft NOTE Install wheel bearing spacer 1 with the tapered side of its inner diameter directed toward outs...

Page 1614: ...eel nuts 2 temporarily by hand 11 Fill reservoir with brake fluid and bleed brake system For bleeding operation refer to BLEEDING BRAKES in Sec tion 5 12 Install wheel and tighten wheel nuts to specif...

Page 1615: ...VAL 1 Remove rear axle shaft referring to item 1 to 8 of REAR AXLE SHAFT AND WHEEL BEARING in this section 2 Disconnect brake pipes 2 right left from flexible hoses 1 and remove E rings 3 3 Remove bra...

Page 1616: ...le housing 2 and remove differential car rier assembly 9 Remove lateral rod 1 10 Loosen trailing arm rear mounting nuts 3 right left from axle housing but don t remove bolts 11 Remove shock absorber l...

Page 1617: ...ghten nuts 2 temporarily by hand 2 Install coil springs 3 right left on spring seat 2 of axle housing 1 and raise axle housing 3 Install shock absorber 1 right and left to axle housing 2 and install b...

Page 1618: ...igning match marks 1 and tighten flange bolts to specified torque Tightening torque Companion flange bolts a 23 N m 2 3 kg m 17 0 lb ft 8 Install LSPV spring to rear axle Tighten LSPV adjust nut tempo...

Page 1619: ...flare nuts b 16 N m 1 6 kg m 11 5 lb ft 17 Apply water tight sealant where brake back plate 1 and parking brake cable contact Connect parking brake cable 2 to brake back plate right left and secure it...

Page 1620: ...fied torque Tightening torque Rear trailing arm nuts a 80 N m 8 0 kg m 58 0 lb ft Rear shock absorber lower bolts b 63 N m 6 3 kg m 45 5 lb ft Lateral rod axle housing side nut c 50 N m 5 0 kg m 36 5...

Page 1621: ...differential carrier and axle housing Gear oil For gear oil information refer to Section 7F Differential gear Rear axle housing Water tight sealant SUZUKI SEALING COMPOUND 366E 99000 31090 Joint seam...

Page 1622: ...ust be replaced The propeller shaft is a balanced unit Handle it carefully so that balance can be maintained A viscous coupling is used for the coupling system which distributes an optimum driving for...

Page 1623: ...s showing in the drive line On Vehicle Service PRECEDENTIAL INSPECTION Check propeller shaft connecting bolts for looseness If looseness is found tighten to specified torque Check propeller shaft join...

Page 1624: ...6 yoke 7 of propeller shaft No 1 with center support 8 and transfer output flange 9 3 Loosen propeller shaft bolt at front and rear end and sepa rate propeller shafts from transfer and rear differenti...

Page 1625: ...h center support 4 all together 6 Disconnect propeller shaft No 1 with center support and pro peller shaft No 2 from viscous coupling with center support INSPECTION Inspect propeller shaft and flange...

Page 1626: ...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 bolts a 23 N m 2 3 kg...

Page 1627: ...tening portion Tightening torque N m kg m lb ft Propeller shaft bolts 23 2 3 17 0 Center support bolts 55 5 5 40 0 Viscous coupling nuts 23 2 3 17 0 Material Recommended SUZUKI Material Part Number Us...

Page 1628: ...of the system or could 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...

Page 1629: ...992 lbs Rear axle weight L 4 500 N 450 kg 992 lbs 2 Install special tool to front and rear brake Special tool Front brake A 09956 02310 B 09952 36310 C 55473 82030 Air bleeder plug as a spare part Rea...

Page 1630: ...anging bolt 2 position as follows If rear brake pressure is higher than specification move bolt and nut 1 center side a and if it is lower out side b Repeat steps 3 and 4 until rear brake pressure is...

Page 1631: ...N m kg m lb ft Brake pipe flare nut 16 1 6 11 5 Brake bleeder plug Front caliper 6 5 0 65 5 0 Brake bleeder plug Wheel cylinder 8 5 0 85 6 5 LSPV spring adjust nut 25 2 5 18 0 09956 02310 09952 36310...

Page 1632: ...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 may result...

Page 1633: ...luded within the brake circuit which connects the master cylinder and the rear wheel brake It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehic...

Page 1634: ...rvoir Bleed brake system Perform brake test and check each installed part for fluid leakage CAUTION Do not use lubricated shop air on brake parts as damage to rubber components may result If any hydra...

Page 1635: ...e 3 Disconnect brake pipes from LSPV assembly 1 Special tool A 09950 78230 10 x 11 mm 1 LSPV assembly 2 Spring 3 Adjust nut 4 Brake pipe Tightening Torque 3 2 1 25 N m 2 5 kg m 4 16 N m 1 6 kg m 25 N...

Page 1636: ...tening torque LSPV adjust nut a 25 N m 2 5 kg m 18 0 lb ft Brake pipe flare nut b 16 N m 1 6 kg m 11 5 lb ft 3 Fill reservoir with specified fluid and bleed air from brake system 4 After bleeding air...

Page 1637: ...cification by changing LSPV adjust ing bolt and nut position as shown in figure After adjustment tighten nut 1 to specified torque Tightening torque LSPV adjust nut a 25 N m 2 5 kg m 18 0 lb ft 5 Conf...

Page 1638: ...m or could 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 th...

Page 1639: ...sing 8 mm bolts INSTALLATION 1 Put flat head rod or the like between rod 1 and ratchet 2 and pull ratchet as shown to maximize clearance between shoe and drum 2 Install brake drum after making sure th...

Page 1640: ...ut b 85 N m 8 5 kg m 61 5 lb ft 6 Check to ensure that brake drum is free from dragging and proper braking is obtained Then remove vehicle from hoist and perform brake test foot brake and parking brak...

Page 1641: ...5C 4 PARKING AND REAR BRAKE...

Page 1642: ...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 may res...

Page 1643: ...p 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 preve...

Page 1644: ...sor Right front 2 ABS control module 8 EBD warning lamp Brake warning lamp 14 Wheel speed sensor Left front 3 ABS hydraulic unit 9 Lamp driver module 15 Wheel speed sensor Right rear 4 Fail safe relay...

Page 1645: ...5E1 4 ANTILOCK BRAKE SYSTEM ABS System Circuit...

Page 1646: ...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 Red Or Orange W R White Red Bl W Blu...

Page 1647: ...ndicated by ABS warn ing lamp ABS warning lamp flashing pattern DIAGNOSTIC ITEMS NO DTC 12 Normal C1013 13 ABS control module C1015 15 G sensor circuit C1021 21 RF Wheel speed sensor circuit C1025 25...

Page 1648: ...55 LR Inlet solenoid valve circuit C1056 56 Outlet solenoid valve circuit C1057 57 Power source C1061 61 ABS pump motor and or motor relay circuit C1063 63 Fail safe relay C1071 71 ABS control module...

Page 1649: ...1 terminals 5 While turning wheel at a speed of approximately 1 2 to 1 rotation per second check AC voltage of sensor If measured voltage is not as specified check sensor rotor and their installation...

Page 1650: ...68 F Between sensor terminal and sensor body No continuity Rear Wheel Speed Sensor Ring INSPECTION Check rotor serration teeth for being missing damaged or deformed Turn wheel and check if rotor rota...

Page 1651: ...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 1652: ...ANTILOCK BRAKE SYSTEM ABS 5E1 11 Tightening Torque Specification Fastening part Tightening torque N m kg m lb ft G sensor bolt 3 0 0 3 2 2...

Page 1653: ...5E1 12 ANTILOCK BRAKE SYSTEM ABS...

Page 1654: ...ts 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 Fail...

Page 1655: ...nting bracket bolt 4 Left mounting body bracket 13 Right mounting body bolt 22 Rear mounting bracket nut 5 Left mounting 14 Right mounting bracket swing bolt 23 Rear mounting bush bolt 6 Left mounting...

Page 1656: ...r outlet No 1 hose 1 and No 2 hose 2 with air intake joint 3 7 Remove suction pipe 5 and remove air cleaner assembly 4 by removing its fastening bolt 6 8 Disconnect the following cables Accelerator ca...

Page 1657: ...and remove exhaust No 1 pipe 2 15 Drain engine oil transmission oil and transfer oil 16 Remove propeller shafts referring to Section 4B 17 Remove stabilizer bar 1 referring to Section 3D of the Ser v...

Page 1658: ...ve the following bolts and nuts referring to the figure of Engine Mounting in this section a Remove engine rear mounting bush bolt b Remove engine left mounting nuts c Remove engine right mounting bra...

Page 1659: ...RD of this manual Install exhaust No 1 pipe Install right and left engine under covers Connect each hoses securely Clamp electric wire securely 8 Adjust clutch pedal free travel referring to Section 7...

Page 1660: ...w under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system components or wiring Please observe all WARNINGS and Ser vic...

Page 1661: ...nizing mechanism 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...

Page 1662: ...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 Countershaft 2nd gear 22...

Page 1663: ...7D 7 By using large size screwdrivers 2 pull out drive shaft joint 1 so as to release snap ring fitting of joint spline at differen tial side Pushing knuckle portion outward detach drive shaft at dif...

Page 1664: ...d in the FOREWORD of this manual 14 Install stabilizer mount brackets fasten bolts to specified torque referring to Section 3D of the Service Manual men tioned in the FOREWORD of this manual 15 Pour t...

Page 1665: ...elect control cable 8 Cable nut 2 Lever boot holder 6 Gear shift control cable guide nut 9 Cable mounting bolt 3 Gear shift lever boot 7 Gear shift control lever assembly Apply grease 99000 25010 to p...

Page 1666: ...ver assembly from body 4 Disconnect shift and select cables from transmission in the same manner as step 2 5 Remove cable grommet and cable clamp and then remove shift and select cables from body INST...

Page 1667: ...31230 to mating surface of left case and right case 8 Differential assembly 13 Left case plate bolts and screw 3 Gear shifter assembly 9 Oil level filler plug Apply sealant 99000 31230 to all around...

Page 1668: ...MANUAL TRANSMISSION 7A 9...

Page 1669: ...ronizer spring 24 Reverse shaft washer 40 Bearing set shim 8 High speed sleeve hub 25 Countershaft right bearing 41 Countershaft 5th gear 9 High speed synchronizer key 26 Countershaft 42 Countershaft...

Page 1670: ...MANUAL TRANSMISSION 7A 11...

Page 1671: ...gear shift lever bolt Apply thread lock 99000 32110 to all around thread part of bolt 4 Gear shift select lever 15 Differential side pinion gear 26 5th gear shift fork plug Apply thread lock 99000 321...

Page 1672: ...ting motor plate should also come down 7 Support engine by using lifting device On lift 8 Drain transmission oil referring to Section 7A of the Service Manual mentioned in the FOREWORD of this manual...

Page 1673: ...mentioned in the FORE WORD of this manual for fastener specified torque Refer to Section 7D for installing transfer Push in drive shaft joints right left fully so as to snap ring of shaft engages wit...

Page 1674: ...y with soft jawed vise and apply measuring tip of dial gauge to top surface of gear Using 2 screwdrivers 1 move gear 2 up and down and read movement of dial gauge pointer Special tool A 09900 20607 B...

Page 1675: ...ntial assembly 1 as illustrated so as to left bearing 2 is floating and then press fit right bearing 3 like left bearing in Step 5 Special tool C 09951 76010 D 09951 16060 7 Hold differential assembly...

Page 1676: ...and straight edge by 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 adjust...

Page 1677: ...2 and springs 1 Synchronizer 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 and bolts Be sure to use new...

Page 1678: ...shaft at once aligning hub oil groove A with shaft mark B 13 Drive in spring pin facing its slit A outward 14 Install steel ball tighten shift fork plug 3 to which thread lock cement has been applied...

Page 1679: ...Transmission oil level filler and drain plugs 21 2 1 15 5 Gear shift control lever assembly nut 13 1 3 9 5 Final gear bolts 90 9 0 65 0 Reverse gear shift lever bolts 23 2 3 17 0 Transmission case bo...

Page 1680: ...on case Mating surface of side cover Gear shift interlock bolt 5th to reverse interlock guide bolt Thread lock cement THREAD LOCK 1322 99000 32110 Reverse gear shift lever bolts Oil gutter bolt Left c...

Page 1681: ...09925 68210 09925 78210 09925 88210 09925 98221 Bearing outer race installer Spring pin remover 6 mm Bearing puller attachment Bearing installer 09927 76010 09930 30104 09940 53111 09940 54910 Gear h...

Page 1682: ...g 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 system componen...

Page 1683: ...Release shaft seal will also be pushed out Special tool A 09922 46010 6 Remove release shaft and return spring 7 Install tap M16 X 1 5 1 to clutch release shaft No 1 bush 8 Pull out No 1 bush by usin...

Page 1684: ...se 99000 25010 2 Install release shaft with return spring applied to it 3 Apply grease to No 2 bush 1 inside and press fit it by using the same special tool as in removal A Grease 99000 25010 Special...

Page 1685: ...well B Grease 99000 25210 9 Set release lever to release shaft aligning their punch marks 1 then tighten nut Tightening torque Release lever nut a 23 N m 2 3 kg m 17 0 lb ft 10 Install pin 2 to relea...

Page 1686: ...e shaft bushes and seal Release shaft arm Release bearing inside SUZUKI SUPER GREASE I 99000 25210 Input shaft spline and front end 09917 58010 09922 46010 09923 36330 09923 46020 Bearing remover Bush...

Page 1687: ...7C 6 CLUTCH...

Page 1688: ...ransfer assembly 7D 6 Reduction driven gear assembly 7D 7 Intermediate shaft 7D 9 Transfer output retainer assembly 7D 9 Component Inspection 7D 10 Unit Assembly 7D 11 Reduction driven gear assembly 7...

Page 1689: ...gears are pro vided Hypoid gears have an advantage of preventing gear noise at the same time they require accurate adjustment of tooth contact and backlash Diagnosis 1 Intermediate shaft 6 Shim 11 Tra...

Page 1690: ...99000 31230 Tightening torque Transfer oil drain plug a 21 N m 2 1 kg m 15 5 lb ft Transfer gear oil Hypoid gear oil API GL 5 For oil viscosity refer to the chart Oil Capacity 0 5 liters 1 1 0 9 US lm...

Page 1691: ...to all around surface 14 Reduction driven gear 24 Transfer stiffener 5 Bevel pinion shim 15 Flange 25 Intermediate shaft right bearing 6 Drain plug Apply sealant 99000 31230 to all around thread part...

Page 1692: ...ansaxle oil and transfer oil 4 Remove exhaust pipe 1 5 Remove propeller shaft referring to Section 4B 6 Remove right side drive shaft 1 referring to Section 4A 7 Disconnect breather hose from transfer...

Page 1693: ...r assembly from transmission assembly 12 Remove dynamic damper 1 from transfer assembly if equipped 13 Remove rear mounting 1 and rear mounting bracket 2 from transfer assembly 14 Remove breather hose...

Page 1694: ...th plastic hammer 5 Remove reduction drive gear bearings 2 right and left from reduction drive gear by using bearing puller and hydraulic press Reduction driven gear assembly DISASSEMBLY 1 Drive out l...

Page 1695: ...tool A 09941 58020 B 09924 57610 4 Drive out bevel gear 1 by using special tool Special tool A 09913 65135 5 Remove driven gear bearing outer race from left case 1 by using special tool Special tool...

Page 1696: ...ft by using bearing puller and hydraulic press 3 Remove reduction drive gear oil seals 1 by using hydraulic press and special tools Special tool A 09924 84510 005 B 09913 75821 Transfer output retaine...

Page 1697: ...sing special tool Special tool A 09913 50121 8 Drive out pinion shaft bearing outer races 2 front and rear by using brass bar 1 Component Inspection Check each bearing for smooth rotation wear or disc...

Page 1698: ...olding bevel gear with special tool and vise and then caulk nut Tightening torque Transfer bevel gear nut 150 N m 15 0 kg m 108 5 lb ft Special tool B 09941 58020 C 09924 57610 3 Press fit driven gear...

Page 1699: ...from mating face of right left case to face processed for installation of driven gear bearing 3 Calculate shim thickness to be inserted Shim thickness b c a 0 1 mm 0 004 in 2 4 Select shim s closest t...

Page 1700: ...face to pinion dummy top face 2 Left case c Distance from retainer installation face to end face of bearing race b a 3 Pinion shaft bearing d Pinion shaft mounting distance 61 5 mm 2 421 in 4 Reducti...

Page 1701: ...erly by using adjusting shim bevel pinion shim as selected below 1 Press fit pinion shaft bearing outer races front and rear by using special tools Special tool A 09913 75821 B 09924 84510 005 2 Insta...

Page 1702: ...using calculated value in following equation NOTE This installation requires no spacer or oil seal NOTE Before taking measurement check for rotation by hand more than 15 revolutions Distance c Height...

Page 1703: ...fer Output Retainer Assembly in this section Special tool A 09913 75810 10 Install bevel pinion shaft with new pinion shaft spacer 1 to transfer output retainer 11 Press fit pinion shaft bearing rear...

Page 1704: ...e by using special tool and apply grease to oil seal lips Special tool A 09924 84510 005 B 09913 75821 A Grease 99000 25010 Transfer reduction drive gear oil seal installing depth a 16 0 16 5 mm 0 630...

Page 1705: ...00 25010 6 Install bevel gear shim s 2 selected in item Bevel Gear Shim Adjustment and driven gear bearing outer race 3 to right case 1 Left case ASSEMBLY 1 Install the bevel gear shim s selected in i...

Page 1706: ...y ASSEMBLY 1 Clean mating surface of right case and left case 1 and apply sealant to left case 1 by using a nozzle as shown in figure by such amount that its section is 1 5 mm 0 059 in in diameter A S...

Page 1707: ...ontact as follows a After cleaning tooth surface of bevel gear 1 paint them with gear marking compound evenly by using brush or sponge etc b Turn gear to bring its painted part in mesh with bevel pini...

Page 1708: ...IGH CONTACT Pinion is positioned too fat from the center of drive bevel gear 1 Decrease thickness of bevel pinion shim and position pinion closer to gear center 2 Adjust drive bevel gear backlash to s...

Page 1709: ...ipped Tightening torque Dynamic damper bolts a 50 N m 5 0 kg m 36 5 lb ft These contact patterns located on toe or heel on both drive and coast sides mean that 1 both pinion and gear are defective 2 r...

Page 1710: ...bolts 4 to specified torque Tightening torque Transfer stiffener bolts a 50 N m 5 0 kg m 36 5 lb ft Tighten transfer to engine stiffener bolts to specified torque if equipped Tightening torque Transf...

Page 1711: ...sfer output retainer bolts 50 5 0 36 5 Transfer to transmission bolts 50 5 0 36 5 Transfer rear mounting bracket bolts 55 5 5 40 0 Transfer rear mounting bracket nuts 50 5 0 36 5 Transfer mounting bol...

Page 1712: ...09922 76140 09922 76150 09922 76340 Bearing installer attach ment Bevel pinion shaft Bevel pinion nut Rear collar 09922 76430 09924 57610 09924 74510 09924 84510 005 Front collar Gear holder Installe...

Page 1713: ...7D 26 TRANSFER 09941 54911 09941 58020 09945 16070 09952 76011 Bearing outer race remover Socket wrench 40 mm Retainer ring installer set Snap ring pliers closing type...

Page 1714: ...8E 9 10 10A 10B SECTION 7F REAR DIFFERENTIAL CONTENTS General Description 7F 2 Diagnosis 7F 3 On Vehicle Service 7F 4 Oil Change 7F 4 Differential Unit 7F 5 Unit Repair Overhaul 7F 7 Tightening Torqu...

Page 1715: ...urther because of sliding tooth meshing with high pressure between drive bevel pinion and gear it is mandatory to lubricate them by hypoid gear oil The hypoid gears have an advantage of preventing gea...

Page 1716: ...inion and gear Adjust or replace Loose drive bevel gear securing bolts Replace or retighten Damaged side gear s or side pinion s Replace Bearing noise Constant noise Deteriorated or water mixed lubric...

Page 1717: ...d torque Tightening torque Rear differential oil drain plug a 55 N m 5 5 kg m 40 0 lb ft 5 Pour proper amount of new hypoid gear oil as specified below roughly up to level hole 6 Install new gasket to...

Page 1718: ...fts referring to Rear Axle Shaft and Wheel Bearing Removal in Section 3E 5 Before removing propeller shaft give match marks 1 on companion flange and propeller shaft as shown 6 Remove 4 propeller shaf...

Page 1719: ...n propeller shaft bolts to specified torque Tightening torque Propeller shaft bolts b 23 N m 2 3 kg m 17 0 lb ft Rear axle shaft For installation of rear axle shaft refer to Rear Axle Shaft and Wheel...

Page 1720: ...l seal lip 12 Drive bevel pinion bearing 21 Differential side bearing cap 4 Dynamic damper 13 Drive bevel pinion shim 22 Differential carrier bolt Apply sealant 99000 31110 to thread part 5 Spacer 14...

Page 1721: ...nd remove differential gear assembly 2 4 With aluminum plates placed on vise first grip differential case with it and remove drive bevel gear by removing its bolts 5 Using special tools pull out diffe...

Page 1722: ...nion Use special tool if it is hard to remove Special tool B 09913 65135 11 Remove drive bevel pinion 1 with rear bearing and spacer from carrier 12 Remove drive bevel pinion rear bearing 2 by using b...

Page 1723: ...t for wear or damage Check differential 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...

Page 1724: ...ed vise and apply measuring tip of dial gauge to top surface of gear 2 Using 2 screwdrivers 1 move gear 2 up and down and read movement of dial gauge pointer Left side Using similar procedure to the a...

Page 1725: ...hread lock cement for bolts 3 A Thread lock cement 99000 32110 Tightening torque Drive bevel gear bolts a 90 N m 9 0 kg m 65 0 lb ft 4 Press fit differential side bearings 3 to differential case 1 by...

Page 1726: ...Install dial gauge 1 to bearing form dummy with dammy shaft A Dummy height of pinion form dummy 40 mm 1 757 in D Drive bevel pinion mounting distance 68 00 mm 2 677 in 3 Differential carrier B Radius...

Page 1727: ...Tighten pinion form dummy nut special tool 1 so that specified bearing preload is obtained Drive bevel pinion bearing preload at 50 rpm 0 5 1 3 N m 5 0 13 0 kg cm 0 35 0 90 lb ft 7 Set dial gauge to...

Page 1728: ...24 1 27 and 1 30 mm 0 012 0 039 0 041 0 042 0 043 0 044 0 045 0 046 0 048 0 049 0 050 and 0 051 in 11 With new pinion spacer 3 inserted as shown install front bearing to differential carrier NOTE Rep...

Page 1729: ...l A 09930 40113 NOTE Before taking measurement check for smooth rotation with turning drive bevel pinion 15 revolutions or more by hand Drive bevel pinion bearing preload is adjusted by tight ening co...

Page 1730: ...in 2 Divide selected shim s between both sides right and left and install them to differential carrier Then install differential side bearing cap Tightening torque Differential side bearing cap bolts...

Page 1731: ...the following chart If contact pattern is not normal read just or replace as necessary according to instruction in chart 5 After completing of gear tooth contact check caulk compan ion flange nut 2 wi...

Page 1732: ...ve bevel gear 1 Decrease thickness of pinion height adjusting shim and position pinion farther from gear center 2 Adjust drive bevel gear backlash to specification These contact patterns indicate that...

Page 1733: ...l drain plug 55 5 5 40 0 Rear differential oil level filler plug 50 5 0 36 5 Companion flange nut reference 70 250 7 0 25 0 51 0 181 0 Dynamic damper bolts 23 2 3 17 0 Drive bevel gear bolts 90 9 0 65...

Page 1734: ...puller attachment 09913 60910 09913 80113 09900 20701 09900 20607 Bearing puller Bearing installer Magnetic stand Dial gauge 09922 76140 09922 76150 09922 76430 09922 76350 Bevel pinion shaft Bevel pi...

Page 1735: ...7F 22 REAR DIFFERENTIAL 09922 76340 09930 40113 09913 65135 09913 50121 Rear collar Flange holder Bearing puller Oil seal remover 09913 76010 Bearing installer...

Page 1736: ...section of Wiring Diagram Manual mentioned in FOREWORD of this manual LIST OF CONNECTORS Note For the connectors not found in this section refer to the same section of Wiring Diagram Manual 8A 8 menti...

Page 1737: ...Prepared by Service Department 1st Ed June 2001 Printing August 2001 144...

Page 1738: ...another vehicle sys tem both need repair Suzuki recommends that the air bag system be repaired first to help avoid unintended air bag deployment Do not modify the steering wheel instru ment panel or...

Page 1739: ...als lubricant sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product information available at the t...

Page 1740: ...5A 5B 5C 5E1 ENGINE General Information and Engine Diagnosis Engine Mechanical Engine Cooling Engine Fuel Engine and Emission Control System Ignition System Cranking System Charging System Exhaust Sys...

Page 1741: ...nd 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 may r...

Page 1742: ...en SE or SF grade oil is used Replace every 10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R R 1 6 Exhaust system leakage damage tightness I I I 2 IGNITION SYSTEM 2 1 Spark plugs When unleaded...

Page 1743: ...I I I Brake drums and shoes wear damage I I I 5 2 Brake hoses and pipes leakage damage clamp I I I 5 3 Brake fluid R R R 5 4 Brake lever and cable damage stroke operation Inspect at first 15 000 km 9...

Page 1744: ...km 9 000 miles or 12 months B C D Drive belt V rib belt R Every 45 000 km 27 000 miles or 36 months A C D E F H ITEM 1 4 Engine oil and filter R Every 5 000 km 3 000 miles or 4 months A B C E F H ITE...

Page 1745: ...100 N 10 kg or 22 lb pressure NOTE When replacing belt with a new one adjust belt tension to 6 7 mm 0 24 0 27 in A C compressor drive belt inspection If equipped 1 Hoist vehicle and remove engine unde...

Page 1746: ...oil viscosity according to the left chart Before draining engine oil check engine for oil leakage If any evi dence of leakage is found make sure to correct defective part be fore proceeding to followi...

Page 1747: ...Filler inlet is at the top of cyl inder head cover 8 Start engine and run it for three minutes Stop it and wait another 5 minutes before checking oil level Add oil as necessary to bring oil level to F...

Page 1748: ...f corrosion protec tion and lubrication Refer to SECTION 6B for COOLANT CAPACITY 1 Remove radiator cap when engine is cool 2 Loosen radiator drain plug 1 to drain coolant 3 Remove reservoir and drain...

Page 1749: ...heck nearby body areas for damaged missing or mispositioned parts open seams holes loose connections or other defects which could permit exhaust fumes to seep into vehicle Make sure that exhaust syste...

Page 1750: ...Cleaner Filter Inspection ITEM 3 2 Fuel Lines Inspection Check fuel lines for loose connection deterioration or damage which could cause leakage Make sure all clamps are secure Replace any damaged or...

Page 1751: ...TEM 5 1 Brake Discs Pads Drums and Shoes Inspection Brake discs and pads 1 Remove wheel and caliper but don t disconnect brake hose from caliper 2 Check front disc brake pads and discs for excessive w...

Page 1752: ...urge operation ITEM 5 3 Brake Fluid Change CAUTION Do not use old or used brake fluid or any fluid from any un sealed container Change brake fluid as follows Drain existing fluid from brake system com...

Page 1753: ...ear cuts or damage If de fective replace 2 Check inflating pressure of each tire and adjust pressure to specification as necessary NOTE Tire inflation pressure should be checked when tires are cool Sp...

Page 1754: ...ront struts rear shock absorbers for evidence of oil leakage dents or any other damage on sleeves and inspect an chor ends for deterioration Replace defective parts if any Check front and rear suspens...

Page 1755: ...speed than when it is stopped Repair if found faulty 8 Check wheel alignment referring to Section 3A ITEM 6 6 Manual Transmission Oil Inspection and Change Inspection 1 Inspect transmission case for...

Page 1756: ...d fluid Fluid change 1 Perform steps 1 and 2 of above Fluid Level Inspection 2 Change fluid with new specified fluid referring to SECTION 7B ITEM 6 8 All Latches Hinges and Locks Inspection Doors Chec...

Page 1757: ...ing unit by removing filter cover located on bottom of case 2 Check filter for dirt Replace excessively dirty filter 3 Blow off dust by compressed air from air outlet side of filter 4 Install filter t...

Page 1758: ...celerating Clutch itself is free from any abnormal condition Gearshift or Select Lever Transmission Check gear shift or select lever for smooth shifting to all positions and for good performance of tr...

Page 1759: ...that steering wheel is free from in stability or abnormally heavy feeling Check that the vehicle does not wander or pull to one side Engine Check that engine responds readily at all speeds Check that...

Page 1760: ...rve energy in the Sensing and Diagnostic Module SDM CAUTION The air conditioning system of this vehicle uses refrigerant HFC 134a R 134a None of refrigerant compressor oil and component parts is inter...

Page 1761: ...fan motor 5 Ignition switch 6 Circuit fuse box 7 A C switch 8 Dual pressure switch 9 Blower fan motor relay 10 Blower fan motor 11 Blower fan motor resistor 12 Blower fan switch 13 A C evaporator ther...

Page 1762: ...cooling fan motor relay 13 Radiator and condenser cooling fan motor 14 ECM E21 E23 E22 AIR CONDITIONING OPTIONAL 1B 3 A C SYSTEM INSPECTION OF ECM AND ITS CIRCUITS ECM and its Circuits can be checked...

Page 1763: ...h relay output g Fig B 10 14 V Except the above mentioned with engine running E21 26 B Y ECM ground for power circuit Ground to body Fig A 0 3 0 3 V Ignition switch ON E22 09 G R Evaporator thermistor...

Page 1764: ...FORMATION AND ENGINE DIAGNOSIS WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho...

Page 1765: ...it Malfunction 6 1 70 DTC P0340 CMP Sensor Circuit Malfunction 6 1 72 DTC P0420 Catalyst System Efficiency Below Threshold 6 1 74 DTC P0443 Purge Control Valve Circuit Malfunction 6 1 77 DTC P0480 Rad...

Page 1766: ...ables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire har ness or other electrical parts Throughout this manual the th...

Page 1767: ...under high fuel pressure even after engine was stopped loosen ing or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected Before loosening o...

Page 1768: ...stall it 5 Start engine and run it till it stops for lack of fuel Repeat cranking engine 2 3 times for about 3 seconds each time to dissipate fuel pressure in lines Fuel connections are now safe for s...

Page 1769: ...tions When the ignition switch is turned ON with the engine at a stop malfunction indicator lamp MIL 1 turns ON to check the bulb of the malfunction indicator lamp 1 When ECM PCM detects a malfunction...

Page 1770: ...driving conditions in the from of data as shown at the left at the moment of the detection of a mal function in its memory This data is called Freeze frame data Therefore it is possible to know engin...

Page 1771: ...1 P0400 EGR detected Data at P0400 detection Data at P0400 detection 2 P0171 Fuel system detected Data at P0171 detection Data at P0400 detection Data at P0171 detection 3 P0300 Misfire detected Data...

Page 1772: ...oceed to the flow table of the DTC which has detected earliest in the order and follow the instruction in that table If no instructions are given troubleshoot diagnostic trouble codes according to the...

Page 1773: ...tion 1 Confirm trouble symptom referring to the next page Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame da...

Page 1774: ...sed on information obtained in Step 1 Customer complaint analysis and Step 2 DTC freeze frame data check confirm trouble symptoms Also reconfirm DTC according to DTC Confirmation Procedure described i...

Page 1775: ...Condition Weather Temperature Frequency Road Fair Cloudy Rain Snow Always Other Hot Warm Cool Cold F C Always Always Sometimes times day month Only once Under certain condition Urban Suburb Highway M...

Page 1776: ...t panel at driver s seat side Special Tool A SUZUKI scan tool B Mass storage cartridge C 16 14 pin DLC cable 3 Turn ignition switch ON and confirm that MIL lights 4 Read DTC pending DTC and freeze fra...

Page 1777: ...efer to scan tool operator s manual for fur ther details 4 After completing the clearance turn ignition switch off and dis connect scan tool from data link connector NOTE DTC and freeze frame data sto...

Page 1778: ...O2S circuit no activity detected Sensor 1 HO2S 1 output voltage is high or low continuously 2 driving cycles P0135 HO2S heater circuit malfunction Sensor 1 Terminal voltage is lower than specification...

Page 1779: ...rget range with CTP switch ON or drive voltage exists though ECM PCM is not outputting ISC drive command 1 driving cycle P0510 Closed throttle position switch malfunction Switch does not change from O...

Page 1780: ...Intake air temp circuit malfunction ECM PCM controls actuators assuming that intake air temperature is 20 C 68 F P0115 Engine coolant temp circuit malfunction ECM PCM controls actuators assuming that...

Page 1781: ...nnectors of electric wire harness disconnection friction Fuses burning Parts installation bolt looseness Parts deformation Other parts that can be checked visually Also check following items at engine...

Page 1782: ...TABLE Check ignition control related parts referring to Section 6F 7 Check immobilizer system malfunction as follows 1 Check immobilizer indicator lamp for flashing Is it flashing when ignition switch...

Page 1783: ...6 1 20 GENERAL INFORMATION AND ENGINE DIAGNOSIS Select DATA LIST mode SELECT MENU F4 MISC TEST Fig 1 for Step 5 Fig 2 for Step 6 Fig 3 for Step 6 Fig 4 for Step 8 Fig 5 for Step 11...

Page 1784: ...aulty ECT sensor or MAP sensor Faulty ECM PCM Low compression Poor spark plug tightening or faulty gasket Compression leak from valve seat Sticky valve stem Weak or damaged valve springs Compression l...

Page 1785: ...spring Warped or bent valve Piston ring and cylinder noise Worn piston ring and cylinder bore Connecting rod noise Worn rod bearing Worn crank pin Loose connecting rod nuts Low oil pressure Crankshaf...

Page 1786: ...r MAP sensor Faulty fuel injector Faulty fuel injector resistor Faulty ECM PCM Low compression Others Poor valve seating Dragging brakes Slipping clutch Thermostat out of order Improper tire pressure...

Page 1787: ...Faulty spark plug excess carbon deposits improper gap and burned electrodes etc Fuel system out of order Variable fuel pressure Kinky or damaged fuel hose and lines Faulty fuel pump clogged fuel filte...

Page 1788: ...Engine and emission control system out of order Maladjusted accelerator cable play Poor performance of TP sensor ECT sensor or MAP sensor Faulty fuel injector Faulty ECM PCM Low compression Others Dr...

Page 1789: ...l system Faulty fuel injector Faulty fuel injector resistor Poor performance of ECT sensor TP sensor or MAP sensor Faulty ECM PCM Engine overheating Low compression Others Loose connection or disconne...

Page 1790: ...igh tension cords in Section 6F Ignition coil assembly in Section 6F Refer to Low compression section Check for absence of filler neck restrictor EVAP control system in Section 6E1 Diagnostic Flow Tab...

Page 1791: ...TATUS At specified idle speed after warming up CLOSED closed loop CALC LOAD CALCULATED LOAD At specified idle speed with no load after warming up 3 5 VALUE At 2500 r min with no load after warming up...

Page 1792: ...ST PRG DUTY EVAP CANISTER PURGE FLOW DUTY At specified idle speed after warming up 0 100 CLOSED THROT POS CLOSED THROTTLE Throttle valve at idle position ON CLOSED THROTTLE POSITION Throttle valve ope...

Page 1793: ...by using the timing light INTAKE AIR TEMP C F It is detected by intake air temp sensor and used to determine the amount of air passing into the intake manifold as air density varies with temperature M...

Page 1794: ...used for altitude correction of the fuel injection quantity and ISC actuator control FUEL PUMP ON OFF ON is displayed when the ECM or PCM activates the fuel pump via the fuel pump relay switch VSS A...

Page 1795: ...ECM PCM AND ITS CIRCUITS ECM PCM and its circuits can be checked at ECM PCM wiring couplers by measuring voltage and resistance CAUTION ECM PCM cannot be checked by itself It is strictly prohib ited t...

Page 1796: ...elay 0 1 0 V Ignition switch ON 17 PPL WHT Malfunction indicator lamp 0 2 0 V Ignition switch ON 17 PPL WHT Malfunction indicator lamp 10 14 V When engine running 18 Blank 18 Blank 19 BLU RED Heater o...

Page 1797: ...rottle position sensor 2 8 4 8 V Ignition switch ON Throttle valve at full open position 7 YEL GRN Engine coolant temp sensor 0 55 0 95 V Ignition switch ON Engine coolant temp 80 C 176 F 8 YEL Heater...

Page 1798: ...chart 9 GRN RED A C evaporator temp sensor 10 YEL RED Fuel level sensor gauge 0 2 V Ignition switch ON fuel tank fully filled g g 4 5 7 5 V Ignition switch ON fuel tank emptied 11 Blank 12 WHT BLK Da...

Page 1799: ...r this check Resistance in table below represents that when parts temperature is 20 C 68 F TERMINALS CIRCUIT STANDARD RESISTANCE E23 8 to E22 20 H02S 1 heater 11 7 14 3 E21 19 to E22 20 H02S 2 heater...

Page 1800: ...1 CKP sensor 12 CTP switch in ISC actuator 13 Heated oxygen sensor 2 14 Stop lamp switch 15 A C EVAP temp sensor if equipped OTHERS A ECM PCM B Main relay C EVAP canister D Injector resistor E EFE hea...

Page 1801: ...N STEP ACTION YES NO 1 MIL Power Supply Check 1 Turn ignition switch ON Do other indicator warning lights in combination meter comes ON Go to Step 2 IG COIL fuse blown main fuse blown ignition switch...

Page 1802: ...ouble Code DTC check 1 Check DTC referring to DTC CHECK section Is there any DTC s Go to Step 2 of ENGINE DIAG FLOW TABLE Go to Step 2 2 DTC check Start engine and recheck DTC while engine running Is...

Page 1803: ...r proper connection to main relay 1 at terminal C and D 3 Check resistance between each two terminals See Fig 1 and 2 Between terminals A and B Infinity Between terminals C and D 100 120 4 Check that...

Page 1804: ...between terminal E21 2 and ground at ignition switch ON Is it 10 14 V Check ground circuits BLK and BLK YEL for open If OK then substitute a known good ECM PCM and recheck Go to Step 6 6 Is operating...

Page 1805: ...e Low vacuums High voltage BRN WHT circuit open WHT GRN circuit open or shorted to ground LT GRN RED circuit open or shorted to ground MAP sensor malfunction ECM PCM malfunction NOTE When DTC P0105 an...

Page 1806: ...r at LT GRN RED and BRN WHT wire terminals 3 If OK then with ignition switch ON check voltage at each of WHT GRN and LT GRN RED wire terminals See Fig 2 Is voltage about 4 6 V at each terminal Go to S...

Page 1807: ...mperature Low voltage Low resistance LT GRN circuit open or shorted to power BRN WHT circuit open IAT sensor malfunction ECM PCM malfunction NOTE When DTC P0105 P0110 P0115 and P0120 are indicated tog...

Page 1808: ...T GRN wire terminals 3 If OK then with ignition switch ON is voltage applied to LT GRN wire terminal about 4 6 V See Fig 2 Go to Step 4 LT GRN wire open or shorted to power or poor E23 14 connection I...

Page 1809: ...e High resistance or High engine coolant temperature Low voltage Low resistance YEL GRN circuit open or shorted to power BRN WHT circuit open ECT sensor malfunction ECM PCM malfunction NOTE Before ins...

Page 1810: ...T wire terminals 3 If OK then with ignition switch ON is voltage applied to YEL GRN wire terminal about 4 6 V See Fig 2 Go to Step 4 YEL GRN wire open or shorted to power or poor E23 7 connection If w...

Page 1811: ...GRY circuit open or shorted to ground WHT GRN circuit open or shorted to power or ground TP sensor malfunction ECM PCM malfunction NOTE When DTC P0105 P0110 P0115 and or P0120 are indicated together...

Page 1812: ...ction 0 A 3 Check Wire Harness 1 Disconnect connector from TP sensor with ignition switch OFF 2 Check for proper connection to TP sensor at WHT GRN GRY and BRN WHT wire terminals 3 If OK then with ign...

Page 1813: ...M malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid o...

Page 1814: ...ithin specified value linearly as shown in figure If voltmeter was used check terminal E23 6 for poor connection If OK substitute a known good ECM PCM and recheck Go to Step 3 3 Check TP Sensor 1 Turn...

Page 1815: ...FIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accid...

Page 1816: ...d 2 Does HO2S 1 output voltage deflect between 0 3 V and over 0 6 V repeatedly Intermittent trouble Check for intermittent referring to Intermittent and Poor Connection in Section 0A Check RED and BRN...

Page 1817: ...open or short Heated oxygen sensor malfunction Fuel system malfunction Exhaust gas leakage DTC CONFIRMATION PROCEDURE Refer to DTC P0130 section INSPECTION STEP ACTION YES NO 1 Was ENGINE DIAG FLOW T...

Page 1818: ...ving cycle detection logic Continuous monitoring HO2S 1 heater circuit open or shorted to ground ECM PCM malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where...

Page 1819: ...ing to Intermittent and Poor Connection Go to Step 3 terminal E23 8 See Fig 1 Voltage should be over 10 V 5 Start engine run it at idle and check voltage at the same terminal Voltage should be below 1...

Page 1820: ...DTC will set when A or B condition is detected A Max output voltage of HO2S 2 is lower than specified value or Min output voltage is higher than specified value while vehicle driving B Engine is warm...

Page 1821: ...rmal operating temperature 3 Drive vehicle under usual driving condition for 5 min and check HO2S 2 output voltage and short term fuel trim with Data List mode on scan tool and write it down 4 Stop ve...

Page 1822: ...HO2S 2 and Its Circuit Was HO2S 2 output voltage indicated on scan tool in step 3 of DTC confirmation test less than 1 275 V Go to Step 4 BLU or BRN WHT circuit open or HO2S 2 malfunction 4 Check Shor...

Page 1823: ...ime after engine start or while engine running at high load B High voltage at terminal E21 19 while engine running under other than above condition 2 driving cycle detection logic continuous monitorin...

Page 1824: ...voltage at the same terminal after 1 min from engine start Voltage should be below 1 9 V Are check result as specified Intermittent trouble Check for intermittent referring to Intermittent and Poor C...

Page 1825: ...C P0171 FUEL SYSTEM TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE When following condition occurs while engine running under closed loop condition...

Page 1826: ...ON 3 Check vehicle and environmental condition for Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C 158 F or lower 4 St...

Page 1827: ...g cm2 22 7 29 9 psi At specified idle speed 90 140 kPa 0 9 1 4 kg cm2 12 8 20 0 psi Is measured value as specified Go to Step 5 Go to Diag Flow Table B 3 Fuel Pressure Check 5 Check Fuel Injector and...

Page 1828: ...to Step 9 Replace engine coolant temp sensor 9 Check intake air temp sensor for performance See Section 6E1 Is it in good condition Go to Step 10 Replace intake air temp sensor 10 Check throttle posi...

Page 1829: ...culates the change in the crankshaft revolution speed and from how many times such change occurred in every 200 or 1000 engine revolutions it detects occurrence of misfire When ECM PCM detects a misfi...

Page 1830: ...sor malfunction Engine coolant temp sensor malfunction PCV valve malfunction EVAP control system malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there i...

Page 1831: ...6F 4 Check Fuel Pressure Refer to Section 6E1 for details 1 Release fuel pressure from fuel feed line 2 Install fuel pressure gauge See Fig 3 3 Check fuel pressure With fuel pump operating and engine...

Page 1832: ...E1 Go to Step 8 8 Check intake manifold pressure sensor for performance See Section 6E1 Is it in good condition Go to Step 9 Repair or replace 9 Check engine coolant temp sensor for performance See Se...

Page 1833: ...sensor signal during 1 revolution of camshaft CKP sensor circuit open or short Crankshaft timing belt pulley teeth damaged CKP sensor malfunction foreign material being attached or improper installat...

Page 1834: ...68 F 4 Measure resistance between each terminal and ground Insulation resistance 1 M or more Were measured resistance valves in step 3 and 4 as specified Go to Step 3 Replace CKP sensor 3 Check visua...

Page 1835: ...IPTION DTC DETECTING CONDITION POSSIBLE CAUSE No CMP sensor signal for 2 seconds at engine cranking CKP sensor signal is inputted CMP sensor circuit open or short Signal rotor teeth damaged CMP sensor...

Page 1836: ...Faulty CMP sensor 4 Check Wire Harness 1 With ignition switch at OFF position disconnect ECM PCM electrical connectors 2 Measure resistance from terminal E23 2 to E23 10 of ECM PCM connector Is resis...

Page 1837: ...r by HO2S 2 When the catalyst is functioning properly the variation cycle of HO2S 2 output voltage oxygen concentration is slower than that of HO2S 1 output voltage because of the amount of oxygen in...

Page 1838: ...min or longer While this driving if Catalyst Monitoring TEST COMPLETED is displayed in READINESS TESTS mode and DTC is not displayed in DTC mode confirmation test is completed If TEST NOT COMPLTD is...

Page 1839: ...nfirmation test Go to Step 3 Check fuel system Go to DTC P0171 P0172 Diag Flow Table 3 Check HO2S 2 for Output Voltage Perform steps 1 through 9 of DTC confirmation procedure for DTC P0136 HO2S 2 malf...

Page 1840: ...shorted RED BLK circuit open or short BLK RED circuit open Canister purge valve malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC with ignition switch ON 2 Select DTC mode on scan tool and check DTC...

Page 1841: ...AUSE Low voltage at terminal E21 20 when engine coolant temp is below 91 C 195 F 2 driving cycle detection logic continuous monitoring BLK RED or BLU circuit open or short Radiator fan relay malfuncti...

Page 1842: ...temp is lower than 91 C 196 F and A C switch turns OFF 10 14 V Is voltage as specified Intermittent trouble or faulty ECM PCM Check for intermittent referring to Intermittent and Poor Connection in S...

Page 1843: ...gear malfunction ECM malfunction Speedometer malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident a...

Page 1844: ...oltage from terminal c of VSS connector to ground See Fig 2 Is voltage within 4 5 V Faulty speedometer PPL wire open or short Poor connection of ECM connector terminal If OK substitute a known good EC...

Page 1845: ...aladjusted accelerator cable Poor movement of throttle valve Closed throttle position switch malfunction Idle speed control actuator malfunction Idle speed control relay malfunction BLU RED GRN WHT GR...

Page 1846: ...ulty ECM PCM Check for intermittent referring to Intermittent and Poor Connection in Section 0A Go to Step 3 3 Check ISC Relay 1 Ignition switch OFF and remove ISC relay ISCA 2 Check for proper connec...

Page 1847: ...vehicle 3 Repeat above step 2 15 times 4 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INSPECTION STEP ACTION YES NO 1 Was ENGINE DIAG FLOW TABLE performed Go to Step 2 G...

Page 1848: ...when written into ECM PCM 2 driving cycle detection logic continuous monitoring ECM PCM DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON and then turn ignition...

Page 1849: ...c continuous monitoring WHT BLU RED WHT or WHT circuit open or short EFE heater relay malfunction EFE heater malfunction ECM PCM malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Cle...

Page 1850: ...per connection to relay at terminal 3 and 4 See Fig 3 3 Check resistance between each two terminals Between terminals 1 and 2 Infinity Between terminals 3 and 4 100 120 4 Check that there is continuit...

Page 1851: ...CM PCM barometric pressure sensor malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Turn ignition switch ON for 2 sec crank engine for 2 sec and r...

Page 1852: ...FF 2 Clear DTC with ignition switch ON crank engine and run it at idle for 3 min 3 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INSPECTION STEP ACTION YES NO 1 Was ENGINE...

Page 1853: ...starting engine WHT BLU circuit open ECM PCM malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and run it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION STEP...

Page 1854: ...tor is as specified respectively and then substitute known good ECM PCM and recheck Go to Step 3 3 Injector Check 1 Check injector for fuel Injection referring to FUEL INJECTOR ON VEHICLE INSPECTION i...

Page 1855: ...or connector with ignition switch OFF 2 Check for proper connection to resistor at each terminals 3 If connection is OK check resistance Is resistance 1 9 2 1 at 20 C 68 F BLK RED BLU ORN or BLU WHT w...

Page 1856: ...heck Fuel Pump for Operation 1 Remove fuel pump relay from relay box with ignition switch OFF 2 Check for proper connection to relay at each terminals 3 If OK using service wire connect terminals of r...

Page 1857: ...6 1 94 GENERAL INFORMATION AND ENGINE DIAGNOSIS Fig 1 for Step 2 Fig 2 for Step 3 Fig 3 for Step 4 Fuel pump relay connector...

Page 1858: ...Normal fuel pressure Go to Step 3 3 1 Start engine and warm it up to normal operating temperature 2 Keep it running at specified idle speed Is fuel pressure then within 90 140 kPa 0 9 1 4 kg cm2 12 8...

Page 1859: ...kg cm2 63 9 psi or more Faulty fuel pressure regulator Clogged fuel filter Restricted fuel feed hose or pipe Faulty fuel pump or Fuel leakage from hose connection in fuel tank 10 1 Disconnect fuel re...

Page 1860: ...INSPECTION STEP ACTION YES NO 1 1 Disconnect ECM connectors with ignition switch at OFF position 2 Check resistance between E22 9 terminal and E23 9 terminal 3 Is it within specification Reference va...

Page 1861: ...3 terminal under each condition given in table below NOTE When A C evaporator thermistor temp is below 2 5 C 36 5 F A C remain OFF E21 23 terminal voltage become 0 1 V This condition is not abnormal 2...

Page 1862: ...se 2 Operator s manual 3 Tech 1 A 4 DLC cable 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor 1 Pressure gauge 09912 58441 2 Pressure hose 09912 58...

Page 1863: ...64 SPECIAL TOOLS 6A 75 REQUIRED SERVICE MATERIALS 6A 76 SECTION 6A ENGINE MECHANICAL WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system...

Page 1864: ...t equipped with a direct act ing type S O H C Single Overhead Camshaft valve mechanism The single overhead camshaft is mounted over the cylinder head it is driven from crankshaft through tim ing belt...

Page 1865: ...cted from a small hole provided on big end of connecting rod to lubricate piston rings and cylinder wall In another path oil goes up to cylinder head and lubri cates camshaft journals and hydraulic va...

Page 1866: ...ush the bucket body the bucket body is pushed against the cam and the body against the stem by the plunger spring force In this state the valve lash is kept to O At O valve lash the oil pressure becom...

Page 1867: ...CTING RODS The piston is cast aluminum alloy and has two compression rings and one oil ring Among two compression rings top and 2nd rings the top ring is plated with hard chromium for improvement in a...

Page 1868: ...1 PCV valve 12 EFE heater 13 To fuel tank 14 To EVAP canister 15 To EVAP canister purge valve A Forward 1 MAP sensor 2 Filter 3 EVAP canister purge valve 4 Air chamber case 5 Vacuum pipe 6 Fuel pipe 7...

Page 1869: ...on 5 Install special tool Compression gauge into spark plug hole Special Tool A 09915 64510 6 Disengage clutch to lighten starting load on engine and de press accelerator pedal all the way to make thr...

Page 1870: ...specified idle speed see Section 6E1 and read vacuum gauge Vacuum should be within following specifica tion Vacuum specification 52 6 65 8 kPa 40 50 cm Hg 15 7 19 7 in Hg at specified idling speed 4...

Page 1871: ...sealing tape and tighten switch to speci fied torque NOTE If sealing tape edge is bulged out from screw threads of switch cut it off Tightening Torque a 14 N m 1 4 kg m 10 5 lb ft 9 After oiling oil f...

Page 1872: ...ir from air outlet side of element INSTALLATION Reverse removal procedure for installation AIR CLEANER ASSEMBLY REMOVAL 1 Disconnect air cleaner outlet hose 1 from air cleaner assembly 2 2 Remove suct...

Page 1873: ...inder head cover gasket 1 to cylinder head cover 2 NOTE Be sure to check each of these parts for deterioration or any damage before installation and replace if found defective 2 Install cylinder head...

Page 1874: ...REMOVAL 1 Relieve fuel pressure according to procedure described in Sec tion 6 1 2 Disconnect negative cable at battery 3 Drain cooling system WARNING To help avoid danger of being burned do not remov...

Page 1875: ...ipes 7 Disconnect coolant hoses from intake manifold and throttle body 8 Remove EVAP surge tank with EVAP canister purge valve 9 Disconnect the following vacuum hoses Pressure sensor hose from intake...

Page 1876: ...ose to PCV valve 5 Connect vacuum hoses 6 Connect coolant hoses 7 Connect fuel return and feed hoses to throttle body 8 Connect electric lead wire 9 Install EVAP surge tank with EVAP canister purge va...

Page 1877: ...eal ring 7 Exhaust No 1 pipe 8 Oxygen sensor No 2 9 Catalytic converter case 10 Catalytic converter case gasket EXHAUST MANIFOLD WARNING To avoid danger of being burned do not service exhaust system w...

Page 1878: ...uts to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 3 Install exhaust manifold cover 2 4 Connect oxygen sensor No 1 1 coupler and clamp its wire se curely 5 Install catalytic conver...

Page 1879: ...ensioner spring screw Tightening Torque TIMING BELT AND BELT TENSIONER REMOVAL 1 Disconnect negative cable at battery 2 Remove right side of engine under cover 1 3 Disconnect A C suction and discharge...

Page 1880: ...rankshaft pulley by removing pulley bolts 1 10 Release harness clamps 11 Remove timing belt outside cover 1 12 For installation of timing belt align 4 timing marks as shown in figure by turning cranks...

Page 1881: ...ft and crankshaft independently more than such an extent as shown in figure If turned interference may occur among piston and valves and parts related to piston and valves may be damaged Never bend ti...

Page 1882: ...ft but be careful not to turn it more than its allowable turning range which is described on previous page 4 Check that timing mark 2 on crankshaft timing belt pulley 4 is aligned with arrow mark 3 on...

Page 1883: ...ively Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft b 27 N m 2 7 kg m 19 5 lb ft 7 Install timing belt outside cover Before installing make sure that rubber seal 1 is between wa ter pump and oil pump...

Page 1884: ...ssor bracket and A C compressor if equipped 14 Connect A C suction and discharge hoses if equipped 15 Adjust drive belt tension referring to ENGINE COOLING sec tion 16 Adjust A C compressor belt tensi...

Page 1885: ...ainer bolt 11 Oil pump strainer bracket bolt Tightening Torque Do not reuse OIL PAN AND OIL PUMP STRAINER REMOVAL 1 Raise vehicle 2 Drain engine oil by removing drain plug 1 3 Remove right side of eng...

Page 1886: ...shown in figure Install oil pump strainer to cylinder block Tighten strainer bolt 3 first and then bracket bolt 4 to specified torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 3 Install oil pan t...

Page 1887: ...m 7 5 lb ft 5 Install exhaust No 1 pipe and connect oxygen sensor No 2 con nector Tighten bolts to specified torque Tightening Torque a 42 N m 4 2 kg m 30 5 lb ft NOTE Use new gasket for exhaust No 1...

Page 1888: ...crew 13 Bolt short 14 Bolt long Tightening Torque Do not reuse OIL PUMP REMOVAL 1 Disconnect negative cable at battery 2 Remove timing belt as previously outlined 3 Remove generator and its bracket NO...

Page 1889: ...ENGINE MECHANICAL 6A 27 DISASSEMBLY 1 Remove oil level gauge guide bolt 3 and pull out guide 2 from oil pump 1 2 Remove rotor plate 1 3 Remove outer rotor 1 and inner rotor 2...

Page 1890: ...r rotors rotor plate and oil pump case for excessive wear or damage MEASUREMENT Radial clearance Check radial clearance between outer rotor 1 and case using thickness gauge If clearance exceeds its li...

Page 1891: ...by hand Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 5 Apply engine oil to O ring 1 and install O ring and guide 2 INSTALLATION 1 Install two oil pump pins and oil pump gasket to cylinder block Use a...

Page 1892: ...m 94 0 lb ft 6 Install timing belt tensioner oil pump strainer oil pan and other parts as previously outlined 7 Check to ensure that all removed parts are back in place Reinstall any necessary parts w...

Page 1893: ...ach part Do not reuse CAMSHAFT AND HYDRAULIC VALVE LASH ADJUSTER REMOVAL 1 Disconnect negative cable at battery 2 Remove cylinder head cover as previously outlined 3 Remove distributor and then its ca...

Page 1894: ...to body of adjuster for oil in high pres sure chamber in adjuster will leak Immerse removed adjuster 2 in clean engine oil 1 and keep it there till reinstalling it so as to prevent oil leakage If it i...

Page 1895: ...Cam Wear Using a micrometer measured height of cam If measured height is below limit replace camshaft Intake exhaust cam Standard Limit Intake exhaust cam height 40 415 40 575 mm 1 5911 1 5974 in 40 3...

Page 1896: ...lts to specified torque Housings MUST be torqued to specification in order to assure proper reading of camshaft journal clearance NOTE Do not rotate camshaft while gaging plastic is installed 5 Remove...

Page 1897: ...lash adjuster to cylinder head Apply engine oil around valve lash adjuster and then install it to cylinder head 3 Install camshaft to cylinder head After applying engine oil to camshaft journal and al...

Page 1898: ...ll camshaft oil seal After applying engine oil to oil seal lip press fit camshaft oil seal till oil seal surface becomes flush with housing surface 6 Install camshaft timing belt pulley 1 to camshaft...

Page 1899: ...ADJUSTER NOISE DIAGNOSIS In case of the followings valve lash adjuster noise may be caused by air trapped into valve lash adjusters Vehicle is left for 24 hours or more Engine oil is changed Hydraulic...

Page 1900: ...e 11 Valve stem seal 12 Valve spring seat 13 Exhaust valve 14 Intake valve 15 Oil seal 16 Gasket 17 Camshaft housing bolt Tightening Torque Do not reuse Apply engine oil to sliding surfaces of each pa...

Page 1901: ...above wire harnesses from clamps 7 Disconnect following hoses Canister purge hose from EVAP canister purge valve Radiator inlet hose from thermostat case Brake booster hose from intake manifold Heate...

Page 1902: ...gine right mounting swing bracket 2 14 Remove support device 15 Loosen cylinder head bolts in such order as indicated in figure and remove them 16 Check all around cylinder head for any other parts re...

Page 1903: ...pecial tool and remove spring retainer and valve spring 5 Remove valve from combustion chamber side 6 Remove valve stem oil seal 1 from valve guide and then valve spring seat 2 NOTE Do not reuse oil s...

Page 1904: ...08 0 0018 in 0 07 mm 0 0027 in g clearance Ex 0 045 0 072 mm 0 0018 0 0028 in 0 09 mm 0 0035 in If bore gauge is not available check end deflection of valve stem with a dial gauge instead Move stem en...

Page 1905: ...must be a continuous ring without any break and the width of pattern must be within specified range Standard seating width revealed In 1 3 1 5 mm by contact pattern on valve face Ex 0 0512 0 0590 in...

Page 1906: ...o valves and valve seats too Check cylinder head for cracks in intake and exhaust ports com bustion chambers and head surface Flatness of gasketed surface Using a straightedge and thickness gauge chec...

Page 1907: ...eakened valve springs can cause chatter not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure Item Standard Limit Valve spring free length 42 29 m...

Page 1908: ...le with special tools Drive in new valve guide until special tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrudes by 11 5 mm 0 45 in from cylinder he...

Page 1909: ...only by pushing special tool by hand Tapping or hitting special tool may cause damage to seal 6 Install valve to valve guide Before installing valve to valve guide apply engine oil to stem seal valve...

Page 1910: ...e manner as in a again tighten them to specified torque Tightening Torque a 75 N m 7 5 kg m 54 lb ft 3 Install rubber seal 3 between water pump 2 and cylinder head 1 4 Install cylinder head cover 5 In...

Page 1911: ...as previously out lined 2 Drain engine oil 3 Remove oil pan and oil pump strainer as previously outlined 4 Mark cylinder number on all pistons connecting rods and rod bearing caps using silver pencil...

Page 1912: ...Using piston ring expander remove two compression rings Top and 2nd and oil ring from piston 2 Fit piston 1 and connecting rod assembly to special tool and then press piston pin out of connecting rod...

Page 1913: ...ence between thrust and axial measurements exceeds out of round limit Cylinder bore dia limit 74 15 mm 2 9193 in Tapper and out of round limit 0 10 mm 0 0039 in NOTE If any one of three cylinders has...

Page 1914: ...tion at two positions Ring groove clearance Before checking piston grooves must be clean dry and free of carbon Fit new piston ring 1 into piston groove and measure clearance between ring and ring lan...

Page 1915: ...end gap 2nd ring 0 2 0 35 mm 0 0079 0 0138 in 0 7 mm 0 0275 in ga Oil ring 0 2 0 6 mm 0 0079 0 0236 in 1 8 mm 0 0709 in Connecting Rod Big end side clearance Check big end of connecting rod for side...

Page 1916: ...ition must be replaced Two kinds of rod bearing are available standard size bearing and 0 25 mm undersize bearing To distinguish them 0 25 mm under size bearing has the stamped number USO25 on its bac...

Page 1917: ...ing a standard size piston make sure to match piston with cylinder as follows a Each piston has stamped number 1 or 2 as shown It represents outer diameter of piston b There are also stamped numbers o...

Page 1918: ...e oil to piston pin holes in piston and con necting rod fit connecting rod to piston as shown in figure Oil hole 4 should be come on intake side 2 Fit piston pin 2 to piston 3 and connecting rod 4 a P...

Page 1919: ...rom 2nd ring by referring to figure When installing oil ring 3 install spacer first and then two rails 4 After installing three rings 1st 2nd and oil rings distribute their end gaps as shown in figure...

Page 1920: ...t 6 Reverse removal procedure for installation nothing the follow ing points Adjust water pump drive belt tension referring to ENGINE COOLING section Adjust A C compressor belt tension if equipped Ref...

Page 1921: ...1 bolt 22 Rear mounting bracket No 1 to No 2 bolt 23 Rear mounting bush bolt 24 Rear mounting body bolt Tightening Torque 1 Right mounting 2 Right mounting swing bracket 3 Right mounting bracket 4 Lef...

Page 1922: ...ill hot Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon 5 Disconnect radiator inlet hose from thermostat case and outlet hose from water inlet pipe 6 Re...

Page 1923: ...t and left engine under covers 14 Disconnect oxygen sensor No 2 coupler 1 and remove ex haust No 1 pipe 2 15 Drain engine and transmission oil 16 Remove stabilizer bar 1 referring to Section 3D of the...

Page 1924: ...tall support device 20 Remove engine rear mounting nuts 1 21 Remove engine left mounting nuts 2 22 Remove engine right mounting bracket bolts 3 and nut 4 23 Before removing engine with transmission fr...

Page 1925: ...ith differential gear Use care not to damage oil seal lip when inserting Install stabilizer bar refer to Section 3D of the Service Manu al mentioned in FOREWORD of this manual Install exhaust No 1 pip...

Page 1926: ...e oil to sliding surfaces of each part 76 N m 7 6 kg m 11 N m 1 1 kg m 53 N m 5 3 kg m MAIN BEARINGS CRANKSHAFT AND CYLINDER BLOCK REMOVAL 1 Remove engine with transmission from body as previously out...

Page 1927: ...bearing with new standard one or oversize one to obtain standard thrust play Crankshaft Thrust Play Standard 0 11 0 31 mm 0 0044 0 0122 in Limit 0 38 mm 0 0149 in Thickness of crankshaft thrust bearin...

Page 1928: ...3 and 4 Tighten cap bolts to specified torque Inspection Check bearings for pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Never replace one half wit...

Page 1929: ...clearance is out of specifica tion select a new standard bearing according to following proce dure and install it 1 First check journal diameter by using following procedure As shown in figure crank w...

Page 1930: ...caps 1 2 3 and 4 respectively For example in figure the first leftmost alphabet B indicates that cap bore dia of bearing cap 1 is within 49 006 49 012 mm and the fifth rightmost alphabet A indicates t...

Page 1931: ...eck bearing clearance with newly selected standard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block due to any...

Page 1932: ...r block select an under size bearing by referring to table given below Check bearing clearance with newly selected undersize bear ing Measured journal diameter 44 744 44 750 mm 1 7616 1 7618 in 44 738...

Page 1933: ...of gasketed surface Using straightedge and thickness gauge check gasketed surface for distortion and if flatness exceeds its limit correct it Item Standard Limit Flatness 0 03 mm 0 0012 in 0 06 mm 0...

Page 1934: ...n Be sure to oil crankshaft journals journal bearings thrust bearings crankpins connecting rod bearings pistons pis ton rings and cylinder bores Journal bearings bearing caps connecting rods rod bear...

Page 1935: ...s smoothly when turning it by 7 0 N m 0 7 kg 5 1 lb ft torque or below 5 Install new gasket and oil seal housing Do not reuse gasket removed in disassembly Apply engine oil to oil seal lip before inst...

Page 1936: ...ad bolts to specified torque as pre viously outlined Whenever installing cylinder head to new cylinder block use following procedure to tighten cylinder head bolts Tighten cylinder head bolts to speci...

Page 1937: ...r attachment 09916 84511 Forceps 09916 44910 Valve guide remover 09916 34541 Reamer handle 09916 38210 Reamer 11 mm 09916 58210 Valve guide installer handle 09916 56011 Valve guide installer attachmen...

Page 1938: ...se 2 Base cap 3 Driver handle 4 Piston pin guide for installation 5 Piston pin guide for removal 6 Spring 7 Spring guide REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Sealant SUZ...

Page 1939: ...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 1940: ...ck Cylinder head Intake manifold Throttle body Heater unit Water inlet pipe GENERAL DESCRIPTION The cooling system consists of the radiator cap radiator coolant reservoir hoses water pump cooling fan...

Page 1941: ...mperature lower than 36 C 33 F NOTE Alcohol or methanol base coolant or plain wa ter alone should not be used in cooling system at any time as damage to cooling system could occur Even in a market whe...

Page 1942: ...ust or replace Adjust MAINTENANCE WATER PUMP BELT TENSION WARNING Disconnect negative cable at battery before checking and adjusting belt tension 1 Inspect belt for cracks cuts deformation wear and cl...

Page 1943: ...ove radiator inlet hose 2 at thermostat cap 3 Remove water inlet pipe bolt 4 Remove thermostat cap 1 5 Remove thermostat 1 INSTALLATION 1 When positioning thermostat 1 on thermostat case 3 be sure to...

Page 1944: ...f this manual only for RE MOVAL and INSTALLATION of timing belt belt tensioner and tim ing belt outside cover refer to TIMING BELT AND TENSIONER of Section 6A in this manual REQUIRED SERVICE MATERIAL...

Page 1945: ...tentional activation of the system or could 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 th...

Page 1946: ...level gauge 13 Fuel pump 14 Fuel cut valve 15 Fuel pump gasket 16 Fuel return line 6C 2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM The main components of the fuel system are fuel tank fuel pump assem...

Page 1947: ...line 6 Fuel vapor line 7 Fuel tank inlet valve 8 Fuel tank bolt 9 Fuel pump bolt 10 Fuel filler hose clamp 11 Fuel pump gasket 12 Fuel return line Tightening Torque Do not reuse CAUTION Do not disasse...

Page 1948: ...l system fol lowing cautions should be always observed Disconnect negative cable at battery DO NOT smoke and place NO SMOKING signs at work area Be sure to have CO2 fire extinguisher handy Be sure to...

Page 1949: ...ction 3B of the Service Manual mentioned in FOREWORD of this manual 4 Remove pipe cover 2 from vehicle 5 Disconnect fuel pipe joints and fuel vapor hoses from the front end and the rear end of each fu...

Page 1950: ...oken replace it with a new one 2 Install pipes with pipe clamps to vehicle 3 Connect fuel hoses and pipes to each pipe CAUTION When connecting joint clean outside surfaces of pipe where joint is to be...

Page 1951: ...fuel pipe joints and fuel vapor hose from fuel pipes For quick joint 1 disconnect it as follows a Remove mud dust and or foreign material between pipe and joint by blowing compressed air b Unlock join...

Page 1952: ...r leaks and damage Replace any damaged or malconditioned parts INSTALLATION 1 If parts have been removed from fuel tank install them before installing fuel tank to vehicle 2 Raise fuel tank with jack...

Page 1953: ...securely CAUTION When connecting joint clean outside surfaces of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely o...

Page 1954: ...stem 6E1 32 PCV System 6E1 34 SPECIAL TOOLS 6E1 36 TIGHTENING TORQUE SPECIFICATIONS 6E1 36 SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air...

Page 1955: ...ivided into 3 major sub systems air fuel delivery system electronic control system and emission control system Air fuel delivery system includes fuel pump throttle body etc Electronic control system i...

Page 1956: ...r 1 17 Warm up three way catalytic convertor WU TWC 18 Three way catalytic convertor 19 IAT sensor 20 ECT sensor 21 EFE heater 22 EVAP canister purge valve 23 EVAP canister 24 Heated oxygen sensor 2 2...

Page 1957: ...s the fuel pres sure applied to the fuel injector the fuel pressure in the fuel feed line is always kept a certain amount higher than the pressure in the intake manifold by the fuel pressure regulator...

Page 1958: ...elay OTHERS A ECM PCM B Main relay C EVAP canister D Injector resistor E EFE heater F Data link connector ENGINE AND EMISSION CONTROL SYSTEM 6E1 5 The electronic control system consists of 1 various s...

Page 1959: ...6E1 6 ENGINE AND EMISSION CONTROL SYSTEM IG COIL MAIN FUSE...

Page 1960: ...0 11 12 13 14 15 16 Power source for sensors Camshaft position sensor Crankshaft position sensor Closed throttle position switch Manifold absolute pressure sensor Throttle position sensor Engine coola...

Page 1961: ...02 0 07 in With pedal depressed fully If out of specification loosen accelerator cable lock nut and ad just by turning adjusting nut 3 Be sure to tighten lock nut 4 securely after adjustment IDLE SPEE...

Page 1962: ...range there is a faulty condition somewhere Check each of related systems and parts AIR AND FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION 1 Relieve fuel pressure referring to Section 6 1 2 Separate ai...

Page 1963: ...cm2 90 140 kPa 12 8 20 0 psi With fuel pump operating and engine at stop 1 6 2 1 kg cm2 160 210 kPa 22 7 29 9 psi Within 1 min after engine fuel pump stop Pressure reduces as time passes Over 0 9 kg...

Page 1964: ...fuel filler cap after checking If above check result is not satisfactory advance to DIAGNOS TIC FLOW TABLE B 2 2 Fuel pressure should be felt at fuel return hose for 2 seconds af ter ignition switch O...

Page 1965: ...m hose 5 ISC actuator 6 Fuel return hose 7 Fuel feed hose THROTTLE BODY ON VEHICLE INSPECTION Check that throttle valve lever moves smoothly Vacuum passage inspection With fingers placed against vacuu...

Page 1966: ...parts While disassembling and assembling throttle body use spe cial care not to deform levers on throttle valve shaft or cause damage to any other parts 1 Remove fuel injector from throttle body accor...

Page 1967: ...ody 3 Install upper body on gasket using care not to cause gasket to slip out of place 4 Make sure to injector wire harness to fit in grooves of throttle body and install wire cover to throttle body T...

Page 1968: ...eck for fuel leaks and engine coolant leaks Adjust accelerator cable to specification according to proce dure described in ACCELERATOR CABLE ADJUSTMENT FUEL INJECTOR ON VEHICLE INSPECTION 1 With batte...

Page 1969: ...6 1 2 Disconnect battery negative cable at battery 3 Remove air chamber case 4 Remove air chamber case mounting stay from throttle body 5 Remove injector wire and then remove fuel injector from throt...

Page 1970: ...h engine OFF and ignition switch ON check for fuel leaks 6 Install air chamber case mounting stay as shown left 7 Install air chamber case ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE ECM CAUTION A...

Page 1971: ...egative terminal to Ground terminal Then check voltage between Vout and Ground Also check if voltage reduces when vacuum is applied up to 40 cmHg by using vacuum pump Output voltage Vin voltage 4 5 5...

Page 1972: ...from throttle body INSTALLATION 1 Install TP sensor to throttle body Fit TP sensor to throttle body in such way that its adjusting holes are a little away from TP sensor screw holes as shown in the fi...

Page 1973: ...in DLC cable b Select Data List mode on SUZUKI scan tool c Observe TP sensor voltage 4 Turn TP sensor clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified...

Page 1974: ...ure replace IAT sensor INSTALLATION Reverse removal procedure noting the following Clean mating surfaces of IAT sensor and air cleaner outlet hose Connect IAT sensor coupler securely ENGINE COOLANT TE...

Page 1975: ...sensor terminals while heating water gradually If measured resistance doesn t show such characteristic as shown in the figure replace ECT sensor INSTALLATION Reverse removal procedure noting the foll...

Page 1976: ...WARNING To avoid danger of being burned do not touch exhaust system when system is hot Oxygen sensor removal should be per formed when system is cool 1 Disconnect negative cable from battery 2 Hoist v...

Page 1977: ...OL SYSTEM VEHICLE SPEED SENSOR VSS INSPECTION Check vehicle speed sensor referring to step 3 of DTC P0500 Flow Chart If malfunction is found replace REMOVAL INSTALLATION Refer to Section 7A FUEL LEVEL...

Page 1978: ...ition sensor and pulley tooth is free from any metal particles and damage 2 Install crankshaft position sensor to oil pan 3 Connect connector to it securely MAIN RELAY INSPECTION 1 Disconnect negative...

Page 1979: ...with A T model selector lever in P range A C is OFF and that parking brake lever is pulled all the way up 1 Warm up engine to normal operating temperature 2 While listening to sound of injector by usi...

Page 1980: ...that plunger of ISC actuator moves when ignition switch is turned from OFF to ON once If abnormality is found in Steps 4 and 5 check ISC relay ISC actuator ISC electric circuit and closed throttle po...

Page 1981: ...check that CTP switch is ON If it is OFF move ISC actuator again and turn CTP switch ON When positive terminal is connected to E terminal while plunger is contracted Plunger expands When positive term...

Page 1982: ...er to EFE terminals and check for voltage under each condition given below CONDITION VOLTAGE Fast idle condition Coolant temp below 80 C 176 F Engine speed over 750 r min Battery voltage After warming...

Page 1983: ...cture of EFE heater relay is the same as that of main relay Check its resistance and operation using the same procedure as that for main relay If found defective replace RADIATOR FAN CONTROL SYSTEM SY...

Page 1984: ...relay box 3 Structure of RFC relay is the same as that of main relay Check its resistance and operation using the same procedure as that for main relay If found defective replace RADIATOR FAN INSPECT...

Page 1985: ...and 4000 r min NOTE The EVAP canister purge system does not perform purging vacuum is not detected at the purge hose unless the en gine is sufficiently warmed up and the heated oxygen sen sor is activ...

Page 1986: ...e of EVAP canister purge valve 30 34 at 20 C 68 F If resistance is as specified proceed to next operation check If not replace 3 Disconnect vacuum hoses from intake manifold and its pipe 4 With couple...

Page 1987: ...tank pipe there should be no restriction of flow through purge pipe and air pipe If operation differs from above description EVAP canister must be replaced 3 Install EVAP canister and connect hoses to...

Page 1988: ...cking vacuum stop engine and check PCV valve for sticking With engine stopped connect a new hose to PCV valve for in spection Blow air into the hose and check that air flows with difficulty from cylin...

Page 1989: ...lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor 6E1 36 ENGINE AND EMISSION CONTROL SYSTEM SPECIAL TOOLS TIGHTENING TORQUE SPECIFICATIONS Fastening parts Tightening torque Fast...

Page 1990: ...n timing under every en gine condition Receiving signals which indicate the engine condition from the sensors e g engine revo lution intake air pressure coolant temperature etc it selects the most sui...

Page 1991: ...2 Main fuse 3 Ignition switch 4 Main relay 5 Ignition coil 6 Igniter 7 Noise suppressor 8 Distributor 9 Rotor 10 Signal rotor 11 CMP sensor signal generator 12 Spark plug 13 MAP sensor 14 TP sensor 15...

Page 1992: ...tic Flow Table in SECTION 6 1 performed Go to Step 2 Go to Engine Diagnostic Flow Table in SECTION 6 1 2 Ignition Spark Test 1 Check all spark plug for condition and type referring to Spark Plugs in t...

Page 1993: ...signal YEL BLU wire circuit for open short and poor connection Are circuits in good condition Go to Step 10 Repair or replace 10 Igniter Check 1 Check igniter referring to Igniter in this section Is c...

Page 1994: ...f each spark plug sparks 4 If no spark is emitted inspect high tension cords spark plugs ignition coil distributor etc HIGH TENSION CORDS 1 Remove high tension cord at ignition coil while gripping its...

Page 1995: ...with spark plug cleaner or replace them with specified new plugs Spark plug air gap a 1 0 1 1 mm 0 039 0 043 in Spark plug type NGK BPR6ES 11 DENSO W20EPR U11 4 Install spark plugs and torque them to...

Page 1996: ...rged 1 Disconnect igniter coupler 1 2 Remove igniter 2 from its bracket 3 Arrange 3 new batteries in series 1 check total voltage is about 4 7 V 4 Connect light bulb 2 between d terminal of igniter 3...

Page 1997: ...adjust gap to specification After adjustment tighten securing screws and recheck gap NOTE Check to make sure that CMP sensor signal generator tooth is free from any metal particles 4 Install distribu...

Page 1998: ...8 Using timing light check that timing is within specification Initial ignition timing Ignition timing fixed 5 3 BTDC at idle speed Ignition order 1 3 2 Special Tool A 09900 27301 or 09930 76420 9 If...

Page 1999: ...ood condition If new O ring is installed apply oil 1 Install distributor without cap to camshaft Fit the dogs of distributor coupling into the slots of camshaft when installing The dogs of distributor...

Page 2000: ...idge 09931 76030 16 14 pin DLC cable 09930 76420 Timing light Dry cell type 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...

Page 2001: ...unting 6G2 4 Disassembly 6G2 5 Inspection 6G2 6 Reassembly 6G2 10 Performance Test 6G2 10 Pull in test 6G2 10 Hold in test 6G2 10 Plunger and pinion return test 6G2 11 No load performance test 6G2 11...

Page 2002: ...in battery terminal connection Loose grounding cable connection Fuse set loose or blown off Poor contacting action of ignition switch and magnetic switch Lead wire coupler loose in place Open circuit...

Page 2003: ...n tip Poor sliding of over running clutch Over running clutch slipping Worn teeth of ring gear Replace over running clutch Repair Replace over running clutch Replace flywheel M T or drive plate A T No...

Page 2004: ...ightening Torque Apply lithium grease 6 5 N m 0 65 kg m 5 0 lb ft UNIT REPAIR OVERHAUL DISMOUNTING AND REMOUNTING 1 Disconnect positive and negative battery lead cables at battery 2 Disconnect EVAP ca...

Page 2005: ...sible mistakes can be avoided Do not clamp yoke in a vise or strike it with a hammer during disassembling and reassembling 1 Remove nut securing the end of field coil lead to terminal on the head of m...

Page 2006: ...Inspect commutator for dirt or burn Correct with sandpaper or lathe if necessary Check commutator for uneven wear with armature 1 supported on V blocks 2 If deflection of dial gauge pointer exceeds l...

Page 2007: ...ity ar mature is grounded and must be replaced Open circuit test Check for continuity between segments If there is no continuity at any point there is an open circuit and armature must be re placed FI...

Page 2008: ...ive side If continuity exists brush holder is grounded due to defective in sulation and should be replaced SPRING Inspect brush spring for wear damage or other abnormal condi tions Replace if necessar...

Page 2009: ...nd release it Plunger should return quickly to its original position Replace if necessary Pull in coil open circuit test Check for continuity across magnetic switch S terminal and M terminal If no con...

Page 2010: ...rque 9 N m 0 9 kg m 6 5 lb ft PERFORMANCE TEST WARNING When performing the following test be sure to connect the battery and the starting motor with a lead wire of the same size as the cable that was...

Page 2011: ...disassemble and inspect start ing motor 4 No Load Performance Test a Connect motor lead wire switch to motor 1 to terminal M 2 b Connect battery and ammeter to starter as shown c Check that starter ro...

Page 2012: ...ic 11 5V 50 A maximum 7500 rpm minimum Around at 20 C Load characteristic 8 V 200 A 4 3 N m 0 43 kg m 3 1 lb ft minimum 1400 rpm minimum 68 F Locked characteristic 5 V 400 A maximum 8 4 N m 0 84 kg m...

Page 2013: ...d in this section refer to the same section of service manual men tioned in the FOREWORD of this manual CONTENTS GENERATOR 6H 2 GENERAL DESCRIPTION 6H 2 DIAGNOSIS 6H 3 UNIT REPAIR OVERHAUL 6H 6 Dismou...

Page 2014: ...attery terminal E Ground L Lamp terminal 1 Pulley 2 Pulley nut 3 Rotor fan 4 Stator coil 5 Stator core 6 Field coil 7 Regulator 8 Brush 9 Front housing 10 Rear housing 11 Rectifier 6H 2 CHARGING SYSTE...

Page 2015: ...pewing of electrolyte from vents Noise from generator may be caused by a loose drive pulley loose mounting bolts worn or dirty bearings defective diode or defective stator FAULTY INDICATOR LAMP OPERAT...

Page 2016: ...tery defect is suspected referring to BATTERY section 4 Inspect wiring for defects Check all connections for tightness and cleanliness battery cable connections at battery starting motor and ignition...

Page 2017: ...nerator LOAD CHECK 1 Run engine at 2 000 rpm and turn on head light and heater mo tor 2 Measure current and if it is less than 20 A replace generator OVERCHARGED BATTERY 1 To determine battery conditi...

Page 2018: ...ttery 2 Hoist vehicle and remove right side splash cover 3 Loosen generator belt adjusting bolt and generator pivot bolt When servicing vehicle equipped with A C remove compressor drive belt before re...

Page 2019: ...Brush 16 Connector 17 Rear end cover Tightening torque 80 N m 8 0 kg m 5 CHARGING SYSTEM 6H 7 DISASSEMBLY AND ASSEMBLY SPECIFICATIONS GENERATOR Rated voltage 12 V Nominal output 70 A Permissible max s...

Page 2020: ...Prepared by Service Department 1st Ed March 2001 Printed in Belgium Printing March 2001 288...

Page 2021: ...another vehicle sys tem both need repair Suzuki recommends that the air bag system be repaired first to help avoid unintended air bag deployment Do not modify the steering wheel instru ment panel or...

Page 2022: ...to obtain the full performance of the vehicle When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricant sealants etc as spe...

Page 2023: ......

Page 2024: ...mation and Engine Diagnosis Engine Mechanical Engine Cooling Engine Fuel Engine and Emission Control System Ignition System Cranking System 1 2kW Reduction Type Cranking System 0 9kW No Reduction Type...

Page 2025: ......

Page 2026: ...Service 0A 10 Electrical Circuit Inspection Procedure 0A 11 Intermittents and Poor Connection 0A 14 IDENTIFICATION INFORMATION 0A 16 Vehicle Identification Number 0A 16 Engine ldentification Number 0A...

Page 2027: ...a CONTENTS on the first page of EACH SECTION where the main items in that section are listed 2 Each section of this manual has its own pagination It is indicated at the top of each page along with the...

Page 2028: ...void unintended air bag system activation Do not modify the steering wheel dashboard or any other air bag system components Modifications can adversely affect air bag system performance and lead to in...

Page 2029: ...of the module When placing a live air bag inflator module on a bench or other surface always face the bag up away from the surface As the live passenger air bag inflator module must be placed with it...

Page 2030: ...lace where the ambient temperature below 65 C 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wires or con nector on the underside of the pretens...

Page 2031: ...passenger or seat belt pretensioners driver and passenger wipe off im mediately with a dry cloth Air bag wire harness can be identified easily as it is cov ered with a yellow protection tube Be very...

Page 2032: ...ble materials such as gasoline and refrigerant make sure that the area you work in is well ventilated To avoid getting burned keep away from hot metal parts such as the radiator exhaust manifold tail...

Page 2033: ...in the proper order and position Whenever you use oil seals gaskets packing O rings lock ing washers split pins self locking nuts and certain other parts as specified be sure to use new ones Also bef...

Page 2034: ...ctor without first releasing the fuel pressure or fuel can be sprayed out under pressure PRECAUTIONS FOR CATALYTIC CONVERTER For vehicles equipped with a catalytic converter use only un leaded gasolin...

Page 2035: ...mage to coupler When connecting lock type coupler insert it till clicking sound is heard and connect it securely Never connect any tester voltmeter ohmmeter or whatever to electronic control unit when...

Page 2036: ...etc Before measuring voltage at each terminal check to make sure that battery voltage is 11V or higher Such terminal volt age check at low battery voltage will lead to erroneous diag nosis ELECTRICAL...

Page 2037: ...act possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is locked in the connector fully 4 Using continuity check or voltage check...

Page 2038: ...ured values were as listed below it means that there is a resistance abnormality of such level that corre sponds to the voltage drop in the circuit between terminals A 1 and B 1 Voltage Between C 1 an...

Page 2039: ...solenoid can occasionally be at fault When checking it for proper connection perform careful check of suspect circuits for Poor mating of connector halves or terminals not fully seated in the connect...

Page 2040: ...n sion or replace Poor terminal to wire connection Check each wire harness in problem circuits for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace Wi...

Page 2041: ...HICLE IDENTIFICATION NUMBER The vehicle identification number is located on the front dash panel in the engine room ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block TRANSMISSIO...

Page 2042: ...g label on contact coil and combination switch assemblies Air bag warning label on driver air bag inflator module GENERAL INFORMATION 0A 17 WARNING CAUTION AND INFORMATION LABELS The figure below show...

Page 2043: ...y change depending on what part to be removed Before lifting up the vehicle check to be sure that end of hoist arm is not in contact with brake pipe fuel pipe bracket or any other part When using fram...

Page 2044: ...it may get deformed WARNING If the vehicle to be jacked up only at the front or rear end be sure to block the wheels on ground in order to ensure safety After the vehicle is jacked up be sure to suppo...

Page 2045: ...ng Light DTC Diagnostic Trouble Code Diagnostic Code E EBCM Electronic Brake Control Module ABS Control Module ECM Engine Control Module ECT Sensor Engine Coolant Temperature Sensor Water Temp Sensor...

Page 2046: ...rtrain Control Module PCV Positive Crankcase Ventilation R RH Right Hand S SAE Society of Automotive Engineers SDM Sensing and Diagnostic Module SFI Sequential Multiport Fuel Injection SOHC Single Ove...

Page 2047: ...ssion fluid Apply SEALING COMPOUND 366E 99000 31090 Apply SUZUKI SUPER GREASE A 99000 25010 Apply SUZUKI SUPER GREASE C 99000 25030 Apply THREAD LOCK 1322 99000 32110 Apply SUZUKI SUPER GREASE E 99000...

Page 2048: ...hen tighten it by hand temporarily If it is tight re check the thread pitch JIS TO ISO Main Fasteners Comparison Table Nominal diameter M6 M8 M10 M12 M14 Standard M6 M8 M10 M12 M14 Thread pitch 1 0 1...

Page 2049: ...160 kg m 0 15 0 30 0 55 1 3 2 9 4 5 6 5 10 5 16 lb ft 1 0 2 5 4 0 9 5 21 0 32 5 47 0 76 0 116 0 A equivalent of 6 8 strength fastener without flange N m 2 4 4 7 8 4 20 42 80 125 193 280 g kg m 0 24 0...

Page 2050: ...m section before performing service on or 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 in...

Page 2051: ...and When SG SH or SJ grade oil is used R R R R R R Engine oil filter When SE or SF grade oil is used Replace every 10 000 km 6 000 miles or 8 months 1 5 Engine coolant R R R 1 6 Exhaust system leakag...

Page 2052: ...DY 6 1 Clutch pedal For manual transmission I I I 6 2 Tires wheel discs wear damage rotation I I I I I I 6 3 Drive shaft boots breakage damage I I 6 4 Suspension system tightness damage rattle breakag...

Page 2053: ...D Drive belt V rib belt R Every 45 000 km 27 000 miles or 36 months A C D E H Engine oil and oil filter R Every 5 000 km 3 000 miles or 4 months A B C E H Spark plugs R Every 10 000 km 6 000 miles or...

Page 2054: ...100 N 10 kg or 22 lb pressure NOTE When replacing belt with a new one adjust belt tension to 6 7 mm 0 24 0 27 in A C compressor drive belt inspection If equipped 1 Hoist vehicle and remove engine unde...

Page 2055: ...mm 0 009 0 011 in 0 27 0 31 mm 0 011 0 012 in Special Tool A 09917 18210 Tightening Torque a 12 N m 1 2 kg m 8 5 lb ft 3 Install cylinder head cover and tighten bolts to specification ITEM 1 4 Engine...

Page 2056: ...it is important to accurately identify the position at which filter O ring first contacts mounting surface 6 Tighten filter 3 4 turn from the point of contact with mounting sur face using an oil filte...

Page 2057: ...antici pated mixture of 70 water and 30 ethylene glycol base coolant should be used for the purpose of corrosion protec tion and lubrication Refer to SECTION 6B of this manual for COOLANT CAPACITY 1...

Page 2058: ...r damage and deterioration Check exhaust system for leakage loose connections dents and damages If bolts or nuts are loose tighten them to specification Refer to SECTION 6K for torque specification of...

Page 2059: ...Install air cleaner filter into case referring to Section 6A1 6 Clamp case securely Air Cleaner Filter Replacement Replace air cleaner filter with new one according to procedure de scribed in Section...

Page 2060: ...operation referring to SECTION 6E1 If a problem is found replace BRAKE ITEM 5 1 Brake Discs Pads Drums and Shoes Inspection Brake discs and pads 1 Remove wheel and caliper but don t disconnect brake h...

Page 2061: ...rge operation ITEM 5 3 Brake Fluid Change CAUTION Do not use old or used brake fluid or any fluid from any un sealed container Change brake fluid as follows Drain existing fluid from brake system comp...

Page 2062: ...e wear or damage If defec tive replace 2 Check inflating pressure of each tire and adjust pressure to specification as necessary NOTE Tire inflation pressure should be checked when tires are cool Spec...

Page 2063: ...ront struts rear shock absorbers for evidence of oil leakage dents or any other damage on sleeves and inspect an chor ends for deterioration Replace defective parts if any Check front and rear suspens...

Page 2064: ...speed than when it is stopped Repair if found faulty 8 Check wheel alignment referring to Section 3A ITEM 6 6 Manual Transmission Oil Inspection and Change Inspection 1 Inspect transmission case for...

Page 2065: ...d fluid Fluid change 1 Perform steps 1 and 2 of above Fluid Level Inspection 2 Change fluid with new specified fluid referring to SECTION 7B ITEM 6 8 All Latches Hinges and Locks Inspection Doors Chec...

Page 2066: ...t box or cooling unit referring to Sec tion 1B 2 Check filter for dirt Replace excessively dirty filter 3 Blow off dust by compressed air from air outlet side of filter 4 Install filter to air inlet b...

Page 2067: ...rom any abnormal condition Gearshift or Select Lever Transmission Check gear shift or select lever for smooth shifting to all positions and for good performance of transmis sion in any position With a...

Page 2068: ...that steering wheel is free from in stability or abnormally heavy feeling Check that the vehicle does not wander or pull to one side Engine Check that engine responds readily at all speeds Check that...

Page 2069: ......

Page 2070: ...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 injur...

Page 2071: ...r 11 Recirculation air 12 Center ventilation air 13 Air inlet select door 14 Blower motor 15 Heater core heater radiator 16 Temperature control door 17 Foot air control door 18 Defroster air control d...

Page 2072: ...ce motor Repair as necessary Incorrect temperature output Control cables broken or binding Temperature control lever faulty Control cable clamp position is faulty Air damper broken Air ducts clogged H...

Page 2073: ...L 1 Disconnect negative cable at battery 2 If equipped with air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Drain engine coolant and disconnect heater hoses 1...

Page 2074: ...2 Disable air bag system if equipped Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove column hole cover 4 Remove clutch pedal assembly RH steering vehicle or brake pedal assembly 1 and accele...

Page 2075: ...1 8 If measured resistance is incorrect replace heater blower motor re sistor REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to DISABLING AIR BAG SYSTEM in S...

Page 2076: ...Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to DISABLING AIR BAG SYSTEM in Section 10B 3 Remove ashtray center upper garnish 1 center lower garnish 2 heater contro...

Page 2077: ...ol knob c fully in arrow direction as shown in figure ii Push mode lever d temperature lever e and door link f fully in arrow direction and fix cable with clamp in position as shown in figure NOTE Aft...

Page 2078: ...rnish 2 and radio or accessory case if equipped 3 Disconnect blower fan switch coupler 4 Remove blower fan switch 4 with unlocked the locking part 5 as shown in figure INSTALLATION Reverse removal seq...

Page 2079: ...tor case 9 Air resistance board 2 Rag 1A 10 HEATER AND VENTILATION AIR INLET BOX REMOVAL AND INSTALLATION Refer to COOLING UNIT in AIR CONDITIONING section VENTILATION LOUVER REMOVAL AND INSTALLATION...

Page 2080: ...ll WARNINGS and Service Precau tions 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 WARNINGS could...

Page 2081: ...ndenser Cooling Air HFC 134a R 134a 2 CFC 12 R 12 Liquid Vapor 1B 2 AIR CONDITIONING OPTIONAL GENERAL DESCRIPTION Whether the A C in the vehicle being serviced uses HFC 134a R 134a or CFC 12 R 12 is i...

Page 2082: ...e hose 6 Suction hose 7 Liquid pipe 8 Expansion valve 9 Side ventilation air 10 Center ventilation air 11 Foot air 12 Front defroster air 13 Side defroster air 14 Fresh air 15 Recirculation air 16 Eva...

Page 2083: ...R fuse and check short circuit to ground Check radiator cooling fan relay Repair as necessary Check radiator cooling fan motor Check ECM Blower motor inoperative Fuse blown Blower resistor faulty Blow...

Page 2084: ...faulty Excessive charge of refrigerant Repair as necessary Check expansion valve Replace receiver dryer and evacuation and charging Check magnetic clutch Check charge of refrigerant Cool air comes ou...

Page 2085: ...ck system for leaks with a leak tester 2 No bubbles observed in sight glass No or insufficient charge of refrigerant in system Refer to the items 3 and 4 3 No temperature difference between compressor...

Page 2086: ...s is heard immediately tighten nut CAUTION Do not interchange high and low pressure charging hoses by mistake 5 Warm up engine to normal operating temperature and keep it at specified idle speed 6 Tur...

Page 2087: ...high pressure gauge HI 1400 1750 kPa 14 0 17 5 kg cm2 Pressure on low pressure gauge LO 230 350 kPa 2 3 3 5 kg cm2 If each gauge reading is out of specified pressure correct de fective part referring...

Page 2088: ...ve malfunction valve opens too wide Compressor malfunction Insufficient compression Check expansion valve Check compressor Pressure low B area of high side graph Insufficient refrigerant Insufficient...

Page 2089: ...Continuous air bubbles are visible through sight glass Output air is slightly cold Insufficient refrigerant in system Refrigerant leaking Using a gas leak detector check for leaks and repair as necess...

Page 2090: ...ower motor relay 7 Radiator and condenser cooling fan relay 8 Radiator and condenser cooling fan motor 9 Compressor 10 Main relay 11 Ignition switch 12 A C evaporator thermistor 13 ECT sensor Main 80A...

Page 2091: ...TEM INSPECTION OF ECM AND ITS CIRCUITS ECM and its Circuits can be checked at ECM wiring couplers by measuring voltage CAUTION ECM cannot be checked by itself It is strictly prohibited to connect volt...

Page 2092: ...R Power supply for engine control Ground to engine Fig B 10 14 volts Ignition switch ON E22 10 Bl B Main relay Ground to engine 0 1 volt Ignition switch ON E22 10 Bl B Main relay g Fig B 10 14 volts...

Page 2093: ...pressor pulley 1 and crankshaft pulley 2 with about 100 N 10 kg 22 lbs force a 7 9 mm 0 27 0 35 in as deflection 100N 10 kg 22 lbs If belt tension is without above specification adjust belt tension by...

Page 2094: ...valve 1 Manifold gauge set 2 Low pressure gauge 3 High pressure gauge 4 Recovery equipment AIR CONDITIONING OPTIONAL 1B 15 RECOVERY EVACUATION AND CHARGING OPERATION PROCEDURE FOR CHARGING A C WITH R...

Page 2095: ...bserve the following instructions When disconnecting any line from the system install a blinding plug or cap to fitting of such line immedi ately When connecting hoses and pipes to each other respecti...

Page 2096: ...amage condenser fins If condenser fin is bent straighten it by using a screwdriver or pair of pliers If any leakage is found from fitting or tube repair or replace con denser RECEIVER DRYER REMOVAL 1...

Page 2097: ...replace radiator and condenser cooling fan motor 2 Connect battery 1 to radiator and condenser cooling fan mo tor coupler 2 as shown in figure then check that the radiator and condenser cooling fan mo...

Page 2098: ...trol cable main harness clamp 5 Loosen suction hose liquid pipe bolt 4 6 Loosen cooling unit bolt 1 nuts 2 and screw 3 as shown in figure 7 Remove cooling unit 5 INSPECTION Check the following Evapora...

Page 2099: ...charge system according to previously described procedure Adjust heater control cable refer to HEATER CONTROL LEVER ASSEMBLY in HEATER AND VENTILATION section Enable air bag system if equipped A C EV...

Page 2100: ...ECTION 1 Check dual pressure switch 1 for continuity at normal tempera ture approx 25 C 77 F when A C system has a proper charge of refrigerant and when A C system compressor is un der operation In ea...

Page 2101: ...ob and check it indicator lamp lights REMOVAL AND INSTALLATION Refer to HEATER CONTROL LEVER ASSEMBLY in Section 1A for A C Switch 1 removal and installation RADIATOR AND CONDENSER COOLING FAN RELAY I...

Page 2102: ...from vehicle 3 Check that there is no continuity between terminal c and d If there is continuity replace relay 4 Connect battery positive terminal to terminal b and connect battery negative terminal...

Page 2103: ...nsion pulley bolt 1 and adjust bolt 2 8 Disconnect suction and discharge hoses from compressor NOTE Cap open fittings immediately to keep moisture out of sys tem 9 Remove compressor with magnet clutch...

Page 2104: ...en it is unavoidable to change gas without replacing any compo nent part for engine removal and installation or for some other rea son replenish 50 cc oil When replenishing gas only oil replenish ment...

Page 2105: ...AIR CONDITIONING OPTIONAL MAGNET CLUTCH INSPECTION Check clutch plate and clutch pulley for wear and oil soaked conditions respectively Check clutch pulley bearing for noise wear and grease leakage Me...

Page 2106: ...B if necessary remove clutch plate 1 Special Tool B 09991 06030 4 Remove shims from shaft 5 Using special tool C remove circlip Special Tool C 09900 06107 6 Remove clutch coil read wire clamp by loose...

Page 2107: ...lutch pulley 1 squarely over clutch pulley installation boss II Place special tool D onto clutch coil bearing Ensure that edge rests only on inner race of bearing III Install circlip Special Tool D 09...

Page 2108: ...d 1 mounting bolts a b 3 Remove front head 1 by pushing cylinder shaft 2 NOTE Be careful not to remove cylinder from front head 4 Remove O ring 5 Remove lip seal from front head using special tool G S...

Page 2109: ...0 3 Install O ring 2 to case 4 Apply compressor oil to lip seal and O ring 5 Install front head 1 Special Tool F 09991 06040 6 Tighten front head mounting bolts a b Tightening Torque a 14 N m 1 4 kg m...

Page 2110: ...Armature plate remover 09991 06040 Lip type seal protector 09991 06050 Lip type seal installer 09923 73210 Bearing remover REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Compress...

Page 2111: ......

Page 2112: ...ECTRICAL POWER STEERING P S SYSTEM IF EQUIPPED SECTION 3B1 AIR BAG STEERING WHEEL AND COLUMN SECTION 3C FRONT SUSPENSION SECTION 3D REAR SUSPENSION SECTION 3E WHEELS AND TIRES SECTION 3F CONTENTS DIAG...

Page 2113: ...eel Loose bent or broken front or rear suspension parts Replacement tires in Section 3F Inflation of tires in Section 3F Strut damper assembly in Section 3D or coil spring in Section 3E Replacement ti...

Page 2114: ...inion adjustment Bind in steering column Inflation of tires in Section 3F Refer to Diagnosis in Section 3B1 Tie rod end in Section 3B or suspension arm bushing in Section 3D Section 3A Steering rack p...

Page 2115: ...mper assembly in Section 3D or coil spring in Section 3E Strut damper assembly in Section 3D Wander or Poor Steering Stability Mismatched or uneven tires Loosen ball joints and tie rod ends Faulty str...

Page 2116: ...r sagging springs Check loading Strut damper assembly in Section 3D Strut damper assembly in Section 3D or coil spring in Section 3E Body Leans or Sways in Corners Loose stabilizer bar Faulty struts s...

Page 2117: ...ve built in tread wear indicators to show when they need replacement These indicators will appear as 12 mm 0 47 in wide bands when the tire tread depth becomes 1 6 mm 0 063 in When the indicators appe...

Page 2118: ...E LEAD CORRECTED REPLACE TIRE LEAD REMAINS KNOWN GOOD TIRES ARE NOT GOOD LEAD CORRECTED REPLACE TIRE STEERING SUSPENSION WHEELS AND TIRES 3 7 1 Ride vehicle to determine whether the front or rear wadd...

Page 2119: ...procedure in above figure Lead Diagnosis should be used to make sure that front alignment is not mistaken for tire lead 1 Part of the lead diagnosis procedure is different from the proper tire rotati...

Page 2120: ...red for front alignment is toe setting Camber and caster can t be adjusted Therefore should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision...

Page 2121: ...ation must be given to excess loads such as tool boxes If this excess load is normally carried in ve hicle it should remain in vehicle during alignment checks 8 Consider condition of equipment being u...

Page 2122: ...eft tie rods are equal in length A in left figure NOTE If tie rod lengths were changed to adjust steering angle rein spect toe in Steering angle inside 35 3 outside 31 3 Reference Information Side sli...

Page 2123: ......

Page 2124: ...ervice 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 the battery Otherwise the system may be activated b...

Page 2125: ...the steering shaft joint 4 and then to the pinion 2 Since the pinion teeth mesh with teeth on rack the motion is further transferred to the rack and changed to linear motion The force is then transmi...

Page 2126: ...joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness STEERING RACK BOOT CHECK Hoist vehicle Inspect each boot for tear A torn boot allows entry of dust and water w...

Page 2127: ...small tear is noted replace with new one STEERING SHAFT JOINT CHECK Check shaft joint for wear breakage and other damage and replace if any defect exists TIE ROD END CHECK 1 Inspect for play in ball j...

Page 2128: ...50 to sliding part of plunger 14 Steering rack housing and gear case Apply sealant 99000 31120 between boot and grooves of gear case 15 Steering rack side mount 16 Steering pinion side mount 17 Tie ro...

Page 2129: ...after installation make marking 1 of tie rod end lock nut 2 position on tie rod end thread Then loosen lock nut 2 and remove tie rod end 3 from tie rod 4 INSTALLATION 1 Install tie rod end lock nut 1...

Page 2130: ...o FRONT END ALIGNMENT 4 After confirming proper toe tighten tie rod end lock nut to speci fied torque Tightening Torque a 45 N m 4 5 kg m 32 5 lb ft 5 Tighten wheel to specified torque and lower hoist...

Page 2131: ...back as possible 2 Pull off front part of floor mat on driver s side and remove steer ing shaft joint cover 3 For ease of installation loosen steering shaft upper joint bolt 1 but don t remove 4 Remov...

Page 2132: ...lb ft 2 Install engine rear mounting bolt 1 Tighten bolts to specified torque Tightening Torque a 55 N m 5 5 kg m 40 0 lb ft 3 Remove transmission jack 4 Install tie rod ends to knuckles right left Ti...

Page 2133: ...Install both wheels and tighten wheel nuts to specified torque Tightening Torque for wheel nuts 85 N m 8 5 kg m 61 5 lb ft 10 Lower hoist 11 Check toe setting Adjust as required Refer to Section 3A F...

Page 2134: ...of this section 2 For ease of adjustment after installation make marking 1 of tie rod end lock nut position of tie rod end thread 3 Loosen tie rod end lock nut and remove tie rod end 4 Remove boot ba...

Page 2135: ...roperly in grooves of gear case or rack side mount and tie rod After this check to ensure that boot is free from twist and dent 5 Fasten boot with new band and clip securely Special Tool A 09943 55010...

Page 2136: ...sealant to all around thread part of rack damper screw 3 and tighten it to specified torque with special tool Special Tool A 09944 28320 A Sealant 1207C 99000 31150 Tightening Torque a 7 12 N m 0 7 1...

Page 2137: ...mbly 1 from housing and remove pinion assembly 1 4 Remove oil seal 2 with special tool from pinion bearing plug 1 Special Tool A 09913 50121 INSPECTION Inspect pinion teeth surface 1 for wear or damag...

Page 2138: ...bed in STEERING RACK PLUNG ER of this section STEERING RACK REMOVAL 1 Remove steering gear case 2 Remove boot bands 2 and clips 1 3 Move both boots toward tie rod end 4 Remove tie rods right and left...

Page 2139: ...ON Inside of steering rack bushing is coated with special coating As it is damageable be very careful not to cause damage to it when inserting rack into steering gear case 3 Install pinion assembly to...

Page 2140: ...h special tools as shown Special Tool A 09921 20200 B 09930 30102 INSTALLATION 1 Apply grease to rollers of pinion bearing 2 Press fit pinion bearing 1 into gear case with special tool as shown After...

Page 2141: ...OMMENDED SUZUKI PRODUCT USE Lithium Grease Should be applicable for 40 C 130 C SUZUKI SUPER GREASE E 99000 25050 Sliding part of rack against steering housing All around rack plunger and rack Sliding...

Page 2142: ...ard diagnostic system 3B1 27 Inspection of Steering Wheel Play 3B1 28 Inspection of Steering Force 3B1 28 ON VEHICLE SERVICE 3B1 29 P S Control Module 3B1 29 Torque Sensor 3B1 30 Motor Assembly with c...

Page 2143: ...ON This electrical power steering EPS system consists of a P S control module a torque sensor and a motor assem bly with clutch incorporated installed to the steering column In this system the P S con...

Page 2144: ...To vehicle speed sensor VSS 10 ECM PCM 11 To data link connector DLC 12 Monitor coupler 13 Diagnosis switch terminal for P S system 14 Ground terminal 15 To ABS hydraulic unit control module assembly...

Page 2145: ...free from any trouble after the engine start while engine is running EPS warning lamp turns OFF When P S control module detects a trouble which has occurred in the areas it makes EPS warning lamp turn...

Page 2146: ...d repair referring to applicable DTC TABLE in this section 2 Clear DTC referring to DTC CLEARANCE in this section Does the trouble recur Go to Step 5 Go to Step 4 3 1 Test drive the vehicle and turn s...

Page 2147: ...occurrence Continuous Intermittent times a day a month other Conditions for Occurrence of Problem Vehicle at stop ignition switch is ON position When starting at initial start only at every start Oth...

Page 2148: ...fore starting diagnosis according to flow table STEP ACTION YES NO 1 1 Make sure that battery voltage is about 11 V or higher 2 Note EPS warning lamp as ignition switch is turned to ON position Does E...

Page 2149: ...o Step 5 Repair high resistance or open in B W wire circuit 5 1 Turn ignition switch to OFF position 2 Remove combination meter 3 Remove and check EPS bulb Is EPS bulb in good condition Go to Step 6 R...

Page 2150: ...ELECTRICAL POWER STEERING EPS SYSTEM IF EQUIPPED 3B1 9 Fig for Step 3 Fig for Step 4 Fig for Step 6 Fig for Step 7 Fig for Step 8...

Page 2151: ...nitor coupler for P S system Is it connected diagnosis switch terminal for P S system and ground terminal in monitor coupler by service wire Remove service wire Go to Step 3 3 1 With ignition switch O...

Page 2152: ...B wire circuit on monitor coupler Go to Step 3 3 1 Turn ignition switch to OFF position 2 Remove steering column lower cover 3 Disconnect 8 pin A connector from P S control module 4 Check proper conn...

Page 2153: ...can tool cannot display DTC perform SERIAL DATA LINK CIRCUIT CHECK described in this section 5 After completing the check turn ignition switch to OFF position and disconnect SUZUKI scan tool from DLC...

Page 2154: ...2 flashing pattern 12 is indicated when engine is started it means noth ing abnormal Current DTC and history DTC can be identified by lighting and flashing of EPS warning lamp EPS warning lamp operate...

Page 2155: ...ial Tool A 09931 76011 B Mass storage cartridge C 09931 76030 3 Turn ignition switch to ON position 4 Erase DTC according to instructions displayed on SUZUKI scan tool referring to SUZUKI SCAN TOOL OP...

Page 2156: ...ain fuse box 11 Data link connector DLC 12 To ECM PCM SDM and ABS hydraulic unit control module assembly if equipped 13 P S control module 14 P S control module body ground 15 Connector A 15 ELECTRICA...

Page 2157: ...ntroller ECM PCM ABS hydraulic unit control module assembly if equipped or SDM Is it possible to communicate with other controller Go to Step 4 Repair open in common section of serial data circuit W R...

Page 2158: ...ITEM DIAGNOSIS NO DTC 12 Normal This code appears when none of the other codes are identified C1111 11 C1113 13 Torque sensor C1114 14 Torque sensor C1115 15 C1121 21 C1123 23 VSS signal C1124 24 C112...

Page 2159: ...IT FAIL STEP ACTION YES NO 1 Was SYSTEM CHECK FLOW TABLE performed Go to Step 2 Go to SYSTEM CHECK FLOW TABLE in this section 2 Is DTC C1114 indicated Proceed to DTC C1114 TORQUE SENSOR 5 V POWER SUPP...

Page 2160: ...steering column hole cover 2 Check proper connection for 5 pin C connector to P S control module 3 If OK turn ignition switch to ON position 4 Check voltage between C4 R wire terminal of 5 pin C conn...

Page 2161: ...emove steering column hole cover 3 Disconnect 8 pin A connector from P S control module 4 Check proper connection to P S control module at terminal A4 V wire 5 If OK connect voltmeter between A4 V wir...

Page 2162: ...ontrol module and ECM PCM at each Br Y wire terminal P S control module side A5 terminal ECM PCM side Refer to WIRING DIAGRAM in SECTION 6E then check intermittent trouble referring to INTERMITTENT TR...

Page 2163: ...hole cover 2 Check proper connection for 4 pin B connector to P S control module 3 If OK start engine 4 Check voltage between B1 terminal and body ground and B2 terminal and body ground with B connec...

Page 2164: ...etween B3 terminal and body ground with B connector connected to P S control module Is it 0 V Go to Step 3 Repair poor connection high resistance open or short to power circuit or ground in B3 circuit...

Page 2165: ...BLE in this section 2 1 Remove steering column hole cover 2 Check proper connection to P S control module at A2 B R wire terminal 3 If OK check voltage between A2 terminal and body ground with A conne...

Page 2166: ...ule wiring couplers 2 by measuring voltage and resistance CAUTION P S control module cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to P S control module with c...

Page 2167: ...Diagnosis switch terminal About 5 V Ignition switch is ON position A8 SUZUKI scan tool B1 Motor output 2 5 7 V Engine idling and steering wheel held at position for vehicle to run straight B2 Motor o...

Page 2168: ...SSIBLE CAUSE INSPECTION Steering wheel feels heavy Perform INSPECTION OF STEERING FORCE on next page before diagnosis Steering wheel installed improperly twisted Poor performance of torque sensor Poor...

Page 2169: ...ball stud for wear Lower ball joint for wear Steering shaft joint for wear Steering pinion or rack gear for wear or breakage Each part for looseness INSPECTION OF STEERING FORCE 1 Place vehicle on lev...

Page 2170: ...tem 2 P S control module Tightening Torque LH ELECTRICAL POWER STEERING EPS SYSTEM IF EQUIPPED 3B1 29 ON VEHICLE SERVICE P S CONTROL MODULE REMOVAL 1 Disconnect negative cable at battery 2 Remove stee...

Page 2171: ...ut 2 5 V About 3 9 V If check result is not satisfactory replace steering column as sembly MOTOR ASSEMBLY WITH CLUTCH INCORPORATED ON VEHICLE INSPECTION 1 Remove steering column hole cover 2 Disconnec...

Page 2172: ...smoothly then messure current between B1 and B2 us ing ammeter 2 as shown in left figure Standard current reference value About 0 65 A If check result is not satisfactory replace steering column as se...

Page 2173: ......

Page 2174: ...SERVICE MATERIALS 3C 20 SECTION 3C STEERING WHEEL AND COLUMN WARNING The procedures in this section must be followed in the order listed to temporarily disable the air bag system and prevent false dia...

Page 2175: ...gth and position STEERING WHEEL AND DRIVER AIR BAG INFLATOR MODULE The driver air bag inflator module is one of the supplemental restraint air bag system components and is mounted to the center of the...

Page 2176: ...o avoid an accidental deployment Never use air bag component parts from another vehicle If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process remove...

Page 2177: ...SECTION 10B HANDLING PRECAUTION LIVE UNDEPLOYED DRIVER AIR BAG INFLATOR MODULE WARNING Never attempt to measure the resistance of the air bag in flator module It is very dangerous as the electric cur...

Page 2178: ...ector on the underside of the module When placing a live air bag inflator module on a bench or other surface always face the bag up away from the surface It is also prohibited to place anything on top...

Page 2179: ...oes not interfere with other parts Make sure all air bag system grounding points are clean and grounds are securely fastened for optimum metal to metal con tact Poor grounding can cause intermittent p...

Page 2180: ...itch assembly 9 Turn dimmer switch assembly Tightening Torque 10 Steering column assembly 11 Ignition switch assembly 12 Immobilizer control module 13 Ignition switch cylinder assembly 14 Ignition swi...

Page 2181: ...terminal 2 Disable air bag system Refer to Disabling Air Bag System un der Precautions earlier in this section 3 Loosen 2 bolts 1 mounting driver air bag inflator module till it turns freely 4 Remove...

Page 2182: ...1 of driver air bag inflator module and then lock 2 securely as shown in figure 2 Install driver air bag inflator module to steering wheel taking care so that no part of wire harness is caught between...

Page 2183: ...teering shaft bolt 6 Make alignment marks 1 on steering wheel and shaft for a guide during reinstallation 7 Remove steering wheel CAUTION Do not hammer the end of the shaft Hammering it will loosen th...

Page 2184: ...talled with out these conditions contact coil will break when steer ing wheel is turned 2 Install steering wheel to steering shaft with 2 grooves 1 on con tact coil fitted in two lugs 2 in the back of...

Page 2185: ...negative battery cable at battery terminal 2 Disable air bag system Refer to Disabling Air Bag System un der Precautions earlier in this section 3 Remove steering wheel from steering column Refer to...

Page 2186: ...vehicle s front tires are set at straight ahead position and then ignition switch is at LOCK position 2 Install contact coil cable assembly 1 to steering column se curely NOTE New contact coil cable a...

Page 2187: ...xtremely susceptible to damage Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length Leaning on the column assembly co...

Page 2188: ...nition switch cylinder assembly 1 as follows a Turn ignition switch key to ACC position b Insert 2 mm 0 078 in rod 2 through hole 3 and push ignition switch cylinder lock 5 1 Remove immobilizer contro...

Page 2189: ...ft 1 with bolt hole B of upper joint 2 as shown Then insert upper joint 2 onto lower shaft 1 For manual steering align flat part A of steering column 3 with bolt hole B of upper joint 2 and insert ste...

Page 2190: ...t have been removed in Removal 8 Install contact coil cable assembly and steering wheel Refer to CONTACT COIL CABLE ASSEMBLY and STEERING WHEEL in this section 9 Connect negative battery cable 10 Enab...

Page 2191: ...lower shaft 2 or steering column 4 with bolt hole of upper joint 1 as shown Then insert lower shaft or steering column into upper joint 2 Be sure that front wheels and steering wheel are in straight f...

Page 2192: ...s shown If it is shorter than spe cified length replace column assembly with new one Power steering column length a 518 1 5 mm 20 4 0 06 in b 479 2 1 5 mm 18 9 0 06 in Manual steering column length a...

Page 2193: ...3C 20 STEERING WHEEL AND COLUMN REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Thread lock cement THREAD LOCK 1342 99000 32050 Steering shaft bolt...

Page 2194: ...ified during reassembly to assure proper retention of this part Never attempt to heat quench or straighten any front suspension part Replace it with a new part or dam age to the part may result CONTEN...

Page 2195: ...o installed a little lower to the rubber mount The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached to the stud of a ball joint which is...

Page 2196: ...h push and note strut resistance both when pushed and rebounding Also note how many times vehicle body rebounds before com ing to stop after hands are off Do the same for strut on the other side Compa...

Page 2197: ...rol arm assembly must be re placed as a complete unit WHEEL DISC NUT BEARING CHECK 1 Inspect each wheel disc for dents distortion and cracks A disc in badly damaged condition must be replaced 2 Check...

Page 2198: ...Remove front wheels 3 Remove split pins 1 and then castle nuts 2 4 Remove stabilizer bar mount bushing bracket bolts 9 5 Remove stabilizer bar 6 from front suspension control arms 5 NOTE If it is hard...

Page 2199: ...specified torque Tightening torque for stabilizer bar bracket bolts 45 N m 4 5 kg m 32 5 lb ft After tightening castle nut 1 to specified torque install new split pin 2 as shown Tightening Torque a 4...

Page 2200: ...Bearing lower washer 8 Bearing spacer 9 Coil spring upper seat 10 Coil spring seat 11 Bump stopper 12 Coil spring Tightening Torque FRONT SUSPENSION 3D 7 STRUT ASSEMBLY REMOVAL 1 Disconnect negative c...

Page 2201: ...ll its force pressing the spring seat is released CAUTION Use a commercially available spring compressor and fol low the operation procedure described in the Instruction Manual supplied with that spri...

Page 2202: ...bearing and sliding part of strut rod Mate spring end with stepped part of spring lower seat as shown Install spring seat mating stepped part of seat with spring upper end as shown Using special tool...

Page 2203: ...hose when installing it Install E ring as far as it fits to bracket as shown Torque all fasteners to specification referring to assembly figure on 3D 7 Install wheel and tighten wheel nuts to specifi...

Page 2204: ...rive shaft nut Calk after tightening Tightening Torque Do not reuse 14 Wheel hub nut 15 Brake disc STEERING KNUCKLE BEARING REMOVAL 1 Hoist vehicle and remove wheel 2 Uncalk drive shaft nut 1 3 Depres...

Page 2205: ...and disconnect tie rod end 2 from knuckle 1 with puller CAUTION Never reuse tie rod end nut Reused nut will not be locked securely 9 Remove wheel speed sensor 1 from knuckle if equipped 10 Remove str...

Page 2206: ...o replace them with new ones as a set 4 Remove wheel bearing inner race 1 Special Tool C 09913 61110 D 09925 88210 5 Remove hub bolts 1 CAUTION Never remove bolt unless replacement is necessary Be sur...

Page 2207: ...s shown CAUTION When drive in dust cover be careful not to deform it 4 Caulk with a punch 5 Insert new stud 2 in hub hole Rotate stud 2 slowly to assure serrations are aligned with those made by origi...

Page 2208: ...que Tightening Torque a 115 N m 11 5 kg m 83 5 lb ft b 60 N m 6 0 kg m 43 5 lb ft 3 Install wheel speed sensor if equipped 4 Connect tie rod end 1 to knuckle 2 and install new tie rod end nut 3 Tighte...

Page 2209: ...orque Tightening Torque c 175 N m 17 5 kg m 127 0 lb ft 10 Calk drive shaft nut as shown CAUTION Be careful while caulking nut so that no crack will occur in caulked part of nut Cracked nut must be re...

Page 2210: ...tening Torque Do not reuse 10 SUSPENSION CONTROL ARM BUSHING REMOVAL 1 Hoist vehicle and remove wheel 2 Remove split pin 12 stabilizer bar castle nut 10 washer 9 and bushing 8 3 Remove stabilizer bar...

Page 2211: ...installed bush should be equal on the right and left of arm as shown 2 Install suspension control arm to vehicle body and tighten sus pension control arm bolt 1 temporarily 3 Install ball stud 2 to k...

Page 2212: ...tening Torque a 60 N m 6 0 kg m 43 5 lb ft Install stabilizer bar referring to STABILIZER BAR INSTALLA TION in this section REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Lithic whe...

Page 2213: ...ring puller 09913 75810 Bearing installer 09924 84510 002 Bearing installer attachment 09925 88210 Bearing puller attachment 09940 53111 Bearing installer 09942 15511 Sliding hammer 09943 17912 Front...

Page 2214: ...oper retention of this part Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may result CONTENTS GENERAL DESCRIPTION 3E 2 DIAGNOSIS 3E 3...

Page 2215: ...pension is Isolated Trailing Link l T L type which consists of coil springs rear axle shock absorbers lateral rod and trailing arms The lateral rod is installed to the body and axle by using bushes so...

Page 2216: ...le it Don t put it into the fire Don t store it where it gets hot Before disposing it be sure to drill a hole in it where shown by an arrow in figure and let gas and oil out Lay it down sideways for t...

Page 2217: ...ion and cracks A disc in badly damaged condition must be replaced Check wheel nuts for tightness and as necessary retighten to specification Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft Check wheel...

Page 2218: ...rber upper bolt Insert from vehicle outside 19 Shock absorber lower bolt 20 Trailing arm front bolt Insert from vehicle inside 21 Trailing arm rear bolt Insert from vehicle inside 22 Brake back plate...

Page 2219: ...rear axle and vehicle body 3 referring to figure for proper installing direction of bolt 4 and washer 2 Tighten nuts 5 temporarily by hand 2 Lower hoist 3 Tighten lateral rod nuts 1 to specified torq...

Page 2220: ...ON 1 Install shock absorber 5 referring to left figure Tighten bolt and nut temporarily by hand 2 Remove floor jack from rear axle 1 and lower hoist 3 Tighten bolts to specified torque Tightening Torq...

Page 2221: ...le 7 Remove coil spring INSTALLATION 1 Install coil spring 1 with its small pitch end facing up and large pitch end down and make sure that spring end comes in contact with stepped part 2 of spring se...

Page 2222: ...od body side nut 2 to specified torque Tightening Torque a 90 N m 9 0 kg m 65 0 lb ft b 63 N m 6 3 kg m 45 5 lb ft BUMP STOPPER REMOVAL 1 Hoist vehicle and remove rear wheel 2 Remove bump stopper usin...

Page 2223: ...ling direction of spring upper seat refer to figure at left 2 Install coil spring For details refer to COIL SPRING INSTALLA TION in this section TRAILING ARM REMOVAL 1 Hoist vehicle and remove rear wh...

Page 2224: ...mp 1 6 Remove trailing arm rear bolts 1 7 Remove trailing arm front bolt 2 and then remove trailing arm 1 INSTALLATION 1 Install trailing arm 1 to vehicle body and rear axle referring to figure for pr...

Page 2225: ...rom rear axle 7 Install wheel and tighten wheel nuts to specified torque Tightening Torque for wheel nuts a 85 N m 8 5 kg m 61 5 lb ft 8 Lower hoist and vehicle in non loaded condition tighten trailin...

Page 2226: ...REMOVAL in SECTION 5C 4 Remove E rings 2 right left securing brake hose 1 5 Disconnect brake pipe flare nuts 1 from wheel cylinders 3 right left and put bleeder plug cap 4 onto pipe 2 to prevent flui...

Page 2227: ...PV spring 1 from rear axle 2 if equipped 11 Lower rear axle gradually as far down as where coil springs 1 right left can be removed CAUTION Be careful not to let rear axle down too much It may cause d...

Page 2228: ...e rear axle on floor jack Then install lateral rod to rear axle and tighten nut temporarily by hand 2 Install trailing arm rear bolts 1 right left in proper direction as shown in figure Then tighten n...

Page 2229: ...5 lb ft 8 Connect wheel speed sensor and lead wire clamps right left if equipped CAUTION Since there are two holes on each side of rear axle be sure to install wheel speed sensor at the position as s...

Page 2230: ...bleed brake system For bleeding operation see SECTION 5 14 Install wheel and tighten wheel nuts to specified torque Tightening Torque d 85 N m 8 5 kg m 61 5 lb ft 15 Upon completion of all jobs depres...

Page 2231: ...ue NOTE When tightening these nuts and bolts be sure that vehicle is off hoist and in non loaded condition Tightening Torque e 80 N m 8 0 kg m 58 0 lb ft f 63 N m 6 3 kg m 45 5 lb ft g 50 N m 5 0 kg m...

Page 2232: ...ess Special Tool A 09913 76010 CAUTION Never reuse wheel bearing Reused bearing should have excessive play 4 Remove wheel stud bolt by using hydraulic press 1 INSTALLATION 1 Insert new stud in drum ho...

Page 2233: ...ake drum remover 3 Install circlip 1 Special Tool A 09900 06108 4 Install brake drum and wheel referring to BRAKE DRUM INSTALLATION in SECTION 5C REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUK...

Page 2234: ...acement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it may result in exte...

Page 2235: ...sures from kPa to psi REPLACEMENT WHEELS Wheels must be replaced if they are bent dented have excessive lateral or radial runout air leak through welds have elongated bolt holes if lug nuts won t sta...

Page 2236: ...and wheels are matchmounted at the assembly plant This means that the radially stiffest part of the tire or high spot is matched to the smallest radius or low spot of the wheel This is done to provid...

Page 2237: ...ure on same axle can cause 1 Uneven braking 2 Steering lead 3 Reduced handling 4 Swerve on acceleration Lower than recommended pressure can cause 1 Tire squeal on turns 2 Hard Steering 3 Rapid and une...

Page 2238: ...rosion on wheel mounting surface and brake disc mounting surface by scraping and wire brushing Installing wheels without good metal to metal contact at mounting surfaces can cause wheel nuts to loosen...

Page 2239: ...pressure TIRE REPAIR There are many different materials and techniques on the market to repair tires As not all of these work on all types of tires tire manufacturers have published detailed instruct...

Page 2240: ...is overcome by their accuracy usually to within 1 8 ounce ON VEHICLE BALANCING On vehicle balancing methods vary with equipment and tool manufacturers Be sure to follow each manufacturer s instruction...

Page 2241: ......

Page 2242: ...on the differential side of the left side drive shaft assembly A constant velocity tripod joint is used on the differential side or center shaft side of the right side drive shaft assem bly A constant...

Page 2243: ...ilizer 6 Oil filler level plug Apply sealant 99000 31110 to plug thread 7 Oil drain plug Apply sealant 99000 31110 to plug thread 8 Tie rod end nut 9 Ball stud bolt 10 Drive shaft nut 11 Wheel nut 12...

Page 2244: ...ort circlip 17 Center bearing support 18 Center bearing 19 Center shaft Do not reuse 1 Right side drive shaft assembly 2 Left side drive shaft assembly 3 Wheel side joint Constant velocity ball joint...

Page 2245: ...lease snap ring fitting of joint spline at differential side B For vehicle with center shaft Using plastic hammer 3 drive out drive shaft joint so as to release snap ring fitting of joint spline at ce...

Page 2246: ...t disassemble tripod joint spider If any malcondi tion is found in it replace it as differential side joint as sembly 1 Remove differential side boot big band 1 as follows A For boot big band without...

Page 2247: ...nt housing B For boot big band with joint a Draw hooks of boot big band together and remove band 8 Remove wheel side small band then pull out wheel side boot from shaft For DOJ type drive shaft left s...

Page 2248: ...ve of shaft 3 Remove snap ring 1 and then remove cage 2 with retaining ring 3 from housing 4 if necessary 4 Remove differential side boot damper and wheel side boot from shaft referring to steps 5 6 7...

Page 2249: ...ot in degreaser such as gasoline or kerosene etc Washing in degreaser causes de terioration of boot 3 Install new wheel side boot on shaft temporarily 4 Apply grease to wheel side joint Use grease in...

Page 2250: ...below For M T model only Length a 347 353 mm 13 7 13 9 in 11 Set new differential side small band and differential side boot 1 on shaft temporarily 12 Install tripod joint spider 2 on shaft by using...

Page 2251: ...d fasten new big and small bands at that position of step 14 in the same procedure as previous steps 6 to 9 For DOJ type drive shaft left side 1 Wash disassembled parts except boots After washing dry...

Page 2252: ...ir pressure in boot becomes the same as atmospheric pres sure Length d 80 90 mm 3 15 3 54 in CAUTION To prevent any problem caused by washing solution do not wash joint boots Degreasing of those parts...

Page 2253: ...g drive shaft Do not hit joint boot with hammer Inserting joint only by hands is allowed Make sure that differential side joint is inserted fully and its snap ring is seated as it was Install drive sh...

Page 2254: ...clamp plier 09900 06108 Snap ring pliers Closing type REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain and filler level plugs for man...

Page 2255: ......

Page 2256: ...all WARNINGS and Service Precau tions 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 WARNINGS could...

Page 2257: ...rear The master cylinder is a tandem master cylinder Brake pipes are connected to the master cylinder and they make two independent circuits One connects front right rear left brakes and the other con...

Page 2258: ...voir refilling is necessary Fill reservoir with specified brake fluid Brake fluid Refer to reservoir tank cap SUBSTANDARD OR CONTAMINATED BRAKE FLUID Improper brake fluid mineral oil or water in the f...

Page 2259: ...ment in some brakes Malfunctioning auto adjusting mechanism Drum is out of round in some brakes Wheel tires are inflated unequally Malfunctioning wheel cylinders Disturbed front end alignment Unmatche...

Page 2260: ...ster cylinder Check for soft hoses or damaged pipes and replace with new hoses and or new brake pipes Check and adjust to correct specifications Replace Repair or replace Repair as necessary Check sys...

Page 2261: ...n when brake is applied Brake fluid leaking from brake line Insufficient amount of brake fluid Investigate leaky point correct it and add brake fluid Add brake fluid Brake warning light fails to turn...

Page 2262: ...ng operation must be performed at both ends of the line of the removed pipe or hose When any joint part of the master cylinder or other joint part between the master cylinder and each brake wheel was...

Page 2263: ...brake pedal tighten bleeder plug Tightening Torque b 8 5 N m 0 85 kg m 6 5 lb ft for rear brake 6 5 N m 0 65 kg m 5 0 lb ft for front brake 7 Then attach bleeder plug cap 8 After completing bleeding o...

Page 2264: ...edal is depressed the specified distance Distance b 10 20 mm 0 4 0 8 in If check result is not as specified adjust stop light switch 1 posi tion so that stop light lights when brake pedal is depressed...

Page 2265: ...ed level CAUTION Do not use shock absorber fluid or any other fluid which contains mineral oil Do not use a container which has been used for mineral oil or a container which is wet from water Mineral...

Page 2266: ...e limit all linings must be re placed at the same time BRAKE SHOE CHECK Inspection should be carried out on the following points after brake pedal travel c pedal to silencer clearance check as describ...

Page 2267: ...E Make sure for the following conditions before cable adjust ment No air is trapped in brake system Brake pedal travel is proper Brake pedal is depressed repeatedly with about 300 N 30 kg 66 lbs load...

Page 2268: ...ximately about 1 000 N 100 kg 220 lbs weight 1 on rear housing so that rear axle weighs 4 500 N 450 kg 992 lbs Rear axle weight L 4 500 N 450 kg 992 lbs 2 Install special tool to front and rear brake...

Page 2269: ...nt brake Rear brake 10 000 kPa 100 kg cm2 1 422 psi 6 300 7 900 kPa 63 79 kg cm2 896 1 123 psi 4 If rear brake pressure is not within specification adjust it by changing spring bracket 2 position as f...

Page 2270: ...Check Air Tightness 1 Start engine 2 Stop engine after running for 1 to 2 minutes 3 Depress brake pedal several times with the same load as in ordi nary braking and observe pedal travel If pedal goes...

Page 2271: ...ile depressing brake pedal If pedal travel in creases a little operation is satisfactory But no change in pedal travel indicates malfunction Check Air Tightness Under Load 1 With engine running depres...

Page 2272: ...1 1 8 0 Brake pipe flare nut 16 1 6 11 5 Brake bleeder plug Front caliper 6 5 0 65 5 0 Brake bleeder plug Wheel cylinder 8 5 0 85 6 5 LSPV mounting bolt 26 2 6 19 0 LSPV spring end nut 26 2 6 19 0 LS...

Page 2273: ......

Page 2274: ...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 SDM NOTE All brake fasteners are impo...

Page 2275: ...alve ASSEMBLY if equipped As shown in figure below LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake It controls the hydraulic pressure applied to t...

Page 2276: ...id to get on painted surfaces Painted surfaces will be damaged by brake fluid FRONT BRAKE HOSE PIPE REMOVAL 1 Raise and suitably support vehicle Remove tire and wheel This operation is not necessary w...

Page 2277: ...From ABS hydraulic unit to left front brake 4 From ABS hydraulic unit to right front brake 5 ABS hydraulic unit 6 To rear brakes Tightening Torque Viewed from A Viewed from B Top Right Right Front Ri...

Page 2278: ...mp 1 From master cylinder primary to right front brake 2 From master cylinder secondary to left front brake 3 To rear brakes Viewed from A Viewed from B Top Front Top Front Top Right Right Front Top F...

Page 2279: ...se and suitably support vehicle Remove tire and wheel 2 Clean dirt and foreign material from both hose end or pipe end fittings Remove brake hose or pipe INSTALLATION 1 Reverse removal procedure for b...

Page 2280: ...ll master cyl inder reservoir according to procedure of MASTER CYLINDER ASSEMBLY REMOVAL and INSTALLATION in this section REMOVAL 1 Clean outside of reservoir 2 Disconnect reservoir lead wire at coupl...

Page 2281: ...to fill reservoir with Then fit grommets 3 to master cylinder Grommets must be seated in place 3 Install reservoir 4 and drive in reservoir pin 5 Drive in reservoir pin till both of its ends at the r...

Page 2282: ...new one Observe CAUTION at the beginning of ON VEHICLE SER VICE REMOVAL 1 Clean around master cylinder and reservoir 2 Disconnect reservoir lead wire at coupler 1 3 Remove reservoir cap 2 and take out...

Page 2283: ...o replace corroded cylinder Corrosion can be identified as pits or excessive roughness INSTALLATION 1 For vehicle with ABS install pin washer retainer 1 if removed and apply thin coat of brake fluid t...

Page 2284: ...ng Torque a 13 N m 1 3 kg m 9 5 lb ft 5 Connect hydraulic lines and torque flare nuts to specification Special Tool A 09950 78240 Tightening Torque b 16 N m 1 6 kg m 12 0 lb ft 6 Connect reservoir lea...

Page 2285: ...tion If it is found faulty replace it with new one Observe CAUTION at the beginning of ON VEHICLE SER VICE REMOVAL 1 Remove master cylinder assembly referring to steps 1 to 5 of its REMOVAL in this se...

Page 2286: ...oster push rod clevis 1 to pedal arm 2 with clevis pin 3 and clip 4 A Grease A 99000 25010 2 Tighten booster attaching nuts to the specified torque Tightening Torque a 13 N m 1 3 kg m 9 5 lb ft 3 Conn...

Page 2287: ...ssemble LSPV assembly Disassembly will spoil its original performance Replace with new one if de tective Observe CAUTION at the beginning of ON VEHICLE SER VICE REMOVAL 1 Clean around reservoir cap an...

Page 2288: ...r with specified fluid and bleed air from brake system 4 Check or adjust spring installation position For used LSPV assembly check that it is installed properly refer ring to the following INSPECTION...

Page 2289: ...evel floor 2 Check spring length between spring end 1 and spring bolt cen ter 2 Spring length L About 99 3 mm 3 9 in If it is out of specification adjust it as follows 3 Loosen spring bracket bolt 1 a...

Page 2290: ...KI SUPER GREASE A 99000 25010 to outside surface of spacer 18 Pedal shaft nut Tightening Torque Do not reuse 3 BRAKES PIPE HOSE MASTER CYLINDER 5A 17 BRAKE PEDAL AND BRAKE PEDAL BRACKET REMOVAL 1 Disc...

Page 2291: ...e nut wrench 10 x 11 mm 09950 78240 Flare nut socket 10 mm REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED PRODUCT USE Brake fluid DOT 4 or SAE J1704 To fill master cylinder reservoir To clean and app...

Page 2292: ...Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of all parts There is to be no welding as it...

Page 2293: ...nverted by the caliper to friction The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move slide the caliper inward resulting in a...

Page 2294: ...Brake caliper carrier 1 9 Caliper bolt 1 10 Bleeder plug 1 11 Bleeder plug cap 1 12 Caliper pin bolt 1 13 Flexible hose bolt 1 14 Gasket Tightening Torque Do not reuse ON VEHICLE SERVICE CAUTION Lubr...

Page 2295: ...ke pedal with pads removed 4 Remove pads 3 INSPECTION Brake Pad Check pad lining for wear When wear exceeds limit replace with new one CAUTION Never polish pad lining with sandpaper If lining is polis...

Page 2296: ...unt a dial indicator as shown and measure the runout at 20 mm 0 79 in from the outer edge of the disc Limit on disc deflection 0 15 mm 0 006 in NOTE Check front wheel bearing for looseness before meas...

Page 2297: ...2 to vehicle center side 2 Install caliper 1 and torque caliper pin bolts 2 to specification Tightening Torque a 30 N m 3 0 kg m 22 0 lb ft NOTE Make sure that boots 3 are fit into groove securely 3 T...

Page 2298: ...per DISASSEMBLY WARNING Do not apply too much highly compressed air which will cause piston to jump out of cylinder It should be taken out gradually with moderately compressed air Do not place your fi...

Page 2299: ...k and damage If defective replace Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth re turn of the piston In such a case replace rubber seal ASSEMBLY Reassemble front brake in r...

Page 2300: ...ng stepped end 4 of boot to groove side 2 Insert piston into cylinder by hand 3 Drive in boot 1 into cylinder till its end surface becomes flush with cylinder end surface using special tools Special T...

Page 2301: ...bolt 2 to specification Tightening Torque b 23 N m 2 3 kg m 17 0 lb ft 4 Torque wheel nuts to specification Tightening Torque c 85 N m 8 5 kg m 61 5 lb ft 5 After completing installation fill reservoi...

Page 2302: ...o wheel hub 2 Install caliper assembly to steering knuckle 3 Torque caliper carrier bolts 1 to specification Tightening Torque a 95 N m 9 5 kg m 69 0 lb ft 4 Torque front wheel nuts to specifications...

Page 2303: ...MENDED PRODUCT USE Brake fluid DOT 4 or SAE J1704 To fill master cylinder reservoir To clean and apply to inner parts of caliper and wheel cylinder when they are disassembled Rubber grease An equivale...

Page 2304: ...ed 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 the S...

Page 2305: ...rum brake and has a self shoe clearance adjusting system so that drum to shoe clearance is maintained appropriate at all times The parking brake is mechanical and applies brake force to only rear whee...

Page 2306: ...1 Parking lever spring 12 Parking brake shoe lever 13 Brake Drum 14 Spindle nut Calk spindle nut after tightening 15 Sensor ring if equipped 16 Stud bolt 17 Back plate bolt 18 Wheel cylinder bolt 19 B...

Page 2307: ...ualizer 3 7 Remove console box bracket 4 from parking brake lever as sembly NOTE Don t disassemble parking brake lever switch It must be re moved and installed as a complete switch assembly INSTALLATI...

Page 2308: ...ING BRAKE CABLE REMOVAL 1 Remove brake drum Refer to steps 1 to 5 of BRAKE DRUM REMOVAL of this section 2 Disconnect parking brake cable from brake shoe lever Refer to steps 2 to 4 of BRAKE SHOE REMOV...

Page 2309: ...000 31090 3 Install brake cable spring 1 and nipple end 2 to parking brake shoe lever 3 securely as shown in figure 4 For brake shoe installation refer to steps 1 to 3 of BRAKE SHOE INSTALLATION of th...

Page 2310: ...alk spindle nut remove spindle nut 1 4 Release parking brake lever 5 Remove brake drum If brake drum can not be removed easily increase clearance be tween brake shoes and drum as follows a Remove cons...

Page 2311: ...ar of its braking surface by measuring its inside diameter Inside diameter Standard 180 mm 7 09 in Service Limit 182 mm 7 16 in Whenever brake drums are removed they should be thoroughly cleaned and i...

Page 2312: ...hed with sandpaper hard particles of sandpaper will be deposited in lining and may damage drum When it is required to correct lining replace it with a new one INSTALLATION 1 Install new sensor ring 1...

Page 2313: ...f cap until collar comes closely into contact with brake drum If fitting part of cap is deformed or damaged or if it is fitted loosely replace with new one 9 Upon completion of all jobs depress brake...

Page 2314: ...of BRAKE DRUM REMOVAL 2 Remove shoe hold down springs 1 by turning shoe hold down pins 2 3 Remove return springs brake shoes and strut 4 Disconnect parking brake cable 1 from parking brake shoe le ver...

Page 2315: ...hoe return spring and shoe hold down spring for damage corrosion and weakening Springs Inspect for damage or weakening Inspect each part with arrow for rust If found defective replace Brake Shoe Refer...

Page 2316: ...INSTALLATION in this section WHEEL CYLINDER REMOVAL 1 Perform steps 1 to 5 of BRAKE DRUM REMOVAL 2 Perform steps 2 to 4 of BRAKE SHOE REMOVAL 3 Loosen brake pipe flare nut but only within the extent t...

Page 2317: ...step 1 to specification Tightening Torque a 12 N m 1 2 kg m 9 0 lb ft b 16 N m 1 6 kg m 12 0 lb ft 4 Install bleeder plug cap taken off from pipe back to bleeder plug 5 For procedure hereafter refer...

Page 2318: ...31090 NOTE In case of vehicle equipped with ABS do not apply sealant around hole for wheel speed sensor 2 Install brake back plate and tighten back plate bolts to specified torque Tightening Torque a...

Page 2319: ...peration see BLEEDING BRAKES in SECTION 5 8 Install wheel and tighten wheel nuts to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 lb ft 9 Upon completion of all jobs depress brake pedal wi...

Page 2320: ...OT 4 or SAE J1704 To fill master cylinder reservoir To clean and apply to inner parts of caliper and wheel cylinder when they are disassembled Water tight sealant SEALING COMPOUND 366E 99000 31090 To...

Page 2321: ......

Page 2322: ...eed Sensor Ring 5E1 37 SPECIAL TOOLS 5E1 37 SECTION 5E1 ANTILOCK BRAKE SYSTEM ABS WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system comp...

Page 2323: ...llowing parts in addition to those of the conventional brake system Wheel speed sensor which senses revolution speed of each wheel and outputs its signal ABS warning lamp which lights to inform abnorm...

Page 2324: ...link connector Fail safe relay Hydraulic unit OUTPUT INPUT ABS control module 1 ABS hydraulic unit control module assembly 2 ABS control module 3 ABS hydraulic unit 4 Fail safe relay 5 Pump motor rela...

Page 2325: ...Steering Vehicle For RH Steering Vehicle 1 Brake master cylinder 2 ABS hydraulic unit control module assembly 3 Front disk brakes 4 Rear drum brakes 5E1 4 ANTILOCK BRAKE SYSTEM ABS BRAKE HOSE PIPE RO...

Page 2326: ...nds 3 When an abnormality in the system is detected ABS warning lamp is kept light and the area where that abnormality lies is stored in the memory in ABS control module 4 When diagnosis switch termin...

Page 2327: ...5E1 6 ANTILOCK BRAKE SYSTEM ABS SYSTEM CIRCUIT...

Page 2328: ...ANTILOCK BRAKE SYSTEM ABS 5E1 7...

Page 2329: ...e was stuck in mud sand etc Wheel spin occurred while driving Wheel s was rotated while the vehicle was jacked up Be sure to read Precautions for Electronic Circuit Service in Section 0A before inspec...

Page 2330: ...o 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 Ins...

Page 2331: ...ise while vehicle is running from motor from valve other Wheel is locked at braking Pump motor does not stop running Braking does not work Other Frequency of occurrence Continuous Intermittent times a...

Page 2332: ...nd check if any trouble symptom such as abnormal lighting of ABS warning light exists If the malfunction DTC is confirmed again at ignition switch ON driving test as described in above is not neces sa...

Page 2333: ...rning lamp 1 is turned ON 3 Release parking brake with ignition switch ON and check that brake warning lamp goes off If it doesn t go off go to TABLE E in this section ABS WARNING LAMP CHECK 1 Turn ig...

Page 2334: ...ON for 2 seconds and then turns it OFF If an abnormality in the system is detected ABS warning lamp is turned ON continuously by ABS control module Also it is turned ON continuously by lamp driver mo...

Page 2335: ...nnection to ABS hydraulic unit control module connector at terminals 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 St...

Page 2336: ...indicated if no malfunction DTC is detected in the ABS A history malfunction DTC is indicated by flashing of the lamp if a current malfunction DTC is not detected at that point although a history mal...

Page 2337: ...d diagnosis switch terminal and ground terminal by service wire properly Go to Step 2 Connect service wire securely 2 1 Disconnect service wire 2 Disconnect ABS hydraulic unit control module connector...

Page 2338: ...brake completely and or replenish brake fluid 2 Does ABS warning lamp come on Perform TABLE B previously outlined Go to Step 3 3 1 Disconnect ABS hydraulic unit control module connector 2 Check for pr...

Page 2339: ...connect diagnosis switch terminal 2 of monitor coupler 3 to ground 4 3 Turn ignition switch ON 4 Read flashing of ABS warning lamp which represents DTC as shown in example below and write it down Whe...

Page 2340: ...e where there is neither any traffic nor any traffic accident possibil ity and be very careful during testing to avoid occurrence of an accident After repair or replace malfunction part s clear all DT...

Page 2341: ...rcuit C1035 35 LR C1022 22 RF C1026 26 LF Wheel speed sensor circuit or C1032 32 RR sensor ring C1036 36 LR C1041 41 RF Inlet solenoid valve circuit C1042 42 RF Outlet solenoid valve circuit C1045 45...

Page 2342: ...ensor while the ignition switch is ON When the voltage is not within the specified range an applicable DTC will be set Also when no sensor signal is inputted at starting or while running an applicable...

Page 2343: ...nsor This check result should be the same as above STEP 1 Either terminal of wheel speed sensor coupler and body ground This check result should be no continuity Are both check results OK Go to Step 4...

Page 2344: ...specified value compared with the signal sent from ABS control mod ule this DTC is set DTC 41 45 51 55 42 46 52 56 SOLENOID CIRCUIT INSPECTION STEP ACTION YES NO 1 1 Check solenoid operation referring...

Page 2345: ...oltmeter between battery positive terminal and body ground 2 Start the engine and measure the maximum voltage when racing the engine Is it over 18V Check charging system referring to CHARGING SYSTEM s...

Page 2346: ...mp motor referring to item ABS HYDRAULIC UNIT OPERATION CHECK in this section Is it in good condition Check terminals E20 25 and E20 23 connection If connections OK substitute a known good ABS hydraul...

Page 2347: ...hing faulty is found in the initial check and when the voltage is low with ignition switch turned ON this DTC will be set INSPECTION STEP ACTION YES NO 1 Check battery voltage Is it about 11 V or high...

Page 2348: ...module INSPECTION STEP ACTION YES NO 1 Clear all DTCs and check DTC Is it DTC 71 Go to Step 2 Could be a temporary malfunction of the ABS control module 2 1 Check proper connection of ABS hydraulic un...

Page 2349: ...DRAULIC CONTROL TEST under miscellaneous test MISC TEST mode of SUZUKI scan tool ABS HYDRAULIC UNIT OPERATION CHECK NOT USING SUZUKI SCAN TOOL 1 Check that basic brake system other than ABS is in good...

Page 2350: ...Perform the following checks with help of another person Brake pedal should be depressed and then ignition switch turned ON by one person and wheel should be turned by another person s hand At this t...

Page 2351: ...m ABS hydraulic unit control module assembly 3 Special Tool 09950 78220 NOTE Put bleeder plug cap onto pipe to prevent fluid from spilling Do not allow brake fluid to get on painted surfaces 5 Remove...

Page 2352: ...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 Hy draulic Unit Operation Check in this sec...

Page 2353: ...eter 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 sen sor Output AC voltage at 1 to 1 1 3 ro...

Page 2354: ...to enter its installa tion hole SENSOR INSPECTION Check sensor for damage Check sensor for resistance and continuity Between both terminals 1 sensor 1 2 1 6 k at 20 C 68 F Between sensor terminal and...

Page 2355: ...el sensor ring can not be removed or replaced alone If front wheel sensor ring needs to be replaced replace it as a wheel side joint assembly of drive shaft For removal and installation of wheel side...

Page 2356: ...ct voltmeter between connector terminals 5 While turning wheel at a speed of approximately 1 full rotation to 1 1 3 rotation per second check AC voltage of sensor Output AC voltage at 1 to 1 1 3 rotat...

Page 2357: ...r for damage Check sensor for resistance and continuity Between both terminals of sensor 0 9 1 3 k at 20 C 68 F Between sensor terminal and sensor body No continuity If the check result is not as spec...

Page 2358: ...cable 5 Test lead probe 6 Power source cable 7 DLC cable adapter 8 Self test adapter Mass storage cartridge 09931 76030 16 14 pin DLC cable 09950 78220 Flare nut wrench 10 mm REAR WHEEL SPEED SENSOR...

Page 2359: ......

Page 2360: ...nt Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under...

Page 2361: ...t System Efficiency Below Threshold 6 84 DTC P0443 Purge Control Valve Circuit Malfunction 6 87 DTC P0480 Radiator Fan Control System Malfunction 6 88 DTC P0500 Vehicle Speed Sensor Malfunction 6 90 D...

Page 2362: ...major work is performed on the engine Failure to disconnect cables may result in damage to wire har ness or other electrical parts Throughout this manual the four cylinders of the engine are iden tif...

Page 2363: ...igh fuel pressure even after engine was stopped loosen ing or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected Before loosening or discon...

Page 2364: ...5 Start engine and run it till it stops for lack of fuel Repeat cranking engine 2 3 times for about 3 seconds each time to dissipate fuel pressure in lines Fuel connections are now safe for servicing...

Page 2365: ...ns When the ignition switch is turned ON with the engine at a stop malfunction indicator lamp MIL 1 turns ON to check the bulb of the malfunction indicator lamp 1 When ECM detects a malfunction which...

Page 2366: ...wn at the left at the moment of the detection of a malfunction in its memory This data is called Freeze frame data Therefore it is possible to know engine and driving conditions e g whether the engine...

Page 2367: ...1 P0400 EGR detected Data at P0400 detection Data at P0400 detection 2 P0171 Fuel system detected Data at P0171 detection Data at P0400 detection Data at P0171 detection 3 P0300 Misfire detected Data...

Page 2368: ...has occurred in the above areas it makes malfunction indicator lamp 1 turn ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the trouble ar...

Page 2369: ...v en in the applicable DTC flow chart these should be followed If no instructions are given troubleshoot diagnostic trouble codes according to the following priorities 1 Diagnostic trouble codes DTCs...

Page 2370: ...referring to the next page Is trouble symptom identified Go to Step 6 Go to Step 7 6 Rechecking and Record of DTC Freeze Frame Data 1 Recheck for DTC and freeze frame data referring to DTC Check sect...

Page 2371: ...NFIRMATION Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC freeze frame data check confirm trouble symptoms Also reconfirm DTC according to DTC Confirmation Procedur...

Page 2372: ...mperature Frequency Road Fair Cloudy Rain Snow Not related Other Hot Warm Cool Cold F C Not related Always Sometimes times day month Only once Under certain condition Urban Suburb Highway Mountainous...

Page 2373: ...unication is possible in this case scan tool is in good condition Then check data link connector and se rial data line circuit in the vehicle with which communication was not possible 5 After completi...

Page 2374: ...e data stored in ECM memory are also cleared in following cases Be careful not to clear them be fore keeping their record When power to ECM is cut off by disconnecting battery cable removing fuse or d...

Page 2375: ...is longer than specification 2 driving cycles Not applicable P0135 No 14 HO2S heater circuit malfunction Sensor 1 Terminal voltage is lower than specification at heater OFF or it is higher at heater O...

Page 2376: ...P0500 No 16 Vehicle speed sensor malfunction No signal while running in D range or during fuel cut at decelerating 2 driving cycles 1 driving cycle P0505 No 26 Idle control system malfunction No close...

Page 2377: ...tion Refer to Section 7B P0753 No 21 No 22 Shift Solenoid No 1 Circuit P0758 No 23 No 24 Shift Solenoid No 2 Circuit P0763 No 43 Shift Solenoid No 3 Circuit P0768 No 45 Shift Solenoid No 4 Circuit P07...

Page 2378: ...mp circuit malfunction ECM controls actuators assuming that intake air temperature is 20 C 68 F P0115 Engine coolant temp circuit malfunction ECM controls actuators assuming that engine coolant temper...

Page 2379: ...electric wire harness disconnection friction Fuses burning Parts installation bolt looseness Parts deformation Other parts that can be checked visually Also check following items at engine start if po...

Page 2380: ...Remove air cleaner bolt and clips and shift air cleaner position to observe ignition timing 3 Using timing light 1 check initial ignition timing See Fig 4 Is it 5 3 BTDC at specified idle speed Go to...

Page 2381: ...mode SELECT MENU F4 MISC TEST When using SUZUKI scan tool When not using SUZUKI scan tool 6 22 ENGINE DIAGNOSIS Fig 1 for Step 5 Fig 2 for Step 6 Fig 3 for Step 6 Fig 4 for Step 6 Fig 5 for Step 7 Fi...

Page 2382: ...sor or MAP sensor Faulty ECM Low compression Poor spark plug tightening or faulty gasket Compression leak from valve seat Sticky valve stem Weak or damaged valve springs Compression leak at cylinder h...

Page 2383: ...bent valve Piston ring and cylinder noise Worn piston ring and cylinder bore Connecting rod noise Worn rod bearing Worn crank pin Loose connecting rod nuts Low oil pressure Crankshaft noise Low oil pr...

Page 2384: ...AP sensor Faulty EGR valve if equipped Faulty fuel injector s Faulty ECM Low compression Others Poor valve seating Dragging brakes Slipping clutch Thermostat out of order Improper tire pressure High t...

Page 2385: ...burned electrodes etc Fuel system out of order Variable fuel pressure Kinky or damaged fuel hose and lines Faulty fuel pump clogged fuel filter Engine and emission control system out of order Malfunct...

Page 2386: ...ning EGR valve if equipped Maladjusted accelerator cable play Poor performance of TP sensor ECT sensor or MAP sensor Faulty fuel injector s Faulty ECM Low compression Others Dragging brakes Slipping c...

Page 2387: ...ty evaporative emission control system Faulty EGR system if equipped Faulty fuel injector s Poor performance of ECT sensor TP sensor or MAP sensor Faulty ECM Engine overheating Low compression Others...

Page 2388: ...igh tension cords in Section 6F1 Ignition coil assembly in Section 6F1 Refer to Low compression section Check for absence of filler neck restrictor EVAP control system in Section 6E Diagnostic Flow Ta...

Page 2389: ...UEL SYSTEM B1 FUEL SYSTEM STATUS At specified idle speed after warming up CLOSED closed loop CALC LOAD CALCULATED LOAD At specified idle speed with no load after warming up 3 9 VALUE At 2500 r min wit...

Page 2390: ...UT Other than fuel cut condition OFF RADIATOR FAN RADIATOR FAN Ignition switch ON Engine coolant temp Lower than 92 5 C 199 F OFF CONTROL RELAY ON Engine coolant temp 97 5 C 208 F or higher ON ELECTRI...

Page 2391: ...TAKE AIR TEMP C F It is detected by intake air temp sensor and used to determine the amount of air passing into the intake manifold as air density varies with temperature MAF MASS AIR FLOW RATE gm s l...

Page 2392: ...not being out put ELECTRIC LOAD ON OFF ON Headlight small light heater fan or rear win dow defogger ON signal inputted OFF Above electric loads all turned OFF A C SWITCH ON OFF ON Command for A C ope...

Page 2393: ...stance CAUTION ECM cannot be checked by itself It is strictly prohibited to connect voltmeter or ohmmeter to ECM with coupler dis connected from it Voltage Check 1 Remove ECM 1 from body referring to...

Page 2394: ...iag flow table 14 Engine coolant temp sensor 0 55 0 95 V Ignition switch ON Engine coolant temp 80 C 176 F 15 Intake air temp sensor 2 0 2 7 V Ignition switch ON Intake air temp 20 C 68 F 16 Test swit...

Page 2395: ...or 2 Vehicle with EGR valve Refer to DTC P0130 diag flow table 14 D range ID up signal A T 10 14 V Ignition switch ON 15 R range signal A T 0 V Ignition switch ON 16 A C input signal 10 14 V Ignition...

Page 2396: ...n 5 Throttle position sensor 2 8 4 8 V Ignition switch ON Throttle valve at full open position 6 Ignition switch 10 14 V Ignition switch ON 7 Blank 8 Blank 9 Stop lamp switch 0 V Ignition switch ON St...

Page 2397: ...6 E22 4 to E23 6 HO2S 2 heater 11 7 15 6 E21 9 to E22 5 6 No 1 injector 12 0 13 0 E21 21 to E22 5 6 No 2 injector 12 0 13 0 E21 31 to E22 5 6 No 3 injector 12 0 13 0 E21 8 to E22 5 6 No 4 injector 12...

Page 2398: ...12 Stop lamp switch 13 Knock sensor OTHERS A ECM B Main relay C EVAP canister D Monitor connector If equipped E Data link connector F A C EVAP thermistor if equipped G Transmission control module A T...

Page 2399: ...g INSPECTION STEP ACTION YES NO 1 MIL Power Supply Check 1 Turn ignition switch ON Do other indicator warning lights in combination meter comes ON Go to Step 2 IG fuse blown main fuse blown ignition s...

Page 2400: ...ode DTC check 1 Check DTC referring to DTC CHECK section Is there any DTC s Go to Step 2 of ENGINE DIAG FLOW TABLE Go to Step 2 2 DTC check Start engine and recheck DTC while engine running Is there a...

Page 2401: ...er connection to main relay 1 at terminal 3 and 4 3 Check resistance between each two terminals See Fig 1 and 2 Between terminals 1 and 2 Infinity Between terminals 3 and 4 70 110 4 Check that there i...

Page 2402: ...between terminal E22 5 and ground at ignition switch ON Is it 10 14 V Check ground circuits Bl B and B Y for open If OK then substitute a known good ECM and recheck Go to Step 6 6 Is operating sound...

Page 2403: ...ss Low pressure High vacuums Low voltage MAP 114 7 kpa 860mmHg or more High pressure Low vacuums High voltage Br W circuit open W G circuit open or shorted to ground Lg R circuit open or shorted to gr...

Page 2404: ...s when vacuum is applied up to 400 mmHg by using vacuum pump 3 Output voltage Vin voltage 4 5 5 5 V ambient temp 20 30 C 68 86 F ALTITUDE BAROMETRIC OUTPUT Reference PRESSURE VOLTAGE ft m mmHg kPa V 0...

Page 2405: ...MAP sensor at Lg R and Br W wire terminals 3 If OK then with ignition switch ON check voltage at each of W G and Lg R wire terminals See Fig 2 Is voltage about 4 6 V at each terminal Go to Step 4 W G...

Page 2406: ...take air temperature Low voltage Low resistance Lg circuit open or shorted to power Br W circuit open IAT sensor malfunction ECM malfunction NOTE When DTC P0115 and P0120 are indicated together it is...

Page 2407: ...terminals 3 If OK then with ignition switch ON is voltage applied to Lg wire terminal about 4 6 V See Fig 2 Go to Step 4 Lg wire open or shorted to power or poor E21 15 connection If wire and connect...

Page 2408: ...TCM after completion of repair DTC P0115 ENGINE COOLANT TEMPERATURE ECT CIRCUIT DTC No 19 MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE Low engine coolant temperature High vol...

Page 2409: ...s 3 If OK then with ignition switch ON is voltage applied to Y G wire terminal about 4 6 V See Fig 2 Go to Step 4 Y G wire open or shorted to power or poor E21 14 connection If wire and connection are...

Page 2410: ...DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE Signal voltage high Signal voltage low Br W circuit open Gr circuit open or shorted to ground W G circuit open or shorted to power or ground TP senso...

Page 2411: ...oor Connection in Section 0 A 3 Check Wire Harness 1 Disconnect connector from TP sensor with ignition switch OFF 2 Check for proper connection to TP sensor at W G Gr and Br W wire terminal 3 If OK th...

Page 2412: ...ENGINE DIAGNOSIS 6 53 MEMO...

Page 2413: ...RE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test sho...

Page 2414: ...Check voltage at terminal E23 5 of ECM connector connected when throttle valve is at idle position and fully opened See Fig 2 and 3 Dose voltage vary within specified value linearly as shown in figure...

Page 2415: ...performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident Road test should be carried...

Page 2416: ...e to normal operating temperature and keep it at 2000 r min for 60 sec 3 Repeat racing engine Repeat depressing accelerator pedal 5 to 6 times continuously and take foot off from pedal to enrich and e...

Page 2417: ...speed response time time to change from lean to rich or from rich to lean of HO2S 1 output voltage is about 1 sec at minimum or average time of 1 cycle is 5 sec at minimum See Fig 1 2 driving cycle d...

Page 2418: ...ving cycle detection logic Continuous monitoring HO2S 1 heater circuit open or shorted to ground ECM malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where the...

Page 2419: ...Intermittent and Poor Connection Go to Step 3 terminal E21 7 See Fig 1 Voltage should be over 10 V 5 Start engine run it at idle and check voltage at the same terminal Voltage should be below 1 9 V Ar...

Page 2420: ...USE DTC will set when A or B condition is detected A Max output voltage of HO2S 2 is lower than specified value or Min output voltage is higher than specified value while vehicle driving B Engine is w...

Page 2421: ...arm up engine to normal operating temperature 3 Drive vehicle under usual driving condition for 5 min and check HO2S 2 output voltage and short term fuel trim with Data List mode on scan tool and writ...

Page 2422: ...d Its Circuit Was HO2S 2 output voltage indicated on scan tool in step 3 of DTC confirmation test less than 1 275 V Go to Step 4 Br W or Bl circuit open or HO2S 2 malfunction 4 Check Short Term Fuel T...

Page 2423: ...d time after engine start or while engine running at high load B High voltage at terminal E22 4 while engine running under other than above condition 2 driving cycle detection logic continuous monitor...

Page 2424: ...ltage at the same terminal after 1 min from engine start Voltage should be below 1 9 V Are check result as specified Intermittent trouble Check for intermittent referring to Intermittent and Poor Conn...

Page 2425: ...TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE When following condition occurs while engine running under closed loop condition Air fuel ratio too l...

Page 2426: ...n for Indication of fuel level meter in combination meter 1 4 or more Altitude barometric pressure 2400 m 8000 ft or less 560 mmHg 75 kPa or more Ambient temp 10 C 14 F or higher Intake air temp 70 C...

Page 2427: ...cope 1 or such check operating sound of each injector 2 when engine is running Cycle of operating sound should vary according to engine speed See Fig 3 If no sound or an unusual sound is heard check i...

Page 2428: ...n good condition Go to Step 9 Replace engine coolant temp sensor 9 Check intake air temp sensor for performance See Section 6E Is it in good condition Go to Step 10 Replace intake air temp sensor 10 C...

Page 2429: ...No via the camshaft position sensor Then it calculates the change in the crankshaft revolution speed and from how many times such change occurred in every 200 or 1000 engine revolutions it detects occ...

Page 2430: ...andom misfire if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2 simulta neously it may not possible to reconfirm DTC by using the following DTC confirmation procedure When diagnosing the tro...

Page 2431: ...e at stop 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi At specified idle speed 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi Is measured value as specified Go to Step 5 Go to Diag Flow Table B 3 fuel pressure...

Page 2432: ...Step 8 8 Check intake manifold pressure sensor for performance See DTC P0105 Diag Flow Table Is it in good condition Go to Step 9 Repair or replace 9 Check engine coolant temp sensor for performance S...

Page 2433: ...ABLE 2 1 With engine running check voltage from E21 12 terminal of ECM connector to body ground See Fig 1 2 Is voltage about 1 25 3 75 V Knock sensor and its circuit are in good condition Intermittent...

Page 2434: ...E21 12 ENGINE DIAGNOSIS 6 75 Fig 1 for Step 2 Fig 2 for Step 2...

Page 2435: ...3 MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE NO CKP sensor signal for 2 seconds at engine cranking CKP sensor circuit open or short Crankshaft timing belt pulley teeth dama...

Page 2436: ...check for proper connection to CKP sensor at P and Bl wire terminals 3 If OK measure sensor resistance between terminals See Fig 1 CKP sensor resistance 360 460 at 20 C 68 F 4 Measure resistance betwe...

Page 2437: ...POSSIBLE CAUSE No CMP sensor signal during engine running CKP sensor signal is inputted CMP sensor circuit open or short Signal rotor teeth damaged CMP sensor malfunction foreign material being attach...

Page 2438: ...Step 3 check Or wire open short or poor connection If wire and connection are OK substitute a known good ECM and recheck B W or B wire open short or poor connection 5 Check Ground Circuit for Open 1...

Page 2439: ...following using mirror See Fig 4 Damage No foreign material attached Is it in good condition Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection in...

Page 2440: ...specified vehicle speed after engine warm up During deceleration engine speed high with closed throttle position ON in which fuel cut is involved difference in intake manifold absolute pressure betwee...

Page 2441: ...art engine and warm it up to normal operating temperature 70 110 C 158 230 F and run it at idle for 5 min 3 Increase vehicle speed to 50 55 mph 80 88 km h in 5th gear or in D range 4 Hold throttle val...

Page 2442: ...lve or clogged EGR gas passage If all above are OK substitute a known good ECM and recheck 5 Check EGR system referring to EGR SYSTEM system inspection in Section 6E Is check result satisfactory Subst...

Page 2443: ...the catalyst is functioning properly the variation cycle of HO2S 2 output voltage oxygen concentration is slower than that of HO2S 1 output voltage because of the amount of oxygen in the exhaust gas...

Page 2444: ...h 55 65 km h for 8 min or longer While this driving if Catalyst Monitoring TEST COMPLETED is displayed in READINESS TESTS mode and DTC is not displayed in DTC mode confirmation test is completed If TE...

Page 2445: ...tion test Go to Step 3 Check fuel system Go to DTC P0171 P0172 Diag Flow Table 3 Check HO2S 2 for Output Voltage Perform steps 1 through 9 of DTC confirmation procedure for DTC P0136 HO2S 2 malfunctio...

Page 2446: ...B R wire open Canister purge valve malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC with ignition switch ON 2 Select DTC mode on scan tool and check DTC INSPECTION STEP ACTION YES NO 1 Check EVAP ca...

Page 2447: ...Low voltage at terminal E22 18 when engine coolant temp is below 93 C 200 F 2 driving cycle detection logic continuous monitoring B R or BI circuit open or short Radiator cooling fan relay malfunctio...

Page 2448: ...temp is lower than 93 C 200 F and A C switch turns OFF 10 14 V Is voltage as specified Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and Poor Connection in Sectio...

Page 2449: ...rt VSS speedometer driven gear malfunction ECM malfunction Speedometer malfunction DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibilit...

Page 2450: ...g engine 5 Measure voltage from terminal c of VSS connector to ground Is voltage within 4 5 V Faulty speedometer Faulty P S control module V wire open or short Poor connection of ECM connector termina...

Page 2451: ...TION POSSIBLE CAUSE No closed signal to IAC valve is detected after engine start 2 driving cycle detection logic continuous monitoring B R G Y or B circuit open or short IAC valve malfunction ECM malf...

Page 2452: ...peed by using SUZUKI scan tool When not using SUZUKI scan tool 1 Remove IAC valve from throttle boy referring to IAC Valve Removal in Section 6E 2 Check IAC valve for operation referring to IAC Valve...

Page 2453: ...itten into ECM 2 driving cycle detection logic continuous monitoring ECM DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON and then turn ignition switch OFF 3 S...

Page 2454: ...ssure sensor and its circuit malfunction ECM barometric pressure sensor malfunction DTC CONFIRMATION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON 3 Turn ignition switch ON...

Page 2455: ...Step 2 STEP ACTION YES NO 2 Check MAP Sensor 1 Remove MAP sensor from intake manifold and connect vacuum pump gauge to MAP sensor See Fig 2 2 Connect scan tool to DLC and turn ignition switch ON 3 Che...

Page 2456: ...TION PROCEDURE 1 Turn ignition switch OFF 2 Clear DTC with ignition switch ON crank engine and run it at idle for 3 min 3 Check pending DTC in ON BOARD TEST or PENDING DTC mode and DTC in DTC mode INS...

Page 2457: ...ing engine W Bl circuit open ECM malfunction DTC CONFIRMATION PROCEDURE 1 Clear DTC start engine and run it at idle for 1 min 2 Select DTC mode on scan tool and check DTC INSPECTION STEP ACTION YES NO...

Page 2458: ...judgement was made or not with re spect to all detectable DTCs as well as whether or not abnormality exists after judgement DTC DETECTING CONDITION POSSIBLE CAUSE No signal inputted from TCM to ECM or...

Page 2459: ...onnection in Section 0A Go to Step 3 3 Is it about 12 V at Step 2 Bl W wire open poor E13 20 connection or TCM power or ground circuit open If wires and connections are OK substitute a known good TCM...

Page 2460: ...DTC CONFIRMATION PROCEDURE WARNING When performing a road test select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of...

Page 2461: ...n display Is 0 1 V indicated no matter which of R D 2 and L range positions selector lever may be at See Fig 3 Intermittent trouble or faulty ECM Check for intermittent referring to Intermittent and p...

Page 2462: ...k each injector for operating sound at engine cranking Do all 4 injectors make operating sound Fuel injector circuit is in good condition Go to Step 3 3 Dose none of 4 injectors make operating sound a...

Page 2463: ...n 1 Remove fuel pump relay from relay box with ignition switch OFF 2 Check for proper connection to relay at each terminals 3 If OK using service wire connect terminals E52 3 and E52 4 of relay connec...

Page 2464: ...ENGINE DIAGNOSIS 6 105 Fig 1 for Step 2 Fig 2 for Step 3 Fig 3 for Step 4 Fuel pump relay connector...

Page 2465: ...n 270 310 kPa 2 7 3 1 kg cm2 38 4 44 0 psi Go to Step 2 Go to Step 4 2 Is 250 kPa 2 5 kg cm2 35 6 psi or higher fuel pressure retained for 1 minute after fuel pump is stopped at Step 1 Normal fuel pre...

Page 2466: ...ENGINE DIAGNOSIS 6 107 Fig 1 for Step 1 4 Fuel pressure gauge 3way joint...

Page 2467: ...anister purge control system Clog of IAC air passage Accessory engine load Closed throttle position TP sensor Stuck of PCV valve 3 Is engine idle speed kept specified speed even with headlight ON Syst...

Page 2468: ...F See Fig 1 2 Turn ignition switch ON and check PNP signal P N and D range on display when shifting selector lever to each range When not using SUZUKI scan tool 1 Turn ignition switch ON 2 Check volta...

Page 2469: ...ECM connectors with ignition switch at OFF position 2 Check resistance between E23 14 terminal and E23 10 terminal 3 Is it within specification Reference value See Fig 1 At 0 C 6 3 6 9 k At 25 C 1 8 2...

Page 2470: ...al under each condition given in table below NOTE When A C evaporator thermistor temp is below 2 5 C 36 5 F A C remain OFF E22 1 terminal voltage become 0 1 V This condition is not abnormal 2 Is check...

Page 2471: ...scan tool 3 Check electric load signal under following each condition See Fig 1 Ignition switch ON Small light heater blower fan and rear defogger all turned OFF OFF 0 V E21 17 10 14 V E23 13 Ignitio...

Page 2472: ...good condition Go to Step 2 2 Check Radiator Cooling Fan Relay and Its Circuit 1 Check DTC and pending DTC with scan tool Is DTC P0480 displayed Go to DTC P0480 Diag Flow Table Go to Step 3 3 Check R...

Page 2473: ...6 114 ENGINE DIAGNOSIS Fig 1 for Step 1 Fig 2 for Step 3 Fig 3 for Step 4 When using SUZUKI scan tool Radiator cooling fan relay...

Page 2474: ...ble 14 26 pin 09931 76040 5 Test lead probe 6 Power source cable 7 DLC cable adaptor 8 Self test adaptor 1 Pressure gauge 09912 58441 2 Pressure hose 09912 58431 3 3 way joint hose 09912 58490 4 Check...

Page 2475: ......

Page 2476: ...on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in...

Page 2477: ...C Single Overhead Camshaft valve mechanism arranged for V type valve configuration and 16 valves IN2 and EX2 one cylinder The single overhead camshaft is mounted over the cylinder head it is driven fr...

Page 2478: ...g rod bearings by means of intersecting passages drilled in crankshaft and then injected from a small hole provided on big end of connecting rod to lubricate piston rings and cylinder wall In another...

Page 2479: ...one spacer The piston pin is offset 0 5 mm towards the major thrust side This allows a gradual change in thrust pressure against the cylinder wall as the piston travels its path Pins made of chromium...

Page 2480: ...2 Brake booster vacuum hose 3 EVAP canister 4 EVAP canister purge valve 5 TP sensor 6 CMP sensor 7 Ignition coil assembly 8 PCV valve 9 IAC valve ENGINE MECHANICAL 6A1 5 ON VEHICLE SERVICE HOSE AND P...

Page 2481: ...001 B 09915 64510 002 C 09915 64530 D 09915 67010 6 Disengage clutch to lighten starting load on engine for M T model and depress accelerator pedal all the way to make throttle valve full open 7 Cran...

Page 2482: ...310 B 09918 08210 x 2 pcs Spare Part C 09367 04002 D 09355 35754 6010 3 Run engine at specified idle speed see Section 6E1 and read vacuum gauge Vacuum should be within following specifica tion Vacuum...

Page 2483: ...reads with a sealing tape and tighten switch to specified torque NOTE If sealing tape edge is bulged out from screw threads of switch cut it off Tightening Torque a 14 N m 1 4 kg m 10 5 lb ft 7 After...

Page 2484: ...cam riding face of rocker arm 7 If valve lash is out of specification adjust it to specification by turning adjusting screw after loosening lock nut After adjustment tighten lock nut to specified torq...

Page 2485: ...allation AIR CLEANER ELEMENT This air cleaner element is of dry type Remember that it needs cleaning according to following procedure REMOVAL 1 Disconnect air cleaner outlet No 1 hose from air cleaner...

Page 2486: ...g ure INSTALLATION Reverse removal procedure for installation noting the following Install suction pipe grommet 5 in the direction indicated in figure Clamp each hose securely AIR CLEANER OUTLET HOSE...

Page 2487: ...valve from head cover 3 Remove suction pipe from air cleaner assembly 4 Remove ignition coil assemblies with high tension cord 5 Remove cylinder head cover 1 with cylinder head cover gasket 2 and O r...

Page 2488: ...pipe to air cleaner assembly referring to INSTAL LATION of AIR CLEANER ASSEMBLY in this section 6 Connect negative cable at battery THROTTLE BODY AND INTAKE MANIFOLD REMOVAL 1 Relieve fuel pressure ac...

Page 2489: ...s EGR valve 1 EVAP canister purge valve 2 Ground wire 3 from intake manifold Fuel injectors 4 TP sensor 5 IAC valve 6 MAP sensor 7 7 Disconnect following hoses Brake booster hose 1 from intake manifol...

Page 2490: ...wings Use new intake manifold gasket When installing intake manifold install clamps at positions as shown in figure Adjust accelerator cable play referring to Section 6E Check to ensure that all remov...

Page 2491: ...ts 14 Exhaust pipe bolts 15 Catalytic converter case nuts Tightening Torque Do not reuse 6A1 16 ENGINE MECHANICAL EXHAUST MANIFOLD WARNING To avoid danger of being burned do not service exhaust system...

Page 2492: ...ust manifold Tighten manifold bolts and nuts to specified torque Tightening Torque a 23 N m 2 3 kg m 17 0 lb ft 3 Install exhaust manifold cover 4 Connect oxygen sensor No 1 coupler 1 and clamp 2 its...

Page 2493: ...rque 14 6A1 18 ENGINE MECHANICAL TIMING BELT AND BELT TENSIONER REMOVAL 1 Disconnect negative cable at battery 2 Remove right side of engine under cover 1 3 Disconnect A C suction and discharge hoses...

Page 2494: ...MECHANICAL 6A1 19 8 Remove water pump pulley 1 and drive belt 9 Remove crankshaft pulley by removing pulley bolts 1 10 Release harness clamps 11 Remove timing belt outside cover 12 For installation o...

Page 2495: ...ming belt is removed never turn camshaft and crankshaft independently more than such an extent as shown in figure If turned interference may occur among piston and valves and parts related to piston a...

Page 2496: ...than its allowable turning range which is described on previous page 4 Check that timing mark 2 on crankshaft timing belt pulley is aligned with arrow mark 1 on oil pump case If not align two marks b...

Page 2497: ...orque a 11 N m 1 1 kg m 8 0 lb ft b 22 N m 2 2 kg m 16 0 lb ft 7 Install timing belt outside cover Before installing make sure that seal is between water pump and oil pump case Tightening Torque a 11...

Page 2498: ...A C compressor if equipped 14 Connect A C suction and discharge hoses if equipped 15 Adjust drive belt tension referring to ENGINE COOLING sec tion 16 Adjust A C compressor belt tension if equipped Re...

Page 2499: ...ainer bracket bolt 6A1 24 ENGINE MECHANICAL OIL PAN AND OIL PUMP STRAINER REMOVAL 1 Raise vehicle 2 Drain engine oil by removing drain plug 1 3 Remove right side of engine under cover 4 Disconnect oxy...

Page 2500: ...O ring 2 into cylinder block securely as shown in figure Install oil pump strainer to cylinder block Tighten strainer bolt first and then bracket bolt to specified torque Tightening Torque a 11 N m 1...

Page 2501: ...m 7 5 lb ft 5 Install exhaust No 1 pipe and connect oxygen sensor No 2 con nector Tighten bolts to specified torque Tightening Torque a 42 N m 4 2 kg m 30 5 lb ft NOTE Use new gasket for exhaust No 1...

Page 2502: ...ing Torque Do not reuse ENGINE MECHANICAL 6A1 27 OIL PUMP REMOVAL 1 Disconnect negative cable at battery 2 Remove timing belt as previously outlined 3 Remove generator and its bracket NOTE When instal...

Page 2503: ...6A1 28 ENGINE MECHANICAL DISASSEMBLY 1 Remove oil level gauge guide bolt 3 and pull out guide 2 from oil pump 1 2 Remove rotor plate 1 3 Remove outer rotor 1 and inner rotor 2...

Page 2504: ...r rotors rotor plate and oil pump case for excessive wear or damage MEASUREMENT Radial clearance Check radial clearance between outer rotor 1 and case using thickness gauge If clearance exceeds its li...

Page 2505: ...by hand Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 5 Apply engine oil to O ring 1 and install O ring and guide 2 INSTALLATION 1 Install two oil pump pins and oil pump gasket to cylinder block Use a...

Page 2506: ...m 94 0 lb ft 6 Install timing belt tensioner oil pump strainer oil pan and other parts as previously outlined 7 Check to ensure that all removed parts are back in place Reinstall any necessary parts...

Page 2507: ...w 11 Clip 12 Lock nut 13 Rocker arm spring 14 Intake valve 15 Exhaust valve 16 Valve spring 17 Valve spring retainer 18 Valve cotter 19 Valve spring seat 20 Valve stem seal Tightening Torque 5 12 ROCK...

Page 2508: ...emoval of case 9 After loosening all valve adjusting screw lock nuts 2 turn ad justing screws 1 back all the way to allow all rocker arms 3 to move freely 10 Remove camshaft housing and camshaft NOTE...

Page 2509: ...ion side 15 Remove O ring from rocker arm shaft INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw 1 is badly worn replace it Rocker arm 2 must be replaced if its cam riding face 3 is...

Page 2510: ...0035 in Cam Wear Using a micrometer measured height of cam If measured height is below limit replace camshaft Cam height Standard Limit Intake cam 36 184 36 344 mm 1 4246 1 4309 in 36 084 mm 1 4206 i...

Page 2511: ...torque Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft NOTE Do not rotate camshaft while plasticgange is installed 6 Remove housing and using scale 2 on plasticgauge envelope measure plasticgauge 1 widt...

Page 2512: ...side 2 and rocker arm spring 1 3 Check O ring for damage or deterioration Install O ring to rocker arm shaft 4 Install rocker arm shaft bolts and tighten them to specified torque Tightening Torque a 1...

Page 2513: ...n each camshaft housing in dicating position and direction for installation Install housings as indicated by these marks As camshaft housing No 1 retains camshaft in proper position as to thrust direc...

Page 2514: ...engine right mounting bracket and stiffener as previously outlined 12 Remove cylinder head cover 13 After applying sealant to part A as shown in figure at the left install CMP sensor case to cylinder...

Page 2515: ...rk provided on gasket comes to crankshaft pulley side facing up toward cylinder head side 14 Dowel pin 1 Valve cotters Apply engine oil 2 Valve spring retainer Apply engine oil 3 Valve spring Apply en...

Page 2516: ...gnition coil assembly ECT sensor Ground wire from intake manifold and cylinder head Injectors TP sensor IAC valve Oxygen sensor if equipped EVAP canister purge valve if equipped and then release above...

Page 2517: ...feed hose 1 from fuel delivery pipe 11 Disconnect water inlet pipe 1 from its bracket 12 Remove cylinder head cover as previously outlined Loosen all valve lash adjusting screws fully 13 Remove timin...

Page 2518: ...ting swing bracket 3 15 Remove support device 16 Loosen cylinder head bolts in such order as indicated in figure and remove them 17 Check all around cylinder head for any other parts required to be re...

Page 2519: ...se special tool and remove spring retainer and valve spring 5 Remove valve from combustion chamber side 6 Remove valve stem oil seal 1 from valve guide and then valve spring seat 2 NOTE Do not reuse o...

Page 2520: ...0 0008 0 0018 in 0 07 mm 0 0027 in g clearance Ex 0 045 0 072 mm 0 0018 0 0028 in 0 09 mm 0 0035 in If bore gauge is not available check end deflection of valve stem with a dial gauge instead Move ste...

Page 2521: ...ve must be a continuous ring without any break and the width of pattern must be within specified range Standard seating width revealed In 1 1 1 3 mm by contact pattern on valve face Ex 0 0433 0 0512 i...

Page 2522: ...to valves and valve seats too Check cylinder head for cracks in intake and exhaust ports com bustion chambers and head surface Flatness of gasketed surface Using a straightedge and thickness gauge che...

Page 2523: ...Remember weakened valve springs can cause chatter not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure Item Standard Limit Valve spring free leng...

Page 2524: ...ole with special tools Drive in new valve guide until special tool Valve guide installer contacts cylinder head After installing make sure that valve guide protrudes by 11 5 mm 0 45 in from cylinder h...

Page 2525: ...ling never tap or hit special tool with a ham mer or else Install seal to guide only by pushing special tool by hand Tapping or hitting special tool may cause damage to seal 6 Install valve to valve g...

Page 2526: ...t venturi plug is installed and if it is that it is not clogged When installing it be sure to tighten to specified torque Tightening Torque a 3 5 N m 0 35 kg m 2 5 lb ft 3 Apply engine oil to cylinder...

Page 2527: ...lashes as previously outlined Adjust accelerator cable play Refer to Section 6E Check to ensure that all removed parts are back in place Reinstall any necessary parts which have not been reinstalled...

Page 2528: ...head from cylinder block as previously out lined 2 Install engine right mounting bracket 3 Drain engine oil 4 Remove oil pan and oil pump strainer as previously outlined 5 Mark cylinder number on all...

Page 2529: ...g expander remove two compression rings Top and 2nd and oil ring from piston 2 Remove piston pin from connecting rod Ease out piston pin circlips 1 as shown Force piston pin out CLEANING Clean carbon...

Page 2530: ...rence between thrust and axial measurements exceeds out of round limit Cylinder bore dia limit 74 15 mm 2 9196 in Tapper and out of round limit 0 10 mm 0 0039 in NOTE If any one of four cylinders has...

Page 2531: ...nd by using thickness gauge 2 If clearance is out of specification replace piston Ring groove clearance Top 0 03 0 07 mm 0 0012 0 0027 in 2nd 0 02 0 06 mm 0 0008 0 0023 in Piston pin Check piston pin...

Page 2532: ...end gap 2nd ring 0 2 0 35 mm 0 0079 0 0137 in 0 7 mm 0 0275 in ga Oil ring 0 2 0 7 mm 0 0079 0 0275 in 1 7 mm 0 0669 in Connecting Rod Big end side clearance Check big end of connecting rod for side...

Page 2533: ...ndition must be replaced Two kinds of rod bearing are available standard size bearing and 0 25 mm undersize bearing To distinguish them 0 25 mm under size bearing has the stamped number USO25 on its b...

Page 2534: ...its limit even by using a new standard size bearing regrind crankpin to undersize and use 0 25 mm undersize bearing ASSEMBLY NOTE Two sizes of piston are available as standard size spare part so as t...

Page 2535: ...piston head but ordinarily it is not necessary to discriminate each piston by this letter 1 Install piston pin to piston 1 and connecting rod 2 After applying engine oil to piston pin and piston pin...

Page 2536: ...ecting rod assembly into cylin der bore point front mark punch mark or arrow mark on piston head to crankshaft pulley side 1 4 Install piston and connecting rod assembly into cylinder bore Use special...

Page 2537: ...on 6E Check to ensure that all removed parts are back in place Rein stall any necessary parts which have not been reinstalled Refill engine with engine oil referring to item ENGINE OIL CHANGE in Secti...

Page 2538: ...bracket No 1 to No 2 bolt 23 Rear mounting bush bolt 24 Rear mounting body bolt Tightening Torque 1 Right mounting 2 Right mounting swing bracket 3 Right mounting bracket 4 Left mounting body bracket...

Page 2539: ...nd steam can be blown out under pressure if plug and cap are taken off too soon 5 Disconnect radiator inlet hose from thermostat case and outlet hose from water inlet pipe 6 Remove air cleaner outlet...

Page 2540: ...m fuel delivery pipe 12 Disconnect heater inlet and outlet hoses 13 Remove right and left engine under covers 14 Disconnect oxygen sensor No 2 coupler 1 and remove ex haust No 1 pipe 2 15 Drain engine...

Page 2541: ...ll support device 20 Remove engine rear mounting bush bolt 1 21 Remove engine left mounting nuts 2 22 Remove engine right mounting bracket bolts 3 and nut 4 23 Before removing engine with transmission...

Page 2542: ...or center bearing support Use care not to damage oil seal lip when inserting Install stabilizer bar refer to Section 3D Install exhaust No 1 pipe Install right and left engine under covers Connect ea...

Page 2543: ...not reuse 6 Timing pulley key 7 Crankshaft Apply engine oil to crankshaft journals 8 Thrust bearing Set oil grooves of bearing to crank weds Apply engine oil 9 Rear oil seal Apply engine oil to conta...

Page 2544: ...10 3 Remove crankshaft pulley timing belt and crankshaft timing pulley 4 Remove cylinder head assembly 5 Remove oil pan and oil pump strainer 6 Remove oil pump 1 7 Remove oil seal housing 8 Remove con...

Page 2545: ...bearing with new standard one or oversize one to obtain standard thrust play Crankshaft Thrust Play Standard 0 11 0 31 mm 0 0044 0 0122 in Limit 0 38 mm 0 0149 in Thickness of crankshaft thrust bearin...

Page 2546: ...4 and 5 Tighten cap bolts to specified torque Inspection Check bearings for pitting scratches wear or damage If any malcondition is found replace both upper and lower halves Never replace one half wi...

Page 2547: ...tion select a new standard bearing according to following proce dure and install it 1 First check journal diameter by using following procedure As shown in figure crank webs of No 2 and No 3 cylinder...

Page 2548: ...ng caps 1 2 3 4 and 5 respectively For example in figure the first leftmost alphabet B indicates that cap bore dia of bearing cap 1 is within 49 006 49 012 mm and the fifth rightmost alphabet A indica...

Page 2549: ...1 check bearing clearance with newly selected standard bearing If clearance still exceeds its limit use next thicker bearing and recheck clearance 6 When replacing crankshaft or cylinder block due to...

Page 2550: ...er block select an under size bearing by referring to table given below Check bearing clearance with newly selected undersize bear ing Measured journal diameter 44 744 44 750 mm 1 7616 1 7618 in 44 73...

Page 2551: ...of gasketed surface Using straightedge and thickness gauge check gasketed surface for distortion and if flatness exceeds its limit correct it Item Standard Limit Flatness 0 03 mm 0 0012 in 0 06 mm 0...

Page 2552: ...an Be sure to oil crankshaft journals journal bearings thrust bearings crankpins connecting rod bearings pistons pis ton rings and cylinder bores Journal bearings bearing caps connecting rods rod bear...

Page 2553: ...0 N m 0 8 kg 5 8 lb ft torque or below 5 Install new gasket and oil seal housing Do not reuse gasket removed in disassembly Apply engine oil to oil seal lip before installation Tighten housing bolts t...

Page 2554: ...Install cylinder head assembly to cylinder block as previously outlined 11 Install camshaft crankshaft timing belt pulley timing belt crankshaft pulley water pump pulley etc as previously out lined 12...

Page 2555: ...h 09926 18210 Oil seal guide Vinyl resin 09917 68220 Camshaft pulley holder 1 09916 14510 Valve lifter 2 09916 14910 Valve lifter attachment 09916 84511 Forceps 09916 44910 Valve guide remover 09916 3...

Page 2556: ...HANICAL 6A1 81 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED SUZUKI PRODUCT USE Sealant SUZUKI BOND NO 1207C 99000 31150 Mating surfaces of cylinder block and oil pan Sealant SUZUKI BOND NO 1215 99...

Page 2557: ......

Page 2558: ...llow 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 must be st...

Page 2559: ...block Cylinder head Throttle body Heater unit A T oil cooler Water inlet pipe GENERAL DESCRIPTION The cooling system consists of the radiator cap radiator coolant reservoir hoses water pump cooling f...

Page 2560: ...wer than 36 C 33 F NOTE Alcohol or methanol base coolant or plain wa ter alone should not be used in cooling system at any time as damage to cooling system could occur Even in a market where no freezi...

Page 2561: ...s Coolant leakage on cooling system Defective cooling fan motor Faulty fan motor control circuit Plugged radiator Faulty radiator cap Dragging brakes Slipping clutch Adjust or replace Check coolant le...

Page 2562: ...proper coolant to reservoir to bring coolant level up to FULL level mark Then reinstall cap and align match marks on tank and cap NOTE If proper quality antifreeze is used there is no need to add extr...

Page 2563: ...s a stop Do not press down while turning it Wait until pressure is relieved indicated by a hissing sound then press down on cap and continue to turn it counterclockwise WARNING To help avoid danger of...

Page 2564: ...0 With engine idling add coolant to radiator until level reaches the bottom of filler neck Install radiator cap making sure that the ear of cap lines is parallel to radiator WATER PUMP BELT TENSION WA...

Page 2565: ...on radiator 2 to drain coolant 3 After draining coolant be sure to tighten drain plug securely 4 Fill cooling system Refer to COOLANT in GENERAL DE SCRIPTION COOLING WATER PIPES OR HOSES REMOVAL 1 Dra...

Page 2566: ...k thermostat seal 2 for breakage deterioration or any oth er damage 4 Check thermostatic movement of wax pellet as follows 1 Immerse thermostat 1 in water and heat water gradually 2 Check that valve s...

Page 2567: ...t adjusting bolt 2 and generator pivot bolt 3 When servicing car equipped with A C remove compressor drive belt before removing water pump belt 1 3 Slacken belt by displacing generator and then remove...

Page 2568: ...ng fan motor 4 Remove front bumper see Section 9 5 Remove reservoir 6 Disconnect radiator inlet 2 and outlet hoses 1 from radiator 3 7 Remove cooling fan assembly 4 from radiator 8 Remove radiator sup...

Page 2569: ...ling system 3 Remove timing belt and tensioner refer to TIMING BELT AND TENSIONER of SECTION 6A1 4 Remove generator adjusting arm 1 5 Remove oil level gauge guide 2 with oil level gauge 6 Remove water...

Page 2570: ...BELT AND TENSIONER of SECTION 6A1 5 Install generator adjusting arm 1 6 With engine oil applied to O ring install oil level gauge guide 2 7 Adjust water pump belt tension Refer to WATER PUMP BELT TENS...

Page 2571: ......

Page 2572: ...tional activation of the system or could 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 i...

Page 2573: ...filter 12 Fuel level gauge 13 Fuel pressure regulator 14 Fuel cut valve 15 Fuel pump gasket 15 6C 2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM The main components of the fuel system are fuel tank fue...

Page 2574: ...cle with EVAP canister only 7 Fuel tank inlet valve 8 Fuel tank bolts 9 Fuel pump bolts 10 Fuel filler hose clamp 11 Fuel pump gasket Tightening Torque Do not reuse CAUTION Do not disassemble fuel pum...

Page 2575: ...l system fol lowing cautions should be always observed Disconnect negative cable at battery DO NOT smoke and place NO SMOKING signs at work area Be sure to have CO2 fire extinguisher handy Be sure to...

Page 2576: ...e steering gear box assembly Refer to Section 3B for de tails 4 Remove pipe cover 2 from vehicle 5 Disconnect fuel pipe joint and fuel hoses from the front end and the rear end of each fuel pipe For q...

Page 2577: ...en connecting joint clean outside surfaces of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely or fuel leak may occu...

Page 2578: ...in space A in the figure CAUTION Do not force pump hose into fuel tank or pump hose may damage fuel tank inlet valve 3 Hoist vehicle and remove clamp 2 and fuel filler hose 1 from fuel tank 4 Remove f...

Page 2579: ...TALLATION 1 Install fuel tank inlet valve 1 to fuel tank 2 Install fuel filler hose 1 to fuel tank and secure it with clamp 2 For proper installation refer to the figure on 6C 3 3 Lower vehicle and in...

Page 2580: ...xplosion 1 Remove fuel filler cap 2 Insert hose of a hand operated pump into fuel filler hose and drain fuel in space A in the figure CAUTION Do not force pump hose into fuel tank or pump hose may dam...

Page 2581: ...fuel filler cap REMOVAL WARNING Refer to the WARNING at the beginning of ON VEHICLE SERVICE in this section 1 Relieve fuel pressure in fuel feed line 2 Disconnect negative cable at battery 3 Drain fu...

Page 2582: ...nnect joint from pipe WARNING A small amount of fuel may be released after the fuel hose is disconnected In order to reduce the chance of personal injury cover the hose and pipe to be dis connected wi...

Page 2583: ...r tap water and shake it well and then drain Repeat this cycle until inside of tank is clean Replace tank if its inside is rusty 4 Completely flush out remaining water after washing CAUTION Never rema...

Page 2584: ...cting joint clean outside surfaces of pipe where joint is to be inserted push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely or fuel leak may occur 5 Conn...

Page 2585: ...ather hose 1 fuel vapor hose 2 and fuel feed hose 3 from fuel pump assembly When disconnecting joint of fuel feed line from pipe unlock joint by inserting special tool between pipe and joint lock firs...

Page 2586: ...a 10 N m 1 0 kg m 7 5 lb ft 3 Connect fuel breather hose 1 fuel vapor hose 2 and fuel feed hose 3 to fuel pump assembly CAUTION When connecting joint clean outside surface of pipe where joint is to be...

Page 2587: ...6C 16 ENGINE FUEL 09919 47020 Quick joint remover SPECIAL TOOL...

Page 2588: ...on 6E 37 Vacuum Passage Inspection 6E 37 Vacuum Hose Inspection 6E 37 EVAP Canister Purge Valve Inspection 6E 38 EVAP Canister Inspection 6E 38 PCV System 6E 39 PCV Hose Inspection 6E 39 PCV Valve Ins...

Page 2589: ...control system and emission control system Air intake system includes air cleaner throttle body IAC valve and intake manifold Fuel delivery system includes fuel pump delivery pipe fuel pressure regul...

Page 2590: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 3...

Page 2591: ...6E 4 ENGINE AND EMISSION CONTROL SYSTEM...

Page 2592: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 5...

Page 2593: ...ponding to the throttle valve 6 opening and engine speed is filtered by the air cleaner 1 passes through the throttle body 3 is distributed by the intake manifold 5 and finally drawn into each combust...

Page 2594: ...gh the fuel vapor line 10 into the EVAP canister 12 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 whi...

Page 2595: ...nction indicator lamp f Ignition coil assembly g Radiator fan control relay h IAC valve The electronic control system consists of 1 various sensors which detect the state of engine and driving conditi...

Page 2596: ...CTRIC CONTROL DEVICE DIAGNOSIS SWITCH VEHICLE WITHOUT EGR VALVE FUEL LEVEL SENSOR VEHICLE WITH EGR VALVE For detecting fuel level BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWIT...

Page 2597: ...6E 10 ENGINE AND EMISSION CONTROL SYSTEM...

Page 2598: ...ENGINE AND EMISSION CONTROL SYSTEM 6E 11...

Page 2599: ...n V Violet V W Violet White W White W B White Black W Bl White Blue W G White Green W R White Red R Red R B Red Black R Bl Red Blue R W Red White Y Yellow Y B Yellow Black Y Bl Yellow Blue Y G Yellow...

Page 2600: ...he 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 is not tight Valve lash is checked...

Page 2601: ...nal and Ground terminal of monitor connector 3 If duty and or idle speed is out of specifications inspect idle air control system referring to Diagnostic Flow Chart B 4 IDLE AIR CONTROL SYSTEM CHECK i...

Page 2602: ...isassembly spoils its original performance CAUTION Do not remove or adjust throttle stop screw as it is factory adjusted precisely AIR INTAKE SYSTEM THROTTLE BODY On Vehicle Inspection Check that thro...

Page 2603: ...AC valve from throttle body Cleaning Clean throttle body bore 1 and idle air passage 2 by blowing compressed air NOTE TP sensor idle air control valve or other components con taining rubber must not b...

Page 2604: ...Install throttle body 1 to intake manifold 4 Connect coupler to TP sensor 2 and IAC valve 3 securely 5 Install air cleaner outlet hose 1 and pipe 6 Connect accelerator cable and adjust cable play to s...

Page 2605: ...ed by two people one per son turns on ignition switch while the other checks valve operation As valve operation is momentary it may be overlooked To prevent this perform this operation check 3 times o...

Page 2606: ...cloth in an approved con tainer 3 Connect special tools and hose between fuel delivery pipe and fuel feed hose as shown in figure and clamp hoses securely to ensure no leaks occur during checking Spe...

Page 2607: ...of it is impossible 1 Remove filler cap and turn ON ignition switch Then fuel pump operating sound should be heard from fuel filler for about 2 se conds and stop Be sure to reinstall fuel filler cap a...

Page 2608: ...r circuit wire or coupler or injector 2 2 Disconnect coupler 1 from injector connect ohmmeter be tween terminals of injector and check resistance Resistance of injector 12 0 13 0 at 20 C 68 F If resis...

Page 2609: ...flames Use special care to prevent sparking when connecting and disconnecting test lead to and from battery 1 Install injector to special tool injector checking tool Special Tool A 09912 58421 B 09912...

Page 2610: ...931 76030 16 14 pin DLC cable When not using SUZUKI scan tool 1 Remove fuel pump relay from connector 2 Connect two terminals of relay connector using service wire 1 as shown in figure CAUTION Check t...

Page 2611: ...place with new one Apply thin coat of fuel to O rings 1 and then install injectors 3 into delivery pipe 4 and intake manifold Make sure that injectors 3 rotate smoothly 6 If not probable cause is inco...

Page 2612: ...er to DISABLING THE AIR BAG SYSTEM in Section 9J 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 Installation 1 Re...

Page 2613: ...e difference be tween when throttle valve is at idle position and when it is fully open If check result is not satisfactory replace TP sensor 3 Connect TP sensor coupler securely 4 Connect negative ca...

Page 2614: ...t hose 3 Inspection Immerse temperature sensing part of IAT sensor in water or ice and measure resistance between sensor terminals while heating water gradually If measured resistance doesn t show suc...

Page 2615: ...nsor 4 Remove ECT sensor 1 from thermostat case Inspection Immerse temperature sensing part of ECT sensor 1 in water or ice and measure resistance between terminal A and B while heating water graduall...

Page 2616: ...when system is hot Oxygen sensor removal should be performed when system is cool 1 Disconnect negative cable at battery 2 For sensor 1 remove exhaust manifold cover 1 and discon nect coupler of heate...

Page 2617: ...isconnect connector from camshaft position sensor 3 Remove camshaft position sensor from sensor case distributorless ignition case Installation 1 Check that O ring is free from damage 2 Check that cam...

Page 2618: ...sensor from oil pan Installation 1 Check to make sure that crankshaft position sensor and pulley tooth is free from any metal particles and damage 2 Install crankshaft position sensor to oil pan 3 Con...

Page 2619: ...and d If there is no continuity when relay is connected to the battery replace relay FUEL CUT OPERATION Inspection NOTE Before inspection check to make sure that gear shift lever is in neutral positi...

Page 2620: ...rcuit Radiator Fan Inspection 1 Check continuity between each two terminals If there is no continuity replace radiator fan motor 2 Connect battery 1 to radiator fan motor coupler 2 as shown in figure...

Page 2621: ...TEM Engine Coolant Temp Signal Inspection Check engine coolant temp signal referring to step 1 of DTC P1705 DTC NO 51 Flow Chart in Section 7B If check result is not satisfactory check each wire harne...

Page 2622: ...KPH Engine coolant temp 80 C Engine speed 3000 rpm 4 Clear DTC by using CLEAR INFO mode 5 With engine idling without depressing accelerator pedal open EGR valve by using STEP EGR mode in MISC TEST me...

Page 2623: ...4 If found faulty replace EGR valve assy 2 Remove carbon from EGR valve gas passage NOTE Do not use any sharp edged tool to remove carbon Be careful not to damage or bend EGR valve valve seat and rod...

Page 2624: ...e EVAP canister purge system does not perform purging vacuum is not detected at the purge hose unless the en gine is sufficiently warmed up and the heated oxygen sen sor is activated fully Also when t...

Page 2625: ...EVAP Canister Inspection WARNING DO NOT SUCK nozzles on EVAP canister Fuel vapor inside EVAP canister is harmful 1 Check outside of EVAP canister visually 2 Disconnect vacuum hoses from EVAP canister...

Page 2626: ...lace as necessary PCV Valve Inspection 1 Disconnect PCV valve 1 from cylinder head cover and install plug to head cover hole 2 Run engine at idle 3 Place your finger over end of PCV valve 1 to check f...

Page 2627: ...nt 1 4 4 Holder 4 5 Return hose clamp 4 6 Body attachment 2 washer 4 7 Hose attachment 1 4 8 Hose attachment 2 5 Checking tool plate 09912 57610 1 Storage case 2 Operator s manual 3 Tech 1A 4 DLC cabl...

Page 2628: ...nder Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Pr...

Page 2629: ...w to the primary coil accord ing to the signal from ECM When the current flow to the primary coil is turned OFF a high voltage is induced in the secondary coil High tension cords and spark plugs CMP s...

Page 2630: ...e Correction Engine cranks but will not start or hard to start No spark Blown fuse for ignition coil Loose connection or disconnection of lead wire or high tension cord s Faulty high tension cord s Fa...

Page 2631: ...ground circuits for open and short Are circuits in good condition Go to Step 7 Repair or replace 7 Ignition Coil Assembly Check 1 Check ignition coil for resistance referring to Ignition Coil Assembly...

Page 2632: ...park plug 4 Crank engine and check if each spark plug sparks 5 If no spark is emitted inspect the related parts as described un der Diagnosis earlier in this section HIGH TENSION CORDS 1 Disconnect hi...

Page 2633: ...y abnormality 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...

Page 2634: ...inspection and installation IGNITION TIMING NOTE Ignition timing is not adjustable If ignition timing is out of specification check system related parts Before starting engine place transmission gear...

Page 2635: ...BTDC at idle speed Ignition order 1 3 4 2 8 If ignition timing is out of specification check the followings CKP sensor Crankshaft timing belt pulley signal rotor TP sensor Test switch signal circuit V...

Page 2636: ...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 Mass storage cartridge 09931 76030 16 14 pin DLC cable IGNI...

Page 2637: ......

Page 2638: ...ts CONTENTS GENERAL DESCRIPTION 6G 2 Cranking Circuit 6G 2 Starting Motor Circuit 6G 2 Starting Motor 6G 2 DIAGNOSIS 6G 3 UNIT REPAIR OVERHAUL 6G 5 Dismounting and Remounting 6G 5 Disassembly 6G 6 Ins...

Page 2639: ...ANKING CIRCUIT The cranking circuit consists of the battery starting motor ignition switch and related electrical wiring These com ponents are connected electrically Only the starting motor will be co...

Page 2640: ...ever switch is not in P or N or not adjusted A T Battery run down Battery voltage too low due to battery deterioration Poor contact in battery terminal connection Loose grounding cable connection Fuse...

Page 2641: ...lace bush Starting motor running but not cranking engine Worn pinion tip Poor sliding of over running clutch Over running clutch slipping Worn teeth of ring gear Replace over running clutch Repair Rep...

Page 2642: ...10 to spline 15 Packing 16 Ball Apply lithium grease 99000 25010 17 York 18 Armature Apply grease 99000 25010 to spline 19 Brush holder 20 Brush spring 21 Brush 22 Rear bracket bush Apply lithium grea...

Page 2643: ...put match marks at two locations A B as shown so that any possible mistake can be avoided Do not clamp yoke in a vise or strike it with a hammer during repair operations 1 Remove nut 1 securing the en...

Page 2644: ...gears 2 5 Remove seal rubber 1 and plate 2 6 Remove shaft assembly 1 with lever 2 7 Loosen pinion stop ring 1 fixed by snap ring 2 8 Remove snap ring 1 and then pull out pinion stop ring 2 over runnin...

Page 2645: ...acket 1 with brush holder 10 Remove armature 1 from yoke 2 11 Remove brush holder 1 from rear bracket 2 12 Remove brush springs 1 and brushes 2 13 Remove armature shaft bushes 1 using special tools Sp...

Page 2646: ...sary Pull In Coil Open Circuit Test Check for continuity across magnetic switch S terminal 1 and M terminal 2 If no continuity exists coil is open and should be replaced Hold In Coil Open Circuit Test...

Page 2647: ...ndi tions Replace if necessary BRUSH HOLDER Check movement of brush in brush holder If brush movement within brush holder is sluggish check brush holder for distortion and sliding faces for contaminat...

Page 2648: ...or out of round Standard 0 05 mm 0 002 in or less Limit 0 4 mm 0 015 in Inspect commutator 1 for wear If diameter is below limit replace armature Commutator outside diameter Standard 29 4 mm 1 16 in L...

Page 2649: ...ear and planetary gears for wear damage or other abnormal conditions Replace if necessary PINION AND OVER RUNNING CLUTCH Inspect pinion for wear damage or other abnormal conditions Check that clutch l...

Page 2650: ...holder 3 4 Install brush holder to armature while pushing 4 brushes out ward 5 Install new rear armature shaft bush 6 Install rear bracket 1 to brush holder 2 7 Tighten brush holder screws 3 8 Instal...

Page 2651: ...ly grease to ball 1 and install ball into shaft hole Grease 99000 25010 15 Install yoke armature brush holder and rear bracket to front housing by aligning match marks provided before removal 16 Tight...

Page 2652: ...magnetic switch as shown Check the plunger and pinion over running clutch move out ward If plunger and pinion over running clutch don t move replace magnetic switch 2 Hold In Test While connected as...

Page 2653: ...witch to motor 1 to terminal M 2 b Connect battery and ammeter to starter as shown c Check that starter rotates smoothly and steadily with pinion moving out Check that ammeter indicates specified curr...

Page 2654: ...d characteristic 11 0 V 90 A maximum 2 500 rpm minimum Around at 20 C Load characteristic 7 5 V 300 A 10 5 N m 1 05 kg m 7 59 lb ft minimum 880 rpm minimum 68 F Locked characteristic 4 0 V 760 A maxim...

Page 2655: ......

Page 2656: ...TENTS GENERAL DESCRIPTION 6G1 2 Cranking Circuit 6G1 2 Starting Motor Circuit 6G1 2 Starting Motor 6G1 2 DIAGNOSIS 6G1 3 UNIT REPAIR OVERHAUL 6G1 5 Dismounting and Remounting 6G1 5 Disassembly 6G1 6 I...

Page 2657: ...ranking circuit consists of the battery starting motor ignition switch and related electrical wiring These com ponents are connected electrically as shown below Only the starting motor will be covered...

Page 2658: ...in battery terminal connection Loose grounding cable connection Fuse set loose or blown off Poor contacting action of ignition switch and magnetic switch Lead wire coupler loose in place Open circuit...

Page 2659: ...g engine Worn pinion tip Poor sliding of over running clutch Over running clutch slipping Worn teeth of ring gear Replace over running clutch Repair Replace over running clutch Replace flywheel M T or...

Page 2660: ...ams of armature shaft bush and over running clutch 11 Starting motor yoke 12 Brush 13 Brush holder 14 Armature shaft washer Thickness 1 8 mm 0 07 in 15 Armature shaft washer Thickness 0 5 mm 0 02 in 1...

Page 2661: ...rike it with a hammer during disassembling and reassembling 1 Remove nut securing the end of field coil lead to terminal on the head of magnetic switch 2 Take off magnetic switch 1 by removing 2 mount...

Page 2662: ...t with sandpaper or lathe if necessary Check commutator for uneven wear with armature 1 supported on V blocks 2 If deflection of dial gauge pointer exceeds limit repair or replace NOTE Below specifica...

Page 2663: ...ity ar mature is grounded and must be replaced Open circuit test Check for continuity between segments If there is no continuity at any point there is an open circuit and armature must be re placed FI...

Page 2664: ...ive side If continuity exists brush holder is grounded due to defective in sulation and should be replaced SPRING Inspect brush spring for wear damage or other abnormal condi tions Replace if necessar...

Page 2665: ...in plunger and release it Plunger should return quickly to its original position Replace if necessary Pull in coil open circuit test Check for continuity across magnetic switch S terminal and M termin...

Page 2666: ...to specified torque Tightening Torque 11 N m 1 1 kg m 8 0 lb ft PERFORMANCE TEST WARNING When performing the following test be sure to connect the battery and the starting motor with a lead wire of th...

Page 2667: ...disassemble and inspect start ing motor 4 No Load Performance Test a Connect motor lead wire switch to motor 1 to terminal M 2 b Connect battery and ammeter to starter as shown c Check that starter ro...

Page 2668: ...Condition Guarantee No load characteristic 11 5V 53 A maximum 6000 rpm minimum Around at 20 C Load characteristic 9 V 150 A 2 8 N m 0 28 kg m 2 0 lb ft minimum 2000 rpm minimum 68 F Locked characteri...

Page 2669: ......

Page 2670: ...H 3 DIAGNOSIS 6H 4 UNIT REPAIR OVERHAUL 6H 6 Jump Starting in Case of Emergency 6H 6 Removal 6H 7 Handling 6H 7 Installation 6H 7 GENERATOR 6H 8 GENERAL DESCRIPTION 6H 8 DIAGNOSIS 6H 9 UNIT REPAIR OVE...

Page 2671: ...battery from shaking in its carrier the hold down bolts should be tight enough but not over tightened ELECTROLYTE FREEZING The freezing point of electrolyte depends on its specific gravity Since free...

Page 2672: ...harge the battery twice a month to prevent it from dis charging excessively This is especially important when ambi ent temperature is low The battery discharges even when it is not used while ve hicle...

Page 2673: ...damage such as cracked or broken case or cov er that could permit loss of electrolyte If obvious damage is noted replace battery Determine cause of damage and correct as need ed HYDROMETER TEST The d...

Page 2674: ...the 1 28 specific gravity line The intersection is within the A zone shaded area in the graph and that means CHARGED STATE To know how much the battery is charged draw a line parallel to the zone dema...

Page 2675: ...tive battery terminal or metal in contact with it and any other metal on vehicle because a short circuit could occur 1 Set parking brake and place automatic transmission in PARK NEUTRAL on manual tran...

Page 2676: ...ns should be followed Hydrogen gas is produced by battery A flame or spark near bat tery may cause the gas to ignite Battery fluid is highly acidic Avoid spilling on clothing or other fab ric Any spil...

Page 2677: ...terminal E Ground IG Ignition terminal L Lamp terminal 1 Pulley 2 Pulley nut 3 Rotor fan 4 Stator coil 5 Stator core 6 Field coil 7 Regulator 8 Brush 9 Front housing 10 Rear housing 11 Rectifier 6H 8...

Page 2678: ...y slow cranking or indi cator dark 3 An overcharged battery as evidenced by excessive spewing of electrolyte from vents Noise from generator may be caused by a loose drive pulley loose mounting bolts...

Page 2679: ...battery defect is suspected referring to BATTERY section 4 Inspect wiring for defects Check all connections for tightness and cleanliness battery cable connections at battery starting motor and ignit...

Page 2680: ...ECK 1 Run engine at 2 000 rpm and turn on head light and heater mo tor 2 Measure current and if it is less than 20 A repair or replace gen erator OVERCHARGED BATTERY 1 To determine battery condition r...

Page 2681: ...h air cleaner outlet No 1 hose 3 and suction pipe 4 4 Remove generator cover 5 Disconnect B terminal wire 1 and coupler 2 from generator 3 6 Remove upper generator bolt 4 7 Hoist vehicle 8 Remove left...

Page 2682: ...emoval procedure and giving specified tension to water pump and generator drive belt referring to SECTION 6B Tightening Torque a 22 N m 2 2 kg m 16 0 lb ft b 50 N m 5 0 kg m 36 5 lb ft c 7 8 N m 0 78...

Page 2683: ...nstalling direction and the detail refer to page 6H 19 13 Rectifier 14 IC regulator assembly 15 Rear housing 16 B terminal 17 B terminal nut 6H 14 CHARGING SYSTEM DISASSEMBLY 1 For easier reinstallati...

Page 2684: ...pulley nut 1 using vise 2 and take off pulley 3 NOTE When using vise put clean cloth 4 between rotor 5 and vise so as not to cause damage to rotor Be sure to hold the location A Do not hold the locati...

Page 2685: ...emove three screws 1 and generator B terminal nut 2 9 Remove stator with IC regulator assembly from rear housing 10 Unsolder stator leads 1 and remove stator 2 from IC regula tor assembly 11 To remove...

Page 2686: ...lip rings for roughness or scoring If rough or scored replace rotor Stator 1 Using ohmmeter 1 check all stator coil leads 2 for continuity If there is no continuity replace stator 2 Using ohmmeter 1 c...

Page 2687: ...heck continuity between each of upper and lower rectifier bodies and each diode lead 2 Check both directions by reversing probes of ohmmeter and there should be only one way continuity in each case If...

Page 2688: ...4 and vise so as not to cause damage to rotor Be sure to hold the location A Do not hold the location B as it does not have enough structural strength Push brushes into brush holder then support brush...

Page 2689: ...28 Ah 5 h 36 Ah 5 h Cold cranking amperes 332 A 390 A Electrolyte 3 8 L 8 03 6 69 US lmp pt Electrolyte specified gravity 1 28 when fully charged at 25 C 77 F Battery dimension GENERATOR Rated voltage...

Page 2690: ...ipe seal ring 5 Exhaust pipe bolt 6 Oxygen sensor No 2 7 Muffler mounting 8 Exhaust No 1 pipe bracket 9 Exhaust pipe gasket Tightening Torque Do not reuse EXHAUST SYSTEM 6K 1 SECTION 6K EXHAUST SYSTEM...

Page 2691: ...er mountings 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 Check nearby...

Page 2692: ...RNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air...

Page 2693: ...ter shaft and engaged with counter shaft first gear or second gear while the high speed synchronizer is done on input shaft and engaged with input shaft third gear or fourth gear The fifth speed synch...

Page 2694: ...shift lever 10 5th reverse gear shift guide shaft 11 5th reverse gear shift shaft 12 Gear shift select shaft Shift direction Select direction MANUAL TRANSMISSION 7A 3 GEAR SHIFT MECHANISM The gear shi...

Page 2695: ...e and gear Hard shifting Maladjusted gear shift select control cables Inadequate lubricant Improper clutch pedal free travel Distorted or broken clutch disc Damaged clutch pressure plate Worn synchron...

Page 2696: ...leakage If leakage exists correct it 3 Drain old oil and fill new specified oil by specified amount up to level hole 4 Apply sealant to thread of drain plug 2 and level filler plug 3 and torque them a...

Page 2697: ...d detach drive shaft at differen tial side 7 Remove oil seal 1 and install a new one until it becomes flush with case surface by using special tool and hammer NOTE When installing oil seal face its sp...

Page 2698: ...rring to Section 4 11 Connect tie rod end with knuckle and fasten new nut to speci fied torque referring to Section 4 12 Install stabilizer mount brackets fasten bolts to specified torque referring to...

Page 2699: ...shift lever boot 4 Gear shift control cable 5 Gear select control cable 6 Gear shift control cable guide nut 7 Gear shift control lever assembly 8 Cable nut 9 Cable mounting bolt Tightening Torque 7A...

Page 2700: ...e grommet and cable clamp and then remove shift and select cables from body INSTALLATION Reverse removal procedure for installation and note as follows Tighten gear shift control lever assembly mounti...

Page 2701: ...are aligned as shown NOTE After select cable adjustment tighten lock nut 4 to speci fied torque Tightening Torque a 5 5 N m 0 55 kg m 4 0 lb ft VEHICLE SPEED SENSOR VSS REMOVAL 1 Disconnect negative c...

Page 2702: ...ransmission to engine bolts 12 Engine left mounting bracket bolts 13 Starting motor 14 Starting motor plate 15 Starting motor bolts 16 Engine rear mounting bracket stiffener 17 Stiffener bolts 18 Clut...

Page 2703: ...1110 to mating surface of side cover and left case 6 Back up light switch 7 O ring Tightening Torque Do not reuse 8 Differential assembly 9 Oil level filler plug Apply sealant 99000 31110 to all aroun...

Page 2704: ...type 6 High speed synchronizer ring 7 High speed synchronizer spring 8 High speed sleeve hub 9 High speed synchronizer key 10 Circlip 11 Input shaft 4th gear 12 Input shaft left bearing 13 Input shaft...

Page 2705: ...erential side gear 17 Side gear washer 18 Differential side oil seal 19 Differential side bearing 20 Speed sensor ring 21 Differential case 22 Final gear 23 5th to reverse interlock guide bolt Apply s...

Page 2706: ...n 7 Support engine by using lifting device ON LIFT 8 Drain transmission oil referring to OIL CHANGE of ON VE HICLE SERVICE in this section 9 Remove left and right drive shaft referring to Section 4 10...

Page 2707: ...1 to the original position of transmission before mount ing transmission assembly to engine assembly Refer to the first figure of UNIT REPAIR OVERHAUL for fastener specified torque Push in drive shaft...

Page 2708: ...emove circlip 4 by using circlip plier 6 Remove gear shift fork 2 sleeve hub assembly 3 synchro nizer ring spring synchronizer ring and 5th gear all together Use gear puller 1 for removal if spline fi...

Page 2709: ...and steel balls 4 Remove back up light switch 2 5 Remove reverse shaft bolt 1 with washer 6 Remove case bolts 2 from outside and another bolts from clutch housing side 7 Tapping left case 3 flanges w...

Page 2710: ...m left case 13 Remove differential side left oil seal also from left case RIGHT CASE 1 Remove differential gear assembly 1 from right case 2 2 Remove bolt and then pull out VSS 3 3 If input shaft righ...

Page 2711: ...cup 2 by using special tools and hammer Special Tool B 09924 74510 C 09925 68210 LEFT CASE 1 If input oil gutter has been removed install it with bolt applied with thread lock cement A Thread lock 13...

Page 2712: ...ar tooth from being damaged support it at flat side of bearing puller 3 Take out 4th gear needle bearing and high speed synchronizer ring 4 Using circlip pliers remove circlip 1 5 Drive out high speed...

Page 2713: ...rance a Standard 1 0 1 4 mm 0 039 0 055 in Clearance a Service limit 0 5 mm 0 019 in 3 To ensure lubrication air blow oil holes 1 and make sure that they are free from any obstruction 4 Fit high speed...

Page 2714: ...assembly Check free rotation of 3rd gear after press fitting sleeve hub assembly Synchronizer rings for 3rd and 4th are identical Special Tool B 09913 84510 8 Install circlip 1 and confirm that circl...

Page 2715: ...m counter shaft CAUTION If compression exceeds 5 ton 11 000 lb release com pression once reset puller support and then continue press work again To avoid gear tooth from being damaged support it at fl...

Page 2716: ...the cone 2 together and then measure the step difference between the outer ring and the inner ring And also check each chamfered tooth of gear and synchronizer ring and replace with new one if necessa...

Page 2717: ...ring 8 Drive in low speed sleeve hub assembly 1 by using special tools and hammer facing B side of sleeve to 1st gear NOTE Support shaft with special tool as shown in figure so that retainer of bearin...

Page 2718: ...Press fit 3rd gear 2 and spacer 1 by using special tools and press CAUTION Press fit 3rd gear and spacer first and then 4th gear lat er separately so that counter shaft will not be com pressed excess...

Page 2719: ...them and replace with new ones as required 3 Assemble component parts by reversing removal procedure NOTE When driving in spring pins prevent shaft from being bent by supporting it with wood block Ass...

Page 2720: ...sure that component parts are in proper order as shown in figure NOTE Distinguish reverse gear shift arm spring Blue 2 from low speed locating spring Yellow Install 2 steel balls 3 in reverse gear sh...

Page 2721: ...Using 2 screwdrivers 1 move gear 2 up and down and read movement of dial gauge pointer Right side Using similar procedure to the above set dial gauge tip to gear 1 shoulder Move gear up and down by h...

Page 2722: ...ear ing 2 is floating and then press fit right bearing 3 like left bearing in Step 5 Special Tool C 09951 76010 D 09951 16060 7 Hold differential assembly with soft jawed vise 3 install final gear 2 a...

Page 2723: ...4 has to be joined with reverse gear shift lever 3 at the same time 5 Place reverse gear shift lever fasten it with bolts after applying thread lock cement A Thread lock cement 99000 32110 Tightening...

Page 2724: ...washer and tighten it A Thread lock 1322 99000 32110 Tightening Torque c 23 N m 2 3 kg m 17 0 lb ft 10 Install another case bolts from clutch housing side and tighten them to specification 11 Check lo...

Page 2725: ...adjusts clearance a to specification and put it on bearing cup NOTE Insert 0 1 mm 0 004 in feeler to know whether or not a shim fulfills specification quickly Available shim thickness 0 40 0 45 0 50...

Page 2726: ...ter shaft facing machined boss A in ward 7 Install needle bearing of separated steel cage type to input shaft apply oil then install 5th gear 1 and special tool to stop shaft rotation Special Tool B 0...

Page 2727: ...4 to the end of 5th reverse gear shift guide shaft CAUTION Coat shift fork plug with thread lock cement reason ably If it is done to much excess may interfere in ball movement and cause hard shift to...

Page 2728: ...ightening Torque a 23 N m 2 3 kg m 17 0 lb ft 4 Install washer and gear shift interlock bolt 2 applied with seal ant and them tighten it to specified torque B Sealant Bond No 1215 99000 31110 Tighteni...

Page 2729: ...MATERIALS RECOMMENDED SUZUKI PRODUCTS USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Oil seal lips Sealant SUZUKI BOND NO 1215 99000 31110 Oil drain plug and filler level plug Gear shift shaft...

Page 2730: ...g shaft 09940 53111 Bearing installer 09940 54910 Sensor rotor installer 09951 16060 Bush remover 09951 76010 Bearing installer 09925 98221 Bearing installer 09925 18010 Bearing installer 09925 88210...

Page 2731: ......

Page 2732: ...47 Inspection of TCM and Its Circuits 7B 48 ON VEHICLE SERVICE 7B 50 MAINTENANCE SERVICE 7B 50 Fluid Level 7B 50 Fluid Change Intervals 7B 51 Changing Fluid 7B 51 SELECTOR LEVER 7B 52 SHIFT SWITCH 7B...

Page 2733: ...DISMOUNTING 7B 66 REMOUNTING 7B 67 DISASSEMBLY 7B 68 DISASSEMBLY OF SUBASSEMBLY 7B 78 Oil Pump 7B 79 Front Clutch 7B 81 Rear Clutch 7B 86 Direct Clutch 7B 91 Planetary Set 7B 96 Valve Body 7B 98 Diff...

Page 2734: ...lutch ass y 19 Transmission housing 20 Torque converter AUTOMATIC TRANSMISSION 4 A T 7B 3 GENERAL DESCRIPTION This automatic transmission is a full automatic type with 3 speed plus overdrive O D The t...

Page 2735: ...rse brake B2 18 Rear clutch C1 19 Differential drive pinion shaft 1 Final gear 2 Differential gear ass y 3 Parking gear 4 Counter driven gear 5 1st and 2nd brake B1 6 Overdrive brake B0 7 Direct clutc...

Page 2736: ...4th automatic gear change Forward 1st 2nd 3rd automatic gear change Forward 1st 2nd reduction and fixed at 1st gear change device 1st 2 962 device 2nd 1 515 Number of teeth Front sun gear 34 R 21 Gea...

Page 2737: ...s input shaft and rear sun gear TABLE OF COMPONENT OPERATION Part Rear Front Overdrive 1st 2nd Reverse Direct One way Selector position Gear position Rear clutch Front clutch Overdrive brake 1st 2nd b...

Page 2738: ...15 Ignition switch 16 Battery 17 A T Relay A Input revolution signal B A T fluid temp signal C Shift lock up control signal D A T VSS signal E Shift position signal F O D off switch signal F O D off l...

Page 2739: ...oid No 1 14 Shift solenoid No 2 15 Shift solenoid No 3 16 Shift solenoid No 4 17 Shift solenoid No 5 18 Dropping resister 19 O D Over Drive off switch 20 O D OFF lamp 21 To IG 1 22 Monitor coupler 23...

Page 2740: ...contact sensor consisting of a perma nent magnet coil and gears As the gear of the counter driven gear rotor turns the magne flux from the permanent magnet varies and a voltage of the frequency corres...

Page 2741: ...h OFF 1 O D cut switch 2 Shift lever 7B 10 AUTOMATIC TRANSMISSION 4 A T O D CUT SWITCH The gear shift up or shift down to and from the O D gear can be se lected with this switch O D cut switch O D OFF...

Page 2742: ...found vehicle at stop the gear is selected as follows P P R R N N D 3rd 2 2nd L 1st Shift switch and its circuit 1 No shift switch signal input 2 Two or more shift switch signals input 1 The gear is f...

Page 2743: ...g 7B 12 AUTOMATIC TRANSMISSION 4 A T AUTOMATIC GEAR SHIFT DIAGRAM Automatic shift schedule as a result of shift control is shown below Unit km h Shift 1 2 2 3 3 4 4 3 3 2 2 1 Throttle opening Full thr...

Page 2744: ...TRANSMISSION 4 A T 7B 13 TCC Lock up Diagram 3rd gear and O D is cut 4th gear 4th gear 3rd gear and O D on 3rd gear and O D on 3rd gear and O D is cut Vehicle Speed Throttle Valve Opening Lock up ON L...

Page 2745: ...e DTC 12 Trouble still present Trouble fixed 7B 14 AUTOMATIC TRANSMISSION 4 A T DIAGNOSIS This vehicle is equipped with an electronic transmission control system which controls the automatic shift up...

Page 2746: ...ear change shock Other VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental Condition Weather Temperature Frequency Road fair cloudy rain snow not related other hot warm cool cold C not r...

Page 2747: ...tomatic transmission INSPECTION ITEM REFERRING SECTION Engine oil level leakage Engine coolant level leakage A T fluid level leakage color Battery fluid level corrosion of terminal A T fluid hoses dis...

Page 2748: ...ss and Coupler Check Check the connection of the harness coupler Check for the loose connection of the harness loose connec tion of the terminals 5 1 DIAGNOSTIC TROUBLE CODE CHECK Check diagnostic tro...

Page 2749: ...eplace TCM 4th 3rd 3rd 2nd 2nd 1st Shift solenoid No 1 4th 3rd No 2 2nd 1st No 3 3rd 2nd No 4 4th 3rd No 5 3rd 2nd or its circuit faulty Throttle position sensor or its circuit faulty TCM faulty Repai...

Page 2750: ...faulty Clean or replace 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 Repair or replac...

Page 2751: ...lever shifted to P 4 Depress brake pedal fully 5 Shift select lever to D and depress accelerator pedal fully while watching tachometer Read engine rpm quickly when it has be come constant stall speed...

Page 2752: ...s shifted back to N range Engine should be warmed up fully for this test Test result Possible cause When N D time lag exceeds specification Low line pressure Worn rear clutch Worn 1st 2nd brake When N...

Page 2753: ...leakage from D range pressure circuit Fluid leakage from 1st 2nd brake Fluid leakage from rear clutch Line pressure lower than standard level only in R range Fluid leakage from R range pressure circui...

Page 2754: ...ake pedal gradually and check that vehicle re mains 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...

Page 2755: ...cle with EGR valve MIL 1 comes on when TCM de tects the malfunction of transmission system But MIL does not come on in case of DTC P0710 DTC 36 and 38 The DTC stored in the TCM memory is output by fla...

Page 2756: ...C 09931 96030 16 14 pin DLC cable 3 Turn ignition switch ON 4 Read DTC according to instructions displayed on scan tool and print it or write it down Refer to SUZUKI scan tool operator s manual for f...

Page 2757: ...0 O D OFF lamp 2 1 3 2 Diag switch terminal 3 Ground terminal O D OFF 7B 26 AUTOMATIC TRANSMISSION 4 A T 4 Read DTC from flashing pattern of O D OFF light 5 After completing the DTC check turn igniti...

Page 2758: ...16 14 pin DLC cable 3 Turn ignition switch ON 4 Erase DTC according to instructions displayed on scan tool Re fer to SUZUKI scan tool operator s manual for further details 5 After completing the check...

Page 2759: ...hift solenoid No 1 circuit P0758 23 Shift solenoid No 2 circuit P0758 24 Shift solenoid No 2 circuit P0743 25 Lock up solenoid No 2 circuit P0743 26 Lock up solenoid No 2 circuit P0741 29 Torque conve...

Page 2760: ...N DOESN T SHIFT TO 1ST GEAR AT VEHICLE START IN D RANGE STEP ACTION YES NO 1 Check voltage between terminal A12 of TCM coupler and body ground with ignition switch ON Is it 10 14 V Go to Step 2 P Bl w...

Page 2761: ...then disconnect TCM couplers 2 Measure resistance between terminal B10 and B2 of disconnected harness side coupler Is it 160 200 Go to Step 3 Open Lg or Lg B wire or shorted to each other 3 1 Turn ign...

Page 2762: ...18 INPUT REV SENSOR A T VSS OR A T ITSELF INPUT VEHICLE SPEED TOO HIGH OR TOO LOW COMPARING TO INPUT REV SENSOR SIGNAL STEP ACTION YES NO 1 Check if DTC 14 or 31 is displayed Is DTC 14 or 31 displayed...

Page 2763: ...1 Connect shift solenoid coupler then disconnect TCM couplers 2 Measure the resistance between each solenoid terminal of the disconnected harness side TCM coupler and body ground See chart and figure...

Page 2764: ...2 Shift solenoid No 2 terminal 3 Lock up solenoid terminal 4 Solenoid coupler 5 Shift switch 1 A4 terminal 2 A17 terminal 3 A18 terminal 4 TCM coupler AUTOMATIC TRANSMISSION 4 A T 7B 33 Figure for st...

Page 2765: ...the resistance between each solenoid terminal of solenoid coupler and transmission ground See chart and figure below Is it about 12 Go to Step 2 Short in between solenoid lead wire and ground Malfunc...

Page 2766: ...AUTOMATIC TRANSMISSION 4 A T 7B 35 DTC 29 LOCK UP CLUTCH Substitute known good torque converter and recheck Check if fluid has an odor and is discolored and replace as necessary...

Page 2767: ...low Is it 160 200 Go to Step 2 Replace A T VSS 2 1 Connect A T VSS coupler then disconnect TCM couplers 2 Measure resistance between terminal B11 and B3 of disconnected harness side coupler See figure...

Page 2768: ...n terminal B3 of disconnected harness side coupler body ground Is it about 0 Short in between W wire and ground or B wire and ground Go to Step 5 5 Measure resistance between terminal B11 B12 of disco...

Page 2769: ...ction 6E Does the DTC show normal code Go to Step 3 Inspect and repair referring to DTC flow table of electronic fuel injection system in Section 6E 3 1 Turn ignition switch OFF and disconnect TCM and...

Page 2770: ...heck DTC of electronic fuel injection system referring to Section 6E Does the DTC show normal code Go to Step 3 Inspect and repair referring to DTC table of electronic fuel injection system in Section...

Page 2771: ...between terminal B7 and A25 of disconnected harness side TCM coupler Is it 10 14 V at R range and 0 V at other range Go to Step 3 Go to Step 7 3 While ignition switch ON check voltage between termina...

Page 2772: ...CM coupler Is it 10 14 V at L range and 0 V at other range Intermittent trouble or faulty TCM Check for intermittent trouble referring to Intermittent troubles in Section 0B Go to Step 7 7 Check shift...

Page 2773: ...ction 6E 2 1 Turn ignition switch OFF and disconnect ECM and TCM couplers 2 Check continuity between E9 and B4 Is there continuity Go to Step 3 Br Y wire open 3 1 Turn ignition switch OFF and disconne...

Page 2774: ...TCM If all the above are in good condition substitute a known good TCM and restart the troubleshooting 2 1 Turn ignition switch OFF and connect solenoid wire harness coupler 2 Turn ignition switch ON...

Page 2775: ...sister A1 A2 or A3 See chart below Is it about 8 Go to Step 3 Inspect dropping resister referring to ON VEHICLE SERVICE in this section If OK circuit between TCM and dropping resister or dropping resi...

Page 2776: ...7 Dropping resister terminal for shift solenoid No 4 8 Dropping resister terminal for shift solenoid No 5 9 Dropping resister coupler Chart for step 2 Solenoid TCM terminal No Solenoid coupler lead w...

Page 2777: ...ignition switch OFF and disconnect ECM and TCM couplers 2 Check continuity between terminals A22 and C5 of harness Is the continuity Go to Step 3 Gr wire open 3 Check resistance between terminal A22...

Page 2778: ...TO TURN OFF OR RELAY OUTPUT VOLTAGE TOO LOW EVEN THOUGH TCM ORDERS THE RELAY TO TURN ON STEP ACTION YES NO 1 1 Turn ignition switch ON 2 Erase all DTCs referring to HOW TO CLEAR DTC in this section 3...

Page 2779: ...sistance CAUTION TCM cannot be checked by itself it is strictly prohibited to connect voltmeter or ohmmeter to TCM with coupler dis connected from it Voltage Check 1 Remove TCM from vehicle referring...

Page 2780: ...ure signal A21 Not used A22 ECT and MAP sensor signal IG ON A23 O D cut switch 10 14 V IG switch ON O D cut switch OFF O D OFF not illuminated A23 O D cut switch approx 0 V IG switch ON O D cut switch...

Page 2781: ...ngine idling pull out dipstick wipe it off with 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 LO...

Page 2782: ...h as taxi police vehicle or delivery service CHANGING FLUID 1 Lift up vehicle 2 When engine has cooled down remove drain plug 1 from oil pan and drain A T fluid 3 Install drain plug Tightening Torque...

Page 2783: ...r lever knob ass y 3 Screw 4 Selector indicator ass y 5 Screw 6 Illumination lamp ass y SELECTOR LEVER INSPECTION Check selector lever for smooth and clear cut movement and posi tion indicator for cor...

Page 2784: ...ch from transmission case CAUTION Do not overhaul shift switch INSPECTION 1 Disconnect shift switch coupler 2 2 Check that continuity exists at terminals shown below by moving selector lever B A H C E...

Page 2785: ...m 13 0 lb ft 4 Move selector lever in cabin to each range and check the conti nuity of each terminal of shift switch referring to INSPECTION 5 Connect shift switch coupler 6 Check that the engine can...

Page 2786: ...ip SELECTOR CABLE REMOVAL 1 Remove parking brake lever cover 2 Remove console box 3 Disconnect selector cable from selector lever and then detach from bracket 4 Remove clip and disconnect selector cab...

Page 2787: ...elector lever to N position 6 Apply grease to selector pin and install adjuster cable end to it Grease 99000 25010 7 With both selector lever and shift switch kept each N position drive cable end hold...

Page 2788: ...T VSS input rev sensor by removing its bolt INSTALLATION 1 Apply A T fluid to A T VSS O ring 2 Install A T VSS to A T case and tighten bolt to specified torque Tightening Torque a 8 N m 0 8 kg m 6 0...

Page 2789: ...VSS input rev sensor coupler 4 Connect negative cable to battery VEHICLE SPEED SENSOR VSS SPEEDOMETER DRIVEN GEAR Refer to SECTION 6E for removal installation and inspection THROTTLE POSITION SENSOR I...

Page 2790: ...3 Resister terminal for shift solenoid No 5 Circuit DROPPING RESISTER REMOVAL INSTALLATION Refer to left figure for removal installation Tightening Torque a 20 N m 2 0 kg m 14 5 lb ft INSPECTION Meas...

Page 2791: ...D cut switch terminals O D cut switch ON OFF Continuity Continuity No continuity SHIFT SOLENOID VALVES AND A T FLUID TEMP SENSOR REMOVAL 1 Disconnect negative cable at battery 2 Drain A T fluid 3 Rem...

Page 2792: ...olenoid body Standard resistance 11 5 12 5 Shift solenoid No 3 No 4 or No 5 Standard resistance 2 5 3 5 Operation check When solenoids is connected to the battery as shown in figure check that the sol...

Page 2793: ...m 1 0 kg m 7 5 lb ft NOTE Do not forget to install O ring 4 to oil strainer first 4 Connect A T fluid temperature sensor coupler 3 5 Clean mating surface of A T oil pan 1 and A T case 6 Install new g...

Page 2794: ...discon nect drive shaft joints For differential side oil seal removal it is not necessary to re move drive shafts from steering knuckle 3 Remove differential side oil seal 1 by using flat end rod or l...

Page 2795: ...han dling it or them be careful not to expose to excessive shock REMOVAL 1 Disconnect negative cable at battery 2 If the vehicle is equipped with air bag system disable air bag system Refer to Disabli...

Page 2796: ...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 system after TCM and ECM are back in place...

Page 2797: ...ve plate gear 4 Remove starting motor 5 Remove bolts and nut fastening engine and transmission then detach transmission from engine NOTE When detaching transmission from engine move it in paral lel wi...

Page 2798: ...converter may fall off and cause personal injury 3 Tighten drive plate torque converter bolts Align drive plate bolt hole and torque converter through starter motor mounting opening then tighten bolt...

Page 2799: ...special care to handle aluminum parts so as not to damage them Do not expose removed parts to dust Keep them always clean 1 Remove torque converter 1 2 Remove engine mounting LH bracket 3 Remove oil c...

Page 2800: ...t 3 10 Remove oil pan and oil pan gasket NOTE For removal of oil pan do not turn transmission over as this will contaminate valve body with foreign materials in the bottom of oil pan When removing oil...

Page 2801: ...emove accumulator pistons and springs To remove C0 1 C2 2 and B1 3 accumulator pistons and springs position a rag on pistons to catch each piston To remove pistons force low pressure compressed air 1...

Page 2802: ...s b Remove housing while tapping around it lightly with a plastic hammer NOTE Never reuse bolts A shown in figure 17 Remove thrust needle roller bearing 1 and thrust bearing race 2 from the top of cou...

Page 2803: ...rust bearing race 1 and thrust needle roller bearing 2 22 Remove rear disc clutch assembly 1 23 Remove intermediate shaft assembly 1 and follow shaft as sembly 2 24 Remove B2 brake snap ring brake fla...

Page 2804: ...king lock pawl 4 26 Remove parking lock pawl sleeve 5 27 Remove counter driven gear assembly 1 and thrust needle roller bearing 2 28 Remove control shift lever 1 nuts 2 washer 3 from manu al shift sha...

Page 2805: ...ust needle roller bearing 3 Remove gasket 4 32 Remove C0 direct clutch assembly 1 thrust roller bearing 2 and rear planetary sun gear No 1 assembly 3 33 Remove planetary set 1 with bearing thrust need...

Page 2806: ...e brake discs and plates B1 brake 38 Remove snap ring 1 then O D brake return spring seat 2 return spring 3 and spring retainer 4 39 Remove snap ring 1 then remove 1st 2nd brake piston re turn spring...

Page 2807: ...special tool to compress wave spring 4 then remove snap ring 1 Special Tool A 09926 96040 NOTE Do not compress wave spring more than necessary Do not reuse snap ring 1 42 Remove reverse brake piston s...

Page 2808: ...Brake Plates and Flanges Dry plates and check for discoloration If plate surface is smooth and even color smear is indicated the plate should be reused If se vere heat spot discoloration or surface s...

Page 2809: ...ts Check mating surface for irregularities and remove them if any and clean it again Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly Replace all gasket...

Page 2810: ...ove 11 bolts 4 Separate pump body from stator shaft ass y 5 Remove oil seal from pump body INSPECTION 1 Inspect pump body oil seal Check for wear damage or cracks Replace oil seal if necessary and app...

Page 2811: ...iven gear and drive gear to pump body 2 after applying A T fluid to gears 3 Install stator shaft ass y to pump body and tighten 11 pump cover bolts to specification Tightening Torque a 10 N m 1 0 kg m...

Page 2812: ...1 FRONT CLUTCH C2 CLUTCH DISASSEMBLY 1 Remove snap ring 2 Remove flange 1 discs and plates 3 Remove shaft snap ring 1 Compress piston return springs and remove shaft snap ring Place special tool clutc...

Page 2813: ...liding surfaces of discs plates and flanges are not worn or burnt If necessary replace NOTE If disc lining is exfoliated or discolored replace all discs Before assembling new discs soak them in A T fl...

Page 2814: ...ng 3 seat and front clutch balancer 2 4 Install shaft snap ring 1 Compress return springs and install shaft snap ring in groove by using a flat end rod or the like 3 Place special tool clutch spring c...

Page 2815: ...B Clutch drum seal ring 22831 83E10 NOTE Clutch drum seal set has two seal rings in a set Do not use the seal rings removed from oil pump ass y It is not necessary to remove seal rings from special to...

Page 2816: ...to dial gauge 2 and set them on the low est clutch plate Special Tool B 09952 06010 Measure piston stroke by blowing compressed air 4 kg cm2 57 psi as shown in figure Piston Stroke 1 46 1 64 mm 0 0575...

Page 2817: ...NSMISSION 4 A T REAR CLUTCH C1 CLUTCH DISASSEMBLY 1 Remove snap ring 2 Remove flange 1 discs and plates 3 Remove shaft snap ring 1 Compress piston return springs and remove shaft snap ring Place speci...

Page 2818: ...CTION Clutch Discs Plates and Flange Check that sliding surfaces of discs plates and flanges are not worn or burnt If necessary replace NOTE If disc lining is exfoliated or discolored replace all disc...

Page 2819: ...ing seat 5 and rear clutch balancer 4 4 Install shaft snap ring 1 Compress return springs and install shaft snap rings in groove by using a flat end rod or the like 3 Place special tool clutch spring...

Page 2820: ...C on soft jawed vise 2 with wider opening 1 facing up Special Tool C 09926 26040 8 Place rear clutch assembly 1 on special tool C 9 Set dial gauge 2 on the top of clutch flange 3 and measure clearance...

Page 2821: ...to dial gauge 4 and set them on the low est clutch plate 2 Special Tool B 09952 06010 Measure piston stroke by blowing compressed air 4kg cm2 57 psi as shown in figure Piston Stroke 1 93 2 13 mm 0 076...

Page 2822: ...B 91 DIRECT CLUTCH C0 CLUTCH DISASSEMBLY 1 Remove snap ring 2 Remove flange 1 discs and plates 3 Remove shaft snap ring 1 Compress piston return springs and remove shaft snap ring Place special tool c...

Page 2823: ...ding surfaces of discs plates and flanges are not worn or burnt If necessary replace NOTE If disc lining is exfoliated or discolored replace all discs Before assembling new discs soak them in A T flui...

Page 2824: ...urn spring seat 3 and direct clutch ba lancer 2 4 Install new shaft snap ring 1 Compress return springs and install shaft snap ring in groove by using a flat end rod or the like 3 Place special tool c...

Page 2825: ...TS B Rear cover seal ring 24742 78F10 NOTE Rear cover seal set has two seal rings in a set Do not use the seal rings removed from rear cover It is not necessary to remove seal rings from special tool...

Page 2826: ...to dial gauge 2 and set them on the low est clutch plate Special Tool B 09952 06010 Measure piston stroke by blowing compressed air 4kg cm2 57 psi as shown in figure Piston Stroke 0 96 1 14 mm 0 0378...

Page 2827: ...Snap ring 1 2 4 5 3 7B 96 AUTOMATIC TRANSMISSION 4 A T PLANETARY SET DISASSEMBLY 1 Remove snap ring Remove planetary ring gear No 2 2 Remove planetary oil receiver No 1 1 and planetary gear ass y No...

Page 2828: ...direction of needle roller bearing Take care not to break the claw of oil receiver 2 Install planetary gear ass y No 1 2 to planetary gear ass y No 2 5 3 Install new planetary oil receiver No 1 1 NOTE...

Page 2829: ...e No 1 24 Fail valve No 1 sleeve 25 Key short 26 Key long 27 Oil strainer 28 Cooler by pass valve 29 Cooler by pass valve spring 30 Steel ball 31 Lock up control valve 11 Lock up control valve sleeve...

Page 2830: ...ferent kinds of bolt fixing upper and lower valve body Do not mix them up and remember where they belong to When separating lower and upper valve body be careful not to let the steel ball to fall off...

Page 2831: ...spring plunger sleeve and key Insert primary regulator valve 2 about half way then place plate washer and spring Push in primary regulator valve ass y all the way in Insert plunger with sleeve and ho...

Page 2832: ...0 Secondary regulator valve plug LOWER VALVE BODY Disassembly 1 Remove oil strainers 1 2 Remove solenoid valves if still attached 3 Remove keys 2 and pull out all sleeve plug spring and valves Referen...

Page 2833: ...econdary regulator valve 9 Secondary regulator valve spring 10 Secondary regulator valve plug Assembly 1 Apply A T fluid to each valve spring sleeve and key Insert them then fix with key NOTE Make sur...

Page 2834: ...ion shown in figure 3 Assemble lower valve body with gaskets and plate over upper valve body First tighten bolts A then the other bolts Tightening Torque a 5 5 N m 0 55 kg m 4 0 lb ft NOTE Be careful...

Page 2835: ...ing 1 Differential gear ass y DIFFERENTIAL ASSEMBLY Servicing procedure for differential assembly is similar to that for manual transmission Refer to Section 7A of this manual for adjustment procedure...

Page 2836: ...at all parts are clean 1 Install differential gears Measure and adjust thrust play referring to Section 7A If thrust play is out of specification select suitable thrust washer from among following ava...

Page 2837: ...nd copper hammer Special Tool F 09951 76010 G 09940 54910 5 Support differential assembly as illustrated so as to float L bear ing and then press fit R bearing by using special tool and copper hammer...

Page 2838: ...is hard to take it out force low pressure compressed air 1 kg cm2 15 psi 100 kPa max into hole 5 shown in figure and pop out piston into a rag 2 Remove O ring 3 and seal ring 4 Replace them if damage...

Page 2839: ...ner race 4 and washer 5 from planetary sun gear No 1 6 ASSEMBLY Reverse removal procedure noting followings When installing retainer fit 2 hooks of retainer on planetary sun gear No 1 and tap the othe...

Page 2840: ...0 ASSEMBLY 1 Install counter bearing to torque converter housing Use special tools and a hammer to press fit the bearing to torque converter housing Special Tool D 09924 74510 E 09944 68510 2 Install...

Page 2841: ...ng special tools Special Tool A 09930 30102 C 09941 64511 ASSEMBLY 1 Install counter bearing using special tools Special Tool D 09924 74510 E 09944 68510 2 Install new oil seal to transmission case Us...

Page 2842: ...efore assembly Use yellow petrolatum grease or Suzuki Super Grease C to retain parts in place Be sure to install thrust bearings and races in correct direction and position Make sure that snap ring en...

Page 2843: ...ide with spring holes comes to the top Make sure that the O rings are not twisted or caught 7 Place 1st 2nd brake piston return spring subass y 2 on pis ton 3 Make sure that each spring fits the holes...

Page 2844: ...nd brake B1 brake piston as shown Blow compressed air into hole 4 shown in figure Then measure the difference as the compressed air is blown in Standard Value for B1 Brake Stroke 1 79 2 01 mm 0 0705 0...

Page 2845: ...o 2 2 right and left to match the brake discs and the spline of planetary sun gear No 2 16 Install thrust needle roller bearing 3 and planetary set 4 Turn planetary set 4 right and left to match the g...

Page 2846: ...ston 4 then measure the distance between the top of B0 brake plate and the transmission case rear cover mat ing surface Call this value A Measure the distance from top of B0 piston adapter on rear cov...

Page 2847: ...of thrust washer and rear cover in the fol lowing manner Measure the shaft and play of planetary set 1 with dial gauge 2 NOTE Make sure that tip of dial gauge is not in contact with counter drive gear...

Page 2848: ...wo nuts 5 Apply grease to the washers Tightening Torque a 30 N m 3 0 kg m 22 0 lb ft A Grease 99000 25030 27 Install detent spring 1 to transmission case Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft...

Page 2849: ...hen hold them with 2 bolts Tightening Torque a 11 N m 1 1 kg m 8 0 lb ft 33 Install B2 brake plates discs flange and cushion plate in fol lowing order 1 Cushion plate 2 Plate 3 Disc 4 Plate 5 Disc 6 P...

Page 2850: ...al gauge and place the other end of special tool on the claw of B2 brake piston Blow com pressed air into the hole 4 shown in figure and measure the value for piston stroke Special Tool B 09952 06020...

Page 2851: ...rust needle roller bearing 1 to intermediate shaft 2 39 Install intermediate shaft 1 to transmission case 40 Install rear disc clutch assembly 1 by turning it right and left to match the clutch disc o...

Page 2852: ...n case Tightening Torque a 12 N m 1 2 kg m 9 0 lb ft 46 Measure input shaft end 2 play Set dial gauge 1 as shown in figure and measure the play of the input shaft Standard Value of Input Shaft End Pla...

Page 2853: ...he transmission case and torque converter housing 48 Install thrust bearing race 1 and thrust needle roller bearing 2 to the top of counter driven gear 3 49 Apply grease to oil pump D ring Install new...

Page 2854: ...C TRANSMISSION 4 A T 7B 123 50 Install O rings to each accumulator piston and apply grease or ATF to them Grease 99000 25030 NOTE C1 and B0 accumulator pistons are the same 51 Install C1 and B0 accumu...

Page 2855: ...rst tighten bolt B 3 then tighten other bolts Tightening Torque for Valve Body Bolt 10 N m 1 0 kg m 7 5 lb ft Bolt Length a Pieces A 30 mm 1 20 in 7 B 31 mm 1 22 in 2 C 25 mm 0 98 in 2 55 Connect coup...

Page 2856: ...5 lb ft 60 Install oil cooler 1 and ground cable 2 Tightening Torque a 60 N m 6 0 kg m 43 5 lb ft 61 Install vehicle speed sensor for speedometer 1 shift cable bracket 2 and connector clamp bracket 3...

Page 2857: ...ning Torque a 18 N m 1 8 kg m 13 0 lb ft 67 Install torque converter 1 to input shaft Install torque converter using care not to damage oil seal of oil pump After installing torque converter check to...

Page 2858: ...r 09922 85811 Spring pin remover 6 mm 09923 74510 Bearing remover 09924 74510 Installer handle 09925 37810 Oil pressure gauge 09925 88210 Bearing puller attachment 09926 26030 Air installer No 1 09926...

Page 2859: ...9931 76011 SUZUKI scan tool Tech 1A kit 09941 64511 Bearing remover 09944 68510 Bearing installer 09951 16060 Bush remover 09952 06010 Dial gauge plate No 1 09952 06020 Dial gauge plate No 2 Mass stor...

Page 2860: ...RON III or DEXRON IIE Automatic transmission Parts lubrication when installing Sealant SUZUKI BOND NO 1215 99000 31110 Case housing star shaped recess bolts 3 pcs only Lithium grease SUZUKI SUPER GREA...

Page 2861: ......

Page 2862: ...ption in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On...

Page 2863: ...with an involute spline fit The clutch cover is secured to the flywheel and car ries the diaphragm spring in such a way that the pe ripheral edge part of the spring pushes on the pres sure plate agai...

Page 2864: ...Release bearing slides unsmoothly on input shaft bearing retainer Wobbly clutch disc or poor facing contact Weakened torsion springs in clutch disc Clutch disc rivets loose Distorted pressure plate o...

Page 2865: ...clutch pedal height is specification 2 Depress clutch pedal 1 stop the moment clutch resistance is felt and measure distance clutch pedal free travel Free travel should be within the following specifi...

Page 2866: ...H 7C 5 ON VEHICLE SERVICE CLUTCH CABLE REMOVAL 1 Disconnect negative cable at battery 2 Remove clutch cable joint nut 1 3 Remove joint pin 2 from clutch release lever 3 4 Remove clutch cable outer bol...

Page 2867: ...al by using screwdriver or long nose pli ers from cabin inside then join inner cable wire joint pin in re lease lever 3 Fasten cable with 2 bolts 1 to dash panel 2 Tightening Torque a 11 N m 1 1 kg m...

Page 2868: ...l pad 14 Pedal return cushion 15 Adjusting bolt cap 16 Adjusting bolt 17 Lock nut 18 Packing in cabin CLUTCH 7C 7 CLUTCH PEDAL AND CLUTCH PEDAL BRACKET REMOVAL 1 Disconnect clutch cable hook from clut...

Page 2869: ...99000 25010 to joint of bearing and release shaft and also bearing inside 8 Clutch cover 9 Clutch disc 10 Clutch cover bolt Tightening Torque Do not reuse UNIT REPAIR OVERHAUL CLUTCH COVER CLUTCH DIS...

Page 2870: ...ver 1 Check diaphragm spring 1 for abnormal wear or damage 2 Inspect pressure plate 2 for wear or heat spots 3 If abnormality is found replace it as assembly Do not disas semble it into diaphragm and...

Page 2871: ...ess clutch disc with special tool C by hand so that disc centered Tighten cover bolts little by little evenly in diagonal order Special Tool A 09924 17810 C 09923 36330 Tightening Torque b 23 N m 2 3...

Page 2872: ...return spring by using pliers 4 Drive out No 2 bush by using special tool and hammer Release shaft seal will also be pushed out Special Tool A 09922 46010 5 Remove release shaft and return spring 6 In...

Page 2873: ...1 by using special tools and then ap ply grease to bush inside Special Tool A 09930 30102 B 09923 46030 A Grease A 99000 25010 2 Install release shaft with return spring applied to it 3 Apply grease t...

Page 2874: ...ase shaft arm 2 then set bearing A Grease A 99000 25010 8 Apply small amount of grease to input shaft 3 spline and front end as well B Grease I 99000 25210 9 Set release lever to release shaft alignin...

Page 2875: ...Input shaft bearing installer 09925 98221 Bearing installer 09930 30102 Sliding shaft REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT USE SUZUKI SUPER GREASE A Cable end hook and joint...

Page 2876: ...NGS 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 must be started at l...

Page 2877: ...inals for inspection or service works on the electric systems always confirm first that the ignition switch and all the other switches have been turned OFF Other wise the semi conductor part may be da...

Page 2878: ...other part To avoid damage to the harness protect its part which may con tact against a part forming a sharp angle by winding tape or the like around it When replacing a fuse make sure to use a fuse o...

Page 2879: ...e electrical part s beforehand Use care not to expose connectors and electrical parts to water which will be a cause of a trouble When using a tester for checking continuity or measuring voltage be su...

Page 2880: ...le colored wire uses only one color symbol i e G The dual colored wire uses two color symbols i e G Y The first symbol represents the base color of the wire G in the figure and the second symbol repre...

Page 2881: ...8 6 BODY ELECTRICAL SYSTEM POWER SUPPLY DIAGRAM Refer to Wiring Diagram Manual...

Page 2882: ...ht 8B 19 SECTION 8B LIGHTING SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an...

Page 2883: ...n signal light coupler 9 Position light coupler 8B 2 LIGHTING SYSTEM GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8 SYMBOLS AND MARKS Refer to Section 8 WIRING COLOR SYMBOLS Refer to Sec...

Page 2884: ...R L controller The illustration shows LH steering vehicle And RH steering vehicle is symmetrical LIGHTING SYSTEM 8B 3 HEADLIGHT WITH LEVELING SYSTEM DAYTIME RUNNING LIGHT D R L SYSTEM IF EQUIPPED The...

Page 2885: ...blown Leveling switch faulty Supply voltage too low Check circuit and replace fuse Check switch or replace it as necessary Recharge or replace battery One of headlights either Right or Left does not...

Page 2886: ...Wiring or grounding faulty Replace Repair as necessary Only right side or left side lights or only licence plate light do not light Fuse blown Wiring faulty Replace fuse Repair All lights do not light...

Page 2887: ...D LICENCE PLATE LIGHTS Replace fuse to check for short Check switch Replace relay Repair as necessary Front fog lights light when lighting switch is in OFF position Front fog light relay faulty Wiring...

Page 2888: ...ble cause Correction Interior light does not light up Bulb burnt out Fuse blown Wiring or grounding faulty Door open switch faulty Interior light faulty Lighting switch faulty Replace Replace Repair a...

Page 2889: ...each switch position If any continuity is not obtained replace switch Terminal EL T H Switch Position EL T H OFF SMALL HEAD INSTALLATION Reverse removal procedure for installation DIMMER AND PASSING...

Page 2890: ...mmer switch 2 Push turn dimmer switch into steering column till it clicks 3 Install steering column cover Reverse removal procedure D R L CONTROLLER if equipped INSPECTION 1 Disconnect negative cable...

Page 2891: ...ight assembly off vehicle INSTALLATION Reverse removal procedure for installation Make sure to follow HEADLIGHT AIMING WITH SCREEN and aim headlight after installation BULB REPLACEMENT WARNING Don t t...

Page 2892: ...ng headlight with leveling sys tem make sure to set the leveling switch to 0 position with IG switch ON Before adjustment make sure the following a Place vehicle on a flat surface in front of blank wa...

Page 2893: ...istance value is out of specification replace switch Resistance Position Between terminal A and B Between terminal B and C 1 136 150 2 278 308 3 421 465 522 576 INSTALLATION Reverse removal procedure...

Page 2894: ...arance light position Check headlights go off If check result is OK D R L controller 1 is OK 3 Disconnect negative cable at battery 4 Disconnect D R L controller coupler and connect negative cable at...

Page 2895: ...REMOVAL in Section 3C 3 Pull out turn dimmer switch 4 Disconnect turn dimmer switch lead wire couplers INSPECTION Check the continuity at each switch position If any continuity is not obtained replace...

Page 2896: ...EMBLY REMOVAL in Section 1A 2 Remove hazard switch 1 from hazard switch case 2 installed instrument panel with unlocked the locking part 3 as shown in figure INSPECTION Check the continuity of each sw...

Page 2897: ...coupler 3 Connect battery and tester as the left illustration 4 Unless a continued click sound is heard replace relay 1 FRONT FOG LIGHTS IF EQUIPPED FRONT FOG LIGHT SWITCH REMOVAL 1 Disconnect negativ...

Page 2898: ...ights are ON again REAR FOG LIGHT REAR FOG LIGHT SWITCH REMOVAL 1 Disconnect negative cable at battery 2 Remove garnish 1 of instrument panel switches 3 Remove rear fog light switch 2 from instrument...

Page 2899: ...rmi nals are specifications Terminals Condition Specification G53 1 and ground 10 15 V G53 2 and When headlight switch is in OFF 10 15 V ground When headlight switch is in ON 0 V G53 3 and Continuity...

Page 2900: ...sconnect negative cable at battery 2 Remove garnish 1 of instrument panel switches 3 Remove lighting switch 2 from instrument panel INSPECTION Check the continuity at each switch position If any conti...

Page 2901: ......

Page 2902: ...RUMENTATION DRIVER INFORMATION WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho...

Page 2903: ...driver side B O 31 To ECM Br Y 32 Blank 13 To dimmer switch R 14 Blank 15 To speed sensor V 16 Blank 17 To positive terminal at battery W Bl 18 To lighting switch R Y 19 To ground Br 20 To fuel level...

Page 2904: ...blown ECT meter faulty ECT sensor faulty Wiring or grounding faulty ECM faulty Check fuse Check ECT meter Check ECT sensor Repair Check input signal from ECM OIL PRESSURE LIGHT Trouble Possible Cause...

Page 2905: ...L CONTROLLER of HEADLIGHTS in Section 8B IGNITION KEY REMAINDER WARNING BUZZER Trouble Possible Cause Correction Ignition key remainder warning buzzer does not sound DOME fuse blown Buzzer faulty Wiri...

Page 2906: ...ition switch key to ACC position b Insert screw driver 1 through coupler hole c Unlock coupler lock 2 by pushing it in arrow direction with screw driver 1 d With unlocked disconnect ignition main swit...

Page 2907: ...Connect negative cable at battery 5 Enable air bag system Refer to ENABLING AIR BAG SYSTEM in Section 10B COMBINATION METER REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system Ref...

Page 2908: ...R VEHICLE SPEED SENSOR VSS Refer to VEHICLE SPEED SENSOR VSS in Section 7A FUEL METER FUEL GAUGE UNIT FUEL METER INSPECTION 1 Disconnect Y R lead wire going to gauge unit 2 Turn ignition switch ON and...

Page 2909: ...ance Full Upper a 56 mm 2 20 in 38 42 Middle 1 2 b 119 2 mm 4 69 in 157 163 Full Lower c 200 5 mm 7 89 in 276 284 If measured resistance is out of specification replace ENGINE COOLANT TEMP ECT METER A...

Page 2910: ...PECTION Warm up ECT sensor 1 Thus make sure ECT sensor for meter 2 resistance is decreased with increase of its temperature Temperature Resistance 50 C 122 F 136 216 120 C 248 F 16 4 19 4 OIL PRESSURE...

Page 2911: ...eck switch 1 for continuity If found defective replace switch 1 OFF position parking brake lever released No continuity ON position parking brake lever pulled up Continuity DOOR SWITCH INSPECTION 1 Re...

Page 2912: ...rk must be 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...

Page 2913: ...CKS GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8 SYMBOLS AND MARKS Refer to Section 8 WIRING COLOR SYMBOLS Refer to Section 8 ABBREVIATIONS Refer to Section 8 JOINT CONNECTOR Refer to...

Page 2914: ...oller Back Door Actuator Power Door Lock Switch Front Door Actuator Rear Door Actuator The illustration shows LH steering vehicle And RH steering vehicle is symmetrical WINDOWS MIRRORS SECURITY AND LO...

Page 2915: ...Wiper switch faulty Intermittent timer faulty Wiring or grounding faulty Check switch Check timer Repair Washer and wiper does not operate when washer switch is in ON Washer hose or nozzle clogged Wa...

Page 2916: ...orrection All power door locks do not operate as interlocked with door lock key DOOR LOCK fuse blown Power door lock controller faulty Wiring or grounding faulty Replace fuse to check for short Replac...

Page 2917: ...column cover Refer to step 5 of CONTACT COIL CABLE ASSEMBLY REMOVAL in Section 3C 3 Pull out wiper and washer switch assembly 4 Disconnect wiper and washer switch lead wire coupler INSPECTION Check th...

Page 2918: ...proper For high speed check connect battery terminal to terminal B and its terminal to bracket 1 wiper ground If motor 2 rotates at a high revolution speed of 67 to 83 rpm it is proper 2 Testing auto...

Page 2919: ...5 Disconnect pump 2 lead wires and hoses 6 Remove washer tank 1 7 Remove pump 2 from tank 1 INSPECTION 1 Connect battery terminal to pump a terminal and battery terminal to pump b terminal Check that...

Page 2920: ...n following termi nals are specification Terminals Condition Specification G51 8 and ground Continuity When wiper blades are stopped at windshield base Continuity G51 5 and ground Turn ignition switch...

Page 2921: ...nd resistance between following termi nals are specifications Terminals Condition Specification G51 2 and When ignition switch is in OFF 0 V ground When ignition switch is in ON 10 15 V G51 6 and grou...

Page 2922: ...termi nals are specification Terminals Condition Specification G51 2 and When ignition switch is in OFF 0 V ground When ignition switch is in ON 10 15 V G51 6 and ground Continuity G51 8 and ground C...

Page 2923: ...PECTION Check the continuity at each switch position If any continuity is not obtained replace switch Terminal Position a i f g h OFF ON RR WASHER INSTALLATION 1 Connect wiper and washer switch lead w...

Page 2924: ...r 1 turns once again then stops at a given posi tion d Repeat these steps several times and inspect if the motor 1 stops at the given position every time REAR WIPER ARM REMOVAL 1 Remove rear wiper arm...

Page 2925: ...ty If switch has no continuity between terminals replace INSTALLATION Reverse removal procedure for installation DEFOGGER WIRE CAUTION When cleaning rear window glass use a dry cloth to wipe it along...

Page 2926: ...itive end If voltage is zero wire must be damaged between its center and ground 2 Locating damage in wire a Touch voltmeter positive lead to heat wire positive termi nal end b Touch voltmeter negative...

Page 2927: ...masking tape 1 at both upper and lower sides of heat wire 3 to be repaired 3 Apply commercially available repair agent 4 with a fine tip brush 2 4 Two to three minutes later remove masking tapes 1 pre...

Page 2928: ...Inspect switch for continuity between terminals LH steering vehicle Driver Side Window Switch 1 Passenger Side Window Switch 2 Terminal Switch G E F A G J I A UP UP OFF OFF DOWN DOWN RH steering vehic...

Page 2929: ...WS MIRRORS SECURITY AND LOCKS LH steering vehicle RH steering vehicle POWER WINDOW SUB SWITCH INSPECTION Inspect switch for continuity between terminals Terminal Switch Position C A D B E UP UP OFF OF...

Page 2930: ...le RH steering vehicle Switch POWER DOOR LOCK SYSTEM IF EQUIPPED POWER DOOR LOCK SWITCH INSPECTION Inspect continuity between terminals according to door lock switch 1 action For LH steering Vehicle t...

Page 2931: ...door locks are in lock position Connect battery terminal to G02 8 and its terminal to G02 2 Check all power door locks except back door lock are in dead lock position Connect battery terminal to G02 2...

Page 2932: ...and ground When driver side key switch is in OFF position No continuity G02 13 and ground When driver side key switch is in lock position Continuity G02 13 and ground When driver side key switch is in...

Page 2933: ...1 Disconnect power door lock actuator coupler 2 Connect 12 V battery positive and negative terminals to the door lock actuator terminals shown below If it does not operate as specified in table below...

Page 2934: ...ive cable at battery 2 Remove door trim Refer to steps 1 to 5 of FRONT DOOR GLASS REMOVAL in Section 9 3 Disconnect door mirror coupler 4 Check that door mirror operates properly when battery voltage...

Page 2935: ...09913 60910 Bearing puller 8D 24 WINDOWS MIRRORS SECURITY AND LOCKS SPECIAL TOOL...

Page 2936: ...8G 21 ON VEHICLE SERVICE 8G 22 Precautions in handling immobilizer control system 8G 22 Immobilizer control module 8G 22 Registration procedure of immobilizer system components 8G 23 Immobilizer syst...

Page 2937: ...l module at ignition key switch 2 Immobilizer control module compares FC read in step 1 and that registered in immobilizer control module and checks if they match 3 ECM sends variable generated random...

Page 2938: ...ed in immobilizer control module up to 5 different FIX CODE can be registered Immobilizer control module controls serial communication between scan tool and ECM Immobilizer control module has 3 differ...

Page 2939: ...e diagnosis switch terminal of diagnosis connector 3 diag nosis monitor connector 1 for ECM not grounded the ignition switch turned at ON position but engine at stop and regardless of the condition of...

Page 2940: ...s well as checked by using SUZUKI scan tool Before using scan tool read its Operator s Instruction Manual Carefully to have good understanding as to what func tions are available and how to use it Be...

Page 2941: ...registered in ECM by performing procedure described in PROCEDURE AF TER ECM REPLACEMENT When immobilizer control module is replaced including when re placed because rechecking by using a known good im...

Page 2942: ...is failed Proceed ENGINE DIAGNOSTIC FLOW TABLE in SECTION 6 DIAGNOSTIC PROCEDURE FOR NON EC spec vehicle equipped with diagnosis connector 3 STEP ACTION YES NO 1 Check MIL malfunction indicator lamp f...

Page 2943: ...tem in another vehicle If communication is possible in this case scan tool is in good condition Then check data link connector and serial data line circuit in the vehicle with which communication was...

Page 2944: ...is detected ECM DTC NO Display on scan tool MIL flashing pattern DETECTED ITEM DETECTING CONDITION P1610 89 Secret key and password not registered Secret key and password are not registered in ECM P16...

Page 2945: ...switch at ON position OFF Ignition switch at OFF position TRANSPONDER DETECTED Transponder in ignition key is detected by immobilizer control module NOT DETECTED Transponder in ignition key is not de...

Page 2946: ...e affects each terminal voltage confirm that it is 11 V or more when ignition switch is turned to ON position TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION 1 Not used 2 V W MIL 0 1 V MIL lights on 3 Not u...

Page 2947: ...r control module TROUBLE SHOOTING DTC B1000 STEP ACTION YES NO 1 1 Ignition switch at OFF position 2 Disconnect connector from immobilizer control module 3 Check for proper connection to immobilizer c...

Page 2948: ...terminal Is it in good condition Go to step 2 Repair or replace 2 1 Ignition switch at OFF position 2 Disconnect connector from immobilizer control module 3 Check for proper connection to immobilizer...

Page 2949: ...TC B3042 STEP ACTION YES NO 1 1 Ignition switch at OFF position 2 Disconnect connector from ECM 3 Check for proper connection to ECM at E22 3 terminal Is it in good condition Go to step 2 Repair or re...

Page 2950: ...P ACTION YES NO 1 1 Ignition switch at OFF position 2 Disconnect connector from ECM 3 Check for proper connection to ECM at E22 3 terminal Is it in good condition Go to step 2 Repair or replace 2 1 Co...

Page 2951: ...repair or replace Ignition key with built in transponder unusable Replace register it if necessary and recheck DTC B3056 NO FIX CODE REGISTERED DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING C...

Page 2952: ...A No request from ECM via MIL circuit Ignition switch is not reset correctly MIL circuit faulty Communication between ECM and immobilizer Ignition switch is not reset correctly Communication between E...

Page 2953: ...control module TROUBLE SHOOTING DTC B3060 STEP ACTION YES NO 1 Is DTC B3056 also output Proceed DTC FLOW TABLE of DTC B3056 Then go to step 2 Go to step 2 2 Check DATA LIST TRANSPONDER FC Is it regis...

Page 2954: ...ring PROCEDURE AFTER ECM REPLACEMENT 2 Check DTC Is DTC B3061 still output Go to step 6 If there is other DTC proceed the DTC FLOW TABLE 6 1 Replace ignition key with new one and register it by referr...

Page 2955: ...ition switch to ON position Is DTC P1611 still output Substitute a known good ECM according to PROCEDURE FOR ECM REPLACEMENT and recheck ECM is in good condition DTC P1612 P1613 NO SIGNAL FROM IMMOBIL...

Page 2956: ...and transponder Unregistered ignition key with built in transponder FIX CODE is detected No FIX CODE in immobilizer control module TROUBLE SHOOTING DTC P1614 STEP ACTION YES NO 1 Proceed DTC FLOW TABL...

Page 2957: ...h built in transponder where high temperature is anticipated High temperature will cause trans ponder in ignition key to be abnormal or damaged Do not turn ignition switch to ON position II with a rad...

Page 2958: ...ollows STEP ACTION YES NO 1 DTC CHECK Check for DTC referring to DTC CHECK Are there DTC B1000 B3040 B3042 and or B3043 Proceed to each diagnostic flow table corresponding to that DTC number Go to ste...

Page 2959: ...registered clear all FIX CODEs registered in immobilizer control module by executing CLEAR FC com mand in IMMOBI CONT menu with scan tool 6 If FIX CODE is already registered in immobilizer control mod...

Page 2960: ...a tion procedure Or the ignition key will be unusable 4 Check for number of registered FIX CODEs by referring DATA LIST of scan tool If any FIX CODEs are registered clear FIX CODEs by executing CLEAR...

Page 2961: ...I scan tool Tech 1A 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 Mass storage cartridge Immobilizer cartr...

Page 2962: ...der Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Pre...

Page 2963: ...ass run 4 Door trim 5 Door sealing cover 6 Door sash 7 Power window switch assembly 8 Window regulator handle 9 Door glass mounting screw 1 2 GLASS WINDOWS AND MIRRORS FRONT DOOR GLASS REMOVAL 1 Remov...

Page 2964: ...window switch lead wire at coupler if equipped 5 Remove door sealing cover 1 6 Remove door mirror Refer to DOOR MIRROR in this section 7 Remove glass run 1 Lower window all the way down Then use a ta...

Page 2965: ...Tighten glass attaching screws 1 to specified torque Tighten rear screw first then front screw Tightening Torque 6 N m 0 6 kg m 4 3 lb ft When door window front glass 1 is installed fit weatherstrip 2...

Page 2966: ...coupler and loosen clamp if equipped 3 Loosen regulator mounting nuts 1 and take out regulator through hole 2 as shown in figure INSPECTION 1 Check regulator sliding and rotating parts for greasing 2...

Page 2967: ...9 6 BODY SERVICE DOOR MIRROR REMOVAL AND INSTALLATION When removing or installing door mirror refer to figure shown below Tightening Order a b...

Page 2968: ...ndow regulator Apply SUZUKI SUPER GREASE A 99000 25010 to moving section 3 Glass run 4 Door trim 5 Door sealing cover 6 Door sash 7 Window regulator handle 8 Door glass mounting screw BODY SERVICE 9 7...

Page 2969: ...door trim fitting screw 4 Remove door trim 1 With inside handle bezel 2 tilted as shown in figure turn door trim 90 counterclockwise to remove it 5 Remove door sealing cover 1 6 Remove glass run 1 Lo...

Page 2970: ...ng screws 1 to specified torque Tighten rear screw first then front screw Tightening Torque 6 N m 0 6 kg m 4 3 lb ft Secure door sealing cover 1 with adhesive 2 Install door window regulator handle 1...

Page 2971: ...re for damage INSTALLATION Reverse removal procedure to install window regulator noting fol lowing Tighten window regulator attaching nuts to proper tightening or der Tightening Order a b c Tighten do...

Page 2972: ...he adhesive in any way hinders its inherent adhesive property Therefore before the work make sure to read carefully the instruction and description given by the maker of the adhesive to be used and be...

Page 2973: ...this section 6 If necessary remove head lining Refer to HEAD LINING in this section 7 Remove or cut windshield molding 8 Drill hole with eyeletter 1 through adhesive and let piano string through it 9...

Page 2974: ...r side of windshield 3 To determine installing position of glass 1 to body 2 position glass against body so that clearance between upper end of glass 1 and body 2 is about 5 mm 0 197 in and clearances...

Page 2975: ...stance from the edge of glass a 30 50 mm 1 18 1 97 in 7 Install new spacer 1 to glass 4 8 Using new brush apply sufficient amount of primer for glass along glass surface to be adhered to body NOTE Be...

Page 2976: ...9 in Position f Approx 10 mm 0 39 in g Approx 17 mm 0 67 in section a Press glass 3 against fittings surface of body panel quickly after adhesive 2 is applied Use of rubber sucker grip is helpful to h...

Page 2977: ...it down with a tape until adhesive is completely set Each adhesive has its own setting time Be sure to refer to its maker s instruction check set ting time of adhesive to be used and observe precau ti...

Page 2978: ...me However note the following NOTE Observe the following precautions when applying adhesive 4 along glass 2 edge Adhesive 4 should be applied evenly especially in height Be careful not to damage prime...

Page 2979: ...euse BODY STRUCTURE FRONT AND REAR DOOR ASSEMBLY FRONT DOOR ASSEMBLY REMOVAL 1 Remove front fender 2 Disconnect door harness lead wires at each coupler 3 Remove stopper pin 1 from door open stopper 2...

Page 2980: ...fer to UNDERCOATING ANTI CORROSION COMPOUND APPLICATION AREA in BODY REPAIR MANUAL When door hinge pin 1 is installed to install door to body turn hinge pin cut section to vihecle forward Drive in doo...

Page 2981: ...latch striker position by referring to FRONT DOOR LOCK INSTALLATION Section so that door is positioned correctly Adjust front door cushion 2 into dimension A so that bring cushion into contact with bo...

Page 2982: ...t its body side 5 Remove door hinge nuts 5 and remove back door assembly 6 WARNING Handling of Back Door Balancer Damper Do not disassemble balancer because its cylinder is filled with gas Handle bala...

Page 2983: ...CK DOOR LOCK ASSEMBLY INSTALLATION so that door is positioned correctly Adjust door cushion so that door contacts body when closed Adjust door clearance by loosening door hinge mounting bolts and nuts...

Page 2984: ...e right or left of hood is not level with front fender make it level by tightening or loosening hood cushion 4 Hood lock position adjustment When installing hood lock 1 bring bolt at highest position...

Page 2985: ...side turn signal or side marker lamp 3 Remove front fender lining 1 4 Remove front fender 2 INSTALLATION Reverse removal procedure for installation NOTE If paint on fender bolt is peeled off be sure t...

Page 2986: ...that they could affect the performance of vital components 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...

Page 2987: ...s section REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system if equipped Refer to Disabling Air Bag System in Section 10B 3 Remove steering column assembly 1 Refer to Section 3C 4...

Page 2988: ...ehicle with Air Bag instrument panel could not be removed with Air Bag harness coupler connected Use are not to damage Air Bag harness 9 Loosen brake pedal bracket mounting nuts 1 and clutch pedal bra...

Page 2989: ...ness When installing brake pedal assembly 1 refer to Section 5A BRAKE BOOSTER INSTALLATION Tighten each parts to specified torque and proper tightening order for instrument panel attaching Tightening...

Page 2990: ...3 Seat back bolt 4 Seat cushion bolt 5 Folding bolt FRONT SEAT REAR SEAT SEATS FRONT SEAT AND REAR SEAT REMOVAL 1 Remove four mounting bolts to remove seat cushion 2 Remove four mounting bolts front s...

Page 2991: ...L 1 Remove door trim and door sealing cover refer to steps 1 to 9 of FRONT DOOR GLASS REMOVAL in this section 2 Raise window all the way up 3 Remove door sash 4 Remove door lock cover 1 5 Disconnect d...

Page 2992: ...lb ft Move door latch striker 1 sideways to adjust door outer panel surface 2 flush with rear door outer panel or body outer panel surface 3 as shown In order to correctly obtain door lock operates in...

Page 2993: ...door sealing cover refer to steps 1 to 4 of REAR DOOR GLASS REMOVAL in this section 2 Disconnect door opening control rod 1 and door lock control rod 2 3 Loosen door lock mounting screw 3 door lock a...

Page 2994: ...nnect door lock motor lead wire if equipped 4 Loosen door lock mounting screw 3 and remove door lock as sembly 4 INSTALLATION Reverse removal procedure to install back door lock assembly not ing the f...

Page 2995: ...on both edges to make them reversible Key identification is obtained from five character key code stamped on key code tag Using this key code key code cutting combination can be determined from a cod...

Page 2996: ...de 11 Front guide with detent lever 12 Gutter guide 13 Rear guide 14 Sliding roof glass bolt 15 Sliding roof handle screw 16 Sliding roof mounting bolts Apply Thread lock 1333B 99000 32020 SUNROOF SLI...

Page 2997: ...times In this way sunroof glass can be positioned in both vertical and horizontal directions by elasticity of sliding roof weather strip 2 Position sunroof glass by such dimensions with respect to roo...

Page 2998: ...e sliding roof glass Refer to SLIDING ROOF GLASS in this section 2 Remove water gutter 1 as shown 3 Close sun shade 3 4 Detach front slider 1 and rear slider 2 by pushing arrow direc tion as shown 5 P...

Page 2999: ...heck crack and deformation for pinion gear 1 and drive lock pin 2 If replace as necessary INSTALLATION 1 Adjust sliding roof assembly and crank drive for assemblying position Refer to SLIDING ROOF ASS...

Page 3000: ...ss Refer to SLIDING ROOF GLASS in this section 2 Remove head lining 1 Refer to HEAD LINING in this section 3 Disconnect drain hose 1 connected to sliding roof assembly at 4 locations 4 Loosen sliding...

Page 3001: ...edure for assembly observing the fol lowing instructions Adjust crank drive position as follows 1 Install crank handle 3 to crank drive 1 temporary 2 Push crank 1 onto drive 2 by pushing press bottom...

Page 3002: ...ight and left positioning pins on sliding roof assembly with holes in body side for installation Clean sliding roof mounting bolts 1 16 pieces Then apply thread lock cement A to them A Thread lock 990...

Page 3003: ...lower anchor bolt 3 Remove dash side trims front side sill scuffs center pillar inner lower trims and rear side sill scuffs 4 Remove parking brake lever cover console box 5 Remove front floor carpet I...

Page 3004: ...nish 3 if equipped sliding roof 6 Remove roof trim 1 if equipped sliding roof 7 Remove assistant grips 2 8 Remove door opening trims 3 and remove inner trims cover ing headlinings 4 9 Remove rear spea...

Page 3005: ...igure Install interior trims in order of a b c When install roof handle 1 match marks 2 on roof handle 1 and roof garnish 3 Tighten roof handle screw 4 to specified torque Tightening Torque 2 N m 0 2...

Page 3006: ...Remove roof rail front and rear caps as shown in figure 2 Remove nuts 3 Remove roof rail assembly Installation Reverse removal procedure for installation Confirm that each roof rail fixing nut is tig...

Page 3007: ...9 46 BODY SERVICE BACK DOOR EMBLEM DIMENSION Position Dimension Position mm in a 568 22 36 b 76 2 99 c 69 2 72 d 574 22 6 e 74 5 2 93 f 74 2 91 g 43 1 69...

Page 3008: ...6 0 16 0 24 j 5 7 0 2 0 28 b 5 7 0 2 0 28 k 6 8 0 24 0 31 c 5 7 0 2 0 28 l 5 8 0 2 0 31 d 5 7 0 2 0 28 m 2 5 4 5 0 1 0 18 e 3 5 5 5 0 14 0 22 n 4 5 6 5 0 18 0 26 f 4 6 0 16 0 24 o 5 7 0 2 0 28 g 3 5 5...

Page 3009: ...emover REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED SUZUKI PRODUCTS USE Lithium grease SUZUKI SUPER GREASE A 99000 25010 Window regulator Grease Carl Bechem GmbH B0401137 Door hinge Grease Carl Bec...

Page 3010: ...ere injury The procedures in this section must be followed in the order listed to temporarily disable the air bag system and prevent false diagnostic codes from setting Failure to follow procedures co...

Page 3011: ...all the way back into the retractor which releases the lock and allows the webbing to be pulled out Seat belt with ELR and pretensioner The seat belt with ELR and a pretensioner has a pretensioner me...

Page 3012: ...could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury The procedures in this section must be followed...

Page 3013: ...speci fied value When servicing seat belt retractor assembly with pretensioner be sure to observe all WARNINGS and CAUTIONS in this section and Service Precautions under On Vehicle Service in SECTION...

Page 3014: ...assemblies with new replacement parts Keep belts dry and clean at all times If there exist any parts in question replace such parts Replace belts whose webbing is cut or otherwise damaged Do not put a...

Page 3015: ...ice Precautions earlier in this sec tion before starting to work and observe every precaution during work Neglecting them may result in personal inju ry or unactivation of the seat belt pretensioner w...

Page 3016: ...d the fore and aft or right and left directions Anchor bolt Anchor bolts should be torqued to specification Belt latch It should be secure when latched Check retractor assembly with seat belt pretensi...

Page 3017: ...ar seat belt 2 INSPECTION Check rear seat belt for the same items as front seat belt inspection other than related to pretensioner INSTALLATION Install the rear seat belt observing the following preca...

Page 3018: ...source voltage low 10B 31 DTC 41 Driver pretensioner initiator circuit resistance high 10B 34 DTC 42 Driver pretensioner initiator circuit resistance low 10B 34 SECTION 10B AIR BAG SYSTEM WARNING For...

Page 3019: ...ONS REQUIRED AFTER AN ACCIDENT 10B 40 Accident with Deployment Activation Component Replacement 10B 40 Accident with or without Deployment Activation Component Inspections 10B 41 ON VEHICLE SERVICE 10...

Page 3020: ...rom the center of the steering column and the passenger air bag inflator module from the top of the instru ment panel in front of the front passenger seat in occurrence of a front collision with an im...

Page 3021: ...ontact coil assembly 7 Driver air bag inflator module 8 Passenger air bag inflator module 9 Seat belt pretensioners Q01 CONNECTOR Q02 CONNECTOR Q03 CONNECTOR Q04 CONNECTOR Q07 CONNECTOR DRIVER SIDE Q0...

Page 3022: ...Red Br Brown G Green Gr Gray CONNECTOR Q06 SDM connector TERMINAL ARRANGEMENT OF SDM VIEWED FROM HARNESS SIDE Q01 Q07 Connector number G R Green Red Lg Lightgreen P Pink V Violet Y Yellow Y B Yellow...

Page 3023: ...ent such as a battery powered or AC powered voltmeter ohmmeter etc or any type of electrical equipment other than that specified in this manual Do not use a non powered probe type tester Instructions...

Page 3024: ...ING WHEEL is used to substitute the load of the followings driver air bag inflator module when it is connected at the top of the column to the contact coil assembly passenger air bag inflator module w...

Page 3025: ...eck each connector terminal in problem circuits carefully to en sure good contact tension by using the corresponding mating ter minal included in the connector test adapter kit special tool If contact...

Page 3026: ...tic flow tables and follow the sequence listed below A PERFORM THE AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE The Air Bag Diagnostic System Check Flow Table must be the starting point of any air bag s...

Page 3027: ...is ON Air bag warning lamp flashes Proceed to Table C Go to step 4 4 Does air bag warning lamp turn OFF after flashing 6 times Go to step 5 Go to step 6 5 1 Check DTC Refer to DTC CHECK 2 Not using S...

Page 3028: ...to TABLE E 6 After completing the check turn ignition switch OFF and discon nect scan tool cable from data link connector DLC Not using SUZUKI scan tool 1 Perform Step 1 to 4 in AIR BAG DIAGNOSTIC FLO...

Page 3029: ...ZUKI scan tool Refer to SUZUKI scan tool operator s manual for further details 5 After completing the check turn ignition switch OFF and discon nect SUZUKI scan tool from data link connector DLC 6 Per...

Page 3030: ...C indicated by air bag warning lamp Air bag warning lamp flashing pattern DIAGNOSIS NO DTC 12 Normal B1015 15 Resistance high B1016 16 Passenger air Resistance low B1018 18 bag circuit Short to ground...

Page 3031: ...numbered code will appear first If a code not listed on the table is displayed then the SDM is faulty After ignition switch is turned ON air bag warning lamp flashes 6 times and then operates as show...

Page 3032: ...P FLASHES EVEN AFTER INITIAL 6 TIME FLASHING TABLE D AIR BAG WARNING LAMP CANNOT INDICATE FLASHING PATTERN OF DTC TABLE E SCAN TOOL CANNOT COMMUNICATE SDM CAUTION Be sure to perform Air Bag Diagnostic...

Page 3033: ...onnector and body ground with ignition switch ON See figure below Is it 8 V more Go to step 3 Bl R wire between AIR BAG fuse and SDM connector open Bl B wire between ignition switch and air bag fuse o...

Page 3034: ...t terminal for air bag warning lamp and to SDM at terminal Q06 30 3 If OK then check resistance between Bl wire terminal of combination meter connector and Q06 30 terminal of SDM connector See figure...

Page 3035: ...ition switch OFF disconnect SDM connector 2 Check continuity between Q06 8 terminal of SDM connector and body ground See figure below Is there continuity Repair short from V wire circuit to ground Sub...

Page 3036: ...tor coupler to body ground by service wire 2 1 Disconnect SDM connector from SDM 2 Check for proper connection at V wire terminal Q06 8 terminal of SDM connector 3 If OK then check continuity between...

Page 3037: ...dule Go to step 3 Repair open in common section of serial data circuit W R wire circuit used by all controllers or short to ground or power circuit which has occurred somewhere in serial data circuit...

Page 3038: ...r test adapter kit When a check for proper connection is required refer to Intermittent and Poor Connections in this section If there is open circuit in the air bag wire harness connector or terminal...

Page 3039: ...enger air bag inflator module 3 1 With ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at terminals Q06 23 and Q06 24 3 Release shorting bar in SDM connector inserting Sp...

Page 3040: ...ition switch OFF disconnect SDM connector 2 Check proper connection to SDM at terminals Q06 23 and Q06 24 3 Release shorting bar in SDM connector by inserting special tool A referring to the figure be...

Page 3041: ...n switch ON is DTC 18 current Go to step 3 1 Ignition switch OFF 2 Replace passenger air bag inflator module 3 1 With ignition switch OFF disconnect Special Tool B and SDM connector 2 Check continuity...

Page 3042: ...N is DTC 19 current Go to step 3 1 Ignition switch OFF 2 Replace passenger air bag inflator module 3 1 With ignition switch OFF disconnect Special Tool B and SDM connector 2 Measure voltage from Q06 2...

Page 3043: ...When a check for proper connection is required refer to Intermittent and Poor Connections in this section If there is open circuit in the air bag wire harness connector or terminal is found damaged re...

Page 3044: ...al Tools Is resistance 5 1 or less Substitute a known good SDM and recheck Repair high resistance or open in G or G R wire circuit 4 1 With ignition switch OFF disconnect Special Tools then reconnect...

Page 3045: ...bstitute a known good SDM and recheck Repair short from G wire circuit to G R wire circuit or from G other G R wire circuit to other wire circuit 4 1 With ignition switch OFF disconnect Special Tool B...

Page 3046: ...wn good SDM and recheck 4 1 With ignition switch OFF disconnect Special Tools then reconnect contact coil connector located near the base of the steering column 2 Remove driver air bag inflator module...

Page 3047: ...from G or G R wire circuit to power circuit 4 1 With ignition switch OFF disconnect Special Tools then reconnect contact coil connector located near the base of the steering column 2 Remove driver air...

Page 3048: ...s section along with a correct terminal adapter from special tool Con nector test adapter kit When a check for proper connection is required refer to Intermittent and Poor Connections in this section...

Page 3049: ...low Is voltage 10 V or less Go to step 3 Check Charging System and repair as necessary Refer to SECTION 6H Charging System 3 1 With ignition switch OFF reconnect SDM connector With ignition switch ON...

Page 3050: ...en ignition switch ON and then check voltage from Bl R wire terminal in Q03 connector on instrument panel harness to body ground Is voltage 8 V or more Repair poor connection high resistance in Bl R o...

Page 3051: ...al digital multimeter refer to SPECIAL TOOLS in this section along with a correct terminal adapter from special tool Con nector test adapter kit When a check for proper connection is required refer to...

Page 3052: ...ch OFF 2 Replace seat belt pretensioner Refer to SECTION 10A 3 1 With ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at terminals Q06 33 and Q06 34 or Q06 35 and Q06 36...

Page 3053: ...CTION 10A 3 1 With ignition switch OFF disconnect SDM connector 2 Check proper connection to SDM at terminals Q06 33 and Q06 34 or Q06 35 and Q06 36 3 If OK then measure resistance between Q06 33 and...

Page 3054: ...ition switch ON is DTC 43 or 47 still current Go to step 3 1 Ignition switch OFF 2 Replace seat belt pretensioner Refer to SECTION 10A 3 1 With ignition switch OFF disconnect Special Tools and SDM con...

Page 3055: ...itch ON is DTC 44 or 48 still current Go to step 3 1 Ignition switch OFF 2 Replace seat belt pretensioner Refer to SECTION 10A 3 1 With ignition switch OFF disconnect Special Tools and SDM 2 Measure v...

Page 3056: ...imeter refer to SPECIAL TOOLS in this section along with a correct terminal adapter from special tool Con nector test adapter kit When a check for proper connection is required refer to Intermittent a...

Page 3057: ...did not occur Never use air bag system parts from another vehicle Do not attempt to service the parts below Service of these parts is by replacement only Driver Passenger air bag inflator module Driv...

Page 3058: ...s replace faulty part Steering column bracket and capsules Check for damage and bent If any faulty condition is found in above checks replace faulty part Steering wheel and driver air bag inflator mod...

Page 3059: ...elting or damage Check that connector is connected securely or locked Check SDM connector and terminals for tightness Check SDM sets a diagnostic trouble code Refer to DTC Check in this section and th...

Page 3060: ...s or poor connections Refer to Intermittents and Poor Connections in this section Check wire harness clamps for tightness If any faulty condition is found correct or replace Seat belt pretensioner Che...

Page 3061: ...you to the correct chart to diagnose any air bag malfunctions Bypassing these procedures may result in extended diagnostic time incor rect diagnosis and incorrect parts replacements Never use air bag...

Page 3062: ...mponents and Wiring Location View and Connectors in this section for location of circuit fuse box 4 Remove steering column upper and lower covers 5 Disconnect connector 1 from contact coil assembly 6...

Page 3063: ...stem when SDM is not rigidly at tached to the vehicle Otherwise personal injury may result CAUTION After detecting one time of such collision as to meet deploy ment conditions the SDM must not be used...

Page 3064: ...nd be sure to replace it with new one as an assembly When an abnormality is noted as existing in the live undeployed air bag inflator module be sure to deploy it before discarding it When grease clean...

Page 3065: ...ial care is necessary when handling and storing a live inacti vated seat belt pretensioners Also when the seat belt pretensioners activate gas is generated and the seat belt is retracted into the retr...

Page 3066: ...ctivation is very hot Wait for at least 10 minutes to cool it off before proceeding the work Do not apply water oil etc to deployed air bag inflator module and to activate seat belt pretensioner After...

Page 3067: ...to diagnose DISPOSAL Do not dispose of the live undeployed air bag inflator modules and the live inactivated seat belt pretensioners When disposal is necessary be sure to deploy activate the air bag...

Page 3068: ...m SDM CAUTION As this connector has a connector lock lever refer to the left figure for its removal procedure 5 Remove SDM from vehicle INSPECTION CAUTION Do not connect a tester whatever type it may...

Page 3069: ...able air bag system Refer to Disabling Air Bag System ear lier in this section 5 Remove passenger air bag inflator module attaching bolts 3 and passenger air bag inflator module 4 from vehicle WARNING...

Page 3070: ...l glove box clips 3 4 Connect negative battery cable to battery 5 Enable air bag system Refer to Enabling Air Bag System earli er in this section DRIVER AIR BAG INFLATOR MODULE Refer to SECTION 3C for...

Page 3071: ...g precautions must be observed for this work Failure to observe any of them may result in personal injury To avoid an accidental deployment this work should be performed by no more than one person The...

Page 3072: ...shorted and not be connected to a power source until the air bag is to be deployed and seat belt pretensioner is to be activated 4 Remove air bag inflator module s and seat belt pretension er s from...

Page 3073: ...tion where there is no activity is preferred If an outdoor location is not available a space on the shop floor where there is no activity and sufficient ven tilation is recommended Ensure no loose or...

Page 3074: ...to use the following bolt and nut for fixing pas senger air bag inflator module to mounting attach ment Size M8 Strength 7T Securely hand tighten all fastener prior to deployment In case of seat belt...

Page 3075: ...of Seat Belt Pretensioner Verify that the seat belt pretensioner with its warning label at tached side facing up as shown in the figure on the ground in the space just cleared Connect adaptor cable t...

Page 3076: ...rness to the power source 12 V ve hicle battery to immediately deploy activate the air bag or seat belt pretensioner 14 Disconnect the deployment harness from power source 12 V vehicle battery and sho...

Page 3077: ...pretensioner did not activate after following these proce dures 20 Ensure that the deployment harness has been disconnected from the power source and that its two banana plugs have been shorted toget...

Page 3078: ...nect contact coil connector Yellow connector located near the base of the steering column For passenger air bag inflator module Remove glove box from instrument panel and disconnect pas senger air bag...

Page 3079: ...acti vates the rapid gas expansion will create a substantial report Wear suitable ear protection Notify all people in the immediate area that you intend to deploy the air bag inflator module or to act...

Page 3080: ...er each deployment activation and replaced if necessary 19 Carefully remove drop cloth from vehicle and clean off any frag ments or discard drop cloth entirely 20 Repeat Steps 2 through 19 to deploy a...

Page 3081: ...and the seat belt pretensioner im mediately after deployment activation is very hot Wait for 10 min utes to cool it off before handling them Never apply water oil etc to deployed air bag inflator mod...

Page 3082: ...9932 75050 PAB deployment fixture bracket PAB Passenger air bag inflator module 09932 78310 Adapter cable 09932 78320 Deployment adapter cable 09931 76011 SUZUKI scan tool Tech 1A kit 09931 76030 16 1...

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Page 3086: ...Prepared by Overseas Service Department 1st Ed December 1999 Printing January 2000 1064...

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Suzuki WagonR+ RB310, Service Manual

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