Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 Strict observance of the so specified items will enable one 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 as specified in each description.
Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Page 5: Table Of Contents
TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Steering ............... 6-i General Information ..........0A-1 Precautions .............. 6-1 Maintenance and Lubrication ......... 0B-1 Steering General Diagnosis ........6A-1 Steering Wheel and Column ........6B-1 Engine .................
Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions for Electrical Circuit Service .... 00-8 Air Bag Warning ..........00-10 Precautions............00-1 Air Bag System Service Warning ...... 00-10 Precautions for Vehicles Equipped with a Fastener Caution..........00-11 Supplemental Restraint (Air Bag) System ..
Page 8: Precautions
• If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 9 Precautions: 00-2 Servicing and Handling • After an air bag (inflator) module has been deployed, the surface of the air bag may WARNING contain a powdery residue. This powder consists primarily of cornstarch (used to Many of service procedures require lubricate the bag as it inflates) and by- disconnection of “A/B”...
Page 10: General Precautions
00-3 Precautions: • Even when the accident was light enough not to WARNING cause air bags to activate, be sure to inspect system parts and other related parts according to instructions • For handling and storage of a SDM, select under “Repair and Inspection Required after Accident a place where the ambient temperature in Section 8B”.
Page 11: Exhaust System
Precautions: 00-4 – Do not swallow any of these service WARNING materials. It would cause diarrhea or nausea. • Whenever raising a vehicle for service, be sure to follow the instructions under – Keep all these materials out of children’s “Vehicle Lifting Points in Section 0A”.
Page 12 “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 • When removing parts that are to be reused, be sure to...
Page 13: Warning For Wheel (With Tire) Removal
Precautions: 00-6 • After servicing fuel, oil, coolant, vacuum, exhaust or • Always be careful not to handle electrical parts brake systems, check all lines related to the system (computer, relay, etc.) in a rough manner or drop for leaks. them.
Page 14: Precautions In Servicing 4Wd Model
00-7 Precautions: Precautions in Servicing 4WD Model • When testing with 2-wheel brake tester, be S6RW0D0000014 sure to observe the following instructions. CAUTION Otherwise, drivetrain damage and personal injury may result. • Never perform any of the following [A], [B] –...
Page 15: Precautions For Installing Mobile Communication Equipment
Precautions: 00-8 Precautions for Installing Mobile Precautions for Electrical Circuit Service S6RW0D0000007 Communication Equipment • When replacing a fuse, make sure to use a fuse of the S6RW0D0000005 When installing mobile communication equipment such specified capacity. Use of a fuse with a larger capacity as CB (Citizens-Band)-radio or cellular-telephone, be will cause a damage to the electrical parts and a fire.
Page 16 00-9 Precautions: • When connecting connectors, also hold connectors • Be careful not to touch the electrical terminals of parts and put them together until they lock securely (a click which use microcomputers (e.g. electronic control unit is heard). like as ECM, PCM, P/S controller, etc.). The static electricity from your body can damage these parts.
Page 17: Air Bag Warning
Never connect probe where male terminal is only by an authorized SUZUKI dealer. Refer supposed to fit. to “Air Bag System Components, Wiring and Connectors Location in Section 8B” in...
Page 18: Fastener Caution
00-11 Precautions: Fastener Caution Wheels and Tires Caution S6RW0D0000010 S6RW0D0000012 CAUTION CAUTION When fasteners are removed, always reinstall All wheel fasteners are important attaching them at the same location from which they parts in that they could affect the were removed. If a fastener needs to be performance of vital parts and systems, and/ replaced, use the correct part number or could result in major repair expense.
Page 19: Repair Instructions
Precautions: 00-12 Repair Instructions Electrical Circuit Inspection Procedure 4) Using continuity check or voltage check the following S6RW0D0006001 procedure, check the wire harness for open circuit While there are various electrical circuit inspection and poor connection with its terminals. Locate methods, described here is a general method to check abnormality, if any.
Page 20 00-13 Precautions: Voltage Check Short Circuit Check (Wire Harness to Ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect negative (–) cable at battery. check can be used as circuit check. 2) Disconnect connectors at both ends of the circuit to 1) With all connectors connected and voltage applied to be checked.
Page 21: Intermittent And Poor Connection Inspection
Precautions: 00-14 Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S6RW0D0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.
Page 22 00-15 Precautions:...
Page 23: Maintenance And Lubrication
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 PCV Valve Inspection .........0B-6 Fuel Evaporative Emission Control System General Description ..........0A-1 Inspection............0B-6 Abbreviations ............0A-1 Brake Discs and Pads (Front) Inspection....0B-7 Symbols .............. 0A-2 Brake Drums and Shoes (Rear) Inspection ..0B-7 Wire Color Symbols ..........
Page 24 0A-1 General Information: General Information General Information General Description Abbreviations S6RW0D0101001 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center GEN: Generator ABS: Anti-lock Brake System GND: Ground AC: Alternating Current GPS: Global Positioning System A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HAVC: Heating, Ventilating and Air Conditioning A/F: Air Fuel Mixture Ratio HC: Hydrocarbons...
Page 25: Differential
WU-TWC: Warm Up Three Way Catalytic Converter Symbols S6RW0D0101002 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
Page 26 0A-3 General Information: There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “GRN”). The dual-colored wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of the wire (“GRN”...
Page 27 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 28: Rear Suspension
0A-5 General Information: Vehicle Lifting Points S6RW0D0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may 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.
Page 29: Vehicle Identification Number
General Information: 0A-6 Vehicle Identification Number In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against engine front mounting S6RW0D0101006 The number is punched on the front dash panel in member (1) or rear jacking bracket (2). engine room and it is also attached on the left side of instrument panel depending on the vehicle specification.
Page 30 0A-7 General Information: Component Location Warning, Caution and Information Labels Location S6RW0D0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
Page 31 General Information: 0A-8 I6RW0D010001-01 1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM 2. Air bag label on contact coil assembly 7. Pretensioner label on seat belt retractor 3. Air bag label on passenger air bag (inflator) module 8.
Page 32: Fuel System
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S6RW0D0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S6RW0D0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
Page 33 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Fluid level (I: — — — Replace every 165,000 km (99,000 Automatic transaxle fluid Fluid change (R: miles) Fluid hose (i: — — — — — Transfer oil (4WD) (leakage, level) (I: —...
Page 34 0B-3 Maintenance and Lubrication: Severe Maintenance Maintenance Maintenance interval condition code operation First time only: 15,000 km (9,000 miles) or 12 Manual transaxle oil months – B – – E – – H Transfer oil (4WD) Second time and after: Differential oil (4WD) Every 30,000 km (18,000 miles) or 24 months reckoning from 0 km (0...
Page 35: Engine Oil And Filter Change
Maintenance and Lubrication: 0B-4 Engine Oil and Filter Change NOTE S6RW0D0206004 Before fitting new oil filter, be sure to oil its WARNING O-ring. Use engine oil for this purpose. • New and used engine oil can be hazardous. Be sure to read “WARNING” in “General Precautions in Section 00”...
Page 36: Engine Coolant Change
0B-5 Maintenance and Lubrication: Engine Coolant Change 6) Replenish oil until oil level is brought to FULL level mark on dipstick (oil pan and oil filter capacity). The S6RW0D0206005 Change engine coolant with new one referring to filler inlet is at the top of the cylinder head cover. It is “Cooling System Flush and Refill in Section 1F”.
Page 37: Air Cleaner Filter Inspection
Maintenance and Lubrication: 0B-6 Air Cleaner Filter Inspection Fuel Filter Replacement S6RW0D0206008 S6RW0D0206041 Fuel filter is installed in fuel pump assembly in fuel tank. 1) Remove air cleaner case clamps. Replace fuel filter or fuel pump assembly with new one, 2) Take air cleaner filter out of case.
Page 38: Brake Discs And Pads (Front) Inspection
0B-7 Maintenance and Lubrication: Brake Discs and Pads (Front) Inspection Brake Hoses and Pipes Inspection S6RW0D0206014 S6RW0D0206016 Perform this inspection where these is enough light and 1) Remove wheel and caliper but don’t disconnect use a mirror as necessary. brake hose from caliper. •...
Page 39: Clutch Fluid Inspection
Maintenance and Lubrication: 0B-8 Tires Inspection 2) Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. S6RW0D0206020 1) Check tires for uneven or excessive wear, or 3) Check parking brake lever for proper operation and damage.
Page 40: Suspension System Inspection
0B-9 Maintenance and Lubrication: Suspension System Inspection 2) Check bolts and nuts for tightness and retighten S6RW0D0206023 them as necessary. Repair or replace defective • Inspect front struts and rear shock absorbers for parts, if any. evidence of oil leakage, dents or any other damage on 3) Check steering linkage for looseness and damage.
Page 41: Propeller Shaft (4Wd) Inspection
Maintenance and Lubrication: 0B-10 Propeller Shaft (4WD) Inspection Transfer Oil Inspection (4WD) S6RW0D0206026 S6RW0D0206040 Check transfer oil for leakage, contamination and level 1) Check propeller shaft connecting bolts for referring to “Transfer Oil Level Check in Section 3C”. looseness. If looseness is found, tighten to specified torque.
Page 42: Hvac Air Filter (If Equipped) Inspection
0B-11 Maintenance and Lubrication: HVAC Air Filter (If Equipped) Inspection On automatic transaxle vehicles, try to start the engine in S6RW0D0206034 each select lever position. The starting motor should Check HVAC air filter for dirt and dust referring to “HVAC crank only in “P”...
Page 43: Specifications
Maintenance and Lubrication: 0B-12 Meters and Gauge Steering Check that speedometer, odometer, fuel meter, • Check to ensure that steering wheel is free from temperature gauge, etc. are operating accurately. instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one Lights side.
Page 44 0B-13 Maintenance and Lubrication:...
Page 45 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 For Vehicle Equipped with A/T......1A-36 Fail-Safe Table..........1A-36 Precautions............. 1-1 Scan Tool Data ..........1A-38 Precautions for Engine.......... 1-1 Visual Inspection ..........1A-43 Engine General Information and Engine Basic Inspection........1A-43 Engine Symptom Diagnosis ......1A-45 Diagnosis ..........
Page 46 1-ii Table of Contents DTC P0123: Throttle Position Sensor (Main) DTC P2101: Throttle Actuator Control Motor Circuit High .............1A-89 Circuit Range / Performance......1A-144 DTC P0131 / P0132: O2 Sensor (HO2S) DTC P2102: Throttle Actuator Control Motor Circuit Low Voltage / High Voltage (Sensor- Circuit Low ............1A-146 1) ..............1A-92 DTC P2103: Throttle Actuator Control Motor...
Page 47 Table of Contents 1-iii EGR Valve Removal and Installation (If Diagnostic Information and Procedures ....1D-5 Equipped)............1B-4 Compression Check..........1D-5 EGR Valve Inspection (If Equipped) ....1B-4 Engine Vacuum Check........1D-6 PCV Hose Inspection .......... 1B-5 Valve Lash (Clearance) Inspection .....1D-7 PCV Valve Inspection ......... 1B-5 Repair Instructions ..........1D-10 Special Tools and Equipment ......1B-5 Air Intake System Components......1D-10...
Page 48 1-iv Table of Contents Crankshaft Inspection ........1D-63 Radiator Removal and Installation ...... 1F-9 Main Bearings Inspection........1D-65 Water Pump / Generator Drive Belt Tension Sensor Plate Inspection ........1D-70 Inspection and Adjustment......1F-10 Rear Oil Seal Inspection ........1D-70 Water Pump / Generator Drive Belt Removal Flywheel Inspection...........1D-70 and Installation ..........
Page 49 Table of Contents 1-v Diagnostic Information and Procedures....1H-4 Charging System ........1J-1 Ignition System Symptom Diagnosis....1H-4 General Description ..........1J-1 Reference Waveform of Ignition System.....1H-4 Battery Description..........1J-1 Ignition System Check ........1H-4 Generator Description ......... 1J-3 Ignition Spark Test ..........1H-6 Diagnostic Information and Procedures .... 1J-4 Repair Instructions ..........1H-6 Battery Inspection ..........
Page 50: Precautions
1-1 Precautions: Precautions Engine Precautions Precautions for Engine S6RW0D1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions of ECM Circuit Inspection Refer to “Precautions of ECM Circuit Inspection in Section 1A”.
Page 51: Engine General Information And Diagnosis
• Diagnostic information stored in ECM memory can be S6RW0D1100006 There are two types of On-Board Diagnostic (OBD) cleared as well as checked by using SUZUKI scan system, Euro OBD system and non-Euro-OBD system, tool or CAN communication OBD generic scan tool.
Page 52: Precautions For Dtc Troubleshooting
• Before performed trouble shooting, be sure to read the scan tool used. the “Precautions of ECM Circuit Inspection”. – SUZUKI scan tool displays DTC detected by ECM. • When measuring circuit voltage, resistance and/or – CAN communication OBD generic scan tool...
Page 53: Precaution On Can Troubleshooting
Engine General Information and Diagnosis: 1A-3 Precaution on CAN Troubleshooting S6RW0D1100007 CAN schematic and routing diagram : [C] : [D] : [E] I6RW0D110001-01...
Page 54 Bus check with SUZUKI scan tool SUZUKI scan tool (SUZUKI-SDT) efficiently diagnoses a CAN bus malfunction by “Communication Bus Check” and “Communication Malfunction DTC” under “Bus check”.
Page 55: General Description
Engine General Information and Diagnosis: 1A-5 General Description Statement on Cleanliness and Care Engine Diagnosis General Description S6RW0D1101001 S6RW0D1101002 An automobile engine is a combination of many NOTE machined, honed, polished and lapped surfaces with There are two types of OBD system tolerances that are measured in the thousands of an depending on the vehicle specification.
Page 56 1 driving cycle of the DTC which is • It is possible to communicate via DLC (3) by using not detected in the 2 driving cycle detection logic. only SUZUKI scan tool (2) but also CAN communication OBD generic scan tool. (Diagnostic Freeze Frame Data information can be accessed by using a scan tool.)
Page 57 • Knock sensor erased unless the power to ECM is shut off for • Wheel speed sensor specified time or it is cleared by SUZUKI scan tool (SUZUKI-SDT) (2).) • CPU (Central Processing Unit) of ECM For further detail of the checking / clearing procedure, •...
Page 58: Data Link Connector (Dlc)
OBD CAN Hi line (6) and Low line (3) (CAN line of ISO 15765-4) are used for SUZUKI scan tool (SUZUKI-SDT) (7) or CAN communication OBD generic scan tool to communicate with ECM (included in immobilizer control) and TCM (Transmission Control Module) (for A/T model).
Page 59: Can Communication System Description
Engine General Information and Diagnosis: 1A-9 CAN Communication System Description S6RW0D1101005 ECM (1), ABS control module (2), BCM (3), combination meter (4), keyless start control module (if equipped with keyless start control system) (5), 4WD control module (for 4WD model) (6)and TCM (for A/T model) (7) of this vehicle communicate control data between each control module.
Page 60 1A-10 Engine General Information and Diagnosis: ECM Transmission Data Keyless Start Combination 4WD Control Control Meter Module Module Driving cycle active Warm up cycle active Throttle position signal A/C compressor clutch signal A/C refrigerant pressure signal Fuel consumption signal Engine coolant temperature signal Fuel level signal Transmit DATA...
Page 61: Air Intake System Description
Engine General Information and Diagnosis: 1A-11 Air Intake System Description S6RW0D1101006 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Description of Electric Throttle Body System”.), and intake manifold (4). The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner, distributed by the intake, and finally drawn into each combustion chamber.
Page 62: Immobilizer Control System
1A-12 Engine General Information and Diagnosis: Operation Description ECM (5) detects opening (depressed extent of pedal) of the accelerator pedal based on signal voltage of the APP sensor (1) and using that data and engine operation condition, it calculates the optimum throttle valve opening. On the other hand, it detects the throttle valve opening based on the signal voltage of the throttle position sensor (3) included in the throttle body (2) and compares it with the above calculated optimum throttle valve opening.
Page 63 Engine General Information and Diagnosis: 1A-13 Engine and Emission Control System Flow Diagram I6RW0D110004-03...
Page 64 1A-14 Engine General Information and Diagnosis: ECM Input / Output Circuit Diagram E01-35 E01-45 E01-37 E01-32 E01-52 C01-45 E01-34 C01-44 E01-36 C01-43 E01-51 C01-54 E01-50 C01-40 C01-42 RED/YEL C01-20 C01-41 C01-1 BLU/YEL C01-2 BLU/WHT C01-21 BLK/ORN C01-16 BLU/RED C01-17 BLU/ORN C01-57 C01-10 C01-29...
Page 65 Engine General Information and Diagnosis: 1A-15 7. HO2S-2 (if equipped) 31. Fuel injector No.1 55. Starting motor control relay 8. Knock sensor 32. Fuel injector No.2 56. Transmission range switch (A/T model) 9. MAF and IAT sensor 33. Fuel injector No.3 57.
Page 66 1A-16 Engine General Information and Diagnosis: Connector: C01 Terminal Wire color Circuit Terminal Wire color Circuit BLU/YEL Fuel injector No.1 output — — BLU/WHT Fuel injector No.2 output — — EGR valve (stepper motor coil 2) GRN/ORN — — output EGR valve (stepper motor coil 1) GRN/RED —...
Page 67 Engine General Information and Diagnosis: 1A-17 Connector: E01 Terminal Wire color Circuit Terminal Wire color Circuit BLK/RED Main power supply Ground for ECM Power source for ECM internal Power supply of throttle WHT/RED memory actuator drive circuit. CAN communication line (active high signal) to ABS control —...
Page 68: Engine And Emission Control Input / Output Table
1A-18 Engine General Information and Diagnosis: Engine and Emission Control Input / Output Table S6RW0D1101010 ELECTRIC CONTROL DEVICE OUTPUT INPUT BAROMETRIC PRESSURE SENSOR BRAKE LIGHT SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C) BLOWER SWITCH A/C SWITCH (if equipped with A/C) A/C EVAP OUTLET AIR TEMP.
Page 69: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-19 Schematic and Routing Diagram Engine and Emission Control System Diagram S6RW0D1102001 I5RW0C110009-02...
Page 70 1A-20 Engine General Information and Diagnosis: 1. Air cleaner 17. Radiator cooling fan 33. A/C switch (A/C model) 2. EVAP canister purge valve 18. A/C condenser cooling fan 34. A/C evaporator outlet air temp. sensor (manual A/C model) 3. MAF and IAT sensor 19.
Page 71: Component Location
Engine General Information and Diagnosis: 1A-21 Component Location Electronic Control System Components Location S6RW0D1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0D110016-03 Information sensors Control devices Others 1.
Page 72: Diagnostic Information And Procedures
1A-22 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine and Emission Control System Check S6RW0D1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Page 73 Engine General Information and Diagnosis: 1A-23 Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition?
Page 74 1A-24 Engine General Information and Diagnosis: Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 75: Malfunction Indicator Lamp (Mil) Check
Engine General Information and Diagnosis: 1A-25 Step 2: DTC / Freeze Frame Data Check, Record and Step 10: Intermittent Problems Check Clearance Check parts where an intermittent trouble is easy to First, check DTC (including pending DTC), referring to occur (e.g., wire harness, connector, etc.), referring to “DTC Check”.
Page 76: Dtc Clearance
Board Diagnostic (OBD) System”. – 4WD control module – HVAC control module (Auto A/C model) 1) Connect SUZUKI scan tool or CAN communication – P/S control module OBD generic scan tool to data link connector in the same manner as when making this connection for...
Page 77 Engine General Information and Diagnosis: 1A-27 Wiring Diagram C06-17 C06-7 G26-22 G26-23 C01-13 C01-12 E01-3 G241-9 E01-18 G241-6 G241-7 G241-10 E08-12 E08-1 E08-2 E08-13 G16-19 G16-18 E04-2 E04-1 G04-4 G04-2 G04-3 G04-1 G26-22 C06-17 G26-23 C06-7 C01-13 G241-9 C01-12 E01-3 G241-6 E01-18 G241-7...
Page 78 1A-28 Engine General Information and Diagnosis: [A]: Non-Taiwan model [K]: Combination meter connector (viewed from terminal side) [B]: Taiwan model 1. ECM [C]: DLC connector (viewed from terminal side) 2. ABS control module [D]: ECM connector (viewed from harness side) 3.
Page 79 Engine General Information and Diagnosis: 1A-29 Troubleshooting Step Action Scan tool check Go to Step 2. Scan tool faulty. Refer to its operator’s manual. 1) Disconnect scan tool from DLC with ignition switch turned OFF. 2) Check for proper connection to all terminals of scan tool connector.
Page 80 1A-30 Engine General Information and Diagnosis: Step Action CAN line check between DLC and BCM Go to Step 6. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect BCM connector from BCM. 3) Check for proper connection to all terminals of BCM connector.
Page 81 Engine General Information and Diagnosis: 1A-31 Step Action Communication check between scan tool and ECM A/T model: Go to Step Go to Step 4 through Step 11 of 1) Turn ignition switch to OFF position. “Troubleshooting for M/T model: Substitute a 2) Connect ECM, BCM, ABS control module and CAN-DTC”.
Page 82: Dtc Table
1A-32 Engine General Information and Diagnosis: DTC Table S6RW0D1104005 NOTE • There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. • For non-Euro-OBD model, some of DTC No. with delta ( ) mark in the following table can not be detected by ECM depending on vehicle specification.
Page 83 Engine General Information and Diagnosis: 1A-33 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Engine coolant temperature circuit 1 driving *P0117 Circuit voltage of ECT sensor is less than specification. cycle Engine coolant temperature circuit 1 driving *P0118 Circuit voltage of ECT sensor is more than specification.
Page 84 1A-34 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Catalyst system efficiency below 2 driving Output waveforms of HO2S-1 and HO2S-2 are similar. *P0420 threshold cycles Evaporative emission system purge Monitor signal of EVAP canister purge valve is different 2 driving *P0443 control valve circuit...
Page 85 Engine General Information and Diagnosis: 1A-35 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Difference between the opening angle based on Pedal position sensor (main / sub) accelerator pedal position sensor (main) and the opening 1 driving *P2138 voltage correlation angle based on accelerator pedal position sensor (sub) is...
Page 86: For Vehicle Equipped With A
1A-36 Engine General Information and Diagnosis: For Vehicle Equipped with A/T S6RW0D1104081 NOTE There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. When using CAN communication OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on CAN communication OBD generic scan tool simultaneously.
Page 87 Engine General Information and Diagnosis: 1A-37 DTC No. Detected item Fail-safe operation • ECM turns off throttle actuator control relay and throttle valve is fixed at the opening of about 7° from its completely closed position (default P0122 Throttle position sensor (main) circuit low opening).
Page 88: Scan Tool Data
1A-38 Engine General Information and Diagnosis: Scan Tool Data S6RW0D1104007 As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 89 Engine General Information and Diagnosis: 1A-39 Normal condition / Scan tool data Vehicle condition reference values SHORT FT B1 At specified idle speed after warming up –20 – +20% (SHORT TERM FUEL TRIM) LONG FT B1 At specified idle speed after warming up –20 –...
Page 90 1A-40 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values Engine coolant temp.: lower RADIATOR FAN than 97.5 °C (207.5 °F) (RADIATOR COOLING FAN Ignition switch ON Engine coolant temp.: 100 CONTROL RELAY) °C (212 °F) Blower motor switch and A/C A/C COND FAN switch turned ON/ECT over...
Page 91 Engine General Information and Diagnosis: 1A-41 Scan Tool Data Definitions FUEL SYSTEM B1 (FUEL SYSTEM STATUS) Air/fuel ratio feedback loop status displayed as one of COOLANT TEMP (ENGINE COOLANT TEMPERATURE, °C, °F) the followings. OPEN: Open-loop has not yet satisfied conditions to go It is detected by engine coolant temp.
Page 92 1A-42 Engine General Information and Diagnosis: A/C COND FAN (A/C CONDENSER COOLING FAN CANIST PRG DUTY (EVAP CANISTER PURGE FLOW DUTY, %) CONTROL RELAY, ON/OFF) This parameter indicates valve ON (valve open) time ON: Command for A/C condenser cooling fan control rate within a certain set cycle of EVAP canister purge relay operation being output.
Page 93: Visual Inspection
Engine General Information and Diagnosis: 1A-43 INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH, THROTTLE MOTOR RELAY (ON/OFF) ON: Throttle actuator (motor) control activated by ECM. msec.) OF: Throttle actuator (motor) control stopped by ECM. This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (but injector VEHICLE SPEED (km/h, mph) drive time of NO.1 cylinder for multiport fuel injection).
Page 94 1A-44 Engine General Information and Diagnosis: Step Action Check keyless start control system malfunction Go to Step 5. Keyless start control system malfunction. 1) Check keyless start control system referring to “Keyless Start System Operation Inspection in Section 10E”. Is check result satisfactory? Is engine cranked? Go to Step 6.
Page 95: Engine Symptom Diagnosis
Engine General Information and Diagnosis: 1A-45 Engine Symptom Diagnosis S6RW0D1104010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H”...
Page 96 1A-46 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noise – Valve Improper valve lash “Camshaft, Tappet and Shim Inspection in noise Section 1D” Worn valve stem and guide “Valves and Valve Guides Inspection in NOTE Section 1D”...
Page 97 Engine General Information and Diagnosis: 1A-47 Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection in Section 1F” Poor water pump performance “Water Pump Inspection in Section 1F” Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning in Section 1F”...
Page 98 1A-48 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive engine oil Sticky piston ring “Cylinders, Pistons and Piston Rings consumption – Oil Inspection in Section 1D” entering combustion Worn piston and cylinder “Cylinders, Pistons and Piston Rings chamber Inspection in Section 1D”...
Page 99 Engine General Information and Diagnosis: 1A-49 Condition Possible cause Correction / Reference Item Excessive detonation – Faulty spark plug “Spark Plug Inspection in Section 1H” Engine makes Loose connection of high-tension cord “High-Tension Cord Removal and Installation continuously sharp in Section 1H” metallic knocks that Engine overheating Condition “Engine overheating”...
Page 100 1A-50 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection in Section 1H” engine fails to idle Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation in Section 1H”...
Page 101 Engine General Information and Diagnosis: 1A-51 Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation monoxide (CO) in Section 1H”...
Page 102: Malfunction Indicator Lamp Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)
1A-52 Engine General Information and Diagnosis: Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S6RW0D1104011 Wiring Diagram C01-13 C01-12 E01-3 E01-18 RED/BLK BLK/ORN G241-31 G241-16 BLK/YEL BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30...
Page 103 Engine General Information and Diagnosis: 1A-53 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action MIL power supply check...
Page 104: Malfunction Indicator Lamp Remains On After Engine Starts
1A-54 Engine General Information and Diagnosis: Malfunction Indicator Lamp Remains ON after Engine Starts S6RW0D1104012 Wiring Diagram Refer to “Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)”. Circuit Description When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point).
Page 105: Dtc P0010: Camshaft Position Actuator Circuit (For Engine With Vvt System)
Engine General Information and Diagnosis: 1A-55 DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system) S6RW0D1104013 System and Wiring Diagram GRN/RED C01-60 C01-58 BLK/ORN C01-59 GRN/WHT C01-15 C01-30 E01-31 [A]: 39 38 32 31 39 38 32 31 54 53 47 46 54 53...
Page 106 1A-56 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 107: Dtc P0011 / P0012: Camshaft Position - Timing Over-Advanced Or System Performance / Retarded (For Engine With Vvt System)
Engine General Information and Diagnosis: 1A-57 Step Action Oil control valve check Substitute a known- Faulty oil control valve. Check oil control valve referring to “Oil Control Valve good ECM and recheck. Inspection (For Engine with VVT) in Section 1D”. Is resistance within specified value? DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system)
Page 108 Installation in Section temperature. 1D”. If OK, go to Step 5. 3) Select menu to “Data List”. 4) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 3°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.
Page 109: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)
Engine General Information and Diagnosis: 1A-59 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S6RW0D1104015 Wiring Diagram BLK/WHT E01-29 BLK/WHT BLK/RED C01-46 C01-10 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110020-01...
Page 110 1A-60 Engine General Information and Diagnosis: Step Action HO2S-1 heater power circuit check Go to Step 3. “BLK/WHT” wire is open circuit or shorted to 1) Disconnect connector from HO2S-1 with ignition switch ground circuit. turned OFF. 2) Check for proper connection to HO2S-1 at “BLK/WHT” and “BLK/RED”...
Page 111: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2)
Engine General Information and Diagnosis: 1A-61 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) S6RW0D1104016 Wiring Diagram BLK/WHT E01-29 BLK/WHT RED/BLU C01-47 C01-11 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110021-01...
Page 112 1A-62 Engine General Information and Diagnosis: Step Action HO2S-2 heater power circuit check Go to Step 3. “BLK/WHT” wire is open circuit or shorted to 1) Disconnect connector from HO2S-2 with ignition switch ground circuit. turned OFF. 2) Check for proper connection to HO2S-2 at “BLK/WHT” and “RED/BLU”...
Page 113: Dtc P0101: Mass Air Flow Circuit Range / Performance
Engine General Information and Diagnosis: 1A-63 DTC P0101: Mass Air Flow Circuit Range / Performance S6RW0D1104017 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED E01-16 BLK/RED GRN/BLK C01-26 C01-27 BLK/YEL C01-25 GRY/BLU GRY/BLU...
Page 114 1A-64 Engine General Information and Diagnosis: 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 an accident. •...
Page 115 Engine General Information and Diagnosis: 1A-65 Step Action MAF sensor output voltage check Poor “C01-26” and/or Go to Step 5. “C01-27” terminal 1) Turn OFF ignition switch. connection. 2) Remove ECM from its bracket with ECM connectors If OK, substitute a connected.
Page 116: Dtc P0102: Mass Air Flow Circuit Low Input
1A-66 Engine General Information and Diagnosis: Step Action 10 MAF sensor signal circuit check Faulty MAF and IAT “GRN/BLK” wire is open sensor. or high resistance 1) Measure resistance between “GRN/BLK” wire terminal circuit. of MAF and IAT sensor connector and “C01-26” terminal of ECM connector.
Page 117: Dtc P0103: Mass Air Flow Circuit High Input
Engine General Information and Diagnosis: 1A-67 Step Action MAF sensor ground circuit check Go to Step 6. Go to Step 5. 1) Turn OFF ignition switch, measure resistance between “GRY” wire terminal of MAF and IAT sensor connector and engine ground. Ω...
Page 118 1A-68 Engine General Information and Diagnosis: 3) Start engine and run it for 10 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check”...
Page 119: Dtc P0106: Manifold Absolute Pressure Range / Performance
Engine General Information and Diagnosis: 1A-69 DTC P0106: Manifold Absolute Pressure Range / Performance S6RW0D1104020 Wiring Diagram GRY/RED GRY/RED C01-14 RED/BLK C01-53 C01-58 BLK/ORN GRY/BLU GRY/BLU C01-55 C01-15 C01-30 E01-31 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 120: Dtc P0107: Manifold Absolute Pressure Circuit Low Input
1A-70 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 121 Engine General Information and Diagnosis: 1A-71 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 122: Dtc P0108: Manifold Absolute Pressure Circuit High Input
1A-72 Engine General Information and Diagnosis: Step Action MAP sensor output signal check Substitute a known- Faulty MAP sensor. good ECM and recheck. 1) Check MAP sensor according to “Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped) in Section 1C”. Is it in good condition? DTC P0108: Manifold Absolute Pressure Circuit High Input S6RW0D1104022...
Page 123 Engine General Information and Diagnosis: 1A-73 Step Action MAP sensor power supply voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from MAP sensor with ignition switch turned OFF. 2) Check for proper connection of MAP sensor at “GRY/ RED”, “RED/BLK”...
Page 124: Dtc P0111: Intake Air Temperature Circuit Range / Performance
1A-74 Engine General Information and Diagnosis: Step Action MAP sensor output signal check Substitute a known- Faulty MAP sensor. good ECM and recheck. 1) Check MAP sensor according to “Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped) in Section 1C”. Is it in good condition? DTC P0111: Intake Air Temperature Circuit Range / Performance S6RW0D1104023...
Page 125 Engine General Information and Diagnosis: 1A-75 5) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 126: Dtc P0112: Intake Air Temperature Sensor Circuit Low
1A-76 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 6. “BLK/YEL” wire is shorted to ground or 1) Disconnect connectors from ECM with ignition switch other circuit. turned OFF. If wire is OK, substitute 2) Measure resistance between “BLK/YEL” wire terminal of a known-good ECM and MAF and IAT sensor connector and vehicle body recheck.
Page 127 Engine General Information and Diagnosis: 1A-77 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and run it for 10 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to...
Page 128: Dtc P0113: Intake Air Temperature Sensor Circuit High
1A-78 Engine General Information and Diagnosis: Step Action IAT short circuit check Go to Step 6. “BLK/YEL” wire is shorted to other circuit. 1) Turn ON ignition switch. If wire is OK, substitute 2) Measure voltage between “BLK/YEL” wire terminal of a known-good ECM and MAF and IAT sensor connector and vehicle body recheck.
Page 129 Engine General Information and Diagnosis: 1A-79 Step Action IAT sensor voltage check Go to Step 7. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “BLK/YEL”...
Page 130: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance
1A-80 Engine General Information and Diagnosis: Step Action Ground circuit check “GRY/BLU” wire is open Faulty ECM ground circuit or high resistance circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors circuit. Poor “C01-55” substitute a known- connected.
Page 131 Engine General Information and Diagnosis: 1A-81 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 an accident. •...
Page 132 1A-82 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Disconnect ECT sensor connector with ignition switch turned OFF. 2) Check for proper connection to ECT sensor connector at “GRY/BLU” and “LT GRN” wire terminals. 3) If OK, then with ignition switch ON, measure voltage between “LT GRN”...
Page 133: Dtc P0117: Engine Coolant Temperature Circuit Low
Engine General Information and Diagnosis: 1A-83 Step Action 10 Ground circuit check “GRY/BLU” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C01-55” If circuit is OK, connection. substitute a known- 2) Measure resistance between “C01-55”...
Page 134 1A-84 Engine General Information and Diagnosis: Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “LT GRN” and “GRY/BLU”...
Page 135: Dtc P0118: Engine Coolant Temperature Circuit High
Engine General Information and Diagnosis: 1A-85 DTC P0118: Engine Coolant Temperature Circuit High S6RW0D1104028 Wiring Diagram Refer to “DTC P0116: Engine Coolant Temperature Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of ECT sensor output is more than specified value with engine running. •...
Page 136 1A-86 Engine General Information and Diagnosis: Step Action ECM voltage check “LT GRN” wire is open Go to Step 5. circuit. If wire and 1) Turn OFF ignition switch. connection are OK, go 2) Remove ECM from its bracket with ECM connectors to Step 5.
Page 137: Dtc P0122: Throttle Position Sensor (Main) Circuit Low
Engine General Information and Diagnosis: 1A-87 DTC P0122: Throttle Position Sensor (Main) Circuit Low S6RW0D1104029 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 E01-45 E01-32 C01-45 C01-44 C01-43 C01-54 C01-40 C01-42...
Page 138 1A-88 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 139: Dtc P0123: Throttle Position Sensor (Main) Circuit High
Engine General Information and Diagnosis: 1A-89 Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C01-43” terminal of ECM connector and engine ground.
Page 140 1A-90 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 141 Engine General Information and Diagnosis: 1A-91 Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Measure voltage between “GRN” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned ON. Is voltage 4 –...
Page 142: Dtc P0131 / P0132: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-1)
1A-92 Engine General Information and Diagnosis: DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) S6RW0D1104031 Wiring Diagram BLK/WHT E01-29 BLK/WHT BLK/RED C01-46 C01-10 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 143 Engine General Information and Diagnosis: 1A-93 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 an accident. •...
Page 144 1A-94 Engine General Information and Diagnosis: Step Action HO2S-1 ground check Go to Step 5. “ORN” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-1 with ignition switch Poor “C01-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-1 connector at ground.
Page 145: Dtc P0133: O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)
Engine General Information and Diagnosis: 1A-95 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) S6RW0D1104032 Wiring Diagram Refer to “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Response time (time to change from lean to rich or from rich to lean) of HO2S-1 output...
Page 146: Dtc P0134: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-1)
1A-96 Engine General Information and Diagnosis: DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1) S6RW0D1104033 Wiring Diagram Refer to “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S voltage is higher than specified value for 1 min.
Page 147 Engine General Information and Diagnosis: 1A-97 Step Action HO2S-1 output voltage check Intermittent trouble. Go to Step 3. Check for intermittent 1) Connect scan tool to DLC with ignition switch turned referring to “Intermittent OFF. and Poor Connection 2) Warm up engine to normal operating temperature and Inspection in Section keep it at 2000 r/min.
Page 148: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2)
1A-98 Engine General Information and Diagnosis: Step Action Air intake system check Replace HO2S-1 Repair or replace air referring to “Heated intake system. 1) Check air intake system for clog or leak. Oxygen Sensor (HO2S- Is it OK? 1 and HO2S-2) Removal and Installation (If Equipped) in Section 1C”.
Page 149 Engine General Information and Diagnosis: 1A-99 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 an accident. •...
Page 150 1A-100 Engine General Information and Diagnosis: Step Action HO2S-2 ground check Go to Step 5. “ORN” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-2 with ignition switch Poor “C01-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-2 connector at ground.
Page 151: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2)
Engine General Information and Diagnosis: 1A-101 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S6RW0D1104035 Wiring Diagram Refer to “DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S-2 voltage is higher than specified value after warming up engine...
Page 152 1A-102 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 4. “BRN” wire is high resistance circuit or 1) Turn OFF ignition switch. open circuit. Poor “C01- 2) Remove ECM from its bracket with ECM connectors 11”...
Page 153: Dtc P0171 / P0172: Fuel System Too Lean / Rich
Engine General Information and Diagnosis: 1A-103 DTC P0171 / P0172: Fuel System Too Lean / Rich S6RW0D1104036 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0171: • Vacuum leakage Total fuel trim is higher than specified value or short term fuel trim is higher •...
Page 154 1A-104 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 155: Dtc P0222: Throttle Position Sensor (Sub) Circuit Low
Engine General Information and Diagnosis: 1A-105 DTC P0222: Throttle Position Sensor (Sub) Circuit Low S6RW0D1104037 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 E01-45 E01-32 C01-45 C01-44 C01-43 C01-54 C01-40 C01-42...
Page 156 1A-106 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 157: Dtc P0223: Throttle Position Sensor (Sub) Circuit High
Engine General Information and Diagnosis: 1A-107 Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C01-43” terminal of ECM connector and engine ground.
Page 158 1A-108 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 159 Engine General Information and Diagnosis: 1A-109 Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Measure voltage between “WHT” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned ON. Is voltage 4 –...
Page 160: Dtc P0301, P0302, P0303, P0304
1A-110 Engine General Information and Diagnosis: DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S6RW0D1104039 System Description ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 161 Engine General Information and Diagnosis: 1A-111 DTC Troubleshooting NOTE If the vehicle runs under fuel deficient condition (such as a condition in which the fuel pump is unable to draw fuel properly), DTC of misfire may possibly be detected due to fuel pressure drop even though there is no abnormal condition existing in the Engine and Emission System.
Page 162: Dtc P0327 / P0328: Knock Sensor Circuit Low / High
1A-112 Engine General Information and Diagnosis: Step Action Engine mechanical system check Check wire harness and Repair or replace connection of ECM defective part. 1) Check engine mechanical parts or system which can ground, ignition system cause engine rough idle or poor performance. and fuel injector for •...
Page 163 Engine General Information and Diagnosis: 1A-113 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 164: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit
1A-114 Engine General Information and Diagnosis: Step Action Knock sensor circuit for high resistance check Faulty knock sensor. “RED” wire is high resistance circuit. 1) Turn OFF ignition switch, measure resistance between “C01-56” terminal of ECM connector and “RED” wire terminal of knock sensor harness connector.
Page 165 Engine General Information and Diagnosis: 1A-115 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to...
Page 166: Dtc P0340: Camshaft Position (Cmp) Sensor Circuit
1A-116 Engine General Information and Diagnosis: Step Action Ground circuit check Go to Step 6. “BLK/ORN” wire is open or high resistance. 1) Turn ignition switch to OFF position. 2) Measure resistance between “BLK/ORN” wire terminal of CKP sensor connector and engine ground. Ω...
Page 167 Engine General Information and Diagnosis: 1A-117 System Description The CMP sensor located on the transmission side of cylinder head (VVT model) or timing chain cover (non-VVT model) consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion (VVT model) or exhaust camshaft timing sprocket (non-VVT model)).
Page 168 1A-118 Engine General Information and Diagnosis: Step Action Wire harness and connection check Go to Step 7. Go to Step 4. 1) Disconnect connector from CMP sensor. 2) Check for proper connection to CMP sensor at “BLK/ RED”, “RED/YEL” and “BLK/ORN” wire terminals. 3) If OK, turn ON ignition switch and check voltage at “BLK/ RED”, “RED/YEL”...
Page 169: Dtc P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
Engine General Information and Diagnosis: 1A-119 Step Action CMP sensor check Substitute a known- Replace CMP sensor good ECM and recheck. and/or intake camshaft. 1) Check CMP sensor and signal rotor tooth referring to “Camshaft Position (CMP) Sensor Inspection in Section 1C”.
Page 170 1A-120 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0401: • EGR valve Difference in intake manifold absolute pressure between opened EGR valve and closed • EGR passage EGR valve is smaller than specified value. •...
Page 171 Go to Step 5. EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection (If Equipped) in Section 1B”.
Page 172: Dtc P0403: Exhaust Gas Recirculation Control Circuit
1A-122 Engine General Information and Diagnosis: DTC P0403: Exhaust Gas Recirculation Control Circuit S6RW0D1104044 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 GRN/RED C01-4 BLK/RED GRN/ORN C01-3 BLK/RED WHT/RED C01-19 BRN/YEL...
Page 173 Engine General Information and Diagnosis: 1A-123 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Description”.
Page 174: Dtc P0420: Catalyst System Efficiency Below Threshold
1A-124 Engine General Information and Diagnosis: DTC P0420: Catalyst System Efficiency below Threshold S6RW0D1104045 System and Wiring Diagram C01-10 C01-57 C01-11 BLU WHT 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110038-01 1.
Page 175 Engine General Information and Diagnosis: 1A-125 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 an accident. •...
Page 176: Dtc P0443: Evaporative Emission System Purge Control Valve Circuit
1A-126 Engine General Information and Diagnosis: DTC P0443: Evaporative Emission System Purge Control Valve Circuit S6RW0D1104046 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL E01-16 BLK/RED BLK/RED C01-29 BLU/BLK 39 38 32 31 39 38 32 31...
Page 177 Engine General Information and Diagnosis: 1A-127 DTC Troubleshooting WARNING In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”.
Page 178: Dtc P0462 / P0463: Fuel Level Sensor Circuit Low / High
1A-128 Engine General Information and Diagnosis: DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High S6RW0D1104047 Wiring Diagram 12 V YEL/RED 12 V E01-24 YEL/RED YEL/RED BLK/ORN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110040-01...
Page 179: Dtc P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
Engine General Information and Diagnosis: 1A-129 Step Action Wire harness check Go to Step 4. Repair fuel level sensor signal circuit. 1) Check that fuel level sensor signal circuit (“YEL/RED” wire circuit) is in good condition. Is it in good condition? ECM power and ground circuit check Substitute a known- Repair ECM power and/...
Page 180 1A-130 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 181: Dtc P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit
Engine General Information and Diagnosis: 1A-131 Step Action Radiator cooling fan control check Intermittent trouble. Faulty ECM. Check for intermittent 1) Run engine until ECT is over 100 °C, 212 °F. Substitute a known- referring to “Intermittent good ECM and recheck. 2) Measure voltage between vehicle body ground and and Poor Connection “E01-46”...
Page 182 1A-132 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up engine to normal operating temperature. 4) Run engine at idle and turn both A/C switch and heater blower switch ON (turn ON air conditioning) for 3 min.
Page 183 Engine General Information and Diagnosis: 1A-133 Step Action Check wire circuit Faulty A/C compressor Go to Step 4. control relay. 1) Disconnect A/C compressor control relay (1) from individual circuit fuse box No.1 with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “BLK/WHT”...
Page 184: Dtc P0500: Vehicle Speed Sensor (Vss) Malfunction
1A-134 Engine General Information and Diagnosis: Step Action Check A/C condenser cooling fan control Intermittent trouble. Faulty ECM. Check for intermittent 1) Ignition switch turned OFF. refer to “Intermittent and 2) Remove ECM from vehicle body referring to “Engine Poor Connection Control Module (ECM) Removal and Installation in Inspection in Section Section 1C”...
Page 185 Engine General Information and Diagnosis: 1A-135 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 an accident. •...
Page 186: Dtc P0532: A/C Refrigerant Pressure Sensor Circuit Low
1A-136 Engine General Information and Diagnosis: DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low S6RW0D1104051 Wiring Diagram GRY/RED GRY/RED C01-14 RED/BLU E01-55 C01-58 BLK/ORN E01-54 C01-15 C01-30 E01-31 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110044-01...
Page 187 Engine General Information and Diagnosis: 1A-137 Step Action A/C refrigerant pressure sensor power supply circuit Go to Step 5. Go to Step 3. check 1) Disconnect connector from A/C refrigerant pressure sensor with ignition switch turned OFF. 2) Check for proper connection of A/C refrigerant pressure sensor at “GRY/RED”, “RED/BLU”...
Page 188: Dtc P0533: A/C Refrigerant Pressure Sensor Circuit High
1A-138 Engine General Information and Diagnosis: DTC P0533: A/C Refrigerant Pressure Sensor Circuit High S6RW0D1104052 Wiring Diagram Refer to “DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area A/C refrigerant pressure sensor signal voltage is higher than specified •...
Page 189: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
Engine General Information and Diagnosis: 1A-139 Step Action A/C refrigerant pressure sensor signal circuit check “RED/BLU” wire is “RED/BLU” wire is open shorted to power supply or high resistance 1) Disconnect connectors from ECM with ignition switch circuit. circuit. turned OFF. 2) Measure resistance between “RED/BLU”...
Page 190: Dtc P0616: Starter Relay Circuit Low
1A-140 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action DTC recheck Go to Step 2. Intermittent trouble. 1) Clear DTC referring to “DTC Clearance”. Check for intermittent referring to “Intermittent 2) Turn OFF ignition switch.
Page 191: Dtc P0617: Starter Relay Circuit High
Engine General Information and Diagnosis: 1A-141 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Engine starts even though vehicle is at stop and engine starter signal is low voltage. • Engine starter signal circuit (2 driving cycle detection logic) •...
Page 192 1A-142 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 193: Dtc P1510: Ecm Back-Up Power Supply Malfunction
Engine General Information and Diagnosis: 1A-143 DTC P1510: ECM Back-Up Power Supply Malfunction S6RW0D1104056 Wiring Diagram WHT/RED E01-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110046-02 1. ECM 2. “DOME” fuse 3.
Page 194: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance
1A-144 Engine General Information and Diagnosis: Step Action Battery voltage supply circuit check Poor “E01-2” “DOME” fuse blown, connection or “WHT” or “WHT/RED” 1) Turn OFF ignition switch. intermittent trouble. wire is circuit open or 2) Remove ECM from its bracket with ECM connectors short circuit.
Page 195 Engine General Information and Diagnosis: 1A-145 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of throttle actuator output (duty output) is inconsistent with • Throttle actuator circuit throttle actuator control command. • Electric throttle body assembly (1 driving detection logic) •...
Page 196: Dtc P2102: Throttle Actuator Control Motor Circuit Low
1A-146 Engine General Information and Diagnosis: Step Action Throttle actuator circuit check Substitute a known- Replace electric throttle good ECM and recheck. body assembly. 1) Check throttle actuator referring to “Throttle Actuator Performance Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”. Is check result satisfactory? DTC P2102: Throttle Actuator Control Motor Circuit Low S6RW0D1104058...
Page 197: Dtc P2103: Throttle Actuator Control Motor Circuit High
Engine General Information and Diagnosis: 1A-147 Step Action Throttle actuator control relay circuit check Go to Step 5. “BLK/RED” wire and/or “GRY” wire is open or 1) Remove throttle actuator control relay from individual high resistance. circuit fuse box No.1 with ignition switch turned OFF. 2) Check for proper connection to throttle actuator control relay at “BLK/RED”, “GRY”, “BRN”...
Page 198: Dtc P2111: Throttle Actuator Control System - Stuck Open
1A-148 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 199: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance
Engine General Information and Diagnosis: 1A-149 DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 200 1A-150 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 201: Dtc P2122: Pedal Position Sensor (Main) Circuit Low Input
Engine General Information and Diagnosis: 1A-151 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input S6RW0D1104062 Wiring Diagram E01-35 E01-37 E01-52 E01-34 E01-36 E01-51 E01-50 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110048-01 1.
Page 202 1A-152 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 203: Dtc P2123: Pedal Position Sensor (Main) Circuit High Input
Engine General Information and Diagnosis: 1A-153 Step Action Wire harness check Substitute a known- “BRN” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “E01-35” terminal of ECM connector and engine ground.
Page 204 1A-154 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 205: Dtc P2127: Pedal Position Sensor (Sub) Circuit Low Input
Engine General Information and Diagnosis: 1A-155 Step Action Wire harness check Go to Step 7. “GRN” wire is shorted to “BRN” wire and/or 1) Disconnect connectors from ECM with ignition switch “RED” wire. turned OFF. 2) Check for proper connection of ECM connector at “E01- 35”, “E01-37”...
Page 206 1A-156 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 207 Engine General Information and Diagnosis: 1A-157 Step Action ECM voltage check “RED” wire is open or Go to Step 6. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “E01- 34”...
Page 208: Dtc P2128: Pedal Position Sensor (Sub) Circuit High Input
1A-158 Engine General Information and Diagnosis: DTC P2128: Pedal Position Sensor (Sub) Circuit High Input S6RW0D1104065 Wiring Diagram Refer to “DTC P2122: Pedal Position Sensor (Main) Circuit Low Input”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of APP sensor (sub) is higher than specified value.
Page 209 Engine General Information and Diagnosis: 1A-159 Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from APP sensor assembly with ignition switch turned OFF. 2) Check for proper connection to APP sensor assembly at “RED”, “YEL”...
Page 210: Dtc P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
1A-160 Engine General Information and Diagnosis: Step Action Ground circuit check “WHT” wire is open or Faulty ECM ground high resistance circuit. circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors substitute a known- connected. good ECM and recheck.
Page 211 Engine General Information and Diagnosis: 1A-161 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the opening angle based on throttle position • Throttle position sensor (main) and (sub) circuit sensor (main) and the opening angle based on throttle position •...
Page 212 1A-162 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 5. “RED” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C01-43” terminal of ECM connector and engine ground.
Page 213: Dtc P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
Engine General Information and Diagnosis: 1A-163 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation S6RW0D1104067 Wiring Diagram E01-35 E01-37 E01-52 E01-34 E01-36 E01-51 E01-50 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110050-01 1.
Page 214 1A-164 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 215: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
Engine General Information and Diagnosis: 1A-165 Step Action Wire harness check Go to Step 7. “GRN” wire or “YEL” wire is shorted to other 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Check for proper connection of ECM connector at “E01- 37”, “E01-52”, “E01-36”...
Page 216: Dtc U0073: Control Module Communication Bus Off
1A-166 Engine General Information and Diagnosis: DTC Confirmation Procedure DTC P2227: 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. •...
Page 217: Troubleshooting For Can-Dtc
Before troubleshooting, check to make sure that fuse, battery voltage and generator status are normal. • When performing “Communication Bus Check” using SUZUKI scan tool (SUZUKI-SDT) in each step of this troubleshooting, use the following table to determine whether the control module is in good condition or not.
Page 218 1A-168 Engine General Information and Diagnosis: Troubleshooting Step Action DTC Check Go to applicable Go to Step 2. troubleshooting of DTC 1) Turn ignition switch to OFF position. other than CAN-DTC. 2) Connect scan tool to DLC. 3) Check DTC in the following control modules. •...
Page 219 1) Turn ignition switch to OFF position. 2) Connect BCM, ECM, ABS control module and combination meter connectors. 3) Perform “Communication Bus Check” under “Bus Check” using SUZUKI-SDT with ignition switch turned Are all of BCM, ECM, ABS control module and combination meter normally displayed?
Page 220 1A-170 Engine General Information and Diagnosis: Step Action Terminating resistance check in ECM and combination Go to Step 7. Go to Step 8. meter 1) Turn ignition switch to OFF position and then disconnect negative (–) cable at battery. 2) Measure resistance between CAN High terminal (2) and CAN Low terminal (3) on DLC (1).
Page 221 “DTC C1240: 3) Perform “Communication Bus Check” under “Bus 4WD Control Module Check” on SUZUKI-SDT with ignition switch turned ON. Power Supply Circuit Malfunction in Section Are all of BCM, ECM, ABS control module, combination 3B”. If OK, substitute a...
Page 222: Inspection Of Ecm And Its Circuits
1A-172 Engine General Information and Diagnosis: Inspection of ECM and Its Circuits S6RW0D1104072 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 223 Engine General Information and Diagnosis: 1A-173 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ 10 – 14 V Output signal is active low BLU/ Fuel injector No.1 (“Reference C01-1 Engine running at idle...
Page 224 1A-174 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V Ignition switch turned ON. *Deflects between over 0.5 V and under Oxygen signal of 0.45 V While engine running at C01-10 heated oxygen —...
Page 225 Engine General Information and Diagnosis: 1A-175 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — EGR valve *0 – 1 V Output signal is active low ↑↓ WHT/ (stepper motor coil duty pulse. Number of C01-19 Ignition switch is turned to 3) output (if...
Page 226 1A-176 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color C01-34 — — — — — C01-35 — — — — — C01-36 — — — — — C01-37 — — — — — C01-38 — —...
Page 227 Engine General Information and Diagnosis: 1A-177 Terminal Wire Circuit Normal voltage Condition Remarks color YEL/ Starting motor 0 – 1 V Ignition switch turned ON. C01-48 — signal 6 – 14 V While engine cranking. C01-49 — — — — —...
Page 228 1A-178 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON 0 – 0.8 V — with engine at stop. Output signal is pulse. *0 – 1 V Pulse frequency varies ↑↓ Engine revolution depending on engine E01-4 signal output for P/...
Page 229 Engine General Information and Diagnosis: 1A-179 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. With engine running at idle RED/ E01-26 EPS signal speed, and steering wheel — 0 – 1 V turned to the right or left as far as it stops.
Page 230 1A-180 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON and ECT is 97.5 °C (206 10 – 14 V °F) or less without Radiator cooling E01-46 LT GRN operating A/C. — fan relay output Ignition switch turned ON and ECT is 100 °C (212...
Page 231 Engine General Information and Diagnosis: 1A-181 Terminal Wire Circuit Normal voltage Condition Remarks color Blower speed selector ON A/C or defroster switch ON Engine running or Engine A/C condenser fan 0 – 1 V coolant temperature at RED/ relay more than 110 °C (230 °F) E01-58 —...
Page 232 1A-182 Engine General Information and Diagnosis: Reference waveform No.3 Reference waveform No.4 No.2 fuel injector signal (2) with engine idling EGR valve signal Measurement CH1: “C01-20” to “C01-58” CH1: “C01-4” to “C01-58” terminal CH2: “C01-2” to “C01-58” Measurement CH2: “C01-3” to “C01-58” Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV terminal...
Page 233 Engine General Information and Diagnosis: 1A-183 Reference waveform No.5 Ignition coil No.2 and No.3 signal (2) with engine idling Measurement CH1: “C01-20” to “C01-58” terminal CH2: “C01-5” to “C01-58” Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV setting TIME: 40 ms/DIV •...
Page 234 1A-184 Engine General Information and Diagnosis: Reference waveform No.8 Reference waveform No.10 Heated oxygen sensor-1 signal (1) with engine idling Heated oxygen sensor-2 heater signal (4) with engine idling Measurement CH1: “C01-10” to “C01-57” terminal CH2: “C01-46” to “C01-58” Measurement CH1: “C01-11”...
Page 235 Engine General Information and Diagnosis: 1A-185 Reference waveform No.11 Reference waveform No.12 No.3 fuel injector signal (2) with engine idling No.4 fuel injector signal (2) with engine idling Measurement CH1: “C01-20” to “C01-58” Measurement CH1: “C01-20” to “C01-58” terminal CH2: “C01-16” to “C01-58” terminal CH2: “C01-17”...
Page 236 1A-186 Engine General Information and Diagnosis: Reference waveform No.13 Reference waveform No.14 CMP sensor signal with engine idling CMP sensor signal with engine idling Measurement CH1: “C01-20” to “C01-58” Measurement CH1: “C01-20” to “C01-58” terminal CH2: “C01-21” to “C01-58” terminal CH2: “C01-21”...
Page 237 Engine General Information and Diagnosis: 1A-187 Reference waveform No.15 Reference waveform No.17 Mass air flow sensor signal (1) with engine racing Manifold absolute pressure sensor signal (1) with ignition switch turned ON Measurement CH1: “C01-26” to “C01-27” terminal CH2: “C01-54” to “C01-55” Measurement CH1: “C01-53”...
Page 238 1A-188 Engine General Information and Diagnosis: Reference waveform No.19 Reference waveform No.21 Knock sensor signal at engine speed 4000 r/min. Oil control valve signal with engine idling (for engine with VVT system) Measurement CH1: “C01-56” to “C01-58” terminal Measurement CH1: “C01-60” to “C01-59” Oscilloscope CH1: 1 V/DIV terminal...
Page 239 Engine General Information and Diagnosis: 1A-189 Reference waveform No.23 Reference waveform No.24 CAN communication line signal from ABS / ESP® Ignition pulse (engine revolution) signal (2) with engine control module assembly or TCM with ignition switch idling turned ON Measurement CH1: “C01-20”...
Page 240 1A-190 Engine General Information and Diagnosis: Reference waveform No.25 Ignition pulse (engine revolution) signal (2) with engine idling Measurement CH1: “C01-20” to “C01-58” terminal CH2: “E01-4” to “C01-58” Oscilloscope CH1: 5 V/DIV, CH2: 5 V/DIV setting TIME: 10 ms/DIV • After warmed up to normal Measurement operating temperature condition...
Page 241 Engine General Information and Diagnosis: 1A-191 Reference waveform No.28 Reference waveform No.29 Ignition coil signal and fuel injector signal with engine Throttle position sensor main (1) and sub (2) signal cranking Measurement CH1: “C01-54” to “C01-58” CH1: “C01-20” to “C01-58” terminal CH2: “C01-40”...
Page 242 1A-192 Engine General Information and Diagnosis: Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation in Section 1C”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors (1) securely. NOTE Do not connect the other connector of special tool to ECM.
Page 243: Ecm Power And Ground Circuit Check
Engine General Information and Diagnosis: 1A-193 ECM Power and Ground Circuit Check S6RW0D1104073 Wiring Diagram WHT/RED E01-2 BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BLK/YEL BRN/WHT E01-60 E01-31 BLK/RED BLK/RED E01-1 BLK/YEL E01-16 BLK/RED GRY/RED C01-14 RED/BLK C01-53 E01-55 RED/BLU E01-54 GRY/BLU C01-55...
Page 244 1A-194 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Circuit fuse check...
Page 245 Engine General Information and Diagnosis: 1A-195 Step Action ECM ground circuit check Substitute a known- “BLK/ORN” or “BLK” good ECM and recheck. wire is open or high 1) Turn ignition switch to OFF position. resistance circuit. 2) Disconnect connectors from ECM. 3) Measure resistance between each “E01-31”, “C01-58”, “C01-15”...
Page 246: Fuel Injector Circuit Check
1A-196 Engine General Information and Diagnosis: Step Action Sensor power source circuit check ECM power and ground Go to Step 12. circuit is in good 1) Connect connectors to ECM with ignition switch turned condition. OFF. 2) Turn ON ignition switch, measure each voltage between “C01-14”, “E01-35”, “E01-34”...
Page 247 Engine General Information and Diagnosis: 1A-197 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Fuel injector check for operating sound...
Page 248: Fuel Pump And Its Circuit Check
1A-198 Engine General Information and Diagnosis: Fuel Pump and Its Circuit Check S6RW0D1104075 Wiring Diagram BLK/WHT BLK/WHT E01-29 BLK/WHT E01-15 GRN/WHT BLK/YEL C01-58 BLK/ORN BLK/RED C01-15 C01-30 E01-31 BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 BRN/WHT E01-60 BLK/YEL 39 38 32 31 39 38 32 31 54 53...
Page 249 Engine General Information and Diagnosis: 1A-199 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Fuel pump control system check for operation...
Page 250 1A-200 Engine General Information and Diagnosis: Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 second after ignition switch is turned ON. Is voltage 0 – 1 V? Wire circuit check Go to Step 8.
Page 251: Fuel Pressure Check
Engine General Information and Diagnosis: 1A-201 Fuel Pressure Check S6RW0D1104076 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I3RM0A110081-01 1. Injector 2. Delivery pipe 3. Fuel filter and fuel pump Troubleshooting NOTE Before using following flow, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 252: A/C Condenser Cooling Fan Control System Inspection
1A-202 Engine General Information and Diagnosis: Step Action Fuel line check Faulty fuel pressure Repair or replace regulator. damaged or damaged 1) Check fuel pipe, fuel hose and joint for damage or part. deform. Are they in good condition? Was fuel pressure higher than specification in Step 1? Go to Step 6.
Page 253 Engine General Information and Diagnosis: 1A-203 Troubleshooting Step Action Check A/C condenser fan control system Intermittent trouble. Go to Step 2. Check for intermittent Is A/C condenser fan started when A/C is operating? referring to “Intermittent and Poor Connection Inspection in Section 00”.
Page 254 1A-204 Engine General Information and Diagnosis: Step Action Check wire circuit Go to Step 10. Open wire in “RED” circuit. 1) Install “A/C” fuse “20 A” to individual circuit fuse box No.1. 2) Connect A/C condenser cooling fan control relay to individual circuit fuse box No.1 with ignition switch turn OFF.
Page 255: A/C System Circuits Check
Engine General Information and Diagnosis: 1A-205 A/C System Circuits Check S6RW0D1104078 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED E01-1 BLK/YEL 12V 5V BLK/RED RED/BLK E01-58 BLU/YEL BLK/RED E01-47 BLU/YEL BLK/YEL BLK/WHT BLU/WHT E01-19 BLU/WHT E01-19 E01-18 GRN/WHT WHT/BLU E01-3 GRY/RED C01-14 RED/BLU E01-55...
Page 256 1A-206 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. •...
Page 257 Engine General Information and Diagnosis: 1A-207 Step Action A/C evaporator outlet air temp. sensor check Go to Step 7. Faulty A/C evaporator outlet air temp. sensor 1) Disconnect connectors from ECM with ignition switch or its circuit. turned OFF. 2) Check for proper connection to “E01-57” and “E01-54” wire terminals of ECM connector.
Page 258 1A-208 Engine General Information and Diagnosis: Step Action A/C compressor relay circuit check Go to Step 12. Go to Step 13. 1) Measure voltage between “E01-47” wire terminal of ECM connector and vehicle body ground under following conditions respectively. Voltage between “E01-47” terminal of ECM connector and ground While engine running and A/C switch turned OFF: 10 –...
Page 259: Electric Load Signal Circuit Check
Engine General Information and Diagnosis: 1A-209 Electric Load Signal Circuit Check S6RW0D1104079 Wiring Diagram BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30 BLK/YEL BRN/WHT E01-60 E01-31 12V 5V BLK/RED E01-1 BLK/YEL E01-16 BLK/RED /BLU BLK/YEL BLU/WHT E01-19 E01-19 BLU/WHT BLK/WHT E01-18 E01-3 E01-18 E01-3 39 38...
Page 260 1A-210 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action DTC check...
Page 261: Radiator Cooling Fan Control System Check .1A-211
Engine General Information and Diagnosis: 1A-211 Radiator Cooling Fan Control System Check S6RW0D1104080 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 E01-46 LT GRN BLU/RED C01-58 BLK/ORN C01-15 C01-30 E01-31 LT GRN C01-24 C01-55 39 38 32 31 39 38 32 31...
Page 262: Repair Instructions
1A-212 Engine General Information and Diagnosis: Step Action Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 / Go to corresponding Go to Step 2. P0118) and/or radiator cooling fan circuit (DTC P0480)? DTC flow. Radiator cooling fan control circuit check Radiator cooling fan Perform from Step 2 to control system is in...
Page 263: Special Tools And Equipment
Engine General Information and Diagnosis: 1A-213 1) Connect SUZUKI scan tool to DLC (1) with ignition 2) Warm up engine to normal operating temperature. switch turned OFF. 3) Check engine idle speed and “IAC throttle opening” by using “Data List” mode on scan tool to check “IAC Special tool throttle opening”.
Page 264: Aux. Emission Control Devices
5) With engine idling (without depressing accelerator S6RW0D1204001 pedal), open EGR valve by using “Step EGR 1) Connect SUZUKI scan tool to data link connector Control” mode in “Engine / Active Test” menu. In this (DLC) (1) with ignition switch turned OFF.
Page 265: Vacuum Passage Inspection
1) Prepare to operate EVAP canister purge valve as follows. passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. a) When using SUZUKI scan tool: If check result is not satisfactory, check vacuum...
Page 266: Vacuum Hose Inspection
1B-3 Aux. Emission Control Devices: Vacuum Hose Inspection 3) Check resistance between two terminals of EVAP S6RW0D1206004 canister purge valve. Check hoses for connection, leakage, clog and If resistance is not as specified, replace EVAP deterioration. canister purge valve. Replace as necessary. EVAP canister resistance 30 –...
Page 267: Evap Canister Inspection
Aux. Emission Control Devices: 1B-4 EVAP Canister Inspection EGR Valve Inspection (If Equipped) S6RW0D1206006 S6RW0D1206008 1) Check resistance between following terminals of WARNING EGR valve (1) in each pair. DO NOT SUCK nozzles on EVAP canister. If found faulty, replace EGR valve assembly. Fuel vapor inside EVAP canister is harmful.
Page 268: Pcv Hose Inspection
7) After checking, remove plug and install PCV valve. 8) Install air cleaner assembly securely. Special Tools and Equipment Special Tool S6RW0D1208001 09917–47011 SUZUKI scan tool (SUZUKI- SDT) Vacuum pump gauge — This kit includes following items. 1. SUZUKI-SDT 2.
Page 269: Engine Electrical Devices
Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Repair Instructions Engine Control Module (ECM) Removal and Installation Reverse removal procedure noting the following: Installation S6RW0D1306001 • Tighten ECM mounting bolts to specified torque. CAUTION Tightening torque As ECM consists of precision parts, be ECM mounting bolt (a): 8 N·m (0.8 kgf-m, 6.0 lb- careful not to expose it to excessive shock.
Page 270: Manifold Absolute Pressure (Map) Sensor Inspection (If Equipped)
1C-2 Engine Electrical Devices: Manifold Absolute Pressure (MAP) Sensor Electric Throttle Body Assembly On-Vehicle Inspection (If Equipped) Inspection S6RW0D1306002 S6RW0D1306003 1) Remove air cleaner assembly. WARNING 2) Disconnect connector from MAP sensor. Never touch throttle valve with finger while 3) Remove MAP sensor. ignition switch is turned ON and accelerator pedal is depressed.
Page 271 Engine Electrical Devices: 1C-3 Throttle Valve Visual Check Electric Throttle Body Assembly Operation Check 1) Remove air cleaner outlet hose. 1) Remove air cleaner outlet hose. 2) Check that there isn’t any foreign matter caught 2) Turn ON ignition switch. between throttle valve and throttle body housing.
Page 272 1C-4 Engine Electrical Devices: Throttle Position Sensor Performance Check If sensor voltage is out of specified value and linear variation as the following graph, replace electric throttle 1) Remove air cleaner outlet hose. body assembly. 2) Turn OFF ignition switch. TP sensor output voltage 3) Disconnect connector from electric throttle body TP sensor (main) [A]: 0.45 –...
Page 273: Electric Throttle Body System Calibration
Engine Electrical Devices: 1C-5 Electric Throttle Body System Calibration 4) Check that accelerator pedal position sensor voltage S6RW0D1306004 varies as the following graph. NOTE If sensor voltage is out of specified value or does not If the service described under the vary linearly as the following graph, check APP “Precautions of Electric Throttle Body sensor assembly referring to “Accelerator Pedal...
Page 274: Accelerator Pedal Position (App) Sensor Assembly Inspection
1C-6 Engine Electrical Devices: Removal 2) For APP sensor (sub), arrange 3 new 1.5 V batteries (1) in series (check that total voltage is 4.5 – 5.0 V) 1) Disconnect negative cable at battery. and connect its positive terminal to “Vin 2” terminal 2) Disconnect connector from APP sensor assembly.
Page 275: Engine Coolant Temperature (Ect) Sensor Removal And Installation
Engine Electrical Devices: 1C-7 Engine Coolant Temperature (ECT) Sensor Engine Coolant Temperature (ECT) Sensor Removal and Installation Inspection S6RW0D1306008 S6RW0D1306009 Removal Immerse temperature sensing part of ECT sensor (1) in water (or ice) and measure resistance between sensor 1) Disconnect negative cable at battery. terminals while heating water gradually.
Page 276: Heated Oxygen Sensor (Ho2S-1 And Ho2S-2) Heater On-Vehicle Inspection (If Equipped)
1C-8 Engine Electrical Devices: Heated Oxygen Sensor (HO2S-1 and HO2S-2) Installation Reverse removal procedure noting the following. Heater On-Vehicle Inspection (If Equipped) S6RW0D1306010 • Tighten heated oxygen sensor (1) to specified torque. 1) Disconnect sensor connector. Tightening torque 2) Using ohmmeter, measure resistance between Heated oxygen sensor (a): 45 N·m (4.5 kgf-m, terminals “V ”...
Page 277: Camshaft Position (Cmp) Sensor Removal And Installation
Engine Electrical Devices: 1C-9 Camshaft Position (CMP) Sensor Removal and Camshaft Position (CMP) Sensor Inspection S6RW0D1306013 Installation Visual check S6RW0D1306012 Removal • Check that O-ring is free from damage. 1) Disconnect negative cable at battery. • Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
Page 278: Crankshaft Position (Ckp) Sensor Removal And Installation
1C-10 Engine Electrical Devices: Crankshaft Position (CKP) Sensor Removal and Performance check Installation 1) Remove metal particles on end face of CMP sensor, S6RW0D1306014 if any. Removal 2) Arrange 12 V battery (1) and connect its positive 1) Disconnect negative cable at battery. terminal to “Vin”...
Page 279: Crankshaft Position (Ckp) Sensor Inspection
Engine Electrical Devices: 1C-11 Crankshaft Position (CKP) Sensor Inspection Knock Sensor Removal and Installation S6RW0D1306015 S6RW0D1306016 Removal Visual check 1) Disconnect negative cable at battery. • Check that O-ring is free from damage. 2) Hoist vehicle. • Check that end face of sensor and signal pulley tooth 3) Remove right side drive shaft referring to “Front are free from any metal particles and damage.
Page 280: Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay And Radiator Cooling Fan Relay Inspection
1C-12 Engine Electrical Devices: Main Relay, Fuel Pump Relay, Starting Motor 1) Disconnect negative cable at battery. Control Relay, Throttle Actuator Control Relay 2) Disconnect MAF and IAT sensor connector. and Radiator Cooling Fan Relay Inspection 3) Connect voltmeter to “BLK/RED” wire terminal (2) of S6RW0D1306017 MAF and IAT sensor connector (1) disconnected and 1) Disconnect negative cable at battery.
Page 281: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Removal And Installation
Engine Electrical Devices: 1C-13 Mass Air Flow (MAF) and Intake Air Intake Air Temperature (IAT) Sensor Inspection S6RW0D1306020 Temperature (IAT) Sensor Removal and Installation CAUTION S6RW0D1306019 Do not heat up MAF and IAT sensor more CAUTION than 100 °C (212 °F). Otherwise, MAF and IAT sensor will be damaged.
Page 282: Specifications
1C-14 Engine Electrical Devices: Specifications Tightening Torque Specifications S6RW0D1307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft ECM mounting bolt ECT sensor 11.0 Heated oxygen sensor 32.5 CMP sensor bolt (non-VVT model) CMP sensor bolt (VVT model) CKP sensor bolt Knock sensor 16.0 MAF and IAT sensor screw...
Page 283: Engine Mechanical
Engine Mechanical: 1D-1 Engine Mechanical Engine General Description Engine Construction Description S6RW0D1401001 The engine is water-cooled, in line 4 cylinders, 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 mounted over the cylinder head;...
Page 284 1D-2 Engine Mechanical: I5RW0C140033-01 [A]: For engine with VVT system [B]: For engine without VVT system...
Page 285: Camshaft Position Control (Vvt Variable Valve Timing) System Description
Engine Mechanical: 1D-3 Camshaft Position Control (VVT Variable Valve Timing) System Description S6RW0D1401002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
Page 286 1D-4 Engine Mechanical: Oil Control Valve Timing Holding The oil control valve switches and adjusts the hydraulic When the duty ratio of the signal output from the ECM pressure applied to the cam timing sprocket by moving shows that of holding, the spool valve of the oil control the spool valve (1) according to the duty pulse signals valve is located at hold position.
Page 287: Diagnostic Information And Procedures
Engine Mechanical: 1D-5 Targeted Timing Varying Operation Driving condition Valve timing Target of control Effect To shorten the valve opening overlap in Engine running at idle Stabilization of the engine Most retarded order to prevent the exhaust gas speed rotation at idle speed. counterflow to intake manifold.
Page 288: Engine Vacuum Check
1D-6 Engine Mechanical: Engine Vacuum Check 8) Disengage clutch (1) (to lighten starting load on engine) for M/T vehicle, and depress accelerator S6RW0D1404002 The engine vacuum that develops in the intake line is a pedal (2) all the way to make throttle fully open. good indicator of the condition of the engine.
Page 289: Valve Lash (Clearance) Inspection
Engine Mechanical: 1D-7 7) Install air cleaner assembly with air suction hose referring to “Air Cleaner Assembly Removal and Installation”. 8) Run engine at specified idle speed and read vacuum gauge. Vacuum should be within specification. Vacuum specification (at sea level) 59 –...
Page 290 1D-8 Engine Mechanical: 2) Lift down the valve by turning crankshaft to 360°. 4) Turn camshaft by approximately 90° clockwise and remove shim (3). 3) Hold tappet at that position using special tool as follows. WARNING a) Remove its housing bolts. Never put in the hand between camshaft and b) Check housing No.
Page 291 Engine Mechanical: 1D-9 6) Select new shim No. (1) with a thickness as close as 8) Lift valve by turning crankshaft counterclockwise (in possible to calculated value. opposite direction against above Step 4)) and remove special tool. Available new shims No. Special tool Thickness mm Thickness mm...
Page 292: Repair Instructions
1D-10 Engine Mechanical: Repair Instructions Air Intake System Components S6RW0D1406045 I6RW0B140001-01 1. Air cleaner assembly 5. To throttle body 2. Air cleaner outlet hose 6. Marking : Align marking (6) of air cleaner assembly with marking (6) of air cleaner outlet hose. 3.
Page 293: Air Cleaner Assembly Removal And Installation
Engine Mechanical: 1D-11 Air Cleaner Assembly Removal and Installation Cylinder Head Cover Removal and Installation S6RW0D1406046 S6RW0D1406003 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Disconnect MAF sensor connector (1). 2) Remove air cleaner assembly with air suction hose referring to “Air Cleaner Assembly Removal and 3) Remove EVAP canister purge valve (2).
Page 294 (2) to cylinder head cover “A”: Water tight sealant 99000–31250 (3) as shown in figure. (SUZUKI Bond No.1207F) I2RH0B140037-01 3) Install cylinder head cover to cylinder head. NOTE When installing cylinder head cover, use care...
Page 295: Throttle Body And Intake Manifold Components
Engine Mechanical: 1D-13 Throttle Body and Intake Manifold Components S6RW0D1406010 I6RW0D140001-01 1. Intake manifold 8. To cylinder head cover 15. Brake booster hose 22. Throttle body outlet water hose No.2 2. O-ring 9. Gasket (with EGR) 16. To brake booster 23.
Page 296: Throttle Body On-Vehicle Inspection
1D-14 Engine Mechanical: Throttle Body On-Vehicle Inspection Installation S6RW0D1406006 1) Clean mating surfaces and install new throttle body Check electric throttle body assembly referring to gasket (1) to intake manifold. “Throttle Valve Operation Check” and “Electric Throttle Body Assembly Operation Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”.
Page 297: Intake Manifold Removal And Installation
Engine Mechanical: 1D-15 Intake Manifold Removal and Installation Installation S6RW0D1406011 Reverse removal procedure for installation noting the following. Removal • Use new gasket and O-ring. 1) Remove throttle body referring to “Electric Throttle • Tighten EVAP canister purge valve bracket bolt to Body Assembly Removal and Installation”.
Page 298: Engine Mountings Components
1D-16 Engine Mechanical: Engine Mountings Components S6RW0D1406012 I6RW0D140002-01 [A]: For 4WD model 4. Engine left mounting 12. Dynamic damper : Be sure to direct paint mark to forward. [B]: For 2WD model 5. Engine rear mounting 13. Mounting member cushion : Be sure to direct paint mark to forward.
Page 299: Engine Assembly Removal And Installation
Engine Mechanical: 1D-17 F: Vehicle forward 8. Engine front mounting bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 1. Engine right mounting bracket 9. Engine front mounting : 95 N⋅m (9.5 kgf-m, 69.0 lb-ft) : Be sure to direct yellow mark to forward. 2.
Page 300 1D-18 Engine Mechanical: [B]: For M/T model 34. steering gear box 17) Remove oil pressure switch bracket (1). I5RW0A140011-01 2. Exhaust manifold 18) Remove suspension control arm referring to “Suspension Control Arm / Bushing Removal and Installation in Section 2B”. 19) Disconnect right and left drive shaft joints from differential gear referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”.
Page 301 Engine Mechanical: 1D-19 25) Remove engine right mounting bracket (1) and 27) Lower engine with transaxle, front suspension frame, engine left mounting bush bolt (2). front lower cross member, transfer (for 4WD model) and steering gear case. CAUTION Before lowering engine, in order to avoid damage to A/C compressor, make clearance by rising it.
Page 302 1D-20 Engine Mechanical: 6) Install engine right mounting bracket (1) and engine 8) Connect steering lower shaft from pinion shaft left mounting bush bolt (2), and then tighten bolt and referring to “Steering Lower Shaft Removal and nuts to specified torque. Installation in Section 6B”.
Page 303 Engine Mechanical: 1D-21 12) Install oil pressure switch bracket (1). 16) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and Installation in Section 7B” or “Compressor Assembly Removal and Installation in Section 7B”. 17) Adjust A/C compressor drive belt referring to “Compressor Drive Belt Removal and Installation in Section 7B”...
Page 304: Timing Chain Cover Components
1D-22 Engine Mechanical: Timing Chain Cover Components S6RW0D1406014 I5RW0C140041-01 [A]: For engine with VVT 8. Timing chain cover mounting 17. Oil control valve [B]: For engine without VVT 9. Oil gallery pipe No.1 18. Oil control valve mounting nut 1. Crankshaft pulley bolt 10.
Page 305: Timing Chain Cover Removal And Installation
Engine Mechanical: 1D-23 Timing Chain Cover Removal and Installation 5) Remove cylinder head cover referring to “Cylinder S6RW0D1406015 Head Cover Removal and Installation”. 6) Remove oil pan referring to “Oil Pan and Oil Pump CAUTION Strainer Removal and Installation in Section 1E”. •...
Page 306 “B” to mating surface of timing Timing chain cover nut (b): 25 N·m (2.5 kgf-m, chain cover as shown in figure. 18.0 lb-ft) “A”: Water tight sealant 99000–31140 (SUZUKI 6) Apply engine oil to new O-rings (2) and install them Bond No.1207B) to cap (3).
Page 307: Timing Chain Cover Inspection
Engine Mechanical: 1D-25 Timing Chain Cover Inspection 8) For engine with VVT, install new O-ring (1) to oil gallery pipes No.2 (2) and No.3 (3). S6RW0D1406016 9) For engine with VVT, install oil gallery pipes No.2 Oil Seal and No.3 to cylinder head (4) and timing chain cover Check oil seal lip for fault or other damage.
Page 308: Oil Control Valve Removal And Installation (For Engine With Vvt)
1D-26 Engine Mechanical: Oil Control Valve Removal and Installation (For Oil Control Valve Inspection (For Engine with Engine with VVT) VVT) S6RW0D1406017 S6RW0D1406018 Removal Oil Control Valve Remove oil gallery pipe No.1 and oil control valve from 1) Inspect strainer (1) and mating surface (2) of oil timing chain cover.
Page 309: Timing Chain And Chain Tensioner Components
Engine Mechanical: 1D-27 Timing Chain and Chain Tensioner Components S6RW0D1406019 I5RW0C140044-01 1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Timing chain 6. Chain tensioner adjuster mounting bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : Apply engine oil.
Page 310 1D-28 Engine Mechanical: Installation 3) Install timing chain to camshaft timing sprockets as follows. CAUTION • For engine with VVT After timing chain is removed, never turn Install timing chain by aligning dark blue plates (1) crankshaft and camshafts independently of timing chain and triangle mark (2) on camshaft more than such an extent (“a”, “b”) as shown timing sprockets.
Page 311 Engine Mechanical: 1D-29 5) Apply engine oil to sliding surface of timing chain 7) Check that triangle mark (2) and/or circle mark (5) on No.1 guide (1) and install it as shown in figure. intake and exhaust camshaft timing sprockets are in Tighten guide bolts to specified torque.
Page 312 1D-30 Engine Mechanical: 8) Screw in plunger (1) by turning body (2) in arrow 10) Apply engine oil to timing chain, and then turn direction and install a retainer (3) (wire) to hold crankshaft clockwise by 2 revolutions and check that plunger in place.
Page 313: Timing Chain And Chain Tensioner Inspection
Engine Mechanical: 1D-31 Timing Chain and Chain Tensioner Inspection Timing Chain S6RW0D1406021 Check timing chain for wear or damage. Timing Chain No.1 Guide Check shoe (1) for wear or damage. I2RH01140077-01 Timing Chain Tensioner Adjuster Check that tooth surface (1) are free from damage. I2RH0B140068-01 Timing Chain Tensioner Check shoe (1) for wear or damage.
Page 314: Camshaft, Tappet And Shim Components
1D-32 Engine Mechanical: Camshaft, Tappet and Shim Components S6RW0D1406022 I4RS0B140014-03 [A]: For engine with VVT 4. Exhaust camshaft 9. Camshaft bearing : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing. [B]: For engine without VVT 5.
Page 315: Camshaft, Tappet And Shim Removal And Installation
Engine Mechanical: 1D-33 Camshaft, Tappet and Shim Removal and 4) Loosen camshaft housing bolts in such order as indicated in figure and remove them. Installation S6RW0D1406023 “12” “13” “20” “21” “16” “17” “8” “9” CAUTION “2” • Keep working table, tools and hands clean “5”...
Page 316 1D-34 Engine Mechanical: Installation 3) Install intake camshaft (1) and exhaust camshaft (2). Align knock pin (3) and match mark (4) with notches 1) Install tappets and shims to cylinder head. (5) as shown in figure. Apply engine oil around tappet and then install it to cylinder head.
Page 317 Engine Mechanical: 1D-35 6) Check position of camshaft housings. 8) For engine with VVT, with hexagonal section (1) of Embossed marks are provided on each camshaft intake camshaft (2) held stationary with spanner or housing, indicating position and direction for the like, tighten bolt of intake cam timing sprocket installation.
Page 318: Camshaft, Tappet And Shim Inspection
1D-36 Engine Mechanical: Camshaft, Tappet and Shim Inspection Camshaft Runout S6RW0D1406024 Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. Intake Cam Timing Sprocket Assembly (For engine If measured runout exceeds limit, replace camshaft. with VVT) Camshaft runout limit Fit intake cam timing sprocket assembly to camshaft (2)
Page 319 Engine Mechanical: 1D-37 6) Tighten camshaft housing bolts evenly and gradually If measured camshaft journal clearance exceeds in numerical order (“1” through “21”) by repeating limit, measure journal (housing) bore and outside tightening sequence two or three times until diameter of camshaft journal. Replace camshaft or specified torque is obtained.
Page 320 1D-38 Engine Mechanical: Camshaft bearing thickness (For engine with Wear of Tappet and Shim VVT) Check tappet and shim for pitting, scratches, or damage. : 1.5120 – 1.5180 mm (0.0596 – 0.0597 in.) If any malcondition is found, replace. I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance.
Page 321: Valves And Cylinder Head Components
Engine Mechanical: 1D-39 Valves and Cylinder Head Components S6RW0D1406025 I4RS0A140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2. Valve spring retainer 8.
Page 322: Valves And Cylinder Head Removal And Installation
1D-40 Engine Mechanical: Valves and Cylinder Head Removal and 8) Check all around cylinder head for any other parts required to be removed or disconnected and remove Installation or disconnect whatever necessary. S6RW0D1406026 9) Remove exhaust manifold, if necessary referring to Removal “Exhaust Manifold Removal and Installation in 1) Remove engine assembly from vehicle referring to...
Page 323 Engine Mechanical: 1D-41 5) Install cylinder head to cylinder block. Cylinder head bolt diameter measurement Apply engine oil to new cylinder head bolts and points tighten them gradually as follows. “a”: 83.5 mm (2.81 in.) “b”: 115 mm (4.53 in.) a) Tighten cylinder head bolts (“1”...
Page 324: Valves And Cylinder Head Disassembly And Assembly
1D-42 Engine Mechanical: Valves and Cylinder Head Disassembly and 3) Release special tools (Valve lifter), and remove spring retainer and valve spring. Assembly S6RW0D1406027 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide and Disassembly valve spring seat (2).
Page 325 Engine Mechanical: 1D-43 3) Ream valve guide bore with special tool (5.5 mm Assembly reamer). After reaming, clean bore. 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as Special tool to remove burrs and make it truly round.
Page 326 1D-44 Engine Mechanical: 6) Install valve to valve guide. 8) Using special tools (Valve lifter), compress valve Before installing valve to valve guide, apply engine spring and fit two valve cotters (1) into groove in oil to stem seal, valve guide bore and valve stem. valve stem.
Page 327: Valves And Valve Guides Inspection
Engine Mechanical: 1D-45 Valves and Valve Guides Inspection S6RW0D1406028 Valve Guide Valve stem-to-guide clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
Page 328 1D-46 Engine Mechanical: Valve head radial runout Valve seat repair Check each valve for radial runout with a dial gauge and A valve seat not producing a uniform contact with its “V” block. To check runout, rotate valve slowly. If runout valve or showing width of seating contact that is out of exceeds its limit, replace valve.
Page 329: Cylinder Head Inspection
Engine Mechanical: 1D-47 Cylinder Head Inspection Distortion for cylinder head surface on piston side S6RW0D1406029 Limit: 0.03 mm (0.001 in.) • Remove all carbon deposits from combustion chambers. NOTE Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing.
Page 330: Valve Spring Inspection
1D-48 Engine Mechanical: Valve Spring Inspection Spring Squareness S6RW0D1406030 Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve Valve Spring Free Length and Preload spring and square. Valve springs found to exhibit a Referring to data, check to be sure that each spring is in larger clearance than limit must be replaced.
Page 331: Pistons, Piston Rings, Connecting Rods And Cylinders Components
Engine Mechanical: 1D-49 Pistons, Piston Rings, Connecting Rods and Cylinders Components S6RW0D1406031 I5RW0C140045-01 1. Top ring 8. Piston pin 2. 2nd ring 9. Piston pin circlip 3. Oil ring 10. Bearing cap nut 4. Piston : Tighten 15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45° and 45° by the specified procedure. 5.
Page 332 1D-50 Engine Mechanical: Installation 4) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring 1) Apply engine oil to pistons, rings, cylinder walls, compressor) to compress rings. Guide connecting connecting rod bearings and crank pins. rod into place on crankshaft.
Page 333: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
Engine Mechanical: 1D-51 Pistons, Piston Rings, Connecting Rods and NOTE Cylinders Disassembly and Assembly Circlip should be installed with its cut part S6RW0D1406033 facing as shown in figure. Install so that circlip end gap comes within such range as Disassembly indicated by arrow.
Page 334: Cylinders, Pistons And Piston Rings Inspection
1D-52 Engine Mechanical: Cylinders, Pistons and Piston Rings Inspection S6RW0D1406034 Cylinder Visual inspection Inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston. Cylinder bore diameter, taper and out-of-round Using a cylinder gauge (1), measure cylinder bore in thrust and axial directions at two positions (“a”...
Page 335 Engine Mechanical: 1D-53 Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. NOTE Cylinder bore diameters used here are measured in thrust direction at two positions.
Page 336: Piston Pins And Connecting Rods Inspection
1D-54 Engine Mechanical: Piston Pins and Connecting Rods Inspection Connecting Rod S6RW0D1406035 Big-end side clearance Check big-end of connecting rod for side clearance, with Piston Pin rod fitted and connected to its crank pin in the normal Visual inspection manner. If measured clearance is found to exceed its Check piston pin, connecting rod small end bore and limit, replace connecting rod.
Page 337: Crank Pin And Connecting Rod Bearings Inspection
Engine Mechanical: 1D-55 Crank Pin and Connecting Rod Bearings Connecting rod bolt deformation (Plastic deformation tightening bolt) Inspection Measure each thread diameter of connecting rod bolt (2) S6RW0D1406036 at “A” on 32 mm (1.25 in.) from bolt mounting surface Crank Pin Diameter and “B”...
Page 338 1D-56 Engine Mechanical: Connecting Rod Bearing General Information 4) Install rod bearing cap (1) to connecting rod. Service connecting rod bearings are available in When installing cap, be sure to point arrow mark (2) standard size and 0.25 mm (0.0098 in.) undersize on cap to crankshaft pulley side, as shown in figure.
Page 339 Engine Mechanical: 1D-57 Selection of Connecting Rod Bearings 2) Next, check crankshaft pin diameter. On crank web No.3, four alphabets are stamped as shown in figure. NOTE Three kinds of alphabet (“A”, “B” and “C”) represent the following crankshaft pin diameter respectively. •...
Page 340 1D-58 Engine Mechanical: 3) There are five kinds of standard bearings differing in 4) From number stamped on connecting rod and its cap thickness. To distinguish them, they are painted in and alphabets stamped on crank web No.3, the following colors at the position as indicated in determine new standard bearing to be installed to figure.
Page 341: Main Bearings, Crankshaft And Cylinder Block Components
Engine Mechanical: 1D-59 Main Bearings, Crankshaft and Cylinder Block Components S6RW0D1406037 I6RW0D140003-01 1. CKP sensor 11. Rear oil seal 21. Oil filter adapter bolt : See “A” 2. Knock sensor 12. Input shaft bearing 22. Spring pin 3. Cylinder block 13.
Page 342: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
1D-60 Engine Mechanical: 5. Main bearing 15. Flywheel or drive plate bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) : See “B” 6. Sensor plate 16. Rear oil seal housing mounting bolt : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) 7. Crankshaft timing sprocket key 17.
Page 343 Engine Mechanical: 1D-61 Installation 2) Install main bearings to cylinder block. Upper half of bearing (1), has an oil groove (2). NOTE Install it to cylinder block (3), and the other half without oil groove to bearing cap. • Use new bearing cap No.1 bolts. They are Make sure that two halves are painted in the same deformed once they are used because they color.
Page 344 Main bearing cap No.1 bolt ((1) – (10)): housing (1). Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) and 60° by the specified “A”: Water tight sealant 99000–31250 (SUZUKI procedure Bond No.1207F) Main bearing cap No.2 bolt ((11) – (20)): Sealant amount for rear oil seal housing Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) by the...
Page 345: Crankshaft Inspection
Engine Mechanical: 1D-63 9) Install rear oil seal housing (1) and tighten new bolts 13) Install camshafts, tappet and shim referring to to specified torque by using special tool. “Camshaft, Tappet and Shim Removal and Installation”. Special tool 14) Install timing chain referring to “Timing Chain and (A): 09911–97720 Chain Tensioner Removal and Installation”.
Page 346 1D-64 Engine Mechanical: 2) Tighten main bearing cap No.1 bolts (1) – (10) and 3) Use a dial gauge to read displacement in axial main bearing cap No.2 bolts (11) – (20) gradually as (thrust) direction of crankshaft. follows. If its limit is exceeded, replace thrust bearing with new standard one or oversize one to obtain standard a) Tighten bolts (1) –...
Page 347: Main Bearings Inspection
Engine Mechanical: 1D-65 Main Bearings Inspection 4) Tighten main bearing cap No.1 bolts (1) – (10) and S6RW0D1406040 main bearing cap No.2 bolts (11) – (20) gradually as follows. General Information a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m, •...
Page 348 1D-66 Engine Mechanical: Selection of Main Bearings 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five Standard bearing alphabets are stamped as shown in figure. If bearing is in malcondition, or bearing clearance is out Three kinds of alphabets (“A”, “B”...
Page 349 Engine Mechanical: 1D-67 3) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing. Standard size of crankshaft main bearing thickness Color...
Page 350 1D-68 Engine Mechanical: 5) Using scale (1) on gauging plastic (2), check bearing clearance with newly selected standard bearing. If clearance still exceeds its limit, use next thicker bearing and recheck clearance. I2RH0B140141-01 6) When replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new cylinder block.
Page 351 Engine Mechanical: 1D-69 • If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. a. Regrind journal to the following finished diameter. Finished journal diameter 51.7320 – 51.7500 mm (2.0367 – 2.0374 in.) b. Using micrometer, measure regrind journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
Page 352: Sensor Plate Inspection
1D-70 Engine Mechanical: Rear Oil Seal Inspection Main Bearing Cap No.1 Bolt Measure each thread diameter main bearing cap No.1 S6RW0D1406042 Carefully inspect oil seal (1) for wear or damage. If its lip bolts (1) at “A” on 60 mm (2.36 in.) from seat side of is worn or damaged, replace it.
Page 353: Specifications
Engine Mechanical: 1D-71 Honing or Reboring Cylinders 4) Rebore and hone cylinder to the following dimension. 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time. NOTE 2) Select oversized piston according to amount of Before reboring, install all main bearing caps cylinder wear.
Page 354 1D-72 Engine Mechanical: Tightening torque Fastening part Note N⋅m kgf-m lb-ft Cylinder head bolt for M10 Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N⋅m (4.0 kgf-m, 29.0 lb-ft), 60° and 60° by the specified procedure Connecting rod bearing cap nut Tighten 15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45°...
Page 355: Special Tools And Equipment
Engine Mechanical: 1D-73 Special Tools and Equipment Recommended Service Material S6RW0D1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 356 1D-74 Engine Mechanical: 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310 Tappet holder Piston ring compressor (50- 125 mm) 09916–84511 09917–68221...
Page 357: Engine Lubrication System
Engine Lubrication System: 1E-1 Engine Lubrication System Engine General Description Engine Lubrication Description S6RW0D1501001 The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.
Page 358: Diagnostic Information And Procedures
1E-2 Engine Lubrication System: Diagnostic Information and Procedures Oil Pressure Check 3) Install special tools (oil pressure gauge) to vacated S6RW0D1504001 threaded hole of oil pressure switch. WARNING Special tool To avoid the danger of being burned, do not (A): 09915–77310 touch the exhaust system when the system is (B): 09915–78211 hot.
Page 359: Repair Instructions
Engine Lubrication System: 1E-3 8) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) Connect oil pressure switch coupler (1). I2RH0B150006-01 Repair Instructions Oil Pan and Oil Pump Strainer Components S6RW0D1506001 I5RH0A150002-02 1.
Page 360: Oil Pan And Oil Pump Strainer Removal And Installation
I4RS0A150005-01 3) Apply sealant continuously to oil pan mating surface as shown in the figure. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)
Page 361: Oil Pan And Oil Pump Strainer Cleaning
Engine Lubrication System: 1E-5 4) Install oil pan to cylinder block temporarily. 9) Install clutch housing lower plate (1) and then tighten clutch housing lower plate bolt to specified torque. 5) Insert dowel pin (1) in hole (2) of oil pan in order to locate oil pan precisely.
Page 362: Oil Pump Components
1E-6 Engine Lubrication System: Oil Pump Components S6RW0D1506004 I4RS0A150010-01 1. Rotor plate 6. Rotor plate bolt : 11 N⋅m (1.1 kgf-m 8.0 lb-ft) 2. O-ring 7. Relief valve : Do not reuse. 3. Outer rotor 8. Spring : Apply thin coat of engine oil to sliding surface. 4.
Page 363: Oil Pump Inspection
Engine Lubrication System: 1E-7 Oil Pump Inspection Reassembly S6RW0D1506007 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
Page 364 1E-8 Engine Lubrication System: Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure. If the measured valve spring length is lower If clearance exceeds its limit, replace outer rotor or case.
Page 365: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0D1508001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 366: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System Engine General Description Cooling System Description The coolant recovery system is standard. The coolant in S6RW0D1601001 the radiator expands with heat, and the coolant is The cooling system consists of the radiator cap, radiator, overflowed to the reservoir.
Page 367: Schematic And Routing Diagram
Engine Cooling System: 1F-2 Schematic and Routing Diagram Coolant Circulation S6RW0D1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I5RW0C160001-02 1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core 2. Radiator outlet hose 4.
Page 368: Diagnostic Information And Procedures
1F-3 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S6RW0D1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 369: Repair Instructions
Engine Cooling System: 1F-4 Repair Instructions Cooling System Components S6RW0D1606001 I5RW0C160012-01 1. Radiator 11. Thermostat case water outlet pipe 21. Heater outlet No.1 hose 2. Reservoir 12. Thermostat case 22. Radiator cooling fan assembly For disassembly and reassembly, refer to “Radiator Cooling Fan Disassembly and Reassembly”.
Page 370: Coolant Level Check
1F-5 Engine Cooling System: Coolant Level Check NOTE S6RW0D1606002 After installing radiator cap to radiator, make WARNING sure that the ear of cap lines is parallel to radiator. To help avoid danger of being burned, do not remove radiator cap while engine and Cooling system and radiator cap holding radiator are still hot.
Page 371: Cooling System Flush And Refill
Engine Cooling System: 1F-6 Cooling System Flush and Refill 7) Remove reservoir cap (2) and reservoir (1). S6RW0D1606005 8) Pour out any fluid, scrub and clean inside of WARNING reservoir with soap and water. Flush it well with clean water and drain, Reinstall To help avoid danger of being burned, do not reservoir.
Page 372: Thermostat Removal And Installation
1F-7 Engine Cooling System: Thermostat Removal and Installation Thermostat Inspection S6RW0D1606007 S6RW0D1606008 Removal • Make sure that air bleed valve (1) of thermostat is 1) Drain coolant referring to “Cooling System Draining”. clean. 2) Remove intake manifold referring to “Intake Manifold •...
Page 373: Radiator Cooling Fan Assembly On-Vehicle Inspection
Engine Cooling System: 1F-8 Radiator Cooling Fan Assembly On-Vehicle Inspection S6RW0D1606009 1) Check continuity between terminals. If there is no continuity, replace radiator fan assembly. “ a ” “ c ” I5RW0A160004-01 2) Connect battery to radiator fan motor coupler as shown in figure, then check that the radiator fan “...
Page 374: Radiator Cooling Fan Disassembly And Reassembly
1F-9 Engine Cooling System: Radiator On-Vehicle Inspection and Cleaning 5) Remove cooling fan mounting bolts (1). S6RW0D1606012 6) Remove radiator cooling fan assembly (2). Inspection Check radiator for leakage or damage. Straighten bent fins, if any. Cleaning Clean frontal area of radiator cores. I5RW0C160014-01 Installation Reverse removal procedure for installation noting the...
Page 375: Water Pump / Generator Drive Belt Tension Inspection And Adjustment
Engine Cooling System: 1F-10 Water Pump / Generator Drive Belt Tension 5) Check belt tension for specification after turning crankshaft two rotations clockwise. Inspection and Adjustment S6RW0D1606014 6) Tighten generator adjusting bolt (1) as specified WARNING torque. Tightening torque • Disconnect negative cable at battery Generator adjusting bolt (c): Tighten 7.0 N⋅m before checking and adjusting belt (0.7 kgf-m, 5.0 lb-ft) by the specified procedure.
Page 376: Water Pump Removal And Installation
1) Apply sealant to mating surface of water pump (1) as pulley (3) and generator pulley (4). shown in figure. 2) Adjust belt tension referring to “Water Pump / “A”: Water tight sealant 99000–31250 (SUZUKI Generator Drive Belt Tension Inspection and Bond No.1207F) Adjustment”.
Page 377: Water Pump Inspection
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0D1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 378: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions on Fuel System Service S6RW0D1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. •...
Page 379: General Description
Fuel System: 1G-2 General Description Fuel System Description Fuel Pump Description S6RW0D1701001 S6RW0D1701003 The fuel pump (1) is an in-tank type electric pump. CAUTION Incorporated in the pump assembly are; This engine requires the unleaded fuel only. a fuel filter (2), a fuel pressure regulator (3) and a fuel The leaded and/or low lead fuel can result in level sensor (gauge) (4).
Page 380: Schematic And Routing Diagram
1G-3 Fuel System: Schematic and Routing Diagram Fuel Delivery System Diagram S6RW0D1702001 I7RW01170002-02 1. Fuel tank 4. Delivery pipe 7. Fuel filter 2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge) 3. Fuel pressure regulator 6. Fuel feed line 9.
Page 381: Fuel Cut Operation Inspection
Fuel System: 1G-4 4) Check that battery voltage is 11 V or more. 7) Remove special tools from fuel delivery pipe and fuel feed hose. 5) Measure fuel pressure at each condition. If measured pressure is out of specification, refer to 8) Connect fuel feed hose to fuel delivery pipe and “Fuel Pressure Check in Section 1A”...
Page 382: Repair Instructions
1G-5 Fuel System: Repair Instructions Fuel System Components S6RW0D1706001 I6RW0D170001-01 1. Fuel tank 11. Fuel vapor line 21. Fuel pump bolt 2. Fuel pump assembly 12. Fuel tank protector 22. Fuel tank inlet valve 3. Fuel tank filler hose 13. Insulator 23.
Page 383: Fuel Hose Disconnecting And Reconnecting
Fuel System: 1G-6 9. Fuel tank bolt 19. Grommet 10. Fuel tank belt 20. O-ring Fuel Hose Disconnecting and Reconnecting S6RW0D1706002 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury. For Connection Other Than Quick Joint •...
Page 384: Fuel Pressure Relief Procedure
1G-7 Fuel System: Clamp other than around fuel tank 4. Red mark For Quick Joint Disconnecting 1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (fuel pipe) (2) by blowing compressed air. 2) Unlock joint lock by inserting special tool between pipe and quick joint.
Page 385: Fuel Leakage Check Procedure
Fuel System: 1G-8 Fuel Pipe Removal and Installation 6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3 S6RW0D1706006 seconds each time in order to dissipate fuel pressure WARNING in lines.
Page 386: Fuel Injector On-Vehicle Inspection
1G-9 Fuel System: Fuel Injector On-Vehicle Inspection Fuel Injector Removal and Installation S6RW0D1706007 S6RW0D1706008 1) Using sound scope (1) or such, check operating WARNING sound of injector (2) when engine is running or cranking. Before starting the following procedure, be Cycle of operating sound should vary according to sure to observe “Precautions on Fuel System engine speed.
Page 387: Fuel Injector Inspection
Fuel System: 1G-10 Fuel Injector Inspection Installation Reverse removal procedure for installation noting the S6RW0D1706009 following. WARNING • Replace injector O-ring (1) with new one using care not to damage it. • Before starting the following procedure, be sure to observe “Precautions on Fuel •...
Page 388 If fuel leaks (1) more than the following iii) Turn fuel pump ON by using scan tool. specifications, replace. Special tool Fuel leakage (A): SUZUKI scan tool (SUZUKI-SDT) Less than 1 drop/min. I2RH0B170013-01 9) Remove injector from special tool (A) and disconnect I5RW0C110011-01 b) When not using scan tool: special tool (B) from injector.
Page 389: Fuel Filler Cap Inspection
Fuel System: 1G-12 Fuel Filler Cap Inspection S6RW0D1706010 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury. Remove cap (1), and check gasket for even filler neck imprint, and deterioration or any damage.
Page 390: Fuel Tank Removal And Installation
1G-13 Fuel System: Fuel Tank Removal and Installation 6) Remove exhaust center pipe referring to “Exhaust S6RW0D1706011 Pipe and Muffler Removal and Installation in Section WARNING 1K”. 7) Remove propeller shaft (For 4WD model) referring to Before starting the following procedure, be “Propeller Shaft Assembly Removal and Installation sure to observe “Precautions on Fuel System in Section 3D”.
Page 391: Fuel Tank Inspection
Fuel System: 1G-14 Installation 4) Connect fuel filler hose (1) and breather hose (2) to filler neck (3) as shown in figure, and clamp them CAUTION securely. • When connecting joint, clean outside Tightening torque surfaces of pipe where joint is to be Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m, inserted, push joint into pipe till joint lock 1.0 lb-ft)
Page 392: Fuel Tank Purging Procedure
1G-15 Fuel System: Fuel Tank Purging Procedure S6RW0D1706013 WARNING • Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury. • This purging procedure will not remove all fuel vapor.
Page 393: Main Fuel Level Sensor Removal And Installation
Fuel System: 1G-16 Installation 5) Install fuel tank to vehicle. Refer to “Fuel Tank Removal and Installation”. CAUTION Main Fuel Level Sensor Removal and When connecting joint, clean outside surface of pipe where joint is to be inserted, push Installation joint into pipe till joint lock clicks and check S6RW0D1706019 CAUTION...
Page 394: Fuel Pump Inspection
1G-17 Fuel System: Fuel Pump Inspection S6RW0D1706016 • Check fuel pump assembly for damage. • Check fuel suction filter for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. • For electrical circuit, refer to “Fuel Pump and Its Circuit Check in Section 1A”.
Page 395: Special Tools And Equipment
(09912- 58413). 58413). 09912–58490 09919–47020 3-way joint & hose Quick joint remover 09930–88530 SUZUKI scan tool (SUZUKI- SDT) Injector test lead — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.
Page 396: Ignition System
1H-1 Ignition System: Ignition System Engine General Description Ignition System Construction S6RW0D1801001 The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 397: Schematic And Routing Diagram
Ignition System: 1H-2 Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S6RW0D1802001 BLK/WHT GRN/WHT C01-5 GRN/YEL C01-6 BLK/WHT E01-29 BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED E01-16 BLK/RED C01-58 BLK/ORN RED/YEL C01-20 C01-15 C01-30 C01-21 E01-31 BLK/ORN 39 38 32 31 39 38...
Page 398: Component Location
1H-3 Ignition System: Component Location Ignition System Components Location S6RW0D1803001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I5RW0C180002-01 1. ECM 7. ECT sensor 13. Battery fuse box 2.
Page 399: Diagnostic Information And Procedures
Ignition System: 1H-4 Diagnostic Information and Procedures Ignition System Symptom Diagnosis S6RW0D1804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to start Loose connection or disconnection of Connect securely.
Page 400 1H-5 Ignition System: Step Action Ignition coil assembly power supply and ground circuit Go to Step 7. Repair or replace. check 1) Check ignition coil assembly power supply and ground circuits for open and short. Are circuits in good condition? Ignition coil assembly check Go to Step 8.
Page 401: Repair Instructions
Ignition System: 1H-6 Ignition Spark Test 5) Crank engine and check if each spark plug sparks. S6RW0D1804004 1) Remove air cleaner assembly with air intake pipe. 2) Disconnect all injector couplers from injectors. WARNING Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.
Page 402: High-Tension Cord Inspection
1H-7 Ignition System: High-Tension Cord Inspection Spark Plug Inspection S6RW0D1806002 S6RW0D1806004 Measure resistance of high-tension cord (1) by using CAUTION ohmmeter. If resistance exceeds specification, replace high-tension • When servicing the iridium / platinum cord(s). spark plugs (slender center electrode type plugs), do not touch the center electrode High-tension cord resistance to avoid damage to it.
Page 403: Ignition Coil Assembly (Including Ignitor) Removal And Installation
OFF. Ignition coil bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) Special tool 3) Install high-tension cord (3) to ignition coil assembly (A): SUZUKI scan tool (SUZUKI-SDT) while gripping its cap. I5RW0C110011-01 I3RM0A180004-01 4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
Page 404 • Timing chain cover installation Initial ignition timing 8) After checking initial ignition timing, release ignition fixed with SUZUKI scan tool: 5 ± 3° BTDC (at timing fixation by using scan tool. specified idle speed) 9) With engine idling (throttle opening at closed position...
Page 405: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S6RW0D1808001 09930–76420 SUZUKI scan tool (SUZUKI- SDT) Timing-light (dry cell type) — This kit includes following items.
Page 406: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Cranking System Circuit Diagram S6RW0D1902001 I4RS0A190001-01 1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch 2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery 3. Magnetic switch 8.
Page 407 Starting System: 1I-2 Condition Possible cause Correction / Reference Item Motor not running (No Transmission range sensor is not in P or Shift in P or N, or adjust sensor. (A/T model) operating sound of N, or not adjusted (A/T model) magnetic switch) Battery run down Recharge battery.
Page 408: Cranking System Test
1I-3 Starting System: Condition Possible cause Correction / Reference Item Starting motor does not Fused contact points of magnetic switch Replace magnetic switch. stop running Short-circuit between turns of magnetic Replace magnetic switch. switch coil (layer short-circuit) Failure of returning action in ignition Replace.
Page 409: Repair Instructions
Starting System: 1I-4 Repair Instructions Starting Motor Dismounting and Remounting S6RW0D1906001 I4RS0A190002-01 : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) Dismounting 1) Disconnect negative (–) battery lead at battery. 2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) Detach shift &...
Page 410: Starting Motor Components
1I-5 Starting System: Starting Motor Components S6RW0D1906002 I4RS0A190003-01 1. Front housing 7. Plate 13. Planetary gear 19. Rear bush 2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut 3. Pinion stop ring 9. Magnetic switch 15. Yoke : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) 4.
Page 411: Starting Motor Inspection
Starting System: 1I-6 Starting Motor Inspection Hold-in coil open circuit test S6RW0D1906003 Check for continuity across magnetic switch “S” terminal (1) and coil case. If no continuity, coil is open and should Plunger be replaced. Inspect plunger for wear. Replace if necessary. I2RH01190011-01 Rear Bracket Bush I2RH01190008-01...
Page 412 1I-7 Starting System: Spring • Check commutator for uneven wear with armature (1) Inspect brush springs for wear, damage or other supported on V-blocks (2). If deflection of dial gauge abnormal conditions. Replace if necessary. (4) pointer exceeds limit, repair or replace. Brush spring tension NOTE Standard: 2.2 kg (4.85 lb)
Page 413 Starting System: 1I-8 • Inspect the commutator (1) for insulator (2) depth. Gears Correct or replace if below limit. Inspect the internal gear and the planetary gears for wear, damage or other abnormal conditions. Replace if Commutator insulator depth “a” necessary.
Page 414: Specifications
1I-9 Starting System: Front Housing Bush Inspect the bush for wear or damage. Replace if necessary. I2RH01190024-01 Specifications Cranking System Specifications S6RW0D1907002 Voltage 12 volts Output 1.2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.)
Page 415: Charging System
Charging System: 1J-1 Charging System Engine General Description Battery Description Built-In Indicator (If Equipped) S6RW0D1A01001 The battery has a built-in temperature compensated The battery has three major functions in the electrical indicator in the top of the battery. This indicator is to be system.
Page 416 1J-2 Charging System: Care of battery WARNING • Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. • Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid.
Page 417: Generator Description
Charging System: 1J-3 Generator Description S6RW0D1A01002 The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown below. I6RW0D1A0002-01 1. Pulley 6. Field coil B: Generator output (Battery terminal) L: Lamp terminal 2.
Page 418: Diagnostic Information And Procedures
1J-4 Charging System: Diagnostic Information and Procedures Battery Inspection Generator Symptom Diagnosis S6RW0D1A04001 S6RW0D1A04002 Common Causes of Failure CAUTION A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If • Do not mistake polarities of “IG” terminal and “L”...
Page 419: Generator Test (Undercharged Battery Check)
Charging System: 1J-5 Charging Indicator Lamp Operation Condition Possible cause Correction / Reference Item Charge light does not Fuse blown Check fuse. light with ignition ON and Indicator lamp (LED) faulty Check BCM, combination meter and/or CAN engine off communication line. Wiring connection loose Tighten loose connection.
Page 420: Generator Test (Overcharged Battery Check)
1J-6 Charging System: Generator Test (Overcharged Battery Check) 3) Ground “F” terminal and start engine, then measure voltage at “B” terminal as shown in figure. S6RW0D1A04004 1) To determine battery condition, refer to “Battery • Voltage is higher than standard value. It is Description”.
Page 421: Battery Dismounting And Remounting
Charging System: 1J-7 1) Set parking brake and place automatic transaxle in Remounting PARK (NEUTRAL on manual transaxle). Turn off 1) Reverse removal procedure. ignition, turn off lights and all other electrical loads. 2) Tighten battery cables securely. 2) Check electrolyte level. If it is below low level line, NOTE add distilled water.
Page 422: Water Pump / Generator Drive Belt Removal And Installation
1J-8 Charging System: Water Pump / Generator Drive Belt Removal and Installation S6RW0D1A06007 Removal 1) Disconnect negative cable at battery. 2) If vehicle equipped with A/C, remove compressor drive belt before removing water pump belt (1). Refer to “Compressor Drive Belt Removal and Installation in Section 7B”...
Page 423: Generator Dismounting And Remounting
Charging System: 1J-9 Generator Dismounting and Remounting S6RW0D1A06003 1) Disconnect negative cable at battery. 2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A” 3) Dismount in numerical order as shown in figure. 4) Reverse dismounting procedure for remounting.
Page 424: Generator Components
1J-10 Charging System: Generator Components S6RW0D1A06004 I4RS0A1A0004-01 1. Pulley nut 7. Bearing retainer 13. Seal plate 19. Brush holder cover : 3.6 N⋅m (0.36 kgf-m, 3.0 lb-ft) 2. Pulley 8. Rotor 14. Rectifier 20. Rear end cover : 2.0 N⋅m (0.2 kgf-m, 1.5 lb-ft) 3.
Page 425: Generator Inspection
Charging System: 1J-11 Generator Inspection S6RW0D1A06005 Rotor 1) Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
Page 426 1J-12 Charging System: 4) Check slip rings for roughness or scoring. If rough or scored, replace the rotor. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor. Slip ring diameter Standard: 14.2 –...
Page 427: Specifications
Charging System: 1J-13 Specifications Charging System Specifications S6RW0D1A07003 Battery NOTE The battery used in each vehicle is one of the following two types, depending on specification. Battery type 46B24R 55B24R Rated capacity AH/5HR, 12 Volts 40.6 42.5 Electrolyte L (US / lmp pt.) —...
Page 428: Exhaust System
1K-1 Exhaust System: Exhaust System Engine General Description Exhaust System Description S6RW0D1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 429: Repair Instructions
Exhaust System: 1K-2 Repair Instructions Exhaust System Components S6RW0D1B06001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I5RW0C1B0001-01 [A]: Installing location of exhaust manifold bolt and nut.
Page 430: Exhaust Manifold Removal And Installation
1K-3 Exhaust System: 10. Exhaust center pipe 21. Exhaust pipe clamp : Do not reuse. Exhaust Manifold Removal and Installation 6) Remove exhaust manifold (1) and its gasket from S6RW0D1B06002 cylinder head. Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot.
Page 431: Exhaust Pipe And Muffler Removal And Installation
Exhaust System: 1K-4 2) Install new seal ring and connect exhaust No.1 pipe 6) Connect HO2S-1 connector (1) (connector color: (1) to exhaust manifold. black) and HO2S-2 connector (2) (connector color: Tighten pipe fasteners to specified torque. green), and then fit coupler to bracket securely. Tightening torque Exhaust No.1 pipe bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
Page 432 1K-5 Exhaust System: Specifications Tightening Torque Specifications S6RW0D1B07001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust manifold bolt 36.5 Exhaust manifold nut 36.5 Exhaust No.1 pipe bolt 36.5 Exhaust manifold stiffener bolt 36.5 Exhaust No.2 pipe bolt 31.0 NOTE The specified tightening torque is also described in the following.
Page 433 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Front Suspension Fasteners Check....2B-20 Specifications .............2B-21 Precautions............. 2-1 Tightening Torque Specifications......2B-21 Precautions on Suspension ........2-1 Special Tools and Equipment ......2B-22 Suspension General Diagnosis....2A-1 Recommended Service Material .......2B-22 Special Tool ............2B-22 Diagnostic Information and Procedures....2A-1 Suspension, Wheels and Tires Symptom...
Page 434: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions on Suspension S6RW0D2000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. General Precautions Refer to “General Precautions in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points in Section 0A”.
Page 435: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S6RW0D2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tires. Tires not adequately inflated Adjust tire pressure. Broken or sagging coil springs Replace coil springs.
Page 436 2A-2 Suspension General Diagnosis: Condition Possible cause Correction / Reference Item Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes. Faulty strut (shock absorber) or Replace strut (shock absorber) or tighten mounting mounting.
Page 437: Specifications
Suspension General Diagnosis: 2A-3 Specifications Wheel Alignment Specifications Side Slip (On one person) S6RW0D2107001 Front: 0 to IN 3.0 mm/m (0 to IN 0.118 (in./3.3 ft)) (Reference information) Toe “b” – “a” Front: IN 1 ± 1 mm (IN 0.0393 ± 0.0393 (in.)) Steering Angle (Turning Angle) Rear: IN 5 ±...
Page 438: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension General Description Front Suspension Construction S6RW0D2201001 I7RW01220002-03 1. Front strut assembly 8. Front suspension frame : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft) 2. Front drive shaft 9. Suspension control arm : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) 3.
Page 439: Front Wheel Alignment Construction
Front Suspension: 2B-2 Front Wheel Alignment Construction • Check all tires for proper inflation pressures and S6RW0D2201002 approximately the same tread wear. Among factors for front wheel alignment, only toe setting • Check for loose of ball joints. Check tie-rod ends; if can be adjusted.
Page 440 2B-3 Front Suspension: Adjustment Steering Angle Check and Adjustment When tie-rod or tie-rod end was replaced, check toe and 1) Loosen right and left tie-rod end lock nuts (1) first. then also steering angle with turning radius gauge (1). 2) Rotate right and left tie-rods (2) by the same amount If steering angle is not correct, check whether right and to align toe to specification.
Page 441: Front Strut Assembly Components
Front Suspension: 2B-4 Front Strut Assembly Components S6RW0D2206002 I7RW01220003-03 1. Front strut 6. Coil spring upper seat 11. Strut nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 2. Coil spring 7. Strut bearing 12. Strut bracket bolt : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) : Insert from vehicle front side.
Page 442: Front Strut Assembly Removal And Installation
2B-5 Front Suspension: Front Strut Assembly Removal and Installation 4) Remove brake hose mounting bolt (1). Remove S6RW0D2206003 brake hose (2) from bracket and wheel speed sensor harness (3) from strut bracket as shown in figure. CAUTION 5) Remove strut bracket bolts and nuts (4). When rebound stopper and strut assembly were removed, check strut support lower nut for specified torque before installing strut...
Page 443 Front Suspension: 2B-6 Installation Install strut assembly by reversing removal procedure, noting the following instructions. • Insert bolts in such direction as shown in figure. • Tighten all fasteners to specified torque. Tightening torque Strut bracket nut (a): 140 N·m (14.0 kgf-m, 101.5 lb-ft) Brake hose mounting bolt (c): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Page 444: Front Strut Assembly Disassembly And Reassembly
2B-7 Front Suspension: Front Strut Assembly Disassembly and Reassembly For assembly, reverse disassembly procedure, noting Reassembly the following instructions. S6RW0D2206004 1) Compress coil spring with special tool (A) until total Disassembly length becomes about 280 mm (11.0 in.) as shown. 1) Attach special tool (A) to coil spring as shown.
Page 445: Front Strut Assembly Check
Front Suspension: 2B-8 Front Strut Assembly Check 3) Install bump stopper and strut dust cover onto strut rod. For installing direction, refer to the figure in S6RW0D2206005 • Inspect strut for oil leakage, damage or deformation. “Front Strut Assembly Components”. If defect is found, replace strut as an assembly unit, 4) Pull strut rod as far up as possible and use care not because it can not be disassembled.
Page 446: Front Wheel Hub And Steering Knuckle Components
2B-9 Front Suspension: Front Wheel Hub and Steering Knuckle Components S6RW0D2206006 I7RW01220014-01 1. Front wheel hub 4. Steering knuckle 7. Dust cover 2. Circlip 5. Drive shaft nut : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft) : Calk, after tightening. 3. Wheel bearing 6.
Page 447 Front Suspension: 2B-10 6) Pull out wheel hub (1) with special tools. 9) Loosen strut bracket nuts (1). 10) Remove ball joint bolt (4) and washer (3). Special tool (A): 09943–17912 11) Remove strut bracket bolts (5) from strut bracket and then steering knuckle (2).
Page 448 2B-11 Front Suspension: 15) Remove wheel bearing outside inner race (1). Installation For installation, reverse removal procedure, noting the Special tool following instructions. (A): 09913–65810 1) Face grooved rubber seal side (1) of new wheel (B): 09913–85230 bearing (2) upward as shown in figure and press-fit it into knuckle (3) using special tool.
Page 449 2B-12 4) Drive in dust cover so that dimensions “a” and “b” 7) Apply grease lightly to end face of inner ring (1). become equal as shown in the figure. “A”: Grease 99000–25121 (SUZUKI Super Grease H) CAUTION NOTE When drive in dust cover, be careful not to deform it.
Page 450 2B-13 Front Suspension: 9) Install ball joint bolt (1), washer (2), strut bracket 13) Connect tie-rod end (1) to steering knuckle (2), bolts (4) and new nuts (3) from the direction shown tighten new nut (3) to specified torque. in figure. Tightening torque 10) Tighten suspension arm ball joint bolt (2) to specified Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
Page 451: Front Wheel Hub, Disc, Bolt And Bearing Check
Front Suspension: 2B-14 Front Wheel Hub, Disc, Bolt and Bearing Check Suspension Control Arm / Bushing Removal S6RW0D2206008 and Installation • Inspect each wheel disc for dents, distortion and S6RW0D2206009 cracks. CAUTION A disc in badly damaged condition must be replaced. When removal and installing steering •...
Page 452: Suspension Control Arm / Bushing Disassembly And Assembly
2B-15 Front Suspension: Suspension Control Arm / Bushing Installation Disassembly and Assembly 1) Install suspension control arm as shown but tighten S6RW0D2206010 suspension control arm bolts (1) only temporarily. Disassembly CAUTION 1) Cut off bushing flange (rubber) (1) with knife. Use new control arm bolt.
Page 453: Suspension Control Arm / Steering Knuckle Check
Front Suspension: 2B-16 Suspension Control Arm / Steering Knuckle Assembly Check 1) Front bushing S6RW0D2206011 Press-fit front bushing (1) by using special tools and Inspect for cracks, deformation or damage. press (2). If defective, replace. Special tool (A): 09943–76310 Suspension Control Arm Bushing Check (B): 09913–75821 S6RW0D2206012 Inspect for damage, wear or deterioration.
Page 454: Front Suspension Frame, Stabilizer Bar And/Or Bushing Components
2B-17 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or Bushing Components S6RW0D2206014 I6RW0D220001-02 1. Stabilizer bar 4. Stabilizer bar mounting 7. Front suspension frame : 95 N⋅m (9.5 kgf-m, 36.5 lb-ft) bracket bolt 2. Stabilizer bushing 5. Suspension control arm 8.
Page 455: Front Suspension Frame, Stabilizer Bar And/Or Bushing Removal And Installation
Front Suspension: 2B-18 Front Suspension Frame, Stabilizer Bar and/or 10) Remove engine rear mounting nut and mounting member nut referring to “Engine Mountings Bushing Removal and Installation Components in Section 1D”. S6RW0D2206015 11) Support front suspension frame (2) with mission jack WARNING (1).
Page 456 2B-19 Front Suspension: Installation 4) Align lugs (1) (right and left) of front suspension frame with whole (2) in vehicle body. 1) Install stabilizer bar (1), stabilizer bushing (2) and stabilizer mounting bracket (3) to front suspension frame as shown in figure while ensuring that stabilizer is centered, side-to-side.
Page 457: Front Suspension Frame Check
Front Suspension: 2B-20 12) Install exhaust No.1, No.2 and center pipe referring Stabilizer Bushing to “Exhaust System Components in Section 1K”. Inspect for damage, wear or deterioration. If defective, replace. 13) Install wheel and tighten nut to specified torque. Tightening torque Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) 14) Install air cleaner assembly referring to “Air Cleaner Assembly Removal and Installation in Section 1D”.
Page 458 2B-21 Front Suspension: Specifications Tightening Torque Specifications S6RW0D2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 32.5 Strut bracket nut 14.0 101.5 Brake hose mounting bolt 19.0 Stabilizer joint nut 36.5 Strut nut 36.5 Wheel nut 61.5 Strut support lower nut 40.0...
Page 459: Special Tools And Equipment
Front Suspension: 2B-22 Special Tools and Equipment Recommended Service Material S6RW0D2208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease H P/No.: 99000–25121 Special Tool S6RW0D2208002 09913–65810 09913–75510 Crankshaft bearing puller Bearing installer 09913–75821 09913–85230 Bearing installer attachment Bearing remover tool 09925–14520...
Page 460: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components S6RW0D2306001 I6RW0D230001-01 F: Forward 7. Vehicle body 16. Rear drive shaft nut [A]: 2WD model 8. Rear shock absorber 17. Rear wheel hub assembly [B]: 4WD model 9. Lower washer : 73 N⋅m (7.3 kgf-m, 53.0 lb-ft) 1.
Page 461: Rear Shock Absorber Removal And Installation
Rear Suspension: 2C-2 Rear Shock Absorber Removal and Installation Installation S6RW0D2306002 1) Install absorber upper bushes (1). Removal 1) Hoist vehicle and remove rear wheel. NOTE 2) Remove access hole cover (1) in quarter inner trim For proper installing direction of shock (2).
Page 462: Rear Shock Absorber Inspection
2C-3 Rear Suspension: Rear Shock Absorber Inspection 3) Remove floor jack from rear axle. S6RW0D2306003 4) Install rear wheel and tighten wheel nuts to specified • Inspect for deformation or damage. torque. • Inspect bushings for wear or damage. Tightening torque •...
Page 463: Rear Coil Spring Removal And Installation
Rear Suspension: 2C-4 Rear Coil Spring Removal and Installation 5) Detach each lower end (2) of shock absorbers (1) S6RW0D2306005 (right and left) from rear axle. CAUTION 6) Lower rear axle gradually as far down as the coil spring can be removed. Removal and Installation both coil springs (right and left) at the same time to avoid rear CAUTION...
Page 464: Spring Upper Seat / Spring Lower Seat Inspection
2C-5 Rear Suspension: Installation 4) Remove floor jacks from rear axle. 1) Install spring upper seat (1) to vehicle body and 5) Remount rear differential (4WD model) referring to lower seat (2) to rear axle. “Rear Differential Dismounting and Remounting in Section 3B”.
Page 465: Rear Axle Removal And Installation
Rear Suspension: 2C-6 Rear Axle Removal and Installation Installation S6RW0D2306007 CAUTION CAUTION Never reuse rear axle bolts and rear wheel Do not drop brake fluid onto painted surface. hub mounting bolts. Painted surfaces will be damaged. 1) Install brake pipes to rear axle, if removed. Removal 2) Using floor jacks, install rear axle and new rear axle 1) Hoist vehicle and remove exhaust center pipe and...
Page 466: Rear Axle And Coil Spring Inspection
2C-7 Rear Suspension: Rear Axle Bush Inspection 6) Connect rear height sensor link (if equipped) to rear axle referring to “Height Sensor Removal and S6RW0D2306010 Inspect for cracks, deformation or damage. If necessary, Installation (If Equipped) in Section 9B”. replace rear axle assembly. 7) Install exhaust center pipe and muffler.
Page 467: Rear Wheel Hub Assembly Removal And Installation
Rear Suspension: 2C-8 Rear Wheel Hub Assembly Removal and 5) Disconnect wheel speed sensor (1). Installation 6) Remove brake back plate (2) and rear wheel hub S6RW0D2306012 from rear axle. CAUTION Do not allow brake fluid to get on painted surfaces.
Page 468 2C-9 Rear Suspension: Installation 4) Connect wheel speed sensor and tighten wheel speed sensor bolt (2WD model) to specified torque. 1) Insert wheel stud bolt (1) in hub hole. Rotate wheel stud bolt slowly to assure that serrations are aligned Tightening torque with those made by original bolt.
Page 469: Specifications
Rear Suspension: 2C-10 Specifications Tightening Torque Specifications S6RW0D2307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Wheel nut 61.5 Rear shock absorber upper nut 22.0 Rear shock absorber lower nut 65.0 Rear axle bolt 53.0 Brake pipe flare nut 11.5 Rear wheel hub mounting bolt 53.0 Drive shaft nut...
Page 470: Wheels And Tires
2D-1 Wheels and Tires: Wheels and Tires Suspension General Description Tires Description Lower than recommended pressure can cause: S6RW0D2401001 • Tire squeal on turns The tire is of tubeless type. The tire is designed to • Hard Steering operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation •...
Page 471: Wheels Description
Wheels and Tires: 2D-2 How to Measure Wheel Runout Replacement Tires When replacement is necessary, the original equipment To measure the wheel runout, it is necessary to use an type tire should be used. Refer to the Tire Placard. accurate dial indicator. The tire may be on or off the Replacement tires should be of the same size, load wheel.
Page 472: Irregular And/Or Premature Wear Description
2D-3 Wheels and Tires: Irregular and/or Premature Wear Description S6RW0D2401003 Irregular and premature wear has many causes. Some of them are as follows: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, tire rotation is necessary: •...
Page 473: Radial Tire Lead / Pull Description
Wheels and Tires: 2D-4 Equipment manufacture’s recommendations Inflate tires to recommended pressure Road test vehicle on level unrouned road in both directions Switch front tires side to side and road test again Lead corrected, Leads reverses direction Leads in same direction if roughness results, replace tires Put tires back in original position Install a known-good tire on one front side...
Page 474: Repair Instructions
2D-5 Wheels and Tires: Repair Instructions Wheel Discs Inspection Tire Rotation S6RW0D2406006 S6RW0D2406002 Inspect each wheel disc for dents, distortion and cracks. To equalize wear, rotate tires periodically as shown in A disc in badly damaged condition must be replaced. figure.
Page 475: Wheel (With Tire) Removal And Installation
Wheels and Tires: 2D-6 Wheel (with Tire) Removal and Installation Tire Mounting and Dismounting S6RW0D2406003 S6RW0D2406004 Removal WARNING CAUTION Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety Never use heat to loosen tight wheel because hump and cause serious personal injury.
Page 476: Specifications
2D-7 Wheels and Tires: Specifications Wheels and Tires Specifications S6RW0D2407001 Tire size (Standard) : 205/60 R16 92H Wheel size (Standard) : 16 x 6J (for 205/60 R16) Tightening torque Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) NOTE • Tire inflation pressure should be checked when tires are cool. •...
Page 477 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Precautions............3B-1 Precaution for Rear Differential Oil Leakage..3B-1 Precautions............. 3-1 Precautions in Diagnosing Trouble .....3B-1 Precautions on Driveline / Axle ......3-1 General Description ..........3B-2 Drive Shaft / Axle ........3A-1 Rear Differential Description .......3B-2 Coupling Description ...........3B-2 Front .................3A-1...
Page 478 3-ii Table of Contents DTC U0100: Lost Communication with ECM ..3B-27 Diagnostic Information and Procedures ....3C-1 DTC U0121: Lost Communication with ABS / Transfer Symptom Diagnosis......3C-1 ESP® Control Module........3B-27 Repair Instructions ..........3C-2 DTC U0155: Lost Communication with Transfer Oil Level Check........3C-2 Instrument Panel Cluster (IPC) Control Transfer Oil Change..........3C-2 Module ............3B-27...
Page 479: Precautions
Precautions: Precautions Driveline / Axle Precautions Precautions on Driveline / Axle S6RW0D3000001 Precaution for Rear Differential Oil Leakage Refer to “Precaution for Rear Differential Oil Leakage in Section 3B”. Precaution in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 3B”. Precaution on CAN Troubleshooting Refer to “Precaution on CAN Troubleshooting in Section 1A”.
Page 480: Drive Shaft / Axle
3A-1 Drive Shaft / Axle: Front Drive Shaft / Axle Driveline / Axle Front General Description Front Drive Shaft Construction S6RW0D3111001 A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side.
Page 481: Diagnostic Information And Procedures
Drive Shaft / Axle: Front 3A-2 Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S6RW0D3114001 Condition Possible cause Correction / Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace. Worn or breakage of the center bearing Replace. Repair Instructions Front Drive Shaft Components S6RW0D3116001...
Page 482: Front Drive Shaft Assembly On-Vehicle Inspection
3A-3 Drive Shaft / Axle: Front Front Drive Shaft Assembly On-Vehicle 5) Remove brake hose mounting bolt (1) and brake hose (2) from bracket and then detach wheel speed Inspection sensor harness (3) from strut bracket. S6RW0D3116002 • Check boots for breakage or deterioration. 6) Remove suspension control arm ball joint bolt (4) •...
Page 483: Front Drive Shaft Disassembly And Reassembly
Drive Shaft / Axle: Front 3A-4 Front Drive Shaft Disassembly and Reassembly 9) Remove drive shaft assembly. S6RW0D3116004 10) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from Disassembly differential side gear, if equipped. For DOJ type CAUTION Disassembly of wheel side joint is not...
Page 484 3A-5 Drive Shaft / Axle: Front 2) Remove differential side (or center shaft side) boot 5) Draw away cage (1) by using bearing puller (2), and small band (1) using flat end rod (2) or the like. remove boot (3) from shaft. I5RS0B310005-01 3) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out...
Page 485 Drive Shaft / Axle: Front 3A-6 For tripod joint type 2) Wipe off grease from shaft and take off snap ring (1) using snap ring pliers (2). CAUTION • Disassembly of wheel side joint is not allowed. If any noise or damage exists in it, replace it as assembly.
Page 486 3A-7 Drive Shaft / Axle: Front Reassembly For DOJ type Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly and DOJ housing are washed thoroughly and air dried.
Page 487 Drive Shaft / Axle: Front 3A-8 10) Install damper (1) to specified position on drive shaft. 14) Apply grease to entire surface of cage. Use specified grease in tube included in spare parts. Drive shaft damper installing position 15) Insert cage into joint housing (2) and fit snap ring (1) “a”: 354 mm (13.9 in.) (right side) into groove of joint housing (2).
Page 488 3A-9 Drive Shaft / Axle: Front 17) Fit boot (1) to grooves of shaft and housing (2) and 19) Fasten differential side (or center shaft side) boot adjust length to specification below. band. Insert screw driver into boot and allow air to enter •...
Page 489 Drive Shaft / Axle: Front 3A-10 For tripod joint type Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly (1) and tripod joint housing (2) are washed thoroughly and air dried.
Page 490 3A-11 Drive Shaft / Axle: Front 8) Install damper (1) to specified position on drive shaft, 12) Fit boot (1) to grooves of shaft and housing (2) adjust if equipped. length to specification below. 13) Insert screw driver into boot and allow air to enter Drive shaft damper installing position boot so that air pressure in boot becomes the same “a”: 354 mm (13.9 in.) (right side)
Page 491: Center Shaft And Center Bearing Support
Drive Shaft / Axle: Front 3A-12 Center Shaft and Center Bearing Support 15) Fasten differential side (or center shaft side) boot big band (1) and small band (5) by drawing hooks (2) Disassembly and Reassembly (If Equipped) with special tool and engage hooks (3) in slot and S6RW0D3116005 Disassembly window (4).
Page 492: Specifications
“a”: 0 – 1 mm (0 – 0.04 in.) “b”: 8 – 9 mm (0.13 – 0.35 in.) • Be sure to apply grease to oil seal lip and bearing side space indicated in the figure. I5RW0A311008-01 “A”: Grease 99000–25011 (SUZUKI Super Grease “A” “A” “a” “b”...
Page 493: Special Tools And Equipment
Drive Shaft / Axle: Front 3A-14 Special Tools and Equipment Recommended Service Material S6RW0D3118001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 NOTE Required service material is also described in the following. “Front Drive Shaft Components”...
Page 494: Rear
3A-15 Drive Shaft / Axle: Rear Rear General Description Rear Drive Shaft Construction S6RW0D3121001 Refer to “Front Drive Shaft Construction”. Repair Instructions Rear Drive Shaft Components S6RW0D3126001 I5RW0A312001-01 1. Differential side joint (Constant velocity DOJ joint) 6. Wheel side joint (Constant velocity ball joint) 11.
Page 495: Rear Drive Shaft Assembly Removal And Installation
Drive Shaft / Axle: Rear 3A-16 Rear Drive Shaft Assembly Removal and Rear Drive Shaft Disassembly and Reassembly S6RW0D3126003 Installation Disassembly S6RW0D3126002 Refer to “Front Drive Shaft Disassembly and Removal Reassembly” note the following point which is different 1) Hoist vehicle and remove rear wheel. from the front drive shaft is described.
Page 496 3A-17 Drive Shaft / Axle: Rear Reassembly • Fasten differential side boot band as follows. Refer to “Front Drive Shaft Disassembly and CAUTION Reassembly” note the following points which is different from the front drive shaft is described. • Bend each boot band against forward •...
Page 497: Specifications
Drive Shaft / Axle: Rear 3A-18 Specifications Tightening Torque Specifications S6RW0D3127001 NOTE The specified tightening torque is also described in the following. “Rear Drive Shaft Components” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0D3128001...
Page 498: Differential
– Disconnect main fuse from fuse box • Diagnostic information stored in 4WD control module memory can be cleared as 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 functions are available and how to use it.
Page 499: General Description
Differential: 3B-2 General Description Rear Differential Description S6RW0D3201001 The differential assembly uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between hypoid bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Page 500 3B-3 Differential: 4WD Control System Components S6RW0D3201003 I5RW0A320002-04 1. 4WD control module 3. 4WD LOCK indicator 5. Coupling assembly 2. 4WD AUTO indicator 4. 2WD/4WD switch 6. Coupling air temperature sensor...
Page 501: 4Wd Control System Description
Differential: 3B-4 4WD Control System Description S6RW0D3201004 4WD Shift Control The 4WD control module operates the coupling assembly according to the 2WD/4WD switch operation to the selected position (2WD, 4WD-auto or 4WD-lock). Also, the 4WD control system has 4WD AUTO indicator and 4WD LOCK indicator in order to inform the 4WD control system condition.
Page 502: 4Wd Control System Wiring Circuit Diagram
3B-5 Differential: 4WD Control System Wiring Circuit Diagram S6RW0D3201006 L174-1 G26-13 RED/WHT L102-1 G26-3 G26-2 L102-4 L174-5 L174-4 BLK/ORN G26-14 GRY/YEL G26-25 G26-21 G26-24 G26-12 RED/BLK G26-22 G26-23 G26-11 WHT/RED G26-10 I7RW01320001-01 1. Coupling assembly 6. ECM 11. Data link connector (DLC) 2.
Page 503: Input / Output Signal Table Of 4Wd Control Module
– Coupling air temperature sensor – Coupling assembly • DTC can be checked by using SUZUKI scan tool (3) connected to DLC (4). • When 4WD control module detects any malfunction, 4WD control module will switch off the current to coupling assembly and vehicle is changed to 2WD position.
Page 504: Can Communication System Description
3B-7 Differential: CAN Communication System Description S6RW0D3201010 Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. When 4WD control module receive the signal of abnormal as following information, vehicle is not changed to 4WD- auto and 4WD-lock position. 4WD Control Module Transmission Data ESP®...
Page 505: Diagnostic Information And Procedures
Differential: 3B-8 Diagnostic Information and Procedures 4WD Control System Check S6RW0D3204001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC check, record and clearance Print DTC or write them...
Page 506 3B-9 Differential: Detail of 4WD Control System Check Step 1. Customer complaint analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 507: 4Wd Position Indicator Operation Check
Differential: 3B-10 4WD Position Indicator Operation Check Step 2. DTC check, record and clearance First, referring to “DTC Check”, check DTC and pending S6RW0D3204002 1) Turn ignition switch to OFF position. DTC. If DTC exists, print or write down DTC and then clear malfunction DTC(s) by referring to “DTC 2) Check that 4WD position indicators turn on for about Clearance”.
Page 508: Visual Inspection
4) Read DTC according to instructions displayed on 4) Erase DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer SUZUKI scan tool. Refer to SUZUKI scan tool to SUZUKI scan tool operator’s manual for further operator’s manual for further details.
Page 509: Dtc Table
Differential: 3B-12 DTC Table S6RW0D3204007 Detecting condition DTC No. Detecting item position (DTC will set when detecting) Indicator 4WD control module power Battery voltage is lower than lower limit voltage for C1240 supply circuit malfunction 4WD control module diagnosis. Internal circuit malfunction of Internal power supply malfunction of 4WD control C1243 4WD control module...
Page 510: Scan Tool Data
3B-13 Differential: Scan Tool Data S6RW0D3204009 Normal condition / reference Scan tool data Vehicle condition values Accelerator pedal released 0 – 5% Ignition switch ON after Accel pedal Pos Accelerator pedal depressed warmed up engine 90 – 100% fully Engine speed At engine idle speed Engine idle speed is display 2WD/4WD switch selected to 2WD position...
Page 511: Rear Differential Symptom Diagnosis
Differential: 3B-14 Rear Differential Symptom Diagnosis S6RW0D3204011 Condition Possible cause Correction / Reference Item Gear noise Deteriorated or water mixed lubricant Repair and replenish referring to “Rear Differential Oil Change”. Inadequate or insufficient lubricant Repair and replenish referring to “Rear Differential Oil Change”.
Page 512: 4Wd Position Indicator Does Not Come On At Ignition Switch On But Engine Stops
3B-15 Differential: 4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops S6RW0D3204013 Wiring Diagram G26-11 WHT/RED RED/BLK G26-12 WHT/RED G26-22 G26-23 G26-10 I7RW01320004-01 [A]: 4WD control module connector “G26” (viewed from harness side) 4. Combination meter 1.
Page 513: 4Wd Position Indicator Remains On Steady At Ignition Switch
Differential: 3B-16 Step Action CAN communication circuit check Go to Step 4. Repair or replace. 1) Check CAN communication circuit between combination meter and 4WD control module referring to “DTC U0073: Control Module Communication Bus Off”. Is CAN communication circuit in good condition? “METER”...
Page 514: Dtc C1240: 4Wd Control Module Power Supply Circuit Malfunction
3B-17 Differential: DTC C1240: 4WD Control Module Power Supply Circuit Malfunction S6RW0D3204015 Wiring Diagram G26-12 RED/BLK WHT/RED G26-11 G26-10 I7RW01320005-01 [A]: 4WD control module connector “G26” (viewed from harness side) 3. “4WD” fuse 1. 4WD control module 4. Main fuse box 2.
Page 515: Dtc C1243: Internal Circuit Malfunction Of 4Wd Control Module
Differential: 3B-18 Step Action Ground circuit check Substitute a known- Repair ground circuit. good 4WD control 1) Turn ignition switch to OFF position. module and recheck. 2) Check for proper connection to “G26-10” terminal of 4WD control module connector. 3) If OK, measure resistance between “G26-10” terminal of 4WD control module connector and vehicle body ground.
Page 516: Dtc C1250: Coupling Air Temperature Sensor Circuit Open
3B-19 Differential: DTC C1250: Coupling Air Temperature Sensor Circuit Open S6RW0D3204017 Wiring Diagram G26-25 G26-24 I7RW01320006-01 [A]: 4WD control module connector “G26” (viewed from harness side) 2. 4WD control module 1. Coupling air temperature sensor DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Input signal from coupling air temperature sensor is higher than...
Page 517 Differential: 3B-20 Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check”. Coupling air temperature sensor circuit check Go to Step 3. Go to Step 5. 1) Disconnect connector from coupling air temperature sensor with ignition switch turned OFF.
Page 518: Dtc C1251: Coupling Air Temperature Sensor Circuit Short
3B-21 Differential: DTC C1251: Coupling Air Temperature Sensor Circuit Short S6RW0D3204018 Wiring Diagram G26-25 G26-24 I7RW01320006-01 [A]: 4WD control module connector “G26” (viewed from harness side) 2. 4WD control module 1. Coupling air temperature sensor DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Input signal from coupling air temperature sensor is lower than...
Page 519: Dtc C1252: Coupling Assembly Circuit Open
Differential: 3B-22 Step Action Coupling assembly ground circuit check Go to Step 4. “ORN” wire is shorted to ground circuit. 1) Disconnect connector from 4WD control module with ignition switch turned OFF. 2) Measure resistance between “ORN” terminal of coupling air temperature sensor connector and “G26-24”...
Page 520 3B-23 Differential: DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Start engine and select 2WD/4WD switch to “LOCK” position. 3) Keep engine running at 2000 rpm for 10 seconds. or more. 4) Stop engine and check DTC. Troubleshooting Step Action Was “4WD control system check”...
Page 521: Dtc C1253: Coupling Assembly Circuit Short
Differential: 3B-24 DTC C1253: Coupling Assembly Circuit Short S6RW0D3204020 Wiring Diagram L102-1 G26-3 L102-4 G26-2 I7RW01320007-01 [A]: 4WD control module connector “G26” (viewed from harness side) 1. Coupling assembly [B]: Coupling assembly connector “L102” (viewed from harness side) 2. 4WD control module DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 522: Dtc C1254: 2Wd/4Wd Switch Malfunction
3B-25 Differential: Step Action Coupling assembly check Substitute a known- Replace coupling good 4WD control assembly. 1) Check coupling assembly referring to “Coupling module and recheck. Assembly Inspection”. Is it in good condition? Coupling assembly circuit check “YEL” wire is shorted to Substitute a known- ground circuit.
Page 523 Differential: 3B-26 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area 2WD/4WD switch combination different from specification is • 2WD/4WD switch detected for more than 5 seconds. • 2WD/4WD switch circuit • 4WD control module DTC Confirmation Procedure 1) Clear DTC using scan tool.
Page 524: Dtc U0073: Control Module Communication Bus Off
3B-27 Differential: DTC U0073: Control Module Communication Bus Off S6RW0D3204022 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0100: Lost Communication with ECM S6RW0D3204023 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0121: Lost Communication with ABS / ESP® Control Module S6RW0D3204024 Refer to “Troubleshooting for CAN-DTC in Section 1A”.
Page 525 Differential: 3B-28 Terminal arrangement of 4WD control module connector (Viewed from harness side) I4JA01332054-01 Terminal Normal Wire Color Circuit Condition Number Voltage G26-1 — — — — Coupling assembly G26-2 About 5 V Ignition switch turned ON position (ground) • Run engine at idle speed and 2WD/4WD switch at 4WD lock position 10 –...
Page 526 3B-29 Differential: Terminal Normal Wire Color Circuit Condition Number Voltage Coupling air G26-24 temperature sensor About 2.5 V Ignition switch turned ON position (ground) Coupling air G26-25 temperature sensor About 2.5 V Ignition switch turned ON position (power) G26-26 — —...
Page 527: Repair Instructions
3) Apply sealant to thread of level / filler plug, and then • It is highly recommended to use API GL-5 tighten it to specified torque. 80W-90 gear oil. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Differential oil specification : API GL-5 (For SAE classification, refer to Tightening torque viscosity chart [A] in figure.)
Page 528: 2Wd/4Wd Switch Removal And Installation
3B-31 Differential: 2WD/4WD Switch Removal and Installation 4WD Control Module Removal and Installation S6RW0D3206003 S6RW0D3206005 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Remove console box (2). 2) Remove center ventilation louver referring to “Center Ventilation Louver Removal and Installation in 3) Remove 2WD/4WD switch (1) from console box.
Page 529: Coupling Air Temperature Sensor Inspection
Differential: 3B-32 Coupling Air Temperature Sensor Inspection Coupling Assembly Inspection S6RW0D3206007 S6RW0D3206008 • Check coupling assembly for oil leakage. If leakage CAUTION exists, replace it. Do not heat up coupling air temperature • Measure resistance between “a” terminal and “b” sensor more than 100 °C (212 °F).
Page 530: Rear Differential Mountings Components
3B-33 Differential: Rear Differential Mountings Components S6RW0D3206009 I5RW0A320022-04 1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt 2. Front mounting arm 7. Front mounting to body nut : 80 N⋅m (8.0 kgf-m, 58.0 lb-ft) 3. Mounting arm bolt 8.
Page 531: Front Mounting Arm And/Or Rear Mounting Bracket Assembly Removal And Installation
Differential: 3B-34 Front Mounting Arm and/or Rear Mounting Rear Differential Dismounting and Remounting S6RW0D3206012 Bracket Assembly Removal and Installation Dismounting S6RW0D3206010 Remove and install front mounting arm and/or rear 1) Lift up vehicle and drain oil from rear differential. mounting bracket after rear differential removed. 2) Remove propeller shaft referring to “Propeller Shaft For tightening torque of each bolt and nut, refer to “Rear Assembly Removal and Installation in Section 3D”.
Page 532: Rear Differential Components
3B-35 Differential: Rear Differential Components S6RW0D3206013 1217G 1217G I5RW0A320026-02 1. Flange nut 13. Differential cover bolt 25. Differential gear 2. Companion flange 14. Spacer 26. Spring washer 3. Oil seal 15. Rear bearing 27. Thrust washer : Apply grease 99000-25010 to oil seal lip. 4.
Page 533: Rear Differential Disassembly And Reassembly
Differential: 3B-36 Rear Differential Disassembly and Reassembly 6) Remove coupling assembly (1) by using hydraulic S6RW0D3206014 press. Disassembly CAUTION 1) Remove rear mounting bracket from rear differential Do not drop coupling assembly. If it is referring to “Front Mounting Arm and/or Rear dropped, replace it with a new one.
Page 534 3B-37 Differential: 8) Remove oil seals from rear differential (1) using special tool. Special tool (A): 09913–50121 I5RW0A320035-01 b) Drive out differential side pinion shaft pin with special tool and hammer. Special tool (B): 09922–85811 I5RW0A320032-01 c) Disassemble differential gears (2), pinions (3), 9) Remove differential cover (1) using special tool, and washers and shaft (4) in differential case (1).
Page 535 Differential: 3B-38 14) Using a hammer and brass bar (1), drive out front 1) Press-fit bevel pinion bearing outer races to bearing outer race (2). differential carrier (1) by using special tools and hydraulic press as shown in the figure. Special tool (A): 09913–85210 (B): 09913–75510...
Page 536 3B-39 Differential: 4) Align holes of pinion shaft and differential case and 6) Press-fit differential right side bearing (1) with special drive in differential pinion shaft pin till they are flush tools and hydraulic press. with end surface of case. Special tool Special tool (A): 09913–80113...
Page 537 Differential: 3B-40 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 538 3B-41 Differential: 9) Set special tools and make drive bevel pinion 12) Apply gear oil to drive bevel pinion bearings, install mounting dummy. special tools with bearings to differential carrier as shown in figure. Special tool (A): 09922–76120 Special tool (B): 09922–76250 (A): 09922–76140 (B): 09922–76420...
Page 539 Differential: 3B-42 14) Set dial gauge to bevel pinion mounting dummy and 16) Necessary adjusting shim thickness is the same make 0 (zero) adjustment on surface plate. value as measured value by dial gauge. Necessary shim thickness Dial gauge measured NOTE “e”...
Page 540 Install oil seal horizontally to surface of differential carrier. Bevel pinion bearing preload (Bevel pinion rotational torque) “A”: Grease 99000–25010 (SUZUKI Super : 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb- Grease A) in.) Distance between differential carrier and oil seal “a”...
Page 541 Differential: 3B-44 Special tool 23) Remove differential cover. (A): 09900–20607 24) To measure bevel gear backlash, set dial gauge at (B): 09900–20701 right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. If bevel gear backlash is out of specification, repeat Step 22).
Page 542 3B-45 Differential: Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
Page 543 1.5 mm “a” (0.059 in.) in diameter, mate differential cover with differential carrier, and then tighten bolts to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Differential cover bolt: 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Page 544: Rear Differential Inspection
NOTE differential carrier as shown in figure, and then tighten bolts to specified torque. Install oil seal horizontally to surface of rear differential case. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) “A”: Grease 99000–25010 (SUZUKI Super Grease A) Tightening torque Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0...
Page 545: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0D3208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 546: Special Tool
3B-49 Differential: Special Tool S6RW0D3208002 09900–20607 09900–20701 Dial gauge Magnetic stand 09912–34510 09913–50121 Case separator Oil seal remover 09913–60910 09913–65135 Bearing and gear puller (40- Bearing puller 60mm) 09913–70123 09913–75510 Bearing installing tool Bearing installer 09913–75810 09913–75830 Bearing installer Steering pinion bush installer 09913–80113 09913–85210...
Page 547 Universal joint assembling tool 09927–27910 09930–40113 Holder, bevel pinion Flywheel rotor holder 09951–26020 SUZUKI scan tool Bush remover & installer — support This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 548: Transfer
3C-1 Transfer: Transfer Driveline / Axle General Description Transfer Description S6RW0D3301001 The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction drive gear, reduction driven gear and bevel gear of transfer.
Page 549: Repair Instructions
5) Apply sealant to thread of drain plug (1), and tighten S6RW0D3306001 it to specified torque. 1) Lift up vehicle and check oil leakage. Repair leaky “A”: Sealant 99000–31260 (SUZUKI Bond point, if any. No.1217G) 2) Remove oil level / filler plug (1) and check oil...
Page 550: Transfer Dismounting And Remounting
1) Disconnect negative cable at battery. • Apply grease to left case (1) as shown in figure. 2) Drain transaxle oil and transfer oil. “A”: Grease 99000–25010 (SUZUKI Super Grease 3) Remove drive shafts assembly referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”.
Page 551: Transfer Assembly Components
Transfer: 3C-4 • Pour transaxle oil and transfer oil referring to “Manual Transaxle Oil Change in Section 5B” and “Transfer Oil Change”. Transfer Assembly Components S6RW0D3306004 1217G 1322 1217G 1217G I5RW0A330007-05 1. Transfer output flange nut 15. Dowel pin 29. Transfer right case : After tightening nut so as rotational torque : Apply sealant 99000-31260 to of bevel pinion to be in specified value,...
Page 552: Transfer Assembly Disassembly And Reassembly
3C-5 Transfer: 9. Pump seal 23. Reduction drive gear right bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 10. Pinion shaft front taper roller bearing 24. Intermediate shaft : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft) 11. Bevel pinion 25. Oil protect plate bolt : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) : Apply thread lock cement 99000-32110 to thread part.
Page 553 2) Clean mating surface of right and left cases, and m, 40.0 lb-ft) apply sealant to right case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) 1, (a) “A” 1, (a)
Page 554: Reduction Drive Gear Assembly Disassembly And Reassembly
I5RW0A330016-02 2) Install bearings (1) to reduction drive gear (2) using 12) Apply grease to new right case oil seal No.1 lip. special tool, bearing puller (3) and hydraulic press “A”: Grease 99000–25010 (SUZUKI Super (4). Grease A) Special tool 13) Drive right case oil seal No.1 (1) in transfer right...
Page 555: Reduction Driven Gear Assembly Disassembly And Reassembly
Transfer: 3C-8 Reduction Driven Gear Assembly Disassembly Reassembly and Reassembly CAUTION S6RW0D3306007 Disassembly • Bevel gear and pinion must be replaced as 1) Remove left bearing (1) and bevel gear (2) using a set when either replacement becomes special tool, bearing puller (3) and hydraulic press necessary.
Page 556: Transfer Right Case And Left Case Disassembly And Reassembly
Apply grease to oil seal lip. (B): 09924–84510–005 Special tool (A): 09925–15410 “A”: Grease 99000–25010 (SUZUKI Super Grease A) Oil seals installing depth “a”: 23.5 – 24.0 mm (0.925 – 0.945 in.) “b”: 38.0 – 39.0 mm (1.496 – 1.535 in.) “b”...
Page 557: Transfer Output Retainer Assembly Disassembly And Reassembly
Transfer: 3C-10 Transfer Output Retainer Assembly 5) Drive out front taper roller bearing (1) from bevel pinion (3) by using bearing puller (2) and hydraulic Disassembly and Reassembly press. S6RW0D3306009 Disassembly 1) Uncaulk transfer output flange nut. 2) Remove transfer output flange nut while holding flange (1) by using special tool.
Page 558 3C-11 Transfer: Reassembly b) Install bevel pinion dummy (1), rear taper roller bearing (2) and special tools to transfer output CAUTION retainer (3). • Bevel gear and pinion must be replaced as Special tool a set when either replacement becomes (A): 09922–76140 necessary.
Page 559 Transfer: 3C-12 c) Tighten bevel pinion nut (special tool) so that e) Obtain adjusting shim thickness by the following specified bearing preload is obtained. equation. NOTE Distance Distance Necessary Before taking measurement, check for Distance “d” “e” shim – rotation by hand more than 15 revolutions. “c”...
Page 560 3) Press-fit front taper roller bearing (1) by using I5RW0A330041-02 6) Apply grease to new oil seal lip. special tool and hydraulic press. “A”: Grease 99000–25010 (SUZUKI Super Special tool Grease A) (A): 09925–18011 7) Drive in oil seal (1) by using special tools and hammer.
Page 561: Transfer Assembly Inspection
Transfer: 3C-14 Transfer Assembly Inspection 8) Install transfer output flange (1) by tapping with plastic hammer and tighten transfer output flange nut S6RW0D3306010 • Check each bearing for smooth rotation, wear or gradually so as rotational torque of bevel pinion to be discoloration in specified value.
Page 562 3C-15 Transfer: 4) Bring painted part up and check contact pattern referring to the following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart. NOTE • Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check. •...
Page 563: Specifications
Transfer: 3C-16 Tooth contact pattern Diagnosis and remedy These contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) retainer is not true, or 3) gear is not properly seated on transfer case.
Page 564: Special Tools And Equipment
3C-17 Transfer: Special Tools and Equipment Recommended Service Material S6RW0D3308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 565 Transfer: 3C-18 09922–76430 09924–07710 Bevel pinion front collar Synchronizer hub installer 09924–74510 09924–84510–005 Bearing and oil seal handle Bearing installer attachment 09925–15410 09925–16310 Oil seal installer Bearing installer 09925–18011 09925–98221 Transmission gear, bush Bearing installer and bearing installer 09930–40113 09940–54910 Flywheel rotor holder Front fork oil seal install driver...
Page 566: Propeller Shafts
3D-1 Propeller Shafts: Propeller Shafts Driveline / Axle Precautions Propeller Shaft Caution S6RW0D3400001 CAUTION • All propeller shaft fasteners are an important attaching part in that it could affect the performance 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.
Page 567: Repair Instructions
Propeller Shafts: 3D-2 Repair Instructions Propeller Shaft Joint Check 4) Remove propeller shaft by removing center support S6RW0D3406001 nuts (1). If universal joints and ball joint are suspected of producing chattering or rattling noise, inspect them for CAUTION wear. For universal joint, check to see if cross spider Use care not to drop it.
Page 568: Specifications
3D-3 Propeller Shafts: Specifications Tightening Torque Specifications S6RW0D3407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Propeller shaft bolt 17.0 Center support nut 40.0 NOTE The specified tightening torque is also described in the following. “Propeller Shaft Construction” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Page 569 Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Front Brakes ..........4B-1 Precautions............. 4-1 Repair Instructions ..........4B-1 Precautions for Brakes.......... 4-1 Front Disc Brake Components ......4B-1 Front Disc Brake Pad On-Vehicle Inspection..4B-2 Brake Control System and Diagnosis ... 4A-1 Front Disc Brake Pad Removal and Precautions............4A-1 Installation ............4B-2...
Page 570 4-ii Table of Contents Specifications............4D-4 DTC C1057: Power Supply Voltage Too High Tightening Torque Specifications......4D-4 / Too Low ............4E-27 DTC C1061: Pump Motor Circuit ......4E-28 ABS............4E-1 DTC C1063: Solenoid Valve Power Supply Driver Circuit ...........4E-29 Precautions............4E-1 Precautions in Diagnosing Troubles ....4E-1 DTC C1071: Control Module Internal Defect ..4E-30 ABS Hydraulic Unit / Control Module Precautions in On-Vehicle Service......
Page 571: Precautions
Precautions: Precautions Brakes Precautions Precautions for Brakes S6RW0D4000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. Brake Caution Refer to “Brake Caution in Section 00”. General Precautions Refer to “General Precautions in Section 00”.
Page 572: Brake Control System And Diagnosis
4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brakes Precautions Precautions on Brake S6RW0D4100001 Air Bag Warning Refer to“Air Bag Warning in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note”. General Description Brakes Construction S6RW0D4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear).
Page 573: Brake Pedal Foot Protection System Construction (If Equipped)
Brake Control System and Diagnosis: 4A-2 Brake Pedal Foot Protection System Construction (If Equipped) S6RW0D4101004 Should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also pushed toward the interior side. In this case, the brake pedal lever comes off from the brake pedal, thereby preventing the brake pedal from moving rearward.
Page 574: Front Brake Hose / Pipe Construction
4A-3 Brake Control System and Diagnosis: Front Brake Hose / Pipe Construction S6RW0D4101002 I6RW0C410002-01 [A]: LHD 4. From ABS hydraulic unit to left front brake 9. Master cylinder fixing nut [B]: RHD 5. ABS hydraulic unit / control module assembly : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) 1.
Page 575: Rear Brake Hose / Pipe Construction
Brake Control System and Diagnosis: 4A-4 Rear Brake Hose / Pipe Construction S6RW0D4101003 I6RW0D410001-01 1. To left rear brake hose 5. Left rear brake hose to left brake 2. To right rear brake hose 6. Right rear brake hose to right brake 3.
Page 576: Brakes Symptom Diagnosis
4A-5 Brake Control System and Diagnosis: Brakes Symptom Diagnosis S6RW0D4104002 Condition Possible cause Correction / Reference Item Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair. Brake disc or pad stained with oil Clean or replace. Overheated brakes Determine cause and repair.
Page 577 Brake Control System and Diagnosis: 4A-6 Condition Possible cause Correction / Reference Item Dragging brakes (Without Master cylinder pistons not returning Replace master cylinder. a very light drag is correctly present in all brakes Restricted brake pipes or hoses Check for soft hoses or damaged pipes and immediately after pedal is replace with new hoses and/or new brake released)
Page 578: Repair Instructions
4A-7 Brake Control System and Diagnosis: Repair Instructions Brake Pedal Components 6) Check brake booster push rod for length. S6RW0D4106018 CAUTION Brake Pedal Play Inspection S6RW0D4106002 If equipped Brake Pedal Foot Protection Pedal play should be within the following specification. If System, never disassemble brake pedal out of specification, check brake light switch for proper assembly.
Page 579: Brake Fluid Level Inspection
Brake Control System and Diagnosis: 4A-8 Brake Fluid Level Inspection Brake Light Switch Adjustment S6RW0D4106004 S6RW0D4106005 Adjustment should be made as follows. Pull up brake CAUTION pedal toward you and while holding it there, adjust Do not use shock absorber fluid or any other switch position so that clearance between end of thread fluid which contains mineral oil.
Page 580: Front Brake Hose / Pipe Removal And Installation
4A-9 Brake Control System and Diagnosis: Front Brake Hose / Pipe Removal and 1) Fill master cylinder reservoir with specified brake fluid and keep at least one-half full of fluid during Installation bleeding operation. S6RW0D4106007 CAUTION Brake fluid : Refer to reservoir cap Do not allow brake fluid to get on painted surfaces.
Page 581: Rear Brake Hose / Pipe Removal And Installation
Brake Control System and Diagnosis: 4A-10 Rear Brake Hose / Pipe Removal and Installation S6RW0D4106008 CAUTION Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled. Removal 1) Raise and support vehicle properly.
Page 582: Master Cylinder And Brake Booster Components
4A-11 Brake Control System and Diagnosis: Master Cylinder and Brake Booster Components S6RW0D4106010 CAUTION Never disassemble master cylinder and brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I7RW01410017-03 1. Reservoir 6.
Page 583: Master Cylinder Removal And Installation
Brake Control System and Diagnosis: 4A-12 4) Connect clutch reservoir hose to reservoir (M/T 3) Drain brake fluid in reservoir. model). 4) Disconnect clutch reservoir hose from reservoir (M/T model). 5) Connect fluid level switch coupler (1) and clamp (3) to reservoir (2).
Page 584: Master Cylinder Inspection
4A-13 Brake Control System and Diagnosis: 3) Drain brake fluid in reservoir. 4) Connect brake pipe to master cylinder and tighten flare nuts to specified torque. 4) Disconnect clutch reservoir hose from reservoir (M/T model). Tightening torque 5) Disconnect brake pipes (1) connected to master Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5 cylinder.
Page 585: Booster Operation Inspection
Brake Control System and Diagnosis: 4A-14 Booster Operation Inspection Check Operation S6RW0D4106014 1) With engine stopped, depress brake pedal several There are two ways to perform this inspection, with and times with the same load and make sure that pedal without a tester.
Page 586: Brake Booster Removal And Installation
4A-15 Brake Control System and Diagnosis: 2) Hold brake pedal depressed for 30 seconds. If pedal Installation height does not change, condition is good. But it isn’t 1) Install booster to dash panel. Then connect push rod if pedal rises. clevis pin (2) and clip (1).
Page 587: Special Tool
Brake Control System and Diagnosis: 4A-16 Booster Push Clevis Rod Adjustment S6RW0D4106017 Install push clevis rod (1) so that measurement “a” is obtained and torque nut (2) to specification. Tightening torque Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft) Clevis installing position (length “a”) “a”: 129.5 - 130.5 mm (5.10 - 5.13 in.) IYSQ01410050-01...
Page 588: Front Brakes
4B-1 Front Brakes: Front Brakes Brakes Repair Instructions Front Disc Brake Components S6RW0D4206001 I7RW01420001-05 1. Caliper 9. Disk brake piston 17. Brake flexible hose : Apply rubber grease included in piston : Be sure to direct mark (18) to seal set or brake fluid to contact surface of inside of vehicle “I”...
Page 589: Front Disc Brake Pad On-Vehicle Inspection
Front Brakes: 4B-2 Front Disc Brake Pad On-Vehicle Inspection 4) Remove brake pads (3). S6RW0D4206002 Inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end and inspection hole of caliper and check lining thickness of outside and inside pads.
Page 590: Front Disc Brake Pad Inspection
4B-3 Front Brakes: 3) Install caliper and tighten caliper pin bolts to Front Disc Brake Caliper Removal and specified torque. Installation S6RW0D4206005 Tightening torque Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft) Removal 1) Hoist vehicle and remove front wheel. 2) Remove brake flexible hose joint bolt (1) from caliper (2).
Page 591: Front Disc Brake Caliper Disassembly And Assembly
Front Brakes: 4B-4 Front Disc Brake Caliper Disassembly and 3) Connect flexible hose (3) to caliper as shown in figure. Assembly S6RW0D4206006 4) Torque flexible hose joint bolt to specification. Disassembly Tightening torque Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m, CAUTION 17.0 lb-ft) Clean around caliper with brake fluid before...
Page 592 4B-5 Front Brakes: Assembly 2) Before inserting piston (1) into cylinder, apply rubber Assemble parts in reverse order of disassembly, grease included in piston seal set or brake fluid to observing the following instructions. new boot (a) and install it onto piston as shown. CAUTION •...
Page 593: Front Disc Brake Caliper Inspection
Front Brakes: 4B-6 Front Brake Disc Removal and Installation 5) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not S6RW0D4206008 take it all out. CAUTION NOTE During removal, be careful not to damage brake flexible hose and not to depress brake Boot’s face (1) should be at the same level pedal.
Page 594: Front Brake Disc Inspection
4B-7 Front Brakes: Front Brake Disc Inspection Installation S6RW0D4206009 1) Install caliper assembly to steering knuckle. • Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of CAUTION disc, measure deflection of disc. Make sure that flexible hose is not twisted If it exceeds the limit, correct or replace the brake when installing caliper assembly.
Page 595: Specifications
Front Brakes: 4B-8 Specifications Tightening Torque Specifications S6RW0D4207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Caliper pin bolt 19.0 Flexible hose joint bolt 17.0 Bleeder plug Caliper carrier bolt 61.5 NOTE The specified tightening torque is also described in the following. “Front Disc Brake Components”...
Page 596: Rear Brakes
4C-1 Rear Brakes: Rear Brakes Brakes Repair Instructions Rear Drum Brake Components S6RW0D4306001 I6RW0D430001-01 1. Brake drum 10. Wheel cylinder 19. Bleeder plug 2. Brake shoe 11. Brake back plate : 73 N⋅m (7.3 kgf-m, 53 lb-ft) 3. Shoe return spring 12.
Page 597: Rear Brake Drum Removal And Installation
Rear Brakes: 4C-2 Rear Brake Drum Removal and Installation 2) Confirm that inside of brake drum and brake shoes S6RW0D4306002 are free from dirt and oil. And then install brake Removal drum. 1) Hoist vehicle and remove rear wheel. 3) Start engine and then depress brake pedal with 2) Release parking brake lever.
Page 598: Rear Brake Shoe On-Vehicle Inspection
4C-3 Rear Brakes: Rear Brake Shoe On-Vehicle Inspection Cracked, Scored or Grooved Drum A cracked drum is unsafe for further service and must be S6RW0D4306004 Amount of brake shoe wear can be checked as follows. replaced. Do not attempt to weld a cracked drum. 1) Hoist vehicle.
Page 599: Rear Brake Shoe Inspection
Rear Brakes: 4C-4 Rear Brake Shoe Inspection 3) Remove return springs, brake shoes and adjuster. S6RW0D4306006 4) Disconnect parking brake shoe lever (1) from • Check ratchet of brake adjuster (1) assembly for wear parking brake cable (2). or damage. •...
Page 600: Wheel Cylinder Inspection
4C-5 Rear Brakes: Wheel Cylinder Inspection Installation S6RW0D4306008 1) Take off bleeder plug cap from brake pipe and Inspect wheel cylinder disassembled parts for wear, connect pipe to wheel cylinder (1) just enough to cracks, corrosion or damage. prevent fluid from leaking. NOTE 2) Install wheel cylinder (1) to brake back plate (2), and tighten wheel cylinder mounting bolt to specified...
Page 601: Specifications
Rear Brakes: 4C-6 Installation Install brake back plate by reversing removal procedure, noting the instructions. CAUTION Never reuse rear wheel hub mounting bolts. • Install rear wheel hub and brake back plate, and then tighten mounting bolt. Refer to “Rear Drum Brake Components”.
Page 602: Parking Brake
4D-1 Parking Brake: Parking Brake Brakes General Description Parking Brake Cable Construction S6RW0D4401001 ( a ) ( a ) ( a ) ( a ) ( a ) ( b ) ( b ) ( b ) ( a ) ( b ) I6RW0D440001-01 T: Top side...
Page 603: Repair Instructions
Parking Brake: 4D-2 Repair Instructions Parking Brake Inspection and Adjustment After confirming that the conditions are all satisfied, S6RW0D4406001 adjust parking brake lever stroke by loosening or Inspection tightening adjust nut (1). Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force.
Page 604: Parking Brake Lever Removal And Installation
4D-3 Parking Brake: Parking Brake Lever Removal and Installation Installation S6RW0D4406003 1) Install in reverse order of removal procedure. Check equalizer inclined angle. Removal Tightening torque 1) Remove console box. Parking brake lever bolt (a): 26 N·m (2.6 kgf-m, 2) Block vehicle wheels and release parking brake 19.0 lb-ft) lever.
Page 605: Specifications
Parking Brake: 4D-4 Specifications Tightening Torque Specifications S6RW0D4407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Parking brake lever bolt 19.0 NOTE The specified tightening torque is also described in the following. “Parking Brake Cable Construction” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Page 606: Abs
• Diagnostic information stored in ABS control module lever (2) until it locks. memory can be cleared as 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 functions are available and how to use it.
Page 607: General Description
ABS: 4E-2 General Description ABS Description • ABS hydraulic unit / control module assembly is S6RW0D4501001 incorporated ABS control module, ABS hydraulic unit The ABS (Antilock Brake System) controls the fluid (actuator assembly), solenoid valve power supply pressure applied to the wheel cylinder of each brake driver (transistor), solenoid valve driver (transistor), from the master cylinder so that each wheel is not locked pump motor driver (transistor).
Page 608: Abs Hydraulic Unit / Control Module Assembly Description
4E-3 ABS: ABS Hydraulic Unit / Control Module Assembly Description S6RW0D4501002 ABS control module is a component of ABS hydraulic unit / control module assembly and has the following functions. Self-Diagnosis Function I4RS0A450001-01 ABS control module diagnoses conditions of the system •...
Page 609: Schematic And Routing Diagram
ABS: 4E-4 Schematic and Routing Diagram ABS Schematic S6RW0D4502001 INPUT OUTPUT ABS control module Hydraulic unit Wheel speed sensor (LF) Pump motor Pump motor driver (transistor) Wheel speed sensor (LR) Solenoid valve power Wheel speed sensor (RF) supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve Brake light switch...
Page 610: Abs Wiring Circuit Diagram
4E-5 ABS: 1. ABS hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (Left-rear) 2. ABS control module 10. ABS warning light 18. Battery 3. ABS hydraulic unit 11. EBD warning light (Brake warning light) 19.
Page 611 ABS: 4E-6 WHT/RED WHT/BLU GRN/ORN E08-9 E08-7 GRN/WHT GRN/ORN GRN/YEL E08-6 E08-23 GRN/BLK E08-3 RED/BLK E08-24 WHT/BLU E08-25 WHT/RED E08-26 RED/BLK E08-2 RED/BLU E08-13 E08-16 E08-1 E08-12 E08-11 RED/BLK E08-22 E08-18 WHT/BLK E08-17 E08-21 LT GRN/BLK LT GRN E08-10 E08-20 E08-19 I6RW0D450001-02 [A]: Junction block with BCM...
Page 612 4E-7 ABS: Terminal Circuit CAN communication line (high) for ECM CAN communication line (high) for BCM G sensor ground (4WD model only) — — G sensor signal (4WD mode only) Brake light switch — Ignition switch Left-rear wheel speed sensor (–) Left-front wheel speed sensor (+) CAN communication line (low) for ECM CAN communication line (low) for BCM...
Page 613: Component Location
ABS: 4E-8 Component Location ABS Components Location S6RW0D4503001 I5RW0A450006-02 1. ABS hydraulic unit / control module assembly 5. EBD warning light (Brake warning light) 2. Wheel speed sensors 6. Wheel speed sensor encoder (included in wheel hub assembly) 3. Brake light switch 7.
Page 614 4E-9 ABS: Step Action Check for intermittent problem Go to Step 4. Go to Step 7. 1) Check intermittent troubles referring to “Intermittent and Poor Connection Inspection in Section 00” and related circuit of trouble code recorded in Step 1. Does trouble recur? Final confirmation test Go to Step 3.
Page 615: Abs Warning Light Check
ABS: 4E-10 ABS Warning Light Check Problem symptom confirmation Check if what the customer claimed in “Customer S6RW0D4504002 1) Turn ignition switch ON. Questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. 2) Check that ABS warning light (1) comes ON for (This step should be shared with the customer if about 2 seconds and then goes off.
Page 616: Dtc Table
4) Read DTC according to instructions displayed on any traffic accident possibility and be very SUZUKI scan tool and print it or write it down. Refer careful during testing to avoid occurrence of to SUZUKI scan tool operator’s manual for further an accident.
Page 617: Scan Tool Data
ABS: 4E-12 Scan Tool Data Scan Tool Data Definition S6RW0D4504007 Battery Volt (V) The parameter data below are values measured with the Battery Voltage is an analog input signal read by the scan tool when the normally operating vehicle is under ABS control module.
Page 618 4E-13 ABS: ABS Warning Light Does Not Come ON at Ignition Switch ON S6RW0D4504008 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 RED/BLK E08-23 G241-31 G241-16 G241-7 G241-10 G04-4 G04-2 E04-1 E08-2 E04-2 E08-13 RED/BLK E04-5 L01-6 RED/BLU G241 4 5 6 7 8 9 10 11 12 13 14 15 16 20 2122 23 24 25 26 27 28 29 30 3132 I6RW0D450007-01...
Page 619: Ignition Switch
ABS: 4E-14 WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 RED/BLK E08-26 G241-31 G241-16 G241-7 E08-2 G241-10 E08-13 G241 G05-1 4 5 6 7 8 9 10 11 12 13 14 15 16 G05-3 20 2122 23 24 25 26 27 28 29 30 3132 G05-7 RED/BLK RED/BLU...
Page 620: Abs Warning Light Comes On Steady
4E-15 ABS: Step Action Combination meter power source circuit check Go to Step 4. Repair power source circuit for combination 1) Remove combination meter with ignition switch turned meter. OFF. 2) Check for proper connection to “RED/BLK” and “BLK” wire of combination meter connector. 3) If OK then turn ON ignition switch and measure voltage at “RED/BLK”...
Page 621: Ebd Warning Light (Brake Warning Light) Comes On Steady
ABS: 4E-16 EBD Warning Light (Brake Warning Light) Comes ON Steady S6RW0D4504010 Wiring Diagram Referring to “Wiring Diagram” under “ABS Warning Light Does Not Come ON at Ignition Switch ON”. Circuit Description EBD warning lamp (brake warning lamp) is controlled by ABS control module and BCM through lamp driver module in combination meter.
Page 622 4E-17 ABS: Step Action CAN communication line circuit check Substitute a known- Repair CAN good combination meter communication line 1) Turn ignition switch to OFF position. and recheck. If EBD circuit. 2) Disconnect connectors of all control modules warning light remains communicating by means of CAN.
Page 623 ABS: 4E-18 WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 E08-23 RED/BLK E08-26 G241-31 G241-16 G241-7 E08-2 G241-10 E08-13 G05-1 G05-3 G05-4 G05-2 E08-16 G241 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 13 12 20 2122 23 24 25 26 27 28 29 30 3132 39 38 34 33 32 31...
Page 624 4E-19 ABS: Trouble shooting Step Action Scan tool communication check Go to Step 2. Go to Step 3. Can scan tool communicate with BCM? ABS hydraulic unit / control module assembly power Go to Step 3. Repair ABS hydraulic and ground circuit check unit / control module assembly power or 1) Check that ABS hydraulic unit / control module assembly...
Page 625: Dtc C1013: Control Module Mismatch
ABS: 4E-20 DTC C1013: Control Module Mismatch S6RW0D4504012 Wiring Diagram GRN/ORN E08-9 GRN/ORN E08-6 GRN/YEL GRN/BLK E08-3 I7RW01450005-04 [A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. ABS hydraulic unit / control module assembly 1. Battery 4.
Page 626: Dtc C1015: G Sensor Circuit (4Wd Model)
4E-21 ABS: DTC C1015: G Sensor Circuit (4WD Model) S6RW0D4504013 Wiring Diagram Refer to “Wiring Diagram” under “DTC C1013: Control Module Mismatch”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • G sensor signal voltage is out of specified range. •...
Page 627: Dtc 1016: Brake Light Switch
ABS: 4E-22 DTC 1016: Brake Light Switch S6RW0D4504014 Wiring Diagram GRN/ORN E08-9 GRN/WHT E08-7 I7RW01450006-05 [A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. Brake light 1. Battery 4. Junction block assembly 7. ABS hydraulic unit / control module assembly 2.
Page 628: Dtc C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor Or Encoder
4E-23 ABS: DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder S6RW0D4504015 DTC C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit DTC C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor or Encoder...
Page 629 ABS: 4E-24 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. Check tire condition Go to Step 3. Replace tire or adjust tire pressure and 1) Check that tire pressure is specifications. recheck. Are they in good condition? Wheel speed sensor circuit check Go to Step 4.
Page 630: Dtc C1033: Wheel Speed Sensor Deviation
4E-25 ABS: DTC C1033: Wheel Speed Sensor Deviation S6RW0D4504016 Wiring Diagram Refer to “Wiring Diagram” under “DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 631: Dtc C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid
ABS: 4E-26 DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid S6RW0D4504017 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left- Rear Inlet Solenoid DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left- Rear Outlet Solenoid Wiring Diagram E08-24...
Page 632: Dtc C1057: Power Supply Voltage Too High / Too Low
4E-27 ABS: DTC C1057: Power Supply Voltage Too High / Too Low S6RW0D4504018 Wiring Diagram GRN/ORN E08-9 E08-23 I7RW01450009-03 [A]: ABS control module connector (viewed from terminal side) 2. Main fuse box 4. Junction block assembly 1. Battery 3. Ignition switch 5.
Page 633: Dtc C1061: Pump Motor Circuit
ABS: 4E-28 DTC C1061: Pump Motor Circuit S6RW0D4504019 Wiring Diagram E08-25 WHT/RED E08-26 I7RW01450010-02 [A]: ABS control module connector (viewed from terminal side) 3. Pump motor driver (transistor) 1. Battery 4. ABS pump motor 2. Main fuse box 5. ABS hydraulic unit / control module assembly DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 634: Dtc C1063: Solenoid Valve Power Supply Driver Circuit
4E-29 ABS: DTC C1063: Solenoid Valve Power Supply Driver Circuit S6RW0D4504020 Wiring Diagram GRN/ORN E08-9 WHT/BLU E08-24 E08-23 I7RW01460015-01 [A]: ABS control module connector (viewed from terminal side) 4. Junction block assembly 1. Battery 5. Solenoid valve power supply driver (transistor) 2.
Page 635: Dtc C1071: Control Module Internal Defect
ABS: 4E-30 DTC C1071: Control Module Internal Defect S6RW0D4504021 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area ABS control module internal defect is detected. • ABS control module DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”.
Page 636: Repair Instructions
4) Set transmission to neutral (P range for A/T) and release parking brake. 5) Turn each wheel gradually by hand to check if brake dragging occurs. If it does, correct. 6) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. I5RW0A450007-01 Special tool...
Page 637: Abs Hydraulic Unit / Control Module Assembly Components
8) Perform the following checks with help of another person. Brake pedal (1) should be depressed and then select testing wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this time, check that: •...
Page 638: Abs Hydraulic Unit / Control Module Assembly On-Vehicle Inspection
4E-33 ABS: ABS Hydraulic Unit / Control Module Assembly 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit / On-Vehicle Inspection control module assembly (3). S6RW0D4506003 CAUTION Special tool Never disassemble ABS hydraulic unit / (A): 09950-78220 control module assembly, loosen blind plug NOTE...
Page 639: Front And Rear Wheel Speed Sensor On-Vehicle Inspection
ABS: 4E-34 Installation 2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”. 1) Install hydraulic unit / control module assembly by reversing removal procedure noting the following. 3) Check each installed part for fluid leakage and Install ABS hydraulic unit / control module assembly perform “ABS Hydraulic Unit Operation Check”.
Page 640: Front Wheel Speed Sensor Removal And Installation
4E-35 ABS: Front Wheel Speed Sensor Removal and 5) Measure voltage at resistance without wheel rotation.If voltage is out of specification, check Installation sensor, mating encoder and their installation S6RW0D4506006 conditions. CAUTION Voltage at the resistance (115 Ω) without wheel •...
Page 641: Front And Rear Wheel Speed Sensor Inspection
ABS: 4E-36 Rear Wheel Speed Sensor Removal and Installation Installation (4WD Model) 1) Check that no foreign material is attached to sensor S6RW0D4506008 (1) and wheel speed sensor encoder (included in CAUTION wheel hub assembly). Rear wheel speed sensor is included in rear 2) Install it by reversing removal procedure.
Page 642: Front Wheel Speed Sensor Encoder On-Vehicle Inspection
4E-37 ABS: Front Wheel Speed Sensor Encoder On-Vehicle Rear Wheel Speed Sensor Encoder On-Vehicle Inspection Inspection S6RW0D4506010 S6RW0D4506012 Before inspecting front wheel speed sensor encoder, For 4WD model remove front drive shaft referring to “Front Drive Shaft Refer to “Rear Wheel Speed Sensor On-Vehicle Assembly Removal and Installation in Section 3A”.
Page 643: G Sensor Removal And Installation (4Wd Model)
ABS: 4E-38 G Sensor Removal and Installation (4WD Model) G Sensor Inspection (4WD Model) S6RW0D4506014 S6RW0D4506015 Connect positive cable of 12 V battery to “A” terminal of CAUTION sensor and ground cable to “C” terminal. • Do not drop and shock G sensor. It will Then using voltmeter, check voltage between terminals affect its original performance.
Page 644: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S6RW0D4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 645: Automatic Transmission/Transaxle
Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON Precautions............. 5-1 (Non-Euro-OBD Model)........5A-41 Precautions on Transmission / Transaxle ..... 5-1 Transmission Warning Light Circuit Check – Automatic Transmission/Transaxle..
Page 646: Manual Transmission/Transaxle
5-ii Table of Contents DTC P1723: Range Select Switch Differential Side Oil Seal Replacement .....5A-98 Malfunction............5A-68 A/T Fluid Cooler Hoses Replacement ....5A-98 DTC P1878: Torque Converter Clutch Automatic Transaxle Unit Components.....5A-99 Shudder ............5A-69 Automatic Transaxle Unit Dismounting and DTC P2762: Torque Converter Clutch (TCC) Remounting...........5A-100 Automatic Transaxle Assembly Components .5A-102 Pressure Control Solenoid Control Circuit...
Page 647 Table of Contents 5-iii Diagnostic Information and Procedures....5B-5 Differential Disassembly and Reassembly..5B-36 Manual Transaxle Symptom Diagnosis....5B-5 Specifications .............5B-38 Repair Instructions ..........5B-5 Tightening Torque Specifications......5B-38 Manual Transaxle Oil Level Check ..... 5B-5 Special Tools and Equipment ......5B-39 Manual Transaxle Oil Change ......5B-6 Recommended Service Material .......5B-39 Differential Side Oil Seal Replacement ....
Page 648: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions on Transmission / Transaxle S6RW0D5000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 5A”. Precautions for Disassembly and Reassembly Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Page 649 • Diagnostic information stored in TCM memory can be may occur and often time would be wasted. cleared as well as checked by using SUZUKI scan As the automatic transaxle consists of high precision tool or CAN communication OBD generic scan tool.
Page 650 5A-2 Automatic Transmission/Transaxle: Part Inspection and Correction Table CAUTION Part Inspect for Correction • Keep component parts in group for each Casted part, Small flaw, burr Remove with oil subassembly and avoid mixing them up. machined part stone. • Clean all parts with cleaning solvent Deep or grooved Replace part.
Page 651: General Description
Automatic Transmission/Transaxle: 5A-3 General Description A/T Description S6RW0D5101001 This automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up mechanism.
Page 652 5A-4 Automatic Transmission/Transaxle: I5RW0C510070-01 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23. Short planet pinion 4. Input shaft 14.
Page 653 Wet type multiple-disc brake... 3 sets One-way clutch... 2 sets Reduction gear ratio 1.023 Final gear reduction ratio 4.277 Lubrication Lubrication system Force feed system by oil pump Cooling Cooling system Radiator assisted cooling (water-cooled) Fluid used SUZUKI ATF 3317 or Mobil ATF 3309...
Page 654: Clutch / Brake / Planetary Gear Function Of Automatic Transaxle
5A-6 Automatic Transmission/Transaxle: Clutch / Brake / Planetary Gear Function of Automatic Transaxle S6RW0D5101002 I4RS0A510001-01 1. Input shaft and intermediate shaft 8. One-way No.2 clutch 15. Front sun gear 2. Direct clutch 9. 2nd brake 16. Rear sun gear 3. Reduction drive gear 10.
Page 655: Table Of Component Operation
Automatic Transmission/Transaxle: 5A-7 Table of Component Operation S6RW0D5101003 Part Selector Gear Shift solenoid Shift solenoid TCC solenoid Forward Reverse position position Direct clutch valve-A (No.1) valve-B (No.2) valve clutch clutch × × × × Parking × × × Reverse × ×...
Page 656: On-Board Diagnostic System Description
• For Euro OBD model, it is possible to communicate with TCM through data link connector (DLC) (2) by using not only SUZUKI scan tool (3) but also CAN communication OBD generic scan tool. (Diagnostic information can be checked and erased by using scan I6RW0B510001-01 tool.)
Page 657: Can Communication System Description
Automatic Transmission/Transaxle: 5A-9 CAN Communication System Description S6RW0D5101006 Refer to “CAN Communication System Description in Section 1A” for CAN communication System description. TCM communicates control data with each control module as follows. TCM Transmission Data 4WD control Combination module meter (if equipped) Transmission oil temperarure signal...
Page 658: Schematic And Routing Diagram
5A-10 Automatic Transmission/Transaxle: Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S6RW0D5102001 C07-6 LT/GRN C06-11 C07-16 2.5V C06-12 C06-16 BLK/WHT C07-25 BLK/ORN C06-15 BLK/YEL WHT RED WHT RED C06-7 C06-14 BLU/BLK C06-17 WHT/BLU C06-5 12V 12V C06-3 WHT/BLK C06-4 C06-2 LT GRN/BLK...
Page 659 Automatic Transmission/Transaxle: 5A-11 Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve Solenoid Shift Shift Selector Gear Timing solenoid solenoid Condition position position solenoid solenoid valve-A valve-B valve valve (No.1) (No. 2) × × Parking When vehicle is traveling forwards in ×...
Page 660: Automatic Gear Shift Table
5A-12 Automatic Transmission/Transaxle: Automatic Gear Shift Table S6RW0D5102002 Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D position. M16A Engine Model 1.Shift Point in D, 3 and/or 2 position Throttle opening (%) Shift Vehicle speed km/h (mph)
Page 661 Automatic Transmission/Transaxle: 5A-13 M15A Engine Model 1.Shift Point in D, 3 and/or 2 position Throttle opening (%) Shift Vehicle speed km/h (mph) Remark 1st → 2nd 50 – 55 (31 - 34) D, 3, 2 range 2nd → 3rd Over 90% 100 –...
Page 662: Component Location
5A-14 Automatic Transmission/Transaxle: Component Location Electronic Shift Control System Components Location S6RW0D5103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0D510004-01 [A]: Junction block with BCM model 7. Input shaft speed sensor 15.
Page 663 Automatic Transmission/Transaxle: 5A-15 6. Output shaft speed sensor (VSS) 14. Transmission range sensor Torque converter with Planetary gear Final gear Engine unit torque converter clutch reduction unit Clutches and Regulator valves Oil pump brakes in valve body Control valves in valve body Pressure control solenoid valve Shift solenoid valves,...
Page 664: Diagnostic Information And Procedures
5A-16 Automatic Transmission/Transaxle: Diagnostic Information and Procedures A/T System Check S6RW0D5104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC / freeze frame data check, record and clearance Print DTC or write them...
Page 665 Automatic Transmission/Transaxle: 5A-17 Step 1. Customer Complaint Analysis Record details of the problem such as failure, complaint and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 666 5A-18 Automatic Transmission/Transaxle: Step 2. DTC / Freeze Frame Data Check, Record and Step 8. A/T Basic Check and A/T Symptom Clearance Diagnosis First, referring to “DTC Check”, check DTC and pending Perform basic check of A/T according to “A/T Basic DTC.
Page 667: Transmission Warning Light Check
Automatic Transmission/Transaxle: 5A-19 Inspection item Referring Also check the following items at engine start, if possible. • Malfunction indicator lamp ----- Operation “Malfunction Indicator Lamp (MIL) Check” • Transmission warning light ----- Operation “Transmission Warning Light Check (Non-Euro- OBD model)” •...
Page 668 5A-20 Automatic Transmission/Transaxle: Detecting condition DTC No. Detecting item (DTC will set when detecting) Control module Programming P0602 Data programming error. — — Error Transmission range sensor circuit 1 driving 1 driving P0705 Multiple signals are inputted simultaneously. malfunction (PRNDL input) cycle cycle Transmission range sensor circuit...
Page 669: Dtc Check
(DTC) in its memory and outputs the DTC to the scan tool. Therefore, check both of the control modules for any DTC with the SUZUKI scan tool because the DTC stored in ECM I5RW0C510072-01 3) Turn ignition switch ON.
Page 670: Dtc Clearance
Be careful not to clear them before by performing the following procedure. keeping their record. 1) Connect SUZUKI scan tool to data link connector in • When the same malfunction (DTC) is not the same manner as when making this connection detected again during 40 engine warm-up for “DTC Check”.
Page 671 Automatic Transmission/Transaxle: 5A-23 DTC No. Trouble area Fail-safe operation P0787 Shift / Timing solenoid Control Circuit Low P0788 Shift / Timing solenoid Control Circuit High Pressure control solenoid control circuit P0962 • Power supply for all solenoid valves is cut. •...
Page 672: Scan Tool Data
5A-24 Automatic Transmission/Transaxle: DTC No. Trouble area Fail-safe operation • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. • Engine revolution is assumed to be 0 RPM. •...
Page 673 Automatic Transmission/Transaxle: 5A-25 Normal condition / reference Scan tool data Vehicle condition values At vehicle stop SHIFT SOLENOID- At 60 km/h (37.5 mile/h) constant speed, 20% or less B COMMAND throttle opening and 3rd gear (“3” range) At vehicle stop SHIFT SOLENOID- At 60 km/h (37.5 mile/h) constant speed, 20% or less B MONITOR...
Page 674 5A-26 Automatic Transmission/Transaxle: Scan Tool Data Definitions: TCC SOLENOID Electric current value ratio between electric current value GEAR POSITION being outputted from TCM to solenoid and maximum Current gear position computed by throttle position value can be outputted by TCM. coming from ECM and vehicle speed.
Page 675: A/T Basic Check
Automatic Transmission/Transaxle: 5A-27 MIL REQUEST OFF: Signal which TCM does not require combination ON: Signal which TCM requires combination meter to meter to turn on malfunction indicator lamp. turn on malfunction indicator lamp. A/T Basic Check S6RW0D5104009 This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in “Visual Inspection”.
Page 676 5A-28 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Faulty oil pump Inspect. If NG, replace. Seized or broken planetary gear Inspect. If NG, replace. Faulty one-way No.2 clutch Inspect.
Page 677 Automatic Transmission/Transaxle: 5A-29 Condition Possible cause Correction / Reference Item → 3 downshift fails to Malfunction of shift solenoid valve-A Inspect. If NG, replace. occur Malfunction of “3” position switch Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor (VSS) Malfunction of input shaft speed sensor Inspect.
Page 678: Manual Road Test
5A-30 Automatic Transmission/Transaxle: Manual Road Test S6RW0D5104011 WARNING Carry out test in very little traffic area to prevent an accident. Test requires 2 persons, a driver and a tester. The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transaxle is electrical or mechanical by disconnecting valve body harness connector (1) and fixing automatic transaxle gear position.
Page 679: Stall Test
Automatic Transmission/Transaxle: 5A-31 Stall Test S6RW0D5104013 This test is to check overall performance of automatic transaxle and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transaxle fluid is at normal operating temperature and its level is between FULL and LOW marks.
Page 680: Time Lag Test
5A-32 Automatic Transmission/Transaxle: Time Lag Test S6RW0D5104014 This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal. 2) Start engine.
Page 681: P" Range Test
Automatic Transmission/Transaxle: 5A-33 CAUTION After attaching oil pressure gauge, check that no fluid leakage exists. 4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D” or “R” range. CAUTION • Do not continue running engine at stall speed longer than 5 seconds. •...
Page 682: A/T Symptom Diagnosis
5A-34 Automatic Transmission/Transaxle: A/T Symptom Diagnosis S6RW0D5104017 Trouble Diagnosis 1 Electrical repair Condition Possible cause Correction / Reference Item Excessive shift shock Shift solenoid valve-A and/or -B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent.
Page 683 Automatic Transmission/Transaxle: 5A-35 Condition Possible cause Correction / Reference Item → Poor 2 3 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor (VSS) circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 684 5A-36 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor 4 3 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 685 Automatic Transmission/Transaxle: 5A-37 Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC solenoid valve circuit faulty Inspect circuit for open, short and intermittent. up) system If NG, repair. Shift solenoid valve-A and/or-B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 686 5A-38 Automatic Transmission/Transaxle: Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Excessive shift shock Engine abnormal condition Inspect and repair engine. Malfunction of shift solenoid valve-A Inspect.
Page 687 Automatic Transmission/Transaxle: 5A-39 Condition Possible cause Correction / Reference Item → Poor 3 4 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace. Malfunction of timing solenoid valve Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor (VSS) Malfunction of input shaft speed sensor Inspect.
Page 688 5A-40 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item Non operate TCC (lock- Malfunction of TCC solenoid valve Inspect. If NG, replace. up) system Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of output shaft speed Inspect.
Page 689: Transmission Warning Light Circuit Check - Light Remains "On" At Ignition Switch On (Non-Euro-Obd Model)
Automatic Transmission/Transaxle: 5A-41 Condition Possible cause Correction / Reference Item Non operate TCC (lock- Faulty torque converter Replace. up) system → Excessive “N” “D” time Faulty oil pump Inspect. If NG, replace. Faulty forward clutch Inspect. If NG, replace. Faulty one-way No.2 clutch Inspect.
Page 690: Dtc P0602: Control Module Programming Error
5A-42 Automatic Transmission/Transaxle: DTC P0602: Control Module Programming Error S6RW0D5104047 System Description Internal control module is installed in ECM. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Data programming error (1 driving cycle detection logic) DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 691 Check transmission range sensor circuit for operation Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent OFF. and Poor Connection Inspection in Section 2) Turn ignition switch ON and check transmission range 00”.
Page 692: Dtc P0707: Transmission Range Sensor Circuit Low
5A-44 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor Inspection and “RED”, “GRN/ORN”, range sensor. Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? shorted to power circuit or shorted each other.
Page 693 Check transmission range sensor circuit for operation Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent OFF. and Poor Connection Inspection in Section 2) Turn ignition switch ON and check transmission range 00”.
Page 694: Dtc P0711: Transmission Fluid Temperature Sensor "A" Control Range / Performance
5A-46 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor Inspection and “RED”, “GRN/ORN”, range sensor. Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? open or short to ground. If wires and connections are OK, substitute a know-good TCM and...
Page 695: Dtc P0712: Transmission Fluid Temperature Sensor Circuit Low
Automatic Transmission/Transaxle: 5A-47 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Inspect transmission fluid temperature sensor Go to Step 3 Replace transmission fluid temperature 1) Inspect transmission fluid temperature sensor referring sensor.
Page 696: Dtc P0713: Transmission Fluid Temperature Sensor Circuit High
5A-48 Automatic Transmission/Transaxle: 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 an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
Page 697 Automatic Transmission/Transaxle: 5A-49 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 an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
Page 698: Dtc P0717: Input / Turbine Speed Sensor Circuit Malfunction
5A-50 Automatic Transmission/Transaxle: DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction S6RW0D5104024 Wiring Diagram C07-6 C07-16 2.5V I6RW0B510010-01 1. TCM 2. Input shaft speed sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No input shaft speed sensor signal is detected although...
Page 699: Dtc P0722: Output Speed Sensor (Vss) Circuit No Signal
Automatic Transmission/Transaxle: 5A-51 Step Action Inspect input shaft speed sensor “WHT” or “BLK” circuit Replace input shaft open or short. speed sensor. 1) Inspect input shaft speed sensor referring to “Input Shaft Speed Sensor Inspection”. Is result satisfactory? Check visually input shaft speed sensor and direct Intermittent trouble or Clean, repair or replace.
Page 700 5A-52 Automatic Transmission/Transaxle: 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 an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
Page 701: Dtc P0741 / P0742: Tcc Circuit Performance Or Stuck Off / Tcc Circuit Stuck
Automatic Transmission/Transaxle: 5A-53 Step Action Check output shaft speed sensor (VSS) gears visually Intermittent trouble or Replace drive gear and/ faulty TCM. or driven gear of output 1) Check output shaft speed sensor gears for the shaft speed sensor. followings. Check for intermittent referring to “Intermittent •...
Page 702: Dtc P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction
5A-54 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. 1) Check TCC solenoid valve for operation referring to Clean fluid passage or Replace TCC solenoid “Solenoid Valves (Shift Solenoid Valves and Timing replace valve body valve.
Page 703: Dtc P0787: Shift / Timing Solenoid Control Circuit Low
Automatic Transmission/Transaxle: 5A-55 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 an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
Page 704 5A-56 Automatic Transmission/Transaxle: DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory. 3) Start engine and shift select lever to “N” range. 4) Repeat shifting select lever from “N” range to “D” range and vice versa for 3 times. 5) Check DTC.
Page 705: Dtc P0788: Shift / Timing Solenoid Control Circuit High
Automatic Transmission/Transaxle: 5A-57 DTC P0788: Shift / Timing Solenoid Control Circuit High S6RW0D5104029 Wiring Diagram C06-14 BLU/BLK I6RW0B510012-01 1. TCM 3. A/T 2. Timing solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of timing solenoid valve TCM terminal is high...
Page 706: Dtc P0961: Pressure Control Solenoid "A" Control Circuit Range / Performance
5A-58 Automatic Transmission/Transaxle: Step Action Check timing solenoid valve resistance “BLU/BLK” circuit open. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1), (2) on transaxle. 3) Check for proper connection to solenoid valve at “BLU/ BLK”...
Page 707 Automatic Transmission/Transaxle: 5A-59 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between actual current of control solenoid valve • Malfunction of pressure control solenoid valve or its circuit and current of control solenoid valve circuit calculated circuit malfunction by ECM is more than specification.
Page 708: Dtc P0962: Pressure Control Solenoid Control Circuit Low
5A-60 Automatic Transmission/Transaxle: Step Action Check for pressure control solenoid valve circuit Intermittent trouble or Repair “LT GRN/BLK” faulty TCM. Check for and/or “GRY” circuit. 1) Disconnect TCM connectors. intermittent referring to 2) Check for proper connection to TCM at terminals “C06- “Intermittent and Poor 2”...
Page 709 Automatic Transmission/Transaxle: 5A-61 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid valve resistance Go to Step 3. Replace pressure control solenoid valve or 1) Turn ignition switch OFF. valve body harness.
Page 710: Dtc P0963: Pressure Control Solenoid Control Circuit High
5A-62 Automatic Transmission/Transaxle: Step Action Check pressure control solenoid valve circuit for open “GRY” or “LT GRN/BLK” Intermittent trouble or circuit open. faulty TCM. 1) Check resistance continuity between terminals “C06-2” and “C06-4” of disconnected harness side TCM Check for intermittent connector.
Page 711 Automatic Transmission/Transaxle: 5A-63 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid circuit for IG short Go to Step 3. “BRN/YEL” or “LT GRN” circuit shorted to power 1) Connect valve body harness connector.
Page 712: Dtc P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low
5A-64 Automatic Transmission/Transaxle: DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low S6RW0D5104032 Wiring Diagram C06-16 BLK/YEL C06-15 16 15 I6RW0B510014-01 1. TCM 3. Shift solenoid valve-B (No.2) 2. Shift solenoid valve-A (No.1) [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition...
Page 713 Automatic Transmission/Transaxle: 5A-65 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve resistance Go to Step 3. Replace applicable shift solenoid valve or valve 1) Turn ignition switch OFF. body harness.
Page 714: Dtc P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High
5A-66 Automatic Transmission/Transaxle: DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High S6RW0D5104033 Wiring Diagram C06-16 BLK/YEL C06-15 16 15 I6RW0B510014-01 1. TCM 3. Shift solenoid valve-B (No.2) [A]: Terminal arrangement of TCM connector (viewed from harness side) 2.
Page 715 Automatic Transmission/Transaxle: 5A-67 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve circuit for IG short Go to Step 3. DTC P0974: “BRN” circuit shorted to power 1) Connect valve body harness connector.
Page 716: Dtc P1702: Internal Control Module Memory Check Sum Error
5A-68 Automatic Transmission/Transaxle: DTC P1702: Internal Control Module Memory Check Sum Error S6RW0D5104034 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Calculation of current data stored in TCM is not correct comparing with pre-stored checking data in TCM. DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
Page 717: Dtc P1878: Torque Converter Clutch Shudder
Substitute a known- Go to Step 3. good TCM and recheck. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check “3” position switch signal on scan tool data display when shifting select lever to each range.
Page 718: Dtc P2762: Torque Converter Clutch (Tcc) Pressure Control Solenoid Control Circuit Range / Performance
5A-70 Automatic Transmission/Transaxle: DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance S6RW0D5104050 Wiring Diagram C06-5 WHT/BLU C06-3 WHT/BLK I6RW0D510007-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 719 Automatic Transmission/Transaxle: 5A-71 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid valve or valve body 1) Turn ignition switch OFF. harness.
Page 720: Dtc P2763: Torque Converter Clutch (Tcc) Pressure Control Solenoid Control Circuit High
5A-72 Automatic Transmission/Transaxle: DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High S6RW0D5104042 Wiring Diagram C06-5 WHT/BLU C06-3 WHT/BLK I6RW0D510007-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 721 Automatic Transmission/Transaxle: 5A-73 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve circuit for IG short Go to Step 3. “WHT/BLU” or “WHT/ BLK” circuit shorted to 1) Connect valve body harness connector.
Page 722: Dtc P2764: Torque Converter Clutch (Tcc) Circuit Pressure Control Solenoid Control Circuit Low
5A-74 Automatic Transmission/Transaxle: DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low S6RW0D5104043 Wiring Diagram C06-5 WHT/BLU C06-3 WHT/BLK I6RW0D510007-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 723 Automatic Transmission/Transaxle: 5A-75 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid valve or valve body 1) Turn ignition switch OFF. harness.
Page 724: Dtc U0073: Control Module Communication Bus Off
5A-76 Automatic Transmission/Transaxle: DTC U0073: Control Module Communication Bus Off S6RW0D5104051 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0100: Lost Communication with ECM / PCM “A” S6RW0D5104052 Refer to “Troubleshooting for CAN-DTC in Section 1A”. Inspection of TCM and Its Circuits S6RW0D5104044 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance.
Page 725 Automatic Transmission/Transaxle: 5A-77 Connector “C06” Standard Terminal Wire color Circuit Condition voltage Ground 0 – 1 V Ignition switch ON LT GRN/ Pressure control 0.6 – 1.0 V Ignition switch ON solenoid valve (–) WHT/BLK TCC solenoid valve (–) 0.6 – 1.0 V Ignition switch ON *0 –...
Page 726 5A-78 Automatic Transmission/Transaxle: Connector “C07” Standard Terminal Wire color Circuit Condition voltage Transmission range 8 – 14 V Ignition switch ON, select lever at “R” range sensor (“R” range) 0 – 1 V Ignition switch ON, select lever at other than “R” range —...
Page 727 Automatic Transmission/Transaxle: 5A-79 Reference waveform No. 1 Reference waveform No. 3 Pressure control solenoid valve signal at engine idling. CAN communication line (High & Low) signal at engine idling. Measurement CH1: “C06-4” to “C06-1” terminal Measurement CH1: “C06-7” to “C06-1” Oscilloscope CH1: 5 V/DIV terminal...
Page 728: Tcm Power And Ground Circuit Check
5A-80 Automatic Transmission/Transaxle: Reference waveform No. 5 Output shaft speed sensor (VSS) signal at vehicle speed 60 km/h (37 mile/h). Measurement CH1: “C07-25” to “C06-1” terminal Oscilloscope CH1: 5 V/DIV setting TIME: 20 ms/DIV • After warmed up to normal operating temperature Measurement condition...
Page 729: Brake Interlock System Inspection
Automatic Transmission/Transaxle: 5A-81 Troubleshooting Step Action Check TCM back-up power circuit Go to Step 2. “WHT/RED” circuit open or shorted to ground. 1) Disconnect TCM connector with ignition switch OFF. 2) Check for proper connection to TCM at “C06-24” terminal. 3) If OK, check voltage at terminal “C06-24”...
Page 730: Repair Instructions
1) Connect san tool to DLC (1) with ignition switch OFF. CAUTION Special tool Do not use any fluid other than the specified (A): SUZUKI scan tool (SUZUKI-SDT) ATF. Use of any fluid other than the specified ATF may cause juddering or some other faulty condition to occur.
Page 731: A/T Fluid Change
Fluid level check at room (cold) temperature between FULL HOT (2) and LOW HOT (3). If it is is recommended only for preparation of level below LOW HOT, add SUZUKI ATF 3317 or Mobil check under normal (hot) operating ATF 3309 up to FULL HOT.
Page 732: Select Lever Components
5A-84 Automatic Transmission/Transaxle: 5) Lower vehicle and pour proper amount of SUZUKI Select Lever Assembly Removal and ATF 3317 or Mobil ATF 3309. Installation S6RW0D5106059 6) Check fluid level referring to “A/T Fluid Level Check”. Remove and install select lever referring to “Select Lever Components”.
Page 733: Select Lever Inspection
Automatic Transmission/Transaxle: 5A-85 Select Lever Inspection Shift Lock Solenoid Inspection S6RW0D5106005 S6RW0D5106024 Check select lever for smooth and clear-cut movement Check that shift lock solenoid (1) actuate when battery individually. If a malfunction is found, replace select lever voltage is conducted. assembly.
Page 734: Select Cable Components
5A-86 Automatic Transmission/Transaxle: Select Cable Components S6RW0D5106006 I5RW0C510031-01 [A]: View [A] 5. Clip 11. Radiator inlet hose [B]: View [B] 6. Manual select lever pin : 23 N⋅m (2.0 kgf-m, 17.0 lb-ft) : Apply lithium grease 99000-25011 to all around pin (0.15 g) 1.
Page 735: Key Interlock Cable Removal And Installation
6) Shift select lever to “N” position. 7) Apply grease to select lever pin and install adjuster (cable end) to it. : Grease 99000–25011 (SUZUKI Super Grease I5RW0C510045-01 5) Turn ignition switch to LOCK position. 8) With both select lever and transmission range 6) Remove console box referring to “Console Box...
Page 736 5A-88 Automatic Transmission/Transaxle: Installation 1) Lay interlock cable to its original cabling route. I5RW0C510073-01 [A]: LH steering vehicle 2. Clamp 6. EPS control module [B]: RH steering vehicle 3. Steering lock assembly / Steering lock unit (if equipped with Keyless 7.
Page 737: Transmission Range Sensor Inspection And Adjustment
Automatic Transmission/Transaxle: 5A-89 2) Turn ignition switch to ACC position. 9) With select lever set at “P” position, turn ignition key to ACC position and then check for the following 3) Insert cable casing cap (1) into key cylinder cover (2) conditions.
Page 738: Output Shaft Speed Sensor (Vss) Removal And Installation
5A-90 Automatic Transmission/Transaxle: 3) Connect output shaft speed sensor connector (2) to 3) Check that engine starts in “N” and “P” ranges but it doesn’t start in “D”, “2”, “L” or “R” range. Also, check output shaft speed sensor (VSS) (1). that back-up lamp lights in “R”...
Page 739: Input Shaft Speed Sensor Removal And Installation
Automatic Transmission/Transaxle: 5A-91 Input Shaft Speed Sensor Removal and Input Shaft Speed Sensor Inspection S6RW0D5106013 Installation 1) Disconnect negative cable at battery. S6RW0D5106012 Removal 2) Disconnect input shaft speed sensor connector (2). 1) Disconnect negative cable at battery. 3) Check resistance between input shaft speed sensor 2) Disconnect input shaft speed sensor connector (2).
Page 740: Transmission Fluid Temperature Sensor Inspection
5A-92 Automatic Transmission/Transaxle: Installation Transmission Fluid Temperature Sensor Reverse removal procedure to install valve body Inspection harness and valve body assembly noting the following S6RW0D5106015 Warm up transmission fluid temperature sensor (2). points. Check resistance between terminals of valve body •...
Page 741 Automatic Transmission/Transaxle: 5A-93 Installation 7) Remove oil strainer assembly (3). 1) Install shift solenoid valve-A (No.1) (1), shift solenoid valve-B (No.2) (2) and timing solenoid valve (3). Tightening torque Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb- I4RS0A510029-01 2) Connect solenoid connectors identifying their installing positions by wire color.
Page 742: Solenoid Valves (Shift Solenoid Valves And Timing Solenoid Valve) Inspection
5A-94 Automatic Transmission/Transaxle: Operation Check 4) Install oil strainer assembly (1). Shift solenoid valve-A (No.1) and -B (No.2) Tightening torque Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) CAUTION • Do not insert air gun against strainer installed on inlet of solenoid valve too deeply, when blowing air into solenoid valve.
Page 743: Pressure Control Solenoid Valves (Pressure Control Solenoid And Tcc Solenoid) Removal And Installation
Automatic Transmission/Transaxle: 5A-95 Timing solenoid valve Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Solenoid) Removal CAUTION and Installation S6RW0D5106063 • Do not insert air gun against strainer Removal installed on inlet of solenoid valve too 1) Disconnect negative cable at battery. deeply, when blowing air into solenoid 2) Lift up vehicle.
Page 744: Pressure Control Solenoid Valves Inspection
5A-96 Automatic Transmission/Transaxle: 10) Remove valve body assembly referring to Operation Check “Automatic Transaxle Unit Disassembly”. Check pressure control solenoid valves (Pressure control solenoid and TCC pressure control solenoid) 11) Remove pressure control solenoid valve and TCC operation in the either manner of the following. pressure control solenoid valve referring to “Valve Body Assembly Disassembly and Reassembly”.
Page 745: Transmission Control Module (Tcm) Removal And Installation
Automatic Transmission/Transaxle: 5A-97 Installation 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 “Enabling Air Bag System in Section 8B”. A/T Relay Inspection S6RW0D5106022 1) Disconnect negative cable at battery.
Page 746: Differential Side Oil Seal Replacement
2. Outlet hose (Inlet to A/T fluid cooler) I5RW0A520006-02 4) Apply grease to new differential side oil seal lips. : Grease 99000–25030 (SUZUKI Super Grease C) 5) Install new differential side oil seals (1) by using special tool. Special tool (A): 09913–75510...
Page 747: Automatic Transaxle Unit Components
Automatic Transmission/Transaxle: 5A-99 Automatic Transaxle Unit Components S6RW0D5106028 I5RW0C510050-01 1. Drive plate 6. Transaxle and engine fastening bolt : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft) 2. Drive plate bolt 7. Transaxle and engine fastening nut : 69 N⋅m (6.9 kgf-m, 50.0 lb-ft) 3.
Page 748: Automatic Transaxle Unit Dismounting And Remounting
5A-100 Automatic Transmission/Transaxle: Automatic Transaxle Unit Dismounting and 4) Remove starting motor. Remounting 5) Remove bolts and nut fastening engine and S6RW0D5106029 transaxle, then detach transaxle from engine. Dismounting WARNING 1) Take down transaxle with engine. For its procedure, Be sure to keep transaxle with torque refer to “Engine Assembly Removal and Installation converter horizontal or facing up throughout in Section 1D”.
Page 749 Automatic Transmission/Transaxle: 5A-101 Remounting 3) Tighten drive plate to torque converter bolts. Align bolt hole of drive plate and torque converter then 1) Make sure that torque converter is installed correctly tighten bolts through torque converter housing lower to transaxle. plate opening.
Page 750: Automatic Transaxle Assembly Components .5A-102
5A-102 Automatic Transmission/Transaxle: Automatic Transaxle Assembly Components S6RW0D5106030 I5RW0C510057-01...
Page 751 Automatic Transmission/Transaxle: 5A-103 1. Torque converter 37. Transmission range sensor 73. Rear planetary sun gear subassembly 2. Torque converter housing 38. Cooler check valve 74. Rear sun gear thrust bearing race : Apply sealant 99000-31230 to mating surface to transaxle case. 3.
Page 752: Automatic Transaxle Unit Disassembly
5A-104 Automatic Transmission/Transaxle: Automatic Transaxle Unit Disassembly 4) Uncaulk lock washer (1), then remove lock nut (2) S6RW0D5106031 and lock washer. CAUTION • Thoroughly clean transaxle exterior before overhauling it. • Keep working table, tools and hands clean while overhauling. •...
Page 753 Automatic Transmission/Transaxle: 5A-105 9) Remove fluid cooler pipes (1) and pipe unions (2). 13) Disconnect connectors (2) from solenoid valves and transmission fluid temperature sensor (1). 10) Remove fluid level gauge (3) and fluid filler tube (4). I5RW0C510060-01 I5RW0C510038-02 11) Remove oil pan (1) and oil pan gasket (2). 14) Remove valve body assembly bolts.
Page 754 5A-106 Automatic Transmission/Transaxle: 19) Remove accumulator pistons and springs. 16) Remove valve body harness (1). To remove C2 (1), C1 (2) and B1 (3) accumulator CAUTION pistons and springs, position rag on pistons to catch each piston. To remove pistons, force low-pressure When pulling valve body harness out of compressed air (1 kg/cm , 15 psi, 100 kPa, max) into...
Page 755 Automatic Transmission/Transaxle: 5A-107 20) Remove transaxle case plug (1). I2RH0B510098-01 26) Remove oil pump assembly (1). I2RH0B510095-01 21) Remove torque converter housing bolts. 22) Remove torque converter housing (1) while tapping around it lightly with plastic hammer. I2RH0B510099-01 27) Remove direct clutch assembly (1). I3RM0B510060-01 23) Remove breather hose (1).
Page 756 5A-108 Automatic Transmission/Transaxle: 29) Remove input shaft rear thrust bearing (1) and thrust 32) Remove governor apply No.2 gasket (1). bearing race (2). NOTE If input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly.
Page 757 Automatic Transmission/Transaxle: 5A-109 36) Remove 2nd brake gasket (1). I2RH0B510109-01 37) Measure O/D and 2nd coast brake piston stroke. If piston stroke exceeds specification, inspect and replace plates and discs. • Measure dimension “a” from mating surface of transaxle case to O/D and 2nd coast brake rear plate (1) using straightedge and micrometer caliper.
Page 758 5A-110 Automatic Transmission/Transaxle: 44) Remove rear planetary sun gear subassembly (1) 40) Remove O/D and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). and one-way clutch No.1 assembly (2). I2RH0B510113-01 I2RH0B510117-01 41) Remove forward clutch hub (1). 45) Remove planetary gear thrust bearing (1).
Page 759 Automatic Transmission/Transaxle: 5A-111 2nd brake piston stroke 48) Remove O/D and 2nd coast brake retaining plate snap ring (1). “a”: 0.40 – 1.25 mm (0.016 – 0.049 in.) “a” I2RH0B510120-01 49) Remove front planetary sun gear (1). I2RH0B510123-01 52) Using special tool and hydraulic press, remove 2nd brake piston snap ring (1).
Page 760 5A-112 Automatic Transmission/Transaxle: 53) Remove 2nd brake piston assembly (1). 58) Check one-way clutch No.2 as follows. 54) Remove 2nd brake return spring subassembly (2). • Ensure planetary carrier (1) rotates only in counterclockwise direction “A”, never in clockwise direction “B”. •...
Page 761 Automatic Transmission/Transaxle: 5A-113 61) Measure 1st and reverse brake piston stroke. 63) Remove 1st and reverse brake retaining plate, discs If piston stroke exceeds specified value, and separator plates. disassemble, inspect and replace discs and plates. 64) Remove 1st and reverse brake return spring •...
Page 762 5A-114 Automatic Transmission/Transaxle: 67) Using special tools and hydraulic press, remove 69) Screwing 3 bolts (1), remove reduction drive gear planetary ring gear subassembly (1). (2). CAUTION CAUTION Do not reuse planetary ring gear Screw 3 bolts into reduction drive gear subassembly.
Page 763 Automatic Transmission/Transaxle: 5A-115 71) Remove parking lock pawl bracket (1). 75) Remove parking lock pawl rod (2) from manual valve lever (1). I2RH0B510145-01 76) Remove manual detent spring (1). I2RH0B510142-01 72) With slotted screwdriver, cut and unfold manual valve lever spacer (1) and proceed to remove manual valve lever spacer.
Page 764: Oil Pump Assembly Components
5A-116 Automatic Transmission/Transaxle: Oil Pump Assembly Components S6RW0D5106032 I5RW0C510061-01 1. Oil seal 5. Oil pump drive gear : Apply automatic transaxle fluid. : Apply grease 99000-25030 to oil seal lip. 2. O-ring 6. Stator shaft assembly : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft) 3.
Page 765: Oil Pump Assembly Inspection
Special tool driven gear and body. If clearance exceeds its (A): 09913–85210 standard value, replace oil pump assembly. “A”: Grease 99000–25030 (SUZUKI Super Clearance between oil pump driven gear and oil Grease C) pump body Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.) I2RH0B510151-01 2.
Page 766 5A-118 Automatic Transmission/Transaxle: 3) Check side clearance of both gears. 5) Install direct clutch assembly (1) to stator shaft Using a straightedge (1) and a feeler gauge (2), assembly (2), then ensure that direct clutch measure side clearance between gears and pump assembly turns smoothly.
Page 767: Direct Clutch Assembly Components
Automatic Transmission/Transaxle: 5A-119 Direct Clutch Assembly Components S6RW0D5106035 I2RH0B510160-01 1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate 2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring 3. Input shaft subassembly 8.
Page 768: Direct Clutch Assembly Disassembly And Reassembly
5A-120 Automatic Transmission/Transaxle: Direct Clutch Assembly Disassembly and 4) Using a finger to block oil hole (1), apply compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – Reassembly 113 psi) to opposite hole, which will assist in removal S6RW0D5106037 of the clutch piston.
Page 769 Automatic Transmission/Transaxle: 5A-121 Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new seal ring and O-ring. Apply A/T fluid before installation. • Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return spring subassembly passing through its original installing position over 0.7 mm (0.027 in.).
Page 770: Direct Clutch Assembly Inspection
5A-122 Automatic Transmission/Transaxle: Direct Clutch Assembly Inspection Direct Clutch Return Spring Subassembly S6RW0D5106038 Measure free length of direct clutch return spring subassembly. Clutch Discs, Plates and Retaining Plate Direct clutch return spring subassembly free length Check that sliding surfaces of discs, separator plates “a”: 36.04 mm (1.419 in.) and retaining plate are not worn hard or burnt.
Page 771: Forward And Reverse Clutch Assembly Components
Automatic Transmission/Transaxle: 5A-123 Forward and Reverse Clutch Assembly Components S6RW0D5106039 I3RM0B510061-01 1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate 2. Forward clutch return spring subassembly 9. Reverse clutch plate snap ring 16. Forward clutch disc 3.
Page 772: Forward And Reverse Clutch Assembly Disassembly And Reassembly
5A-124 Automatic Transmission/Transaxle: 2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm 2) Remove forward clutch plate snap ring (1) and take 57 – 113 psi) through oil hole (1) of transaxle rear out forward clutch retaining plate, discs and cover with the special tool attached on the upper separator plates from forward clutch drum.
Page 773 Automatic Transmission/Transaxle: 5A-125 6) Install intermediate shaft subassembly (1) to 9) Remove forward clutch drum O-ring (1) from forward transaxle rear cover (2). Apply compressed air (400 clutch drum (2). – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) to oil hole (3) of transaxle rear cover to remove forward clutch piston (4).
Page 774 5A-126 Automatic Transmission/Transaxle: • Apply A/T fluid to forward clutch separator plates (1), • Measure forward clutch piston stroke in the same discs (2) and retaining plate (3). manner as “Forward and Reverse Clutch Assembly Preliminary Check”. • Install forward clutch separator plates (1), discs (2) When piston stroke is out of specification, select and retaining plate (3), then snap ring (4) to forward forward clutch retaining plate with proper thickness...
Page 775: Forward And Reverse Clutch Assembly Inspection
Automatic Transmission/Transaxle: 5A-127 • Install reverse clutch plate snap ring so that its both Forward and Reverse Clutch Assembly ends would be positioned in correct locations as Inspection shown in figure. S6RW0D5106042 Clutch, Discs, Separator Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt.
Page 776: 2Nd Brake Piston Assembly Components
5A-128 Automatic Transmission/Transaxle: Forward Clutch Drum Lip Forward Clutch Piston Lip and Forward Clutch Balancer Lip Check each lip for wear, deformation, cut and/or Check each lip for wear, deformation, cut and/or hardening. If necessary, replace. hardening. If necessary, replace. I2RH0B510194-01 I2RH0B510195-01 2nd Brake Piston Assembly Components...
Page 777: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Components
Automatic Transmission/Transaxle: 5A-129 2) Remove inner O-ring (1) and outer O-ring (2). Reassembly Reverse disassembly 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 cylinder (2).
Page 778: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Disassembly And Reassembly
5A-130 Automatic Transmission/Transaxle: Transaxle Rear Cover (O/D and 2nd Coast Brake 4) Remove O/D and 2nd coast brake piston front O-ring (1) and rear O-ring (2). Piston) Assembly Disassembly and Reassembly S6RW0D5106046 Disassembly 1) Remove snap ring by using special tools and hydraulic press.
Page 779: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Inspection
Automatic Transmission/Transaxle: 5A-131 Transaxle Rear Cover (O/D and 2nd Coast Brake Reassembly Reverse disassembly procedure for assembly, noting the Piston) Assembly Inspection following points. S6RW0D5106047 • Use new seal rings and O-rings. Apply A/T fluid to O/D and 2nd Coast Brake Return Spring seal rings and O-rings before installation.
Page 780: Countershaft Assembly Components
5A-132 Automatic Transmission/Transaxle: Countershaft Assembly Components 2) Remove countershaft RH bearing (1) by using S6RW0D5106048 special tools. Special tool (A): 09913–61510 (B): 09926–58010 I2RH0B510211-01 Reassembly I2RH0B510209-01 1) Install new countershaft RH bearing (1) by using 1. Countershaft RH bearing 5. Bearing cap 2.
Page 781: Valve Body Assembly Components
Automatic Transmission/Transaxle: 5A-133 3) Install countershaft LH bearing (1) with special tools and hydraulic press. Special tool (A): 09913–84510 (B): 09925–88210 I2RH0B510214-01 Valve Body Assembly Components S6RW0D5106050 I4RS0A510044-01 1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid. 2.
Page 782: Valve Body Assembly Disassembly And Reassembly
5A-134 Automatic Transmission/Transaxle: Valve Body Assembly Disassembly and 4) Remove shift solenoid valve-A (1). Reassembly S6RW0D5106051 CAUTION When replacing pressure control solenoid valve and/or TCC pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing pressure control solenoid valve and/or TCC pressure control solenoid valve independently may cause excessive shift...
Page 783: Differential Assembly Components
Automatic Transmission/Transaxle: 5A-135 Reassembly Reverse disassembly procedure for assembly, noting the following points. • Shift solenoid valve-A and -B are identical • After applying A/T fluid to new O-rings, fit them to solenoid valves, then install solenoid valves to valve body.
Page 784: Differential Assembly Disassembly And Reassembly
5A-136 Automatic Transmission/Transaxle: Differential Assembly Disassembly and 4) Remove differential side LH bearing by using special tools. Reassembly S6RW0D5106053 Special tool (A): 09926–37610 Disassembly (B): 09926–37610–001 1) Remove final gear bolts (1), and then final gear (2). (C): 09926–37610–003 (D): 09926–37610–002 I2RH0B510225-01 2) Remove differential side RH bearing by using special tools.
Page 785: Differential Assembly Inspection
Automatic Transmission/Transaxle: 5A-137 2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. I2RH0B510233-01 6) Install new differential side LH bearing (1) by using I2RH0B510230-01 special tool and hydraulic press. 3) Tighten final gear bolts (1) to specified torque. NOTE NOTE Replace differential side LH bearing together...
Page 786: Torque Converter Housing Disassembly And Reassembly
5A-138 Automatic Transmission/Transaxle: Torque Converter Housing Disassembly and 4) Remove countershaft RH bearing cup by using special tools. Reassembly S6RW0D5106055 Special tool (A): 09944–96011 Disassembly (B): 09942–15511 1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2). I2RH0B510239-01 5) Remove differential side RH bearing cup by using special tools.
Page 787 Differential side oil seal installing depth Torque converter housing plug (a): 7.5 N·m (0.75 “a”: 13.2 – 14.2 mm (0.52 – 0.56 in.) kgf-m, 5.5 lb-ft) 5) Apply grease to oil seal lip. “A”: Grease 99000–25030 (SUZUKI Super Grease C) “a” “A” I2RH0B510242-01 2) Using special tools, assemble differential side RH bearing cup.
Page 788: Transaxle Case Disassembly And Reassembly
5A-140 Automatic Transmission/Transaxle: Transaxle Case Disassembly and Reassembly Reassembly S6RW0D5106056 1) Using special tools, assemble shim and differential side LH bearing cup. Disassembly 1) Remove differential side oil seal (1). NOTE Use shim with same thickness as the removed one. Special tool (A): 09924–74510 (B): 09944–88220...
Page 789: Automatic Transaxle Unit Inspection And Adjustment
Differential side oil seal installing depth “a”: 3.8 – 4.8 mm (0.15 – 0.19 in.) 4) Apply grease to oil seal lip. “A”: Grease 99000–25030 (SUZUKI Super Grease C) “a” I2RH0B510253-01 Brake return spring subassembly “A”...
Page 790 5A-142 Automatic Transmission/Transaxle: One-way clutch No.1 assembly 3) Measure bearing preload (a) by using a special tool. 1) Install one-way clutch No.1 assembly (2) to rear Special tool planetary sun gear subassembly (1). (A): 09928–06050 2) Securing rear planetary sun gear subassembly, Differential side bearing preload (a) measured as ensure that one-way clutch No.1 assembly rotates starting torque...
Page 791 Automatic Transmission/Transaxle: 5A-143 Countershaft bearing preload 4) If bearing preload is out of specification, select shim with suitable thickness from among the list below 1) After applying A/T fluid to countershaft assembly (1) and replace it. Then adjust countershaft bearing and differential assembly (2), fit them.
Page 792: Automatic Transaxle Unit Assembly
3) Install parking lock pawl rod (2) to manual valve lever or rotating surfaces of the parts before (1). assembly. • Use Suzuki Super Grease “C” to retain parts in place. • Be sure to install thrust bearings and races in correct direction and position.
Page 793 Automatic Transmission/Transaxle: 5A-145 6) Install parking lock pawl bracket (1) to transaxle 9) Install 1st and reverse brake return spring case. subassembly (1) to transaxle case (2). Tightening torque Parking lock pawl bracket bolt (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) I2RH0B510265-01 10) Apply A/T fluid to 1st and reverse brake discs (3), separator plates (2) and retaining plate (1), then...
Page 794 5A-146 Automatic Transmission/Transaxle: 12) Install 1st and reverse brake plate snap ring so that 14) Install reduction drive gear (1) to transaxle case (3) its both ends would be positioned in correct locations by using special tools and hydraulic press. as shown in figure.
Page 795 Automatic Transmission/Transaxle: 5A-147 16) Install new planetary ring gear subassembly (1) to 17) Using a small torque wrench, while turning to reduction drive gear (3) by using special tools and counter drive gear 100 rpm and measure the hydraulic press. preload.
Page 796 5A-148 Automatic Transmission/Transaxle: 20) Check for correct installation of planetary gear 22) Install one-way clutch outer race retainer (1). assembly as follows. Measure the distance “a” by using micrometer caliper (1) and straightedge (2). If measured value is out of specification, remove planetary gear assembly and reinstall it properly.
Page 797 Automatic Transmission/Transaxle: 5A-149 26) Apply A/T fluid to 2nd brake piston assembly (1), and 2nd brake piston stroke align the projection of 2nd brake piston assembly Standard: 0.40 – 1.25 mm (0.016 – 0.049 in.) with the groove of transaxle case, then put together. I2RH0B510282-01 27) Install 2nd brake piston snap ring (1) by using special tool and hydraulic press.
Page 798 I2RH0B510287-01 32) After applying grease to slide contact face of planetary carrier thrust washer (1), install it to planetary gear assembly. “A”: Grease 99000–25030 (SUZUKI Super Grease C) I2RH0B510291-01 37) After applying A/T fluid to rear sun gear thrust bearing (1), install it to forward clutch hub (2).
Page 799 Automatic Transmission/Transaxle: 5A-151 39) After applying A/T fluid to intermediate shaft thrust 41) Check for correct installation of forward and reverse bearing rear race (3), thrust bearing (2) and front clutch assembly as follows. race (1), install them to forward and reverse clutch Measure distance “a”...
Page 800 1.2 mm (0.047 in.) in 1.8 mm (0.071 in.) diameter. 2.0 mm (0.079 in.) 2.2 mm (0.087 in.) “A”: Sealant 99000–31230 (SUZUKI Bond 2.4 mm (0.094 in.) No.1216B) 2.6 mm (0.102 in.) “A” I2RH0B510301-01...
Page 801 Automatic Transmission/Transaxle: 5A-153 48) Install transaxle rear cover assembly on transaxle 53) After applying A/T fluid to differential assembly (1) case. and countershaft assembly (2), install them to transaxle case. 49) Install hook (2) to location shown in figure. 50) Tighten rear cover bolts (1). Tightening torque Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) I4RS0A510036-01...
Page 802 5A-154 Automatic Transmission/Transaxle: 57) Apply A/T fluid to direct clutch assembly (1). 59) Install oil pump assembly (1) to transaxle case. Install direct clutch assembly while rotating Tightening torque clockwise and counterclockwise frequently to fit Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m, clutch discs to mating hub.
Page 803 (0.14 in.) (1.90 in.) (1.30 in.) 4.05 mm 48.5 mm 32.5 mm “A”: Sealant 99000–31230 (SUZUKI Bond (0.16 in.) (1.90 in.) (1.28 in.) No.1216B) Tightening torque Torque converter housing bolt (a): 33 N·m (3.3 kgf-m, 24.0 lb-ft)
Page 804 5A-156 Automatic Transmission/Transaxle: 68) Install new O-rings to each accumulator piston and apply A/T fluid to them. Accumulator O-ring dimension Inside Section O-ring name diameter diameter Large B1 accumulator O-ring (2) Large C1 accumulator O-ring (2) 29.4 mm 2.6 mm Large C2 accumulator O-ring (2) (1.16 in.) (0.10 in.)
Page 805 Automatic Transmission/Transaxle: 5A-157 72) After applying A/T fluid to new O-ring, fit it to valve Valve body bolt length body harness connector (3), then install valve body Bolt Length “a” Pieces harness to transaxle case. A (1) 20 mm (0.79 in.) B (2) 28 mm (1.10 in.) CAUTION...
Page 806 5A-158 Automatic Transmission/Transaxle: 76) Install oil strainer assembly (1). 80) After applying A/T fluid to new O-rings, fit it to fluid cooler pipe unions (1). Then install fluid cooler pipe Tightening torque unions to transaxle case. Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) Tightening torque Fluid cooler pipe union (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Page 807 Automatic Transmission/Transaxle: 5A-159 83) Install select cable bracket (1). 87) Install lock washer (1) and tighten lock nut (2) to specified torque. Tightening torque Select cable bracket bolt (a): 23 N·m (2.3 kgf-m, Tightening torque 17.0 lb-ft) Transmission range sensor lock nut (a): 7 N·m ( 0.7 kgf-m, 5.0 lb-ft) 2, (a) I5RW0C510069-02...
Page 808 “a”: More than 19.9 mm (0.783 in.) • Check torque converter for smooth rotation. • Apply grease around cup (6) at the center of torque converter. “C”: Grease 99000–25011 (SUZUKI Super Grease A) I2RH0B510335-01 95) Install engine mounting LH bracket (1). Tighten engine mounting LH bracket bolts and nut to specified torque referring to “Engine Mountings...
Page 809 Automatic Transmission/Transaxle: 5A-161 Specifications Tightening Torque Specifications S6RW0D5107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft A/T fluid drain plug 12.5 Transmission range sensor bolt 0.55 Output shaft speed sensor (VSS) bolt Input shaft speed sensor bolt 0.55 Valve body harness connector bolt 0.55 Shift solenoid bolt Oil strainer bolt...
Page 810: Special Tools And Equipment
5A-162 Automatic Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S6RW0D5108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 SUZUKI Super Grease C P/No.: 99000–25030 Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 NOTE Required service material is also described in the following.
Page 811 Automatic Transmission/Transaxle: 5A-163 09913–84510 09913–85210 Bearing installer Bearing installer 09923–78210 09924–74510 Bearing installer Bearing and oil seal handle 09925–37811–001 09925–88210 Oil pressure gauge Bearing puller attachment 09925–98210 09925–98221 Input shaft bearing installer Bearing installer 09926–37610 09926–37610–001 Bearing remover Bearing puller 09926–37610–002 09926–37610–003 Bearing puller attachment...
Page 812 Transfer bearing dummy 09951–18210 09952–06020 Oil seal remover & installer Dial gauge plate No.2 No. 2 SUZUKI scan tool (SUZUKI- SDT) — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.
Page 813: General Description
Manual Transmission/Transaxle: 5B-1 Manual Transmission/Transaxle Transmission / Transaxle General Description Manual Transaxle Construction S6RW0D5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 814 5B-2 Manual Transmission/Transaxle: 2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub 3. Input shaft 5th gear 8. Reverse gear shaft 13. Countershaft 5th gear 18. Countershaft 1st gear 4. Input shaft 4th gear 9.
Page 815 Manual Transmission/Transaxle: 5B-3 Gear Shift Mechanism The gear shifting control system consists of the following main parts. Movement of gear shift control lever is transmitted to gear shift & select shaft through gear shift and gear select cables. I5RW0A520003-02 1. Gear shift control cable 7.
Page 816 5B-4 Manual Transmission/Transaxle: 5th & Reverse Gear Shift Cam 3) When shift lever is shifted to 5th gear, shift & select 5th & reverse gear shift cam, cam guide return spring shaft (1) turns clockwise letting shift cam (2) off from and 5th to reverse interlock guide bolt are provided to guide bolt and pushed up by return spring.
Page 817: Diagnostic Information And Procedures
3) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Transaxle oil level / filler plug (a): 21 N·m (2.1 kgf-m, 15.5 lb-ft)
Page 818: Manual Transaxle Oil Change
7) Apply sealant to thread of level / filler plug, and then S6RW0D5206002 tighten it to specified torque. 1) Before changing or inspecting oil, be sure to stop “A”: Sealant 99000–31260 (SUZUKI Bond engine and lift vehicle horizontally. No.1217G) 2) With vehicle lifted up, check leakage.
Page 819: Differential Side Oil Seal Replacement
1) Lift up vehicle and drain transaxle oil. sure of its smoothness. 2) Remove drive shaft assembly and center shaft “A”: Grease 99000–25011 (SUZUKI Super referring to “Front Drive Shaft Assembly Removal Grease A) and Installation in Section 3A”.
Page 820: Gear Shift Control Lever And Cable Components
5B-8 Manual Transmission/Transaxle: Gear Shift Control Lever and Cable Components S6RW0D5206004 I5RW0A520008-02 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft) 2. Cable bracket bolt 7. Gear shift control lever assembly : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) 3.
Page 821: Gear Shift Control Lever And Cable Removal
Manual Transmission/Transaxle: 5B-9 Gear Shift Control Lever and Cable Removal Gear Select Control Cable Adjustment S6RW0D5206006 and Installation 1) Release lock plate (1) which restricts moving of S6RW0D5206005 cable end holder (2). Removal 2) Push cable end holder (2) out from adjuster (4) using 1) Remove console box.
Page 822: Back Up Light Switch Removal And Installation
S6RW0D5206007 Removal lever securely. 1) Remove battery and tray with ECM. “A”: Grease 99000–25011 (SUZUKI Super 2) Disconnect back up light switch coupler (1). Grease A) 3) Remove back up light switch. 4) Push cable end holder (2) in the direction of A.
Page 823: Manual Transaxle Unit Components
Manual Transmission/Transaxle: 5B-11 Manual Transaxle Unit Components S6RW0D5206009 I5RW0A520010-02 [A]: Forward 5. Ground cable bolt 10. Transaxle to engine nut 1. Engine 6. Ground cable 11. Stiffener bolt 2. Transaxle 7. Transaxle to engine bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 3.
Page 824: Manual Transaxle Unit Dismounting And Remounting
5B-12 Manual Transmission/Transaxle: Manual Transaxle Unit Dismounting and 16) Remove transfer referring to “Transfer Dismounting and Remounting in Section 3C”, if equipped. Remounting S6RW0D5206010 17) Remove clutch housing lower plate. 18) Support transaxle with transmission jack. Dismounting 19) Remove left mounting (1) and left mounting bracket 1) Drain coolant.
Page 825: Gear Shift And Select Shaft Assembly Components
Manual Transmission/Transaxle: 5B-13 Gear Shift and Select Shaft Assembly Components S6RW0D5206011 1217G 1217G 1217G I6RW0C520001-01 1. Gear shift & select shaft 7. Gear shift guide case bolt No.1 13. Oil seal : Apply sealant 99000-31260 to bolt thread. : Apply grease 99000-25011 to oil seal lip. 2.
Page 826: Gear Shift And Select Shaft Assembly Removal And Installation
2) Install guide case bolts No.1 to which sealant has been applied and guide case bolts No.2 (2), and tighten them to specified torque. : Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque I5RW0A520017-02 Guide case bolt No.1: 23 N·m (2.3 kgf-m, 17.0 lb- 5) Connect gear shift and gear select control cables to transaxle.
Page 827: Gear Shift And Select Shaft Assembly Disassembly And Reassembly
Manual Transmission/Transaxle: 5B-15 Gear Shift and Select Shaft Assembly Disassembly and Reassembly S6RW0D5206013 1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown bellow. Special tool (A): 09922–85811 4.5 mm (B): 09925–78210 6.0 mm...
Page 828: Manual Transaxle Assembly Components
5B-16 Manual Transmission/Transaxle: Manual Transaxle Assembly Components S6RW0D5206014 I5RW0A520018-03 1. Transaxle right case 22. Shift fork bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case 23. 5th gear shift fork : Apply sealant 99000-31260 to mating surface of left case and right case.
Page 829: Fifth Gear Disassembly And Reassembly
: Apply thread lock 99000-32110 to all around thread part of bolt. 12. Left case plate bolt 33. Oil seal : Apply thread lock 99000-32110 to all around thread part of bolt. : Apply SUZUKI SUPER GREASE A 99000-25010 to Oil seal lip. 13. Side cover bolts 34. Outer race 14.
Page 830 5B-18 Manual Transmission/Transaxle: a) Install hub (1) to 5th speed synchronizer sleeve Reassembly (2) in specified direction as shown in figure. 1) Install countershaft 5th gear (1) to countershaft facing machined boss “A” inward. I4RH01520048-01 A: Chamfered side B: Long boss I2RH01520088-01 b) Fit 5th speed synchronizer levers (1) to hub (2) in A: Machined boss (Inside)
Page 831: Manual Transaxle Assembly Disassembly And Reassembly
(5) on input shaft. (0.059 in.) in diameter, mate it with left case, and then tighten side cover bolts with specified torque. “B”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Page 832 5B-20 Manual Transmission/Transaxle: 2) Remove bearing set shim. 8) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3). 3) Remove snap ring (1) using special tool. 9) Remove reverse gear shift lever bolts (4) and Special tool reverse gear shift lever (5).
Page 833 Manual Transmission/Transaxle: 5B-21 Reassembly 4) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) and washer (6) 1) Install differential assembly into right case. into case (4) through idler gear and then align bolt 2) Join input shaft (5), countershaft (4), low speed gear hole “a”...
Page 834 1.5 mm (0.059 in.) Locating spring in diameter then mate it with right case (1). Locating spring free length Standard Service limit “A”: Sealant 99000–31260 (SUZUKI Bond 53.1 mm 47.8 mm Low speed (2) No.1217G)
Page 835 Manual Transmission/Transaxle: 5B-23 12) To seat countershaft left bearing outer race (2) to 15) By repeating step 14), select a suitable shim which bearing cone, tap cup by using special tool and adjusts clearance “a” to specification and put it on plastic hammer.
Page 836: Right Case Disassembly And Reassembly
2) Remove differential side bearing outer race (1) using grease to oil seal lip. brass bar (2), if necessary. : Grease 99000–25011 (SUZUKI Super Grease A) Special tool (A): 09913–76010 I4RH01520024-01 I5RW0A520028-01...
Page 837: Left Case Disassembly And Reassembly
Manual Transmission/Transaxle: 5B-25 Left Case Disassembly and Reassembly 2) Install countershaft right bearing outer race (1) by using special tools and hammer. S6RW0D5206018 Special tool Disassembly (A): 09913–75821 1) Removal oil gutter (1), if necessary. (B): 09924–84510–004 I4RH01520028-01 I5RW0A520029-02 2) Remove oil seal using flat end rod or the like. 3) Install differential side bearing outer race by using special tool and hammer.
Page 838 5B-26 Manual Transmission/Transaxle: Reassembly 3) Select shim closest to clearance “d” from among the following available sizes. 1) If oil gutter has been removed, install it with bolt to which thread lock cement has been applied. Available shim thickness Clearance “d” Select shim “A”: Thread lock cement 99000–32110 (Thread 0.800 –...
Page 839: Input Shaft And Countershaft Components
Manual Transmission/Transaxle: 5B-27 Input Shaft and Countershaft Components S6RW0D5206019 I3RH0A520017-01 1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone 2. Oil seal 13. Circlip 24. 2nd gear synchronizer inner ring : Apply grease 99000-25010 to oil seal lip. 3.
Page 840: Input Shaft Disassembly And Reassembly
5B-28 Manual Transmission/Transaxle: Input Shaft Disassembly and Reassembly 3) Take out 4th gear needle bearing and high speed S6RW0D5206020 synchronizer ring. 4) Using special tool, remove circlip (1). Disassembly 1) Remove input shaft right bearing (2) from input shaft NOTE (1) using bearing puller (3) and hydraulic press.
Page 841 Manual Transmission/Transaxle: 5B-29 Reassembly 4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as 1) Clean all components thoroughly, inspect them for shown in figure. any abnormality and replace with new ones as necessary.
Page 842 5B-30 Manual Transmission/Transaxle: 6) Install 3rd gear needle bearing (4), apply oil to it, 8) Install circlip (1) and confirm that circlip is installed in then install 3rd gear (1) and synchronizer ring (2). groove securely. Install needle bearing (2) of apply oil to it and then install synchronizer ring (3) and 4th 7) Drive in high speed sleeve &...
Page 843: Countershaft Disassembly And Reassembly
Manual Transmission/Transaxle: 5B-31 Countershaft Disassembly and Reassembly 3) Take out 2nd synchronizer outer ring, center cone S6RW0D5206021 and inner ring. 4) Using special tool, remove circlip (1). Disassembly 1) Drive out left bearing cone (2) with 4th gear (3) by NOTE using puller (4) and hydraulic press.
Page 844 5B-32 Manual Transmission/Transaxle: 6) Disassemble synchronizer sleeve & hub assembly. 7) Take out 1st gear needle bearing from shaft. 8) In order to remove right bearing (1) from countershaft, grind with a grinder (2) one part “a” of right bearing (1) as illustrated till it becomes thin. CAUTION Be careful not to grind too far not to damage the shaft (3).
Page 845 Manual Transmission/Transaxle: 5B-33 5) Fit low speed synchronizer sleeve (4) to hub (3), 7) Install needle bearing (4), apply oil to it, then install insert 3 keys (2) in it and then set springs (1) as 1st gear and 1st gear synchronizer ring (2). shown in figure.
Page 846 5B-34 Manual Transmission/Transaxle: 9) Install circlip (1) and confirm that circlip is installed in 11) Press-fit 4th gear (2) by using the same procedure at groove securely. step 10). Install needle bearing (2) and apply oil to needle 12) Install left bearing cone (1) by using special tool and bearing.
Page 847: Gear Shift Shaft Components
Manual Transmission/Transaxle: 5B-35 Gear Shift Shaft Components S6RW0D5206022 I5RW0A520041-01 1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft 7. 5th & reverse gear shift yoke 2. High speed gear shift shaft 5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) 3.
Page 848: Differential Components
5B-36 Manual Transmission/Transaxle: Differential Components S6RW0D5206025 I5RW0A520043-02 1. Differential pinion washer 6. Differential case : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 2. Differential pinion 7. Final gear : Do not reuse. 3. Differential side gear 8. Final gear bolt : Apply transaxle oil. 4.
Page 849 Manual Transmission/Transaxle: 5B-37 3) Support differential case (1) with soft jawed vise and Available side gear washer thickness remove final gear bolts then take out final gear. 0.85 mm (0.033 in.) 1.05 mm (0.041 in.) 0.9 mm (0.035 in.) 1.1 mm (0.043 in.) 4) Drive out differential pinion shaft (3) pin by using 0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
Page 850 5B-38 Manual Transmission/Transaxle: 5) Hold differential assembly with soft jawed vise (3), 4) Press-fit right bearing (1) by using special tools and hydraulic press. install final gear (2) and then tighten new final gear bolts (1). Special tool (A): 09925–15410 CAUTION (B): 09924–07720 Use of any other bolts than specified ones is...
Page 851: Special Tools And Equipment
Manual Transmission/Transaxle: 5B-39 Special Tools and Equipment Recommended Service Material S6RW0D5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 852 5B-40 Manual Transmission/Transaxle: 09913–76010 09913–80113 Bearing installer Bearing installer 09913–84510 09913–85210 Bearing installer Bearing installer 09913–85230 09922–85811 Bearing remover tool Spring pin remover (4.5 mm) 09923–78210 09924–07710 Bearing installer Synchronizer hub installer 09924–07720 09924–74510 Synchronizer hub installer Bearing and oil seal handle 09924–84510–004 09925–14520 Bearing installer attachment...
Page 853 Manual Transmission/Transaxle: 5B-41 09940–54910 09940–54950 Front fork oil seal install Bearing installer attachment driver 09941–64511 09942–15511 Bearing and oil seal remover Sliding hammer (30 mm Min.) 09944–96011 09952–06010 Bearing outer race remover Dial gauge plate No.1...
Page 854: Clutch
5C-1 Clutch: Clutch Transmission / Transaxle General Description Clutch (Hydraulic Type) Construction S6RW0D5301001 The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
Page 855: Diagnostic Information And Procedures
Clutch: 5C-2 Diagnostic Information and Procedures Clutch System Symptom Diagnosis S6RW0D5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Bleed air or replace master cylinder. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
Page 856: Repair Instructions
5C-3 Clutch: Repair Instructions Clutch Pedal Inspection 6) If “c” is not within specification, it is possible that air S6RW0D5306001 is trapped in this system. If suspected so, bleed air Cylinder Push Rod Play “a” referring to “Air Bleeding of Clutch System”.Upon 1) Press clutch pedal (1) gradually with finger, stop completion of above inspection, start engine and when slight increase of resistance is felt and...
Page 857: Clutch Fluid Pipe And Hose Location
Clutch: 5C-4 Clutch Fluid Pipe and Hose Location S6RW0D5306004 I5RW0A530003-02 [A]: RH steering vehicle 3. Clutch reservoir hose 1. Clutch master cylinder 4. Brake master cylinder reservoir 2. Clutch fluid pipe Clutch Fluid Pipe Removal and Installation Installation S6RW0D5306005 Reverse removal procedure for installation noting the following.
Page 858: Clutch Master Cylinder Removal And Installation
I5RW0A530006-01 3. Brake booster Installation Reverse removal procedure for installation noting the following. • Apply grease to push rod tip. “A”: Grease 99000–25100 (SUZUKI Silicone Grease) I5RW0A530008-01 “A” I5RW0A530007-01 • Tighten clutch master cylinder nut to specified torque. Tightening torque Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5...
Page 859: Clutch Operating Cylinder Assembly Inspection
Clutch: 5C-6 Installation 4) Remount transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting in 1) Install clutch operating cylinder assembly (2) to Section 5B”. transaxle. Tighten new mounting bolts to specified torque. 5) Bleed air from system and check clutch pedal free travel.
Page 860: Clutch Cover, Clutch Disc And Flywheel Removal And Installation
5C-7 Clutch: Clutch Cover, Clutch Disc and Flywheel 4) Remove flywheel (1) from crankshaft using special tool. Removal and Installation S6RW0D5306011 Special tool (A): 09924–17810 Removal 1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting in Section 5B”. 2) Hold flywheel with special tool and remove clutch cover bolts (1), clutch cover (2) and clutch disc.
Page 861: Clutch Cover, Clutch Disc And Flywheel Inspection
“Manual Transaxle Unit Dismounting and Special tool Remounting in Section 5B”. (B): 09925–98210 “A”: Grease 99000–25210 (SUZUKI Super Grease I) NOTE When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the splines.
Page 862: Specifications
5C-9 Clutch: Clutch Disc Clutch Cover Measure depth of rivet head depression, i.e. distance 1) Check diaphragm spring (1) for abnormal wear or between rivet head and facing surface. damage. If depression is found to have reached service limit at 2) Inspect pressure plate (2) for wear or heat spots.
Page 863: Special Tools And Equipment
Clutch: 5C-10 Special Tools and Equipment Recommended Service Material S6RW0D5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210 Special Tool S6RW0D5308002 09921–26020 09923–36320 Bearing remover Clutch center guide (15 mm) 09924–17810...
Page 864 5C-11 Clutch:...
Page 865: Steering General Diagnosis
Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 General Description ..........6C-2 P/S System Description ........6C-2 Precautions............. 6-1 EPS Diagnosis General Description ....6C-3 Precautions on Steering........6-1 On-Board Diagnostic System Description...6C-3 Steering General Diagnosis....6A-1 Schematic and Routing Diagram ......6C-4 EPS System Wiring Circuit Diagram ....6C-4 Precautions............6A-1 Diagnostic Information and Procedures ....6C-5...
Page 866 6-ii Table of Contents Tie-Rod End Inspection........6C-37 P/S Control Module Removal and Installation...6C-41 Steering Shaft Joint On-Vehicle Inspection..6C-37 Torque Sensor and Its Circuit Inspection ..6C-41 Steering Gear Case Assembly Removal and P/S Motor and Its Circuit Inspection ....6C-42 Installation ............6C-37 Specifications .............6C-43 Steering Rack Boot Inspection......6C-38 Tightening Torque Specifications......6C-43...
Page 867: Precautions
Precautions: Precautions Steering Precautions Precautions on Steering S6RW0D6000001 Air Bag Warning Refer to “Air Bag System Service Warning in Section 00”. Precautions for Steering Diagnosis Refer to “Precautions for Steering Diagnosis in Section 6A”. Service Precautions of Steering Wheel and Column Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.
Page 868: Precautions
6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Precautions Precautions for Steering Diagnosis S6RW0D6100001 Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 869: Steering System Inspection
Steering General Diagnosis: 6A-2 Condition Possible cause Correction / Reference Item Erratic steering when Worn wheel bearings Replace wheel bearing. braking Broken or sagging coil springs Replace coil spring. Wheel tires are inflated unequally Inflate tires to proper pressure. Disturbed front wheel alignment Check and adjust front wheel alignment.
Page 870: Steering Wheel And Column
6B-1 Steering Wheel and Column: Steering Wheel and Column Steering Precautions Service Precautions of Steering Wheel and Column S6RW0D6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Service and Diagnosis For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Disabling Air Bag System For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.
Page 871: Diagnostic Information And Procedures
Steering Wheel and Column: 6B-2 Diagnostic Information and Procedures Checking Steering Column for Accident • Check that there is no axial looseness “d” and no axially-vertical looseness “e” for steering column Damage shaft. S6RW0D6204001 NOTE If found defective, replace steering column assembly Vehicles involved in accidents resulting in with new one.
Page 872: Repair Instructions
6B-3 Steering Wheel and Column: Repair Instructions Steering Wheel and Column Construction S6RW0D6206001 I6RW0C620001-01 1. Steering wheel 9. Steering column assembly mounting nut No.1 2. Steering shaft nut 10. Steering column assembly mounting nut No.2 : After tightening column mounting nut No.2, tighten column mounting nut No.1. 3.
Page 873: Steering Wheel Removal And Installation
Steering Wheel and Column: 6B-4 Steering Wheel Removal and Installation 6) Remove steering wheel using special tool. S6RW0D6206002 Special tool CAUTION (A): 09944–36011 Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will break.
Page 874: Contact Coil Cable Assembly Removal And Installation
6B-5 Steering Wheel and Column: 4) Connect horn connector and audio control switch 6) Remove contact coil cable assembly (1) from connector, if necessary. steering column. 5) Install driver air bag (inflator) module to steering wheel. Refer to “Driver Air Bag (Inflator) Module Removal and Installation in Section 8B”.
Page 875: Centering Contact Coil Cable Assembly
Steering Wheel and Column: 6B-6 4) From the position where contact coil became unable 3) Install steering column upper cover (1) and lower cover (2). to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark CAUTION with alignment mark (1).
Page 876 6B-7 Steering Wheel and Column: Installation Removal CAUTION WARNING After tightening steering column mounting Never rest a steering column assembly on nuts, shaft joint bolts should be tightened. the steering wheel with the air bag (inflator) Wrong tightening order could cause a module face down and column vertical.
Page 877: Steering Column Inspection
Steering Wheel and Column: 6B-8 Ignition Switch Cylinder Assembly Removal 3) Align flat part “a” of steering lower shaft (1) with bolt hole “b” of shaft joint (2) of column as shown. Then and Installation (Non- Keyless Start Model) insert lower shaft into shaft joint of steering column. S6RW0D6206010 Removal 4) Tighten lower shaft upper joint bolt (3) to specified...
Page 878: Steering Lock Assembly (Ignition Switch) Removal And Installation
6B-9 Steering Wheel and Column: Steering Lock Assembly (Ignition Switch) Installation Removal and Installation 1) Position oblong hole (1) of steering shaft (2) in the S6RW0D6206011 center of hole (3) in column (4). Removal 2) Turn ignition key to “ACC” or “ON” position and 1) Remove steering column.
Page 879: Steering Lower Shaft Removal And Installation
Steering Wheel and Column: 6B-10 Steering Lower Shaft Removal and Installation Installation S6RW0D6206012 1) Be sure that front wheels are in straight forward state. CAUTION 2) Align flat part “a” of steering lower shaft (1) with bolt Never turn steering wheel while steering hole “b”...
Page 880: Specifications
6B-11 Steering Wheel and Column: Specifications Tightening Torque Specifications S6RW0D6207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Steering shaft nut 24.0 Steering column mounting nut No.1 10.5 Steering column mounting nut No.2 10.5 Steering lower shaft assembly upper joint bolt 18.5 Steering lower shaft assembly lower joint bolt 18.5...
Page 881: Power Assisted Steering System
Precautions in Diagnosing Troubles S6RW0D6300002 • Take a note of DTC indicated on the SUZUKI scan tool. • Before inspection, be sure to read “Precautions for Electrical Circuit Service in Section 00” and understand what is written there.
Page 882: General Description
6C-2 Power Assisted Steering System: General Description P/S System Description S6RW0D6301001 This electronic power steering (EPS) system consists of a power steering (P/S) control module (3), a torque sensor (4), a P/S motor (5). In this system, the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the signal from the torque sensor and the vehicle speed signal from BCM (9).
Page 883: Eps Diagnosis General Description
Power Assisted Steering System: 6C-3 EPS Diagnosis General Description S6RW0D6301002 The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “On-Board Diagnostic System Description”...
Page 884: Schematic And Routing Diagram
6C-4 Power Assisted Steering System: Schematic and Routing Diagram EPS System Wiring Circuit Diagram S6RW0D6302001 E13-1 LT GRN/ E11-1 E12-1 E61-2 E13-2 E12-2 E61-1 RED/BLK G241-31 G241-25 E11-5 E11-18 E31-5 L313-3 BLU/ E04-9 E11-11 E11-8 E31-3 G04-15 E11-4 [I]:G04-22 E31-2 E11-10 RED/ E01-26...
Page 885: Eps System Check
Power Assisted Steering System: 6C-5 Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side) Terminal Circuit Terminal Circuit Ignition switch signal for P/S control E11-1 E11-13 — module E11-2 — E11-14 P/S active signal (idle up signal) E11-3 —...
Page 886 6C-6 Power Assisted Steering System: Step Action Steering symptom diagnosis and P/S system Go to Step 11. Check and repair symptom diagnosis malfunction part(s), and go to Step 11. 1) Check and repair according to “Steering Symptom Diagnosis in Section 6A” and “P/S System Symptom Diagnosis”.
Page 887 Power Assisted Steering System: 6C-7 Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 888: Eps" Warning Light Check
Perform basic steering system check according to “Steering Symptom Diagnosis in Section 6A” first. When 2) Connect SUZUKI scan tool to data link connector the end of the flow has been reached, check the parts of (DLC) (1) located on underside of instrument panel the system suspected as a possible cause referring to at driver’s seat side.
Page 889: Dtc Clearance
S6RW0D6304004 4) Erase DTC according to the instructions displayed 1) Turn ignition switch to OFF position. on SUZUKI scan tool. For further details, refer to 2) Connect SUZUKI scan tool to data link connector operator’s manual for SUZUKI scan tool.
Page 890 6C-10 Power Assisted Steering System: “EPS” Detecting condition DTC No. Detecting item Trouble area warning (DTC will set when detecting) light Vehicle speed signal is 0 km/h • Vehicle speed signal even though engine speed is circuit more than 4000 rpm for more than 60 seconds continuously •...
Page 891: Visual Inspection
Power Assisted Steering System: 6C-11 “EPS” Detecting condition DTC No. Detecting item Trouble area warning (DTC will set when detecting) light Voltage between both motor drive circuit is more than 8.5 V or P/S motor circuit 1 driving 1 driving less than 0.2 V for 0.5 second C1141 voltage...
Page 892: Scan Tool Data
6C-12 Power Assisted Steering System: Scan Tool Data S6RW0D6304007 NOTE When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with asterisk (*) mark in the following table is displayed on scan tool Scan tool data Vehicle condition Normal condition...
Page 893: P/S System Symptom Diagnosis
Power Assisted Steering System: 6C-13 Motor Drive Voltage (V) Torque sensor Status (ON, OFF) This parameter indicates the voltage between motor This parameter indicates the output status of the torque terminals. sensor power supply. System Power Status (EPS System Power, ON, OFF) Fail Safe FET Status (ON, OFF) This parameter indicates input status of EPS system This parameter indicates the status of the motor drive...
Page 894: Dlc And Its Communication Check (No Communication To P/S Control Module)
Scan tool condition check Go to step 3. Repair or replace defective part. 1) Make sure that SUZUKI scan tool is as follows. • Correct PCMCIA card (software) is used. • There are no deformation and wear for DLC cable terminals.
Page 895 Go to Step 4. Go to Step 6. 1) Check DLC terminal for deformation and wear. 2) If it is in good condition, connect SUZUKI scan tool to DLC with ignition switch tuned OFF. 3) Check if communication is possible by making communication with other control modules (BCM, ABS, HVAC control module or SDM).
Page 896: Eps" Warning Light Does Not Come On With Ignition Switch Turned On Before Engine Starts
6C-16 Power Assisted Steering System: Step Action Scan tool operation check Scan tool is in good Recheck PCMCIA card condition, check and DLC cable for faulty 1) Check if communication is possible by making intermittent trouble condition. If they are communication with other vehicles.
Page 897 Power Assisted Steering System: 6C-17 Circuit Description Operation (ON/OFF) of “EPS” warning light is controlled by P/S control module through combination meter. If the P/S system is in good condition, P/S control module turns “EPS” warning light ON at the ignition switch ON, and then turns it OFF at the engine start.
Page 898: Eps" Warning Light Remains On Steady After Engine Starts
Action Check DTC referring to “DTC Check”. Go to applicable DTC Go to Step 2. diag. flow. Is there any DTC(s) (NO CODES on SUZUKI scan tool)? “EPS” warning light circuit check Go to Step 3. Replace P/S control module.
Page 899: Dtc C1111 / C1113 / C1115: Torque Sensor Circuit Failure
Power Assisted Steering System: 6C-19 DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure S6RW0D6304012 DTC C1111: Steering Torque Sensor (Main) Circuit Voltage DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation DTC C1115: Steering Torque Sensor (Sub) Circuit Voltage Wiring Diagram E13-1 E11-18...
Page 900 6C-20 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable diag. Go to Step 3. flow. Is DTC C1153 or C1116 indicated, together? Torque sensor signal circuit check Go to Step 4.
Page 901: Dtc C1116: Steering Torque Sensor Power Supply Circuit
Power Assisted Steering System: 6C-21 DTC C1116: Steering Torque Sensor Power Supply Circuit S6RW0D6304013 Wiring Diagram E13-1 E11-18 E31-5 LT GRN/ E11-1 E11-8 E31-3 E31-2 E11-10 E11-20 E31-4 E11-9 E31-1 12 13 14 15 16 17 18 19 20 E11-19 E13-2 I6RW0C630005-02 [A]: P/S control module connector No.1 “E11”...
Page 902: Dtc C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure
6C-22 Power Assisted Steering System: Step Action Torque sensor power supply circuit check Replace P/S control Repair or replace module. defective circuit. 1) Check that torque sensor power supply circuit is as follows. • Insulation resistance of wire harness is infinity between “Torque sensor power supply circuit”...
Page 903 Power Assisted Steering System: 6C-23 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1121: • Vehicle speed signal circuit Vehicle speed signal is 0 km/h even though engine speed • BCM is more than 4000 rpm for more than 60 seconds •...
Page 904: Dtc C1122: Engine Speed Signal
6C-24 Power Assisted Steering System: Step Action Vehicle speed signal circuit check Go to Step 7. Go to Step 8. 1) With ignition switch turned OFF, disconnect connectors from BCM. 2) Check BCM connector for proper connection. 3) If OK, turn ON ignition switch, measure voltage between “G04-15”...
Page 905 Power Assisted Steering System: 6C-25 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Engine speed signal is less than 220 rpm for more than • Engine speed signal circuit 0.8 seconds. • ECM • P/S control module Engine speed signal is less than 220 rpm for more than 20 seconds continuously even though vehicle speed signal is more than 50 km/h.
Page 906: Dtc C1141 / C1142 / C1143 / C1145: Motor Circuit Failure
6C-26 Power Assisted Steering System: DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure S6RW0D6304016 DTC C1141: P/S Motor Circuit Voltage DTC C1142: P/S Motor Circuit Range/Performance DTC C1143: P/S Motor Circuit Current Too High DTC C1145: P/S Motor Circuit Current Too Low Wiring Diagram E13-1 LT GRN/...
Page 907: Dtc C1153: P/S Control Module Power Supply Circuit
Power Assisted Steering System: 6C-27 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. Is DTC C1153 and/or C1155 indicated, together? Power supply and ground circuit check Go to Step 4.
Page 908: Dtc C1155: P/S Control Module Internal Failure
6C-28 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. Battery voltage check Go to Step 3. Check charging system referring to “Generator 1) Check circuit fuse for P/S control module. Test (Undercharged 2) If OK, measure voltage between positive (+) battery Battery Check) in...
Page 909: P/S Control Module Power Supply And Ground Circuit Check
Power Assisted Steering System: 6C-29 P/S Control Module Power Supply and Ground Circuit Check S6RW0D6304019 Wiring Diagram Refer to “DTC C1153: P/S Control Module Power Supply Circuit”. DTC Troubleshooting Step Action Circuit fuse check Go to Step 2. Replace fuse (s) and check for short in 1) Disconnect P/S control module connector with ignition circuits connected to...
Page 910: Inspection Of P/S Control Module And Its Circuits
6C-30 Power Assisted Steering System: Inspection of P/S Control Module and Its Circuits S6RW0D6304020 The P/S control module and its circuits can be checked at the P/S control module wiring couplers 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 the P/S control module with connectors disconnected from the P/S control module.
Page 911 Power Assisted Steering System: 6C-31 Terminal Wire color Circuit Normal voltage Condition Ignition switch signal for P/S E11-1 LT GRN/BLK 10 – 14 V Ignition switch ON control module E11-2 — — — — E11-3 — — — — *0 – 1 V ↑↓...
Page 912 6C-32 Power Assisted Steering System: Terminal Wire color Circuit Normal voltage Condition • Ignition switch ON Reference sensor power supply E11-20 About 3.0 – 3.5 V • Check voltage between “E11-20” and for torque sensor “E11-9” terminals *0 – 1 V ↑↓...
Page 913 Power Assisted Steering System: 6C-33 Reference waveform No.2 Reference waveform No.3 Motor output signal 1(1), Motor output signal 2(2), with Motor output signal 1(1), Motor output signal 2(2), with engine idling engine idling Measurement CH1: “E12-1” to vehicle body ground Measurement CH1: “E12-1”...
Page 914: Steering Wheel Play Check
6C-34 Power Assisted Steering System: Steering Wheel Play Check Steering Force Check S6RW0D6304021 S6RW0D6304022 • Check steering wheel for looseness or rattle by 1) Place vehicle on level road and set steering wheel at moving it in its shaft direction and lateral direction. straight-ahead position.
Page 915: Repair Instructions
Power Assisted Steering System: 6C-35 Repair Instructions Steering Gear Case Assembly Components S6RW0D6306001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical. 1207F I6RW0C630010-01 1. Steering gear case 11. Clip 21. O-ring 2. Tie-rod lock washer 12.
Page 916: Tie-Rod End Boot On-Vehicle Inspection
6C-36 Power Assisted Steering System: Tie-Rod End Boot On-Vehicle Inspection 4) For ease of adjustment after installation, make S6RW0D6306002 marking (1) of tie-rod end lock nut (2) position on tie- Check boot for crack and damage. If any defect is found, rod end thread.
Page 917: Tie-Rod End Inspection
Power Assisted Steering System: 6C-37 Steering Gear Case Assembly Removal and 3) Inspect for proper toe referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B”. Installation S6RW0D6306006 4) After confirming proper toe, tighten tie-rod end lock nut to specified torque. Removal Tightening torque CAUTION...
Page 918: Steering Rack Boot Inspection
6C-38 Power Assisted Steering System: Steering Rack Boot Inspection 2) Install steering gear case to vehicle, and then install front suspension frame referring to “Front S6RW0D6306007 Hoist vehicle. Suspension Frame, Stabilizer Bar and/or Bushing Inspect each boot for tear. A torn boot allows entry of Removal and Installation in Section 2B”.
Page 919 Position boot properly in grooves of gear case (or Earth cable bolt (a): 4.0 N·m (0.4 kgf-m, 2.8 lb-ft) rack side mount) and tie-rod. After this, check to ensure that boot is free from twist and dent. “A”: Grease 99000–25050 (SUZUKI Super “a” Grease E) “A” I6RW0C630011-01...
Page 920: Steering Rack Plunger Removal And Installation
If any abnormality is found, replace. torque, turn it back by 10° or less. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Tightening torque Rack damper screw (a): Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and loosen 180° and then tighten 3.9 N⋅m (0.39 kgf-m, 3.0 lb-ft) and turn...
Page 921: P/S Control Module Removal And Installation
Power Assisted Steering System: 6C-41 P/S Control Module Removal and Installation Torque Sensor and Its Circuit Inspection S6RW0D6306011 S6RW0D6306012 Removal 1) Check that torque sensor circuit is in good condition referring to Step 2 to 3 of “DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure”.
Page 922: P/S Motor And Its Circuit Inspection
6C-42 Power Assisted Steering System: P/S Motor and Its Circuit Inspection 5) Turn ON ignition switch without engine running and select scan tool “Data List” mode due to checking S6RW0D6306013 1) Check motor circuit referring to Step 2 to 3 of “DTC “Sensor (Main) Torque”...
Page 923: Specifications
Power Assisted Steering System: 6C-43 8) Using ammeter (2), check that P/S motor current (1) is as following table with idling engine. If check result is not satisfactory, check P/S control module for torque sensor signal and P/S motor output referring to “Inspection of P/S Control Module and Its Circuits”.
Page 924: Special Tools And Equipment
6C-44 Power Assisted Steering System: Special Tools and Equipment Recommended Service Material S6RW0D6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 925 Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 A/C System Caution..........7B-1 Precautions on Servicing A/C System ....7B-1 Precautions............. 7-1 General Description ..........7B-2 Precautions on HVAC ........... 7-1 Sub-Cool A/C System Description ......7B-2 Heater and Ventilation......7A-1 Manual A/C Electronic Input Output Table..7B-3 A/C Operation Description at ECM .....7B-3 General Description ..........7A-1 Schematic and Routing Diagram ......7B-4...
Page 926 7-ii Table of Contents Compressor Drive Belt Removal and DTC B1514: Air Flow Control Actuator (Motor) Installation ............7B-31 and/or Its Circuit Malfunction......7B-67 Compressor Assembly Removal and DTC B1520 / B1521 / B1522: Temperature / Installation ............7B-31 Blower Speed / Air Flow Selector Compressor Assembly Components....
Page 927 Table of Contents 7-iii Condenser Assembly Removal and Compressor Drive Belt Removal and Installation ............7B-87 Installation ............7B-87 Evaporator Inspection ........7B-87 Compressor Assembly Removal and Evaporator Temperature Sensor Removal Installation ............7B-87 and Installation ..........7B-87 Compressor Assembly Components....7B-87 Evaporator Temperature Sensor Inspection ..7B-87 Magnet Clutch Removal and Installation...7B-87 Expansion Valve Removal and Installation ..
Page 928: Precautions
7-1 Precautions: Precautions HVAC Precautions Precautions on HVAC S6RW0D7000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. A/C System Caution Refer to “A/C System Caution in Section 7B” or “A/C System Caution in Section 7B”. Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System in Section 7B”...
Page 929: Heater And Ventilation
Heater and Ventilation: 7A-1 Heater and Ventilation HVAC General Description Heater and Ventilation Construction S6RW0D7101001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C710001-02 Air flow 7. Defroster air 15.
Page 930: Schematic And Routing Diagram
7A-2 Heater and Ventilation: Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S6RW0D7102001 Non–A/C RED/BLK G155-1 BLK/YEL BLK/WHT BLK/RED BLK/WHT G155-6 G155-7 BLU/WHT G155-3 G155-2 G154-9 BLU/WHT BLK/ORN RED/BLK G154-14 G154-13 G154-10 GRN/YEL G154-8 BLK/RED G154-7 RED/YEL G154-4 G154-3 RED/BLU I6RW0C710003-01...
Page 931: Diagnostic Information And Procedures
Heater and Ventilation: 7A-3 Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S6RW0D7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground. speed selector ON Blower motor relay faulty Check blower motor relay referring to “Blower...
Page 932: Repair Instructions
7A-4 Heater and Ventilation: Repair Instructions HVAC Unit Components Installation S6RW0D7106001 Reverse removal procedure noting the following For non-A/C and manual A/C, refer to “HVAC Unit instructions. Components in Section 7B”. • Be careful not to catch any cable and wiring harness For auto A/C, refer to “HVAC Unit Components in in inappropriate position.
Page 933: Blower Motor Resistor Removal And Installation
Heater and Ventilation: 7A-5 • Check for operation and current. 4) Disconnect connector (1) from blower motor resistor (2), and then remove blower motor resistor from a. Put blower motor (1) in a soft-jawed vise. HVAC unit by removing screws (3). b.
Page 934: Blower Motor Relay Inspection
7A-6 Heater and Ventilation: Blower Motor Relay Inspection S6RW0D7106007 1) Disconnect negative (–) cable at battery. 2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”. 3) Remove junction block assembly (2). 4) Disconnect blower motor relay (1) from junction block assembly (2).
Page 935: Hvac Control Unit Removal And Installation
Heater and Ventilation: 7A-7 HVAC Control Unit Removal and Installation RH steering vehicle S6RW0D7106009 Removal 1) Disconnect negative (–) cable at battery. 2) Remove steering column hole cover from instrument panel. 3) Remove audio unit from instrument panel referring to “Audio Unit Removal and Installation (If Equipped) in Section 9C”.
Page 936 7A-8 Heater and Ventilation: b. Move temperature control lever (1) to “MAX HOT” c. Move air flow control plate (1) to “DEF” position “c” position “a” (LH steering vehicle) or “MAX COOL” (LH steering vehicle) or “VENT” position “d” (RH position “b”...
Page 937: Blower Speed Selector Inspection
Heater and Ventilation: 7A-9 Blower Speed Selector Inspection Air Intake Control Actuator Removal and S6RW0D7106010 Installation Check blower speed selector for each terminal to S6RW0D7106012 terminal continuity. If check result does not meet the following conditions, replace HVAC control unit. Removal 1) Disconnect negative cable from battery.
Page 938: Air Intake Control Actuator Inspection
7A-10 Heater and Ventilation: Air Intake Control Actuator Inspection Installation Reverse removal procedure noting the following S6RW0D7106013 Check air intake control actuator as follows: instruction. 1) Using service wire, connect battery positive terminal • Be sure to insert the linkage rod (1) into the hole (2) of to “d”...
Page 939: Center Ventilation Louver Removal And Installation
Heater and Ventilation: 7A-11 Center Ventilation Louver Removal and 3) Remove side ventilation louver (1) from instrument panel while pressing clips (2). Installation S6RW0D7106014 Removal 1) Disconnect negative (–) cable from battery. 2) Remove audio unit from instrument panel referring to “Audio Unit Removal and Installation (If Equipped) in Section 9C”.
Page 940: Rear Duct Removal And Installation (If Equipped)
7A-12 Heater and Ventilation: Rear Duct Removal and Installation (If HVAC Air Filter Removal and Installation (If Equipped) Equipped) S6RW0D7106016 S6RW0D7106017 Removal 1) Remove glove box from instrument panel. 2) Remove air filter (1) from HVAC unit while releasing claws (2). I6RW0C710010-01 Installation I7RW01710019-01...
Page 941: Air Conditioning System
Air Conditioning System: Manual Type 7B-1 Air Conditioning System HVAC Manual Type Precautions A/C System Caution S6RW0D7210001 CAUTION The A/C system of this vehicle uses HFC-134a (R-134a) refrigerant, specified compressor oil and specified parts. Do not use CFC-12 (R-12) refrigerant, R-12 exclusive use compressor oil and R-12 exclusive parts in this A/C system, do not attempt to use R-12 servicing equipment.
Page 942: General Description
7B-2 Air Conditioning System: Manual Type Refrigerant Recovery When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments referring to “Recovery” in “Operation Procedure for Refrigerant Charge”. Refrigerant Charge After performing compressor oil replenishment and evacuation, charge a proper amount of refrigerant to A/C system referring to “Charge”...
Page 943: Manual A/C Electronic Input Output Table
Air Conditioning System: Manual Type 7B-3 Manual A/C Electronic Input Output Table S6RW0D7211002 A/C refrigerant pressure sensor Condensor cooling fan relay A/C evaporator temperature sensor Compressor relay ECT sensor Wheel speed sensor (VSS) ABS control module HVAC control unit Blower speed selector Blower motor resistor Blower motor Air intake selector...
Page 944: Schematic And Routing Diagram
7B-4 Air Conditioning System: Manual Type Schematic and Routing Diagram A/C System Air Flow Diagram S6RW0D7212001 I7RW01721002-03 A: Air flow 5. Discharge hose 11. Foot air 17. Air intake door B: Refrigerant flow 6. Suction hose 12. Front defroster air 18.
Page 945: A/C System Wiring Diagram
Air Conditioning System: Manual Type 7B-5 A/C System Wiring Diagram S6RW0D7212002 BLK/YEL BLU/YEL E01-49 RED/BLK E01-48 G155-1 BLK/RED E01-1 BLK/WHT BLK/YEL BLK/RED E01-16 BRN/WHT E01-60 G155-6 BLK/WHT G155-7 BLK/WHT E01-29 G155-3 BLU/WHT G155-2 BLU/WHT E01-35 G155-5 RED/BLK GRY/RED C01-14 G154-6 C01-12 RED/BLU G154-5...
Page 946: Component Location
7B-6 Air Conditioning System: Manual Type Component Location A/C System Major Components Location S6RW0D7213001 I7RW01721004-03 1. HVAC unit 6. Discharge hose : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Compressor 7. Suction hose : 3.5 N⋅m (0.35 kgf-m, 2.51 lb-ft) 3.
Page 947: Electronic Control System Components Location
Air Conditioning System: Manual Type 7B-7 Electronic Control System Components Location S6RW0D7213002 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C721003-01 [A]: Junction block assembly viewed from relay side 6.
Page 948: Diagnostic Information And Procedures
7B-8 Air Conditioning System: Manual Type Diagnostic Information and Procedures A/C System Performance Inspection 5) Warm up engine to the normal operating S6RW0D7214001 temperature and keep it at the specified idle speed. 1) Confirm that vehicle and environmental conditions 6) Turn A/C switch ON, set blower speed selector at are as follows.
Page 949 Air Conditioning System: Manual Type 7B-9 10) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to the following table. When diagnosing troubles of abnormal pressure on the low side and high side for each pressure more specifically, refer to “Trouble Diagnosis for Abnormal Pressure”.
Page 950 7B-10 Air Conditioning System: Manual Type Condition Possible cause Correction Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary acceptable range leakage) and recharge. (“B” area) Expansion valve malfunction (valve opens too Check expansion valve. wide) Compressor malfunction (Insufficient Check compressor.
Page 951: Trouble Diagnosis For Abnormal Pressure
Air Conditioning System: Manual Type 7B-11 Thermometer at center ventilation louver Condition Possible cause Correction Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure. than acceptable range Dirty or bent A/C evaporator fins Clean or repair. (“E”...
Page 952: A/C System Inspection At Ecm
7B-12 Air Conditioning System: Manual Type Condition Manifold gauge MPa (kgf/cm ) (psi) Possible cause Correction Detail 0.05 – 0.15 0.7 – 1.0 Both low and high Insufficient refrigerant Using leak detector, (0.5 – 1.5) (7 – 10) pressure sides indicate in system check for leaks and (4.2 –...
Page 953: A/C System Symptom Diagnosis
Air Conditioning System: Manual Type 7B-13 A/C System Symptom Diagnosis S6RW0D7214004 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C compressor does not referring to “Operation Procedure for operate) Refrigerant Charge”.
Page 954 7B-14 Air Conditioning System: Manual Type Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C compressor normal Condenser clogged Check condenser referring to “Condenser operation)
Page 955: Abnormal Noise Symptom Diagnosis Of A/C System
Air Conditioning System: Manual Type 7B-15 Condition Possible cause Correction / Reference Item Insufficient air flow of A/C evaporator clogged or frosted Check A/C evaporator and evaporator cooled air temperature sensor referring to “Evaporator Inspection” and “Evaporator Temperature Sensor Inspection”. Air leaking from HVAC unit or air duct Repair as necessary.
Page 956 7B-16 Air Conditioning System: Manual Type Abnormal Noise from Tubing Condition Possible cause Correction / Reference Item A droning noise is heard Faulty tubing clamps Reposition clamps or increase the number of from inside of the vehicle, clamps. but not particularly Resonance caused by pulsation from Attach a silencer to tubing, or modify its noticeable in engine...
Page 957: Repair Instructions
Air Conditioning System: Manual Type 7B-17 Repair Instructions Operation Procedure for Refrigerant Charge S6RW0D7216001 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately – 6 °C (21.2 °F) below freezing point.
Page 958 7B-18 Air Conditioning System: Manual Type Recovery When charging refrigerant only When discharging refrigerant out of A/C system, always When charging refrigerant without replacing any recover it by using refrigerant recovery and recycling component, replenish the same amount of measured oil equipment because discharging refrigerant HFC-134a when recovering refrigerant (if not measure, replenish 10 (R-134a) into atmosphere would cause adverse effect to...
Page 959 Air Conditioning System: Manual Type 7B-19 Evacuation 5) Evacuation should be carried out for a total of at least 15 minutes. CAUTION 6) Continue evacuation until low pressure gauge Do not evacuate before recovering indicates a vacuum less than –100 kPa (–1.0 kgf/ refrigerant in A/C system.
Page 960 7B-20 Air Conditioning System: Manual Type Charge The initial charge of the A/C system is performed through the high pressure side with the engine stopped. CAUTION And next, this method must be followed by charging from the low pressure side with the engine running. •...
Page 961 Air Conditioning System: Manual Type 7B-21 7) When refrigerant container (1) is emptied, use the 8) After the system has been charged with specified following procedure to replace it with a new amount of refrigerant or when low pressure gauge refrigerant container.
Page 962: Condenser Cooling Fan Removal And Installation
7B-22 Air Conditioning System: Manual Type Condenser Cooling Fan Removal and Check A/C System for Refrigerant Leaks Whenever a refrigerant leak is suspected in the system Installation or any service operation has been performed which may S6RW0D7216002 CAUTION result in malfunction of lines and connections, it is advisable to check for leaks.
Page 963: Condenser Cooling Fan Inspection
Air Conditioning System: Manual Type 7B-23 Condenser Cooling Fan Inspection Condenser Assembly On-Vehicle Inspection S6RW0D7216003 S6RW0D7216004 Check the followings. 1) Check condenser cooling fan motor for resistance between terminal “a” and “b” as shown. • Clog of condenser fins If there is no continuity, replace condenser cooling If any clog is found, condenser fins should be washed fan motor.
Page 964: Desiccant Removal And Installation
7B-24 Air Conditioning System: Manual Type 5) Move condenser assembly from the vehicle in the Installation arrow direction in the order of 1, 2 and 3 as shown, Reverse the removal procedure noting the following and it can be removed. instructions.
Page 965: Hvac Unit Components
Air Conditioning System: Manual Type 7B-25 HVAC Unit Components S6RW0D7216007 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C721006-01 1. Blower upper case 8. Air intake control actuator 15.
Page 966: Hvac Unit Removal And Installation
7B-26 Air Conditioning System: Manual Type 7. Cover (without HVAC air 14. Heater core 21. Temperature control lever : Do not reuse. filter) HVAC Unit Removal and Installation 6) Remove HVAC unit (1) from vehicle body by S6RW0D7216008 removing nuts (2). Removal 1) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery”...
Page 967: Evaporator Inspection
Air Conditioning System: Manual Type 7B-27 Evaporator Temperature Sensor Removal and Installation Reverse removal procedure noting the following Installation instructions. S6RW0D7216010 Removal • Replenish specified amount of compressor oil to 1) Remove HVAC unit from vehicle body referring to compressor suction side referring to “Replenishing “HVAC Unit Removal and Installation”.
Page 968: Evaporator Temperature Sensor Inspection
7B-28 Air Conditioning System: Manual Type Evaporator Temperature Sensor Inspection Expansion Valve Removal and Installation S6RW0D7216011 S6RW0D7216012 Check resistance between terminals of evaporator temperature sensor (1). Removal If check results are as not specified, replace evaporator 1) Recover refrigerant from the A/C system with temperature sensor.
Page 969: A/C Refrigerant Pressure Sensor And Its Circuit Inspection
Air Conditioning System: Manual Type 7B-29 A/C Refrigerant Pressure Sensor and Its Circuit Installation Reverse removal procedure noting the following Inspection instructions. S6RW0D7216014 1) Disconnect A/C refrigerant pressure sensor • Apply compressor oil to O-ring of A/C refrigerant connector. pressure sensor. 2) Turn ignition switch to ON position.
Page 970: A/C System Relay Inspection
7B-30 Air Conditioning System: Manual Type A/C System Relay Inspection Compressor Drive Belt Inspection and S6RW0D7216017 Adjustment NOTE S6RW0D7216018 Inspection Do not use blue relay for the substitute of • Check compressor drive belt (1) for wear, crack, white relay because internal durability of a deformation and cleanliness.
Page 971: Compressor Drive Belt Removal And Installation
Air Conditioning System: Manual Type 7B-31 Compressor Drive Belt Removal and NOTE Installation Cap open fittings immediately to keep S6RW0D7216019 moisture out of the system. Removal 1) Loosen tension pulley nut (1). 2) Loosen belt tension loosening tension pulley adjusting bolt (2). 3) Remove compressor drive belt (3).
Page 972: Compressor Assembly Components
7B-32 Air Conditioning System: Manual Type Compressor Assembly Components S6RW0D7216021 I7RW01721023-01 1. Armature plate bolt 5. Shim 9. O-ring : Do not reuse. : Apply compressor oil. 2. Compressor 6. Magnet clutch coil 10. Thermal switch 3. Relief valve 7. Magnet clutch pulley : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) 4.
Page 973: Magnet Clutch Removal And Installation
Air Conditioning System: Manual Type 7B-33 Magnet Clutch Removal and Installation 6) Remove magnet clutch pulley (2). S6RW0D7216023 Removal NOTE 1) Remove compressor from vehicle referring to • If it is difficult to remove magnet clutch “Compressor Assembly Removal and Installation”. pulley by hand, use puller (1).
Page 974 7B-34 Air Conditioning System: Manual Type Installation 6) Tighten new armature plate bolt to specified torque. 1) Install magnet clutch coil (2) fitting protrusion (4) of Tightening torque magnet clutch coil onto hole (5) of compressor (3). Armature plate nut (a): 16 N·m (1.6 kgf-m, 11.5 2) Install circlip (1) directing chamfer side (6) lb-ft) downward.
Page 975: Thermal Switch Inspection
• Apply silicon sealant to contact face (2) of thermal Measured thermal switch for resistance at 20 °C (68 °F) switch (1). Thermal switch resistance “A”: Silicon sealant 99000–34220 (SUZUKI Standard: 50 mΩ (DC 16 V, 5A at 20 °C (68 °F)) SILICON SEALANT KE-347W (100g)) 2, “A”...
Page 976: Relief Valve Inspection
7B-36 Air Conditioning System: Manual Type Relief Valve Inspection Installation S6RW0D7216026 Reverse removal procedure noting the following By using special tool, check is there is refrigerant instructions. leakage. • Use new O-ring If there is refrigerant leakage, replace the relief valve. •...
Page 977: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0D7218001 Material SUZUKI recommended product or Specification Note Compressor oil MATSUSHITADENKI GU10 P/No.: 99000–99015– Silicon sealant SUZUKI SILICON SEALANT KE- P/No.: 99000–34220...
Page 978: Automatic Type
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC control module. Also, it can be checked by using SUZUKI scan tool. Before checking diagnostic information (diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read diagnostic information (diagnostic trouble code).
Page 979: General Description
Air Conditioning System: Automatic Type 7B-39 General Description Auto A/C System Description S6RW0D7221001 The automatic type air conditioning system (auto A/C) is provided with the function to automatically control the inside air temperature, fan speed, air flow outlet direction and air intake position by HVAC control module in addition to functions of the manual type air conditioning system (manual A/C).
Page 980: Hvac Control Description
7B-40 Air Conditioning System: Automatic Type HVAC Control Description A/C Compressor Relay Control S6RW0D7221002 HVAC control module outputs A/C switch ON signal to Temperature Control ECM via BCM when the vehicle state satisfy conditions HVAC control module calculates the target temperature described below.
Page 981: On-Board Diagnostic System Description
– ECT sensor signal The diagnostic information as diagnostic – A/C refrigerant pressure sensor signal trouble code (DTC) can be known by using SUZUKI scan tool. For further details, refer to – VSS signal “DTC Check”. – Engine type signal –...
Page 982: A/C System Wiring Diagram
7B-42 Air Conditioning System: Automatic Type A/C System Wiring Diagram S6RW0D7222002 RED/YEL BLK/RED BLU/YEL BLU/YEL RED/BLK WHT/BLU BLK/YEL BLK/RED RED/BLK BLK/RED BRN/WHT WHT/RED G20-7 BLK/WHT BLK/WHT BLU/RED G20-30 G20-8 BLU/WHT G20-29 GRY/RED RED/BLU G20-10 PNK/BLK LT GRN WHT/BLK G20-9 G20-25 RED/BLK RED/BLK G20-22...
Page 983: Component Location
Air Conditioning System: Automatic Type 7B-43 [A]: Illumination control model 10. Air intake actuator 22. Compressor 34. “A/C” indicator light [B]: Junction block with BCM 11. Air flow control actuator 23. HVAC control module 35. Rear defogger switch [C]: Junction block without BCM 12.
Page 984: Electronic Control System Components Location
7B-44 Air Conditioning System: Automatic Type Electronic Control System Components Location S6RW0D7223002 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C722003-01 [A]: Junction block assembly viewed from relay 8.
Page 985: Diagnostic Information And Procedures
Air Conditioning System: Automatic Type 7B-45 Diagnostic Information and Procedures Air Conditioning System Check S6RW0D7224001 Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform ”Customer complaint analysis”. Was customer complaint analysis performed? Visual inspection Repair or replace Go to Step 3.
Page 986: A/C System Symptom Diagnosis
7B-46 Air Conditioning System: Automatic Type Description for Each Step Step 1. Customer complaint analysis Talk to customer, and then record details of the problem. Customer questionnaire (Example) I4RH01722014-01 NOTE The form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 987 Air Conditioning System: Automatic Type 7B-47 A/C System Symptom Diagnosis S6RW0D7224002 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C system does not referring to “Operation Procedure for operate) Refrigerant Charge”.
Page 988 7B-48 Air Conditioning System: Automatic Type Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C compressor normal Condenser clogged Check condenser referring to “Condenser operation)
Page 989: Abnormal Noise Symptom Diagnosis Of A/C System
Using SUZUKI Scan Tool 1) Turn ignition switch to OFF position. 4) Turn ignition switch to ON position. 2) Connect SUZUKI scan tool to data link connector 5) Read DTC displayed on SUZUKI scan tool. (DLC) (1) located on underside of instrument panel NOTE at driver’s seat side.
Page 990 In case of malfunction of temperature selector, blower speed selector and air flow selector, DTC can not be checked by the following procedure. Use SUZUKI scan tool for DTC check. 1) Light over sunload sensor vertically with an incandescent light of approximately 100 W apart from about 100 mm (3.94 in.).
Page 991: Dtc Clearance
“Not Using SUZUKI Scan Tool” under 1) Turn ignition switch to OFF position. “DTC Check”. 2) Connect SUZUKI scan tool to data link connector 2) Press air intake selector (1) and “A/C” switch (2) at (DLC) (1) located on underside of instrument panel the same time for 5 seconds or more.
Page 992: Dtc Table
DTC (indicated on HVAC control DTC No. module) “A/C” (displayed Condition when trouble detected (DTC is Detection item Indicated Indicated indicator on SUZUKI determined when following condition detected) by “REC” by “FRE” light scan tool) indicator indicator light light Inside Air...
Page 993 HVAC control DTC No. module) “A/C” (displayed Condition when trouble detected (DTC is Detection item Indicated Indicated indicator on SUZUKI determined when following condition detected) by “REC” by “FRE” light scan tool) indicator indicator light light Signal voltage of blower speed selector in HVAC...
Page 994: Fail-Safe Table
7B-54 Air Conditioning System: Automatic Type DTC of A/C System detected by ECM Detecting condition DTC No. Detection item (DTC will set when detecting) P0481 Fan 2 Control Circuit A/C Refrigerant Pressure P0532 Sensor Circuit Low Refer to “Fail-Safe Table in Section 1A”. A/C Refrigerant Pressure P0533 Sensor Circuit High...
Page 995 Air Conditioning System: Automatic Type 7B-55 Fail-Safe Operation DTC No. Trouble Area When ignition switch is turned ON When malfunction is detected during after malfunction is already detected ignition switch is ON Serial communication • HVAC control module maintains last HVAC control module controls actuators B1551 circuit...
Page 996 7B-56 Air Conditioning System: Automatic Type Normal Condition / Reference Scan Tool Data Condition Value COOLANT TEMP Engine coolant temperature is Ignition switch turned ON displayed SUN LOAD Reference value depends on the situation 0 W/m – 1988 W/m MODE CONT Ignition switch turned ON and air flow selector at AUTO (Selected position of air flow SWITCH...
Page 997: Visual Inspection
Air Conditioning System: Automatic Type 7B-57 SUN LOAD (W/m ): This parameter indicates the BLOWER LOAD SIG (Blower fan load signal, ON, amount of sunlight detected by sunload sensor. OFF): ON: Position of blower speed selector is 1st MODE CONT SWITCH (Air flow selector position, position or more.
Page 998 7B-58 Air Conditioning System: Automatic Type DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Inside air temperature sensor signal voltage is higher than or lower than • Inside air temperature sensor circuit specified value for specified time continuously. •...
Page 999: Dtc B1503: Evaporator Temperature Sensor Circuit Malfunction
Air Conditioning System: Automatic Type 7B-59 DTC B1503: Evaporator Temperature Sensor Circuit Malfunction S6RW0D7224011 Wiring Diagram WHT/BLK G20-9 G20-24 I7RW01722005-01 [S]: Evaporator temperature sensor signal circuit 1. HVAC control module 3. To other sensors [G]: Evaporator temperature sensor ground circuit 2.
Page 1000: Dtc B1504: Sunload Sensor Circuit Malfunction
7B-60 Air Conditioning System: Automatic Type Step Action Evaporator temperature sensor reference voltage check Go to Step 4. Substitute a known- good HVAC control 1) Connect connector to HVAC control module with ignition module and recheck. switch turned OFF. 2) Turn ignition switch to ON position. 3) Measure voltage between signal terminal and ground terminal of evaporator temperature sensor connector.
Page 1001: Dtc B1511: Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-61 DTC Troubleshooting Step Action Was “Air Conditioning System Check” performed? Go to Step 2. Go to “Air Conditioning System Check”. Wire harness check Go to Step 3. Sunload sensor power supply circuit and/or 1) Turn ignition switch to OFF position. signal circuit are open, 2) Disconnect connectors from sunload sensor and HVAC short or high resistance.
Page 1002 7B-62 Air Conditioning System: Automatic Type DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Temperature control actuator position sensor signal voltage is higher than or • Temperature control actuator circuit lower than specified value for specified time continuously. •...

Suzuki 2006 SX4 Service Manual

Table of Contents

Section 0 General Information

General Information

Specifications

Special Tools and Equipment

Section 1 Engine

Precautions

Engine General Information and Diagnosis

Precautions

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Aux. Emission Control Devices

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Electrical Devices

Repair Instructions

Specifications

Engine Mechanical

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Specifications

Diagnostic Information and Procedures

Schematic and Routing Diagram

Starting System

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Exhaust System

General Description

Diagnostic Information and Procedures

Repair Instructions

Quick Links

Chapters

Troubleshooting

Related Manuals for Suzuki 2006 SX4

Summary of Contents for Suzuki 2006 SX4