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Suzuki Swift Sport (RS416) 2004-2008 Service/Repair Manual This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnostic, disassembly, repair and installation procedures along with complete specifications and tightening references.
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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.
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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.
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TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Transmission / Transaxle .......... 5-i General Information ..........0A-1 Precautions .............. 5-1 Maintenance and Lubrication ......... 0B-1 Automatic Transmission/Transaxle ......5A-1 Manual Transmission/Transaxle ......5B-1 Engine .................
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..........00-10 Supplemental Restraint (Air Bag) System ..
• 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.
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Precautions: 00-2 Servicing and Handling WARNING Many of service procedures require disconnection of “A/BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from...
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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”.
Precautions: 00-4 General Precautions • Be sure to observe following instructions S7RS0B0000002 when handling service materials such as The WARNING and CAUTION describe some general fuel, oil, fluid, coolant, grease, sealant, precautions that you should observe when servicing a thread lock cement, etc. Otherwise, your vehicle.
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When use of a certain type of lubricant, bond or first and then the negative cable, and replace the sealant is specified, be sure to use the specified type. terminal cover. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 I2RH01010030-01...
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Precautions: 00-6 • Be sure to use special tools when instructed. • For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump Special tool and injector without first releasing the fuel pressure, or (A): 09917-98221 fuel can be sprayed out under pressure.
00-7 Precautions: Warning for Wheel (with tire) Removal Precautions for Installing Mobile S7RS0B0000003 Communication Equipment WARNING S7RS0B0000006 When installing mobile communication equipment such When removing any of these wheels installed as CB (Citizens-Band)-radio or cellular-telephone, be with wheel bolts, never remove all wheel sure to observe the following precautions.
Precautions: 00-8 Precautions for Electrical Circuit Service • When connecting connectors, also hold connectors S7RS0B0000008 and put them together until they lock securely (a click • When replacing a fuse, make sure to use a fuse of the is heard). specified capacity.
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00-9 Precautions: • Be careful not to touch the electrical terminals of parts • When connecting meter probe (2) from terminal side which use microcomputers (e.g. electronic control unit of coupler (1) because it can’t be connected from like as ECM, PCM, P/S controller, etc.). The static harness side, use extra care not to bend male electricity from your body can damage these parts.
If the correct only by an authorized SUZUKI dealer. Refer part number fastener is not available, a to “Air Bag System Components, Wiring fastener of equal size and strength (or and Connectors Location in Section 8B”...
00-11 Precautions: Precaution for Vehicle Equipped with ESP® Brake Caution S7RS0B0000014 System CAUTION S7RS0B0000015 • When testing with any of the following equipments All brake fasteners are important attaching (when vehicle is tested by rotating wheels (tires) parts in that they could affect the under vehicle stop), be sure to deactivate ESP®...
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Precautions: 00-12 4) Using continuity check or voltage check the following Voltage Check procedure, check the wire harness for open circuit If voltage is supplied to the circuit being checked, voltage and poor connection with its terminals. Locate check can be used as circuit check. abnormality, if any.
00-13 Precautions: Short Circuit Check (Wire Harness to Ground) 4) Disconnect the connector included in circuit (connector-B) and measure resistance between “A- 1) Disconnect negative (–) cable at battery. 1” and body ground. If continuity is indicated, it 2) Disconnect connectors at both ends of the circuit to means that the circuit is shorted to the ground be checked.
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Precautions: 00-14 • Improperly formed or damaged terminals. • Wire insulation which is rubbed through, causing an Check each connector terminal in problem circuits intermittent short as the bare area touches other carefully to ensure good contact tension by using the wiring or parts of the vehicle.
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Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Lines and Connections Inspection ....0B-6 Fuel Filter Replacement ........0B-7 General Description ..........0A-1 Fuel Tank Inspection...........0B-7 Abbreviations ............0A-1 PCV Valve Inspection .........0B-7 Symbols .............. 0A-2 Fuel Evaporative Emission Control System Wire Color Symbols ..........
0A-1 General Information: General Information General Information General Description Abbreviations EVAP Canister: Evaporative Emission Canister S7RS0B0101001 (Charcoal Canister) ABDC: After Bottom Dead Center 4WD: 4 Wheel Drive ABS: Anti-lock Brake System AC: Alternating Current GEN: Generator A/C: Air Conditioning GND: Ground A-ELR: Automatic-Emergency Locking Retractor GPS: Global Positioning System A/F: Air Fuel Mixture Ratio...
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WU-TWC: Warm Up Three Way Catalytic Converter Symbols S7RS0B0101002 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...
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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”...
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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.
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0A-5 General Information: Vehicle Lifting Points S7RS0B0101005 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.
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General Information: 0A-6 When Using Floor Jack In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against front suspension frame WARNING (1) or rear jacking bracket (2). If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety.
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0A-7 General Information: Engine Supporting Points Vehicle Identification Number S7RS0B0101006 S7RS0B0101007 The number is punched close by the right side strut WARNING support in engine room and it is also attached on the left When using engine supporting device (1), be side of instrument panel depending on the vehicle sure to observe the followings.
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General Information: 0A-8 Component Location Warning, Caution and Information Labels Location S7RS0B0103001 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.
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0A-9 General Information: I4RS0B010002-03 1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM 2. Air bag label on combination switch and contact coil assembly 7. Pretensioner label on seat belt retractor 3. Air bag label on passenger air bag (inflator) module 8.
Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S7RS0B0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S7RS0B0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
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0B-2 Maintenance and Lubrication: 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: — — — — — All latches, hinges and locks (I: —...
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Maintenance and Lubrication: 0B-3 Severe Maintenance Maintenance Maintenance interval condition code operation Every 30,000 km (18,000 miles) or – B – – E – – H Automatic transaxle fluid 24 months Every 15,000 km (9,000 miles) or 12 months – – C D – – – – HVAC air filter (if equipped) *2 Every 45,000 km (27,000 miles) or 36 months...
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0B-4 Maintenance and Lubrication: Accessory Drive Belt Replacement Before draining engine oil, check engine for oil leakage. S7RS0B0206002 If any evidence of leakage is found, make sure to correct Water Pump and Generator Drive Belt defective part before proceeding to the following work. Replace belt with new one referring to “Water Pump / 1) Drain engine oil by removing drain plug.
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Maintenance and Lubrication: 0B-5 4) Screw new filter on oil filter stand by hand until the 7) Check oil filter and drain plug for oil leakage. filter O-ring contacts mounting surface. 8) Start engine and run it for 3 minutes. Stop it and wait another 5 minutes before checking oil level.
0B-6 Maintenance and Lubrication: Exhaust System Inspection Air Cleaner Filter Inspection S7RS0B0206006 S7RS0B0206008 1) Remove air cleaner case clamps. WARNING 2) Take air cleaner filter out of case. To avoid danger of being burned, do not 3) Check that filter is not excessively dirty, damaged or touch exhaust system when it is still hot.
Maintenance and Lubrication: 0B-7 Fuel Filter Replacement 2) Check disc brake pads and discs for excessive wear, S7RS0B0206011 damage and deflection. Replace parts as necessary. Fuel filter is installed in fuel pump assembly in fuel tank. For details, refer to “Front Disc Brake Pad Inspection Replace fuel filter or fuel pump assembly with new one, in Section 4B”, “Front Brake Disc Inspection in referring to “Fuel Pump Assembly Removal and...
0B-8 Maintenance and Lubrication: Brake Fluid Inspection S7RS0B0206035 1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct. 2) Check fluid level. If fluid level is lower than the minimum level of reservoir, refilling is necessary. Fill reservoir with specified brake fluid.
Maintenance and Lubrication: 0B-9 Tires Inspection Wheel Bearing Inspection S7RS0B0206020 S7RS0B0206022 1) Check tires for uneven or excessive wear, or 1) Check front wheel bearing for wear, damage, damage. If defective, replace. abnormal noise or rattles. For details, refer to “Front Refer to “Irregular and/or Premature Wear Wheel Hub, Disc, Nut and Bearing Check in Section Description in Section 2D”...
0B-10 Maintenance and Lubrication: Steering System Inspection Drive Shaft (Axle) Boots Inspection S7RS0B0206024 S7RS0B0206025 Check drive shaft boots (wheel side and differential side) 1) Check steering wheel for play and rattle, holding for leaks, detachment, tear or other damage. vehicle straight on ground. Replace defective parts as necessary.
Maintenance and Lubrication: 0B-11 Automatic Transaxle Fluid Level Inspection Automatic Transaxle Fluid Cooler Hose S7RS0B0206028 Inspection 1) Inspect transaxle case for evidence of fluid leakage. S7RS0B0206030 Check automatic transaxle fluid cooler hose for fluid Repair leaky point, if any. leakage, cracks, damage and deterioration. 2) Make sure that vehicle is placed level for fluid level Replace hose and/or clamp if any faulty condition is check.
0B-12 Maintenance and Lubrication: HVAC Air Filter (If Equipped) Inspection Accelerator Pedal Operation S7RS0B0206032 Check that pedal operates smoothly without getting 1) Remove HVAC air filter from HVAC unit referring to caught or interfered by any other part. “HVAC Air Filter Removal and Installation (If Equipped) in Section 7A”.
Maintenance and Lubrication: 0B-13 • Check that the vehicle does not wander or pull to one Brake side. Foot brake Check the following: Engine • that brake pedal has proper travel, • Check that engine responds readily at all speeds. •...
0B-14 Maintenance and Lubrication: Special Tool S7RS0B0208002 09915–47331 Oil filter wrench...
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Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 Scan Tool Data ..........1A-33 Visual Inspection ..........1A-37 Precautions............. 1-1 Engine Basic Inspection........1A-38 Precautions for Engine.......... 1-1 Engine Symptom Diagnosis ......1A-41 Engine General Information and MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Diagnosis ..........
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1-ii Table of Contents DTC P0123: Throttle / Pedal Position Sensor DTC P1510: ECM Back-Up Power Supply / Switch “A” (Main) Circuit High ....... 1A-85 Malfunction............1A-143 DTC P0131 / P0132: O2 Sensor (HO2S) DTC P1603: TCM Trouble Code Detected ..1A-144 Circuit Low Voltage / High Voltage (Sensor- DTC P1674: CAN Communication (Bus Off 1) ..............1A-88...
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Table of Contents 1-iii EVAP Canister Purge Valve and Its Circuit Air Cleaner Element Inspection and Cleaning ..1D-10 Inspection............1B-2 Cylinder Head Cover Removal and Vacuum Passage Inspection ......1B-3 Installation ............1D-10 Vacuum Hose and Purge Valve Chamber Throttle Body and Intake Manifold Inspection............
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1-iv Table of Contents Engine Lubrication System .....1E-1 Precautions on Fuel System Service ....1G-1 General Description ..........1G-1 General Description ..........1E-1 Fuel System Description ........1G-1 Engine Lubrication Description ......1E-1 Fuel Delivery System Description ...... 1G-1 Diagnostic Information and Procedures.... 1E-2 Fuel Pump Description........
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Table of Contents 1-v Ignition Timing Inspection ........1H-8 Generator Test (Undercharged Battery Check)............... 1J-5 Specifications............1H-9 Generator Test (Overcharged Battery Check) ..1J-6 Tightening Torque Specifications......1H-9 Repair Instructions ..........1J-6 Special Tools and Equipment ......1H-9 Jump Starting in Case of Emergency....1J-6 Special Tool ............1H-9 Battery Dismounting and Remounting ....
1-1 Precautions: Precautions Engine Precautions Precautions for Engine S7RS0B1000001 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”.
• Diagnostic information stored in ECM memory can be that 12-volt electrical system is capable of violent and cleared as well as checked by using SUZUKI scan damaging short circuits. tool or OBD generic scan tool. Before using scan tool, When performing any work where electrical terminals read its Operator’s (Instruction) Manual carefully to...
1A-2 Engine General Information and Diagnosis: Precautions of ECM Circuit Inspection • Be sure to read “Precautions for Electrical Circuit S7RS0B1100003 Service in Section 00” before inspection and observe • ECM connectors are waterproofed. Each terminal of what is written there. the ECM connectors is sealed up with the grommet.
Diagnostic (OBD) System”. • It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. This vehicle is equipped with an engine and emission (Diagnostic information can be accessed by using a control system which are under control of ECM.
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1A-4 Engine General Information and Diagnosis: Driving Cycle detected. Utilizing this function, it is possible to know the A “Driving Cycle” consists of engine startup and engine order of malfunctions that have been detected. Its use is shutoff. helpful when rechecking or diagnosing a trouble. 2 Driving Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC) but...
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• Heated oxygen sensor For Hong Kong model, DTC can be read by not only • ECT sensor using SUZUKI scan tool but also displayed on • TP sensor odometer (5) of the combination meter. (i.e. when • APP sensor diagnosis switch terminal (3) is grounded with a service wire (4) and ignition switch is turned ON.) For...
OBD serial data line (3) (K line of ISO 9141) is used for and controlled devices. SUZUKI scan tool or OBD generic scan tool to Emission control system includes EGR, EVAP and PCV system. communicate with ECM, Air bag SDM, HVAC control...
Engine General Information and Diagnosis: 1A-7 CAN Communication System Description S7RS0B1101005 The following control modules and sensors communicate each other. • ECM (2) • TCM (1) • BCM (4) • ABS control module (3) or ESP® control module (7) • Combination meter (5) •...
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1A-8 Engine General Information and Diagnosis: CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple control modules can communicate simultaneously.
Engine General Information and Diagnosis: 1A-9 Air Intake System Description S7RS0B1101006 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.
1A-10 Engine General Information and Diagnosis: I4RS0B110007-02 6. CPU 11. APP sensor (main) signal 15. Drive signal of throttle actuator 7. Drive circuit of throttle actuator 12. APP sensor (sub) signal 16. Power supply of throttle actuator 9. From “TH MOT” fuse 13.
Engine General Information and Diagnosis: 1A-11 Generator Control System Description S7RS0B1101010 Generator Control System consists of a generator (1), electric load current sensor (7) located in the main fuse box (4) and ECM (5). ECM controls generated electricity (adjusting voltage of IC regulator (2)) so that it is suitable for the engine and electric load conditions.
1A-12 Engine General Information and Diagnosis: Electronic Control System Description S7RS0B1101011 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices. Functionally, it is divided into the following sub systems: •...
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Engine General Information and Diagnosis: 1A-13 Engine and Emission Control System Flow Diagram I7RS0B110004-01...
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Engine General Information and Diagnosis: 1A-15 [A]: Manual A/C model 24. ABS / ESP® control module 49. Radiator cooling fan motor [B]: Auto A/C model 25. TCM 50. “RDTR FAN” fuse 1. ECM 26. To other control module connected CAN 51.
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1A-16 Engine General Information and Diagnosis: Connector: C37 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 GRN/ORN — — 2) output EGR valve (stepper motor coil GRN/RED —...
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Engine General Information and Diagnosis: 1A-17 Connector: E23 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 RED/YEL memory actuator drive circuit CAN communication line (active high signal) for ABS/ —...
Engine General Information and Diagnosis: 1A-19 Schematic and Routing Diagram Engine and Emission Control System Diagram S7RS0B1102001 I7RS0B110010-01...
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1A-20 Engine General Information and Diagnosis: 1. Air cleaner 16. CMP sensor 31. Battery 2. EVAP canister purge valve 17. CKP sensor 32. A/C compressor relay 3. MAF and IAT sensor 18. Radiator cooling fan 33. A/C switch 4. TP sensor 19.
Engine General Information and Diagnosis: 1A-21 Component Location Electronic Control System Components Location S7RS0B1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I7RS0B110011-02 Information sensors Control devices Others 1.
1A-22 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine and Emission Control System Check S7RS0B1104001 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”.
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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?
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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.
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”.
DTC stored in ECM and TCM is read and displayed at a time. Using Scan Tool 1) Prepare OBD generic scan tool or SUZUKI scan tool. 2) With ignition switch turned OFF, connect it to DLC (1) located on underside of instrument panel at driver’s seat side.
ECM connectors). Using Scan Tool • When the same malfunction (DTC) is not 1) Connect OBD generic scan tool or SUZUKI scan tool detected again during 40 engine warm-up to data link connector in the same manner as when cycles.
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1A-28 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) HO2S heater control circuit low 2 driving *P0031 Heater voltage is less than specification while heater ON. (Sensor-1) cycles HO2S heater control circuit Heater voltage is more than specification while heater 2 driving *P0032...
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Engine General Information and Diagnosis: 1A-29 Detecting condition DTC No. Detecting item (DTC will set when detecting:) O2 sensor (HO2S) circuit no Output voltage of HO2S-2 is more than specification after 2 driving *P0140 activity detected (Sensor-2) warming up engine. cycles Total fuel trim is larger than specification for specified time 2 driving...
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1A-30 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Starter signal is high voltage for specified time while 2 driving Starter relay circuit high *P0617 engine is running. cycles Battery voltage is higher than specification even through generator control is maximum regulation, or battery P0620 Generator control circuit voltage is lower than specification even through generator...
Engine General Information and Diagnosis: 1A-31 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Throttle/pedal position sensor/ Output voltage of APP sensor (main) is higher than 1 driving *P2123 switch “D” (main) circuit high specification. cycle input Throttle/pedal position sensor/ Output voltage of APP sensor (sub) is lower than 1 driving...
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1A-32 Engine General Information and Diagnosis: DTC No. Detected item Fail-safe operation P0117 Engine coolant temperature circuit low • ECM controls actuators assuming that engine coolant temperature is 80 °C (176 °F). P0118 Engine coolant temperature circuit high • ECM operates radiator cooling fan. Throttle/pedal position sensor/switch/“A”...
Engine General Information and Diagnosis: 1A-33 DTC No. Detected item Fail-safe operation Throttle/pedal position sensor/switch/“D” (main) P2122 circuit low input Throttle/pedal position sensor/switch/“D” (main) • ECM turns off throttle actuator control relay and P2123 circuit high input throttle valve is fixed at the specified opening from Throttle/pedal position sensor/switch/“E”...
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1A-34 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values O2S B1 S1 At specified idle speed after warming up 0.1 – 0.95 V O2S B1 S1 ACT At specified idle speed after warming up ACTIVE O2S B1 S2 At 2000 r/min.
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Engine General Information and Diagnosis: 1A-35 Normal condition / Scan tool data Vehicle condition reference values Accelerator pedal released 1.4 – 1.8 V Ignition switch ON after TP SENSOR 2 VOLT Accelerator pedal depressed warmed up engine 3.58 – 4.76 V fully Accelerator pedal released 0.5 –...
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1A-36 Engine General Information and Diagnosis: O2S B1 S1 ACT (HEATED OXYGEN SENSOR-1, CANIST PRG DUTY (EVAP CANISTER PURGE FLOW ACTIVE / INACTIVE) DUTY, %) This parameter indicates activation condition of HO2S-1. This parameter indicates valve ON (valve open) time ACTIVE: Activating rate within a certain set cycle of EVAP canister purge INACTIVE: warming up or at stop...
Engine General Information and Diagnosis: 1A-37 TP SENSOR 2 VOLT (THROTTLE POSITION SENSOR THROTTLE TARGET POSI (TARGET THROTTLE (SUB) OUTPUT VOLTAGE, V) VALVE POSITION, %) The TP sensor (sub) reading provides throttle valve Target throttle valve position is ECM internal parameter opening information in the form of voltage.
1A-38 Engine General Information and Diagnosis: Engine Basic Inspection S7RS0B1104009 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in “Visual Inspection”. Follow the flow carefully. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
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Check ignition timing Go to “Engine Symptom Check ignition control Diagnosis”. related parts referring to 1) Using SUZUKI scan tool, select “Misc Test” mode on “Ignition Timing SUZUKI scan tool and fix ignition timing to initial one. Inspection in Section 1H”.
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1A-40 Engine General Information and Diagnosis: Step Action Check fuel pump for operation Go to “Fuel Pressure Go to “Fuel Pump and Check”. Its Circuit Check”. Was fuel pump operating sound heard from fuel filler for about 2 seconds after ignition switch ON and stop? 12 Check ignition spark Go to Step 13.
Engine General Information and Diagnosis: 1A-41 Engine Symptom Diagnosis S7RS0B1104010 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”...
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1A-42 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noise – Piston, Worn piston, ring and cylinder bore “Cylinders, Pistons and Piston Rings ring and cylinder noise Inspection in Section 1D” NOTE Before checking mechanical noise, make sure that: •...
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Engine General Information and Diagnosis: 1A-43 Condition Possible cause Correction / Reference Item Poor gasoline mileage Leaks or loose connection of high- “High-Tension Cord Removal and Installation tension cord in Section 1H” Faulty spark plug (improper gap, heavy “Spark Plug Inspection in Section 1H” deposits and burned electrodes, etc.) Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”...
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1A-44 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine hesitates – Spark plug faulty “Spark Plug Inspection in Section 1H” Momentary lack of Leaky high-tension cord “High-Tension Cord Inspection in Section 1H” response as accelerator Fuel pressure out of specification “Fuel Pressure Check”...
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Engine General Information and Diagnosis: 1A-45 Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection in Section 1H” Leaks, loose connection or “High-Tension Cord Removal and Installation disconnection of high-tension cord...
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1A-46 Engine General Information and Diagnosis: 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”...
Engine General Information and Diagnosis: 1A-47 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S7RS0B1104011 Wiring Diagram E23-3 E23-18 G28-31 G28-16 BLK/ORN RED/BLK C37-13 C37-12 BLK/WHT E23-29 C37-58 C37-15 C37-30 BLK/ORN BLK/YEL BLK/YEL BRN/WHT...
1A-48 Engine General Information and Diagnosis: Troubleshooting NOTE 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 Go to Step 2.
Engine General Information and Diagnosis: 1A-49 Troubleshooting NOTE 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 Go to Step 2 of “Engine Go to Step 2.
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1A-50 Engine General Information and Diagnosis: Circuit Description Actual valve timing fails to become close to target advance level of each function although advance control function or retarded advance control function is at work. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of oil control valve is different from...
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Engine General Information and Diagnosis: 1A-51 Step Action Oil control valve electrical circuit for ground short Go to Step 9. “YEL/GRN” wire is check shorted to ground circuit. 1) Measure resistance between “C37-59” terminal of ECM connector and engine ground. Is resistance infinity? Oil control valve electrical circuit for short check Go to Step 9.
1A-52 Engine General Information and Diagnosis: DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System Performance / - Retarded S7RS0B1104014 System Description Actual value of advanced valve timing does not reach target value. Valve timing is advanced although ECM command is most retarding. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
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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 – 5°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.
1A-54 Engine General Information and Diagnosis: DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S7RS0B1104015 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/RED C37-46 C37-10 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RS0C110006-03...
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Engine General Information and Diagnosis: 1A-55 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. 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.
1A-56 Engine General Information and Diagnosis: DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) S7RS0B1104016 Wiring Diagram BLK/WHT E23-29 BLK/WHT RED/BLU C37-47 C37-11 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RS0C110007-01...
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Engine General Information and Diagnosis: 1A-57 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. 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.
1A-58 Engine General Information and Diagnosis: DTC P0101: Mass or Volume Air Flow Circuit Range / Performance S7RS0B1104017 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-31 BLK BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED E23-16 BLK/RED C37-26 GRN/BLK C37-27 BLK/YEL...
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Engine General Information and Diagnosis: 1A-59 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. •...
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1A-60 Engine General Information and Diagnosis: Step Action MAF sensor output voltage check Poor “C37-26” and/or Go to Step 5. “C37-27” terminal 1) Turn OFF ignition switch. connection. 2) Remove ECM from its bracket with ECM connectors If OK, substitute a connected.
Engine General Information and Diagnosis: 1A-61 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 “C37-26” terminal of ECM connector.
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1A-62 Engine General Information and Diagnosis: Step Action MAF sensor power supply voltage check Go to Step 4. “BLK/RED” wire is open circuit. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “BLK/RED”...
Engine General Information and Diagnosis: 1A-63 DTC P0103: Mass or Volume Air Flow Circuit High Input S7RS0B1104019 Wiring Diagram Refer to “DTC P0101: Mass or Volume Air Flow Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area MAF sensor output voltage is higher than 4.85 V for 0.5 seconds •...
1A-64 Engine General Information and Diagnosis: Step Action MAF sensor signal circuit check Go to Step 7. “GRY/BLK” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure voltage between “GRY/BLK” wire terminal of MAF and IAT sensor connector and engine ground.
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Engine General Information and Diagnosis: 1A-65 DTC Confirmation Procedure NOTE Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temperature at engine start: –10 °C (14 °F) to 80 °C (176 °F) •...
Engine General Information and Diagnosis: 1A-67 Step Action MAP sensor power supply circuit check Faulty A/C refrigerant “GRY/RED” wire is pressure sensor (if shorted to ground 1) Disconnect connectors from A/C refrigerant pressure equipped with A/C). circuit. sensor (if equipped with A/C) with ignition switch turned OFF.
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1A-68 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-69 Step Action Ground circuit check “ORN” wire is open or ECM grounds “E23-31”, high resistance circuit. “C37-58”, “C37-15” and/ 1) Measure resistance between “C37-55” terminal of ECM or “C37-30” circuit are connector and vehicle body ground. open or high resistance.
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1A-70 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference of maximum IAT minus minimum IAT is less than 0.3 °C • High resistance circuit (32.5 °F) while ECT is over 70 °C (158 °F) after 10 min from cold •...
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Engine General Information and Diagnosis: 1A-71 Step Action Wire harness check Go to Step 8. Go to Step 4. 1) Disconnect MAF and IAT sensor connector (1) with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor connector (1) at “BLK/YEL”...
1A-72 Engine General Information and Diagnosis: Step Action Ground circuit check Go to Step 10. Go to Step 9. 1) Connect connectors to ECM. 2) Check for proper connection of MAF and IAT sensor connector at “GRY/BLU” wire terminal. 3) Measure resistance between “GRY/BLU” wire terminal of MAF and IAT sensor connector and vehicle body ground with ignition switch turned OFF.
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Engine General Information and Diagnosis: 1A-73 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. IAT sensor and its circuit check Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch turned Check for intermittent OFF.
1A-74 Engine General Information and Diagnosis: DTC P0113: Intake Air Temperature 1 Sensor Circuit High S7RS0B1104025 Wiring Diagram Refer to “DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area IAT sensor output voltage is higher than 4.85 V for 0.5 seconds •...
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Engine General Information and Diagnosis: 1A-75 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”...
1A-76 Engine General Information and Diagnosis: Step Action Ground circuit check “GRY/BLU” wire and/or Faulty ECM ground “ORN” wire is open circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors circuit or high resistance substitute a known- connected.
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Engine General Information and Diagnosis: 1A-77 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. •...
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1A-78 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 “ORN” and “LT GRN” wire terminals. 3) If OK, then with ignition switch ON, measure voltage between “LT GRN”...
Engine General Information and Diagnosis: 1A-79 Step Action 10 Ground circuit check “ORN” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C37-55” If circuit is OK, connection. substitute a known- 2) Measure resistance between “C37-55”...
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1A-80 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-81 DTC P0118: Engine Coolant Temperature Circuit High S7RS0B1104028 Wiring Diagram Refer to “DTC P0116: Engine Coolant Temperature Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area ECT sensor output voltage is higher than 4.85 V for 0.5 seconds •...
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1A-82 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.
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1A-84 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-85 Step Action Wire harness check Go to Step 9. Go to Step 7. 1) Measure voltage between “GRN” wire terminal of electric throttle body connector and engine ground with ignition switch turned ON. Is voltage 4 – 6 V? Wire harness check Go to Step 8.
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1A-86 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
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Engine General Information and Diagnosis: 1A-87 Step Action Wire harness check “GRN” wire is open or Go to Step 7. 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 “C37- 43”...
1A-88 Engine General Information and Diagnosis: DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) S7RS0B1104031 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/RED C37-46 C37-10 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
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Engine General Information and Diagnosis: 1A-89 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. •...
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1A-90 Engine General Information and Diagnosis: Step Action HO2S-1 ground check Go to Step 5. “YEL” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-1 with ignition switch Poor “C37-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-1 connector at ground.
Engine General Information and Diagnosis: 1A-91 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) S7RS0B1104032 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 Heated oxygen sensor-1 voltage is about 1 sec.
1A-92 Engine General Information and Diagnosis: DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1) S7RS0B1104033 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 0.6 V for more than 1 min...
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Engine General Information and Diagnosis: 1A-93 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.
1A-94 Engine General Information and Diagnosis: DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2) S7RS0B1104034 Wiring Diagram BLK/WHT E23-29 BLK/WHT RED/BLU C37-47 C37-11 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
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Engine General Information and Diagnosis: 1A-95 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. •...
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1A-96 Engine General Information and Diagnosis: Step Action HO2S-2 ground check Go to Step 5. “YEL” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-2 with ignition switch Poor “C37-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-2 connector at ground.
Engine General Information and Diagnosis: 1A-97 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S7RS0B1104035 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...
1A-98 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 “C37- 2) Remove ECM from its bracket with ECM connectors 11”...
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Engine General Information and Diagnosis: 1A-99 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and print Freeze Frame Data or write them down using scan tool. 3) Clear DTC using scan tool. 4) Start engine and warm up to normal operating temperature. 5) Operate vehicle with condition as noted freeze frame data for 5 min.
1A-100 Engine General Information and Diagnosis: Step Action HO2S-1 for performance check Substitute a known- Faulty HO2S-1 or its good ECM and recheck. circuit. 1) Check HO2S-1 referring to Step 3 of “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)”.
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Engine General Information and Diagnosis: 1A-101 NOTE When DTC P0122 and P0222 are indicated together, it is possible that “RED” wire open circuit. 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.
1A-102 Engine General Information and Diagnosis: Step Action ECM voltage check “RED” wire is open or Go to Step 5. 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 “C37- 43”...
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Engine General Information and Diagnosis: 1A-103 NOTE When DTC P0123 and P0223 are indicated together, it is possible that “RED” wire shorted to power circuit and/or “BLK” wire open. DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool.
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1A-104 Engine General Information and Diagnosis: Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. power circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Check for proper connection of ECM connector at “C37- 43”...
Engine General Information and Diagnosis: 1A-105 Step Action Electric throttle body check Substitute a known- Replace electric throttle good ECM and recheck. body. 1) Check TP sensor referring to “Throttle Position Sensor Performance Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”. Is output voltage within specified value? DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...
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1A-106 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-107 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 •...
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1A-108 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-109 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 “C37-56” terminal of ECM connector and “RED” wire terminal of knock sensor harness connector.
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1A-110 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-111 Step Action Was terminal “B+” voltage in Step 3 within specification? Go to Step 7. “BLK/RED” wire is open circuit. If wire and connection are OK, substitute a known- good ECM and recheck. Engine start signal check Go to Step 8.
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1A-112 Engine General Information and Diagnosis: System Description The CMP sensor located on the transmission side of cylinder head consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion). The signal generator generates reference signal through slits in the slit plate which turns together with the camshaft. Reference signal The CMP sensor generates 6 pulses of signals each of which has a different waveform length while the camshaft makes one full rotation.
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Engine General Information and Diagnosis: 1A-113 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”...
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Engine General Information and Diagnosis: 1A-115 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
1A-116 Engine General Information and Diagnosis: DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected S7RS0B1104044 System and Wiring Diagram I6RS0C110019-02 1. EGR valve 5. Fresh air 9. Ignition switch 2. Intake manifold 6. Exhaust gas 10.
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Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Do you have SUZUKI scan tool? Go to Step 3. Go to Step 5.
Action 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 in Section 1B”. Is it in good condition?
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Engine General Information and Diagnosis: 1A-119 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
1A-120 Engine General Information and Diagnosis: DTC P0420: Catalyst System Efficiency below Threshold S7RS0B1104046 System and Wiring Diagram C37-10 C37-57 C37-11 BLU WHT I4RS0A110037-01 1. HO2S-1 3. Warm up three way catalytic converter 5. ECM 2. HO2S-2 4. Three way catalytic converter Circuit Description ECM monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by HO2S-2.
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Engine General Information and Diagnosis: 1A-121 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Response delay of HO2S-2 signal (shifting delay from rich to lean and • Exhaust gas leak from lean to rich with threshold at 0.45 V) compared to switching cycle •...
1A-122 Engine General Information and Diagnosis: Step Action HO2S-2 output voltage check Replace exhaust Check “BRN” and / or manifold (built in warm “YEL” wires for open 1) Check output voltage of HO2S-2 referring to “DTC up three way catalytic and short, and P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / converter) and exhaust...
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Engine General Information and Diagnosis: 1A-123 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. •...
1A-124 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 6. “BLU/BLK” wire is open circuit. 1) Connect connector to purge control valve with ignition switch turned OFF. 2) Turn ON ignition switch and measure voltage between “C37-29”...
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Engine General Information and Diagnosis: 1A-125 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of radiator cooling fan relay is different from • Radiator cooling fan relay circuit malfunction command signal. • Radiator cooling fan relay malfunction (1 driving cycle detection logic) •...
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1A-126 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 4. Open wire in “BLK/RED” and/or “GRY” wire are 1) Disconnect radiator cooling fan relay No. 1 (1) from open circuit. individual circuit fuse box No.1 (2) with ignition switch turned OFF.
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Engine General Information and Diagnosis: 1A-127 Step Action Radiator cooling fan control No. 1 check Go to Step 9. Faulty ECM. 1) Run engine until ECT is over 97.5 °C, 207.5 °F. Substitute a known- good ECM and recheck. 2) Measure voltage between vehicle body ground and “E23-46”...
1A-128 Engine General Information and Diagnosis: Step Action 12 Wire circuit check Go to Step 13. “GRN” wire is shorted to ground circuit. 1) Disconnect radiator cooling fan control relay No. 2 and No. 3 from individual circuit fuse box No.1 with ignition switch turned OFF.
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Engine General Information and Diagnosis: 1A-129 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Vehicle speed signal is not input while fuel is cut at • Wheel speed sensor and/or its circuit deceleration for 4 seconds continuously at 3600 rpm or •...
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Engine General Information and Diagnosis: 1A-131 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
1A-132 Engine General Information and Diagnosis: Step Action A/C refrigerant pressure sensor check Substitute a known- Faulty A/C refrigerant good ECM and recheck. pressure sensor. 1) Check A/C refrigerant pressure sensor referring to “A/C Refrigerant Pressure Sensor and Its Circuit Inspection in Section 7B”...
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Engine General Information and Diagnosis: 1A-133 Step Action A/C refrigerant pressure sensor power supply circuit Faulty MAP sensor. “GRY/RED” wire is open check or shorted to power circuit. 1) Disconnect connectors from MAP sensor with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “GRY/RED”...
1A-134 Engine General Information and Diagnosis: DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance S7RS0B1104054 System Description Internal control module is installed in ECM. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0601:...
1A-136 Engine General Information and Diagnosis: Step Action Signal circuit check Poor “C37-48” “YEL/GRN” wire is open connection or or high resistance 1) Turn OFF ignition switch. intermittent trouble. circuit. 2) Remove ECM from its bracket with ECM connectors Check for intermittent connected.
Engine General Information and Diagnosis: 1A-137 Step Action Wire circuit check Go to Step 4. For A/T model, “YEL” or “YEL/GRN” wire is 1) Disconnect starting motor control relay in individual shorted to power circuit. circuit fuse box No.1 with ignition switch turned OFF. For M/T model, “YEL/ 2) Check for proper connection to starting motor control GRN”...
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1A-138 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Battery voltage is higher than specification even through • Generator and/or its circuit generator control is maximum regulation (duty 100%). • Electric load current sensor •...
Engine General Information and Diagnosis: 1A-139 Step Action Generator control circuit check Go to Step 3. Repair or replace defective wire. 1) Disconnect connector from generator and ECM with ignition switch turned OFF. 2) Check for proper connection of wire terminal to generator connector and to ECM connector.
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1A-140 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool to DLC. 2) Turn ON ignition switch and clear DTC. 3) Make sure that all accessory switch is tuned OFF. 4) Start engine and warm it up to normal operating temperature (ECT approx. 90 – 95 °C, 193 – 203 °F). 5) Turn ON following accessory switch.
Engine General Information and Diagnosis: 1A-141 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High S7RS0B1104059 System and Wiring Diagram BLK/WHT E23-29 BLK/WHT C37-23 PNK/BLU BLK/ORN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5RS0C110014-01...
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1A-142 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
1A-144 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-145 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
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1A-146 Engine General Information and Diagnosis: Non ESP® model E23-3 E03-10 E23-18 E03-8 C34-17 C37-13 E03-6 C34-7 C37-12 E03-12 E46-1 E46-2 G28-8 G37-4 G28-10 G37-2 G49-19 G28-7 G37-1 WHT/BLK G49-18 G28-9 G37-3 RED/BLK 1716 1514 1312 1110 9 161514131211 10 9 8 7 2423 1817 2625...
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Engine General Information and Diagnosis: 1A-147 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
1A-148 Engine General Information and Diagnosis: DTC P1676: CAN Communication (Reception Error for TCM) S7RS0B1104064 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for TCM is •...
Engine General Information and Diagnosis: 1A-149 DTC P1678: CAN Communication (Reception Error for BCM) S7RS0B1104065 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for BCM is •...
1A-150 Engine General Information and Diagnosis: Step Action CAN communication circuit check Go to Step 7. Repair circuit. 1) Turn ignition switch to OFF position. 2) Disconnect connectors form ECM, BCM and ABS/ESP® control modules. 3) Check CAN communication circuit for open, short or high resistance.
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Engine General Information and Diagnosis: 1A-151 Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check in ECM Go to “DTC P1674: Go to Step 3. CAN Communication 1) Check ECM for DTC.
1A-152 Engine General Information and Diagnosis: DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance S7RS0B1104067 Wiring Diagram C37-58 BLK/ORN BLK/WHT E23-29 C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-31 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 E23-45 BLU/ORN RED/YEL E23-32 YEL/BLU LT GRN/RED...
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Engine General Information and Diagnosis: 1A-153 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
1A-154 Engine General Information and Diagnosis: DTC P2102: Throttle Actuator Control Motor Circuit Low S7RS0B1104068 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control circuit is •...
Engine General Information and Diagnosis: 1A-155 Step Action Throttle actuator control relay circuit check Go to Step 6. “BLU/ORN” wire and/or “RED/YEL” wire is open 1) Disconnect connectors from ECM with ignition switch or high resistance. turned OFF. 2) Measure resistance at the following connector terminals. •...
1A-156 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-157 DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
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1A-158 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.
Engine General Information and Diagnosis: 1A-159 Step Action Electric throttle body check Substitute a known- Replace electric throttle good ECM and recheck. body. 1) Check electric throttle body referring to” Electric Throttle Body Assembly and Its Circuit Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”.
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1A-160 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-161 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 “E23-35” terminal of ECM connector and engine ground.
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1A-162 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
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Engine General Information and Diagnosis: 1A-163 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 “E23- 35”, “E23-37”...
1A-164 Engine General Information and Diagnosis: DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input S7RS0B1104074 Wiring Diagram Refer to “DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of APP sensor (sub) is less than specified...
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Engine General Information and Diagnosis: 1A-165 Step Action ECM voltage check Go to Step 7. Go to Step 5. 1) Disconnect connector from APP sensor with ignition switch turned OFF. 2) Check for proper connection to APP sensor at “RED”, “YEL”...
1A-166 Engine General Information and Diagnosis: Step Action 10 APP sensor check Substitute a known- Replace APP sensor. good ECM and recheck. 1) Check APP sensor (sub) referring to “APP Sensor Assembly Inspection in Section 1C”. Is output voltage within specified value? DTC P2128: Throttle / Pedal Position Sensor / Switch “E”...
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Engine General Information and Diagnosis: 1A-167 Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from APP sensor with ignition switch turned OFF. 2) Check for proper connection to APP sensor at “RED”, “YEL”...
1A-168 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.
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Engine General Information and Diagnosis: 1A-169 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the opening angle based on TP • Throttle position sensor (main) and (sub) circuit sensor (main) and the opening angle based on TP sensor •...
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1A-170 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 “C37-43” terminal of ECM connector and engine ground.
Engine General Information and Diagnosis: 1A-171 DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage Correlation S7RS0B1104077 Wiring Diagram E23-35 E23-37 E23-52 E23-34 E23-36 E23-51 E23-50 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
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1A-172 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • 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”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Engine General Information and Diagnosis: 1A-173 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 “E23- 37”, “E23-52”, “E23-36”...
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1A-174 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. •...
Engine General Information and Diagnosis: 1A-175 Inspection of ECM and Its Circuits S7RS0B1104079 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.
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1A-176 Engine General Information and Diagnosis: 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 C37-1 Engine running at idle...
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Engine General Information and Diagnosis: 1A-177 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 C37-10 — HO2S-1 (“Reference 2,000 r/min.
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1A-178 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *0 – 0.6 V Sensor signal is pulse. ↑↓ Pulse frequency varies RED/ 4 –...
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Engine General Information and Diagnosis: 1A-179 Terminal Wire Circuit Normal voltage Condition Remarks color C37-32 — — — — — C37-33 — — — — — C37-34 — — — — — C37-35 — — — — — C37-36 — —...
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1A-180 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ground of ECM for C37-50 — Below 0.3 V Ignition switch turned ON. — shield wire Ground of ECM for C37-51 — Below 0.3 V Ignition switch turned ON. —...
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Engine General Information and Diagnosis: 1A-181 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 E23-4 signal output for P/...
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1A-182 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Sensor signal is pulse. *0 – 1 V Pulse frequency varies ↑↓ Vehicle speed depending on vehicle E23-25 signal output for P/ 10 – 14 V Vehicle running.
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Engine General Information and Diagnosis: 1A-183 Terminal Wire Circuit Normal voltage Condition Remarks color BLU/ Throttle actuator E23-45 0 – 1 V Ignition switch turned ON. — control relay output Ignition switch turned ON, engine coolant temp.: below 95 °C (203 °F), or A/C refrigerant pressure (if 10 –...
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1A-184 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Engine running, A/C switch OFF and blower 1.38 – 1.52 V selector at OFF position, A/C refrigerant pressure: 800 kPa (116 psi) Engine running, A/C switch ON and blower A/C refrigerant selector at 1st position or 2.15 –...
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Engine General Information and Diagnosis: 1A-185 Reference waveform No.2 Reference waveform No.4 No.1 fuel injector signal (2) with engine idling EGR valve signal Measurement CH1: “C37-20” to “C37-58” CH1: “C37-4” to “C37-58” terminal CH2: “C37-1” to “C37-58” Measurement CH2: “C37-3” to “C37-58” Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV terminal...
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1A-186 Engine General Information and Diagnosis: Reference waveform No.6 Reference waveform No.8 Ignition coil signal (1) with engine idling Generator field coil monitor signal (1) at engine idling Measurement Measurement CH1: “C37-6” to “C37-58” CH1: “C37-8” to “C37-58” terminal terminal Oscilloscope CH1: 2 V/DIV Oscilloscope...
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Engine General Information and Diagnosis: 1A-187 Reference waveform No.10 Reference waveform No.12 HOS2-1 signal (1) with engine idling HO2S-2 heater signal (4) with engine idling Measurement CH1: “C37-10” to “C37-57” Measurement CH1: “C37-11” to “C37-57” terminal CH2: “C37-46” to “C37-58” terminal CH2: “C37-47”...
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1A-188 Engine General Information and Diagnosis: Reference waveform No.14 Reference waveform No.16 No.3 fuel injector signal (2) with engine idling CMP sensor signal with engine idling Measurement CH1: “C37-20” to “C37-58” Measurement CH1: “C37-20” to “C37-58” terminal CH2: “C37-16” to “C37-58” terminal CH2: “C37-21”...
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Engine General Information and Diagnosis: 1A-189 Reference waveform No.18 Reference waveform No.20 MAF sensor signal (1) with engine racing EVAP canister purge valve signal Measurement CH1: “C37-26” to “C37-27” Measurement CH1: “C37-29” to “C37-58” terminal CH2: “C37-54” to “C37-55” terminal Oscilloscope CH1: 1 V/DIV, CH2: 1 V/DIV Oscilloscope...
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1A-190 Engine General Information and Diagnosis: Reference waveform No.21 Reference waveform No.22 Throttle actuator output signal with ignition switch turned Ignition coil signal and fuel injector signal with engine cranking Measurement CH1: “C37-45” to “C37-58” CH1: “C37-20” to “C37-58” terminal CH2: “C37-44”...
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Engine General Information and Diagnosis: 1A-191 Reference waveform No.24 Reference waveform No.26 MAP sensor signal (1) with engine racing Knock sensor signal at engine speed 4000 r/min. Measurement CH1: “C37-53” to “C37-55” Measurement CH1: “C37-56” to “C37-58” terminal CH2: “C37-54” to “C37-55” terminal Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV...
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1A-192 Engine General Information and Diagnosis: Reference waveform No.30 Reference waveform No.28 Oil control valve signal with engine racing Ignition pulse (engine revolution) signal (2) with engine idling Measurement CH1: “C37-60” to “C37-59” terminal Measurement CH1: “C37-20” to “C37-58” Oscilloscope CH1: 5 V/DIV terminal CH2: “E23-4”...
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Engine General Information and Diagnosis: 1A-193 Reference waveform No.32 VSS signal at 30 km/h (19 mph) Measurement CH1: “E23-25” to “C37-58” terminal Oscilloscope CH1: 5 V/DIV, CH2: 5 V/DIV setting TIME: 40 ms/DIV • After warmed up to normal operating temperature Measurement condition •...
1A-194 Engine General Information and Diagnosis: Terminals Circuit Standard resistance Condition C37-3 to E23-1/16 EGR valve (stepping motor No.2 coil) 20 – 31 Ω C37-18 to E23-1/16 EGR valve (stepping motor No.4 coil) — C37-19 to E23-1/16 EGR valve (stepping motor No.3 coil) 2 –...
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Engine General Information and Diagnosis: 1A-195 Circuit Description When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM. Troubleshooting NOTE 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”.
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1A-196 Engine General Information and Diagnosis: Step Action Main relay circuit check Go to Step 7. Go to Step 6. 1) Connect connectors to ECM with ignition switch turned OFF. 2) Turn ignition switch to ON position. 3) Measure voltage between “E23-60” terminal of ECM connector and body ground.
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Engine General Information and Diagnosis: 1A-197 Step Action 10 Main relay check “BRN/WHT” wire is Replace main relay. open or high resistance 1) Check main relay referring to “Main Relay, Fuel Pump circuit. Relay and Starting Motor Control Relay Inspection in Section 1C”.
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Engine General Information and Diagnosis: 1A-199 Troubleshooting NOTE 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 Fuel injectors circuit is Go to Step 2.
1A-200 Engine General Information and Diagnosis: Fuel Pump and Its Circuit Check S7RS0B1104082 Wiring Diagram BLK/WHT BLK/WHT E23-29 BLK/WHT E23-15 GRN/WHT BLK/YEL C37-58 BLK/ORN BLK/RED C37-15 C37-30 E23-31 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED E23-16 BLK/YEL E23-60 BRN/WHT 39 38 32 31 39 38 32 31 54 53...
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Engine General Information and Diagnosis: 1A-201 Troubleshooting NOTE 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 Fuel pump circuit is in Go to Step 2.
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1A-202 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.
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Engine General Information and Diagnosis: 1A-203 Fuel Pressure Check S7RS0B1104083 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...
1A-204 Engine General Information and Diagnosis: 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.
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1A-206 Engine General Information and Diagnosis: Troubleshooting NOTE • 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”. • When A/C evaporator outlet air temp. is below 2.5 °C (36.5 °F), A/C remains OFF (“E23-47” terminal voltage becomes 10 –...
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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 “E23-57” and “E23-54” wire terminals of ECM connector.
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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 “E23-47” wire terminal of ECM connector and vehicle body ground under following conditions respectively. Voltage between “E23-47” terminal of ECM connector and ground While engine running and A/C switch turned OFF: 10 –...
Engine General Information and Diagnosis: 1A-209 Electric Load Signal Circuit Check S7RS0B1104085 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 E23-31 BLK/YEL BLK/YEL BRN/WHT E23-60 12V 5V BLK/RED E23-1 BLK/YEL /BLU BLK/RED E23-16 BLK/YEL BLU/WHT E23-9 BLK/WHT E23-3 E23-18 32 31 39 38 32 31 39 38...
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1A-210 Engine General Information and Diagnosis: Step Action Electric load signal circuit check Electric load signal Check defective signal circuit is in good circuit. 1) Start engine and select “Data List” mode on scan tool. condition. 2) Check electric load signal under following conditions respectively.
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Engine General Information and Diagnosis: 1A-211 Radiator Cooling Fan Low Speed Control System Check S7RS0B1104086 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED BLK/RED E23-46 LT GRN BLU/RED BLU/RED C37-58 BLK/ORN C37-15 C37-30 BLU/BLK E23-31 L– H–...
1A-212 Engine General Information and Diagnosis: Troubleshooting WARNING Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch at the “ON”...
Engine General Information and Diagnosis: 1A-213 Radiator Cooling Fan High Speed Control System Check S7RS0B1104087 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED BLK/RED E23-46 LT GRN BLU/RED BLU/RED C37-58 BLK/ORN C37-15 C37-30 BLU/BLK E23-31 L– H–...
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1A-214 Engine General Information and Diagnosis: Troubleshooting WARNING Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch at the “ON”...
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Engine General Information and Diagnosis: 1A-215 Step Action Radiator cooling fan No. 2 wire circuit check Go to Step 8. “BLU/BLK” wire is shorted to power supply 1) Turn ON ignition switch. circuit. 2) Measure voltage between “BLU/BLK” wire terminal of disconnected radiator cooling fan control relay No.
“Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): SUZUKI scan tool...
Engine Diagnostic Information and Procedures EGR System Inspection S7RS0B1204001 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu. 3) Start engine and warm it up to normal operating temperature, then select “DATA LIST”...
2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. If check result is not satisfactory, check vacuum hoses, EVAP canister purge valve, wire harness and connections.
1B-3 Aux. Emission Control Devices: Vacuum Passage Inspection S7RS0B1206003 Start engine and run it at idle speed. Disconnect vacuum hose (1) from EVAP canister purge valve (2). With finger placed against disconnected hose, check that vacuum is applied. If it is not applied, clean vacuum passage by blowing compressed air.
Aux. Emission Control Devices: 1B-4 EVAP Canister Inspection EGR Valve Inspection S7RS0B1206006 S7RS0B1206008 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.
Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Repair Instructions ECM Removal and Installation Installation S7RS0B1306001 Reverse removal procedure noting the following: CAUTION • Connect connectors to ECM as follows. As ECM consists of precision parts, be a. Make sure that lock lever of ECM connector is careful not to expose it to excessive shock.
1C-2 Engine Electrical Devices: MAP Sensor Inspection Electric Throttle Body Assembly On-Vehicle S7RS0B1306002 Inspection 1) Remove air cleaner assembly. S7RS0B1306003 WARNING 2) Disconnect connector from MAP sensor. 3) Remove MAP sensor. Never touch throttle valve with finger while 4) Arrange 3 new 1.5 V batteries (2) in series (check ignition switch is turned ON and accelerator that total voltage is 4.5 –...
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Engine Electrical Devices: 1C-3 Throttle Valve Operation Check Electric Throttle Body Assembly Operation Check 1) Remove air cleaner outlet hose. 1) Remove air cleaner outlet hose. 2) Turn OFF ignition switch. 2) Turn ON ignition switch. 3) Move throttle valve with finger to its full open position 3) Depress accelerator pedal gradually and check that and check that it moves smoothly.
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1C-4 Engine Electrical Devices: TP 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) [C]: 0.45 –...
Engine Electrical Devices: 1C-5 Electric Throttle Body System Calibration APP Sensor Assembly Removal and Installation S7RS0B1306004 S7RS0B1306006 NOTE CAUTION If working the service described under the • Do not expose APP sensor assembly to “Precautions of Electric Throttle Body excessive shock like a dropping it. If APP System Calibration in Section 1A”...
1C-6 Engine Electrical Devices: APP Sensor Assembly Inspection S7RS0B1306007 Check APP sensor (main and sub) output voltage as following steps. 1) For APP sensor (main), arrange 3 new 1.5 V batteries (1) in series (check that total voltage is 4.5 - 5.0 V) and connect its positive terminal to “Vin 1”...
Engine Electrical Devices: 1C-9 CKP Sensor Removal and Installation CKP Sensor Inspection S7RS0B1306014 S7RS0B1306015 Removal Visual check 1) Disconnect negative (–) cable at battery. • Check that O-ring is free from damage. 2) Remove generator drive belt refer to “Water Pump / Generator Drive Belt Removal and Installation in •...
1C-10 Engine Electrical Devices: Knock Sensor Removal and Installation Main Relay, Fuel Pump Relay and Starting Motor S7RS0B1306016 Control Relay Inspection Removal S7RS0B1306017 1) Disconnect negative (–) cable at battery. 1) Disconnect negative (–) cable at battery. 2) Hoist vehicle. 2) Remove main relay (1), fuel pump relay (3) and/or starting motor control relay (2) from individual circuit 3) Remove right side drive shaft referring to “Front...
Engine Electrical Devices: 1C-11 MAF and IAT Sensor On-Vehicle Inspection 10) If check result is not as specified above, cause may S7RS0B1306018 lie in wire harness, connector connection, MAF and NOTE IAT sensor or ECM. Before performed this inspection, be sure to read the “Precautions of ECM Circuit MAF and IAT Sensor Removal and Installation Inspection in Section 1A”.
Electric Load Current Sensor On-Vehicle S7RS0B1306020 Inspection S7RS0B1306021 CAUTION Using SUZUKI Scan Tool Do not heat up MAF and IAT sensor more 1) Connect scan tool to DLC with ignition switch turned than 100 °C (212 °F). Otherwise, MAF and IAT OFF.
Engine Electrical Devices: 1C-13 Without Using SUZUKI Scan Tool If electric load current sensor circuit and charging system is in good condition, electric load current sensor 1) Measure sensor voltage between “C37-23” terminal (1) is faulty. of ECM connector and vehicle body ground referring to “Inspection of ECM and Its Circuits in Section 1A”.
1D-1 Engine Mechanical: Engine Mechanical Engine General Description Engine Construction Description S7RS0B1401001 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;...
Engine Mechanical: 1D-2 Camshaft Position Control (VVT Variable Valve Timing) System Description S7RS0B1401002 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.
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1D-3 Engine Mechanical: Oil Control Valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM. By this operation, the intake valve timing is varied continuously.
Engine Mechanical: 1D-4 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.
1D-5 Engine Mechanical: 11) Connect negative cable at battery. 15) Carry out Steps 12) through 14) on each cylinder to obtain 4 readings. 12) Install special tools (Compression gauge) into spark plug hole. 16) Disconnect negative cable at battery. 17) After checking, install spark plugs and ignition coil Special tool assemblies (2) with high-tension cord (3).
Engine Mechanical: 1D-6 6) Connect special tool (Vacuum gauge) to PCV hose 5) Check valve lashes with thickness gauge (4) (1). according to the following procedure. a) Check valve lashes at valves “1” and “7”. Special tool b) Turn camshafts by 90° (by turning crankshaft (A): 09915–67311 with wrench).
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1D-7 Engine Mechanical: Replacement of Shim 1) Close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside as shown in the figure. I6RS0B141028-01 4) Turn camshaft by approximately 90° clockwise and remove shim (3).
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Engine Mechanical: 1D-8 For example of intake side: 8) Lift valve by turning crankshaft counterclockwise (in When thickness of removed shim is 2.40 mm (0.094 opposite direction against above Step 4)) and in.), and measured valve clearance is 0.45 mm remove special tool.
Engine Mechanical: 1D-10 Air Cleaner Element Inspection and Cleaning S7RS0B1406003 Inspection Check air cleaner element for dirt. Replace excessive dirty element. Cleaning Blow off dust by compressed air from air outlet side of element. I2RH0B140033-01 10) Remove cylinder head cover (1) with cylinder head cover gasket (2).
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“A”: Water tight sealant 99000–31250 fall off. (SUZUKI Bond No.1207F) 4) Tighten cylinder head cover bolts as follows. a) Tighten cylinder head cover bolts to 3 N⋅m (0.3 kgf-m, 2.5 lb-ft) according to numerical order (“1”...
1D-13 Engine Mechanical: Throttle Body On-Vehicle Inspection Installation S7RS0B1406006 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”.
Engine Mechanical: 1D-14 Throttle Body Cleaning 7) Remove stiffener (1) and ground terminal (2) from S7RS0B1406008 intake manifold. Clean electric throttle body assembly referring to “Throttle Valve Visual Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”. Intake Manifold Removal and Installation S7RS0B1406009 Removal 1) Remove cowl top plate referring to “Cowl Top...
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1D-15 Engine Mechanical: Installation • Install intake manifold rear stiffener (1) as shown in Reverse removal procedure for installation noting the figure. followings. • Connect ground terminal (2) to intake manifold to • Use new intake manifold gasket (1). specified torque. •...
1D-17 Engine Mechanical: Engine Assembly Removal and Installation 12) Disconnect the following electric wires: S7RS0B1406011 • MAP sensor (1) NOTE • ECT sensor (2) After replacing electric throttle body • EGR valve (3) assembly, perform calibration of throttle valve referring to “Electric Throttle Body •...
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Engine Mechanical: 1D-18 17) Disconnect right and left drive shaft joints from differential gear referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”. NOTE For engine and transaxle removal, it is not necessary to remove drive shafts from steering knuckle.
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1D-19 Engine Mechanical: 24) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transaxle. 25) Lower engine with transaxle from engine compartment. CAUTION 1, (a) Before lowering engine, to avoid damage to A/C compressor and clutch operating cylinder, make clearance by rising them.
Engine Mechanical: 1D-20 15) Install A/C compressor to its bracket (if equipped) 19) Refill engine with engine oil referring to “Engine Oil referring to “Compressor Assembly Removal and and Filter Change in Section 0B”. Installation in Section 7B” or “Compressor Assembly 20) Refill transaxle with transaxle oil referring to“Manual Removal and Installation in Section 7B”.
Engine Mechanical: 1D-24 Oil Control Valve Inspection S7RS0B1406016 Oil Control Valve 1) Inspect strainer (1) and mating surface (2) of oil control valve for clog or damage. Clean oil control valve if clog or foreign matter is present on strainer or mating surface of oil control valve.
1D-25 Engine Mechanical: Timing Chain and Chain Tensioner Removal Installation and Installation CAUTION S7RS0B1406018 After timing chain is removed, never turn Removal crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown CAUTION in figure. After timing chain is removed, never turn If turned, interference may occur between crankshaft and camshafts independently piston and valves and valves themselves,...
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Engine Mechanical: 1D-26 3) Install timing chain by aligning dark blue plate (1) of 6) Apply engine oil to sliding surface of chain tensioner timing chain and triangle mark (2) on camshaft (1) and install chain tensioner and spacer. timing sprocket as shown in figure. Tighten tensioner bolt to specified torque.
1D-27 Engine Mechanical: 8) Screw in plunger (1) by turning body (2) in arrow direction and install a retainer (3) (wire) to hold plunger in place. I2RH0B140065-01 9) Install timing chain tensioner adjuster assembly (1) with a retainer (2). Tighten adjuster bolts to specified torque and then remove a retainer from chain tensioner adjuster assembly.
1D-29 Engine Mechanical: Camshaft, Tappet and Shim Removal and 4) Loosen camshaft housing bolts in such order as indicated in the figure and remove them. Installation S7RS0B1406021 “12” “13” “20” “21” “16” “17” “8” “9” CAUTION “2” • Keep working table, tools and hands clean “5”...
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Engine Mechanical: 1D-30 NOTE Installation 1) Install tappets and shims to cylinder head. Before installing camshafts, turn crankshaft Apply engine oil around tappet and then install it to until key position faces upward. cylinder head. Refer to “Timing Chain and Chain Tensioner Removal and Installation”.
1D-31 Engine Mechanical: Camshaft, Tappet and Shim Inspection 7) Install camshaft housing. S7RS0B1406022 8) Tighten camshaft housing bolts as follows. a) Apply engine oil to camshaft housing bolts. Intake Cam Timing Sprocket Assembly Fit intake cam timing sprocket assembly to camshaft (2) b) Tighten camshaft housing bolts by hand.
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Engine Mechanical: 1D-32 Camshaft Runout 6) Install camshaft housing as follows. Set camshaft between two “V” blocks, and measure its After applying engine oil to camshaft housing bolts, runout by using a dial gauge. tighten them temporarily first. Then tighten them as If measured runout exceeds limit, replace camshaft.
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1D-33 Engine Mechanical: If measured camshaft journal clearance exceeds Wear of Tappet and Shim limit, measure journal (housing) bore and outside Check tappet and shim for pitting, scratches, or damage. diameter of camshaft journal. Replace camshaft or If any malcondition is found, replace. cylinder head assembly whichever the difference from specification is greater.
Engine Mechanical: 1D-34 Valves and Cylinder Head Components S7RS0B1406023 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.
1D-35 Engine Mechanical: Valves and Cylinder Head Removal and Installation Installation 1) Clean mating surface of cylinder head and cylinder S7RS0B1406024 block. Remove oil, old gasket and dust from mating surface. Removal 2) Install knock pins (1) to cylinder block. 1) Remove engine assembly from vehicle referring to 3) Install new cylinder head gasket (2) to cylinder block.
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Engine Mechanical: 1D-36 5) Install cylinder head to cylinder block. NOTE Apply engine oil to new cylinder head bolts and • If they are reused, check thread diameters tighten them gradually as follows. of cylinder head bolt (1) for deformation a) Tighten cylinder head bolts (“1”...
1D-37 Engine Mechanical: Valves and Cylinder Head Disassembly and 3) Release special tools (Valve lifter), and remove spring retainer and valve spring. Assembly S7RS0B1406025 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide and Disassembly valve spring seat (2).
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Engine Mechanical: 1D-38 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.
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1D-39 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.
Engine Mechanical: 1D-40 Valves and Valve Guides Inspection S7RS0B1406026 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.
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1D-41 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.
Engine Mechanical: 1D-42 Cylinder Head Inspection S7RS0B1406027 • 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. The same applies to valves and valve seats, too. I2RH0B140106-01 •...
1D-43 Engine Mechanical: Valve Spring Inspection Spring Squareness S7RS0B1406028 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.
Engine Mechanical: 1D-44 Pistons, Piston Rings, Connecting Rods and Cylinders Components S7RS0B1406029 I6RS0C140021-02 1. Top ring 6. Connecting rod bearing cap : Tighten15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45° : See “B” and 45° by the specified procedure. 2. 2nd ring 7.
1D-45 Engine Mechanical: Pistons, Piston Rings, Connecting Rods and 3) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring Cylinders Removal and Installation compressor) to compress rings. Guide connecting S7RS0B1406030 rod into place on crankshaft. Removal Using a hammer handle, tap piston head to install 1) Remove engine assembly from vehicle referring to...
Engine Mechanical: 1D-46 Pistons, Piston Rings, Connecting Rods and NOTE Cylinders Disassembly and Assembly Circlip should be installed with its cut part S7RS0B1406031 facing as shown in figure. Install so that circlip end gap comes within such range as Disassembly indicated by arrow.
1D-47 Engine Mechanical: Cylinders, Pistons and Piston Rings Inspection Piston S7RS0B1406032 Visual inspection Inspect piston for faults, cracks or other damages. Cylinder Damaged or faulty piston should be replaced. Visual inspection Inspect cylinder walls for scratches, roughness or ridges Piston diameter which indicate excessive wear.
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Engine Mechanical: 1D-48 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.
1D-49 Engine Mechanical: Piston Pins and Connecting Rods Inspection Connecting Rod S7RS0B1406033 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.
Engine Mechanical: 1D-50 Connecting rod bearing cap bolt deformation Out-of-round (Plastic deformation tightening bolt) A – B Measure each thread diameter of connecting rod Taper bearing cap bolt (1) at “A” on 32 mm (1.25 in.) from bolt a – b mounting surface and “B”...
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1D-51 Engine Mechanical: Connecting Rod Bearing Clearance 5) Remove cap and using a scale (1) on gauging plastic envelope (2), measure gauging plastic (2) 1) Before checking bearing clearance, clean bearing width at the widest point (clearance). and crank pin. If clearance exceed its limit, use a new standard size 2) Install bearing in connecting rod and bearing cap.
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Engine Mechanical: 1D-52 3) There are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in the figure. Each color indicated the following thickness at the center of bearing.
Engine Mechanical: 1D-54 “A”: When servicing CKP sensor, refer to “CMP Sensor Removal and Installation in Section : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 1C”. “B”: Upper half of bearing has an oil groove. : Do not reuse. “C”: Apply sealant 99000-31250 to mating surface. : Apply engine oil to inside / sliding surface.
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1D-55 Engine Mechanical: Installation 2) Install piston cooling valves and nozzles, if removed. NOTE NOTE Install piston cooling valve while matching • Use new bearing cap No.1 bolts. They are piston cooling nozzle (1) to positioning (3) of deformed once they are used because they cylinder block when installed piston cooling are plastic deformation tightening bolts.
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22.0 lb-ft) according to numerical order as housing (1). shown by using a 12 corner socket wrenches. “A”: Water tight sealant 99000–31250 (SUZUKI b) In the same manner as in Step a), tighten them Bond No.1207F) to 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
1D-57 Engine Mechanical: Crankshaft Inspection 11) Install flywheel (drive plate for A/T). Using special tool, lock flywheel or drive plate, and S7RS0B1406037 tighten flywheel or drive plate bolts to specified Crankshaft Runout torque. Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly.
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Engine Mechanical: 1D-58 2) Tighten main bearing cap No.1 bolts (a) and main 3) Use a dial gauge to read displacement in axial bearing cap No.2 bolts (b) gradually as follows. (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with a) Tighten bolts (“1”...
1D-59 Engine Mechanical: Main Bearings Inspection 4) Tighten main bearing cap No.1 bolts (a) and main S7RS0B1406038 bearing cap No.2 bolts (b) gradually as follows. a) Tighten bolts (“1” through “10”) to 30 N⋅m (3.0 General Information kgf-m, 22.0 lb-ft) according to numerical order in •...
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Engine Mechanical: 1D-60 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”...
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1D-61 Engine Mechanical: 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 Bearing thickness...
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Engine Mechanical: 1D-62 Undersize bearing (0.25 mm (0.0098 in.)) • 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure. Each color represents the following thickness at the center of bearing.
1D-63 Engine Mechanical: Main Bearing Cap No.1 Bolt Rear Oil Seal Inspection Measure each thread diameter main bearing cap No.1 S7RS0B1406040 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.
Engine Mechanical: 1D-64 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.
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1D-65 Engine Mechanical: Tightening torque Fastening part Note N⋅m kgf-m lb-ft Connecting rod bearing cap bolt 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) and then retighten by turning through 45° twice Sensor plate bolt Piston cooling valve Main bearing cap No.1 bolt (a) 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) and then retighten by turning through 60°...
Engine Mechanical: 1D-66 Special Tools and Equipment Recommended Service Material S7RS0B1408001 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.
Engine Lubrication System: 1E-1 Engine Lubrication System Engine General Description Engine Lubrication Description In one path, oil reaches the crankshaft journal bearings. S7RS0B1501001 Oil from the crankshaft journal bearings is supplied to The oil pump is of a trochoid type, and mounted on the the connecting rod bearings by means of intersecting crankshaft.
1E-2 Engine Lubrication System: Diagnostic Information and Procedures Oil Pressure Check 1) Remove front bumper referring to “Front Bumper S7RS0B1504001 and Rear Bumper Components in Section 9K”. WARNING 2) Remove engine front cover (1). To avoid danger of being burned, do not touch exhaust system when it is still hot.
Engine Lubrication System: 1E-3 6) Start engine and warm engine up to normal operating temperature. NOTE Be sure to shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T vehicle), set parking brake and block drive wheels.
1E-4 Engine Lubrication System: Heat Exchanger On-Vehicle Inspection Installation S7RS0B1506002 Reverse removal procedure for installation noting the • Check heat exchanger for deformation wear or followings. damage. • Use new stand bolt gasket. • Check heat exchanger for coolant leakage and oil •...
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1) Install new O-rings (2) in the position as shown in figure and install oil pump strainer (1). “A”: Sealant 99000–31260 (SUZUKI Bond Tighten strainer bolt (3) first and then bracket bolt (4) No.1217G) to specified torque.
Engine Lubrication System: 1E-7 6) After fitting oil pan to cylinder block, run in securing 10) Install clutch housing lower plate (1). bolts and start tightening at the center: move wrench outward, tightening one bolt at a time. Tighten bolts and nuts to specified torque.
Engine Lubrication System: 1E-9 Oil Pump Inspection Reassembly S7RS0B1506010 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.
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1E-10 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.
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 S7RS0B1508001 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.
1F-1 Engine Cooling System: Engine Cooling System Engine General Description Cooling System Description S7RS0B1601001 The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. Coolant Description S7RS0B1601002 WARNING •...
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1F-3 Engine Cooling System: When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be cooled as follows. I6RS0C160002-01 1. Radiator inlet hose 6. Water pump 11. Heater core 2. Radiator outlet hose 7.
Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S7RS0B1604001 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.
Engine Cooling System: 1F-6 Coolant Level Check NOTE S7RS0B1606002 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.
1F-7 Engine Cooling System: Cooling System Flush and Refill 7) Remove reservoir (1) and remove cap (2) from S7RS0B1606005 reservoir (1). WARNING 8) Pour out any fluid, scrub and clean inside of reservoir with soap and water. To help avoid danger of being burned, do not Flush it well with clean water and drain, Reinstall remove radiator cap while engine and reservoir.
Engine Cooling System: 1F-8 Thermostat Removal and Installation • Refill cooling system referring to Step 7) to 22) of S7RS0B1606007 “Cooling System Flush and Refill”. Removal • Verify that there is no coolant leakage at each 1) Drain coolant referring to “Cooling System Draining”. connection.
Engine Cooling System: 1F-10 Radiator Cooling Fan Removal and Installation Radiator On-Vehicle Inspection and Cleaning S7RS0B1606011 S7RS0B1606012 Inspection Removal Check radiator for leakage or damage. Straighten bent fins, if any. 1) Disconnect negative (–) cable at battery. 2) Disconnect connector (1) of cooling fan motor. Cleaning Clean frontal area of radiator cores.
Section 7B” or “Compressor Drive Belt Inspection and Adjustment in Section 7B”. “A”: Water tight sealant 99000–31250 (SUZUKI 6) Refill cooling system referring to Step 7) to 22) of Bond No.1207F) “Cooling System Flush and Refill”.
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 S7RS0B1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
1G-1 Fuel System: Fuel System Engine Precautions Precautions on Fuel System Service S7RS0B1700001 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. •...
Fuel System: 1G-2 Fuel Pump Description S7RS0B1701003 The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) and a fuel pressure regulator (3) are included and a fuel level gauge (4) is attached. Addition of the fuel pressure regulator to the fuel pump makes it possible to maintain the fuel pressure at constant level and ECM controls compensation for...
1G-3 Fuel System: Fuel Cut Operation Inspection 4) Check that battery voltage is 11 V or more. S7RS0B1704002 5) Measure fuel pressure at each condition. NOTE If measured pressure is out of specification, refer to Before inspection, make sure that gear shift “Fuel Pressure Check in Section 1A”...
1G-5 Fuel System: Fuel Hose Disconnecting and Reconnecting S7RS0B1706002 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in figure. For Connection Other Than Quick Joint Clamp around fuel tank NOTE...
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Fuel System: 1G-6 Clamp other than around fuel tank [A]: With short pipe, fit hose as far as it reaches pipe joint as shown. [B]: With the following type pipe, fit hose as far as its peripheral projection as shown. [C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
1G-7 Fuel System: Fuel Pressure Relief Procedure Fuel Lines On-Vehicle Inspection S7RS0B1706003 S7RS0B1706005 CAUTION CAUTION This work must not be done when engine is Due to the fact that fuel feed line (1) is under hot. If done so, it may cause adverse effect to high pressure, use special care when catalyst.
Fuel System: 1G-8 Installation Fuel Injector Removal and Installation S7RS0B1706008 1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with WARNING new one. Before starting the following procedure, be 2) Install pipes with pipe clamps to vehicle.
1G-9 Fuel System: Fuel Injector Inspection Installation Reverse removal procedure for installation noting the S7RS0B1706009 following. WARNING • Replace injector O-ring (1) with new one using care Before starting the following procedure, be not to damage it. sure to observe “Precautions on Fuel System •...
“MISC TEST” mode on scan tool. specifications, replace. iii) Turn fuel pump ON by using scan tool. Fuel leakage Special tool Less than 1 drop/min. (A): SUZUKI scan tool I2RH0B170013-01 I4RS0A170021-01 Fuel Filler Cap Inspection b) When not using scan tool: S7RS0B1706010 WARNING Remove fuel pump relay from connector.
1G-11 Fuel System: Fuel Tank Inlet Valve Removal and Installation 4) Remove fuel tank inlet valve (1) using flat head rod S7RS0B1706011 (2) or the like. WARNING CAUTION Before starting the following procedure, be Be careful not to damage fuel tank inlet valve sure to observe “Precautions on Fuel System (1) with flat head rod (2) or the like.
Fuel System: 1G-12 Fuel Tank Inlet Valve Inspection 7) Disconnect fuel pipe joint and fuel hoses (1) from S7RS0B1706012 fuel pipes (2) referring to “Fuel Hose Disconnecting and Reconnecting”. WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service”...
1G-13 Fuel System: 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): 2 N·m (0.2 kgf-m, 1.5 inserted, push joint into pipe till joint lock lb-ft)
Fuel System: 1G-14 Fuel Tank Purging Procedure S7RS0B1706015 WARNING • Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk or fire and personal injury. • This purging procedure will not remove all fuel vapor.
1G-15 Fuel System: 3) Remove fuel pump assembly (1) from fuel tank (2). 4) Connect fuel feed line (1) (pipe joint) to fuel pump assembly (2). I3RM0A170021-01 I4RS0A170014-01 5) Install fuel tank to vehicle. Refer to “Fuel Tank Installation Removal and Installation”. CAUTION Main Fuel Level Sensor Removal and When connecting joint, clean outside surface...
Ignition System: 1H-1 Ignition System Engine General Description Ignition System Construction S7RS0B1801001 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.
Ignition System: 1H-3 Component Location Ignition System Components Location S7RS0B1803001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RS0C180001-01 1. ECM 7. ECT sensor 13. Data link connector 2.
1H-4 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis S7RS0B1804001 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.
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Ignition System: 1H-5 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.
1H-6 Ignition System: Ignition Spark Test 5) Crank engine and check if each spark plug sparks. S7RS0B1804004 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.
Ignition System: 1H-7 High-Tension Cord Inspection Spark Plug Inspection S7RS0B1806002 S7RS0B1806004 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.
OFF. 3) Install high-tension cord (3) to ignition coil assembly Special tool while gripping its cap. (A): SUZUKI scan tool I4RS0B180003-01 I3RM0A180004-01 2) Start engine and warm it up to normal operating 4) Install cylinder head upper cover and air cleaner temperature.
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Cranking System Circuit Diagram S7RS0B1902001 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.
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Starting System: 1I-2 Condition Possible cause Correction / Reference Item Motor not running (No Shift lever switch is not in P or N, or not Shift in P or N, or adjust switch. (A/T) operating sound of adjusted (A/T) magnetic switch) Battery run down Recharge battery.
1I-3 Starting System: Cranking System Test Plunger and Pinion Return Test S7RS0B1904002 Disconnect negative lead from starting motor body. CAUTION Check that plunger and pinion return inward. If plunger and pinion don’t return, replace the magnetic Each test must be performed within 3 – 5 switch.
Starting System: 1I-6 Starting Motor Inspection Hold-in coil open circuit test S7RS0B1906003 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...
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1I-7 Starting System: Spring Inspect brush springs for wear, damage or other abnormal conditions. Replace if necessary. Brush spring tension Standard: 2.2 kg (4.85 lb) Limit: 0.6 kg (1.33 lb) Brush Holder • Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for I2RH01190016-01...
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Starting System: 1I-8 • Check the commutator and armature core. If there is Pinion and Over-Running Clutch continuity, the armature is grounded and must be • Inspect the pinion for wear, damage or other abnormal replaced. conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction.
1I-9 Starting System: Specifications Cranking System Specifications S7RS0B1907001 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.) Number of pinion teeth Performance Condition Guarantee...
Charging System: 1J-1 Charging System Engine General Description Battery Description Built-In Indicator (If Equipped) S7RS0B1A01001 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.
1J-2 Charging System: Generator Description S7RS0B1A01002 The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown below. I5JB0A1A0004-01 1. Pulley 6. Field coil 11. Rear housing IG: Ignition terminal 2. Pulley nut 7.
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Charging System: 1J-3 Charging System Circuit The generator features solid state regulator that it mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage is being controlled by ECM under some conditions while driving.
1J-4 Charging System: Diagnostic Information and Procedures Battery Inspection S7RS0B1A04001 Common Causes of Failure A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test but fails to operate properly for no apparent reason, the following are some factors that may point to the cause of trouble: •...
Charging System: 1J-5 Generator Test (Undercharged Battery Check) NOTE S7RS0B1A04003 Consideration should be taken that voltage This condition, as evidenced by slow cranking or will differ somewhat with regulator case indicator clear with dark or light yellow dot can be temperature as shown in figure.
1J-6 Charging System: Generator Test (Overcharged Battery Check) 3) If measured voltage is higher than upper limit value, S7RS0B1A04004 proceed to disassemble generator. 1) To determine battery condition, refer to “Battery 4) Check ground of brushes. If brushes are not Description”.
Charging System: 1J-7 With Charging Equipment Water Pump / Generator Drive Belt Tension Inspection and Adjustment CAUTION S7RS0B1A06003 WARNING When jump starting engine with charging equipment, be sure equipment used is 12- Disconnect negative cable at battery before volt and negative ground. Do not use 24-volt checking and adjusting belt tension.
1J-8 Charging System: Water Pump / Generator Drive Belt Removal and 3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tension to specification described Installation at step 2) by loosening / tightening generator adjust S7RS0B1A06004 Removal bolt (1).
Charging System: 1J-11 Generator Inspection S7RS0B1A06008 Rotor • 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.
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1J-12 Charging System: • Using an ohmmeter (1), check that there is no continuity between slip ring (2) and rotor core (3). If there is continuity, replace the rotor. I4RS0B1A0008-01 • Check slip rings for roughness or scoring. If rough or scored, replace the rotor. Stator Brush and Brush Holder Check each brush (1) for wear by measuring its length...
Charging System: 1J-13 Specifications Charging System Specifications S7RS0B1A07001 Battery Battery : 48AH/20H, 40.6AH/5H 12 V Nominal output 12 V Rated capacity 48 Ah/20 h 40.6 Ah/5 h Cold cranking amperes 300 A (DIN) Generator Type 80A type Rated voltage 12 V Nominal output Permissible max.
1K-1 Exhaust System: Exhaust System Engine General Description Exhaust System Description S7RS0B1B01001 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.
Exhaust System: 1K-2 Repair Instructions Exhaust System Components S7RS0B1B06001 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. I7RS0B1B0001-01 [A]: MT model 14.
1K-3 Exhaust System: Exhaust Manifold Removal and Installation S7RS0B1B06002 Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 1) Disconnect negative cable at battery. 2) Remove engine cover.
Exhaust System: 1K-4 2) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust manifold. Tighten pipe fasteners to specified torque. Tightening torque Exhaust No.1 pipe bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) 3) Install exhaust manifold stiffener (2). Tighten exhaust manifold stiffener bolts to specified torque.
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1K-5 Exhaust System: Specifications Tightening Torque Specifications S7RS0B1B07001 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.
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Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Tightening Torque Specifications......2B-20 Special Tools and Equipment ......2B-21 Precautions............. 2-1 Special Tool ............2B-21 Precautions on Suspension ........2-1 Rear Suspension ........2C-1 Suspension General Diagnosis....2A-1 General Description ..........2C-1 Diagnostic Information and Procedures....2A-1 Rear Suspension Construction ......2C-1 Suspension, Wheels and Tires Symptom...
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2-ii Table of Contents Balancing Wheels Description ......2D-5 Tire Repair ............2D-8 Tire Repair for Emergency Repaired-Tire with Repair Instructions ..........2D-6 Sealant ..............2D-8 General Balance Procedures ......2D-6 Tire Rotation............2D-6 Specifications ............2D-9 Wheel Removal and Installation......2D-7 Wheels and Tires Specifications ......2D-9 Tire Mounting and Dismounting ......2D-8 Tightening Torque Specifications......2D-9...
Precautions: Precautions Suspension Precautions Precautions on Suspension S7RS0B2000001 Emergency Flat Tire Repair Kit handle Warning Refer to “Warning for Handling Emergency Flat Tire Repair Kit in Section 00”. Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”.
2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S7RS0B2104001 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.
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Suspension General Diagnosis: 2A-2 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.
Front Suspension: 2B-2 Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S7RS0B2201002 excessive looseness is noted, it must be corrected Among factors for front wheel alignment, only toe setting before adjusting. can be adjusted. Camber and caster are not adjustable. •...
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2B-3 Front Suspension: Adjustment 1) Loosen right and left tie-rod end lock nuts (1) first. 2) Rotate right and left tie-rods (2) by the same amount to align toe to specification. In this adjustment, the lengths “A” of both right and left tie-rod should be equal.
Front Suspension: 2B-4 Reference Information Side slip 0 to IN 3.0 mm/m (0 to IN 0.118 in/3.3 ft) Side slip When checked with side slip tester, side slip should If side slip is greatly different, toe or front wheel satisfy following specification. alignment may not be correct.
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2B-5 Front Suspension: Tightening torque 5) Remove brake hose mounting bolt (1) and remove brake hose (2) from bracket and then wheel speed Strut bracket nut (a): 90 N·m (9.0 kgf-m, 65.5 lb-ft) sensor harness (3) from strut bracket as shown in Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m, figure.
Front Suspension: 2B-6 • Tighten wheel nuts to specified torque. Assembly For assembly, reverse disassembly procedure, noting Tightening torque the following instructions. Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) 1) Compress coil spring with special tool (A) until total •...
2B-7 Front Suspension: Front Strut Assembly Check 3) Install bump stopper onto strut rod. For installing direction, refer to the figure in “Front Suspension S7RS0B2206005 • Inspect strut for oil leakage, damage or deformation. Construction”. • 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.
Front Suspension: 2B-8 Front Wheel Hub and Steering Knuckle Components S7RS0B2206006 I7RS0B220005-03 1. Front wheel hub 3. Wheel bearing 5. Drive shaft nut : 200 N⋅m (20.0 kgf-m, 145 lb-ft) : Face grooved rubber seal side to wheel hub. : Calk, after tightening. 2.
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2B-9 Front Suspension: 8) Loosen strut bracket nuts (1). 14) Remove wheel bearing outside inner race (1). 9) Remove ball joint bolt (3) and nut (4). Special tool 10) Remove strut bracket bolts from strut bracket and (C): 09913-65810 then steering knuckle (2). (D): 09913–85230 I6RS0C220004-01 15) Remove hub bolts (1) with copper hammer or...
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Front Suspension: 2B-10 2) Face grooved rubber seal side (1) of new wheel 5) Caulk more than 6 places with a punch. bearing (2) upward as shown in figure and press-fit it into knuckle (3) using special tool. Special tool (A): 09913-75510 (B): 09926–68310 (C): 09951–18210...
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2B-11 Front Suspension: 7) Install ball joint bolt (1) and nut (2) from the direction 11) Connect tie-rod end to steering knuckle and then as shown in figure. install cotter pin referring to “Tie-Rod End Removal and Installation in Section 6C”. 8) Tighten new suspension control arm ball joint nut (2) to specified torque.
Front Suspension: 2B-12 Front Wheel Hub, Disc, Nut and Bearing Check Suspension Control Arm / Bushing Removal S7RS0B2206008 and Installation • Inspect each wheel disc for dents, distortion and S7RS0B2206009 cracks. CAUTION A disc in badly damaged condition must be replaced. When removing and installing steering •...
2B-13 Front Suspension: Installation Tightening torque Suspension control arm front bolt (a): 95 N·m ( 1) Install suspension control arm as shown but tighten 9.5 kgf-m, 68.0 lb-ft) new suspension control arm bolts (1) only Suspension control arm rear bolt (b): 95 N·m ( temporarily.
Front Suspension: 2B-14 Suspension Control Arm / Steering Knuckle Assembly Check 1) Front bushing S7RS0B2206011 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 S7RS0B2206012 Inspect for damage, wear or deterioration.
2B-15 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or Bushings Components S7RS0B2206014 I6RS0C220016-01 A: View A 4. Stabilizer bar mounting 8. Suspension control arm mounting bolt : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) bracket bolt 1. Stabilizer bar 5. Stabilizer joint 9.
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Front Suspension: 2B-16 4) Hoist vehicle and remove both wheels referring to 11) Remove engine rear mounting bolts (1) from engine “Wheel Removal and Installation in Section 2D”. rear mounting (2). 5) Remove cotter pins and tie-rod end nuts, and then disconnect both tie-rod ends from steering knuckles referring to “Tie-Rod End Removal and Installation in Section 6C”.
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2B-17 Front Suspension: 15) Remove stabilizer bar (1) and bushing from front 4) Mount steering gear case (1) to front suspension suspension frame (2). frame (2) and tighten gear case mounting No.1 bolts (3) and No.2 bolts (4) to specified torque. Tightening torque Steering gear case mounting No.1 bolt (a): 55 N·m (5.5 kgf-m, 40.0 lb-ft)
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Front Suspension: 2B-18 7) Tighten front suspension frame mounting bolts (a) to 11) Remove supporting device from engine. specified torque. 12) Install stabilizer joints (1), and tighten nuts to specified torque. Tightening torque When tightening, hold stud with special tools. Front suspension frame mounting bolt (a): 150 N·m (15.0 kgf-m, 108.5 lb-ft) Special tool...
2B-19 Front Suspension: Front Stabilizer Bar, Bushing and/or Joint 13) Install suspension control arm referring to “Suspension Control Arm / Bushing Removal and Check Installation”. S7RS0B2206017 Stabilizer Bar 14) Connect couplers of torque sensor and P/S motor. Inspect for damage or deformation. 15) Connect tie-rod ends to knuckles (right &...
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Front Suspension: 2B-20 Specifications Tightening Torque Specifications S7RS0B2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 32.5 Strut bracket nut 65.5 Brake hose mounting bolt 18.0 Stabilizer joint nut 36.5 Strut nut 36.5 Wheel nut 61.5 Strut support lower nut 36.5 Suspension control arm ball joint nut...
2C-2 Rear Suspension: Repair Instructions Rear Wheel Alignment Inspection Installation S7RS0B2306017 1) Install shock absorber (1), a pair of upper washers Measure toe and camber referring to “Front Wheel (2) and lower washer. Alignment Inspection and Adjustment in Section 2B”. Tighten new rear shock absorber upper nut (4) and NOTE lower nut temporarily at this step.
Rear Suspension: 2C-5 Installation 3) Remove floor jacks from rear axle. 1) Install coil spring (1) on spring seat (2) of rear axle 4) Install wheels and tighten wheel nuts to specified and mate spring open end with stepped part (3) of torque.
2C-6 Rear Suspension: Spring Upper Seat and Lower Seat Removal and Installation S7RS0B2306007 Removal 1) Remove coil spring referring to “Rear Coil Spring Removal and Installation”. 2) Remove spring upper seat (1) and lower seat (2). I4RS0A230017-01 A: Vehicle body side (Upper side) F: Vehicle front 3.
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Rear Suspension: 2C-7 3) Remove rear brake caliper assemblies (right & left) 9) Disconnect wheel speed sensor clamp and parking and brake discs (right & left). For details, refer to brake cable clamp from rear axle. Step 2) to 3) of “Removal” under “Rear Brake Disc Removal and Installation in Section 4C”.
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2C-8 Rear Suspension: 3) Install coil springs (right & left) on spring seats of rear 8) Install wheel speed sensor clamp and parking brake axle referring to “Spring Upper Seat and Lower Seat clamp and tighten parking brake clamp bolts (1) to Removal and Installation”...
Rear Suspension: 2C-9 Trailing Arm, Rear Axle and Coil Spring 12) Fill reservoir with brake fluid and bleed brake system. For bleeding operation, see “Air Bleeding of Inspection Brake System in Section 4A”. S7RS0B2306009 • Inspect for cracks, deformation or damage. 13) Install wheel and tighten wheel nuts to specified •...
Rear Suspension: 2C-11 Installation • Caulk new rear axle nut (1) as shown. Install wheel hub by reversing removal procedure noting CAUTION the following instructions. Take care while staking nut. If a split occurs • Insert new wheel stud bolt in wheel hub hole and in staked area of nut, replace it with new one.
2C-12 Rear Suspension: • Check noise and smooth rotation of wheel by rotating Installation wheel. If it is defective, replace bearing. 1) Install brake disc dust cover (1), spindle (2) and new spindle bolts (3) and then tighten spindle bolts to specified torque.
Rear Suspension: 2C-13 Spindle Inspection Rear Suspension Fasteners Inspection S7RS0B2306015 S7RS0B2306016 Check each bolt and nut fastening suspension parts for • Inspect for cracks, deformation or damage. tightness. Tighten loose one, if any, to specified torque Replace any defective part. referring to the figure in “Rear Suspension Construction”.
2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precaution for Emergency Flat Tire Repair Kit CAUTION S7RS0B2400001 WARNING • When tire repaired with Emergency Flat Tire Repair Kit is brought in, remove flat Flat tire repair sealant including in kit is tire repair sealant from tire and repair flat harmful.
Wheels and Tires: 2D-2 Wheels Description Lower than recommended pressure can cause: S7RS0B2401002 • Tire squeal on turns Wheel Maintenance • Hard Steering Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced. •...
2D-3 Wheels and Tires: Metric Lug Nuts and Wheel Studs All models use metric lug nuts and wheel studs. Metric lug nuts and wheel studs size M12 x 1.25 If broken stud or nut are found, be sure to replace both stud and nut with new one.
Wheels and Tires: 2D-4 Radial Tire Waddle Description S7RS0B2401005 Waddle is side to side movement at the front and/or rear of the vehicle. It is caused by the steel belt not being straight within the tire. It is most noticeable at a low speed, 8 to 48 kph (5 to 30 mph).
2D-5 Wheels and Tires: Radial Tire Lead / Pull Description Balancing Wheels Description S7RS0B2401006 S7RS0B2401007 “Lead / Pull” is the deviation of the vehicle from a straight There are two types of wheel and tire balance: static and path on a level road even with no pressure on the dynamic.
Wheels and Tires: 2D-6 Repair Instructions General Balance Procedures Tire Rotation S7RS0B2406001 S7RS0B2406002 Deposits of mud, etc. must be cleaned from inside of rim. To equalize wear, rotate tires according to figure. Radial tires should be rotated periodically. Set tire pressure. WARNING Stones should be removed from the tread in order to avoid operator injury during spin...
2D-7 Wheels and Tires: Wheel Removal and Installation For installation, reverse removal procedure, noting the S7RS0B2406003 following. Removal • Wheel nuts must be tightened in sequence and to specified torque to avoid bending wheel or brake disc. WARNING NOTE Do not removal all of the wheel nuts at once, because all the wheels of this vehicle are Before installing wheels, remove any build- mounted by the wheel nuts.
Wheels and Tires: 2D-8 Tire Mounting and Dismounting 1) Remove flat tire repair sealant from tire using plug S7RS0B2406004 (1), filler hose (2), sealant bottle (3) and extension CAUTION hose (4) in kit as follows. a) Remove plug from filler hose of sealant bottle. When installing tire which has arrow Then connect extension hose to tip of filler hose.
2D-9 Wheels and Tires: 2) Check tire if it can be repaired, referring to “Tire CAUTION Repair”. If it cannot be repaired, replace it with new Be sure to use new valve core. Otherwise, air one. leak may occur due to sealant attached to 3) Replace valve core of flat tire with new one if tire is valve core.
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Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Front Drive Shaft Assembly On-Vehicle Inspection............3A-4 Precautions............. 3-1 Front Drive Shaft Assembly Removal and Precautions for Driveline / Axle ......3-1 Installation ............3A-4 Drive Shaft / Axle ........3A-1 Front Drive Shaft Disassembly and Reassembly ............3A-6 General Description ..........3A-1...
Drive Shaft / Axle: 3A-1 Drive Shaft / Axle Driveline / Axle General Description Front Drive Shaft Construction S7RS0B3101001 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.
3A-2 Drive Shaft / Axle: Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S7RS0B3104001 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.
3A-4 Drive Shaft / Axle: [A]: Right side drive shaft assembly (M/T model) 8. Wheel side joint (Constant velocity ball joint) : Apply black grease included in spare part to joint. [B]: Left side drive shaft assembly (M/T model) 9. Center shaft side joint (Constant velocity tripod joint) : Apply dark gray grease included in spare part to joint.
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Drive Shaft / Axle: 3A-5 8) Disconnect front suspension control arm ball joint Installation stud from steering knuckle. CAUTION 9) Pull out drive shaft joint as follows. • For differential side • Be careful not to damage oil seals and Using tire lever (1), pull out drive shaft joint (2) so boots when installing drive shaft.
3A-6 Drive Shaft / Axle: Front Drive Shaft Disassembly and Reassembly 2) Wipe off grease from shaft and take off snap ring (1) S7RS0B3106004 using snap ring pliers (2). Disassembly Tripod joint CAUTION • Disassembly of wheel side joint is not allowed.
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Drive Shaft / Axle: 3A-7 CAUTION Disassembly of wheel side joint is not allowed. If any noise or damage exists in it, replace it as assembly. 1) Remove differential side (or center shaft side) boot big band (1) as follows. •...
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3A-8 Drive Shaft / Axle: Reassembly 1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air. Tripod joint Judging from abnormality noted before disassembly and 2) Clean boots with cloth. what is found through visual check of component parts 3) Apply grease to wheel side joint.
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Drive Shaft / Axle: 3A-9 7) Fasten boot bands (1) securely using special tool as 8) Set new differential side (or center shaft side) small shown in figure. band and new differential side (or center shaft side) boot (1) on shaft temporarily, and then apply grease Distance “a”...
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3A-10 Drive Shaft / Axle: 11) Fit boot (1) to grooves of shaft and housing (2) adjust 14) Fasten differential side (or center shaft side) boot length to specification below. band. 12) Insert screw driver into boot and allow air to enter •...
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Drive Shaft / Axle: 3A-11 Judging from abnormality noted before disassembly and what is found through visual check of components 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. Replace boot(s) with new one(s).
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3A-12 Drive Shaft / Axle: 10) Set new differential side (or center shaft side) small band and new differential side (or center shaft side) boot on shaft temporarily. 11) Drive in the cage (1) by using special tool. Special tool (A): 09913–84510 I5RS0B310011-02 16) Fit boot (1) to grooves of shaft and housing (2) adjust...
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Drive Shaft / Axle: 3A-13 18) Place differential side boot (or center shaft side) new big band (3) and new small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure. I5JB0A311006-01 19) Fasten differential side (or center shaft side) boot band.
Remove bearing support circlip (1) using snap ring pliers (2) and then remove center bearing “A”: Grease 99000–25011 (SUZUKI Super Grease from center bearing support. M/T model a) Remove bearing support circlip (1) using snap ring pliers (2) and then remove center bearing from center bearing support.
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 S7RS0B3108001 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.
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Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Recommended Service Material .......4A-18 Precautions............. 4-1 Front Brakes ..........4B-1 Precautions for Brakes.......... 4-1 Repair Instructions ..........4B-1 Brake Control System and Diagnosis ... 4A-1 Front Disc Brake Components ......4B-1 Front Disc Brake Pad On-Vehicle Inspection..4B-2 Precautions............4A-1 Front Disc Brake Pad Removal and...
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4-ii Table of Contents Repair Instructions ..........4D-2 DTC U1073: Control Module Communication Parking Brake Inspection and Adjustment ..4D-2 Bus Off ............4E-25 Parking Brake Cable Removal and DTC U1100: Lost Communication with ECM Installation ............4D-3 (Reception Error)..........4E-27 Parking Brake Lever Removal and Installation ..4D-3 Repair Instructions ..........4E-28 Specifications............4D-4 ABS Hydraulic Unit Operation Check....4E-28...
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Table of Contents 4-iii ABS Warning Lamp Check ....... 4F-14 DTC C1073: Lost Communication With Yaw EBD Warning Lamp (Brake Warning Lamp) Rate / G Sensor Assembly......4F-45 Check.............. 4F-15 DTC C1075 / 1076 / 1078: Sensor Calibration DTC Check ............4F-15 Incomplete............
4-1 Precautions: Precautions Brakes Precautions Precautions for Brakes S7RS0B4000001 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”. ESP®...
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brakes Precautions Precautions on Brake S7RS0B4100001 Air Bag Warning Refer to “Air Bag System Service Warning in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note”. General Description Brakes Construction S7RS0B4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two...
4A-2 Brake Control System and Diagnosis: Brake Pedal Foot Protection System Construction S7RS0B4101004 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.
4A-4 Brake Control System and Diagnosis: [A]: ABS model 6. Master cylinder 13. ESP® hydraulic unit [B]: ESP® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft) 1. From master cylinder primary to hydraulic unit 8.
Brake Control System and Diagnosis: 4A-5 If deterioration of rubber is evident, disassemble all If master cylinder piston seals are satisfactory, check for hydraulic parts and wash with alcohol. Dry these parts leakage or excessive heat conditions. If leakage is not with compressed air before assembly to keep alcohol out found, drain fluid, flush with brake fluid, refill and bleed of the system.
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4A-6 Brake Control System and Diagnosis: Condition Possible cause Correction / Reference Item Pedal pulsation (Pedal Damaged or loose wheel bearings Replace wheel bearings. pulsates when depressed Distorted steering knuckle or rear wheel Replace knuckle or rear wheel spindle. for braking) spindle Excessive disc lateral runout Check per instructions.
Brake Control System and Diagnosis: 4A-7 Repair Instructions Brake Pedal Components 2) Check measurement between booster mounting S7RS0B4106019 surface and center of clevis pin hole. When booster CAUTION push rod clevis has been reinstalled, it is important that the measurement is adjusted (refer to “Brake Never disassemble brake pedalassembly.
4A-8 Brake Control System and Diagnosis: Excessive Pedal Travel Inspection NOTE S7RS0B4106003 Be sure to use particular brake fluid either as 1) Start engine. indicated on reservoir cap of that vehicle or 2) Depress brake pedal a few times. recommended in owner’s manual which 3) With brake pedal depressed with approximately 300 comes along with that vehicle.
Brake Control System and Diagnosis: 4A-9 Air Bleeding of Brake System 2) Remove bleeder plug cap. Attach a vinyl tube (1) to S7RS0B4106006 bleeder plug, and insert the other end into container CAUTION (2). Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface.
4A-10 Brake Control System and Diagnosis: Rear Brake Hose / Pipe Removal and 7) Then attach bleeder plug cap. Installation 8) After completing bleeding operation, apply fluid S7RS0B4106008 pressure to pipe line and check for leakage. CAUTION 9) Replenish fluid into reservoir up to specified level. Do not allow brake fluid to get on painted surfaces.
Brake Control System and Diagnosis: 4A-11 Brake Hose and Pipe Inspection S7RS0B4106009 Hose The brake hose assembly should be checked for road hazard damage, for cracks and chafing of outer cover, for leaks and blisters. A light and mirror may be needed for an adequate inspection.
4A-12 Brake Control System and Diagnosis: Master Cylinder Assembly Removal and 7) Remove master cylinder and master cylinder seal. Installation Installation S7RS0B4106011 1) Install new master cylinder seal. CAUTION 2) Apply small amount of silicon grease (included in Do not allow brake fluid to get on painted spare parts) to piston rod.
Brake Control System and Diagnosis: 4A-13 7) Remove reservoir bolt (1). 6) Connect clutch reservoir hose (1) to reservoir (2) and install reservoir hose clamp (3) (M/T model). 8) Remove reservoir (2) and grommets (3). I4RS0A410023-01 7) Fill reservoir with specified brake fluid up to its MAX I4RS0A410011-01 mark.
4A-14 Brake Control System and Diagnosis: Assembly 6) Fill reservoir with specified fluid. 7) After completing the work, bleed air from brake and CAUTION clutch system referring to “Air Bleeding of Brake System” and “Air Bleeding of Clutch System in •...
Brake Control System and Diagnosis: 4A-15 Master Cylinder Assembly Inspection 5) Apply small amount of rubber grease (included in spare parts) to mating surface of “a” (piston cup (3) S7RS0B4106014 Inspect all disassembled parts for wear or damage, and and piston guide (1)) and “b” piston guide (1) and O- replace parts if necessary.
4A-16 Brake Control System and Diagnosis: Booster Operation Inspection Check Operation S7RS0B4106016 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.
Brake Control System and Diagnosis: 4A-17 2) Hold brake pedal depressed for 30 seconds. If pedal Installation height does not change, condition is good. But it isn’t 1) Loosen brake pedal bracket mounting bolt. if pedal rises. 2) Install booster (2) to dash panel. Then connect push rod clevis (3) to pedal arm with clevis pin (1) and clip (4).
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4A-18 Brake Control System and Diagnosis: 10) Check pedal height and play referring to “Brake Distance “a” between center of booster clevis pin Pedal Free Height Inspection” and “Brake Pedal hole and booster surface Play Inspection”. Standard: 114.5 – 115.5 mm (4.51 – 4.54 in.) 11) Check each installed part for fluid leakage and perform brake test.
4B-2 Front Brakes: Front Disc Brake Pad On-Vehicle Inspection 3) Remove caliper (1) from caliper carrier (2). S7RS0B4206002 Inspect pad linings (1) periodically according to NOTE maintenance schedule whenever wheels are removed Hang removed caliper (1) with a wire hook (4) (for tire rotation or other reason).
Front Brakes: 4B-3 NOTE 2) Set brake pad springs (1), shim (2) and install brake pads (3). When pads are removed, visually inspect caliper for brake fluid leak. Correct leaky NOTE point, if any. Install right side brake pad with wear indicator (4) to vehicle center side.
4B-4 Front Brakes: Installation Front Disc Brake Caliper Disassembly and Assembly 1) Torque caliper pin bolts (a) to specification. S7RS0B4206006 NOTE Disassembly • Make sure that boots are fit into groove CAUTION securely. • If brake pads are replaced, use new caliper •...
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Front Brakes: 4B-5 Assembly 2) Before inserting piston (1) into cylinder, apply rubber Assemble parts in reverse order of disassembly, grease (included in repair kit) or brake fluid to new observing the following instructions. boot “a” and install it onto piston as shown. CAUTION •...
4B-6 Front Brakes: 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 S7RS0B4206008 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.
Front Brakes: 4B-7 Front Brake Disc Inspection Installation S7RS0B4206009 1) Install disc to wheel hub. • Install wheel nuts to hub bolts and fasten to fix the 2) Install caliper assembly to steering knuckle. brake disc. 3) Torque caliper carrier bolts to specification. Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of Tightening torque...
4C-2 Rear Brakes: Rear Disc Brake Pad Removal and Installation Installation S7RS0B4306002 1) Turn brake caliper piston clockwise to obtain NOTE clearance between brake disc and pads. When replacing brake pad, replace it on the Special tool right and left. (A): 09945–16060 Removal 1) Hoist vehicle and remove wheel.
Rear Brakes: 4C-3 Rear Disc Brake Caliper Removal and 6) With lug (1) of brake pad matched with dent (2) of brake piston, install caliper (3) to caliper carrier. Installation S7RS0B4306003 7) Tighten caliper pin bolts (4) to specified torque. CAUTION Tightening torque Do not allow brake fluid to get on painted...
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4C-4 Rear Brakes: 5) Remove caliper pin bolts (1). Installation 6) Remove caliper (2) from brake caliper carrier (3). 1) Install brake caliper carrier (1) to spindle (2). Tightening torque Brake caliper carrier bolt (a): 60 N·m (6.0 kgf-m, 43.5 lb-ft) I6RS0C430008-01 7) Disconnect parking brake cable (1) from lever (2) while rotating lever in direction of arrow.
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Rear Brakes: 4C-5 4) Pass parking brake cable (1) through bracket (3) of 8) Install brake cable clip (1) securely to bracket (2). caliper. 5) Hang parking brake cable on lever (2) as follows. NOTE Make sure that lever (4) contacts pin (5). I6RS0C430012-01 9) After reassembling brake lines, bleed air from them referring to “Air Bleeding of Brake System in Section...
4C-6 Rear Brakes: Rear Disc Brake Pad Inspection S7RS0B4306004 Check pad lining for wear. When wear exceeds limit, replace with new one. CAUTION Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc.
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Rear Brakes: 4C-7 Assembly 4) Install bleeder plug and cap to caliper. 5) Install new piston seal to caliper. CAUTION 6) Before inserting piston (2) into cylinder, install boot • Wash each part cleanly before installation (1) onto piston as shown. in the same fluid as the one used in master cylinder reservoir.
Rear Brakes: 4C-11 Special Tools and Equipment Recommended Service Material S7RS0B4308001 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following. “Rear Disc Brake Components”...
4D-1 Parking Brake: Parking Brake Brakes General Description Parking Brake Cable Construction S7RS0B4401001 I6RS0B440001-01 T: Top side 3. Equalizer 8. Lever [C]: View [C] F: Front side 4. Parking cable bracket 9. Parking cable clamp bolt [D]: View [D] R: Right side 5.
Parking Brake: 4D-2 Repair Instructions Parking Brake Inspection and Adjustment 1) Release parking brake lever (1). S7RS0B4406001 2) Loosen parking brake lever adjust nut (2) fully. Inspection Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches.
4D-3 Parking Brake: Parking Brake Lever Removal and Installation 6) Release parking brake lever and then make sure that there is no drag in rear wheel. S7RS0B4406003 If there is, repeats go to step 2). Removal 7) Make sure that the number of notch is between 4 1) Remove console box.
Parking Brake: 4D-4 Installation 2) After all parts are installed, parking brake lever needs to be adjusted. Refer to “Parking Brake 1) Install in reverse order of removal procedure. Inspection and Adjustment”. Check equalizer inclined angle. 3) Check brake drum or disc for dragging and brake Tightening torque system for proper performance.
Mobile Communication Equipment in Section 00” memory can be cleared as well as checked by using before inspection and handle CAN communication SUZUKI scan tool. Before using scan tool, read its line. Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and Precautions in On-Vehicle Service how to use it.
ABS: 4E-2 General Description ABS Description ABS Hydraulic Unit / Control Module Assembly S7RS0B4501001 Description The ABS (Antilock Brake System) controls the fluid S7RS0B4501002 pressure applied to the wheel cylinder of each brake ABS control module is a component of ABS hydraulic from the master cylinder so that each wheel is not locked unit / control module assembly and has the following even when hard braking is applied.
4E-3 ABS: CAN Communication System Description S7RS0B4501003 Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. ABS communicates control data with each control module as follows. ABS Transmission Data Combination meter Torque request Wheel speed signal (front right) Wheel speed signal (front left) Wheel speed signal (rear right) ABS control...
ABS: 4E-8 Rear Wheel Speed Sensor Components Location S7RS0B4503003 I6RS0C450006-01 [A]: OK 1. Rear wheel speed sensor 3. Connector : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) [B]: NG 2. Sensor ring 4. Grommet Diagnostic Information and Procedures ABS Check S7RS0B4504001 Refer to the following items for the details of each step.
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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.
ABS: 4E-10 ABS Warning Light Check Problem symptom confirmation Check if what the customer claimed in “Customer S7RS0B4504002 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.
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Inlet solenoid valve circuit 4) Read DTC according to instructions displayed on C1052 Outlet solenoid valve circuit SUZUKI scan tool and print it or write it down. Refer C1055 Inlet solenoid valve circuit to SUZUKI scan tool operator’s manual for further...
SUZUKI turn it) scan tool. • Turn OFF all electric loads (except ignition). 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection • No DTC. for DTC check.
ABS: 4E-14 Step Action Check CAN communication circuit between combination Go to Step 5. Repair or replace. meter and ABS control module referring to “DTC U1073: Control Module Communication Bus Off”. Is CAN communication circuit in good condition? 1) Remove combination meter with ignition switch turned Go to Step 6.
4E-15 ABS: Step Action 1) Turn ignition switch to OFF and measure resistance Go to Step 6. Ground circuit for ABS between each terminal of “E03-13”, “E03-26” and vehicle hydraulic unit / control body ground. module open or high resistance. Ω...
4E-17 ABS: Step Action 1) Turn ignition switch to OFF position. Go to Step 6. Ground circuit for ABS hydraulic unit / control 2) Check for proper connection to ABS hydraulic unit / module open or high control module connector at terminals “E03-13” and resistance.
4E-21 ABS: DTC C1057: Power Source Circuit S7RS0B4504014 Wiring Diagram WHT/BLU E03-14 E03-13 E03-26 I6RS0C450011-01 [A]: ABS hydraulic unit / control module connector 2. Main fuse box (viewed from terminal side) 1. Battery 3. ABS hydraulic unit / control module assembly DTC Detecting Condition The ABS control module monitors the power source voltage at terminal “E03-14”.
ABS: 4E-22 Step Action 1) Measure voltage between terminals “E03-14” and “E03- Poor connection of Check charging system 13” with engine running. “E03-14” and/or “E03- referring to “Generator 13” terminals. If the Test (Overcharged ± Is voltage 18 1.0 V or less? terminals are in good Battery Check) in condition, substitute a...
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ABS: 4E-26 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. 1) Check connection of connectors of all control modules Go to Step 3. Intermittent trouble. communicating by means of CAN. Check for intermittent 2) Recheck DTC.
4E-27 ABS: DTC U1100: Lost Communication with ECM (Reception Error) S7RS0B4504019 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off”. DTC Detecting Condition Reception error of communication data for ECM is detected more than specified time continuously. DTC Troubleshooting Step Action Was “ABS Check”...
3) Lift up vehicle. Brake pedal (1) should be depressed and then select 4) Set transmission to neutral and release parking testing wheel by SUZUKI scan tool and the wheel (2) brake. should be turned by another person’s hand. At this...
4E-29 ABS: ABS Hydraulic Unit / Control Module Assembly Components S7RS0B4506002 CAUTION Never disassemble ABS hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit / control module assembly.
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ABS: 4E-30 3) Using special tool, loosen flare nuts (1) and 4) Remove ABS hydraulic unit / control module with disconnect brake pipes (2) from ABS hydraulic unit / bracket from vehicle by removing three bracket bolts. control module assembly (3). 5) Remove bolt and pull out ABS hydraulic unit / control module assembly (1) from bracket (3) using flat end Special tool...
4E-31 ABS: 2) Bleed air from brake system referring to “Air 6) Measure voltage at resistance without wheel Bleeding of Brake System in Section 4A”. rotation. If voltage is out of specification, check sensor, 3) Check each installed part for fluid leakage and mating encoder and their installation conditions.
ABS: 4E-32 Front Wheel Speed Sensor Removal and Installation Installation 1) Check that no foreign material is attached to sensor S7RS0B4506006 (1) and sensor ring (2). 2) Install it by reversing removal procedure. Removal 1) Disconnect negative cable from battery. Tightening torque Front wheel speed sensor bolt (a): 25 N·m (2.5 2) Disconnect front wheel speed sensor coupler (1).
4E-33 ABS: Rear Wheel Speed Sensor Removal and Installation Reverse removal procedure for installation noting the Installation following. S7RS0B4506008 • Check that no foreign material is attached to sensor Removal (1) and mating encoder (2). 1) Disconnect negative (–) cable from battery. •...
ABS: 4E-34 Rear Wheel Speed Sensor Inspection Rear Wheel Encoder On-Vehicle Inspection S7RS0B4506009 S7RS0B4506012 Refer to “Front Wheel Speed Sensor Inspection” since Before inspect rear wheel encoder, hoist vehicle and rear wheel speed sensor is the same as front wheel remove wheel.
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S7RS0B4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
• Diagnostic information stored in ESP® 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.
ESP® OFF switch or using SUZUKI scan tool to complete the tests correctly. When using SUZUKI scan tool, set to the “MISC. TEST” mode to stop the ESP® function. Refer to SUZUKI scan tool operator's manual for further details.
Electronic Stability Program: 4F-5 Yaw rate / G sensor The yaw rate / G sensor consists of the yaw rate (angular velocity in the vehicle turning direction) sensor and right-left G (acceleration in right-left direction) sensor and is mounted to the P/S controller B/K at the lower part of the center console.
4F-6 Electronic Stability Program: Warning Lamp, Indicator Lamp Description S7RS0B4601003 There are five types of warning lamp and indicator lamp in instrument cluster, which are controlled by ESP® control module. They give warning / indication to driver by changing the modes light ON / blinking / light OFF. I6RS0B460002-01 1.
Electronic Stability Program: 4F-7 ESP® Control Module Reception Data Steering angle sensor Engine torque signal Accelerator pedal position signal Engine speed signal Brake pedal switch signal ESP® control Receive DATA module Brake fluid level switch signal Parking brake switch signal Steering angle signal Steering angle sensor related malfunction I7RS0B460005-01...
4F-12 Electronic Stability Program: Diagnostic Information and Procedures Electronic Stability Program System Check S7RS0B4604001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”.
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Electronic Stability Program: 4F-13 Customer questionnaire (Example) I6JB01460011-02 Problem symptom confirmation If symptom in “Customer Questionnaire” is found or reproduced in the vehicle, confirm the symptom is problem or not. (This step should be done with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check”, “ABS Warning Lamp Check”...
4F-14 Electronic Stability Program: Step 2: Driving Test Test the vehicle at 40 km/h for more than a minute including left and right turns and check if any trouble symptom (such as ESP® warning lamp and/or ABS warning lamp) exists. If the malfunction DTC is confirmed at ignition switch ON, proceed to Step 3.
I4RS0B450003-01 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on I4RS0A450008-01 SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. NOTE If SUZUKI scan tool can not communicate ESP®...
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4F-16 Electronic Stability Program: DTC (displayed ESP® Detecting condition (DTC will on SUZUKI scan Diagnostic Items warning warning warning beset when detecting) tool) lamp lamp lamp Right-front wheel speed Abnormal wheel speed sensor C1022 sensor or encoder failure signal is detected.
When performing a driving test, select a safe place where there is neither any traffic nor any traffic accident possibility and be very careful during testing to avoid occurrence of an accident. 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check.
Electronic Stability Program: 4F-19 Fail-Safe Table S7RS0B4604023 When any of the following DTC(s) is detected, ESP® system is in fail-safe mode per its DTC and ABS, EBD and/or TCS / stability functions are deactivated until the resolution is applied. Fail-safe operation DTC No.
4F-20 Electronic Stability Program: NOTE • : Activated • X: Deactivated • *1: If two or more wheel speed sensor are defective, ABS warning lamp, EBD warning lamp and ESP® warning lamp are lit and all the control functions are deactivated. If one wheel speed sensor is defective, ABS warning lamp and ESP®...
Electronic Stability Program: 4F-21 Stability control (ACTIVE, INACTIVE): This indicates ESP® off state (cont) (ESP® ON, ESP® OFF): State stability control in activation / deactivation. of ESP® OFF switch. TCS control (brake) (ACTIVE, INACTIVE): This Steering angle Sen (Neutral, NON newtral): This indicates brake function of TCS in activation / indicates steering wheel angle measured by steering deactivation.
4F-22 Electronic Stability Program: Troubleshooting Step Action Check warning lamp Substitute a known- Go to Step 2. good combination meter 1) Turn ignition switch to ON position. and recheck. If ESP® Do other warning lamps come ON? warning lamp remains OFF, substitute a known-good ESP®...
Electronic Stability Program: 4F-23 Step Action Check ESP® control module power supply circuit Go to Step 5. “WHT/BLU” and/or “WHT/RED” circuit 1) Turn ignition switch to OFF position. open. 2) Check for proper connection to ESP® control module connector at terminals “E85-1” and “E85-32”. 3) If OK, then turn ignition switch to ON position and measure voltage between each terminal of “E85-1”, “E85-32”...
4F-24 Electronic Stability Program: Circuit Description Operation (ON/OFF) of ABS warning lamp is controlled by ESP® control module through lamp driver module in combination meter. If antilock brake system is in good condition, ESP® control module turns ABS warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.
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Electronic Stability Program: 4F-25 Circuit Description EBD warning lamp (brake warning lamp) is controlled by ESP® control module and BCM through lamp driver module in combination meter. If EBD system is in good condition, ESP® control module turns EBD warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.
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Electronic Stability Program: 4F-27 Step Action Check ESP® control module power supply circuit Go to Step 5. “WHT/BLU” and/or “WHT/RED” wire circuit 1) Turn ignition switch to OFF position. open. 2) Check for proper connection to ESP® control module connector at terminals “E85-1” and “E85-32”. 3) If OK, then turn ignition switch to ON position and measure voltage between each terminal of “E85-1”, “E85-32”...
4F-28 Electronic Stability Program: Step Action Check serial data circuit Substitute a known- Check high resistance good ESP® hydraulic or open in “PPL/WHT” 1) Turn ignition switch to OFF position. unit / control module wire circuit for electronic 2) Check proper connection at “E85-33” (“PPL/WHT” wire) and recheck.
Electronic Stability Program: 4F-29 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Vehicle behavior and stop lamp switch signal is disagreed • Back up light switch circuit for specified time. • Back up light switch • ECM •...
4F-30 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
Electronic Stability Program: 4F-31 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check brake fluid level Go to Step 3. Replenish brake fluid to reservoir. 1) Check brake fluid level in reservoir. Is brake fluid level upper than the minimum level? DTC check for ESP®...
4F-34 Electronic Stability Program: Step Action Check wheel speed sensor Substitute a known- Replace wheel speed good ESP® hydraulic sensor and recheck. 1) Refer to “Front / Rear Wheel Speed Sensor On-Vehicle unit / control module Inspection”, check output voltage or waveform. assembly and recheck.
Electronic Stability Program: 4F-35 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Mechanical switch failure, failure in switch wiring is • ESP® OFF switch shorted to ground. • ESP® OFF switch circuit • ESP® control module DTC Troubleshooting Step Action Was “Electronic Stability Program Check”...
Electronic Stability Program: 4F-37 Step Action Check yaw rate / G sensor assembly power supply Go to Step 5. “BLU/RED” wire circuit circuit is shorted to power circuit. 1) Turn ignition switch to OFF position. 2) Disconnect ESP® control module connector. 3) Check for proper connection to ESP®...
4F-38 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2 Go to “Electronic Stability Program System Check”. Check fuse Go to Step 3. Replace fuse and check for short circuit to 1) Check circuit fuses for steering angle sensor and its ground.
Electronic Stability Program: 4F-39 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check DTC Go to applicable DTC Substitute a known- diag. flow. good steering angle 1) Connect scan tool to DLC with ignition switch turned sensor and recheck.
4F-42 Electronic Stability Program: Step Action Check power supply circuit from battery Poor connection of Check charging system “E85-1”, “E85-16” and/ referring to “Generator 1) Measure voltage between terminals “E85-1” and “E85- or “E85-47” terminals. If Test (Overcharged 16”, “E85- 47" with engine running. the terminals are in Battery Check) in ±...
Electronic Stability Program: 4F-43 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check ESP® control module power supply circuit Go to Step 3. “WHT/RED” circuit open. 1) Turn Ignition switch to OFF position. 2) Disconnect ESP®...
4F-44 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check power supply circuit from battery Go to Step 3. Check charging system referring to “Battery 1) Check battery voltage.
4F-46 Electronic Stability Program: Step Action Check yaw rate / G sensor assembly Check ESP® control Yaw rate / G sensor module power and assembly was 1) Check yaw rate / G sensor assembly power and ground ground circuit. If circuits malfunction.
Electronic Stability Program: 4F-47 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
4F-48 Electronic Stability Program: DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control Communication with S7RS0B4604041 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area C1091: • Engine control system ECM sent invalid signal to ESP® control module. •...
4F-50 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to Step 3. Intermittent trouble. Check for intermittent 1) Check connection of connectors of all control modules referring to “Intermittent communicating by means of CAN.
Electronic Stability Program: 4F-51 Step Action Check each control module connectors Go to Step 5. Check for intermittent trouble referring to 1) Check connection of connectors of all control modules “Intermittent and Poor communicating by means of CAN. Connection Inspection 2) Check DTC for ESP®.
4F-52 Electronic Stability Program: Step Action Check each control module connectors Go to Step 4. Check for intermittent trouble referring to 1) Check connection of connectors of all control modules “Intermittent and Poor communicating by means of CAN. Connection Inspection 2) Check DTC for ESP®.
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Electronic Stability Program: 4F-53 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to “DTC U1073: Go to Step 3. Control Module 1) Check DTC for ESP®. Communication Bus Is DTC U1140 and DTC U1073 detected together? Off”.
Step off brake pedal (1) and then select testing 1) Check that basic brake system other than ESP® is wheel by SUZUKI scan tool and the wheel (2) in good condition. should be turned by another person’s hand. At this time, check whether the wheel locks due to brake 2) Check that battery voltage is 11 V or higher.
SUZUKI Scan Tool) 1) Set steering wheel in straight-ahead position. 1) Set steering wheel in straight-ahead position. 2) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. 2) Connect battery terminals and/or fuse and start engine.
4F-56 Electronic Stability Program: ESP® Hydraulic Unit / Control Module Assembly Removal and Installation S7RS0B4606037 CAUTION Never disassemble ESP® hydraulic unit / control module assembly loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ESP® hydraulic unit / control module assembly.
4F-58 Electronic Stability Program: Front Wheel Speed Sensor Removal and 6) Measure voltage at resistance without wheel rotation. Installation If voltage is out of specification, check sensor, S7RS0B4606029 mating encoder and their installation conditions. Removal Voltage at the resistance (115 Ω) without wheel 1) Disconnect negative (–) cable from battery.
Electronic Stability Program: 4F-59 Front Wheel Speed Sensor Inspection Installation S7RS0B4606030 Check sensor for damage. CAUTION If any malcondition is found, replace. Do not pull or twist wire harness more than necessary when installing front wheel speed sensor. 1) Check that no foreign material is attached to sensor(1) and mating encoder (2).
If front wheel encoder needs refer to “Brakes Diagnosis Note in Section 4A”. to replaced, replace it as a front wheel 3) Connect SUZUKI scan tool to data link connector bearing. (DLC) (1) with ignition switch OFF. Special tool...
Before each inspection, confirm steering angle sensor calibration is completed. If calibration is incompleted, calibrate sensor referring to “Sensor Calibration”. 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool I6RS0B460041-02 3) Connect connector to yaw rate / G sensor assembly.
2) Remove rear console box referring to “Console Box 3) Check “Steering angle Sen” under “DATA LIST” of Components in Section 9H”. SUZUKI scan tool in the following steering wheel conditions. 3) Disconnect ESP® OFF switch coupler. • Front wheels in straight-ahead position 4) Remove ESP®...
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation” Special Tools and Equipment Special Tool S7RS0B4608001 09956–02311 SUZUKI scan tool Brake pressure gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
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Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 No Gear Shift to 4th gear ........5A-41 No Lock-Up Occurs...........5A-42 Precautions............. 5-1 Transmission Warning Light Circuit Check – Precautions on Transmission / Transaxle ..... 5-1 Light Does Not Come “ON” at Ignition Switch Automatic Transmission/Transaxle..
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5-ii Table of Contents DTC P1878: Torque Converter Clutch Automatic Transaxle Unit Disassembly...5A-110 Shudder ............5A-75 Oil Pump Assembly Components ....5A-121 DTC P2762: Torque Converter Clutch (TCC) Oil Pump Assembly Disassembly and Pressure Control Solenoid Control Circuit Reassembly ..........5A-122 Range /Performance ........5A-76 Oil Pump Assembly Inspection .......5A-122 DTC P2763: Torque Converter Clutch Direct Clutch Assembly Components....5A-124...
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Table of Contents 5-iii Gear Shift Control Lever and Cable Special Tool ............5B-36 Components............5B-5 Clutch ............5C-1 Gear Shift Control Lever and Cable Removal and Installation ..........5B-6 General Description ..........5C-1 Gear Select Control Cable Adjustment ....5B-6 Clutch Construction..........5C-1 Back Up Light Switch Removal and Diagnostic Information and Procedures ....5C-2 Installation ............
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions on Transmission / Transaxle S7RS0B5000001 Air Bag Warning Refer to “Air Bag System Service 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”.
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• 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 generic scan tool. Before using scan tool, read component, the following cautions should be strictly its Operator’s (Instruction) Manual carefully to have...
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5A-2 Automatic Transmission/Transaxle: • A new discs should be soaked in ATF at least 2 hours CAUTION before use. • Keep component parts in group for each subassembly and avoid mixing them up. Part Inspection and Correction Table • Clean all parts with cleaning solvent Part Inspect for Correction...
Automatic Transmission/Transaxle: 5A-3 General Description A/T Description S7RS0B5101001 This automatic transaxle is electronic control full automatic transaxle with forward 4-speed 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.
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5A-4 Automatic Transmission/Transaxle: 20 21 22 I3RM0B510001-01 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.
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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...
DTC in its memory. slot unless select lever is in “P” range. • It is possible to communicate with TCM through data link connector (DLC) (3) by using SUZUKI scan tool Shift Lock Solenoid Manual Release (2). Diagnostic information can be checked and When push down shift lock solenoid valve release button erased by using SUZUKI scan tool.
Automatic Transmission/Transaxle: 5A-9 CAN Communication System Description S7RS0B5101007 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 Combination meter Transmission oil temperarure signal Torque request signal Vehicle speed pulse signal...
5A-12 Automatic Transmission/Transaxle: Automatic Gear Shift Table S7RS0B5102002 Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D, 3, 2 position. 1. Shift Point in D, 3 or 2 position Throttle opening (%) Shift Vehicle speed km/h (mph)
Automatic Transmission/Transaxle: 5A-13 Component Location Electronic Shift Control System Components Location S7RS0B5103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RS0C510006-01 1. Engine 8. TCC pressure control solenoid valve (TCC 15.
Automatic Transmission/Transaxle: 5A-15 Diagnostic Information and Procedures A/T System Check S7RS0B5104001 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...
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5A-16 Automatic Transmission/Transaxle: 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.
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Automatic Transmission/Transaxle: 5A-17 Step 2. DTC / Freeze Frame Data Check, Record and Clearance First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been restored.
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5A-18 Automatic Transmission/Transaxle: Visual Inspection S7RS0B5104002 Visually check the following parts and systems. Inspection item Referring • A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in Section 0B” • A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement” •...
Automatic Transmission/Transaxle: 5A-19 DTC Table S7RS0B5104005 NOTE • A: Driving cycles when transmission warning light lighting and storing DTC in TCM memory. • *1: Transmission warning light does not light up but TCM detects and stores DTC. • For details of driving cycle, refer to “On-Board Diagnostic System Description”. Detecting condition DTC No.
TCM connector). • When the same malfunction (DTC) is not detected again during 40 engine warm-up cycles. 1) Turn ignition switch OFF. 2) Connect SUZUKI scan tool to data link connector (DLC) (1). Special tool I4RS0B510004-01 (A): SUZUKI scan tool 3) Read DTC according to instructions displayed on SUZUKI scan tool and write it down.
Automatic Transmission/Transaxle: 5A-21 Fail-Safe Table S7RS0B5104008 This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The following table shows the fail-safe function for each fail condition of sensor, solenoid or its circuit. DTC No.
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5A-22 Automatic Transmission/Transaxle: DTC No. Trouble area Fail-safe operation • Power supply for all solenoid valves is cut. • Gear position is fixed in 3rd gear. Internal control module memory check P1702 sum error • Line pressure control at gear shifting is inhibited. •...
Automatic Transmission/Transaxle: 5A-23 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. •...
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5A-24 Automatic Transmission/Transaxle: Normal condition / reference Scan tool data Vehicle condition values ENGINE SPEED At engine idle speed Engine idle speed is displayed Ignition switch ON and engine stop 0 RPM INPUT SHAFT At 60 km/h (37.5 mile/h) constant speed, 20% or less 2300 RPM REVOLUTION throttle opening and 3rd gear (“3”...
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Automatic Transmission/Transaxle: 5A-25 Normal condition / reference Scan tool data Vehicle condition values While on gear upshifting with 25% or more throttle TORQUE opening REDUCTION SIGNAL Under condition of not shifting gear ENGINE COOLANT Engine coolant temperature is Ignition switch ON TEMPERATURE displayed AIR CONDITIONER...
5A-26 Automatic Transmission/Transaxle: TRANSAXLE RANGE AIR CONDITIONER SIGNAL Transaxle range detected by signal fed from ON: Signal which inform that air conditioner compressor transmission range sensor. is turned ON. OFF: Signal which inform that air conditioner D RANGE SIGNAL compressor is not turned ON. ON: Signal which TCM require ECM to increase idle speed ENGINE TORQUE SIGNAL (N⋅m)
Automatic Transmission/Transaxle: 5A-27 Step Action Proceed to “Trouble Diagnosis 2” in “A/T Symptom Repair or replace faulty Proceed to “Trouble Diagnosis”. parts. Diagnosis 3” in “A/T Symptom Diagnosis”. Is trouble identified? Road Test S7RS0B5104011 This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road.
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5A-28 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → 4 upshift fails to Malfunction of shift solenoid valve-B Inspect. If NG, replace. occur Malfunction of “3” position switch Inspect. If NG, replace. Malfunction of engine coolant Inspect. If NG, replace. temperature sensor Malfunction of output shaft speed Inspect.
Automatic Transmission/Transaxle: 5A-29 Condition Possible cause Correction / Reference Item TCC (lock-up) function Malfunction of TCC pressure control Inspect. If NG, replace. pressure control does not solenoid valve operate Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of brake light switch Inspect.
5A-30 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item Operated gear is not Faulty valve body component Replace valve body assembly. correct Faulty clutch or brake Inspect clutch and brake. If any parts are faulty, replace them. Engine Brake Test S7RS0B5104013 WARNING Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.
Automatic Transmission/Transaxle: 5A-31 Troubleshooting Condition Possible cause Correction / Reference Item Lower than standard level Engine output torque failure Inspect and repair engine. in both “D” and “R” range Faulty one-way clutch of torque Replace torque converter. converter Higher than standard Malfunction of pressure control solenoid Inspect.
5A-32 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item → “N” “D” time lag Malfunction of transmission fluid Inspect. If NG, replace. exceeds specification temperature sensor Malfunction of pressure control solenoid Inspect. If NG, replace valve body assembly. valve (Low line pressure) Faulty valve body component Replace valve body assembly.
Automatic Transmission/Transaxle: 5A-33 Troubleshooting Condition Possible cause Correction / Reference Item Higher than standard Malfunction of pressure control solenoid Inspect. If NG, replace valve body assembly. level in each range valve (Low line pressure) Faulty valve body component Replace valve body assembly. Lower than standard level Malfunction of pressure control solenoid Inspect.
5A-34 Automatic Transmission/Transaxle: A/T Symptom Diagnosis S7RS0B5104018 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.
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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 circuit faulty Inspect circuit for open, short and intermittent. If NG, repair.
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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.
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Automatic Transmission/Transaxle: 5A-37 Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC pressure control solenoid valve Inspect circuit for open, short and intermittent. up) system circuit faulty If NG, repair. Shift solenoid valve-A and/or-B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
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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.
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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 Malfunction of input shaft speed sensor Inspect.
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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.
5A-42 Automatic Transmission/Transaxle: Step Action 1) Perform running test under the following conditions and Faulty shift solenoid “BRN” circuit shorted to measure voltage between terminal “C34-16” of TCM valve, circuit or power circuit or open, or connector and ground, terminal “C34-15” of TCM transaxle.
Automatic Transmission/Transaxle: 5A-43 Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check DTC Go to applicable DTC Go to Step 3. diag. flow. Is DTC P0705, P0707, P0712, P0713, P0717, P0722, P0787, P0788, P0961, P0962, P0963, P0973, P0974, P0976, P0977, P1702, P1703, P1774, P1777, P2762, P2763 and/or P2764 detected? Brake light switch signal inspection...
5A-44 Automatic Transmission/Transaxle: DTC P0602: Control Module Programming Error S7RS0B5104048 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.
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Go to Step 5. operation Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection in Section 00”. 2) Turn ignition switch ON and check transmission range signal (“P”, “R”, “N”, “D”, “3”, “2”...
5A-46 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor (switch) referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor (Shift Switch) Inspection “RED”, “GRN/ORN”, range sensor. and Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? shorted to power circuit or shorted each other.
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Go to Step 5. operation Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection in Section 00” 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 3, 2 or L) on display when shifting select lever to each range.
5A-48 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor (switch) referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor (Shift Switch) Inspection “RED”, “GRN/ORN”, range sensor. and 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...
Automatic Transmission/Transaxle: 5A-49 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory and start engine. 3) Keep engine running at idle speed for 10 minutes or more. 4) Stop vehicle and check DTC. DTC Troubleshooting Step Action...
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5A-50 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.
5A-52 Automatic Transmission/Transaxle: 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.
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Automatic Transmission/Transaxle: 5A-53 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory and start engine. 3) Shift select lever to “D” range and drive vehicle at 50 km/h (31 mile/h) or more vehicle speed at least for 3 minutes. 4) Stop vehicle and check DTC.
5A-54 Automatic Transmission/Transaxle: DTC P0787: Shift / Timing Solenoid Low S7RS0B5104029 Wiring Diagram C34-14 BLU/BLK I4RS0A510014-01 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 low although TCM...
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Automatic Transmission/Transaxle: 5A-55 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check timing solenoid valve resistance Go to Step 3. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1), (2) on transaxle.
5A-58 Automatic Transmission/Transaxle: DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance S7RS0B5104049 Wiring Diagram C34-4 C34-2 LT GRN/BLK I4RS0A510015-01 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
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Automatic Transmission/Transaxle: 5A-59 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 position. valve body harness.
5A-60 Automatic Transmission/Transaxle: DTC P0962: Pressure Control Solenoid “A” Control Circuit Low S7RS0B5104031 Wiring Diagram C34-4 C34-2 LT GRN/BLK I4RS0A510015-01 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Pressure control solenoid valve output voltage is too low...
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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.
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 “C34-2” and “C34-4” of disconnected harness side TCM Check for intermittent connector.
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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. “GRY” or “LT GRN/BLK” circuit shorted to power 1) Connect valve body harness connector.
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Automatic Transmission/Transaxle: 5A-65 DTC Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Table” Go to Step 2. Go to “A/T System performed? Check”. Check shift solenoid valve resistance Go to Step 3. Replace applicable shift solenoid valve or valve 1) Turn ignition switch OFF. body harness.
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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.
5A-68 Automatic Transmission/Transaxle: DTC P1702: Internal Control Module Memory Check Sum Error S7RS0B5104035 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.
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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.
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5A-72 Automatic Transmission/Transaxle: DTC Troubleshooting NOTE Upon completion of inspection and repair work, perform “DTC Confirmation Procedure:” and confirm that the trouble has been corrected. Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”.
Automatic Transmission/Transaxle: 5A-73 DTC P1777: TCM Lost Communication with ECM (Reception Error) S7RS0B5104040 Wiring Diagram Refer to “DTC P1774: CAN Communication Bus Off” DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ECM is detected more than specified •...
5A-74 Automatic Transmission/Transaxle: DTC P1778: TCM Lost Communication with BCM (Reception Error) S7RS0B5104041 Wiring Diagram Refer to “DTC P1774: CAN Communication Bus Off”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for BCM is detected more than specified •...
Automatic Transmission/Transaxle: 5A-75 DTC P1878: Torque Converter Clutch Shudder S7RS0B5104042 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area The acceleration slip control function stops when the variation in the output • Mismatching ATF revolution speed of the specified amplitude and specified cycle is detected •...
5A-76 Automatic Transmission/Transaxle: DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance S7RS0B5104050 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019-01 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...
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Automatic Transmission/Transaxle: 5A-77 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 to OFF position. harness.
5A-78 Automatic Transmission/Transaxle: DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High S7RS0B5104043 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019-01 1. TCM 3. A/T 2. TCC lock-up pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
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Automatic Transmission/Transaxle: 5A-79 Step Action 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. power circuit. 2) Disconnect TCM connectors. 3) Check for proper connection to TCM at terminal “C34-3” and “C34-5”.
5A-82 Automatic Transmission/Transaxle: Inspection of TCM and Its Circuits S7RS0B5104045 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance. CAUTION TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
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Automatic Transmission/Transaxle: 5A-83 Connector “C34” 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 (–) TCC pressure control WHT/BLK 0.6 – 1.0 V Ignition switch ON solenoid valve (–) *0 –...
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5A-84 Automatic Transmission/Transaxle: Connector “C35” 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 —...
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Automatic Transmission/Transaxle: 5A-85 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: “C34-4” to “C34-1” terminal Measurement CH1: “C34-7” to “C34-1” Oscilloscope CH1: 5 V/DIV terminal...
5A-86 Automatic Transmission/Transaxle: Reference waveform No. 5 Output shaft speed sensor signal at vehicle speed 60 km/h (37 mile/h). Measurement CH1: “C35-25” to “C34-1” terminal Oscilloscope CH1: 5 V/DIV setting TIME: 2 ms/DIV • After warmed up to normal operating temperature Measurement condition •...
Automatic Transmission/Transaxle: 5A-87 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 “C34-24” terminal. 3) If OK, check voltage at terminal “C34-24”...
Learning Control Initialization S7RS0B5106001 1) Connect san tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool I4RS0B510004-01 2) Start engine and shift select lever to “P” range. 3) Select “Misc Test” mode on scan tool.
FULL HOT (2) and LOW HOT (3). If it is (hot) temperature. Checking procedure itself is the same below LOW HOT, add SUZUKI ATF 3317 or Mobil as that described in “Level Check at Normal Operating ATF 3309 up to FULL HOT.
Select Lever Assembly Removal and Installation I3RM0B510033-01 S7RS0B5106005 4) Lower vehicle and pour proper amount of SUZUKI Remove and install select lever referring to “Select Lever ATF 3317 or Mobil ATF 3309. Components.” When installing select lever noting the following.
Automatic Transmission/Transaxle: 5A-91 Select Lever Inspection Shift Lock Solenoid Inspection S7RS0B5106007 S7RS0B5106009 Check select lever for smooth and clear-cut movement Check that shift lock solenoid rod (1) moves smoothly individually. If a malfunction is found, replace select lever when battery voltage is conducted and it moves back. If assembly.
5) Shift select lever to “N” position. 6) Apply grease to select lever pin and install adjuster (cable end) to it. : Grease 99000–25011 (SUZUKI Super Grease 7) With both select lever and transmission range sensor kept each “N” position, drive cable end holder (1) in until it locks cable.
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5A-94 Automatic Transmission/Transaxle: 5) Turn ignition switch to LOCK position. 6) Remove parking brake cover and console box. 7) Detach cable end (1) from interlock cam (2) while pressing claws (3) of interlock cam boss. At this time, be careful not to cause damage to its claws.
Automatic Transmission/Transaxle: 5A-95 Transmission Range Sensor (Shift Switch) 5) Shift select lever to “N” position. Inspection and Adjustment NOTE S7RS0B5106015 1) Shift manual select lever (4) to “N” range. If select lever is in “P” position, shift select lever referring to “Select Lever Inspection”. 2) Check that needle direction shaped on lock washer (2) and “N”...
Automatic Transmission/Transaxle: 5A-97 7) Remove valve body assembly referring to Installation “Automatic Transaxle Unit Disassembly”. 1) Apply A/T fluid to input shaft speed sensor O-ring. 2) Install input shaft speed sensor (1) to A/T case and CAUTION tighten bolt to specified torque. When pulling solenoid wire harness out of Tightening torque transaxle case, take care not to damage...
5A-98 Automatic Transmission/Transaxle: Transmission Fluid Temperature Sensor Inspection S7RS0B5106021 Warm up transmission fluid temperature sensor (2). Check resistance between terminals of valve body harness connector (1). Thus make sure its resistance decrease as its temperature increase. Transmission fluid temperature sensor resistance 10 °C (50 °F): 5.8 –...
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5A-100 Automatic Transmission/Transaxle: Operation Check Timing solenoid valve Shift solenoid valve-A (No.1) and -B (No.2) CAUTION CAUTION • Do not insert air gun against strainer installed on inlet of solenoid valve too • Do not insert air gun against strainer deeply, when blowing air into solenoid installed on inlet of solenoid valve too valve.
Automatic Transmission/Transaxle: 5A-101 Pressure Control Solenoid Valves (Pressure 9) Remove valve body assembly referring to “Automatic Transaxle Unit Disassembly”. Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation 10) Remove pressure control solenoid valve and TCC S7RS0B5106024 pressure control solenoid valve referring to “Valve Removal Body Assembly Disassembly and Reassembly”.
5A-102 Automatic Transmission/Transaxle: Operation Check Check pressure control solenoid valves (Pressure control solenoid and TCC pressure control solenoid) operation in the either manner of the following. Using regulated DC power supply 1) Connect pressure control solenoid valve (1) with regulated DC power supply (2) as shown in figure. 2) Turn regulated DC power supply switch ON and increase voltage of power supply keeping current within 1.0 A.
Automatic Transmission/Transaxle: 5A-103 Installation Differential Side Oil Seal Replacement Reverse removal procedure noting the following. S7RS0B5106028 1) Lift up vehicle and drain automatic transaxle fluid. • Connect TCM connectors securely. 2) Remove drive shaft joints from differential gear of • If the vehicle is equipped with air bag system, be sure transaxle.
A/T Fluid Cooler Hoses Replacement 4) Apply grease to new differential side oil seal lips. S7RS0B5106029 : Grease 99000–25030 (SUZUKI Super Grease C) The rubber hoses for the A/T fluid cooler should be checked at specified interval. If replacing them, be sure 5) Install new differential side oil seals (1) by using to note the following.
5A-106 Automatic Transmission/Transaxle: Automatic Transaxle Unit Dismounting and 4) Remove starting motor. Remounting 5) Remove bolts and nut fastening engine and S7RS0B5106031 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”.
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Automatic Transmission/Transaxle: 5A-107 Remounting 4) Tighten transaxle stiffener bolts to specified torque. 1) Make sure that torque converter is installed correctly 5) Install transaxle housing lower plates (1). to transaxle. Tightening torque Refer to “Automatic Transaxle Unit Assembly”. Transaxle stiffener bolt (a): 55 N·m (5.5 kgf-m, 2) Attach transaxle to engine.
5A-110 Automatic Transmission/Transaxle: Automatic Transaxle Unit Disassembly 4) Uncaulk lock washer (1), then remove lock nut (2) S7RS0B5106033 and lock washer. CAUTION • Thoroughly clean transaxle exterior before overhauling it. • Keep working table, tools and hands clean while overhauling. •...
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Automatic Transmission/Transaxle: 5A-111 12) Disconnect connectors (2) from solenoid valves and 8) Remove fluid cooler pipes (1) and pipe union (2). transmission fluid temperature sensor (1). 9) Remove fluid level gauge (3) and fluid filler tube (4). I4RS0A510027-01 13) Remove valve body assembly bolts. CAUTION Be careful not to let manual valve fall off when removing valve body assembly.
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5A-112 Automatic Transmission/Transaxle: 18) Remove accumulator pistons and springs. 15) 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...
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Automatic Transmission/Transaxle: 5A-113 19) Remove transaxle case plug (1). I2RH0B510098-01 25) Remove oil pump assembly (1). I2RH0B510095-01 20) Remove torque converter housing bolts. 21) Remove torque converter housing (1) while tapping around it lightly with plastic hammer. I2RH0B510099-01 26) Remove direct clutch assembly (1). I3RM0B510060-01 22) Remove breather hose (1).
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5A-114 Automatic Transmission/Transaxle: 28) Remove input shaft rear thrust bearing (1) and thrust 31) 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.
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Automatic Transmission/Transaxle: 5A-115 35) Remove 2nd brake gasket (1). 37) Remove forward and reverse clutch assembly (1). I2RH0B510109-01 I2RH0B510111-01 36) Measure O/D and 2nd coast brake piston stroke. 38) Remove intermediate shaft thrust bearing front race If piston stroke exceeds specification, inspect and (1), thrust bearing (2) and rear race (3) from forward replace plates and discs.
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5A-116 Automatic Transmission/Transaxle: 40) Remove forward clutch hub (1). 43) Remove rear planetary sun gear subassembly (1) and one-way clutch No.1 assembly (2). I2RH0B510114-01 41) Remove rear sun gear thrust bearing (1) from I2RH0B510117-01 forward clutch hub (2). 44) Remove planetary gear thrust bearing (1). NOTE NOTE If rear sun gear thrust bearing is not found on...
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Automatic Transmission/Transaxle: 5A-117 47) Remove O/D and 2nd coast brake retaining plate snap ring (1). I2RH0B510124-01 51) Remove 2nd brake piston assembly (1). 52) Remove 2nd brake return spring subassembly (2). I2RH0B510120-01 48) Remove front planetary sun gear (1). I4RS0A510038-01 53) Remove 2nd brake separator plates (1), discs (2) I2RH0B510121-01 and retaining plate (3).
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Automatic Transmission/Transaxle: 5A-119 60) Remove snap ring while the 1st and reverse brake 64) Secure reduction drive gear (1) with parking lock piston return springs are compressed using special pawl, then remove reduction drive gear nut. tool and hydraulic press. CAUTION CAUTION •...
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5A-120 Automatic Transmission/Transaxle: 67) Screwing 3 bolts (1), remove reduction drive gear 69) Remove parking lock pawl bracket (1). (2). CAUTION Screw 3 bolts into reduction drive gear uniformly, or reduction drive gear, bearing and transaxle case may be damaged. Bolt length 35 mm (1.38 in.) I2RH0B510142-01...
If clearance exceeds its Special tool standard value, replace oil pump assembly. (A): 09913–85210 Clearance between oil pump driven gear and oil “A”: Grease 99000–25030 (SUZUKI Super pump body Grease C) Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.) I2RH0B510151-01 2.
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Automatic Transmission/Transaxle: 5A-123 2) Check tip clearance of both drive and driven gears. Using a feeler gauge, measure clearance between drive and driven gear tips. If clearance exceeds its standard value, replace oil pump assembly. Tip clearance between oil pump drive gear and oil pump driven gear Standard: 0.07 –...
Automatic Transmission/Transaxle: 5A-125 Direct Clutch Assembly Disassembly and 5) Remove outer O-ring (1). Reassembly S7RS0B5106039 Disassembly 1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates. I2RH0B510165-01 2. Direct clutch piston 6) Remove inner O-ring (2). I2RH0B510162-01 2) Using special tool and hydraulic press, remove shaft snap ring (1).
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5A-126 Automatic Transmission/Transaxle: 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.).
Automatic Transmission/Transaxle: 5A-127 Direct Clutch Assembly Inspection Direct Clutch Piston S7RS0B5106040 Shake direct clutch piston lightly and check that check ball (1) is not stuck. Clutch Discs, Plates and Retaining Plate Blow in low pressure air (Max. 100 kPa, 1 kg/cm , 15 psi) Check that sliding surfaces of discs, separator plates to check ball to check that there is no leakage.
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Automatic Transmission/Transaxle: 5A-131 Reassembly • Install forward clutch plate snap ring so that its both Reverse disassembly procedure for assembly, noting the ends would be positioned in correct locations as following points. shown in figure. • Before assembling, apply automatic transaxle fluid to component parts.
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5A-132 Automatic Transmission/Transaxle: • Install reverse clutch plate snap ring so that its both • Measure forward clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly ends would be positioned in correct locations as Preliminary Check”. shown in figure.
Automatic Transmission/Transaxle: 5A-133 Forward and Reverse Clutch Assembly Forward Clutch Piston Lip and Forward Clutch Balancer Lip Inspection Check each lip for wear, deformation, cut and/or S7RS0B5106044 hardening. If necessary, replace. Clutch, Discs, Separator Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt.
Automatic Transmission/Transaxle: 5A-135 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). Do not damage O-ring when installing 2nd brake piston.
5A-136 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 S7RS0B5106048 Disassembly 1) Remove snap ring by using special tools and hydraulic press.
Automatic Transmission/Transaxle: 5A-137 Transaxle Rear Cover (O/D and 2nd Coast Brake Reassembly Reverse disassembly procedure for assembly, noting the Piston) Assembly Inspection following points. S7RS0B5106049 • 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.
5A-140 Automatic Transmission/Transaxle: Valve Body Assembly Disassembly and 4) Remove shift solenoid valve-A (1). Reassembly S7RS0B5106053 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...
Automatic Transmission/Transaxle: 5A-141 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.
5A-142 Automatic Transmission/Transaxle: Differential Assembly Disassembly and 4) Remove differential side LH bearing by using special tools. Reassembly S7RS0B5106055 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.
Automatic Transmission/Transaxle: 5A-143 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...
5A-144 Automatic Transmission/Transaxle: Torque Converter Housing Disassembly and 4) Remove countershaft RH bearing cup by using special tools. Reassembly S7RS0B5106057 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.
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1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque 5) Apply grease to oil seal lip. converter housing. : Grease 99000–25030 (SUZUKI Super Grease C) Tightening torque Torque converter housing plug (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
5A-146 Automatic Transmission/Transaxle: Transaxle Case Disassembly and Reassembly Reassembly S7RS0B5106058 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...
Differential side oil seal installing depth “a”: 3.8 – 4.8 mm (0.15 – 0.19 in.) 4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C) I2RH0B510253-01 Brake return spring subassembly Measure free length of each brake return spring subassembly.
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5A-148 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...
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Automatic Transmission/Transaxle: 5A-149 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.
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.
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Automatic Transmission/Transaxle: 5A-151 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 (2), separator plates (3) and retaining plate (1), then...
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5A-152 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.
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Automatic Transmission/Transaxle: 5A-153 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.
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5A-154 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.
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(1), install it to planetary gear assembly. I2RH0B510283-01 28) After applying A/T fluid to front sun gear thrust “A”: Grease 99000–25030 (SUZUKI Super bearing race (2), install it to front planetary sun gear Grease C) (1).
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5A-156 Automatic Transmission/Transaxle: 32) Apply A/T fluid to one-way clutch No.1 assembly (3) 35) After applying A/T fluid to rear sun gear thrust and install one-way clutch No.1 assembly (3) to rear bearing race (1), install it to rear planetary sun gear planetary sun gear subassembly (2).
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Automatic Transmission/Transaxle: 5A-157 38) After applying A/T fluid to intermediate shaft thrust 40) 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”...
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46) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) “A” I2RH0B510298-01...
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Automatic Transmission/Transaxle: 5A-159 47) Install transaxle rear cover assembly on transaxle 52) After applying A/T fluid to differential assembly (1) case. and countershaft assembly (2), install them to transaxle case. 48) Install hook (2) to location shown in figure. 49) Tighten rear cover bolts (1). Tightening torque Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) I4RS0A510036-01...
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5A-160 Automatic Transmission/Transaxle: 55) After applying A/T fluid to input shaft front thrust bearing (1), install it to direct clutch assembly (2). “a” I2RH0B510308-01 56) Apply A/T fluid to direct clutch assembly (1). Install direct clutch assembly while rotating clockwise and counterclockwise frequently to fit clutch discs to mating hub.
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Special tool section is 1.2 mm (0.047 in.) in diameter. (A): 09900–20607 (B): 09900–20701 “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) Input shaft thrust play 0.3 – 0.9 mm (0.012 – 0.035 in.) When input shaft thrust play is out of specification,...
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5A-162 Automatic Transmission/Transaxle: 66) After applying A/T fluid to new O-ring, fit it to transaxle case plug (1). Then install the transaxle case plug to transaxle case (2). Tightening torque Transaxle case plug (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) I2RH0B510317-01 67) Install new O-rings to each accumulator piston and apply A/T fluid to them.
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Automatic Transmission/Transaxle: 5A-163 70) After applying A/T fluid to new governor apply No.1 72) Install manual valve rod (1) to manual valve lever (3) gasket (1), install it to transaxle case. and then install valve body assembly (2) to transaxle case.
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5A-164 Automatic Transmission/Transaxle: 74) Connect solenoid connectors to solenoid valves 76) Install oil cleaner magnets (1) in oil pan (2). identifying their installing positions by wire colors, NOTE and install transmission fluid temperature sensor to its clamp. If metal particles are attached to the magnets, clean them before installing.
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Automatic Transmission/Transaxle: 5A-165 81) After applying A/T fluid to new O-ring, fit it to fluid 84) Install transmission range sensor to transaxle case, filler tube. Then install fluid filler tube to transaxle tighten bolts temporarily at this step. case. Tightening torque Fluid filler tube bolt (d): 10 N·m (1.0 kgf-m, 7.5 lb-ft) I3RM0B510072-01...
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“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) I3RM0B510076-01 93) Install engine mounting LH bracket (1).
5A-168 Automatic Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S7RS0B5108001 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.
Manual Transmission/Transaxle: 5B-1 Manual Transmission/Transaxle Transmission / Transaxle General Description Manual Transaxle Construction and Servicing S7RS0B5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs 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.
5) Apply sealant to thread of drain plug (1), and tighten S7RS0B5206001 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 oil level and leakage.
7) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. S7RS0B5206002 1) Lift up vehicle and drain transaxle oil. “A”: Sealant 99000–31260 (SUZUKI Bond 2) Remove front drive shaft and/or center shaft No.1217G) referring to “Front Drive Shaft Assembly Removal Tightening torque and Installation in Section 3A”.
Manual Transmission/Transaxle: 5B-5 Gear Shift Control Lever and Cable Components S7RS0B5206003 I7RS0A521001-03 1. Gear shift control lever knob 9. Cable bracket 2. Cable bracket bolt 10. Clip Be sure to direct claw of clip to M/T side as shown in figure. 3.
5B-6 Manual Transmission/Transaxle: Gear Shift Control Lever and Cable Removal Gear Select Control Cable Adjustment S7RS0B5206005 and Installation 1) Release lock plate (1) which restricts moving of S7RS0B5206004 cable end holder (2). Removal 2) Push cable end holder (2) out from adjuster (4) using 1) Remove console box.
S7RS0B5206006 Removal lever securely. 1) Remove battery and tray with coolant reservoir. “A”: Grease 99000–25011 (SUZUKI Super 2) Disconnect back up light switch coupler (1). Grease A) 3) Remove back up light switch (2). 4) Push cable end holder (2) in the direction of A.
Manual Transmission/Transaxle: 5B-9 Manual Transaxle Unit Dismounting and 12) Support engine using supporting device (1). Remounting CAUTION S7RS0B5206009 Dismounting Do not apply supporting device to projection 1) Drain coolant and transaxle oil. part A. If do so, it may be deformed. 2) Remove coolant reservoir with reservoir hose.
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5B-10 Manual Transmission/Transaxle: 16) Remove engine under covers. Remounting 17) Support transaxle with transmission jack. CAUTION 18) Remove transaxle to engine bolts and nut of lower side. • Care should be taken not to scratch oil seal lip with drive shaft while raising 19) Remove engine left mounting (1) with bracket (2).
• Set new gear shift & select lever inner pin to specified torque. (8) and outer pin (9) facing each gap (“a”, “B”: Sealant 99000–31260 (SUZUKI Bond “b”) in the opposite direction as shown in No.1217G) figure.
Manual Transmission/Transaxle: 5B-13 Manual Transaxle Assembly Components S7RS0B5206013 I6RS0C520005-01 1. Transaxle right case 24. Shift fork bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case 25. 5th gear shift fork : Apply sealant 99000-31260 to mating surface of left case and right case.
5B-14 Manual Transmission/Transaxle: 11. Sensor cap 34. Washer 12. Oil gutter bolt 35. Side bearing retainer : Apply thread lock 99000-32110 to all around thread part of bolt. 13. Left case plate bolts 36. O-ring : Apply thread lock 99000-32110 to all around thread part of bolt. 14.
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Manual Transmission/Transaxle: 5B-15 Assembly c) Install synchronizer ring (1) to hub (2) as shown in figure. 1) Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and synchronizer ring (4) as follows. I4RH01520055-01 2) Install 5th gear (1) to countershaft facing machined boss A inward.
(5) on input shaft. (0.059 in.) in diameter, mate it with left case and then tighten bolts to 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)
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Manual Transmission/Transaxle: 5B-17 13) Tapping input shaft end with plastic hammer, push it 5) Remove gear shift locating bolts (1) with washers, then take out locating springs and steel balls. out as assembly from case a little, then take out input shaft assembly (1), countershaft assembly (2), 6) Remove back up light switch (2).
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5B-18 Manual Transmission/Transaxle: 18) Remove differential bearing shim. 2) Join input shaft assembly (5), countershaft assembly (4), low speed gear shift shaft (2) and high speed 19) Remove differential side bearing outer race from left gear shift shaft (3) assemblies all together, then case (1) using special tools.
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1.5 mm (0.059 in.) in case. in diameter then mate it with left case (1). 5) Fasten reverse gear shift lever bolts after applying “B”: Sealant 99000–31260 (SUZUKI Bond thread lock cement. No.1217G) : Thread lock cement 99000–32110 (Thread Lock...
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5B-20 Manual Transmission/Transaxle: 9) Install side bearing retainer as follows. iii) Calculate clearance a – b, and select differential shim according to the following a) Install differential side bearing outer race to left table. case and then tap and accustom outer race using special tool and plastic hammer.
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Apply oil to new O-ring of side bearing retainer (3), and install side bearing retainer with new O- “A”: Sealant 99000–31260 (SUZUKI Bond ring to left case. No.1217G) e) Tighten side bearing retainer bolts (1) to Tightening torque specified torque.
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5B-22 Manual Transmission/Transaxle: 14) With putting a shim (2) on bearing outer race (3), 16) Place left case plate (2) inserting its end in groove of place straightedge (1) over it and compress it by shift guide shaft (4) and tighten bolts (1) to which hand through straightedge, and then measure thread lock cement has been applied.
Use special tool (A): 09925–15410 and hammer for installation and apply grease to oil seal lip. “B”: Grease 99000–25011 (SUZUKI Super Grease A) Special tool (A): 09913–84510 3) If countershaft right bearing outer race (2) has been removed, install it using special tools and hammer.
5B-24 Manual Transmission/Transaxle: Transaxle Left Case Disassembly and Assembly S7RS0B5206017 Disassembly 1) Replace differential side oil seal from left case referring to “Differential Side Oil Seal Replacement”, if necessary. 2) Remove input oil gutter (1) from left case, if necessary. I4RH01520028-01 Assembly 1) If input oil gutter (1) has been removed, install it with bolt to which thread lock cement has been applied.
5B-26 Manual Transmission/Transaxle: Input Shaft Assembly Disassembly and 5) Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) from input Reassembly shaft (1) using bearing puller (4) and hydraulic press. S7RS0B5206019 Disassembly CAUTION 1) Remove input shaft right bearing (2) from input shaft Make sure to use flat side of bearing puller to (1) using bearing puller (3) and hydraulic press.
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Manual Transmission/Transaxle: 5B-27 NOTE 3) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as • While press-fitting sleeve & hub, make shown in figure. sure that synchronizer ring key slots are aligned with keys in sleeve &...
5B-28 Manual Transmission/Transaxle: 8) Press-fit left bearing (2) using special tool and 2) Apply bearing puller (5) to 2nd gear (4) and drive out hammer. 3rd & 4th gear spacer (2) and 3rd gear (3) together with 2nd gear from countershaft (1) using hydraulic Special tool press.
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Manual Transmission/Transaxle: 5B-29 5) Apply bearing puller (3) to 1st gear (2) and drive out 3) Fit low speed synchronizer sleeve (4) to hub (3), low speed synchronizer sleeve & hub assembly (1) insert 3 keys (2) in it and then set springs (1) as with 1st gear using hydraulic press.
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5B-30 Manual Transmission/Transaxle: 8) Press-fit 3rd gear (2) and spacer (1) using special 5) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring. tools and hydraulic press. 6) Drive in low speed synchronizer sleeve & hub CAUTION assembly (1) using special tools and hammer.
Manual Transmission/Transaxle: 5B-31 Synchronizer Parts Inspection Put the 2nd gear synchronizer outer ring (1), inner ring S7RS0B5206021 (3) and the cone (2) together and then measure the step Check clearance “a” between synchronizer ring (2) and difference between the outer ring and the inner ring. And gear (1), each chamfered tooth of gear, synchronizer also check each chamfered tooth of gear and ring and sleeve, then determine parts replacement.
5B-32 Manual Transmission/Transaxle: 5th and Reverse Gear Shift Shafts Disassembly Gear Shift Shaft and Fork Inspection S7RS0B5206024 and Assembly Using feeler gauge, check clearance between fork (1) S7RS0B5206023 and sleeve (2) and replace those parts if it exceeds limit. Disassembly NOTE Disassemble component parts using special tool and For correct judgement of parts replacement,...
Manual Transmission/Transaxle: 5B-33 Differential Components S7RS0B5206025 I6RS0C520007-01 1. Differential pinion washer 8. Final gear 2. Differential side pinion gear 9. Final gear bolt 3. Differential side gear 10. Differential pinion shaft 4. Side gear washer : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 5.
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5B-34 Manual Transmission/Transaxle: Assembly 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 all parts are clean. 1) Assemble differential gear and measure thrust play of differential gear as follows.
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Manual Transmission/Transaxle: 5B-35 6) Hold differential assembly with soft jawed vise (3), install final gear (2) as shown in figure and then tighten bolts (1) to specified torque. CAUTION Use of any other bolts than specified ones is prohibited. Tightening torque Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft) I4RS0A520043-01 Specifications...
5B-36 Manual Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S7RS0B5208001 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.
Clutch: 5C-1 Clutch Transmission / Transaxle General Description Clutch Construction S7RS0B5301001 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.
5C-4 Clutch: Clutch Pedal Position (CPP) Switch Removal 3) Depress clutch pedal several times, and then release clutch pedal, push snap ring (2) and pull pipe and Installation connector (1) one notch. S7RS0B5306004 Removal 1) Disconnect connector of CPP switch (1) with ignition switch OFF.
Clutch: 5C-5 Clutch Pedal Position (CPP) Switch Inspection Adjustment With clutch pedal depressed, adjust switch (1) position and Adjustment so that clearance between end of thread and clutch S7RS0B5306005 pedal arm is within specification, and then tighten lock Inspection nut to specified torque. Check for resistance between terminals under each Clearance between end of thread and clutch pedal condition below.
• Do not allow fluid to get on painted • Apply grease to push rod tip. surface. “A”: Grease 99000–25100 (SUZUKI Silicone • Do not allow pipe to contact hard against Grease) vehicle body or other parts. • Install each clamp securely.
Clutch: 5C-7 Clutch Operating Cylinder Removal and • Apply grease to push rod tip. Installation “A”: Grease 99000–25100 (SUZUKI Silicone S7RS0B5306010 Grease) Removal 1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake master cylinder reservoir.
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Clutch: 5C-9 3) Pull out input shaft bearing (1) from flywheel (2), use Installation the following special tool if necessary. CAUTION Special tool Do not reuse flywheel bolts. Otherwise, bolts (A): 09921–26020 may loosen. Be sure to use new bolts with (B): 09930–30104 pre-coated adhesive.
“Manual Transaxle Unit Dismounting and Remounting in Section 5B”. I4RS0A530019-01 “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.
Release shaft seal will also be pushed out. Special tool Special tool (A): 09943–88211 (A): 09922–46010 (B): 09923–46030 4) Remove release shaft (1). “A”: Grease 99000–25011 (SUZUKI Super Grease A) I4RS0A530020-01 I3RM0A530016-01...
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(2), then set release bearing (1). 3) Apply grease to No.2 bush (1) inside and press-fit it using the same special tool as in removal. “A”: Grease 99000–25011 (SUZUKI Super Grease A) “A”: Grease 99000–25011 (SUZUKI Super Grease A) 7) Apply small amount of grease to input shaft (3) spline (0.3 g (0.01 oz)) and front end (0.15 g (0.005...
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Clutch: 5C-13 Clutch Release System Inspection Clutch Release Shaft S7RS0B5306017 Check clutch release shaft and its pin for deflection or damage. Clutch Release Bearing If abnormality is found, replace it. Check clutch release bearing for smooth rotation. If abnormality is found, replace it. CAUTION Do not wash release bearing.
5C-14 Clutch: Special Tools and Equipment Recommended Service Material S7RS0B5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210 NOTE Required service material is also described in the following.
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Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering System Note .........6C-1 Precautions in Diagnosing Troubles ....6C-1 Precautions............. 6-1 General Description ..........6C-2 Precautions on Steering........6-1 P/S System Description ........6C-2 Steering General Diagnosis....6A-1 EPS Diagnosis General Description ....6C-3 On-Board Diagnostic System Description...6C-3 Precautions............6A-1 Schematic and Routing Diagram ......6C-4...
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6-ii Table of Contents Steering Wheel Play Check ......6C-39 Steering Rack Plunger Removal and Steering Force Check ........6C-39 Installation ............6C-45 Steering Rack Plunger Inspection .....6C-45 Repair Instructions ..........6C-40 P/S Control Module Removal and Installation...6C-46 Steering Gear Case Assembly Components ..6C-40 Torque Sensor and Its Circuit Inspection ..6C-46 Tie-Rod End Boot On-Vehicle Inspection ..6C-41 P/S Motor and Its Circuit Inspection ....6C-47...
Precautions: Precautions Steering Precautions Precautions on Steering S7RS0B6000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Air Bag System Service Warning Refer to “Air Bag System Service Warning in Section 00”. Precautions for Steering Diagnosis Refer to “Precautions for Steering Diagnosis in Section 6A”. Service Precautions of Steering Wheel and Column Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.
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6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Precautions Precautions for Steering Diagnosis S7RS0B6100001 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.
Steering General Diagnosis: 6A-2 Diagnostic Information and Procedures Steering Symptom Diagnosis S7RS0B6104001 Condition Possible cause Correction / Reference Item Hard steering Tire not adequately inflated Inflate tires to proper pressure. Malfunction of power steering system Check and correct. Bind in tie-rod end ball studs or lower Replace tie-rod end or front suspension arm.
6B-1 Steering Wheel and Column: Steering Wheel and Column Steering Precautions Service Precautions of Steering Wheel and Enabling Air Bag System For enabling air bag system, refer to “Enabling Air Bag Column System in Section 8B”. S7RS0B6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Steering Wheel and Column: 6B-2 Diagnostic Information and Procedures Checking Steering Column for Accident 3) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or Damage excessive play. S7RS0B6204001 NOTE If anything is found faulty, replace as lower shaft Vehicles involved in accidents resulting in assembly or steering column assembly.
Steering Wheel and Column: 6B-4 Steering Wheel Removal and Installation Installation S7RS0B6206002 CAUTION CAUTION Following 2 Steps (Step 1) and 2)) are Do not turn the contact coil more than prerequisite for installation of steering wheel. allowable number of turns (about two and a If steering wheel has been installed without half turns from the center position clockwise these 2 Steps, contact coil will break when...
6B-5 Steering Wheel and Column: Contact Coil Cable Assembly Removal and Installation Installation 1) Check to make sure that vehicle’s front tires are set S7RS0B6206003 at straight-ahead position and then ignition switch is at LOCK position. CAUTION 2) Install contact coil cable assembly to steering Do not turn contact coil more than allowable column securely.
Steering Wheel and Column: 6B-6 Centering Contact Coil Cable Assembly Contact Coil Cable Assembly Inspection S7RS0B6206004 S7RS0B6206005 Refer to “Contact Coil Cable and Its Circuit Check in 1) Check that vehicle’s wheels (front tires) are set at Section 8B”. straight-ahead position. 2) Check that ignition switch is at LOCK position.
6B-7 Steering Wheel and Column: Steering Column Removal and Installation Removal S7RS0B6206006 WARNING CAUTION Never rest a steering column assembly on Once the steering column is removed from the steering wheel with the air bag (inflator) the vehicle, the column is extremely module face down and column vertical.
Steering Wheel and Column: 6B-8 Installation CAUTION After tightening steering column mounting nuts, shaft joint bolts should be tightened. Wrong tightening order could cause a damage to shaft joint. 1) Be sure that front wheels are in straight. 2) Install steering column assembly to lower and upper brackets.
Steering Wheel and Column: 6B-10 5) Tighten new bolts (1) until head of each bolt is Installation broken off. 1) Be sure that front wheels are in straight forward 6) Turn ignition key to “ACC” or “ON” position and state. check to be sure that steering shaft (2) rotates 2) Align flat part “A”...
Precautions in Diagnosing Troubles S7RS0B6300002 • 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.
6C-2 Power Assisted Steering System: General Description P/S System Description S7RS0B6301001 This power steering (P/S) system consists of a P/S control module (3), a torque sensor (4), a 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 signals from the torque sensor and vehicle speed signal from ECM.
Power Assisted Steering System: 6C-3 EPS Diagnosis General Description S7RS0B6301002 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”...
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Power Assisted Steering System: 6C-5 Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side) Terminal Circuit Terminal Circuit Main power supply for internal memory E49-1 E52-9 Ground for torque sensors and EPS motor E49-2 Ground for P/S control module E52-10 —...
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6C-6 Power Assisted Steering System: Step Action Rechecking and record of DTC Go to Step 9. Go to Step 10. 1) Recheck for DTC referring to “DTC Check”. Is there any DTC(s)? Steering symptom diagnosis and P/S system Go to Step 11. Check and repair symptom diagnosis malfunction part(s), and...
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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.
1) Turn ignition switch to OFF position. the end of the flow has been reached, check the parts of 2) Connect SUZUKI scan tool to data link connector the system suspected as a possible cause referring to (DLC) (1) located on underside of instrument panel “P/S System Symptom Diagnosis”...
4) Read DTC according to the instructions displayed on 1) Turn ignition switch to OFF position. SUZUKI scan tool. For further details, refer to 2) Connect SUZUKI scan tool to data link connector operator’s manual for SUZUKI scan tool. (DLC) (1) located on underside of instrument panel NOTE at driver’s seat side.
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6C-10 Power Assisted Steering System: Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) Vehicle speed signal is 0 km/h even though engine speed is • Vehicle speed signal circuit more than 4000 rpm for more than •...
Power Assisted Steering System: 6C-11 Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) P/S motor circuit current too Measured motor drive current is 1 driving C1143 high more than 50 A. cycle Measured motor drive current is less than 2 A continuously for more than 3 seconds even though •...
6C-12 Power Assisted Steering System: Scan Tool Data Definitions Motor Control (Motor Control Current, A) Based on the input signal, the P/S control module Battery Voltage determines the assist amount and controls the current to This parameter indicates battery positive voltage. the motor suitable for that assist amount.
Power Assisted Steering System: 6C-13 Condition Possible cause Correction / Reference Item Vehicle pulls to one side Poor performance of torque sensor Check torque sensor referring to “Torque during straight driving Sensor and Its Circuit Inspection”. Steering gear case assembly faulty Replace.
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Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. 1) Make sure that SUZUKI scan tool is free from Go to Step 3. Connect SUZUKI scan malfunction and that correct program card (software) for tool to DLC properly.
1) 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)? 1) With ignition switch OFF, disconnect P/S control module Go to Step 3. Replace the P/S control connector (“E52”).
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6C-18 Power Assisted Steering System: Step Action Torque sensor signal (main) voltage check Go to Step 5. Torque sensor signal circuit is shorted to 1) Check for voltage between “E53-5” (“WHT” wire) other circuit. terminal and body ground with ignition switch ON. Is it about 0 V? Torque sensor signal (main) resistance check Go to Step 6.
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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 DTC Go to Step 3. diag. flow. Is DTC C1153 and/or DTC C1155 indicated together? Torque sensor 5 V reference power supply circuit Go to Step 4.
6C-22 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 C1113, C1114 and/or DTC C1119 indicated together? Torque sensor internal failure signal circuit check Go to Step 4.
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Power Assisted Steering System: 6C-23 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 C1113, C1114 and/or DTC C1119 indicated together? Torque sensor internal failure signal voltage check Substitute a known- Go to Step 4.
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Power Assisted Steering System: 6C-25 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to DTC C1153 diag. Go to Step 3. flow. Is DTC C1153 indicated together? Torque sensor main power supply voltage check Go to Step 4.
6C-26 Power Assisted Steering System: DTC C1121 / C1123 / C1124: VSS Circuit Failure S7RS0B6304017 DTC C1121: No Vehicle Speed Signal (60 Seconds or More) DTC C1123: No Vehicle Speed Signal (30 Seconds or More) DTC C1124: Vehicle Speed Performance (Impossible Deceleration) Wiring Diagram E49-1 [B ]...
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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. DTC Check for ECM referring to “DTC Check in Section 1A”. diag.
6C-28 Power Assisted Steering System: DTC C1122: Engine Speed Signal S7RS0B6304018 NOTE DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON position and engine is not running, but means there is nothing abnormal if indication changes to a normal one when engine is started.
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Power Assisted Steering System: 6C-29 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to Step 3. Check intermittent trouble referring to 1) Clear DTC(s) referring to “DTC Clearance”. “Intermittent and Poor 2) Run engine at idle speed.
6C-30 Power Assisted Steering System: DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure S7RS0B6304019 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 E49-1...
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Power Assisted Steering System: 6C-31 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1141: • P/S motor circuit Voltage between both motor drive circuits is more than 8.5 • P/S motor V or less than 0.2 V for 0.5 seconds continuously while •...
Power Assisted Steering System: 6C-33 DTC C1155: P/S Control Module Failure S7RS0B6304021 Wiring Diagram Refer to “DTC C1153: P/S Control Module Power Supply Circuit Voltage Low”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Internal memory (EEPROM) is data error. •...
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6C-34 Power Assisted Steering System: P/S Control Module Power Supply and Ground Circuit Check S7RS0B6304022 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E51-2 E49-2 [B ] [A ] 12 13 14 15 16 17 18 19 20 I7RS0B630012-01 [A]: Connector “E52” (viewed from harness side) 2.
Power Assisted Steering System: 6C-35 Step Action P/S control module ground circuit check P/S Control Module “BLK” wire is open or Power Supply and high resistance circuit. 1) Connect connectors to P/S control module. Ground Circuit is in 2) Start engine. good condition.
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6C-36 Power Assisted Steering System: Voltage Check 1) Remove console box. 2) Check for voltage at each terminal with connectors connected to the P/S control module. NOTE As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or more when ignition switch is ON.
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Power Assisted Steering System: 6C-37 Terminal Wire color Circuit Normal voltage Remarks E52-11 PPL/WHT Data link connector — — *0 – 1 V ↑↓ 8 – 14 V (“Reference waveform No.30” E52-12 Engine speed signal Engine idling and “Reference waveform No.31” under “Inspection of ECM and Its Circuits in Section 1A”.)
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6C-38 Power Assisted Steering System: Reference waveform No.1 Reference waveform No.2 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: “E51-1” to vehicle body ground Measurement CH1: “E51-1”...
Power Assisted Steering System: 6C-39 • Steering pinion or rack gear for wear or breakage Reference waveform No.3 Motor output signal 1(1), Motor output signal 2(2), with • Each part for looseness engine idling Steering wheel play “a” Measurement CH1: “E51-1” to vehicle body ground : 0 –...
6C-42 Power Assisted Steering System: Steering Shaft Joint On-Vehicle Inspection 2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to specified torque. S7RS0B6306005 Check shaft joint for wear, breakage and any other 3) Bend new split pin (2). damage and replace if any defect exists.
Power Assisted Steering System: 6C-43 Steering Rack Boot Inspection Installation S7RS0B6306007 1) Mount steering gear case (1) to front suspension Hoist vehicle. frame (2) and tighten gear case mounting No.1 bolts Inspect each boot for tear. A torn boot allows entry of (3), No.2 bolts (4) and No.3 bolts (5) to specified dust and water which can cause wear to steering rack torque.
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6C-44 Power Assisted Steering System: 6) Unbend bent part of tie-rod lock washer (1). 4) Apply sealant to gear case groove “A” indicated in figure. Position boot properly in grooves of gear case 7) Hold rack with soft jawed vise (3) and remove tie-rod (or rack side mount) and tie-rod.
1.5 lb-ft) I4RS0A630045-01 Installation 1) Apply grease lightly to sliding part of plunger (1) against rack. “A”: Grease 99000–25050 (SUZUKI Super Grease E) I3RM0A630055-02 2) Install plunger and spring (2) as shown. 5) After adjustment, tighten lock nut to specified torque 3) Apply thread lock cement to rack damper screw (3) with holding damper screw at the position.
Power Assisted Steering System: 6C-47 P/S Motor and Its Circuit Inspection 5) Hoist vehicle. S7RS0B6306013 6) Connect “E51” connector to P/S control module with 1) Remove console box. ignition switch OFF position. 2) Disconnect motor connector (“E51”) from P/S control 7) Using ammeter (2), check that P/S motor (1) current module with ignition switch OFF.
Power Assisted Steering System: 6C-49 Special Tools and Equipment Recommended Service Material S7RS0B6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Silicone sealant Silicone sealant P/No.: 99000–31120 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110...
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Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 Schematic and Routing Diagram ......7B-5 Major Components of A/C System......7B-5 Precautions............. 7-1 A/C System Wiring Diagram .......7B-6 Precautions on HVAC ........... 7-1 Diagnostic Information and Procedures ....7B-7 Heater and Ventilation......7A-1 A/C System Symptom Diagnosis ......7B-7 Abnormal Noise Symptom Diagnosis of A/C General Description ..........7A-1...
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7-ii Table of Contents Recommended Service Material ....... 7B-33 DTC B1562: Outside Air Temperature Sensor Special Tool ............7B-33 Signal Malfunction...........7B-66 DTC B1563: A/C Refrigerant Pressure Automatic Type .............7B-34 Sensor Signal Malfunction ......7B-66 Precautions............7B-34 Inspection of HVAC Control Module and Its A/C System Caution..........
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Table of Contents 7-iii Special Tools and Equipment ......7B-79 Special Tool ............7B-79...
7-1 Precautions: Precautions HVAC Precautions Precautions on HVAC S7RS0B7000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. A/C System Caution Refer to “A/C System Caution in Section 7B”. Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System in Section 7B”.
Heater and Ventilation: 7A-1 Heater and Ventilation HVAC General Description Heater and Ventilation Construction S7RS0B7101001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I4RS0B710001-01 1. HVAC unit 5. Side ventilation air 9.
7A-2 Heater and Ventilation: 2. Ventilator duct 6. Foot air 10. Recirculation air 14. Resistance board 3. Defroster nozzle 7. Front defroster air 11. Center ventilation air 15. Rear duct (if equipped) 4. Heater core 8. Side defroster air 12. Air intake door Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S7RS0B7102001...
Heater and Ventilation: 7A-3 Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S7RS0B7104001 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...
7A-4 Heater and Ventilation: Repair Instructions HVAC Unit Components Blower Motor Removal and Installation S7RS0B7106001 S7RS0B7106003 For manual type A/C, refer to “HVAC Unit Components in Section 7B”. Removal For automatic type A/C, refer to “HVAC Unit 1) Disconnect negative (–) cable from battery. Components in Section 7B”.
Heater and Ventilation: 7A-5 6) Remove connector (1) from blower motor resistor • Check for operation and current. (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.
7A-6 Heater and Ventilation: Blower Motor Relay Inspection S7RS0B7106007 1) Remove junction block assembly referring to “BCM (Included in Junction Block Assembly) Removal and Installation in Section 10B”. 2) Disconnect blower motor relay (1) from junction block assembly (2). 3) Check that there is no continuity between terminal “C”...
Heater and Ventilation: 7A-7 HVAC Control Unit Removal and Installation 7) Remove two connectors from HVAC control unit. S7RS0B7106009 8) Remove HVAC control unit (1) from instrument panel. Removal 1) Disconnect negative (–) cable at battery. NOTE 2) Disable air bag system referring to “Disabling Air Be careful not to damage HVAC control unit Bag System in Section 8B”.
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7A-8 Heater and Ventilation: b. Move temperature control lever (1) and air flow c. Fix temperature control inner cable (1) to pin of control plate (2) fully to the arrow direction. temperature control lever and air flow control inner cable (2) to pin of air flow control plate, and then fix each outer cable (3) to each cable lock clamp.
Heater and Ventilation: 7A-9 Blower Speed Selector Inspection Air Intake Control Actuator Removal and S7RS0B7106010 Installation Check blower speed selector for each terminal to S7RS0B7106012 terminal continuity. If check result does not meet the following conditions, replace HVAC control unit. Removal 1) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and...
7A-10 Heater and Ventilation: Air Intake Control Actuator Inspection Center Ventilation Louver Removal and S7RS0B7106013 Installation Check air intake control actuator as follows: S7RS0B7106014 Removal 1) Using service wire, connect battery positive terminal to “a” terminal and battery negative terminal to 1) Disconnect negative (–) cable from battery.
Heater and Ventilation: 7A-11 Side Ventilation Louver Removal and Passenger side ventilation louver Installation Removal S7RS0B7106015 1) Disconnect negative (–) cable from battery. Driver side ventilation louver 2) Disable air bag system referring to “Disabling Air Removal Bag System in Section 8B”. 1) Disconnect negative (–) cable from battery.
7A-12 Heater and Ventilation: HVAC Air Filter Removal and Installation (If HVAC Air Filter Inspection (If Equipped) S7RS0B7106017 Equipped) Check that filter is not excessively dirty, damage or oily, S7RS0B7106016 clean filter with compressed air from air outlet side of filter.
Air Conditioning System: Manual Type 7B-1 Air Conditioning System HVAC Manual Type Precautions A/C System Caution S7RS0B7210001 CAUTION • The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
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7B-2 Air Conditioning System: Manual Type Refrigerant Line I4RS0B720001-02 1. Suction hose 4. Expansion valve : Apply compressor oil (refrigerant oil) to O-ring. : Apply compressor oil (refrigerant oil) to O-ring. 2. Discharge hose 5. A/C refrigerant pressure sensor : Apply compressor oil (refrigerant oil) to O-ring. : Apply compressor oil (refrigerant oil) to O-ring.
Air Conditioning System: Manual Type 7B-3 General Description Refrigerant Type Identification S7RS0B7211001 Whether the A/C system in the vehicle uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on label (1) on the compressor. Also, it can be checked by the shape of the service (charge) valve (2). I4RS0A720002-01 [A]: HFC-134a (R-134a) [B]: CFC-12 (R-12)
7B-4 Air Conditioning System: Manual Type Sub-Cool A/C System Description S7RS0B7211003 In the sub-cool A/C system (condenser integrated with receiver/dryer), the inside of the condenser is divided into the condensation part and the sub-cooler part, and the receiver/dryer is located between those. In the receiver/dryer, the refrigerant is separated into the vapor refrigerant and the liquid refrigerant.
Air Conditioning System: Manual Type 7B-5 Schematic and Routing Diagram Major Components of A/C System S7RS0B7212001 Airflow diagram I4RS0A720003-01 Major components of A/C system I4RS0B720002-01 1. HVAC unit 5. Discharge hose 9. Side ventilation air 13. Side defroster air 2. Compressor 6.
Air Conditioning System: Manual Type 7B-7 Diagnostic Information and Procedures A/C System Symptom Diagnosis S7RS0B7214001 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”.
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7B-8 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 system normal Condenser clogged Check condenser referring to “Condenser operation)
Air Conditioning System: Manual Type 7B-9 Condition Possible cause Correction / Reference Item Insufficient airflow of A/C evaporator clogged or frosted Check A/C evaporator and evaporator cooled air thermistor (evaporator temperature sensor) referring to “Evaporator Inspection” and “Evaporator Thermistor (Evaporator Temperature Sensor) Inspection”.
7B-10 Air Conditioning System: Manual Type Abnormal Noise from Tension Pulley Condition Possible cause Correction / Reference Item Clattering noise is heard Worn or damaged bearing Replace tension pulley. from pulley Pulley cranks upon Cracked or loose bracket Replace or retighten bracket. contact Abnormal Noise from A/C Evaporator Condition...
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Air Conditioning System: Manual Type 7B-11 5) Warm up engine to the normal operating 10) Check for each pressure of low side and high side if temperature and keep it at the specified idle speed. it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective 6) Turn A/C switch ON, set blower speed selector at part referring to the following table.
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7B-12 Air Conditioning System: Manual Type High pressure gauge Condition Possible cause Correction Refrigerant overcharged Recharge. Expansion valve frozen or clogged Check expansion valve. Clogged refrigerant passage of high pressure side Clean or replace. Radiator cooling fan malfunction Check radiator cooling fan. Pressure is higher than (Insufficient cooling of condenser) acceptable range...
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Air Conditioning System: Manual Type 7B-13 11) Check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature near air inlet of HVAC unit is 30 °C (86 °F) and the one at air outlet of center ventilation louver is 17 °C (62.6 °F), their crossing point is within acceptable range as shown in the graph.
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7B-14 Air Conditioning System: Manual Type Condition Manifold gauge MPa (kg/cm ) (psi) Possible cause Correction Detail 0.27 – 0.43 1.59 – 1.94 (2.7 – 4.3) (15.9 – 19.4) Normal condition — — (38 – 61) (226 – 276) The low pressure side Clean expansion reads a negative Dust particles or water...
Air Conditioning System: Manual Type 7B-15 Condition Manifold gauge MPa (kg/cm ) (psi) Possible cause Correction Detail Overcharged A/C Adjust refrigerant to system. specified amount. High pressure reading on Faulty condenser both low and high Clean condenser. cooling operation. pressure sides. Faulty radiator cooling Inspect and repair fan operation.
7B-16 Air Conditioning System: Manual Type Repair Instructions Operation Procedure for Refrigerant Charge S7RS0B7216001 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.
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Air Conditioning System: Manual Type 7B-17 NOTE • After recovering refrigerant from system, the amount of removed compressor oil must be measured for replenishing compressor oil. • When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
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7B-18 Air Conditioning System: Manual Type NOTE When replacing other parts Replenish the following amount of oil to compressor. • If the system does not show a vacuum Amount of compressor oil to be replenished below –100 kPa (–1.0 kg/cm , –760 mmHg, Evaporator: 25 cm (25 ml, 0.85 US.
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Air Conditioning System: Manual Type 7B-19 Charge Charge proper amount of refrigerant accurately in accordance with the following procedure. CAUTION Specified amount of refrigerant 370 ± 20 g (13.0 ± 0.7 oz) • Because the sight glass is not used for this A/C system, do not perform an additional The initial charge of the A/C system is performed charge to the A/C system.
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7B-20 Air Conditioning System: Manual Type 7) When refrigerant container (1) is emptied, use the 8) After the system has been charged with specified amount (370 ± 20 g) of refrigerant or when low following procedure to replace it with a new refrigerant container.
Air Conditioning System: Manual Type 7B-21 Condenser Assembly On-Vehicle Inspection Removal of Manifold Gauge Set S7RS0B7216002 Check the followings. WARNING • Clog of condenser fins High pressure side is under high pressure. If any clog is found, condenser fins should be washed Therefore, be careful not to get injured with water and should be dried with compressed air.
7B-22 Air Conditioning System: Manual Type 5) Remove condenser assembly (1) as shown. Installation Reverse the removal procedure noting the following instructions. • Replenish specified amount of compressor oil to compressor suction side referring to “When replacing other parts” in “Operation Procedure for Refrigerant Charge”.
Air Conditioning System: Manual Type 7B-23 HVAC Unit Components S7RS0B7216005 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side 21 * 15 * 15 * 15 * 14 * 14 * 10 * 11 *...
7B-24 Air Conditioning System: Manual Type 2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing 3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever 21. Filter cover (if equipped) 4. HVAC Air filter (if equipped) 10.
Air Conditioning System: Manual Type 7B-25 Evaporator Thermistor (Evaporator Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation Temperature Sensor) Inspection S7RS0B7216008 S7RS0B7216009 Removal Check resistance between terminals of evaporator thermistor (1). 1) Disconnect negative (–) cable from battery. If check results are as not specified, replace evaporator 2) Remove HVAC unit from vehicle body referring to thermistor.
Air Conditioning System: Manual Type 7B-27 A/C Switch Inspection Compressor Drive Belt Inspection and S7RS0B7216014 Adjustment • Check that there is continuity between terminal (1) S7RS0B7216016 Inspection and terminal (2) when A/C switch is at ON position. • Check compressor drive belt (1) for wear, crack, •...
7B-28 Air Conditioning System: Manual Type Compressor Drive Belt Removal and Installation S7RS0B7216017 Removal 1) Loosen tension pulley nut (1). 2) Loosen belt tension by loosening tension pulley adjusting bolt (2). 3) Remove compressor drive belt (3). I7RS0A721009-01 9) Remove compressor mounting bolts (1), and then remove compressor (2) from its bracket.
Air Conditioning System: Manual Type 7B-31 e) Disconnect battery negative terminal (–) to 4) Install magnet clutch lead wire clamp. compressor body assembly. (At this point, 5) Install magnet clutch pulley (1). magnet clutch plate and magnet clutch pulley are 6) Install new circlip (2) directing chamfer side (3) not in contact.) upward.
7B-32 Air Conditioning System: Manual Type Relief Valve Removal and Installation Installation S7RS0B7216030 Reverse removal procedure nothing the following instructions. Removal • Use new O-ring. 1) Recover refrigerant from the A/C system with • Apply compressor oil to O-ring. recovery and recycling equipment referring to •...
Air Conditioning System: Manual Type 7B-33 Special Tools and Equipment Recommended Service Material S7RS0B7218001 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 347W (100g) NOTE Required service material is also described in the following.
• 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).
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Air Conditioning System: Automatic Type 7B-35 Electronic Control System Location NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 10 * I5RS0C722001-01 1. ECT sensor 7. Blower motor 13. AUTO switch 19.
7B-36 Air Conditioning System: Automatic Type Auto A/C Electronic Control Input / Output Table HVAC control module Temperature selector Data link connector MODE (air flow) selector Blower speed selector Air intake selector A/C refrigerant pressure sensor A/C switch AUTO switch Temperature control actuator ECT sensor Compressor...
• CAN communication line trouble code (DTC) can be known by using When HVAC control module detects malfunction, the SUZUKI scan tool. For further details, refer to “AUTO” indicator lamp (1) flashes to warn and the “DTC Check”. diagnostic trouble code (DTC) is stored in the memory of the module.
Air Conditioning System: Automatic Type 7B-39 4. Rear defogger relay 15. Evaporator temperature sensor 26. Radiator cooling fan relay No.1 37. Rear defogger switch 5. Rear defogger 16. Sunload sensor 27. Radiator cooling fan relay No.2 38. To BCM 6. Blower motor relay 17.
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7B-40 Air Conditioning System: Automatic Type Condition Possible cause Correction / Reference Item No cool air comes out Fuse blown Check related fuses, and then check for short (radiator cooling fan circuit to ground. motor does not operate) Wiring or grounding faulty Repair as necessary.
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Air Conditioning System: Automatic Type 7B-41 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 system normal Condenser clogged Check condenser referring to “Condenser operation)
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.
DTC(s) can not be cleared unless the problem(s) is fixed. Using SUZUKI Scan tool 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side. I5RS0A722006-02...
5) Erase DTC according to instructions displayed on SUZUKI scan tool. NOTE To know how to use SUZUKI scan tool, refer to operator’s manual for SUZUKI scan tool. 6) After completing the clearance, turn ignition switch to OFF position, and then disconnect SUZUKI scan tool from DLC.
7B-46 Air Conditioning System: Automatic Type Scan Tool Data S7RS0B7224007 As the data values given in the following are standard values estimated on the basis of values obtained from the normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good condition, there may be cases where the checked values do not fall within each specifies data range.
Air Conditioning System: Automatic Type 7B-47 Scan Tool Data Definitions AIR MIX POS SEN (TEMPERATURE CONTROL TEMP CONT SWITCH (TEMPERATURE ACTUATOR POSITION SENSOR): Input signal SELECTOR): Position of temperature control from position sensor in temperature control actuator selector of HVAC control module MODE POS SENSOR (AIR FLOW CONTROL CABIN TEMPERATURE: In-car temperature detected ACTUATOR POSITION SENSOR): Input signal...
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7B-48 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 from is a standard sample. It should be modified according to conditions characteristic of each market.
Air Conditioning System: Automatic Type 7B-49 Step 7. Final confirmation test Confirm if the problem symptom is troubleshoot and the A/C system is free from any abnormal conditions. If there existed DTC, clear the DTC. Then, check if the DTC is still detected and if there is any other DTC. Visual Inspection S7RS0B7224009 Check visually the following parts and systems.
7B-50 Air Conditioning System: Automatic Type Step Action Inside air temperature sensor signal circuit check Go to Step 3. “PNK/BLK” wire open or high resistance circuit. 1) Disconnect connector from HVAC control module with ignition switch turned OFF. 2) Check for proper connection to HVAC control module connector at “G52-6”...
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Air Conditioning System: Automatic Type 7B-51 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Evaporator temperature sensor signal voltage is higher than or lower than • Evaporator temperature sensor specified value for specified time continuously. circuit • Evaporator temperature sensor •...
7B-52 Air Conditioning System: Automatic Type Step Action Evaporator temperature sensor check HVAC control module Evaporator temperature faulty. sensor faulty. 1) Check evaporator temperature sensor referring to “Evaporator Thermistor (Evaporator Temperature Sensor) Inspection”. Is it in good condition? DTC B1504: Sunload Sensor and/or Its Circuit Malfunction S7RS0B7224012 Wiring Diagram G52-2...