Table of Contents
Metric Fasteners
Engine Coolant Change
Steering, Suspension
Wear Indicators
Steering Rack
Diagnostic System
Torque Sensor
Handling Precaution
Steering Wheel
Rear Shock Absorber
Rear Axle
Balancing Wheels
Road Testing Brakes
Substandard or Contaminated Brake Fluid
Brake Fluid Leaks
Excessive Pedal Travel Check
Brake Pedal Play Check
Brake Fluid Level Check
Flushing Brake Hydraulic System
Booster Operation Check
Master Cylinder Assembly
Brake Booster
Knock Sensor
Fuel Filler Cap
Egr System
Pcv System
Body Electrical System
Brake Lights
Oil Pressure Light
Oil Pressure Warning Light
Door Switch
Rear Wiper and Washer
Rear Wiper Arm
Front Door Window Regulator
Door Mirror
Rear Door Glass
Rear Door Window Regulator
Quarter Window
Rear Door Assembly
Key Coding
PROPELLER SHAFT Front Drive Shaft
Brakes
Fuel Injector
Manifold Absolute Pressure Sensor
Main Relay
Radiator Fan
Noise Suppressor
Disassembly and Assembly
Intermediate Shaft
Component Inspection
Transfer Assembly
Front Seat
Rear Seat
Electronic Ignition System
Key Cylinder Switch
General Information
Precaution for Can Communication System
Electrical Circuit Inspection Procedure
Intermittents and Poor Connection
Identification Information
Warning, Caution and Information Labels
Vehicle Lifting Points
Abbreviations and Symbols May be Used in this Manual
Symbols
Metric Fasteners
Fasteners Strength Identification
How to Use this Manual
Precautions
Diagnosis
Servicing and Handling
General Precautions
Precautions for Catalytic Converter
Precautions for Electrical Circuit Service
Electrical Circuit Inspection Procedure
Intermittent and Poor Connection
Blower Motor
Air Filter Element
Camshaft Inspection
Evaporative Emission Control System
Multi Information Display
Vorsichtsmaßregeln
Voorzorgsmaatregelen
Allgemeines Informationen
Bezeichnungen des Steckverbindungsplans
Algemene Informatie
Lezen Van Een Stekkerschema
Ablesen der Steckverbindungscodes und Klemmennummern
Lezen Van Stekkercodes en Aansluitingnummers
Ermittlung des Massepunkts
Lezen Van Een Massapunt
Erklärung eines Stromversorgungsdiagramm
Lezen Van Een Voedingsschema
Fuse Number
Erklärung eines Systemschaltdiagramms
Lezen Van Een Elektrisch Schema
Symbole und Markierungen
Symbolen en Merktekens
Abkürzungen
Afkortingen
Symbole der Kabel und Steckerfarben
Kleurcodes Voor Draden/Stekkers
Stecker-Layout-Diagramm
Motorraum
A: Batterie-Kabelbfaum
A: Faisceau de Câbles de la Batterie
C: Motor-Kabelbaum
Stekkerschema
Motorruimte
A: Accubedradingsbundel
C: Motorbedradingsbundel
B: Klimaanlagen-Kabelbaum
G: Instrumententafel-Kabelbaum
B: A/C-Bedradingsbundel
G: Instrumentenpaneelbedradingsbundel
D:einspritzventil-Kabelbaum (G10)
D: Verstuiverbedradingsbundel (G10)
D:einspritzventil-Kabelbaum (DSL)
E: Haupt-Kabelbaum (G10)
E: Hoofdbedradingsbundel (G10)
E: Haupt-Kabelbaum (M13A)
E: Hoofdbedradingsbundel (M13A)
E: Haupt-Kabelbaum (DSL)
E: Hoofdbedradingsbundel (DSL)
Armaturenbrett
E: Haupt-Kabelbaum
Instrumentenpaneel
E: Hoofdbedradingsbundel
G: Instrumententafel-Kabelbaum
G: Instrumentenpaneelbedradingsbundel
Dach, Heck
K: Dachleitung, Hinterer Dachdraht,Kabel für Oberes Bremslicht, Draht für Heckscheibenwischer, Heckscheibenbeheizungsdraht
O: Hecktür-Kabelbaum
R: Kraftstoffpumpen-Signalleitung
Dak, Achter
K: Dakdraad, Achterdakdraad, Draad Van Hooggemonteerd Remlicht, Achterruitwisserdraad, Achterruitverwarmingsdraad
O: Kofferdekselbedradingsbundel
R: Brandstofpompdraad
J: Fronttürkabel, Hecktürkable
J: Voorportierdraad, Achterportierdraad
Boden
L: Boden-Kabelbaum
Vloer
L: Vloerbedradingsbundel
G: Instrumententafel-Kabelbaum
Q: Gurtstrafferkabel
G: Instrumentenpaneelbedradingsbundel
Q: Gordelvoorspannerdraad
Massepunkt (G10 / M13A)
Massapunt (G10 / M13A)
Massepunkt (DSL)
Massapunt (DSL)
Stromversorgungsdiagramm
Stromversorgungsdiagramm (G10 / M13A)
Voedingsschema
Voedingsschema (G10 / M13A)
Stromversorgungsdiagrammåidsl)
Voedingsschema (DSL)
Sicherungen und Geschützte Teile
Hauptsicherungskasten
Zekeringen en Beschermde Onderdelen
Hoofdzekeringenkast
Einzelschaltkreissicherungskasten
Individuele Circuitzekeringenkast
Zusatzsicherungskasten (DSL)
Hulpzekeringenkast (DSL)
Systemschaltdiagramm
Kurbelsystem
Elektrisch Schema
Startsysteem
Ladesystem
Laadsysteem
Kühlsystem (G10 / M13A)
Koelsysteem (G10 / M13A)
Kühlsystem (DSL)
Koelsysteem (DSL)
Zündanlage (G10)
Ontstekingssysteem (G10)
Zündanlage (M13A)
Ontstekingssysteem (M13A)
Motor-Und Klimaanlagen-Steuerystem (G10)
Motor- en A/C-Regelsysteem (G10)
Motor-Und Klimaanlagen-Steuerystem (M13A)
Motor- en A/C-Regelsysteem (M13A)
Motor-Und Klimaanlagen-Steuerystem (DSL)
Motor- en A/C-Regelsysteem (DSL)
A/T-Steuersystem
A/T-Regelsysteem
Wegfahrsperrensystem
Startblokkeersysteem
Frontschweibnwischer und Waschanlage
Voorruitwisser- en Sproeier
Heckschweibenwischer und Waschanlage
Achterruitwisser- en Sproeier
Heckscheibenentfeuchter
Achterruitverwarming
Elektrische Fensterheber
Elektrische Ruitbediening
Elektrische Türverriegelung
Centrale Portiervergrendeling
Elektrisch Verstellbarer Spiegel
Elektrisch Verstelbare Spiegel
Hupe
Claxon
Kombinationsinstrument (Meter) (G10)
Combinatiemeter (Meter) (G10)
Kombinationsinstrument (Meter) (M13A / DSL)
Combinatiemeter (Meter) (M13A / DSL)
Kombinationsinstrument (Anzeigelampe)
Combinatiemeter (Indicator)
Kombinationsinstrument (Wrnleuchte)
Combinatiemeter (Waarschuwingslampje)
Scheinwerferanlage (ohne DRL-System)
Koplampsysteem (Zonder DRL-Systeem)
Scheinwerferanlage (mit DRL-System)
Koplampsysteem (Met DRL-Systeem)
Begrenzungs-,Heck-Und Kennzeichenleuchte
Parkeerlicht, Achterlicht en Kentekenplaatverlichting
Beleuchtungslampe
Verlichting
Innenbeleuchtung (ohne Zentralverriegelung)
Interieurverlichting (Zonder Centrale Portiervergrendeling)
Innenbeleuchtung (mit Zentralverriegelung)
Interieurverlichting (Met Centrale Portiervergrendeling)
Scheinwerfer-Nivelliersystem
Koplamphoogteverstellingssysteem
Blinklicht und Warnleuchte
Richtingaanwijzer en Alarmknipperlicht
Bremsleuchte
Remlicht
Rückfahrleuchte
Achteruitrijlicht
Vordere Nebelleuchten
Voormistlicht
Hecknebelleuchte
Heizung und Klimaanlage (G10 / M13A)
Heizung und Klimaanlage (DSL)
Antiblockiersystem
Airbag-Steuersystem
Servolenkung
Radio
Zigarettenanzünder
Uhr
Liste der Stecker
Connector List

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See also: Owner's Manual , Instruction Manual

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions

carefully. To emphasize special information, the

words WARNING, CAUTION and NOTE have spe-

cial meanings. Pay special attention to the messages

highlighted by these signal words.

WARNING:

Indicates a potential hazard that could result in

death or injury.

CAUTION:

Indicates a potential hazard that could result in

vehicle damage.

NOTE:

Indicates special information to make mainte-

nance easier or instructions clearer.

WARNING:

This service manual is intended for authorized

Suzuki dealers and qualified service mechan-

ics only. Inexperienced mechanics or mechan-

ics without the proper tools and equipment

may not be able to properly perform the ser-

vices described in this manual.

Improper repair may result in injury to the me-

chanic and may render the vehicle unsafe for

the driver and passengers.

WARNING:

For vehicles equipped with a Supplemental

Restraint Air Bag System:

D Service on and around the air bag system

components or wiring must be performed

only by an authorized SUZUKI dealer.

Please observe all WARNINGS and CAU-

TIONS in SECTION 10B and Precautions, Air

Bag System Components and Wiring Loca-

tion View in SECTION 10B or before perform-

ing service on or around the air bag system

components or wiring. Failure to follow

WARNINGS could result in unintentional ac-

tivation of the system or could render the

system inoperative. Either of these two

conditions may result in severe injury.

D If the air bag system and another vehicle sys-

tem both need repair, Suzuki recommends

that the air bag system be repaired first, to

help avoid unintended air bag deployment.

D Do not modify the steering wheel, instru-

ment panel or any other air bag system com-

ponent (on or around air bag system compo-

nents or wiring). Modifications can adverse-

ly affect air bag system performance and

lead to injury.

D If the vehicle will be exposed to tempera-

tures over 93_C (200_F)(for example, during

a paint baking process), remove the air bag

system components (air bag (inflator) mod-

ules, SDM and/or seatbelt with pretension-

er) beforehand to avoid component damage

or unintended deployment.

Table of Contents

Chapters

Table of Contents

Summary of Contents for Suzuki Wagon R

Page 1 D Service on and around the air bag system cial meanings. Pay special attention to the messages components or wiring must be performed highlighted by these signal words. only by an authorized SUZUKI dealer. Please observe all WARNINGS and CAU- WARNING: TIONS in SECTION 10B and Precautions, Air...
Page 2 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 (lubricant, sealants, etc.) as specified in each description.
Page 4 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION GENERAL INFORMATION ENGINE General Information General Information and Engine Diagnosis Maintenance and Lubrication Engine Mechanical HEATING AND AIR Engine Cooling CONDITIONING Engine Fuel Heater and Ventilation Engine and Emission Air Conditioning Control System (If Equipped) Ignition System STEERING, SUSPENSION,...
Page 6: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ............. . . 0A- 2 PRECAUTIONS .
Page 7 0A-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
Page 8 D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 9 0A-4 GENERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WARNING: WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BODY. Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment.
Page 10 GENERAL INFORMATION 0A-5 WARNING: D During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. D Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
Page 11 0A-6 GENERAL INFORMATION CAUTION: D Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in SECTION 10B. D When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, re- move those parts beforehand.
Page 12 GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
Page 13 0A-8 GENERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position.
Page 14 GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never dis- connect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
Page 15 0A-10 GENERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g.
Page 16 GENERAL INFORMATION 0A-11 D When connecting meter probe (2) from terminal side of cou- pler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its fe- male terminal open for connection. In case of such coupler as shown connect probe as shown to avoid opening female terminal.
Page 17 0A-12 GENERAL INFORMATION When checking system circuits including an electronic control unit such as ECM, TCM, ABS control module, etc., it is important to per- form careful check, starting with items which are easier to check. 1) Disconnect negative cable from battery. 2) Check each connector at both ends of the circuit being checked Sensor for loose connection.
Page 18 GENERAL INFORMATION 0A-13 Voltage check If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. 1) With all connectors connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.
Page 19 0A-14 GENERAL INFORMATION 4) Disconnect the connector included in circuit (connector B) and measure resistance between A-1 and body ground. To other parts If continuity is indicated, it means that the circuit is shorted to the ground between terminals A-1 and B-1. INTERMITTENTS AND POOR CONNECTION Most intermittents are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at...
Page 20 GENERAL INFORMATION 0A-15 D Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to en- sure good contact tension by using the corresponding mating ter- minal. If contact tension is not enough, reform it to increase contact ten- sion or replace.
Page 21 0A-16 GENERAL INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is located on the front dash panel in the engine room. ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block. TRANSMISSION IDENTIFICATION NUMBER For M / T The number is located on the transmission case.
Page 22 GENERAL INFORMATION 0A-17 WARNING, CAUTION AND INFORMATION LABELS The figure below 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. Air bag caution label Tire information placard Seat belt pretensioner warning label on retracter...
Page 23 0A-18 GENERAL INFORMATION VEHICLE LIFTING POINTS WARNING: D Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending on what part to be removed. D Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 24 GENERAL INFORMATION 0A-19 In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the wooden block (5) on the jack against front jacking bracket (1) or the center portion of rear axle (2). CAUTION: D Never apply jack against suspension parts (i.e., stabilizer (3), etc.), front bumper (4) or vehicle floor, otherwise it may...
Page 25 0A-20 GENERAL INFORMATION ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL ABBREVIATIONS : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Engine Control Module : Automatic Locking Retractor ECT Sensor...
Page 26 GENERAL INFORMATION 0A-21 : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch MAF Sensor : Mass Air Flow Sensor : Transmission Control Module (Air Flow Sensor, AFS, Air (A/T Controller, A/T Control Flow Meter, AFM) Module)
Page 27 GREASE E 99000-25050 1333B 99000-32020 Apply SUZUKI SUPER Apply THREAD LOCK GREASE H 99000-25120 1342 99000-32050 Apply SUZUKI SUPER GREASE I 99000-25210 Apply SUZUKI BOND NO. Do not reuse 1215 99000-31110 Apply SUZUKI BOND NO. Note on reassembly 1207C 99000-31150...
Page 28: Metric Fasteners
GENERAL INFORMATION 0A-23 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are JIS-defined and ISO- defined metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. CAUTION: Even when the nominal diameter (1) of thread is the same, the thread pitch (2) or the width across flats (3) may vary be-...
Page 29 0A-24 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation 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 fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
Page 30 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 31 0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), Interval: carry out the same services at the same intervals respectively. This inter al sho ld be j dged b odometer This interval should be judged by odometer km (x 1,000) reading or months whichever comes first...
Page 32 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), Interval: carry out the same services at the same intervals respectively. Thi i t This interval should be judged by odometer ld b j d km (x 1,000) reading or months whichever comes first...
Page 33 0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 34 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and adjusting belt tension. Water pump belt inspection 1) Remove engine under cover of right side from vehicle body. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
Page 35 0B-6 MAINTENANCE AND LUBRICATION ITEM 1-2 Camshaft Timing Belt Replacement Replace belt with new one. Refer to SECTION 6A1 for replacement procedure. CAUTION: D Do not bend or twist timing belt. D Do not allow timing belt to come into contact with oil, wa- ter, etc.
Page 36 MAINTENANCE AND LUBRICATION 0B-7 3) Loosen oil filter (1) by using oil filter wrench (Special tool). Special Tool (A): 09915-47330 4) Apply engine oil to new oil filter “O” ring. 5) Screw new filter on oil filter stand by hand until filter “O” ring con- tacts mounting surface.
Page 37: Engine Coolant Change
0B-8 MAINTENANCE AND LUBRICATION ITEM 1-5 Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove radia- tor cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
Page 38 MAINTENANCE AND LUBRICATION 0B-9 ITEM 1-6 Exhaust System Inspection WARNING: To avoid danger of being burned, do not touch exhaust sys- tem when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance or vehicle is raised for oth- er service, check exhaust system as follows: D Check rubber mountings for damage and deterioration.
Page 39 0B-10 MAINTENANCE AND LUBRICATION IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1. FUEL SYSTEM ITEM 3-1 Air Cleaner Filter Inspection 1) Unclamp air cleaner case clamps. 2) Take cleaner filter out of air cleaner case. 3) Visually check that air cleaner filter is not excessively dirty, dam- aged or oily.
Page 40 MAINTENANCE AND LUBRICATION 0B-11 EMISSION CONTROL SYSTEM ITEM 4-1 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hoses and PCV hoses for leaks, cracks or clog, and PCV valve (1) for stick or clog. Refer to Section 6E for PCV valve checking procedure. ITEM 4-2 Fuel Evaporative Emission Control System Inspection WARNING:...
Page 41 0B-12 MAINTENANCE AND LUBRICATION ITEM 5-2 Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use a mirror as necessary. D Check brake hoses and pipes for proper hook-up, leaks, cracks, chafing, wear, corrosion, bends, twists and other damage. Replace any of these parts as necessary.
Page 42 MAINTENANCE AND LUBRICATION 0B-13 CHASSIS AND BODY ITEM 6-1 Clutch Pedal Free Travel Inspection (Cable type only) Check clutch pedal free travel “a”. Refer to SECTION 7C for proce- dure to check and adjust it. ITEM 6-2 Tire/Wheel Disc Inspection [Tire inspection] 1) Check tire for uneven or excessive wear, or damage.
Page 43 0B-14 MAINTENANCE AND LUBRICATION Wheel Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to FRONT SUSPENSION INSPEC- TION of SECTION 3D. 2) Check rear wheel bearing for wear, damage abnormal noise or rattle.
Page 44 MAINTENANCE AND LUBRICATION 0B-15 3) Check steering linkage for looseness and damage. Repair or re- place defective parts, if any. 4) Check boots of steering linkage and steering gear case for dam- age (leaks, detachment, tear, etc.). If damage is found, replace defective boot with new one.
Page 45 0B-16 MAINTENANCE AND LUBRICATION ITEM 6-7 Automatic Transmission Fluid Inspection and Change [Fluid level inspection] 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Unclamp dipstick and pull out it.
Page 46 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-9 Ventilator Air Filter (if equipped) Inspection 1) Remove air filter from air inlet box or cooling unit referring to Sec- tion 1B. 2) Check filter for dirt. Replace excessively dirty filter. 3) Blow off dust by compressed air from air outlet side of filter. 4) Install filter to air inlet box or cooling unit referring to Section 1B.
Page 47 0B-18 MAINTENANCE AND LUBRICATION FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.
Page 48 MAINTENANCE AND LUBRICATION 0B-19 Steering Body, Wheels and Power Transmitting System D Check to ensure that steering wheel is free from in- Check that body, wheels and power transmitting sys- stability, or abnormally heavy feeling. tem are free from abnormal noise and abnormal D Check that the vehicle does not wander or pull to vibration or any other abnormal condition.
Page 50 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 51 1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heater and ventilation consist of the following parts. 1. Heater Unit 2. Air inlet box 3. Ventilator duct 4. Defroster nozzle 5. Ventilator outlet 6. Side ventilation air 7. Foot air 8. Front defroster air 9.
Page 52 HEATER AND VENTILATION 1A-3 DIAGNOSIS DIAGNOSIS TABLE Trouble Possible Cause Remedy Heater blower won’t work D Blower fuse blown Check for short to ground and replace even when its switch is fuse. D Blower resistor faulty Check resistor. D Blower switch faulty Check blower switch.
Page 53 1A-4 HEATER AND VENTILATION ON VEHICLE SERVICE HEATER UNIT 1. Heater core 2. Blower motor assembly 3. Blower resistor 4. Temperature door assembly 5. Mode door assembly 6. Mode lever 7. Temperature lever 8. Heater case REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system.
Page 54 HEATER AND VENTILATION 1A-5 INSTALLATION Install heater unit by reversing removal procedure, noting the fol- lowing items. D When installing each part, be careful not to catch any cable or wir- ing harness. D Adjust heater control cable (refer to heater control lever assembly in this section).
Page 55 1A-6 HEATER AND VENTILATION INSTALLATION 1) Reverse removal procedure for installation. 2) Enable air bag system, if equipped. Refer to ENABLING AIR BAG SYSTEM in Section 10B. BLOWER MOTOR RESISTOR INSPECTION Measure each terminal-to-terminal resistance on resistor. Resistance H – Mh : Approx. 0.6 Ω Mh –...
Page 56 HEATER AND VENTILATION 1A-7 HEATER CONTROL LEVER ASSEMBLY 1. Heater control body assembly 2. Temperature control knob assembly (& A / C switch, if equipped) 3. Blower fan & defogger switch assembly 4. Bulb 5. Fresh air control cable 6. Mode control cable 7.
Page 57 1A-8 HEATER AND VENTILATION INSTALLATION LH VEHICLE 1) Reverse removal procedure for installation. 2) Adjust cables as follows. i) Move mode control knob (a), temperature control knob (b) and fresh air control knob (c) fully in arrow direction as shown in figure.
Page 58 HEATER AND VENTILATION 1A-9 BLOWER FAN & DEFOGGER SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove ashtray, instrument center upper garnish (1), heater control knob (3), instrument center lower garnish (2) and radio or accessory case (if equipped). 3) Disconnect blower fan switch coupler.
Page 59 1A-10 HEATER AND VENTILATION AIR INLET BOX 1. Cooling unit packing 2. Dash packing 3. Packing 4. Drain hose 5. Blank 6. Door link 7. Air inlet door 8. Evaporator case 9. Air resistance board REMOVAL AND INSTALLATION Refer to “COOLING UNIT” in “AIR CONDITIONING” section. VENTILATION LOUVER REMOVAL AND INSTALLATION Remove ventilation louver (1) as shown in figure, and reverse re-...
Page 60 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 61 1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on LABEL (1) on the com- pressor. Also, it can be checked by the shape of the service (charge) valve (2).
Page 62 AIR CONDITIONING (OPTIONAL) 1B-3 MAJOR COMPONENTS AND LOCATION 1. Cooling unit 2. Compressor 3. Condenser assembly 4. Receiver / dryer 5. Discharge hose 6. Suction hose 7. Liquid pipe 8. Expansion valve 9. Side ventilation air 10. Center ventilation air 11.
Page 63 1B-4 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction Cool air does not come A/C system inoperative out (A/C system D No refrigerant Recover, evacuation and charging. improper operative) D Fuse blown Check “IG COIL” fuse, “HEATER” fuse and check for short circuit to ground.
Page 64 AIR CONDITIONING (OPTIONAL) 1B-5 Condition Possible Cause Correction Cool air does not come D Compressor faulty Check compressor. out or insufficient D Air in A/C system Replace receiver/dryer, and cooling (A/C system evacuation and charging. normal operative) D Air leaking from cooling unit or air duct Repair as necessary.
Page 65 1B-6 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT CHARGE CHARGE OF REFRIGERANT When the A/C inlet temperature is within 30 – 35_C. The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its maximum cooling ca- pacity for a few minutes.
Page 66 AIR CONDITIONING (OPTIONAL) 1B-7 DIAGNOSIS TEST 1) Confirm that vehicle and environmental conditions are as follows. – Vehicle is not exposed to direct sun. – Ambient temperature is within 15_C – 35_C (59_F – 95_F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
Page 67 1B-8 AIR CONDITIONING (OPTIONAL) 9) Check for each pressure of low side and high side if it is within shaded range of left graph. NOTE: Pressure registered on gauge varies with ambient temper- ature. Therefore, use left graphs when determining if pres- sures are normal or not.
Page 68 AIR CONDITIONING (OPTIONAL) 1B-9 DIAGNOSIS TEST TABLE TESTING RESULTS POSSIBLE CAUSE REMEDY Pressure high D Refrigerant overcharged D Recharge (“A” area of high side D Expansion valve frozen or clogged D Check expansion valve graph) D Clogged refrigerant passage of high side D Clean or replace D Condenser fan malfunction Insufficient...
Page 69 1B-10 AIR CONDITIONING (OPTIONAL) DETAIL DIAGNOSIS TABLE AT AMBIENT TEMPERATURE WITHIN 30 – 35_C (85 – 95_F) MANIFOLD kg / cm GAUGE CONDITION CAUSE CORRECTION 0.23 – 0.35 1.4 – 1.75 ––––––––– ––––––––– 2.3 – 3.5 14 – 17.5 Normal condition. 33 –...
Page 70 AIR CONDITIONING (OPTIONAL) 1B-11 WIRING CIRCUIT Main Main Main Main HEATER COIL 1. Blower motor 2. Blower resistor 3. Blower fan switch 4. Dual pressure switch 5. A / C switch 6. A / C blower motor relay 7. Radiator (and condenser) cooling fan relay 8.
Page 71 1B-12 AIR CONDITIONING (OPTIONAL) A/C SYSTEM INSPECTION OF ECM AND ITS Fig. A CIRCUITS ECM and its Circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers dis- connected from it.
Page 72 AIR CONDITIONING (OPTIONAL) 1B-13 ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL Measurement Terminal Wire Circuit Normal value Condition ground ECM ground for Ground to body E21-01 sensor circuit –0.5 – 0 volt Ignition switch ON (Fig A) (E21-10, E23-10) ECM ground for Ground to body E21-02...
Page 73 1B-14 AIR CONDITIONING (OPTIONAL) A/C COMPRESSOR DRIVE BELT INSPECTION 1) Check belt for wear and cracks, and replace as required. 2) Check belt tension by measuring how much it deflects when “a” pushed at intermediate point between compressor pulley (1) and crankshaft pulley (2) with about 100 N (10 kg, 22 lbs) force.
Page 74 AIR CONDITIONING (OPTIONAL) 1B-15 RECOVERY, EVACUATION AND CHARGING OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT Start evacuating Start evacuating Start evacuating Start evacuating Start evacuating 15 minutes (above 750 mmHg) Stop evacuating Inspect and repair connections Wait 10 minutes If gauge shows abnormal conditions Check system for pressure tightness...
Page 75 1B-16 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE NOTE: When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe the following instructions. D When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immedi- ately.
Page 76 AIR CONDITIONING (OPTIONAL) 1B-17 INSTALLATION Reverse removal sequence to install condenser, noting the follow- ing point. D If replace condenser, pour 15 cc of refrigerating oil to compressor suction-side. D Evacuate and charge system according to previously described procedure. INSPECTION Check the following.
Page 77 1B-18 AIR CONDITIONING (OPTIONAL) RADIATOR (AND CONDENSER) COOLING FAN MOTOR INSPECTION 1) Check continuity between each two terminals. If there is no continuity, replace radiator (and condenser) cooling fan motor. 2) Connect battery (1) to radiator (and condenser) cooling fan mo- tor coupler (2) as shown in figure, then check that the radiator (and condenser) cooling fan motor operates smoothly.
Page 78 AIR CONDITIONING (OPTIONAL) 1B-19 COOLING UNIT (EVAPORATOR) 1. Evaporator 2. Expansion valve 3. Evaporator case 4. Packing 5. Drain hose 6. Air inlet door 7. Evaporator thermistor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Recover refrigerant from refrigeration system by using recovery and recycling equipment.
Page 79 1B-20 AIR CONDITIONING (OPTIONAL) INSTALLATION Reverse removal sequence to install cooling unit, noting the follow- ing points. D If cooling unit or evaporator is replaced, pour 25 cc of refrigerating oil to compressor suction-side. D Install uniformly the padding (1) to installation hole. D Evacuate and charge system according to previously described procedure.
Page 80 AIR CONDITIONING (OPTIONAL) 1B-21 EXPANSION VALVE INSPECTION Refer to “Troubleshooting Procedure Using Manifold Gauge Set” earlier in this section for inspection. REMOVAL 1) Recover refrigerant from refrigeration system by using recovery and recycling equipment. 2) Loosen liquid pipe mounting bolt (1). 3) Loosen expansion attaching bolts (2) and remove expansion valve (3).
Page 81 1B-22 AIR CONDITIONING (OPTIONAL) A/C SWITCH INSPECTION 1) Remove heater control lever assembly, refer to “HEATER CON- TROL LEVER ASSEMBLY” in Section 1A. 2) Check following points for A/C switch. D Pull A/C Switch nob and check it there is continuity between terminals “A”...
Page 82 AIR CONDITIONING (OPTIONAL) 1B-23 A/C BLOWER FAN RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove A/C blower fan relay (1) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay. 4) Connect battery positive (+) terminal to terminal “b”...
Page 83 1B-24 AIR CONDITIONING (OPTIONAL) COMPRESSOR REMOVAL 1) RUN engine at idle speed with air conditioning ON for 10 min- utes. After that stop the engine. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system by using recov- ery and recycling equipment.
Page 84 AIR CONDITIONING (OPTIONAL) 1B-25 D Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION” in this section. CAUTION: Be sure to use HFC-134a (R-134a) compressor oil. NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Oil amount in compressor: 120 cm (120 cc, 7.5 in REPLENISHING COMPRESSOR OIL...
Page 85 1B-26 AIR CONDITIONING (OPTIONAL) MAGNET CLUTCH a. Front head bolt b. Front head bolt : Tighten bolt (a) first, and next (b). c. Armature plate bolt 1. Thermal switch 2. Compressor body 3. O-ring 4. Lip type seal 5. Front head 6.
Page 86 AIR CONDITIONING (OPTIONAL) 1B-27 REMOVAL 1) Remove compressor from vehicle. Refer to COMPRESSOR in this section. 2) Fix clutch plate (1) with special tool (A) and remove clutch plate bolt (2) and washer (3). Special Tool (A): 09991-06020 3) Using special tool (B) if necessary, remove clutch plate (1). Special Tool (B): 09991-06030 4) Remove shims from shaft.
Page 87 1B-28 AIR CONDITIONING (OPTIONAL) INSTALLATION 1) Install clutch coil (2). Protrusion on under side of clutch coil must match hole in com- pressor (3) to prevent movement and correctly locate lead wire. 2) Using special tool (C), install circlip (1) as shown. Special Tool (C): 09900-06107 3) Install clutch pulley (1).
Page 88 AIR CONDITIONING (OPTIONAL) 1B-29 LIP SEAL REMOVAL 1) Remove magnet clutch, referring to “MAGNET CLUTCH” in this section. 2) Remove front head (1) mounting bolts (a), (b). 3) Remove front head (1) by pushing cylinder shaft (2). PUSH NOTE: Be careful not to remove cylinder from front head. 4) Remove O-ring.
Page 89 1B-30 AIR CONDITIONING (OPTIONAL) 2) Coat special tool (F) surface with oil and place it on the shaft. Special Tool (F): 09991-06040 3) Install O-ring (2) to case. 4) Apply compressor oil to lip seal and O-ring. 5) Install front head (1). Special Tool (F): 09991-06040 6) Tighten front head mounting bolts (a), (b).
Page 90 AIR CONDITIONING (OPTIONAL) 1B-31 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Compressor oil COMPRESSOR OIL RS20 (150 cc) D O-ring (Refrigerant oil) 99000-99088 D Each Component REFRIGERANT DRUM (200 g) Refrigerant D Refrigerant charge 95794-50G00 SPECIAL TOOLS 09900-06107 Snap ring pliers...
Page 92: Steering, Suspension
STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ..............FRONT END ALIGNMENT .
Page 93 3-2 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS GENERAL DIAGNOSIS Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 94 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Reference Item Shimmy, Shake or D Tire or wheel out of balance Balance wheels or general balance Vibration procedure in Section 3F D Loosen wheel bearings Knuckle/Bearing in Section 3D and/or wheel bearing and wheel stud in Section D Worn tie rod ends Tie rod end in Section 3B...
Page 95 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Reference Item Rack and Pinion D Loose steering gear case bolts Manual rack and pinion assembly in Noise Section 3B (Rattle or Chuckle) D Worn rack bush Rack bushing in Section 3B D Rack and pinion adjustment Steering rack plunger in Section 3B Abnormal Noise,...
Page 96 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Condition Possible Cause Reference Item Low or Uneven Trim D Broken or sagging springs Strut damper assembly in Section 3D or Height coil spring in Section 3E Right-to-left trim D Over loaded Check loading height (H) difference D Incorrect springs Strut damper assembly in Section 3D or...
Page 97: Wear Indicators
3-6 STEERING, SUSPENSION, WHEELS AND TIRES TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, im- proper alignment. If the following conditions are noted, rotation is necessary: 1) Front tire wear is different from rear.
Page 98 STEERING, SUSPENSION, WHEELS AND TIRES 3-7 1) Ride vehicle to determine whether the front or rear waddles. 2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end of ve- hicle.
Page 99 3-8 STEERING, SUSPENSION, WHEELS AND TIRES RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment 2) Uneven brake adjustment 3) Tire construction The way in which a tire is built can produce lead in a vehicle.
Page 100 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ..... SECTION 3 Preliminary Checks Prior to Adjusting Front Alignment .
Page 101 3A-2 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel.
Page 102 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length (“A”...
Page 104 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 105 3B-2 MANUAL RACK AND PINION GENERAL DESCRIPTION The rack and pinion steering system consists of two components, the rack (1) and the pinion (2). When the steering wheel (3) is turned, the motion is transmitted to the steering shaft joint (4) and then to the pinion (2). Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear motion.
Page 106 MANUAL RACK AND PINION 3B-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. STEERING WHEEL CHECK Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.1 in.) If steering wheel play is not within specification, inspect as follows and replace if found defective.
Page 107 3B-4 MANUAL RACK AND PINION TIE ROD END BOOTS CHECK Inspect each boot for tear. If even a small tear is noted, replace with new one. STEERING SHAFT JOINT CHECK Check shaft joint for wear, breakage and other damage and replace if any defect exists.
Page 108 20. Steering shaft join LUBRICATION When inner parts of the steering gear case were dis- * SUZUKI SUPER GREASE (E) 99000- assembled, they should be washed clean before 25050, or Lithium grease (applicable for reassembly. It is recommended to use the grease as –40_C X 130_C or –40_F X 266_F)
Page 109 3B-6 MANUAL RACK AND PINION TIE ROD END REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove tie rod end nut (1) from steering knuckle. 3) Disconnect tie rod end from knuckle, using puller (1). 4) For ease of adjustment after installation, make marking (1) of tie rod end lock nut (2) position on tie rod end thread.
Page 110 MANUAL RACK AND PINION 3B-7 3) Inspect for proper toe (Refer to FRONT END ALIGNMENT). 4) After confirming proper toe, tighten tie rod end lock nut to speci- fied torque. Tightening Torque (a): 45 N m (4.5 kg-m, 32.5 lb-ft) 5) Tighten wheel to specified torque and lower hoist.
Page 111 3B-8 MANUAL RACK AND PINION MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL CAUTION: Be sure to set front wheels in straight direction and remove ignition key from key cylinder before these steps, otherwise contact coil of air bag system may get damaged. 1) Slide driver’s seat as far back as possible.
Page 112 MANUAL RACK AND PINION 3B-9 9) Remove steering gear case mount bolts (1), nuts (2) and gear case brackets, then remove gear case (3). INSTALLATION 1) Apply grease to inside of pinion packing and install pinion pack- ing onto pinion. Mount steering gear case (1) to body and tighten gear case mount bolts (2) and nuts (3) to specified torque.
Page 113 3B-10 MANUAL RACK AND PINION 7) Reinstall cover (1) removed previously to steering shaft joint. 8) Put back floor mat as it was. 9) Install both wheels and tighten wheel nuts to specified torque. Tightening Torque for wheel nuts: 85 N m (8.5 kg-m, 61.5 lb-ft) 10) Lower hoist.
Page 114 MANUAL RACK AND PINION 3B-11 RACK BOOT/TIE ROD REMOVAL 1) Remove steering gear case by performing Steps 1) – 9) in MANUAL RACK AND PINION REMOVAL of this section. 2) For ease of adjustment after installation, make marking (1) of tie rod end lock nut position of tie rod end thread.
Page 115 3B-12 MANUAL RACK AND PINION INSTALLATION 1) Install new tie rod (1) to rack (2). 2) Hold rack with soft jawed vise and tighten tie rod to specified torque. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) 3) Caulk a part of tie rod indicated in figure with punch (1). 4) Apply sealant to gear case groove “A”...
Page 116 MANUAL RACK AND PINION 3B-13 STEERING RACK PLUNGER REMOVAL 1) Remove rack boots and tie rods. 2) Loosen lock nut (1) with holding damper screw (2) with special tool. Special Tool (A): 09944-28320 3) Remove lock nut (1), rack damper screw (2), rack plunger spring (3) and rack plunger (4).
Page 117 3B-14 MANUAL RACK AND PINION STEERING PINION REMOVAL 1) Remove rack plunger as shown in STEERING RACK PLUNG- 2) Remove bearing plug with special tool. Special Tool (A): 09944-28310 3) Tap on position as shown with plastic hammer (2) to separate pinion assembly (1) from housing, and remove pinion assembly (1).
Page 118: Steering Rack
MANUAL RACK AND PINION 3B-15 2) Apply grease to all around pinion teeth (1), pinion needle bear- ing, gear case, O-ring and gear case oil seal lip (2). Fill inside of pinion bearing plug (3) with grease. “A”: Grease E, 99000-25050 3) Apply thread lock cement to pinion bearing plug thread.
Page 119 3B-16 MANUAL RACK AND PINION INSPECTION Inspect for deflection, teeth wear, or damage, back surface wear or damage. Limit of rack deflection: 0.4 mm (0.016 in.) If deflection exceeds limit, replace rack. Do not use a wire brush when cleaning. INSTALLATION 1) Apply grease to entire teeth surface of rack and its periphery.
Page 120 MANUAL RACK AND PINION 3B-17 PINION BEARING REMOVAL 1) Remove rack from steering gear case, referring to STEERING RACK REMOVAL of this section. 2) Remove pinion bearing (1) from gear case with special tools as shown. Special Tool (A): 09921-20200 (B): 09930-30102 INSTALLATION 1) Apply grease to rollers of pinion bearing.
Page 121 MATERIAL SUZUKI PRODUCT D Sliding part of rack against steering housing (All around rack plunger and rack) Lithium Grease SUZUKI SUPER GREASE (E) D Sliding part against steering pinion (Should be applicable (Oil seal lip, needle bearing) (99000-25050) for – 40_C X 130_C)
Page 122 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 123 3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) GENERAL DESCRIPTION This electrical power steering (EPS) system consists of a P/S control module, a torque sensor and a motor assem- bly (with clutch incorporated) installed to the steering column. In this system, the P/S control module determines the level and direction of the assist force for the steering wheel according to the signals from the torque sensor and the vehicle speed, runs the motor so as to assist operation of the steering wheel.
Page 124 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-3 WIRING DIAGRAM 1. Main fuse box 9. To vehicle speed sensor (VSS) 16. P / S control module 2. “EPS” fuse (30 A) 10. ECM / PCM 17. Motor assembly (with clutch incorporated) 3.
Page 125 3B1-4 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DIAGNOSIS The P/S system in this vehicle are controlled by P/S control module. 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 SYS- TEM”...
Page 126 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-5 SYSTEM CHECK FLOW TABLE STEP ACTION 1) Record details of the problem (failure, Go to Step 2. Go to Step 3. complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 127 3B1-6 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) CUSTOMER QUESTIONNAIRE (EXAMPLE) Customer’s name: Model: VIN: Date of issue: Date Reg.: Date of problem: Mileage: D Steering wheel feels heavy D Vehicle pulls to one side during straight driving D Poor recovery from turns Problem Symptoms D Too much play in steering D Abnormal noise while vehicle is running: from motor, from rack and pinon,...
Page 128 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-7 “EPS” WARNING LAMP CIRCUIT CHECK FLOW TABLE CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table. STEP ACTION 1) Make sure that battery voltage is about 11 V or Go to Step 2.
Page 129 3B1-8 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) TABLE-A “EPS” WARNING LAMP DOES NOT LIGHT STEP ACTION Was “SYSTEM CHECK FLOW TABLE” Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. Are “EPS” fuses in good condition? Go to Step 3.
Page 130 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-9 Fig. for Step 3 Fig. for Step 4 Fig. for Step 6 Fig. for Step 7 Fig. for Step 8...
Page 131 3B1-10 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) TABLE-B “EPS” WARNING LAMP FLASHES STEP ACTION Was “SYSTEM CHECK FLOW TABLE” Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. 1) Check monitor coupler for P/S system. Remove service wire.
Page 132 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-11 TABLE-C “EPS” WARNING LAMP REMAINS ON (EVEN THOUGH DIAGNOSIS SWITCH TERMINAL GROUNDED) STEP ACTION Was “SYSTEM CHECK FLOW TABLE” Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. 1) Short diagnosis switch terminal to body ground Repair high resistance Go to Step 3.
Page 133 (C): 09931-76030 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down referring to SUZUKI SCAN TOOL OPERATOR’S MANUAL for further details. NOTE: If Suzuki scan tool cannot display DTC, perform “SERIAL DATA LINK CIRCUIT CHECK”...
Page 134 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-13 Example: When VSS circuit fail (DTC C1121) is set Turn ON “EPS” warning lamp Turn OFF TIME (sec.) NOTE: D When more than 2 DTCs are stored in memory, flashing for each DTC is repeated three times starting with the smallest DTC number in increasing order.
Page 135 DTC CLEARANCE USING SUZUKI SCAN TOOL 1) Turn ignition switch to OFF position. 2) After setting cartridge to SUZUKI scan tool, connect scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
Page 136 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-15 SERIAL DATA LINK CIRCUIT CHECK CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table. 1. Main fuse box 9. To vehicle speed sensor (VSS) 2. “EPS” fuse (30 A) 10.
Page 137 Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. 1) Make sure that SUZUKI scan tool is free from Go to Step 3. Properly connect malfunction and correct cartridge for P/S SUZUKI scan tool to system is used.
Page 138 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-17 DTC TABLE CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table of each DTC. “EPS” light flashing pattern DIAGNOSTIC ITEM DIAGNOSTIC ITEM DIAGNOSIS DIAGNOSIS Model This code appears when Normal none of the other codes are...
Page 139 3B1-18 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1111 TORQUE SENSOR MAIN CIRCUIT FAIL DTC C1113 TORQUE SENSOR MAIN AND SUB CIRCUIT FAIL DTC C1115 TORQUE SENSOR SUB CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2.
Page 140 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-19 DTC C1114 TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2. “EPS” fuse (30 A) 7. Torque sensor 3. Ignition switch 8. P / S control module body ground 4.
Page 141 3B1-20 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1121/C1123/C1124 VSS CIRCUIT FAIL 1. Main fuse box 2. “EPS” fuse 3. Ignition switch 4. Circuit fuse box 5. “IG coil” fuse (15A) 6. Combination meter 7. Speedometer 8. “EPS” warning lamp 9.
Page 142 OPERATOR’S MANUAL”. recheck. “Br/Y” wire circuit. 3) Check engine speed. If OK, check engine Is proper engine speed indicated? speed signal of ECM/ PCM. NOTE 1: It is necessary for SUZUKI scan tool to perform STEP 4 of this table.
Page 143 3B1-22 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1141/C1142/C1143/C1144/C1145 MOTOR CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2. “EPS” fuse (30 A) 7. Motor assembly (with clutch incorporated) 3. Ignition switch 8. P / S control module body ground 4.
Page 144 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-23 DTC C1151 CLUTCH CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2. “EPS” fuse (30 A) 7. Motor assembly (with clutch incorporated) 3. Ignition switch 8. P / S control module body ground 4.
Page 145 3B1-24 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1153 P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAIL 1. Main fuse box 5. “IG coil” fuse (15A) 2. “EPS” fuse (30 A) 6. P / S control module 3. Ignition switch 7.
Page 146 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-25 INSPECTION OF P/S CONTROL MODULE AND ITS CIRCUITS P/S control module (1) and its circuits can be checked at P/S control module wiring couplers (2) by measuring voltage and resistance. CAUTION: P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to P/S control module with coupler disconnected from it.
Page 147 10 – 14 V Engine idling “EPS” light OFF Diagnosis switch terminal About 5 V Ignition switch is ON position SUZUKI scan tool – – Motor output 2 5 – 7 V Engine idling and steering wheel held at position for vehicle to run...
Page 148: Diagnostic System
ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-27 TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON-BOARD DIAGNOSTIC SYSTEM) This section describes trouble diagnosis of P/S system parts whose trouble is not indicated by the on-board diag- nostic system (self-diagnostic function). When DTC No.12 (flashing pattern:12) is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in “DIAGNOSIS CHART”...
Page 149 3B1-28 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) INSPECTION OF STEERING WHEEL PLAY Check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. Check steering wheel for play, holding vehicle in straight forward condition on the ground and with engine stopped.
Page 150 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-29 ON-VEHICLE SERVICE [LH] 1. Steering column assembly CAUTION: Never disassemble steering column assembly, remove torque sensor or motor assem- bly (with clutch incorporated). Performing any of these prohib- ited services will affect original performance of EPS system.
Page 151: Torque Sensor
3B1-30 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) TORQUE SENSOR ON-VEHICLE INSPECTION 1) Remove steering column lower cover. 2) Turn ignition switch to ON position. 3) Check voltage between terminals of torque sensor connector (1) with connecting it to P/S control module (2) and not running en- gine.
Page 152 1. Storage case 2. Operator’s manual 3. Tech 1A 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09931-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16/14 pin DLC cable...
Page 154 STEERING WHEEL AND COLUMN 3C-1 SECTION 3C STEERING WHEEL AND COLUMN WARNING: The procedures in this section must be followed in the order listed to temporarily disable the air bag system and prevent false diagnostic codes from setting. Failure to follow procedures could result in possible air bag system activation, personal injury or other- wise unneeded air bag system repairs.
Page 155 3C-2 STEERING WHEEL AND COLUMN GENERAL DESCRIPTION STEERING COLUMN This double tube type steering column has the following three important features in addition to the steering function: D The column is energy absorbing, designed to compress in a front-end collision. D The ignition switch and lock are mounted conveniently on this column.
Page 156 (if equipped)). Be sure to follow the instructions. WARNING: D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 157: Handling Precaution
3C-4 STEERING WHEEL AND COLUMN ENABLING AIR BAG SYSTEM 1) Turn ignition switch to “LOCK” and remove key. 2) Connect connector to contact coil assembly, and install steering column upper cover and lower cover. 3) Connect Yellow connector of passenger air bag (inflator) module if equipped, and be sure to lock connector with lock lever and close glove box panel.
Page 158 STEERING WHEEL AND COLUMN 3C-5 D If air bag (inflator) module was dropped from a height of 90 cm (3 ALWAYS CARRY AIR BAG (INFLATOR) MODULE ft) or more, it should be replaced. WITH TRIM COVER (AIR BAG OPENING) AWAY D When an abnormality is noted as existing in the live (undeployed) FROM BODY.
Page 159 3C-6 STEERING WHEEL AND COLUMN CONTACT COIL CABLE ASSEMBLY Do not turn contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counter- clockwise respectively), or coil will break. AIR BAG WIRE HARNESS AND CONNECTOR CAUTION: When an open in air bag wire harness, damaged wire har- ness, connector or terminal is found, replace wire harness,...
Page 160 STEERING WHEEL AND COLUMN 3C-7 ON-VEHICLE SERVICE 10. Steering column assembly 1. Driver air bag (inflator) module 11. Ignition switch assembly 2. Steering shaft bolt: 12. Immobilizer control module Apply thread lock 99000-32050 to all around 13. Ignition switch cylinder assembly thread part of steering shaft bolt.
Page 161 3C-8 STEERING WHEEL AND COLUMN DRIVER AIR BAG (INFLATOR) MODULE WARNING: When handling an air bag (inflator) module, be sure to read “Precautions” given earlier in this section and observe each instruction. Failure to follow them could cause a dam- age to the air bag (inflator) module or result in personal inju- REMOVAL 1) Disconnect negative battery cable at battery terminal.
Page 162 STEERING WHEEL AND COLUMN 3C-9 Check air bag (inflator) module visually and if any of the following is found, replace it with a new one. D Air bag being deployed D Trim cover (pad surface) (1) being cracked D Terminal (2) being damaged D Air bag (inflator) module being damaged or having been exposed to strong impact (dropped) INSTALLATION...
Page 163: Steering Wheel
3C-10 STEERING WHEEL AND COLUMN STEERING WHEEL CAUTION: Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will break. REMOVAL 1) Disconnect negative battery cable at battery terminal.
Page 164 STEERING WHEEL AND COLUMN 3C-11 4) From the position where contact coil became unable to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark with alignment mark (1). INSTALLATION 1) Check that vehicle’s front tires are at straight-ahead position and contact coil is centered.
Page 165 3C-12 STEERING WHEEL AND COLUMN CONTACT COIL CABLE ASSEMBLY CAUTION: Do not turn contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively), or coil will break. REMOVAL 1) Disconnect negative battery cable at battery terminal.
Page 166 STEERING WHEEL AND COLUMN 3C-13 7) Remove contact coil cable assembly (1) from steering column. INSPECTION Check contact coil cable assembly wire harness for any signs of scorching, melting or other damage. If it is damaged, replace. INSTALLATION 1) Check to make sure that vehicle’s front tires are set at straight- ahead position and then ignition switch is at “LOCK”...
Page 167 3C-14 STEERING WHEEL AND COLUMN 4) Install steering column upper cover (1) and lower cover (2). 5) Install steering column hole cover (2) and instrument panel switch garnish (1). 6) Install steering wheel to steering column. Refer to “Steering Wheel” earlier in this section. 7) Connect battery negative cable.
Page 168 STEERING WHEEL AND COLUMN 3C-15 REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Disable air bag system. Refer to “Disabling Air Bag System” under “Precautions” earlier in this section. 3) Remove steering wheel and contact coil cable assembly. Refer to “Steering Wheel”...
Page 169 3C-16 STEERING WHEEL AND COLUMN 11) When disconnecting upper joint (3) from power steering col- umn shaft (2), make alignment marks (1) on column shaft and upper joint, and be sure to align marks (1) when reconnecting. INSPECTION Check steering column for damage and operation referring to CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE lat- er in this section.
Page 170 STEERING WHEEL AND COLUMN 3C-17 4) Install ignition switch assembly and immobilizer control module to steering column. 5) Install ignition switch cylinder assembly as follows. a) Push steering lock (2) down till it clicks, using screw driver (1), so that it is at unlock position. b) Turn ignition key of ignition switch cylinder assembly to “ACC”...
Page 171 3C-18 STEERING WHEEL AND COLUMN 4) Remove steering shaft joint bolts (1) and then remove steering Power steering Manual steering lower shaft (2). INSTALLATION Power steering Manual steering 1) Align flat part of steering lower shaft (2) or steering column (4) with bolt hole of upper joint (1) as shown.
Page 172 STEERING WHEEL AND COLUMN 3C-19 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering col- umn. CHECKING PROCEDURE 1) Check that two capsules (1) are attached to steering column bracket securely.
Page 173 3C-20 STEERING WHEEL AND COLUMN REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT THREAD LOCK 1342 Thread lock cement Steering shaft bolt (99000-32050)
Page 174 FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: D All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 175 3D-2 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehicle body by a strut support. The strut and strut support are isolated by a rubber mount. A strut bearing is also installed a little lower to the rubber mount.
Page 176 FRONT SUSPENSION 3D-3 DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STABILIZER BAR AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. STRUT ASSEMBLY CHECK 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
Page 177 3D-4 FRONT SUSPENSION SUSPENSION CONTROL ARM/KNUCKLE CHECK Inspect control arm/knuckle for cracks, deformation or damage. Inspect control arm bushing for damage, wear or deterioration. SUSPENSION CONTROL ARM JOINT CHECK Cannot be separated 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage.
Page 178 FRONT SUSPENSION 3D-5 ON-VEHICLE SERVICE STABILIZER BAR AND/OR BUSHINGS REMOVAL 1) Hoist vehicle and allow the front suspension control arms (5) to hang free. 2) Remove front wheels. 3) Remove split pins (1) and then castle nuts (2). 4) Remove stabilizer bar mount bushing bracket bolts (9). 5) Remove stabilizer bar (6) from front suspension control arms (5).
Page 179 3D-6 FRONT SUSPENSION D Install mounting bracket (1) so that its oblong hole side (2) comes to the rear. Front D Tighten stabilizer bar bracket bolts to specified torque. Tightening torque for stabilizer bar bracket bolts: 45 N m (4.5 kg-m, 32.5 lb-ft) D After tightening castle nut (1) to specified torque, install new split pin (2) as shown.
Page 180 1. Strut nut 7. Bearing lower washer 13. Shock absorber: 2. Strut rock washer 8. Bearing spacer Apply SUZUKI SUPER GREASE A 3. Strut support 9. Coil spring upper seat 99000-25010 to sliding part of rod. 4. Bearing seal: 10. Coil spring seat 14.
Page 181 3D-8 FRONT SUSPENSION 8) Remove strut support nuts (1). Hold strut by hand so that it will not fall off. 9) Remove strut assembly. DISASSEMBLY 1) Using a spring compressor, compress the strut spring till its force pressing the spring seat is released. CAUTION: Use a commercially available spring compressor and fol- low the operation procedure described in the Instruction...
Page 182 FRONT SUSPENSION 3D-9 ASSEMBLY For assembly, reverse disassembly procedure, observing following instructions. D Apply grease to bearing seal, strut bearing and sliding part of strut rod. D Mate spring end with stepped part of spring lower seat as shown. D Install spring seat, mating stepped part of seat with spring upper end as shown.
Page 183 3D-10 FRONT SUSPENSION INSTALLATION D Install strut assembly by reversing REMOVAL procedure. CAUTION: Don’t twist brake hose when installing it. Install E-ring as far as it fits to bracket as shown. D Torque all fasteners to specification, referring to assembly figure on 3D-7.
Page 184 FRONT SUSPENSION 3D-11 STEERING KNUCKLE/BEARING : Tightening Torque : Do not reuse 1. Wheel hub 5. Dust cover 10. Ball stud bolt 14. Wheel hub nut 2. Circlip 6. Tie-rod end 11. Strut bracket bolt: 15. Brake disc 3. Wheel bearing: 7.
Page 185 3D-12 FRONT SUSPENSION 7) Pull out wheel hub (1) with special tools. Special Tool (A): 09943-17912 (B): 09942-15511 8) Remove tie-rod end nut and disconnect tie-rod end (2) from knuckle (1) with puller. CAUTION: Never reuse tie-rod end nut. Reused nut will not be locked securely. 9) Remove wheel speed sensor (1) from knuckle (if equipped).
Page 186 FRONT SUSPENSION 3D-13 2) Remove circlip (1). Special Tool (A): 09900-06108 3) Remove wheel bearing using special tool and hydraulic press. Special Tool (A): 09913-75810 CAUTION: D Never reuse wheel bearing. Reused bearing should have excessive play. D When replacing bearing, inner races or outer race, be sure to replace them with new ones as a set.
Page 187 3D-14 FRONT SUSPENSION 2) Install circlip (1). Special Tool (A): 09900-06108 3) Drive in dust cover (1) so that dimensions “a” and “b” become equal as shown. CAUTION: When drive in dust cover, be careful not to deform it. 4) Caulk with a punch. 5) Insert new stud (2) in hub hole.
Page 188 FRONT SUSPENSION 3D-15 2) Install knuckle (2) to ball stud (3) on suspension control arm (4) FORWARD and strut bracket (1). Installing direction of each bolt is as shown. Align knuckle bolt hole with ball stud groove and install ball stud bolt (5).
Page 189 3D-16 FRONT SUSPENSION 9) Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque. Tightening Torque (c): 175 N m (17.5 kg-m, 127.0 lb-ft) 10) Calk drive shaft nut as shown. Calking drive CAUTION: shaft nut Be careful while caulking nut so that no crack will occur...
Page 190 FRONT SUSPENSION 3D-17 SUSPENSION CONTROL ARM/BUSHING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove split pin (12), stabilizer bar castle nut (10), washer (9) and bushing (8). FORWARD 3) Remove stabilizer bar mount bracket (right & left) bolts (5). 4) Remove ball stud bolt (2).
Page 191 3D-18 FRONT SUSPENSION INSTALLATION 1) Place suspension control arm onto flat surface side of special tool and install new bushing with special tool and oil hydraulic Press press as shown. Special Tool (A): 09943-77910 NOTE: D Before installing bushing, apply soap water on its circum- ference to facilitate installation.
Page 192 D Install stabilizer bar, referring to STABILIZER BAR INSTALLA- TION in this section. REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Outside inner race Lithic wheel bearing SUZUKI SUPER GREASE (A) D Bearing seal grease (99000-25010) D Strut bearing D Sliding part of strut rod...
Page 193 3D-20 FRONT SUSPENSION SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09900-06108 09913-61110 09913-75810 Hexagon wrench bit (6 mm) Snap ring pliers (closing type) Bearing puller Bearing installer 09924-84510-002 09925-88210 09940-53111 09942-15511 Bearing installer attachment Bearing puller attachment Bearing installer Sliding hammer 09943-17912 09945-26010...
Page 194 REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 195 3E-2 REAR SUSPENSION GENERAL DESCRIPTION Rear suspension is Isolated Trailing Link (l.T.L.) type which consists of coil springs, rear axle, shock absorbers, lateral rod and trailing arms. The lateral rod is installed to the body and axle by using bushes so as to prevent axle movement in the lateral direc- tion.
Page 196 REAR SUSPENSION 3E-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. REAR SHOCK ABSORBER CHECK D Inspect for deformation or damage. D Inspect bushings for wear or damage. D Inspect for evidence of oil leakage. Replace any defective part. WARNING: When handling rear shock absorber in which high-pressure gas is sealed, make sure to observe the following precau- tions.
Page 197 3E-4 REAR SUSPENSION REAR SUSPENSION FASTENERS CHECK Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to ON-VE- HICLE SERVICE in this section. WHEEL DISC, NUT & BEARING CHECK D Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced.
Page 198 REAR SUSPENSION 3E-5 ON-VEHICLE SERVICE 90 N m (9.0 kg-m) 1. Rear coil spring 10. Brake drum 17. Lateral rod body side bolt: 2. Rear bump stopper: 11. Circlip Insert from the direction as shown Apply soap water, when installing. 12.
Page 199 3E-6 REAR SUSPENSION LATERAL ROD REMOVAL 1) Hoist vehicle. 2) Remove lateral rod nuts (1). 3) Remove lateral rod (2). INSTALLATION 1) Install lateral rod (1) to rear axle and vehicle body (3) referring to figure for proper installing direction of bolt (4) and washer (2). Tighten nuts (5) temporarily by hand.
Page 200: Rear Shock Absorber
REAR SUSPENSION 3E-7 REAR SHOCK ABSORBER REMOVAL 1) Hoist vehicle. Vehicle center side 2) Support rear axle (1) by using floor jack to prevent it from lower- ing. 3) Remove lower bolt (2). 4) Remove upper bolt (3) and nut (4). Then remove shock absorber (5).
Page 201 3E-8 REAR SUSPENSION 5) Remove shock absorber lower bolt (1). 6) Lower rear axle gradually as far down as where coil spring (1) can be removed. CAUTION: Be careful not to let rear axle down too much. It may cause damage to brake flexible hose and parking brake cable.
Page 202 REAR SUSPENSION 3E-9 6) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) 7) Lower hoist and vehicle in non-loaded condition, tighten absorb- er lower bolt (1) and lateral rod body side nut (2) to specified torque.
Page 203 3E-10 REAR SUSPENSION SPRING UPPER SEAT REMOVAL 1) Remove coil spring. For details, refer to COIL SPRING RE- MOVAL in this section. 2) Remove spring upper seat (1). INSTALLATION 1) Install spring upper seat (1). Vehicle body side NOTE: For proper installing direction of spring upper seat, refer to figure at left.
Page 204 REAR SUSPENSION 3E-11 5) Remove parking brake cable clamp (1). 6) Remove trailing arm rear bolts (1). 7) Remove trailing arm front bolt (2) and then remove trailing arm FORWARD (1). INSTALLATION 1) Install trailing arm (1) to vehicle body and rear axle, referring to Vehicle Vehicle figure for proper installing direction of bolts (2) and then tighten...
Page 205 3E-12 REAR SUSPENSION 3) Install parking brake cable clamp (1). 4) Install shock absorber (1) to rear axle (2). 5) Tighten shock absorber lower bolt (3) temporarily by hand. 6) Remove floor jack from rear axle. 7) Install wheel and tighten wheel nuts to specified torque. Tightening Torque for wheel nuts (a): 85 N m (8.5 kg-m, 61.5 lb-ft)
Page 206: Rear Axle
REAR SUSPENSION 3E-13 REAR AXLE REMOVAL 1) Hoist vehicle and remove rear wheels (right & left). 2) Support rear axle (1) by using floor jack (2). 3) Remove rear brake drums (right & left). For details, refer to steps 2) to 6) of BRAKE DRUM REMOVAL in SECTION 5C. 4) Remove E-rings (2) (right &...
Page 207 3E-14 REAR SUSPENSION 8) Disconnect wheel speed sensor and lead wire clamps (right & left) (if equipped). 9) Remove shock absorber lower bolts (1) (right & left). 10) Remove LSPV spring (1) from rear axle (2) (if equipped). 11) Lower rear axle gradually as far down as where coil springs (1) (right &...
Page 208 REAR SUSPENSION 3E-15 14) While supporting rear axle at both ends (right & left), remove trailing arm rear side bolts and then remove rear axle from chassis by lowering floor jack gradually. INSTALLATION Install removed parts in reverse order of removal, noting the follow- ing points.
Page 209 3E-16 REAR SUSPENSION 6) Clean mating surface of rear axle (right & left) with brake back plate and apply water tight sealant as shown in figure. “A”: Sealant 99000-31090 7) Install brake back plates (1) and tighten back plate bolts (2) to specified torque.
Page 210 REAR SUSPENSION 3E-17 11) Install LSPV spring (1) to rear axle (2) (if equipped). Tightening Torque (a): 26 N·m (2.6 kg-m, 19.0 lb-ft) 12) Install brake drums (right & left). For details, refer to steps 3) to 8) of BRAKE DRUM INSTALLATION in Section 5C. 13) Fill reservoir with brake fluid and bleed brake system.
Page 211 3E-18 REAR SUSPENSION 18) Tighten right and left trailing arm rear nuts, shock absorber low- er bolts and lateral rod rear axle side nut to specified torque. NOTE: When tightening these nuts and bolts, be sure that vehicle is off hoist and in non loaded condition. Tightening Torque (e): 80 N·m (8.0 kg-m, 58.0 lb-ft) (f): 63 N·m (6.3 kg-m, 45.5 lb-ft)
Page 212 REAR SUSPENSION 3E-19 WHEEL BEARING AND WHEEL STUD REMOVAL 1) Remove rear brake drum, referring to REAR BRAKE DRUM RE- MOVAL in SECTION 5C. 2) Remove circlip (1). Special Tool (A): 09900-06108 3) Remove wheel bearing by using special tool and hydraulic press.
Page 213 (A): 09900-06108 4) Install brake drum and wheel, referring to BRAKE DRUM INSTALLATION in SECTION 5C. REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Brake fluid DOT4 Brake reservoir tank SEALING COMPOUND 366E Water tight sealant Join seam of rear axle and brake back plate...
Page 214 WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 215 3F-2 WHEELS AND TIRES WARNING: kgf/cm Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emergencies, because handling may be seriously affected and may result in loss of control. It is recommended that new tires be installed in pairs on the same axle.
Page 216 WHEELS AND TIRES 3F-3 When the measured runout exceeds the specification and correc- tion by the balancer adjustment is impossible, replace the wheel. If the reading is affected by welding, paint or scratch, it should be ignored. Radial Lateral runout limit runout limit 2.0 mm 2.0 mm...
Page 217 3F-4 WHEELS AND TIRES INFLATION OF TIRES The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread wear, tire life and resistance to bruises. Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should be checked monthly or before any extended trip.
Page 218 WHEELS AND TIRES 3F-5 ON-VEHICLE SERVICE SERVICE OPERATIONS METRIC LUG NUTS AND WHEEL STUDS All models use metric lug nuts and wheel studs (size: M12 x 1.25). WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180_ (half a rotation). 2) Hoist vehicle. 3) Remove wheel.
Page 219: Balancing Wheels
3F-6 WHEELS AND TIRES After mounting, inflate to specified pressure shown on tire placard so that beads are completely seated. WARNING: Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety hump and cause serious per- sonal injury.
Page 220 WHEELS AND TIRES 3F-7 GENERAL BALANCE PROCEDURES Deposits of mud, etc. must be cleaned from inside of rim. WARNING: Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain good balance. Each tire should be inspected for any damage, then balanced according to equipment manufacturer’s recommen- dation.
Page 222 FRONT DRIVE SHAFT 4-1 SECTION 4 FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ..............4- 1 DIAGNOSIS .
Page 223 4-2 FRONT DRIVE SHAFT ON-VEHICLE SERVICE Removal & Installation 1. Transmission 8. Tie-rod end nut 2. Drive shaft assembly 9. Ball stud bolt 3. Tie-rod end 10. Drive shaft nut 4. Suspension control arm 11. Wheel nut 5. Stabilizer 12. Washer 6.
Page 224 FRONT DRIVE SHAFT 4-3 Disassembly & Reassembly [A] : For M / T model [B] : For A / T model [C] : Both models 9. Differential (or center shaft) side joint 1. Right side drive shaft assembly (Constant velocity tripod joint): 2.
Page 225 4-4 FRONT DRIVE SHAFT REMOVAL CAUTION: To prevent breakage of boots, be careful not to bring them into contact with other parts when removing drive shaft as- sembly. 1) Undo caulking (1) and remove drive shaft nut (2). 2) Loosen wheel nuts. 3) Hoist vehicle.
Page 226 FRONT DRIVE SHAFT 4-5 INSPECTION D Check boots for breakage or deterioration. D Check wheel side joint for rattle or smooth movement. D Check differential side joint or center shaft side joint for smooth movement. If malfunction is found, replace. DISASSEMBLY For Tripod joint type drive shaft (right side) CAUTION:...
Page 227 4-6 FRONT DRIVE SHAFT 4) Remove spider (1) by using 3 arms puller (2). CAUTION: To prevent needle bearing of joint from being degreased, do not wash it if it is to be reused. 5) Remove boot small band, then pull out differential side boot from shaft.
Page 228 FRONT DRIVE SHAFT 4-7 2) Remove DOJ from shaft as follows. a) Fold over boot and remove old grease so that retaining ring (1) is accessible. b) Clamp drive shaft in soft jawed vise. Spread retaining ring using snap ring pliers (opening type) and tap DOJ of drive shaft using plastic hammer until retain- ing ring no longer engages in groove of shaft.
Page 229 4-8 FRONT DRIVE SHAFT INSPECTION D Check shaft and joint for damage, wear or bend. Replace them as necessary. D Check retaining ring and snap ring for breakage or deformation. Replace as necessary. ASSEMBLY For Tripod joint type drive shaft (right side) 1) Wash disassembled parts (except boots and needle bearing of spider).
Page 230 FRONT DRIVE SHAFT 4-9 8) Place new wheel side small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure. 9) Confirm that wheel side boot is not stretched or contracted and fasten boot small band (1) securely at that position. Special Tool (A): 09943-55010 10) Install damper (1) on drive shaft according to dimension speci-...
Page 231 4-10 FRONT DRIVE SHAFT 14) Fit boot to grooves of shaft and housing and adjust boot length to specification below. Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
Page 232 FRONT DRIVE SHAFT 4-11 7) Set new differential side small band (2) and differential side boot (1) on shaft temporarily. 8) Apply grease to DOJ and inside of housing. Use grease supplied with spare parts. “A”: Thermax grease/Color: Black Grease capacity: About 50 – 70 g (1.8 – 2.5 oz) 9) Place DOJ onto spline of drive shaft and drive onto drive shaft by using plastic hammer until retaining ring engages.
Page 233 4-12 FRONT DRIVE SHAFT D When installing left oil seal (1) and right oil seal (2), use care so that oil seals in proper direction and position as shown figure. Distance “a”: 11 – 12 mm (0.43 – 0.47 in.) “b”: 2 –...
Page 234 FRONT DRIVE SHAFT 4-13 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI BOND NO. 1215 Oil drain and filler/level plugs for manual Sealant (99000-31110) transmission SUZUKI SUPER GREASE A Lithium grease Center bearing side space of oil seal (99000-25010) SPECIAL TOOLS...
Page 236 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 237 5-2 BRAKES GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two independent circuits.
Page 238: Road Testing Brakes
BRAKES 5-3 DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE FLUID Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid test brakes by making brake applications with both may cause the brake fluid to boil or the rubber compo- light and heavy pedal forces at various speeds to de- nents in the hydraulic system to deteriorate.
Page 239 5-4 BRAKES DIAGNOSIS TABLE Condition Possible Cause Correction Not enough D Brake oil leakage from brake lines. Locate leaking point and repair. braking force D Brake disc or pads stained with oil. Clean or replace. D Overheated brakes. Determine cause and repair. D Poor contact of shoes on brake drum.
Page 240 BRAKES 5-5 Condition Possible Cause Correction Excessive pedal D Partial brake system failure. Check brake systems and repair as travel (Pedal necessary. stroke too large) D Insufficient fluid in master cylinder Fill reservoirs with approved brake reservoirs. fluid. Check for leaks and air in brake systems.
Page 241 5-6 BRAKES Condition Possible Cause Correction Brake warning light D Parking brake applied. Release parking brake and check that turns on after brake warning light turns off. engine start D Insufficient amount of brake fluid. Add brake fluid. D Brake fluid leaking from brake line. Investigate leaky point, correct it and add brake fluid.
Page 242 BRAKES 5-7 CHECK AND ADJUSTMENT BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: For vehicle equipped with ABS, make sure that ignition switch turns off.
Page 243 5-8 BRAKES 4) When fluid pressure in the cylinder is almost depleted, retigh- ten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hy- draulic line. 6) When bubbles stop, with depressing brake pedal, tighten bleeder plug.
Page 244: Excessive Pedal Travel Check
BRAKES 5-9 BRAKE PEDAL FREE HEIGHT CHECK Peel off carpet and check brake pedal for free height. Brake pedal free height “a” from silencer (1) : 150 – 160 mm (5.9 – 6.3 in.) If it is not within specification, check and adjust the following items 1) to 4).
Page 245: Brake Pedal Play Check
5-10 BRAKES BRAKE PEDAL PLAY CHECK Pedal play should be within specification. If out of specification, check brake light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective. Pedal play “d”: 1 –...
Page 246 BRAKES 5-11 BRAKE DISC CHECK Refer to item FRONT DISC BRAKE PAD INSPECTION of Section 5B for inspection point and procedure. BRAKE PAD CHECK Inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through hole of caliper and check lining (1) thickness of each pad.
Page 247 5-12 BRAKES PARKING BRAKE INSPECTION AND ADJUSTMENT 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. There should be 4 to 9 notches. Also, check if both right and left rear wheels are locked firmly.
Page 248: Flushing Brake Hydraulic System
BRAKES 5-13 FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in hydraulic system. Periodical change of brake fluid is also recommended. FLUID PRESSURE TEST (if equipped with LSPV) Test procedure for LSPV assembly is as follows.
Page 249 5-14 BRAKES 3) Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake then. It should be within specification given below. Front brake Rear brake 7,500 kPa 5,600 – 7,100 kPa 75 kg/cm 56 –...
Page 250: Booster Operation Check
BRAKES 5-15 BOOSTER OPERATION CHECK There are two ways to perform this inspection, with and without a tester. Ordinarily, it is possible to roughly determine its condition without using a tester. NOTE: For this check, make sure that no air is in hydraulic line. INSPECTION WITHOUT TESTER Check Air Tightness 1) Start engine.
Page 251 5-16 BRAKES Check Operation 1) With engine stopped, depress brake pedal several times with the same load and make sure that pedal travel doesn’t change. 2) Start engine while depressing brake pedal. If pedal travel in- creases a little, operation is satisfactory. But no change in pedal travel indicates malfunction.
Page 252 BRAKES 5-17 TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts kg-m lb-ft Brake pipe 4-way joint bolt Brake pipe flare nut 11.5 Front caliper 0.65 Brake bleeder plug Brake bleeder plug Wheel cylinder 0.85 LSPV mounting bolt 19.0 LSPV spring end nut 19.0 LSPV spring bracket screw Wheel nut...
Page 254 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 255 5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER GENERAL DESCRIPTION LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped) As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Page 256 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3 DIAGNOSIS Refer to Section 5 BRAKES. CHECK AND ADJUSTMENT Refer to Section 5 BRAKES. ON-VEHICLE SERVICE CAUTION: D Lubricate rubber parts with clean, fresh brake fluid to ease assembly. D Do not use lubricated shop air on brake parts as damage to rubber components may result. D If any hydraulic component is removed or brake line disconnected, bleed the brake system.
Page 257 5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER For vehicle with ABS Viewed from A Viewed from B Right Right Front Front Front Front Right Right Front Right Front Front Front Front Front Front Front [A]: For left-hand steering vehicle [B]: For right-hand steering vehicle a –...
Page 258 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-5 For vehicle without ABS Viewed from A Viewed from B Right Front Front Right Front Front Front Front [A]: For left-hand steering vehicle [B]: For right-hand steering vehicle a – g: Clamp 1.
Page 259 5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER REAR BRAKE HOSE/PIPE REMOVAL 1) Raise and suitably support vehicle. Remove tire and wheel. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. INSTALLATION 1) Reverse removal procedure for brake hose or pipe installation procedure.
Page 260 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7 MASTER CYLINDER RESERVOIR CAUTION: Observe CAUTION at the beginning of ON-VEHICLE SER- VICE. NOTE: For right hand steering vehicle, remove and install master cyl- inder reservoir according to procedure of MASTER CYLINDER ASSEMBLY REMOVAL and INSTALLATION in this section.
Page 261 5A-8 BRAKES PIPE / HOSE / MASTER CYLINDER INSTALLATION 1) For vehicle with ABS, install pin washer retainer (1) to secondary reservoir port of master cylinder (2) if removed. 2) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with.
Page 262: Master Cylinder Assembly
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-9 MASTER CYLINDER ASSEMBLY 1. Master cylinder assembly 2. Grommet [A]: with ABS 3. O-ring [B]: without ABS 4. Pin washer retainer : Tightening Torque 5. Reservoir CAUTION: D Never disassemble master cylinder. Disassembly will spoil its original performance.
Page 263 5A-10 BRAKES PIPE / HOSE / MASTER CYLINDER INSPECTION Inspect each parts for wear, deterioration or damage, and replace parts if necessary. Inspect master cylinder for scoring, corrosion and smooth opera- tion. It is best to replace corroded cylinder. Corrosion can be identified as pits or excessive roughness. [A]: with ABS [B]: without ABS INSTALLATION...
Page 264 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-11 3) Install master cylinder to brake booster. 4) Torque master cylinder attaching nuts to specification. Tightening Torque (a): 13 N m (1.3 kg-m, 9.5 lb-ft) 5) Connect hydraulic lines and torque flare nuts to specification. Special Tool (A): 09950-78240 Tightening Torque...
Page 265: Brake Booster
1. Brake master cylinder assembly 2. Brake booster assembly 3. Gasket 4. Push rod clevis 5. Nut 6. Clevis pin: Apply SUZUKI SUPER GREASE A 99000-25010 to clevis pin. 7. Clip 8. Nut 9. Brake vacuum hose : Tightening Torque...
Page 266 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-13 INSTALLATION NOTE: Check for push rod length referring to above BRAKE BOOST- ER INSPECTION. 3, “A” 1) Install new gasket and booster to dash panel as shown. Then connect booster push rod clevis (1) to pedal arm (2) with clevis pin (3) and clip (4).
Page 267 5A-14 BRAKES PIPE / HOSE / MASTER CYLINDER LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped) 1. LSPV bracket 26 N m (2.6 kg-m) 2. LSPV assembly 2-1. Spring 2-2. Spring bracket 2-3. Screw 3. Brake pipe m (0.5 kg-m) : Tightening Torque CAUTION: D Never disassemble LSPV assembly.
Page 268 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15 INSTALLATION NOTE: New LSPV assembly is supplied with held in specified spring length with adjusting block (1). Do not remove adjusting block until spring (2) installation position is adjusted. 1) Install LSPV assembly with bracket to vehicle body. 2) Torque each bolt and nut to specification as indicated respec- tively in figure.
Page 269 5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER INSPECTION & ADJUSTMENT 1) Confirm the following before inspection and adjustment. D Fuel tank is filled with fuel fully. D Vehicle is equipped with spare tire, tools, jack and jack handle. D Vehicle is free from any other load. D Vehicle is placed on level floor.
Page 270 BRAKE PEDAL AND BRAKE PEDAL BRACKET 1. Brake booster assembly 2. Push rod clevis 3. Brake pedal bracket 4. Clevis pin: Apply SUZUKI SUPER GREASE A 99000-25010 to clevis pin. 5. Clip 6. Stop light switch 7. Stop light switch coupler 8.
Page 271 5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of caliper Brake fluid DOT 4 or SAE J1704 and wheel cylinder when they are disassembled.
Page 272 FRONT BRAKE 5B-1 SECTION 5B FRONT BRAKE NOTE: All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary.
Page 273 5B-2 FRONT BRAKE GENERAL DESCRIPTION DISC BRAKE CALIPER ASSEMBLY This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
Page 274 FRONT BRAKE 5B-3 ON-VEHICLE SERVICE CAUTION: Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo- nents may result. If any component is removed or line disconnected, bleed the brake system. Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners. 1-1.
Page 275 5B-4 FRONT BRAKE FRONT DISC BRAKE PAD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolts (1). 3) Remove E-ring from strut and then remove caliper (1) from cali- per carrier. NOTE: Hang removed caliper with a wire hook (2) or the like so as to prevent brake hose from bending and twisting exces- sively or being pulled.
Page 276 FRONT BRAKE 5B-5 Brake Disc Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replace- ment are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc sur- face, replace it.
Page 277 5B-6 FRONT BRAKE INSTALLATION CAUTION: Observe CAUTION at the beginning of ON-VEHICLE SER- VICE. 1) Install pads (1). NOTE: Install pad with sensor (2) to vehicle center side. 2) Install caliper (1) and torque caliper pin bolts (2) to specification. Tightening Torque (a): 30 N m (3.0 kg-m, 22.0 lb-ft)
Page 278 FRONT BRAKE 5B-7 FRONT DISC BRAKE CALIPER REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake flexible hose bolt (1) from caliper (2). As this will allow fluid to flow out of hose, have a container (3) ready before- hand.
Page 279 5B-8 FRONT BRAKE 2) Remove piston boot (1) prying it with a metal tool (2) (no sharp edge). CAUTION: Be careful not to damage inside (bore side) of cylinder. 3) Remove piston seal using a thin blade like a thickness gauge, etc.
Page 280 FRONT BRAKE 5B-9 Piston Seal Piston seal is used to seal piston and cylinder and to adjust clear- ance between pad and disc. Replace with a new one at every over- haul. Fit piston seal into groove in cylinder taking care not to twist Piston and Boot 1-grooved side directed pad side...
Page 281 5B-10 FRONT BRAKE INSTALLATION CAUTION: Observe CAUTION at the beginning of ON-VEHICLE SER- VICE. 1) Install caliper (1) to caliper carrier (2). 2) Torque caliper pin bolts (3) to specifications. Tightening Torque (a): 30 N m (3.0 kg-m, 22.0 lb-ft) NOTE: Make sure that boots are fit into groove securely.
Page 282 FRONT BRAKE 5B-11 INSPECTION Refer to FRONT DISC BRAKE PAD INSPECTION. INSTALLATION 1) Install disc to wheel hub. 2) Install caliper assembly to steering knuckle. 3) Torque caliper carrier bolts (1) to specification. Tightening Torque (a): 95 N m (9.5 kg-m, 69.0 lb-ft) 4) Torque front wheel nuts to specifications.
Page 283 5B-12 FRONT BRAKE REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of caliper Brake fluid DOT 4 or SAE J1704 and wheel cylinder when they are disassembled. An equivalent of Molykote PG 54 Rubber grease plastislip or Molykote Q5-7544 To caliper guiding and locking pins.
Page 284 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 285 5C-2 PARKING AND REAR BRAKE GENERAL DESCRIPTION DRUM BRAKE ASSEMBLY The drum brake assembly is of leading and trailing type drum brake and has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. The parking brake is mechanical and applies brake force to only rear wheels by means of the cable, linkage and shoes.
Page 286 PARKING AND REAR BRAKE 5C-3 ON-VEHICLE SERVICE CAUTION: D Replace all components included in repair kits to service this drum brake. Lubricate parts as speci- fied. D If any hydraulic component is removed or brake line disconnected, bleed the brake system. D The torque values specified are for dry, unlubricated fasteners.
Page 287 5C-4 PARKING AND REAR BRAKE PARKING BRAKE LEVER REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove console box. 3) Block vehicle wheels and release parking brake lever. 4) Disconnect lead wire of parking brake switch at coupler. 5) Loosen parking brake cable adjusting nut (1). 6) Remove parking brake lever bolts (1) and then remove parking brake lever assembly (2) with equalizer (3).
Page 288 PARKING AND REAR BRAKE 5C-5 PARKING BRAKE CABLE 1. Parking brake lever assembly 6. Grommet 2. Equalizer 7. Parking brake cable bolt 3. Adjusting nut 8. Parking brake lever bolt 4. Parking cable bracket 5. Parking brake cable: Apply water tight sealant 99000-31090 to plate and : Tightening Torque cable contact.
Page 289 5C-6 PARKING AND REAR BRAKE INSTALLATION Install parts in reverse order of REMOVAL procedure, noting the fol- lowing. 1) Distinguish right side parking brake cable from left side one with its clamp width. Parking brake cable with narrow clamp should be installed to right side of vehicle.
Page 290 PARKING AND REAR BRAKE 5C-7 BRAKE DRUM REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause damage to seat- ing part of cap). 3) Uncalk spindle nut, remove spindle nut (1).
Page 291 5C-8 PARKING AND REAR BRAKE 7) Remove sensor ring (1) from brake drum (2) using special tools (if equipped with ABS). CAUTION: Pull out sensor ring from brake drum gradually and even- ly. Attempt to pull it out partially may cause it to be de- formed.
Page 292 PARKING AND REAR BRAKE 5C-9 Brake shoe Where lining is worn out beyond service limit, replace shoe. Thickness (lining + shoe rim) Standard : 5.5 mm (0.22 in.) Service limit : 2.6 mm (0.10 in.) If one of brake linings is to service limit, all linings must be replaced at the same time.
Page 293 5C-10 PARKING AND REAR BRAKE 3) Put flat head rod or the like between rod (1) and rachet (2) and pull rachet as shown to maximize clearance between shoe and drum. 4) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil.
Page 294 PARKING AND REAR BRAKE 5C-11 BRAKE SHOE REMOVAL 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL. 2) Remove shoe hold down springs (1) by turning shoe hold down pins (2). 3) Remove return springs, brake shoes and strut. 4) Disconnect parking brake cable (1) from parking brake shoe le- ver (2).
Page 295 5C-12 PARKING AND REAR BRAKE INSPECTION Parking Shoe Lever Inspect brake shoe lever for smooth movement along shoe rim. If defective, correct or replace. Brake Strut D Check ratchet of brake strut (1) assembly for wear or damage. D Check shoe return spring, strut shoe return spring and shoe hold down spring for damage, corrosion and weakening.
Page 296 PARKING AND REAR BRAKE 5C-13 3) Install shoe hold down springs (2) by pushing them down in place and turning hold down pins (1). 4) For procedure hereafter, refer to steps 3) to 12) of BRAKE DRUM INSTALLATION in this section. WHEEL CYLINDER REMOVAL 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
Page 297 5C-14 PARKING AND REAR BRAKE INSPECTION Inspect wheel cylinder disassembled parts for wear, cracks, corro- sion or damage. NOTE: Clean wheel cylinder components with brake fluid. INSTALLATION 1) Take off bleeder plug cap from brake pipe and connect pipe (for pipes) to wheel cylinder just enough to prevent fluid from leak- ing.
Page 298 PARKING AND REAR BRAKE 5C-15 5) Remove brake back plate (1) from rear axle. INSTALLATION 1) Apply water tight sealant to mating surfaces of brake back plate and rear axle. “A”: Sealant 366E, 99000-31090 NOTE: In case of vehicle equipped with ABS, do not apply sealant around hole for wheel speed sensor.
Page 299 5C-16 PARKING AND REAR BRAKE 4) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut to specified torque. (Refer to steps 1) to 4) of WHEEL CYLINDER INSTALLATION in this section.) 5) Install brake shoes, referring to steps 1) to 3) of BRAKE SHOE INSTALLATION in this section.
Page 300 PARKING AND REAR BRAKE 5C-17 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of caliper Brake fluid DOT 4 or SAE J1704 and wheel cylinder when they are disassembled.
Page 302 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 303 5E1-2 ANTILOCK BRAKE SYSTEM (ABS) GENERAL DESCRIPTION COMPONENTS AND PARTS LOCATION The ABS (Antilock Brake System) controls the fluid pressure applied to the Wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS has also the following function.
Page 304 ANTILOCK BRAKE SYSTEM (ABS) 5E1-3 SYSTEM SCHEMATIC 1. ABS hydraulic unit / control module assembly 2. ABS control module 3. ABS hydraulic unit 4. Fail safe relay 5. Pump motor relay 6. Stop lamp switch 7. “ABS” warning lamp 8. Brake warning lamp 9.
Page 305 5E1-4 ANTILOCK BRAKE SYSTEM (ABS) BRAKE HOSE/PIPE ROUTING For LH Steering Vehicle For RH Steering Vehicle 1. Brake master cylinder 2. ABS hydraulic unit / control module assembly 3. Front disk brakes 4. Rear drum brakes...
Page 306 ANTILOCK BRAKE SYSTEM (ABS) 5E1-5 ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY ABS control module is a component of ABS hydraulic unit/control module assembly and has the following functions. Self-Diagnosis Function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the “ABS”...
Page 307 5E1-6 ANTILOCK BRAKE SYSTEM (ABS) SYSTEM CIRCUIT...
Page 308 ANTILOCK BRAKE SYSTEM (ABS) 5E1-7...
Page 309 5E1-8 ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSIS To ensure that the trouble diagnosis is done accurately and smooth- ly, observe “Precautions in Diagnosing Troubles” and follow “ABS Diagnostic Flow Table”. PRECAUTIONS IN DIAGNOSING TROUBLES D If the vehicles was operated in any of the following ways, “ABS” warning lamp may light momentarily but this does not indicate anything abnormal in ABS.
Page 310 ANTILOCK BRAKE SYSTEM (ABS) 5E1-9 ABS DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION 1) Perform “Customer Complaint Analysis”. Go to Step 2. Go to Step 5. 2) Perform “Problem Symptom Confirmation”. 3) Perform “Diagnostic Trouble Code Check, Record and Clearance”.
Page 311 5E1-10 ANTILOCK BRAKE SYSTEM (ABS) 1. MALFUNCTION ANALYSIS i) Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 312 ANTILOCK BRAKE SYSTEM (ABS) 5E1-11 ii) Problem Symptom Confirmation Check if what the customer claimed in CUSTOMER QUESTIONNAIRE is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) Check warning lamps related to brake system referring to “Brake Warning Lamp Check”...
Page 313 5E1-12 ANTILOCK BRAKE SYSTEM (ABS) BRAKE WARNING LAMP CHECK NOTE: Perform this check on a level place. 1) Turn ignition switch ON with parking brake applied. 2) Check that brake warning lamp (1) is turned ON. 3) Release parking brake with ignition switch ON and check that brake warning lamp goes off.
Page 314 ANTILOCK BRAKE SYSTEM (ABS) 5E1-13 TABLE – A “ABS” WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON 1. Main fuse 2. Ignition switch 3. Circuit fuse 4. Combination meter 5. “ABS” warning lamp 6. Brake warning lamp 7.
Page 315 Perform diagnostic trouble code check. Is there any Go to Step 2. Go to Step 3. DTC (including code No.12, NO CODES on SUZUKI scan tool) exists? Does malfunction DTC (other than code No.12) exist at Go to Step 7 of “ABS Go to Step 3.
Page 316 ANTILOCK BRAKE SYSTEM (ABS) 5E1-15 TABLE – C “ABS” WARNING LAMP CIRCUIT CHECK – THE LAMP FLASHES CONTINUOUSLY WHILE IGNITION SWITCH IS ON “ABS” warning lamp in combination meter ABS hydraulic unit / control module assembly Diagnosis monitor coupler 3-1. Diagnosis switch terminal 3-2.
Page 317 5E1-16 ANTILOCK BRAKE SYSTEM (ABS) TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAGNOSIS SWITCH TERMINAL CONNECTED TO GROUND. “ABS” warning lamp in combination meter ABS hydraulic unit / control module assembly Diagnosis monitor coupler 3-1. Diagnosis switch terminal 3-2.
Page 318 ANTILOCK BRAKE SYSTEM (ABS) 5E1-17 TABLE – E BRAKE WARNING LAMP CHECK-LAMP COMES “ON” STEADY CIRCUIT DESCRIPTION Brake warning lamp is controlled by parking brake switch, brake fluid level switch and ABS control module/hydrau- lic unit assembly through lamp driver module in combination meter. Refer to “TABLE-A” for circuit diagram. STEP ACTION 1) Make sure that:...
Page 319 5E1-18 ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE (DTC) CHECK (USING “ABS” WARNING LAMP) 1) Perform “ABS” WARNING LAMP CHECK described above. 2) Using service wire (1), connect diagnosis switch terminal (2) of monitor coupler (3) to ground (4). 3) Turn ignition switch ON. 4) Read flashing of “ABS”...
Page 320 2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool opera- tor’s manual for further details. 4) After completing the check, turn ignition switch off and discon- nect SUZUKI scan tool from DLC.
Page 321 DIAGNOSTIC TROUBLE CODE (DTC) TABLE CAUTION: Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” before starting diagnosis. (displayed (indicated by “ABS” ABS warning lamp flashing pattern DIAGNOSTIC ITEMS SUZUKI warning scan tool) lamp) NO DTC Normal C1021 C1025 Wheel speed sensor circuit...
Page 322 ANTILOCK BRAKE SYSTEM (ABS) 5E1-21 DTC 21, 22 – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 25, 26 – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 31, 32 – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 35, 36 – LEFT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 1.
Page 323 5E1-22 ANTILOCK BRAKE SYSTEM (ABS) DTC 21, 22, 25, 26, 31, 32, 35 or 36 INSPECTION STEP ACTION 1) Disconnect applicable ABS wheel speed sensor Go to Step 2. Replace ABS wheel coupler with ignition switch OFF. speed sensor 2) Measure resistance between terminals of ABS assembly.
Page 324 ANTILOCK BRAKE SYSTEM (ABS) 5E1-23 DTC 41 – RIGHT-FRONT INLET SOLENOID CIRCUIT 45 – LEFT-FRONT INLET SOLENOID CIRCUIT 51 – RIGHT-REAR INLET SOLENOID CIRCUIT 55 – LEFT-REAR INLET SOLENOID CIRCUIT 42 – RIGHT-FRONT OUTLET SOLENOID CIRCUIT 46 – LEFT-FRONT OUTLET SOLENOID CIRCUIT 52 –...
Page 325 5E1-24 ANTILOCK BRAKE SYSTEM (ABS) DTC 57 – POWER SOURCE CIRCUIT 1. Ignition switch 2. Main fuse 3. ABS hydraulic unit / control module assembly 4. ABS hydraulic unit / control module connector DESCRIPTION The ABS control module monitors the power source voltage at terminal “E20-18”. When the power source voltage becomes extremely high or low, this DTC will be set.
Page 326 ANTILOCK BRAKE SYSTEM (ABS) 5E1-25 DTC 61 – ABS PUMP MOTOR CIRCUIT 1. ABS hydraulic unit / control module assembly 2. ABS pump motor relay 3. ABS pump motor 4. ABS fail safe relay 5. ABS hydraulic unit / control module connector DESCRIPTION The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition...
Page 327 5E1-26 ANTILOCK BRAKE SYSTEM (ABS) DTC 63 – ABS FAIL-SAFE RELAY CIRCUIT 1. Ignition switch 2. ABS hydraulic unit / control module assembly 3. ABS hydraulic unit / control module connector 4. To solenoid valves 5. To pump motor relay 6.
Page 328 ANTILOCK BRAKE SYSTEM (ABS) 5E1-27 DTC 71 – ABS CONTROL MODULE 1. ABS hydraulic unit / control module assembly 2. ABS pump motor relay 3. ABS pump motor 4. ABS fail safe relay 5. ABS hydraulic unit / control module connector DESCRIPTION This DTC will be set when an internal malfunction is detected in the ABS control module.
Page 329 ON. Then DTC will be set in ABS control module. ABS HYDRAULIC UNIT OPERATION CHECK (USING SUZUKI SCAN TOOL) 1) Remove steering column hole cover. 2) Connect SUZUKI scan tool (Tech-1) to data link connector (DLC) (1) with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 330 ANTILOCK BRAKE SYSTEM (ABS) 5E1-29 9) Perform the following checks with help of another person. Brake pedal should be depressed and then ignition switch turned ON by one person and wheel should be turned by another person’s hand. At this time, check that: D Operation sound of solenoid is heard and wheel turns only about 0.5 sec.
Page 331 5E1-30 ANTILOCK BRAKE SYSTEM (ABS) REMOVAL 1) Disconnect negative cable from battery. 2) For LH vehicle, remove air cleaner outlet pipe (1) referring to “Engine Mechanical” section. 3) Disconnect ABS hydraulic unit/control module assembly con- nector (1) by pulling up lock (2). 4) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly (3).
Page 332 ANTILOCK BRAKE SYSTEM (ABS) 5E1-31 INSTALLATION 1) Install hydraulic unit by reversing removal procedure. Tightening Torque (a): 16 N m (1.6 kg-m, 11.5 lb-ft) (b): 9 N m (0.9 kg-m, 6.5 lb-ft) (c): 9 N m (0.9 kg-m, 6.5 lb-ft) (d): 26 N m (2.6 kg-m, 18.0 lb-ft) 2) Bleed air from brake system referring to “BRAKE”...
Page 333 5E1-32 ANTILOCK BRAKE SYSTEM (ABS) FRONT WHEEL SPEED SENSOR 1. Left front wheel speed sensor 2. Clamp bolt 3. Grommet 4. Connector 5. Sensor ring OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch OFF. 2) Hoist vehicle a little. 3) Disconnect wheel speed sensor connector (1). 4) Disconnect wheel speed sensor grommet from vehicle body.
Page 334 ANTILOCK BRAKE SYSTEM (ABS) 5E1-33 REMOVAL 1) Disconnect negative cable from battery. 2) Disconnect front wheel speed sensor coupler (1). 3) Hoist vehicle and remove wheel. 4) Remove harness clamp bolts (2) and grommet (3). 5) Remove front wheel speed sensor (4) from knuckle. CAUTION: D Do not pull wire harness when removing front wheel speed sensor.
Page 335 5E1-34 ANTILOCK BRAKE SYSTEM (ABS) FRONT WHEEL SPEED SENSOR RING NOTE: The front wheel sensor ring can not be removed or replaced alone. If front wheel sensor ring needs to be replaced, replace it as a wheel side joint assembly of drive shaft. For removal and installation of wheel side joint assembly of drive shaft, refer to “FRONT DRIVE SHAFTS”...
Page 336 ANTILOCK BRAKE SYSTEM (ABS) 5E1-35 REAR WHEEL SPEED SENSOR 1. Left rear wheel sensor 2. Trailing arm 3. Sensor ring 4. Sensor coupler OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch “OFF”. 2) Hoist vehicle. 3) Disconnect connector of wheel speed sensor. 4) Connect voltmeter between connector terminals.
Page 337 5E1-36 ANTILOCK BRAKE SYSTEM (ABS) REMOVAL 1) Disconnect negative cable from battery. 2) Hoist vehicle. 3) Disconnect rear wheel speed sensor coupler (1). 4) Detach ABS wheel sensor wire harness (2) from suspension frame (3). Do not detach crip of rear wheel speed sensor connector from vehicle body unless replacement is necessary.
Page 338 3. Tech 1A 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09931-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16/14 pin DLC cable 09950-78220 Flare nut wrench (10 mm)
Page 340 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 341 6-2 ENGINE GENERAL INFORMATION DTC P0120 Throttle Position Circuit DTC P0443 Purge Control Valve Circuit Malfunction ......6- 51 Malfunction .
Page 342 ENGINE GENERAL INFORMATION 6-3 GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 343 6-4 ENGINE GENERAL INFORMATION PRECAUTION ON FUEL SYSTEM SERVICE HOSE CONNECTION D Work must be done with no smoking, in a well-ventilated area and With short pipe, fit hose as far as it reaches pipe joint as away from any open flames. shown.
Page 344 ENGINE GENERAL INFORMATION 6-5 FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
Page 345 ECM memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool (Tech-1) (2) but also generic scan tool. (Diagnostic information...
Page 346 ENGINE DIAGNOSIS 6-7 Warm-up Cycle A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22_C (40_F) from engine starting and reaches a minimum temperature of 70_C (160_F). Driving Cycle A “Driving Cycle” consists of engine startup and engine shutoff. 2 Driving Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC and freeze frame data) but the...
Page 347 Data Link Connector (DLC) DLC (1) is in compliance with SAEJ1962 in its installation position, the shape of connector and pin assignment. Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) to communicate with ECM. Body ground...
Page 348 ENGINE DIAGNOSIS 6-9 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITHOUT EGR VALVE) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is run- ning, and indicates the result by turning on or flashing malfunction indicator lamp (1).
Page 349 ECM memory. D Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 350 ENGINE DIAGNOSIS 6-11 ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to the complaint analysis. next page. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) and Freeze Frame Data 1) Print DTC and...
Page 351 6-12 ENGINE DIAGNOSIS 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 352 ENGINE DIAGNOSIS 6-13 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS j Difficult Starting j Poor Driveability j No cranking j Hesitation on acceleration j No initial combustion j Back fire/jAfter fire j No combustion j Lack of power...
Page 353 1) Check malfunction indicator lamp referring to “Malfunction Indi- cator Lamp Check” in this section. 2) With the ignition switch OFF position, disconnect SUZUKI scan tool if connected and using service wire (1), ground diagnosis switch terminal (2) in monitor coupler (3).
Page 354 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool (Tech-1) to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch ON. 3) Erase DTC and pending DTC according to instructions dis- played on scan tool.
Page 355 6-16 ENGINE DIAGNOSIS DIAGNOSTIC TROUBLE CODE (DTC) TABLE (vehicle (vehicle DETECTING CONDITION DETECTING ITEM with without (DTC will set when detecting:) valve) valve) Low pressure-high vacuum-low voltage P0105 Manifold absolute pressure (or MAP sensor circuit shorted to ground) 1 driving 1 driving (No.11) circuit malfunction...
Page 356 ENGINE DIAGNOSIS 6-17 (vehicle (vehicle DETECTING CONDITION DETECTING ITEM with without (DTC will set when detecting:) valve) valve) P0325 Knock sensor circuit Knock sensor circuit low input 1 driving 1 driving (No.17) malfunction Knock sensor circuit high input cycle cycle P0335 Crankshaft position sensor 1 driving...
Page 357 6-18 ENGINE DIAGNOSIS DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) P0702 P1702 Internal Malfunction of TCM (No.52) P0705 Transmission Range Switch Circuit (No.34) Malfunction lP0710l Transmission Fluid Temperature No.36 Signal Circuit Malfunction No.38 P0715 Input/Turbine Speed Sensor (No.14) Circuit Malfunction P0720 A/T VSS Signal Circuit Malfunction...
Page 358 ENGINE DIAGNOSIS 6-19 FAIL-SAFE TABLE When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC NO. DETECTED ITEM FAIL-SAFE OPERATION D ECM uses value determined by throttle Manifold absolute pressure circuit...
Page 359 6-20 ENGINE DIAGNOSIS VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil – – – – – level, leakage Section 0B D Engine coolant – – – – – level, leakage Section 0B D Fuel – – – – – level, leakage Section 0B D A/T fluid –...
Page 360 See Fig. 2. When using SUZUKI scan tool, select “MISC” mode on SUZUKI scan tool and fix ignition timing to initial one. See Fig. 3. 2) Remove air cleaner bolt and clips and shift air cleaner position to observe ignition timing.
Page 361 6-22 ENGINE DIAGNOSIS Fig. 1 for Step 5 Fig. 2 for Step 6 Fig. 3 for Step 6 When not using SUZUKI scan tool: When using SUZUKI scan tool Select “DATA LIST” mode SELECT MENU F4: MISC TEST Fig. 4 for Step 6 Fig.
Page 362 ENGINE DIAGNOSIS 6-23 ENGINE DIAGNOSIS TABLE Perform troubleshooting referring to following table when ECM has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Referring Item Hard Starting Ignition system out of order (Engine cranks OK) D Faulty spark plug Spark plugs in Section 6F1...
Page 363 6-24 ENGINE DIAGNOSIS Condition Possible Cause] Referring Item Low oil pressure D Improper oil viscosity Engine oil and oil filter change in Section 0B D Malfunctioning oil pressure switch Oil pressure switch inspection in Section 8 D Clogged oil strainer Oil pan and oil pump strainer cleaning in Section 6A1 D Functional deterioration of oil pump...
Page 364 ENGINE DIAGNOSIS 6-25 Condition Possible Cause Referring Item Overheating D Inoperative thermostat Thermostat in Section 6B D Poor water pump performance Water pump in Section 6B D Clogged or leaky radiator Radiator in Section 6B D Improper engine oil grade Engine oil and oil filter change in Section 0B D Clogged oil filter or oil strainer...
Page 365 6-26 ENGINE DIAGNOSIS Condition Possible Cause Referring Item Engine hesitates Ignition system out of order (Momentary lack of D Spark plug faulty or plug gap out of adjustment Spark plugs in Section 6F1 response as D Leaky high-tension cord High-tension cords in Section 6F1 accelerator is Fuel system out of order depressed.
Page 366 ENGINE DIAGNOSIS 6-27 Condition Possible Cause Referring Item Engine has no Ignition system out of order power D Faulty spark plug Spark plugs in Section 6F1 D Faulty ignition coil with ignitor Ignition coil in Section 6F1 D Leaks, loose connection or disconnection of High-tension cords in Section 6F1 high-tension cord D Faulty knock sensor...
Page 367 6-28 ENGINE DIAGNOSIS Condition Possible Cause Referring Item Improper engine Ignition system out of order idling or engine D Faulty spark plug Spark plugs in Section 6F1 fails to idle D Leaky or disconnected high-tension cord High-tension cords in Section 6F1 D Faulty ignition coil with ignitor Ignition coil in Section 6F1 Fuel system out of order...
Page 368 ENGINE DIAGNOSIS 6-29 Condition Possible Cause Referring Item Excessive Ignition system out of order hydrocarbon (HC) D Faulty spark plug Spark plugs in Section 6F1 emission or carbon D Leaky or disconnected high-tension cord High-tension cords in Section 6F1 monoxide (CO) D Faulty ignition coil with ignitor Ignition coil assembly in Section Low compression...
Page 369 6-30 ENGINE DIAGNOSIS SCAN TOOL DATA As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 370 ENGINE DIAGNOSIS 6-31 NORMAL CONDITION / SCAN TOOL DATA CONDITION REFERENCE VALUES M / T 700 r / min DESIRED IDLE At idling with no load after warming up, M / T (DESIRED IDLE SPEED) at neutral, A / T at “P” range A / T 750 r / min TP SENSOR VOLT...
Page 371 6-32 ENGINE DIAGNOSIS SCAN TOOL DATA DEFINITIONS FUEL SYSTEM (FUEL SYSTEM STATUS) MAF (MASS AIR FLOW RATE, gm/s, lb/min) Air/fuel ratio feedback loop status displayed as either It represents total mass of air entering intake manifold open or closed loop. Open indicates that ECM ig- which is computed based on signals from MAP sen- nores feedback from the exhaust oxygen sensor.
Page 372 ENGINE DIAGNOSIS 6-33 CANIST PURGE DUTY (EVAP CANISTER PURGE FLOW DUTY, %) This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP purge solenoid valve which controls the amount of EVAP purge. 0% means that the purge valve is completely closed while 100% is a fully open valve.
Page 373 6-34 ENGINE DIAGNOSIS INSPECTION OF ECM AND ITS CIRCUITS ECM and its circuits can be checked at ECM wiring couplers by measuring voltage and resistance. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with coupler dis- connected from it.
Page 374 ENGINE DIAGNOSIS 6-35 TERMINAL NORMAL CIRCUIT CONDITION VOLTAGE Ground — — Ground — — Ground — — EVAP canister purge valve 10 – 14 V Ignition switch ON Indication deflection deflection Engine coolant temp and Engine coolant tem . and repeated barometric pressure signal Ignition switch ON...
Page 375 6-36 ENGINE DIAGNOSIS TERMINAL NORMAL CIRCUIT CONDITION VOLTAGE A/C compressor clutch Ignition switch ON 0 – 1 V More than 3 seconds after ignition switch ON EGR valve (stepper motor coil 1) (if equipped) 0 – 14 V After engine start Data link connector 10 –...
Page 376 ENGINE DIAGNOSIS 6-37 TERMINAL NORMAL CIRCUIT CONDITION VOLTAGE 0 – 1 V Ignition switch ON Malfunction indicator lamp Malfunction indicator lamp 10 – 14 V When engine running Indicator deflection Ignition switch ON Vehicle speed sensor repeated Front left tire turned slowly with front right 0 V and tire locked 4 –...
Page 377 6-38 ENGINE DIAGNOSIS Resistance Check 1) Disconnect ECM couplers from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itself or connect voltmeter or ohmmeter. 2) Check resistance between each terminal of couplers discon- nected. CAUTION: D Be sure to connect ohmmeter probe from wire harness side of coupler.
Page 378 ENGINE DIAGNOSIS 6-39 COMPONENT LOCATION INFORMATION SENSORS CONTROL DEVICES OTHERS -1. MAP sensor a: Fuel injector A: ECM -2. TP sensor b: EVAP canister purge valve B: Main relay -3. IAT sensor c: Fuel pump relay C: EVAP canister -4. ECT sensor d: EGR valve (step motor) (if equipped) D: Monitor connector (If equipped) -5.
Page 379 6-40 ENGINE DIAGNOSIS TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON (BUT ENGINE AT STOP) CIRCUIT DESCRIPTION Malfunction indicator lamp in combination meter Fuse box Ignition switch Main relay Relay Main fuse E23-1 When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point).
Page 380 ENGINE DIAGNOSIS 6-41 TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION Go to Step 2 of ENGINE Diagnostic Trouble Code (DTC) check Go to Step 2. 1) Check DTC referring to DTC CHECK section.
Page 381 6-42 ENGINE DIAGNOSIS TABLE A-3 ECM POWER AND GROUND CIRCUIT CHECK – MIL DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE DOESN’T START THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTION Malfunction indicator lamp in combination meter Ignition switch Main relay Relay Main fuse...
Page 382 ENGINE DIAGNOSIS 6-43 STEP ACTION ECM Power Circuit Check Check ground circuits Go to Step 6. 1) Using service wire, ground terminal E22-10 and “Bl/B” and “B/Y” for measure voltage between terminal E22-5 and open. ground at ignition switch ON. If OK, then substitute a Is it 10 –...
Page 383 6-44 ENGINE DIAGNOSIS DTC P0105 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT (DTC No.11) MALFUNCTION CIRCUIT DESCRIPTION To TP sensor Vout sensor To other sensors E21-10 E21-26 E21-22 DTC DETECTING CONDITION POSSIBLE CAUSE D MAP: 4.9 kpa, 37 mmHg or less D “Br/W” circuit open (Low pressure –...
Page 384 ENGINE DIAGNOSIS 6-45 MAP Sensor Individual Check 1) Disconnect coupler from MAP sensor (1). 2) Remove MAP sensor (1). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total volt- age is 4.5 – 5.0 V) and connect its positive terminal to “Vin” termi- nal of sensor and negative terminal to “Ground”...
Page 385 6-46 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Check MAP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF.
Page 386 ENGINE DIAGNOSIS 6-47 DTC P0110 (DTC No.18) INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION IAT sensor To other sensors E21-15 E21-10 DTC DETECTING CONDITION POSSIBLE CAUSE D Low intake air temperature (High voltage-High resistance) D “Lg” circuit open or shorted to power. D High intake air temperature (Low voltage-Low resistance) D “Br/W”...
Page 387 6-48 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch Check for intermittent OFF.
Page 388 ENGINE DIAGNOSIS 6-49 DTC P0115 ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT (DTC No.19) MALFUNCTION CIRCUIT DESCRIPTION To combination To other sensors (ECT) meter E21-10 E21-14 DTC DETECTING CONDITION POSSIBLE CAUSE D Low engine coolant temperature (High voltage-High resistance) D “Y/G” circuit open or shorted to power D High engine coolant temperature (Low voltage-Low resistance) D “Br/W”...
Page 389 6-50 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check ECT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent 2) Turn ignition switch ON.
Page 390 ENGINE DIAGNOSIS 6-51 DTC P0120 (DTC No.13) THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To other sensors Throttle position sensor To other sensors E21-10 E23-5 E21-22 DTC DETECTING CONDITION POSSIBLE CAUSE D Signal voltage high D “Br/W” circuit open D Signal voltage low D “Gr”...
Page 391 6-52 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Check TP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch referring to “Intermittent...
Page 392 ENGINE DIAGNOSIS 6-53 MEMO...
Page 393 6-54 ENGINE DIAGNOSIS DTC P0121 THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION To other sensors Throttle position sensor To other sensors E21-10 E23-5 E21-22 DTC DETECTING CONDITION POSSIBLE CAUSE D After engine warmed up. D TP sensor malfunction D While vehicle running at specified engine speed. D High resistance in the circuit D No change in intake manifold pressure (constant throttle opening) D ECM malfunction...
Page 394 If voltmeter was Go to Step 3. When using SUZUKI scan tool: used, check 1) Turn ignition switch OFF and connect SUZUKI scan tool to terminal E23-5 for DLC. poor connection. 2) Turn ignition switch ON and check TP sensor output...
Page 395 6-56 ENGINE DIAGNOSIS DTC P0130 HEATED OXYGEN SENSOR (HO2S) CIRCUIT (DTC No.14) MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION To other sensor Fuse box Ignition switch Heater Main fuse To HO2S-2 heater E21-7 E21-13 E21-10 DTC DETECTING CONDITION POSSIBLE CAUSE D When running at idle speed after engine warmed up D Heated oxygen sensor-1 malfunction and running at specified vehicle speed, HO2S-1 D “Br/W”...
Page 396 ENGINE DIAGNOSIS 6-57 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than HO2S-1 Go to applicable DTC Go to Step 3. (DTC P0130)? Diag. Flow Table. 1) Connect scan tool to DLC with ignition switch Intermittent trouble.
Page 397 6-58 ENGINE DIAGNOSIS DTC P0133 HEATED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE (SENSOR-1) WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to DTC P0130 section. DTC DETECTING CONDITION POSSIBLE CAUSE D When running at specified idle speed after engine D Heated oxygen sensor-1 malfunction warmed up and running at specified vehicle speed, response time (time to change from lean to rich or from rich to lean) of HO2S-1 output voltage is about...
Page 398 ENGINE DIAGNOSIS 6-59 DTC P0135 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT (DTC No.14) MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION To other sensor Fuse box Ignition switch Heater Main E21-7 fuse To HO2S-2 heater E21-13 E21-10 DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is met. D HO2S-1 heater circuit open or shorted to ground D ECM malfunction D Low voltage at terminal E21-7 when engine is...
Page 399 6-60 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go t o“ENGINE DIAG. FLOW TABLE”. Check Heater for Operation. Intermittent trouble Go to Step 3. 1) Check voltage at terminal E21-7. See Fig. 1. Check for intermittent 2) Warm up engine to normal operating temperature.
Page 400 ENGINE DIAGNOSIS 6-61 DTC P0136 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION To other sensor Ignition Main switch fuse Heater To HO2S-1 heater E22-4 E23-10 E22-13 DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is detected. D Exhaust gas leakage A.
Page 401 6-62 ENGINE DIAGNOSIS DTC CONFIRMATION PROCEDURE WARNING: D 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. D Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Turn ignition switch OFF.
Page 402 ENGINE DIAGNOSIS 6-63 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check exhaust system for leakage, loose Go to Step 3. Repair or replace. connection and damage. Is it good condition? Check HO2S-2 and Its Circuit.
Page 403 6-64 ENGINE DIAGNOSIS DTC P0141 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION To other sensor Ignition Main switch fuse Heater To HO2S-1 heater E22-4 E23-10 E22-13 DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition it met. D HO2S-2 heater circuit open or shorted A.
Page 404 ENGINE DIAGNOSIS 6-65 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check HO2S-2 Heater and Its Circuit. Intermittent trouble. Go to Step 3. 1) Warm up engine to normal operating temperature. Check for intermittent 2) Stop engine.
Page 405 6-66 ENGINE DIAGNOSIS DTC P0171 FUEL SYSTEM TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH CIRCUIT DESCRIPTION Signal to decrease amount of fuel injection Signal to increase amount of fuel injection Sensed information High voltage Low voltage HEATED OXYGEN INJECTOR SENSOR-1 Fuel injector A / F mixture...
Page 406 ENGINE DIAGNOSIS 6-67 DTC CONFIRMATION PROCEDURE WARNING: D 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. D Road test should be carried out with 2 persons, a driver and a tester on a level road. 1) Turn ignition switch OFF.
Page 407 6-68 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than fuel system Go to applicable Go to Step 3. (DTC P0171/P0172)? DTC Diag. Flow Table.
Page 408 ENGINE DIAGNOSIS 6-69 STEP ACTION Check engine coolant temp. sensor for performance Go to Step 9. Replace engine (See Section 6E). coolant temp. sensor. Is it in good condition? Check intake air temp. sensor for performance Go to Step 10. Replace intake air (See Section 6E).
Page 409 6-70 ENGINE DIAGNOSIS DTC P0300 RANDOM MISFIRE DETECTED (Misfire detected at 2 or more cylinders) DTC P0301 CYLINDER 1 MISFIRE DETECTED DTC P0302 CYLINDER 2 MISFIRE DETECTED DTC P0303 CYLINDER 3 MISFIRE DETECTED DTC P0304 CYLINDER 4 MISFIRE DETECTED Ignition coil assembly for No.1 &...
Page 410 ENGINE DIAGNOSIS 6-71 DTC DETECTING CONDITION POSSIBLE CAUSE D Engine under other than high revolution condition D Engine overheating D Not on rough road D Vacuum leaks (air inhaling) from air intake system D Engine speed changing rate D Ignition system malfunction (spark plug(s), high- Below D Manifold absolute tension cord(s), ignition coil assembly)
Page 411 6-72 ENGINE DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE“. Is there DTC other than Fuel system (DTC P0171/P0172) Go to applicable Go to Step 3. and misfire (DTC P0300-P0304)? DTC Diag.
Page 412 ENGINE DIAGNOSIS 6-73 STEP ACTION Check PCV valve for clogging (See Section 6E). Go to Step 7. Replace PCV valve. Is it in good condition? Check EVAP Canister Purge Valve for Closing. Check EVAP Go to Step 8. 1) Disconnect purge hose (1) from EVAP canister. control system 2) Place finger against the end of disconnected hose.
Page 413 6-74 ENGINE DIAGNOSIS DTC P0325 (DTC No.17) KNOCK SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION To other sensor E21-25 E21-12 DTC DETECTING CONDITION POSSIBLE CAUSE D KNOCK: 3.75 V or more D “W” circuit open or shorted to ground D KNOCK: 1.25 V or less D KNOCK sensor malfunction D ECM malfunction DTC CONFIRMATION PROCEDURE...
Page 414 ENGINE DIAGNOSIS 6-75 Fig. 1 for Step 2 Fig. 2 for Step 2 E21-12...
Page 415 6-76 ENGINE DIAGNOSIS DTC P0335 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT (DTC No.23) MALFUNCTION CIRCUIT DESCRIPTION Crankshaft timing belt pulley sensor E21-24 E21-23 DTC DETECTING CONDITION POSSIBLE CAUSE D NO CKP sensor signal for 2 seconds at engine D CKP sensor circuit open or short. cranking.
Page 416 ENGINE DIAGNOSIS 6-77 INSPECTION NOTE: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even though CKP sensor is in good condition. When starter motor fails to run and this DTC appears, check starter circuit first. STEP ACTION Was “ENGINE DIAG.
Page 417 6-78 ENGINE DIAGNOSIS DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT (DTC No.15) MALFUNCTION CIRCUIT DESCRIPTION To ignition Camshaft switch position sensor Signal rotor on Camshaft E21-11 DTC DETECTING CONDITION POSSIBLE CAUSE D No CMP sensor signal during engine running D CMP sensor circuit open or short. (CKP sensor signal is inputted).
Page 418 ENGINE DIAGNOSIS 6-79 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check CMP Sensor and connector for proper Go to Step 3. Correct. installation. Is CMP sensor installed properly and connector connected securely? Check Wire Harness and Connection.
Page 419 6-80 ENGINE DIAGNOSIS STEP ACTION Check signal rotor for the following, using mirror. Intermittent trouble or Clean rotor teeth or See Fig. 4. faulty ECM. replace CMP sensor. D Damage Check for intermittent D No foreign material attached referring to Is it in good condition? “Intermittent and Poor Connection”...
Page 420 ENGINE DIAGNOSIS 6-81 DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION CIRCUIT DESCRIPTION Main relay Ignition switch Relay EGR valve Main fuse DTC DETECTING CONDITION POSSIBLE CAUSE D While running at specified vehicle speed after D EGR valve or its circuit engine warm-up D EGR passage D During deceleration (engine speed high with closed...
Page 421 6-82 ENGINE DIAGNOSIS DTC CONFIRMATION PROCEDURE WARNING: D 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. D Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Turn ignition switch OFF.
Page 422 Next turn ignition switch to ON, check voltage between E22-2, 8, 9, 17 terminals of ECM and body ground. Is voltage within 10 – 14 V? Do you have SUZUKI scan tool? Go to Step 5. Stuck or faulty EGR valve or clogged EGR gas passage.
Page 423 6-84 ENGINE DIAGNOSIS DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD CIRCUIT DESCRIPTION To other sensor Heated Heated oxygen oxygen sensor-2 sensor-1 Warm up three way Three way catalytic converter catalytic converter ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by HO2S-2.
Page 424 ENGINE DIAGNOSIS 6-85 DTC CONFIRMATION PROCEDURE WARNING: D 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. D Road test should be carried out with 2 persons, a driver and tester, on a level road. 1) Turn ignition switch OFF.
Page 425 6-86 ENGINE DIAGNOSIS DTC P0420 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Short Term Fuel Trim. Go to Step 3. Check fuel system. Did short term fuel trim vary within –20% –+20% Go to DTC P0171/P0172 range in step 3) of DTC confirmation test? Diag.
Page 426 ENGINE DIAGNOSIS 6-87 DTC P0443 PURGE CONTROL VALVE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. EVAP canister purge valve 2. To main relay 3. ECM 4. Sensed information 5. Intake manifold 6. EVAP canister 7. Tank pressure control valve 8. Fuel vapor line 9.
Page 427 6-88 ENGINE DIAGNOSIS DTC P0480 RADIATOR COOLING FAN CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION Radiator cooling fan relay Bl / R Main Radiator cooling relay Fan motor Relay “Fl” “RDTR” (Radiator fan) DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal E22-18 when engine coolant D “B/R”...
Page 428 ENGINE DIAGNOSIS 6-89 DTC P0480 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Radiator Cooling Fan Relay and Its Circuit. Intermittent trouble or Go to Step 3. 1) Turn ignition switch ON. faulty ECM.
Page 429 6-90 ENGINE DIAGNOSIS DTC P0500 (DTC NO.16) VEHICLE SPEED SENSOR (VSS) MALFUNCTION CIRCUIT DESCRIPTION 1. VSS sensing rotor 2. VSS (vehicle speed sensor) 3. VSS connector 4. Power supply from ignition switch 5. Speedometer, P / S control module 6. ECM / PCM connector 7.
Page 430 ENGINE DIAGNOSIS 6-91 DTC P0500 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Does speedometer indicate vehicle speed? Go to Step 3. Go to Step 5. Check Vehicle Speed Signal. Intermittent trouble or Go to Step 4.
Page 431 6-92 ENGINE DIAGNOSIS DTC P0505 (DTC No.26) IDLE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION Main relay Relay box Main fuse To other valve IAC valve DTC DETECTING CONDITION POSSIBLE CAUSE D No closed signal to IAC valve is detected after D “B/R”, “G/Y” or “B” circuit open or short engine start.
Page 432 Check Idle Air Control System. Intermittent trouble or Go to Step 3. When using SUZUKI scan tool: faulty ECM. 1) Connect SUZUKI scan tool to DLC with ignition Check for intermittent switch OFF, set parking brake and block drive referring to “Intermittent wheels.
Page 433 6-94 ENGINE DIAGNOSIS DTC P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601: Data write error (or check sum error) when written into ECM 2 driving cycle detection logic, continuous monitoring. DTC CONFIRMATION PROCEDURE 1) Turn ignition switch OFF.
Page 434 2) Turn ignition switch ON and select “DATA LIST” mode on scan tool. 3) Check manifold absolute pressure. See Fig. 1. Is it barometric pressure (approx. 100 kPa, 760 mmHg) at sea level? Fig. 1 for Step 1 When using SUZUKI scan tool:...
Page 435 6-96 ENGINE DIAGNOSIS STEP ACTION Check MAP Sensor Check air intake Replace MAP 1) Remove MAP sensor from intake manifold and connect system for air sensor. vacuum pump gauge to MAP sensor. See Fig. 2. being drawn in 2) Connect scan tool to DLC and turn ignition switch ON. and engine 3) Check intake manifold absolute pressure displayed on compression.
Page 436 ENGINE DIAGNOSIS 6-97 DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION M/T vehicle Main fuse Ignition switch (starter switch) Starter A/T vehicle Transmission Main range sensor (switch) fuse Ignition switch (starter switch) Starter DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal E23-17 when cranking D “B/Y”...
Page 437 6-98 ENGINE DIAGNOSIS DTC P1510 ECM BACK-UP POWER SUPPLY MALFUNCTION CIRCUIT DESCRIPTION Main Fuse box fuse DOME RADIO “LAMP” Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM, etc. are kept in ECM even when the ignition switch is turned OFF. DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal E22-7 after starting engine.
Page 438 ENGINE DIAGNOSIS 6-99 DTC P1600 SERIAL COMMUNICATION PROBLEM BETWEEN ECM AND TCM CIRCUIT DESCRIPTION The serial data line is pulled up to about 12 V by ECM and TCM transmits information to ECM through it by control- ling its grounding. TCM constantly sends information while ignition switch is ON as to whether judgement was made or not with re- spect to all detectable DTCs as well as whether or not abnormality exists after judgement.
Page 439 6-100 ENGINE DIAGNOSIS DTC P1600 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check signal voltage. Intermittent trouble or Go to Step 3. Check voltage between terminal E22-23 and body faulty ECM or TCM.
Page 440 ENGINE DIAGNOSIS 6-101 DTC P1717 A/T DRIVE RANGE (PARK/NEUTRAL POSITION) SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION From ignition switch Transmission range switch DTC DETECTING CONDITION POSSIBLE CAUSE D “W” circuit open D “D” range signal not inputted (Park/Neutral position signal D Transmission range switch malfunction inputted) to ECM while vehicle running D “R”, “D”, “2”...
Page 441 Intermittent trouble or Go to Step 3. When using SUZUKI scan tool: faulty ECM. Check for 1) Connect SUZUKI scan tool to DLC with ignition intermittent referring to switch OFF. See Fig. 1. “Intermittent and poor 2) Turn ignition switch ON and check PNP signal connection”...
Page 442 ENGINE DIAGNOSIS 6-103 TABLE B-1 FUEL INJECTOR CIRCUIT CHECK Fuse box Main relay Ignition switch No.1 injector No.2 injector Relay box No.3 injector No.4 injector Main fuse E21-9 E21-8 E21-21 E21-31 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2.
Page 443 6-104 ENGINE DIAGNOSIS TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK Ignition Main relay switch Main relay Fuel pump relay Main fuse Fuel pump E22-19 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.
Page 444 ENGINE DIAGNOSIS 6-105 Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4 Fuel pump relay connector...
Page 445 6-106 ENGINE DIAGNOSIS TABLE B-3 FUEL PRESSURE CHECK 1. Injector 2. Delivery pipe 3. Fuel pump (A): Fuel pressure gauge (B): Hose (C): Attachment INSPECTION STEP ACTION Check Fuel Pressure (Refer to Section 6E for details). Go to Step 2. Go to Step 4.
Page 446 ENGINE DIAGNOSIS 6-107 Fig. 1 for Step 1 4. Fuel pressure gauge & 3way joint...
Page 447 Go to Step 6. Repair or replace A/C Step 1 of Table B-5 A/C Signal Circuit Check, signal circuit or A/C if equipped. (A/C signal can be also checked system. by using SUZUKI scan tool.) Is it in good condition?
Page 448 Go to Step 9. Repair or replace. When using SUZUKI scan tool: 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. See Fig. 1. 2) Turn ignition switch ON and check PNP signal (“P/N” and “D” range) on display when shifting selector lever to each range.
Page 449 6-110 ENGINE DIAGNOSIS TABLE B-5 A/C SIGNAL CIRCUITS CHECK (VEHICLE WITH A/C) “HEATER” Blower fan switch Blower fan motor Heater fan relay Dual pressure switch Evaporator A / C switch thermistor A / C compressor INSPECTION STEP ACTION 1) Disconnect ECM connectors with ignition Go to Step 2.
Page 450 ENGINE DIAGNOSIS 6-111 STEP ACTION 1) Check voltage at E22-1 terminal under each A/C control system D “B/Y” wire open or condition given in table below. circuits are in good short condition. D Poor E22-1 terminal While engine running, connection A/C switch OFF If wire and connection While engine running,...
Page 451 Electric load signal “R /W” and/or When using SUZUKI scan tool: circuit is in good “P/Bl” circuit open 1) Connect SUZUKI scan tool to DLC with ignition condition. or short, Electric switch OFF. load diodes 2) Start engine and select “DATA LIST” mode on malfunction or scan tool.
Page 452 ENGINE DIAGNOSIS 6-113 TABLE B-7 RADIATOR COOLING FAN CONTROL SYSTEM CHECK Radiator cooling fan relay Bl / R Main Radiator cooling relay Fan motor Relay “Fl” “RDTR” (Radiator fan) E22-18 INSPECTION STEP ACTION Check Fan Control System. Radiator cooling Go to Step 2. 1) Connect scan tool to DLC with ignition switch OFF.
Page 453 6-114 ENGINE DIAGNOSIS Fig. 1 for Step 1 Fig. 2 for Step 3 Radiator cooling fan relay When using SUZUKI scan tool: Fig. 3 for Step 4...
Page 454 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09917-47910 09930-88530 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1 A) kit 09931-76030 Mass storage cartridge 16 / 14 pin DLC cable...
Page 456 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 457 6A1-2 ENGINE MECHANICAL GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 The single overhead camshaft is mounted over the stroke cycle gasoline unit with its S.O.H.C. (Single cylinder head; it is driven from crankshaft through tim- Overhead Camshaft) valve mechanism arranged for ing belt, and no push rods are provided in the valve “V”-type valve configuration and 16 valves (IN2 and...
Page 458 ENGINE MECHANICAL 6A1-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted on In another path, oil goes up to cylinder head and lubri- crankshaft at crankshaft pulley side. cates camshaft journals, rocker arms, camshaft, etc., Oil is drawn up through oil pump strainer and passed after passing through the internal oilway of rocker arm through pump to oil filter.
Page 459 6A1-4 ENGINE MECHANICAL CYLINDER BLOCK The cylinder block is made of cast aluminum alloy and This allows a gradual change in thrust pressure has 4 cylinders arranged “In-Line”. against the cylinder wall as the piston travels its path. A cylindrical cast iron sleeve is installed in each cylin- Pins, made of chromium steel, have a floating fit in the der.
Page 460 ENGINE MECHANICAL 6A1-5 ON-VEHICLE SERVICE HOSE AND PIPE ROUTING 1. MAP sensor 2. Brake booster vacuum hose 3. EVAP canister 4. EVAP canister purge valve 5. TP sensor 6. CMP sensor 7. Ignition coil assembly 8. PCV valve 9. IAC valve...
Page 461 6A1-6 ENGINE MECHANICAL COMPRESSION CHECK Check compression pressure on all four cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 462 ENGINE MECHANICAL 6A1-7 ENGINE VACUUM CHECK The engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) Warm up engine to normal operating temperature. 2) With engine stopped, disconnect EVAP canister purge valve (1) hose from intake manifold (2) and connect 3-way joint, hoses and special tool (vacuum gauge and joint) between intake man-...
Page 463 6A1-8 ENGINE MECHANICAL 2) Install special tool (Oil pressure gauge) to vacated threaded hole. Special Tool (A): 09915-77310 3) Start engine and warm it up to normal operating temperature. 4) After warming up, raise engine speed to 4,000 r/min and mea- sure oil pressure.
Page 464 ENGINE MECHANICAL 6A1-9 6) Check if the rocker arms of No.1 cylinder are off the respective cam lobes (of camshaft); if so, valves (1), (2), (5) and (7) in left figure are ready for clearance checking and adjustment. Check valve lashes at valves (1), (2), (5) and (7). If the rocker arms of No.4 cylinder are off the respective cam lobes, check valve lashes at valves (3), (4), (6) and (8).
Page 465 6A1-10 ENGINE MECHANICAL 8) After checking and adjusting valve lashes at valves (1), (2), (5) and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly one full turn (360_) and check the same at valves (3), (4), (6) and (8) (or (1), (2), (5), and (7)).
Page 466 ENGINE MECHANICAL 6A1-11 AIR CLEANER ASSEMBLY REMOVAL 1) Disconnect air cleaner outlet No.1 hose (1) from air cleaner as- sembly (2). 2) Remove suction pipe (3) from air cleaner assembly. 3) Remove air cleaner assembly by removing bolt (4) shown in fig- ure.
Page 467: Knock Sensor
6A1-12 ENGINE MECHANICAL KNOCK SENSOR REMOVAL 1) Disconnect negative cable from battery. 2) Hoist vehicle. 3) Remove intake manifold rear stiffener. 4) Disconnect knock sensor connector (1). 5) Remove knock sensor (2) from cylinder block. INSPECTION Check sensor for damage. If any faulty is found, replace.
Page 468 ENGINE MECHANICAL 6A1-13 3) Install ignition coil assemblies (1) with high-tension cord. 4) Connect PCV valve and breather hose to head cover. 5) Install suction pipe to air cleaner assembly, referring to INSTAL- LATION of AIR CLEANER ASSEMBLY in this section. 6) Connect negative cable at battery.
Page 469 6A1-14 ENGINE MECHANICAL 4) Disconnect accelerator cable (1) from throttle body. 5) Remove air cleaner outlet No.1 hose (2) and No.2 hose (4) with air intake joint (3). 6) Disconnect following electric lead wires and release clamps. D EGR valve (1) D EVAP canister purge valve (2) D Ground wire (3) from intake manifold D Fuel injectors (4)
Page 470 ENGINE MECHANICAL 6A1-15 9) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold (3). 10) Remove intake manifold with throttle body from cylinder head, and then its gasket. INSTALLATION Reverse removal procedure for installation noting the followings. D Use new intake manifold gasket.
Page 471 6A1-16 ENGINE MECHANICAL EXHAUST MANIFOLD 1. Exhaust manifold 8. Oxygen sensor No.2 2. Engine hook 9. Catalytic converter case 3. Exhaust manifold cover 10. Catalytic converter case gasket 4. Oxygen sensor No.1 11. Exhaust manifold bolts (long) 5. Exhaust manifold gasket 12.
Page 472 ENGINE MECHANICAL 6A1-17 6) Remove exhaust manifold (1) and its gasket from cylinder head. 7) Remove catalytic converter case gasket and exhaust No.1 pipe seal ring (rear side). INSTALLATION 1) Install new gaskets to cylinder head, catalytic converter case and exhaust No.1 pipe (rear side). 2) Install exhaust manifold.
Page 473 6A1-18 ENGINE MECHANICAL TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seals 10. Inside cover 11. Outside cover seal 12.
Page 474 ENGINE MECHANICAL 6A1-19 8) Remove water pump pulley (1) and drive belt. 9) Remove crankshaft pulley by removing pulley bolts (1). 10) Release harness clamps. 11) Remove timing belt outside cover. 12) For installation of timing belt, align 4 timing marks as shown in figure by turning crankshaft.
Page 475 6A1-20 ENGINE MECHANICAL CAUTION: D After timing belt is removed, never turn camshaft and crankshaft independently more than such an extent as shown in figure. If turned, interference may occur among piston and valves, and parts related to piston and valves may be damaged.
Page 476 ENGINE MECHANICAL 6A1-21 2) Install tensioner (2) and tensioner plate (3): Do not tighten tensioner bolt (1) with wrench yet. Hand tighten only at this time. Check to ensure that plate movement in arrow direction as shown in figure causes tensioner to move in the same direction. If no associated movement between plate and tensioner occurs, remove tensioner and plate again and reinsert plate lug into ten- sioner hole.
Page 477 6A1-22 ENGINE MECHANICAL 6) To take up slack of timing belt, turn crankshaft two rotations clockwise after installing it. After making sure that belt is free from slack, tighten tensioner stud first and then tensioner bolt to each specified torque. Then confirm again that two sets of marks are aligned respec- tively.
Page 478 ENGINE MECHANICAL 6A1-23 11) Install engine right mounting bracket (1), stiffener (2) and en- gine right mounting swing bracket (3). Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 lb-ft) 12) Remove support device. 13) Install A/C compressor bracket and A/C compressor, if equipped.
Page 479 6A1-24 ENGINE MECHANICAL OIL PAN AND OIL PUMP STRAINER 1. Oil pan: Apply sealant 99000-31150 to oil pan mating surface 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. CKP sensor 7. Oil pan bolts 8.
Page 480 ENGINE MECHANICAL 6A1-25 CLEANING D Clean mating surface of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. D Clean oil pump strainer screen. INSTALLATION 1) Apply sealant to oil pan mating surface continuously as shown “A”...
Page 481 6A1-26 ENGINE MECHANICAL 4) Install CKP sensor (1) and connect its coupler, then clamp its harness. Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) 5) Install exhaust No.1 pipe and connect oxygen sensor No.2 con- nector. Tighten bolts to specified torque. Tightening Torque (a): 42 N m (4.2 kg-m, 30.5 lb-ft)
Page 482 ENGINE MECHANICAL 6A1-27 OIL PUMP 1. Rotor plate 2. Inner rotor: Apply thin coat of engine oil. 3. Outer rotor: Apply thin coat of engine oil. 4. Gasket 5. Pin 6. Pin 7. Relief valve: Apply thin coat of engine oil. 8.
Page 483 6A1-28 ENGINE MECHANICAL DISASSEMBLY 1) Remove oil level gauge guide bolt (3) and pull out guide (2) from oil pump (1). 2) Remove rotor plate (1). 3) Remove outer rotor (1) and inner rotor (2).
Page 484 ENGINE MECHANICAL 6A1-29 INSPECTION D Check oil seal lip for fault or other damage. Replace as necessary. NOTE: When installing oil seal (1), press-fit it till its end face is flush with oil pump case (2) end face. D Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
Page 485 6A1-30 ENGINE MECHANICAL ASSEMBLY 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner rotor (2) and outer rotor (1), oil seal lip portion, and inside surfaces of oil pump case and plate.
Page 486 ENGINE MECHANICAL 6A1-31 4) Install rubber seal between oil pump and water pump. 5) Install key (2) and crank timing belt pulley (3). Refer to figure 1. Dowel pin for proper installation of these parts. (crankshaft pulley pin) With crankshaft locked using flat end rod or the like (5), tighten crank timing belt pulley bolt (4) to specified torque.
Page 487 6A1-32 ENGINE MECHANICAL ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT 1. Camshaft: Apply engine oil to sliding surface of camshaft. 2. Camshaft oil seal: Apply engine oil to oil seal lip. 3. Rocker arm shaft: Apply engine oil to sliding surface of rocker arm shaft.
Page 488 ENGINE MECHANICAL 6A1-33 7) Remove engine harness clamp bracket from CMP sensor case (1). 8) Disconnect CMP sensor connector and remove CMP sensor case from cylinder head. Place a container or rag under CMP sensor case, for a small amount of oil flows out during removal of case. 9) After loosening all valve adjusting screw lock nuts (2), turn ad- justing screws (1) back all the way to allow all rocker arms (3) to move freely.
Page 489 6A1-34 ENGINE MECHANICAL 13) Remove rocker arm shaft bolts (1). 14) Remove exhaust rocker arms (1) and rocker arm spring (2) by pulling rocker arm shaft to transmission side. 15) Remove O-ring from rocker arm shaft. INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw (1) is badly worn, replace it.
Page 490 ENGINE MECHANICAL 6A1-35 Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm I.D. Difference between two readings is arm-to-shaft clearance on which a limit is specified. If limit is exceeded, replace shaft or arm, or both. Item Standard Limit...
Page 491 6A1-36 ENGINE MECHANICAL Check clearance by using plasticgauge. The procedure is as follows. 1) Clean housings and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of plasticgauge the full width of journal of camshaft (parallel to camshaft). 4) Install camshaft housing, referring to INSTALLATION of follow- ing page.
Page 492 ENGINE MECHANICAL 6A1-37 INSTALLATION 1) Apply engine oil to rocker arm shaft and rocker arms. 2) Install rocker arm shaft (3) with shaft bolt holes (4) facing up, rocker arm (exhaust side) (2) and rocker arm spring (1). 3) Check O-ring for damage or deterioration. Install O-ring to rocker arm shaft.
Page 493 6A1-38 ENGINE MECHANICAL 6) Apply engine oil to cams and journals on camshaft and put cam- shaft on cylinder head. Install camshaft housing to camshaft and cylinder head. D Apply engine oil to sliding surface of each housing against camshaft journal. D Apply sealant to mating surface of No.6 housing (1) which will mate with cylinder head.
Page 494 ENGINE MECHANICAL 6A1-39 9) Install camshaft timing belt pulley (1) to camshaft while fitting pin (2) on camshaft into slot at “E” mark. 10) Using special tool, tighten pulley bolt to specified torque. Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) Special Tool (A): 09917-68220 11) After place cylinder head cover on proper position, install belt...
Page 495 6A1-40 ENGINE MECHANICAL VALVES AND CYLINDER HEAD 1. Valve cotters: 5. Valve spring seat: 10. Camshaft housing: Apply engine oil. Apply engine oil. Apply engine oil to sliding surface of 2. Valve spring retainer: 6. Exhaust valve: each housing against camshaft journal. Apply engine oil.
Page 496 ENGINE MECHANICAL 6A1-41 5) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold (3). 6) Disconnect oxygen sensor No.2 coupler (1) and remove ex- haust No.1 pipe (2) with catalytic converter case (3). 7) Disconnect following electric wires: D MAP sensor D CMP sensor D Engine oil pressure switch...
Page 497 6A1-42 ENGINE MECHANICAL 10) Disconnect fuel feed hose (1) from fuel delivery pipe. 11) Disconnect water inlet pipe (1) from its bracket. 12) Remove cylinder head cover as previously outlined. Loosen all valve lash adjusting screws fully. 13) Remove timing belt and camshaft as previously outlined.
Page 498 ENGINE MECHANICAL 6A1-43 14) Install engine right mounting bracket (1), stiffener (2) and en- gine right mounting swing bracket (3). 15) Remove support device. 16) Loosen cylinder head bolts in such order as indicated in figure and remove them. 17) Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect what- ever necessary.
Page 499 6A1-44 ENGINE MECHANICAL DISASSEMBLY 1) For ease in servicing cylinder head, remove thermostat case, in- take manifold with throttle body and exhaust manifold from cylin- der head. 2) Remove rocker arms and springs by pulling its shaft out to trans- mission side.
Page 500 ENGINE MECHANICAL 6A1-45 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
Page 501 6A1-46 ENGINE MECHANICAL D Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve.
Page 502 ENGINE MECHANICAL 6A1-47 2. INTAKE VALVE SEAT: Cutting sequence is the same as for ex- haust valve seats (1). Seat width for intake valve seat: 1.1 – 1.3 mm (0.0433 – 0.0512 in.) 3. VALVE LAPPING: Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the second with fine-size compound, each time using valve lapper accord- ing to usual lapping method.
Page 503 6A1-48 ENGINE MECHANICAL D Distortion of manifold seating faces: Check seating faces of cylinder head for manifolds, using a straightedge and thickness gauge, in order to determine whether these faces should be corrected or cylinder head replaced. Limit of distortion: 0.10 mm (0.004 in.) Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak-...
Page 504 ENGINE MECHANICAL 6A1-49 ASSEMBLY 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so remove burrs and make it truly round. Special Tool (A): 09916-34541 (B): 09916-38210 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100_C (176 to 212_F) so that head will not be distorted, and drive new valve guide into hole with special tools.
Page 505 6A1-50 ENGINE MECHANICAL 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Page 506 ENGINE MECHANICAL 6A1-51 9) Install rocker arms, springs, rocker arm shaft as previously out- lined. 10) Install thermostat case, intake manifold and exhaust manifold. INSTALLATION 1) Remove old gasket and oil on mating surfaces and install new head gasket (1) as shown in figure, that is, “TOP” mark provided on gasket comes to crankshaft pulley side, facing up (toward cyl- inder head side).
Page 507 6A1-52 ENGINE MECHANICAL 4) Reverse removal procedure for installation, nothing the follow- ing points. D Adjust drive belt tension, referring to “ENGINE COOLING” section. D Adjust A/C compressor belt tension, if equipped. Refer to Section 1B. D Adjust intake and exhaust valve lashes as previously outlined. D Adjust accelerator cable play.
Page 508 ENGINE MECHANICAL 6A1-53 PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring: Apply engine oil. 2. 2nd ring: Apply engine oil. 3. Oil ring: Apply engine oil. 4. Piston: Apply engine oil. 5. Connecting rod 6. Connecting rod bearing cap 7.
Page 509 6A1-54 ENGINE MECHANICAL DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips (1), as shown. D Force piston pin out. CLEANING Clean carbon from piston head and ring grooves, using a suitable tool.
Page 510 ENGINE MECHANICAL 6A1-55 INSPECTION Cylinders D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. D Using a cylinder gauge, measure cylinder bore in thrust and axial directions at two positions as shown in figure.
Page 511 6A1-56 ENGINE MECHANICAL D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
Page 512 ENGINE MECHANICAL 6A1-57 Piston Rings To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
Page 513 6A1-58 ENGINE MECHANICAL Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin to undersize and use undersize bearing.
Page 514 ENGINE MECHANICAL 6A1-59 5) Remove cap and using a scale (2) on plasticgauge envelope, measure gaging plastic (1) width at the widest point (clear- ance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit Bearing...
Page 515 6A1-60 ENGINE MECHANICAL c) Stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with number 2 and a number 1 piston to cylin- der with number 1. Unit: mm (in.) Piston Cylinder...
Page 516 ENGINE MECHANICAL 6A1-61 INSTALLATION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) Install guide hoses over connecting rod bolts. These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assem- bly.
Page 517 6A1-62 ENGINE MECHANICAL 6) Reverse removal procedure for installation, nothing the follow- ing points. D Adjust water pump drive belt tension, referring to “ENGINE COOLING” section. D Adjust A/C compressor belt tension, if equipped. Refer to Section 1B. D Adjust accelerator cable play. Refer to Section 6E. D Check to ensure that all removed parts are back in place.
Page 518 ENGINE MECHANICAL 6A1-63 UNIT REPAIR OVERHAUL ENGINE MOUNTING 1. Right mounting 13. Right mounting body bolt 2. Right mounting swing bracket 14. Right mounting bracket & swing bolt 3. Right mounting bracket 15. Right mounting bracket & swing nut 4. Left mounting body bracket 16.
Page 519 6A1-64 ENGINE MECHANICAL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line by referring to Section 6. 2) After disconnect negative and positive cables at battery, remove battery and battery tray. 3) Remove engine hood after disconnecting windshield washer hose.
Page 520 ENGINE MECHANICAL 6A1-65 10) Disconnect following electric wires: D Back-up light switch (M/T) D Shift switch (A/T) D Forward clutch revolution sensor (4 A/T) D A/T vehicle speed sensor (A/T) D Battery negative cable from transmission D Vehicle speed sensor D e.t.c.
Page 521 6A1-66 ENGINE MECHANICAL 18) Disconnect A/C suction and discharge hoses and then remove A/C compressor and its bracket (if equipped), refer to Section 19) Install support device. 20) Remove engine rear mounting bush bolt (1). 21) Remove engine left mounting nuts (2). 22) Remove engine right mounting bracket bolts (3) and nut (4).
Page 522 ENGINE MECHANICAL 6A1-67 INSTALLATION 1) Lift engine with transmission into engine compartment, but do not remove support device. 2) Install engine right mounting bracket bolts and nut. 3) Install engine left mounting nuts. 4) Install engine rear mounting bush bolt. 5) Tighten bolts and nuts to specified torque.
Page 523 6A1-68 ENGINE MECHANICAL MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 6. Timing pulley key 10. Pin 2. Front oil seal: 7. Crankshaft: 11. Oil seal housing gasket Apply engine oil to contact part Apply engine oil to crankshaft 12.
Page 524 ENGINE MECHANICAL 6A1-69 REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (1) (drive plate for A/T). Special Tool (A): 09924-17810 3) Remove crankshaft pulley, timing belt and crankshaft timing pulley. 4) Remove cylinder head assembly.
Page 525 6A1-70 ENGINE MECHANICAL INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing (1) and journal bearing caps installed.
Page 526 ENGINE MECHANICAL 6A1-71 Main Bearings General information D Service main bearings are available in standardsize and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. D Upper half of bearing (2) has oil groove (3) as shown in figure. Install this half with oil groove to cylinder block (1).
Page 527 6A1-72 ENGINE MECHANICAL 5) Remove cap and using scale (2) on plasticgauge (1) envelope, measure plasticgauge width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use of 0.25 mm undersize bearing.
Page 528 ENGINE MECHANICAL 6A1-73 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent following cap bore diameters. Bearing cap bore diameter Alphabet stamped (without bearing) 49.000 –...
Page 529 6A1-74 ENGINE MECHANICAL 4) From numerals stamped on crank webs of No.2 and No.3 cylin- ders (1) and the alphabets stamped on mating surface of cylin- der block, determine new standard bearing to be installed to journal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
Page 530 ENGINE MECHANICAL 6A1-75 D If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 44.732 – 44.750 mm (1.7611 – 1.7618 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
Page 531 6A1-76 ENGINE MECHANICAL Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. D Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout: 0.2 mm (0.0078 in.) Cylinder Block Distortion of gasketed surface...
Page 532 ENGINE MECHANICAL 6A1-77 4) Calculate cylinder bore diameter to be rebored. D = A + B – C D: Cylinder bore diameter to be rebored. A: Piston diameter as measured. B: Piston clearance = 0.02 – 0.04 mm (0.0008 – 0.0015 in.) C: Allowance for honing = 0.02 mm (0.0008 in.) 5) Rebore and hone cylinder to calculated dimension.
Page 533 6A1-78 ENGINE MECHANICAL 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side. Tighten bearing cap bolts in such order as shown in figure a little at a time and repeat it till they are tightened to specified torque.
Page 534 ENGINE MECHANICAL 6A1-79 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously A: Camshaft pulley side outlined. B: CMP sensor case side 11) Install camshaft, crankshaft timing belt pulley, timing belt, crankshaft pulley, water pump pulley, etc., as previously out- lined.
Page 535 6A1-80 ENGINE MECHANICAL SPECIAL TOOLS 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 Hose 09915-67310 09918-08210 09915-77310 4. 09915-67010 Attachment Vacuum gauge Vacuum gauge hose joint Oil pressure gauge 1. 09916-14510 Valve lifter 09917-18210 09926-18210 09917-68220 2. 09916-14910 Tappet adjuster wrench Oil seal guide (Vinyl resin) Camshaft pulley holder Valve lifter attachment...
Page 536 Piston ring compressor Flywheel holder Oil filter wrench REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI BOND NO.1207C Sealant D Mating surfaces of cylinder block and oil pan. (99000-31150) D Mating surfaces of camshaft housing (No.6). SUZUKI BOND NO.1215 Sealant...
Page 538 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 539 6B-2 ENGINE COOLING GENERAL DESCRIPTION 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. COOLING SYSTEM CIRCULATION 1) While the engine is warmed up (thermostat closed), coolant circulates as follows. Throttle body Water pump Cylinder block...
Page 540 ENGINE COOLING 6B-3 COOLANT The coolant recovery system is standard. The coolant D Add ethylene glycol base coolant when coolant has in the radiator expands with heat, and the overflow is to be added because of coolant loss or to provide collected in the reservoir.
Page 541 6B-4 ENGINE COOLING DIAGNOSIS Condition Possible Cause Correction Engine overheats D Loose or broken water pump belt Adjust or replace. D Not enough coolant Check coolant level and add as necessary. D Faulty thermostat Replace. D Faulty water pump Replace. D Dirty or bent radiator fins Clean or remedy.
Page 542 ENGINE COOLING 6B-5 MAINTENANCE COOLANT LEVEL CHECK Coolant Level To check level, lift hood and look at “see-through” coolant reservoir (1). It is not necessary to remove radiator cap to check coolant level. WARNING: To help avoid danger of being burned: D Do not remove reservoir cap while coolant is “boiling”.
Page 543 6B-6 ENGINE COOLING 4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity 110 kPa (1.1 kg/cm 15.6 psi). If replacement of cap is required, use specified cap for this vehicle. NOTE: After installing radiator cap to radiator, make sure that the ear of cap lines is parallel to radiator.
Page 544 ENGINE COOLING 6B-7 7) Remove reservoir (1) and remove cap (2) from reservoir and pour out any fluid, scrub and clean inside of tank with soap and water. Flush it well with clean water and drain. Reinstall reservoir. 8) Disconnect coolant hose from throttle body for improving air purging efficiency and add 50/50 mixture of good quality ethyl- ene glycol antifreeze and water to radiator until coolant over- flow disconnected hose.
Page 545 6B-8 ENGINE COOLING ON-VEHICLE SERVICE WARNING: D Check to make sure that engine coolant temperature is cold before removing any part of cooling system. D Also be sure to disconnect negative cord from battery ter- minal before removing any part. COOLING SYSTEM DRAINING 1) Remove radiator cap.
Page 546 ENGINE COOLING 6B-9 THERMOSTAT REMOVAL 1) Drain coolant and tighten drain plug. 2) Remove radiator inlet hose (2) at thermostat cap. 3) Remove thermostat cap (1). 4) Remove thermostat (1). INSPECTION 1) Make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat.
Page 547 6B-10 ENGINE COOLING INSTALLATION 1) When positioning thermostat (1) on thermostat case (3), be sure Upside to position it so that air bleed valve (2) comes at position as shown in figure. 2) Install thermostat cap to thermostat case. 3) Connect cooling water hose. 4) Fill cooling system (refer to COOLING SYSTEM FLUSH AND REFILL in this section).
Page 548 ENGINE COOLING 6B-11 RADIATOR REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system by loosening drain plug (1) of radiator (2). 3) Disconnect coupler of cooling fan motor. 4) Remove front bumper (see Section 9). 5) Remove reservoir. 6) Disconnect radiator inlet (2) and outlet hoses (1) from radiator (3).
Page 549 6B-12 ENGINE COOLING INSTALLATION Reverse removal procedures. NOTE: D Refill cooling system with proper coolant referring to COOL- ANT in GENERAL DESCRIPTION. D After installation, check each joint for leakage. WATER PUMP 1) Disconnect negative cable at battery. 2) Drain cooling system. 3) Remove timing belt and tensioner refer to TIMING BELT AND TENSIONER of SECTION 6A1.
Page 550 ENGINE COOLING 6B-13 INSTALLATION 1) Install new pump gasket (1) to cylinder block. 2) Install water pump (1) to cylinder block. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 3) After installing water pump, install rubber seal (2) between wa- ter pump and oil pump.
Page 552 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 553 6C-2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM The main components of the fuel system are fuel tank, fuel pump assembly (with fuel filter, fuel level gauge, fuel pressure regulator and fuel cut valve), fuel feed line and fuel vapor line. For the details of fuel flow and fuel vapor flow, refer to “ENGINE AND EMISSION CONTROL SYSTEM”...
Page 554 ENGINE FUEL 6C-3 ON-VEHICLE SERVICE DOT MARK ON HOSE VIEW: X VIEW: Y VIEW: Y VIEW: X 1. Fuel tank 5. Fuel feed line 2. Fuel pump assembly 6. Fuel vapor line (vehicle with EVAP canister only) 7. Fuel tank inlet valve CAUTION: 8.
Page 555 6C-4 ENGINE FUEL With short pipe, fit hose as far as it reaches WARNING: pipe joint as shown. Before attempting service of any type on fuel system, fol- Pipe Hose lowing cautions should be always observed. D Disconnect negative cable at battery. D DO NOT smoke, and place “NO SMOKING”...
Page 556 ENGINE FUEL 6C-5 FUEL LINES Due to the fact that fuel feed line is under high pressure, use special care when servicing it. INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose crack and deterioration, or damage. Make sure that all clamps are secure. Replace parts as needed.
Page 557: Fuel Filler Cap
6C-6 ENGINE FUEL 6) Mark the location of clamps on fuel pipes, so that the clamps can be reinstalled to where they were. 7) Remove pipes (3) with clamp (2) from vehicle. 8) Remove clamp from pipes. 1. Clamp location mark INSTALLATION 1) Install clamps to marked location on pipes.
Page 558 ENGINE FUEL 6C-7 FUEL TANK INLET VALVE WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section. REMOVAL 1) Remove fuel filler cap. 2) Insert hose of a hand operated pump into fuel filler hose and drain fuel in space “A”...
Page 559 6C-8 ENGINE FUEL INSTALLATION 1) Install fuel tank inlet valve (1) to fuel tank. 2) Install fuel filler hose (1) to fuel tank and secure it with clamp (2). For proper installation, refer to the figure on 6C-3. 3) Lower vehicle and install fuel filler cap.
Page 560 ENGINE FUEL 6C-9 FUEL TANK FUEL TANK DRAINING PROCEDURE WARNING: D This draining procedure will not remove all fuel. Do not at- tempt any service on tank using heat or flame as an explo- sion resulting in personal injury could occur. D Never drain or store fuel in an open container due to the possibility of fire or explosion.
Page 561 6C-10 ENGINE FUEL 7) Reinstall fuel filler hose (1) to fuel tank and secure it with clamp (2). For proper installation, refer to the figure on 6C-3. 8) Lower vehicle and reinstall fuel filler cap. REMOVAL WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section.
Page 562 ENGINE FUEL 6C-11 6) Disconnect fuel pipe joint and fuel hoses from fuel pipes. Before Pipe For quick joint (1), disconnect it as follows: disconnecting, blow off a) Remove mud, dust and/or foreign material between pipe and dust, etc. of this portion with joint by blowing compressed air.
Page 563 6C-12 ENGINE FUEL FUEL TANK PURGING PROCEDURE WARNING: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank using heat or flame as an explosion resulting in personal injury could occur. Following procedure is used purging fuel tank. 1) After removing fuel tank, remove all hoses, pipes, fuel pump as- sembly from fuel tank.
Page 564 ENGINE FUEL 6C-13 4) Connect fuel hose (1) and vapor hose (2) to pipes as shown in figure and clamp them securely. CAUTION: When connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
Page 565 6C-14 ENGINE FUEL FUEL PUMP ASSEMBLY (WITH FUEL FILTER, FUEL LEVEL GAUGE, FUEL PRESSURE REGULATOR AND FUEL CUT VALVE) Before disconnecting, Pipe blow off WARNING: dust, etc. of this portion Refer to the WARNING at the beginning of ON-VEHICLE with compressed SERVICE in this section.
Page 566 ENGINE FUEL 6C-15 INSTALLATION 1) Clean mating surfaces of fuel pump assembly and fuel tank. 2) Install new gasket (2) and plate (3) to fuel pump assembly (1) then install fuel pump assembly to fuel tank. Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) 3) Connect fuel breather hose (1), fuel vapor hose (2) and fuel feed hose (3) to fuel pump assembly.
Page 567 6C-16 ENGINE FUEL SPECIAL TOOL 09919-47020 Quick joint remover...
Page 568 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 569 6E-2 ENGINE AND EMISSION CONTROL SYSTEM GENERAL DESCRIPTION The engine and emission control system is divided Fuel delivery system includes fuel pump, delivery into 4 major sub-systems: air intake system, fuel de- pipe, fuel pressure regulator, etc. Electronic control livery system, electronic control system and emission system includes ECM, various sensors and con- trolled devices.
Page 570 ENGINE AND EMISSION CONTROL SYSTEM 6E-3...
Page 571 6E-4 ENGINE AND EMISSION CONTROL SYSTEM...
Page 572 ENGINE AND EMISSION CONTROL SYSTEM 6E-5...
Page 573 6E-6 ENGINE AND EMISSION CONTROL SYSTEM AIR INTAKE SYSTEM The main components of the air intake system are air is distributed by the intake manifold (5) and finally cleaner (1), air cleaner outlet hose (2), throttle body drawn into each combustion chamber. (3), idle air control valve (4) and intake manifold (5).
Page 574 ENGINE AND EMISSION CONTROL SYSTEM 6E-7 FUEL DELIVERY SYSTEM The fuel system consists of fuel tank (1), fuel pump (2) (with built-in fuel filter (3) and fuel pressure regulator (4)), delivery pipe (5), injectors (6) and fuel feed line (7). The fuel (8) in the fuel tank (1) is pumped up by the fuel pump (2), sent into delivery pipe (5) and injected by the injectors (6).
Page 575 6E-8 ENGINE AND EMISSION CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM The electronic control system consists of 1) various D A/C control system (if equipped) sensors which detect the state of engine and driving D Radiator fan control system conditions, 2) ECM which controls various devices D EGR system (if equipped) according to the signals from the sensors and 3) vari- D Evaporative emission control system...
Page 576 ENGINE AND EMISSION CONTROL SYSTEM 6E-9 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE ELECTRIC CONTROL DEVICE OUTPUT INPUT DIAGNOSIS SWITCH (VEHICLE WITHOUT EGR VALVE) FUEL LEVEL SENSOR (VEHICLE WITH EGR VALVE) For detecting fuel level BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH LIGHTING SWITCH...
Page 577 6E-10 ENGINE AND EMISSION CONTROL SYSTEM...
Page 578 ENGINE AND EMISSION CONTROL SYSTEM 6E-11...
Page 579 6E-12 ENGINE AND EMISSION CONTROL SYSTEM WIRE WIRE CON- CON- TERMINAL CIRCUIT TERMINAL CIRCUIT COLOR COLOR NECTOR NECTOR Ground for ECM —— ——— B / Y Ground for drive circuit Heated oxygen sensor-2 B / Y Ground for drive circuit “D”, “2”, “L”-range ID-UP signal R / B Canister purge valve...
Page 580 ENGINE AND EMISSION CONTROL SYSTEM 6E-13 ON-VEHICLE SERVICE ACCELERATOR CABLE ADJUSTMENT 1) With accelerator pedal depressed fully (1), check clearance be- tween throttle lever (2) and lever stopper (3) (throttle body) which should be within following specification. Clearance “a” : 0.5 – 2.0 mm (0.02 – 0.07 in.) (With pedal depressed fully) If measured value is out of specification, adjust it to specification...
Page 581 6E-14 ENGINE AND EMISSION CONTROL SYSTEM 1) Connect SUZUKI scan tool to DLC with ignition switch OFF, if it When using SUZUKI scan tool: is available. 2) Warm up engine to normal operating temperature. 3) Check engine idle speed and “IAC duty” as follows: When using SUZUKI scan tool: (a) Select “Data List”...
Page 582 ENGINE AND EMISSION CONTROL SYSTEM 6E-15 AIR INTAKE SYSTEM THROTTLE BODY CAUTION: Do not remove or adjust throttle stop screw as it is factory adjusted precisely CAUTION: Do not disassemble IAC valve. Disassembly spoils its original performance 1. Throttle body 2.
Page 583 6E-16 ENGINE AND EMISSION CONTROL SYSTEM 5) Disconnect electric coupler from TP sensor (1) and IAC valve (2). 6) Remove throttle body from intake manifold. 7) Disconnect engine coolant hoses from throttle body. Disassembly NOTE: While disassembling and assembling throttle body, use spe- cial care not to deform levers on throttle valve shaft or cause damage to any other parts.
Page 584 ENGINE AND EMISSION CONTROL SYSTEM 6E-17 2) Connect engine coolant hoses. 3) Install throttle body (1) to intake manifold. 4) Connect coupler to TP sensor (2) and IAC valve (3) securely. 5) Install air cleaner outlet hose (1) and pipe. 6) Connect accelerator cable and adjust cable play to specifica- tion.
Page 585 6E-18 ENGINE AND EMISSION CONTROL SYSTEM IDLE AIR CONTROL VALVE (IAC VALVE) Removal 1) Remove throttle body from intake manifold referring to “Throttle Body Removal” section. 2) Remove IAC valve from throttle body. Inspection 1) Connect each connector to IAC valve (1), TP sensor and IAT sensor.
Page 586 ENGINE AND EMISSION CONTROL SYSTEM 6E-19 FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure”...
Page 587 6E-20 ENGINE AND EMISSION CONTROL SYSTEM 9) Remove special tools from fuel delivery pipe. 10) Connect fuel feed hose to fuel delivery pipe and clamp it se- curely. 11) With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP WITH PRESSURE REGULATOR On-Vehicle Inspection CAUTION:...
Page 588 ENGINE AND EMISSION CONTROL SYSTEM 6E-21 Installation 1) Install fuel pump to its bracket. 2) Install fuel pump to fuel tank and then install fuel tank to body ac- cording to procedure described in Section 6C. FUEL INJECTOR On-Vehicle Inspection 1) Using sound scope (1) or such, check operating sound of injec- tor (2) when engine is running or cranking.
Page 589 6E-22 ENGINE AND EMISSION CONTROL SYSTEM Inspection WARNING: As fuel is injected in this inspection, perform in a well venti- lated area and away from open flames. Use special care to prevent sparking when connecting and disconnecting test lead to and from battery. 1) Install injector to special tool (injector checking tool).
Page 590 6) Operate fuel pump and apply fuel pressure to injector as follows: When using SUZUKI scan tool : (1) Connect SUZUKI scan tool to DLC with ignition switch OFF. (2) Turn ignition switch ON, clear DTC and select “MISC TEST”...
Page 591 6E-24 ENGINE AND EMISSION CONTROL SYSTEM Installation For installation, reverse removal procedure and note following pre- cautions. D Replace injector O-ring (1) with new one using care not to dam- age it. D Check if cushion (2) is scored or damaged. If it is, replace with new one.
Page 592 ENGINE AND EMISSION CONTROL SYSTEM 6E-25 ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE (ECM) CAUTION: As ECM consists of precision parts, be careful not to ex- pose it to excessive shock. Removal 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “DISABLING THE AIR BAG SYSTEM”...
Page 593 6E-26 ENGINE AND EMISSION CONTROL SYSTEM THROTTLE POSITION SENSOR (TP SENSOR) Inspection 1) Disconnect negative cable at battery and coupler from TP sen- sor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. TERMINALS RESISTANCE Between 1 and 2.5 –...
Page 594 ENGINE AND EMISSION CONTROL SYSTEM 6E-27 INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) Removal 1) Disconnect battery negative cable at battery. 2) Disconnect coupler (1) from IAT sensor (2). 3) Remove IAT sensor (2) from air cleaner outlet hose (3). Inspection Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
Page 595 6E-28 ENGINE AND EMISSION CONTROL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) Removal 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to Section 6B. WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure if cap is taken off too soon.
Page 596 ENGINE AND EMISSION CONTROL SYSTEM 6E-29 HEATED OXYGEN SENSOR (Sensor-1 and Sensor-2) Oxygen Sensor Heater Inspection 1) Disconnect sensor coupler. 2) Using ohmmeter, measure resistance between terminals “V ” and “GND” of sensor coupler. NOTE : Temperature of sensor affects resistance value largely. Make sure that sensor heater is at correct temperature.
Page 597 6E-30 ENGINE AND EMISSION CONTROL SYSTEM CAMSHAFT POSITION SENSOR Inspection Check camshaft position sensor referring to DTC P0340 (DTC No. 15) Diag. Flow Table in Section 6. If malfunction is found, re- place. Removal 1) Disconnect negative cable at battery. 2) Disconnect connector from camshaft position sensor.
Page 598 ENGINE AND EMISSION CONTROL SYSTEM 6E-31 CRANKSHAFT POSITION SENSOR Inspection Check crankshaft position sensor referring to step 1 and 2 of DTC P0335 Flow Chart. If malfunction is found, replace. Removal 1) Hoist vehicle. 2) Remove engine under cover on right side. 3) Disconnect connector from crankshaft position sensor.
Page 599 6E-32 ENGINE AND EMISSION CONTROL SYSTEM MAIN RELAY, FUEL PUMP RELAY AND RADIATOR FAN CONTROL RELAY Inspection 1) Disconnect negative cable at battery. 2) Remove main relay (1), fuel pump relay (2) and radiator fan con- trol relay (3) from vehicle. 3) Check that there is no continuity between terminal “c”...
Page 600 ENGINE AND EMISSION CONTROL SYSTEM 6E-33 RADIATOR FAN CONTROL SYSTEM System Inspection 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 in the “ON”...
Page 601 6E-34 ENGINE AND EMISSION CONTROL SYSTEM Engine Coolant Temp. Signal Inspection Check engine coolant temp. signal referring to step 1 of DTC P1705/DTC NO.51 Flow Chart in Section 7B. If check result is not satisfactory, check each wire harness, circuit connection and ECT sensor.
Page 602: Egr System
EMISSION CONTROL SYSTEM EGR SYSTEM System Inspection (using SUZUKI scan tool) 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and then select “DATA LIST” mode on scan tool. 3) Make sure that vehicle condition is as following.
Page 603 6E-36 ENGINE AND EMISSION CONTROL SYSTEM Inspection 1) Check resistance between following terminals of EGR valve in each pair. Terminal Standard resistance A – B C – B 20 – 24 Ω F – E D – E 1. EGR valve 2.
Page 604 ENGINE AND EMISSION CONTROL SYSTEM 6E-37 EVAPORATIVE EMISSION CONTROL SYSTEM EVAP Canister Purge Inspection NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up. 1) Disconnect purge hose (1) from EVAP canister.
Page 605 6E-38 ENGINE AND EMISSION CONTROL SYSTEM EVAP Canister Purge Valve Inspection Check EVAP canister purge valve referring to step 1 of DTC P0443 Flow Chart. If found malfunction, replace. EVAP Canister Inspection WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful.
Page 606: Pcv System
ENGINE AND EMISSION CONTROL SYSTEM 6E-39 PCV SYSTEM NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking IAC duty, for obstructed PCV valve or hose hampers its accurate adjustment. PCV Hose Inspection Check hoses for connection, leakage, clog and deterioration.
Page 607 7. DLC cable adaptor 8. Self-test adaptor 09917-47910 09930-88530 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1A) kit 09931-76030 16 / 14 pin DLC cable Mass storage cartridge TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts...
Page 608 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 609 6F1-2 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) GENERAL DESCRIPTION The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. D ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 610 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-3 SYSTEM WIRING DIAGRAM 1. Ignition switch 5. CMP sensor 11. Sensed information 2. Main relay 6. CKP sensor D MAP sensor D Park / Neutral position signal 3. Ignition coil assembly 7. No.1 spark plug D ECT sensor D Electric load signal for No.1 and No.4...
Page 611 6F1-4 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) IGNITION SYSTEM DIAGNOSTIC FLOW TABLE STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE” in section 6. Ignition Spark Test Go to Step 11. Go to Step 3. 1) Check all spark plugs for condition and type referring to “Spark Plugs”...
Page 612 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F1-5 ON-VEHICLE SERVICE IGNITION SPARK TEST 1) Disconnect all injector couplers (1) 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. 2) Remove spark plug and check it for condition and type referring to “Spark Plugs”...
Page 613 6F1-6 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 5) Install high-tension cords (2) to spark plugs and ignition coil as- semblies (1) while gripping each cap. CAUTION: D Never attempt to use metal conductor high-tension cords as replacing parts. D Insert each cap portion fully when installing high-ten- sion cords.
Page 614 D Before starting engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake. INSPECTION 1) When using SUZUKI scan tool, connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 615 6F1-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 5) Fix ignition timing to initial one as follows. When using SUZUKI scan tool: Select “MISC” mode on SUZUKI scan tool and fix ignition tim- ing to initial one. When not using SUZUKI scan tool:...
Page 616 4. DLC cable (14 / 26 pin, 09931-76040) 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09931-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16 / 14 pin DLC cable...
Page 618 CRANKING SYSTEM 6G-1 SECTION 6G CRANKING SYSTEM (1.2 kW Reduction Type) NOTE: Starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. CONTENTS GENERAL DESCRIPTION ..............6G- 2 Cranking Circuit .
Page 619 6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT In the circuit shown in the following, the magnetic switch coils are magnetized when the ignition switch is closed.
Page 620 CRANKING SYSTEM 6G-3 DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: D Starting motor does not run (or runs slowly) D Starting motor runs but fails to crank engine D Abnormal noise is heard D Starting motor does not stop running Proper diagnosis must be made to determine exactly where the cause of each trouble lies..in battery, wiring har- ness, (including ignition and starting motor switch), starting motor or engine.
Page 621 6G-4 CRANKING SYSTEM Condition Possible Cause Correction Motor not running D Burnt commutator Replace armature. D Grounding of field coil Repair. D Layer short-circuit of armature Replace. D Crankshaft rotation obstructed Repair. Starting motor running If battery and wiring are satisfactory, but too slow (small torque) inspect starting motor D Insufficient contact of magnetic switch...
Page 622 CRANKING SYSTEM 6G-5 UNIT REPAIR OVERHAUL 13.3 N m (1.33 kg-m) 6.0 N 1. Front housing (0.6 kg-m) 2. Front armature shaft bush: Apply lithium grease 99000-25010 to inside and outside. 3. Snap ring 4. Pinion stop ring: 10. Plunger: Note the installing Apply lithium grease direction, and the detail...
Page 623 6G-6 CRANKING SYSTEM 4) Disconnect magnetic switch lead wire and battery cable from starting motor (1). 5) Remove two starting motor mount bolts (2). 6) Remove starting motor. 7) To install, reverse the above procedure. DISASSEMBLY NOTE: D Before disassembling starting motor, be sure to put match marks at two locations (A &...
Page 624 CRANKING SYSTEM 6G-7 4) Remove packing (1) and planetary gears (2). 5) Remove seal rubber (1) and plate (2). 6) Remove shaft assembly (1) with lever (2). 7) Loosen pinion stop ring (1) fixed by snap ring (2). 8) Remove snap ring (1), and then pull out pinion stop ring (2), over-running clutch (3) and internal gear (4).
Page 625 6G-8 CRANKING SYSTEM 9) Remove rear bracket (1) with brush holder. 10) Remove armature (1) from yoke (2). 11) Remove brush holder (1) from rear bracket (2). 12) Remove brush springs (1) and brushes (2). 13) Remove armature shaft bushes (1) using special tools. Special Tool (A): 09921-20200 (B): 09930-30102...
Page 626 CRANKING SYSTEM 6G-9 INSPECTION PLUNGER Inspect plunger for wear. Replace if necessary. MAGNETIC SWITCH Push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary. D Pull-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’ terminal (1) and ‘M’...
Page 627 6G-10 CRANKING SYSTEM BRUSH D Check brushes for wear. Measure length of brushes and if below limit, replace brush. Brush length Standard 12.3 mm (0.44 in.) Limit 7 mm (0.28 in.) D Install brushes to each brush holder and check for smooth move- ment.
Page 628 CRANKING SYSTEM 6G-11 D Check commutator for uneven wear with armature (1) supported on V-blocks (2). If deflection of dial gauge (3) pointer exceeds lim- it, repair or replace. NOTE: Below specification presupposes that armature is free from bend. Bent armature must be replaced. Commutator out of round Standard : 0.05 mm (0.002 in.) or less Limit...
Page 629 6G-12 CRANKING SYSTEM D Open Circuit Test Check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced. GEARS Inspect internal gear and planetary gears for wear, damage or other abnormal conditions.
Page 630 CRANKING SYSTEM 6G-13 REASSEMBLY CAUTION: New oilless bearing have been lubricated when they are supplied as spare parts. DO NOT wash with grease dissolv- ing solvent nor lubricate them with other lubricant. 1) Apply grease (Refer to page 6G-5). 2) Install armature to yoke. 3) Install brushes (1) and brush springs (2) to brush holder (3).
Page 631 6G-14 CRANKING SYSTEM 12) Install packing (1) so that cuts in packing align with bolt holes (2) for through bolts in front housing. 13) Install plate and seal rubber (3) to front housing (4). 14) Apply grease to ball (1) and install ball into shaft hole. Grease: 99000-25010 15) Install yoke, armature, brush holder and rear bracket to front housing by aligning match marks provided before removal.
Page 632 CRANKING SYSTEM 6G-15 PERFORMANCE TEST WARNING: When performing the following test, be sure to connect the battery and the starting motor with a lead wire of the same size as the cable that was originally used there. CAUTION: Each test must be performed within 3 – 5 seconds to avoid coil from burning.
Page 633 6G-16 CRANKING SYSTEM 4) No-Load Performance Test a) Connect motor lead wire (switch to motor) (1) to terminal ‘M‘ (2). b) Connect battery and ammeter to starter as shown. c) Check that starter rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current. Specified current: 90 A MAX.
Page 634 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Front and rear bush D Plunger D Pinion drive lever D Internal gear SUZUKI SUPER GREASE A Lithium grease D Planetary carrier shaft (99000-25010) D Planetary gear D Ball D Armature SPECIAL TOOLS...
Page 636 CRANKING SYSTEM 6G1-1 SECTION 6G1 CRANKING SYSTEM (0.9 kW No-Reduction Type) NOTE: Starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. CONTENTS GENERAL DESCRIPTION ..............6G1- 2 Cranking Circuit .
Page 637 6G1-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically as shown below. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT In the circuit shown in the following, the magnetic switch coils are magnetized when the ignition switch is closed.
Page 638 CRANKING SYSTEM 6G1-3 DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: D Starting motor does not run (or runs slowly) D Starting motor runs but fails to crank engine D Abnormal noise is heard D Starting motor does not stop running Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..
Page 639 6G1-4 CRANKING SYSTEM Condition Possible Cause Correction Starting motor running If battery and wiring are satisfactory, but too slow (small inspect starting motor torque) D Insufficient contact of magnetic switch Replace magnetic switch. main contacts D Layer short-circuit of armature Replace.
Page 640 CRANKING SYSTEM 6G1-5 UNIT REPAIR OVERHAUL 1. Magnetic switch mounting screw 2. Front housing 3. Pinion drive lever: Apply lithium grease 99500-25010 to joint of magnetic switch and over-running clutch. Note the installation direction. 4. Magnetic switch: Apply lithium grease 99500-25010 to plunger part.
Page 641 6G1-6 CRANKING SYSTEM DISASSEMBLY NOTE: D Before disassembling starting motor, be sure to put match marks at two locations (A and B) as shown in left figure so that any possible mistakes can be avoided. D Do not clamp yoke in a vise or strike it with a hammer during disassembling and reassembling.
Page 642 CRANKING SYSTEM 6G1-7 6) Loosen pinion stop ring (1) fixed by snap ring (2). 7) Remove snap ring, and then pull out pinion stop ring and over- running clutch (3). 8) Remove armature shaft bushes (1) using special tools. Special Tool (A): 09921-20200 (B): 09930-30102 INSPECTION...
Page 643 6G1-8 CRANKING SYSTEM D Inspect commutator for wear or abnormal limit. Replace if neces- “a” sary. Commutator insulator reference depth “a” Standard: 0.4 – 0.6 mm (0.015 – 0.023 in.) Limit: 0.2 mm (0.0078 in.) CORRECT INCORRECT D Ground test Check commutator and armature core.
Page 644 CRANKING SYSTEM 6G1-9 BRUSH HOLDER Check movement of brush in brush holder. If brush movement with- in brush holder is sluggish, check brush holder for distortion and sliding faces for correct contamination. Clean or correct as necessary. Clean for continuity across insulated brush holder (positive side) and grounded brush holder (negative side).
Page 645 6G1-10 CRANKING SYSTEM D Inspect spline teeth for wear or damage. Replace if necessary. In- spect pinion for smooth movement. ARMATURE SHAFT BUSH Inspect bushes for wear or damage. Replace if necessary. MAGNETIC SWITCH Push in plunger and release it. Plunger should return quickly to its original position.
Page 646 CRANKING SYSTEM 6G1-11 REASSEMBLY Reverse disassembly procedure for reassembly noting the follow- ing. D Apply grease to current part referring to figure in page 6G1-5. D Install pinion drive lever into drive housing referring to page 6G1-5 especially for its direction. D Do not reuse armature shaft bushes.
Page 647 6G1-12 CRANKING SYSTEM 3) Plunger and Pinion Return Test Disconnect negative lead (1) from switch body (2). Check that plunger and pinion return inward. If plunger and pinion don’t return, disassemble and inspect start- ing motor. 4) No-Load Performance Test a) Connect motor lead wire (switch to motor) (1) to terminal ‘M‘...
Page 648 (0.7 kg-m, 5.1 lb-ft) minimum Magnetic switch operating voltage 8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Armature shaft. SUZUKI SUPER GREASE A D Over-running clutch. Lithium grease (99000-25010) D Armature shaft bushes. D Drive lever. SPECIAL TOOLS 09900-06107...
Page 650 CHARGING SYSTEM 6H-1 SECTION 6H CHARGING SYSTEM CONTENTS BATTERY ................. 6H- 2 GENERAL DESCRIPTION .
Page 651 6H-2 CHARGING SYSTEM BATTERY GENERAL DESCRIPTION The battery has three major functions in the electrical system. D It is a source of electrical energy for cranking the engine. D It acts as a voltage stabilizer for the electrical system. D It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Page 652 CHARGING SYSTEM 6H-3 CARE OF BATTERY WARNING: D Never expose battery to open flame or electric spark be- cause of battery generate gas which is flammable and ex- plosive. D Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid.
Page 653 6H-4 CHARGING SYSTEM DIAGNOSIS 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: D Accessories left on overnight or for an extended period without...
Page 654 CHARGING SYSTEM 6H-5 HOW TO USE THE TEMPERATURE-CORRECTED STATE-OF-CHARGE GRAPH Suppose your specific gravity reading is 1.28 and the battery tem- perature is –5_C (23_F). Locate the intersection of the –5_C line and the 1.28 specific gravity line. The intersection is within the “A” zone (shaded area in the graph) and that means CHARGED STATE.
Page 655 6H-6 CHARGING SYSTEM UNIT REPAIR OVERHAUL JUMP STARTING IN CASE OF EMERGENCY WITH AUXILIARY (BOOSTER) BATTERY CAUTION: If vehicle is manual transmission model and has a catalytic converter, do not push or tow it to start. Damage to its emis- sion system and/or to other parts may result.
Page 656 CHARGING SYSTEM 6H-7 WITH CHARGING EQUIPMENT CAUTION: When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equipment can cause serious damage to electrical system or electronic parts.
Page 657 6H-8 CHARGING SYSTEM GENERATOR GENERAL DESCRIPTION The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown. 1. Generator with regulator assembly 6. Charge indicator light 2. I.C. regulator 7.
Page 658 CHARGING SYSTEM 6H-9 DIAGNOSIS CAUTION: D Do not mistake polarities of IG terminal and L terminal. D Do not create a short circuit between IG and L terminals. Always connect these terminals through a lamp. D Do not connect any load between L and E. D When connecting a charger or a booster battery to vehicle battery, refer to this section describing battery charging.
Page 659 6H-10 CHARGING SYSTEM UNDERCHARGED BATTERY This condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. The following procedure also applies to cars with voltmeter and am- meter.
Page 660 CHARGING SYSTEM 6H-11 Higher Voltage If voltage is higher than standard value, check ground of brushes. If brushes are not grounded, replace IC regulator. Lower Voltage If voltage is below or in standard value, increase engine speed up to 2000 – 2500 rpm soon after starting engine, and read maximum value on ammeter immediately.
Page 661 6H-12 CHARGING SYSTEM UNIT REPEIR OVERHAUL REMOVAL 1) Disconnect negative (–) cable (1) at battery (2). 2) Disconnect IAT sensor coupler (1). 3) Remove air cleaner assembly (2) with air cleaner outlet No.1 hose (3) and suction pipe (4). 4) Remove generator cover. 5) Disconnect “B”...
Page 662 CHARGING SYSTEM 6H-13 INSTALLATION Reverse removal procedure and giving specified tension to water pump and generator drive belt referring to SECTION 6B. Tightening Torque (a): 22 N m (2.2 kg-m, 16.0 lb-ft) (b): 50 N m (5.0 kg-m, 36.5 lb-ft) (c): 7.8 N m (0.78 kg-m, 5.5 lb-ft) (d): 45 N...
Page 663 6H-14 CHARGING SYSTEM DISASSEMBLY 1. Pulley nut 11. IC regulator 2. Pulley 12. Brush: 3. Bolt Note the installing direction, 4. Bolt and the detail refer to page 6H-19. 5. Front housing 13. Rectifier 6. Bearing 14. IC regulator assembly 7.
Page 664 CHARGING SYSTEM 6H-15 3) Insert flat tip screwdriver (1) between stator core (2) and front housing (3), and then separate generator into front and rear sides. 4) Loosen pulley nut (1) using vise (2) and take off pulley (3). NOTE: D When using vise, put clean cloth (4) between rotor (5) and vise so as not to cause damage to rotor.
Page 665 6H-16 CHARGING SYSTEM 7) When removing rear bearing (1), use oil hydraulic press (2) general rod (3) and general tool (4). 8) Remove three screws (1) and generator “B” terminal nut (2). 9) Remove stator with IC regulator assembly from rear housing. 10) Unsolder stator leads (1) and remove stator (2) from IC regula- tor assembly.
Page 666 CHARGING SYSTEM 6H-17 INSPECTION Rotor 1) Using ohmmeter (1), check for continuity between slip rings of rotor (2). If there is no continuity, replace rotor. Standard resistance: 2.5 – 2.9 Ω 2) Using ohmmeter (1), check that there is no continuity between slip ring (2) and rotor core (3).
Page 667 6H-18 CHARGING SYSTEM Rectifier Using ohmmeter (1), check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace rectifier.
Page 668 CHARGING SYSTEM 6H-19 ASSEMBLY Reverse disassembly procedure for installation, noting the follow- ing instruction. D Be sure to install brushes (1) in the proper direction as shown and solder brush wires (2) and stator leads (3). D Tighten generator pulley nut (1) to specified torque. Tightening Torque (a): 118 N m (11.8 kg-m, 85.5 lb-ft)
Page 669 6H-20 CHARGING SYSTEM SPECIFICATIONS BATTERY Battery type PERION 6A3625 PERION 6A4425 Nominal output 12 V 36 Ah/20 h 44 Ah/20 h Rated capacity Rated capacity 28 Ah/5 h 36 Ah/5 h Cold cranking amperes 332 A 390 A Electrolyte 3.8 L (8.03/6.69 US/lmp pt) Electrolyte specified gravity 1.28 when fully charged at 25_C (77_F) Battery dimension...
Page 670 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS ON-VEHICLE SERVICE ..............6K-1 MAINTENANCE .
Page 671 6K-2 EXHAUST SYSTEM MAINTENANCE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system as follows: D Check rubber mountings for damage, deterioration, and out of position.
Page 672 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 673 7A-2 MANUAL TRANSMISSION GENERAL DESCRIPTION CONSTRUCTION AND SERVICING The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 674 MANUAL TRANSMISSION 7A-3 GEAR SHIFT MECHANISM The gear shifting control system consists of the following main parts. Movement of gear shift control lever is trans- mitted to gear shift & select shaft through gear shift and gear select cables. Shift direction Select direction 1.
Page 675 7A-4 MANUAL TRANSMISSION DIAGNOSIS Condition Possible Cause Correction Gears slipping out of D Maladjusted gear shift/select control cables Adjust. mesh D Worn shift fork shaft Replace. D Worn shift fork or synchronizer sleeve Replace. D Weak or damaged locating springs Replace.
Page 676 MANUAL TRANSMISSION 7A-5 ON-VEHICLE SERVICE CAUTION: Do not reuse circlip, spring pin, E-ring, oil seal, gasket, self locking nut and specified parts. Reuse of it can result in trouble. OIL CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
Page 677 7A-6 MANUAL TRANSMISSION DIFFERENTIAL SIDE OIL SEAL REPLACEMENT 1) Lift up vehicle and drain transmission oil. 2) Remove wheel, and then remove tie-rod end nut. 3) Disconnect tie-rod end from knuckle by using puller (1). 4) Remove two stabilizer mount brackets from vehicle body. 5) Remove ball stud bolt and then separate suspension arm from knuckle.
Page 678 MANUAL TRANSMISSION 7A-7 10) Connect ball stud with knuckle and fasten with bolt to specifica- tion referring to Section 4. 11) Connect tie-rod end with knuckle and fasten new nut to speci- fied torque referring to Section 4. 12) Install stabilizer mount brackets, fasten bolts to specified torque referring to Section 4.
Page 679 7A-8 MANUAL TRANSMISSION GEAR SHIFT CONTROL LEVER AND CABLE 1. Gear shift control lever knob 2. Lever boot holder 3. Gear shift lever boot 4. Gear shift control cable 5. Gear select control cable 6. Gear shift control cable guide nut 7.
Page 680 MANUAL TRANSMISSION 7A-9 REMOVAL 1) Remove console box. 2) Disconnect gear shift and select control cables (1) from gear shift control lever assembly (2). a) Disconnect cable end from pivot while pushing cable end bush (4). b) Detach cable from bracket (5) while pulling pin (6). 3) Remove gear shift lever assembly mounting control cable guide nuts (3) and gear shift lever assembly from body.
Page 681 7A-10 MANUAL TRANSMISSION D Adjustment of select cable. With shift control lever in NEUTRAL position, adjust select cable adjusting nut (3) so that the tip of select arm (cable joint point) (1) and the center rib of gear shift control lever assembly (2) are aligned as shown.
Page 682 MANUAL TRANSMISSION 7A-11 UNIT REPAIR OVERHAUL TRANSMISSION UNIT 1. Engine 10. VSS connector 19. Engine rear mounting bolt 2. Transmission 11. Transmission to engine bolts 20. Engine rear mounting 3. Engine rear mounting No.1 bracket 12. Engine left mounting bracket bolts 21.
Page 683 7A-12 MANUAL TRANSMISSION TRANSMISSION CASE 1. Transmission right case 8. Differential assembly 2. Transmission left case: 9. Oil level / filler plug: Apply sealant 99000-31110 Apply sealant 99000-31110 to mating surface of left case and to all around thread part of plug. right case.
Page 684 MANUAL TRANSMISSION 7A-13 1. Input shaft -16. 5th speed synchronizer ring 32. Circlip 2. Oil seal -17. 5th synchronizer spring 33. 2nd gear synchronizer outer ring 3. Input shaft right bearing -18. 5th speed sleeve & hub 34. Needle bearing (separated steel cage type) 4.
Page 685 20. Speed sensor ring 21. Differential case 22. Final gear 23. 5th to reverse interlock guide bolt: Apply sealant, SUZUKI Bond No. 1215, 99000-31110 to bolt thread. 24. Gear shift interlock bolt: Apply sealant, SUZUKI Bond No. 1215, 99000-31110 to bolt thread.
Page 686 MANUAL TRANSMISSION 7A-15 DISMOUNTING OF TRANSMISSION UNDER HOOD 1) Disconnect negative cable at battery. 2) Undo wiring harness clamps, disconnect back up light switch coupler, VSS coupler and ground cable. 3) Disconnect clutch cable from clutch release lever and bracket. 4) Disconnect gear shift and select control cables.
Page 687 7A-16 MANUAL TRANSMISSION REMOUNTING CAUTION: Care should be taken not to scratch oil seal lip with drive shaft while raising transmission. Do not hit drive shaft joint with hammer when installing it into differential gear. Remount transmission in reverse order of dismounting procedure noting the following.
Page 688 MANUAL TRANSMISSION 7A-17 DISASSEMBLING UNIT FIFTH GEARS 1) Remove side cover bolts and take off transmission side cover. CAUTION: Care should be taken not to distort side cover when it is removed from left case. 2) Using special tool, remove circlip (1) and then hub plate (2). Special Tool (A): 09900-06107 3) Remove shift fork plug (1) and guide ball (2).
Page 689 7A-18 MANUAL TRANSMISSION GEAR SHIFTER, INPUT SHAFT AND COUNTER SHAFT 1) Remove gear shift interlock bolt (1) and 5th to reverse interlock guide bolt (2) from transmission case. 2) Remove gear shifter assembly (3). 3) Remove gear shift locating bolts (1) with washers, then take out locating springs and steel balls.
Page 690 MANUAL TRANSMISSION 7A-19 11) Tapping input shaft end with plastic hammer, push it out as as- sembly from case a little, then take out input shaft assembly (1), counter shaft assembly (2), high speed gear shift shaft (3) and low speed gear shift shaft (4) all at once. 12) Remove counter shaft left bearing cup from left case.
Page 691 1) Install input shaft oil seal (1) facing its spring side upward. Use special tool and hammer for installation and apply grease to oil seal lip. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09951-76010 2) Install countershaft right bearing cup (2) by using special tools and hammer.
Page 692 MANUAL TRANSMISSION 7A-21 INPUT SHAFT ASSEMBLY DISASSEMBLY 1) Remove input shaft right bearing (2) from input shaft (1) by using bearing puller (3) and press. 2) Drive out 5th gear spacer (2), left bearing (3) and 4th gear (4) all at once from input shaft (1) by using puller (5) and press.
Page 693 7A-22 MANUAL TRANSMISSION INSPECTION AND REASSEMBLY 1) Clean all components thoroughly, inspect them for any ab- normality and replace with new ones as necessary. 2) If synchronizer parts need to be repaired, check clearance “a” between ring (2) and gear (1), each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Page 694 MANUAL TRANSMISSION 7A-23 6) Install 3rd gear needle bearing of resin cage type, apply oil to it, then install 3rd gear (1) and synchronizer ring (2). 7) Drive in high speed sleeve & hub assembly (3) by using special gear tool and hammer, facing long flange side of hub to 3rd gear.
Page 695 7A-24 MANUAL TRANSMISSION COUNTER SHAFT ASSEMBLY DISASSEMBLY 1) Drive out left bearing cone (2) with 4th gear (3) from counter shaft (1) by using puller (4) and press. CAUTION: D Use puller and press that will bear at least 5 ton (11,000 lb) safely.
Page 696 MANUAL TRANSMISSION 7A-25 INSPECTION AND REASSEMBLY 1) Clean all components thoroughly, inspect them for any ab- normality and replace with new ones as necessary. 2) If synchronizer parts need to be repaired, check clearance “a” between ring (2) and gear (1), each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Page 697 7A-26 MANUAL TRANSMISSION 6) Install right bearing cone (1) to counter shaft (2) by using special tool and hammer. Special Tool (A): 09923-78210 7) Install needle bearing of resin cage type, apply oil to it, then install 1st gear and 1st gear synchronizer ring. 8) Drive in low speed sleeve &...
Page 698 MANUAL TRANSMISSION 7A-27 9) Install circlip (1) and confirm that circlip is installed in groove se- curely. Install needle bearing (2) of separated steel cage type, apply oil to bearing. With synchronizer outer ring (3), center cone (4) & inner ring (5) put together and installed to 2nd gear (6) as shown in figure.
Page 699 7A-28 MANUAL TRANSMISSION GEAR SHIFTER GEAR SHIFT AND SELECT SHAFT ASSEMBLY 1) To disassemble component parts, use special tools and 2.8 – 3.0 mm (0.11 in.) pin remover in addition. Special Tool (A): 09922-85811(4.5 mm) (B): 09925-78210 (6.0 mm) 2) Clean all parts thoroughly, inspect them and replace with new ones as required.
Page 700 MANUAL TRANSMISSION 7A-29 5TH & REVERSE GEAR SHIFTER 1) Disassemble component parts by using special tool and ham- mer. Special Tool (A): 09922-85811 (4.5 mm) 2) Replace or correct parts as required and assemble shafts mak- ing sure that component parts are in proper order as shown in figure.
Page 701 7A-30 MANUAL TRANSMISSION ADJUSTMENT AND REASSEMBLY Left side 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 differen- tial gear as follows.
Page 702 MANUAL TRANSMISSION 7A-31 5) Press-fit left bearing by using special tools and copper hammer. 6) Support differential assembly (1) as illustrated so as to left bear- ing (2) is floating, and then press-fit right bearing (3) like left bearing in Step 5). Special Tool (C): 09951-76010 (D): 09951-16060...
Page 703 7A-32 MANUAL TRANSMISSION ASSEMBLING UNIT DIFFERENTIAL TO LEFT CASE 1) Install differential assembly (1) into right case (2). 2) Insert VSS (3) applied with oil to its O-ring, then tighten it with bolt. 3) Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft (3) assemblies all together, then install them into right case (1).
Page 704 MANUAL TRANSMISSION 7A-33 7) Clean mating surfaces of both right and left cases, coat mating surface of left case (1) with sealant evenly then mate it with right case (2). “B”: Sealant, Bond No.1215, 99000-31110 8) Tighten case bolts (3) from left case side to specified torque. Tightening Torque (b): 19 N m (1.9 kg-m, 14.0 Ib-ft)
Page 705 7A-34 MANUAL TRANSMISSION FIFTH GEARS 1) To seat countershaft left bearing cup (1) to bearing cone, tap cup by using special tool and plastic hammer. Special Tool (A): 09913-84510 2) Put a shim (2) on bearing cup (3) provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure “a”...
Page 706 MANUAL TRANSMISSION 7A-35 5) Assemble 5th speed synchronizer sleeve (4) and hub (3) with keys (2) and springs (1). NOTE: Short Long Short side C in keys, long flange D in hub and chamfered side C side spline F in sleeve should face inward (5th gear side). A = B C: Short side (Inward) D: Long flange (Inward)
Page 707 7A-36 MANUAL TRANSMISSION 12) Drive in spring pin facing its slit A outward. 13) Install steel ball, tighten shift fork plug (3) applied with thread lock cement. “A”: Thread lock 1322, 99000-32110 Tightening Torque (c): 10 N m (1.0 kg-m, 7.5 lb-ft) 14) Fit hub plate (1) and fix it with circlip (2).
Page 708 MANUAL TRANSMISSION 7A-37 GEAR SHIFT AND SELECT SHAFT ASSEMBLY 1) Clean mating surface of guide case. 2) Apply grease to select lever shaft bush and select lever washer, and install gear shift and select shaft assembly with new gasket 1, (a), “B” into transmission.
Page 709 7A-38 MANUAL TRANSMISSION REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS SUZUKI SUPER GREASE A Lithium grease D Oil seal lips (99000-25010) D Oil drain plug and filler/level plug D Gear shift shaft bolt D Mating surface of transmission case SUZUKI BOND NO.1215...
Page 710 MANUAL TRANSMISSION 7A-39 09924-74510 09923-74510 09925-18010 09923-78210 Installer attachment Bearing remover Bearing installer Bearing installer 09925-68210 09925-78210 09925-88210 09925-98221 Bearing outer race installer Spring pin remover 6 mm Bearing puller attachment Bearing installer 09930-30102 09940-53111 09940-54910 09927-76010 Sliding shaft Bearing installer Sensor rotor installer Gear holder 09951-16060...
Page 712 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 713 7B-2 AUTOMATIC TRANSMISSION (4 A / T) DROPPING RESISTER ....7B- 59 Rear Clutch ..... . . 7B- 86 O/D CUT SWITCH .
Page 714 AUTOMATIC TRANSMISSION (4 A / T) 7B-3 GENERAL DESCRIPTION This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type equipped with lock-up mechanism. The gear shift device consists of 2 sets of planetary gear units, 3 sets of disc type clutches, 3 sets of disc type brakes and one-way clutch.
Page 715 7B-4 AUTOMATIC TRANSMISSION (4 A / T) 1. Final gear 7. Direct clutch (C0) 13. Oil pump 2. Differential gear ass’y 8. Rear planetary gear 14. Input shaft 3. Parking gear 9. Front planetary gear 15. Torque converter 4. Counter driven gear 10.
Page 716 AUTOMATIC TRANSMISSION (4 A / T) 7B-5 Item Specifications Torque Type 3-element, 1-step, 2-phase type converter Stall torque ratio 1.75 Type Internal gear type oil pump Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P”...
Page 717 7B-6 AUTOMATIC TRANSMISSION (4 A / T) FUNCTIONS NOTE: For operation of each part, refer to TABLE OF COMPONENT OPERATION. PART NAME FUNCTION Rear clutch Meshes input shaft and rear sun gear through one-way clutch. Front clutch Meshes input shaft and front internal gear and rear carrier. Overdrive brake Fixes rear sun gear.
Page 718 L. Engine coolant temp. / MAP sensor signal 12. Stop lamp M. Idle up signal 13. Monitor coupler N. A / T failure signal 14. Suzuki scan tool O. Engine rev. 15. Ignition switch P. A / C signal. 16. Battery...
Page 719 7B-8 AUTOMATIC TRANSMISSION (4 A / T) TRANSMISSION CONTROL MODULE (TCM) The TCM is an electronic circuit component that controls gear shift and idle-up according to the signal from each sensor. It is a microcomputer consisting of an IC, transistor, diode, etc. It is installed behind glove box. 1.
Page 720 AUTOMATIC TRANSMISSION (4 A / T) 7B-9 THROTTLE POSITION SENSOR This sensor is installed to the throttle valve shaft. Throttle valve opening signal is transmitted from TP sensor to ECM as voltage sig- nal. The signal is converted to duty signal in ECM and it is sent to TCM.
Page 721 7B-10 AUTOMATIC TRANSMISSION (4 A / T) O/D CUT SWITCH O / D cut switch ON The gear shift up or shift down to and from the O/D gear can be se- lected with this switch. O/D cut switch O/D OFF indicator light 1.
Page 722 AUTOMATIC TRANSMISSION (4 A / T) 7B-11 FAIL SAFE FUNCTION This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sen- sor or its circuit fails. The table below shows the fail safe function for each fail condition of sensor, solenoid or its circuit. AREA Fail safe condition Fail safe function...
Page 723 7B-12 AUTOMATIC TRANSMISSION (4 A / T) AUTOMATIC GEAR SHIFT DIAGRAM Automatic shift schedule as a result of shift control is shown below. Unit: km/h Shift 1 ! 2 2 ! 3 3 ! 4 4 ! 3 3 ! 2 2 ! 1 Throttle opening Full throttle...
Page 724 AUTOMATIC TRANSMISSION (4 A / T) 7B-13 TCC Lock-up Diagram : Lock-up ON : Lock-up OFF 3rd gear and O/D is cut 4th gear 4th gear 3rd gear and O / D on 3rd gear and O / D on 3rd gear and O/D is cut Vehicle Speed...
Page 725 7B-14 AUTOMATIC TRANSMISSION (4 A / T) DIAGNOSIS This vehicle is equipped with an electronic transmission control system, which controls the automatic shift up and shift down timing, etc. suitably to vehicle driving conditions. When diagnosing a trouble in the transmission including this system, follow “AUTOMATIC TRANSMISSION DIAG- NOSTIC FLOW TABLE”...
Page 726 AUTOMATIC TRANSMISSION (4 A / T) 7B-15 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point re- quired for proper analysis and diagnosis.
Page 727 CHECK. Attempt to diagnose the trouble based on the DTC recorded in this step or failure to clear the DTC in this step may mislead the diagnosis or make diagnosing difficult. Even after checking the DTC with the SUZUKI scan tool, diagnosis should be performed according to this flow chart to check TCM for proper self-diagnosis function.
Page 728 AUTOMATIC TRANSMISSION (4 A / T) 7B-17 5. AUTOMATIC TRANSMISSION BASIC CHECK Perform basic automatic transmission check according to the list below first. AUTOMATIC TRANSMISSION BASIC CHECK LIST 1. Power Supply Voltage Check Check that the battery voltage is within 10 – 14 V at engine stop. 2.
Page 729 7B-18 AUTOMATIC TRANSMISSION (4 A / T) TROUBLE DIAGNOSIS TABLE NOTE: For the inspection of throttle position sensor, refer to TP SENSOR in Section 6E of Service Manual men- tioned in the FOREWORD of this manual. TABLE 1 (ELECTRICAL) Condition Possible Cause Correction 1st ! 2nd...
Page 730 AUTOMATIC TRANSMISSION (4 A / T) 7B-19 TABLE 2 (MECHANICAL) Condition Possible Cause Correction Vehicle does not move D Manual valve faulty Clean or replace. at any range D Primary regulator valve faulty Clean or replace. 1st { 2nd D Shift solenoid No.2 and/or No.5 stuck Clean or replace.
Page 731 7B-20 AUTOMATIC TRANSMISSION (4 A / T) STALL TEST This test is to check overall performance of automatic transmission and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transmission fluid is at normal operat- ing temperature and its level is between FULL and LOW marks.
Page 732 AUTOMATIC TRANSMISSION (4 A / T) 7B-21 TIME LAG TEST This test is to check conditions of clutch, reverse brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed in front and behind front and rear wheels re- spectively, depress brake pedal.
Page 733 7B-22 AUTOMATIC TRANSMISSION (4 A / T) 4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D” or “R” range. CAUTION: Do not continue running engine at stall speed longer than 5 seconds. Line pressure Engine running mode...
Page 734 AUTOMATIC TRANSMISSION (4 A / T) 7B-23 “P” RANGE TEST 1) Stop vehicle on a slope, shift select lever to “P” range and at the same time apply parking brake. 2) After stopping engine, depress brake pedal and release parking brake.
Page 735 7B-24 AUTOMATIC TRANSMISSION (4 A / T) ELECTRONIC CONTROL SYSTEM DIAGNOSIS TCM has on-board diagnostic system (a system self-diagnosis function). Investigate where the trouble is by referring to “DIAGNOSTIC FLOW TABLE” and “DIAGNOSTIC TROUBLE CODE TABLE” on later pages. PRECAUTIONS IN DIAGNOSING TROUBLES [PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE] D For the vehicle with EGR valve, MIL (1) comes on when TCM de-...
Page 736 DIAGNOSTIC TROUBLE CODE(S) CHECK [Check DTC with SUZUKI scan tool] 1) Turn ignition switch OFF. 2) After setting cartridge to SUZUKI scan tool, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
Page 737 7B-26 AUTOMATIC TRANSMISSION (4 A / T) 4) Read DTC from flashing pattern of O/D OFF light. 5) After completing the DTC check, turn ignition switch OFF and disconnect service wire from monitor coupler (1). 2. Diag. switch terminal 3. Ground terminal DTC 21 DTC 21 DTC21...
Page 738 3) Turn ignition switch ON. 4) Erase DTC according to instructions displayed on scan tool. Re- fer to SUZUKI scan tool operator’s manual for further details. 5) After completing the check, turn ignition switch OFF and discon- nect scan tool from data link connector (DLC).
Page 739 Malfunction indicator lamp (“O / D OFF” light) turn ON Time (sec.) DIAGNOSTIC ITEM Displayed on “O/D OFF” lamp flashing pattern SUZUKI scan tool NO DTC Normal P0715 Input revolution sensor Input revolution sensor signal circuit, A/T VSS P0730 signal circuit or automatic transmission itself...
Page 740 AUTOMATIC TRANSMISSION (4 A / T) 7B-29 TCM POWER AND GROUND CIRCUIT CHECK (AUTOMATIC TRANSMISSION DOESN’T SHIFT TO 1ST GEAR AT VEHICLE START IN “D” RANGE) 1. Battery 2. Main fuse 3. Ignition switch Terminal arrangement of TCM coupler 4. Circuit fuse (IG) (Viewed from harness side) 5.
Page 741 7B-30 AUTOMATIC TRANSMISSION (4 A / T) DTC 14 – INPUT REV. SENSOR SIGNAL (INPUT SIGNAL TOO HIGH OR TOO LOW) 1. Input rev. sensor 2. TCM coupler (viewed from harness side) STEP ACTION 1) Turn ignition switch OFF and disconnect A/T Go to Step 2.
Page 742 AUTOMATIC TRANSMISSION (4 A / T) 7B-31 DTC 18 – INPUT REV. SENSOR, A/T VSS OR A/T ITSELF (INPUT VEHICLE SPEED TOO HIGH OR TOO LOW COMPARING TO INPUT REV. SENSOR SIGNAL) 1. Input rev. sensor 2. A / T VSS 3.
Page 743 7B-32 AUTOMATIC TRANSMISSION (4 A / T) DTC 21 – SHIFT SOLENOID NO.1 23 – SHIFT SOLENOID NO.2 25 – LOCK-UP SOLENOID (SHIFT SOLENOID OUTPUT VOLTAGE TOO HIGH EVEN THOUGH TCM ORDERS SHIFT SOLENOID TO TURN OFF) 1. Shift solenoid No.1 2.
Page 744 AUTOMATIC TRANSMISSION (4 A / T) 7B-33 Figure for step 1 Figure for steps 2 and 3 1. Shift solenoid No.1 terminal 1. “A4” terminal 2. Shift solenoid No.2 terminal 2. “A17” terminal 3. Lock-up solenoid terminal 3. “A18” terminal 4.
Page 745 7B-34 AUTOMATIC TRANSMISSION (4 A / T) DTC 22 – SHIFT SOLENOID NO.1 24 – SHIFT SOLENOID NO.2 26 – LOCK-UP SOLENOID 1. Shift solenoid No.1 2. Shift solenoid No.2 3. Lock-up solenoid 4. Solenoid coupler 5. TCM coupler (viewed from harness side) STEP ACTION 1) Turn ignition switch OFF and disconnect...
Page 746 AUTOMATIC TRANSMISSION (4 A / T) 7B-35 DTC 29 – LOCK-UP CLUTCH D Substitute known-good torque converter and recheck. D Check if fluid has an odor and is discolored, and replace as necessary.
Page 747 7B-36 AUTOMATIC TRANSMISSION (4 A / T) DTC 31 – A /T VEHICLE SPEED SENSOR (A / T VSS) (INPUT VOLTAGE TOO HIGH OR TOO LOW) 1. A / T VSS 2. Coupler 3. Shield wire 4. TCM coupler (viewed from harness side) STEP ACTION 1) Turn ignition switch OFF and disconnect A/T...
Page 748 AUTOMATIC TRANSMISSION (4 A / T) 7B-37 STEP ACTION 1) Turn ignition switch OFF and connect A/T VSS Short in between Go to Step 5. coupler. “W” wire and 2) Measure resistance between terminal “B11” ground or “B” wire (of disconnected harness side coupler) – and ground.
Page 749 7B-38 AUTOMATIC TRANSMISSION (4 A / T) DTC 32 – THROTTLE POSITION SIGNAL (THROTTLE OPENING SIGNAL OF OVER 100% INPUTTED) 1. TCM coupler (viewed from harness side) 2. ECM coupler (viewed from harness side) STEP ACTION Check throttle opening signal referring to Intermittent trouble or Go to Step 2.
Page 750 AUTOMATIC TRANSMISSION (4 A / T) 7B-39 DTC 33– THROTTLE POSITION SIGNAL (THROTTLE OPENING SIGNAL OF UNDER 0% INPUTTED OR INPUT SIGNAL FIXED TO HIGH (12V) OR LOW (0V)) 1. TCM coupler (viewed from harness side) 2. ECM coupler (viewed from harness side) STEP ACTION Check throttle opening signal referring to...
Page 751 7B-40 AUTOMATIC TRANSMISSION (4 A / T) DTC 34 – SHIFT SWITCH (NO SHIFT SWITCH SIGNAL INPUTTED OR TWO OR MORE SHIFT SWITCH SIGNALS INPUTTED AT THE SAME TIME) 1. Shift switch 2. TCM coupler (viewed from harness side) STEP ACTION 1) Turn ignition switch OFF, disconnect TCM Go to Step 2.
Page 752 AUTOMATIC TRANSMISSION (4 A / T) 7B-41 STEP ACTION While ignition switch ON, check voltage between Intermittent trouble or Go to Step 7. terminal “B14” and “A25” of disconnected harness faulty TCM. side TCM coupler. Check for intermittent Is it 10 – 14 V at “L” range and 0 V at other range? trouble referring to “Intermittent troubles”...
Page 753 7B-42 AUTOMATIC TRANSMISSION (4 A / T) DTC 35 – ENGINE REV. SIGNAL (NO ENGINE REV. SIGNAL INPUTTED EVEN THOUGH STANDARD VALUE OF VEHICLE SPEED SIGNAL AND THROTTLE OPENING SIGNAL INPUTTED) 1. TCM coupler (viewed from harness side) 2. ECM coupler (viewed from harness side) STEP ACTION...
Page 754 AUTOMATIC TRANSMISSION (4 A / T) 7B-43 DTC 36 – A/T FLUID TEMPERATURE SIGNAL (NO A/T FLUID TEMPERATURE SIGNAL INPUTTED) DTC 38 – A/T FLUID TEMPERATURE SIGNAL (A/T FLUID TEMPERATURE SIGNAL INPUT VOLTAGE DOES NOT GO DOWN EVEN THOUGH STANDARD VALUE OF ENGINE REV. SIGNAL INPUTTED) 1.
Page 755 7B-44 AUTOMATIC TRANSMISSION (4 A / T) DTC 43 – SHIFT SOLENOID NO.3 DTC 45 – SHIFT SOLENOID NO.4 DTC 48 – SHIFT SOLENOID NO.5 1. Dropping resister 2. Solenoid coupler 3. Shift solenoid No.3 4. Shift solenoid No.4 5. Shift solenoid No.5 6.
Page 756 AUTOMATIC TRANSMISSION (4 A / T) 7B-45 Chart for step 2 Solenoid coupler lead wire color Solenoid TCM terminal No. (body side) No.3 W/Bl No.4 Y/Bl No.5 Chart for step 3 Solenoid coupler lead wire color Solenoid TCM terminal No. (body side) No.3 W/Bl...
Page 757 7B-46 AUTOMATIC TRANSMISSION (4 A / T) DTC 51 – ENGINE COOLANT TEMPERATURE SENSOR 1. TCM coupler (viewed from harness side) 2. ECM coupler (viewed from harness side) STEP ACTION 1) Check DTC of “Engine and Emission Control Go to Step 2. Inspect and repair System”...
Page 758 AUTOMATIC TRANSMISSION (4 A / T) 7B-47 DTC 52 – POWER SOURCE RELAY IN TCM (RELAY OUTPUT VOLTAGE TOO HIGH EVEN THOUGH TCM ORDERS THE RELAY TO TURN OFF OR RELAY OUTPUT VOLTAGE TOO LOW EVEN THOUGH TCM ORDERS THE RELAY TO TURN ON) 1.
Page 759 7B-48 AUTOMATIC TRANSMISSION (4 A / T) INSPECTION OF TCM AND ITS CIRCUITS TCM and its circuits can be checked at TCM wiring couplers by measuring voltage and resistance. CAUTION: TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with coupler dis- connected from it.
Page 760 Vehicle speed sensor shield – – Serial communication (SUZUKI scan tool) 10 – 14 V When SUZUKI scan tool not used. 10 – 14 V IG switch ON, select lever at “L” range Transmission range “L” switch Transmission range L switch approx.
Page 761 7B-50 AUTOMATIC TRANSMISSION (4 A / T) ON-VEHICLE SERVICE MAINTENANCE SERVICE FLUID LEVEL LEVEL CHECK AT NORMAL OPERATING TEMPERATURE 1) Stop vehicle and place it level. 2) Apply parking brake and place chocks against wheels. 3) With selector at P position, start engine. 4) Warm up engine till fluid temperature reaches normal operating temperature (70 –...
Page 762 AUTOMATIC TRANSMISSION (4 A / T) 7B-51 FLUID CHANGE INTERVALS If the vehicle is usually driven under one or more of the following se- vere conditions, change the transmission fluid every 160,000 km (100,000 miles). D In heavy city traffic. Where the outside temperature regularly reaches 32°C (90°F).
Page 763 7B-52 AUTOMATIC TRANSMISSION (4 A / T) SELECTOR LEVER 1. Selector lever ass’y 2. Selector lever knob ass’y 3. Screw 4. Selector indicator ass’y 5. Screw 6. Illumination lamp ass’y INSPECTION Check selector lever for smooth and clear cut movement and posi- tion indicator for correct indication.
Page 764 AUTOMATIC TRANSMISSION (4 A / T) 7B-53 SHIFT SWITCH REMOVAL 1) Block wheels and turn selector lever to “N” range. 2) Disconnect shift switch coupler and selector cable. 3) Remove shift switch from transmission case. CAUTION: Do not overhaul shift switch. INSPECTION 1) Disconnect shift switch coupler (2).
Page 765 7B-54 AUTOMATIC TRANSMISSION (4 A / T) 3) Install shift switch (1) to transmission case. Tightening Torque (a): 18 N·m (1.8 kg-m, 13.0 lb-ft) 4) Move selector lever in cabin to each range and check the conti- nuity of each terminal of shift switch referring to INSPECTION. 5) Connect shift switch coupler.
Page 766 AUTOMATIC TRANSMISSION (4 A / T) 7B-55 SELECTOR CABLE 1. Selector lever ass’y 7. Selector housing bolt 2. Selector cable 8. Shift control lever pin: 3. Selector housing Apply lithium grease 4. Cable bracket 99000-25010 to all around pin 5. Shift control lever 9.
Page 767 7B-56 AUTOMATIC TRANSMISSION (4 A / T) ADJUSTMENT 1) Turn shift switch to have the match marks (1) line up (shift switch “N” range). 2) Remove adjuster (cable end) from selector pin. 3) Release lock plate (1) which restrict moving of cable end holder (2).
Page 768 AUTOMATIC TRANSMISSION (4 A / T) 7B-57 A/T VEHICLE SPEED SENSOR (A/T VSS) INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect A/T VSS – input rev. sensor coupler (1). 3) Check resistance between A/T VSS terminals(2). A/T VSS standard resistance: 160 – 200 Ω at 20°C (68°F) REMOVAL 1) Disconnect negative cable at battery.
Page 769 7B-58 AUTOMATIC TRANSMISSION (4 A / T) INSTALLATION 1) Apply A/T fluid to input revolution sensor O-ring. 2) Install input revolution sensor (2) to A/T case and tighten bolt to specified torque. Tightening Torque (b): 8 N·m (0.8 kg-m, 6.0 lb-ft) 3) Connect A/T VSS –...
Page 770 AUTOMATIC TRANSMISSION (4 A / T) 7B-59 DROPPING RESISTER REMOVAL/INSTALLATION Refer to left figure for removal/installation. Tightening Torque (a): 20 N m (2.0 kg-m, 14.5 lb-ft) INSPECTION Measure resistance between each resister terminals. CIRCUIT RESISTANCE 7.5 Ω Shift solenoid No.3 7.5 Ω...
Page 771 7B-60 AUTOMATIC TRANSMISSION (4 A / T) O/D CUT SWITCH INSPECTION 1) Remove console box. 2) Disconnect O/D cut switch coupler (1). 3) Check continuity between O/D cut switch terminals. O/D cut switch Continuity Continuity No continuity 2. O / D cut switch ON 3.
Page 772 AUTOMATIC TRANSMISSION (4 A / T) 7B-61 SHIFT SOLENOID VALVES INSPECTION Resistance Check D Shift solenoid No.1, No.2 and lock-up solenoid Check resistance between terminal and solenoid body. Standard resistance: 11.5 – 12.5 Ω D Shift solenoid No.3, No.4 or No.5 Standard resistance: 2.5 –...
Page 773 7B-62 AUTOMATIC TRANSMISSION (4 A / T) INSTALLATION 1) Install shift solenoid No.1, No.2, No.3 and No.4. Tightening Torque (a): 8 N·m (0.8 kg-m, 6.0 lb-ft) 2) Connect shift solenoid couplers. 3) Install oil strainer (2) and A/T fluid temperature sensor (1). Tightening Torque (b): 10 N·m (1.0 kg-m, 7.5 lb-ft) NOTE:...
Page 774 AUTOMATIC TRANSMISSION (4 A / T) 7B-63 DIFFERENTIAL SIDE OIL SEAL REPLACEMENT 1) Lift up vehicle and drain transmission oil. 2) Remove drive shaft joints from differential gear of transmission. Refer to SECTION 4 (DRIVE SHAFT) for procedure to discon- nect drive shaft joints.
Page 775 7B-64 AUTOMATIC TRANSMISSION (4 A / T) TRANSMISSION CONTROL MODULE (TCM) CAUTION: TCM and ECM consist of highly precise parts, so when han- dling it (or them), be careful not to expose to excessive shock. REMOVAL 1) Disconnect negative cable at battery. 2) If the vehicle is equipped with air bag system, disable air bag system.
Page 776 AUTOMATIC TRANSMISSION (4 A / T) 7B-65 INSTALLATION Reverse removal procedure noting the following. D Connect ECM and TCM couplers securely. D If the vehicle is equipped with air bag system, be sure to enable air bag system after TCM and ECM are back in place. Refer to “Enabling Air Bag System”...
Page 777 7B-66 AUTOMATIC TRANSMISSION (4 A / T) TRANSMISSION UNIT REPAIR OVERHAUL DISMOUNTING 1) Take down transmission with engine. For its procedure, refer to Section 6A1. 2) Remove torque converter housing lower plate (1). 3) Remove drive plate bolts. To lock drive plate (1), engage a flat head rod or the like (2) with drive plate gear.
Page 778 AUTOMATIC TRANSMISSION (4 A / T) 7B-67 REMOUNTING 1) Make sure that torque converter is installed correctly to trans- mission. Refer to UNIT ASSEMBLY in this section. 2) Attach transmission to engine. Tightening Torque (a): 50 N m (5.0 kg-m, 36.0 lb-ft) WARNING: Be sure to keep transmission with torque converter hori- zontal or facing up throughout the work.
Page 779 7B-68 AUTOMATIC TRANSMISSION (4 A / T) DISASSEMBLY CAUTION: D Thoroughly clean transmission exterior before overhaul- ing it. D Keep working table, tools and hands clean while over- hauling. D Use special care to handle aluminum parts so as not to damage them.
Page 780 AUTOMATIC TRANSMISSION (4 A / T) 7B-69 8) Remove A/T fluid level gauge (1) and filler tube (2). 9) Remove vehicle speed sensor (1) (for speedometer), shift cable bracket (2) and connector clamp bracket (3). 10) Remove oil pan and oil pan gasket. NOTE: D For removal of oil pan, do not turn transmission over as this will contaminate valve body with foreign materials...
Page 781 7B-70 AUTOMATIC TRANSMISSION (4 A / T) 12) Disconnect couplers from solenoid valves, and A/T fluid tem- perature sensor. Remove A/T fluid temperature sensor. 13) Remove valve body assembly (1). CAUTION: Be careful not to let manual valve fall off when removing valve body assembly.
Page 782 AUTOMATIC TRANSMISSION (4 A / T) 7B-71 16) Remove torque converter housing (1). a) Remove housing internal bolts and external bolts. b) Remove housing while tapping around it lightly with a plastic hammer. NOTE: Never reuse bolts A shown in figure. 17) Remove thrust needle roller bearing (1) and thrust bearing race (2) from the top of counter driven gear ass’y (3).
Page 783 7B-72 AUTOMATIC TRANSMISSION (4 A / T) 21) Remove thrust bearing race (1) and thrust needle roller bearing (2). 22) Remove rear disc clutch assembly (1). 23) Remove intermediate shaft assembly (1) and follow shaft as- sembly (2). 24) Remove B2 brake snap ring, brake flange, brake discs, brake plates and cushion plate.
Page 784 AUTOMATIC TRANSMISSION (4 A / T) 7B-73 25) Remove oil guide plate (1) parking lock pawl cover (2), shaft, torsional spring (3) and parking lock pawl (4). 26) Remove parking lock pawl sleeve (5). 27) Remove counter driven gear assembly (1) and thrust needle roller bearing (2).
Page 785 7B-74 AUTOMATIC TRANSMISSION (4 A / T) 31) Remove rear cover assembly (1), thrust washer (2) and thrust needle roller bearing (3). Remove gasket (4). 32) Remove C0 (direct clutch) assembly (1), thrust roller bearing (2) and rear planetary sun gear No.1 assembly (3). 33) Remove planetary set (1) with bearing, thrust needle roller bearing (2).
Page 786 AUTOMATIC TRANSMISSION (4 A / T) 7B-75 35) Remove planetary sun gear No.2 (1) and thrust needle roller bearing (2). 36) Remove snap ring, then remove brake flange and disc. 37) Remove snap ring, then remove brake discs and plates (B1 brake).
Page 787 7B-76 AUTOMATIC TRANSMISSION (4 A / T) 40) Remove counter drive gear (1). 41) Use hydraulic press (8) and special tool to compress wave 2. Flad end rod or the like spring (4), then remove snap ring (1). Special Tool: (A): 09926-96040 NOTE: D Do not compress wave spring more than necessary.
Page 788 AUTOMATIC TRANSMISSION (4 A / T) 7B-77 INSPECTION Clutch and Brake Discs Dry and inspect them for pitting, burn flaking, wear, glazing, crack- ing, charring and chips or metal particles imbedded in lining. If discs show any of the above conditions, replacement is required. NOTE: D If disc lining is exfoliated or discolored, replace all discs.
Page 789 7B-78 AUTOMATIC TRANSMISSION (4 A / T) DISASSEMBLY OF SUBASSEMBLY CAUTION: D Keep component parts in group for each subassembly and avoid mixing them up. D Clean all parts with cleaning solvent thoroughly and air dry them. D Use kerosene or automatic transmission fluid as cleaning solvent. D Do not use wiping cloths or rags to clean or dry parts.
Page 790 AUTOMATIC TRANSMISSION (4 A / T) 7B-79 OIL PUMP 1. Oil seal 2. D-ring 3. Oil pump body 4. Oil pump drive gear 5. Oil pump driven gear 6. Stator shaft ass’y 7. Clutch drum thrust washer 8. Clutch drum oil seal ring DISASSEMBLY 1) Remove D-ring from pump body.
Page 791 7B-80 AUTOMATIC TRANSMISSION (4 A / T) ASSEMBLY 1) Install pump body oil seal (1). Use special tool and hammer to install it, and then apply grease to its lip portion. Special Tool (A): 09913-85210 “A”: Grease 99000-25030 2) Install driven gear and drive gear to pump body (2) after applying A/T fluid to gears.
Page 792 AUTOMATIC TRANSMISSION (4 A / T) 7B-81 FRONT CLUTCH (C2 CLUTCH) 1. Front clutch No.1 drum 2. D-ring 3. Front clutch piston 4. Front clutch return spring seat 5. Front clutch balancer 6. Shaft snap ring 7. Clutch plate 8. Clutch disc 9.
Page 793 7B-82 AUTOMATIC TRANSMISSION (4 A / T) 4) Remove front clutch balancer (1) and front clutch return spring seat (2). 5) Remove front clutch piston (3). Blow compressed air through input shaft oil hole to remove pis- ton. If piston does not pop out, take it out with long nose pliers. 6) Remove D-ring (4) from front clutch No.1 drum (5).
Page 794 AUTOMATIC TRANSMISSION (4 A / T) 7B-83 ASSEMBLY 1) Install new D-ring (5) to front clutch No.1 drum. Apply grease to D-ring and fit it to drum. “A”: Grease 99000-25030 2) Install piston (4) into front clutch No.1 drum (6). Use care that the piston lip does not get twisted or caught.
Page 795 7) Place special tool (A) on soft jawed vise (1) and install 2 oil seal rings on special tool. Special Tool (A): 09926-26030 SUZUKI GENUINE PARTS (B): Clutch drum seal ring 22831-83E10 NOTE: D Clutch drum seal set has two seal rings in a set.
Page 796 AUTOMATIC TRANSMISSION (4 A / T) 7B-85 10) Attach special tool (B) to dial gauge (2) and set them on the low- est clutch plate. Special Tool (B): 09952-06010 Measure piston stroke by blowing compressed air (4 kg/cm 57 psi) as shown in figure. Piston Stroke: 1.46 –...
Page 797 7B-86 AUTOMATIC TRANSMISSION (4 A / T) REAR CLUTCH (C1 CLUTCH) 1. Input shaft oil seal ring 2. Input shaft subassembly 3. D-ring 4. Rear clutch piston 5. Rear clutch return spring seat 6. Rear clutch balancer 7. Shaft snap ring 8.
Page 798 AUTOMATIC TRANSMISSION (4 A / T) 7B-87 4) Remove rear clutch balancer (1) and rear clutch return spring seat (2). 5) Remove rear clutch piston (3). If piston does not pop out, blow compressed air through input shaft oil hole to remove piston. 6) Remove D-ring, and oil seals from input shaft subass’y (4).
Page 799 7B-88 AUTOMATIC TRANSMISSION (4 A / T) ASSEMBLY 1) Install new D-ring (7) and oil seals (2) to input shaft subass’y. Apply grease to D-ring and fit it to input shaft subass’y (1). “A”: Grease 99000-25030 2) Install piston (6) into input shaft subass’y. Apply grease to the lip of the piston.
Page 800 AUTOMATIC TRANSMISSION (4 A / T) 7B-89 6) Install snap ring (1). NOTE: Make sure that the ends of the snap ring do not come to the opening of the input shaft subass’y. 7) Place special tool (C) on soft jawed vise (2) with wider opening (1) facing up.
Page 801 7B-90 AUTOMATIC TRANSMISSION (4 A / T) 10) Attach special tool (B) to dial gauge (4) and set them on the low- est clutch plate (2). Special Tool (B): 09952-06010 Measure piston stroke by blowing compressed air (4kg/cm 57 psi) as shown in figure. Piston Stroke: 1.93 –...
Page 802 AUTOMATIC TRANSMISSION (4 A / T) 7B-91 DIRECT CLUTCH (C0 CLUTCH) 1. Direct clutch (C0) No.1 drum 2. D-ring 3. Direct clutch piston 4. Direct clutch return spring seat 5. Direct clutch balancer 6. Shaft snap ring 7. Clutch plate 8.
Page 803 7B-92 AUTOMATIC TRANSMISSION (4 A / T) 4) Remove direct clutch balancer (1) and direct clutch return spring seat (2). 5) Remove direct clutch piston (3). Blow compressed air through input shaft oil hole to remove pis- ton. If piston does not pop out, take it out with long nose pliers. 6) Remove D-ring (4) from direct clutch No.1 drum (5).
Page 804 AUTOMATIC TRANSMISSION (4 A / T) 7B-93 ASSEMBLY 1) Install new D-ring (5) to direct clutch No.1 drum (6). Apply grease to D-ring and fit it to drum. “A”: Grease 99000-25030 2) Install piston (4) into direct clutch No.1 drum. Use care that the piston lip does not get twisted or caught.
Page 805 7) Place special tool (A) on soft jawed vise (1) and install 2 oil seal rings on special tool. Special Tool (A): 09926-26050 SUZUKI GENUINE PARTS (B): Rear cover seal ring 24742-78F10 NOTE: D Rear cover seal set has two seal rings in a set.
Page 806 AUTOMATIC TRANSMISSION (4 A / T) 7B-95 10) Attach special tool (B) to dial gauge (2) and set them on the low- est clutch plate. Special Tool (B): 09952-06010 Measure piston stroke by blowing compressed air (4kg/cm 57 psi) as shown in figure. Piston Stroke: 0.96 –...
Page 807 7B-96 AUTOMATIC TRANSMISSION (4 A / T) PLANETARY SET 1. Planetary ring gear No.2 2. Planetary gear ass’y No.2 3. Planetary oil receiver No.2 4. Thrust needle roller bearing 5. Planetary gear ass’y No.1 6. Planetary oil receiver No.1 7. Snap ring DISASSEMBLY 1) Remove snap ring.
Page 808 AUTOMATIC TRANSMISSION (4 A / T) 7B-97 ASSEMBLY 1) Install new planetary oil receiver No.2 (4) and needle roller bear- ing (3) to planetary gear ass’y No.2 (5). NOTE: D Note the direction of needle roller bearing. D Take care not to break the claw of oil receiver. 2) Install planetary gear ass’y No.1 (2) to planetary gear ass’y No.2 (5).
Page 809 7B-98 AUTOMATIC TRANSMISSION (4 A / T) VALVE BODY 11. Lock-up control valve sleeve 1. Upper valve body 21. Secondary regulator valve 12. Lock-up control valve 2. Upper valve body gasket 22. Manual valve 13. Lock-up control valve spring 3. Valve body plate 23.
Page 810 AUTOMATIC TRANSMISSION (4 A / T) 7B-99 VALVE BODY ASS’Y Disassembly 1) Remove manual valve. 2) Remove 12 bolts from lower valve body. NOTE: D There are 4 different kinds of bolt fixing upper and lower valve body. Do not mix them up and remember where they belong to.
Page 811 7B-100 AUTOMATIC TRANSMISSION (4 A / T) Reference Primary regulator valve spring (compression spring) Outside diameter “b” Spring Free length “a” (mm) (mm) Primary regulator 79.2 18.0 valve spring Lock-up control 31.1 valve spring Lock-up signal 36.1 valve spring Assembly 1) Apply A/T fluid to each valve, plate washer, spring, plunger, sleeve and key.
Page 812 AUTOMATIC TRANSMISSION (4 A / T) 7B-101 LOWER VALVE BODY Disassembly 1) Remove oil strainers (1). 2) Remove solenoid valves, if still attached. 3) Remove keys (2) and pull out all sleeve, plug, spring and valves. 3. Fail valve No.1 sleeve 4.
Page 813 7B-102 AUTOMATIC TRANSMISSION (4 A / T) Assembly 1) Apply A/T fluid to each valve, spring, sleeve and key. Insert them, then fix with key. NOTE: Make sure that the fail valve No.2 and secondary regulator valve is inserted in the right direction. 2) Insert oil strainers to lower valve body.
Page 814 AUTOMATIC TRANSMISSION (4 A / T) 7B-103 VALVE BODY ASSEMBLY Assembly 1) Install gasket for lower valve body (3), valve body plate (2) and gasket for upper valve body (1) to lower valve body (4). 2) Make sure that steel balls (2) are at the location shown in figure. 1.
Page 815 7B-104 AUTOMATIC TRANSMISSION (4 A / T) DIFFERENTIAL ASSEMBLY Servicing procedure for differential assembly is similar to that for manual transmission. Refer to Section 7A of this manual for adjustment procedure. 1. Differential pinion 2. Differential gear 3. Washer (for pinion) 4.
Page 816 AUTOMATIC TRANSMISSION (4 A / T) 7B-105 4) Remove side pinion shaft pin. 1. Differential case Use special tool and hammer for its removal. 2. Differential gear 3. Differential pinion shaft Special Tool (C): 09922-85811 5) Remove side pinion shaft, differential pinions with each washer, differential gears with each washer.
Page 817 7B-106 AUTOMATIC TRANSMISSION (4 A / T) 4) Press-fit new sensor rotor (1) with groove (2) side downward as shown by using special tools and copper hammer. Special Tool (F): 09951-76010 (G): 09940-54910 5) Support differential assembly as illustrated so as to float L bear- ing, and then press-fit R bearing by using special tool and copper hammer.
Page 818 AUTOMATIC TRANSMISSION (4 A / T) 7B-107 REAR COVER (B0 Piston Assembly) DISASSEMBLY 1) Remove O/D brake piston (1) from rear cover (2). NOTE: If O/D brake piston is hard to take it out, force low-pressure compressed air (1 kg/cm , 15 psi, 100 kPa max) into hole (5) shown in figure and pop out piston into a rag.
Page 819 7B-108 AUTOMATIC TRANSMISSION (4 A / T) PLANETARY SUN GEAR NO.1 ASSEMBLY DISASSEMBLY 1) Remove one-way clutch retainer (1) from planetary sun gear No.1 assembly. NOTE: Do not reuse retainer. 2) Remove one-way clutch bearings (2), one-way clutch (3), inner race (4) and washer (5) from planetary sun gear No.1 (6).
Page 820 AUTOMATIC TRANSMISSION (4 A / T) 7B-109 TORQUE CONVERTER HOUSING DISASSEMBLY 1) Remove oil seal (1). 2) Remove counter bearing (1) using special tools. Special Tool: (A): 09930-30102 (B): 09923-74510 ASSEMBLY 1) Install counter bearing to torque converter housing. Use special tools and a hammer to press fit the bearing to torque converter housing.
Page 821 7B-110 AUTOMATIC TRANSMISSION (4 A / T) TRANSMISSION CASE DISASSEMBLY 1) Remove oil seal (1). 1. Oil seal 2) Remove counter bearing (1) using special tools. Special Tool: (A): 09930-30102 (C): 09941-64511 ASSEMBLY 1) Install counter bearing using special tools. Special Tool: (D): 09924-74510 (E): 09944-68510...
Page 822 D Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly. D Use yellow petrolatum grease or Suzuki Super Grease C to retain parts in place. D Be sure to install thrust bearings and races in correct direction and position.
Page 823 7B-112 AUTOMATIC TRANSMISSION (4 A / T) 4) Install counter drive gear (1). 2. Transmission case Tightening Torque (a): 5.5 N m (0.55 kg-m, 4.0 lb-ft) 5) Install new inner and outer O-rings (4) to 1st & 2nd brake piston (3) and apply grease to them.
Page 824 AUTOMATIC TRANSMISSION (4 A / T) 7B-113 11) Install brake flange (1) and snap ring (2) to transmission case (3). NOTE: The flat surface of the flange comes to the top (must face B0 piston). 12) Measure B1 brake stroke and clearance in following manner. B1 Brake Stroke: Set the dial gauge (1) to 1st &...
Page 825 7B-114 AUTOMATIC TRANSMISSION (4 A / T) 13) Install O/D (B0) brake return spring seat (4), return spring (3) and then retainer (2). 14) While compressing retainer (2), install snap ring (1). CAUTION: Position return spring (3) to be centered so that rear cover not be caught.
Page 826 AUTOMATIC TRANSMISSION (4 A / T) 7B-115 19) Measure the clearance of B0 brake in the following manner. Blow compressed air into hole shown in figure to activate B1 brake piston (4), then measure the distance between the top of B0 brake plate and the transmission case – rear cover mat- ing surface.
Page 827 7B-116 AUTOMATIC TRANSMISSION (4 A / T) 21) Install thrust needle roller bearing (3). 1. Rear cover 22) Install thrust washer (2). 4. Gasket 23) Install new gasket to transmission case and install rear cover (1). Tightening Torque: (a): 19 N m (1.9 kg-m, 14.0 lb-ft) NOTE: Install the hook (2) to the location shown in figure.
Page 828 AUTOMATIC TRANSMISSION (4 A / T) 7B-117 25) Attach parking lock rod (2) to manual shift shaft (1). 26) Install manual shift shaft and washer (3) to transmission case. Fix manual shift shaft with washer, control shift lever (4) and two nuts (5).
Page 829 7B-118 AUTOMATIC TRANSMISSION (4 A / T) 31) Install parking lock pawl (2). 32) Install parking lock pawl shaft (4), torsional spring (3), and cov- er, then hold them with 2 bolts. Tightening Torque: (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 1.
Page 830 AUTOMATIC TRANSMISSION (4 A / T) 7B-119 35) Inspect B2 brake piston stroke and clearance by blowing com- Clearance pressed air into hole (4) shown in figure. Make sure that the obtained piston stroke and clearance satis- fy the standard value. To Measure Clearance: Set dial gauge (1) to the top of B2 brake flange and blow com- pressed air into the hole shown in figure.
Page 831 7B-120 AUTOMATIC TRANSMISSION (4 A / T) 37) Install follow shaft (1) to transmission case. Turn it right and left to match the B2 brake discs and the spline of follow shaft. NOTE: When installing follow shaft, do not let the thrust washer fall off from follow shaft.
Page 832 AUTOMATIC TRANSMISSION (4 A / T) 7B-121 43) Apply grease to thrust needle roller bearing (1) and install it. “A”: Grease 99000-25030 44) Apply grease to clutch drum thrust washer (1) and install it to oil pump ass’y (2). , “A” “A”: Grease 99000-25030 45) Install gasket to transmission case and install oil pump assem- bly (1) to transmission case.
Page 833 7B-122 AUTOMATIC TRANSMISSION (4 A / T) 47) Install differential gear assembly (1). NOTE: Grease can be applied around the R and L bearing of differ- ential gear assembly to ease fitting to the transmission case and torque converter housing. 48) Install thrust bearing race (1) and thrust needle roller bearing (2) to the top of counter driven gear (3).
Page 834 AUTOMATIC TRANSMISSION (4 A / T) 7B-123 50) Install O-rings to each accumulator piston and apply grease or ATF to them. Grease 99000-25030 NOTE: C1 and B0 accumulator pistons are the same. 51) Install C1 and B0 accumulator pistons (1 and 6), springs (2, 3 and 7) and spacers (4).
Page 835 7B-124 AUTOMATIC TRANSMISSION (4 A / T) 54) Install valve body to transmission case. First match the pin of the manual valve to the slot of the manual shift shaft. To fix valve body to transmission case, first tighten bolt B (3), then tighten other bolts.
Page 836 AUTOMATIC TRANSMISSION (4 A / T) 7B-125 58) Install magnet (1) in oil pan (2). NOTE: If metal particles are attached to the magnet, clean them before installing. 59) Install gasket to transmission case and install oil pan (1). Tightening Torque: (a): 7.5 N m (0.75 kg-m, 5.5 lb-ft) 60) Install oil cooler (1) and ground cable (2).
Page 837 7B-126 AUTOMATIC TRANSMISSION (4 A / T) 63) Install A/T VSS (1) and input revolution sensor (2). Apply grease to O-ring of each sensor. Tightening Torque: (a): 8 N m (0.8 kg-m, 6.0 lb-ft) 64) Install engine mounting LH bracket. Tightening Torque: (a): 55 N m (5.5 kg-m, 40.0 lb-ft)
Page 838 AUTOMATIC TRANSMISSION (4 A / T) 7B-127 SPECIAL TOOLS 09900-06108 Snap ring plier 09900-20606 09900-20701 09913-75510 (Closing type) Dial gauge Magnetic stand Bearing installer 09913-80112 09913-85210 09922-85811 09923-74510 Bearing installer Bearing installer Spring pin remover (6 mm) Bearing remover 09924-74510 09925-37810 09925-88210 09926-26030...
Page 839 4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09931-76011 09941-64511 09944-68510 SUZUKI scan tool (Tech 1A) kit Bearing remover Bearing installer 09951-16060 09952-06010 09952-06020 Bush remover Dial gauge plate No.1 Dial gauge plate No.2...
Page 840 SUZUKI BOND NO.1215 D Case housing star-shaped recess bolts Sealant (99000-31110) (3 pcs only) D Retaining parts in place when SUZUKI SUPER GREASE C assembling (99000-25030) D Oil seal lips Lithium grease D Oil pump D-ring SUZUKI SUPER GREASE A...
Page 842 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 843 7C-2 CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm-spring clutch of a dry single Depressing the clutch pedal causes the release bear- disc type. The diaphragm spring is of a tapering-finger ing to advance and pushes on the tips of the tapered type, which is a solid ring in the outer diameter part, fingers of the diaphragm spring.
Page 844 CLUTCH 7C-3 DIAGNOSIS Condition Possible Cause Correction Slipping D Improper clutch pedal free travel. Adjust free travel. D Worn or oily clutch disc facing. Replace disc. D Warped disc, pressure plate or flywheel Replace disc, clutch cover or surface. flywheel. D Weakened diaphragm spring.
Page 845 7C-4 CLUTCH CLUTCH PEDAL HEIGHT CHECK Adjust clutch pedal (1) height with adjusting bolt (2) located on ped- al bracket (3) so that clutch pedal height is same as brake pedal (4) height. View from A Height difference “a”: 0 mm (0 in.) CLUTCH PEDAL FREE TRAVEL CHECK 1) Confirm that clutch pedal height is specification.
Page 846 CLUTCH 7C-5 ON-VEHICLE SERVICE CLUTCH CABLE 1. Clutch cable 2. Release lever 3. Joint pin: Apply grease 99000-25010 to joint pin and also cable end hook. 4. Joint nut 5. Clutch pedal 6. Pedal bracket 7. Adjusting bolt 8. Lock nut 9.
Page 847 7C-6 CLUTCH INSTALLATION 1) Apply grease to cable end hook and also joint pin before instal- ling cable. “A”: Grease A, 99000-25010 2) Hook cable end with pedal by using screwdriver or long nose pli- ers from cabin inside, then join inner cable wire joint pin in re- lease lever.
Page 848 CLUTCH 7C-7 CLUTCH PEDAL AND CLUTCH PEDAL BRACKET 1. Clutch cable hook: Apply grease A 99000-25010 to cable hook. 2. Clutch pedal bracket 3. Bolt 4. Nut 5. Pedal shaft nut 6. Pedal bush 7. Pedal spring: Apply grease A 99000-25010 to inside surface of spring.
Page 849 7C-8 CLUTCH UNIT REPAIR OVERHAUL CLUTCH COVER, CLUTCH DISC AND FLYWHEEL 1. Flywheel 2. Clutch release shaft seal: Apply grease A 99000-25010 to seal lip. 3. Clutch release shaft No.2 bush: Apply grease A 99000-25010 to bush inside. 4. Return spring 5.
Page 850 CLUTCH 7C-9 INSPECTION Input Shaft Bearing Check bearing (1) for smooth rotation and replace it if abnormality is found. Clutch Disc Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 851 7C-10 CLUTCH 2) Using special tool, install input shaft bearing to flywheel. Special Tool (B): 09925-98210 3) Aligning clutch disc to flywheel center by using special tool, install clutch cover (1) and bolts. Then tighten bolts to specifica- tion. NOTE: D While tightening clutch cover bolts, compress clutch disc with special tool (C) by hand so that disc centered.
Page 852 CLUTCH 7C-11 CLUTCH RELEASE SYSTEM REMOVAL 1) Remove release lever by loosening its bolt. 2) Take out release bearing by turning release shaft (1). 3) Unhook return spring by using pliers. 4) Drive out No.2 bush by using special tool and hammer. Release shaft seal will also be pushed out.
Page 853 7C-12 CLUTCH INSPECTION Clutch release bearing Check clutch release bearing for smooth rotation. If abnormality is found, replace it. CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage. Clutch release shaft Check clutch release shaft and its pin for deflection or damage. If abnormality is found, replace it.
Page 854 CLUTCH 7C-13 6) Hook return spring. 7) Apply grease to release bearing (1) inside and release shaft arm (2), then set bearing. “A”: Grease A, 99000-25010 8) Apply small amount of grease to input shaft (3) spline and front end as well. “B”: Grease I, 99000-25210 9) Set release lever to release shaft aligning their punch marks (1), then tighten bolt.
Page 855 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Cable end hook and joint pin. D Release shaft bushes and seal. SUZUKI SUPER GREASE A D Release shaft arm. (99000-25010) Lithium grease D Release bearing inside. SUZUKI SUPER GREASE I Input shaft spline and front end.
Page 856: Body Electrical System
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 857 8-2 BODY ELECTRICAL SYSTEM GENERAL DESCRIPTION The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery. The electrical system utilizes negative ground polarity. CAUTIONS IN SERVICING When performing works related to electric systems, observe follow- ing cautions for the purpose of protection of electrical parts and pre- vention of a fire from occurrence.
Page 858 BODY ELECTRICAL SYSTEM 8-3 D When installing the wiring harness, fix it with clamps so that no slack is left. D When installing vehicle parts, be careful so that the wiring har- ness is not interfered with or caught by any other part. D To avoid damage to the harness, protect its part which may con- tact against a part forming a sharp angle by winding tape or the like around it.
Page 859 8-4 BODY ELECTRICAL SYSTEM D When performing a work that produces a heat exceeding 80_C in the vicinity of the electrical parts, remove the heat sensitive electrical part(s) beforehand. D Use care not to expose connectors and electrical parts to water which will be a cause of a trouble.
Page 860 BODY ELECTRICAL SYSTEM 8-5 WIRING COLOR SYMBOLS The wire color is abbreviated to the first (or first two) alphabet(s) of each color. There are two kinds of colored wire used in this vehicle. One is G (Base Color) single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e.
Page 861 8-6 BODY ELECTRICAL SYSTEM POWER SUPPLY DIAGRAM Refer to Wiring Diagram Manual.
Page 862 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 863 8B-2 LIGHTING SYSTEM GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8. WIRING COLOR SYMBOLS Refer to Section 8. ABBREVIATIONS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8.
Page 864 LIGHTING SYSTEM 8B-3 HEADLIGHT WITH LEVELING SYSTEM 1. Headlight leveling switch 2. Headlight leveling unit (actuator) 3. Headlight 4. Headlight leveling unit shaft Switch Headlight beam Position down angle ——— 0.75_ 1.5_ 2.25_ DAYTIME RUNNING LIGHT (D.R.L.) SYSTEM (IF EQUIPPED) The D.R.L.
Page 865 8B-4 LIGHTING SYSTEM DIAGNOSIS HEADLIGHTS Trouble Possible cause Correction Only one light does not D Bulb burnt out Replace bulb light D Fuse blown Replace fuse D Socket, wiring or grounding faulty Repair as necessary Headlights do not light D Main fuse and/or fuses blown Replace main fuse and/or fuses when lighting switch is to check for short...
Page 866 LIGHTING SYSTEM 8B-5 TURN SIGNAL AND HAZARD WARNING LIGHTS Trouble Possible cause Correction Flash rate high or one side D Faulty ground Repair only flashes D Incorrect bulb Replace D One of light bulbs burnt out Replace D Turn signal/hazard warning relay faulty D Turn signal/hazard warning relay faulty Replace Re lace...
Page 867: Brake Lights
8B-6 LIGHTING SYSTEM BRAKE LIGHTS Trouble Possible cause Correction Stop lights do not light D Fuse blown Replace fuse to check for short D Bulb burnt out Replace D Stop light switch faulty Adjust or replace switch D Wiring or grounding faulty Repair as necessary Stop lights stay on D Stop light switch faulty...
Page 868 LIGHTING SYSTEM 8B-7 INTERIOR LIGHT Trouble Possible cause Correction Interior light does not D Bulb burnt out Replace light up D Fuse blown Replace D Wiring or grounding faulty Repair as necessary D Door open switch faulty Check switch D Interior light faulty Check light D Lighting switch faulty Check switch...
Page 869 8B-8 LIGHTING SYSTEM ON-VEHICLE SERVICE HEADLIGHTS LIGHTING SWITCH REMOVAL 1) Disconnect negative cable at battery. 2) Remove garnish (1) of instrument panel switches. 3) Remove lighting switch (2) from instrument panel. INSPECTION SMALL Check the continuity at each switch position. If any continuity is not obtained, replace switch.
Page 870 LIGHTING SYSTEM 8B-9 INSPECTION Check the continuity at each switch position. If any continuity is not obtained, replace switch. Terminal Switch Position PASS Passing (PASS) Low Beam High Beam (HI) INSTALLATION 1) Connect couplers to turn & dimmer switch. 2) Push turn & dimmer switch into steering column till it clicks. 3) Install steering column cover.
Page 871 8B-10 LIGHTING SYSTEM REMOVAL 1) Disconnect negative cable at battery. 2) Remove front bumper. 3) Disconnect harness and couplers from headlight assembly. 4) Remove four bolts and pull headlight assembly off vehicle. INSTALLATION Reverse removal procedure for installation. Make sure to follow HEADLIGHT AIMING WITH SCREEN and aim headlight after installation.
Page 872 LIGHTING SYSTEM 8B-11 HEADLIGHT AIMING WITH SCREEN NOTE: D Unless otherwise obligated by local regulations, adjust headlight aiming according to following procedure. D After replacing headlight, be sure to perform its aiming. D When inspecting and adjusting headlight with leveling sys- tem, make sure to set the leveling switch to “0”...
Page 873 8B-12 LIGHTING SYSTEM HEADLIGHTS WITH LEVELING SYSTEM LEVELING SWITCH REMOVAL 1) Disconnect negative cable at battery. 2) Remove garnish (1) of instrument panel switches. 3) Remove leveling switch (2) from instrument panel. INSPECTION Check the resistance between terminal “A” and “B” and terminal “B” and “C”...
Page 874 LIGHTING SYSTEM 8B-13 DAYTIME RUNNING LIGHT (D.R.L.) SYSTEM (IF EQUIPPED) DAYTIME RUNNING LIGHT CIRCUIT INSPECTION 1) Apply parking brake and stop engine. With turned on lighting switch and operated dimmer switch, check headlights come on. 2) Start engine. Turn lighting switch at “OFF”. Check headlights come on.
Page 875 8B-14 LIGHTING SYSTEM TURN SIGNAL AND HAZARD WARNING LIGHTS TURN SIGNAL SWITCH (IN TURN AND DIMMER SWITCH) REMOVAL 1) Disconnect negative cable at battery. 2) Remove steering column cover. Refer to step 5) of CONTACT COIL CABLE ASSEMBLY REMOVAL in Section 3C. 3) Pull out turn &...
Page 876 LIGHTING SYSTEM 8B-15 HAZARD SWITCH REMOVAL 1) Remove center lower garnish. Refer to step 3) of HEATER CON- TROL LEVER ASSEMBLY REMOVAL in Section 1A. 2) Remove hazard switch (1) from hazard switch case (2) installed instrument panel with unlocked the locking part (3) as shown in figure.
Page 877 8B-16 LIGHTING SYSTEM HAZARD RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect hazard relay lead wire coupler. 3) Connect battery and tester as the left illustration. 4) Unless a continued click sound is heard, replace relay (1). The illustration shows LH steering vehicle. And RH steering vehicle is symmetrical.
Page 878 LIGHTING SYSTEM 8B-17 INSTALLATION Reverse removal procedure for installation. NOTE: Front fog lights light up only when headlights (low or high beams) or position lights are ON. Front fog lights turn OFF automatically when position lights are turned OFF. If front fog light switch holds ON position, front fog lights turn ON automatically when headlights or position lights are ON again.
Page 879 8B-18 LIGHTING SYSTEM REAR FOG LIGHT INSPECTION 1) Check headlights and front fog lights (if equipped) come on. 2) Disconnect negative cable at battery. 3) Disconnect rear fog controller (1) coupler and connect negative cable at battery. 4) Check that the voltage and resistance between following termi- nals are specifications.
Page 880 LIGHTING SYSTEM 8B-19 INTERIOR LIGHT INTERIOR LIGHT SWITCH (IN LIGHTING SWITCH) REMOVAL 1) Disconnect negative cable at battery. 2) Remove garnish (1) of instrument panel switches. 3) Remove lighting switch (2) from instrument panel. INSPECTION Check the continuity at each switch position. If any continuity is not obtained, replace switch.
Page 882 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 883 8C-2 INSTRUMENTATION / DRIVER INFORMATION GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8. WIRING COLOR SYMBOLS Refer to Section 8. ABBREVIATIONS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8.
Page 884: Oil Pressure Light
INSTRUMENTATION / DRIVER INFORMATION 8C-3 DIAGNOSIS SPEEDOMETER AND VSS Trouble Possible Cause Correction Speedometer shows no IG METER fuse blown Check fuse operation VSS faulty Check VSS Speedometer faulty Check speedometer Wiring or grounding faulty Repair FUEL METER AND FUEL GAUGE UNIT Trouble Possible Cause Correction...
Page 885 8C-4 INSTRUMENTATION / DRIVER INFORMATION LIGHT REMAINDER WARNING BUZZER Trouble Possible Cause Correction Light remainder warning LICENCE fuse blown Check fuse buzzer does not sound Buzzer faulty Replace buzzer Wiring or grounding faulty Repair Driver or passenger door switch faulty Check door switch Lighting switch faulty Check switch...
Page 886 INSTRUMENTATION / DRIVER INFORMATION 8C-5 ON-VEHICLE SERVICE IGNITION (MAIN) SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove steering column cover. Refer to step 5) of CONTACT COIL CABLE ASSEMBLY REMOVAL in Section 3C.
Page 887 8C-6 INSTRUMENTATION / DRIVER INFORMATION INSTALLATION 1) Install ignition (main) switch to steering column. 2) Install ignition switch cylinder assembly. Refer to step 5) of STEERING COLUMN INSTALLATION in Section 3C. 3) Connect ignition (main) switch coupler. 4) Connect negative cable at battery. 5) Enable air bag system.
Page 888 INSTRUMENTATION / DRIVER INFORMATION 8C-7 INSTALLATION Reverse removal procedure for installation, noting the following. D Be sure to enable air bag system after installation. Refer to ENAB- LING AIR BAG SYSTEM in Section 10B for details. SPEEDOMETER AND SENSOR VEHICLE SPEED SENSOR (VSS) Refer to VEHICLE SPEED SENSOR (VSS) in Section 7A.
Page 889 8C-8 INSTRUMENTATION / DRIVER INFORMATION FUEL SENDER GAUGE INSPECTION 1) Remove fuel tank. Refer to FUEL TANK REMOVAL in Section 2) Remove fuel pump assembly (1). Refer to FUEL PUMP AS- SEMBLY REMOVAL in Section 6C. 3) Check the resistance between terminals (2) and (3) of fuel send- er gauge under the following each float (4) position.
Page 890: Oil Pressure Warning Light
INSTRUMENTATION / DRIVER INFORMATION 8C-9 ENGINE COOLANT TEMP. (ECT) SENSOR FOR METER WARNING: D Make sure that engine coolant temperature is cold before removing any part of cooling system. D Also be sure to disconnect negative (–) cable at battery before removing any part.
Page 891: Door Switch
8C-10 INSTRUMENTATION / DRIVER INFORMATION BRAKE WARNING LIGHT BRAKE FLUID LEVEL SWITCH INSPECTION Check switch for continuity. If found defective, replace switch (reservoir). OFF position (float up) No continuity ON position (float down) Continuity PARKING BRAKE SWITCH INSPECTION Check switch (1) for continuity. If found defective, replace switch (1).
Page 892 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 893 8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8. WIRING COLOR SYMBOLS Refer to Section 8. ABBREVIATIONS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8.
Page 894: Rear Wiper And Washer
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3 REAR WIPER AND WASHER Rear Wiper & Washer Switch Rear Wiper Assembly POWER DOOR LOCK SYSTEM (IF EQUIPPED) Back Door Actuator Power Door Lock Controller Rear Door Actuator The illustration shows LH steering vehicle. And RH steering vehicle is symmetrical.
Page 895 8D-4 WINDOWS, MIRRORS, SECURITY AND LOCKS DIAGNOSIS WINDSHIELD WIPER AND WASHER FRONT WIPER AND WASHER Trouble Possible cause Correction Wiper does not operate or D WIPER WASHER fuse blown Replace blown fuse to check for move at a specified speed short D Wiper motor faulty Check motor...
Page 896 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-5 REAR WINDOW DEFOGGER Trouble Possible cause Correction Defogger does not work D REAR DEFG fuse blown Replace fuse to check for short D HEATER fuse blown Replace fuse to check for short D Defogger switch faulty Check switch D Defogger heat wire faulty Check heat wire...
Page 897 8D-6 WINDOWS, MIRRORS, SECURITY AND LOCKS ON-VEHICLE SERVICE WINDSHIELD WIPER AND WASHER FRONT WIPER AND WASHER SWITCH REMOVAL 1) Disconnect negative cable at battery. 2) Remove steering column cover. Refer to step 5) of CONTACT COIL CABLE ASSEMBLY REMOVAL in Section 3C. 3) Pull out wiper and washer switch assembly.
Page 898 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-7 INSTALLATION 1) Connect wiper and washer switch lead wire coupler. 2) Push wiper and washer switch assembly into steering column till it clicks. 3) Install steering column cover. Reverse removal procedure. FRONT WIPER MOTOR INSPECTION 1) As illustrated, use a 12 V battery to connect its (+) terminal to ter- minal “A”...
Page 899 8D-8 WINDOWS, MIRRORS, SECURITY AND LOCKS FRONT AND REAR WASHER PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Remove front fender lining (LH). 3) Remove inlet pipe (3) from washer tank (1). 4) Remove washer tank (1) fitting nuts. 5) Disconnect pump (2) lead wires and hoses.
Page 900 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-9 AUTO STOP CIRCUIT INSPECTION 1) Check that wiper motor operates with the wiper switch at low position. 2) Disconnect negative cable at battery. 3) Disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B.
Page 901 8D-10 WINDOWS, MIRRORS, SECURITY AND LOCKS INTERMITTENT CIRCUIT INSPECTION 1) Check that wiper motor operates with the wiper switch at low position, and return to original position with the wiper switch turned OFF. 2) Disconnect negative cable at battery. 3) Disable air bag system. Refer to DISABLILNG AIR BAG SYS- TEM in Section 10B.
Page 902 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-11 WASHER LINKED CIRCUIT INSPECTION 1) Check that wiper motor operates with the wiper switch at low position, and return to original position with the wiper switch turned OFF. 2) Disconnect negative cable at battery. 3) Disable air bag system.
Page 903 8D-12 WINDOWS, MIRRORS, SECURITY AND LOCKS REAR WIPER AND WASHER SWITCH REMOVAL 1) Disconnect negative cable at battery. 2) Remove steering column cover. Refer to step 5) of CONTACT COIL CABLE ASSEMBLY REMOVAL in Section 3C. 3) Pull out wiper and washer switch assembly. 4) Disconnect wiper and washer switch lead wire coupler.
Page 904: Rear Wiper Arm
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-13 2) TESTING AUTOMATIC STOP ACTION a) First, connect battery (+) terminal to terminal “B” and its (–) terminal to black lead wire (2), and let the motor (1) turn. b) Then disconnect terminal “B” from battery and let the motor (1) stop.
Page 905 8D-14 WINDOWS, MIRRORS, SECURITY AND LOCKS REAR WINDOW DEFOGGER DEFOGGER SWITCH (IN BLOWER FAN AND DEFOGGER SWITCH) REMOVAL Remove blower fan and defogger switch. Refer to BLOWER FAN & DEFOGGER SWITCH REMOVAL in Section 1A. INSPECTION Check defogger switch for continuity. If switch has no continuity between terminals, replace.
Page 906 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-15 INSPECTION 1) Checking wire damage a. Turn main switch ON. b. Turn defogger switch ON. c. Check voltage at the center of each heat wire, as shown. At center Voltage Criteria Approx. 5 V Good (No break in wire) Good Approx.
Page 907 8D-16 WINDOWS, MIRRORS, SECURITY AND LOCKS DEFOGGER CIRCUIT REPAIR 1) Use white gasoline for cleaning. 2) Apply masking tape (1) at both upper and lower sides of heat wire (3) to be repaired. 3) Apply commercially-available repair agent (4) with a fine-tip brush (2).
Page 908 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-17 POWER WINDOW CONTROL SYSTEM (IF EQUIPPED) POWER WINDOW MAIN SWITCH INSPECTION Inspect switch for continuity between terminals. LH steering vehicle Driver Side Passenger Side Window Switch (1) Window Switch (2) Terminal Switch DOWN DOWN RH steering vehicle Driver Side Passenger Side...
Page 909 8D-18 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER WINDOW SUB SWITCH LH steering vehicle INSPECTION Inspect switch for continuity between terminals. Terminal Switch Position DOWN DOWN RH steering vehicle...
Page 910 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-19 POWER DOOR LOCK SYSTEM (IF EQUIPPED) LH steering vehicle POWER DOOR LOCK SWITCH INSPECTION Inspect continuity between terminals according to door lock switch (1) action. For LH steering Vehicle terminal For RH steering Vehicle terminal PUSH FREE RH steering vehicle...
Page 911 8D-20 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR LOCK CIRCUIT INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect door lock controller coupler. 3) Use a 12 V battery to connect its (+) terminal to terminal G02-3, and its (–) terminal to terminal G02-2. Check all power door locks are in lock position.
Page 912 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-21 Terminals Condition Specification G02-16 and ground ——— 10 – 15 V When ignition switch is in OFF position G02 11 and ground G02-11 and ground When ignition switch is in ON position 10 – 15 V When ignition switch is in OFF position G02 10 and ground G02-10 and ground...
Page 913 8D-22 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR LOCK ACTUATOR Front Door (Right & Left) INSPECTION 1) Disconnect power door lock actuator coupler. 2) Connect 12 V battery positive and negative terminals to the door lock actuator terminals shown below. If it does not operate as specified in table below, replace door lock actuator.
Page 914 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-23 POWER DOOR MIRROR CONTROL SYSTEM (IF EQUIPPED) MIRROR SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Pull out mirror switch from door trim. 3) Disconnect mirror switch lead wire coupler. 4) Check continuity between terminals at each switch position. If any continuity is not obtained, replace mirror switch.
Page 915 8D-24 WINDOWS, MIRRORS, SECURITY AND LOCKS SPECIAL TOOL 09913-60910 Bearing puller...
Page 916 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to AIR BAG SYSTEM COMPONENTS AND WIRING LOCATION VIEW under GENERAL DESCRIPTION in air bag section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 917 8G-2 IMMOBILIZER CONTROL SYSTEM GENERAL DESCRIPTION COMPONENTS The immobilizer control system designed to prevent vehicle burglar and it consists of following components. D Engine control module (ECM) D Immobilizer control module (including coil antenna) D Ignition key with built-in transponder Operation of this system is as follows.
Page 918 DLC is in compliance with SAE J1962 in its installation position, the shape of connector and pin assignment. OBD-II serial data line (K line of ISO 9141) is used for SUZUKI scan tool to communicate with immobilizer control module, Airbag SDM, ABS control module, etc.
Page 919 #3) It is impossible to know whether immobilizer system have troubles or not by referring MIL. It is possible to communicate by using only SUZUKI scan tool. For non-EC spec vehicle (equipped with diagnosis connector #3) With the diagnosis switch terminal of diagnosis connector #3 (diag-...
Page 920 D Diagnostic trouble code stored in immobilizer 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 func- tions are available and how to use it.
Page 921 8G-6 IMMOBILIZER CONTROL SYSTEM PRECAUTIONS AFTER REPLACING ECM OR IMMOBILIZER CONTROL MODULE D When ECM is replaced, including when replaced because re- checking by using a known-good ECM is necessary during trouble diagnosis, secret key and password must be registered in ECM by performing procedure described in PROCEDURE AF- TER ECM REPLACEMENT.
Page 922 IMMOBILIZER CONTROL SYSTEM 8G-7 DIAGNOSTIC FLOW TABLE DIAGNOSTIC PROCEDURE FOR EC spec vehicle (not equipped with diagnosis connector #3) STEP ACTION Turn ignition switch to start engine. Go to step 5. Go to step 2. Does engine run? W-line circuit check W-line circuit is in good W-line circuit open or Measure terminal voltage of immobilizer control module...
Page 923 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE IMMOBILIZER CONTROL MODULE 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch to ON position. 3) Erase DTC according to instructions displayed on scan tool. Re- fer to scan tool operator’s manual for further details.
Page 924 IMMOBILIZER CONTROL SYSTEM 8G-9 DIAGNOSTIC TROUBLE CODE (DTC) TABLE IMMOBILIZER CONTROL MODULE DTC NO. DETECTED ITEM DETECTING CONDITION B1000 Immobilizer control module internal failure Immobilizer control module failure B3040 W-line communication failure Communication not finished correctly B3042 W-line circuit shorted to ground W-line circuit voltage low B3043 W-line circuit shorted to battery...
Page 925 WAIT TIME (SEC, MIN) The time it must be waited for reinput password for programming SUZUKI scan tool indicates “0 SEC.” when a correct password is input after wait time. If failed to input correct password, it increase according to the times of misinput.
Page 926 IMMOBILIZER CONTROL SYSTEM 8G-11 INSPECTION OF IMMOBILIZER CONTROL MODULE AND ITS CIRCUITS VOLTAGE INSPECTION Immobilizer control module can be checked at wiring connectors by measuring voltage. CAUTION: Immobilizer control module can not be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to immobilizer control module with coupler disconnected from it.
Page 927 8G-12 IMMOBILIZER CONTROL SYSTEM DTC B1000 IMMOBI CONT MODULE INTERNAL FAIL DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Immobilizer control module internal fail. Immobilizer control module TROUBLE SHOOTING (DTC B1000) STEP ACTION 1) Ignition switch at OFF position. Substitute a known- Repair or replace.
Page 928 IMMOBILIZER CONTROL SYSTEM 8G-13 DTC B3040 W-LINE COMMUNICATION FAIL WIRING CIRCUIT 1. ECM 2. Immobilizer control module 3. Main relay DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA No response from ECM while immobilizer control W-line circuit module requests signal.
Page 929 8G-14 IMMOBILIZER CONTROL SYSTEM DTC B3042 W-LINE CKT MALF (SHORT TO GROUND) WIRING CIRCUIT 1. ECM 2. Immobilizer control module DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA W-line circuit voltage is low. W-line circuit is shorted to ground TROUBLE SHOOTING (DTC B3042) STEP ACTION...
Page 930 IMMOBILIZER CONTROL SYSTEM 8G-15 DTC B3043 W-LINE CKT MALF (SHORT TO BATTERY) WIRING CIRCUIT 1. ECM 2. Immobilizer control module DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA W-line circuit voltage is high. W-line circuit is shorted to power supply circuit. TROUBLE SHOOTING (DTC B3043) STEP ACTION...
Page 931 Transponder FIX Transponder according to HOW TO REGISTER IGNITION CODE(s) is registered. registration procedure KEY under ON-VEHICLE SERVICE. is not completed Check SUZUKI scan tool DATA LIST correctly. “NUMBER OF FC”. Register ignition key Is it 1 or more? again.
Page 932 Password is not registered in immobilizer control Immobilizer control module module. TROUBLE SHOOTING (DTC B3057) STEP ACTION 1) Register password by using SUZUKI scan tool. Password Register Refer to HOW TO REGISTER PASSWORD. registration is password again 2) Confirm that password is registered correctly, completed.
Page 933 Register transponder according to HOW TO Transponder FIX Transponder REGISTER IGNITION KEY under ON-VEHICLE CODE is registered. registration procedure SERVICE. is not completed Check SUZUKI scan tool DATA LIST for correctly. “FIX CODE”. Register ignition key Is it registered? again.
Page 934 IMMOBILIZER CONTROL SYSTEM 8G-19 DTC B3061 TRANSPONDER COMMUNICATION FAIL DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA No response from transponder. Ignition key with built-in transponder internally faulty Secret key is not matched between ignition key Secret key is not registered in transponder (transponder) Secret key is not registered in ECM Secret keys are different between ECM and transponder...
Page 935 SKC and PWD are not registered in ECM. TROUBLE SHOOTING (DTC P1610) STEP ACTION 1) Register password and secret key by using Perform registration ECM is registered SUZUKI scan tool. procedure again and correctly. Refer to PROCEDURE AFTER ECM recheck. REPLACEMENT. 2) Check DTC.
Page 936 IMMOBILIZER CONTROL SYSTEM 8G-21 DTC P1614 INCORRECT SIGNAL FROM IMMOBILIZER DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Signal from immobilizer control module is not Ignition key with built-in transponder internally faulty matched. SKC is not registered in transponder SKC key is not registered in ECM SKCs are different between ECM and transponder Unregistered ignition key with built-in transponder...
Page 937 8G-22 IMMOBILIZER CONTROL SYSTEM ON-VEHICLE SERVICE PRECAUTIONS IN HANDLING IMMOBILIZER CONTROL SYSTEM D Do not turn ignition switch to ON position (II) with ignition key with built-in transponder put together with another one or placed quite close to another one. Or the system may detect abnormal condi- tion and prevent engine from running.
Page 938 IMMOBILIZER CONTROL SYSTEM 8G-23 REGISTRATION PROCEDURE OF IMMOBILIZER SYSTEM COMPONENTS IMMOBILIZER SYSTEM COMPONENTS REGISTRATION FLOW TABLE When replacing any component of immobilizer system, perform registration procedure according to following flow table. NOTE: When replacing immobilizer control module and ECM at the same time, the ignition key with built-in trans- ponder that has been registered to the system (SKC registered transponder) can not be used.
Page 939 5 or less. 3) Prepare SUZUKI scan tool and immobilizer cartridge. Connect SUZUKI scan tool to DLC with ignition switch at OFF position. NOTE: For operation procedure of SUZUKI scan tool, refer to its operator’s manual.
Page 940 1) Perform IMMOBILIZER SYSTEM COMPONENTS REGISTRA- TION FLOW TABLE. 2) Prepare SUZUKI scan tool and IMMOBILIZER cartridge. Con- nect scan tool to DLC with ignition switch at OFF position. NOTE: For operation procedure of scan tool, refer to operator’s manual.
Page 941 3. Tech-1A 4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09931-76011 Mass storage cartridge / 09931-76030 SUZUKI scan tool (Tech-1A) kit Immobilizer cartridge 16 / 14 pin DLC cable...
Page 942 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 943 9-2 BODY SERVICE GLASS, WINDOWS AND MIRRORS FRONT DOOR GLASS 1. Door glass 2. Window regulator: Apply SUZUKI SUPER GREASE A(99000-25030) to sliding part. 3. Glass run 4. Door trim 5. Door sealing cover 6. Door sash 7. Power window switch assembly 8.
Page 944 BODY SERVICE 9-3 2) Remove inside handle bezel (1). 3) Remove inside lock knob and door trim fitting screw. 4) Remove door trim (1). With inside handle bezel (2) tilted as shown in figure, turn door trim (1) 90_ counterclockwise to remove it. And disconnect power window switch lead wire at coupler (if equipped).
Page 945 9-4 BODY SERVICE INSTALLATION NOTE: If there is deformity for glass run, replace new one. Reverse removal procedure to install door glass noting the follow- ing points: D Tighten glass attaching screws (1) to specified torque. Tighten rear screw first, then front screw. Tightening Torque: 6 N m (0.6 kg-m, 4.3 lb-ft) D When door window front glass (1) is installed, fit weatherstrip (2)
Page 946: Front Door Window Regulator
BODY SERVICE 9-5 D Install door window regulator handle (1) so that it has a 45° angle when glass is fully closed, as shown in figure. FRONT DOOR WINDOW REGULATOR REMOVAL 1) Remove door glass, referring to steps 1) to 9) of FRONT DOOR GLASS REMOVAL in this section.
Page 947: Door Mirror
9-6 BODY SERVICE DOOR MIRROR REMOVAL AND INSTALLATION When removing or installing door mirror, refer to figure shown below. D Tightening Order: (a) ! (b)
Page 948: Rear Door Glass
BODY SERVICE 9-7 REAR DOOR GLASS 1. Door glass 2. Window regulator: Apply SUZUKI SUPER GREASE A (99000-25010) to moving section. 3. Glass run 4. Door trim 5. Door sealing cover 6. Door sash 7. Window regulator handle 8. Door glass mounting screw...
Page 949 9-8 BODY SERVICE REMOVAL 1) Remove window regulator handle (1). For its removal, pull off snap by using a cloth (2) as shown in fig- ure. 2) Remove inside handle bezel (1). 3) Remove inside lock knob and door trim fitting screw. 4) Remove door trim (1).
Page 950: Rear Door Window Regulator
BODY SERVICE 9-9 7) Remove door sash mounting bolts (1). 8) Remove glass attaching screws (2). 9) Turn door glass (3) 90_. 10) Take out door glass (3). INSTALLATION NOTE: If there is deformity for glass run, replace new one. Reverse removal procedure to install door glass noting following points: D Tighten glass attaching screws (1) to specified torque.
Page 951 9-10 BODY SERVICE INSPECTION 1) Check regulator sliding and rotating parts for greasing. 2) Check rollers for wear and damage. 3) Check wire for damage. Window regulator lubrication point INSTALLATION Reverse removal procedure to install window regulator noting fol- lowing. D Tighten window regulator attaching nuts to proper tightening or- der.
Page 952 BODY SERVICE 9-11 WINDOW SHIELD The front windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For the Windshield replacement, it is important to use an adhesive which provides sufficient adhesion strength and follow the proper procedure.
Page 953 9-12 BODY SERVICE REMOVAL 1) Clean both inside and outside of glass and around it. 2) Remove wiper arms and garnish. 3) Using tape, cover body surface around glass to prevent any damage. 4) Remove rear view mirror, sunvisor, and front pillar trims (right & left).
Page 954 BODY SERVICE 9-13 10) Using knife (1), smoothen adhesive (2) remaining on body side (3) so that it is 1 to 2 mm thick all around. NOTE: Before using knife, clean it with alcohol or the like to re- move oil from it. 11) When reusing windshield, remove the adhesive (1) from it, us- ing care not to damage primer coated surface (2).
Page 955 9-14 BODY SERVICE 5) Install new molding (1) to glass (2). 6) Clean glass surface to be adhered to body with clean cloth. If cleaning solvent is used, let it dry for more than 10 minutes. Cleaning Area Distance from the edge of glass “a”: 30 –...
Page 956 BODY SERVICE 9-15 10) Apply adhesive referring to figure. NOTE: D Start from bottom side of glass (3). D Be careful not to damage primer. D Height of adhesive (2) applied to lower side should be higher than that of other three sides. Upper, right and left sides Width “d”: Approx.
Page 957: Quarter Window
9-16 BODY SERVICE 12) Check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again. NOTE: D Do not use high pressure water.
Page 958 BODY SERVICE 9-17 BACK DOOR GLASS REMOVAL AND INSTALLATION Refer to “WINDSHIELD” section as removal and installation proce- dures are basically the same. However, note the following. NOTE: Observe the following precautions when applying adhesive (4) along glass (2) edge. D Adhesive (4) should be applied evenly especially in height.
Page 959 9-18 BODY SERVICE BODY STRUCTURE FRONT AND REAR DOOR ASSEMBLY REAR DOOR FRONT DOOR 1. Door panel 2. Door hinge pin: APPLY GREASE (B0401137) to hinge pin 3. Door stopper pin: APPLY GREASE (BERULUB XP 719) to stopper pin 4. Door open stopper : Do not reuse FRONT DOOR ASSEMBLY REMOVAL...
Page 960 BODY SERVICE 9-19 INSTALLATION Reverse removal procedure to install door assembly, noting the fol- lowing points. NOTE: When replacing door, coat replacement door inside with wax for proper anticorrosion treatment. Refer to “UNDERCOATING/ANTI-CORROSION COMPOUND APPLICATION AREA” in “BODY REPAIR MANUAL”. D When door hinge pin (1) is installed to install door to body, turn Lower door hinge shown hinge pin cut section to vihecle forward.
Page 961: Rear Door Assembly
9-20 BODY SERVICE D Adjust door clearance as following procedure. Using special tool (B), (C) and adjust clearance between rear door and body at the beginning, refer to “PANEL CLEARANCE” in this section. Next, adjust clearance between front door and body, front door and rear door, refer to “PANEL CLEARANCE”...
Page 962 BODY SERVICE 9-21 BACK DOOR ASSEMBLY 1. Back door panel assembly 2. Back door window glass 3. Back door hinge: APPLY SUZUKI SUPER GREASE A (99000-25010) to door hinge moving section 4. Back door balancer unit 5. Back door trim REMOVAL 1) Remove back door trim (1).
Page 963 9-22 BODY SERVICE INSTALLATION Reverse removal procedure to install back door noting the following points. D Secure wiring harness. D Adjust door latch striker position by referring “BACK DOOR LOCK ASSEMBLY INSTALLATION” so that door is positioned correctly. D Adjust door cushion so that door contacts body when closed. D Adjust door clearance by loosening door hinge mounting bolts and nuts referring to “PANEL CLEARANCE”...
Page 964 BODY SERVICE 9-23 HOOD REMOVAL 1) Remove window washer hose (1) from hood (2). 2) Remove four mounting bolts (3) to detach hood (2). INSTALLATION Reverse removal procedure to install hood. ADJUSTMENT Hood position adjustment. Fore-and-aft and right-and-left adjustment. Adjust hood clearance by loosening hood mounting bolts, refer to “PANEL CLEARANCE”...
Page 965 9-24 BODY SERVICE FRONT FENDER REMOVAL 1) Remove front bumper. 2) Disconnect connector of side turn signal (or side marker) lamp. 3) Remove front fender lining (1). 4) Remove front fender (2). INSTALLATION Reverse removal procedure for installation. NOTE: If paint on fender bolt is peeled off, be sure to apply paint again. Adjust panel clearance referring to “PANEL CLEARANCE”...
Page 966 BODY SERVICE 9-25 FRONT BUMPER AND REAR BUMPER NOTE: Fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 967 9-26 BODY SERVICE INSTRUMENTATION AND DRIVER INFORMATION INSTRUMENT PANEL WARNING: See WARNING at the beginning of this section. REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to “Disabling Air Bag System” in Section 10B. 3) Remove steering column assembly (1).
Page 968 BODY SERVICE 9-27 6) Disconnect harness (1) and cables (2) from heater unit and air inlet box assembly. 7) Disconnect each connector (3) and cables which need to be disconnected for removal for instrument panel. 8) Remove air bag harness (4) in instrument panel. CAUTION: For vehicle with Air Bag, instrument panel could not be removed with Air Bag harness coupler connected.
Page 969 9-28 BODY SERVICE INSTALLATION 1) Install instrument panel by reversing removal procedure, noting the following items. D When installing each part, be careful not to catch any cable or wiring harness. D When installing brake pedal assembly (1), refer to Section 5A “BRAKE BOOSTER INSTALLATION”.
Page 970 BODY SERVICE 9-29 SEATS FRONT SEAT AND REAR SEAT 1. Seat cushion 6. Seat adjuster FRONT SEAT 2. Seat back 7. Tray bracket 3. Head rest 8. Tray 4. Cover 9. Seat adjuster bolt 5. Bracket 10. Reclining bolt 11. Bracket bolt REAR SEAT 1.
Page 971 9-30 BODY SERVICE SECURITY AND LOCKS FRONT DOOR LOCK ASSEMBLY 1. Door latch 2. Outside handle 3. Inside handle bezel 4. Latch striker 5. Cover 6. Key cylinder 7. Key cylinder retainer 8. Door lock screw 9. Door latch striker screw REMOVAL 1) Remove door trim and door sealing cover, refer to steps 1) to 9) of FRONT DOOR GLASS REMOVAL in this section.
Page 972 BODY SERVICE 9-31 INSTALLATION To install front door lock, reverse removal procedure, noting the fol- lowing. D Door latch striker. Move door latch striker (2) up or down so its center aligns with the center of groove “A” on the door lock assembly (1), as shown. NOTE: Striker should be moved vertically and placed level.
Page 973 9-32 BODY SERVICE REAR DOOR LOCK ASSEMBLY 1. Outside handle 2. Inside handle bezel 3. Door lock assembly 4. Latch striker 5. Door lock screw 6. Door latch striker screw REMOVAL 1) Remove door trim and door sealing cover, refer to steps 1) to 4) of REAR DOOR GLASS REMOVAL in this section.
Page 974 BODY SERVICE 9-33 BACK DOOR LOCK ASSEMBLY 1. Door lock assembly 2. Door opener 3. Latch striker 4. Door lock screw 5. Latch striker screw REMOVAL 1) Remove door trim. 2) Disconnect door lock control rod (1). Disconnect control rod (2). 3) Disconnect door lock motor lead wire if equipped.
Page 975: Key Coding
9-34 BODY SERVICE INSPECTION Check that door open and closes smoothly and properly. Also check that door latch half lock operates properly (Check that door latch half lock keeps door from opening all the way) and door latch full locks securely closed. Adjust door latch striker position if necessary.
Page 976 BODY SERVICE 9-35 SUNROOF SLIDING ROOF (IF EQUIPPED) 1. Sliding roof glass 2. Sliding roof cover 3. Sun shade 4. Roof deflector 5. Water gutter 6. Sliding roof trim 7. Sliding roof frame 8. Crank drive 9. Sliding roof handle 10.
Page 977 9-36 BODY SERVICE INSTALLATION Reverse removal procedure for installation, noting the following point. 1) Tighten glass fixing bolts (1) temporarily. 2) Position sliding roof glass by closing sliding roof glass complete- 3) Tighten glass fixing bolts (1). Tightening Torque: Sliding roof bolt 4 N m (0.4 kg-m, 3 lb-ft) ADJUSTMENT 1) Loosen sunroof glass fixing screws (at 4 locations) and move...
Page 978 BODY SERVICE 9-37 INSTALLATION Reverse removal procedure to install deflector. SUNSHADE REMOVAL 1) Remove sliding roof glass. Refer to “SLIDING ROOF GLASS” in this section. 2) Remove water gutter (1) as shown. 3) Close sun shade (3). 4) Detach front slider (1) and rear slider (2) by pushing arrow direc- tion as shown.
Page 979 9-38 BODY SERVICE CRANK DRIVE REMOVAL 1) Close sliding roof glass. 2) Remove sliding roof handle (1) and remove sliding roof handle garnish (2). 3) Loosen crank drive screws (3) and then remove crank drive (4). INSPECTION D Check that the crank drive operates smoothly. D Check crack and deformation for pinion gear (1) and drive lock pin (2).
Page 980 BODY SERVICE 9-39 SLIDING ROOF ASSEMBLY REMOVAL 1) Remove sliding roof glass. Refer to “SLIDING ROOF GLASS” in this section. 2) Remove head lining (1). Refer to “HEAD LINING” in this section. 3) Disconnect drain hose (1) connected to sliding roof assembly at 4 locations.
Page 981 9-40 BODY SERVICE DISASSEMBLY 1) Remove sunshade. Refer to “SUNSHADE” in this section. 2) Remove sliding roof deflector. Refer to “SLIDING ROOF DE- FLECTOR” in this section. 3) Remove crank drive. Refer to “CRANK DRIVE” in this section. 4) Pull-out side guide (1) and rear guide (2) with action cable from guide rail.
Page 982 BODY SERVICE 9-41 D Adjust both actuation cables as follows. 1) Push block guide assembly (1) forward until stopping (catch le- ver engages in front most recess (2) of guide rail). 2) Press front guide backward. 3) Push rear guide (6) connecting pins meet with adjusting notches (3) of side guide.
Page 983 9-42 BODY SERVICE EXTERIOR AND INTERIOR TRIM FLOOR CARPET 1. Floor carpet 2. Luggage floor carpet 3. Dash panel insulator REMOVAL 1) Remove front seats and rear seat cushions. 2) Remove seat belt lower anchor bolt. 3) Remove dash side trims, front side sill scuffs, center pillar inner lower trims and rear side sill scuffs.
Page 984 BODY SERVICE 9-43 HEAD LINING REMOVAL 1) Remove interior light (1). 2) Remove head lining clip (2). 3) Remove sun visor (3). 4) Mark mating marks (1) on roof handle (2) and roof garnish (3), if equipped sliding roof. 5) Remove roof handle (2) and roof garnish (3), if equipped sliding roof.
Page 985 9-44 BODY SERVICE INSTALLATION Reverse removal procedure for installation, noting the following items. D Attach adhesive tapes (1) to head lining (2) as shown figure. D Install interior trims in order of (a), (b), (c). D When install roof handle (1), match marks (2) on roof handle (1) and roof garnish (3).
Page 986 BODY SERVICE 9-45 ROOF RAIL (IF EQUIPPED) 1. Roof rail assembly 2. Front cap 3. Rear cap 4. Base seals 5. Nuts Removal 1) Remove roof rail front and rear caps as shown in figure. 2) Remove nuts. 3) Remove roof rail assembly. Installation Reverse removal procedure for installation.
Page 987 9-46 BODY SERVICE BACK DOOR EMBLEM DIMENSION Dimension Position Position 22.36 2.99 2.72 22.6 74.5 2.93 2.91 1.69...
Page 988 BODY SERVICE 9-47 PANEL CLEARANCE Dimension Dimension Position Position Position Position 4 – 6 0.16 – 0.24 5 – 7 0.2 – 0.28 5 – 7 0.2 – 0.28 6 – 8 0.24 – 0.31 5 – 7 0.2 – 0.28 5 –...
Page 989 9-48 BODY SERVICE REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCTS SUZUKI SUPER GREASE A Lithium grease D Window regulator (99000-25010) Carl Bechem GmbH Grease D Door hinge B0401137 Carl Bechem GmbH Grease D Door open stopper BERULUB XP 719 Thread Lock Cement Super “1333B”...
Page 990 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system compo- nents or wiring.
Page 991 10-2 RESTRAINT SYSTEM 1. Front seat belts 2. Rear seat belts 3. Driver side air bag (inflator) module 4. Passenger air bag (inflator) module (if equipped) D Seat belt with ELR The seat belt with emergency locking retractor (ELR) is designed so that it locks immediately (to prevent the webbing from being pulled out of the retractor any further) when any of the following items is detected as exceed- ing each set value;...
Page 992 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system compo- nents or wiring.
Page 993 10A-2 SEAT BELT GENERAL DESCRIPTION Front seat belt SEAT BELT Refer to SECTION 10. SEAT BELT PRETENSIONER Seat belts of the driver and front passenger seats are provided with a pretensioner as an optional function unit. The pretensioner is in- corporated in retractor assembly and controlled by SDM as one of air bag system components.
Page 994 If these parts are replaced individually, such a locking condition may become unreliable. For this rea- son, SUZUKI will supply only the spare buckle and ELR (or webbing) in a set part. Before servicing or replacing seat belts, read the following precautionary items and observe them.
Page 995 10A-4 SEAT BELT FRONT SEAT BELT WITH PRETENSIONER Tightening torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) (b): 5.5 N m (0.55 kg-m, 4.0 lb-ft) WARNING: D Never attempt to disassemble or repair the seat belt pre- tensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly.
Page 996 SEAT BELT 10A-5 INSPECTION WARNING: Never measure resistance of pretensioner or disassemble it. Otherwise, personal injury may result. CAUTION: If seat belt pretensioner (retractor assembly) was dropped from a height of 30 cm (1 ft) or more, it should be replaced. Seat belts and attaching parts can affect the vital components and systems of a vehicle.
Page 997 10A-6 SEAT BELT REAR SEAT BELT WARNING: Be sure to read “Service Precautions” earlier in this section before starting to work and observe every precaution dur- ing work. REMOVAL 1) Remove rear seat (1) referring to “BODY SERVICE” section. 2) Refer to the left figure to remove rear seat belt (2). INSPECTION Check rear seat belt for the same items as front seat belt inspection other than related to pretensioner.
Page 998 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system compo- nents or wiring.
Page 999 10B-2 AIR BAG SYSTEM DTC 43 - Driver pretensioner initiator ON-VEHICLE SERVICE ....10B-44 circuit short to ground ....10B-34 Service Precautions .
Page 1000 AIR BAG SYSTEM 10B-3 GENERAL DESCRIPTION With the air bag system which includes air bags for both the driver’s and passenger’s (if equipped) sides as well as the seat belt preten- sioners, the sag of the seat belt is taken up, the driver air bag (infla- tor) module is deployed from the center of the steering column and the passenger air bag (inflator) module from the top of the instru- ment panel in front of the front passenger seat in occurrence of a...
Page 1001 10B-4 AIR BAG SYSTEM SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS Q01 CONNECTOR Q03 CONNECTOR Q02 CONNECTOR Q04 CONNECTOR Q06 CONNECTOR CONNECTOR CONNECTOR (DRIVER SIDE) (PASSENGER SIDE) 1. Air bag harness 6. Contact coil assembly 2. SDM 7. Driver air bag (inflator) module 3.
Page 1002 AIR BAG SYSTEM 10B-5 SYSTEM WIRING DIAGRAM : Shorting bar : Air bag harness Q01 X Q07: Connector number TERMINAL ARRANGEMENT OF SDM (VIEWED FROM HARNESS SIDE) 1. From main fuse 2. Ignition switch 3. “AIR BAG” warning lamp in combination meter CONNECTOR “Q06”...
Page 1003 You should be familiar with the tools listed in this section under the heading “Special Tools”. You should be able to measure voltage and resistance. You should be familiar with proper use of SUZUKI scan tool, Air Bag Driver/Pas- senger Load Tool, Connector Test Adapter Kit and the Digital Multimeter.
Page 1004 AIR BAG SYSTEM 10B-7 An SDM short bar release tool is included in the connector test adapter kit. Inserting it into the SDM connector will release the shorting bar. Special Tool (Air Bag Driver/Passenger Load Tool) (B): 09932-75010 This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag (in- flator) module deployment and seat belt pretensioner activation.
Page 1005 10B-8 AIR BAG SYSTEM INTERMITTENTS AND POOR CONNECTIONS Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diag- nostic flow table, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 1006 AIR BAG SYSTEM 10B-9 AIR BAG DIAGNOSTIC SYSTEM CHECK WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment other than that specified in this manual.
Page 1007 Go to step 6. after flashing 6 times? 1) Check DTC. Refer to DTC CHECK. Air bag system is in good An intermittent trouble has 2) Not using SUZUKI scan tool: condition. occurred at some place. Is DTC 12 indicated? Check the connector Using SUZUKI scan tool: harness, etc.
Page 1008 DIAGNOSTIC TROUBLE CODE (DTC) CHECK [Using SUZUKI scan tool] 1) Turn ignition switch OFF. 2) After setting cartridge to SUZUKI scan tool, connect it to data link connector (DLC) located on underside of instrument panel at driver’s seat side. Special Tool...
Page 1009 DTCs before servicing. [Using SUZUKI scan tool] 1) Turn ignition switch OFF. 2) Connect SUZUKI scan tool to data link connector (DLC) in the same manner as when making this connection for DTC check. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 1010 EXAMPLE: WHEN DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (CODE NO.21) IS SET Turn ON Turn OFF (indicated by (displayed on Air bag warning lamp air bag DIAGNOSIS SUZUKI flashing pattern warning scan tool) lamp) NO DTC Normal B1015 Resistance high...
Page 1011 For grounding diagnosis switch terminal to check DTC, refer to “DIAGNOSIS TROUBLE CODE (DTC) CHECK – [Not using SUZUKI scan tool]” in this section. AIR BAG WARNING LAMP...
Page 1012 AIR BAG SYSTEM 10B-15 TABLE A – AIR BAG WARNING LAMP COMES ON STEADY WITHOUT FLASHING TABLE B – AIR BAG WARNING LAMP DOES NOT COME ON WITH IGNITION SWITCH ON TABLE C – AIR BAG WARNING LAMP FLASHES EVEN AFTER INITIAL 6-TIME FLASHING TABLE D –...
Page 1013 10B-16 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE Table A: AIR BAG WARNING LAMP COMES ON STEADY WITHOUT FLASHING STEP ACTION 1) Check connections at Q03 and Q06 Go to step 2. Reconnect and secure connectors with ignition switch OFF. them with lock levers. Are they properly connected and secured by lock levers of couplers? 1) Ignition switch OFF.
Page 1014 AIR BAG SYSTEM 10B-17 Table B: AIR BAG WARNING LAMP DOES NOT COME ON WITH IGNITION SWITCH ON STEP ACTION 1) Set parking brake. Go to step 2. “B/W” wire (between 2) Note combination meter when ignition ignition switch and switch is turned ON.
Page 1015 10B-18 AIR BAG SYSTEM Table C: AIR BAG WARNING LAMP FLASHES EVEN AFTER INITIAL 6-TIME FLASHING STEP ACTION 1) Check air bag monitor coupler. Go to step 2. Remove service wire. Is diagnosis switch terminal in air bag monitor coupler grounded by service wire? 1) With ignition switch OFF, disconnect Repair short from “V”...
Page 1016 AIR BAG SYSTEM 10B-19 Table D: AIR BAG WARNING LAMP CANNOT INDICATE FLASHING PATTERN OF DTC EVEN WITH DIAGNOSIS SWITCH TERMINAL GROUNDED STEP ACTION 1) Inspect service wire between diagnostic Go to step 2. Properly connect and switch terminal on air bag monitor ground diagnostic switch coupler and body ground.
Page 1017 10B-20 AIR BAG SYSTEM TABLE E: SCAN TOOL CANNOT COMMUNICATE WITH SDM STEP ACTION 1) Make sure that SUZUKI scan tool is free Go to step 2. Properly connect SUZUKI from malfunction and correct cartridge scan tool to DLC. for air bag system is used.
Page 1018 AIR BAG SYSTEM 10B-21 DTC 15 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH DTC 16 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW DTC 18 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND DTC 19 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT Q06-31 1.
Page 1019 10B-22 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC 15: PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH STEP ACTION Was item “AIR BAG SYSTEM CHECK Go to step 2. Perform “AIR BAG FLOW TABLE” described in this section SYSTEM CHECK FLOW performed? TABLE”...
Page 1020 AIR BAG SYSTEM 10B-23 DTC 16: PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW STEP ACTION Was item “AIR BAG SYSTEM CHECK Go to step 2. Perform “AIR BAG FLOW TABLE” described in this section SYSTEM CHECK FLOW performed? TABLE” in this section. 1) With ignition switch OFF, disconnect Go to step 3.

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