Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Page 5: Table Of Contents
TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Transmission / Transaxle .......... 5-i General Information ..........0A-1 Precautions .............. 5-1 Maintenance and Lubrication ......... 0B-1 Automatic Transmission/Transaxle ......5A-1 Manual Transmission/Transaxle ......5B-1 Engine .................
Page 7: Precautions
Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions for Electrical Circuit Service .... 00-9 Precautions for Installing Mobile Precautions............00-1 Communication Equipment ......00-11 Precautions for Vehicles Equipped with a Air Bag Warning ..........00-11 Supplemental Restraint (Air Bag) System ..00-1 Discharge Headlight Warning ......
Page 8: Precautions
• If the air bag system and another vehicle 3. Contact coil assembly 11. Side-sensor (if equipped) system both need repair, SUZUKI 4. Air bag harness in main harness 12. Seat belt pretensioner recommends that the air bag system be 5.
Page 9 Precautions: 00-2 Diagnosis Servicing and Handling • When troubleshooting air bag system, be sure to WARNING follow “Air Bag Diagnostic System Check in Section 8B”. Bypassing these procedures may result in Many of service procedures require extended diagnostic time, incorrect diagnosis, and disconnection of “A/B”...
Page 10 00-3 Precautions: • Never dispose of live (undeployed) air bag WARNING (inflator) modules (driver, passenger, side Driver and Passenger Seat Belt and curtain). If disposal is necessary, be Pretensioners sure to deploy them according to deployment procedures described in “Air •...
Page 11: General Precautions
Precautions: 00-4 General Precautions CAUTION S6JB0A0000002 The WARNING and CAUTION describe some general • Even when the accident was light enough precautions that you should observe when servicing a not to cause air bags to activate, be sure to vehicle. These general precautions apply to many of the inspect system parts and other related service procedures, and they will not necessarily be parts according to instructions under...
Page 12 00-5 Precautions: – For vehicle equipped with power sliding CAUTION roof (sunroof), initialize sliding roof • Before starting any service work, cover position data in motor unit by fenders, seats and any other parts that are performing “How to reactivate the likely to get scratched or stained during system to prevent being pinched by the servicing.
Page 13 • When use of a certain type of lubricant, bond or sealant is specified, be sure to remove the old one thoroughly and use the specified type. “A”: Sealant 99000–31150 (SUZUKI Bond No.1207C) I2RH01010033-01 • When servicing fuel system, be sure to observe WARNING in “Precautions on Fuel...
Page 14: Precaution In Servicing Full-Time 4Wd Vehicle
00-7 Precautions: Precaution in Servicing Full-Time 4WD Vehicle • Use care not to expose connectors and electrical parts to water which will be a S6JB0A0000003 WARNING cause of a trouble. This full-time 4WD vehicle can not be converted to 2WD manually. Observe the following caution in servicing.
Page 15 Precautions: 00-8 • When testing with 2-wheel brake tester, be • When testing with 4-wheel free chassis sure to observe the following instructions. dynamometer or speedometer tester Otherwise, drive train damage and (which tester roller is driven by vehicle personal injury may result. wheels), be sure to shift transfer to 4H- Lock position according to the step 4) in –...
Page 16: Precaution For Vehicle Equipped With Esp® System
00-9 Precautions: Precaution for Vehicle Equipped with ESP® Precaution for CAN Communication System S6JB0A0000006 System • The loose (1) in the wire harnesses twist of the CAN S6JB0A0000004 lines except around the connector (3) should be within • When testing with any of the following equipments 100 mm (3.9 in.).
Page 17 Precautions: 00-10 • When disconnecting and connecting coupler, make • When installing vehicle parts, be careful so that the sure to turn ignition switch OFF, or electronic parts wiring harness is not interfered with or caught by any may get damaged. other part.
Page 18: Precautions For Installing Mobile Communication Equipment
Restraint (Air Bag) System: • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components, Wiring and Connectors Location in Section 8B” in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 19: A/C System Caution
Precautions: 00-12 A/C System Caution Suspension Caution S6JB0A0000011 S6JB0A0000013 CAUTION CAUTION The air conditioning system of this vehicle • All suspension fasteners are an important uses refrigerant HFC-134a (R-134a). attaching part in that it could affect the None of refrigerant, compressor oil and performance of vital parts and systems, component parts is interchangeable between and/or could result in major repair...
Page 20: Brakes Caution And Note
00-13 Precautions: Brakes Caution and Note NOTE S6JB0A0000015 Before inspecting and servicing brakes for CAUTION vehicle equipped with ABS (ESP®), make All brake fasteners are important attaching sure that ABS (ESP®) is in good condition. parts in that they could affect the performance of vital parts and systems, and/ Differential Gear Oil Note or could result in major repair expense.
Page 21 Precautions: 00-14 Continuity Check Voltage Check If voltage is supplied to the circuit being checked, voltage 1) Measure resistance between connector terminals at check can be used as circuit check. both ends of the circuit being checked (between “A- 1” and “C-1” in the figure). If no continuity is indicated 1) With all connectors connected and voltage applied to (infinity or over limit), that means that the circuit is the circuit being checked, measure voltage between...
Page 22 00-15 Precautions: Short Circuit Check (Wire Harness to Ground) 4) Disconnect the connector included in circuit (connector B) and measure resistance between “A- 1) Disconnect negative cable at battery. 1” and body ground. 2) Disconnect connectors at both ends of the circuit to If continuity is indicated, it means that the circuit is be checked.
Page 23: Intermittent And Poor Connection Inspection
Precautions: 00-16 Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S6JB0A0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.
Page 24 00-17 Precautions:...
Page 25: General Information
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Air Cleaner Filter Replacement ......0B-10 Fuel Lines and Connections Inspection ....0B-10 General Description ..........0A-1 Fuel Filter Replacement (Petrol Engine Abbreviations ............0A-1 Model) .............0B-11 Symbols .............. 0A-2 Fuel Filter Replacement (Diesel Engine Wire Color Symbols ..........
Page 26 0-ii Table of Contents Recommended Fluids and Lubricants (Diesel Special Tool (Petrol Engine Model)....0B-20 Engine Model) ..........0B-20...
Page 27: General Information
General Information: 0A-1 General Information General Information General Description Abbreviations S6JB0A0101001 EBCM: Electronic Brake Control Module, ABS Control Module ABDC: After Bottom Dead Center EBD: Electronic Brake Force Distribution ABS: Anti-lock Brake System ECM: Engine Control Module AC: Alternating Current ECT Sensor: Engine Coolant Temperature Sensor A/C: Air Conditioning (Water Temp.
Page 28: Symbols
Max: Maximum Apply fluid MFI: Multiport Fuel Injection (Multipoint Fuel Injection) (brake, power steering, automatic fluid) MIL: Malfunction Indicator Lamp (“SERVICE ENGINE Apply SUZUKI SUPER GREASE A SOON” Light) 99000-25011 Min: Minimum Apply SUZUKI SUPER GREASE C M/T: Manual Transmission...
Page 29: Wire Color Symbols
General Information: 0A-3 Wire Color Symbols There are two kinds of colored wire used in this vehicle. S6JB0A0101003 One is single-colored wire and the other is dual-colored Symbol Wire Color (striped) wire. As the color symbol, the single-colored Black wire uses only one, three or five alphabets (i.e. “G” or Blue “GRN”);...
Page 30 0A-4 General Information: Fastener Strength Identification Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark strength identification on the nut face.
Page 31: General Information
General Information: 0A-5 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 32: Vehicle Lifting Points
0A-6 General Information: Vehicle Lifting Points S6JB0A0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending of what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 33 General Information: 0A-7 When using floor jack To perform service with either front or rear vehicle end jacked up, be sure to place safety stands (1) under WARNING chassis frame so that body is securely supported. And then check to ensure that chassis frame does not •...
Page 34: Engine Supporting Points
0A-8 General Information: Engine Supporting Points Vehicle Identification Number S6JB0A0101006 S6JB0A0101007 The vehicle identification number is punched on the front WARNING dash panel in engine room and it is also attached on the When using engine supporting device (1), be left front top of instrument panel depending on vehicle sure to observe the followings.
Page 35: Engine Identification Number
General Information: 0A-9 Engine Identification Number Transmission Identification Number S6JB0A0101008 S6JB0A0101009 The number is punched on the cylinder block. The number is located on the transmission case. I6JB0A010001-01 [A]: Petrol engine model I6JB0A010002-01 [B]: Diesel engine model [A]: M/T (Petrol engine model) [B]: 4A/T [C]: M/T (Diesel engine model)
Page 36: Component Location
0A-10 General Information: Component Location Warning, Caution and Information Label Location S6JB0A0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
Page 37 General Information: 0A-11 I5JB0A010009-03 1. Air bag label on driver air bag (inflator) module 4. Air bag label on passenger air bag (inflator) module 7. Air bag label on side air bag module 2. Air bag label on contact coil assembly 5.
Page 38: Maintenance And Lubrication
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S6JB0A0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions (Petrol Engine Model) S6JB0A0205001 NOTE •...
Page 39 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Chassis and body Clutch (fluid leakage, level) (I: — — — Tires (wear, damage, rotation) / wheels (damage) (I: Suspension system (tightness, damage, rattle, breakage) (I: — — —...
Page 40: Maintenance Schedule Under Normal Driving Conditions (Diesel Engine Model)
0B-3 Maintenance and Lubrication: Maintenance Schedule under Normal Driving Conditions (Diesel Engine Model) S6JB0A0205003 NOTE • This interval should be judged by odometer reading or months, whichever comes first. • This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively.
Page 41: Maintenance Recommended Under Severe Driving Conditions (Petrol Engine Model)
Maintenance and Lubrication: 0B-4 Maintenance Recommended under Severe Driving Conditions (Petrol Engine Model) S6JB0A0205002 If the vehicle is usually used under the conditions corresponding to any severe condition code, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table. Severe condition code: A: Repeated short trips B: Driving on rough and/or muddy roads...
Page 42: Maintenance Recommended Under Severe Driving Conditions (Diesel Engine Model)
0B-5 Maintenance and Lubrication: Maintenance Recommended under Severe Driving Conditions (Diesel Engine Model) S6JB0A0205004 If the vehicle is usually used under the conditions corresponding to any severe condition code, IT IS RECOMMENDED that applicable maintenance operation be performed at the particular interval as shown in the following table. Severe condition code: A: Repeated short trips B: Driving on rough and/or muddy roads...
Page 43: Repair Instructions
Maintenance and Lubrication: 0B-6 Repair Instructions Engine Accessory Drive Belt Inspection (Petrol Power Steering Pump and A/C Compressor (If Equipped) Drive Belt (M16 Engine) Engine Model) Inspect belt for cracks, cuts, deformation, wear S6JB0A0206001 WARNING cleanliness and tension. If any defect exists, adjust or replace.
Page 44: Camshaft Timing Belt And Tensioner Replacement
0B-7 Maintenance and Lubrication: Camshaft Timing Belt and Tensioner Engine Oil and Filter Change (Petrol Engine Replacement Model) S6JB0A0206042 S6JB0A0206004 Replace camshaft timing belt (1) and tensioner (2) with WARNING new ones referring to “Timing Belt and Belt Tensioner Removal and Installation: For F9Q Engine in Section •...
Page 45 Maintenance and Lubrication: 0B-8 4) Apply engine oil to new oil filter O-ring. Engine oil specifications (M16 Engine) Oil pan capacity: About 4.0 liters (8.4 US pt. / 7.0 lmp pt.) Oil filter capacity: About 0.2 liters (0.4 US pt. / 0.3 lmp pt.) Others: About 0.3 liters (0.6 US pt.
Page 46: Engine Oil And Filter Change (Diesel Engine Model)
0B-9 Maintenance and Lubrication: Engine Oil and Filter Change (Diesel Engine 3) Loosen oil filter by using oil filter wrench (special tool) accessing from between engine mounting and Model) radiator outlet hose and from below vehicle. S6JB0A0206043 WARNING Special tool (A): 09915–46510 •...
Page 47: Engine Coolant Change
Maintenance and Lubrication: 0B-10 Engine Coolant Change 7) Replenish oil until oil level is brought to FULL level mark on dipstick. S6JB0A0206005 WARNING Engine oil specifications : About 5.1 liters (9.0 lmp pt.) To help avoid danger of being burned, do not remove radiator cap while engine and The filler inlet is at the top of the cylinder head cover.
Page 48: Fuel Filter Replacement (Petrol Engine Model)
0B-11 Maintenance and Lubrication: Fuel Filter Replacement (Petrol Engine Model) S6JB0A0206011 WARNING This work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter is installed in fuel pump assembly in fuel tank. Replace fuel filter or fuel pump assembly with new one, referring to “Fuel Pump Assembly Removal and Installation: For Petrol Engine Model in Section 1G”.
Page 49: Brake Hoses And Pipes Inspection
Maintenance and Lubrication: 0B-12 Brake Hoses and Pipes Inspection 2) Check tooth tip of each notch for damage or wear. If S6JB0A0206018 any damage or wear is found, replace parking lever. Perform this inspection where there is enough light and 3) Check parking brake lever for proper operation and use a mirror as necessary.
Page 50: Tire / Wheel Inspection And Rotation
0B-13 Maintenance and Lubrication: Tire / Wheel Inspection and Rotation Wheel Bearing Inspection S6JB0A0206022 S6JB0A0206024 1) Check tires for uneven or excessive wear, or 1) Check front wheel bearing for wear, damage, damage. abnormal noise or rattles. If defective, replace. Refer to “Irregular and/or For details, refer to “Front Wheel Hub, Disc, Nut and Premature Wear Description in Section 2D”...
Page 51: Steering System Inspection
Maintenance and Lubrication: 0B-14 Rear 2) Check universal joints of steering shaft for rattle and damage. If rattle or damage is found, replace • - Check shock absorber for damage, deformation, oil defective part with a new one. leakage and operation. 3) Check steering linkage for looseness and damage.
Page 52: Propeller Shafts And Drive Shafts Inspection
0B-15 Maintenance and Lubrication: Propeller Shafts and Drive Shafts Inspection Manual Transmission Oil Inspection S6JB0A0206027 S6JB0A0206028 Propeller Shafts Inspection 1) Inspect transmission case for evidence of oil 1) Check universal joint and spline of propeller shaft for leakage. Repair leaky point if any. rattle.
Page 53: Manual Transmission Oil Change
Maintenance and Lubrication: 0B-16 Manual Transmission Oil Change Transfer Oil Inspection (If Equipped) S6JB0A0206029 S6JB0A0206033 Change transmission oil with new specified oil referring 1) Check transfer case for evidence of oil leakage. to “Manual Transmission Oil Change: For Petrol Engine Repair leaky point if any.
Page 54: Transfer (If Equipped) And Differential Oil Change
0B-17 Maintenance and Lubrication: Transfer (If Equipped) and Differential Oil 2) Check fluid level with engine stopped. If it is lower than LOWER level line, fill fluid up to UPPER level Change line. S6JB0A0206035 Change transfer oil and differential oil (front and rear) with new specified oil respectively.
Page 55: All Hinges, Latches And Locks Inspection
Maintenance and Lubrication: 0B-18 All Hinges, Latches and Locks Inspection Final Inspection for Maintenance Service S6JB0A0206037 S6JB0A0206040 Doors WARNING Check that each door of front, rear and back (rear end) When carrying out road tests, select a safe doors opens and closes smoothly and locks securely place where no man or no running vehicle is when closed.
Page 56: Specifications
0B-19 Maintenance and Lubrication: Clutch (for Manual Transmission) Parking brake Check for the following. Check that lever has proper travel. • Clutch is completely released when depressing clutch WARNING pedal, With vehicle parked on a fairly steep slope, • No slipping clutch occurs when releasing pedal and make sure nothing is in the way downhill to accelerating.
Page 57: Special Tools And Equipment
Maintenance and Lubrication: 0B-20 Special Tools and Equipment Recommended Fluids and Lubricants (Petrol Engine Model) S6JB0A0208001 Fluids / Lubricants List Engine oil Refer to “Engine Oil and Filter Change (Petrol Engine Model)”. Engine coolant “Antifreeze / Anticorrosion coolant” (Ethylene glycol base coolant) Brake fluid Refer to reservoir cap of brake master cylinder.
Page 58 0B-21 Maintenance and Lubrication:...
Page 59: Engine
Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC Clearance ..........1A-32 DTC Table............1A-33 Precautions............. 1-1 Fail-Safe Table..........1A-39 Precautions for Engine (Petrol Engine Model) ..1-1 Scan Tool Data ..........1A-41 Precautions for Engine (Diesel Engine Model) ..1-1 Visual Inspection ..........1A-47 Engine General Information and Engine Basic Inspection........1A-48...
Page 60 1-ii Table of Contents DTC P0122: Throttle Position Sensor (Main) DTC P0620: Generator Control Circuit ...1A-167 Circuit Low ............ 1A-104 DTC P0625 / P0626: Generator Field DTC P0123: Throttle Position Sensor (Main) Terminal Circuit Low / High ......1A-169 Circuit High ........... 1A-107 DTC P0660: Intake Manifold Tuning Valve DTC P0131 / P0132 / P0134: O2 Sensor Control Circuit / Open (For J20 Engine)..1A-171...
Page 61 Table of Contents 1-iii Precautions............1A-266 DTC P0480: Radiator Fan Low Control Circuit 1A-320 Precautions on Engine Service ....... 1A-266 DTC P0481: Radiator Fan High Control Precautions in Diagnosing Trouble ....1A-266 Circuit ............1A-321 DTC P0486: EGR Stroke Sensor Circuit..1A-322 General Description .........1A-267 DTC P0500: VSS Malfunction......1A-323 Statement on Cleanliness and Care ....
Page 62 1-iv Table of Contents Table 2: The Engine Does Not Start ....1A-359 For Petrol Engine Model .........1C-1 Table 3: The Engine Starts with Difficulty ..1A-360 Repair Instructions ..........1C-1 Table 4: Injection Noise........1A-361 Engine Control Module (ECM) Removal and Table 5: Poor Performance with Smoke ..
Page 63 Table of Contents 1-v Registration Procedure for the Fuel Injector Air Cleaner Filter Removal and Installation..1D-9 Calibration Code ..........1C-23 Air Cleaner Filter Inspection and Cleaning..1D-9 EGR Valve Data Initialization ......1C-23 Cylinder Head Cover Removal and Inlet Throttle Valve Data Initialization....1C-24 Installation ............1D-9 Diesel Particulate Filter Data Initialization..1C-24 Throttle Body and Intake Manifold...
Page 64 1-vi Table of Contents Special Tool ............1D-63 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly ..1D-110 For J20 Engine ............1D-65 Pistons, Piston Rings, Connecting Rods and General Description ...........1D-65 Cylinders Inspection and Cleaning....1D-112 Engine Construction Description.......1D-65 Main Bearings, Crankshaft and Cylinder Air Cleaner Element Introduction ......1D-67 Block Components ........1D-119 IMT (Intake Manifold Tuning) System...
Page 65 Table of Contents 1-vii Valve and Cylinder Head Assembly Oil Pan and Oil Pump Strainer Components..1E-14 Components..........1D-171 Oil Pan and Oil Pump Strainer Removal and Valve and Cylinder Head Assembly Removal Installation ............1E-15 and Installation ..........1D-172 Oil Pan and Oil Pump Strainer Cleaning...1E-16 Valve and Cylinder Head Assembly Oil Pump Components ........1E-17 Inspection............1D-174...
Page 66 1-viii Table of Contents Radiator Cooling Fan Motor On-Vehicle Schematic and Routing Diagram ....... 1G-2 Inspection............1F-10 Fuel Delivery System Diagram......1G-2 Radiator Cooling Fan Relay Inspection..... 1F-10 Diagnostic Information and Procedures ... 1G-3 Radiator Cooling Fan Assembly Removal and Fuel Pressure Inspection ........
Page 67 Table of Contents 1-ix Injection Pump Components ......1G-40 Starting System .........1I-1 Injection Pump Removal and Installation ..1G-41 For Petrol Engine Model .......... 1I-1 Fuel Flow Actuator Inspection (Type 2) ....1G-44 Precautions............1I-1 Fuel Flow Actuator Removal and Installation Cranking System Note ......... 1I-1 (Type 2)............1G-44 General Description ..........
Page 68 1-x Table of Contents Generator Dismounting and Remounting..1J-11 Special Tool ............1J-30 Generator Components........1J-12 Exhaust System........1K-1 Generator Inspection......... 1J-13 For Petrol Engine Model .........1K-1 Specifications............. 1J-16 Charging System Specifications ....... 1J-16 General Description ..........1K-1 Tightening Torque Specifications...... 1J-16 Exhaust System Description .......1K-1 For Diesel Engine Model ........
Page 69: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine (Petrol Engine Model) Precaution in Replacing ECM S6JB0A1000001 Refer to “Precaution in Replacing ECM: For Petrol Air Bag Warning Engine Model in Section 10C”. Refer to “Air Bag Warning in Section 00”. Precautions for Engine (Diesel Engine Model) Precautions on Engine Service S6JB0A1000002 Refer to “Precautions on Engine Service: For Petrol...
Page 70: Engine General Information And Diagnosis
• Diagnostic information stored in ECM memory can be • When raising or supporting engine for any reason, do cleared as well as checked by using SUZUKI scan not use a jack under oil pan. Due to small clearance tool or OBD generic scan tool (Euro OBD model).
Page 71: Precautions For Dtc Troubleshooting
Engine General Information and Diagnosis: For Petrol Engine Model 1A-2 Precautions of ECM Circuit Inspection • Be sure to read “Precautions for Electrical Circuit S6JB0A1110004 Service in Section 00” before inspection and observe • ECM connectors are waterproofed. Each terminal of what is written there.
Page 72: General Description
1A-3 Engine General Information and Diagnosis: For Petrol Engine Model General Description Statement on Cleanliness and Care S6JB0A1111001 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).
Page 73: On-Board Diagnostic System Description
• It is possible to communicate by using not only ECM diagnosis troubles which may occur in the area SUZUKI scan tool (2) but also OBD generic scan tool. including the following parts when the ignition switch is (Diagnostic information can be accessed by using a ON and the engine is running, and indicates the result by scan tool.)
Page 74 In addition, for vehicle equipped with diagnosis connector, DTC can be read by not only using SUZUKI scan tool but also displayed on odometer (5) of the combination meter. (i.e. when diagnosis switch terminal (3) is grounded with a service wire (4) and ignition switch is turned ON.) For further detail of the...
Page 75 Engine General Information and Diagnosis: For Petrol Engine Model 1A-6 Freeze Frame Data (Euro OBD Model) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”.
Page 76: Engine And Emission Control System Description
OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module (in ECM), BCM (Body electrical Control...
Page 77 Engine General Information and Diagnosis: For Petrol Engine Model 1A-8 CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple control modules can communicate simultaneously.
Page 78 1A-9 Engine General Information and Diagnosis: For Petrol Engine Model ECM Reception Data ABS control module control module Receives data of ECM assmbly (Non-ESP (for A/T model) (ESP model) model) Torque reduction request Slip control signal Transmission malfunction indication on Transmission emissions related malfunction active Transmission gear selector...
Page 79: Air Intake System Description
Engine General Information and Diagnosis: For Petrol Engine Model 1A-10 Air Intake System Description S6JB0A1111006 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Electric Throttle Body System Description: For Petrol Engine Model”.), intake manifold tuning (IMT) valve (4) which adjusts the distributor pipe length of intake manifold to (A) or (B) (for J20 engine) (for the details, refer to “IMT (Intake Manifold Tuning) System Description: For J20 Engine in Section 1D”.) and intake manifold (5).
Page 80: Electric Throttle Body System Description
1A-11 Engine General Information and Diagnosis: For Petrol Engine Model Electric Throttle Body System Description S6JB0A1111007 The Electric Throttle Body System consists of electric throttle body assembly, accelerator pedal position (APP) sensor assembly, ECM and throttle actuator control relay. Among them, assembly components are as follows. •...
Page 81: Description Of Electric Throttle Body System Calibration
Engine General Information and Diagnosis: For Petrol Engine Model 1A-12 Description of Electric Throttle Body System Calibration S6JB0A1111008 ECM calculates controlled opening of the throttle valve on the basis of the completely closed throttle valve position of the electric throttle body system. The completely closed position data is saved in memory of ECM. However, the completely closed position of the throttle valve of the electric throttle body system (signal voltage from throttle position sensor when throttle is completely closed) differs one from the other depending on individual differences of the throttle valve and throttle position sensor.
Page 82: A/F Sensor Description
1A-13 Engine General Information and Diagnosis: For Petrol Engine Model I5JB0A110009-01 6. Ignition switch 8. Battery A/F Sensor Description S6JB0A1111010 A/F sensor (1), in place of the conventional heated Oxygen sensor-1, is installed in the center of the exhaust manifold joining section and it consists of a zirconia element (2) which causes the output current to vary according to difference in the oxygen concentration, a heater (3) which activates the element and an adjusting resistor (4) which adjusts individual difference of the sensor (J20A engine).
Page 83: Electronic Control System Description
Engine General Information and Diagnosis: For Petrol Engine Model 1A-14 AFS- AFS+ AFH+ AFH- AFRV AFRG I6JB0A111001-06 [A]: J20A engine 12. CPU 15. 0.4 V 10. Electrode 13. Lean 11. A/F signal processing circuit 14. Rich Electronic Control System Description S6JB0A1111011 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 84: Engine And Emission Control Input / Output Table
1A-15 Engine General Information and Diagnosis: For Petrol Engine Model Engine and Emission Control Input / Output Table S6JB0A1111012 ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C) BLOWER SWITCH A/C SWITCH (if equipped with A/C)
Page 85: Schematic And Routing Diagram
Engine General Information and Diagnosis: For Petrol Engine Model 1A-16 Schematic and Routing Diagram Engine and Emission Control System Diagram S6JB0A1112001 I5JB0A110015-04...
Page 86 1A-17 Engine General Information and Diagnosis: For Petrol Engine Model 1. Air cleaner 18. Radiator cooling fan motor 35. Immobilizer coil antenna (if equipped) 2. EVAP canister purge valve 19. Combination meter 36. Main relay 3. MAF and IAT sensor 20.
Page 87: Engine And Emission Control System Flow Diagram
Engine General Information and Diagnosis: For Petrol Engine Model 1A-18 Engine and Emission Control System Flow Diagram S6JB0A1112002 I6JB0A111002-01...
Page 88: Ecm Input / Output Circuit Diagram
1A-19 Engine General Information and Diagnosis: For Petrol Engine Model ECM Input / Output Circuit Diagram S6JB0A1112003 For J20A Engine BLU/BLK BLU/ORN E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 BLU/RED C37-44 BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41...
Page 89 Engine General Information and Diagnosis: For Petrol Engine Model 1A-20 3. CMP sensor 29. DLC 55. Ignition coil assembly (for No.2 spark plug) 30. To TCM (A/T model), BCM, ABS / ESP® control 56. Ignition coil assembly (for No.3 spark plug) CKP sensor module and 4WD control module (4WD model) 5.
Page 90 1A-21 Engine General Information and Diagnosis: For Petrol Engine Model For M16A Engine BLU/ORN BLU/BLK E23-50 E23-56 E23-17 BLU/RED WHT/BLU E23-55 E23-54 C37-45 BLU/YEL ORN/BLU E23-53 C37-44 BLU/RED BLU/GRN E23-52 C37-53 BLUYEL E23-51 C37-54 C37-40 C37-41 WHT/RED C37-52 C37-1 C37-51 WHT/BLU BLK/YEL C37-2...
Page 91 Engine General Information and Diagnosis: For Petrol Engine Model 1A-22 1. Accelerator pedal position (APP) sensor 24. DLC 47. A/C compressor (A/C model) assembly 2. Shield wire 25. To BCM and ABS / ESP® control module 48. “CPRSR” fuse 3. CMP sensor 26.
Page 92 1A-23 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire color Circuit Terminal Wire color Circuit CO adjusting resistor signal (if Throttle position sensor (sub) GRN/WHT equipped) signal Oxygen signal of heated Ground for throttle position oxygen sensor-2 sensor A/C refrigerant pressure GRY/BLK...
Page 93 Engine General Information and Diagnosis: For Petrol Engine Model 1A-24 Terminal Wire color Circuit Terminal Wire color Circuit Cruise control main switch BLK/WHT — — signal (cruise control model) Clutch pedal position switch — — signal (cruise control model) Brake pedal position switch YEL/GRN —...
Page 94: Component Location
1A-25 Engine General Information and Diagnosis: For Petrol Engine Model Component Location Electronic Control System Components Location S6JB0A1113001 For J20 Engine NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 11-1 8 10 I5JB0A110016-04...
Page 95 Engine General Information and Diagnosis: For Petrol Engine Model 1A-26 Information sensors Control devices Others 15. Rear wheel speed sensor (RH, LH) (VSS) 16. Electric load current sensor For M16 Engine NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side.
Page 96: Diagnostic Information And Procedures
1A-27 Engine General Information and Diagnosis: For Petrol Engine Model Diagnostic Information and Procedures Engine and Emission Control System Check S6JB0A1114001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis.
Page 97 Engine General Information and Diagnosis: For Petrol Engine Model 1A-28 Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition? Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer.
Page 98 1A-29 Engine General Information and Diagnosis: For Petrol Engine Model Customer problem inspection form (Example) I2RH01110010-02 NOTE This form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 99: Malfunction Indicator Lamp (Mil) Check
Engine General Information and Diagnosis: For Petrol Engine Model 1A-30 Step 2: DTC / Freeze Frame Data Check, Record and Step 9: Troubleshooting for DTC (See each DTC Clearance Diag. Flow) First, check DTC (including pending DTC), referring to Based on the DTC indicated in Step 6 or 7 and referring “DTC Check: For Petrol Engine Model”.
Page 100: Dtc Check
5) After completing the check, turn ignition switch OFF Using Scan Tool and disconnect scan tool from data link connector. 1) Prepare SUZUKI scan tool or OBD generic scan tool (Euro OBD model). 2) With ignition switch turned OFF, connect it to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
Page 101: Dtc Clearance
S6JB0A1114004 Using Scan Tool 1) Turn ignition switch to OFF position. 1) Connect SUZUKI scan tool or OBD generic scan tool 2) Using service wire, ground diagnosis switch terminal (Euro OBD model) to data link connector in the same (1) of diagnosis connector (2).
Page 102: Dtc Table
1A-33 Engine General Information and Diagnosis: For Petrol Engine Model DTC Table S6JB0A1114005 NOTE • For the non-Euro OBD model or vehicle equipped with diagnosis connector, some of DTC No. with delta ( ) mark in the following table can not be detected by ECM depending on vehicle specification and local regulation.
Page 103 Engine General Information and Diagnosis: For Petrol Engine Model 1A-34 Detecting condition DTC No. Detecting item (DTC will set when detecting:) • MAF volume is greater than 25 g/sec even if engine revolution is less than 900 rpm and intake manifold pressure is less than 45 kPa (6.35 psi) with TP less than 3.0°.
Page 104 1A-35 Engine General Information and Diagnosis: For Petrol Engine Model Detecting condition DTC No. Detecting item (DTC will set when detecting:) Ratio between integrated value of A/F sensor output variation and integrated value of short term fuel trim O2 sensor (HO2S) circuit slow 2 driving variation is more than specification while vehicle is *P0133...
Page 105 Engine General Information and Diagnosis: For Petrol Engine Model 1A-36 Detecting condition DTC No. Detecting item (DTC will set when detecting:) • CMP sensor pulse is less than 20 pulses per crankshaft 8 revolutions • CMP sensor pulse is more than 28 pulses per crankshaft 8 revolutions 1 driving *P0340 Camshaft position sensor circuit...
Page 106 1A-37 Engine General Information and Diagnosis: For Petrol Engine Model Detecting condition DTC No. Detecting item (DTC will set when detecting:) Generator field coil duty is 100% (low voltage) for more than specified time even through generator control is Generator field terminal circuit P0625 maximum regulation (control duty 100%) or Generator —...
Page 107 Engine General Information and Diagnosis: For Petrol Engine Model 1A-38 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Difference between the opening angle based on throttle Throttle position sensor (main / position sensor (main) and the opening angle based on 1 driving *P2135 sub) voltage correlation...
Page 108: Fail-Safe Table
1A-39 Engine General Information and Diagnosis: For Petrol Engine Model For Vehicle Equipped with A/T When using OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on OBD generic scan tool simultaneously. Detecting condition DTC No.
Page 109 Engine General Information and Diagnosis: For Petrol Engine Model 1A-40 DTC No. Detected item Fail-safe operation • ECM turns off throttle actuator control relay and throttle valve is fixed at the opening of about 7° from its completely closed position (default P0123 Throttle position sensor (main) circuit high opening).
Page 110: Scan Tool Data
1A-41 Engine General Information and Diagnosis: For Petrol Engine Model Scan Tool Data S6JB0A1114007 As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 111 Engine General Information and Diagnosis: For Petrol Engine Model 1A-42 Normal condition / Scan tool data Vehicle condition reference values LONG FT B1 (LONG At specified idle speed after warming up –20 – +20% TERM FUEL TRIM) TOTAL FUEL TRIM B1 At specified idle speed after warming up –35 –...
Page 112 1A-43 Engine General Information and Diagnosis: For Petrol Engine Model Normal condition / Scan tool data Vehicle condition reference values Ignition switch ON / Headlight, small light, all turned ELECTRIC LOAD Ignition switch ON / Headlight, small light, turned At specified idle speed and steering wheel at PSP SWITCH (POWER straight ahead position STEERING PUMP...
Page 113 Engine General Information and Diagnosis: For Petrol Engine Model 1A-44 Scan Tool Data Definitions BATTERY VOLTAGE (V) This parameter indicates battery positive voltage COOLANT TEMP (ENGINE COOLANT TEMPERATURE, °C, °F) inputted from main relay to ECM. It is detected by engine coolant temp. sensor. BATTERY CURRENT (for J20 engine, A): INTAKE AIR TEMP.
Page 114 1A-45 Engine General Information and Diagnosis: For Petrol Engine Model TOTAL FUEL TRIM B1 (%) GENERATOR CONT DUTY (GENERATOR CONTROL The value of Total Fuel Trim is obtained by calculating DUTY, %): based on values of Short Term Fuel Trim and Long Term This parameter indicates generator control duty which Fuel Trim.
Page 115 Engine General Information and Diagnosis: For Petrol Engine Model 1A-46 PSP SWITCH (POWER STEERING PUMP PRESSURE ACCEL POSITION (ABSOLUTE ACCELERATOR SWITCH, ON / OFF): PEDAL POSITION, %) ON: PSP SW is ON (P/S high pressure switch is ON) When accelerator pedal is at fully released position, OFF: PSP SW is OFF (P/S high pressure switch is OFF) accelerator pedal is indicated as 0 –...
Page 116: Visual Inspection
1A-47 Engine General Information and Diagnosis: For Petrol Engine Model Visual Inspection S6JB0A1114008 Visually check the following parts and systems. Inspection item Reference section • Engine oil – level, leakage “Engine Oil and Filter Change (Petrol Engine Model) in Section 0B” •...
Page 117: Engine Basic Inspection
Engine General Information and Diagnosis: For Petrol Engine Model 1A-48 Engine Basic Inspection S6JB0A1114009 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in “Visual Inspection: For Petrol Engine Model”. Follow the flow carefully.
Page 118 Go to “Engine Symptom Check ignition control Diagnosis: For Petrol related parts referring to 1) Using SUZUKI scan tool, select “Misc Test” mode on Engine Model”. “Ignition Timing SUZUKI scan tool and fix ignition timing to initial one. Inspection: For Petrol Engine Model in Section 1H”.
Page 119 Engine General Information and Diagnosis: For Petrol Engine Model 1A-50 Step Action 10 Check fuel supply Go to Step 12. Go to Step 11. 1) Check to make sure that enough fuel is filled in fuel tank. 2) Turn ON ignition switch for 2 seconds and then OFF. 3) Repeat Step 2) a few times.
Page 120 1A-51 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 13 Check fuel injector for operation Go to “Engine Symptom Go to “Fuel Injector Diagnosis: For Petrol Circuit Check: For 1) Install spark plugs and connect injector connectors. Engine Model”.
Page 121: Engine Symptom Diagnosis
Engine General Information and Diagnosis: For Petrol Engine Model 1A-52 Engine Symptom Diagnosis S6JB0A1114010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection: For Petrol Engine Model” and “Engine Basic Inspection: For Petrol Engine Model”. Condition Possible cause Correction / Reference Item...
Page 122 1A-53 Engine General Information and Diagnosis: For Petrol Engine Model Condition Possible cause Correction / Reference Item Hard starting (Engine Sticky valve stem “Valves and Valve Guides Inspection: For J20 cranks OK) Engine in Section 1D” or “Valves and Valve Guides Inspection: For M16A Engine with VVT in Section 1D”.
Page 123 Engine General Information and Diagnosis: For Petrol Engine Model 1A-54 Condition Possible cause Correction / Reference Item Engine noise – Piston, Worn piston, ring and cylinder bore “Pistons, Piston Rings, Connecting Rods and ring and cylinder noise Cylinders Inspection and Cleaning: For J20 Engine in Section 1D”...
Page 124 1A-55 Engine General Information and Diagnosis: For Petrol Engine Model Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection: For Petrol Engine Model in Section 1F” Poor water pump performance “Water Pump Inspection: For Petrol Engine Model in Section 1F”...
Page 125 Engine General Information and Diagnosis: For Petrol Engine Model 1A-56 Condition Possible cause Correction / Reference Item Poor gasoline mileage Leaks or loose connection of high- “High-Tension Cord Removal and Installation tension cord (for M16 engine) (For M16 Engine): For Petrol Engine Model in Section 1H”...
Page 126 1A-57 Engine General Information and Diagnosis: For Petrol Engine Model Condition Possible cause Correction / Reference Item Excessive engine oil Sticky piston ring “Pistons, Piston Rings, Connecting Rods and consumption – Oil Cylinders Inspection and Cleaning: For J20 entering combustion Engine in Section 1D”...
Page 127 Engine General Information and Diagnosis: For Petrol Engine Model 1A-58 Condition Possible cause Correction / Reference Item Surge – Engine power Leaky or loosely connected high-tension “High-Tension Cord Removal and Installation variation under steady cord (for M16 engine) (For M16 Engine): For Petrol Engine Model in throttle or cruise.
Page 128 1A-59 Engine General Information and Diagnosis: For Petrol Engine Model Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection: For Petrol Engine Model in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection: For Petrol Engine Model in Section 1H”...
Page 129 Engine General Information and Diagnosis: For Petrol Engine Model 1A-60 Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection: For Petrol Engine engine fails to idle Model in Section 1H” Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation (for M16 engine) (For M16 Engine): For Petrol Engine Model in...
Page 130 1A-61 Engine General Information and Diagnosis: For Petrol Engine Model Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection: For Petrol Engine (HC) emission or carbon Model in Section 1H” monoxide (CO) Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation (for M16 engine) (For M16 Engine): For Petrol Engine Model in...
Page 131 Engine General Information and Diagnosis: For Petrol Engine Model 1A-62 Condition Possible cause Correction / Reference Item Excessive nitrogen Improper ignition timing “Ignition Timing Inspection: For Petrol Engine oxides (NOx) emission Model in Section 1H” Lead contamination of catalytic Check for absence of filler neck restrictor. converter Faulty EGR system “EGR System Inspection: For Petrol Engine...
Page 132: Malfunction Indicator Lamp Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)
1A-63 Engine General Information and Diagnosis: For Petrol Engine Model Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S6JB0A1114011 Wiring Diagram E23-4 WHT/RED WHT/RED E23-19 WHT/BLU WHT/BLU G28-13 G28-15 PPL/RED BLK/YEL BLK/WHT...
Page 133 Engine General Information and Diagnosis: For Petrol Engine Model 1A-64 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: For Petrol Engine Model”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: For Petrol Engine Model”.
Page 134: Malfunction Indicator Lamp Remains On After Engine Starts
1A-65 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Combination meter circuit check Substitute a known- “BLK” wire is open or good combination meter high resistance circuit. 1) Turn ignition switch to OFF position. and recheck. If MIL still 2) Measure resistance between “G28-15”...
Page 135: Dtc P0010: Camshaft Position Actuator Circuit (For M16 Engine)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-66 DTC P0010: Camshaft Position Actuator Circuit (For M16 Engine) S6JB0A1114013 System and Wiring Diagram BRN/WHT C37-60 C37-15 BLK/ORN C37-59 BRN/YEL C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL [A]: 39 38 32 31 39 38 32 31...
Page 136 1A-67 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 137: Dtc P0011 / P0012: Camshaft Position - Timing Over-Advanced Or System Performance / -Retarded (For M16 Engine)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-68 Step Action Oil control valve electrical circuit check Go to Step 9. “BRN/WHT” wire or “BRN/YEL” wire circuit 1) Disconnect connector from oil control valve with ignition is open or high switch turned OFF.
Page 138 Engine with VVT in 3) Select menu to DATA LIST. Section 1D”. If OK, go to 4) Check that “VVT GAP” displayed on SUZUKI scan tool is Step 5. 0 – 5°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.
Page 139: Dtc P0030: Ho2S Heater Control Circuit (Sensor-1)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-70 Step Action Oil control valve and oil gallery pipe check Go to Step 7. Clean oil control valve and oil gallery pipe. 1) Remove oil control valve referring to “Oil Control Valve Replace oil control valve Removal and Installation: For M16A Engine with VVT in if a problem is not...
Page 140 1A-71 Engine General Information and Diagnosis: For Petrol Engine Model DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Impedance of A/F sensor element is more than 44 Ω for 200 • A/F sensor heater circuit sec. even though A/F sensor heater is turned ON for more than •...
Page 141: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-72 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S6JB0A1114016 Wiring Diagram Refer to “DTC P0030: HO2S Heater Control Circuit (Sensor-1): For Petrol Engine Model”. A/F Sensor Description Refer to “A/F Sensor Description: For Petrol Engine Model”.
Page 142 1A-73 Engine General Information and Diagnosis: For Petrol Engine Model Step Action HO2S heater fuse check Go to Step 5. Go to Step 4. 1) Check for “O2 HTR” fuse (1) blown. For J20 engine I5JB0A110028-02 For M16 engine I5JB0A110029-02 Is “O2 HTR”...
Page 143 Engine General Information and Diagnosis: For Petrol Engine Model 1A-74 Step Action HO2S heater relay power circuit check Go to Step 6. Power circuit is open. 1) Remove integration relay No.2 (for J20 engine) (1) or HO2S heater relay (for M16 engine) (2) with ignition switch turned OFF.
Page 144: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2)
1A-75 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 10 A/F sensor heater control circuit check Go to Step 11. Repair or replace defective wire circuit. 1) Disconnect connector from ECM with ignition switch turned OFF. 2) Check for proper connection of A/F sensor heater circuit terminal to ECM connector.
Page 145 Engine General Information and Diagnosis: For Petrol Engine Model 1A-76 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0037: • HO2S-2 heater HO2S-2 circuit voltage is lower than specification for 5 sec • HO2S-2 heater circuit continuously even though control duty ratio of HO2S-2 heater is less •...
Page 146 1A-77 Engine General Information and Diagnosis: For Petrol Engine Model Step Action HO2S heater fuse check Go to Step 5. Go to Step 4. 1) Check for “O2 HTR” fuse (1) blown. For J20 engine I5JB0A110028-02 For M16 engine I5JB0A110029-02 Is “O2 HTR”...
Page 147 Engine General Information and Diagnosis: For Petrol Engine Model 1A-78 Step Action HO2S heater relay power circuit check Go to Step 6. Power circuit is open. 1) Remove integration relay No.2 (for J20 engine) (1) or HO2S heater relay (for M16 engine) (2) with ignition switch turned OFF.
Page 148: Dtc P0101: Mass Air Flow Circuit Range / Performance
1A-79 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 10 HO2S heater control circuit check Go to Step 11. Repair or replace defective wire circuit. 1) Disconnect connector from ECM with ignition switch turned OFF. 2) Check for proper connection of HO2S-2 heater circuit terminal to ECM connector.
Page 149 Engine General Information and Diagnosis: For Petrol Engine Model 1A-80 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • MAF volume is greater than 25 g/sec even if engine • Air intake system (clog or leakage) revolution is less than 900 rpm and intake manifold •...
Page 150 1A-81 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 151 Engine General Information and Diagnosis: For Petrol Engine Model 1A-82 Step Action MAF sensor ground circuit check Go to Step 8. Go to Step 7. 1) Turn OFF ignition switch, measure resistance between “BLU” wire terminal of MAF and IAT sensor connector and engine ground.
Page 152: Dtc P0102: Mass Air Flow Circuit Low Input
1A-83 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0102: Mass Air Flow Circuit Low Input S6JB0A1114019 Wiring Diagram Refer to “DTC P0101: Mass Air Flow Circuit Range / Performance: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of MAF sensor output is less than 0.15 V for 0.5...
Page 153: Dtc P0103: Mass Air Flow Circuit High Input
Engine General Information and Diagnosis: For Petrol Engine Model 1A-84 Step Action MAF sensor signal circuit check Go to Step 7. “RED” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure voltage between “RED” wire terminal of MAF and IAT sensor connector and engine ground with ignition switch turned ON.
Page 154 1A-85 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 155: Dtc P0106: Manifold Absolute Pressure Range / Performance
Engine General Information and Diagnosis: For Petrol Engine Model 1A-86 DTC P0106: Manifold Absolute Pressure Range / Performance S6JB0A1114021 Wiring Diagram GRY/RED GRY/RED C37-14 RED/WHT C37-55 C37-15 BLK/ORN C37-30 BLK/ORN GRY/GRN GRY/GRN C37-57 C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL 39 38 32 31 39 38 32 31...
Page 156: Dtc P0107: Manifold Absolute Pressure Circuit Low Input
1A-87 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 157 Engine General Information and Diagnosis: For Petrol Engine Model 1A-88 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 158: Dtc P0108: Manifold Absolute Pressure Circuit High Input
1A-89 Engine General Information and Diagnosis: For Petrol Engine Model Step Action MAP sensor signal circuit check Go to Step 7. “RED/WHT” wire is shorted to ground 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Measure resistance between “C37-55” terminal of ECM connector and vehicle body ground.
Page 159 Engine General Information and Diagnosis: For Petrol Engine Model 1A-90 Step Action MAP sensor power supply voltage check Go to Step 4. “GRY/RED” wire shorted to power circuit. 1) Disconnect connector from MAP sensor with ignition switch turned OFF. 2) Check for proper connection of MAP sensor at “GRY/ RED”, “RED/WHT”...
Page 160: Dtc P0111: Intake Air Temperature Circuit Range / Performance
1A-91 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0111: Intake Air Temperature Circuit Range / Performance S6JB0A1114024 Wiring Diagram BLU/BLK C37-26 C37-27 C37-25 LT GRN GRY/GRN C37-57 GRY/GRN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 161 Engine General Information and Diagnosis: For Petrol Engine Model 1A-92 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 162: Dtc P0112: Intake Air Temperature Sensor Circuit Low
1A-93 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire circuit check Go to Step 6. “LT GRN” wire is shorted to ground or 1) Disconnect connectors from ECM with ignition switch other circuit. turned OFF. If wire is OK, substitute 2) Measure resistance between “LT GRN”...
Page 163 Engine General Information and Diagnosis: For Petrol Engine Model 1A-94 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and run it for 10 sec. 4) Check DTC and pending DTC.
Page 164: Dtc P0113: Intake Air Temperature Sensor Circuit High
1A-95 Engine General Information and Diagnosis: For Petrol Engine Model Step Action IAT short circuit check Go to Step 6. “LT GRN” wire is shorted to other circuit. 1) Turn ON ignition switch. If wire is OK, substitute 2) Measure voltage between “LT GRN” wire terminal of a known-good ECM and MAF and IAT sensor connector and vehicle body recheck.
Page 165 Engine General Information and Diagnosis: For Petrol Engine Model 1A-96 Step Action IAT sensor voltage check Go to Step 7. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “LT GRN”...
Page 166: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance
1A-97 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Ground circuit check “GRY/GRN” wire is Faulty ECM ground open circuit or high circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors resistance circuit. Poor substitute a known- connected.
Page 167 Engine General Information and Diagnosis: For Petrol Engine Model 1A-98 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 168 1A-99 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Disconnect ECT sensor connector with ignition switch turned OFF. 2) Check for proper connection to ECT sensor connector at “PPL/YEL”...
Page 169: Dtc P0117: Engine Coolant Temperature Circuit Low
Engine General Information and Diagnosis: For Petrol Engine Model 1A-100 Step Action 10 Ground circuit check “GRY/GRN” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C37-57” If circuit is OK, connection.
Page 170 1A-101 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from ECT sensor with ignition switch turned OFF. 2) Check for proper connection to ECT sensor at “PPL/ YEL”...
Page 171: Dtc P0118: Engine Coolant Temperature Circuit High
Engine General Information and Diagnosis: For Petrol Engine Model 1A-102 DTC P0118: Engine Coolant Temperature Circuit High S6JB0A1114029 Wiring Diagram Refer to “DTC P0116: Engine Coolant Temperature Circuit Range / Performance: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of ECT sensor output is more than 4.8 V for 0.5 sec...
Page 172 1A-103 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM voltage check “PPL/YEL” wire is open Go to Step 5. circuit. If wire and 1) Turn OFF ignition switch. connection are OK, go 2) Remove ECM from its bracket with ECM connectors to Step 5.
Page 173: Dtc P0122: Throttle Position Sensor (Main) Circuit Low
Engine General Information and Diagnosis: For Petrol Engine Model 1A-104 DTC P0122: Throttle Position Sensor (Main) Circuit Low S6JB0A1114030 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK BLU/BLK...
Page 174 1A-105 Engine General Information and Diagnosis: For Petrol Engine Model DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 175 Engine General Information and Diagnosis: For Petrol Engine Model 1A-106 Step Action ECM voltage check “WHT” wire is open or Go to Step 5. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected.
Page 176: Dtc P0123: Throttle Position Sensor (Main) Circuit High
1A-107 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0123: Throttle Position Sensor (Main) Circuit High S6JB0A1114031 Wiring Diagram Refer to “DTC P0122: Throttle Position Sensor (Main) Circuit Low: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of throttle position sensor (main) is more than...
Page 177 Engine General Information and Diagnosis: For Petrol Engine Model 1A-108 Step Action ECM voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “WHT”, “GRN”...
Page 178 1A-109 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire harness check Go to Step 8. “BLK” wire is shorted to “WHT” wire. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “BLK” and “WHT” wire terminals of electric throttle body assembly connector.
Page 179: Dtc P0131 / P0132 / P0134: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-110 DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1) S6JB0A1114032 Wiring Diagram BLK/WHT *GRN C37-38 C37-37 RED/YEL C37-35 RED/BLU C37-34 PNK/BLU C37-32...
Page 180 1A-111 Engine General Information and Diagnosis: For Petrol Engine Model DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Run engine at idle speed for 1 min.
Page 181: Dtc P0133: O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-112 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) S6JB0A1114033 Wiring Diagram Refer to “DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1): For Petrol Engine Model”.
Page 182: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2)
1A-113 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 183 Engine General Information and Diagnosis: For Petrol Engine Model 1A-114 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0137: • HO2S-2 HO2S-2 voltage is lower than 0.4 V for more than specified time • HO2S-2 circuit continuously while vehicle is driving with high engine load (high speed).
Page 184 1A-115 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 185: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-116 Step Action Exhaust system check Go to Step 4 in “DTC Repair leakage of P0171 / P0172 / P2195 / exhaust system. 1) Check exhaust system for exhaust gas leakage. P2196: Fuel System Is it OK? Too Lean / Rich / Stuck...
Page 186 1A-117 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 187: Dtc P0171 / P0172 / P2195 / P2196: Fuel System Too Lean / Rich / Stuck Lean / Stuck Rich
Engine General Information and Diagnosis: For Petrol Engine Model 1A-118 DTC P0171 / P0172 / P2195 / P2196: Fuel System Too Lean / Rich / Stuck Lean / Stuck Rich S6JB0A1114036 Wiring Diagram BLK/WHT *GRN C37-38 C37-37 RED/YEL C37-35 RED/BLU C37-34 PNK/BLU C37-32...
Page 188 1A-119 Engine General Information and Diagnosis: For Petrol Engine Model DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 189 Engine General Information and Diagnosis: For Petrol Engine Model 1A-120 Step Action MAF sensor for performance check Go to Step 8. Go to “DTC P0101: Mass Air Flow Circuit 1) With ignition switch turned OFF, connect scan tool to Range / Performance: DLC.
Page 190 1A-121 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 12 A/F sensor adjusting resistor check Go to Step 13. Replace A/F sensor. 1) 1)Check for resistance of A/F sensor adjusting resistor referring to “Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection: For Petrol Engine Model in Section 1C”.
Page 191 Engine General Information and Diagnosis: For Petrol Engine Model 1A-122 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of throttle position sensor (sub) is less than 0.3 V for • Throttle position sensor (sub) circuit specified time continuously.
Page 192 1A-123 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM voltage check Go to Step 5. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “RED”, “WHT”...
Page 193: Dtc P0223: Throttle Position Sensor (Sub) Circuit High
Engine General Information and Diagnosis: For Petrol Engine Model 1A-124 Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. ground circuit. 1) Measure resistance between “RED” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned OFF.
Page 194 1A-125 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 195 Engine General Information and Diagnosis: For Petrol Engine Model 1A-126 Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Measure voltage between “RED” wire terminal of electric throttle body assembly connector and engine ground with ignition switch turned ON. Is voltage 4 –...
Page 196: Dtc P0301, P0302, P0303, P0304
1A-127 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S6JB0A1114039 System Description ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 197 Engine General Information and Diagnosis: For Petrol Engine Model 1A-128 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 198: Dtc P0327 / P0328: Knock Sensor Circuit Low / High
1A-129 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Engine mechanical system check Check wire harness and Repair or replace connection of ECM defective part. 1) Check engine mechanical parts or system which can ground, ignition system cause engine rough idle or poor performance.
Page 199 Engine General Information and Diagnosis: For Petrol Engine Model 1A-130 DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool. 3) Start engine and run it for 10 sec.
Page 200: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit (For J20 Engine)
1A-131 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Knock sensor circuit for short check Go to Step 7. “WHT” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between “C37- 56”...
Page 201 Engine General Information and Diagnosis: For Petrol Engine Model 1A-132 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No CKP sensor signal for 2 sec. even if starting motor • CKP sensor circuit open or short signal is inputted at engine cranking. •...
Page 202: Dtc P0335: Crankshaft Position (Ckp) Sensor Circuit (For M16 Engine)
1A-133 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire circuit check Go to Step 6. “PNK” wire and/or “BLU” wire is open or high 1) Measure resistance at following connector terminals. resistance. • Between “C37-51” terminal of ECM connector and “BLU”...
Page 203 Engine General Information and Diagnosis: For Petrol Engine Model 1A-134 4. Main relay 9. Fuse box No.2 14. “IGN” fuse 5. Ignition switch 10. “FI” fuse 15. Starting motor magnet clutch DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No CKP sensor signal for 2 sec.
Page 204 1A-135 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire harness and connection check Go to Step 7. Go to Step 4. 1) Disconnect connector from CKP sensor with ignition switch turned OFF. 2) Check for proper connection to CKP sensor at “BLU/ BLK”, “WHT/BLU”...
Page 205 Engine General Information and Diagnosis: For Petrol Engine Model 1A-136 Step Action CKP sensor check Substitute a known- Replace CKP sensor good ECM and recheck. and/or sensor plate. 1) Check CKP sensor and sensor plate tooth referring to “Camshaft Position (CMP) Sensor Inspection: For Petrol Engine Model in Section 1C”.
Page 206: Dtc P0340: Camshaft Position (Cmp) Sensor Circuit
1A-137 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0340: Camshaft Position (CMP) Sensor Circuit S6JB0A1114043 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL WHT/GRN C37-48 BLK/YEL BLK/RED BLK/RED E23-60 BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED E23-16 BLU/BLK...
Page 207 Engine General Information and Diagnosis: For Petrol Engine Model 1A-138 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 208 1A-139 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Was terminal “Vout” voltage in Step 3 within specification? Go to Step 5. “WHT/RED” wire is open or shorted to ground / power supply circuit. If wire and connection are OK, substitute a known-good ECM and recheck.
Page 209: Dtc P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
Engine General Information and Diagnosis: For Petrol Engine Model 1A-140 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected S6JB0A1114044 System and Wiring Diagram I5JB0A110051-01 1. EGR valve 4. Sensed information 7. “IG COIL” fuse 10. Main relay 2.
Page 210 1A-141 Engine General Information and Diagnosis: For Petrol Engine Model DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0401: • EGR valve Difference in intake manifold absolute pressure between opened EGR valve • EGR passage and closed EGR valve is smaller than specified value. •...
Page 211 EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection: For Petrol Engine Model in Section 1B”.
Page 212: Dtc P0403: Exhaust Gas Recirculation Control Circuit
1A-143 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0403: Exhaust Gas Recirculation Control Circuit S6JB0A1114045 Wiring Diagram Refer to “DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitored voltage of EGR valve drive pulse is different from its output...
Page 213: Dtc P0420: Catalyst System Efficiency Below Threshold
Engine General Information and Diagnosis: For Petrol Engine Model 1A-144 Step Action Wire circuit check Go to Step 5. Faulty wire(s) are shorted to ground 1) With ignition switch turned OFF, measure resistance circuit. between engine ground and each “YEL/BLK”, “YEL/ RED”, “YEL/GRN”, “YEL”...
Page 214 1A-145 Engine General Information and Diagnosis: For Petrol Engine Model A/F Sensor Description Refer to “A/F Sensor Description: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Ratio of integrated value of HO2S-2 output variation per integrated •...
Page 215: Dtc P0443: Evaporative Emission System Purge Control Valve Circuit
Engine General Information and Diagnosis: For Petrol Engine Model 1A-146 Step Action HO2S-2 output voltage check Replace exhaust Check “BRN” and/or manifold (built in warm “YEL” wires for open 1) Check output voltage of HO2S-2 referring to “DTC up three way catalytic and short, and P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / converter) and exhaust...
Page 216 1A-147 Engine General Information and Diagnosis: For Petrol Engine Model 1) With ignition switch OFF, connect scan tool to DLC. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up normal operating temperature. 4) Drive vehicle at more than 40 km/h, 25 mph for 5 min.
Page 217: Dtc P0462: Fuel Level Sensor Circuit Low
Engine General Information and Diagnosis: For Petrol Engine Model 1A-148 Step Action EVAP canister purge control circuit check Faulty ECM. Substitute “GRN/BLK” and/or a known-good ECM and “BLU/BLK” wire are high 1) With ignition switch turn OFF, measure resistance recheck. resistance circuit.
Page 218 Go to Step 5. Intermittent trouble. tool Check for intermittent referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection turned OFF. Inspection in Section 2) Turn ON ignition switch and check fuel level displayed 00”.
Page 219: Dtc P0463: Fuel Level Sensor Circuit High
Go to Step 6. Intermittent trouble. tool Check for intermittent referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection turned OFF. Inspection in Section 2) Turn ON ignition switch and check fuel level displayed 00”.
Page 220 1A-151 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Short circuit check for fuel level sensor output signal Go to Step 8. “YEL/RED” wire shorted circuit to other circuit. 1) Turn ON ignition switch and measure voltage between “E23-24”...
Page 221: Dtc P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
Engine General Information and Diagnosis: For Petrol Engine Model 1A-152 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit S6JB0A1114050 Wiring Diagram YEL/GRN RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL BLU/BLK BLK/YEL C37-58 E23-48 YEL/GRN...
Page 222 1A-153 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 223 Engine General Information and Diagnosis: For Petrol Engine Model 1A-154 Step Action Wire circuit check Go to Step 7. “RED/BLK” wire is shorted to other circuit. 1) Measure voltage between “RED/BLK” wire terminal of radiator cooling fan relay No.1 connector and vehicle body ground with ignition switch turned ON.
Page 224 1A-155 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 12 Wire circuit check Go to Step 13. “RED” wire is shorted to other circuit. 1) Measure voltage between “RED” wire terminal of radiator cooling fan relay No.2 connector and vehicle body ground with ignition switch turned ON.
Page 225: Dtc P0500: Vehicle Speed Sensor (Vss) Malfunction
Engine General Information and Diagnosis: For Petrol Engine Model 1A-156 Step Action 18 Wire circuit check Go to Step 19. “RED/YEL” wire is shorted to other circuit. 1) Measure voltage between “RED/YEL” wire terminal of radiator cooling fan relay No.3 connector and vehicle body ground with ignition switch turned ON.
Page 226 1A-157 Engine General Information and Diagnosis: For Petrol Engine Model DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 227: Dtc P0504: Brake Switch "A"/"B" Correlation (For J20 Engine)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-158 DTC P0504: Brake Switch “A”/“B” Correlation (For J20 Engine) S6JB0A1114052 Wiring Diagram BLK/YEL BLU/BLK YEL/GRN E23-8 WHT/GRN GRN/WHT GRN/WHT E23-20 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 228 1A-159 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 229: Dtc P0532: A/C Refrigerant Pressure Sensor Circuit Low
Engine General Information and Diagnosis: For Petrol Engine Model 1A-160 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low S6JB0A1114053 Wiring Diagram GRY/RED GRY/RED C37-14 GRY/BLK C37-12 C37-15 BLK/ORN C37-30 BLK/ORN GRY/GRN GRY/GRN C37-57 C37-29 BLK/YEL C37-48 BLK/YEL C37-58 BLK/YEL 39 38 32 31 39 38 32 31...
Page 230 1A-161 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 231: Dtc P0533: A/C Refrigerant Pressure Sensor Circuit High
Engine General Information and Diagnosis: For Petrol Engine Model 1A-162 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High S6JB0A1114054 Wiring Diagram Refer to “DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area A/C refrigerant pressure sensor signal voltage is higher...
Page 232: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
1A-163 Engine General Information and Diagnosis: For Petrol Engine Model Step Action A/C refrigerant pressure sensor ground circuit check Go to Step 7. Go to Step 6. 1) Turn OFF ignition switch, measure resistance between engine ground and “GRY/GRN” wire terminal of A/C refrigerant pressure sensor connector.
Page 233: Dtc P0616: Starter Relay Circuit Low
Engine General Information and Diagnosis: For Petrol Engine Model 1A-164 Step Action DTC recheck Go to Step 2. Intermittent trouble. 1) Clear DTC referring to “DTC Clearance: For Petrol Check for intermittent Engine Model”. referring to “Intermittent and Poor Connection 2) Turn OFF ignition switch.
Page 234: Dtc P0617: Starter Relay Circuit High
1A-165 Engine General Information and Diagnosis: For Petrol Engine Model DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to...
Page 235 Engine General Information and Diagnosis: For Petrol Engine Model 1A-166 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 236: Dtc P0620: Generator Control Circuit
1A-167 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0620: Generator Control Circuit S6JB0A1114058 System and Wiring Diagram BRN/BLK C37-8 C37-28 BRN/BLK 39 38 32 31 39 38 32 31 47 46 54 53 47 46 54 53 I5JB0A110063-01 1.
Page 237 Engine General Information and Diagnosis: For Petrol Engine Model 1A-168 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 238: Dtc P0625 / P0626: Generator Field Terminal Circuit Low / High
1A-169 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0625 / P0626: Generator Field Terminal Circuit Low / High S6JB0A1114059 System and Wiring Diagram Refer to “DTC P0620: Generator Control Circuit: For Petrol Engine Model”. Generator Control System Description Refer to “Generator Control System Description: For Petrol Engine Model”.
Page 239 Engine General Information and Diagnosis: For Petrol Engine Model 1A-170 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 240: Dtc P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine)
1A-171 Engine General Information and Diagnosis: For Petrol Engine Model DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine) S6JB0A1114060 Wiring Diagram I5JB0A110064-02 1. IMT vacuum solenoid valve 4. Fuse box No.2 7. “FI” fuse 2. Main relay 5.
Page 241 Engine General Information and Diagnosis: For Petrol Engine Model 1A-172 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 242: Dtc P1501 / P1502: Electric Load Current Sensor Circuit Low / High
1A-173 Engine General Information and Diagnosis: For Petrol Engine Model DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High S6JB0A1114061 System and Wiring Diagram GRY/RED C37-14 GRY/RED C37-9 GRY/GRN C37-57 GRY/GRN GRY/GRN 39 38 32 31 39 38 32 31 54 53 47 46...
Page 243 Engine General Information and Diagnosis: For Petrol Engine Model 1A-174 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 244: Dtc P1510: Ecm Back-Up Power Supply Malfunction
1A-175 Engine General Information and Diagnosis: For Petrol Engine Model DTC P1510: ECM Back-Up Power Supply Malfunction S6JB0A1114062 Wiring Diagram E23-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5JB0A110066-01 1. ECM 2.
Page 245: Dtc P1603: Tcm Trouble Code Detected (For J20 Engine)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-176 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 246 1A-177 Engine General Information and Diagnosis: For Petrol Engine Model DTC Detecting Condition When ECM receives a trouble code from TCM, which indicates that some problem occurred in sensor circuits and its calculated values used for operations such as idle speed control, engine power control, and so on by TCM, ECM sets DTC P1603.
Page 247: Dtc P1674: Can Communication (Bus Off Error)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-178 DTC P1674: CAN Communication (Bus Off Error) S6JB0A1114064 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 G31-4 G31-2 G31-1 G31-3 E53-46 E03-8 WHT/BLU E53-42 E03-10 WHT/RED E91-22 E53-13 E03-12 E91-23 E53-44 E03-6 G45-9 E92-17 E92-7...
Page 248 1A-179 Engine General Information and Diagnosis: For Petrol Engine Model DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Transmission error that is inconsistent between • ECM transmission data and transmission monitor (CAN bus • BCM monitor) data is detected more than 7 times continuously. •...
Page 249 Engine General Information and Diagnosis: For Petrol Engine Model 1A-180 Step Action ECM, TCM (for A/T model), BCM, ABS / ESP® control Go to Step 4. Intermittent trouble. module, 4WD control module (if equipped), combination Check for intermittent meter, keyless start control module (if equipped) and referring to “Intermittent steering angle sensor (for vehicle with ESP®) and Poor Connection...
Page 250 1A-181 Engine General Information and Diagnosis: For Petrol Engine Model Step Action DTC check in ECM Go to Step 9. CAN communication circuit wire between 1) Disconnect connectors from TCM (for A/T model) with TCM and CAN circuit ignition switch turned OFF. junction connector is 2) Check ECM for DTC.
Page 251: Dtc P1676: Can Communication (Reception Error For Tcm (For A/T Model))
Engine General Information and Diagnosis: For Petrol Engine Model 1A-182 Step Action 13 ABS or EPS® control module check Go to Step 14. Substitute a known- good ABS or ESP® 1) Measure resistance at following connector terminals. control module and •...
Page 252 1A-183 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 253 Engine General Information and Diagnosis: For Petrol Engine Model 1A-184 Step Action CAN communication circuit check Go to Step 9. Go to Step 8. 1) Disconnect connectors from TCM and ECM with ignition switch turned OFF. 2) Check that CAN communication circuit is as follows. •...
Page 254 1A-185 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 12 DTC check Go to Step 13. CAN communication circuit wire between 1) Disconnect connector from 4WD control module (if 4WD control module equipped) with ignition switch turned OFF. and CAN circuit 2) Check ECM for DTC.
Page 255: Dtc P1678: Can Communication (Reception Error For Bcm)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-186 DTC P1678: CAN Communication (Reception Error for BCM) S6JB0A1114066 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error): For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for BCM is...
Page 256 1A-187 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM power and ground circuit check Go to Step 6. Repair ECM power and/ or ground circuits. 1) Check ECM power and ground circuits referring to “ECM Power and Ground Circuit Check: For Petrol Engine Model”.
Page 257 Engine General Information and Diagnosis: For Petrol Engine Model 1A-188 Step Action DTC check Go to Step 12. CAN communication circuit wire between 1) Disconnect connector from combination meter with combination meter and ignition switch turned OFF. CAN circuit junction 2) Check ECM for DTC.
Page 258 1A-189 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 14 CAN communication circuit check Go to Step 15. Repair or replace defective CAN 1) Disconnect connectors from all control modules (ECM, communication circuit. TCM (if equipped), BCM, ABS or ESP® control module, 4WD control module (if equipped), keyless start control module (if equipped), combination meter, steering angle sensor (vehicle with ESP®) with ignition switch turned...
Page 259: Dtc P1685: Can Communication (Reception Error For Abs Or Esp® Control Module)
Engine General Information and Diagnosis: For Petrol Engine Model 1A-190 DTC P1685: CAN Communication (Reception Error for ABS or ESP® Control Module) S6JB0A1114067 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error): For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ABS or ESP®...
Page 260 1A-191 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM power and ground circuit check Go to Step 6. Repair ECM power and/ or ground circuits. 1) Check ECM power and ground circuits referring to “ECM Power and Ground Circuit Check: For Petrol Engine Model”.
Page 261 Engine General Information and Diagnosis: For Petrol Engine Model 1A-192 Step Action 10 DTC check in ECM Go to Step 9. CAN communication circuit wire between 1) Disconnect connectors from TCM (for A/T model) with TCM and CAN circuit ignition switch turned OFF. junction connector is 2) Check ECM for DTC.
Page 262 1A-193 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 14 DTC check Go to Step 15. CAN communication circuit wire between 1) Disconnect connector from steering angle sensor steering angle sensor (vehicle with ESP®) with ignition switch turned OFF. and CAN circuit junction 2) Check ECM for DTC.
Page 263: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance
Engine General Information and Diagnosis: For Petrol Engine Model 1A-194 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance S6JB0A1114068 Wiring Diagram BLK/WHT E23-29 BLK/YEL C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL BLK/RED BLK/RED E23-60 C37-48 BLK/YEL BLK/YEL C37-58 BLU/BLK BLU/BLK E23-1 BLK/RED...
Page 264 1A-195 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 265: Dtc P2102: Throttle Actuator Control Motor Circuit Low
Engine General Information and Diagnosis: For Petrol Engine Model 1A-196 DTC P2102: Throttle Actuator Control Motor Circuit Low S6JB0A1114069 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control circuit is...
Page 266 1A-197 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Throttle actuator control relay circuit check Go to Step 6. “BLU/ORN” wire and/or “GRN” wire is open or 1) Disconnect connectors from ECM with ignition switch high resistance. turned OFF.
Page 267: Dtc P2103: Throttle Actuator Control Motor Circuit High
Engine General Information and Diagnosis: For Petrol Engine Model 1A-198 DTC P2103: Throttle Actuator Control Motor Circuit High S6JB0A1114070 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control circuit is...
Page 268: Dtc P2111: Throttle Actuator Control System - Stuck Open
1A-199 Engine General Information and Diagnosis: For Petrol Engine Model DTC P2111: Throttle Actuator Control System - Stuck Open S6JB0A1114071 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Throttle valve default opening is greater than 7° from •...
Page 269: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance
Engine General Information and Diagnosis: For Petrol Engine Model 1A-200 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance S6JB0A1114072 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the measured (actual) throttle valve...
Page 270 1A-201 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Throttle actuator circuit check Go to Step 4. “BLU/YEL” wire and/or “BLU/RED” wire is open 1) Disconnect connector from electric throttle body or high resistance. assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “BLU/YEL”...
Page 271: Dtc P2122: Pedal Position Sensor (Main) Circuit Low Input
Engine General Information and Diagnosis: For Petrol Engine Model 1A-202 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input S6JB0A1114073 Wiring Diagram E23-56 WHT/BLU E23-55 E23-54 ORN/BLU E23-53 BLU/GRN E23-52 BLU/YEL E23-51 39 38 32 31 39 38 32 31 54 53 47 46 54 53...
Page 272 1A-203 Engine General Information and Diagnosis: For Petrol Engine Model DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 273 Engine General Information and Diagnosis: For Petrol Engine Model 1A-204 Step Action ECM voltage check “WHT” wire is open or Go to Step 6. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected.
Page 274: Dtc P2123: Pedal Position Sensor (Main) Circuit High Input
1A-205 Engine General Information and Diagnosis: For Petrol Engine Model DTC P2123: Pedal Position Sensor (Main) Circuit High Input S6JB0A1114074 Wiring Diagram Refer to “DTC P2122: Pedal Position Sensor (Main) Circuit Low Input: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of accelerator pedal position sensor (main)
Page 275 Engine General Information and Diagnosis: For Petrol Engine Model 1A-206 Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from accelerator pedal position (APP) sensor assembly with ignition switch turned OFF. 2) Check for proper connection to accelerator pedal position (APP) sensor assembly at “WHT”, “WHT/BLU”...
Page 276: Dtc P2127: Pedal Position Sensor (Sub) Circuit Low Input
1A-207 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Ground circuit check “ORN” wire is open or Faulty ECM ground high resistance circuit. circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors substitute a known- connected.
Page 277 Engine General Information and Diagnosis: For Petrol Engine Model 1A-208 DTC Troubleshooting NOTE Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting: For Petrol Engine Model”. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 278 1A-209 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM voltage check “ORN/BLU” wire is open Go to Step 6. or high resistance 1) Turn OFF ignition switch. circuit. 2) Remove ECM from its bracket with ECM connectors connected.
Page 279: Dtc P2128: Pedal Position Sensor (Sub) Circuit High Input
Engine General Information and Diagnosis: For Petrol Engine Model 1A-210 DTC P2128: Pedal Position Sensor (Sub) Circuit High Input S6JB0A1114076 Wiring Diagram Refer to “DTC P2122: Pedal Position Sensor (Main) Circuit Low Input: For Petrol Engine Model”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of accelerator pedal position sensor (sub)
Page 280 1A-211 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from accelerator pedal position (APP) sensor assembly with ignition switch turned OFF. 2) Check for proper connection to accelerator pedal position (APP) sensor assembly at “ORN/BLU”, “BLU/ GRN”...
Page 281: Dtc P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
Engine General Information and Diagnosis: For Petrol Engine Model 1A-212 Step Action Ground circuit check “BLU/YEL” wire is open Faulty ECM ground or high resistance circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors circuit. substitute a known- connected.
Page 282 1A-213 Engine General Information and Diagnosis: For Petrol Engine Model 2. Throttle actuator control relay 7. “FI” fuse DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the opening angle based on throttle • Throttle position sensor (main) and (sub) circuit position sensor (main) and the opening angle based on •...
Page 283 Engine General Information and Diagnosis: For Petrol Engine Model 1A-214 Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from electric throttle body assembly with ignition switch turned OFF. 2) Check for proper connection to electric throttle body assembly at “RED”, “GRN”, “WHT”...
Page 284: Dtc P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
1A-215 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire harness check Go to Step 8. “BLK” wire or “RED” wire is shorted to other 1) Turn OFF ignition switch. circuit. 2) Disconnect connectors from ECM. 3) Check for proper connection of ECM connector at “C37- 54”...
Page 285 Engine General Information and Diagnosis: For Petrol Engine Model 1A-216 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the opening angle based on • Accelerator pedal position (APP) sensor (main) and accelerator pedal position sensor (main) and the opening (sub) circuit angle based on accelerator pedal position sensor (sub) is •...
Page 286 1A-217 Engine General Information and Diagnosis: For Petrol Engine Model Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from accelerator pedal position (APP) sensor assembly with ignition switch turned OFF. 2) Check for proper connection to accelerator pedal position (APP) sensor assembly at “BLU/YEL”, “BLU/ GRN”, “ORN/BLU”, “ORN”, “WHT/BLU”...
Page 287: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
Engine General Information and Diagnosis: For Petrol Engine Model 1A-218 Step Action Wire harness check Go to Step 8. “WHT/BLU” wire or “BLU/GRN” wire is 1) Turn ON ignition switch. shorted to other circuit. 2) Measure voltage between “E23-55” terminal of ECM connector and engine ground, between “E23-52”...
Page 288 1A-219 Engine General Information and Diagnosis: For Petrol Engine Model DTC Confirmation Procedure DTC P2227: WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 289: Inspection Of Ecm And Its Circuits
Engine General Information and Diagnosis: For Petrol Engine Model 1A-220 Inspection of ECM and Its Circuits S6JB0A1114080 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 290 1A-221 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ 10 – 14 V (“Reference waveform No.1: For Output signal is active low C37-1 Fuel injector No.1...
Page 291 Engine General Information and Diagnosis: For Petrol Engine Model 1A-222 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. BRN/ *0 – 1 V ↑↓ (M16A 10 – 14 V Signal is duty pulse. Duty engine) Generator field coil (“Reference...
Page 292 1A-223 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire Circuit Normal voltage Condition Remarks color Output of 5 V power source for MAP sensor, A/C refrigerant pressure sensor, GRY/ C37-14 electric load 4.5 – 5.5 V Ignition switch turned ON. —...
Page 293 Engine General Information and Diagnosis: For Petrol Engine Model 1A-224 Terminal Wire Circuit Normal voltage Condition Remarks color Ignition coil No.2 and No.3 (M16A 0 – 0.6 V Ignition switch turned ON. — engine) *0 – 0.6 V ↑↓ BRN/ 3 –...
Page 294 1A-225 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire Circuit Normal voltage Condition Remarks color BLK/ C37-29 Ground for ECM Below 0.3 V Ignition switch turned ON. — BLK/ C37-30 Ground for ECM Below 0.3 V Ignition switch turned ON. —...
Page 295 Engine General Information and Diagnosis: For Petrol Engine Model 1A-226 Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON and accelerator pedal at 0 – 1 V idle position after warmed up engine. *0 – 1 V Output signal is duty ↑↓...
Page 296 1A-227 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *4 – 5 V ↑↓ Sensor signal is pulse. 0 –...
Page 297 Engine General Information and Diagnosis: For Petrol Engine Model 1A-228 Terminal Wire Circuit Normal voltage Condition Remarks color GRY/ C37-57 Ground for sensors Below 0.3 V Ignition switch turned ON. — BLK/ C37-58 Ground for ECM Below 0.3 V Ignition switch turned ON. —...
Page 298 1A-229 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire Circuit Normal voltage Condition Remarks color Clock signal for PNK/ immobilizer coil E23-13 10 – 14 V Ignition switch turned ON. — antenna (if equipped) E23-14 — — —...
Page 299 Engine General Information and Diagnosis: For Petrol Engine Model 1A-230 Terminal Wire Circuit Normal voltage Condition Remarks color E23-35 — — — — — E23-36 — — — — — E23-37 — — — — — E23-38 — — — —...
Page 300 1A-231 Engine General Information and Diagnosis: For Petrol Engine Model Terminal Wire Circuit Normal voltage Condition Remarks color Engine running, A/C 10 – 14 V switch OFF and blower A/C compressor selector at OFF position. E23-49 relay output (if Engine running, A/C —...
Page 301 Engine General Information and Diagnosis: For Petrol Engine Model 1A-232 Reference waveform No.1 Reference waveform No.3 Fuel injector signal (1) with engine idling No.2 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-2” to “C37-58” terminal terminal CH2: “C37-2”...
Page 302 1A-233 Engine General Information and Diagnosis: For Petrol Engine Model Reference waveform No.5 Reference waveform No.7 Generator field coil monitor signal (1) at engine idling Heated oxygen sensor-2 signal (1) with engine idling Measurement CH1: “C37-8” to “C37-58” Measurement CH1: “C37-11” to “C37-57” terminal CH2: “C37-28”...
Page 303 Engine General Information and Diagnosis: For Petrol Engine Model 1A-234 Reference waveform No.9 Reference waveform No.11 EVAP canister purge valve signal No.4 fuel injector signal (2) with engine idling Measurement Measurement CH1: “C37-52” to “C37-58” CH1: “C37-13” to “C37-58” terminal terminal CH2: “C37-17”...
Page 304 1A-235 Engine General Information and Diagnosis: For Petrol Engine Model Reference waveform No.12 Reference waveform No.13 Ignition coil signal (1) with engine idling Ignition coil No.4 signal (2) with engine idling (J20A engine) Measurement CH1: “C37-20” to “C37-58” terminal Measurement CH1: “C37-52”...
Page 305 Engine General Information and Diagnosis: For Petrol Engine Model 1A-236 Reference waveform No.15 Reference waveform No.16 • Ignition coil No.2 signal (1) with engine idling (J20A • Ignition coil No.1 signal (1) with engine idling (J20A engine) engine) • Ignition coil No.2 and No.3 signal (2) with engine idling •...
Page 306 1A-237 Engine General Information and Diagnosis: For Petrol Engine Model Reference waveform No.19 Reference waveform No.17 Mass air flow sensor signal (1) with engine racing Intake manifold tuning vacuum solenoid valve signal with engine racing (J20A engine) Measurement CH1: “C37-26” to “C37-27” terminal CH2: “C37-54”...
Page 307 Engine General Information and Diagnosis: For Petrol Engine Model 1A-238 Reference waveform No.20 Reference waveform No.21 CMP sensor signal with engine idling CMP sensor signal with engine idling CH1: “C37-52” to “C37-58” CH1: “C37-52” to “C37-58” Measurement Measurement CH2: “C37-51” to “C37-36” (J20A CH2: “C37-51”...
Page 308 1A-239 Engine General Information and Diagnosis: For Petrol Engine Model Reference waveform No.22 Reference waveform No.23 Throttle actuator output signal with ignition switch turned Throttle actuator output signal with ignition switch turned Measurement CH1: “C37-45” to “C37-58” Measurement CH1: “C37-45” to “C37-58” terminal CH2: “C37-44”...
Page 309 Engine General Information and Diagnosis: For Petrol Engine Model 1A-240 Reference waveform No.25 Reference waveform No.27 Manifold absolute pressure sensor signal (1) with engine Knock sensor signal at engine speed 4000 r/min. racing Measurement CH1: “C37-56” to “C37-58” Measurement CH1: “C37-55” to “C37-57” terminal terminal CH2: “C37-54”...
Page 310 1A-241 Engine General Information and Diagnosis: For Petrol Engine Model Reference waveform No.31 Reference waveform No.29 Oil control valve signal with engine racing (M16A engine) Ignition coil signal and fuel injector signal with engine cranking Measurement CH1: “C37-60” to “C37-59” terminal CH1: “C37-52”...
Page 311 Engine General Information and Diagnosis: For Petrol Engine Model 1A-242 Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation: For Petrol Engine Model in Section 1C”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors securely.
Page 312: Ecm Power And Ground Circuit Check
1A-243 Engine General Information and Diagnosis: For Petrol Engine Model ECM Power and Ground Circuit Check S6JB0A1114081 Wiring Diagram E23-2 BLK/YEL BLK/WHT E23-29 C37-15 BLK/ORN C37-30 BLK/ORN WHT/GRN C37-29 BLK/YEL C37-48 BLK/YEL BLK/RED BLK/RED E23-60 C37-58 BLK/YEL BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16...
Page 313 Engine General Information and Diagnosis: For Petrol Engine Model 1A-244 Circuit Description When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM. And then ECM supplies 5 V power to each sensor (electric load current sensor (for J20 engine), MAP sensor, A/C refrigerant pressure sensor, APP sensor and TP sensor).
Page 314 1A-245 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Main relay circuit check Go to Step 5. Go to Step 9. 1) Turn ignition switch to OFF position. 2) Check “FI” fuse (1) (20 A) in fuse box No.2 for blowing. For J20 engine I5JB0A110097-02 For M16 engine...
Page 315 Engine General Information and Diagnosis: For Petrol Engine Model 1A-246 Step Action Main relay circuit check Go to Step 9. “BLU/BLK” wire is open circuit or high resistance 1) Remove main relay (1) from fuse box No.2. circuit. For J20 engine I5JB0A110099-02 For M16 engine I5JB0A110100-02...
Page 316: Fuel Injector Circuit Check
1A-247 Engine General Information and Diagnosis: For Petrol Engine Model Step Action 12 Sensor 5 V power source circuit check Check internal short “GRY/RED”, “WHT” circuit of TP sensor, and/or “ORN/BLU” wire 1) Disconnect connectors from ECM, TP sensor, MAP MAP sensor, A/C is shorted to ground sensor, A/C refrigerant pressure sensor (if equipped with...
Page 317 Engine General Information and Diagnosis: For Petrol Engine Model 1A-248 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: For Petrol Engine Model”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: For Petrol Engine Model”.
Page 318: Fuel Pump And Its Circuit Check
1A-249 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Fuel injector drive signal check Check fuel injector “PNK”, “PNK/BLK”, referring to “Fuel “PNK/GRN” and/or 1) Connect connectors to each fuel injector and ECM with Injector Inspection: For “PNK/BLU”...
Page 319 Engine General Information and Diagnosis: For Petrol Engine Model 1A-250 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: For Petrol Engine Model”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: For Petrol Engine Model”.
Page 320 1A-251 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 second after ignition switch is turned ON. Is voltage 0 –...
Page 321: Fuel Pressure Check
Engine General Information and Diagnosis: For Petrol Engine Model 1A-252 Fuel Pressure Check S6JB0A1114084 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I2RH01110133-01 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter and fuel pump Troubleshooting NOTE Before using following flow, check to make sure that battery voltage is higher than 11 V.
Page 322 1A-253 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Fuel line check Faulty fuel pressure Repair or replace regulator. damaged or damaged 1) Check fuel pipe, fuel hose and joint for damage or part. deform. Are they in good condition? Was fuel pressure higher than specification in Step 2? Go to Step 7.
Page 323: A/C System Circuits Check
Engine General Information and Diagnosis: For Petrol Engine Model 1A-254 A/C System Circuits Check S6JB0A1114085 Wiring Diagram WHT/BLU WHT/RED PNK/GRN YEL/RED WHT/BLK WHT/RED E23-4 BLK/RED WHT/BLU E23-19 *RED WHT/RED YEL/GRN YEL/GRN E23-49 RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 BLU/BLK RED/YEL E23-48 YEL/GRN...
Page 324 1A-255 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Reception data check from BCM Go to applicable DTC Go to Step 2. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch. 3) Check DTC for reception data from BCM.
Page 325 Engine General Information and Diagnosis: For Petrol Engine Model 1A-256 Step Action 10 Radiator cooling fan check Radiator cooling fan Replace radiator cooling drive circuit malfunction. fan motor. 1) Check radiator cooling fan referring to “Radiator Cooling If circuit is OK, go to Fan Motor On-Vehicle Inspection: For Petrol Engine Step 7.
Page 326: Electric Load Signal Circuit Check
1A-257 Engine General Information and Diagnosis: For Petrol Engine Model Electric Load Signal Circuit Check S6JB0A1114086 Wiring Diagram WHT/RED E23-4 WHT/BLU E23-19 C37-7 BLU/ORN E03-8 WHT/BLU WHT/RED E03-10 G31-1 E03-12 E03-6 G31-3 39 38 32 31 39 38 32 31 54 53 47 46 54 53...
Page 327 Engine General Information and Diagnosis: For Petrol Engine Model 1A-258 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection: For Petrol Engine Model”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: For Petrol Engine Model”.
Page 328: Radiator Cooling Fan Low Speed Control System Check
1A-259 Engine General Information and Diagnosis: For Petrol Engine Model Radiator Cooling Fan Low Speed Control System Check S6JB0A1114087 Wiring Diagram YEL/GRN RED/BLK E23-46 BLU/WHT BLU/RED BLU/YEL YEL/GRN E23-47 C37-15 BLK/ORN C37-30 BLK/ORN C37-29 BLK/YEL C37-48 BLK/YEL BLU/BLK BLK/YEL C37-58 E23-48 YEL/GRN RED/YEL...
Page 329 Engine General Information and Diagnosis: For Petrol Engine Model 1A-260 Step Action Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 / Go to corresponding Go to Step 2. P0118) and/or radiator cooling fan circuit (DTC P0480)? DTC flow. Low speed radiator cooling fan control circuit check Radiator cooling fan low Perform from Step 2 to...
Page 330 1A-261 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire circuit check Go to Step 8. “BLU/YEL” wire is shorted to ground 1) Disconnect radiator cooling fan motor No.1 connector circuit. with ignition switch turned OFF. 2) Measure resistance between “BLU/YEL” wire terminal of radiator cooling fan relay No.2 connector and vehicle body ground.
Page 331: Radiator Cooling Fan High Speed Control System Check
Engine General Information and Diagnosis: For Petrol Engine Model 1A-262 Step Action 15 Radiator cooling fan relay check Substitute a known- Replace radiator cooling good ECM and recheck. fan relay. 1) Check radiator cooling fan relay referring to “Radiator Cooling Fan Relay Inspection: For Petrol Engine Model in Section 1F”.
Page 332 1A-263 Engine General Information and Diagnosis: For Petrol Engine Model Step Action Wire circuit check Go to Step 5. “BLU/BLK” wire is open circuit. 1) Disconnect radiator cooling fan relay No.3 from relay box with ignition switch turned OFF. 2) Turn ON ignition switch. 3) Measure voltage between “BLU/BLK”...
Page 333: Repair Instructions
“Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): SUZUKI scan tool...
Page 334: Special Tools And Equipment
58413). 09912–58490 09930–76420 3-way joint & hose Timing-light (dry cell type) 09933–06320 SUZUKI scan tool ECM check harness (120P) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 335: For Diesel Engine Model
• Diagnostic information stored in ECM memory can be reliable engine performance. cleared as well as checked by using SUZUKI scan tool or OBD generic scan tool. Before using scan tool, • When raising or supporting engine for any reason, do read its Operator’s (Instruction) Manual carefully to...
Page 336: General Description
1A-267 Engine General Information and Diagnosis: For Diesel Engine Model General Description Statement on Cleanliness and Care Engine Diagnosis General Description S6JB0A1121007 S6JB0A1121002 An automobile engine is a combination of many The engine and emission control system in this vehicle machined, honed, polished and lapped surfaces with are controlled by ECM.
Page 337 DLC (1) is in compliance with SAE J1962 in its installation position, the shape of connector and pin assignment. K line (3) of ISO 9141 is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module, BCM (Body electrical Control Module), 4WD control module and ABS or ESP®...
Page 338: Can Communication System Description
1A-269 Engine General Information and Diagnosis: For Diesel Engine Model CAN Communication System Description S6JB0A1121005 ECM (1), ABS or ESP® control module (2), BCM (3), 4WD control module (4), keyless start control module (5) combination meter (6), immobilizer control module (7) and steering angle sensor (8) (ESP® model) of this vehicle communicate control data between each control module.
Page 339 Engine General Information and Diagnosis: For Diesel Engine Model 1A-270 ECM Transmission Data Keyless start Transmits data Combination 4WD control ESP® control ABS control control of ECM meter module module module module Engine torque signal Accelerator position Engine speed signal MIL control signal Injection warning light control signal (Gravity 1 Fault)
Page 340: Diesel Particulate Filter Regeneration Description
In this situation, “After-sales regeneration” using temperature, ECM will memorize it as “Regeneration SUZUKI scan tool will be necessary or diesel particulate failure”. When the “regeneration failure” number (5 filter has to be replaced in the worst case.
Page 341 Engine General Information and Diagnosis: For Diesel Engine Model 1A-272 I6JB0A112003-02 1. ECM 20. Boost pressure control solenoid valve 39. 4WD control module 2. Exhaust gas temperature sensor 3* 21. Common rail (High pressure fuel injection 40. Immobilizer control module rail) 3.
Page 342: Electronic Control System Wiring Circuit Diagram
1A-273 Engine General Information and Diagnosis: For Diesel Engine Model 5. Oxidation catalytic converter 24. Vacuum pump 43. A/C refrigerant pressure sensor 6. Turbocharger 25. CMP sensor 44. Cruise control switch 7. Boost pressure control valve actuator 26. Glow plug 45.
Page 343 Engine General Information and Diagnosis: For Diesel Engine Model 1A-274 C85-32 C85-8 YEL/GRN C85-27 E66-28 GRN/WHT PNK/BLK C85-29 E66-30 RED/BLK C85-25 PNK/GRN C85-30 RED/GRN C85-26 C86-7 PNK/BLU C85-31 C85-17 BRN/YEL RED/BLU C85-28 C85-1 WHT/BLU C86-17 BRN/WHT WHT/RED C86-16 BRN/BLK WHT/GRN C86-15 BRNYEL BLK/YEL...
Page 344 1A-275 Engine General Information and Diagnosis: For Diesel Engine Model 5. Fuel injector No.4 26. Glow plug 49. ABS or ESP® control module 6. CKP sensor 27. Fuel pump relay 50. 4WD control module 7. CMP sensor 28. Fuel pump 51.
Page 345 Engine General Information and Diagnosis: For Diesel Engine Model 1A-276 Connector: C86 Terminal Circuit Terminal Circuit — EGR valve output — EGR valve output Main power supply Inlet throttle valve feedback — — — Exhaust gas temperature sensor 3 signal —...
Page 346: Component Location
1A-277 Engine General Information and Diagnosis: For Diesel Engine Model Component Location Electronic Control System Components Location S6JB0A1123001 NOTE • The figure shows left-hand steering vehicle. For right-hand steering vehicle, alphabets / numbers / parts with asterisks (**) are installed at the opposite side. •...
Page 347: Diagnostic Information And Procedures
Engine General Information and Diagnosis: For Diesel Engine Model 1A-278 Information sensors Control devices Others r: Red stop warning light (gravity 2 warning light) s: Diesel particulate filter warning light* t: Inlet throttle valve u: EGR valve v: Boost pressure control solenoid valve w: Additional heater relay No.1 x: Additional heater relay No.2 y: Additional heater relay No.3...
Page 348: Engine And Emission Control System Check
1A-279 Engine General Information and Diagnosis: For Diesel Engine Model Engine and Emission Control System Check S6JB0A1124004 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Step 1: Customer Complaint Analysis: For Diesel Engine Model”.
Page 349 Engine General Information and Diagnosis: For Diesel Engine Model 1A-280 Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 350: Dtc Check
Step 8: Final Confirmation Test Confirm that the problem symptom has gone and the 1) Connect SUZUKI scan tool to data link connector in engine is free from any abnormal conditions. If what has the same manner as when making this connection been repaired is related to the DTC, clear the DTC once for DTC check.
Page 351: Dtc Table
S6JB0A1124007 NOTE For vehicle without diesel particulate filter, DTCs with asterisk (*) in table below are not detected. DTC No. Detecting Condition (SUZUKI scan Detecting Item (DTC will set when detecting:) tool) CMP sensor signal frequency above a given P0016 CKP –...
Page 352 1A-283 Engine General Information and Diagnosis: For Diesel Engine Model DTC No. Detecting Condition (SUZUKI scan Detecting Item (DTC will set when detecting:) tool) • EGR valve actuator circuit shorted to ground circuit P0403 EGR Control Circuit • EGR valve actuator circuit open or shorted to power circuit •...
Page 353 Engine General Information and Diagnosis: For Diesel Engine Model 1A-284 DTC No. Detecting Condition (SUZUKI scan Detecting Item (DTC will set when detecting:) tool) Monitor signal of main relay is different from P0685 Main Relay Control Circuit command signal. Sensor power source voltage is too high or too low...
Page 354: Indicator Light Operation Table
• For indicator / warning light operation of items with asterisks (**), refer to corresponding Faulty Finding – Fault Interpretation in this section. • “–” marked in above table indicates that indicator / warning light does not light. Malfunction Injection Red Stop DTC No. (SUZUKI Detecting Item Indicator Warning Light Warning Light scan tool)
Page 355 Engine General Information and Diagnosis: For Diesel Engine Model 1A-286 Malfunction Injection Red Stop DTC No. (SUZUKI Detecting Item Indicator Warning Light Warning Light scan tool) Lamp (MIL) (Gravity 1 Fault) (Gravity 2 Fault) P0641 Sensor Reference Voltage 1 Circuit —...
Page 356: Scan Tool Data
As the data values below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a SUZUKI 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. Therefore, judgment as abnormal should not be made by checking with these data alone.
Page 357 Engine General Information and Diagnosis: For Diesel Engine Model 1A-288 Normal condition / reference Scan tool data Vehicle condition values Cyl 1 FF Correction Cyl 2 FF Correction At specified idle speed without engine load after –1.0 mg/str – 1.0 mg/str Cyl 3 FF Correction warming up to normal operating temperature Cyl 4 FF Correction...
Page 358: Visual Inspection
1A-289 Engine General Information and Diagnosis: For Diesel Engine Model Visual Inspection S6JB0A1124009 Visually check the following parts and systems. Inspection item Referring section • Engine oil-level, leakage “Engine Oil and Filter Change (Petrol Engine Model) in Section 0B” • Engine coolant-level, leakage “Coolant Level Check: For Diesel Engine Model in Section 1F”...
Page 359: Dtc P0016: Ckp - Cmp Correlation
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Inconsistency of signal Troubleshooting Check the CKP sensor and CMP sensor connections.
Page 360: Dtc P0033: Boost Pressure Control Solenoid Valve Control Circuit
The fault is declared present after: – Engine start. – A road test. – Output test “Boost pressure valve” on SUZUKI scan tool. • If the fault is present: – Turbocharging is no longer authorized. – The EGR function is inhibited.
Page 361: Dtc P0089: Fuel Flow Actuator Performance 1A-292
“C90-2” wire. – Clear any solenoid valve faults and perform output test “Boost pressure valve” on SUZUKI scan tool. The voltmeter should display five cycles of two successive voltages: ~ 2.5 V (opening cyclic ratio of 20%) then ~ 8.75 V (opening cyclic ratio of 70%).
Page 362 1A-293 Engine General Information and Diagnosis: For Diesel Engine Model Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to +12 V Short circuit to vehicle body ground Open circuit Internal electronic fault Measured pressure too low Measured pressure too high Insufficient pressure Pressure <...
Page 363 “C83-2” wire of the fuel flow actuator connector, clear any fuel flow actuator faults, then perform “IMV/Flow actuator” on SUZUKI scan tool: The oscilloscope should display a square-wave signal of an amplitude of 12.5 V at a frequency of 185 Hz (with an opening cyclic ratio alternating from 25 to 75%).
Page 364 Check that the fuel pressure sensor is operating correctly using command “IMV/Flow actuator” on SUZUKI scan tool. Display the parameter “Fuel pressure” on Data List of SUZUKI scan tool, and refer to “SUZUKI Scan Tool Data” to check the operating values.
Page 365: Dtc P0100: Mass Or Volume Air Flow Circuit 1A-296
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to +12 V Open circuit or short circuit to vehicle body ground...
Page 366 1A-297 Engine General Information and Diagnosis: For Diesel Engine Model Troubleshooting for D1: Offset at maximum threshold and D2: Offset at minimum threshold NOTE Conditions for applying fault finding procedures to stored faults: The fault is declared present after ignition switch has been turned OFF for 40 seconds. Check the MAF sensor assembly with IAT sensor connections.
Page 367: Dtc P0105: Barometric Pressure Circuit
The fault is declared present after an attempted start, or with the engine running. • If the fault is present: – The air temperature value changes to safe mode, “Intake Air Temp” on Data List of SUZUKI scan tool = 45.1 °C, 113.2 °F.
Page 368 1A-299 Engine General Information and Diagnosis: For Diesel Engine Model Troubleshooting for CO1: Open circuit or short circuit to +12 V Check the MAF sensor assembly with IAT sensor connections. Check the ECM connections. Repair if necessary. Check the continuity of the following connection: •...
Page 369: Dtc P0115: Ect Circuit
– With the engine running • If the fault is present: – The coolant temperature: “Coolant Temp” on Data List of SUZUKI scan tool is fixed at 118.1 °C, 244.6 °F with engine running, 0.1 °C, 32 °F with engine stopping –...
Page 370: Dtc P0190: Fuel Pressure Sensor Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to vehicle body ground Open circuit or short circuit to +12 V...
Page 371 Engine General Information and Diagnosis: For Diesel Engine Model 1A-302 Troubleshooting for D1: Offset at minimum threshold Check the fuel pressure sensor connectors. Check the ECM connections. Repair if necessary. Check the following connections for continuity and make sure there is no interference resistance: •...
Page 372: Dtc P0201: Fuel Injector No.1 Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to +12 V Open circuit Short circuit...
Page 373: Dtc P0202: Fuel Injector No.2 Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to +12 V Open circuit Short circuit...
Page 374: Dtc P0203: Fuel Injector No.3 Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to +12 V Open circuit Short circuit...
Page 375: Dtc P0204: Fuel Injector No.4 Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Short circuit to +12 V Open circuit Short circuit...
Page 376: Dtc P0225: App Sensor (Main) Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V...
Page 377 • Pedal blocked by an external component. Repair if necessary. Vary the position of the pedal and display the parameter “Pedal position” on Data List of SUZUKI scan tool. If the values displayed are inconsistent, replace the accelerator pedal position (APP) sensor assembly.
Page 378: Dtc P0235: Boost Pressure Sensor Circuit
– The EGR function is inhibited. – The turbocharging pressure value changes to safe mode: “Turbo Pressure” on Data List of SUZUKI scan tool = 1000 hPa. – The Injection warning light (gravity 1 warning light) is lit. • Order of priority in the event of more than one fault: Deal with fault “DTC P0641: Sensor Reference Voltage 1 Circuit: For Diesel Engine Model”...
Page 379: Dtc P0243: Boost Pressure Malfunction
In the event of a number of faults with “DTC P0105: Barometric Pressure Circuit: For Diesel Engine Model”, display parameter “Turbo Pressure” on Data List of SUZUKI scan tool. If this value is locked at 1000 hPa and “Barometric Pres” on Data List of SUZUKI scan tool is displaying a different value, replace the boost pressure sensor.
Page 380 Check the connections of the boost pressure control solenoid valve. Check the ECM connections. Repair if necessary. Check the conformity of the turbocharging pressure signal. (Refer to “Turbo Pressure” on Data List of SUZUKI scan tool). Make sure the turbocharging limit solenoid valve is not blocked open: •...
Page 381: Dtc P0297: Vehicle Overspeed Condition
Troubleshooting Check that the fuel injector No.1 calibration code using SUZUKI scan tool is correctly entered and that it corresponds to the code inscribed on the corresponding injector. Enter the code into an fuel injector that has not been programmed or where the code has been entered incorrectly, if necessary.
Page 382: Dtc P0302: Cylinder No.2 Misfire Detected
Troubleshooting Check that the fuel injector No.2 calibration code using SUZUKI scan tool is correctly entered and that it corresponds to the code inscribed on the corresponding injector. Enter the code into an fuel injector that has not been programmed or where the code has been entered incorrectly, if necessary.
Page 383: Dtc P0304: Cylinder No.4 Misfire Detected
Troubleshooting Check that the fuel injector No.4 calibration code using SUZUKI scan tool is correctly entered and that it corresponds to the code inscribed on the corresponding injector. Enter the code into an fuel injector that has not been programmed or where the code has been entered incorrectly, if necessary.
Page 384: Dtc P0340: Cmp Sensor Circuit
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition No signal Inconsistency of signal Troubleshooting Check the CMP sensor connections.
Page 385: Dtc P0380: Glow Plug Control Module Circuit
NOTE • Conditions for applying fault finding procedures to stored faults: The fault is declared present after output test “Pre/Post Heater Relay Control” on SUZUKI scan tool, or after an attempted engine start. • If the fault is present, it is difficult or even impossible to start the vehicle when cold.
Page 386: Dtc P0403: Egr Control Circuit
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 387: Dtc P0409: Egr Motor Malfunction
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 388: Dtc P0470: Differential Sensor Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit Open circuit or short circuit to vehicle body ground...
Page 389: Dtc P0480: Radiator Fan Low Control Circuit 1A-320
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V Troubleshooting for CO0: Open circuit or short circuit to vehicle body ground Check the condition of the radiator fan relay No.1 (Low).
Page 390: Dtc P0481: Radiator Fan High Control Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V Troubleshooting for CO0: Open circuit or short circuit to vehicle body ground Check the condition of the radiator fan relay No.2 (High) and radiator fan relay No.3 (High).
Page 391: Dtc P0486: Egr Stroke Sensor Circuit
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 392: Dtc P0500: Vss Malfunction
Check the operation of the EGR valve: Perform “Initialize EGR valve data” on SUZUKI scan tool to reinitialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 393: Dtc P0530: A/C Refrigerant Pressure Sensor Circuit
Repair if necessary. Connect an air conditioning filling station (equipped with a high pressure gauge) to the vehicle. Display parameter “REFRIGERANT PRESSURE” on HVAC control module with SUZUKI scan tool and compare the value displayed by the filling station. If the values match, carry out a fault finding procedure as described in the fault finding note for that vehicle.
Page 394: Dtc P0544: Exhaust Gas Temperature Sensor 3 Circuit
Check for the presence of ground on “C88-2” wire of the exhaust gas temperature sensor 3 connector. Check the sensor resistance between “C88-1” and “C88-2” terminals of the exhaust gas temperature sensor 3 connector according to parameter “Diesel PF out Temp” on Data list of SUZUKI scan tool. Exhaust gas temperature sensor resistance: 132500 Ω...
Page 395: Dtc P0560: System Voltage
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Overvoltage Undervoltage Troubleshooting for D1: Overvoltage Check the charge circuits: Condition of the battery.
Page 396: Dtc P0571: Brake Light Switch Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit Inconsistency of signal Troubleshooting for D1: Open circuit or short circuit Check the connections of the brake lamp switch.
Page 397: Dtc P0575: Cruise Control Input Circuit
Connect SUZUKI scan tool to DLC with IG switch OFF. b. Turn IG switch to ON position. c. Select “Clear DTC (current P0606 D6)” under “Trouble Code” mode of SUZUKI scan tool and follow instructions displayed on SUZUKI scan tool.
Page 398 1A-329 Engine General Information and Diagnosis: For Diesel Engine Model Detecting Condition Displaying on SUZUKI scan tool Detecting condition Permanent high level Permanent low signal Configuration absent or incorrect Analogue/digital converter fault Communication disrupted EEPROM fault Watchdog Activation Signal outside upper limit...
Page 399: Dtc P0611: Ecm Performance
Program the fuel injector codes again. If the fault is still present, substitute a known-good ECM and recheck. • Otherwise clear the fault memory using DTC clearance on SUZUKI Scan tool referring to “DTC Clearance: For Diesel Engine Model”. Troubleshooting for D2: No code in memory NOTE This fault appears on any blank computer (new or recently reprogrammed).
Page 400: Dtc P0615: Ignition Switch Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Voltage outside permitted range of values Troubleshooting Check continuity and make sure there is no interference resistance on the following connection: •...
Page 401: Dtc P0627: Fuel Pump Control Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V Troubleshooting for CO0: Open circuit or short circuit to vehicle body ground Check the condition of the fuel pump relay.
Page 402: Dtc P0638: Inlet Throttle Valve Control Range / Performance
NOTE After any inlet throttle valve procedures, it is necessary to perform “Initialize inlet throttle valve data” on SUZUKI scan tool. Then turn OFF ignition switch and wait 40 seconds. Check the connections of the inlet throttle valve. Check the ECM connections.
Page 403 NOTE After any inlet throttle valve procedures, it is necessary to perform “Initialize inlet throttle valve data” on SUZUKI scan tool. Inlet throttle valve fault adaptives. Then turn OFF ignition switch and wait 40 seconds. Check the connections of the inlet throttle valve.
Page 404: Dtc P0641: Sensor Reference Voltage 1 Circuit
• Between “C75-4” wire of inlet throttle valve connector and “C86-27” terminal of ECM connector Repair if necessary. • Perform “Initialize inlet throttle valve data” on SUZUKI scan tool. • If the fault is still present, check that the ECM output stage is working correctly.
Page 405 Engine General Information and Diagnosis: For Diesel Engine Model 1A-336 Troubleshooting NOTE Priorities when dealing with a number of faults: If fault “DTC P0225: APP Sensor (Main) Circuit: For Diesel Engine Model” is present at the same time, check that the sensor is connected correctly. In the event of the simultaneous presence of fault “DTC P0235: Boost Pressure Sensor Circuit: For Diesel Engine Model”...
Page 406: Dtc P0645: A/C Compressor Relay Control Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V Troubleshooting for CO0: Open circuit or short circuit to vehicle body ground Check the condition of the A/C compressor relay.
Page 407: Dtc P0651: Sensor Reference Voltage 2 Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Sensor reference voltage too low Sensor reference voltage too high...
Page 408 1A-339 Engine General Information and Diagnosis: For Diesel Engine Model Troubleshooting The sensors connected to supply No.2 are: • EGR valve position sensor. • Sensor for accelerator pedal position (APP) sensor (sub). To locate any faulty sensor and/or connection, disconnect one of the sensors then check whether the fault becomes stored.
Page 409: Dtc P0670: Glow Plug Control Circuit
• Conditions for applying fault finding procedures to stored faults: The fault is declared present after several attempts to start the engine, or perform output test “Pre/ post Heater Relay Control” on SUZUKI scan tool. • It is difficult or even impossible to start the engine when cold.
Page 410: Dtc P0685: Main Relay Control Circuit
Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Relay cut out too soon Relay cut out too late Troubleshooting •...
Page 411 Engine General Information and Diagnosis: For Diesel Engine Model 1A-342 Troubleshooting The sensors connected to supply No.3 are: • Fuel pressure sensor. • MAF sensor assembly with IAT sensor. To locate any faulty sensor and/or connection, disconnect one of the sensors then check whether the fault becomes stored.
Page 412: Dtc P0830: Cpp Switch Circuit
• Use service wire for all operations on the ECM connectors. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Signal absent Inconsistency of signal Troubleshooting Check the condition and adjustment of the clutch pedal position (CPP) switch.
Page 413: Dtc P1431: Clogged Diesel Particulate Filter Failures
The parameters must be reinitialised after any procedure is carried out on the diesel particulate filter. Use command “Initialize Diesel PF data” on SUZUKI scan tool, and diesel particulate filter after-sales regeneration referring to “Diesel Particulate Filter After-sales Regeneration Procedure: For Diesel Engine Model in Section 1C”...
Page 414: Dtc P1480: Upstream Side Differential Pressure Sensor Failure
• Fault appears following several failed regeneration attempts when driving, or if the weight of soot in the filter is above 50 g. • Do not start diesel particulate filter after-sales regeneration with SUZUKI scan tool. Regeneration must absolutely be carried out when driving insofar as possible.
Page 415: Dtc P1642: Additional Heater Relay No.2 And 3 Control Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V...
Page 416: Dtc P2002: Diesel Particulate Filter Efficiency Below Threshold
The parameters must be reinitialised after any procedure is carried out on the diesel particulate filter. Use command “Initialize Diesel PF data” on SUZUKI scan tool, and diesel particulate filter after-sales regeneration referring to “Diesel Particulate Filter After-sales Regeneration Procedure: For Diesel Engine Model in Section 1C”...
Page 417: Dtc P2031: Exhaust Gas Temperature 2 Sensor Circuit
Check for the presence of ground on “C87-1” wire of the exhaust gas temperature sensor 2 connector. Check the exhaust gas temperature sensor 2 resistance between “C87-1” and “C87-2” terminals of the connector according to parameter “Diesel PF in Temp” on Data List of SUZUKI scan tool. Diesel particulate filter upstream temperature: 106000 Ω...
Page 418: Dtc P2120: App Sensor (Sub) Circuit
For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”. Detecting Condition Displaying on SUZUKI scan tool Detecting condition Open circuit or short circuit to vehicle body ground Short circuit to +12 V...
Page 419 Engine General Information and Diagnosis: For Diesel Engine Model 1A-350 Troubleshooting for CC1: Short circuit to +12 V NOTE Priorities when dealing with a number of faults: If fault “DTC P0225: APP Sensor (Main) Circuit: For Diesel Engine Model” is present at the same time, check that the sensor is connected correctly.
Page 420: Dtc P2141: Egr Motor Control Circuit Low
Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve: For Diesel Engine Model”. • If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reintialise the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 421: Dtc P2142: Egr Motor Control Circuit High .1A-352
Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve: For Diesel Engine Model”. • If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reinitialize the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 422: Dtc P2264: Fuel Filter Water Detection Sensor Circuit
1A-353 Engine General Information and Diagnosis: For Diesel Engine Model DTC P2264: Fuel Filter Water Detection Sensor Circuit S6JB0A1124140 NOTE Conditions for applying fault finding procedures to stored faults: The fault is declared present after the engine is started or following a road test. Wiring Diagram For wiring circuit and connector number, refer to “A-5 Engine and A/C Control System Circuit Diagram (DSL) in Section 9A”.
Page 423: Dtc P2413: Egr System Performance
Perform Test 7 referring to “Test 7: Exhaust gas recirculation valve: For Diesel Engine Model”. • If the fault if still present, perform “Initialization EGR valve data” on SUZUKI scan tool to reinitialize the operating values of the valve and launch a programming procedure for the EGR offsets (Refer to “EGR Valve Data Initialization: For Diesel Engine Model in Section 1C”).
Page 424: Dtc P242A: Exhaust Gas Temperature Sensor 1 Circuit
Check the exhaust gas temperature sensor 1 resistance between “C73-1” and “C73-2” terminals of the yellow connector according to parameter “Turbo upst temp.” on Data List of SUZUKI scan tool. exhaust gas temperature sensor 1 resistance: 1572 – 1972 Ω at 400 °C, 752 °F 675 –...
Page 425: Dtc P242B: Exhaust Gas Temperature Sensor 1 Regulation Failure
Check for the presence of ground on “C73-2” wire of the exhaust gas temperature sensor 1 connector. Check the sensor resistance between “C73-1” and “C73-2” terminals of the connector according to parameter “Turbo upst temp.” on Data List of SUZUKI scan tool. exhaust gas temperature sensor 1 resistance: 1572 –...
Page 426: Dtc P2600: Turbocharger Electric Water Pump Control Circuit
• Conditions for applying the fault finding procedure to stored faults: The fault is declared present after ignition switch has been turned OFF and after an interval of 40 seconds, or after output test “Turbo charger cooling pump” on SUZUKI scan tool. • If the fault is present: –...
Page 427: Dtc P3031: Exhaust Gas Temperature Sensor 2 Threshold Overshoot Failures During After-Sales Regeneration
Before carrying out the procedures associated with customer complaints, check for the absence of faults and the conformity (or otherwise) of the parameters and statuses, using SUZUKI scan tool. If the customer complaint is not eliminated, then proceed according to the corresponding fault finding chart.
Page 428 1A-359 Engine General Information and Diagnosis: For Diesel Engine Model Table 1: No dialogue with the ECM S6JB0A1124154 Troubleshooting Try the scan tool on another vehicle. Check the ECM earth point. Check: • Check the connection between the scan tool and the data link connector •...
Page 429 Go to Step 3. Carry out the required Check that engine speed reaches 250 rpm under the starter repairs. motor, as displayed on SUZUKI scan tool. Is the starter motor working properly? Check ECM for DTC(s). Go to “DTC P0335: Go to Step 4.
Page 430 Check the conformity of the air flow signal “MAF” on Data List of SUZUKI scan tool or perform test 3 referring to “Test 3: Checking the turbocharged air inlet circuit: For Diesel Engine Model”. Is there in good condition? If the injection noise occur at all engine speeds: End of fault finding.
Page 431 Engine General Information and Diagnosis: For Diesel Engine Model 1A-362 Table 5: Poor Performance with Smoke S6JB0A1124158 NOTE In the case of engine overheating to more than 119 °C, 246°F the computer deliberately limits the fuel flow (overheating warning light illuminates from 115 °C, 239 °F). Troubleshooting Step Action...
Page 432 For Diesel Engine Model”. • The oil vapour rebreathing system is connected. • The fuel flow actuator (blocked/seized, perform output test “IMV/Flow actuator” on SUZUKI scan tool.). • The engine timing (and the position of the high pressure pump sprocket).
Page 433 Engine General Information and Diagnosis: For Diesel Engine Model 1A-364 Table 7: Irregular Engine Operation S6JB0A1124160 Troubleshooting Step Action If the engine races during gear changes, check, if there is a Go to Step 2. Carry out the required floor carpet, that this is not blocking the accelerator pedal, repairs.
Page 434 1A-365 Engine General Information and Diagnosis: For Diesel Engine Model Table 8: Fuel System Leaks S6JB0A1124161 WARNING When servicing fuel system, be sure to observe WARNING in “Precautions on Fuel System Service: For Diesel Engine Model in Section 1G” to reduce the risk of fire and personal injury. Procedure for checking for an external leak on the fuel circuit: Clean away traces of grease with clean thinner and wipe the part or the parts concerned with cleaning cloths.
Page 435 Is there in good condition? Check the conformity of the fuel injector calibration codes Go to Step 6. Register the fuel injector using SUZUKI scan tool. calibration code into ECM referring to Is it correct codes? “Registration Procedure...
Page 436: Fault Finding-Tests
Substitute a known- pressure”, “Engine speed” and “Metering unit duty” on Data good ECM and recheck. List of SUZUKI scan tool for 30 seconds. Does the fuel pressure difference between min. and max. less than 50 bar? Table 10: Oil leaks from the turbocharger...
Page 437 Engine General Information and Diagnosis: For Diesel Engine Model 1A-368 Test 1: Exhaust system check S6JB0A1124166 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Step Action Engine stopped: Check that the muffler tail end is not...
Page 438: Test 2: Low Pressure Circuit Check
1A-369 Engine General Information and Diagnosis: For Diesel Engine Model Test 2: Low pressure circuit check S6JB0A1124167 Step Action Check the fuel filter: Go to Step 2. Repair or replace the defective part. • Conformity of the fuel filter. • Positioning and degree of contamination of the filter cartridge.
Page 439: Test 3: Checking The Turbocharged Air Inlet Circuit
Engine General Information and Diagnosis: For Diesel Engine Model 1A-370 Test 3: Checking the turbocharged air inlet circuit S6JB0A1124168 Step Action Engine stopped: Check the low and high pressure air circuits Go to Step 2. Carry out the necessary for leaks (air leaks in or out, before and after the repairs.
Page 440: Test 4: Maf Sensor
1A-371 Engine General Information and Diagnosis: For Diesel Engine Model Test 4: MAF sensor S6JB0A1124169 Step Action BREAKAGE OF ELECTRICAL COMPONENTS: Go to Step 2. Replace the MAF Visual inspection: remove the MAF sensor assembly with sensor assembly with IAT sensor, the components must not be broken IAT sensor if necessary.
Page 441: Test 6: Rotating Part Of A Turbocharger
Engine General Information and Diagnosis: For Diesel Engine Model 1A-372 Step Action Reconnect the electrical connector of the boost pressure Replace the Go to Step 6. control solenoid valve. turbocharger. On the control diaphragm of the variable geometry blades, disconnect the pipe coming from the solenoid valve. Connect a pressure gauge in place of the diaphragm.
Page 442: Test 7: Exhaust Gas Recirculation Valve
• Switch ON the ignition again. • Check the movement of the valve with displaying “EGR position sensor” on Data List of SUZUKI scan tool (0 to 2.5 mm travel for an opening cyclic ratio of 40% and when fully open, ~ 5 mm, for an opening cyclic ratio of 95%).
Page 443: Test 8: Injector Malfunction
• With the engine at idle speed, coolant temperature > 80 °C, 176 °F, display the each injector fuel flow correction values “Cyl # FF Correction” on Data List of SUZUKI scan tool. The normal value for fuel flow correction for an injector is ±...
Page 444 1A-375 Engine General Information and Diagnosis: For Diesel Engine Model Step Action CHECK THE FUEL REGULATION BALANCE, INJECTOR Go to Step 3. Repair as necessary. BY INJECTOR: 1) If at least one of these values is > +5.0 mm /stroke •...
Page 445 Engine General Information and Diagnosis: For Diesel Engine Model 1A-376 Step Action INJECTOR RETURN FLOW BALANCE CHECK: Go to Step 5. Repair as necessary. • Allow the engine to heat up to a coolant temperature of > 80 °C, 176 °F. •...
Page 446: Special Tools And Equipment
1A-377 Engine General Information and Diagnosis: For Diesel Engine Model Special Tools and Equipment Special Tool S6JB0A1128001 09912–96540 SUZUKI scan tool Injector flow measuring kit — Mot. 1711 This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 447: Aux. Emission Control Devices
For Petrol Engine Model Diagnostic Information and Procedures EGR System Inspection S6JB0A1214001 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.
Page 448: Evap Canister Purge Valve And Its Circuit Inspection
Connect SUZUKI scan tool to DLC (1) with passage for clog when valve is switched ON and ignition switch turned OFF and disconnect OFF by using SUZUKI scan tool or service wire. purge valve vacuum hoses from intake If check result is not satisfactory, check vacuum manifold and purge pipe.
Page 449: Vacuum Passage Inspection
Aux. Emission Control Devices: For Petrol Engine Model 1B-3 Vacuum Passage Inspection EVAP Canister Purge Valve Inspection S6JB0A1216003 S6JB0A1216005 Start engine and run it at idle speed. Disconnect vacuum WARNING hose (1) from EVAP canister purge valve (2). With finger Do not apply vacuum by mouth;...
Page 450: Evap Canister Inspection
1B-4 Aux. Emission Control Devices: For Petrol Engine Model 4) With coupler disconnected, apply vacuum (–60 kPa 3) Check that there is no restriction of flow through (–8.7 psi)) to pipe (1). If vacuum can be applied, go purge pipe (1) and air pipe (2) when air is blown (4) to next step.
Page 451: Pcv Hose Inspection
Installation Reverse removal procedure noting the following. • For J20 engine, apply sealant to thread part of PCV valve (1). “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I5JB0A120009-04 • For J20 engine, tighten PCV valve to specified torque. [A]: For J20 engine...
Page 452: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A1218001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 453: For Diesel Engine Model
Aux. Emission Control Devices: For Diesel Engine Model 1B-7 For Diesel Engine Model Repair Instructions EGR Valve Inspection If EGR valve does not operate at all, go to next S6JB0A1226006 step. CAUTION If EGR valve operates correctly, EGR valve is in good condition.
Page 454: Exhaust Gas Temperature Sensor 1, 2 And 3
1B-8 Aux. Emission Control Devices: For Diesel Engine Model Exhaust Gas Temperature Sensor 1, 2 and 3 3) Remove exhaust gas temperature sensor 1 (1), 2 (2) and/or 3 (3). Removal and Installation S6JB0A1226007 NOTE Exhaust gas temperature sensor 2 and 3 are equipped with only vehicle with diesel particulate filter.
Page 455: Exhaust Gas Temperature Sensor 1, 2 And
Aux. Emission Control Devices: For Diesel Engine Model 1B-9 Installation 2) Connect exhaust gas temperature sensor 1, 2 and/or 3 connectors (1). 1) Install exhaust gas temperature sensor 1, 2 and/or 3. Tightening torque Exhaust gas temperature sensor 1 (a): 40 N·m ( 4.0 kgf-m, 29.0 lb-ft) Exhaust gas temperature sensor 2 (b): 30 N·m ( 3.0 kgf-m, 22.0 lb-ft)
Page 456: Specifications
1B-10 Aux. Emission Control Devices: For Diesel Engine Model Exhaust Gas Temperature Sensor 1, 2 and 3 Differential Pressure Sensor Removal and Inspection Installation (with Diesel Particulate Filter) S6JB0A1226008 S6JB0A1226009 Removal NOTE 1) Disconnect negative (–) cable at battery. Exhaust gas temperature sensor 2 and 3 are 2) Detach diesel particulate filter differential pressure equipped with only vehicle with diesel sensor (1) from its bracket.
Page 457: Engine Electrical Devices
Engine Electrical Devices: For Petrol Engine Model 1C-1 Engine Electrical Devices Engine For Petrol Engine Model Repair Instructions Engine Control Module (ECM) Removal and Installation Reverse removal procedure noting the following: Installation S6JB0A1316001 • Connect connectors to ECM as follows. CAUTION a.
Page 458: Manifold Absolute Pressure (Map) Sensor Inspection
1C-2 Engine Electrical Devices: For Petrol Engine Model Manifold Absolute Pressure (MAP) Sensor Electric Throttle Body Assembly On-Vehicle Inspection Inspection S6JB0A1316002 S6JB0A1316003 1) Disconnect connector from MAP sensor. WARNING 2) Remove MAP sensor from intake manifold. Never touch throttle valve with finger while 3) Arrange 3 new 1.5 V batteries (2) in series (check ignition switch is turned ON and accelerator that total voltage is 4.5 –...
Page 459 Engine Electrical Devices: For Petrol Engine Model 1C-3 Throttle Valve Operation Check Electric Throttle Body Assembly Operation Check 1) Remove air cleaner outlet hose (for J20 engine) or 1) Remove air cleaner outlet hose (for J20 engine) or air intake pipe (for M16 engine). air intake pipe (for M16 engine).
Page 460 1C-4 Engine Electrical Devices: For Petrol Engine Model Throttle Position Sensor Performance Check b) For throttle position sensor (sub), arrange 3 new 1.5 V batteries (1) in series (check that total 1) Remove air cleaner outlet hose (for J20 engine) or voltage is 4.5 –...
Page 461: Electric Throttle Body System Calibration
Engine Electrical Devices: For Petrol Engine Model 1C-5 Electric Throttle Body System Calibration If sensor voltage is out of specified value and linear variation as the following graph, replace electric throttle S6JB0A1316004 NOTE body assembly. If the service described under the Throttle position sensor output voltage “Precautions of Electric Throttle Body Throttle position sensor (main) [A]: 0.45 –...
Page 462: Accelerator Pedal Position (App) Sensor Assembly On-Vehicle Inspection
1C-6 Engine Electrical Devices: For Petrol Engine Model Accelerator Pedal Position (APP) Sensor Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection Assembly Removal and Installation S6JB0A1316005 S6JB0A1316006 1) Check that accelerator pedal position (APP) sensor CAUTION assembly has been mounted to vehicle body •...
Page 463: Accelerator Pedal Position (App) Sensor Assembly Inspection
Engine Electrical Devices: For Petrol Engine Model 1C-7 Accelerator Pedal Position (APP) Sensor 3) Measure output voltage variation while accelerator pedal is no depressed and fully depressed as Assembly Inspection following specification. S6JB0A1316007 Check accelerator pedal position (APP) sensor (main If sensor voltage is out of specified value or does not and sub) output voltage as following steps.
Page 464: Engine Coolant Temperature (Ect) Sensor Removal And Installation
1C-8 Engine Electrical Devices: For Petrol Engine Model Engine Coolant Temperature (ECT) Sensor Engine Coolant Temperature (ECT) Sensor Removal and Installation Inspection S6JB0A1316008 S6JB0A1316009 Removal Immerse temperature sensing part of ECT sensor in water (or ice) and measure resistance between sensor 1) Disconnect negative cable at battery.
Page 465: Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
Engine Electrical Devices: For Petrol Engine Model 1C-9 Air Fuel Ratio (A/F) Sensor On-Vehicle Adjusting Resistor (J20A Engine) Inspection 1) Disconnect A/F sensor connector. S6JB0A1316010 2) Using ohmmeter, measure resistance of adjusting Heater resistor between terminals “R+” and “R–” at A/F 1) Disconnect A/F sensor connector.
Page 466: Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (Ho2S-2) Removal And Installation
1C-10 Engine Electrical Devices: For Petrol Engine Model Air Fuel Ratio (A/F) Sensor, Heated Oxygen Camshaft Position (CMP) Sensor Removal and Sensor (HO2S-2) Removal and Installation Installation S6JB0A1316012 S6JB0A1316013 Removal Removal 1) Disconnect negative cable at battery. 2) Disconnect connector from CMP sensor. WARNING 3) Remove camshaft position sensor from cylinder To avoid danger of being burned, do not...
Page 467: Camshaft Position (Cmp) Sensor Inspection
Engine Electrical Devices: For Petrol Engine Model 1C-11 Camshaft Position (CMP) Sensor Inspection S6JB0A1316014 Visual check • Check that O-ring is free from damage. • Check that end face of sensor and signal rotor tooth are free from any metal particles and damage. I4RS0B130015-01 Performance check 1) Remove metal particles on end face of CMP sensor,...
Page 468: Crankshaft Position (Ckp) Sensor Removal And Installation
1C-12 Engine Electrical Devices: For Petrol Engine Model Crankshaft Position (CKP) Sensor Removal and For M16 Engine Installation Removal S6JB0A1316015 1) Disconnect negative cable at battery. For J20 Engine 2) Remove generator drive belt, loosen pivot bolt and Removal move generator outward. 1) Remove transmission assembly from vehicle 3) Disconnect connector from crankshaft position referring to “Automatic Transmission Assembly...
Page 469: Crankshaft Position (Ckp) Sensor Inspection
Engine Electrical Devices: For Petrol Engine Model 1C-13 Crankshaft Position (CKP) Sensor Inspection For M16 Engine S6JB0A1316016 Visual check • Check that O-ring is free from damage. For J20 Engine • Check that end face of sensor and signal pulley tooth Waveform Check are free from any metal particles and damage.
Page 470: Knock Sensor Removal And Installation
1C-14 Engine Electrical Devices: For Petrol Engine Model Knock Sensor Removal and Installation Control Relay Inspection S6JB0A1316017 S6JB0A1316018 Removal Control Relay 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Hoist vehicle. 2) Remove main relay (1), fuel pump relay (3), starting motor control relay (2), throttle actuator control relay 3) For M16 engine, remove starting motor referring to (4) and HO2S heater relay (5) (for M16 engine) from...
Page 471: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor On-Vehicle Inspection
Engine Electrical Devices: For Petrol Engine Model 1C-15 Mass Air Flow (MAF) and Intake Air Integration Relay No.2 (For J20 Engine) Temperature (IAT) Sensor On-Vehicle 1) Disconnect negative cable at battery. Inspection 2) Remove included in integration relay No.2 (1) from S6JB0A1316019 fuse box No.2 (2).
Page 472: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Removal And Installation
1C-16 Engine Electrical Devices: For Petrol Engine Model Mass Air Flow (MAF) and Intake Air 6) Turn ON ignition switch and check MAF signal voltage between “C37-26” terminal circuit and “C37- Temperature (IAT) Sensor Removal and 27” terminal circuit of special tool. Installation S6JB0A1316020 MAF signal voltage between “C37-26”...
Page 473: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Inspection
Engine Electrical Devices: For Petrol Engine Model 1C-17 Mass Air Flow (MAF) and Intake Air Vacuum Tank Assembly Inspection (For J20 Temperature (IAT) Sensor Inspection Engine) S6JB0A1316021 S6JB0A1316022 CAUTION CAUTION Do not apply vacuum more than –86 kPa (– Do not heat up MAF and IAT sensor more 12.47 psi);...
Page 474 1C-18 Engine Electrical Devices: For Petrol Engine Model 5) With connector disconnected, apply vacuum to hose Vacuum Tank (1). Air goes into nozzle (2). 1) Check outside of vacuum tank for damage visually. 2) Disconnect vacuum hoses from intake manifold and intake manifold tuning vacuum solenoid valve.
Page 475: Electric Load Current Sensor On-Vehicle Inspection (For J20 Engine)
Engine Electrical Devices: For Petrol Engine Model 1C-19 Electric Load Current Sensor On-Vehicle Without Using SUZUKI Scan Tool Inspection (For J20 Engine) 1) Measure sensor voltage between “C37-9” terminal of S6JB0A1316023 ECM connector and vehicle body ground referring to Using SUZUKI Scan Tool “Inspection of ECM and Its Circuits: For Petrol...
Page 476: Specifications
1C-20 Engine Electrical Devices: For Petrol Engine Model 3) Remove fuse block cover. 4) Disconnect connector from electric load current sensor. 5) Remove electric load current sensor (1) from fuse box No.1 (2). I5JB0A130011-01 Installation Reverse removal procedure noting the following. •...
Page 477: For Diesel Engine Model
Engine Electrical Devices: For Diesel Engine Model 1C-21 For Diesel Engine Model Precautions Precaution in Replacing ECM After replacing ECM, register these information to new S6JB0A1320001 ECM according to “Registration Procedure for the NOTE ECM: For Diesel Engine Model”. Vehicle information with asterisk (*) below –...
Page 478: Repair Instructions
1) Shift transmission into Neutral. 2) Start engine and warm it up to normal operating temperature. 3) Turn all electrical loads OFF. 4) Using SUZUKI scan tool, verify that idle speed is within specification. Engine idle speed : 750 – 850 rpm 5) If not, refer to “SUZUKI Scan Tool Operator’s...
Page 479: Registration Procedure For The Fuel Injector Calibration Code
Engine Electrical Devices: For Diesel Engine Model 1C-23 Registration Procedure for the Fuel Injector 1) Register fuel injector calibration codes as follows. Calibration Code a) Connect SUZUKI scan tool to DLC with ignition S6JB0A1326006 switch OFF. After one or more fuel injector(s) is replaced, register the b) Turn IG switch to ON position.
Page 480: Inlet Throttle Valve Data Initialization
1C-24 Engine Electrical Devices: For Diesel Engine Model Inlet Throttle Valve Data Initialization Diesel Particulate Filter After-sales S6JB0A1326026 Regeneration Procedure 1) Connect SUZUKI scan tool to data link connector S6JB0A1326028 (DLC) (1) with ignition switch OFF. WARNING Special tool During after-sales regeneration, exhaust gas...
Page 481 If faulty condition is found, repair or replace it. 7) Confirm “Diesel PF inlet Temp” under “Data list” of b) Restart aftersales-regeneration referring to SUZUKI scan tool, and wait until it decreases to 200 “Diesel Particulate Filter After-sales °C (392 °F) or less.
Page 482: Glow Plug Removal And Installation
(APP) sensor assembly properly referring to I5JB0B130021-01 “Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation: For Diesel Engine Model”. Installation 2) Connect SUZUKI scan tool to DLC with ignition For installation, reverse removal procedure noting the switch turned OFF. following. Special tool •...
Page 483: Accelerator Pedal Position (App) Sensor Assembly Removal And Installation
Engine Electrical Devices: For Diesel Engine Model 1C-27 4) Check that accelerator pedal position sensor voltage Installation varies as the following graph. Reverse removal procedure for installation noting the If sensor voltage is out of specified value or does not following.
Page 484: Engine Coolant Temperature (Ect) Sensor Removal And Installation
1C-28 Engine Electrical Devices: For Diesel Engine Model Engine Coolant Temperature (ECT) Sensor 2) For accelerator pedal position (APP) sensor (sub), arrange 3 new 1.5 V batteries (1) in series (check Removal and Installation that total voltage is 4.7 – 5.0 V) and connect its S6JB0A1326011 Removal positive terminal to “Vin 2”...
Page 485: Engine Coolant Temperature (Ect) Sensor Inspection
Engine Electrical Devices: For Diesel Engine Model 1C-29 Engine Coolant Temperature (ECT) Sensor Camshaft Position (CMP) Sensor Removal and Inspection Installation S6JB0A1326012 S6JB0A1326013 Removal 1) Remove ECT sensor referring to “Engine Coolant Temperature (ECT) Sensor Removal and 1) Disconnect negative cable at battery. Installation: For Diesel Engine Model”.
Page 486: Crankshaft Position (Ckp) (Engine Speed Sensor) Sensor Inspection
1C-30 Engine Electrical Devices: For Diesel Engine Model Boost Pressure Sensor Removal and Installation Reverse removal procedure for installation noting the Installation following. S6JB0A1326020 Removal • Clean CKP sensor and sensor rotor teeth before 1) Disconnect negative cable at battery. installation.
Page 487: Main Relay And Fuel Heater Relay Inspection
Engine Electrical Devices: For Diesel Engine Model 1C-31 Main Relay and Fuel Heater Relay Inspection Boost Pressure Control Solenoid Valve S6JB0A1326022 Removal and Installation 1) Disconnect negative cable at battery. S6JB0A1326029 Removal 2) Remove main relay (1) and fuel heater relay (2) from 1) Disconnect negative cable at battery.
Page 488: Boost Pressure Control Solenoid Valve Inspection
1C-32 Engine Electrical Devices: For Diesel Engine Model Boost Pressure Control Solenoid Valve NOTE Inspection • It is necessary to pump lever of special S6JB0A1326030 tool several times quickly in order to 1) Remove boost pressure control solenoid valve increase vacuum up to specified value. referring to “Boost Pressure Control Solenoid Valve •...
Page 489: Turbocharger Electric Water Pump Inspection
Engine Electrical Devices: For Diesel Engine Model 1C-33 Turbocharger Electric Water Pump Inspection Installation S6JB0A1326032 Reverse removal procedure noting the followings. 1) Connect 12 V battery terminals to turbocharger • Tighten MAF and IAT sensor screws to specified electric water pump terminals. torque.
Page 490: Specifications
Do not disassembly inlet throttle valve. 4) Confirm the inlet throttle valve operates five times. If inlet throttle valve does nit operate, replace inlet 1) Connect SUZUKI scan tool to data link connector throttle valve referring to “Inlet Throttle Valve (DLC) with ignition switch OFF.
Page 491: Engine Mechanical
Engine Mechanical: For M16A Engine with VVT 1D-1 Engine Mechanical Engine For M16A Engine with VVT General Description Engine Construction Description S6JB0A1411001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V”...
Page 492: Camshaft Position Control (Vvt Variable Valve Timing) System Description
1D-2 Engine Mechanical: For M16A Engine with VVT Camshaft Position Control (VVT Variable Valve Timing) System Description S6JB0A1411002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
Page 493 Engine Mechanical: For M16A Engine with VVT 1D-3 Oil Control Valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM. By this operation, the intake valve timing is varied continuously.
Page 494: Diagnostic Information And Procedures
1D-4 Engine Mechanical: For M16A Engine with VVT Targeted Timing Varying Operation Driving condition Valve timing Target of control Effect To shorten the valve opening overlap in Engine running at idle Stabilization of the engine Most retarded order to prevent the exhaust gas speed rotation at idle speed.
Page 495: Engine Vacuum Check
Engine Mechanical: For M16A Engine with VVT 1D-5 7) Install special tools (Compression gauge) into spark Compression pressure plug hole. Standard: 1400 kPa (14.0 kg/cm , 199.0 psi) Limit: 1100 kPa (11.0 kg/cm , 156.0 psi) Special tool Max. difference between any two cylinders: 100 (A): 09915–64512 kPa (1.0 kg/cm , 14.2 psi)
Page 496: Valve Lash (Clearance) Inspection
1D-6 Engine Mechanical: For M16A Engine with VVT • Exhaust: 0.28 – 0.32 mm (0.011 – 0.013 in.) 4) Connect special tool (Vacuum gauge) to PCV hose When hot (Coolant temperature is 60 – 68 °C (140 – (1). 154 °F)): Special tool •...
Page 497 Engine Mechanical: For M16A Engine with VVT 1D-7 2) Lift down the valve by turning crankshaft to 360°. 4) Turn camshaft by approximately 90° clockwise and remove shim (3). 3) Hold tappet at that position using special tool as follows. WARNING a) Remove its housing bolts.
Page 498 1D-8 Engine Mechanical: For M16A Engine with VVT For example of intake side: 8) Lift valve by turning crankshaft counterclockwise (in When thickness of removed shim is 2.40 mm (0.094 opposite direction against above Step 4)) and in.), and measured valve clearance is 0.45 mm remove special tool.
Page 499: Repair Instructions
Engine Mechanical: For M16A Engine with VVT 1D-9 Repair Instructions Air Cleaner Filter Removal and Installation Cylinder Head Cover Removal and Installation S6JB0A1416001 S6JB0A1416003 Removal Removal 1) Open air cleaner case (1) by unhooking its clamps 1) Disconnect negative cable at battery. (2).
Page 500 “A” to the following point. • Cylinder head cover gasket (1) sealing surface area (2) as shown. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I6RS0B141004-01 Installation 1) Install new cylinder head cover gasket (2) to cylinder head cover (1) as shown in the figure.
Page 501: Throttle Body And Intake Manifold Components
Engine Mechanical: For M16A Engine with VVT 1D-11 8) Install wire harness clamp to cylinder head cover. 5) Connect PCV hose (2) to PCV valve (3). 6) Connect breather hose (4). 9) Install ignition coil assemblies with high-tension cord. 10) Connect ignition coil couplers and clamp harness 7) Install oil level gauge (1).
Page 502: Throttle Body On-Vehicle Inspection
1D-12 Engine Mechanical: For M16A Engine with VVT Throttle Body On-Vehicle Inspection S6JB0A1416005 Check electric throttle body assembly referring to “Throttle Valve Operation Check” and “Electric Throttle Body Assembly Operation Check” under “Electric Throttle Body Assembly On-Vehicle Inspection: For Petrol Engine Model in Section 1C”.
Page 503: Throttle Body Cleaning
Engine Mechanical: For M16A Engine with VVT 1D-13 Throttle Body Cleaning 8) Remove intake manifold (1) and EGR pipe bolt (2) S6JB0A1416007 from cylinder head, and then remove its gaskets. Clean electric throttle body assembly referring to “Throttle Valve Visual Check” under “Electric Throttle Body Assembly On-Vehicle Inspection: For Petrol Engine Model in Section 1C”.
Page 504: Engine Mountings Components
1D-14 Engine Mechanical: For M16A Engine with VVT Engine Mountings Components S6JB0A1416009 I5JB0A141015-02 1. Engine front mounting 4. Engine rear mounting member : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Engine front mounting right bracket 5. Engine rear mounting : 17 N⋅m (1.7 kgf-m, 12.5 lb-ft) 3.
Page 505 Engine Mechanical: For M16A Engine with VVT 1D-15 • Each wire harness clamps 7) Disconnect MAF sensor connector (1). 8) Remove air cleaner case (2). 12) Disconnect the following hoses: • Brake booster hose (22) from intake manifold • Radiator inlet and outlet hoses (26) from each pipe •...
Page 506 1D-16 Engine Mechanical: For M16A Engine with VVT 17) With hose connected, detach A/C compressor from 22) Before lowering engine with transmission and front its bracket (if equipped) referring to “Compressor suspension frame from engine compartment, Assembly Removal and Installation for M16 Engine recheck to make sure all hoses, electric wires and Model in Section 7B”.
Page 507 Engine Mechanical: For M16A Engine with VVT 1D-17 3) Connect transmission to engine referring to “Manual 15) Install air cleaner case (2). Transmission Assembly Dismounting and 16) Connect MAF sensor connector (1). Remounting: For Petrol Engine Model in Section 5B”, if necessary. 4) Lift engine with transmission and front suspension frame into engine compartment with jack.
Page 508: Timing Chain Cover Components
1D-18 Engine Mechanical: For M16A Engine with VVT Timing Chain Cover Components S6JB0A1416011 I5JB0A141020-02 1. Crankshaft pulley bolt 9. Oil gallery pipe No.1 17. Oil control valve 2. Crankshaft pulley 10. Copper washer : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.
Page 509: Timing Chain Cover Removal And Installation
Engine Mechanical: For M16A Engine with VVT 1D-19 Timing Chain Cover Removal and Installation 5) Remove crankshaft pulley (1). S6JB0A1416012 If it is hard to remove, use special tools as shown in the figure. CAUTION Special tool • Keep working table, tools and hands clean (A): 09944–36011 while overhauling.
Page 510 Tightening torque chain cover as shown in the figure. Timing chain cover bolt and nut (a): 25 N·m (2.5 “A”: Water tight sealant 99000–31140 (SUZUKI kgf-m, 18.0 lb-ft) Bond No.1207B) 6) Apply engine oil to new O-rings and install them to “B”: Sealant 99000–31260 (SUZUKI Bond...
Page 511: Timing Chain Cover Inspection
Engine Mechanical: For M16A Engine with VVT 1D-21 8) Install new O-ring (1) to oil gallery pipes No.2 (2) and 14) Install water pump and generator drive belt referring No.3 (3). to “Water Pump and Generator Drive Belt Removal and Installation (For M16 Engine): For Petrol Engine 9) Install oil gallery pipes No.2 and No.3 to cylinder Model in Section 1J”.
Page 512: Oil Control Valve Inspection
1D-22 Engine Mechanical: For M16A Engine with VVT Oil Control Valve Inspection 4) Remove P/S pump bracket. S6JB0A1416015 5) Remove oil gallery pipe No.1 (1) and oil control valve (2) from timing chain cover (3). Oil Control Valve 1) Inspect strainer (1) and mating surface (2) of oil Installation control valve for clog or damage.
Page 513: Timing Chain And Chain Tensioner Components
Engine Mechanical: For M16A Engine with VVT 1D-23 Timing Chain and Chain Tensioner Components S6JB0A1416016 I4RS0A140012-04 1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Timing chain 6. Chain tensioner adjuster mounting bolt : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) : Apply engine oil.
Page 514 1D-24 Engine Mechanical: For M16A Engine with VVT Installation 3) Install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft CAUTION timing sprocket as shown in the figure. After timing chain is removed, never turn 4) Fit crankshaft timing sprocket to timing chain by crankshaft and camshafts independently aligning gold plate (3) of timing chain and circle mark...
Page 515 Engine Mechanical: For M16A Engine with VVT 1D-25 6) Apply engine oil to sliding surface of chain tensioner 8) Screw in plunger (1) by turning body (2) in arrow (1) and install chain tensioner and spacer. direction and install a retainer (3) (wire) to hold Tighten tensioner bolt to specified torque.
Page 516: Timing Chain And Chain Tensioner Inspection
1D-26 Engine Mechanical: For M16A Engine with VVT 10) Apply engine oil to timing chain and then turn Timing Chain Tensioner crankshaft clockwise by 2 revolutions and check that Check shoe (1) for wear or damage. match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is in match with notch (4) on cylinder black as shown in the figure.
Page 517: Camshaft, Tappet And Shim Components
Engine Mechanical: For M16A Engine with VVT 1D-27 Camshaft, Tappet and Shim Components S6JB0A1416019 I4RS0A140013-01 1. Intake camshaft 5. Shim 9. Upper camshaft bearing : Shim No. on it faces tappet side. : Install a bearing half with some holes to upper side of intake camshaft No.1 bearing.
Page 518 1D-28 Engine Mechanical: For M16A Engine with VVT 4) Loosen camshaft housing bolts in such order as Installation indicated in the figure and remove them. 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to “12”...
Page 519 Engine Mechanical: For M16A Engine with VVT 1D-29 3) Install intake camshaft (1) and exhaust camshaft (2). 6) Check position of camshaft housings. Align knock pin (3) and match mark (4) with notches Embossed marks are provided on each camshaft (5) as shown in the figure.
Page 520: Camshaft, Tappet And Shim Inspection
1D-30 Engine Mechanical: For M16A Engine with VVT 9) Install timing chain with crankshaft sprocket referring Camshaft Runout to “Timing Chain and Chain Tensioner Removal and Set camshaft between two “V” blocks, and measure its Installation: For M16A Engine with VVT”. runout by using a dial gauge.
Page 521 Engine Mechanical: For M16A Engine with VVT 1D-31 Tightening torque If measured camshaft journal clearance exceeds Camshaft housing bolt (a): 11 N·m (1.1 kgf-m, limit, measure journal (housing) bore and outside 8.0 lb-ft) diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater.
Page 522 1D-32 Engine Mechanical: For M16A Engine with VVT Wear of Tappet and Shim Check tappet and shim for pitting, scratches, or damage. If any malcondition is found, replace. I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.
Page 523: Valves And Cylinder Head Components
Engine Mechanical: For M16A Engine with VVT 1D-33 Valves and Cylinder Head Components S6JB0A1416022 I4RS0A140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2.
Page 524: Valves And Cylinder Head Removal And Installation
1D-34 Engine Mechanical: For M16A Engine with VVT Valves and Cylinder Head Removal and Installation Installation 1) Clean mating surface of cylinder head and cylinder S6JB0A1416023 block. Remove oil, old gasket and dust from mating surface. Removal 2) Install knock pins (1) to cylinder block. 1) Remove engine assembly from vehicle referring to 3) Install new cylinder head gasket (2) to cylinder block.
Page 525: Valves And Cylinder Head Disassembly And Assembly
Engine Mechanical: For M16A Engine with VVT 1D-35 10) Install oil pan referring to “Oil Pan and Oil Pump 5) Install cylinder head to cylinder block. Apply engine oil to new cylinder head bolts and Strainer Removal and Installation: For M16A Engine tighten them gradually as follows.
Page 526 1D-36 Engine Mechanical: For M16A Engine with VVT 3) Release special tools (Valve lifter), and remove Assembly spring retainer and valve spring. 1) Before installing valve guide into cylinder head, ream 4) Remove valve from combustion chamber side. guide hole with special tool (10.5 mm reamer) so as to remove burrs and make it truly round.
Page 527 Engine Mechanical: For M16A Engine with VVT 1D-37 3) Ream valve guide bore with special tool (5.5 mm 6) Install valve to valve guide. reamer). After reaming, clean bore. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore and valve stem. Special tool (A): 09916–34542 (B): 09916–34550...
Page 528: Valves And Valve Guides Inspection
1D-38 Engine Mechanical: For M16A Engine with VVT 8) Using special tools (Valve lifter), compress valve Valve stem and valve guide specification spring and fit two valve cotters (1) into groove in Item Standard Limit valve stem. 5.465 – 5.480 mm Valve stem —...
Page 529 Engine Mechanical: For M16A Engine with VVT 1D-39 Valve Valve head radial runout Check each valve for radial runout with a dial gauge and Visual inspection “V” block. To check runout, rotate valve slowly. If runout • Remove all carbon from valves. exceeds its limit, replace valve.
Page 530: Cylinder Head Inspection
1D-40 Engine Mechanical: For M16A Engine with VVT NOTE Valve seat repair A valve seat not producing a uniform contact with its Do not use any sharp-edged tool to scrape valve or showing width of seating contact that is out of off carbon deposits.
Page 531: Valve Spring Inspection
Engine Mechanical: For M16A Engine with VVT 1D-41 Valve Spring Inspection • Distortion of manifold seating faces: Check seating faces of cylinder head for manifolds, S6JB0A1416027 using a straightedge and thickness gauge, in order to Valve Spring Free Length and Preload determine whether these faces should be corrected or Referring to data, check to be sure that each spring is in cylinder head replaced.
Page 532: Pistons, Piston Rings, Connecting Rods And Cylinders Components
1D-42 Engine Mechanical: For M16A Engine with VVT Pistons, Piston Rings, Connecting Rods and Cylinders Components S6JB0A1416028 I2RH0B140108-01 [A]: 1) Tighten all nuts to 15 N⋅m (1.5 kgf-m). 7. Connecting rod bearing 2) Then retighten all nuts by turning through 45°. 3) Repeat Step 2) again.
Page 533 Engine Mechanical: For M16A Engine with VVT 1D-43 Installation Special tool (A): 09916–77310 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. NOTE Do not apply oil between connecting rod and bearing or between bearing cap and bearing. 2) Install guide hoses (1) over connecting rod bolts.
Page 534: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
1D-44 Engine Mechanical: For M16A Engine with VVT Pistons, Piston Rings, Connecting Rods and NOTE Cylinders Disassembly and Assembly Circlip should be installed with its cut part S6JB0A1416030 facing as shown in the figure. Install so that circlip end gap comes within such range as Disassembly indicated by arrow.
Page 535: Cylinders, Pistons And Piston Rings Inspection
Engine Mechanical: For M16A Engine with VVT 1D-45 Cylinders, Pistons and Piston Rings Inspection Piston S6JB0A1416031 Visual inspection Inspect piston for faults, cracks or other damages. Cylinder Damaged or faulty piston should be replaced. Visual inspection Inspect cylinder walls for scratches, roughness or ridges Piston diameter which indicate excessive wear.
Page 536 1D-46 Engine Mechanical: For M16A Engine with VVT Piston clearance Piston Ring Standard: 0.032 – 0.061 mm (0.0013 – 0.0024 in.) Piston ring end gap Standard (piston with coating (new one)): 0.016 – To measure end gap, insert piston ring (2) into cylinder 0.045 mm (0.0006 –...
Page 537: Piston Pins And Connecting Rods Inspection
Engine Mechanical: For M16A Engine with VVT 1D-47 Piston Pins and Connecting Rods Inspection Connecting Rod S6JB0A1416032 Big-end side clearance Check big-end of connecting rod for side clearance, with Piston Pin rod fitted and connected to its crank pin in the normal Visual inspection manner.
Page 538: Crank Pin And Connecting Rod Bearings Inspection
1D-48 Engine Mechanical: For M16A Engine with VVT Connecting rod bolt deformation (Plastic Out-of-round deformation tightening bolt) A – B Measure each thread diameter of connecting rod bolt (2) Taper at “A” on 32 mm (1.25 in.) from bolt mounting surface a –...
Page 539 Engine Mechanical: For M16A Engine with VVT 1D-49 Connecting Rod Bearing Clearance Connecting rod bearing clearance Standard: 0.029 – 0.047 mm (0.0011 – 0.0018 in.) 1) Before checking bearing clearance, clean bearing Limit: 0.065 mm (0.0026 in.) and crank pin. 2) Install bearing in connecting rod and bearing cap.
Page 540 1D-50 Engine Mechanical: For M16A Engine with VVT 3) There are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in the figure. Each color indicated the following thickness at the center of bearing.
Page 541: Main Bearings, Crankshaft And Cylinder Block Components
Engine Mechanical: For M16A Engine with VVT 1D-51 Main Bearings, Crankshaft and Cylinder Block Components S6JB0A1416034 I5JB0A141026-02 1. CKP sensor (if equipped) 10. Rear oil seal housing 19. Spring pin : See “A” : See “C” 2. Knock sensor 11. Rear oil seal 20.
Page 542: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
1D-52 Engine Mechanical: For M16A Engine with VVT 4. Venturi plug 13. Flywheel : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) 5. Main bearing 14. Main bearing cap : 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) : See “B” 6. Sensor plate 15.
Page 543 Engine Mechanical: For M16A Engine with VVT 1D-53 1) Install sensor plate (1) to crankshaft (2) and tighten 5) Install crankshaft to cylinder block. bolts to specified torque. 6) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley NOTE side.
Page 544 I4RS0A140019-01 8) Apply sealant to mating surface of rear oil seal A: Crankshaft side housing (1). “A”: Water tight sealant 99000–31250 (SUZUKI 10) Install flywheel (for M/T). Bond No.1207F) Using special tool, lock flywheel, and tighten flywheel bolts to specified torque.
Page 545: Crankshaft Inspection
Engine Mechanical: For M16A Engine with VVT 1D-55 Crankshaft Inspection a) Tighten bolts (1) – (10) to 30 N⋅m (3.0 kgf-m, S6JB0A1416036 22.0 lb-ft) according to numerical order in the figure. Crankshaft Runout b) In the same manner as in Step a), tighten them Using a dial gauge, measure runout at center journal.
Page 546: Main Bearings Inspection
1D-56 Engine Mechanical: For M16A Engine with VVT Out-of-Round and Taper (Uneven Wear) of Journals Visual Inspection An unevenly worn crankshaft journal shows up as a Check bearings for pitting, scratches, wear or damage. difference in diameter at a cross section or along its If any malcondition is found, replace both upper and length (or both).
Page 547 Engine Mechanical: For M16A Engine with VVT 1D-57 Tightening torque Selection of Main Bearings Main bearing cap No.1 bolt ((1) – (10)): 30 Standard bearing Nm (3.0 kgf-m, 22.0 lb-ft), 50 Nm (5.0 kgf-m, If bearing is in malcondition, or bearing clearance is out 36.5 lb-ft) and then retighten by turning of specification, select a new standard bearing according through 60°...
Page 548 1D-58 Engine Mechanical: For M16A Engine with VVT 2) Next, check bearing cap bore diameter without 3) There are 5 kinds of standard bearings differing in bearing. On mating surface of cylinder block, five thickness. To distinguish them, they are painted in alphabets are stamped as shown in the figure.
Page 549 Engine Mechanical: For M16A Engine with VVT 1D-59 6) When replacing crankshaft or cylinder block due to 5) Using scale (1) on gauging plastic (2), check bearing clearance with newly selected standard bearing. any reason, select new standard bearings to be If clearance still exceeds its limit, use next thicker installed by referring to number stamped on new bearing and recheck clearance.
Page 550 1D-60 Engine Mechanical: For M16A Engine with VVT • If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. a. Regrind journal to the following finished diameter. Finished journal diameter 51.732 – 51.750 mm (2.0367 – 2.0374 in.) b.
Page 551: Sensor Plate Inspection
Engine Mechanical: For M16A Engine with VVT 1D-61 Sensor Plate Inspection Cylinder Block Inspection S6JB0A1416038 S6JB0A1416041 Check sensor plate for crack damage. If malcondition is found, replace it. Distortion of Gasketed Surface Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It.
Page 552: Specifications
1D-62 Engine Mechanical: For M16A Engine with VVT Specifications Tightening Torque Specifications S6JB0A1417001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolts 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) for tightening of special tool Camshaft housing bolt Cylinder head cover bolt Air intake pipe bolt Starting motor terminal nut Generator terminal nut...
Page 553: Special Tools And Equipment
Engine Mechanical: For M16A Engine with VVT 1D-63 Special Tools and Equipment Recommended Service Material S6JB0A1418001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 554 1D-64 Engine Mechanical: For M16A Engine with VVT 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310 Tappet holder...
Page 555: For J20 Engine
Engine Mechanical: For J20 Engine 1D-65 For J20 Engine General Description Engine Construction Description S6JB0A1421001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 556 1D-66 Engine Mechanical: For J20 Engine I5JB0A142069-02...
Page 557: Air Cleaner Element Introduction
Engine Mechanical: For J20 Engine 1D-67 Air Cleaner Element Introduction S6JB0A1421002 This air cleaner element is dry type. Remember that it needs cleaning according to “Air Cleaner Filter Inspection and Cleaning: For J20 Engine”. IMT (Intake Manifold Tuning) System Description S6JB0A1421003 I5JB0A142062-01 IMT (Intake manifold tuning) system consists of the following items:...
Page 558 1D-68 Engine Mechanical: For J20 Engine [A + B] (rpm) (rpm) [A]: [B]: I5JB0A142063-03 [A]: IMT valve open 1. IMT valve 3. Engine torque [B]: IMT valve closed 2. Intake manifold 4. Engine speed IMT (Intake manifold tuning) system varies effective length of intake pipe by opening and closing IMT valve in order to improve air volumetric efficiency.
Page 559: Diagnostic Information And Procedures
Engine Mechanical: For J20 Engine 1D-69 System Operation IMT vacuum solenoid valve open: When IMT vacuum solenoid valve is OFF, the actuator side of IMT vacuum solenoid valve is lead to relief port. Under this condition, the negative pressure is not applied to IMT valve actuator. The IMT valve, therefore, is totally opened due to the force of return spring in IMT valve actuator.
Page 560: Engine Vacuum Check
12) After checking, install spark plugs (2) and ignition Special tool coils (1). (A): 09915–67311 (B): 09918–08210 (C): 09355–35754–600 Hose, SUZUKI GENUINE PARTS (D): 09367–04002 3-way joint, SUZUKI GENUINE PARTS I2RH01140002-01 13) Install ignition coil couplers. 14) Connect injector wire harness at coupler. 15) Install engine cover. I5JB0A142002-01 5) Start engine and run engine at specified idle speed, and read vacuum gauge.
Page 561: Valve Lash (Clearance) Inspection
Engine Mechanical: For J20 Engine 1D-71 Valve Lash (Clearance) Inspection If valve lash is out of specification, record valve lash and S6JB0A1424003 adjust it to specification by replacing shim. 1) Remove negative cable at battery. Valve clearance specification 2) Remove cylinder head cover referring to “Cylinder When cold (Coolant temperature is 15 –...
Page 562 1D-72 Engine Mechanical: For J20 Engine 2) Lift down the valve by turning crankshaft to 360°. 4) Turn camshaft by approximately 90° clockwise and remove shim (3). 3) Hold tappet at that position using special tool as follows. WARNING a) Remove its housing bolts. Never put in the hand between camshaft and b) Check housing No.
Page 563 Engine Mechanical: For J20 Engine 1D-73 For example of intake side: 8) Lift valve by turning crankshaft counterclockwise (in When thickness of removed shim is 2.40 mm (0.094 opposite direction against above Step 4)) and in.), and measured valve clearance is 0.45 mm remove special tool.
Page 564: Repair Instructions
1D-74 Engine Mechanical: For J20 Engine Repair Instructions Air Cleaner Assembly Removal and Installation Air Cleaner Filter Removal and Installation S6JB0A1426001 S6JB0A1426002 Removal Removal 1) Disconnect breather hose (1) from air cleaner outlet 1) Remove air cleaner upper case (1) from lower case hose (2).
Page 565: Throttle Body And Intake Manifold Components
Engine Mechanical: For J20 Engine 1D-75 Throttle Body and Intake Manifold Components S6JB0A1426004 I5JB0A142005-01 1. Intake manifold 4. Electric throttle body assembly : Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. 2.
Page 566: Throttle Body On-Vehicle Inspection
1D-76 Engine Mechanical: For J20 Engine Throttle Body On-Vehicle Inspection 3) Connect connector (2) to electric throttle body S6JB0A1426005 assembly securely. Check electric throttle body assembly referring to 4) Connect engine coolant hoses (3) to electric throttle “Throttle Valve Operation Check” and “Electric Throttle body assembly (1).
Page 567: Cylinder Head Cover Removal And Installation
Engine Mechanical: For J20 Engine 1D-77 2) Drain cooling system referring to “Cooling System Installation Draining: For Petrol Engine Model in Section 1F”. Reverse removal procedure for installation noting the followings. 3) Remove engine cover. • Use new intake manifold O-ring. 4) Remove air cleaner outlet hose (1) and breather hose (2).
Page 568 4) Apply sealant “A” to cylinder head sealing surface 10) Connect breather hose (2) and PCV hose (3) to area as shown in figure. cylinder head cover. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I5JB0A142067-01 I5JB0A142015-01 11) Install ignition coils referring to “Ignition Coil Assembly (Including ignitor) Removal and Installation: For Petrol Engine Model in Section 1H”.
Page 569: Engine Mountings Components
Engine Mechanical: For J20 Engine 1D-79 Engine Mountings Components S6JB0A1426010 I6JB0A142001-01 [A]: Type A 4. Engine rear mounting member 10. Heat protector panel [B]: Type B 5. Engine rear mounting 11. Exhaust pipe No.1 bracket [C]: View [A], [B] 6. Engine splash cover 12.
Page 570: Engine Assembly Removal And Installation
1D-80 Engine Mechanical: For J20 Engine Engine Assembly Removal and Installation 10) Disconnect the following hoses: S6JB0A1426011 • Brake booster hose (21) from intake manifold • Radiator inlet and outlet hoses (22) from each Removal pipe 1) Relieve fuel pressure according to “Fuel Pressure •...
Page 571 Engine Mechanical: For J20 Engine 1D-81 12) For M/T model, remove shift control lever referring to 20) Remove engine rear mounting member bolts (1). “Transmission Shift Control Lever Removal and Installation: For Petrol Engine Model in Section 5B”. 13) Remove exhaust No.1, No.2 and center pipes referring to “Exhaust System Components: For Petrol Engine Model in Section 1K”.
Page 572 1D-82 Engine Mechanical: For J20 Engine Installation 11) Install P/S pump to its bracket referring to “P/S Pump Removal and Installation (J20A Engine Model) in 1) Install clutch cover and clutch disk referring to Section 6C”. “Clutch Cover, Clutch Disc and Flywheel Removal and Installation in Section 5C”, if removed.
Page 573: Timing Chain Cover Components
Engine Mechanical: For J20 Engine 1D-83 Timing Chain Cover Components S6JB0A1426012 1207B 1207F I5JB0A142021-01 1. Crankshaft pulley bolt 6. Timing chain cover bolt and nut : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) 2. Crankshaft pulley 7. Idler pulley : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.
Page 574 1D-84 Engine Mechanical: For J20 Engine 5) Remove crankshaft pulley (1). Installation To remove crankshaft pulley, use special tools 1) Clean sealing surfaces on timing chain cover, (Steering wheel remover, Bearing puller attachment) cylinder block and cylinder head. with it as shown in figure. Remove oil, oil sealant and dust from sealing surface.
Page 575 4) Apply engine oil to oil seal lip, then install timing in figure. chain cover (1). Tighten bolts and nut to specified torque. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) NOTE “B”: Water tight sealant 99000–31140 (SUZUKI Before installing timing chain cover, check Bond No.1207B)
Page 576: Timing Chain Cover Cleaning And Inspection
1D-86 Engine Mechanical: For J20 Engine 10) Install crankshaft pulley. To lock crankshaft pulley 11) Install engine assembly to vehicle referring to (1), use special tool (camshaft pulley holder) as “Engine Assembly Removal and Installation: For J20 shown in figure. Engine”.
Page 577: 2Nd Timing Chain And Chain Tensioner Removal And Installation
Engine Mechanical: For J20 Engine 1D-87 4. Intake camshaft timing sprocket 9. Pin : Do not reuse. 5. Exhaust camshaft timing sprocket 10. Oil relief valve 2nd Timing Chain and Chain Tensioner Removal Removal and Installation 1) Remove engine assembly from vehicle referring to S6JB0A1426016 “Engine Assembly Removal and Installation: For J20 Engine”.
Page 578 1D-88 Engine Mechanical: For J20 Engine 6) Remove timing chain tensioner adjuster No.2 (1) and Installation gasket. To remove them, slacken 2nd timing chain 1) Check that match mark (1) on crank timing sprocket by turning intake camshaft counterclockwise a little is in match with timing mark (2) on lower crankcase while pushing back pad.
Page 579 Engine Mechanical: For J20 Engine 1D-89 5) Install sprockets to intake and exhaust camshafts by 7) Push back plunger (1) into tensioner body (2), and aligning dark blue plate of 2nd timing chain, match hold it at the position by inserting stopper (3) into marks on intake sprocket and exhaust sprocket body.
Page 580: 2Nd Timing Chain And Chain Tensioner Inspection
1D-90 Engine Mechanical: For J20 Engine 2nd Timing Chain and Chain Tensioner 10) Turn crankshaft two rotations clockwise, and then align timing mark (1) on crankshaft and timing mark Inspection (2) on cylinder block as shown in figure. S6JB0A1426017 At this time, check timing marks (3, 5 and 7) of Timing Chain Guide No.2 sprockets are in match with timing marks (4, 6 and 8) Check shoe (2) for wear or damage.
Page 581: 1St Timing Chain And Chain Tensioner Components
Engine Mechanical: For J20 Engine 1D-91 1st Timing Chain and Chain Tensioner Components S6JB0A1426018 I5JB0A142027-01 1. 1st timing chain 6. Timing chain tensioner adjuster No.1 : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Idler sprocket 7. Timing chain guide No.1 : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft) 3.
Page 582 1D-92 Engine Mechanical: For J20 Engine 2) Check that match mark (1) on crankshaft timing 7) Apply engine oil to sliding surface of timing chain sprocket is in match with timing mark (2) on lower tensioner (1) and then install it as shown in figure. crankcase.
Page 583: Inspection
Engine Mechanical: For J20 Engine 1D-93 11) Apply engine oil to sliding surface of timing chain 13) Install 2nd timing chain. Refer to “2nd Timing Chain guide No.1 (1) and then install it. and Chain Tensioner Removal and Installation: For Tighten guide bolts to specified torque.
Page 584: Camshafts, Tappet And Shim Components
1D-94 Engine Mechanical: For J20 Engine 1st Timing Chain Crankshaft Timing Sprocket Check teeth of sprocket for wear or damage. Check timing chain for wear or damage. I2RH01140077-01 Timing Chain Tensioner Adjuster No.1 Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.
Page 585: Camshafts, Tappet And Shim Removal And Installation
Engine Mechanical: For J20 Engine 1D-95 Camshafts, Tappet and Shim Removal and 2) Match match mark (1) on crank timing sprocket and mating surface of cylinder block and lower Installation crankcase (2). S6JB0A1426022 CAUTION • Keep working table, tools and hands clean while overhauling.
Page 586: Camshaft, Tappet And Shim Inspection
1D-96 Engine Mechanical: For J20 Engine 5) Check position of camshaft housings. 8) Install 2nd timing chain. Refer to “2nd Timing Chain Embossed marks are provided on each camshaft and Chain Tensioner Removal and Installation: For housing, indicating position and direction for J20 Engine”...
Page 587 Engine Mechanical: For J20 Engine 1D-97 Camshaft Runout 5) Tighten camshaft housing bolts in such order as Set camshaft between two “V” blocks, and measure its indicated in figure a little at a time till they are runout by using a dial gauge. tightened to specified torque.
Page 588 1D-98 Engine Mechanical: For J20 Engine Camshaft journal Cylinder head bore and tappet outside diameter Item Standard Item Standard Limit Camshaft journal bore 26.000 – 26.033 mm Tappet outside 32.456 – 32.472 mm — diameter. (IN & EX) [A] (1.0236 – 1.0249 in.) diameter [A] (1.2778 –...
Page 589: Valves And Cylinder Head Components
Engine Mechanical: For J20 Engine 1D-99 Valves and Cylinder Head Components S6JB0A1426024 I5JB0A142039-01 1. Cylinder block 7. Valve stem seal 13. Cylinder head bolt (M6) : Be sure to tighten cylinder head bolt (M8) after securing cylinder head bolt (M10). 2.
Page 590: Valves And Cylinder Head Removal And Installation
1D-100 Engine Mechanical: For J20 Engine Valves and Cylinder Head Removal and Installation Installation 1) Match match mark (1) on crank timing sprocket and S6JB0A1426025 mating surface (2) of cylinder block and lower crankcase. Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation: For J20 Engine”.
Page 591 Engine Mechanical: For J20 Engine 1D-101 5) Install cylinder head to cylinder block. Tighten cylinder head bolt (M6) to specified Apply engine oil to cylinder head bolts and tighten torque. them gradually as follows. Tightening torque a) Tighten cylinder head bolts (M10) to 52 N⋅m (5.2 Cylinder head bolt (M10) (a): Tighten 52 N⋅m kgf-m, 38.0 lb-ft) according to numerical order in (5.2 kgf-m, 38.0 lb-ft), 82 N⋅m (8.2 kgf-m, 59.5...
Page 592: Valves And Cylinder Head Disassembly And Assembly
1D-102 Engine Mechanical: For J20 Engine Valves and Cylinder Head Disassembly and 3) Release special tool, and remove spring retainers and valve springs. Assembly S6JB0A1426026 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide, and Disassembly then valve spring seat (2).
Page 593 Engine Mechanical: For J20 Engine 1D-103 Assembly 3) Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore. 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to Special tool remove burrs and make it truly round.
Page 594 1D-104 Engine Mechanical: For J20 Engine 6) Install valve to valve guide. 8) Using special tool (Valve lifter), compress valve Before installing valve to valve guide, apply engine spring and fit two valve cotters (1) into groove in oil to stem seal, valve guide bore, and valve stem. valve stem.
Page 595: Valves And Valve Guides Inspection
Engine Mechanical: For J20 Engine 1D-105 Valves and Valve Guides Inspection S6JB0A1426027 Valve Guide Valve stem-to-guide clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
Page 596 1D-106 Engine Mechanical: For J20 Engine Valve Valve head radial runout Check each valve for radial runout with a dial gauge and Visual inspection “V” block. To check runout, rotate valve slowly. If runout • Remove all carbon from valves. exceeds its limit, replace valve.
Page 597: Cylinder Head Inspection
Engine Mechanical: For J20 Engine 1D-107 Cylinder Head Inspection Valve seat repair A valve seat not producing a uniform contact with its S6JB0A1426028 • Remove all carbon deposits from combustion valve or showing width of seating contact that is out of chambers.
Page 598: Valve Spring Inspection
1D-108 Engine Mechanical: For J20 Engine Valve Spring Inspection Distortion for cylinder head surface on piston side Limit: 0.03 mm (0.001 in.) S6JB0A1426029 Valve Spring Free Length and Preload Referring to data, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening.
Page 599: Pistons, Piston Rings, Connecting Rods And Cylinders Components
Engine Mechanical: For J20 Engine 1D-109 Pistons, Piston Rings, Connecting Rods and Cylinders Components S6JB0A1426030 I5JB0A142048-02 1. Top ring 8. Piston pin : “TOP” mark provided on piston ring comes to facing up. 2. 2nd ring 9. Piston pin circlip : “TOP”...
Page 600: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
1D-110 Engine Mechanical: For J20 Engine 3) Install piston and connecting rod assembly into 5) Install cylinder head. Refer to “Valves and Cylinder cylinder bore. Use special tool (Piston ring Head Removal and Installation: For J20 Engine” for compressor) to compress rings. Guide connecting installation.
Page 601 Engine Mechanical: For J20 Engine 1D-111 Assembly NOTE Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. 1) Each piston (1) has stamped number (2) as shown.
Page 602: Pistons, Piston Rings, Connecting Rods And Cylinders Inspection And Cleaning
1D-112 Engine Mechanical: For J20 Engine 4) Install piston pin to piston (1) and connecting rod (3): • When installing oil ring (3), install spacer first and After applying engine oil to piston pin and piston pin then two rails. holes in piston and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin...
Page 603 Engine Mechanical: For J20 Engine 1D-113 NOTE • Piston clearance: Measure cylinder bore diameter and piston diameter If any one of four cylinders has to be rebored, to find their difference which is piston clearance. rebore all four to the same next oversize. Piston clearance should be within specification as This is necessary for the sake of uniformity follows.
Page 604 1D-114 Engine Mechanical: For J20 Engine NOTE Piston pin • Check piston pin, connecting rod small end bore and Clean carbon and any other dirt from top of piston bore for wear or damage, paying particular cylinder bore before inserting piston ring. attention to condition of small end bore bush.
Page 605 Engine Mechanical: For J20 Engine 1D-115 • Connecting rod alignment: • Connecting rod bearing general information: Mount connecting rod on aligner to check it for bow Inspect bearing shells for signs of fusion, pitting, burn and twist. If limit is exceeded, replace it. or flaking and observe contact pattern.
Page 606 1D-116 Engine Mechanical: For J20 Engine d. Install connecting rod bearing cap (1) as follows. If clearance can not be brought to within its limit even by using a new standard size bearing, Point arrow mark (2) on cap to crankshaft replace crankshaft or regrind crankpin to pulley side.
Page 607 Engine Mechanical: For J20 Engine 1D-117 b. Next, check crank pin diameter. On crank web of a. Check stamped numbers on connecting rod and No. 3 cylinder, four alphabets are stamped as its cap as shown. shown in the figure. Three kinds of numbers (“1”, “2”...
Page 608 1D-118 Engine Mechanical: For J20 Engine c. There are 5 kinds of standard bearings differing in e. Check bearing clearance with newly selected thickness. To distinguish them, they are painted in standard bearing referring to “Crank pin and the following colors at the position as indicated in connecting rod bearings: For J20 Engine”.
Page 609: Main Bearings, Crankshaft And Cylinder Block Components
Engine Mechanical: For J20 Engine 1D-119 Main Bearings, Crankshaft and Cylinder Block Components S6JB0A1426034 I5JB0A142056-02 1. Cylinder block 9. Check valve 17. Knock sensor 2. Lower crankcase 10. Flywheel : Tighten 40 N⋅m (4.0 kgf-m, 29.0 lb-ft), 0 : Apply sealant 99000-31250 to mating surface. N⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) and 58 N⋅m (5.8 kgf-m, 42.0 lb-ft) by the specified procedure.
Page 610: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
1D-120 Engine Mechanical: For J20 Engine Main Bearings, Crankshaft and Cylinder Block 5) Remove water pump (1) and heater outlet pipe. Removal and Installation 6) Remove engine front mounting brackets (2). S6JB0A1426035 Removal 1) Remove engine assembly from vehicle. Refer to “Engine Assembly Removal and Installation: For J20 Engine”.
Page 611 One of two halves of main bearing (4) has oil groove surface area as shown in figure. (3). “A”: Water tight sealant 99000–31250 (SUZUKI Install this half with oil groove to cylinder block and Bond No.1207F) another half without oil groove to lower crankcase.
Page 612 1D-122 Engine Mechanical: For J20 Engine NOTE 11) Install CKP sensor (1) and fix its wire harness with bracket. • After tightening crankcase bolts, check to Tightening torque be sure that crankshaft rotates smoothly CKP sensor bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) when turned by hand.
Page 613: Main Bearings, Crankshaft And Cylinder Block Inspection
Engine Mechanical: For J20 Engine 1D-123 15) Install pistons and connecting rods. Refer to Crankshaft thrust play “Pistons, Piston Rings, Connecting Rods and Measure this play with crankshaft set in cylinder block in Cylinders Removal and Installation: For J20 Engine”. the normal manner, that is, with thrust bearing and lower crankcase installed.
Page 614 1D-124 Engine Mechanical: For J20 Engine Out-of-round and taper (uneven wear) of journals Main bearing clearance An unevenly worn crankshaft journal shows up as a Check clearance by using gauging plastic according to difference in diameter at a cross section or along its the following procedure.
Page 615 Engine Mechanical: For J20 Engine 1D-125 Selection of main bearings Stamped alphabets on lower crankcase represent journal diameter marked with an arrow in figure STANDARD BEARING: respectively. If engine is under the following conditions, select a new For example, stamped alphabet “A” at No.2 journal standard bearing as followings and install it.
Page 616 1D-126 Engine Mechanical: For J20 Engine 4) From number stamped on crank web No.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal by referring to table shown. For example, if number stamped on crank web No.2 is “5” and alphabet stamped on lower crankcase is “A”, install new standard bearings painted in “Green”...
Page 617 Engine Mechanical: For J20 Engine 1D-127 b. 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. c. Using journal diameter measured and alphabets stamped on lower crankcase, select an undersize bearing by referring to the following table.
Page 618 1D-128 Engine Mechanical: For J20 Engine Cylinder Block 5) Measure piston clearance after honing. • Distortion of gasketed surface • Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It. Flatness Limit 0.06 mm (0.0024 in.) I2RH01140199-01 Honing or reboring cylinders...
Page 619: Specifications
Engine Mechanical: For J20 Engine 1D-129 Specifications Tightening Torque Specifications S6JB0A1427001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolts 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) for tightening of special tool Camshaft housing bolt Cylinder head cover nut Starting motor terminal nut Generator terminal nut Timing chain cover bolt and nut...
Page 620: Special Tools And Equipment
1D-130 Engine Mechanical: For J20 Engine Special Tools and Equipment Recommended Service Material S6JB0A1428001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 621 Engine Mechanical: For J20 Engine 1D-131 09916–16510 09916–34542 Valve lifter attachment Reamer handle 09916–37810 09916–38210 Valve guide reamer (6 mm) Valve guide reamer (11 mm) 09916–46020 09916–57340 Valve guide remover Valve guide installer attachment 09916–57350 09916–66510 Valve guide installer handle Tappet holder (6 mm) 09916–77310...
Page 622 1D-132 Engine Mechanical: For J20 Engine 09944–36011 Steering wheel remover...
Page 623: For F9Q Engine
Engine Mechanical: For F9Q Engine 1D-133 For F9Q Engine Diagnostic Information and Procedures Compression Check 5) Remove all glow plugs referring to “Glow Plug S6JB0A1434001 Removal and Installation: For Diesel Engine Model Check compression pressure on all 4 cylinders as in Section 1C”.
Page 624: Valve Lash (Clearance) Inspection
1D-134 Engine Mechanical: For F9Q Engine 9) Crank engine with fully charged battery, and read the If valve lash (clearance) is out of specification, highest pressure on compression gauge. record valve lash (clearance) and adjust it to specification referring to “Valve Lash (Clearance) NOTE Adjustment: For F9Q Engine”.
Page 625: Valve Lash (Clearance) Adjustment
Engine Mechanical: For F9Q Engine 1D-135 Valve Lash (Clearance) Adjustment 5) Select new tappet with a thickness as close as S6JB0A1434004 possible to calculated value. 1) Measure valve lash (clearance) referring to “Valve Lash (Clearance) Inspection: For F9Q Engine”. Available new tappet Thickness 2) Remove tappet referring to “Camshaft and Tappet mm (in.)
Page 626: Repair Instructions
1D-136 Engine Mechanical: For F9Q Engine Repair Instructions Air Cleaner Components S6JB0A1436072 I5JB0B140143-01 1. MAF sensor 3. Air cleaner filter 5. Gasket 2. Air cleaner upper case 4. Air cleaner lower case : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) Air Cleaner Removal and Installation Air Cleaner Filter Removal and Installation S6JB0A1436073 S6JB0A1436001...
Page 627: Air Cleaner Filter Inspection And Cleaning
Engine Mechanical: For F9Q Engine 1D-137 Air Cleaner Filter Inspection and Cleaning S6JB0A1436002 Inspection Check air cleaner filter for dirt. Replace excessive dirty filter. Cleaning Blow off dust by compressed air from air outlet side of filter. I2RH0B140150-01 Intercooler and Air Intake Pipe Components S6JB0A1436045 I5JB0B140006-04 1.
Page 628: Intercooler Removal And Installation
1D-138 Engine Mechanical: For F9Q Engine Intercooler Removal and Installation 3) Install resonator (1). S6JB0A1436046 Removal 1) Remove front bumper referring to “Front Bumper Components in Section 9K”. 2) Remove resonator (1). I5JB0B140007-01 4) Install front bumper referring to “Front Bumper Components in Section 9K”.
Page 629 Engine Mechanical: For F9Q Engine 1D-139 Tightening torque Intercooler outlet pipe clamp: Tighten 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) and 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) after 5 minutes Cylinder Head Cover Components S6JB0A1436047 I5JB0B140010-01 1. Cylinder head cover 3. Cylinder head cover gasket : Do not reuse.
Page 630 1D-140 Engine Mechanical: For F9Q Engine 7) Remove cylinder head cover bolts evenly and 3) Tighten cylinder head cover bolts evenly and gradually in numerical order (“1” through “3”) as gradually in numerical order (“1” through “3”) by shown in figure. repeating tightening sequence two or three times until specified torque is obtained.
Page 631 Engine Mechanical: For F9Q Engine 1D-141 9) Install timing belt cover No.2 (1) and harness bracket. Tightening torque Timing belt cover No.2 bolt (a): 55 N·m (5.5 kgf- m, 40.0 lb-ft) I5JB0B140018-01 Oil Separator Components S6JB0A1436075 I5JB0B140145-02 1. Ventilation hose No.2 6.
Page 632: Oil Separator Removal And Installation
1D-142 Engine Mechanical: For F9Q Engine Oil Separator Removal and Installation Vacuum Pump Removal and Installation S6JB0A1436049 S6JB0A1436077 Removal Removal 1) Disconnect negative (–) cable at battery. 1) Remove intercooler outlet pipe referring to “Air intake 2) Remove engine cover. Pipe Removal and Installation: For F9Q Engine”.
Page 633: Vacuum Pump Inspection
Engine Mechanical: For F9Q Engine 1D-143 Vacuum Pump Inspection Special tool S6JB0A1436076 (A): 09915–67311 Install a vacuum gauge to the vacuum circuit using 3- (B): 09918–08210 way joint (1) as shown in the figure and measure vacuum. If vacuum is out of specification, check vacuum leakage, if OK than replace vacuum pump.
Page 634: Timing Belt And Belt Tensioner Removal And Installation
1D-144 Engine Mechanical: For F9Q Engine Timing Belt and Belt Tensioner Removal and 3) Turn crankshaft pulley clockwise, and stop turning crankshaft pulley immediately before mark (2) of Installation camshaft pulley (3) matches with mark (1) of belt S6JB0A1436051 inner cover. CAUTION •...
Page 635 Engine Mechanical: For F9Q Engine 1D-145 6) Remove crankshaft pulley as follows. 7) Remove tensioner pulley (1) and timing belt (2). a) Lock ring gear (2) of flywheel by inserting flat head screw driver (1) or the like into hole of clutch housing.
Page 636 1D-146 Engine Mechanical: For F9Q Engine Installation 4) Install crankshaft timing belt pulley (1), if removed. 1) Confirm that special tool (A) is inserted into TDC pin 5) Install timing belt tensioner plate (2), if removed. hole. Tightening torque If special tool (A) is removed, insert special tool (A) Timing belt tensioner plate bolt (a): 10 N·m (1.0 referring to Step 5) of “Installation”...
Page 637 Engine Mechanical: For F9Q Engine 1D-147 8) Remove special tool (A) from TDC pin hole. d) Measure timing belt tension using special tool as follows. 9) Adjust timing belt tension as follows. a) Tighten crankshaft pulley bolt to crankshaft Special tool temporarily by hand.
Page 638 1D-148 Engine Mechanical: For F9Q Engine Turn crankshaft two revolutions clockwise until n) Confirm number of timing belt teeth between mark (1) of camshaft pulley (2) matches with mark (1) of camshaft pulley (2) and mark (3) of mark (3) of timing belt inner cover (4). injection pump pulley (4) is 29.
Page 639: Timing Belt And Belt Tensioner Inspection
Engine Mechanical: For F9Q Engine 1D-149 Timing Belt and Belt Tensioner Inspection 11) Apply sealant “A” to thread of TDC pin cap (1), and tighten TDC pin cap as specified torque. S6JB0A1436052 Tightening torque Timing belt TDC pin cap (a): 20 N·m (2.0 kgf-m, 14.5 lb-ft) Inspect timing belt for wear or crack.Replace it as necessary.
Page 640: Engine Mounting Components
1D-150 Engine Mechanical: For F9Q Engine Engine Mounting Components S6JB0A1436011 I5JB0B140039-01 A: Forward 5. Engine left mounting bracket damper 1. Engine right mounting bracket 6. Engine rear mounting 2. Engine right mounting 7. Engine rear mounting bracket : Be sure to align dowel pin with dowel hole of engine right mounting bracket. 3.
Page 641 Engine Mechanical: For F9Q Engine 1D-151 Engine Assembly Removal and Installation 11) Disconnect P/S suction hose and low pressure S6JB0A1436053 return hose from P/S fluid reservoir referring to “P/S WARNING Hose / Pipe Components in Section 6C”. 12) Disconnect MAF sensor connector (1), and remove Before servicing fuel system, be sure to air cleaner case (2) and turbocharger inlet hose (3).
Page 642 1D-152 Engine Mechanical: For F9Q Engine 15) Remove relay box (1), fuse box No.1 (2) and boost pressure control solenoid valve (3) from vehicle body. I5JB0B140042-01 16) Disconnect the following hoses. CAUTION After disconnecting, plug fuel line with plug cap immediately referring to “Precautions on Fuel System Service: For Diesel Engine Model in Section 1G”.
Page 643 Engine Mechanical: For F9Q Engine 1D-153 I5JB0B140043-01 17) Support front suspension frame and engine rear 21) Before lowering engine with transmission and front mounting member using engine jack (2). suspension frame from engine compartment, recheck to make sure all hoses, electric wires and 18) Carry out Step 1) through 12) of “Removal”...
Page 644 1D-154 Engine Mechanical: For F9Q Engine Installation CAUTION Before starting engine (including when performing oil level check and air bleeding process of cooling system) for the first time after installing turbocharger, be sure to lubricate turbocharger, referring to “CAUTION” in “Installation” under “Turbocharger Assembly Removal and Installation”. Otherwise, lack of lubrication will cause turbocharger damage.
Page 645 Engine Mechanical: For F9Q Engine 1D-155 7) Connect connectors and wire harness disconnected 11) Connect P/S suction hose and low pressure return in removal procedure. hose referring to “P/S Hose / Pipe Components in Section 6C”. 8) Connect hoses disconnected in removal procedure. 12) Install A/C compressor to its bracket referring to 9) Install intercooler inlet pipe (1).
Page 646: Egr Valve Components
1D-156 Engine Mechanical: For F9Q Engine EGR Valve Components S6JB0A1436054 I5JB0B140047-06 1. EGR valve 5. EGR cooler : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Gasket 6-1. EGR pipe stiffener bolt (with washer) : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3-1.
Page 647: Egr Valve Removal And Installation
Tightening torque EGR valve bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) When replacing EGR valve, perform “Initialize EGR valve data” mode of SUZUKI 2) Connect EGR valve connector (2) and EGR pipe (3) scan tool referring to “EGR Valve Data to EGR valve.
Page 648: Egr Pipe And Egr Cooler Removal And Installation
1D-158 Engine Mechanical: For F9Q Engine EGR Pipe and EGR Cooler Removal and 9) Remove EGR pipe as follows, if necessary. Installation CAUTION S6JB0A1436055 EGR pipe clamp has two types as shown in Removal figure. And, Type A is disposable one and it 1) Remove engine assembly referring to “Engine has not already been supplied.
Page 649 Engine Mechanical: For F9Q Engine 1D-159 Installation 2) Install EGR pipe as follows, if necessary. 1) Install EGR cooler (1), EGR pipe (2) and EGR joint • For Type A (3) with new gaskets. Type A EGR pipe clamp is disposable one, install new Type B EGR pipe clamp as below-mentioned.
Page 650: Turbocharger Components
1D-160 Engine Mechanical: For F9Q Engine Turbocharger Components S6JB0A1436056 CAUTION Before starting engine (including when performing oil level check and air bleeding process of cooling system) for the first time after installing turbocharger, be sure to lubricate turbocharger, referring to “CAUTION”...
Page 651: Turbocharger Assembly Removal And Installation
Engine Mechanical: For F9Q Engine 1D-161 Turbocharger Assembly Removal and Installation S6JB0A1436057 CAUTION Never disassemble turbocharger assembly. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. Removal 1) Remove engine assembly referring to “Engine Assembly Removal and Installation: For F9Q Engine”.
Page 652 1D-162 Engine Mechanical: For F9Q Engine Installation 2) Install turbocharger (1) to exhaust manifold with new gasket. CAUTION Tightening torque Before starting engine (including when Turbocharger nut (a): 37 N·m (3.7 kgf-m, 27.0 lb- performing oil level check and air bleeding process of cooling system) for the first time 3) Fit turbocharger inlet pipe (2) to turbocharger.
Page 653: Turbocharger Assembly Inspection
Engine Mechanical: For F9Q Engine 1D-163 Turbocharger Assembly Inspection 11) Connect turbocharger outlet hose (10) to turbocharger (1). S6JB0A1436069 Tightening torque Turbocharger Turbocharger outlet hose clamp (turbocharger Rotate turbine shaft (1) by hand and verify that it turns side) (j): 5 N·m (0.5 kgf-m, 4.0 lb-ft) smoothly without any abnormal noise and excessive runout.
Page 654: Turbocharger Assembly Adjustment
1D-164 Engine Mechanical: For F9Q Engine Turbocharger Assembly Adjustment S6JB0A1436070 1) Loosen lock nut (1). 2) Tighten or loose adjusting wheel (2) so as to adjust stroke of boost presser control valve rod with applying specified pressure. For correct stroke and specified pressure, refer to “Boost Presser Control Valve”...
Page 655: Intake Manifold And Exhaust Manifold Removal And Installation
Engine Mechanical: For F9Q Engine 1D-165 Intake Manifold and Exhaust Manifold Removal Installation and Installation 1) Install exhaust gas temperature sensor-1 to exhaust S6JB0A1436059 manifold “Exhaust Gas Temperature Sensor 1, 2 and 3 Removal and Installation: For Diesel Engine Model Removal in Section 1B”, if removed.
Page 656: Camshaft And Tappet Components
1D-166 Engine Mechanical: For F9Q Engine Camshaft and Tappet Components S6JB0A1436060 I5JB0B140062-02 1. Camshaft : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) : Apply engine oil to sliding surface. 2. Tappet : Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) by the specified : Apply engine oil to sliding surface.
Page 657: Camshaft And Tappet Removal And Installation
Engine Mechanical: For F9Q Engine 1D-167 Camshaft and Tappet Removal and Installation 7) Remove cylinder head cover referring to “Cylinder S6JB0A1436061 Head Cover Removal and Installation: For F9Q Engine”. Removal 8) Loosen camshaft housing bolts evenly and gradually 1) Remove engine assembly referring to “Engine in numerical order “1”...
Page 658 1D-168 Engine Mechanical: For F9Q Engine Installation d) Install camshaft pulley (2) to camshaft (4) aligning key (1) to groove (3). 1) Apply engine oil around tappet (1), and then install it to cylinder head. I5JB0B140068-01 I5JB0B140065-01 e) Tighten camshaft pulley bolt temporarily by 2) Install camshaft to cylinder head as follows.
Page 659 Engine Mechanical: For F9Q Engine 1D-169 iii) Fit camshaft holder to cylinder head. 5) Install camshaft pulley (2) to camshaft (4) aligning key (1) to groove (3). iv) Apply “A” to camshaft housing bolt thread. v) Tighten camshaft housing bolts evenly and gradually in numerical order (“1”...
Page 660: Camshaft And Tappet Inspection
1D-170 Engine Mechanical: For F9Q Engine Camshaft and Tappet Inspection S6JB0A1436023 Camshaft • Check journals and cam faces for wear or damage. If any malcondition is found, replace camshaft. I5JB0B140075-01 Wear of Tappet Check tappet for pitting, scratches, or damage. If any malcondition is found, replace.
Page 661: Valve And Cylinder Head Assembly Components
Engine Mechanical: For F9Q Engine 1D-171 Valve and Cylinder Head Assembly Components S6JB0A1436024 I5JB0B140076-01 1. Valve cotter 6. Intake valve 11. Cylinder head gasket 2. Valve spring retainer 7. Exhaust valve 12. Dowel pin 3. Valve spring 8. Valve guide : Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 100°, 0 N⋅m (0.0 kgf-m, 0.0 lb-ft), 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and 213°...
Page 662: Valve And Cylinder Head Assembly Removal And Installation
1D-172 Engine Mechanical: For F9Q Engine Valve and Cylinder Head Assembly Removal 10) Check all around cylinder head for any other parts required to be removed or disconnected, and and Installation remove or disconnect whatever necessary. S6JB0A1436062 11) Remove cylinder head and cylinder head gasket Removal from cylinder block.
Page 663 Engine Mechanical: For F9Q Engine 1D-173 Installation 13) Install cylinder head to cylinder block, and tighten new cylinder head bolts as follows. 1) Remove oil, old sealant and dust from bolt holes and mating surface of cylinder head and cylinder block. a) Tighten cylinder head bolts to 30 N⋅m (3.0 kgf-m, 22.0 lb-ft) according to numerical order (“1”...
Page 664: Valve And Cylinder Head Assembly Inspection
1D-174 Engine Mechanical: For F9Q Engine Valve and Cylinder Head Assembly Inspection 2) Release special tool and remove spring retainer, S6JB0A1436063 valve spring and spring seat from cylinder head. 3) Remove valve from combustion chamber side. Cylinder Head Assembly Specifications (for Reference) Valve and cylinder head specification Item...
Page 665 Engine Mechanical: For F9Q Engine 1D-175 5) Remove stem seal (1) from valve guide using special a) Install fitting (2) to valve stem in order to prevent tool. stem seal from damage, and install stem seal (1) to valve stem. Special tool (A): 09916–48110 NOTE...
Page 666: Valves And Valve Guides Inspection
1D-176 Engine Mechanical: For F9Q Engine 3) Install spring seat, valve spring and spring retainer. 4) Using special tool (A) and (B), compress valve spring. And, fit two valve cotters (1) into groove of valve stem using special tool (C) as shown in figure. Special tool (A): 09916–19030 (B): 09916–14521...
Page 667 Engine Mechanical: For F9Q Engine 1D-177 Valve Valve seat Visual inspection Item Specification 1.8 mm • Remove all carbon from valves. Valve seat width “a” (0.071 in.) • Inspect each valve for wear, burn or distortion at its Valve seat angle “b” 89.5°...
Page 668: Cylinder Head Inspection
1D-178 Engine Mechanical: For F9Q Engine Cylinder Head Inspection Distortion for cylinder head surface on piston side S6JB0A1436028 Limit: 0.05 mm (0.0020 in.) • Remove all carbon deposits from combustion chambers. NOTE Do not use any sharp-edged tool to scrape off carbon deposits.
Page 669: Valve Spring Inspection
Engine Mechanical: For F9Q Engine 1D-179 Cylinder head Cylinder head gasket Item Specification Item Specification 161.00 – 164.50 mm Cylinder head gasket 1.27 – 1.37 mm Cylinder head height “a” (6.3386 – 6.4763 in.) thickness “a” (0.0500 – 0.0539 in.) 36.877 –...
Page 670: Piston, Piston Ring, Connecting Rod And Cylinder Components
1D-180 Engine Mechanical: For F9Q Engine Piston, Piston Ring, Connecting Rod and Cylinder Components S6JB0A1436030 I5JB0B140096-01 1. Top ring 8. Piston pin 2. 2nd ring 9. Piston pin circlip 3. Oil ring : Tighten 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) and 40° by the specified procedure. 4.
Page 671 Engine Mechanical: For F9Q Engine 1D-181 5) Mark cylinder number on all pistons, connecting rods Installation (1) and connecting rod bearing caps (2) using silver 1) Decarbonize piston head and ring grooves using a pencil or quick drying paint (3) for installation. suitable tool.
Page 672 1D-182 Engine Mechanical: For F9Q Engine b) Set connecting rod (1) and bearing (2) to special 5) Apply engine oil to pistons, rings, cylinder walls, tool (A) and (B) as shown in figure. connecting rod bearings and crank pins. c) Install connecting rod bearing to connecting rod NOTE by pushing special tool (B) as shown in figure.
Page 673: Cylinders, Pistons And Piston Rings Inspection
Engine Mechanical: For F9Q Engine 1D-183 8) Install piston and connecting rod assembly into 10) Turn crankshaft clockwise until key groove (1) cylinder bore with matching cylinder number marked comes in middle of two ribs (2) and install special in removal. Use special tool to compress rings. tool (A) to TDC pin hole.
Page 674: Piston Pins And Connecting Rods Inspection .1D-184
1D-184 Engine Mechanical: For F9Q Engine Piston Pins and Connecting Rods Inspection Piston diameter As indicated in the figure, piston diameter should be S6JB0A1436034 measured at a position “a” from piston skirt end in the Piston Pin direction perpendicular to piston pin. Visual inspection Piston diameter specification Check piston pin, connecting rod small end bore and...
Page 675: Crank Pin And Connecting Rod Bearings Inspection
Engine Mechanical: For F9Q Engine 1D-185 Crank Pin and Connecting Rod Bearings Connecting Rod Connecting rod thrust play Inspection S6JB0A1436035 Check big-end of connecting rod for thrust play, with rod fitted and connected to its crank pin in the normal Crank Pin Diameter manner.
Page 676 1D-186 Engine Mechanical: For F9Q Engine 4) Install bearing cap referring to connecting rod and 3) Check connecting rod length referring to bearing cap referring to Step 9) of “Installation” under “Connecting Rod and Related Parts Specification “Piston, Piston Ring and Connecting Rod Removal (for Reference)”...
Page 677: Main Bearing, Crankshaft And Cylinder Block Component
Engine Mechanical: For F9Q Engine 1D-187 e) Replace piston with selected piston. Check piston protrusion, again. I5JB0B140132-01 Main Bearing, Crankshaft and Cylinder Block Component S6JB0A1436068 I5JB0B140111-01 1. Cylinder block 6. Oil jet 2. Flywheel side crankshaft oil seal 7. Bearing cap seal 3.
Page 678: Main Bearing, Crankshaft And Cylinder Block Removal And Installation
1D-188 Engine Mechanical: For F9Q Engine Main Bearing, Crankshaft and Cylinder Block 5) Remove main bearing caps (No.2 through No.5) and crankshaft from cylinder block. Removal and Installation S6JB0A1436066 6) Remove main bearings (1) and thrust bearings (2). Removal 1) Remove piston and connecting rod referring to “Piston, Piston Ring and Connecting Rod Removal and Installation: For F9Q Engine”.
Page 679 Engine Mechanical: For F9Q Engine 1D-189 c) Desorb swarf from cylinder and oil jet. 1) Remove oil, old sealant and dust from mating surface of cylinder block, bearing caps and d) Install special tool (A) to drilled hole of oil jet (1). crankshaft.
Page 680 1D-190 Engine Mechanical: For F9Q Engine d) Insert oil jet into pushrod (1), and install pushrod b) Fit main bearing (1) in special tool (A) as shown to plate (2) facing oil jet with center of cylinder. in figure, and then press bearing end “a” until it becomes flush with cylinder block.
Page 681 Engine Mechanical: For F9Q Engine 1D-191 4) Install oil fresh air vent pipe using special tool as 6) Install thrust bearings (1) to crankshaft journal No.2 follows, if removed. facing its oil groove (2) to outside. Special tool (A): 09914–86510 I5JB0B140127-01 I5JB0B140125-02 7) Apply engine oil to bearings and crankshaft.
Page 682: Crankshaft Inspection
1D-192 Engine Mechanical: For F9Q Engine 10) Install main bearing caps in proper position mating 14) Install piston and connecting rod referring to “Piston, cylinder number marked in removal. Piston Ring and Connecting Rod Removal and Installation: For F9Q Engine”. 11) Tighten new main bearing cap bolts as follows.
Page 683: Main Bearings Inspection
Engine Mechanical: For F9Q Engine 1D-193 2) Use a dial gauge, to read displacement in axial Main Bearing Clearance (thrust) direction of crankshaft. NOTE If it is out of specification, replace new thrust bearing and recheck. Do not rotate crankshaft while gauging plastic is installed.
Page 684: Specifications
1D-194 Engine Mechanical: For F9Q Engine Specifications Tightening Torque Specifications S6JB0A1437001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Intercooler inlet hose clamp 0.45 Intercooler outlet hose clamp 0.45 Air intake pipe bolt and nut 15.5 Intercooler outlet pipe clamp Tighten 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) and 5 N⋅m (0.5 kgf-m, 4.0 lb-ft) after 5 minutes Cylinder head cover bolt...
Page 685: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A1438001 Material SUZUKI recommended product or Specification Note Thread lock cement Loctite 518® — Loctite FRENETANCH®...
Page 686 1D-196 Engine Mechanical: For F9Q Engine 09912–56540 09912–57821 Compression gauge adapter Compression gauge 09912–86510 09912–86520 Oil jet installer Oil jet installer plate Mot. 1516 Mot. 1516-02 09913–56520 09913–86510 Camshaft oil seal fitting Main bearing fitting Mot. 988-02 Mot. 1493 09913–86520 09913–98110 Bearing fitting adapter Connecting rod bearing...
Page 687 Engine Mechanical: For F9Q Engine 1D-197 09916–84511 09916–98110 Forceps Flywheel locking tool (Mot. 582-01) 09917–47011 09917–56510 Vacuum pump gauge Bearing cap remover Mot. 1423 09917–68221 09917–96530 Camshaft pulley holder Valve stem seal fitting Mot. 1511 09918–08210 09918–26510 Vacuum gauge hose joint Dummy heater plug (F9Q) Mot.
Page 688: Engine Lubrication System
1E-1 Engine Lubrication System: For M16A Engine with VVT Engine Lubrication System Engine For M16A Engine with VVT General Description Engine Lubrication Description S6JB0A1511001 The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter.
Page 689 Engine Lubrication System: For M16A Engine with VVT 1E-2 I3RH0B150001-01...
Page 690: Diagnostic Information And Procedures
1E-3 Engine Lubrication System: For M16A Engine with VVT Diagnostic Information and Procedures Oil Pressure Check 3) Install special tools (oil pressure gauge) to vacated S6JB0A1514001 threaded hole of oil pressure switch. NOTE Special tool Prior to checking oil pressure, check the (A): 09915–77310 following.
Page 691: Repair Instructions
Engine Lubrication System: For M16A Engine with VVT 1E-4 8) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 9) Connect oil pressure switch coupler (1). I5JB0A151003-01 Repair Instructions Oil Pan and Oil Pump Strainer Components S6JB0A1516001 I5JB0A151005-01 1.
Page 692: Oil Pan And Oil Pump Strainer Removal And Installation
3) Apply sealant continuously to oil pan mating surface as shown in the figure. I5JB0A151006-01 5) Remove oil pan, and then oil pump strainer (1) from “A”: Sealant 99000–31260 (SUZUKI Bond cylinder block. No.1217G) Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.)
Page 693: Oil Pan And Oil Pump Strainer Cleaning
Engine Lubrication System: For M16A Engine with VVT 1E-6 4) Install oil pan to cylinder block temporarily. 9) Install clutch housing lower plate No.1 (1) and clutch housing lower plate No.2 (2). 5) Insert knock pin (1) in hole (2) of oil pan in order to locate oil pan precisely.
Page 694: Oil Pump Components
1E-7 Engine Lubrication System: For M16A Engine with VVT Oil Pump Components S6JB0A1516004 I4RS0A150010-01 1. Rotor plate 6. Rotor plate bolt 10. Circlip 2. O-ring 7. Relief valve : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3. Outer rotor 8. Spring : Do not reuse.
Page 695: Oil Pump Inspection
Engine Lubrication System: For M16A Engine with VVT 1E-8 Oil Pump Inspection Reassembly S6JB0A1516007 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
Page 696 1E-9 Engine Lubrication System: For M16A Engine with VVT Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure.
Page 697: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A1518001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 698: For J20 Engine
1E-11 Engine Lubrication System: For J20 Engine For J20 Engine General Description Engine Lubrication Description S6JB0A1521001 The oil pump is trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.
Page 699 Engine Lubrication System: For J20 Engine 1E-12 I5JB0A151013-01...
Page 700: Diagnostic Information And Procedures
1E-13 Engine Lubrication System: For J20 Engine Diagnostic Information and Procedures Oil Pressure Check S6JB0A1524001 WARNING To avoid danger of being burned, do not touch exhaust manifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down.
Page 701: Repair Instructions
Engine Lubrication System: For J20 Engine 1E-14 Repair Instructions Oil Pan and Oil Pump Strainer Components S6JB0A1526001 1217G I5JB0A152004-02 1. Oil pan 8. Gasket : Apply sealant 99000-31260 to mating surface. 2. Oil pump strainer 9. Baffle plate 3. O-ring : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 4.
Page 702: Oil Pan And Oil Pump Strainer Removal And Installation
Installation 1) Apply sealant to oil pan (1) mating surface S6JB0A1526002 continuously as shown in figure. Removal “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) 1) Remove oil level gauge. 2) Raise vehicle. Sealant amount for oil pan Width “a”: 3 mm (0.12 in.) 3) Remove engine under cover (1).
Page 703: Oil Pan And Oil Pump Strainer Cleaning
Engine Lubrication System: For J20 Engine 1E-16 3) After fitting oil pan (1) to cylinder block, run in 5) Install front suspension frame referring to “Front securing bolts and start tightening at the center: Suspension Frame, Stabilizer Bar and/or Bushings move wrench outward, tightening one bolt at a time.
Page 704: Oil Pump Components
1E-17 Engine Lubrication System: For J20 Engine Oil Pump Components S6JB0A1526004 I5JB0A152010-02 1. Cylinder block 6. Oil pump mounting bolt (M8 bolt) 11. Oil pump chain guide nut : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Oil pump relief valve set 7.
Page 705: Oil Pump Disassembly And Assembly
Engine Lubrication System: For J20 Engine 1E-18 Oil Pump Disassembly and Assembly Installation S6JB0A1526006 1) Install oil pump (2) and baffle plate to lower crank CAUTION case (1) and tighten bolts to specified torque. Don’t remove sprocket and inner rotor from NOTE oil pump, otherwise damage of oil pump When installing oil pump, be careful not to...
Page 706: Oil Pump Inspection
1E-19 Engine Lubrication System: For J20 Engine Oil Pump Inspection Radial Clearance S6JB0A1526007 Check radial clearance between outer rotor (2) and case • Check outer rotor (3), inner rotor and oil pump cases No.1 (1), using thickness gauge (4). (1), (2) for excessive wear or damage. If clearance exceeds its limit, replace oil pump assembly.
Page 707: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A1528001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 708: For F9Q Engine
1E-21 Engine Lubrication System: For F9Q Engine For F9Q Engine General Description Engine Lubrication Description S6JB0A1531001 The oil pump is of a gear type, and mounted downward in the cylinder block. Oil is drawn up through the oil pump strainer and passed through the pump to the heat exchanger, then the oil filter, and the filtered oil flow to each engine part.
Page 709: Repair Instructions
Engine Lubrication System: For F9Q Engine 1E-22 6) After checking oil pressure, stop engine and remove special tool. 2, (a) 7) Tighten oil pressure switch (2) to specified torque. Tightening torque Oil pressure switch (a): 38 N·m (3.8 kgf-m, 27.5 lb-ft) 8) Start engine and check oil pressure switch for oil leakage.
Page 710: Oil Pan And Oil Pump Strainer Removal And Installation
1E-23 Engine Lubrication System: For F9Q Engine Oil Pan and Oil Pump Strainer Removal and 7) Loosen lower oil pan stiffener bolts in numerical order (“1” through “4”) as shown in figure, and Installation remove them. S6JB0A1536002 8) Remove lower oil pan stiffener No.1 (1) and No.2 (2). Removal 1) Drain engine oil referring to “Engine Oil and Filter Change (Diesel Engine Model) in Section 0B”.
Page 711 Engine Lubrication System: For F9Q Engine 1E-24 12) Lower suspension member referring to “Front 17) Remove oil pan baffle plate (1), if necessary. Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation in Section 2B”. 13) Disconnect ventilation pipe No.1 (1) and ventilation hose No.3 (2) from upper oil pan.
Page 712 1E-25 Engine Lubrication System: For F9Q Engine Installation 5) Apply sealant to hatched part of cylinder block, gasket holder plate and main bearing cap No.1 as 1) Remove oil, old sealant and dust from mating shown in figure. surface of upper oil pan, cylinder block and lower oil pan.
Page 713 Engine Lubrication System: For F9Q Engine 1E-26 7) Tighten transmission to engine bolts referring to 11) Install lower oil pan (1) to upper oil pan with new “Manual Transmission Assembly Dismounting and gasket, and tighten lower oil pan bolts evenly and Remounting: For Diesel Engine Model in Section gradually in numerical order (“1”...
Page 714 1E-27 Engine Lubrication System: For F9Q Engine 13) Install oil pump strainer No.1 (1) and oil separator 15) Connect lower oil pan hose (1) to oil separator return return pipe (2) with new O-rings. pipe. 16) Connect oil separator return hose (2) to oil separator Tightening torque return pipe.
Page 715: Oil Pump, Oil Pump Chain And Gasket Holder Plate Component
Engine Lubrication System: For F9Q Engine 1E-28 Oil Pump, Oil Pump Chain and Gasket Holder Plate Component S6JB0A1536003 CAUTION Never disassemble oil pump. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I5JB0B150043-01 1.
Page 716 1E-29 Engine Lubrication System: For F9Q Engine 3) Remove timing belt and crankshaft timing pulley Installation referring to “Timing Belt and Belt Tensioner Removal 1) Remove oil and dust from mating surfaces of oil and Installation: For F9Q Engine in Section 1D”. pump drive sprocket, crankshaft gasket holder plate 4) Remove gasket holder plate (1) from cylinder block.
Page 717: Oil Pump, Oil Pump Chain And Gasket Holder Plate Inspection
Engine Lubrication System: For F9Q Engine 1E-30 Oil Pump, Oil Pump Chain and Gasket Holder 5) Install oil pump (1) and tighten oil pump bolts to specified torque. Plate Inspection S6JB0A1536005 Tightening torque Oil pump bolt (a): 24 N·m (2.4 kgf-m, 17.5 lb-ft) Oil Pump Check teeth of oil pump sprocket for wear or damage.
Page 718: Heat Exchanger Removal And Installation
1E-31 Engine Lubrication System: For F9Q Engine Heat Exchanger Removal and Installation Installation S6JB0A1536006 1) Install heat exchanger (1) with new gasket. Removal Tightening torque 1) Remove oil filter referring to “Engine Oil and Filter Oil filter stand bolt (a): 15 N·m (1.5 kgf-m, 11.0 Change (Diesel Engine Model) in Section 0B”.
Page 719: Special Tools And Equipment
Engine Lubrication System: For F9Q Engine 1E-32 Special Tools and Equipment Recommended Service Material S6JB0A1538001 Material SUZUKI recommended product or Specification Note Thread lock cement Loctite rhodorseal 5661® — Thread Lock Cement Super 1303B P/No.: 99000–32030 NOTE Required service material is also described in the following.
Page 720: Engine Cooling System
1F-1 Engine Cooling System: For Petrol Engine Model Engine Cooling System Engine For Petrol Engine Model General Description Cooling System Description • Maintain cooling system freeze protection at –36 °C (– S6JB0A1611001 33 °F) to ensure protection against corrosion and loss The cooling system consists of the radiator cap, radiator, of coolant from boiling.
Page 721: Schematic And Routing Diagram
Engine Cooling System: For Petrol Engine Model 1F-2 Schematic and Routing Diagram Coolant Circulation S6JB0A1612001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I5JB0A161001-01 1. Radiator inlet hose 5. Thermostat 9. Heater core inlet hose 2. Radiator outlet hose 6.
Page 722: Diagnostic Information And Procedures
1F-3 Engine Cooling System: For Petrol Engine Model Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S6JB0A1614001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary.
Page 723: Repair Instructions
Engine Cooling System: For Petrol Engine Model 1F-4 Repair Instructions Cooling System Components S6JB0A1616001 I5JB0A161003-03...
Page 724 1F-5 Engine Cooling System: For Petrol Engine Model I5JB0A161004-03 [A]: M16 engine model 14. Thermostat 29. To cylinder head [B]: J20 engine model 15. Thermostat cap 30. To water pump 1. Radiator 16. Radiator inlet No.2 hose 31. To heater core 2.
Page 725: Coolant Level Check
Engine Cooling System: For Petrol Engine Model 1F-6 Coolant Level Check Engine Cooling System Inspection and S6JB0A1616002 Cleaning WARNING S6JB0A1616003 WARNING To help avoid danger of being burned, do not remove radiator cap while engine and To help avoid danger of being burned, do not radiator are still hot.
Page 726: Cooling System Draining
1F-7 Engine Cooling System: For Petrol Engine Model Cooling System Draining 2) With radiator cap removed, run engine until upper S6JB0A1616004 radiator hose is hot (this shows that thermostat is 1) Remove radiator cap. open and coolant is flowing through system). 2) Drain coolant from radiator drain plug (1).
Page 727: Cooling Water Pipes Or Hoses Removal And Installation
Engine Cooling System: For Petrol Engine Model 1F-8 Thermostat Removal and Installation (For M16 15) Add coolant to radiator up to bottom of radiator filler neck, and install radiator cap, making sure that the Engine Model) ear of cap lines is parallel to radiator. S6JB0A1616007 Removal 16) Repeat Step 12) through 15).
Page 728: Thermostat Removal And Installation (For J20 Engine Model)
1F-9 Engine Cooling System: For Petrol Engine Model Thermostat Removal and Installation (For J20 Thermostat Inspection S6JB0A1616009 Engine Model) • Make sure that air bleed valve (1) of thermostat is S6JB0A1616008 Removal clean. Should this valve be clogged, engine would tend to 1) Drain coolant referring to “Cooling System Draining: overheat.
Page 729: Radiator Cooling Fan Motor On-Vehicle Inspection
Engine Cooling System: For Petrol Engine Model 1F-10 Radiator Cooling Fan Motor On-Vehicle 3) Check radiator cooling fan relay No.1 (1) and No.3 (2) as follows. Inspection S6JB0A1616010 a) Check that there is no continuity between 1) Check main and/or sub fan operation of radiator terminals “C”...
Page 730: Radiator Cooling Fan Assembly Removal And Installation
1F-11 Engine Cooling System: For Petrol Engine Model Radiator Cooling Fan Assembly Removal and Radiator On-Vehicle Inspection and Cleaning S6JB0A1616013 Installation Inspection S6JB0A1616012 Check radiator for leakage or damage. Straighten bent fins, if any. Removal 1) Disconnect negative (–) cable at battery. Cleaning 2) Disconnect connectors (1) of cooling fan motors.
Page 731: Water Pump Removal And Installation (For M16 Engine Model)
Compressor (If Equipped) Drive Belt Removal and shown in the figure. Installation (M16A Engine Model) in Section 6C”. 6) Refill cooling system referring to Step 7) to 17) of “A”: Water tight sealant 99000–31250 (SUZUKI “Cooling System Flush and Refill: For Petrol Engine Bond No.1207F) Model”.
Page 732: Water Pump Inspection
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A1618001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 733: For Diesel Engine Model
Engine Cooling System: For Diesel Engine Model 1F-14 For Diesel Engine Model General Description Cooling System Description The coolant recovery system is standard. The coolant in S6JB0A1621001 the radiator expands with heat, and the coolant is The cooling system consists of a degassing tank, a overflowed to the reservoir.
Page 734: Schematic And Routing Diagram
1F-15 Engine Cooling System: For Diesel Engine Model Schematic and Routing Diagram Coolant Circulation S6JB0A1622001 I5JB0B160001-03 [A]: When thermostat is close 4. Cylinder block and cylinder head 9. Water pump [B]: When thermostat is open 5. Radiator 10. Turbo charger electric water pump 1.
Page 735: Diagnostic Information And Procedures
Engine Cooling System: For Diesel Engine Model 1F-16 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S6JB0A1624001 Condition Possible cause Correction / Reference Item Engine overheats Loose or timing belt Adjust. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 736: Repair Instructions
1F-17 Engine Cooling System: For Diesel Engine Model Repair Instructions Cooling System Components S6JB0A1626001 I5JB0B160013-01 1. Radiator 13. Radiator inlet hose No.2 25. Turbocharger inlet hose 2. Degassing tank cap 14. Radiator outlet hose No.1 26. Heater outlet hose No.1 3.
Page 737: Coolant Level Check
Engine Cooling System: For Diesel Engine Model 1F-18 Coolant Level Check 3) Check coolant for proper level and freeze protection. S6JB0A1626002 4) Using a pressure tester (1), check system and WARNING degassing tank cap (2) for proper pressure holding capacity. To help avoid danger of being burned, do not If replacement of cap is required, use a proper cap remove degassing tank cap while engine and...
Page 738: Cooling System Refilling
1F-19 Engine Cooling System: For Diesel Engine Model Cooling System Refilling 6) Run engine as follows in order to bleed air remained S6JB0A1626005 in engine and radiator. WARNING a) Run engine at 1500 r/min until upper radiator hose is hot. To help avoid danger of being burned, do not b) Race engine at 3500 r/min 4 times.
Page 739: Cooling System Flushing
Engine Cooling System: For Diesel Engine Model 1F-20 Cooling System Flushing Cooling Water Pipe or Hose Removal and S6JB0A1626018 Installation WARNING S6JB0A1626006 To help avoid danger of being burned, do not Removal remove degassing tank cap while engine and 1) Drain coolant referring to “Cooling System Draining: radiator are still hot.
Page 740: Radiator Cooling Fan Motor On-Vehicle Inspection
1F-21 Engine Cooling System: For Diesel Engine Model Radiator Cooling Fan Motor On-Vehicle Installation Inspection 1) Install ECT sensor referring to “Engine Coolant S6JB0A1626009 Temperature (ECT) Sensor Removal and 1) Check main and/or sub fan operation of radiator Installation: For Diesel Engine Model in Section 1C”, cooling fans as follows.
Page 741 Engine Cooling System: For Diesel Engine Model 1F-22 Radiator Cooling Fan Relay Inspection S6JB0A1626010 1) Disconnect negative (–) cable at battery. 2) Remove radiator cooling fan relay No.1 (1), No.3 (2) and/or No.2 (3) from relay box. 3) Check radiator cooling fan relay No.1 (1) and No.3 (2) as follows.
Page 742: Radiator Cooling Fan Assembly Removal And Installation
1F-23 Engine Cooling System: For Diesel Engine Model Radiator Cooling Fan Assembly Removal and Radiator On-Vehicle Inspection and Cleaning S6JB0A1626012 Installation Inspection S6JB0A1626011 Check radiator for leakage or damage. Straighten bent fins, if any. Removal 1) Disconnect negative (–) cable at battery. Cleaning 2) Disconnect connectors (1) of cooling fan motors.
Page 743: Water Pump Inspection
Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A1628001 Material SUZUKI recommended product or Specification Note Thread lock cement Loctite FRENETANCH® —...
Page 744: Fuel System
1G-1 Fuel System: For Petrol Engine Model Fuel System Engine For Petrol Engine Model Precautions Precautions on Fuel System Service S6JB0A1710001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. •...
Page 745: Fuel Pump Description
Fuel System: For Petrol Engine Model 1G-2 Fuel Pump Description S6JB0A1711003 The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) included and a fuel level gauge (3) attached. Also, the jet pump (4) installed in the fuel pump sucks up the fuel from the sub fuel level sensor side to main fuel level sensor side through the fuel suction pipe / hose by using the negative pressure produced when the part of...
Page 746: Diagnostic Information And Procedures
1G-3 Fuel System: For Petrol Engine Model Diagnostic Information and Procedures Fuel Pressure Inspection 4) Check that battery voltage is 11 V or more. S6JB0A1714001 5) Measure fuel pressure at each condition. WARNING If measured pressure is out of specification, refer to “Fuel Pressure Check: For Petrol Engine Model in Before starting the following procedure, be Section 1A”...
Page 747: Fuel Cut Operation Inspection
Fuel System: For Petrol Engine Model 1G-4 Fuel Cut Operation Inspection 6) After checking fuel pressure, remove fuel pressure gauge. S6JB0A1714002 NOTE WARNING Before inspection, make sure that gear shift lever is in neutral position (shift select lever As fuel feed line is still under high fuel is “P”...
Page 748: Repair Instructions
1G-5 Fuel System: For Petrol Engine Model Repair Instructions Fuel System Components S6JB0A1716001 I6JB0A171001-01...
Page 749 Fuel System: For Petrol Engine Model 1G-6 I6JB0A171002-01 [A]: For M16 engine model 11. Fuel pump gasket 24. To fuel tank [B]: For J20 engine model 12. Fuel tank bolt 25. To EVAP canister purge valve [C]: View A 13. Fuel pump bolt 26.
Page 750 1G-7 Fuel System: For Petrol Engine Model 6. Fuel feed line 19. Fuel delivery pipe insulator : Do not reuse. 7. Fuel return line 20. Fuel pressure regulator : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 8. Fuel tank inlet valve 21.
Page 751: Fuel Hose Disconnecting And Reconnecting
Fuel System: For Petrol Engine Model 1G-8 Fuel Hose Disconnecting and Reconnecting S6JB0A1716002 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: For Petrol Engine Model” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in figure.
Page 752 1G-9 Fuel System: For Petrol Engine Model The other than fuel tank system 4. Red mark For Quick Joint (other than Fuel Vapor Line) Disconnecting 1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed air.
Page 753: Fuel Pressure Relief Procedure
Fuel System: For Petrol Engine Model 1G-10 Fuel Pressure Relief Procedure Fuel Lines On-Vehicle Inspection S6JB0A1716003 S6JB0A1716005 CAUTION CAUTION This work must not be done when engine is Due to the fact that fuel feed line (1) is under hot. If done so, it may cause adverse effect to high pressure, use special care when catalyst.
Page 754: Fuel Injector On-Vehicle Inspection
1G-11 Fuel System: For Petrol Engine Model Fuel Injector Removal and Installation Installation S6JB0A1716008 1) Install clamps to marked®® location on pipes. If clamp is deformed, its claw is bent or broken, WARNING replace it with new one. Before starting the following procedure, be 2) Install pipes with pipe clamps to vehicle.
Page 755: Fuel Injector Inspection
Make sure that injectors rotate smoothly (6). If not, probable cause is incorrect installation of O-ring. Replace O-ring with new one. “A”: Oil 99000–25320 (SUZUKI DI O RING OIL(500CC)) • Tighten delivery pipe bolts (5) to specified torque and make sure that injectors rotate smoothly.
Page 756 (For M16 engine model) Approx. 46 cc / 15 sec. Special tool (1.62/1.55 US/Imp oz / 15 sec.) (A): SUZUKI scan tool (For J20 engine model) Approx. 65 cc / 15 sec. (2.20/2.29 US/Imp oz / 15 sec.) 9) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should be at work).
Page 757: Fuel Pressure Regulator Removal And Installation
Fuel System: For Petrol Engine Model 1G-14 Fuel Pressure Regulator Removal and Installation Reverse removal procedure for installation noting the Installation following. S6JB0A1716010 WARNING • Replace O-ring with new one using care not to damage it. Before starting the following procedure, be •...
Page 758: Fuel Filler Cap Inspection
1G-15 Fuel System: For Petrol Engine Model Fuel Filler Cap Inspection 3) Hoist vehicle, and remove clamp (2) and fuel filler S6JB0A1716012 hose (1) from fuel filler neck. WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: For Petrol Engine Model”...
Page 759: Fuel Tank Inlet Valve Inspection
Fuel System: For Petrol Engine Model 1G-16 3) Lower vehicle and install fuel filler cap. 7) Disconnect fuel filler hose and breather hose from filler neck referring to “Fuel Tank Inlet Valve Removal and Installation: For Petrol Engine Model”. Fuel Tank Inlet Valve Inspection S6JB0A1716014 8) For J20 engine, disconnect fuel pump connector (1).
Page 760 1G-17 Fuel System: For Petrol Engine Model 12) Support fuel tank (1) with jack (2) and remove its 3) Install fuel tank to vehicle. mounting bolts. Tightening torque Fuel tank bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) I5JB0A171018-01 13) For M16 engine, lower fuel tank a little as to disconnect connectors (1) of fuel pump (2) and sub I5JB0A171020-01 fuel level gauge (3), then remove fuel tank.
Page 761: Fuel Tank Inspection
Fuel System: For Petrol Engine Model 1G-18 Fuel Pump On-Vehicle Inspection 7) Install parking brake cable clamp to fuel tank cover referring to “Parking Brake Cable Location in Section S6JB0A1716018 WARNING 4D” 8) Install rear propeller shaft referring to “Propeller Before starting the following procedure, be Shaft Removal and Installation in Section 3D”...
Page 762: Fuel Pump Assembly Removal And Installation
1G-19 Fuel System: For Petrol Engine Model Fuel Pump Assembly Removal and Installation Installation S6JB0A1716019 CAUTION WARNING When connecting joint, clean outside surface Before starting the following procedure, be of pipe where joint is to be inserted, push sure to observe “Precautions on Fuel System joint into pipe till joint lock clicks and check Service: For Petrol Engine Model”...
Page 763: Main Fuel Level Sensor Removal And Installation
Fuel System: For Petrol Engine Model 1G-20 Main Fuel Level Sensor Removal and Fuel Pump Inspection S6JB0A1716021 Installation • Check fuel pump assembly for damage. S6JB0A1716020 CAUTION • Check fuel suction filter for evidence of dirt and contamination. • Do not touch resister plate (1) and deform If present, replace or clean and check for presence of arm (2).
Page 764: Sub Fuel Level Sensor Inspection
1G-21 Fuel System: For Petrol Engine Model Removal Installation Reverse removal procedure for installation noting the 1) Remove fuel tank from vehicle Referring to “Fuel following. Tank Removal and Installation: For Petrol Engine Model” • Replace O-ring with new one using care not to damage it.
Page 765: Special Tools And Equipment
Fuel System: For Petrol Engine Model 1G-22 Special Tools and Equipment Recommended Service Material S6JB0A1718001 Material SUZUKI recommended product or Specification Note SUZUKI DI O RING OIL(500CC) P/No.: 99000–25320 NOTE Required service material is also described in the following. “Fuel System Components: For Petrol Engine Model”...
Page 766: For Diesel Engine Model
1G-23 Fuel System: For Diesel Engine Model For Diesel Engine Model Precautions Precautions on Fuel System Service S6JB0A1720001 WARNING • Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. –...
Page 767 Fuel System: For Diesel Engine Model 1G-24 • The fuel system must be checked for leaks after service work referring to “Fuel Leakage Check Procedure: For Diesel Engine Model”. • The fuel system is very sensitive to contamination. The risks caused by the introduction of contamination are: –...
Page 768 1G-25 Fuel System: For Diesel Engine Model I6JB0A172005-01 1. Plug cap : Do not reuse.
Page 769 Fuel System: For Diesel Engine Model 1G-26 • Ensure that you have hermetically resalable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away. I4RH0A170052-01 •...
Page 770: General Description
1G-27 Fuel System: For Diesel Engine Model General Description Fuel System Description S6JB0A1721001 CAUTION This engine requires the unleaded fuel only. The leaded and/or low lead fuel can result in engine damage and reduce the effectiveness of the emission control system. Low-pressure fuel supply circuit [A] The fuel in the fuel tank (1) is pumped up to the high pressure fuel supply circuit [B] through the priming pump (2), the fuel filter (3) and the fuel heater (4) by the low pressure fuel pump (5) built in the injection pump (6).
Page 771: Repair Instructions
Fuel System: For Diesel Engine Model 1G-28 Repair Instructions Fuel System Components S6JB0A1726001 I6JB0A172004-01 1. Fuel tank 13. O-ring 25. To injection pump 2. Fuel pump assembly 14. Fuel heater 26. To fuel filter...
Page 772: Fuel Pressure Relief Procedure
Fuel Leakage Check Procedure S6JB0A1726002 S6JB0A1726003 1) Check that engine is cold. 1) Prime fuel line using priming pump (1). 2) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): SUZUKI scan tool I5JB0B170002-01 2) Check low pressure fuel supply circuit for fuel leakage.
Page 773: Water Draining Of Fuel Filter
Fuel System: For Diesel Engine Model 1G-30 Water Draining of Fuel Filter Fuel Filter and Fuel Heater Removal and S6JB0A1726023 Installation 1) Disconnect negative (–) cable at battery. S6JB0A1726025 Removal 2) Place container under fuel filter (1). 1) Disconnect negative (–) cable at battery. 3) Loosen bleed screw (2), and drain water until fuel 2) Disconnect fuel heater connector (1) and fuel filter flow out from fuel filter.
Page 774: Fuel Heater Inspection
1G-31 Fuel System: For Diesel Engine Model Installation 3) Install fuel filter (1) to its bracket. 4) Remove plug cup from fuel hoses (2) and fuel filter. CAUTION 5) Connect fuel hoses to fuel filter. Be sure to position claw (5) of the fuel filter 6) Connect fuel heater connector (3) and fuel filter case (3) to such position of the fuel heater(1) water detection sensor (4).
Page 775: Fuel Hose Disconnecting And Reconnecting
Fuel System: For Diesel Engine Model 1G-32 Fuel Hose Disconnecting and Reconnecting S6JB0A1726038 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: For Diesel Engine Model” in order to reduce the risk or fire and personal injury. For Connection Other Than Quick Joint •...
Page 776 1G-33 Fuel System: For Diesel Engine Model • Other than clamp around fuel tank [A]: With short pipe, fit hose as far as it reaches pipe joint as shown. [B]: With the following type pipe, fit hose as far as its peripheral projection as shown.
Page 777: Fuel Lines Inspection
Fuel System: For Diesel Engine Model 1G-34 Fuel Lines Inspection Fuel Pipe Removal and Installation S6JB0A1726004 S6JB0A1726005 CAUTION WARNING Due to the fact that fuel feed line is under Before servicing fuel system, be sure to high pressure, use special care when observe “Precautions on Fuel System servicing it.
Page 778: High Pressure Pipe Removal And Installation
1G-35 Fuel System: For Diesel Engine Model High Pressure Pipe Removal and Installation 8) Remove high pressure pipe as follows. S6JB0A1726027 • For high pressure pipe between fuel injector and WARNING common rail a. Loosen high pressure pipe union nut (1) using Before servicing fuel system, be sure to special tool and wrench.
Page 779 Fuel System: For Diesel Engine Model 1G-36 Installation • For high pressure pipe between injection pump and common rail CAUTION a. Loosen high pressure pipe union nut (1) using special tool and wrench. • Do not touch pipes with wrench when tightening union nut to avoid a damage of CAUTION high pressure pipe.
Page 780 1G-37 Fuel System: For Diesel Engine Model CAUTION CAUTION When tightening union nut of injection pump • Be sure not to interfere high pressure pipe side, hold union nut (2) with wrench (3) as with glow plug. shown in figure. •...
Page 781: Fuel Injector On-Vehicle Inspection
Fuel System: For Diesel Engine Model 1G-38 Fuel Injector On-Vehicle Inspection 3) Tighten common rail bolts. S6JB0A1726006 Tightening torque 1) Disconnect negative (–) cable at battery. Common rail bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) 2) Remove engine cover. 4) Install fuel injector cover (1), throttle body (2) with 3) Remove fuel injector cover referring to Step 4) throttle body to EGR valve pipe (3) and vacuum pipe through 7) in “Removal”...
Page 782 DTC is stored in ECM and warning light is turned ON. Also calibration codes registration in ECM can be checked by SUZUKI scan tool. I5JB0B170017-02 8) Install new high pressure pipe referring to “High Pressure Pipe Removal and Installation: For Diesel Engine Model”.
Page 783: Injection Pump Components
Fuel System: For Diesel Engine Model 1G-40 Injection Pump Components S6JB0A1726037 I6JB0A172008-01 [A]: Type 2 : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft) [B]: Type 3 : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft) 1. Injection pump pulley : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft) 2.
Page 784: Injection Pump Removal And Installation
1G-41 Fuel System: For Diesel Engine Model Injection Pump Removal and Installation 6) Clean and vacuum any contamination, and plug all S6JB0A1726030 joint part of disconnected fuel circuit with plug cap referring to “Precautions on Fuel System Service: WARNING For Diesel Engine Model” Before servicing fuel system, be sure to 7) Remove injection pump to common rail high observe “Precautions on Fuel System...
Page 785 Fuel System: For Diesel Engine Model 1G-42 11) Remove injection pump pulley (1) as follows, if 12) Remove injection pump (1) from injection pump front necessary. bracket (2), if necessary. a) Support injection pump front bracket (2) using vise (3). b) Install special tool (A) to injection pump front bracket in order to fix injection pump pulley.
Page 786 1G-43 Fuel System: For Diesel Engine Model b) Install special tool to injection pump front bracket 6) Install injection pump rear bracket (1). (1) in order to fit injection pump pulley (2). Tightening torque Special tool Injection pump rear bracket to cylinder block (A): 09912–96530 bolt (a): 44 N·m (4.4 kgf-m, 32.0 lb-ft) Injection pump rear bracket to injection pump...
Page 787: Fuel Flow Actuator Inspection (Type 2)
Fuel System: For Diesel Engine Model 1G-44 Fuel Flow Actuator Inspection (Type 2) 7) Connect fuel flow actuator connector (1). S6JB0A1726033 8) Connect fuel feed hose (2) and fuel return hose (3) Check resistance between terminals of fuel flow to injection pump. actuator.
Page 788: Common Rail (High Pressure Fuel Injection Rail) Removal And Installation
1G-45 Fuel System: For Diesel Engine Model Common Rail (High Pressure Fuel Injection Removal Rail) Removal and Installation 1) Relief fuel pressure referring to “Fuel Pressure Relief S6JB0A1726034 Procedure: For Diesel Engine Model”. WARNING 2) Disconnect negative (–) cable at battery. Before servicing fuel system, be sure to 3) Clean fuel flow actuator and its surrounding area.
Page 789: Fuel Rail Presser Sensor Inspection
Fuel System: For Diesel Engine Model 1G-46 Remove cap (1), and check gasket for even filler neck 4) Install oil separator referring to “Oil Separator Removal and Installation”. imprint, and deterioration or any damage. If gasket (2) is in malcondition, replace cap. 5) Install fuel injector cover, throttle body and engine cover referring to Step 4) through 8) of “Installation”...
Page 790 1G-47 Fuel System: For Diesel Engine Model 8) Due to absence of fuel tank drain plug, drain fuel 11) For 3 door model, lower fuel tank a little so as to tank by pumping fuel out through fuel tank filler. disconnect connectors (1) of fuel pump (2) and sub Use hand operated pump device to drain fuel tank.
Page 791: Fuel Tank Inspection
Fuel System: For Diesel Engine Model 1G-48 Fuel Tank Purging Procedure 4) Connect fuel filler hose (1) and breather hose to filler neck as shown in figure, and clamp them securely. S6JB0A1726014 WARNING Tightening torque Fuel filler hose clamp (a): 2 N·m (0.2 kgf-m, 1.5 This purging procedure will not remove all lb-ft) fuel vapor.
Page 792: Fuel Tank Inlet Valve Inspection
1G-49 Fuel System: For Diesel Engine Model 3) Lower vehicle and install fuel filler cap. 3) Hoist vehicle, and remove clamp (2) and fuel filler hose (1) from fuel filler neck. Fuel Tank Inlet Valve Inspection S6JB0A1726016 Check fuel tank inlet valve for the following. If any damage or malfunction is found, replace.
Page 793: Fuel Pump Inspection
Fuel System: For Diesel Engine Model 1G-50 Fuel Pump Inspection Installation S6JB0A1726043 CAUTION • Check fuel pump assembly for damage. • Check fuel suction filter for evidence of dirt and When connecting joint, clean outside surface contamination. of pipe where joint is to be inserted, push If present, replace or clean and check for presence of joint into pipe till joint lock clicks and check dirt in fuel tank.
Page 794: Main Fuel Level Gauge Inspection
1G-51 Fuel System: For Diesel Engine Model Main Fuel Level Gauge Inspection Removal S6JB0A1726041 1) Remove fuel tank from vehicle Referring to “Fuel • Check main fuel level gauge for damage. Tank Removal and Installation: For Diesel Engine • For inspection of main fuel level gauge (1), refer to Model”...
Page 795: Specifications
Fuel System: For Diesel Engine Model 1G-52 Specifications Tightening Torque Specifications S6JB0A1727001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Fuel filter case bolt Common rail bolt 16.0 High pressure pipe union nut (Type 2) 18.0 High pressure pipe union nut (Common rail to 19.5 fuel injector) (Type 3) Common rail mounting bolt...
Page 796: Special Tools And Equipment
09912–96530 09919–47020 Injection pump pulley Quick joint remover locking Mot. 1668 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loop back adapter, 7.
Page 797: Ignition System
Ignition System: For Petrol Engine Model 1H-1 Ignition System Engine For Petrol Engine Model General Description Ignition System Construction For M16 engine, this ignition system does not have a S6JB0A1801001 distributor, it has two ignition coil assemblies (one is for The ignition system is an electronic (distributor less) No.1 and No.4 spark plugs and the other is for No.2 and ignition system.
Page 798: Schematic And Routing Diagram
1H-2 Ignition System: For Petrol Engine Model Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S6JB0A1802001 BLK/WHT BLK/WHT BLK/ORN BLK/ORN C37-21 BRN/BLK C37-20 BLK/WHT E23-29 BLK/YEL E23-60 BLK/RED BLK/RED BLU/BLK BLU/BLK E23-1 BLK/RED BLU/BLK E23-16 WHT/GRN C37-15 BLK/ORN C37-30 BLK/ORN WHT/RED C37-52...
Page 799 Ignition System: For Petrol Engine Model 1H-3 2. Main relay 10. No.4 spark plug 18. Ignition coil assembly for No.1 3. Ignition coil assembly for No.1 and No.4 spark 11. Sensed information (MAP sensor, ECT 19. Ignition coil assembly for No.2 plugs sensor, MAF and IAT sensor, TP sensor, Knock sensor, wheel speed signal (ABS),...
Page 800: Component Location
1H-4 Ignition System: For Petrol Engine Model Component Location Ignition System Components Location S6JB0A1803001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I5JB0A180002-03 [A]: For M16 engine 7. ECT sensor 15.
Page 801: Diagnostic Information And Procedures
Ignition System: For Petrol Engine Model 1H-5 Diagnostic Information and Procedures Ignition System Symptom Diagnosis S6JB0A1804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to start Loose connection or disconnection of Connect securely.
Page 802 1H-6 Ignition System: For Petrol Engine Model Step Action High-tension cords check (for M16 engine) Go to Step 6. Replace high-tension cord(s). 1) Check high-tension cord for resistance referring to “High-Tension Cord Inspection (For M16 Engine): For Petrol Engine Model”. Is check result satisfactory? Ignition coil assembly power supply and ground circuit Go to Step 7.
Page 803 Ignition System: For Petrol Engine Model 1H-7 Ignition Spark Test S6JB0A1804004 1) Remove engine cover. 2) Disconnect all injector couplers from injectors. WARNING Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room. 3) Remove spark plug and check it for condition and type referring to “Spark Plug Inspection: For Petrol Engine Model”.
Page 804: Repair Instructions
1H-8 Ignition System: For Petrol Engine Model Repair Instructions High-Tension Cord Removal and Installation High-Tension Cord Inspection (For M16 Engine) S6JB0A1806002 (For M16 Engine) Measure resistance of high-tension cord (1) by using S6JB0A1806001 ohmmeter. Removal If resistance exceeds specification, replace high-tension 1) Remove engine cover.
Page 805: Spark Plug Inspection
Ignition System: For Petrol Engine Model 1H-9 Spark Plug Inspection Ignition Coil Assembly (Including ignitor) S6JB0A1806004 Removal and Installation S6JB0A1806005 CAUTION Removal 1) Disconnect negative cable at battery. • When servicing the iridium / platinum spark plugs (slender center electrode type 2) Remove engine cover.
Page 806: Ignition Coil Assembly (Including Ignitor) Inspection
“P” range for A/T model), and set parking brake. 1) Connect scan tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool I5JB0A180006-01 [A]: For M16 engine [B]: For J20 engine 4) Install engine cover.
Page 807 • CKP sensor plate Initial ignition timing (M16 Engine) • TP sensor Fixed with SUZUKI scan tool: 7° – 17° BTDC (at • CMP sensor specified idle speed) • CMP sensor rotor tooth of camshaft Initial ignition timing (J20 Engine) •...
Page 808: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Special Tool S6JB0A1808001 09930–76420 SUZUKI scan tool Timing-light (dry cell type) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 809: Starting System
Starting System: For Petrol Engine Model 1I-1 Starting System Engine For Petrol Engine Model Precautions Cranking System Note S6JB0A1910001 NOTE Starting motor varies depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts.
Page 810: Diagnostic Information And Procedures
1I-2 Starting System: For Petrol Engine Model Diagnostic Information and Procedures Cranking System Symptom Diagnosis S6JB0A1914001 Possible symptoms due to starting system trouble would be as follows: • Starting motor does not run (or runs slowly) • Starting motor runs but fails to crank engine •...
Page 811: Starting Motor Performance Test
Starting System: For Petrol Engine Model 1I-3 Condition Possible cause Correction / Reference Item Starting motor running, Insufficient contact of magnetic switch Replace magnetic switch. but too slow (small main contacts torque) – Battery and Layer short-circuit of armature Replace. wiring are satisfactory Disconnected, burnt or worn Repair commutator or replace armature.
Page 812 1I-4 Starting System: For Petrol Engine Model Hold-In Test 1) While connected as above with plunger out, disconnect negative lead (2) from terminal “M” (1). 2) Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch. IYSQ01190004-01 Plunger and Pinion Return Test 1) Disconnect negative lead (1) from switch body (2).
Page 813: Repair Instructions
Starting System: For Petrol Engine Model 1I-5 Repair Instructions Starting Motor Dismounting and Remounting S6JB0A1916001 Dismounting 1) Disconnect negative (–) battery lead at battery. 2) Hoist vehicle 3) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 4) Remove starting motor mount bolts (3).
Page 814: Starting Motor Components
1I-6 Starting System: For Petrol Engine Model Starting Motor Components S6JB0A1916002 The starting motor consists of parts shown in below and has permanent magnets mounted in starting motor yoke (frame). The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash.
Page 815: Starting Motor Inspection
Starting System: For Petrol Engine Model 1I-7 Starting Motor Inspection Hold-In coil open circuit test S6JB0A1916003 Check for continuity across magnetic switch “S” terminal and coil case. If no continuity exists, coil is open and Plunger should be replaced. Inspect plunger for wear. Replace if necessary. IYSQ01190030-01 IYSQ01190027-01 Rear Bracket Bush...
Page 816 1I-8 Starting System: For Petrol Engine Model Brush Spring • Check commutator for uneven wear with armature (1) Inspect brush springs for wear, damage or other supported on V-blocks (2). If deflection of dial gauge abnormal conditions. Replace if necessary. (4) pointer exceeds limit, repair or replace.
Page 817 Starting System: For Petrol Engine Model 1I-9 • Inspect commutator for insulator depth. Correct or Gears replace if below limit. Inspect internal gear and the planetary gears for wear, damage or other abnormal conditions. Replace if Commutator insulator depth “a” necessary.
Page 818: Specifications
1I-10 Starting System: For Petrol Engine Model Specifications Starting Motor Specifications S6JB0A1917001 1.2 kW Type [1.4 kW Type] Voltage 12 volts Output 1.2 kW [1.4 kW] Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 5.5 mm (0.22 in.) Number of pinion teeth...
Page 819: For Diesel Engine Model
Starting System: For Diesel Engine Model 1I-11 For Diesel Engine Model General Description Cranking Circuit Introduction S6JB0A1921001 The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These components are connected electrically. Starting Motor Circuit Description S6JB0A1921002 •...
Page 820: Diagnostic Information And Procedures
1I-12 Starting System: For Diesel Engine Model Diagnostic Information and Procedures Cranking System Symptom Diagnosis S6JB0A1924001 Possible symptoms due to starting system trouble would be as follows: • Starting motor does not run (or runs slowly) • Starting motor runs but fails to crank engine •...
Page 821: Starting Motor Performance Test
Starting System: For Diesel Engine Model 1I-13 Condition Possible cause Correction / Reference Item Noise Abnormally worn bearing Replace front housing. Worn pinion or worn teeth of ring gear Replace over-running clutch or flywheel (M/T). Poor sliding of pinion (failure in return Repair or replace.
Page 822: Repair Instructions
1I-14 Starting System: For Diesel Engine Model No-Load Performance Test 1) Connect battery and ammeter to starter as shown. 2) Check that starter rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current. Specified current (no-load performance test) 90A MAX.
Page 823: Starting Motor Dismounting And Remounting
Starting System: For Diesel Engine Model 1I-15 3. Magnetic switch bolt 7. Spring 11. Nut 15. Snap ring 4. Through bolt 8. Magnetic switch 12. Washer : Do not reuse. Starting Motor Dismounting and Remounting 3) Loosen magnetic switch screw (1) and then remove S6JB0A1926001 front housing (2).
Page 824 1I-16 Starting System: For Diesel Engine Model 7) Remove planetary carrier shaft assembly (1) from Assembly yoke (2). 1) Install over-running clutch (1) to planetary carrier shaft (3), using care for installing direction of pinion CAUTION stop ring (2). Don’t disassemble motor. If defective, replace as a complete assembly.
Page 825: Starting Motor Inspection
Starting System: For Diesel Engine Model 1I-17 Starting Motor Inspection 4) Install spring (5) and magnetic switch (2) to plunger and then tighten magnetic switch inner screw (4). S6JB0A1926004 Plunger CAUTION Inspect plunger for wear. Replace if necessary. With marks (1) on magnetic switch (2) and planetary carrier shaft assembly (3) marked before remove aligned to each other.
Page 826: Specifications
1I-18 Starting System: For Diesel Engine Model Hold-in coil open circuit test Pinion and Over-Running Clutch Check for continuity across magnetic switch “S” terminal • Inspect pinion for wear, damage or other abnormal and coil case. If no continuity exists, coil is open and conditions.
Page 827: Charging System
Charging System: For Petrol Engine Model 1J-1 Charging System Engine For Petrol Engine Model General Description Battery Description S6JB0A1A11001 The battery has three major functions in the electrical system. • It is a source of electrical energy for cranking the engine. •...
Page 828: Generator Description
1J-2 Charging System: For Petrol Engine Model • Green Dot: Battery is sufficiently charged for testing. • Dark: Battery must be charged before testing. If there is a cranking complaint, battery should be tested as described in “Battery Inspection: For Petrol Engine Model”.
Page 829: Diagnostic Information And Procedures
Charging System: For Petrol Engine Model 1J-3 Charging System Circuit The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage is being controlled by ECM under some conditions while driving.
Page 830: Generator Symptom Diagnosis
1J-4 Charging System: For Petrol Engine Model Generator Symptom Diagnosis S6JB0A1A14002 A charging circuit wiring diagram for generator connection is shown in “Generator Description: For Petrol Engine Model”. To avoid damage, always follow these precautions: CAUTION • Do not mistake polarities of “IG” terminal and “L” terminal. •...
Page 831: Generator Test (Overcharged Battery Check)
Charging System: For Petrol Engine Model 1J-5 No-Load Check Load Check 1) Run engine from idling up to 2000 rpm and read 1) Run engine at 2000 rpm and turn on head light and meters. heater motor. 2) Measure current and if it is less than 30 A repair or NOTE replace generator.
Page 832: Repair Instructions
1J-6 Charging System: For Petrol Engine Model Repair Instructions Jump Starting in Case of Emergency 1) Set parking brake and place automatic transmission S6JB0A1A16001 in PARK (NEUTRAL on manual transmission). With Auxiliary (Booster) Battery 2) Turn OFF ignition switch, turn OFF lights and all other electrical loads.
Page 833: Battery Dismounting And Remounting
Charging System: For Petrol Engine Model 1J-7 Battery Dismounting and Remounting Water Pump and Generator Drive Belt Removal S6JB0A1A16002 and Installation (For M16 Engine) WARNING S6JB0A1A16003 Removal When handling battery, following safety 1) Disconnect negative cable at battery. precautions should be followed: 2) If vehicle equipped with A/C, remove compressor •...
Page 834: Water Pump And Generator Drive Belt Tension Inspection And Adjustment (For M16 Engine)
1J-8 Charging System: For Petrol Engine Model Water Pump and Generator Drive Belt Tension 3) If belt is too tight or too loose, adjust it to proper tension by displacing generator position. Inspection and Adjustment (For M16 Engine) S6JB0A1A16004 4) To adjust belt tension, loosen generator adjusting WARNING bolt (3) and displace generator position by loosening on tightening adjuster bolt.
Page 835: Water Pump And Generator Drive Belt On-Vehicle Inspection (For J20 Engine)
Charging System: For Petrol Engine Model 1J-9 Water Pump and Generator Drive Belt On-Vehicle Inspection (For J20 Engine) S6JB0A1A16005 [Type A] 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace belt, referring to “Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine): For Petrol Engine Model”.
Page 836: Water Pump And Generator Drive Belt Removal And Installation (For J20 Engine)
1J-10 Charging System: For Petrol Engine Model Water Pump and Generator Drive Belt Removal Installation and Installation (For J20 Engine) 1) Loosen tensioner by turning the tensioner pulley (2) S6JB0A1A16006 clockwise. Removal 2) While holding the tensioner, install generator belt (1). WARNING NOTE Disconnect negative (–) cable at battery...
Page 837: Generator Dismounting And Remounting
Charging System: For Petrol Engine Model 1J-11 Generator Dismounting and Remounting S6JB0A1A16007 I5JB0A1A0003-02 [A]: For M16 Engine 4. Generator adjusting bolt (For M16 Engine) 9. Generator [B]: For J20 Engine 5. Generator mounting bolt (For J20 Engine) : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) 1.
Page 838: Generator Components
1J-12 Charging System: For Petrol Engine Model Dismounting 1) Disconnect negative (–) cable at battery. 2) Disconnect MAF sensor coupler (For J20 Engine). 3) Remove air cleaner case and air cleaner outlet hose (For J20 Engine). 4) Disconnect generator lead wire (“B” terminal wire) and coupler from generator. 5) Remove generator belt.
Page 839: Generator Inspection
Charging System: For Petrol Engine Model 1J-13 Generator Inspection S6JB0A1A16009 Rotor • Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
Page 840 1J-14 Charging System: For Petrol Engine Model Stator • Using ohmmeter, check all leads for continuity. If there is no continuity, replace stator (1). IYSQ011A0037-01 • Using ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator.
Page 841 Charging System: For Petrol Engine Model 1J-15 Rectifier 1) Using ohmmeter, 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 (1).
Page 842: Specifications
1J-16 Charging System: For Petrol Engine Model Specifications Charging System Specifications S6JB0A1A17001 Battery NOTE The battery used in each vehicle is one of the following two types, depending on specification. Battery : 55B24R (S) (36AH/5HR), 55D23L (48AH/5HR) 12 V Battery type 55B24R (S) 55D23L Rated Capacity...
Page 843: For Diesel Engine Model
Charging System: For Diesel Engine Model 1J-17 For Diesel Engine Model General Description Battery Description Care of battery S6JB0A1A21001 The battery has three major functions in the electrical WARNING system. • Never expose battery to open flame or • It is a source of electrical energy for cranking the electric spark because of battery generate engine.
Page 844: Generator Description
1J-18 Charging System: For Diesel Engine Model Generator Description S6JB0A1A21002 The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown in the following figure. The generator features are as follows: •...
Page 845: Diagnostic Information And Procedures
Charging System: For Diesel Engine Model 1J-19 Diagnostic Information and Procedures Battery Inspection How to use the temperature-corrected state-of- S6JB0A1A24001 charge graph Common Causes of Failure Suppose your S.G. reading is 1.28 and the battery A battery is not designed to last indefinitely; however, temperature is –5 °C (23 °F).
Page 846: Generator Symptom Diagnosis
1J-20 Charging System: For Diesel Engine Model Generator Symptom Diagnosis Noise from generator may be caused by loose drive S6JB0A1A24002 pulley, loose mounting bolts, worn or dirty bearings, CAUTION defective diode, or defective stator. • Do not connect any load between “L” and “E”...
Page 847: Generator Test (Overcharged Battery Check)
Charging System: For Diesel Engine Model 1J-21 Generator Test (Overcharged Battery Check) 2) Run engine from idling up to 5,000 rpm with all accessories turned off and read meters. S6JB0A1A24004 1) To determine battery condition, refer to “Battery If voltage is higher than standard value, check Description: For Diesel Engine Model”.
Page 848: Repair Instructions
1J-22 Charging System: For Diesel Engine Model Repair Instructions Jump Starting in Case of Emergency 1) Set parking brake and place automatic transmission S6JB0A1A26001 in PARK (NEUTRAL on manual transmission). With Auxiliary (Booster) Battery 2) Turn OFF ignition switch, turn OFF lights and all other electrical loads.
Page 849: Generator Components
Charging System: For Diesel Engine Model 1J-23 Dismounting 1) Disconnect negative cable (1). 2) Disconnect positive cable (2). 3) Remove retainer (3). 4) Remove battery (4). Remounting 1) Reverse removal procedure. 2) Torque battery cables to specification. NOTE I5JB0B1A0006-01 Check to be sure that ground cable has enough clearance to hood panel by terminal.
Page 850: Generator Dismounting And Remounting
1J-24 Charging System: For Diesel Engine Model Generator Dismounting and Remounting Generator Disassembly and Assembly S6JB0A1A26003 S6JB0A1A26009 Dismounting Disassembly 1) Disconnect negative (–) cable at battery. NOTE 2) Remove accessory drive belt. Refer to “Accessory Before disassembling generator, be sure to Drive Belt and Idler Pulley Removal and Installation: put match marks at 1 locations (A (drive end For Diesel Engine Model”.
Page 851 Charging System: For Diesel Engine Model 1J-25 5) Remove coil assembly (1) from rotor (2) and then 3) Install wave washer (3) and coil assembly (2) to rotor remove wave washer (3). (1). NOTE With marks on drive end frame and coil assembly marked before remove aligned to each other.
Page 852: Drive End Frame / Bearing Disassembly And Assembly
1J-26 Charging System: For Diesel Engine Model c) Remove pin from brush holder. Assembly 6) Install insulator (3). 1) Press-fit drive end bearing by using special tools and press (1). 7) Install rear end cover (2) to coil assembly and tighten rear end cover nut (1) to specified torque.
Page 853 Charging System: For Diesel Engine Model 1J-27 Stator Rectifier 1) Check resistance between the following leads of 1) Check continuity of rectifier by using an ohm meter. stator. If there is no continuity, replace coil assembly. 2) Reverse the polarity of the tester probes and repeat Step 1).
Page 854: Accessory Drive Belt And Idler Pulley Removal And Installation
1J-28 Charging System: For Diesel Engine Model Accessory Drive Belt and Idler Pulley Removal Installation and Installation 1) Install adapter (6) and then tighten adapter. S6JB0A1A26006 2) Install idler pulley (5) and then tighten idler pulley Removal bolt (7) to specified torque. WARNING Tightening torque Idler pulley bolt (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
Page 855: Accessory Drive Belt Inspection
Charging System: For Diesel Engine Model 1J-29 Accessory Drive Belt Inspection Installation S6JB0A1A26007 1) Install accessory drive belt tensioner. Check accessory drive belt for cracks, cuts, deformation, 2) Tighten accessory drive belt tensioner bolt No.1 and wear and cleanliness, and replace as required. No.2 to specified torque.
Page 856: Tightening Torque Specifications
1J-30 Charging System: For Diesel Engine Model Tightening Torque Specifications S6JB0A1A27002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Battery ground bolt Generator mounting bolt 32.0 “B” terminal nut Idler pulley bolt 36.5 Accessory drive belt and belt tensioner bolt 36.5 No.1 Accessory drive belt tensioner bolt No.2...
Page 857: Exhaust System
Exhaust System: For Petrol Engine Model 1K-1 Exhaust System Engine For Petrol Engine Model General Description Exhaust System Description S6JB0A1B11001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 858 1K-2 Exhaust System: For Petrol Engine Model For M16 Engine Model I5JB0A1B1002-03 [A]: Installing location of exhaust manifold bold and nut. 9. Exhaust pipe No.2 18. Exhaust pipe No.1 bracket bolt 1. Exhaust manifold gasket 10. Exhaust center pipe 19. Exhaust center pipe nut 2.
Page 859 Exhaust System: For Petrol Engine Model 1K-3 For J20 Engine Model I5JB0A1B1003-05 [A]: Installing location of exhaust manifold bold and nut. 10. Exhaust center pipe 20. Exhaust center pipe gasket 1. Exhaust manifold gasket 11. Muffler 21. Muffler mounting 2. Exhaust manifold 12.
Page 860: Exhaust Manifold Removal And Installation (For M16 Engine Model)
1K-4 Exhaust System: For Petrol Engine Model Exhaust Manifold Removal and Installation (For 2) Install exhaust pipe No.1 bracket (1). M16 Engine Model) Tightening torque S6JB0A1B16002 Exhaust pipe No.1 bracket bolt and nut (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Removal WARNING To avoid danger of being burned, do not...
Page 861: Exhaust Pipe And Muffler Removal And Installation
Exhaust System: For Petrol Engine Model 1K-5 7) Remove exhaust pipe No.1 bracket (1). 3) Install exhaust manifold cover (1). 8) Remove exhaust manifold (2) and its gasket (3) from 4) Connect water outlet pipe (2) from radiator inlet cylinder head. hose.
Page 862: Specifications
1K-6 Exhaust System: For Petrol Engine Model Specifications Tightening Torque Specifications S6JB0A1B17001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust manifold bolt and nut 36.5 Exhaust pipe No.1 bracket bolt and nut 36.5 Exhaust No.1 pipe nut 36.5 NOTE The specified tightening torque is also described in the following.
Page 863: For Diesel Engine Model
Exhaust System: For Diesel Engine Model 1K-7 For Diesel Engine Model General Description Exhaust System Description Diesel Particurate Filter Description S6JB0A1B21001 S6JB0A1B21002 The exhaust system consists of an exhaust manifold, a The diesel particurate filter is emission control device turbo charger, a catalytic converter in a catalyst case, a added to the exhaust system after catalytic converter, diesel particurate filter (if equipped), an exhaust pipes, a and it accumulates the diesel particular in the exhaust...
Page 864: Repair Instructions
1K-8 Exhaust System: For Diesel Engine Model Repair Instructions Exhaust System Components S6JB0A1B26001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I6JB0A1B2001-04 [A]: Diesel particulate filter model 3.
Page 865: Diesel Particulate Filter Removal And Installation
“Exhaust System Components: For Diesel Engine Model”. CAUTION • When replacing diesel particulate filter, perform “Initialize diesel PF data” mode of SUZUKI scan tool When replacing diesel particulate filter, referring to “SUZUKI Tech 2 Operator's Manual”. perform “Initialize diesel PF data” mode of SUZUKI scan tool referring to “SUZUKI Tech...
Page 866 1K-10 Exhaust System: For Diesel Engine Model...
Page 867: Suspension
Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Front Stabilizer Bar, Bushing and/or Joint Check ..............2B-19 Precautions............. 2-1 Front Suspension Fasteners Check....2B-19 Precautions on Suspension ........2-1 Specifications .............2B-20 Suspension General Diagnosis....2A-1 Tightening Torque Specifications......2B-20 Special Tools and Equipment ......2B-21 Diagnostic Information and Procedures....2A-1 Recommended Service Material .......2B-21 Suspension, Wheels and Tires Symptom...
Page 868 2-ii Table of Contents Rear Suspension frame / Bushing Wheels and Tires ........2D-1 Disassembly and Assembly ......2C-22 General Description ..........2D-1 Rear Suspension Frame, Bushing and Pad Tires Description ..........2D-1 Check ..............2C-23 Wheels Description ..........2D-2 Rear Wheel Hub Assembly and Rear Irregular and/or Premature Wear Description ..2D-3 Suspension Knuckle Components ....2C-23 Wear Indicators Description ........2D-3...
Page 869: Precautions
Precautions: Precautions Suspension Precautions Precautions on Suspension S6JB0A2000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. General Precautions Refer to “General Precautions in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points in Section 0A”.
Page 870: Suspension General Diagnosis
2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S6JB0A2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tires. Tires not adequately inflated Adjust tire pressure. Broken or sagging coil springs Replace coil springs.
Page 871 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes. Faulty strut (shock absorber) or Replace strut (shock absorber) or tighten mounting mounting.
Page 872: Specifications
2A-3 Suspension General Diagnosis: Specifications Wheel Alignment Specifications Side Slip Limit *1 S6JB0A2107001 Front: IN 1.5 to OUT 1.5 mm/m (IN 0.0591 to OUT 0.0591 in./3.3 ft) Toe (“b” – “a”) Front: 0.0 ± 2.0 mm (0 ± 0.0787 in.) Rear: IN 7.5 mm/m (IN 0.2953 in./3.3 ft) Rear: IN 6.0 ±...
Page 873: Front Suspension
Front Suspension: 2B-1 Front Suspension Suspension General Description Front Suspension Construction S6JB0A2201001 I6JB0A220001-03 1. Front strut assembly 8. Stabilizer bar joint : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 2. Stabilizer bar 9. Strut nut : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft) : Do not reuse caulking nut if used.
Page 874: Front Wheel Alignment Construction
2B-2 Front Suspension: Front Wheel Alignment Construction • Check all tires for proper inflation pressures and S6JB0A2201002 approximately the same tread wear. Among factors for front wheel alignment, only toe setting • Check for loose of ball joints. Check tie-rod ends; if can be adjusted.
Page 875 Front Suspension: 2B-3 Adjustment Steering Angle Check and Adjustment When tie-rod or tie-rod end was replaced, check toe and 1) Loosen right and left tie-rod end lock nuts (1) first. then also steering angle with turning radius gauge (1). 2) Rotate right and left tie-rods (2) by the same amount If steering angle is not correct, check whether right and to align toe to specification.
Page 876: Front Strut Assembly Components
2B-4 Front Suspension: Front Strut Assembly Components S6JB0A2206002 I6JB0A220002-01 1. Strut assembly 7. Strut support 13. Stabilizer joint 2. Coil spring 8. Strut support nut 14. Strut dust cover 3. Bump stopper 9. Strut nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) : Do not reuse caulking nut if used.
Page 877: Front Strut Assembly Removal And Installation
Front Suspension: 2B-5 Front Strut Assembly Removal and Installation 6) Remove strut bracket bolts and nuts (4). S6JB0A2206003 Removal NOTE When servicing component parts of strut assembly, remove strut rod cap and then loosen strut nut a little before removing strut assembly.
Page 878: Front Strut Assembly Disassembly And Assembly
2B-6 Front Suspension: • Lower hoist and vehicle in unloaded condition, tighten • Tighten wheel nuts to specified torque. strut support nuts (b) to specified torque. Tightening torque Tightening torque Wheel nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) Strut support nut (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft) •...
Page 879: Front Strut Assembly Check
Front Suspension: 2B-7 7) Install bearing (3), strut support (2) and strut nut (1) Assembly For assembly, reverse disassembly procedure, noting in this sequence. the following instructions. Tighten strut nut (1) holding stud with special tools. 1) Compress coil spring with special tool (A) until total NOTE length becomes about 310 mm (12.2 in.) as shown.
Page 880: Front Wheel Hub Assembly And Steering Knuckle Components
2B-8 Front Suspension: • Inspect bearing for wear, abnormal noise or gripping. • Inspect bump stopper for deterioration. If defective, replace. If defective, replace. • Inspect coil spring seat for cracks or deformation. • Inspect rebound stopper and strut mount for wear, If defective, replace.
Page 881 I5JB0A220014-01 section to avoid the encoder malfunction. 7) Remove wheel hub housing bolts (3), and then remove wheel hub assembly (1) and dust cover (2). “A”: Grease 99000–25010 (SUZUKI Super Grease A) 2, "A" I5JB0A220015-01 8) Remove hub bolts (1) with copper hammer or...
Page 882: Steering Knuckle Removal And Installation
2B-10 Front Suspension: 5) Install brake disk and brake caliper. Installation For installation, reverse removal procedure, noting the 6) Tighten caliper carrier bolt to specified torque. following instructions. Tightening torque 1) Connect steering knuckle to suspension control arm. Caliper carrier bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft) 2) Install strut bracket bolts (2) and nuts (1) as shown in 7) Install front wheel spindle (if equipped).
Page 883: Front Wheel Hub, Disc, Nut And Bearing Check
Front Suspension: 2B-11 6) Connect front height sensor (if equipped) to • Check wheel bearing noise and smooth wheel rotation suspension control arm for left side referring to by rotating wheel in figure. “Height Sensor Removal and Installation (If If defective, replace bearing. Equipped) in Section 9B”.
Page 884: Suspension Control Arm / Bushing Disassembly And Assembly
2B-12 Front Suspension: 2) Connect steering knuckle to suspension control arm 4) Push out bushing by using hydraulic press (2) and referring to “Steering Knuckle Removal and special tools. Installation”. Special tool 3) Tighten suspension control arm nuts to specified (A): 09945–55410 torque with vehicle weight on suspension.
Page 885: Suspension Control Arm / Steering Knuckle Check
Front Suspension: 2B-13 Suspension Control Arm Joint Check 2) Install rubber stopper (1). S6JB0A2206014 • Check smooth rotation of ball stud. • Check damages of ball stud. • Check damages of dust cover. NOTE Suspension control arm and arm joint cannot be separated.
Page 886: Front Suspension Frame, Stabilizer Bar And/Or Bushings Components
2B-14 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or Bushings Components S6JB0A2206015 I6JB01220006-01 F: Forward 6. Stabilizer joint nut 12. Stabilizer mount 1. Stabilizer bar 7. Suspension control arm : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 2. Stabilizer bushing 8. Control arm mounting bolt : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) : If bolt is reused, apply engine oil to thread, bearing and trunk surface.
Page 887: Front Suspension Frame, Stabilizer Bar And/Or Bushings Removal And Installation
Front Suspension: 2B-15 Front Suspension Frame, Stabilizer Bar and/or 9) Disconnect front height sensor connector (1) (auto leveling headlight model) and then detach clip (2). Bushings Removal and Installation S6JB0A2206016 Removal 1) Hoist vehicle and remove wheels (right & left). 2) Drain front differential oil (if equipped).
Page 888 2B-16 Front Suspension: 15) Support suspension frame at the specified positions 18) Remove P/S gear box assembly (1) and front (1) indicated in figure. differential assembly (2) (if equipped) referring to “P/ S Gear Case Assembly Removal and Installation in WARNING Section 6C”...
Page 889 Front Suspension: 2B-17 3) Tighten stabilizer bar mounting bracket bolts (4) to 5) Install suspension frame. specified torque. WARNING Tightening torque When installing suspension frame, be sure to Stabilizer bar mounting bracket bolt (a): 50 N·m ( apply some supporting equipment under it at 5.0 kgf-m, 36.5 lb-ft) well-balanced position as shown in the figure section so as to prevent from its drop.
Page 890 2B-18 Front Suspension: 6) Tighten suspension frame mounting bolts (1) and 8) Install hood referring to “Hood Removal and engine front body side mounting nuts (2) to specified Installation in Section 9J”. torque. 9) Install front propeller shaft (if equipped) referring to “Propeller Shaft Removal and Installation in Section CAUTION 3D”.
Page 891: Front Suspension Frame Check
Front Suspension: 2B-19 Front Suspension Frame Check Stabilizer Bushing S6JB0A2206017 Inspect for damage, wear or deterioration. Inspect for cracks, deformation or damage. If defective, replace. If defective, replace. I5JB0D220002-01 Stabilizer Joint 1) Check for smooth rotation. 2) Check damages of ball stud. I5JB0A220056-01 3) Check damages of dust cover.
Page 892 2B-20 Front Suspension: Specifications Tightening Torque Specifications S6JB0A2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 47.0 Strut bracket nut 13.5 98.0 Brake hose mounting bolt 18.0 Stabilizer joint nut 43.5 Wheel speed sensor harness clamp bolt Strut support nut 36.5 Wheel nut...
Page 893: Special Tools And Equipment
Front Suspension: 2B-21 Special Tools and Equipment Recommended Service Material S6JB0A2208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 NOTE Required service material is also described in the following. “Front Suspension Construction: ” “Front Strut Assembly Components: ”...
Page 894: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension General Description Rear Suspension Construction S6JB0A2301001 I6JB0A230001-03 [A]: View A 4. Control rod 9. Lower Arm : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) [B]: View B 5. Trailing rod : 105 N⋅m (10.5 kgf-m, 76.0 lb-ft) : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 1.
Page 895: Repair Instructions
Rear Suspension: 2C-2 Repair Instructions Rear Wheel Alignment Inspection and Adjustment Adjustment Control rod adjustment S6JB0A2306001 1) Loosen right and left control rod mount nuts (1). Among factors for rear wheel alignment, only toe and camber setting can be adjusted. Caster can’t be adjusted.
Page 896 2C-3 Rear Suspension: Lower arm adjustment 3) After adjustment, tighten right and left nuts to specified torque while holding cam bolt with another 1) Loosen right and left lower arm mount nuts (1). wrench to prevent it from turning. Tightening torque Lower arm mount nut: 135 N·m (13.5 kgf-m, 98.0 lb-ft) Reference Information...
Page 897: Rear Shock Absorber And Rear Coil Spring Components
Rear Suspension: 2C-4 Rear Shock Absorber and Rear Coil Spring Components S6JB0A2306002 I6JB0A230002-01 1. Rear shock absorber 8. Lower arm inner bolt F: Forward 2. Rear coil spring 9. Lower arm washer : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Coil spring rubber seat 10.
Page 898: Rear Shock Absorber Removal And Installation
2C-5 Rear Suspension: Rear Shock Absorber Removal and Installation Installation S6JB0A2306003 Install shock absorber by reversing removal procedure, noting the following instructions. Removal • Tighten all fasteners to specified torque. 1) Hoist vehicle, allowing rear suspension to hang free. Tightening torque 2) Remove wheel.
Page 899: Shock Absorber Check
Rear Suspension: 2C-6 Shock Absorber Check Rear Coil Spring and Bump Stopper Removal S6JB0A2306004 and Installation • Inspect for deformation or damage. S6JB0A2306005 • Inspect bushings for wear or damage. Removal • Inspect for evidence of oil leakage. 1) Hoist vehicle, allowing rear suspension to hang free. Replace any defective part.
Page 900 2C-7 Rear Suspension: 9) Remove bump stopper (1) from suspension upper 3) Installing coil spring on lower arm and place coil arm (2) by using special tool (A). spring end (1) onto lower arm (2) as shown. Special tool CAUTION (A): 09941–66010 •...
Page 901: Rear Coil Spring Check
Rear Suspension: 2C-8 6) With marks (1) on lower arm washer (2) and rear 11) Tighten lower arm outer bolt and lower arm mount suspension frame (3) marked before remove aligned nut, shock absorber bolts to specified torque with to each other, tighten lower arm mount nut (4) vehicle weight on suspension.
Page 902: Rod And Arm Components
2C-9 Rear Suspension: Rod and Arm Components S6JB0A2306007 I6JB0A230003-01 1. Upper arm 10. Lower arm mount nut 19. Trailing rod mount nut : If reuse nut, apply engine oil to thread and : If reuse nut, apply engine oil to bearing.
Page 903: Control Rod Removal And Installation
Rear Suspension: 2C-10 Control Rod Removal and Installation Installation S6JB0A2306008 1) Install control rod (1). a) Install control rod (1) to rear suspension frame. Removal b) Insert control rod inner bolt (2) from the vehicle 1) Hoist vehicle and remove rear wheels. frontward.
Page 904: Control Rod / Bushing Disassembly And Assembly
2C-11 Rear Suspension: Control Rod / Bushing Disassembly and 2) Tighten parking cable hanger bolt (1) to specified torque. Assembly S6JB0A2306009 Tightening torque Parking cable hanger bolt (a): 10 N·m (1.0 kgf- Disassembly m, 7.5 lb-ft) 1) Push out control rod bushing by using hydraulic press (1) and special tool.
Page 905: Control Rod Check
Rear Suspension: 2C-12 2) Press-fit bushing so that dimensions “A” and “B” in 4) Remove trailing rod front bolt (1) and trailing rod rear figure become equal. bolt (2) and then trailing rod (3). I5JB0A230024-01 I5JB0A230027-01 5) Remove trailing rod mount bracket bolt (1) and then Control Rod Check trailing rod mount bracket (2).
Page 906: Trailing Rod / Bushing Disassembly And Assembly
2C-13 Rear Suspension: 2) Install trailing rod (4). 7) Tighten trailing rod mount nut and trailing rod rear bolt to specified torque with vehicle weight on a) Install trailing rod and insert trailing rod front bolt suspension. (1) from the body inside. b) Insert trailing rod rear bolt (2).
Page 907: Trailing Rod Check
Rear Suspension: 2C-14 Trailing Rod Check Assembly S6JB0A2306013 1) Press-fit trailing rod bushing (2) by using press (1) • Inspect for cracks, deformation or damage. and special tool. • Inspect bushing for wear and breakage. CAUTION If any faulty condition is found, replace. •...
Page 908: Lower Arm / Bushing Disassembly And Assembly
2C-15 Rear Suspension: 4) Remove rear coil spring referring to “Rear Coil 2) Install rear coil spring referring to “Rear Coil Spring Spring and Bump Stopper Removal and Installation”. and Bump Stopper Removal and Installation”. 5) Remove suspension rod mount bolt (1) and then 3) Install wheel with nuts and lower vehicle.
Page 909: Lower Arm Check
Rear Suspension: 2C-16 Upper Arm Removal and Installation Assembly S6JB0A2306017 1) Press-fit suspension lateral link bushing (2) by using press (1) and special tool. Removal 1) Hoist vehicle and remove rear wheels. CAUTION 2) Remove control rod refer to “Control Rod Removal Be sure to use new bushing.
Page 910 2C-17 Rear Suspension: Installation 3) Install rear suspension knuckle refer to “Rear Suspension Knuckle Removal and Installation”. 1) Install upper arm. 4) Install trailing rod refer to “Trailing Rod Removal and a) Install upper arm (2) to rear suspension frame. Installation”.
Page 911: Upper Arm / Bushing Disassembly And Assembly
Rear Suspension: 2C-18 Upper Arm / Bushing Disassembly and Assembly Assembly CAUTION S6JB0A2306018 Apply grease (included in the repair kit) to Disassembly ball joint and inside of ball stud boot when 1) Cut rubber (1) of flange of upper arm bushing. the ball stud boot is replaced.
Page 912: Rear Suspension Frame Components
2C-19 Rear Suspension: Rear Suspension Frame Components S6JB0A2306020 I6JB0A230005-01 F: Forward 5. Upper mount stopper washer 10. Dynamic damper bolt 1. Rear suspension frame 6. Rear suspension frame busing : 135 N⋅m (13.5 kgf-m, 98.0 lb-ft) 2. Rear suspension frame mount bolt 7.
Page 913 Rear Suspension: 2C-20 4) Remove rear wheel hub assembly referring to “Rear 14) Support rear suspension frame with rear differential Wheel Hub Assembly Removal and Installation”. by using mission jack (1). 5) Remove control rod referring to “Control Rod Removal and Installation”. 6) Remove trailing rod referring to “Trailing Rod Removal and Installation”.
Page 914 2C-21 Rear Suspension: Installation 5) Connect rear height sensor connector (3) and rear height sensor harness clamp (4) (if equipped) for left 1) Install rear suspension frame stiffeners (1) and side. dynamic damper (2) to rear suspension frame (3), if removed.
Page 915: Rear Suspension Frame / Bushing Disassembly And Assembly
Rear Suspension: 2C-22 Rear Suspension frame / Bushing Disassembly 12) Install trailing rod referring to “Trailing Rod Removal and Installation”. and Assembly S6JB0A2306022 13) Install control rod referring to “Control Rod Removal and Installation”“Control Rod Removal and Disassembly Installation”. 1) Cut rubber (1) of flange of rear suspension frame 14) Install rear wheel hub assembly referring to “Rear bushing.
Page 916: Rear Suspension Frame, Bushing And Pad Check
2C-23 Rear Suspension: NOTE Assembly 1) Press-fit rear suspension frame bushing (2) by using Use bearing installer in dimensions of outer press (1) and special tool. diameter 43.0 to 49.0 mm (1.69 to 1.92 in.), inner diameter 41.0 mm (1.61 in.) or more and CAUTION length 21.0 mm (0.82 in.) or more.
Page 917: Rear Wheel Hub Assembly Removal And Installation
(3) onto Do not apply the grease to the encoder pipe to prevent fluid from spilling. section to avoid the encoder malfunction. “A”: Grease 99000–25010 (SUZUKI Super Grease A) 2, "A" I5JB0A230059-01 6) Loosen parking cable cap nut (1).
Page 918 2C-25 Rear Suspension: 3) Install rear wheel assembly and back plate to rear 6) Install rear break shoe referring to “Rear Brake Shoe suspension knuckle and tighten rear wheel hub Removal and Installation in Section 4C”. housing new bolts (1) to specified torque. 7) Pull up parking brake lever fully and tighten new rear axle nut (1) to specified torque.
Page 919: Rear Wheel Hub Assembly, Wheel Bearing And Wheel Stud Inspection
Rear Suspension: 2C-26 Rear Wheel Hub Assembly, Wheel Bearing and • By rotating wheel actually, check wheel bearing for noise and smooth rotation. If it is defective, replace Wheel Stud Inspection bearing. S6JB0A2306026 • Wheel bearing and wheel hub form a solid unit. •...
Page 920 2C-27 Rear Suspension: 5) Support lower arm with jack. 3) Install lower arm, trailing rod and control rod to rear suspension knuckle referring to the figure in “Rod 6) Loosen control rod outer bolt, trailing rod rear bolt and Arm Components” and tighten bolts temporarily and lower arm outer bolt referring to the figure in by hand.
Page 921: Rear Suspension Knuckle Check
Rear Suspension: 2C-28 Rear Suspension Knuckle Check 7) Install rear wheel hub assembly referring to “Rear Wheel Hub Assembly Removal and Installation”. S6JB0A2306029 • Inspect for cracks, deformation or damage. 8) Fill reservoir with brake fluid and bleed brake • Inspect bushing for damage, wear or breakage. If any system.
Page 922 2C-29 Rear Suspension: Specifications Tightening Torque Specifications S6JB0A2307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Control rod mount nut 13.5 98.0 Lower arm mount nut 13.5 98.0 Shock absorber upper bolt 43.5 Shock absorber lower bolt 65.0 Wheel nut 10.0 72.5 Bump stopper...
Page 923: Special Tools And Equipment
Rear Suspension: 2C-30 Special Tools and Equipment Recommended Service Material S6JB0A2308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 NOTE Required service material is also described in the following. “Rear Suspension Construction: ” “Rear Shock Absorber and Rear Coil Spring Components: ”...
Page 924: Wheels And Tires
2D-1 Wheels and Tires: Wheels and Tires Suspension General Description Tires Description Lower than recommended pressure can cause: S6JB0A2401001 • Tire squeal on turns The tire is of tubeless type. The tire is designed to • Hard Steering operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation •...
Page 925: Wheels Description
Wheels and Tires: 2D-2 Replacement Tires How to Measure Wheel Runout When replacement is necessary, the original equipment To measure the wheel runout, it is necessary to use an type tire should be used. Refer to the “Tire Placard”. accurate dial indicator. The tire may be on or off the Replacement tires should be of the same size, load wheel.
Page 926: Irregular And/Or Premature Wear Description
2D-3 Wheels and Tires: Irregular and/or Premature Wear Description Wear Indicators Description S6JB0A2401003 S6JB0A2401004 Irregular and premature wear has many causes. Some Original equipment tires have built-in tread wear of them are as follows: incorrect inflation pressures, lack indicators (1) to show when they need replacement. of tire rotation, driving habits, improper alignment.
Page 927: Radial Tire Waddle Description
Wheels and Tires: 2D-4 Radial Tire Waddle Description S6JB0A2401005 Waddle is side to side movement at the front and/or rear of the vehicle. It is caused by the steel belt not being straight within the tire. It is most noticeable at a low speed, 8 to 48 kph (5 to 30 mph). It is possible to locate the faulty tire by road testing the vehicle.
Page 928: Radial Tire Lead / Pull Description
2D-5 Wheels and Tires: Radial Tire Lead / Pull Description Balancing Wheels Description S6JB0A2401006 S6JB0A2401007 “Lead / Pull” is the deviation of the vehicle from a straight There are two types of wheel and tire balance: static and path on a level road even with no pressure on the dynamic.
Page 929: Repair Instructions
Wheels and Tires: 2D-6 Repair Instructions General Balance Procedures Tire Rotation S6JB0A2406001 S6JB0A2406002 Deposits of mud, etc. must be cleaned from inside of rim. To equalize wear, rotate tires according to figure. Radial tires should be rotated periodically. Set tire pressure. WARNING NOTE Stones should be removed from the tread in...
Page 930: Wheel Removal And Installation
2D-7 Wheels and Tires: Wheel Removal and Installation Tire Mounting and Dismounting S6JB0A2406003 S6JB0A2406004 Removal Use a tire changing machine to mount or dismount tires. Follow equipment manufacturer’s instructions. Do not 1) Loosen wheel nuts by approximately 180 ° (half a use hand tools or tire irons alone to change tires as they rotation).
Page 931: Specifications
Wheels and Tires: 2D-8 Specifications Wheels and Tires Specifications S6JB0A2407001 Tire size : 225/70R16 102S, 225/65R17 101S or P225/70R16 101H Wheel size : 16 x 6 1/2 J or 17 x 6 1/2 J Tightening torque Wheel nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) NOTE •...
Page 932 2D-9 Wheels and Tires:...
Page 933: Driveline / Axle
Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Front Differential Unit Components.....3B-3 Front Differential Dismounting and Precautions............. 3-1 Remounting............3B-3 Precautions for Driveline / Axle ......3-1 Front Differential Components ......3B-4 Drive Shaft / Axle ........3A-1 Front Differential Assembly Disassembly and Reassembly ............3B-5 Front .................3A-1...
Page 934 3-ii Table of Contents Input / Output Signal Table of 4WD Control Transfer Oil Change..........3C-55 Module ............3C-10 Transfer Oil Seal Removal and Installation ..3C-56 On-Board Diagnostic System Description..3C-11 Transfer Switch Removal and Installation ..3C-56 CAN Communication System Description..3C-12 Transfer Switch Inspection........3C-57 4WD Control Module Removal and Schematic and Routing Diagram......3C-13 Installation ............3C-57...
Page 935 Table of Contents 3-iii Propeller Shaft Caution ........3D-1 Propeller Shaft Disassembly and Assembly ..3D-3 Propeller Shaft Inspection ........3D-5 General Description ..........3D-1 Propeller Shaft Construction .......3D-1 Specifications ............3D-6 Tightening Torque Specifications......3D-6 Diagnostic Information and Procedures....3D-2 Propeller Shaft Symptom Diagnosis ....3D-2 Special Tools and Equipment ......3D-6 Recommended Service Material ......3D-6 Repair Instructions ..........3D-2 Special Tool ............3D-6...
Page 936: Precautions
3-1 Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle S6JB0A3000001 Differential Gear Oil Note Refer to “Differential Gear Oil Note in Section 00”. Fastener Caution Refer to “Fastener Caution in Section 00”. Precautions for Transfer Refer to “Precautions in Diagnosing Trouble: Motor-Shift Type (Transfer with Shift Actuator) in Section 3C”.
Page 937: Drive Shaft / Axle
Drive Shaft / Axle: Front 3A-1 Drive Shaft / Axle Driveline / Axle Front General Description Front Drive Shaft Construction S6JB0A3111001 A constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies.
Page 938: Repair Instructions
3A-2 Drive Shaft / Axle: Front Repair Instructions Front Drive Shaft Boot and Joint Check S6JB0A3116001 • Check boot for tear. If even a small tear is found, replace with new one. I5JB0A311001-01 • Check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found. Front Drive Shaft Components S6JB0A3116002 I5JB0A311002-03...
Page 939: Front Drive Shaft Assembly Removal And Installation
Drive Shaft / Axle: Front 3A-3 Front Drive Shaft Assembly Removal and Installation Installation CAUTION S6JB0A3116003 • Be careful not to damage oil seals and Removal boots when installing drive shaft. 1) Undo caulking (1) and remove drive shaft nut (2). •...
Page 940 3A-4 Drive Shaft / Axle: Front 2) Wipe off grease from shaft and take off snap ring (1) Assembly using snap ring plier (2). 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.
Page 941 Drive Shaft / Axle: Front 3A-5 5) Apply grease (including in spare parts) to inside of 9) Fasten differential side boot big band. tripod joint housing (1), joint it with tripod joint. • For differential side boot big band Fasten band (1) by drawing hooks (2) with special Grease color tool and engage hooks (3) in slot and window (4).
Page 942: Specifications
3A-6 Drive Shaft / Axle: Front Specifications Tightening Torque Specifications S6JB0A3117001 NOTE The specified tightening torque is also described in the following. “Front Drive Shaft Components: Front” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A3118001...
Page 943: Rear
Drive Shaft / Axle: Rear 3A-7 Rear General Description Rear Drive Shaft Construction S6JB0A3121001 Refer to “Front Drive Shaft Construction: Front”. Repair Instructions Rear Drive Shaft Components S6JB0A3126001 I6JB01312001-02 [A]: 4WD model with A/T 4. Boot (Differential side) 9. Rear drive shaft flange nut [B]: Other models 5.
Page 944: Rear Drive Shaft Assembly Removal And Installation
3A-8 Drive Shaft / Axle: Rear Rear Drive Shaft Assembly Removal and CAUTION Installation • Protect oil seals and boots from any S6JB0A3126002 Removal damage, preventing them from 1) Undo caulking (1) of drive shaft nut (2) and then unnecessary contact while installing drive remove drive shaft nut.
Page 945: Specifications
Drive Shaft / Axle: Rear 3A-9 Specifications Tightening Torque Specifications S6JB0A3127001 NOTE The specified tightening torque is also described in the following. “Rear Drive Shaft Components: Rear” Reference: For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A3128001...
Page 946: Differential
3B-1 Differential: Front Differential Driveline / Axle Front General Description Front Differential Construction S6JB0A3211001 The differential assembly uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory.
Page 947: Repair Instructions
7) Apply sealant to thread of level / filler plug, and then S6JB0A3216001 tighten it to specified torque. 1) Before changing oil, be sure to stop engine and lift “A”: Sealant 99000–31260 (SUZUKI Bond vehicle horizontally. No.1217G) 2) With vehicle lifted up, check leakage.
Page 948: Front Differential Unit Components
3B-3 Differential: Front Front Differential Unit Components S6JB0A3216002 I6JB0A321002-01 1. Front differential 5. Rear mounting bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 2. Right mounting bracket 6. Rear mounting bracket : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 3. Right mounting bolt 7.
Page 949: Front Differential Components
Differential: Front 3B-4 Front Differential Components S6JB0A3216004 I5JB0A321003-08 1. Universal joint flange 17. Pinion washer 2. Hypoid gear set 18. Retainer bolt 3. Bevel pinion spacer 19. Differential side right retainer : Apply sealant 99000-31260 to mating surface of right retainer, carrier and rear cover.
Page 950: Front Differential Assembly Disassembly And Reassembly
3B-5 Differential: Front 15. Differential side bearing : Apply differential oil. 16. Spring washer Front Differential Assembly Disassembly and 4) Disassembly front drive shaft retainer as follows, if necessary. Reassembly S6JB0A3216005 a) Remove oil seal (1) from front drive shaft retainer Disassembly using special tool.
Page 951 Differential: Front 3B-6 5) Support differential side right retainer (1) with soft 8) Remove drive bevel gear (hypoid gear), differential jawed vise and remove oil seal (2) from differential gears, differential pinions and pinion shaft as follows. side right retainer using special tool, if necessary. a) With aluminum plates (2) placed on vise first, grip differential case with it and remove drive Special tool...
Page 952 3B-7 Differential: Front b) Make mating marks (1) on drive bevel pinion and e) Remove drive bevel pinion rear bearing (2) by companion flange. using bearing puller (3) and hydraulic press. CAUTION CAUTION Do not make mating mark on the coupling To avoid rear bearing from being damaged, surface of the flange.
Page 953 Differential: Front 3B-8 12) Drive out rear bearing outer race (1) in the same 2) After applying differential oil to differential gear (4), manner as Step 11). pinions (5), pinion shaft (6), pinion washer, thrust washer (2) and spring washer (1), install them in differential right case (3).
Page 954 3B-9 Differential: Front 5) Install special tool to differential case assembly (2) 6) Press-fit left side bearing (1) with special tool and and check that preload is within specification. If hydraulic press. preload exceeds specified value, check if foreign Special tool matter is caught or gear is damaged.
Page 955 Differential: Front 3B-10 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 956 3B-11 Differential: Front 9) Install special tools with bearings (3) and flange (2) 11) Set dial gauge to mounting dummy and make 0 to differential carrier (1). (zero) adjustment on surface plate (1). NOTE NOTE This installation requires no spacer or oil •...
Page 957 Then apply grease “A” to oil seal lip. 14) Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and “A”: Grease 99000–25010 (SUZUKI Super put it in place and then press-fit rear bearing (1). Grease A)
Page 958 3B-13 Differential: Front 17) While tightening flange nut gradually with special 18) Select differential side bearing shim as follows. tool and power wrench (4 – 10 magnification) (1), set a) Measure dimension “a” and “b” using vernier preload of pinion to specification. caliper.
Page 959 Differential: Front 3B-14 19) To measure bevel gear backlash, set dial gauge (1) 22) As final step, check gear tooth contact as follows. at right angle to bevel gear tooth, fix drive bevel a) After cleaning 10 drive bevel gear teeth, paint pinion and read dial gauge while moving bevel gear.
Page 960 3B-15 Differential: Front Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
Page 961 (1) using special tools as shown in figure. differential carrier, and then tighten bolts to specified Distance between retainer surface and oil torque. seal “A”: Sealant 99000–31260 (SUZUKI Bond “a”: 4.7 – 5.2 mm (0.185 – 0.205 in.) No.1217G) “A”: Grease 99000–25010 (SUZUKI Super Tightening torque Grease A) Rear cover bolt No.1 (a): 50 N·m (5.0 kgf-m, 36.5...
Page 962 Distance between retainer surface and oil seal mate front drive shaft retainer with carrier and rear “a”: 0.65 – 1.65 mm (0.026 – 0.065 in.) cover, and then tighten bolts to specified torque. “A”: Grease 99000–25010 (SUZUKI Super “A”: Sealant 99000–31260 (SUZUKI Bond Grease A) No.1217G)
Page 963 For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6JB0A3218001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 964 3B-19 Differential: Front 09913–50121 09913–65135 Oil seal remover Bearing puller 09913–75510 09913–75520 Bearing installer Bearing installer 09913–75821 09913–85210 Bearing installer attachment Bearing installer 09922–66021 09922–75222 Flange holder Differential gear preload adjuster 09922–76520 09924–74510 Bevel pinion gauge block Bearing and oil seal handle 09924–84510–004 09924–84510–005 Bearing installer attachment...
Page 965 Differential: Front 3B-20 09926–78311–002 09926–78320 Pinion mounting dummy Mounting dummy 09928–06510 09930–30104 Differential torque checking Sliding shaft tool 09940–53111 09941–64511 Differential side bearing Bearing and oil seal remover installer (30 mm Min.) 09951–16070 09951–16090 Shim adjuster attachment Oil seal installer 09951–18210 09951–46010 Oil seal remover &...
Page 966: Rear
3B-21 Differential: Rear Rear General Description Rear Differential Construction S6JB0A3221001 Refer to “Front Differential Construction: Front”. Diagnostic Information and Procedures Rear Differential Symptom Diagnosis S6JB0A3224001 Refer to “Front Differential Symptom Diagnosis: Front”. Repair Instructions Rear Differential Oil Change S6JB0A3226001 Refer to “Front Differential Oil Change: Front”. The point which is different from the front differential is described.
Page 967: Rear Differential Unit Components
Differential: Rear 3B-22 Rear Differential Unit Components S6JB0A3226002 I6JB01322001-02 [A]: 4WD model 4. Front mounting bracket bolt [B]: 2WD model 5. Front mounting bolt 1. Rear differential : 120 N⋅m (12.0 kgf-m, 87.0 lb-ft) 2. Front mounting bracket : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 3.
Page 968 3B-23 Differential: Rear b. Support rear differential with transmission e. Loosen rear suspension frame mount rear jack. bolts gradually within 8 turns until rear differential mounting front bolts can be c. Loosen rear differential mounting front bolts removed. (1) and rear bolts (2). Do not remove them in this step.
Page 969: Rear Differential Components
Differential: Rear 3B-24 Rear Differential Components S6JB0A3226004 1322 I6JB0A322001-01 1. Universal joint flange 18. Retainer bolt 2. Hypoid gear set 19. Rear drive right retainer : Apply sealant 99000-31260 to mating surface of right retainer, carrier and rear cover. 3. Bevel pinion spacer 20.
Page 970: Rear Differential Assembly Disassembly And Reassembly
3B-25 Differential: Rear Rear Differential Assembly Disassembly and b) Remove snap ring. Reassembly S6JB0A3226005 Disassembly 1) Drive out rear drive right and left shaft using special tools. Special tool (A): 09942–15511 (B): 09943–17912 I5JB0A322010-01 c) Drive out rear drive shaft bearing using special tools.
Page 971 Differential: Rear 3B-26 7) Pull out differential side bearing (1) using special 9) Remove drive bevel pinion (hypoid gear) assembly tools. as follows. a) Hold joint flange with special tool and then Special tool remove flange nut by using power wrench (4 – (A): 09913–65135 10 magnification) (2).
Page 972 3B-27 Differential: Rear d) Remove drive bevel pinion (1) with rear bearing, 10) Remove oil seal (1) using special tool. shim and spacer from carrier. Special tool If it is hard to remove, screw an used nut (2) into (A): 09913–50121 drive bevel pinion and hammer (3) on that nut with a plastic hammer but never directly on drive bevel pinion.
Page 973 Differential: Rear 3B-28 Reassembly 2) After applying differential oil to differential gear (4), Judging from faulty conditions noted before disassembly pinions (5), pinion shafts (6), pinion washer, thrust and what is found through visual check of bearing and washer (2) and spring washer (1), install them in gear tooth etc.
Page 974 3B-29 Differential: Rear 5) Install special tool to differential case assembly (2) 6) Press-fit left side bearing (1) with special tool and and check differential gear for preload. If preload hydraulic press. exceeds specified value, check if foreign matter is Special tool caught or gear is damaged.
Page 975 Differential: Rear 3B-30 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 976 3B-31 Differential: Rear 9) Install special tools with bearings (3) and flange (2) 11) Set dial gauge to mounting dummy and make 0 to differential carrier (1). (zero) adjustment on surface plate (1). NOTE NOTE This installation requires no spacer or oil •...
Page 977 Differential: Rear 3B-32 12) Place zero-adjusted mounting dummy and dial 14) Select adjusting shim(s) (2) closest to calculated gauge set on pinion mounting dummy and take value from among the following available sizes and measurement between zero position and extended put it in place and then press-fit rear bearing (1).
Page 978 Special tool (2) into differential carrier (1) as shown in figure. (A): 09922–75222 Then apply grease “A” to oil seal lip. (B): 09922–66021 “A”: Grease 99000–25010 (SUZUKI Super Grease A) Special tool (A): 09951–18210 I5JB0A321035-01 17) While tightening flange nut gradually with special tool and power wrench (4 –...
Page 979 Differential: Rear 3B-34 b) Calculate dimension “a” – “b”, and select shims 20) Place bearing outer races on their respective from among following available size so that total bearings. Used left and right outer races are not of thickness of right side and left side shims may interchangeable.
Page 980 3B-35 Differential: Rear Tooth Contact Pattern Diagnosis and Remedy Normal I5JB0A321041-05 High Contact Pinion is positioned too far from the center of drive bevel gear (1). • Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. •...
Page 981 1.5 mm (0.059 in.) in diameter, mate rear cover with differential carrier, and then tighten bolts to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Rear cover bolt No.1 (a): 50 N·m (5.0 kgf-m, 17.0...
Page 982: Rear Differential Inspection
1.5 mm (0.059 in.) in diameter, mate right retainer with carrier and rear cover, and then tighten bolts to “A”: Sealant 99000–31260 (SUZUKI Bond specified torque. No.1217G) “A”: Sealant 99000–31260 (SUZUKI Bond Tightening torque No.1217G)
Page 983: Special Tools And Equipment
Differential: Rear 3B-38 Special Tools and Equipment Recommended Service Material S6JB0A3228001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 984 3B-39 Differential: Rear 09924–84510–004 09924–84510–005 Bearing installer attachment Bearing installer attachment 09925–14520 09925–86010 Bearing and oil seal installer Bearing puller attachment (80 x 50 mm) 09925–88210 09926–78311 Bearing puller attachment Differential bevel pinion dummy 09926–78311–002 09926–78320 Pinion mounting dummy Mounting dummy 09928–06510 09930–30104 Differential torque checking...
Page 985 Differential: Rear 3B-40 09951–18210 09951–46010 Oil seal remover & installer Drive shaft oil seal installer No. 2...
Page 986: Transfer
• Diagnostic information stored in 4WD control module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 987: General Description
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-2 General Description Transfer Description S6JB0A3311001 The aluminum transfer case directly connected to the back of the transmission contains input gear, counter gear, rear output shaft, front output shaft, center differential, drive chain and their accompanying gears, hubs, sleeves, fork, etc. The center differential is installed in the transfer.
Page 988: 4Wd Control System Description
3C-3 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 4WD Control System Description S6JB0A3311003 Transfer Shift Control The 4WD control module controls the transfer shift actuator based on the signal from the transfer switch so that the transfer is shifted to the selected position (4H, 4H-lock, N or 4L-lock). (Shifting to the N position requires that the switch to “...
Page 989 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-4 Operation Condition Indicator Buzzer • Ignition switch is OFF. — • Transfer is at 4H/N position. • Within 2 seconds after ignition switch is turn ON (checking indicator operation). — • Transfer is at 4H-lock/4L-lock position. Flashes at 0.25 Sounds at 1 seconds for 3...
Page 990: Function Of 4Wd Control System Component
3C-5 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Function of 4WD Control System Component S6JB0A3311004 Part Name Function Detects transfer shift position combining center differential lock 4L/N switch switch. Center differential lock switch Detects transfer shift position combining 4L/N switch. Transfer switch Shifts transfer shift position.
Page 991 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-6 I5JB0A332003-02 [A]: Transfer position indicator 5. Shift cam 11. Front drive shaft [B]: Transfer switch 6. High / Low shift fork 12. Front drive sprocket 1. 4L/N switch 7. Differential lock shift fork 13.
Page 992 3C-7 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 4H-lock (4WD High Center Differential Lock) Position When 4H-lock position is selected from 4H position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the differential lock shift fork in the arrow direction “B”, and the differential lock clutch sleeve also moves in the arrow direction “B”.
Page 993 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-8 4. Shift fork pin 10. Front drive sprocket N (Neutral) Position When N position is selected from 4H position by turning the transfer switch, the transfer shift control actuator motor runs and shift cam rotates in the arrow direction “A”. The shift cam shifts the High / Low shift fork in the arrow direction “B”, and the reduction shift sleeve moves in the arrow direction “B”.
Page 994 3C-9 Transfer: Motor-Shift Type (Transfer with Shift Actuator) [B]: Transfer switch 5. Shift cam 10. Differential lock clutch sleeve 1. 4L/N switch 6. High / Low shift fork 11. Rear output shaft 2. Center differential lock switch 7. Differential lock shift fork 12.
Page 995: Input / Output Signal Table Of 4Wd Control Module
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-10 [A]: Transfer position indicator 6. High / Low shift fork 13. Rear output shaft [B]: Transfer switch 7. Differential lock shift fork 14. Center LSD case 1. 4L/N switch 8. Input gear 15.
Page 996: On-Board Diagnostic System Description
• DTC can be checked by either one of the following ways. – DTC can be checked by using SUZUKI scan tool (4) connected to DLC (5). – If equipped with diagnosis connector, DTC can be displayed on digital display odometer by shorting diagnosis connector (6).
Page 997: Can Communication System Description
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-12 CAN Communication System Description S6JB0A3311010 Refer to “CAN Communication System Description: For Diesel Engine Model in Section 1A”. 4WD Control Module Transmission Data ABS control ESP® control Combination module module Meter (ESP® model) (Non-ESP®...
Page 998: Schematic And Routing Diagram
3C-13 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Schematic and Routing Diagram 4WD Control System Wiring Circuit Diagram S6JB0A3312001 E91-18 LT GRN G59-2 C54-1 E91-2 E91-19 BLU/BLK G59-3 E91-3 C54-4 E91-20 BLU/ORN G59-4 C54-2 E91-25 C54-3 RED/BLK E91-26 C54-5 BLK/YEL E91-24 E91-13 PNK/WHT...
Page 999 Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-14 Terminal Arrangement of 4WD Control Module I4JA01332038-01 [A]: Connector “E91” viewed from harness side Terminal Circuit Terminal Circuit E91-1 Ground E91-18 Transfer switch 1 E91-2 Transfer actuator motor 1 E91-19 Transfer switch 2 E91-3 Transfer actuator motor 2 E91-20...
Page 1000: Component Location
3C-15 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Component Location Transfer Shift Control System Components Location S6JB0A3313001 I5JB0A332001-01 1. Transfer switch 4. N indicator 7. Center differential lock switch 2. Differential lock indicator 5. 4WD control module 8. 4L/N switch 3.
Page 1001: Diagnostic Information And Procedures
Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-16 Diagnostic Information and Procedures 4WD Control System Check S6JB0A3314001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis.
Page 1002 3C-17 Transfer: Motor-Shift Type (Transfer with Shift Actuator) Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test. Is there any problem symptom, DTC or abnormal condition? Detail of 4WD Control System Check Step 1: Customer complaint analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer.

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Suzuki Grand Vitara 2011 Manual

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Section 0 General Information

Section 1 Engine

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