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 2 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 4 TABLE OF CONTENTS General Information GENERAL INFORMATION Maintenance and Lubrication Heater and Ventilation HEATING AND AIR CONDITIONING Air Conditioning (Optional) Steering, Suspension, Wheels and Tires Front Wheel Alignment Steering Gear Box (Manual Type) and Linkage Power Steering (P/S) System (if equipped) STEERING, SUSPENSION, WHEELS AND TIRES Steering Wheel and Column...
Page 6: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS How to Use This Manual.........0A-2 Identification Information......0A-17 Precautions............0A-3 Body Number ..........0A-17 Engine Identification Number ...... 0A-17 Precaution for Vehicles Equipped with a Transmission Identification Number.... 0A-17 Supplemental Restraint (Air Bag) System..0A-3 Diagnosis...........0A-3 Warning, Caution and Information Servicing and handling ......0A-4...
Page 7: How To Use This Manual
0A-2 GENERAL INFORMATION How to Use This Manual 1) There is a “Table of Contents” on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of each section, where the main items in that section are listed.
Page 8: Precautions
• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 9: Servicing And Handling
0A-4 GENERAL INFORMATION Servicing and handling WARNING: Many of service procedures require disconnection of “Air Bag” fuse and all air bag (inflator) module(s) from initia- tor circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise.
Page 10 GENERAL INFORMATION 0A-5 WARNING: • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
Page 11 0A-6 GENERAL INFORMATION CAUTION: • Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys- tem parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in Section 10B. •...
Page 12: General Precautions
GENERAL INFORMATION 0A-7 General Precautions The WARNING and CAUTION below describe some general precautions that you should observe when servic- ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: •...
Page 13 0A-8 GENERAL INFORMATION • When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. •...
Page 14 GENERAL INFORMATION 0A-9 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly. • After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks.
Page 15: Precautions For Catalytic Converter
0A-10 GENERAL INFORMATION Precautions For Catalytic Converter For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged. • Conduct a spark jump test only when necessary, make it as short as possible, and do not open the throttle.
Page 16 GENERAL INFORMATION 0A-11 • When connecting connectors, also hold connectors and push them together until they lock securely (a click is heard). • When installing the wiring harness, fix it with clamps so that no slack is left. • When installing vehicle parts, be careful so that the wir- ing harness is not interfered with or caught by any other part.
Page 17 0A-12 GENERAL INFORMATION • Never connect any tester (voltmeter, ohmmeter, or what- ever) to electronic control unit when its coupler is dis- connected. Attempt to do it may cause damage to it. • Never connect an ohmmeter to electronic control unit with its coupler connected to it.
Page 18: Electrical Circuit Inspection Procedure
GENERAL INFORMATION 0A-13 Electrical Circuit Inspection Procedure While there are various electrical circuit inspection methods, described here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. Open circuit check Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.
Page 19 0A-14 GENERAL INFORMATION CONTINUITY CHECK 1) Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1. 2) Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance between terminals A-1 and B-1.
Page 20: Short Circuit Check (Wire Harness To Ground)
GENERAL INFORMATION 0A-15 Short circuit check (wire harness to ground) 1) Disconnect negative cable from battery. 2) Disconnect connectors at both ends of the circuit to be checked. NOTE: If the circuit to be checked is connected to other parts (1), disconnect all connectors of those parts.
Page 21: Precaution For Installing Mobile Communication Equipment
0A-16 GENERAL INFORMATION • Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal. If contact tension is not enough, reform it to increase contact tension or replace. 1.
Page 22: Identification Information
GENERAL INFORMATION 0A-17 Identification Information Body Number The vehicle body number is punched on the chassis inside the tire housing on the right rear side. 1. Right rear tire Engine Identification Number The number is punched on the cylinder block. M 13- Serial number Engine displacement...
Page 23: Warning, Caution And Information Labels
0A-18 GENERAL INFORMATION Warning, Caution and Information Labels The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Page 24: Vehicle Lifting Points
GENERAL INFORMATION 0A-19 Vehicle Lifting Points WARNING: • Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending on what part to be removed. • 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 25: When Using Floor Jack
0A-20 GENERAL INFORMATION When Using Floor Jack WARNING: If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands.
Page 26: Abbreviations May Be Used In This Manual
GENERAL INFORMATION 0A-21 Abbreviations May Be Used In This Manual Abbreviations Anti-lock Brake System EBCM Electronic Brake Control Module, ATDC After Top Dead Center ABS Control Module American Petroleum Institute Engine Control Module Automatic Transmission Fluid ECT Sensor Engine Coolant Temperature Automatic Locking Retractor Sensor (Water Temp.
Page 27 0A-22 GENERAL INFORMATION Left Hand Throttle Body Fuel Injection LSPV Load Sensing Proportioning Valve (Single-Point Fuel Injection, SPI) Torque Converter Clutch MAF Sensor Mass Air Flow Sensor Transmission Control Module (Air Flow Sensor, AFS, Air Flow (A/T Controller, A/T Control Mod- Meter, AFM) MAP Sensor Manifold Absolute Pressure...
Page 28 GENERAL INFORMATION 0A-23 SYMBOLS SYMBOL DEFINITION SYMBOL DEFINITION Tightening torque Apply SUZUKI BOND NO. 1216 99000-31160 Apply oil (engine, transmission, trans- Apply SILICONE SEALANT fer, differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E automatic transmission fluid)
Page 29: Fasteners Information
0A-24 GENERAL INFORMATION Fasteners Information Metric Fasteners Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most impor- tant that replacement fasteners be the correct diameter, thread pitch and strength. 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.
Page 30 GENERAL INFORMATION 0A-25 Tightening torque chart Thread Diameter (Nominal Diameter) (mm) An equivalent of 4T strength N·m fastener kg-m 0.15 0.30 0.55 10.5 lb-ft 21.0 32.5 47.0 76.0 116.0 An equivalent of 6.8 strength N·m fastener without flange kg-m 0.24 0.47 0.84 12.5 19.3 lb-ft 14.5 30.5 58.0 90.5 139.5 202.5...
Page 31 0A-26 GENERAL INFORMATION...
Page 32 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 33: Maintenance Schedule
0B-2 MAINTENANCE AND LUBRICATION Maintenance Schedule Maintenance Schedule Under Normal Driving Conditions 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 34 MAINTENANCE AND LUBRICATION 0B-3 Km (x 1,000) Interval Miles (x 1,000) Months CHASSIS AND BODY Clutch (pedal height and travel) – – – Brake discs and pads (thickness, wear, damage) Brake drums and shoes (wear, damage) – – – Brake hoses and pipes (leakage, damage, clamp) –...
Page 35: Maintenance Recommended Under Severe Driving Conditions
0B-4 MAINTENANCE AND LUBRICATION Maintenance Recommended Under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as shown in the fol- lowing table.
Page 36: Maintenance Service
MAINTENANCE AND LUBRICATION 0B-5 Maintenance Service Engine Drive Belt WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. WATER PUMP AND GENERATOR DRIVE BELT INSPEC- TION 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness.
Page 37: Valve Lash
0B-6 MAINTENANCE AND LUBRICATION 3) Check belt for tension. Power steering pump and/or A/C compressor drive belt tension “a”: 6 – 9 mm (0.24 – 0.35 in.) deflection under 100 N (10 kg, 22 lb) pressure. 4) If belt tension is out of above specification, adjust it referring to “Compressor Drive Belt”...
Page 38 MAINTENANCE AND LUBRICATION 0B-7 1) Drain engine oil by removing drain plug. 2) After draining oil, wipe drain plug clean. Reinstall drain plug, and tighten it securely as specified below. Tightening torque (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 3) Loosen oil filter by using oil filter wrench (special tool).
Page 39: Engine Coolant
0B-8 MAINTENANCE AND LUBRICATION 6) Replenish oil until oil level is brought to FULL level mark on dipstick. (oil pan and oil filter capacity). The filler inlet is at the top of the cylinder head cover. It is recommended to use engine oil of SE, SF, SG, SH, SJ or SL grade.
Page 40: Ignition System
MAINTENANCE AND LUBRICATION 0B-9 When carrying out periodic maintenance, or the vehicle is raised for other service, check exhaust system as follows: • Check rubber mountings for damage, deterioration, and out of position. • Check exhaust system for leakage, loose connections, dents and damages.
Page 41: Fuel Lines And Connections
0B-10 MAINTENANCE AND LUBRICATION REPLACEMENT Replace air cleaner filter with new one according to steps 1), 2) and 5), 6) of inspection procedure. Fuel Lines and Connections INSPECTION 1) Visually inspect fuel lines and connections for evidence of fuel leakage, hose cracking and damage. Make sure all clamps are secure.
Page 42: Pcv (Positive Crankcase Ventilation) Valve
MAINTENANCE AND LUBRICATION 0B-11 PCV (Positive Crankcase Ventilation) Valve INSPECTION Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog. Refer to “PCV System” of Section 6E for PCV valve checking procedure. Fuel Evaporative Emission Control System INSPECTION 1) Visually inspect hoses for cracks, damage, or excessive...
Page 43: Brake Drums And Shoes
0B-12 MAINTENANCE AND LUBRICATION Brake Drums and Shoes INSPECTION 1) Remove wheel and brake drum. 2) Check rear brake drums and brake linings for excessive wear and damage, while wheels and drums are removed. At the same time, check wheel cylinders for leaks. Replace these parts as necessary.
Page 44: Parking Brake Lever And Cable
MAINTENANCE AND LUBRICATION 0B-13 Parking Brake Lever and Cable INSPECTION 1) Inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorated condition. 2) Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever.
Page 45: Suspension System
0B-14 MAINTENANCE AND LUBRICATION 3) Rotate tires. For details, refer to “Tire Rotation” in Section 3F. WHEEL DISCS INSPECTION Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. WHEEL BEARING INSPECTION 1) Check front wheel bearing for wear, damage, abnormal noise or rattles.
Page 46: Propeller Shafts
MAINTENANCE AND LUBRICATION 0B-15 REAR 1) Check shock absorber (1) for damage, deformation, oil leak- age and operation. 2) Check bushings for wear and damage. 3) Check coil spring (4), trailing arm (6) and lateral rod (5) for deformation and damage. 4) Check trailing arm (6) and lateral rod bushings and bump stopper (2) for wear, damage and deterioration.
Page 47: Manual Transmission Oil
0B-16 MAINTENANCE AND LUBRICATION Manual Transmission Oil INSPECTION 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove level plug (2) of transmission. 4) Check oil level.
Page 48: Transfer And Differential Oil
MAINTENANCE AND LUBRICATION 0B-17 FLUID COOLER HOSE CHANGE Replace inlet and outlet hoses of cooler hose and their clamps. For replacement procedure, refer to “Oil Cooler Hoses” in Section Transfer and Differential Oil INSPECTION 1) Check transfer case and differential for evidence of oil leak- age.
Page 49: Steering System
0B-18 MAINTENANCE AND LUBRICATION Steering System INSPECTION 1) Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.2 in.) 2) Check universal joints of steering lower shaft (1) for rattle and damage.
Page 50: Power Steering (P/S) System (If Equipped)
MAINTENANCE AND LUBRICATION 0B-19 Power Steering (P/S) System (if equipped) INSPECTION 1) Visually check power steering system for fluid leakage and hose for damage and deterioration. Repair or replace defective parts, if any. 2) With engine stopped, check fluid level indicated on fluid tank or level gauge of tank cap, which should be between MAX and MIN marks.
Page 51: Final Inspection
0B-20 MAINTENANCE AND LUBRICATION Final Inspection WARNING: When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to prevent any accident. SEATS Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front seat back allows it to be locked at any angle.
Page 52 MAINTENANCE AND LUBRICATION 0B-21 GEARSHIFT OR SELECTOR LEVER (TRANSMISSION) Check gear shift or selector lever for smooth shifting to all positions and for good performance of transmission in any position. With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to which position selector lever is shifted to.
Page 53: Recommended Fluids And Lubricants
An equivalent of DEXRON -II, DEXRON -IIE or DEXRON -III Clutch linkage pivot points Water resistance chassis grease (SUZUKI SUPER GREASE A 99000-25010) Steering knuckle seal Door hinges Engine oil or water resistance chassis grease Hood latch assembly Key lock cylinder...
Page 54 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 55: General Description
1A-2 HEATER AND VENTILATION General Description The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets at places, right and left, along the windshield glass.
Page 56: Diagnosis
HEATER AND VENTILATION 1A-3 Diagnosis Diagnosis Table Condition Possible Cause Correction Heater blower won’t Blower fuse blown Replace fuse to check for short. work even when its Blower resistor faulty Check resistor. switch is ON. Blower fan switch faulty Check blower fan switch. Blower motor faulty Replace motor.
Page 57: On Vehicle Service
1A-4 HEATER AND VENTILATION On Vehicle Service Heater Blower Motor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to “Disabling Air Bag System” in Section 10B. 3) Remove column hole cover. 4) Disconnect blower motor couplers. 5) Remove blower motor (1).
Page 58: Heater Blower Resistor
HEATER AND VENTILATION 1A-5 Heater Blower Resistor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to “Disabling Air Bag System” in Section 10B. 3) Disconnect resistor coupler. 4) Remove blower motor resistor (3) as shown figure. 1.
Page 59 1A-6 HEATER AND VENTILATION 4) Disconnect blower fan switch coupler and A/C switch coupler (if equipped) 5) Disconnect each heater control cables. 6) Remove heater control lever assembly (1). 7) Remove blower fan switch screw (3). 8) Remove blower fan switch (2) as shown figure. 1.
Page 60: Heater Blower Fan Switch
HEATER AND VENTILATION 1A-7 Heater Blower Fan Switch INSPECTION Check blower fan switch for each terminal-to-terminal continuity. For the detail refer to “Wiring Circuit” earlier in this section. TERMINAL POSITION Heater Unit/Boost Ventilation REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system disable air bag system.
Page 61 1A-8 HEATER AND VENTILATION CAUTION: When the heater unit is disassembled and reassembled, locking force of the heater case lock may reduce. In such a case, tighten the heater case with a tapping screw of M4×L16 (1) as shown in the figure, or air may leak from its joint section.
Page 62 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 63 1B-2 AIR CONDITIONING (OPTIONAL) Evacuating ..........1B-23 Cooling Unit (Evaporator) ......1B-34 Evacuating procedure ......1B-23 A/C Evaporator Thermistor (A/C Evaporator Charging ............ 1B-25 Temperature Sensor)......... 1B-37 Charging procedure ....... 1B-25 Expansion Valve ........1B-37 Removing Manifold Gauge Set ....1B-28 Dual Pressure Switch ........
Page 64: General Description
AIR CONDITIONING (OPTIONAL) 1B-3 General Description Major Components and Location 1. Cooling unit 6. Suction hose 11. Foot air 16. Heater unit 2. Compressor 7. Receiver / dryer outlet pipe 12. Defroster air 17. A/C evaporator 3. Condenser assembly 8. Condenser outlet pipe 13.
Page 65: Refrigerant Circulation
1B-4 AIR CONDITIONING (OPTIONAL) Refrigerant Circulation A: Liquid 1. Compressor 4. Receiver / dryer 7. Evaporator B: Vapor 2. Magnet clutch 5. Dual pressure switch C: Superheated vapor 3. Condenser assembly 6. Expansion valve Refrigerant Type Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on compressor label (1).
Page 66: Diagnosis
AIR CONDITIONING (OPTIONAL) 1B-5 Diagnosis General Diagnosis Table Condition Possible Cause Correction Cool air won’t come No refrigerant Perform recover, evacuation and charging. out (A/C system won’t Fuse blown Check fuses in main and circuit fuse operative) boxes, and check short circuit to ground. A/C switch faulty Check A/C switch.
Page 67 1B-6 AIR CONDITIONING (OPTIONAL) Condition Possible Cause Correction Cool air won’t come Insufficient or excessive charge of Check charge of refrigerant and system for out or insufficient refrigerant leaks. cooling (A/C system Condenser clogged Check condenser. normal operative) A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator thermistor.
Page 68: Abnormal Noise Diagnosis
AIR CONDITIONING (OPTIONAL) 1B-7 Abnormal Noise Diagnosis There are various types of noise, ranging from those produced in the engine compartment to those from the passenger compartment, also from rumbling noises to whistling noises. Abnormal noise from compressor Condition Possible Cause Correction During compressor Inadequate clearance in piston area (piston or...
Page 69: Abnormal Noise From Crankshaft Pulley
1B-8 AIR CONDITIONING (OPTIONAL) Abnormal noise from crankshaft pulley Condition Possible Cause Correction A large rattling noise Loosen crankshaft pulley bolt. Retighten bolt. is heard at idle or sud- den acceleration. Abnormal noise from tension pulley Condition Possible Cause Correction Clattering noise is Worn or damaged bearing.
Page 70: Quick Checking Of Refrigerant Charge
AIR CONDITIONING (OPTIONAL) 1B-9 Quick Checking of Refrigerant Charge The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its maximum cooling capacity for a few minutes.
Page 71: Performance Diagnosis
1B-10 AIR CONDITIONING (OPTIONAL) Performance Diagnosis 1) Confirm that vehicle and environmental conditions are as fol- lows. • Vehicle is not exposed to direct sun. • Ambient temperature is within 15 – 35 °C (59 – 95 °F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge set (3) are firmly closed.
Page 72 AIR CONDITIONING (OPTIONAL) 1B-11 8) Check if each pressure on low side and on high side is within shaded range of the graph. If each gauge reading is out of specified pressure, correct defective part referring to “Performance Diagnosis Table” in this section.
Page 73: Performance Diagnosis Table
1B-12 AIR CONDITIONING (OPTIONAL) Performance diagnosis table NOTE: If ambient temperature is approximately 30 °C (86 °F), it is possible to diagnose A/C system in detail referring to “Detail Diagnosis Table (Ambient Temperature At 30 °C (86 °F))” under “Performance Diagnosis”...
Page 74: Detail Diagnosis Table
AIR CONDITIONING (OPTIONAL) 1B-13 CROSSING POINT OF CENTER VENTILATION LOUVER TEMPERATURE AND RECIRCULATION AIR INLET TEMPERATURE Condition Possible Cause Correction Crossing point is Insufficient or excessive charge of refrigerant Check refrigerant pressure higher than accept- Dirty or bent A/C evaporator fins Clean or repair able range Air leakage from cooling (heater) unit or air duct Repair or replace...
Page 75 1B-14 AIR CONDITIONING (OPTIONAL) Condition MANIFOLD Possible Cause Correction (kg/cm GAUGE Detail (psi) Both low and high pres- Insufficient refrigerant in Using leak detector, sure sides indicate low system. check for leaks and repair readings. (Refrigerant leaking) as necessary. Continuous air bub- Recharge refrigerant to a 0.05 –...
Page 76: Compressor Drive Belt
AIR CONDITIONING (OPTIONAL) 1B-15 Compressor Drive Belt INSPECTION • Check belt for wear and cracks, and replace as required. • Check belt tension by measuring how much it deflects when pushed at intermediate point between compressor pulley (1) and crankshaft pulley (2) with about 100 N (10 kg, 22 lb) force.
Page 77: Electronical Diagnosis
1B-16 AIR CONDITIONING (OPTIONAL) Electronical Diagnosis Wiring Diagram [A]: 4WD model 4. Dual pressure switch 9. Thermal switch 14. Circuit fuse box [B]: 2WD model 5. 4WD controller 10. Ignition switch 15. Main fuse box 1. Blower fan motor 6. Condenser cooling fan motor relay 11.
Page 78: A/C System Inspection Of Ecm And Its Circuits
AIR CONDITIONING (OPTIONAL) 1B-17 A/C System Inspection of ECM and ITS Cir- cuits ECM and its circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from ECM.
Page 79 1B-18 AIR CONDITIONING (OPTIONAL) 1. Blower fan motor 8. Compressor [A]: To “A/C” fuse (25A) in main fuse box 2. Dual pressure switch 9. Thermal switch [B]: To “HEATER” fuse (20A) in circuit fuse box 3. A/C switch 10. Main relay [C]: To “FI”...
Page 80 AIR CONDITIONING (OPTIONAL) 1B-19 ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL Measurement Terminal Wire Circuit Normal value Condition ground Blower fan motor switch and A/C Compressor 10 – 14 volt Ground to switch ON with engine running E18-1 magnet clutch engine (Fig B) Except the above-mentioned condi-...
Page 81 1B-20 AIR CONDITIONING (OPTIONAL) Measurement Terminal Wire Circuit Normal value Condition ground Engine coolant temperature at 0.73 – 0.83 volts approximately 80 °C (176 °F) with (315 – 355 Ω) engine running Engine coolant temperature at ECT sensor Ground to approximately 110 °C (230 °F) with E19-14 input...
Page 82: Refrigerant Recovery, Evacuating And Charging
AIR CONDITIONING (OPTIONAL) 1B-21 Refrigerant Recovery, Evacuating and Charging WARNING: • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately –6 °C (21 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious injury.
Page 83: Recovery
1B-22 AIR CONDITIONING (OPTIONAL) Recovery REFRIGERANT RECOVERY When evacuating A/C system, always recover refrigerant by using equipment (1) for refrigerant recovery and recycling. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments. NOTE: • After recover refrigerant from system, the amount of removed compressor oil must be measured for replen- ishing compressor oil.
Page 84: Evacuating
AIR CONDITIONING (OPTIONAL) 1B-23 WHEN REPLACING COMPRESSOR Compressor oil is sealed in each new compressor by the amount required for A/C system. Therefore, when using a new compres- sor for replacement, drain oil from new compressor by the amount calculated as follows. “C”...
Page 85 1B-24 AIR CONDITIONING (OPTIONAL) 1) Connect high charging hose (1) and low charging hose (2) of manifold gauge set (3) respectively as follows: High charging hose (1) → High pressure charging valve (4) on discharge hose Low charging hose (2) → Low pressure charging valve (5) on suction hose 2) Attach center charging hose (6) of manifold gauge set (3) to vacuum pump (7).
Page 86: Charging
AIR CONDITIONING (OPTIONAL) 1B-25 Charging CAUTION: • Always charge through low pressure side of A/C sys- tem at after the initial charging is performed from the high pressure side with the engine stopped. • Never charge to high pressure side of A/C system with engine running.
Page 87 1B-26 AIR CONDITIONING (OPTIONAL) 2) Connect Low charging hose (1) and High charging hose (2) of the manifold gauge set (3) in position. Thus open refriger- ant container valve (4) to purge the charging line. 3) Open the high pressure side valve (5) and charge refrigerant to system.
Page 88 AIR CONDITIONING (OPTIONAL) 1B-27 8) After the system has been charged with specified amount (500 – 600 g) of refrigerant or when low pressure gauge (1) and high pressure gauge (2) have indicated the following specified amount, close low pressure side valve (3) on mani- fold gauge set (4).
Page 89: Removing Manifold Gauge Set
1B-28 AIR CONDITIONING (OPTIONAL) Removing Manifold Gauge Set When A/C system has been charged with a specified amount of refrigerant, remove manifold gauge set as follows: 1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously during the process of charging.) 2) Close refrigerant container valve.
Page 90: On-Vehicle Service
AIR CONDITIONING (OPTIONAL) 1B-29 On-Vehicle Service Service Precaution When servicing air conditioning system, note the following instructions. Refrigerant line 1. Suction hose: 4. Condenser outlet pipe: Apply compressor oil to O-ring. Apply compressor oil to O-ring. 2. Discharge hose: 5. Expansion valve: Apply compressor oil to O-ring.
Page 91: Handling Refrigerant Hfc-134A
1B-30 AIR CONDITIONING (OPTIONAL) Handling refrigerant HFC-134a (R-134a) WARNING: Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately. • Do not use your hand to rub affected eye(s). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
Page 92: Condenser Assembly
AIR CONDITIONING (OPTIONAL) 1B-31 Condenser Assembly CAUTION: Be careful not to damage condenser fins. If condenser fin is bent, straighten it by using flat head screwdriver or pair of pliers. INSPECTION Check the following. • Check clog of condenser fins. If, any clogs are found, condenser fins should be washed with water, and should be dried with compressed air.
Page 93: Receiver / Dryer
1B-32 AIR CONDITIONING (OPTIONAL) Receiver / Dryer REMOVAL 1) Recover refrigerant from A/C system by referring to “Recov- ery” in this section. NOTE: The amount of removed compressor oil must be mea- sured for replenishing compressor oil. 2) Remove front bumper referring to “Front Bumper” in Section 3) Disconnect receiver / dryer outlet hose (1) and condenser outlet pipe (2) from receiver / dryer (3).
Page 94: Condenser Cooling Fan Assembly
AIR CONDITIONING (OPTIONAL) 1B-33 Condenser Cooling Fan Assembly ASSEMBLY CAUTION: Be careful not to damage condenser fins. If condenser fin is bent, straighten condenser fin by using flat head screwdriver or pair of pliers. INSPECTION 1) Check continuity between each two terminals about the con- denser cooling fan motor (1).
Page 95: Cooling Unit (Evaporator)
1B-34 AIR CONDITIONING (OPTIONAL) Cooling Unit (Evaporator) CAUTION: Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten A/C evaporator fin by using flat head screwdriver or pair of pliers. 1. A/C evaporator 3. Expansion valve 5.
Page 96 AIR CONDITIONING (OPTIONAL) 1B-35 3) Drain engine coolant and disconnect heater hoses (1) from heater unit. 4) Disable air bag system referring to “Disabling Air Bag Sys- tem” in Section 10B (if equipped). 5) Remove attaching bolt (1). 6) Disconnect suction hose (2) and receiver / dryer outlet pipe (3) from expansion valve (4).
Page 97 1B-36 AIR CONDITIONING (OPTIONAL) INSTALLATION Reverse removal procedure to install cooling unit, and then noting the following instructions. • If A/C evaporator thermistor removed, its should be rein- stalled in original position. • Install uniformly the packing (1) to installation hole. •...
Page 98: A/C Evaporator Thermistor (A/C Evaporator Temperature Sensor)
AIR CONDITIONING (OPTIONAL) 1B-37 A/C Evaporator Thermistor (A/C Evaporator Temperature Sensor) INSPECTION Check resistance between terminals for A/C evaporator ther- mistor (1). If check results are as not specified, replace thermistor. A/C evaporator temperature sensor resistance Sensor Temperature (°C (°F)) Resistance (kΩ) 0 (32) 6.4 –...
Page 99: Dual Pressure Switch
1B-38 AIR CONDITIONING (OPTIONAL) INSTALLATION Reverse removal procedure for installation, and then note the fol- lowing instructions. • Replenish specified amount of compressor oil to compressor suction side by referring to “Replenishing Compressor Oil” in this section. • Evacuate and charge refrigerant by referring to “Evacuation” and “Charging”...
Page 100: A/C Switch
AIR CONDITIONING (OPTIONAL) 1B-39 A/C Switch REMOVAL AND INSTALLATION Refer to “Heater Control Lever Assembly” in Section 1A. INSPECTION • Press A/C switch button and check if there is continuity between terminals “A” and “B”. • With battery voltage (+) connected to terminal “C” and (–) to terminal “A”, press A/C Switch button and blower fan switch to “Hi”...
Page 101 1B-40 AIR CONDITIONING (OPTIONAL) 4) Remove compressor drive belt (1) as follows. For vehicle with P/S Loosen tension pulley bolts (2). For vehicle without P/S Loosen tension pulley tightening nut (3) and adjusting bolt (4). [A] : Vehicle with P/S [B] : Vehicle without P/S 5) Disconnect thermal switch connector.
Page 102: Magnet Clutch
AIR CONDITIONING (OPTIONAL) 1B-41 Magnet Clutch 1. Thermal switch 6. Magnet clutch coil a. Front head bolt : Tighten bolt “a” first, and next “b”. 2. Compressor body assembly 7. Compressor pulley b. Front head bolt : Tighten bolt “a” first, and next “b”. 3.
Page 103 1B-42 AIR CONDITIONING (OPTIONAL) INSPECTION • Check clutch plate and clutch pulley for leaks of compressor oil. • Check clutch bearing of compressor pulley for noise, wear and grease leakage. • Measure resistance of magnet clutch coil (1) between mag- net clutch lead wire (2) and compressor body assembly.
Page 104 AIR CONDITIONING (OPTIONAL) 1B-43 4) Remove circlip (1) using special tool. Special tool (A) : 09900-06107 5) Remove magnet clutch lead wire clamp screw, and discon- nect magnet clutch lead wire. 6) Remove magnet clutch pulley (1) by using a puller (2). NOTE: •...
Page 105 1B-44 AIR CONDITIONING (OPTIONAL) 3) Install magnet clutch. a) Set magnet clutch squarely over clutch installation boss. b) Place special tool onto clutch bearing. Ensure that edge rests only on inner race of bearing. Special tool (A) : 09991-06010 4) Install snap ring (1) using special tool. Special tool (A) : 09900-06107 CAUTION:...
Page 106: Lip Type Seal
AIR CONDITIONING (OPTIONAL) 1B-45 Lip Type Seal REMOVAL 1) Remove magnet clutch referring to “Magnet Clutch” in this section. 2) Remove front head mounting bolts (10 pcs). 1. Front head 3) Remove front head (1) by pushing compressor shaft (2). NOTE: Be careful not to remove cylinder (3) from compressor body assembly (4).
Page 107: Tightening Torque Specification
1B-46 AIR CONDITIONING (OPTIONAL) 2) Coat special tool surface with compressor oil and place it on compressor shaft (1). Special tool (A) : 09991-06040 3) Install O-ring (1) to compressor body assembly (2). 4) Apply compressor oil to lip type seal and O-ring (1). 5) Install front head (3) to compressor body assembly (2).
Page 108: Required Service Materials
AIR CONDITIONING (OPTIONAL) 1B-47 Required Service Materials Recommended SUZUKI product Material (Part Number) Compressor oil COMPRESSOR OIL RS20 (150 cc) • O-ring (Refrigerant oil) 99000-99088-00D0 • Each component Special Tools 09900-06107 09991-06010 09991-06020 09991-06030 Snap ring pliers Magnet clutch pulley...
Page 109 1B-48 AIR CONDITIONING (OPTIONAL)
Page 110 STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ..............3-1 FRONT END ALIGNMENT.
Page 111: Diagnosis
3-2 STEERING, SUSPENSION, WHEELS AND TIRES General Diagnosis Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid- ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspections and correct any defects which are found.
Page 112 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Correction Shimmy, Shake or Tire or wheel out of balance Balance wheels or replace tire Vibration and/or wheel. Loose wheel bearings Replace wheel bearing. Loose wheel hub nuts Retighten. Worn tie rod ends Replace tie rod end.
Page 113 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction Abnormal Noise, Worn, sticky or loose tie rod ends, drug rod ball Replace tie rod end, king pin bear- Front End joints, king pin bearings or axle shaft joints ing or axle shaft joint. Damaged shock absorbers or mountings Replace or repair.
Page 114: Wear Indicators
STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Tire Diagnosis Irregular and/or Premature Wear Irregular and premature wear has many possible causes. Some of them are: incorrect inflation pressures lack of tire rotation, driv- ing habits, improper alignment. If the following conditions are noted rotation is in order: •...
Page 115 3-6 STEERING, SUSPENSION, WHEELS AND TIRES 1) Ride vehicle to determine whether the front or rear waddles. 2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on wadding end of vehicle. If wadding end cannot be identified, substitute rear ones. 3) Road test again.
Page 116: Radial Tire Lead
STEERING, SUSPENSION, WHEELS AND TIRES 3-7 Radial Tire Lead “Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment.
Page 117 3-8 STEERING, SUSPENSION, WHEELS AND TIRES...
Page 118 FRONT WHEEL ALIGNMENT 3A-1 SECTION 3A FRONT WHEEL ALIGNMENT CONTENTS General Description ........3A-2 Toe Adjustment..........3A-3 Camber And Caster Check And Toe Setting ............3A-2 Adjustment ............ 3A-4 Camber ............3A-2 Steering Angle Check And Adjustment ..3A-4 Alignment Service Data (Reference).....3A-2 Side Slip(Reference) ........
Page 119 3A-2 FRONT WHEEL ALIGNMENT General Description Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Generally, the only adjustment required for front wheel alignment is toe setting. Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be determined.
Page 120 FRONT WHEEL ALIGNMENT 3A-3 Diagnosis Diagnosis Table For the details, refer to “Diagnosis Table” in Section 3. Preliminary Checks Prior To Adjusting Front Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires.
Page 121 3A-4 FRONT WHEEL ALIGNMENT Camber And Caster Check And Adjustment Should camber or caster be found out of specifications upon inspection, locate its cause first. If it is in damaged, loose, bent, dented or worn suspension parts and axle housing, they should be replaced.
Page 122 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 123: General Description
3B-2 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE General Description 1. Steering gear box 5. Tie rod 9. Worm shaft 13. Sector shaft 2. Pitman arm 6. Steering lower shaft 10. Ball 14. Rack gear 3. Drag rod 7. Steering wheel 11.
Page 124: Diagnosis
STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-3 Diagnosis Diagnosis Table Refer to “Diagnosis Table” in Section 3. Steering Wheel Play Check Check steering wheel for play and rattle, holding vehicle in straight forward condition on ground. Steering wheel play “a”...
Page 125: Steering Gear Box Oil Level Check
3B-4 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE Steering Gear Box Oil Level Check Oil surface should be up to the level as shown in figure. If not, add prescribed gear oil, SAE 90. Steering gear box oil level “a” : 23 mm (0.91 in.) Apply sealant to thread parts of breathing plug and tighten breath- ing plug to specified torque.
Page 126 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-5 3) Measure worm shaft starting torque from its position in straight forward state as described in Step 2). Starting Torque for Worm shaft (a) : 50 – 100 N·cm (5.0-10.0 kg-cm, 0.4-0.7 lb-ft) Special tool (A) : 09944-18211 1.
Page 127: On-Vehicle Service
3B-6 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE On-Vehicle Service Steering Gear Box REMOVAL 1) Remove steering lower shaft joint bolt (2). 2) Remove drag rod end nut from pitman arm (1). 3) Disconnect drag rod end (2) from pitman arm (1), using spe- cial tool.
Page 128 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-7 INSTALLATION Reverse removal procedure to install steering gear box. 1) Install pitman arm (1) to sector shaft (2) of steering gear box with match marks (3) aligned as shown in figure and torque to specification.
Page 129: Tie Rod And Drag Rod
3B-8 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE Tie Rod And Drag Rod REMOVAL 1) Hoist vehicle and remove wheel (s). 2) Remove tie rod end nut from steering knuckle. 3) Mark (3) one end of tie rod before removing the rod as shown in figure to distinguish the correct installing direction easy.
Page 130 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-9 2) Adjust tie rod (and/or drag rod) length to the measurement shown in figure; then tighten tie rod end lock nuts temporarily by finger. Tie rod and drag rod length Tie rod length “a” : 1132 mm (44.6 in.) Drag rod length “a”...
Page 131: Tightening Torque Specifications
Drag rod end nut (pitman arm side) 36.5 Required Service Material Recommended SUZUKI product Material (Part Number) Sealant SUZUKI BOND NO. 1215 • Thread of oil breathing plug (99000-31110) Special Tools 09913-65210 09944-18211 Tie-rod end remover Pinion torque checking socket...
Page 132 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 133: General Description
3B1-2 POWER STEERING (P/S) SYSTEM (If equipped) General Description The power steering system in this vehicle reduces the driver’s effort needed in turning the steering wheel by uti- lizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an integral type with the mechanical gear unit, hydraulic pressure cylinder unit and control valve unit all housed in the gear box.
Page 134: Diagnosis
POWER STEERING (P/S) SYSTEM (If equipped) 3B1-3 Diagnosis Diagnosis Table Condition Possible Cause Correction Steering wheel feels Fluid deteriorated, low viscosity, different type of Change fluid. heavy fluid mixed (at low speed) Pipes or hoses deformed, air entering through Correct or replace. joint Insufficient air bleeding from piping Bleed air.
Page 135 3B1-4 POWER STEERING (P/S) SYSTEM (If equipped) Condition Possible Cause Correction Abnormal noise Air drawn in due to insufficient fluid Replenish fluid. (See NOTE “D”.) Air drawn in through pipe or hose joints Retighten or replace. Belt slipping (loose) Adjust. Worn belt Replace.
Page 136: Steering Wheel Play Check
POWER STEERING (P/S) SYSTEM (If equipped) 3B1-5 Steering Wheel Play Check • With engine ON, check steering wheel play as follows. Move steering wheel to the right and left from its straight position and measure along its circumference how much it must be turned before tires start to move.
Page 137: Power Steering Belt Check
3B1-6 POWER STEERING (P/S) SYSTEM (If equipped) Power Steering Belt Check INSPECTION • Check that belt is free from any damage and properly fitted in pulley groove. • Check belt tension by measuring how much it deflects when pushed at mid-point between pulley with about 10 kg (22 lb) force.
Page 138: Idle-Up System Check
POWER STEERING (P/S) SYSTEM (If equipped) 3B1-7 Idle-Up System Check 1) Warm up engine to normal operating temperature. 2) Turn A/C switch OFF, if equipped. 3) Turn steering wheel fully and check idle speed. Engine idle speed drops a little momentarily when steering wheel is turned fully but returns to its specified level immediately.
Page 139: Air Bleeding Procedure
3B1-8 POWER STEERING (P/S) SYSTEM (If equipped) Air Bleeding Procedure AIR BLEEDING FROM SYSTEM CAUTION: When air bleeding is not complete, it is indicated by foaming fluid on level gauge or humming noise from P/S pump. NOTE: Bleed air from system when P/S system has been ser- viced in any way other than replacement of steering gear box (e.g., disconnection of piping, replacement of P/S pump).
Page 140 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-9 3) After running engine at idling speed for 3 to 5 seconds, stop it and add fluid up to specified level. Repeat this step a few times. NOTE: Don’t operate steering system for this step. 4) Set steering gear box (1) to state [A] as shown.
Page 141: Hydraulic Pressure In P/S Circuit Check
3B1-10 POWER STEERING (P/S) SYSTEM (If equipped) Hydraulic Pressure In P/S Circuit Check 1) Clean where pipe is connected thoroughly, then disconnect high pressure hose from high pressure pipe connector and connect oil pressure gauge (special tool) as shown. Special tool (A) : 09915-77410 (B) : 09915-77420 1.
Page 142 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-11 5) Relief pressure check CAUTION: • Be sure not to keep gauge valve closed for longer than 10 seconds. • Never keep steering wheel turned fully for longer than 10 seconds. a) Increase engine speed to about 1,500 to 1,600 rpm. Close valve (6) gradually while watching pressure increase indicated on gauge (4) and take reading of relief pressure (maximum hydraulic pressure).
Page 143: On-Vehicle Service
3B1-12 POWER STEERING (P/S) SYSTEM (If equipped) On-Vehicle Service Power Steering Belt REMOVAL 1) Disconnect negative cable at battery. 2) Loosen tension pulley bolts (2). 3) Remove power steering belt (1). INSPECTION • Check power steering belt for wear and cracks, and replace as required.
Page 144 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-13 5) Remove P/S pump (1) removing 3 mounting bolts (3). CAUTION: • Clean couplers at intake and discharge ports com- pletely before disconnection. • Plug ports of removed pump to prevent dust and any foreign object from entering.
Page 145 3B1-14 POWER STEERING (P/S) SYSTEM (If equipped) CAM RING AND SIDE PLATE Check vane sliding surface of cam ring (2) for wear and damage. If any defect is found, replace pump assembly. 2. Side plate ROTOR AND VANE • Check sliding surfaces of rotor and vane for wear and dam- age.
Page 146 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-15 • Check free length of relief valve spring (1). Replace pump assembly if any defective is found. Relief valve spring free length Standard : 36.5 mm (1.44 in.) Limit : 33.5 mm (1.32 in.) ASSEMBLY Reverse disassembly procedure for assembly, noting the follow- ing.
Page 147 3B1-16 POWER STEERING (P/S) SYSTEM (If equipped) 7) Apply power steering fluid to sliding surface of cam ring (1). 8) Install cam ring (1) to pump body. The tapered end of cam ring (1) should face the side plate (2). 9) Apply power steering fluid to each vane (2).
Page 148 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-17 16) Apply power steering fluid to relief valve (flow control valve) (1). 17) Install relief valve (flow control valve) (1) to pump body. NOTE: Check that relief valve (flow control valve) slides smoothly. 18) Apply power steering fluid to O-ring of plug (3).
Page 149: Power Steering (P/S) Gear Box
3B1-18 POWER STEERING (P/S) SYSTEM (If equipped) INSTALLATION CAUTION: After installation, fill A/T fluid (an equivalent to ® ® ® DEXRON -II, DEXRON -IIE or DEXRON -III) and be sure to bleed air referring to “Air Bleeding Procedure” in this section.
Page 150 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-19 8) Disconnect high pressure hose (2) and return hose (3) from gear box (1). NOTE: Plug up the section where hose disconnection. 9) Remove gear box assy from vehicle. CAUTION: Never turn gear box input shaft. Otherwise, air goes into gear box, which needs air bleeding for gear box.
Page 151 3B1-20 POWER STEERING (P/S) SYSTEM (If equipped) • Install pitman arm (1) to sector shaft (2) of P/S gear box (3) with match marks “A” and “B” aligned as shown in figure and torque to specification. Tightening torque Pitman arm mounting nut (a) : 135 N·m (13.5 kg-m, 98.0 lb-ft) •...
Page 152: Tightening Torque Specifications
Pitman arm mounting nut 13.5 98.0 Steering shaft joint bolt 18.5 Plug 43.5 Required Service Materials Recommended SUZUKI product Material (Part Number) ® • To fill P/S fluid reservoir Power steering An equivalent of DEXRON -II, • Parts lubrication when installing fluid ®...
Page 153 3B1-22 POWER STEERING (P/S) SYSTEM (If equipped)
Page 154 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On- Vehicle Service” in air bag system section before performing service on or around the air bag sys- tem components or wiring.
Page 155: General Description
3C-2 STEERING WHEEL AND COLUMN General Description This double tube type steering column has the following three important features in addition to the steering func- tion: • The column is energy absorbing, designed to compress in a front-end collision. • The ignition switch and lock are mounted conveniently on this column. •...
Page 156: Diagnosis
STEERING WHEEL AND COLUMN 3C-3 Diagnosis For maintenance service of the steering wheel and column, refer to “Steering System Inspection” in Section 0B. For diagnosis of the steering wheel and column, refer to “Diagnosis Table” in Section 3. For diagnosis of the air bag system, refer to “Air Bag Diagnosis System Check Flow Table” in Section 10B. Inspection and Repair Required After Accident •...
Page 157: Drive Air Bag (Inflator) Module (For Vehicle With Air Bag System)
3C-4 STEERING WHEEL AND COLUMN Drive Air Bag (Inflator) Module (For Vehicle with Air Bag System) WARNING: When handling an air bag (inflator) module, be sure to read “Service Precautions” given earlier in this section and observe each instruction. Failure to follow them could cause a damage to the air bag (inflator) module or result in personal injury.
Page 158: Steering Wheel
STEERING WHEEL AND COLUMN 3C-5 Check air bag (inflator) module visually and if any of the following is found, replace it with a new one. • Air bag being deployed • Trim cover (1) (pad surface) being cracked • Wire harness (3) or connector being damaged •...
Page 159 3C-6 STEERING WHEEL AND COLUMN REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Remove steering wheel pad (for vehicle without air bag sys- tem) or driver air bag (inflator) module (for vehicle with air bag system) as follows. •...
Page 160 STEERING WHEEL AND COLUMN 3C-7 5) Remove steering wheel (1) with special tool. Special tool (A) : 09944-36011 CAUTION: Do not hammer the end of the shaft. Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column. INSTALLATION 1) Check that vehicle’s front tires are at straight-ahead position.
Page 161: Centering Contact Coil (For Vehicle With Air Bag System)
3C-8 STEERING WHEEL AND COLUMN 3) Tighten steering shaft nut to specified torque. Tightening torque Steering shaft nut (a) : 33 N·m (3.3 kg-m, 23.5 lb-ft) NOTE: After installing the steering wheel, turn the steering wheel about 1 full rotation so that the cancel cam pin fits into the pin hole in the steering wheel and then check the turn signal lever for proper function.
Page 162: Combination Switch (For Vehicle Without Air Bag System)/Contact Coil And Combination Switch Assembly (For Vehicle With Air Bag System)
STEERING WHEEL AND COLUMN 3C-9 4) From the position where contact coil became unable to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark with alignment mark (1). Combination Switch (For Vehicle without Air Bag System)/Contact Coil and Combination Switch Assembly (For Vehicle with Air Bag System)
Page 163 3C-10 STEERING WHEEL AND COLUMN 7) Remove combination switch/contact coil and combination switch assembly (1) from steering column. INSPECTION • For vehicle with air bag system Check contact coil and combination switch wire harness for any signs of scorching, melting or other damage. If it is dam- aged, replace.
Page 164: Steering Column Assembly
STEERING WHEEL AND COLUMN 3C-11 5) Tighten steering column mounting nuts and bolts by hand and then tighten mounting nuts (1) first, and then tighten mounting bolts (2). Tightening torque Steering column mounting bolts and nuts (a) : 14 N·m (1.4 kg-m, 10.5 lb-ft) 6) Install steering column hole cover (1).
Page 165 3C-12 STEERING WHEEL AND COLUMN REMOVAL WARNING: For vehicle with air bag system Never rest a steering column assembly on the steering wheel with the air bag (inflator) module face down and column vertical. Otherwise, personal injury may result. 1) Disconnect negative battery cable at battery terminal. 2) For vehicle equipped with air bag system, disable air bag system referring to “Disabling Air Bag System”...
Page 166 STEERING WHEEL AND COLUMN 3C-13 8) If equipped with shift (key) interlock cable (1), remove shift (key) interlock cable screw (2) and then disconnect its cable from ignition switch in order a) – c) as shown in the figure. 9) Remove steering column from vehicle. 10) Remove steering column seal (1) from steering column lower bracket.
Page 167 3C-14 STEERING WHEEL AND COLUMN 3) Take measurement “a” as shown. If it is shorter than specified length, replace column assem- bly (1) with new one. Steering column assembly length “a” : 733.2 – 734.8 mm (28.87 – 28.93 in.) 4) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play.
Page 168: Steering Lock Assembly (Ignition Switch)
STEERING WHEEL AND COLUMN 3C-15 4) Insert steering lower shaft (1) to steering shaft. 5) Put the steering column upper cover (3) on top of the steer- ing column (2), if necessary and then tighten steering col- umn mounting nuts (5) and bolts (4) by hand. 6) Tighten mounting nuts (5) first and then mounting bolts (4) to specified torque.
Page 169: Steering Lower Shaft
3C-16 STEERING WHEEL AND COLUMN 2) Loosen and remove steering lock mounting bolts (2) using center punch (1) as shown. NOTE: Use care not to damage aluminum part of steering lock body with center punch. 3) Turn ignition key to “ACC” or “ON” position and remove steering lock assembly from steering column.
Page 170 STEERING WHEEL AND COLUMN 3C-17 3) Make alignment marks (3) on lower shaft (2) and shaft (col- umn side) (1) and lower shaft (2) and gear box shaft (gear box side) (4) for a guide during reinstallation. 4) Remove lower shaft joint bolts. 5) Remove steering lower shaft.
Page 171: Checking Steering Column For Accident Damage
3C-18 STEERING WHEEL AND COLUMN Checking Steering Column for Accident Damage NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted (or air bag deployed) may have a damaged or misaligned steering column. CHECKING PROCEDURE 1) Check that two capsules (1) are attached to steering column bracket (2) securely.
Page 172: Tightening Torque Specifications
23.5 Steering column mounting bolts and nuts 10.5 Steering shaft joint bolts 18.0 Required Service Material Material Recommended SUZUKI product Water tight sealant SEALING COMPOUND 366E • To apply to steering column seal. (99000-31090) Lithium grease SUZUKI GREASE CE-T • Contact plate...
Page 173 3C-20 STEERING WHEEL AND COLUMN...
Page 174: Front Suspension
FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION WARNING: When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec- tion 0A. NOTE: • All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.
Page 175: General Description
3D-2 FRONT SUSPENSION General Description 1. Front axle housing 3. Steering knuckle 5. Wheel spindle 7. Wheel bearing 2. Shock absorber 4. Kingpin 6. Wheel hub 8. Front axle shaft (4WD) 4WD Control System The 4WD control system consists of a 4WD switch, a vacuum switch, a vacuum tank, two vacuum switching valves (VSV1 and VSV2) and air locking hub assemblies.
Page 176 FRONT SUSPENSION 3D-3 1. Air locking hub assembly 4. VSV2 7. 4WD controller 10. 4WD indicator light 13. ABS controller 2. VSV1 5. Vacuum accumulation tank 8. Intake manifold 11. 4WD switch 14. Transfer 3. Check valve 6. Vacuum switch 9.
Page 177 3D-4 FRONT SUSPENSION SYSTEM CIRCUIT 1. 4WD controller 4. 4WD indicator lamp 7. Blower fan switch 10. Vacuum switch 13. IG fuse 2. VSV1 5. ECM 8. A/C switch (if equipped) 11. Main fuse 14. A/C controller (if equipped) 3. VSV2 6.
Page 178 FRONT SUSPENSION 3D-5 Components and Functions Component Function 4WD switch When the transfer shift lever is shifted to 4L or 4H position from 2H, this switch turns ON and cause the 4WD control system to turn ON. 4WD controller When the 4WD switch turns on, the 4WD controller activates VSV2 to lock the air locking hubs and when it receives an “ON”...
Page 179 3D-6 FRONT SUSPENSION OPERATION 2WD → 4WD When the transfer shift control lever is shifted from the 2WD (2H) position to the 4WD (4H or 4L) position, a 4WD “ON” signal is transmitted to the 4WD controller which then activates VSV2 to apply vacuum in the intake mani- fold to the chamber “B”...
Page 180 FRONT SUSPENSION 3D-7 4WD → 2WD When the transfer shift control lever is shifted from the 4WD (4H or 4L) to the 2WD (2H) position, the 4WD con- troller activates VSV1 and the intake manifold vacuum is applied to the chamber “A” in the hub housing. As the slide gear is shifted to the wheel side by the vacuum force and disengaged from the outer gear, rotation of the front wheel hub is not transmitted to the front axle shaft.
Page 181: Diagnosis
3D-8 FRONT SUSPENSION Diagnosis Diagnosis Table For description not found in the table below, refer to “Diagnosis Table” in Section 3. 4WD CONTROL SYSTEM Condition Possible Cause Correction 4WD Indicator light • Hub locking procedure error Shift transfer shift control lever 2WD →...
Page 182 FRONT SUSPENSION 3D-9 Step Action Check 4WD switch circuit. Go to Step 4. Check 4WD switch (refer 1) Connect coupler to 4WD controller. to “4WD Switch” in Sec- 2) Turn ignition switch ON and check voltage tion 7D), “Bl/B” and “B” between A7 terminal and ground.
Page 183: 4Wd Controller And Its Circuit Check
3D-10 FRONT SUSPENSION 4WD Controller and ITS Circuit Check VOLTAGE CHECK Check for input or output voltage of 4WD controller (1) (voltage between each circuit and body ground) with 4WD controller con- nector connected and ignition switch turned START (engine run). CAUTION: •...
Page 184: 4Wd Control System Check
FRONT SUSPENSION 3D-11 4WD Control System Check AIR LOCKING HUB 1) Start engine and shift transfer shift control lever to 2H posi- tion. 2) Connect vacuum pump gauge (special tool) to the spindle hose (2) which is disconnected from upper side pipe as shown.
Page 185 3D-12 FRONT SUSPENSION 2) Blow air from B and check that air comes out of C. If found faulty, replace. 3) Connect 12 V-battery to VSV1 (VSV2) terminals and check continuity between A and B. Blow air from B and check that air comes out of A. If found faulty, replace.
Page 186: Stabilizer Bar / Bushing Check
FRONT SUSPENSION 3D-13 CHECK VALVE 1) Remove check valve (1). 2) Close B side of check valve with finger as shown and apply –50 cmHg vacuum by means of vacuum pump. Then check that vacuum is applied. Apply vacuum to another side of check valve and check that vacuum is not applied.
Page 187: Shock Absorber And/Or Coil Spring Check
3D-14 FRONT SUSPENSION Shock Absorber and/or Coil Spring Check 1) Inspect shock absorber for oil leakage. If shock absorber is found faulty, replace it as an assembly unit, because it can not be disassembled. 2) Shock absorber function check Check and adjust tire pressures as specified. Bounce body three or four times continuously by pushing front end on the side with shock absorber to be checked.
Page 188: Leading Arm Bushing / Lateral Rod Bushing Check
FRONT SUSPENSION 3D-15 Leading Arm Bushing / Lateral Rod Bushing Check Inspect for damage, wear or deterioration. If defective, replace. Kingpin / Kingpin Bearing Check 1) Inspect for wear or deterioration. 2) Inspect for crack, damage or deformation of kingpin. If defective, replace.
Page 189: Wheel Disc, Nut And Bearing Check
3D-16 FRONT SUSPENSION Wheel Disc, Nut and Bearing Check 1) Inspect each wheel disc for dents, distortion and cracks. Disc in badly damaged condition must be replaced. 2) Check wheel nuts for tightness and as necessary, retighten them to specification. Tightening torque Wheel nuts (a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
Page 190: On-Vehicle Service
FRONT SUSPENSION 3D-17 On-Vehicle Service Stabilizer Bar / Bushings REMOVAL 1) Hoist vehicle. 2) Remove front bumper. 3) Disconnect stabilizer ball joints (right & left) (1) from front axle housing (2). 4) Remove stabilizer bar mount bush bracket bolts (1). 5) Remove stabilizer bar with its ball joint.
Page 191 3D-18 FRONT SUSPENSION NOTE: For correct installation of stabilizer bar, side-to-side, be sure that color paint (1) on stabilizer bar aligns with mount bush, both right and left, as shown. 2) When installing stabilizer, loosely assemble all components while insuring that stabilizer is centered, side-to-side. 3) Tighten stabilizer bracket bolts (2) and stabilizer ball joint nuts to specified torque.
Page 192: Front Shock Absorber
FRONT SUSPENSION 3D-19 Front Shock Absorber REMOVAL 1) Hoist vehicle. 2) Support front axle housing by using floor jack to prevent it from lowering, refer to “When Using Floor Jack” under “Vehi- cle Lifting Points” in Section 0A. 3) Remove shock absorber lower mounting bolt (6). 4) Remove shock absorber upper mounting lock nut (2) and absorber nut (3).
Page 193 3D-20 FRONT SUSPENSION 4) Support front axle housing by using floor jack. NOTE: When supporting axle housing, it should be in non-load condition. 5) Remove shock absorber lower mounting bolt (1). 6) Lower front axle housing (2) gradually as far down as where coil spring (1) can be removed.
Page 194: Bump Stopper And Spring Upper Seat
FRONT SUSPENSION 3D-21 5) Install wheel and tighten wheel nuts to specified torque. Tightening torque Wheel nuts (a) : 95 N·m (9.5 kg-m, 69.0 lb-ft) 6) Lower hoist. 7) Confirm front end (wheel) alignment, referring to “Prelimi- nary Checks Prior to Adjusting Front Alignment” in Section Bump Stopper and Spring Upper Seat REMOVAL 1) Remove coil spring, refer to “Coil Spring”...
Page 195 3D-22 FRONT SUSPENSION 4) Remove brake disc. NOTE: If brake disc can not be removed by hand, using 8 mm bolts. 5) Remove front wheel bearing lock nut as follows. For 2WD model : a) Remove hub cap. b) Remove front wheel bearing lock plate (1) by loosening 4 screws (2).
Page 196 FRONT SUSPENSION 3D-23 6) Remove front wheel bearing lock nut by using special tool. Special tool (A) : 09944-77020 (For 4WD) (A) : 09951-16050 (For 2WD) 7) Remove front wheel bearing washer. 8) Remove wheel hub complete (1) with bearings (2) and oil seal (4).
Page 197 3D-24 FRONT SUSPENSION 11) Using hydraulic press (1) and special tool remove wheel bearing (2). Special tool (A) : 09913-75520 12) Remove hub bolts from hub. INSTALLATION 1) Insert new stud in hub hole. Rotate stud slowly to assure ser- rations are aligned with those made by original bolt.
Page 198 FRONT SUSPENSION 3D-25 5) Apply lithium grease to lip portion and hollow of oil seal (1). NOTE: Amount of grease applied to hollow in oil seal (1) should be more than 60% of its vacant space. “A” : Grease 99000-25010 2.
Page 199 3D-26 FRONT SUSPENSION For 2WD model: a) Using lock plate (1), lock bearing lock nut. If lock screw hole is not aligned with screw hole in lock nut, turn lock nut in tightening direction till they align. Tightening torque Wheel bearing lock washer screw (a) : 1.5 N·m (0.15 kg-m, 1.0 lb-ft) b) Remove grease, old sealant and dusts from mating sur- faces of hub cap (1) and wheel hub (2) to clean, apply...
Page 200 FRONT SUSPENSION 3D-27 c) Install front axle shaft circlip (1) and apply thin coat of grease to spline part of axle shaft. NOTE: When installing circlip (1) to front axle shaft, utilize screw hole in axle shaft to pull it out and bring large diameter (2) of circlip at right as shown.
Page 201: Steering Knuckle / Wheel Spindle
3D-28 FRONT SUSPENSION Steering Knuckle / Wheel Spindle REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove wheel hub assembly, refer to “Wheel Hub / Bearing / Oil Seal” in this section. 3) Disconnect spindle vacuum hoses (1) from wheel spindle (for 4WD).
Page 202 FRONT SUSPENSION 3D-29 7) Remove lower and upper kingpins (1). NOTE: Upper and lower kingpins (1), when removed, must be marked off one from the other. 8) Remove steering knuckle (1). NOTE: • When steering knuckle (1) is pulled, lower kingpin bearing sometimes falls off.
Page 203 3D-30 FRONT SUSPENSION INSTALLATION 1) Set knuckle seal cover (2), knuckle seal (4) and knuckle seal retainer (5) on front axle housing (6). 2) Apply grease within the knuckle (1). Amount of grease to be applied within the knuckle (1) is approximately 100 g (for 4WD).
Page 204 FRONT SUSPENSION 3D-31 8) Press-fit spindle bushing (2) to wheel spindle (1) by using special tool. Set cut part (4) of spindle bushing (2) as shown in figure (opposite side of the groove (3) of wheel spindle). Special tool (A) : 09922-55131 9) Press-fit spindle oil seal (1) until it becomes flush with wheel spindle (2) surface by using special tool, and then apply grease to its lip.
Page 205: Front Axle Shaft / Oil Seal / Kingpin Bearing Outer Race
3D-32 FRONT SUSPENSION 14) Blow air into pipes at the top and the front of wheel spindle and check that it comes out of the hole as shown in figure (for 4WD). CAUTION: As this hole is a part of the passage of the vacuum that activates the air locking hub, if it is clogged with grease, the air locking hub cannot be locked or unlocked.
Page 206 FRONT SUSPENSION 3D-33 5) Remove oil seal (1) from axle housing (for 4WD). 6) Drain out kingpin bearing outer race (1) from front axle hous- ing (2). INSTALLATION 1) Install kingpin bearing outer race (1) to front axle housing by using special tools.
Page 207: Steering Knuckle Seal
3D-34 FRONT SUSPENSION 4) Install axle shaft (2) to front axle housing (1) (for 4WD). 5) Install knuckle to front axle housing. For details, refer to “Steering Knuckle / Wheel Spindle” in this section. 6) Refill front axle (differential) housing with new specified gear oil (for 4WD).
Page 208: Lateral Rod
FRONT SUSPENSION 3D-35 2) Apply grease to oil seal lip. “A” : Grease 99000-25010 3) Install oil seal retainer (1), oil seal (2) and oil seal cover (3) to steering knuckle (4). Tighten bolts to specified Torque NOTE: Install the seal (2) in oil seal retainer (1), bringing the split part (5) to top side and locating it about 30°...
Page 209: Leading Arm / Bushing
3D-36 FRONT SUSPENSION Leading Arm / Bushing REMOVAL 1) Hoist vehicle. 2) Remove air locking hub vacuum pipe clamp bolts (2) (for 4WD). 1. Leading arm (right side) 3) Support front axle housing by using floor jack. 4) Remove shock absorber lower mounting bolt, refer to “Front Shock Absorber”...
Page 210 FRONT SUSPENSION 3D-37 INSTALLATION 1) Install bushings (1) by using hydraulic press and special tools, noting the following point. • Install bushings (1) so that either face of bushing are aligned with housing edge of leading arm (2), also the length between the aligned side end of bushing and leading arm (2) are within specification below.
Page 211: Front Axle Housing
3D-38 FRONT SUSPENSION Front Axle Housing REMOVAL 1) Hoist vehicle. 2) Remove front wheels. 3) Drain front differential gear oil (for 4WD). 4) Remove caliper carrier bolts (R&L) and suspend caliper. CAUTION: During removal, be careful not to damage brake flexible hose and not to depress brake pedal.
Page 212 FRONT SUSPENSION 3D-39 9) Remove knuckle seal cover bolts, take off knuckle seal cover (1), knuckle seal and knuckle seal retainer. 10) Remove upper and lower kingpins (2) from steering knuckle. NOTE: The removed upper and lower kingpins (2) must be kept separated so as to prevent an error when putting them back in their place in reassembly.
Page 213 3D-40 FRONT SUSPENSION 19) Lower floor jack until tension of suspension coil spring becomes a little loose and remove right and left sides lower mounting bolt of shock absorber (1). 20) Remove front mounting bolts of leading arm. 21) Lower front axle housing gradually. 22) Remove axle housing.
Page 214 FRONT SUSPENSION 3D-41 3) Install air locking hub vacuum pipe and tighten clamp bolts to specified torque (for 4WD). Tightening torque Vacuum pipe clamp bolts (a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 4) Install stabilizer bar, refer to “Stabilizer Bar / Bushings” in this section.
Page 215 3D-42 FRONT SUSPENSION 9) Install right and left axle shafts to axle housing (for 4WD). Install knuckle to axle housing (for 2WD). NOTE: Place knuckle seal and retainer in axle housing before installing axle shaft (knuckle), using care for installation direction of knuckle seal.
Page 216 FRONT SUSPENSION 3D-43 17) Tighten lateral rod (1) mounting bolt and nut to specified torque. NOTE: When tightening bolt and nut, be sure that vehicle is off hoist and in non loaded condition. Tightening torque Lateral rod bolt and nut (a) : 90 N·m (9.0 kg-m, 65.0 lb-ft) 18) Tighten right and left shock absorber lower mounting nuts and leading arm mounting nuts to specified torque.
Page 217: Tightening Torque Specifications
0.55 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE (A) • Knuckle seal / axle shaft oil seal (99000-25010) • Recess of wheel spindles • Wheel hub oil seal • Wheel bearing • Spindle thrust washer •...
Page 218: Special Tool
FRONT SUSPENSION 3D-45 Special Tool 09917-47910 09913-50121 09913-65210 09913-75520 Vacuum pump gauge Oil seal remover Tie rod end remover Bearing installer 09951-76010 09924-74510 09942-15510 09943-35511 or 09943- 35512 Bearing installer Bearing installer handle Sliding hammer Brake drum remover 09944-66010 09944-68510 09951-16050 09944-77020 Wheel hub / knuckle oil...
Page 219 3D-46 FRONT SUSPENSION 09944-66020 09913-85210 09951-16030 09951-26010 Bearing installer Oil seal installer Bush remover Bush remover plate...
Page 220: Rear Suspension
REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION WARNING: When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec- tion 0A. NOTE: • All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.
Page 221: General Description
3E-2 REAR SUSPENSION General Description 1. Rear axle housing 4. Bearing oil seal 7. Brake drum 10. Bump stopper 2. Rear wheel bearing 5. Oil seal protector 8. Rear axle shaft 11. Coil spring 3. Bearing retainer ring 6. Lateral rod 9.
Page 222: Diagnosis
REAR SUSPENSION 3E-3 Diagnosis Diagnosis Table Refer to “Diagnosis Table” in Section 3. Rear Shock Absorber Check • Inspect for deformation or damage. • Inspect bushings for wear or damage. • Inspect for evidence of oil leakage. Replace any defective part. WARNING: When handling rear shock absorber in which high-pres- sure gas is sealed, make sure to observe the following...
Page 223: Rear Suspension Fasteners
3E-4 REAR SUSPENSION Rear Suspension Fasteners Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to “Tighten- ing Torque Specifications” of this section. Bearing Retainer and Axle Shaft Oil Seal Check •...
Page 224: On-Vehicle Service
REAR SUSPENSION 3E-5 • Check wheel bearings for wear. When measuring thrust play, apply a dial gauge to axle shaft center after removing wheel center cap from wheel disc. When measurement exceeds limit, replace bearing. Rear wheel bearing thrust play limit : 0.8 mm (0.03 in.) •...
Page 225: Coil Spring
3E-6 REAR SUSPENSION 3) Remove upper mounting bolt (2). 4) Remove lower mounting bolt (3). 5) Remove shock absorber (1). INSTALLATION 1) Install shock absorber (1), refer to figure for proper installing direction of bush and washer (2). Tighten bolts (3) temporarily by hand. 2) Remove floor jack.
Page 226 REAR SUSPENSION 3E-7 4) Remove shock absorber lower mounting bolt (2). 1. Shock absorber 5) Lower rear axle housing (2) gradually as far down as where coil spring (1) can be removed. 6) Remove coil spring (1). 7) Remove spring rubber seat (1).
Page 227 3E-8 REAR SUSPENSION INSTALLATION 1) Install spring rubber seat (1). NOTE: Before installing spring rubber seat (1), apply soap water on it. 2) Install coil spring (2) on spring seat (1) of axle housing and then raise axle housing. NOTE: •...
Page 228: Bump Stopper
REAR SUSPENSION 3E-9 Bump Stopper REMOVAL 1) Hoist vehicle. 2) Remove wheel. 3) Remove bump stopper (1) by using special tool. Special tool (A) : 09941-66010 INSTALLATION 1) Tighten bump stopper (1) to specified torque by using spe- cial tool. Special tool (A) : 09941-66010 Tightening torque...
Page 229: Trailing Arm / Bushing
3E-10 REAR SUSPENSION INSTALLATION 1) Install lateral rod to vehicle body and rear axle housing. Tighten bolt and nut temporarily by hand. 2) Lower hoist and with vehicle in non-loaded condition, tighten lateral rod bolt and nut to specified torque. Tightening torque Lateral rod bolt and nut (a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Page 230 REAR SUSPENSION 3E-11 7) Remove bushings (1) by using hydraulic press and special tools. Special tool (A) : 09924-74510 (B) : 09951-16030 (C) : 09951-26010 INSTALLATION 1) Install bushings (1) by using hydraulic press and special tools, noting the following points. Special tool (A) : 09913-85210 (B) : 09951-26010...
Page 231: Rear Axle Shaft And Wheel Bearing
3E-12 REAR SUSPENSION • Install bushings so that either face of bushing are aligned with housing edge of leading arm, also the length between the aligned side end of bushing and trailing arm (1) are within specification below. Specification for trailing arm bushing protrusion “a”...
Page 232 REAR SUSPENSION 3E-13 4) Remove wheel speed sensor (4) from rear axle housing (if equipped with ABS). CAUTION: • Do not pull wire harness or twist more than necessary when removing rear wheel speed sensor (4). • Do not cause damage to surface of rear wheel speed sensor (4) or pole piece and do not allow dust, etc.
Page 233 3E-14 REAR SUSPENSION 10) In order to remove the retainer ring (1) from the shaft (3), grind with a grinder (2) two parts of the bearing retainer ring (1) as illustrated till it becomes thin. CAUTION: Be careful not to go so far as to grind the shaft (3). 11) Break with a chisel the thin ground retainer ring, and it can be removed.
Page 234 REAR SUSPENSION 3E-15 INSTALLATION Install removed parts in reverse order of removal procedure, not- ing the following. 1) Aligning serrations between new stud bolt(s) (1) and flange, install new stud bolt(s) (1) by tightening nut (2) as shown. 3. Washer 4.
Page 235 3E-16 REAR SUSPENSION 7) Install rear axle shaft to rear axle housing (2) and tighten brake back plate nuts (4) to specified torque. NOTE: When installing rear axle shaft, be careful not to cause damage to oil seal lip in axle housing (2). Tightening torque Brake back plate nuts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Page 236: Rear Axle Shaft Inner Oil Seal
REAR SUSPENSION 3E-17 16) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load over ten times so as to obtain proper drum-to shoe clearance. Adjust parking brake cable. (For adjustment, refer to “Parking Brake Check and Adjustment” in Section 5.) 17) Tighten parking brake lever cover screws.
Page 237: Rear Axle Housing
3E-18 REAR SUSPENSION Rear Axle Housing REMOVAL 1) Hoist vehicle and remove wheels. 2) Remove rear axle shaft, refer to “Rear Axle Shaft and Wheel Bearing” in this section. 3) Disconnect brake pipe (3) from flexible hose (1) and remove E-ring (2).
Page 238 REAR SUSPENSION 3E-19 10) Loosen rear mounting nuts of trailing arm (2) but don’t remove bolt. 11) Remove shock absorber (1) lower mounting bolt. 12) Lower floor jack until tension of suspension coil spring becomes a little loose and remove rear mount bolts of trailing arm.
Page 239 3E-20 REAR SUSPENSION 3) Install lower part of shock absorber (1) to right and left sides of axle housing and tighten bolts (2) temporarily by hand. 4) Install lateral rod (1) and install bolts in proper direction as shown. At this time, mount bolt and nut but don’t tighten them. 5) Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side.
Page 240 REAR SUSPENSION 3E-21 11) Connect brake flexible hose (2) to bracket on axle housing and secure it with E-ring (1). 12) Connect brake pipe to brake flexible hose and tighten brake pipe flare nut to specified torque. Tightening torque Brake pipe flare nut (a) : 16 N·m (1.6 kg-m, 11.5 lb-ft) 13) Clean mating surface of axle housing (2) (right &...
Page 241: Tightening Torque Specifications
69.0 Wheel speed sensor bolt and harness clamp bolt Required Service Materials Recommended SUZUKI product Material (Part Number) SUZUKI SUPER GREASE A Lithium grease Oil seal lip (99000-25010) SUZUKI BOND NO. 1215 • Joint seam of differential carrier and Sealant...
Page 242: Special Tools
REAR SUSPENSION 3E-23 Special Tools 09913-75520 09913-85210 09924-74510 1) 09927-18411 Universal puller Bearing installer Oil seal installer Bearing installer handle 2) 09921-57810 Bearing remover 09941-66010 09942-15510 09943-35511 or 09944-96010 09943-35512 Bearing outer race remover Bump stopper wrench Sliding hammer Brake drum remover 09921-26010 Bearing outer race remover collar...
Page 243 3E-24 REAR SUSPENSION...
Page 244: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 245: General Description
3F-2 WHEELS AND TIRES General Description Tires This vehicle is equipped with following tire. Tire size : 205/70 R15 or 175/80 R15 The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressure.
Page 246: Replacement Wheels
WHEELS AND TIRES 3F-3 Replacement Wheels Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, if lug nuts won’t stay tight, or if they are heavily rusted. Wheels with greater runout than shown in “How to Measure Wheel Runout”...
Page 247: Diagnosis
3F-4 WHEELS AND TIRES Diagnosis Diagnosis Table Refer to “Diagnosis Table” in Section 3. Balancing Wheels There are two types of wheel and tire balance: static and dynamic. Static balance, as shown in figure, is equal distribution of weight around wheel. Wheels that are statically unbalanced cause bouncing action called tramp.
Page 248 WHEELS AND TIRES 3F-5 WARNING: Wheel spin should be limited to 35 mph (55 km/h) as indicated on speedometer. This limit is necessary because speedometer only indicates one-half of actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped. Unless care is taken in limiting drive wheel spin, spinning wheel can reach excessive speeds.
Page 249: Maintenance And Minor Adjustments
3F-6 WHEELS AND TIRES Maintenance and Minor Adjustments Wheel and Tire Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced. Studs If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure. Matched tires and wheels (For vehicle equipped with steel wheels) Tires and wheels are matchmounted at the assembly plant.
Page 250: Tire Placard
WHEELS AND TIRES 3F-7 Lower than Recommended Pressure Can Cause: 1) Tire squeal on turns 2) Hard steering 3) Rapid and uneven wear on the edges of the tread 4) Tire rim bruises and rupture 5) Tire cord breakage 6) High tire temperatures 7) Reduced handling 8) High fuel consumption Tire placard...
Page 251: On-Vehicle Service
3F-8 WHEELS AND TIRES On-Vehicle Service Wheel REMOVAL 1) Loosen wheel nuts by approximately 180° (half a rotation). 2) Hoist vehicle. 3) Remove wheel. CAUTION: Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings.
Page 252: Tire
WHEELS AND TIRES 3F-9 Tire Mounting and demounting Use tire changing machine to mount or demount tires. Follow equipment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim. Rim bead seats should be cleaned with wire brush or coarse steel wool to remove lubricants, old rubber and light rust.
Page 253 3F-10 WHEELS AND TIRES...
Page 254 PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: • All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 255: General Description
4B-2 PROPELLER SHAFTS General Description Components 1. Propeller shaft No.1 2. Propeller shaft No.2 3. Propeller shaft No.3 Tightening Torque Diagnosis Diagnosis Table Condition Possible Cause Correction Abnormal noise • Loose universal joint bolt. Tighten universal joint bolt. • Spider bearing worn out or stuck. Replace.
Page 256: On-Vehicle Service
PROPELLER SHAFTS 4B-3 On-Vehicle Service Propeller Shafts REMOVAL 1) Hoist vehicle. 2) Drain transmission oil only when servicing propeller shaft No. 1. 3) Before removing propeller shaft (2), give match marks (1) on each joint flange (3) and propeller shaft (2) as shown. 4) Remove propeller shaft(s).
Page 257 4B-4 PROPELLER SHAFTS INSTALLATION Install propeller shaft(s) reversing removal procedure noting fol- lowing points : • When installing propeller shaft, align the match marks. Otherwise, vibration may occur during driving. • Use following specification to torque universal joint flange. Tightening torque Propeller shaft bolt (propeller shaft No.1, No.2 and No.3 rear differential side) (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Page 258: Universal Joint
PROPELLER SHAFTS 4B-5 Universal Joint DISASSEMBLY 1) Using special tool, remove 4 circlips (1). Special tool (A) : 09900-06108 2) Apply penetrate lubricant between bearing race outer diame- ter and shaft yoke bore. 3) Using a set of special tool, push spider bearing race (1) out 3 –...
Page 259 4B-6 PROPELLER SHAFTS 6) Push out bearing race (2) on flange yoke (1) in the same way as Step 2). 7) Holding bearing race (2) by a vise (3), tap flange yoke (1) and take out race. 8) Take out bearing race (2) on the opposite side of flange yoke (1) in the same way as Step 5) to Step 6).
Page 260: Tightening Torque Specification
Propeller shaft bolt (propeller shaft No.1 No.2 and No.3 rear dif- 36.5 ferential side) Propeller shaft bolt (propeller shaft No.3 transfer case side) Required Service Material Recommended SUZUKI product Material (Part Number) SUPER GREASE C • To apply to spider bearing race and propel-...
Page 261: Special Tool
4B-8 PROPELLER SHAFTS Special Tool 09900-06108 09926-48010 Snap ring pliers (Closing Universal joint disassem- type) bling tool set...
Page 262: Brakes
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 263 5-2 BRAKES Master Cylinder..........5-38 Front brake hose/pipe ....... 5-48 Fill Reservoir ..........5-40 Rear Brake Hose/Pipe ........5-51 Parking Brake Lever/Cable......5-52 LSPV (Load Sensing Proportioning Valve) Parking brake lever ........5-52 Assembly (If Equipped) ......... 5-42 Parking Brake Cable........5-53 LSPV Assembly ...........
Page 264: General Description
BRAKES 5-3 General Description When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis- tons (two in front and four in rear). The master cylinder is a tandem master cylinder. Three (or two) brake pipes are connected to the master cylin- der and they make two independent circuits.
Page 265: Diagnosis
5-4 BRAKES Diagnosis Road Testing Brakes Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if the vehicle stops evenly and effectively.
Page 266: Diagnosis Table
BRAKES 5-5 Diagnosis Table Condition Possible Cause Correction Not enough braking Brake oil leakage from brake lines Locate leaking point and repair. force Brake disc or pads stained with oil Clean or replace. Overheated brakes Determine cause and repair. Poor contact of shoes on brake drum Repair for proper contact.
Page 267 5-6 BRAKES Condition Possible Cause Correction Excessive pedal travel Partial brake system failure Check brake systems and repair as (Pedal stroke too necessary. large) Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake fluid. Check for leaks and air in brake systems.
Page 268 BRAKES 5-7 Condition Possible Cause Correction Brake warning light Brake fluid leaking from brake line Investigate leaky point, correct it turns on when brake and add brake fluid. is applied Insufficient amount of brake fluid Add brake fluid. Faulty P & Differential valve (Differential switch) Replace. Brake warning light Bulb burnt out Replace bulb.
Page 269: Brake Pedal Free Height Adjustment
5-8 BRAKES Brake Pedal Free Height Adjustment 1) Check brake pedal free height. If it is not within specification, check and adjust following item 2) and 3). Brake pedal free height “a” from wall LH steering vehicle : 221 – 227 mm (8.70 – 8.94 in.) RH steering vehicle : 217 –...
Page 270: Excessive Pedal Travel Check
BRAKES 5-9 Excessive Pedal Travel Check 1) Start engine. 2) Depress brake pedal a few times. 3) With brake pedal depressed with approximately 30 kg (66 Ibs) load, measure brake pedal to wall clearance “d” or “e”. Clearance “d” or “e” between brake pedal and wall LH steering vehicle clearance “d”...
Page 271: Rear Brake Shoe Check
5-10 BRAKES Rear Brake Shoe Check Inspection should be carried out on following points after brake pedal travel (pedal to wall clearance) check, even when pedal travel is normal. Amount of brake shoe wear can be checked as follows. 1) Hoist vehicle. 2) Remove rubber plug (1) from brake back plate.
Page 272: Rear Drum Brake Shoe Adjustment
BRAKES 5-11 NOTE: Be sure to use particular brake fluid either as indicated on reservoir cap of that vehicle or recommended in owner’s manual which comes along with that vehicle. Use of any other fluid is strictly prohibited. Fluid level should be between MIN and MAX lines marked on reservoir.
Page 273: Booster Operation Check
5-12 BRAKES If number of notches is out of specification, adjust cable by refer- ring to adjustment procedure described on the following so as to obtain specified parking brake stroke. NOTE: Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking brake lever.
Page 274 BRAKES 5-13 CHECK AIR TIGHTNESS 1) Start engine. 2) Stop engine after running for 1 to 2 minutes. 3) Depress brake pedal several times with the same load as in ordinary braking and observe pedal travel. If pedal goes down deep the first time but its travel decreases as it is depressed the second and more times, air tightness is obtained.
Page 275 5-14 BRAKES CHECK AIR TIGHTNESS UNDER LOAD 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed. H : Hold 2) Hold brake pedal depressed for 30 seconds. If pedal height does not change, condition is good. But it isn’t if pedal rises. H : Hold T : 30 seconds...
Page 276: Fluid Pressure Test (If Equipped With Lspv)
BRAKES 5-15 Fluid Pressure Test (If Equipped with LSPV) Test procedure for LSPV assembly is as follows. Before testing, confirm the following. • Fuel tank is filled with fuel fully. • Vehicle is equipped with spare tire, tools, jack and jack han- dle.
Page 277 5-16 BRAKES 4) If rear brake pressure is not within specification, adjust it by changing stay position as follows. • If rear brake pressure is higher than specification, move stay “A” to direction “l” and if it is lower, to direction “r”. •...
Page 278: On-Vehicle Service
BRAKES 5-17 On-Vehicle Service Air Bleeding of Brake System CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Bleeding operation is necessary to remove air whenever it entered hydraulic brake system.
Page 279: Brake Hose And Pipe Inspection
5-18 BRAKES 4) When fluid pressure in the cylinder is almost depleted, retighten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hydraulic line. 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. Tightening torque Front caliper bleeder plug (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Page 280: Front Disc Brake
BRAKES 5-19 PIPE Inspect the tube for damage, cracks, dents and corrosion. If any defect is found, replace it. Front Disc Brake 1. Caliper pin bolt 10. Carrier bolt 2. Boot 11. Brake caliper carrier 3. Cylinder slide bush 12. Pad clip : Apply rubber grease to mating surface of caliper 4.
Page 281: Brake Pad
5-20 BRAKES Brake pad REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolts (2). 1. Caliper 3. Disc 3) Remove caliper (1) from caliper carrier. NOTE: Hang removed caliper (1) with a wire hook (2) or the like so as to prevent brake hose from bending and twisting excessively or being pulled.
Page 282 BRAKES 5-21 INSTALLATION NOTE: See NOTE at the beginning of this section. 1) Install pad shim (1) (to outside pad) and pads (2) to caliper carrier (3). 2) Install caliper and torque caliper pin bolts (1) to specification. NOTE: Make sure that boots are fit into groove securely. Tightening torque Brake caliper pin bolts (a) : 22 N·m (2.2 kg-m, 16.0 Ib-ft)
Page 283: Caliper Assembly
5-22 BRAKES Caliper assembly REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake flexible hose mounting bolt from caliper. As this will allow fluid to flow out of hose, have a container ready beforehand. 3) Remove caliper pin bolts. 4) Remove caliper from carrier.
Page 284 BRAKES 5-23 INSPECTION Cylinder Slide Bush Check slide bush for smooth movement as shown. If it is found faulty, correct or replace. Apply rubber grease to bush outer surface. Rubber grease should be the one whose viscosity is less affected by such low temperature as – 40 °C (– 40 °F). 1.
Page 285 5-24 BRAKES ASSEMBLY CAUTION: • Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir. • Never use other fluid or thinner. • Before installing piston and piston seal to cylinder, apply fluid to them. •...
Page 286 BRAKES 5-25 5) Fit boot as it is in figure into boot groove in cylinder with fin- gers. 6) Insert piston into cylinder by hand and fit boot in boot groove in piston. 7) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.
Page 287: Brake Disc
5-26 BRAKES 3) Install brake flexible hose (4) as shown and torque hose mounting bolt (3) to specification. Tightening torque Front brake flexible hose bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) 4) Install wheel and torque wheel nuts to specification. 5) After completing installation, fill reservoir with brake fluid and bleed brake system.
Page 288 BRAKES 5-27 INSPECTION Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replace- ment are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc sur- face, replace it.
Page 289 5-28 BRAKES CHECK FOR FRONT BRAKE AFTER INSTALLATION Mount tires and make certain that they rotate smoothly, with a force of less than 3.0 kg (6.6 Ib). NOTE: For above check the following must be observed. • Jack up front wheels, both right and left, off the ground.
Page 290: Rear Brake
BRAKES 5-29 Rear Brake 1. Brake back plate 5. Shoe return spring lower 9. Shoe hold down pin 2. Brake shoe 6. Adjuster lever 10. Wheel cylinder : Apply brake fluid to piston cap 3. Spring and rod assembly 7. Adjuster spring Tightening torque 4.
Page 291 5-30 BRAKES 5) To increase clearance between brake shoe and brake drum, remove rubber plug from brake back plate and turn adjuster downward with flat-head screw driver. 6) Remove brake drum (1) off by using 8 mm bolts (2). INSPECTION Brake Drum Inspect drum for cleanliness.
Page 292: Brake Shoe
BRAKES 5-31 Brake Shoe Where lining is worn out beyond service limit, replace shoe. If one of brake linings is to service limit, all linings must be replaced at the same time. Brake shoe thickness (lining + shoe rim) “a” Standard (lining + rim) : 6.5 mm (0.26 in.) Service limit : 3.0 mm (0.12 in.) NOTE:...
Page 293 5-32 BRAKES Brake shoe REMOVAL 1) Remove brake drum referring to “Brake Drum” in this sec- tion. 2) Remove shoe return spring lower (3), spring and rod assem- bly (4) and shoe hold down springs (2) by turning shoe hold down pins (1).
Page 294: Wheel Cylinder
BRAKES 5-33 2) Install shoe hold down springs (2) by pushing them down in place and turning hold down pins (1). 3) Install shoe return spring and parking brake shoe lever spring. 4) For procedure hereafter, refer to “Brake Drum” in this sec- tion.
Page 295: Brake Back Plate
5-34 BRAKES INSTALLATION 1) Apply sealant to wheel cylinder. Then take off bleeder plug cap from brake pipe and connect pipe (for pipes) (3) to wheel cylinder just enough to prevent fluid from leaking. “A” : Sealant 99000-31090 2) Tighten wheel cylinder to brake back plate (1) to specified torque.
Page 296 BRAKES 5-35 7) Using special tools, draw out rear axle shaft with brake back plate. Special tool (A) : 09943-35511 (B) : 09942-15510 8) Remove wheel bearing retainer and wheel sensor ring (if equipped with ABS), refer to “Rear Axle Shaft and Wheel Bearing”...
Page 297: Master Cylinder
5-36 BRAKES Master Cylinder Master Cylinder Reservoir REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir (1). 3) Take out fluid with syringe or such. 4) Remove reservoir connector pin (2) by using special tool. Special tool (A) : 09922-85811 Remove reservoir (1).
Page 298: Master Cylinder Assembly
BRAKES 5-37 INSTALLATION NOTE: See NOTE at the beginning of this section. 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then press-fit grommets to master cylinder. Grommets must be seated in place. 2) Install reservoir (1) and drive in reservoir pin (2).
Page 299: Master Cylinder
5-38 BRAKES INSTALLATION NOTE: • See NOTE at the beginning of this section. • Check clearance between booster piston rod and pri- mary. 1) Install master cylinder as shown and torque attaching nuts to specification. Tightening torque Master cylinder nuts (a) : 13 N·m (1.3 kg-m, 9.5 Ib-ft) 2) Attach hydraulic lines and torque flare nuts to specification.
Page 300 BRAKES 5-39 DISASSEMBLY 1) Remove circlip (1). 2) Remove primary piston. 2. Master cylinder 3) [For vehicle with ABS] Pull out primary piston assembly straight so as not to cause any damage to inside o cylinder wall. Pull out secondary piston assembly straight so as not to cause any damage to inside of cylinder wall and by tapping flange with a piece of wood or something soft.
Page 301: Fill Reservoir
5-40 BRAKES • Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot be kept from cylinder bore surfaces. ASSEMBLY NOTE: • See NOTE at the beginning of this section. •...
Page 302 BRAKES 5-41 Fluid to fill reservoir with is indicated on reservoir cap of that vehi- cle with embossed letters or in owner’s manual supplied with it. Add fluid up to MAX line.
Page 303: Lspv (Load Sensing Proportioning Valve) Assembly (If Equipped)
5-42 BRAKES LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped) CAUTION: Brake fluid is extremely damaging to paint. Do not allow brake fluid to get on painted surface. LSPV assembly must not be disassembled. Replace with new one if defective. REMOVAL 1) Clean around reservoir cap and take out fluid with syringe or such.
Page 304: Lspv Assembly
BRAKES 5-43 LSPV Assembly INSPECTION AND ADJUSTMENT 1) Confirm the following before inspection and adjustment. • Fuel tank is filled with fuel fully. • Vehicle is equipped with spare tire, tools, jack and jack han- dle. • Vehicle is free from any other load. •...
Page 305: P (Proportioning) Valve
5-44 BRAKES P (Proportioning) Valve REMOVAL CAUTION: Do not allow brake fluid to get on painted surfaces. 1) Clean around reservoir cap and take out fluid with syringe or such. 2) Disconnect brake pipes from P valve. 3) Remove P valve. WARNING: Never disassemble P valve assembly.
Page 306: Brake Booster
BRAKES 5-45 Brake Booster 1. Brake master cylinder assembly 5. Nut 9. Brake vacuum hose 2. Brake booster assembly 6. Clevis pin Tightening torque 3. Gasket 7. Clip 4. Push rod clevis 8. Nut CAUTION: Never disassemble brake booster. Disassembly will spoil its original function.
Page 307: Inspection And Adjustment
5-46 BRAKES 4) Disconnect push rod clevis pin (4) from brake pedal arm (3). 5) Remove attaching nuts (6) and then booster as shown. 1. Steering column 2. Push rod clevis 5. Clip INSTALLATION NOTE: • See NOTE at the beginning of this section. •...
Page 308 BRAKES 5-47 CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON The length of booster piston rod (1) is adjusted to provide speci- fied clearance “a” between piston rod end and master cylinder piston (2). • Before measuring clearance, push piston rod several times so as to make sure reaction disc is in place.
Page 309: Brake Hose/Pipe
5-48 BRAKES Brake Hose/Pipe Front brake hose/pipe For left-hand steering vehicle [A] : For vehicle without ABS X : View X 5. Brake caliper 12. To front left brake caliper [B] : For vehicle with ABS Y : View Y 6.
Page 310 BRAKES 5-49 For right-hand steering vehicle [A] : For vehicle without ABS X : View X 5. Brake caliper 12. To front left brake caliper [B] : For vehicle with ABS Y : View Y 6. 4 way joint 13. To rear brake F : Front side Z : View Z 7.
Page 311 5-50 BRAKES REMOVAL 1) Raise, suitably support vehicle. Remove wheel if necessary. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose and pipe. INSTALLATION 1) Install brake hose and pipe by reversing removal procedure, noting the following points. For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink.
Page 312: Rear Brake Hose/Pipe
BRAKES 5-51 Rear Brake Hose/Pipe REMOVAL 1) Raise, suitably support vehicle. Remove wheel if necessary. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose and pipe. INSTALLATION 1) Install brake hose and pipe by reversing removal procedure, noting the following points. Fill and maintain brake fluid level in reservoir.
Page 313: Parking Brake Lever/Cable
5-52 BRAKES Parking Brake Lever/Cable Parking brake lever REMOVAL 1) Hoist vehicle and release parking brake lever. 2) Disconnect negative cable at battery. 3) Remove parking brake lever cover. 4) Disconnect lead wire of parking brake switch at coupler. NOTE: Don’t disassemble parking brake lever switch.
Page 314: Parking Brake Cable
BRAKES 5-53 Parking Brake Cable REMOVAL 1) Raise, suitably support vehicle and remove wheel if necessary. 2) Remove parking brake cable. INSTALLATION 1) Install it by reversing removal procedure, noting the following points. • Install clamps properly referring to figure below. •...
Page 315: Tightening Torque Specifications
• To apply to mating surfaces of brake back 99000-31090 plate and rear wheel cylinder. Sealant SUZUKI BOND NO. 1215 • To apply to mating surfaces of brake back 99000-31110 plate and rear axle housing. • To apply to mating surfaces of brake back...
Page 316: Special Tool
BRAKES 5-55 Special Tool 09900-20205 09900-20602 09900-20701 09956-02210 Micrometer (0 – 25 mm) Dial gauge (1/1000 mm) Magnetic stand Brake circuit plug 09922-85811 09942-15510 09943-35511 09950-78220 Connector pin remover Sliding hammer Brake drum remover Flare nut wrench (10 mm) (Front wheel hub remover) 09950-96010 09952-16010...
Page 317 5-56 BRAKES...
Page 318: Antilock Brake System (Abs)
DTC C1055 (DTC 55), DTC C1056 Diagnostic Trouble Code (DTC) Check..5E-9 (DTC 56) – Rear Solenoid Circuit ....5E-24 DTC Check (Using SUZUKI Scan Tool)..5E-10 DTC C1057 (DTC 57) – Power Source Diagnostic Trouble Code (DTC) Circuit............5E-25 Clearance ...........
Page 319: General Description
5E-2 ANTILOCK BRAKE SYSTEM (ABS) General Description The ABS (Antilock Brake System) is a system to prevent each wheel to lock during hard braking or braking on a slippery road by controlling the fluid pressure from master cylinder to each brake (either brake caliper or wheel cylinder).
Page 320: System Schematic
ANTILOCK BRAKE SYSTEM (ABS) 5E-3 System Schematic OUTPUT Pump motor Pump motor transistor INPUT Fail-safe transistor Wheel speed sensor (RF) Wheel speed sensor (RR) LF hold solenoid Wheel speed sensor (LR) Wheel speed sensor (LF) ABS control LF release solenoid Stop lamp switch module G sensor...
Page 321: Abs Component Parts Location
5E-4 ANTILOCK BRAKE SYSTEM (ABS) ABS Component Parts Location 1. Wheel speed sensor (Right front) 6. ABS hydraulic unit / control module assembly 11. Proportioning valve 2. Stop lamp switch 7. Monitor connector [A] : For LH steering vehicle 3. “ABS” warning lamp 8.
Page 322: Abs Control Module
ANTILOCK BRAKE SYSTEM (ABS) 5E-5 ABS Control Module Self-diagnosis function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the “ABS”...
Page 323: Diagnosis
5E-6 ANTILOCK BRAKE SYSTEM (ABS) Diagnosis To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Trou- bles” and follow “ABS Diagnostic Flow Table”. Precaution in Diagnosing Troubles • If the vehicles was operated in any of the following ways, “ABS” warning lamp may light momentarily but this does not indicate anything abnormal in ABS.
Page 324 ANTILOCK BRAKE SYSTEM (ABS) 5E-7 1) MALFUNCTION ANALYSIS a) Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 325 5E-8 ANTILOCK BRAKE SYSTEM (ABS) 2) DRIVING TEST Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnor- mal lighting of “ABS” warning lamp) exists. If the malfunction DTC is confirmed again at ignition switch ON, driving test as described in above is not nec- essary.
Page 326: Abs" Warning Lamp Check
ANTILOCK BRAKE SYSTEM (ABS) 5E-9 “ABS” Warning Lamp Check Turn ignition switch ON and check that “ABS” warning lamp comes ON for about 2 seconds and then goes OFF. If any faulty condition is found, advance to Diagnostic Flow Table-A, B or C. Diagnostic Trouble Code (DTC) Check 1) Test drive vehicle at 40 km/h for more than a minute.
Page 327: Dtc Check (Using Suzuki Scan Tool)
2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator's manual for further details. 4) After completing the check, turn ignition switch off and dis- connect SUZUKI scan tool from DLC.
Page 328: Diagnostic Trouble Code (Dtc) Table
ANTILOCK BRAKE SYSTEM (ABS) 5E-11 Diagnostic Trouble Code (DTC) Table (displayed on (indicated by ABS warning light flashing DIAGNOSTIC ITEMS SUZUKI scan ABS warn- pattern tool) ing lamp) – Normal C1015 G sensor circuit (for 4WD model only) C1016 Stop lamp switch circuit...
Page 329: System Circuit
5E-12 ANTILOCK BRAKE SYSTEM (ABS) (displayed on (indicated by ABS warning light flashing DIAGNOSTIC ITEMS SUZUKI scan ABS warn- pattern tool) ing lamp) C1057 Power source C1061 ABS pump motor circuit C1063 ABS solenoid valve circuit C1071 ABS control module System Circuit 1.
Page 330 ANTILOCK BRAKE SYSTEM (ABS) 5E-13 TERMINAL CIRCUIT Idle up signal Stop lamp switch Right front wheel speed sensor (+) Right front wheel speed sensor (–) – Right rear wheel speed sensor (–) Right rear wheel speed sensor (+) – – –...
Page 331: At Ignition Switch
5E-14 ANTILOCK BRAKE SYSTEM (ABS) Table – A “ABS” Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON 1. Main fuse 6. Monitor connector (Blue) 8. ABS hydraulic unit / control module connector of harness 2.
Page 332 Perform diagnostic trouble code check. Is there Go to step 2. Go to step 3. any DTC (including code No.12, NO CODES on SUZUKI scan tool) exists? Is malfunction DTC (other than code No.12) Go to step 7 of ABS diag- Go to step 3.
Page 333: While Ignition Switch Is
5E-16 ANTILOCK BRAKE SYSTEM (ABS) Table – C “ABS” Warning Lamp Circuit Check – Lamp Flashes Continuously While Ignition Switch is ON 1. “ABS” warning lamp in combination meter 3-1. Diag. switch terminal 5. Pedal bracket 2. ABS hydraulic unit / control module assembly 3-2.
Page 334: Connected To Ground
ANTILOCK BRAKE SYSTEM (ABS) 5E-17 Table – D Code (DTC) is Not Outputted Even With Diag. Switch Terminal Con- nected to Ground. 1. “ABS” warning lamp in combination meter 3-1. Diag. switch terminal 4-1. Lock position 2. ABS hydraulic unit / control module assembly 3-2.
Page 335: Dtc C1015 (Dtc 15) - G Sensor Circuit
5E-18 ANTILOCK BRAKE SYSTEM (ABS) DTC C1015 (DTC 15) – G Sensor Circuit 1. Ignition switch 3. ABS hydraulic unit / control module assembly 2. G sensor 4. ABS hydraulic unit / control module connector of harness DESCRIPTION While a vehicle is at stop or running, if the potential difference between the sensor signal terminal “A11” and the sensor ground terminal “A13”...
Page 336 ANTILOCK BRAKE SYSTEM (ABS) 5E-19 INSPECTION Step Action Is G sensor installed floor securely? Go to step 2. Tighten sensor or bracket screw securely. If not, use new screw. 1) Ignition switch OFF. Go to step 3. Replace G sensor. 2) Remove G sensor with bracket.
Page 337: Dtc C1016 (Dtc 16) - Stop Lamp Circuit
5E-20 ANTILOCK BRAKE SYSTEM (ABS) DTC C1016 (DTC 16) – Stop Lamp Circuit 1. Main fuse 4. IG fuse 7. ABS hydraulic unit / control module assembly 2. Ignition switch 5. Stop lamp switch 8. ABS hydraulic unit / control module connector of harness 3.
Page 338: Dtc C1021 (Dtc 21), Dtc C1022 (Dtc 22) - Right Front Wheel Speed Sensor Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E-21 DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right Front Wheel Speed Sensor Circuit DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left Front Wheel Speed Sensor Circuit DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right Rear Wheel Speed Sensor Circuit DTC C1035 (DTC 35), DTC C1036 (DTC 36) –...
Page 339 5E-22 ANTILOCK BRAKE SYSTEM (ABS) INSPECTION Step Action 1) Disconnect the applicable sensor connector with ignition Go to step 2. Replace sensor. switch OFF. 2) Measure resistance between sensor terminals. Resistance of wheel speed sensor: 1.4 – 1.8 kΩ (at 20°C, 68°F) 3) Measure resistance between each terminal and body ground.
Page 340 ANTILOCK BRAKE SYSTEM (ABS) 5E-23 1. ABS hydraulic unit / control module connector 2. Lock position 3. Unlock position...
Page 341: Dtc C1041 (Dtc 41), Dtc C1042 (Dtc 42) - Right Front Solenoid Circuit
5E-24 ANTILOCK BRAKE SYSTEM (ABS) DTC C1041 (DTC 41), DTC C1042 (DTC 42) – Right Front Solenoid Circuit DTC C1045 (DTC 45), DTC C1046 (DTC 46) – Left Front Solenoid Circuit DTC C1055 (DTC 55), DTC C1056 (DTC 56) – Rear Solenoid Circuit 1.
Page 342: Dtc C1057 (Dtc 57) - Power Source Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E-25 DTC C1057 (DTC 57) – Power Source Circuit 1. Ignition switch 3. ABS hydraulic unit / control module assembly 5. ABS hydraulic unit / control module connector 2. Main fuse 4. Circuit fuse DESCRIPTION The ABS control module monitors the power source voltage at terminal “A18”. When the power source voltage becomes extremely low, this DTC will be set.
Page 343: Dtc C1061 (Dtc 61) - Abs Pump Motor Circuit
5E-26 ANTILOCK BRAKE SYSTEM (ABS) DTC C1061 (DTC 61) – ABS Pump Motor Circuit 1. ABS hydraulic unit / control module assembly 1-3. ABS fail safe transistor 2-2. Unlock position 1-1. ABS pump motor transistor 2. ABS hydraulic unit / control module connector of harness 1-2.
Page 344: Dtc C1063 (Dtc 63) - Abs Fail Safe Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E-27 DTC C1063 (DTC 63) – ABS Fail Safe Circuit 1. Ignition switch 3-1. Lock position 2. ABS hydraulic unit / control module assembly 3-2. Unlock position 3. ABS hydraulic unit / control module connector of harness DESCRIPTION The ABS control module monitors the voltage at the terminal of the solenoid circuit constantly with the ignition switch turned ON.
Page 345: Dtc C1071 (Dtc 71) - Abs Control Module
5E-28 ANTILOCK BRAKE SYSTEM (ABS) DTC C1071 (DTC 71) – ABS Control Module DESCRIPTION This DTC will be set when an internal fault is detected in the ABS control module. INSPECTION Step Action 1) Ignition switch OFF. Substitute a known-good Repair or replace.
Page 346: On-Vehicle Service
ANTILOCK BRAKE SYSTEM (ABS) 5E-29 On-Vehicle Service Precaution When connectors are connected to ABS hydraulic unit / control module assembly, do not disconnect connectors of sensors, fuse etc. and turn ignition switch ON. Then DTC will be set in ABS con- trol module.
Page 347: Abs Hydraulic Unit / Control Module Assembly
5E-30 ANTILOCK BRAKE SYSTEM (ABS) ABS Hydraulic Unit / Control Module Assembly CAUTION: Do not disassemble ABS hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit / control module assembly.
Page 348 ANTILOCK BRAKE SYSTEM (ABS) 5E-31 3) Disconnect ABS hydraulic unit / control module assembly connector (1) by pulling up lock. 4) Remove ABS hydraulic unit / control module assembly with its bracket. 2. Lock position 3. Unlock position 5) Remove three bolts (3) and take out ABS hydraulic unit / control module assembly (1) from bracket (2).
Page 349: Front Wheel Speed Sensor
5E-32 ANTILOCK BRAKE SYSTEM (ABS) Front Wheel Speed Sensor 1. Front wheel speed sensor 3. Knuckle 2. Sensor ring OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch OFF. 2) Hoist vehicle a little. 3) Disconnect connector of wheel speed sensor. 4) Connect voltmeter between connector terminals. 5) While turning wheel at a speed of approximately 1 full rota- tion to 1 1/3 rotation per second, check AC voltage of sensor.
Page 350 ANTILOCK BRAKE SYSTEM (ABS) 5E-33 Reference When using oscilloscope for this check, check if peak-to-peak voltage (1) meets specification and waveform is complete. Peak-to-peak voltage at 1 to 1 1/3 rotation per second : 340 mV or more at 42 – 54 Hz REMOVAL 1) Disconnect negative cable at battery.
Page 351 5E-34 ANTILOCK BRAKE SYSTEM (ABS) SENSOR RING INSPECTION • Check ring teeth for being missing, damaged or deformed. • Turn drive shaft and check if ring rotation is free from eccen- tricity and looseness. • Check that no foreign material is attached. If any faulty is found, repair or replace.
Page 352: Front Wheel Sensor Ring
ANTILOCK BRAKE SYSTEM (ABS) 5E-35 Front Wheel Sensor Ring REMOVAL 1) Remove wheel hub with sensor ring. Refer to “Wheel Hub / Bearing / Oil Seal” in Section 3D. 2) Remove sensor ring (1) from wheel hub (2) as shown. CAUTION: Pull out sensor ring (1) from wheel hub (2) gradually and evenly.
Page 353: Rear Wheel Speed Sensor
5E-36 ANTILOCK BRAKE SYSTEM (ABS) Rear Wheel Speed Sensor 1. Left rear wheel sensor 3. Sensor ring Tightening torque 2. Trailing arm 4. Clamp bolt OUTPUT VOLTAGE INSPECTION Check in the same procedure as that used of front wheel speed sensor check.
Page 354 ANTILOCK BRAKE SYSTEM (ABS) 5E-37 5) Remove rear wheel speed sensor (1) from rear axle housing. CAUTION: • Do not pull wire harness when removing rear wheel speed sensor (1). • Do not cause damage to surface of rear wheel speed sensor and do not allow dust, etc.
Page 355: Rear Wheel Sensor Ring
5E-38 ANTILOCK BRAKE SYSTEM (ABS) Rear Wheel Sensor Ring REMOVAL 1) Remove rear axle shaft. Refer to “Rear Axle Shaft and Wheel Bearing” in Section 3E. 2) In order to remove sensor ring (3) from retainer ring (2), grind with a grinder one part of the sensor ring (3) as illus- trated till it becomes thin.
Page 356: G Sensor
ANTILOCK BRAKE SYSTEM (ABS) 5E-39 G Sensor REMOVAL 1) Turn ignition switch “OFF” and disconnect battery negative cable. 2) Remove rear center console box. 3) Disconnect connector from G sensor (2). 4) Remove G sensor (2) from floor. CAUTION: Sensor must not be dropped or shocked. It will affect its original performance.
Page 357: Tightening Torque Specification
G sensor bolts 17.0 Special Tool 09950-78220 09931-76011 09931-76030 Flare nut wrench (10 mm) Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC cable for tool) See NOTE “A” below Tech 1A Tech 1A Tech 2 kit (SUZUKI scan tool) See NOTE “B”...
Page 358 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 359 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS Diagnostic trouble code (DTC) table ..6-16 DTC P0301 Cylinder 1 Misfire Detected..6-72 Fail-safe table..........6-19 DTC P0302 Cylinder 2 Misfire Detected..6-72 Visual inspection ........6-20 DTC P0303 Cylinder 3 Misfire Detected..6-72 Engine basic inspection ......6-21 DTC P0304 Cylinder 4 Misfire Detected..6-72 Engine diagnosis table ......
Page 360: General Information
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-3 General Information Statement on Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 361: Precaution On Fuel System Service
6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS Precaution on fuel system service • Work must be done with no smoking, in a well-ventilated area and away from any open flames. • As fuel feed line (between fuel pump and fuel delivery pipe) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened...
Page 362: Fuel Pressure Relief Procedure
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-5 Fuel pressure relief procedure CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
Page 363: Engine Diagnosis
ECM memory as freeze frame data. (For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
Page 364 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-7 DRIVING CYCLE A “Driving Cycle” consists of engine startup and engine shutoff. 2 DRIVING CYCLES DETECTION LOGIC The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC and freeze frame data) but the malfunction indicator lamp does not light at this time.
Page 365 DLC (1) is in compliance with SAEJ1962 in its installation posi- tion, the shape of connector and pin assignment. Serial data line (K line of ISO 9141) (3) is used for SUZUKI scan tool or generic scan tool to communicate with ECM, TCM, Air Bag SDM and ABS control module.
Page 366: On-Board Diagnostic System (Vehicle With Immobilizer Indicator Lamp)
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-9 On-Board Diagnostic System (Vehicle without Immobilizer Indicator Lamp) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running, and indicates the result by turning on or flashing mal- function indicator lamp (1).
Page 367 Such disconnection will erase memorized information in ECM memory. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 368 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-11 Engine Diagnostic Flow Table Refer to the following pages for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform cus- 1) Perform customer complaint analysis referring to the tomer complaint followings.
Page 369 6-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal- ysis and diagnosis.
Page 370 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-13 Customer problem inspection form (example) NOTE: The above form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 371: Malfunction Indicator Lamp (Mil) Check
5) After completing the check, turn ignition switch off and dis- connect scan tool from data link connector. [Without Using SUZUKI Scan Tool] (Vehicle Without Immobilizer Indicator Lamp) 1) Check malfunction indicator lamp referring to “Malfunction Indicator Lamp Check”...
Page 372: Diagnostic Trouble Code (Dtc) Clearance
Diagnostic trouble code (DTC) clearance [Using SUZUKI Scan Tool] 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch ON.
Page 373: Diagnostic Trouble Code (Dtc) Table
6-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS Diagnostic trouble code (DTC) table DETECTING ITEM DETECTING CONDITION (DTC will set when detecting :) (vehicle (vehicle with immo- without bilizer indi- immobi- cator lamp) lizer indica- tor lamp) Low pressure-high vacuum-low voltage P0105 Manifold absolute pressure (or MAP sensor circuit shorted to ground) 1 driving...
Page 374 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-17 DETECTING ITEM DETECTING CONDITION (DTC will set when detecting :) (vehicle (vehicle with immo- without bilizer indi- immobi- cator lamp) lizer indica- tor lamp) P0335 Crankshaft position sensor No signal for 2 sec. During engine crank- 1 driving 1 driving (No.23)
Page 375 These DTCs can not be read on vehicle without P0743 Torque Converter Clutch Circuit Electrical Immobilizer indicator lamp (by ECM application of P0753 Shift Solenoid A Electrical SUZUKI scan tool). P0758 Shift Solenoid B Electrical P0763 Shift Solenoid C Electrical P0768...
Page 376: Fail-Safe Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-19 Fail-safe table When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC NO. DETECTED ITEM FAIL-SAFE OPERATION (SYMPTOM) P0105...
Page 377: Visual Inspection
6-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS Visual inspection Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION • Engine oil – level, leakage Section 0B • Engine coolant – level, leakage Section 0B • Fuel – level, leakage Section 0B •...
Page 378: Engine Basic Inspection
Is it 5° ± 3° BTDC at specified idle speed? Check ignition timing as follows : Go to “Engine Diagnosis Check ignition control 1) Select “MISC” mode on SUZUKI scan tool Table”. related parts referring to and fix ignition timing to initial one. See Fig.
Page 379 Was injector operating sound heard from all injectors? [A] Fig. 1 for Step 5 / [B] Fig. 2 for Step 7 / [C] Fig. 3 for Step 8 [B] : When not using SUZUKI scan tool : [C] : When using SUZUKI scan tool...
Page 380: Engine Diagnosis Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-23 [D] Fig. 4 for Step 7 or 8 / [E] Fig. 5 for Step 10 / [F] Fig. 6 for Step 13 Engine diagnosis table Perform troubleshooting referring to following table when ECM has no DTC and no abnormality found in visual inspection and engine basic inspection previously.
Page 381 6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Engine has no power Engine overheating Refer to “Overheating” of this table. • Faulty ignition coil Ignition coil assembly in Section 6F. • Faulty knock sensor Knock sensor malfunction in this sec- tion.
Page 382 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-25 Condition Possible Cause Reference Item Excessive detonation Engine overheating Refer to “Overheating” of this table. (The engine makes • Faulty spark plug Spark plugs in Section 6F. sharp metallic knocks • Clogged fuel filter and fuel lines Diagnostic Flow Table B-3 that change with throt- •...
Page 383 6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Excessive engine oil • Sticky piston ring Pistons, piston rings, connecting rods consumption and cylinders in Section 6A1. • Worn piston and cylinder Pistons, piston rings, connecting rods and cylinders in Section 6A1. •...
Page 384 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-27 Condition Possible Cause Reference Item Excessive hydrocar- • Faulty ignition coil Ignition coil assembly in Section 6F. bon (HC) emission or • Fuel pressure out of specification Diagnostic Flow Table B-3 Excessive carbon mon- •...
Page 385: Scan Tool Data
6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS Scan Tool Data As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi- tion, there may be cases where the checked value does not fall within each specified data range.
Page 386 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-29 SCAN TOOL DATA CONDITION REFERENCE VALUES ∆ ✱ ✱ ✱ ✱ O2S B1 S2 (HEATED OXY- When engine is running at 2000 r/min. for 0.01 – 0.95 V GEN SENSOR-2) 3 min or longer after warming up. ∆...
Page 387: Scan Tool Data Definitions
6-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS SCAN TOOL DATA CONDITION REFERENCE VALUES Ignition switch Brake pedal is depressing BRAKE SW Brake pedal is releasing Blower fan switch ON Ignition switch BLOWER FAN Blower fan switch OFF A/C operating Ignition switch A/C MAG CLUTCH A/C not operating Scan tool data definitions...
Page 388 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-31 THROTTLE POS (ABSOLUTE THROTTLE POSITION, %) When throttle position sensor is fully closed position, throttle opening is indicated as 0% and 100% full open position. OXYGEN SENSOR B1 S1 (HEATED OXYGEN SENSOR-1, V) It indicates output voltage of HO2S-1 installed on exhaust manifold (pre-catalyst). OXYGEN SENSOR B1 S2 (HEATED OXYGEN SENSOR-2, V) It indicates output voltage of HO2S-2 installed on exhaust pipe (post-catalyst).
Page 389 6-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS FUEL TANK LEVEL (%) This parameter indicates approximate fuel level in the fuel tank. As the detectable range of the fuel level sensor is set as 0 to 100%, however, with some models whose fuel tank capacity is smaller, the indicated fuel level may be only 70% even when the fuel tank is full.
Page 390: Inspection Of Ecm And Its Circuits
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-33 Inspection of ECM and Its Circuits ECM and its circuits can be checked at ECM wiring connectors by measuring voltage and resistance. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with connector disconnected from it.
Page 391 6-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS ECM TERMINAL VOLTAGE VALUES TABLE For TYPE A (See NOTE) NOTE: • Type A is other than follows. • Type B is left hand steering vehicle equipped with fasten seat belt light and EGR valve or right hand steering vehicle equipped with fasten seat belt light and immobilizer control system.
Page 392 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-35 TERMINAL CIRCUIT NORMAL CONDITION VOLTAGE Ignition switch ON Manifold absolute pressure sensor 3.3 – 4.0 V Barometric pressure : 100 kPa (760 mmHg) Ignition switch ON A/C evaporation temp. A/C evaporator temp. sensor 2.0 – 2.3 V sensor at 25 °C (77 °F) EGR valve (stepper motor coil 4, if Ignition switch ON position leaving engine...
Page 393 6-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL CONDITION VOLTAGE EGR valve (stepper motor coil 1, if Ignition switch ON position leaving engine 10 – 14 V equipped) Ignition coil #2 – – Ignition coil #1 – – Fuel injector NO.2 10 –...
Page 394 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-37 TERMINAL CIRCUIT NORMAL CONDITION VOLTAGE Diag. Switch terminal (without 4 – 5 V Ignition switch ON immobilizer indicator lamp) Test switch terminal (without immo- 4 – 5 V Ignition switch ON bilizer indicator lamp) Ignition switch ON 10 –...
Page 395 6-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL CONDITION VOLTAGE Ignition switch 10 – 14 V Ignition switch ON 10 – 14 V Ignition switch OFF Main relay 0.4 – 1.5 V Ignition switch ON Ignition switch 10 – 14 V Ignition switch ON Ignition switch ON and rear defogger 10 –...
Page 396 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-39 TERMINAL CIRCUIT NORMAL CONDITION VOLTAGE Blank – – Ignition switch ON and ECT less than 0 – 1.0 V 60 °C Overdrive cut signal (A/T) Ignition switch ON and ECT more than 10 – 14 V 60 °C Ignition switch ON and shift select switch 10 –...
Page 397 6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL CONDITION VOLTAGE Ignition switch ON and ECT less than 0 – 1.0 V 60° C Overdrive cut signal (A/T) Ignition switch ON and ECT more than 10 – 14 V 60 °C Ignition switch ON and shift select switch 10 –...
Page 398 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-41 Resistance Check 1) Disconnect ECM couplers (1) from ECM with ignition switch OFF. CAUTION: Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Check resistance between each terminal of couplers discon- nected.
Page 399: Component Location
6-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS Component Location NOTE: The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the other side. 1. IAT sensor a : Immobilizer indicator lamp (if equipped) A : ECM 2.
Page 400 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-43 Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come “ON” at Ignition Switch ON (But Engine at Stop) CIRCUIT DESCRIPTION 1. Main fuse 4. Main relay 7. “IG” fuse [A] : Case of TYPE A is shown (See NOTE) 2.
Page 401 6-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action ECM Power and Ground Circuit Check Go to Step 3. Go to “Table A-5 ECM Does engine start? Power and Ground Circuit Check”. If engine is not cranked, go to “Diagnosis” in Sec- tion 8G.
Page 402: Switch On (But Engine At Stop)
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-45 Table A-3 Malfunction Indicator Lamp Circuit Check - Mil Flashes at Ignition Switch ON WIRING DIAGRAM / CIRCUIT DESCRIPTION Refer to table A-1. INSPECTION Step Action MIL flashing pattern check : Go to Step 2. Go to “Diagnosis”...
Page 403 6-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table A-5 ECM Power and Ground Circuit Check - MIL Doesn’t Light at Ignition Switch ON and Engine Doesn’t Start Though It Is Cranked Up CIRCUIT DESCRIPTION 1. Main fuse 4. Main relay 7. “IG” fuse [A] : Case of TYPE A is shown (See NOTE) 2.
Page 404 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-47 Step Action Fuse Check Go to Step 4. Check for Is main “FI” fuse in good condition? See Fig. 1. short in cir- cuits con- nected to this fuse. ECM Power Circuit Check Go to Step 5. “B/W”, “Or” or 1) Turn OFF ignition switch, disconnect connectors from ECM and “Bl/B”...
Page 405: Dtc P0105 (Dtc No.11) Manifold Absolute Pressure (Map) Circuit Malfunction
6-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunc- tion CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • MAP sensor signal is 0.19 V or lower. • “B/Bl” circuit open (Low pressure – High vacuums – Low voltage) •...
Page 406 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-49 Step Action Check Wire Harness. Go to Step 4. “Lg/R” wire open or 1) Disconnect MAP sensor connector with shorted to ground circuit ignition switch OFF. or shorted to power circuit 2) Check for proper connection of MAP sensor (See NOTE), “G”...
Page 407 6-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS MAP Sensor Individual Check 1) Disconnect connector from MAP sensor (1). 2) Remove MAP sensor (1). 3) Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 – 5.0 V) and connect its positive terminal to “Vin”...
Page 408 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-51 DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • Low intake air temperature (High voltage-High resistance) • “Lg/R” circuit open or shorted to power. • High intake air temperature (Low voltage-Low resistance) •...
Page 409 6-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Check Wire Harness. Go to Step 5. “Lg/B” wire open or 1) Disconnect IAT sensor connector with igni- shorted to power, or poor tion switch OFF. E19-15 connection. 2) Check for proper connection to IAT sensor If wire and connection are at “Lg/B”...
Page 410: Dtc P0115 (Dtc No.19) Engine Coolant Temperature (Ect) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-53 DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunc- tion CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • Low engine coolant temperature (High voltage-High resis- • “G/B” circuit open or shorted to power tance) •...
Page 411 6-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check ECT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent See Fig.
Page 412: Dtc P0120 (Dtc No.13) Throttle Position Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-55 DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • Signal voltage high • “B/Bl” circuit open • Signal voltage low • “Lg” circuit open or shorted to ground •...
Page 413 6-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check TP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch ON.
Page 414: Dtc P0121 Throttle Position Circuit Range / Performance Problem
Go to Step 5. 1) Turn ignition switch OFF and connect ECM and recheck. SUZUKI scan tool to DLC. See Fig. 1. 2) Turn ignition switch ON and check TP sen- sor output voltage when throttle valve is at idle position and fully opened. See Fig. 3.
Page 415 [A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 4 / [C] Fig. 3 for Step 3 and 4 [A] : When using SUZUKI scan tool. [B] : When not using SUZUKI scan tool. Fig. 4 for Step 5...
Page 416: Dtc P0130 (Dtc No.14) Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-1)
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-59 DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-1 (HO2S-1) DTC DETECTING CONDITION POSSIBLE CAUSE • When running at idle speed after engine warmed up and •...
Page 417 6-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than HO2S-1 Go to applicable DTC Go to Step 3. (DTC P0130)? Diag.
Page 418: Dtc P0133 Heated Oxygen Sensor (Ho2S) Circuit Slow Response (Sensor-1)
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-61 DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1) WIRING DIAGRAM Refer to DTC P0130 section. CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • When running at specified idle speed after engine warmed up and •...
Page 419: Dtc P0135 (Dtc No.14) Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-1)
6-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Mal- function (Sensor-1) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-1 (HO2S-1) heater DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition is met. •...
Page 420 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-63 INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check Heater for Operation. Intermittent trouble Check Go to Step 3. 1) Check voltage at terminal E19-7. See Fig. 1. for intermittent referring to 2) Warm up engine to normal operating tem- “Intermittent and Poor...
Page 421: Dtc P0136 Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-2)
6-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-2 (HO2S-2) [A] : Case of TYPE A is shown (See NOTE) [B] : Case of TYPE B is shown (See NOTE) NOTE: For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table”...
Page 422 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-65 6) Repeat above steps 5) 4 times. 7) Increase vehicle speed to about 50 mph (80 km/h) in 3rd gear or 2 range. 8) Release accelerator pedal and with engine brake applied, keep vehicle coasting (fuel cut condition) for 10sec.
Page 423: Dtc P0141 Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-2)
6-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sen- sor-2) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE DTC will set when A or B condition it met. • HO2S-2 heater circuit open or shorted to ground 1) Low voltage at terminal E18-4 for specified time after •...
Page 424 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-67 INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check HO2S-2 Heater and Its Circuit. Intermittent trouble. Go to Step 3. 1) Warm up engine to normal operating tem- Check for intermittent perature.
Page 425: Dtc P0171 Fuel System Too Lean
6-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0171 Fuel System Too Lean DTC P0172 Fuel System Too Rich CIRCUIT DESCRIPTION [a] : Signal to decrease amount of fuel injection [d] : A/F mixture becomes richer 1. Injector (Oxygen concentration decreases) [b] : Signal to increase amount of fuel injection [e] : High voltage 2.
Page 426 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-69 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 427 6-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Check Fuel Injectors and Circuit. Go to Step 6. Check injector circuit or 1) Using sound scope (4) or such, check operating replace fuel injector(s). sound of each injector (5) when engine is run- ning.
Page 428 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-71 [A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 4 / [C] Fig. 3 for Step 5 1. Fuel delivery pipe 2. Fuel feed hose 3. Fuel pressure gauge & 3 way joint [D] Fig.
Page 429: Dtc P0300 Random Misfire Detected (Misfire Detected At 2 Or More Cylinders)
6-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders) DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected 1.
Page 430 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-73 DTC DETECTING CONDITION POSSIBLE CAUSE • Engine under other than high revolution condition • Engine overheating • Not on rough road • Vacuum leaks (air inhaling) from air intake system • Engine speed changing rate (below specified value) •...
Page 431 6-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Check Ignition System. Go to Step 4. Check ignition sys- 1) Remove spark plugs and check them for; tem parts (Refer to • Air gap : 1.0 – 1.1 mm (0.040 – 0.043 in.) See Fig. 1. Section 6F).
Page 432 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-75 Step Action Check EVAP Canister Purge Valve for Closing. Check EVAP control Go to Step 8. 1) Disconnect purge hose (1) from EVAP canister. system 2) Place finger against the end of disconnected hose. (See Section 6E).
Page 433 6-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS [F] Fig. 6 for Step 5 / [G] Fig. 7 for Step 7...
Page 434: Dtc P0325 (Dtc No.17) Knock Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-77 DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • Knock sensor voltage is 3.91 V or more • “W” circuit open or shorted to ground • Knock sensor voltage is 1.23 V or less •...
Page 435 6-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS [A] Fig. 1 for Step 2 / [B] Fig. 2 for Step 3...
Page 436: Dtc P0335 (Dtc No.23) Crankshaft Position (Ckp) Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-79 DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • NO CKP sensor signal for 2 seconds at engine crank- • CKP sensor circuit open or short. ing.
Page 437 6-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check CKP Sensor and connector for proper Go to Step 3. Correct. installation. Is CKP sensor installed properly and connector connected securely? Check Wire Harness and Connection.
Page 438 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-81 [A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 6 / [C] Fig. 3 for Step 6 Fig. 4 for Step 7...
Page 439: Dtc P0340 (Dtc No.15) Camshaft Position (Cmp) Sensor Circuit Malfunction
6-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • The number of CMP sensor signal pulses is incor- • CMP sensor circuit open or short. rect during 8 revolution of crankshaft.
Page 440 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-83 INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check CMP Sensor and connector for proper installa- Go to Step 3. Correct. tion. Is CMP sensor installed properly and connector con- nected securely? Check Wire Harness and Connection.
Page 441 6-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS [A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 6 / [C] Fig. 3 for Step 6 Fig. 4 for Step 7...
Page 442: Dtc P0400 Exhaust Gas Recirculation Flow Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-85 DTC P0400 Exhaust Gas Recirculation Flow Malfunction CIRCUIT DESCRIPTION 1. EGR valve DTC DETECTING CONDITION POSSIBLE CAUSE • While running at specified vehicle speed after engine warm-up • EGR valve or its circuit • During deceleration (engine speed high with closed throttle position •...
Page 443 6-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS 2) Start engine and warm it up to normal operating temperature (70 – 110 °C, 158 – 230 °F) and run it at idle for 5 min. 3) Increase vehicle speed to 50 – 55 mph, 80 – 88 km/h in 5th gear or in “D” range. 4) Hold throttle valve at that opening position for 2 min.
Page 444 E19-28, 17, 29, 18 terminals of ECM and body ground. See Fig. 2. Is voltage within 10 – 14 V? Do you have SUZUKI scan tool? Go to Step 6. Stuck or faulty EGR valve or clogged EGR gas pas- sage.
Page 445: Dtc P0420 Catalyst System Efficiency Below Threshold
6-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0420 Catalyst System Efficiency below Threshold CIRCUIT DESCRIPTION 1. Heated oxygen sensor-1 3. Three way catalytic converter 5. To the sensor [B] : Case of TYPE B is shown (See NOTE) 2. Warm up three way catalytic 4.
Page 446 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-89 DTC DETECTING CONDITION POSSIBLE CAUSE • While vehicle running at constant speed under other than • Exhaust gas leak high load. • Three way catalytic converter malfunction • Time from rich or lean switching command is output till HO2S- •...
Page 447 6-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS Test Result Confirmation Flow Table Step Action Check DTC in “DTC” mode and pending DTC in Proceed to applicable Go to Step 2. “ON BOARD TEST” or “PENDING DTC” mode. DTC Diag. Flow Table. Is DTC or pending DTC displayed? Set scan tool to “READINESS TESTS”...
Page 448: Dtc P0443 Purge Control Valve Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-91 DTC P0443 Purge Control Valve Circuit Malfunction CIRCUIT DESCRIPTION 1. EVAP canister purge vale DTC DETECTING CONDITION POSSIBLE CAUSE Canister Purge control valve circuit is opened or • “Bl/G” circuit open or short shorted. •...
Page 449: Dtc P0481 A/C Condenser Fan Control Circuit Malfunction
6-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0481 A/C Condenser Fan Control Circuit Malfunction CIRCUIT DESCRIPTION 1. Ignition switch 3. A/C condenser fan relay 5. A/C condenser fan 7. Fuse box DTC DETECTING CONDITION POSSIBLE CAUSE • Low voltage at terminal E18-18 when ECM doesn’t out- •...
Page 450 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-93 INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check A/C Condenser Fan Control Relay and its Intermittent trouble or Go to Step 3. Circuit.
Page 451: Dtc P0500 (Dtc No.16) Vehicle Speed Sensor (Vss) Malfunction
6-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction CIRCUIT DESCRIPTION 1. VSS 3. VSS connector [B] : Case of TYPE B is shown (See NOTE) 2. Combination meter [A] : Case of TYPE A is shown (See NOTE) NOTE: For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table”...
Page 452 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-95 INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Does speedometer indicate vehicle speed? Go to Step 3. Go to Step 5. Check Vehicle Speed Signal. Intermittent trouble or Go to Step 4.
Page 453: Dtc P0505 Idle Control System Malfunction
3) Start engine and run it at idle for 1 min. 4) Check DTC and pending DTC. INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Is SUZUKI scan tool available? Go to Step 3. Go to Step 4.
Page 454 Action Check Idle Air Control System. Intermittent trouble or Go to Step 5. 1) Connect SUZUKI scan tool to DLC with igni- faulty ECM. tion switch OFF, set parking brake and block Check for intermittent drive wheels. See Fig. 1.
Page 455: Dtc P0601 Internal Control Module Memory Check Sum Error (Dtc No.71)
6-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0601 Internal Control Module Memory Check Sum Error (DTC No.71) DTC DETECTING CONDITION POSSIBLE CAUSE DTC P0601 : Data write error (or check sum error) when written into ECM ✱ ✱ ✱ ✱ 2 driving cycle detection logic, continuous monitoring. DTC CONFIRMATION PROCEDURE 1) Turn ignition switch OFF.
Page 456: Dtc P1450 Barometric Pressure Sensor Low / High Input
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-99 DTC P1450 Barometric Pressure Sensor Low / High Input DTC P1451 Barometric Pressure Sensor Performance Problem WIRING DIAGRAM / CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM. DTC DETECTING CONDITION POSSIBLE CAUSE DTC P1450 : •...
Page 457 6-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Check MAP Sensor Check air intake system Replace MAP sensor. 1) Remove MAP sensor from intake manifold for air being drawn in and and connect vacuum pump gauge to MAP engine compression. sensor.
Page 458: Dtc P1500 Engine Starter Signal Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-101 DTC P1500 Engine Starter Signal Circuit Malfunction CIRCUIT DESCRIPTION 1. Starter 3. Ignition switch (starter switch) [A] : Case of TYPE A is shown (See NOTE) [C] : M/T vehicle 2. Transmission range sensor (switch) 4.
Page 459 6-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow Table”. Check for voltage at terminal E17-13 (Case of Poor E17-13 (Case of “B/Y” or “B/R” circuit TYPE A) (See NOTE) or E18-20 (Case of TYPE TYPE A) (See NOTE) or open.
Page 460: Dtc P1510 Ecm Back-Up Power Supply Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-103 DTC P1510 ECM Back-up Power Supply Malfunction CIRCUIT DESCRIPTION 1. Main fuse 2. Fuse box Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM, etc. are kept in ECM even when the ignition switch is turned OFF. DTC DETECTING CONDITION POSSIBLE CAUSE •...
Page 461: Dtc P1570 (Dtc No.21) Abs Signal Circuit Malfunction
6-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P1570 (DTC No.21) ABS Signal Circuit Malfunction CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE • ABS signal input is low when engine start. • ABS signal circuit short to ground • ABS control module DTC CONFIRMATION PROCEDURE 1) Clear DTC, start engine and keep it at idle for 1 min.
Page 462: Dtc P1600 Serial Communication Problem Between Ecm And Tcm
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-105 DTC P1600 Serial Communication Problem Between ECM and TCM CIRCUIT DESCRIPTION The serial data line is pulled up to about 12 V by ECM and TCM transmits information to ECM through it by con- trolling its grounding.
Page 463 6-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Is it about 12 V at Step 2? “B/R” wire open, poor Go to Step 4. E21-11 connection or TCM power or ground cir- cuit open. If wires and connections are OK, substitute a known-good TCM and recheck.
Page 464: Dtc P1717 A/T Drive Range
ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-107 DTC P1717 A/T Drive Range (Park / Neutral Position) Signal Circuit Malfunc- tion CIRCUIT DESCRIPTION 1. Transmission range switch 2. From ignition switch 3. TCM DTC DETECTING CONDITION POSSIBLE CAUSE • “D” range signal not inputted (Park / Neutral position •...
Page 465 Go to Step 4. Check PNP signal (“D” range signal). Intermittent trouble or Go to Step 5. 1) Connect SUZUKI scan tool to DLC with igni- faulty ECM. Check for tion switch OFF. See Fig. 1. intermittent referring to 2) Turn ignition switch ON and check PNP sig- “Intermittent and Poor...
Page 466 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-109 [D] Table 1 for Step 3 and 4 Scan tool voltmeter SUZUKI SCAN TOOL VOLTAGE AT E17-6 DISPLAY Selector lever “P” and “N” range P/N range 10 – 14V position “R”, “D”, “2” and “L” range D range 0 –...
Page 467 6-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table B-2 Fuel Pump and Its Circuit Check 1. Ignition switch 3. Main relay 5. Fuel pump relay [A] : Case of TYPE A is shown (See NOTE) 2. Main relay 4. Main fuse 6.
Page 468 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-111 Step Action Check Fuel Pump Relay for Operation. “W/G” circuit open or poor Replace fuel pump 1) Check resistance between each two termi- E18-19 connection. relay. nals of fuel pump relay. See Fig.3. If wire and connection are Fuel pump relay resistance OK, substitute a known- Between terminals “A”...
Page 469 6-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table B-3 Fuel Pressure Check 1. Injector 3. Fuel pump (B) : Hose 2. Delivery pipe (A) : Fuel pressure gauge (C) : Attachment INSPECTION Step Action Check Fuel Pressure (Refer to Section 6E for Go to Step 2.
Page 470 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-113 Fig. 1 for Step 1 Special tool (A) : 09912-58441 (B) : 09912-58431 (C) : 09912-58490...
Page 471 6-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS Table B-4 Idle Air Control System Check 1. Main fuse 2. Fuse box 3. Main relay 4. IAC valve INSPECTION Step Action Check engine idle speed and IAC duty referring to Go to Step 2. Go to Step 4.
Page 472: Check
Check PNP signal (“D” range signal). Go to Step 11. Repair or replace. 1) Connect SUZUKI scan tool to DLC with igni- tion switch OFF. 2) Turn ignition switch ON and check PNP signal (“P/N” and “D” range) on display when shifting selector lever to each range.
Page 473 6-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS Fig. 1 for Step 10 Table 1 for Step 9 and 10 Scan tool or voltmeter SUZUKI SCAN TOOL VOLTAGE AT E17-6 DISPLAY Selector lever “P” and “N” range P/N range 10 – 14V position “R”, “D”, “2”...
Page 474 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-117 Table B-5 A/C Signal Circuits Check (Vehicle with A/C) 1. A/C compressor magnet clutch 4. A/C condenser fan 7. Evaporator temp. sensor 2. A/C switch 5. Refrigerant pressure switch [A] : Case of TYPE A is shown (See NOTE) 3.
Page 475 6-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION Step Action Check evaporator temp. sensor. Go to Step 2. Faulty A/C evaporator 1) Disconnect ECM connectors with ignition thermistor or its circuit. switch at OFF position. 2) Check resistance between E19-14 terminal and E19-10 terminal.
Page 476 Go to Step 3. Check Electric Load Signal Circuit. Electric load signal circuit “R/W”, “R/Y” and/or “Bl/Y” 1) Connect SUZUKI scan tool to DLC with igni- is in good condition. circuit open or short, Elec- tion switch OFF. See Fig.1.
Page 477 6-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS [A] Fig. 1 for Step 2 / [B] Fig. 2 for Step 3 Table 1 for Step 2 and 3 Scan tool or voltmeter SUZUKI VOLTAGE VOLTAGE SCAN TOOL AT E18-17, AT E18-24 or...
Page 478 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-121 TAble B-7 A/C Condenser Fan Control System Check INSPECTION Step Action Check Fan Control System. A/C condenser fan con- Go to Step 2. 1) Connect scan tool to DLC with ignition switch OFF. See trol system is in good Fig.
Page 479 6-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Check A/C Condenser Fan (1). “R”, “R/Bl” or “B” circuit Replace A/C 1) Turn ignition switch OFF. open. condenser fan 2) Disconnect fan motor connector (2). motor. 3) Check for proper connection to motor at “R/Bl” and “B” terminals.
Page 480: Special Tool
1A) kit (See NOTE “B”.) 09931-76030 Mass storage cartridge 16 / 14 pin DLC cable Tech 2 kit (SUZUKI scan tool) (See NOTE “C”.) NOTE: • “A” : This kit includes the following items. 1. Tool body & washer, 2. Body plug, 3. Body attachment, 4. Holder, 5. Return hose & clamp, 6.
Page 481 6-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS...
Page 482 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 483: General Description
6A1-2 ENGINE MECHANICAL (M13 ENGINE) General Description Engine The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves / one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 484: Engine Lubrication
ENGINE MECHANICAL (M13 ENGINE) 6A1-3 Engine Lubrication The oil pump is of a 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 2 paths in cylinder block. In one path, oil reaches the crankshaft journal bearings.
Page 485: Diagnosis
6A1-4 ENGINE MECHANICAL (M13 ENGINE) Diagnosis Diagnosis Table Refer to “Engine Diagnosis Table” in Section 6. Compression Check Check compression pressure on all 4 cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift lever in “Neutral”...
Page 486 ENGINE MECHANICAL (M13 ENGINE) 6A1-5 10) Disengage clutch (1) (to lighten starting load on engine) for M/T vehicle, and depress accelerator pedal (2) all the way to make throttle fully open. 11) Crank engine with fully charged battery, and read the highest pressure on compression gauge.
Page 487: Engine Vacuum Check
6A1-6 ENGINE MECHANICAL (M13 ENGINE) Engine Vacuum Check The engine vacuum that develops in the intake line is a good indi- cator of the condition of the engine. The vacuum checking proce- dure is as follows: 1) Warm up engine to normal operating temperature. NOTE: After warming up engine, be sure to place transmission gear shift lever in “Neutral”...
Page 488: Oil Pressure Check
ENGINE MECHANICAL (M13 ENGINE) 6A1-7 Oil Pressure Check NOTE: Prior to checking oil pressure, check the following items. • Oil level in oil pan. If oil level is low, add oil up to Full level mark (hole) (1) on oil level gauge.
Page 489 6A1-8 ENGINE MECHANICAL (M13 ENGINE) 6) Before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and tighten switch to specified torque. NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off.
Page 490: Valve Lash (Clearance)
ENGINE MECHANICAL (M13 ENGINE) 6A1-9 Valve Lash (Clearance) 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to “Cylinder Head Cover” in this section. 3) Using 17 mm wrench, turn crankshaft pulley (1) clockwise until cam lobes (2) become perpendicular to shim faces (3) at valves “1”...
Page 491 6A1-10 ENGINE MECHANICAL (M13 ENGINE) 2) Lift valve by turning crankshaft and then remove camshaft housing bolts (1) where the shim to be replaced. 2. Plug hole 3) Install special tool with camshaft housing bolts as shown in figure. Special tool (A) : 09916-67020 Tightening torque Camshaft housing bolts (for tightening of special tool)
Page 492 ENGINE MECHANICAL (M13 ENGINE) 6A1-11 5) Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by cal- culating the thickness of new shim with the following formula and table. Intake side A = B + C – 0.20 mm (0.008 in.) Exhaust side A = B + C –...
Page 493 6A1-12 ENGINE MECHANICAL (M13 ENGINE) 8) Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4) and remove special tool. Special tool (A) : 09916-67020 1. Tappet 2. Camshaft 9) Install camshaft housing (1) and tighten them to specified torque.
Page 494: On-Vehicle Service
ENGINE MECHANICAL (M13 ENGINE) 6A1-13 On-Vehicle Service Air Cleaner Element REMOVAL 1) Open air cleaner case by unhooking its clamps. 2) Remove air cleaner element from case. INSPECTION Check air cleaner element for dirt. Replace excessively dirty ele- ment. CLEANING Blow off dust by compressed air from air outlet side of element.
Page 495: Air Cleaner Assembly
6A1-14 ENGINE MECHANICAL (M13 ENGINE) Air Cleaner Assembly REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect IAT sensor coupler (1). 3) Disconnect breather hose from air cleaner outlet No.2 hose (2). 4) Remove air cleaner outlet No.2 hose fastening bolt (3). 5) Loosen air cleaner outlet No.2 hose clamp bolt (4).
Page 496: Cylinder Head Cover
ENGINE MECHANICAL (M13 ENGINE) 6A1-15 Cylinder Head Cover REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect accelerator cable (1) from clamp (2) (For left hand steering vehicle only). 3) Remove cylinder head upper cover (3). 4) Disconnect ignition coil couplers (1). 5) Remove ignition coil assemblies (2) with high-tension cord (3).
Page 497 6A1-16 ENGINE MECHANICAL (M13 ENGINE) INSTALLATION 1) Install new spark plug hole gaskets (1) and new cylinder head cover gasket (2) to cylinder head cover (3) as shown in figure. NOTE: Be sure to check each of these parts for deterioration or any damage before installation and replace if found defective.
Page 498 ENGINE MECHANICAL (M13 ENGINE) 6A1-17 3) Install cylinder head cover to cylinder head. NOTE: When installing cylinder head cover, use care so that cyl- inder head cover gasket or spark plug hole gaskets will not get out of place or fall off. 4) Tighten bolts in such order as indicated in figure a little at a time till they are tightened to specified torque.
Page 499: Throttle Body And Intake Manifold
6A1-18 ENGINE MECHANICAL (M13 ENGINE) Throttle Body and Intake Manifold 1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting nut 19. Injector assembly 2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (short) 20. Cushion 3.
Page 500 ENGINE MECHANICAL (M13 ENGINE) 6A1-19 4) Remove air cleaner outlet No.1 (1) and No.2 (2) hoses and breather hose (3). 5) Remove intake manifold bracket (1) with main harness from intake manifold. 6) Disconnect the following electric lead wires: • IAC valve (2) •...
Page 501 6A1-20 ENGINE MECHANICAL (M13 ENGINE) 13) Remove intake manifold (1) with throttle body (2) and EGR pipe (3) from cylinder head (4), and then its gasket. INSTALLATION Reverse removal procedure for installation noting the followings. • Use new intake manifold gasket and EGR pipe gasket. •...
Page 502: Exhaust Manifold
ENGINE MECHANICAL (M13 ENGINE) 6A1-21 Exhaust Manifold 1. Exhaust manifold 4. Exhaust manifold cover Tightening torque 2. Exhaust manifold gasket 5. Engine hook Do not reuse. 3. Heated oxygen sensor (if equipped) 6. Exhaust manifold mounting nut WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot.
Page 503 6A1-22 ENGINE MECHANICAL (M13 ENGINE) 5) Disconnect exhaust pipe (1) from exhaust manifold. 6) Remove exhaust manifold (1) and its gasket from cylinder head. INSTALLATION 1) Install new gasket to cylinder head. Then install exhaust manifold. Tighten manifold nuts to specified torque. Tightening torque Exhaust manifold nuts (a) : 55 N·m (5.5 kg-m, 40.0 lb-ft) 2) Install seal ring and install exhaust pipe (1) to exhaust mani-...
Page 504 ENGINE MECHANICAL (M13 ENGINE) 6A1-23 3) Install exhaust manifold stiffener (1). Tighten exhaust manifold stiffener bolts to specified torque. Tightening torque Exhaust manifold stiffener bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 4) Install exhaust manifold cover (1). 5) Connect heated oxygen sensor coupler (2) and fit coupler to bracket securely (if equipped).
Page 505: Oil Pan And Oil Pump Strainer
6A1-24 ENGINE MECHANICAL (M13 ENGINE) Oil Pan and Oil Pump Strainer [A] : Sealant application amount 3. O-ring 8. Oil pan nut “a” : 3 mm (0.12 in.) 4. Gasket 9. Oil pan bolt “b” : 2 mm (0.08 in.) 5.
Page 506 ENGINE MECHANICAL (M13 ENGINE) 6A1-25 4) Drain engine oil by removing drain plug. 5) Remove clutch housing (torque converter housing for A/T vehicle) lower plate (1). 6) Remove oil pan and then oil pump strainer (1) from cylinder block. CLEAN •...
Page 507 6A1-26 ENGINE MECHANICAL (M13 ENGINE) INSTALLATION 1) Apply sealant continuously to oil pan mating surface as shown in figure. “A” sealant : 99000-31150 Sealant amount for oil pan Width “a” : 3 mm, 0.12 in. Height “b” : 2 mm, 0.08 in. 2) Install new O-rings (1) in the position as shown in figure and install oil pump strainer (2).
Page 508 ENGINE MECHANICAL (M13 ENGINE) 6A1-27 6) Lower engine and tighten engine mounting bracket bolts to specified torque. Tightening torque Engine mounting bracket bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 7) Install oil level gauge. 8) Refill engine with engine oil referring to “Engine Oil and Filter Change”...
Page 509: Timing Chain Cover
6A1-28 ENGINE MECHANICAL (M13 ENGINE) Timing Chain Cover [A] : Sealant application 3. Oil seal 8. Cylinder head cover amount : Apply engine oil to oil seal lip. : Apply sealant 99000-31150 to the sealing point for timing chain cover mating surface and cylinder head gasket sealing point.
Page 510 ENGINE MECHANICAL (M13 ENGINE) 6A1-29 5) Drain coolant. WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
Page 511 6A1-30 ENGINE MECHANICAL (M13 ENGINE) 12) Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool with it as shown in figure. Special tool (A) : 09917-68221 13) Remove crankshaft pulley (1). If it is hard to remove, use special tools as shown in figure. If bolts of special tool are too long, replace them with those of suitable length.
Page 512 ENGINE MECHANICAL (M13 ENGINE) 6A1-31 INSPECTION • Check oil seal (1) lip for fault or other damage. Replace as necessary. NOTE: When installing new oil seal, tap it in until its surface is flash with edge of timing chain cover (2). To install oil seal, use special tool (Bearing installer).
Page 513 6A1-32 ENGINE MECHANICAL (M13 ENGINE) 3) Install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use special tool with it as shown in figure. Special tool (A) : 09917-68221 Tightening torque Crankshaft pulley bolt (a) : 150 N·m (15.0 kg-m, 108.5 lb-ft) 4) Install P/S pump bracket (1), P/S pump (2) and A/C com- pressor and/or P/S pump belt tension pulley (3) (if equipped) referring to “Power Steering Pump”...
Page 514: Oil Pump
ENGINE MECHANICAL (M13 ENGINE) 6A1-33 Oil Pump [A] : Sealant application 4. Timing chain cover 10. Circlip amount : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head. : Apply sealant 99000-31150 to mating surface of timing chain cover referring to the figure of Step 1) in “Timing Chain Cover Installation”.
Page 515 6A1-34 ENGINE MECHANICAL (M13 ENGINE) 2) Remove outer rotor (1) and inner rotor (2). 3) Remove relief valve (1), spring (2) and retainer (3) by remov- ing circlip (4). INSPECTION • Check oil seal lip for fault or other damage. Replace as nec- essary.
Page 516 ENGINE MECHANICAL (M13 ENGINE) 6A1-35 • Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage. • Check relief valve (1) for excessive wear or damage and operates smoothly. MEASUREMENT Radial clearance Check radial clearance between outer rotor (1) and case (2), using thickness gauge (3).
Page 517 6A1-36 ENGINE MECHANICAL (M13 ENGINE) ASSEMBLY 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, and inside surfaces of oil pump case and plate. 3) Install outer (1) and inner rotors (2) to oil pump case.
Page 518: Timing Chain And Chain Tensioner
ENGINE MECHANICAL (M13 ENGINE) 6A1-37 Timing Chain and Chain Tensioner 1. Crankshaft timing sprocket 5. Timing chain tensioner adjuster assembly Tightening torque 2. Timing chain 6. Chain tensioner adjuster mounting bolt Apply engine oil to sliding surface. 3. Timing chain No.1 guide 7.
Page 519 6A1-38 ENGINE MECHANICAL (M13 ENGINE) INSPECTION Timing chain tensioner • Check shoe (1) for wear or damage. Crankshaft timing sprocket • Check teeth of sprocket for wear or damage. Timing chain • Check timing chain for wear or damage. Timing chain tensioner adjuster •...
Page 520 ENGINE MECHANICAL (M13 ENGINE) 6A1-39 INSTALLATION CAUTION: After timing chain is removed, never turn crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown in figure. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.
Page 521 6A1-40 ENGINE MECHANICAL (M13 ENGINE) 6) Apply engine oil to sliding surface of chain tensioner (1) and install chain tensioner and spacer. Tighten tensioner bolt to specified torque Tightening torque Timing chain tensioner bolt (a) : 22 N·m (2.2 kg-m, 16.0 lb-ft) 7) Check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with dark blue plates (2) of tim- ing chain and match mark (3) on crankshaft timing sprocket...
Page 522 ENGINE MECHANICAL (M13 ENGINE) 6A1-41 10) Apply engine oil to timing chain and then turn crankshaft clockwise by 2 revolutions and check that match marks (1) on intake and exhaust camshaft timing sprockets are in match with notches (2) on cylinder head and key (3) is on upside of crankshaft as shown in figure.
Page 523: Camshaft, Tappet And Shim
6A1-42 ENGINE MECHANICAL (M13 ENGINE) Camshaft, Tappet and Shim 1. Intake camshaft 4. Tappet Tightening torque 2. Exhaust camshaft 5. Camshaft housing Apply engine oil to sliding surface of each part. 3. Shim 6. Camshaft housing bolt : Shim No. on it faces tappet side. REMOVAL 1) Remove cylinder head cover and oil pan referring to “Cylin- der Head Cover”...
Page 524 ENGINE MECHANICAL (M13 ENGINE) 6A1-43 7) Remove tappets (1) with shims (2). INSPECTION Cam Wear Using a micrometer, measure cam height “a”. If measured height is below its limit, replace camshaft. Cam height “a” of camshaft Standard Limit Intake cam 44.919 –...
Page 525 6A1-44 ENGINE MECHANICAL (M13 ENGINE) Check clearance by using gauging plastic. Checking procedure is as follows. 1) Clean housings and camshaft journals. 2) Remove all tappets with shims. 3) Install camshafts to cylinder head. 4) Place a piece of gauging plastic to full width of journal of camshaft (parallel to camshaft).
Page 526 ENGINE MECHANICAL (M13 ENGINE) 6A1-45 Wear of Tappet and Shim Check tappet and shim for pitting, scratches or damage. If any malcondition is found, replace. Measure cylinder head bore and tappet outside diameter to deter- mine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.
Page 527 6A1-46 ENGINE MECHANICAL (M13 ENGINE) INSTALLATION 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. NOTE: When installing shim, make sure to direct shim No. side toward tappet. 2) Install camshafts (1). Apply engine oil to sliding surface of each camshaft and camshaft journal then install them as shown in figure.
Page 528 ENGINE MECHANICAL (M13 ENGINE) 6A1-47 5) After applying engine oil to housing bolts, tighten them tem- porarily first. Then tighten them by the following numerical order in figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque.
Page 529: Valves And Cylinder Head
6A1-48 ENGINE MECHANICAL (M13 ENGINE) Valves and Cylinder Head 1. Valve cotters 6. Intake valve 11. Cylinder head gasket : “TOP” mark provided on gasket comes to crankshaft pulley side, facing up. 2. Valve spring retainer 7. Exhaust valve 12. Knock pin 3.
Page 530 ENGINE MECHANICAL (M13 ENGINE) 6A1-49 REMOVAL 1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro- cedure” in Section 6. 2) Disconnect negative cable at battery. 3) Drain engine oil. 4) Drain coolant by loosening drain plug (1). WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot.
Page 531 6A1-50 ENGINE MECHANICAL (M13 ENGINE) 9) Disconnect accelerator cable (1) from throttle body. 10) Disconnect the following hoses: • Brake booster hose (2) from intake manifold • Canister purge hose (3) from EVAP canister purge valve • Fuel feed and return hoses (4) from each pipe •...
Page 532 ENGINE MECHANICAL (M13 ENGINE) 6A1-51 19) Remove exhaust manifold stiffener (1). 20) Loosen cylinder head bolts in such order as indicated in fig- ure by using a 12 corner socket wrenches and remove them. NOTE: Don’t forget to remove bolt (M8) (1) as shown in figure. 21) Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
Page 533 6A1-52 ENGINE MECHANICAL (M13 ENGINE) DISASSEMBLY 1) For ease in servicing cylinder head, remove intake manifold, injectors and exhaust manifold from cylinder head. 2) Using special tools (Valve lifter), compress valve spring and then remove valve cotters (1) by using special tool (For- ceps).
Page 534 ENGINE MECHANICAL (M13 ENGINE) 6A1-53 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 535 6A1-54 ENGINE MECHANICAL (M13 ENGINE) Valves • Remove all carbon from valves. • Inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it. • Measure thickness “a” of valve head. If measured thickness exceeds limit, replace valve.
Page 536 ENGINE MECHANICAL (M13 ENGINE) 6A1-55 • Valve seat repair: A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 537 6A1-56 ENGINE MECHANICAL (M13 ENGINE) • Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface. Using a straightedge and thickness gauge, check flatness of gasketed surface at a total of 2 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place abrasive paper on and...
Page 538 ENGINE MECHANICAL (M13 ENGINE) 6A1-57 Valve Springs • Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of break- age or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 539 6A1-58 ENGINE MECHANICAL (M13 ENGINE) 2) Install valve guide to cylinder head. Heat cylinder head uniformly to a temperature of 80 to 100 °C (176 to 212 °F) so that head will not be distorted, and drive new valve guide into hole with special tools. Drive in new valve guide until special tool (Valve guide installer) con- tacts cylinder head.
Page 540 ENGINE MECHANICAL (M13 ENGINE) 6A1-59 6) Install valve to valve guide Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore and valve stem. 7) Install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1)) and bot- tom end (small-pitch end (2)).
Page 541 6A1-60 ENGINE MECHANICAL (M13 ENGINE) 4) Make sure that oil jet (venturi plug) (1) is installed and if it is, that it is not clogged. When installing it, be sure to tighten to specified torque. Tightening torque Venturi plug (a) : 5 N·m (0.5 kg-m, 3.5 lb-ft) 5) Install cylinder head to cylinder block.
Page 542 ENGINE MECHANICAL (M13 ENGINE) 6A1-61 6) Install exhaust manifold stiffener and exhaust pipe referring to “Exhaust Manifold” in this section. 7) Install camshafts, timing chain and chain cover referring to “Camshaft, Tappet and Shim”, “Timing Chain and Chain Tensioner” and “Timing Chain Cover” in this section. 8) Install cylinder head cover and oil pan referring to “Cylinder Head Cover”...
Page 543: Pistons, Piston Rings, Connecting Rods And Cylinders
6A1-62 ENGINE MECHANICAL (M13 ENGINE) Pistons, Piston Rings, Connecting Rods and Cylinders 1. Top ring 8. Piston pin 2. 2nd ring 9. Piston pin circlip 3. Oil ring 10. Bearing cap nut 1) Tighten all nuts to 15 N·m (1.5 kg-m) 2) Turn all nuts to 45°...
Page 544 ENGINE MECHANICAL (M13 ENGINE) 6A1-63 8) Install guide hose (1) over threads of rod bolts. This prevents damage to bearing journal and rod bolt threads when removing connecting rod. 9) Decarbon top of cylinder bore before removing piston from cylinder. 10) Push piston and connecting rod assembly out through the top of cylinder bore.
Page 545 6A1-64 ENGINE MECHANICAL (M13 ENGINE) • Using a cylinder gauge (1), measure cylinder bore in thrust and axial directions at two positions (“a” and “b”) as shown in figure. If any of the following conditions is noted, rebore cylinder. 1) Cylinder bore dia. exceeds limit. 2) Difference of measurements at two positions exceeds taper limit.
Page 546 ENGINE MECHANICAL (M13 ENGINE) 6A1-65 • Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance Standard : 0.032 –...
Page 547 6A1-66 ENGINE MECHANICAL (M13 ENGINE) • Piston pin clearance: Check piston pin clearance in small end and piston. Replace connecting rod and/or piston if its small end is badly worn or damaged or if measured clearance exceeds limit. Piston pin clearance in connecting rod small end 0.003 –...
Page 548 ENGINE MECHANICAL (M13 ENGINE) 6A1-67 • Connecting rod alignment: Mount connecting rod on aligner to check it for bow and twist. If limit is exceeded, replace it. Connecting rod alignment Limit on bow : 0.05 mm (0.0020 in.) Limit on twist : 0.10 mm (0.0039 in.) •...
Page 549 6A1-68 ENGINE MECHANICAL (M13 ENGINE) • Rod bearing : Inspect bearing shells for signs of fusion, pitting, burn or flak- ing and observe contact pattern. Bearing shells found in defective condition must be replaced. Two kinds of rod bearing are available; standard size bear- ing and 0.25 mm (0.0098 in.) undersize bearing.
Page 550 ENGINE MECHANICAL (M13 ENGINE) 6A1-69 6) If clearance can not be brought to within its limit even by using a new standard size bearing, regrind crankpin to undersize and use 0.25 mm undersize bearing. NOTE: After checking the rod bearing clearance, make sure to check connecting rod bolt diameter.
Page 551 6A1-70 ENGINE MECHANICAL (M13 ENGINE) INSTALLATION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or between bearing cap and bearing. 2) Install guide hoses (1) over connecting rod bolts. These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly.
Page 552 ENGINE MECHANICAL (M13 ENGINE) 6A1-71 5) Install bearing cap (1): Point arrow mark (2) on cap to crankshaft pulley side. After applying oil to rod bolts and tighten cap nuts (3) gradu- ally as follows. NOTE: Before installing bearing cap, make sure to check con- necting rod bolt diameter.
Page 553: Engine Mountings
6A1-72 ENGINE MECHANICAL (M13 ENGINE) Engine Mountings Tightening torque...
Page 554: Unit Repair Overhaul
ENGINE MECHANICAL (M13 ENGINE) 6A1-73 Unit Repair Overhaul Engine Assembly REMOVAL 1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro- cedure” in Section 6. 2) Disconnect negative cable at battery. 3) Remove engine hood after disconnecting windshield washer hose. 4) Remove A/C compressor and/or P/S pump belt (if equipped).
Page 555 6A1-74 ENGINE MECHANICAL (M13 ENGINE) a) For right hand steering vehicle: With hose connected, detach A/C compressor from its bracket. NOTE: Suspend removed A/C compressor at a place where no damage will be caused during removal and installation of engine assembly. b) For left hand steering vehicle: i) Recover refrigerant from refrigeration system using recov- ery and recycling equipment.
Page 556 ENGINE MECHANICAL (M13 ENGINE) 6A1-75 18) Remove heated oxygen sensor bracket from cylinder head and detach No.1 heated oxygen sensor coupler from its bracket. 19) Release accelerator cable (1) from clamp (2) (for left hand steering vehicle only) and disconnect accelerator cable from throttle body.
Page 557 6A1-76 ENGINE MECHANICAL (M13 ENGINE) 26) Remove bolts and nuts fastening cylinder block and trans- mission. 27) Install board (1) or the like on A/C condenser. This prevents damage to condenser fins when lifting and lowering engine assembly. 28) Install lifting device. 29) Remove right and left engine mounting bracket bolts (1).
Page 558 ENGINE MECHANICAL (M13 ENGINE) 6A1-77 INSTALLATION 1) Lower engine assembly into engine compartment. Connect engine to transmission. Hard-tighten bolts and nuts fastening cylinder block and transmission. 2) Tighten right and left engine mounting bracket bolts to speci- fied torque. Tightening torque Engine mounting bracket bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 3) Tighten bolts and nuts fastening cylinder block and transmis-...
Page 559 6A1-78 ENGINE MECHANICAL (M13 ENGINE) • Install seal ring and exhaust pipe to exhaust manifold. Tighten pipe fasteners to specified torque. Tightening torque Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 6) Reverse disconnected hoses, cables and electric wires for connection.
Page 560: Main Bearings, Crankshaft And Cylinder Block
ENGINE MECHANICAL (M13 ENGINE) 6A1-79 Main Bearings, Crankshaft and Cylinder Block Tightening torque 4. Venturi plug 12. Input shaft bearing Do not reuse. 5. Main bearing 13. Flywheel Apply engine oil to inside / sliding 6. Sensor plate 14. Main bearing cap surface.
Page 561 6A1-80 ENGINE MECHANICAL (M13 ENGINE) REMOVAL 1) Remove engine assembly from vehicle as previously out- lined. 2) Remove clutch cover, clutch disc and flywheel (drive plate for A/T) by using special tool. Special tool (A) : 09924-17810 3) Remove the following parts from engine as previously out- lined.
Page 562 ENGINE MECHANICAL (M13 ENGINE) 6A1-81 INSPECTION Main bearing cap No.1 bolt Measure each thread diameter of bearing cap No.1 bolts (1) at “A” “B” “A” on 60 mm (2.36 in.) from seat side of flange bolt and “B” on 90 mm (3.54 in.) from seat side of flange bolt by using a micrometer (2).
Page 563 6A1-82 ENGINE MECHANICAL (M13 ENGINE) Tighten bearing cap No.1 bolts (1) – (10) and No.2 bolts (11) – (20) gradually as follows. 1) Tighten bolts (1) – (10) to 30 N·m (3.0 kg-m, 22.0 lb-ft) according to numerical order in figure. 2) In the same manner as in Step 1), tighten them to 50 N·m (5.0 kg-m, 36.5 lb-ft).
Page 564 ENGINE MECHANICAL (M13 ENGINE) 6A1-83 • Upper half of bearing (1) has an oil groove (2) as shown in figure. Install this half with oil groove to cylinder block. • Lower half of bearing does not have an oil groove. Visual inspection Check bearings for pitting, scratches, wear or damage.
Page 565 6A1-84 ENGINE MECHANICAL (M13 ENGINE) 5) Remove bearing caps and using scale (1) on gauging plastic (2) envelop, measure gauging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
Page 566 ENGINE MECHANICAL (M13 ENGINE) 6A1-85 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent the fol- lowing cap bore diameters. Stamped alphabets on cylinder block represent bearing cap bore diameter marked with an arrow in figure respectively.
Page 567 6A1-86 ENGINE MECHANICAL (M13 ENGINE) 4) From number stamped on crank web No.2 and alphabets stamped on cylinder block, determine new standard bearing to be installed to journal, by referring to table shown below. For example, if number stamped on crank web No.2 is “1” and alphabet stamped on cylinder block is “B”, install a new standard bearing painted in “Purple”...
Page 568 ENGINE MECHANICAL (M13 ENGINE) 6A1-87 • If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. a) Regrind journal to the following finished diameter. Finished diameter 44.732 – 44.750 mm (1.7611 – 1.7618 in.) 1) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicu- lar to each other in order to check for out-of-round.
Page 569 6A1-88 ENGINE MECHANICAL (M13 ENGINE) Flywheel • If ring gear is damaged, cracked or worn, replace flywheel. • If the surface contacting clutch disc is damaged, or exces- sively worn, replace flywheel. • Check flywheel for face runout with a dial gauge. If runout exceeds its limit, replace flywheel.
Page 570 ENGINE MECHANICAL (M13 ENGINE) 6A1-89 3) Using micrometer, measure piston diameter. Measurement position for piston diameter “a” : 19.5 mm (0.77 in.) 4) Calculate cylinder bore diameter to be rebored as follows. D = A + B – C D : Cylinder bore diameter to be rebored. A : Piston diameter as measured.
Page 571 6A1-90 ENGINE MECHANICAL (M13 ENGINE) INSTALLATION NOTE: • All parts to be installed must be perfectly clean. • Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores. • Journal bearings, bearings caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets.
Page 572 ENGINE MECHANICAL (M13 ENGINE) 6A1-91 5) Install crankshaft to cylinder block. 6) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
Page 573 6A1-92 ENGINE MECHANICAL (M13 ENGINE) 8) Install rear oil seal housing (1) and tighten bolts to specified torque by using special tool. Special tool (A) : 09911-97720 Tightening torque Rear oil seal housing bolts : 11 N·m (1.1 kg-m, 8.0 lb-ft) A : Crankshaft side 9) Install flywheel (drive plate for A/T).
Page 574: Required Service Material
Required Service Material Recommended SUZUKI product Material (Part Number) Sealant SUZUKI BOND NO. 1207C • To apply to mating surface of cylinder block and oil (99000-31150) pan. • To apply to mating surface of cylinder block and timing chain cover.
Page 575: Special Tool
6A1-94 ENGINE MECHANICAL (M13 ENGINE) Tightening torque Fastening part N•m kg-m lb-ft Crankshaft bearing cap No.1 bolts 50.0 36.5 (for inspection of crankshaft thrust play) Crankshaft bearing cap No.2 bolts 22.0 16.0 Sensor plate bolts 11.0 Crankshaft bearing cap No.1 bolts a) Tighten 50 N·m a) Tighten 5.0 kg-m a) Tighten 36.5 lb-ft...
Page 576 ENGINE MECHANICAL (M13 ENGINE) 6A1-95 09915-67310 09915-77310 09915-78211 09916-14510 Vacuum gauge Oil pressure gauge Oil pressure gauge Valve lifter attachment 09916-14521 09916-34542 09916-34550 09916-37320 Valve lifter attachment Reamer handle Reamer (5.5 mm) Reamer (10.5 mm) 09916-44910 09916-56011 09916-58210 09916-67020 Valve guide remover Valve guide installer Valve guide installer han- Tappet holder...
Page 577 6A1-96 ENGINE MECHANICAL (M13 ENGINE) 09924-17810 09926-58010 09944-36011 Flywheel holder Bearing puller attachment Steering wheel remover...
Page 578: Engine Cooling
ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS General Description ........6B-2 Cooling System Flush and Refill ....6B-8 Water Pump Belt Tension ......6B-9 Cooling System Circulation ......6B-2 Radiator Cap ..........6B-3 On-Vehicle Service ........6B-10 Coolant Reservoir .........6B-3 Cooling System Component ....... 6B-10 Water Pump ..........6B-4 Coolant Draining .........
Page 579: General Description
6B-2 ENGINE COOLING General Description The cooling system consists of the radiator cap, radiator, reservoir, hoses, water pump, cooling fan & clutch, thermostat. The radiator is of tube-and-fin type. Cooling System Circulation 1. Radiator inlet hose 5. Water pump 9. Heater outlet hose 2.
Page 580: Radiator Cap
ENGINE COOLING 6B-3 Radiator Cap A pressure-vent cap is used on the radiator. The cap contains a pressure valve (1) and ventilation valve (2). The cap has its face marked 1.1, which means that its pressure valve opens at 1.1 kg/cm (15.6 psi, 110 kPa).
Page 581: Water Pump
6B-4 ENGINE COOLING Water Pump The centrifugal type water pump is used in the cooling system. The pump impeller is supported by a totally sealed bearing. The water pump can not be disassembled. Thermostat A wax pellet type thermostat is used in the cooling system. The temperature at which the valve begins to open is stamped on thermostat.
Page 582: Diagnosis
ENGINE COOLING 6B-5 Diagnosis Condition Possible Cause Correction Engine overheats • Loose or broken water pump belt Adjust or replace. • Not enough coolant Check coolant level and add as necessary. • Faulty thermostat Replace. • Faulty water pump Replace. •...
Page 583: Maintenance
6B-6 ENGINE COOLING Maintenance Coolant The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col- lected in the reservoir. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled at the factory with a quality coolant that is either 50/50 mixture of water and anti-freeze / anti-corrosion coolant (ethylene glycol antifreeze).
Page 584: Coolant Level
ENGINE COOLING 6B-7 Coolant Level WARNING: To help avoid danger of being burned: • Do not remove reservoir cap while coolant is “boiling”, • Do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pres- sure if either cap is taken off too soon.
Page 585: Cooling System Flush And Refill
6B-8 ENGINE COOLING NOTE: After installing radiator cap (1) to radiator, make sure that its ear (2) is aligned with reservoir hose (3) as shown in figure. If not, turn cap more to align its ear with hose. 5) Tighten hose clamps and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise deteriorated.
Page 586: Water Pump Belt Tension
ENGINE COOLING 6B-9 9) Run engine, with radiator cap removed, until radiator upper hose is hot. 10) With engine idling, add coolant to radiator until level reaches the bottom of filler neck. Install radiator cap, making sure that the ear of cap lines up with reservoir hose. Water Pump Belt Tension WARNING: Disconnect negative cable at battery before checking and...
Page 587: On-Vehicle Service
6B-10 ENGINE COOLING On-Vehicle Service CAUTION: • Check to make sure that engine coolant temperature is cold before removing any part of cooling system. • Disconnect negative cable at battery before removing any part. Cooling System Component 15 N·m (1.5 kg-m) 25 N·m (2.5 kg-m) 11 N·m (1.1 kg-m)
Page 588: Coolant Draining
ENGINE COOLING 6B-11 Coolant Draining 1) Remove radiator cap (1). 2) Loosen drain plug on radiator to drain coolant. 3) After draining coolant, be sure to tighten drain plug securely. 4) Fill cooling system. Refer to “Coolant” in this section. Cooling Water Pipes or Hoses REMOVAL 1) Drain cooling system.
Page 589 6B-12 ENGINE COOLING INSPECTION 1) Make sure that air bleed valve (1) of thermostat is clear. Should this valve be clogged, engine would tend to overheat. 2) Check valve seat for some foreign matters being stuck which prevent valve from seating tight. 3) Check thermostatic movement of wax pellet as follows: a) Immerse thermostat (1) in water, and heat water gradually.
Page 590: Water Pump Belt And Cooling Fan
ENGINE COOLING 6B-13 Water Pump Belt and Cooling Fan REMOVAL 1) Remove radiator shroud securing bolts (1). 2) Remove radiator by referring to “Radiator” in this section. 3) Loosen water pump drive belt tension. 4) Remove cooling fan by removing securing nuts. Remove power steering and/or compressor drive belt before removing water pump belt.
Page 591: Radiator
6B-14 ENGINE COOLING Radiator REMOVAL 1) Drain cooling system. 2) Remove radiator shroud. 3) Disconnect water hoses from radiator. 4) With automatic transmission (A/T) vehicle, disconnect addi- tional two fluid hoses from radiator. Place some container under radiator to receive A/T fluid which will flow out when hose is disconnected.
Page 592: Water Pump
ENGINE COOLING 6B-15 Water Pump COMPONENTS 1. Water pump 4. Radiator cooling fan 7. Radiator cooling fan mounting bolt 2. Water pump pulley 5. Water pump mounting bolts Tightening Torque 3. Radiator cooling fan clutch 6. Water pump pulley and fan clutch mounting nuts REMOVAL 1) Drain cooling system.
Page 593 6B-16 ENGINE COOLING INSPECTION NOTE: Do not disassemble water pump. If any repair is required on pump, replace it as assembly. • Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes an abnormal noise, replace it.
Page 594: Required Service Material
ENGINE COOLING 6B-17 Required Service Material Recommended SUZUKI product Material (Part Number) Ethylene glycol base Additive to engine cooling system for improving coolant (Anti-freeze / – cooling efficiency and for protection against Anti-corrosion coolant) rusting. SUZUKI BOND NO.1207C Sealant To apply to water pump mating surface.
Page 595 6B-18 ENGINE COOLING...
Page 596 ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CONTENTS General Description ........6C-2 Fuel Lines ............ 6C-4 Fuel Filler Cap..........6C-4 Fuel System ..........6C-2 Fuel Tank ............. 6C-4 Fuel Tank ............. 6C-2 Fuel Pump Assembly ........6C-7 Fuel Pump Assembly ........6C-3 Fuel Filler Cap ..........
Page 597: General Description
6C-2 ENGINE FUEL General Description Fuel System The main components of the fuel system are fuel tank, fuel pump assembly with fuel filter and fuel level gauge and fuel cut valve, fuel feed line, fuel return line and fuel vapor line. For the details of fuel flow and fuel vapor flow, refer to “Fuel Delivery System”...
Page 598: Fuel Pump Assembly
ENGINE FUEL 6C-3 Fuel Pump Assembly The fuel pump assembly (1) consists of fuel pump (6), fuel filter (2), fuel level gauge (5) and fuel cut valve (4). 3. Suction filter FUEL PUMP For structure and operation of the fuel pump, refer to “Fuel Deliv- ery System”...
Page 599: On-Vehicle Service
6C-4 ENGINE FUEL On-Vehicle Service Before work, refer to “Precaution on Fuel System Service” in Sec- tion 6. Fuel Lines Due to the fact that fuel feed line is under high pressure, use spe- cial care when servicing it. INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose crack and deterioration, or damage.
Page 600 ENGINE FUEL 6C-5 4) Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space “A” in the figure (drain fuel through it till fuel stops). CAUTION: Do not force hose of a hand operated pump into fuel tank.
Page 601 6C-6 ENGINE FUEL 12) Remove fuel tank (1) from vehicle. Remove fuel tank protec- tor (3) and inlet valve (2) as necessary. FUEL TANK PURGING PROCEDURE CAUTION: This purging procedure will not remove all fuel vapor. Do not attempt any repair on tank where heat or flame is required, as an explosion resulting in personal injury could occur.
Page 602: Fuel Pump Assembly
ENGINE FUEL 6C-7 INSTALLATION 1) Install fuel pump (1) assembly to fuel tank. Refer to “Fuel Pump Assembly” in this section. Install protector to fuel tank. 2) Install inlet valve to fuel tank. If deformed or damaged in any other way, replace with a new one.
Page 603 6C-8 ENGINE FUEL INSPECTION Check fuel pump assembly for damage. Check fuel suction filter (1) for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. For inspection of fuel pump itself, refer to “Table B – 3 Fuel Pres- sure Check”...
Page 604 ENGINE FUEL 6C-9 CAUTION: • While removing fuel level gauge, do not contact resis- tor plate (2) or deform arm (3). It may cause fuel level gauge to fail. • When removing grommet from fuel tube or bracket sub assembly, be very careful not to cause damage to grommet installed section (sealed section in bore).
Page 605: Tightening Torque Specification
6C-10 ENGINE FUEL Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Fuel pump assembly bolt Special Tool 09919-47020 Quick joint remover...
Page 606 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 607 6E-2 ENGINE AND EMISSION CONTROL SYSTEM EGR system (If equipped)...... 6E-38 Special Tools ..........6E-42 Evaporative emission (EVAP) control Tightening Torque Specifications....6E-43 system............ 6E-39 PCV system ........... 6E-41...
Page 608: General Description
ENGINE AND EMISSION CONTROL SYSTEM 6E-3 General Description The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, IAC valve and intake manifold. Fuel delivery system includes fuel pump, delivery pipe, fuel pressure regulator, etc.
Page 609 6E-4 ENGINE AND EMISSION CONTROL SYSTEM...
Page 610: Air Intake System
ENGINE AND EMISSION CONTROL SYSTEM 6E-5 1. Air Cleaner 17. Knock sensor 31-2. Test switch terminal (vehicle w/o immobilizer indicator lamp) 2. EVAP canister purge valve 18. ECT sensor 31-3. Duty output terminal (vehicle w/o immobilizer indicator lamp) 3. IAT sensor 19.
Page 611: Fuel Delivery System
6E-6 ENGINE AND EMISSION CONTROL SYSTEM Fuel Delivery System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel pressure regulator (11), delivery pipe (9) and fuel injectors (10). The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector through the delivery pipe.
Page 612: Electronic Control System
ENGINE AND EMISSION CONTROL SYSTEM 6E-7 Electronic Control System The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 613: Engine & Emission Control Input / Output Table
6E-8 ENGINE AND EMISSION CONTROL SYSTEM Engine & emission control input / output table ELECTRIC CONTROL DEVICE OUTPUT INPUT DIAGNOSIS SWITCH TERMINAL (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP) BAROMETRIC PRESSURE SENSOR (VEHICLE WITH IMMOBILIZER INDICATOR LAMP) STOP LAMP SWITCH STARTER SWITCH IGNITION SWITCH LIGHTING SWITCH REAR DEFOGGER SWITCH (IF EQUIPPED)
Page 614 ENGINE AND EMISSION CONTROL SYSTEM 6E-9 ECM INPUT / OUTPUT CIRCUIT DIAGRAM For TYPE A (See NOTE) NOTE: Type A is other than follows. Type B is left hand steering vehicle equipped with fasten seat belt light and EGR valve or right hand steering vehicle equipped with fasten seat belt light and immobilizer control system.
Page 615 6E-10 ENGINE AND EMISSION CONTROL SYSTEM 1. CKP sensor 20. Power steering pressure switch 39. Ignition coil assembly (for No.1 and No.4 spark plugs) (if equipped) 2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs) 3.
Page 616 ENGINE AND EMISSION CONTROL SYSTEM 6E-11 For TYPE B (See NOTE) NOTE: See NOTE in “ECM INPUT / OUTPUT CIRCUIT DIAGRAM” for applicable model.
Page 617 6E-12 ENGINE AND EMISSION CONTROL SYSTEM 1. CKP sensor 20. Power steering pressure switch 39. Ignition coil assembly (for No.1 and No.4 spark plugs) (if equipped) 2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs) 3.
Page 618 ENGINE AND EMISSION CONTROL SYSTEM 6E-13 ECM TERMINAL ARRANGEMENT TABLE For TYPE A (See NOTE) CONNEC- CONNEC- TERMINAL WIRE COLOR CIRCUIT TERMINAL WIRE COLOR CIRCUIT Ground for ECM Backup power source Immobilizer indicator lamp Ground for drive circuit (if equipped) Duty output terminal (vehicle without Ground for drive circuit immobilizer indicator lamp)
Page 619 6E-14 ENGINE AND EMISSION CONTROL SYSTEM For TYPE B (See NOTE) CONNEC- CONNEC- TERMINAL WIRE COLOR CIRCUIT TERMINAL WIRE COLOR CIRCUIT Ground for ECM Backup power source Immobilizer indicator lamp Ground for drive circuit (if equipped) Duty output terminal (vehicle without Ground for drive circuit immobilizer indicator lamp) Bl/G...
Page 620: On-Vehicle Service
ENGINE AND EMISSION CONTROL SYSTEM 6E-15 On-Vehicle Service Accelerator cable adjustment 1) With throttle valve closed, check accelerator pedal play which should be within following specification. If measured value is out of specification, adjust it to specifi- cation with cable adjusting nut (1). Accelerator pedal play “a”...
Page 621 6E-16 ENGINE AND EMISSION CONTROL SYSTEM 1) Connect SUZUKI scan tool to DLC with ignition switch OFF, if it is available. 2) Warm up engine to normal operating temperature. 3) Check engine idle speed and “IAC duty” as follows: a) When using SUZUKI scan tool: i) Select “Data List”...
Page 622: Idle Mixture Inspection / Adjustment (Vehicle Without Heated Oxygen Sensor)
ENGINE AND EMISSION CONTROL SYSTEM 6E-17 Idle mixture inspection / adjustment (vehicle without heated oxygen sensor) All vehicles not equipped with heated oxygen sensor are shipped with their CO % factory adjusted as follows. Engine idle mixture (CO %) 0.5 – 1.5 % at specified idle speed Idle mixture adjustment should never be changed from the origi- nal factory setting.
Page 623: Air Intake System
6E-18 ENGINE AND EMISSION CONTROL SYSTEM Air Intake System Throttle body 1. Throttle body 4. Gasket 7. TP sensor screws 2. Throttle body gasket 5. Idle air control valve Tightening torque 3. TP sensor 6. IAC valve screws Do not reuse ON-VEHICLE INSPECTION •...
Page 624 ENGINE AND EMISSION CONTROL SYSTEM 6E-19 4) Disconnect air cleaner outlet NO.2 hose (1) from throttle body. 5) Disconnect electric connector from TP sensor (1) and IAC valve (2). 6) Remove throttle body from intake manifold. 7) Disconnect engine coolant hoses from throttle body. DISASSEMBLY NOTE: While disassembling and assembling throttle body, use...
Page 625 6E-20 ENGINE AND EMISSION CONTROL SYSTEM INSTALLATION 1) Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket. 2) Connect engine coolant hoses. 3) Install throttle body (1) to intake manifold. 4) Connect connectors to TP sensor (2) and IAC valve (3) securely.
Page 626: Idle Air Control Valve (Iac Valve)
ENGINE AND EMISSION CONTROL SYSTEM 6E-21 Idle air control valve (IAC valve) REMOVAL 1) Remove throttle body from intake manifold referring to “Throttle Body” in this section for removal. 2) Remove IAC valve from throttle body. INSPECTION 1) Connect each connector to IAC valve (1), TP sensor and IAT sensor.
Page 627: Fuel Delivery System
6E-22 ENGINE AND EMISSION CONTROL SYSTEM Fuel Delivery System Fuel pressure inspection WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres- sure Relief Procedure”...
Page 628: Fuel Pump
ENGINE AND EMISSION CONTROL SYSTEM 6E-23 6) Start engine and warm it up to normal operating tempera- ture. 7) Measure fuel pressure at idling. If measured pressure doesn’t satisfy specification, refer to “Diagnostic Flow Table B-3” in Section 6 and check each possibly defective part.
Page 629: Fuel Pressure Regulator
6E-24 ENGINE AND EMISSION CONTROL SYSTEM 3) Fuel pressure should be felt at fuel feed hose (1) for 2 sec- onds after ignition switch ON. If fuel pressure is not felt, advance to “Diagnostic Flow Table B-3” in Section 6. REMOVAL Remove fuel tank from body according to procedure described in “Fuel Tank”...
Page 630: Fuel Injector
ENGINE AND EMISSION CONTROL SYSTEM 6E-25 INSTALLATION For installation, reverse removal procedure and note following precautions. • Use new O-ring (1). • Apply thin coat of gasoline to O-ring to facilitate installation. • Tighten fuel pressure regulator bolts to specified torque. Tightening torque Fuel pressure regulator bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Page 631 6E-26 ENGINE AND EMISSION CONTROL SYSTEM REMOVAL 1) Relieve fuel pressure according to procedure described in “Fuel Pressure Relief Procedure” in Section 6. 2) Disconnect battery negative cable at battery. 3) Disconnect fuel injector couplers and release wire harness from clamps. 4) Remove clamp bolt for fuel feed pipe and return pipe.
Page 632 6) Operate fuel pump and apply fuel pressure to injector as fol- lows: a) When using SUZUKI scan tool : i) Connect SUZUKI scan tool to DLC with ignition switch OFF. ii) Turn ignition switch ON, clear DTC and select “MISC TEST”...
Page 633 6E-28 ENGINE AND EMISSION CONTROL SYSTEM INSTALLATION For installation, reverse removal procedure and note following precautions. • Replace injector O-ring (1) with new one using care not to damage it. • Check if cushion (2) is scored or damaged. If it is, replace with new one.
Page 634: Electronic Control System
ENGINE AND EMISSION CONTROL SYSTEM 6E-29 Electronic Control System Engine control module (ECM) CAUTION: As ECM consists of precision parts, be careful not to expose it to excessive shock. REMOVAL 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “Disabling Air Bag System” in Section 10B if equipped.
Page 635: Throttle Position Sensor (Tp Sensor)
6E-30 ENGINE AND EMISSION CONTROL SYSTEM Throttle position sensor (TP sensor) INSPECTION 1) Disconnect negative cable at battery and connector from TP sensor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. If check result is not satisfactory, replace TP sensor. TP sensor resistance TERMINALS RESISTANCE...
Page 636: Intake Air Temperature Sensor (Iat Sensor)
ENGINE AND EMISSION CONTROL SYSTEM 6E-31 Intake air temperature sensor (IAT sensor) REMOVAL 1) Disconnect battery negative cable at battery. 2) Disconnect connector from IAT sensor (1). 3) Remove IAT sensor (1) from air cleaner case (2). INSPECTION Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
Page 637: Engine Coolant Temperature Sensor (Ect Sensor)
6E-32 ENGINE AND EMISSION CONTROL SYSTEM Engine coolant temperature sensor (ECT sensor) REMOVAL 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to Step 6) of “Cooling System Flush and Refill” in Section 6B. WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot.
Page 638: Heated Oxygen Sensor (Sensor-1 And Sensor-2)
ENGINE AND EMISSION CONTROL SYSTEM 6E-33 • Tighten ECT sensor (1) to specified torque. Tightening torque ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft) • Connect connector to ECT sensor (1) securely. • Refill coolant referring to “Cooling System Flush and Refill” in Section 6B.
Page 639: Camshaft Position Sensor
6E-34 ENGINE AND EMISSION CONTROL SYSTEM 1) Disconnect negative cable at battery. 2) For sensor-1, remove exhaust manifold cover (1) and dis- connect connector of heated oxygen sensor and release its wire harness from clamps. 3) For sensor-2, disconnect connector of heated oxygen sensor and release its wire harness from clamp.
Page 640: Crankshaft Position Sensor
ENGINE AND EMISSION CONTROL SYSTEM 6E-35 Crankshaft position sensor INSPECTION Check crankshaft position sensor referring to step 2 and 6 of “DTC P0335 (No.23) Flow Table” in Section 6. If malfunction is found, replace. REMOVAL 1) Disconnect negative cable at battery. 2) Remove generator drive belt, loosen pivot bolt and move generator outward.
Page 641: Vehicle Speed Sensor (Vss)
6E-36 ENGINE AND EMISSION CONTROL SYSTEM Vehicle speed sensor (VSS) INSPECTION Check vehicle speed sensor referring to step 7 of “DTC P0500 (No.16) Flow Table” in Section 6. If malfunction is found, replace. Fuel level sensor (GAUGE) INSPECTION Refer to “Fuel Meter / Fuel Gauge Unit” in Section 8. REMOVAL / INSTALLATION Refer to “Fuel Pump Assembly”...
Page 642: Fuel Cut Operation
ENGINE AND EMISSION CONTROL SYSTEM 6E-37 Fuel cut operation INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model, selector lever in “P” range), A/C is OFF and that parking brake lever is pulled all the way up.
Page 643: Output Signals Of Throttle Valve Opening And Engine Coolant Temp
Emission Control System EGR system (If equipped) SYSTEM INSPECTION (USING SUZUKI SCAN TOOL) 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and then select “DATA LIST” mode on scan tool. 3) Make sure that vehicle condition is as following.
Page 644 ENGINE AND EMISSION CONTROL SYSTEM 6E-39 REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect EGR valve connector. 3) Remove EGR pipe. 4) Remove EGR valve and gasket from cylinder head. INSPECTION 1) Check resistance between following terminals of EGR valve (1) in each pair.
Page 645 6E-40 ENGINE AND EMISSION CONTROL SYSTEM 1) Disconnect purge hose (1) from EVAP canister. 2) Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is cool and running at idle speed. 3) Connect purge hose to EVAP canister and warm up engine to normal operating temperature.
Page 646 ENGINE AND EMISSION CONTROL SYSTEM 6E-41 EVAP CANISTER INSPECTION WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful. 1) Check outside of EVAP canister visually. 2) Disconnect vacuum hoses from EVAP canister. 3) Check that there should be no restriction of flow through purge pipe (1) and air pipe (2) when air is blown (4) into tank pipe (3).
Page 647 Special Tools 09912-57610 09912-58421 09912-58432 09912-58442 Checking tool plate Checking tool set Pressure hose Pressure gauge (See NOTE “A”.) 09912-58490 09930-88530 09931-76011 3-way joint & hose Injector test lead SUZUKI scan tool Mass storage cartridge (Tech 1A) kit (See NOTE “B”.)
Page 648 ENGINE AND EMISSION CONTROL SYSTEM 6E-43 09931-76030 16/14 pin DLC cable Tech 2 kit (SUZUKI scan tool) (See NOTE “C”.) NOTE: • “A”: This kit includes the following items. 1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose & clamp, 6.
Page 649 6E-44 ENGINE AND EMISSION CONTROL SYSTEM...
Page 650 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 651: General Description
6F-2 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) General Description The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suit- able ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 652: Diagnosis
IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-3 SYSTEM WIRING DIAGRAM 1. Ignition switch 7. No.1 spark plug 2. Main relay 8. No.2 spark plug 3. Ignition coil assembly for No.1 and No.4 spark plugs 9. No.3 spark plug 4. Ignition coil assembly for No.2 and No.3 spark plugs 10.
Page 653 6F-4 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) IGNITION SYSTEM DIAGNOSTIC FLOW TABLE Step Action Was “Engine Diagnostic Flow Table” in Section 6 per- Go to Step 2. Go to “Engine Diag. formed? Flow Table” in Section Ignition Spark Test Go to Step 11. Go to Step 3.
Page 654: On-Vehicle Service
IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-5 On-Vehicle Service Ignition Spark Test 1) Disconnect all injector connectors (1) from injectors. WARNING: Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room. 2) Remove cylinder head upper cover.
Page 655: Spark Plugs
6F-6 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 5) Install high-tension cords (2) to spark plugs and ignition coil assemblies (1) while gripping each cap. CAUTION: • Never attempt to use metal conductor high-tension cords as replacing parts. • Insert each cap portion fully when installing high-ten- sion cords.
Page 656: Ignition Coil Assembly (Including Ignitor)
IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-7 4) If any abnormality is found, adjust air gap, clean with spark plug cleaner or replace them with specified new plugs. For iridium/platinum spark plugs, replace them with new plugs. Spark plug air gap “a” 1.0 –...
Page 657: Crankshaft Position Sensor (Ckp Sensor)
“Neutral” (shift selector lever to “P” range for A/T model), and set parking brake. INSPECTION 1) When using SUZUKI scan tool (1), connect SUZUKI scan tool to DLC (2) with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Start engine and warm it up to normal operating tempera- ture.
Page 658 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-9 5) Fix ignition timing to initial one as follows. a) When using SUZUKI scan tool: Select “MISC” mode on SUZUKI scan tool and fix ignition timing to initial one. b) Without using SUZUKI scan tool: (vehicle without immobi-...
Page 659: Special Tools
6F-10 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) Special Tools 09931-76011 09931-76030 Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC adapter for Tech 2 kit (SUZUKI scan tool) (See NOTE “A”.) Tech 1A Tech 1A tool) (See NOTE “B”. ) NOTE: •...
Page 660 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 661: General Description
6G-2 CRANKING SYSTEM General Description Cranking Circuit 1. Pinion drive lever 5. Plunger 9. A/T: Transmission range switch (shift lever switch) 2. Pinion & Over-running clutch 6. Magnetic switch contacts 10. Ignition & Starter switch 3. Magnetic switch 7. Pull-in coil 11.
Page 662 CRANKING SYSTEM 6G-3 Condition Possible Cause Correction Motor not running Shift lever switch is not in P or N, or not adjusted Shift in P or N, or adjust switch. (No operating sound of (A/T) magnetic switch) Battery run down Recharge battery.
Page 663: Performance Test
6G-4 CRANKING SYSTEM Condition Possible Cause Correction Starting motor does Fused contact points of magnetic switch Replace magnetic switch. not stop running Short-circuit between turns of magnetic switch coil Replace magnetic switch. (layer short-circuit) Failure of returning action in ignition switch Replace.
Page 664: On-Vehicle Service
CRANKING SYSTEM 6G-5 NO-LOAD PERFORMANCE TEST Connect battery and ammeter to starter as shown. Check that starter rotates smoothly and steadily with pinion mov- ing out. Check that ammeter indicates specified current. Specified current (No-load performance test) : 90 A MAX. at 11 V On-Vehicle Service Starting Motor 1.
Page 665 6G-6 CRANKING SYSTEM DISASSEMBLY AND REASSEMBLY NOTE: • Make sure to apply grease before assembly, where are indicated “A” in the figure below. • Spare parts have been lubricated. 1. Front housing 6. Over-running clutch 11. Magnetic switch 16. Packing 21.
Page 666: Specifications
CRANKING SYSTEM 6G-7 Specifications Voltage 12 volts Output 0.9 kW 1.2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length 12.3 mm (0.48 in.) 12.3 mm (0.48 in.) Number of pinion teeth Performance Condition Guarantee 90 A maximum 90 A maximum...
Page 667 6G-8 CRANKING SYSTEM...
Page 668: Charging System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 669: General Description
6H-2 CHARGING SYSTEM General Description Battery The battery has three major functions in the electrical system. • It is a source of electrical energy for cranking the engine. • It acts as a voltage stabilizer for the electrical system. • It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Page 670 CHARGING SYSTEM 6H-3 BUILT-IN INDICATOR (IF EQUIPPED) The battery has a built-in temperature compensated indicator in the top of the battery. This indicator is to be used with the follow- ing diagnostic procedure. When checking the indicator, make sure that the battery has a clean top. A light may be needed in some poorly-lit areas.
Page 671: Generator
6H-4 CHARGING SYSTEM When keeping battery on vehicle over a long period of time, follow instructions given below. • Weekly, start the engine and run it until it reaches normal operating temperature with engine speed of 2,000 to 3,000 rpm. Make sure all electric switches are off before storing the vehicle.
Page 672 CHARGING SYSTEM 6H-5 1. Generator with regulator assembly 3. Stator coil 5. Field coil (rotor coil) 7. Main switch 2. I.C. regulator 4. Diode 6. Charge indicator light 8. Battery 1. Pulley 5. Stator core 9. Front housing IG: Ignition terminal 2.
Page 673: Diagnosis
6H-6 CHARGING SYSTEM Diagnosis Battery COMMON CAUSES OF FAILURE A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test but fails to operate properly for no appar- ent reason, the followings are some factors that may point to the cause of trouble: •...
Page 674: Generator
CHARGING SYSTEM 6H-7 How to use the temperature-corrected state-of-charge graph Suppose your S.G. reading is 1.28 and the battery temperature is –5 °C (23 °F). Locate the intersection of the –5 °C line and the 1.28 S.G. line. The intersection is within the “A” zone (shaded area in the graph) and that means CHARGED STATE.
Page 675 6H-8 CHARGING SYSTEM UNDERCHARGED BATTERY This condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and ammeter.
Page 676: On-Vehicle Service
CHARGING SYSTEM 6H-9 2) Ground F terminal and start engine, then measure voltage at B terminal as shown in left figure. • Voltage is higher than standard value It is considered that generator itself is good but IC regulator has been damaged, replace IC regulator. •...
Page 677 6H-10 CHARGING SYSTEM WARNING: • Departure from these conditions procedure described below could result in: – Serious personal injury (particularly to eyes) or property damage from such causes as battery explo- sion, battery acid, or electrical burns. – Damage to electronic components of either vehicle. •...
Page 678: Dismounting
CHARGING SYSTEM 6H-11 Dismounting 1) Disconnect negative cable (3). 2) Disconnect positive cable (2). 3) Remove retainer (5). 4) Remove battery (1). 4. Body ground bolt Handling When handling battery, following safety precautions should be followed: • Hydrogen gas is produced by battery. A flame or spark near battery may cause the gas to ignite.
Page 679: Unit Repair Overhaul
6H-12 CHARGING SYSTEM Unit Repair Overhaul Generator Dismounting 1) Disconnect negative (–) cable (2) at battery (1). 2) Remove bolts (2) and then canister (1) together with its bracket. 3) Disconnect “B” terminal wire (3) and coupler (2) from gener- ator (1).
Page 680: Remounting
CHARGING SYSTEM 6H-13 Remounting 1) Mount generator on the generator bracket. 2) Tighten generator bolts. Tightening torque Generator pivot bolt (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft) (b) : 50 N·m (5.0 kg-m, 36.0 lb-ft) 3) Install generator (cooling fan) belt. Refer to “Water Pump Belt and Cooling Fan”...
Page 681: Inspection
6H-14 CHARGING SYSTEM Inspection Rotor 1) Using ohmmeter, check for continuity between slip rings of rotor (1). If there is no continuity, replace rotor. Standard resistance between slip rings of rotor 1.8 – 2.1 Ω Ω Ω Ω 2) Using ohmmeter, check that there is no continuity between slip ring and rotor core.
Page 682 CHARGING SYSTEM 6H-15 2) Using ohmmeter, check that there is no continuity between coil leads (2) and stator core. If there is continuity, replace stator (1). Brush and Brush Holder Check each brush for wear by measuring its length. If brush is found worn down to service limit, replace brush. Brush length “a”...
Page 683 6H-16 CHARGING SYSTEM Drive End Bearing Check that the bearing is not rough or worn. End Housing Bearing Check that the bearing is not rough or worn. When removal is necessary, use bearing puller to remove end housing bearing (1). CAUTION: Be careful not to distort cooling fan blade while applying puller.
Page 684: Specifications
CHARGING SYSTEM 6H-17 Specifications Battery 55B24R TYPE Rated capacity 36 AH/5HR, 12 Volts Electrolyte 3.1 L (6.55/5.46 US/lmp pt) Electrolyte S.G. 1.28 when fully charged at 20 °C (68 °F) 38B20R TYPE Rated capacity 28 AH/5HR, 12 Volts Electrolyte 2.1 L (4.44/3.70 US/lmp pt) Electrolyte S.G.
Page 685 6H-18 CHARGING SYSTEM...
Page 686 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS General Description ........6K-1 On-Vehicle Service ......... 6K-2 Maintenance ............6K-1 Exhaust Manifold .......... 6K-2 Exhaust Pipe..........6K-2 NOTE: Whether following parts are used in the particular vehicle or not depends on specification. Be sure to bear this in mind when performing service work.
Page 687: Exhaust Pipe
6K-2 EXHAUST SYSTEM On-Vehicle Service COMPONENTS 1. Exhaust pipe (Vehicle without TWC) 6. Gasket 11. Mounting nuts 2. Exhaust pipe (Vehicle with TWC) 7. Spring Tightening torque 3. Exhaust center pipe 8. Mounting Do not reuse. 4. Muffler 9. Oxygen sensor 5.

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Suzuki Jimny Service Manual

General Information

How to Use this Manual

Precautions

Identification Information

Warning, Caution and Information Labels

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Fasteners Information

Maintenance and Lubrication

Maintenance Schedule

Maintenance Service

Final Inspection

Recommended Fluids and Lubricants

Heater and Ventilation

General Description

Diagnosis

On Vehicle Service

Air Conditioning (Optional)

General Description

Diagnosis

Electronical Diagnosis

Refrigerant Recovery, Evacuating and Charging

On-Vehicle Service

Tightening Torque Specification

Special Tools

Required Service Materials

Steering, Suspension, Wheels and Tires

And Linkage

General Description

Diagnosis

On-Vehicle Service

Required Service Material

Special Tools

Tightening Torque Specifications

(If Equipped)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Special Tools

Required Service Materials

Steering Wheel and Column

General Description

On-Vehicle Service

Diagnosis

Checking Steering Column for Accident Damage

Special Tool

Required Service Material

Tightening Torque Specifications

Front Suspension

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Required Service Material

Special Tool

Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Required Service Materials

Special Tools

Wheels and Tires

General Description

Diagnosis

Maintenance and Minor Adjustments

On-Vehicle Service

Propeller Shafts

Brakes

General Description

Diagnosis

On-Vehicle Service

Master Cylinder

LSPV (Load Sensing Proportioning Valve) Assembly (if Equipped)

P (Proportioning) Valve

Brake Booster

Required Service Material

Tightening Torque Specifications