Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Page 5: Table Of Contents
TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Steering ............... 6-i General Information ..........0A-1 Precautions .............. 6-1 Maintenance and Lubrication ......... 0B-1 Steering General Diagnosis ........6A-1 Steering Wheel and Column ........6B-1 Engine .................
Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precaution for CAN Communication System ..00-8 Precautions for Electrical Circuit Service .... 00-9 Precautions............00-1 Air Bag Warning ..........00-11 Precautions for Vehicles Equipped with a Fastener Caution..........00-11 Supplemental Restraint (Air Bag) System ..
Page 8: Precautions
• If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 9 Precautions: 00-2 Servicing and Handling • After an air bag (inflator) module has been deployed, the surface of the air bag may WARNING contain a powdery residue. This powder consists primarily of cornstarch (used to Many of service procedures require lubricate the bag as it inflates) and by- disconnection of “A/B”...
Page 10: General Precautions
00-3 Precautions: • Even when the accident was light enough not to WARNING cause air bags to activate, be sure to inspect system parts and other related parts according to instructions • For handling and storage of a SDM, select under “Repair and Inspection Required after Accident a place where the ambient temperature in Section 8B”.
Page 11: Exhaust System
Precautions: 00-4 – Do not swallow any of these service WARNING materials. It would cause diarrhea or nausea. • Whenever raising a vehicle for service, be sure to follow the instructions under – Keep all these materials out of children’s “Vehicle Lifting Points in Section 0A”.
Page 12 “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 • When removing parts that are to be reused, be sure to...
Page 13: Warning For Wheel (With Tire) Removal
Precautions: 00-6 • After servicing fuel, oil, coolant, vacuum, exhaust or • Use care not to expose connectors and electrical brake systems, check all lines related to the system parts to water which will be a cause of a trouble. for leaks.
Page 14: Precautions In Servicing 4Wd Model
00-7 Precautions: Precautions in Servicing 4WD Model • When testing with 2-wheel chassis S6RW0C0000004 dynamometer or speedometer tester, be CAUTION sure to select 4WD system to 4WD-auto or 4WD-lock modes and use 2-wheel free • Never perform any of the following [A], [B] roller together or make the vehicle as front and [C] types of service work.
Page 15: Precautions For Catalytic Converter
Precautions: 00-8 Precautions for Catalytic Converter Precaution for CAN Communication System S6RW0C0000005 S6RW0C0000007 For vehicles equipped with a catalytic converter, use • The loose (1) in the wire harnesses twist of the CAN only unleaded gasoline and be careful not to let a large lines except around the connector (3) should be within amount of unburned gasoline enter the converter or it 100 mm (3.9 in.).
Page 16: Precautions For Electrical Circuit Service
00-9 Precautions: Precautions for Electrical Circuit Service • When connecting connectors, also hold connectors S6RW0C0000008 and put them together until they lock securely (a click • When replacing a fuse, make sure to use a fuse of the is heard). specified capacity.
Page 17 Precautions: 00-10 • Be careful not to touch the electrical terminals of parts • When connecting meter probe (2) from terminal side which use microcomputers (e.g. electronic control unit of coupler (1) because it can’t be connected from like as ECM, PCM, P/S controller, etc.). The static harness side, use extra care not to bend male electricity from your body can damage these parts.
Page 18: Air Bag Warning
They must be replaced with one only by an authorized SUZUKI dealer. Refer of the same part number or with an to “Air Bag System Components, Wiring equivalent part if replacement becomes and Connectors Location in Section 8B”...
Page 19: Repair Instructions
Precautions: 00-12 Repair Instructions Electrical Circuit Inspection Procedure 4) Using continuity check or voltage check the following S6RW0C0006001 procedure, check the wire harness for open circuit While there are various electrical circuit inspection and poor connection with its terminals. Locate methods, described here is a general method to check abnormality, if any.
Page 20 00-13 Precautions: Voltage Check Short Circuit Check (Wire Harness to Ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect negative (–) cable at battery. check can be used as circuit check. 2) Disconnect connectors at both ends of the circuit to 1) With all connectors connected and voltage applied to be checked.
Page 21: Intermittent And Poor Connection Inspection
Precautions: 00-14 Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S6RW0C0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.
Page 22 00-15 Precautions:...
Page 23: Maintenance And Lubrication
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Filter Replacement ........0B-3 Fuel Tank Inspection...........0B-3 General Description ..........0A-1 PCV Valve Inspection .........0B-3 Abbreviations ............0A-1 Fuel Evaporative Emission Control System Symbols .............. 0A-2 Inspection............0B-4 Wire Color Symbols ..........
Page 24 0A-1 General Information: General Information General Information General Description Abbreviations S6RW0C0101001 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center GEN: Generator ABS: Anti-lock Brake System GND: Ground AC: Alternating Current GPS: Global Positioning System A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HAVC: Heating, Ventilating and Air Conditioning A/F: Air Fuel Mixture Ratio HC: Hydrocarbons...
Page 25: Differential
WU-TWC: Warm Up Three Way Catalytic Converter Symbols S6RW0C0101002 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
Page 26 0A-3 General Information: There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “GRN”). The dual-colored wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of the wire (“GRN”...
Page 27 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 28: Rear Suspension
0A-5 General Information: Vehicle Lifting Points S6RW0C0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 29: Vehicle Identification Number
General Information: 0A-6 Vehicle Identification Number In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against engine front mounting S6RW0C0101006 The number is punched on the front dash panel in member (1) or rear jacking bracket (2). engine room and it is also attached on the left side of instrument panel depending on the vehicle specification.
Page 30 0A-7 General Information: Component Location Warning, Caution and Information Labels Location S6RW0C0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
Page 31 General Information: 0A-8 I6RW0C010001-02 1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM 2. Air bag label on contact coil assembly 7. Pretensioner label on seat belt retractor 3. Air bag label on passenger air bag (inflator) module 8.
Page 32: Fuel System
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S6RW0C0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S6RW0C0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
Page 33 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Fluid level (I: — — — Replace every 165,000 km (99,000 Automatic transaxle fluid Fluid change (R: miles) Fluid hose (i: — — — — — Transfer oil (4WD) (leakage, level) (I: —...
Page 34 0B-3 Maintenance and Lubrication: Severe Maintenance Maintenance Maintenance interval condition code operation Every 30,000 km (18,000 miles) or – B – – E – – H Automatic transaxle fluid 24 months Every 15,000 km (9,000 miles) or 12 months – – C D – – – – HVAC air filter (if equipped) *2 Every 45,000 km (27,000 miles) or 36 months...
Page 35 Maintenance and Lubrication: 0B-4 Fuel Evaporative Emission Control System Drive Shaft (Axle) Boots Inspection S6RW0C0206025 Inspection Check front and rear (if equipped) drive shaft boots S6RW0C0206013 referring to “Front Drive Shaft Assembly On-Vehicle Check EVAP canister and fuel vapor hose referring to Inspection in Section 3A”.
Page 36 0B-5 Maintenance and Lubrication: HVAC Air Filter (If Equipped) Inspection On automatic transaxle vehicles, try to start the engine in S6RW0C0206034 each select lever position. The starting motor should Check HVAC air filter for dirt and dust referring to “HVAC crank only in “P”...
Page 37 Maintenance and Lubrication: 0B-6 Meters and Gauge Steering Check that speedometer, odometer, fuel meter, • Check to ensure that steering wheel is free from temperature gauge, etc. are operating accurately. instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one Lights side.
Page 38 0B-7 Maintenance and Lubrication:...
Page 39 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 Troubleshooting for Communication Error with Scan Tool Using CAN......1A-29 Precautions............. 1-1 DTC Table............1A-34 Precautions for Engine.......... 1-1 Fail-Safe Table..........1A-40 Engine General Information and Scan Tool Data ..........1A-42 Visual Inspection ..........1A-47 Diagnosis ..........
Page 40 1-ii Table of Contents DTC P0171 / P0172: System Too Lean / Too DTC U0101: Lost Communication with TCM ..1A-125 Rich (Sensor-1, Bank-1) ......... 1A-81 DTC U0121: Lost Communication with ABS / DTC P0222 / P0223: Throttle Position Sensor ESP® Control Module........1A-125 (Sub) Circuit Low / High ........1A-83 DTC U0140: Lost Communication with Body DTC P0300 / P0301 / P0302 / P0303 / P0304:...
Page 41 Table of Contents 1-iii Accelerator Pedal Position (APP) Sensor Engine Assembly Removal and Installation ..1D-15 Assembly Inspection .........1C-5 Timing Chain Cover Components .....1D-19 Engine Coolant Temperature (ECT) Sensor Timing Chain Cover Removal and Installation ..1D-19 Removal and Installation........1C-6 Timing Chain Cover Cleaning and Inspection...1D-22 Engine Coolant Temperature (ECT) Sensor 2nd Timing Chain and Chain Tensioner Inspection............1C-6...
Page 42 1-iv Table of Contents Oil Pump Components ........1E-8 Fuel Tank, Cap Gasket and Fuel Line Oil Pump Removal and Installation ..... 1E-9 Inspection............1G-8 Oil Pump Disassembly and Reassembly ..1E-10 Fuel Pipe Removal and Installation....1G-9 Oil Pump Inspection .......... 1E-10 Fuel Injector On-Vehicle Inspection ....
Page 43 Table of Contents 1-v Starting Motor Components ......... 1I-5 Water Pump and Generator Drive Belt Starting Motor Inspection ........1I-6 Removal and Installation........1J-8 Generator Unit Components ....... 1J-9 Specifications............1I-9 Generator Dismounting and Remounting..1J-10 Cranking System Specifications......1I-9 Generator Components........
Page 44: Precautions
1-1 Precautions: Precautions Engine Precautions Precautions for Engine S6RW0C1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions for DTC Troubleshooting Refer to “Precautions for DTC Troubleshooting in Section 1A”.
Page 45: Engine General Information And Diagnosis
Be sure to keep it in mind during servicing the vehicle. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or CAN communication OBD generic scan tool. Before using scan tool, read its Operator’s...
Page 46: Precautions For Dtc Troubleshooting
• When measuring circuit voltage, resistance and/or the scan tool used. pulse signal at ECM connector, connect the special – SUZUKI scan tool displays DTC detected by ECM. tool to ECM and/or the ECM connectors referring to – CAN communication OBD generic scan tool “Inspection of ECM and Its Circuits”.
Page 47: Precaution On Can Troubleshooting
Engine General Information and Diagnosis: 1A-3 Precaution on CAN Troubleshooting S6RW0C1100008 CAN schematic and routing diagram : [A] : [B] : [C] I6RW0C110002-03 [A]: CAN high line (RED) [B]: CAN low line (WHT) [C]: K-line Part Name Communication with scan tool Monitor of CAN-DTC ABS control module K-line...
Page 48: General Description
Bus check with SUZUKI scan tool SUZUKI scan tool (SUZUKI-SDT) efficiently diagnoses a CAN bus malfunction by “Communication Bus Check” and “Communication Malfunction DTC” under “Bus check”.
Page 49: Engine Diagnosis General Description
• It is possible to communicate via DLC (data link For identification, refer to “Precaution on On- connector) (3) by using not only SUZUKI scan tool Board Diagnostic (OBD) System”. (SUZUKI-SDT) (2) but also CAN communication OBD generic scan tool.
Page 50 1A-6 Engine General Information and Diagnosis: Freeze Frame Data ECM stores the engine and driving conditions (in the Freeze flame data (for example) form of data as shown) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”.
Page 51: Dlc (Data Link Connector)
And it is not erased unless the power to ECM is shut off for specified time or it is cleared by SUZUKI scan tool (SUZUKI SDT) (2).) For further detail of the checking / cleaning DTC procedure, refer to “DTC Check”...
Page 52: Can Communication System Description
1A-8 Engine General Information and Diagnosis: CAN Communication System Description S6RW0C1101015 ECM (2), ABS control module (1), TCM (3), BCM (4), 4WD control module (6), combination meter (7) and keyless start control module (5) communicate control data between each control module. Communication of each control module is established by CAN (Controller Area Network) communication system.
Page 53 Engine General Information and Diagnosis: 1A-9 ECM Transmission Data Combination Keyless Start control meter control module module Engine torque signal Accelerator pedal position signal Engine speed signal Throttle position signal Driving cycle active Warm up cycle active Immobiliz er indicator light control signal MIL control signal Engine coolant...
Page 54: Air Intake System Description
1A-10 Engine General Information and Diagnosis: ECM Reception Data ABS control 4WD control module module Torque request signal Transmission actual gear position signal MIL control signal Tansmission warning lignt signal Transmission selector lever position signal Transmission oil temperature signal Vehicle speed pulse signal Receive DATA A/C switch ON signal...
Page 55: Description Of Electric Throttle Body System
Engine General Information and Diagnosis: 1A-11 Description of Electric Throttle Body System S6RW0C1101017 The Electric Throttle Body System consists of electric throttle body assembly, accelerator pedal position (APP) sensor assembly, ECM and throttle actuator control relay. Among them, assembly components are as follows. •...
Page 56: Description Of Electric Throttle Body System Calibration
1A-12 Engine General Information and Diagnosis: Description of Electric Throttle Body System Calibration S6RW0C1101018 ECM calculates controlled opening of the throttle valve on the basis of the completely closed throttle valve position of the electric throttle body system. The completely closed position data is saved in memory of ECM. However, the completely closed position of the throttle valve of the electric throttle body system (signal voltage from TP sensor when throttle is completely closed) differs one from the other depending on individual differences of the throttle valve and TP sensor.
Page 57: Electronic Control System Description
Engine General Information and Diagnosis: 1A-13 AFS- AFS+ AFH+ AFH- I7RW01110007-02 4. 0.4 V 10. Electrode 12. CPU 14. Rich 8. A/F sensor connector 11. A/F signal processing circuit 13. Lean Electronic Control System Description S6RW0C1101022 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 58 1A-14 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram I6RW0C110006-01...
Page 59 Engine General Information and Diagnosis: 1A-15 ECM Input / Output Circuit Diagram E01-56 E01-55 E01-50 BLK/RED E01-54 E01-17 E01-53 C01-45 E01-52 C01-44 E01-51 C01-53 C01-54 C01-52 RED/YEL C01-40 BLK/ORN C01-41 C01-33 C01-51 C01-1 BLU/YEL C01-36 C01-2 BLU/WHT C01-16 BLU/RED PNK/BLK C01-26 C01-17 BLU/ORN...
Page 60 1A-16 Engine General Information and Diagnosis: 6. MAF and IAT sensor 31. Throttle actuator 56. Brake light switch 7. ECT sensor 32. TP sensor 57. “STOP” fuse 8. A/C refrigerant pressure sensor 33. Fuel injector No.1 58. “IG COIL” fuse 9.
Page 61 Engine General Information and Diagnosis: 1A-17 Terminal Wire color Circuit Terminal Wire color Circuit CAN (high) communication line GRN/WHT Ignition coil No.2 (active high signal) to TCM GRN/YEL Ignition coil No.1 CKP sensor (+) YEL/GRN Starting motor signal RED/YEL CMP sensor signal Output for 5 V power source of —...
Page 62: Engine And Emission Control Input / Output Table
1A-18 Engine General Information and Diagnosis: Terminal Wire color Circuit Terminal Wire color Circuit YEL/RED Fuel level sensor signal Ground for APP sensor (main) — — APP sensor (main) signal Output for 5 V power source of — — APP sensor (main) EPS active signal (idle up RED/BLU —...
Page 63 Engine General Information and Diagnosis: 1A-19 Function Output Input • CKP sensor • MAF sensor • IAT sensor • TP sensor • ECT sensor • APP sensor • Wheel speed sensor (VSS) • A/C refrigerant pressure sensor • A/C evaporator outlet air temp. sensor •...
Page 64 1A-20 Engine General Information and Diagnosis: Function Output Input • Ignition switch • A/C switch • Blower fan selector Radiator cooling fan Radiator cooling fan relay • Wheel speed sensor (VSS) control No.1, No.2 and No.3 • ECT sensor • A/C refrigerant pressure sensor •...
Page 65 Engine General Information and Diagnosis: 1A-21 Function Output Input • Wheel speed sensor (VSS) • A/C refrigerant pressure sensor • A/C evaporator outlet air temp. sensor A/C condenser cooling A/C condenser cooling • ECT sensor fan control fan relay • A/C switch •...
Page 66: Schematic And Routing Diagram
1A-22 Engine General Information and Diagnosis: Schematic and Routing Diagram Engine and Emission Control System Diagram S6RW0C1102001 I6RW0C110008-01...
Page 67 Engine General Information and Diagnosis: 1A-23 1. Air cleaner 15. HO2S 29. Throttle actuator control relay 2. MAF and IAT sensor 16. Warm-up three way catalytic converter 30. Radiator cooling fan relay 3. TP sensor 17. Three way catalytic converter 31.
Page 68: Component Location
1A-24 Engine General Information and Diagnosis: Component Location Electronic Control System Components Location S6RW0C1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C110009-02 Information sensors Control devices Others 1.
Page 69: Diagnostic Information And Procedures
Engine General Information and Diagnosis: 1A-25 Diagnostic Information and Procedures Engine and Emission Control System Check S6RW0C1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Page 70 1A-26 Engine General Information and Diagnosis: Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition?
Page 71 Engine General Information and Diagnosis: 1A-27 Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 72: Malfunction Indicator Lamp (Mil) Check
1A-28 Engine General Information and Diagnosis: Step 2: DTC / Freeze Frame Data Check, Record and Step 9: Troubleshooting for DTC (See each DTC Clearance Diag. Flow) First, check DTC (including pending DTC), referring to Based on the DTC indicated in Step 6 or 7 and referring “DTC Check”.
Page 73: Dtc Check
– 4WD control module and disconnect scan tool from DLC. – HVAC control module (Auto A/C model) DTC Clearance – P/S control module S6RW0C1104004 1) With ignition switch OFF, connect CAN communication OBD generic scan tool or SUZUKI scan tool to DLC.
Page 74 1A-30 Engine General Information and Diagnosis: Wiring Diagram C06-17 G16-19 C06-7 G16-18 C01-49 C01-50 E01-4 G26-22 E01-19 G26-23 G241-9 G241-6 E08-12 G241-7 E08-1 G241-10 E08-2 E08-13 E04-2 E04-1 G04-4 G04-2 G04-3 8 7 6 5 4 3 2 1 G04-1 14 13 12 11 10 9 8 7 3938...
Page 75 Engine General Information and Diagnosis: 1A-31 Trouble area – TCM • Scan tool – ABS control module • Connector related to CAN line (included in DLC) – BCM • CAN line – Combination meter • Power or ground circuit of DLC –...
Page 76 1A-32 Engine General Information and Diagnosis: Step Action DTC Check Go to applicable Go to Step 5. troubleshooting of DTC 1) Turn ignition switch to OFF position. other than CAN-DTC. 2) Connect scan tool to DLC. 3) Check DTC in the following control modules that communicate with scan tool by K-line.
Page 77 Engine General Information and Diagnosis: 1A-33 Step Action CAN line check Go to Step 8. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect connectors of all control module communicated by CAN. 3) Check all the following CAN lines for open, short to power circuit, short to ground circuit, short to other CAN line and high resistance.
Page 78: Dtc Table
1A-34 Engine General Information and Diagnosis: DTC Table S6RW0C1104006 NOTE • There are two types of OBD system depending on the vehicle specification. For non-Euro-OBD model, refer to “Precaution on On-Board Diagnostic (OBD) System”. • For non-Euro-OBD model, some of DTC No. with delta ( ) mark in the following table can not be detected by ECM depending on vehicle specification and local regulation.
Page 79 Engine General Information and Diagnosis: 1A-35 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Throttle/Pedal Position 1 driving 1 driving Sensor/Switch “A” (Main) Output voltage of TP sensor (main) is lower than 0.3 V. *P0122 cycle cycle Circuit Low Throttle/Pedal Position 1 driving...
Page 80 1A-36 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Crankshaft Position CKP sensor signal is not detected for 2 sec. even though 1 driving 1 driving *P0335 (CKP) Sensor “A” Circuit starter is operated. cycle cycle If either of the following condition is fulfilled:...
Page 81 Engine General Information and Diagnosis: 1A-37 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Intake Manifold Tuning Monitor signal of IMT valve is different from command 1 driving Valve Control Circuit/ P0660 signal for 5 sec. cycle applicable Open Intake Manifold Tuning...
Page 82 1A-38 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Transmission error that is inconsistent between Control Module transmission data and transmission monitor (CAN bus 1 driving U0073 Communication Bus Off monitor) data is detected more than 30 times cycle applicable continuously.
Page 83 Engine General Information and Diagnosis: 1A-39 For Vehicle Equipped with A/T NOTE There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. When using CAN communication OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on CAN communication OBD generic scan tool simultaneously.
Page 84: Fail-Safe Table
1A-40 Engine General Information and Diagnosis: Fail-Safe Table S6RW0C1104007 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.
Page 85 Engine General Information and Diagnosis: 1A-41 DTC No. Detected item Fail-safe operation P0327 Knock Sensor 1 Circuit Low • ECM stops knock control. • ECM controls fuel cut at specified engine P0328 Knock Sensor 1 Circuit High speed. • ECM controls ignition timing. P0335 Crankshaft Position (CKP) Sensor “A”...
Page 86: Scan Tool Data
1A-42 Engine General Information and Diagnosis: DTC No. Detected item Fail-safe operation P2228 Barometric Pressure Circuit Low ECM controls actuators assuming that P2229 Barometric Pressure Circuit High barometric pressure is 10 1kPa (760 mmHg). Scan Tool Data S6RW0C1104008 As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values.
Page 87 Engine General Information and Diagnosis: 1A-43 Normal condition / Scan tool data Vehicle condition reference values LONG FT B1 (LONG At specified idle speed after warming up –20 – +20% TERM FUEL TRIM) TOTAL FT B1 (TOTAL At specified idle speed after warming up –35 –...
Page 88 1A-44 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values APP SENSOR 2 VOLT Ignition switch ON Accelerator pedal released 0.17 – 0.58 V (APP SENSOR (SUB) after warmed up Accelerator pedal depressed 1.65 – 2.20 V OUTPUT VOLTAGE) engine fully...
Page 89 Engine General Information and Diagnosis: 1A-45 MAF (MASS AIR FLOW RATE, g/s, lb/min.) SHORT FT B1 (SHORT TERM FUEL TRIM, %) It represents total mass of air entering intake manifold Short term fuel trim value represents short term which is measured by mass air flow sensor. corrections to the air/fuel mixture computation.
Page 90 1A-46 Engine General Information and Diagnosis: STARTER SW (STARTER SWITCH, ON / OFF) TARGET THROTTLE POSI (TARGET THROTTLE This parameter indicates condition of starting motor relay VALVE POSITION, %) output. Target Throttle Valve Position is ECM internal parameter ON: Starting motor relay is ON which indicates the ECM requested throttle valve OFF: Starting motor relay is OFF position.
Page 91: Visual Inspection
Engine General Information and Diagnosis: 1A-47 Visual Inspection S6RW0C1104009 Visually check the following parts and systems. Inspection Item Referring section Engine oil Level, leakage “Engine Oil and Filter Change in Section 0B” Engine coolant Level, leakage “Coolant Level Check in Section 1F” “Fuel Leakage Check Procedure in Section Fuel Level, leakage...
Page 92 1A-48 Engine General Information and Diagnosis: Step Action Is engine cranked? Go to Step 6. Go to “Cranking System Symptom Diagnosis in Section 1I”. Does engine start? Go to Step 7. Go to Step 9. Check idle speed Go to Step 8. Go to “Engine Symptom Diagnosis”.
Page 93: Engine Symptom Diagnosis
Engine General Information and Diagnosis: 1A-49 Engine Symptom Diagnosis S6RW0C1104011 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H”...
Page 94 1A-50 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noise – Piston, Worn piston, ring and cylinder bore “Pistons, Piston Rings, Connecting Rods and ring and cylinder noise Cylinders Inspection and Cleaning in Section 1D” NOTE Before checking mechanical noise, make...
Page 95 Engine General Information and Diagnosis: 1A-51 Condition Possible cause Correction / Reference Item Poor gasoline mileage Faulty spark plug (improper gap, heavy “Spark Plug Inspection in Section 1H” deposits and burned electrodes, etc.) High idle speed Condition “Improper engine idling or engine fails to idle”...
Page 96 1A-52 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Surge – Engine power Faulty spark plug (excess carbon “Spark Plug Inspection in Section 1H” variation under steady deposits, improper gap, burned throttle or cruise. Feels electrodes, etc.) like vehicle speeds up Variable fuel pressure “Fuel Pressure Check”...
Page 97 Engine General Information and Diagnosis: 1A-53 Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection in Section 1H” Faulty knock sensor “DTC P0327 / P0328: Knock Sensor Circuit Low / High”...
Page 98 1A-54 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection in Section 1H” (HC) emission or carbon Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) monoxide (CO) Inspection in Section 1H”...
Page 99: Mil Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)
Engine General Information and Diagnosis: 1A-55 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S6RW0C1104012 Wiring Diagram E01-4 E01-19 G241-31 G241-16 RED/BLK C01-50 C01-49 BLK/WHT E01-29 C01-15 C01-30 BLK C01-29 C01-48 BLK/ORN BLK/YEL BLK/YEL...
Page 100 1A-56 Engine General Information and Diagnosis: Troubleshooting NOTE When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action MIL power supply check Go to Step 2.
Page 101: Mil Remains On After Engine Starts
Engine General Information and Diagnosis: 1A-57 MIL Remains ON after Engine Starts S6RW0C1104013 Wiring Diagram Refer to “MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)”. Circuit Description When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point). Then, ECM being supplied with the main power, transmits indication ON signal of MIL to combination meter in order to turn MIL ON.
Page 102: Dtc P0030: Ho2S Heater Control Circuit (Sensor-1, Bank-1)
1A-58 Engine General Information and Diagnosis: DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1) S6RW0C1104014 Wiring Diagram C01-38 C01-37 BLK/WHT C01-32 C01-31 C01-39 BLK/RED C01-11 C01-47 RED/BLU 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I7RW01110088-02 A1: Signal (+) circuit of A/F sensor...
Page 103: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1, Bank-1)
Engine General Information and Diagnosis: 1A-59 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check Go to applicable DTC Go to Step 3. diag.
Page 104 1A-60 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. A/F sensor heater circuit check Go to Step 3. Repair or replace defective wiring harness 1) Disconnect connector from A/F sensor with ignition / connector.
Page 105: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2, Bank-1)
Engine General Information and Diagnosis: 1A-61 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2, Bank-1) S6RW0C1104016 Wiring Diagram Refer to “DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0037: •...
Page 106: Dtc P0101: Mass Or Volume Air Flow Circuit Range / Performance
1A-62 Engine General Information and Diagnosis: Step Action HO2S heater circuit check Go to Step 5. Repair or replace defective wiring harness 1) Disconnect connectors from ECM and check for proper / connector. terminal connection to ECM connector. 2) If connections are OK, check that HO2S heater circuit is as follows.
Page 107 Engine General Information and Diagnosis: 1A-63 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area MAF sensor signal is higher or lower than estimated range based on • Air intake system (Clog or leakage) engine speed and throttle angle for 7 sec. •...
Page 108: Dtc P0102 / P0103: Mass Or Volume Air Flow Circuit Low / High Input
1A-64 Engine General Information and Diagnosis: Step Action MAF sensor signal check Substitute a known- Replace MAF and IAT good ECM and recheck. sensor. 1) Turn ignition switch OFF position. 2) Connect connectors to MAF sensor and ECM. 3) Check MAF sensor signal voltage referring to “Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection in Section 1C”.
Page 109 Engine General Information and Diagnosis: 1A-65 Step Action MAF sensor power supply voltage check Go to Step 4. Repair or replace MAF sensor power supply 1) Disconnect connector from MAF sensor with ignition circuit. switch turned OFF. 2) Check for proper terminal connection to MAF sensor and ECM connectors.
Page 110: Dtc P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance
1A-66 Engine General Information and Diagnosis: DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance S6RW0C1104019 Wiring Diagram Refer to “DTC P0101: Mass or Volume Air Flow Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Variation of IAT sensor signal is less than 15 mV for 10 minutes even •...
Page 111 Engine General Information and Diagnosis: 1A-67 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0112: • IAT sensor and/or its circuit Circuit voltage of IAT sensor is lower than 0.15 V for 5 sec. • ECM (1 driving cycle detection logic) P0113: Circuit voltage of IAT sensor is higher than 4.85 V for 5 sec.
Page 112: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance
1A-68 Engine General Information and Diagnosis: DTC P0116: Engine Coolant Temperature Circuit Range / Performance S6RW0C1104021 Wiring Diagram LT GRN C01-24 GRY/BLU C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I7RW01110049-03 A1: ECT sensor signal circuit 1.
Page 113 Engine General Information and Diagnosis: 1A-69 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check Go to applicable DTC Go to Step 3. diag.flow.
Page 114: Dtc P0117 / P0118: Engine Coolant Temperature Circuit Low / High
1A-70 Engine General Information and Diagnosis: DTC P0117 / P0118: Engine Coolant Temperature Circuit Low / High S6RW0C1104022 Wiring Diagram Refer to “DTC P0116: Engine Coolant Temperature Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0117: •...
Page 115: Dtc P0122 / P0123: Throttle / Pedal Position Sensor / Switch "A" Circuit Low / High
Engine General Information and Diagnosis: 1A-71 Step Action ECT sensor check Substitute a known- Replace ECT sensor. good ECM and recheck. 1) Check ECT sensor for performance referring to “Engine Coolant Temperature (ECT) Sensor Inspection in Section 1C”. Is it in good condition? DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch “A”...
Page 116 1A-72 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0122: • Electric throttle body assembly Output voltage of TP sensor (main) is lower than 0.3 V. • TP sensor main circuit (1 driving cycle detection logic) •...
Page 117 Engine General Information and Diagnosis: 1A-73 Step Action Wire harness check Go to Step 4. Repair or replace defective wire harness. 1) Turn ignition switch OFF position. 2) Disconnect connectors from TP sensor and ECM. 3) Check for proper terminal connection to electric throttle body assembly and ECM connectors.
Page 118: Dtc P0131 / P0132: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-1, Bank-1)
1A-74 Engine General Information and Diagnosis: DTC P0131 / P0132: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-1, Bank-1) S6RW0C1104026 Wiring Diagram Refer to “DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0131: •...
Page 119: Dtc P0133: O2 Sensor Circuit Slow Response / Performance (Sensor-1, Bank-1)
Engine General Information and Diagnosis: 1A-75 Step Action A/F sensor circuit check Replace A/F sensor and Repair or replace recheck. If this DTC is defective wire. 1) Disconnect connector from A/F sensor and ECM with detected again, ignition switch turned OFF. substitute a known- 2) Check for proper connection of each A/F sensor circuit good ECM.
Page 120 1A-76 Engine General Information and Diagnosis: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 121: Dtc P0134: O2 Sensor Circuit No Activity Detected (Sensor-1, Bank-1)
Engine General Information and Diagnosis: 1A-77 DTC P0134: O2 Sensor Circuit No Activity Detected (Sensor-1, Bank-1) S6RW0C1104028 Wiring Diagram Refer to “DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1)”. A/F Sensor Description Refer to “A/F Sensor Description”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Impedance of A/F sensor element is higher than 500 Ω...
Page 122: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2, Bank-1)
1A-78 Engine General Information and Diagnosis: Step Action A/F sensor circuit check Replace A/F sensor and Repair or replace recheck. If this DTC is defective wiring harness 1) Disconnect connector from A/F sensor with ignition detected again, / connector. switch turned OFF. substitute a known- 2) Check for proper terminal connection to A/F sensor good ECM and recheck.
Page 123 Engine General Information and Diagnosis: 1A-79 6) Repeat Step 4). 7) Keep above vehicle speed for 8 min. or more. (Throttle valve opening is kept constant in this step.) 8) Repeat Step 5). 9) Check DTC and pending DTC. DTC Troubleshooting Step Action Was “Engine and Emission Control System Check”...
Page 124: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2, Bank-1)
1A-80 Engine General Information and Diagnosis: Step Action Air intake system check Replace HO2S and Repair or replace air recheck. If this DTC is intake system. 1) Check air intake system for clog or leak. detected again, Is it OK? substitute a known- good ECM.
Page 125: Dtc P0171 / P0172: System Too Lean / Too Rich (Sensor-1, Bank-1)
Engine General Information and Diagnosis: 1A-81 Step Action HO2S heater circuit check Replace HO2S and Repair or replace recheck. If this DTC is defective wiring harness 1) Check HO2S heater circuit referring to Step 2 to 4 of detected again, / connector.
Page 126 1A-82 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Is there DTC(s) other than fuel system (DTC P0171 / P0172 Go to applicable DTC Go to Step 3.
Page 127: Dtc P0222 / P0223: Throttle Position Sensor (Sub) Circuit Low / High
Engine General Information and Diagnosis: 1A-83 DTC P0222 / P0223: Throttle Position Sensor (Sub) Circuit Low / High S6RW0C1104034 Wiring Diagram Refer to “DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit Low / High”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DCT P0222:...
Page 128 1A-84 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 4. Repair or replace defective wire harness. 1) Turn ignition switch OFF position. 2) Disconnect connectors from TP sensor and ECM. 3) Check for proper terminal connection to electric throttle body assembly and ECM connectors.
Page 129 Engine General Information and Diagnosis: 1A-85 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S6RW0C1104035 System Description ECM measure the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 130 1A-86 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Does fuel level meter indicate “E” level (empty)? Add fuel and recheck. Go to Step 3.
Page 131: Dtc P0327 / P0328: Knock Sensor Circuit Low / High
Engine General Information and Diagnosis: 1A-87 DTC P0327 / P0328: Knock Sensor Circuit Low / High S6RW0C1104036 Wiring Diagram C01-56 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I7RW01110055-02 A1: Knock sensor signal circuit 1.
Page 132: Dtc P0335: Crankshaft Position Sensor "A" Circuit
1A-88 Engine General Information and Diagnosis: Step Action Wire harness check Substitute a known- Repair or replace good ECM and recheck. defective wire harness. 1) Disconnect connector from ECM with ignition switch turned OFF. 2) Check that knock sensor signal circuit is as follows. •...
Page 133 Engine General Information and Diagnosis: 1A-89 DTC Confirmation Procedure NOTE Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • The following DTCs are not detected: DTCs related to starter relay 1) With ignition switch OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC by using scan tool.
Page 134: Dtc P0340: Camshaft Position Sensor "A" Circuit
1A-90 Engine General Information and Diagnosis: DTC P0340: Camshaft Position Sensor “A” Circuit S6RW0C1104038 Wiring Diagram BLK/WHT E01-29 C01-15 C01-30 C01-29 C01-48 BLK/ORN BLK/YEL BLK/YEL BRN/WHT E01-60 C01-58 BLK/ORN BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 RED/YEL C01-52 BLK/ORN 39 38 32 31 39 38 32 31...
Page 135 Engine General Information and Diagnosis: 1A-91 DTC Confirmation Procedure NOTE Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • The following DTCs are not detected: DTCs related to CKP sensor 1) With ignition switch OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC by using scan tool.
Page 136: Dtc P0420: Catalyst System Efficiency Below Threshold (Bank-1)
1A-92 Engine General Information and Diagnosis: Step Action CMP sensor check Substitute a known- Replace CMP sensor good ECM and recheck. and/or sensor rotor. 1) Check CMP sensor and sensor rotor referring to “Camshaft Position (CMP) Sensor Inspection in Section 1C”.
Page 137 Engine General Information and Diagnosis: 1A-93 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during testing to avoid occurrence of an accident. •...
Page 138: Dtc P0443: Evap Emission System Purge Control Valve Circuit
1A-94 Engine General Information and Diagnosis: DTC P0443: EVAP Emission System Purge Control Valve Circuit S6RW0C1104041 Wiring Diagram BLK/WHT E01-29 C01-15 C01-30 C01-29 C01-48 BLK/ORN BLK/YEL BLK/YEL BRN/WHT E01-60 C01-58 BLK/ORN BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 C01-13 BLU/BLK 39 38 32 31 39 38...
Page 139 Engine General Information and Diagnosis: 1A-95 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. EVAP canister purge valve power supply voltage check Go to Step 3. Repair or replace EVAP canister purge valve 1) Disconnect connector from EVAP canister purge valve...
Page 140: Dtc P0462 / P0463: Fuel Level Sensor Circuit Low / High
1A-96 Engine General Information and Diagnosis: DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High S6RW0C1104045 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT BLK/YEL BLK/RED BLK/RED BLK/RED GRN/WHT E 01 -15 BLK/WHT BLK/RED 12 V YEL/RED E01-24 BLK/ORN 39 38 32 31 39 38 32 31...
Page 141 Engine General Information and Diagnosis: 1A-97 DTC Confirmation Procedure 1) With ignition switch OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC by using scan tool. 3) Start engine and run it for 10 sec. 4) Check DTC and pending DTC. DTC Troubleshooting Step Action...
Page 142: Dtc P0480: Fan 1 Control Circuit
1A-98 Engine General Information and Diagnosis: DTC P0480: Fan 1 Control Circuit S6RW0C1104046 Wiring Diagram BLK/WHT E01-29 BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED E01-1 BLK/YEL BLK/RED E01-46 LT GRN BLU/RED E01-47 BLU/BLK C01-15 BLU/WHT C01-30 C01-29 C01-48 BLK/ORN LT GRN C01-24 C01-58 BLK/ORN GRY/BLU...
Page 143 Engine General Information and Diagnosis: 1A-99 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Wire harness check Go to Step 3. Intermittent trouble. 1) Turn ignition switch to OFF position. 2) Check for proper terminal connection to radiator cooling fan relay (No.1, No.2 or No.3) and ECM connectors.
Page 144 1A-100 Engine General Information and Diagnosis: Step Action Radiator cooling fan control circuit voltage check Go to Step 6. Repair or replace power supply circuit of radiator 1) Turn ignition switch to OFF position. cooling fan relay (No.1, 2) Remove radiator cooling fan relay No.1 (1), No.2 (2) or No.2 or No.3).
Page 145: Dtc P0481: Fan 2 Control Circuit
Engine General Information and Diagnosis: 1A-101 DTC P0481: Fan 2 Control Circuit S6RW0C1104048 Wiring Diagram BLK/WHT E01-29 BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED E01-1 BLK/YEL RED/BLK E01-48 BLK/RED BLU/YEL C01-15 C01-30 E01-49 BLK/RED C01-29 C01-48 BLK/ORN BLU/YEL C01-58 BLK/ORN 39 38 32 31 39 38 32 31...
Page 146 1A-102 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Wire harness check Go to Step 3. Intermittent trouble. 1) Turn ignition switch to OFF position. 2) Check for proper terminal connection to A/C condenser cooling fan relay and ECM connectors.
Page 147: Dtc P0500: Vehicle Speed Sensor
Engine General Information and Diagnosis: 1A-103 DTC P0500: Vehicle Speed Sensor “A” S6RW0C1104050 Wiring Diagram RED/BLK E01-4 E01-19 WHT/BLK 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I7RW01110069-01 1. Front left side wheel speed sensor (VSS 1) 3.
Page 148: Dtc P0504: Brake Switch "A"/"B" Correlation 1A-104
1A-104 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Make sure that DTC of CAN communication is not detected by ECM. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 149 Engine General Information and Diagnosis: 1A-105 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area If either of the following condition is fulfilled: • Brake light switch and/or its circuit • Brake pedal switch signal (ON) and brake light switch •...
Page 150: Dtc P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit Low / High
1A-106 Engine General Information and Diagnosis: Step Action Brake switch signal circuit check Substitute a known- Repair or replace good ECM and recheck. defective wire. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Check for proper connection of each switch circuit terminal to ECM connector.
Page 151: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
Engine General Information and Diagnosis: 1A-107 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0532: • A/C refrigerant pressure sensor and/or its Output voltage of A/C refrigerant pressure sensor is lower than 0.2 circuit V for 5 sec. •...
Page 152: Dtc P0616 / P0617: Starter Relay Circuit Low / High
1A-108 Engine General Information and Diagnosis: DTC Troubleshooting Step Action DTC recheck Go to Step 2. Intermittent trouble. Check for intermittent 1) Clear DTC referring to “DTC Clearance”. referring to “Intermittent 2) Turn OFF ignition switch. and Poor Connection 3) Turn ON ignition switch and check DTC. Inspection in Section 00”.
Page 153 Engine General Information and Diagnosis: 1A-109 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area P0616: • Engine start signal circuit Starter switch signal is not detected even though engine speed is 500 rpm or • ECM more. (2 driving cycle detection logic) P0617: Starter switch signal is detected for 180 sec.
Page 154: Dtc P0660 / P0662: Intake Manifold Tuning Valve Control Circuit Open / High
1A-110 Engine General Information and Diagnosis: DTC P0660 / P0662: Intake Manifold Tuning Valve Control Circuit Open / High S6RW0C1104057 Wiring Diagram C01-42 C01-43 YEL/BLK 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I7RW01110073-04 [A]: Open A1: IMT valve control circuit (+)
Page 155: Dtc P1510: Ecm Back-Up Power Supply Malfunction
Engine General Information and Diagnosis: 1A-111 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. IMT valve control circuit check Go to Step 3. Repair or replace IMT valve control circuit.
Page 156: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance
1A-112 Engine General Information and Diagnosis: Circuit Description Battery voltage is supplied so that DTC memory, values for engine control learned by ECM, etc. are kept in ECM even when the ignition switch is turned OFF. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Backup power voltage of internal circuit is lower than specified...
Page 157: Dtc P2102: Throttle Actuator Control Motor Circuit Low
Engine General Information and Diagnosis: 1A-113 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check Go to applicable DTC Go to Step 3. diag.
Page 158 1A-114 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Throttle actuator control relay circuit check Go to Step 3. Repair or replace power supply circuit of throttle 1) Remove throttle actuator control relay with ignition...
Page 159: Dtc P2103: Throttle Actuator Control Motor Circuit High
Engine General Information and Diagnosis: 1A-115 DTC P2103: Throttle Actuator Control Motor Circuit High S6RW0C1104067 Wiring Diagram Refer to “DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit Low / High”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control relay is...
Page 160: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance
1A-116 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Electric throttle body assembly check Substitute a known- Repair or replace good ECM and recheck.
Page 161: Dtc P2122 / P2123: Throttle / Pedal Position Sensor / Switch "D" Circuit Low / High
Engine General Information and Diagnosis: 1A-117 Step Action Wire harness check Go to Step 4. Repair or replace control circuit of throttle 1) Disconnect connectors from electric throttle body actuator (+) and/or (–) is assembly and ECM with ignition switch turned OFF. open, short or high 2) Check for proper terminal connection to electric throttle resistance.
Page 162 1A-118 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P2122: • APP sensor (main) and/or its circuit Output voltage of APP sensor (main) is lower than 0.45 V for 0.5 • ECM sec.
Page 163: Dtc P2127 / P2128: Throttle / Pedal Position Sensor / Switch "E" Circuit Low / High Input . 1A-119
Engine General Information and Diagnosis: 1A-119 Step Action Wire harness check Go to Step 5. Repair or replace APP sensor (main) power 1) Turn ignition switch OFF position. supply, signal and/or 2) Disconnect connectors from APP sensor and ECM. ground circuit(s). 3) Check for proper terminal connection to APP sensor and ECM connectors.
Page 164 1A-120 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC by using scan tool. 3) Keep the accelerator pedal at idle position for 2 sec. 4) Keep the accelerator pedal at fully depressed position for 2 sec.
Page 165: Dtc P2135: Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correction
Engine General Information and Diagnosis: 1A-121 Step Action APP sensor power supply voltage check Go to Step 6. Substitute a known- good ECM and recheck. 1) Connect connectors to ECM. 2) Turn ignition switch ON position. 3) Check that circuit voltage is 5 V between APP sensor (sub) power supply terminal and vehicle body ground.
Page 166: Dtc P2138: Pedal Position Sensor (Main / Sub) Voltage Correction
1A-122 Engine General Information and Diagnosis: Step Action Wire harness check Substitute a known- Repair or replace. good ECM and recheck. 1) Check TP sensor (main and sub) circuit for condition. For TP sensor (main) circuit, refer to Step 3 of “DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch “A”...
Page 167: Dtc P2195 / P2196: O2 Sensor Signal Stuck Lean / Stuck Rich (Sensor-1, Bank-1)
Engine General Information and Diagnosis: 1A-123 Step Action Wire harness check Substitute a known- Repair or replace. good ECM and recheck. 1) Check APP sensor (main and sub) circuit for condition. For APP sensor (main) circuit, refer to Step 4 of “DTC P2122 / P2123: Throttle / Pedal Position Sensor / Switch “D”...
Page 168: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Performance / Low / High
1A-124 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check Go to applicable DTC. Go to Step 3. Is there any DTC(s)? A/F sensor circuit check Replace A/F sensor and...
Page 169: Dtc U0073: Control Module Communication Bus Off
Before troubleshooting, check to make sure that fuse, battery voltage and generator status are normal. • When performing “Communication Bus Check” using SUZUKI scan tool (SUZUKI-SDT) in each step of this troubleshooting, use the following table to determine whether the control module is in good condition or not.
Page 170 1A-126 Engine General Information and Diagnosis: Troubleshooting Step Action DTC Check Go to applicable Go to Step 2. troubleshooting of DTC 1) Turn ignition switch to OFF position. other than CAN-DTC. 2) Connect scan tool to DLC. 3) Check DTC in the following control modules. •...
Page 171 1) Turn ignition switch to OFF position. 2) Connect BCM, ECM, ABS control module and combination meter connectors. 3) Perform “Communication Bus Check” under “Bus Check” using SUZUKI-SDT with ignition switch turned Are all of BCM, ECM, ABS control module and combination meter normally displayed?
Page 172 1A-128 Engine General Information and Diagnosis: Step Action Terminating resistance check in ECM and combination Go to Step 7. Go to Step 8. meter 1) Turn ignition switch to OFF position and then disconnect negative (–) cable at battery. 2) Measure resistance between CAN High terminal (2) and CAN Low terminal (3) on DLC (1).
Page 173 “DTC C1240: 3) Perform “Communication Bus Check” under “Bus 4WD Control Module Check” on SUZUKI-SDT with ignition switch turned ON. Power Supply Circuit Malfunction in Section Are all of BCM, ECM, ABS control module, combination 3B”. If OK, substitute a...
Page 174: Inspection Of Ecm And Its Circuits
1A-130 Engine General Information and Diagnosis: Inspection of ECM and Its Circuits S6RW0C1104086 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 175 Engine General Information and Diagnosis: 1A-131 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V IG switch: ON — *0 – 0.6 V ↑↓ 10 – 14 V Output signal is active low BLU/ (“Reference C01-1 Fuel injector No.1 Engine: Idle speed after pulse.
Page 176 1A-132 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color C01-15 Ground for ECM Below 0.3 V IG switch: ON — 10 – 14 V IG switch: ON — *0 – 0.6 V ↑↓ Output signal is active low BLU/ 10 –...
Page 177 Engine General Information and Diagnosis: 1A-133 Terminal Wire Circuit Normal voltage Condition Remarks color IG switch: ON 3.3 – 3.8 V ECT: 0 °C (32 °F) IG switch: ON C01-24 LT GRN ECT sensor signal 1.38 – 1.72 V — ECT: 50 °C (122 °F) IG switch: ON 0.40 –...
Page 178 1A-134 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color IG switch: ON Engine: After warmed up 1.33 – 1.63 V Accelerator pedal: TP sensor (sub) Released C01-40 — signal IG switch: ON Engine: After warmed up 3.67 –...
Page 179 Engine General Information and Diagnosis: 1A-135 Terminal Wire Circuit Normal voltage Condition Remarks color CAN communication signal is serial CAN (low) communication signal 1.5 – 2.5 V communication line Engine: Stop pulse. Pulse signal C01-49 (“Reference (active low signal) IG switch: ON displayed with a regular waveform No.25: ”) to TCM...
Page 180 1A-136 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color BLK/ E01-1 Main power supply 10 – 14 V IG switch: ON — Power source for WHT/ E01-2 ECM internal 10 – 14 V IG switch: ON —...
Page 181 Engine General Information and Diagnosis: 1A-137 Terminal Wire Circuit Normal voltage Condition Remarks color Cruise control E01-22 LT GRN command switch 4 – 6 V IG switch: ON — signal E01-23 — — — — — YEL/ Fuel level sensor Voltage varies depends on E01-24 0 –...
Page 182 1A-138 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Output signal is pulse. *0 – 1 V Pulse frequency varies ↑ ↓ depending on engine Engine speed 8 – 14 V speed. E01-44 signal output for P/ (“Reference While engine running.
Page 183 Engine General Information and Diagnosis: 1A-139 Terminal Wire Circuit Normal voltage Condition Remarks color IG switch: ON Engine: After warmed up 0.17 – 0.58 V Accelerator pedal: APP sensor (sub) Released E01-52 — signal IG switch: ON Engine: After warmed up 1.65 –...
Page 184 1A-140 Engine General Information and Diagnosis: Reference waveform No.3 Reference waveform No.5 No.2 fuel injector signal (2) with engine idling HO2S signal (1) with engine racing Measurement CH1: “C01-52” to “C01-58” Measurement CH1: “C01-11” to “C01-39” terminal CH2: “C01-2” to “C01-58” terminal CH2: “C01-47”...
Page 185 Engine General Information and Diagnosis: 1A-141 Reference waveform No.7 Reference waveform No.9 No.3 fuel injector signal (2) with engine idling Ignition coil signal (1) with engine idling Measurement CH1: “C01-52” to “C01-58” Measurement CH1: “C01-18”, “C01-19”, “C01-20” terminal CH2: “C01-16” to “C01-58” terminal or “C01-21”...
Page 186 1A-142 Engine General Information and Diagnosis: Reference waveform No.11 Reference waveform No.13 Ignition coil No.3 signal (2) with engine idling Ignition coil No.1 signal (1) with engine idling Measurement CH1: “C01-52” to “C01-58” Measurement CH1: “C01-52” to “C01-58” terminal CH2: “C01-19” to “C01-58” terminal CH2: “C01-21”...
Page 187 Engine General Information and Diagnosis: 1A-143 Reference waveform No.15 Reference waveform No.17 A/F sensor signal with engine idling CMP sensor signal with engine idling CH1: “C01-38” to “C01-58” Measurement CH1: “C01-52” to “C01-58” Measurement CH2: “C01-37” to “C01-58” terminal CH2: “C01-51” to “C01-36” terminal CH3: “C01-32”...
Page 188 1A-144 Engine General Information and Diagnosis: Reference waveform No.19 Reference waveform No.20 Throttle actuator output signal with ignition switch turned Throttle actuator output signal with ignition switch turned Measurement CH1: “C01-45” to “C01-58” Measurement CH1: “C01-45” to “C01-58” terminal CH2: “C01-44” to “C01-58” terminal CH2: “C01-44”...
Page 189 Engine General Information and Diagnosis: 1A-145 Reference waveform No.22 Reference waveform No.24 Knock sensor signal at engine speed 4000 r/min. Ignition coil signal and fuel injector signal with engine cranking Measurement CH1: “C01-56” to “C01-58” terminal CH1: “C01-52” to “C01-58” Oscilloscope CH1: 1 V/DIV Measurement...
Page 190 1A-146 Engine General Information and Diagnosis: Reference waveform No.26 Reference waveform No.27 Ignition pulse (engine revolution) signal (2) with engine Ignition pulse (engine revolution) signal (2) with engine idling idling Measurement CH1: “C01-52” to “C01-58” Measurement CH1: “C01-52” to “C01-58” terminal CH2: “E01-44”...
Page 191 Engine General Information and Diagnosis: 1A-147 Resistance Check 1) Remove ECM from its bracket referring to “Engine Control Module (ECM) Removal and Installation in Section 1C”. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Connect special tool to ECM connectors (1) securely. NOTE Do not connect the other connector of special tool to ECM.
Page 192: Ecm Power And Ground Circuit Check
1A-148 Engine General Information and Diagnosis: ECM Power and Ground Circuit Check S6RW0C1104087 Wiring Diagram WHT/RED E01-2 BLK/WHT E01-29 C01-15 C01-30 C01-29 C01-48 BLK/ORN BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/ORN C01-58 BLK/RED BLK/RED BLK/YEL E01-1 E01-16 BLK/RED GRY/RED C01-14 RED/BLU C01-12 E01-36 E01-56 11-1...
Page 193 Engine General Information and Diagnosis: 1A-149 Circuit Description When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM. And then ECM supplies 5 V power to each sensor (A/C refrigerant pressure sensor, APP sensor and TP sensor).
Page 194 1A-150 Engine General Information and Diagnosis: Step Action Main relay circuit check Go to Step 7. Go to Step 6. 1) Connect connectors to ECM with ignition switch turned OFF. 2) Turn ignition switch to ON position. 3) Measure voltage between “E01-60” terminal of ECM connector and body ground.
Page 195: Fuel Injector Circuit Check
Engine General Information and Diagnosis: 1A-151 Step Action 10 Main relay check “BRN/WHT” wire is Replace main relay. open or high resistance 1) Check main relay referring to “Engine and Emission circuit. Control System Relay Inspection in Section 1C”. Is main relay in good condition? Sensor 5 V power source circuit check ECM power and ground Go to Step 12.
Page 196 1A-152 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Fuel injector check for operating sound...
Page 197: Fuel Pump And Its Circuit Check
Engine General Information and Diagnosis: 1A-153 Fuel Pump and Its Circuit Check S6RW0C1104089 Wiring Diagram BLK/WHT E01-29 BLK/WHT BLK/WHT E01-15 GRN/WHT BLK/YEL C01-15 C01-30 BLK/RED C01-29 C01-48 BLK/ORN C01-58 BLK/ORN E01-1 BLK/YEL BLK/RED BLK/RED BLK/RED E01-16 BLK/YEL E01-60 BRN/WHT 39 38 32 31 39 38 32 31...
Page 198 1A-154 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Fuel pump control system check for operation...
Page 199 Engine General Information and Diagnosis: 1A-155 Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 sec. after ignition switch is turned ON. Is voltage 0 – 1 V? Wire circuit check Go to Step 8.
Page 200: Fuel Pressure Check
1A-156 Engine General Information and Diagnosis: Fuel Pressure Check S6RW0C1104090 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I7RW01110038-01 1. Injector 2. Delivery pipe 3. Fuel pump 4. Fuel filter 5. Fuel pressure regulator...
Page 201 Engine General Information and Diagnosis: 1A-157 Troubleshooting NOTE Before using the following flow chart, chart check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 202: A/C Condenser Cooling Fan Control System Inspection
1A-158 Engine General Information and Diagnosis: A/C Condenser Cooling Fan Control System Inspection S6RW0C1104091 Wiring Diagram BLK/WHT E01-29 C01-15 C01-30 C01-29 C01-48 BLK/ORN BLK/YEL BLK/YEL BRN/WHT E01-60 C01-58 BLK/ORN BLK/RED E01-1 BLK/YEL E01-16 BLK/RED BLK/RED BLK/RED RED/BLK E01-48 BLU/YEL BLU/YEL BLK/RED E01-49 BLU/YEL...
Page 203 Engine General Information and Diagnosis: 1A-159 Step Action Check wire circuit Go to Step 7. Go to Step 5. 1) Disconnect A/C condenser cooling fan relay from fuse box No.2 with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “BLU/YEL”...
Page 204: A/C System Circuits Check
1A-160 Engine General Information and Diagnosis: A/C System Circuits Check S6RW0C1104092 Wiring Diagram BLK/WHT E01-29 C01-15 C01-30 C01-29 C01-48 BLK/ORN BLK/YEL BRN/WHT E01-60 BLK/ORN C01-58 12V 5V BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 BLK/RED RED/BLK E01-48 BLU/YEL BLU/YEL BLK/RED E01-49 BLU/YEL BLK/YEL BLK/WHT...
Page 205 Engine General Information and Diagnosis: 1A-161 Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. •...
Page 206 1A-162 Engine General Information and Diagnosis: Step Action A/C evaporator temperature sensor check Go to Step 10. Faulty A/C evaporator temperature sensor. 1) Check A/C evaporator temperature sensor referring to “Evaporator Temperature Sensor Inspection in Section 7B”. Is resistance within specification? 10 A/C condenser cooling fan check A/C condenser cooling Replace A/C condenser...
Page 207: Electric Load Signal Circuit Check
Engine General Information and Diagnosis: 1A-163 Electric Load Signal Circuit Check S6RW0C1104093 Wiring Diagram BLK/WHT E01-29 C01-15 C01-30 C01-29 BLK/ORN C01-48 BLK/YEL BRN/WHT E01-60 BLK/ORN C01-58 12V 5V BLK/RED E01-1 BLK/YEL E01-16 BLK/RED /BLU BLK/YEL BLU/WHT E01-35 E01-35 BLU/WHT BLK/WHT E01-19 E01-4 39 38...
Page 208 1A-164 Engine General Information and Diagnosis: Troubleshooting NOTE • Before performed troubleshooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action DTC check...
Page 209 Engine General Information and Diagnosis: 1A-165 Radiator Cooling Fan Low Speed Control System Check S6RW0C1104094 Wiring Diagram BLK/WHT E01-29 BLK/YEL BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/RED E01-1 BLK/YEL BLK/RED E01-46 LT GRN BLU/RED E01-47 BLU/BLK C01-15 BLU/WHT C01-30 C01-29 C01-48 BLK/ORN LT GRN C01-24 C01-58...
Page 210: Radiator Cooling Fan Low Speed Control
1A-166 Engine General Information and Diagnosis: Troubleshooting WARNING Keep hands, tools, and clothing away from radiator cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch at the “ON”...
Page 211: System Check
Engine General Information and Diagnosis: 1A-167 Radiator Cooling Fan High Speed Control System Check S6RW0C1104095 Wiring Diagram Refer to “Radiator Cooling Fan Low Speed Control System Check”. Troubleshooting WARNING Keep hands, tools, and clothing away from radiator cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running.
Page 212: Repair Instructions
1A-168 Engine General Information and Diagnosis: Repair Instructions Idle Speed and IAC Throttle Valve Opening 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Inspection S6RW0C1106001 Special tool Before idle speed check, make sure of the following.
Page 213: Special Tools And Equipment
(09912- 58413). 58413). 09912–58490 09933–06320 3-way joint & hose ECM check harness (120P) SUZUKI scan tool (SUZUKI- SDT) — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.
Page 214: Aux. Emission Control Devices
1B-1 Aux. Emission Control Devices: Aux. Emission Control Devices Engine Diagnostic Information and Procedures EVAP Canister Purge System Inspection S6RW0C1204003 1) Warm up engine to normal operating temperature. 2) Hoist vehicle so that all wheels rotate freely. IYSQ01124001-01 3) Set M/T in “Neutral” or A/T in “P” position and parking brake. 4) Disconnect purge hose (1) from purge valve chamber.
Page 215: Repair Instructions
Aux. Emission Control Devices: 1B-2 Repair Instructions EVAP System Components S6RW0C1206001 I6RW0C120001-01 1. EVAP canister 7. Purge hose No.1 13. Clamp 2. EVAP canister bracket 8. Purge pipe No.1 14. Vapor control hose 3. Suction hose 9. Purge pipe No.2 15.
Page 216: Evap Canister Purge Valve And Its Circuit Inspection
2) Check purge valve (2) for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. If check result is not satisfactory, check hoses, EVAP canister purge valve, wire harness and connections.
Page 217: Vacuum Passage Inspection
Aux. Emission Control Devices: 1B-4 Vacuum Passage Inspection S6RW0C1206004 Start engine and run it at idle speed. Disconnect purge hose No.3 (1) from EVAP canister purge valve (2). With finger placed against disconnected hose, check that vacuum is applied. If it is not applied, clean vacuum passage by blowing compressed air.
Page 218: Evap Canister Removal And Installation
• When installing hoses, do not apply soap, grease or • Apply sealant to thread part of PCV valve (1). oil to insertion part. “A”: Water tight sealant 99000–31250 (SUZUKI • For quick joint, push joint into pipe till joint lock clicks Bond No.1207F) and check that quick joint does not pull out without unlocking joint lock.
Page 219: Pcv Valve Inspection
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0C1208001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 220: Engine Electrical Devices
1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Repair Instructions Engine Control Module (ECM) Removal and Installation Reverse removal procedure noting the following: Installation S6RW0C1306001 • Connect connectors to ECM as follows. CAUTION a. Make sure that lock lever of ECM connector is As ECM consists of precision parts, be unlock position.
Page 221: Electric Throttle Body Assembly On-Vehicle Inspection
Engine Electrical Devices: 1C-2 Electric Throttle Body Assembly On-Vehicle Throttle Valve Operation Check Inspection 1) Remove air cleaner outlet hose. S6RW0C1306004 2) Turn OFF ignition switch. WARNING 3) Move throttle valve with finger to its full open position Never touch throttle valve with finger while and check that it moves smoothly.
Page 222 1C-3 Engine Electrical Devices: Electric Throttle Body Assembly Operation Check Throttle Position (TP) Sensor Performance Check 1) Remove air cleaner outlet hose. 1) Remove air cleaner outlet hose. 2) Turn ON ignition switch. 2) Turn OFF ignition switch. 3) Depress accelerator pedal gradually and check that 3) Disconnect connector from electric throttle body throttle valve moves smoothly until it opens fully.
Page 223: Electric Throttle Body System Calibration
Engine Electrical Devices: 1C-4 TP sensor (sub) [B]: 1.33 – 5.007 V, varying Accelerator Pedal Position (APP) Sensor according to throttle valve opening by finger Assembly On-Vehicle Inspection (Voltage should vary by about 0.032 V for each 1° S6RW0C1306006 1) Check that APP sensor assembly has been mounted valve opening) to vehicle body properly (no pinched floor carpet, etc.).
Page 224: Accelerator Pedal Position (App) Sensor Assembly Removal And Installation
1C-5 Engine Electrical Devices: Accelerator Pedal Position (APP) Sensor Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation Assembly Inspection S6RW0C1306007 S6RW0C1306008 Check APP sensor (main and sub) output voltage as the CAUTION following steps. • Do not expose APP sensor assembly to 1) For APP sensor (main), arrange 3 new 1.5 V excessive shock like a dropping it.
Page 225: Engine Coolant Temperature (Ect) Sensor Removal And Installation
Engine Electrical Devices: 1C-6 3) Measure output voltage variation while accelerator Installation pedal is released and fully depressed as the Reverse removal procedure noting the following. following graph. • Clean mating surfaces of ECT sensor and water outlet If sensor voltage is out of specified value or does not cap.
Page 226: Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
1C-7 Engine Electrical Devices: Air Fuel Ratio (A/F) Sensor On-Vehicle Air Fuel Ratio (A/F) Sensor, Heated Oxygen Inspection Sensor (HO2S) Removal and Installation S6RW0C1306011 S6RW0C1306013 Heater Removal 1) Disconnect A/F sensor connector. 2) Using ohmmeter, measure resistance of Sensor WARNING heater between terminals “V ”...
Page 227: Camshaft Position (Cmp) Sensor Removal And Installation
Engine Electrical Devices: 1C-8 Camshaft Position (CMP) Sensor Removal and Performance Check Installation 1) Remove metal particles on end face of CMP sensor, S6RW0C1306014 if any. Removal 2) Arrange 12 V battery (1) and connect its positive 1) Disconnect negative cable at battery. terminal to “Vin”...
Page 228: Crankshaft Position (Ckp) Sensor Inspection
1C-9 Engine Electrical Devices: Installation Resistance Check Reverse removal procedure noting the following. Measure resistance between “1” and “2” terminals of CKP sensor. • Apply engine oil to O-ring of sensor. • Tighten CKP sensor bolt to specified torque. CKP sensor resistance 480 –...
Page 229: Engine And Emission Control System Relay Inspection
Engine Electrical Devices: 1C-10 Engine and Emission Control System Relay Inspection S6RW0C1306019 Main, Fuel Pump, Starting Motor Control, Throttle Actuator Control and Radiator Cooling Fan Relays 1) Disconnect negative cable at battery. 2) Remove main relay (1), fuel pump relay (3), starting motor control relay (2), throttle actuator control relay I7RW01130013-01 (4) and/or radiator cooling fan relay (5) from...
Page 230: Mass Air Flow (Maf) And Intake Air Temperature (Iat) Sensor Removal And Installation
1C-11 Engine Electrical Devices: Mass Air Flow (MAF) and Intake Air Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Temperature (IAT) Sensor Inspection S6RW0C1306022 Installation S6RW0C1306021 CAUTION CAUTION Do not heat up MAF and IAT sensor more than 100 °C (212 °F).
Page 231: Imt Valve Actuator Inspection
Engine Electrical Devices: 1C-12 IMT Valve Actuator Inspection S6RW0C1306023 CAUTION Be sure not to apply battery voltage to IMT valve actuator for 10 seconds or more. 1) Connect battery positive (+) and negative (–) terminals to IMT valve actuator (1) as shown in table below.
Page 232: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine General Description Engine Construction S6RW0C1401001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double over head camshaft) valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 233: Imt (Intake Manifold Tuning) System
Engine Mechanical: 1D-2 IMT (Intake Manifold Tuning) System S6RW0C1401002 [A + B] I7RW01140002-04 [A]: IMT valve open 1. IMT valve actuator 3. Engine torque [B]: IMT valve closed 2. Intake manifold 4. Engine speed IMT (Intake manifold tuning) system varies effective length of intake pipe by opening and closing IMT valve in order to improve air volumetric efficiency.
Page 234: Diagnostic Information And Procedures
1D-3 Engine Mechanical: Diagnostic Information and Procedures Compression Check 6) Disengage clutch (to lighten starting load on engine) S6RW0C1404001 for M/T vehicle, and depress accelerator pedal all Check compression pressure on all 4 cylinders as the way to make throttle fully open. follows: 1) Warm up engine.
Page 235: Engine Vacuum Check
Engine Mechanical: 1D-4 Engine Vacuum Check 9) After checking, remove air cleaner assembly. S6RW0C1404002 10) Disconnect special tool (Vacuum gauge) from PCV The engine vacuum that develops in the intake line is a valve. good indicator of the condition of the engine. The 11) Detach blind cap from PCV valve.
Page 236 1D-5 Engine Mechanical: 5) Check valve lashes with thickness gauge (1) 2) Lift down the valve by turning crankshaft to 360°. according to the following procedure. 3) Hold tappet at that position using special tool as a) Check valve lashes of cylinder No.1. follows.
Page 237 Engine Mechanical: 1D-6 4) Turn camshaft by approximately 90° clockwise and 6) Select new shim No. (1) with a thickness as close as remove shim (3). possible to calculated value. Available new shims No. WARNING Thickness mm Thickness mm Shim No. Shim No.
Page 238: Repair Instructions
1D-7 Engine Mechanical: 10) Turn crankshaft pulley more than 4 rotations. 9) Install camshaft housing (1) and tighten bolts to specified torque. 11) Check valve clearance again. 12) After checking and adjusting all valves, install Tightening torque cylinder head cover referring to “Cylinder Head Camshaft housing bolt (a): 11 N·m (1.1 kgf-m, Cover Removal and Installation”.
Page 239: Air Cleaner Assembly Removal And Installation
Engine Mechanical: 1D-8 Air Cleaner Assembly Removal and Installation Air Cleaner Filter Removal and Installation S6RW0C1406002 S6RW0C1406003 Removal Removal 1) Open air cleaner case (1) by unhooking its clamps 1) Remove air cleaner inlet hose (2) and outlet hose. (2). 2) Disconnect MAF sensor connector (3).
Page 240: Electric Throttle Body And Intake Manifold Components
1D-9 Engine Mechanical: Electric Throttle Body and Intake Manifold Components S6RW0C1406005 I7RW01140021-03 1. Intake manifold 4. Electric throttle body assembly : Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is found, replace it with new one. 2.
Page 241: Electric Throttle Body On-Vehicle Inspection
Engine Mechanical: 1D-10 Electric Throttle Body On-Vehicle Inspection Installation S6RW0C1406006 1) Clean mating surfaces, and install new throttle body Check electric throttle body assembly referring to gasket to intake manifold. “Throttle Valve Operation Check” and “Electric Throttle 2) Install electric throttle body assembly (2) with Body Assembly Operation Check”...
Page 242: Intake Manifold Removal And Installation
1D-11 Engine Mechanical: Intake Manifold Removal and Installation Installation S6RW0C1406009 Reverse removal procedure for installation noting the followings. CAUTION • Use new intake manifold O-ring. Never disassemble intake manifold. • Install intake manifold bolts (2) and nuts (1) as shown Disassembly will spoil its original in figure.
Page 243: Imt Valve Actuator Removal And Installation
Engine Mechanical: 1D-12 IMT Valve Actuator Removal and Installation Cylinder Head Cover Removal and Installation S6RW0C1406010 S6RW0C1406012 Removal Removal 1) Disconnect negative (–) cable at battery. 1) Disconnect negative (–) cable at battery. 2) Disconnect IMT valve actuator connector. 2) Remove ignition coils referring to “Ignition Coil Assembly (Including ignitor) Removal and 3) Remove IMT valve actuator (1) and O-ring (2) from Installation in Section 1H”.
Page 244 8.0 lb-ft) by the specified procedure 4) Apply sealant “A” to cylinder head sealing surface area as shown in figure. “5”, (a) “1”, (a) “3”, (a) “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) “4”, (a) “2”, (a) “6”, (a) I5JB0A142014-01 9) Install oil level gauge (1).
Page 245: Engine Mountings Components
Engine Mechanical: 1D-14 Engine Mountings Components S6RW0C1406013 I7RW01140031-02 [A]: 2WD model 6. Engine left mounting 16. Yellow mark :Be sure to direct paint mark to forward. [B]: 4WD model 7. Engine rear mounting 17. Mounting member :Be sure to direct paint mark to forward. [C]: M/T model 8.
Page 246: Engine Assembly Removal And Installation
1D-15 Engine Mechanical: 4. Engine right mounting 14. Dynamic damper : Do not reuse. 5. Engine left mounting bracket 15. Mounting member cushion Engine Assembly Removal and Installation 14) Disconnect the following electric wires/connectors S6RW0C1406014 and each clamps. • Electric throttle body (1) Removal •...
Page 247: Front Suspension
Engine Mechanical: 1D-16 17) Disconnect right and left drive shaft joints from 16) Disconnect the following hoses. differential gear referring to “Front Drive Shaft • Brake booster hose (29) from intake manifold Assembly Removal and Installation in Section 3A”. • Radiator inlet and outlet hoses from radiator 18) Remove exhaust center pipe referring to “Exhaust •...
Page 248 1D-17 Engine Mechanical: 24) Remove engine right mounting (1), engine right Installation mounting No.1 bracket (2) and engine left mounting 1) Install clutch cover and clutch disk referring to bracket bolt and nuts(3). “Clutch Cover, Clutch Disc and Flywheel Removal and Installation in Section 5C”, if necessary (M/T model).
Page 249 Engine Mechanical: 1D-18 7) Install engine right mounting, engine right mounting 14) Install condenser cooling fan to radiator referring to No.1 bracket and engine left mounting bracket, and “Condenser Cooling Fan Removal and Installation in then tighten bolts and nuts to specified torque Section 7B”.
Page 250: Timing Chain Cover Components
1D-19 Engine Mechanical: Timing Chain Cover Components S6RW0C1406015 1207B 1217G I7RW01140039-01 1. Crankshaft pulley bolt 6. Timing chain cover bolt and nut : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) 2. Crankshaft pulley 7. Idler pulley : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.
Page 251 Engine Mechanical: 1D-20 5) Remove crankshaft pulley (1). Installation To remove crankshaft pulley, use special tools 1) Clean sealing surfaces on timing chain cover, (Steering wheel remover, Bearing puller attachment) cylinder block and cylinder head. with it as shown in figure. Remove oil, old sealant and dust from sealing surface.
Page 252 (1). Tighten bolts and nut to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) NOTE “B”: Water tight sealant 99000–31140 (SUZUKI Before installing timing chain cover, check Bond No.1207B) that pin is securely fitted. Sealant amount for timing chain cover Tightening torque “a”: 3 mm (0.12 in.)
Page 253: Timing Chain Cover Cleaning And Inspection
Engine Mechanical: 1D-22 8) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”. 9) Install oil pan. Refer to “Oil Pan and Oil Pump Strainer Removal and Installation in Section 1E” for installation. 10) Install crankshaft pulley. To lock crankshaft pulley (1), use special tool (camshaft pulley holder) as shown in figure.
Page 254: 2Nd Timing Chain And Chain Tensioner Removal And Installation
1D-23 Engine Mechanical: 2nd Timing Chain and Chain Tensioner Removal Removal and Installation 1) Remove timing chain cover. Refer to “Timing Chain S6RW0C1406019 Cover Removal and Installation” for removal. CAUTION 2) Turn crankshaft clockwise to meet the following conditions. After 2nd timing chain is removed, never turn •...
Page 255 Engine Mechanical: 1D-24 4) Remove intake and exhaust camshaft timing 4) Install 2nd timing chain by aligning yellow plate (1) of sprocket bolts (1). To remove them, fit a spanner (4) 2nd timing chain and match marks on idler sprocket. to hexagonal part (3) at the center of camshaft to hold it stationary.
Page 256 1D-25 Engine Mechanical: 6) Tighten intake and exhaust camshaft timing sprocket 10) Turn crankshaft two rotations clockwise, and then bolts (1) to specified torque. To tighten it, fit a align timing mark (1) on crankshaft and timing mark spanner (2) to hexagonal part (3) at the center of (2) on cylinder block as shown in figure.
Page 257: 2Nd Timing Chain And Chain Tensioner Inspection
Engine Mechanical: 1D-26 2nd Timing Chain and Chain Tensioner Timing Chain Check timing chain for wear or damage. Inspection S6RW0C1406020 Timing Chain Guide No.2 Check shoe (2) for wear or damage. I2RH01140077-01 Tensioner Adjuster No.2 Check shoe (1) for wear or damage and latch functions properly.
Page 258: 1St Timing Chain And Chain Tensioner Components
1D-27 Engine Mechanical: 1st Timing Chain and Chain Tensioner Components S6RW0C1406021 I5JB0A142027-01 1. 1st timing chain 6. Timing chain tensioner adjuster No.1 : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Idler sprocket 7. Timing chain guide No.1 : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft) 3.
Page 259 Engine Mechanical: 1D-28 2) Check that match mark (1) on crankshaft timing 7) Apply engine oil to sliding surface of timing chain sprocket is in match with timing mark (2) on lower tensioner (1) and then install it as shown in figure. crankcase.
Page 260: 1St Timing Chain And Chain Tensioner Inspection
1D-29 Engine Mechanical: 1st Timing Chain and Chain Tensioner 11) Apply engine oil to sliding surface of timing chain guide No.1 (1) and then install it. Inspection Tighten guide bolts to specified torque. S6RW0C1406023 Tightening torque Timing Chain Guide No.1 Timing chain guide No.1 bolt (a): 9 N·m (0.9 kgf- Check shoe for wear or damage.
Page 261: Camshafts, Tappet And Shim Components
Engine Mechanical: 1D-30 Idler Sprocket 1st Timing Chain Check teeth and bush (1) of sprocket for wear or Check timing chain for wear or damage. damage. I2RH01140077-01 Timing Chain Tensioner Adjuster No.1 Check that latch (1) and tooth surface (2) are free from damage and latch functions properly.
Page 262: Camshafts, Tappet And Shim Removal And Installation
1D-31 Engine Mechanical: Camshafts, Tappet and Shim Removal and 2) Match match mark (1) on crank timing sprocket and mating surface of cylinder block (3) and lower Installation crankcase (2) as shown in figure. S6RW0C1406025 At this time, make sure that arrow mark (4) on idler CAUTION sprocket (5) at the position as shown in figure.
Page 263: Camshaft, Tappet And Shim Inspection
Engine Mechanical: 1D-32 5) Check position of camshaft housings. 8) Install 2nd timing chain. Refer to “2nd Timing Chain Embossed marks are provided on each camshaft and Chain Tensioner Removal and Installation” for housing, indicating position and direction for installation. installation.
Page 264 1D-33 Engine Mechanical: Camshaft Journal Wear 6) Remove housing, and using scale (2) on gauging Check camshaft journals and camshaft housings for plastic envelop (1), measure gauging plastic width at pitting, scratches, wear or damage. its widest point. If any malcondition is found, replace camshaft or cylinder Journal clearance head with housing.
Page 265 Engine Mechanical: 1D-34 Wear of Tappet and Shim Oil Relief Valve Check tappet and shim for pitting, scratches, or damage. Check oil relief valve for clogging and ball for being If any malcondition is found, replace. stuck. I2RH01140111-01 I2RH0B140085-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance.
Page 266: Valves And Cylinder Head Components
1D-35 Engine Mechanical: Valves and Cylinder Head Components S6RW0C1406027 I5JB0A142039-01 1. Cylinder block 7. Valve stem seal 13. Cylinder head bolt (M6) : Be sure to tighten cylinder head bolt (M6) after securing cylinder head bolt (M10). 2. Cylinder head 8.
Page 267 Engine Mechanical: 1D-36 3) Check all around cylinder head for any other parts 5) Install cylinder head to cylinder block. required to be removed or disconnected and remove Apply engine oil to cylinder head bolts and tighten or disconnect whatever necessary. them gradually as follows.
Page 268: Valves And Cylinder Head Disassembly And Reassembly
1D-37 Engine Mechanical: Valves and Cylinder Head Disassembly and d) Tighten cylinder head bolts (M10) to 52 N⋅m (5.2 kgf-m, 38.0 lb-ft) according to numerical order in Reassembly figure. S6RW0C1406029 e) In the same manner as in step b), retighten Disassembly cylinder head bolts (M10) to 103 N⋅m (10.3 kgf- 1) When servicing cylinder head, remove intake...
Page 269 Engine Mechanical: 1D-38 3) Release special tool, and remove spring retainers Reassembly and valve springs. 1) Before installing valve guide into cylinder head, ream 4) Remove valve from combustion chamber side. guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round.
Page 270 1D-39 Engine Mechanical: 3) Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore. Special tool (A): 09916–34542 (B): 09916–37810 I2RH01140130-01 7) Install valve spring and spring retainer. Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)).
Page 271: Valves And Valve Guides Inspection
Engine Mechanical: 1D-40 Valves and Valve Guides Inspection S6RW0C1406030 Valve Guide Valve stem-to-guide clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
Page 272 1D-41 Engine Mechanical: Valve Valve head radial runout Check each valve for radial runout with a dial gauge and Visual inspection “V” block. To check runout, rotate valve slowly. If runout • Remove all carbon from valves. exceeds its limit, replace valve. •...
Page 273: Cylinder Head Inspection
Engine Mechanical: 1D-42 Cylinder Head Inspection Valve seat repair A valve seat not producing a uniform contact with its S6RW0C1406031 • Remove all carbon deposits from combustion valve or showing width of seating contact that is out of chambers. specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 274: Valve Spring Inspection
1D-43 Engine Mechanical: • Check cylinder head for cracks on intake and exhaust • Distortion of manifold seating faces: ports, combustion chambers, and head surface. Using Check seating faces of cylinder head for manifolds, a straightedge and thickness gauge, check flatness of using a straightedge and thickness gauge, in order to gasketed surface at a total of 6 locations.
Page 275: Pistons, Piston Rings, Connecting Rods And Cylinders Components
Engine Mechanical: 1D-44 Spring Squareness Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit must be replaced. Valve spring squareness Limit: 2.2 mm (0.087 in.) I2RH01140144-01...
Page 276: Pistons, Piston Rings, Connecting Rods And Cylinders Removal And Installation
1D-45 Engine Mechanical: Pistons, Piston Rings, Connecting Rods and 3) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring Cylinders Removal and Installation compressor) to compress rings. Guide connecting S6RW0C1406034 rod into place on crankshaft. Removal Using a hammer handle, tap piston head to install 1) Remove oil pump with oil pump strainer.
Page 277: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Reassembly
Engine Mechanical: 1D-46 5) Install cylinder head. Refer to “Valves and Cylinder Pistons, Piston Rings, Connecting Rods and Head Removal and Installation” for installation. Cylinders Disassembly and Reassembly S6RW0C1406035 6) Install oil pan. Refer to “Oil Pan and Oil Pump Strainer Removal and Installation in Section 1E”...
Page 278 1D-47 Engine Mechanical: Reassembly NOTE Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. 1) Each piston (1) has stamped number (2) as shown. It represents outer diameter of piston. 2) There are also painted color (3) of red or blue on cylinder block (2) as shown.
Page 279: Pistons, Piston Rings, Connecting Rods And Cylinders Inspection And Cleaning
Engine Mechanical: 1D-48 4) Install piston pin to piston (1) and connecting rod (3): 6) After installing three rings (1st, 2nd and oil rings), After applying engine oil to piston pin, piston pin distribute their end gaps as shown in figure. holes in piston and inner surface of connecting rod small end, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting...
Page 280 1D-49 Engine Mechanical: NOTE • Piston clearance: Measure cylinder bore diameter and piston diameter If any one of four cylinders has to be rebored, to find their difference which is piston clearance. rebore all four to the same next oversize. Piston clearance should be within specification as This is necessary for the sake of uniformity follows.
Page 281 Engine Mechanical: 1D-50 Piston pin Piston rings To measure end gap, insert piston ring (2) into cylinder • Check piston pin, connecting rod small end bore and bore and then measure the gap by using thickness piston bore for wear or damage, paying particular gauge (1).
Page 282 1D-51 Engine Mechanical: Connecting rod Crank pin and connecting rod bearings • Big-end side clearance: • Inspect crank pin for uneven wear or damage. Check big-end of connecting rod for side clearance, Measure crank pin for out-of-round or taper with a with rod fitted and connected to its crank pin in the micrometer.
Page 283 Engine Mechanical: 1D-52 • Connecting rod bearing clearance: e. Remove connecting rod bearing cap, and using a scale (2) on gauging plastic envelope, measure a. Before checking bearing clearance, clean bearing gauging plastic (1) width at the widest point and crank pin. (clearance).
Page 284 1D-53 Engine Mechanical: • Selection of connecting rod bearings: b. Next, check crank pin diameter. On crank web of No. 3 cylinder, four alphabets are stamped as NOTE shown in the figure. Three kinds of alphabet (“A”, “B” and “C”) •...
Page 285 Engine Mechanical: 1D-54 c. There are 5 kinds of standard bearings differing in e. Check bearing clearance with newly selected thickness. To distinguish them, they are painted in standard bearing referring to “Crank pin and the following colors at the position as indicated in connecting rod bearings: ”.
Page 286: Main Bearings, Crankshaft And Cylinder Block Components
1D-55 Engine Mechanical: Main Bearings, Crankshaft and Cylinder Block Components S6RW0C1406039 I7RW01140065-01 1. Cylinder block 10. Flywheel : Tighten 40 N⋅m (4.0 kgf-m, 29.0 lb-ft), 0 N⋅m (0 kgf-m, 0 lb-ft), 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) and 58 N⋅m (5.8 kgf-m, 42.0 lb-ft) by the specified procedure.
Page 287: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: 1D-56 8. Rear oil seal 17. Knock sensor : Apply engine oil to inside / sliding surface. 9. Check valve 18. Oil pump chain guide Main Bearings, Crankshaft and Cylinder Block 5) Remove water pump (1) and heater outlet pipe (3). Removal and Installation 6) Remove engine front mounting brackets (2).
Page 288 One of two halves of main bearing (4) has oil groove surface area as shown in figure. (3). “A”: Water tight sealant 99000–31250 (SUZUKI Install this half with oil groove to cylinder block and Bond No.1207F) another half without oil groove to lower crankcase.
Page 289 Engine Mechanical: 1D-58 c) Tighten bolts ((1) – (10)) to 40 N⋅m (4.0 kgf-m, 8) Pull out dowel pin (2) from crankshaft (1) and then 29.0 lb-ft) according to numerical order in figure. install rear oil seal (3) until it becomes flush with cylinder block surface using special tools and plastic d) In the same manner as in step c), retighten bolts hammer.
Page 290: Main Bearings, Crankshaft And Cylinder Block Inspection
1D-59 Engine Mechanical: 11) Install flywheel (drive plate for A/T). 14) Install pistons and connecting rods. Refer to Using special tool, lock flywheel or drive plate, and “Pistons, Piston Rings, Connecting Rods and tighten flywheel or drive plate bolts (1) to specified Cylinders Removal and Installation”.
Page 291 Engine Mechanical: 1D-60 Crankshaft thrust play Out-of-round and taper (uneven wear) of journals Measure this play with crankshaft set in cylinder block in An unevenly worn crankshaft journal shows up as a the normal manner, that is, with thrust bearing and lower difference in diameter at a cross section or along its crankcase installed.
Page 292 1D-61 Engine Mechanical: Selection of main bearings Main bearing clearance Check clearance by using gauging plastic according to STANDARD BEARING: the following procedure. If engine is under the following conditions, select a new standard bearing as followings and install it. 1) Remove lower crankcase.
Page 293 Engine Mechanical: 1D-62 Stamped alphabets on lower crankcase represent journal diameter marked with an arrow in figure respectively. For example, stamped alphabet “A” at No.2 journal indicates that (journal) bore diameter of No.2 journal is 61.9940 – 62.0000 mm (2.44070 – 2.44094 in.). I4RH01140048-01 1.
Page 294 1D-63 Engine Mechanical: 5) Check main bearing clearance with newly selected standard bearing referring to “Main Bearing Clearance”. If clearance still exceeds its limit, use next thicker bearing and recheck clearance. UNDERSIZE BEARING (0.25 mm): • 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted (1) in the following colors at such position as indicated in figure.
Page 295 Engine Mechanical: 1D-64 Crankshaft Position Sensor Plate Flywheel Check teeth of plate for damage. • If ring gear is damaged, cracked or worn, replace If any damage is found, replace crankshaft (1). flywheel. • If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel.
Page 296 1D-65 Engine Mechanical: Honing or reboring cylinders 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time. Oversize piston specification Size Piston diameter 83.970 – 83.990 mm (3.3059 – 3.3067 in.) O/S 0.50 84.470 –...
Page 297 Engine Mechanical: 1D-66 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Timing chain cover bolt and nut Idler pulley nut 30.5 Generator belt tensioner bolt 18.5 Crankshaft pulley bolt 15.0 108.5 Camshaft timing sprocket bolt 57.5 Timing chain tensioner adjuster No.2 bolt Timing chain tensioner adjuster No.2 nut 33.0 Timing chain tensioner nut...
Page 298: Special Tools And Equipment
1D-67 Engine Mechanical: Special Tools and Equipment Recommended Service Material S6RW0C1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140...
Page 299 Engine Mechanical: 1D-68 09916–37810 09916–38210 Valve guide reamer (6 mm) Valve guide reamer (11 mm) 09916–46020 09916–57340 Valve guide remover Valve guide installer attachment 09916–57350 09916–66510 Valve guide installer handle Tappet holder (6 mm) 09916–77310 09916–84511 Piston ring compressor (50- Forceps 125 mm) 09917–68221...
Page 300: Engine Lubrication System
1E-1 Engine Lubrication System: Engine Lubrication System Engine General Description Engine Lubrication Description S6RW0C1501001 The oil pump is trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.
Page 301: Diagnostic Information And Procedures
Engine Lubrication System: 1E-2 Diagnostic Information and Procedures Oil Pressure Check S6RW0C1504001 WARNING To avoid danger of being burned, do not touch exhaust manifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has cooled down. NOTE Prior to checking oil pressure, check the following.
Page 302: Repair Instructions
1E-3 Engine Lubrication System: Repair Instructions Engine Oil and Filter Change Before draining engine oil, check engine for oil leakage. S6RW0C1506008 If any evidence of leakage is found, make sure to correct WARNING defective part before proceeding to the following work. 1) Remove right side engine under cover.
Page 303 Engine Lubrication System: 1E-4 5) Screw new filter on oil filter stand by hand until the 8) Check oil filter and drain plug for oil leakage. filter O-ring contacts mounting surface. 9) Start engine and run it for 3 minutes. Stop it and wait another 5 minutes before checking oil level.
Page 304: Oil Pan And Oil Pump Strainer Components
1E-5 Engine Lubrication System: Oil Pan and Oil Pump Strainer Components S6RW0C1506001 1217G I7RW01150005-01 1. Oil pan 10. Clutch housing plate upper bolt : Apply sealant 99000-31260 to mating surface. : Tighten upper bolt first, then tighten lower bolt. 2. Oil pump strainer 11.
Page 305: Oil Pan And Oil Pump Strainer Removal And Installation
Engine Lubrication System: 1E-6 Oil Pan and Oil Pump Strainer Removal and 8) Cut sealant at hatched part shown in the figure using special tool and hammer (1). Installation S6RW0C1506002 Special tool (A): 09921–96510 Removal 1) Remove oil level gauge. NOTE 2) Raise vehicle.
Page 306: Oil Pan And Oil Pump Strainer Cleaning
2) Apply sealant to oil pan (1) mating surface kgf-m, 22.0 lb-ft) continuously as shown in figure. Clutch housing plate lower bolt (b): 11 N·m (1.1 “A”: Sealant 99000–31260 (SUZUKI Bond kgf-m, 8.0 lb-ft) No.1217G) Sealant amount for oil pan Width “a”: 2 mm (0.08 in.)
Page 307: Oil Pump Components
Engine Lubrication System: 1E-8 Oil Pump Components S6RW0C1506004 I7RW01150011-01 1. Cylinder block 8. Oil pump relief valve retainer 15. Baffle plate bolt (M6 bolt) 2. Oil pump relief valve set 9. Oil pump chain guide 16. Oil pump sprocket cover : Replace as a set.
Page 308: Oil Pump Removal And Installation
1E-9 Engine Lubrication System: Oil Pump Removal and Installation S6RW0C1506005 CAUTION Don’t remove sprocket and inner rotor from oil pump, otherwise damage of oil pump center shaft and abnormal operation of oil pump could result. Removal 1) Disconnect negative (–) cable at battery. I2RH01150017-01 2) Drain engine oil.
Page 309: Oil Pump Disassembly And Reassembly
Engine Lubrication System: 1E-10 Oil Pump Disassembly and Reassembly Oil Pump Inspection S6RW0C1506006 S6RW0C1506007 CAUTION Visual Inspection Don’t remove sprocket and inner rotor from • Check outer rotor (3), inner rotor and oil pump cases oil pump, otherwise damage of oil pump (1), (2) for excessive wear or damage.
Page 310: Specifications
1E-11 Engine Lubrication System: Radial Clearance Side Clearance Check radial clearance between outer rotor (2) and case Using straightedge (5) and thickness gauge (4), No.1 (1), using thickness gauge (4). measure side clearance. If clearance exceeds its limit, replace oil pump assembly. If side clearance exceeds its limit, replace oil pump assembly.
Page 311: Special Tools And Equipment
Engine Lubrication System: 1E-12 Special Tools and Equipment Recommended Service Material S6RW0C1508001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following. “Oil Pan and Oil Pump Strainer Components”...
Page 312: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System Engine General Description Cooling System • Maintain cooling system freeze protection at –36 °C (– S6RW0C1601001 33 °F) to ensure protection against corrosion and loss The cooling system consists of the radiator cap, radiator, of coolant from boiling.
Page 313: Schematic And Routing Diagram
Engine Cooling System: 1F-2 Schematic and Routing Diagram Coolant Circulation S6RW0C1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I5RW0C160001-02 1. Radiator inlet hose 3. Thermostat 5. Throttle body 7. Heater core 2. Radiator outlet hose 4.
Page 314: Diagnostic Information And Procedures
1F-3 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S6RW0C1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 315: Repair Instructions
Engine Cooling System: 1F-4 Repair Instructions Cooling System Components S6RW0C1606001 I7RW01160001-03 1. Radiator 9. Water outlet cap gasket 17. Radiator cooling fan assembly For disassembly and reassembly, refer to “Radiator Cooling Fan Disassembly and Reassembly”. 2. Reservoir 10. O-ring 18. To cylinder head 3.
Page 316: Coolant Level Check
1F-5 Engine Cooling System: Coolant Level Check NOTE S6RW0C1606002 After installing radiator cap to radiator, make WARNING sure that the ear of cap lines is parallel to radiator. To help avoid danger of being burned, do not remove radiator cap while engine and Cooling system and radiator cap holding radiator are still hot.
Page 317: Cooling System Flush And Refill
Engine Cooling System: 1F-6 Cooling System Flush and Refill 7) Remove reservoir cap (2) and reservoir (1). S6RW0C1606005 8) Pour out any fluid, scrub and clean inside of WARNING reservoir with soap and water. Flush it well with clean water and drain, Reinstall To help avoid danger of being burned, do not reservoir.
Page 318: Thermostat Removal And Installation
1F-7 Engine Cooling System: Thermostat Removal and Installation Thermostat Inspection S6RW0C1606007 S6RW0C1606008 Removal • Make sure that air bleed valve (1) of thermostat is 1) Drain coolant. clean. 2) Disconnect radiator outlet hose from thermostat cap • Check to make sure that valve seat (2) is free from (1).
Page 319: Radiator Cooling Fan Assembly Inspection
Engine Cooling System: 1F-8 Radiator Cooling Fan Assembly Inspection S6RW0C1606009 1) Check continuity between each terminals. If there is no continuity, replace radiator fan assembly. I7RW01160002-02 2) Connect battery to radiator fan motor connector as shown in figure, then check that the radiator fan motor operates smoothly, fan speed varies and that “C”...
Page 320: Radiator Cooling Fan Disassembly And Reassembly
1F-9 Engine Cooling System: Radiator On-Vehicle Inspection and Cleaning 5) Remove cooling fan mounting bolts (1). S6RW0C1606013 6) Remove radiator cooling fan assembly (2). Inspection Check radiator for leakage or damage. Straighten bent fins, if any. Cleaning Clean frontal area of radiator cores. I7RW01160006-01 Installation Reverse removal procedure for installation noting the...
Page 321: Water Pump Removal And Installation
Engine Cooling System: 1F-10 Water Pump Removal and Installation Installation S6RW0C1606015 Reverse removal procedure for installation noting the Removal following points. 1) Disconnect negative (–) cable at battery. • Use new O-ring when installing. 2) Drain coolant referring to “Cooling System Draining”. •...
Page 322: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions on Fuel System Service S6RW0C1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. •...
Page 323: General Description
Fuel System: 1G-2 General Description Fuel System Fuel Pump S6RW0C1701001 S6RW0C1701003 The fuel pump (1) is an in-tank type electric pump. CAUTION Incorporated in the pump assembly are; This engine requires the unleaded fuel only. a fuel filter (2), a fuel pressure regulator (3) and a fuel The leaded and/or low lead fuel can result in level sensor (gauge) (4).
Page 324: Schematic And Routing Diagram
1G-3 Fuel System: Schematic and Routing Diagram Fuel Delivery System Diagram S6RW0C1702001 I7RW01170002-02 1. Fuel tank 4. Delivery pipe 7. Fuel filter 2. Fuel pump assembly 5. Fuel injector 8. Fuel level sensor (gauge) 3. Fuel pressure regulator 6. Fuel feed line 9.
Page 325: Fuel Cut Operation Inspection
Fuel System: 1G-4 4) Check that battery voltage is 11 V or more. 7) Remove special tools from fuel delivery pipe and fuel feed hose. 5) Measure fuel pressure at each condition. If measured pressure is out of specification, refer to 8) Connect fuel feed hose to fuel delivery pipe and “Fuel Pressure Check in Section 1A”...
Page 326: Repair Instructions
1G-5 Fuel System: Repair Instructions Fuel System Components S6RW0C1706001 I6RW0C170001-01 1. Fuel tank 10. Fuel tank belt 20. O-ring 2. Fuel pump assembly 11. Fuel vapor line 21. Fuel pump bolt 3. Fuel tank filler hose 12. Fuel tank protector 22.
Page 327: Fuel Hose Disconnecting And Reconnecting
Fuel System: 1G-6 8. Delivery pipe bolt 18. Cushion : Do not reuse. 9. Fuel tank bolt 19. Grommet Fuel Hose Disconnecting and Reconnecting S6RW0C1706002 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk of fire and personal injury.
Page 328 1G-7 Fuel System: Clamp other than around fuel tank Quick Joint Disconnecting 1) Remove mud, dust and/or foreign material between pipe (1) and quick joint (2) by blowing compressed air. 2) Unlock joint lock by inserting special tool between pipe and quick joint. Special tool (A): 09919–47020 3) Disconnect quick joint from pipe.
Page 329: Fuel Pressure Relief Procedure
Fuel System: 1G-8 Fuel Pressure Relief Procedure Fuel Leakage Check Procedure S6RW0C1706003 S6RW0C1706004 After performing any service on fuel system, check to CAUTION make sure that there are no fuel leakages as follows. This work must not be done when engine is 1) Turn ON ignition switch for 3 seconds (to operate hot.
Page 330: Fuel Pipe Removal And Installation
1G-9 Fuel System: Fuel Pipe Removal and Installation Fuel Injector On-Vehicle Inspection S6RW0C1706006 S6RW0C1706007 1) Using sound scope (1) or such, check operating WARNING sound of injector (2) when engine is running or cranking. Before starting the following procedure, be Cycle of operating sound should vary according to sure to observe “Precautions on Fuel System engine speed.
Page 331: Fuel Injector Removal And Installation
Fuel System: 1G-10 Fuel Injector Removal and Installation Installation S6RW0C1706008 Reverse removal procedure for installation noting the following. WARNING • Replace injector O-ring (1) with new one using care Before starting the following procedure, be not to damage it. sure to observe “Precautions on Fuel System •...
Page 332: Fuel Injector Inspection
Turn fuel pump ON by using scan tool. disconnecting test lead to/from battery. Special tool 1) Relieve fuel pressure according to “Fuel Pressure (A): SUZUKI scan tool (SUZUKI-SDT) Relief Procedure” if equipped. 2) Disconnect fuel feed hose from delivery pipe. 3) Set special tools as follows.
Page 333: Fuel Filler Cap Inspection
Fuel System: 1G-12 7) Apply battery voltage to injector (1) for 15 seconds Fuel Filler Cap Inspection and measure injected fuel volume with graduated S6RW0C1706010 WARNING cylinder. Test each injector two or three times. If injected volume is out of reference value greatly, Before starting the following procedure, be replace injector.
Page 334: Fuel Tank Inlet Valve Removal And Installation
1G-13 Fuel System: Fuel Tank Inlet Valve Removal and Installation Fuel Tank Inlet Valve Inspection S6RW0C1706011 S6RW0C1706012 WARNING WARNING Before starting the following procedure, be Before starting the following procedure, be sure to observe “Precautions on Fuel System sure to observe “Precautions on Fuel System Service”...
Page 335 Fuel System: 1G-14 5) Hoist vehicle, and remove clamp (2), fuel filler hose 11) Support fuel tank (1) with jack (2) and remove its (1) and breather hose (3) from fuel filler neck. mounting bolts (3). I7RW01170014-01 I5RW0A170013-01 6) Remove EVAP canister referring to “EVAP Canister 12) Lower fuel tank a little as to disconnect wire harness Removal and Installation in Section 1B”.
Page 336 1G-15 Fuel System: Installation 4) Connect fuel filler hose (1) and breather hose (2) to filler neck (3) as shown in figure, and clamp them CAUTION securely. • When connecting joint, clean outside Tightening torque surfaces of pipe where joint is to be Fuel tank hose clamp (a): 1.5 N·m (0.15 kgf-m, inserted, push joint into pipe till joint lock 1.0 lb-ft)
Page 337: Fuel Tank Inspection
Fuel System: 1G-16 Fuel Tank Inspection Fuel Pump On-Vehicle Inspection S6RW0C1706014 S6RW0C1706016 After removing fuel tank, check hoses and pipes WARNING connected to fuel tank for leaks, loose connections, Before starting the following procedure, be deterioration or damage. Also check fuel pump sure to observe “Precautions on Fuel System assembly gaskets for leaks, visually inspect fuel tank for Service”...
Page 338: Fuel Filter Replacement
1G-17 Fuel System: Fuel Filter Replacement Installation S6RW0C1706020 CAUTION WARNING When connecting joint, clean outside surface This work must be performed in a well of pipe where joint is to be inserted, push ventilated area and away from any open joint into pipe till joint lock clicks and check flames (such as gas hot water heaters).
Page 339: Main Fuel Level Sensor Removal And Installation
Fuel System: 1G-18 Main Fuel Level Sensor Removal and Fuel Pump Inspection S6RW0C1706019 Installation • Check fuel pump assembly for damage. S6RW0C1706018 CAUTION • Check fuel suction filter for evidence of dirt and contamination. • Do not touch resister plate (1) and deform If present, replace or clean and check for presence of arm (2).
Page 340: Specifications
(09912- 58413). 58413). 09912–58490 09919–47020 3-way joint & hose Quick joint remover 09930–88530 SUZUKI scan tool (SUZUKI- SDT) Injector test lead — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.
Page 341: Ignition System
Ignition System: 1H-1 Ignition System Engine General Description Ignition System Construction S6RW0C1801001 The ignition system is an electronic (distributor less) ignition system. Especially, a direct ignition system is adopted. They consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 342: Schematic And Routing Diagram
1H-2 Ignition System: Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S6RW0C1802001 BLK/WHT GRN/YEL C01-21 GRN/WHT C01-20 BLK/WHT GRN/BLK C01-19 C01-18 BLK/WHT E01-29 C01-15 C01-30 C01-29 BLK/ORN C01-48 BLK/YEL BLK/YEL BRN/WHT E01-60 BLK/ORN C01-58 BLK/RED BLK/RED E01-1 BLK/YEL BLK/RED BLK/RED E01-16 RED/YEL...
Page 343: Component Location
Ignition System: 1H-3 Component Location Ignition System Components Location S6RW0C1803001 I7RW01180002-01 1. ECM 6. Electric throttle body assembly 11. Ignition coil assembly for No.1 2. CMP sensor 7. Knock sensor 12. Ignition coil assembly for No.2 3. CKP sensor 8. DLC 13.
Page 344 1H-4 Ignition System: Step Action Electrical connection check Go to Step 5. Connect securely. 1) Check ignition coil assemblies for electrical connection. Are they connected securely? Ignition coil assembly power supply and ground circuit Go to Step 6. Repair or replace. check 1) Check ignition coil assembly power supply and ground circuits for open and short.
Page 345: Ignition System Symptom Diagnosis
Ignition System: 1H-5 Ignition System Symptom Diagnosis S6RW0C1804002 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to start Loose connection or disconnection of Connect securely. (No spark) lead wire Faulty spark plug(s) Replace.
Page 346: Repair Instructions
1H-6 Ignition System: Repair Instructions Spark Plug Removal and Installation 4) Remove ignition coil bolts (1), and then pull out S6RW0C1806001 ignition coil assembly (2). Removal 1) Remove ignition coil assemblies referring to “Ignition Coil Assembly (Including ignitor) Removal and Installation”.
Page 347: Ignition Timing Inspection
• Ignition timing is not adjustable. If ignition Initial ignition timing timing is out of specification, check Fixed with SUZUKI scan tool: 2° – 8° BTDC (at system related parts. specified idle speed) • Before starting engine, place transmission Ignition order gear shift lever in “Neutral”...
Page 348: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S6RW0C1808001 09930–76420 SUZUKI scan tool (SUZUKI- SDT) Timing-light (dry cell type) — This kit includes following items.
Page 349: Starting System
Starting System: 1I-1 Starting System Engine Schematic and Routing Diagram Cranking System Circuit Diagram S6RW0C1902001 I4RS0A190001-01 1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch 2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery 3. Magnetic switch 8.
Page 350 1I-2 Starting System: Condition Possible cause Correction / Reference Item Motor not running (No Transmission range sensor is not in P or Shift in P or N, or adjust sensor. operating sound of N, or not adjusted (A/T model) magnetic switch) Battery run down Recharge battery.
Page 351: Cranking System Test
Starting System: 1I-3 Cranking System Test Plunger and Pinion Return Test S6RW0C1904002 Disconnect negative lead from starting motor body. CAUTION Check that plunger and pinion return inward. If plunger and pinion don’t return, replace the magnetic Each test must be performed within 3 – 5 switch.
Page 352: Repair Instructions
1I-4 Starting System: Repair Instructions Starting Motor Unit Components S6RW0C1906001 I7RW01190001-01 1. Starting motor 4. Plate 2. Magnetic switch lead wire : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3. Battery cable : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft) Starting Motor Dismounting and Remounting Remounting S6RW0C1906002 Reverse dismounting procedure for remounting noting...
Page 353: Starting Motor Components
Starting System: 1I-5 Starting Motor Components S6RW0C1906003 I7RW01190004-01 1. Front housing 7. Lever 13. Internal gear 19. Brush 2. Bush 8. Plunger 14. Planetary carrier shaft 20. Brush holder 3. Snap ring 9. Plate 15. Planetary gear 21. Rear bracket 4.
Page 354: Starting Motor Inspection
1I-6 Starting System: Starting Motor Inspection Hold-in coil open circuit test S6RW0C1906004 Check for continuity across magnetic switch “S” terminal (1) and coil case. If no continuity, coil is open and should Plunger be replaced. Inspect plunger for wear. Replace if necessary. I2RH01190011-01 Rear Bracket Bush I2RH01190008-01...
Page 355 Starting System: 1I-7 Brush Holder • Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or correct as necessary. • Check for continuity across insulated brush holder (positive side) and grounded brush holder (negative side).
Page 356 1I-8 Starting System: • Check the commutator and armature core. If there is Pinion and Over-running Clutch continuity, the armature is grounded and must be • Inspect the pinion for wear, damage or other abnormal replaced. conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction.
Page 357: Specifications
Starting System: 1I-9 Specifications Cranking System Specifications S6RW0C1907001 Voltage 12 volts Output 1.4 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.) Number of pinion teeth Performance Condition Guarantee...
Page 358: Charging System
1J-1 Charging System: Charging System Engine General Description Battery Description S6RW0C1A01001 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. •...
Page 359: Generator Description
Charging System: 1J-2 • Green Dot: Battery is sufficiently charged for testing. • Dark: Battery must be charged before testing. If there is a cranking complaint, battery should be tested as described in “Battery Inspection”. Charging and electrical systems should also be checked at this time. •...
Page 360 1J-3 Charging System: I7RW011A0006-02 1. Generator with regulator assembly 6. Charge indicator light 11. Combination meter 2. I.C. regulator 7. Main switch 12. CAN driver 3. Stator coil 8. Battery 13. IG fuse 4. Diode 9. ECM 14. METER fuse 5.
Page 361: Diagnostic Information And Procedures
Charging System: 1J-4 Diagnostic Information and Procedures Battery Inspection S6RW0C1A04001 Common Causes of Failure A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test but fails to operate properly for no apparent reason, the following are some factors that may point to the cause of trouble: •...
Page 362: Generator Test
1J-5 Charging System: Generator Test (Undercharged Battery Check) NOTE S6RW0C1A04003 Consideration should be taken that voltage This condition, as evidenced by slow cranking or will differ somewhat with regulator case indicator clear with dark or light yellow dot can be temperature as shown in figure.
Page 363: Repair Instructions
Charging System: 1J-6 Generator Test (Overcharged Battery Check) 3) If measured voltage is higher than upper limit value, S6RW0C1A04004 proceed to disassemble generator. 1) To determine battery condition, refer to “Battery 4) Check ground of brushes. If brushes are not Description”.
Page 364: Battery Dismounting And Remounting
1J-7 Charging System: 6) Start engine of vehicle with booster battery and turn Handling off electrical accessories. Then start engine of the When handling battery, the following safety precautions vehicle with discharged battery. should be followed: 7) Disconnect jumper cable in the exact reverse order. •...
Page 365: Water Pump And Generator Drive Belt On-Vehicle Inspection
Charging System: 1J-8 Water Pump and Generator Drive Belt On-Vehicle Inspection S6RW0C1A06003 • Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of these conditions are found, replace belt, referring to “Water Pump and Generator Drive Belt Removal and Installation”. •...
Page 366: Generator Unit Components
1J-9 Charging System: Installation 1) Loosen tensioner by turning the tensioner pulley (2) clockwise. 2) While holding the tensioner, install generator belt (1). 3) Install right side engine under cover. NOTE • Make sure that the belt fits each pulley’s groove properly.
Page 367: Generator Dismounting And Remounting
Charging System: 1J-10 Generator Dismounting and Remounting Remounting S6RW0C1A06006 Reverse dismounting procedure, noting the following. • Tighten each bolts and nuts to specified torque. Dismounting Tightening torque 1) Disconnect negative (–) cable at battery. “B” terminal nut (a): 5 N·m (0.5 kgf-m, 4.0 lb-ft) 2) Remove water pump and generator drive belt Generator mounting bolt (b): 25 N·m (2.5 kgf-m, 18.5 referring to “Water Pump and Generator Drive Belt...
Page 368: Generator Components
1J-11 Charging System: Generator Components S6RW0C1A06007 I4RS0B1A0007-01 1. Pulley nut 6. Drive end bearing 11. Rear housing 16. “B” terminal nut 2. Pulley 7. Bearing retainer 12. Rectifier : 118 N⋅m (11.8 kgf-m, 85.5 lb-ft) 3. Front housing 8. Rotor 13.
Page 369: Generator Inspection
Charging System: 1J-12 Generator Inspection S6RW0C1A06008 Rotor • Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
Page 370 1J-13 Charging System: Stator • Using ohmmeter, check all leads for continuity. If there is no continuity, replace stator (1). IYSQ011A0037-01 • Using ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator.
Page 371 Charging System: 1J-14 Rectifier 1) Using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace rectifier (1).
Page 372: Specifications
1J-15 Charging System: Specifications Charging System Specifications S6RW0C1A07001 Battery Battery : 55B24R (42.5AH/5HR) 12V Battery type 55B24R Rated Capacity 42.5 AH/5HR, 12 Volts Electrolyte L (US/Imp. pt) (5.92/4.93) 1.28 when fully charged at 20 °C (68 °F) Electrolyte S.G. Generator Type 80 A type Rated voltage...
Page 373: Exhaust System
Exhaust System: 1K-1 Exhaust System Engine General Description Exhaust System S6RW0C1B01001 The exhaust system consists of the exhaust manifold, exhaust No.1 pipe with WU-TWC (Warm Up Three Way Catalytic Converter), exhaust No.2 pipe and exhaust center pipe with TWC (Three Way Catalytic Converter), muffler, seal, gasket and etc.
Page 374: Repair Instructions
1K-2 Exhaust System: Repair Instructions Exhaust System Components S6RW0C1B06001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I7RW011B0001-04...
Page 375: Exhaust Manifold Removal And Installation
Exhaust System: 1K-3 [A]: View A 11. Exhaust No.2 pipe 23. Exhaust pipe No.1 stiffener bolt [B]: View B 12. Exhaust center pipe 24. Catalyst heat insulator nut 1. Exhaust manifold cover 13. Exhaust pipe clamp 25. Exhaust pipe clamp bolt 2.
Page 376: Exhaust Pipe And Muffler Removal And Installation
1K-4 Exhaust System: Installation 3) Install engine right mounting No.1 bracket and engine right mounting No.2 bracket referring to 1) Install new exhaust manifold gasket (1) to cylinder “Engine Mountings Components in Section 1D”. head. 4) Install exhaust No.1 pipe referring to “Exhaust Pipe and Muffler Removal and Installation”.
Page 377: Specifications
Exhaust System: 1K-5 Specifications Tightening Torque Specifications S6RW0C1B07001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust manifold bolt Tighten 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) by the specified procedure Exhaust manifold nut Tighten 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) by the specified procedure NOTE The specified tightening torque is also described in the following.
Page 378 1K-6 Exhaust System:...
Page 379 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Front Suspension Frame, Stabilizer Bar and/ or Bushing Removal and Installation (2WD Precautions............. 2-1 Model) .............2B-17 Precautions on Suspension ........2-1 Front Suspension Frame, Stabilizer Bar and/ Suspension General Diagnosis....2A-1 or Bushing Removal and Installation (4WD Model) .............2B-19 Diagnostic Information and Procedures....2A-1...
Page 380 2-ii Table of Contents Repair Instructions ..........2D-5 Tire Mounting and Dismounting ......2D-6 Wheel Discs Inspection........2D-5 Tire Repair ............2D-6 Tires Inspection...........2D-5 Specifications ............2D-6 Wheel Balance Inspection and Adjustment..2D-5 Wheels and Tires Specifications ......2D-6 Tire Rotation............2D-5 Tightening Torque Specifications......2D-6 Wheel (with Tire) Removal and Installation..2D-5...
Page 381: Precautions
Precautions: Precautions Suspension Precautions Precautions on Suspension S6RW0C2000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. General Precautions Refer to “General Precautions in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points in Section 0A”.
Page 382: Suspension General Diagnosis
2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S6RW0C2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tires. Tires not adequately inflated Adjust tire pressure. Broken or sagging coil springs Replace coil springs.
Page 383 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes. Faulty strut (shock absorber) or Replace strut (shock absorber) or tighten mounting mounting.
Page 384: Repair Instructions
2A-3 Suspension General Diagnosis: Repair Instructions Suspension System Inspection Wheel Bearing Inspection S6RW0C2106001 S6RW0C2106002 • Inspect front struts and rear shock absorbers for 1) Check front wheel bearing for wear, damage, evidence of oil leakage, dents or any other damage on abnormal noise or rattles.
Page 385 Suspension General Diagnosis: 2A-4 Specifications • Rear: –1° ± 1° Wheel Alignment Specifications S6RW0C2107001 Caster Toe “b” – “a” 2WD: 3° 40’ ± 2° 2WD: 4WD: 3° 34’ ± 2° • Front: IN 1 ± 1 (mm) IN 0.0393 ± 0.0393 (in.) •...
Page 386: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension General Description Front Suspension Construction S6RW0C2201001 I7RW01220002-03 1. Front strut assembly 8. Front suspension frame : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft) 2. Front drive shaft 9. Suspension control arm : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) 3.
Page 387: Front Wheel Alignment Construction
Front Suspension: 2B-2 Front Wheel Alignment Construction • Check all tires for proper inflation pressures and S6RW0C2201002 approximately the same tread wear. Among factors for front wheel alignment, only toe setting • Check for looseness of ball joints. Check tie-rod ends; can be adjusted.
Page 388 2B-3 Front Suspension: Adjustment Steering Angle Check and Adjustment When tie-rod or tie-rod end was replaced, check toe and 1) Loosen right and left tie-rod end lock nuts (1) first. then also steering angle with turning radius gauge (1). 2) Rotate right and left tie-rods (2) by the same amount If steering angle is not correct, check whether right and to align toe to specification.
Page 389: Front Strut Assembly Components
Front Suspension: 2B-4 Front Strut Assembly Components S6RW0C2206002 I7RW01220003-03 1. Front strut 6. Coil spring upper seat 11. Strut nut : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) 2. Coil spring 7. Strut bearing 12. Strut bracket bolt : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) : Insert from vehicle front side.
Page 390: Front Strut Assembly Removal And Installation
2B-5 Front Suspension: Front Strut Assembly Removal and Installation 4) Remove brake hose mounting bolt (1). Remove S6RW0C2206003 brake hose (2) from bracket and wheel speed sensor harness (3) from strut bracket as shown in figure. CAUTION 5) Remove strut bracket bolts and nuts (4). When rebound stopper and strut assembly were removed, check strut support lower nut for specified torque before installing strut...
Page 391: Front Strut Assembly Disassembly And Reassembly
Front Suspension: 2B-6 Front Strut Assembly Disassembly and • Lower hoist and vehicle in unloaded condition, tighten strut nut (b) to specified torque. Reassembly S6RW0C2206004 Tightening torque Strut nut (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Disassembly 1) Attach special tool (A) to coil spring as shown. Turn NOTE special tool bolts alternately until coil spring tension Don’t twist brake hose and wheel speed...
Page 392: Front Strut Assembly Check
2B-7 Front Suspension: 6) Install bearing (3), strut support (2) and strut support Reassembly For assembly, reverse disassembly procedure, noting lower nut (1) in this sequence. the following instructions. Tighten strut support lower nut (1) to specified torque. 1) Compress coil spring with special tool (A) until total When tightening strut support lower nut, hold stud length becomes about 280 mm (11.0 in.) as shown.
Page 393: Front Wheel Hub And Steering Knuckle Components
Front Suspension: 2B-8 • Inspect bump stopper for deterioration. If conditions of struts are in doubt, compare them with known-good vehicle or strut. If defective, replace. • Inspect bearing for wear, abnormal noise or gripping. • Inspect rebound stopper and strut mount for wear, If defective, replace.
Page 394 2B-9 Front Suspension: 8) Remove wheel speed sensor (1) from knuckle. 4) Remove caliper carrier bolts and then caliper (1) with carrier. NOTE Hang removed caliper with a wire hook or the like (3) so as to prevent brake hose (4) from bending, twisting or tension.
Page 395 Front Suspension: 2B-10 13) Remove circlip from knuckle. 14) Using hydraulic press (1) and special tool, remove wheel bearing. Special tool (A): 09913–75510 (B): 09943–37910 I7RW01220006-01 Installation For installation, reverse removal procedure, noting the following instructions. 1) Face grooved rubber seal side (1) of new wheel bearing (2) upward as shown in figure and press-fit it into knuckle (3) using special tool.
Page 396 I7RW01220007-01 CAUTION 7) Apply grease lightly to end face of inner ring (1). When drive in dust cover, be careful not to “A”: Grease 99000–25121 (SUZUKI Super deform it. Grease H) NOTE Do not apply the grease to the encoder section to avoid the encoder malfunction.
Page 397 Front Suspension: 2B-12 9) Install ball joint bolt (1), washer (2), strut bracket 13) Connect tie-rod end (1) to steering knuckle (2), bolts (4) and new nuts (3) from the direction shown tighten new nut (3) to specified torque. in figure. Tightening torque 10) Tighten suspension arm ball joint bolt (2) to specified Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
Page 398: Front Wheel Hub, Disc, Bolt And Bearing Check
2B-13 Front Suspension: Front Wheel Hub, Disc, Bolt and Bearing Check Suspension Control Arm / Bushing Removal S6RW0C2206008 and Installation • Inspect each wheel disc for dents, distortion and S6RW0C2206009 cracks. CAUTION A disc in badly damaged condition must be replaced. When removing and installing steering •...
Page 399: Suspension Control Arm / Bushing Disassembly And Assembly
Front Suspension: 2B-14 Suspension Control Arm / Bushing Installation Disassembly and Assembly 1) Install suspension control arm as shown but tighten S6RW0C2206010 suspension control arm bolts (1) only temporarily. Disassembly CAUTION 1) Cut off bushing flange (rubber) (1) with knife. Use new control arm bolt.
Page 400: Suspension Control Arm / Steering Knuckle Check
2B-15 Front Suspension: Suspension Control Arm / Steering Knuckle Assembly Check 1) Front bushing S6RW0C2206011 Press-fit front bushing (1) by using special tools and Inspect for cracks, deformation or damage. press (2). If defective, replace. Special tool (A): 09943–76310 Suspension Control Arm Bushing Check (B): 09913–75821 S6RW0C2206012 Inspect for damage, wear or deterioration.
Page 401: Front Suspension Frame, Stabilizer Bar And/Or Bushing Components
Front Suspension: 2B-16 Front Suspension Frame, Stabilizer Bar and/or Bushing Components S6RW0C2206014 I6RW0C220001-01 1. Stabilizer bar 4. Stabilizer bar mounting 7. Front suspension frame : 95 N⋅m (9.5 kgf-m, 36.5 lb-ft) bracket bolt 2. Stabilizer bushing 5. Suspension control arm 8.
Page 402: Front Suspension Frame, Stabilizer Bar And/Or Bushing Removal And Installation (2Wd Model)
2B-17 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or 11) Support front suspension frame (2) with mission jack (1). Bushing Removal and Installation (2WD Model) S6RW0C2206015 WARNING When supporting and installing front suspension frame, be sure to apply some supporting equipment (such as mission jack) at well-balanced position in the center section of front suspension frame so as to prevent from its drop.
Page 403 Front Suspension: 2B-18 Installation 3) Install steering gear case assembly to front suspension frame referring to “Steering Gear Case 1) Install stabilizer bar (1), stabilizer bushing (2) and Assembly Removal and Installation in Section 6C” or stabilizer mounting bracket (3) to front suspension “Steering Gear Case Assembly Removal and frame as shown in figure while ensuring that Installation in Section 6C”.
Page 404: Front Suspension Frame, Stabilizer Bar And/Or Bushing Removal And Installation (4Wd Model)
2B-19 Front Suspension: 6) Tighten front suspension frame bolts to specified 19) Connect negative (–) cable at battery. torque. 20) Confirm front wheel alignment referring to “Front Wheel Alignment Inspection and Adjustment”. Tightening torque Front suspension frame mounting bolt: 150 N·m Front Suspension Frame, Stabilizer Bar and/or (15.0 kgf-m, 108.5 lb-ft) Bushing Removal and Installation (4WD Model)
Page 405: Front Suspension Frame Check
Front Suspension: 2B-20 Front Suspension Frame Check Stabilizer Joint S6RW0C2206017 1) Check for smooth rotation. Inspect for cracks, deformation or damage. 2) Check damages of ball stud. If defective, replace. 3) Check damages of dust cover. NOTE Stabilizer joint (1) cannot be disassembled. If there is any damage to either parts, stabilizer joint must be replaced as a complete unit.
Page 406 2B-21 Front Suspension: Specifications Tightening Torque Specifications S6RW0C2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 32.5 Strut bracket nut 14.0 101.5 Brake hose mounting bolt 19.0 Stabilizer joint nut 36.5 Strut nut 36.5 Wheel nut 61.5 Strut support lower nut 40.0...
Page 407: Special Tools And Equipment
Front Suspension: 2B-22 Special Tools and Equipment Recommended Service Material S6RW0C2208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease H P/No.: 99000–25121 Special Tool S6RW0C2208002 09913–65810 09913–75510 Crankshaft bearing puller Bearing installer 09913–75821 09913–85230 Bearing installer attachment Bearing remover tool 09925–14520...
Page 408: Rear Suspension
2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components S6RW0C2306001 I6RW0C230004-01 F: Forward 7. Vehicle body 16. Brake dust cover [A]: 2WD model 8. Rear shock absorber 17. Rear wheel hub assembly [B]: 4WD model 9. Lower washer : 73 N⋅m (7.3 kgf-m, 53.0 lb-ft) 1.
Page 409: Rear Shock Absorber Removal And Installation
Rear Suspension: 2C-2 Rear Shock Absorber Removal and Installation Installation S6RW0C2306002 1) Install absorber upper bushes (1). Removal 1) Hoist vehicle and remove rear wheel. NOTE 2) Remove access hole cover (1) in quarter inner trim For proper installing direction of shock (2).
Page 410: Rear Shock Absorber Inspection
2C-3 Rear Suspension: Rear Shock Absorber Inspection 3) Remove floor jack from rear axle. S6RW0C2306003 4) Install rear wheel and tighten wheel nuts to specified • Inspect for deformation or damage. torque. • Inspect bushings for wear or damage. Tightening torque •...
Page 411: Rear Coil Spring Removal And Installation
Rear Suspension: 2C-4 Rear Coil Spring Removal and Installation 5) Detach each lower end (2) of shock absorbers (1) S6RW0C2306005 (right and left) from rear axle. CAUTION 6) Lower rear axle gradually as far down as the coil spring can be removed. Removal and Installation both coil springs (right and left) at the same time to avoid rear CAUTION...
Page 412: Spring Upper Seat / Spring Lower Seat Inspection
2C-5 Rear Suspension: Installation 4) Remove floor jacks from rear axle. 1) Install spring upper seat (1) to vehicle body and 5) Remount rear differential (4WD model) referring to lower seat (2) to rear axle. “Rear Differential Dismounting and Remounting in Section 3B”.
Page 413: Rear Axle Removal And Installation
Rear Suspension: 2C-6 Rear Axle Removal and Installation Installation S6RW0C2306008 CAUTION CAUTION Never reuse rear axle bolts and rear wheel Do not drop brake fluid onto painted surface. hub mounting bolts. Painted surfaces will be damaged. 1) Install brake pipes to rear axle, if removed. Removal 2) Using floor jacks, install rear axle and new rear axle 1) Hoist vehicle and remove rear wheels, exhaust...
Page 414: Rear Axle And Coil Spring Inspection
2C-7 Rear Suspension: Rear Axle Bush Inspection 6) Remount rear differential (4WD model) referring to “Rear Differential Dismounting and Remounting in S6RW0C2306010 Inspect for cracks, deformation or damage. If necessary, Section 3B”. replace rear axle assembly. 7) Install exhaust center pipe and muffler. 8) After installing removed parts, bleed air from brake Rear Wheel Disc, Bolt and Bearing Inspection system referring to “Air Bleeding of Brake System in...
Page 415: Rear Wheel Hub Assembly Removal And Installation
Rear Suspension: 2C-8 Rear Wheel Hub Assembly Removal and 6) If necessary, remove wheel stud bolts (1) with copper hammer or hydraulic press. Installation S6RW0C2306013 Removal CAUTION 1) Hoist vehicle and remove rear wheel. Never remove bolt unless replacement is 2) Remove rear drive shaft (4WD model) referring to necessary.
Page 416 2C-9 Rear Suspension: 3) Connect wheel speed sensor (3) and tighten wheel 4) Install rear brake disc and rear brake caliper speed sensor bolt (2WD model) to specified torque. assembly referring to “Rear Brake Disc Removal and Installation in Section 4C”. Tightening torque 5) Install rear drive shaft (4WD model) referring to Wheel speed sensor bolt (b): 11 N·m (1.1 kgf-m,...
Page 417: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires Suspension General Description Tires Description Lower than recommended pressure can cause: S6RW0C2401001 • Tire squeal on turns The tire is of tubeless type. The tire is designed to • Hard Steering operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation •...
Page 418: Wheels Description
2D-2 Wheels and Tires: How to Measure Wheel Runout Replacement Tires When replacement is necessary, the original equipment To measure the wheel runout, it is necessary to use an type tire should be used. Refer to the Tire Placard. accurate dial indicator. The tire may be on or off the Replacement tires should be of the same size, load wheel.
Page 419: Irregular And/Or Premature Wear Description
Wheels and Tires: 2D-3 Irregular and/or Premature Wear Description S6RW0C2401003 Irregular and premature wear has many causes. Some of them are as follows: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, tire rotation is necessary: •...
Page 420: Radial Tire Lead / Pull Description
2D-4 Wheels and Tires: Equipment manufacture’s recommendations Inflate tires to recommended pressure Road test vehicle on level unrouned road in both directions Switch front tires side to side and road test again Lead corrected, Leads reverses direction Leads in same direction if roughness results, replace tires Put tires back in original position Install a known-good tire on one front side...
Page 421 Wheels and Tires: 2D-5 Repair Instructions Wheel Discs Inspection CAUTION S6RW0C2406006 Inspect each wheel disc for dents, distortion and cracks. For vehicle equipped with ABS, using on- A disc in badly damaged condition must be replaced. vehicle balancing method with ignition switch ON may set malfunction diagnostic Tires Inspection trouble code (DTC) of ABS even when system...
Page 422 2D-6 Wheels and Tires: Tire Mounting and Dismounting Installation For installation, reverse removal procedure, noting the S6RW0C2406004 WARNING following. • Wheel nuts must be tightened in sequence and to Do not stand over tire when inflating. Bead specified torque to avoid bending wheel or brake disc may break when bead snaps over rim’s safety or drum as shown in the figure.
Page 423 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Precautions............3B-1 Precaution for Rear Differential Oil Leakage..3B-1 Precautions............. 3-1 Precautions in Diagnosing Trouble .....3B-1 Precautions on Driveline / Axle ......3-1 General Description ..........3B-2 Drive Shaft / Axle ........3A-1 Rear Differential Description .......3B-2 Coupling Description ...........3B-2 Front .................3A-1...
Page 424 3-ii Table of Contents DTC U0100: Lost Communication with ECM ..3B-26 Diagnostic Information and Procedures ....3C-1 DTC U0121: Lost Communication with ABS / Transfer Symptom Diagnosis......3C-1 ESP® Control Module........3B-26 Repair Instructions ..........3C-2 DTC U0155: Lost Communication with Transfer Oil Level Check........3C-2 Instrument Panel Cluster (IPC) Control Transfer Oil Change..........3C-2 Module ............3B-26...
Page 425: Precautions
Precautions: Precautions Driveline / Axle Precautions Precautions on Driveline / Axle S6RW0C3000001 Precaution for Rear Differential Oil Leakage Refer to “Precaution for Rear Differential Oil Leakage in Section 3B”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 3B”. Precaution on CAN Troubleshooting Refer to “Precaution on CAN Troubleshooting in Section 1A”.
Page 426: Drive Shaft / Axle
3A-1 Drive Shaft / Axle: Front Drive Shaft / Axle Driveline / Axle Front General Description Front Drive Shaft Construction S6RW0C3111001 A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. A tripod type constant velocity joint is used on the differential side and center shaft side.
Page 427: Diagnostic Information And Procedures
Drive Shaft / Axle: Front 3A-2 Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S6RW0C3114001 Condition Possible cause Correction / Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace. Worn or breakage of the center bearing Replace. Repair Instructions Front Drive Shaft Components S6RW0C3116001...
Page 428 3A-3 Drive Shaft / Axle: Front 3) Drain transaxle oil and transfer oil (4WD model). 9) Remove drive shaft assembly. 4) Disconnect tie-rod end (1) from steering knuckle (2) 10) Remove center bearing support bolts (3) and remove using puller (3). center bearing support (2) with center shaft (1) from differential side gear.
Page 429: Front Drive Shaft Disassembly And Reassembly
Drive Shaft / Axle: Front 3A-4 Front Drive Shaft Disassembly and Reassembly 2) Wipe off grease from shaft and take off snap ring (1) S6RW0C3116004 using snap ring pliers (2). Disassembly CAUTION • Disassembly of wheel side joint is not allowed.
Page 430 3A-5 Drive Shaft / Axle: Front Reassembly Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly (1) and tripod joint housing (2) are washed thoroughly and air dried.
Page 431 Drive Shaft / Axle: Front 3A-6 8) Install damper (1) to specified position on drive shaft, 12) Fit boot (1) to grooves of shaft and housing (2) adjust if equipped. length to specification below. 13) Insert screw driver into boot and allow air to enter Drive shaft damper installing position (right side) boot so that air pressure in boot becomes the same “a”: 359 mm (14.1 in.) (2WD model)
Page 432: Center Shaft And Center Bearing Support Disassembly And Reassembly (2Wd Model)
3A-7 Drive Shaft / Axle: Front Center Shaft and Center Bearing Support 15) Fasten differential side (or center shaft side) boot big band (1) and small band (5) by drawing hooks (2) Disassembly and Reassembly (2WD Model) with special tool and engage hooks (3) in slot and S6RW0C3116005 Disassembly window (4).
Page 433: Specifications
• Be sure to apply grease to oil seal lip and bearing side [A]: A/T model [B]: M/T model space indicated in figure. • Press-fit center shaft (1) from left oil seal (2) side. “A”: Grease 99000–25011 (SUZUKI Super Grease I7RW01311008-03 [A]: A/T model [B]: M/T model Specifications...
Page 434: Special Tools And Equipment
3A-9 Drive Shaft / Axle: Front Special Tools and Equipment Recommended Service Material S6RW0C3118001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 NOTE Required service material is also described in the following. “Front Drive Shaft Components”...
Page 435: Rear
Drive Shaft / Axle: Rear 3A-10 Rear General Description Rear Drive Shaft Construction S6RW0C3121001 Refer to “Front Drive Shaft Construction”. Repair Instructions Rear Drive Shaft Components S6RW0C3126001 I5RW0A312001-01 1. Differential side joint (Constant velocity DOJ) 6. Wheel side joint (Constant velocity ball joint) 11.
Page 436: Rear Drive Shaft Assembly Removal And Installation
3A-11 Drive Shaft / Axle: Rear Rear Drive Shaft Assembly Removal and Rear Drive Shaft Disassembly and Reassembly S6RW0C3126003 Installation Disassembly S6RW0C3126002 Refer to “Front Drive Shaft Disassembly and Removal Reassembly” note the following point which is different 1) Hoist vehicle and remove rear wheel. from the front drive shaft is described.
Page 437 Drive Shaft / Axle: Rear 3A-12 Reassembly • Fasten differential side boot band as follows. Refer to “Front Drive Shaft Disassembly and CAUTION Reassembly” note the following points which is different from the front drive shaft is described. • Bend each boot band against forward •...
Page 438: Specifications
3A-13 Drive Shaft / Axle: Rear Specifications Tightening Torque Specifications S6RW0C3127001 NOTE The specified tightening torque is also described in the following. “Rear Drive Shaft Components” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0C3128001...
Page 439: Differential
– Disconnect main fuse from fuse box • Diagnostic information stored in 4WD control module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 440: General Description
3B-2 Differential: General Description Rear Differential Description S6RW0C3201001 The differential assembly uses a hypoid bevel pinion and gear. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between hypoid bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Page 441 Differential: 3B-3 4WD Control System Components S6RW0C3201003 I5RW0A320002-04 1. 4WD control module 3. 4WD LOCK indicator 5. Coupling assembly 2. 4WD AUTO indicator 4. 2WD/4WD switch 6. Coupling air temperature sensor...
Page 442: 4Wd Control System Description
3B-4 Differential: 4WD Control System Description S6RW0C3201004 4WD Shift Control The 4WD control module operates the coupling assembly according to the 2WD/4WD switch operation to obtain the selected position (2WD, 4WD-auto or 4WD-lock). Also, the 4WD control system has 4WD AUTO indicator and 4WD LOCK indicator in order to inform the 4WD control system condition.
Page 443: 4Wd Control System Wiring Circuit Diagram
Differential: 3B-5 4WD Control System Wiring Circuit Diagram S6RW0C3201006 L174-1 G26-13 RED/WHT L102-1 G26-3 G26-2 L102-4 L174-5 L174-4 BLK/ORN G26-14 GRY/YEL G26-25 G26-21 G26-24 G26-12 RED/BLK G26-22 G26-23 G26-11 WHT/RED G26-10 I7RW01320001-01 1. Coupling assembly 6. ECM 11. Data link connector (DLC) 2.
Page 444: Input / Output Signal Table Of 4Wd Control Module
– Coupling air temperature sensor – Coupling assembly • DTC can be checked by using SUZUKI scan tool (3) connected to DLC (4). • When 4WD control module detects any malfunction, 4WD control module will switch off the current to coupling assembly and vehicle is changed to 2WD position.
Page 445: Can Communication System Description
Differential: 3B-7 CAN Communication System Description S6RW0C3201010 Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. When 4WD control module receive the signal of abnormal as following information, vehicle is not changed to 4WD- auto and 4WD-lock mode. 4WD Control Module Transmission Data ESP®...
Page 446: Diagnostic Information And Procedures
3B-8 Differential: Diagnostic Information and Procedures 4WD Control System Check S6RW0C3204001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC check, record and clearance Print DTC or write them...
Page 447 Differential: 3B-9 Detail of 4WD Control System Check Step 1. Customer complaint analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 448: 4Wd Position Indicator Operation Check
3B-10 Differential: Step 5. Trouble symptom confirmation 4WD Control System Operation Inspection Check trouble symptoms based on information obtained S6RW0C3204003 NOTE in “Step 1. Customer complaint analysis: ” and “Step 2. DTC check, record and clearance: ”. • It automatically changes into “4WD-auto” Also, reconfirm DTC according to “DTC Confirmation position, when the vehicle speed becomes Procedure”...
Page 449: Dtc Check
4) Read DTC according to instructions displayed on 4) Erase DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer SUZUKI scan tool. Refer to SUZUKI scan tool to SUZUKI scan tool operator’s manual for further operator’s manual for further details.
Page 450: Dtc Table
3B-12 Differential: DTC Table S6RW0C3204007 Detecting condition DTC No. Detecting item position (DTC will set when detecting) Indicator 4WD control module power Battery voltage is lower than lower limit voltage for C1240 supply circuit malfunction 4WD control module diagnosis. Internal circuit malfunction of Internal power supply malfunction of 4WD control C1243 4WD control module...
Page 451: Scan Tool Data
Differential: 3B-13 Scan Tool Data S6RW0C3204009 Normal condition / reference Scan tool data Vehicle condition values Accelerator pedal released 0 – 5% Ignition switch ON after Accel pedal Pos Accelerator pedal depressed warmed up engine 90 – 100% fully Engine speed At engine idle speed Engine idle speed is display 2WD/4WD switch selected to 2WD position...
Page 452: Rear Differential Symptom Diagnosis
3B-14 Differential: Rear Differential Symptom Diagnosis S6RW0C3204010 Condition Possible cause Correction / Reference Item Gear noise Deteriorated or water mixed lubricant Repair and replenish referring to “Rear Differential Oil Change”. Inadequate or insufficient lubricant Repair and replenish referring to “Rear Differential Oil Change”.
Page 453: 4Wd Position Indicator Does Not Come On At Ignition Switch On But Engine Stops
Differential: 3B-15 4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops S6RW0C3204012 Wiring Diagram G26-11 WHT/RED RED/BLK G26-12 WHT/RED G26-22 G26-23 G26-10 I7RW01320004-01 [A]: 4WD control module connector “G26” (viewed from harness side) 4. Combination meter 1.
Page 454: 4Wd Position Indicator Remains On Steady
3B-16 Differential: Step Action CAN communication circuit check Go to Step 4. Repair or replace. 1) Check CAN communication circuit between combination meter and 4WD control module referring to “DTC U0073: Control Module Communication Bus Off”. Is CAN communication circuit in good condition? “METER”...
Page 455: Dtc C1240: 4Wd Control Module Power Supply Circuit Malfunction
Differential: 3B-17 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction S6RW0C3204014 Wiring Diagram G26-12 RED/BLK WHT/RED G26-11 G26-10 I7RW01320005-01 [A]: 4WD control module connector “G26” (viewed from harness side) 3. “4WD” fuse 1. 4WD control module 4. Main fuse box 2.
Page 456: Dtc C1243: Internal Circuit Malfunction Of
3B-18 Differential: Step Action Ground circuit check Substitute a known- Repair ground circuit. good 4WD control 1) Turn ignition switch to OFF position. module and recheck. 2) Check for proper connection to “G26-10” terminal of 4WD control module connector. 3) If OK, measure resistance between “G26-10” terminal of 4WD control module connector and vehicle body ground.
Page 457 Differential: 3B-19 DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Turn ignition switch to ON position for 10 seconds. 3) Check DTC. Troubleshooting Step Action Was “4WD control system check” performed? Go to Step 2. Go to “4WD Control System Check”.
Page 458: Dtc C1251: Coupling Air Temperature Sensor Circuit Short
3B-20 Differential: DTC C1251: Coupling Air Temperature Sensor Circuit Short S6RW0C3204017 Wiring Diagram G26-25 G26-24 I7RW01320006-01 [A]: 4WD control module connector “G26” (viewed from harness side) 2. 4WD control module 1. Coupling air temperature sensor DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Input signal from coupling air temperature sensor is lower than...
Page 459: Dtc C1252: Coupling Assembly Circuit Open
Differential: 3B-21 Step Action Coupling assembly ground circuit check Go to Step 4. “ORN” wire is shorted to ground circuit. 1) Disconnect connector from 4WD control module with ignition switch turned OFF. 2) Measure resistance between “ORN” terminal of coupling air temperature sensor connector and “G26-24”...
Page 460 3B-22 Differential: DTC Confirmation Procedure 1) Clear DTC using scan tool. 2) Start engine and select 2WD/4WD switch to “LOCK” position. 3) Keep engine running at 2000 rpm for 10 seconds. or more. 4) Stop engine and check DTC. Troubleshooting Step Action Was “4WD control system check”...
Page 461: Dtc C1253: Coupling Assembly Circuit Short
Differential: 3B-23 DTC C1253: Coupling Assembly Circuit Short S6RW0C3204019 Wiring Diagram L102-1 G26-3 L102-4 G26-2 I7RW01320007-01 [A]: 4WD control module connector “G26” (viewed from harness side) 1. Coupling assembly [B]: Coupling assembly connector “L102” (viewed from harness side) 2. 4WD control module DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 462: Dtc C1254: 2Wd/4Wd Switch Malfunction
3B-24 Differential: Step Action Coupling assembly check Substitute a known- Replace coupling good 4WD control assembly. 1) Check coupling assembly referring to “Coupling module and recheck. Assembly Inspection”. Is it in good condition? Coupling assembly circuit check “YEL” wire is shorted to Substitute a known- ground circuit.
Page 463 Differential: 3B-25 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area 2WD/4WD switch combination different from specification is • 2WD/4WD switch detected for more than 5 seconds. • 2WD/4WD switch circuit • 4WD control module DTC Confirmation Procedure 1) Clear DTC using scan tool.
Page 464: Dtc U0073: Control Module Communication Bus Off
3B-26 Differential: DTC U0073: Control Module Communication Bus Off S6RW0C3204021 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0100: Lost Communication with ECM S6RW0C3204022 Refer to “Troubleshooting for CAN-DTC in Section 1A”. DTC U0121: Lost Communication with ABS / ESP® Control Module S6RW0C3204023 Refer to “Troubleshooting for CAN-DTC in Section 1A”.
Page 465 Differential: 3B-27 Terminal arrangement of 4WD control module connector (Viewed from harness side) I4JA01332054-01 Terminal Normal Wire Color Circuit Condition Number Voltage G26-1 — — — — Coupling assembly G26-2 About 5 V Ignition switch turned ON position (ground) • Run engine at idle speed and 2WD/4WD switch at 4WD lock position 10 –...
Page 466 3B-28 Differential: Terminal Normal Wire Color Circuit Condition Number Voltage Coupling air G26-24 temperature sensor About 2.5 V Ignition switch turned ON position (ground) Coupling air G26-25 temperature sensor About 2.5 V Ignition switch turned ON position (power) G26-26 — —...
Page 467: Repair Instructions
3) Apply sealant to thread of level / filler plug, and then • It is highly recommended to use API GL-5 tighten it to specified torque. 80W-90 gear oil. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Differential oil specification : API GL-5 (For SAE classification, refer to Tightening torque viscosity chart [A] in figure.)
Page 468: 2Wd/4Wd Switch Removal And Installation
3B-30 Differential: 2WD/4WD Switch Removal and Installation 4WD Control Module Removal and Installation S6RW0C3206003 S6RW0C3206005 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Remove console box (2). 2) Remove center ventilation louver referring to “Center Ventilation Louver Removal and Installation in 3) Remove 2WD/4WD switch (1) from console box.
Page 469: Coupling Air Temperature Sensor Inspection
Differential: 3B-31 Coupling Air Temperature Sensor Inspection Coupling Assembly Inspection S6RW0C3206007 S6RW0C3206008 • Check coupling assembly for oil leakage. If leakage CAUTION exists, replace it. Do not heat up coupling air temperature • Measure resistance between “a” terminal and “b” sensor more than 100 °C (212 °F).
Page 470: Rear Differential Mountings Components
3B-32 Differential: Rear Differential Mountings Components S6RW0C3206009 I7RW01320010-01 1. Rear differential 6. Front mounting to body bolt 11. Rear mounting bolt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Front mounting arm 7. Front mounting to body nut 12. Damper : Do not reuse.
Page 471: Front Mounting Arm And/Or Rear Mounting Bracket Assembly Removal And Installation
Differential: 3B-33 Front Mounting Arm and/or Rear Mounting Rear Differential Dismounting and Remounting S6RW0C3206012 Bracket Assembly Removal and Installation Dismounting S6RW0C3206010 Remove and install front mounting arm and/or rear 1) Lift up vehicle and drain oil from rear differential. mounting bracket after rear differential removed. 2) Remove propeller shaft referring to “Propeller Shaft For tightening torque of each bolt and nut, refer to “Rear Assembly Removal and Installation in Section 3D”.
Page 472: Rear Differential Components
3B-34 Differential: Rear Differential Components S6RW0C3206013 1217G 1217G I5RW0A320026-02 1. Flange nut 13. Differential cover bolt 25. Differential gear 2. Companion flange 14. Spacer 26. Spring washer 3. Oil seal 15. Rear bearing 27. Thrust washer : Apply grease 99000-25010 to oil seal lip. 4.
Page 473: Rear Differential Disassembly And Reassembly
Differential: 3B-35 12. Differential cover 24. Pinion Rear Differential Disassembly and Reassembly 6) Remove coupling assembly (1) by using hydraulic S6RW0C3206014 press. Disassembly CAUTION 1) Remove rear mounting bracket from rear differential Do not drop coupling assembly. If it is referring to “Front Mounting Arm and/or Rear dropped, replace it with a new one.
Page 474 3B-36 Differential: 8) Remove oil seals from rear differential (1) using 11) Remove drive bevel gear (hypoid gear), differential special tool. gears, differential pinions and pinion shaft as follows. a) With aluminum plates (2) placed on vise first, Special tool grip differential case with it and remove drive (A): 09913–50121 bevel gear (hypoid gear) (3) by removing its bolts...
Page 475 Differential: 3B-37 13) Remove rear bearing (2) from drive bevel pinion (1) 1) Press-fit bevel pinion bearing outer races to by using bearing puller (3) and hydraulic press. differential carrier (1) by using special tools and hydraulic press as shown in the figure. Special tool (A): 09913–85210 (B): 09913–75510...
Page 476 3B-38 Differential: 4) Align holes of pinion shaft and differential case and 6) Press-fit differential right side bearing (1) with special drive in differential pinion shaft pin till they are flush tools and hydraulic press. with end surface of case. Special tool Special tool (A): 09913–80113...
Page 477 Differential: 3B-39 8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 478 3B-40 Differential: 9) Set special tools and make drive bevel pinion 12) Apply gear oil to drive bevel pinion bearings, install mounting dummy. special tools with bearings to differential carrier as shown in figure. Special tool (A): 09922–76120 Special tool (B): 09922–76250 (A): 09922–76140 (B): 09922–76420...
Page 479 Differential: 3B-41 14) Set dial gauge to bevel pinion mounting dummy and 16) Necessary adjusting shim thickness is the same make 0 (zero) adjustment on surface plate. value as measured value by dial gauge. Necessary shim thickness Dial gauge measured NOTE “e”...
Page 480 Install oil seal horizontally to surface of differential carrier. Bevel pinion bearing preload (Bevel pinion rotational torque) “A”: Grease 99000–25010 (SUZUKI Super : 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb- Grease A) in.) Distance between differential carrier and oil seal “a”...
Page 481 Differential: 3B-43 Special tool 23) Remove differential cover. (A): 09900–20607 24) To measure bevel gear backlash, set dial gauge at (B): 09900–20701 right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. If bevel gear backlash is out of specification, repeat Step 22).
Page 482 (0.059 in.) in diameter, mate differential cover with Special tool differential carrier, and then tighten bolts to specified (A): 09913–75830 torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Differential cover bolt: 23 N·m (2.3 kgf-m, 17.0 lb-ft) “A”...
Page 483 (1) using special tool as shown in figure. NOTE Install oil seal horizontally to surface of coupling case. “A”: Grease 99000–25010 (SUZUKI Super Grease A) I5RW0A320061-01 Distance between case and oil seal “a” 31) Clean mating surface of differential carrier (1) and : 1.5 –...
Page 484 Install oil seal horizontally to surface of rear differential case. Rear Differential Inspection S6RW0C3206015 “A”: Grease 99000–25010 (SUZUKI Super • Check companion flange for wear or damage. Grease A) • Check bearings for wear or discoloration. Distance between rear differential and oil seal •...
Page 485: Special Tools And Equipment
Differential: 3B-47 Special Tools and Equipment Recommended Service Material S6RW0C3208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 486 3B-48 Differential: 09922–76120 09922–76140 Mounting dummy shaft Bevel pinion shaft 09922–76150 09922–76250 Bevel pinion nut Bevel gear dummy 09922–76330 09922–76340 Bevel pinion rear collar Bevel pinion rear collar 09922–76420 09922–76530 Bevel pinion front collar Bevel pinion gauge block 09922–85811 09925–18011 Spring pin remover (4.5 mm) Transmission gear, bush and bearing installer...
Page 487 Differential: 3B-49 09951–26020 SUZUKI scan tool Bush remover & installer — support This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loop back adapter, 7. Battery power cable, 8.
Page 488: Transfer
3C-1 Transfer: Transfer Driveline / Axle General Description Transfer Description S6RW0C3301001 The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction drive gear, reduction driven gear and bevel gear of transfer.
Page 489: Repair Instructions
3) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. Transfer oil specification : API GL-5 (For SAE classification, refer to “A”: Sealant 99000–31260 (SUZUKI Bond viscosity chart [A] in figure.) No.1217G) Transfer oil capacity Tightening torque Reference: 0.6 liters (1.2/1.0 US/lmp.
Page 490: Transfer Dismounting And Remounting
3C-3 Transfer: Transfer Dismounting and Remounting 7) Carry out Step 2) to 12) of “Removal” under “Front S6RW0C3306003 Suspension Frame, Stabilizer Bar and/or Bushing Dismounting Removal and Installation (2WD Model) in Section 1) Disconnect negative (–) cable at battery. 2B” in order to lower transfer with front suspension frame.
Page 491 • Apply grease to left case (1) and new O-ring (2) as shown in figure. • Use new O-ring. • Apply grease to O-ring (2). “A”: Grease 99000–25010 (SUZUKI Super Grease I7RW01330003-01 • Tighten front suspension bolts to specified torque referring to “Front Suspension Construction in Section 2B”.
Page 492: Transfer Assembly Components
3C-5 Transfer: Transfer Assembly Components S6RW0C3306004 1217G 1322 1217G 1217G I5RW0A330007-05 1. Transfer output flange nut 15. Dowel pin 29. Transfer right case : After tightening nut so as rotational torque : Apply sealant 99000-31260 to of bevel pinion to be in specified value, mating surface with right case.
Page 493: Transfer Assembly Disassembly And Reassembly
Transfer: 3C-6 12. Bevel gear 26. Snap ring : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft) 13. Reduction driven gear 27. Oil protect plate : Do not reuse. 14. Intermediate shaft bearing 28. Shim : Apply transfer oil. Transfer Assembly Disassembly and Reassembly S6RW0C3306005 Disassembly...
Page 494 2) Clean mating surface of right and left cases, and m, 40.0 lb-ft) apply sealant to right case (1) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) 1, (a) “A” 1, (a)
Page 495: Reduction Drive Gear Assembly Disassembly And Reassembly
I5RW0A330016-02 2) Install bearings (1) to reduction drive gear (2) using 12) Apply grease to new right case oil seal No.1 lip. special tool, bearing puller (3) and hydraulic press “A”: Grease 99000–25010 (SUZUKI Super (4). Grease A) Special tool 13) Drive right case oil seal No.1 (1) in transfer right...
Page 496: Reduction Driven Gear Assembly Disassembly And Reassembly
3C-9 Transfer: Reduction Driven Gear Assembly Disassembly Reassembly and Reassembly CAUTION S6RW0C3306007 Disassembly • Bevel gear and pinion must be replaced as 1) Remove left bearing (1) and bevel gear (2) using a set when either replacement becomes special tool, bearing puller (3) and hydraulic press necessary.
Page 497: Transfer Right Case And Left Case Disassembly And Reassembly
Apply grease to oil seal lip. (B): 09924–84510–005 Special tool (A): 09925–15410 “A”: Grease 99000–25010 (SUZUKI Super Grease A) Oil seals installing depth “a”: 23.5 – 24.0 mm (0.925 – 0.945 in.) “b”: 38.0 – 39.0 mm (1.496 – 1.535 in.) “b”...
Page 498: Transfer Output Retainer Assembly Disassembly And Reassembly
3C-11 Transfer: Transfer Output Retainer Assembly 5) Drive out front taper roller bearing (1) from bevel pinion (3) by using bearing puller (2) and hydraulic Disassembly and Reassembly press. S6RW0C3306009 Disassembly 1) Uncaulk transfer output flange nut. 2) Remove transfer output flange nut while holding flange (1) by using special tool.
Page 499 Transfer: 3C-12 NOTE Reassembly This installation requires no spacer or oil CAUTION seal. • Bevel gear and pinion must be replaced as a set when either replacement becomes necessary. • When replacing taper roller bearing, “a” “b” replace as inner race and outer race assembly.
Page 500 3C-13 Transfer: d) Measure height “b” in figure by using vernier Select a shim closest to the calculated value caliper. (necessary shim thickness) from among the Calculate “c” by using measured value. available shims or combine shims to become closest to calculated value. For example: Height “a”...
Page 501 : 0.5 – 1.3 N⋅m (0.05 – 0.13 kgf-m, 0.35 – 0.95 lb-ft) (A): 09913–84510 Special tool (A): 09930–40113 I5RW0A330041-02 6) Apply grease to new oil seal lip. “A”: Grease 99000–25010 (SUZUKI Super Grease A) 7) Drive in oil seal (1) by using special tools and hammer. Special tool (A): 09940–54910 (B): 09913–76010...
Page 502: Transfer Assembly Inspection
3C-15 Transfer: Transfer Assembly Inspection 2) Install transfer output retainer assembly referring to S6RW0C3306010 “Transfer Assembly Disassembly and Reassembly”. • Check each bearing for smooth rotation, wear or 3) Turn transfer output flange clockwise and discoloration counterclockwise repeatedly, and remove transfer If found abnormal, replace.
Page 503 Transfer: 3C-16 Gear tooth contact table Tooth contact pattern Diagnosis and remedy Normal I5RW0A330045-01 High contact Pinion is positioned too far from the center of drive bevel gear. • Decrease thickness of bevel pinion shim and position pinion closer to gear center. •...
Page 504 3C-17 Transfer: Specifications Tightening Torque Specifications S6RW0C3307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Transfer oil level / filler plug 17.0 Transfer oil drain plug 17.0 Stiffener No.1 bolt and No.2 bolt 40.0 Transfer to transaxle bolt 71.0 Engine rear mounting upper nut 18.0 Engine rear mounting lower nut 40.0...
Page 505: Special Tools And Equipment
Transfer: 3C-18 Special Tools and Equipment Recommended Service Material S6RW0C3308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 506 3C-19 Transfer: 09922–76430 09924–07710 Bevel pinion front collar Synchronizer hub installer 09924–74510 09924–84510–005 Bearing and oil seal handle Bearing installer attachment 09925–15410 09925–16310 Oil seal installer Bearing installer 09925–18011 09925–98220 Transmission gear, bush Bearing installer and bearing installer 09930–40113 09940–54910 Flywheel rotor holder Front fork oil seal install driver...
Page 507: Propeller Shafts
Propeller Shafts: 3D-1 Propeller Shafts Driveline / Axle General Description Propeller Shaft Construction S6RW0C3401001 Universal joints and ball joint require no maintenance. They are lubricated for life and can not be lubricated on the vehicle. If a universal joint becomes noisy or worn, it must be replaced. The propeller shaft is a balanced unit.
Page 508: Propeller Shaft Assembly Removal And Installation
3D-2 Propeller Shafts: Propeller Shaft Assembly Removal and 4) Remove propeller shaft by removing center support nuts (1). Installation S6RW0C3406002 CAUTION Removal Use care not to drop it. Otherwise, vibration 1) Hoist vehicle. may occur during driving. 2) Before removing propeller shaft assembly, give match marks (2) on joint flange and propeller shaft as shown.
Page 509 Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Special Tool ............4A-16 Precautions............. 4-1 Front Brakes ..........4B-1 Precautions for Brakes.......... 4-1 Repair Instructions ..........4B-1 Brake Control System and Diagnosis ... 4A-1 Front Disc Brake Components ......4B-1 Front Disc Brake Pad On-Vehicle Inspection..4B-2 Precautions............4A-1 Front Disc Brake Pad Removal and Precautions on Brake..........
Page 510 4-ii Table of Contents Parking Brake Lever and Cable Inspection DTC C1041 / C1042 / C1045 / C1046 / C1051 and Adjustment ..........4D-1 / C1052 / C1055 / C1056: Inlet / Outlet Parking Brake Cable Removal and Solenoid ............4E-23 Installation ............4D-3 DTC C1057: Power Supply Voltage Too High Parking Brake Lever Removal and Installation ..4D-3 / Too Low ............4E-24...
Page 511: Precautions
Precautions: Precautions Brakes Precautions Precautions for Brakes S6RW0C4000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. Brake Caution Refer to “Brake Caution in Section 00”. General Precautions Refer to “General Precautions in Section 00”.
Page 512: Brake Control System And Diagnosis
4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brakes Precautions Precautions on Brake S6RW0C4100001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note”. General Description Brakes Construction S6RW0C4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear).
Page 513: Brake Pedal Foot Protection System Construction (If Equipped)
Brake Control System and Diagnosis: 4A-2 Brake Pedal Foot Protection System Construction (If Equipped) S6RW0C4101004 Should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also pushed toward the interior side. In this case, the brake pedal lever comes off from the brake pedal, thereby preventing the brake pedal from moving rearward.
Page 514: Front Brake Hose / Pipe Construction
4A-3 Brake Control System and Diagnosis: Front Brake Hose / Pipe Construction S6RW0C4101002 I6RW0C410002-01 [A]: LHD 4. From ABS hydraulic unit to left front brake 9. Master cylinder fixing nut [B]: RHD 5. ABS hydraulic unit / control module assembly : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) 1.
Page 515: Rear Brake Hose / Pipe Construction
Brake Control System and Diagnosis: 4A-4 Rear Brake Hose / Pipe Construction S6RW0C4101003 I6RW0C410003-01 1. To left rear brake hose 5. Left rear brake hose to left brake 2. To right rear brake hose 6. Right rear brake hose to right brake 3.
Page 516: Diagnostic Information And Procedures
4A-5 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brakes Diagnosis Note for leakage. If even a slight evidence of leakage is noted, S6RW0C4104001 the cause should be corrected or defective parts should Road Testing Brakes be replaced. Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned.
Page 517 Brake Control System and Diagnosis: 4A-6 Condition Possible cause Correction / Reference Item Dragging brakes (Without Master cylinder pistons not returning Replace master cylinder. a very light drag is correctly present in all brakes Restricted brake pipes or hoses Check for soft hoses or damaged pipes and immediately after pedal is replace with new hoses and/or new brake released)
Page 518: Repair Instructions
4A-7 Brake Control System and Diagnosis: Repair Instructions Brake Pedal Components 6) Check brake booster push rod for length. S6RW0C4106018 CAUTION Brake Pedal Play Inspection S6RW0C4106002 If equipped Brake Pedal Foot Protection Pedal play should be within the following specification. If System, never disassemble brake pedal out of specification, check brake light switch for proper assembly.
Page 519: Brake Fluid Level Inspection
Brake Control System and Diagnosis: 4A-8 Brake Fluid Level Inspection Brake Light Switch Adjustment S6RW0C4106004 S6RW0C4106005 Adjustment should be made as follows. Pull up brake CAUTION pedal toward you and while holding it there, adjust Do not use shock absorber fluid or any other switch position so that clearance between end of thread fluid which contains mineral oil.
Page 520: Front Brake Hose / Pipe Removal And Installation
4A-9 Brake Control System and Diagnosis: Front Brake Hose / Pipe Removal and 1) Fill master cylinder reservoir with specified brake fluid and keep at least one-half full of fluid during Installation bleeding operation. S6RW0C4106007 CAUTION Brake fluid : Refer to reservoir cap Do not allow brake fluid to get on painted surfaces.
Page 521: Rear Brake Hose / Pipe Removal And Installation
Brake Control System and Diagnosis: 4A-10 Rear Brake Hose / Pipe Removal and Installation Reverse brake flexible hose removal procedure, noting Installation the following. S6RW0C4106008 • Make sure that steering wheel is in straight-forward CAUTION position and flexible hose has not twist or kink. Do not allow brake fluid to get on painted •...
Page 522: Master Cylinder And Brake Booster Components
4A-11 Brake Control System and Diagnosis: Master Cylinder and Brake Booster Components S6RW0C4106010 CAUTION Never disassemble master cylinder and brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. I7RW01410017-03 1. Reservoir 6.
Page 523: Master Cylinder Removal And Installation
Brake Control System and Diagnosis: 4A-12 4) Connect clutch reservoir hose to reservoir (M/T 3) Drain brake fluid in reservoir. model). 4) Disconnect clutch reservoir hose from reservoir (M/T model). 5) Connect fluid level switch coupler (1) and clamp (3) to reservoir (2).
Page 524: Master Cylinder Inspection
4A-13 Brake Control System and Diagnosis: 3) Drain brake fluid in reservoir. 4) Connect brake pipe to master cylinder and tighten flare nuts to specified torque. 4) Disconnect clutch reservoir hose from reservoir (M/T model). Tightening torque 5) Disconnect brake pipes (1) connected to master Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5 cylinder.
Page 525: Booster Operation Inspection
Brake Control System and Diagnosis: 4A-14 Booster Operation Inspection Check Operation S6RW0C4106014 1) With engine stopped, depress brake pedal several There are two ways to perform this inspection, with and times with the same load and make sure that pedal without a tester.
Page 526: Brake Booster Removal And Installation
4A-15 Brake Control System and Diagnosis: 2) Hold brake pedal depressed for 30 seconds. If pedal Installation height does not change, condition is good. But it isn’t 1) Install booster to dash panel. Then connect push rod if pedal rises. clevis pin (2) and clip (1).
Page 527: Booster Push Clevis Rod Adjustment
Brake Control System and Diagnosis: 4A-16 Booster Push Clevis Rod Adjustment S6RW0C4106017 Install push clevis rod (1) so that measurement “a” is obtained and torque nut (2) to specification. Tightening torque Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft) Clevis installing position (length “a”) “a”: 129.5 - 130.5 mm (5.10 - 5.13 in.) IYSQ01410050-01...
Page 528: Repair Instructions
4B-1 Front Brakes: Front Brakes Brakes Repair Instructions Front Disc Brake Components S6RW0C4206001 I7RW01420001-05 1. Caliper 9. Disk brake piston 17. Brake flexible hose : Apply rubber grease included in piston : Be sure to direct mark (18) to seal set or brake fluid to contact surface of inside of vehicle “I”...
Page 529: Front Disc Brake Pad On-Vehicle Inspection
Front Brakes: 4B-2 Front Disc Brake Pad On-Vehicle Inspection 4) Remove brake pads (3). S6RW0C4206002 Inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end and inspection hole of caliper and check lining thickness of outside and inside pads.
Page 530: Front Disc Brake Pad Inspection
4B-3 Front Brakes: 3) Install caliper and tighten caliper pin bolts to Front Disc Brake Caliper Removal and specified torque. Installation S6RW0C4206005 Tightening torque Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft) Removal 1) Hoist vehicle and remove front wheel. 2) Remove brake flexible hose joint bolt (1) from caliper (2).
Page 531: Front Disc Brake Caliper Disassembly And Assembly
Front Brakes: 4B-4 Front Disc Brake Caliper Disassembly and 3) Connect flexible hose (3) to caliper as shown in figure. Assembly S6RW0C4206006 4) Torque flexible hose joint bolt to specification. Disassembly Tightening torque Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m, CAUTION 17.0 lb-ft) Clean around caliper with brake fluid before...
Page 532 4B-5 Front Brakes: Assembly 2) Before inserting piston (1) into cylinder, apply rubber Assemble parts in reverse order of disassembly, grease included in piston seal set or brake fluid to observing the following instructions. new boot (a) and install it onto piston as shown. CAUTION •...
Page 533: Front Disc Brake Caliper Inspection
Front Brakes: 4B-6 Front Brake Disc Removal and Installation 5) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not S6RW0C4206008 take it all out. CAUTION NOTE During removal, be careful not to damage brake flexible hose and not to depress brake Boot’s face (1) should be at the same level pedal.
Page 534: Front Brake Disc Inspection
4B-7 Front Brakes: Front Brake Disc Inspection Installation S6RW0C4206009 1) Install caliper assembly to steering knuckle. • Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of CAUTION disc, measure deflection of disc. Make sure that flexible hose is not twisted If it exceeds the limit, correct or replace the brake when installing caliper assembly.
Page 535: Tightening Torque Specifications
Front Brakes: 4B-8 Specifications Tightening Torque Specifications S6RW0C4207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Caliper pin bolt 19.0 Flexible hose joint bolt 17.0 Bleeder plug Caliper carrier bolt 61.5 NOTE The specified tightening torque is also described in the following. “Front Disc Brake Components”...
Page 536: Rear Brakes
4C-1 Rear Brakes: Rear Brakes Brakes Repair Instructions Rear Disc Brake Components S6RW0C4306001 I7RW01432001-02 1. Caliper 11. Brake caliper carrier 21. Shaft cover : Apply rubber grease. 2. Caliper pin bolt 12. Caliper carrier bolt 22. Lever 3. Boot 13. Rear caliper bleeder plug 23.
Page 537: Rear Disc Brake Pad Removal And Installation
Rear Brakes: 4C-2 Rear Disc Brake Pad Removal and Installation S6RW0C4306002 NOTE When replacing brake pad, replace it on the right and left. Removal 1) Hoist vehicle and remove wheel. 2) Release parking brake lever. 3) Remove caliper pin bolts (1). 4) Remove caliper (2) from caliper carrier.
Page 538: Rear Disc Brake Caliper Removal And Installation
4C-3 Rear Brakes: 8) Install rear wheel referring to “Wheel (with Tire) 6) Remove caliper pin bolts. Removal and Installation in Section 2D”. 7) Remove caliper from brake caliper carrier. 9) After completion of installation, check for brake 8) Disconnect parking brake cable (1) from lever (2) effectiveness.
Page 539 Rear Brakes: 4C-4 2) Install new slide pin boots (1) to brake caliper carrier. 6) Install brake pads and caliper referring to “Rear Disc Brake Pad Removal and Installation”. 3) Apply rubber grease to slide pins, then install slide pin (2) to front side and slide pin (3) to rear side of 7) Connect flexible hose (4) with new washers (5) to brake caliper carrier.
Page 540: Rear Disc Brake Pad Inspection
4C-5 Rear Brakes: 10) After reassembling brake lines, bleed air from them 1) Remove disc brake piston (1) by turning piston referring to “Air Bleeding of Brake System in Section counterclockwise with special tool. 4A”. CAUTION 11) Check to make sure that system is free from fluid Be careful not to damage inside (bore side) of leakage.
Page 541 Rear Brakes: 4C-6 Assembly 4) Install bleeder plug and cap to caliper. 5) Install new piston seal to caliper. CAUTION 6) Before inserting piston (2) into cylinder, install boot • Wash each part cleanly before installation (1) onto piston as shown. in the same fluid as the one used in master cylinder reservoir.
Page 542: Rear Disc Brake Caliper Inspection
4C-7 Rear Brakes: Rear Disc Brake Caliper Inspection Slide Pin S6RW0C4306006 Check guide pin for smooth movement as shown. Pin Boot and Cylinder Boot If it is found faulty, correct or replace. Check boots (1) for breakage, crack and damage. Apply rubber grease to guide pin outer surface.
Page 543: Rear Brake Disc Inspection
Rear Brakes: 4C-8 Special tool Installation Install in reverse order of removal nothing the following. (A): 09900–20607 (B): 09900–20701 • Tighten caliper carrier bolts to specified torque. Tightening torque Caliper carrier bolt (a): 60 N·m (6.0 kgf-m, 43.5 lb- I6RS0B431031-01 •...
Page 544: Special Tools And Equipment
4C-9 Rear Brakes: Special Tools and Equipment Recommended Service Material S6RW0C4308001 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following. “Rear Disc Brake Components”...
Page 545: Parking Brake
Parking Brake: 4D-1 Parking Brake Brakes General Description Parking Brake Cable Construction S6RW0C4401001 ( a ) ( a ) ( a ) ( a ) ( a ) ( b ) ( b ) ( a ) ( b ) I6RW0C440001-01 T: Top side 3.
Page 546 4D-2 Parking Brake: • Check tooth tip of each notch for damage or wear. If 1) Release parking brake lever. any damage or wear is found, replace parking brake 2) Loosen parking brake lever adjust nut (1) fully. lever. • Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force.
Page 547: Parking Brake Cable Removal And Installation
Parking Brake: 4D-3 Parking Brake Cable Removal and Installation 5) Remove parking brake lever bolts (1) and then S6RW0C4406002 remove parking brake lever assembly (2) with equalizer (3). Removal NOTE NOTE Don’t disassemble parking brake lever When it is necessary to remove both right switch.
Page 548: Tightening Torque Specifications
4D-4 Parking Brake: Specifications Tightening Torque Specifications S6RW0C4407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Parking brake lever bolt 19.0 NOTE The specified tightening torque is also described in the following. “Parking Brake Cable Construction” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Page 549: Precautions In Diagnosing Troubles
Therefore, be sure to read “Precautions for Installing memory can be cleared as well as checked by using Mobile Communication Equipment in Section 00” SUZUKI scan tool. Before using scan tool, read its before inspection and handling CAN communication Operator's (Instruction) Manual carefully to have good line.
Page 550: General Description
4E-2 ABS: General Description ABS Description • ABS hydraulic unit / control module assembly is S6RW0C4501001 incorporated ABS control module, ABS hydraulic unit The ABS (Antilock Brake System) controls the fluid (actuator assembly), solenoid valve power supply pressure applied to the wheel cylinder of each brake driver (transistor), solenoid valve driver (transistor), from the master cylinder so that each wheel is not locked pump motor driver (transistor).
Page 551: Abs Hydraulic Unit / Control Module Assembly Description
ABS: 4E-3 ABS Hydraulic Unit / Control Module Assembly Description S6RW0C4501002 ABS control module is a component of ABS hydraulic unit / control module assembly and has the following functions. Self-Diagnosis Function I4RS0A450001-01 ABS control module diagnoses conditions of the system •...
Page 552: Schematic And Routing Diagram
4E-4 ABS: Schematic and Routing Diagram ABS Schematic S6RW0C4502001 INPUT OUTPUT ABS control module Hydraulic unit Wheel speed sensor (LF) Pump motor Pump motor driver (transistor) Wheel speed sensor (LR) Solenoid valve power Wheel speed sensor (RF) supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve Brake light switch...
Page 553: Abs Wiring Circuit Diagram
ABS: 4E-5 1. ABS hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (Left-rear) 2. ABS control module 10. ABS warning light 18. Battery 3. ABS hydraulic unit 11. EBD warning light (Brake warning light) 19.
Page 554 4E-6 ABS: 5. Combination meter 17. Data link connector (DLC) 29. Pump motor driver (transistor) 6. ABS warning light 18. To BCM, 4WD control module, P/S control 30. Pump motor module, HVAC control module (auto A/C model) and SDM 7. EBD warning light (brake warning light) 19.
Page 555: Component Location
ABS: 4E-7 Component Location ABS Components Location S6RW0C4503001 I5RW0A450006-02 1. ABS hydraulic unit / control module assembly 5. EBD warning light (Brake warning light) 2. Wheel speed sensors 6. Wheel speed sensor encoder (included in wheel hub assembly) 3. Brake light switch 7.
Page 556 4E-8 ABS: Step Action Check for intermittent problem Go to Step 4. Go to Step 7. 1) Check intermittent troubles referring to “Intermittent and Poor Connection Inspection in Section 00” and related circuit of trouble code recorded in Step 1. Does trouble recur? Final confirmation test Go to Step 3.
Page 557: Abs Warning Light Check
ABS: 4E-9 Problem symptom confirmation Step 7: Final Confirmation Test Check if what the customer claimed in “Customer Confirm that the problem symptom has gone and the Questionnaire” is actually found in the vehicle and if that ABS is free from any abnormal conditions. If what has symptom is found, whether it is identified as a failure.
Page 558: Dtc Check
4) Read DTC according to instructions displayed on any traffic accident possibility and be very SUZUKI scan tool and print it or write it down. Refer careful during testing to avoid occurrence of to SUZUKI scan tool operator’s manual for further an accident.
Page 559: Scan Tool Data
ABS: 4E-11 Scan Tool Data Scan Tool Data Definition S6RW0C4504007 Battery Volt (V) The parameter data below are values measured with the Battery Voltage is an analog input signal read by the scan tool when the normally operating vehicle is under ABS control module.
Page 560: Ignition Switch
4E-12 ABS: ABS Warning Light Does Not Come ON at Ignition Switch ON S6RW0C4504008 Wiring Diagram WHT/RED E08-25 WHT/BLU E08-24 GRN/ORN E08-9 RED/BLK E08-23 G241-31 G241-16 G241-7 G241-10 G04-4 G04-2 E04-1 E08-2 E04-2 E08-13 RED/BLK E04-5 L01-6 RED/BLU G241 4 5 6 7 8 9 10 11 12 13 14 15 16 20 2122 23 24 25 26 27 28 29 30 3132 I6RW0C450002-01 [A]: ABS control module connector (viewed from terminal side)
Page 561: Abs Warning Light Comes On Steady
ABS: 4E-13 Troubleshooting Step Action Warning light check Substitute a known- Go to Step 2. good combination meter 1) Turn ignition switch to ON position. and recheck. If warning Do other warning lights come ON? light remains OFF, substitute a known- good ABS hydraulic unit / control module assembly and recheck.
Page 562 4E-14 ABS: Step Action CAN communication line circuit check Substitute a known- Repair circuit and good combination meter recheck. 1) Turn ignition switch to OFF position. and recheck. If warning 2) Disconnect connectors of all control modules light remains ON, communicating by means of CAN.
Page 563: Ebd Warning Light (Brake Warning Light)
ABS: 4E-15 Step Action DTC check of BCM Go to “DTC U0073 (No. Go to Step 5. 0073): Control Module 1) Connect scan tool to data link connector with ignition Communication Bus Off switch turned OFF. in Section 10B”. 2) Turn ignition switch to ON position and check DTC of BCM.
Page 564 4E-16 ABS: 2. Main fuse box 8. Light driver module 14. To BCM, 4WD control module, P/S control module, HVAC control module (auto A/C model) and SDM 3. Ignition switch 9. CAN driver Trouble shooting Step Action Scan tool communication check Go to Step 2.
Page 565: Dtc C1013: Control Module Mismatch
ABS: 4E-17 DTC C1013: Control Module Mismatch S6RW0C4504012 Wiring Diagram GRN/ORN E08-9 GRN/ORN E08-6 GRN/YEL GRN/BLK E08-3 I7RW01450005-04 [A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. ABS hydraulic unit / control module assembly 1. Battery 4.
Page 566: Dtc C1015: G Sensor Circuit (4Wd Model)
4E-18 ABS: DTC C1015: G Sensor Circuit (4WD Model) S6RW0C4504013 Wiring Diagram Refer to “Wiring Diagram” under “DTC C1013: Control Module Mismatch”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • G sensor signal voltage is out of specified range. •...
Page 567: Dtc 1016: Brake Light Switch
ABS: 4E-19 DTC 1016: Brake Light Switch S6RW0C4504014 Wiring Diagram GRN/ORN E08-9 GRN/WHT E08-7 I7RW01450006-05 [A]: ABS control module connector (viewed from terminal side) 3. Ignition switch 6. Brake light 1. Battery 4. Junction block assembly 7. ABS hydraulic unit / control module assembly 2.
Page 568: Dtc C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor Or Encoder
4E-20 ABS: DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder S6RW0C4504015 DTC C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit DTC C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor or Encoder...
Page 569 ABS: 4E-21 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. Check tire condition Go to Step 3. Replace tire or adjust tire pressure and 1) Check that tire pressure is specifications. recheck. Are they in good condition? Wheel speed sensor circuit check Go to Step 4.
Page 570: Dtc C1033: Wheel Speed Sensor Deviation
4E-22 ABS: DTC C1033: Wheel Speed Sensor Deviation S6RW0C4504016 Wiring Diagram Refer to “Wiring Diagram” under “DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder”. DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 571: Dtc C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid
ABS: 4E-23 DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid S6RW0C4504017 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left- Rear Inlet Solenoid DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left- Rear Outlet Solenoid Wiring Diagram E08-24...
Page 572: Dtc C1057: Power Supply Voltage Too High / Too Low
4E-24 ABS: DTC C1057: Power Supply Voltage Too High / Too Low S6RW0C4504018 Wiring Diagram GRN/ORN E08-9 E08-23 I7RW01450009-03 [A]: ABS control module connector (viewed from terminal side) 2. Main fuse box 4. Junction block assembly 1. Battery 3. Ignition switch 5.
Page 573: Dtc C1061: Pump Motor Circuit
ABS: 4E-25 DTC C1061: Pump Motor Circuit S6RW0C4504019 Wiring Diagram E08-25 WHT/RED E08-26 I7RW01450010-02 [A]: ABS control module connector (viewed from terminal side) 3. Pump motor driver (transistor) 1. Battery 4. ABS pump motor 2. Main fuse box 5. ABS hydraulic unit / control module assembly DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 574: Dtc C1063: Solenoid Valve Power Supply Driver Circuit
4E-26 ABS: DTC C1063: Solenoid Valve Power Supply Driver Circuit S6RW0C4504020 Wiring Diagram GRN/ORN E08-9 WHT/BLU E08-24 E08-23 I7RW01460015-01 [A]: ABS control module connector (viewed from terminal side) 4. Junction block assembly 1. Battery 5. Solenoid valve power supply driver (transistor) 2.
Page 575: Dtc C1071: Control Module Internal Defect
ABS: 4E-27 DTC C1071: Control Module Internal Defect S6RW0C4504021 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area ABS control module internal defect is detected. • ABS control module DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”.
Page 576: Abs Hydraulic Unit / Control Module Assembly Power And Ground Circuit Check
4) Set transmission to neutral (P range for A/T) and release parking brake. 5) Turn each wheel gradually by hand to check if brake dragging occurs. If it does, correct. 6) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. I5RW0A450007-01 Special tool...
Page 577: Abs Hydraulic Unit / Control Module Assembly Components
8) Perform the following checks with help of another person. Brake pedal (1) should be depressed and then select testing wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this time, check that: •...
Page 578: Abs Hydraulic Unit / Control Module Assembly On-Vehicle Inspection
4E-30 ABS: ABS Hydraulic Unit / Control Module Assembly 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit / On-Vehicle Inspection control module assembly (3). S6RW0C4506003 CAUTION Special tool Never disassemble ABS hydraulic unit / (A): 09950-78220 control module assembly, loosen blind plug NOTE...
Page 579: Front And Rear Wheel Speed Sensor On-Vehicle Inspection
ABS: 4E-31 Installation 2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”. 1) Install hydraulic unit / control module assembly by reversing removal procedure noting the following. 3) Check each installed part for fluid leakage and Install ABS hydraulic unit / control module assembly perform “ABS Hydraulic Unit Operation Check”.
Page 580: Front Wheel Speed Sensor Removal And Installation
4E-32 ABS: Front Wheel Speed Sensor Removal and 5) Measure voltage at resistance without wheel rotation.If voltage is out of specification, check Installation sensor, mating encoder and their installation S6RW0C4506006 conditions. CAUTION Voltage at the resistance (115 Ω) without wheel •...
Page 581: Front And Rear Wheel Speed Sensor Inspection
ABS: 4E-33 Rear Wheel Speed Sensor Removal and Installation Installation (4WD Model) 1) Check that no foreign material is attached to sensor S6RW0C4506008 (1) and wheel speed sensor encoder (included in CAUTION wheel hub assembly). Rear wheel speed sensor is included in rear 2) Install it by reversing removal procedure.
Page 582: Front Wheel Speed Sensor Encoder On-Vehicle Inspection
4E-34 ABS: Front Wheel Speed Sensor Encoder On-Vehicle Rear Wheel Speed Sensor Encoder On-Vehicle Inspection Inspection S6RW0C4506010 S6RW0C4506012 Before inspecting front wheel speed sensor encoder, For 4WD model remove front drive shaft referring to “Front Drive Shaft Refer to “Rear Wheel Speed Sensor On-Vehicle Assembly Removal and Installation in Section 3A”.
Page 583: G Sensor Removal And Installation (4Wd Model)
ABS: 4E-35 G Sensor Removal and Installation (4WD Model) G Sensor Inspection (4WD Model) S6RW0C4506014 S6RW0C4506015 Connect positive cable of 12 V battery to “A” terminal of CAUTION sensor and ground cable to “C” terminal. • Do not drop and shock G sensor. It will Then using voltmeter, check voltage between terminals affect its original performance.
Page 584: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S6RW0C4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 585 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Line Pressure Test ..........5A-30 Engine Brake Test..........5A-32 Precautions............. 5-1 “P” Range Test..........5A-32 Precautions on Transmission / Transaxle ..... 5-1 A/T Symptom Diagnosis........5A-33 Automatic Transmission/Transaxle..5A-1 Transmission Warning Light Circuit Check – Light Does Not Come “ON”...
Page 586 5-ii Table of Contents DTC P0602 / P1702: Control Module Oil Pump 2nd Coast Brake and 2nd Brake Programming Error / Internal Control Module Components............5A-95 Check Sum Error ..........5A-55 2nd Coast Brake and 2nd Brake Preliminary DTC P1723: Range select switch malfunction ..5A-56 Check ..............5A-96 DTC P2763: Torque Converter Clutch Oil Pump, 2nd Coast Brake and 2nd Brake...
Page 587 Table of Contents 5-iii Specifications...........5A-142 5th and Reverse Gear Shift Shafts Tightening Torque Specifications....5A-142 Disassembly and Reassembly ......5B-36 Gear Shift Shaft and Fork Inspection ....5B-36 Special Tools and Equipment ......5A-143 Differential Components........5B-37 Recommended Service Material ..... 5A-143 Differential Disassembly and Reassembly..5B-37 Special Tool ............
Page 588: Precautions On Transmission / Transaxle
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions on Transmission / Transaxle S6RW0C5000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 5A”. Precautions for Disassembly and Reassembly Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Page 589: Automatic Transmission/Transaxle
• Diagnostic information stored in TCM memory can be may occur and often time would be wasted. cleared as well as checked by using SUZUKI scan tool or CAN communication OBD generic scan tool. Precautions for Disassembly and Reassembly Before using scan tool, read its Operator’s...
Page 590: General Description
5A-2 Automatic Transmission/Transaxle: Part Inspection and Correction Table Part Inspect for Correction Casted part, machined part Small flaw, burr Remove with oil stone Deep or grooved flaw Replace part Clogged fluid passage Clean with air or wire Flaw on installing surface, residual gasket Remove with oil stone or replace part Crack...
Page 591 Automatic Transmission/Transaxle: 5A-3 I4RH01510001-01 1. Torque converter clutch (TCC) 7. 1st / reverse brake 13. Countershaft 19. Torque converter 2. One-way No. 1 clutch 8. Rear planetary gear 14. One-way No. 3 clutch 20. Oil pump 3. 2nd coast brake 9.
Page 592 5A-4 Automatic Transmission/Transaxle: I7RW01510061-01 1. Torque converter clutch (TCC) 7. 1st / reverse brake 13. Countershaft 19. Torque converter 2. One-way No. 1 clutch 8. Rear planetary gear 14. One-way No. 3 clutch 20. Oil pump 3. 2nd coast brake 9.
Page 593 Automatic Transmission/Transaxle: 5A-5 Specifications Item Specifications Torque converter Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism) Type Internal gear type oil pump Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P” range Gear in neutral, output shaft fixed, engine start “R”...
Page 594: Clutch / Brake / Planetary Gear Function Of Automatic Transaxle
5A-6 Automatic Transmission/Transaxle: Clutch / Brake / Planetary Gear Function of Automatic Transaxle S6RW0C5101002 I4RH01510003-01 1. 2nd coast brake 6. One-way No. 2 clutch 11. U/D planetary gear 16. Countershaft 2. 2nd brake 7. Front planetary gear 12. U/D clutch 17.
Page 595: Table Of Component Operation
Automatic Transmission/Transaxle: 5A-7 Table of Component Operation S6RW0C5101003 Forward Direct 2nd coast 1st/reverse One-way One-way One-way clutch clutch clutch brake brake brake brake No. 1 clutch No. 2 clutch No. 3 clutch × × × × × × × × ×...
Page 596: A/T Diagnosis General Description
TCM through data link connector (DLC) (2) by This vehicle is equipped with an electronic transaxle using not only SUZUKI scan tool (3) but also CAN control system, which controls the automatic shift up and communication OBD generic scan tool. (Diagnostic shift down timing, TCC operation, etc.
Page 597: Can Communication System Description
Automatic Transmission/Transaxle: 5A-9 CAN Communication System Description S6RW0C5101007 Refer to “CAN Communication System Description in Section 1A” for CAN communication System description. TCM communicates control data with each control module as follows. TCM Transmission Data 4WD control Reception unit Combination module meter Transmit data of TCM...
Page 598: Electronic Shift Control Input / Output Table
5A-10 Automatic Transmission/Transaxle: Electronic Shift Control Input / Output Table S6RW0C5101008 OUTPUT INPUT -Accelerator pedal position -Torque request -Throttle position -MIL control Gear shift control -Coolant temperature -Transmission actual gear -Engine torque position -Engine speed -ATF temp. Line pressure control -Brake pedal switch -A/C compressor clutch -Vehicle speed pulse...
Page 599: Schematic And Routing Diagram
Automatic Transmission/Transaxle: 5A-11 Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S6RW0C5102001 C07-6 C07-16 C06-11 LT GRN 2.5V C06-12 C07-5 C07-14 2.5V WHT RED C06-16 BRN C06-7 C06-17 WHT RED C06-15 BLK/YEL 12V 12V C06-5 WHT/BLU C06-4 GRY C06-2 LT GRN/BLK C07-9 C06-24...
Page 600: Automatic Gear Shift Table
5A-12 Automatic Transmission/Transaxle: Operation of Shift Solenoid Valves and TCC Solenoid Valve Range P & N Gear — × × × × × × Shift solenoid valve–A (No. 1) × × × Solenoids Shift solenoid valve–B (No. 2) × × ×...
Page 601 Automatic Transmission/Transaxle: 5A-13 Non-Euro-OBD Model 1. Shift Point in “D”, “3” and/or “2” range Throttle Shift Vehicle speed km/h (mph) Remark opening (%) 1st → 2nd 57 – 62 (35 – 39) 2nd → 3rd Over 90% 112 – 117 (70 – 73) 3rd →...
Page 602: Bearing And Race Installation Diagram
5A-14 Automatic Transmission/Transaxle: Bearing and Race Installation Diagram S6RW0C5102003 I4RH01510243-01 Bearing and race dimensions Diameter mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) Outer 58 (2.3) — 54 (2.1) 74 (2.9) —...
Page 603: Component Location
Automatic Transmission/Transaxle: 5A-15 Component Location Electronic Shift Control System Components Location S6RW0C5103001 NOTE Below figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C510005-01 1. Engine 6. A/T relay 11. Output shaft speed sensor 16.
Page 604: Diagnostic Information And Procedures
5A-16 Automatic Transmission/Transaxle: Diagnostic Information and Procedures A/T System Check S6RW0C5104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC / freeze frame data check, record and clearance Print DTC and freeze...
Page 605 Automatic Transmission/Transaxle: 5A-17 Step 1. Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form as shown in the following page as an example will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 606 5A-18 Automatic Transmission/Transaxle: Step 2. DTC / Freeze Frame Data Check, Record and Step 6 and 7. Rechecking and Record of DTC Clearance Refer to “DTC Check” for checking procedure. First, referring to “DTC Check”, check DTC (including pending DTC). If DTC exists, print or write down DTC Step 8.
Page 607: Malfunction Indicator Lamp (Mil) Check
Automatic Transmission/Transaxle: 5A-19 Visual Inspection S6RW0C5104002 Visually check the following parts and systems. Inspection item Referring section • A/T fluid – level, leakage, color “A/T Fluid Level Check” • A/T fluid hoses – disconnection, looseness, “A/T Fluid Cooler Hoses Inspection” deterioration •...
Page 608: Dtc Table
5A-20 Automatic Transmission/Transaxle: DTC Table S6RW0C5104004 NOTE • There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System in Section 1A”. • With the CAN communication OBD generic scan tool, DTC No. with delta ( ) mark in the following table can not be read.
Page 609 Automatic Transmission/Transaxle: 5A-21 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Actual gear position is different from commanded Shift Solenoid “B” 2 driving 2 driving P0756 gear position of TCM (Shift solenoid valve – B Performance or Stuck Off cycles cycles* does not turn ON).
Page 610: Dtc Check
TCM is read and displayed at a time. In case using CAN communication OBD 1) Connect SUZUKI scan tool to data link connector in generic scan tool, refer to “DTC Table in the same manner as when making this connection Section 1A”.
Page 611 Automatic Transmission/Transaxle: 5A-23 DTC No. Trouble area Fail safe operation Transmission Fluid P0712 Temperature Sensor “A” TCM assumes transmission fluid temperature to be 200 °C (392 °F) and Circuit Low Transmission Fluid controls transaxle. P0713 Temperature Sensor “A” Circuit High Input Speed Sensor “A”...
Page 612: Scan Tool Data
5A-24 Automatic Transmission/Transaxle: DTC No. Trouble area Fail safe operation TCM is controlled as follows. • Line pressure is controlled to maximum pressure. • Lock-up function is inhibited. • TCM assumes throttle position signal to be 100%. • TCM assumes engine speed to be 0 RPM. Lost Communication With •...
Page 613 Automatic Transmission/Transaxle: 5A-25 Normal condition / reference Scan tool data Vehicle condition values At vehicle stop Shift solenoid A At 60 km/h (37.5 mile/h) constant speed, 20% or less (CMD) throttle opening and 3rd gear (“3” range) At vehicle stop Shift solenoid B At 60 km/h (37.5 mile/h) constant speed, 20% or less (CMD)
Page 614: A/T Basic Check
5A-26 Automatic Transmission/Transaxle: Shift solenoid B (COM) (command signal of shift Shift solenoid B (Mon) (monitor signal of shift solenoid valve - B) (ON, OFF) solenoid valve - B) (ON, OFF) ON: ON command being outputted to shift solenoid ON: Electricity being passed to shift solenoid valve-B. valve-B.
Page 615: Road Test
Automatic Transmission/Transaxle: 5A-27 Road Test 1) Warm up engine. S6RW0C5104010 2) With engine running at idle, shift select “D” range. This test is to check if upshift, downshift and lock-up take 3) Accelerate vehicle speed by depressing accelerator place at specified speeds while actually driving vehicle pedal gradually.
Page 616: Manual Road Test
5A-28 Automatic Transmission/Transaxle: Manual Road Test S6RW0C5104011 WARNING • Carry out test in very little traffic area to prevent an accident. • Test requires 2 persons, a driver and a tester. The purpose of this test is to judge whether causal factor of trouble which occurred in automatic transaxle is electrical or mechanical by disconnecting valve body harness connector (1) and fixing automatic transaxle gear position.
Page 617: Stall Test
Automatic Transmission/Transaxle: 5A-29 Stall Test 1) Apply parking brake and block wheels. S6RW0C5104012 2) Warm up engine to normal operating temperature. This test is to check overall performance of automatic 3) Turn OFF all electrical loads. transaxle and engine by measuring stall speed at “D” and “R”...
Page 618: Time Lag Test
5A-30 Automatic Transmission/Transaxle: Time Lag Test 4) Similarly measure time lag by shifting select lever S6RW0C5104013 from “N” to “R” range. This test is to check conditions of clutch, reverse brake Gear shifting time lag and fluid pressure. “Time lag” means time elapsed since “N”...
Page 619 Automatic Transmission/Transaxle: 5A-31 1) Apply parking brake securely and place chocks against wheels. 2) Remove fluid pressure check hole plug bolt. 3) Attach oil pressure gauge to fluid pressure check hole in transaxle case. Special tool (A): 09925–37811–001 CAUTION After attaching oil pressure gauge, check that no fluid leakage exists. I4RH01510010-01 4) Depress foot brake fully, run engine at idle and stall then check fluid pressure in “D”...
Page 620: Engine Brake Test
5A-32 Automatic Transmission/Transaxle: Engine Brake Test S6RW0C5104015 WARNING Before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake operates.
Page 621: A/T Symptom Diagnosis
Automatic Transmission/Transaxle: 5A-33 A/T Symptom Diagnosis S6RW0C5104017 Trouble Diagnosis 1 Electrical repair Condition Possible cause Correction / Reference Item No up-shift (fixed gear Battery voltage abnormality Inspect charging system referring to position) “Generator Test (Undercharged Battery Check) in Section 1J” or “Generator Test (Overcharged Battery Check) in Section 1J”.
Page 622 5A-34 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC solenoid valve circuit faulty Inspect circuit for open, short and intermittent. up) system If NG, repair. Transmission range sensor circuit faulty Inspect circuit for open, short and intermittent. If NG, repair.
Page 623 Automatic Transmission/Transaxle: 5A-35 Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. → Poor 1 2 shift, Engine abnormal condition Inspect and repair engine. excessive shock or Malfunction of shift solenoid valve–A Inspect.
Page 624: Transmission Warning Light Circuit Check - Light Does Not Come "On" At Ignition Switch On (Non-Euro-Obd Model)
5A-36 Automatic Transmission/Transaxle: Trouble Diagnosis 3 Off-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in any Faulty forward clutch Inspection. If NG, replace. forward positions Unable to run in reverse Faulty direct clutch Inspection. If NG, replace. position Faulty 1st / reverse brake Inspection.
Page 625: Transmission Warning Light Circuit Check - Light Remains "On" At Ignition Switch On (Non-Euro-Obd Model)
Automatic Transmission/Transaxle: 5A-37 Step Action Combination Meter Function Check Replace combination Substitute a known- meter. good TCM and recheck. 1) Turn ignition switch ON. Does A/T selector position indicator show correct select lever position? Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON (Non-Euro- OBD Model) S6RW0C5104044 Troubleshooting...
Page 626: Dtc P0707: Transmission Range Sensor Circuit Low
Check transmission range sensor circuit Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent turned OFF. and Poor Connection Inspection in Section 2) Turn ignition switch to ON position and then check 00”.
Page 627 Check transmission range sensor circuit for operation Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent turned OFF. and Poor Connection Inspection in Section 2) Turn ignition switch to ON position and then check 00”.
Page 628: Dtc P0711: Transmission Fluid Temperature Sensor "A" Circuit Range / Performance
5A-40 Automatic Transmission/Transaxle: Step Action Check transmission range sensor “RED/BLK”, “GRN”, Replace Transmission “RED”, “GRN/YEL” or range sensor. 1) Check transmission range sensor referring to “LT GRN/BLK” circuit “Transmission Range Sensor Inspection and open. If wires and Adjustment”. connections are OK, Are check results satisfactory? substitute a known- good TCM and recheck.
Page 629: Dtc P0712: Transmission Fluid Temperature Sensor "A" Circuit Low
Automatic Transmission/Transaxle: 5A-41 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. Is DTC P0712 or DTC P0713 detected? Check transmission fluid temperature sensor Go to Step 4.
Page 630: Dtc P0713: Transmission Fluid Temperature Sensor "A" Circuit High
5A-42 Automatic Transmission/Transaxle: Step Action Check transmission fluid temperature sensor Intermittent trouble or Replace transmission faulty TCM. fluid temperature 1) Check transmission temperature sensor for resistance sensor. referring to “Transmission Fluid Temperature Sensor Check for intermittent Inspection”. referring to “Intermittent and Poor Connection Is it in good condition? Inspection in Section...
Page 631: Dtc P0717: Input Speed Sensor "A" Circuit No Signal
Automatic Transmission/Transaxle: 5A-43 Step Action Check transmission fluid temperature sensor circuit for “LT GRN” circuit shorted Intermittent trouble or IG short to power circuit. If circuit faulty TCM. Check for is OK, go to Step 4. intermittent referring to 1) Cool down A/T fluid temperature under ambient “Intermittent and Poor temperature.
Page 632 5A-44 Automatic Transmission/Transaxle: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and tester, on a level road. 1) Clear DTC.
Page 633: Dtc P0722: Output Speed Sensor Circuit No Signal
Automatic Transmission/Transaxle: 5A-45 DTC P0722: Output Speed Sensor Circuit No Signal S6RW0C5104024 Wiring Diagram C07-5 C07-14 2.5V 17 16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 21 20 19 26 25 23 22 24 23 18 17 I7RW01510011-01...
Page 634: Dtc P0741 / P0742: Torque Converter Clutch Circuit Performance Or Stuck Off / Stuck
5A-46 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check output shaft speed sensor circuit Go to Step 4. Go to Step 3. 1) Disconnect TCM connectors with ignition switch turned OFF.
Page 635: Dtc P0751 / P0752: Shift Solenoid "A" Performance Or Stuck Off / Shift Solenoid "A" Stuck
Automatic Transmission/Transaxle: 5A-47 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and tester, on a level road. 1) Clear DTC.
Page 636: Dtc P0756 / P0757: Shift Solenoid "B" Performance Or Stuck Off / Shift Solenoid "B" Stuck
5A-48 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve – A (No. 1) Clean fluid passage or Replace shift solenoid replace valve body valve – A (No. 1). 1) Check shift solenoid valve –...
Page 637: Dtc P0961: Pressure Control Solenoid "A" Control Circuit Range / Performance
Automatic Transmission/Transaxle: 5A-49 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance S6RW0C5104028 Wiring Diagram C06-4 LT GRN/BLK C06-2 17 16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 21 20 19 26 25 23 22 24 23...
Page 638: Dtc P0962: Pressure Control Solenoid "A" Control Circuit Low
5A-50 Automatic Transmission/Transaxle: DTC P0962: Pressure Control Solenoid “A” Control Circuit Low S6RW0C5104029 Wiring Diagram Refer to “DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Value of pressure control solenoid valve output •...
Page 639: Dtc P0963: Pressure Control Solenoid "A" Control Circuit High
Automatic Transmission/Transaxle: 5A-51 Step Action Check pressure control solenoid valve circuit for open “LT GRN/BLK” or “GRY” Intermittent trouble or circuit open. faulty TCM. Check for 1) Check resistance between terminals “C06-2” and “C06- intermittent referring to 4” of disconnected harness side TCM connector. “Intermittent and Poor Is it infinity? Connection Inspection...
Page 640: Dtc P0973 / P0976: Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low
5A-52 Automatic Transmission/Transaxle: Step Action Check pressure control solenoid valve resistance Intermittent trouble or Replace pressure faulty TCM. Check for control solenoid valve or 1) Turn ignition switch to OFF position. intermittent referring to lead wire. 2) Disconnect valve body harness connector (1) on “Intermittent and Poor transaxle.
Page 641 Automatic Transmission/Transaxle: 5A-53 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0973: • Shift solenoid valve – A (No. 1) or its circuit Difference between command signal and monitor signal of malfunction. (P0973) shift solenoid valve – A (shift solenoid valve – A circuit is •...
Page 642: Dtc P0974 / P0977: Shift Solenoid "A" Control Circuit High / Shift Solenoid "B" Control Circuit High
5A-54 Automatic Transmission/Transaxle: Step Action Check shift solenoid circuit for ground short valve “BRN” or “BLK/YEL” Intermittent trouble or circuit circuit shorted to faulty TCM. Check for ground. intermittent referring to 1) Disconnect TCM connectors. “Intermittent and Poor 2) Check for proper connection to “C06-15” and “C06-16” Connection Inspection terminals of TCM connector.
Page 643: Dtc P0602 / P1702: Control Module Programming Error / Internal Control Module Check Sum Error
Automatic Transmission/Transaxle: 5A-55 Step Action Check shift solenoid valve resistance Go to Step 4. Replace shift solenoid valve or lead wire. 1) Turn ignition switch to OFF position. 2) Disconnect valve body harness connector (1) on transaxle. 3) Check for proper connection to “BRN” and “BLK/YEL” terminals of valve body harness connector.
Page 644: Dtc P1723: Range Select Switch Malfunction
Go to Step 3. Check “3” position switch signal Intermittent trouble. Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent turned OFF. and Poor Connection 2) Turn ignition switch to ON position and check “3”...
Page 645: Dtc P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High
Automatic Transmission/Transaxle: 5A-57 Step Action Check “3” position switch circuit Intermittent trouble. “YEL” wire is open or Check for intermittent shorted to ground. If 1) Measure voltage between “C07-9” terminal of TCM referring to “Intermittent wire is OK, replace “3” connector and ground.
Page 646: Dtc P2764: Torque Converter Clutch Pressure Control Solenoid Control Circuit Low
5A-58 Automatic Transmission/Transaxle: Step Action Check TCC solenoid valve resistance Intermittent trouble or Replace TCC solenoid faulty TCM. Check for valve or lead wire. 1) Turn ignition switch to OFF position. intermittent referring to 2) Disconnect valve body harness connector (1) on “Intermittent and Poor transaxle.
Page 647: Dtc U0073: Control Module Communication Bus Off
Automatic Transmission/Transaxle: 5A-59 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid valve or lead wire. 1) Turn ignition switch to OFF position. 2) Disconnect valve body harness connector (1) on transaxle.
Page 648: Inspection Of Tcm And Its Circuits
5A-60 Automatic Transmission/Transaxle: Inspection of TCM and Its Circuits S6RW0C5104039 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage and resistance. CAUTION TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
Page 649 Automatic Transmission/Transaxle: 5A-61 Connector “C06” Standard Terminal Wire color Circuit Condition voltage C06-1 Ground for TCM 0 – 1 V Ignition switch is at ON position. LT GRN/ Ground for pressure control C06-2 0.6 – 1.0 V Ignition switch is at ON position. solenoid valve C06-3 —...
Page 650 5A-62 Automatic Transmission/Transaxle: Connector “C07” Standard Terminal Wire color Circuit Condition voltage Ignition switch is at ON position and select lever is 10 – 14 V “R” range signal for at “R” range. C07-1 transmission range sensor Ignition switch is at ON position and select lever is 0 –...
Page 651 Automatic Transmission/Transaxle: 5A-63 Reference waveform No. 1 Reference waveform No. 3 Signal of pressure control solenoid valve. High and low of CAN communication signals. Measurement Measurement CH1: “C06-7” to “C06-1” CH1: “C06-4” to “C06-2” terminal terminal CH2: “C06-17” to “C06-1” Oscilloscope CH1: 5 V/DIV Oscilloscope...
Page 652: Tcm Power And Ground Circuit Check
5A-64 Automatic Transmission/Transaxle: Reference waveform No. 5 Signal of input shaft speed sensor. Measurement CH1: “C07-6” to “C06-1” terminal Oscilloscope CH1: 1 V/DIV setting TIME: 4 ms/DIV Measurement Engine running at specified idle condition speed after warmed up engine. I7RW01510023-01 TCM Power and Ground Circuit Check S6RW0C5104040 Wiring Diagram...
Page 653 Automatic Transmission/Transaxle: 5A-65 Troubleshooting Step Action Check TCM back-up power supply circuit Go to Step 2. “WHT/RED” circuit is open or shorted to 1) Disconnect connectors from TCM with ignition switch ground. turned OFF. 2) Check for proper connection to “C06-6” and “C06-24” terminals of TCM connector.
Page 654: Brake Interlock System Inspection
5A-66 Automatic Transmission/Transaxle: Brake Interlock System Inspection • When ignition switch is turned ON and brake S6RW0C5104041 pedal is depressed, select lever can be shifted 1) Check that select lever cannot be moved to any from “P” range position to any other range. other range from “P”...
Page 655: Repair Instructions
Automatic Transmission/Transaxle: 5A-67 Repair Instructions A/T Fluid Level Check S6RW0C5106001 Level Check at Normal Operation Temperature 1) Stop vehicle and place it level. 2) Apply parking brake and place chocks against wheels. 3) With select lever at “P” position, start engine. 4) Warm up engine till fluid temperature reaches normal operating temperature (70 –...
Page 656: Select Lever Components
5A-68 Automatic Transmission/Transaxle: Select Lever Assembly Removal and 5) Lower vehicle and fill proper amount of an equivalent of DEXRON ® -III Installation S6RW0C5106004 6) Check fluid level referring to “A/T Fluid Level Check”. Remove and install select lever referring to “Select Lever Components”.
Page 657: 3" Position Switch Inspection
Automatic Transmission/Transaxle: 5A-69 “3” Position Switch Inspection Shift Lock Solenoid Inspection S6RW0C5106007 S6RW0C5106008 Check that shift lock solenoid rod (1) moves smoothly 1) Remove console box referring to “Console Box when battery voltage is conducted and it moves back. Components in Section 9H”. If solenoid rod does not move smoothly, replace.
Page 658: Select Cable Components
5A-70 Automatic Transmission/Transaxle: Select Cable Components S6RW0C5106010 I7RW01510034-01 1. Select lever assembly 6. Manual select lever pin 11. Heater inlet hose : Apply lithium grease 99000-25010 to all around pin (0.15 g) 2. Select cable 7. Select lever pin 12. Clamp : Apply lithium grease 99000-25010 to all around pin (0.15 g) 3.
Page 659: Key Interlock Cable Removal And Installation
5) Shift select lever to “N” position. 6) Apply grease to select lever pin and install adjuster (cable end) to it. : Grease 99000–25010 (SUZUKI Super Grease A) I5RW0C510045-01 7) With both select lever and transmission range 5) Turn ignition switch to LOCK position.
Page 660 5A-72 Automatic Transmission/Transaxle: Installation 1) Lay interlock cable to its original cabling route. I5RW0C510073-01 [A]: LH steering vehicle 2. Clamp 6. EPS control module [B]: RH steering vehicle 3. Steering lock assembly / Steering lock unit (if equipped with keyless start 7.
Page 661: Transmission Range Sensor Inspection And Adjustment
Automatic Transmission/Transaxle: 5A-73 2) Turn ignition switch to ACC position. 9) With select lever set at “P” position, turn ignition key to ACC position and then check for the following 3) Insert cable casing cap (1) into key cylinder cover (2) conditions.
Page 662: Output Shaft Speed Sensor Removal And Installation
5A-74 Automatic Transmission/Transaxle: Output Shaft Speed Sensor Removal and Adjustment Installation 1) Shift manual shift lever (1) to “N” range. S6RW0C5106015 2) Connect ohmmeter between 6 and 10 terminals of Removal disconnected transmission range sensor connector 1) Disconnect negative cable at battery. (3).
Page 663: Output Shaft Speed Sensor Inspection
Automatic Transmission/Transaxle: 5A-75 Output Shaft Speed Sensor Inspection 3) Connect input shaft speed sensor connector (2) to S6RW0C5106016 input shaft speed sensor (1). 1) Disconnect negative cable at battery. 2) Disconnect output shaft speed sensor connector (2). 3) Check resistance between output shaft speed sensor (1) terminals.
Page 664: Transmission Fluid Temperature Sensor Inspection
5A-76 Automatic Transmission/Transaxle: Transmission Fluid Temperature Sensor 3) Lift up vehicle. Inspection 4) With engine is cool, drain A/T fluid referring to “A/T S6RW0C5106020 Fluid Change”. 1) Remove transmission temperature sensor referring 5) Remove transmission fluid temperature sensor (1) to “Transmission Fluid Temperature Sensor Removal with O-ring.
Page 665 Automatic Transmission/Transaxle: 5A-77 4) Remove solenoid harness from clamp. 5) Disconnect solenoid connectors (1). I4RH01510042-01 4) Install pressure control solenoid (1). I4RH01510039-01 Tightening torque 6) Remove pressure control solenoid valve (2) after Pressure control solenoid bolt (a): 7.0 N·m (0.7 removing bolt (1).
Page 666: Solenoid Valves (Shift Solenoid Valves And Tcc Solenoid Valve) Inspection
Resistance Check mm (0.059 in) in diameter. Shift solenoid valve-A (No. 1), -B (No. 2) and TCC solenoid valve “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) Shift solenoid valve-A resistance Standard: 12 – 16 Ω at 20 °C (68 °F) "A"...
Page 667 Automatic Transmission/Transaxle: 5A-79 Operation Check TCC solenoid valve Shift solenoid valve-A (No. 1) and -B (No. 2) • Check that solenoid valve (1) actuate with click sound • Check that solenoid valve (1) actuate with click sound when battery voltage is conducted. when battery voltage is conducted.
Page 668: Pressure Control Solenoid Valve Inspection
5A-80 Automatic Transmission/Transaxle: Pressure Control Solenoid Valve Inspection Not using regulated DC power supply S6RW0C5106023 1) Connect pressure control solenoid valve (1) to battery (2) setting the 8 – 10 W bulb (4) on the way Resistance Check as shown in the figure. Check resistance between pressure control solenoid 2) Check for movement of valve (3) in the direction of valve (1) terminals.
Page 669: Transmission Control Module (Tcm) Removal And Installation
Refer to “Disabling Air Bag 4) Apply grease to new differential side oil seal lip. System in Section 8B”. : Grease 99000–25030 (SUZUKI Super Grease C) 3) Remove glove box. 4) Disconnect connectors from TCM (1).
Page 670: A/T Fluid Cooler Hoses Inspection
5A-82 Automatic Transmission/Transaxle: A/T Fluid Cooler Hoses Inspection A/T Relay Inspection S6RW0C5106072 S6RW0C5106027 Check automatic transaxle fluid cooler hoses (1) for fluid 1) Disconnect negative cable at battery. leakage, cracks, damage and deterioration. Replace 2) Remove A/T relay (1), from fuse box. hose and/or clamp if any faulty condition is found.
Page 671: Automatic Transaxle Unit Components
Automatic Transmission/Transaxle: 5A-83 Automatic Transaxle Unit Components S6RW0C5106028 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 30 N·m (3.0 kg-m) 11 N·m (1.1 kg-m) 23 N·m (2.3 kg-m) 70 N·m (7.0 kg-m) 85 N·m (8.5 kg-m) I7RW01510044-02 1. Clutch housing plate 4.
Page 672 5A-84 Automatic Transmission/Transaxle: 7) Remove starting motor. Tightening torque Drive plate to torque converter bolts (a): 23 N·m 8) Remove bolts and nut fastening engine and (2.3 kgf-m, 16.5 lb-ft) transaxle, then detach transaxle from engine. NOTE When detaching transaxle from engine, move it in parallel with crankshaft and use care so as not to apply excessive force to drive plate and torque converter.
Page 673: Automatic Transaxle Assembly Components
Automatic Transmission/Transaxle: 5A-85 Automatic Transaxle Assembly Components S6RW0C5106030 25 N·m(2.5 kg-m) 7.0 N·m(0.7 kg-m) 5.5 N·m(0.55 kg-m) 10 N·m(1.0 kg-m) 10 N·m(1.0 kg-m) 10 N·m(1.0 kg-m) 5.5 N·m(0.55 kg-m) I7RW01510050-02 1. Torque converter 6. Input shaft speed sensor 11. O-ring : Tightening torque 2.
Page 674 5A-86 Automatic Transmission/Transaxle: 5. Transmission fluid temperature sensor 10. Underdrive brake accumulator piston 15. Manual detent spring 25 N·m(2.5 kg-m) 10 N·m(1.0 kg-m) 24 N·m(2.4 kg-m) 10 N·m(1.0 kg-m) I4RH01510251-01 1. Transaxle rear cover 14. Planetary front gear 27. Thrust washer 40.
Page 675 Automatic Transmission/Transaxle: 5A-87 6. Bearing race 19. Snap ring 32. Bearing race 45. Differential side right bearing race 7. Input shaft 20. Retaining plate 33. Underdrive gear assembly 46. Differential gear 8. Thrust bearing 21. Friction plate 34. Thrust bearing 47.
Page 676: Automatic Transaxle Unit Disassembly
5A-88 Automatic Transmission/Transaxle: Automatic Transaxle Unit Disassembly 2) Remove fluid level gauge (1), fluid filler tube (2), S6RW0C5106031 output shaft speed sensor (3) and input shaft speed sensor (4) (for speedometer). CAUTION 3) Disconnect transmission fluid temperature sensor • Thoroughly clean transaxle exterior before connector (6) and remove transmission fluid overhauling it.
Page 677 Automatic Transmission/Transaxle: 5A-89 5) Remove transaxle side cover (1) by removing bolts. 10) Remove 2 gaskets (1). I4RH01510057-01 I4RH01510060-01 6) Remove solenoid harness from clamp. 11) Remove 17 bolts (1) of transaxle housing. 7) Disconnect pressure control solenoid, shift solenoid– 12) Remove 8 bolts (2) of oil pump body.
Page 678 5A-90 Automatic Transmission/Transaxle: 13) Remove transaxle housing with oil pump (1), using 17) Remove countershaft front bearing (1) using bearing special tool, and then remove oil pump body (2) by puller. hand. Special tool (A): 09912–34510 I4RH01510064-01 18) Remove differential gear assembly (1). 19) Remove one-way No.
Page 679 Automatic Transmission/Transaxle: 5A-91 21) Loosen 11 bolts of transaxle rear cover. 26) Remove forward and direct clutch assembly (1), thrust bearing (2) and bearing front race (3) of input 22) Lightly and uniformly tap two rib sections of transaxle shaft rear side. rear cover (1), using plastic hammer.
Page 680 5A-92 Automatic Transmission/Transaxle: 31) Remove front thrust bearing (2) and bearing race (1) 35) Remove oil reservoir LH plate (1). of front planetary ring gear. 32) Remove retainer ring (3) and 1st / reverse brake piston return spring (4). I4RH01510074-01 36) Remove parking lock pawl bracket and manual detent spring (1).
Page 681 Automatic Transmission/Transaxle: 5A-93 39) Remove underdrive gear assembly (1) with bearing 42) Remove underdrive brake band anchor bolt (1) with (2) and bearing race (3). O-ring (2), using special tool. Special tool (A): 09927–68010 I4RH01510076-01 40) Remove torsion spring (1), spacer (2) and I7RW01510062-02 underdrive brake accumulator bracket (3).
Page 682 5A-94 Automatic Transmission/Transaxle: 46) Remove underdrive brake piston as follows. 49) Remove 2 oil seal rings (1). a) Using special tool, compress underdrive brake piston cover (2) and remove snap ring using pliers or the like. b) Remove cover (2), piston (3) and spring (4) by applying compressed air (400 –...
Page 683: Oil Pump 2Nd Coast Brake And 2Nd Brake Components
Automatic Transmission/Transaxle: 5A-95 Oil Pump 2nd Coast Brake and 2nd Brake Components S6RW0C5106032 I4RH01510087-01 1. Oil pump oil seal 8. O-ring 15. Snap ring 22. Friction plate 2. Oil pump body 9. 2nd brake piston 16. 2nd coast brake piston 23.
Page 684: 2Nd Coast Brake And 2Nd Brake Preliminary Check
5A-96 Automatic Transmission/Transaxle: 2nd Coast Brake and 2nd Brake Preliminary Oil Pump, 2nd Coast Brake and 2nd Brake Check Disassembly and Reassembly S6RW0C5106033 S6RW0C5106034 1) Measure 2nd brake piston stroke while applying and Disassembly releasing compressed air (400 – 800 kPa, 4 – 8 kg/ , 57 –...
Page 685 Automatic Transmission/Transaxle: 5A-97 4) Using special tool and hydraulic press (1), compress 7) Remove snap ring (1), using flat end rod or the like. 2nd coast brake piston return spring (2) until spring 8) Remove retaining plate, friction plates, separator seat is pushed down to 1 –...
Page 686 6) After applying A/T fluid to new O-rings and install it to Special tool 2nd brake piston. (A): 09913–85210 7) Press 2nd brake piston into starter shaft. : Grease 99000–25030 (SUZUKI Super Grease C) NOTE Do not twist or deviate O-rings during installation. I4RH01510099-01...
Page 687 Automatic Transmission/Transaxle: 5A-99 8) Install 2nd brake piston return spring. 13) Install 2nd coast brake piston return spring (1). 9) Install cushion plate “C”, separator plates “S”, friction 14) Using special tool and hydraulic press (2), compress plates “F” and retaining plate “R” with flat end facing 2nd coast brake piston return spring (1) until spring to friction plates side in the following order.
Page 688 5A-100 Automatic Transmission/Transaxle: 15) Install separator plates “S”, friction plates “F” and retaining plate “R” in the following order. S → F → S → F → R NOTE Make sure that 2nd brake piston return spring is inserted in 2nd coast brake retaining plate boss.
Page 689: Oil Pump, 2Nd Brake And 2Nd Coast Brake Inspection
Automatic Transmission/Transaxle: 5A-101 Oil Pump, 2nd Brake and 2nd Coast Brake 3) Check side clearance of both gears. Using a straightedge (1) and a feeler gauge, Inspection measure side clearance between gears and pump S6RW0C5106035 1) Check body clearance of driven gear (1). body.
Page 690 5A-102 Automatic Transmission/Transaxle: 5) Measure inside diameter of starter shaft bushing, 7) Measure height of 2nd brake return spring and 2nd using special tools. coast brake return spring. If necessary, replace. If inside diameter exceeds limit, replace starter shaft. 2nd brake return spring height Starter shaft bushing inside diameter limit: Standard: 25.17 mm (0.99 in.) 21.57 mm (0.849 in.)
Page 691: One-Way No. 1 Clutch Components
Automatic Transmission/Transaxle: 5A-103 One-Way No. 1 Clutch Components S6RW0C5106036 I4RH01510114-01 1. One-way No. 1 clutch inner race 4. One-way No. 1 clutch outer race 2. One-way No. 1 clutch front thrust washer 5. One-way No. 1 clutch rear thrust washer 3.
Page 692: One-Way No. 1 Clutch Inspection
5A-104 Automatic Transmission/Transaxle: 2) Remove one-way No. 1 clutch inner race (1) and 4) Check that one-way No. 1 clutch (1) turns freely one-way No. 1 clutch front thrust washer (2). when turned counterclockwise [A] and looks when turned clockwise [B]. 3) Remove one-way No.
Page 693: Forward And Direct Clutch Components
Automatic Transmission/Transaxle: 5A-105 Forward and Direct Clutch Components S6RW0C5106040 I4RH01510119-01 1. Snap ring 6. Retaining plate 11. O-ring 16. Input shaft rear thrust bearing front race 2. Retaining plate 7. Friction plate 12. Direct clutch piston 17. Input shaft rear thrust bearing 3.
Page 694: Forward And Direct Clutch Preliminary Check 5A-106
5A-106 Automatic Transmission/Transaxle: Forward and Direct Clutch Preliminary Check Forward and Direct Clutch Disassembly and S6RW0C5106041 Reassembly 1) Install forward and direct clutch assembly (1) to S6RW0C5106042 transaxle rear cover (2). Disassembly 2) Measure forward clutch piston stroke while applying 1) Remove snap ring (1) using flat end rod or the like.
Page 695 Automatic Transmission/Transaxle: 5A-107 5) Using special tool and hydraulic press, compress 9) Remove forward clutch piston (1) with O-rings by direct clutch piston return spring and remove snap applying compressed air (400 – 800 kPa, 4 – 8 kg/ ring (1). , 57 –...
Page 696 5A-108 Automatic Transmission/Transaxle: 2) Apply A/T fluid to new O-rings and install new O- 8) Install separator plates “S”, friction plates “F” and rings to forward clutch piston. retaining plate “R” in the following order. S → F → S → F → S → F → S → F → R 3) Press forward clutch piston to input shaft.
Page 697 Automatic Transmission/Transaxle: 5A-109 12) Measure forward clutch piston stroke again, using 13) Measure direct clutch piston stroke again, using special tools. special tools. If measured piston stroke exceeds specified value, If measured piston stroke exceeds specified value, replace forward clutch retaining plate with new one replace direct clutch retaining plate with new one so so that piston stroke is within standard value.
Page 698: Forward And Direct Clutch Inspection
5A-110 Automatic Transmission/Transaxle: Forward and Direct Clutch Inspection 3) Check that ball makes creaking noise when shaking S6RW0C5106043 forward clutch piston and direct clutch piston. (i.e., 1) Check that sliding surfaces of friction, separator and check that ball is free.) retaining plates are not worn or burnt.
Page 699: 1St / Reverse Brake And One-Way No. 2 Clutch Components
Automatic Transmission/Transaxle: 5A-111 1st / Reverse Brake and One-Way No. 2 Clutch Components S6RW0C5106044 I7RW01510054-01 1. O-ring 6. Friction plate 11. One-way No. 2 clutch inner race 16. Front planetary ring gear flange 2. 1st / reverse brake piston 7. Retaining plate 12.
Page 700: 1St / Reverse Brake And One-Way No. 2 Clutch Operation Check
5A-112 Automatic Transmission/Transaxle: 1st / Reverse Brake and One-Way No. 2 Clutch 4) Remove snap ring (1), using pliers or the like. Operation Check 5) Remove front planetary ring gear flange (2) from S6RW0C5106045 front planetary ring gear (3). One-Way No. 2 Clutch 1) Check that one-way No.
Page 701: 1St / Reverse Brake And One-Way No. 2 Clutch Inspection
Automatic Transmission/Transaxle: 5A-113 4) Fit flat surface of thrust washer (1) to front planetary 1st / Reverse Brake and One-Way No. 2 Clutch ring gear with petroleum jelly so as not to fall washer Inspection off when reassembling. S6RW0C5106047 1) Check that sliding surfaces of friction, separator and retaining plates are not worn or burnt.
Page 702: Underdrive Clutch And One-Way No. 3 Clutch Components
5A-114 Automatic Transmission/Transaxle: Underdrive Clutch and One-Way No. 3 Clutch Components S6RW0C5106048 I7RW01510055-01 1. Snap ring 5. Snap ring 9. Underdrive clutch drum 13. Cushion plate 2. Separator plate 6. Underdrive clutch piston return spring 10. Underdrive clutch thrust bearing : Apply automatic transaxle fluid.
Page 703: Underdrive Clutch And One-Way No. 3 Clutch Preliminary Check
Automatic Transmission/Transaxle: 5A-115 Underdrive Clutch and One-Way No. 3 Clutch Underdrive Clutch and One-Way No. 3 Clutch Preliminary Check Operation Check S6RW0C5106049 S6RW0C5106050 1) Install underdrive clutch (1) to transaxle case (2). 1) Install one-way No. 3 clutch (1) to underdrive clutch drum (2).
Page 704 5A-116 Automatic Transmission/Transaxle: 3) Using special tool and hydraulic press (2), compress 5) For removing underdrive clutch piston (1), install underdrive clutch piston return spring (1) until spring underdrive clutch drum to transaxle case (2). seat is pushed down to 1 – 2 mm (0.039 – 0.078 in.) 6) Remove underdrive clutch piston with O-rings by lower than snap ring groove and remove snap ring applying compressed air (400 –...
Page 705 Automatic Transmission/Transaxle: 5A-117 3) Using special tool and hydraulic press (2), compress 4) Install cushion plate “C”, separate plates “S”, friction underdrive clutch piston return spring (1) until spring plates “F” and retaining plate “R” of coast clutch in seat is pushed down to 1 – 2 mm (0.039 – 0.078 in.) the following order.
Page 706: Underdrive Clutch And One-Way No. 3 Clutch Inspection
5A-118 Automatic Transmission/Transaxle: Underdrive Clutch and One-Way No. 3 Clutch 3) Shake underdrive clutch piston lightly and check that check ball (1) is not stuck. Check that valve does not Inspection have leaks by applying low-pressure cam pressed S6RW0C5106052 1) Check that sliding surfaces of friction, separator and air.
Page 707: Planetary Gear Components
Automatic Transmission/Transaxle: 5A-119 Planetary Gear Components S6RW0C5106053 I4RH01510150-01 1. Planetary front gear 5. Rear planetary ring gear flange 9. Planetary sun gear 2. Front planetary carrier rear thrust bearing race 6. Snap ring 10. Input shaft front thrust bearing 3. Front planetary carrier rear thrust bearing 7.
Page 708: Planetary Gear Disassembly And Reassembly
5A-120 Automatic Transmission/Transaxle: Planetary Gear Disassembly and Reassembly Planetary Gear Inspection S6RW0C5106054 S6RW0C5106055 Disassembly Rear Planetary Ring Gear Assembly Visually check the following parts for scratches or Rear planetary ring gear assembly discoloration. 1) Remove snap ring (1) using flat end rod or the like. •...
Page 709: Underdrive Brake Components
Automatic Transmission/Transaxle: 5A-121 Underdrive Brake Components S6RW0C5106056 I4RH01510154-01 1. Underdrive brake band anchor bolt 6. Underdrive brake piston rod washer 11. O-ring 2. O-ring 7. Underdrive brake piston rod spring 12. Underdrive brake piston cover 3. Underdrive brake band 8. O-ring 13.
Page 710: Underdrive Brake Inspection
5A-122 Automatic Transmission/Transaxle: Underdrive Brake Inspection 4) Remove O-rings (1) from underdrive brake piston cover (2). S6RW0C5106058 1) Measure free length underdrive brake piston return NOTE spring. If necessary, replace. Never reuse removed O-rings. Underdrive brake piston return spring free length Standard: 63.20 mm (2.49 in.) NOTE Do not apply excessive force when...
Page 711: Underdrive Gear Assembly Components
Automatic Transmission/Transaxle: 5A-123 Underdrive Gear Assembly Components S6RW0C5106060 I4RH01510161-01 1. Countershaft front thrust bearing 3. Underdrive gear assembly 5. Countershaft rear thrust bearing race 2. Countershaft front thrust bearing race 4. Countershaft rear thrust bearing : Apply automatic transaxle fluid. Underdrive Gear Preliminary Check S6RW0C5106061 Measure starting torque of underdrive gear, using spring force gauge, attach cord at gear of underdrive gear.
Page 712: Valve Body Assembly Components
5A-124 Automatic Transmission/Transaxle: Valve Body Assembly Components S6RW0C5106062 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) 7 N·m(0.7 kg-m) I4RH01510176-01 1. Valve body assembly 5. Pressure control solenoid valve clamp 9. Shift solenoid valve–B (No. 2) 13.
Page 713: Valve Body Assembly Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-125 Valve Body Assembly Disassembly and Reassembly Reassembly 1) Apply A/T fluid to new O-rings and install O-rings to S6RW0C5106063 each solenoid valves. 2) Install solenoid valves to valve body and tighten Disassembly bolts to specified torque. 1) Pull out manual valve. Tightening torque 2) Remove solenoid valves with O-ring by removing Shift solenoid bolts (a): 7.0 N·m (0.7 kgf-m, 5.0...
Page 714: Differential Components
5A-126 Automatic Transmission/Transaxle: Differential Components S6RW0C5106064 99 N·m(9.9 kg-m) I4RH01510178-01 1. Differential side right bearing race 5. Ring gear set bolt lock plate : Apply automatic transaxle fluid. 2. Bolt 6. Differential side left bearing race : Tightening torque 3. Differential gear assembly 7.
Page 715: Differential Gear Assembly Removal And
Automatic Transmission/Transaxle: 5A-127 Differential Gear Assembly Removal and Available differential side bearing shim thickness (Thickness: Identification) Installation S6RW0C5106066 1.00 mm (0.039 in.): 21 1.48 mm (0.058 in.): 33 1.05 mm (0.041 in.): 22 1.51 mm (0.059 in.): 34 Removal 1.10 mm (0.043 in.): 23 1.54 mm (0.060 in.): 35 Final gear 1.15 mm (0.045 in.): 24...
Page 716 5A-128 Automatic Transmission/Transaxle: 2) Install differential side left bearing race (1) to 6) Install differential assembly to transaxle case and transaxle housing (2), using special tool. tighten case bolts to specified torque. Special tool Tightening torque (A): 09924–07710 Transaxle housing bolts: 30 N·m (3.0 kgf-m, 22.0 lb-ft) 7) Measure differential assembly starting torque, using special tool.
Page 717: Transaxle Rear Cover Components
Automatic Transmission/Transaxle: 5A-129 Transaxle Rear Cover Components S6RW0C5106067 10 N·m(1.0 kg-m) 10 N·m(1.0 kg-m) 24 N·m(2.4 kg-m) 24 N·m(2.4 kg-m) 10 N·m(1.0 kg-m) I4RH01510190-02 1. Forward clutch accumulator 5. Transaxle rear cover : Apply automatic transaxle fluid. 2. Forward clutch accumulator spring 6.
Page 718: Transaxle Rear Cover Inspection
1.0 kgf-m, 7.5 lb-ft) S6RW0C5106070 1) Apply lithium grease to new manual shift shaft oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C) 2) Press-fit new manual shift shaft oil seal (1) to transaxle case, using special tool. Special tool (A): 09943–88211...
Page 719 Automatic Transmission/Transaxle: 5A-131 4) Install one-way No. 3 clutch (1) to transaxle case. 8) Push underdrive brake accumulator cover and install underdrive brake accumulator bracket (1), spacer (2) NOTE ® and torsion spring (3) by tighten 2 torx bolts to Make sure that groove section of one-way specified torque.
Page 720 5A-132 Automatic Transmission/Transaxle: 11) Apply special tools and push in underdrive brake 17) Measure underdrive brake piston stroke while piston cover (1). applying and releasing compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) through oil hole (2). Special tool If measured piston stroke exceeds specified value, (A): 09916–14510...
Page 721 Automatic Transmission/Transaxle: 5A-133 20) Apply petroleum jelly to underdrive clutch thrust 27) Install parking lock pawl (1). Place torsion spring (2) bearing (1) and countershaft rear thrust bearing race on parking lock pawl shaft (3) and install them into (2). transaxle case.
Page 722 5A-134 Automatic Transmission/Transaxle: 32) Apply A/T fluid to new O-rings and install O-rings to 38) Apply petroleum jelly to front planetary ring gear 1st / reverse brake piston (1). front thrust bearing (1) and front planetary ring gear rear thrust bearing (2). 33) Place 1st / reverse brake piston (1) into transaxle case.
Page 723 Automatic Transmission/Transaxle: 5A-135 44) Measure 1st / reverse brake piston stroke while 49) Install input shaft front thrust bearing (1), planetary applying and releasing compressed air (400 – 800 sun gear (3), and rear planetary ring gear rear thrust kPa, 4 – 8 kg/cm , 57 –...
Page 724 I4RH01510223-01 61) Apply sealant to mating surface of transaxle case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter. “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) I4RH01510226-01 "A" I4RH01510224-01...
Page 725 72) Apply sealant to mating surface of transaxle case by using a nozzle as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter. “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) I4RH01510227-01 69) Install oil reservoir LH plate (1) and tighten 2 bolts to specified torque.
Page 726 5A-138 Automatic Transmission/Transaxle: 73) Install transaxle housing to transaxle case by 15 75) Check for correct installation of each component tightening bolts to specified torque. parts as follows. Measure the distance “a” by using vernier (1) and Bolt Size Length (mm) Pieces straight edge (2).
Page 727 Automatic Transmission/Transaxle: 5A-139 77) Measure end play of input shaft (1), using special tool. If end play is out of specification, replace input shaft rear thrust bearing front race in the following so as end play to be in standard value. Special tool (A): 09900–20607 (B): 09900–20701...
Page 728 1.5 mm (0.059 in.) in diameter. speed sensor (3) and fluid filler tube (4). 88) Install input shaft speed sensor and output shaft “A”: Sealant 99000–31230 (SUZUKI Bond speed sensor (with new O-rings installed) by No.1216B) tightening bolts to specified torque.
Page 729 Automatic Transmission/Transaxle: 5A-141 91) Install transmission range sensor assembly. 92) Install torque converter (1) to input shaft. a) Install transmission range sensor plate (1) to a) Install torque converter (1), using care not to groove of solenoid harness. damage oil seal of oil pump. b) Install transmission range sensor (2) to manual b) After installing torque converter (1), check that valve lever shaft (3).
Page 730 5A-142 Automatic Transmission/Transaxle: Specifications Tightening Torque Specifications S6RW0C5107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft A/T fluid drain plug 29.0 Transmission range sensor bolt 18.0 Transmission range sensor nut 0.75 Output shaft speed sensor bolt 0.55 Input shaft speed sensor bolt 0.55 Transmission fluid temperature sensor Shift solenoid bolts...
Page 731: Recommended Service Material
Automatic Transmission/Transaxle: 5A-143 Special Tools and Equipment Recommended Service Material S6RW0C5108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 SUZUKI Super Grease C P/No.: 99000–25030 Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 NOTE Required service material is also described in the following.
Page 732 Anchor Bolt Socket Adaptor, Differential Preload 09940–51710 09941–51010 Bearing installer Lock ring wrench 09943–88211 SUZUKI scan tool (SUZUKI- SDT) Pinion bearing installer — This kit includes following items. 1. SUZUKI-SDT 2. DLC3 cable 3. USB cable 4. AC/DC power supply 5.
Page 733: Manual Transmission/Transaxle
Manual Transmission/Transaxle: 5B-1 Manual Transmission/Transaxle Transmission / Transaxle General Description Manual Transaxle Construction S6RW0C5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 734 5B-2 Manual Transmission/Transaxle: I5RW0A520001-01 1. Input shaft 6. Input shaft 3rd gear 11. Countershaft 16. Countershaft 2nd gear 2. 5th speed sleeve & hub 7. Left case 12. Side cover 17. Low speed sleeve & hub 3. Input shaft 5th gear 8.
Page 735 Manual Transmission/Transaxle: 5B-3 I5RW0A520002-05 1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear 22. Transfer driven gear 2. 5th speed sleeve & hub 9. Reverse idler gear 16. Countershaft 2nd gear 23. Transfer bevel gear 3. Input shaft 5th gear 10.
Page 736 5B-4 Manual Transmission/Transaxle: Gear Shift Mechanism The gear shifting control system consists of the following main parts. Movement of gear shift control lever is transmitted to gear shift & select shaft through gear shift and gear select cables. I7RW01520011-01 1. Gear shift control cable 7.
Page 737 Manual Transmission/Transaxle: 5B-5 5th & Reverse Gear Shift Cam 3) When shift lever is shifted to 5th gear, shift & select 5th & reverse gear shift cam, cam guide return spring shaft (1) turns clockwise letting shift cam (2) off from and 5th to reverse interlock guide bolt are provided to guide bolt and pushed up by return spring.
Page 738: Diagnostic Information And Procedures
3) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. “A”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Transaxle oil level / filler plug (a): 21 N·m (2.1 kgf-m, 15.5 lb-ft)
Page 739: Manual Transaxle Oil Change
7) Apply sealant to thread of level / filler plug, and then S6RW0C5206002 tighten it to specified torque. 1) Before changing oil, be sure to stop engine and lift “A”: Sealant 99000–31260 (SUZUKI Bond vehicle horizontally. No.1217G) 2) With vehicle lifted up, check leakage.
Page 740: Differential Side Oil Seal Replacement
1) Lift up vehicle and drain transaxle oil. sure of its smoothness. 2) Remove drive shaft assembly and center shaft “A”: Grease 99000–25011 (SUZUKI Super referring to “Front Drive Shaft Assembly Removal Grease A) and Installation in Section 3A”.
Page 741: Gear Shift Control Lever And Cable Components
Manual Transmission/Transaxle: 5B-9 Gear Shift Control Lever and Cable Components S6RW0C5206004 I7RW01520009-02 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut 11. Shift cable seal 2. Cable bracket bolt 7. Gear shift control lever assembly : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) 3.
Page 742: Gear Shift Control Lever And Cable Removal And Installation
(1) into pin of gear shift control lever securely. Installation Reverse removal procedure for installation nothing the “A”: Grease 99000–25011 (SUZUKI Super following. Grease A) • Tighten each bolts and nuts to specified torque 4) Push cable end holder (2) in the direction of A.
Page 743: Back Up Light Switch Removal And Installation
Manual Transmission/Transaxle: 5B-11 5) Slide lock plate (3) in the direction of C, until it gets Installation over the claw (4) of cable end holder. 1) Apply oil to new O-ring (1) and tighten back up light switch (2) to specified torque. Tightening torque Back up light switch (a): 23 N·m (2.3 kgf-m, 17.0 lb-ft)
Page 744: Manual Transaxle Unit Components
5B-12 Manual Transmission/Transaxle: Manual Transaxle Unit Components S6RW0C5206009 I7RW01520001-01 [A]: Forward 4. Back up light switch connector 8. Transaxle to engine nut 1. Engine 5. Ground cable bolt 9. Stiffener bolt 2. Transaxle 6. Ground cable : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 3.
Page 745: Manual Transaxle Unit Dismounting And Remounting
Manual Transmission/Transaxle: 5B-13 Manual Transaxle Unit Dismounting and 15) For 2WD model, remove front suspension frame, engine front mounting member and engine mounting Remounting member referring to “Front Suspension Frame, S6RW0C5206010 Stabilizer Bar and/or Bushing Removal and Dismounting Installation (2WD Model) in Section 2B” and “Engine 1) Drain coolant.
Page 746: Gear Shift And Select Shaft Assembly Components
5B-14 Manual Transmission/Transaxle: Gear Shift and Select Shaft Assembly Components S6RW0C5206011 1217G 1217G 1217G I6RW0C520001-01 1. Gear shift & select shaft 7. Gear shift guide case bolt No.1 13. Oil seal : Apply sealant 99000-31260 to bolt thread. : Apply grease 99000-25011 to oil seal lip. 2.
Page 747: Gear Shift And Select Shaft Assembly Removal And Installation
2) Install guide case bolts No.1 to which sealant has been applied and guide case bolts No.2 (2), and tighten them to specified torque. : Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque I5RW0A520017-02 Guide case bolt No.1: 23 N·m (2.3 kgf-m, 17.0 lb- 5) Connect gear shift and gear select control cables to transaxle.
Page 748: Gear Shift And Select Shaft Assembly Disassembly And Reassembly
5B-16 Manual Transmission/Transaxle: Gear Shift and Select Shaft Assembly Disassembly and Reassembly S6RW0C5206013 1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown bellow. Special tool (A): 09922–85811 4.5 mm (B): 09925–78210 6.0 mm...
Page 749: Manual Transaxle Assembly Components
Manual Transmission/Transaxle: 5B-17 Manual Transaxle Assembly Components S6RW0C5206014 I7RW01520004-01 1. Transaxle right case 22. Shift fork bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case 23. 5th gear shift fork : Apply sealant 99000-31260 to mating surface of left case and right case.
Page 750: Fifth Gear Disassembly And Reassembly
: Apply thread lock 99000-32110 to all around thread part of bolt. 12. Left case plate bolt 33. Oil seal : Apply thread lock 99000-32110 to all around thread part of bolt. : Apply SUZUKI SUPER GREASE A 99000-25010 to Oil seal lip. 13. Side cover bolts 34. Outer race 14.
Page 751 Manual Transmission/Transaxle: 5B-19 Reassembly a) Install hub (1) to 5th speed synchronizer sleeve (2) in specified direction as shown in figure. 1) Install countershaft 5th gear (1) to countershaft facing machined boss “A” inward. I4RH01520048-01 A: Chamfered side B: Long boss I2RH01520088-01 b) Fit 5th speed synchronizer levers (1) to hub (2) in A: Machined boss (Inside)
Page 752: Manual Transaxle Assembly Disassembly And Reassembly
(5) on input shaft. (0.059 in.) in diameter, mate it with left case, and then tighten side cover bolts with specified torque. “B”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Page 753 Manual Transmission/Transaxle: 5B-21 2) Remove bearing set shim. 8) Pull out reverse gear shaft (1) with washer (2), then take off reverse idler gear (3). 3) Remove snap ring (1) using snap ring pliers (4). 9) Remove reverse gear shift lever bolts (4) and reverse gear shift lever (5).
Page 754 5B-22 Manual Transmission/Transaxle: Reassembly 4) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) and washer (6) 1) Install differential assembly into right case. into case (4) through idler gear and then align bolt 2) Join input shaft (5), countershaft (4), low speed gear hole “a”...
Page 755 1.5 mm (0.059 in.) Locating spring in diameter then mate it with right case (1). Locating spring free length Standard Service limit “A”: Sealant 99000–31260 (SUZUKI Bond 53.1 mm 47.8 mm Low speed (2) No.1217G)
Page 756 5B-24 Manual Transmission/Transaxle: 12) To seat countershaft left bearing outer race (2) to 15) By repeating step 14), select a suitable shim which bearing cone, tap cup by using special tool and adjusts clearance “a” to specification and put it on plastic hammer.
Page 757: Right Case Disassembly And Reassembly
Manual Transmission/Transaxle: 5B-25 Right Case Disassembly and Reassembly 16) Place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten bolts (1) to S6RW0C5206017 which thread lock cement has been applied. Disassembly NOTE 1) Remove differential side oil seal from right case referring to “Differential Side Oil Seal Replacement”, After tightening bolts, make sure that...
Page 758: Left Case Disassembly And Reassembly
Disassembly special tool and hammer for installation and apply 1) Removal oil gutter (1), if necessary. grease to oil seal lip. : Grease 99000–25011 (SUZUKI Super Grease A) Special tool (A): 09913–76010 I4RH01520028-01 2) Remove oil seal using flat end rod or the like.
Page 759 Manual Transmission/Transaxle: 5B-27 2) Select differential side shim as follows. 3) Select shim closest to clearance “d” from among the following available sizes. a) Keep pushing outer race (4) with the power of 35 N (3.5 kgf) and turn differential case 10 times or Available shim thickness more.
Page 760: Input Shaft And Countershaft Components
5B-28 Manual Transmission/Transaxle: Input Shaft and Countershaft Components S6RW0C5206019 I3RH0A520017-01 1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone 2. Oil seal 13. Circlip 24. 2nd gear synchronizer inner ring : Apply grease 99000-25010 to oil seal lip. 3.
Page 761: Input Shaft Disassembly And Reassembly
Manual Transmission/Transaxle: 5B-29 Input Shaft Disassembly and Reassembly 3) Take out 4th gear needle bearing and high speed S6RW0C5206020 synchronizer ring. 4) Using snap ring pliers (2), remove circlip (1). Disassembly 1) Remove input shaft right bearing (2) from input shaft NOTE (1) using bearing puller (3) and hydraulic press.
Page 762 5B-30 Manual Transmission/Transaxle: Reassembly 4) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as 1) Clean all components thoroughly, inspect them for shown in figure. any abnormality and replace with new ones as necessary.
Page 763 Manual Transmission/Transaxle: 5B-31 6) Install 3rd gear needle bearing (4), apply oil to it, 8) Install circlip (1) and confirm that circlip is installed in then install 3rd gear (1) and synchronizer ring (2). groove securely. Install needle bearing (2) of apply oil to it and then install synchronizer ring (3) and 4th 7) Drive in high speed sleeve &...
Page 764: Countershaft Disassembly And Reassembly
5B-32 Manual Transmission/Transaxle: Countershaft Disassembly and Reassembly 3) Take out 2nd synchronizer outer ring, center cone S6RW0C5206021 and inner ring. 4) Using snap ring pliers (3), remove circlip (1). Disassembly 1) Drive out left bearing cone (2) with 4th gear (3) by NOTE using puller (4) and hydraulic press.
Page 765 Manual Transmission/Transaxle: 5B-33 6) Disassemble synchronizer sleeve & hub assembly. 7) Take out 1st gear needle bearing from shaft. 8) In order to remove right bearing (1) from countershaft, grind with a grinder (2) one part “a” of right bearing (1) as illustrated till it becomes thin. CAUTION Be careful not to grind too far not to damage the shaft (3).
Page 766 5B-34 Manual Transmission/Transaxle: 5) Fit low speed synchronizer sleeve (4) to hub (3), 7) Install needle bearing (4), apply oil to it, then install insert 3 keys (2) in it and then set springs (1) as 1st gear and 1st gear synchronizer ring (2). shown in figure.
Page 767 Manual Transmission/Transaxle: 5B-35 9) Install circlip (1) and confirm that circlip is installed in 11) Press-fit 4th gear (2) by using the same procedure at groove securely. step 10). Install needle bearing (2) and apply oil to needle 12) Install left bearing cone (1) by using special tool and bearing.
Page 768: Gear Shift Shaft Components
5B-36 Manual Transmission/Transaxle: Gear Shift Shaft Components S6RW0C5206022 I5RW0A520041-01 1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft 7. 5th & reverse gear shift yoke 2. High speed gear shift shaft 5. Reverse gear shift arm : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) 3.
Page 769: Differential Components
Manual Transmission/Transaxle: 5B-37 Differential Components S6RW0C5206025 I5RW0A520043-02 1. Differential pinion washer 6. Differential case : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 2. Differential pinion 7. Final gear : Do not reuse. 3. Differential side gear 8. Final gear bolt : Apply transaxle oil. 4.
Page 770 5B-38 Manual Transmission/Transaxle: 3) Support differential case (1) with soft jawed vise and Available side gear washer thickness remove final gear bolts then take out final gear. 0.9 mm (0.035 in.) 1.1 mm (0.043 in.) 0.95 mm (0.037 in.) 1.15 mm (0.045 in.) 4) Drive out differential pinion shaft (3) pin by using 1.0 mm (0.039 in.) 1.20 mm (0.047 in.)
Page 771 Manual Transmission/Transaxle: 5B-39 5) Hold differential assembly with soft jawed vise (3), 4) Press-fit right bearing (1) by using special tools and hydraulic press. install final gear (2) and then tighten new final gear bolts (1). Special tool (A): 09925–15410 CAUTION (B): 09924–07720 Use of any other bolts than specified ones is...
Page 772: Recommended Service Material
5B-40 Manual Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S6RW0C5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 773 Manual Transmission/Transaxle: 5B-41 09913–80113 09913–84510 Bearing installer Bearing installer 09913–85210 09913–85230 Bearing installer Bearing remover tool 09922–85811 09923–78210 Spring pin remover (4.5 mm) Bearing installer 09924–07710 09924–07720 Synchronizer hub installer Synchronizer hub installer 09924–74510 09924–84510–004 Bearing and oil seal handle Bearing installer attachment 09925–14520 09925–15410...
Page 774 5B-42 Manual Transmission/Transaxle: 09940–54950 09941–64511 Bearing installer attachment Bearing and oil seal remover (30 mm Min.) 09942–15511 09944–96011 Sliding hammer Bearing outer race remover 09952–06010 Dial gauge plate No.1...
Page 775: General Description
Clutch: 5C-1 Clutch Transmission / Transaxle General Description Clutch (Hydraulic Type) Construction S6RW0C5301001 The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
Page 776: Diagnostic Information And Procedures
5C-2 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis S6RW0C5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Bleed air or replace master cylinder. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
Page 777: Repair Instructions
Clutch: 5C-3 Repair Instructions Clutch Pedal Inspection 6) If “c” is not within specification, it is possible that air S6RW0C5306001 is trapped in this system. If suspected so, bleed air Cylinder Push Rod Play “a” referring to “Air Bleeding of Clutch System”. Upon 1) Press clutch pedal (1) gradually with finger, stop completion of above inspection, start engine and when slight increase of resistance is felt and...
Page 778: Air Bleeding Of Clutch System
5C-4 Clutch: Air Bleeding of Clutch System 6) When bubbles stop, depress and hold clutch pedal, S6RW0C5306003 and tighten bleeder plug. CAUTION Tightening torque Clutch bleeder plug: 5 N·m (0.5 kgf-m, 4.0 lb-ft) • Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted 7) Then attach bleeder plug cap.
Page 779: Clutch Pedal Position (Cpp) Switch Inspection And Adjustment
Clutch: 5C-5 Clutch Pedal Position (CPP) Switch Inspection Adjustment With clutch pedal (1) depressed, adjust switch (2) and Adjustment position so that clearance between end of thread and S6RW0C5306005 clutch pedal arm is within specification and then tighten Inspection lock nut to specified torque. Check for resistance between terminals under each Clearance between end of thread and clutch pedal condition below.
Page 780: Clutch Fluid Pipe Removal And Installation
5C-6 Clutch: Clutch Fluid Pipe Removal and Installation Clutch Fluid Pipe Inspection S6RW0C5306007 S6RW0C5306008 Check pipe (1) for damage, dirt and leak. Replace if Removal check result is not satisfactory. CAUTION Do not allow fluid to get on painted surface. It may cause painted surface damage.
Page 781: Clutch Operating Cylinder Assembly Removal And Installation
5) Remove clutch operating cylinder assembly from Reverse removal procedure for installation noting the transaxle. following. • Apply grease to push rod tip. “A”: Grease 99000–25100 (SUZUKI Silicone Grease) “A” I5RW0A530007-01 I5RW0A530008-01 • Tighten clutch master cylinder nut to specified torque.
Page 782: Clutch Operating Cylinder Assembly Inspection
5C-8 Clutch: 4) Remount transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting in Section 5B”. 5) Bleed air from system and check clutch pedal free travel. Refer to “Air Bleeding of Clutch System” and “Clutch Pedal Inspection”. I5RW0B530005-03 Clutch Operating Cylinder Assembly Inspection S6RW0C5306014 Check clutch fluid leakage, spring for damage and...
Page 783: Clutch Cover, Clutch Disc And Flywheel Removal And Installation
Clutch: 5C-9 Clutch Cover, Clutch Disc and Flywheel 4) Remove flywheel (1) from crankshaft using special tool. Removal and Installation S6RW0C5306012 Special tool (A): 09924–17810 Removal 1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and Remounting in Section 5B”. 2) Hold flywheel with special tool and remove clutch cover bolts (1), clutch cover (2) and clutch disc.
Page 784 “Manual Transaxle Unit Dismounting and Special tool Remounting in Section 5B”. (B): 09925–98210 “A”: Grease 99000–25210 (SUZUKI Super Grease I) NOTE When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the splines.
Page 785 Clutch: 5C-11 Clutch Cover and Clutch Disc Inspection Clutch Cover S6RW0C5306013 1) Check diaphragm spring (1) for abnormal wear or damage. Clutch Disc 2) Inspect pressure plate (2) for wear or heat spots. Measure depth of rivet head depression, i.e. distance between rivet head and facing surface.
Page 786: Special Tools And Equipment
5C-12 Clutch: Special Tools and Equipment Recommended Service Material S6RW0C5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210 Special Tool S6RW0C5308002 09921–26020 09923–36320 Bearing remover Clutch center guide (15 mm) 09924–17810...
Page 787 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Precautions in Diagnosing Troubles ....6C-1 General Description ..........6C-2 Precautions............. 6-1 P/S System Description ........6C-2 Precautions on Steering........6-1 EPS Diagnosis General Description ....6C-3 Steering General Diagnosis....6A-1 On-Board Diagnostic System Description...6C-3 Schematic and Routing Diagram ......6C-4 Precautions............6A-1 EPS System Wiring Circuit Diagram ....6C-4...
Page 788 6-ii Table of Contents Tie-Rod End Removal and Installation....6C-37 P/S Control Module Removal and Installation...6C-42 Tie-Rod End Inspection........6C-38 Torque Sensor and Its Circuit Inspection ..6C-42 Steering Shaft Joint On-Vehicle Inspection..6C-38 P/S Motor and Its Circuit Inspection ....6C-43 Steering Gear Case Assembly Removal and Specifications .............6C-45 Installation ............6C-38 Tightening Torque Specifications......6C-45...
Page 789: Precautions
Precautions: Precautions Steering Precautions Precautions on Steering S6RW0C6000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions for Steering Diagnosis Refer to “Precautions for Steering Diagnosis in Section 6A”. Service Precautions of Steering Wheel and Column Refer to “Service Precautions of Steering Wheel and Column in Section 6B”. P/S System Note Refer to “P/S System Note in Section 6C”.
Page 790: Steering General Diagnosis
6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Precautions Precautions for Steering Diagnosis S6RW0C6100001 Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 791: Steering System Inspection
Steering General Diagnosis: 6A-2 Condition Possible cause Correction / Reference Item Erratic steering when Worn wheel bearings Replace wheel bearing. braking Broken or sagging coil springs Replace coil spring. Wheel tires are inflated unequally Inflate tires to proper pressure. Disturbed front wheel alignment Check and adjust front wheel alignment.
Page 792: Steering Wheel And Column
6B-1 Steering Wheel and Column: Steering Wheel and Column Steering Precautions Service Precautions of Steering Wheel and Enabling Air Bag System For enabling air bag system, refer to “Enabling Air Bag Column System in Section 8B”. S6RW0C6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Page 793: Diagnostic Information And Procedures
Steering Wheel and Column: 6B-2 Diagnostic Information and Procedures Checking Steering Column for Accident • Check that there is no axial looseness “d” and no axially-vertical looseness “e” for steering column Damage shaft. S6RW0C6204001 NOTE If found defective, replace steering column assembly Vehicles involved in accidents resulting in with new one.
Page 794: Repair Instructions
6B-3 Steering Wheel and Column: Repair Instructions Steering Wheel and Column Construction S6RW0C6206001 I6RW0C620001-01 1. Steering wheel 9. Steering column assembly mounting nut No.1 2. Steering shaft nut 10. Steering column assembly mounting nut No.2 : After tightening column mounting nut No.2, tighten column mounting nut No.1. 3.
Page 795: Steering Wheel Removal And Installation
Steering Wheel and Column: 6B-4 Steering Wheel Removal and Installation 6) Remove steering wheel using special tool. S6RW0C6206002 Special tool CAUTION (A): 09944–36011 Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will break.
Page 796: Contact Coil Cable Assembly Removal And Installation
6B-5 Steering Wheel and Column: 4) Connect horn connector and audio control switch 6) Remove contact coil cable assembly (1) from connector, if necessary. steering column. 5) Install driver air bag (inflator) module to steering wheel. Refer to “Driver Air Bag (Inflator) Module Removal and Installation in Section 8B”.
Page 797: Centering Contact Coil Cable Assembly
Steering Wheel and Column: 6B-6 4) From the position where contact coil became unable 3) Install steering column upper cover (1) and lower cover (2). to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark CAUTION with alignment mark (1).
Page 798 6B-7 Steering Wheel and Column: Installation Removal CAUTION WARNING After tightening steering column mounting Never rest a steering column assembly on nuts, shaft joint bolts should be tightened. the steering wheel with the air bag (inflator) Wrong tightening order could cause a module face down and column vertical.
Page 799: Steering Column Inspection
Steering Wheel and Column: 6B-8 Ignition Switch Cylinder Assembly Removal 3) Align flat part “a” of steering lower shaft (1) with bolt hole “b” of shaft joint (2) of column as shown. Then and Installation (Non- Keyless Start Model) insert lower shaft into shaft joint of steering column. S6RW0C6206010 Removal 4) Tighten lower shaft upper joint bolt (3) to specified...
Page 800: Steering Lock Assembly (Ignition Switch) Removal And Installation
6B-9 Steering Wheel and Column: Steering Lock Assembly (Ignition Switch) Installation Removal and Installation 1) Position oblong hole (1) of steering shaft (2) in the S6RW0C6206011 center of hole (3) in column (4). Removal 2) Turn ignition key to “ACC” or “ON” position and 1) Remove steering column.
Page 801: Steering Lower Shaft Removal And Installation
Steering Wheel and Column: 6B-10 Steering Lower Shaft Removal and Installation Installation S6RW0C6206012 1) Be sure that front wheels are in straight forward state. CAUTION 2) Align flat part “a” of steering lower shaft (1) with bolt Never turn steering wheel while steering hole “b”...
Page 802: Tightening Torque Specifications
6B-11 Steering Wheel and Column: Specifications Tightening Torque Specifications S6RW0C6207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Steering shaft nut 24.0 Steering column mounting nut No.1 10.5 Steering column mounting nut No.2 10.5 Steering lower shaft assembly upper joint bolt 18.5 Steering lower shaft assembly lower joint bolt 18.5...
Page 803: Power Assisted Steering System
Precautions in Diagnosing Troubles S6RW0C6300002 • Take a note of DTC indicated on the SUZUKI scan tool. • Before inspection, be sure to read “Precautions for Electrical Circuit Service in Section 00” and understand what is written there.
Page 804: General Description
6C-2 Power Assisted Steering System: General Description P/S System Description S6RW0C6301001 This electronic power steering (EPS) system consists of a power steering (P/S) control module (3), a torque sensor (4), a P/S motor (5). In this system, the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the signal from the torque sensor and the vehicle speed signal from BCM (9).
Page 805: Eps Diagnosis General Description
Power Assisted Steering System: 6C-3 EPS Diagnosis General Description S6RW0C6301002 The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “On-Board Diagnostic System Description”...
Page 806: Schematic And Routing Diagram
6C-4 Power Assisted Steering System: Schematic and Routing Diagram EPS System Wiring Circuit Diagram S6RW0C6302001 E13-1 LT GRN/ E11-1 E12-1 E61-2 E13-2 E12-2 E61-1 RED/BLK G241-31 G241-25 E11-5 E11-18 E31-5 BLU/ E04-9 E11-11 L313-3 E11-8 E31-3 G04-15 E11-4 E31-2 E11-10 RED/ E11-20 E31-4...
Page 807 Power Assisted Steering System: 6C-5 Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side) Terminal Circuit Terminal Circuit Ignition switch signal for P/S control E11-1 E11-13 — module E11-2 — E11-14 P/S active signal (idle up signal) E11-3 —...
Page 808 6C-6 Power Assisted Steering System: Step Action Rechecking and record of DTC Go to Step 9. Go to Step 10. 1) Recheck for DTC referring to “DTC Check”. Is there any DTC(s)? Steering symptom diagnosis and P/S system Go to Step 11. Check and repair symptom diagnosis malfunction part(s), and...
Page 809 Power Assisted Steering System: 6C-7 Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 810: Eps" Warning Light Check
Perform basic steering system check according to “Steering Symptom Diagnosis in Section 6A” first. When 2) Connect SUZUKI scan tool to data link connector the end of the flow has been reached, check the parts of (DLC) (1) located on underside of instrument panel the system suspected as a possible cause referring to at driver’s seat side.
Page 811: Dtc Clearance
S6RW0C6304004 4) Erase DTC according to the instructions displayed 1) Turn ignition switch to OFF position. on SUZUKI scan tool. For further details, refer to 2) Connect SUZUKI scan tool to data link connector operator’s manual for SUZUKI scan tool.
Page 812 6C-10 Power Assisted Steering System: “EPS” Detecting condition Detecting item Trouble area warning (DTC will set when detecting) light Vehicle speed signal is 0 km/h even though engine speed is • Vehicle speed signal more than 4000 rpm for more circuit than 60 seconds continuously (before elapse of 5 min from...
Page 813: Visual Inspection
Power Assisted Steering System: 6C-11 “EPS” Detecting condition Detecting item Trouble area warning (DTC will set when detecting) light Voltage between both motor drive circuit is more than 8.5 V or less P/S motor circuit 1 driving 1 driving than 0.2 V for 0.5 second C1141 voltage cycle...
Page 814: Scan Tool Data
6C-12 Power Assisted Steering System: Scan Tool Data S6RW0C6304007 NOTE When P/S motor is cold condition (that is, armature coil of P/S motor is not heated), normal value with asterisk (*) mark in the following table is displayed on scan tool Scan tool data Vehicle condition Normal condition...
Page 815: P/S System Symptom Diagnosis
Power Assisted Steering System: 6C-13 Motor Drive Voltage (V) Torque sensor Status (ON, OFF) This parameter indicates the voltage between motor This parameter indicates the output status of the torque terminals. sensor power supply. System Power Status (EPS System Power, ON, OFF) Fail Safe FET Status (ON, OFF) This parameter indicates input status of EPS system This parameter indicates the status of the motor drive...
Page 816: Dlc And Its Communication Check (No Communication To P/S Control Module)
Scan tool condition check Go to step 3. Repair or replace defective part. 1) Make sure that SUZUKI scan tool is as follows. • Correct PCMCIA card (software) is used. • There are no deformation and wear for DLC cable terminals.
Page 817 Go to Step 4. Go to Step 6. 1) Check DLC terminal for deformation and wear. 2) If it is in good condition, connect SUZUKI scan tool to DLC with ignition switch tuned OFF. 3) Check if communication is possible by making communication with other control modules (BCM, ABS, HVAC control module or SDM).
Page 818: Eps" Warning Light Does Not Come On With Ignition Switch Turned On Before Engine Starts
6C-16 Power Assisted Steering System: Step Action Scan tool operation check Scan tool is in good Recheck PCMCIA card condition, check and DLC cable for faulty 1) Check if communication is possible by making intermittent trouble condition. If they are communication with other vehicles.
Page 819 Power Assisted Steering System: 6C-17 Troubleshooting Step Action “EPS” warning light power supply check Go to Step 2. “GRN”, “RED/BLK” wire circuit or circuit fuse for 1) Turn ignition switch ON. combination meter is Do the other warning light come on? open or short to ground.
Page 820: Eps" Warning Light Remains On Steady After Engine Starts
Action Check DTC referring to “DTC Check”. Go to applicable DTC Go to Step 2. diag. flow. Is there any DTC(s) (NO CODES on SUZUKI scan tool)? “EPS” warning light circuit check Go to Step 3. Replace P/S control module.
Page 821: Dtc C1111 / C1113 / C1115: Torque Sensor Circuit Failure
Power Assisted Steering System: 6C-19 DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure S6RW0C6304012 DTC C1111: Steering Torque Sensor (Main) Circuit Voltage DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation DTC C1115: Steering Torque Sensor (Sub) Circuit Voltage Wiring Diagram E13-1 E11-18...
Page 822 6C-20 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable diag. Go to Step 3. flow. Is DTC C1153 or C1116 indicated, together? Torque sensor signal circuit check Go to Step 4.
Page 823: Dtc C1116: Steering Torque Sensor Power Supply Circuit
Power Assisted Steering System: 6C-21 DTC C1116: Steering Torque Sensor Power Supply Circuit S6RW0C6304013 Wiring Diagram E13-1 E11-18 E31-5 LT GRN/ E11-1 E11-8 E31-3 E31-2 E11-10 E11-20 E31-4 E11-9 E31-1 12 13 14 15 16 17 18 19 20 E11-19 E13-2 I6RW0C630005-02 [A]: P/S control module connector No.1 “E11”...
Page 824 6C-22 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. Is DTC C1153 indicated, together? Torque sensor power supply voltage check Go to Step 4.
Page 825: Dtc C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure
Power Assisted Steering System: 6C-23 DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure S6RW0C6304014 DTC C1121: No Vehicle Speed Signal (60 Seconds or More) DTC C1123: No Vehicle Speed Signal (30 Seconds or More) DTC C1124: Vehicle Speed Performance (Impossible Deceleration) Wiring Diagram BLU/ E11-11...
Page 826 6C-24 Power Assisted Steering System: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1121: • Vehicle speed signal circuit Vehicle speed signal is 0 km/h even though engine speed • BCM is more than 4000 rpm for more than 60 seconds •...
Page 827: Dtc C1122: Engine Speed Signal
Power Assisted Steering System: 6C-25 Step Action BCM voltage check Replace P/S control Replace BCM. module. 1) With ignition switch turned OFF, connect BCM connector. 2) Check BCM for vehicle speed signal output referring to “Inspection of P/S Control Module and Its Circuits”. Is it in good condition? Vehicle speed signal circuit check Replace P/S control...
Page 828 6C-26 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. 1) Check ECM for DTC referring to “DTC Check in Section 1A”.
Page 829: Dtc C1141 / C1142 / C1143 / C1145: Motor Circuit Failure
Power Assisted Steering System: 6C-27 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure S6RW0C6304016 DTC C1141: P/S Motor Circuit Voltage DTC C1142: P/S Motor Circuit Range/Performance DTC C1143: P/S Motor Circuit Current Too High DTC C1145: P/S Motor Circuit Current Too Low Wiring Diagram E13-1 LT GRN/...
Page 830: Dtc C1153: P/S Control Module Power Supply Circuit
6C-28 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. Is DTC C1153 and/or C1155 indicated, together? Power supply and ground circuit check Go to Step 4.
Page 831: Dtc C1155: P/S Control Module Internal Failure
Power Assisted Steering System: 6C-29 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. Battery voltage check Go to Step 3. Check charging system referring to “Generator 1) Check circuit fuse for P/S control module. Test (Undercharged 2) If OK, measure voltage between positive (+) battery Battery Check) in...
Page 832: P/S Control Module Power Supply And
6C-30 Power Assisted Steering System: P/S Control Module Power Supply and Ground Circuit Check S6RW0C6304019 Wiring Diagram Refer to “DTC C1153: P/S Control Module Power Supply Circuit”. DTC Troubleshooting Step Action Circuit fuse check Go to Step 2. Replace fuse (s) and check for short in 1) Disconnect P/S control module connector with ignition circuits connected to...
Page 833: Inspection Of P/S Control Module And Its Circuits
Power Assisted Steering System: 6C-31 Inspection of P/S Control Module and Its Circuits S6RW0C6304020 The P/S control module and its circuits can be checked at the P/S control module wiring couplers by measuring voltage and resistance. CAUTION P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to the P/S control module with connectors disconnected from the P/S control module.
Page 834 6C-32 Power Assisted Steering System: Terminal Wire color Circuit Normal voltage Condition Ignition switch signal for P/S E11-1 LT GRN/BLK 10 – 14 V Ignition switch ON control module E11-2 — — — — E11-3 — — — — *0 – 1 V ↑↓...
Page 835 Power Assisted Steering System: 6C-33 Terminal Wire color Circuit Normal voltage Condition • Ignition switch ON Reference sensor power supply E11-20 About 3.0 – 3.5 V • Check voltage between “E11-20” and for torque sensor “E11-9” terminals *0 – 1 V ↑↓...
Page 836 6C-34 Power Assisted Steering System: Reference waveform No.2 Reference waveform No.3 Motor output signal 1(1), Motor output signal 2(2), with Motor output signal 1(1), Motor output signal 2(2), with engine idling engine idling Measurement CH1: “E12-1” to vehicle body ground Measurement CH1: “E12-1”...
Page 837: Steering Wheel Play Check
Power Assisted Steering System: 6C-35 Steering Wheel Play Check Steering Force Check S6RW0C6304021 S6RW0C6304022 • Check steering wheel for looseness or rattle by 1) Place vehicle on level road and set steering wheel at moving it in its shaft direction and lateral direction. straight-ahead position.
Page 838: Repair Instructions
6C-36 Power Assisted Steering System: Repair Instructions Steering Gear Case Assembly Components S6RW0C6306001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical. 1207F I6RW0C630010-01 1. Steering gear case 10. Boot 19. Washer 2. Tie-rod lock washer 11.
Page 839: Tie-Rod End Boot On-Vehicle Inspection
Power Assisted Steering System: 6C-37 Tie-Rod End Boot On-Vehicle Inspection 4) For ease of adjustment after installation, make S6RW0C6306002 marking (1) of tie-rod end lock nut (2) position on tie- Check boot for crack and damage. If any defect is found, rod end thread.
Page 840: Tie-Rod End Inspection
6C-38 Power Assisted Steering System: Steering Gear Case Assembly Removal and 3) Inspect for proper toe referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B”. Installation S6RW0C6306006 4) After confirming proper toe, tighten tie-rod end lock nut to specified torque. Removal Tightening torque CAUTION...
Page 841: Steering Rack Boot Inspection
Power Assisted Steering System: 6C-39 Steering Rack Boot Inspection 2) Install steering gear case to suspension frame (3) as follows. S6RW0C6306007 Hoist vehicle. a) Set member bracket (2) to steering gear case Inspect each boot for tear. A torn boot allows entry of (1).
Page 842 Position boot properly in grooves of gear case (or Earth cable bolt (a): 4.0 N·m (0.4 kgf-m, 2.8 lb-ft) rack side mount) and tie-rod. After this, check to ensure that boot is free from twist and dent. “A”: Grease 99000–25050 (SUZUKI Super “a” Grease E) “A” I6RW0C630011-01...
Page 843: Steering Rack Plunger Removal And Installation
If any abnormality is found, replace. torque, turn it back by 10° or less. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) Tightening torque Rack damper screw (a): Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and loosen 180° and then tighten 3.9 N⋅m (0.39 kgf-m, 3.0 lb-ft) and turn...
Page 844: P/S Control Module Removal And Installation
6C-42 Power Assisted Steering System: P/S Control Module Removal and Installation Torque Sensor and Its Circuit Inspection S6RW0C6306011 S6RW0C6306012 Removal 1) Check that torque sensor circuit is in good condition referring to Step 2 to 3 of “DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure”.
Page 845: P/S Motor And Its Circuit Inspection
Power Assisted Steering System: 6C-43 P/S Motor and Its Circuit Inspection 5) Turn ON ignition switch without engine running and select scan tool “Data List” mode due to checking S6RW0C6306013 1) Check motor circuit referring to Step 2 to 3 of “DTC “Sensor (Main) Torque”...
Page 846 6C-44 Power Assisted Steering System: 5) Hoist vehicle 6) Check that steering wheel turns to left and right smoothly. If steering wheel does not turn smoothly, inspect and repair defective steering and suspension parts. 7) Connect “E12” connector with ignition switch turned OFF.
Page 847 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0C6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Water tight sealant SUZUKI Bond No.1207F...
Page 848 6C-46 Power Assisted Steering System:...
Page 849 Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 A/C System Caution..........7B-1 Precautions on Servicing A/C System ....7B-1 Precautions............. 7-1 General Description ..........7B-2 Precautions on HVAC ........... 7-1 Sub-Cool A/C System Description ......7B-2 Heater and Ventilation......7A-1 Manual A/C Electronic Input Output Table..7B-3 A/C Operation Description at ECM .....7B-3 General Description ..........7A-1 Schematic and Routing Diagram ......7B-4...
Page 850 7-ii Table of Contents Compressor Drive Belt Removal and DTC B1514: Air Flow Control Actuator (Motor) Installation ............7B-30 and/or Its Circuit Malfunction......7B-67 Compressor Assembly Removal and DTC B1520 / B1521 / B1522: Temperature / Installation ............7B-30 Blower Speed / Air Flow Selector Compressor Assembly Components....
Page 851 Table of Contents 7-iii Condenser Assembly Removal and Compressor Drive Belt Removal and Installation ............7B-87 Installation ............7B-87 Evaporator Inspection ........7B-87 Compressor Assembly Removal and Evaporator Temperature Sensor Removal Installation ............7B-87 and Installation ..........7B-87 Compressor Assembly Components....7B-87 Evaporator Temperature Sensor Inspection ..7B-87 Magnet Clutch Removal and Installation...7B-87 Expansion Valve Removal and Installation ..
Page 852: Precautions On Hvac
7-1 Precautions: Precautions HVAC Precautions Precautions on HVAC S6RW0C7000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. A/C System Caution Refer to “A/C System Caution in Section 7B” or “A/C System Caution in Section 7B”. Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System in Section 7B”...
Page 853: Heater And Ventilation
Heater and Ventilation: 7A-1 Heater and Ventilation HVAC General Description Heater and Ventilation Construction S6RW0C7101001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C710001-02...
Page 854 7A-2 Heater and Ventilation: I6RW0C710011-01 Air flow 7. Defroster air 15. Rear duct (if equipped) B: Water flow 8. Demister air 16. Foot duct 1. HVAC unit 9. Fresh air 17. Engine 2. Ventilator duct 10. Recirculation air 18. Radiator 3.
Page 855: Schematic And Routing Diagram
Heater and Ventilation: 7A-3 Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S6RW0C7102001 Non–A/C RED/BLK G155-1 BLK/YEL BLK/WHT BLK/RED BLK/WHT G155-6 G155-7 BLU/WHT G155-3 G155-2 G154-9 BLU/WHT BLK/ORN RED/BLK G154-14 G154-13 G154-10 GRN/YEL G154-8 BLK/RED G154-7 RED/YEL G154-4 G154-3 RED/BLU I6RW0C710003-01...
Page 856: Diagnostic Information And Procedures
7A-4 Heater and Ventilation: Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S6RW0C7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground. speed selector ON Blower motor relay faulty Check blower motor relay referring to “Blower...
Page 857: Repair Instructions
Heater and Ventilation: 7A-5 Repair Instructions HVAC Unit Components Installation S6RW0C7106001 Reverse removal procedure noting the following For non-A/C and manual A/C, refer to “HVAC Unit instructions. Components in Section 7B”. • Be careful not to catch any cable and wiring harness For auto A/C, refer to “HVAC Unit Components in in inappropriate position.
Page 858: Blower Motor Resistor Removal And Installation
7A-6 Heater and Ventilation: • Check for operation and current. 4) Disconnect connector (1) from blower motor resistor (2), and then remove blower motor resistor from a. Put blower motor (1) in a soft-jawed vise. HVAC unit by removing screws (3). b.
Page 859: Blower Motor Relay Inspection
Heater and Ventilation: 7A-7 Blower Motor Relay Inspection S6RW0C7106007 1) Disconnect negative (–) cable at battery. 2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”. 3) Remove junction block assembly (2). 4) Disconnect blower motor relay (1) from junction block assembly (2).
Page 860: Hvac Control Unit Removal And Installation
7A-8 Heater and Ventilation: HVAC Control Unit Removal and Installation RH steering vehicle S6RW0C7106009 Removal 1) Disconnect negative (–) cable at battery. 2) Remove steering column hole cover from instrument panel. 3) Remove audio unit from instrument panel referring to “Audio Unit Removal and Installation (If Equipped) in Section 9C”.
Page 861 Heater and Ventilation: 7A-9 b. Move temperature control lever (1) to “MAX HOT” c. Move air flow control plate (1) to “DEF” position “c” position “a” (LH steering vehicle) or “MAX COOL” (LH steering vehicle) or “VENT” position “d” (RH position “b”...
Page 862: Blower Speed Selector Inspection
7A-10 Heater and Ventilation: Blower Speed Selector Inspection Air Intake Control Actuator Removal and S6RW0C7106010 Installation Check blower speed selector for each terminal to S6RW0C7106012 terminal continuity. If check result does not meet the following conditions, replace HVAC control unit. Removal 1) Disconnect negative cable from battery.
Page 863: Air Intake Control Actuator Inspection
Heater and Ventilation: 7A-11 Air Intake Control Actuator Inspection Installation Reverse removal procedure noting the following S6RW0C7106013 Check air intake control actuator as follows: instruction. 1) Using service wire, connect battery positive terminal • Be sure to insert the linkage rod (1) into the hole (2) of to “d”...
Page 864: Center Ventilation Louver Removal And Installation
7A-12 Heater and Ventilation: Center Ventilation Louver Removal and Side Ventilation Louver Removal and Installation Installation S6RW0C7106014 S6RW0C7106015 Removal Removal 1) Disconnect negative (–) cable from battery. 1) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and 2) Remove audio unit from instrument panel referring to Installation in Section 9C”...
Page 865: Rear Duct Removal And Installation (If Equipped)
Heater and Ventilation: 7A-13 Rear Duct Removal and Installation (If HVAC Air Filter Removal and Installation (If Equipped) Equipped) S6RW0C7106016 S6RW0C7106017 Removal 1) Remove glove box from instrument panel. 2) Remove air filter (1) from HVAC unit while releasing claws (2). I6RW0C710010-01 Installation I7RW01710019-01...
Page 866: Air Conditioning System
7B-1 Air Conditioning System: Manual Type Air Conditioning System HVAC Manual Type Precautions A/C System Caution S6RW0C7210001 CAUTION The A/C system of this vehicle uses HFC-134a (R-134a) refrigerant, specified compressor oil and specified parts. Do not use CFC-12 (R-12) refrigerant, R-12 exclusive use compressor oil and R-12 exclusive parts in this A/C system, do not attempt to use R-12 servicing equipment.
Page 867: General Description
Air Conditioning System: Manual Type 7B-2 Refrigerant Recovery When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments referring to “Recovery” in “Operation Procedure for Refrigerant Charge”. Refrigerant Charge After performing compressor oil replenishment and evacuation, charge a proper amount of refrigerant to A/C system referring to “Charge”...
Page 868: Manual A/C Electronic Input Output Table
7B-3 Air Conditioning System: Manual Type Manual A/C Electronic Input Output Table S6RW0C7211002 A/C refrigerant pressure sensor Condensor cooling fan relay A/C evaporator temperature sensor Compressor relay ECT sensor Wheel speed sensor (VSS) ABS control module HVAC control unit Blower speed selector Blower motor resistor Blower motor Air intake selector...
Page 869: Schematic And Routing Diagram
Air Conditioning System: Manual Type 7B-4 Schematic and Routing Diagram A/C System Air Flow Diagram S6RW0C7212001 I7RW01721002-03 A: Air flow 5. Discharge hose 11. Foot air 17. Air intake door B: Refrigerant flow 6. Suction hose 12. Front defroster air 18.
Page 870: A/C System Wiring Diagram
7B-5 Air Conditioning System: Manual Type A/C System Wiring Diagram S6RW0C7212002 BLK/YEL BLU/YEL E01-49 RED/BLK E01-48 G155-1 BLK/RED E01-1 BLK/WHT BLK/YEL BLK/RED E01-16 BRN/WHT E01-60 G155-6 BLK/WHT G155-7 BLK/WHT E01-29 G155-3 BLU/WHT G155-2 BLU/WHT E01-35 G155-5 RED/BLK GRY/RED C01-14 G154-6 C01-12 RED/BLU G154-5...
Page 871: Component Location
Air Conditioning System: Manual Type 7B-6 Component Location A/C System Major Components Location S6RW0C7213001 I7RW01721004-03 1. HVAC unit 6. Discharge hose : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Compressor 7. Suction hose : 3.5 N⋅m (0.35 kgf-m, 2.51 lb-ft) 3.
Page 872: Electronic Control System Components Location
7B-7 Air Conditioning System: Manual Type Electronic Control System Components Location S6RW0C7213002 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C721003-01 [A]: Junction block assembly viewed from relay side 6.
Page 873: Diagnostic Information And Procedures
Air Conditioning System: Manual Type 7B-8 Diagnostic Information and Procedures A/C System Performance Inspection 5) Warm up engine to the normal operating S6RW0C7214001 temperature and keep it at the specified idle speed. 1) Confirm that vehicle and environmental conditions 6) Turn A/C switch ON, set blower speed selector at are as follows.
Page 874 7B-9 Air Conditioning System: Manual Type 10) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to the following table. When diagnosing troubles of abnormal pressure on the low side and high side for each pressure more specifically, refer to “Trouble Diagnosis for Abnormal Pressure”.
Page 875 Air Conditioning System: Manual Type 7B-10 Condition Possible cause Correction Pressure is lower than Insufficient refrigerant (Insufficient charge or Check for leakage, repair if necessary acceptable range leakage) and recharge. (“B” area) Expansion valve malfunction (valve opens too Check expansion valve. wide) Compressor malfunction (Insufficient Check compressor.
Page 876: Trouble Diagnosis For Abnormal Pressure
7B-11 Air Conditioning System: Manual Type Thermometer at center ventilation louver Condition Possible cause Correction Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure. than acceptable range Dirty or bent A/C evaporator fins Clean or repair. (“E”...
Page 877: A/C System Inspection At Ecm
Air Conditioning System: Manual Type 7B-12 Condition Manifold gauge MPa (kgf/cm ) (psi) Possible cause Correction Detail 0.05 – 0.15 0.7 – 1.0 Both low and high Insufficient refrigerant Using leak detector, (0.5 – 1.5) (7 – 10) pressure sides indicate in system check for leaks and (4.2 –...
Page 878: A/C System Symptom Diagnosis
7B-13 Air Conditioning System: Manual Type A/C System Symptom Diagnosis S6RW0C7214004 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C compressor does not referring to “Operation Procedure for operate) Refrigerant Charge”.
Page 879 Air Conditioning System: Manual Type 7B-14 Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C compressor normal Condenser clogged Check condenser referring to “Condenser operation)
Page 880: Abnormal Noise Symptom Diagnosis Of A/C System
7B-15 Air Conditioning System: Manual Type Condition Possible cause Correction / Reference Item Insufficient air flow of A/C evaporator clogged or frosted Check A/C evaporator and evaporator cooled air temperature sensor referring to “Evaporator Inspection” and “Evaporator Temperature Sensor Inspection”. Air leaking from HVAC unit or air duct Repair as necessary.
Page 881 Air Conditioning System: Manual Type 7B-16 Abnormal Noise from Condenser Assembly Condition Possible cause Correction / Reference Item Considerable vibration in Resonance from condenser assembly Firmly insert a silencer between condenser condenser assembly bracket and body assembly bracket and body. Abnormal Noise from Crankshaft Pulley Condition Possible cause...
Page 882: Repair Instructions
7B-17 Air Conditioning System: Manual Type Repair Instructions Operation Procedure for Refrigerant Charge S6RW0C7216001 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately – 6 °C (21.2 °F) below freezing point.
Page 883 Air Conditioning System: Manual Type 7B-18 Recovery When replacing compressor When discharging refrigerant out of A/C system, always CAUTION recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a Be sure to use specified compressor oil or an (R-134a) into atmosphere would cause adverse effect to equivalent compressor oil.
Page 884 7B-19 Air Conditioning System: Manual Type Evacuation 5) Evacuation should be carried out for a total of at least 15 minutes. CAUTION 6) Continue evacuation until low pressure gauge Do not evacuate before recovering indicates a vacuum less than –100 kPa (–1.0 kgf/ refrigerant in A/C system.
Page 885 Air Conditioning System: Manual Type 7B-20 Charge The initial charge of the A/C system is performed through the high pressure side with the engine stopped. CAUTION And next, this method must be followed by charging from the low pressure side with the engine running. •...
Page 886 7B-21 Air Conditioning System: Manual Type 7) When refrigerant container (1) is emptied, use the 8) After the system has been charged with specified following procedure to replace it with a new amount of refrigerant or when low pressure gauge refrigerant container.
Page 887: Condenser Cooling Fan Removal And Installation
Air Conditioning System: Manual Type 7B-22 Condenser Cooling Fan Removal and Check A/C System for Refrigerant Leaks Whenever a refrigerant leak is suspected in the system Installation or any service operation has been performed which may S6RW0C7216002 CAUTION result in malfunction of lines and connections, it is advisable to check for leaks.
Page 888: Condenser Cooling Fan Inspection
7B-23 Air Conditioning System: Manual Type Condenser Cooling Fan Inspection Condenser Assembly On-Vehicle Inspection S6RW0C7216003 S6RW0C7216004 Check the followings. 1) Check condenser cooling fan motor for resistance between terminal “a” and “b” as shown. • Clog of condenser fins If there is no continuity, replace condenser cooling If any clog is found, condenser fins should be washed fan motor.
Page 889: Desiccant Removal And Installation
Air Conditioning System: Manual Type 7B-24 5) Move condenser assembly from the vehicle in the Installation arrow direction in the order of 1, 2 and 3 as shown, Reverse the removal procedure noting the following and it can be removed. instructions.
Page 890: Hvac Unit Components
7B-25 Air Conditioning System: Manual Type HVAC Unit Components S6RW0C7216007 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0C721006-01 1. Blower upper case 8. Air intake control actuator 15.
Page 891: Hvac Unit Removal And Installation
Air Conditioning System: Manual Type 7B-26 7. Cover (without HVAC air 14. Heater core 21. Temperature control lever : Do not reuse. filter) HVAC Unit Removal and Installation 6) Remove HVAC unit (1) from vehicle body by S6RW0C7216008 removing nuts (2). Removal 1) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery”...
Page 892: Evaporator Inspection
7B-27 Air Conditioning System: Manual Type Evaporator Temperature Sensor Removal and Installation Reverse removal procedure noting the following Installation instructions. S6RW0C7216010 Removal • Replenish specified amount of compressor oil to 1) Remove HVAC unit from vehicle body referring to compressor suction side referring to “Replenishing “HVAC Unit Removal and Installation”.
Page 893: Evaporator Temperature Sensor Inspection
Air Conditioning System: Manual Type 7B-28 Evaporator Temperature Sensor Inspection Expansion Valve Removal and Installation S6RW0C7216011 S6RW0C7216012 Check resistance between terminals of evaporator temperature sensor (1). Removal If check results are as not specified, replace evaporator 1) Recover refrigerant from the A/C system with temperature sensor.
Page 894: A/C Refrigerant Pressure Sensor And Its Circuit Inspection
7B-29 Air Conditioning System: Manual Type A/C Refrigerant Pressure Sensor and Its Circuit Installation Reverse removal procedure noting the following Inspection instructions. S6RW0C7216014 1) Disconnect A/C refrigerant pressure sensor • Apply compressor oil to O-ring of A/C refrigerant connector. pressure sensor. 2) Turn ignition switch to ON position.
Page 895: A/C System Relay Inspection
Air Conditioning System: Manual Type 7B-30 A/C System Relay Inspection Compressor Assembly Removal and S6RW0C7216017 Installation NOTE S6RW0C7216020 Removal Do not use blue relay for the substitute of 1) Run engine at idle speed with A/C ON for 10 white relay because internal durability of a minutes.
Page 896: Compressor Assembly Components
7B-31 Air Conditioning System: Manual Type Installation • Tighten compressor mounting bolts to specified Reverse removal procedure noting the following torque. instructions. Tightening torque • If compressor is replaced, pour new compressor oil Compressor mounting bolt: 25 N·m (2.5 kgf-m, referring to “Replenishing Compressor Oil”...
Page 897: Magnet Clutch Removal And Installation
Air Conditioning System: Manual Type 7B-32 Magnet Clutch Removal and Installation 6) Remove magnet clutch pulley (2). S6RW0C7216023 Removal NOTE 1) Remove compressor from vehicle referring to • If it is difficult to remove magnet clutch “Compressor Assembly Removal and Installation”. pulley by hand, use puller (1).
Page 898 7B-33 Air Conditioning System: Manual Type Installation 6) Tighten new armature plate bolt to specified torque. 1) Install magnet clutch coil (2) fitting protrusion (4) of Tightening torque magnet clutch coil onto hole (5) of compressor (3). Armature plate nut (a): 16 N·m (1.6 kgf-m, 11.5 2) Install circlip (1) directing chamfer side (6) lb-ft) downward.
Page 899: Thermal Switch Inspection
• Apply silicon sealant to contact face (2) of thermal Measured thermal switch for resistance at 20 °C (68 °F) switch (1). Thermal switch resistance “A”: Silicon sealant 99000–34220 (SUZUKI Standard: 50 mΩ (DC 16 V, 5A at 20 °C (68 °F)) SILICON SEALANT KE-347W (100g)) 2, “A”...
Page 900: Relief Valve Inspection
7B-35 Air Conditioning System: Manual Type Relief Valve Inspection Installation S6RW0C7216026 Reverse removal procedure noting the following By using special tool, check is there is refrigerant instructions. leakage. • Use new O-ring If there is refrigerant leakage, replace the relief valve. •...
Page 901 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S6RW0C7218001 Material SUZUKI recommended product or Specification Note Compressor oil MATSUSHITADENKI GU10 P/No.: 99000–99015– Silicon sealant SUZUKI SILICON SEALANT KE- P/No.: 99000–34220...
Page 902: A/C System Caution
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC control module. Also, it can be checked by using SUZUKI scan tool. Before checking diagnostic information (diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read diagnostic information (diagnostic trouble code).
Page 903: General Description
Air Conditioning System: Automatic Type 7B-38 General Description Auto A/C System Description S6RW0C7221001 The automatic type air conditioning system (auto A/C) is provided with the function to automatically control the inside air temperature, fan speed, air flow outlet direction and air intake position by HVAC control module in addition to functions of the manual type air conditioning system (manual A/C).
Page 904: Hvac Control Description
7B-39 Air Conditioning System: Automatic Type HVAC Control Description A/C Compressor Relay Control S6RW0C7221002 HVAC control module outputs A/C switch ON signal to Temperature Control ECM via BCM when the vehicle state satisfy conditions HVAC control module calculates the target temperature described below.
Page 905: On-Board Diagnostic System Description
– ECT sensor signal The diagnostic information as diagnostic – A/C refrigerant pressure sensor signal trouble code (DTC) can be known by using SUZUKI scan tool. For further details, refer to – VSS signal “DTC Check”. – Engine type signal –...
Page 906 7B-41 Air Conditioning System: Automatic Type A/C System Wiring Diagram S6RW0C7222002 RED/YEL BLK/RED BLU/YEL BLU/YEL RED/BLK WHT/BLU BLK/YEL BLK/RED RED/BLK BLK/RED BRN/WHT WHT/RED G20-7 BLK/WHT BLK/WHT BLU/RED G20-30 G20-8 BLU/WHT G20-29 GRY/RED RED/BLU G20-10 PNK/BLK LT GRN WHT/BLK G20-9 G20-25 RED/BLK RED/BLK G20-22...
Page 907 Air Conditioning System: Automatic Type 7B-42 [A]: Illumination control model 10. Air intake actuator 22. Compressor 34. “A/C” indicator light [B]: Junction block with BCM 11. Air flow control actuator 23. HVAC control module 35. Rear defogger switch [C]: Junction block without BCM 12.
Page 908: Component Location
7B-43 Air Conditioning System: Automatic Type Component Location A/C System Major Components Location S6RW0C7223001 Refer to “A/C System Major Components Location”. Electronic Control System Components Location S6RW0C7223002 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side.
Page 909: Diagnostic Information And Procedures
Air Conditioning System: Automatic Type 7B-44 Diagnostic Information and Procedures Air Conditioning System Check S6RW0C7224001 Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform ”Customer complaint analysis”. Was customer complaint analysis performed? Visual inspection Repair or replace Go to Step 3.
Page 910: A/C System Symptom Diagnosis
7B-45 Air Conditioning System: Automatic Type Description for Each Step Step 1. Customer complaint analysis Talk to customer, and then record details of the problem. Customer questionnaire (Example) I4RH01722014-01 NOTE The form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 911 Air Conditioning System: Automatic Type 7B-46 A/C System Symptom Diagnosis S6RW0C7224002 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C system does not referring to “Operation Procedure for operate) Refrigerant Charge”.
Page 912 7B-47 Air Conditioning System: Automatic Type Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C compressor normal Condenser clogged Check condenser referring to “Condenser operation)
Page 913: Abnormal Noise Symptom Diagnosis Of A/C System
Air Conditioning System: Automatic Type 7B-48 Condition Possible cause Correction / Reference Item Insufficient air flow of A/C evaporator clogged or frosted Check A/C evaporator and evaporator cooled air temperature sensor referring to “Evaporator Inspection” and “Evaporator Temperature Sensor Inspection”. Air leaking from HVAC unit or air duct Repair as necessary.
Page 914: Dtc Check
DTC of sunload sensor is 1) Turn ignition switch to OFF position. detected as current DTC even though there is 2) Connect SUZUKI scan tool to data link connector not any malfunction. (DLC) (1) located on underside of instrument panel at driver’s seat side.
Page 915: Dtc Clearance
(Open) is set S6RW0C7224005 Using SUZUKI Scan tool 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side. Special tool...
Page 916: Dtc Table
DTC (indicated on HVAC control DTC No. module) “A/C” (displayed Condition when trouble detected (DTC is Detection item Indicated Indicated indicator on SUZUKI determined when following condition detected) by “REC” by “FRE” light scan tool) indicator indicator light light Inside Air...
Page 917 HVAC control DTC No. module) “A/C” (displayed Condition when trouble detected (DTC is Detection item Indicated Indicated indicator on SUZUKI determined when following condition detected) by “REC” by “FRE” light scan tool) indicator indicator light light Signal voltage of blower speed selector in HVAC...
Page 918 7B-53 Air Conditioning System: Automatic Type DTC of A/C System detected by ECM Detecting condition DTC No. Detection item (DTC will set when detecting) P0481 Fan 2 Control Circuit A/C Refrigerant Pressure P0532 Sensor Circuit Low Refer to “DTC Table in Section 1A”. A/C Refrigerant Pressure P0533 Sensor Circuit High...
Page 919: Fail-Safe Table
Air Conditioning System: Automatic Type 7B-54 Fail-Safe Table S6RW0C7224007 When any of the following malfunctions (DTCs) is detected, fail-safe mode is activated. However, when HVAC control module detects normal operation of A/C system, fail-safe mode is canceled. Fail-Safe Operation DTC No. Trouble Area When ignition switch is turned ON When malfunction is detected during...
Page 920: Scan Tool Data
7B-55 Air Conditioning System: Automatic Type Fail-Safe Operation DTC No. Trouble Area When ignition switch is turned ON When malfunction is detected during after malfunction is already detected ignition switch is ON HVAC control module maintains last normal value of outside air Outside air HVAC control module controls actuators temperature.
Page 921 Air Conditioning System: Automatic Type 7B-56 Normal Condition / Reference Scan Tool Data Condition Value Ignition switch turned ON and air intake selector at fresh air (FRE) position Ignition switch turned ON and air intake selector at AIR INTAKE MODE recirculation air (REC) position Ignition switch turned ON, air flow selector and AUTO...
Page 922: Visual Inspection
7B-57 Air Conditioning System: Automatic Type Visual Inspection S6RW0C7224009 Check visually the following parts and systems. Inspection item Correction • Refrigerant leakage and amount • A/C pipe or hose disconnection, looseness and deterioration • A/C compressor drive belt looseness and damage Refer to “Compressor Drive Belt Inspection and Adjustment”.
Page 923 Air Conditioning System: Automatic Type 7B-58 DTC Troubleshooting NOTE When DTC B1503, B1504, B1511 and B1512 are indicated together, it is possible that sensor ground circuit is open. Step Action Was “Air Conditioning System Check” performed? Go to Step 2. Go to “Air Conditioning System Check”.
Page 924: Dtc B1503: Evaporator Temperature Sensor Circuit Malfunction
7B-59 Air Conditioning System: Automatic Type DTC B1503: Evaporator Temperature Sensor Circuit Malfunction S6RW0C7224011 Wiring Diagram WHT/BLK G20-9 G20-24 I7RW01722005-01 [S]: Evaporator temperature sensor signal circuit 1. HVAC control module 3. To other sensors [G]: Evaporator temperature sensor ground circuit 2.
Page 925: Dtc B1504: Sunload Sensor Circuit Malfunction
Air Conditioning System: Automatic Type 7B-60 Step Action Evaporator temperature sensor reference voltage check Go to Step 4. Substitute a known- good HVAC control 1) Connect connector to HVAC control module with ignition module and recheck. switch turned OFF. 2) Turn ignition switch to ON position. 3) Measure voltage between signal terminal and ground terminal of evaporator temperature sensor connector.
Page 926: Dtc B1511: Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
7B-61 Air Conditioning System: Automatic Type DTC Troubleshooting Step Action Was “Air Conditioning System Check” performed? Go to Step 2. Go to “Air Conditioning System Check”. Wire harness check Go to Step 3. Sunload sensor power supply circuit and/or 1) Turn ignition switch to OFF position. signal circuit are open, 2) Disconnect connectors from sunload sensor and HVAC short or high resistance.
Page 927 Air Conditioning System: Automatic Type 7B-62 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Temperature control actuator position sensor signal voltage is higher than or • Temperature control actuator circuit lower than specified value for specified time continuously. •...
Page 928: Dtc B1512: Air Flow Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
7B-63 Air Conditioning System: Automatic Type Step Action Temperature control actuator check Substitute a known- Replace temperature good HVAC control control actuator. 1) Check position sensor of temperature control actuator module and recheck. for performance referring to “Temperature Control Actuator and Its Circuit Inspection”. Is it in good condition? Position sensor of temperature control actuator power Check air flow control...
Page 929 Air Conditioning System: Automatic Type 7B-64 DTC Troubleshooting NOTE • When DTC B1502, B1503, B1504 and B1511 are indicated together, it is possible that sensor ground circuit is open. • When DTC B1511 is indicated together, it is possible that position sensor power supply circuit is open.
Page 930: Dtc B1513: Temperature Control Actuator (Motor) And/Or Its Circuit Malfunction
7B-65 Air Conditioning System: Automatic Type Step Action Position sensor of temperature control actuator power Check temperature Substitute a known- supply voltage check control actuator and its good HVAC control circuit. module and recheck. 1) Turn ignition switch to OFF position. 2) Disconnect connector from temperature control actuator.
Page 931 Air Conditioning System: Automatic Type 7B-66 DTC Troubleshooting Step Action Was “Air Conditioning System Check” performed? Go to Step 2. Go to “Air Conditioning System Check”. DTC check Go to “DTC B1511: Go to Step 3. Temperature Control 1) Connect scan tool to DLC with ignition switch turned Actuator (Position OFF.
Page 932: Dtc B1514: Air Flow Control Actuator (Motor) And/Or Its Circuit Malfunction
7B-67 Air Conditioning System: Automatic Type DTC B1514: Air Flow Control Actuator (Motor) and/or Its Circuit Malfunction S6RW0C7224016 Wiring Diagram BRN/YEL G20-15 BRN/WHT G20-16 G20-12 WHT/BLU G20-28 G20-24 I6RW0C722007-01 [D]: Air flow actuator motor drive circuit 2. Air flow control actuator 4.
Page 933: Dtc B1520 / B1521 / B1522: Temperature / Blower Speed / Air Flow Selector Malfunction
Air Conditioning System: Automatic Type 7B-68 Step Action Wire harness check Go to Step 6. Repair or replace. Check position sensor circuit of temperature control actuator for condition referring to Step 2 of “DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction”.
Page 934: Dtc B1541: Back-Up Power Supply Circuit Malfunction
7B-69 Air Conditioning System: Automatic Type DTC B1541: Back-Up Power Supply Circuit Malfunction S6RW0C7224018 Wiring Diagram WHT/RED G20-7 I7RW01722011-01 [B]: Back-up power supply circuit 2. Main fuse 1. HVAC control module 3. Circuit fuse DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area •...
Page 935: Dtc B1546: A/C Refrigerant Pressure Malfunction
Air Conditioning System: Automatic Type 7B-70 DTC B1546: A/C Refrigerant Pressure Malfunction S6RW0C7224019 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • A/C refrigerant pressure sensor signal voltage is lower than specified value • Insufficient of refrigerant even though outside air temperature is higher than specified value for •...
Page 936 7B-71 Air Conditioning System: Automatic Type DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Serial communication signal is higher than or lower than specified value for • Back-up power supply circuit specified time continuously. • Serial communication circuit •...
Page 937: Dtc B1552: Hvac Control Module Check Sum Error
Air Conditioning System: Automatic Type 7B-72 DTC B1552: HVAC Control Module Check Sum Error S6RW0C7224021 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Data received by HVAC control module from BCM is erroneous continuously. • BCM • HVAC control module DTC Troubleshooting Step Action...
Page 938: Dtc B1557: Vss Signal Failure
7B-73 Air Conditioning System: Automatic Type DTC B1557: VSS Signal Failure S6RW0C7224023 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HVAC control module receives invalid data of VSS signal from BCM. • VSS circuit • VSS • HVAC control module DTC Troubleshooting Step Action...
Page 939: Dtc B1562: Outside Air Temperature Signal Failure
Air Conditioning System: Automatic Type 7B-74 DTC B1562: Outside Air Temperature Signal Failure S6RW0C7224025 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HVAC control module receives invalid data of outside air temperature signal • Outside air temperature sensor from BCM.
Page 940: Dtc B1570: Engine Type Signal Failure
7B-75 Air Conditioning System: Automatic Type DTC B1570: Engine Type Signal Failure S6RW0C7224027 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HVAC control module receives invalid data of engine type signal from BCM. • CAN communication circuit •...
Page 941: Inspection Of Hvac Control Module And Its Circuit
Air Conditioning System: Automatic Type 7B-76 Inspection of HVAC Control Module and Its Circuit S6RW0C7224029 HVAC control module and its circuits can be checked at HVAC control module wiring couplers by measuring voltage. CAUTION HVAC control module can not be checked by itself. It is strictly prohibited to connect voltmeter to HVAC control module with couplers disconnected from it.
Page 942 7B-77 Air Conditioning System: Automatic Type Normal Terminal Wire Color Circuit Condition Voltage • Ignition switch turned ON, blower speed selector OFF or 1st position 10 – 14 V • Ignition switch turned ON, blower speed selector Electric load signal for from 1st to 2nd position G20-8 BLU/WHT...
Page 943 Air Conditioning System: Automatic Type 7B-78 Normal Terminal Wire Color Circuit Condition Voltage Ignition switch turned ON, amount of insolation is Approx. 3.5 V 500 W/m G20-25 Sunload sensor signal Ignition switch turned ON, amount of insolation is 0 Approx. 5 V 0 –...
Page 944 7B-79 Air Conditioning System: Automatic Type Reference waveform No. 1 Reference waveform No. 2 Rear defogger switch or A/C switch signal (1) Serial communication line of BCM (1) Measurement terminal Rear defogger switch Measurement terminal CH1: “G20-13” to “G20-23” CH1: “G20-4” to “G20-23” A/ Oscilloscope setting CH1: 5 V / DIV C switch...
Page 945: Repair Instructions
Air Conditioning System: Automatic Type 7B-80 Repair Instructions Operation Procedure for Refrigerant Charge S6RW0C7226001 Refer to “Operation Procedure for Refrigerant Charge”. HVAC Unit Components S6RW0C7226002 I6RW0C722008-01 1. Blower upper case 9. Air intake control link 17. Expansion valve 25. Inside air temperature sensor 2.
Page 946: Hvac Unit Removal And Installation
7B-81 Air Conditioning System: Automatic Type 3. Heater unit upper case 11. Blower motor 19. Air flow control actuator 27. Aspirator hose 4. Heater unit lower case 12. Blower motor cap 20. Air flow control links 28. Drain hose 5. Foot duct 13.
Page 947 Air Conditioning System: Automatic Type 7B-82 6) Measure output voltage variation while temperature 9) Measure resistance between terminal “1” and “2”. control actuator is operated from “MAX COOL” Temperature control actuator resistance between position (B) to “MAX HOT” position (A) as following terminal “1”...
Page 948: Air Flow Control Actuator Removal And Installation
7B-83 Air Conditioning System: Automatic Type Air Flow Control Actuator Removal and Air Flow Control Actuator and Its Circuit Installation Inspection S6RW0C7226006 S6RW0C7226007 Removal 1) Remove air flow control actuator from HVAC unit 1) Disconnect negative cable at battery. referring to “Air Flow Control Actuator Removal and Installation”.
Page 949: Air Intake Actuator Removal And Installation
Air Conditioning System: Automatic Type 7B-84 7) Set air flow selector of HVAC control module to 13) Measure resistance between terminal “1” and “2”. “DEF” position with ignition switch turned ON, and Air flow control actuator resistance between make sure if the position of actuator lever is “DEF” terminal “1”...
Page 950: Blower Motor Controller Inspection
7B-85 Air Conditioning System: Automatic Type Blower Motor Controller Inspection HVAC Control Module Removal and Installation S6RW0C7226012 S6RW0C7226013 Removal 1) Check internal circuit of controller for resistance as follows. 1) Remove audio unit from instrument panel referring to “Audio Unit Removal and Installation (If Equipped) in a) Measure resistance between “1”...
Page 951: Sunload Sensor Inspection
Air Conditioning System: Automatic Type 7B-86 Inside Air Temperature Sensor Removal and Installation Reverse removal procedure noting the following Installation instructions. S6RW0C7226018 Removal • Install sunload sensor (1) to instrument panel fitting 1) Disconnect negative (–) cable at battery. tab (2) of sunload sensor into the groove (3) of 2) Remove audio unit from instrument panel referring to instrument panel as shown in figure.
Page 952: Condenser Cooling Fan Relay Inspection
7B-87 Air Conditioning System: Automatic Type Condenser Cooling Fan Relay Inspection A/C Refrigerant Pressure Sensor Removal and S6RW0C7226020 Installation Refer to “A/C System Relay Inspection”. S6RW0C7226031 Refer to “A/C Refrigerant Pressure Sensor Removal and Installation”. Condenser Cooling Fan Removal and Installation S6RW0C7226021 Compressor Relay Inspection...
Page 953 NOTE Required service material is also described in the following. “HVAC Unit Components” Special Tool S6RW0C7228002 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 954 7B-89 Air Conditioning System: Automatic Type...
Page 955 Table of Contents 8- i Section 8 Restraint CONTENTS Precautions ..........8-1 DTC Check............8B-18 DTC Clearance ..........8B-18 Precautions............. 8-1 Scan Tool Data ..........8B-19 Precautions on Restraint........8-1 “AIR BAG” Warning Light Comes ON Steady ...8B-19 Seat Belts ..........8A-1 “AIR BAG” Warning Light Does Not Come ON ..8B-22 Serial Data Link Circuit Check ......8B-23 Precautions............8A-1 DTC B1013: SDM Internal Failure ....8B-25...
Page 956 8-ii Table of Contents DTC B1062 / B1066: Side-Air Bag Circuit Low Repair and Inspection Required after Resistance ............8B-59 Accident ............8B-90 DTC B1063 / B1067: Side-Air Bag Circuit Repair Instructions ..........8B-93 Shorted to Ground .......... 8B-61 Disabling Air Bag System........8B-93 DTC B1064 / B1068: Side-Air Bag Circuit Enabling Air Bag System ........8B-93 Shorted to Power Supply ........
Page 957: Precautions On Restraint
Precautions: Precautions Restraint Precautions Precautions on Restraint S6RW0C8000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Fastener Caution Refer to “Fastener Caution in Section 00”. Precautions on Service and Diagnosis of Seat Belt Refer to “Precautions on Service and Diagnosis of Seat Belt in Section 8A”. Precautions on Service and Diagnosis of Air Bag System Refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Page 958: Seat Belts
If replacing seat belt is necessary, replace buckle and seat belt together as a set. This is for the reason of ensuring locking of tongue plate with buckle. If these parts are replaced individually, such a locking condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and seat belt assembly in a set part.
Page 959: General Description
Seat Belts: 8A-2 General Description Seat Belt Construction S6RW0C8101001 I6RW0C810001-01 [A]: A-ELR rear center seat belt model 4. Buckle for front seat belt [B]: Non-A-ELR rear center seat belt model 5. Buckle for rear seat belt 1. Front seat belt (with ELR and pretensioner) 6.
Page 960: Diagnostic Information And Procedures
8A-3 Seat Belts: Seat Belt with ELR The pretensioner is incorporated in retractor and The seat belt with emergency locking retractor (ELR) is controlled by SDM as one of air bag system designed so that it locks immediately (to prevent the components.
Page 961: Repair Instructions
Seat Belts: 8A-4 Repair Instructions Front Seat Belt Components S6RW0C8106001 WARNING • Never attempt to disassemble or repair the seat belt pretensioner (retractor). If any abnormality is found, be sure to replace it with new one as an assembly. • Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and observe every precaution during work.
Page 962: Front Seat Belt Removal And Installation
8A-5 Seat Belts: Front Seat Belt Removal and Installation Installation S6RW0C8106002 Install in reverse order of removal, noting the following. • Seat belt anchor bolts should have an unified fine WARNING thread (7/16-20 UNF). Under no circumstances • Never attempt to disassemble or repair the should any different sized or metric screw threads be retractor (seat belt pretensioner).
Page 963: Front Seat Belt Inspection
Seat Belts: 8A-6 Front Seat Belt Inspection 2) Check retractor (1) with seat belt pretensioner S6RW0C8106003 appearance visually for following symptoms and if any one of them is applicable, replace it with a new WARNING one as an assembly. • Never attempt to disassemble or repair the •...
Page 964: Rear Seat Belt Components
8A-7 Seat Belts: Rear Seat Belt Components S6RW0C8106004 WARNING Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and observe every precaution during work. I6RW0C810002-01 [A]: A-ELR rear center seat belt model 9. Anchor bolt : Tighten retractor mounting bolts and sash guide bolt first, then tighten anchor bolt.
Page 965: Rear Seat Belt Removal And Installation
Seat Belts: 8A-8 Rear Seat Belt Removal and Installation Installation S6RW0C8106005 Reverse removal procedure for installation noting the WARNING following. • Seat belt anchor bolts should have an unified fine Be sure to read “Precautions on Service and thread (7/16-20 UNF). Under no circumstances Diagnosis of Seat Belt”...
Page 966: Air Bag System
• If the air bag system and another vehicle an impact to it. If an excessive impact was applied system both need repair, SUZUKI (e.g., SDM, forward impact-sensor are dropped, air recommends that the air bag system be...
Page 967 Air Bag System: 8B-2 • Never attempt disassembly of SDM. • When storing SDM, select a place where neither high temperature nor high humidity is anticipated and oil, water and dust are kept off. I7RW01821001-01 I5RW0A820001-03 • If SDM has been dropped, replace it with a new one. •...
Page 968 8B-3 Air Bag System: WARNING • 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. • When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you.
Page 969 Air Bag System: 8B-4 Deployed Air Bag (Inflator) Module and Activated • Never attempt to disassemble the seat belt Seat Belt Pretensioner pretensioners (retractor assembly). • If any abnormality is found, be sure to replace it with WARNING new one as an assembly. •...
Page 970: Precautions On Disposal Of Air Bag And Seat
8B-5 Air Bag System: Precautions on Disposal of Air Bag and Seat WARNING Belt Pretensioner Failure to follow proper air bag (inflator) S6RW0C8200003 Do not dispose of the live (undeployed) air bag (inflator) module and seat belt pretensioner disposal modules and the live (inactivated) seat belt procedures can result in air bag deployment pretensioners.
Page 971: Air Bag System Block Diagram
Air Bag System: 8B-6 The air bag system is designed to activate only in severe frontal “a” and sideward “b” collisions. It is not designed to activate in rear impacts, rollovers, or minor frontal and sideward collisions, since it would offer no protection in those types of accidents.
Page 972: Air Bag System Input / Output Table
8B-7 Air Bag System: Air Bag System Input / Output Table S6RW0C8201002 OUTPUT Driver side-air bag Passenger side-air (deployment & Driver & Passenger Driver & Passenger & driver side bag & passenger activation air bag inflator seat belt curtain-air bag side curtain-air bag INPUT device)
Page 973: Schematic And Routing Diagram
Air Bag System: 8B-8 Schematic and Routing Diagram Air Bag System Wiring Circuit Diagram S6RW0C8202001 “G241” “L04” WHT/RED YEL/BLK “L378” “G345” “G347” “S172” RED/BLK GRN/RED GRN/RED L04-4 “G271” “L04” “G272” L04-3 “E324” “L313” “L377” “G344” “G259” YEL/BLK L04-2 BLU/RED BLU/RED “G273”...
Page 974 8B-9 Air Bag System: [A]: Shorting bar 11. BCM 25. Driver seat belt pretensioner [B]: Connector 12. Combination meter 26. Passenger seat belt pretensioner [C]: Junction block with BCM model “AIR BAG” warning light 27. Driver side-air bag (inflator) module (8-channel system) [D]: Junction block without BCM model 14.
Page 975 Air Bag System: 8B-10 Connector “L04” (SDM connector) Terminal Circuit Terminal Circuit L04-1 — L04-27 Ignition switch (power source) L04-2 “AIR BAG” warning light L04-28 Ground L04-3 Driver air bag (–) L04-29 — L04-4 Driver air bag (+) L04-30 — L04-5 Passenger air bag (+) L04-31...
Page 976: Component Location
8B-11 Air Bag System: Component Location Air Bag System Components, Wiring and Connectors Location S6RW0C8203001 I6RW0C820004-01 A: Combination meter 6. Side curtain-air bag (inflator) module (8- “A/B” fuse in junction block assembly channel system)
Page 977: Diagnostic Information And Procedures
Air Bag System: 8B-12 B: Steering wheel 7. Contact coil assembly 15. Air bag harness in main harness C: Seat 8. Forward impact-sensor 16. Air bag harness in instrument panel harness “AIR BAG” warning light 9. Apron-side-member (driver side) 17. Air bag harness in floor harness 2.
Page 978: Air Bag Diagnostic System Check Flow
Step 6. DTC check Air bag system is in Check intermittent good condition. troubles referring to 1) Check DTC using SUZUKI scan tool referring to “DTC “Inspection of Check”. Intermittent and Poor Is “NO CODES” displayed on SUZUKI scan tool? Connections”.
Page 979: Dtc Table
Air Bag System: 8B-14 DTC Table S6RW0C8204003 NOTE The DTCs (B1022 and B1023) shown with asterisk (*) below have been established only for the M15A engine model with 4A/T equipped with slip-control (i.e., Hong Kong model). These codes are meant to be recorded when External Scrapping Deployment Controller is operated by a Japanese authorized special scrapping trader.
Page 980 8B-15 Air Bag System: Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) If this DTC has been recorded even though pretensioner has not been activated Activation of seat belt Seat belt pretensioner • SDM B1026 pretensioner has been recorded activation record in SDM.
Page 981 Air Bag System: 8B-16 Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) Passenger seat belt Passenger seat belt pretensioner B1057 pretensioner circuit shorted to circuit has been shorted to • Passenger seat belt ground ground for more than 4 sec. pretensioner circuit Passenger seat belt Passenger seat belt pretensioner...
Page 982 8B-17 Air Bag System: Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) Driver side impact-sensor has Driver side impact-sensor • Driver side impact-sensor been communicated with B1085 communication data inconsistent ID code for more • SDM inconsistent than 4 sec.
Page 983: Dtc Check
(A): SUZUKI scan tool 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between scan tool and SDM is not possible, check if scan tool is communicable by connecting it to SDM in another vehicle.
Page 984: Scan Tool Data
8B-19 Air Bag System: Scan Tool Data Driv Preten Ini Res (Driver pretensioner initiator S6RW0C8204006 resistance) (ohm) Data list of SDM This parameter indicates the resistance of the driver seat Normal Condition / belt pretensioner initiator circuit. Scan Tool Data Reference Value Buck Up Volt 27.0 –...
Page 985 Air Bag System: 8B-20 4. Individual circuit fuse box No.1 “A/B” fuse 12. “AIR BAG” warning light Troubleshooting Step Action Was “Air Bag Diagnostic System Check Flow” performed? Go to Step 2. Go to “Air Bag Diagnostic System Check Flow”. SDM power supply and ground circuit check Go to Step 3.
Page 986 8B-21 Air Bag System: Step Action “AIR BAG” warning light circuit check Replace combination Go to Step 6. meter. 1) Connect SDM connector “L04” and combination meter connector “G241”. 2) With ignition switch turned ON, measure voltage between “G241-5” terminal and body ground. Special tool (A): 09932–76010 “G241-5”...
Page 987 Air Bag System: 8B-22 “AIR BAG” Warning Light Does Not Come ON S6RW0C8204008 Wiring Diagram Refer to ““AIR BAG” Warning Light Comes ON Steady”. Troubleshooting Step Action Was “Air Bag Diagnostic System Check Flow” performed? Go to Step 2. Go to “Air Bag Diagnostic System Check Flow”.
Page 988: Serial Data Link Circuit Check
8B-23 Air Bag System: Serial Data Link Circuit Check S6RW0C8204051 Wiring Diagram “G241” YEL/BLK RED/BLK “L04” WHT/RED “G272” “G271” “L313” YEL/BLK L04-2 L04-27 “G273” L04-37 PPL/WHT WHT/RED L04-32 “G04” L04-28 BLK/ PPL/WHT I6RW0C820006-01 [A]: Junction block with BCM model 4. Individual circuit fuse box No.1 “METER”...
Page 989 Go to Step 4. Go to Step 6. 1) Check DLC terminal for deformation and wear. 2) If it is in good condition, connect SUZUKI scan tool to DLC with ignition switch turned OFF. 3) Check if communication is possible by making...
Page 990: Dtc B1013: Sdm Internal Failure
8B-25 Air Bag System: Step Action Serial communication circuit check Go to Step 8. Repair or replace defective circuit. 1) With ignition switch turned OFF, disconnect SDM connector “L04” and check for proper connection at SDM connector terminal. 2) If connections are OK, check that “Serial data circuit” is as follows.
Page 991: Dtc B1014: "Air Bag" Warning Light Circuit
Air Bag System: 8B-26 DTC B1014: “AIR BAG” Warning Light Circuit S6RW0C8204011 Wiring Diagram Refer to““AIR BAG” Warning Light Comes ON Steady”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area “AIR BAG” warning light circuit “AIR BAG” warning light circuit has been shorted to •...
Page 992: Dtc B1017: Power Supply Voltage Too Low
8B-27 Air Bag System: DTC Troubleshooting Step Action Was “Air Bag Diagnostic System Check Flow” performed? Go to Step 2. Go to “Air Bag Diagnostic System Check Flow”. SDM power supply voltage check Go to Step 3. Check charging system and repair as necessary 1) With ignition switch turned OFF, disconnect SDM referring to “Generator...
Page 993: Dtc B1021: Front Air Bag Deployment Record
Air Bag System: 8B-28 DTC Troubleshooting Step Action Was “Air Bag Diagnostic System Check Flow” performed? Go to Step 2. Go to “Air Bag Diagnostic System Check Flow”. SDM power supply and ground circuit check Go to Step 3. Repair defective wire circuit.
Page 994: Dtc B1024 / B1025: Side Air-Bag Deployment Record
8B-29 Air Bag System: NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected. •...
Page 995: Dtc B1027: Number Of Deployment Times Exceeded Limit
Air Bag System: 8B-30 DTC Troubleshooting Step Action Was “Air Bag Diagnostic System Check Flow” performed? Go to Step 2. Go to “Air Bag Diagnostic System Check Flow”. Seat belt pretensioner activation check Inspect and replace Go to Step 3. components according 1) Turn OFF ignition switch.
Page 996: Dtc B1031: Driver Air Bag Circuit High Resistance
8B-31 Air Bag System: NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected. •...
Page 997 Air Bag System: 8B-32 Step Action Drive air bag circuit check Go to Step 3. Go to Step 5. 1) With ignition switch turned OFF, disconnect contact coil connector located under the steering column. 2) Check for proper connection to contact coil at terminal in “G347”...
Page 998 8B-33 Air Bag System: Step Action Floor harness circuit check Repair high resistance Repair high resistance or open wire in “GRN/ or open wire in “GRN/ 1) Disconnect “L378” connector located near the driver side RED” or “GRN” circuit at RED”...
Page 999: Dtc B1032: Driver Air Bag Circuit Low Resistance
Air Bag System: 8B-34 DTC B1032: Driver Air Bag Circuit Low Resistance S6RW0C8204019 Wiring Diagram Refer to “DTC B1031: Driver Air Bag Circuit High Resistance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Driver air bag circuit •...
Page 1000 8B-35 Air Bag System: Step Action Driver air bag circuit check Substitute a known- Go to Step 4. good SDM and recheck. 1) Disconnect SDM connector “L04”. 2) Check for proper connection to SDM connector at terminal “L04-3” and “L04-2”. 3) If OK, release shorting bar in SDM connector inserting release tool (1) included in special tool (A).
Page 1001: Dtc B1033: Driver Air Bag Circuit Shorted To Ground
Air Bag System: 8B-36 DTC B1033: Driver Air Bag Circuit Shorted to Ground S6RW0C8204020 Wiring Diagram Refer to “DTC B1031: Driver Air Bag Circuit High Resistance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Driver air bag circuit Driver air bag circuit has been shorted to ground for more than 4 sec.
Page 1002 8B-37 Air Bag System: Step Action Floor harness circuit check Repair “GRN/RED” Repair “GRN/RED” circuit or “GRN” circuit circuit or “GRN” circuit 1) Disconnect “L378” connector located near the driver side for short to ground at for short to ground at front pillar lower trim.

Suzuki 2006 SX4 Service Manual

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

Precautions

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Aux. Emission Control Devices

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Electrical Devices

Repair Instructions

Specifications

Engine Mechanical

General Description

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Lubrication System

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Precautions

Fuel System

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

General Description

Diagnostic Information and Procedures

Exhaust System

Repair Instructions

Specifications

Quick Links

Chapters

Troubleshooting

Related Manuals for Suzuki 2006 SX4

Summary of Contents for Suzuki 2006 SX4