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Suzuki K9K Service Manual
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Suzuki K9K Service Manual

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WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
,
WARNING
CAUTION
!
!
lighted by these signal words.
WARNING
!
Indicates a potential hazard that could result in death or injury.
CAUTION
!
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING
!
This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
WARNING
!
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. 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.
• Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking
process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
The circle with a slash in this manual means "Don't do this" or "Don't let this happen".
IMPORTANT
and NOTE have special meanings. Pay special attention to the messages high-

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Summary of Contents for Suzuki K9K

  • Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 2 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 3 TIAL Power Steering (P/S) System (if equipped) 3B1 Steering Wheel and Column Manual Transmission (M13 Engine Model) Front Suspension Manual Transmission (K9K Engine Model) Rear Suspension Automatic Transmission Wheels and Tires Clutch (M13 Engine Model) DRIVE SHAFT AND PROPELLER SHAFT...
  • Page 4 ENGINE MECHANICAL (K9K ENGINE) 6A2-5 4) Install special tools (Oil pressure gauge) to vacated threaded hole. CAUTION: Be careful not to make special tool touch exhaust mani- fold when installing because exhaust manifold becomes very hot. Special tool (A): 09915-77311...
  • Page 5 6A2-6 ENGINE MECHANICAL (K9K ENGINE) Valve Lash (Clearance) Measurement of valve lash (clearance) 1) Disconnect negative (–) cable at battery. 2) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation” in this section. 3) Turn crankshaft pulley clockwise until cam lobes become perpendicular to tappet faces at valves “1”...
  • Page 6 ENGINE MECHANICAL (K9K ENGINE) 6A2-7 Example of intake side: When thickness of removed tappet is 7.8875 mm (0.310531 in.), and measured valve lash (clearance) is 0.200 mm (0.00787 in.). A = 7.8875 mm (0.310531 in.) + 0.200 mm (0.00787 in.) – 0.1875 mm (0.007382 in.) = 7.900 mm (0.31102 in.)

  • Page 7: Repair Instructions

    6A2-8 ENGINE MECHANICAL (K9K ENGINE) Repair Instructions Air Cleaner Filter Removal and Installation Removal 1) Open air cleaner case (2) unhooking its clamps (1). 2) Remove air cleaner filter from case. Installation Reverse removal procedure for installation. Air Cleaner Filter Inspection and Cleaning Inspection Check filter for dirt.

  • Page 8: Tightening Torque

    ENGINE MECHANICAL (K9K ENGINE) 6A2-9 Installation Reverse removal procedure for installation noting the following. • Tighten air cleaner outlet hose clamp (1) to specified torque. Tightening torque Air cleaner outlet hose clamp (a): 2.5 N·m (0.25 kg-m, 2.0 lb-ft) 1, (a) Intercooler Components 5 N·m (0.5 kg-m)
  • Page 9 6A2-10 ENGINE MECHANICAL (K9K ENGINE) Intercooler Removal and Installation Removal 1) Remove front bumper. 2) Remove intercooler inlet hose (1) and outlet hose (2) from intercooler. 3) Remove intercooler (3) and its bracket (4). Installation Reverse removal procedure for installation noting the following.
  • Page 10 ENGINE MECHANICAL (K9K ENGINE) 6A2-11 Cylinder Head Cover Components 1. Cylinder head cover bolt 3. Cylinder head cover gasket Tightening torque : Tighten 12 N·m (1.2 kg-m, 9.0 lb-ft) by the specified procedure. 2. Cylinder head cover 4. Cylinder head Do not reuse.
  • Page 11 6A2-12 ENGINE MECHANICAL (K9K ENGINE) 5) Loosen cylinder head cover bolts in such order (“1” to “8”) as “1” “5” “3” “7” shown in the figure and remove them. 6) Remove cylinder head cover (1). “4” “2” “8” “6” Installation 1) Remove oil, old sealant and dust from sealing surfaces.
  • Page 12 ENGINE MECHANICAL (K9K ENGINE) 6A2-13 Oil Pressure Switch Removal and Installation Removal 1) Disconnect negative (–) cable at battery. 2) Detach degassing tank from its bracket. 3) Disconnect oil pressure switch connector (1). 4) Remove oil pressure switch (2). Installation 1) Install oil pressure switch (1) with new gasket.
  • Page 13 6A2-14 ENGINE MECHANICAL (K9K ENGINE) 8) Remove compressor bracket (1). 9) Install lifting device (1). 10) Remove oil filter unit bracket (1). 11) Disconnect heat exchanger hose (4). 12) Remove engine left mounting bracket (2), and then remove heat exchanger (3).
  • Page 14 ENGINE MECHANICAL (K9K ENGINE) 6A2-15 4) Install oil filter unit bracket (1) as shown in figure. NOTE: Be sure to align lug (2) of oil filter unit bracket (1) with hole (3) of heat exchanger (4). Tightening torque Oil filter unit bracket bolt (a): 45 N·m (4.5 kg-m, 32.5 lb-ft) 5) Install generator and compressor bracket (1) referring to “Generator Drive Belt Tensioner Components”...
  • Page 15 6A2-16 ENGINE MECHANICAL (K9K ENGINE) EGR Valve and Intake Pipe Components 12 N·m (1.2 kg-m) 11 N·m (1.1 kg-m) 21 N·m (2.1 kg-m) 21 N·m (2.1 kg-m) 12 N·m (1.2 kg-m) 12 N·m (1.2 kg-m) 12 N·m (1.2 kg-m) 42 N·m (4.2 kg-m)
  • Page 16 ENGINE MECHANICAL (K9K ENGINE) 6A2-17 EGR Valve and Intake Pipe Removal and Installation Removal 1) Disconnect negative (–) cable at battery. 2) Disconnect EGR valve connector (1) and boost pressure sensor connector (2). 3) Disconnect hose (3) from oil vapor recirculation valve (4), and then remove oil vapor recirculation valve.
  • Page 17 6A2-18 ENGINE MECHANICAL (K9K ENGINE) 7) Remove EGR valve body (1) with EGR pipe (2). Installation 1) Install EGR valve body assembly (1) with new gasket and EGR pipe bolt. Tightening torque EGR pipe bolt (a): 42 N·m (4.2 kg-m, 30.5 lb-ft) EGR cooler pipe bolt (b): 21 N·m (2.1 kg-m, 15.5 lb-ft)
  • Page 18 ENGINE MECHANICAL (K9K ENGINE) 6A2-19 3) Install intake pipe No.1 with new gasket. Tightening torque Intake pipe No.1 nut: 11 N·m (1.1 kg-m, 8.0 lb-ft) 4) Apply engine oil to new O-ring, and install intake pipe No.2 (2) with new O-ring.
  • Page 19 6A2-20 ENGINE MECHANICAL (K9K ENGINE) Reassembly 1) Hold EGR valve body with soft jawed vise (1), and install EGR cooler (3) with new gasket. 2) Install EGR cooler pipe (2) with new gasket. Tightening torque EGR cooler bolt (a): 12 N·m (1.2 kg-m, 9.0 lb-ft) EGR cooler pipe bolt (b): 12 N·m (1.2 kg-m, 9.0 lb-ft)

  • Page 20: Turbocharger Components

    ENGINE MECHANICAL (K9K ENGINE) 6A2-21 Turbocharger Components WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 23 N·m (2.3 kg-m) 12 N·m (1.2 kg-m) 23 N·m (2.3 kg-m)
  • Page 21 6A2-22 ENGINE MECHANICAL (K9K ENGINE) Turbocharger Removal and Installation Removal 1) Disconnect negative (–) cable at battery. 2) Remove air cleaner assembly referring to “Air Cleaner Assembly Removal and Installation” in this section. 3) Remove EGR valve body referring to “EGR Valve and Intake Pipe Removal and Installation”...
  • Page 22 8) Install air cleaner assembly referring to “Air Cleaner Assem- bly Removal and Installation” in this section. 9) Connect negative (–) cable to battery. 10) Using SUZUKI scan tool, cut fuel injection referring to “Oper- ation Manual”. 11) Crank engine for 15 seconds in order to lubricate turbo- charger.
  • Page 23 6A2-24 ENGINE MECHANICAL (K9K ENGINE) Exhaust Manifold Removal and Installation WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. Removal 1) Disconnect negative (–) cable at battery.
  • Page 24 ENGINE MECHANICAL (K9K ENGINE) 6A2-25 Oil Pan and Oil Pump Strainer Components 21 N·m (2.1 kg-m) 8 N·m (0.8 kg-m) 12 N·m (1.2 kg-m) 35 N·m (3.5 kg-m) 1. Upper oil pan gasket 7. Oil pump strainer 13. Engine oil drain plug 2.
  • Page 25 6A2-26 ENGINE MECHANICAL (K9K ENGINE) Oil Pan and Oil Pump Strainer Removal and Installation Removal 1) Disconnect negative (–) cable at battery. 2) Drain engine oil referring to “Engine Oil and Filter Change” in Section 0B. 3) Remove engine hood after disconnecting windshield washer hose.
  • Page 26 ENGINE MECHANICAL (K9K ENGINE) 6A2-27 10) Loosen lower oil pan bolts in numerical order (“1” to “22”) as “15” “9” “7” “17” “11” “13” “5” “19” “3” shown in figure, and remove them. 11) Remove lower oil pan from upper oil pan.
  • Page 27 6A2-28 ENGINE MECHANICAL (K9K ENGINE) Installation 1) Clean sealing surfaces on cylinder block, upper oil pan and lower oil pan. 2) Clean Inside of oil pan and oil pump strainer screen (1). 3) Install oil pan baffle plate to upper oil pan.
  • Page 28 ENGINE MECHANICAL (K9K ENGINE) 6A2-29 5) Install upper oil pan to cylinder block as follows. a) Fit upper oil pan to cylinder block with new gasket. b) Tighten upper oil pan bolts temporarily by hand. “12” “14” “16” “18” “10”...
  • Page 29 6A2-30 ENGINE MECHANICAL (K9K ENGINE) 10) Install engine to vehicle as follows. 5, (c) a) Install engine left mounting (1). b) Lower engine. 2, (a) c) Tighten engine mounting nuts (2) to specified torque. 5, (c) Tightening torque Engine mounting nut (a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
  • Page 30 ENGINE MECHANICAL (K9K ENGINE) 6A2-31 8) Remove fuel filter referring to “Fuel Filter Removal and Installation” in Section 6C2. 9) Disconnect discharge hose pipe from A/C compressor refer- ring to “Major Components and Location” in section 1B. 10) Remove transmission referring to “Transmission Dismount- ing and Remounting”...
  • Page 31 6A2-32 ENGINE MECHANICAL (K9K ENGINE) 16) Install lifting device (1). 17) Remove engine mounting nuts (2). 18) Before lifting engine, check to ensure all hoses, electric wires and cables are disconnected from engine. 19) Remove engine assembly from vehicle.
  • Page 32 ENGINE MECHANICAL (K9K ENGINE) 6A2-33 Installation CAUTION: Before installing intake air pressure sensor hose, degrease connect part of hose and intercooler outlet hose. Otherwise hose may become detached and cause turbo system failure. Reverse removal procedure for installation noting the following.
  • Page 33 6A2-34 ENGINE MECHANICAL (K9K ENGINE) Timing Belt and Belt Tensioner Components 21 N·m (2.1 kg-m) 27 N·m (2.7 kg-m) 9 N·m (0.9 kg-m) 8 N·m (0.8 kg-m) 1. Timing belt upper cover 7. Timing belt pulley 13. Generator upper bracket support bolt 2.
  • Page 34 ENGINE MECHANICAL (K9K ENGINE) 6A2-35 Timing Belt and Belt Tensioner Removal and Installation Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation” in this section. 2) Remove injector cover (1) and generator upper bracket (2).
  • Page 35 6A2-36 ENGINE MECHANICAL (K9K ENGINE) 7) Remove TDC pin cap (1). 8) Turn crankshaft pulley clockwise, and stop it just before aligning slit (1) of camshaft pulley hub (2) matches with hole (3) of cylinder head. 9) Insert special tool (A) into TDC pin hole as shown in figure.
  • Page 36 ENGINE MECHANICAL (K9K ENGINE) 6A2-37 12) Loosen crankshaft pulley bolt as follows. a) Lock flywheel using special tool (C). Special tool (C): 09916-98110 b) Remove special tools (A) and (B). c) Loosen crankshaft pulley bolt, and remove crank shaft pul- ley.
  • Page 37 6A2-38 ENGINE MECHANICAL (K9K ENGINE) 3) Install timing belt inner cover (1), timing belt pulley (2) and timing belt tensioner (3), if necessary. CAUTION: Install timing belt pulley so that boss side (6) may come to the gasket holder plate side.
  • Page 38 ENGINE MECHANICAL (K9K ENGINE) 6A2-39 7) Check that camshaft pulley bolts (1) do not touch long slot- ted end (2). 8) Install removed camshaft pulley bolt, and tighten all cam- shaft pulley bolts to specified torque. Tightening torque Camshaft pulley bolt (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) 9) Remove special tools (A) and (B).
  • Page 39 6A2-40 ENGINE MECHANICAL (K9K ENGINE) 14) Check that special tool (B) inserts holes of camshaft belt pul- ley hub and cylinder head smoothly. If not, loosen camshaft pulley bolts (1) by one turn, and turn camshaft pulley hub (2) to just aligning slit (3) of camshaft pulley hub with hole (4) of cylinder head.
  • Page 40 ENGINE MECHANICAL (K9K ENGINE) 6A2-41 18) Turn crankshaft two revolutions clockwise, and stop it just before aligning slit (1) of camshaft pulley (2) with hole (3) of cylinder head. 19) Insert special tool (A) into TDC pin hole as shown in figure.
  • Page 41 6A2-42 ENGINE MECHANICAL (K9K ENGINE) 23) Apply sealant “A” to thread of TDC pin cap (1), and tighten TDC pin cap as specified torque. Tightening torque TDC pin cap (a): 20 N·m (2.0 kg-m, 14.5 lb-ft) “A”: RHODORSEAL 5661® 24) Install generator upper bracket support (1).
  • Page 42 ENGINE MECHANICAL (K9K ENGINE) 6A2-43 Timing Belt and Belt Tensioner Inspection • Inspect timing belt for wear or crack. Replace it as necessary. • Inspect timing belt tensioner and roller for smooth rotation. Replace it as necessary.
  • Page 43 6A2-44 ENGINE MECHANICAL (K9K ENGINE) Oil Pump and Oil Pump Chain Components CAUTION: Never disassemble oil pump. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. 25 N·m (2.5 kg-m) 1. Oil pump drive sprocket 5.
  • Page 44 ENGINE MECHANICAL (K9K ENGINE) 6A2-45 3) Remove oil pump (1) from cylinder block. 4) Remove timing belt referring to “Timing Belt and Belt Ten- sioner Removal and Installation” in this section. 5) Remove gasket holder plate (1). 6) Remove gasket holder plate oil seal (2).
  • Page 45 6A2-46 ENGINE MECHANICAL (K9K ENGINE) 2) Install gasket holder plate (1) to cylinder block with new gas- ket, and tighten gasket holder plate bolts as follows. a) Tighten gasket holder plate bolts (“1” and “6”) to 11 N·m (1.1 kg-m, 8.0 lb-ft).
  • Page 46 ENGINE MECHANICAL (K9K ENGINE) 6A2-47 a) Install bolt (3) and spacer (4) of special tool to crankshaft. b) Install protector (2) together with new oil seal (1) to spacer (4). c) Install oil seal installer (5) to bolt (3). d) Tighten nut (6) of special tool until oil seal installer (5) comes into contact with gasket holder plate (7).
  • Page 47 6A2-48 ENGINE MECHANICAL (K9K ENGINE) • Check oil pump chain for wear or damage. If any malcondition is found, replace oil pump chain. Camshaft and Tappet Components 16 N·m (1.6 kg-m) 1. Camshaft housing bolt 6. Camshaft pulley 11. Vacuum pump oil hose : Tighten 10 N·m (1.0 kg-m, 7.5 lb-ft)
  • Page 48 ENGINE MECHANICAL (K9K ENGINE) 6A2-49 Camshaft and Tappet Removal and Installa- tion Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation” in this section. 2) Remove timing belt referring to “Timing Belt and Tensioner Removal and Installation” in this section.
  • Page 49 6A2-50 ENGINE MECHANICAL (K9K ENGINE) 10) Remove tappet (1) from cylinder head. CAUTION: Note original position in which each tappet was installed when valve lash (clearance) adjustment is not necessary. If each tappet is not installed to original position, engine will spoil its original performance.
  • Page 50 ENGINE MECHANICAL (K9K ENGINE) 6A2-51 b) Install camshaft pulley (1) to camshaft with aligning key (3) of camshaft pulley to key groove (4) of camshaft (2), and then tighten camshaft pulley nut to temporary. c) Apply engine oil to sliding surface of each camshaft and camshaft journal.
  • Page 51 6A2-52 ENGINE MECHANICAL (K9K ENGINE) 8) Install new oil seal (1) together with protector (2) using spe- cial tool and plastic hammer until special tool comes into contact with cylinder head. CAUTION: Do not touch oil seal (1) so that it is extremely fragile. Be sure to install new oil seal using special tool (A) and pro- tector (2) supplied with new oil seal.
  • Page 52 ENGINE MECHANICAL (K9K ENGINE) 6A2-53 Camshaft and Tappet Inspection Camshaft • Check teeth of sprocket for wear or damage. • Check journals and cam faces for wear or damage. If any malcondition is found, replace camshaft. • Using a micrometer, measure cam height “a”. If measured height is out of specification, replace camshaft.
  • Page 53 6A2-54 ENGINE MECHANICAL (K9K ENGINE) e) Install camshaft housing to cylinder head as follows. i) Fit camshaft housing to cylinder head. "8", (a) "12", (a) "11", (a) "7", (a) "4", (a) "3", (a) ii) Tighten camshaft housing bolts temporarily by hand.
  • Page 54 Power Door Lock System with Keyless Entry System (If Equipped) Power door lock system with keyless entry system component location [A]: M13 engine model 3. LOCK position 7. Transmitter [B]: K9K engine model 4. UNLOCK position 8. Door switch 1. Power door lock controller 5. Front door actuator 2.
  • Page 55 BODY ELECTRICAL SYSTEM 8-11 System description Only for M13 Engine Model The keyless entry system has the following signal modes in order to feed back the signal when the controller received LOCK and UNLOCK signals from transmitter. Received signal LOCK signal UNLOCK signal Signal mode Hazard warning light signal...
  • Page 56 15 seconds with the interior light switch in the middle position. [A]: M13 engine model [B]: K9K engine model If check result is not satisfied, go to “Keyless Entry System Circuit Inspection” in this section.
  • Page 57 BODY ELECTRICAL SYSTEM 8-13 Keyless Entry System Circuit Check M13 Engine Model Terminal Circuit Specification Condition 10 – 14 V Ignition key is in ignition switch. Key remainder circuit 0 – 1 V Ignition key is not in ignition switch. 0 –...
  • Page 58 8-14 BODY ELECTRICAL SYSTEM K9K Engine Model Terminal Circuit Specification Condition Figure “A” Push “LOCK” button on transmitter once. Hazard waning signal circuit (right side) Figure “B” Push “UNLOCK” button on transmitter once. Figure “A” Push “LOCK” button on transmitter once.
  • Page 59 6) Install transmitter cover (2) and screw (1). 7) Make sure the door locks can be operated with transmitter. K9K Engine Model 1) Put the edge of a coin (1) or a flat blade screwdriver in the slot (2) of transmitter (3) and pry it open.
  • Page 60 • Two transmitter codes can be registered. • When a new transmitter code is registered, the oldest one will be cleared. K9K Engine Model 1) Make sure that all doors are closed and ignition key is out of ignition key cylinder.
  • Page 61 BODY ELECTRICAL SYSTEM 8-17 Power Door Mirror Control System (If Equipped) Door mirror actuator Inspection 1) Remove front door inner garnish from front door. 2) Disconnect door mirror coupler. 3) Check that door mirror operates properly when battery volt- age is applied to coupler terminals. Connect battery positive and negative terminal to the door mirror terminal shown below.
  • Page 62 8-18 BODY ELECTRICAL SYSTEM Door Mirror Heater (If Equipped) Mirror heater (if equipped) Inspection 1) Remove door inner garnish from front door. 2) Disconnect door mirror coupler (1). 3) Check for continuity between terminals “a” and “b”. if not continuity, replace outside mirror.

This manual is also suitable for:

M13