Page 1 SUZUKI ──────────── SQ 416-420-625 ──────────── M.Y 1998 - 2005 SERVICE MANUAL VOLUME 1 - CHASSIS SECTIONS - ELECTRICAL - BODY SECTIONS...
Page 2 RELATED MANUAL MANUAL NAME MANUAL NO. APPLICABILITY SQ416/SQ420/SQ625 99501-65D01-xxx Transmission, Transfer and Differentials Unit Repair Manual (Front and Rear) of SQ series. SQ416/SQ420/SQ625 99512-65D10-015 Applicable model mentioned in FOREWORD Wiring Diagram Manual of this manual. SQ416/SQ420/SQ625 99500-65D00-xxx Vehicles before the vehicle identification number Service Manual mentioned in FOREWORD of this manual.
Page 3 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION ENGINE GENERAL INFORMATION General Information and General Information Diagnosis (G16/J20) Maintenance and Lubrication General Information and HEATING AND AIR Diagnosis (H25) CONDITIONING Engine Mechanical (G16) Heater and Ventilation Engine Mechanical (H25) Air Conditioning Engine Mechanical (J20) STEERING, SUSPENSION, Engine Cooling...
Page 4: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ............. . . 0A- 2 PRECAUTIONS .
Page 5: How To Use This Manual
0A-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
Page 6: Precautions
D If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 7: Servicing And Handling
0A-4 GENERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY WARNING: FROM BODY. Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment.
Page 8 GENERAL INFORMATION 0A-5 WARNING: D During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
Page 9 0A-6 GENERAL INFORMATION CAUTION: D Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in SECTION 10B. D When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, re- move those parts beforehand.
Page 10: General Precautions
GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
Page 11 0A-8 GENERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position.
Page 12: Precautions For Catalytic Converter
GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never dis- connect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
Page 13: Precautions For Electrical Circuit Service
0A-10 GENERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g.
Page 14 GENERAL INFORMATION 0A-11 D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage at each terminal, check to make sure that battery voltage is 11V or higher. Such terminal volt- age check at low battery voltage will lead to erroneous diag- nosis.
Page 15: Electrical Circuit Inspection Procedure
0A-12 GENERAL INFORMATION ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various electrical circuit inspection methods, de- scribed here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.
Page 16 GENERAL INFORMATION 0A-13 Continuity Check 1) Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1. 2) Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance between terminals A-1 and B-1.
Page 17 0A-14 GENERAL INFORMATION SHORT CIRCUIT CHECK (Wire harness to ground) To other 1) Disconnect negative cable from battery. parts 2) Disconnect connectors at both ends of the circuit to be checked. NOTE: If the circuit to be checked is connected to other parts, dis- connect all connectors of those parts.
Page 18: Intermittent And Poor Connection
GENERAL INFORMATION 0A-15 INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 19: Precaution For Installing Mobile Communication Equipment
0A-16 GENERAL INFORMATION D Poor terminal-to-wire connection. Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. D Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle.
Page 20: Identification Information
GENERAL INFORMATION 0A-17 IDENTIFICATION INFORMATION BODY NUMBER The vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side. It is possible to identify the country of origin (the production plant) of the vehicle by the first three digits of the body number as shown below.
Page 21: Warning, Caution And Information Labels
0A-18 GENERAL INFORMATION WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Page 22: Vehicle Lifting Points
GENERAL INFORMATION 0A-19 VEHICLE LIFTING POINTS WARNING D When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying to move vehicle body in both ways.
Page 23 0A-20 GENERAL INFORMATION In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the jack against the center portion of the front suspension frame or rear axle housing. WARNING: D Never apply jack against suspension parts (i.e., stabilizer, etc.) or vehicle floor, or it may get deformed.
Page 24: Abbreviations May Be Used In This Manual
GENERAL INFORMATION 0A-21 ABBREVIATIONS MAY BE USED IN THIS MANUAL : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Electric Brake force Distribution : Automatic Locking Retractor : Engine Control Module : Alternating Current...
Page 25 0A-22 GENERAL INFORMATION : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch : Transmission Control Module MAF Sensor : Mass Air Flow Sensor (A/T Controller, A/T Control (Air Flow Sensor, AFS, Air Module) Flow Meter, AFM)
Page 26: Metric Information
GENERAL INFORMATION 0A-23 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt.
Page 27: Standard Tightening Torque
0A-24 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
Page 28 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 29: 0B-2 Maintenance And Lubrication
0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry Interval: out the same services at the same intervals respectively. This interval should be judged by This interval should be judged by (x 1,000)
Page 30 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry Interval: out the same services at the same intervals respectively. This interval should be judged by This interval should be judged by (x 1,000) odometer reading or months, whichever comes first.
Page 31: Maintenance Recommended Under Severe Driving Conditions
0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 32: Maintenance Service
MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt (G16 and H25 engines) Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
Page 33 0B-6 MAINTENANCE AND LUBRICATION Water pump, generator, power steering and/or A/C compressor (if equipped) drive belt (J20 engine) Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace. Also, check belt for tension.
Page 34 MAINTENANCE AND LUBRICATION 0B-7 Power steering pump and/or A/C compressor drive belts (if G16 with P / S equipped) for G16 and H25 engines. Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any defect exists, replace.
Page 35 0B-8 MAINTENANCE AND LUBRICATION ITEM 1-2 Camshaft Timing Belt Replacement (G16 engine only) Replace timing belt referring to Section 6A1. ITEM 1-3 Valve Lash Inspection (G16 engine only) 1) Remove cylinder head cover. 2) Inspect intake and exhaust valve lash and adjust as necessary. Refer to Section 6A1 for valve lash inspection and adjustment procedure.
Page 36 MAINTENANCE AND LUBRICATION 0B-9 3) Loosen oil filter by using oil filter wrench (special tool). Special Tool (A): 09915-47310 (H25 engine) 09915-47330 (G16 and J20 engines) NOTE: Before fitting new oil filter, be sure to oil its O-ring. Use engine oil for this purpose.
Page 37 0B-10 MAINTENANCE AND LUBRICATION NOTE: Engine oil capacity is specified. However, note that the amount of oil required when actually changing oil may somewhat differ from the data in the table depending on various conditions (temperature, viscosity, etc.). 7) Check oil filter and drain plug for oil leakage. 8) Start engine and run it for three minutes.
Page 38 MAINTENANCE AND LUBRICATION 0B-11 6) Add coolant to reservoir so that its level aligns with Full mark. 1. Reservoir Then, reinstall cap aligning arrow marks on reservoir and cap. 2. FULL level mark 3. LOW level mark 4. Arrow mark NOTE: 5.
Page 39: Ignition System
0B-12 MAINTENANCE AND LUBRICATION IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1 or 6F2. FUEL SYSTEM ITEM 3-1 Air Cleaner Filter Inspection 1) Remove air cleaner case clamps. 2) Take cleaner filter out of air cleaner case. 3) Check air cleaner filter for dirt.
Page 40 MAINTENANCE AND LUBRICATION 0B-13 ITEM 3-3 Fuel Filter Replacement WARNING: This work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter is located at the front part of fuel tank, inside the right- hand side of chassis.
Page 41: Emission Control System
0B-14 MAINTENANCE AND LUBRICATION EMISSION CONTROL SYSTEM ITEM 4-1 Crankcase Ventilation Hoses and Connections Inspection (Vehicle not equipped with oxygen sensor) Refer to the following item 4-2, PCV valve inspection. ITEM 4-2 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog.
Page 42: Chassis And Body
MAINTENANCE AND LUBRICATION 0B-15 CHASSIS AND BODY ITEM 6-1 Clutch Pedal inspection Check clutch pedal for height and free travel referring to Section 7C1. Adjust or correct if necessary. 1. Clutch pedal free travel Fluid inspection 1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct.
Page 43 0B-16 MAINTENANCE AND LUBRICATION ITEM 6-3 Brake Hoses and Pipes Inspection Check brake hoses and pipes for proper hookup, leaks, cracks, chafing and other damage. Replace any of these parts as necessary. CAUTION: After replacing any brake pipe or hose, be sure to carry out air purge operation.
Page 44 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-6 Tire Inspection and Rotation 1) Check tires for uneven or excessive wear, or damage. If defective, replace. Refer to Section 3 for details. 1. Wear indicator 2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
Page 45 0B-18 MAINTENANCE AND LUBRICATION ITEM 6-8 Suspension System Inspection Check suspension bolts and nuts for tightness and retighten them as necessary. Repair or replace defective parts, if any. NOTE: For details of check points, refer to tables of Tightening Torque Specification in Section 3D and 3E.
Page 46 MAINTENANCE AND LUBRICATION 0B-19 11) Check coil spring, upper rod, lower rod and lateral rod for de- formation and damage. 12) Check upper rod, lower rod and lateral rod bushings and bump stopper for wear, damage and deterioration. 13) Check other suspension parts for damage, loose or missing parts;...
Page 47 0B-20 MAINTENANCE AND LUBRICATION ITEM 6-10 Type 1 Manual Transmission Oil Inspection and Change Inspection 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove level plug of transmission.
Page 48 MAINTENANCE AND LUBRICATION 0B-21 Change 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Change fluid. For its procedure, refer to On-vehicle service in Section 7B1.
Page 49 0B-22 MAINTENANCE AND LUBRICATION ITEM 6-14 Steering System Inspection 1) Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.2 in.) 2) Check universal joints of steering shaft for rattle and damage. If The figure shows right-hand steering vehicle rattle or damage is found, replace defective part with a new one.
Page 50 MAINTENANCE AND LUBRICATION 0B-23 3) Visually check pump drive belt for cracks and wear. 4) Check belt for tension, referring to item 1-1. If necessary, have belt adjusted or replaced. ITEM 6-16 All Hinges, Latches and Locks Inspection Doors Check that each door of front, rear and back doors opens and closes smoothly and locks securely when closed.
Page 51: Final Inspection
0B-24 MAINTENANCE AND LUBRICATION FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual transmission) When carrying out road tests, select a safe Check for the following: place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.
Page 52: Recommended Fluids And Lubricants
MAINTENANCE AND LUBRICATION 0B-25 Steering D Check to ensure that steering wheel is free from in- stability, or abnormally heavy feeling. D Check that the vehicle does not wander or pull to one side. Engine D Check that engine responds readily at all speeds. D Check that engine is free from abnormal noise and abnormal vibration.
Page 53 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 54: General Description
1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets at places, right and left, along the windshield glass.
Page 55: Body Ventilation
HEATER AND VENTILATION 1A-3 BODY VENTILATION The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
Page 56: Wiring Circuit
1A-4 HEATER AND VENTILATION WIRING CIRCUIT FOR LH VEHICLE FOR RH VEHICLE 1. From ignition switch 1 6. Blower motor relay 11. To illumination controller 15. TAIL fuse 15 A 2. From ignition switch 2 7. Blower motor switch (if equipped) or body ground 16.
Page 57: On-Vehicle Service
HEATER AND VENTILATION 1A-5 ON-VEHICLE SERVICE BLOWER UNIT 1. Blower unit 2. Blower motor resistor 3. Blower motor relay 4. Blower fan 5. Blower motor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B.
Page 58 1A-6 HEATER AND VENTILATION 6) Remove cooling unit (If equipped). Refer to item COOLING UNIT (EVAPORATOR) REMOVAL in Section 1B. 7) Disconnect fresh air control cable from blower motor case. 8) Remove blower motor unit (1) by removing its fastening nuts (2).
Page 59: Blower Motor
HEATER AND VENTILATION 1A-7 BLOWER MOTOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove ECM with bracket from blower motor unit. 4) Disconnect harness clamps from dash panel. 5) Loosen three nuts fastening blower unit.
Page 60: Blower Motor Relay
1A-8 HEATER AND VENTILATION BLOWER MOTOR RELAY REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Open glove box, then remove screw. 4) Remove glove box. 5) Disconnect relay coupler.
Page 61: Blower Motor Resistor
HEATER AND VENTILATION 1A-9 BLOWER MOTOR RESISTOR REMOVAL 1) Disconnect negative (–) cable (2) at battery (1). 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Open glove box (1), then remove screw (2). 4) Remove glove box.
Page 62: Heater Mode Control Switch
1A-10 HEATER AND VENTILATION HEATER MODE CONTROL SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove meter cluster hood (1) by removing its mounting screws (2).
Page 63 HEATER AND VENTILATION 1A-11 7) Disconnect heater blower motor switch connector (1). 8) Remove mode control switch with heater control lever assem- bly from the removed hole in mentioned step (5). 9) Pull off heater control lever knob. 10) Remove heater mode control switch (2) with heater control panel (3) from heater control lever assembly (1).
Page 64: Heater Mode Control Actuator
1A-12 HEATER AND VENTILATION INSTALLATION 1) Install in reverse order of removal procedure. 2) Adjust cables as follows. (1) Move control lever fully in arrow direction. 1. Temperature control lever 2. Fresh air control lever (2) Push heater lever fully in arrow direction and fix cable with clamp in position as shown in left figure.
Page 65 HEATER AND VENTILATION 1A-13 4) Disconnect heater mode control actuator coupler (1). 5) Disconnect heater mode control actuator rod (2) from heater unit. 6) Remove heater mode control actuator from heater unit by re- moving its mounting screw (3). INSPECTION 1) Connect battery voltage (+) to terminal “b’”...
Page 66: Heater Control Lever Assembly
1A-14 HEATER AND VENTILATION HEATER CONTROL LEVER ASSEMBLY REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove mode control switch. Refer to item HEATER MODE CONTROL SWITCH in this section.
Page 67: Heater Control Cables
HEATER AND VENTILATION 1A-15 HEATER CONTROL CABLES 1. Heater unit 2. Blower unit 3. Fresh air control cable 4. Temperature control cable 5. Heater control lever assembly REMOVAL 1) Remove heater control lever assembly. Refer to HEATER CONTROL LEVER ASSEMBLY in this sec- tion.
Page 68: Heater Unit
1A-16 HEATER AND VENTILATION HEATER UNIT 1. Heater unit 2. Heater core 3. Damper 4. Heater mode control actuator 5. Heater mode control switch 6. Heater control lever assembly...
Page 69 HEATER AND VENTILATION 1A-17 REMOVAL WARNING: Failure to follow the following procedure and WARNING may cause air bag deployment, personal injury, damage to parts, or air bag being unable to deploy. D Never rest a steering column assembly on steering wheel with air bag (inflator) module face down and column verti- cal.
Page 70 1A-18 HEATER AND VENTILATION 11) Remove heater core pipe clamps (1) and grommet (2). 12) Pull out heater core (1) from unit (2). INSTALLATION 1) Install heater unit by reversing removal procedure, noting the following items. D When installing each part, be careful not to catch any cable or wiring harness.
Page 71: Rear Duct
HEATER AND VENTILATION 1A-19 REAR DUCT 1. Heater unit 2. Rear duct 3. SDM REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove front seat. 3) Remove console box. 4) Take off carpet till rear duct is totally exposed. 5) Remove rear duct.
Page 72 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 73 1B-2 AIR CONDITIONING (OPTIONAL) Condenser Dryer (Receiver/Dryer) ..1B-36 A/C Compressor Relay and A/C Condenser Cooling Fan Relay ..1B-48 Air Filter Element ..... 1B-37 Compressor Assembly .
Page 74: General Description
AIR CONDITIONING (OPTIONAL) 1B-3 GENERAL DESCRIPTION The air conditioning system of this model differs by the country of origin (the production plant.). One is Japan (IWATA) produced, other one is Canada (CAMI) produced. For the details of the identification, please refer to IDENTIFICATION INFORMATION of Section 0A in this manual. The compressor used of Japan (IWATA) produced vehicle is made of SEIKO SEIKI and the compressor used of Canada (CAMI) produced vehicle is made of DENSO.
Page 75: Refrigerant Flow Of Air Conditioning System
1B-4 AIR CONDITIONING (OPTIONAL) REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM : Liquid : Vapor : Superheated vapor 1. Compressor 2. Magnet clutch 3. Condenser assembly 4. Receiver / dryer 5. Dual pressure switch 6. Expansion valve 7. Evaporator...
Page 76: Major Components And Location
AIR CONDITIONING (OPTIONAL) 1B-5 MAJOR COMPONENTS AND LOCATION CAMI PRODUCTION VEHICLE IWATA PRODUCTION VEHICLE 1. Cooling unit 9. Expansion valve 17. Air inlet box 2. Compressor 10. Ventilation air 18. Dual pressure switch 3. Condenser assembly 11. Foot air 19. Low pressure charge valve 4.
Page 77: Diagnosis
1B-6 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL Condition Possible Cause Correction D No refrigerant Cool air won’t come out Recover, evacuation and charging. D Fuse blown (A /C system won’t Check “IG METER” fuse, “REAR DEFG” operative) fuse, and “A/C FUSE” and check for short circuit to ground.
Page 78 AIR CONDITIONING (OPTIONAL) 1B-7 Condition Possible Cause Correction D Compressor faulty Cool air does not come Check compressor. D Air in A/C system out or insufficient Replace condenser dryer, and cooling (A/C system evacuation and charging. D Air leaking from cooling unit or air normal operative) Repair as necessary.
Page 79: Diagnosis Of Abnormal Noise
1B-8 AIR CONDITIONING (OPTIONAL) DIAGNOSIS OF ABNORMAL NOISE There are various types of noise, ranging from those produced in the engine compartment to those from the pas- senger compartment, also from rumbling noises to whistling noises. ABNORMAL NOISE FROM COMPRESSOR Condition Possible Cause Correction...
Page 80 AIR CONDITIONING (OPTIONAL) 1B-9 ABNORMAL NOISE FROM CRANKSHAFT PULLEY Condition Possible Cause Correction D A large rattling noise is heard at D Loosen pulley mounting bolt. D Retighten bolt. D Worn or broken bearings. D Replace bearings. idle or sudden acceleration. ABNORMAL NOISE FROM TENSION PULLEY Condition Possible Cause...
Page 81: Quickly Checking Of Refrigerant Charge
1B-10 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT 3. Bubbles CHARGE (IF EQUIPPED WITH SIGHT GLASS) CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its max.
Page 82: Compression System Diagnosis
AIR CONDITIONING (OPTIONAL) 1B-11 COMPRESSION SYSTEM DIAGNOSIS Compressor troubles are mainly following three types: gas leakage, noise and insufficient pressure. Compressor gas leakages in most cases develop from the shaft seal. When detecting gas leakage, always use a leak tester. If a small amount of oil seeps out from the shaft seal, there is no necessity of replacing the seal. The shaft seal has been designed to allow a small amount of oil to leak out for lubricating purpose.
Page 83: Performance Diagnosis
1B-12 AIR CONDITIONING (OPTIONAL) PERFORMANCE DIAGNOSIS For CAMI production vehicle 1) Confirm that vehicle and environmental conditions are as fol- lows. D Vehicle is not exposed to direct sun. D Ambient temperature is within 15_C – 35_C (59_F – 95_F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
Page 84 AIR CONDITIONING (OPTIONAL) 1B-13 9) 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 de- fective part referring to following Test Diagnosis table. Example: Gauges should read as follows when ambient temperature is 30DC.
Page 85 1B-14 AIR CONDITIONING (OPTIONAL) PERFORMANCE DIAGNOSIS TABLE TESTING RESULTS POSSIBLE CAUSE REMEDY D Refrigerant overcharged D Recharge Pressure high D Expansion valve frozen or clogged D Check expansion valve (“A” area of high side D Clogged refrigerant passage of high side D Clean or replace graph) D Condenser fan malfunction...
Page 86 AIR CONDITIONING (OPTIONAL) 1B-15 AMBIENT TEMPERATURE WITHIN 30 – 35_C (85 – 95_F) CONDITION MANIFOLD (kg / cm CAUSE CORRECTION GAUGE DETAIL (psi) 0.23 – 0.35 1.4 – 1.75 (2.3 – 3.5) (14 – 17.5) Normal condition. —— —— (33 – 50) (200 –...
Page 87: Wiring Circuit
1B-16 AIR CONDITIONING (OPTIONAL) WIRING CIRCUIT FOR LH VEHICLE 1. Blower motor main relay 10. Compressor relay 19. Battery 2. Blower motor 11. Compressor 20. Generator 3. Blower motor resistor 12. Condenser cooling fan relay 21. Ignition main fuse 60 A 4.
Page 88 AIR CONDITIONING (OPTIONAL) 1B-17 FOR RH VEHICLE 1. Blower motor main relay 10. Compressor relay 19. Battery 2. Blower motor 11. Compressor 20. Generator 3. Blower motor resistor 12. Condenser cooling fan relay 21. Ignition main fuse 60 A 4. Blower motor switch 13.
Page 89: Inspection Of A/C Controller And Its Circuits
1B-18 AIR CONDITIONING (OPTIONAL) INSPECTION OF A/C CONTROLLER AND ITS CIRCUITS CAUTION: A/C controller and ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to A/C controller and ECM with couplers disconnected from it. A/C controller (1) and its circuits can be checked at A/C controller wiring couplers by measuring voltage.
Page 90 AIR CONDITIONING (OPTIONAL) 1B-19 SYSTEM CIRCUIT H25 engine E61-27 G16, J20 engines E61-8 H25 engine E61-28 G16, J20 engines E61-17 H25 engine E61-5 G16, J20 engines E61-22 A. To heater fuse 1. Blower motor relay 7. Dual pressure (refrigerant 11. Condenser fan motor relay B.
Page 91 1B-20 AIR CONDITIONING (OPTIONAL) A/C CONTROLLER VOLTAGE VALUES TABLE Measurement Terminal Wire Circuit Normal value Condition ground Controller main Ground to Ignition switch ON with engine AC1-1 10 – 14 volts power supply engine (Fig. B) stopped Controller main Ground to body AC1-2 –...
Page 92 AIR CONDITIONING (OPTIONAL) 1B-21 Measurement Terminal Wire Circuit Normal value Condition ground Ground to body AC2-1 L / Y Sensor ground – 0.4 – 0 volt Engine running (Fig. A) Evaporator thermistor temperature at 1.5 volts approx. 15_C (59_F) with engine (3150 f) running Evaporator thermistor temperature at...
Page 93: Drive Belt
1B-22 AIR CONDITIONING (OPTIONAL) DRIVE BELT G16 engine INSPECTION For G16 and H25 engines Refer to Section 3B1 for details. For J20 engine Refer to Section 6H for details. J20 engine H25 engine 1. Generator belt 3. Compressor pulley 2. Compressor drive belt 4.
Page 94: Refrigerant Recovery, Evacuation And Charging
AIR CONDITIONING (OPTIONAL) 1B-23 REFRIGERANT RECOVERY, EVACUATION AND CHARGING WARNING: D Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6_C (42.8_F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a seri- ous injury.
Page 95: Recovery
1B-24 AIR CONDITIONING (OPTIONAL) RECOVERY For CAMI production vehicle NOTE: D When discharging refrigerant out of A/C system, always re- cover it by using refrigerant recovery and recycling equip- ment (1). Discharging it into atmosphere would cause ad- verse effect to environments. D When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
Page 96: Evacuating
AIR CONDITIONING (OPTIONAL) 1B-25 EVACUATING EVACUATING PROCEDURE CAUTION: For CAMI production vehicle Do not evacuate before recovering refrigerant in system. NOTE: Whenever opened (exposed to atmospheric air), air condition- ing system must be evacuated by using a vacuum pump. The A/C system should be attached with a manifold gauge set, and should be evacuated for approx.
Page 97: Charging
1B-26 AIR CONDITIONING (OPTIONAL) CHARGING CAUTION: D ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A/C system at after the initial charging is per- formed from the high-pressure side with the engine stopped. D NEVER CHARGE TO HIGH PRESSURE-SIDE of A/C system with engine running. D Do not charge while compressor is hot.
Page 98 AIR CONDITIONING (OPTIONAL) 1B-27 7) When refrigerant container (3) is emptied, use following proce- dure to replace it with a new refrigerant container (3). a. Close low pressure valve. b. Replace empty container (3) with a refrigerant container which has been charged with refrigerant. When using refrig- erant container tap valve (4), use following procedure for re- placement.
Page 99 1B-28 AIR CONDITIONING (OPTIONAL) 8) After the system has been charged with specified amount of re- For CAMI production vehicle frigerant or when low pressure gauge (1) and high pressure gauge (2) have indicated about 2 and 15 kg/cm respectively, close low pressure side vale (3) of manifold gauge set (4).
Page 100: Removing Manifold Gauge Set
AIR CONDITIONING (OPTIONAL) 1B-29 REMOVING MANIFOLD GAUGE SET When A/C system has been charged with a specified amount of re- frigerant, remove manifold gauge set as follows: 1) Close low pressure-side valve of manifold gauge set, (The high pressure-side valve is closed continuously during the process of charging.).
Page 101: On-Vehicle Service
1B-30 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE WARNING: Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately. D DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
Page 102 AIR CONDITIONING (OPTIONAL) 1B-31 D Tighten flared nuts to specified torque. Tightening Torque (Flared Nut Used for) 8 mm pipe: 13 N m (1.3 kg-m, 9.5 lb-ft) 14.5 mm pipe: 23 N m (2.3 kg-m, 16.6 lb-ft) 16 mm pipe: 33 N m (3.3 kg-m, 23.8 lb-ft) D Route drain hose so that drained water does not make any contact to vehicle components.
Page 103 1B-32 AIR CONDITIONING (OPTIONAL) REPLENISHING COMPRESSOR OIL When replacing air conditioning parts with new ones, it is necessary to replenish oil by the amount supposedly remaining in each part. When changing gas only When it is unavoidable to change gas without replacing any compo- nent part for engine removal and installation or for some other rea- son, replenish 20 cc oil.
Page 104: A/C Condenser Assembly
AIR CONDITIONING (OPTIONAL) 1B-33 A/C CONDENSER ASSEMBLY INSPECTION Check a) condenser fins for blockage b) condenser fittings for leakage c) condenser fins for damage Clogged condenser fins should be washed with water, and should be dried with compressed air. CAUTION: Be careful not to damage condenser fins.
Page 105 1B-34 AIR CONDITIONING (OPTIONAL) 5) Disconnect coupler from dual pressure switch (1). 6) Disconnect condenser outlet pipe (3). 7) Disconnect condenser cooling fan motor coupler (2). 8) Remove condenser with fan. NOTE: Be careful not to damage fins of condenser and radiator. 9) Remove A/C condenser cooling fan assembly from condenser.
Page 106: Condenser Cooling Fan Assembly
AIR CONDITIONING (OPTIONAL) 1B-35 CONDENSER COOLING FAN ASSEMBLY INSPECTION D Remove condenser assembly (Refer to “A/C CONDENSER AS- SEMBLY REMOVAL” in this section). D Check continuity between terminal to terminal as shown. If check results are continuity, proceed to next operation check. If not, replace.
Page 107: Condenser Dryer (Receiver/Dryer)
1B-36 AIR CONDITIONING (OPTIONAL) CONDENSER DRYER (RECEIVER/DRYER) REMOVAL 1) Remove A/C condenser assembly (1) from vehicle (Refer to “A/C CONDENSER ASSEMBLY REMOVAL” in this section.). 2) Remove the condenser dryer cap from condenser. 2. Condenser dryer section 3) Remove the filter (1) from the condenser (2). 4) Remove the dryer (1) using a plier (2).
Page 108: Air Filter Element
AIR CONDITIONING (OPTIONAL) 1B-37 AIR FILTER ELEMENT REMOVAL 1) Disconnect negative (–) cable at battery. 2) For vehicle with air bag system, disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” in Section 10B. 3) Pull down glove box (1) by pushing the shown part (a). 4) Remove filter cover (1).
Page 109 1B-38 AIR CONDITIONING (OPTIONAL) CLEAN Blow off dust by compressed air from air outlet side of the filter ele- ment. 1. Air flow INSTALLATION Reverse removal procedure for installation noting the followings: D Install filter into cooling unit directing arrow mark on its end face to heater unit.
Page 110: Cooling Unit (Evaporator)
AIR CONDITIONING (OPTIONAL) 1B-39 COOLING UNIT (EVAPORATOR) REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system. Refer to “Disabling Air Bag System” in Section 10B. 3) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.
Page 111 1B-40 AIR CONDITIONING (OPTIONAL) 3) Remove upper case (1) and remove evaporator (2) from lower case (3). 4) Remove following components from evaporator. D Expansion valve (5) D Thermistor (evaporator temperature sensor) (4) DISASSEMBLY (FOR IWATA PRODUCTION VEHICLE) 1) Remove filter (2) from cooling unit (3) assembly by removing fil- ter cover (1).
Page 112 AIR CONDITIONING (OPTIONAL) 1B-41 INSPECTION 1) Check evaporator fins for blockage. If found clogged, use com- pressed air to clean the fins. CAUTION: Do not use water for cleaning of evaporator. Be careful not to damage evaporator fins. If evaporator fin is bent, straighten it by using a screwdriver or pair of pliers.
Page 113: Expansion Valve
1B-42 AIR CONDITIONING (OPTIONAL) EXPANSION VALVE INSPECTION Refer to “Troubleshooting Procedure Using Manifold Gauge Set” in this section. REMOVAL 1) Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment. The amount of compressor oil removed must be measured and the same amount added to the system.
Page 114: A/C Evaporator Thermistor (Evaporator Temperature Sensor)
AIR CONDITIONING (OPTIONAL) 1B-43 A/C EVAPORATOR THERMISTOR (EVAPORATOR TEMPERATURE SENSOR) A thermistor is a temperature sensor to sense the temperature of air discharged from evaporator. The electrical characteristic is shown in the figure. When temperature is lower than preset temperature, amplifier makes magnet clutch turn off to prevent evaporator from frosting.
Page 115: Refrigerant Pipes And Hoses
1B-44 AIR CONDITIONING (OPTIONAL) REFRIGERANT PIPES AND HOSES INSPECTION 1) Use a leak tester to check hoses and pipes for any gas leakage. 2) Check each hose or pipe clamp for tightness. Retighten or replace loose clamp as required, if any. REMOVAL 1) Recover refrigerant by using recovery and recycling equipment.
Page 116: A/C Switch
AIR CONDITIONING (OPTIONAL) 1B-45 A/C SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” in Section 10B. 3) Remove mode control switch (Refer to “MODE CONTROL SWITCH”...
Page 117: A/C Controller
1B-46 AIR CONDITIONING (OPTIONAL) A/C CONTROLLER REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to “DISABLING AIR BAG SYSTEM” in Section 10B. 3) Open glove box, then remove screw. 4) Remove glove box. 5) Disconnect A/C controller coupler (2), evaporator thermistor coupler (3).
Page 118: Dual Pressure Switch
AIR CONDITIONING (OPTIONAL) 1B-47 DUAL PRESSURE SWITCH INSPECTION 1) Check dual pressure switch (1) on liquid pipe for continuity at normal temperature (approx. 25_C (77_F)) when A/C system has a proper charge of refrigerant and when A/C system (com- pressor) is under operation. In each of these cases, switch should show proper continuity.
Page 119: A/C Compressor Relay And A/Ccondenser Cooling Fan Relay
1B-48 AIR CONDITIONING (OPTIONAL) A/C COMPRESSOR RELAY AND A/C CONDENSER COOLING FAN RELAY INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove condenser cooling fan motor relay (2) and/or compres- sor relay (1) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
Page 120: Compressor Assembly
AIR CONDITIONING (OPTIONAL) 1B-49 COMPRESSOR ASSEMBLY CAUTION: None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a). For identification between these two types, refer to page 1B-2. When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Page 121 1B-50 AIR CONDITIONING (OPTIONAL) REMOVAL 1) Run engine at idle with A/C ON for 10 minutes. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system using recovery and recycling equipment. NOTE: The amount of compressor oil at removed must be mea- sured and the same amount must be poured when installing the compressor.
Page 122 AIR CONDITIONING (OPTIONAL) 1B-51 INSTALLATION G16 engine FOR IWATA PRODUCTION VEHICLE 1) Pour new compressor oil. The amount must be the same with the amount measured in REMOVAL. NOTE: Compressor assembly supplied from factory is filled up with following amount of oil. Amount of oil in compressor: 120 cm (120 cc, 7.5 in 2) For G16 engine:...
Page 123 1B-52 AIR CONDITIONING (OPTIONAL) FOR CAMI PRODUCTION VEHICLE G16 engine 1) Pour new compressor oil. The amount must be the same with the amount measured in REMOVAL. NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Amount of oil in compressor: 120 cm (120 cc, 7.5 in 2) For G16 engine:...
Page 124: Magnet Clutch Assembly
AIR CONDITIONING (OPTIONAL) 1B-53 MAGNET CLUTCH ASSEMBLY (FOR DENSO) 1. Clutch plate bolt 2. Clutch plate 3. Circlip 4. Clutch pulley 5. Shim 6. Clutch coil 7. Compressor INSPECTION D Inspect clutch plate and clutch pulley for signs of oil. D Check clutch pulley for noise and grease leakage.
Page 125 1B-54 AIR CONDITIONING (OPTIONAL) 4) Remove shims from shaft. 5) Using special tool (C), remove circlip. Special Tool (C): 09900-06107 6) Remove clutch coil lead wire clamp screw, and remove clutch coil read wire ground terminal. 7) Remove clutch pulley with puller (1) from compressor (2). NOTE: Be careful not to damage pulley when tapping magnet clutch assembly.
Page 126 AIR CONDITIONING (OPTIONAL) 1B-55 4) Clutch pulley (1). (1) Set clutch pulley squarely over clutch pulley installation boss. (2) Place special tool (D) onto clutch pulley bearing. Ensure that edge rests only on inner race of bearing. (3) Install snap ring. Special Tool (D): 09991-06010 CAUTION:...
Page 127: Magnet Clutch Assembly
1B-56 AIR CONDITIONING (OPTIONAL) MAGNET CLUTCH ASSEMBLY (FOR SEIKO SEIKI) 1. Clutch plate bolt 2. Clutch plate 3. Circlip 4. Clutch pulley 5. Washer 6. Shim 7. Oil felt ring 8. Clutch coil 9. Lip type seal 10. Compressor front head 11.
Page 128 AIR CONDITIONING (OPTIONAL) 1B-57 3) Using special tool (B), remove clutch plate (1). Special Tool (B): 09991-06030 4) Disconnect clutch coil lead wire from compressor thermal switch led wire. 5) Remove felt ring (if equipped) and shims from shaft. 6) Using special tool (C), remove circlip. Special Tool (C): 09900-06107 7) Remove clutch coil lead wire clamp screw.
Page 129 1B-58 AIR CONDITIONING (OPTIONAL) 4) Install clutch pulley (1). (1) Set clutch pulley squarely over clutch pulley installation boss. (2) Place special tool (D) onto clutch pulley bearing. Ensure that edge rests only on inner race of bearing. (3) Install snap ring. Special Tool (D): 09991-06010 CAUTION:...
Page 130: Lip Type Seal (For Seiko Seiki)
AIR CONDITIONING (OPTIONAL) 1B-59 LIP TYPE SEAL (FOR SEIKO SEIKI) REMOVAL 1) Remove magnet clutch assembly, referring to “MAGNET CLUTCH ASSEMBLY” in this section. 2) Remove compressor front head (1) mounting bolt (10 pcs.). 3) Remove compressor front head (1) by pushing cylinder shaft PUSH (2).
Page 131 1B-60 AIR CONDITIONING (OPTIONAL) 2) Coat special tool (F) surface with oil and place it on the shaft. Special Tool (F): 09991-06040 3) Install O-ring (2) to case. 4) Apply compressor (refringent) oil to lip seal and O-ring. 5) Install compressor front head (1). 6) Tighten compressor front head bolt.
Page 132: Required Service Material
AIR CONDITIONING (OPTIONAL) 1B-61 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D O-ring Compressor oil for DENSO COMPRESSOR OIL (ND-OIL 8, 250 cc) D Each component compressor (Refrigerant oil) 99000-27080 Compressor oil for D O-ring COMPRESSOR OIL RS20 (150 cc)
Page 133: Wheels And Tires
STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ..............FRONT END ALIGNMENT .
Page 134 3-2 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction D Sagging or broken springs. Abnormal or Replace spring. D Tire out of balance. Excessive Tire Wear Adjust balance or replace tire. D Disturbed front end alignment. Check front end alignment. D Faulty shock absorber.
Page 135 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Correction D Wheel bearings worn. Too Much Play in Replace wheel bearing. D Loose steering gear case bolts. Steering Tighten. D Rack and pinion not properly adjusted. Check and adjust rack and pinion (if equipped with manual steering gear torque.
Page 136 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction D Mismatched or uneven tires. Wander or Poor Replace tire or inflate tires to Steering Stability proper pressure. D Loose ball joints and tie rod Replace suspension control arm or ends.
Page 137 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Condition Possible Cause Correction D Loose stabilizer bar. Body Leans or Sways Tighten stabilizer bar bolts or in Corners replace bushes. D Faulty shock absorbers, struts Replace shock absorber, strut or or mounting. tighten mounting. D Broken or sagging springs.
Page 138 3-6 STEERING, SUSPENSION, WHEELS AND TIRES TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many possible causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, rotation is in order: 1.
Page 139 STEERING, SUSPENSION, WHEELS AND TIRES 3-7 1. Ride vehicle to determine if the waddle is coming from the front or rear. 2. Install tires and wheels that are known to be good (on similar ve- hicle) in place of those on the offending end of the vehicle. If the waddle cannot be isolated to front or rear, substitute the rears.
Page 140 3-8 STEERING, SUSPENSION, WHEELS AND TIRES RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level road with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment. 3) Tire construction.
Page 141 STEERING, SUSPENSION, WHEELS AND TIRES 3-9 SUSPENSION MOVEMENT (Loaded Runout) SMOOTH ROAD Caused by TIRE OUT TIRE RIM BENT STIFFNESS ROUND VARIATION OUT OF ROUND...
Page 142 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ................GENERAL INFORMATION .
Page 143 3A-2 FRONT END ALIGNMENT CAMBER Camber is the tilting of the front wheels from the vertical, as viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive. When the wheels tilt inward at the top, the camber is negative. The amount of tilt is measured in degrees.
Page 144 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod end was replaced, check toe and then also steering angle with turning radius gauges. If steering angle is not correct, check if right and left tie-rods are equal in length (“A” in left figure). Steering angle 35D X 3D inside:...
Page 145 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 146: General Description
3B1-2 POWER STEERING (P / S) SYSTEM GENERAL DESCRIPTION POWER STEERING SYSTEM The power steering (P/S) system in this vehicle reduces the driver’s effort needed in turning the steering wheel by utilizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all built in the steering gear box.
Page 147: Steering Gear Box
POWER STEERING (P / S) SYSTEM 3B1-3 STEERING GEAR BOX The steering gear box consists of two sections: one including a cyl- inder and the other a valve. Main components of the cylinder sec- tion are a gear box, a rack and a tube and those of the valve section are a valve case, a sleeve and a stub shaft.
Page 148: Power Steering (P/S) Pump
3B1-4 POWER STEERING (P / S) SYSTEM POWER STEERING (P/S) PUMP The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft. 1. Suction connector 2. O-ring 3. Pressure switch 4. Flow control valve (Relief valve) 5.
Page 149: Diagnosis
POWER STEERING (P / S) SYSTEM 3B1-5 DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction D Fluid deteriorated, low viscosity, different Steering wheel Replace fluid. feels heavy type of fluid mixed D Pipes or hoses deformed, air entering (at low speed) Replace defective part.
Page 150 3B1-6 POWER STEERING (P / S) SYSTEM Condition Possible Cause Correction D Mismatched or uneven tire Vehicle pulls to Replace tire. D Low or uneven tire inflation pressure one side during Inflate tires to proper pressure or straight driving adjust right & left tires inflation pressure.
Page 151: Steering Wheel
POWER STEERING (P / S) SYSTEM 3B1-7 STEERING WHEEL STEERING WHEEL PLAY CHECK Check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. Check steering wheel for play, holding car in straight forward condi- tion on the ground and with engine stopped.
Page 152: Power Steering Pump Drive Belt
3B1-8 POWER STEERING (P / S) SYSTEM POWER STEERING PUMP DRIVE BELT NOTE: For J20 Type engine, refer to Section 6H “GENERATOR BELT”. INSPECTION Check that belt is free from any damage and properly fitted in pulley groove. BELT TENSION CHECK Check belt tension by measuring how much it deflects when pushed at intermediate point between pulleys with about 10 kg (22 lb) force.
Page 153: Idle Up System
POWER STEERING (P / S) SYSTEM 3B1-9 IDLE UP SYSTEM IDLE UP SYSTEM CHECK 1) Warm up engine to normal operating temperature. 2) Turn A/C switch OFF, if equipped. 3) Turn steering wheel fully and check idle speed. Engine idle speed drops a little momentarily when steering wheel is turned fully but returns to its specified level immediately.
Page 154: Hydraulic Pressure In P/S Circuit
3B1-10 POWER STEERING (P / S) SYSTEM HYDRAULIC PRESSURE IN P/S CIRCUIT HYDRAULIC PRESSURE CHECK 1) After cleaning joint of high pressure hose and P/S pump thor- oughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose). Tighten each flare nut to specified torque.
Page 155: Boot
POWER STEERING (P / S) SYSTEM 3B1-11 5) Check relief pressure D Increase engine speed to about 1,500 r/min (rpm). Close gauge valve gradually while watching pressure increase indi- cated by gauge and take reading of relief pressure (maximum hydraulic pressure). Relief pressure: 6200 –...
Page 156: Tie-Rod End Boot Check
3B1-12 POWER STEERING (P / S) SYSTEM TIE-ROD END BOOT CHECK Check boot for crack and damage and if any, replace it with a new one. AIR BLEEDING PROCEDURE 1) Hoist the front end of vehicle and apply safety stands. 2) Fill P/S fluid reservoir with fluid up to specified level.
Page 157: On-Vehicle Service
POWER STEERING (P / S) SYSTEM 3B1-13 ON-VEHICLE SERVICE TIE-ROD END REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove tie-rod end nut. 1. Tie-rod end 2. Knuckle 3. Nut 3) Disconnect tie-rod end by using puller. 4) To facilitate adjustment after installation, put a mark on tie-rod thread indicating position of tie-rod end lock nut.
Page 158: Power Steering Gear Box Assembly
3B1-14 POWER STEERING (P / S) SYSTEM 3) After installing wheels, lower vehicle and tighten wheel nuts to specified torque. Tightening Torque (a): 100 N m (10.0 kg-m, 72.5 lb-ft) 4) Check that proper amount of toe-in is obtained by referring to “FRONT WHEEL ALIGNMENT”.
Page 159 POWER STEERING (P / S) SYSTEM 3B1-15 7) Remove steering gear box mounting bolts and then remove steering gear box from vehicle. Steering gear box found to be in defective condition should be replaced with a new one. CAUTION: Never disassemble P/S gear box. If perform this prohib- ited service, it will affect original performance.
Page 160: Rack Boot And Tie-Rod (Except Canvas Top Lh Model)
3B1-16 POWER STEERING (P / S) SYSTEM RACK BOOT AND TIE-ROD (EXCEPT CANVAS TOP LH MODEL) REMOVAL CAUTION: Never disassemble tie-rod except for canvas top LH model. Performing this prohibited service will affect original per- formance. 1) Remove steering gear box by referring to “POWER STEERING GEAR BOX ASSEMBLY REMOVAL”...
Page 161: Rack Boot And Tie-Rod (For Canvas Top Lh Model)
POWER STEERING (P / S) SYSTEM 3B1-17 2) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to the mark made in removal. 3) Install steering gear box assembly by referring “POWER STEERING GEAR BOX ASSEMBLY INSTALLATION” in this section.
Page 162 3B1-18 POWER STEERING (P / S) SYSTEM INSTALLATION 1) Install new tie-rod lock washer and tie-rod to rack. 2) Tighten tie-rod ball nut to specified torque. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) 3) Bend lock washer 2 place at the flat part of tie-rod ball nut. 1.
Page 163: Power Steering Pump
POWER STEERING (P / S) SYSTEM 3B1-19 POWER STEERING PUMP [G16 ENGINE MODEL] Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) (b):25 N m (2.5 kg-m, 18.5 lb-ft) (c): 55 N m (5.5 kg-m, 40.0 lb-ft) (d):11 N m (1.1 kg-m, 8.0 lb-ft) (e): 35 N m (3.5 kg-m, 25.5 lb-ft)
Page 164 3B1-20 POWER STEERING (P / S) SYSTEM REMOVAL NOTE: Be sure to clean each joint of suction and discharge sides thoroughly before removal. 1) Remove suction hose from pump, then disconnect battery nega- tive cable. 1. P/S fluid 2) Remove P/S fluid reservoir with suction hose. reservoir 2.
Page 165 POWER STEERING (P / S) SYSTEM 3B1-21 INSPECTION Pump Body, Cover, Side Plate and Shaft Check sliding surfaces of each part for wear and damage. If any defect is found, replace pump assembly. Cam Ring Check vane sliding surface of cam ring for wear and damage. If any defect is found, replace pump assembly.
Page 166 3B1-22 POWER STEERING (P / S) SYSTEM D Check free length of relief valve spring. Free length: Standard 22.0 mm (0.866 in.) Limit 19.0 mm (0.748 in.) Replace if any defective is found. 1. Flow control spring ASSEMBLY Reverse disassembly procedure for assembly, noting the following. 1) Apply grease to oil seal lip and apply power steering fluid to slid- ing surface of the shaft then insert pulley’s shaft from oil seal side of the pump body.
Page 167 POWER STEERING (P / S) SYSTEM 3B1-23 7) Apply power steering fluid to sliding surface of cam ring. 8) Install cam ring to pump body. The tapered end of cam ring should face the side plate. 1. Cam ring 2. Side plate 9) Apply power steering fluid to each vane.
Page 168 3B1-24 POWER STEERING (P / S) SYSTEM 15) Gradually tighten new pump cover bolts to specified torque. NOTE: After installing pump cover, check to make sure that shaft can be turned by hand. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 1.
Page 169 POWER STEERING (P / S) SYSTEM 3B1-25 INSTALLATION Reverse removal procedure, and then noting the following instruc- tions. D For tightening torques, refer to structural diagram on previous page. D Adjust power steering pump drive belt by referring to “BELT TEN- SION ADJUSTMENT”...
Page 170: Tightening Torque Specification
35.0 Tie-rod (for canvas top LH model only) 61.5 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT SUPER GREASE (A) D Oil seal lip of P/S pump pulley shaft Lithium grease (99000-25010) D To fill P/S fluid reservoir An equivalent of DEXRON...
Page 171 STEERING WHEEL AND COLUMN 3C-1 SECTION 3C STEERING WHEEL AND COLUMN (NOT EQUIPPED WITH AIR BAG) NOTE: All steering wheel and column fasteners are important parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 172: Diagnosis
3C-2 STEERING WHEEL AND COLUMN 1. Steering wheel pad 2. Steering wheel pad screw 3. Steering wheel nut 4. Steering wheel 5. Combination switch 6. Steering column upper cover 7. Steering column lower cover 8. Steering column assembly 9. Steering lock assembly 10.
Page 173: On-Vehicle Service
STEERING WHEEL AND COLUMN 3C-3 ON-VEHICLE SERVICE STEERING WHEEL REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Remove steering wheel pad screw. 3) Remove steering wheel pad and disconnect horn harness. 1. Steering wheel 2. Steering wheel pad 3.
Page 174: Combination Switch
3C-4 STEERING WHEEL AND COLUMN COMBINATION SWITCH REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Remove steering wheel from steering column. Refer to “STEERING WHEEL” in this section. 3) Remove steering column hole cover. 1. Steering column hole cover : If equipped 4) Remove steering column cover screws (3 pieces).
Page 175: Steering Column Assembly
STEERING WHEEL AND COLUMN 3C-5 3) Install steering column upper and lower cover. 4) Tighten steering column cover screws. CAUTION: When installing lower cover and upper cover, be careful so that combination switch lead wire is not caught be- tween covers. 1.
Page 176 3C-6 STEERING WHEEL AND COLUMN 2) Remove steering wheel and combination switch, if necessary. Refer to “STEERING WHEEL” and “COMBINATION SWITCH” in this section. Perform the following procedure if not removing steering wheel and/or combination switch. i) Turn steering wheel so that vehicle’s front tires are at straight- ahead position.
Page 177 STEERING WHEEL AND COLUMN 3C-7 7) Remove steering column mounting bolts (6 pieces). 1. Steering column 2. Steering column mounting bolt 3. Steering column lower seal 8) If equipped with shift (key) interlock cable, remove shift (key) in- terlock cable screw and then disconnect its cable from ignition switch.
Page 178 3C-8 STEERING WHEEL AND COLUMN 4) Check steering column lower seal for breakage or deformation. If found defective, replace. 1. Steering column lower seal 5) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play. If anything is found faulty, replace as steering lower shaft assem- bly or steering column assembly.
Page 179 STEERING WHEEL AND COLUMN 3C-9 4) Install steering shaft joint to steering shaft by matching it to marks made before removal. 1. Steering shaft joint 2. Steering shaft (column side) 3. Marks 5) Install shaft joint bolt (column side) to steering shaft joint. Tighten shaft joint bolt (column side) to specified torque first and then shaft joint bolt (lower shaft assembly side) to specified torque.
Page 180: Steering Lock Assembly (Ignition Switch)
3C-10 STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column. Refer to “STEERING COLUMN” in this section. 1. Steering column 2. Steering lock 2) Using center punch as shown, loosen and remove steering lock mounting bolts. NOTE: Use care not to damage aluminum part of steering lock body with center punch.
Page 181: Steering Lower Shaft Assembly
STEERING WHEEL AND COLUMN 3C-11 STEERING LOWER SHAFT ASSEMBLY REMOVAL 1) Turn steering wheel so that vehicle’s front tires are at straight- ahead position. 2) Turn ignition switch to “LOCK” position and remove key. 3) Make alignment marks on shaft joint and shaft (column side) for a guide during reinstallation.
Page 182 3C-12 STEERING WHEEL AND COLUMN INSTALLATION 1) Be sure that front wheels and steering wheel are in straightfor- ward position. 2) Align flat part “A” of lower shaft assembly with bolt hole “B” of shaft joint as shown. Then insert shaft joint into lower shaft as- sembly.
Page 183: Checking Steering Column For Accident Damage
STEERING WHEEL AND COLUMN 3C-13 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted, may have a dam- aged or misaligned steering column. CHECKING PROCEDURE 1) Check that two capsules are attached to steering column brack- et securely.
Page 184: Adjustable Steering Column Release Lever
3C-14 STEERING WHEEL AND COLUMN ADJUSTABLE STEERING COLUMN RELEASE LEVER INSPECTION Check to make sure that the following: D Steering column moves smoothly when adjustable steering col- umn release lever is at lower position (i.e., steering column is not locked). D Steering column is fixed securely when adjustable steering col- umn release lever is at higher position (i.e., steering column is locked).
Page 185 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system compo- nents or wiring.
Page 186: General Description
3C1-2 AIR BAG STEERING WHEEL AND COLUMN GENERAL DESCRIPTION This double tube type steering column has the following three important features in addition to the steering function: D The column is energy absorbing, designed to compress in a front-end collision. D The ignition switch and lock are mounted conveniently on this column.
Page 187: Diagnosis
AIR BAG STEERING WHEEL AND COLUMN 3C1-3 DIAGNOSIS For diagnosis of the steering wheel and steering column, refer to Section 3. For diagnosis of the air bag system, refer to Section 10B. INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and repairs described under “CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE”...
Page 188: Driver Air Bag (Inflator) Module
3C1-4 AIR BAG STEERING WHEEL AND COLUMN DRIVE AIR BAG (INFLATOR) MODULE WARNING: When handling an air bag (inflator) module, be sure to read “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B and observe each instruction. Failure to fol- low them could cause a damage to the air bag (inflator) mod- ule or result in personal injury.
Page 189 AIR BAG STEERING WHEEL AND COLUMN 3C1-5 INSPECTION WARNING: Never disassemble air bag (inflator) module or measure its resistance. Otherwise, personal injury may result. CAUTION: If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module visually and if any of the following is found, replace it with a new one.
Page 190: Steering Wheel
3C1-6 AIR BAG STEERING WHEEL AND COLUMN STEERING WHEEL CAUTION: Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the combination switch) more than allowable number of turns (about two and a half turns from the center position clockwise or counter- clockwise respectively), or coil will break.
Page 191: Contact Coil And Combination Switch Assembly
AIR BAG STEERING WHEEL AND COLUMN 3C1-7 INSTALLATION 1) Check that vehicle’s front tires are at straight-ahead position and contact coil is centered. Refer to “CENTERING CONTACT COIL” in this section. CAUTION: These two conditions are prerequisite for installation of steering wheel.
Page 192 3C1-8 AIR BAG STEERING WHEEL AND COLUMN 6) Remove contact coil and combination switch assembly from steering column. 1. Contact coil and combination switch assembly 2. Screw INSPECTION Check contact coil and combination switch wire harness for any signs of scorching, melting or other damage. If it is damaged, re- place.
Page 193: Steering Column
AIR BAG STEERING WHEEL AND COLUMN 3C1-9 3) Connect all connectors that have been removed in removal. 4) Install steering column upper and lower cover, and then tighten steering column cover screws. CAUTION: When installing lower cover and upper cover, be careful so that contact coil and combination switch lead wire is not caught between covers.
Page 194 3C1-10 AIR BAG STEERING WHEEL AND COLUMN REMOVAL WARNING: Never rest a steering column assembly on the steering wheel with air bag (inflator) module face down and column vertical. Otherwise personal injury may result. 1) Disconnect negative battery cable at battery terminal. 2) Disable air bag system.
Page 195 AIR BAG STEERING WHEEL AND COLUMN 3C1-11 8) Remove steering column mounting bolts (6 pieces). 1. Steering column 2. Steering column mounting bolt 3. Steering column lower seal 9) If equipped with shift (key) interlock cable, remove shift (key) interlock cable screw and then disconnect its cable from igni- tion switch.
Page 196 3C1-12 AIR BAG STEERING WHEEL AND COLUMN 4) Check steering column lower seal for breakage or deformation. If found defective, replace. 1. Steering column lower seal 5) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or excessive play. If anything is found faulty, replace as steering lower shaft assem- bly or steering column assembly.
Page 197 AIR BAG STEERING WHEEL AND COLUMN 3C1-13 4) Install steering shaft joint to steering shaft by matching it to marks made before removal. 1. Steering shaft joint 2. Steering shaft (column side) 3. Marks 5) Install shaft joint bolt (column side) to steering shaft joint. Tighten shaft joint bolt (column side) to specified torque first and then shaft joint bolt (lower shaft assembly side) to specified torque.
Page 198: Steering Lock Assembly (Ignition Switch)
3C1-14 AIR BAG STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column. Refer to “STEERING COLUMN” in this section. 1. Steering column 2. Steering lock 2) Using center punch as shown, loosen and remove steering lock mounting bolts.
Page 199: Steering Lower Shaft Assembly
AIR BAG STEERING WHEEL AND COLUMN 3C1-15 STEERING LOWER SHAFT ASSEMBLY CAUTION: Never turn steering wheel while steering lower shaft assem- bly is removed. Should it have been turned and contact coil (on combina- tion switch) have got out of its centered position, it needs to be centered again.
Page 200 3C1-16 AIR BAG STEERING WHEEL AND COLUMN INSTALLATION 1) Be sure that front wheels and steering wheel are in straight ahead position. 2) Align flat part “A” of lower shaft assembly with bolt hole “B” of shaft joint as shown. Then insert shaft joint into lower shaft as- sembly.
Page 201: Checking Steering Column For Accident Damage
AIR BAG STEERING WHEEL AND COLUMN 3C1-17 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering col- umn.
Page 202: Adjustable Steering Column Release Lever
3C1-18 AIR BAG STEERING WHEEL AND COLUMN ADJUSTABLE STEERING COLUMN RELEASE LEVER INSPECTION Check to make sure that the following: D Steering column moves smoothly when adjustable steering col- umn release lever is at lower position (i.e., steering column is not locked).
Page 203: Front Suspension
FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION CAUTION: D All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 204: General Description
3D-2 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the body by a strut support. The strut and strut support are isolated by a rubber mount. The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached to the stud of a ball joint which is incorporated in a unit with a suspension control arm.
Page 205: Diagnosis
FRONT SUSPENSION 3D-3 DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STABILIZER BAR AND BUSHING CHECK Inspect for damage or deformation. If defective, replace. BUSHING Inspect for damage, wear or deterioration. If defective, replace. STRUT DAMPER AND/OR COIL SPRING CHECK 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
Page 206: Suspension Control Arm Joint Check
3D-4 FRONT SUSPENSION SUSPENSION CONTROL ARM JOINT CHECK 1) Check for smoothness of rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. Replace any parts found defective in steps 1) – 3). SUSPENSION CONTROL ARM BUSHING CHECK Inspect for damage, wear or deterioration.
Page 207: On-Vehicle Service
FRONT SUSPENSION 3D-5 ON-VEHICLE SERVICE STABILIZER BAR/BUSHINGS REMOVAL 1) Hoist vehicle. 2) Remove stabilizer bar mount bush bracket bolts. 3) Remove stabilizer ball joint nuts, washers and bushings. 4) Remove stabilizer bar with its ball joints. 5) Disconnect stabilizer ball joints from stabilizer bar. 1.
Page 208: Strut Damper
3D-6 FRONT SUSPENSION STRUT DAMPER REMOVAL 1) Remove strut tower bar (if equipped). 1. Strut tower bar 2) Hoist vehicle, allowing front suspension to hang free. 3) Remove wheel. 4) Remove E-ring securing brake hose and take brake hose off strut bracket as shown.
Page 209 FRONT SUSPENSION 3D-7 INSTALLATION 1) Install strut by reversing removal steps 1) – 8). Insert bolts in such a direction as shown. 2) Torque all fasteners to specifications. Tightening Torque (a): 55 N m (5.5 kg-m, 40.0 lb-ft) (b): 95 N m (9.5 kg-m, 69.0 lb-ft) (c): 50 N m (5.0 kg-m, 36.5 lb-ft)
Page 210: Coil Spring
3D-8 FRONT SUSPENSION COIL SPRING REMOVAL 1) Hoist vehicle, allowing front suspension to hang free. 2) Remove wheels. 3) Remove axle shaft drive flange (For 4WD vehicle). 4) Remove front drive shaft circlip and washer (For 4WD vehicle). 1. Circlip 2.
Page 211 FRONT SUSPENSION 3D-9 8) Remove stabilizer bar, refer to steps 2) to 5) of item STABILIZ- ER BAR/BUSHINGS REMOVAL in this section. 9) Disconnect tie rod end from knuckle by using puller. 10) Support lower arm, using jack as shown. 11) Remove strut bracket bolts.
Page 212 3D-10 FRONT SUSPENSION INSTALLATION Reverse removal procedure to install coil spring. NOTE: Upper and lower diameters of coil spring are different. “a” < “b” Bring larger diameter end at bottom and set its open end in place on spring seat. 1.
Page 213: Bump Stopper/Spring Rubber Seat
FRONT SUSPENSION 3D-11 D Check that no foreign material is attached to sensor and rotor. Install wheel speed sensor and its harness clamp. 2, (b) Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft) (b): 23 N m (2.3 kg-m, 17.0 lb-ft) CAUTION: D Do not pull wire harness or twist more than necessary when installing front wheel speed sensor.
Page 214: Wheel Hub (Included Wheel Bearing)
3D-12 FRONT SUSPENSION WHEEL HUB (INCLUDED WHEEL BEARING) REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove axle shaft drive flange (4WD vehicle) or hub cap (2WD vehicle). 1. Axle shaft drive flange 3) If equipped with ABS, remove wheel speed sensor from knuckle and harness clamp from strut.
Page 215 FRONT SUSPENSION 3D-13 NOTE: If wheel hub can not be removed by hand, use special tools as shown. Special Tool (B): 09943-35512 (C): 09942-15510 CAUTION: If wheel bearing inner race remains on wheel spindle when removing wheel hub, which means break of wheel bearing, replace wheel hub component (included wheel bearing).
Page 216 3D-14 FRONT SUSPENSION 2) Install new sensor rotor by using special tool (if equipped with ABS). NOTE: Use care not to insert wheel hub diagonally. Special Tool (A): 09952-86510 (B): 09924-74510 Wheel speed sensor rotor installing position Reference Dimension “a” : 4.9 8 0.1 mm (0.19 8 0.004 in.) 1.
Page 217 FRONT SUSPENSION 3D-15 7) For 4WD vehicle, apply lithium grease to front drive shaft wash- er and front wheel spindle outer. “A”: Grease 99000-25010 8) For 4WD vehicle, when installing circlip to drive shaft, utilize screw hole in drive shaft to pull it out and bring large diameter of circlip at right as shown.
Page 218 3D-16 FRONT SUSPENSION 11) Apply sealant and install axle shaft drive flange or hub cap. For 4WD vehicle D For 4WD vehicle Apply sealant mating surface of axle shaft drive flange, then install axle shaft drive flange and tighten flange bolt to speci- fied torque.
Page 219: Knuckle/Wheel Spindle
FRONT SUSPENSION 3D-17 KNUCKLE/WHEEL SPINDLE REMOVAL 1) Remove wheel hub. Refer to “WHEEL HUB (INCLUDED WHEEL BEARING)” in this section. 2) Remove front drive shaft circlip and front spindle thrust washer (for 4WD vehicle) or front hub cap (for 2WD vehicle). 1.
Page 220 3D-18 FRONT SUSPENSION 11) For 4WD vehicle Remove drive shaft bearing by using special tool. Special Tool (A): 09923-74510 (B): 09930-30102 1. Wheel spindle 2. Drive shaft bearing INSTALLATION Reverse removal sequence to install knuckle, wheel spindle oil seal and drive shaft bearing,noting following points. Type A Type B 1.
Page 221 FRONT SUSPENSION 3D-19 D Tighten wheel spindle nut to specified torque. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) D For 4WD vehicle Press-fitting inner oil seal. Drive in inner oil seal until its end contacts stepped surface of knuckle by using special tools.
Page 222 3D-20 FRONT SUSPENSION D Tighten control arm ball stud nut When tightening ball stud nut, use new nut and tighten it to speci- fied torque. Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) D For 2WD vehicle Apply water tight sealant to mating surface of wheel hub and install hub cap to wheel hub.
Page 223: Suspension Control Arm/Bushings
FRONT SUSPENSION 3D-21 SUSPENSION CONTROL ARM/BUSHINGS Cut off flange REMOVAL 1) Remove coil spring. Refer to COIL SPRING in this section. 2) Remove control arm bolts and nuts. Then remove control arm. 3) Cut flange part of control arm bush (rubber and steel) with using care not to damage control arm end surface.
Page 224 3D-22 FRONT SUSPENSION INSTALLATION 1) Front bushing Press-fit front bushing until its flange contacts housing edge of control arm, use special tools as shown. Special Tool (C): 09951-16060 (F): 09913-85210 NOTE: When press-fitting bushing, compounding oil or soap water applied to inside of control arm housing will facilitate work. 1.
Page 225: Tightening Torque Specifications
FRONT SUSPENSION 3D-23 TIGHTENING TORQUE SPECIFICATIONS...
Page 226: Required Service Materials
REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Bearing inner oil seal/drive shaft oil seal Recess of wheel spindles SUZUKI SUPER GREASE (A) Spindle outer washer Lithium grease Spindle part of drive shaft (99000-25010) Spindle bush (inside and flange part) Spindle inner washer SUZUKI BOND NO.
Page 227: Special Tools
FRONT SUSPENSION 3D-25 SPECIAL TOOLS 09923-74510 09930-30102 09924-74510 09941-66010 Bearing remover Sliding shaft Bearing installer handle Bump stopper wrench 09944-66010 09942-15510 09943-35512 Wheel hub / knuckle oil 09944-68210 Sliding hammer Brake drum remover seal installer Bearing & oil seal installer 09951-16060 09951-16050 Control arm bush remover...
Page 228: Rear Suspension
REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 229: General Description
The shock absorber is installed between the body and axle to absorb up-and-down movement of the vehicle body. NOTE: When installing differential gear oil drain plug, clean the thread portion of the plug and then apply sealant (SUZUKI BOND No. 1215, 99000-31110) to the portion. 1. Rear axle housing 2. Coil spring 3.
Page 230: Diagnosis
REAR SUSPENSION 3E-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. SHOCK ABSORBER CHECK D Inspect for deformation or damage. D Inspect bushings for wear or damage. D Inspect for evidence of oil leakage. Replace any defective part. WARNING: When handling rear shock absorber in which high-pressure gas is sealed, make sure to observe the following precau- tions.
Page 231: Bearing Retainer & Axle Shaft Inner Oil Seal Check
3E-4 REAR SUSPENSION REAR SUSPENSION FASTENERS Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to “TIGHT- ENING TORQUE SPECIFICATIONS” of this section. BEARING RETAINER AND AXLE SHAFT INNER OIL SEAL CHECK D When brake drum has been removed, check inside of brake drum for gear oil leakage.
Page 232: On-Vehicle Service
REAR SUSPENSION 3E-5 ON-VEHICLE SERVICE SHOCK ABSORBER The shock absorber is non-adjustable, non-refillable, and cannot be disassembled. The only service the shock absorber requires is replacement when it has lost its resistance, is damaged, or leaking fluid. REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack to prevent it from lowering.
Page 233: Coil Spring
3E-6 REAR SUSPENSION COIL SPRING REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack. 1. Rear axle housing 2. Floor jack 3) Disconnect parking brake cable hanger from chassis frame and clamp from cross member. 1.
Page 234 REAR SUSPENSION 3E-7 INSTALLATION 1) Install coil spring on spring seat of axle housing and then raise axle housing. NOTE: When seating coil spring, mate spring end with stepped part of rear axle spring seat as shown. 1. Rear axle housing 2.
Page 235: Lower Rod
3E-8 REAR SUSPENSION LOWER ROD REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack. 1. Axle housing 2. Floor jack 3) Remove lower rod front mount bolt. 1. Lower rod 2. Front mount bolt 4) Remove lower rod rear mount bolt.
Page 236: Upper Rod
REAR SUSPENSION 3E-9 UPPER ROD REMOVAL 1) Hoist vehicle and remove rear wheel. 2) If equipped with ABS, disconnect wheel speed sensor harness clamp from left upper rod. 1. Clamp 2. Upper rod 3) Remove upper rod. 1. Upper rod 2.
Page 237: Lateral Rod
3E-10 REAR SUSPENSION LATERAL ROD REMOVAL 1) Hoist vehicle. 2) Remove lateral rod mounting bolts. 3) Remove lateral rod. 1. Bolt 2. Washer 3. Lateral rod INSTALLATION 1) Install lateral rod to rear axle, and vehicle body. 2) Lower hoist. 3) Tighten lateral rod mounting bolts to specified torque.
Page 238 REAR SUSPENSION 3E-11 4) Remove wheel speed sensor from rear axle housing (if equipped with ABS). CAUTION: D Do not pull wire harness or twist more than necessary when removing rear wheel speed sensor. D Do not cause damage to surface of rear wheel speed sensor or pole piece and do not allow dust, etc.
Page 239 3E-12 REAR SUSPENSION 9) Break with a chisel the thin ground sensor rotor, and it can be removed (if equipped with ABS). 10) In order to remove the retainer ring from the shaft, grind with a grinder two parts of the bearing retainer ring as illustrated till it becomes thin.
Page 240 REAR SUSPENSION 3E-13 INSTALLATION Install removed parts in reverse order of removal procedure, noting the following. 1) Apply grease to oil seal lip as shown and install it to axle shaft. NOTE: Amount of grease applied to hollow in oil seal should be more than 60% of its vacant space.
Page 241 3E-14 REAR SUSPENSION 5) For vehicle with ABS, press-fit new sensor rotor as shown. NOTE: Use care not to cause any damage to outside of retainer ring. 1. Sensor rotor 6) Apply grease to axle shaft inner oil seal lip as shown. “A”: Grease 99000-25010 1.
Page 242: Rear Axle Shaft Inner Oil Seal
REAR SUSPENSION 3E-15 REAR AXLE SHAFT INNER OIL SEAL REMOVAL 1) Remove rear axle shaft. For details, refer to steps 1) to 7) of REAR AXLE SHAFT REMOVAL in this section. 2) Fix brake back plate by inserting screwdriver to the hole for bear- ing retainer mounting.
Page 243: Rear Axle Housing
3E-16 REAR SUSPENSION REAR AXLE HOUSING REMOVAL 1) Drain differential gear oil. Carry out steps 2) to 7) and 15) to 18) on both right and left wheels. Note that left wheel and its related parts are used in illustrations in this section.
Page 244 REAR SUSPENSION 3E-17 7) Using special tools (B) & (C) indicated below, draw out axle shafts. For vehicle equipped with ABS, remove wheel speed sensor from axle housing before drawing out axle shaft. NOTE: Use care not to pull brake back plate along with shaft. Special Tool (C): 09943-35512 (B): 09942-15510...
Page 245 3E-18 REAR SUSPENSION 13) For jobs hereafter, support rear axle housing by using floor jack under axle housing. 1. Axle housing 2. Jack 14) Remove differential carrier assembly. 1. Differential carrier assembly 2. Differential carrier nut 15) Loosen rear mount nut of upper rod but don’t remove bolt. 16) Loosen rear mount nut of lower rod but don’t remove bolt.
Page 246 REAR SUSPENSION 3E-19 INSTALLATION Install removed parts in reverse order of removal, noting the follow- ing. 1) Place rear axle housing on floor jack. Then install upper/lower rod rear mounting bolts (right & left) in proper direction as shown (refer to UPPER ROD INSTALLATION for upper rod bolts). At this time, mount nuts but don’t tighten them.
Page 247 3E-20 REAR SUSPENSION 7) For vehicle with ABS, connect wheel speed sensor coupler and install harness. 8) Install propeller shaft and torque nuts to specification. Tightening Torque (b): 50 N m (5.0 kg-m, 36.5 lb-ft) 9) Remove floor jack from axle housing and connect breather hose onto axle housing and clamp it securely.
Page 248 REAR SUSPENSION 3E-21 16) Apply sealant to mating surface of bearing retainer with brake back plate. NOTE: Make sure to remove old sealant before applying it anew. “B”: Sealant 99000-31110 1. Bearing retainer 17) Install rear axle shaft to rear axle housing and tighten bearing retainer nuts to specified torque.
Page 249 3E-22 REAR SUSPENSION 23) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (h): 100 N m (10.0 kg-m, 72.5 lb-ft) 24) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to ten times so as to obtain proper drum- to-shoe clearance.
Page 250: Tightening Torque Specifications
16.0 Wheel nut 10.0 72.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithium grease Oil seal lip (99000-25010) Brake fluid DOT 3 Brake reservoir tank D Joint seam of axle and brake back SUZUKI BOND NO. 1215...
Page 251: Special Tools
3E-24 REAR SUSPENSION SPECIAL TOOLS 09924-74510 09926-88310 09942-15510 09943-35512 Bush remover handle Oil seal installer Sliding hammer Brake drum remover 09913-75510 Oil seal installer...
Page 252: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 253: Tires
3F-2 WHEELS AND TIRES The metric term for tire inflation pressure is the kilopascal (kPa). kgf/cm Tire pressures will usually be printed in both kPa and psi on the Tire Placard. Metric tire gauges are available from tool suppliers. The chart, left table, converts commonly used inflation pressures from kPa to psi.
Page 254: Diagnosis
WHEELS AND TIRES 3F-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. BALANCING WHEELS There are two types of wheel and tire balance: static and dynamic. Static balance, as shown in left figure, is equal distribution of weight [A]: Before correction [B]: Corrective weights around wheel.
Page 255: Maintenance And Minor Adjustments
3F-4 WHEELS AND TIRES MAINTENANCE AND MINOR ADJUSTMENTS WHEEL AND TIRE Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced. STUDS If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure. MATCHED TIRES AND WHEELS (For vehicle equipped with steel wheels) Tires and wheels are matchmounted at the assembly plant.
Page 256 WHEELS AND TIRES 3F-5 TIRE PLACARD The tire placard is located on the driver’s side door lock pillar and should be referred to for tire information. The placard lists the maxi- mum load, tire size and cold tire pressure where applicable. TIRE ROTATION To equalize wear, rotate tires periodically as shown in figure.
Page 257: On-Vehicle Service
3F-6 WHEELS AND TIRES ON-VEHICLE SERVICE WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180D (half a rotation). 2) Hoist vehicle. 3) Remove wheel. NOTE: Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings.
Page 258: Tire
WHEELS AND TIRES 3F-7 TIRE MOUNTING AND DEMOUNTING Use tire changing machine to mount or demount tires. Follow equip- ment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim.
Page 259: Tightening Torque Specifications
3F-8 WHEELS AND TIRES TIGHTENING TORQUE SPECIFICATIONS Tightening Torque for wheel nut (a): 100 N m (10.0 kg-m, 72.5 lb-ft)
Page 260: General Description
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-1 SECTION 4A2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL CONTENTS GENERAL DESCRIPTION ..............4A2- 1 DIAGNOSIS .
Page 261: Diagnosis
4A2-2 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction D Loose wheel nuts. When starting: Tighten wheel nuts. D Loose drive shaft flange bolts. Abnormal Noise Tighten drive shaft flange bolts. D Broken or otherwise damaged wheel Replace or change.
Page 262: On-Vehicle Service
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3 ON-VEHICLE SERVICE DRIVE SHAFT REMOVAL (LEFT SIDE) 1) Hoist vehicle and remove wheel. 1. Oil filler / level plug 2. Front drain plug 2) Remove axle shaft drive flange. 3) Remove drive shaft circlip and front spindle thrust washer. 1.
Page 263 4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL REMOVAL (RIGHT SIDE) 1) Hoist vehicle and remove wheel. 2) Drain differential gear oil. 1. Oil filler / level plug 2. Front drain plug 3) Remove axle shaft drive flange. 4) Remove circlip and front spindle thrust washer. 5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and 9) to 14) of item COIL SPRING REMOVAL in Section 3D.
Page 264 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5 DISASSEMBLY 1) Remove boot band of differential side joint. 2) Slide boot toward the center of shaft and remove snap ring from outer race, then take shaft out of outer race. 1.
Page 265 4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL ASSEMBLY CAUTION: D To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed. D For M/T vehicle with H25 engine To ensure full performance of joint as designed, be sure to distinguish between two types of grease in repair set and apply specified volume to respective joint.
Page 266 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7 7) Apply grease to entire surface of cage. Use joint grease in tube included in spare part or joint grease (99000-25120). 8) Insert cage into outer race and fit circlip into groove of outer race.
Page 267 4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points. D Clean front drive shaft oil seal and then apply lithium grease to oil seal and DOJ shaft. “A”...
Page 268: Shaft Bearing/Oil Seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-9 SHAFT BEARING/OIL SEAL REMOVAL 1) Remove drive shaft assembly. Refer to item DRIVE SHAFT REMOVAL (LEFT and RIGHT) in this section. For right side shaft bearing/oil seal removal, drain differential gear oil. 2) Remove left drive shaft by using tire lever.
Page 269 4A2-10 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL INSTALLATION 1) Clean drive shaft oil seal and then apply lithium grease. “A”: Grease 99000-25010 Check oil seal for breakage or deterioration. Replace it as necessary. “A” 2) Drive in drive shaft bearing with special tool (A) (on left hand side).
Page 270: Tightening Torque Specifications
Refer to standard tightening torque specifications, if no description or specification is provided. REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT Joint grease SUZUKI SUPER GREASE H Drive axle joint (Molybdenum grease) (99000-25120) Drive shaft oil seal SUZUKI SUPER GREASE A...
Page 271: Propeller Shafts
PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: D All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 272 4B-2 PROPELLER SHAFTS DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction D Loose universal joint bolt. Abnormal noise Tighten universal joint bolt. D Spider bearing worn out or stuck. Replace. D Wear spider. Replace propeller shaft. D Deformed propeller shaft. Vibration Replace.
Page 273: Propeller Shaft
PROPELLER SHAFTS 4B-3 ON-VEHICLE SERVICE PROPELLER SHAFT REMOVAL 1) Hoist vehicle. 2) Drain transfer oil only when servicing front propeller shaft. 3) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown. 4) Remove propeller shaft. 1.
Page 274 4B-4 PROPELLER SHAFTS 5) Push out bearing race on flange yoke side as described in 1) and 2), and then, holding bearing race in a vise, tap flange yoke and take out race. (Refer to the figure.) Remove bearing race on the opposite side in the same way. NOTE: D Take care not to lose rollers in spider bearing race when removing it.
Page 275 PROPELLER SHAFTS 4B-5 1) Insert bearing race into yoke, tapping it with a hammer, until it is flush with yoke face. When doing this, insert spider into bearing race to prevent rollers in bearing race from coming out. 1. Copper hammer 2.
Page 276 Tightening torque Fastener Fastener kg-m lb-ft Propeller shaft nut/Center support bolt 36.5 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUPER GREASE C Lithium grease To apply to spider bearing race. (99000-25030) SPECIAL TOOLS 09900-06108 09926-48010 Snap ring pliers Universal joint...
Page 277 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 278: General Description
5-2 BRAKES GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two independent circuits.
Page 279: Diagnosis
BRAKES 5-3 DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE FLUID Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid test brakes by making brake applications with both may cause the brake fluid to boil or the rubber compo- light and heavy pedal forces at various speeds to de- nents in the hydraulic system to deteriorate.
Page 280: Diagnosis Table
5-4 BRAKES DIAGNOSIS TABLE Condition Possible Cause Correction D Brake oil leakage from brake lines. Not enough brak- Locate leaking point and repair. D Brake disc or pads stained with oil. ing force Clean or replace. D Overheated brakes. Determine cause and repair. D Poor contact of shoes on brake drum.
Page 281 BRAKES 5-5 Condition Possible Cause Correction D Partial brake system failure. Excessive pedal Check brake systems and repair as travel (Pedal necessary. D Insufficient fluid in master cylinder stroke too large) Fill reservoirs with approved brake reservoirs. fluid. Check for leaks and air in brake systems.
Page 282 5-6 BRAKES Condition Possible Cause Correction D Parking brake applied. Brake warning light Release parking brake and check turns on after that brake warning light turns off. D Insufficient amount of brake fluid. engine start Add brake fluid. D Brake fluid leaking from brake line. Investigate leaky point, correct it and add brake fluid.
Page 283: Check And Adjustment
BRAKES 5-7 CHECK AND ADJUSTMENT BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: For vehicle equipped with ABS, make sure that ignition switch turns off.
Page 284 5-8 BRAKES 4) When fluid pressure in the cylinder is almost depleted, retigh- ten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hy- draulic line. 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug.
Page 285: Brake Pedal Free Height Check
BRAKES 5-9 BRAKE PEDAL FREE HEIGHT CHECK Remove foot rest and displace carpet and dash silencer(s) so as to measure brake pedal free height between pedal face and asphalt sheet installed on dash panel. Brake pedal free height “a” from asphalt sheet: 208 –...
Page 286: Brake Pedal Play Check
5-10 BRAKES BRAKE PEDAL PLAY CHECK Pedal play should be within specification. If out of specification, check brake light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective. Pedal play “d”: 1 –...
Page 287: Brake Disc Check
BRAKES 5-11 BRAKE DISC CHECK Refer to FRONT DISC BRAKE PAD of Section 5B for inspection point and procedure. BRAKE PAD CHECK Inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through hole of caliper and check lining thickness of in- side pad.
Page 288: Parking Brake Check And Adjustment
5-12 BRAKES PARKING BRAKE CHECK AND ADJUSTMENT CHECK Hold center of parking brake lever grip and pull it up with 20 kg (40 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 5 to 7 notches. Also, check if both right and left rear wheels are locked firmly.
Page 289: Flushing Brake Hydraulic System
BRAKES 5-13 FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in hydraulic system. Periodical change of brake fluid is also recommended. FLUID PRESSURE TEST(if equipped with LSPV) Test procedure for LSPV assembly is as follows.
Page 290 5-14 BRAKES 3) Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake then. It should be within specification given below. Front brake Rear brake 6,000 – 7,300 kPa 3 Door 60 –...
Page 291: Booster Operation Check
BRAKES 5-15 6) Upon completion of fluid pressure test, bleed brake system and perform brake test. BOOSTER OPERATION CHECK There are two ways to perform this inspection, with and without a tester. Ordinarily, it is possible to roughly determine its condition without using a tester.
Page 292 5-16 BRAKES Check Operation 1) With engine stopped, depress brake pedal several times with the same load and make sure that pedal travel doesn’t change. 2) Start engine while depressing brake pedal. If pedal travel in- creases a little, operation is satisfactory. But no change in pedal travel indicates malfunction.
Page 293: Tightening Torque Specifications
72.5 Stop light switch lock nut 0.75 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT D To fill master cylinder reservoir. Indicated on reservoir D To clean and apply to inner parts of master Brake fluid cap or described in owner’s...
Page 294: Special Tools
5-18 BRAKES SPECIAL TOOLS 09950-78220 09900-20205 09956-02310 09956-02210 Flare nut wrench (10 mm) Micrometer (0 – 25 mm) Fluid pressure gauge Brake circuit plug 09952-36310/ 09952-46510 Pressure gauge attachment...
Page 295 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 296: General Description
5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER GENERAL DESCRIPTION MASTER CYLINDER ASSEMBLY The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the figure below) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on the front (for vehicle without ABS, rear) wheel brakes.
Page 297: Lspv (Load Sensing Proportioning Valve) Assembly
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3 LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped) As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Page 298: Diagnosis
5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER DIAGNOSIS Refer to Section 5 (BRAKES) CHECK AND ADJUSTMENT Refer to Section 5 (BRAKES) ON-VEHICLE SERVICE FRONT BRAKE HOSE/PIPE REMOVAL 1) Raise and suitably support vehicle. Remove tire and wheel. This operation is not necessary when removing pipes connecting master cylinder and flexible hose. 2) Clean dirt and foreign material from both hose end or pipe end fittings.
Page 299 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-5 A: View A a: Clamp a t: Top side B: View B b: Clamp b f: Front side C: View C c: Clamp c d: Clamp d NOTE: Insert E-ring till its end surface is flush [A]: Vehicle with ABS for right hand steering vehicle with or lower than bracket end surface.
Page 300 5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER D: View D a: Clamp a t: Top side b: Clamp b f: Front side c: Clamp c d: Clamp d [C]: Vehicle without ABS for right hand steering vehicle NOTE: [D]: Vehicle without ABS for left hand steering vehicle Insert E-ring till its end surface is flush with or lower than bracket end surface.
Page 301: Rear Brake Hose/Pipe
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7 REAR BRAKE HOSE/PIPE REMOVAL 1) Raise and suitably support vehicle. Remove tire and wheel. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. INSTALLATION 1) Reverse removal procedure for brake hose or pipe installation procedure.
Page 302: Master Cylinder Reservoir
5A-8 BRAKES PIPE / HOSE / MASTER CYLINDER MASTER CYLINDER RESERVOIR REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir. 3) Take out fluid with syringe or such. 4) Remove reservoir connector pin by using special tool. Special Tool (A): 09922-85811 1.
Page 303 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-9 INSTALLATION NOTE: See NOTE at the beginning of this section. 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then press-fit grommets to mas- ter cylinder.
Page 304: Master Cylinder Assembly
5A-10 BRAKES PIPE / HOSE / MASTER CYLINDER MASTER CYLINDER ASSEMBLY 1. Piston stopper circlip 2. Piston stopper 3. Cylinder cup and plate 4. Primary piston 5. Piston cup 6. Secondary piston pressure cup 7. Primary piston Assy 8. Secondary piston 9.
Page 305 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-11 DISASSEMBLY 1) Remove reservoir pin and reservoir. 2) Remove circlip. 1. Pin 2. Master cylinder 3. Reservoir 4. Circlip 3) For vehicle with ABS Pull out primary piston assembly straight so as not to cause any damage to inside of cylinder wall.
Page 306 5A-12 BRAKES PIPE / HOSE / MASTER CYLINDER INSPECTION Vehicle equipped with ABS Inspect all disassembled parts for wear or damage, and replace parts if necessary. NOTE: D Wash disassembled parts with brake fluid. D Do not reuse piston cups. Inspect master cylinder bore for scoring or corrosion.
Page 307 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-13 5) Apply thin coat of brake fluid to all around new grommets (2pcs.) and install them to cylinder body, then install reservoir. 6) Set a new pin in reservoir hole and drive it in. At this time, make end of pin and end face margin of reservoir equal.
Page 308: Brake Booster
5A-14 BRAKES PIPE / HOSE / MASTER CYLINDER BRAKE BOOSTER 1. Brake master cylinder ass’y 2. Brake booster ass’y 3. Gasket 4. Push rod clevis 5. Nut 6. Clevis pin 7. Clip 8. Nut 9. Brake vacuum hose REMOVAL 1. ABS hydraulic unit NOTE: 2.
Page 309 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15 CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON ADJUSTMENT The length of booster piston rod is adjusted to provide specified clearance “a” between piston rod end and master cylinder piston. 1. Booster piston rod 2.
Page 310 5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER BOOSTER PUSH ROD CLEVIS ADJUSTMENT 1. Clevis 2. Nut Install push rod clevis so that measurement “a” is obtained and torque nut to specification. Tightening Torque (a): 25 N m (2.5 kg-m, 18.0 lb-ft) Length “a”: 109.5 –...
Page 311: Lspv (Load Sensing Proportioning Valve) Assembly
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-17 LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped) REMOVAL 1) Clean around reservoir cap and take out fluid with syringe or such. 2) Hoist vehicle. 3) Disconnect brake pipes from LSPV. 1. LSPV 2.
Page 312 5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER 2) Torque each bolt and nut to specification as indicated respec- tively in figure. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) (b): 16 N m (1.6 kg-m, 11.5 lb-ft) (brake flare nut) (c): 7.5 N m (0.75 kg-m, 9.0 lb-ft) (bleeder plug) 3) Upon completion of installation, fill reservoir tank with specified...
Page 313: Tightening Torque Specifications
10.0 72.5 Wheel nut REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT D To fill master cylinder reservoir. Indicated on reservoir D To clean and apply to inner parts of master Brake fluid cap or described in owner’s cylinder caliper and wheel cylinder when manual of vehicle they are disassembled.
Page 314: Front Brake
FRONT BRAKE 5B-1 SECTION 5B FRONT BRAKE NOTE: All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary.
Page 315: Note
5B-2 FRONT BRAKE GENERAL DESCRIPTION DISC BRAKE CALIPER ASSEMBLY This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
Page 316: Diagnosis
FRONT BRAKE 5B-3 DIAGNOSIS Refer to Section 5 (BRAKES). CHECK AND ADJUSTMENT Refer to Section 5 (BRAKES). ON-VEHICLE SERVICE FRONT DISC BRAKE PAD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolts. 1. Caliper 2. Caliper pin bolts 3.
Page 317 5B-4 FRONT BRAKE Brake Disc Before this inspection, brake pads must be removed. Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replace- ment are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc sur- face, replace it.
Page 318 FRONT BRAKE 5B-5 INSTALLATION NOTE: See NOTE at the beginning of this section. 1) Install pad clips and pads. NOTE: Install pad with sensor to body center side of caliper. 1. Clips 2. Pads 3. Disc 4. Caliper carrier 5. Sensor 6.
Page 319: Front Disc Brake Caliper
5B-6 FRONT BRAKE FRONT DISC BRAKE CALIPER REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake flexible hose mounting bolt from caliper. As this will allow fluid to flow out of hose, have a container ready before- hand. Caliper Flexible hose Hose mounting bolt Wire hook...
Page 320 FRONT BRAKE 5B-7 2) Remove piston seal using a thin blade like a thickness gauge, etc. CAUTION: Be careful not to damage inside (bore side) of cylinder. INSPECTION Cylinder Boot Check boots for breakage, crack and damage. If defective, replace. Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth re- turn of the piston.
Page 321 5B-8 FRONT BRAKE Piston and Boot 1) Before inserting piston into cylinder, install boot onto piston as shown. 1. Boot 2. Piston 2) Fit boot as it is in above figure into boot groove in cylinder with fingers. Check to make sure that boot is fitted into boot groove in cylinder completely in its circumference.
Page 322 FRONT BRAKE 5B-9 Caliper Before installing caliper (cylinder body) to carrier, check to ensure that guide pin (pin bolt) inserted in each caliper carrier hole can be moved smoothly in thrust direction. NOTE: Where temperature gets as low as –30_C in cold weather, use rubber grease whose viscosity varies very little even at –40_C (–40_F).
Page 323: Front Brake Disc
5B-10 FRONT BRAKE FRONT BRAKE DISC REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper assembly by loosening carrier bolts (2 pcs.). CAUTION: During removal, be careful not to damage brake flexible hose and not to depress brake pedal. 3) Remove disc by using 8 mm bolts (2 pcs.).
Page 324: Tightening Torque Specifications
Wheel nut 10.0 72.5 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIALS SUZUKI PRODUCT D To fill master cylinder reservoir. Indicated on reservoir D To clean and apply to inner parts of master Brake fluid cap or described in owner’s cylinder caliper and wheel cylinder when manual of vehicle they are disassembled.
Page 325 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 326: General Description
5C-2 PARKING AND REAR BRAKE GENERAL DESCRIPTION DRUM BRAKE ASSEMBLY The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main- tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road.
Page 327: Diagnosis
PARKING AND REAR BRAKE 5C-3 DIAGNOSIS Refer to Section 5 (BRAKES). CHECK AND ADJUSTMENT Refer to Section 5 (BRAKES). ON-VEHICLE SERVICE PARKING BRAKE LEVER REMOVAL 1) Disconnect negative (–) cable at battery. 2) Block vehicle wheels and release parking brake lever. 3) Remove rear center console box.
Page 328 5C-4 PARKING AND REAR BRAKE INSTALLATION 1) Install in reverse order of REMOVAL procedure. Check equalizer inclined angle. Angle “a”: within 15 degrees Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 2) After all parts are installed, parking brake lever needs to be ad- justed.
Page 329: Parking Brake Cable
PARKING AND REAR BRAKE 5C-5 PARKING BRAKE CABLE B-1. Parking brake switch B-2. Parking brake lever B-3. Parking brake lever bolt B-4. Floor B-5. Locking nut B-6. Spacer B-7. Pin B-8. Equalizer B-9. Adjust rod B-10. Coupler A-1. Color ring A-6.
Page 330 5C-6 PARKING AND REAR BRAKE INSTALLATION Install parts in reverse order of removal procedure, noting the fol- lowing. 1) Install brake cable cap to brake back plate securely as shown in figure. NOTE: Color ring or tape on brake cable is for the purpose of identi- fication.
Page 331: Brake Drum
PARKING AND REAR BRAKE 5C-7 BRAKE DRUM REMOVAL 1) Hoist vehicle and pull up parking brake lever. 2) Remove wheel. 3) Release parking brake lever. 4) Remove rear center console box screws and with rear part of rear center console box lifted a little, loosen parking brake cable locking nut.
Page 332 5C-8 PARKING AND REAR BRAKE Cracked, Scored, or Grooved Drum A cracked, drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will probably be necessary to re- surface drum braking surface.
Page 333: Brake Shoe
PARKING AND REAR BRAKE 5C-9 2) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil. 3) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to ten times so as to obtain proper drum-to- shoe clearance.
Page 334 5C-10 PARKING AND REAR BRAKE 6) Remove parking brake shoe lever from brake shoe. 1. Retainer 2. Parking brake shoe lever 3. Brake shoe INSPECTION Parking Shoe Lever Inspect brake shoe lever for free movement against brake shoe web. If defective, correct or replace. Strut, Adjuster Check thread or ratchet of strut and adjuster for wear, sticking and corrosion.
Page 335 PARKING AND REAR BRAKE 5C-11 INSTALLATION 1) Assemble parts as shown in reverse order of removal. 1. Lower return spring 2. Lower strut 2) Install shoe hold down springs by pushing them down in place and turning hold down pins. 3) Install adjuster and upper shoe return spring.
Page 336: Wheel Cylinder
5C-12 PARKING AND REAR BRAKE WHEEL CYLINDER REMOVAL 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL. 2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL. 3) Loosen brake pipe flare nut (or nuts) but only within the extent that fluid does not leak.
Page 337 PARKING AND REAR BRAKE 5C-13 4) Install bleeder plug cap taken off from pipe back to bleeder plug. 5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE INSTALLATION. NOTE: Be sure to bleed brake system. (for bleeding operation, re- fer to BLEEDING BRAKES in Section 5.) INSTALLATION (For gasket sealed type) 1) Install gasket to joint seam of wheel cylinder and brake back...
Page 338: Brake Back Plate
5C-14 PARKING AND REAR BRAKE BRAKE BACK PLATE REMOVAL 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL. 2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL. 3) Perform steps 3) and 4) of WHEEL CYLINDER REMOVAL. 4) Remove cable from brake back plate by squeezing parking brake cable cap.
Page 339 PARKING AND REAR BRAKE 5C-15 INSTALLATION 1) Apply sealant to mating surface of bearing retainer with brake “A” back plate. “A”: Sealant 99000-31110 NOTE: Make sure to remove old sealant before applying it anew. 1. Rear axle shaft 2) Install brake back plate to rear axle shaft. 1.
Page 340 5C-16 PARKING AND REAR BRAKE 6) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut (or nuts) to specified torque. (Refer to steps 1) to 4) of WHEEL CYLINDER INSTALLATION of this section.) 7) Install parking brake cable to brake back plate. 1.
Page 341: Tightening Torque Specifications
SEALING COMPOUND 366E sealant 99000-31090 plate and rear wheel cylinder. D To apply to mating surfaces of brake back SUZUKI BOND NO. 1215 plate and rear axle housing. Sealant D To apply mating surfaces of brake back 99000-31110 plate and rear wheel bearing retainer.
Page 342 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 343: General Description
5E1-2 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) Diagnostic Trouble Code (DTC) Table . . . 5E1-14 Removal ......5E1-32 System Circuit .
Page 344: Brake Hose/Pipe Routing
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-3 BRAKE HOSE/PIPE ROUTING LH steering vehicle RH steering vehicle 1. Front disk brake 2. Rear drum brake 3. ABS hydraulic unit / control module assembly with ABS pump motor relay and fail-safe relay 4. Brake master cylinder / Reservoir...
Page 345: System Schematic
5E1-4 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) SYSTEM SCHEMATIC 1. Wheel speed sensor (Right-front) 7. Wheel speed sensor (Left-rear) 13. ABS hydraulic unit 2. Stop lamp switch 8. “ABS” warning lamp 14. G sensor (For 4WD model only) 3. ABS control module 9.
Page 346 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-5 ABS COMPONENT PARTS LOCATION LH steering vehicle RH steering vehicle 1. Wheel speed sensor 6. Wheel speed sensor 10. ABS hydraulic unit/control module assembly (Right-front) (Left-rear) with ABS pump motor relay 2. Stop lamp switch 7.
Page 347 5E1-6 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY ABS control module is a component of ABS hydrauli unit/control module assembly and has the following functions. Self-Diagnosis Function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the “ABS”...
Page 348: Diagnosis
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-7 DIAGNOSIS To ensure that the trouble diagnosis is done accurately and smooth- ly, observe “Precautions in Diagnosing Troubles” and follow “ABS Diagnostic Flow Table”. PRECAUTION IN DIAGNOSING TROUBLES D If the vehicle was operated in any of the following ways, “ABS” warning light may light momentarily but this does not indicate any- thing abnormal in ABS.
Page 349: Abs Diagnostic Flow Table
5E1-8 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) ABS DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Perform customer complaint analysis, problem Go to step 2. Go to step 5. symptom confirmation and diagnostic trouble code check record and clearance.
Page 350 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-9 1-1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 351 5E1-10 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 1-2. PROBLEM SYMPTOM CONFIRMATION Check if what the customer claimed in CUSTOMER QUESTIONNAIRE is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) When “ABS”...
Page 352: Ebd Warning Lamp (Brake Warning Lamp) Check
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-11 EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK NOTE: Perform this check on a level place. 1) Turn ignition switch ON with parking brake applied. 2) Check that brake warning lamp is turned ON. 3) Release parking brake with ignition switch ON and check that EBD warning lamp (brake warning lamp) goes off.
Page 353 5E1-12 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) NOTE: “ABS” warning lamp indicates only following DTC’s, DTC 12 which means that no malfunction DTC is stored and his- tory DTC which indicates history trouble area. When there is a current trouble, “ABS” warning lamp remains ON and therefore DTC is not indicated.
Page 354: Dtc Check (Using Suzuki Scan Tool)
2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool opera- tor’s manual for further details. 4) After completing the check, turn ignition switch off and discon- nect SUZUKI scan tool from DLC.
Page 355: Diagnostic Trouble Code (Dtc) Table
DIAGNOSTIC TROUBLE CODE (DTC) TABLE (indicated (indicated (displayed (dis layed VOLTMETER INDICATION VOLTMETER INDICATION (or “ABS” warning by ABS DIAGNOSTIC AREA lamp flashing pattern) warning SUZUKI SUZUKI lamp) scan tool) C1015 G sensor (for 4WD model only) Right- C1021 C1021 front Left- C1025...
Page 356: System Circuit
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-15 SYSTEM CIRCUIT 1. Battery Wire color TERMINAL CIRCUIT 2. Main fuses : Black Right-rear wheel speed sensor (+) 3. Ignition switch B / Bl : Black / Blue 4. Circuit fuses Right-front wheel speed sensor (–) B / O : Black / Orange 5.
Page 357 5E1-16 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) TABLE – A “ABS” WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON -1. Main fuse -2. Ignition switch -3. Circuit fuse for IG -4. “ABS” warning lamp -5. ABS hydraulic unit / control module assembly 5-1.
Page 358 Perform diagnostic trouble code check. Is there any DTC Go to step 2. Go to step 3. (including code No.12, NO CODES on SUZUKI scan tool) exists? Is malfunction DTC (other than code No.12) exists at step Go to step 7 of ABS Go to step 3.
Page 359 5E1-18 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) TABLE – C “ABS” WARNING LAMP CIRCUIT CHECK – THE LAMP FLASHES CONTINUOUSLY WHILE IGNITION SWITCH IS ON -1. “ABS” warning lamp -2. ABS hydraulic unit / control module assembly -3. Diagnosis connector 3-1. Diag. switch terminal 3-2.
Page 360 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-19 TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAG. SWITCH TERMINAL CONNECTED TO GROUND -1. “ABS” warning lamp -2. ABS hydraulic unit / control module assembly -3. Diagnosis connector 3-1. Diag. switch terminal 3-2.
Page 361 5E1-20 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) TABLE – E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK-LAMP COMES “ON” STEADY CIRCUIT DESCRIPTION EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS control module/hydraulic unit assembly through lamp driver module in combination meter. Refer to “TABLE-A” for circuit diagram.
Page 362: Dtc 15 - G Sensor Circuit
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-21 DTC 15 (DTC C1015) – G SENSOR CIRCUIT (FOR 4WD MODEL ONLY) 1. Ignition switch 2. G sensor 3. ABS hydraulic unit control module assembly 4. ABS hydraulic unit/ control module connector of harness O / G DESCRIPTION While a vehicle is at stop or running, if the potential difference between the sensor signal terminal “A14”...
Page 363 5E1-22 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) INSPECTION STEP ACTION Is G sensor installed floor securely? Go to step 2. Tighten sensor or bracket screw securely. If not, using new screw. 1) Ignition switch OFF. Go to step 3. Replace G sensor. 2) Remove G sensor with bracket.
Page 364 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-23 DTC 21 (DTC C1021), 22 (DTC C1022) – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT 25 (DTC C1025), 26 (DTC C1026) – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT 31 (DTC C1031), 32 (DTC C1032) – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT 35 (DTC C1035), 36 (DTC C1036) –...
Page 365 5E1-24 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) INSPECTION STEP ACTION 1) Disconnect the applicable sensor connector with Go to step 2. Replace sensor. ignition switch OFF. 2) Measure resistance between sensor terminals. Resistance of wheel speed sensor: 1.2 – 1.6 kf (at 20_C, 68_F) 3) Measure resistance between each terminal and body ground.
Page 366 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-25 Fig. 1 Fig. 2 Fig. 3 1. ABS hydraulic unit / control module connector Fig. 4 Fig. 5...
Page 367 5E1-26 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DTC 41 (DTC C1041/C1042) – RIGHT-FRONT SOLENOID CIRCUIT 45 (DTC C1045/C1046) – LEFT-FRONT SOLENOID CIRCUIT 56 (DTC C1055/C1056) – REAR SOLENOID CIRCUIT 1. ABS hydraulic unit/ control module assembly 2. ABS hydraulic unit/ control module connector of harness DESCRIPTION The ABS control module monitors the voltage of the terminal of the solenoid circuit constantly with the ignition...
Page 368: Power Source Circuit
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-27 DTC 57 (DTC C1057) – SOLENOID AND PUMP MOTOR POWER SOURCE CIRCUIT 1. ABS hydraulic unit/ control module assembly 2. ABS hydraulic unit/ control module connector DESCRIPTION The ABS control module monitors the voltage at terminal ( “A11” and “A27”) of the fail-safe and pump motor relays circuit constantly with the ignition switch turned ON.
Page 369: Dtc 61 - Abs Pump Motor Circuit
5E1-28 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DTC 61 (DTC C1061) – ABS PUMP MOTOR CIRCUIT -1. ABS hydraulic unit / control module assembly 1-1. ABS pump motor relay 1-2. ABS pump motor 1-3. ABS fail safe relay -2. ABS hydraulic unit/ control module connector of harness DESCRIPTION...
Page 370: Dtc 63 - Abs Fail-Safe Relay Circuit
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-29 DTC 63 (DTC C1063) – ABS FAIL-SAFE RELAY CIRCUIT 1. Ignition switch 2. ABS hydraulic unit/ control module assembly 3. ABS hydraulic unit/ control module connector of harness DESCRIPTION The ABS control module monitors the voltage at the terminal of the solenoid circuit constantly with the ignition switch turned ON.
Page 371: Dtc 71 - Abs Control Module
5E1-30 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DTC 71 (DTC C1071) – ABS CONTROL MODULE DESCRIPTION This DTC will be set when an internal fault is detected in the ABS control module. INSPECTION STEP ACTION 1) Ignition switch OFF. Substitute a Repair or replace.
Page 372: Precaution
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-31 ON-VEHICLE SERVICE PRECAUTION When connector are connected to ABS hydraulic unit/control mod- ule assembly, do not disconnect connectors of sensors and turn ignition switch ON. Then DTC will be set in ABS control module. ABS HYDRAULIC UNIT OPERATION CHECK 1) Check that basic brake system other than ABS is in good condi- tion.
Page 373: Abs Hydraulic Unit/Control Module Assembly
5E1-32 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY CAUTION: Never disassemble ABS hydraulic unit/control module as- sembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit/control module assembly. 1.
Page 374: Installation
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-33 4) Remove three nuts and take out ABS hydraulic unit/control 1. ABS hydraulic unit / module assembly from bracket. control module assembly 2. Nut CAUTION: D Do not give an impact to hydraulic unit. D Use care not to allow dust to enter hydraulic unit.
Page 375: Front Wheel Speed Sensor
5E1-34 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) FRONT WHEEL SPEED SENSOR 1. Left front wheel speed sensor 2. Left front strut 3. Sensor rotor OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch OFF. 2) Hoist vehicle a little. 3) Disconnect connector of wheel speed sensor. 4) Connect voltmeter between connector terminals.
Page 376: Removal
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-35 REMOVAL 1) Disconnect negative cable at battery. 2) Hoist vehicle and remove wheel. 3) Disconnect front wheel speed sensor connector. 1. Front wheel speed sensor connector 2. Headlight assembly FORWARD 4) Remove harness clamp bolts and remove front wheel speed sensor from knuckle.
Page 377: Installation
5E1-36 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) INSTALLATION 1) Check that no foreign material is attached to sensor and rotor. 2) Install it by reversing removal procedure. CAUTION: D Do not pull wire harness or twist more than necessary when installing front wheel speed sensor. D Fit harness grommet to inner fender securely.
Page 378: Rear Wheel Speed Sensor
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-37 REAR WHEEL SPEED SENSOR 1. Rear wheel speed sensor 2. Sensor rotor 3. Rear axle housing OUTPUT VOLTAGE INSPECTION Check in the same procedure as that used of front wheel speed sensor check. Output AC voltage at 2/3 to one rotation per second (25 –...
Page 379: Sensor Inspection
5E1-38 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) SENSOR INSPECTION D Check sensor (pole piece) for damage or bent. D Check sensor for resistance. Resistance between terminals : 1.2 – 1.6 kf at 20_C, 68_F Resistance between terminal and sensor body: 1 Mf or more If any faulty is found, replace.
Page 380: Rear Sensor Rotor
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-39 REAR SENSOR ROTOR REMOVAL 1) Remove rear axle shaft. Refer to REAR AXLE SHAFT RE- MOVAL in Section 3E. 2) In order to remove sensor rotor from retainer ring, grind with a grinder one part of the sensor rotor as illustrated till it becomes thin.
Page 381: G Sensor
5E1-40 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) G SENSOR (FOR 4WD MODEL ONLY) REMOVAL 1) Turn ignition switch OFF and disconnect battery negative cable. 2) Remove rear center console box. 3) Remove parking brake lever bolts “1” and G sensor with bracket from floor.
Page 382: Transfer 4Wd Switch
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-41 TRANSFER 4WD SWITCH For removal, inspection and installation of this switch, refer to SWITCHES in Section 7A. TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts kg-m lb-ft Brake pipe flare nut: (a) 11.5 ABS hydraulic unit nut: (b) 15.5 ABS hydraulic unit bracket bolt: (c)
Page 383: Special Tools
4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09950-78220 Flare nut wrench 09931-76011 (10 mm) SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 09931-76030 16 / 14 pin DLC cable...
Page 384 MANUAL TRANSMISSION (TYPE 1) 7A-1 SECTION 7A MANUAL TRANSMISSION (TYPE 1) TYPE 1 CONTENTS GENERAL DESCRIPTION ....7A- 1 Extension Case (2WD MODEL) ..7A-13 Extension Case Oil Seal DIAGNOSIS...
Page 385: Diagnosis
7A-2 MANUAL TRANSMISSION (TYPE 1) DIAGNOSIS Condition Possible Cause Correction D Worn shift fork shaft Gear slipping out of mesh Replace D Worn shift fork or synchronizer sleeve Replace D Weak or damaged locating spring Replace D Worn bearings on input shaft or main shaft Replace D Worn chamfered tooth on sleeve or gear Replace sleeve and gear...
Page 386: On-Vehicle Service
MANUAL TRANSMISSION (TYPE 1) 7A-3 ON-VEHICLE SERVICE GEAR OIL INSPECTION AND CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage ex- ists, correct or repair it.
Page 387: Shift Control Levers
7A-4 MANUAL TRANSMISSION (TYPE 1) SHIFT CONTROL LEVERS REMOVAL 1) Remove 4 screws at the front and rear and 2 clips at the center then take off front and rear center console boxes. NOTE: To remove clip, push in its center pin first. 2) Remove console box bracket by removing bolts and lift up boot 1.
Page 388 MANUAL TRANSMISSION (TYPE 1) 7A-5 5) Install transmission boot No. 1 from inside of cabin and clamp 1. Boot No. 1 2. Boot clamp it with a new clamp securely. 3. Boot cover 4. Boot No. 2 6) Install transfer boot No. 1 securely on lift and clamp it by using a new clamp.
Page 389: Switches
7A-6 MANUAL TRANSMISSION (TYPE 1) SWITCHES TRANSFER 4WD SWITCH 1) Remove console box and lift transmission control lever boots 3, (a) No. 2 and No. 3. (Refer to page 7A-4.) 2) Remove transfer control lever boot No. 2, unclamp wiring on transfer case to free it and pull off coupler.
Page 390 MANUAL TRANSMISSION (TYPE 1) 7A-7 3) Replace switch, connect and clamp as they were. [Type 1] 1, (a) Tightening Torque (a): 20 N m (2.0 kg-m, 14.5 lb-ft) (Type 1) (a): 45 N m (4.5 kg-m, 32.5 lb-ft) (Type 2) 4) When back up light switch has been replaced, check switch for proper function with ignition switch turned ON and gear shifted to reverse position.
Page 391: Engine Rear Mounting
7A-8 MANUAL TRANSMISSION (TYPE 1) ENGINE REAR MOUNTING FRONT SIDE When replacement of mounting parts are necessary, torque bolts and nut as specified below. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) REAR SIDE 1. Engine rear mounting member 2.
Page 392: Dismounting Of Trans. Unit
MANUAL TRANSMISSION (TYPE 1) 7A-9 DISMOUNTING OF TRANS. UNIT IN CABIN Remove transmission shift control lever (refer to page 7A-4) and transfer shift control lever knob. IN ENGINE ROOM 1) Disconnect negative (–) cable of battery. 2) Remove breather hose from clamp at the rear end of cylinder head.
Page 393 7A-10 MANUAL TRANSMISSION (TYPE 1) ON LIFT 1) Drain oil from transmission and transfer. 2) Give match marks on joint flange and propeller shaft as shown in figure. (front and rear) 3) Remove flange bolts of rear propeller shaft universal joint and pull out propeller shaft.
Page 394 MANUAL TRANSMISSION (TYPE 1) 7A-11 10) Remove wiring harness and breather hose. 11) Separate gear shift lever case and transfer assembly (or exten- sion case: 2WD model) from transmission. 1. Transmission assembly 4. Breather hose 2. Transfer assembly 5. Gear shift lever case 3.
Page 395: Remounting Of Trans. Unit
7A-12 MANUAL TRANSMISSION (TYPE 1) REMOUNTING OF TRANS. UNIT For remounting, reverse dismounting procedure. Use specified torques as given below. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) (b): 50 N m (5.0 kg-m, 36.5 lb-ft) D For tightening torque of transmission stiffener bolt, refer to “ENGINE MECHANICAL”...
Page 396: Extension Case (2Wd Model)
MANUAL TRANSMISSION (TYPE 1) 7A-13 EXTENSION CASE (2WD MODEL) DISASSEMBLY 2,“A”,(a) 1) Remove oil seal. 3,“A” 2) Remove select return spring bolts and then springs and guide 5,“A” pins. 3) Remove speed sensor assembly. REASSEMBLY 1) Install oil seal. 2) After applying grease, install select guide pins, select return springs and spring bolts and torque them to specification.
Page 397: Unit Repair
Select return spring bolts 17.0 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Shift control lever. SUZUKI SUPER GREASE A Lithium grease D Select return springs, bolts and guides. (99000-25010) THREAD LOCK CEMENT D Shift control lever locating bolts. Thread lock cement SUPER 1333B (99000-32020) SUZUKI BOND No.
Page 398 MANUAL TRANSMISSION (TYPE 2) 7A1-1 SECTION 7A1 MANUAL TRANSMISSION (TYPE 2) TYPE 2 CONTENTS GENERAL DESCRIPTION ....7A1-1 Dismounting/Remounting of Trans. Unit ......7A1-4 DIAGNOSIS .
Page 399: Diagnosis
7A1-2 MANUAL TRANSMISSION (TYPE 2) DIAGNOSIS Condition Possible Cause Correction D Worn shift fork shaft Gear slipping out of mesh Replace D Worn shift fork or synchronizer sleeve Replace D Weak or damaged locating spring Replace D Worn bearings on input shaft or main shaft Replace D Worn chamfered tooth on sleeve or gear Replace sleeve and gear...
Page 400: On-Vehicle Service
MANUAL TRANSMISSION (TYPE 2) 7A1-3 ON-VEHICLE SERVICE GEAR OIL INSPECTION AND CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage ex- ists, correct or repair it.
Page 401: Shift Control Levers
7A1-4 MANUAL TRANSMISSION (TYPE 2) SHIFT CONTROL LEVERS Refer to SECTION 7A in this manual. SWITCHES Refer to SECTION 7A in this manual. ENGINE REAR MOUNTING Refer to SECTION 7A in this manual. DISMOUNTING/REMOUNTING OF TRANS. UNIT Refer to the same item in SECTION 7A “MANUAL TRANSMIS- SION”.
Page 402: Tightening Torque Specifications
Muffler to exhaust No. 2 pipe nuts 36.5 Universal joint flange bolts 36.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI SUPER GREASE A D Shift control lever Lithium grease (99000-25010) THREAD LOCK CEMENT D Shift control lever locating bolts Thread lock cement SUPER 1333B (99000-32020) SUZUKI BOND No.
Page 403: Automatic Transmission
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 404 7B1-2 AUTOMATIC TRANSMISSION (4 A / T) DTC P0753 Shift Solenoid-A (#1) TRANSMISSION RANGE SWITCH ..7B1-64 Electrical ......7B1-50 A / T OUTPUT SPEED SENSOR .
Page 405: General Description
AUTOMATIC TRANSMISSION (4 A / T) 7B1-3 GENERAL DESCRIPTION This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 4 disc type brakes and 3 one-way clutches.
Page 406 7B1-4 AUTOMATIC TRANSMISSION (4 A / T) Item Specifications Torque Type 3-element, 1-step, 2-phase type (with TCC (lock-up) conver- mechanism) Stall torque ratio 2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine) Type Trochoid type oil pump pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type...
Page 407: Clutch/Brake Functions
AUTOMATIC TRANSMISSION (4 A / T) 7B1-5 CLUTCH/BRAKE FUNCTIONS 1. Overdrive clutch 2. Overdrive brake 3. Forward clutch 4. Direct clutch 5. Second coast brake 6. Second brake 7. Reverse brake 8. One-way clutch No.2 9. One-way clutch No.1 10. Overdrive one-way clutch 11.
Page 408: Table Of Component Operation
7B1-6 AUTOMATIC TRANSMISSION (4 A / T) TABLE OF COMPONENT OPERATION Direct clutch Reverse brake Solenoid Solenoid Second One-way One-way Element O / D O / D Forward Forward O / D O / D Second Second valve valve coast one-way clutch clutch...
Page 409: Electronic Shift Control System
AUTOMATIC TRANSMISSION (4 A / T) 7B1-7 ELECTRONIC SHIFT CONTROL SYSTEM The gear ratio change in “D” or “2” range and torque converter clutch operation are controlled by Powertrain (En- gine) Control Module. Torque converter Planetary gear Engine Final gear reduction unit Oil pump Clutch and brake...
Page 410 7B1-8 AUTOMATIC TRANSMISSION (4 A / T) G16 / J20 Engines Bl / Y C51-1-11 Bl / G C51-1-10 C51-1-23 C51-1-22 1. PCM (ECM) 9. Shift solenoid-A 17. O / D cut switch 2. VSS 10. Shift solenoid-B 18. P / N change switch 3.
Page 411 AUTOMATIC TRANSMISSION (4 A / T) 7B1-9 H25 Engine Bl / Y C51-1-16 Bl / G C51-1-8 C51-1-10 C51-1-9 1. PCM (ECM) 9. Transmission range switch 17. MIL 2. VSS 10. Shift solenoid-A 18. O / D cut switch 3. CMP sensor 11.
Page 412 7B1-10 AUTOMATIC TRANSMISSION (4 A / T) Fail Safe Function This function is provided by the safe mechanism that assures safe driveability even when the shift solenoid valve or speed sensor fails. The table below shows the gear position in each shift under a normal/abnormal condition. Condition Shift solenoid Shift solenoid...
Page 413 AUTOMATIC TRANSMISSION (4 A / T) 7B1-11 AUTOMATIC GEAR SHIFT DIAGRAM Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a higher than 52 km/h or 33 mile/h speed for G16 engine (45 km/h or 28 mile/h for J20 engine, 55 km/h or 34 mile/h for H25 engine), 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that.
Page 414 7B1-12 AUTOMATIC TRANSMISSION (4 A / T) Normal Mode For G16 Engine Unit: km/h (mile/h) Shift Throttle opening Full throttle (28) (58) (85) (77) (46) (24) Closed throttle (20) (28) (22) (18) Gear Shift Diagram Upshift Downshift (km / h) Vehicle speed TCC Lock-up Diagram gear...
Page 415 AUTOMATIC TRANSMISSION (4 A / T) 7B1-13 Power Mode For J20 Engine Unit: km/h (mile/h) Shift Throttle opening Full throttle — (31) (61) (84) (52) (29) Closed throttle (11) (21) (31) (27) (16) Gear Shift Diagram Upshift Downshift (km / h) Vehicle speed TCC Lock-up Diagram gear...
Page 416 7B1-14 AUTOMATIC TRANSMISSION (4 A / T) Normal Mode For J20 Engine Unit: km/h (mile/h) Shift Throttle opening Full throttle (31) (61) (91) (84) (52) (26) Closed throttle (17) (25) (23) (15) Gear Shift Diagram Upshift Downshift (km / h) Vehicle speed TCC Lock-up Diagram gear...
Page 417 AUTOMATIC TRANSMISSION (4 A / T) 7B1-15 Power Mode For H25 Engine Unit: km/h (mile/h) Shift Throttle opening Full throttle (30) (62) (99) (93) (56) (25) Closed throttle (10) (19) (28) (24) (15) Gear Shift Diagram Upshift Downshift (km / h) Vehicle speed TCC Lock-up Diagram gear...
Page 418 7B1-16 AUTOMATIC TRANSMISSION (4 A / T) Normal Mode For H25 Engine Unit: km/h (mile/h) Shift Throttle opening Full throttle (30) (62) (99) (93) (56) (25) Closed throttle (17) (25) (22) (13) Gear Shift Diagram Upshift Downshift (km / h) Vehicle speed TCC Lock-up Diagram gear...
Page 419: Automatic Transmission Diagnosis
AUTOMATIC TRANSMISSION (4 A / T) 7B1-17 AUTOMATIC TRANSMISSION DIAGNOSIS This vehicle is equipped with an electronic transmission control system, which control the automatic shift up and shift down timing, TCC operation, etc. suitably to vehicle driving conditions. PCM (ECM) has an On-Board Diagnosis system which detects a malfunction in this system and abnormality of those parts that influence the engine exhaust emission.
Page 420 7B1-18 AUTOMATIC TRANSMISSION (4 A / T) [For Vehicle without Monitor Connector] ON-BOARD DIAGNOSTIC SYSTEM For automatic transmission control system, PCM (ECM) has follow- ing functions. Refer to Section 6/6-1 for details. D When the ignition switch is turned ON with the engine at a stop, malfunction indicator lamp (MIL) turns ON to check the bulb of the MIL.
Page 421 AUTOMATIC TRANSMISSION (4 A / T) 7B1-19 [For Vehicle with Monitor Connector] ON-BOARD DIAGNOSTIC SYSTEM For automatic transmission control system, PCM (ECM) has follow- ing functions. Refer to Section 6/6-1 for details. D When the ignition switch is turned ON with the engine at a stop, malfunction indicator lamp (MIL) turns ON to check the bulb of the MIL.
Page 422: Precaution In Diagnosing Trouble
Such disconnection will clear memorized information in PCM memory. D Using SUZUKI scan tool (Tech-1), or also generic scan tool for vehicle without monitor connector, the diagnostic information stored in PCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (instruction) Manual supplied with it carefully to have good understanding of its functions and usage.
Page 423: Automatic Transmission Diagnostic Flow Table
AUTOMATIC TRANSMISSION (4 A / T) 7B1-21 AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to complaint analysis.
Page 424 7B1-22 AUTOMATIC TRANSMISSION (4 A / T) 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 inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 425: Customer Problem Inspection Form
AUTOMATIC TRANSMISSION (4 A / T) 7B1-23 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date of Reg: Date of problem: Mileage: PROBLEM SYMPTOMS jEngine stops jEngine does not start jVehicle does not move jTransmission does not shift (1st, 2nd, 3rd, 4th, Rev) gear (forward, rearward) jAutomatic shift does not occur...
Page 426: Malfunction Indicator Lamp (Mil) Check
7B1-24 AUTOMATIC TRANSMISSION (4 A / T) MALFUNCTION INDICATOR LAMP (MIL) CHECK Refer to the same item in Section 6/6-1 for checking procedure. “O/D OFF” LAMP CHECK 1) Check that O/D cut switch button is at OFF position (pushed). 2) Turn ignition switch ON. 3) Check that “O/D OFF”...
Page 427: Fail-Safe Table
AUTOMATIC TRANSMISSION (4 A / T) 7B1-25 DIAGNOSTIC TROUBLE CODE (DTC) TABLE (A/T RELATED CODE) (cont’d) DTC NO. Vehicle Vehicle DETECTED ITEM DETECTING CONDITION Using Not using without with scan tool scan tool monitor monitor connector connector Shift solenoid B (#2) Gear change control from PCM to 2 driving P0756...
Page 428: Visual Inspection
7B1-26 AUTOMATIC TRANSMISSION (4 A / T) VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D A/T fluid – – – – – level, leakage, color Section 0B D A/T fluid hoses – – – – – disconnection, looseness, deterioration Section 7B1 D Throttle (accelerator) cable –...
Page 429: A/T Basic Check
AUTOMATIC TRANSMISSION (4 A / T) 7B1-27 A/T BASIC CHECK This inspection is important for troubleshooting when PCM (ECM) has detected no DTC and no abnormality has been noted in visual inspection. Follow flow table carefully. STEP ACTION Was “A/T DIAG. FLOW TABLE” performed? Go to Step 2.
Page 430 7B1-28 AUTOMATIC TRANSMISSION (4 A / T) TROUBLE DIAGNOSIS TABLE 1 Condition Possible Cause Correction D Brake pedal (stop lamp) switch or its TCC does not operate DIAGNOSTIC FLOW TABLE A-1 circuit faulty (H25 engine only) D 4WD low switch or its circuit faulty D Engine coolant temp.
Page 431 AUTOMATIC TRANSMISSION (4 A / T) 7B1-29 Condition Possible Cause Correction D 3–4 shift valve sticking Poor 3–4 shift, ex- Replace. cessive slippage D Shift solenoid valve-B sticking Replace. D Regulator valve sticking Excessive shock on Replace. 1–2 shift D Faulty accumulator, second brake piston Replace.
Page 432: Inspection Of Pcm And Its Circuit
7B1-30 AUTOMATIC TRANSMISSION (4 A / T) Condition Possible Cause Correction D Fluid pressure leakage from forward clutch Poor 1st speed run- Replace. due to wear or breakage of O/D case seal ning or excessive slippage in “D” or “2” ring D Overdrive clutch slipping Replace.
Page 433: Diagnostic Flow Table A-1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-31 DIAGNOSTIC FLOW TABLE A-1 (NO TCC LOCK-UP OCCURS) SYSTEM DESCRIPTION PCM turns TCC solenoid OFF under any of the following conditions. D Brake pedal switch: ON D 4WD LOW switch: ON D Cruise control module: TCC OFF command signal is output (if equipped). D ECT: ECT <...
Page 434 7B1-32 AUTOMATIC TRANSMISSION (4 A / T) STEP ACTION “4WD LOW” switch signal inspection: Go to Step 7. Faulty “4WD LOW” (1) With ignition switch ON, check voltage switch or its circuit. between C51-1-26 (G16/J20 engines) or If OK, substitute a known- C51-1-5 (H25 engine) terminal of PCM good PCM and recheck.
Page 435: Diagnostic Flow Table A-2
AUTOMATIC TRANSMISSION (4 A / T) 7B1-33 DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O/D) SYSTEM DESCRIPTION PCM does not shift to O/D gear under any of the following conditions. D O/D cut switch: ON D 4WD LOW switch: ON D Cruise control module: O/D OFF command signal is output (if equipped).
Page 436 7B1-34 AUTOMATIC TRANSMISSION (4 A / T) STEP ACTION 4WD LOW switch signal inspection: Go to Step 6. Faulty 4WD LOW switch (1) With ignition switch ON, check voltage or its circuit. between C51-1-26 (G16/J20 engines) or If OK, substitute a known- C51-1-5 (H25 engine) terminal of PCM good PCM and recheck.
Page 437 AUTOMATIC TRANSMISSION (4 A / T) 7B1-35 DIAGNOSTIC FLOW TABLE B-1 “O/D OFF” LIGHT CIRCUIT CHECK (“O /D OFF” LIGHT DOESN’T LIGHT AT IGNITION SWITCH ON BUT ENGINE STARTS UP) WIRING DIAGRAM G16 / J20 Engines 1. PCM 2. J / B 3.
Page 438 7B1-36 AUTOMATIC TRANSMISSION (4 A / T) DIAGNOSTIC FLOW TABLE B-2 “O/D OFF” LIGHT CIRCUIT CHECK (“O/D OFF” LIGHT COMES ON STEADILY) WIRING DIAGRAM – Refer to Table B-1 in this section. TROUBLESHOOTING STEP ACTION Check O/D cut Switch Position. Go to Step 2.
Page 439 AUTOMATIC TRANSMISSION (4 A / T) 7B1-37 DIAGNOSTIC FLOW TABLE B-3 “POWER” LIGHT CIRCUIT CHECK (“POWER” LIGHT DOESN’T LIGHT AT IGNITION SWITCH ON BUT ENGINE STARTS UP) WIRING DIAGRAM G16 / J20 Engines 1. PCM 2. J / B 3. O / D cut switch 4.
Page 440 7B1-38 AUTOMATIC TRANSMISSION (4 A / T) DIAGNOSTIC FLOW TABLE B-4 “POWER” LIGHT CIRCUIT CHECK (“POWER” LIGHT COMES ON STEADILY) WIRING DIAGRAM – Refer to Table B-3 in this section. TROUBLESHOOTING STEP ACTION Check Power/Normal Change Switch Position. Go to Step 2. Set Power/Normal Is switch button at Normal position? change switch at...
Page 441 AUTOMATIC TRANSMISSION (4 A / T) 7B1-39 DTC P0705 (DTC NO.72) TRANSMISSION RANGE SENSOR (SWITCH) CIRCUIT MALFUNCTION WIRING DIAGRAM G16 / J20 Engines 1. PCM 2. J / B 3. Transmission range sensor (switch) H25 Engine 1. PCM 2. Fuse 3.
Page 442 7B1-40 AUTOMATIC TRANSMISSION (4 A / T) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Transmission range switch signal (P, R, N, D, 2 or L) D Transmission range sensor (switch) maladjusted. D Transmission range sensor (switch) or its circuit mal- is not inputted for 25 sec.
Page 443: Check
Go to Step 3. Operation. Check for intermittent When using SUZUKI scan tool: referring to “Intermit- 1) Connect SUZUKI scan tool to DLC with ignition tent and Poor switch OFF. Connection” in 2) Turn ignition switch ON and check transmission section 0A.
Page 444 7B1-42 AUTOMATIC TRANSMISSION (4 A / T) DTC P0715 (DTC NO.76) INPUT/TURBINE SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM G16/J20 Engines H25 Engine Bl / Y Bl / G Bl / Y Bl / G G16/J20 Engines 1. PCM 2. A / T input speed sensor H25 Engine DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION...
Page 445 AUTOMATIC TRANSMISSION (4 A / T) 7B1-43 TROUBLESHOOTING (DTC P0715) STEP ACTION Was “A/T DIAG. FLOW TABLE” performed? Go to Step 2. Go to “A/T DIAG. FLOW TABLE”. Input speed sensor circuit check: Go to Step 4. Go to Step 3. 1) Remove PCM cover.
Page 446 7B1-44 AUTOMATIC TRANSMISSION (4 A / T) DTC P0720 (DTC NO.75) OUTPUT SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM G16/J20 Engines H25 Engine G16/J20 Engines 1. PCM 2. A / T output speed sensor H25 Engine DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D With 4WD LOW switch OFF, no output speed sensor...
Page 447 AUTOMATIC TRANSMISSION (4 A / T) 7B1-45 TROUBLESHOOTING (DTC P0720) STEP ACTION Was “A/T DIAG. FLOW TABLE” performed? Go to Step 2. Go to “A/T DIAG. FLOW TABLE”. Output speed sensor circuit check: Go to Step 4. Go to Step 3. 1) Remove PCM cover.
Page 448 7B1-46 AUTOMATIC TRANSMISSION (4 A / T) DTC P0741 TCC (LOCK-UP) SOLENOID VALVE PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D TCC (lock-up) solenoid valve stuck While running in 2nd or 4th gear, D range, TCC control D TCC control valve stuck of PCM does not agree with actual operation of trans- D Valve body fluid passage clogged...
Page 449 AUTOMATIC TRANSMISSION (4 A / T) 7B1-47 DTC P0743 (DTC NO.65/66) TCC (LOCK-UP) SOLENOID ELECTRICAL WIRING DIAGRAM G16/J20 Engines H25 Engine 1. PCM 2. Shift solenoid-A 3. Shift solenoid-B 4. TCC solenoid G16/J20 Engines H25 Engine DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D TCC (lock-up) solenoid valve...
Page 450 7B1-48 AUTOMATIC TRANSMISSION (4 A / T) TROUBLESHOOTING STEP ACTION Was “A/T DIAG. FLOW TABLE” performed? Go to Step 2. Go to “A/T DIAG. FLOW TABLE”. Is the vehicle equipped with monitor connector? Go to Step 3. Go to Step 4. Is DTC NO.65? G to Step 4.
Page 451: Dtc P0751 Shift Solenoid Valve-A (#1)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-49 DTC P0751 SHIFT SOLENOID VALVE-A (#1) PERFORMANCE OR STUCK OFF DTC P0756 SHIFT SOLENOID VALVE-B (#2) PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA While running in D range, gear change control from DTC P0751: D Shift solenoid valve-A stuck or leakage.
Page 452 7B1-50 AUTOMATIC TRANSMISSION (4 A / T) DTC P0753 (DTC NO.61/62) SHIFT SOLENOID-A (#1) ELECTRICAL DTC P0758 (DTC NO.63/64) SHIFT SOLENOID-B (#2) ELECTRICAL WIRING DIAGRAM G16/J20 Engines H25 Engine 1. PCM 2. Shift solenoid-A 3. Shift solenoid-B 4. TCC solenoid G16/J20 Engines H25 Engine DTC DETECTING CONDITION AND TROUBLE AREA...
Page 453 AUTOMATIC TRANSMISSION (4 A / T) 7B1-51 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 454: Dtc P1875 4Wd Low Switch Circuit Malfunction
7B1-52 AUTOMATIC TRANSMISSION (4 A / T) DTC P1875 4WD LOW SWITCH CIRCUIT MALFUNCTION (if equipped) WIRING DIAGRAM G16 / J20 Engines 1. PCM H25 Engine 2. 4WD low switch 3. J / C DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D 4WD LOW switch or its circuit...
Page 455 Check for poor con- Go to Step 3. When using SUZUKI scan tool: nection at the termi- 1) Connect SUZUKI scan tool to DLC with ignition nal of PCM if voltme- switch OFF. ter is used in Step 2. 2) Turn ignition switch ON.
Page 456: Line Pressure Test
7B1-54 AUTOMATIC TRANSMISSION (4 A / T) LINE PRESSURE TEST Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions. D Automatic fluid is at normal operating temperature (70 to 80_C / 158 –...
Page 457: Stall Test
AUTOMATIC TRANSMISSION (4 A / T) 7B1-55 Check result Possible cause D Malfunctioning regulator valve Line pressure higher D Malfunctioning throttle valve than standard level in D Maladjusted A / T throttle cable each range D Defective O/D clutch Line pressure lower than D Defective oil pump standard level in each D Malfunctioning throttle valve...
Page 458: Road Test
7B1-56 AUTOMATIC TRANSMISSION (4 A / T) 8) Stall speed should be within the following specification. Stall speed: 2,100 – 2,400 r/min. for G16 engine 2,300 – 2,600 r/min. for J20 engine 2,300 – 2,600 r/min. for H25 engine Check result Possible cause D Faulty engine output Lower than standard...
Page 459: Manual Road Test
AUTOMATIC TRANSMISSION (4 A / T) 7B1-57 MANUAL ROAD TEST This test check the gear being used in “L”, “2” or “D” range when driven with unoperated gear shift control system. Test drive vehicle on a level road. NOTE: Before this test, check diagnostic trouble code (DTC). 1) Disconnect coupler of shift solenoid valves on transmission.
Page 460: Engine Brake Test
7B1-58 AUTOMATIC TRANSMISSION (4 A / T) ENGINE BRAKE TEST 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”...
Page 461: On-Vehicle Service
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59 ON-VEHICLE SERVICE MAINTENANCE SERVICE FLUID LEVEL LEVEL CHECK AT NORMAL OPERATING TEMPERATURE 1) Stop vehicle and place it level. 2) Apply parking brake and place chocks against wheels. 3) With selector at P position, start engine. 4) Warm up engine till fluid temperature reaches normal operating temperature (70 –...
Page 462: Fluid Change
7B1-60 AUTOMATIC TRANSMISSION (4 A / T) LEVEL CHECK AT ROOM TEMPERATURE The fluid level check at room temperature performed after repair or fluid change before test driving is just preparation for level check of normal operating temperature. The checking procedure itself is the same as that described previously.
Page 463: Oil Cooler Hoses
AUTOMATIC TRANSMISSION (4 A / T) 7B1-61 OIL COOLER HOSES When replacing them, be sure to note the followings. D to replace clamps at the same time. D to insert hose as far as its limit mark. D to clamp hose securely. 1.
Page 464: Manual Selector Assembly
7B1-62 AUTOMATIC TRANSMISSION (4 A / T) MANUAL SELECTOR ASSEMBLY Type-1 Type-2 1. Manual lever Tightening Torque assembly (a): 18 N m (1.8 kg-m, 13.5 lb-ft) 2. Select indicator assembly 1. Manual selector assembly 7. Spring 3. Illumination lamp (Select lever assembly) 8.
Page 465: Select Cable
AUTOMATIC TRANSMISSION (4 A / T) 7B1-63 INSPECTION Check select lever for smooth and clear-cut movement and position indicator for correct indication. For operation of select lever, refer to left figure. SELECT CABLE 1. Select lever assembly 2. Bolt 3. Select cable 4.
Page 466: Transmission Range Switch
7B1-64 AUTOMATIC TRANSMISSION (4 A / T) TRANSMISSION RANGE SWITCH (SENSOR) INSPECTION & ADJUSTMENT 1) Shift select lever to “N” range. 2) Check that center line on manual valve shaft and “N” reference line on switch are aligned. If not, loosen switch bolt and align them.
Page 467 AUTOMATIC TRANSMISSION (4 A / T) 7B1-65 H25 Engine Terminal Arrangement of PCM Coupler (Viewed from harness side) Shift solenoid valve – A (#1) C51-1-6 Shift solenoid valve – B (#2) C51-1-1 TCC (Lock-up) solenoid valve C51-1-2 REMOVAL 1) Pull out dipstick and lift up vehicle. 2) With engine cooled, remove drain plug from oil pan and drain A/T fluid.
Page 468: Throttle Position Sensor
7B1-66 AUTOMATIC TRANSMISSION (4 A / T) INSTALLATION Reverse removal procedure to install solenoid valves and noting the following points. D For details of solenoid valve installation, refer to “Unit Repair” section. Use new gasket and O-ring. D Install oil tubes in such order as shown in figure. D For details of oil pan installation, refer to “Unit Repair”...
Page 469: Oil Cooler Pipes
AUTOMATIC TRANSMISSION (4 A / T) 7B1-67 OIL COOLER PIPES REMOVAL 1) Lift up vehicle. 2) Make sure to wash dirt off from around pipe joints. 3) With engine is cool, loosen oil cooler pipe union bolts with oil out- let union locked and remove oil cooler pipes from oil outlet unions and hoses.
Page 470: Brake Interlock System
7B1-68 AUTOMATIC TRANSMISSION (4 A / T) BRAKE INTERLOCK SYSTEM SHIFT LOCK SOLENOID CONTROL This system consists of shift lock solenoid control system and inter- lock cable control system. The shift lock solenoid control system is so designed that the selec- tor lever can not be shifted from “P”...
Page 471: Shift Lock (Solenoid) Manual Release
AUTOMATIC TRANSMISSION (4 A / T) 7B1-69 Type-2 1. Select lever 4. Lock plate 2. Detent pin 5. Shift lock solenoid 3. Detent plate SHIFT LOCK (SOLENOID) MANUAL RELEASE 1. Cover 3. Select lever 2. Screw 4. Button Shift lock can be manually released by following procedure. 1) Remove access hole cover by unfastening screw.
Page 472 7B1-70 AUTOMATIC TRANSMISSION (4 A / T) D With shift lock solenoid rod (or manual release plate) moved 1. Cover 4. Select lever in arrow direction and ignition key turned to “ACC” position, se- 2. Screw 5. Button 3. Shift lock solenoid rod lect lever can be shifted from “P”...
Page 473: Key Interlock Cable
AUTOMATIC TRANSMISSION (4 A / T) 7B1-71 KEY INTERLOCK CABLE NOTE: Don’t bend interlock cable excessively when removing and installing it, or system will not operate correctly. Removal 1) Disconnect negative (–) cable from battery. 2) If equipped with air bag system, disable air bag system. Refer to “Disabling Air bag System”...
Page 474 7B1-72 AUTOMATIC TRANSMISSION (4 A / T) Installation 1) Shift select lever to “N” range and turn ignition key to “ACC” position. 2) Connect inner end of interlock cable to key interlock lever (Igni- tion switch side). 3) Install outer end bracket of interlock cable to ignition switch as- sembly, and tighten screw to specified torque.
Page 475 AUTOMATIC TRANSMISSION (4 A / T) 7B1-73 TYPE-2 Type-2 5) With key release cam set as shown at the left figure, connect inner end of interlock cable to key release cam. (Select lever side.) 1. Inner end of interlock cable 2.
Page 476: Dismounting Of Transmission (With Transfer If Equipped)
7B1-74 AUTOMATIC TRANSMISSION (4 A / T) DISMOUNTING OF TRANSMISSION (WITH TRANSFER IF EQUIPPED) IN CABIN 1) Remove console box. NOTE: To remove clip, push in its center pin first. 2) Remove boot cover and boot No.2. (if equipped) 1. Boot No.2 2.
Page 477 AUTOMATIC TRANSMISSION (4 A / T) 7B1-75 ON LIFT 1) Drain transfer oil for 4WD vehicle or A/T fluid for 2WD vehicle. NOTE: If 4WD automatic transmission is overhauled later on, draining A/T fluid at this point will facilitate work. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft)
Page 478 7B1-76 AUTOMATIC TRANSMISSION (4 A / T) 12) Remove engine to transmission nuts. 13) Disconnect connectors from VSS, output speed sensor, input speed sensor, TR switch, shift & TCC solenoid valves and oth- er electrical parts, and release their wire harness from clamps. 14) Apply transmission jack and take off rear mounting member by removing its bolts.
Page 479: Remounting
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77 REMOUNTING WARNING: When moving transmission assembly with torque convert- er equipped in it, be sure to keep it horizontal. Tilting it with its front facing down may allow converter to fall off. Where- by an injury may result.
Page 480: Unit Repair
7B1-78 AUTOMATIC TRANSMISSION (4 A / T) UNIT REPAIR Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual. TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening portion Fastening portion N·m kg-m lb-ft Automatic transmission fluid drain plug 17.0 Transfer oil filler / level and drain plugs 17.0...
Page 481: Required Service Materials
(OBD-II adapter) cable Mass storage cartridge 1. Storage case 2. Operator’s manual 3. Tech 1A 4. DLC cable 5. Test lead / probe 6. Power source cable 7. DLC cable adapter 8. Self–test adapter 09931-76011 SUZUKI scan tool (Tech 1A) kit...
Page 482 CLUTCH 7C1-1 SECTION 7C1 CLUTCH CONTENTS GENERAL DESCRIPTION ... . . 7C1- 2 Clutch Operating Cylinder ... . 7C1- 8 DIAGNOSIS .
Page 483: General Description
7C1-2 CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm-spring clutch of a dry single Depressing the clutch pedal causes the release bear- disc type. The diaphragm spring is of a tapering-finger ing to advance and pushes on the tips of the tapered type, which is a solid ring in the outer diameter part, fingers of the diaphragm spring.
Page 484: Diagnosis
CLUTCH 7C1-3 DIAGNOSIS Condition Possible Cause Correction D Improper clutch pedal free travel. Slipping Bleed air or replace master cylinder. D Worn or oily clutch disc facing. Replace disc. D Warped disc, pressure plate or flywheel Replace disc, clutch cover or surface.
Page 485: On-Vehicle Service
7C1-4 CLUTCH ON-VEHICLE SERVICE CLUTCH PEDAL HEIGHT Adjust clutch pedal height by loosening clevis lock nut and turning push rod as shown. Clutch pedal height is normal if clutch pedal is about 2, (a) 20 mm (0.79 in.) higher than brake pedal. After adjusting, tighten lock nut to specified torque.
Page 486: Clutch Master Cylinder
CLUTCH 7C1-5 INSPECTION Check pipe and hose for dent, kink, crack, dirt and dust. Replace if check result is not satisfactory. 1. Pipe 2. Hose 3. Flare nut INSTALLATION Reverse removal sequence noting following points. Tighten flare nuts to specified torque. Tightening Torque (a): 16 N m (1.6 kg-m, 11.5 lb-ft)
Page 487: Fluid Inspection
7C1-6 CLUTCH INSTALLATION 1) To bleed air from master cylinder itself, tilt it as shown in figure and add fluid into it. NOTE: After bleeding air from master cylinder, plug pipe hole in it to prevent fluid from spilling out of it till pipe is connected. 2) Install master cylinder assembly and new gasket to body, attach- ing bolt, nuts and push rod clevis pin.
Page 488: Disassembly And Assembly Clutch Master Cylinder
CLUTCH 7C1-7 DISASSEMBLY AND ASSEMBLY CLUTCH 1. Reservoir cap 2. Cylinder MASTER CYLINDER 3. Piston assembly 4. Push rod 5. Piston stopper 6. Circlip 7. Boot 8. Lock nut 9. Clevis DISASSEMBLY 1) Remove boot and then circlip with piston pushed in. 2) Remove push rod and blow compressed air gradually into hole for pipe connection to remove piston assembly, using care to prevent it from jumping out.
Page 489: Clutch Operating Cylinder
7C1-8 CLUTCH 4) Tighten lock nut to specified torque. 1. Reservoir cap 2. Cylinder 3. Piston assembly Tightening Torque 4. Push rod (a): 10 N m (1.0 kg-m, 7.5 lb-ft) 5. Piston stopper 5) For installation of master cylinder to vehicle, refer to INSTALLA- TION described previously.
Page 490 CLUTCH 7C1-9 5) Fill reservoir with specified brake fluid and check for fluid leak- age. 6) Bleed air from system and check clutch pedal free travel. Refer to BRAKE section for air bleeding procedure.
Page 491: Unit Repair
7C1-10 CLUTCH UNIT REPAIR CLUTCH COVER, CLUTCH DISC AND FLYWHEEL 1. Input shaft bearing 2. Flywheel 3. Clutch disc 4. Clutch cover 5. Bolt 6. Release bearing 7. Clutch release fork 8. Boot 9. Clip 10. Clutch release fork support DISMOUNTING/REMOUNTING Refer to SECTION 7A “Dismounting/Remounting of Trans Unit”.
Page 492 CLUTCH 7C1-11 INSPECTION Input Shaft Bearing and Release Bearing Check bearing for smooth rotation and replace it if abnormality is found. Clutch Disc Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 493 7C1-12 CLUTCH INSTALLATION NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly. 1) Install flywheel to crankshaft and tighten bolts to which sealant is applied to specification. Special Tool (A): 09924-17810 “A”: Sealant 99000-31110 “A”, (a) Tightening Torque...
Page 494 CLUTCH 7C1-13 4) Install clip to release fork and apply grease. “A”: Grease 99000-25010 Then install release fork and release bearing as shown in figure. 5) Slightly apply grease to input shaft and install clutch disc. Then “B” join transmission transfer assembly with engine. Refer to SEC- TION 7A.
Page 495: Tightening Torque Specifications
16.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Clutch master cylinder clevis pin. SUZUKI SUPER GREASE A D Release fork. (99000-25010) D Push rod tip of operating cylinder. Lithium grease SUZUKI SUPER GREASE I Input shaft spline front end.
Page 496 TRANSFER 7D-1 SECTION 7D TRANSFER CONTENTS GENERAL DESCRIPTION ..............7D-1 DIAGNOSIS .
Page 497 7D-2 TRANSFER DIAGNOSIS DIAGNOSIS TABLE Before attempting to repair the transfer or related components for any reason other than mechanical failure, the condition and probable causes should be identified. Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding. When any of these conditions occur, the following inspections should be made before disassembling the transfer.
Page 498 TRANSFER 7D-3 ON-VEHICLE SERVICE GEAR OIL Refer to “ON-VEHICLE SERVICE” of Section 7A or 7A1. TRANSFER OIL SEALS REAR CASE OIL SEAL 1) Lift up vehicle horizontally. 2) Give match marks on joint flange and propeller shaft as shown in figure. 3) Remove 4 bolts from rear propeller shaft flange and remove pro- peller shaft.
Page 499 7D-4 TRANSFER SPEEDOMETER DRIVEN GEAR REMOVAL 1) Lift up vehicle horizontally or rear up. 2) Disconnect speed sensor coupler at transfer case. 3) Remove bolt and take off speed sensor from transfer. INSTALLATION 1) Make sure that O-ring and speed sensor have not been dam- aged.
Page 500: Transfer Assembly
TRANSFER 7D-5 TRANSFER ASSEMBLY Dismounting and remounting of transfer and transmission together as a unit is described in Section 7A for Manual Transmission or 7B1 for Automatic Transmission, but it is also possible to dismount and remount transfer assembly by itself as described below. DISMOUNTING IN ENGINE ROOM 1) Disconnect negative (–) cable from battery.
Page 501 7D-6 TRANSFER IN CABIN Remove gear shift lever case and then remove transfer center case bolt. 1. Bolt 2. Transfer assembly ON LIFT 1) Remove transfer mounting (engine rear mounting) by removing bolts. 1. Bolt 3. Transfer assembly 2. Engine rear mounting 2) Apply transmission jack to transfer to support it.
Page 502 Speed sensor bolt REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Oil seal lips and O-rings. D Splines of propeller shaft. SUZUKI SUPER GREASE A Lithium grease D Select return system. (99000-25010) D Shift control lever. SPECIAL TOOL 09940-53111 Bearing installer...
Page 503 DIFFERENTIAL (FRONT) 7E-1 SECTION 7E DIFFERENTIAL (FRONT) CONTENTS GENERAL DESCRIPTION ..............7E- 1 4WD CONTROL SYSTEM .
Page 504 7E-2 DIFFERENTIAL (FRONT) 4WD CONTROL SYSTEM When the 4WD switch is turned ON by shifting the transfer shift lever, ECM (PCM) (G16 and J20 engine models) or 4WD controller (H25 engine model) actuates (energizes) the air pump assembly. Then positive pressure is sent from the air pump assembly to the actuator installed to the differential case and causes the axle lock clutch and the free axle hub in the differential case to be engaged, resulting in the 4WD mode.
Page 505: Power Supply
DIFFERENTIAL (FRONT) 7E-3 System Circuit and Operation 1. 4WD switch 6. Transfer 2. Air pump assembly 7. Front differential 3. Pump motor 8. Air hose and pipe 4. Release valve 9. 4WD indicator lamp 5. Pressure switch 10. To ignition switch 11.
Page 506 7E-4 DIFFERENTIAL (FRONT) Components and Functions Component Function When the transfer shift lever is shifted to 4L or 4H position, this switch turns ON 4WD switch and causes the 4WD control system to turn ON, unless it is shifted to N or 2H within 1 second.
Page 507 DIFFERENTIAL (FRONT) 7E-5 DIAGNOSIS DIAGNOSIS TABLE Differential Assembly Condition Possible Cause Correction D Deteriorated or water mixed lubricant Gear noise Repair and replenish D Inadequate or insufficient lubricant Repair and replenish D Maladjusted backlash between bevel Adjust pinion and gear D Improper tooth contact in the mesh between Adjust or replace bevel pinion and gear...
Page 508 7E-6 DIFFERENTIAL (FRONT) STEP ACTION Turn ON ignition switch (but engine at stop) and Go to step 2. A trouble has check malfunction indicator lamp. occurred at some Does lamp light up? place. Repair it referring to MALFUNCTION INDICATOR LAMP (“CHECK ENGINE”...
Page 509 DIFFERENTIAL (FRONT) 7E-7 4WD CONTROL CIRCUIT INSPECTION Voltage Check [G16 and J20 engine models] Check for input or output voltage (voltage between each circuit and body ground) of ECM (PCM) with ECM (PCM) connector con- nected and ignition switch turned ON. NORMAL TER- WIRE...
Page 510 7E-8 DIFFERENTIAL (FRONT) Voltage Check [H25 engine model] NORMAL TER- WIRE CIRCUIT CONDITION MINAL COLOR VOLTAGE 10 – 14 V Transfer shift lever: 2H or N C51 1 C51-1 4WD Indicator lamp Or/B 4 seconds after transfer shift lever shifted 0 –...
Page 511 DIFFERENTIAL (FRONT) 7E-9 ON-VEHICLE SERVICE MAINTENANCE SERVICE NOTE: D When having driven through water, check immediately if wa- ter has entered (if so, oil is cloudy). Water mixed oil must be changed at once. D Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breather hoses.
Page 512 7E-10 DIFFERENTIAL (FRONT) INSPECTION 4WD Control System 1) Install special tool to air hose connecting between air pump as- sembly and differential (actuator) as shown in figure. Tighten ad- justing screw of special tool as far as it stops. Close air check side opening by using fuel hose as blind plug.
Page 513 DIFFERENTIAL (FRONT) 7E-11 Actuator 1) Disconnect air hose from pump assembly and install special tool to air hose as shown in figure. Loosen adjusting screw of special tool. Special Tool (A): 09918-18110 2) Connect compressor air hose to special tool. Blow air and turn adjusting screw to obtain specified pressure.
Page 514 7E-12 DIFFERENTIAL (FRONT) Air Pump Assembly Removal/Installation 1) Disconnect air hoses and coupler from air pump assembly. 2) Remove pump assembly by removing bolts. 3) Reverse removal procedure for installation. Tightening Torque (a): 13 N m (1.3 kg-m, 9.5 lb-ft) Inspection 1) Install special tool, voltmeter and battery to pump assembly as shown in figure.
Page 515: Removal And Installation
DIFFERENTIAL (FRONT) 7E-13 REMOVAL AND INSTALLATION Differential Mountings 1) Lift up vehicle and turn steering wheel all way to the right. 2) Separate mounting bracket R from differential housing by re- moving bolts from its lower part. 3) Remove mounting bracket R by removing mounting front bolt from its upper part.
Page 516 7E-14 DIFFERENTIAL (FRONT) 7) Position each bush to bracket as shown. Length “a”: 3.0 mm (0.12 in.) 1. Mounting bracket R 2. Mounting bracket L 8) Use following torque for reinstallation. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) (b): 50 N m (5.0 kg-m, 36.5 lb-ft) REAR MOUNTING...
Page 517 DIFFERENTIAL (FRONT) 7E-15 DISMOUNTING 1) Lift up vehicle and drain oil. 2) Disconnect air hose and breather hose from differential housing. 3) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown. 4) Remove propeller shaft flange by removing its 4 bolts and sus- pend it with cord or the like.
Page 518 7E-16 DIFFERENTIAL (FRONT) 8) Using 2 large screwdrivers as levers, pull out right side drive shaft joint from differential and dismount housing assembly from vehicle. CAUTION: During above work, use care not to cause damage to drive shaft boot. 1. Drive shaft joint R 3.
Page 519 Front drive shaft flange bolts 36.5 Propeller shaft flange bolts 36.5 Pump assembly bolts REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI BOND NO. 1215 Sealant Front differential drain plug (99000-31110) SPECIAL TOOLS 09918-18110 Air pressure regulator 09951-16080 09951-26010 09367-04002...
Page 520 DIFFERENTIAL (REAR) 7F-1 SECTION 7F DIFFERENTIAL (REAR) CONTENTS GENERAL DESCRIPTION ..............7F-1 DIAGNOSIS .
Page 521 7F-2 DIFFERENTIAL (REAR) DIAGNOSIS Condition Possible Cause Correction D Deteriorated or water mixed lubricant Gear noise Repair and replenish D Inadequate or insufficient lubricant Repair and replenish D Maladjusted backlash between bevel Adjust as prescribed pinion and gear D Improper tooth contact in the mesh between Adjust or replace bevel pinion and gear D Loose bevel gear securing bolts...
Page 522 DIFFERENTIAL (REAR) 7F-3 ON-VEHICLE SERVICE MAINTENANCE SERVICE NOTE: D When having driven through water, check immediately if wa- ter has entered (if so, oil is cloudy). Water mixed oil must be changed at once. D Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breather hoses.
Page 523 7F-4 DIFFERENTIAL (REAR) DISMOUNTING 1) Lift up vehicle and drain oil from rear differential housing. 2) Remove rear brake drums and pull out right and left rear axle shafts. (Refer to rear axle shaft removal of SECTION 3E.) 3) Before removing propeller shaft, give match marks on joint flange and propeller shaft as shown.
Page 524 DIFFERENTIAL (REAR) 7F-5 REMOUNTING 1) Clean mating surfaces of rear axle and differential assembly and apply sealant (Suzuki bond 1215) to axle side evenly. “A”: Sealant 99000-31110 2) Install differential assembly to axle and fix it with nuts tightened to specified torque.
Page 525 Propeller shaft flange bolts 36.5 Differential carrier nuts 40.0 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Rear differential oil drain plug D Mating surface of differential SUZUKI BOND NO. 1215 Sealant (99000-31110) housing D Mating surface of rear axle housing...
Page 526: Body Electrical System
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 527 8-2 BODY ELECTRICAL SYSTEM GENERAL DESCRIPTION The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery. The electrical system utilizes negative ground polarity. CAUTIONS IN SERVICING When performing works related to electric systems, observe follow- ing cautions for the purpose of protection of electrical parts and pre- vention of a fire from occurrence.
Page 528 BODY ELECTRICAL SYSTEM 8-3 D When installing the wiring harness, fix it with clamps so that no slack is left. D When installing vehicle parts, be careful so that the wiring har- ness is not interfered with or caught by any other part. D To avoid damage to the harness, protect its part which may con- tact against a part forming a sharp angle by winding tape or the like around it.
Page 529 8-4 BODY ELECTRICAL SYSTEM D When performing a work that produces a heat exceeding 80_C in the vicinity of the electrical parts, remove the heat sensitive electrical part(s) beforehand. D Use care not to expose connectors and electrical parts to water which will be a cause of a trouble.
Page 530 BODY ELECTRICAL SYSTEM 8-5 WIRE COLOR SYMBOLS The wire color is abbreviated to the first (or first two) alphabet(s) of each color. There are two kinds of colored wire used in this vehicle. One is G (Base Color) single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e.
Page 531 8-6 BODY ELECTRICAL SYSTEM POWER SUPPLY DIAGRAM Refer to Section 8A.
Page 532: Lighting System
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 533: Cautions In Servicing
8B-2 LIGHTING SYSTEM GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8. WIRING COLOR SYMBOLS Refer to Section 8. ABBREVIATIONS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8.
Page 534: Headlight With Leveling System (If Equipped)
LIGHTING SYSTEM 8B-3 HEADLIGHT WITH LEVELING SYSTEM (IF EQUIPPED) 1. Headlight leveling switch 2. Headlight leveling unit (actuator) 3. Headlight 4. Headlight leveling unit shaft Switch Headlight beam Position down angle ——— 0.624_ 1.243_ 1.867_ 2.479_...
Page 535: Diagnosis
8B-4 LIGHTING SYSTEM DIAGNOSIS NOTE: Fuse name (“ ”) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box (Canvas Top Model). HEADLIGHTS Trouble Possible cause Correction D Bulb blown Only one light does not Replace bulb D Headlight L or R fuse blown light...
Page 536: Back-Up Lights
LIGHTING SYSTEM 8B-5 CLEARANCE, TAIL AND LICENCE PLATE LIGHTS Trouble Possible cause Correction D “TAIL” fuse blown All lights do not light Replace fuse to check for short D Lighting switch faulty Replace switch D Wiring or grounding faulty Repair D Bulb(s) blown Some lights do not light Replace bulb(s)
Page 537: On-Vehicle Service
8B-6 LIGHTING SYSTEM ON-VEHICLE SERVICE HEADLIGHTS HEADLIGHT SWITCH (IN COMBINATION SWITCH) INSPECTION HEAD 1) Disconnect negative cable at battery. SMALL 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below. If check result is not as specified, replace switch. PASS Lighting Switch Terminal...
Page 538: Bulb Replacement
LIGHTING SYSTEM 8B-7 BULB REPLACEMENT WARNING: Don’t touch when the bulb is hot. 1) Disconnect negative cable at battery. 2) Disconnect harness from bulb. 3) Remove socket cover and bulb. 4) Replace bulb and install in reverse removal procedure. HEADLIGHT AIMING WITH SCREEN NOTE: D Unless otherwise obligated by local regulations, adjust headlight aiming according to following procedure.
Page 539: Headlights With Leveling System (If Equipped)
8B-8 LIGHTING SYSTEM HEADLIGHTS WITH LEVELING SYSTEM (IF EQUIPPED) LEVELING SWITCH INSPECTION To check the switch operation, substitute it with a new one. If proper operation is obtained, it means the switch is defective. Replace it with a new one. LEVELING ACTUATOR INSPECTION All headlight system couples connected including leveling actuator...
Page 540: Turn Signal And Hazard Warning Lights
LIGHTING SYSTEM 8B-9 TURN SIGNAL AND HAZARD WARNING LH steering vehicle shown LIGHTS TURN SIGNAL SWITCH (IN COMBINATION SWITCH) INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below.
Page 541 8B-10 LIGHTING SYSTEM HAZARD RELAY INSPECTION Connect battery and tester as shown. Unless a continued click sound is heard, replace relay. Type A Type B 1. Hazard relay 2. Junction box 3. Fuse box...
Page 542: Rear Fog Light (If Equipped)
LIGHTING SYSTEM 8B-11 REAR FOG LIGHT (IF EQUIPPED) REAR FOG LIGHT SWITCH INSPECTION Check for continuity between terminals at each switch position shown below. Hold the switch button (ON or OFF) pushed in during checking switch. NOTE: Rear fog light lights up only when headlights (low or high beams) or front fog lights (if equipped) are ON.
Page 543 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 544: Cautions In Servicing
8C-2 INSTRUMENTATION / DRIVER INFORMATION GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8. WIRING COLOR SYMBOLS Refer to Section 8. ABBREVIATIONS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8.
Page 545 INSTRUMENTATION / DRIVER INFORMATION 8C-3 if equipped or CHECK ENGINE or ABS if equipped if equipped NOTE: Terminal arrangement of coupler viewed from harness side. Coupler A Coupler B Coupler C Coupler A Coupler B Coupler C 1. Blank —— 1.
Page 546: Diagnosis
8C-4 INSTRUMENTATION / DRIVER INFORMATION DIAGNOSIS NOTE: Fuse name (“ ”) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box (Canvas Top Model). SPEEDOMETER AND VSS Trouble Possible Cause Correction D “IG/METER” fuse blown (Hard Top Speedometer shows no Replace fuse to check for short operation...
Page 547 INSTRUMENTATION / DRIVER INFORMATION 8C-5 BRAKE AND PARKING BRAKE WARNING LIGHT Trouble Possible Cause Correction D Bulb in combination meter blown Brake warning light does Replace bulb D “IG/METER” fuse blown (Hard Top not light up Replace fuse to check for short Model) “IG”...
Page 548 8C-6 INSTRUMENTATION / DRIVER INFORMATION ON-VEHICLE SERVICE IGNITION (MAIN) SWITCH INSPECTION 1) Disconnect negative cable at battery. 2) Disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B of this manual. 3) Disconnect main switch lead wire coupler. 4) Check for continuity between terminals at each switch position shown below.
Page 549 INSTRUMENTATION / DRIVER INFORMATION 8C-7 COMBINATION METER REMOVAL 1) Disconnect negative cable at battery. 2) If the vehicle is equipped with air bag system, disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B of this manual. 3) Remove column hole cover.
Page 550 8C-8 INSTRUMENTATION / DRIVER INFORMATION SPEEDOMETER AND VSS VEHICLE SPEED SENSOR (VSS) REMOVAL 1) Hoist vehicle. 2) Disconnect coupler from VSS (1). 3) Remove VSS. INSTALLATION Reverse removal procedure for installation. Tightening Torque (a): 5.5 N m (0.55 kg-m, 4.0 lb-ft)
Page 551 INSTRUMENTATION / DRIVER INFORMATION 8C-9 FUEL METER/FUEL GAUGE UNIT FUEL METER INSPECTION 1) Remove rear bumper facing. 2) Detach grommet (3) from vehicle. 3) Disconnect coupler (2) of fuel pump and gauge. 4) Turning switch ON, and check that fuel meter indicates E. 5) Turn ignition switch OFF.
Page 552: Engine Coolant Temp. (Ect) Meter And Sensor
8C-10 INSTRUMENTATION / DRIVER INFORMATION ENGINE COOLANT TEMP. (ECT) METER AND SENSOR ENGINE COOLANT TEMPERATURE (ECT) METER INSPECTION 1) Disconnect Y/W lead wire going to ECT sensor. 2) Turn ignition switch ON, and check that ECT meter indicates COOL. 3) Turn ignition switch OFF. 4) Ground Y/W lead wire through a 3.4 W test bulb (1) as illustrated.
Page 553 INSTRUMENTATION / DRIVER INFORMATION 8C-11 INSPECTION 1) Warm up ECT sensor (1) observing resistance between sensor terminal (2) and sensor unit (1). Resistance should be de- creased with increase of its temperature. 2) Check resistance between sensor terminal (2) and sensor unit (1) shown below.
Page 554: Brake And Parking Brake Warning
8C-12 INSTRUMENTATION / DRIVER INFORMATION BRAKE AND PARKING BRAKE WARNING LIGHT BRAKE FLUID LEVEL SWITCH INSPECTION Check switch (1) for continuity. If check result is not as specified, replace switch (reservoir). OFF position (float up) No continuity ON position (float down) Continuity PARKING BRAKE SWITCH INSPECTION...
Page 555: Door Switch
INSTRUMENTATION / DRIVER INFORMATION 8C-13 DOOR SWITCH INSPECTION Remove door switch (1) from body and check switch for continuity. If found defective, replace switch. OFF position No continuity (Door closed) ON position Continuity (Door open) SEAT BELT WARNING LIGHT (IF EQUIPPED) SEAT BELT BUCKLE SWITCH buckle out INSPECTION...
Page 556 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 557: General Description
8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS GENERAL DESCRIPTION CAUTIONS IN SERVICING Refer to Section 8. SYMBOLS AND MARKS Refer to Section 8. WIRING COLOR SYMBOLS Refer to Section 8. ABBREVIATIONS Refer to Section 8. JOINT CONNECTOR Refer to Section 8. FUSE BOX AND RELAY Refer to Section 8.
Page 558 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3 REAR WIPER AND WASHER (IF EQUIPPED) Rear Wiper Assembly Rear Wiper Switch Rear Wiper Intermittent Relay...
Page 559: Power Door Lock And Keyless Entry (If Equipped) System
8D-4 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR LOCK AND KEYLESS ENTRY (IF EQUIPPED) SYSTEM Power Door Lock and Keyless Entry (if equipped) Keyless Entry Transmitter Controller (Hard Top Model) (If keyless entry is equipped) The illustration shows LH steering vehicle. And RH steering vehicle is symmetrical.
Page 560: Diagnosis 8D
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-5 DIAGNOSIS NOTE: Fuse name (“ ”) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box (Canvas Top Model). WINDSHIELD WIPER AND WASHER FRONT WIPER AND WASHER REAR WIPER AND WASHER (IF EQUIPPED) Trouble Possible cause...
Page 561: Power Door Lock System (If Keyless Entry Is Not Equipped)
8D-6 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT EQUIPPED) Trouble Possible cause Correction D “DOOR LOCK” fuse blown (Hard Top All power doors are not Replace fuse to check for short locked/unlocked by both Model) driver side door key “D/L”...
Page 562: Power Door Lock And Keyless Entry System (If Keyless Entry Is Equipped)
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-7 POWER DOOR LOCK AND KEYLESS ENTRY SYSTEM (IF KEYLESS ENTRY IS EQUIPPED) Trouble Possible cause Correction D All power doors are not D “DOOR LOCK” fuse blown Replace fuse to check for short D Power door lock and keyless entry system locked/unlocked by Refer to SYSTEM INSPECTION both driver side door key...
Page 563: Power Door Mirror Control System
8D-8 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR MIRROR CONTROL SYSTEM Trouble Possible cause Correction D “CIGAR” fuse blown (Hard Top Model) All power mirrors do not Replace fuse to check for short operate “CIG” fuse blown (Canvas Top Model) D Power door mirror switch faulty Replace switch D Wiring or grounding faulty...
Page 564: On-Vehicle Service
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-9 ON-VEHICLE SERVICE WINDSHIELD WIPER AND WASHER FRONT WIPER AND WASHER INSPECTION Front Wiper and Washer Switch (in Combination Switch) 1) Disconnect negative cable at battery. WASHER 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position as shown below.
Page 565 8D-10 WINDOWS, MIRRORS, SECURITY AND LOCKS 2) Testing automatic stop action. Type A a) Connect 12 V battery (+) terminal to terminal “A” of wiper mo- tor (1) and (–) terminal to Black lead wire (2) (Type A, B) or terminal “E”...
Page 566 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-11 Intermittent Wiper Relay Circuit 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Turn the front wiper switch to INT position. 4) Turn the intermittent time control switch to FAST position. 5) Connect battery positive terminal to terminal “B3”...
Page 567 8D-12 WINDOWS, MIRRORS, SECURITY AND LOCKS Washer Linked Operation 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Make sure that front wiper switch is at OFF position. 4) Connect battery positive terminal to terminal “B3” and battery negative terminal to terminal “E”.
Page 568 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-13 REAR WIPER AND WASHER (IF EQUIPPED) INSPECTION Rear Wiper and Washer Switch (in Combination Switch) 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position WASHER as shown below.
Page 569 8D-14 WINDOWS, MIRRORS, SECURITY AND LOCKS 2) TESTING AUTOMATIC STOP ACTION a) First, connect battery (+) terminal to terminal “D” and battery (–) terminal to black lead wire (2) and let the motor (1) turn. b) Then disconnect terminal “D” from battery and let the motor stop.
Page 570 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-15 2) Disconnect positive terminal from terminal “7” checking voltage between terminal “6” and “5” of relay. If measured voltage changes from battery voltage to about 0 V 2.7 to 4.6 seconds after disconnecting positive terminal from ter- minal “7”, relay is in good condition.
Page 571: Rear Window Defogger (If Equipped)
8D-16 WINDOWS, MIRRORS, SECURITY AND LOCKS REAR WINDOW DEFOGGER (IF EQUIPPED) INSPECTION DEFOGGER SWITCH Check for continuity between terminals at each switch position as shown below. If check result is not as specified, replace switch. DEFOGGER WIRE NOTE: D When cleaning rear window glass, use a dry cloth to wipe it along wire direction.
Page 572 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-17 2) Locating damage in wire a. Touch voltmeter positive (+) lead to heat wire positive termi- nal end. b. Touch voltmeter negative (–) lead with a foil strip to heat wire positive terminal end, then move it along wire to the negative terminal end.
Page 573: Power Window Control System
8D-18 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER WINDOW CONTROL SYSTEM Type 1 INSPECTION POWER WINDOW MAIN SWITCH Check switch for continuity between terminals as shown below. Type 1 Driver Side Passenger Side Window Window Window Switch (2) Window Switch (3) Lock Lock Terminal...
Page 574 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-19 Type 2 RH steering vehicle Type 2 RH steering vehicle Driver Passenger Rear RH Rear LH Side Side Window Window Window Window Window Switch (4) Switch (5) Lock Switch (2) Switch (3) Switch (1) Switch (1) Terminal K C E F K C A B K C I J K C G H...
Page 575: Power Door Lock System (If Keyless Entry Is Not Equipped)
8D-20 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR LOCK SYSTEM (IF KEYLESS Type 1 ENTRY IS NOT EQUIPPED) INSPECTION POWER DOOR LOCK SWITCH Check for continuity between terminals at each switch position as shown below. Type 1 Terminal Type 2 Switch LOCK NEUTRAL...
Page 576 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-21 6) Connect negative cable at battery. 7) Check that the voltage and resistance between following termi- nals are specifications. Terminals Condition Specification E02-7 and Anytime 10 – 14 V ground E02-14 and Anytime continuity ground When driver side door key No continuity...
Page 577 8D-22 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR LOCK ACTUATOR Front Door 1) Disconnect power door lock actuator coupler. 2) Connect 12 V battery positive and negative terminals to the door lock actuator terminals shown below and check operation. LOCK If it does not operate as specified in table below, replace door lock actuator.
Page 578: Power Door Lock And Keyless Entry System (If Keyless Entry Is Equipped)
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-23 POWER DOOR LOCK AND KEYLESS ENTRY SYSTEM (IF KEYLESS ENTRY IS EQUIPPED) SYSTEM INSPECTION STEP ACTION Check power door lock operation referring to its Go to Step 2. Go to Step 3. INSPECTION in this section. Is this operation OK? Check keyless entry operation referring to its Go to Step 4.
Page 579 8D-24 WINDOWS, MIRRORS, SECURITY AND LOCKS STEP ACTION Check that hazard warning lights flash with hazard Go to Step 11. Refer to “Turn Signal switch ON. and Hazard Warning Is check result OK? Lights” in DIAGNOSIS and repair. And go to Step 4. Check door knob switch and turn signal relay Replace controller and Repair circuit referring...
Page 580 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-25 POWER DOOR LOCK ACTUATOR CIRCUIT INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect coupler of power door lock and keyless entry con- troller. 3) Use a 12 V battery to connect its (+) terminal to terminal E02-1, and its (–) terminal to terminal E02-2 and E02-3.
Page 581 8D-26 WINDOWS, MIRRORS, SECURITY AND LOCKS IGNITION SWITCH AND DOOR SWITCH CIRCUIT INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect coupler of power door lock and keyless entry con- troller, and connect negative cable at battery. 3) Check that the voltage and resistance between following termi- nals are specifications.
Page 582 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-27 POWER DOOR LOCK SWITCH INSPECTION Refer to POWER DOOR LOCK SWITCH INSPECTION of POWER DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT EQUIPPED) in this section. KEY CYLINDER SWITCH (DRIVER SIDE) INSPECTION Refer to KEY CYLINDER SWITCH (DRIVER SIDE) INSPECTION of POWER DOOR LOCK SYSTEM (IF KEYLESS ENTRY IS NOT EQUIPPED) in this section.
Page 583 8D-28 WINDOWS, MIRRORS, SECURITY AND LOCKS TRANSMITTER REPLACEMENT OF THE BATTERY If the transmitter becomes unreliable, replace the battery. As the battery power is consumed, the operation distance will be shorter. 1) Put the edge of a coin or a flat blade screw driver in the slot (1) of the transmitter and pry it open.
Page 584 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-29 CODE REGISTRATION PROCEDURE 1) Confirm that IG switch is OFF position and all doors are closed. 2) Open driver side door and then turn the IG switch to ON position within 10 seconds. 3) Turn the IG switch to OFF position within 10 seconds after it is turned to ON position.
Page 585: Power Door Mirror Control System
8D-30 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER DOOR MIRROR CONTROL SYSTEM INSPECTION MIRROR SWITCH 1) Remove mirror switch from instrument panel. 2) Check for continuity between terminals at each switch position as shown below. If check result is not as specified, replace mirror switch. DOOR MIRROR ACTUATOR 1) Remove garnish from door.
Page 586: Door Mirror Heater (If Equipped)
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-31 DOOR MIRROR HEATER (IF EQUIPPED) INSPECTION MIRROR HEATER SWITCH 1) Remove mirror heater switch from instrument panel. 2) Check for continuity between terminals at each switch position as shown below. If check result is not as specified, replace switch.
Page 587: Power Sliding Roof (If Equipped)
8D-32 WINDOWS, MIRRORS, SECURITY AND LOCKS POWER SLIDING ROOF (IF EQUIPPED) INSPECTION SLIDING ROOF SWITCH Check switch for continuity between terminals as shown below. Slide Switch (1) Terminal Switch OPEN CLOSE Tilt Switch (2) Terminal Switch DOWN 3. To open 4.
Page 588: Front Seat Heater (If Equipped)
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-33 FRONT SEAT HEATER (IF EQUIPPED) SEAT HEATER SWITCH (DRIVER AND PASSENGER SIDE) INSPECTION 1) Confirm that ignition switch is OFF position. 2) Pull out seat heater switch from front center console box. 3) Disconnect seat heater switch coupler. LOAD2 LOAD1 4) Check for continuity between terminals at each switch position...
Page 589: Immobilizer Control System
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 590: General Description
8G-2 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) GENERAL DESCRIPTION The immobilizer control system designed to prevent vehicle burglar consists of following components. D Engine control module (ECM)/Powertrain control module (PCM) D Immobilizer control module D Ignition key (with built-in transponder) D Coil antenna Operation of this system is as follows.
Page 591: Ignition Key
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-3 WIRE WIRE SYMBOL COLOR BI/B BI/B R / Y 1. Coil antenna 2. Immobilizer Control Module 3. ECM/PCM 4. Immobilizer diagnostic coupler 4-1. Diagnostic output terminal 4-2. Ground terminal 5. Malfunction indicator lamp 6. Main relay A1 A2 A3 A4 7.
Page 592: Immobilizer Control Module
8G-4 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) IMMOBILIZER CONTROL MODULE Immobilizer Control Module is installed to the underside of the instrument panel at the driver’s seat side. As main functions, Immobilizer Control Module checks matching not only between the Transponder Code transmitted from the igni- tion key and that registered in Immobilizer Control Module (Up to 4 different Transponder codes can be registered.) but also between the ECM/Immobilizer Control Module code transmitted from...
Page 593 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-5 <Vehicle equipped with monitor coupler> With the diagnosis switch terminal of monitor coupler for ECM/PCM not grounded, the ignition switch turned ON (but the en- gine at stop) and regardless of the condition of the electronic fuel injection system, ECM/PCM indicates whether a trouble has oc- curred in the immobilizer control system or not by causing the mal- function indicator lamp to flash or turn ON.
Page 594: Diagnosis
8G-6 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DIAGNOSIS ECM/PCM and Immobilizer Control Module have on-board diag- nostic system (a system self-diagnosis function) as described pre- viously. Investigate where the trouble is by referring to “Diagnostic Flow Table” and “Diagnostic Trouble Code Table” on later pages. PRECAUTIONS IN DIAGNOSING TROUBLES [PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE] ECM/PCM...
Page 595 OFF ignition switch and then ON. Then check what Suzuki scan tool and/or output of diagnostic out- put terminal indicates. Only when they indicate trouble code again, substitute a known- good ECM/PCM or Immobilizer Control Module and check again.
Page 596 8G-8 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) [NOTES ON SYSTEM CIRCUIT INSPECTION] Refer to “Precautions for Electrical Circuit Service” and “Intermit- tents and Poor Connection” in Section 0A. [Precaution after replacing ECM/PCM or Immobilizer Control Mod- ule] D When ECM/PCM was replaced, including when replaced be- cause rechecking by using a known-good ECM/PCM was neces- sary during trouble diagnosis, the ECM/Immobilizer Control Mod- ule code must be registered in ECM/PCM and Immobilizer...
Page 597: Diagnostic Flow Table
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-9 DIAGNOSTIC FLOW TABLE <Vehicle equipped with monitor coupler> STEP ACTION D If malfunction indicator lamp 1) Make sure that diagnosis switch Go to Step 3. terminal in monitor coupler is not remains ON, go to Step 2. D If malfunction indicator lamp grounded by service wire.

Page 598: Diagnostic Flow Table
8G-10 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DIAGNOSTIC FLOW TABLE <Vehicle not equipped with monitor coupler> STEP ACTION D If immobilizer indicator lamp 1) Check immobilizer indicator lamp Go to Step 3. while ignition switch is ON (but without remains ON, go to Step 2. D If immobilizer indicator lamp starting engine).

Page 599: (Immobilizer Control Module)
High Voltmeter indicator TIME (sec.) DIAGNOSTIC TROUBLE CODE (DTC) CHECK (ECM/PCM) [Not using SUZUKI scan tool] (Vehicle equipped with monitor coupler) 1) Using service wire, ground diagnostic switch terminal in monitor coupler. 2) Read DTC from flashing pattern of malfunction indicator lamp as shown in example below and write it down.
Page 600 (C): 09931-76030 (16/12 pin DLC adapter) 3) Turn ignition switch ON. 4) Read DTC according to instructions displayed on Suzuki scan tool and print it or write it down. Refer to Suzuki scan tool opera- tor’s manual for further details. NOTE: D When reading DTC stored in ECM/PCM using Suzuki scan tool, select “ECM”...
Page 601: (Ecm/Pcm)
Ignition switch circuit Serial data link wire ECM/PCM side (indicated on Malfunction Indicator lamp (indicated DIAGNOSTIC AREA DIAGNOSIS Suzuki (MIL) flashing pattern by MIL) scan tool) This code appears when it is confirmed that none of other NO DTC Normal...
Page 602 8G-14 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) TABLE A DTC IS NOT OUTPUT FROM DIAGNOSTIC OUTPUT TERMINAL In cabin 1. Main fuse 2. Main relay 3. Immobilizer Control Module 4. Immobilizer diagnostic coupler 4-1. Ground terminal 4-2. Diagnostic output terminal 5. To ECM / PCM STEP ACTION Check voltage between A3 terminal...
Page 603 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-15 TABLE B IMMOBILIZER INDICATOR LAMP CHECK (IMMOBILIZER INDICATOR LAMP DOSE NOT LIGHT AT IGNITION SWITCH ON) For G16 / J20 engine For H25 engine 1. Main fuse 2. Main relay 3. ECM/PCM 4. Immobilizer indicator lamp (Vehicle not equipped with G16 / J20 Engine monitor coupler)
Page 604 8G-16 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) TABLE C IMMOBILIZER INDICATOR LAMP CHECK (IMMOBILIZER INDICATOR LAMP REMAINS ON AFTER ENGINE STARTS) For G16 / J20 engine For H25 engine 1. Main fuse 2. Main relay 3. ECM / PCM 4. Immobilizer indicator lamp (Vehicle not equipped with G16 / J20 Engine monitor coupler)
Page 605: Dtc11 Transponder Code Not Matched
Control Module match when ignition switch is ON. If they do not, this DTC is set. INSPECTION: Register ignition key with built-in transponder by using Suzuki scan tool (TECH1 cartridge for immobilizer control system and TECH 1A kit) and performing following steps.
Page 606 8G-18 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC13 NO TRANSPONDER CODE TRANSMITTED OR COIL ANTENNA OPENED/SHORTED 1. Main fuse 2. Main relay 3. Immobilizer Control Module 4. Coil antenna 5. To ECM / PCM DESCRIPTION: Immobilizer Control Module energizes the coil antenna when the ignition switch is ON and reads Transponder code from the ignition key.
Page 607: Dtc13 No Transponder Code Transmitted Or Coil Antenna Opened/Shorted
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-19 DTC13 NO TRANSPONDER CODE TRANSMITTED OR COIL ANTENNA OPENED/SHORTED (CONTINUED) STEP ACTION Poor A1 or A2 connection. Go to Step 9. Faulty coil antenna. 1) If connections are OK, connect Immobilizer Control Module coupler and substitute a known- good coil antenna.
Page 608: Dtc21 Ecm/Immobilizer Control Module Code Not Matched (Immobilizer Control Module Side)
8G-20 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC21 ECM/IMMOBILIZER CONTROL MODULE CODE NOT MATCHED (IMMOBILIZER CONTROL MODULE SIDE) DTC81 ECM/IMMOBILIZER CONTROL MODULE CODE NOT MATCHED (P1623) (ECM/PCM SIDE) DTC84 ECM/IMMOBILIZER CONTROL MODULE CODE NOT REGISTERED (P1620) DESCRIPTION: D DTC21 Immobilizer Control Module checks if ECM/Immobilizer Control Module code transmitted from ECM/PCM and that registered in Immobilizer Control Module match when ignition switch is ON.
Page 609: Dtc22 Ignition Switch Circuit Open/Short
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-21 DTC22 IGNITION SWITCH CIRCUIT OPEN/SHORT 1. Main fuse 2. Ignition switch 3. Immobilizer Control Module DESCRIPTION: Immobilizer Control Module monitors ignition signal when the ignition switch is ON. This DTC is set when no ignition signal input is detected by Immobilizer Control Module.
Page 610: Dtc23 No Ecm/Immobilizer Control Module Code Transmitted From Ecm/ Pcm Or Dlc Circuit Opened/Shorted
8G-22 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC23 NO ECM/IMMOBILIZER CONTROL MODULE CODE TRANSMITTED FROM ECM/PCM OR DLC CIRCUIT OPENED/SHORTED DTC83 NO ECM/IMMOBILIZER CONTROL MODULE CODE TRANSMITTED (P1621) FROM IMMOBILIZER CONTROL MODULE OR DLC CIRCUIT OPENED/SHORTED To SDM (if equipped with AIRBAG) 1.
Page 611: Dtc82 (P1622) Fault In Ecm/Pcm
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-23 DTC82 (P1622) FAULT IN ECM/PCM DESCRIPTION: This DTC is set when an internal fault is detected in ECM/PCM. INSPECTION: STEP ACTION 1) Ignition switch OFF. Substitute a known-good ECM / PCM and Repair or replace. 2) Disconnect connectors from recheck.
Page 612: Inspection Of Ecm/Pcm, Immobilizer Control Module And Its Circuit
8G-24 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) INSPECTION OF ECM/PCM, IMMOBILIZER CONTROL MODULE AND ITS CIRCUIT ECM/PCM, Immobilizer Control Module and its circuit can be checked at ECM/PCM wiring couplers and Immobilizer Control Module wiring coupler by measuring voltage and resistance. De- scribed here is only inspection of Immobilizer Control Module.
Page 613: Resistance Check
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-25 Resistance Check 1) Disconnect Immobilizer Control Module couplers from Immobi- lizer Control Module with ignition switch OFF. CAUTION: Never touch terminals of Immobilizer Control Module it- self or connect voltmeter or ohmmeter. 2) Check resistance between each terminal of coupler discon- nected.
Page 614: On-Vehicle Service
8G-26 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) ON-VEHICLE SERVICE PRECAUTIONS IN HANDLING IMMOBILIZER CONTROL SYSTEM D Do not turn ON ignition switch with ignition key for immobilizer control system put together with another one or placed quite close to another one. Or the system may detect abnormal condition and prevent engine from starting.
Page 615: Immobilizer Control Module
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-27 IMMOBILIZER CONTROL MODULE Removal 1) Disconnect negative (–) cable at battery. 2) Remove steering column hole cover. 3) Disconnect coupler at Immobilizer Control Module. 4) Remove Immobilizer Control Module. Installation Reverse removal procedure for installation. NOTE: After replacing Immobilizer Control Module, be sure to register Transponder code and ECM/Immobilizer Control Module code...
Page 616: How To Register Ignition Key
Register the ignition key with a built-in transponder in Immobilizer Control Module by using the following procedure. 1) Prepare Suzuki scan tool (TECH 1A kit and cartridge for immobi- lizer control system). 2) With ignition switch OFF, connect Suzuki scan tool to data link connector (DLC) located on underside of instrument panel at driver’s seat side.
Page 617: Procedure After Immobilizer Control Module Replacement
2) Prepare ignition key with a built-in transponder. And then turn ignition switch ON by using it. 3) Using Suzuki scan tool, clear all transponder codes registered in Immobilizer Control Module by executing “CLR. TRANS COD (CLEAR TP CODE)” command in SELECT MODE menu.
Page 618: Procedure After Ecm/Pcm Replacement
ECM/PCM by executing “RECORD ECU (RECORD ECM/PCM/ ICM)” command in SELECT MODE menu. NOTE: For operation procedure of Suzuki scan tool, refer to TECH1 operator’s manual. 3) [Vehicle equipped with monitor coupler] Make sure that malfunction indicator lamp lights when ignition switch is turned OFF once and then ON.
Page 619 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 620: Front Door Glass
9-2 BODY SERVICE GLASS, WINDOWS AND MIRROR FRONT DOOR GLASS 1. Door glass 6. Door trim 2. Weatherstrip 7. Door hinge 3. Opening weatherstrip 8. Door open stop 4. Window regulator 9. Door sealing cover 5. Glass run 10. Window regulator handle (if equipped)
Page 621 BODY SERVICE 9-3 REMOVAL 1) Remove inside handle bezel. 2) Remove door mirror bezel (if equipped). 3) Remove inside lock knob and door inside pull handle case fitting screw. 3-1) Remove window regulator handle (if equipped). To remove regulator handle, pull off snap ring by using a cloth as shown below.
Page 622 9-4 BODY SERVICE INSTALLATION Reverse removal procedure to install door glass noting following points: D Tighten glass attaching screws to specified torque. Tighten front screw first, then rear screw. Tightening Torque (a): 2.5 N m (0.25 kg-m, 1.8 lb-ft) D When window becomes hard to raise and lower, adjust screws to 1.
Page 623: Front Door Window Regulator
BODY SERVICE 9-5 FRONT DOOR WINDOW REGULATOR REMOVAL 1) Remove door glass, referring to steps 1) to 9) of FRONT DOOR GLASS REMOVAL in this section. 2) Disconnect power window motor lead wire at coupler and loosen clamp. 3) Loosen regulator mounting bolts, nuts and take out regulator through hole as shown in left figure.
Page 624: Windshield
9-6 BODY SERVICE WINDSHIELD The front windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For the Windshield replacement, it is important to use an adhesive which provides sufficient adhesion strength and the follow the proper procedure. 1.
Page 625 BODY SERVICE 9-7 REMOVAL 1) Clean both inside and outside of glass and around it. 2) Remove wiper arms and garnish. 3) Using tape, cover body surface around glass to prevent any damage. 4) Remove rear view mirror, sunvisor, and front pillar trims (right &...
Page 626 9-8 BODY SERVICE 11) Using knife, smoothen adhesive remaining on body side so that it is 1 to 2 mm thick all around. NOTE: Before using knife, clean it with alcohol or the like to re- move oil from it. 1.
Page 627 BODY SERVICE 9-9 INSTALLATION 1) Using cleaning solvent, clean windshield edge where wind- shield glass is to be adhered. (Let it dry for more than 10 min- utes.) 2) Install new glass stoppers (2pcs.) to lower side of windshield and new fastener to body.
Page 628 9-10 BODY SERVICE 7) Using new brush, apply sufficient amount of primer for glass along glass surface to be adhered to body. NOTE: D Be sure to refer to maker’s instruction for proper han- dling and drying time. D Do not apply primer on outside of ceramic coated sur- face.
Page 629 BODY SERVICE 9-11 11) Check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again. CAUTION: Upon completion of installation, note the following.
Page 630: Rear Door Glass
9-12 BODY SERVICE REAR DOOR GLASS 1. Door glass 7. Door hinge 2. Weatherstrip (outside) 8. Door open stop 3. Glass run 9. Door sealing cover 4. Window regulator 10. Door center sash 5. Partition weather strip 11. Partition glass 6.
Page 631 BODY SERVICE 9-13 5) Remove outer weatherstrip. CAUTION: Using a tape-wrapped putty knife (or tape-wrapped screwdriver), pry off weatherstrip. Use of an unwrapped tool will cause damage to painting. 1. Door outer weatherstrip 2. Screw 6) Remove glass fitting screws. Then down door glass. 1.
Page 632: Rear Door Window Regulator
9-14 BODY SERVICE REAR DOOR WINDOW REGULATOR REMOVAL 1) Remove door glass, refer to steps 1) to 10) of REAR DOOR GLASS REMOVAL in this section. 2) Disconnect power window motor lead wire at coupler and clamp. 3) Remove door window regulator attaching nuts (6 pcs.), and take out regulator through hole as shown in left figure.
Page 633: Quarter Window
BODY SERVICE 9-15 QUARTER WINDOW REMOVAL AND INSTALLATION Refer to “WINDSHIELD” section as removal and installation proce- dures and cautions are basically the same. However, note the fol- lowing. NOTE: D Before applying primer to glass edge, install molding ac- cording to installing position shown in figure.
Page 634: Back Door Glass
9-16 BODY SERVICE BACK DOOR GLASS REMOVAL AND INSTALLATION Refer to “WINDSHIELD” section as removal and installation proce- dures and cautions are basically the same. However, note the fol- lowing. NOTE: D Before applying primer to glass edge, install molding ac- 1.
Page 635: Body Structure
BODY SERVICE 9-17 BODY STRUCTURE FRONT DOOR ASSEMBLY REMOVAL 1) Remove front fender. Refer to “FRONT FENDER” in this section. 2) Disconnect door harness lead wires at each coupler. 3) Remove stopper pin. 1. Stopper pin 4) Support door panel using a jack with a piece of wood placed be- tween jack and panel, as shown.
Page 636: Rear Door Assembly
9-18 BODY SERVICE REAR DOOR ASSEMBLY REMOVAL/INSTALLATION Follow procedures for Front Door removal/installation in this sec- tion.
Page 637: Back Door/Rear Gate Assembly
BODY SERVICE 9-19 BACK DOOR/REAR GATE ASSEMBLY 1. Back door panel assy 2. Back door window glass 3. Back door hinge 4. Back door / Rear gate balancer unit REMOVAL 1) Remove back door trim, and door/rear gate sealing cover, refer to steps 1) to 4) of BACK DOOR LOCK ASSEMBLY in this sec- tion.
Page 638 9-20 BODY SERVICE INSTALLATION Reverse removal procedure to install back door/rear gate noting following points. D Secure wiring harness. D Secure back door/rear gate sealing cover. 1. Sealing cover 2. Adhesive NOTE: Use adhesive to seal sealing cover to back door/rear gate. D Adjust back door/rear gate latch striker position by referring “BACK DOOR LOCK ASSEMBLY INSTALLATION”...
Page 639: Hood
BODY SERVICE 9-21 HOOD REMOVAL 1) Remove window washer hose from hood. 2) Remove four mounting bolts to detach hood. ADJUSTMENT D Fore-and-aft and right-and-left adjustment. Loosen four mounting bolts for adjustment. D Hood lock adjustment When installing hood lock, bring bolt at intersection point of match marks and move it in vertical direction for adjustment, if neces- sary.
Page 640: Front Fender
9-22 BODY SERVICE FRONT FENDER 1. Front fender 2. Front fender lining 3. Fender attaching bolts 4. Fender lining attaching screws REMOVAL 1) Remove front bumper. 2) Remove fender splush guard (H25 engine). 3) Remove front fender lining. 4) Remove front fender. INSTALLATION 1) Remove pad from side body and (or) fender, using care not to damage painted surface.
Page 641: Front Bumper
BODY SERVICE 9-23 FRONT BUMPER NOTE: D Fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 642: Rear Bumper
9-24 BODY SERVICE REAR BUMPER 1. Rear bumper 2. Rear bumper screws 3. Rear bumper member...
Page 643: Under Body Dimensions
BODY SERVICE 9-25 UNDER BODY DIMENSIONS a. Front bumper a – g : 1315 mm (51.77 in.) h – m : 803 mm (31.61 in.) b. 1st mounting a – g’ : 1534 mm (60.39 in.) h – n : 1161 mm (45.71 in.) c.
Page 644: Body Dimensions
9-26 BODY SERVICE BODY DIMENSIONS 4 door model, 2 door model Front bumper installation clip hole b (b’). Front bumper installation hole c (c’). Headlight installation hole d (d’). Headlight installation resin nut hole e (e’). Headlight installation hole f (f’). Front fender installation hole Center member installation hole h (h’).
Page 645 BODY SERVICE 9-27 4 door model Garnish installation clip hole b (b’). Front end of front windshield lower installation section c (c’). Front end of front windshield upper installation section Hole in F door lower hinge at rear Trim installation clip hole f (f’).
Page 646 9-28 BODY SERVICE 4 door model a. Hole in F door upper hinge at rear b. Hole in F door lower hinge at rear c. Trim installation clip hole d. ø7 jig hole e. Scuff installation hole (rearmost end) f. Hole n R door upper hinge in upper part g.
Page 647 BODY SERVICE 9-29 4 door model Clip hole in the center of head lining rear installation section b (b’). Innermost end of roof panel installation section Installation hole in upper part of back door striker Installation hole in uppermost part of upper hinge Installation hole in uppermost part of lower hinge f (f’).
Page 648 9-30 BODY SERVICE 2 door model Garnish installation clip hole b (b’). Front end of front windshield lower installation section c (c’). Front end of front windshield upper installation section Hole in F door lower hinge at rear Trim installation clip hole f (f’).
Page 649 BODY SERVICE 9-31 2 door model a. Hole in door upper hinge at rear b. Hole in door lower hinge at rear c. Trim installation clip hole d. f7 jig hole e. Scuff installation hole (rearmost end) f. Door striker lower section installation hole g.
Page 650 9-32 BODY SERVICE 2 door model a (a’). Trim installation clip hole Installation hole in uppermost part of upper hinge Installation hole in outside part of lower hinge Installation hole in uppermost part of rear gate striker e (e’). Installation hole in outer upper section of R-COMB R (L) lamp f (f’).
Page 651: Instrumentation And Driver Information
BODY SERVICE 9-33 INSTRUMENTATION AND DRIVER INFORMATION INSTRUMENT PANEL 1. (a) 1. (a) Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 1. Bolt WARNING: See WARNING at the beginning of this section. REMOVAL 1) Disconnect negative cable at battery. 2) Disable air bag system.
Page 652: Seat
9-34 BODY SERVICE SEAT FRONT SEAT 1. Seat cushion 2. Seat back 3. Reclining assy (RH side) 4. Reclining assy (LH side) 5. Seat adjuster (RH outside) 6. Seat adjuster (RH inside) 7. Seat adjuster (LH outside) 8. Seat adjuster (LH inside) Tightening Torque (a): 35 N m (3.5 kg-m, 25.5 lb-ft)
Page 653: Rear Seat
BODY SERVICE 9-35 REAR SEAT 1. Seat cushion 2. Seat back 3. Seat auto lock release handle 4. Seat hinge male 5. Hinge male cover REMOVAL 1) Remove four mounting bolt to remove seat cushion. 2) Remove four mounting bolts to remove seat back. 3) Disassemble and repair seat as necessary.
Page 654: Paint And Coatings
9-36 BODY SERVICE PAINT AND COATINGS ANTI-CORROSION TREATMENT Sealer is applied to the specific joints of a vehicle dur- WARNING: ing production. The sealer is intended to prevent dust Standard shop practices, particularly eye from entering the vehicle and serves also as an anti- protection, should be followed during the per- corrosion barrier.
Page 655: Metal Replacement Parts Finishing
BODY SERVICE 9-37 When the welding or heating operation causes the Scrape the accessible places. If a standard putty knife original galvanization or other anticorrosive materials or scraper does not fit to the elevant place, consider to be burnt, the interior and under-body panel sur- to use a more flexible scraper to a place narrowly en- faces must be cleaned.
Page 656 9-38 BODY SERVICE SEALANT APPLICATION AREA 4 door model 1. Side body inner panel “A”: Apply sealant 2. Rear wheel housing outer rear panel “B”: Brush treatment 3. Rear wheel housing panel 4. Rear floor panel 5. Tail lower member 6.
Page 657 BODY SERVICE 9-39 1. Cowl top panel “A”: Apply sealant 2. Dash panel “B”: Brush treatment 3. Cowl front panel 4. Front floor panel 5. Front pillar inner lower panel...
Page 658 9-40 BODY SERVICE 1. Side body inner panel “A”: Apply sealant 2. Side body outer panel “B”: Brush treatment 3. Back pillar outer panel 4. Front pillar inner panel 5. Roof panel 6. Front pillar upper reinforcement 7. Rear wheel housing panel 8.
Page 659 BODY SERVICE 9-41 “A”: Apply sealant “B”: Brush treatment 1. Side body outer panel...
Page 660 9-42 BODY SERVICE Vehicle produced in IWATA 2, “A” Sealant width “W”: more than 5 mm between a and b “A”: Apply sealant “B”: Brush treatment “C”: Wipe sealant away 1. Sealant application area 2. Outside of body...
Page 661 BODY SERVICE 9-43 Vehicle produced in IWATA “A”: Apply sealant Sealant width “W”: more than 5 mm between c and d “B”: Brush treatment 1. Sealant application area “C”: Wipe sealant away “D”: Role sealant between d and e...
Page 662 9-44 BODY SERVICE Vehicle produced in IWATA “A”: Apply sealant Sealant width “W”: more than 5 mm between c and d...
Page 663 BODY SERVICE 9-45 Vehicle produced in CAMI Be free from protrude of sealant outside from this line Sealant width “W”: more than 5 mm between a and b “A”: Apply sealant 1. Sealant application area 2. Outside of body...
Page 664 9-46 BODY SERVICE Vehicle produced in CAMI Sealant width “W”: more than 5 mm between a and b, between c and d “A”: Apply sealant 1. Sealant application area...
Page 665 BODY SERVICE 9-47 2 DOOR MODEL 1. Side body inner panel “A”: Apply sealant 2. Rear wheel housing panel “B”: Brush treatment 3. Rear floor panel 4. Center floor panel 5. Front floor panel 6. Center floor member 7. Side sill inner panel...
Page 666 9-48 BODY SERVICE 1. Cowl top panel “A”: Apply sealant 2. Dash panel “B”: Brush treatment 3. Cowl front panel 4. Front floor panel 5. Front pillar inner lower panel...
Page 667 BODY SERVICE 9-49 1. Side body inner panel “A”: Apply sealant 2. Side body outer panel “B”: Brush treatment 3. Front pillar inner panel “C”: Wipe 4. Front pillar upper reinforcement 5. Rear wheel housing panel 6. Fuel inlet box 7.
Page 668 9-50 BODY SERVICE Be free from protrude of sealant outside from this line. Sealant width “W”: more than 5 mm “A”: Apply sealant...
Page 669 BODY SERVICE 9-51 UNDERCOATING/ANTI-CORROSION COMPOUND APPLICATION AREA 4 door model “a”: 200 mm (7.87 in.) 1. Side body outer “b”: 100 mm (3.94 in.) 2. Side sill inner 3. Frame 4. Main floor “A”: Apply rust proof wax (hot wax 50 mm or more) 5.
Page 670 9-52 BODY SERVICE Vehicle produced in IWATA VIEW: Z “a”: 30 mm (1.18 in.) 1. Side body outer “b”: 100 mm (3.94 in.) 2. Side sill inner 3. Main floor 4. Front fender “A”: Apply undercoating (PVC, 400 fm or more) 5.
Page 671 BODY SERVICE 9-53 Vehicle produced in CAMI VIEW : Z “a”: 30 mm (1.18 in.) 1. Side body outer “b”: 100 mm (3.94 in.) 2. Side sill inner 3. Main floor 4. Front fender “A”: Apply undercoating (PVC, 400 fm or more) 5.
Page 672 9-54 BODY SERVICE Vehicle produced in CAMI “e” “A” “a”: 240 mm (9.45 in.) “b”: 20 mm (0.79 in.) “c”: 40 mm (1.57 in.) “d”: 134 mm (5.28 in.) “e”: 177 mm (6.97 in.) “A”: Black paint...
Page 673 BODY SERVICE 9-55 2 DOOR MODEL C – C B – B...
Page 674 9-56 BODY SERVICE B – B A – A C – C VIEW : Z “a”: 30 mm (1.18 in.) 1. Side body outer “b”: 100 mm (3.93 in.) 2. Side sill inner 3. Main floor 4. Front fender “A”: Apply undercoating (PVC, 400 mm or more) 5.
Page 675 BODY SERVICE 9-57 VIEW : A VIEW : C VIEW : B VIEW : D “a”: 240 mm (9.45 in.) “b”: 20 mm (0.79 in.) “c”: 40 mm (1.57 in.) “d”: 134 mm (5.28 in.) “e”: 177 mm (6.97 in.) “A”: Black paint...
Page 676: Plastic Parts Finishing
9-58 BODY SERVICE PLASTIC PARTS FINISHING Paintable plastic parts are ABS plastic parts. Painting Rigid or hard ABS plastic needs no primer coating. General acrylic lacquers can be painted properly over hard ABS plastic in terms of adherence. 1) Use cleaning solvent for paint finish to wash each part. 2) Apply conventional acrylic color lacquer to part surface.
Page 677: Security And Locks
BODY SERVICE 9-59 SECURITY AND LOCKS FRONT DOOR LOCK ASSEMBLY 1. Door latch 2. Outside handle 3. Inside handle bezel 4. Latch striker REMOVAL 1) Raise window all the way up. 2) Remove door trim and door sealing cover, refer to steps 1) to 6) of FRONT DOOR GLASS REMOVAL in this section.
Page 678 9-60 BODY SERVICE INSTALLATION To install front door lock, reverse removal procedure, noting follow- ing. D Door latch striker. Move door latch striker up or down so its center aligns with the center of groove “A” on the door, as shown. NOTE: Striker should be moved vertically and placed level.
Page 679: Rear Door Lock Assembly
BODY SERVICE 9-61 REAR DOOR LOCK ASSEMBLY 1. Outside handle 2. Inside handle bezel 3. Latch assembly 4. Latch striker REMOVAL 1) Remove door trim and door sealing cover, refer to steps 1) to 4) of REAR DOOR GLASS REMOVAL in this section. 2) Remove door opening control rod and door lock control rod.
Page 680: Back Door/Rear Gate Lock Assembly
9-62 BODY SERVICE BACK DOOR/REAR GATE LOCK ASSEMBLY REMOVAL 1) Remove inside handle bezel (if equipped). 2) Remove inside lock knob. 3) Remove door trim. With inside handle bezel tilted as shown in figure, turn door trim 90_ counterclockwise to remove it (if equipped with inside han- dle).
Page 681: Key Coding
BODY SERVICE 9-63 KEY CODING KEY USAGE AND IDENTIFICATION Key is used for ignition and door lock cylinder. Keys are cut on both edges to make them reversible. Key identification is obtained from five character key code stamped on key code tag. Using this key code, key code cutting combination can be determined from a code list (available to owners of key cut- ting equipment from suppliers).
Page 682: Sunroof/Convertible Top
9-64 BODY SERVICE SUNROOF/CONVERTIBLE TOP SLIDING ROOF (IF EQUIPPED) SLIDING ROOF GLASS 1. Sliding roof glass 2. Bolt REMOVAL 1) Open sunshade fully and tilt up sliding roof. 2) Disconnect battery negative cable at battery. 1. Sun shade 3) Remove sliding roof glass by removing bolts (torx). 1.
Page 683 BODY SERVICE 9-65 ADJUSTMENT 1) Loosen sunroof glass fixing screws (at 4 locations) and move sunroof glass up and down 2 to 3 times. In this way, sunroof glass can be positioned in both vertical and horizontal directions by elasticity of sliding roof weather strip. Section A –...
Page 684 9-66 BODY SERVICE SLIDING ROOF MOTOR/RELAY REMOVAL 1) Remove head lining, refer to HEAD LINING REMOVAL in this section. 1. Spot light 2. Head lining 3. Sunvisor assemblies 4. Room light 5. Trim 6. Assist grips 2) Disconnect coupler and remove sliding roof motor assembly by removing 3 screws.
Page 685 BODY SERVICE 9-67 SLIDING ROOF ASSEMBLY REMOVAL 1) Remove roof lining. Refer to HEAD LINING REMOVAL in this section. 2) Remove sliding roof glass. Refer to SLIDING ROOF GLASS REMOVAL. 3) Disconnect drain hoses connected to sliding roof assembly at 4 locations.
Page 686 9-68 BODY SERVICE DISASSEMBLY 1. Sunroof frame 2. Sunshade 3. Deflector 4. Rear drip 5. Guide 6. Drip shoe 7. Cable 8. Drip rail 9. Drip link Before disassembling, be sure that sliding roof is “CLOSE” state. 1) Remove rear drip. 1.
Page 687 BODY SERVICE 9-69 6) Remove sliding roof deflector. 7) Pull out drip shoe, guide and cable assy as a set. 1. Drip shoe 2. Frame 3. Guide ASSEMBLY Reverse disassembly procedure for assembly, observing following instructions. CAUTION: Match protrusion of guide and dent in cable for completely closed position of sliding roof drive cable and match marks (holes) for completely closed position of sliding roof motor assembly and then install sliding roof motor assembly.
Page 688 9-70 BODY SERVICE INSTALLATION For installation, reverse removal procedure, noting following points. D Align positioning holes in sliding roof assembly at right and left and pins on body side for installation. 1. Pin on body side 2. Sliding roof D Connect drain hoses to sliding roof assembly at 4 locations. Pass front drain hose between roof panel and inner panel and through front pillar down to sill side.
Page 689: Canvas Top And Topbow Frames
BODY SERVICE 9-71 CANVAS TOP AND TOPBOW FRAMES Removal 1) Open canvas to referring to Owner’s Manual. 2) Remove fording top and rear canvas top. 3) Remove topbow bracket cover. 1. Topbow center frame 2. Bracket cover 4) Remove topbow center frame. 5) Remove topbow front frame.
Page 690: Exterior And Interior Trim
9-72 BODY SERVICE EXTERIOR AND INTERIOR TRIM FLOOR CARPET 1. Front floor carpet 2. Luggage floor carpet 3. Dash panel insulation FRONT FLOOR CARPET REMOVAL 1) Remove front seats and rear seat cushions. 2) Remove seat belt lower anchor bolt. 3) Remove dash side trims, front side sill scuffs (4 door model), center pillar inner lower rims (4 door model), rear side sill scuffs (4 door model), side sill scuffs (2 door model) and rear quarter...
Page 691: Head Lining
BODY SERVICE 9-73 HEAD LINING REMOVAL 1) Remove spot light and sliding roof switch (if equipped). 2) Remove sunshade assembly. 3) Remove room light and spacer. 4) Remove assistant grips. 5) Remove inner trims covering head lining and door opening trim. 6) Remove rear speaker cover (if equipped).
Page 692 9-74 BODY SERVICE 5) Install door opening trim. 1. Door opening trim 2. Head lining 6) Install spot light, sunshade assembly, speaker cover, room light and inner trims covering head lining. IWATA CAMI 1. Room light 4. Assistant grip 2. Sunshade assembly 5.
Page 693: Roof Trim (2 Door Model)
BODY SERVICE 9-75 ROOF TRIM (2 DOOR MODEL) REMOVAL 1) Remove canvas top. 2) Remove rear topbow. 3) Remove side body garnishes. 4) Remove luggage mat end garnish. 5) Remove assistant grips. 6) Remove sunshade assemblies. 7) Remove sunshade hooks. 8) Remove front topbow locks.
Page 694 9-76 BODY SERVICE INSTALLATION 1) Set room light and clip to roof trim. 2) Set room light harness to roof trim with marking tape. 1. Roof trim 4. Clip 2. Room light 5. Screw 3. Room light lens 6. Room light harness 7.
Page 695: Side Moldings (If Equipped)
BODY SERVICE 9-77 SIDE MOLDINGS (IF EQUIPPED) 1. Front door molding 2. Rear door molding 3. Front fender molding INSTALLATION 1) Bonding surfaces should be cleaned thoroughly. 2) Install molding by aligning it to clip holes and pulling it to the rear so that fender or door will not interfere with it when door is opened.
Page 696: Splash Guard (If Equipped)
9-78 BODY SERVICE SPLASH GUARD (IF EQUIPPED) 1. Fender splash guard 2. Front door splash guard 3. Rear door splash guard 4. Rear splash guard 5. Side sill splash guard 6. Rear door guard holder...
Page 697: Roof Rail (If Equipped)
BODY SERVICE 9-79 ROOF RAIL (IF EQUIPPED) 1. Roof rail assembly 2. Front cap 3. Rear cap 4. Base seal 5. Nut Removal 1) Remove roof rail front and rear caps as shown in figure. 2) Remove nuts. 3) Remove roof rail assembly. Installation Reverse removal procedure for installation.
Page 698: Luggage Under Box
9-80 BODY SERVICE LUGGAGE UNDER BOX 1. Bolt 2. Member WARNING: Do not remove member in the center of luggage under box. If member had to be removed temporarily for repair or for some oth- er reason, be sure to reinstall it by using specified new bolts until head of bolt is broken off.
Page 699: Restraint System
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 700 10-2 RESTRAINT SYSTEM GENERAL DESCRIPTION Driver Side Seat Belt: Seat belt with ELR Front Passenger Side Seat And Rear Left And Right Seat Belts: Seat belt with A-ELR Rear Center Seat Belt (If Equipped): Seat belt without ELR and A-ELR Supplemental Restraint System: Driver and front passenger side air bags 1.
Page 701: Seat Belt
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 702 If these parts are replaced individually, such a locking condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and ELR (or webbing) in a set part.
Page 703: Front Seat Belt
SEAT BELT 10A-3 FRONT SEAT BELT WARNING: Be sure to read “Service Precautions” before starting to work and observe every precaution during work. REMOVAL Refer to the figure below to remove front seat belts. 1. Upper anchor 2. Lower anchor 3.
Page 704 10A-4 SEAT BELT INSPECTION Seat belts and attaching parts can affect the vital components and systems of a vehicle. Therefore, they should be inspected carefully and replaced with genuine parts only. Seat belt D The seat belt webbing or strap should be free from damage. D Fully extend the seat belt to make sure there are no twists or tears in it.
Page 705 SEAT BELT 10A-5 INSTALLATION Install in reverse order of removal, noting the following. D Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances should any different sized or metric screw threads be used. D Be sure to tighten seat belt anchor bolts to specified torque. Tightening torque (a): 35 N m (3.5 kg-m, 25.5 lb-ft)
Page 706 10A-6 SEAT BELT REAR SEAT BELT WARNING: Be sure to read “Service Precautions” before starting to work and observe every precaution during work. REMOVAL Refer to the figure below to remove rear seat belts. 1. Upper anchor : If equipped 2.
Page 707: Air Bag System
D Service on or around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in this section before performing service on or around the air bag system components or wiring.
Page 708 10B-2 AIR BAG SYSTEM Code 46 - Passenger pretensioner Accident with or without deployment initiator circuit resistance low ..10B-46 - component inspections ... 10B-64 Code 43 - Driver pretensioner initiator Driver Air Bag (Inflator) Module...
Page 709: General Description
AIR BAG SYSTEM 10B-3 GENERAL DESCRIPTION With the air bag system which includes air bags for both the driver’s and passenger’s sides as well as the seat belt pretensioners (if equipped), the sag of the seat belt is taken up, the driver air bag (in- flator) module is deployed from the center of the steering column and the passenger air bag (inflator) module from the top of the instrument panel in front of the front passenger seat in occurrence...
Page 710: System Components And Wiring Location View And Connectors
10B-4 AIR BAG SYSTEM SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS CONNECTOR “E” CONNECTOR “H” CONNECTOR “B” CONNECTOR “C”, “D” CONNECTOR “G” CONNECTOR “F” CONNECTOR “A” 1. Air bag harness 2. “AIR BAG” fuse box 3. “AIR BAG” monitor coupler 4.
Page 711: System Wiring Diagram
AIR BAG SYSTEM 10B-5 SYSTEM WIRING DIAGRAM WIRE HARNESS COLOR : Black : Green : Yellow B/W : Black/White : Gray Y / G : Yellow/Green : Blue G/R : Green/Red Y/R : Yellow/Red Bl/B : Blue/Black : Lightgreen : White Bl/R : Blue/Red : Pink W/B : White/Black...
Page 712: Diagnosis
10B-6 AIR BAG SYSTEM DIAGNOSIS WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment other than that specified in this manual. Do not use a non-powered probe type tester. Instructions in this manual must be followed carefully, otherwise personal injury may result.
Page 713 AIR BAG SYSTEM 10B-7 Special Tool (Air Bag Driver/Passenger Load Tool) (B): 09932-75010 This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag (in- flator) module deployment and seat belt pretensioner activation.
Page 714 10B-8 AIR BAG SYSTEM INTERMITTENT AND POOR CONNECTIONS Most intermittent are caused by faulty electrical connections or wir- ing. When a check for proper connection is requested in a diagnos- tic flow table, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 715 AIR BAG SYSTEM 10B-9 D Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. D Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand-type wire are intact, resistance could be far too high.
Page 716 10B-10 AIR BAG SYSTEM AIR BAG DIAGNOSTIC SYSTEM CHECK WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equipment other than that specified in this manual.
Page 717: Intermittent And Poor Connections
Trouble Code (DTC) Check” on good condition. As execution of the “Diag- p.10B-12. nostic Trouble Code (DTC) 2) [Using SUZUKI scan tool] Clearance” will clear all Is “NO CODES” displayed ? DTCs, be sure to record all DTCs before servicing.
Page 718 1. Data link connector (DLC) 2. DLC cable adapter 3. DLC cable [Not using SUZUKI scan tool] 1) Check that malfunction indicator lamp (“AIR BAG” warning lamp) comes ON when ignition switch is turned ON. If it does not come “ON”, proceed to “Table B” on p.10B-18.
Page 719: Diagnostic Trouble Code (Dtc) Clearance
2. DLC cable adapter 3. DLC cable clear DTC. [Not using SUZUKI scan tool] 1) Turn ignition switch ON and wait about 6 seconds or more. 2) Using service wire, repeat shorting and opening between diag- nosis switch terminal and ground terminal on “AIR BAG” monitor coupler 5 times at about 1 second intervals.
Page 720: Diagnostic Trouble Code Table
10B-14 AIR BAG SYSTEM DIAGNOSTIC TROUBLE CODE TABLE (Page 1 of 2) EXAMPLE: WHEN DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (CODE NO.21) IS SET Code No. 21 Code No. 21 Code No. 21 Malfunction indicator lamp (“AIR BAG” warning lamp) Turn ON Turn OFF Time (sec.)
Page 721 AIR BAG SYSTEM 10B-15 DIAGNOSTIC TROUBLE CODE TABLE (Page 2 of 2) DIAGNOSTIC TROUBLE CODE DIAGNOSIS DIAGNOSIS MODE Resistance high Driver Resistance low pretensioner circuit Short to ground (if equipped) Short to power circuit Resistance high Diagnose trouble according to “Diagnos- t “Di Passenger Resistance low...
Page 722 10B-16 AIR BAG SYSTEM TABLE A – “AIR BAG” WARNING LAMP COMES “ON” STEADY (Page 1 of 2) : Air bag harness 1. From main fuse 4. “AIR BAG” warning lamp in combination meter 7. SDM 2. Ignition switch 5. “AIR BAG” fuse in “AIR BAG” fuse box 7-1.
Page 723 AIR BAG SYSTEM 10B-17 TABLE A – “AIR BAG” WARNING LAMP COMES “ON” STEADY (Page 2 of 2) Fig. for STEP 2 Fig. for STEP 3 “A5” Special Tool (A): 09932-76010 NOTE: Upon completion of inspection and repair work, perform following items. 1) Reconnect all air bag system components, ensure all components are properly mounted.
Page 724 10B-18 AIR BAG SYSTEM TABLE B – “AIR BAG” WARNING LAMP DOES NOT COME “ON” (Page 1 of 2) : Air bag harness 1. From main fuse 4. “AIR BAG” warning lamp in combination meter 7. SDM 2. Ignition switch 5.
Page 725 AIR BAG SYSTEM 10B-19 TABLE B – “AIR BAG” WARNING LAMP DOES NOT COME “ON” (Page 2 of 2) STEP ACTION 1) Remove combination meter, referring to Go to step 5. Repair high resistance SECTION 8C. or open in “BI” or “Y/G” 2) Check proper connection to combination wire circuit (between meter at terminal for “AIR BAG”...
Page 726 10B-20 AIR BAG SYSTEM TABLE C – “AIR BAG” WARNING LAMP FLASHES (Page 1 of 2) : Air bag harness 6–1 -5. “AIR BAG” fuse in “AIR BAG” fuse box 7. Connection detection pin 1. From main fuse -6. “AIR BAG” monitor coupler 8.
Page 727 AIR BAG SYSTEM 10B-21 TABLE C – “AIR BAG” WARNING LAMP FLASHES (Page 2 of 2) Fig. for STEP 2 Special Tool (A): 09932-76010 NOTE: Upon completion of inspection and repair work, perform following items. 1) Reconnect all air bag system components, ensure all components are properly mounted. 2) Repeat “Air Bag Diagnostic System Check Flow Table”, referring to p.10B-11 to confirm that the trouble has been corrected.
Page 728 10B-22 AIR BAG SYSTEM TABLE D – SDM CANNOT COMMUNICATE THROUGH THE SERIAL DATA CIRCUIT (Page 1 of 2) : Air bag harness 1. From main fuse 6. DLC 2. Ignition switch 7. To, ICM (if equipped) 3. “IG COIL METER” fuse in J/B 8.
Page 729 AIR BAG SYSTEM 10B-23 TABLE D – SDM CANNOT COMMUNICATE THROUGH THE SERIAL DATA CIRCUIT (Page 2 of 2) STEP ACTION 1) Check if communication is possible by Go to step 3. Repair open in common trying communication with other section of serial data circuit controller (ECM (or PCM), ICM or ABS (“W/B”...
Page 730: Code 15 - Passenger Air Bag Initiator Circuit Resistance High
10B-24 AIR BAG SYSTEM CODE 15 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (Page 1 of 2) : Shorting bar : Air bag harness 1. SDM 2. Passenger air bag (inflator) module CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 731 AIR BAG SYSTEM 10B-25 CODE 15 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, disconnect Go to step 2.
Page 732: Code 16 - Passenger Air Bag Initiator Circuit Resistance Low
10B-26 AIR BAG SYSTEM CODE 16 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW (Page 1 of 2) : Shorting bar : Air bag harness 1. SDM 2. Passenger air bag (inflator) module CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 733 AIR BAG SYSTEM 10B-27 CODE 16 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, disconnect Go to step 2.
Page 734: Code 18 - Passenger Air Bag Initiator Circuit Short To Ground
10B-28 AIR BAG SYSTEM CODE 18 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND (Page 1 of 2) : Shorting bar : Air bag harness 1. SDM 2. Passenger air bag (inflator) module CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 735 AIR BAG SYSTEM 10B-29 CODE 18 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, disconnect Go to step 2.
Page 736: Code 19 - Passenger Air Bag Initiator Circuit Short To Power Circuit
10B-30 AIR BAG SYSTEM CODE 19 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT (Page 1 of 2) : Shorting bar : Air bag harness 1. From ignition switch 2. “AIR BAG” fuse in “AIR BAG” fuse box 3.
Page 737 AIR BAG SYSTEM 10B-31 CODE 19 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, disconnect Go to step 2.
Page 738: Code 21 - Driver Air Bag Initiator Circuit Resistance High
10B-32 AIR BAG SYSTEM CODE 21 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (Page 1 of 2) : Shorting bar : Air bag harness 1. SDM 2. Contact coil assembly 3. Driver air bag (inflator) module CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 739 AIR BAG SYSTEM 10B-33 CODE 21 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (Page 2 of 2) STEP ACTION 1) With ignition switch OFF, disconnect Special 1) Ignition switch OFF. 1) Ignition switch OFF. Tool (B) then reconnect contact coil connector 2) Replace contact coil 2) Replace driver air located near the base of the steering column.
Page 740: Code 22 - Driver Air Bag Initiator Circuit Resistance Low
10B-34 AIR BAG SYSTEM CODE 22 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW (Page 1 of 2) : Shorting bar : Air bag harness 1. SDM 2. Contact coil assembly 3. Driver air bag (inflator) module CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 741 AIR BAG SYSTEM 10B-35 CODE 22 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW (Page 2 of 2) STEP ACTION 1) With ignition switch OFF, disconnect Special 1) Ignition switch OFF. 1) Ignition switch OFF. Tool (B) then reconnect contact coil connector 2) Replace contact coil 2) Replace driver air located near the base of the steering column.
Page 742: Code 24 -Driver Air Bag Initiator Circuit Short To Ground
10B-36 AIR BAG SYSTEM CODE 24 –DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND (Page 1 of 2) : Shorting bar : Air bag harness 1. SDM 2. Contact coil assembly 3. Driver air bag (inflator) module CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 743 AIR BAG SYSTEM 10B-37 CODE 24 –DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND (Page 2 of 2) STEP ACTION 1) With ignition switch OFF, disconnect Special 1) Ignition switch OFF. 1) Ignition switch OFF. Tool (B) then reconnect contact coil connec- 2) Replace contact coil 2) Replace driver air bag tor located near the base of the steering...
Page 744: Code 25 - Driver Air Bag Initiator Circuit Short To Power Circuit
10B-38 AIR BAG SYSTEM CODE 25 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT (Page 1 of 2) : Shorting bar : Air bag harness 1. From ignition switch 2. “AIR BAG” fuse in “AIR BAG” fuse box 3.
Page 745 AIR BAG SYSTEM 10B-39 CODE 25 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT (Page 2 of 2) STEP ACTION 1) With ignition switch OFF, disconnect Special 1) Ignition switch OFF. 1) Ignition switch OFF. Tool (B) then reconnect contact coil connector 2) Replace contact coil 2) Replace driver air bag located near the base of the steering column.
Page 746 10B-40 AIR BAG SYSTEM CODE 31 – POWER SOURCE VOLTAGE HIGH (Page 1 of 2) : Air bag harness 1. From main fuse 2. Ignition switch 3. “AIR BAG” fuse in “AIR BAG” fuse box 4. SDM CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 747 AIR BAG SYSTEM 10B-41 CODE 31 – POWER SOURCE VOLTAGE HIGH (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, disconnect SDM. Go to step 2.
Page 748 10B-42 AIR BAG SYSTEM CODE 32 – POWER SOURCE VOLTAGE LOW (Page 1 of 2) : Air bag harness 1. From main fuse 2. Ignition switch 3. “AIR BAG” fuse in “AIR BAG” fuse box 4. SDM CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal adapter from special tool (Connector test adapter kit).
Page 749 AIR BAG SYSTEM 10B-43 CODE 32 – POWER SOURCE VOLTAGE LOW (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) Measure voltage on battery. Go to step 2. Check Charging System 2) Is voltage 11 V or more? and repair as necessary.
Page 750: Code 41 - Driver Pretensioner Initiator Circuit Resistance High
10B-44 AIR BAG SYSTEM CODE 41 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH CODE 45 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH (Page 1 of 2) 1. SDM 2. Passenger seat belt pretensioner 3. Driver seat belt pretensioner : Shorting bar : Air bag harness CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal...
Page 751 AIR BAG SYSTEM 10B-45 CODE 41 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH CODE 45 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, remove front...
Page 752: Code 42 - Driver Pretensioner Initiator Circuit Resistance Low
10B-46 AIR BAG SYSTEM CODE 42 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW CODE 46 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW (Page 1 of 2) 1. SDM 2. Passenger seat belt pretensioner 3. Driver seat belt pretensioner : Shorting bar : Air bag harness CAUTION: D When measurements are requested in this chart use specified digital multimeter with correct terminal...
Page 753 AIR BAG SYSTEM 10B-47 CODE 42 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW CODE 46 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, remove front...
Page 754 10B-48 AIR BAG SYSTEM CODE 43 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND CODE 47 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND (Page 1 of 2) 1. SDM 2. Passenger seat belt pretensioner 3. Driver seat belt pretensioner : Shorting bar : Air bag harness CAUTION:...
Page 755 AIR BAG SYSTEM 10B-49 CODE 43 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND CODE 47 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, remove front...
Page 756 10B-50 AIR BAG SYSTEM CODE 44 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT CODE 48 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT (Page 1 of 2) 1. From ignition switch : Shorting bar 2. “AIR BAG” fuse in “AIR BAG” fuse box 3.
Page 757 AIR BAG SYSTEM 10B-51 CODE 44 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT CODE 48 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”. STEP ACTION 1) With ignition switch OFF, remove front pillar...
Page 758 10B-52 AIR BAG SYSTEM CODE 51 – FRONTAL CRASH DETECTED (SYSTEM ACTIVATION COMMAND IS OUT- PUTTED) DTC WILL SET WHEN: The SDM detects a frontal crash of sufficient force to warrant activation of the air bag system. (SDM outputs a de- ployment/activation command.) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic Check Flow Table”.
Page 759 AIR BAG SYSTEM 10B-53 CODE 61 – “AIR BAG” WARNING LAMP CIRCUIT FAILURE (Page 1 of 2) : Air bag harness 1. From main fuse 4. “AIR BAG” warning lamp in combination meter 7. Connection detection pin 2. Ignition switch 5.
Page 760 10B-54 AIR BAG SYSTEM CODE 61 – “AIR BAG” WARNING LAMP CIRCUIT FAILURE (Page 2 of 2) NOTE: Before executing items in this table, be sure to perform “Air Bag Diagnostic System Check Flow Table”. STEP ACTION 1) This DTC is set when there is a trouble in Go to step 2.
Page 761 Be sure to follow the instructions. WARNING: D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 762 10B-56 AIR BAG SYSTEM DISABLING AIR BAG SYSTEM 1) Turn steering wheel so that vehicle’s wheels (front tires) and pointing straight ahead. 2) Turn ignition switch to “LOCK” position and remove key. 3) Remove “AIR BAG” fuse from “AIR BAG” fuse box. 4) Disconnect Yellow connector of contact coil and combination switch assembly.
Page 763 AIR BAG SYSTEM 10B-57 3) Connect Yellow connector of passenger air bag (inflator) mod- ule, and be sure to lock connector with lock lever. ii) Connect connector. ii) Lock connector with lock lever. 4) Install glove box. 5) Install “AIR BAG” fuse to “AIR BAG” fuse box. 6) Turn ignition switch to ON and verify that “AIR BAG”...
Page 764 10B-58 AIR BAG SYSTEM LIVE (UNDEPLOYED) AIR BAG (INFLATOR) MODULES Special care is necessary when handling and storing a live (unde- ployed) air bag (inflator) modules. The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, or an object in front of the air bag (inflator) module, to be thrown through the air in the unlikely event of an accidental deployment.
Page 765 AIR BAG SYSTEM 10B-59 WARNING: ALWAYS PLACE AIR BAG (INFLATOR) MODULE ON WORKBENCH WITH TRIM COVER (AIR BAG When placing a live air bag (inflator) module on bench or OPENING) UP, AWAY FROM LOOSE OBJECTS. other surface, always face the bag up, away from the sur- face.
Page 766 10B-60 AIR BAG SYSTEM D Never attempt to disassemble the seat belt pretensioners (retrac- tor assembly). D If any abnormality is found, be sure to replace it with new one as an assembly. D When an abnormality is noted as existing in the live (inactivated) seat belt pretensioner, be sure to activate it before discarding it.
Page 767 AIR BAG SYSTEM 10B-61 DEPLOYED AIR BAG (INFLATOR) MODULES WARNING: D The air bag (inflator) module immediately after deploy- ment is very hot. Wait for at least 30 minutes to cool it off before proceeding the work. D Do not apply water, oil, etc. to deployed air bag (inflator) module.
Page 768 10B-62 AIR BAG SYSTEM AIR BAG WIRE HARNESS AND CONNECTORS Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very careful when handling it. D When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly.
Page 769 AIR BAG SYSTEM 10B-63 REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT CAUTION: D All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be replaced even if air bag system activation did not occur.
Page 770 10B-64 AIR BAG SYSTEM ACCIDENT WITH OR WITHOUT DEPLOYMENT – COM- PONENT INSPECTIONS Certain air bag and restraint system components must be in- spected after any crash, whether the air bag deployed or not. Those components are: D Steering column and shaft joints –...
Page 771 AIR BAG SYSTEM 10B-65 D Passenger air bag (inflator) module – Check for dents, cracks, damage or fitness. – Check trim cover for cracks or deformities. – Check harness and connector for damage or tightness. If any faulty condition is found in above checks, replace. D SDM and SDM plate –...
Page 772: Seat Belt Pretensioner
10B-66 AIR BAG SYSTEM D Seat belt pretensioner – Check for dents, cracks, damage or fitness. – Check harness and connector for damage or tightness. If any faulty condition is found in above checks, replace. 2-1. Webbing 2-2. Retractor assembly 2-1.
Page 773 AIR BAG SYSTEM 10B-67 WARNING: During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Be sure to read “Service Precautions” in this section before starting to work and observe every precaution during work. Neglecting them may result in personal injury or inactiva- tion of the air bag system when necessary.
Page 774 10B-68 AIR BAG SYSTEM INSTALLATION 1) Check that none of following faulty conditions exists. D Bend, scratch, deformity in vehicle body mounted on SDM D Foreign matter or rust on mating surface of vehicle body mounted on SDM 2) Install SDM (with SDM plate) to vehicle. CAUTION: Ensure that arrow on the SDM is pointing toward the front of the vehicle.
Page 775 AIR BAG SYSTEM 10B-69 PASSENGER AIR BAG (INFLATOR) MODULE WARNING: D Never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. D Be sure to read “Service Precautions” in this section before starting to work and observe every pre- caution during work.
Page 776 10B-70 AIR BAG SYSTEM INSPECTION WARNING: Never measure resistance of passenger air bag (inflator) module or disassemble it. Otherwise personal injury may result. CAUTION: If air bag (Inflator) module was dropped from a height or 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module appearance visually for following symptoms and if any one of them is applicable, replace with a new one.
Page 777 AIR BAG SYSTEM 10B-71 AIR BAG (INFLATOR) MODULES DISPOSAL WARNING: Failure to follow proper air bag (inflator) module disposal procedures can result in air bag deployment which may cause personal injury. Undeployed air bag (inflator) module must not be disposed of through normal refuse channels.
Page 778 10B-72 AIR BAG SYSTEM 1) Turn ignition switch to “LOCK”, remove key and put on safety glasses. 2) Check that there is no open, short or damage in special tool (de- ployment harness). If any faulty is found, do not use it and be sure to use new deployment harness.
Page 779 AIR BAG SYSTEM 10B-73 6) [In case of Driver Air Bag (Inflator) Module] ii) Clear a space on the ground about 185 cm (6 ft) in diameter where the driver air bag (inflator) module is to be deployed. A paved, outdoor location where there is no activity is pre- ferred.
Page 780 10B-74 AIR BAG SYSTEM 7) Stretch the deployment harness from the driver or passenger air bag (inflator) module to its full length 10 m (33 ft). 8) Place a power source near the shorted end of the deployment harness. Recommended application: 12 Volts minimum, 2 amps minimum.
Page 781 AIR BAG SYSTEM 10B-75 WARNING: D After deployment, the metal surfaces of the air bag (in- flator) module will be very hot. Do not touch the metal areas of the air bag (inflator) module for about 30 min- utes after deployment. D Do not place the deployed air bag (inflator) module near any flammable objects.
Page 782 10B-76 AIR BAG SYSTEM 17) Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling the deployed air bag (inflator) For driver air bag (inflator) module module. NOTE: As a precaution, gloves and safety glasses are recom- mended to prevent any possible irritation of the skin or eyes.
Page 783 AIR BAG SYSTEM 10B-77 ALWAYS CARRY AIR BAG (INFLATOR) MODULE WARNING: WITH TRIM COVER (AIR BAG OPENING) AWAY D Always carry a live air bag (inflator) module with trim FROM BODY. cover away from you. D When storing a live air bag (inflator) module or when leaving a live air bag (inflator) module unattended on a bench or other surface, always face the bag and trim cover up and away from the surface.
Page 784 10B-78 AIR BAG SYSTEM DEPLOYMENT INSIDE VEHICLE Use this procedure when scrapping the entire vehicle including the driver and passenger air bag (inflator) modules. CAUTION: When vehicle itself will be used again, deploy the air bag outside vehicle according to “Deployment Outside Vehicle”, for deploying it inside will cause the instrument panel, glove box and their vicinity to be deformed.
Page 785 AIR BAG SYSTEM 10B-79 4) Confirm that each air bag (inflator) module is securely mounted. 5) Check that there is no open/short or damage in special tool (de- ployment harness). If any faulty condition is found, do not use it and be sure to use new deployment harness.
Page 786 10B-80 AIR BAG SYSTEM 8) Route deployment harness out the vehicle. 9) Verify that the inside of the vehicle and the area surrounding Driver side for left hand steering vehicle the vehicle are clear of all people and loose or flammable ob- jects.
Page 787 AIR BAG SYSTEM 10B-81 14) Separate the two banana plugs on the deployment harness. 15) Connect the deployment harness to the power source (12 V ve- hicle battery) to immediately deploy the driver or passenger air bag. 16) Disconnect the deployment harness from the power source (12 V vehicle battery) and short the two deployment harness leads together by fully seating one banana plug into the other.
Page 788 10B-82 AIR BAG SYSTEM 21) In the unlikely event that either or both of the air bag (inflator) modules proceed immediately with Steps 23) through 25). If the air bag (inflator) module did deploy, proceed with Steps 22). 22) With air bags deployed the vehicle may be scrapped in the same manner as a non-air bag system equipped vehicle.
Page 789 AIR BAG SYSTEM 10B-83 SEAT BELT PRETENSIONERS DISPOSAL WARNING: Failure to follow proper seat belt pretensioner (retractor assembly) disposal procedures can result in pretensioner activation which may cause personal injury. Inactivated seat belt pretensioner must not be disposed of through normal refuse channels. The inactivated seat belt pretensioner contain substances that can cause severe illness or personal injury if the sealed container is damaged during disposal.
Page 790 10B-84 AIR BAG SYSTEM 1) Turn ignition switch to “LOCK”, remove key and put on safety glasses. 2) Check that there is no open, short or damage in special tool (de- ployment harness). If any faulty is found, do not use it and be sure to use new deployment harness.
Page 791 AIR BAG SYSTEM 10B-85 6) Pull out the webbing fully as shown at the left and cut it at the root of the pretensioner (retractor assembly) as shown in the figure. WARNING: As the drum of the retractor assembly turns very quick- ly as soon as the webbing is cut, fix the retractor assem- bly with a vise on the workbench and keep your hands and fingers away from it when cutting the webbing.
Page 792 10B-86 AIR BAG SYSTEM 14) Notify all people in the immediate area that you intend to acti- vate the seat belt pretensioner. NOTE: D When the pretensioner activates, the rapid gas expan- sion will create a substantial report. Wear suitable ear protection.
Page 793 AIR BAG SYSTEM 10B-87 18) In the unlikely event that the seat belt pretensioner did not acti- vate after following these procedures, proceed immediately with Steps 23) through 26). If the the seat belt pretensioner did activate, proceed with Steps 19) through 22). 19) Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling the activated seat belt preten- sioner.
Page 794 10B-88 AIR BAG SYSTEM NOTE: The remaining steps are to be followed in the unlikely event that the seat belt pretensioner did not activate after following these procedures. 23) Ensure that the deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the oth- 24) Disconnect the deployment harness from the seat belt preten- sioner.
Page 795 AIR BAG SYSTEM 10B-89 ACTIVATION INSIDE VEHICLE Use this procedure when scrapping the entire vehicle including the seat belt pretensioners. CAUTION: When vehicle itself will be used again, activate pretensioner outside vehicle according to “Activation Outside Vehicle”, for activating it inside will cause the center pillar inner garnish and their vicinity to be deformed.
Page 796 10B-90 AIR BAG SYSTEM 5) Check that there is no open/short or damage in special tool (de- ployment harness). If any faulty condition is found, do not use it and be sure to use new deployment harness. Special Tool (A): 09932-75030 6) Short the two deployment harness leads together by fully seat- ing one banana plug into the other.
Page 797 AIR BAG SYSTEM 10B-91 NOTE: When the pretensioner activates, the rapid gas expansion will create a substantial report. Wear suitable ear protec- tion. Notify all people in the immediate area that you intend to activate the seat belt pretensioner and suitable ear protection should be worn.
Page 798 10B-92 AIR BAG SYSTEM 17) Put on a pair of shop gloves to protect your hands from possible irritation and heat when handling the activated seat belt preten- sioner. NOTE: As a precaution, gloves and safety glasses are recom- mended to prevent any possible irritation of the skin or eyes.
Page 799 AIR BAG SYSTEM 10B-93 24) Temporarily store the seat belt pretensioner. At that time, be sure NOT to face its exhaust hole provided side down. It must face up. Refer to “Service Precautions” in this section for de- tails. 25) Contact your local distributor for further assistance. DEPLOYED AIR BAG (INFLATOR) MODULES DISPOSAL WARNING:...
Page 800 10B-94 AIR BAG SYSTEM ACTIVATED SEAT BELT PRETENSIONERS DISPOSAL WARNING: Failure to follow proper seat belt pretensioner (retractor as- sembly) disposal procedures can result in pretensioner ac- tivation which may cause personal injury. Inactivated seat belt pretensioner must not be disposed of through normal refuse channels.
Page 801 3. Tech 1A 4. DLC cable 5. Test lead/probe 6. Power source cable 09931-76011 7. DLC cable adapter Suzuki scan tool (tech 1A) kit 8. Self-test adapter Mass storage cartridge for air bag system 09932-75010 09931-76030 Air bag driver/passenger 09932-76010...

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Suzuki sq-416-420-625 Service Manual

Section 0A General Information

How to Use this Manual

Precautions

Identification Information

Warning, Caution and Information Labels

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Metric Information

Maintenance and Lubrication

Maintenance Schedule

0B-2 Maintenance and Lubrication

Maintenance Service

Recommended Fluids and Lubricants

Heater and Ventilation

General Description

Diagnosis

On-Vehicle Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Refrigerant Recovery, Evacuation and Charging

On-Vehicle Service

Required Service Material

Special Tools

Section 3B1 Power Steering (P/S) System

General Description

Diagnosis

On-Vehicle Service

Special Tool

Required Service Material

Tightening Torque Specification

Section 3C Steering Wheel and Column (Not Equipped with Air Bag)

Diagnosis

General Description

On-Vehicle Service

Tightening Torque Specifications

Special Tool

Section 3C1 Air Bag Steering Wheel and Column

General Description

On-Vehicle Service

Diagnosis

Special Tool

Tightening Torque Specifications

Sectiond Front Suspension

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Required Service Materials

Special Tools

Section 3E Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Required Service Materials

Tightening Torque Specifications

Special Tools

Section 3F Wheels and Tires

Diagnosis

Maintenance and Minor Adjustments

On-Vehicle Service

Tightening Torque Specifications

Section 4A2 Front Drive Shaft/Shaft Bearing, Oil Seal

General Description

General Description

Section 5 Brakes

General Description

Diagnosis

Check and Adjustment

Required Service Material

Tightening Torque Specifications

Special Tools

Section 5A Brakes Pipe/Hose/Master Cylinder

General Description

Diagnosis

Check and Adjustment

On-Vehicle Service

Required Service Material

Tightening Torque Specifications