Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 5 TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Transmission / Transaxle .......... 5-i General Information ..........0A-1 Precautions .............. 5-1 Maintenance and Lubrication ......... 0B-1 Automatic Transmission/Transaxle ......5A-1 Manual Transmission/Transaxle ......5B-1 Engine .................
Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions in Servicing Full-Time 4WD Vehicle ............00-10 Precautions............00-1 Air Bag Warning ..........00-11 Precautions for Vehicles Equipped with a Air Bag System Service Warning ...... 00-11 Supplemental Restraint (Air Bag) System ..00-1 Fastener Caution..........
Page 8 • If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 9 Precautions: 00-2 Servicing and handling WARNING 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. Driver, Passenger and Side Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from...
Page 10 00-3 Precautions: WARNING WARNING Driver and Passenger Seat Belt Pretensioners (If equipped) • For handling and storage of a SDM, select a place where the ambient temperature • For handling and storage of a live seat belt below 65 °C (150 °F), without high humidity pretensioner, select a place where the ambient temperature below 65 °C (150 °F), and away from electric noise.
Page 11 Precautions: 00-4 General Precautions • Even when the accident was light enough not to S3RH0A0000002 cause air bags to activate, be sure to inspect system The WARNING and CAUTION describe some general parts and other related parts according to instructions precautions that you should observe when servicing a under “Repairs and Inspections Required after an vehicle.
Page 12 00-5 Precautions: • Before starting any service work, cover fenders, seats • When removing parts that are to be reused, be sure to and any other parts that are likely to get scratched or keep them arranged in an orderly manner so that they stained during servicing.
Page 13 Precautions: 00-6 • Be sure to use special tools when instructed. Special tool (A): 09917-98221 (B): 09916–58210 I2RH01010034-01 • Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. I2RH01010031-01 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly.
Page 14 00-7 Precautions: Precautions for Electrical Circuit Service • When connecting connectors, also hold S3RH0A0000004 connectors and put them together until CAUTION they lock securely (a click is heard). • When replacing a fuse, make sure to use a fuse of the specified capacity. Use of a fuse with a larger capacity will cause a damage to the electrical parts and a fire.
Page 15 Precautions: 00-8 • Be careful not to touch the electrical • When connecting meter probe (2) from terminals of parts which use terminal side of coupler (1) because it can’t microcomputers (e.g. electronic control be connected from harness side, use extra unit like as ECM, PCM, P/S controller, etc).
Page 16 00-9 Precautions: Precautions for Installing Mobile Communication Equipment S3RH0A0000005 CAUTION When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular- telephone, be sure to observe the following precautions. Failure to follow cautions may adversely affect electronic control system. • Keep the antenna as far away as possible from the vehicle’s electronic control unit. •...
Page 17 Precautions: 00-10 Precautions in Servicing Full-Time 4WD Vehicle • When testing with 2-wheel chassis S3RH0A0000013 dynamometer, speedometer tester or brake CAUTION tester, be sure to make the vehicle as front wheel drive by removing rear propeller This full-time 4WD vehicle can not be shaft.
Page 18 If the correct only by an authorized SUZUKI dealer. Refer part number fastener is not available, a to “Air Bag System Components, Wiring fastener of equal size and strength (or and Connectors Location in Section 8B”...
Page 19 Precautions: 00-12 Brake Note NOTE S3RH0A0000012 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 20 00-13 Precautions: Continuity Check Voltage Check If voltage is supplied to the circuit being checked, voltage 1) Measure resistance between connector terminals at check can be used as circuit check. both ends of the circuit being checked (between “A- 1” and “C-1” in the figure). If no continuity is indicated 1) With all connectors connected and voltage applied to (infinity or over limit), that means that the circuit is the circuit being checked, measure voltage between...
Page 21: Intermittent And Poor Connection Inspection
Precautions: 00-14 Intermittent and Poor Connection Inspection Short Circuit Check (wire harness to ground) S3RH0A0006002 1) Disconnect negative (–) cable at battery. Most intermittent are caused by faulty electrical 2) Disconnect connectors at both ends of the circuit to connections or wiring, although a sticking relay or be checked.
Page 22 00-15 Precautions: • Poor terminal-to-wire connection. • Wiring broken inside the insulation. This condition Check each wire harness in problem circuits for poor could cause continuity check to show a good circuit, connection by shaking it by hand lightly. If any but if only 1 or 2 strands of a multi-strand-type wire abnormal condition is found, repair or replace.
Page 23: General Information
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 PCV Valve Inspection .........0B-7 Fuel Evaporative Emission Control System General Description ..........0A-1 Inspection............0B-7 Abbreviations ............0A-1 Brake Discs and Pads (Front) Inspection....0B-7 Symbols .............. 0A-2 Brake Drums and Shoes (Rear) Inspection ..0B-7 Wire Color Symbols ..........
Page 24 0A-1 General Information: General Information General Information General Description Abbreviations S3RH0A0101001 FWD: Front Wheel Drive 4WD: 4 Wheel Drive ABS: Anti-lock Brake System ATDC: After Top Dead Center GEN: Generator API: American Petroleum Institute GND: Ground ATF: Automatic Transmission Fluid, Automatic Transaxle Fluid HC: Hydrocarbons ALR: Automatic Locking Retractor...
Page 25 WU-TWC: Warm Up Three Way Catalytic Converter Symbols S3RH0A0101003 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
Page 26 0A-3 General Information: Wire Color Symbols S3RH0A0101004 Symbol Wire Color Symbol Wire Color Black O, Or Orange Blue Brown White Green Yellow Gray Pink LT BLU Light blue Violet LT GRN Light green There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire.
Page 27 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 28 0A-5 General Information: Vehicle Lifting Points S3RH0A0101006 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 29 General Information: 0A-6 When Using Floor Jack WARNING If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands.
Page 30: Engine Identification Number
0A-7 General Information: Engine Identification Number To perform service with either front or rear vehicle end jacked up, be sure to place safety stands (1) under S3RH0A0101008 The number is punched on cylinder block. shaded positions of vehicle body so that vehicle body is securely supported.
Page 31 General Information: 0A-8 Component Location Warning, Caution and Information Labels Location S3RH0A0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
Page 32 0A-9 General Information: I3RH0A010003-01 1. Air bag label on driver air bag (inflator) module 5. Pretensioner label on seat belt retractor 2. Air bag label on combination switch and contact coil assembly 6. Child seat label (if equipped) 3. Air bag label on passenger air bag (inflator) module 7.
Page 33: Maintenance And Lubrication
Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S3RH0A0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Normal Condition Schedule S3RH0A0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
Page 34 0B-2 Maintenance and Lubrication: Km (x 1,000) Interval Miles (x 1,000) Months Suspension system (tightness, damage, rattle, breakage) (I: — — — Steering system (tightness, damage, breakage, rattle) (I: — — — Drive shaft (axle) boots / Propeller shafts (4WD) (I: —...
Page 35 Maintenance and Lubrication: 0B-3 Severe Maintenance Maintenance Maintenance Interval Condition Code Operation First time only: 15,000 km (9,000 miles) or 12 months Manual transaxle oil, transfer oil (4WD Second time and after: – B – – E – – H A/T) and differential oil (4WD) Every 30,000 km (18,000 miles) or 24 months reckoning from 0 km (0 mile)
Page 36 0B-4 Maintenance and Lubrication: Drive Belt Replacement Before draining engine oil, check engine for oil leakage. S3RH0A0206036 If any evidence of leakage is found, make sure to correct WARNING defective part before proceeding to the following work. 1) Drain engine oil by removing drain plug. Be sure to disconnect negative cable from 2) After draining oil, wipe drain plug clean.
Page 37 Maintenance and Lubrication: 0B-5 4) Screw new filter on oil filter stand by hand until the 7) Check oil filter and drain plug for oil leakage. filter O-ring contacts mounting surface. 8) Start engine and run it for three minutes. Stop it and wait another 5 minutes before checking oil level.
Page 38 0B-6 Maintenance and Lubrication: Spark Plugs Replacement Fuel Lines and Connections Inspection S3RH0A0206006 S3RH0A0206010 Replace spark plugs with new ones referring to “Spark Visually inspect fuel lines and connections for evidence Plug Removal and Installation in Section 1H”. of fuel leakage, hose cracking and damage. Make sure all clamps are secure.
Page 39 Maintenance and Lubrication: 0B-7 Fuel Tank Inspection Brake Drums and Shoes (Rear) Inspection S3RH0A0206037 S3RH0A0206014 Check fuel tank damage, cracks, fuel leakage, corrosion Check rear brake drums and brake linings for excessive and tank bolts looseness. wear and damage, while wheels and drums are If a problem is found, repair or replace.
Page 40 0B-8 Maintenance and Lubrication: Brake Lever and Cable Inspection Tires / Wheels Inspection S3RH0A0206018 S3RH0A0206021 1) Inspect brake cable for damage and smooth 1) Check tires for uneven or excessive wear, or damage. If defective, replace. movement. Replace cable if it is in deteriorated condition. Refer to “Irregular and/or Premature Wear Description in Section 2D”and “Wear Indicators Description in Section 2D”...
Page 41 Maintenance and Lubrication: 0B-9 Suspension System Inspection Steering System Inspection S3RH0A0206024 S3RH0A0206025 1) Inspect front & rear struts for evidence of oil leakage, 1) Check steering wheel for play and rattle, holding dents or any other damage on sleeves; and inspect vehicle straight on ground.
Page 42 0B-10 Maintenance and Lubrication: Drive Shaft (Axle) Boots Inspection Manual Transaxle Oil Inspection S3RH0A0206026 S3RH0A0206027 Check drive shaft boots (wheel side and differential side) 1) Inspect transaxle case for evidence of oil leakage. for leaks, detachment, tear or other damage. Repair leaky point if any.
Page 43 Maintenance and Lubrication: 0B-11 Automatic Transaxle Fluid Inspection Automatic Transaxle Fluid Cooler Hose S3RH0A0206029 Inspection 1) Inspect transaxle case for evidence of fluid leakage. S3RH0A0206031 Check automatic transaxle fluid cooler hose for fluid Repair leaky point, if any. leakage, cracks, damage and deterioration. 2) Make sure that vehicle is placed level for fluid level Replace hose and/or clamp if any faulty condition is check.
Page 44 0B-12 Maintenance and Lubrication: 3) Remove level plug of transfer or differential and check oil level. Oil level can be checked roughly by means of level plug hole. That is, if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled.
Page 45 Maintenance and Lubrication: 0B-13 Final Inspection for Maintenance Service Clutch (for Manual Transaxle) S3RH0A0206034 Check for the following. WARNING • Clutch is completely released when depressing clutch pedal. When carrying out road tests, select a safe • No slipping clutch occurs when releasing pedal and place where no man or no running vehicle is accelerating.
Page 46 0B-14 Maintenance and Lubrication: Lights Body, Wheels and Power Transmitting System Check that body, wheels and power transmitting system Check that all lights operate properly. are free from abnormal noise and abnormal vibration or any other abnormal condition. Windshield Defroster Periodically check that air comes out from defroster Meters and Gauge outlet when operating heater or air conditioning.
Page 47: Table Of Contents
Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Precautions............. 1-1 Terminal (Vehicle without Immobilizer Precautions for Engine.......... 1-1 Indicator Lamp) ..........1A-43 Engine General Information and MIL Does Not Light at Ignition Switch ON and Engine Does Not Start Through It Is Cranked Diagnosis ..........
Page 48 Specifications ............1C-8 Aux. Emission Control Devices ..... 1B-1 Tightening Torque Specifications......1C-8 Diagnostic Information and Procedures....1B-1 Engine Mechanical ........1D-1 EGR System Inspection (Using SUZUKI Scan General Description ..........1D-1 Tool) ..............1B-1 Engine Construction Description ......1D-1 Repair Instructions ..........1B-1 Diagnostic Information and Procedures ....1D-2 EVAP Canister Inspection........
Page 49 Table of Contents 1-iii Throttle Body Cleaning ........1D-8 Diagnostic Information and Procedures ....1E-2 Throttle Body and Intake Manifold Oil Pressure Check ..........1E-2 Components............1D-9 Repair Instructions ..........1E-3 Throttle Body and Intake Manifold Removal Oil Pan and Oil Pump Strainer Components..1E-3 and Installation ..........1D-9 Oil Pan and Oil Pump Strainer Removal and Cylinder Head Cover Removal and Installation ............1E-3...
Page 50 1-iv Table of Contents General Description ..........1G-2 Ignition Coil Assembly (Including Igniter) Fuel System Description ........1G-2 Removal and Installation........1H-7 Fuel Delivery System Description ...... 1G-2 Ignition Coil Assembly (Including Igniter) Fuel Pump Description........1G-2 Inspection............1H-8 Ignition Timing Inspection ........1H-8 Schematic and Routing Diagram.......
Page 51: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine S3RH0A1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions on Fuel System Service Refer to “Precautions on Fuel System Service in Section 1G”.
Page 52: Engine General Information And Diagnosis
ECM memory. shorted to ground. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or generic scan tool (Vehicle with immobilizer General Description Statement on Cleanliness and Care •...
Page 53: Engine Diagnosis General Description
(For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
Page 54 1A-3 Engine General Information and Diagnosis: Pending DTC Pending DTC means a DTC detected and stored temporarily at 1 driving cycle of the DTC which is detected in the 2 driving cycle detection logic. Freeze frame data ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.
Page 55 • Heated oxygen sensor (if equipped) with ECM, Air bag SDM, TCM and ABS control module. • ECT sensor SUZUKI serial data line (6) is used for SUZUKI scan tool • TP sensor to communicate with immobilizer control module. • IAT sensor •...
Page 56: Engine And Emission Control System
(1) lights and remains ON as long as the control module and Air bag SDM. trouble exists but it turns OFF when the SUZUKI serial data line (6) is used for SUZUKI scan tool normal condition is restored. to communicate with immobilizer control module.
Page 57: Air Intake System Description
Engine General Information and Diagnosis: 1A-6 Air Intake System Description S3RH0A1101017 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air control valve (4) and intake manifold (5). The air (by the amount corresponding to manifold absolute pressure (6) and engine speed) is filtered by the air cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each combustion chamber.
Page 58 1A-7 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram I2RH0B110006-01...
Page 59 Engine General Information and Diagnosis: 1A-8 ECM Input / Output Circuit Diagram C41-9 BLU/YEL C41-11 BLK/RED C41-21 BLU/WHT C41-31 BLU/RED YEL/BLK C41-23 C41-8 BLU/GRN BLK/ORN GRY/RED C41-22 C41-6 GRN/RED GRY/BLU C41-16 BLK/RED C41-4 BLU/BLK LT GRN/RED C41-26 C41-18 GRY/WHT C41-29 C41-13 GRY/YEL C41-17...
Page 60 1A-9 Engine General Information and Diagnosis: [A]: Automatic A/C type 21. A/C pressure switch 43. Diagnosis connector (vehicle without immobilizer indicator lamp) [B]: Manual A/C type 22. A/C condenser fan relay 44. Ignition coil assembly (for No.1 and No.4 spark plugs) 1.
Page 61 D-range ID-up signal (A/T) Fuel level sensor (gauge) (vehicle with immobilizer indicator lamp) PPL/YEL Malfunction indicator lamp — — Data link connector (SUZUKI GRN/YEL Serial data for TCM serial data line) YEL/GRN Engine coolant temp. signal PNK/GRN Monitor output (vehicle without...
Page 62: Engine And Emission Control Input / Output Table
1A-11 Engine General Information and Diagnosis: Engine and Emission Control Input / Output Table S3RH0A1101019 ELECTRIC CONTROL DEVICE OUTPUT INPUT DIAGNOSIS SWITCH (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP) FUEL LEVEL SENSOR For detecting fuel level (VEHICLE WITH IMMOBILIZER INDICATOR LAMP) BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH...
Page 63: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-12 Schematic and Routing Diagram Engine and Emission Control System Diagram S3RH0A1102001 I2RH0B110010-01...
Page 64 1A-13 Engine General Information and Diagnosis: 1. Air cleaner 18. Knock sensor (vehicle with EGR valve) 33-2. Test switch terminal (vehicle without immobilizer indicator lamp) 2. EVAP canister purge valve 19. ECT sensor 33-3. Duty output terminal (vehicle without immobilizer indicator lamp) 3.
Page 65: Component Location
Engine General Information and Diagnosis: 1A-14 Component Location Electronic Control System Components Location S3RH0A1103001 I3RH0A110006-01 INFORMATION SENSORS CONTROL DEVICES OTHERS 1. MAP sensor a: Fuel injector A: ECM 2. TP sensor b: EVAP canister purge valve B: Main relay 3. IAT sensor c: Fuel pump relay C: EVAP canister 4.
Page 66 1A-15 Engine General Information and Diagnosis: I3RH0A110007-01 1. TP sensor 10. Radiator fan control relay No.2 19. ECM 2. MAP sensor 11. Radiator fan control relay No.3 20. Diagnosis connector (vehicle without immobilizer indicator lamp) 3. IAC valve 12. EVAP canister purge valve 21.
Page 67: Diagnostic Information And Procedures
Engine General Information and Diagnosis: 1A-16 Diagnostic Information and Procedures Engine and Emission Control System Check S3RH0A1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Page 68 1A-17 Engine General Information and Diagnosis: Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition? Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer.
Page 69 Engine General Information and Diagnosis: 1A-18 Customer problem inspection form (example) I2RH01110010-02 NOTE The form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 70: Malfunction Indicator Lamp (Mil) Check
1A-19 Engine General Information and Diagnosis: Step 2: DTC(s) / Freeze Frame Data Check, Record Step 9: Troubleshooting for DTC (See each DTC and Clearance Diag. Flow) First, check DTC (including pending DTC), referring to Based on the DTC indicated in Step 6 or 7 and referring “DTC Check”.
Page 71: Dtc Check
Without Using SUZUKI Scan Tool (Vehicle without S3RH0A1104004 Using Scan Tool Immobilizer Indicator Lamp) 1) Connect SUZUKI scan tool or generic scan tool 1) Check malfunction indicator lamp referring to (Vehicle with immobilizer indicator lamp) to data link “Malfunction Indicator Lamp (MIL) Check”.
Page 72 1A-21 Engine General Information and Diagnosis: NOTE Without Using Scan Tool 1) Turn the ignition switch OFF position. DTC and freeze frame data stored in ECM memory are also cleared in the following 2) Disconnect battery negative cable for specified time cases.
Page 73: Malfunction
Engine General Information and Diagnosis: 1A-22 MIL (vehicle MIL (vehicle Detecting condition with without DTC No. Detecting item (DTC will set when detecting:) immobilizer immobilizer indicator lamp) indicator lamp) MIL flashing P0300 Random misfire detected Misfire of such level as to cause damage to during misfire Not applicable P0301...
Page 74 OFF. Bear these in mind when diagnosing troubles. • DTC No.12 appears when none of the other codes is identified. • For vehicle with immobilizer indication lamp, star (*) marked DTCs can be read with SUZUKI scan tool ECM application.
Page 75 Engine General Information and Diagnosis: 1A-24 Fail-Safe Table S3RH0A1104006 When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM detects normal condition after that. DTC No.
Page 76 1A-25 Engine General Information and Diagnosis: Scan Tool Data S3RH0A1104007 As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 77 Engine General Information and Diagnosis: 1A-26 Normal condition / Scan tool data Vehicle condition reference values When engine is running at 2000 r/min. for 3 min. 0 – 0.95 V O2S B1 S2 (HEATED or longer after warming up. OXYGEN SENSOR-2) At idling with radiator cooling fan stopped and all 1.3 L M/T: 700 r/min.
Page 78 1A-27 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values Engine running at Steering wheel at straight PSP SWITCH (POWER idle speed ahead position STEERING PRESSURE Steering wheel turned to the SWITCH) right or left as far as it stop Engine running Blower motor switch and A/ A/C COND FAN (if equipped...
Page 79 Engine General Information and Diagnosis: 1A-28 OXYGEN SENSOR B1 S1 (HEATED OXYGEN RADIATOR FAN (RADIATOR FAN CONTROL RELAY, SENSOR-1, V) ON/OFF) It indicates output voltage of HO2S-1 installed on ON: Command for radiator fan control relay operation exhaust manifold (pre-catalyst). being output.
Page 80 1A-29 Engine General Information and Diagnosis: BLOWER FAN (ON/OFF) A/C PRESSURE SW (ON/OFF) ON: A/C pressure switch not detected insufficient This parameter indicates the state of the blower fan refrigerant amount. motor switch. OFF: A/C pressure switch detected insufficient refrigerant amount. A/C MAG SWITCH (A/C COMPRESSOR RELAY, ON/ OFF) This parameter indicates the state of the A/C switch.
Page 81 4) Check engine idle speed with scan tool. I2RH01110005-01 Is it 650 – 750 r/min. (700 – 800 r/min. for A/T vehicle)? Do you have SUZUKI scan tool? Go to Step 8. Go to Step 7. Check ignition timing as follows: Go to “Engine Symptom...
Page 82 Action Check ignition timing as follows: Go to “Engine Symptom Check ignition control Diagnosis”. related parts referring to 1) Select “MISC” mode on SUZUKI scan tool and fix “Ignition Timing ignition timing to initial one. Inspection in Section 1H”. I2RH01110006-01 2) Using timing light, check initial ignition timing.
Page 83 Engine General Information and Diagnosis: 1A-32 Step Action 13 Check ignition spark as follows: Go to Step 14. Go to “Ignition System Symptom Diagnosis in 1) Disconnect injector couplers. Section 1H”. 2) Remove spark plugs and connect them to high tension cords.
Page 84 1A-33 Engine General Information and Diagnosis: Engine Symptom Diagnosis S3RH0A1104010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H”...
Page 85 Engine General Information and Diagnosis: 1A-34 Condition Possible cause Correction / Reference Item Engine noise – Piston, Worn piston, ring and cylinder bore “Cylinders, Pistons and Piston Rings ring and cylinder noise Inspection in Section 1D” NOTE Before checking mechanical noise, make sure that: •...
Page 86 Faulty spark plug (improper gap, heavy “Spark Plug Inspection in Section 1H” deposits and burned electrodes, etc.) Malfunctioning EGR valve (if equipped) “EGR System Inspection (Using SUZUKI Scan Tool) in Section 1B” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including Igniter) Inspection in Section 1H”...
Page 87 Can occur Fuel pressure out of specification “Fuel Pressure Check” at all vehicle speeds. Malfunctioning EGR valve (if equipped) “EGR System Inspection (Using SUZUKI Scan Usually most severe when Tool) in Section 1B” first trying to make TP sensor, ECT sensor or MAP sensor “Throttle Position (TP) Sensor On-Vehicle vehicle move, as from a Inspection in Section 1C”, “Engine Coolant...
Page 88 Condition “Slipping clutch” in “Clutch System Symptom Diagnosis in Section 5C”. Blown cylinder head gasket Replace. Malfunctioning EGR valve (if equipped) “EGR System Inspection (Using SUZUKI Scan Tool) in Section 1B” Maladjusted accelerator cable play “Accelerator Cable Adjustment in Section 1D”...
Page 89 Fuel pressure out of specification “Fuel Pressure Check” Leaky manifold, throttle body, or cylinder head gasket Malfunctioning EGR valve (if equipped) “EGR System Inspection (Using SUZUKI Scan Tool) in Section 1B” Faulty idle air control system “Idle Air Control System Check”...
Page 90 Lead contamination of catalytic Check for absence of filler neck restrictor. converter Faulty EGR system (if equipped) “EGR System Inspection (Using SUZUKI Scan Tool) in Section 1B” Fuel pressure out of specification “Fuel Pressure Check” Closed loop system (A/F feed back “Throttle Position (TP) Sensor On-Vehicle...
Page 91 Engine General Information and Diagnosis: 1A-40 Troubleshooting Step Action MIL power supply check Go to Step 4. Go to Step 2. 1) Turn ignition switch to ON position. Do other warning lights come ON? METER fuse check Go to Step 3. Replace “METER”...
Page 92 1A-41 Engine General Information and Diagnosis: Malfunction Indicator Lamp Remains ON after Engine Starts S3RH0A1104012 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 G04-15 PNK/BLK BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7 PPL/YEL BLK/RED G04-5 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110012-01...
Page 93 Engine General Information and Diagnosis: 1A-42 MIL Flashes at Ignition Switch ON (Vehicle without Immobilizer Indicator Lamp) S3RH0A1104013 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 PNK/BLK G04-15 BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7 PPL/YEL BLK/RED G04-5 C41 (31P) G04 (24P) G03 (17P) 13 12...
Page 94 1A-43 Engine General Information and Diagnosis: MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Terminal (Vehicle without Immobilizer Indicator Lamp) S3RH0A1104014 Wiring Diagram C41-27 PPL/WHT BLK/WHT G04-23 PNK/BLK G04-15 BLK/YEL BRN/WHT G04-10 G03-17 PNK/GRN BLK/RED BLK/RED G04-6 G03-7...
Page 95 Engine General Information and Diagnosis: 1A-44 MIL Does Not Light at Ignition Switch ON and Engine Does Not Start Through It Is Cranked Up S3RH0A1104015 Wiring Diagram G04-23 BLK/WHT BLK/ORN C41-1 BLK/YEL BRN/WHT G04-10 C41-2 BLK/RED G04-6 C41-3 BLK/RED G04-5 C41 (31P) G04 (24P) G03 (17P)
Page 96 1A-45 Engine General Information and Diagnosis: Step Action Main relay circuit check Go to Step 3. Open wire in “BLK/YEL” circuit. 1) Turn ignition switch to OFF position. 2) Remove main relay (2) from main fuse box. I2RH01110054-01 3) Check for proper connection to main relay connector at “BLK/YEL”...
Page 97 Engine General Information and Diagnosis: 1A-46 Step Action ECM ground circuit check Intermittent trouble. Open or high resistance wire in “BLK/ORN” or 1) Turn ignition switch to OFF position. Check for intermittent “BLK” circuit. referring to “Intermittent 2) Disconnect connectors from ECM. and Poor Connection 3) Measure resistance between each “C41-1”, “C41-2”...
Page 98 1A-47 Engine General Information and Diagnosis: DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause • MAP sensor signal is 0.19 V or lower • “ORN” circuit open (Low pressure – High vacuums – Low voltage) • “GRY/RED” circuit open or shorted to ground •...
Page 99 Engine General Information and Diagnosis: 1A-48 Step Action Check MAP sensor “GRY/RED” wire Replace MAP sensor. shorted to “ORN” wire, 1) Check MAP sensor referring to “Manifold Absolute “LT GRN/RED” wire Pressure (MAP) Sensor Inspection in Section 1C”. open, poor “C41-10” Is it in good condition? connection.
Page 100 1A-49 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check IAT sensor and its circuit Go to Step 3. Intermittent trouble.
Page 101 Engine General Information and Diagnosis: 1A-50 DTC P0115 (No. 19): Engine Coolant Temp. (ECT) Circuit Malfunction S3RH0A1104021 Wiring Diagram C41-14 LT GRN C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110025-01 1. From other sensors DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
Page 102 1A-51 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check ECT sensor and its circuit Go to Step 3. Intermittent trouble.
Page 103 Engine General Information and Diagnosis: 1A-52 DTC P0120 (No. 13): Throttle Position Circuit Malfunction S3RH0A1104023 Wiring Diagram C41-22 GRY/RED C41-16 GRY/BLU C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110026-01 1. To MAP sensor and CO adjust resistor (if equipped) 2.
Page 104 1A-53 Engine General Information and Diagnosis: Step Action Check TP sensor and its circuit Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch OFF and Check for intermittent then turn ignition switch ON. referring to “Intermittent and Poor Connection 2) Check throttle valve opening percentage displayed on Inspection in Section...
Page 105 Engine General Information and Diagnosis: 1A-54 DTC P0121: Throttle Position Circuit Range / Performance Problem S3RH0A1104024 Wiring Diagram C41-22 GRY/RED C41-16 GRY/BLU C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110026-01 1. To MAP sensor and CO adjust resistor (if equipped) 2.
Page 106 Substitute a known- Go to Step 5. good ECM and recheck. 1) Turn OFF ignition switch and connect SUZUKI scan tool to DLC. 2) Turn ON ignition switch and check TP sensor output voltage when throttle valve is at idle position and fully opened.
Page 107 Engine General Information and Diagnosis: 1A-56 Step Action Check TP sensor High resistance in Replace TP sensor. “GRY/RED”, “GRY/ 1) Turn OFF ignition switch. BLU” or “ORN” circuit. 2) Disconnect TP sensor connector. If wire and connection 3) Check for proper connection to TP sensor at each are OK, substitute a terminal.
Page 108 1A-57 Engine General Information and Diagnosis: DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause • When running at idle speed after engine warmed up and • Heated oxygen sensor-1 malfunction running at specified vehicle speed, HO2S-1 output voltage •...
Page 109 Engine General Information and Diagnosis: 1A-58 DTC P0133: Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1) S3RH0A1104030 Wiring Diagram C41-13 C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110015-01 1. From other sensors DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
Page 110 1A-59 Engine General Information and Diagnosis: 3) Drive vehicle at 50 – 60 km/h, 30 – 40 mph for 2 min. 1) Turn ignition switch OFF. Clear DTC with ignition switch ON. 4) Stop vehicle and run engine at idle for 2 min. 2) Warm up engine to normal operating temperature.
Page 111 Engine General Information and Diagnosis: 1A-60 3) Drive vehicle at 50 – 60 km/h, 30 – 40 mph for 2 min. 1) Turn ignition switch OFF. Clear DTC with ignition switch ON. 4) Stop vehicle and run engine at idle for 2 min. 2) Warm up engine to normal operating temperature.
Page 112 1A-61 Engine General Information and Diagnosis: 1) Turn ignition switch OFF. DTC Confirmation Procedure 2) Clear DTC with ignition switch ON, start engine and WARNING keep it at idle for 1 min. 3) Start vehicle and depress accelerator pedal fully for •...
Page 113 Engine General Information and Diagnosis: 1A-62 DTC P0136: Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2) S3RH0A1104033 Wiring Diagram G04-13 C41-10 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110017-01 1. From other sensors DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause DTC will set when one of the following conditions is detected.
Page 114 1A-63 Engine General Information and Diagnosis: 11) Stop vehicle (do not turn ignition switch OFF). Confirm test results according to “Test Result Confirmation Flow” in “DTC Confirmation Procedure” of “DTC P0420: Catalyst System Efficiency below Threshold”. IYSY01111045-01 A: *Usual driving – Driving at 50 - 60 km/h, 30 - 40 mph including short stop according to traffic signal. (under driving condition other than high-load, high- engine speed, rapid accelerating and decelerating) DTC Troubleshooting Step...
Page 115 Engine General Information and Diagnosis: 1A-64 DTC P0141: Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2) S3RH0A1104034 Wiring Diagram BLK/WHT PNK/BLU G04-4 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110018-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause DTC will set when one of the following conditions is met.
Page 116 1A-65 Engine General Information and Diagnosis: Step Action Check HO2S-2 heater and its circuit Intermittent trouble. Go to Step 3. 1) Warm up engine to normal operating temperature. Check for intermittent referring to “Intermittent 2) Stop engine. and Poor Connection 3) Turn ignition switch ON and check voltage at terminal Inspection in Section “G04-4”.
Page 117 Engine General Information and Diagnosis: 1A-66 DTC P0171 / P0172: Fuel System Too Lean / Rich S3RH0A1104035 Wiring Diagram C41-9 BLU/YEL BLU/WHT C41-21 BLU/RED C41-31 BLU/GRN C41-8 C41-1 BLK/ORN C41-3 C41-13 C41-10 I2RH0B110037-01 1. Injector [a]: Signal to decrease amount of fuel injection [f]: A/F mixture becomes leaner 2.
Page 118 1A-67 Engine General Information and Diagnosis: DTC Confirmation Procedure NOTE Check to make sure that the following WARNING conditions are satisfied when using this DTC confirmation procedure. • When performing a road test, select a • Altitude (barometric pressure): 2400 m, place where there is no traffic or 8000 ft or less (560 mmHg, 75 kPa or more) possibility of a traffic accident and very...
Page 119 Engine General Information and Diagnosis: 1A-68 Step Action Check fuel pressure Go to Step 5. Go to “Fuel Pressure Check”. 1) Release fuel pressure from fuel feed line. 2) Install fuel pressure gauge. 3) Check fuel pressure. Fuel pressure specification With fuel pump operating and engine at stop: 270 –...
Page 120 1A-69 Engine General Information and Diagnosis: Step Action Check fuel injectors and its circuit Go to Step 6. Check injector circuit or replace fuel injector(s). 1) Using sound scope (1) or such, check operating sound of each injector (2) when engine is running. Cycle of operating sound should vary according to engine speed.
Page 121 Engine General Information and Diagnosis: 1A-70 Step Action 7) Check each injector for fuel leakage (1) after injector Go to Step 6. Check injector circuit or closed. replace fuel injector(s). Fuel leakage Less than 1 drop/min. I2RH0B110041-01 Is check result in Step 1) and 3) to 7) satisfactory? Check EVAP canister purge valve Check evaporative Go to Step 7.
Page 122 1A-71 Engine General Information and Diagnosis: Step Action Check PCV valve for performance Substitute a known- Replace PCV valve. good ECM and recheck. 1) See “PCV Valve Inspection in Section 1B”. Is it in good condition? DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected (Misfire Detected at 2 or More Cylinders) / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S3RH0A1104036 Wiring Diagram...
Page 123 Engine General Information and Diagnosis: 1A-72 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause • Engine under other than high revolution condition • Engine overheating • Not on rough road • Vacuum leaks (air inhaling) from air intake system •...
Page 124 1A-73 Engine General Information and Diagnosis: Step Action Check ignition system Go to Step 4. Check ignition system parts. 1) Remove spark plugs and check them. If abnormality is found, adjust, clean or replace. • Air gap “a”: 1.0 – 1.1 mm (0.040 – 0.043 in.) •...
Page 125 Engine General Information and Diagnosis: 1A-74 Step Action Check fuel injectors and circuit Go to Step 6. Check injector circuit or replace fuel injector(s). 1) Using sound scope (1) or such, check operating sound of each injector (2) when engine is running. Cycle of operating sound vary according to engine speed.
Page 126 1A-75 Engine General Information and Diagnosis: Step Action Check fuel injectors and circuit Go to Step 6. Check injector circuit or replace fuel injector(s). 7) Check each injector for fuel leakage (1) after injector closed. Fuel leakage Less than 1 drop/min. I2RH0B110041-01 Is check result in Step 1) and 3) to 7) satisfactory? Check PCV valve for clogging...
Page 127 Engine General Information and Diagnosis: 1A-76 Step Action 10 Check parts or system which can cause engine rough Check wire harness and Repair or replace. idle or poor performance connection of ECM ground, ignition system 1) Check engine mechanical parts or system which can and fuel injector for cause engine rough idle or poor performance.
Page 128 1A-77 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check knock sensor signal Intermittent trouble or Go to Step 3. faulty ECM.
Page 129 Engine General Information and Diagnosis: 1A-78 DTC P0335 (No. 23): Crankshaft Position (CKP) Sensor Circuit Malfunction S3RH0A1104038 Wiring Diagram I2RH0B110046-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause No CKP sensor signal for 2 sec. at engine cranking. •...
Page 130 1A-79 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check CKP sensor and connector for proper installation Go to Step 3. Correct.
Page 131 Engine General Information and Diagnosis: 1A-80 Step Action Check CKP sensor for operation Go to Step 7. Replace CKP sensor. 1) Remove CKP sensor from cylinder block. 2) Remove metal particles on end face of CKP sensor, if any. 3) Connect each connector to ECM and CKP sensor. 4) Turn ignition switch ON.
Page 132 1A-81 Engine General Information and Diagnosis: DTC P0340 (No. 15): Camshaft Position (CMP) Sensor Circuit Malfunction S3RH0A1104039 Wiring Diagram BLK/RED C41-11 BLK/ORN C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110051-01 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause No CMP sensor signal during engine running (CKP sensor •...
Page 133 Engine General Information and Diagnosis: 1A-82 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check CMP sensor and connector for proper installation Go to Step 3. Correct.
Page 134 1A-83 Engine General Information and Diagnosis: Step Action Check CMP sensor for operation Go to Step 7. Replace CMP sensor. 1) Remove CMP sensor from timing chain cover. 2) Remove metal particles on end face of CMP sensor, if any. 3) Connect each connector to ECM and CMP sensor.
Page 135 Engine General Information and Diagnosis: 1A-84 DTC P0400: Exhaust Gas Recirculation Flow Malfunction S3RH0A1104040 Wiring Diagram 12 V C41-18 12 V BLK/RED GRY/WHT C41-29 12 V C41-17 GRY/YEL 12 V BRN/WHT C41-28 BLK/ORN C41-1 C41-3 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110055-01...
Page 136 EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch OFF, install SUZUKI scan tool. 2) Check EGR system referring to “EGR System Inspection (Using SUZUKI Scan Tool) in Section 1B”. Is it in good condition?
Page 137 Engine General Information and Diagnosis: 1A-86 Step Action EGR valve power supply circuit check Go to Step 6. Faulty “BLK/RED” wire. 1) With ignition switch OFF, disconnect EGR valve coupler. 2) With ignition switch ON, check voltage between terminal “2” and terminal “5” of EGR valve coupler (1) and ground.
Page 138 1A-87 Engine General Information and Diagnosis: DTC P0420: Catalyst System Efficiency below Threshold S3RH0A1104042 System / Wiring Diagram C41-13 C41-10 G04-13 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I3RH0A110022-01 1. HO2S-1 3. Warm up three way catalytic converter 2.
Page 139 Engine General Information and Diagnosis: 1A-88 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause • While vehicle running at constant speed under other than high load. • Exhaust gas leak • Time from rich or lean switching command is output till HO2S-2 output •...
Page 140 1A-89 Engine General Information and Diagnosis: Test Result Confirmation Flow Step Action 1) Check DTC and pending DTC in “DTC” mode. Proceed to applicable Go to Step 2. DTC flow. Is DTC or pending DTC displayed? 1) Set scan tool to “READINESS TESTS” mode and check No DTC is detected.
Page 141 Engine General Information and Diagnosis: 1A-90 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check EVAP canister purge valve operation “BLU/BLK” circuit open Replace EVAP canister or short.
Page 142 1A-91 Engine General Information and Diagnosis: DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Check wire circuit Go to Step 3. “BLK/WHT” and/or “BLU/WHT” wire open 1) Disconnect radiator fan control relay No.1 (1) from relay circuit.
Page 143 Engine General Information and Diagnosis: 1A-92 Step Action Check wire circuit Go to Step 6. “BRN” wire shorted to power supply circuit. 1) Turn ON ignition switch. 2) Check voltage between “G04-18” terminal wire and vehicle body ground. Is voltage 0 V? Check radiator fan control relay No.1 “BRN”...
Page 144 1A-93 Engine General Information and Diagnosis: Step Action Check wire circuit Go to Step 12. “GRN/RED” wire shorted to ground 1) Disconnect radiator fan control relay No.2 and No.3 from circuit. relay box. 2) Measure resistance between “G04-3” terminal wire and vehicle body ground.
Page 145 Engine General Information and Diagnosis: 1A-94 DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause • Vehicle speed signal is not inputted while vehicle • “BLK/ORN” circuit open running in “D” range or during fuel cut at deceleration. •...
Page 146 1A-95 Engine General Information and Diagnosis: Step Action Check VSS power supply Go to Step 7. “BLK/RED” or “BLK/ ORN” wire open or 1) With turn OFF ignition switch, disconnect connector from short. VSS. 2) Turn ON ignition switch, without running engine. 3) Measure voltage from “b”...
Page 147 Engine General Information and Diagnosis: 1A-96 Step Action Check VSS Go to Step 9. Poor connection of VSS connector terminal. If 1) Turn OFF ignition switch. OK, substitute a known- 2) Remove VSS. good VSS and recheck. 3) Remove metal particles on end face of VSS, if any. 4) Connect connector to VSS.
Page 148 1A-97 Engine General Information and Diagnosis: Step Action 13 Check vehicle speed signal circuit for short Go to Step 14. “PPL” wire shorted to power supply. 1) Turn ignition switch OFF position. 2) Disconnect connector from ECM and combination meter. 3) Turn ignition switch ON position without engine running.
Page 149 Check idle air control system Intermittent trouble or Go to Step 5. faulty ECM. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF, set parking brake and block drive wheels. Check for intermittent referring to “Intermittent 2) Warm up engine to normal operating temperature.
Page 150 1A-99 Engine General Information and Diagnosis: DTC P0601: Internal Control Module Memory Check Sum Error S3RH0A1104078 System Description Internal control module is installed in ECM. DTC Detecting Condition and trouble Area DTC detecting condition Possible cause Data write error or check sum error DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
Page 151 Engine General Information and Diagnosis: 1A-100 DTC Troubleshooting (DTC P1451) NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude. Take that into consideration when performing these check. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 152 1A-101 Engine General Information and Diagnosis: Wiring Diagram C41-30 BLK/YEL C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110068-01 1. Ignition switch 2. Transmission range switch (A/T) 3. Starter motor DTC Detecting Condition and Possible Cause DTC detecting condition Possible cause •...
Page 153 Engine General Information and Diagnosis: 1A-102 DTC P1510: ECM Back-Up Power Supply Malfunction S3RH0A1104062 Wiring Diagram WHT/RED G03-11 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110069-01 Circuit Description Battery voltage is supplied so that DTC memory, values for engine control learned by ECM, etc. are kept in ECM even when the ignition switch is turned OFF.
Page 154 1A-103 Engine General Information and Diagnosis: DTC P1600: Serial Communication Problem between ECM and TCM S3RH0A1104063 Wiring Diagram GRN/YEL G08-7 G03-17 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110070-01 Circuit Description TCM constantly sends information while ignition switch is ON as to whether judgement was made or not with respect to all detectable DTCs as well as whether or not abnormality exists after judgement.
Page 155 Engine General Information and Diagnosis: 1A-104 DTC Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check for TCM Go to applicable DTC Go to Step 3. flow.
Page 156 1A-105 Engine General Information and Diagnosis: Step Action Signal circuit check Go to Step 8. “GRN/YEL” wire in open or high resistance 1) Disconnect connectors from ECM and TCM with ignition circuit. switch turned OFF. 2) Measure resistance between “G03-17” terminal in ECM harness connector and “G08-7”...
Page 157 Check PNP signal (“D” range signal) Intermittent trouble or Go to Step 5. faulty ECM. Check for 1) Connect SUZUKI scan tool to DLC with ignition switch intermittent referring to OFF. “Intermittent and Poor 2) Turn ignition switch ON and check PNP signal (“P/N” or Connection Inspection “D”...
Page 158 1A-107 Engine General Information and Diagnosis: Step Action Check PNP signal (“D” range signal) Intermittent trouble or Go to Step 5. faulty ECM. 1) Turn ignition switch ON. Check for intermittent 2) Check voltage at terminal “G03-6” of ECM connector referring to “Intermittent connected.
Page 159 Engine General Information and Diagnosis: 1A-108 Inspection of ECM and Its Circuits S3RH0A1104064 ECM and its circuits can be checked at ECM wiring couplers by measuring voltage, pulse signal and resistance. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with coupler disconnected from it.
Page 160 1A-109 Engine General Information and Diagnosis: Terminal No. Circuit Normal Voltage Condition *0 – 2 V Engine running at idling with after warming ↑↓ C41-6 Idle air control valve 8 – 14 V (Output signal is active low duty pulse. (Reference waveform Duty ratio varies as engine load and No.4)
Page 161 Engine General Information and Diagnosis: 1A-110 Terminal No. Circuit Normal Voltage Condition 0 – 1 V Ignition switch ON *0 – 2 V Ignition switch is turned to ST (cranking) ↑↓ position. C41-18 EGR valve (stepper motor coil 1) 8 – 14 V (Output signal is active low duty pulse.
Page 162 1A-111 Engine General Information and Diagnosis: Terminal No. Circuit Normal Voltage Condition 10 – 14 V Ignition switch ON *0 – 0.6 V Engine running. ↑↓ C41-31 Fuel injector No.3 (Output signal is active low pulse. Pulse 10 – 14 V frequency varies depending on engine (Reference waveform speed.)
Page 163 0 – 1 V Ignition switch ON G03-7 Malfunction indicator lamp 10 – 14 V When engine running Data link connector (SUZUKI G03-8 serial data line) (vehicle with 4 – 6 V Ignition switch ON immobilizer) *0 – 1 V Ignition switch turned ON.
Page 164 1A-113 Engine General Information and Diagnosis: Terminal No. Circuit Normal Voltage Condition Ignition switch turned ON and blower 4 – 14 V motor switch turned to 1st speed position or OFF G03-10 Electric load signal (–) Ignition switch turned ON and blower 0 –...
Page 165 Engine General Information and Diagnosis: 1A-114 3. Reference waveform No.3 5. Reference waveform No.5 Heated oxygen sensor-1 heater signal at engine idling EGR valve signal Measurement CH1: C41-13 to C41-10 Measurement CH1: C41-18 to C41-1 terminal CH2: C41-7 to C41-1 terminal CH2: C41-29 to C41-1 Oscilloscope...
Page 166 1A-115 Engine General Information and Diagnosis: 7. Reference waveform No.7 9. Reference waveform No.9 Ignition coil No.1 and No.4 signal at engine idling No.4 fuel injector signal at engine idling Measurement CH1: C41-11 to C41-1 Measurement CH1: C41-11 to C41-1 terminal CH2: C41-20 to C41-1 terminal...
Page 167 Engine General Information and Diagnosis: 1A-116 11. Reference waveform No.11 13. Reference waveform No.13 No.2 fuel injector signal at engine idling Knock sensor signal at engine speed 4000 r/min. Measurement CH1: C41-11 to C41-1 Measurement CH1: C41-25 to C41-1 terminal CH2: C41-21 to C41-1 terminal Oscilloscope setting CH1: 5 V/DIV, CH2: 20 V/DIV...
Page 168 1A-117 Engine General Information and Diagnosis: 15. Reference waveform No.15 17. Reference waveform No.17 CMP sensor signal at engine idling Manifold absolute pressure sensor signal at engine racing Measurement CH1: C41-11 to C41-1 terminal CH2: C41-23 to C41-1 Measurement CH1: C41-26 to C41-10 Oscilloscope setting CH1: 2 V/DIV, CH2: 2 V/DIV terminal CH2: C41-16 to C41-10...
Page 169 Engine General Information and Diagnosis: 1A-118 19. Reference waveform No.19 21. Reference waveform No.21 Tachometer (Ignition pulse) signal at engine idling Engine coolant temperature signal at engine idling Measurement CH1: C41-11 to C41-1 Measurement CH1: C41-14 to C41-10 terminal CH2: G03-1 to C41-1 terminal CH2: G03-9 to C41-1 Oscilloscope setting CH1: 5 V/DIV, CH2: 5 V/DIV...
Page 170 1A-119 Engine General Information and Diagnosis: 23. Reference waveform No.23 24. Reference waveform No.24 Ignition coil signal and fuel injector signal at engine Fuel injector signal at engine cranking cranking Measurement CH1: C41-11 to C41-1 Measurement CH1: C41-20 to C41-1 terminal CH2: C41-21 to C41-1 terminal...
Page 171 Engine General Information and Diagnosis: 1A-120 Resistance Check 1) Disconnect ECM couplers (1) from ECM with ignition switch OFF. CAUTION Never touch terminals of ECM itself or connect voltmeter or ohmmeter (2). 2) Check resistance between each pair of terminals of disconnected couplers as listed in the following table. CAUTION •...
Page 172 1A-121 Engine General Information and Diagnosis: Fuel Injector Circuit Check S3RH0A1104066 Wiring Diagram C41-9 BLU/YEL BLK/RED BLU/WHT C41-21 BLU/RED C41-31 BLU/GRN C41-8 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110078-01 1. No.1 injector 3. No.3 injector 2. No.2 injector 4.
Page 173 Engine General Information and Diagnosis: 1A-122 Fuel Pump and Its Circuit Check S3RH0A1104067 Wiring Diagram C41-24 BLK/RED BLK/RED C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110079-01 1. Fuel pump relay 2. Fuel pump Troubleshooting CAUTION Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness, etc.
Page 174 1A-123 Engine General Information and Diagnosis: Step Action Check fuel pump for operation Go to Step 4. “PNK”, “BLK” or “BLK/ RED” circuit open or 1) Remove fuel pump relay from relay box with ignition fuel pump malfunction. switch turned OFF. 2) Check for proper connection to fuel pump relay at each terminals.
Page 175 Engine General Information and Diagnosis: 1A-124 Fuel Pressure Check S3RH0A1104068 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I2RH0B110082-01 1. Injector 3. Fuel pressure regulator 2. Delivery pipe 4. Fuel pump...
Page 176 1A-125 Engine General Information and Diagnosis: Troubleshooting Step Action Check fuel pressure Go to Step 2. Go to Step 5. 1) Release fuel pressure from fuel feed line. 2) Install fuel pressure gauge. 3) Check fuel pressure by repeating ignition switch ON and OFF.
Page 177 Engine General Information and Diagnosis: 1A-126 Idle Air Control System Check S3RH0A1104069 System / Wiring Diagram GRY/RED G03-6 C41-6 GRN/RED G04-5 G04-6 G04-10 BLK/RED BRN/WHT BLK/RED BLK/YEL C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110083-01 1. IAC valve 3.
Page 178 10 Check PNP signal (“D” range signal) Go to Step 12. Repair or replace. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check PNP signal (“P/N” and “D” range) on display when shifting selector lever to each range.
Page 179 Engine General Information and Diagnosis: 1A-128 Step Action Check PNP signal (“D” range signal) Go to Step 12. Repair or replace. 1) Turn ignition switch ON. 2) Check voltage at terminal “G03-6” of ECM connector connected. PNP signal “P” and “N” range: 10 – 14 V “R”, “D”, “2”...
Page 180 1A-129 Engine General Information and Diagnosis: A/C Control System Check (Vehicle with A/C) S3RH0A1104076 Wiring Diagram WHT/BLK G04-14 G04-11 YEL/WHT C41-10 12 V 12 V G03-10 BLU/BLK 12 V GRN/WHT GRN/BLK G04-16 G04-7 BLU/ORN G04-9 LT GRN BLU/YEL RED/BLU LT GRN BRN/YEL G04-1 C41 (31P)
Page 181 Engine General Information and Diagnosis: 1A-130 Step Action Check evaporator temp. sensor resistance Go to Step 2. Faulty A/C evaporator temp. sensor or its 1) Disconnect ECM connectors with ignition switch at OFF circuit. position. 2) Check resistance between terminals “C41-10” and “G04- 14”...
Page 182 1A-131 Engine General Information and Diagnosis: Step Action Check A/C condenser fan control relay Go to Step 6. Replace A/C condenser fan control relay. 1) Turn ignition switch OFF and remove A/C condenser fan control relay (1). 2) Check for proper connection to relay at terminals “c” and “d”.
Page 183 Engine General Information and Diagnosis: 1A-132 Step Action Check A/C compressor signal Go to Step 9. “BRN/YEL” wire open or short. Poor “G04-1” 1) Check voltage at “G04-1” terminal under each condition terminal connection. given as follows. If wire and connection Voltage at “G04-1”...
Page 184 Check electric load signal circuit Electric load signal “YEL/BLK” and/or “BLU/ circuit is in good BLK” circuit open or 1) Connect SUZUKI scan tool to DLC with ignition switch condition. short, electric load OFF. diodes malfunction or 2) Start engine and select “DATA LIST” mode on scan tool.
Page 185 Engine General Information and Diagnosis: 1A-134 Step Action Check electric load signal circuit Electric load signal “YEL/BLK” and/or “BLU/ circuit is in good BLK” circuit open or 1) Turn ignition switch ON. condition. short, electric load 2) Check voltage at each terminals “G04-17” and “G03-10” diodes malfunction or of ECM connector connected, under above each each electric load circuit...
Page 186 1A-135 Engine General Information and Diagnosis: Troubleshooting Step Action Is there DTC(s) ECT sensor circuit (DTC P0115) and/or Go to corresponding Go to Step 2. radiator fan circuit (DTC P0480)? DTC flow. Check low speed radiator fan control circuit Go to Step 3. Perform from Step 2 to Step 7 in DTC P0480 1) Connect scan tool to DLC with ignition switch OFF.
Page 187 Engine General Information and Diagnosis: 1A-136 Step Action Check radiator fan control No.3 Go to Step 11. “BLU” wire is open circuit or high resistance 1) Connect radiator fan control relay No.3 to relay box with in circuit. ignition switch turn OFF. 2) Run engine until ECT is over 102 °C, 216 °F.
Page 188 PSP switch signal circuit check Signal circuit is in good Go to Step 4. condition. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Start engine and select “DATA LIST” mode on scan tool. 3) Check power steering pressure switch.
Page 189 Engine General Information and Diagnosis: 1A-138 Generator Control Signal Circuit Check S3RH0A1104075 Wiring Diagram RED/BLU C41-12 C41 (31P) G04 (24P) G03 (17P) 13 12 28 27 I2RH0B110090-01 1. Generator Circuit Description ECM sends signal (0 – 1 V) to generator terminal C to suspend charging during vehicle take off or fast acceleration. Troubleshooting Step Action...
Page 190 2) Warm up engine to normal operating temperature. Inspection 3) Check engine idle speed and IAC duty as follows: S3RH0A1106001 If you have SUZUKI scan tool, perform Step a). If Before idle speed / IAC duty check, make sure of the not, perform Step b). following.
Page 191 Engine General Information and Diagnosis: 1A-140 6) Check that specified engine idle speed is obtained with A/C ON if vehicle is equipped with A/C. If not, check A/C control circuits and idle air control system referring to “A/C Control System Check (Vehicle with A/ C)”...
Page 192 This tool is included in fuel pressure gauge set (09912- pressure gauge set (09912- 58413). 58413). 09912–58490 SUZUKI scan tool 3-way joint & hose — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 193 Tool) cause is clogged EGR gas passage, stuck or faulty S3RH0A1204001 1) Connect SUZUKI scan tool to data link connector EGR valve, poor performance of ECT sensor or TP (DLC) with ignition switch turn OFF. sensor or DTC and/or pending DTC is (are) stored in ECM memory.
Page 194 2) Check purge valve for operation and vacuum Inspection passage for clog when valve is switched ON and S3RH0A1206019 OFF by using SUZUKI scan tool or service wire. WARNING If check result is not described, check vacuum Do not apply vacuum by mouth; otherwise hoses, purge valve referring to “EVAP Canister...
Page 195 Aux. Emission Control Devices: 1B-3 3) Disconnect vacuum hoses. 4) Apply vacuum (–53 kPa (–7.69 psi) to –67 kPa (– 9.72 psi)) to hose (1) using a special tool. Check that vacuum can not be applied to hose (2). If check result is not satisfactory, replace EVAP canister purge valve.
Page 196 1B-4 Aux. Emission Control Devices: Vacuum Passage Inspection EGR Valve Inspection S3RH0A1206011 S3RH0A1206014 Start engine and run it at idle speed. Disconnect vacuum 1) Check resistance between the following terminals of hose (1) from EVAP canister purge valve (2). With finger EGR valve (1) in each pair.
Page 197 Replace as necessary. I2RH0B120008-01 I2RH0B120007-01 Special Tools and Equipment Special Tool S3RH0A1208001 09917–47911 SUZUKI scan tool Vacuum pump gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 198 1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Repair Instructions Idle Air Control (IAC) Valve Removal and Idle Air Control (IAC) Valve Inspection S3RH0A1306004 Installation 1) Connect each connector to IAC valve (1), TP sensor S3RH0A1306003 Removal and IAT sensor. 1) Remove throttle body from intake manifold referring 2) Check that rotary valve (2) of lAC valve opens and to “Throttle Body Removal and Installation in Section...
Page 199 Engine Electrical Devices: 1C-2 Engine Control Module (ECM) Removal and NOTE Installation Be careful not to damage ventilation duct. S3RH0A1306005 CAUTION As ECM consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “Disabling Air Bag System in Section 8B”.
Page 200 1C-3 Engine Electrical Devices: Throttle Position (TP) Sensor On-Vehicle Throttle Position (TP) Sensor Removal and Inspection Installation S3RH0A1306008 S3RH0A1306009 1) Disconnect negative cable at battery and connector Removal from IAT sensor. 1) Disconnect battery negative cable at battery. 2) Remove air cleaner assembly with air cleaner outlet hose and disconnect TP sensor connector.
Page 201 Engine Electrical Devices: 1C-4 Engine Coolant Temperature (ECT) Sensor Installation Reverse removal procedure noting the following. Removal and Installation S3RH0A1306014 • Clean mating surface of IAT sensor and air cleaner Removal case (2). 1) Disconnect negative cable from battery. • Connect IAT sensor connector (1) securely. 2) Drain coolant referring to “Cooling System Flush and Refill in Section 1F”.
Page 202 1C-5 Engine Electrical Devices: Engine Coolant Temperature (ECT) Sensor Installation Reverse removal procedure noting the following. Inspection S3RH0A1306013 • Tighten heated oxygen sensor (1) to specified torque. Immerse temperature sensing part of ECT sensor in water (or ice) and measure resistance between sensor Tightening torque terminals while heating water gradually.
Page 203 Engine Electrical Devices: 1C-6 Oxygen Sensor Heater Inspection Camshaft Position (CMP) Sensor and Its Circuit S3RH0A1306016 Inspection 1) Disconnect sensor connector. S3RH0A1306019 1) Confirm that terminal voltages and ground circuit 2) Using ohmmeter, measure resistance between continuity at CMP sensor connector terminals are in terminals “V ”...
Page 204: Circuit Inspection
1C-7 Engine Electrical Devices: Main Relay, Fuel Pump Relay, A/C Compressor 3) Connect connector to it securely. Relay and A/C Condenser Fan Relay Inspection 4) Adjust generator drive belt tension referring to S3RH0A1306023 “Water Pump / Generator Drive Belt Tension 1) Disconnect negative cable at battery.
Page 205 Engine Electrical Devices: 1C-8 Radiator Fan Relay No.1, No.2 and No.3 3) Check that there is no continuity between terminal “C” and “D”. If there is continuity, replace relay. Inspection S3RH0A1306024 4) Connect battery positive (+) terminal to terminal “B” 1) Disconnect negative cable at battery.
Page 206: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine General Description Engine Construction Description S3RH0A1401001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration consisting of 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 207 Engine Mechanical: 1D-2 Diagnostic Information and Procedures Compression Check S3RH0A1404001 Check compression pressure on all 4 cylinders as follows: 1) Warm up engine to normal operating temperature. 2) Stop engine after warming up. NOTE After warming up engine, place transaxle gear shift lever in “Neutral”...
Page 208 1D-3 Engine Mechanical: 4) Connect special tool (Vacuum gauge) to intake manifold side. Special tool (A): 09915–67311 I3RH0A140001-01 15) Check cylinder head upper cover gasket for deterioration and then install it into groove of cylinder head upper cover (1) securely. 16) Install cylinder head upper cover with gasket on to I2RH0B140008-01 5) Run engine at specified idle speed and read vacuum...
Page 209 Engine Mechanical: 1D-4 If valve lash is out of specification, record valve lash and Replacement of Shim adjust it to specification by replacing shim. 1) Close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut Valve clearance specification section (1) faces inside as shown in the figure.
Page 210 1D-5 Engine Mechanical: For example of intake side: When thickness of removed shim is 2.40 mm (0.094 in.), and measured valve clearance is 0.45 mm (0.018 in.). A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20 mm (0.008 in.) = 2.65 mm (0.104 in.) Calculated thickness of new shim = 2.65 mm (0.104 in.)
Page 211 Engine Mechanical: 1D-6 9) Install camshaft housing (1) and tighten bolts to 8) Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4) and remove specified torque. special tool. Tightening torque Special tool Camshaft housing bolt (a): 11 N·m (1.1 kgf-m, (A): 09916–67020 8.0 lb-ft) I2RH0B140149-01...
Page 212 1D-7 Engine Mechanical: Accelerator Cable Adjustment Throttle Body On-Vehicle Inspection S3RH0A1406005 S3RH0A1406007 With accelerator pedal depressed fully, check clearance Check that throttle valve lever (1) moves smoothly. between throttle lever (1) and lever stopper (2) (throttle body) which should be within the following specification. If measured value is out of specification, adjust it to specification with cable adjusting nut (3).
Page 213: Throttle Body Cleaning
Engine Mechanical: 1D-8 Throttle Body Disassembly and Assembly Installation S3RH0A1406042 1) Clean mating surfaces and install throttle body gasket to intake manifold. Disassembly Use new gasket. Remove TP sensor and IAC valve from throttle body. NOTE While disassembling and assembling throttle body, use special care not to deform levers on throttle valve shaft or cause damage to any other parts.
Page 214: Throttle Body And Intake Manifold Components
1D-9 Engine Mechanical: Throttle Body and Intake Manifold Components S3RH0A1406010 I3RH0A140004-01 1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting bolt (short) 19. Cushion 2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (long) 20.
Page 215 Engine Mechanical: 1D-10 5) Disconnect the following electric lead wires: 10) Remove intake manifold stiffener (1). • IAC valve (1) • TP sensor (2) • EVAP canister purge valve (3) • MAP sensor (4) • Fuel injector wire harness at couplers (5) •...
Page 216: Cylinder Head Cover Removal And Installation
1D-11 Engine Mechanical: 8) Remove cylinder head cover mounting bolts in such • Check to ensure that all removed parts are back in order as indicated in the figure. place. Reinstall any necessary parts which have not been reinstalled. • Adjust accelerator cable play referring to “Accelerator Cable Adjustment”.
Page 217 Engine Mechanical: 1D-12 2) Remove oil, old sealant, and dust from sealing 5) Connect PCV hose (2) to PCV valve (3). surface on cylinder head and cover. After cleaning, 6) Connect breather hose (4). apply sealant “A” to the following point. 7) Install oil level gauge (1).
Page 218: Engine Mountings Components
1D-13 Engine Mechanical: Engine Mountings Components S3RH0A1406043 I2RH0B140040-01 [A]: 4WD model 3. Engine left mounting 8. Mounting member [B]: A/T model 4. Engine left mounting bracket No.1 9. Suspension frame [C]: M/T model 5. Engine left mounting bracket No.2 : Tightening torque 1.
Page 219 Engine Mechanical: 1D-14 6) Remove water pump belt. 12) Remove fuse box from its bracket. 7) Drain engine oil, transaxle oil or A/T fluid (for A/T 13) Disconnect the following cables. vehicle) and transfer oil (for 4WD vehicle). • Accelerator cable 8) Drain coolant referring to “Cooling System Flush and •...
Page 220 1D-15 Engine Mechanical: 14) Disconnect the following hoses: 20) Remove clutch operation cylinder from transaxle. (For M/T vehicle) Brake booster hose (1) Heater inlet and outlet hoses from intake manifold from each pipe 21) Install lifting device. Canister purge hose (2) Radiator inlet and outlet 22) Remove engine left mounting bolts (1) and engine from EVAP canister...
Page 221 Engine Mechanical: 1D-16 Installation 11) Install suspension frame (1) with stabilizer bar and suspension control arms referring to “Front 1) Install clutch cover and clutch disk referring to Suspension Frame Removal and Installation in “Clutch Cover, Clutch Disc and Flywheel Removal Section 2B”.
Page 222: Timing Chain Cover Components
1D-17 Engine Mechanical: Timing Chain Cover Components S3RH0A1406019 I3RH0A140005-01 [A]: Sealant application amount 2. Crankshaft pulley 6. Timing chain cover mounting bolts “a”: 3 mm (0.12 in.) 3. Oil seal : Tightening torque : Apply engine oil to oil seal lip. “b”: 2 mm (0.08 in.) 4.
Page 223 Engine Mechanical: 1D-18 2) Apply sealant “A” to mating surface between cylinder and cylinder head, and apply sealant “B” to mating surface of timing chain cover as shown in the figure. “A”: Sealant 99000–31140 “B”: Water tight sealant 99000–31250 Sealant amount for timing chain cover Width “a”: 3 mm (0.12 in.) Height “b”: 2 mm (0.08 in.) I2RH0B140052-01...
Page 224: Timing Chain Cover Cleaning And Inspection
1D-19 Engine Mechanical: 4) Install water pump pulley. 5) Install P/S pump bracket (if equipped). 6) Install cylinder head cover referring to “Cylinder Head Cover Removal and Installation”. 7) Install oil pan referring to “Oil Pan and Oil Pump Strainer Removal and Installation in Section 1E”. 8) Install crankshaft pulley (1).
Page 225: Timing Chain And Chain Tensioner Removal And Installation
Engine Mechanical: 1D-20 Timing Chain and Chain Tensioner Removal Installation and Installation CAUTION S3RH0A1406026 After timing chain is removed, never turn Removal crankshaft and camshafts independently 1) Remove timing chain cover referring to “Timing more than such an extent (“a”, “b”) as shown Chain Cover Removal and Installation”.
Page 226 1D-21 Engine Mechanical: 3) Install timing chain by aligning dark blue plate (1) of timing chain and mark (2) on camshaft timing sprocket and then aligning dark blue plate (3) and triangle mark (4) as shown in the figure. 4) Fit crankshaft timing sprocket to timing chain by aligning gold plate (5) of timing chain and mark (6) on crankshaft timing sprocket.
Page 227: Timing Chain And Chain Tensioner Inspection
Engine Mechanical: 1D-22 Timing Chain and Chain Tensioner Inspection 9) Install timing chain tensioner adjuster assembly (1) with a retainer (2). S3RH0A1406027 Tighten adjuster bolts to specified torque and then Timing Chain No.1 Guide remove a retainer from chain tensioner adjuster Check shoe (1) for wear or damage.
Page 228: Camshaft, Tappet And Shim Components
1D-23 Engine Mechanical: Timing Chain Tensioner Adjuster Check that tooth surface (1) are free from damage. I2RH0B140071-01 Camshaft, Tappet and Shim Components S3RH0A1406028 I3RH0A140006-01 1. Intake camshaft 4. Tappet : Tightening torque 2. Exhaust camshaft 5. Camshaft housing : Apply engine oil to sliding surface of each part.
Page 229 Engine Mechanical: 1D-24 6) Remove tappets (2) with shims (1). 3) Install camshaft housing pins (1) as shown in the figure. I2RH0B140074-01 I2RH0B140077-01 Installation 4) Check position of camshaft housings. 1) Install tappets and shims to cylinder head. Embossed marks are provided on each camshaft Apply engine oil around tappet and then install it to housing, indicating position and direction for cylinder head.
Page 230: Camshaft, Tappet And Shim Inspection
1D-25 Engine Mechanical: 6) Install timing chain with crankshaft sprocket referring Camshaft Journal Wear to “Timing Chain and Chain Tensioner Removal and Check camshaft journals and camshaft housings for Installation”. pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder 7) Install timing chain cover referring to “Timing Chain head with housing.
Page 231 Engine Mechanical: 1D-26 7) Remove housing, and using scale (2) on gauging Wear of Tappet and Shim plastic envelop, measure gauging plastic (1) width at Check tappet and shim for pitting, scratches or damage. its widest point. If any malcondition is found, replace. Camshaft journal clearance Standard: 0.045 –...
Page 232: Valves And Cylinder Head Components
1D-27 Engine Mechanical: Valves and Cylinder Head Components S3RH0A1406031 I3RH0A140007-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt for M8 : Tighten 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) by the specified procedure. 2. Valve spring retainer 8. Valve guide : Tightening torque 3.
Page 233: Valves And Cylinder Head Removal And Installation
Engine Mechanical: 1D-28 Valves and Cylinder Head Removal and 9) Check all around cylinder head for any other parts required to be removed or disconnected and remove Installation or disconnect whatever necessary. S3RH0A1406032 10) Remove exhaust manifold, if necessary referring to Removal “Exhaust Manifold Removal and Installation in 1) Remove engine assembly from vehicle referring to...
Page 234 1D-29 Engine Mechanical: 5) Install cylinder head to cylinder block. Cylinder head bolt diameter measurement Apply engine oil to cylinder head bolts and tighten points them gradually as follows. “a”: 83.5 mm (2.81 in.) “b”: 115 mm (4.53 in.) a) Tighten cylinder head bolts (“1” – “10”) to 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) according to numerical Cylinder head bolt diameter difference order as shown by using a 12 corner socket...
Page 235: Valves And Cylinder Head Disassembly And Assembly
Engine Mechanical: 1D-30 Valves and Cylinder Head Disassembly and 3) Release special tool, and remove spring retainer and valve spring. Assembly S3RH0A1406033 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide, and Disassembly then valve spring seat (2).
Page 236 1D-31 Engine Mechanical: 3) Ream valve guide bore with special tool (5.5 mm Assembly reamer). After reaming, clean bore. 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as Special tool to remove burrs and make it truly round.
Page 237: Valves And Valve Guides Inspection
Engine Mechanical: 1D-32 6) Install valve to valve guide. Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem. I2RH0B140101-01 9) Install intake manifold, injectors and exhaust manifold to cylinder head. I2RH0B140099-01 7) Install valve spring and spring retainer.
Page 238 1D-33 Engine Mechanical: Valve stem end deflection limit • Check each valve for radial runout with a dial gauge In: 0.14 mm (0.005 in.) and “V” block. To check runout, rotate valve slowly. If Ex: 0.18 mm (0.007 in.) runout exceeds its limit, replace valve. Limit on valve head radial runout 0.08 mm (0.003 in.) IYSQ01141096-01...
Page 239: Cylinder Head Inspection
Engine Mechanical: 1D-34 Cylinder Head Inspection • Valve seat repair: A valve seat not producing a uniform contact with its S3RH0A1406044 • Remove all carbon deposits from combustion valve or showing width of seating contact that is out of chambers. specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 240: Valve Spring Inspection
1D-35 Engine Mechanical: Valve Spring Inspection S3RH0A1406045 • Referring to data, check to be sure that each spring is in standard condition, free of any evidence of breakage or weakening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 241: Pistons, Piston Rings And Connecting Rods Components
Engine Mechanical: 1D-36 Pistons, Piston Rings and Connecting Rods 3) Mark cylinder number on all pistons, connecting rods and connecting rod caps using silver pencil or quick Components drying paint. S3RH0A1406035 4) Remove rod bearing caps. 5) Install guide hose (1) over threads of rod bolts. This prevents damage to bearing journal and rod bolt threads when removing connecting rod.
Page 242: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
1D-37 Engine Mechanical: 3) When installing piston and connecting rod assembly into cylinder bore, point front mark (1) on piston head to crankshaft pulley side. I2RH0B140112-01 6) Reverse removal procedure. I2RH0B140110-01 7) Perform Steps 3) to 8) of “Installation” of “Timing A: Crankshaft pulley side Chain Cover Removal and Installation”.
Page 243: Cylinders, Pistons And Piston Rings Inspection
Engine Mechanical: 1D-38 Assembly 4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure. 1) Check connecting rod bolts for deformation referring to “Connecting Rod Bolt” under “Crank Pin and Connecting Rod Bearings Inspection”. If connecting rod bolt is deformed, use new connecting rod in next step.
Page 244 1D-39 Engine Mechanical: Standard (piston with coating (new one)): 0.016 – 0.045 mm (0.0006 – 0.0018 in.) Limit: 0.161 mm (0.0065 in.) NOTE Cylinder bore diameters used here are measured in thrust direction at two positions. I2RH0B140117-01 “a”: 50 mm (1.96 in.) “b”: 95 mm (3.74 in.) Pistons I3RH0A140015-01...
Page 245: Piston Pins And Connecting Rods Inspection
Engine Mechanical: 1D-40 Piston Rings Piston pin diameter To measure end gap, insert piston ring (1) into cylinder 19.997 – 20.000 mm (0.7873 – 0.7874 in.) bore and then measure the gap by using thickness Piston bore gauge (2). 20.006 – 20.014 mm (0.7876 – 0.7880 in.) If measured gap is out of specification, replace ring.
Page 246: Crank Pin And Connecting Rod Bearings Inspection
1D-41 Engine Mechanical: Connecting Rod Bolt • Connecting rod bolt deformation (Plastic deformation tightening bolt): Measure each thread diameter of connecting rod (1) bolt (2) at “A” and “B” by using a micrometer (3). Calculate difference in diameters (“A” – “B”). If it is exceeds limit, replace connected rod.
Page 247 Engine Mechanical: 1D-42 Connecting Rod Bearing Visual Inspection 5) Remove cap, and measure gauging plastic (2) width Inspect bearing shells for signs of fusion, pitting, burn or at the widest point (clearance) using a scale (1) on flaking and observe contact pattern. Bearing shells gauging plastic envelope.
Page 248 1D-43 Engine Mechanical: Selection of Connecting Rod Bearings 2) Next, check crankshaft pin diameter. On crank web No.3, four alphabets are stamped as shown in figure. NOTE Three kinds of alphabet (“A”, “B” and “C”) represent the following crankshaft pin diameter respectively. •...
Page 249 Engine Mechanical: 1D-44 3) There are five kinds of standard bearings differing in 4) From number stamped on connecting rod and its cap thickness. To distinguish them, they are painted in and alphabets stamped on crank web No.3, the following colors at the position as indicated in determine new standard bearing to be installed to figure.
Page 250: Main Bearings, Crankshaft And Cylinder Block Components
1D-45 Engine Mechanical: Main Bearings, Crankshaft and Cylinder Block Components S3RH0A1406039 I3RH0A140012-01 [A]: Sealant application amount 6. Sensor plate 14. Main bearing cap “a”: 3 mm (0.12 in.) 7. Crankshaft timing 15. Flywheel mounting bolt sprocket key : See “C” “b”: 2 mm (0.08 in.) 8.
Page 251: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: 1D-46 1. CKP sensor (if equipped) 9. Thrust bearing 17. Main bearing mounting No.2 bolt : See “A” : Tighten 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) by the specified procedure. 2. Knock sensor 10. Rear oil seal housing 18.
Page 252 1D-47 Engine Mechanical: Installation NOTE • Use new bearing cap No.1 bolts. If they are reused, check thread diameters of bearing cap No.1 bolt for deformation according to previous mentioned “Bearing Cap Bolt” under “Main Bearings Inspection”, check and replace them with new ones if thread diameter exceeds limit.
Page 253 Engine Mechanical: 1D-48 NOTE 9) Install flywheel (drive plate for A/T). Using special tool, lock flywheel or drive plate, and After tightening cap bolts, check to be sure tighten flywheel or drive plate bolts applied with that crankshaft rotates smoothly when sealant to specification.
Page 254: Crankshaft Inspection
1D-49 Engine Mechanical: Crankshaft Inspection Tightening torque S3RH0A1406041 Crankshaft bearing cap No.1 bolt ((1) – (10)): Tighten 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf- Runout m, 36.5 lb-ft) and 60° by the specified procedure Using a dial gauge, measure runout at center journal. Crankshaft bearing cap No.2 bolt ((11) –...
Page 255: Main Bearings Inspection
Engine Mechanical: 1D-50 Out-of-Round and Taper (Uneven Wear) of Journals Visual Inspection An unevenly worn crankshaft journal shows up as a Check bearings for pitting, scratches, wear or damage. difference in diameter at a cross section or along its If any malcondition is found, replace both upper and length (or both).
Page 256 1D-51 Engine Mechanical: NOTE Selection of Main Bearings Standard bearing Do not rotate crankshaft while gauging If bearing is in malcondition, or bearing clearance is out plastic is installed. of specification, select a new standard bearing according to the following procedure and install it. 1) First check journal diameter.
Page 257 Engine Mechanical: 1D-52 2) Next, check bearing cap bore diameter without 3) There are 5 kinds of standard bearings differing in bearing. On mating surface of cylinder block, five thickness. To distinguish them, they are painted in alphabets are stamped as shown in the figure. the following colors at the position as indicated in the Three kinds of alphabets (“A”, “B”...
Page 258 1D-53 Engine Mechanical: 4) From number stamped on crank web No.2 and Undersize bearing (0.25 mm) alphabets stamped on cylinder block, determine new • 0.25 mm undersize bearing is available, in five kinds standard bearing to be installed to journal, by varying in thickness.
Page 259: Sensor Plate Inspection
Engine Mechanical: 1D-54 [For M16 engine] • If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. Measured journal diameter 51.7320 – 51.7380 – 51.7440 – a. Regrind journal to the following finished diameter. 51.7379 mm 51.7439 mm 51.7500 mm Finished journal diameter...
Page 260: Rear Oil Seal Inspection
1D-55 Engine Mechanical: Rear Oil Seal Inspection Cylinder Block Inspection S3RH0A1406050 S3RH0A1406052 Carefully inspect oil seal (1) for wear or damage. Distortion of Gasketed Surface If its lip is worn or damaged, replace it. • Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It.
Page 261: Specifications
Engine Mechanical: 1D-56 Specifications Tightening Torque Specifications S3RH0A1407001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Camshaft housing bolt (for tightening of special tool) Camshaft housing bolt Intake manifold bolt and nut 18.0 Cylinder head cover bolt Tighten 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure Engine cover bolt Tighten 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) by the...
Page 262: Special Tools And Equipment
1D-57 Engine Mechanical: Special Tools and Equipment Recommended Service Material S3RH0A1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1215 P/No.: 99000–31110 SUZUKI Bond No.1207B P/No.: 99000–31140 Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 263 Engine Mechanical: 1D-58 09916–34542 09916–34550 Reamer handle Reamer handle 09916–37320 09916–44910 Valve guide outer reamer Valve guide installer & (10.5 mm) remover 09916–56011 09916–58210 Valve guide installer Valve guide installer handle attachment (protrusion: 11.5 09916–67020 09916–67021 Tappet holder (Overseas) Tappet holder 09916–77310 09916–84511 Piston ring compressor (50-...
Page 264: Engine Lubrication System
1E-1 Engine Lubrication System: Engine Lubrication System Engine General Description Engine Lubrication Description passages drilled in the crankshaft, and then injected S3RH0A1501001 from the big end of connecting rod to lubricate piston, The oil pump is of a trochoid type, and mounted on the rings and cylinder wall.
Page 265: Diagnostic Information And Procedures
Engine Lubrication System: 1E-2 Diagnostic Information and Procedures Oil Pressure Check 4) Install special tools (Oil pressure gauge) to vacated S3RH0A1504001 threaded hole. WARNING Special tool To avoid danger of being burned, do not (A): 09915–77311 touch exhaust manifold when exhaust (B): 09915–78211 system is hot.
Page 266: Repair Instructions
1E-3 Engine Lubrication System: 9) Start engine and check oil pressure switch for oil leakage. If oil leakage is found, repair it. 10) Connect oil pressure switch coupler (1). I2RH0B150005-01 I2RH0B150006-01 Repair Instructions Oil Pan and Oil Pump Strainer Components S3RH0A1506001 I3RH0A150001-01 [A]: Sealant application amount...
Page 267 Engine Lubrication System: 1E-4 4) For 4WD vehicle, remove clutch housing (torque 10) Remove oil pump strainer (1) from cylinder block. converter housing for A/T vehicle) lower plate (1). I2RH0B150010-01 I2RH0B150009-01 5) For 2WD vehicle, remove transaxle stiffener Installation referring to “Manual Transaxle Unit Dismounting and 1) Apply sealant to oil pan mating surface continuously Remounting in Section 5B”...
Page 268: Oil Pan And Oil Pump Strainer Cleaning
1E-5 Engine Lubrication System: 3) After fitting oil pan (3) to cylinder block, run in Oil Pan and Oil Pump Strainer Cleaning securing bolts and start tightening at the center: S3RH0A1506003 • Clean mating surface of oil pan and cylinder block. move wrench outward, tightening one bolt at a time.
Page 269: Oil Pump Removal And Installation
Engine Lubrication System: 1E-6 Oil Pump Removal and Installation Assembly S3RH0A1506005 1) Wash, clean and then dry all disassembled parts. Refer to “Timing Chain Cover Removal and Installation 2) Apply thin coat of engine oil to inner and outer rotors, in Section 1D”.
Page 270: Oil Pump Inspection
1E-7 Engine Lubrication System: Oil Pump Inspection Radial Clearance S3RH0A1506007 Check radial clearance between outer rotor (1) and case • Check oil seal lip for fault or other damage. If damage (2), using thickness gauge (3). is found, replace oil seal referring to “Timing Chain If clearance exceeds its limit, replace outer rotor or case.
Page 271: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A1508001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 272: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System Engine General Description Cooling System Description The coolant recovery system is standard. The coolant in S3RH0A1601001 the radiator expands with heat, and the overflow is The cooling system consists of the radiator cap, radiator, collected in the reservoir.
Page 273: Schematic And Routing Diagram
Engine Cooling System: 1F-2 Schematic and Routing Diagram Coolant Circulation S3RH0A1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. Throttle body Water pump Cylinder block Cylinder head Water intake pipe Heater unit Thermostat closed I2RH01160001-01 When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be cooled as well as the flow circuit.
Page 274: Diagnostic Information And Procedures
Steering (P/S) System Inspection in Section 0B”). EGR system faulty Check EGR system (Refer to “EGR System Inspection (Using SUZUKI Scan Tool) in Section 1B”). IAC system faulty Check IAC system (Refer to “Idle Air Control System Check in Section 1A”).
Page 275: Repair Instructions
Engine Cooling System: 1F-4 Repair Instructions Cooling System Components S3RH0A1606001 I3RH0A160001-01 1. Radiator 14. Radiator cooling fan assembly 27. Thermostat case bolts 2. Reservoir tank 15. Water inlet pipe No.1 28. Heater circulation hose (if equipped) 3. Radiator cap 16. Water inlet pipe No.2 29.
Page 276: Coolant Level Check
1F-5 Engine Cooling System: Coolant Level Check Engine Cooling System Inspection and S3RH0A1606002 Cleaning To check level, lift hood and look at “see-through” S3RH0A1606003 coolant reservoir tank. WARNING It is not necessary to remove radiator cap to check coolant level. To help avoid danger of being burned, do not remove radiator cap while engine and WARNING...
Page 277: Cooling System Flush And Refill
Engine Cooling System: 1F-6 Cooling System Flush and Refill 9) Reinstall reservoir tank cap and align match marks S3RH0A1606004 (4) on reservoir tank and its tank cap. 1) Remove radiator cap when engine is cool. a) Turn cap counterclockwise slowly until it reaches a “stop”.
Page 278: Thermostat Removal And Installation
1F-7 Engine Cooling System: Thermostat Removal and Installation • Use new O-rings when installing. S3RH0A1606006 • Adjust water pump belt tension referring to “Water Removal Pump / Generator Drive Belt Tension Inspection and 1) Drain cooling system by loosening drain plug of Adjustment”.
Page 279: Water Valve (If Equipped) Removal And Installation
Engine Cooling System: 1F-8 Water Valve (If Equipped) Inspection If valve starts to open at a temperature substantially below or above specific temperature, thermostat unit S3RH0A1606017 Check water valve operation as follows: should be replaced with a new one. Such a unit, if 1) Connect water valve (1) to vacuum pump gauge (A) reused, will bring about overcooling or overheating discharge side as shown, and then check that air...
Page 280: Radiator Cooling Fan Relay Inspection
1F-9 Engine Cooling System: Radiator Cooling Fan Removal and Installation 2) Check high speed operation of radiator cooling fan as follows. S3RH0A1606010 a) Connect battery to fan motor coupler as shown Removal in figure. 1) Disconnect negative cable at battery. b) Check that radiator cooling fan rotates smoothly 2) Disconnect connector of cooling fan motor.
Page 281: Radiator On-Vehicle Inspection And Cleaning
Engine Cooling System: 1F-10 Radiator On-Vehicle Inspection and Cleaning Water Pump / Generator Drive Belt Tension S3RH0A1606011 Inspection and Adjustment Inspection S3RH0A1606018 Check radiator for leakage or damage. Straighten bent WARNING fins, if any. • Disconnect negative cable at battery Cleaning before checking and adjusting belt Clean frontal area of radiator cores.
Page 282: Water Pump / Generator Drive Belt Removal And Installation
1F-11 Engine Cooling System: 3) If belt is too tight or too loose, adjust it to proper Installation tension by displacing generator position. 1) Install belt (1) to water pump pulley (2), crankshaft 4) Tighten generator adjusting bolt and pivot bolts as pulley (3) and generator pulley (4).
Page 283: Water Pump Inspection
Engine Cooling System: 1F-12 4) Loosen water pump / generator drive belt adjusting 2) Install water pump assembly (1) to cylinder block bolt (2) and generator pivot bolt (3). Then remove and tighten bolts and nut to specified torque. water pump / generator drive belt (1) and water Tightening torque pump pulley.
Page 284: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 285: Fuel System
Fuel System: 1G-1 Fuel System Engine Precautions Precautions on Fuel System Service S3RH0A1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. •...
Page 286: General Description
1G-2 Fuel System: General Description Fuel System Description Fuel Pump Description S3RH0A1701001 S3RH0A1701003 An in-tank type electric pump has been adopted for the CAUTION fuel pump (1). Incorporated in the pump assembly are; The engine of this vehicle requires the use of •...
Page 287: Schematic And Routing Diagram
Fuel System: 1G-3 Schematic and Routing Diagram Fuel Delivery System Diagram S3RH0A1702001 I2RH0B170002-01 1. Fuel tank 5. Fuel tank pressure control valve 9. Delivery pipe 2. Fuel pump 6. To EVAP canister 10. Fuel injector 3. Fuel filter 7. Fuel feed line 11.
Page 288: Fuel Cut Operation Inspection
1G-4 Fuel System: Fuel Cut Operation Inspection 7) Measure fuel pressure at idling. If measured pressure doesn’t satisfy specification, S3RH0A1704002 NOTE refer to “Fuel Pressure Check in Section 1A” and Before inspection, check to make sure that check each possibly defective part. Replace if found gear shift lever is in neutral position (with A/T defective.
Page 289: Repair Instructions
Fuel System: 1G-5 Repair Instructions Fuel System Components S3RH0A1706001 I3RH0A170001-01 1. Fuel tank 7. Fuel purge line 13. Fuel return line 19. Fuel tank belt pad 2. Fuel pump assembly 8. To EVAP canister 14. Tank protector 20. Fuel pump 3.
Page 290: Fuel Pressure Relief Procedure
1G-6 Fuel System: Fuel Pressure Relief Procedure Fuel Lines On-Vehicle Inspection S3RH0A1706002 S3RH0A1706004 CAUTION CAUTION This work must not be done when engine is Due to the fact that fuel feed line is under hot. If done so, it may cause adverse effect to high pressure, use special care when catalyst.
Page 291: Fuel Injector On-Vehicle Inspection
Fuel System: 1G-7 Fuel Injector On-Vehicle Inspection S3RH0A1706006 1) Using sound scope (1) or such, check operating sound of injector (2) when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, check injector circuit (wire or coupler) or injector.
Page 292: Fuel Injector Removal And Installation
1G-8 Fuel System: Fuel Injector Removal and Installation Tightening torque S3RH0A1706007 Fuel delivery pipe bolt (a): 28 N·m (2.8 kgf-m, 20.5 lb-ft) WARNING Before servicing fuel system, be sure to observe “Precautions on Fuel System Service”. Removal CAUTION A small amount of fuel may come out after removal of fuel injectors, cover them with shop cloth.
Page 293 OFF. ii) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on SUZUKI scan tool. iii) Turn fuel pump ON by using SUZUKI scan tool. Special tool (A): SUZUKI scan tool b) When not using SUZUKI scan tool:...
Page 294: Fuel Pressure Regulator On-Vehicle Inspection
1G-10 Fuel System: 8) Check fuel leakage from injector nozzle. Do not Installation operate injector for this check (but fuel pump should For installation, reverse removal procedure and note the be at work). If fuel leaks (1) more than the following following precautions.
Page 295: Fuel Tank Removal And Installation
Fuel System: 1G-11 NOTE 8) Remove EVAP canister with its bracket (1) from vehicle. If cap requires replacement, only a cap with the same features should be used. Failure to use correct cap can result in critical malfunction of system. I2RH01170009-01 9) Disconnect fuel filler hose (1) and breather hose (2) from filler neck (3).
Page 296 1G-12 Fuel System: Installation WARNING 1) If parts have been removed from fuel tank, install A small amount of fuel may be released after them before installing fuel tank to vehicle. the fuel hose is disconnected. In order to 2) Raise fuel tank (1) with jack and connect fuel pump reduce the chance of personal injury, cover connector and ground wire harness and clamp wire the hose and pipe to be disconnected with a...
Page 297: Fuel Tank Inspection
Fuel System: 1G-13 2) Drain all remaining fuel from tank. 3) Move tank to flushing area. 4) Fill tank with warm water or tap water, and agitate vigorously and drain. Repeat this washing until inside of tank is clean. Replace tank if its inside is rusty.
Page 298: Fuel Tank Inlet Valve Inspection
1G-14 Fuel System: Fuel Tank Inlet Valve Inspection 2) Turn ignition switch OFF, and wait for 10 minutes or S3RH0A1706013 more. 3) Fuel pressure should be felt at fuel feed hose (1) for WARNING about 2 seconds after ignition switch ON. Before servicing fuel system, be sure to If fuel pressure is not felt, advance to “Fuel Pressure observe “Precautions on Fuel System...
Page 299: Fuel Pump Assembly Removal And Installation
Fuel System: 1G-15 Fuel Pump Assembly Removal and Installation 2) Put plate (2) on fuel pump assembly (1) by matching S3RH0A1706023 the protrusion of fuel pump assembly (3) to plate hole (4) as shown. WARNING Before servicing fuel system, be sure to observe “Precautions on Fuel System Service”.
Page 300: Fuel Pump Assembly Disassembly And Assembly
1G-16 Fuel System: Fuel Pump Assembly Disassembly and WARNING Assembly Do not such air through fuel vapor line hose. S3RH0A1706024 Fuel vapor inside valve is harmful. WARNING Before servicing fuel system, be sure to observe “Precautions on Fuel System Service”. Disassemble and reassemble fuel pump assembly, noting the followings.
Page 301: Specifications
Fuel System: 1G-17 Specifications Tightening Torque Specifications S3RH0A1707001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Fuel delivery pipe bolt 20.5 Fuel pressure regulator bolt Fuel tank bolt 36.5 Fuel filler hose clamp 0.15 Fuel pump assembly bolt NOTE The specified tightening torque is also described in the following. “Fuel System Components”...
Page 302 1G-18 Fuel System: 09930–88530 SUZUKI scan tool Injector test lead — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loop back adapter, 7. Battery power cable, 8.
Page 303: Ignition System
Ignition System: 1H-1 Ignition System Engine General Description Ignition System Construction S3RH0A1801001 The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter (power unit) in the ignition coil assembly.
Page 304: Schematic And Routing Diagram
1H-2 Ignition System: Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S3RH0A1802001 BLK/WHT GRN/WHT C41-19 C41-20 GRN/YEL BLK/WHT G04-23 BLK/YEL BRN/WHT G04-10 BLK/YEL BLK/RED G04-6 BLK/RED G04-5 BLK/RED C41-1 BLK/ORN WHT/BLU C41-11 C41-2 60A 15A C41-3 C41-23 YEL/BLK BLK/ORN C41 (31P) G04 (24P) G03 (17P)
Page 305: Component Location
Ignition System: 1H-3 Component Location Ignition System Components Location S3RH0A1803001 I3RH0A180002-01 1. ECM 6. MAP sensor 11. Transmission range switch (A/T) 2. Ignition coil assembly for No.1 and No.4 spark plugs 7. ECT sensor 12. High-tension cords 3. Ignition coil assembly for No.2 and No.3 spark plugs 8.
Page 306: Diagnostic Information And Procedures
1H-4 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis S3RH0A1804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to start Loose connection or disconnection of Connect securely.
Page 307 Ignition System: 1H-5 Step Action CKP sensor check Go to Step 9. Tighten CKP sensor bolt, replace CKP 1) Check CKP sensor referring to Steps 3 and 4 of “DTC sensor or CKP sensor P0335 (No. 23): Crankshaft Position (CKP) Sensor plate.
Page 308: Repair Instructions
1H-6 Ignition System: Repair Instructions High-Tension Cord Removal and Installation Installation S3RH0A1806006 1) Install No.1 cylinder high-tension cord (2) and No.3 Removal high-tension cord (3) to spark plugs and ignition coil 1) Remove engine cover from cylinder head cover assemblies (1) while gripping each cap. referring to Step 3) of “Removal”...
Page 309: Spark Plug Removal And Installation
Ignition System: 1H-7 Spark Plug Removal and Installation NOTE S3RH0A1806001 NGK IFR6E11 / IFR6J11 is highly Removal recommended for better engine starting 1) Remove engine cover from cylinder head cover performance under –25 °C (–13 °F). referring to Step 3) of “Removal” under “Cylinder Head Cover Removal and Installation in Section 1D”.
Page 310: Ignition Coil Assembly (Including Igniter) Inspection
7.6 – 10.2 kΩ at 20 °C, 68 °F 5) Fix ignition timing to initial one as follows. Select “MISC” mode on SUZUKI scan tool and fix ignition timing to initial one. If scan tool is not available (vehicle without...
Page 311: Specifications
7) If ignition timing is out of specification, check the 8) After checking initial ignition timing, release ignition followings. timing fixation by using SUZUKI scan tool or disconnect service wire from diagnosis connector. • CKP sensor 9) With engine idling (test switch terminal ungrounded, •...
Page 312: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Cranking System Circuit Diagram S3RH0A1902001 I2RH01190001-01 1. Pinion drive lever 5. Plunger 9. Blank 2. Pinion & Over-running clutch 6. Magnetic switch contacts 10. A/T: Transmission range switch (shift lever switch) 3.
Page 313 Starting System: 1I-2 Condition Possible cause Correction / Reference Item Motor not running (No Shift lever switch is not in P or N, or not Shift in P or N, or adjust switch. (A/T) operating sound of adjusted (A/T) magnetic switch) Battery run down Recharge battery.
Page 314: Cranking System Test
1I-3 Starting System: Cranking System Test Plunger and Pinion Return Test S3RH0A1904002 Disconnect negative lead from starting motor body. CAUTION Check that plunger and pinion return inward. If plunger and pinion don’t return, replace the magnetic Each test must be performed within 3 – 5 switch.
Page 315: Repair Instructions
Starting System: 1I-4 Repair Instructions Starting Motor Dismounting and Remounting S3RH0A1906001 Dismounting 1) Disconnect negative (–) battery lead at battery. 2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) Remove starting motor mount bolt (3) and nut (4). 4) Remove starting motor (5).
Page 316: Starting Motor Components
1I-5 Starting System: Starting Motor Components S3RH0A1906002 1.0 kW type I3RH0A190002-01 1. Front housing 7. Plunger 13. Oilless bearing 19. Rear bush 2. Needle bearing 8. Seal rubber 14. Center bearing with shock absorber 20. Starting motor battery cable nut 3.
Page 317 Starting System: 1I-6 1.2 kW and 1.4 kW type I3RH0A190003-01 1. Front housing 8. Plunger 15. Planetary gear 22. Rear bush 2. Bush 9. Plate 16. Packing 23. Starting motor battery cable nut 3. Snap ring 10. Seal rubber 17. Yoke : Tightening torque 4.
Page 318: Starting Motor Inspection
1I-7 Starting System: Starting Motor Inspection Hold-in coil open circuit test S3RH0A1906003 Check for continuity across magnetic switch “S” terminal (1) and coil case. If no continuity, coil is open and should Plunger be replaced. Inspect plunger for wear. Replace if necessary. I2RH01190011-01 Rear Bracket Bush I2RH01190008-01...
Page 319 Starting System: 1I-8 • Check commutator for uneven wear with armature (1) Brush spring tension supported on V-blocks (2). If deflection of dial gauge 1.2 kW and 1.4 kW 1.0 kW type (4) pointer exceeds limit, repair or replace. type Standard 1.6 kg (3.53 lb) 2.2 kg (4.85 lb)
Page 320 1I-9 Starting System: I2RH01190021-01 Pinion and Over-Running Clutch • Inspect the pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction. Replace if necessary. I3RH0A190005-01 [A]: Correct [B]: Incorrect •...
Page 321: Specifications
Starting System: 1I-10 Specifications Cranking System Specifications S3RH0A1907001 NOTE Starting motor varies depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. 1.0 kW type Voltage 12 volts Output 1.0 kW Rating 30 seconds Direction of rotation...
Page 322: Tightening Torque Specifications
1I-11 Starting System: Tightening Torque Specifications S3RH0A1907002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Starting motor battery cable nut for 1.0 kW type Starting motor battery cable nut for 1.2 kW and 1.4 kW type NOTE The specified tightening torque is also described in the following. “Starting Motor Components”...
Page 323: Charging System
Charging System: 1J-1 Charging System Engine General Description Battery Description • Clear or light yellow S3RH0A1A01001 This means that fluid level is below the bottom of The battery has three major functions in the electrical hydrometer. Its possible cause is excessive or system.
Page 324: Generator Description
1J-2 Charging System: The battery discharges even when it is not 1) The battery is a very reliable component, but needs periodical attentions. used, while vehicles are being stored. Battery electrolyte can freeze and battery case can • Keep the battery carrier clean. crack at cold ambient condition if battery is not •...
Page 325: Diagnostic Information And Procedures
Charging System: 1J-3 I2RH0B1A0002-01 1. Pulley 5. Stator core 9. Rear end frame E: Ground 2. Pulley nut 6. Field coil 10. Drive end frame F: Field coil terminal 3. Rotor fan 7. Regulator B: Generator output (Battery terminal) IG: Ignition terminal 4.
Page 326: Generator Symptom Diagnosis
1J-4 Charging System: Generator Symptom Diagnosis Noise from generator may be caused by loose drive S3RH0A1A04002 pulley, loose mounting bolts, worn or dirty bearings, CAUTION defective diode, or defective stator. • Do not mistake polarities of “IG” terminal and “L” terminal. •...
Page 327: Generator Test (Overcharged Battery Check)
Charging System: 1J-5 2) Run engine from idling up to 2,000 rpm with all accessories turned off and read meters. If voltage is higher than standard value, check ground of brushes. If brushes are not grounded, replace IC regulator. If voltage is lower than standard value, proceed to the following check.
Page 328: Repair Instructions
1J-6 Charging System: Repair Instructions Jump Starting in Case of Emergency 1) Set parking brake and place automatic transaxle in S3RH0A1A06002 PARK (NEUTRAL on manual transaxle). Turn off With Auxiliary (Booster) Battery ignition, turn off lights and all other electrical loads. 2) Check electrolyte level.
Page 329: Generator Dismounting And Remounting
Charging System: 1J-7 Remounting 1) Reverse removal procedure. 2) Torque battery cables to specification. NOTE Check to be sure that ground cable has enough clearance to hood panel by terminal. Tightening torque Body ground bolt (a): 8.0 N·m (0.8 kgf-m, 6.0 lb- I2RH0B1A0006-01 5.
Page 330: Generator Components
1J-8 Charging System: Generator Components S3RH0A1A06006 I2RH0B1A0008-01 1. Pulley nut 6. Drive end bearing 11. Wave washer 16. Regulator 21. Terminal plate 2. Pulley 7. Bearing retainer 12. Rear end frame 17. Brush : Tightening torque 3. Drive end frame 8.
Page 331 Charging System: 1J-9 Rectifier 1) Using an ohmmeter, connect one tester probe to the “B” terminal (1) and the other to each rectifier terminal (2). IYSQ011A0044-01 Stator 1) Using an ohmmeter, check all leads for continuity. If there is no continuity, replace the stator. I1JA011A0002-01 2) Reverse the polarity of the tester probes and repeat Step 1).
Page 332: Specifications
1J-10 Charging System: Specifications Charging System Specifications S3RH0A1A07001 NOTE The battery used in each vehicle is one of the following three types, depending on specification. Battery Battery type 38B20L 55B24L 75D23L Rated capacity AH/5HR, 12 Volts Electrolyte L (US / lmp pt.) 2.1 (4.44 / 3.70) 2.8 (5.92 / 4.93) 3.9 (8.24 / 6.86)
Page 333: Exhaust System
Exhaust System: 1K-1 Exhaust System Engine General Description Exhaust System Description S3RH0A1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 334: Exhaust Manifold Components
1K-2 Exhaust System: Exhaust Manifold Components S3RH0A1B06002 I3RH0A1B0002-01 1-1. Exhaust manifold (with oxygen sensor) 4-2. Exhaust manifold cover (without oxygen sensor) 9. Exhaust manifold stiffener bolt 1-2. Exhaust manifold (without oxygen sensor) 5. Engine hook 10. Exhaust pipe bolt 2. Exhaust manifold gasket 6.
Page 335: Exhaust Pipe Removal And Installation
Exhaust System: 1K-3 Tightening torque 4) Install exhaust manifold cover (2). Exhaust manifold bolt and nut (a): 50 N·m (5.0 5) Connect heated oxygen sensor coupler (1) and fit kgf-m, 36.5 lb-ft) coupler to bracket securely (if equipped). I2RH0B1B0003-01 I2RH0B1B0006-01 6) Connect negative cable at battery.
Page 336 1K-4 Exhaust System:...
Page 337 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Suspension Control Arm Joint Check ....2B-18 Front Suspension Frame Components .....2B-18 Precautions............. 2-1 Front Suspension Frame Removal and Precautions on Suspension ........2-1 Installation ............2B-19 Suspension General Diagnosis....2A-1 Front Suspension Frame Check .......2B-20 Front Suspension Fasteners Check....2B-20 Diagnostic Information and Procedures....2A-1...
Page 338 2-ii Table of Contents Wheel Hub, Wheel Stud / Wheel Bearing Wheels and Tires ........2D-1 Outside Inner Race Removal and General Description ..........2D-1 Installation (4WD Model).........2C-17 Tires Description ..........2D-1 Rear Wheel Hub, Wheel Bearing and Wheel Wheels Description ..........2D-2 Stud Inspection ..........2C-19 Irregular and/or Premature Wear Description ..2D-3 Rear Wheel Disc, Nut and Bearing Check ..2C-19...
Page 339: Precautions
Precautions: Precautions Suspension Precautions Precautions on Suspension S3RH0A2000001 Suspension Caution Refer to “Wheels and Tires Note in Section 00”. Wheels and Tires Note Refer to “Brake Note in Section 00”. Precautions for Steering, Suspension, Wheels and Tires Diagnosis Refer to “Precautions for Steering, Suspension, Wheels and Tires Diagnosis in Section 6A”.
Page 340: 2A-1 Suspension General Diagnosis
2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S3RH0A2104001 NOTE Refer to “Precautions for Steering, Suspension, Wheels and Tires Diagnosis in Section 6A”. Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tire.
Page 341 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Ride too soft Faulty struts (shock absorber) Replace strut. Suspension bottoms Overloaded Check loading. Faulty struts (shock absorber) Replace strut. Incorrect, broken or sagging springs Replace. Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners...
Page 342: Specifications
2A-3 Suspension General Diagnosis: Specifications Wheel Alignment Specifications S3RH0A2107001 Wheel alignment specifications Item Front Rear IN 2.0 ± 2 mm (0.079 ± IN 6.2 ± 2 mm (0.244 ± Toe (“B” – “A”) (total) 0.079 in.) 0.079 in.) –0 ° 10’ ± 1 ° –1 °...
Page 343: Front Suspension
Front Suspension: 2B-1 Front Suspension Suspension General Description Front Suspension Construction S3RH0A2201001 I3RH0A220010-03 1. Strut assembly 5. Suspension control arm 9. Brake disc : Do not reuse. 2. Stabilizer bar 6. Vehicle body 10. Rubber cap [A]: 8.8 strength bolt & nut 3.
Page 344: Front Wheel Alignment Construction
2B-2 Front Suspension: Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S3RH0A2201002 excessive looseness is noted, it must be corrected Among factors for front wheel alignment, only tow setting before adjusting. can be adjusted. Camber and caster can’t be adjusted. •...
Page 345 Front Suspension: 2B-3 Adjustment Steering Angle Check and Adjustment When tie-rod or tie-rod end was replaced, check toe and 1) Loosen right and left tie-rod end lock nuts (1) first. then also steering angle with turning radius gauge (1). 2) Rotate right and left tie-rods (2) by the same amount If steering angle is not correct, check if right and left tie- to align toe to specification.
Page 346: Front Stabilizer Bar And/Or Bushings Components
2B-4 Front Suspension: Front Stabilizer Bar and/or Bushings Components S3RH0A2206002 I4RH01220002-01 1. Stabilizer bar 3. Mount bracket 5. Joint nut 7. Strut assembly 2. Mount bush 4. Joint 6. Mount bolt : Tightening torque Front Stabilizer Bar and/or Bushings Removal Installation and Installation 1) Loosely assemble all components in reverse order of...
Page 347: Front Stabilizer Bar, Bushing And/Or Joint Check
Front Suspension: 2B-5 Stabilizer Bushing Inspect for damage, wear or deterioration. If defective, replace. I4RH01220006-01 Stabilizer Joint 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. NOTE Stabilizer joint (1) cannot be disassembled. If there is any damage to either, stabilizer joint assembly must be replaced as a complete unit.
Page 348: Front Strut Assembly Components
2B-6 Front Suspension: Front Strut Assembly Components S3RH0A2206005 I3RH0A220011-02 1. Strut assembly 6. Strut bearing 11. Strut bracket nut : Do not reuse. 2. Coil spring 7. Strut support 12. Rubber cap [A]: 8.8 strength bolt & nut 3. Bump stopper 8.
Page 349: Front Strut Assembly Removal And Installation
Front Suspension: 2B-7 Front Strut Assembly Removal and Installation 4) Remove strut bracket bolts (4). S3RH0A2206006 Removal NOTE When servicing component parts of strut assembly, remove rubber cap and then loosen strut nut a little before removing strut assembly. This will make service work easier. Note, however, nut must not be removed at this point.
Page 350 2B-8 Front Suspension: Installation Install strut assembly by reversing removal procedure, noting the following instructions. • Insert bolts in such direction as shown in figure. • Tighten all fasteners to specified torque. Tightening torque Strut bracket nut (For 8.8 strength bolt) (a): 105 N·m (10.5 kgf-m, 76.0 lb-ft) Strut bracket nut (For 12.9 strength bolt) (e): 90 N·m (9.0 kgf-m, 65.0 lb-ft) Strut support nut (b): 28 N·m (2.8 kgf-m, 20.5 lb-ft) Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Page 351: Front Strut Assembly Disassembly And Assembly
Front Suspension: 2B-9 Front Strut Assembly Disassembly and Assembly For assembly, reverse disassembly procedure, noting Assembly the following instructions. S3RH0A2206007 1) Compress spring with special tool (A) until total Disassembly length becomes about 250 mm (9.8 in.) as shown. 1) With special tool (A) placed to spring as shown, turn Length special tool bolts alternately until spring tension is “a”: 250 mm (9.8 in.)...
Page 352: Front Strut Assembly Check
2B-10 Front Suspension: Front Strut Assembly Check 3) Install bump stopper and dust cover onto strut rod. For installing direction, refer to the figure in “Front S3RH0A2206008 • Inspect strut for oil leakage, damage or deformation. Suspension Construction”. • If strut is found faulty, replace it as an assembly unit, 4) Pull strut rod as far up as possible and use care not because it can not be disassembled.
Page 353: Front Wheel Hub And Steering Knuckle Components
Front Suspension: 2B-11 Front Wheel Hub and Steering Knuckle Components S3RH0A2206009 I2RH01220025-01 1. Front wheel hub 4. Steering knuckle : Tightening torque 2. Circlip 5. Drive shaft nut : Do not reuse. : Calk, after tightening. 3. Wheel bearing 6. Hub bolt : Face grooved rubber seal side to wheel hub.
Page 354 2B-12 Front Suspension: 7) Pull out wheel hub (1) with special tools. 10) Loosen strut bracket nuts (1). 11) Remove ball joint bolt (3) and nut (4). Special tool (A): 09943-17912 12) Remove strut bracket bolts from strut bracket and then steering knuckle (2).
Page 355 Front Suspension: 2B-13 • Tighten strut bracket nuts (3) to specified torque. • Connect tie-rod end (1) to steering knuckle (2). Tighten castle nut (3) until holes for split pin (4) are Tightening torque aligned, but only within specified torque. Strut bracket nut (For 8.8 strength bolt) (b): 105 N·m (10.5 kgf-m, 76.0 lb-ft) Tightening torque...
Page 356: Front Wheel Hub And Steering Knuckle Disassembly And Assembly
2B-14 Front Suspension: Front Wheel Hub and Steering Knuckle 4) Remove wheel bearing outside inner race (1). Disassembly and Assembly Special tool S3RH0A2206011 (C): 09913-65810 (D): 09913-85230 Disassembly 1) Uncaulk and remove dust cover (1). I2RH01220032-01 2) Remove circlip. 3) Using hydraulic press (1) and special tool, remove wheel bearing.
Page 357: Front Wheel Disc, Nut And Bearing Check
Front Suspension: 2B-15 5) Insert new hub bolt (1) in hub hole. Rotate hub bolt slowly to assure that serrations are aligned with those made by original bolt. I3RH01220003-01 2) Install circlip (1). I2RH01220040-01 Front Wheel Disc, Nut and Bearing Check S3RH0A2206012 •...
Page 358: Suspension Control Arm / Bushing Removal And Installation
2B-16 Front Suspension: • By rotating wheel actually, check wheel bearing for Installation noise and smooth rotation. 1) Install suspension control arm as shown but tighten If defective, replace bearing. suspension control arm bolts (1) only temporarily. I2RH01220011-01 I4RH01220014-01 2) Install suspension control arm ball joint to steering Suspension Control Arm / Bushing Removal knuckle.
Page 359: Suspension Control Arm / Bushing Disassembly And Assembly
Front Suspension: 2B-17 Suspension Control Arm / Bushing Assembly Disassembly and Assembly 1) Press-fit front bushing (1) by using special tool (C) S3RH0A2206014 and press (2). Disassembly Special tool (C): 09913-75810 1) Cut rubber (1) of flange of suspension control arm front bushing.
Page 360: Suspension Control Arm Joint Check
2B-18 Front Suspension: Suspension Control Arm Joint Check If there is any damage to either, control arm assembly S3RH0A2206017 must be replaced as a complete unit. • Check for smooth rotation. • Inspect ball stud for damage. • Inspect dust cover for damage. NOTE Suspension control arm and arm joint cannot be separated.
Page 361: Front Suspension Frame Removal And Installation
Front Suspension: 2B-19 Front Suspension Frame Removal and Installation Installation 1) Install suspension frame (1) to body, and tighten bolt S3RH0A2206019 to specified torque. Removal Tightening torque Suspension frame mounting bolt (a): 90 N·m ( 1) Hoist vehicle and remove wheels (right & left). 9.0 kgf-m, 65.0 lb-ft) 2) Remove stabilizer bar.
Page 362: Front Suspension Frame Check
2B-20 Front Suspension: Front Suspension Frame Check 3) Install suspension arms (2) (right & left). Refer to “Suspension Control Arm / Bushing Removal and S3RH0A2206020 • Inspect for cracks, deformation or damage. Installation”. • Inspect cushion for deterioration or damage (2WD 4) Install stabilizer bar (3).
Page 363: Specifications
Front Suspension: 2B-21 Specifications Tightening Torque Specifications S3RH0A2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 32.5 Stabilizer bar mounting bracket bolt 17.0 Stabilizer joint nut 36.5 Strut bracket nut (For 8.8 strength bolt) 10.5 76.0 Strut bracket nut (For 12.9 strength bolt) 65.0 Strut support nut...
Page 364: Special Tools And Equipment
2B-22 Front Suspension: Special Tools and Equipment Special Tool S3RH0A2208001 09900–00411 09900–00414 Hexagon bit socket Hexagon bit (6 mm) 09913–65210 09913–65810 Tie-rod end remover Crankshaft bearing puller 09913–75510 09913–75520 Bearing installer Bearing installer 09913–75810 09913–75821 Bearing installer Bearing installer attachment 09913–85230 09940–71431 Bearing remover tool...
Page 365: Rear Suspension
Rear Suspension: 2C-1 Rear Suspension Suspension General Description Rear Suspension Construction S3RH0A2301001 2WD Vehicle I3RH0A230008-03 1. Vehicle body 4. Suspension frame 7. Brake drum : Do not reuse. 2. Strut assembly 5. Control rod 8. Wheel Bearing [A]: 8.8 strength bolt & nut 3.
Page 366 2C-2 Rear Suspension: NOTE • Strut bracket nut (for 12.9 strength bolt) is pre-coated with friction stabilizer and provided with marks indicating the strength class. Never reuse this nut to prevent it from loosening. Be sure to replace nut with a new one whenever loosening once. •...
Page 367: Rear Wheel Alignment Construction
Rear Suspension: 2C-3 3. Rear knuckle 7. Brake drum 11. ABS wheel speed sensor ring (if equipped) [B]: 12.9 strength bolt & nut (See NOTE.) 4. Suspension frame 8. Wheel bearing : Do not reuse. NOTE • Strut bracket nut (for 12.9 strength bolt) is pre-coated with friction stabilizer and provided with marks indicating the strength class.
Page 368: Rear Stabilizer Bar And/Or Bushings Components
2C-4 Rear Suspension: Reference Information Side slip limit When checked with side slip tester, side slip should satisfy following specification. Side slip limit IN 7.0 – IN 10.0 mm/m (IN 0.276 – IN 0.393 in/3.3 ft) If side slip exceeds the limit, toe or wheel alignment may not be correct.
Page 369: Rear Stabilizer Bar And/Or Bushings Removal And Installation
Rear Suspension: 2C-5 Rear Stabilizer Bar and/or Bushings Removal and Installation S3RH0A2306003 Removal CAUTION To avoid the risk of being burned, start your work after the exhaust system has cooled down. 1) Hoist vehicle. 2) Remove stabilizer joint nuts. When loosening joint nut, hold stud with wrench.
Page 370: Rear Strut Assembly Components
2C-6 Rear Suspension: Stabilizer Joint 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage. NOTE Stabilizer joint (1) cannot be disassembled. If there is any damage to either, stabilizer joint assembly must be replaced as a complete unit. I4RH01230006-01 Rear Strut Assembly Components S3RH0A2306005...
Page 371: Rear Strut Assembly Removal And Installation
Rear Suspension: 2C-7 Rear Strut Assembly Removal and Installation 6) Remove strut support nuts (1). S3RH0A2306006 Hold strut by hand so that it will not fall off. Removal NOTE When servicing component parts of strut assembly, loosen strut upper nut a little before removing strut assembly.
Page 372: Rear Strut Assembly Disassembly And Assembly
2C-8 Rear Suspension: 2) While keeping spring compressed with special tool as shown, remove strut nut. Special tool (A): 09945-26010 17 mm (B): 09900-00411 (C): 09900-00414 6 mm I2RH01230018-01 3) Disassemble strut assembly. Assembly 1) Compress spring with special tool (A) until total length becomes about 290 mm (11.42 in.) as shown.
Page 373 Rear Suspension: 2C-9 2) Install coil spring lower seat (2) and compressing coil 8) Put strut support (2) on spring upper seat (3). spring, mate large-diameter spring end with stepped Tighten strut nut (1) to specified torque. part of lower seat as shown. Tightening torque Strut upper nut (a): 70 N·m (7.0 kgf-m, 50.5 lb-ft) I2RH01230020-01...
Page 374: Rear Strut Assembly Check
2C-10 Rear Suspension: Rear Strut Assembly Check S3RH0A2306008 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled. 2) Strut function check Check and adjust tire pressure as specified. Bounce vehicle body three or four times continuously by pushing rear end on the side with strut to be checked.
Page 375: Control Rod Removal And Installation
Rear Suspension: 2C-11 Control Rod Removal and Installation 2) Install control rod No.2 (2). S3RH0A2306010 a) Install control rod No.2 (2), setting it so that its welded nut (8) comes toward the front. Removal b) Insert control rod No.2 bolt (9) from the vehicle 1) Hoist vehicle and remove rear wheels.
Page 376: Control Rod Check
2C-12 Rear Suspension: Trailing Rod Removal and Installation Tightening torque Control rod No.1 (front side) inner nut and outer S3RH0A2306012 Removal bolt (c): 98 N·m (9.8 kgf-m, 71.0 lb-ft) 1) Hoist vehicle. Control rod No.2 (rear side) outer bolt (c): 98 N·m (9.8 kgf-m, 71.0 lb-ft) 2) Detach parking brake cable clamp (2) from trailing Control rod No.2 (rear side) inner nut (d): 90 N·m...
Page 377: Rear Suspension Frame Components
Rear Suspension: 2C-13 Rear Suspension Frame Components S3RH0A2306014 2WD Model I4RH01230012-01 1. Suspension frame 5. Control rod No.2 (rear side) F: Forward 2. Suspension frame cap 6. Joint : Tightening torque 3. Suspension frame bolt 7. Stabilizer bar 4. Control rod No.1 (front side) 8.
Page 378: Rear Suspension Frame Removal And Installation (2Wd Model)
2C-14 Rear Suspension: 2. Control rod No.1 (front side) 6. Differential mounting bracket 10. Stabilizer bar joint 3. Control rod No.2 (rear side) 7. Stabilizer bar F: Forward 4. Differential 8. Stabilizer bar mount bush : Tightening torque Rear Suspension Frame Removal and 9) Remove suspension frame bushings (1) by using a pipe (2) whose outer diameter “a”...
Page 379: Rear Suspension Frame Removal And Installation (4Wd Model)
Rear Suspension: 2C-15 5) Remove stabilizer bar referring to “Rear Stabilizer Bar and/or Bushings Removal and Installation”. 6) Detach LSPV spring end from left side control rod (No.2) (if equipped with LSPV). 7) To facilitate toe adjustment after reinstallation, put match marks (4) on washer (3) and on suspension frame (2) (right and left).
Page 380: Rear Suspension Frame, Bushing And Pad Check
2C-16 Rear Suspension: Rear Suspension Frame, Bushing and Pad Check S3RH0A2306017 Inspect for cracks, deformation or damage. If any faulty condition is found, replace. I3RH01232007-01 I2RH01230009-01 2) Install differential mounting bracket and differential with differential mounting to suspension frame. Wheel Hub with Wheel Bearing and Wheel Stud Tighten each bolt to specified torque.
Page 381: Wheel Hub, Wheel Stud / Wheel Bearing Outside Inner Race Removal And Installation (4Wd Model)
Rear Suspension: 2C-17 5) Remove wheel sensor ring (if equipped with ABS). 5) Install new spindle cap. Refer to “Rear Wheel Speed Sensor Ring Removal NOTE and Installation in Section 4E”. When installing spindle cap, hammer lightly 6) Remove hub bolts. Refer to “Front Wheel Hub and several locations on the collar of cap until Steering Knuckle Disassembly and Assembly in collar comes closely into contact with wheel...
Page 382 Steering Knuckle Disassembly and Assembly in Section 2B”. I3RH01232013-01 3) Apply grease to outside bearing, outside inner race and oil seal lip. “A”: Grease 99000–25010 (SUZUKI Super I3RH01232011-01 Grease A) 8) Remove wheel bearing inner race (1). Special tool...
Page 383: Rear Wheel Hub, Wheel Bearing And Wheel Stud Inspection
Rear Suspension: 2C-19 Rear Wheel Disc, Nut and Bearing Check 5) Install brake drum (1). Refer to “Rear Brake Drum Removal and Installation in Section 4C”. S3RH0A2306021 • Inspect each wheel disc for dents, distortion and 6) Pull up parking brake lever fully and tighten new cracks.
Page 384: Rear Knuckle Removal And Installation (2Wd Model)
2C-20 Rear Suspension: Rear Knuckle Removal and Installation (2WD 6) Loosen control rod outer bolts, trailing rod rear bolt and strut bracket nuts. Model) S3RH0A2306022 7) Disconnect control rods No.1 (2) and No.2 (3) from Removal knuckle (1). 1) Hoist vehicle and remove wheel hub referring to 8) Disconnect trailing rod (4) from knuckle (1).
Page 385 (if equipped). I3RH0A230012-01 3) Apply water tight sealant to mating surfaces of brake back plate and rear knuckle. “A”: Sealant 99000–31090 (SUZUKI sealing compound 366E) I4RH01230016-01 8) Install wheel hub referring to “Wheel Hub with Wheel Bearing and Wheel Stud Removal and Installation (2WD Model)”.
Page 386: Rear Knuckle, Wheel Bearing / Oil Seal Removal And Installation (4Wd Model)
2C-22 Rear Suspension: 11) Upon completion of all jobs, depress brake pedal 4) Remove inside oil seal (6) from knuckle (5). with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable. Refer to “Parking Brake Inspection and Adjustment in Section 4D”.
Page 387: Rear Suspension Knuckle Check
Rear Suspension: 2C-23 Rear Suspension Knuckle Check 2) Apply grease (lithic grease) to bearing outer race and bearings. S3RH0A2306024 • Inspect for cracks, deformation or damage. 3) Press-fit new inside oil seal (2) until special tool • Inspect bushing for damage, wear or breakage. If any contacts with knuckle (1).
Page 388: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A2308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010...
Page 389: Special Tool
Rear Suspension: 2C-25 Special Tool S3RH0A2308002 09900–00411 09900–00414 Hexagon bit socket Hexagon bit (6 mm) 09913–61510 09913–75520 Bearing puller Bearing installer 09924–84510–004 09925–88210 Bearing installer attachment Bearing puller attachment 09940–53111 09940–71431 Differential side bearing Suspension spring installer compressor 09942–15511 09943–17912 Sliding hammer Wheel hub remover 09944–78210...
Page 390: Wheels And Tires
2D-1 Wheels and Tires: Wheels and Tires Suspension General Description Tires Description Lower than recommended pressure can cause: S3RH0A2401001 • Tire squeal on turns The tire is of tubeless type. The tire is designed to • Hard Steering operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation •...
Page 391: Wheels Description
Wheels and Tires: 2D-2 Replacement Tires How to Measure Wheel Runout When replacement is necessary, the original equipment To measure the wheel runout, it is necessary to use an type tire should be used. Refer to the Tire Placard. accurate dial indicator. The tire may be on or off the Replacement tires should be of the same size, load wheel.
Page 392: Irregular And/Or Premature Wear Description
2D-3 Wheels and Tires: Irregular and/or Premature Wear Description S3RH0A2401003 Irregular and premature wear has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, improper alignment. If the following conditions are noted, rotation is necessary: •...
Page 393: Radial Tire Lead / Pull Description
Wheels and Tires: 2D-4 Equipment manufacture’s recommendations Inflate tires to recommended pressure Road test vehicle on level unrouned road in both directions Switch front tires side to side and road test again Lead corrected, Leads reverses direction Leads in same direction if roughness results, replace tires Put tires back in original position Install a known-good tire on one front side...
Page 394: Repair Instructions
2D-5 Wheels and Tires: Repair Instructions General Balance Procedures Tire Rotation S3RH0A2406001 S3RH0A2406002 Deposits of mud, etc. must be cleaned from inside of rim. To equalize wear, rotate tires according to figure. Radial tires should be rotated periodically. Set tire pressure. WARNING NOTE Stones should be removed from the tread in...
Page 395: Wheel Removal And Installation
Wheels and Tires: 2D-6 Wheel Removal and Installation Tire Mounting and Dismounting S3RH0A2406003 S3RH0A2406004 Removal Use a tire changing machine to mount or dismount tires. Follow equipment manufacturer’s instructions. Do not 1) Loosen wheel nuts by approximately 180 ° (half a use hand tools or tire irons alone to change tires as they rotation).
Page 396: Specifications
2D-7 Wheels and Tires: Specifications Wheels and Tires Specifications S3RH0A2407001 Tire size (Standard) 185/65R14 or 195/55R15 Wheel size (Standard) 14 x 5 1/2 JJ (for 185/65R14) or 15 x 6 JJ (for 195/55R15) Tightening torque Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) NOTE •...
Page 397 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Rear Differential Front Mounting Removal and Installation ..........3B-3 Precautions............. 3-1 Rear Differential Rear Mounting Removal and Precautions on Driveline / Axle ......3-1 Installation ............3B-3 Drive Shaft / Axle ........3A-1 Rear Differential Assembly Dismounting and Remounting............3B-5 Front .................3A-1...
Page 398 3-ii Table of Contents Propeller Shaft Description .........3D-1 Propeller Shaft Inspection ........3D-3 Repair Instructions ..........3D-1 Specifications ............3D-3 Propeller Shaft Components .......3D-1 Tightening Torque Specifications......3D-3 Propeller Shaft Removal and Installation ....3D-2...
Page 399: Precautions
Precautions: Precautions Driveline / Axle Precautions Precautions on Driveline / Axle S3RH0A3000001 Precaution for Rear Differential Oil Leakage Refer to “Precaution for Rear Differential Oil Leakage in Section 3B”.
Page 400: Drive Shaft / Axle
3A-1 Drive Shaft / Axle: Front Drive Shaft / Axle Driveline / Axle Front General Description Front Drive Shaft Construction S3RH0A3111001 A ball fixed type constant velocity joint is used on the wheel side of front drive shaft. For A/T vehicle, a tripod type constant velocity joint is used on the differential side and transfer side.
Page 401: Repair Instructions
Drive Shaft / Axle: Front 3A-2 Repair Instructions Front Drive Shaft Components S3RH0A3116001 I3RH0A311001-01 [A]: Tripod joint type 11. Damper (LH of M/T model) [B]: DOJ type 12. Center shaft side joint for RH of M/T vehicle : Apply light black grease included in spare part to joint. [C]: Center shaft for 2WD M/T model 13.
Page 402: Drive Shaft Boot On-Vehicle Inspection
3A-3 Drive Shaft / Axle: Front 9. Differential side joint (LH of M/T model) : Do not reuse. : Apply light black grease included in spare part to joint. 10. Damper (2WD A/T model and LH of 4WD A/T model) Drive Shaft Boot On-Vehicle Inspection S3RH0A3116004 Inspect drive shaft boot for tear.
Page 403: Front Drive Shaft Disassembly And Assembly
Drive Shaft / Axle: Front 3A-4 • Fill transaxle with oil referring to “Manual Transaxle 11) Remove drive shaft assembly. Oil Change in Section 5B” for M/T model, “A/T Fluid CAUTION Change in Section 5A” for A/T model. To prevent damage of boots, be careful not to •...
Page 404 3A-5 Drive Shaft / Axle: Front 2) Wipe off grease from shaft and take off snap ring (1) For DOJ type by using special tool. 1) Remove differential side boot big band (1). Special tool (A): 09900-06107 I2RH01310011-01 2) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out of outer race (3).
Page 405 Drive Shaft / Axle: Front 3A-6 4) Draw away cage (1) by using bearing puller (2), and Assembly remove boot (3) from shaft. For tripod joint type Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly.
Page 406 3A-7 Drive Shaft / Axle: Front 1) Wash disassembled parts (except boots). After 7) Set new differential side small band and new washing, dry parts completely by blowing air. differential side boot (1) on shaft temporarily, and then apply grease to tripod joint (2). Use specified 2) Clean boots with cloth.
Page 407 Drive Shaft / Axle: Front 3A-8 10) When fixing boot (1) to tripod joint housing (2) with For DOJ type differential side big band (3), adjust so that Judging from abnormality noted before disassembly and measured dimensions become as indicated in the what is found though visual check of component parts following.
Page 408 3A-9 Drive Shaft / Axle: Front 1) Wash disassembled parts (except boots). After 5) Set new differential side small band and new washing, dry parts completely by blowing air. differential side boot on shaft temporarily. 2) Apply grease to wheel side joint. Use specified 6) Drive in the cage (1) by using a pipe (2).
Page 409 Drive Shaft / Axle: Front 3A-10 8) Apply grease to entire surface of cage. Use specified Drive shaft boot fixing position (distance grease in tube included in spare parts. between reference position and small boot band) Left side drive shaft for 2WD model “d”: 166.5 – 9) Insert cage into joint housing (2) and fit snap ring (1) 176.5 mm (6.56 –...
Page 410: Specifications
3A-11 Drive Shaft / Axle: Front Specifications Tightening Torque Specifications S3RH0A3117001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Ball stud bolt 43.5 Tie-rod end castle nut 32.5 Drive shaft nut 17.5 127.0 Wheel nut 61.5 Center bearing support bolt 40.0 NOTE The specified tightening torque is also described in the following.
Page 411: Rear
Drive Shaft / Axle: Rear 3A-12 Rear General Description Rear Drive Shaft Description S3RH0A3121001 A ball fixed type constant velocity joint is used on the wheel side of rear drive shaft and a double offset type constant velocity joint (DOJ) on the differential side. Repair Instructions Rear Drive Shaft Components S3RH0A3126001...
Page 412: Rear Drive Shaft Disassembly And Assembly
3A-13 Drive Shaft / Axle: Rear Tightening torque Rear Drive Shaft Disassembly and Assembly Rear control rod outer bolt (a): 90 N·m (9.0 kgf- S3RH0A3126003 m, 65.0 lb-ft) Disassembly Rear trailing rod rear bolt (b): 90 N·m (9.0 kgf-m, Refer to “Front Drive Shaft Disassembly and Assembly”. 65.0 lb-ft) Drive shaft nut (c): 175 N·m (17.5 kgf-m, 126.5 lb- Assembly...
Page 413: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A3128001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 NOTE Required service material is also described in the following.
Page 414: Differential
3B-1 Differential: Differential Driveline / Axle Precautions Precaution for Rear Differential Oil Leakage S3RH0A3200001 Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage. General Description Rear Differential Description S3RH0A3201001 The differential assembly uses a hypoid bevel pinion and gear.
Page 415: Diagnostic Information And Procedures
Differential: 3B-2 Diagnostic Information and Procedures Rear Differential Symptom Diagnosis S3RH0A3204001 Condition Possible cause Correction / Reference Item Gear noise Deteriorated or water mixed lubricant Repair and replenish. Inadequate or insufficient lubricant Repair and replenish. Maladjusted backlash between bevel Adjust as prescribed. pinion and gear Improper tooth contact in the mesh Adjust or replace.
Page 416: Rear Differential Front Mounting Removal And Installation
3B-3 Differential: Rear Differential Front Mounting Removal and 2) Install differential front mounting (1), and tighten mounting bracket bolts (2) and mounting nut (3) to Installation specified torque. S3RH0A3206002 Removal Tightening torque 1) Hoist vehicle. Differential front mounting bracket bolts (a): 50 2) Remove mounting bracket bolts (1), mounting bolt N·m (5.0 kgf-m, 36.5 lb-ft) (2), nut (3) and differential front mounting (4).
Page 417 Differential: 3B-4 5) Drive mountings out with special tools and hydraulic 2) Install differential rear mounting (4), and tighten press (1). mounting bracket bolts (5) and mounting bolts (6) to specified torque. Special tool (C): 09951-16080 Tightening torque (D): 09951-26020 Differential rear mounting bracket bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) Differential rear mounting bolt (b): 80 N·m (8.0...
Page 418: Rear Differential Assembly Dismounting And Remounting
3B-5 Differential: Rear Differential Assembly Dismounting and Remounting Reverse dismounting procedure for remounting noting Remounting the following points. S3RH0A3206004 Dismounting • Install propeller shaft (1) to companion flange (2) 1) Hoist vehicle and remove wheels. aligning match marks (3). 2) Drain oil from rear differential. Refer to “Rear •...
Page 419: Rear Differential Components
Differential: 3B-6 Rear Differential Components S3RH0A3206005 I3RH0A320001-01 1. Bevel pinion nut 13. Retainer stopper 25. Differential pinion shaft pin : Caulk nut after tightening nut so as rotational torque of bevel pinion shaft to be in specified torque. 2. Companion flange 14.
Page 420: Rear Differential Disassembly And Assembly
3B-7 Differential: 9. Differential side taper roller bearing 21. Differential cover : Apply differential oil. : Apply sealant 99000-31260 to mating surface with differential carrier. 10. O-ring 22. Differential side washer : Tightening torque 11. Differential side oil seal 23. Differential side gear : Apply grease 99000-25010 to seal lip.
Page 421 Differential: 3B-8 14) Using a hammer and brass bar (1), drive out rear bearing outer race (2). I3RH01322024-01 2. Companion flange I3RH01322028-01 11) Remove companion flange (1) and washer from Assembly drive bevel pinion, and then drive out drive bevel Judging from faulty conditions noted before disassembly pinion.
Page 422 3B-9 Differential: Differential case 3) Align pinion shaft hole position with differential case and drive in differential pinion shaft pin till they are 1) After applying differential oil to side gears (4), flush with end surface of case. pinions (5), pinion shaft (3), side washers (1) and pinion washers (2), install them in differential case Special tool (6).
Page 423 Differential: 3B-10 Differential side bearing Differential unit 1) Press-fit differential side bearing (1) with special tool. 1) Install side oil seal to bearing outer race (1). Then apply grease to oil seal lip. Special tool (A): 09951-16060 : Grease 99000–25010 (B): 09924-74510 Special tool (A): 09913-75520...
Page 424 3B-11 Differential: 5) To measure bevel gear backlash, set dial gauge at 6) With bevel gear installed, measure rotational torque right angle to bevel gear tooth, fix drive bevel pinion, while turning bevel pinion about 50 rpm by using tighten both retainers and read dial gauge while special tool.
Page 425 Differential: 3B-12 7) Install retainer stoppers (2). NOTE Change shape of retainer stopper depending on position of tooth on retainer (1). Tightening torque Retainer stopper bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) I3RH0A320006-01 8) Check gear tooth contact. Apply red lead paste to tooth of drive bevel gear and turn it by hand to check its contact with drive bevel pinion. Check contact pattern, referring to the following chart.
Page 426 3B-13 Differential: Tooth contact pattern Diagnosis and remedy Low contact Pinion is positioned too close to the center of drive bevel gear. 1. Decrease thickness of pinion height adjusting shim and position pinion farther from gear center. 2. Adjust drive bevel gear backlash to I3RH01322044-01 specification.
Page 427: Rear Differential Inspection
Differential: 3B-14 9) Apply thread lock cement to thread of breather cover bolts (5). 10) Upon completion of gear tooth contact check in Step 8), after applying sealant to breather cover (3), install breather plug (2) to differential cover (4). 11) After applying sealant to differential cover (4), install differential cover (4) to differential carrier (1).
Page 428: Drive Bevel Pinion Shim Adjustment
3B-15 Differential: Drive Bevel Pinion Shim Adjustment S3RH0A3206008 Description To mesh bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described on the following steps. Shown in the following figure are relative positions of bevel pinion, differential carrier and mounting dummy.
Page 429 Differential: 3B-16 Adjustment 5) Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate (1) by 1) Install bevel pinion dummy with front and rear screw (2). bearings into differential carrier and then tighten 36 mm nut (Spare parts No.
Page 430 3B-17 Differential: 7) Necessary adjusting shim thickness is the same 10) With new pinion spacer (2) inserted as shown in the valve as measured value by dial gauge. figure, install front bearing (4) to differential carrier (3). Necessary shim thickness Dial gauge measured “e”...
Page 431 Differential: 3B-18 Special tool (E): 09922-75222 (F): 09930-40113 Tightening torque Bevel pinion nut: 100 – 300 N·m (10.0 – 30.0 kgf- m, 72.5 – 217.0 lb-ft) Bevel pinion bearing preload (Bevel pinion rotational torque) 5 – 13 kg-cm (4.4 – 11.2 lb-in.) Rotational force with special tool 1.0 –...
Page 432: Special Tools And Equipment
3B-19 Differential: Special Tools and Equipment Recommended Service Material S3RH0A3208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 433 Differential: 3B-20 09925–18011 09930–40113 Transmission gear, bush Flywheel rotor holder and bearing installer 09951–16060 09951–16080 Control arm bush remover Bearing installer 09951–16090 09951–26020 Oil seal installer Bush remover & installer support...
Page 434: Transfer
3C-1 Transfer: Transfer Driveline / Axle General Description Transfer Description S3RH0A3301001 The transfer is mounted on transaxle case by fastening bolt with reduction drive gear in transfer and differential case in transaxle coupled by involute spline. Driving force from transaxle is transmitted to propeller shaft through reduction drive gear, reduction idler gear, reduction driven gear and bevel gear of transfer.
Page 435: Diagnostic Information And Procedures
Transfer: 3C-2 Diagnostic Information and Procedures Transfer Symptom Diagnosis S3RH0A3304001 Condition Possible cause Correction / Reference Item Noise Inadequate or insufficient lubricant Replenish. Damaged or worn bearing(s) Replace. Damaged or worn gear(s) Replace. Preload of taper roller bearing is Adjust. reduced Repair Instructions Transfer Oil Change...
Page 436 3C-3 Transfer: 14) Remove exhaust No.2 pipe (10) by removing its 16) Remove transfer to transaxle stiffener (1) by bolts (11). removing its 5 bolts (2). I3RH01332004-01 17) Remove transfer to engine stiffener (1) by removing its 6 bolts. I3RH01332005-01 18) Remove transfer mounting bolts (1).
Page 437 Transfer: 3C-4 20) Remove mounting (1) and breather hose (2) from transfer assembly. I3RH01332008-01 Remounting Remount transfer assembly by reversing dismounting procedure noting the following points. • Tighten bolts and nuts to specified torque as follows. Tightening torque Engine rear mounting bracket nuts (a): 25 N·m ( 2.5 kgf-m, 18.0 lb-ft) Transfer mounting bolts (b): 50 N·m (5.0 kgf-m, 36.5 lb-ft)
Page 438: Transfer Assembly Components
3C-5 Transfer: • Pour automatic transaxle fluid to automatic transaxle • Pour transfer oil to transfer referring to “Transfer Oil Change”. referring to “A/T Fluid Change in Section 5A”. • Check oil level and leakage. Transfer Assembly Components S3RH0A3306003 23 N·m(2.3 kg-m) 90-150 N·m (9.0-15.0 kg-m) 12 N·m(1.2 kg-m)
Page 439: Transfer Assembly Disassembly And Assembly
Transfer: 3C-6 14. O-ring 29. Reduction idler gear taper roller bearing : Apply transfer oil. : Apply grease 99000-25010 to all around surface. 15. Bevel gear adjuster 30. Reduction idler gear Transfer Assembly Disassembly and Assembly Special tool S3RH0A3306004 (B): 09941–54911 Disassembly NOTE It is possible to disassemble transfer...
Page 440 3C-7 Transfer: Starting torque “a” of reduction drive 2) Clean mating surface of right and left cases, and apply sealant to right case (1) by using a nozzle (2) gear as shown in the figure by such amount that its 0.5 –...
Page 441 Transfer: 3C-8 v) Remove transfer output retainer assembly and bevel gear shims to measure reduction 1,(a),“A” driven gear taper roller bearing preload. c) Adjust reduction driven gear taper roller bearing preload as follows. Using special tools and torque wrench (2), screw bevel gear adjuster (1) on left case while measuring starting torque “b”...
Page 442: Reduction Drive Gear, Reduction Idler Gear And Reduction Driven Gear Disassembly And Assembly
3C-9 Transfer: 14) Apply grease to new intermediate output oil seal lip. Assembly “A”: Grease 99000–25010 CAUTION 15) Drive intermediate output oil seal (1) in transfer right • Bevel gear and pinion must be replaced as case (2) by using special tool and hammer. a set when either replacement becomes necessary.
Page 443: Transfer Right Case And Left Case Disassembly And Assembly
Transfer: 3C-10 Transfer Right Case and Left Case Disassembly Special tool : 09913–75520 and Assembly S3RH0A3306006 Transfer reduction drive gear oil seal installing depth Disassembly “a”: 13.3 – 14.3 mm (0.524 – 0.563 in.) 1) Remove oil seals (1) from transfer right case and left “b”: 2.8 –...
Page 444: Transfer Output Retainer Assembly Disassembly And Assembly
3C-11 Transfer: Special tool 5) Install oil protect plate (1) and oil receiver (2) to right case (3). (A): 09940–14940 Tightening torque NOTE Oil protect plate bolts (a): 12 N·m (1.2 kgf-m, 9.0 Do not screw in bevel gear adjuster lb-ft) excessively, or preload of reduction idler Oil receiver bolt (b): 12 N·m (1.2 kgf-m, 9.0 lb-ft)
Page 445 Transfer: 3C-12 4) Drive out bevel pinion shaft (1) from transfer output Assembly retainer by tapping it with plastic hammer (2). CAUTION • Bevel gear and pinion must be replaced as a set when either replacement becomes necessary. • When replacing taper roller bearing, replace as inner race &...
Page 446 3C-13 Transfer: d) Measure height “b” in the figure by using vernier caliper. Calculate “c” by using measured value. Height “a” 40 mm Distance “c” = Height “b” – (1.575 in.) e) Obtain adjusting shim thickness by the following equation. Distance Distance Necessary...
Page 447 Transfer: 3C-14 1,“A” “a” I3RH01332027-01 I3RH01332024-01 8) Install transfer output flange (1) by tapping with 3) Press-fit pinion shaft front taper roller bearing by plastic hammer and tighten transfer output flange nut using special tools and hydraulic press. gradually so as rotational torque of bevel pinion shaft to be in specified value.
Page 448: Transfer Assembly Inspection
3C-15 Transfer: 9) Caulk transfer output flange nut (1). Bevel Gear Tooth Contact Inspection S3RH0A3306009 1) After cleaning tooth surface of bevel gear (1), paint them with gear marking compound evenly by using brush or sponge etc. NOTE When applying red lead paste to teeth, be sure to paint tooth surfaces uniformly.
Page 449 Transfer: 3C-16 Gear tooth contact table Tooth contact pattern Diagnosis and remedy Normal I4RH01330009-01 High contact Pinion is positioned too far from the center of drive bevel gear. 1. Decrease thickness of bevel pinion shim and position pinion closer to gear center. 2.
Page 450 3C-17 Transfer: Specifications Tightening Torque Specifications S3RH0A3307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Transfer oil drain plug 17.0 Transfer oil level/filler plug 17.0 Engine rear mounting bracket nuts 18.0 Transfer mounting bolts 36.5 Transfer to engine stiffener bolts 36.5 Transfer to transaxle stiffener bolts 36.5...
Page 451: Special Tools And Equipment
Transfer: 3C-18 Special Tools and Equipment Recommended Service Material S3RH0A3308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 452 3C-19 Transfer: 09924–84510–002 09924–84510–005 Bearing installer (blue) Bearing installer attachment 09925–15410 09925–88210 Oil seal installer Bearing puller attachment 09928–36010 09930–40113 Reduction drive holder Flywheel rotor holder 09940–14940 09941–54911 Swing arm adjuster lock nut Bearing outer race remover wrench 09941–74910 09944–66060 Steering stem bearing Bearing installer remover and installer...
Page 453: Propeller Shafts
Propeller Shafts: 3D-1 Propeller Shafts Driveline / Axle General Description Propeller Shaft Description S3RH0A3401001 Most universal joints require no maintenance. They are lubricated for life and can not be lubricated on the vehicle. If a universal joint becomes noisy or worn, it must be replaced. The propeller shaft is a balanced unit.
Page 454 3D-2 Propeller Shafts: Propeller Shaft Removal and Installation 5) Remove propeller shaft center support brackets (4) S3RH0A3406001 from vehicle body. Removal CAUTION 1) Hoist vehicle. • Bracket and No.1 & No.2 shaft are removed 2) Before removing propeller shaft, give match marks in one without separation.
Page 455 Propeller Shafts: 3D-3 Propeller Shaft Inspection S3RH0A3406002 1) Check propeller shaft connecting bolts for looseness. If looseness is found, tighten to specified torque. 2) Check propeller shaft joints for wear, play and damage. If any defect is found, replace. 3) Check propeller shaft center support for biting of foreign matter, crack, abnormal noise and damage.
Page 456 3D-4 Propeller Shafts:...
Page 457 Table of Contents 4- i Section 4 Brakes CONTENTS Brake Control System and Diagnosis ... 4A-1 Special Tools and Equipment ......4A-26 Recommended Service Material .......4A-26 Precautions............4A-1 Special Tool ............4A-26 Precautions on Brake.......... 4A-1 General Description ..........4A-1 Front Brakes ..........4B-1 Brakes Construction..........
Page 458 4-ii Table of Contents Parking Brake Cable Removal and DTC C1021, C1022 / C1025, C1026 / C1031, Installation ............4D-2 C1032 / C1035, C1036 (No. 21, 22 / 25, 26 / 31, 32 / 35, 36): Wheel Speed Sensor Circuit Specifications............4D-3 or Sensor Ring ..........4E-24 Tightening Torque Specifications......4D-3 DTC C1041 / C1045 / C1051 / C1055, DTC...
Page 459: Brake Control System And Diagnosis
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brakes Precautions Precautions on Brake S3RH0A4100001 Air Bag Warning Refer to “Air Bag System Service Warning in Section 00”. Brake Note Refer to “Precautions in Servicing Full-Time 4WD Vehicle in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note”.
Page 460 4A-2 Brake Control System and Diagnosis: I3RH0A410001-01 [A]: For vehicle without ABS 3. Secondary side 7. P (Proportioning) valve or 5-way joint [B]: For vehicle with ABS 4. Primary side 8. LSPV (Load Sensing Proportioning Valve) if equipped 1. Brake booster 5.
Page 461: Front Brake Hose / Pipe Construction
Brake Control System and Diagnosis: 4A-3 Front Brake Hose / Pipe Construction S3RH0A4101002 For Vehicle with ABS I3RH0A410005-01 [A]: For LH steering vehicle 2. From master cylinder secondary to ABS 9. From ABS hydraulic unit to ABS 4-way joint hydraulic unit T: Top side 3.
Page 462 4A-4 Brake Control System and Diagnosis: I3RH0A410004-01 [B]: For RH steering vehicle 2. From master cylinder secondary to ABS 9. From ABS hydraulic unit to ABS 4-way joint hydraulic unit T: Top side 3. From ABS hydraulic unit to left front brake 10.
Page 463 Brake Control System and Diagnosis: 4A-5 For Vehicle without ABS I3RH0A410002-01 [A]: For LH steering vehicle X: View X 4. Front brake hose [B]: For RH steering vehicle Y: View Y 5. 5-way joint or P valve T: Top side 1.
Page 464: Rear Brake Hose / Pipe Construction
4A-6 Brake Control System and Diagnosis: Rear Brake Hose / Pipe Construction S3RH0A4101003 I3RH0A410003-01 [A]: with ABS or P valve F: Front side 1. 4 way joint a-f: Clamp [B]: with LSPV R: Right side 2. LSPV assembly : Tightening torque T: Top side L: Left side 3.
Page 465: Diagnostic Information And Procedures
Brake Control System and Diagnosis: 4A-7 Diagnostic Information and Procedures Brakes Diagnosis Note Substandard or Contaminated Brake Fluid S3RH0A4104001 Improper brake fluid, mineral oil or water in the fluid may Road Testing Brakes cause the brake fluid to boil or the rubber components in Brakes should be tested on dry, clean, smooth and the hydraulic system to deteriorate.
Page 466 4A-8 Brake Control System and Diagnosis: Condition Possible cause Correction / Reference Item Brake pull (Brakes not Pad linings and/or shoe linings are wet Replace. working in unison) with water or stained with oil in some brakes Drum-to-shoe clearance out of Check for inoperative auto adjusting adjustment in some brakes mechanism.
Page 467: Fluid Pressure Test (If Equipped With Lspv)
Brake Control System and Diagnosis: 4A-9 Condition Possible cause Correction / Reference Item Pedal pulsation (Pedal Damaged or loose wheel bearings Replace wheel bearings. pulsates when depressed Distorted steering knuckle or rear wheel Replace knuckle or rear wheel spindle. for braking) spindle Excessive disc lateral runout Check per instructions.
Page 468 4A-10 Brake Control System and Diagnosis: 3) Depress brake pedal gradually till fluid pressure of • For front brake front brake becomes as specified below and check Special tool corresponding pressure of rear brake then. It should (A): 09956–02311 be within specification given below. (B): 09952–36320 Front brake Rear brake...
Page 469: Repair Instructions
Brake Control System and Diagnosis: 4A-11 Repair Instructions Brake Pedal Free Height Inspection Brake Pedal Play Inspection S3RH0A4106001 S3RH0A4106002 Pedal play should be within the following specification. If 1) Check brake pedal free height. If it is not within out of specification, check stop light switch for proper specification, check and adjust following item 2) and installation position and adjust if necessary.
Page 470: Master Cylinder And Brake Fluid Level Inspection
4A-12 Brake Control System and Diagnosis: CAUTION Do not use shock absorber fluid or any other fluid which contains mineral oil. Do not use a container which has been used for mineral oil or a container which is wet from water. Mineral oil will cause swelling and distortion of rubber parts in hydraulic brake system and water mixed into brake fluid will lower fluid...
Page 471 Brake Control System and Diagnosis: 4A-13 NOTE 3) Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one- Perform bleeding operation starting with third to one-half turn. wheel cylinder farthest from master cylinder 4) When fluid pressure in cylinder is almost depleted, and then at front caliper of the same brake retighten bleeder plug.
Page 472: Front Brake Hose / Pipe Removal And Installation
4A-14 Brake Control System and Diagnosis: Front Brake Hose / Pipe Removal and Brake Hose and Pipe Inspection S3RH0A4106009 Installation S3RH0A4106007 Hose The brake hose assembly should be checked for road Removal hazard damage, for cracks and chafing of outer cover, 1) Raise and support vehicle properly.
Page 473: Master Cylinder Components
Brake Control System and Diagnosis: 4A-15 Master Cylinder Components S3RH0A4106010 NOTE The figure shows LH steering vehicle. I2RH01410020-01 [A]: For vehicle without ABS 5. Piston cup: Apply brake fluid. Confirm 11. Secondary piston stopper bolt (for LH steering For RH steering vehicle with ABS installing direction.
Page 474: Master Cylinder Assembly Removal And Installation
4A-16 Brake Control System and Diagnosis: Installation 6) Remove master cylinder fixing nuts (3). 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then press-fit grommets to master cylinder. Grommets must be seated in place. 2) Install reservoir (1) to master cylinder with pin (2).
Page 475: Master Cylinder Assembly Disassembly And Assembly
Brake Control System and Diagnosis: 4A-17 4) Connect fluid level switch connector (1) of reservoir. 2) [For LH steering vehicle equipped with ABS] Push in primary piston (1) to remove secondary piston stopper pin (2) from master cylinder as shown. I2RH01410025-01 3) Remove circlip (1).
Page 476: Master Cylinder Assembly Inspection
4A-18 Brake Control System and Diagnosis: 1) Apply brake fluid to inside of cylinder and contact 5) Install circlip (1). surface of piston assembly (new piston cups, new cylinder cup). 2) Install secondary return spring and secondary piston (1) into cylinder body (4). NOTE For LH steering vehicles equipped with ABS, align oblong hole in secondary piston (2)
Page 477: Brake Booster Components
Brake Control System and Diagnosis: 4A-19 Brake Booster Components S3RH0A4106015 CAUTION Never disassemble brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with new one. NOTE The figure shows LH steering vehicle. I3RH0A410022-01 1. Booster assembly 5.
Page 478: Brake Booster Removal And Installation
4A-20 Brake Control System and Diagnosis: 4) If pedal travel doesn’t change, air tightness isn’t Check Air Tightness Under Load obtained. 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed. NOTE If defective, inspect vacuum lines and sealing parts, and replace any faulty part.
Page 479 Brake Control System and Diagnosis: 4A-21 4) [For RH steering vehicle] 5) [For LH steering vehicle with ABS] Install brake vacuum pipe to dash panel. a) Remove air cleaner case assembly from vehicle body. 6) [For RH steering vehicle] b) Support engine with support device. a) Install right side engine mounting bracket to timing chain cover and tighten right side engine c) Loosen right side engine mounting bolt (1) and...
Page 480: Brake Booster Inspection And Adjustment
4A-22 Brake Control System and Diagnosis: Brake Booster Inspection and Adjustment 2) Turn special tool upside down and place it on S3RH0A4106018 booster (1). Adjust booster piston rod (2) length until rod end contacts pin head. Installation Position of Push Rod Clearance “b”...
Page 481: Lspv (Load Sensing Proportioning Valve) Assembly (If Equipped)
Brake Control System and Diagnosis: 4A-23 LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped) S3RH0A4106019 CAUTION Never disassemble LSPV assembly. Disassembly will spoil its original performance. Replace with new one if detective. I3RH0A410016-01 1. LSPV assembly 3. Adjust nut 5. LSPV mounting bolt 2.
Page 482: Lspv (Load Sensing Proportioning Valve) Inspection And Adjustment
4A-24 Brake Control System and Diagnosis: 3) Torque each bolt and nut to specification as LSPV (Load Sensing Proportioning Valve) indicated respectively in figure. Inspection and Adjustment S3RH0A4106021 Tightening torque Inspection and Adjustment LSPV adjust nut (a): 23 N·m (2.3 kgf-m, 17.0 lb- 1) Confirm the following before inspection and adjustment.
Page 483 Brake Control System and Diagnosis: 4A-25 Specifications Tightening Torque Specifications S3RH0A4107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft LSPV adjust nut 17.0 Front brake caliper bleeder plug (for NISSIN made 0.85 caliper) Front brake caliper bleeder plug (for other than NISSIN 11.0 made caliper) Rear wheel cylinder bleeder plug...
Page 484: Special Tools And Equipment
4A-26 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material S3RH0A4108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 3 — DOT 3 NOTE Required service material is also described in the following. “Master Cylinder Components”...
Page 485: Front Brakes
Front Brakes: 4B-1 Front Brakes Brakes Repair Instructions Front Disc Brake Components S3RH0A4206001 I3RH0A420001-01 [A]: For NISSIN made caliper 6. Cylinder boot 13. Brake disc : Apply grease included in spare parts. [B]: For other than NISSIN made caliper 7. Brake pad 14.
Page 486: Front Disc Brake Pad On-Vehicle Inspection
4B-2 Front Brakes: Front Disc Brake Pad On-Vehicle Inspection 4) Remove brake pads (3). S3RH0A4206002 Inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end (or hole) of caliper and check lining thickness of outside and inside pads.
Page 487: Front Disc Brake Pad Inspection
Front Brakes: 4B-3 Front Disc Brake Caliper Removal and 4) Install wheel and lower lift. Installation 5) Tighten wheel nuts to specified torque. S3RH0A4206005 Tightening torque Removal Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft) 1) Hoist vehicle and remove wheel. 2) Loosen flexible hose joint bolt (1) a little at caliper.
Page 488: Front Disc Brake Caliper Disassembly And Assembly
4B-4 Front Brakes: Front Disc Brake Caliper Disassembly and Assembly S3RH0A4206006 Disassembly CAUTION 1, (a) Clean around caliper with brake fluid before disassembly. 1) Remove piston with air blown into flexible hose bolt I2RH01420022-01 installation hole. 3) Connect caliper to flexible hose. WARNING 4) Torque flexible hose joint bolt to specification.
Page 489 Front Brakes: 4B-5 1) Replace with a new piston seal (1) at every overhaul. 4) Remove piston seal using a thin blade like a thickness gauge, etc. After applying grease, fit piston seal (1) into groove in cylinder taking care not to twist it. CAUTION Be careful not to damage inside (bore side) of cylinder.
Page 490: Front Disc Brake Caliper Inspection
4B-6 Front Brakes: Piston Seal 4) Insert piston into cylinder by hand and fit boot in boot groove in piston. Excessive or uneven wear of pad lining may indicate unsmooth return of piston. NOTE In such case, replace rubber seal. Check that boot is fitted in boot groove securely all around piston and cylinder.
Page 491: Front Brake Disc Inspection
Front Brakes: 4B-7 Front Brake Disc Inspection 3) Pull brake disc off by using 8 mm bolts (1) (2 pcs). S3RH0A4206009 • Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of disc, measure deflection of disc.
Page 492: Special Tools And Equipment
4B-8 Front Brakes: Specifications Tightening Torque Specifications S3RH0A4207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Caliper pin bolt for NISSIN made 16.0 caliper Caliper pin bolt for other than NISSIN 25.5 made caliper Wheel nut 61.5 Flexible hose joint bolt 17.0 Bleeder plug for NISSIN made...
Page 493: Rear Brakes
Rear Brakes: 4C-1 Rear Brakes Brakes Repair Instructions Rear Drum Brake Components S3RH0A4306001 I2RH01430001-01 1. Brake back plate 9. Shoe hold down pin : Apply water tight sealant (99000-31090) to mating surfaces of brake back plate and rear axle. 2. Brake shoe 10.
Page 494 4C-2 Rear Brakes: 5) Remove back plate plug (1) attached to the back Installation side of brake back plate so as to increase clearance 1) Before installing brake drum, to maximize brake between brake shoe and brake drum. shoe-to-drum clearance, put screwdriver between Insert a screwdriver into plug hole till its tip contacts rod (1) and ratchet (2) and push down ratchet as shoe hold down spring and push screwdriver in the...
Page 495: Rear Brake Drum Inspection
Rear Brakes: 4C-3 3) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil. 4) Tighten brake drum screws (1) to specified torque. Tightening torque Brake drum screw (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft) I2RH01430006-01 Cracked, Scored or Grooved Drum I3RH01430027-01...
Page 496: Rear Brake Shoe Removal And Installation
4C-4 Rear Brakes: Rear Brake Shoe Removal and Installation Installation S3RH0A4306004 Install parts in reverse order of removal, noting the following. Removal • Install shoe hold down springs (2) by pushing them 1) Remove brake drum referring to “Rear Brake Drum down in place and turning hold down pins (1).
Page 497: Wheel Cylinder Removal And Installation
Rear Brakes: 4C-5 Wheel Cylinder Removal and Installation 2) Tighten wheel cylinder to brake back plate to S3RH0A4306006 specified torque. Tightening torque Removal Wheel cylinder mounting bolt (a): 12 N·m (1.2 1) Remove brake drum referring to “Rear Brake Drum kgf-m, 9.0 lb-ft) Removal and Installation”.
Page 498: Wheel Cylinder Inspection
4C-6 Rear Brakes: Wheel Cylinder Inspection 5) Remove wheel hub referring to “Wheel Hub with S3RH0A4306007 Wheel Bearing and Wheel Stud Removal and Inspect wheel cylinder disassembled parts for wear, Installation (2WD Model) in Section 2C” or “Wheel cracks, corrosion or damage. Hub, Wheel Stud / Wheel Bearing Outside Inner Race Removal and Installation (4WD Model) in NOTE...
Page 499: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A4308001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Sealing Compound 366E P/No.: 99000–31090 NOTE Required service material is also described in the following.
Page 500: Parking Brake
4D-1 Parking Brake: Parking Brake Brakes General Description Parking Brake Cable Construction S3RH0A4401001 I3RH0A440001-01 T: Top side 3. Inner cable end 8. Equalizer [E]: View E F: Front side 4. Spring [A]: View A [F]: View F R: Rear side 5.
Page 501: Repair Instructions
Parking Brake: 4D-2 Repair Instructions Parking Brake Inspection and Adjustment After confirming that the conditions are all satisfied, S3RH0A4406001 adjust parking brake lever stroke by loosening or Inspection tightening adjust nut (3). Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force.
Page 502: Specifications
4D-3 Parking Brake: Tightening torque Installation Install it by reversing removal procedure, noting the Parking brake lever bolt: 23 N·m (2.3 kgf-m, 17.0 following points. lb-ft) Parking brake cable clamp bolt: 11 N·m (1.1 kgf- • Install clamps properly referring to “Parking Brake m, 8.0 lb-ft) Cable Construction”.
Page 503: Abs
ABS: 4E-1 Brakes Precautions Precautions in Diagnosing Troubles • Inspect the vehicle for any mechanical conditions S3RH0A4500001 related the brake system. To ensure that the trouble diagnosis is done accurately – Brake reservoir fluid level correct. and smoothly, observe the following and follow “ABS –...
Page 504: General Description
4E-2 ABS: General Description ABS Construction ABS Hydraulic Unit / Control Module Assembly S3RH0A4501001 Description The ABS (Antilock Brake System) controls the fluid S3RH0A4501002 pressure applied to the wheel cylinder of each brake ABS control module is a component of ABS hydraulic from the master cylinder so that each wheel is not locked unit / control module assembly and has the following even when hard braking is applied.
Page 505 ABS: 4E-3 Fail-Safe Function • When diag. switch terminal (2) of diagnosis connector When an abnormality occurs (an abnormal DTC is (1) (monitor connector) is grounded, the abnormal detected), ABS control module turns OFF the fail-safe area is output as DTC. It is indicated by flashing of relay (transistor) which supplies power to it self.
Page 506: Schematic And Routing Diagram
4E-4 ABS: Schematic and Routing Diagram ABS Schematic S3RH0A4502001 I4RH01450002-01 1. ABS hydraulic unit / control module assembly 7. ABS warning lamp 13. Wheel speed sensor (Right-front) 2. ABS control module 8. EBD warning lamp (Brake warning lamp) 14. Wheel speed sensor (Left-front) 3.
Page 507: Abs Wiring Circuit Diagram
ABS: 4E-5 ABS Wiring Circuit Diagram S3RH0A4502002 WHT/BLU WHT/GRN BLK/RED GRN/ORN E43-7 RED/BLK GRN/WHT E43-3 RED/WHT E43-17 E43-5 PNK/GRN E43-23 WHT/BLU E43-21 E43-14 E43-1 RED/BLK E43-22 E43-19 WHT/BLK E43-18 LT GRN/RED E43-15 LT GRN/BLK E43-16 E43-25 E43-24 E43-20 E43-26 E43-13 I3RH0A450009-01 [A]: Terminal arrangement of ABS hydraulic unit 9.
Page 508 4E-6 ABS: Terminal Wire color Circuit WHT/BLU ABS pump motor relay (Transistor) — — GRN/WHT Brake light switch — — Dark link connector — — GRN/ORN Ignition switch — — — — — — — — — — Ground WHT/BLU ABS fail–safe relay (Transistor) LT GRN/RED Left–rear wheel speed sensor (+)
Page 509: Component Location
ABS: 4E-7 Component Location ABS Components Location S3RH0A4503001 NOTE As for the difference of RH steering vehicle and LH steering vehicle, the location of the combination meter, monitor connector, data link connector, stop lamp switch and the brake master cylinder assembly only changes.
Page 510: Front Wheel Speed Sensor Components Location
4E-8 ABS: Front Wheel Speed Sensor Components Location S3RH0A4503002 I3RH0A450010-01 1. Left front wheel speed sensor 3. Grommet 5. Sensor ring 2. Clamp bolt No.1 4. Connector 6. Clamp bolt No.2 Rear Wheel Speed Sensor Components Location S3RH0A4503003 23 N·m (2.3 kg-m) 10 N·m (1.0 kg-m) 10 N·m (1.0 kg-m) 23 N·m (2.3 kg-m)
Page 511: Diagnostic Information And Procedures
ABS: 4E-9 Diagnostic Information and Procedures ABS Check S3RH0A4504001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”. 3) Perform “DTC check, record and clearance: ”...
Page 512 4E-10 ABS: Step 1: Malfunction Analysis Customer complaint analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 513: Abs Warning Lamp Check
ABS: 4E-11 Step 2: Driving Test Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnormal lighting of ABS warning light) exists. If the malfunction DTC is confirmed again at ignition switch ON, driving test as described is not necessary. Proceed to Step 3.
Page 514: Dtc Check
5) After completing the check, turn ignition switch off, disconnect service wire from monitor coupler. Using SUZUKI Scan Tool 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (1). Special tool (A): SUZUKI scan tool...
Page 515: Dtc Table
4) Read DTC according to instructions displayed on If SUZUKI scan tool can not communicate SUZUKI scan tool and print it or write it down. Refer ABS hydraulic unit / control module, perform to SUZUKI scan tool operator’s manual for further “Serial Data Link Circuit Check”.
Page 516: Dtc Clearance
(2) of monitor connector (blue) (1) to ground terminal (3). Using SUZUKI Scan Tool 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch to ON position.
Page 517: Abs Warning Lamp Does Not Come On At Ignition Switch
ABS: 4E-15 • No DTC. Scan Tool Data Definition Battery Volt (V): Battery Voltage is an analog input • ABS is not operated. (Normal braking operation) signal read by the ABS control module. Certain ABS Scan Tool Standards Condition control module functions will be modified if the Data battery voltage falls below or rises above Battery...
Page 518: Abs Warning Lamp Comes On Steady
4E-16 ABS: Troubleshooting Step Action 1) Turn ignition switch to ON position. Go to Step 2. Go to Step 4. Do other warning lamps come ON? 1) Turn OFF ignition switch. Replace ABS hydraulic Go to Step 3. unit / control module 2) Disconnect ABS hydraulic unit / control module assembly.
Page 519 ABS: 4E-17 Circuit Description Operation (ON/OFF) of ABS warning lamp is controlled by ABS control module through lamp driver module in combination meter. If the Antilock brake system is in good condition, ABS control module turns ABS warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.
Page 520 4E-18 ABS: ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON S3RH0A4504010 Wiring Diagram I3RH0A450005-01 [A]: ABS hydraulic unit / control module connector E15 5. Combination meter 9-1. Diagnosis switch terminal 1. Battery 6. ABS warning lamp 9-2. Diagnosis ground terminal 2.
Page 521: Abs Warning Lamp Flashes Continuously
ABS: 4E-19 Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground S3RH0A4504011 Wiring Diagram I3RH0A450005-01 [A]: ABS hydraulic unit / control module connector E15 5. Combination meter 9-1. Diagnosis switch terminal 1. Battery 6. ABS warning lamp 9-2.
Page 522: Ebd Warning Lamp (Brake Warning Lamp) Comes On Steady
4E-20 ABS: Step Action 1) Measure resistance between ground terminal of monitor Substitute a known- “BLK” circuit open or in coupler and body ground. good ABS hydraulic unit high resistance. / control module Ω Is resistance less than 2 assembly and recheck. EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady S3RH0A4504012 Wiring Diagram...
Page 523: Serial Data Link Circuit Check
ABS: 4E-21 Step Action 1) Disconnect ABS hydraulic unit / control module Substitute a known- “PNK/GRN” circuit connector. good ABS hydraulic unit open. If wire and / control module connection are OK, 2) Check for proper connection to ABS hydraulic unit / assembly and recheck.
Page 524 4E-22 ABS: Step Action 1) Turn ignition switch to OFF position. Go to Step 5. “WHT/BLU” wire circuit open. 2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E15-1” and “E15- 14”. 3) If OK then turn ignition switch to ON position and measure voltage between each terminal of “E15-1”, “E15-14”...
Page 525: Dtc C1015 (No. 15): G Sensor Circuit
ABS: 4E-23 Step Action 1) Turn ignition switch to OFF position. Substitute a known- Repair high resistance good ABS hydraulic unit or open in “BLU” wire 2) Check proper connection at “E15-5” (“BLU” wire) / control module and circuit for anti lock brake terminal for serial data circuit.
Page 526: Dtc C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036 (No. 21, 22 / 25, 26 / 31, 32 / 35, 36): Wheel Speed Sensor Circuit Or Sensor Ring
4E-24 ABS: DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036 (No. 21, 22 / 25, 26 / 31, 32 / 35, 36): Wheel Speed Sensor Circuit or Sensor Ring S3RH0A4504015 DTC C1021, C1022 (No. 21, 22): Right-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1025, C1026 (No.
Page 527 ABS: 4E-25 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. 1) Disconnect applicable ABS wheel speed sensor coupler Go to Step 3. Replace ABS wheel with ignition switch OFF. speed sensor assembly. 2) Measure resistance between terminals of ABS wheel speed sensor.
Page 528: Dtc C1041 / C1045 / C1051 / C1055, Dtc
4E-26 ABS: DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056 (No. 41 / 45 / 51 / 55, No. 42 / 46 / 52 / 56): Inlet Solenoid Circuit, Outlet Solenoid Circuit S3RH0A4504016 DTC C1041 / C1045 (No.
Page 529: Dtc C1057 (No. 57): Power Source Circuit
ABS: 4E-27 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. 1) Check solenoid operation referring to item “ABS Check terminal “E15- Go to Step 3. Hydraulic Unit Operation Check”. 14” connection. If connection is OK, Is it in good condition? substitute a known-...
Page 530 4E-28 ABS: DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. 1) Disconnect ABS hydraulic unit / control module Go to Step 5. Go to Step 3. connector with ignition switch turned OFF. 2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E15-14”...
Page 531: Dtc C1061 (No. 61): Abs Pump Motor And/Or Motor Relay Circuit
ABS: 4E-29 DTC C1061 (No. 61): ABS Pump Motor and/or Motor Relay Circuit S3RH0A4504018 Wiring Diagram I3RH0A450020-01 [A]: ABS hydraulic unit / control module connector E15 2. Main fuse box 4. ABS pump motor 1. Battery 3. Pump motor relay (transistor) 5.
Page 532: Dtc C1063 (No. 63): Abs Fail-Safe Relay Circuit
4E-30 ABS: DTC C1063 (No. 63): ABS Fail-Safe Relay Circuit S3RH0A4504019 Wiring Diagram I3RH0A450007-01 [A]: ABS hydraulic unit / control module connector E15 4. Circuit fuse box 8. ABS (10 A) fuse 1. Battery 5. Fail-safe relay (transistor) 9. ABS (60 A) fuse 2.
Page 533: Dtc C1071 (No. 71): Abs Control Module
ABS: 4E-31 DTC C1071 (No. 71): ABS Control Module S3RH0A4504020 Wiring Diagram I3RH0A450021-01 [A]: ABS hydraulic unit / control module connector E15 2. Main fuse box 4. ABS hydraulic unit / control module assembly 1. Battery 3. ABS power control module DTC Detecting Condition This DTC will be set when an internal malfunction is detected in the ABS control module.
Page 534: Repair Instructions
Brake pedal (1) should be depressed and then select 1) Check that basic brake system other than ABS is in testing wheel by SUZUKI scan tool and the wheel (2) good condition. should be turned by another person’s hand. At this 2) Check that battery voltage is 11 V or higher.
Page 535 ABS: 4E-33 Not Using SUZUKI Scan Tool 8) Turn ignition switch OFF. 1) Check that basic brake system other than ABS is in 9) Perform the following checks with help of another good condition. person. Brake pedal (1) should be depressed and then ignition switch (2) turned ON by one person and 2) Check that battery voltage is 11 V or higher.
Page 536: Abs Hydraulic Unit / Control Module Assembly Components
4E-34 ABS: ABS Hydraulic Unit / Control Module Assembly Components S3RH0A4506002 CAUTION Never disassemble ABS hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit / control module assembly.
Page 537: Abs Hydraulic Unit / Control Module Assembly On-Vehicle Inspection
ABS: 4E-35 ABS Hydraulic Unit / Control Module Assembly 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit / On-Vehicle Inspection control module assembly (3). S3RH0A4506003 CAUTION Special tool Never disassemble ABS hydraulic unit / (A): 09950-78220 control module assembly, loosen blind plug NOTE...
Page 538 4E-36 ABS: Installation 1) Install hydraulic unit / control module assembly by reversing removal procedure. Tightening torque Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5 lb-ft) ABS hydraulic unit / control module assembly bolt (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft) ABS hydraulic unit / control module assembly bracket bolt (c): 23 N·m (2.3 kgf-m, 17.0 lb-ft) I4RH01450017-01 2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”.
Page 539: Front Wheel Speed Sensor On-Vehicle Inspection
ABS: 4E-37 Front Wheel Speed Sensor On-Vehicle Front Wheel Speed Sensor Removal and Inspection Installation S3RH0A4506005 S3RH0A4506006 Output Voltage Inspection Removal 1) Disconnect negative cable from battery. 1) Disconnect negative cable from battery. 2) Hoist vehicle a little. 2) Disconnect front wheel speed sensor coupler (1). 3) Disconnect wheel speed sensor connector.
Page 540: Front Wheel Speed Sensor Inspection
4E-38 ABS: Rear Wheel Speed Sensor On-Vehicle CAUTION Inspection Do not pull or twist wire harness more than S3RH0A4506008 Output Voltage Inspection necessary when installing front wheel speed sensor. 1) Disconnect negative cable from battery. 2) Remove quarter inner trim (1). I3RH0A450015-01 [A]: OK I3RH0A450023-01...
Page 541: Rear Wheel Speed Sensor Removal And Installation
ABS: 4E-39 8) If measured voltage is not as specified, check 3) Turn over floor carpet. sensor, ring and their installation conditions. 4) Hoist vehicle. 5) Disconnect rear wheel speed sensor coupler (1). Reference 6) Detach ABS wheel sensor wire harness (2). When using oscilloscope for this check, check if peak-to- peak voltage (1) meets specification and waveform is NOTE...
Page 542: Rear Wheel Speed Sensor Inspection
4E-40 ABS: Rear Wheel Speed Sensor Inspection Installation Reverse removal procedure for installation noting the S3RH0A4506010 • Check sensor for damage. following. • Measure resistance of sensor. • Check that no foreign material is attached to sensor and ring (1). Between both terminals (1) of sensor 1.2 –...
Page 543: Front Wheel Speed Sensor Ring Removal And Installation
ABS: 4E-41 Front Wheel Speed Sensor Ring Removal and Rear Wheel Speed Sensor Ring Removal and Installation Installation S3RH0A4506012 S3RH0A4506014 NOTE NOTE The front wheel sensor ring can not be The rear wheel sensor ring can not be removed or replaced alone. If front wheel removed or replaced alone.
Page 544: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S3RH0A4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 545 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 No Lock-Up Occurs...........5A-45 DTC P0705 (No. 34): Transmission Range Precautions............. 5-1 Sensor Circuit Malfunction ......5A-46 Precautions on Transmission / Transaxle ..... 5-1 DTC P0710 (No. 36 or 38): Transmission Automatic Transmission/Transaxle..
Page 546 5-ii Table of Contents Select Cable Removal and Installation ..... 5A-82 Transaxle Rear Cover and O/D and 2nd Selector Cable Adjustment........ 5A-82 Coast Brake Piston Assembly Inspection ..5A-128 Transmission Range Sensor (Shift Switch) Countershaft Assembly Components....5A-129 Inspection and Adjustment......5A-83 Countershaft Assembly Disassembly and Output Shaft Speed Sensor / VSS Removal Reassembly ..........5A-129...
Page 547 Table of Contents 5-iii Gear Shift Shaft Components ......5B-33 Clutch Fluid Pipe and Hose Inspection ....5C-5 Gear Shift Shaft Disassembly and Assembly..5B-33 Clutch Master Cylinder Removal and Differential Components ........5B-34 Installation ............5C-6 Differential Disassembly and Assembly .... 5B-35 Clutch Master Cylinder Components ....5C-7 Transfer Components ........
Page 548: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions on Transmission / Transaxle S3RH0A5000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 5A”. Precautions for Disassembly and Reassembly Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Page 549 TCM and/or ECM memory. S3RH0A5100002 When repairing automatic transaxle, it is necessary to • Using SUZUKI scan tool the diagnostic information conduct the on-vehicle test to investigate where the stored in ECM memory can be checked and cleared cause of the trouble lies first.
Page 550 5A-2 Automatic Transmission/Transaxle: • Wash the disassembled parts in ATF (Automatic Part Inspection and Correction Table Transaxle Fluid) or kerosene and confirm that each Part Inspect for Correction fluid passage is not clogged by blowing air into it. But Casted part, Small flaw, burr Remove with oil do not use kerosene to wash the discs, resin washers...
Page 551: General Description
Automatic Transmission/Transaxle: 5A-3 General Description A/T Description S3RH0A5101001 This automatic transaxle is electronic control full automatic transaxle with forward 3-speed plus overdrive (O/D) and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up mechanism.
Page 552 5A-4 Automatic Transmission/Transaxle: 16 15 14 13 12 I3RH0A510001-01 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23.
Page 553 Automatic Transmission/Transaxle: 5A-5 I3RH0A510002-01 1. Transfer...
Page 554: Clutch / Brake / Planetary Gear Function Of Automatic Transaxle
5A-6 Automatic Transmission/Transaxle: Specifications Item Specifications Type 3-element, 1-step, 2-phase type with TCC / lock-up mechanism Torque converter Stall torque ratio 2.0 – 2.2 Type Internal involute gear and non crescent type oil pump Oil pump Drive system Engine driven Type Forward 4-step, reverse 1-step planetary gear type “P”...
Page 555: Table Of Component Operation
Automatic Transmission/Transaxle: 5A-7 5. Long planet pinion C1: Forward clutch F2: One-way clutch No.2 6. Final drive gear C2: Direct clutch 7. Final driven gear C3: Reverse clutch Functions Part name Function Forward clutch Meshes intermediate shaft and front sun gear Direct clutch Meshes input shaft and planet carrier Reverse clutch...
Page 556: Brake Interlock System Construction
5A-8 Automatic Transmission/Transaxle: Brake Interlock System Construction A/T Diagnosis General Description S3RH0A5101004 S3RH0A5101005 Shift Lock Solenoid Control This vehicle is equipped with an electronic transaxle This system consists of shift lock solenoid control control system, which controls the automatic shift up and system and interlock cable control system.
Page 557: On-Board Diagnostic System Description
• It is possible to communicate with ECM and/or TCM through data link connector (DLC) (3) by using SUZUKI scan tool (4). Diagnostic information can be checked and erased by using scan tool. • It is also possible to check DTC stored in TCM memory by displaying DTC on digital display odometer (6).
Page 558 “O/D OFF” lamp (1) and stores malfunction DTC in its memory. • It is possible to communicate with TCM through data link connector (DLC) (2) by using SUZUKI scan tool (3). Diagnostic information can be checked and erased by using scan tool.
Page 559: Schematic And Routing Diagram
Automatic Transmission/Transaxle: 5A-11 Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S3RH0A5102001 G07-5 G07-17 2.5V BLU/ORN G08-5 G08-14 LT GRN PPL/RED G07-24 G08-4 GRN/BLK G07-3 GRN/ORN G08-3 G08-10 GRN/YEL GRN/WHT G08-16 G08-12 BLU/WHT G03-17 GRN/YEL G08-7 G08-11 GRY/RED G08-8 GRY/BLK G03-6...
Page 560 5A-12 Automatic Transmission/Transaxle: 8. ABS control module 17. Shift solenoid valve-B / No.2 26. Starter motor relay 9. ECM 18. Timing solenoid valve 27. Terminal arrangement of TCM connector viewed from harness side Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve Solenoid Shift Shift...
Page 561: Automatic Gear Shift Diagram
Automatic Transmission/Transaxle: 5A-13 Automatic Gear Shift Diagram S3RH0A5102002 For 2WD Vehicle Automatic shift schedule as a result of shift control is shown in the following. In case that selector lever is shifted to “L” range at a higher than 50 km/h (31 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that.
Page 562 5A-14 Automatic Transmission/Transaxle: For 4WD Vehicle Automatic shift schedule as a result of shift control is shown below. In case that selector lever is shifted to “L” range at a higher than 47 km/h (29.5 mile/h) speed, 2nd gear is operated and then down shifts to 1st at a speed lower than that. The same as, the select lever is shifted to “2”...
Page 563: Component Location
Automatic Transmission/Transaxle: 5A-15 Component Location Electronic Shift Control System Components Location S3RH0A5103001 I3RH0A510017-02 1. Engine 8. Brake light switch 15. Timing solenoid valve 2. Transaxle 9. TCM 16. Transmission fluid temperature sensor...
Page 564 5A-16 Automatic Transmission/Transaxle: 3. ECM 10. Input shaft speed sensor 17. TCC / Lock-up solenoid valve 4. Monitor connector 11. Transmission range sensor 18. Output shaft speed sensor / VSS 5. Throttle position (TP) sensor 12. Pressure control solenoid valve 19.
Page 565: Diagnostic Information And Procedures
Automatic Transmission/Transaxle: 5A-17 Diagnostic Information and Procedures A/T System Check S3RH0A5104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC / freeze frame data check, record and clearance Print DTC and freeze...
Page 566 5A-18 Automatic Transmission/Transaxle: Step 1. Customer Complaint Analysis Record details of the problem such as failure, complaint and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 567 Automatic Transmission/Transaxle: 5A-19 Step 2. DTC / Freeze Frame Data Check, Record and Clearance First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been restored.
Page 568: Malfunction Indicator Lamp (Mil) Check
I type II type I type II type I type II type I type II × × × × × SUZUKI scan tool × × × × × × × Generic scan tool Not using scan tool × × ×...
Page 569 Automatic Transmission/Transaxle: 5A-21 DTC No. Detecting condition Detecting item Type I Type II (DTC will set when detecting:) — No malfunction is detected — — — Transmission range sensor • No sensor signal is inputted. *3 *4 circuit malfunction P0705 2 driving 2 driving •...
Page 570 5A-22 Automatic Transmission/Transaxle: DTC No. Detecting condition Detecting item Type I Type II (DTC will set when detecting:) Shift solenoid-B / No.2 Voltage of shift solenoid terminal is high electrical although TCM is commanding shift solenoid to turn OFF. 1 driving 1 driving P0758 Voltage of shift solenoid terminal is low...
Page 571: Dtc Check
2) Remove glove box (1) from instrument panel. of the following 3 methods. 3) Using service wire, connect diagnosis switch Reading DTC from ECM Using SUZUKI Scan Tool – terminal (3) with ground terminal (4) of blue monitor Method-1 connector (2).
Page 572: Dtc Clearance
To Clear DTC Stored in TCM with Scan Tool – Method-2 1) Turn ignition switch OFF. 2) After setting cartridge, connect SUZUKI scan tool to data link connector (DLC) (1) located In underside of instrument panel at driver’s seat side.
Page 573: Fail-Safe Table
Automatic Transmission/Transaxle: 5A-25 Fail-Safe Table S3RH0A5104008 This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The following table shows the fail-safe function for each fail condition of sensor, solenoid or its circuit. DTC No.
Page 574: Scan Tool Data
5A-26 Automatic Transmission/Transaxle: DTC No. Trouble area Fail-safe operation Throttle position signal circuit • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. P1700 •...
Page 575 Automatic Transmission/Transaxle: 5A-27 Normal condition / reference Scan tool data Vehicle condition values After driving at 60 km/h (37.5 mile/h) for 15 minutes or 70 – 80 °C (158 – 176 °F) ATF TEMP. more, and A/T fluid temperature around reaches 70 – 80 °C (158 –...
Page 576 5A-28 Automatic Transmission/Transaxle: Scan Tool Data Definitions: SHIFT TIMING SOL MON ON: Electricity being passed to timing solenoid valve GEAR POSITION OFF: Electricity not being passed to timing solenoid Current gear position computed by throttle position valve coming from ECM and vehicle speed. TCC SOLENOID COM ENGINE SPEED (RPM) ON: ON command being outputted to TCC solenoid...
Page 577: A/T Basic Check
Automatic Transmission/Transaxle: 5A-29 ENGINE TORQUE (N⋅m) A/C SWITCH ON: Signal which inform that air conditioner compressor Engine torque computed by duty pulse signal outputted is turned ON. from ECM. OFF: Signal which inform that air conditioner compressor is not turned ON. A/T Basic Check S3RH0A5104010 This check is important for troubleshooting when TCM has detected no DTC and no abnormality has been noted in...
Page 578 5A-30 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Faulty oil pump Inspect. If NG, replace. Seized or broken planetary gear Inspect. If NG, replace. Faulty one-way clutch No.2 Inspect.
Page 579 Automatic Transmission/Transaxle: 5A-31 Condition Possible cause Correction / Reference Item → 3 downshift fails to Malfunction of shift solenoid valve-A Inspect. If NG, replace. occur Malfunction of O/D off switch Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor / VSS Malfunction of input shaft speed sensor Inspect.
Page 580: Manual Road Test
5A-32 Automatic Transmission/Transaxle: Manual Road Test 3) With select lever in “L” range, start vehicle and check S3RH0A5104012 that 3rd gear is being used referring to the following This test checks the gears being used in “L”, “2” or “D” table.
Page 581: Stall Test
Automatic Transmission/Transaxle: 5A-33 Stall Test 1) Apply parking brake and block wheels. S3RH0A5104013 2) Install tachometer. This test is to check overall performance of automatic 3) Start engine with select lever shifted to “P” range. transaxle and engine by measuring stall speed at “D” and “R”...
Page 582: Time Lag Test
5A-34 Automatic Transmission/Transaxle: Time Lag Test Gear shifting time lag “N” → “D”: Less than 0.7 sec. S3RH0A5104014 This test is to check conditions of clutch, brake and fluid “N” → “R”: Less than 1.2 sec. pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt.
Page 583: Line Pressure Test
Automatic Transmission/Transaxle: 5A-35 Line Pressure Test S3RH0A5104015 Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires the following conditions. • Automatic fluid is at normal operating temperature (70 –...
Page 584: P" Range Test
5A-36 Automatic Transmission/Transaxle: “P” Range Test 4) Depress brake pedal and shift select lever to “N” S3RH0A5104017 range. 1) Stop vehicle on a slope of 5 degrees or more, shift 5) Then, release brake pedal gradually and check that select lever to “P” range and at the same time apply vehicle moves.
Page 585 Automatic Transmission/Transaxle: 5A-37 Condition Possible cause Correction / Reference Item No gear shift as 3rd gear Shift solenoid valve-A and/or -B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 586 5A-38 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor 3 O/D shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 587 Automatic Transmission/Transaxle: 5A-39 Condition Possible cause Correction / Reference Item → Poor 3 2 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor / VSS circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 588 5A-40 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC solenoid valve circuit faulty Inspect circuit for open, short and intermittent. up) system If NG, repair. Shift solenoid valve-A and/or -B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 589 Automatic Transmission/Transaxle: 5A-41 Condition Possible cause Correction / Reference Item Excessive shift shock Engine abnormal condition Inspect and repair engine. Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of output shaft speed Inspect. If NG, replace. sensor / VSS Malfunction of input shaft speed sensor Inspect.
Page 590 5A-42 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor O/D 3 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace. Malfunction of timing solenoid valve Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor / VSS Malfunction of input shaft speed sensor Inspect.
Page 591 Automatic Transmission/Transaxle: 5A-43 Trouble Diagnosis 3 Off-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty oil pump Inspect. If NG, replace. Seized or broken planetary gear Inspect. If NG, replace. Faulty one-way clutch No.2 Inspect.
Page 592: No Gear Shift To O
5A-44 Automatic Transmission/Transaxle: No Gear Shift to O/D S3RH0A5104019 System Description TCM does not shift to O/D gear under any of the following condition. • O/D off switch is turned ON, that is, “O/D OFF” lamp lights. • Engine coolant temperature is less than 50 °C (122 °F) •...
Page 593: No Lock-Up Occurs
Automatic Transmission/Transaxle: 5A-45 No Lock-Up Occurs S3RH0A5104020 System Description TCM turns TCC solenoid OFF under any of the following conditions. • Brake light switch is turned ON, that is, brake pedal is depressed. • Engine coolant temperature is less than 60 °C, 140 °F. •...
Page 594: Dtc P0705 (No. 34): Transmission Range Sensor Circuit Malfunction
5A-46 Automatic Transmission/Transaxle: DTC P0705 (No. 34): Transmission Range Sensor Circuit Malfunction S3RH0A5104021 Wiring Diagram WHT/BLK G07-2 IG11 G07-1 RED/BLK G07-9 WHT/RED G07-8 YEL/RED G07-21 G07-20 RED/BLU 21 20 I2RH0B510017-01 1. TCM 3. Brake light switch 5. Backup lamp 2. Transmission range sensor 4.
Page 595 Check transmission range sensor circuit for operation Intermittent trouble. Go to Step 5. Check by using SUZUKI scan tool: Check for intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch referring to “Intermittent OFF. and Poor Connection Inspection in Section 2) Turn ignition switch ON and check transmission range 00”.
Page 596: Dtc P0710 (No. 36 Or 38): Transmission Fluid Temperature Sensor Circuit Malfunction
5A-48 Automatic Transmission/Transaxle: DTC P0710 (No. 36 or 38): Transmission Fluid Temperature Sensor Circuit Malfunction S3RH0A5104023 Wiring Diagram BLU/ORN G08-5 G08-14 LT GRN I2RH0B510018-01 1. TCM 3. A/T 2. Transmission fluid temperature sensor 4. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 597 Automatic Transmission/Transaxle: 5A-49 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check transmission fluid temperature circuit for open Go to Step 3. “BLU/ORN” or “LT GRN” circuit open. 1) Turn ignition switch OFF. 2) Disconnect TCM connectors from TCM.
Page 598: Dtc P0715 (No. 14): Input / Turbine Speed Sensor Circuit Malfunction
5A-50 Automatic Transmission/Transaxle: DTC P0715 (No. 14): Input / Turbine Speed Sensor Circuit Malfunction S3RH0A5104024 Wiring Diagram G07-5 G07-17 2.5V I2RH0B510019-01 1. TCM 2. Input shaft speed sensor 3. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No input shaft speed sensor signal is detected although...
Page 599 Automatic Transmission/Transaxle: 5A-51 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check input shaft speed sensor circuit Go to Step 4. Go to Step 3. 1) Disconnect TCM connectors with ignition switch OFF. 2) Check for proper connection to input shaft speed sensor at “G07-5”...
Page 600: Dtc P0720 (No. 31): Output Speed Sensor / Vss Circuit Malfunction
5A-52 Automatic Transmission/Transaxle: DTC P0720 (No. 31): Output Speed Sensor / VSS Circuit Malfunction S3RH0A5104025 Wiring Diagram BLK/RED PPL/RED G07-24 BLK/ORN I2RH0B510021-01 1. TCM 2. Output shaft speed sensor / VSS 3. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 601 Automatic Transmission/Transaxle: 5A-53 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check output shaft speed sensor / VSS power circuit Go to Step 3. “BLK/RED” wire open or shorted to ground. 1) Turn ignition switch OFF.
Page 602: Dtc P0725 (No. 35): Engine Speed Input Circuit Malfunction
5A-54 Automatic Transmission/Transaxle: DTC P0725 (No. 35): Engine Speed Input Circuit Malfunction S3RH0A5104026 Wiring Diagram LT GRN/BLK G07-15 G03-1 I2RH0B510022-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 603 Automatic Transmission/Transaxle: 5A-55 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check engine speed input signal circuit for open Go to Step 3. “LT GRN/BLK” circuit open. 1) Turn ignition switch OFF. 2) Disconnect TCM and ECM connectors from TCM and ECM.
Page 604: Dtc P0741 (No. 29): Tcc Circuit Performance Or Stuck Off
5A-56 Automatic Transmission/Transaxle: DTC P0741 (No. 29): TCC Circuit Performance or Stuck OFF S3RH0A5104027 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • When driving vehicle with 4th gear in “D” range, difference • Mechanical malfunction of TCC solenoid valve in revolution between engine and A/T input is larger than •...
Page 605: Dtc P0743 (No. 25 Or 26): Tcc Circuit Electrical
Automatic Transmission/Transaxle: 5A-57 DTC P0743 (No. 25 or 26): TCC Circuit Electrical S3RH0A5104028 Wiring Diagram G08-12 BLU/WHT I2RH0B510023-01 1. TCM 3. A/T 2. TCC solenoid valve 4. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area •...
Page 606 5A-58 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve circuit for IG short Go to Step 3. “BLU/WHT” circuit shorted to power circuit 1) Turn ignition switch ON and measure voltage between or open.
Page 607: Dtc P0748 (No. 41 Or 42): Pressure Control Solenoid Electrical
Automatic Transmission/Transaxle: 5A-59 DTC P0748 (No. 41 or 42): Pressure Control Solenoid Electrical S3RH0A5104029 Wiring Diagram G08-11 GRY/RED GRY/BLK G08-8 I2RH0B510024-01 1. TCM 3. A/T 2. Pressure control solenoid valve 4. Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition TrouBle Area...
Page 608 5A-60 Automatic Transmission/Transaxle: Step Action Check pressure control solenoid valve resistance Go to Step 4. Replace pressure control solenoid valve or 1) Turn ignition switch OFF. lead wire. 2) Disconnect valve body harness connector (1, 2) on transaxle. 3) Check for proper connection to solenoid at “GRY/RED” and “GRY/BLK”...
Page 609: Dtc P0751 / P0756 (No. 17 / No. 28): Shift Solenoid-A (No. 1) / -B (No. 2) Performance Or Stuck Off
Automatic Transmission/Transaxle: 5A-61 DTC P0751 / P0756 (No. 17 / No. 28): Shift Solenoid-A (No. 1) / -B (No. 2) Performance or Stuck OFF S3RH0A5104030 DTC Detecting Condition and Trouble Area [DTC P0751 / DTC No. 17] DTC detecting condition Trouble area •...
Page 610: Dtc P0753 / P0758 (No. 21 Or 22 / No. 23 Or 24): Shift Solenoid-A (No. 1) / -B (No. 2) Electrical
5A-62 Automatic Transmission/Transaxle: DTC P0753 / P0758 (No. 21 or 22 / No. 23 or 24): Shift Solenoid-A (No. 1) / -B (No. 2) Electrical S3RH0A5104031 Wiring Diagram G08-4 G08-3 GRN/ORN I2RH0B510026-01 1. TCM 4. A/T 2. Shift solenoid valve-A (No.1) 5.
Page 611 Automatic Transmission/Transaxle: 5A-63 Step Action Check shift solenoid valve resistance Go to Step 4. Replace shift solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1, 2) on transaxle. 3) Check for proper connection to solenoid valve (3) or (4) at “GRY”...
Page 612: Dtc P0785 (No. 13): Timing Solenoid
5A-64 Automatic Transmission/Transaxle: DTC P0785 (No. 13): Timing Solenoid S3RH0A5104042 Wiring Diagram G08-10 GRN/YEL I2RH0B510028-01 1. TCM 3. A/T 2. Timing solenoid valve 4. Terminal arrangement of TCM connector viewed from harness side DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area •...
Page 613 Automatic Transmission/Transaxle: 5A-65 Step Action Check timing solenoid valve resistance Go to Step 4. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1, 2) on transaxle. 3) Check for proper connection to solenoid valve at “GRN/ YEL”...
Page 614: Dtc P1700 (No. 32 Or 33): Throttle Position Signal Circuit Malfunction
5A-66 Automatic Transmission/Transaxle: DTC P1700 (No. 32 or 33): Throttle Position Signal Circuit Malfunction S3RH0A5104032 Wiring Diagram G03-14 PPL/WHT G07-6 I2RH0B510030-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 615: Dtc P1702 (No. 52): Internal Malfunction Of Tcm
Automatic Transmission/Transaxle: 5A-67 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Is there DTC related to throttle position sensor? Go to corresponding Go to Step 3. DTC flow. Check throttle position signal circuit for IG short “PPL/WHT”...
Page 616: Dtc P1705 (No. 51): Engine Coolant Temperature Signal Circuit Malfunction
5A-68 Automatic Transmission/Transaxle: DTC P1705 (No. 51): Engine Coolant Temperature Signal Circuit Malfunction S3RH0A5104034 Wiring Diagram GRY/BLK G04 -8 G07-7 I2RH0B510031-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 617 Automatic Transmission/Transaxle: 5A-69 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Is there DTC related to throttle position sensor? Go to corresponding Go to Step 3. DTC flow. Check engine coolant temperature signal circuit for IG “GRY/BLK”...
Page 618: Dtc P1730 (No. 64): Engine Torque Signal Circuit Malfunction
5A-70 Automatic Transmission/Transaxle: DTC P1730 (No. 64): Engine Torque Signal Circuit Malfunction S3RH0A5104036 Wiring Diagram G03-5 BLU/RED G07-23 I2RH0B510032-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2. ECM 4. Terminal arrangement of ECM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 619: Dtc P1895 (No. 27): Torque Reduction Signal Circuit Malfunction
Automatic Transmission/Transaxle: 5A-71 Step Action Check engine torque signal circuit for open Go to Step 4. “BLU/RED” circuit open. 1) Turn ignition switch OFF. 2) Check continuity between terminal “G07-23” of disconnected harness side TCM connector and terminal “G03-5” of disconnected harness side ECM connector. Is continuity indicated? Check engine torque signal circuit for ground short “BLU/RED”...
Page 620: Inspection Of Tcm And Its Circuits
5A-72 Automatic Transmission/Transaxle: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check torque reduction signal circuit for open Go to Step 3. “LT GRN/RED” circuit open. 1) Turn ignition switch OFF. 2) Disconnect TCM and ECM connectors from TCM and ECM.
Page 621 Automatic Transmission/Transaxle: 5A-73 Terminal arrangement of TCM coupler (Viewed from harness side) 7 6 5 4 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 23 22 21 20 20 19 18 17 16 15 14 28 27 26 25 24...
Page 622 5A-74 Automatic Transmission/Transaxle: Wire Standard Terminal Circuit Condition color voltage 8 – 14 V Ignition switch ON, selector lever at “2” range Transmission range sensor Ignition switch ON, selector lever at other than “2” (“2” range) 0 – 1 V range —...
Page 623: Tcm Power And Ground Circuit Check
Automatic Transmission/Transaxle: 5A-75 Wire Standard Terminal Circuit Condition color voltage BLK/ Power source 10 – 14 V Ignition switch ON TCM Power and Ground Circuit Check S3RH0A5104039 Wiring Diagram G08-20 BLK/WHT IG11 G08-15 G08-19 20 19 I2RH0B510034-01 1. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) 2.
Page 624: O/D Off" Lamp Circuit Check
5A-76 Automatic Transmission/Transaxle: “O/D OFF” Lamp Circuit Check S3RH0A5104040 Wiring Diagram GRN/BLK G07-3 RED/YEL G07-10 I2RH0B510035-01 1. TCM 3. To ignition switch 5. Terminal arrangement of TCM connector (viewed from harness side) 2. “O/D OFF” lamp 4. O/D off switch Circuit Description Operation (ON/OFF) of “O/D OFF”...
Page 625 Automatic Transmission/Transaxle: 5A-77 Step Action Check O/D off switch (2) for operation “GRN/BLK” circuit Replace O/D off switch. shorted to ground. 1) Disconnect O/D off switch coupler (1). 2) Check continuity between switch terminals under each condition. O/D off switch specification O/D off switch under being released (2): No continuity O/D off switch under being pressed (3): Continuity...
Page 626: Brake Interlock System Inspection
5A-78 Automatic Transmission/Transaxle: Step Action Check DTC Proceed to “A/T System Faulty combination Check”. meter or TCM. 1) Check DTC referring to “DTC Check”. Inspect combination Are there any DTC(s)? meter referring to “O/D OFF Indicator Lamp (A/ T Vehicle Only) Symptom Diagnosis in Section 9C”.
Page 627: Repair Instructions
Automatic Transmission/Transaxle: 5A-79 Repair Instructions A/T Fluid Level Check NOTE S3RH0A5106001 Level Check at Normal Operation Temperature – Hot • Do not race engine while checking fluid Check level, even after the engine start. 1) Stop vehicle and place it level. •...
Page 628: A/T Fluid Change
5A-80 Automatic Transmission/Transaxle: A/T Fluid Change Level Check at Room Temperature – Cold Check Fluid level can be checked temporarily at room S3RH0A5106002 1) Lift up vehicle. temperature which correspond to 20 – 30 °C (68 – 86 °F). This level check is considered to be preparation 2) When engine is cool, remove drain plug (1) and before performing level check under normal operating drain A/T fluid.
Page 629: Selector Lever Components
Automatic Transmission/Transaxle: 5A-81 Selector Lever Components S3RH0A5106004 2.5 N·m (0.25 kg-m) 3 N·m (0.3 kg-m) 3.5 N·m (0.35 kg-m) I3RH0A510034-01 1. Selector lever assembly 3. Indicator assembly 5. Illumination lamp 2. Knob assembly 4. Shift lock solenoid (if equipped) Selector Lever Inspection S3RH0A5106005 Check select lever for smooth and clear-cut movement and position indicator for correct indication.
Page 630: Select Cable Components
5A-82 Automatic Transmission/Transaxle: Select Cable Components S3RH0A5106006 I3RH0A510036-01 1. Selector lever assembly 6. Clip 2. Select cable 7. Select cable retainer bolt 3. Select cable retainer 8. Manual shift lever pin : Apply lithium grease 99000-25010 to all around pin (0.15 g) 4.
Page 631: Transmission Range Sensor (Shift Switch) Inspection And Adjustment
Automatic Transmission/Transaxle: 5A-83 Transmission Range Sensor (Shift Switch) 3) Release lock plate (1) which restrict moving of cable end holder (2). Inspection and Adjustment S3RH0A5106008 Inspection 1) Disconnect transmission range sensor connector (1). 2) Check that continuity exists at terminals shown in the following figure by moving selector lever.
Page 632: Output Shaft Speed Sensor / Vss Removal And Installation
5A-84 Automatic Transmission/Transaxle: 3) Connect output shaft speed sensor connector (2) to 3) Check that engine starts in “N” and “P” ranges but it doesn’t start in “D”, “2”, “L” or “R” range. Also, check output shaft speed sensor / VSS (1). that back-up lamp lights in “R”...
Page 633: Input Shaft Speed Sensor Removal And Installation
Automatic Transmission/Transaxle: 5A-85 Input Shaft Speed Sensor Removal and Input Shaft Speed Sensor Inspection S3RH0A5106012 Installation 1) Disconnect negative cable at battery. S3RH0A5106011 Removal 2) Disconnect input shaft speed sensor connector (2). 1) Disconnect negative cable at battery. 3) Check resistance between input shaft speed sensor 2) Disconnect input shaft speed sensor connector (2).
Page 634: Transmission Fluid Temperature Sensor Inspection
5A-86 Automatic Transmission/Transaxle: Installation Reverse removal procedure to install solenoid wire harness and valve body assembly noting the following points. • For details of valve body assembly and their connectors installation, refer to “Automatic Transaxle Unit Assembly”. • For details of A/T oil pan installation, refer to “Automatic Transaxle Unit Assembly”.
Page 635: Solenoid Valves (Shift Solenoid Valves, Tcc Solenoid Valve And Timing Solenoid Valve) Removal And Installation
Automatic Transmission/Transaxle: 5A-87 Solenoid Valves (Shift Solenoid Valves, TCC 10) Remove TCC solenoid valve (1), shift solenoid valve-A (No.1) (2) and shift solenoid valve-B (No.2) Solenoid Valve and Timing Solenoid Valve) (3) and timing solenoid valve by removing bolts. Removal and Installation S3RH0A5106015 Removal 1) Disconnect negative cable at battery.
Page 636: Solenoid Valves (Shift Solenoid Valves, Tcc Solenoid Valve And Timing Solenoid Valve) Inspection
5A-88 Automatic Transmission/Transaxle: Solenoid Valves (Shift Solenoid Valves, TCC 3) Install transmission fluid sensor (5) and sensor wire to clamp. Solenoid Valve and Timing Solenoid Valve) Inspection S3RH0A5106016 Resistance Check Check shift solenoid valves, timing solenoid valve and TCC solenoid valve resistance. Shift solenoid valves, timing solenoid valve and TCC solenoid valve resistance Standard: 11 –...
Page 637 Automatic Transmission/Transaxle: 5A-89 • When solenoid valve (1) is not connected to battery Timing solenoid valve (2), confirm that solenoid valve is open condition by CAUTION blowing air (50 – 200 kpa, 0.5 – 2.0 kg/cm , 7 – 28.5 psi) into solenoid valve as shown in the figure.
Page 638: Pressure Control Solenoid Valve Removal And Installation
5A-90 Automatic Transmission/Transaxle: Pressure Control Solenoid Valve Removal and Installation Reverse removal procedure to install pressure control Installation solenoid valve and valve body assembly noting the S3RH0A5106060 Removal following points. 1) Disconnect negative cable at battery. • For detail of pressure control solenoid valve 2) Lift up vehicle.
Page 639: Transmission Control Module (Tcm) Removal And Installation
Automatic Transmission/Transaxle: 5A-91 Transmission Control Module (TCM) Removal 5) Turn power supply switch OFF. and Installation CAUTION S3RH0A5106018 CAUTION Do not pass current 1.0 A or more, or pressure control solenoid is burned out. TCM consists of highly precise parts, therefore when handling it, be careful not to expose to excessive shock.
Page 640: Learning Control Initialization
5A-92 Automatic Transmission/Transaxle: Learning Control Initialization Brief Learning S3RH0A5106061 S3RH0A5106062 This method is effective to be learned quickly when 1) Remove glove box (1) from instrument panel. learned condition which is suitable for automatic 2) Using service wire, connect diagnosis switch transaxle is necessary immediately.
Page 641: Differential Side Oil Seal Replacement
Automatic Transmission/Transaxle: 5A-93 Differential Side Oil Seal Replacement 5) Install new differential side oil seals (1) by using S3RH0A5106019 special tool. 1) Lift up vehicle and drain automatic transaxle fluid. Special tool 2) Remove drive shaft joints from differential gear of (C): 09944–88220 transaxle.
Page 642: Shift Lock Solenoid Replacement
5A-94 Automatic Transmission/Transaxle: Shift Lock Solenoid Replacement 4) Pull out key interlock cable (1) from key cylinder S3RH0A5106020 cover (2) while pressing checkhook with slotted 1) Remove parking brake cover and console box. screwdriver (3) or the like. 2) Replace shift lock solenoid (1). 3) Install covers as they were.
Page 643: A/T Fluid Cooler Hoses Replacement
Automatic Transmission/Transaxle: 5A-95 Installation 6) Install cable casing cap (3) to selector bracket (4). 1) Lay interlock cable to its original cabling route. 7) Connect cable end (1) to interlock cam (2) with ignition switch turned to ACC position. 2) Turn ignition switch to ACC position. 8) Drive lock button (5) in cable end until it locks cable 3) Insert cable casing cap (1) into key cylinder cover (2) expansion and contraction.
Page 644: Automatic Transaxle Unit Components
5A-96 Automatic Transmission/Transaxle: Automatic Transaxle Unit Components S3RH0A5106023 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 85 N·m (8.5 kg-m) 25 N·m (2.5 kg-m) 50 N·m (5.0 kg-m) 10 N·m (1.0 kg-m) 50 N·m (5.0 kg-m) 69 N·m (6.9 kg-m)
Page 645: Automatic Transaxle Unit Dismounting And Remounting
Automatic Transmission/Transaxle: 5A-97 Automatic Transaxle Unit Dismounting and 14) Remove exhaust No.1 pipe (1). Remounting S3RH0A5106024 CAUTION When transaxle have been replaced, all learned contents, which have been stored in TCM memory by executing learning control, should be initialized referring to “Learning Control Initialization”.
Page 646 5A-98 Automatic Transmission/Transaxle: 16) For 4WD model, remove transaxle housing lower 20) Remove ball stud bolts and lock nuts from both plate. knuckles and detach suspension arms and then pull out both drive shaft joints from differential. 17) Holding drive plate with a flat head rod or the like (2) against rotation, remove drive plate to torque 21) For 2WD vehicle, remove engine rear mounting (1) converter bolts (1).
Page 647 Automatic Transmission/Transaxle: 5A-99 25) Remove transaxle with torque converter from engine compartment. Remounting For remounting, reverse dismounting procedure. Use the following specified torques and note points listed below. Tightening torque Transaxle and engine fastening bolt and nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft) Drive plate to torque converter bolt (b): 25 N·m (2.5 kgf-m, 18.0 lb-ft) Steering knuckle ball stud lock nut (c): 60 N·m (6.0...
Page 648: Automatic Transaxle Assembly Components . 5A-100
5A-100 Automatic Transmission/Transaxle: Automatic Transaxle Assembly Components S3RH0A5106025 I3RH0A510027-01...
Page 649: Automatic Transaxle Unit Disassembly
Automatic Transmission/Transaxle: 5A-101 1. Torque converter 34. A/T fluid drain plug 67. 2nd brake separator plate 2. Torque converter housing 35. Manual select lever 68. 2nd brake return spring subassembly : Apply sealant 99000-31230 to mating surface to transaxle case. 3.
Page 650 5A-102 Automatic Transmission/Transaxle: 2) Remove engine mounting LH bracket (1). 6) Remove output shaft speed sensor / VSS (2) and input shaft speed sensor (1). 7) Remove select cable clamp (3). I2RH0B510079-01 3) Remove manual select lever (1). I2RH0B510083-01 8) Remove select cable bracket (1). I2RH0B510080-01 4) Uncaulk lock washer (1), then remove lock nut (2) and lock washer.
Page 651 Automatic Transmission/Transaxle: 5A-103 11) Remove oil pan (1) and oil pan gasket (2). 14) Remove valve body assembly bolts. NOTE CAUTION Be careful not to let manual valve fall off • For removal of oil pan, do not turn when removing valve body assembly. transaxle over as this will contaminate valve body with foreign materials in bottom of oil pan.
Page 652 5A-104 Automatic Transmission/Transaxle: 19) Remove accumulator pistons and springs. 16) Remove valve body harness (1). To remove C2 (1), C1 (2) and B1 (3) accumulator CAUTION pistons and springs, position rag on pistons to catch each piston. To remove pistons, force low-pressure When pulling valve body harness out of compressed air (1 kg/cm , 15 psi, 100 kPa, max) into...
Page 653 Automatic Transmission/Transaxle: 5A-105 Available input shaft front thrust bearing thickness “a”: 0.8, 1.4 mm (0.032, 0.055 in.) I2RH0B510095-01 21) Remove harness bracket (2) and torque converter housing bolts. 22) Remove torque converter housing (1) while tapping I3RH0A510028-01 around it lightly with plastic hammer. 26) Remove oil pump assembly (1).
Page 654 5A-106 Automatic Transmission/Transaxle: 29) Remove input shaft rear thrust bearing (1) and thrust 32) Remove governor apply No.2 gasket (1). bearing race (2). NOTE If input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly.
Page 655 Automatic Transmission/Transaxle: 5A-107 NOTE If reverse clutch drum thrust bearing is not found, it may have been taken out with rear cover assembly. I2RH0B510108-01 36) Remove 2nd brake gasket (1). I2RH0B510110-01 38) Remove forward and reverse clutch assembly (1). I2RH0B510109-01 37) Measure O/D and 2nd coast brake piston stroke.
Page 656 5A-108 Automatic Transmission/Transaxle: 44) Remove rear planetary sun gear subassembly (1) 40) Remove O/D and 2nd coast brake rear plate (1), discs (2), separator plate (3) and retaining plate (4). and one-way clutch No.1 assembly (2). I2RH0B510113-01 I2RH0B510117-01 41) Remove forward clutch hub (1). 45) Remove planetary gear thrust bearing (1).
Page 657 Automatic Transmission/Transaxle: 5A-109 “a” I2RH0B510120-01 49) Remove front planetary sun gear (1). I2RH0B510123-01 52) Using special tool and hydraulic press, remove 2nd brake piston snap ring (1). I2RH0B510121-01 CAUTION 50) Remove front sun gear thrust bearing race (2) from front planetary sun gear (1). Do not press 2nd brake piston assembly in over 0.4 mm (0.016 in.).
Page 658 5A-110 Automatic Transmission/Transaxle: 54) Remove 2nd brake return spring subassembly (1). 58) Check one-way clutch No.2 as follows. • Ensure planetary carrier (1) rotates only in counterclockwise direction “A”, never in clockwise direction “B”. • If the planetary carrier rotates both ways or does not rotate either way, one-way clutch No.2 assembly will need to be replaced with new one- way clutch No.2 assembly.
Page 659 Automatic Transmission/Transaxle: 5A-111 Special tool 65) Turn over transaxle and uncaulk reduction drive gear (A): 09900–20607 nut (1). (B): 09900–20701 (C): 09952–06020 1st and reverse brake piston stroke Standard: 0.79 – 1.49 mm (0.031 – 0.059 in.) I2RH0B510136-01 66) Secure reduction drive gear (1) with parking lock pawl, then remove reduction drive gear nut.
Page 660 5A-112 Automatic Transmission/Transaxle: 68) Remove parking lock pawl shaft, then spring (2) and 71) Remove parking lock pawl bracket (1). parking lock pawl (1). I2RH0B510142-01 I2RH0B510139-01 72) With slotted screw driver, cut and unfold manual 69) Screwing 3 bolts (1), remove reduction drive gear valve lever spacer (1) and proceed to remove (2).
Page 661: Oil Pump Components
Automatic Transmission/Transaxle: 5A-113 77) Remove manual shift shaft oil seal (1). 76) Remove manual detent spring (1). I2RH0B510146-01 I2RH0B510147-01 Oil Pump Components S3RH0A5106027 I2RH0B510148-01 1. Oil seal 5. Oil pump drive gear : Apply automatic transaxle fluid. : Apply grease 99000-25030 to oil seal lip. 2.
Page 662: Oil Pump Inspection
5A-114 Automatic Transmission/Transaxle: 3) Remove oil seal (1) using special tool. 4) After applying A/T fluid to new O-ring, install it to oil pump body. Special tool (A): 09913–50121 NOTE Do not damage oil seal with slotted screwdriver (2). I2RH0B510150-01 2.
Page 663 Automatic Transmission/Transaxle: 5A-115 5) Install direct clutch assembly (1) to stator shaft assembly (2), then ensure that direct clutch assembly turns smoothly. If unsmooth rotation or noise are found in oil pump assembly, replace oil pump assembly with new one. This check should also be done to input shaft assembly and replace input shaft assembly if necessary.
Page 664: Direct Clutch Components
5A-116 Automatic Transmission/Transaxle: Direct Clutch Components S3RH0A5106030 I2RH0B510160-01 1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate 2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring 3. Input shaft subassembly 8.
Page 665: Direct Clutch Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-117 Direct Clutch Disassembly and Reassembly 4) Using a finger to block oil hole (1), apply S3RH0A5106032 compressed air (400 – 800 kPa, 4 – 8 kg/cm , 57 – 113 psi) to opposite hole, which will assist in removal CAUTION of the clutch piston.
Page 666 5A-118 Automatic Transmission/Transaxle: Reassembly • Install plate snap ring so that its both ends would be Reverse disassembly procedure for assembly, noting the positioned in correct locations as shown in the figure. following points. • Use new seal ring and O-ring. Apply A/T fluid before installation.
Page 667: Direct Clutch Inspection
Automatic Transmission/Transaxle: 5A-119 Direct Clutch Return Spring Subassembly Measure free length of direct clutch return spring. Direct clutch return spring free length “a”: 36.04 mm (1.419 in.) NOTE Do not apply excessive force when measuring spring free length. Perform measurement at several points. “a”...
Page 668: Forward And Reverse Clutch Assembly Components
5A-120 Automatic Transmission/Transaxle: Forward and Reverse Clutch Assembly Components S3RH0A5106034 I3RH0A510029-01 1. Forward clutch balancer 8. Inter mediate shaft seal ring 15. Forward clutch disc 2. Forward clutch return spring 9. Reverse clutch plate snap ring 16. Forward clutch separator plate subassembly 3.
Page 669: Forward And Reverse Clutch Assembly Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-121 Disassembly 1) Remove reverse clutch plate snap ring (1) and take out reverse clutch retaining plate, discs, separator plates and cushion plate from intermediate shaft subassembly. I3RH0A510030-01 2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm 57 –...
Page 670 5A-122 Automatic Transmission/Transaxle: 5) Remove forward clutch return spring subassembly 8) Remove forward clutch piston O-ring (1) from (1). intermediate shaft subassembly (2). I2RH0B510181-01 I2RH0B510184-01 9) Remove forward clutch drum O-ring (1) from forward 2. Intermediate shaft subassembly clutch drum (2). 6) Install intermediate shaft subassembly (1) to transaxle rear cover (2).
Page 671 Automatic Transmission/Transaxle: 5A-123 • Measure forward clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly Preliminary Check”. When piston stroke is out of specification, select forward clutch retaining plate with proper thickness from among the following table and replace it. Special tool (A): 09900–20607 (B): 09900–20701...
Page 672: Forward And Reverse Clutch Assembly Inspection
5A-124 Automatic Transmission/Transaxle: Forward and Reverse Clutch Assembly Inspection S3RH0A5106037 Check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt. If necessary, replace. NOTE • If disc lining is exfoliated or discolored, replace all discs. •...
Page 673: 2Nd Brake Piston Assembly Components
Automatic Transmission/Transaxle: 5A-125 Forward Clutch Drum Lip Forward Clutch Piston Lip and Forward Clutch Balancer Lip Check each lip for wear, deformation, cut and/or Check each lip for wear, deformation, cut and/or hardening. If necessary, replace. hardening. If necessary, replace. I2RH0B510194-01 I2RH0B510195-01 2nd Brake Piston Assembly Components...
Page 674: Transaxle Rear Cover And O/D And 2Nd Coast Brake Piston Assembly Components . 5A-126
5A-126 Automatic Transmission/Transaxle: 2) Remove inner O-ring (1) and outer O-ring (2). Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new O-rings. Apply A/T fluid to the O-rings, before installation. • Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2).
Page 675: Transaxle Rear Cover And O/D And 2Nd Coast Brake Piston Assembly Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-127 Transaxle Rear Cover and O/D and 2nd Coast 4) Remove O/D and 2nd coast brake piston front O-ring (1) and rear O-ring (2). Brake Piston Assembly Disassembly and Reassembly S3RH0A5106044 Disassembly CAUTION Do not press O/D and 2nd coast brake return spring subassembly in over 1.0 mm (0.039 in.).
Page 676: Transaxle Rear Cover And O/D And 2Nd Coast Brake Piston Assembly Inspection
5A-128 Automatic Transmission/Transaxle: Transaxle Rear Cover and O/D and 2nd Coast Reassembly Reverse disassembly procedure for assembly, noting the Brake Piston Assembly Inspection following points. S3RH0A5106045 • Use new seal rings and O-rings. Apply A/T fluid to O/D and 2nd Coast Brake Return Spring seal rings and O-rings before installation.
Page 677: Countershaft Assembly Components
Automatic Transmission/Transaxle: 5A-129 Countershaft Assembly Components 2) Remove countershaft RH bearing (1) by using S3RH0A5106048 special tools. Special tool (A): 09913–61510 (B): 09926–58010 I2RH0B510211-01 Reassembly I2RH0B510209-01 1) Install new countershaft RH bearing (1) by using 1. Countershaft RH bearing 5. Bearing cap 2.
Page 678: Valve Body Assembly Components
5A-130 Automatic Transmission/Transaxle: 3) Install countershaft LH bearing (1) with special tools and hydraulic press. Special tool (A): 09913–84510 (B): 09925–88210 I2RH0B510214-01 Valve Body Assembly Components S3RH0A5106050 I2RH0B510215-01 1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid. 2.
Page 679: Valve Body Assembly Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-131 Valve Body Assembly Disassembly and 4) Remove shift solenoid valve-A (1). Reassembly S3RH0A5106051 CAUTION When replacing pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing pressure control solenoid independently may cause excessive shift shock.
Page 680: Differential Assembly Components
5A-132 Automatic Transmission/Transaxle: Reassembly Reverse disassembly procedure for assembly, noting following points. • Shift solenoid valve-A and -B are identical • After applying A/T fluid to new O-rings, fit them to solenoid valves, then install solenoid valves to valve body. •...
Page 681: Differential Assembly Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-133 Differential Assembly Disassembly and 4) Remove differential side LH bearing by using special tools. Reassembly S3RH0A5106053 Special tool (A): 09926–37610 Disassembly (B): 09926–37610–001 1) Remove final gear bolts (1), and then final gear (2). (C): 09926–37610–003 (D): 09926–37610–002 I2RH0B510225-01 2) Remove differential side RH bearing by using special tools.
Page 682: Differential Assembly Inspection
5A-134 Automatic Transmission/Transaxle: 2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. I2RH0B510233-01 6) Install new differential side LH bearing (1) by using I2RH0B510230-01 special tool and hydraulic press. 3) Tighten final gear bolts (1) to specified torque. NOTE NOTE Replace differential side LH bearing together...
Page 683: Torque Converter Housing Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-135 Torque Converter Housing Disassembly and 4) Remove countershaft RH bearing cup by using special tools. Reassembly S3RH0A5106055 Special tool (A): 09944–96011 Disassembly (B): 09942–15511 1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2). I2RH0B510239-01 5) Remove differential side RH bearing cup by using special tools.
Page 684 5A-136 Automatic Transmission/Transaxle: Reassembly 5) Apply grease to oil seal lip. 1) After applying A/T fluid to new O-rings, fit them to : Grease 99000–25030 housing plugs. Finally install plugs to torque converter housing. Tightening torque Torque converter housing plug (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) I2RH0B510242-01 2) Using special tools, assemble differential side RH...
Page 685: Transaxle Case Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-137 Transaxle Case Disassembly and Reassembly Reassembly S3RH0A5106057 1) Using special tools, assemble shim and differential side LH bearing cup. Disassembly 1) Remove differential side oil seal (1). NOTE Use shim with same thickness as the removed one. Special tool (A): 09924–74510 (B): 09944–68210...
Page 686: Automatic Transaxle Unit Inspection And Adjustment
5A-138 Automatic Transmission/Transaxle: 4) Apply grease to oil seal lip. : Grease 99000–25030 I2RH0B510253-01 Brake return spring subassembly Measure brake return springs. Evidence of extreme heat or burning in the area of clutch may have caused springs to take heat set and would require their replacement.
Page 687 Automatic Transmission/Transaxle: 5A-139 Adjustment 4) If bearing preload is out of specification, select shim with suitable thickness from among the list below Differential side bearing preload and replace it. Then adjust differential side bearing 1) After applying A/T fluid to differential assembly, fit it preload within specification.
Page 688: Automatic Transaxle Unit Assembly
• Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before assembly. • Use Suzuki Super Grease “C” to retain I2RH0B510256-01 parts in place. 4) If bearing preload is out of specification, select shim • Be sure to install thrust bearings and races with suitable thickness from among the list below in correct direction and position.
Page 689 Automatic Transmission/Transaxle: 5A-141 6) Install parking lock pawl bracket (1) to transaxle 2) Install manual detent spring (1) to transaxle case and tighten manual detent spring bolt to specified case. torque. Tightening torque Tightening torque Parking lock pawl bracket bolt (a): 7.5 N·m (0.75 Manual detent spring bolt (a): 10 N·m (1.0 kgf- kgf-m, 5.5 lb-ft) m, 7.5 lb-ft)
Page 690 5A-142 Automatic Transmission/Transaxle: 9) Install 1st and reverse brake return spring subassembly (1) to transaxle case (2). I2RH0B510265-01 10) Apply A/T fluid to 1st and reverse brake discs (2) separator plates (3) and retaining plate (1), then install them to transaxle case. I2RH0B510268-01 [A]: Correct [B]: Incorrect...
Page 691 Automatic Transmission/Transaxle: 5A-143 NOTE Special tool (A): 09951–18210 When replacing reduction drive gear, replace (B): 09944–78210 it together with reduction driven gear as a set. Special tool (A): 09951–18210 (B): 09944–78210 I2RH0B510272-01 2. Stand that can slightly lift transaxle case. 17) Using a small torque wrench, while turning to counter drive gear 100 rpm and measure the preload.
Page 692 5A-144 Automatic Transmission/Transaxle: 18) Caulk reduction drive gear nut (1). “a” I2RH0B510274-01 19) Apply A/T fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly. I2RH0B510275-01 20) Check for correct installation of planetary gear assembly as follows. “a”...
Page 693 Automatic Transmission/Transaxle: 5A-145 23) Apply A/T fluid to new brake drum gasket (1), then 27) Install 2nd brake piston snap ring (1) by using install it to transaxle case. special tool and hydraulic press. CAUTION Do not damage 2nd brake piston assembly, return spring subassembly, plates and discs by pressing in 2nd brake assembly passing through its original installing position over...
Page 694 5A-146 Automatic Transmission/Transaxle: 31) Install O/D and 2nd coast brake retaining plate snap ring (1). CAUTION Be sure to install O/D and 2nd coast brake retaining plate snap ring correctly in groove of transaxle case. I2RH0B510287-01 32) After applying grease to slide contact face of planetary carrier thrust washer (1), install it to I2RH0B510284-01 planetary gear assembly.
Page 695 Automatic Transmission/Transaxle: 5A-147 35) After applying A/T fluid to rear planetary sun gear 39) After applying A/T fluid to intermediate shaft thrust subassembly and one-way clutch No.1 assembly (1), bearing rear race (3), thrust bearing (2) and front install them in transaxle case (2). race (1), install them to forward and reverse clutch assembly (4).
Page 696 5A-148 Automatic Transmission/Transaxle: CAUTION When brake disc, retaining plate, separator plate and/or rear plate of O/D and 2nd coast “a” brake have been replaced, all learned contents, which have been stored in TCM memory by executing learning control, should be initialized referring to “Learning Control Initialization”.
Page 697 Automatic Transmission/Transaxle: 5A-149 45) After applying A/T fluid to reverse clutch drum thrust bearing (1), install it to forward and reverse clutch assembly (2). I2RH0B510300-01 46) Remove sealant attached to mating surface of transaxle rear cover (1) completely. 47) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter.
Page 698 5A-150 Automatic Transmission/Transaxle: 57) Apply A/T fluid to direct clutch assembly (1). Install direct clutch assembly while rotating clockwise and counter clockwise frequently to fit clutch discs to mating hub. NOTE Before installation, align teeth of direct clutch discs to facilitate installation. I2RH0B510305-01 54) After applying A/T fluid to direct clutch hub (1), install it to planetary gear assembly.
Page 699 Automatic Transmission/Transaxle: 5A-151 59) Install oil pump assembly to transaxle case. 62) After applying A/T fluid to new O-ring, fit it to breather union (2). Then install breather union to Tightening torque transaxle case. Oil pump assembly bolt (a): 25 N·m (2.5 kgf-m, 63) Install breather hose (1).
Page 700 5A-152 Automatic Transmission/Transaxle: 70) Install B1, C1, C2 accumulator pistons and springs. Accumulator piston identification Identification as Piston name embossed letters on piston B1 accumulator piston (3) SB-1 C1 accumulator piston (5) SC-1 C2 accumulator piston (8) SC-2 Accumulator spring identification Color of Free Outside...
Page 701 Automatic Transmission/Transaxle: 5A-153 71) After applying A/T fluid to cooler check valve (1) and spring (2), install them to transaxle case (3). I2RH0B510319-01 72) After applying A/T fluid to new governor apply No.1 gasket (1), install it to transaxle case. I2RH0B510321-01 74) Install manual valve rod (1) to manual valve lever (3) and then install valve body assembly (2) to transaxle...
Page 702 5A-154 Automatic Transmission/Transaxle: 77) Install oil strainer assembly (1). Tightening torque Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) I2RH0B510325-01 78) Install oil cleaner magnets (1) in oil pan (2). NOTE If metal particles are attached to the magnets, clean them before installing.
Page 703 Automatic Transmission/Transaxle: 5A-155 81) Install new gaskets (2) and then install fluid cooler 84) Apply A/T fluid to O-rings of each sensor and install pipes. input shaft speed sensor (1) and output shaft speed sensor / VSS (2). Tightening torque Fluid cooler pipe union bolt (b): 22 N·m (2.2 kgf- Tightening torque m, 16.0 lb-ft)
Page 704 5A-156 Automatic Transmission/Transaxle: 88) Install manual select lever (1) temporarily at this 94) Install manual select lever (1). step. Tightening torque 89) After shifting manual select lever counterclockwise Manual select lever nut (a): 13 N·m (1.3 kgf-m, fully, select “N” range position by bringing it back 2 9.5 lb-ft) notches clockwise.
Page 705: Tightening Torque Specifications
Automatic Transmission/Transaxle: 5A-157 • Install torque converter aligning grooves (1) of torque converter and projection (2) of oil pump drive gear. • Install torque converter, using care not to damage oil seal of oil pump. • After installing torque converter, check that distance “a”...
Page 706 5A-158 Automatic Transmission/Transaxle: Tightening torque Fastening part Note N⋅m kgf-m lb-ft Engine LH mounting No.1 bracket bolt 40.0 Engine front mounting bracket bolt 40.0 Oil pump subassembly bolt Rear cover plug 0.75 Solenoid valve bolt Final gear bolt 56.5 Torque converter housing plug 0.75 Lubrication tube clamp bolt 0.55...
Page 707: Special Tools And Equipment
Automatic Transmission/Transaxle: 5A-159 Special Tools and Equipment Recommended Service Material S3RH0A5108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 SUZUKI Super Grease C P/No.: 99000–25030 Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 NOTE Required service material is also described in the following.
Page 708 5A-160 Automatic Transmission/Transaxle: 09913–84510 09913–85210 Bearing installer Bearing installer 09923–78210 09924–74510 Bearing installer Bearing and oil seal handle 09924–84510–002 09925–37811–001 Bearing installer (blue) Oil pressure gauge 09925–88210 09925–98210 Bearing puller attachment Input shaft bearing installer 09925–98221 09926–37610 Bearing installer Bearing remover 09926–37610–001 09926–37610–002 Bearing puller...
Page 709 Transfer bearing dummy 09951–18210 09952–06020 Oil seal remover & installer Dial gauge plate No.2 No. 2 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 710: Manual Transmission/Transaxle
5B-1 Manual Transmission/Transaxle: Manual Transmission/Transaxle Transmission / Transaxle General Description Manual Transaxle Construction S3RH0A5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromesh devices and three shafts-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 711 Manual Transmission/Transaxle: 5B-2 I3RH0A520001-01 1. Input shaft 7. Left case 13. Countershaft 5th gear 19. Final gear 2. 5th speed sleeve & hub 8. Reverse gear shaft 14. Countershaft 4th gear 20. Differential case 3. Input shaft 5th gear 9. Reverse idler gear 15.
Page 712 5B-3 Manual Transmission/Transaxle: I3RH0A520030-01 1. Input shaft 8. Reverse gear shaft 15. Countershaft 3rd gear 22. Transfer drive gear 2. 5th speed sleeve & hub 9. Reverse idler gear 16. Countershaft 2nd gear 23. Transfer output shaft 3. Input shaft 5th gear 10.
Page 713 Manual Transmission/Transaxle: 5B-4 Gear Shift Mechanism The gear shifting control system consists of the following main parts. Movement of gear shift control lever is transmitted to gear shift & select shaft through gear shift and gear select cables. I4RH01520025-01 1. Gear shift control cable 5.
Page 714 5B-5 Manual Transmission/Transaxle: 5th & Reverse Gear Shift Cam 3) When shift lever is shifted to 5th gear, shift & select 5th & reverse gear shift cam, cam guide return spring shaft (1) turns clockwise letting shift cam (2) off from and 5th to reverse interlock guide bolt are provided to guide bolt and pushed up by return spring.
Page 715: Diagnostic Information And Procedures
Manual Transmission/Transaxle: 5B-6 Diagnostic Information and Procedures Manual Transaxle Symptom Diagnosis S3RH0A5204001 Condition Possible cause Correction / Reference Item Gears slipping out of Worn shift fork shaft Replace mesh Worn shift fork or synchronizer sleeve Replace Weak or damaged locating springs Replace Worn bearings on input shaft or Replace...
Page 716: Differential Side Oil Seal Replacement
5B-7 Manual Transmission/Transaxle: 3) Remove oil seal (1) by using special tool. Special tool (A): 09913–50121 I4RH01520003-01 4) Install a new oil seal (1) by using special tool and hammer. NOTE When installing oil seal, face its spring side inward. Special tool (A): 09913–75810 for 4WD (A): 09913–75520 for 2WD...
Page 717: Gear Shift Control Lever And Cable Components
Gear Shift Control Lever and Cable Components S3RH0A5206003 I4RH01520004-01 1. Gear shift control lever knob 5. Gear shift control cable: Apply SUZUKI SUPER 9. Cable bracket bolt GREASE A 99000-25010 to connecting portion of gear shift control cable 2. Lever boot collar 6.
Page 718: Gear Shift Control Lever And Cable Removal And Installation
5B-9 Manual Transmission/Transaxle: Gear Shift Control Lever and Cable Removal Installation and Installation 1) Apply oil to new O-ring (1) and then install VSS to S3RH0A5206004 transaxle. Removal Tightening torque VSS bolt (a): 5.5 N·m (0.55 kgf-m, 4.0 lb-ft) 1) Remove console box. 2) Disconnect gear shift control cables from gear shift control lever assembly.
Page 719: Back Up Lamp Switch Removal And Installation
Manual Transmission/Transaxle: 5B-10 Back Up Lamp Switch Removal and Installation Back Up Lamp Switch Inspection S3RH0A5206006 S3RH0A5206007 Removal Check backup lamp switch for function using ohmmeter. Switch ON: Continuity 1) Disconnect negative cable at battery. Switch OFF: No continuity 2) Disconnect back up lamp switch coupler (1). 3) Remove back up lamp switch.
Page 720: Manual Transaxle Unit Components
5B-11 Manual Transmission/Transaxle: Manual Transaxle Unit Components S3RH0A5206008 I3RH0A520005-01 [A]: Forward 12. Engine left mounting bracket bolts and nuts 24. Engine rear mounting No.2 bracket bolts (M10) 1. Engine 13. Lower stiffener (for 2WD model) 25. Engine rear mounting (for 2WD model) 2.
Page 721: Manual Transaxle Unit Dismounting And Remounting
Manual Transmission/Transaxle: 5B-12 5. Engine left mounting 17. Engine left mounting bolts 29. Engine rear mounting No.2 bracket (for 2WD model) 6. Engine left mounting bracket 18. Engine to transaxle bolts 30. Ground cable bolt 7. Gear shift control cables 19.
Page 722: Gear Shift And Select Shaft Components
5B-13 Manual Transmission/Transaxle: Gear Shift and Select Shaft Components S3RH0A5206010 I3RH0A520007-01 1. Gear shift & select shaft 7. Gear shift guide case bolts 13. Select lever boss : Apply thread lock cement 99000-32110 to bolt : Apply grease 99000-25010 to internal and thread.
Page 723: Gear Shift And Select Shaft Removal And Installation
Manual Transmission/Transaxle: 5B-14 Gear Shift and Select Shaft Removal and 5) Install washer and gear shift interlock bolt (3) to which thread lock cement has been applied and then Installation tighten it to specified torque. S3RH0A5206011 “A”: Thread lock cement 99000–32110 Removal 1) Remove gear shift interlock bolt (1) and 5th to Tightening torque...
Page 724: Gear Shift And Select Shaft Disassembly And Assembly
5B-15 Manual Transmission/Transaxle: Gear Shift and Select Shaft Disassembly and Assembly S3RH0A5206012 1) Push spring pins out using 2.8 – 3.0 mm (0.11 – 0.12 in.) commercially available spring pin remover and specified spring pin removers as shown bellow. Special tool (A): 09922–85811 4.5 mm (B): 09925–78210 6.0 mm 2) Inspect component parts for wear, distortion or...
Page 725: Manual Transaxle Assembly Components
Manual Transmission/Transaxle: 5B-16 Manual Transaxle Assembly Components S3RH0A5206013 I3RH0A520010-01 1. Transaxle right case 23. Countershaft nut : After tightening nut to specified torque, caulk nut securely. 2. Transaxle left case 24. Shift fork bolt : Apply sealant 99000-31260 to mating surface of left case and : Apply thread lock 99000-32110 to all around thread part of bolt.
Page 726: Fifth Gear Disassembly And Assembly
: Apply thread lock 99000-32110 to all around thread part of bolt. 14. VSS bolt 36. O-ring 15. Side cover bolts 37. Oil seal : Apply SUZUKI SUPER GREASE A 99000-25010 to Oil seal lip. 16. Transaxle case bolts 38. Outer race 17. 5th speed synchronizer ring 39.
Page 727 Manual Transmission/Transaxle: 5B-18 a) Install hub (1) to 5th speed synchronizer sleeve Assembly (2) in specified direction as shown in figure. 1) Install countershaft 5th gear (1) to countershaft facing machined boss “A” inward. I4RH01520048-01 A: Chamfered side B: Long boss I2RH01520088-01 b) Fit 5th speed synchronizer levers (1) to hub (2) in “A”: Machined boss (Inside)
Page 728: Manual Transaxle Assembly Disassembly And Assembly
5B-19 Manual Transmission/Transaxle: 10) Clean mating surface of both left case (2) and side 7) Fit 5th gear shift fork (1) to sleeve (3) and hub (2) assembly, and install them into input shaft and gear cover (1), apply sealant to side cover as shown in shift shaft, aligning punch mark (4) with matching figure by such amount that its section is 1.5 mm mark (5) on input shaft.
Page 729 Manual Transmission/Transaxle: 5B-20 2) Remove bearing set shim. 11) Pull out 5th & reverse gear shift guide shaft (6) together with 5th & reverse gear shift shaft (7). 3) Remove snap ring (1) using special tool. NOTE Special tool (A): 09900–06107 When removing 5th &...
Page 730 5B-21 Manual Transmission/Transaxle: I3RH0A520013-01 3) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) into right case (4) through idler gear and then align “A” in shaft with I4RH01520022-01 “B” in case. c) Remove differential side bearing outer race from left case using special tools.
Page 731 Manual Transmission/Transaxle: 5B-22 7) Tighten case bolts (3) from outside to specified b) Select a shim of differential side bearing as torque. follows. Measure depth “a” from left case end face (1) Tightening torque to side bearing outer race (2) using depth Transaxle case bolt (b): 23 N·m (2.3 kgf-m, 17.0 gauge.
Page 732 5B-23 Manual Transmission/Transaxle: 11) Check locating springs (2, 4 and 5) for deterioration Thickness of bearing shim to Clearance “a” – “b” and replace with new ones as necessary. be installed 0.996 – 1.025 mm 1.11 mm (0.044 in.) Locating spring (0.0392 –...
Page 733 Manual Transmission/Transaxle: 5B-24 14) To seat countershaft left bearing outer race (2) to bearing cone, tap cup by using special tool and plastic hammer. Special tool (A): 09913–84510 I2RH01520085-01 1. Input shaft 15) Put a shim (3) on bearing outer race (4) provisionally, place straight edge (1) over it and compress it by hand through straight edge, and then measure “a”...
Page 734: Right Case Disassembly And Assembly
5B-25 Manual Transmission/Transaxle: Right Case Disassembly and Assembly Special tool S3RH0A5206016 (B): 09913–75821 (C): 09924–84510–004 Disassembly 1) Remove VSS referring to “Vehicle Speed Sensor (VSS) Removal and Installation”. 2) Remove differential side oil seal from right case referring to “Differential Side Oil Seal Replacement”, if necessary.
Page 735: Input Shaft And Countershaft Components
Manual Transmission/Transaxle: 5B-26 Assembly 1) If oil gutter has been removed, install it with bolt to which thread lock cement has been applied. “A”: Thread lock cement 99000–32110 Tightening torque Oil gutter bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) I2RH01520043-01 Input Shaft and Countershaft Components S3RH0A5206018...
Page 736: Input Shaft Disassembly And Assembly
5B-27 Manual Transmission/Transaxle: 11. Input shaft 4th gear 22. 2nd gear synchronizer outer ring Input Shaft Disassembly and Assembly 4) Using special tool, remove circlip (1). S3RH0A5206019 NOTE Disassembly For smooth removal of circlip, it is 1) Remove input shaft right bearing (2) from input shaft recommended to correct tool tips to be flat.
Page 737 Manual Transmission/Transaxle: 5B-28 5) Drive in right bering (1) to input shaft (2) using special tool and hammer. Special tool (A): 09913–80113 I2RH01520048-01 3) To ensure lubrication of input shaft (1), air blow oil holes (2) and make sure that they are free from any obstruction.
Page 738: Countershaft Disassembly And Assembly
5B-29 Manual Transmission/Transaxle: Countershaft Disassembly and Assembly 8) Install circlip (1), needle bearing of resin cage type (2), apply oil to bearing, then install synchronizer ring S3RH0A5206020 (3) and 4th gear (4). Disassembly CAUTION 1) Drive out left bearing cone (2) with 4th gear (3) by using puller (4) and hydraulic press.
Page 739 Manual Transmission/Transaxle: 5B-30 NOTE Assembly 1) Clean all components thoroughly, inspect them for Correct tool tips to be flat to facilitate any abnormality and replace with new ones as removal of circlip. necessary. Special tool 2) If synchronizer parts need to be repaired, check (A): 09900–06107 clearance “a”...
Page 740 5B-31 Manual Transmission/Transaxle: 5) Fit low speed synchronizer sleeve (4) to hub (3), 7) Install needle bearing of resin cage type, apply oil to insert 3 keys (2) in it and then set springs (1) as it, then install 1st gear and 1st gear synchronizer shown in figure.
Page 741 Manual Transmission/Transaxle: 5B-32 9) Install circlip (1) and confirm that circlip is installed in 11) Press-fit 4th gear (2) by using the same procedure at groove securely. step 10). Install needle bearing of resin cage type (2) and 12) Install left bearing cone (1) by using special tool and apply oil to bearing.
Page 742: Gear Shift Shaft Components
5B-33 Manual Transmission/Transaxle: Gear Shift Shaft Components S3RH0A5206021 I3RH0A520024-01 1. Low speed gear shift shaft 4. 5th & reverse gear shift guide shaft : Tightening torque 2. High speed gear shift shaft 5. Reverse gear shift arm 3. 5th & reverse gear shift shaft 6.
Page 743: Differential Components
Manual Transmission/Transaxle: 5B-34 NOTE Assembly Replace or correct parts as required and assemble • Install 2 steel balls (3) in reverse gear shift shafts making sure that component parts are in proper arm (1) without fail. order as shown in figure. •...
Page 744: Differential Disassembly And Assembly
5B-35 Manual Transmission/Transaxle: 4. Side gear washer 10. Differential pinion shaft Differential Disassembly and Assembly Assembly S3RH0A5206024 Judging from abnormality noted before disassembly and what is found through visual check of component parts Disassembly after disassembly, prepare replacing parts and proceed 1) Using special tool, remove right bearing (1) and to reassembly.
Page 745 Manual Transmission/Transaxle: 5B-36 3) Drive in spring pin from right side till it is flush with 5) Press-fit new sensor rotor (1), putting groove (2) side differential case surface (for 2WD). upward and using special tools and copper hammer. Special tool (A): 09913–75510 (B): 09944–78210 I3RH0A520027-01...
Page 746: Transfer Components
5B-37 Manual Transmission/Transaxle: “A”: Thread lock cement 99000–32110 Tightening torque Final gear bolt (for 2WD) (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft) Final gear bolt (for 4WD) (a): 73 N·m (7.3 kgf-m, 53.0 lb-ft) I2RH01520077-01 Transfer Components S3RH0A5206026 I3RH0A520029-01 Transfer output case 9.
Page 747: Transfer Assembly Disassembly And Assembly
Manual Transmission/Transaxle: 5B-38 Transfer Assembly Disassembly and Assembly 7) Drive out bevel pinion (1) with plastic hammer (2). S3RH0A5206025 At this time, drive gear bearing (3), drive gear (4) and Disassembly pinion bearing come off at the same time. 1) Remove side bearing retainer referring to “Manual Transaxle Assembly Disassembly and Assembly”.
Page 748 5B-39 Manual Transmission/Transaxle: 10) Using special tool, remove output flange (1). Special tool (A): 09913–60910 I3RH0A520047-01 2. Output case 2) Install output flange (1), washer and new nut. 3) Tighten nut to specified torque by using special tool I3RH0A520037-01 and then caulk nut. 11) Using plastic hammer (1), drive out output shaft (2) with bearings.
Page 749 Manual Transmission/Transaxle: 5B-40 5) Select pinion bearing shim No.2 as follows. c) Place bevel pinion adjuster on surface plate as shown and set dial gauge (1) to “0”. a) Place pinion bearings, spacer (2), shim(s) (1) and drive gear (3) on bevel pinion dummy of Special tool special tool (Bevel pinion dummy set) and (A): 09922–77270...
Page 750 5B-41 Manual Transmission/Transaxle: UNIT (mm) Shim to use 0.60 0.63 0.66 0.69 0.72 0.75 0.78 0.81 0.84 0.87 0.30 Measured level difference Dimension “b” 0.586 – 0.615 0.616 – 0.645 0.646 – 0.675 0.676 – 0.705 0.706 – 0.735 0.736 – 0.765 0.766 –...
Page 751 Manual Transmission/Transaxle: 5B-42 b) Using depth gauge, measure depth “a” down to e) Place pinion bearings (1), spacer, shim(s) and bearing outer race (1) and obtain difference with drive gear (2) to rear case and tighten new bevel dimension “b” of bearing retainer (2); “a” – “b” = pinion nut to specified torque while holding drive “c”.
Page 752 5B-43 Manual Transmission/Transaxle: h) Adjust the driving bevel gear backlash by adding 10) Install rear mounting (2) and tighten nuts (3) to or taking off shims in bearing gap of the left and specified torque. right cases (stopper) so as to obtain the specified Tightening torque value for the backlash.
Page 753: Pinion Shaft Disassembly And Assembly
Manual Transmission/Transaxle: 5B-44 Assembly 14) Check side bearing retainer O-ring (1) for flawlessness, apply oil to O-ring and then install to 1) Select pinion bearing shim No.1 as follows. transaxle. a) Measure length A of drive pinion spacer (1). I3RH0A520049-01 b) Using special tool, measure level difference B I3RH0A520072-01 between other outer race (1) plus outer race (3)
Page 754 5B-45 Manual Transmission/Transaxle: e) Using following table, select necessary shim(s). I3RH0A520051-01 UNIT (mm) Shim to use 0.60 0.63 0.66 0.69 0.72 0.75 0.78 0.81 0.84 0.87 0.30 Measured level difference 0.976 – 1.005 1.006 – 1.035 1.036 – 1.065 1.066 – 1.095 1.096 –...
Page 755: Output Shaft Disassembly And Assembly
Manual Transmission/Transaxle: 5B-46 2) Place shim(s) on bevel pinion shaft and press-fit 3) Drive out No.1 bearing (1) by using puller (2) and front pinion bearing (2) by using special tool. hydraulic press (3). Special tool (A): 09913–84510 I3RH0A520043-01 Assembly I3RH0A520057-01 1) Drive in No.1 bearing (1) by using special tool and 1.
Page 756: Transfer Assembly Inspection
5B-47 Manual Transmission/Transaxle: Transfer Assembly Inspection 3) Drive in No.3 bearing (1) by using special tool and hammer. S3RH0A5206029 • Check each bearing for smooth rotation, wear or Special tool discoloration. (A): 09913–80113 If found abnormal, replace. • Check oil seal for leakage and its lip for excessive hardness.
Page 757 Manual Transmission/Transaxle: 5B-48 Tooth surface contact Possible cause and correction Defect in When tooth contacts occur as shown at the left, proper parts rear case offset (18 mm) in not obtained. Correction: Replace rear case (rear case, right case and left case assembly).
Page 758 5B-49 Manual Transmission/Transaxle: Specifications Tightening Torque Specifications S3RH0A5207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Transaxle oil level / filler and drain plugs 15.5 VSS bolt 0.55 Back up lamp switch 17.0 Gear shift guide case bolt 17.0 Select lever bracket bolt 17.0 Gear shift interlock bolt 17.0...
Page 759: Special Tools And Equipment
Manual Transmission/Transaxle: 5B-50 Special Tools and Equipment Recommended Service Material S3RH0A5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 760 5B-51 Manual Transmission/Transaxle: 09913–80113 09913–84510 Bearing installer Bearing installer 09913–85210 09913–85230 Bearing installer Bearing remover tool 09915–24550 09922–77241 Adapter socket (1/2 x 1/4) Dial depth gauge 09922–77270 09922–85811 Bevel pinion dummy set Spring pin remover (4.5 mm) 09923–74510 09923–78210 Bearing puller (20-35 mm) Bearing installer 09924–74510 09924–84510–004...
Page 761 Manual Transmission/Transaxle: 5B-52 09927–76030 09927–76060 Bevel pinion holder Gear holder 09930–30104 09930–40113 Sliding shaft Flywheel rotor holder 09940–54910 09941–64511 Front fork oil seal install Bearing and oil seal remover driver (30 mm Min.) 09944–78210 09951–16060 Bearing installer support Control arm bush remover 09951–16090 09951–76010 Oil seal installer...
Page 762: Clutch
5C-1 Clutch: Clutch Transmission / Transaxle General Description Clutch Construction S3RH0A5301001 The clutch is a hydraulically controlled diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transmission input shaft with an involute spline fit.
Page 763: Diagnostic Information And Procedures
Clutch: 5C-2 Diagnostic Information and Procedures Clutch System Symptom Diagnosis S3RH0A5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Replace clutch pedal arm or master cylinder. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
Page 764: Repair Instructions
5C-3 Clutch: Repair Instructions Clutch Pedal Inspection S3RH0A5306001 Clutch Pedal Free Travel “A” 1) Depress clutch pedal (1), stop the moment clutch resistance is felt, and measure how much pedal has moved (clutch pedal free travel) as represented by “A” in the figure. Then check its conformance to the specification.
Page 765: Clutch Fluid Inspection
Clutch: 5C-4 Clutch Fluid Inspection S3RH0A5306003 Fluid level should be always between MIN and MAX lines on reservoir. If fluid decreases quickly, check for leakage, repair leaky point, if any, and add fluid up to MAX level. : Fluid SAE J1703 or DOT-3 (brake fluid) CAUTION •...
Page 766: Clutch Fluid Pipe And Hose Removal And Installation
5C-5 Clutch: Clutch Fluid Pipe and Hose Removal and • For air bleeding of master cylinder alone, it must be Installation removed from vehicle body. S3RH0A5306005 (For procedures of removal and installation of master cylinder and air bleeding, refer to “Clutch Master Removal Cylinder Removal and Installation”.) CAUTION...
Page 767: Clutch Master Cylinder Removal And Installation
Clutch: 5C-6 Clutch Master Cylinder Removal and 2) Install master cylinder assembly (1) and new gasket (2) to body, attaching nuts (3). Installation S3RH0A5306007 Removal NOTE Do not reuse gasket. CAUTION Do not allow fluid to get on painted surfaces. 3) Tighten attaching nuts (3) to specified torque.
Page 768: Clutch Master Cylinder Components
5C-7 Clutch: Clutch Master Cylinder Components Reassembly S3RH0A5306008 NOTE Before installation, wash each part in specified brake fluid. 1) Apply brake fluid to piston assembly and inside of cylinder body. 2) Install piston assembly into cylinder. 3) With piston and push rod (3) pushed down, install circlip (2) as shown.
Page 769: Clutch Operating Cylinder Removal And Installation
Clutch: 5C-8 Clutch Operating Cylinder Removal and 2) Install clutch operating cylinder assembly (1) and tighten attaching bolts (2) to specified torque. Installation S3RH0A5306012 Tightening torque Removal Operating cylinder attaching bolt (a): 23 N·m ( CAUTION 2.3 kgf-m, 17.0 lb-ft) Do not allow fluid to get on painted surfaces.
Page 770: Clutch Operating Cylinder Components
5C-9 Clutch: Clutch Operating Cylinder Components S3RH0A5306011 I2RH01530018-01 1. Boot 4. Return spring : Do not reuse. 2. Push rod 5. Cylinder : Apply brake fluid. : Apply grease 99000-25100 to piston side spheral end of push rod. 3. Piston assembly 6.
Page 771: Clutch Cover, Clutch Disc, Flywheel And Clutch Release System Components
Clutch: 5C-10 Clutch Cover, Clutch Disc, Flywheel and Clutch Release System Components S3RH0A5306015 23 N m (2.3 kg-m) 23 N m (2.3 kg-m) I2RH01530021-01 1. Release shaft oil seal 6. Clutch cover 11. Release arm nut : Apply grease 99000-25010 to oil seal lip. 2.
Page 772 5C-11 Clutch: 1) Install flywheel (2) to crankshaft and tighten bolts (1) 3) Align clutch disc with flywheel center by using to specification. special tool, and install clutch cover (1) and bolts (2). Then tighten bolts (2) to specification. Special tool (A): 09924–17811 NOTE Tightening torque...
Page 773: Clutch Cover, Clutch Disc And Flywheel Inspection
Clutch: 5C-12 Clutch Cover, Clutch Disc and Flywheel Clutch Release System Removal and Inspection Installation S3RH0A5306017 S3RH0A5306018 Input Shaft Bearing Removal Check bearing for smooth rotation and replace it if 1) Remove release arm by loosening its nut and bolt. abnormality is found.
Page 774: Clutch Release System Inspection
5C-13 Clutch: 2) Install release shaft with return spring. 8) Apply small amount of grease to input shaft (3) spline and front end as well. “B”: Grease 99000–25210 I2RH01530031-01 3) Apply grease to No.2 bush (1) inside and press-fit it by using the same special tool as in removal.
Page 775: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A5308001 Material SUZUKI recommended product or Specification Note Fluid DOT 3 or SAE J1703 —...
Page 776: Special Tool
5C-15 Clutch: Special Tool S3RH0A5308002 09913–76010 09921–26020 Bearing installer Bearing remover 09922–46010 09923–36320 Clutch bush remover Clutch center guide (15 mm) 09923–46020 09924–17811 Joint pipe Flywheel holder 09925–46010 09925–98221 Clutch release bush Bearing installer remover 09930–30104 09943–88211 Sliding shaft Pinion bearing installer...
Page 777 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Tightening Torque Specifications......6B-12 Special Tools and Equipment ......6B-12 Precautions............. 6-1 Special Tool ............6B-12 Precautions on Steering........6-1 Power Assisted Steering System... 6C-1 Steering General Diagnosis....6A-1 Precautions............6C-1 Precautions............6A-1 P/S System Note..........6C-1 Precautions for Steering, Suspension, General Description ..........6C-2 Wheels and Tires Diagnosis ......
Page 778: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions on Steering S3RH0A6000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Air Bag System Service Warning Refer to “Air Bag System Service Warning in Section 00”. Precautions for Steering, Suspension, Wheels and Tires Diagnosis Refer to “Precautions for Steering, Suspension, Wheels and Tires Diagnosis in Section 6A”.
Page 779: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Precautions Precautions for Steering, Suspension, Wheels and Tires Diagnosis S3RH0A6100001 Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 780: Steering Wheel And Column
6B-1 Steering Wheel and Column: Steering Wheel and Column Steering Precautions Service Precautions of Steering Wheel and Column S3RH0A6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Service and Diagnosis For diagnosis and servicing, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”. Disabling Air Bag System For disabling air bag system, refer to “Disabling Air Bag System in Section 8B”.
Page 781: Steering Wheel And Column Construction
Steering Wheel and Column: 6B-2 Steering Wheel and Column Construction S3RH0A6201003 33 N m (3.3 kg-m) 9 N m (0.9 kg-m) 14 N m (1.4 kg-m) 0.85 N·m (85 kg-cm) 25 N m (2.5 kg-m) I3RH0A620001-01 1. Driver air bag (inflator) module 7.
Page 782: Repair Instructions
6B-3 Steering Wheel and Column: 2) Check steering shaft joints and shaft for any Checking Procedure damages such as crack, breakage, malfunction or 1) Take measurement “a”, “b” and “c” as shown. excessive play. If it is shorter than specified length, replace steering If anything is found faulty, replace as steering column assembly with new one.
Page 783 Steering Wheel and Column: 6B-4 4) Make alignment marks (1) on steering wheel and b) Install audio control switch (1) to steering wheel shaft for a guide during reinstallation. (2). CAUTION Do not hammer the end of the shaft. Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column.
Page 784: Contact Coil And Combination Switch Assembly Removal And Installation
6B-5 Steering Wheel and Column: 3) Remove steering column cover screws (1). 5) Tighten steering shaft nut (1) to specified torque. 4) Separate upper cover (2) and lower cover (3), then Tightening torque remove them. Steering shaft nut (a): 33 N·m (3.3 kgf-m, 24.0 lb- NOTE After installing the steering wheel, turn the steering wheel about 1 full rotation so that...
Page 785: Centering Contact Coil
Steering Wheel and Column: 6B-6 Installation 5) Install steering wheel to steering column. Refer to “Steering Wheel Removal and Installation”. 1) Check to make sure that vehicle’s front tires are set at straight-ahead position and then ignition switch is at “LOCK” position. 2) Install contact coil and combination switch assembly (3) and then connect all connectors disconnected in Removal.
Page 786: Contact Coil And Combination Switch Assembly Inspection
6B-7 Steering Wheel and Column: Contact Coil and Combination Switch Assembly 5) Remove steering column hole cover (1). Inspection S3RH0A6206004 Check contact coil harness (1) for any signs of scorching, melting or other damage. If it is damaged, replace. I3RH0A620005-01 6) Remove steering column cover screws (1).
Page 787 Steering Wheel and Column: 6B-8 10) For A/T vehicle, disconnect shift (key) interlock cable 15) Remove steering column mounting nuts (“A”, “B”). (1) from ignition switch with ignition switch turned at “ACC” position. After disconnecting, turn ignition switch to “LOCK” position.
Page 788 6B-9 Steering Wheel and Column: 5) Tighten joint bolts (1) in order “C” – “D” indicated in 8) If contact coil and combination switch assembly is figure to specified torque. removed, install it. Refer to “Contact Coil and Combination Switch Tightening torque Assembly Removal and Installation”.
Page 789: Steering Column Assembly Inspection
Steering Wheel and Column: 6B-10 Steering Column Assembly Inspection Installation S3RH0A6206006 1) Position oblong hole (1) of steering shaft (2) in the NOTE center of hole (3) in column (4). 2) Turn ignition key to “ACC” or “ON” position and Vehicles involved in accidents resulting in install steering lock assembly (5) onto column (4).
Page 790: Steering Lower Shaft Removal And Installation
6B-11 Steering Wheel and Column: Steering Lower Shaft Removal and Installation Installation S3RH0A6206008 1) Be sure that front wheels and steering wheel are in straight forward state. CAUTION 2) Align flat part “A” of steering lower shaft (1) with bolt Never turn steering wheel while steering hole “B”...
Page 791: Specifications
Steering Wheel and Column: 6B-12 Specifications Tightening Torque Specifications S3RH0A6207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Steering wheel lower cover screw 0.85 0.085 Steering shaft nut 24.0 Steering column mounting nut 10.5 Steering shaft joint bolt 18.5 NOTE The specified tightening torque is also described in the following.
Page 792: Power Assisted Steering System
6C-1 Power Assisted Steering System: Power Assisted Steering System Steering Precautions P/S System Note S3RH0A6300001 NOTE • Some parts in the power steering gear box cannot be disassembled or adjusted. For detailed information, refer to “P/S Gear Box Components”. • All steering gear 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.
Page 793: General Description
Power Assisted Steering System: 6C-2 General Description P/S System Description S3RH0A6301001 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 794: Diagnostic Information And Procedures
6C-3 Power Assisted Steering System: Diagnostic Information and Procedures P/S System Symptom Diagnosis S3RH0A6304001 Condition Possible cause Correction / Reference Item Heavy steering wheel (at Fluid deteriorated, low viscosity, Replace fluid. low speed) different type of fluid mixed Pipes or hoses deformed, air entering Replace defective part.
Page 795: Steering Wheel Play Check
Power Assisted Steering System: 6C-4 Condition Possible cause Correction / Reference Item Abnormal noise Air drawn in due to insufficient amount of Add fluid and purge air. fluid Air mixed into fluid from pipes or hoses Replace pipes or hoses. Slipping (loose) P/S belt Check belt tension.
Page 796: Hydraulic Pressure In P/S Circuit Check
6C-5 Power Assisted Steering System: Hydraulic Pressure in P/S Circuit Check 2) Check each connection for fluid leakage and bleed S3RH0A6304005 air referring to “Air Bleeding Procedure”. 1) After cleaning joint of high pressure hose and P/S 3) With engine idling, turn steering wheel and warm up pump (3) thoroughly, disconnect hose from pump engine till temperature of fluid in tank rises to 50 –...
Page 797: Repair Instructions
Power Assisted Steering System: 6C-6 • When it is higher than specified values, possible • When it is lower than specified values, possible cause is either failure of P/S pump (4) or setting of cause is malfunction of relief valve. relief valve spring.
Page 798: P/S Fluid Leakage Check
6C-7 Power Assisted Steering System: P/S Fluid Leakage Check S3RH0A6306002 Start engine, and then turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided. Then visually check gear box, P/S pump, P/S fluid reservoir and each joint of pipes for leakage. CAUTION Never keep steering wheel turned fully for longer than 10 seconds.
Page 799: Air Bleeding Procedure
Power Assisted Steering System: 6C-8 Air Bleeding Procedure S3RH0A6306003 1) Jack up the front end of vehicle, and then apply safety stands. 2) Fill P/S fluid reservoir with fluid up to specified level. NOTE Before starting engine, set transmission gear shift lever in “Neutral”...
Page 800: P/S Pump Drive Belt Removal And Installation
6C-9 Power Assisted Steering System: P/S Pump Drive Belt Removal and Installation P/S Pump Drive Belt Inspection S3RH0A6306018 S3RH0A6306019 Check power steering belt for wear and cracks, and Removal replace as required. 1) Disconnect negative cable at battery. Tie-Rod End Boot On-Vehicle Inspection 2) Remove engine undercover of right side, and then S3RH0A6306007 loosen tension pulley bolt (1) and nut (2).
Page 801: Tie-Rod End Ball Joint Inspection
Power Assisted Steering System: 6C-10 4) To facilitate adjustment after installation, put a mark 4) After installing wheels, lower vehicle and tighten (2) on tie-rod thread indicating position of tie-rod end wheel nuts to specified torque. lock nut (3). Then loosen lock nut and remove tie-rod Tightening torque end (4) from tie-rod (1).
Page 802: P/S Gear Box Components
6C-11 Power Assisted Steering System: P/S Gear Box Components S3RH0A6306011 NOTE Component enclosed in broken line cannot be disassembled and adjusted. I3RH0A630001-01 1. Steering rack side mount 5. High pressure pipe 9. Rack side boot 13. Steering tie-rod end 17. Split pin 2.
Page 803: Steering Shaft Joint On-Vehicle Inspection
Power Assisted Steering System: 6C-12 Steering Shaft Joint On-Vehicle Inspection S3RH0A6306008 Check each shaft joint for wear, breakage and any other damage. If any, replace it with a new one. I2RH01630025-01 6) Using special tool, remove tie-rod end (2) from knuckle (1).
Page 804 6C-13 Power Assisted Steering System: iv) Remove engine rear mounting nuts (2), and 8) Remove cylinder pipes (3) and (4) from steering gear then remove suspension frame (4) from box using flare nut wrench. body. NOTE v) Remove right (5) and left (6) transfer stiffener As fluid flows out of disconnected joints, put and remove transfer mounting bolts, and a receptacle under joints or a plug to pipe.
Page 805: Steering Rack Boot On-Vehicle Inspection
Power Assisted Steering System: 6C-14 • For installing each part, refer to respective procedures as indicated in the following. Model Part Section Exhaust pipe No.2 “Exhaust Pipe Removal and Installation in Section 1K” Mounting member “Front Suspension Frame Removal and Installation in Section 2B” Engine rear mounting bracket “Front Suspension Frame Removal and Installation in Section 2B”...
Page 806 6C-15 Power Assisted Steering System: Installation 5) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal. 1) Install new tie-rod lock washer, and then tie-rod to rack. NOTE 2) Tighten tie-rod ball nut to specified torque. When tie-rod was replaced, measure length Tightening torque “A”...
Page 807: P/S Pump Components
Power Assisted Steering System: 6C-16 P/S Pump Components S3RH0A6306014 I3RH0A630002-01 A: Match marking with projection of reservoir tank 5. Low pressure return hose (Reservoir side) 11. Belt tension pulley nut B: Tighten bolt with pipe stopper contacted to projection of P/S pump 6.
Page 808: P/S Pump Removal And Installation
6C-17 Power Assisted Steering System: P/S Pump Removal and Installation P/S Pump Disassembly and Assembly S3RH0A6306015 S3RH0A6306016 Removal Disassembly 1) Clean its exterior thoroughly. NOTE 2) With aluminum plates placed on vise first, grip pump Be sure to clean each joint of suction and body with it.
Page 809 Power Assisted Steering System: 6C-18 Assembly 4) Apply power steering fluid to sliding surface of rotor Reverse disassembly procedure for assembly, noting the (1). following. 5) Install rotor to shaft, directing dot (3) marked side of 1) Apply grease to oil seal lip (1). Apply power steering rotor facing up.
Page 810 6C-19 Power Assisted Steering System: 11) Apply power steering fluid to O-ring (1). 15) Gradually tighten pump cover bolts to specified torque. 12) Install O-ring (1) to pump body. NOTE After installing pump cover (1), check that shaft can be turned by hand. Tightening torque Pump cover bolt (a): 28 N·m (2.8 kgf-m, 20.0 lb- I2RH01630052-01...
Page 811: P/S Pump Inspection
Power Assisted Steering System: 6C-20 P/S Pump Inspection 23) Tighten plug (1) to specified torque. S3RH0A6306017 Tightening torque Plug (c): 60 N·m (6.0 kgf-m, 43.5 lb-ft) Pump Body, Cover, Side Plate and Shaft Check sliding surfaces of each part for wear and damage.
Page 812: Specifications
6C-21 Power Assisted Steering System: • Check clearance between rotor and vane. Clearance between rotor and vane Standard: 0.01 mm (0.0004 in.) Limit: 0.06 mm (0.0023 in.) I2RH01630044-01 • Check free length of relief valve spring (1). Free length of relief valve spring I2RH01630043-01 Standard: 22.0 mm (0.866 in.) 1.
Page 813: Tightening Torque Specifications
Power Assisted Steering System: 6C-22 Item Specification For vehicle with A/C system 7 – 9 mm (0.28 – 0.35 in.) deflection for new belt 9 – 11 mm (0.35 – 0.43 in.) deflection for used belt P/S belt tension (The push force should be about 100 N (10 kg, 22lb).) For vehicle without A/C system 4 –...
Page 814: Special Tools And Equipment
6C-23 Power Assisted Steering System: Special Tools and Equipment Recommended Service Material S3RH0A6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 SUZUKI Super Grease E P/No.: 99000–25050 Sealant Silicone Sealant P/No.: 99000–31120 for resin...
Page 815 Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 Blower Motor Controller Inspection ....7A-15 Blower Motor Relay Inspection ......7A-15 Precautions............. 7-1 Heater Unit Components........7A-16 Precautions on HVAC ........... 7-1 Heater Unit Removal and Installation....7A-16 Heater and Ventilation......7A-1 HVAC Control Module Removal and Installation ............7A-17 Precautions............7A-1...
Page 816 7-ii Table of Contents DTC Clearance ..........7B-10 Magnet Clutch Removal and Installation...7B-36 DTC Table............7B-10 Specifications .............7B-38 Fail-Safe Table..........7B-10 Tightening Torque Specifications......7B-38 Scan Tool Data ..........7B-11 Special Tools and Equipment ......7B-38 DTC B1511 (No.11): Temperature Control Recommended Service Material .......7B-38 Actuator (Position Sensor) and/or its Circuit Special Tool ............7B-38 Malfunction............7B-12...
Page 817 Table of Contents 7-iii DTC B1522 (No.22): Air Flow Selector and/or Condenser Cooling Fan Removal and its Circuit Malfunction ........7B-67 Installation ............7B-74 Inspection of HVAC Control Module and its Condenser Cooling Fan Inspection....7B-74 Circuit.............. 7B-67 A/C Evaporator Removal and Installation ..7B-74 A/C System Performance Inspection ....
Page 818: Precautions
7-1 Precautions: Precautions HVAC Precautions Precautions on HVAC S3RH0A7000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Heater and Ventilation Note Refer to “Precautions in Diagnosing Trouble in Section 7A”. A/C System Caution Refer to “A/C System Caution in Section 7B”. Precaution for Charging Refer to “Precaution for Charging in Section 7B”.
Page 819: Heater And Ventilation
SUZUKI scan tool. Before checking diagnostic information (diagnostic trouble code), read this manual and operator’s manual for SUZUKI scan tool to know how to read diagnostic information (diagnostic trouble code). • When checking diagnostic information (diagnostic trouble code) by reading the flashing pattern of the fresh air indicator lamp and recirculation air indicator lamp, keep in your mind that each diagnostic information (diagnostic trouble code) has priority.
Page 820: On-Board Diagnostic System Description
S3RH0A7101002 NOTE The diagnostic information as diagnostic trouble code (DTC) can be known by using SUZUKI scan tool (1). For further details, refer to “DTC Check”. HVAC control module (2) can detect malfunctions, which may occur in the following area.
Page 821: Schematic And Routing Diagram
Heater and Ventilation: 7A-3 Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S3RH0A7102001 BLU/YEL RED/WHT RED/BLK LT GRN WHT/RED BLU/WHT LT GRN G77-16 G77-15 PPL/WHT G77-3 BLU/RED G77-6 BLU/WHT G77-5 BLU/YEL RED/BLK G77-21 YEL/GRN G77-14 RED/YEL YEL/RED G77-22 G77-13 BLK/ORN G77-25...
Page 822: Diagnostic Information And Procedures
7A-4 Heater and Ventilation: Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S3RH0A7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check “Blower motor” fuse and check for short operate with blower circuit for ground. speed selector ON.
Page 823: Dtc Check
2) Set the following selectors to the specified positions 1) Turn ignition switch to OFF position. respectively. 2) Connect SUZUKI scan tool to data link connector • Temperature selector (3): Maximum cool position (DLC) (1) located on underside of instrument panel •...
Page 824: Dtc Clearance
However, SUZUKI scan tool can be 1) Turn ignition switch to OFF position. used to perform DTC clearance. 2) Connect SUZUKI scan tool to data link connector 1) Ensure that fresh air indicator (1) and recirculation (DLC) (1) located on underside of instrument panel air indicator (2) operate properly.
Page 825: Dtc Table
(indicate indicator Recirculation (displayed d by flashing air indicator recircula pattern Priority Diagnosis flashing SUZUKI tion air (See the pattern scan tool) indicator second table.) Temperature control actuator Short to 5 V (position sensor) and/or its circuit electrical power B1511...
Page 826 7A-8 Heater and Ventilation: Example (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) I3RH0A710007-01 [A]: DTC No.12 (Recirculation indicator lamp flashing pattern) [E]: Fresh air indicator lamp flashing pattern No. 3 (a): Indicator ON (e): 1.5 seconds [B]: DTC No.22 (Recirculation indicator lamp flashing pattern) [F]: Normal...
Page 827: Fail-Safe Table
Heater and Ventilation: 7A-9 Fail-Safe Table S3RH0A7104005 When any of the following malfunctions (DTCs) is detected, HVAC control module enters fail-safe mode. However, when HVAC control module detects normal operation of A/C system, fail-safe mode is canceled. Fail-Safe Operation Trouble Area Detection of malfunction when Detection of malfunction during ignition switch is turned ON...
Page 828: Dtc B1511 (No.11): Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
7A-10 Heater and Ventilation: DTC B1512 (No.12): Air Flow Control Actuator Scan Tool Data Definitions TEMP CONT SWITCH: Position of temperature control (Position Sensor) and/or its Circuit malfunction selector of HVAC control module S3RH0A7104008 Refer to “DTC B1512 (No.12): Air Flow Control Actuator MODE CONT SWITCH: Position of airflow selector of (Position Sensor) and/or its Circuit malfunction in HVAC control module...
Page 829: Inspection Of Hvac Control Module And Its Circuit
Heater and Ventilation: 7A-11 Inspection of HVAC Control Module and its Circuit S3RH0A7104014 HVAC control module and its circuits can be checked at HVAC control module wiring coupler by measuring voltage. CAUTION HVAC control module can not be checked by itself. It is strictly prohibited to connect voltmeter to HVAC control module with couplers disconnected from it.
Page 830 7A-12 Heater and Ventilation: Normal Terminal Wire Color Circuit Condition Voltage Serial communication line G77-7 10.0 – 14.0 V Ignition switch ON of data link connector G77-8 — — — — G77-9 BRN/RED Sensor ground about 0.0 V Full-time G77-10 —...
Page 831: Repair Instructions
Heater and Ventilation: 7A-13 Repair Instructions Blower Unit Components S3RH0A7106001 I3RH0A710009-01 1. Blower unit case 3. Air intake selector door 5. Air intake control actuator 7. Blower unit lower case 2. Blower motor assembly 4. Air intake selector link 6. Fresh air inlet duct 8.
Page 832: Blower Motor Removal And Installation
7A-14 Heater and Ventilation: Blower Motor Removal and Installation • Check motor for smooth operation and current. S3RH0A7106003 1) Fix blower motor assembly (1) using soft-jawed vise. 2) Connect battery to blower motor assembly (1) as Removal shown. 1) Disconnect negative (–) cable at battery. 2) Remove glove box.
Page 833: Blower Motor Controller Inspection
Heater and Ventilation: 7A-15 Blower Motor Controller Inspection Blower Motor Relay Inspection S3RH0A7106006 S3RH0A7106007 Check blower motor controller voltage as follows: 1) Disconnect negative (–) cable at battery. 1) Turn ignition switch to ON position. 2) Remove glove box. 2) With blower motor controller connector connected, 3) Remove blower motor relay (1).
Page 834: Heater Unit Components
7A-16 Heater and Ventilation: Heater Unit Components S3RH0A7106008 I3RH0A710012-01 1. Heater core 5. Air flow selector door 9. Heater case 13. Air flow control actuator 2. Air resistive board 6. Air flow selector link assembly 10. Foot air nozzle : Do not reuse. 3.
Page 835: Hvac Control Module Removal And Installation
Heater and Ventilation: 7A-17 HVAC Control Module Removal and Installation 5) Disconnect electrical connectors from HVAC control S3RH0A7106010 module, audio system and hazard switch. Removal 6) Remove instrument panel center garnish. 1) Disconnect negative (–) cable at battery. 7) Remove audio system (1) from instrument panel 2) Gently remove instrument panel center garnish trims center garnish.
Page 836: Air Intake Control Actuator Inspection
7A-18 Heater and Ventilation: Air Intake Control Actuator Inspection Installation S3RH0A7106013 Reverse removal procedure to install temperature Check air intake control actuator as follows: control actuator. 1) Using service wire, connect battery positive terminal to “a” terminal and battery negative terminal to Temperature Control Actuator Inspection terminal “b”.
Page 837: Air Flow Control Actuator Removal And Installation
Heater and Ventilation: 7A-19 6) Connect connector to temperature control actuator. Installation 7) Set temperature selector of HVAC control module to 1) Install air flow control actuator on heater unit, and MAX COOL position with ignition switch ON, and then connect connector to air flow control actuator. make sure if the position of actuator lever is MAX 2) Set air flow selector to DEF position with ignition on.
Page 838: Actuator Linkage Inspection
7A-20 Heater and Ventilation: If check result is not satisfactory, replace the actuator 3) Set air flow selector of HVAC control module to DEF position with ignition switch ON, and make sure if the with new one. position of actuator lever is DEF position (A). Actuator Linkage Inspection 4) Turn ignition switch OFF, and then disconnect S3RH0A7106020...
Page 839: Side Ventilation Louver Removal And Installation
Reverse removal procedure to install side ventilation louver. I3RH0A710018-01 2. Rag Special Tools and Equipment Special Tool S3RH0A7108001 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7.
Page 840: Air Conditioning System
7B-1 Air Conditioning System: Manual Type Air Conditioning System HVAC Manual Type Precautions A/C System Caution S3RH0A7210001 CAUTION The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C system: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Page 841: Precaution In Diagnosing Trouble
Air Conditioning System: Manual Type 7B-2 Precaution in Diagnosing Trouble Handling Refrigerant HFC-134a (R-134a) S3RH0A7210005 • Always wear goggles to protect your eyes. Refer to “Precautions in Diagnosing Trouble in Section • Avoid you direct contact to liquid refrigerant. 7A”. •...
Page 842: General Description
7B-3 Air Conditioning System: Manual Type • Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible. • Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
Page 843: Sub-Cool System Description
Air Conditioning System: Manual Type 7B-4 Sub-Cool System Description S3RH0A7211003 In the sub-cool A/C system (condenser integrated with receiver / dryer), the inside of the condenser is divided into the condensation part and the sub-cooler part, and the receiver / dryer is located between those. In the receiver / dryer, the refrigerant is separated into the vapor refrigerant and the liquid refrigerant.
Page 844: Schematic And Routing Diagram
7B-5 Air Conditioning System: Manual Type Schematic and Routing Diagram Major Components of A/C System S3RH0A7212001 Air flow diagram I4RH01721002-01 Major components of A/C system I3RH0A721002-01 1. Blower unit 6. Suction hose 11. Windscreen demister air 16. A/C refrigerant pressure switch 2.
Page 845: A/C System Wiring Diagram
Air Conditioning System: Manual Type 7B-6 A/C System Wiring Diagram S3RH0A7212002 BLU/YEL RED/WHT RED/BLK LT GRN WHT/RED BLU/WHT LT GRN G77-16 G77-15 LT GRN PPL/WHT G77-3 RED/BLK YEL/GRN G77-21 BLU/RED YEL/RED G77-22 G77-6 BLU/WHT G77-5 BLU/YEL G77-17 GRY/RED GRY/BLK G77-18 G77-12 WHT/BLU G77-14...
Page 846: Diagnostic Information And Procedures
7B-7 Air Conditioning System: Manual Type 5. Rear defogger 11. Air flow control actuator 17. A/C refrigerant pressure switch 6. Blower motor relay 12. Temperature control actuator 18. Condenser cooling fan relay Diagnostic Information and Procedures A/C System Symptom Diagnosis S3RH0A7214001 Condition Possible cause...
Page 847 Air Conditioning System: Manual Type 7B-8 Condition Possible cause Correction / Reference Item No cool air comes out Fuse blown Check related fuses and short circuit to (Blower motor does not ground. operate) Blower motor controller faulty Check blower motor resistor referring to “Blower Motor Controller Inspection in Section 7A”.
Page 848: Abnormal Noise Symptom Diagnosis Of A/C System
7B-9 Air Conditioning System: Manual Type Condition Possible cause Correction / Reference Item Cool air comes out only at Condenser clogged Check condenser referring to “Condenser high speed Assembly Inspection”. Insufficient charge of refrigerant Check amount of refrigerant charged. Air in A/C system Replace desiccant, and perform evacuation and charging.
Page 849: Dtc Check
Air Conditioning System: Manual Type 7B-10 Abnormal Noise from Tubing Condition Possible cause Correction / Reference Item Tubing: A droning noise Faulty tubing clamps Reposition clamps or increase the number of is heard inside vehicle, clamps. but not particularly Resonance caused by pulsation from Attach a silencer to tubing, or modify its noticeable in engine variations in refrigerant pressure...
Page 850: Scan Tool Data
7B-11 Air Conditioning System: Manual Type Scan Tool Data S3RH0A7214009 As the data values given in the following are standard values estimated on the basis of values obtained from the normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good condition, there may be cases where the checked values do not fall within each specifies data range.
Page 851: Dtc B1511 (No.11): Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
Air Conditioning System: Manual Type 7B-12 DTC B1511 (No.11): Temperature Control DTC B1520 (No.20): Temperature Selector and/ Actuator (Position Sensor) and/or its Circuit or its Circuit malfunction S3RH0A7214014 Malfunction Refer to “DTC B1520 (No.20): Temperature Selector S3RH0A7214010 and/or its Circuit malfunction”. Refer to “DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction”.
Page 852 7B-13 Air Conditioning System: Manual Type Description for Each Step Step 1. Customer complaint analysis Talk to customer, and then record details of the problem. Customer questionnaire (Example) I4RH01722014-01 Step 2. Visual inspection As a preliminary step, be sure to perform visual check of the items that support proper function of the air conditioning referring to “Visual Inspection”.
Page 853: Inspection Of Hvac Control Module And Its Circuit
Air Conditioning System: Manual Type 7B-14 Visual Inspection S3RH0A7214018 Check visually the following parts and systems. Inspection item Correction • Refrigerant ---- leakage and amount Refer to “Quick Checking of Refrigerant Charge”. • A/C pipe or hose ---- disconnection, looseness and deterioration •...
Page 854 7B-15 Air Conditioning System: Manual Type Normal Terminal Wire Color Circuit Condition Voltage 10.0 – 14.0 V Ignition switch ON, Blower speed selector OFF Ignition switch ON, Blower speed selector 1st about 8.0 V position Ignition switch ON, Blower speed selector 2nd about 6.5 V position Ignition switch ON, Blower speed selector 3rd...
Page 855: A/C System Performance Inspection
Air Conditioning System: Manual Type 7B-16 Normal Terminal Wire Color Circuit Condition Voltage Ignition switch ON, Temperature selector MAX COOL about 4.0 V Temperature control position G77-28 actuator position sensor Ignition switch ON, Temperature selector MAX HOT about 1.0 V position G77-29 —...
Page 856 7B-17 Air Conditioning System: Manual Type 8) Check for each pressure of low side and high side if it is within shaded range of graph. High pressure gauge If each gauge reading is out of specified pressure, Condition Possible Cause Correction correct defective part referring to the table.
Page 857 Air Conditioning System: Manual Type 7B-18 Crossing point of center ventilation louver 9) Check for crossing point of center ventilation louver air temperature and recirculation air inlet temperature and recirculation air inlet temperature temperature if it is within shaded range of graph. Condition Possible Cause Correction...
Page 858 7B-19 Air Conditioning System: Manual Type Condition MANIFOLD GAUGE MPa (kg/cm ) (psi) Possible Cause Correction Detail Normal: 0.23 – 0.35 Normal: 1.4 – 1.75 During A/C operation, the Expansion valve is Replace expansion (2.3 – 3.5) (33 – 50) (14 –...
Page 859: A/C System Inspection At Ecm
Air Conditioning System: Manual Type 7B-20 A/C System Inspection at ECM S3RH0A7214004 Voltage Check ECM and its circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from ECM.
Page 860 7B-21 Air Conditioning System: Manual Type Measurement Terminal Wire Color Circuit Normal Value Condition Ground Engine coolant temperature at 0.71 – 0.77 V approximately 80 °C (176 °F) with (298 – 320 Ω) engine running Engine coolant temperature at approximately 110 °C (230 °F) with ECT sensor Ground to G41-14...
Page 861: Repair Instructions
Air Conditioning System: Manual Type 7B-22 Measurement Terminal Wire Color Circuit Normal Value Condition Ground Sensor ground for A/C evaporator inlet Ground to body G04-20 –0.5 – 0.5 V Engine running and outlet air (Fig A) temperature sensors Ignition switch ON, Blower speed 10 –...
Page 862: Operation Procedure For Refrigerant Charging
7B-23 Air Conditioning System: Manual Type Operation Procedure for Refrigerant Charging S3RH0A7216002 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately – 6 °C (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious injury.
Page 863 Air Conditioning System: Manual Type 7B-24 I2RH01720015-01 1. New compressor I3RH0A721008-01 2. Removed compressor Replenishing Compressor Oil When replacing other part It is necessary to replenish specified amount of Replenish the following amount of oil to compressor. compressor oil to compressor (1) from compressor suction side hole (2) before evacuating and charging Amount of compressor oil to be replenished refrigerant.
Page 864 7B-25 Air Conditioning System: Manual Type NOTE Procedure of Charging • If the system does not indicate –100 kPa (– CAUTION 1.0 kg/cm , –760 mmHg, –14.7 psi), close • Always charge through low pressure side both valves, stop vacuum pump and watch of A/C system at after the initial charging is movement of low pressure gauge.
Page 865 Air Conditioning System: Manual Type 7B-26 4) After a while, open the low pressure side valve (6) a) Retract needle (3) and remove refrigerant and close the high pressure side valve (5). container tap valve (2) by loosening its plate nut (4).
Page 866: Heater And Cooling Unit Components
7B-27 Air Conditioning System: Manual Type Liquid leak detectors For confined areas, such as sections of the evaporator and condenser, an electronic (refrigerant) leak detector WARNING is more practical for determining leaks. Special tool • To prevent explosions or fires, make sure (A): 09990-86011 that there are no flammables in the vicinity.
Page 867: Heater And Cooling Unit Removal And Installation
Air Conditioning System: Manual Type 7B-28 Heater and Cooling Unit Removal and Installation S3RH0A7216004 CAUTION Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten it by using flat head screwdriver or pair of pliers. Removal 1) Disconnect negative (–) cable at battery.
Page 868: Condenser Assembly Inspection
7B-29 Air Conditioning System: Manual Type 2) Recover refrigerant from A/C system by referring to Condenser Assembly Inspection “Operation Procedure for Refrigerant Charging”. S3RH0A7216009 Check the following. NOTE • Clog of condenser fins. If, any clogs are found, condenser fins should be The amount of removed compressor oil must washed with water, and should be dried with be measured for replenishing compressor...
Page 869: Condenser Cooling Fan Inspection
Air Conditioning System: Manual Type 7B-30 Removal A/C Evaporator Removal and Installation S3RH0A7216013 1) Disconnect negative (–) cable at battery. CAUTION 2) Disconnect condenser cooling fan motor coupler. 3) Remove condenser cooling fan (1) from radiator (2). Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten it by using flat head screwdriver or pair of pliers.
Page 870: A/C Evaporator Inspection
7B-31 Air Conditioning System: Manual Type A/C Evaporator Inspection 7) Remove expansion valve (2) from evaporator. S3RH0A7216014 Check the following. • Clog of A/C evaporator fins If any clogs are found, A/C evaporator fins should be washed with water and should be dried with compressed air.
Page 871: A/C Evaporator Inlet And Outlet Air Temperature Sensors Inspection
Air Conditioning System: Manual Type 7B-32 A/C Evaporator Inlet and Outlet Air Temperature Expansion Valve Inspection S3RH0A7216018 Sensors Inspection Refer to “A/C System Performance Inspection”. S3RH0A7216016 Check resistance between terminals for A/C evaporator inlet air temperature sensor (1) and A/C evaporator A/C Refrigerant Pressure Switch Removal and outlet air temperature sensor (2).
Page 872: A/C Refrigerant Pressure Switch Inspection
7B-33 Air Conditioning System: Manual Type A/C Refrigerant Pressure Switch Inspection Compressor Relay and Condenser Cooling Fan S3RH0A7216020 Relay Inspection S3RH0A7216021 A/C Control Pressure Switch 1) Disconnect negative (–) cable at battery. 1) Run engine and A/C switch ON. 2) Remove condenser cooling fan relay (1) and 2) Check continuity between “a”...
Page 873: Compressor Removal And Installation
Air Conditioning System: Manual Type 7B-34 Compressor Removal and Installation Installation S3RH0A7216024 Reverse removal procedure to install compressor noting Removal the following instructions. 1) Run engine at idle speed with A/C ON for 10 • If compressor is replaced, pour new compressor oil by minutes.
Page 874: Magnet Clutch Components
7B-35 Air Conditioning System: Manual Type Magnet Clutch Components S3RH0A7216026 CAUTION Never disassemble compressor body assembly. Disassembly will affect original performance of A/C system. 18 N·m (1.8 kg-m) I2RH01720042-01 1. Armature plate bolt 5. Shim : Tightening torque 2. Armature plate 6.
Page 875: Magnet Clutch Removal And Installation
Air Conditioning System: Manual Type 7B-36 Magnet Clutch Removal and Installation 6) Remove magnet clutch lead wire clamp screw, and S3RH0A7216027 then remove magnet clutch read wire ground terminal. Removal 7) Remove magnet clutch pulley with puller (1). 1) Remove compressor from vehicle referring to “Compressor Removal and Installation”.
Page 876 7B-37 Air Conditioning System: Manual Type Installation 5) Adjust clearance between armature plate (1) and magnet clutch pulley (2) by putting shim(s) on 1) Install magnet clutch coil (2). compressor shaft. NOTE Standard clearance between armature plate and Protrusion on under side of magnet clutch magnet clutch pulley “a”...
Page 877: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S3RH0A7218001 Material SUZUKI recommended product or Specification Note Compressor oil (ND-Oil8, 250cc) P/No.: 99000–27080 NOTE Required service material is also described in the following.
Page 878: Automatic Type
7B-39 Air Conditioning System: Automatic Type Automatic Type Precautions Air Bag Warning S3RH0A7220002 Refer to “Air Bag Warning in Section 00”. A/C System Caution S3RH0A7220001 Refer to “A/C System Caution”. Precaution for Charging S3RH0A7220003 Refer to “Precaution for Charging”. Precautions in Diagnosing Trouble S3RH0A7220004 Refer to “Precautions in Diagnosing Trouble in Section 7A”.
Page 879 Air Conditioning System: Automatic Type 7B-40 I3RH0A722001-01 1. HVAC control module 3. Outside air temperature sensor 5. Engine coolant temperature (ECT) sensor 2. Inside air temperature sensor 4. Sunload sensor HVAC control module Temperature selector Sunload sensor Air flow selector Outside air temperature sensor Blower speed selector A/C evapoator outlet air temperature...
Page 880: Refrigerant Type Construction
NOTE The diagnostic information as diagnostic trouble code (DTC) can be known by using SUZUKI scan tool (1). For further details, refer to “DTC Check”. HVAC control module (2) can detect malfunctions, which may occur in the following area.
Page 881: A/C System Wiring Diagram
Air Conditioning System: Automatic Type 7B-42 A/C System Wiring Diagram S3RH0A7222002 BLU/YEL RED/WHT RED/BLK LT GRN WHT/RED BLU/WHT LT GRN G77-16 G77-15 LT GRN PPL/WHT G77-11 ORN/BLK BLK/RED G77-3 YEL/BLK G77-29 G77-8 BLK/RED BLU/RED G77-30 WHT/BLK G77-6 BLU/WHT BLK/RED G77-5 BLU/YEL G77-10 G77-27...
Page 882: Diagnostic Information And Procedures
7B-43 Air Conditioning System: Automatic Type 4. Rear defogger relay 11. Air flow control actuator 18. ECM 25. A/C refrigerant pressure switch 5. Rear defogger 12. Temperature control actuator 19. Condenser cooling fan relay a: Lighting switch or DRL controller 6.
Page 883 Air Conditioning System: Automatic Type 7B-44 Condition Possible cause Correction / Reference Item No cool air comes out Fuse blown Check related fuses and short circuit to (Blower motor does not ground. operate) Blower motor controller faulty Check blower motor controller referring to “Blower Motor Controller Inspection in Section 7A”.
Page 884: Abnormal Noise Symptom Diagnosis Of A/C System
Using SUZUKI Scan Tool 1) Turn ignition switch to OFF position. 4) Turn ignition switch to ON position. 2) Connect SUZUKI scan tool to data link connector 5) Read DTC displayed on SUZUKI scan tool. (DLC) (1) located on underside of instrument panel NOTE at driver’s seat side.
Page 885 6) After completing the check, turn ignition switch to 4) Keep air intake switch (6) and rear defogger switch OFF position and disconnect SUZUKI scan tool from (7) pressed, and then turn ignition switch to ON data link connector (DLC).
Page 886: Dtc Clearance
However, SUZUKI scan tool can be 1) Turn ignition switch to OFF position. used to perform DTC clearance. 2) Connect SUZUKI scan tool to data link connector 1) Ensure that fresh air indicator (1) and recirculation (DLC) (1) located on underside of instrument panel air indicator (2) operate properly.
Page 887: Dtc Table
DTC No. (indicated Recirculation lamp (displayed air indicator flashing recirculati Priority Diagnosis lamp flashing pattern SUZUKI on air pattern (See the scan tool) indicator second lamp) table) Open Outside air temperature sensor and/ B1501 or its circuit malfunction Short...
Page 888 7B-49 Air Conditioning System: Automatic Type Example (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) (c) I3RH0A722006-02 [A]: DTC No.12 (Recirculation indicator lamp [F]: Fresh air indicator lamp flashing pattern No.4 (d): 1 second flashing pattern) [B]: DTC No.22 (Recirculation indicator lamp...
Page 889: Scan Tool Data
Air Conditioning System: Automatic Type 7B-50 Fail-Safe Table S3RH0A7224006 When any of the following malfunctions (DTCs) is detected, fail-safe mode is activated. However, when HVAC control module detects normal operation of A/C system, fail-safe mode is canceled. Fail-Safe Operation Trouble Area Detection of malfunction when Detection of malfunction during ignition switch is turned ON...
Page 890 7B-51 Air Conditioning System: Automatic Type Scan Tool Data Condition Normal Condition / Reference Value Reference value is relative to the position of 0 – 15.5 V FAN DESIRE VOLT blower speed selector of HVAC control module. Reference value is relative to the position of about 1.0 V (Max Hot) AIR MIX POS SENSOR temperature selector of HVAC control module.
Page 891: Visual Inspection
Air Conditioning System: Automatic Type 7B-52 Air Conditioning System Check S3RH0A7224008 Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform ”Customer complaint analysis”. Was customer complaint analysis performed? Visual inspection Repair or replace Go to Step 3. malfunctional part.
Page 892 7B-53 Air Conditioning System: Automatic Type Customer questionnaire (Example) I4RH01722014-01 Step 2. Visual inspection As a preliminary step, be sure to perform visual check of the items that support proper function of the air conditioning referring to “Visual Inspection”. Step 3. DTC check Check DTC referring to “DTC Check”.
Page 893: Dtc B1501 (No.01): Outside Air Temperature Sensor And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-54 Visual Inspection S3RH0A7224009 Check visually the following parts and systems. Inspection item Correction • Refrigerant ---- leakage and amount Refer to “Quick Checking of Refrigerant Charge”. • A/C pipe or hose ---- disconnection, looseness and deterioration •...
Page 894: Dtc B1502 (No.02): Inside Air Temperature Sensor And/Or Its Circuit Malfunction
7B-55 Air Conditioning System: Automatic Type Step Action 1) With ignition switch ON position, check voltage between Go to Step 5. “BLK/RED” wire open, “YEL/BLK” wire terminal and “BLK/RED” wire terminal at poor connection of outside air temperature sensor connector. “BLK/RED”...
Page 895: Dtc B1503 (No.03): A/C Evaporator Air Temperature Sensor And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-56 Step Action 1) With ignition switch ON position, check voltage between Go to Step 5. “BLK/RED” wire open, “ORN/BLK” wire terminal and “BLK/RED” wire terminal poor connection of at inside air temperature sensor connector. “BLK/RED”...
Page 896: Dtc B1504 (No.04): Sunload Sensor And/Or Its Circuit Malfunction
7B-57 Air Conditioning System: Automatic Type Step Action 1) Check resistance between “WHT/BLK” wire terminal and Poor connection of “ORN/BLK” wire shorted body ground. “WHT/BLK” wire to ground. terminal at HVAC Ω Is resistance more than 1 M control module connector, and/or HVAC control module faulty.
Page 897: Dtc B1510 (No.10): Engine Coolant Temperature (Ect) Sensor And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-58 Step Action 1) With ignition switch ON position and HVAC control Go to Step 6. Go to Step 4. module connector connected, check voltage between “YEL” wire terminal at sunload sensor connector and body ground. Is voltage about 5 V? 1) Turn ignition switch OFF, and then disconnect HVAC Go to Step 5.
Page 898 7B-59 Air Conditioning System: Automatic Type DTC Troubleshooting Step Action 1) Check if DTC P0115 and/or P1705 are detected referring Perform troubleshooting Go to Step 2. to “DTC Check in Section 1A”. by referring to “DTC P0115 (No. 19): Engine Are DTC P0115 and/or P1705 detected? Coolant Temp.
Page 899: Dtc B1511 (No.11): Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-60 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction S3RH0A7224016 Wiring Diagram G77-26 RED/WHT G77-28 BLK/RED G77-9 I3RH0A722013-01 1. HVAC control module 2. Temperature control actuator 3. HVAC control module connector “G77” (viewed from harness side) DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 900: Dtc B1512 (No.12): Air Flow Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
7B-61 Air Conditioning System: Automatic Type Step Action 1) Turn ignition switch OFF, disconnect HVAC control Go to Step 7. “WHT” wire open or module connector referring to “HVAC Control Module high resistance. Removal and Installation in Section 7A”. 2) Check resistance between “WHT” wire terminal at temperature control actuator connector and “WHT”...
Page 901: Dtc B1513 (No.13): Temperature Control Actuator And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-62 Step Action 1) Check resistance between “RED/WHT” wire terminal Poor connection of “RED/WHT” wire and body ground. “RED/WHT” wire shorted to ground. terminal at HVAC Ω Is resistance more than 1 M control module connector, and/or HVAC control module faulty.
Page 902 7B-63 Air Conditioning System: Automatic Type DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area • Signal from temperature control position sensor is less than the specified • “GRY/BLU”, “GRY”, “RED/WHT”, (3.4 V) in operation to COOL direction after 15 seconds. “WHT”...
Page 903 Air Conditioning System: Automatic Type 7B-64 Step Action 1) Turn ignition switch OFF, and then disconnect HVAC Poor connection of “GRY” wire shorted to control module connector referring to “HVAC Control “GRY” wire terminal at ground. Module Removal and Installation in Section 7A”. HVAC control module connector, and/or HVAC 2) Check resistance between “GRY”...
Page 904: Dtc B1514 (No.14): Air Flow Control Actuator And/Or Its Circuit Malfunction
7B-65 Air Conditioning System: Automatic Type DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction S3RH0A7224019 Wiring Diagram G77-17 GRY/RED G77-18 GRY/BLK G77-26 RED/WHT G77-12 WHT/BLU BLK/RED G77-9 I3RH0A722016-01 1. HVAC control module 2. Air flow control actuator 3.
Page 905 Air Conditioning System: Automatic Type 7B-66 Step Action 1) Check resistance between “GRY/RED” wire terminal and Poor connection of “GRY/RED” wire body ground. “GRY/RED” wire shorted to ground. terminal at HVAC Ω Is resistance more than 1 M control module connector, and/or HVAC control module faulty.
Page 906: Dtc B1520 (No.20): Temperature Selector And/Or Its Circuit Malfunction
7B-67 Air Conditioning System: Automatic Type Step Action 1) Check air flow control actuator referring to “Air Flow HVAC control module Air flow control actuator Control Actuator Inspection in Section 7A”. faulty. faulty. Is air flow control actuator normal? DTC B1520 (No.20): Temperature Selector and/ DTC Troubleshooting Replace HVAC control module with new one referring to or its Circuit malfunction...
Page 907 Air Conditioning System: Automatic Type 7B-68 Normal Terminal Wire Color Circuit Condition Voltage Ignition switch ON, Blower speed selector OFF, 1st or 10.0 – 14.0 V Electric load signal for 2nd position G77-2 BLU/BLK blower motor Ignition switch ON, Blower speed selector between about 2.0 V 3rd and HIGH position 10.0 –...
Page 908 7B-69 Air Conditioning System: Automatic Type Normal Terminal Wire Color Circuit Condition Voltage Air intake actuator about 0.0 V Ignition switch ON, Air intake switch OFF position G77-21 YEL/GRN (FRESH AIR) 10.0 – 14.0 V Ignition switch ON, Air intake switch ON position Air intake actuator about 0.0 V Ignition switch ON, Air intake switch ON position G77-22...
Page 909: A/C System Performance Inspection
Air Conditioning System: Automatic Type 7B-70 A/C System Performance Inspection S3RH0A7224024 Refer to “A/C System Performance Inspection”. A/C System Inspection at ECM S3RH0A7224025 Voltage Check ECM and its circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION ECM cannot be checked by itself.
Page 910 7B-71 Air Conditioning System: Automatic Type Measurement Terminal Wire Color Circuit Normal Value Condition Ground Engine coolant temperature at 0.71 – 0.77 V approximately 80 °C (176 °F) with (298 – 320 Ω) engine running Engine coolant temperature at approximately 110 °C (230 °F) with ECT sensor Ground to G41-14...
Page 911: Repair Instructions
Air Conditioning System: Automatic Type 7B-72 Repair Instructions Quick Checking of Refrigerant Charge S3RH0A7226001 Refer to “Quick Checking of Refrigerant Charge”. Operation Procedure for Refrigerant Charging S3RH0A7226002 Refer to “Operation Procedure for Refrigerant Charging”. Heater and Cooling Unit Components S3RH0A7226003 I3RH0A722023-01 1.
Page 912: Sunload Sensor Inspection
7B-73 Air Conditioning System: Automatic Type Sunload Sensor Inspection S3RH0A7226012 1) Light over sunload sensor vertically with an incandescent lamp of approximately 60 W. The distance between sunload sensor and lamp should be approximately 100 mm (3.94 in.). 2) Measure voltage between terminals of sunload sensor as shown.
Page 913: Inside Air Temperature Sensor Inspection
Air Conditioning System: Automatic Type 7B-74 Inside Air Temperature Sensor Inspection A/C Evaporator Removal and Installation S3RH0A7226043 S3RH0A7226027 Measure resistance between each connector terminal Refer to “A/C Evaporator Removal and Installation”. with an ohmmeter. If resistance is incorrect, replace inside air temperature A/C Evaporator Inspection sensor with new one.
Page 914: Expansion Valve Removal And Installation
Magnet Clutch Removal and Installation S3RH0A7226041 Refer to “Magnet Clutch Removal and Installation”. Special Tools and Equipment Special Tool S3RH0A7228001 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 915 Table of Contents 8- i Section 8 Restraint CONTENTS Precautions ..........8-1 Air Bag Diagnostic System Check Flow....8B-13 DTCs Description ..........8B-14 Precautions............. 8-1 DTC Table............8B-14 Precautions on Restraint........8-1 DTC Check............8B-17 Seat Belts ..........8A-1 DTC Clearance ..........8B-18 Scan Tool Data ..........8B-19 Precautions............8A-1 Scan Tool Data Definition .........8B-19 Precautions on Service and Diagnosis of Seat...
Page 916 8-ii Table of Contents DTC B1056 / B1057: Sideward Crash (Driver DTC B1084 / B1088: Side Air Bag (Driver / / Passenger Side) Detected (Side Air Bag Passenger Side) Initiator Circuit Short to System Activation Command Outputted) ..8B-68 Power Circuit...........8B-93 DTC B1058: Frontal Crash Detected Repair Instructions ..........8B-96 (Pretensioner Activation Command...
Page 917: Precautions
Precautions: Precautions Restraint Precautions Precautions on Restraint S3RH0A8000001 Air Bag System Service Warning Refer to “Air Bag Warning in Section 00”. Fastener Caution Refer to “Fastener Caution in Section 00”. Precautions on Service and Diagnosis of Seat Belt Refer to “Precautions on Service and Diagnosis of Seat Belt in Section 8A”. Precautions on Service and Diagnosis of Air Bag System Refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Page 918: Seat Belts
If these parts are replaced individually, such a locking condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and seat belt assembly in a set part.
Page 919: General Description
Seat Belts: 8A-2 General Description Seat Belt Construction S3RH0A8101001 I3RH0A810001-03 [A]: For sedan model with 3-point rear center seat belt 3. Buckle for front seat belt 8. Buckle for rear seat belt [B]: For wagon model with 3-point rear center seat belt 4.
Page 920: Restraint System Specification
8A-3 Seat Belts: Seat Belt with ELR The seat belt with emergency locking retractor (ELR) is designed so that it locks immediately (to prevent the webbing from being pulled out of the retractor any further) when any of the following items is detected as exceeding each set value;...
Page 921: Repair Instructions
Seat Belts: 8A-4 Repair Instructions Front Seat Belt Components S3RH0A8106001 WARNING • Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an assembly. •...
Page 922: Front Seat Belt Removal And Installation
8A-5 Seat Belts: Front Seat Belt Removal and Installation • Enable air bag system. Refer to “Enabling Air Bag S3RH0A8106002 System in Section 8B”. (If seat belt pretensioner is equipped) Removal 1) Disconnect negative (–) cable at battery. Front Seat Belt Inspection 2) Disable air bag system.
Page 923 Seat Belts: 8A-6 Seat belts and attaching parts can affect the vital Anchor Bolt components and systems of a vehicle. • Anchor bolts should be torqued to specification. Therefore, they should be inspected carefully and replaced with genuine parts only. Belt Latch •...
Page 924: Rear Seat Belt Removal And Installation
8A-7 Seat Belts: Rear Seat Belt Removal and Installation S3RH0A8106004 WARNING Be sure to read “Precautions on Service and Diagnosis of Seat Belt”before starting to work and observe every precaution during work. Removal Remove rear seat belts as shown in figure. Installation Install the rear seat belt observing the same precautions as “Front Seat Belt Removal and Installation”.
Page 925: Rear Seat Belt Inspection
Seat Belts: 8A-8 Rear Seat Belt Inspection S3RH0A8106005 WARNING Be sure to read “Precautions on Service and Diagnosis of Seat Belt”before starting to work and observe every precaution during work. • Check the rear seat belt in the same way as “Front Seat Belt Inspection”. •...
Page 926: Air Bag System
• If the air bag system and another vehicle ft) or more, seat belt pretensioner (retractor assembly) system both need repair, Suzuki is dropped from a height of 30 cm (1 ft) or more), recommends that the air bag system be...
Page 927: Precautions On Handling And Storage Of Air Bag Components
Air Bag System: 8B-2 Precautions on Handling and Storage of Air Bag Live (Undeployed) Air Bag (Inflator) Modules Special care is necessary when handling and storing a Components live (undeployed) air bag (inflator) modules. S3RH0A8200002 The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, WARNING or an object in front of the air bag (inflator) module, to be...
Page 928 8B-3 Air Bag System: WARNING WARNING When placing a live air bag (inflator) module • For handling and storage of a live air bag on bench or other surface, always face the (inflator) module, select a place where the bag up, away from the surface. As the live ambient temperature below 65 °C (150 °F), passenger air bag (inflator) module must be without high humidity and away from...
Page 929 Air Bag System: 8B-4 Live (Inactivated) Seat Belt Pretensioner WARNING Special care is necessary when handling and storing a live (inactivated) seat belt pretensioners. • For handling and storage of a live seat belt Also, when the seat belt pretensioners activate, gas is pretensioner, select a place where the generated and the seat belt (1) is retracted into the ambient temperature below 65 °C (150 °F),...
Page 930: Precautions On Disposal Of Air Bag And Seat
8B-5 Air Bag System: Precautions on Disposal of Air Bag and Seat Air Bag Wire Harness and Connector in Floor Wire Harness Belt Pretensioner Air bag wire harness is included in floor harness. The S3RH0A8200003 Do not dispose of the live (undeployed) air bag (inflator) part of coupler side wire harness can be identified easily modules and the live (inactivated) seat belt as it is covered with a yellow protection tube.
Page 931 Air Bag System: 8B-6 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 (3), the sag of the seat belt is taken up (for seat belt with pretensioner), the driver air bag (1) (inflator) module is deployed from the center of the steering column and the passenger air bag (2) (inflator) module from the top of the instrument panel in front of the front passenger seat in occurrence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver and front passenger seat belts.
Page 932: Schematic And Routing Diagram
8B-7 Air Bag System: Schematic and Routing Diagram Air Bag System Wiring Diagram S3RH0A8202001 NOTE Code (“ ”) in the following figure is connector code described in wiring diagram manual. “L70” “L28” “L81” +12V BLK/RED GRN/RED L70-27 “G21” “G20” “L70” L70-26 YEL/RED “L72”...
Page 933 Air Bag System: 8B-8 SDM connector “L70” Terminal Circuit Terminal Circuit L70-1 — L70-20 Side air bag (inflator) module High L70-2 — L70-21 (passenger side) (if equipped) L70-3 — L70-22 — L70-4 — L70-23 Passenger air bag (inflator) L70-5 Side sensor (passenger side) L70-24 module High...
Page 934: Component Location
8B-9 Air Bag System: Component Location Air Bag System Components, Wiring and Connectors Location S3RH0A8203001 CONECTOR “L28” CONECTOR “L80”, “G14” CONECTOR “L35" CONECTOR “L72”, “G28” CONECTOR “L73“, “L74” CONECTOR “L75“, “L76” CONECTOR “L83”, “G46” CONECTOR “L81” CONECTOR “L77“, “L78” CONECTOR “L70” CONECTOR “L79”...
Page 935: Diagnostic Information And Procedures
Air Bag System: 8B-10 Diagnostic Information and Procedures Repairs and Inspections Required after an If any faulty condition is found in the following checks, replace faulty part. Accident Those components are: S3RH0A8204001 CAUTION • Steering column (1) and shaft joints –...
Page 936: Inspection Of Intermittents And Poor Connections
8B-11 Air Bag System: • SDM – Check for external damage such as deformation, scratch, crack, peeled paint, etc. – Check that SDM cannot be installed properly due to a cause in itself. – Check that connector or lead wire of SDM has a scorching, melting or damage.
Page 937: Air Bag Diagnostic System Check
Air Bag System: 8B-12 • Damaged connector body, exposing the terminals to • Wire broken inside the insulation. This condition could moisture and dirt, as well as not maintaining proper cause a continuity check to show a good circuit, but if terminal orientation with the component or mating only 1 or 2 strands of a multi-strand-type wire are connector.
Page 938: Air Bag Diagnostic System Check Flow
Step 4: Check that “AIR BAG” warning lamp flashes 6 times after ignition switch is turned ON. Step 6: Check that history codes are in SDM memory. (using SUZUKI scan tool) Step 7: Check that history codes are in SDM memory. (using monitor coupler) Step 9: Check that current code is in SDM memory.
Page 939: Dtcs Description
Air Bag System: 8B-14 Step Action 1) Check DTC using SUZUKI scan tool, referring to “DTC Substitute a known- Check and repair Check”. good SDM and recheck. according to flow corresponding to that Is “NO CODES” displayed on SUZUKI scan tool? DTC.
Page 940 8B-15 Air Bag System: “AIR BAG” Warning Lamp Flashing Pattern Diagnosis MODE B1041 Resistance high MCODE00041-0-01 B1042 Resistance low Driver MCODE00042-0-01 pretensioner circuit B1043 Short to ground MCODE00043-0-01 B1044 Short to power circuit MCODE00044-0-01 B1045 Resistance high MCODE00045-0-01 B1046 Resistance low Passenger MCODE00046-0-01 pretensioner...
Page 941 “AIR BAG” warning lamp remains on after ignition switch is turned ON. Therefore, it is not possible to identify any of them as to whether it is a current one or a history one. (But use of SUZUKI scan tool will make identification possible.) Current DTC is set.
Page 942: Dtc Check
(A): SUZUKI scan tool 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between scan tool and SDM is not possible, proceed to “SDM Cannot Communicate...
Page 943: Dtc Clearance
1) Turn ignition switch to OFF position. about 1 second intervals within 10 seconds. 2) Connect SUZUKI scan tool to data link connector 3) Perform “DTC Check” and confirm that normal DTC (DLC) (1) in the same manner as when making this (DTC No.
Page 944: Scan Tool Data
8B-19 Air Bag System: Scan Tool Data Scan Tool Data Definition S3RH0A8204032 S3RH0A8204033 As the data values given below are standard values Back Up Volt (V): This parameter indicates the capacity estimated on basis of obtained from the normally of the backup condenser installed to maintain the ignition operating vehicle by using a scan tool, use them as current (as much as possible) even when the power reference value.
Page 945 Air Bag System: 8B-20 CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow. • When measurement of resistance or voltage is required in this flow, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 946: Air Bag" Warning Lamp Does Not Come
8B-21 Air Bag System: Step Action 1) Disconnect connector “G20” from combination meter Substitute a known- Clear up short circuit referring to “Combination Meter Circuit Diagram in good SDM and recheck. between “YEL/RED” Section 9C”. wire and ground. 2) Release shorting bar of “L70-30” terminal inserting release tool (A).
Page 947 Air Bag System: 8B-22 CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow table. • When measurement of resistance or voltage is required in this flow, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 948 8B-23 Air Bag System: Step Action 1) Turn ignition switch to OFF position. Go to Step 4. Clear up open circuit in “YEL/RED” wire. 2) Disconnect SDM connector “L70” (3). 3) Release shorting bar of “L70-30” terminal inserting release tool (A). 4) Check continuity between “G21-14”...
Page 949: Air Bag" Warning Lamp Flashes
Air Bag System: 8B-24 “AIR BAG” Warning Lamp Flashes S3RH0A8204011 Wiring Diagram “G20” “G21” “L80” “L70” “G14” YEL/RED BLK/RED YEL/RED L70-30 L70-31 L70-32 WHT/RED L70-8 +30V+5V “L79” L70-28 “L83” “G46” BLK/ORN I3RH0A820018-01 1. From main fuse 5. “AIR BAG” fuse 9.
Page 950: Air Bag" Warning Lamp Cannot Indicate Flashing
8B-25 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- Repair short from “PPL” “L70” (1). good SDM and recheck. wire circuit to ground. 2) Measure resistance between “L70-8” terminal in SDM connector “L70” (1) and body ground. Special tool (A): 09932-76010 “L70-8”...
Page 951 Air Bag System: 8B-26 CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow table. • When measurement of resistance or voltage is required in this flow, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 952: Sdm Cannot Communicate Through The Serial Data Circuit
8B-27 Air Bag System: SDM Cannot Communicate through the Serial Data Circuit S3RH0A8204013 Wiring Diagram “L80” “L70” “G14” YEL/RED BLK/RED YEL/RED L70-30 L70-31 L70-32 WHT/RED L70-8 +30V+5V “L79” L70-28 “L83” “G46” BLK/ORN I2RH01820020-01 1. From main fuse 6. SDM 11. Ground on body 2.
Page 953 Air Bag System: 8B-28 Troubleshooting Step Action 1) Make sure that SUZUKI scan tool (2) is free from Go to Step 2. Properly connect malfunction. SUZUKI scan tool to DLC. 2) Ignition switch OFF. 3) Check proper connection of SUZUKI scan tool (2) to DLC (1).
Page 954: Dtc B1015: Passenger Air Bag Initiator Circuit Resistance High
8B-29 Air Bag System: NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected. DTC B1015: Passenger Air Bag Initiator Circuit Resistance High S3RH0A8204014 Wiring Diagram...
Page 955 Air Bag System: 8B-30 DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 2. Ignition switch OFF. (inflator) module connector “L35”. Replace passenger air 2) Check proper connection to passenger air bag (inflator) bag (inflator) module module at terminals in connector “L35”.
Page 956 8B-31 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector. Substitute a known- Repair high resistance good SDM and recheck. or open in “YEL/GRN” 2) Check proper connection to SDM at “L70-24” and “L70- or “YEL” wire circuit. 23”...
Page 957: Dtc B1016: Passenger Air Bag Initiator Circuit Resistance Low
Air Bag System: 8B-32 DTC B1016: Passenger Air Bag Initiator Circuit Resistance Low S3RH0A8204015 Wiring Diagram “L70” “L70” “G14” “L80” “L72” “L38” “L35” +12V YEL/GRN L70-32 L70-24 L70-23 L70-31 I3RH0A820021-02 [A]: Shorting bar 2. Ignition switch 4. SDM 6. Ground for air bag system 1.
Page 958 8B-33 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 2. Ignition switch OFF. (inflator) module connector “L35”. Replace passenger air 2) Check proper connection to passenger air bag (inflator) bag (inflator) module module at terminals in connector “L35”.
Page 959 Air Bag System: 8B-34 Step Action 1) With ignition switch OFF, disconnect SDM connector. Substitute a known- Repair short from “YEL/ good SDM and recheck. GRN” wire circuit to 2) Check proper connection to SDM at “L70-24” and “L70- “YEL” wire circuit or 23”...
Page 960: Dtc B1018: Passenger Air Bag Initiator Circuit Short To Ground
8B-35 Air Bag System: DTC B1018: Passenger Air Bag Initiator Circuit Short to Ground S3RH0A8204016 Wiring Diagram “L70” “L70” “G14” “L80” “L72” “L38” “L35” +12V YEL/GRN L70-32 L70-24 L70-23 L70-31 I3RH0A820021-02 [A]: Shorting bar 2. Ignition switch 4. SDM 6. Ground for air bag system 1.
Page 961 Air Bag System: 8B-36 DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 2. Ignition switch OFF. (inflator) module connector “L35” behind the glove box. Replace passenger air 2) Check proper connection to passenger air bag (inflator) bag (inflator) module module at terminals in connector “L35”.
Page 962: Dtc B1019: Passenger Air Bag Initiator Circuit Short To Power Circuit
8B-37 Air Bag System: Step Action 1) With ignition switch OFF, disconnect Special Tool (A), Substitute a known- Repair short from “YEL/ (B), (C) and SDM connector “L70”. good SDM and recheck. GRN” wire circuit or “YEL” wire circuit to 2) Measure resistance between “L70-24”...
Page 963 Air Bag System: 8B-38 [A]: Shorting bar 2. Ignition switch 4. SDM 6. Ground for air bag system 1. From main fuse 3. “AIR BAG” fuse 5. Passenger air bag (inflator) module CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow table.
Page 964 8B-39 Air Bag System: Step Action 1) With ignition switch OFF, disconnect Special Tool (A), Go to Step 3. Repair short from “YEL/ (B), (C) and SDM connector “L70”. GRN” wire circuit to power circuit. 2) Measure voltage from “L70-24” terminal to body ground. Special tool (A): 09932-76010 (B): 09932-75010...
Page 965: Dtc B1021: Driver Air Bag Initiator Circuit Resistance High
Air Bag System: 8B-40 NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to “DTC Clearance”), if any. •...
Page 966 8B-41 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 3. connector “L28” located near the base of the steering column. 2) Check proper connection to contact coil at terminals in connector “L28”.
Page 967 Air Bag System: 8B-42 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- Repair high resistance “L70” (1). good SDM and recheck. or open in “GRN/RED” or “GRN” wire circuit. 2) Check proper connection to SDM at “L70-27” and “L70- 26”...
Page 968: Dtc B1022: Driver Air Bag Initiator Circuit Resistance Low
8B-43 Air Bag System: Step Action 1) With ignition switch OFF, disconnect Special Tool (B) Ignition switch OFF. Ignition switch OFF. and (C) then reconnect contact coil connector “L28” Replace contact coil Replace driver air bag located near the base of the steering column. assembly referring to (inflator) module 2) Remove driver air bag (inflator) module from steering...
Page 969 Air Bag System: 8B-44 CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 970 8B-45 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- Repair short from “GRN/ “L70” (1). good SDM and recheck. RED” wire circuit to “GRN” wire circuit or 2) Check proper connection to SDM at “L70-27” and “L70- from “GRN/RED”...
Page 971: Dtc B1024: Driver Air Bag Initiator Circuit Short To Ground
Air Bag System: 8B-46 Step Action 1) With ignition switch OFF, disconnect Special Tool (B) Ignition switch OFF. Ignition switch OFF. and (C), then reconnect contact coil connector “L28” Replace contact coil Replace driver air bag located near the base of the steering column. assembly referring to (inflator) module 2) Remove driver air bag (inflator) module from steering...
Page 972 8B-47 Air Bag System: CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 973 Air Bag System: 8B-48 Step Action 1) With ignition switch OFF, disconnect Special Tool (B), Substitute a known- Repair short from “GRN/ (C) and SDM connector “L70” (1). good SDM and recheck. RED” or “GRN” wire circuit to ground. 2) Measure resistance between “L70-27” terminal and body ground and between “L70-26”...
Page 974: Dtc B1025: Driver Air Bag Initiator Circuit Short To Power Circuit
8B-49 Air Bag System: Step Action 1) With ignition switch OFF, disconnect Special Tool (B) Ignition switch OFF. Ignition switch OFF. and (C), then reconnect contact coil connector “L28” Replace contact coil Replace driver air bag located near the base of the steering column. assembly referring to (inflator) module 2) Remove driver air bag (inflator) module from steering...
Page 975 Air Bag System: 8B-50 CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 976 8B-51 Air Bag System: Step Action 1) With ignition switch OFF, disconnect Special Tool (B), Substitute a known- Repair short from “GRN/ (C) and SDM connector “L70” (1). good SDM and recheck. RED” or “GRN” wire circuit to power circuit. 2) Measure voltage from “L70-27”...
Page 977: Dtc B1031: Power Source Voltage High
Air Bag System: 8B-52 Step Action 1) With ignition switch OFF, disconnect Special Tool (B) Ignition switch OFF. Ignition switch OFF. and (C), then reconnect contact coil connector “L28” Replace contact coil Replace driver air bag located near the base of the steering column. assembly referring to (inflator) module 2) Remove driver air bag (inflator) module from steering...
Page 978 8B-53 Air Bag System: CAUTION • Be sure to perform “Air Bag Diagnostic System Check” before starting diagnosis according to flow. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to “Special Tool”.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 979: Dtc B1032: Power Source Voltage Low
Air Bag System: 8B-54 DTC B1032: Power Source Voltage Low S3RH0A8204023 Wiring Diagram “L70” “G14” “L80” L70-32 L70-31 +30V+5V I2RH01820030-02 1. From main fuse 3. “AIR BAG” fuse 5. Ground for air bag system 2. Ignition switch 4. SDM CAUTION •...
Page 980 8B-55 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Go to Step 4. Go to Step 3. “L70” (1). 2) Check proper connection to SDM at “L70-32” terminal. 3) If OK, then ignition switch ON, and then check voltage from “L70-32”...
Page 981: Dtc B1041 / B1045: Driver Pretensioner Initiator Circuit Resistance High
Air Bag System: 8B-56 DTC B1041 / B1045: Driver Pretensioner Initiator Circuit Resistance High S3RH0A8204024 Wiring Diagram “L70” “G14” “L70” “L80” “L75” +12V L70-32 L70-33 L70-34 +12V L70-36 LT GRN L70-31 L70-35 “L76” I2RH01820034-02 [A]: Shorting bar 3. “AIR BAG” fuse 6.
Page 982 8B-57 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar inner Go to Step 2. Turn ignition switch to garnish of applicable side then disconnect seat belt OFF position, and pretensioner connector. replace seat belt pretensioner referring to 2) Check proper connection to applicable seat belt “Front Seat Belt...
Page 983 Air Bag System: 8B-58 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1041: “L70”. good SDM and recheck. Repair high resistance 2) Check proper connection to SDM at “L70-33” and “L70- or open in “PNK” or 34”...
Page 984: Dtc B1042 / B1046: Driver / Passenger Pretensioner Initiator Circuit Resistance Low
8B-59 Air Bag System: NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to “DTC Clearance”), if any. •...
Page 985 Air Bag System: 8B-60 DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar inner Go to Step 2. Turn ignition switch to garnish of applicable side then disconnect seat belt OFF position, and pretensioner connector. replace seat belt pretensioner referring to 2) Check proper connection to applicable seat belt “Front Seat Belt...
Page 986 8B-61 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1042: “L70”. good SDM and recheck. Repair short from “PNK” 2) Check proper connection to SDM at “L70-33” and “L70- wire circuit to “WHT” 34”...
Page 987: Dtc B1043 / B1047: Driver / Passenger Pretensioner Initiator Circuit Short To Ground
Air Bag System: 8B-62 DTC B1043 / B1047: Driver / Passenger Pretensioner Initiator Circuit Short to Ground S3RH0A8204026 Wiring Diagram “L70” “G14” “L70” “L80” “L75” +12V L70-32 L70-33 L70-34 +12V L70-36 LT GRN L70-31 L70-35 “L76” I2RH01820034-02 [A]: Shorting bar 3.
Page 988 8B-63 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower Go to Step 2. Turn ignition switch to garnish of applicable side then disconnect seat belt OFF position, and pretensioner connector. replace seat belt pretensioner referring to 2) Check proper connection to applicable seat belt “Front Seat Belt...
Page 989 Air Bag System: 8B-64 Step Action 1) With ignition switch OFF, disconnect Special Tool (A), (B) Substitute a known- DTC B1043: and (C) and SDM connector “L70”. good SDM and recheck. Repair short “PNK” or “WHT” wire circuit to Special tool ground.
Page 990: Dtc B1044 / B1048: Driver / Passenger Pretensioner Initiator Circuit Short To Power Circuit
8B-65 Air Bag System: NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to “DTC Clearance”), if any. •...
Page 991 Air Bag System: 8B-66 DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower Go to Step 2. Ignition switch OFF. garnish of applicable side then disconnect seat belt Replace seat belt pretensioner connector. pretensioner referring to 2) Check proper connection to applicable seat belt “Front Seat Belt pretensioner at terminals in connector “L75”...
Page 992 8B-67 Air Bag System: Step Action 1) With ignition switch OFF, disconnect Special Tool (A), (B) Substitute a known- DTC B1044: and (C) and SDM connector “L70”. good SDM and recheck. Repair short “PNK” or “WHT” wire circuit to Special tool power circuit.
Page 993: Dtc B1051: Frontal Crash Detected (System Activation Command Outputted)
Air Bag System: 8B-68 NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to “DTC Clearance”), if any. •...
Page 994: Dtc B1058: Frontal Crash Detected (Pretensioner Activation Command Outputted)
8B-69 Air Bag System: DTC Troubleshooting Step Action 1) Ignition switch OFF. Replace components Go to Step 2. and perform inspections Has side air bag (inflator) module deployed? as directed in “Repairs and Inspections Required after an Accident”. 1) Inspect sideward of vehicle and undercarriage for signs Replace components Substitute a known- of impact.
Page 995: Dtc B1061: "Air Bag" Warning Lamp Circuit Failure
Air Bag System: 8B-70 DTC B1061: “AIR BAG” Warning Lamp Circuit Failure S3RH0A8204030 Wiring Diagram “L80” “L70” “G14” YEL/RED BLK/RED YEL/RED L70-30 L70-31 L70-32 WHT/RED L70-28 +30V+5V “L83” “G46” L70-8 “L79” BLK/ORN I2RH01820038-01 1. From main fuse 5. “AIR BAG” fuse 9.
Page 996: Dtc B1063 / B1065: Side Sensor (Driver / Passenger Side) Circuit Short To Ground
8B-71 Air Bag System: NOTE Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to “DTC Clearance”), if any. •...
Page 997 Air Bag System: 8B-72 DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower trim Substitute a known- DTC B1063: and side sill scuff, then disconnect side sensor good side sensor and/or Repair short “GRN/ connector. SDM and recheck. WHT”...
Page 998: Dtc B1064 / B1066: Side Sensor (Driver / Passenger Side) Circuit Short To Power Circuit Or Open
8B-73 Air Bag System: DTC B1064 / B1066: Side Sensor (Driver / Passenger Side) Circuit Short to Power Circuit or Open S3RH0A8204036 Wiring Diagram “L70” “L80” “G14” L70-32 “L77” GRN/WHT L70-17 GRN/BLK L70-6 LT GRN/BLK L70-16 LT GRN L70-5 “L78” L70-31 I3RH0A820034-02 1.
Page 999 Air Bag System: 8B-74 DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower trim Got to Step 2. DTC B1064: and side sill scuff, then disconnect side sensor Repair open in “GRN/ connector. WHT” or “GRN/BLK” 2) Disconnect SDM connector “L70”.
Page 1000 8B-75 Air Bag System: Step Action 1) Measure voltage. Substitute a known- DTC B1064: good side sensor and/or a) DTC B1064: between “L70-17” terminal and body Repair short “GRN/ SDM and recheck. ground, and between “L70-6” terminal and body WHT” or “GRN/BLK” ground.
Page 1001: Dtc B1071: Internal Sdm Fault
Air Bag System: 8B-76 DTC B1071: Internal SDM Fault 3) Repeat “Air Bag Diagnostic System Check”. S3RH0A8204031 DTC Will Set when DTC B1072 / B1074: Internal Side Sensor (Driver An internal SDM fault is detected by SDM. / Passenger Side) Fault S3RH0A8204037 NOTE DTC Will Set when...
Page 1002 8B-77 Air Bag System: DTC Will Set when Side sensor abnormal signal is detected by SDM. Flow Test Description Step 1 to 4: Check side sensor circuit in floor harness. DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect SDM connector Go to Step 2.
Page 1003 Air Bag System: 8B-78 Step Action DTC B1073: Go to Step 3. DTC B1073: Measure resistance between “L70-17” and “L70-6” Repair short from “GRN/ terminals. WHT” wire to “GRN/ BLK” wire. Special tool (A): 09932–76010 DTC B1075: Repair short from “GRN/ “L70-6”...

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Liana rh416

Suzuki Liana RH413 Service Manual

Section 1 Engine

Precautions

General Description

Engine General Information and Diagnosis

Precautions

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Section 2 Suspension

Precautions

Diagnostic Information and Procedures

2A-1 Suspension General Diagnosis

Specifications

Front Suspension

General Description

Repair Instructions

Specifications

Special Tools and Equipment

Rear Suspension

General Description

Repair Instructions

Specifications

Special Tools and Equipment

Wheels and Tires

General Description

Repair Instructions

Specifications

Quick Links

Chapters

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Summary of Contents for Suzuki Liana RH413