Suzuki SWIFT RS415 2017 Service Manual

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WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words

WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by

these signal words.

WARNING:

Indicates a potential hazard that could result in death or injury.

CAUTION:

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING:

This service manual is intended for authorized Suzuki dealers and qualified service technicians only.

Inexperienced technicians or technicians without the proper tools and equipment may not be able to

properly perform the services described in this manual.

Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver

and passengers.

WARNING:

For vehicles equipped with a Supplemental Restraint or Air Bag System:

• Service on and around the air bag system components or wiring must be performed only by an

authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under

"General Description" in air bag system section in order to confirm whether you are performing ser-

vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-

vice Precautions" under "On-Vehicle Service" in air bag system section before performing service

on or around the air bag system components or wiring. Failure to follow WARNINGS could result in

unintentional activation of the system or could render the system inoperative. Either of these two

conditions may result in severe injury.

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air

bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, instrument panel or any other air bag system component on or

around air bag system components or wiring. Modifications can adversely affect air bag system

performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93°C (200°F), for example, during a paint baking

process, remove the air bag system components, that is air bag or inflator modules, SDM and/or

seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

The circle with a slash in this manual means "Don't do this" or "Don't let this happen".

IMPORTANT

Summary of Contents for Suzuki SWIFT RS415 2017

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 .........5A-1 Manual Transmission ..........5B-1 Engine .................
Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Air Bag Warning ..........00-9 Air Bag System Service Warning ......00-9 Precautions............00-1 Fastener Caution..........00-9 Precautions for Vehicles Equipped with Suspension Caution ..........00-9 a Supplemental Restraint (Air Bag) System ..00-1 Wheels and Tires Caution........
Page 8 (driver and passenger). It is • If the air bag system and another vehicle very dangerous as the electric current from system both need repair, SUZUKI the tester may deploy the air bag or activate recommends that the air bag system be the pretensioner.
Page 9 Precautions: 00-2 Servicing and Handling WARNING: Many of service procedures require disconnection of “A/BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain 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: • When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand. • For handling and storage of a SDM, select • When handling the air bag (inflator) modules (driver, a place where the ambient temperature passenger, side and curtain), seat belt pretensioners below 65 C (150 F), without high humidity...
Page 11 Precautions: 00-4 WARNING: – Do not swallow any of these service materials. It would cause diarrhea or • Whenever raising a vehicle for service, be nausea. sure to follow the instructions under – Keep all these materials out of children’s “Vehicle Lifting Points: in Section 0A”.
Page 12 00-5 Precautions: • When removing the battery, be sure to disconnect the • Make sure that all parts used in reassembly are negative cable first and then the positive cable. When perfectly clean. reconnecting the battery, connect the positive cable When use of a certain type of lubricant, bond or first and then the negative cable, and replace the sealant is specified, be sure to use the specified type.
Page 13: Communication Equipment
Precautions: 00-6 • After servicing fuel, oil, coolant, vacuum, exhaust or • Always be careful not to handle electrical parts brake systems, check all lines related to the system (computer, relay, etc.) in a rough manner or drop for leaks. them.
Page 14: Precaution For Can Communication System
00-7 Precautions: Precaution for CAN Communication System • When disconnecting and connecting coupler, make S4RS0A0000014 sure to turn ignition switch OFF, or electronic parts • The loose (1) in the wire harnesses twist of the CAN may get damaged. lines except around the connector (3) should be within 100 mm (3.9 in.).
Page 15 Precautions: 00-8 • When installing vehicle parts, be careful so that the • When taking measurements at electrical connectors wiring harness is not interfered with or caught by any using a tester probe, be sure to insert the probe (2) other part.
Page 16 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 17 Precautions: 00-10 Brake Caution S4RS0A0000013 CAUTION: 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 18 00-11 Precautions: 2) Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance between terminals “A-1” and “B-1”. If no continuity is indicated, that means that the circuit is open between terminals “A-1” and “B-1”. If continuity is indicated, there is an open circuit between terminals “B-1”...
Page 19: Intermittent And Poor Connection Inspection
Precautions: 00-12 Intermittent and Poor Connection Inspection S4RS0A0006002 Most intermittent are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: •...
Page 20 00-13 Precautions: • Poor terminal-to-wire connection. Check each wire harness in problem circuits for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. I2RH01010059- • Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle.
Page 21: General Information
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Filter Replacement ........0B-7 Fuel Tank Inspection...........0B-7 General Description ..........0A-1 PCV Valve Inspection .........0B-7 Abbreviations ............0A-1 Fuel Evaporative Emission Control System Symbols .............. 0A-2 Inspection............0B-7 Wire Color Symbols ..........
Page 22 0A-1 General Information: General Information General Description Abbreviations S4RS0A0101001 GEN: Generator GND: Ground ABS: Anti-lock Brake System ATDC: After Top Dead Center HC: Hydrocarbons API: American Petroleum Institute HO2S: Heated Oxygen Sensor ATF: Automatic Transmission Fluid, Automatic HAVC: Heating, Ventilating and Air Conditioning Transaxle Fluid ALR: Automatic Locking Retractor IAC Valve: Idle Air Control Valve (Idle Speed Control...
Page 23 WU-TWC: Warm Up Three Way Catalytic Converter Catalyst) Symbols S4RS0A0101002 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 automatic transmission fluid)
Page 24 0A-3 General Information: I2RH01010010- Fasteners Information Metric bolts: Identification class numbers or marks S4RS0A0101004 correspond to bolt strength (increasing numbers Metric Fasteners represent increasing strength). Most of the fasteners used for this vehicle are metric. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength.
Page 25 General Information: 0A-4 Thread diameter (Nominal diameter) (mm) Strength Unit A equivalent of 6.8 strength fastener without flange kg-m 0.24 0.47 0.84 12.5 19.3 lb-ft 14.5 30.5 58.0 90.5 139.5 202.5 I2RH01010013-01 A equivalent of 6.8 strength fastener with flange kg-m 0.24 0.49 0.88...
Page 26 0A-5 General Information: When Using Frame Contact Hoist I4RS0A010001- 1. Vehicle front 3. Floor jack position 2. Support position for frame contact hoist and safety stand 4. Body mounting stay 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.
Page 27 General Information: 0A-6 Engine Supporting Points S4RS0A0101008 WARNING: When using engine supporting device (1), be sure to observe the followings. Otherwise, not only deformation of vehicle body but also personal injury may result. • Apply supporting device at the specified positions (2) indicated in figure •...
Page 28 0A-7 General Information: Vehicle Identification Number Engine Identification Number S4RS0A0101006 S4RS0A0101007 The number is punched close by the right side strut The number is punched on cylinder block. support (1) in engine room. I3RM0A010005- Transmission Identification Number S4RS0A0101009 The automatic transmission identification number is located on transmission case.
Page 29 General Information: 0A-8 I4RS0A010007- 1. Air bag label on sun visor (if equipped) 4. Steering shaft joint cover label (if equipped) 2. Radiator cap label 5. Jack label 3. Engine cooling fan label I4RS0A010009- 1. Air bag label on driver air bag (inflator) module 5.
Page 30: Maintenance And Lubrication
0B-1 Maintenance and Lubrication: Maintenance and Lubrication Precautions Precautions for Maintenance and Lubrication S4RS0A0200001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S4RS0A0205001 NOTE: • This interval should be judged by odometer reading or months, whichever comes first. •...
Page 31 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Steering system (tightness, damage, breakage, rattle) (I: — — — Drive shaft (axle) boots (I: — — — — Manual transaxle oil (leakage, level) (I: 1st 15,000 km only) (R: —...
Page 32 0B-3 Maintenance and Lubrication: Severe Maintenance Maintenance Maintenance interval condition code operation First time only: 15,000 km (9,000 miles) or 12 months Second time and after: – B – – E – – H Manual transaxle oil Every 30,000 km (18,000 miles) or 24 months reckoning from 0 km (0 mile) or 0 month Every 30,000 km (18,000 miles) or 24...
Page 33 Maintenance and Lubrication: 0B-4 NOTE: Engine Oil and Filter Change S4RS0A0206004 When replacing belt with a new one, adjust WARNING: belt tension to 6 – 7 mm (0.24 – 0.28 in.). • New and used engine oil can be hazardous. Be sure to read “WARNING”...
Page 34 0B-5 Maintenance and Lubrication: NOTE: Engine oil specification Oil pan capacity: About 3.7 liters (7.8 / 6.5 US / Before fitting new oil filter, be sure to oil its lmp pt.) O-ring. Use engine oil for this purpose. Oil filter capacity: About 0.2 liter (0.4 / 0.3 US / lmp pt.) Others: About 0.3 liter (0.6 / 0.5 US / lmp pt.) Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.)
Page 35 Maintenance and Lubrication: 0B-6 Exhaust System Inspection S4RS0A0206006 WARNING: To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised for other service, check exhaust system as follows: I2RH01140007-...
Page 36 0B-7 Maintenance and Lubrication: Fuel Filter Replacement Brake Discs and Pads (Front) Inspection S4RS0A0206042 S4RS0A0206015 WARNING: 1) Remove wheel and caliper but don’t disconnect brake hose from caliper. This work must be performed in a well 2) Check front disc brake pads and discs for excessive ventilated area and away from any open wear, damage and deflection.
Page 37 Maintenance and Lubrication: 0B-8 Brake Hoses and Pipes Inspection 3) Check parking brake lever for proper operation and S4RS0A0206017 stroke, and adjust it if necessary. Perform this inspection where these is enough light and For checking and adjusting procedures, refer to use a mirror as necessary.
Page 38 0B-9 Maintenance and Lubrication: Tires Inspection Suspension System Inspection S4RS0A0206021 S4RS0A0206024 1) Check tires for uneven or excessive wear, or • Inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on damage. If defective, replace. Refer to “Irregular and/or Premature Wear sleeves;...
Page 39 Maintenance and Lubrication: 0B-10 4) Check boots (1) and (2) of steering linkage and steering gear case for damage (leak, detachment, tear, etc.). If damage is found, replace defective boot with new one. If any dent is found on steering gear case boots, correct it to original shape by turning steering wheel to the right or left as far as it stops and holding it for a few seconds.
Page 40 0B-11 Maintenance and Lubrication: Automatic Transaxle Fluid Level Inspection Automatic Transaxle Fluid Cooler Hose S4RS0A0206039 Inspection 1) Inspect transaxle case for evidence of fluid leakage. S4RS0A0206041 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 41 Maintenance and Lubrication: 0B-12 Air Conditioning Filter (If Equipped) Inspection Engine Start S4RS0A0206036 Check engine start for readiness. 1) Remove the air conditioning filter from the HVAC unit WARNING: referring to “Air Filter Removal and Installation: in Section 7A”. Before performing the following check, be 2) Check for dirt and dust.
Page 42 0B-13 Maintenance and Lubrication: WARNING: • Check that engine is free from abnormal noise and abnormal vibration. With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to Body, Wheels and Power Transmitting System avoid any personal injury or property Check that body, wheels and power transmitting system damage.
Page 43 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance Precautions............. 1-1 / -Retarded ............1A-44 Precautions for Engine.......... 1-1 DTC P0031 / P0032: HO2S Heater Control Engine General Information and Circuit Low / High (Sensor-1) ......1A-46 DTC P0037 / P0038: HO2S Heater Control Diagnosis ..........
Page 44 1-ii Table of Contents DTC P0171 / P0172: Fuel System Too Lean Radiator cooling fan High Speed Control / Rich ............. 1A-103 System Check ..........1A-195 DTC P0300 / P0301 / P0302 / P0303 / Repair Instructions ..........1A-198 P0304: Random Misfire Detected / Cylinder Idle Speed / Idle Air Control (IAC) Duty 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Inspection............1A-198...
Page 45 Table of Contents 1-iii Vehicle Speed Sensor (VSS) Inspection Camshaft, Tappet and Shim Removal and (M/T model)............1C-8 Installation ............1D-29 Knock Sensor Removal and Installation .....1C-8 Camshaft, Tappet and Shim Inspection ....1D-31 Main Relay, Fuel Pump Relay, Starting Valves and Cylinder Head Components ...1D-34 Motor Control Relay and Throttle Actuator Valves and Cylinder Head Removal and Control Relay Inspection ........1C-9...
Page 46 1-iv Table of Contents Engine Cooling System ......1F-1 Fuel Injector Removal and Installation ....1G-9 Fuel Injector Inspection ........1G-10 General Description ..........1F-1 Fuel Filler Cap Inspection ........ 1G-11 Cooling System Description ........ 1F-1 Fuel Tank Inlet Valve Removal and Coolant Description..........
Page 47 Table of Contents 1-v Specifications............1I-9 Generator Components........1J-7 Cranking System Specifications......1I-9 Generator Inspection........... 1J-8 Tightening Torque Specifications......1I-9 Specifications ............. 1J-10 Special Tools and Equipment ......1I-9 Charging System Specifications ....... 1J-10 Recommended Service Material ......1I-9 Tightening Torque Specifications...... 1J-10 Charging System ........1J-1 Exhaust System ........
Page 48 1-1 Precautions: Precautions Precautions Precautions for Engine S4RS0A1000001 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 of ECM Circuit Inspection Refer to “Precautions of ECM Circuit Inspection: in Section 1A”.
Page 49 CAN communication line with care referring to • Diagnostic information stored in ECM memory can be “Precaution for CAN Communication System: in cleared as well as checked by using SUZUKI scan Section 00”. tool or OBD generic scan tool. Before using scan tool, •...
Page 50 1A-2 Engine General Information and Diagnosis: connectors at the harness side, and then measure connectors is same as the one of the ECM voltage, resistance and/or pulse signal. Or, ECM and connectors. Therefore, measure circuit voltage and its circuits may be damaged by water. resistance by identifying the terminal location subject to the measurement.
Page 51 • It is possible to communicate by using not only Therefore, it is possible to know engine and driving SUZUKI scan tool (2) but also OBD generic scan tool. conditions (e.g., whether the engine was warm or not, (Diagnostic information can be accessed by using a where the vehicle was running or stopped, where air/fuel scan tool.)
Page 52 OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module (in ECM), BCM (Body electrical Control Module), TCM (Transmission Control Module) and ABS control module.
Page 53 Engine General Information and Diagnosis: 1A-5 Engine and Emission Control System Description S4RS0A1101004 The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, IAC valve and intake manifold. Fuel delivery system includes fuel pump, delivery pipe, etc.
Page 54 1A-6 Engine General Information and Diagnosis: NOTE: In communication between ECM and combination meter, data is transmitted only from ECM to combination meter. (Combination meter does not transmit data to ECM.) ECM Reception Data Torque down ignition delay request Coast slip control signal Vehicle speed pulse TCM data validity Transmission gear...
Page 55 Engine General Information and Diagnosis: 1A-7 Electronic Control System Description S4RS0A1101006 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices. Functionally, it is divided into the following sub systems: •...
Page 56 1A-8 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram I4RS0A110006-...
Page 57 Engine General Information and Diagnosis: 1A-9 ECM Input / Output Circuit Diagram RED/YEL C37-20 C37-1 BLU/YEL C37-2 BLU/WHT C37-21 BLK/ORN BLU/RED C37-16 BLU/ORN C37-17 GRN/BLK C37-26 C37-27 BLU/BLK C37-29 BLK/YEL C37-25 C37-4 GRN/RED GRN/ORN C37-3 GRY/RED C37-14 WHT/RED C37-19 C37-54 GRY/BLU C37-18 BRN/YEL...
Page 58 1A-10 Engine General Information and Diagnosis: 4. MAP sensor 26. IAC valve 48. Barometric pressure sensor 5. Knock sensor 27. EVAP canister purge valve 49. Oil control valve (Camshaft position control) 6. TP sensor 28. Fuel pump relay 50. Engine ground 7.
Page 59 Engine General Information and Diagnosis: 1A-11 Terminal Wire color Circuit Terminal Wire color Circuit Heater output of heated BLU/RED Fuel injector No.3 output BLK/RED oxygen sensor-1 Heater output of heated BLU/ORN Fuel injector No.4 output RED/BLU oxygen sensor-2 EGR valve (stepper motor coil BRN/YEL YEL/GRN Starting motor signal...
Page 60 1A-12 Engine General Information and Diagnosis: Terminal Wire color Circuit Terminal Wire color Circuit — — — — YEL/RED Fuel level sensor signal Ground for sensors Vehicle speed signal output for A/C refrigerant pressure EPS control module sensor signal RED/BLU EPS signal —...
Page 61 Engine General Information and Diagnosis: 1A-13 Engine and Emission Control Input / Output Table S4RS0A1101007 ELECTRIC CONTROL DEVICE OUTPUT INPUT For detecting fuel level FUEL LEVEL SENSOR BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR BLOWER SWITCH A/C SWITCH A/C EVAP OUTLET AIR TEMP.
Page 62 1A-14 Engine General Information and Diagnosis: Schematic and Routing Diagram Engine and Emission Control System Diagram S4RS0A1102001 I4RS0A110011-...
Page 63 Engine General Information and Diagnosis: 1A-15 1. Air cleaner 15. ECT sensor 29. ECM 2. EVAP canister purge valve 16. CMP sensor 30. Barometric pressure sensor 3. MAF and IAT sensor 17. CKP sensor 31. Battery 4. TP sensor 18. Radiator cooling fan 32.
Page 64 1A-16 Engine General Information and Diagnosis: Information sensors Control devices Others 6. VSS g: IAC valve G: TCM (A/T) 7. Battery h: Ignition coil assembly (with ignitor) H: BCM (included in junction block assembly) 8. CMP sensor i: Main relay I: Immobilizer coil antenna 9.
Page 65 Engine General Information and Diagnosis: 1A-17 Step Action Intermittent problems check Repair or replace Go to Step 11. malfunction part(s), and 1) Check for intermittent problems referring to “Intermittent go to Step 11. Problems Check”. Is there any faulty condition? Final confirmation test Go to Step 6.
Page 66 1A-18 Engine General Information and Diagnosis: Customer problem inspection form (Example) I2RH01110010- NOTE: The form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 67 ECM or other part and repair or replace faulty parts. 1) Prepare OBD generic scan tool or SUZUKI scan tool. Step 10: Intermittent Problems Check Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to...
Page 68 (A): SUZUKI scan tool DTC Clearance S4RS0A1104004 1) Connect OBD generic scan tool or SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch OFF and then ON.
Page 69 Engine General Information and Diagnosis: 1A-21 Detecting condition DTC No. Detecting item (DTC will set when detecting:) HO2S heater control circuit low 2 driving *P0037 Heater current is less than specification while heater ON. (Sensor-2) cycles HO2S heater control circuit high 2 driving *P0038 Heater current is more than specification while heater ON.
Page 70 1A-22 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Total fuel trim is smaller than specification for specified 2 driving *P0172 System too rich time or longer. (Fuel trim toward lean side is large.) cycles Misfire of such level as to cause damage to three way *2 driving...
Page 71 Engine General Information and Diagnosis: 1A-23 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Transmission error that is inconsistent between CAN communication (buss off 1 driving *P1674 transmission data and transmission monitor (CAN bus error) cycle monitor) data is detected more than 7 times continuously. CAN communication Transmission error of communication data for ECM is 1 driving...
Page 72 1A-24 Engine General Information and Diagnosis: Fail-Safe Table S4RS0A1104006 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 73 Engine General Information and Diagnosis: 1A-25 Normal condition / Scan tool data Vehicle condition reference values Accelerator pedal released 0.5 – 1.0 V TP SENSOR VOLT Ignition switch ON / (THROTTLE POSITION warmed up engine Accelerator pedal depressed Less than 4.8 V SENSOR OUTPUT stopped fully...
Page 74 1A-26 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values 1350 – 1650 kPa For more details, refer to A/C ON (A/C is operating) at pressure of high pressure ambient temperature: 30 C gage under “A/C System (86 F) and humidity: 50% Performance Inspection: in A/C PRESSURE (A/C...
Page 75 Engine General Information and Diagnosis: 1A-27 Scan Tool Data Definitions CALC LOAD (CALCULATED LOAD VALUE, %) Engine load displayed as a percentage of maximum COOLANT TEMP (ENGINE COOLANT possible load. Value is calculated mathematically using TEMPERATURE, C, F) the formula: actual (current) intake air volume It is detected by engine coolant temp.
Page 76 1A-28 Engine General Information and Diagnosis: CLOSED THROTTLE POS (CLOSED THROTTLE BRAKE SW (ON/OFF) POSITION, ON/OFF) This parameter indicates the state of the brake switch. This parameter reads ON when throttle valve is fully closed, or OFF when it is not fully closed. RADIATOR COOLING FAN (RADIATOR COOLING FAN CONTROL RELAY, ON/OFF) CANIST PRG DUTY (EVAP CANISTER PURGE FLOW...
Page 77 Engine General Information and Diagnosis: 1A-29 Inspection item Reference section • Tachometer – Operation • Abnormal air being inhaled from air intake system • Exhaust system – leakage of exhaust gas, noise • Other parts that can be checked visually Engine Basic Inspection S4RS0A1104009 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found...
Page 78 Check ignition timing Go to “Engine Symptom Check ignition control Diagnosis: ”. related parts referring to 1) Using SUZUKI scan tool, select “Misc Test” mode on “Ignition Timing SUZUKI scan tool and fix ignition timing to initial one. Inspection: in Section 1H”.
Page 79 Engine General Information and Diagnosis: 1A-31 Step Action Check fuel pump for operation Go to “Fuel Pressure Go to “Fuel Pump and Check: ”. Its Circuit Check: ”. Was fuel pump operating sound heard from fuel filler for about 3 seconds after ignition switch ON and stop? 10 Check ignition spark Go to Step 11.
Page 80 1A-32 Engine General Information and Diagnosis: Engine Symptom Diagnosis S4RS0A1104010 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...
Page 81 Engine General Information and Diagnosis: 1A-33 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 82 1A-34 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Poor gasoline mileage Leaks or loose connection of high- “High-Tension Cord Removal and Installation: tension cord in Section 1H” Faulty spark plug (improper gap, heavy “Spark Plug Inspection: in Section 1H” deposits and burned electrodes, etc.) Malfunctioning EGR valve “EGR Valve Inspection: in Section 1B”...
Page 83 Engine General Information and Diagnosis: 1A-35 Condition Possible cause Correction / Reference Item Surge – Engine power Leaky or loosely connected high-tension “High-Tension Cord Removal and Installation: variation under steady cord in Section 1H” throttle or cruise. Feels Faulty spark plug (excess carbon “Spark Plug Inspection: in Section 1H”...
Page 84 1A-36 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection: in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection: in Section 1H” Leaks, loose connection or “High-Tension Cord Removal and Installation: disconnection of high-tension cord...
Page 85 Engine General Information and Diagnosis: 1A-37 Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection: in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation: monoxide (CO) in Section 1H”...
Page 86 1A-38 Engine General Information and Diagnosis: Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S4RS0A1104011 Wiring Diagram E23-3 E23-18 G28-31 BLK/ORN RED/BLK G28-16 BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT...
Page 87 Engine General Information and Diagnosis: 1A-39 Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action MIL power supply check...
Page 88 1A-40 Engine General Information and Diagnosis: Malfunction Indicator Lamp Remains ON after Engine Starts S4RS0A1104012 Wiring Diagram E23-3 E23-18 G28-31 BLK/ORN RED/BLK G28-16 BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED 39 38 32 31 39 38 32 31...
Page 89 Engine General Information and Diagnosis: 1A-41 Circuit Description When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point). Then, ECM being supplied with the main power, transmits indication ON signal of malfunction indicator lamp (MIL) to combination meter in order to turn MIL ON.
Page 90 1A-42 Engine General Information and Diagnosis: DTC P0010: Camshaft Position Actuator Circuit S4RS0A1104014 System and Wiring Diagram C37-60 YEL/RED C37-58 BLK/ORN C37-59 YEL/GRN C37-15 C37-30 [A]: 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110018- [A]: Oil flow...
Page 91 Engine General Information and Diagnosis: 1A-43 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 92 1A-44 Engine General Information and Diagnosis: Step Action Oil control valve electrical circuit check Go to Step 9. “YEL/RED” wire or “YEL/GRN” wire circuit 1) Disconnect connector from oil control valve with ignition is open or high switch turned OFF. resistance.
Page 93 1) Drive vehicle under following conditions. • Vehicle speed at 80 km/h (50 mile/h). • Gear position at 5th or D range. 2) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 5 . Is it OK? Oil control circuit visual inspection Go to Step 6.
Page 94 1A-46 Engine General Information and Diagnosis: Step Action Oil control valve check Replace camshaft Replace oil control timing sprocket. valve. 1) Check oil control valve referring to“Oil Control Valve Inspection: in Section 1D”. Is it in good condition? DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S4RS0A1104029 Wiring Diagram BLK/WHT...
Page 95 Engine General Information and Diagnosis: 1A-47 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 96 1A-48 Engine General Information and Diagnosis: Step Action HO2S-1 heater check Go to Step 8. Replace HO2S-1. 1) Disconnect HO2S-1 connector with ignition switch turned OFF. 2) Check HO2S-1 heater resistance referring to “Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On- Vehicle Inspection: in Section 1C”.
Page 97 Engine General Information and Diagnosis: 1A-49 DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Start engine and warm up to normal operating temperature. 4) Run engine at idle speed for 1 min. 5) Check DTC and pending DTC.
Page 98 1A-50 Engine General Information and Diagnosis: Step Action HO2S-2 heater check Go to Step 8. Replace HO2S-2. 1) Disconnect HO2S-2 connector with ignition switch turned OFF. 2) Check HO2S-2 heater resistance referring to “Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On- Vehicle Inspection: in Section 1C”.
Page 99 Engine General Information and Diagnosis: 1A-51 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • MAF volume is greater than 20 g/sec even if engine • Air intake system (clog or leakage) revolution is less than 900 rpm and intake manifold •...
Page 100 1A-52 Engine General Information and Diagnosis: Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. Visual inspection Go to Step 3. Repair or replace. Check MAF sensor and air intake system for: •...
Page 101 Engine General Information and Diagnosis: 1A-53 Step Action Ground circuit check “GRY” wire is open or ECM grounds “C37-58”, high resistance circuit. “C37-15” and/or “C37- 1) Measure resistance between “C37-27” terminal of ECM 30” circuit is open or connector and vehicle body ground. high resistance.
Page 102 1A-54 Engine General Information and Diagnosis: DTC P0102: Mass Air Flow Circuit Low Input S4RS0A1104017 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED E23-16 BLK/RED GRN/BLK C37-26 C37-27 BLK/YEL C37-25 C37-55 39 38 32 31 39 38...
Page 103 Engine General Information and Diagnosis: 1A-55 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 104 1A-56 Engine General Information and Diagnosis: Step Action MAF sensor signal circuit check Go to Step 9. “GRN/BLK” wire is open or high resistance 1) Measure resistance between “GRN/BLK” wire terminal circuit. of MAF and IAT sensor connector and “C37-26” terminal of ECM connector.
Page 105 Engine General Information and Diagnosis: 1A-57 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for 0.5 seconds • Open or short in MAF sensor circuit continuously. •...
Page 106 1A-58 Engine General Information and Diagnosis: Step Action MAF sensor signal circuit check Go to Step 7. “GRY/BLK” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure voltage between “GRY/BLK” wire terminal of MAF and IAT sensor connector and engine ground.
Page 107 Engine General Information and Diagnosis: 1A-59 DTC Confirmation Procedure NOTE: Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temperature at engine start: –10 C (14 F) to 80 C (176 F) •...
Page 108 1A-60 Engine General Information and Diagnosis: DTC P0107: Manifold Absolute Pressure Circuit Low Input S4RS0A1104050 Wiring Diagram GRY/RED GRY/RED C37-14 RED/BLK C37-53 C37-58 BLK/ORN C37-55 C37-15 C37-30 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110049- 1.
Page 109 Engine General Information and Diagnosis: 1A-61 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. MAP sensor and its circuit check Go to Step 3. Intermittent trouble. Check for intermittent 1) Connect scan tool to DLC with ignition switch turned referring to “Intermittent...
Page 110 1A-62 Engine General Information and Diagnosis: DTC P0108: Manifold Absolute Pressure Circuit High Input S4RS0A1104051 Wiring Diagram GRY/RED GRY/RED C37-14 RED/BLK C37-53 C37-58 BLK/ORN C37-55 C37-15 C37-30 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110049- 1.
Page 111 Engine General Information and Diagnosis: 1A-63 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 112 1A-64 Engine General Information and Diagnosis: Step Action Ground circuit check “ORN” wire is open or ECM grounds “C37-58”, high resistance circuit. “C37-15” and/or “C37- 1) Measure resistance between “C37-55” terminal of ECM 30” circuit are open or connector and vehicle body ground. high resistance.
Page 113 Engine General Information and Diagnosis: 1A-65 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference of maximum IAT minus minimum IAT is less than 0.3 C • High resistance circuit (32.5 F) while ECT is over 70 C (158 F) after 10 min from cold •...
Page 114 1A-66 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 8. Go to Step 4. 1) Disconnect MAF and IAT sensor connector (1) with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor connector (1) at “BLK/YEL”...
Page 115 Engine General Information and Diagnosis: 1A-67 Step Action Ground circuit check Go to Step 10. Go to Step 9. 1) Connect connectors to ECM. 2) Check for proper connection of MAF and IAT sensor connector at “ORN” wire terminal. 3) Measure resistance between “ORN” wire terminal of MAF and IAT sensor connector and vehicle body ground with ignition switch turned OFF.
Page 116 1A-68 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC will be set when all of following conditions are detected for • IAT sensor circuit 0.5 seconds continuously. • IAT sensor • Engine is running •...
Page 117 Engine General Information and Diagnosis: 1A-69 Step Action ECM voltage check Go to Step 6. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “BLK/YEL”...
Page 118 1A-70 Engine General Information and Diagnosis: DTC P0113: Intake Air Temperature Sensor Circuit High S4RS0A1104020 Wiring Diagram BLK/RED GRN/BLK C37-26 C37-27 C37-25 BLK/YEL C37-55 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110024- 1.
Page 119 Engine General Information and Diagnosis: 1A-71 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. IAT sensor and its circuit check Go to Step 3. Intermittent trouble. Check for intermittent 1) Connect scan tool to DLC with ignition switch turned referring to “Intermittent...
Page 120 1A-72 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 7. “BLK/YEL” wire is high resistance circuit. 1) Measure resistance between “C37-25” terminal of ECM connector and “BLK/YEL” wire terminal of MAF and IAT sensor connector with ignition switch turned OFF. Is resistance below 5 Ground circuit check Go to Step 9.
Page 121 Engine General Information and Diagnosis: 1A-73 DTC P0116: Engine Coolant Temperature Circuit Range / Performance S4RS0A1104069 Wiring Diagram LT GRN C37-24 C37-55 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110025- 1. ECT sensor 2.
Page 122 1A-74 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 123 Engine General Information and Diagnosis: 1A-75 Step Action ECM voltage check “LT GRN” wire is open Go to Step 7. circuit. 1) Turn OFF ignition switch. If wire and connection 2) Remove ECM from its bracket with ECM connectors are OK, go to Step 7. connected.
Page 124 1A-76 Engine General Information and Diagnosis: DTC P0117: Engine Coolant Temperature Circuit Low S4RS0A1104021 Wiring Diagram LT GRN C37-24 C37-55 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110025- 1. ECT sensor 2.
Page 125 Engine General Information and Diagnosis: 1A-77 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 126 1A-78 Engine General Information and Diagnosis: DTC P0118: Engine Coolant Temperature Circuit High S4RS0A1104022 Wiring Diagram LT GRN C37-24 C37-55 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110025- 1. ECT sensor 2.
Page 127 Engine General Information and Diagnosis: 1A-79 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. ECT sensor and its circuit check Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch turned OFF.
Page 128 1A-80 Engine General Information and Diagnosis: Step Action ECT sensor ground circuit check Go to Step 9. Go to Step 8. 1) Connect connectors to ECM. 2) Check for proper connection of ECT sensor connector at “ORN” wire terminal. 3) Measure resistance between “ORN” wire terminal of ECT sensor connector and vehicle body ground.
Page 129 Engine General Information and Diagnosis: 1A-81 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between actual throttle opening (detected from TP • Throttle body sensor) and opening calculated by ECM (obtained on the basis of • TP sensor engine speed and mass air flow) is out of specified range (–20 •...
Page 130 TP sensor and its circuit check Go to Step 14. Go to Step 3. 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 131 Engine General Information and Diagnosis: 1A-83 Step Action Wire harness check Faulty MAP sensor and/ Go to Step 6. or A/C refrigerant 1) Turn ignition switch to OFF position. pressure sensor, check 2) Disconnect connectors from MAP sensor and A/C MAP sensor and/or A/C refrigerant pressure sensor.
Page 132 1A-84 Engine General Information and Diagnosis: Step Action 10 Wire circuit check Go to Step 11. “GRY/RED” and/or “GRY/BLU” wire are 1) Measure resistance between “C37-14” terminal of ECM high resistance circuit. connector and “GRY/RED” wire terminal of TP sensor connector, between “C37-54”...
Page 133 Engine General Information and Diagnosis: 1A-85 DTC P0122: Throttle Position Sensor Circuit Low S4RS0A1104024 Wiring Diagram C37-14 GRY/RED GRY/RED GRY/BLU C37-54 C37-55 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110027- 1. TP sensor 3.
Page 134 1A-86 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 135 Engine General Information and Diagnosis: 1A-87 Step Action Wire harness check Faulty MAP sensor and/ Go to Step 5. or A/C refrigerant 1) Turn ignition switch to OFF position. pressure sensor, check 2) Disconnect connectors from MAP sensor and A/C MAP sensor and/or A/C refrigerant pressure sensor.
Page 136 1A-88 Engine General Information and Diagnosis: DTC P0123: Throttle Position Sensor Circuit High S4RS0A1104025 Wiring Diagram C37-14 GRY/RED GRY/RED GRY/BLU C37-54 C37-55 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110027- 1. TP sensor 3.
Page 137 Engine General Information and Diagnosis: 1A-89 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. TP sensor and its circuit check Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch turned Check for intermittent OFF and then turn ON ignition switch.
Page 138 1A-90 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 7. “GRY/BLU” wire is shorted to power circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. If wire is OK, substitute a known-good ECM and 2) Turn ON ignition switch.
Page 139 Engine General Information and Diagnosis: 1A-91 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) S4RS0A1104026 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/RED C37-46 C37-10 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 140 1A-92 Engine General Information and Diagnosis: NOTE: Check to make sure that following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temperature at engine start: –10 C (14 F) to 80 C (176 F) • Intake air temperature: –10 C (14 F) to 70 C (158 F) •...
Page 141 Engine General Information and Diagnosis: 1A-93 Step Action Wire circuit check Go to Step 6. “WHT” wire is high resistance circuit or 1) Turn OFF ignition switch. open circuit. Poor “C37- 2) Remove ECM from its bracket with ECM connectors 10”...
Page 142 1A-94 Engine General Information and Diagnosis: DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) S4RS0A1104027 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/RED C37-46 C37-10 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110029- 1.
Page 143 Engine General Information and Diagnosis: 1A-95 5) Keep above vehicle speed for 6 min. or more. (Throttle valve opening is kept constant in this step.) 6) Release accelerator pedal and with engine brake applied, keep vehicle coasting (with fuel cut for 3 sec. or more) and then stop vehicle.
Page 144 1A-96 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S voltage is higher than 0.6 V for more than 1 min • HO2S-1 continuously after warming up engine or HO2S voltage is lower •...
Page 145 Engine General Information and Diagnosis: 1A-97 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. HO2S-1 output voltage check Intermittent trouble, Go to Step 3. check for intermittent 1) Connect scan tool to DLC with ignition switch turned referring to “Intermittent OFF.
Page 146 1A-98 Engine General Information and Diagnosis: Step Action Air intake system check Check HO2S-1 referring Repair or replace air to “Heated Oxygen intake system. 1) Check air intake system for clog or leak. Sensor (HO2S-1 and Is it OK? HO2S-2) Heater On- Vehicle Inspection: in Section 1C”.
Page 147 Engine General Information and Diagnosis: 1A-99 DTC Confirmation Procedure WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 148 1A-100 Engine General Information and Diagnosis: Step Action HO2S-2 ground check Go to Step 5. “YEL” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-2 with ignition switch Poor “C37-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-2 connector at ground.
Page 149 Engine General Information and Diagnosis: 1A-101 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S4RS0A1104030 Wiring Diagram BLK/WHT E23-29 BLK/WHT RED/BLU C37-47 C37-11 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110030- 1.
Page 150 1A-102 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 151 Engine General Information and Diagnosis: 1A-103 DTC P0171 / P0172: Fuel System Too Lean / Rich S4RS0A1104032 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0171: • Vacuum leakage Total fuel trim is higher than 35% or short term fuel trim is higher •...
Page 152 1A-104 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 153 Engine General Information and Diagnosis: 1A-105 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected S4RS0A1104033 System Description ECM measures the angle of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 154 1A-106 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 155 Engine General Information and Diagnosis: 1A-107 DTC P0327 / P0328: Knock Sensor Circuit Low / High S4RS0A1104034 Wiring Diagram C37-56 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110031- 1. Knock sensor 2.
Page 156 1A-108 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 157 Engine General Information and Diagnosis: 1A-109 Step Action Knock sensor circuit for high resistance check Faulty knock sensor. “RED” wire is high resistance circuit. 1) Turn OFF ignition switch, measure resistance between “C37-56” terminal of ECM connector and “RED” wire terminal of knock sensor harness connector.
Page 158 1A-110 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Crank engine for 3 – 5 sec. 4) Check DTC and pending DTC. DTC Troubleshooting NOTE: •...
Page 159: Ground Circuit Check
Engine General Information and Diagnosis: 1A-111 Step Action Ground circuit check Go to Step 6. “BLK/ORN” wire is open or high resistance. 1) Turn ignition switch to OFF position. 2) Measure resistance between “BLK/ORN” wire terminal of CKP sensor connector and engine ground. Is measured resistance value less than 3 ? Was terminal “B+”...
Page 160 1A-112 Engine General Information and Diagnosis: System Description The CMP sensor located on the transmission side of cylinder head consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion). The signal generator generates Reference signal through slits in the slit plate which turns together with the camshaft. Reference signal The CMP sensor generates 6 pulses of signals each of which has a different waveform length while the camshaft makes one full rotation.
Page 161 Engine General Information and Diagnosis: 1A-113 Step Action Wire harness and connection check Go to Step 7. Go to Step 4. 1) Disconnect connector from CMP sensor. 2) Check for proper connection to CMP sensor at “BLK/ RED”, “RED/YEL” and “BLK/ORN” wire terminals. 3) If OK, turn ON ignition switch and check voltage at “BLK/ RED”, “RED/YEL”...
Page 162 1A-114 Engine General Information and Diagnosis: DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected S4RS0A1104037 System and Wiring Diagram I4RS0A110035- 1. EGR valve 4. Sensed information 7. “IG COIL” fuse 10. Main relay 2. Intake manifold 5.
Page 163 Engine General Information and Diagnosis: 1A-115 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0401: • EGR valve Difference in intake manifold absolute pressure between opened EGR valve • EGR passage and closed EGR valve is smaller than specified value. •...
Page 164 Go to Step 5. EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection: in Section 1B”.
Page 165 Engine General Information and Diagnosis: 1A-117 DTC P0403: Exhaust Gas Recirculation Control Circuit S4RS0A1104071 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 GRN/RED C37-4 BLK/RED C37-3 GRN/ORN BLK/RED C37-19 WHT/RED C37-18 BRN/YEL...
Page 166 1A-118 Engine General Information and Diagnosis: DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 167 Engine General Information and Diagnosis: 1A-119 DTC P0420: Catalyst System Efficiency below Threshold S4RS0A1104039 System and Wiring Diagram C37-10 C37-57 C37-11 BLU WHT I4RS0A110037- 1. HO2S-1 3. Warm up three way catalytic converter 5. ECM 2. HO2S-2 4. Three way catalytic converter Circuit Description ECM monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by HO2S-2.
Page 168 1A-120 Engine General Information and Diagnosis: DTC Confirmation Procedure WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 169 Engine General Information and Diagnosis: 1A-121 DTC P0443: Evaporative Emission System Purge Control Valve Circuit S4RS0A1104040 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED BLK/RED C37-29 BLU/BLK 39 38 32 31 39 38 32 31 54 53...
Page 170 1A-122 Engine General Information and Diagnosis: DTC Troubleshooting WARNING: In order to reduce risk of fire and personal injury, this work must be performed in a well ventilated area and away from any open flames such as gas water heater. NOTE: •...
Page 171 Engine General Information and Diagnosis: 1A-123 DTC P0462: Fuel Level Sensor Circuit Low S4RS0A1104072 Wiring Diagram 12 V YEL/RED E23-24 BLK/ORN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110039- 1. Fuel level sensor (gauge) 2.
Page 172 Fuel level sensor output signal check with SUZUKI scan Go to Step 5. Intermittent trouble or tool faulty ECM. 1) Connect SUZUKI scan tool to DLC with ignition switch Check for intermittent turned OFF. referring to “Intermittent and Poor Connection...
Page 173 System Check: ”. Does fuel level meter in combination meter indicate “E” Replenish fuel tank with Go to Step 3. (empty)? fuel and go to Step 3. Do you have SUZUKI scan tool? Go to Step 4. Go to Step 5.
Page 174 Fuel level sensor output signal check with SUZUKI scan Go to Step 6. Intermittent trouble or tool faulty ECM. 1) Connect SUZUKI scan tool to DLC with ignition switch Check for intermittent turned OFF. referring to “Intermittent and Poor Connection...
Page 175 Engine General Information and Diagnosis: 1A-127 Step Action High resistance circuit check for fuel level sensor circuit Go to Step 12. “YEL/RED” wire is high resistance circuit. 1) Disconnect connectors from ECM. 2) Measure resistance between “YEL/RED” wire terminal of fuel pump connector and “E23-24”...
Page 176 1A-128 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) Turn OFF ignition switch turned. 2) Clear DTC with ignition switch turned ON. 3) Run engine at idle speed. 4) Check pending DTC in “ON BOARD TEST” or “PENDING DTC” mode and DTC in “DTC” mode. DTC Troubleshooting Step Action...
Page 177 Engine General Information and Diagnosis: 1A-129 Step Action Wire circuit check Go to Step 8. Go to Step 5. 1) Connect radiator cooling fan relay No. 1 to relay box with ignition switch turned OFF. 2) Remove ECM from its bracket with ECM connectors connected.
Page 178 1A-130 Engine General Information and Diagnosis: Step Action Radiator cooling fan control check Go to Step 10. “BLU/RED” wire is open circuit. 1) Disconnect radiator cooling fan relay No. 2 (2) and No. 3 (3) from relay box (1) with ignition switch turned OFF. 2) Run engine until ECT is over 97.5 C, 207.5 F.
Page 179 Engine General Information and Diagnosis: 1A-131 Step Action 14 Radiator cooling fan relay No. 2 and No. 3 check “GRN” wire is open Replace relay. circuit. 1) Check radiator cooling fan relay No. 2 and No. 3 referring to “Radiator Cooling Fan Relay Inspection: in Section 1F”.
Page 180 1A-132 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Vehicle speed signal is not input while fuel is cut at • “BLK/ORN” circuit open deceleration for 4 seconds continuously at 3600 rpm or •...
Page 181 Engine General Information and Diagnosis: 1A-133 Step Action Power supply circuit check Go to Step 6. “BLK/RED” wire is open circuit. 1) With ignition switch turned OFF, disconnect connector from VSS. 2) Check for proper connection to “BLK/RED”, “PPL” and “BLK/ORN”...
Page 182 1A-134 Engine General Information and Diagnosis: Step Action VSS check Substitute a known- Replace VSS or signal good ECM and recheck. rotor. 1) Check VSS and signal rotor tooth referring to “Vehicle Speed Sensor (VSS) Inspection (M/T model): in Section 1C”.
Page 183 Engine General Information and Diagnosis: 1A-135 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 184 1A-136 Engine General Information and Diagnosis: Step Action Idle air control valve circuit check Go to Step 9. “BLK” wire is open circuit. 1) Measure resistance between “BLK” wire terminal of idle air control valve connector and vehicle body ground with ignition switch turned OFF.
Page 185 Engine General Information and Diagnosis: 1A-137 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area A/C refrigerant pressure sensor signal voltage is less than • A/C refrigerant pressure sensor circuit 0.15 V for 0.5 sec. continuously. • A/C refrigerant pressure sensor (1 driving detection logic but MIL does not light up) •...
Page 186 1A-138 Engine General Information and Diagnosis: Step Action A/C refrigerant pressure sensor signal circuit check Go to Step 7. Go to Step 6. 1) Connect connectors to ECM. 2) Turn ON ignition switch, measure voltage between engine ground and “RED” wire terminal of A/C refrigerant pressure sensor connector.
Page 187 Engine General Information and Diagnosis: 1A-139 DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Check DTC and pending DTC. Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. •...
Page 188 1A-140 Engine General Information and Diagnosis: Step Action ECM ground circuit check “ORN” wire is open or ECM grounds “C37-58”, high resistance circuit. “C37-15” and/or “C37- 1) Remove ECM from its bracket with ECM connectors 30” is open or high connected.
Page 189 Engine General Information and Diagnosis: 1A-141 DTC P0616: Starter Relay Circuit Low S4RS0A1104077 Wiring Diagram BLK/WHT E23-29 RED/WHT GRN/WHT E23-30 [A]: YEL C37-48 YEL/GRN [B]: YEL/GRN C37-58 BLK/ORN YEL/GRN C37-15 C37-30 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 190 1A-142 Engine General Information and Diagnosis: Step Action Signal circuit check Poor “C37-48” “YEL/GRN” wire is open connection or or high resistance 1) Turn OFF ignition switch. intermittent trouble. circuit. 2) Remove ECM from its bracket with ECM connectors Check for intermittent connected.
Page 191 Engine General Information and Diagnosis: 1A-143 DTC Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 192 1A-144 Engine General Information and Diagnosis: DTC P1510: ECM Back-Up Power Supply Malfunction S4RS0A1104053 Wiring Diagram WHT/RED E23-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110051- 1. ECM 2. “RADIO” fuse 3.
Page 193 Engine General Information and Diagnosis: 1A-145 Step Action Battery voltage supply circuit check Poor “E23-2” “RADIO” fuse blown, connection or “WHT” or “WHT/RED” 1) Turn OFF ignition switch. intermittent trouble. wire is open or short 2) Remove ECM from its bracket with ECM connectors circuit.
Page 194: Dtc Check
1A-146 Engine General Information and Diagnosis: Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: ”. DTC check Go to applicable DTC Substitute a known- diag. flow. good ECM and recheck.
Page 195 Engine General Information and Diagnosis: 1A-147 Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 196 1A-148 Engine General Information and Diagnosis: Step Action DTC check in ECM Go to Step 9. Substitute a known- good combination meter 1) Disconnect connector from combination meter with and recheck. ignition switch turned OFF. 2) Check ECM for DTC. Is there DTC P1674? CAN communication line circuit insulation check Go to Step 10.
Page 197 Engine General Information and Diagnosis: 1A-149 Step Action 13 CAN communication line circuit ground short check Go to Step 14. Repair short to ground of CAN communication 1) Measure resistance at following connector terminals. line circuit referring to • Between “E23-3” terminal of ECM connector and “Precaution for CAN vehicle body ground Communication...
Page 198: Combination Meter
1A-150 Engine General Information and Diagnosis: DTC P1675: CAN Communication (Transmission Error) S4RS0A1104081 Wiring Diagram E23-3 E46-1 E46-2 E23-18 G28-8 G37-4 G28-10 G37-2 C34-17 C37-13 C37-12 C34-7 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 16 15 14 13 12 11 10 9...
Page 199 Engine General Information and Diagnosis: 1A-151 Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. •...
Page 200 1A-152 Engine General Information and Diagnosis: Step Action Combination meter operation check Substitute a known- Substitute a known- good ECM and recheck. good BCM (included in 1) Check combination meter operation for seat belt warning junction block lamp (fastening and unfastening driver side seat belt) assembly), TCM and shift position indicator lamp (equipped with A/T) with (equipped with A/T) and...
Page 201 Engine General Information and Diagnosis: 1A-153 Step Action 13 Check for short circuit of CAN communication line to Substitute a known- Repair short to power power circuit good ECM and recheck. supply of CAN communication line 1) Measure voltage at following connector terminals with circuit referring to ignition switch turned ON.
Page 202 1A-154 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for TCM is • ECM detected for longer than specified time continuously • TCM (1 driving detection logic) •...
Page 203 Engine General Information and Diagnosis: 1A-155 Step Action CAN communication line circuit continuity check Go to Step 9. Repair open or high resistance of CAN 1) Disconnect connectors from ECM and TCM with ignition communication line switch turned OFF. circuit referring to 2) Measure resistance at following connector terminals.
Page 204 1A-156 Engine General Information and Diagnosis: DTC P1678: CAN Communication (Reception Error for BCM) S4RS0A1104083 Wiring Diagram E23-3 E46-1 E46-2 E23-18 G28-8 G37-4 G28-10 G37-2 C34-17 C37-13 C37-12 C34-7 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 16 15 14 13 12 11...
Page 205 Engine General Information and Diagnosis: 1A-157 Step Action DTC check Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF. 2) Check ECM, TCM (equipped with A/T) and BCM for DTC.
Page 206 1A-158 Engine General Information and Diagnosis: Step Action 10 Check for short circuit of CAN communication line to Go to Step 11. Repair short to power power circuit supply of CAN communication line 1) Measure voltage at following connector terminals with circuit referring to ignition switch turned ON.
Page 207 Engine General Information and Diagnosis: 1A-159 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P2227: • Manifold absolute pressure sensor Difference of barometric pressure value and intake manifold performance problem pressure value is higher than specified value while engine is •...
Page 208 1A-160 Engine General Information and Diagnosis: Inspection of ECM and Its Circuits S4RS0A1104055 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 209 Engine General Information and Diagnosis: 1A-161 Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V 10 – 14 V Output signal is active low BLU/ Fuel injector No.1 (“Reference C37-1 Engine running at idle...
Page 210 1A-162 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V Ignition switch turned ON. *Deflects between over 0.5 V and under Oxygen signal of 0.45 V While engine running at C37-10 heated oxygen —...
Page 211 Engine General Information and Diagnosis: 1A-163 Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *0 – 0.6 V Sensor signal is pulse. Pulse frequency varies RED/ 4 –...
Page 212 1A-164 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color C37-43 — — — — — C37-44 — — — — — C37-45 — — — — — 10 – 14 V Ignition switch turned ON. —...
Page 213 Engine General Information and Diagnosis: 1A-165 Terminal Wire Circuit Normal voltage Condition Remarks color YEL/ Oil control valve C37-59 Below 1.3 V Ignition switch turned ON. — ground *0 – 0.6 V Output signal is active 10 – 14 V YEL/ Oil control valve At the moment of ignition...
Page 214 1A-166 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color E23-17 — — — — — CAN communication line CAN (low) signal is pulse. Pulse communication line *0.5 – 2.5 V Ignition switch turned ON signal displayed with a E23-18 (active low signal) (“Reference...
Page 215 Engine General Information and Diagnosis: 1A-167 Terminal Wire Circuit Normal voltage Condition Remarks color E23-43 — — — — — E23-44 — — — — — E23-45 — — — — — Ignition switch turned ON, engine coolant temp.: below 95 C (203 F), or 10 –...
Page 216 1A-168 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Engine running, A/C switch OFF and blower 1.38 – 1.52 V selector at OFF position, A/C refrigerant pressure: 800 kPa (116 psi) Engine running, A/C switch ON and blower A/C refrigerant selector at 1st position or 2.15 –...
Page 217 Engine General Information and Diagnosis: 1A-169 Reference waveform No.2 Reference waveform No.4 No.1 fuel injector signal (2) with engine idling EGR valve signal Measurement CH1: “C37-20” to “C37-58” CH1: “C37-4” to “C37-58” terminal CH2: “C37-1” to “C37-58” Measurement CH2: “C37-3” to “C37-58” Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV terminal...
Page 218 1A-170 Engine General Information and Diagnosis: Reference waveform No.6 Reference waveform No.8 Ignition coil signal (1) with engine idling VSS signal at 30 km/h (19 mph) (for M/T model) Measurement Measurement CH1: “C37-9” to “C37-58” CH1: “C37-6” to “C37-58” terminal terminal CH2: “E23-25”...
Page 219 Engine General Information and Diagnosis: 1A-171 Reference waveform No.12 Reference waveform No.10 Heated oxygen sensor-1 heater signal (2) with engine CAN communication line signal from TCM (for A/T or idling AMT model) with ignition switch turned ON Measurement CH1: “C37-10” to “C37-57” Measurement CH1: “C37-13”...
Page 220 1A-172 Engine General Information and Diagnosis: Reference waveform No.14 Reference waveform No.16 No.4 fuel injector signal (2) with engine idling CMP sensor signal with engine idling Measurement CH1: “C37-20” to “C37-58” Measurement CH1: “C37-20” to “C37-58” terminal CH2: “C37-17” to “C37-58” terminal CH2: “C37-21”...
Page 221 Engine General Information and Diagnosis: 1A-173 Reference waveform No.20 Reference waveform No.18 EVAP canister purge valve signal IAC valve signal Measurement Measurement CH1: “C37-29” to “C37-58” CH1: “C37-49” to “C37-58” terminal terminal Oscilloscope CH1: 10 V/DIV Oscilloscope CH1: 5 V/DIV setting TIME: 40 ms/DIV setting...
Page 222 1A-174 Engine General Information and Diagnosis: Reference waveform No.22 Reference waveform No.24 Manifold absolute pressure sensor signal (1) with engine Knock sensor signal at engine speed 4000 r/min. racing Measurement CH1: “C37-56” to “C37-58” Measurement CH1: “C37-53” to “C37-55” terminal terminal CH2: “C37-54”...
Page 223 Engine General Information and Diagnosis: 1A-175 Reference waveform No.28 Reference waveform No.26 Oil control valve signal with engine racing (for M15 Ignition pulse (engine revolution) signal (2) with engine engine model) idling Measurement Measurement CH1: “C37-20” to “C37-58” CH1: “C37-60” to “C37-59” terminal terminal CH2: “E23-4”...
Page 224 1A-176 Engine General Information and Diagnosis: Reference waveform No.30 Ignition coil signal and fuel injector signal with engine cranking CH1: “C37-20” to “C37-58” Measurement CH2: “C37-6” to “C37-58” terminal CH3: “C37-1” to “C37-58” CH4: “C37-48” to “C37-58” CH1: 5 V/DIV, CH2: 5 V/DIV Oscilloscope CH3: 50 V/DIV, CH4: 10 V/DIV setting...
Page 225 Engine General Information and Diagnosis: 1A-177 Terminals Circuit Standard resistance Condition C37-4 to E23-1/16 EGR valve (stepping motor No.1 coil) 20 – 31 — C37-29 to E23-1/16 EVAP canister purge valve 28 – 35 — C37-2 to E23-1/16 No.2 fuel injector 10.8 –...
Page 226 1A-178 Engine General Information and Diagnosis: Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action Circuit fuse check...
Page 227 Engine General Information and Diagnosis: 1A-179 Step Action ECM ground circuit check Substitute a known- “BLK/ORN” or “BLK” good ECM and recheck. wire is open or high 1) Turn ignition switch to OFF position. resistance circuit. 2) Disconnect connectors from ECM. 3) Measure resistance between each “C37-58”, “C37-15”...
Page 228 1A-180 Engine General Information and Diagnosis: Step Action Sensor power source circuit check ECM power and ground Go to Step 12. circuit is in good 1) Connect connectors to ECM with ignition switch turned condition. OFF. 2) Turn ON ignition switch, measure each voltage between “C37-14”...
Page 229 Engine General Information and Diagnosis: 1A-181 Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action Fuel injector check for operating sound...
Page 230 1A-182 Engine General Information and Diagnosis: Fuel Pump and Its Circuit Check S4RS0A1104057 Wiring Diagram BLK/WHT BLK/WHT E23-29 BLK/WHT E23-15 GRN/WHT BLK/YEL C37-58 BLK/ORN BLK/RED C37-15 C37-30 BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 E23-60 BRN/WHT BLK/YEL 39 38 32 31 39 38 32 31 54 53...
Page 231 Engine General Information and Diagnosis: 1A-183 Step Action Fuel pump control system check for operation Fuel pump circuit is in Go to Step 2. good condition. Is fuel pump heard to operate 3 sec. after ignition switch is turned ON? I2RH01110132- Fuel pump relay power supply check Go to Step 3.
Page 232 1A-184 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 8. “PNK” wire is shorted to ground. 1) Turn OFF ignition switch. 2) Detach fuel tank referring to “Fuel Tank Removal and Installation: in Section 1G”. 3) Disconnect connector from fuel pump.
Page 233 Engine General Information and Diagnosis: 1A-185 Fuel Pressure Check S4RS0A1104058 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I3RM0A110081- 1. Injector 2. Delivery pipe 3. Fuel filter and fuel pump Troubleshooting NOTE: Before using the following flow, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 234 1A-186 Engine General Information and Diagnosis: Step Action Fuel line check Faulty fuel pressure Repair or replace regulator. damaged or deformed 1) Check fuel pipe, fuel hose and joint for damage or part. deform. Are they in good condition? Was fuel pressure higher than specification in Step 1? Go to Step 6.
Page 235 Engine General Information and Diagnosis: 1A-187 Troubleshooting NOTE: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”. Step Action 1) Check engine idle speed and IAC duty referring to “Idle...
Page 236 1A-188 Engine General Information and Diagnosis: Step Action Idle air control valve circuit check Replace IAC valve. Repair IAC valve circuit. 1) Check idle air control valve circuit referring to Step 4 to 10 of “DTC P0505: Idle Air Control System: ”. Is circuit in good condition? A/C System Circuits Check S4RS0A1104060...
Page 237 Engine General Information and Diagnosis: 1A-189 1. Blower fan motor 8. Radiator cooling fan motor relay 15. BCM 22. “IG ACC” fuse No.1 2. Blower fan switch 9. Radiator cooling fan motor relay 16. Evaporator outlet air temp. 23. “RDTR FAN” fuse No.2 sensor 3.
Page 238 1A-190 Engine General Information and Diagnosis: Step Action A/C evaporator outlet air temp. sensor check Go to Step 7. Faulty A/C evaporator outlet air temp. sensor 1) Disconnect connectors from ECM with ignition switch or its circuit. turned OFF. 2) Check for proper connection to “E23-57” and “E23-54” wire terminals of ECM connector.
Page 239 Engine General Information and Diagnosis: 1A-191 Step Action A/C compressor relay circuit check Go to Step 12. Go to Step 13. 1) Measure voltage between “E23-47” wire terminal of ECM connector and vehicle body ground under following conditions respectively. Voltage between “E23-47” terminal of ECM connector and ground While engine running and A/C switch turned OFF: 10 –...
Page 240 Electric load signal circuit check Electric load signal “BLU/WHT” wire is open circuit is in good circuit or short circuit, or 1) Connect SUZUKI scan tool to DLC with ignition switch condition. blower circuit turned OFF. malfunction. 2) Start engine and select “DATA LIST” mode on scan tool.
Page 241 Engine General Information and Diagnosis: 1A-193 Step Action Electric load signal circuit check Electric load signal “BLU/WHT” wire is open circuit is in good circuit or short circuit, or 1) Turn ON ignition switch. condition. electric load circuit 2) Check voltage at terminal “E23-19” of ECM connector malfunction.
Page 242 1A-194 Engine General Information and Diagnosis: Troubleshooting WARNING: Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch at the “ON”...
Page 243 Engine General Information and Diagnosis: 1A-195 Radiator cooling fan High Speed Control System Check S4RS0A1104084 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 LT GRN E23-46 BLU/RED BLU/RED C37-58 BLK/ORN C37-15 C37-30 BLU/BLK L– H– E23-48 BLUWHT LT GRN...
Page 244 1A-196 Engine General Information and Diagnosis: Step Action Is there DTC(s) of ECT sensor circuit (DTC P0116 / P0117 / Go to corresponding Go to Step 2. P0118) and/or radiator cooling fan circuit (DTC P0480)? DTC flow. Low speed radiator cooling fan control circuit check Go to Step 3.
Page 245 Engine General Information and Diagnosis: 1A-197 Step Action Radiator cooling fan control No. 2 check Go to Step 10. Go to Step 9. 1) Connect radiator cooling fan control relay No. 2 to relay box with ignition switch turned OFF. 2) Run engine when ECT is over 102.5 C, 216.5 F.
Page 246 “Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): SUZUKI scan tool...
Page 247 58413). 58413). 09912–58490 09930–76420 3-way joint & hose Timing-light (dry cell type) 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 248 Aux. Emission Control Devices Diagnostic Information and Procedures EGR System Inspection S4RS0A1204001 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu.
Page 249 “MISC TEST” mode on SUZUKI scan passage for clog when valve is switched ON and tool. OFF by using SUZUKI scan tool or service wire. If check result is not satisfactory, check vacuum Special tool hoses, EVAP canister purge valve, wire harness and (A): SUZUKI scan tool connections.
Page 250 1B-3 Aux. Emission Control Devices: Vacuum Hose Inspection WARNING: S4RS0A1206004 Check hoses for connection, leakage, clog and Do not suck the air through valve. Fuel vapor deterioration. inside valve is harmful. Replace as necessary. Special tool (A): 09917–47011 I4RS0A120005- EVAP Canister Purge Valve Inspection S4RS0A1206005 WARNING: Do not apply vacuum by mouth;...
Page 251 Aux. Emission Control Devices: 1B-4 EGR Valve Removal and Installation PCV Hose Inspection S4RS0A1206007 S4RS0A1206009 Removal NOTE: 1) Disconnect negative cable at battery. Be sure to check that there is no obstruction in PCV valve or its hoses before checking 2) Remove air intake pipe.
Page 252 1B-5 Aux. Emission Control Devices: Special Tools and Equipment Special Tool S4RS0A1208001 09917–47011 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 253 S4RS0A1306002 Using SUZUKI scan tool 1) Remove IAC valve referring to “Idle Air Control (IAC) 1) Connect SUZUKI scan tool to DLC (1) with ignition Valve Removal and Installation: ”. switch turned OFF. 2) Connect each connector to IAC valve (1) and TP sensor.
Page 254 1C-2 Engine Electrical Devices: Idle Air Control (IAC) Valve Removal and 3) Disconnect connectors from ECM as follows. Installation a) Push lock (1) to release locking of lock lever (2). S4RS0A1306003 b) Turn lock lever to arrow direction until it stops. Removal 1) Remove throttle body referring to “Throttle Body Removal and Installation: in Section 1D”.
Page 255 Engine Electrical Devices: 1C-3 5) Install MAP sensor securely. 6) Connect MAP sensor connector securely. 7) Install air cleaner assembly. Throttle Position (TP) Sensor On-Vehicle Inspection S4RS0A1306006 1) Disconnect negative cable at battery. 2) Disconnect TP sensor connector. 3) Using ohmmeter, check resistance between terminals under each condition.
Page 256 1C-4 Engine Electrical Devices: Throttle Position (TP) Sensor Removal and Engine Coolant Temperature (ECT) Sensor Installation Removal and Installation S4RS0A1306007 S4RS0A1306008 Removal Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Drain coolant referring to “Cooling System Draining: 2) Disconnect TP sensor connector and remove TP in Section 1F”.
Page 257 Engine Electrical Devices: 1C-5 Engine Coolant Temperature (ECT) Sensor Viewed from terminal side Inspection S4RS0A1306009 Immerse temperature sensing part of ECT sensor (1) in water (or ice) and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic as shown, replace ECT sensor.
Page 258 1C-6 Engine Electrical Devices: Installation Reverse removal procedure noting the following. • Tighten heated oxygen sensor (1) to specified torque. Tightening torque Heated oxygen sensor (a): 45 N·m (4.5 kg-m, 32.5 lb-ft) • Install exhaust manifold referring to “Exhaust Manifold Removal and Installation: in Section 1K”, if removed.
Page 259 Engine Electrical Devices: 1C-7 Installation 1) Install crankshaft position sensor to cylinder block. Tighten CKP sensor bolt to specified torque. Tightening torque CKP sensor bolt (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) I4RS0A130007- 2) Connect connector to CKP sensor securely. 3) Adjust generator drive belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and Adjustment: in Section 1F”.
Page 260 1C-8 Engine Electrical Devices: Performance check Performance check 1) Remove metal particles on end face of CKP sensor, 1) Remove metal particles on end face of VSS, if any. if any. 2) Arrange 12 V battery (1) and connect its positive 2) Arrange 12 V battery (1) and connect its positive terminal to “Vin”...
Page 261 Engine Electrical Devices: 1C-9 Main Relay, Fuel Pump Relay, Starting Motor Control Relay and Throttle Actuator Control Relay Inspection S4RS0A1306019 1) Disconnect negative cable at battery. 2) Remove main relay (1), fuel pump relay (3) and starting motor control relay (2) from relay box. 3) Check that there is no continuity between terminal I3RB0A130009- “C”...
Page 262 1C-10 Engine Electrical Devices: Mass Air Flow (MAF) and Intake Air Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Temperature (IAT) Sensor Inspection S4RS0A1306022 Installation S4RS0A1306021 CAUTION: CAUTION: Do not heat up MAF and IAT sensor more than 100 C (212 F).
Page 263 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Special Tool S4RS0A1308001 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 264 1D-1 Engine Mechanical: Engine Mechanical General Description Engine Construction Description S4RS0A1401001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 265 Engine Mechanical: 1D-2 Most advanced timing 60˚ (variable angle) Intake valve Exhaust valve Most retarded timing Crank angle Overlap of valves I3RH0B140002- 4. Oil passage to chamber for timing retarding 8. Oil filter 10. Oil pan 12. Oil flow 5. Oil passage to chamber for timing advancing 9.
Page 266 1D-3 Engine Mechanical: Timing Holding Cam Timing Sprocket The cam timing sprocket is equipped with the chambers When the duty ratio of the signal output from the ECM for timing advancing (2) and retarding (3) which are shows that of holding, the spool valve of the oil control separated by the rotor (5).
Page 267 Engine Mechanical: 1D-4 Driving condition Valve timing Target of control Effect Low or average To advance the closing timing of the Improvement of generating the engine speed range To the advanced intake valve in order to improve the engine torque at low and with heavy engine side volumetric efficiency.
Page 268 1D-5 Engine Mechanical: NOTE: 2) Stop engine and turn off the all electric switches. 3) Remove air cleaner case (1) and resonator (2). • For measuring compression pressure, crank engine at least 250 r/min. by using fully charged battery. • If measured compression pressure is lower than limit value, check installation condition of special tool.
Page 269 Engine Mechanical: 1D-6 Valve Lash (Clearance) Inspection S4RS0A1404003 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation: ”. 3) Remove right side engine under cover, if necessary. 4) Using 17 mm wrench, turn crankshaft pulley (1) clockwise until cam lobes (2) become perpendicular to shim faces (3) at valves “1”...
Page 270 1D-7 Engine Mechanical: WARNING: 2) Lift down the valve by turning crankshaft to 360 . 3) Hold tappet at that position using special tool as Never put in the hand between camshaft and follows. tappet. a) Remove its housing bolts. b) Check housing No.
Page 271 Engine Mechanical: 1D-8 Special tool 6) Select new shim No. (1) with a thickness as close as possible to calculated value. (A): 09916–67020 (A): 09916–67021 Available new shims No. Thickness Thickness Shim No. Shim No. mm (in.) mm (in.) 2.175 (0.0856) 2.600 (0.1024) 2.200 (0.0866) 2.625 (0.1033)
Page 272 1D-9 Engine Mechanical: Air Cleaner Element Inspection and Cleaning S4RS0A1406002 Inspection Check air cleaner element for dirt. Replace excessive dirty element. Cleaning Blow off dust by compressed air from air outlet side of element. I2RH0B140032- 9) Remove oil level gauge (1). 10) Disconnect PCV hose (2) from PCV valve (3) and disconnect breather hose (4) from cylinder head cover.
Page 273 Engine Mechanical: 1D-10 3) Install cylinder head cover to cylinder head. NOTE: When installing cylinder head cover, use care so that cylinder head cover gasket or spark plug hole gaskets will not get out of place or fall off. 4) Tightening bolts in such order as indicated in the figure a little at a time till they are tightened to specified torque.
Page 274 1D-11 Engine Mechanical: Accelerator Cable Adjustment S4RS0A1406003 With accelerator pedal depressed fully (1), check clearance between throttle lever (2) and lever stopper (3) of throttle body. If measured value is out of specification, adjust it to specification with cable adjusting nut (4), and then tighten accelerator cable locking nut to specified torque.
Page 275 Engine Mechanical: 1D-12 Throttle Body On-Vehicle Inspection NOTE: S4RS0A1406005 While disassembling and assembling throttle Check that throttle lever (1) moves smoothly. body, use special care not to deform levers on throttle valve shaft or cause damage to any other parts. Installation 1) Install IAC valve to throttle body referring to “Idle Air Control (IAC) Valve Removal and Installation: in...
Page 276 1D-13 Engine Mechanical: Throttle Body Cleaning S4RS0A1406008 Clean throttle body bore (1) and idle air passage (2) by blowing compressed air. NOTE: TP sensor, idle air control valve or other components containing rubber must not be placed in a solvent or cleaner both. A chemical reaction will cause these parts to swell, harden or get distorted.
Page 277 Engine Mechanical: 1D-14 Throttle Body and Intake Manifold Components S4RS0A1406009 I4RS0A140003- 1. Intake manifold 7. EGR pipe 13. EVAP canister purge valve 19. To PCV valve 2. Intake manifold O-ring 8. O-ring 14. EVAP canister purge valve hose 20. To cylinder head cover 3.
Page 278 1D-15 Engine Mechanical: Intake Manifold Removal and Installation Installation S4RS0A1406010 Reverse removal procedure for installation noting the followings. Removal • Use new intake manifold O-ring. 1) Remove throttle body referring to “Throttle Body • Use new EGR pipe gasket and O-ring. Removal and Installation: ”.
Page 279 Engine Mechanical: 1D-16 Engine Mountings Components S4RS0A1406012 I4RS0A140006- [A]: A/T model 10. Engine right mounting bolt 21. Engine rear mounting body bracket bolt [B]: M/T model 11. Engine left mounting bush bolt 22. Engine rear mounting No.3 bracket bolt 1. Engine right mounting bracket 12.
Page 280 1D-17 Engine Mechanical: Engine Assembly Removal and Installation • Oil control valve (10) S4RS0A1406013 • Engine oil pressure switch (11) Removal • CKP sensor (12) 1) Relieve fuel pressure according to “Fuel Pressure • Knock sensor (13) Relief Procedure: in Section 1G”. •...
Page 281 Engine Mechanical: 1D-18 20) Disconnect right and left drive shaft joints from differential gear referring to “Front Drive Shaft Assembly Removal and Installation: in Section 3A”. NOTE: For engine and transaxle removal, it is not necessary to remove drive shafts from steering knuckle.
Page 282 1D-19 Engine Mechanical: 28) Lower engine with transaxle from engine compartment. CAUTION: Before lowering engine, to avoid damage to A/C compressor and clutch operating cylinder, make clearance by rising them. Be sure not to damage suspended A/C 1, (a) compressor and clutch operating cylinder. 2, (b) I4RS0A140010- 5) Support engine assemble by using supporting...
Page 283 Engine Mechanical: 1D-20 15) Adjust A/C compressor belt tension (if equipped) 19) Refill engine with engine oil referring to “Engine Oil referring to “Compressor Drive Belt Inspection and and Filter Change: in Section 0B”. Adjustment: in Section 7B”. 20) Refill transaxle with transaxle oil referring to “Manual 16) Adjust accelerator cable play referring to Transaxle Oil Change: in Section 5B”...
Page 284 1D-21 Engine Mechanical: Timing Chain Cover Removal and Installation 7) Remove water pump pulley. S4RS0A1406015 8) Remove A/C bracket from cylinder block. CAUTION: 9) Remove oil gallery pipes No.2 (1) and No.3 (2). • Keep working table, tools and hands clean while overhauling.
Page 285 Engine Mechanical: 1D-22 NOTE: Before installing timing chain cover, check that pin is securely fitted. Tightening torque Timing chain cover bolt (a): 25 N·m (2.5 kg-m, 18.0 lb-ft) Timing chain cover nut (b): 25 N·m (2.5 kg-m, 18.0 lb-ft) 6) Apply engine oil to new O-rings (2) and install them to cap (3).
Page 286 1D-23 Engine Mechanical: Oil Control Valve Removal and Installation 13) Install crankshaft pulley (1). Tighten bolt (2) to specified torque. To lock crankshaft pulley, use S4RS0A1406043 special tool with it as shown in the figure. Removal Special tool Remove oil gallery pipe No.1 (1) and oil control valve (2) (A): 09917–68221 from timing chain cover (3).
Page 287 Engine Mechanical: 1D-24 Oil Control Valve Inspection S4RS0A1406044 Oil Control Valve 1) Inspect strainer (1) and mating surface (2) of oil control valve for clog or damage. Clean oil control valve if clog or foreign matter is present on strainer or mating surface of oil control valve.
Page 288 1D-25 Engine Mechanical: Timing Chain and Chain Tensioner Removal Installation and Installation CAUTION: S4RS0A1406018 After timing chain is removed, never turn Removal crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown CAUTION: in the figure. After timing chain is removed, never turn If turned, interference may occur between crankshaft and camshafts independently piston and valves and valves themselves,...
Page 289 Engine Mechanical: 1D-26 6) Apply engine oil to sliding surface of chain tensioner 3) Install timing chain by aligning dark blue plate (1) of timing chain and triangle mark (2) on camshaft (1) and install chain tensioner and spacer. timing sprocket as shown in the figure. Tighten tensioner bolt to specified torque.
Page 290 1D-27 Engine Mechanical: 8) Screw in plunger (1) by turning body (2) in arrow direction and install a retainer (3) (wire) to hold plunger in place. I2RH0B140065- 9) Install timing chain tensioner adjuster assembly (1) with a retainer (2). Tighten adjuster bolts to specified torque and then remove a retainer from chain tensioner adjuster assembly.
Page 291: Timing Chain
Engine Mechanical: 1D-28 Crankshaft Timing Sprocket Timing Chain Check teeth of sprocket for wear or damage. Check timing chain for wear or damage. I2RH01140077- Timing Chain Tensioner Adjuster Check that tooth surface (1) are free from damage. I2RH0B140070- I2RH0B140071- Camshaft, Tappet and Shim Components S4RS0A1406020 I4RS0A140013- 1.
Page 292 1D-29 Engine Mechanical: Camshaft, Tappet and Shim Removal and 5) Remove camshaft housings. Installation 6) Remove intake and exhaust camshafts. S4RS0A1406021 7) Remove camshaft bearing (1). CAUTION: • Keep working table, tools and hands clean while overhauling. • Use special care to handle aluminum parts so as not to damage them.
Page 293 Engine Mechanical: 1D-30 I2RH0B140078- I3RH0B140039- A: I: Intake side or E: Exhaust side 3) Install intake camshaft (1) and exhaust camshaft (2). B: Position from timing chain side Align knock pin (3) and match mark (4) with notches C: Pointing to timing chain side (5) as shown in the figure.
Page 294 1D-31 Engine Mechanical: 12) Perform Steps 3) to 8) of “Installation” of “Timing Camshaft Runout Chain Cover Removal and Installation: ”. Set camshaft between two “V” blocks, and measure its runout by using a dial gauge. If measured runout exceeds limit, replace camshaft. Camshaft, Tappet and Shim Inspection S4RS0A1406022 Camshaft runout limit...
Page 295 Engine Mechanical: 1D-32 6) Tighten camshaft housing bolts in such order as Camshaft journal diameter [A] indicated in the figure a little at a time till they are Item Standard tightened to specified torque. Intake side No.1 26.940 – 26.955 mm housing (1.0606 –...
Page 296 1D-33 Engine Mechanical: Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head. Cylinder head to tappet clearance Standard: 0.025 – 0.066 mm (0.0010 – 0.026 in.) Limit: 0.15 mm (0.0059 in.) Tappet outside diameter [A] Standard: 30.959 –...
Page 297 Engine Mechanical: 1D-34 Valves and Cylinder Head Components S4RS0A1406023 I4RS0A140015- 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2. Valve spring retainer 8.
Page 298 1D-35 Engine Mechanical: Valves and Cylinder Head Removal and Installation Installation 1) Clean mating surface of cylinder head and cylinder S4RS0A1406024 block. Remove oil, old gasket and dust from mating surface. Removal 2) Install knock pins (1) to cylinder block. 1) Remove engine assembly from vehicle referring to 3) Install new cylinder head gasket (2) to cylinder block.
Page 299 Engine Mechanical: 1D-36 NOTE: Be sure to tighten M8 bolt “A” after securing “A” “B” the other bolts. Tightening torque Cylinder head bolt for M8 (a): 25 N·m (2.5 kg- “a” m, 18.0 lb-ft) “b” Cylinder head bolt for M10 (b): 20 N m (2.0 kg-m, 14.5 lb-ft), 40 N m (4.0 kg-m, 29.0 lb-ft) and then retighten by turning through to 60 twice...
Page 300 1D-37 Engine Mechanical: Valves and Cylinder Head Disassembly and NOTE: Assembly Do not reuse valve stem seal once S4RS0A1406025 disassembled. Be sure to use new seal when assembling. Disassembly 1) For ease in servicing cylinder head, remove intake manifold, injectors, exhaust manifold from cylinder head.
Page 301 Engine Mechanical: 1D-38 I2RH0B140096- I2RH0B140096- 2) Install valve guide to cylinder head. 4) Install valve spring seat to cylinder head. Heat cylinder head uniformly at a temperature of 80 5) Install new valve stem seal (1) to valve guide. to 100 C (176 to 212 F) so that head will not be After applying engine oil to seal and spindle of distorted, and drive new valve guide into hole with special tool (Valve guide installer handle), fit oil seal...
Page 302 1D-39 Engine Mechanical: 8) Using special tools (Valve lifter), compress valve spring and fit two valve cotters (1) into groove in valve stem. NOTE: When compressing the valve spring, be carefully to free from damage in inside face of tappet installing hole. Special tool (A): 09916–14510 (B): 09916–14521...
Page 303 Engine Mechanical: 1D-40 I3RM0A140035- Valve stem end deflection If bore gauge is not available, check end deflection of valve stem with a dial gauge instead. Move stem end in directions (1) and (2) to measure end deflection. If deflection exceeds its limit, replace valve stem and valve guide.
Page 304 1D-41 Engine Mechanical: Valve head radial runout Valve seat repair Check each valve for radial runout with a dial gauge and A valve seat not producing a uniform contact with its “V” block. To check runout, rotate valve slowly. If runout valve or showing width of seating contact that is out of exceeds its limit, replace valve.
Page 305 Engine Mechanical: 1D-42 Cylinder Head Inspection S4RS0A1406027 • Remove all carbon deposits from combustion chambers. NOTE: Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, too. I2RH0B140106- •...
Page 306 1D-43 Engine Mechanical: Valve spring preload Spring Squareness Standard: 107 – 125 N (10.7 – 12.5 kg) for 31.50 mm Use a square and surface plate to check each spring for (23.6 – 27.6 lb/1.240 in.) squareness in terms of clearance between end of valve Limit: 102 N (10.2 kg) for 31.50 mm (22.5 lb/1.240 in.) spring and square.
Page 307 Engine Mechanical: 1D-44 Pistons, Piston Rings, Connecting Rods and 3) When installing piston and connecting rod assembly into cylinder bore, point front mark (1) on piston head Cylinders Removal and Installation to crankshaft pulley side. S4RS0A1406030 Removal 1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation: ”.
Page 308 1D-45 Engine Mechanical: NOTE: b) Force piston pin out. Before installing bearing cap, make sure that checking for connecting rod bolt deformation. Refer to “Piston Pins and Connecting Rods Inspection: ”. Tightening torque Connecting rod bearing cap nut (a): 15 N m (1.5 kg-m, 11.0 lb-ft) and then retighten by turning through 45 twice I2RH0B140114-...
Page 309 Engine Mechanical: 1D-46 NOTE: If any one of four cylinders has to be rebored, rebore all four to the same next oversize. This is necessary for the sake of uniformity and balance. I2RH0B140116- 4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure.
Page 310 1D-47 Engine Mechanical: Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. NOTE: Cylinder bore diameters used here are measured in thrust direction at two positions.
Page 311 Engine Mechanical: 1D-48 Piston Pins and Connecting Rods Inspection Connecting Rod S4RS0A1406033 Big-end side clearance Piston Pin Check big-end of connecting rod for side clearance, with rod fitted and connected to its crank pin in the normal Visual inspection manner. If measured clearance is found to exceed its Check piston pin, connecting rod small end bore and limit, replace connecting rod.
Page 312 1D-49 Engine Mechanical: Crank Pin and Connecting Rod Bearings Connecting rod bolt deformation (Plastic deformation tightening bolt) Inspection Measure each thread diameter of connecting rod bolt (2) S4RS0A1406034 at “A” on 32 mm (1.25 in.) from bolt mounting surface Crank Pin Diameter and “B”...
Page 313 Engine Mechanical: 1D-50 Connecting Rod Bearing General Information 4) Install rod bearing cap (1) to connecting rod. Service connecting rod bearings are available in When installing cap, be sure to point arrow mark (2) standard size and 0.25 mm (0.0098 in.) undersize on cap to crankshaft pulley side, as shown in the bearing, and standard size bearing has 5 kinds of figure.
Page 314 1D-51 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 the NOTE: figure. Three kinds of alphabet (“A”, “B” and “C”) represent • If bearing is in malcondition, or bearing the following crankshaft pin diameter respectively.
Page 315 Engine Mechanical: 1D-52 I3RH0A140019- 1. Paint 4) From number stamped on connecting rod and its cap and alphabets stamped on crank web No.3, determine new standard bearing to be installed to connecting rod big end inside, by referring to the table.
Page 316 1D-53 Engine Mechanical: Main Bearings, Crankshaft and Cylinder Block Components S4RS0A1406035 I4RS0A140016-...
Page 317 Engine Mechanical: 1D-54 1. CKP sensor (if equipped) 11. Rear oil seal 21. Oil filter adapter bolt : See “A” 2. Knock sensor 12. Input shaft bearing 22. Spring pin 3. Cylinder block 13. Flywheel 23. Sensor plate bolt 4. Venturi plug 14.
Page 318 1D-55 Engine Mechanical: 6) Install bearing cap to cylinder block, making sure to 1) Install sensor plate (1) to crankshaft (2) and tighten bolts to specified torque. point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, NOTE: 3, 4 and 5, starting from pulley side.
Page 319 Engine Mechanical: 1D-56 10) Install flywheel (for M/T). Using special tool, lock flywheel, and tighten flywheel bolts to specified torque. NOTE: Use new flywheel bolts. Special tool (A): 09924–17810 Tightening torque Flywheel bolt (a): 70 N·m (7.0 kg-m, 51.0 lb-ft) I4RS0A140017- 8) Apply sealant to mating surface of rear oil seal housing (1).
Page 320 1D-57 Engine Mechanical: Crankshaft Thrust Play 3) Use a dial gauge to read displacement in axial (thrust) direction of crankshaft. 1) Measure this play with crankshaft set in cylinder If its limit is exceeded, replace thrust bearing with block in the normal manner, that is with thrust new standard one or oversize one to obtain standard bearing (1) and journal bearing caps installed.
Page 321 Engine Mechanical: 1D-58 Main Bearings Inspection 4) Tighten main bearing cap No.1 bolts (1) – (10) and S4RS0A1406038 main bearing cap No.2 bolts (11) – (20) gradually as follows. General Information a) Tighten bolts (1) – (10) to 30 N m (3.0 kg-m, 22.0 •...
Page 322 1D-59 Engine Mechanical: Selection of Main Bearings 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five Standard bearing alphabets are stamped as shown in the figure. If bearing is in malcondition, or bearing clearance is out Three kinds of alphabets (“A”, “B”...
Page 323 Engine Mechanical: 1D-60 I2RH01140191- 1. Paint 4) From number stamped on crank web No.2 and alphabets stamped on cylinder block, determine new standard bearing to be installed to journal, by referring to the table shown. For example, if number stamped on crank web No.2 is “1” and alphabet stamped on cylinder block is “B”, install a new standard bearing painted in “Brown”...
Page 324 1D-61 Engine Mechanical: 6) When replacing crankshaft or cylinder block due to any reason, select new standard bearings to be installed by referring to number stamped on new crankshaft or alphabets stamped on new cylinder block. Undersize bearing (0.25 mm (0.0098 in.)) •...
Page 325 Engine Mechanical: 1D-62 New undersize crankshaft main bearing specification Measured journal diameter 51.7320 – 51.7379 mm 51.7380 – 51.7439 mm 51.7440 – 51.7500 mm (2.0367 – 2.0369 in.) (2.0370 – 2.0371 in.) (2.0372 – 2.0373 in.) A (1) Red and Green Red and Brown Red and Purple Alphabets stamped...
Page 326 1D-63 Engine Mechanical: Sensor Plate Inspection Cylinder Block Inspection S4RS0A1406039 S4RS0A1406042 Check sensor plate for crack damage. If malcondition is found, replace it. Distortion of Gasketed Surface Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct It.
Page 327 Engine Mechanical: 1D-64 Specifications Tightening Torque Specifications S4RS0A1407001 Tightening torque Fastening part Note kg-m lb-ft Camshaft housing bolts (for tightening of special tool) Camshaft housing bolt Cylinder head cover bolt Accelerator cable locking nut EVAP canister purge valve bracket bolt Engine left mounting bracket nut 40.0 Engine right mounting nut...
Page 328 1D-65 Engine Mechanical: Special Tools and Equipment Recommended Service Material S4RS0A1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE: Required service material is also described in the following.
Page 329 Engine Mechanical: 1D-66 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310 Tappet holder Piston ring compressor (50- 125 mm) 09916–84511 09917–68221...
Page 330 1E-1 Engine Lubrication System: Engine Lubrication System General Description Engine Lubrication Description S4RS0A1501001 The oil pump is of a trochoid type, and mounted on the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into two paths in cylinder block.
Page 331 Engine Lubrication System: 1E-2 I3RH0B150001-...
Page 332 1E-3 Engine Lubrication System: Diagnostic Information and Procedures Oil Pressure Check 3) Disconnect oil pressure switch coupler (1). S4RS0A1504001 4) Remove oil pressure switch (2) from cylinder block. NOTE: Prior to checking oil pressure, check the following. • Oil level in oil pan If oil level is low, add oil up to Full level mark (hole) (1) on oil level gauge referring to “Engine Oil and Filter Change: in...
Page 333 Engine Lubrication System: 1E-4 10) Start engine and check oil pressure switch for oil 9) Before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and leakage. If oil leakage is found, repair it. tighten switch to specified torque.
Page 334 1E-5 Engine Lubrication System: Oil Pan and Oil Pump Strainer Removal and Installation Installation 1) Install new O-rings (2) in the position as shown in the S4RS0A1506002 figure and install oil pump strainer (1). Tighten strainer bolt (3) first and then bracket bolt (4) Removal to specified torque.
Page 335 Engine Lubrication System: 1E-6 4) Install oil pan to cylinder block temporarily. 9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.1 5) Insert knock pin (1) in hole (2) of oil pan in order to (connector color: green) (3) referring to “Exhaust locate oil pan precisely.
Page 336 1E-7 Engine Lubrication System: Oil Pump Components S4RS0A1506004 I4RS0A150010- 1. Rotor plate 6. Rotor plate bolt 10. Circlip 2. O-ring 7. Relief valve : 11 N m (1.1 kg-mm 8.0 lb-ft) 3. Outer rotor 8. Spring : Do not reuse. 4.
Page 337 Engine Lubrication System: 1E-8 Oil Pump Inspection Reassembly S4RS0A1506007 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
Page 338 1E-9 Engine Lubrication System: Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure. If the measured valve spring length is lower If clearance exceeds its limit, replace outer rotor or case.
Page 339 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 S4RS0A1508001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE: Required service material is also described in the following.
Page 340: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System General Description Cooling System Description This 50/50 mixture coolant solution provides freezing S4RS0A1601001 protection to –36 C (–33 F). The cooling system consists of the radiator cap, radiator, • Maintain cooling system freeze protection at –36 C (– coolant reservoir, hoses, water pump, cooling fan and 33 F) to ensure protection against corrosion and loss thermostat.
Page 341 Engine Cooling System: 1F-2 Schematic and Routing Diagram Coolant Circulation S4RS0A1602001 While the engine is warmed up (thermostat closed), coolant circulates as follows. I3RM0A160001- 1. Radiator inlet hose 5. Thermostat 9. Heater core inlet hose 2. Radiator outlet hose 6. Water pump 10.
Page 342 1F-3 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S4RS0A1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 343 Engine Cooling System: 1F-4 Repair Instructions Cooling System Components S4RS0A1606001 I4RS0A160001- 1. Radiator 13. Thermostat case 25. Heater outlet No.1 hose 2. Reservoir 14. Thermostat 26. Engine cooling fan assembly 3. Radiator cap 15. Thermostat cap 27. Water bypass No.2 hose 4.
Page 344 1F-5 Engine Cooling System: Coolant Level Check 3) Check coolant for proper level and freeze protection. S4RS0A1606002 4) Using a pressure tester (1), check system and WARNING: radiator cap (2) for proper pressure holding capacity. To help avoid danger of being burned, do not If replacement of cap is required, use a proper cap remove radiator cap while engine and for this vehicle.
Page 345 Engine Cooling System: 1F-6 Cooling System Flush and Refill 13) Tighten air ventilation bolt (4) to specified torque. S4RS0A1606004 Tightening torque WARNING: Air ventilation bolt (a): 4.5 N·m (0.45 kg-m, 3.5 To help avoid danger of being burned, do not lb-ft) remove radiator cap while engine and 14) Fill radiator with coolant up to bottom of radiator filler...
Page 346 1F-7 Engine Cooling System: Cooling Water Pipes or Hoses Removal and 6) Remove water inlet pipe with thermostat cap from thermostat case. Installation S4RS0A1606005 7) Remove thermostat from thermostat case (3). Removal 1) Drain coolant referring to “Cooling System Draining: ”.
Page 347 Engine Cooling System: 1F-8 Thermostat Inspection Radiator Cooling Fan Motor On-Vehicle S4RS0A1606007 Inspection • Make sure that air bleed valve (1) of thermostat is S4RS0A1606010 clean. 1) Check low speed operation of radiator cooling fan as Should this valve be clogged, engine would tend to follows.
Page 348 1F-9 Engine Cooling System: Radiator Cooling Fan Relay Inspection 3) Drain coolant. S4RS0A1606020 4) Remove front bumper, front bumper upper absorber 1) Disconnect negative (–) cable at battery. and upper member referring to “Front Bumper and 2) Remove radiator cooling fan relay No.1 (1), No.2 (2) Rear Bumper Components: in Section 9K”.
Page 349 Engine Cooling System: 1F-10 Radiator Removal and Installation NOTE: S4RS0A1606014 When replacing belt with a new one, adjust belt tension to 3 – 4 mm (0.12 – 0.16 in.). Removal 1) Disconnect negative cable at battery. 2) Drain A/T fluid. 3) Drain coolant.
Page 350 1F-11 Engine Cooling System: Water Pump / Generator Drive Belt Removal and Water Pump Removal and Installation S4RS0A1606017 Installation Removal S4RS0A1606016 Removal 1) Disconnect negative cable at battery. 1) Disconnect negative cable at battery. 2) Drain coolant. 2) If vehicle equipped with A/C, remove compressor 3) Remove water pump / generator drive belt referring drive belt (4) before removing water pump belt (1).
Page 351 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 S4RS0A1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 352: Fuel System
1G-1 Fuel System: Fuel System Precautions Precautions on Fuel System Service S4RS0A1700001 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. • Disconnect negative cable at battery. •...
Page 353 Fuel System: 1G-2 Fuel Pump Description S4RS0A1701003 The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) and a fuel pressure regulator (3) are included and a fuel level gauge (4) is attached. Addition of the fuel pressure regulator to the fuel pump makes it possible to maintain the fuel pressure at constant level and ECM controls compensation for...
Page 354 1G-3 Fuel System: WARNING: 3) Connect special tools and hose between fuel feed hose (1) and fuel delivery pipe as shown in the As fuel feed line is still under high fuel figure, and clamp hoses securely in order to ensure pressure, make sure to release fuel pressure that no leaks occur during checking.
Page 355: Fuel System Components
Fuel System: 1G-4 Repair Instructions Fuel System Components S4RS0A1706001 I4RS0A170003- 1. Fuel tank 10. Fuel tank belt 19. Fuel delivery pipe insulator 2. Fuel pump assembly 11. Fuel pump gasket 20. Wire harness for fuel pump 3. Breather hose 12. Fuel tank bolt 21.
Page 356 1G-5 Fuel System: 7. Fuel vapor line 16. Fuel delivery pipe bolt : 11 N m (1.1 kg-m, 8.0 lb-ft) 8. Fuel tank inlet valve 17. Fuel injector : 25 N m (2.5 kg-m, 18.0 lb-ft) 9. Fuel tank protector 18.
Page 357 Fuel System: 1G-6 1. Pipe 5. Vehicle leftward “d” 30 mm (1.18 in.) 2. Hose “a” 3 – 7 mm (0.12 – 0.28 in.) “e” 38 mm (1.50 in.) 3. Clamp “b” 5 – 12 mm (0.20 – 0.48 in.) : 2 N m (0.2 kg-m, 1.5 lb-ft) 4.
Page 358 1G-7 Fuel System: Fuel Pressure Relief Procedure Fuel Lines On-Vehicle Inspection S4RS0A1706002 S4RS0A1706004 CAUTION: CAUTION: This work must not be done when engine is Due to the fact that fuel feed line (1) is under hot. If done so, it may cause adverse effect to high pressure, use special care when catalyst.
Page 359 Fuel System: 1G-8 Installation Fuel Injector Removal and Installation S4RS0A1706007 1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with WARNING: new one. Before starting the following procedure, be 2) Install pipes with pipe clamps to vehicle.
Page 360 1G-9 Fuel System: Fuel Injector Inspection Installation Reverse removal procedure for installation noting the S4RS0A1706008 following. WARNING: • Replace injector O-ring (1) with new one using care Before starting the following procedure, be not to damage it. sure to observe “Precautions on Fuel System •...
Page 361 8) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should Special tool be at work). If fuel leaks (1) more than the following (A): SUZUKI scan tool specifications, replace. Fuel leakage Less than 1 drop/min.
Page 362 1G-11 Fuel System: Fuel Tank Inlet Valve Removal and Installation 4) Remove fuel tank inlet valve (1) using flat head rod S4RS0A1706015 (2) or the like. WARNING: CAUTION: Before starting the following procedure, be sure to observe “Precautions on Fuel System Be careful not to damage fuel tank inlet valve Service: ”...
Page 363 Fuel System: 1G-12 Fuel Tank Inlet Valve Inspection 7) Disconnect fuel pipe joint and fuel hoses (1) from S4RS0A1706016 fuel pipes (2) referring to “Fuel Hose Disconnecting and Reconnecting: ”. WARNING: Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ”...
Page 364 1G-13 Fuel System: Installation 6) Install exhaust center pipe referring to “Exhaust Pipe and Muffler Removal and Installation: in Section CAUTION: 1K”. • When connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
Page 365 Fuel System: 1G-14 Fuel Pump On-Vehicle Inspection Fuel Pump Assembly Removal and Installation S4RS0A1706017 S4RS0A1706019 WARNING: WARNING: Before starting the following procedure, be Before starting the following procedure, be sure to observe “Precautions on Fuel System sure to observe “Precautions on Fuel System Service: ”...
Page 366 1G-15 Fuel System: Fuel Level Sensor Removal and Installation S4RS0A1706022 CAUTION: • Do not touch resister plate (1) and deform arm (2). It may cause fuel level sensor to fail. • Be very careful not to cause damage to fuel tube installed section (sealed section in bore).
Page 367 Fuel System: 1G-16 Fuel Pump Inspection S4RS0A1706021 • Check fuel pump assembly for damage. • Check fuel suction filter (1) for evidence of dirt and contamination. If present, replace or clean and check for presence of dirt in fuel tank. •...
Page 368 58413). 58413). 09912–58490 09919–47020 3-way joint & hose Quick joint remover 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 loopback adapter, 7.
Page 369: Ignition System
1H-1 Ignition System: Ignition System General Description Ignition System Construction S4RS0A1801001 The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 370 Ignition System: 1H-2 Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S4RS0A1802001 BLK/WHT GRN/WHT C37-5 C37-6 GRN/YEL BLK/WHT E23-29 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED E23-16 BLK/RED C37-58 BLK/ORN RED/YEL C37-20 C37-15 C37-30 C37-21 BLK/ORN 39 38 32 31 39 38 32 31...
Page 371 1H-3 Ignition System: Component Location Ignition System Components Location S4RS0A1803001 I4RS0A180002- 1. ECM 7. ECT sensor 13. Data link connector 2. Ignition coil assembly for No.1 and No.4 8. MAF and IAT sensor 14. Main relay box spark plugs 3. Ignition coil assembly for No.2 and No.3 9.
Page 372 Ignition System: 1H-4 Diagnostic Information and Procedures Ignition System Symptom Diagnosis S4RS0A1804001 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 373 1H-5 Ignition System: Ignition System Check S4RS0A1804003 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check: in Section 1A”. Ignition spark test Go to Step 11. Go to Step 3. 1) Check all spark plugs for condition and type referring to “Spark Plug Inspection: ”.
Page 374 Ignition System: 1H-6 Step Action 12 Knock sensor check Go to Step 13. Substitute a known- good knock sensor and 1) Confirm that knock sensor circuit is in good condition recheck. referring to “DTC P0327 / P0328: Knock Sensor Circuit Low / High: in Section 1A”...
Page 375 1H-7 Ignition System: Repair Instructions High-Tension Cord Removal and Installation S4RS0A1806001 Removal 1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover. 2) Disconnect No.1 cylinder (2) and No.3 cylinder (3) high-tension cords from ignition coil assemblies (1) while gripping each cap.
Page 376 Ignition System: 1H-8 Spark Plug Removal and Installation Ignition Coil Assembly (Including ignitor) S4RS0A1806003 Removal and Installation Removal S4RS0A1806005 Removal 1) Remove air cleaner assembly with air intake pipe and cylinder head upper cover. 1) Disconnect negative cable at battery. 2) Pull out high-tension cords by gripping their caps 2) Remove air cleaner assembly with air intake pipe and then remove ignition coil assemblies referring to...
Page 377 Inspection specification. S4RS0A1806006 Measure secondary coil for resistance. Initial ignition timing (fixed with SUZUKI scan If resistance is out of specification, replace ignition coil tool) assembly. 3 BTDC (at specified idle speed)
Page 378 For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”. Special Tools and Equipment Special Tool S4RS0A1808001 09930–76420 SUZUKI scan tool Timing-light (dry cell type) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 379: Starting System
1I-1 Starting System: Starting System Schematic and Routing Diagram Cranking System Circuit Diagram S4RS0A1902001 I4RS0A190001- 1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch 2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery 3. Magnetic switch 8.
Page 380 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 381 1I-3 Starting System: Condition Possible cause Correction / Reference Item Starting motor does not Fused contact points of magnetic switch Replace magnetic switch. stop running Short-circuit between turns of magnetic Replace magnetic switch. switch coil (layer short-circuit) Failure of returning action in ignition Replace.
Page 382 Starting System: 1I-4 Repair Instructions Starting Motor Dismounting and Remounting S4RS0A1906001 I4RS0A190002- : 9.8 N m (0.98 kg-m, 7.0 lb-ft) Dismounting 1) Disconnect negative (–) battery lead at battery. 2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) Detach shift &...
Page 383 1I-5 Starting System: Starting Motor Components S4RS0A1906002 I4RS0A190003- 1. Front housing 8. Seal rubber 15. Yoke : Do not reuse. 2. Bush 9. Magnetic switch 16. Armature : Apply grease 99000-25010 to sliding surface of each part. 3. Pinion stop ring 10.
Page 384 Starting System: 1I-6 Starting Motor Inspection S4RS0A1906003 Plunger Inspect plunger for wear. Replace if necessary. I2RH01190011- Rear Bracket Bush Inspect bush for wear or damage. Replace if necessary. I2RH01190008- Magnetic Switch Push in plunger and release it. The plunger should return quickly to its original position.
Page 385 1I-7 Starting System: Brush Holder • Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for contamination. Clean or correct as necessary. • Check for continuity across insulated brush (positive side) and grounded brush (negative side).
Page 386 Starting System: 1I-8 • Check the commutator and armature core. If there is continuity, the armature is grounded and must be replaced. I2RH01190022- • Inspect the spline teeth for wear or damage. Replace if necessary. I2RH01190019- Inspect the pinion for smooth movement. •...
Page 387 1I-9 Starting System: Specifications Cranking System Specifications S4RS0A1907002 Voltage 12 volts Output 1.2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.) Number of pinion teeth Performance Condition Guarantee...
Page 388: Charging System
Charging System: 1J-1 Charging System General Description Battery Description • Clear or light yellow S4RS0A1A01001 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 389 1J-2 Charging System: • When keeping battery on vehicle over a long 2) Keep the battery cable connections clean. period of time, follow instructions given below. The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The product –...
Page 390 Charging System: 1J-3 I2RH0B1A0002- 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 391 1J-4 Charging System: Charging Indicator Lamp Operation Condition Possible cause Correction / Reference Item Charge light does not Fuse blown Check fuse. light with ignition ON and Indicator lamp (LED) faulty Replace combination meter. engine off Wiring connection loose Tighten loose connection. IC regulator or field coil faulty Check generator.
Page 392 Charging System: 1J-5 Generator Test (Overcharged Battery Check) 3) Ground “F” terminal and start engine, then measure voltage at “B” terminal as shown in the figure. S4RS0A1A04004 1) To determine battery condition, refer to “Battery • Voltage is higher than standard value. It is Description: ”.
Page 393 1J-6 Charging System: Repair Instructions Jump Starting in Case of Emergency With Charging Equipment S4RS0A1A06001 With Auxiliary (Booster) Battery CAUTION: When jump starting engine with charging CAUTION: equipment, be sure equipment used is 12- If vehicle is manual transaxle model and has volt and negative ground.
Page 394 Charging System: 1J-7 Generator Dismounting and Remounting S4RS0A1A06003 1) Disconnect negative cable at battery. 2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation: in Section 3A” 3) Dismount in numerical order as shown in the figure. 4) Reverse dismounting procedure for remounting.
Page 395 1J-8 Charging System: Generator Components S4RS0A1A06004 I4RS0A1A0004- 1. Pulley nut 7. Bearing retainer 13. Seal plate 19. Brush holder cover : 3.6 N m (0.36 kg-m, 3.0 lb-ft) 2. Pulley 8. Rotor 14. Rectifier 20. Rear end cover : 2.0 N m (0.2 kg-m, 1.5 lb-ft) 3.
Page 396 Charging System: 1J-9 Generator Inspection Stator S4RS0A1A06005 1) Using an ohmmeter, check all leads for continuity. If there is no continuity, replace the stator. Rotor 1) Using an ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace the rotor.
Page 397 1J-10 Charging System: Rectifier 1) Using an ohmmeter, connect one tester probe to the “B” terminal (1) and the other to each rectifier terminal (2). I1JA011A0002- 2) Reverse the polarity of the tester probes and repeat Step 1). 3) Check that one shows continuity and the other shows no continuity.
Page 398 Charging System: 1J-11 Specifications Charging System Specifications S4RS0A1A07002 Battery Battery type 46B24R Rated capacity AH/5HR, 12 Volts Electrolyte L (US / lmp pt.) 3.2 (6.76 / 5.63) Generator Type 70 A type Rated voltage 12 V Nominal output 70 A Permissible max.
Page 399: Exhaust System
Exhaust System: 1K-1 Exhaust System General Description Exhaust System Description S4RS0A1B01001 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 400 1K-2 Exhaust System: Repair Instructions Exhaust System Components S4RS0A1B06001 WARNING: To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I4RS0A1B0001- [A]: Installing location of exhaust manifold bold and 11.
Page 401 Exhaust System: 1K-3 Exhaust Manifold Removal and Installation 9) Remove exhaust manifold (1) and its gasket from S4RS0A1B06003 cylinder head. Removal WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down.
Page 402 1K-4 Exhaust System: Exhaust Pipe and Muffler Removal and 4) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust No.2 pipe. Tighten pipe fasteners to Installation specified torque. S4RS0A1B06004 For replacement of exhaust pipe, be sure to hoist vehicle Tightening torque and observe WARNING under “Exhaust System Exhaust No.2 pipe bolt (c): 43 N·m (4.3 kg-m,...
Page 403 Exhaust System: 1K-5 Specifications Tightening Torque Specifications S4RS0A1B07001 Tightening torque Fastening part Note kg-m lb-ft Exhaust manifold bolt 36.5 Exhaust manifold nut 36.5 Exhaust No.1 pipe bolt 36.5 Exhaust manifold stiffener bolt 36.5 Exhaust No.2 pipe bolt 31.0 NOTE: The specified tightening torque is also described in the following. “Exhaust System Components: ”...
Page 404 1K-6 Exhaust System:...
Page 405 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Special Tools and Equipment ......2B-20 Special Tool ............2B-20 Precautions............. 2-1 Precautions on Suspension ........2-1 Rear Suspension ........2C-1 Suspension General Diagnosis....2A-1 General Description ..........2C-1 Rear Suspension Construction ......2C-1 Diagnostic Information and Procedures....2A-1 Component Location ...........2C-2 Suspension, Wheels and Tires Symptom...
Page 406 2-ii Table of Contents Tire Rotation............2D-5 Specifications ............2D-7 Wheel Removal and Installation......2D-6 Wheels and Tires Specifications ......2D-7 Tire Mounting and Dismounting ......2D-6 Tightening Torque Specifications......2D-7 Tire Repair ............2D-6...
Page 407 Precautions: Precautions Precautions Precautions on Suspension S4RS0A2000001 Suspension Caution Refer to “Suspension Caution: in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution: in Section 00”. General Precautions Refer to “General Precautions: in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points: in Section 0A”.
Page 408 2A-1 Suspension General Diagnosis: Suspension General Diagnosis Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S4RS0A2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tire. Tires not adequately inflated Adjust tire pressure. Broken or sagging springs Replace spring.
Page 409 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes. Faulty struts (shock absorbers) or Replace strut or tighten mounting. mountings Broken or sagging springs Replace.
Page 410 2A-3 Suspension General Diagnosis: Specifications Wheel Alignment Specifications S4RS0A2107001 Wheel alignment specifications Item Front Rear Front toe (“B” – “A”) (total) IN 0 + 1.0 / –0.5 mm (IN 0 + IN 5.2 5.2 mm (0.205 Rear toe (Non adjustable, for reference only) 0.0394 / –0.0197 in.) 0.205 in.) Camber “C”...
Page 411: Front Suspension
Front Suspension: 2B-1 Front Suspension General Description Front Suspension Construction S4RS0A2201001 I4RS0A220001- 1. Strut assembly 7. Drive shaft : 50 N m (5.0 kg-m, 36.5 lb-ft) : 23 N m (2.3 kg-m, 17.0 lb-ft) 2. Stabilizer bar 8. Tie-rod : 105 N m (10.5 kg-m, 76.0 lb-ft) : 85 N m (8.5 kg-m, 61.5 lb-ft) 3.
Page 412 2B-2 Front Suspension: Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S4RS0A2201002 excessive looseness is noted, it must be corrected Among factors for front wheel alignment, only toe setting before adjusting. can be adjusted. Camber and caster can be adjusted. •...
Page 413 Front Suspension: 2B-3 3) After adjustment, tighten lock nuts (1) to specified torque. Tightening torque Tie-rod end lock nut (a): 45 N·m (4.5 kg-m, 32.5 lb-ft) NOTE: Make sure that rack boots are not twisted. I3RH0A220003- Reference Information Side slip When checked with side slip tester, side slip should satisfy following specification.
Page 414 2B-4 Front Suspension: Front Strut Assembly Components S4RS0A2206005 I4RS0A220002- 1. Strut assembly 6. Strut bearing 11. Strut bracket nut : 105 N m (10.5 kg-m, 76.0 lb-ft) 2. Coil spring 7. Strut support 12. Stabilizer joint nut : 50 N m (5.0 kg-m, 36.5 lb-ft) 3.
Page 415 Front Suspension: 2B-5 NOTE: NOTE: When servicing component parts of strut Hold strut by hand so that it will not fall off. assembly, remove strut rod 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 416 2B-6 Front Suspension: I4RS0A220009- WARNING: Use a commercially available spring compressor and follow the operation procedure described in the Instruction Manual supplied with that spring compressor. 2) While keeping spring compressed with special tool as shown, remove strut support lower nut. Special tool (B): 09900-00411 (socket) (C): 09900-00414 (6 mm)
Page 417 Front Suspension: 2B-7 2) Install compressing coil spring, and mate spring end (2) with stepped part of spring lower seat (1) as shown. CAUTION: End of coil spring must not interfere with step of spring lower seat. I4RS0A220011- 3) Install bump stopper onto strut rod. For installing direction, refer to the figure in “Front Suspension Construction: ”.
Page 418 2B-8 Front Suspension: 5) Compare strut resistance and number of rebalance • Inspect spring seat for cracks or deformation. on the right with those on the left. And they must be If defective, replace. equal in both. With proper strut, vehicle body should •...
Page 419 Front Suspension: 2B-9 6) Pull brake disc (2) off by using two 8 mm bolts. I4RS0A220018- 10) Loosen strut bracket nuts (1). I2RH01220027- 7) Pull out wheel hub (1) with special tools. 11) Remove ball joint bolt (3) and nut (4). 12) Remove strut bracket bolts from strut bracket and Special tool then steering knuckle (2).
Page 420 2B-10 Front Suspension: 15) Remove wheel bearing outside inner race (1). Special tool (C): 09913-65810 (D): 09913-85230 I4RS0A220021- 2) Install circlip (1). I3RH0A220006- 16) Remove hub bolts (1) with copper hammer or hydraulic press. I2RH01220037- 3) Insert new hub bolt (1) in hub hole. Rotate hub bolt CAUTION: slowly to assure that serrations are aligned with Never remove bolt unless replacement is...
Page 421 Front Suspension: 2B-11 5) Install ball joint bolt (1) and nut (2) from the direction as shown in figure. 6) Tighten new suspension arm ball joint nut (2) to specified torque. Tightening torque Suspension arm ball joint nut (a): 60 N·m (6.0 kg-m, 43.5 lb-ft) 3, (a) CAUTION:...
Page 422 2B-12 Front Suspension: Front Wheel Hub, Disc, Nut and Bearing Check S4RS0A2206012 • Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. • Check installation face inside of wheel disc for rust. As rust affects adversely, remove it thoroughly.
Page 423 Front Suspension: 2B-13 Suspension Control Arm / Bushing Disassembly and Assembly S4RS0A2206014 Disassembly 1) Cut off bushing flange (rubber) (1) with knife. I4RS0A220027- 2) Install suspension control arm ball joint to steering knuckle. Align ball stud groove with steering knuckle I4RS0A220029- bolt hole.
Page 424 2B-14 Front Suspension: NOTE: Suspension Control Arm / Steering Knuckle Check • Before installing bushing, apply soap S4RS0A2206015 water on its circumference to facilitate Inspect for cracks, deformation or damage. installation. If defective, replace. I2RH01220005- I4RS0A220032- 2) Press-fit bushing (1) so that dimensions and in figure Suspension Control Arm Bushing Check become equal.
Page 425 Front Suspension: 2B-15 Front Suspension Frame, Stabilizer Bar and/or Bushings Components S4RS0A2206018 I4RS0A220037- 1. Stabilizer bar 5. Stabilizer joint 9. Suspension frame : 150 N m (15.0 kg-m, 108.5 lb-ft) 2. Stabilizer bushing 6. Stabilizer joint nut 10. Suspension frame mounting bolt : 170 N m (17.0 kg-m, 123.0 lb-ft) 3.
Page 426 2B-16 Front Suspension: WARNING: When removing suspension frame, be sure to apply some supporting equipment (such as jack) under it at well-balanced position in the center section so as to prevent suspension frame dropping. I4RS0A220039- 3. Suspension frame 6) Disconnect muffler No.1 mounting (1) from suspension frame (2).
Page 427 Front Suspension: 2B-17 NOTE: 5) Align lugs (1) (right and left) of suspension frame with holes (2) in vehicle body respectively. For correct installation of stabilizer bar, side- to-side, be sure that stopper ring (4) on stabilizer bar aligns with mount bush, both right and left, as shown in figure.
Page 428 2B-18 Front Suspension: 9) Connect muffler No.1 mounting (1) to suspension frame (2). I4RS0A220040- 10) Install steering gear case No.1 bolts (a) and No.2 bolts (b) to specified torque Tightening torque Steering gear case No.1 bolt (a): 55 N·m (5.5 kg- m, 40.0 lb-ft) Steering gear case No.2 bolt (b): 55 N·m (5.5 kg- I4RS0A220051-...
Page 429 Front Suspension: 2B-19 Front Stabilizer Bar, Bushing and/or Joint Stabilizer Joint Check 1) Check for smooth rotation. S4RS0A2206022 2) Inspect ball stud for damage. Stabilizer Bar Inspect for damage or deformation. 3) Inspect dust cover for damage. If defective, replace. NOTE: Stabilizer joint (1) cannot be disassembled.
Page 430 2B-20 Front Suspension: NOTE: The specified tightening torque is also described in the following. “Front Suspension Construction: ” “Front Strut Assembly Components: ” “Front Wheel Hub and Steering Knuckle Components: ” “Front Suspension Frame, Stabilizer Bar and/or Bushings Components: ” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners Information: in Section 0A”.
Page 431: Rear Suspension
Rear Suspension: 2C-1 Rear Suspension General Description Rear Suspension Construction S4RS0A2301001 2WD Vehicle I4RS0A230001- 1. Rear coil spring 6. Wheel bearing 11. Rear shock absorber lower nut 16. Rear spindle 2. Rear spring lower seat 7. Brake drum 12. Rear spindle bolt 17.
Page 432 2C-2 Rear Suspension: Component Location Rear Suspension Component Location S4RS0A2303001 2WD Vehicle I4RS0A230002- 1. Rear coil spring 8. Circlip 15. Spindle cap : 90 N m (9.0 kg-m, 65.0 lb-ft) 2. Blank 9. Rear trailing arm bolt 16. Brake back plate : 75 N m (7.5 kg-m, 54.0 lb-ft) 3.
Page 433 Rear Suspension: 2C-3 Repair Instructions Rear Shock Absorber Removal and Installation S4RS0A2306028 Removal 1) Hoist vehicle. 2) Remove tail end member trim (1) and quarter inner trim (2). I4RS0A230003- 3. Clip I4RS0A230004- 3) Support rear axle by using floor jack to prevent it 4) Install tail end member trim (1) and quarter inner trim from lowering.
Page 434 2C-4 Rear Suspension: Rear Shock Absorber Inspection Rear Shock Absorber Bush Removal and S4RS0A2306029 Installation • Inspect for deformation or damage. S4RS0A2306040 Removal • Inspect bushings for wear or damage. 1) Remove rear shock absorber referring to “Rear • Inspect for evidence of oil leakage. Shock Absorber Removal and Installation: ”.
Page 435 Rear Suspension: 2C-5 Rear Shock Absorber Bush Inspection Installation S4RS0A2306041 1) Install coil spring (1) on spring seat (2) of rear axle Inspect for cracks, deformation or damage. Replace any and mate spring open end with stepped part (3) of defective part.
Page 436 2C-6 Rear Suspension: Spring Upper Seat and Lower Seat Removal and 4) Install wheels and tighten wheel nuts to specified torque. Installation S4RS0A2306033 Tightening torque Removal Wheel nut (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 1) Remove coil spring referring to “Coil Spring Removal and Installation: ”.
Page 437 Rear Suspension: 2C-7 I4RS0A230017- A: Vehicle body side (Upper side) LH: Left side F: Front side RH: Right side 3. Stepped part 2) Install coil spring referring to “Coil Spring Removal and Installation: ”. Rear Axle Removal and Installation S4RS0A2306035 Removal 1) Hoist vehicle and remove rear wheels (right &...
Page 438 2C-8 Rear Suspension: 9) Lower rear axle gradually as far down as where coil Installation springs (1) (right & left) can be removed. 1) Install brake pipes to rear axle. 2) Place rear axle on floor jacks. CAUTION: Then install trailing arm and new trailing arm bolts (1) Be careful not to let rear axle down too much.
Page 439 Rear Suspension: 2C-9 I4RS0A230024- 6) Install brake back plates (1), spindles (2) and new spindle bolts (a) and then tighten spindle bolts (a) to I4RS0A230027- specified torque. 9) Connect brake flexible hoses (1) to bracket on rear axle with E-rings (3) (right & left) and tighten brake CAUTION: pipe flare nuts (a) to specified torque.
Page 440 2C-10 Rear Suspension: 13) Install wheel and tighten wheel nuts to specified torque. Tightening torque Wheel nut (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) I2RH01220009- 14) Upon completion of all jobs, depress brake pedal with about 300 N (30 kg, 66 Ibs) load three to five times so as to obtain proper drum-to-shoe clearance.
Page 441 Rear Suspension: 2C-11 Wheel Bearing and Wheel Stud Bolt Removal Installation and Installation 1) Install new wheel bearing (1) by using special tool S4RS0A2306036 and hydraulic press. Removal 1) Remove rear brake drum referring to “Rear Brake NOTE: Drum Removal and Installation: in Section 4C”. Seal side of bearing comes brake back plate 2) Remove circlip (1).
Page 442 2C-12 Rear Suspension: Rear Wheel Disc, Nut and Bearing Inspection S4RS0A2306021 • Check wheel nuts for tightness and, as necessary, retighten to specification. • Check wheel bolt press-fitted into brake drum for wear, damage, poor thread condition, and looseness. Replace defective bolt with a new one. When bolt installation is found loose, replace both bolt and brake drum with new ones.
Page 443 Rear Suspension: 2C-13 Tightening torque Tightening torque Rear spindle bolt (a): 75 N·m (7.5 kg-m, 54.0 lb- Wheel nut (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) I4RS0A230025- 2) Connect wheel speed sensor (1) and tighten wheel speed sensor bolt (a) to specified torque. I2RH01220009- Tightening torque 7) Upon completion of all jobs, depress brake pedal...
Page 444 2C-14 Rear Suspension: Specifications Tightening Torque Specifications S4RS0A2307001 Tightening torque Fastening part Note kg-m lb-ft Rear shock absorber upper nut 18.0 Rear shock absorber lower nut 65.0 Wheel nut 61.5 Rear spindle bolt 54.0 Wheel speed sensor bolt Brake pipe flare nut 11.5 Parking brake cable clamp bolt Rear trailing arm bolt...
Page 445: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires General Description Tires Description • High tire temperature S4RS0A2401001 • Reduced handling The tire is of tubeless type. The tire is designed to • High fuel consumption operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation Matched Tires and Wheels (Steel Type) pressures.
Page 446 2D-2 Wheels and Tires: WARNING: Lateral runout limit “a”: 1.40 mm (0.055 in.) Do not mix different types of tires on the Radial runout limit same vehicle such as radial, bias and bias- “b”: 1.14 mm (0.045 in.) belted tires except in emergencies, because handling may be seriously affected and may result in loss of control.
Page 447 Wheels and Tires: 2D-3 • Front tire treads have scuffed appearance with Wear Indicators Description “feather” edges on one side of tread ribs or blocks. S4RS0A2401004 Original equipment tires have built-in tread wear indicators (1) to show when they need replacement. These indicators (1) will appear as 12 mm (0.47 in) wide bands when the tire tread depth becomes 1.6 mm (0.063 in).
Page 448 2D-4 Wheels and Tires: Equipment manufacture’s recommendations Inflate tires to recommended pressure Road test vehicle on level unrouned road in both directions Switch front tires side to side and road test again Lead corrected, Leads reverses direction Leads in same direction if roughness results, replace tires Put tires back in original position Install a known-good tire on one front side...
Page 449 Wheels and Tires: 2D-5 Repair Instructions General Balance Procedures Tire Rotation S4RS0A2406001 S4RS0A2406002 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 450 2D-6 Wheels and Tires: Wheel Removal and Installation Tire Mounting and Dismounting S4RS0A2406003 S4RS0A2406004 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 451 Wheels and Tires: 2D-7 Specifications Wheels and Tires Specifications S4RS0A2407001 Tire size (Standard) 185/60R15 84H Wheel size (Standard) 15 x 5 1/2 JJ (for 185/60R15) Tightening torque Wheel nut: 85 N·m (8.5 kg-m, 61.5 lb-ft) NOTE: • Tire inflation pressure should be checked when tires are cool. •...
Page 452 2D-8 Wheels and Tires:...
Page 453 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Drive Shaft / Axle ........3A-1 Front Drive Shaft Assembly Removal and Installation ............3A-3 General Description ..........3A-1 Front Drive Shaft Disassembly and Front Drive Shaft Construction......3A-1 Assembly............3A-4 Component Location ...........3A-1 Center Shaft and Center Bearing Front Drive Shaft Assembly Components Support Disassembly and Assembly....3A-7...
Page 454 3A-1 Drive Shaft / Axle: Drive Shaft / Axle General Description Front Drive Shaft Construction S4RS0A3101001 A constant velocity tripod joint is used on the differential side of both right and left side drive shaft assemblies. A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. The drive shaft can slide through the tripod joint in the extension/contraction direction.
Page 455 Drive Shaft / Axle: 3A-2 Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S4RS0A3104001 Condition Possible cause Correction / Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace. Worn or breakage of the center bearing Replace. Repair Instructions Front Drive Shaft Components S4RS0A3106001...
Page 456 3A-3 Drive Shaft / Axle: 1. Circlip 13. Center bearing 2. Differential side joint (Constant velocity tripod joint) 14. Center shaft : Apply dark gray grease included in spare part to joint. 3. Snap ring 15. Tripod joint spider 4. Boot band (Large) 16.
Page 457 Drive Shaft / Axle: 3A-4 Front Drive Shaft Disassembly and Assembly 10) Remove drive shaft assembly. S4RS0A3106007 11) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from Disassembly differential side gear. CAUTION: •...
Page 458 3A-5 Drive Shaft / Axle: 3) Remove tripod joint spider (1) using 3 arms puller (2). CAUTION: To prevent any problem caused by washing solution, do not wash tripod joint except its housing. Degreasing of tripod joint with cloth is allowed. I4RS0A310007- I3RH0A311004- [A]: Wheel side...
Page 459 Drive Shaft / Axle: 3A-6 7) Fasten boot band (1) securely using special tool. 10) Apply grease in the supplied parts to inside of tripod joint housing (1), joint it with tripod joint and fit boot CAUTION: (2) to tripod joint housing. Do not squeeze or distort boot when Grease color fastening it with bands.
Page 460 3A-7 Drive Shaft / Axle: CAUTION: • Bend each boot band against forward rotation. • Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability. I3RH0A311005- 4) Remove center bearing from center bearing support. Assembly Install center shaft by reversing removal procedure and noting the following points.
Page 461 Drive Shaft / Axle: 3A-8 • Press-fit center shaft (1) from left oil seal (2) side. Assembly 1) Install center bearing (1) to center bearing support (2), and then install circlip (3) into groove of bearing support as shown in figure. I4RS0A310015- Type B I4RS0A310016-...
Page 462 3A-9 Drive Shaft / Axle: Front Drive Shaft Inspection 4) Install right oil seal (1) to center bearing support (2) until it become flush with bearing support using S4RS0A3106005 • Check shaft and joint for damage, wear or bend. special tool, and then apply grease to oil seal lip. Replace them as necessary.
Page 463 Drive Shaft / Axle: 3A-10 Special Tools and Equipment Recommended Service Material S4RS0A3108001 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. “Front Drive Shaft Assembly Components Location: ”...
Page 464 3A-11 Drive Shaft / Axle:...
Page 465 Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Front Disc Brake Pad On-Vehicle Inspection............4B-2 Precautions............. 4-1 Front Disc Brake Pad Removal and Precautions for Brakes.......... 4-1 Installation ............4B-2 Brake Control System and Diagnosis ... 4A-1 Front Disc Brake Pad Inspection......4B-3 Front Disc Brake Caliper Removal and Precautions............4A-1 Installation ............4B-3...
Page 466 4-ii Table of Contents ABS............4E-1 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front Precautions............4E-1 / Left-Front / Right-Rear / Left-Rear Inlet Precautions in Diagnosing Troubles ....4E-1 Solenoid Circuit, Right-Front / Left-Front / Precautions in On-Vehicle Service......
Page 467 Precautions: Precautions Precautions Precautions for Brakes S4RS0A4000001 Suspension Caution Refer to “Suspension Caution: in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution: in Section 00”. Brake Caution Refer to “Brake Caution: in Section 00”. General Precautions Refer to “General Precautions: in Section 00”.
Page 468 4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Precautions Precautions on Brake S4RS0A4100001 Air Bag Warning Refer to “Air Bag System Service Warning: in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note: ”. General Description Brakes Construction S4RS0A4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two...
Page 469 Brake Control System and Diagnosis: 4A-2 Front Brake Hose / Pipe Construction S4RS0A4101002 For Vehicle with ABS I4RS0A410002- [A]: For RH steering vehicle 5. ABS hydraulic unit 10. 4-way joint to left rear brake hose 1. From master cylinder primary to ABS hydraulic unit 6.
Page 470 4A-3 Brake Control System and Diagnosis: Rear Brake Hose / Pipe Construction S4RS0A4101003 I4RS0A410003- 1. 4-way joint to left rear brake hose 4: Right rear brake hose 2. 4-way joint to right rear brake hose 5: Left rear brake hose to left brake 3.
Page 471 Brake Control System and Diagnosis: 4A-4 Brakes Symptom Diagnosis S4RS0A4104002 Condition Possible cause Correction / Reference Item Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair. Brake disc or pads stained with oil Clean or replace. Overheated brakes Determine cause and repair.
Page 472 4A-5 Brake Control System and Diagnosis: Condition Possible cause Correction / Reference Item Dragging brakes (A very Master cylinder pistons not returning Replace master cylinder. light drag is present in all correctly brakes immediately after Restricted brake pipes or hoses Check for soft hoses or damaged pipes and pedal is released) replace with new hoses and/or new brake...
Page 473 Brake Control System and Diagnosis: 4A-6 Repair Instructions Brake Pedal Free Height Inspection S4RS0A4106001 1) Check brake pedal free height. If it is not within specification, check and adjust following item 2) and Brake pedal free height “a” from floor panel 130 –...
Page 474 4A-7 Brake Control System and Diagnosis: Master Cylinder and Brake Fluid Level Inspection S4RS0A4106004 1) Check master cylinder, reservoir and reservoir hose (if equipped) for crack, damage and brake fluid leakage. If any faulty condition exists, correct or replace. 2) Check that brake fluid level is between MAX and MIN marks on reservoir.
Page 475 Brake Control System and Diagnosis: 4A-8 I2RH01410017- 7) Then attach bleeder plug cap. I4RS0A410008- 2) Remove bleeder plug cap. Attach a vinyl tube (1) to 8) After completing bleeding operation, apply fluid bleeder plug, and insert the other end into container pressure to pipe line and check for leakage.
Page 476 4A-9 Brake Control System and Diagnosis: • Perform brake test and check installed part for fluid • When installing hose, make sure that it has no twist or leakage. kink. Rear Brake Hose / Pipe Removal and Brake Hose and Pipe Inspection S4RS0A4106009 Installation S4RS0A4106008...
Page 477 Brake Control System and Diagnosis: 4A-10 1. Master cylinder seal 7. Secondary piston stopper pin : 15 N m (1.5 kg-m, 11.0 lb-ft) 2. Circlip 8. Reservoir bolt “a” : Apply small amount of silicon grease (included in spare parts) to mating surfaces of rod seal and primary piston.
Page 478 4A-11 Brake Control System and Diagnosis: Master Cylinder Assembly Removal and 7) Remove master cylinder and master cylinder seal. Installation Installation S4RS0A4106012 1) Install new master cylinder seal. Removal 2) Install master cylinder to booster and tighten master CAUTION: cylinder fixing nuts (a) to specified torque. Do not allow brake fluid to get on painted Tightening torque surfaces.
Page 479 Brake Control System and Diagnosis: 4A-12 Assembly 6) Fill reservoir with specified brake fluid up to its MAX mark. CAUTION: 7) After completing the work, bleed air referring to “Air Bleeding of Brake System: ”. • Never use any mineral oil such as kerosene oil and gasoline when washing 8) Check each installed parts for fluid leakage.
Page 480 4A-13 Brake Control System and Diagnosis: Master Cylinder Assembly Inspection 5) Apply small amount of rubber grease (included in spare parts) to mating surface of “a” (piston cup (3) S4RS0A4106014 Inspect all disassembled parts for wear or damage, and and piston guide (1)) and “b” (piston guide (1) and O- replace parts if necessary.
Page 481 Brake Control System and Diagnosis: 4A-14 Booster Operation Inspection Check Operation S4RS0A4106016 1) With engine stopped, depress brake pedal several There are two ways to perform this inspection, with and times with the same load and make sure that pedal without a tester.
Page 482 4A-15 Brake Control System and Diagnosis: I4RS0A410020- I2RH01410010- 5) Tighten brake pedal bracket mounting bolt. H: Hold Tightening torque T: 30 seconds Brake pedal bracket mounting bolt (a): 13 N·m ( 1.3 kg-m, 9.5 lb-ft) Brake Booster Removal and Installation S4RS0A4106017 Removal 1) Recover refrigerant from A/C system by using...
Page 483 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 S4RS0A4108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 3 — (DOT 3) NOTE: Required service material is also described in the following.
Page 484: Front Brakes
4B-1 Front Brakes: Front Brakes Repair Instructions Front Disc Brake Components S4RS0A4206001 I4RS0A420001- 1. Caliper 9. Piston seal 17. Hose washer : Apply small amount of rubber grease (included in repair kit) to all around part of piston seal. 2. Caliper pin bolt 10.
Page 485 Front Brakes: 4B-2 Front Disc Brake Pad On-Vehicle Inspection 4) Remove brake pads (3). S4RS0A4206002 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 486 4B-3 Front Brakes: NOTE: 3) Install caliper and tighten caliper pin bolts (a) to specified torque. When pads are removed, visually inspect caliper for brake fluid leak. Correct leaky Tightening torque point, if any. Caliper pin bolt (a): 26 N·m (2.6 kg-m, 19.0 lb-ft) I4RS0A420002- 4) Install wheel and lower lift.
Page 487 Front Brakes: 4B-4 4) Remove caliper from caliper carrier. 6) Lower hoist. 5) Disconnect flexible hose from caliper using care not 7) Torque wheel nuts to specifications. to twist it. As this will allow brake fluid to flow out of Tightening torque flexible hose, have a container ready beforehand.
Page 488 4B-5 Front Brakes: 1) Replace with a new piston seal (1) at every overhaul. 3) Remove piston seal using a thin blade like a thickness gauge, etc. After applying rubber grease (included in repair kit), fit piston seal (1) into groove in cylinder taking care CAUTION: not to twist it.
Page 489 Front Brakes: 4B-6 NOTE: Check that boot is fitted in boot groove securely all around piston and cylinder. I2RH01420015- Front Brake Disc Removal and Installation S4RS0A4206008 Removal 1) Hoist vehicle and remove wheel. I2RH01420020- 2) Remove caliper assembly by removing caliper 5) To confirm that boot is fitted in its groove in cylinder carrier bolts (2 pcs) properly, pull piston out of cylinder a little but do not...
Page 490 4B-7 Front Brakes: Installation Front Brake Disc Inspection S4RS0A4206009 1) Install disc to wheel hub. • Install wheel nuts to hub bolts and fasten to fix the 2) Install caliper assembly to steering knuckle. brake disc. Using magnetic stand and with dial gauge positioned CAUTION: at about 10 mm (0.39 in.) inward from periphery of Make sure that flexible hose is not twisted...
Page 491 Front Brakes: 4B-8 Specifications Tightening Torque Specifications S4RS0A4207001 Tightening torque Fastening part Note kg-m lb-ft Caliper pin bolt 19.0 Wheel nut 61.5 Flexible hose joint bolt 17.0 Bleeder plug Caliper carrier bolt 61.5 NOTE: The specified tightening torque is also described in the following. “Front Disc Brake Components: ”...
Page 492: Rear Brakes
4C-1 Rear Brakes: Rear Brakes Repair Instructions Rear Drum Brake Components S4RS0A4306001 I4RS0A430001- 1. Rear brake drum 9. Quadrant spring 17. Brake back plate 2. Spindle 10. Shoe return spring 18. Spindle bolt 3. Spindle nut 11. Antirattle spring : 175 N m (17.5 kg-m, 126.5 lb-ft) 4.
Page 493 Rear Brakes: 4C-2 3) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil. 4) Install new spindle nut (a). 5) Tighten spindle nut (a) to specified torque. Tightening torque Spindle nut (a): 175 N·m (17.5 kg-m, 126.5 lb-ft) I4RS0A430004- 6) Remove wheel bearing from brake drum referring to...
Page 494 4C-3 Rear Brakes: NOTE: 9) Install wheel and tighten wheel nuts to specified torque. When drum is removed, visually inspect wheel cylinder for brake fluid leakage. Tightening torque Correct leaky point, if any. Wheel nut (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) Brake Shoe Measure thickness of brake shoe (1).
Page 495 Rear Brakes: 4C-4 ABS Sensor Ring Inspection S4RS0A4306010 • Check ring serration (teeth) for being missing, damaged or deformed. • Check sensor ring (1) for being deformed (warped). • Check that no foreign material is attached If any malfunction is found, repair or replace. I4RS0A430009- Installation 1) Install new sensor ring (1) to brake drum (2) by using...
Page 496 4C-5 Rear Brakes: Wheel Cylinder Removal and Installation 5) Remove push nut (1). S4RS0A4306006 6) Remove parking brake shoe lever (2) from shoe rim (3). Removal 1) Remove brake drum referring to “Rear Brake Drum Removal and Installation: ”. 2) Remove brake shoe referring to “Rear Brake Shoe Removal and Installation: ”.
Page 497 Rear Brakes: 4C-6 Brake Back Plate Removal and Installation 4) Install bleeder plug cap (4) taken off from pipe back to bleeder plug. S4RS0A4306008 Removal 1) Remove brake drum referring to “Rear Brake Drum Removal and Installation: ”. 2) Remove brake shoe referring to “Rear Brake Shoe Removal and Installation: ”.
Page 498 4C-7 Rear Brakes: Installation 5) Install wheel cylinder and connect brake pipe flare nut, and then tighten wheel cylinder bolts and flare 1) Install brake back plate (1) and spindle (2), and nut to specified torque referring to “Wheel Cylinder tighten spindle bolts (3) by hand.
Page 499 Rear Brakes: 4C-8 Specifications Tightening Torque Specifications S4RS0A4307001 Tightening torque Fastening part Note kg-m lb-ft Spindle nut 17.5 126.5 Wheel nut 61.5 Wheel cylinder mounting bolt Rear brake pipe flare nut 11.5 Rear wheel speed sensor bolt Spindle bolt 53.0 Parking cable cap nut NOTE: The specified tightening torque is also described in the following.
Page 500: Parking Brake
4D-1 Parking Brake: Parking Brake General Description Parking Brake Cable Construction S4RS0A4401001 I4RS0A440001- T: Top side 4. Parking cable bracket 10. Parking cable clamp bolt [D]: View [D] F: Front side 5. Parking cable bracket bolt 11. Rear wheel speed sensor bolt [E]: View [E] R: Right side 6.
Page 501 Parking Brake: 4D-2 Repair Instructions Parking Brake Inspection and Adjustment Adjustment S4RS0A4406001 Inspection NOTE: Hold center of parking brake lever grip and pull it up with Make sure for the following conditions before 200 N (20 kg, 44 lbs) force. cable adjustment.
Page 502 4D-3 Parking Brake: Parking Brake Cable Removal and Installation Parking Brake Lever Removal and Installation S4RS0A4406002 S4RS0A4406003 Removal Removal 1) Disconnect negative (–) cable at battery. NOTE: 2) Remove console box. When it is necessary to remove both right 3) Block vehicle wheels and release parking brake and left parking brake cables, repeat below lever.
Page 503 Parking Brake: 4D-4 Installation 1) Install in reverse order of removal procedure. Check equalizer inclined angle. Tightening torque Parking brake lever bolt (a): 25 N·m (2.5 kg-m, 18.0 lb-ft) I4RS0A440006- 2) After all parts are installed, parking brake lever needs to be adjusted. Refer to “Parking Brake Inspection and Adjustment: ”.
Page 504 4E-1 ABS: Precautions Precautions in Diagnosing Troubles Precautions in On-Vehicle Service S4RS0A4500001 S4RS0A4500002 To ensure that the trouble diagnosis is done accurately When connector is connected to ABS hydraulic unit / and smoothly, observe the following and follow “ABS control module assembly, do not disconnect connectors Check: ”.
Page 505 ABS: 4E-2 General Description ABS Description ABS Hydraulic Unit / Control Module Assembly S4RS0A4501001 Description The ABS (Antilock Brake System) controls the fluid S4RS0A4501002 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 506 4E-3 ABS: Schematic and Routing Diagram ABS Schematic S4RS0A4502001 INPUT OUTPUT ABS control module Hydraulic unit Wheel speed sensor (LF) Pump motor Wheel speed sensor (LR) Pump motor driver (transistor) Wheel speed sensor (RF) Solenoid valve power supply driver (transistor) Wheel speed sensor (RR) Stop lamp switch LF inlet solenoid valve...
Page 507 ABS: 4E-4 1. ABS hydraulic unit / control module assembly 8. Pump motor 15. Wheel speed sensor (Right-front) 2. ABS control module 9. Stop lamp switch 16. Wheel speed sensor (Left-front) 3. ABS hydraulic unit 10. ABS warning lamp 17. Wheel speed sensor (Right-rear) 4.
Page 508 4E-5 ABS: Terminal Wire color Circuit WHT/RED ABS pump motor driver (Transistor) — — GRN/WHT Brake light switch — — Dark link connector — — GRN/ORN Ignition switch — — — — — — — — — — Ground WHT/BLU Solenoid valve power supply driver (Transistor) LT GRN Left–rear wheel speed sensor (+)
Page 509 ABS: 4E-6 Front Wheel Speed Sensor Components Location S4RS0A4503002 I4RS0A450005- [A]: OK 1. Front wheel speed sensor 3. Connector 25 N m (2.5 kg-m, 18.0 lb-ft) [B]: NG 2. Grommet 4. Sensor ring 11 N m (1.1 kg-m, 8.0 lb-ft) Rear Wheel Speed Sensor Components Location S4RS0A4503003 I4RS0A450006-...
Page 510 4E-7 ABS: Diagnostic Information and Procedures ABS Check S4RS0A4504001 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 511 ABS: 4E-8 Customer questionnaire (Example) I2RH01450014- Problem symptom confirmation Check if what the customer claimed in “Customer Questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check: ”...
Page 512 4) Read DTC according to instructions displayed on If it doesn’t go off, go to “EBD Warning Lamp (Brake SUZUKI scan tool and print it or write it down. Refer Warning Lamp) Comes ON Steady: ”. to SUZUKI scan tool operator’s manual for further...
Page 513 Brake pedal released by performing the following procedure or 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 514 4E-11 ABS: RF Wheel Speed, LF Wheel Speed, RR Wheel Speed Scan Tool Data Definition Battery Volt (V): Battery Voltage is an analog input and LF Wheel Speed (km/h, MPH): Wheel speed signal read by the ABS control module. Certain ABS is an ABS control module internal parameter.
Page 515 ABS: 4E-12 Step Action 1) Remove combination meter with ignition switch turned Go to Step 6. “RED/BLU” circuit OFF. shorted to ground. 2) Measure resistance between “RED/BLU” wire of combination meter connector and vehicle body ground. Is it infinite ( )? Is Circuit fuse for combination meter in good condition? Go to Step 5.
Page 516 4E-13 ABS: Troubleshooting Step Action 1) Perform diagnostic trouble code check. Go to Step 7 of “ABS Go to Step 2. Check: ”. Is there any DTC(s)? Are main fuses for ABS pump motor and ABS solenoid in Go to Step 3. Replace fuse and check good condition? circuit for short to...
Page 517 ABS: 4E-14 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON S4RS0A4504010 Wiring Diagram I4RS0A450011- [A]: ABS hydraulic unit / control module connector E03 5. Combination meter 1. Battery 6. ABS warning lamp 2. Main fuse box 7. EBD warning lamp (brake warning lamp) 3.
Page 518 4E-15 ABS: EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady S4RS0A4504012 Wiring Diagram I4RS0A450010- [A]: ABS hydraulic unit / control module connector E03 4. Circuit fuse box 8. Lamp driver module 1. Battery 5. Combination meter 9. ABS hydraulic unit / control module assembly 2.
Page 519 ABS: 4E-16 Serial Data Link Circuit Check S4RS0A4504013 I4RS0A450012- [A]: ABS hydraulic unit / control module connector E03 1. Battery 4. Circuit fuse box 7. Lamp driver module 10. ABS hydraulic unit / control module assembly 2. Main fuse box 5.
Page 520 4E-17 ABS: Step Action 1) Turn ignition switch to OFF position. Go to Step 6. Ground circuit for ABS hydraulic unit / control 2) Check for proper connection to ABS hydraulic unit / module open or high control module connector at terminals “E03-13” and resistance.
Page 521 ABS: 4E-18 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring S4RS0A4504015 Wiring Diagram I4RS0A450014- [A]: ABS hydraulic unit / control module connector E03 3.
Page 522 4E-19 ABS: Step Action 1) Turn ignition switch OFF. Go to Step 4. ABS wheel speed sensor circuit shorted to 2) Connect applicable ABS wheel speed sensor coupler. power. 3) Disconnect ABS hydraulic unit / control module connector. 4) Check for proper connection to ABS control module at each sensor terminal.
Page 523 ABS: 4E-20 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit S4RS0A4504016 Wiring Diagram I4RS0A450015- [A]: ABS hydraulic unit / control module assembly 3.
Page 524 4E-21 ABS: DTC C1057: Power Source Circuit S4RS0A4504017 Wiring Diagram I4RS0A450016- [A]: ABS hydraulic unit / control module connector E03 2. Main fuse box 1. Battery 3. ABS hydraulic unit / control module assembly DTC Detecting Condition The ABS control module monitors the power source voltage at terminal “E03-14”. When the power source voltage becomes extremely high or low while vehicle is running at more than 20 km/h (13 MPH), this DTC will be set.
Page 525 ABS: 4E-22 Step Action 1) Measure voltage between terminals “E03-14” and “E03- Poor connection of Check charging system 13” with engine running. “E03-14” and/or “E03- referring to “Generator 13” terminals. If the Test (Overcharged Is voltage 18 1.0 V or less? terminals are in good Battery Check): in condition, substitute a...
Page 526 4E-23 ABS: DTC C1063: Solenoid Valve Power Supply Driver Circuit S4RS0A4504019 Wiring Diagram I4RS0A450018- [A]: ABS hydraulic unit / control module connector E03 5. Solenoid valve power supply driver (transistor) 1. Battery 6. ABS hydraulic unit / control module assembly 2.
Page 527 ABS: 4E-24 DTC C1071: ABS Control Module S4RS0A4504020 Wiring Diagram I4RS0A450019- [A]: ABS hydraulic unit / control module connector E03 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 528 Brake pedal (1) should be depressed and then select good condition. testing wheel by SUZUKI scan tool and the wheel (2) should be turned by another person’s hand. At this 2) Check that battery voltage is 11 V or higher.
Page 529 ABS: 4E-26 I4RS0A450021- 1. ABS hydraulic unit / control module assembly 3. Connector 9 N m (0.9 kg-m, 6.5 lb-ft) 2. Bracket 16 N m (1.6 kg-m, 11.5 lb-ft) 25 N m (2.5 kg-m, 18.0 lb-ft) ABS Hydraulic Unit / Control Module Assembly ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection Removal and Installation...
Page 530 4E-27 ABS: 5) Remove bolt and pull out ABS hydraulic unit / control 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit / module assembly (1) from bracket (3) using flat end control module assembly (3).
Page 531 ABS: 4E-28 2) Bleed air from brake system referring to “Air Bleeding of Brake System: in Section 4A”. 3) Check each installed part for fluid leakage and perform “ABS Hydraulic Unit Operation Check: ”. NOTE: For new ABS hydraulic unit / control module assembly, if “ABS Hydraulic Unit Operation Check: ”...
Page 532 4E-29 ABS: Installation Front Wheel Speed Sensor Inspection S4RS0A4506007 1) Check that no foreign material is attached to sensor • Check sensor for damage. (1) and sensor ring (2). • Measure resistance of sensor. 2) Install it by reversing removal procedure. Between both terminals (1) of sensor Tightening torque 1.2 –...
Page 533 ABS: 4E-30 Reference 6) Detach ABS wheel sensor wire harness (1). When using oscilloscope for this check, check if peak-to- NOTE: peak voltage (1) meets specification and waveform is complete. Do not detach clip of rear wheel speed sensor connector from vehicle body unless Peak-to-peak voltage at 1/2 to 1 rotation per second replacement is necessary.
Page 534 4E-31 ABS: Rear Wheel Speed Sensor Inspection • Be sure to install wheel speed sensor (2) and its bolt at the correct (upper) position as shown in figure. S4RS0A4506010 • Check sensor for damage. Tighten sensor bolt (1) and harness clamp bolts to specified torque.
Page 535 ABS: 4E-32 Front Wheel Speed Sensor Ring Removal and • Check that no foreign material is attached. If any faulty is found, repair or replace. Installation S4RS0A4506012 NOTE: The front wheel sensor ring can not be removed or replaced alone. If front wheel sensor ring needs to be replaced, replace it as a wheel side joint assembly of drive shaft.
Page 536 4E-33 ABS: Special Tools and Equipment Special Tool S4RS0A4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — 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 537 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low ....5A-47 Precautions............. 5-1 DTC P0713: Transmission Fluid Precautions on Transmission / Transaxle ..... 5-1 Temperature Sensor Circuit High....5A-48 Automatic Transmission......5A-1 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction...........5A-49 Precautions............5A-1...
Page 538 5-ii Table of Contents Inspection of TCM and Its Circuits ....5A-86 Direct Clutch Assembly Disassembly TCM Power and Ground Circuit Check..... 5A-90 and Reassembly ...........5A-127 Brake Interlock System Inspection....5A-91 Direct Clutch Assembly Inspection....5A-129 Forward and Reverse Clutch Assembly Repair Instructions ..........5A-92 Components..........5A-130 Learning Control Initialization......5A-92...
Page 539 Table of Contents 5-iii Vehicle Speed Sensor (VSS) Removal Recommended Service Material .......5B-35 and Installation ..........5B-7 Special Tool ............5B-35 Back Up Lamp Switch Removal and Clutch ............5C-1 Installation ............5B-7 Back Up Lamp Switch Inspection ....... 5B-8 General Description ..........5C-1 Manual Transaxle Unit Components....
Page 540 5-1 Precautions: Precautions Precautions Precautions on Transmission / Transaxle S4RS0A5000001 Air Bag Warning Refer to “Air Bag System Service Warning: in Section 00”.
Page 541: Automatic Transmission
• Diagnostic information stored in TCM memory can be may occur and often time would be wasted. cleared as well as checked by using SUZUKI scan As the automatic transaxle consists of high precision tool or generic scan tool. Before using scan tool, read component, the following cautions should be strictly its Operator’s (Instruction) Manual carefully to have...
Page 542 5A-2 Automatic Transmission: CAUTION: Part Inspection and Correction Table Part Inspect for Correction • Keep component parts in group for each Casted part, Small flaw, burr Remove with oil subassembly and avoid mixing them up. machined part stone. • Clean all parts with cleaning solvent Deep or grooved Replace part.
Page 543 Automatic Transmission: 5A-3 General Description A/T Description S4RS0A5101001 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 544 5A-4 Automatic Transmission: 20 21 22 I3RM0B510001- 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. Short planet pinion 4.
Page 545 Wet type multiple-disc brake... 3 sets One-way clutch... 2 sets Reduction gear ratio 1.023 Final gear reduction ratio 4.052 Lubrication Lubrication system Force feed system by oil pump Cooling Cooling system Radiator assisted cooling (water-cooled) Fluid used SUZUKI ATF 3317 or Mobil ATF 3309...
Page 546 5A-6 Automatic Transmission: Clutch / Brake / Planetary Gear Function of Automatic Transaxle S4RS0A5101002 I4RS0A510001- 1. Input shaft and intermediate shaft 8: One-way No.2 clutch 15. Front sun gear 2: Direct clutch 9: 2nd brake 16. Rear sun gear 3. Reduction drive gear 10: One-way No.1 clutch 17.
Page 547 Automatic Transmission: 5A-7 Part Selector Gear Shift solenoid Shift solenoid TCC solenoid Forward Reverse position position Direct clutch valve-A (No.1) valve-B (No.2) valve clutch clutch Part Selector Gear O/D and 2nd 1st and One-way No.1 One-way No.2 position position 2nd brake coast brake reverse brake clutch...
Page 548 5A-8 Automatic Transmission: Driving Cycle (MIL) does not light at this time. It lights up at the second A “Driving Cycle” consists of engine startup, driving detection of same malfunction also in the next driving mode where a malfunction would be detected if present, cycle.
Page 549 Automatic Transmission: 5A-9 Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S4RS0A5102001 C35-6 C34-11 LT GRN C35-16 2.5V C34-12 BLK/RED C35-25 C34-16 YEL/BLK C34-15 BLK/YEL C34-14 BLU/BLK C34-7 C34-17 C34-5 WHT/BLU C34-3 WHT/BLK C34-4 C34-2 LT GRN/BLK C34-24 WHT/RED LT GRN YEL/BLK...
Page 550 5A-10 Automatic Transmission: Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve Solenoid Shift Shift Selector Gear Timing solenoid solenoid Condition position position solenoid solenoid valve-A valve-B valve valve (No.1) (No. 2) Parking When vehicle is traveling forwards in less than 9 km/h, 6 mile/h vehicle speed Reverse When vehicle is traveling forwards in 9...
Page 551 Automatic Transmission: 5A-11 Automatic Gear Shift Table S4RS0A5102002 Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D position. 1.Shift Point in D, 3 and/or 2 position Throttle opening (%) Shift Vehicle speed km/h (mph) Remark...
Page 552 5A-12 Automatic Transmission: Component Location Electronic Shift Control System Components Location S4RS0A5103001 I4RS0A510006- 1. Engine 8. TCC pressure control solenoid valve 15. ECM 2. Transaxle 9. Transmission fluid temperature sensor 16. TCM 3. MIL 10. Timing solenoid valve 17. AT relay 4.
Page 553 Automatic Transmission: 5A-13 Torque converter with Planetary gear Final gear Engine unit torque converter clutch reduction unit Clutches and Regulator valves brakes Oil pump in valve body Control valves in valve body Pressure control solenoid valve Shift solenoid valves, TCC pressure control solenoid valve and Timing solenoid valve Transmission control module (TCM)
Page 554 5A-14 Automatic Transmission: Diagnostic Information and Procedures A/T System Check S4RS0A5104001 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 or write them...
Page 555 Automatic Transmission: 5A-15 Customer problem inspection form (Example) I2RH01510008- NOTE: The form is a standard sample. It should be modified according to conditions characteristic of each market.
Page 556 5A-16 Automatic Transmission: Step 2. DTC / Freeze Frame Data Check, Record and Step 8. A/T Basic Check and A/T Symptom Clearance Diagnosis First, referring to “DTC Check: ”, check DTC and Perform basic check of A/T according to “A/T Basic pending DTC.
Page 557 Automatic Transmission: 5A-17 Visual Inspection S4RS0A5104002 Visually check the following parts and systems. Inspection item Referring • A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection: in Section 0B” • A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement: ” •...
Page 558 5A-18 Automatic Transmission: Detecting condition Driving cycle DTC No. Detecting item (DTC will set when detecting) when MIL lighted Input / Turbine speed sensor No sensor signal is detected although output P0717 1 driving cycle circuit no signal speed sensor signal is inputted. Output speed sensor circuit no No sensor signal is inputted although input P0722...
Page 559 ECM and TCM is read and displayed 1) Connect SUZUKI scan tool to data link connector in at a time. In case using generic scan tool, the same manner as when making this connection refer to “DTC Table: in Section 1A”.
Page 560 5A-20 Automatic Transmission: Fail-Safe Table S4RS0A5104008 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 561 Automatic Transmission: 5A-21 DTC No. Trouble area Fail-safe operation In case of throttle position signal malfunction: • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. •...
Page 562 5A-22 Automatic Transmission: DTC No. Trouble area Fail-safe operation • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. • Engine revolution is assumed to be 0 RPM. •...
Page 563 Automatic Transmission: 5A-23 Normal condition / reference Scan tool data Vehicle condition values After driving at 60 km/h (37.5 mile/h) for 15 minutes or more, and A/T fluid temperature around sensor 70 – 80 C (158 – 176 F) TEMPERATURE reaches 70 –...
Page 564 5A-24 Automatic Transmission: Normal condition / reference Scan tool data Vehicle condition values Engine running at idle speed and selector lever is in 0 RPM “P” range SLIP RPM Engine running, vehicle stop and selector lever is in Engine speed is displayed “D”...
Page 565 Automatic Transmission: 5A-25 TORQUE REDUCTION SIGNAL ENGINE TORQUE SIGNAL (N m) ON: Signal which TCM require ECM to reduce output Engine torque computed by duty pulse signal outputted torque at shifting gear from ECM. OFF: Signal which TCM does not require ECM to reduce output torque SLIP RPM (RPM) This parameter indicates slipping rotation in the torque...
Page 566 5A-26 Automatic Transmission: Road Test S4RS0A5104011 This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road. WARNING: • Carry out test in very little traffic area to prevent an accident. •...
Page 567 Automatic Transmission: 5A-27 Condition Possible cause Correction / Reference Item 4 upshift fails to Malfunction of shift solenoid valve-B Inspect. If NG, replace. occur Malfunction of “3” position switch Inspect. If NG, replace. Malfunction of engine coolant Inspect. If NG, replace. temperature sensor Malfunction of output shaft speed Inspect.
Page 568 5A-28 Automatic Transmission: Condition Possible cause Correction / Reference Item TCC (lock-up) function Malfunction of TCC pressure control Inspect. If NG, replace. pressure control does not solenoid valve operate Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of brake light switch Inspect.
Page 569 Automatic Transmission: 5A-29 Troubleshooting Condition Possible cause Correction / Reference Item Operated gear is not Faulty valve body component Replace valve body assembly. correct Faulty clutch or brake Inspect clutch and brake. If any parts are faulty, replace them. Engine Brake Test S4RS0A5104016 WARNING: Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.
Page 570 5A-30 Automatic Transmission: Troubleshooting Condition Possible cause Correction / Reference Item Lower than standard level Engine output torque failure Inspect and repair engine. in both “D” and “R” range Faulty one-way clutch of torque Replace torque converter. converter Higher than standard Malfunction of pressure control solenoid Inspect.
Page 571 Automatic Transmission: 5A-31 Time Lag Test S4RS0A5104014 This test is to check conditions of clutch, brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal. 2) Start engine.
Page 572 5A-32 Automatic Transmission: Line Pressure Test S4RS0A5104015 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 – 80 C / 158 – 176 F). •...
Page 573 Automatic Transmission: 5A-33 “P” Range Test S4RS0A5104017 1) Stop vehicle on a slope of 5 degrees or more, shift select lever to “P” range and at the same time apply parking brake. 2) After stopping engine, depress brake pedal and release parking brake. 3) Then, release brake pedal gradually and check that vehicle remains stationary.
Page 574 5A-34 Automatic Transmission: Condition Possible cause Correction / Reference Item Poor 1 2 shift Shift solenoid valve-B 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 575 Automatic Transmission: 5A-35 Condition Possible cause Correction / Reference Item Poor 3 4 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 576 5A-36 Automatic Transmission: 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 577 Automatic Transmission: 5A-37 Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC pressure control solenoid valve Inspect circuit for open, short and intermittent. up) system circuit faulty If NG, repair. Shift solenoid valve-A and/or -B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 578 5A-38 Automatic Transmission: Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Excessive shift shock Engine abnormal condition Inspect and repair engine. Malfunction of shift solenoid valve-A Inspect.
Page 579 Automatic Transmission: 5A-39 Condition Possible cause Correction / Reference Item Poor 3 4 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 580 5A-40 Automatic Transmission: Condition Possible cause Correction / Reference Item Non operate TCC (lock- Malfunction of TCC solenoid valve Inspect. If NG, replace. up) system Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of output shaft speed Inspect.
Page 581 Automatic Transmission: 5A-41 Condition Possible cause Correction / Reference Item Poor 2 1 shift, Faulty 2nd brake Inspect. If NG, replace. excessive shock or Faulty one-way No.2 clutch Inspect. If NG, replace. slippage Non operate TCC (lock- Faulty torque converter Replace.
Page 582 5A-42 Automatic Transmission: Step Action 1) Perform running test under the following conditions and Faulty shift solenoid “BRN” circuit shorted to measure voltage between terminal “C39-16” of TCM valve, circuit or power circuit or open, or connector and ground, terminal “C39-15” of TCM transaxle.
Page 583 4) Keep engine running at idle speed for 25 seconds or more. 5) Stop vehicle and check DTC. DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
Page 584 Go to Step 5. operation Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection: in Section 00”. 2) Turn ignition switch ON and check transmission range signal (“P”, “R”, “N”, “D”, “2”...
Page 585 6) Repeat Step 3) to 4) one time. 7) Stop vehicle and check DTC. DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
Page 586 Go to Step 5. operation Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection: in Section 00”. 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 2 or L) on display when shifting select lever to each range.
Page 587 Automatic Transmission: 5A-47 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low S4RS0A5104046 Wiring Diagram LT GRN C34-11 C34-12 12 11 I4RS0A510011- 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 588 5A-48 Automatic Transmission: DTC P0713: Transmission Fluid Temperature Sensor Circuit High S4RS0A5104023 Wiring Diagram LT GRN C34-11 C34-12 12 11 I4RS0A510011- 1. TCM 3. A/T 2. Transmission fluid temperature sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 589 Automatic Transmission: 5A-49 Step Action Check transmission fluid temperature circuit for IG “LT GRN” circuit shorted Intermittent trouble or short to power circuit. faulty TCM. 1) Cool down A/T fluid temperature under ambient If circuit is OK, go to Check for intermittent temperature.
Page 590 5A-50 Automatic Transmission: DTC Confirmation Procedure WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
Page 591 Automatic Transmission: 5A-51 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal S4RS0A5104025 Wiring Diagram BLK/RED C35-25 YEL/BLK I4RS0A510013- 1. TCM 3. To ECM 2. Output shaft speed sensor (VSS) [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 592 5A-52 Automatic Transmission: Step Action Check output shaft speed sensor (VSS) ground circuit Go to Step 4. “YEL/BLK” wire open. 1) Turn ignition switch OFF. 2) Check continuity between “YEL/BLK” wire terminal of disconnected output shaft speed sensor harness side connector and ground.
Page 593 Automatic Transmission: 5A-53 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON S4RS0A5104027 DTC Detecting Condition and Trouble Area DTC P0741 DTC detecting condition Trouble area When driving vehicle with 3rd or 4th gear in “D” range, •...
Page 594 5A-54 Automatic Transmission: DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction S4RS0A5104030 DTC P0751: Shift Solenoid-A (No.1) Performance or Stuck OFF DTC P0752: Shift Solenoid-A (No.1) Stuck ON DTC P0756: Shift Solenoid-B (No.2) Performance or Stuck OFF DTC P0757: Shift Solenoid-B (No.2) Stuck ON DTC Detecting Condition and Trouble Area DTC P0751...
Page 595 Automatic Transmission: 5A-55 4) Shift select lever to “N” and “D” range for 10 seconds. 5) Start vehicle and increase vehicle speed to 65 km/h (40 mile/h) with throttle position 10% or more. 6) Stop vehicle and turn ignition switch OFF. 7) Repeat Step 3) to 5) one time.
Page 596 5A-56 Automatic Transmission: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check timing solenoid valve resistance Go to Step 3. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1), (2) on transaxle.
Page 597 Automatic Transmission: 5A-57 DTC P0788: Shift / Timing Solenoid Control Circuit High S4RS0A5104050 Wiring Diagram BLU/BLK C34-14 I4RS0A510014- 1. TCM 3. A/T 2. Timing solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of timing solenoid valve TCM terminal is high...
Page 598 5A-58 Automatic Transmission: Step Action Check timing solenoid valve resistance “BLU/BLK” circuit open. 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 “BLU/ BLK”...
Page 599 Automatic Transmission: 5A-59 DTC P0962: Pressure Control Solenoid Control Circuit Low S4RS0A5104032 Wiring Diagram C34-4 C34-2 LT GRN/BLK I4RS0A510015- 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Pressure control solenoid valve output voltage is too low...
Page 600 5A-60 Automatic Transmission: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check pressure control solenoid valve resistance Go to Step 3. Replace pressure control solenoid valve or 1) Turn ignition switch OFF. valve body harness.
Page 601 Automatic Transmission: 5A-61 Step Action Check pressure control solenoid valve circuit for open “GRY” or “LT GRN/BLK” Intermittent trouble or circuit open. faulty TCM. 1) Check resistance continuity between terminals “C34-2” and “C34-4” of disconnected harness side TCM Check for intermittent connector.
Page 602 5A-62 Automatic Transmission: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check pressure control solenoid circuit for IG short Go to Step 3. “BRN/YEL” or “LT GRN” circuit shorted to power 1) Connect valve body harness connector.
Page 603 Automatic Transmission: 5A-63 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low S4RS0A5104051 Wiring Diagram C34-16 BLK/YEL C34-15 16 15 I4RS0A510016- 1. TCM 3. Shift solenoid valve-B (No.2) 2. Shift solenoid valve-A (No.1) [A]: Terminal arrangement of TCM connector (Viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition...
Page 604 5A-64 Automatic Transmission: DTC Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Table” Go to Step 2. Go to “A/T System performed? Check: ”. Check shift solenoid valve resistance Go to Step 3. Replace applicable shift solenoid valve or valve 1) Turn ignition switch OFF.
Page 605 Automatic Transmission: 5A-65 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High S4RS0A5104048 Wiring Diagram C34-16 BLK/YEL C34-15 16 15 I4RS0A510016- 1. TCM 3. Shift solenoid valve-B (No.2) [A]: Terminal arrangement of TCM connector (viewed from harness side) 2.
Page 606 5A-66 Automatic Transmission: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check shift solenoid valve circuit for IG short Go to Step 3. DTC P0974: “BRN” circuit shorted to power 1) Connect valve body harness connector.
Page 607 Automatic Transmission: 5A-67 DTC P1702: Internal Control Module Memory Check Sum Error S4RS0A5104033 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Calculation of current data stored in TCM is not correct comparing with pre-stored checking data in TCM. DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
Page 608 Substitute a known- Go to Step 3. good TCM and recheck. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check “3” position switch signal on scan tool data display when shifting select lever to each range.
Page 609 Automatic Transmission: 5A-69 Step Action “3” position switch signal inspection Substitute a known- Go to Step 4. With ignition switch ON, check voltage between “L01-8” good BCM and recheck. terminal of BCM coupler and ground. “3” position switch specifications Shift selector lever to “3” or “2” range: Battery voltage Shift selector lever to other above range: 0 V Is the result as specified? Check “3”...
Page 610 5A-70 Automatic Transmission: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check DTC Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 611 Automatic Transmission: 5A-71 Step Action Check CAN communication line circuit insulation Go to Step 10. Repair insulation of CAN communication 1) Disconnect connectors from ECM, BCM, TCM and line circuit referring to combination meter with ignition switch OFF. “Precaution for CAN 2) Measure resistance at the following connector terminals.
Page 612 5A-72 Automatic Transmission: Step Action 12 Check CAN communication line circuit power supply Substitute a known- Repair shorted to power short good BCM (included in supply of CAN junction block communication line 1) Measure voltage at the following connector terminals assembly) and recheck.
Page 613 Automatic Transmission: 5A-73 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Transmission error of communication data for TCM is detected more • ECM than specified time continuously. • BCM • TCM • Combination meter • CAN circuit DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
Page 614 5A-74 Automatic Transmission: Step Action Check CAN communication line circuit insulation Go to Step 9. Repair insulation of CAN communication 1) Measure resistance between “C34-17” and “C34-7” line circuit referring to terminals of TCM connector. “Precaution for CAN Is resistance infinity? Communication System: in Section 00”.
Page 615 Automatic Transmission: 5A-75 DTC P1777: TCM Lost Communication with ECM (Reception Error) S4RS0A5104055 Wiring Diagram E46-1 E23-3 E46-2 E23-18 G28-8 G37-4 G28-10 G37-2 C34-17 C37-13 C37-12 C34-7 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 17 16 15 14...
Page 616 5A-76 Automatic Transmission: DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check: ”. Check DTC Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 617 Automatic Transmission: 5A-77 Step Action 10 Check CAN communication line circuit power supply Go to Step 11. Repair shorted to power short supply of CAN communication line 1) Measure voltage at the following connector terminals circuit referring to with ignition switch turned ON. “Precaution for CAN •...
Page 618 5A-78 Automatic Transmission: DTC P1778: TCM Lost Communication with BCM (Reception Error) S4RS0A5104056 Wiring Diagram E46-1 E23-3 E46-2 E23-18 G28-8 G37-4 G28-10 G37-2 C34-17 C37-13 C37-12 C34-7 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 17 16 15 14...
Page 619 Automatic Transmission: 5A-79 Step Action Check TCM for CAN communication error Go to “DTC P1774: Go to Step 4. Control Module 1) Check DTC in TCM. Communication Bus Is there DTC P1774? Off: ”. Check ECM, TCM and BCM connectors Go to Step 5.
Page 620 5A-80 Automatic Transmission: Step Action 10 Check CAN communication line circuit ground short Go to Step 11. Repair shorted to ground of CAN 1) Measure resistance at the following connector terminals. communication line • Between “E23-3” terminal of ECM connector and circuit referring to vehicle body ground “Precaution for CAN...
Page 621 Automatic Transmission: 5A-81 DTC P1878: Torque Converter Clutch Shudder S4RS0A5104057 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area The acceleration slip control function stops when the variation in the • Mismatching ATF output revolution speed of the specified amplitude and specified cycle •...
Page 622 5A-82 Automatic Transmission: DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High S4RS0A5104037 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019- 1. TCC lock-up pressure control solenoid valve 3. A/T 2. TCM [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 623 Automatic Transmission: 5A-83 Step Action Check TCC solenoid valve circuit for IG short Go to Step 3. “WHT/BLU” or “WHT/ BLK” circuit shorted to 1) Connect valve body harness connector. power circuit. 2) Disconnect TCM connectors. 3) Check for proper connection to TCM at terminal “C34-3” and “C34-5”.
Page 624 5A-84 Automatic Transmission: DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low S4RS0A5104036 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019- 1. TCC pressure control solenoid valve 3. A/T 2. TCM [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 625 Automatic Transmission: 5A-85 Step Action Check TCC lock-up pressure control solenoid valve Go to Step 3. Replace TCC lock-up resistance pressure control solenoid valve or lead 1) Turn ignition switch OFF. wire. 2) Disconnect valve body harness connector (1), (2) on automatic transaxle.
Page 626 5A-86 Automatic Transmission: Inspection of TCM and Its Circuits S4RS0A5104038 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance. CAUTION: TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
Page 627 Automatic Transmission: 5A-87 Standard Terminal Wire color Circuit Condition voltage *0 – 0.6 V Engine running at idling (Output signal is duty pulse. TCC pressure control 10 – 14 V WHT/BLU Duty ratio varies depending on torque converter clutch solenoid valve (+) (“Reference operating condition).
Page 628 5A-88 Automatic Transmission: Standard Terminal Wire color Circuit Condition voltage 8 – 14 V Ignition switch ON, selector lever at “D” range Transmission range Ignition switch ON, selector lever at other than “D” sensor (“D” range) 0 – 1 V range 8 –...
Page 629 Automatic Transmission: 5A-89 Reference waveform No. 2 Reference waveform No. 4 TCC pressure control solenoid valve signal at engine Input shaft speed sensor signal at engine idling. idling. Measurement CH1: “C35-6” to “C34-1” Measurement terminal CH1: “C34-5” to “C34-1” terminal Oscilloscope CH1: 2 V/DIV Oscilloscope...
Page 630 5A-90 Automatic Transmission: TCM Power and Ground Circuit Check S4RS0A5104039 Wiring Diagram C34-24 WHT/RED YEL/BLK YEL/BLU C34-6 LT GRN/BLK C34-1 C34-23 24 23 I4RS0A510023- 1. TCM 3. Ignition switch 2. A/T relay [A]: Terminal arrangement of TCM connector (viewed from harness side) Troubleshooting Step Action...
Page 631 Automatic Transmission: 5A-91 Step Action Check TCM ground circuit TCM power and ground “BLK” circuit for TCM circuits are in good ground open. 1) Turn ignition switch OFF. condition. 2) With TCM connectors disconnected, check for proper connection to TCM at “C34-1” / “C34-23” terminal. 3) If OK, check resistance between “C34-1”...
Page 632 FULL HOT (2) and LOW HOT (3). If it is Fluid level check at room (cold) temperature below LOW HOT, add SUZUKI ATF 3317 or Mobil is recommended only for preparation of level ATF 3309 up to FULL HOT.
Page 633 3. Connector 2. Selector lever assembly 4. “3” position switch I3RM0B510033- 4) Lower vehicle and pour proper amount of SUZUKI ATF 3317 or Mobil ATF 3309. 5) Check fluid level referring to “A/T Fluid Level Check: ”. Automatic transaxle fluid...
Page 634 5A-94 Automatic Transmission: Select Lever Assembly Installation CAUTION: S4RS0A5106068 When installing select lever knob, do not turn Note the following when installing select lever assembly: more than specified numbers of rotation. • After installing select lever assembly, adjust select Otherwise select lever knob is damaged. cable referring to “Select Cable Adjustment: ”.
Page 635 Automatic Transmission: 5A-95 1. Selector lever assembly 6. Clip 11. Lock 2. Select cable 7. Select cable retainer bolt (a): 23 N m (2.0 kg-m, 17.0 lb-ft) 3. Select cable retainer 8. Manual select lever pin (b): 5.0 N m (0.55 kg-m, 4.0 lb-ft) : Apply lithium grease 99000-25010 to all around pin (0.15 g) 4.
Page 636 5A-96 Automatic Transmission: Transmission Range Sensor (Shift Switch) Output Shaft Speed Sensor (VSS) Removal and Inspection and Adjustment Installation S4RS0A5106008 S4RS0A5106009 Removal 1) Shift manual select lever (4) to “N” range. 1) Disconnect negative cable at battery. 2) Check that needle direction shaped on lock washer (2) and “N”...
Page 637 Automatic Transmission: 5A-97 Output Shaft Speed Sensor (VSS) Inspection Installation S4RS0A5106010 1) Apply A/T fluid to input shaft speed sensor O-ring. 1) Connect positive cable of 12 volt battery to “A” 2) Install input shaft speed sensor (1) to A/T case and terminal of sensor and ground cable to “C”...
Page 638 5A-98 Automatic Transmission: Transmission Fluid Temperature Sensor Removal and Installation S4RS0A5106059 Removal 1) Disconnect negative cable at battery. 2) Lift up vehicle. 3) With engine is cool, remove drain plug and drain A/T fluid. 4) Install drain plug. Refer to “A/T Fluid Change: ”. 5) Remove A/T oil pan.
Page 639 Automatic Transmission: 5A-99 “3” Position Switch Inspection S4RS0A5106014 1) Remove console box referring to “Console Box Components: in Section 9H”. 2) Disconnect “3” position switch connector (1). 3) Check continuity between “3” position switch terminals. “3” position switch specification Shift selector lever to “3” or “2” range: Continuity Shift other above range: No continuity I2RH0B510054-...
Page 640 5A-100 Automatic Transmission: Installation 1) Install shift solenoid valve-A (No.1) (1), shift solenoid valve-B (No.2) (2) and timing solenoid valve (3). Tightening torque Shift solenoid bolt (a): 11 N·m (1.1 kg-m, 8.0 lb- I2RH0B510059- 5) Install new oil pan gasket (1) and oil pan (2). 6) Tighten oil pan bolts to specified torque diagonally and little by little.
Page 641 Automatic Transmission: 5A-101 Operation Check Timing solenoid valve CAUTION: Shift solenoid valve-A (No.1) and -B (No.2) • Do not insert air gun against strainer CAUTION: installed on inlet of solenoid valve too • Do not insert air gun against strainer deeply, when blowing air into solenoid installed on inlet of solenoid valve too valve.
Page 642 5A-102 Automatic Transmission: Pressure Control Solenoid Valves (Pressure 10) Remove pressure control solenoid valve and TCC pressure control solenoid valve referring to “Valve Control Solenoid and TCC Pressure Control Body Assembly Disassembly and Reassembly: ”. Solenoid) Removal and Installation S4RS0A5106060 Removal Installation 1) Disconnect negative cable at battery.
Page 643 Automatic Transmission: 5A-103 Using regulated DC power supply 1) Connect pressure control solenoid valve (1) with regulated DC power supply (2) as shown in figure. 2) Turn regulated DC power supply switch ON and increase voltage of power supply keeping current within 1.0 A.
Page 644 5A-104 Automatic Transmission: Installation Differential Side Oil Seal Replacement Reverse removal procedure noting the following. S4RS0A5106019 1) Lift up vehicle and drain automatic transaxle fluid. • Connect TCM connectors securely. 2) Remove drive shaft joints from differential gear of • If the vehicle is equipped with air bag system, be sure transaxle.
Page 645 Automatic Transmission: 5A-105 Shift Lock Solenoid Inspection S4RS0A5106064 Check that shift lock solenoid (1) actuate when battery voltage is conducted. I4RS0A510034- Shift Lock Solenoid Replacement S4RS0A5106065 1) Remove console box referring to “Console Box Components: in Section 9H”. 2) Replace shift lock solenoid (1) using flat head or like. 3) Install covers as they were.
Page 646 5A-106 Automatic Transmission: Key Interlock Cable Removal and Installation S4RS0A5106066 NOTE: Don’t bend interlock cable excessively when removing and installing it, or system will not operate correctly. Removal 1) If the vehicle is equipped with air bag system, disconnect negative cable at battery and disable air bag system, referring to “Disabling Air Bag System: in Section 8B”.
Page 647 Automatic Transmission: 5A-107 11) If the vehicle is equipped with air bag system, connect negative cable at battery and enable air bag system, referring to “Enabling Air Bag System: in Section 8B”. A/T Fluid Cooler Hoses Replacement S4RS0A5106022 The rubber hoses for the A/T fluid cooler should be checked at specified interval.
Page 648 5A-108 Automatic Transmission: Automatic Transaxle Unit Dismounting and NOTE: Remounting When detaching transaxle from engine, move S4RS0A5106024 it in parallel with crankshaft and use care so as not to apply excessive force to drive plate Dismounting and torque converter. 1) Take down transaxle with engine. For its procedure, refer to “Engine Assembly Removal and Installation: in Section 1D”.
Page 649 Automatic Transmission: 5A-109 3) Tighten drive plate to torque converter bolts. Align bolt hole of drive plate and torque converter then tighten bolts through torque converter housing lower plate opening. Lock drive plate (1) by engaging flat head rod or the like (2) with drive plate gear.
Page 650 5A-110 Automatic Transmission: Automatic Transaxle Assembly Components S4RS0A5106025 I3RM0B510053-...
Page 651 Automatic Transmission: 5A-111 1. Torque converter 33. Oil pan 65. 2nd brake retaining plate 2. Torque converter housing 34. A/T fluid drain plug 66. 2nd brake disc : Apply sealant 99000-31230 to mating surface to transaxle case. 3. Oil strainer assembly 35.
Page 652 5A-112 Automatic Transmission: Automatic Transaxle Unit Disassembly 4) Uncaulk lock washer (1), then remove lock nut (2) S4RS0A5106026 and lock washer. CAUTION: • Thoroughly clean transaxle exterior before overhauling it. • Keep working table, tools and hands clean while overhauling. •...
Page 653 Automatic Transmission: 5A-113 12) Disconnect connectors (2) from solenoid valves and transmission fluid temperature sensor (1). I4RS0A510027- 13) Remove valve body assembly bolts. CAUTION: I3RM0B510059- Be careful not to let manual valve fall off 10) Remove oil pan (1) and oil pan gasket (2). when removing valve body assembly.
Page 654 5A-114 Automatic Transmission: 18) Remove accumulator pistons and springs. 15) 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 655 Automatic Transmission: 5A-115 19) Remove transaxle case plug (1). I2RH0B510098- 25) Remove oil pump assembly (1). I2RH0B510095- 20) Remove torque converter housing bolts. 21) Remove torque converter housing (1) while tapping around it lightly with plastic hammer. I2RH0B510099- 26) Remove direct clutch assembly (1). I3RM0B510060- 22) Remove breather hose (1).
Page 656 5A-116 Automatic Transmission: 28) Remove input shaft rear thrust bearing (1) and thrust 31) 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 657 Automatic Transmission: 5A-117 35) Remove 2nd brake gasket (1). 37) Remove forward and reverse clutch assembly (1). I2RH0B510109- I2RH0B510111- 36) Measure O/D and 2nd coast brake piston stroke. 38) Remove intermediate shaft thrust bearing front race If piston stroke exceeds specification, inspect and (1), thrust bearing (2) and rear race (3) from forward replace plates and discs.
Page 658 5A-118 Automatic Transmission: 40) Remove forward clutch hub (1). I2RH0B510117- I2RH0B510114- 44) Remove planetary gear thrust bearing (1). 41) Remove rear sun gear thrust bearing (1) from NOTE: forward clutch hub (2). If planetary gear thrust bearing is not found NOTE: on one-way clutch No.1 assembly, it may If rear sun gear thrust bearing is not found on...
Page 659 Automatic Transmission: 5A-119 I2RH0B510124- I2RH0B510120- 51) Remove 2nd brake piston assembly (1). 48) Remove front planetary sun gear (1). 52) Remove 2nd brake return spring subassembly (2). I2RH0B510121- I4RS0A510038- 49) Remove front sun gear thrust bearing race (2) from 53) Remove 2nd brake separator plates (1), discs (2) front planetary sun gear (1).
Page 660 5A-120 Automatic Transmission: 55) Remove one-way clutch outer race retainer (1). I2RH0B510132- 59) Measure 1st and reverse brake piston stroke. I2RH0B510129- If piston stroke exceeds specified value, 56) Check one-way clutch No.2 as follows. disassemble, inspect and replace discs and plates. •...
Page 661 Automatic Transmission: 5A-121 I2RH0B510134- 61) Remove 1st and reverse brake retaining plate, discs I2RH0B510137- 65) Using special tools and hydraulic press, remove and separator plates. planetary ring gear subassembly (1). 62) Remove 1st and reverse brake return spring subassembly (1). CAUTION: Do not reuse planetary ring gear subassembly.
Page 662 5A-122 Automatic Transmission: 67) Screwing 3 bolts (1), remove reduction drive gear (2). CAUTION: Screw 3 bolts into reduction drive gear uniformly, or reduction drive gear, bearing and transaxle case may be damaged. Bolt length 30 mm (1.20 in.) I2RH0B510142- 70) With slotted screwdriver, cut and unfold manual valve lever spacer (1) and proceed to remove manual valve lever spacer.
Page 663 Automatic Transmission: 5A-123 I2RH0B510146- I2RH0B510147- 75) Remove manual shift shaft oil seal (1). Oil Pump Assembly Components S4RS0A5106027 I2RH0B510148- 1. Oil seal 5. Oil pump drive gear : Apply automatic transaxle fluid. : Apply grease 99000-25030 to oil seal lip. 2.
Page 664 5A-124 Automatic Transmission: Oil Pump Assembly Disassembly and 2) Install driven gear and drive gear to oil pump body after applying A/T fluid. Reassembly S4RS0A5106028 3) Install stator shaft assembly to oil pump body and tighten 8 pump subassembly bolts (1) to Disassembly specification.
Page 665 Automatic Transmission: 5A-125 2) Check tip clearance of both drive and driven gears. Using a feeler gauge, measure clearance between drive and driven gear tips. If clearance exceeds its standard value, replace oil pump assembly. Tip clearance between oil pump drive gear and oil pump driven gear Standard: 0.07 –...
Page 666 5A-126 Automatic Transmission: Direct Clutch Assembly Components S4RS0A5106030 I2RH0B510160- 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 667 Automatic Transmission: 5A-127 Direct Clutch Assembly Disassembly and Reassembly S4RS0A5106032 Disassembly 1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates. I2RH0B510165- 2. Direct clutch piston 6) Remove inner O-ring (2). I2RH0B510162- 2) Using special tool and hydraulic press, remove shaft snap ring (1).
Page 668 5A-128 Automatic Transmission: Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new seal ring and O-ring. Apply A/T fluid before installation. • Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return spring subassembly passing through its original installing position over 0.7 mm (0.027 in.).
Page 669 Automatic Transmission: 5A-129 Direct Clutch Assembly Inspection Direct Clutch Piston S4RS0A5106033 Shake direct clutch piston lightly and check that check ball (1) is not stuck. Clutch Discs, Plates and Retaining Plate Blow in low pressure air (Max. 100 kPa, 1 kg/cm , 15 psi) Check that sliding surfaces of discs, separator plates to check ball to check that there is no leakage.
Page 670 5A-130 Automatic Transmission: Forward and Reverse Clutch Assembly Components S4RS0A5106034 I3RM0B510061- 1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate 2. Forward clutch return spring 9. Reverse clutch plate snap ring 16. Forward clutch disc subassembly 3.
Page 671 Automatic Transmission: 5A-131 I2RH0B510178- 2) Remove forward clutch plate snap ring (1) and take out forward clutch retaining plate, discs and I2RH0B510176- separator plates from forward clutch drum. 2) Blow compressed air (400 – 800 kPa, 4 – 8 kg/cm 57 –...
Page 672 5A-132 Automatic Transmission: 5) Remove forward clutch return spring subassembly (1). I2RH0B510184- 9) Remove forward clutch drum O-ring (1) from forward clutch drum (2). I2RH0B510181- 2. Intermediate shaft subassembly 6) Install intermediate shaft subassembly (1) to transaxle rear cover (2). Apply compressed air (400 –...
Page 673 Automatic Transmission: 5A-133 • 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 674 5A-134 Automatic Transmission: • Install reverse clutch plate snap ring so that its both Forward and Reverse Clutch Assembly ends would be positioned in correct locations as Inspection shown in figure. S4RS0A5106037 Clutch, Discs, Separator Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt.
Page 675 Automatic Transmission: 5A-135 I2RH0B510194- Forward Clutch Drum Lip Check each lip for wear, deformation, cut and/or I2RH0B510195- hardening. If necessary, replace. 2nd Brake Piston Assembly Components S4RS0A5106038 I2RH0B510196- 1. 2nd brake cylinder 4. Outer O-ring 2. 2nd brake piston : Apply automatic transaxle fluid. 3.
Page 676 5A-136 Automatic Transmission: • Use new O-rings. Apply A/T fluid to the O-rings, 2) Remove inner O-ring (1) and outer O-ring (2). before installation. • Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2). Do not damage O-ring when installing 2nd brake piston.
Page 677 Automatic Transmission: 5A-137 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly S4RS0A5106044 Disassembly 1) Remove snap ring by using special tools and hydraulic press. Special tool (A): 09926–96030 (B): 09946–06710 I2RH0B510203- 5) Remove rear cover seal rings (1). CAUTION: Do not press O/D and 2nd coast brake return spring subassembly in over 1.0 mm (0.039...
Page 678 5A-138 Automatic Transmission: Transaxle Rear Cover (O/D and 2nd Coast Brake • Do not open rear cover seal ring too wide to attach. Piston) Assembly Inspection S4RS0A5106045 O/D and 2nd Coast Brake Return Spring Subassembly Measure free length of O/D and 2nd coast brake return spring.
Page 679 Automatic Transmission: 5A-139 Countershaft Assembly Components S4RS0A5106048 I2RH0B510211- Reassembly 1) Install new countershaft RH bearing (1) by using special tool and hydraulic press. Special tool (A): 09913–84510 I2RH0B510209- NOTE: 1. Countershaft RH bearing 5. Bearing cap 2. Countershaft 6. Countershaft bearing shim Replace countershaft RH bearing together 3.
Page 680 5A-140 Automatic Transmission: 3) Install countershaft LH bearing (1) with special tools and hydraulic press. Special tool (A): 09913–84510 (B): 09925–88210 I2RH0B510214- Valve Body Assembly Components S4RS0A5106050 I4RS0A510044- 1. Pressure control solenoid valve 6. Temperature sensor clamp : Apply automatic transaxle fluid. 2.
Page 681 Automatic Transmission: 5A-141 Valve Body Assembly Disassembly and Reassembly S4RS0A5106051 CAUTION: When replacing pressure control solenoid valve and/or TCC pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing pressure control solenoid valve and/or TCC pressure control solenoid valve independently may cause excessive shift I2RH0B510219-...
Page 682 5A-142 Automatic Transmission: Reassembly Reverse disassembly procedure for assembly, noting the 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 683 Automatic Transmission: 5A-143 Differential Assembly Disassembly and Special tool (A): 09926–37610 Reassembly (B): 09926–37610–001 S4RS0A5106053 (C): 09926–37610–003 Disassembly (D): 09926–37610–002 1) Remove final gear bolts (1), and then final gear (2). I2RH0B510225- 2) Remove differential side RH bearing by using special I2RH0B510228- tools.
Page 684 5A-144 Automatic Transmission: 2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. I2RH0B510233- 6) Install new differential side LH bearing (1) by using I2RH0B510230- special tool and hydraulic press. 3) Tighten final gear bolts (1) to specified torque. NOTE: NOTE: Replace differential side LH bearing together...
Page 685 Automatic Transmission: 5A-145 Torque Converter Housing Disassembly and Reassembly S4RS0A5106055 Disassembly 1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2). I2RH0B510239- 5) Remove differential side RH bearing cup by using special tools. Special tool (A): 09944–96011 (B): 09942–15511 I2RH0B510236- 2) Remove lubrication LH tube (1) and RH tube (2).
Page 686 5A-146 Automatic Transmission: Differential side oil seal installing depth Reassembly “a”: 2.6 – 3.6 mm (0.10 – 0.14 in.) 1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque 5) Apply grease to oil seal lip. converter housing.
Page 687 Automatic Transmission: 5A-147 Transaxle Case Disassembly and Reassembly Reassembly S4RS0A5106057 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): 09944–88220...
Page 688 5A-148 Automatic Transmission: 4) Apply grease to oil seal lip. : Grease 99000–25030 I2RH0B510253- 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 689 Automatic Transmission: 5A-149 Adjustment Available shim thickness Thickness Identification mark Differential side bearing preload 1.80 mm (0.070 in.) 1.85 mm (0.072 in.) 1) After applying A/T fluid to differential assembly, fit it 1.90 mm (0.074 in.) to transaxle case. 1.95 mm (0.076 in.) 2) Install torque converter housing to transaxle case, 2.00 mm (0.078 in.) then tighten bolts (1) to specified torque.
Page 690 • Apply automatic transaxle fluid on sliding or rotating surfaces of the parts before assembly. • Use Suzuki Super Grease “C” to retain I3RM0B510067- 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 691 Automatic Transmission: 5A-151 Tightening torque Tightening torque Manual detent spring bolt (a): 10 N·m (1.0 kg-m, Parking lock pawl bracket bolt (a): 7.5 N·m (0.75 7.5 lb-ft) kg-m, 5.5 lb-ft) I2RH0B510262- I2RH0B510259- 7) After applying A/T fluid to new O-rings, install them 3) Install parking lock pawl rod (2) to manual valve lever to 1st and reverse brake piston (3).
Page 692 5A-152 Automatic Transmission: 9) Install 1st and reverse brake return spring subassembly (1) to transaxle case (2). I2RH0B510265- 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- [A]: Correct [B]: Incorrect...
Page 693 Automatic Transmission: 5A-153 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- 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 694 5A-154 Automatic Transmission: 18) Caulk reduction drive gear nut (1). “a” I2RH0B510274- 19) Apply A/T fluid to planetary gear assembly (1), then fit it to planetary ring gear assembly. I2RH0B510275- 20) Check for correct installation of planetary gear assembly as follows. “a”...
Page 695 Automatic Transmission: 5A-155 23) Apply A/T fluid to new brake drum gasket (1), then CAUTION: install it to transaxle case. 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 0.4 mm (0.016 in.).
Page 696 5A-156 Automatic Transmission: 30) 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. I2RH0B510290- 35) After applying A/T fluid to rear sun gear thrust bearing race (1), install it to rear planetary sun gear (2).
Page 697 Automatic Transmission: 5A-157 Bearing race dimension Front race Rear race Outside 30.6 mm (1.20 in.) 28.2 mm (1.11 in.) diameter “a” Thickness 2.0 mm (0.08 in.) 2.0 mm (0.08 in.) “a” I2RH0B510294- 39) Apply A/T fluid to forward and reverse clutch assembly (1).
Page 698 5A-158 Automatic Transmission: Available O/D and 2nd coast brake rear plate 45) Remove sealant attached to mating surface of thickness transaxle rear cover (1) completely. Thickness Identification mark 46) Apply sealant to mating surface of transaxle rear 1.8 mm (0.071 in.) cover (1) by using a nozzle (2) as shown in figure by 2.0 mm (0.079 in.) such amount that its section is 1.2 mm (0.047 in.) in...
Page 699 Automatic Transmission: 5A-159 54) After applying A/T fluid to input shaft rear thrust bearing (1) and thrust bearing race (2), install them into direct clutch hub (3). I2RH0B510304- 52) After applying A/T fluid to differential assembly (1) and countershaft assembly (2), install them to I2RH0B510307- transaxle case.
Page 700 5A-160 Automatic Transmission: 57) Check for correct installation of direct clutch assembly as follows. Measure distance “a” by using micrometer caliper (1) and straightedge (2). If out of specification, remove direct clutch assembly, direct clutch hub and reinstall them properly. Distance between direct clutch assembly and mating surface of transaxle case “a”: 10.5 –...
Page 701 Automatic Transmission: 5A-161 63) Wipe off and clean mating surface between transaxle case (1) and torque converter housing. 64) Apply sealant to torque converter housing by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “A”: Sealant 99000–31230 I2RH0B510317- “A”...
Page 702 5A-162 Automatic Transmission: 71) After applying A/T fluid to new O-ring, fit it to valve body harness connector (3), then install valve body harness to transaxle case. CAUTION: When put valve body harness (1) into transaxle case, take care not to damage transmission fluid temperature sensor (2) at narrow entrance of case.
Page 703 Automatic Transmission: 5A-163 Tightening torque Bolt Length “a” Pieces Oil strainer bolt (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) B (2) 28 mm (1.10 in.) C (3) 49 mm (1.93 in.) D (4) 36 mm (1.42 in.) E (5) 40 mm (1.58 in.) I2RH0B510325- 76) Install oil cleaner magnets (1) in oil pan (2).
Page 704 5A-164 Automatic Transmission: 80) Install new gaskets (2) and then install fluid cooler pipes. Tightening torque Fluid cooler pipe union bolt (b): 22 N·m (2.2 kg- m, 16.0 lb-ft) Fluid cooler pipe bracket bolt (c): 10 N·m (1.0 kg-m, 7.5 lb-ft) 81) After applying A/T fluid to new O-ring, fit it to fluid filler tube.
Page 705 Automatic Transmission: 5A-165 94) Install torque converter (3) noting the following points. CAUTION: • Before installing converter, make sure that its pump hub portion is free from nicks, burrs or damage which may cause oil seal to leak. • Be very careful not to drop converter on oil pump gear.
Page 706 5A-166 Automatic Transmission: Specifications Tightening Torque Specifications S4RS0A5107001 Tightening torque Fastening part Note kg-m lb-ft A/T fluid drain plug 12.5 Transmission range sensor bolt 0.55 Output shaft speed sensor (VSS) bolt Input shaft speed sensor bolt 0.55 Valve body harness connector bolt 0.55 Shift solenoid bolt Oil strainer bolt...
Page 707 Automatic Transmission: 5A-167 Special Tools and Equipment Recommended Service Material S4RS0A5108001 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-168 Automatic Transmission: 09923–78210 09924–74510 Bearing installer Bearing and oil seal handle 09925–37811–001 09925–88210 Oil pressure gauge Bearing puller attachment 09925–98210 09925–98221 Input shaft bearing installer Bearing installer 09926–37610–001 09926–37610–002 Bearing puller Bearing puller attachment 09926–37610–003 09926–37610 Bearing remover attachment Bearing remover 09926–58010 09926–96030...
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 5B-1 Manual Transmission: Manual Transmission General Description Manual Transaxle Construction and Servicing S4RS0A5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs 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: 5B-2 I3RM0B521001- 1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 3rd gear 2. Input shaft 5th gear 9. Input shaft 16. Countershaft 2nd gear 3. Input shaft 4th gear 10. Right case 17. Low speed synchronizer sleeve & hub 4.
Page 712 5B-3 Manual Transmission: Diagnostic Information and Procedures Manual Transaxle Symptom Diagnosis S4RS0A5204001 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.
Page 713 Manual Transmission: 5B-4 Differential Side Oil Seal Replacement S4RS0A5206002 1) Lift up vehicle and drain transaxle oil. 2) Remove front drive shaft and/or center shaft referring to “Front Drive Shaft Assembly Removal and Installation: in Section 3A”. 3) Remove oil seal (1) using special tool. Special tool (A): 09913–50121 I4RH01520003-...
Page 714 5B-5 Manual Transmission: Gear Shift Control Lever and Cable Components S4RS0A5206003 I4RS0A520002- 1. Gear shift control lever knob 6. Gear shift control lever assembly mounting nut : 10 N m (1.0 kg-m, 7.5 lb-ft) 2. Cable bracket bolt 7. Gear shift control lever assembly : 55 N m (5.5 kg-m, 40.0 lb-ft) 3.
Page 715 Manual Transmission: 5B-6 Gear Shift Control Lever and Cable Removal and Installation S4RS0A5206004 Removal 1) Remove console box. 2) Disconnect cable ends (5) from pivot (6) of gear shift control lever assembly. 3) Disconnect gear shift and select control cables (1) from gear shift control lever assembly (2) while pulling quick joint (4) as shown in figure.
Page 716 5B-7 Manual Transmission: Vehicle Speed Sensor (VSS) Removal and Tightening torque Cable bracket bolt (a): 55 N·m (5.5 kg-m, 40.0 lb- Installation S4RS0A5206027 Removal 1) Remove battery and tray with coolant reservoir. 2) Disconnect gear shift and select control cables (1) from transaxle.
Page 717 Manual Transmission: 5B-8 Back Up Lamp Switch Inspection Installation S4RS0A5206008 1) Apply oil to new O-ring (1) and tighten back up lamp Check back up lamp switch for function using ohmmeter. switch (2) to specified torque. Back up lamp switch specification Tightening torque Switch ON (Push): Continuity Back up lamp switch (a): 23 N·m (2.3 kg-m, 17.0...
Page 718 5B-9 Manual Transmission: 3. Engine rear mounting and bracket 10. Transaxle to engine nut : 85 N m (8.5 kg-m, 61.5 lb-ft) 4. Back up lamp switch connector 11. Ground cable : 55 N m (5.5 kg-m, 40.0 lb-ft) 5. VSS connector 12.
Page 719 Manual Transmission: 5B-10 16) Remove engine under covers. Remounting 17) Support transaxle with transmission jack. CAUTION: 18) Remove transaxle to engine bolts and nut of lower • Care should be taken not to scratch oil side. seal lip with drive shaft while raising 19) Remove engine left mounting (1) with bracket (2).
Page 720 5B-11 Manual Transmission: Gear Shift and Select Shaft Assembly Components S4RS0A5206029 I4RS0A520014- 1. Gear shift & select shaft 7. Gear shift guide case bolt 13. Select lever boss : Apply sealant 99000-31260 to bolt thread. : Apply grease 99000-25010 to internal and external diameter.
Page 721 Manual Transmission: 5B-12 NOTE: 4) Install washer and gear shift interlock bolt (2) to which sealant have been applied and then tighten it • Set new gear shift & select lever inner pin to specified torque. (8) and outer pin (9) facing each gap (“a”, “B”: Sealant 99000–31260 “b”) in the opposite direction as shown in figure.
Page 722 5B-13 Manual Transmission: Manual Transaxle Assembly Components S4RS0A5206028 I4RS0A520013-...
Page 723 Manual Transmission: 5B-14 1. Transaxle right case 25. 5th gear shift fork 2. Transaxle left case 26. Needle bearing (Separated steel cage type.) : Apply sealant 99000-31260 to mating surface of left case and right case. 3. Gear shift and select shaft assembly 27.
Page 724 5B-15 Manual Transmission: 6) Remove input shaft 5th gear, needle bearing and NOTE: then countershaft 5th gear (1). Gear puller (2) would • Align protrusion A of 5th speed be necessary if spline fitting of countershaft 5th gear synchronizer levers (1) with groove of hub is tight.
Page 725 Manual Transmission: 5B-16 2, (a), “A” 2, (a) I3RM0B521016- 5) Fit 5th gear shift fork (1) to synchronizer sleeve (2) and hub (3) assembly and install them into input I4RS0A520030- shaft and gear shift shaft aligning punch mark (4) 4. Polished surface with matching mark (5) on input shaft.
Page 726 5B-17 Manual Transmission: Manual Transaxle Assembly Disassembly and Reassembly S4RS0A5206034 Disassembly 1) Remove gear shift and select shaft assembly referring to “Gear Shift and Select Shaft Assembly Removal and Installation: ”. 2) Remove fifth gear referring to “Fifth Gear Disassembly and Assembly: ”. 3) Remove left case plate.
Page 727 Manual Transmission: 5B-18 I2RH01520036- 3. VSS I4RH01520021- 15) Remove side bearing retainer bolts. Installation 16) Turn side bearing retainer (1) counterclockwise until 1) Install differential assembly (1) into right case (2). it stops, and remove side bearing retainer using 2 flat end rods (2) or the like.
Page 728 5B-19 Manual Transmission: 6) Clean mating surfaces of both right and left cases, 3) Install 5th & reverse gear shift shaft (1) with 5th & reverse gear shift guide shaft (2) into right case (5). apply sealant to right case (2) as shown in the figure Reverse gear shift arm (4) has to be joined with by such amount that its section is 1.5 mm (0.059 in.) reverse gear shift lever (3) at the same time.
Page 729 Manual Transmission: 5B-20 iii) Calculate clearance a – b, and select differential shim according to the following table. Bearing shim specification Thickness of bearing Clearance “a” – “b” shim to be installed 0.636 – 0.665 mm 0.75 mm (0.030 in.) (0.0250 –...
Page 730 5B-21 Manual Transmission: c) Install differential side bearing shim to left case (4). d) Apply oil to new O-ring of side bearing retainer (3), and install side bearing retainer with new O- ring to left case. e) Tighten side bearing retainer bolts (1) to specified torque.
Page 731 Manual Transmission: 5B-22 15) By repeating Step 14), select a suitable shim which adjusts clearance “a” to specification and put it on bearing outer race. NOTE: Insert 0.15 mm (0.0059 in.) feeler to know whether or not a shim fulfills specification quickly.
Page 732 5B-23 Manual Transmission: 3) Remove input shaft oil seal (1) using special tools, if necessary. Special tool (A): 09930–30104 (B): 09923–74510 4) Pull out countershaft right bearing outer race (2) using special tools, if necessary. Special tool (A): 09930–30104 (C): 09941–64511 I3RM0A520047- 4) Install differential side bearing outer race to right case using special tool and hammer.
Page 733 Manual Transmission: 5B-24 Assembly 1) If input oil gutter (1) 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 kg-m, 7.5 lb-ft) I3RM0A520048- 2) If differential side oil seal is removed, install it to left case referring to “Differential Side Oil Seal...
Page 734 5B-25 Manual Transmission: 8. High speed synchronizer sleeve & hub 19. Low speed synchronizer spring 30. Countershaft left bearing 9. High speed synchronizer key 20. Low speed synchronizer sleeve & hub : Do not reuse. 10. Circlip 21. Low speed synchronizer key : Apply transaxle oil.
Page 735 Manual Transmission: 5B-26 3) Fit high speed synchronizer sleeve (4) to hub (3), 6) Drive in high speed synchronizer sleeve & hub insert 3 keys (2) in it and then set springs (1) as assembly (3) using special tool and hammer, facing shown in the figure.
Page 736 5B-27 Manual Transmission: 8) Press-fit left bearing (2) using special tool and CAUTION: hammer. • If compression exceeds 5 ton (11,000 lb), Special tool release compression once, reset bearing (A): 09913–70123 puller support and then continue press work again. 9) Using the same special tool at Step 8), drive in 5th gear spacer (1).
Page 737 Manual Transmission: 5B-28 6) Disassemble low speed synchronizer sleeve & hub assembly. 7) Take out 1st gear needle bearing of resin cage type from shaft. 8) Remove right bearing cone (2) using bearing puller (3), metal stick (1) and hydraulic press. I2RH01520058- Assembly 1) Clean all components thoroughly, inspect them for...
Page 738 5B-29 Manual Transmission: NOTE: CAUTION: Press-fit spacer (1) and 3rd gear (2) first, and • Support shaft with special tool as shown in then 4th gear later separately so that the figure so that retainer of bearing cone countershaft will not be compressed (4) will be free from compression.
Page 739 Manual Transmission: 5B-30 Synchronizer Parts Inspection Put the 2nd gear synchronizer outer ring (1), inner ring S4RS0A5206036 (3) and the cone (2) together and then measure the step Check clearance “a” between synchronizer ring (2) and difference between the outer ring and the inner ring. And gear (1), each chamfered tooth of gear, synchronizer also check each chamfered tooth of gear and ring and sleeve, then determine parts replacement.
Page 740 5B-31 Manual Transmission: 5th and Reverse Gear Shift Shafts Disassembly Gear Shift Shaft and Fork Inspection S4RS0A5206037 and Assembly Using feeler gauge, check clearance between fork (1) S4RS0A5206024 and sleeve (2) and replace those parts if it exceeds limit. Disassembly NOTE: Disassemble component parts using special tool and For correct judgement of parts replacement,...
Page 741 Manual Transmission: 5B-32 Differential Components S4RS0A5206032 I4RS0A520016- 1. Differential pinion washer 8. Final gear 2. Differential side pinion gear 9. Final gear bolt 3. Differential side gear 10. Differential pinion shaft 4. Side gear washer 11. Differential pinion shaft pin 5.
Page 742 5B-33 Manual Transmission: Assembly Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean. 1) Assemble differential gear and measure thrust play of differential gear as follows.
Page 743 Manual Transmission: 5B-34 I3RM0B521025- 7) Hold differential assembly with soft jawed vise (3), install final gear (2) as shown in the figure and then tighten bolts (1) to specified torque. CAUTION: Use of any other bolts than specified ones is prohibited.
Page 744 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 S4RS0A5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25010 Sealant SUZUKI Bond No.1217G...
Page 745 Manual Transmission: 5B-36 09913–76010 09913–80113 Bearing installer Bearing installer 09913–84510 09913–85210 Bearing installer Bearing installer 09922–85811 09923–74510 Spring pin remover (4.5 mm) Bearing puller (20-35 mm) 09923–78210 09924–07710 Bearing installer Synchronizer hub installer 09924–07730 09924–74510 Bearing installer Bearing and oil seal handle 09924–84510–004 09925–15410 Bearing installer attachment...
Page 746 5B-37 Manual Transmission: 09927–76060 09930–30104 Gear holder Sliding shaft 09940–51710 09940–54910 Bearing installer Front fork oil seal install driver 09941–64511 09951–16060 Bearing and oil seal remover Control arm bush remover (30 mm Min.) 09951–16080 Bearing installer...
Page 747 Clutch: 5C-1 Clutch General Description Clutch Construction S4RS0A5301001 The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
Page 748 5C-2 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis S4RS0A5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
Page 749 Clutch: 5C-3 Repair Instructions Clutch Pedal Inspection S4RS0A5306019 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 specification shown below.
Page 750 5C-4 Clutch: Clutch Fluid Level Inspection S4RS0A5306020 Refer to “Master Cylinder and Brake Fluid Level Inspection: in Section 4A”. Air Bleeding of Clutch System S4RS0A5306021 CAUTION: I4RS0A530004- Brake fluid is extremely damaging to paint. If 4) When fluid pressure in cylinder is almost depleted, fluid should accidentally touch painted push pipe connector.
Page 751 Clutch: 5C-5 Clutch Fluid Pipe and Hose Components S4RS0A5306022 I4RS0A530005- 1. Master cylinder 5. Clamp : Apply grease 99000-25100 to push rod end. 2. Pipe 6. Clutch reservoir hose 3. Operating cylinder : 23 N m (2.3 kg-m, 17.0 lb-ft) : Apply grease 99000-25100 to rod tip.
Page 752 5C-6 Clutch: Installation Reverse removal procedure for installation noting the following. CAUTION: • Do not allow fluid to get on painted surface. • Do not allow pipe to contact hard against vehicle body or other parts. I4RS0A530008- • Install each clamp securely. 3.
Page 753 Clutch: 5C-7 • Tighten clutch operating cylinder bolt to specified Installation Reverse removal procedure for installation noting the torque. following. Tightening torque • Apply grease to push rod tip. Clutch operating cylinder bolt: 23 N·m (2.3 kg-m, 17.0 lb-ft) “A”: Grease 99000–25100 “A”...
Page 754: Removal And Installation
5C-8 Clutch: Clutch Cover, Clutch Disc and Flywheel Components S4RS0A5306014 I4RS0A530013- 1. Flywheel 9. Clutch disc 2. Flywheel bolt 10. Clutch cover bolt 3. Clutch release shaft seal 11. Release arm : Apply grease 99000-25010 to seal lip. (0.3 g (0.01 oz)) 4.
Page 755 Clutch: 5C-9 4) Remove flywheel (1) from crank shaft using special tool. Special tool (A): 09924–17810 I4RS0A530016- 3) Aligning clutch disc to flywheel center using special tool, install clutch cover (1) and bolts (2). Then tighten bolts (2) to specification. NOTE: •...
Page 756 5C-10 Clutch: NOTE: Clutch Cover 1) Check diaphragm spring (1) for abnormal wear or When inserting transaxle input shaft to clutch damage. disc, turn crankshaft little by little to match the splines. 2) Inspect pressure plate (2) for wear or heat spots. 3) If abnormality is found, replace clutch cover.
Page 757 Clutch: 5C-11 4) Coat grease to release shaft seal (2) lip and then 5) Install tap (M16 X 1.5) (1) to clutch release shaft No.1 bush. install it till it is flush with case surface. Use special tool for this installation and face seal lip downward (inside).
Page 758 5C-12 Clutch: Clutch Release System Inspection S4RS0A5306018 Clutch Release Bearing Check clutch release bearing for smooth rotation. If abnormality is found, replace it. CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage. I3RM0A530020- I4RS0A530021- 8) Set release arm (1) to release shaft (2) aligning Clutch Release Shaft punch mark (4) of release arm and punch mark (3) of...
Page 759 Clutch: 5C-13 Special Tools and Equipment Recommended Service Material S4RS0A5308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 3 — (DOT 3) Grease SUZUKI Super Grease A P/No.: 99000– 25010 SUZUKI Silicone Grease P/No.: 99000– 25100 SUZUKI Super Grease I P/No.: 99000–...
Page 760 5C-14 Clutch:...
Page 761 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 DTC Table............6C-6 Scan Tool Data ...........6C-8 Precautions............. 6-1 P/S System Symptom Diagnosis ......6C-9 Precautions on Steering........6-1 Serial Data Link Circuit Check ......6C-9 Steering General Diagnosis....6A-1 “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stop ....6C-11 Precautions............6A-1 “EPS”...
Page 762 6-ii Table of Contents Special Tool ............6C-38...
Page 763 Precautions: Precautions Precautions Precautions on Steering S4RS0A6000001 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 Diagnosis Refer to “Precautions for Steering Diagnosis: in Section 6A”. Service Precautions of Steering Wheel and Column Refer to “Service Precautions of Steering Wheel and Column: in Section 6B”.
Page 764 6A-1 Steering General Diagnosis: Steering General Diagnosis Precautions Precautions for Steering Diagnosis S4RS0A6100001 Since the problems in steering involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 765 Steering General Diagnosis: 6A-2 Diagnostic Information and Procedures Steering Symptom Diagnosis S4RS0A6104001 Condition Possible cause Correction / Reference Item Hard steering Tire not adequately inflated Inflate tires to proper pressure. Malfunction of power steering system Check and correct. Bind in tie-rod end ball studs or lower Replace tie-rod end or front suspension arm.
Page 766 6B-1 Steering Wheel and Column: Steering Wheel and Column Precautions Service Precautions of Steering Wheel and Enabling Air Bag System For enabling air bag system, refer to “Enabling Air Bag Column System: in Section 8B”. S4RS0A6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System: in Section 8B”.
Page 767 Steering Wheel and Column: 6B-2 5) Check steering shaft and steering column for bend, 4) Check steering shaft for smooth rotation. If found defective, replace as steering column cracks or deformation. assembly. If found defective, replace. Repair Instructions Steering Wheel and Column Construction S4RS0A6206009 I4RS0A620004- 1.
Page 768 6B-3 Steering Wheel and Column: 3) Remove driver air bag (inflator) module from steering wheel. Refer to “Driver Air Bag (Inflator) Module Removal and Installation: in Section 8B”. 4) Disconnect horn connector and audio control switch connector, if equipped. 5) Remove steering shaft nut and then make alignment marks (1) on steering wheel and shaft for a guide during reinstallation.
Page 769 Steering Wheel and Column: 6B-4 I4RS0A620008- I4RS0A620011- 5) Remove contact coil cable assembly (1) from 4) Install steering wheel to steering column. Refer to steering column. “Steering Wheel Removal and Installation: ”. 5) Connect battery negative (–) cable. 6) Enable air bag system referring to “Enabling Air Bag System: in Section 8B”.
Page 770 6B-5 Steering Wheel and Column: NOTE: 4) From the position where contact coil became unable to turn any further (it stopped), turn it back clockwise When servicing steering column or any about two and a half rotations and align center mark column-mounted component, remove with alignment mark (1).
Page 771 Steering Wheel and Column: 6B-6 3) Align flat part “A” of steering lower shaft (1) with bolt hole “B” of shaft joint (2) of column as shown. Then insert lower shaft into shaft joint of steering column with matching marks (4). 4) Insert lower shaft (1) into pinion shaft (3) with matching marks (4).
Page 772 6B-7 Steering Wheel and Column: Steering Column Inspection Installation S4RS0A6206006 1) Be sure that front wheels are in straight forward Check steering column for damage and operation state. referring to “Checking Steering Column for Accident 2) Align flat part “A” of steering lower shaft (1) with bolt Damage: ”.
Page 773 Steering Wheel and Column: 6B-8 Specifications Tightening Torque Specifications S4RS0A6207001 Tightening torque Fastening part Note kg-m lb-ft Steering shaft nut 24.0 Steering column nut 10.5 Steering shaft joint bolt 18.5 NOTE: The specified tightening torque is also described in the following. “Steering Wheel and Column Construction: ”...
Page 774 6C-1 Power Assisted Steering System: Power Assisted Steering System Precautions Steering System Note • Take a note of DTC indicated on the SUZUKI scan S4RS0A6300001 tool. NOTE: • Before inspection, be sure to read “Precautions for All steering gear fasteners are important Electrical Circuit Service: in Section 00”...
Page 775 Power Assisted Steering System: 6C-2 I4RS0A630001- 2. Steering column 6. Steering gear case assembly 7. Battery 9. ECM EPS Diagnosis General Description S4RS0A6301003 The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board diagnostic system which detects a malfunction in this system.
Page 776 6C-3 Power Assisted Steering System: Schematic and Routing Diagram EPS System Wiring Circuit Diagram S4RS0A6302001 E49-2 E51-1 E49-1 E51-2 LT GRN/BLK E52-1 RED/BLK E52-18 G28-31 G28-25 E52-5 E52-6 E52-8 E52-4 E52-20 E52-9 E52-16 RED/BLU E52-14 E52-19 E52-12 PPL/WHT E52-11 12 13 14 15 16 17 18 19 20 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 32 31 30 29 28 27...
Page 777 Power Assisted Steering System: 6C-4 [A]: Connector “E52” (viewed from harness side) 3. Junction block assembly 11. P/S control module [B]: Connector “E49” (viewed from harness side) 4. Fuse 12. P/S motor [C]: Connector “E51” (viewed from harness side) 5. VSS 13.
Page 778 6C-5 Power Assisted Steering System: NOTE: • As execution of “DTC Clearance: ” will clear all DTCs, be sure to record all DTCs before service. • DTC C1122 is indicated when ignition switch is at ON position and engine is not running, it means that nothing is abnormal.
Page 779 1) Turn ignition switch to OFF position. 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector 2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel (DLC) (1) located on underside of instrument panel at driver’s seat side.
Page 780 6C-7 Power Assisted Steering System: Detecting condition DTC No. Detecting item (DTC will set when detecting) Voltage at “E52-16” terminal is higher than 1 driving Torque sensor failure (signal voltage low) upper limit voltage for P/S control module C1118 cycle diagnosis for specified period or longer Voltage at “E52-8”...
Page 781 Power Assisted Steering System: 6C-8 Detecting condition DTC No. Detecting item (DTC will set when detecting) Battery voltage is higher than upper limit 1 driving C1155 P/S control module failure voltage for P/S control module diagnosis cycle or internal failure of controller Scan Tool Data ASSIST TORQUE S4RS0A6304011...
Page 782 6C-9 Power Assisted Steering System: P/S System Symptom Diagnosis S4RS0A6304001 This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board diagnostic system (self-diagnostic function). When no malfunction is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in “Steering Symptom Diagnosis: in Section 6A”...
Page 783 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check: ”. 1) Make sure that SUZUKI scan tool is free from Go to Step 3. Connect SUZUKI scan malfunction and that correct program card (software) for tool to DLC properly.
Page 784 6C-11 Power Assisted Steering System: “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stop S4RS0A6304013 Wiring Diagram E49-2 12 13 14 15 16 17 18 19 20 E49-1 LT GRN/BLK E52-1 RED/BLK 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17...
Page 785 Power Assisted Steering System: 6C-12 Step Action 1) Check for proper connection to P/S control module at Go to Step 5. “BLK” or “GRN” wire “E49-1” terminal. circuit open or short to ground. 2) If OK, check for voltage between “E49-1” (“GRN” wire) terminal and body ground with ignition switch ON.
Page 786 1) Perform DTC check. Go to Step 5 of “EPS Go to Step 2. System Check: ”. Is there any DTC (NO CODES on SUZUKI scan tool)? 1) With ignition switch OFF, disconnect P/S control module Connect P/S control Replace the P/S control connector (“E52”).
Page 787 Power Assisted Steering System: 6C-14 DTC C1113 / C1117 /C1118: Torque Sensor Circuit Failure S4RS0A6304015 DTC C1113: Torque Sensor Main and Sub Circuit Voltage Difference High DTC C1117: Torque Sensor Failure (Signal Voltage High) DTC C1118: Torque Sensor Failure (Signal Voltage Low) Wiring Diagram E49-2 E52-18...
Page 788 6C-15 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check: ”. Is DTC C1114 and/or DTC C1119 indicated, too? Go to “DTC C1114: Go to Step 3. Torque Sensor 5 V Power Supply Circuit Failure: ”...
Page 789 Power Assisted Steering System: 6C-16 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage at “E52-20” terminal (5 V) differs from specified • High resistance, open or short in torque sensor circuit voltage for P/S control module diagnosis for specified •...
Page 790 6C-17 Power Assisted Steering System: DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure S4RS0A6304020 Wiring Diagram E49-2 E52-18 E52-6 E52-8 E49-1 E52-20 E52-9 LT GRN/BLK E52-1 E52-16 E52-19 12 13 14 15 16 17 18 19 20 I4RS0B630006- [A]: Connector “E52”...
Page 791 Power Assisted Steering System: 6C-18 Step Action 1) Remove console box. Go to Step 4. Repair high resistance, open or short to power 2) Check P/S control module connector (“E52”) for proper circuit or ground in 12 V connection. power supply (“GRN” 3) If OK, turn ignition switch ON.
Page 792 6C-19 Power Assisted Steering System: DTC C1121 / C1123 / C1124: VSS Circuit Failure S4RS0A6304017 DTC C1121: VSS Circuit Signal Not Input (60 Seconds or More) DTC C1123: VSS Circuit Signal Not Input (30 Seconds or More) DTC C1124: VSS Circuit Failure (Abnormal Deceleration) Wiring Diagram E49-2 12 13 14 15 16 17 18 19 20...
Page 793 Power Assisted Steering System: 6C-20 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1121: • High resistance, open or short in VSS circuit No vehicle speed signal is inputted to P/S control module • VSS in either one of the following two conditions •...
Page 794 6C-21 Power Assisted Steering System: DTC C1122: Engine Speed Signal Circuit Failure S4RS0A6304018 Wiring Diagram E49-2 E49-1 LT GRN/BLK E52-1 12 13 14 15 16 17 18 19 20 RED/BLU E52-14 E52-12 I4RS0B630008- [A]: Connector “E52” (viewed from harness side) 2.
Page 795 Power Assisted Steering System: 6C-22 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure S4RS0A6304019 DTC C1141: Motor Circuit Voltage Abnormal DTC C1142: Motor Circuit Current High Command with P/S Control Module Target Current DTC C1143: Motor Circuit Current Excessive DTC C1145: Motor Circuit Current Low Command with P/S Control Module Target Current Wiring Diagram E49-1...
Page 796 6C-23 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check: ”. Is DTC C1153 and/or DTC C1155 indicated, too? Go to “DTC C1153: P/S Go to Step 3. Control Module Power Supply Circuit Failure: ”...
Page 797 Power Assisted Steering System: 6C-24 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Battery voltage is lower than lower limit voltage for P/S • High resistance, open or short in P/S control module control module diagnosis power supply circuit (1 driving cycle detection logic) •...
Page 798 6C-25 Power Assisted Steering System: DTC C1155: P/S Control Module Failure S4RS0A6304022 Wiring Diagram E49-1 LT GRN/BLK E52-1 12 13 14 15 16 17 18 19 20 E49-2 I4RS0B630010- [A]: Connector “E52” (viewed from harness side) 2. Ignition switch 5. P/S control module [B]: Connector “E49”...
Page 799 Power Assisted Steering System: 6C-26 Voltage Check 1) Remove console box. 2) Check for voltage at each terminal with connectors connected to the P/S control module. NOTE: As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or more when ignition switch is ON.
Page 800 6C-27 Power Assisted Steering System: Terminal Wire color Circuit Normal voltage Condition • Ignition switch ON and steering wheel at straight position E52-6 Torque sensor (Sub) About 2.5 V • Check voltage between “E52-6” and “E52-9” terminals E52-7 — — —...
Page 801 Power Assisted Steering System: 6C-28 Steering Wheel Play Check Steering Force Check S4RS0A6304002 S4RS0A6304003 • Check steering wheel for looseness or rattle by 1) Place vehicle on level road and set steering wheel at moving it in its shaft direction and lateral direction. straight-ahead position.
Page 802 6C-29 Power Assisted Steering System: Repair Instructions Steering Gear Case Assembly Components S4RS0A6306020 I4RS0A630025- 1. Steering gear case 10. Steering gear case mounting No.1 bolt 19. Heat insulator bolt 2. Tie-rod lock washer 11. Steering gear case grommet : 93 N m (9.3 kg-m, 67.5 lb-ft) 3.
Page 803 Power Assisted Steering System: 6C-30 Tie-Rod End Boot On-Vehicle Inspection S4RS0A6306008 Inspect each boot for tear. If evan a small tear is noted, replace it with a new one. I4RS0A630041- Installation 1) Install tie-rod end lock nut (1) and tie-rod end (2) to I3RM0A630024- tie-rod (3).
Page 804 6C-31 Power Assisted Steering System: Steering Gear Case Assembly Removal and 4) After confirming proper toe, tighten tie-rod end lock nut to specified torque. Installation S4RS0A6306013 Tightening torque Tie-rod end lock nut (a): 45 N·m (4.5 kg-m, 32.5 Removal lb-ft) CAUTION: Be sure to set front wheels (tires) in straight direction and remove ignition key from key...
Page 805 Power Assisted Steering System: 6C-32 4,(b) 3,(a) I4RS0A630030- 2) Install front suspension frame with steering gear case assembly referring to “Front Suspension I4RS0A630040- Frame, Stabilizer Bar and/or Bushings Removal and 7) To remove the steering gear case assembly easily, Installation: in Section 2B”. lower the engine with transmission, but don’t remove.
Page 806 6C-33 Power Assisted Steering System: Steering Rack Boot Inspection 7) Tighten steering shaft joint lower bolt (1) and upper bolt (2) to specified torque (Lower side first and then S4RS0A6306014 Hoist vehicle. upper side). Inspect each boot for tear. A torn boot allows entry of Tightening torque dust and water which can cause wear to steering rack Steering shaft joint bolt (a): 25 N·m (2.5 kg-m,...
Page 807 Power Assisted Steering System: 6C-34 7) Hold rack with soft jawed vise (3) and remove tie-rod from rack (2). I3RM0A630050- 5) Fasten boot with new band and clip securely. Special tool (A): 09943–55010 I3RM0A630051- I4RS0A630033- 6) Install tie-rod end lock nut and tie-rod end to tie-rod. Installation Position lock nut to marking (1) made in removal.
Page 808 6C-35 Power Assisted Steering System: Steering Rack Plunger Removal and Installation Special tool S4RS0A6306030 (A): 09944–18310 Tightening torque Removal Rotation torquer of pinion (a): 2.0 N·m (0.2 kg- 1) Remove gear case assembly referring to “Steering m, 1.5 lb-ft) Gear Case Assembly Removal and Installation: ”. 2) Loosen lock nut (1) with holding damper screw (2).
Page 809 Power Assisted Steering System: 6C-36 Motor Assembly Inspection S4RS0A6306029 1) Remove console box. 2) Disconnect motor connector (“E51”) from P/S control module with ignition switch OFF. 3) Check for resistance between terminals of motor connector (“E51”). If check result is not as specified, replace steering gear case assembly.
Page 810 6C-37 Power Assisted Steering System: Specifications Tightening Torque Specifications S4RS0A6307001 Tightening torque Fastening part Note kg-m lb-ft Tie-rod end nut 32.5 Tie-rod end lock nut 32.5 Wheel bolt 61.5 Steering gear case mounting No.1 bolt 40.0 Steering gear case mounting No.3 bolt 29.0 Engine rear mounting bracket bolt Steering shaft joint bolt...
Page 811 Power Assisted Steering System: 6C-38 Special Tools and Equipment Recommended Service Material S4RS0A6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Sealant Silicone Sealant P/No.: 99000–31120 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110...
Page 812 6C-39 Power Assisted Steering System:...
Page 813 Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 A/C System Symptom Diagnosis ......7B-7 Abnormal Noise Symptom Diagnosis of A/C Precautions............. 7-1 System ..............7B-9 Precautions on HVAC ........... 7-1 A/C System Performance Inspection ....7B-10 Heater and Ventilation......7A-1 A/C System Inspection at ECM......7B-15 Repair Instructions ..........7B-17 General Description ..........7A-1...
Page 814 7-1 Precautions: Precautions Precautions Precautions on HVAC S4RS0A7000001 Air Bag Warning Refer to “Air Bag Warning: in Section 00”. A/C System Caution Refer to “A/C System Caution: in Section 7B”. Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System: in Section 7B”.
Page 815 Heater and Ventilation: 7A-1 Heater and Ventilation General Description Heater and Ventilation Construction S4RS0A7101001 I4RS0A710001- 1. HVAC unit 6. Foot air 11. Center ventilation air 2. Ventilator duct 7. Front defroster air 12. Air intake door 3. Defroster nozzle 8. Side defroster air 13.
Page 816 7A-2 Heater and Ventilation: Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S4RS0A7102001 BLK/YEL BLK/WHT G19-6 G19-7 RED/BLK G19-1 BLU/WHT G19-3 G19-2 RED/BLK G18-14 G18-13 G18-9 G18-10 BLK/ORN G18-8 BLK/RED G18-7 RED/YEL G18-4 G18-3 E23-19 BLU/WHT I4RS0A710002- 1. Ignition switch 4.
Page 817 Heater and Ventilation: 7A-3 Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S4RS0A7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground. speed selector ON.
Page 818 7A-4 Heater and Ventilation: Repair Instructions HVAC Unit Components S4RS0A7106001 I4RS0A710003- 1. Fresh air inlet duct 6. Foot duct 11. Blower motor 16. Drain hose 2. Blower upper case 7. Airflow control door assembly 12. Heater unit lower case 17. Packing 3.
Page 819 Heater and Ventilation: 7A-5 HVAC Unit Removal and Installation S4RS0A7106002 Removal 1) Disconnect negative (–) cable from battery. 2) Disable air bag system referring to “Disabling Air Bag System: in Section 8B”. 3) Remove cowl top panel from vehicle body referring to “Cowl Top Components: in Section 9K”.
Page 820 7A-6 Heater and Ventilation: Blower Motor Resistor Removal and Installation Installation S4RS0A7106005 Reverse removal procedure noting the following Removal instruction. 1) Disconnect negative (–) cable from battery. • Enable air bag system referring to “Enabling Air Bag 2) Disable air bag system referring to “Disabling Air System: in Section 8B”.
Page 821 Heater and Ventilation: 7A-7 HVAC Control Unit Components S4RS0A7106008 I4RS0A710012- 1. Heater control body assembly 4. Bulb 7. Air intake switch 10. Rear defogger switch 2. Airflow selector 5. Temperature control cable 8. Temperature selector 3. Blower speed selector 6. Airflow control cable 9.
Page 822 7A-8 Heater and Ventilation: Installation Reverse removal procedure noting the following instructions. • Connect temperature control cable and airflow control cable of HVAC control unit to links of HVAC unit. a. Set airflow selector (1) to “VENT” position and temperature selector (2) to “MAX COOL” position. I4RS0A710016- b.
Page 823 Heater and Ventilation: 7A-9 Air Intake Switch Inspection Installation S4RS0A7106018 Reverse removal procedure noting the following • Check that there is continuity between terminal (1) instruction. and terminal (2) when air intake switch is at fresh • Be sure to insert the linkage pin (1) into the groove (2) position.
Page 824 7A-10 Heater and Ventilation: Center Ventilation Louver Removal and Side Ventilation Louver Removal and Installation Installation S4RS0A7106014 S4RS0A7106015 Removal Right side ventilation louver 1) Disconnect negative (–) cable from battery. Removal 2) Disable air bag system referring to “Disabling Air 1) Disconnect negative (–) cable from battery.
Page 825: Air Filter Cleaning
Heater and Ventilation: 7A-11 4) Remove passenger air bag module from instrument Installation panel referring to “Passenger Air Bag (Inflator) Reverse removal procedure noting the following Module Removal and Installation: in Section 8B”. instructions. 5) Separate left side ventilation louver (1) and •...
Page 826 7B-1 Air Conditioning System: Air Conditioning System Precautions A/C System Caution S4RS0A7200001 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: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12). Be sure to check which refrigerant is used before any service work including inspection and maintenance.
Page 827 Air Conditioning System: 7B-2 I4RS0A720001- 1. Suction hose 4. Expansion valve : Apply compressor oil (refrigerant oil) to O-ring. : Apply compressor oil (refrigerant oil) to O-ring. 2. Discharge hose 5. A/C refrigerant pressure sensor : Apply compressor oil (refrigerant oil) to O-ring. : Apply compressor oil (refrigerant oil) to O-ring.
Page 828 7B-3 Air Conditioning System: General Description Refrigerant Type Construction S4RS0A7201002 Whether the A/C system in the vehicle uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on label (1) on the compressor. Also, it can be checked by the shape of the service (charge) valve (2). I4RS0A720002- [A]: HFC-134a (R-134a) [B]: CFC-12 (R-12)
Page 829 Air Conditioning System: 7B-4 : [A] : [B] : [C] I4RS0A720051- [A]: Liquid 2. Magnet clutch 6. Expansion valve 10. Desiccant [B]: Vapor 3. Condenser 7. A/C evaporator 11. Filter [C]: Superheated vapor 4. Receiver/dryer 8. Condensation part 12. Vapor refrigerant 1.
Page 830 7B-5 Air Conditioning System: Schematic and Routing Diagram Major Components of A/C System S4RS0A7202001 Airflow diagram I4RS0A720003- Major components of A/C system I4RS0A720004- 1. HVAC 5. Discharge hose 9. Side ventilation air 13. Side defroster air 2. Compressor 6. Suction hose 10.
Page 831 Air Conditioning System: 7B-6 A/C System Wiring Diagram S4RS0A7202002 BLK/YEL BLK/WHT G19-6 G19-7 RED/BLK G19-1 BLU/WHT G19-3 G19-2 G19-5 BRN/WHT G18-6 G18-5 GRN/WHT RED/BLK G18-14 G18-13 G18-9 G18-10 BLK/ORN G18-8 BLK/RED G18-7 RED/YEL G18-4 G18-3 BLU/WHT E23-19 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED...
Page 832 7B-7 Air Conditioning System: Diagnostic Information and Procedures A/C System Symptom Diagnosis S4RS0A7204001 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C system does not referring to “Operation Procedure for operate) Refrigerant Charge: ”.
Page 833 Air Conditioning System: 7B-8 Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C system normal Condenser clogged Check condenser referring to “Condenser operation) Assembly On-Vehicle Inspection: ”.
Page 834 7B-9 Air Conditioning System: Condition Possible cause Correction / Reference Item Insufficient airflow of A/C evaporator clogged or frosted Check A/C evaporator and evaporator cooled air thermistor (evaporator temperature sensor) referring to “Evaporator Inspection: ” and “Evaporator Thermistor (Evaporator Temperature Sensor) Inspection: ”. Air leaking from HVAC unit or air duct Repair as necessary.
Page 835 Air Conditioning System: 7B-10 Abnormal Noise from Tension Pulley Condition Possible cause Correction / Reference Item Clattering noise is heard Worn or damaged bearing Replace tension pulley. from pulley Pulley cranks upon Cracked or loose bracket Replace or retighten bracket. contact Abnormal Noise from A/C Evaporator Condition...
Page 836 7B-11 Air Conditioning System: 8) Open front windows, front doors and engine food. 9) With about 20 mm (0.8 in.) of dry bulb thermometer (1) put right in front of center ventilation louver and a wet and dry bulb thermometer (2) near air inlet of HVAC unit.
Page 837 Air Conditioning System: 7B-12 High pressure gauge Condition Possible cause Correction Pressure is higher than Refrigerant overcharged Recharge. acceptable range Expansion valve frozen or clogged Check expansion valve. (“A” area) Clogged refrigerant passage of high pressure side Clean or replace. Radiator cooling fan malfunction (Insufficient Check radiator cooling fan.
Page 838 7B-13 Air Conditioning System: ˚F ˚C 82.4 80.6 78.8 77.0 “E” 75.2 73.4 71.6 69.8 68.0 66.2 64.4 62.6 60.8 59.0 57.2 55.4 53.6 “F” 51.8 50.0 48.2 46.4 ˚C ˚F Temp. near Air Inlet of HVAC unit I4RS0A720009- Thermometer at center duct Condition Possible cause Correction...
Page 839 Air Conditioning System: 7B-14 Condition Manifold gauge MPa (kg/cm ) (psi) Possible cause Correction Detail Normal: Normal: During A/C operation, the Expansion valve is Replace expansion 0.23 – 0.36 1.24 – 1.52 low pressure side frozen due to moisture valve. (2.3 –...
Page 840 7B-15 Air Conditioning System: A/C System Inspection at ECM S4RS0A7204004 Voltage Check ECM and its circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: • ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the grommet.
Page 841 Air Conditioning System: 7B-16 ECM Voltage Values Table for Relation of A/C Control Terminal Wire Color Circuit Normal Value Condition Output of 5 V C37-14 GRY/RED 4.5 – 5.5 V Ignition switch turned ON power source Engine coolant 3.3 – 3.6 V Ignition switch turned ON, ECT at 0 C (32 F) C37-24 LT GRN...
Page 842 7B-17 Air Conditioning System: Repair Instructions Operation Procedure for Refrigerant Charge S4RS0A7206002 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) is exposed to your eyes, it may cause a serious injury.
Page 843 Air Conditioning System: 7B-18 Recovery When charging refrigerant only When discharging refrigerant out of A/C system, always When charging refrigerant without replacing any recover it by using refrigerant recovery and recycling component , replenish the same amount of measured oil equipment because discharging refrigerant HFC-134a when recovering refrigerant (if not measure, replenish 30 (R-134a) into atmosphere would cause adverse effect to...
Page 844 7B-19 Air Conditioning System: Evacuation CAUTION: Do not evacuate before recovering refrigerant in A/C system. NOTE: Once air conditioning system circuit is opened (exposed) to atmospheric air, system must be evacuated by using a vacuum pump. The A/C system should be attached with a manifold gauge set, and should be evacuated for approximately 15 minutes.
Page 845 Air Conditioning System: 7B-20 Charge The initial charge of the A/C system is performed through the high pressure side with the engine stopped. CAUTION: And next, this method must be followed by charging from the low pressure side with the engine running. •...
Page 846 7B-21 Air Conditioning System: b) Replace empty container with a refrigerant 8) After the system has been charged with specified container which has been charged with amount (370 20 g) of refrigerant or when low refrigerant. When using refrigerant container tap pressure gauge (1) and high pressure gauge (2) valve (2), use the following procedure for have indicated the following specified value, close...
Page 847 Air Conditioning System: 7B-22 Check A/C System for Refrigerant Leaks Condenser Assembly Removal and Installation Whenever a refrigerant leak is suspected in the system S4RS0A7206007 CAUTION: or any service operation has been performed which may result in malfunction of lines and connections, it is Do not damage condenser fins.
Page 848 7B-23 Air Conditioning System: Desiccant Removal and Installation Installation Reverse the removal procedure to install condenser S4RS0A7206009 Removal noting the following instructions. 1) Remove condenser assembly referring to • Replenish specified amount of compressor oil to “Condenser Assembly Removal and Installation: ”. compressor suction side referring to “Replenishing 2) Remove cap (1) from receiver/dryer tank.
Page 849 Air Conditioning System: 7B-24 HVAC Unit Components S4RS0A7206003 I4RS0A720021- 1. Fresh air inlet duct 7. Airflow control door assembly 13. Heater core 19. Evaporator thermistor (evaporator temperature sensor) 2. Blower upper case 8. Temperature control door 14. Temperature control lever 20.
Page 850 7B-25 Air Conditioning System: 6. Foot duct 12. Heater unit lower case 18. Expansion valve : Do not reuse. HVAC Unit Removal and Installation S4RS0A7206012 Removal 1) Disconnect negative (–) cable from battery. 2) Disable air bag system referring to “Disabling Air Bag System: in Section 8B”.
Page 851 Air Conditioning System: 7B-26 I4RS0A720052- Installation Reverse the removal procedure noting the following instruction. • Install evaporator thermistor (evaporator temperature sensor) (1) onto evaporator (2) as shown. I4RS0A720027- [A]: Resistance (k ) [B]: Temperature Expansion Valve Removal and Installation S4RS0A7206015 Removal 1) Recover refrigerant from the A/C system with I4RS0A720053-...
Page 852 7B-27 Air Conditioning System: Installation Reverse removal procedure noting the following instructions. • Apply compressor oil to O-ring of expansion valve and pipes. • Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure for Refrigerant Charge: ”. Expansion Valve Inspection S4RS0A7206016 I4RS0A720029-...
Page 853 Air Conditioning System: 7B-28 Compressor Drive Belt Inspection and Adjustment S4RS0A7206021 Inspection • Check compressor drive belt (1) for wear, crack, deformation and cleanliness. If any defect is found, replace the belt with new one referring to “Compressor Drive Belt Removal and Installation: ”. •...
Page 854 7B-29 Air Conditioning System: Compressor Drive Belt Removal and NOTE: Installation Cap open fittings immediately to keep S4RS0A7206036 moisture out of the system. Removal 1) Loosen tension pulley nut (1). 2) Loosen belt tension by loosening tension pulley adjusting bolt (2). 3) Remove compressor drive belt (3).
Page 855 Air Conditioning System: 7B-30 Compressor Assembly Components S4RS0A7206024 I4RS0A720037- 1. Armature plate bolt 4. Circlip 7. Magnet clutch pulley : Do not reuse. 2. Compressor 5. Shim 8. Armature plate : 15 N m (1.5 kg-m, 11.0 lb-ft) 3. Relief valve 6.
Page 856 7B-31 Air Conditioning System: 4) Remove shims from shaft. Installation 5) Remove circlip (1) using special tool. 1) Install magnet clutch coil (2) fitting protrusion (4) of magnet clutch coil onto hole (5) of compressor (3). Special tool 2) Install new circlip (1) directing chamfer side (6) (B): 09900–06107 downward.
Page 857 Air Conditioning System: 7B-32 Relief Valve Inspection S4RS0A7206031 By using special tool, check if there is refrigerant leakage. If there is refrigerant leakage, replace the relief valve. Special tool (A): 09990–86011 I4RS0A720045- 8) Adjust clearance between magnet clutch plate (1) and magnet clutch pulley by putting shim(s) on compressor shaft.
Page 858 7B-33 Air Conditioning System: Installation Reverse removal procedure noting the following instructions. • Use new O-ring. • Apply compressor oil to O-ring. • Tighten relive valve to the specified torque. Tightening torque Relief valve (a): 8 N·m (0.8 kg-m, 6.0 lb-ft) I4RS0A720049- •...
Page 859 Air Conditioning System: 7B-34 Special Tools and Equipment Recommended Service Material S4RS0A7208001 Material SUZUKI recommended product or Specification Note Compressor oil Compressor oil P/No.: 99000–99015– (MATSUSHITADENKI) - Domestic NOTE: Required service material is also described in the following. “Precautions on Servicing A/C System: ”...
Page 860 7B-35 Air Conditioning System:...
Page 861 Table of Contents 8- i Section 8 Restraint CONTENTS Precautions ..........8-1 “AIR BAG” Warning Lamp Does Not Come ON..............8B-15 Precautions............. 8-1 “AIR BAG” Warning Lamp Flashes ....8B-17 Precautions on Restraint........8-1 DTC B1013: SDM fault........8B-18 Seat Belts ..........8A-1 DTC B1014: “AIR BAG” Warning Lamp Circuit Failure ..........8B-18 Precautions............8A-1 DTC B1016: Power Source Voltage High ..8B-19...
Page 862 8-ii Table of Contents DTC B1064 / B1068: Driver / Passenger Repair Instructions ..........8B-105 Side-Air Bag Initiator Circuit Short to Power Disabling Air Bag System........8B-105 Circuit .............. 8B-82 Enabling Air Bag System ........8B-105 DTC B1071: Forward-Sensor Performance SDM Removal and Installation ......8B-106 Problem............
Page 863 Precautions: Precautions Precautions Precautions on Restraint S4RS0A8000001 Air Bag System Service Warning Refer to “Air Bag System Service 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 864: Seat Belts
Replace defective assemblies with condition may become unreliable. For this new replacement parts. reason, SUZUKI will supply only the spare • Keep belts dry and clean at all times. buckle and seat belt assembly in a set part.
Page 865 Seat Belts: 8A-2 Seat Belt with ELR Seat Belt with ELR and Pretensioner The seat belt with emergency locking retractor (ELR) is The seat belt with ELR and a pretensioner has a designed so that it locks immediately (to prevent the pretensioner mechanism which operates in linkage with webbing from being pulled out of the retractor any the air bag in addition to the described ELR.
Page 866 8A-3 Seat Belts: Repair Instructions Front Seat Belt Components S4RS0A8106001 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 867 Seat Belts: 8A-4 Front Seat Belt Inspection S4RS0A8106003 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. • Be sure to read “Precautions on Service I2RH01810003- and Diagnosis of Seat Belt: ”, before 5) Remove front seat belts from the vehicle.
Page 868 8A-5 Seat Belts: Seat Belt Anchor Bolt • The seat belt webbing or strap should be free from • Anchor bolts should be torqued to specification. damage. Belt Latch Retractor Assembly (with Seat Belt Pretensioner) • It should be secure when latched. 1) Let the seat belt retract fully to confirm its easy retraction.
Page 869 Seat Belts: 8A-6 Rear Seat Belt Components S4RS0A8106006 WARNING: Be sure to read “Precautions on Service and Diagnosis of Seat Belt: ” before starting to work and observe every precaution during work. I4RS0A810003- 1. Upper anchor 4. Rear center seat belt 7.
Page 870 8A-7 Seat Belts: Rear Seat Belt Removal and Installation Installation S4RS0A8106004 Reverse removal procedure for installation noting the WARNING: following. Be sure to read “Precautions on Service and • Seat belt anchor bolts should have an unified fine Diagnosis of Seat Belt: ” before starting to thread (7/16-20 UNF).
Page 871 • If the air bag system and another vehicle • When using electric welding, be sure to disconnect air system both need repair, SUZUKI bag (inflator) module connectors (driver, passenger, recommends that the air bag system be...
Page 872 8B-2 Air Bag System: I5RH01820001- • If SDM has been dropped, replace it with a new one. • If SDM installation part of floor was damaged, repair that part completely before reinstallation. • All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointed toward the front of the vehicle to ensure proper operation of the air bag system.
Page 873 Air Bag System: 8B-3 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 874 8B-4 Air Bag System: WARNING: Never attempt to measure the resistance of the seat belt pretensioners. It is very dangerous as the electric current from the tester may activate pretensioner. I2RH01820048- Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner WARNING: •...
Page 875 Air Bag System: 8B-5 Do not dispose of the live (undeployed) air bag (inflator) • Make sure air bag system grounding point (2) is clean and ground is securely fastened for optimum metal-to- modules and the live (inactivated) seat belt metal contact.
Page 876 8B-6 Air Bag System: The air bag system is designed to activate only in severe frontal and sideward collisions. It is not designed to activate in rear impacts, rollovers, or minor frontal and sideward collisions, since it would offer no protection in those types of accidents.
Page 877 Air Bag System: 8B-7 Schematic and Routing Diagram Air Bag System Wiring Circuit Diagram S4RS0A8202001 “L29” “G04” “G26” “L32” L29-3 “G28” BLU/ORN L29-2 “G34” “L29” RED/BLK “G33” “L04” YEL/RED YEL/RED L29-4 BLU/ORN L29-1 YEL/GRN YEL/GRN L29-5 L29-26 “G32” “L10” “G10” L29-31 L29-7 “G35”...
Page 878 8B-8 Air Bag System: Terminal arrangement of SDM (viewed from harness side) I5RH01820003- 1. SDM Connector “L29” Connector “L29” (SDM connector) Terminal Terminal Terminal Circuit Terminal Circuit symbol symbol L29-1 “AIR BAG” warning lamp L29-26 Ignition switch (power source) L29-2 D1–...
Page 879 Air Bag System: 8B-9 Component Location Air Bag System Components, Wiring and Connectors Location S4RS0A8203001 I4RS0A820007-...
Page 880 8B-10 Air Bag System: 1. Passenger air bag (inflator) module 8. Side-air bag (inflator) module (if equipped) 15. “AIR BAG” warning lamp 2. Driver air bag (inflator) module 9. Ground for air bag system : 23 N m (2.3 kg-m, 16.5 lb-ft) 3.
Page 881 Air Bag System: 8B-11 Step Action 1) Check DTC using SUZUKI scan tool referring to “DTC Air bag system is in An intermittent trouble Check: ”. good condition. has occurred at some place. Is “NO CODES” displayed on SUZUKI scan tool? Check the connector harness, etc.
Page 882 4) Read DTC according to instructions displayed on is displayed and not malfunction DTC. SUZUKI scan tool and print it or write it down. Refer 6) Turn ignition switch to OFF position and disconnect to SUZUKI scan tool operator’s manual for further SUZUKI scan tool from DLC.
Page 883 Air Bag System: 8B-13 Scan Tool Data Driv A/B Ini Res (Driver air bag initiator resistance) S4RS0A8204068 (ohm): This parameter indicates the resistance of the driver air bag initiator circuit. Data list of SDM Pass A/B Ini Res (Passenger air bag initiator Normal Condition / resistance) (ohm): This parameter indicates the Scan Tool Data...
Page 884 8B-14 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 flow, use a tester along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 885 Air Bag System: 8B-15 Step Action 1) Disconnect combination meter connector “G28” referring Substitute a known- “BLU/ORN” wire to “Combination Meter Removal and Installation: in good SDM and recheck. (between combination Section 9C”. If “AIR BAG” warning meter and SDM lamp remain lighting, connector) open or 2) Check proper connection to combination meter at “BLU/...
Page 886 8B-16 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 flow, use a tester along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 887 Air Bag System: 8B-17 “AIR BAG” Warning Lamp Flashes S4RS0A8204009 Wiring Diagram “G28” RED/BLK BLU/ORN “L29” “G33” “G34” “L04” BLU/ORN L29-1 L29-26 “G32” L29-31 ST L29-27 “G32” I4RS0A820009- 1. From main fuse 5. “AIR BAG” warning lamp in combination meter 9.
Page 888 8B-18 Air Bag System: DTC B1013: SDM fault S4RS0A8204030 DTC Will Set when An internal SDM fault is detected by SDM. NOTE: DTC B1013 can never be cleared once it has been set. DTC Troubleshooting 1) Turn ignition switch OFF. 2) Replace SDM.
Page 889 Air Bag System: 8B-19 DTC Troubleshooting Step Action 1) This DTC is set when there is a trouble in “AIR BAG” Go to Step 2. Repair “AIR BAG” warning lamp circuit. Failure to properly perform “Air Bag warning lamp circuit. Diagnostic System Check”...
Page 890 8B-20 Air Bag System: DTC Will Set when The power source voltage to SDM is above an approx. 21 V for specified time. Flow Test Description Step 1: Check if voltage applied to SDM is within normal range. Step 2: Check if DTC B1016 still exists. DTC Troubleshooting Step Action...
Page 891 Air Bag System: 8B-21 DTC B1017: Power Source Voltage Low S4RS0A8204021 Wiring Diagram “L04” L29-26 “G32” L29-27 “L29” I4RS0A820011- 1. From main fuse 3. “A/BAG” fuse 5. SDM 2. Ignition switch 4. Junction block assembly 6. Ground for air bag system CAUTION: •...
Page 892 8B-22 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector. Go to Step 4. Go to step 3. 2) Check proper connection to SDM at “L29-26” terminal. 3) If OK, turn ignition switch ON and then check voltage between “L29-26”...
Page 893 Air Bag System: 8B-23 DTC B1021: Front Air Bag Module Deployed S4RS0A8204028 DTC Will Set when The SDM detects a frontal crash of sufficient force to warrant activation of the air bag system. (SDM outputs a deployment command.) Flow Test Description Step 1: Check that DTC B1021 has been set although air bag has not been deployed.
Page 894 8B-24 Air Bag System: DTC Troubleshooting Step Action 1) Turn ignition switch OFF. Replace components Go to Step 2. and perform inspections Has air bag deployed? as directed in “Repair and Inspection Required after Accident: ”. 1) Inspect front of vehicle and undercarriage for signs of Replace components Substitute a known- impact.
Page 895 Air Bag System: 8B-25 DTC B1027: Reusable Number Exceeded S4RS0A8204071 DTC Will Set when The SDM has not been replaced though the side-air bag developed several times in the past. NOTE: DTC B1027 can never be cleared once it has been set. DTC Trouble shooting 1) Turn ignition switch OFF.
Page 896 8B-26 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 4. connector located under of the steering column. 2) Check proper connection to contact coil at terminal in “G26”...
Page 897 Air Bag System: 8B-27 Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. High resistance or open located near the glove box. wire in “GRN” or “YEL” circuit in instrument 2) Check proper connection to floor harness connector at panel harness.
Page 898 8B-28 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- High resistance or open “L29”. good SDM and recheck. wire in “GRN” or “YEL” circuit in floor harness. 2) Check proper connection to SDM at terminals “L29-2” and “L29-3”.
Page 899 Air Bag System: 8B-29 Step Action 1) With ignition switch OFF, disconnect special tools (B) Turn ignition switch Turn ignition switch and (C) from “G26” connector and then reconnect OFF. Replace contact OFF. Replace driver air contact coil connector located under of the steering coil assembly referring bag (inflator) module column.
Page 900 8B-30 Air Bag System: DTC B1032: Driver Air Bag Initiator Circuit Resistance Low S4RS0A8204017 Wiring Diagram “L29” “L04” “L32” “G04” “G26” L29-26 L29-3 “G32” L29-2 L29-27 “L29” I4RS0A820013- [A]: Shorting bar 3. “A/BAG” fuse 6. Contact coil assembly 1. From main fuse 5.
Page 901 Air Bag System: 8B-31 DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 4. connector located under of the steering column. 2) Check proper connection to contact coil at terminal in “G26”...
Page 902 8B-32 Air Bag System: Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. “GRN” circuit shorted to located near the glove box. “YEL” circuit, “GRN” circuit or “YEL” circuit 2) Check proper connection to floor harness connector at shorted to other circuit terminal “L32-1”...
Page 903 Air Bag System: 8B-33 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- “GRN” circuit shorted to “L29”. good SDM and recheck. “YEL” circuit, “GRN” circuit or “YEL” circuit 2) Check proper connection to SDM at terminals “L29-2” shorted to other circuit and “L29-3”.
Page 904 8B-34 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) Turn ignition switch Turn ignition switch and (C) from “G26” connector and reconnect contact coil OFF. Replace contact OFF. Replace driver air connector located under of the steering column. coil assembly referring bag (inflator) module to “Contact Coil Cable...
Page 905 Air Bag System: 8B-35 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground S4RS0A8204018 Wiring Diagram “L29” “L04” “L32” “G04” “G26” L29-26 L29-3 “G32” L29-2 L29-27 “L29” I4RS0A820013- [A]: Shorting bar 3. “A/BAG” fuse 6. Contact coil assembly 1. From main fuse 4.
Page 906 8B-36 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 4. connector located under of the steering column. 2) Check proper connection to contact coil at terminal in “G26”...
Page 907 Air Bag System: 8B-37 Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. “GRN” circuit or “YEL” located near the glove box. circuit shorted to ground in instrument panel 2) Check proper connection to floor harness connector at harness.
Page 908 8B-38 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) Substitute a known- “GRN” circuit or “YEL” and (D) from “L32” connector and SDM connector “L29” good SDM and recheck. circuit shorted to ground from SDM respectively. in floor harness.
Page 909 Air Bag System: 8B-39 Step Action 1) With ignition switch OFF, disconnect special tools (B) Turn ignition switch Turn ignition switch and (C) from “G26” connector and reconnect contact coil OFF. Replace contact OFF. Replace driver air connector located under of the steering column. coil assembly referring bag (inflator) module to “Contact Coil Cable...
Page 910 8B-40 Air Bag System: DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit S4RS0A8204019 Wiring Diagram “L29” “L04” “L32” “G04” “G26” L29-26 L29-3 “G32” L29-2 L29-27 “L29” I4RS0A820013- [A]: Shorting bar 3. “A/BAG” fuse 6. Contact coil assembly 1.
Page 911 Air Bag System: 8B-41 DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 4. connector located under of the steering column. 2) Check proper connection to contact coil at terminal in “G26”...
Page 912 8B-42 Air Bag System: Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. “GRN” circuit or “YEL” located near the glove box. circuit shorted to power supply circuit in 2) Check proper connection to floor harness connector at instrument panel terminal “L32-1”...
Page 913 Air Bag System: 8B-43 Step Action 1) With ignition switch OFF, disconnect special tools (B) Substitute a known- “GRN” circuit or “YEL” and (D) from “L32” connector and SDM connector “L29” good SDM and recheck. circuit shorted to power from SDM respectively. supply circuit.
Page 914 8B-44 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) Turn ignition switch Turn ignition switch and (C) from “G26” connector and reconnect contact coil OFF. Replace contact OFF. Replace driver air connector located under of the steering column. coil assembly referring bag (inflator) module to “Contact Coil Cable...
Page 915 Air Bag System: 8B-45 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High S4RS0A8204012 Wiring Diagram “L29” “L04” “L32” “G04” “G10” L29-26 YEL/RED YEL/RED L29-4 “G32” YEL/GRN YEL/GRN L29-5 L29-27 “L29” I4RS0A820020- [A]: Shorting bar 3. “A/BAG” fuse 6. Passenger air bag (inflator) module 1.
Page 916 8B-46 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 2. Turn ignition switch (inflator) module connector. OFF. Replace passenger air bag 2) Check proper connection to passenger air bag (inflator) (inflator) module module at terminals in “G10”...
Page 917 Air Bag System: 8B-47 Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. High resistance or open located near the glove box. wire “YEL/RED” or “YEL/GRN” circuit in 2) Check proper connection to floor harness connector at instrument panel terminal “L32-3”...
Page 918 8B-48 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- High resistance or open “L29”. good SDM and recheck. wire in “YEL/RED” or “YEL/GRN” circuit in 2) Check proper connection to SDM at terminals “L29-4” floor harness.
Page 919 Air Bag System: 8B-49 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low S4RS0A8204013 Wiring Diagram “L29” “L04” “L32” “G04” “G10” L29-26 YEL/RED YEL/RED L29-4 “G32” YEL/GRN YEL/GRN L29-5 L29-27 “L29” I4RS0A820020- [A]: Shorting bar 3. “A/BAG” fuse 6. Passenger air bag (inflator) module 1.
Page 920 8B-50 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 2. Turn ignition switch (inflator) module connector. OFF. Replace passenger air bag 2) Check proper connection to passenger air bag (inflator) (inflator) module module at terminals in “G10”...
Page 921 Air Bag System: 8B-51 Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. “YEL/RED” circuit located near the glove box. shorted to “YEL/GRN” circuit, “YEL/RED” 2) Check proper connection to floor harness connector at circuit or “YEL/GRN” terminal “L32-3”...
Page 922 8B-52 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- “YEL/RED” circuit “L29”. good SDM and recheck. shorted to “YEL/GRN” circuit, “YEL/RED” 2) Check proper connection to SDM at terminals “L29-4” circuit or “YEL/GRN” and “L29-5”.
Page 923 Air Bag System: 8B-53 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground S4RS0A8204014 Wiring Diagram “L29” “L04” “L32” “G04” “G10” L29-26 YEL/RED YEL/RED L29-4 “G32” YEL/GRN YEL/GRN L29-5 L29-27 “L29” I4RS0A820020- [A]: Shorting bar 3. “A/BAG” fuse 6. Passenger air bag (inflator) module 1.
Page 924 8B-54 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 2. Turn ignition switch (inflator) module connector. OFF. Replace passenger air bag 2) Check proper connection to passenger air bag (inflator) (inflator) module module at terminals in “G10”...
Page 925 Air Bag System: 8B-55 Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. “YEL/RED” or “YEL/ located near the glove box. GRN” circuit shorted to ground in instrument 2) Check proper connection to floor harness connector at panel harness.
Page 926 8B-56 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) Substitute a known- “YEL/RED” or “YEL/ and (C) from “L32” connector and SDM connector “L29” good SDM and recheck. GRN” circuit shorted to from SDM respectively. ground in floor harness.
Page 927 Air Bag System: 8B-57 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit S4RS0A8204015 Wiring Diagram “L29” “L04” “L32” “G04” “G10” L29-26 YEL/RED YEL/RED L29-4 “G32” YEL/GRN YEL/GRN L29-5 L29-27 “L29” I4RS0A820020- [A]: Shorting bar 3. “A/BAG” fuse 6.
Page 928 8B-58 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect passenger air bag Go to Step 3. Turn ignition switch (inflator) module connector. OFF. Replace passenger air bag 2) Check proper connection to passenger air bag (inflator) (inflator) module module at terminals in “G10”...
Page 929 Air Bag System: 8B-59 Step Action 1) With ignition switch OFF, disconnect “L32” connector Go to Step 3. “YEL/RED” or “YEL/ located near the glove box. GRN” circuit shorted to power supply circuit in 2) Check proper connection to floor harness connector at instrument panel terminal “L32-3”...
Page 930 8B-60 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) Substitute a known- “YEL/RED” or “YEL/ and (C) from “L32” connector and SDM connector “L29” good SDM and recheck. GRN” circuit shorted to from SDM respectively. power supply circuit in floor harness.
Page 931 Air Bag System: 8B-61 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High S4RS0A8204024 Wiring Diagram “L29” “L10” “L04” L29-7 L29-26 “G32” L29-6 L29-8 L29-27 LT GRN L29-9 “L29” “L36” I4RS0A820026- [A]: Shorting bar 3. “A/BAG” fuse 6.
Page 932 8B-62 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower trim Go to Step 2. Turn ignition switch of driver or passenger side and disconnect seat belt OFF. Replace seat belt pretensioner connector “L10” or “L36” (1). pretensioner referring to “Front Seat Belt 2) Check proper connection to seat belt pretensioner at...
Page 933 Air Bag System: 8B-63 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1051: High “29”. good SDM and recheck. resistance or open wire in “PNK” or “WHT” 2) Check proper connection to SDM at terminals in “L29-6” circuit.
Page 934 8B-64 Air Bag System: DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low S4RS0A8204025 Wiring Diagram “L29” “L10” “L04” L29-7 L29-26 “G32” L29-6 L29-8 L29-27 LT GRN L29-9 “L29” “L36” I4RS0A820026- [A]: Shorting bar 3. “A/BAG” fuse 6.
Page 935 Air Bag System: 8B-65 DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower trim Go to Step 2. Turn ignition switch of driver or passenger side and disconnect seat belt OFF. Replace seat belt pretensioner connector “L10” or “L36” (1). pretensioner referring to “Front Seat Belt 2) Check proper connection to seat belt pretensioner at...
Page 936 8B-66 Air Bag System: Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1052: “PNK” “29”. good SDM and recheck. circuit shorted to “WHT” circuit, “PNK” circuit or 2) Check proper connection to SDM at terminals in “L29-6” “WHT”...
Page 937 Air Bag System: 8B-67 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground S4RS0A8204026 Wiring Diagram “L29” “L10” “L04” L29-7 L29-26 “G32” L29-6 L29-8 L29-27 LT GRN L29-9 “L29” “L36” I4RS0A820026- [A]: Shorting bar 3. “A/BAG” fuse 6.
Page 938 8B-68 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower trim Go to Step 2. Ignition switch OFF. of driver or passenger side and disconnect seat belt Replace seat belt pretensioner connector “L10” or “L36” (1). pretensioner referring to “Front Seat Belt 2) Check proper connection to seat belt pretensioner at...
Page 939 Air Bag System: 8B-69 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Clear DTCs referring to “DTC Clearance: ”, if any. •...
Page 940 8B-70 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, remove center pillar lower trim Go to Step 2. Turn ignition switch of driver or passenger side and disconnect seat belt OFF. Replace seat belt pretensioner connector “L10” and “L36” (1). pretensioner referring to “Front Seat Belt 2) Check proper connection to seat belt pretensioner at...
Page 941 Air Bag System: 8B-71 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Clear DTCs referring to “DTC Clearance: ”, if any. •...
Page 942 8B-72 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect side-air bag Go to Step 2. Go to Step 3. (inflator) module connector under front seat cushion. 2) Check proper connection to driver or passenger side-air bag (inflator) module at terminals in “L25”...
Page 943 Air Bag System: 8B-73 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1061: Repair “L29”. good SDM and recheck. high resistance or open in “WHT/RED” or “WHT/ 2) Check proper connection to SDM at terminals “L29-10” GRN”...
Page 944 8B-74 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) DTC B1061: Repair Replace side-air bag and (C) then reconnect connector “L25” or “L30”. high resistance or open (inflator) module in “WHT/RED” or “WHT/ referring to “Side-Air 2) Disconnect side-air bag (inflator) module connector (1) GRN”...
Page 945 Air Bag System: 8B-75 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low S4RS0A8204073 Wiring Diagram “L29” “L25” “L04” WHT/RED L29-11 L29-26 WHT/GRN “G32” L29-10 GRY/BLU L29-12 L29-27 LT GRN/RED L29-13 “L29” “L30” I4RS0A820031- [A]: Shorting bar 3.
Page 946 8B-76 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect side-air bag Go to Step 2. Go to Step 3. (inflator) module connector under front seat cushion. 2) Check proper connection to driver or passenger side-air bag (inflator) module at terminals in “L25”...
Page 947 Air Bag System: 8B-77 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1062: Repair “L29”. good SDM and recheck. short from “WHT/RED” wire circuit to “WHT/ 2) Check proper connection to SDM at terminals “L29-10” GRN”...
Page 948 8B-78 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B) DTC B1062: Repair Replace side-air bag and (C) then reconnect connector “L25” or “L30”. short from “WHT/RED” (inflator) module wire circuit to “WHT/ referring to “Side-Air 2) Disconnect side-air bag (inflator) module connector (1) GRN”...
Page 949 Air Bag System: 8B-79 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground S4RS0A8204074 Wiring Diagram “L29” “L25” “L04” WHT/RED L29-11 L29-26 WHT/GRN “G32” L29-10 GRY/BLU L29-12 L29-27 LT GRN/RED L29-13 “L29” “L30” I4RS0A820031- [A]: Shorting bar 3.
Page 950 8B-80 Air Bag System: DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect side-air bag Go to Step 2. Go to Step 3. (inflator) module connector under front seat cushion. 2) Check proper connection to driver or passenger side-air bag (inflator) module at terminals in “L25”...
Page 951 Air Bag System: 8B-81 Step Action 1) With ignition switch OFF, disconnect special tools and Substitute a known- DTC B1063: Repair SDM connector “L29”. good SDM and recheck. short from “WHT/RED” or “WHT/GRN” wire 2) Release shorting bar in SDM connector inserting release circuit to ground in floor tool (1) included in special tool (A).
Page 952 8B-82 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 DTCs referring to “DTC Clearance: ”, if any. • Repeat “Air Bag Diagnostic System Check: ” to confirm that the trouble has been corrected. DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit S4RS0A8204075 Wiring Diagram...
Page 953 Air Bag System: 8B-83 DTC Troubleshooting Step Action 1) With ignition switch OFF, disconnect side-air bag Go to Step 2. Go to Step 3. (inflator) module connector under front seat cushion. 2) Check proper connection to driver or passenger side-air bag (inflator) module at terminals in “L25”...
Page 954 8B-84 Air Bag System: Step Action 1) With ignition switch OFF, disconnect special tools (B), Substitute a known- DTC B1064: Repair (C) and SDM connector “L29”. good SDM and recheck. short from “WHT/RED” or “WHT/GRN” wire 2) Release shorting bar in SDM connector inserting release circuit to power circuit in tool (1) included in special tool (A).
Page 955 Air Bag System: 8B-85 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 DTCs referring to “DTC Clearance: ”, if any. • Repeat “Air Bag Diagnostic System Check: ” to confirm that the trouble has been corrected. DTC B1071: Forward-Sensor Performance Problem S4RS0A8204022 DTC Will Set when...
Page 956 8B-86 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 flow, use a tester along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 957 Air Bag System: 8B-87 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Clear DTCs referring to “DTC Clearance: ”, if any. •...
Page 958 8B-88 Air Bag System: DTC Troubleshooting Step Action 1) Disconnect forward-sensor connector “E13”. Go to Step 2. High resistance or open wire in “GRY/RED” 2) Disconnect SDM connector “L29”. circuit or “GRY” circuit. 3) Check proper connection to SDM connector at terminals “L29-49”...
Page 959 Air Bag System: 8B-89 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Clear DTCs referring to “DTC Clearance: ”, if any. •...
Page 960 8B-90 Air Bag System: DTC Will Set when The resistance measured between side-sensor circuit and ground circuit is below a specified value for specified time. Flow Test Description Step 1: Check for short circuit between side-sensor circuit and ground. Step 2: Check if malfunction is in side-sensor. DTC Troubleshooting Step Action...
Page 961 Air Bag System: 8B-91 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open S4RS0A8204081 Wiring Diagram “L29” “L11” “L04” GRN/WHT L29-45 L29-26 GRN/BLK “G32” L29-46 GRN/YEL L29-44 L29-27 GRN/ORN L29-43 “L29” “L35” I4RS0A820041- 1. From main fuse 4.
Page 962 8B-92 Air Bag System: DTC Troubleshooting Step Action 1) Disconnect side-sensor connector “L11” or “L35”. Go to Step 2. DTC B1084: High resistance or open wire 2) Disconnect SDM connector “L29”. in “GRN/WHT” circuit or 3) Check proper connection to SDM connector at terminals “GRN/BLK”...
Page 963 Air Bag System: 8B-93 NOTE: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components and ensure all components are properly mounted. • Clear DTCs referring to “DTC Clearance: ”, if any. •...
Page 964 8B-94 Air Bag System: DTC Will Set when The combined resistance of the side curtain-air bag (inflator) module (driver or passenger), harness wiring and connector terminal contact is above a specified value for specified time. Flow Test Description Step 1: Check whether malfunction is in side curtain-air bag (inflator) module. Step 2: Check side curtain-air bag initiator circuit.
Page 965 Air Bag System: 8B-95 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1361: Repair “L29”. good SDM and recheck. high resistance or open in “RED/BLU” or “YEL/ 2) Check proper connection to SDM at terminals “L29-18” BLK”...
Page 966 8B-96 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 flow, use a tester along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 967 Air Bag System: 8B-97 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1362: Repair “L29”. good SDM and recheck. short from “RED/BLU” wire circuit to “YEL/BLK” 2) Check proper connection to SDM at terminals “L29-18” wire circuit or from and “L29-19”...
Page 968 8B-98 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 flow, use a tester along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 969 Air Bag System: 8B-99 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1363: Repair “L29”. good SDM and recheck. short from “RED/BLU” or “YEL/BLK” wire 2) Release shorting bar in SDM connector inserting release circuit to ground.
Page 970 8B-100 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 flow, use a tester along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 971 Air Bag System: 8B-101 Step Action 1) With ignition switch OFF, disconnect SDM connector Substitute a known- DTC B1064: Repair “L29”. good SDM and recheck. short from “RED/BLU” or “YEL/BLK” wire 2) Release shorting bar in SDM connector inserting release circuit to power circuit.
Page 972 8B-102 Air Bag System: Repair and Inspection Required after Accident S4RS0A8204033 CAUTION: • All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be replaced even if air bag system activation did not occur.
Page 973 Air Bag System: 8B-103 When side-air bag and side curtain-air bag are deployed, the following components must be replaced. • Deployed side-air bag (inflator) module • Deployed side curtain-air bag (inflator) module • Side-sensor • SDM Accident with or without Deployment / Activation – Component Inspections Certain air bag and restraint system components must be inspected after any crash, whether the air bag system...
Page 974 8B-104 Air Bag System: – Check wire harness clamps for tightness. • Seat belt pretensioner – For air bag harness including in instrument panel – Check for dents, cracks, damage or fitness harness replacement, refer to “Passenger Air Bag – Check harness and connector for damage or (Inflator) Module Repair Harness Installation: ”.
Page 975 Air Bag System: 8B-105 Repair Instructions Disabling Air Bag System S4RS0A8206001 1) Turn steering wheel so that vehicle’s wheels (front tires) are pointing straight ahead. 2) Disconnect negative (–) cable at battery. 3) Turn ignition switch to “LOCK” position and remove key.
Page 976 8B-106 Air Bag System: SDM Removal and Installation S4RS0A8206003 WARNING: During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Be sure to read “Precautions on Service and Diagnosis of Air Bag System: ” before starting to work and observe every precaution during work.
Page 977 Air Bag System: 8B-107 CAUTION: Installation 1) Check that none of the following faulty conditions • Do not connect a tester whatever type it exists. may be. • Bend, scratch, deformity in vehicle body where • Never repair or disassemble SDM. SDM is mounted.
Page 978 8B-108 Air Bag System: Tightening torque Driver air bag (inflator) module mounting bolt (a): 9 N·m (0.9 kg-m, 6.5 lb-ft) I4RS0A820057- I5RH01820103- WARNING: 6) Enable air bag system. Refer to “Enabling Air Bag System: ”. Special care is necessary when handling and 7) Connect negative cable at battery.
Page 979 Air Bag System: 8B-109 Passenger Air Bag (Inflator) Module Removal and Installation S4RS0A8206007 WARNING: • Never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. •...
Page 980 8B-110 Air Bag System: Installation 4) Connect passenger air bag (inflator) module connector (1) securely as shown in figure. 1) Install passenger air bag (inflator) module to air bag hole cover (2). a) Connect connector. b) Lock connector with lock button (2). CAUTION: Confirm claw (1) of passenger air bag (inflator) module hangs in air bag hole cover...
Page 981 Air Bag System: 8B-111 CAUTION: If air bag (Inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module appearance visually for the following symptoms and if any one of them is found, replace with a new one.
Page 982 8B-112 Air Bag System: Side-Air Bag (Inflator) Inspection Installation S4RS0A8206022 1) Confirm sleeve (1) is surely installed in side-air bag WARNING: (inflator) module. • Never attempt to disassemble or repair the 2) Tighten sleeve lock nut (2) to specified torque. side-air bag (inflator) module.
Page 983 Air Bag System: 8B-113 Side Curtain-Air Bag (Inflator) Module Removal WARNING: and Installation • When carrying a live air bag (inflator) S4RS0A8206025 WARNING: module, make sure the bag opening is pointed away from you. • Never attempt to disassemble or repair the Never carry air bag (inflator) module by side curtain-air bag (inflator) module.
Page 984 8B-114 Air Bag System: CAUTION: If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module appearance visually for the following symptoms and if any one of them is found, replace with a new one.
Page 985 Air Bag System: 8B-115 Forward-Sensor Inspection 4) Remove forward-sensor bolt (1) and forward-sensor (2). S4RS0A8206010 WARNING: During service procedures, be very careful when handling a sensor. • Never strike or jar a sensor. • A sensor and mounting bracket bolts must be carefully torqued to assure proper operation.
Page 986 8B-116 Air Bag System: 6) Disconnect side-sensor connector sliding connector outer (1) as shown. I4RS0A820106- 4) Connect negative cable at battery. I4RS0A820109- 5) Enable air bag system. Refer to “Enabling Air Bag System: ”. Installation CAUTION: Side-Sensor Inspection S4RS0A8206024 Proper operation of side-sensor requires WARNING: sensor be rigidly attached to specified During service procedures, be very careful...
Page 987 Air Bag System: 8B-117 1) Disable air bag system. Refer to “Disabling Air Bag • Check sensor (1) for dents, crack, deformation. System: ”. • Check sensor connector (sensor side and harness 2) Disconnect “L32” connector from floor harness side), lock mechanism or sensor lead wire for located near the glove box.
Page 988 8B-118 Air Bag System: Air Bag (Inflator) Module and Seat Belt WARNING: Pretensioner Disposal The following precautions must be observed S4RS0A8206013 for this work. Failure to observe any of them WARNING: may result in personal injury. Failure to follow proper air bag (inflator) •...
Page 989 Air Bag System: 8B-119 WARNING: Deployment / Activation Outside of Vehicle When you intend to return the vehicle to service, deploy • For handing and storage of live air bag the air bag (inflator) module(s) or activate seat belt (inflator) module, select place where pretensioner(s) outside of the vehicle.
Page 990 8B-120 Air Bag System: I4JA01822118- 6) Set air bag (inflator) module or seat belt pretensioner as follows. • For driver air bag (inflator) module a. Clear space (3) on ground about 185 cm (6 ft) in diameter where driver air bag (inflator) module (1) is set for deployment.
Page 991 Air Bag System: 8B-121 c. Fill plastic reservoir in deployment fixture (A) e. Attach side-air bag (inflator) module (1) in with water or sand. This is necessary to deployment fixture using mounting provide sufficient stabilization of fixture during attachment, sleeve lock nut and washer (2). deployment.
Page 992 8B-122 Air Bag System: Paved, outdoor location where there is no d. Tie seat belt pretensioner (2) with wire activity is preferred. If outdoor location is not harness (3) to wheel-installed tire (4) as available, use space on shop floor where shown.
Page 993 Air Bag System: 8B-123 • For passenger air bag (inflator) module [B] Check that passenger air bag (inflator) module is firmly and properly secured on deployment fixture (special tool), and connect adapter cable (B) to passenger air bag (inflator) module. •...
Page 994 8B-124 Air Bag System: 12) Notify all people in immediate area that you intend to deploy / activate air bag (inflator) module or seat belt pretensioner. NOTE: • When air bag (inflator) module deploys and seat belt pretensioner activates, rapid gas expansion will create substantial report.
Page 995 Air Bag System: 8B-125 21) Wash your hands with mild soap and water afterward. NOTE: Remaining steps are to be followed in the unlikely event that air bag (inflator) module did not deploy or seat belt pretensioner did not activate. 22) Ensure that deployment harness has been disconnected from 12 volts vehicle battery and that its two banana plugs have been shorted together by...
Page 996 8B-126 Air Bag System: 5) Check that there is no open, short or damage in special tools (deployment harness (A), adapter cable (B) and (C)). If any faulty condition is found, do not use it and be sure to use new special tool. And connect adapter cable (B), (C) or (D) to deployment harness (A) and lock connectors with lock slider.
Page 997 Air Bag System: 8B-127 12) Completely cover windshield area and front door 15) Connect deployment harness (2) to 12 volts vehicle window openings with drop cloth, a blanket or any battery (3). This will immediately deploy or activate similar item. This reduces possibility of injury due to air bag (inflator) module or seat belt pretensioners.
Page 998 8B-128 Air Bag System: NOTE: Remaining steps are to be followed in the unlikely event that air bag (inflator) module did not deploy or seat belt pretensioner did not activate. 24) Remove undeployed air bag (inflator) module(s) and/ or inactivated seat belt pretensioner(s) from vehicle. For driver air bag (inflator) module, refer to “Driver Air Bag (Inflator) Module Removal and Installation: ”.
Page 999 Air Bag System: 8B-129 Specifications Tightening Torque Specifications S4RS0A8207001 Tightening torque Fastening part Note kg-m lb-ft SDM bolt Driver air bag (inflator) module mounting bolt Passenger air bag (inflator) module attaching 16.5 bolt Sleeve lock nut 0.25 Side curtain-air bag (inflator) module attaching bolts Forward-sensor mounting bolt Side-sensor bolt...
Page 1000 (inflator) module and driver and passenger seat belt pretensioners instrument panel harness for driver and passenger 3. Not used seat belt pretensioners. Recommended Service Material S4RS0A8208004 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1332B P/No.: 99000–32100...
Page 1001 Air Bag System: 8B-131 Special Tool S4RS0A8208005 09932–75010 09932–75031 Air bag load tool Air bag deployment harness 09932–75041 09932–76010 Passenger air bag (inflator) Connector test adapter set module deployment fixture This set includes the following items. 1. Connector test adapter kit (09932-75020), 2.
Page 1002 8B-132 Air Bag System: 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. Battery power cable, 8. RS232 cable, 9.
Page 1003 Table of Contents 9- i Section 9 Body, Cab and Accessories CONTENTS Precautions ..........9-1 BCM side ............... 9A-25 Fuse side ............... 9A-26 Precautions............. 9-1 Junction Block Inner Circuit (Overview) ....9A-27 Precautions on Body, Cab and Accessories ..9-1 Junction Block Inner Circuit (Detail) ....9A-28 Precautions for Body Service........

Suzuki SWIFT RS415 2017 Service Manual

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