Page 1 SERVISE MANUAL 99500-76A01-01E...
Page 2 D Service on or around the air bag system ings. Pay special attention to the messages high- components must be performed only by lighted by these signal words. an authorized SUZUKI dealer. Please ob- serve all WARNINGS, CAUTIONS and WARNING: “Service Precautions” under “On-Vehicle Indicates a potential hazard that could result Service”...
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 (lubricant, sealants, etc.) as specified in each description.
Page 4 TABLE OF CONTENTS SECTION General Information GENERAL INFORMATION Maintenance and Lubrication Heater and Ventilation HEATING AND AIR CONDITIONING Air Conditioning Steering, Suspension, Wheels and Tires Wheel Alignment Manual Rack and Pinion Electrical Power Steering (P/S) System STEERING, SUSPENSION, WHEELS AND TIRES Steering Wheel and Column Front Suspension Rear Suspension...
Page 5: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ..............0A- 2 PRECAUTIONS .
Page 6: How To Use This Manual
0A-2 GENGERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
Page 7 D If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 8 0A-4 GENGERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BODY. WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules D For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature...
Page 9 GENERAL INFORMATION 0A-5 WARNING: During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued to ensure proper operation of the air bag system.
Page 10 0A-6 GENGERAL INFORMATION CAUTION: D When using electric welding, be sure to temporarily disable air bag system. Refer to DISABLING AIR BAG SYSTEM under SERVICE PRECAUTIONS in SECTION 10B. D Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames.
Page 11: General Precautions
GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under VEHICLE LIFTING POINTS on SECTION 0A.
Page 12 0A-8 GENGERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. 1.
Page 13 GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describ- ing the correct installation positions so that the hoses can be reinstalled correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D Never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be sprayed out under pressure.
Page 14 0A-10 GENGERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch to OFF position, or electronic parts may get damaged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g.
Page 15: Electrical Circuit Inspection Procedure
GENERAL INFORMATION 0A-11 D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage to check for electrical system, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.
Page 16 0A-12 GENGERAL INFORMATION 3) Using a test male terminal, check both terminals of the circuit being checked for contact tension of its female terminal. Check contact tension by inserting and removing just for Check each terminal visually for poor contact (possibly caused once by dirt, corrosion, rust entry of foreign object, etc.).
Page 17 GENERAL INFORMATION 0A-13 If measurements were taken as shown in the figure and results were as listed below, it means that the circuit is open between ter- minals B-1 and A-1. Voltage Between: C-1 and body ground: Approx. 5V B-1 and body ground: Approx. 5V A-1 and body ground: 0V Also, if measured values were as listed below, it means that there is a resistance (abnormality) of such level that corresponds to the...
Page 18: Intermittent And Poor Connection
0A-14 GENGERAL INFORMATION INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 19: Precautions For Installing Mobile Communication Equipment
GENERAL INFORMATION 0A-15 PRECAUTIONS FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Cit- izens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely affect electronic control system. D Keep the antenna as far away as possible from the vehicle’s electronic control unit.
Page 20 0A-16 GENGERAL INFORMATION WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Page 21: Vehicle Lifting Points
GENERAL INFORMATION 0A-17 1. Air bag warning label on driver air bag (inflator) module 2. Air bag warning label on passenger air bag (inflator) module 3. Air bag warning label on contact coil and combination assembly 4. Air bag warning label on SDM 5.
Page 22 0A-18 GENGERAL INFORMATION In raising front or rear vehicle end off the floor by jacking, be sure Front to put the jack against the center portion of the front lower cross- member or rear axle housing. WARNING: D Never apply jack against suspension parts (i.e., stabi- lizer, etc.) or vehicle floor, or it may get deformed.
Page 23 GENERAL INFORMATION 0A-19 There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “G”). The dual-colored wire uses two color symbols (i.e. “G/Y”). The first symbol represents the base color of the wire (“G”...
Page 24 0A-20 GENGERAL INFORMATION IAC Valve : Idle Air Control Valve (Idle : Right Hand Speed Control Solenoid Valve, ISC Solenoid Valve) : Society of Automotive IAT Sensor : Intake Air Temperature Engineers Sensor (Air temperature : Sensing and Diagnostic Sensor, ATS) Module (Air bag controller, : Immobilizer Control Module Air bag control module)
Page 25 GENERAL INFORMATION 0A-21 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric. When replac- ing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 7T and radial line with the class identification embossed on the head of each bolt.
Page 26 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 27 0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 ( 4 000 d 90 000 k ( 4 000 miles) carry out the same services at the same intervals miles), carry out the same services at the same intervals Interval: Interval:...
Page 28 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same inter- Interval: vals respectively. This interval should be judged by odometer reading or (x 1,000) months, whichever comes first.
Page 29 0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 30 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Water pump and generator drive belt (V-rib belt) Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
Page 31 0B-6 MAINTENANCE AND LUBRICATION 3) Check belt for tension. A/C compressor drive belt tension “b”: 8 – 9 mm (0.32 – 0.35 in.) deflection under 100 N (10 kg, 22 lb) pressure. 4) If belt tension is out of above specification, adjust it by adjusting compressor position.
Page 32 MAINTENANCE AND LUBRICATION 0B-7 ITEM 1-4 Engine Oil and Filter Change WARNING: New and used engine oil can be hazardous. Be sure to read WARNING in GENERAL PRECAUTION in Proper Engine Oil Viscosity Chart SECTION 0A and observe what in written there. Before draining engine oil, check engine for oil leakage.
Page 33 0B-8 MAINTENANCE AND LUBRICATION 5) Tighten filter 3/4 turn from the point of contact with the mounting surface using an oil filter wrench. Special Tool (A): 09915-40611 Tightening Torque (b): 14 N m (1.4 kg-m, 10.5 lb-ft) 1. Oil filter 6) Replenish oil until oil level is brought to FULL level mark on dip- Proper Engine Oil Viscosity Chart stick.
Page 34 MAINTENANCE AND LUBRICATION 0B-9 ITEM 1-5 Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot. Scald- ing fluid and steam can be blown out under pressure if cap is taken off too soon.
Page 35 0B-10 MAINTENANCE AND LUBRICATION 8) Add coolant to reservoir so that its level aligns with FULL mark. Then, reinstall cap aligning arrow marks on reservoir and cap. NOTE: When installing reservoir cap, align arrow marks on reser- voir and cap. CAUTION: When changing engine coolant, use mixture of 50% water...
Page 36 MAINTENANCE AND LUBRICATION 0B-11 D Make sure that exhaust system components have enough clear- ance from the underbody to avoid overheating and possible damage to the floor carpet. D Any defects should be fixed at once. Mounting replacement Replace muffler rubber mountings with new ones periodically. Refer to ON-VEHICLE SERVICE in SECTION 6K for installation.
Page 37 0B-12 MAINTENANCE AND LUBRICATION ITEM 3-2 Fuel tank Inspection After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check fuel pump assembly gaskets for leaks, visually inspect fuel tank for leaks and damage. Replace any damaged or malconditioned parts.
Page 38 MAINTENANCE AND LUBRICATION 0B-13 EMISSION CONTROL SYSTEM ITEM 4-1 Crankcase Ventilation Hoses and Connections Inspection Refer to following ITEM 4-2 PCV valve inspection. ITEM 4-2 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hose and PCV hose for leaks, cracks or clog, and PCV valve for stick or clog.
Page 39 0B-14 MAINTENANCE AND LUBRICATION CHASSIS AND BODY ITEM 6-1 Clutch Pedal inspection Check clutch pedal for height and free travel. Refer to CLUTCH PEDAL FREE TRAVEL in SECTION 7C. Adjust or correct if neces- sary. 1. Clutch pedal free travel ITEM 6-2 Brake Discs, Pads, Brake Drums and Shoes Inspection [Brake discs and pads (Front)]...
Page 41 0B-16 MAINTENANCE AND LUBRICATION Parking brake cable inspection Inspect brake cable for damage and smooth movement. Replace cable if it is in deteriorated condition. ITEM 6-6 Tires Inspection and Rotation 1) Check tires for uneven or excessive wear, or damage. If defective, replace.
Page 42 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-8 Suspension System Inspection D Inspect front and rear shock absorber for evidence of oil leak- age, dents or any other damage on sleeves; and inspect anchor ends for deterioration. Replace defective parts, if any. 1.
Page 44 MAINTENANCE AND LUBRICATION 0B-19 3) Check universal joints of steering shaft for rattle and damage. If rattle or damage is found, replace defective part with a new one. 4) Check steering linkage for looseness and damage. Repair or replace defective parts, if any. 5) Check bolts and nuts for tightness and retighten them as neces- sary.
Page 45 0B-20 MAINTENANCE AND LUBRICATION FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual Transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is D Clutch is completely released when depressing seen so as to prevent any accident.
Page 46 Differential oil (Refer to OIL CHANGE in SECTION 7F for detail.) Water resistance chassis grease Clutch linkage pivot points (SUZUKI SUPER GREASE A 99000-25010) Door hinges Engine oil or water resistance chassis grease Engine oil or water resistance chassis grease...
Page 47 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 48 1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION HEATER The heater and ventilation of this vehicle consist of such main components as control levers, blower motor, heater core and air ducts. The blower motor runs on electricity to send air inside. In the heater core, the cooling water warmed by the engine keeps circulating.
Page 49 HEATER AND VENTILATION 1A-3 DIAGNOSIS Symptom Possible Cause Remedy Heater blower won’t work Blower fuse blown Replace fuse to check for short. even when its switch is ON. Blower resistor faulty Check continuity. Blower motor faulty Replace motor. Wiring or grounding faulty Repair as necessary.
Page 50 1A-4 HEATER AND VENTILATION HEATER UNIT 1. Heater unit assembly 2. Blower fan 3. Fan motor 4. Resistor 5. Mode lever 6. Air mix link 7. Heater core...
Page 51 HEATER AND VENTILATION 1A-5 REMOVAL WARNING: Please observe all WARNINGS, CAUTIONS, SERVICE PRECAUTIONS under ON VEHICLE SERVICE before per- forming service on Air Bag System Component. Failure to follow WARNINGS could result in unintended air bag deployment or could render the air bag inoperative. Ei- ther of these two conditions may result in severe injury.
Page 52 1A-6 HEATER AND VENTILATION INSTALLATION 1) Install heater unit by reversing removal procedure, noting the following items. D When installing each part, be careful not to catch any cable or wiring harness. D When installing steering column assembly, refer to Section 1.
Page 53 HEATER AND VENTILATION 1A-7 HEATER CONTROL LEVER ASSEMBLY REMOVAL 1) Remove meter cluster and glove box. 2) Remove control cable from link. 3) Disconnect blower motor switch and A/C switch (if equipped) lead wires at coupler. 4) Disconnect instrument harness clamps from stay. 5) Remove control lever assembly.
Page 54 1A-8 HEATER AND VENTILATION Temperature control cable 1) Set control lever to COOL position. 2) Pull lever and link in arrow direction fully as shown in left figure and fix cable there. 1. Temperature control cable 2. Link Fresh air control cable 1) Set control lever to FRESH AIR position.
Page 55: Air Conditioning
D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 56 1B-2 AIR CONDITIONING GENERAL DESCRIPTION This section describes function of its main components, installation, servicing etc. For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CONDI- TIONING BASIC MANUAL (99520-02130). LABEL on the compressor shows whether the A/C system uses R-134a or R-12.
Page 57 AIR CONDITIONING 1B-3 COMPONENT LOCATION [A] : Right hand drive vehicle [B] : Left hand drive vehicle 1. Compressor discharge hose 2. Compressor suction hose/pipe 3. Dual pressure switch 4. Receiver/Dryer 5. Evaporator inlet pipe 6. Condenser 7. Expansion valve 8.
Page 58 1B-4 AIR CONDITIONING WIRING CIRCUIT : Black P/W : Pink/White B/BI : Black/Blue : Orange 1. Battery 10. Magnet clutch relay : Black/Red : Pink 2. Main fuse 11. Condenser fan motor relay Br/B : Brown/Black : Pink/Black 3. Ignition switch 12.
Page 59 AIR CONDITIONING 1B-5 RECOVERY, EVACUATION AND CHARGING OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT REFRIGERANT RECOVERY When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharging it into atmosphere would cause adverse effect to envi- ronments.
Page 60 1B-6 AIR CONDITIONING DIAGNOSIS Symptom Possible Cause Remedy Cool air won’t come out A/C system inoperative D No refrigerant (A/C system improper op- Recover, evacuation and charging. D Fuse blown erative) Check “TURN BACK” fuse, “HEATER” fuse and “A/C FUSE” and check for short circuit.
Page 61 AIR CONDITIONING 1B-7 Symptom Possible Cause Remedy D Compressor faulty Cool air won’t come out or Check compressor. D Air in A/C system insufficient cooling (A/C Replace receiver/dryer, and evacua- system normal operative) tion and charging. D Air leaking from cooling unit or air duct Repair as necessary.
Page 62 1B-8 AIR CONDITIONING A/C CONTROLLER AND ITS CIRCUITS IN- SPECTION A/C controller and its circuits can be checked at couplers by mea- suring voltage with the couplers connected. CAUTION: A/C controller cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to A/C controller with couplers disconnected from it.
Page 63 AIR CONDITIONING 1B-9 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Refer to “INSPECTION OF ECM AND ITS CIR- CUIT” in “ENGINE AND EMISSION CONTROL (A/C signal) SYSTEM” Section Compressor relay 0 – 1 V Blower fan switch ON and A/C switch ON at engine running Terminal “A9”...
Page 64 1B-10 AIR CONDITIONING ON-VEHICLE SERVICE CAUTION: When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe following instructions. D When disconnecting any line from system, install a blind plug or cap to fitting of such line immedi- ately.
Page 65 AIR CONDITIONING 1B-11 Connect battery to A/C condenser fan motor as shown, then check that the condenser fan motor operates smoothly. Reference current : approx. 6.7 – 8.3 A at 12 V 1. A/C condenser fan motor coupler COOLING UNIT (EVAPORATOR) REMOVAL 1) Disconnect negative (–) cable at battery.
Page 66 1B-12 AIR CONDITIONING A/C evapo. thermistor Check resistance between terminals. Sensor Temperature (5C (5F)) Resistance (kW) 0 (32) 6.3 – 7.0 25 (77) 1.8 – 2.2 If it is not within specification, replace thermistor. NOTE: When the thermistor is removed, its should be reinstalled in original position.
Page 67 AIR CONDITIONING 1B-13 INSPECTION D Press A/C Switch button and set blower fan switch other than OFF and check if there is continuity between terminals “A” and “B”. D With battery voltage (+) connected to terminal “B” and (–) to ter- minal “A”, press A/C Switch button and set blower fan switch oth- er than OFF and check if indicator lamp lights.
Page 68 1B-14 AIR CONDITIONING A/C COMPRESSOR REMOVAL AND INSTALLATION Refer to the figure as given below when removing and installing A/C compressor. After installing, be sure to check and adjust drive belt tension, referring to BELT TENSION INSPECTION in Section 6H and A/C COMPRESSOR DRIVE BELT INSPECTION under DIAGNOSIS. Tightening torque (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft) (b) : 50 N·m (5.0 kg-m, 36.0 lb-ft)
Page 69 AIR CONDITIONING 1B-15 DISASSEMBLY 1) Remove compressor. 2) Fix armature plate with special tool (A) and remove armature plate screw. Special Tool (A): 09991-06060 NOTE: 1. Armature plate 2. Screw Do not reuse armature plate screw. 3. Washer 3) Using special tool (B), remove armature plate. Special Tool (B): 09991-06030 1.
Page 70 1B-16 AIR CONDITIONING 11) Remove front head by pushing cylinder shaft. 1. Front head 2. Cylinder shaft 3. Cylinder NOTE: 4. Case 5. O-ring Be careful not to remove cylinder from case. 12) Remove O-ring. 13) Remove lip seal from front head. 1.
Page 71 AIR CONDITIONING 1B-17 6) Tighten front head bolts. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 Ib-ft) (b): 23 N·m (2.3 kg-m, 17.0 Ib-ft) NOTE: D Be sure to use new front head bolt washer. D Tighten bolt (a) first, and next (b). 1.
Page 72 1B-18 AIR CONDITIONING 12) Tighten new armature plate nut as specified below. Tightening Torque (a): 14 N m (1.4 kg-m, 10.5 lb-ft) Special Tool (A): 09991-06060 1. Armature plate 2. Screw 3. Washer REPLENISHING COMPRESSOR OIL When replacing air conditioning parts with new ones, it is neces- sary to replenish oil by the amount supposedly remaining in each part.
Page 73 AIR CONDITIONING 1B-19 PERFORMANCE TEST After finishing all repairs, make sure to carry out performance test of A/C system as follows. PROCEDURE 1) Connect high and low side charging hose of manifold gauge set to hose fittings of compressor. 2) Run engine, and keep speed at 1500 rpm. 3) Set A/C and fan switch at high position.
Page 74 1B-20 AIR CONDITIONING HOW TO READ THE STANDARD PERFORMANCE CURVE 1) Read psychrometer reading at the inlet, and get relative humidity from psychrometric chart. (See following fig- ures.) 2) Measure dry bulb temperature at cool air outlet, then find out the difference between inlet and outlet tempera- tures.
Page 75 AIR CONDITIONING 1B-21 SPECIAL TOOLS 09900-06107 Snap ring pliers 09991-06010 09991-06030 09991-06040 (Opening type) Magnet clutch pulley installer Armature plate remover Lip type seal protector 09991-06050 09991-06060 Lip type seal installer Armature plate holder...
Page 76: Steering, Suspension, Wheels And Tires
D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 77 3-2 STEERING, SUSPENSION, WHEELS AND TIRES GENERAL DIAGNOSIS Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a symptom. To avoid misjudging the symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 78 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Symptom Possible Cause Remedy D Tire or wheel out of balance Shimmy, Shake or Balance wheels or replace tire and/or Vibration wheel. D Loosen wheel bearings Replace wheel bearing. D Worn tie rod ends Replace tie rod end.
Page 79 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Symptom Possible Cause Remedy D Loose steering gear case bolts Rack and Pinion Retighten. D Worn rack bush Noise Replace. D Rack and pinion adjustment (Rattle or Chuckle) Check and adjust rack and pinion torque. D Worn, sticky or loose tie rod ends, lower Abnormal Noise, Replace tie rod end, control arm, steering...
Page 80 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Symptom Possible Cause Remedy D Broken or sagging springs Low or Uneven Trim Replace spring. D Over loaded Height Check loading. D Incorrect springs Right-to-left trim height Replace spring. (H) difference should be within 15 mm (0.6 in.) with curb weight.
Page 81 3-6 STEERING, SUSPENSION, WHEELS AND TIRES TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, im- proper alignment. If the following conditions are noted, rotation is necessary: 1) Front tire wear is different from rear.
Page 82 STEERING, SUSPENSION, WHEELS AND TIRES 3-7 1) Ride vehicle to determine whether the front or rear waddles. 2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end of ve- hicle.
Page 83 3-8 STEERING, SUSPENSION, WHEELS AND TIRES RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level road even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment 2) Uneven brake adjustment 3) Tire construction The way in which a tire is built can produce lead in a vehicle.
Page 84 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ......Preliminary Checks Prior to Adjusting Front Alignment .
Page 85 3A-2 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel.
Page 86 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length (“A” in left figure). NOTE: If tie rod lengths were changed to adjust steering angle, rein- spect toe-in.
Page 87 MANUAL RACK AND PINION 3B-1 SECTION 3B MANUAL RACK AND PINION NOTE: All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 88 3B-2 MANUAL RACK AND PINION DIAGNOSIS DIAGNOSIS TABLE See Section 3. STEERING WHEEL PLAY CHECK Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “ a”: 0 – 30 mm (0 – 1.18 in.) If steering wheel play is not within specification, inspect as follows and replace if found defective.
Page 89 When inner parts of the steering gear case were disassembled, they should be washed clean before reassembly. It is recommended to use the grease to the indicated area as shown below. GREASE: SUZUKI SUPER GREASE E (99000-25050) or Lithium grease (applicable for –405C -1305C (1045F – 2665F)) : Use new nut when installing 1.
Page 90 3B-4 MANUAL RACK AND PINION STEERING GEAR CASE REMOVAL 1) Loosen steering lower shaft upper joint bolt. 2) Remove steering shaft seal from dash panel and then remove steering lower shaft lower joint bolt. Disconnect steering lower shaft from steering pinion. 1.
Page 91 MANUAL RACK AND PINION 3B-5 4) Remove boot from tie-rod. 5) Unbend bent part of tie-rod lock washer and remove tie-rod from rack. 1. Lock washer 2. Tie-rod 3. Steering rack 6) Remove parts as shown. 1. Rack damper screw 2.
Page 92 3B-6 MANUAL RACK AND PINION 11) Remove rack from gear case. Direction for rack removal is as shown. CAUTION: Inside of steering rack bushing is coated with special coating. As it is damageable, be very careful not to cause damage to it when removing rack from steer- ing gear case.
Page 93 MANUAL RACK AND PINION 3B-7 Steering Rack Inspect for deflection, teeth wear, or damage, back surface wear or damage. Limit of rack deflection: 0.35 mm (0.014 in.) If deflection exceeds limit, replace rack. CAUTION: Do not use a wire brush when cleaning. ASSEMBLY Install in reverse order of removal, nothing following points.
Page 94 3B-8 MANUAL RACK AND PINION 6) Install pinion assembly and tighten pinion bearing plug to spe- cified torque. Special Tool (43 mm socket) (A): 09944-26011 Tightening torque (a): 95 N·m (9.5 kg-m, 69.0 Ib-ft) 7) Apply grease lightly to sliding part of plunger against rack. A”: Grease 99000-25050 “...
Page 95 MANUAL RACK AND PINION 3B-9 12) Install steering gear case cover. Fit lip of cover in pinion groove. 13) Install new tie-rod lock washer as shown and tie-rod to rack. Align straight part “ D” of washer with flat part “ E” of rack. 14) Tighten tie-rod inside ball nut to specified torque.
Page 96 3B-10 MANUAL RACK AND PINION 17) Apply grease to part which tie-rod side “ F” of boot. CAUTION: Never apply grease to part which contacts steering gear case side “ G” of boot. 18) Position boot properly in grooves of gear case and tie-rod and clamp it with new wire and clip.
Page 97 MANUAL RACK AND PINION 3B-11 D Install steering lower shaft to steering pinion and then tighten lower joint bolt first and then upper joint bolt. Tightening Torque (b): 25 N·m (2.5 kg-m, 18.0 Ib-ft) D Install steering shaft seal to dash panel securely. Apply grease to shaft seal lip.
Page 98 29.0 REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT D Sliding part of rack against steering gear Lithium grease SUZUKI SUPER GREASE E (should be applicable (99000-25050) case (All around rack plunger, rack bushing for –405C - 1305C) and rack) D Sliding part against steering pinion (Oil seal...
Page 99 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 100 3B1-2 ELECTRICAL POWER STEERING (P/S) SYSTEM GENERAL DESCRIPTION This power steering (P/S) system consists of a P/S control module, a torque sensor and a motor and clutch installed to the steering column. In this system, the P/S control module determines the level and direction of the assist force for the steering wheel according to the signals from the torque sensor and the vehicle speed, runs the motor so as to assist operation of the steering wheel.
Page 101 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-3 WIRING DIAGRAM 1. To main fuse 8. To vehicle speed sensor (VSS) 15. P/S control module 2. Ignition switch 9. ECM 16. P/S control module body ground 3. “EPS” fuse (30A) in fuse box 10.
Page 102 3B1-4 ELECTRICAL POWER STEERING (P/S) SYSTEM DIAGNOSIS The P/S system in this vehicle are controlled by P/S control module. P/S control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of ON-BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diagnosis according to SYSTEM CHECK FLOW TABLE.
Page 103 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-5 SYSTEM CHECK FLOW TABLE STEP ACTION 1) Make sure that battery voltage is about 11 V or Go to STEP 2. Proceed to TABLE A- higher. MIL CIRCUIT 2) Note MIL (“EPS” light) as ignition switch is CHECK (MIL DOES turned to ON position.
Page 104 However, if a multiple number of DTC’s are set an even one of them is a current DTC, “EPS” light remains on after engine is started. Therefore, it is not possible to identify any of them as to whether it is a current one or a history one. (But use of SUZUKI scan tool will make identification possible.)
Page 105 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool oper- ator’s manual for further details. 5) After completing the check, turn ignition switch to OFF position and disconnect SUZUKI scan tool from data link connector (DLC).
Page 106 DTC CLEARANCE USING SUZUKI SCAN TOOL 1) Turn ignition switch to OFF position. 2) After setting cartridge to SUZUKI scan tool connect it to data link connector (DLC) located on underside of instrument panel at driver’s seat side. Special Tool...
Page 107 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-9 DTC TABLE Example: When VSS circuit fail (DTC C1121) is set Turn ON Malfunction indicator lamp (“EPS” light) Turn OFF TIME (sec.) “EPS” light flashing pattern DIAGNOSTIC ITEM DIAGNOSTIC ITEM DIAGNOSIS DIAGNOSIS Model This code appears when –––...
Page 108 3B1-10 ELECTRICAL POWER STEERING (P/S) SYSTEM TABLE A - MIL CIRCUIT CHECK (MIL DOES NOT LIGHT) TABLE B - MIL CIRCUIT CHECK (MIL FLASHES) TABLE C - MIL CIRCUIT CHECK (MIL REMAINS ON) 1. To main fuse 9. Monitor coupler 2.
Page 109 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-11 DIAGNOSTIC FLOW TABLE Table A: STEP ACTION Are “IG·METER” and “EPS” fuses in good condition? Go to STEP 2. Check short to ground in “B/W” (for “IG ME- TER” fuse), “B/R” (for “EPS” fuse) wire, and then replace fuse.
Page 110 3B1-12 ELECTRICAL POWER STEERING (P/S) SYSTEM Fig. for Step 2 Fig. for Step 3 Fig. for Step 5 Fig. for Step 6 Fig. for Step 7 NOTE: Upon completion of inspection and repair work, repeat SYSTEM CHECK FLOW TABLE to confirm that the trouble has been corrected.
Page 111 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-13 Table B: STEP ACTION 1) Check monitor coupler for P/S system. Remove service wire. Go to STEP 2. 2) Is it connected diagnosis switch terminal for P/S system and ground terminal in monitor coupler by service wire? 1) With ignition switch OFF, disconnect 8-pin (“A”) Substitute a known-...
Page 112 3B1-14 ELECTRICAL POWER STEERING (P/S) SYSTEM Table C: STEP ACTION 1) Short diagnosis switch terminal to body ground Repair high resistance Go to STEP 2. by service wire. or open in ground (“B” 2) Does “EPS” light turn ON flash at ignition switch wire) circuit on monitor coupler.
Page 113 Be sure to perform SYSTEM CHECK FLOW TABLE before starting diagnosis according to flow table of each DTC. TABLE TEST DESCRIPTION STEP 1: Check connection of SUZUKI scan tool to DLC. STEP 2: Check serial data link circuit. STEP 3: Check high resistance or open in serial data link circuit for P/S system.
Page 114 3B1-16 ELECTRICAL POWER STEERING (P/S) SYSTEM DIAGNOSTIC FLOW TABLE STEP ACTION 1) Make sure that SUZUKI scan tool is free from Go to STEP 2. Properly connect SU- malfunction and correct cartridge for P/S system ZUKI scan tool to DLC.
Page 115 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-17 DTC C1111 TORQUE SENSOR MAIN CIRCUIT FAIL DTC C1113 TORQUE SENSOR MAIN AND SUB CIRCUIT FAIL DTC C1115 TORQUE SENSOR SUB CIRCUIT FAIL 1. To main fuse 5. P/S control module 2. Ignition switch 6.
Page 116 3B1-18 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC C1114 TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAIL 1. To main fuse 5. P/S control module 2. Ignition switch 6. Torque sensor 3. “EPS” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 117 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-19 DTC C1116 TORQUE SENSOR 8V POWER SUPPLY CIRCUIT FAIL 1. To main fuse 5. P/S control module 2. Ignition switch 6. Torque sensor 3. “EPS” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 118 3B1-20 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC C1121/C1123/C1124 VSS CIRCUIT FAIL 1. To main fuse 2. Ignition switch 3. “EPS” fuse (30A) in fuse box 4. “IG METER” fuse (15A) in fuse box 5. Malfunction indicator lamp (MIL) (“EPS” light) 6.
Page 119 Be sure to perform SYSTEM CHECK FLOW TABLE before starting diagnosis according to flow table of each DTC. NOTE 1: It is necessary for SUZUKI scan tool to perform STEP 3 of this table. STEP ACTION 1) Recheck DTC with engine running.
Page 120 3B1-22 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC C1141/C1142/C1143/C1144/C1145 MOTOR CIRCUIT FAIL 1. To main fuse 5. P/S control module 2. Ignition switch 6. Motor and clutch 3. “EPS” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 121 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-23 DTC C1151 CLUTCH CIRCUIT FAIL 1. To main fuse 5. P/S control module 2. Ignition switch 6. Motor and clutch 3. “EPS” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 122 3B1-24 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC C1153 P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAIL 1. To main fuse 4. “IG METER” fuse (15A) in fuse box 2. Ignition switch 5. P/S control module 3. “EPS” fuse (30A) in fuse box 6.
Page 123 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-25 INSPECTION OF P/S CONTROL MODULE AND ITS CIRCUITS P/S control module and its circuits can be checked at P/S control module wiring couplers by measuring voltage and resistance. CAUTION: P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to P/S control module with coupler disconnected from it.
Page 124 “EPS” light ON 10 – 14V Engine idling “EPS” light OFF Diagnosis switch terminal About 5V Ignition switch ON SUZUKI scan tool – – Motor output 2 5 – 7V Engine idling and steering wheel held at position for vehicle to run...
Page 125 ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-27 TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON BOARD DIAGNOSTIC SYSTEM) This section describes trouble diagnosis of P/S system parts whose trouble is not indicated by the on-board diag- nostic system (self-diagnostic function). When DTC No.12 is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in DIAGNOSIS CHART in SECTION 3 are all in good condition, check following power steering system parts which may be a possible cause for each symptom of the steering.
Page 126 3B1-28 ELECTRICAL POWER STEERING (P/S) SYSTEM INSPECTION OF STEERING WHEEL PLAY Check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. Check steering wheel for play, holding vehicle in straight forward condition on the ground and with engine stopped.
Page 127: Torque Sensor
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-29 ON-VEHICLE SERVICE P/S CONTROL MODULE REMOVAL 1) Disconnect negative cable at battery. 2) Remove steering column lower cover. 3) Disconnect couplers from P/S control module. 4) Remove P/S control module from steering column assembly. INSTALLATION Reverse removal procedure for installation.
Page 128 3B1-30 ELECTRICAL POWER STEERING (P/S) SYSTEM MOTOR AND CLUTCH ON-VEHICLE INSPECTION 1) Remove steering column lower cover. 2) Disconnect motor and clutch coupler from P/S control module with ignition switch OFF. 3) Check resistance between terminals of motor and clutch cou- pler.
Page 129 D Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS of ON-VEHICLE SERVICE in air bag system section before performing service on or around the air bag system components or wiring.
Page 130 3C-2 STEERING WHEEL AND COLUMN GENERAL DESCRIPTION This double tube type steering column has following three important features in addition to the steering function: D The column is energy absorbing, designed to compress in a front-end collision. D The ignition switch and lock are mounted conveniently on this column. D With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
Page 131 STEERING WHEEL AND COLUMN 3C-3 DIAGNOSIS Refer to SECTION 3 for diagnosis of the steering wheel and column. Refer to SECTION 10B for diagnosis of the air bag system. INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT [For vehicle without air bag system] After an accident, be sure to perform checks, inspections and repairs described under CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE in this section.
Page 132 3C-4 STEERING WHEEL AND COLUMN DRIVER AIR BAG (INFLATOR) MODULE (FOR VEHICLE WITH AIR BAG SYSTEM) WARNING: When handling an air bag (inflator) module, be sure to read SERVICE PRECAUTIONS in this section and ob- serve each instruction. Failure to follow them could cause a damage to the air bag (inflator) module or result in personal injury.
Page 133 STEERING WHEEL AND COLUMN 3C-5 CAUTION: If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module visually and if any of the following is found, replace it with a new one. D Air bag being deployed D Trim cover (pad surface) being cracked D Wire harness or connector being damaged...
Page 134: Steering Wheel
3C-6 STEERING WHEEL AND COLUMN STEERING WHEEL For vehicle without air bag system Type A CAUTION: For vehicle with air bag system Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the com- bination switch) more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively), or coil will...
Page 135 For vehicle with air bag system 2) For vehicle without air bag system i) Apply grease to contact plate “A” of steering wheel. GREASE: SUZUKI GREASE CE-T (99000-25290) ii) Install steering wheel onto shaft, aligning them by matching marks. For vehicle with air bag system...
Page 136 3C-8 STEERING WHEEL AND COLUMN CENTERING CONTACT COIL (FOR VEHICLE WITH AIR BAG SYSTEM) 1) Check that vehicle’s wheels (front tires) are set at straight- ahead position. 2) Check that ignition switch is at “LOCK” position. 3) Turn contact coil counterclockwise slowly with a light force till contact coil will not turn any further.
Page 137 STEERING WHEEL AND COLUMN 3C-9 2) Remove steering column cover screws (3 pcs). 3) Loosen steering column mounting bolts (Refer to STEERING COLUMN in this section). 4) Separate upper cover and lower cover, then remove them. 5) If equipped with air bag system, disconnect yellow connector and horn connector of contact coil from harness.
Page 138 3C-10 STEERING WHEEL AND COLUMN 4) Install steering column upper and lower, and then tighten steer- ing column cover screws. CAUTION: When installing lower cover and upper cover, be care- ful so that combination switch/contact coil and com- bination switch lead wirer is not caught between covers.
Page 139 STEERING WHEEL AND COLUMN 3C-11 3) Remove steering wheel and combination switch assembly, if necessary. Refer to REMOVAL of STEERING WHEEL and REMOVAL of COMBINATION SWITCH/CONTACT COIL AND COMBINATION SWITCH ASSEMBLY in this section. Perform the following procedure if not removing steering wheel and/or combination switch assembly.
Page 140 3C-12 STEERING WHEEL AND COLUMN INSPECTION NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted (or air bag deployed), may have a damaged or misaligned steering col- umn. CHECKING PROCEDURE 1) Check that two capsules are attached to steering column brack- et securely.
Page 141 STEERING WHEEL AND COLUMN 3C-13 INSTALLATION CAUTION: After tightening steering column mounting bolts, upper joint bolts should be tightened. 1) Be sure that front wheels and steering wheel are in straightfor- ward state. 2) Connect all connectors that have been disconnected in RE- MOVAL of STEERING COLUMN in this section.
Page 142 3C-14 STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column. Refer to REMOVAL of STEERING COLUMN in this section. 2) Using center punch as shown, loosen and remove steering lock 1. Center punch (with sharp point) mounting bolts.
Page 143 (a): 25 N·m (2.5 kg-m, 18.0 lb-ft) 5) Apply grease to “E” of steering shaft seal. Grease: SUZUKI SUPER GREASE A (99000–25010) 6) Install steering shaft seal to dash panel. 7) Insert upper joint assembly into steering shaft (column side) with matching marks (“A”).
Page 144 3C-16 STEERING WHEEL AND COLUMN 8) Tighten upper joint bolt (column side) to specified torque then tighten upper joint bolt (lower shaft side) to specified torque. Tightening Torque (a): 25 N·m (2.5 kg-m, 18.0 lb-ft) 1. Upper joint bolt (column side) 2.
Page 145 18.0 Steering column mounting bolt 11.0 P/S control module (if equipped) REQUIRED SERVICE MATERIALS MATERIAL RECOMMENDED SUZUKI PRODUCT Lithium grease SUZUKI SUPER GREASE A (99000-25010) Steering shaft seal SUZUKI GREASE CE–T (99000-25290) Contact plate SPECIAL TOOL 09944-36011 Steering wheel remover...
Page 146 FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: D All front suspension fasteners are an important attaching part in that it could affect the perfor- mance of vital parts and systems, and/or could result in major repair expense. They must be re- placed with one of the same part number or with an equivalent part if replacement becomes nec- essary.
Page 147 3D-2 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehicle body by a strut support. The strut and strut support are isolated by a strut rubber support. A strut bearing is also installed a little lower to the strut rubber support.
Page 148 FRONT SUSPENSION 3D-3 STRUT ASSEMBLY 1. Strut support cap 5. Strut support 9. Spring upper seat 2. Strut nut 6. Strut rubber support 10. Spring seat 3. Strut lock washer 7. Strut bearing seat 11. Bump stopper 4. Strut rebound stopper 8.
Page 149 3D-4 FRONT SUSPENSION DIAGNOSIS Refer to Section 3. CHECK AND ADJUSTMENT STABILIZER BAR AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing/Cushion Inspect for damage, wear or deterioration. If defective, replace. COMPRESSION ROD AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration.
Page 150 FRONT SUSPENSION 3D-5 STRUT DAMPER CHECK 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled. 2) Strut function check Check and adjust tire pressures as specified on tire placard. Bounce vehicle body three or four times continuously by push- ing front end on the side with strut to be checked.
Page 151 3D-6 FRONT SUSPENSION WHEEL DISC, NUT & BEARING CHECK 1) Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. 2) Check wheel nuts for tightness and, as necessary retighten them to specification. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 3) Check wheel bearing for wear.
Page 152 FRONT SUSPENSION 3D-7 ON-VEHICLE SERVICE STABILIZER BAR AND/OR BUSHINGS REMOVAL 1) Hoist vehicle and allow the front suspension control arms to hang free. 2) Remove stabilizer link nuts, washers and cushions. When loosening link nut, hold stud with a wrench. 3) Remove stabilizer bar mount bushing bracket bolts.
Page 153 3D-8 FRONT SUSPENSION COMPRESSION ROD AND/OR BUSHINGS REMOVAL 1) Hoist vehicle, allow front suspension to hang free. 2) Remove stabilizer bar, refer to steps 2) to 4) of STABILIZER BAR AND/OR BUSHINGS REMOVAL. 3) Remove compression rod nuts. 4) Remove compression rod. 1.
Page 154 FRONT SUSPENSION 3D-9 STRUT DAMPER ASSEMBLY REMOVAL 1) Disconnect negative cable at battery. 2) Hoist vehicle, allowing front suspension to hang free. 3) Remove wheel. 4) Remove E-ring securing brake flexible hose and take brake flexible hose off strut bracket as shown. 5) Remove wheel speed sensor harness clamp bolt from strut (if equipped with ABS).
Page 155 3D-10 FRONT SUSPENSION DISASSEMBLY 1) Remove strut support cap and loosen strut nut a little by using special tools. Special Tool (A): 09945-26010 (17 mm socket) (B): 09900-00411 (Socket) (C): 09900-00414 (6 mm) NOTE: When disassembling strut assembly, loosen strut nut a little before compressing strut spring.
Page 156 FRONT SUSPENSION 3D-11 ASSEMBLY For assembly, reverse disassembly procedure, observing the fol- lowing instruction. 1. Strut support cap 8. Strut bearing 2. Strut nut 9. Spring upper seat 3. Strut lock washer 10. Spring seat 4. Strut rebound stopper 11. Bump stopper 5.
Page 157 3D-12 FRONT SUSPENSION D Install bump stopper onto strut rod. Refer to the left figure for installing direction. D Clean strut bearing and install it on spring upper seat. Refer to figure at left for installing direction. D Wash bearing seat and install it as shown. D On bearing seat, install rebound stopper, strut support and rub- ber support in this sequence.
Page 158 FRONT SUSPENSION 3D-13 WHEEL HUB/WHEEL STUD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove spindle cap as shown (by hammering lightly at 3 loca- tions around it using care not to deform or cause damage to seating part of cap). 1.
Page 159 3D-14 FRONT SUSPENSION INSTALLATION 1) Insert new stud in hub hole. Rotate stud slowly to assure serra- tions are aligned with those made by original bolt. 1. Oil hydraulic press 2. Rod 3. Hub bolt 2) Install wheel hub to spindle, tighten new spindle nut to specified torque.
Page 160 FRONT SUSPENSION 3D-15 SUSPENSION CONTROL ARM/BUSHING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove compression rod stud nuts from suspension control arm. 3) Remove ball stud bolt and nut. 4) Remove suspension control arm bolt and nut. 5) Remove suspension control arm. 1.
Page 161 3D-16 FRONT SUSPENSION 2) Install suspension control arm to suspension frame, referring to left figure for proper installing direction of bolt and nut. NOTE: Nut should not be tightened. 1. Suspension arm : Forward 3) Install ball stud to knuckle. Align ball stud groove with knuckle bolt hole as shown.
Page 162 FRONT SUSPENSION 3D-17 KNUCKLE REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove wheel hub. Refer to Steps 2) – 8) in WHEEL HUB/ WHEEL STUD REMOVAL of this section. 3) Disconnect tie-rod end from knuckle with puller. 4) Remove wheel speed sensor from knuckle (if equipped with 1.
Page 163 3D-18 FRONT SUSPENSION SUSPENSION FRAME REMOVAL 1) Hoist vehicle and remove wheels. 2) Remove suspension control arms (right & left), refer to steps 2) to 5) of SUSPENSION CONTROL ARM REMOVAL in this sec- tion. 3) Remove steering gear case mount bolts. 1.
Page 164 FRONT SUSPENSION 3D-19 TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts kg-m lb-ft Compression rod bracket bolt 40.0 Compression rod stud nut 69.0 Compression rod lock nut* 47.0 Strut bracket nut 69.0 Strut nut 36.5 Strut support nut 53.0 Ball stud lock nut* 40.0 Suspension control arm nut...
Page 165 REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 166 3E-2 REAR SUSPENSION GENERAL DESCRIPTION COIL SPRING TYPE This suspension consists of coil springs, rear axle, shock absorbers, lateral rod and trailing arms. The lateral rod is installed to the body and axle by using bushes so as to prevent axle movement in the lateral direc- tion.
Page 167 REAR SUSPENSION 3E-3 LEAF SPRING TYPE 1. Rear spring assy 2. Rear spring bumper 3. Spring shackle 4. Shock absorber 5. Spring shackle No.1 bushing 6. Spring shackle No.2 bushing 7. Spring U-bolt 8. U-bolt guide plate...
Page 168 3E-4 REAR SUSPENSION DIAGNOSIS Refer to Section 3. CHECK AND ADJUSTMENT REAR SHOCK ABSORBER CHECK D Inspect for deformation or damage. D Inspect bushings for wear or damage. D Inspect for evidence of oil leakage. Replace any defective part. TRAILING ARM, LATERAL ROD, REAR AXLE AND COIL SPRING CHECK D Inspect for cracks, deformation or damage.
Page 169 REAR SUSPENSION 3E-5 BUMP STOPPER/SPRING UPPER SEAT CHECK Inspect for cracks, deformation or damage. Replace any defective part. LEAF SPRING BUSHING AND SPRING SHACKLE BUSHING CHECK D Inspect for wear and breakage. Replace if defective. D When spring shackle bushings are not worn and yet abnormal sound is noted while driving, remove bushings and apply grease.
Page 170: Rear Shock Absorber
3E-6 REAR SUSPENSION ON-VEHICLE SERVICE REAR SHOCK ABSORBER REMOVAL 1) Hoist vehicle. 2) Support rear axle housing by using floor jack to prevent it from lowering. 3) Remove lower mounting bolt and nut. 4) Remove upper mounting nut. Then remove shock absorber. INSTALLATION 1) Install shock absorber, referring to left figure for proper installing direction of bolt.
Page 171 REAR SUSPENSION 3E-7 4) Remove brake flexible hose E-ring. 1. E-ring 5) Remove parking brake cable clamp bolt. 1. Parking brake cable clamp bolt 6) Remove shock absorber lower mounting bolt and nut. 7) Lower rear axle housing gradually as far down as where coil spring can be removed.
Page 172 3E-8 REAR SUSPENSION 2) Install shock absorber lower mounting bolt. 3) Remove floor jack from rear axle housing. 4) Install parking brake cable clamp bolt and brake flexible hose E-ring. 5) Install lateral rod to vehicle body . NOTE: Nut should not be tightened. 6) Install wheel and tighten wheel nuts to specified torque.
Page 173 REAR SUSPENSION 3E-9 LEAF SPRING AND SPRING BUMPER (LEAF SPRING TYPE) REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack to prevent it from lowering. 3) Remove parking brake cable clamp bolt. 4) Remove spring U-bolt nuts, guide plate, spring bumper and spring U-bolts.
Page 174 3E-10 REAR SUSPENSION LEAF SPRING FRONT BUSHING REPLACEMENT 1) Remove leaf spring as previously outlined. 2) Remove busing with special tool and hydraulic press. Special Tool (A): 09951-16040 (B): 09951-46020 3) Install new bushing and then leaf spring to vehicle by reversing removal procedure.
Page 175 REAR SUSPENSION 3E-11 TRAILING ARM (COIL SPRING TYPE) REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Support rear axle housing by using floor jack. CAUTION: Never apply floor jack against lateral rod as it may get deformed. 3) Remove shock absorber lower mounting bolt and nut. 4) Remove brake drum and brake shoe and disconnect parking brake cable from brake back plate, refer to PARKING BRAKE CABLE REMOVAL of Section 5.
Page 176 3E-12 REAR SUSPENSION LATERAL ROD (COIL SPRING TYPE) REMOVAL 1) Hoist vehicle. 2) Remove lateral rod mounting bolt and nuts. 3) Remove lateral rod. 1. Lateral rod 2. Left side mounting bolt and nut 3. Right side mount- ing nut INSTALLATION 1) Install damper to new lateral rod, if necessary.
Page 177 REAR SUSPENSION 3E-13 REAR AXLE SHAFT AND WHEEL BEARING REMOVAL 1) Hoist vehicle and remove rear wheel. 2) Drain gear oil from rear axle housing by loosening drain plug. 3) Remove brake drum and brake shoe and disconnect parking brake cable from brake back plate, refer to steps 2) – 4) of PARKING BRAKE CABLE REMOVAL of Section 5.
Page 178 3E-14 REAR SUSPENSION 10) Break with a chisel the thin ground retainer ring, and it can be removed. 11) Using special tools, remove bearing from shaft and then re- move brake back plate. Special Tool (C): 09927-18411 (D): 09921-57810 12) Remove stud bolts by using hydraulic press. 1.
Page 179 REAR SUSPENSION 3E-15 2) Press in a new bearing and retainer ring in order by using an hy- 1. Bearing spacer 5. Retainer ring 2. Tapered side 6. Differential side draulic press. 3. Wheel bearing 7. Hydraulic press 4. Sealed side NOTE: D Install wheel bearing spacer with the tapered side of its inner diameter directed toward outside, or brake drum...
Page 180 3E-16 REAR SUSPENSION 9) Connect parking brake cable to brake back plate and install brake shoe and brake drum, refer to PARKING BRAKE CABLE INSTALLATION of Section 5. 10) Refill rear axle (differential) housing with new specified gear oil. Refer to Section 7F for refill. 11) Fill reservoir with brake fluid and bleed brake system.
Page 181 REAR SUSPENSION 3E-17 REAR AXLE HOUSING 1. Flexible hose 2. E-ring REMOVAL 3. Brake pipe 1) Hoist vehicle and remove rear wheels (right & left). 2) Remove rear axle shafts, refer to steps 2) to 7) of REAR AXLE SHAFT REMOVAL in this section. 3) Disconnect brake pipe from flexible hose and remove E-ring.
Page 182 3E-18 REAR SUSPENSION INSTALLATION COIL SPRING Install removed parts in reverse order of removal, noting the following points. 1) Place rear axle on floor jack. Then install trailing arm rear mounting bolts (right & left). At this time, trailing arm nuts but don’t tighten them (Coil spring type). Securely fit leaf spring center bolt in the hole of rear axle hous- ing and spring bumper and U-bolts to guide plate flange (refer to LEAF SPRING/SPRING BUMPER INSTALLATION in this...
Page 183 REAR SUSPENSION 3E-19 6) Install differential carrier assembly, refer to Section 7F. 7) Install wheel speed sensor harness clamps (if equipped with ABS). 8) Connect brake pipes onto axle housing and clamp them se- curely. For clamping positions, refer to Section 5 of this manual. 9) Connect brake flexible hose to bracket on axle housing and secure it with E-ring.
Page 184 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Brake fluid DOT3 Brake reservoir tank SEALING COMPOUND 366E Join seam of rear axle housing and brake Water tight sealant (99000-31090) back plate SUZUKI SUPER GREASE A Lithic wheel bearing grease Oil seal lip (99000-25010)
Page 185 REAR SUSPENSION 3E-21 SPECIAL TOOLS 1. 09927-18411 Universal puller 09941-66010 09942-15511 2. 09921-57810 09913-75520 Bump stopper wrench Sliding hammer Bearing installer Bearing remover 1. 09944-96010 Bearing outer race remover 2. 09921-26010 Bearing outer race remover 09943-17912 collar Brake drum remover...
Page 186: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE : All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 187 3F-2 WHEELS AND TIRES kgf / cm WARNING: Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emer- gencies, because vehicle handling may be seriously af- fected and may result in loss of control. The metric term for tire inflation pressure is the kilopascal (kPa).
Page 188: Balancing Wheels
WHEELS AND TIRES 3F-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. BALANCING WHEELS There are two types of wheel and tire balance: static and dynamic. [A]: Before correction Static balance, as shown in left figure, is equal distribution of weight [B]: Corrective weights around wheel.
Page 189: Wheel And Tire
3F-4 WHEELS AND TIRES MAINTENANCE AND MINOR ADJUSTMENTS WHEEL AND TIRE Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced. STUDS If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure. MATCHED TIRES AND WHEELS (For vehicle equipped with steel wheels) Tires and wheels are match mounted at the assembly plant.
Page 190 WHEELS AND TIRES 3F-5 TIRE PLACARD The tire placard is located on the driver’s side door lock pillar and should be referred to for tire information. The placard lists the maxi- mum load, tire size and cold tire pressure where applicable. TIRE ROTATION To equalize wear, rotate tires periodically as shown in figure.
Page 191 3F-6 WHEELS AND TIRES ON-VEHICLE SERVICE WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180_ (half a rotation). 2) Hoist vehicle. 3) Remove wheel. NOTE: Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings.
Page 192 WHEELS AND TIRES 3F-7 TIRE MOUNTING AND DEMOUNTING Use tire changing machine to mount or demount tires. Follow equipment manufacturer’s instructions. Do not use hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim.
Page 193 PROPELLER SHAFT 4B-1 SECTION 4B PROPELLER SHAFT CONTENTS GENERAL DESCRIPTION ............... . . 4B- 1 DIAGNOSIS .
Page 194 4B-2 PROPELLER SHAFT DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction D Loosen universal joint bolt. Abnormal noise Tighten universal joint bolt. D Spider bearing worn out or stuck. Replace propeller shaft. D Worn spider. Replace propeller shaft. D Deformed propeller shaft. Vibration Replace propeller shaft.
Page 195 PROPELLER SHAFT 4B-3 ON-VEHICLE SERVICE REMOVAL 1) Hoist vehicle. 2) Drain transmission oil. 3) Before removing propeller shaft, give match marks on each joint flange and propeller shaft as shown. 1. Match mark 2. Propeller shaft 3. Joint flange 4) Loosen propeller shaft bolts. 5) Remove propeller shaft.
Page 196 4B-4 PROPELLER SHAFT REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUPER GREASE C Lithium grease To apply to spline part of propeller shaft. (99000-25030)
Page 197 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 198 5-2 BRAKES ON-VEHICLE SERVICE ....5-24 Brake Back Plate ......5-43 Front Brake Hose/Pipe .
Page 199 BRAKES 5-3 GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. The brake pipes are connected to the master cylinder and they make two independent circuits.
Page 200: Front Disc Brake Caliper Assembly
5-4 BRAKES FRONT DISC BRAKE CALIPER ASSEMBLY GENERAL DESCRIPTION This caliper has a single bore. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
Page 201: Rear Drum Brake Assembly
BRAKES 5-5 REAR DRUM BRAKE ASSEMBLY GENERAL DESCRIPTION The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main- tained appropriate at all times. NOTE: Replace all components included in repair kits to service this drum brake. Lubricate parts as specified. WARNING: If any hydraulic component is removed or brake line disconnected, bleed the brake system.
Page 202 5-6 BRAKES MASTER CYLINDER ASSEMBLY GENERAL DESCRIPTION The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the figure below) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on the rear wheel brakes (front wheel brakes for vehicle with ABS).
Page 203 BRAKES 5-7 BOOSTER ASSEMBLY GENERAL DESCRIPTION The booster is located between the master cylinder and the brake pedal. It is so designed that the force created when the brake pedal is depressed is mechanically increased combined with the engine vacuum. CAUTION: When and after removing booster, never drop or deform it.
Page 204 5-8 BRAKES B.P. (BLEND PROPORTIONING) VALVE (If equipped with ABS) The blend proportioning valve is included within the brake circuit which connects the master cylinder and the wheel brakes. It is installed on floor panel and controls the hydraulic pressure applied to the rear wheel brakes after prede- termined pressure has been reached ( “...
Page 205 BRAKES 5-9 LSPV (Load Sensing Proportioning Valve) ASSEMBLY (If equipped) As shown below, LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Page 206: Road Testing Brakes
5-10 BRAKES DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMI- NATED BRAKE FLUID Brakes should be tested on dry, clean, smooth and Improper brake fluid, mineral oil or water in the fluid reasonably level roadway which is not crowned. Road may cause the brake fluid to boil or the rubber compo- test brakes by making brake applications with both nents in the hydraulic system to deteriorate.
Page 207 BRAKES 5-11 Symptom Possible Cause Remedy D Pad linings and/or shoe linings are wet Brake pull (Brakes Replace. not working in with water or stained with oil in some unison) brakes. D Drum-to-shoe clearance out of adjust- Check for inoperative auto adjusting ment in some brakes.
Page 208 5-12 BRAKES Symptom Possible Cause Remedy D Partial brake system failure. Excessive pedal trav- Check brake systems and repair as el (Pedal stroke too necessary. D Insufficient fluid in master cylinder reser- large) Fill reservoirs with approved brake voirs. fluid. Check for leaks and air in brake sys- tems.
Page 209 BRAKES 5-13 Symptom Possible Cause Remedy D Glazed shoe linings, or foreign matters Braking noise Repair or replace shoe linings. stuck to linings. D Worn or distorted shoe linings. Replace shoe linings (or pads). D Loose front wheel bearings. Replace wheel bearing. D Distorted backing plates or loose mounting Replace or retighten securing bolts.
Page 210: Brake Pedal Free Height Adjustment
5-14 BRAKES CHECK AND ADJUSTMENT BRAKE PEDAL FREE HEIGHT ADJUSTMENT Check brake pedal free height (distance). If it is not within specification, check and adjust following item 1) and 2). Brake pedal free distance “a” from dash panel:209–215 mm (8.23–8.46 in.) LHD vehicle 201–207 mm (7.90–8.15 in.) RHD vehicle...
Page 211: Front Brake Disc Check
BRAKES 5-15 FRONT BRAKE DISC CHECK Refer to BRAKE PAD INSPECTION of this section for inspection point and procedure. FRONT BRAKE PAD LINING CHECK Inspect pad linings periodically according to maintenance sched- ule whenever wheels are removed (for tire rotation or other rea- son).
Page 212: Brake Pedal Play Check
5-16 BRAKES BRAKE PEDAL PLAY CHECK Pedal play should be within specification below. If out of specification, check stop light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective.
Page 213: Flushing Brake Hydraulic System
BRAKES 5-17 If number of notches is out of specification, adjust cable by referring to adjustment procedure described on the following steps so as to obtain specified parking brake stroke. NOTE: Check tooth tip of each notch for damage or wear. If any dam- age or wear is found, replace parking brake lever.
Page 214 5-18 BRAKES BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: Before performing bleeding operation, make sure that ABS warning light turns off after ignition switch has turned on (for vehicle equipped with ABS).
Page 215: Brake Fluid Level Check
BRAKES 5-19 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. Tightening Torque (b): 7.5 N·m (0.75 kg-m, 5.5 lb-ft) For Rear brake, LSPV 11 N·m (1.1 kg-m, 8.0 lb-ft) . . . For Front brake 7) Then attach bleeder plug cap.
Page 216: Booster Operation Check
5-20 BRAKES BOOSTER OPERATION CHECK There are two ways to perform this inspection, with and without a tester. Ordinarily, it is possible to roughly determine its condition without using a tester. NOTE: For this check, make sure that no air is in hydraulic line. INSPECTION (WITHOUT TESTER) Check Air Tightness 1) Start engine.
Page 217 BRAKES 5-21 2) Start engine while depressing brake pedal. If pedal travel in- creases a little, operation is satisfactory. But no change in pedal travel indicates malfunction. Check Air Tightness Under Load 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed.
Page 218 5-22 BRAKES FLUID PRESSURE TEST (if equipped with LSPV) Test procedure for LSPV assembly is as follows. Before testing, confirm the following. D Fuel tank is filled with fuel fully. D Vehicle is equipped with spare tire, tools, jack and jack handle. 1) Install pressure gauges to front and rear brake.
Page 219 BRAKES 5-23 3) If rear brake pressure is not within specification, adjust it by changing bolt B tightening position as follows. D If rear brake pressure is higher than specification, move bolt B (LSPV stay) downward and if it is lower, upward. D Repeat steps 2) and 3) until rear brake pressure is within specification.
Page 220: Removal And Installation
5-24 BRAKES ON-VEHICLE SERVICE FRONT BRAKE HOSE/PIPE REMOVAL AND INSTALLATION 1) Raise and support vehicle properly. Remove wheel. This operation is not necessary when removing pipes connecting master cylinder and P valve. 2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose or pipe.
Page 221 BRAKES 5-25 For right-steering vehicle 1. 4-way joint 2. Blend proportioning valve (B.P valve) 3. 4-way cross joint 4. Clamp 5. 2-way joint 6. ABS actuator 7. From master cylinder (Primary) to 4-way joint 8. From master cylinder (Secondary) to 4-way joint 9.
Page 222 5-26 BRAKES REAR BRAKE HOSE/PIPE REMOVAL AND INSTALLATION 1) Raise and support vehicle properly. Remove wheel. 2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose or pipe. 3) Reverse brake flexible hose installation procedure. Fill and maintain brake fluid level in reservoir. Bleed brake system.
Page 223 BRAKES 5-27 For TRACK model 1. Flexible hose 10. From master cylinder (Primary) [A] : For vehicle without ABS 2. E-ring 11. From master cylinder (Secondary) [B] : For vehicle with ABS 3. LSPV 12. To wheel cylinder 4. LSPV bolt 13.
Page 224: Parking Brake Lever
5-28 BRAKES PARKING BRAKE LEVER REMOVAL 1) Remove console box. 2) Disconnect lead wire of parking brake switch at coupler. NOTE: Don’t disassemble parking brake lever switch. It must be removed and installed as a complete switch assembly. 3) Release parking brake lever and remove parking brake cable nuts.
Page 225 BRAKES 5-29 5) Remove cable from vehicle body. 1. Parking brake cable No.1 3. Equalizer 2. Parking brake cable No.2 B-1. Clamp B-2. Stud blot insert direction B-3. Cable A-1. Parking brake lever A-2. Parking brake lever bolt A-3. Cable lock nut A-4.
Page 226 5-30 BRAKES 2) Connect cable to brake shoe lever and install brake shoes to back plate. (Refer to steps 1) to 3) of BRAKE SHOE INSTALLA- TION of this section.) 3) Install brake drum. (Refer to steps 1) to 2) of BRAKE DRUM INSTALLATION of this section.) 4) Connect cable to parking brake lever (Refer to step 1) of PARK- ING BRAKE LEVER INSTALLATION of this section.
Page 227 BRAKES 5-31 BRAKE PAD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolt. 1. Caliper 2. Caliper pin bolt 3. Disc 3) Remove caliper from caliper carrier. 1. Caliper 2. Wire hook 3. Pad NOTE: Hang removed caliper with a wire hook or the like so as to prevent brake flexible hose from bending and twisting ex- cessively or being pulled.
Page 228 5-32 BRAKES Brake Disc Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspec- tion or replacement are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc sur- face, replace it.
Page 229: Caliper Assembly
BRAKES 5-33 CALIPER ASSEMBLY REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove E-ring. 1. E-ring 3) Loosen flexible hose union bolt a little at caliper. CAUTION: Be careful not to twist flexible hose while loosening the bolt. 4) Remove caliper pin bolts. 5) Remove caliper from carrier.
Page 230 5-34 BRAKES 2) Remove piston seal using a thin blade like a thickness gauge, etc. CAUTION: Be careful not to damage inside (bore side) of cylin- der. INSPECTION Cylinder Boot Check boots for breakage, crack and damage. If defective, re- place.
Page 231 BRAKES 5-35 2) Before inserting piston into cylinder, install boot onto piston as shown. 1. Boot 2. Piston 3) Fit boot as it is in figure into boot groove in cylinder with fingers. Check to make sure that boot is fitted into boot groove in cylin- der completely in its circumference.
Page 232 5-36 BRAKES INSTALLATION 1) Before installing caliper (cylinder body) to carrier, check to en- sure that cylinder slide pin inserted in each caliper carrier hole can be moved smoothly in thrust direction. Apply rubber grease to slide pin. NOTE: Where temperature gets as low as – 305C (– 225F) in cold weather, use rubber grease whose viscosity varies very little even at –...
Page 233: Brake Disc
BRAKES 5-37 BRAKE DISC REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper assembly by loosening carrier bolts (2 pcs). CAUTION: During removal, be careful not to damage brake flex- ible hose and not to depress brake pedal. 3) Pull brake disc off by using 8 mm bolts (2 pcs). 1.
Page 234 5-38 BRAKES BRAKE DRUM REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove console box. 3) Release parking brake lever. 4) Loosen parking brake cable nuts. 1. Parking brake lever 2. Brake cable 3. Nuts 5) To increase clearance between brake shoe and brake drum, re- move rubber plug from brake back plate and turn adjuster downward with flat-head screw driver.
Page 235 BRAKES 5-39 Brake Shoe Where lining is worn out beyond service limit, replace shoe. Brake lining thickness (lining + shoe rim) “a” Standard : 6.5 mm (0.26 in.) Service limit : 3.0 mm (0.12 in.) If one of brake linings is worn to service limit, all linings must be re- placed at the same time.
Page 236: Brake Shoe
5-40 BRAKES 5) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 6) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and preform brake test (foot brake and parking brake).
Page 237: Wheel Cylinder
BRAKES 5-41 Springs Inspect for damage, corrosion or weakening. Inspect each part with arrow for rust. If found defective, replace. Parking Shoe Lever Inspect brake shoe lever for smooth movement along shoe rim. If defective, correct or replace. INSTALLATION Assemble parts in reverse order of removal. NOTE: Removed retainer ring should be replaced with new one.
Page 238 5-42 BRAKES 4) Remove wheel cylinder mounting bolts. Disconnect brake pipe from wheel cylinder and put bleeder plug cap onto pipe to pre- vent fluid from spilling. 1. Bleeder plug cap INSPECTION Inspect wheel cylinder disassembled parts for wear, cracks, corro- sion or damage.
Page 239: Brake Back Plate
BRAKES 5-43 5) Install brake shoes, referring to steps 1) to 3) of BRAKE SHOE INSTALLATION. 6) Install brake drum. (Refer to steps 1) and 2) of BRAKE DRUM INSTALLATION of this section. 7) Fill reservoir with brake fluid and bleed brake system. (For bleeding operation, refer to BLEEDING BRAKES.) 8) Upon completion of all jobs, turn adjuster upward by flat-head screw driver and depress brake pedal with about 30 kg (66 lbs)
Page 240 5-44 BRAKES 3) Apply grease to axle shaft oil seal lip as shown. “A”: Grease 99000-25010 4) Apply sealant to mating surface of axle housing with brake back plate. NOTE: Make sure that old sealant was removed before applying new one. 1.
Page 241 BRAKES 5-45 MASTER CYLINDER RESERVOIR 1. Reservoir cap 2. Reservoir 3. Reservoir hoses 4. Reservoir bracket 5. Nut REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir. 3) Take out fluid with syringe or such. 4) Disconnect brake master hoses from reservoir. 5) Remove reservoir bracket nuts.
Page 242 5-46 BRAKES MASTER CYLINDER ASSEMBLY 1. Piston stopper circlip 2. Piston stopper 3. Cylinder cup and plate 4. Primary piston 5. Piston cup 6. Secondary piston pressure cup 7. Primary piston Assy 8. Secondary piston 9. Secondary piston Assy 10. Secondary piston stopper bolt [A] : with ABS 11.
Page 243 BRAKES 5-47 DISASSEMBLY 1) Remove the pin that fixes cylinder body and connector by using special tool. Special Tool (A): 09922-85811 2) Remove connector and 2 grommets. 1. Connector 2. Pin 3. Grommets 3) Remove circlip. 1. Circlip 2. Master cylinder 4) Remove primary piston.
Page 244 5-48 BRAKES INSPECTION Inspect all disassembled parts for wear or damage, and replace parts if necessary. NOTE: D Wash disassembled parts with brake fluid. D Do not reuse piston assembly. Inspect master cylinder bore for scoring or corrosion. It is best to replace corroded cylinder.
Page 245 BRAKES 5-49 5) Apply thin coat of brake fluid to all around new grommets ( 2pcs.) and install them to cylinder body, then install reservoir. 6) Set a new pin in connector hole and drive it in. At this time, make end of pin and end face margin of connector equal.
Page 246: Brake Booster
5-50 BRAKES BRAKE BOOSTER 1. Brake booster ass’y 2. Push rod clevis 3. Nut 4. Clevis pin 5. Clip 6. Nut REMOVAL 1) Remove master cylinder assembly, by referring to step 1) to 6) of MASTER CYLINDER REMOVAL. 2) Disconnect stop light switch lead wire at coupler. 3) Remove pedal bracket extension (For RH steering vehicle).
Page 247 BRAKES 5-51 INSPECTION AND ADJUSTMENT Push Rod Clevis Length Check that dimension “a” as shown is within 99.5 – 100.5 mm (3.92 – 3.99 in.) and torque nut to specification. Dimension “a”: 99.5 – 100.5 mm ( 3.92 – 3.99 in.) Tightening Torque (b): 25 N·m (2.5 kg-m, 18.0 lb-ft) NOTE:...
Page 248 5-52 BRAKES 3) Adjust clearance by turning adjusting screw of piston rod. Special Tool (B) : 09952-16010 Reference When adjusted as above, its negative pressure is applied to boost- er with engine at idle, piston to piston rod clearance ”a” should be- come below.
Page 249 BRAKES 5-53 12) Fill reservoir with specified fluid. 13) Bleed air from brake system (refer to BLEEDING BRAKES). 14) After installing, check pedal height and play, refer to EXCES- SIVE PEDAL TRAVEL CHECK and BRAKE PEDAL PLAY CHECK. 15) Perform brake test and check each installed part for fluid leak- age.
Page 250 5-54 BRAKES 2) Torque each bolt and nut to specification as indicated respec- tively in figure. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) (b): 16 N·m (1.6 kg-m, 12.0 lb-ft) (c): 7.5 N·m (0.75 kg-m, 5.5 lb-ft) 3) Upon completion of installation, fill reservoir tank with specified fluid and bleed air from brake system.
Page 251 BRAKES 5-55 [A]: Van [B]: Track 1. LSPV stay 2. LSPV bracket INSPECTION & ADJUSTMENT Confirm the following before inspection and adjustment. D Fuel tank is filled with fuel fully. D Vehicle is equipped with spare tire, tools, jack and jack handle. D Vehicle is free from any other load.
Page 252 5-56 BRAKES B.P. (BLEND PROPORTIONING) VALVE REMOVAL CAUTION: Do not allow brake fluid to get on painted surfaces. 1) Remove engine lower cover. 2) Disconnect brake pipes from B.P. valve. 3) Remove B.P. valve. WARNING: Never disassemble B.P. valve assembly. If it is found faulty, replace it with new one.
Page 253 Water tight sealant D To apply to mating surfaces of brake back plate and 99000-31090 rear wheel cylinder. D To apply to mating surfaces of brake back plate and SUZUKI BOND NO.1215 Sealant 99000-31110 rear axle housing.
Page 254 5-58 BRAKES SPECIAL TOOLS 09900-20701 09900-20606 09922-85811 09950-78210 Magnetic stand Dial gauge Pin remover Flare nut wrench (10 mm) 09952-46520 09956-02210 09956-02310 09952-16010 Brake circuit plug Fluid pressure gauge Fluid pressure gauge Booster piston rod adjuster...
Page 255 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 256 5E-2 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) GENERAL DESCRIPTION COMPONENTS AND PARTS LOCATION The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS is a 4-wheel type which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel from getting locked.
Page 257 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-3 BRAKE HOSE/PIPE ROUTING For LH Steering Vehicle For RH Steering Vehicle 1. Brake master cylinder 2. Proportioning valve 3. Front disk brake 4. ABS hydraulic unit/control module assembly 5. Rear drum brake...
Page 258 5E-4 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) SYSTEM SCHEMATIC 1. Wheel speed sensor (Right-front) 6. Stop lamp switch 11. ABS fail-safe relay (Solenoid valve relay) 2. Wheel speed sensor (Left-front) 7. Diagnosis connector 12. ABS hydraulic unit 3. Wheel speed sensor (Right-rear) 8.
Page 259 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-5 ABS CONTROL MODULE Self-Diagnosis Function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through “ABS”...
Page 260 5E-6 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DIAGNOSIS To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Troubles” and fol- low “ABS Diagnostic Flow Table”. PRECAUTION IN DIAGNOSING TROUBLES D If the vehicle was operated in any of the following ways, “ABS” warning light may light momentarily but this does not indicate anything abnormal in ABS.
Page 261 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-7 ABS DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Perform “customer complaint analysis”, “problem Go to Step 2. Go to Step 5. symptom confirmation” and “diagnostic trouble code check, record and clearance”.
Page 262 5E-8 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 1. MALFUNCTION ANALYSIS i) Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 263 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-9 ii) Problem Symptom Confirmation Check if what the customer claimed in CUSTOMER QUESTIONNAIRE is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer if possible.) When “ABS”...
Page 264 5E-10 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) “ABS” WARNING LAMP CHECK Turn ON the ignition switch and check that “ABS” warning lamp lights for about 2 seconds and then goes OFF. If anything faulty is found, advance to Diagnostic table – A, B or C. NOTE: If ABS hydraulic unit/control module assembly has been re- placed by a new one, “ABS”...
Page 265 2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool oper- ator’s manual for further details. 4) After completing the check, turn ignition switch off and discon- nect SUZUKI scan tool from DLC.
Page 266 5E-12 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DIAGNOSTIC TROUBLE CODE (DTC) TABLE VOLTMETER INDICATION (or “ABS” DIAGNOSTIC AREA warning lamp flashing pattern) Wheel speed sensor and / or rotor or hydraulic unit Right- front Right- front Left- front Left- front Wheel speed sensor circuit and rotor Wheel speed sensor circuit and rotor Right- rear...
Page 267 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-13 SYSTEM CIRCUIT...
Page 268 5E-14 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
Page 269 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-15 TABLE – A “ABS” WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON 1. Main fuse 2. Ignition switch 3-1. Circuit fuse (for IG) 3-2. Circuit fuse (for ABS) 4.
Page 270 Perform diagnostic trouble code check. Is there any DTC Go to step 2. Go to step 3. (including code No.12, NO CODES on SUZUKI scan tool) exists? Is malfunction DTC (other than code No.12) exists at step Go to step 7 of “ABS Go to step 3.
Page 271 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-17 TABLE – C “ABS” WARNING LAMP CIRCUIT CHECK – THE LAMP FLASHES CONTINUOUSLY WHILE IGNITION SWITCH IS ON “ABS” warning lamp in combination meter ABS hydraulic unit / control module assembly Diagnosis connector 3-1. Diag. switch terminal 3-2.
Page 272 5E-18 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAG. SWITCH TERMINAL CONNECTED TO GROUND. “ABS” warning lamp in combination meter ABS hydraulic unit / control module assembly Diagnosis connector 3-1. Diag. switch terminal 3-2.
Page 273 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-19 DTC 13 – WHEEL SPEED SENSOR/ROTOR OR ABS HYDRAULIC UNIT 1. Ignition switch 4. Left-front wheel speed sensor & rotor 7. Right-rear wheel speed sensor & rotor 2. ABS hydraulic unit / control module assembly 5.
Page 274 5E-20 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) INSPECTION STEP ACTION 1) Remove all speed sensors. Go to step 2. Clean or replace. 2) Check each sensor for damage or foreign material being attached to it. Are they in good condition? (See Fig. 1.) Check visually all wheel speed sensor installation hole for Go to step 3.
Page 275 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-21 DTC 21, 22 – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT 25, 26 – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT 31, 32 – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT 35, 36 – LEFT-REAR WHEEL SPEED SENSOR CIRCUIT 1. Ignition switch 2.
Page 276 5E-22 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) INSPECTION STEP ACTION 1) Disconnect applicable sensor connector with Go to step 2. Replace sensor. ignition switch OFF. 2) Measure resistance between sensor terminals. Resistance of wheel speed sensor: 1.2 – 1.6 kW (at 20 C, 68 F) 3) Measure resistance between each terminal and body ground.
Page 277 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-23 Fig. 1 Fig. 2 Fig. 3 1. ABS hydraulic unit / control module connector Fig. 4 Fig. 5...
Page 278 5E-24 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DTC 41, 42 – RIGHT-FRONT SOLENOID CIRCUIT 45, 46 – LEFT-FRONT SOLENOID CIRCUIT 55, 56 – REAR SOLENOID CIRCUIT 1. ABS hydraulic unit/control module assembly 2. ABS hydraulic unit/control module connector of harness DESCRIPTION ABS control module monitors the voltage of the terminal of solenoid circuit constantly with ignition switch turned ON.
Page 279 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-25 DTC 57 – SOLENOID AND PUMP MOTOR POWER SOURCE CIRCUIT 1. ABS hydraulic unit/control module assembly 2. ABS hydraulic unit/control module connector of harness DESCRIPTION ABS control module monitors the voltage at terminal ( “A11” and “A27”) of the fail-safe and pump motor relay circuits constantly with ignition switch turned ON.
Page 280 5E-26 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DTC 61 – ABS PUMP MOTOR CIRCUIT 1. ABS hydraulic unit/control module assembly 1-1. ABS pump motor relay 1-2. ABS pump motor 1-3. ABS fail safe relay 2. ABS hydraulic unit/control module connector of harness DESCRIPTION ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition switch turned ON.
Page 281 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-27 DTC 63 – ABS FAIL-SAFE RELAY CIRCUIT 1. Ignition switch 2. ABS hydraulic unit/control module assembly 3. ABS hydraulic unit/control module connector of harness DESCRIPTION ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON.
Page 282 5E-28 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) DTC 71 – ABS CONTROL MODULE DESCRIPTION This DTC will be set when internal fault is detected in ABS control module. INSPECTION STEP ACTION 1) Ignition switch OFF. Substitute a known- Repair or replace. 2) Disconnect connectors from ABS control module.
Page 283 ON. Then DTC will be set in ABS control module. ABS HYDRAULIC UNIT OPERATION CHECK (USING SUZUKI SCAN TOOL) 1) Connect SUZUKI scan tool (Tech-1) to DLC with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 284 5E-30 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 9) Perform following checks with help of another person. Brake pedal should be depressed and then ignition switch turned ON by one person and wheel should be turned by another person’s hand. At this time, check that: D Operation sound of solenoid is heard and wheel turns only about 0.5 sec.
Page 285 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-31 REMOVAL 1) Disconnect negative cable from battery. 2) Remove cover and disconnect ABS hydraulic unit/control mod- ule assembly connector. 1. ABS hydraulic unit / control module connector 3) Using special tool, disconnect brake pipes from ABS hydraulic unit/control module assembly and loosen flare nuts as shown figure.
Page 286 5E-32 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) FRONT WHEEL SPEED SENSOR 1. Left front wheel speed sensor 2. Left front strut 3. Sensor ring 4. Knuckle OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch “OFF”. 2) Hoist vehicle a little. 3) Disconnect connector of wheel speed sensor. 4) Connect voltmeter between connector terminals.
Page 287 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-33 REMOVAL 1) Disconnect negative cable from battery. 2) Disconnect front wheel speed sensor coupler. 3) Hoist vehicle and remove wheel. 1. Water pipe 2. Stabilizer 3. Right front wheel speed sensor coupler 1. Front wheel speed sensor 4.
Page 288 5E-34 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) FRONT WHEEL SENSOR RING REMOVAL 1) Remove ABS front wheel sensor from knuckle. 2) Remove front wheel hub referring to Section 3D of this manual. 3) Remove sensor ring from front wheel hub using special tool. Special Tool (A): 09913-61510 (B): 09913-85230...
Page 289 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-35 REAR WHEEL SPEED SENSOR 1. Left rear wheel sensor 2. Trailing arm 3. Sensor ring OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch “OFF”. 2) Hoist vehicle a little. 3) Disconnect connector of wheel speed sensor. 4) Connect voltmeter between connector terminals.
Page 290 5E-36 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) REMOVAL 1) Disconnect negative cable from battery. 2) Hoist vehicle. 3) Disconnect rear wheel speed sensor coupler. 4) Detach ABS wheel sensor wire harness from suspension frame. 1. Left rear wheel sensor 2. Left rear wheel sensor coupler 5) Remove rear wheel speed sensor from rear axle housing.
Page 291 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E-37 REAR WHEEL SENSOR RING REMOVAL 1) Remove ABS rear wheel sensor from rear axle housing. 2) Remove brake drum referring to Section 5 of this manual. 3) Remove sensor ring from brake drum using special tool. 1.
Page 292 5E-38 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Fastening parts Fastening parts kg-m lb-ft Brake pipe flare nut 11.6 ABS hydraulic unit bracket bolt 16.6 ABS hydraulic unit nut ABS hydraulic unit cover bolt Front wheel speed sensor bolt 18.8 Front wheel speed sensor harness clamp bolt Rear wheel speed sensor bolt...
Page 293 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 294 6-2 ENGINE GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch). Accord- ingly, when any internal engine parts are serviced, care and cleanli- ness are important.
Page 295 ENGINE 6-3 GENERAL INFORMATION ON ENGINE SERVICE THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI- ABLE ENGINE PERFORMANCE. D When raising or supporting engine for any reason, do not use a jack under oil pan.
Page 296 6-4 ENGINE FUEL LEAKAGE CHECK PROCEDURE After performing any service on fuel system, check to make sure that there are no fuel leakages as follows. 1) Turn the ignition switch ON position for 3 seconds (to operate fuel pump) and then turn it OFF position. Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure to fuel line (till fuel pressure is felt by hand placed on fuel return hose).
Page 297 ENGINE 6-5 ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) Check, Record and 1) Print DTC or Go to Step 4.
Page 298 6-6 ENGINE 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analy- sis and diagnosis.
Page 299 ENGINE 6-7 2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE First, check DTC. Refer to “DTC Check” in Section 6E. If DTC is indicated, print it or write it down and then clear it. Refer to “DTC Clearance” in Section 6E. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
Page 300 6-8 ENGINE 5. TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” in Section 6E. 6. and 7. RECHECKING AND RECORD OF DTC Refer to “DTC Check”...
Page 301 ENGINE 6-9 9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and repair or replace faulty parts. Refer to the applicable DTC diag.
Page 302 6-10 ENGINE Condition Possible Cause Reference Item Engine has no power Engine overheating. Refer to “Overheating” of this table. Ignition system out of order. D Faulty ignition coil or high-tension cord Diagnosis in Section 6F. Engine and emission control system out of order.
Page 303 ENGINE 6-11 Condition Possible Cause Reference Item Engine hesitates Ignition system out of order. D Faulty ignition coil or high-tension cords (Momentary lack of Diagnosis in Section 6F. response as the accelerator is Engine overheating Refer to “Overheating” of this table. depressed.
Page 304 6-12 ENGINE Condition Possible Cause Reference Item D Inoperative thermostat Overheating Thermostat in Section 6B. D Faulty radiator fan motor or its circuit Diag. Flow Table B-8 in Section 6E. D Loose or slip water pump belt Water pump belt check in Section 6B. D Poor water pump performance Water pump in Section 6B.
Page 305 ENGINE 6-13 Condition Possible Cause Reference Item Excessive engine oil Oil entering combustion chamber D Sticky piston ring consumption Piston cleaning in Section 6A. D Worn piston and cylinder Cylinders, pistons and piston rings in- spection in Section 6A. D Worn piston ring groove and ring Pistons and piston rings inspection in Section 6A.
Page 306 6-14 ENGINE Condition Possible Cause Referring Item Excessive Ignition system out of order D Faulty ignition coil or high-tension cord hydrocarbon (HC) Diagnosis in Section 6F. emission or Excessive carbon Engine and Emission control system monoxide (CO) out of order. D Fuel pressure out of specification emission Fuel pressure check in Section 6E.
Page 307 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 308 6A-2 ENGINE MECHANICAL GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 The single overhead camshaft is mounted over the stroke cycle gasoline unit equipped with its S.O.H.C. cylinder head: it is driven from crankshaft through tim- (Single Overhead Camshaft) valve mechanism ar- ing belt and opens and closes its valves via the rocker ranged for “V”-type valve configuration and 16 valves...
Page 309: Engine Lubrication
ENGINE MECHANICAL 6A-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted on In another path, oil goes up to cylinder head and lubri- crankshaft at crankshaft pulley side. cates camshaft journals, rocker arms, camshaft, etc., Oil is drawn up through oil pump strainer and passed passing through oil gallery in rocker arm shaft.
Page 310: Compression Check
6A-4 ENGINE MECHANICAL ON-VEHICLE SERVICE COMPRESSION CHECK Check compression pressure on all four cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 311 (vacuum gauge and joint) between intake man- ifold and vacuum hose disconnected. Special Tool (A): 09915-67310 (B): 09918-08210 SUZUKI GENUINE PARTS (C): Hose 09343-03087 (D): 3-way joint 09367-04002 3) Run engine at specified idle speed, and read vacuum gauge. Vacuum should be within following specification.
Page 312: Oil Pressure Check
6A-6 ENGINE MECHANICAL OIL PRESSURE CHECK NOTE: Prior to checking oil pressure, check following items. D Oil level in oil pan. If oil level is low, add oil up to Full level mark on oil level gauge. D Oil quality. If oil is discolored, or deteriorated, change it.
Page 313 ENGINE MECHANICAL 6A-7 7) Before reinstalling oil pressure switch, be sure to wrap its screw threads with a sealing tape and tighten switch to specified torque. NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) 8) Start engine and check oil pressure switch for oil leakage.
Page 314 6A-8 ENGINE MECHANICAL 6) If valve lash is out of specification, adjust it to specification by turning adjusting screw after loosening lock nut. After adjustment, tighten lock nut to specified torque while hold- ing adjusting screw stationary, and then make sure again that valve lash is within specification.
Page 315: Air Cleaner Element
ENGINE MECHANICAL 6A-9 AIR CLEANER ELEMENT REMOVAL AND INSTALLATION 1) Remove air cleaner case clamps. 2) Remove air cleaner element from case. 3) Check air cleaner element for dirt. 4) If necessary, blow off dust by compressed air from air outlet side of element.
Page 316 6A-10 ENGINE MECHANICAL 2) Install cylinder head cover to cylinder head and tighten cover bolts to specified torque. Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) NOTE: When installing cylinder head cover, use care so that cylin- der head cover gasket or O-rings will not get out of place or fall off.
Page 317 ENGINE MECHANICAL 6A-11 THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 2. Gasket 3. Intake manifold stiffener 4. Engine hook 5. Throttle body 6. Throttle body gasket REMOVAL WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot.
Page 318 6A-12 ENGINE MECHANICAL 4) Remove air intake hose. 5) Disconnect following electric lead wires: D EGR valve (if equipped) D Ground wires from intake manifold D Engine coolant temperature sensor D Injectors lead wires at the coupler D EVAP canister purge valve D Throttle position sensor D Idle air control valve D MAP sensor...
Page 319 ENGINE MECHANICAL 6A-13 INSPECTION D Using a straight edge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface or replace intake manifold. Limit of distortion: 0.07 mm (0.003 in.) INSTALLATION Reverse removal procedure for installation noting the followings.
Page 320: Exhaust Manifold
6A-14 ENGINE MECHANICAL EXHAUST MANIFOLD WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect heated oxygen sensor coupler (if equipped). 3) Remove exhaust manifold lower cover of exhaust manifold.
Page 321 ENGINE MECHANICAL 6A-15 TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seal 10. Inside cover 11. Outside cover seal 12.
Page 322 6A-16 ENGINE MECHANICAL 7) For installation of timing belt, align 4 timing marks as shown in figure by turning crankshaft. 1. “V” mark on cylinder head cover 2. Timing mark by “E” on camshaft timing belt pulley 3. Arrow mark on oil pump case 4.
Page 323 ENGINE MECHANICAL 6A-17 D Inspect tensioner for smooth rotation. INSTALLATION 1) Install tensioner plate to tensioner. Insert lug of tensioner plate into hole in tensioner. 1. Lug 2. Hole 2) Install tensioner and tensioner plate: Do not tighten tensioner bolt with wrench yet. Hand tighten only at this time.
Page 324 6A-18 ENGINE MECHANICAL 5) Install timing belt and tensioner spring. With two sets of marks aligned and tensioner plate pushed up, install timing belt on two pulleys in such a way that drive side of belt is free from any slack. And then install tensioner spring as shown in figure, and hand- tighten tensioner stud.
Page 325 ENGINE MECHANICAL 6A-19 9) Install water pump pulley and drive belt. Adjust generator drive belt tension, referring to BELT TEN- SION INSPECTION in Section 6H. 10) Install A/C compressor belt, if equipped. Adjust its belt tension, referring to Section 1B. 11) Connect brake booster hose and water hoses to intake man- ifold, thermostat cap and water floor pipe, clamp them secure- 12) Refill cooling system and bleed air from system, referring to...
Page 326: Oil Pan And Oil Pump Strainer
6A-20 ENGINE MECHANICAL OIL PAN AND OIL PUMP STRAINER 1. Baffle plate 2. Oil pump strainer 3. O-ring 4. Upper oil pan 5. Lower oil pan 1) Drain engine oil by removing drain plug. 2) Remove lower oil pan. 1. Lower oil pan 2.
Page 327 ENGINE MECHANICAL 6A-21 CLEANING D Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. D Clean oil pump strainer screen. INSTALLATION 1) Install oil pump strainer. Install seal in such position as shown in figure. Tighten strainer bolt first and then bracket bolt to specified torque.
Page 328 6A-22 ENGINE MECHANICAL 2) Clean mating surfaces of upper and lower oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces. After cleaning, apply sealant to oil pan mating surface continu- ously as shown in figure. “A”: Sealant 99000-31150 1.
Page 329: Oil Pump
ENGINE MECHANICAL 6A-23 OIL PUMP 1. Rotor plate 6. Pin 2. Inner rotor 7. Relief valve 3. Outer rotor 8. Spring 4. Gasket 9. Retainer 5. Pin 10. Retainer ring REMOVAL 1) Disconnect negative cable at battery. 2) Remove timing belt as previously outlined. 3) Remove crankshaft timing belt pulley.
Page 330 6A-24 ENGINE MECHANICAL INSPECTION D Check oil seal lip for fault or other damage. Replace as neces- sary. Apply engine oil to oil seal lip before installing. NOTE: When installing oil seal, press-fit it till its end face is flush with oil pump case end face.
Page 331 ENGINE MECHANICAL 6A-25 INSTALLATION 1) Install two oil pump pins and oil pump gasket to cylinder block. Use a new gasket. 2) To prevent oil seal lip from being damaged or upturned when installing oil pump to crankshaft, fit special tool (Oil seal guide) to crankshaft, and apply engine oil to special tool.
Page 332 6A-26 ENGINE MECHANICAL 6) Install timing belt, tensioner, oil pump strainer, oil pan and oth- er parts as previously outlined. 7) Check to ensure that all removed parts are back in place. Rein- stall any necessary parts which have not been reinstalled. 8) Adjust generator drive belt (water pump drive belt) tension, re- ferring to BELT TENSION INSPECTION in Section 6H.
Page 333 ENGINE MECHANICAL 6A-27 ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT -11. Camshaft -12. Camshaft oil seal -13. Rocker arm shaft -14. O-ring -15. Rocker shaft bolt -16. Rocker arm (IN) -17. Rocker arm No. 1 (EX) -18. Rocker arm No. 2 (EX) -19.
Page 334 6A-28 ENGINE MECHANICAL 8) Remove camshaft housing and camshaft. NOTE: To remove camshaft housing bolts, loosen them in such order as indicated in figure, a little at a time. 9) Remove oil plug and timing belt inside cover. 1. Oil plug 2.
Page 335 ENGINE MECHANICAL 6A-29 13) Remove exhaust rocker arms and rocker arm spring by pulling rocker arm shaft to CMP sensor side. 1. Rocker arm (EX) 2. Rocker arm spring INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw is badly worn, replace it. Rocker arm must be replaced if its cam-riding face is badly worn.
Page 336 6A-30 ENGINE MECHANICAL Cam Wear Using a micrometer, measured height of cam. If measured height is below limit, replace camshaft. Cam height Standard Limit 36.184 – 36.344 mm 36.084 mm Intake cam (1.4246 – 1.4308 in.) (1.4206 in.) 35.900 – 36.060 mm 35.800 mm Exhaust cam (1.4134 –...
Page 337 ENGINE MECHANICAL 6A-31 6) Remove housing and using scale on gaging plastic envelope, 1. Gaging plastic 2. Scale measure gaging plastic width at its widest point. Standard Limit Journal 0.040 – 0.082 mm 0.12 mm clearance (0.0016 – 0.0032 in.) (0.0047 in.) If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft jour-...
Page 338 6A-32 ENGINE MECHANICAL 4) Check O-ring for damage or deterioration. With O-ring groove 1. Rocker arm shaft 2. O-ring in rocker arm shaft exposed to transmission side once, install O-ring to rocker arm shaft. 5) Set rocker arm shaft so that its cut part becomes in parallel with 1.
Page 339 ENGINE MECHANICAL 6A-33 D Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housing as indicated by these marks. Indicates position from timing D As camshaft housing No. 1 retains camshaft in proper posi- belt side.
Page 340 6A-34 ENGINE MECHANICAL 13) After applying sealant to part “A” as shown in figure at the left, install CMP sensor case to cylinder head and tighten its fixing bolts to specified torque. “A” Sealant: 99000-31110 Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) Connect CMP sensor connector.
Page 341 ENGINE MECHANICAL 6A-35 VALVES AND CYLINDER HEAD 1. Valve cotters 2. Valve spring retainer 3. Valve spring 4. Valve stem seal 5. Valve spring seat 6. Exhaust valve 7. Intake valve REMOVAL 1) Relieve fuel pressure according to fuel pressure relief proce- dure described in section 6.
Page 342 6A-36 ENGINE MECHANICAL 5) Remove air intake hose. 6) Disconnect following electric wires: D Ground wires from intake manifold D Camshaft position sensor D EGR valve (if equipped) D EVAP canister purge valve D Engine coolant temp. sensor D Throttle position sensor D Idle air control valve D Fuel injector wires at the connector D Generator...
Page 343 ENGINE MECHANICAL 6A-37 10) Remove cylinder head cover as previously outlined. Loosen all valve lash adjusting screws fully. 11) Remove timing belt and camshaft as previously outlined. 12) Remove exhaust manifold as previously outlined. 13) Loosen cylinder head bolts in such order as indicated in figure and remove them.
Page 344 6A-38 ENGINE MECHANICAL DISASSEMBLY 1) Remove intake rocker arm with clip from rocker arm shaft, re- move rocker arm shaft bolts and remove exhaust rocker arms and springs by pulling its shaft out to transmission side. 2) Using special tool (Valve lifter), compress valve springs and then remove valve cotters by using special tool (Forceps) as shown.
Page 345 ENGINE MECHANICAL 6A-39 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
Page 346 6A-40 ENGINE MECHANICAL D Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve.
Page 347 ENGINE MECHANICAL 6A-41 D Valve seat repair: A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 348 6A-42 ENGINE MECHANICAL D Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive pa- per of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Page 349 ENGINE MECHANICAL 6A-43 Valve Springs D Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 350 6A-44 ENGINE MECHANICAL ASSEMBLY 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so remove burrs and make it truly round. Special Tool (A): 09916-34542 (B): 09916-38210 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100 C (176 to 212 F) so that head will not be distorted, and drive new valve guide into hole with special tools.
Page 351 ENGINE MECHANICAL 6A-45 5) Install new valve stem seal to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Page 352 6A-46 ENGINE MECHANICAL 9) Install rocker arms, springs and rocker arm shaft as previously outlined. INSTALLATION 1) Remove old gasket and oil on mating surfaces and install new head gasket as shown in figure, that is, “TOP” mark provided on gasket comes to crankshaft pulley side, facing up (toward cylinder head side).
Page 353 ENGINE MECHANICAL 6A-47 4) Reverse removal procedure for installation. 5) Adjust generator drive belt tension, referring to BELT TEN- SION INSPECTION in Section 6H. 6) Adjust A/C compressor belt tension, if equipped. Refer to Sec- tion 1B. 7) Adjust intake and exhaust valve lashes as previously outlined. 8) Adjust accelerator cable play.
Page 354 6A-48 ENGINE MECHANICAL PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 6. Connecting rod bearing cap 2. 2nd ring 7. Connecting rod bearing 3. Oil ring 8. Piston pin 4. Piston 9. Piston pin circlip 5. Connecting rod REMOVAL 1) Remove cylinder head from cylinder block as previously out- lined.
Page 355 ENGINE MECHANICAL 6A-49 DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips, as shown. 1. Piston pin circlip D Force piston pin out.
Page 356 6A-50 ENGINE MECHANICAL INSPECTION Cylinders D Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. D Using a cylinder gauge, measure cylinder bore in thrust and ax- ial directions at two positions as shown in figure.
Page 357 ENGINE MECHANICAL 6A-51 D Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
Page 358 6A-52 ENGINE MECHANICAL Piston Rings To measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
Page 359 ENGINE MECHANICAL 6A-53 Crank Pin and Connecting Rod Bearings D Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crank- shaft or regrind crank pin referring to following step 6).
Page 360 6A-54 ENGINE MECHANICAL 5) Remove cap and using a scale on gaging plastic envelope, measure gaging plastic width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bear- ing and remeasure clearance. Item Standard Limit Bearing 0.020 –...
Page 361 ENGINE MECHANICAL 6A-55 c) Stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with number 2 and a number 1 piston to cylin- der with number 1. Piston Cylinder Piston-to-cylinder...
Page 362 6A-56 ENGINE MECHANICAL INSTALLATION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) Install guide hoses over connecting rod bolts. These guide hoses protect crankpin and threads of rod bolt from damage during installation of connecting rod and piston assem- bly.
Page 363 ENGINE MECHANICAL 6A-57 6) Reverse removal procedure for installation, as previously out- lined. 7) Adjust generator drive belt tension, referring to Section 6H. 8) Adjust A/C compressor belt tension, if equipped. Refer to Sec- tion 1B. 9) Adjust intake and exhaust valve lashes as previously outlined. 10) Adjust accelerator cable play.
Page 364 6A-58 ENGINE MECHANICAL UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Release fuel pressure in fuel feed line by referring to Fuel Pres- sure Relief Procedure in section 6. 2) Remove front seats, then remove engine room center member with shift control and parking brake lever. 3) Remove battery and its tray.
Page 365 ENGINE MECHANICAL 6A-59 8) Remove under cover and its stay. 9) Disconnect following hoses: D Canister purge hose from EVAP canister purge valve D Radiator outlet hose from water floor pipe D Brake booster hose from intake manifold D Heater inlet and outlet hose from water floor pipe D Fuel feed hose and return hose from each pipe D Radiator inlet hose, brake booster hose and reservoir hose from water floor pipe...
Page 366 6A-60 ENGINE MECHANICAL 18) Place transmission jack under engine with transmission. When applying the jack to the engine, make sure that its flat face will support the entire oil pan evenly. Engine with trans- mission should be held horizontally even when rear mounting bracket bolts are removed.
Page 367 ENGINE MECHANICAL 6A-61 3) Reverse removal procedure for installation. D Install generator bracket, A/C compressor and generator re- ferring to Section 1B and 6H. D Tighten bolts of exhaust pipes to specified torque. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) 4) Adjust generator drive belt tension, referring to BELT TEN- SION INSPECTION in Section 6H.
Page 368 6A-62 ENGINE MECHANICAL MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 7. Crankshaft 12. Oil seal housing 2. Front oil seal 8. Thrust bearing 13. Housing bolt 3. Main bearing 9. Rear oil seal 14. Input shaft bearing 4. Bearing cap 10.
Page 369 ENGINE MECHANICAL 6A-63 REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Separate transmission from engine, then remove clutch cover, clutch disc and flywheel. Special Tool (A): 09924-17810 1. Flywheel bolt 3) Remove crankshaft pulley, timing belt and crankshaft timing pulley.
Page 370 6A-64 ENGINE MECHANICAL INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed.
Page 371 ENGINE MECHANICAL 6A-65 Main Bearings General information D Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. D Upper half of bearing has oil groove as shown in figure. Install this half with oil groove to cylinder block.
Page 372 6A-66 ENGINE MECHANICAL 5) Remove cap and using scale on gaging plastic envelope, mea- sure gaging plastic width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
Page 373 ENGINE MECHANICAL 6A-67 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent following cap bore diameters. Bearing cap bore diameter Alphabet stamped (without bearing) 49.000 –...
Page 374 6A-68 ENGINE MECHANICAL 4) From numerals stamped on crank webs of No.2 and No.3 cylin- ders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to jour- nal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
Page 375 ENGINE MECHANICAL 6A-69 D If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 44.732 – 44.750 mm (1.7611 – 1.7618 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicu- lar to each other in order to check for out-of-round.
Page 376 6A-70 ENGINE MECHANICAL Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. D Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout: 0.2 mm (0.0078 in.) Cylinder Block Distortion of gasketed surface...
Page 377 ENGINE MECHANICAL 6A-71 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing. INSTALLATION NOTE: D All parts to be installed must be perfectly clean. D Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, pis- ton rings and cylinder bores.
Page 378 6A-72 ENGINE MECHANICAL 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
Page 379 ENGINE MECHANICAL 6A-73 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously outlined. NOTE: Tighten cylinder head bolts to specified torque as pre- viously outlined and loosen them once till tightening torque becomes “zero”.
Page 380 6A-74 ENGINE MECHANICAL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE FASTENING PARTS FASTENING PARTS N·m kg-m lb-ft Oil pressure switch 10.5 Valve adjusting screw lock nuts Cylinder head cover bolts Intake manifold nuts 17.0 Exhaust manifold nuts 17.0 Exhaust pipe bolts 36.5 Timing belt tensioner stud Timing belt tensioner bolt 18.0...
Page 381 ENGINE MECHANICAL 6A-75 SPECIAL TOOLS 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 09915-78211 Hose 09915-77310 09915-67310 Oil pressure gauge 4. 09915-67010 Oil pressure gauge Vacuum gauge Attachment attachment 1. 09916-14510 Valve lifter 2. 09916-14910 09916-34542 09916-38210 09916-34550 Valve lifter attachment Reamer handle Reamer (11 mm) Reamer (5.5 mm)
Page 382 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT D Mating surfaces of cylinder block and oil pan. SUZUKI BOND NO. 1207C Sealant (99000-31150) D Mating surfaces of camshaft housings (No.6). SUZUKI BOND NO. 1215 D Mating surfaces of camshaft position sensor case...
Page 383 ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS GENERAL DESCRIPTION ..............6B- 2 Cooling System Circulation .
Page 384 6B-2 ENGINE COOLING GENERAL DESCRIPTION The cooling system consists of the radiator cap, radiator, coolant reservoir tank, hoses, water pump, cooling fan, thermostat. The radiator is of tube-and-fin type. COOLING SYSTEM CIRCULATION 1) While the engine is warmed up (thermostat closed), coolant circulates as follows. Water pump Õ...
Page 385: Cooling Fan
ENGINE COOLING 6B-3 COOLING FAN The cooling fan is driven by electric motor, and the motor is acti- vated by ECM (and ECT sensor). For its details, refer to “ENGINE AND EMISSION CONTROL SYSTEM” section. WARNING: Keep hands, tools and clothing away from engine cool- ing fan to help prevent personal injury.
Page 386 6B-4 ENGINE COOLING MAINTENANCE COOLANT done even if freezing temperatures are not ex- pected. The coolant recovery system is standard. The coolant D Add ethylene glycol base coolant when coolant has in the radiator expands with heat, and the overflow is to be added because of coolant loss or to provide collected in the reservoir tank.
Page 387: Coolant Level
ENGINE COOLING 6B-5 COOLANT LEVEL Coolant Level To check level, lift hood and look at “see-through” coolant reservoir tank. It is not necessary to remove radiator cap to check coolant level. WARNING: To help avoid danger of being burned: D do not remove reservoir tank cap while coolant is “boiling”, and D do not remove radiator cap while engine and radiator are still hot.
Page 388 6B-6 ENGINE COOLING 4) Using a pressure tester, check system, radiator cap for proper pressure holding capacity 110 kPa (1.1 kg/cm , 15.6 psi). If re- placement of cap is required, use proper cap specified for this vehicle. NOTE: After installing radiator cap to radiator, make sure that the ear of cap lines is parallel to radiator.
Page 389 ENGINE COOLING 6B-7 7) Remove reservoir tank and remove cap from reservoir tank and pour out any fluid, scrub and clean inside of tank with soap and water. Flush it well with clean water and drain. Reinstall tank. 8) Add 50/50 mixture of good quality ethylene glycol antifreeze and water to radiator and tank.
Page 390 6B-8 ENGINE COOLING ON-VEHICLE SERVICE WARNING: D Check to make sure that engine coolant temperature is cold before removing any part of cooling system. D Also be sure to disconnect negative cable from battery terminal before removing any part. COOLING SYSTEM DRAINING 1) Remove radiator cap.
Page 391 ENGINE COOLING 6B-9 THERMOSTAT CAUTION: Do not remove cap part of thermostat cap. REMOVAL 1) Drain coolant and tighten drain plug. 2) Remove engine room center member bolts and lift engine room center member. 3) Remove generator adjusting arm reinforcement and then dis- connect thermostat cap from intake manifold.
Page 392 6B-10 ENGINE COOLING INSTALLATION 1) Install thermostat. 2) Install thermostat cap to intake manifold. 3) Install generator adjusting arm reinforcement. 4) Install engine room center member. 1. Thermostat 2. Intake manifold 5) Fill cooling system (refer to page 6B-6, 6B-7). 6) After installation, check each part for leakage.
Page 393 ENGINE COOLING 6B-11 RADIATOR REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system by loosening drain plug of radiator. 3) Disconnect coupler of cooling fan motor. 4) Remove front bumper (see Section 9). 1. Radiator 2. Radiator drain plug 5) Disconnect radiator inlet and outlet hoses and reservoir tank hose from radiator.
Page 394: Water Pump
6B-12 ENGINE COOLING INSTALLATION Reverse removal procedures. NOTE: D Refill cooling system with proper coolant referring to COOLANT item of MAINTENANCE. D After installation, check each joint for leakage. WATER PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system. 3) Remove front seats.
Page 395 ENGINE COOLING 6B-13 INSTALLATION 1. Rubber seal 1) Install new pump gasket to cylinder block. 2) Install water pump to cylinder block. Tightening Torque (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) 3) After installing water pump, install rubber seal between water pump and oil pump, and another between water pump and cyl- inder head.
Page 396: Engine Fuel
D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 397 6C-2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM Main components of fuel system are fuel tank, fuel pump assembly (with fuel filter and fuel level gauge and fuel cut valve), fuel feed line, fuel return line and fuel vapor line. For the details of fuel flow and fuel vapor flow, refer to “ENGINE AND EMISSION CONTROL SYSTEM” section. 1.
Page 398 ENGINE FUEL 6C-3 FUEL PUMP ASSEMBLY (WITH FUEL FIL- TER, LEVEL GAUGE, FUEL CUT VALVE AND TANK PRESSURE CONTROL VALVE) Fuel pump assembly consists of fuel pump, fuel filter, fuel sender (level) gauge (sensor), fuel cut valve and tank pressure control valve.
Page 399 6C-4 ENGINE FUEL ON-VEHICLE SERVICE WARNING: Before attempting service of any type on fuel system, fol- lowing cautions should be always observed. D Disconnect negative cable at battery. D DO NOT smoke, and place “NO SMOKING” signs near work area. D Be sure to have CO fire extinguisher handy.
Page 400: Fuel Lines
ENGINE FUEL 6C-5 FUEL LINES Due to the fact that fuel feed line is under high pressure, use special care when servicing it. INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose crack and deterioration, or damage. Make sure all clamps are secure. Replace parts as needed.
Page 401 6C-6 ENGINE FUEL 6) Mark the location of clamps on fuel pipes, so that clamps can be reinstalled to where they were. 7) Remove pipes with clamp from vehicle. 8) Remove clamp from pipes. INSTALLATION 1) Install new clamps to marked location on pipes. 2) Install pipes with pipe clamps to vehicle.
Page 402 ENGINE FUEL 6C-7 FUEL TANK REMOVAL WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section. 1) Relieve fuel pressure in fuel feed line referring to “ENGINE” section. 2) Disconnect negative cable at battery. 3) Hoist vehicle. 4) Disconnect fuel pump wire coupler.
Page 403 6C-8 ENGINE FUEL 7) Disconnect fuel feed hose and fuel return hose as previously outlined in “FUEL PIPE”. Special Tool (A): 09919-47020 Disconnect fuel vapor hose from pipe. WARNING: A small amount of fuel may be released after fuel hose is disconnected. In order to reduce the chance of personal injury, cover hose and pipe to be discon- nected with a shop cloth.
Page 404 ENGINE FUEL 6C-9 11) Disconnect fuel feed hose, fuel vapor hose and fuel return hose from fuel pump assembly. When disconnecting joint of fuel feed line or return line from pipe, unlock joint by inserting special tool between pipe and joint lock first.
Page 405 6C-10 ENGINE FUEL INSTALLATION 1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle. 2) Connect fuel vapor hose and pipe joints to fuel pump assembly, and clamp vapor hose securely. CAUTION: 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 406 ENGINE FUEL 6C-11 7) Connect negative cable at battery. With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP ASSEMBLY (WITH FUEL FIL- TER, FUEL LEVEL GAUGE, FUEL CUT VALVE AND TANK PRESSURE CONTROL VALVE) WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section.
Page 407 6C-12 ENGINE FUEL DISASSEMBLY 1. Bracket sub assembly (including fuel filter) 2. Grommet 3. Tube 4. Housing 5. Lead wire 6. Fuel level gauge (Fuel sender gauge) 7. Fuel pump 8. Cushion 9. Bracket 10. Spacer 1) Disconnect gauge lead wire connector from bracket sub as- sembly.
Page 408 ENGINE FUEL 6C-13 6) Remove lead wire, fuel tube and/or grommets as necessary. CAUTION: When removing grommet from fuel tube or bracket sub assembly, be very careful not to cause damage to grommet installed section (sealed section in bore). Should it be damaged, replace it with new one, or fuel will leak from that part.
Page 409 6C-14 ENGINE FUEL 4) Install housing to assembly made in Step 3) above. Check that lug of housing fits in window of bracket securely. 1. Housing 2. Lug 3. Bracket 4. Window 5) Install assembly made in Step 4) above to bracket sub assem- bly.
Page 410 ENGINE FUEL 6C-15 4) Install fuel tank to vehicle. Refer to FUEL TANK INSTALLATION in this section. TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening parts Fastening arts N·m kg-m lb-ft Fuel pump assembly bolt Fuel tank bolt 17.0 SPECIAL TOOL 09919-47020 Quick joint remover...
Page 411 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 412 6E-2 ENGINE AND EMISSION CONTROL SYSTEM ECT Sensor (Removal/Installation and ON-VEHICLE SERVICE ....6E-55 General ....... . 6E-56 Inspection) .
Page 413 ENGINE AND EMISSION CONTROL SYSTEM 6E-3 GENERAL DESCRIPTION The engine and emission control system has 4 major Electronic control system includes ECM, various sen- sors and controlled devices. sub-systems: air intake system, fuel delivery system, electronic control system and emission control sys- Emission control system includes EGR, EVAP and tem.
Page 414 6E-4 ENGINE AND EMISSION CONTROL SYSTEM...
Page 415 ENGINE AND EMISSION CONTROL SYSTEM 6E-5...
Page 416 6E-6 ENGINE AND EMISSION CONTROL SYSTEM AIR INTAKE SYSTEM The main components of the air intake system are air uted by the intake manifold and finally drawn into each cleaner, air cleaner outlet hose, throttle body, idle air combustion chamber. control valve and intake manifold.
Page 417 ENGINE AND EMISSION CONTROL SYSTEM 6E-7 ELECTRONIC CONTROL SYSTEM D Fuel injection control system The electronic control system consists of 1) various D Idle air control system sensors which detect the state of engine and driving D Fuel pump control system conditions, 2) ECM which controls various devices ac- D Evaporative emission control system cording to the signals from the sensors and 3) various...
Page 418 6E-8 ENGINE AND EMISSION CONTROL SYSTEM ECM CONNECTORS TERMINAL ARRANGEMENT (VIEWED FROM TERMINAL SIDE)
Page 419 ENGINE AND EMISSION CONTROL SYSTEM 6E-9 1.Camshaft position sensor Power source 2.Crankshaft position sensor Power source 3.Manifold absolute pressure sensor – blank 4.Throttle position sensor Data link connector 5.Engine coolant temp. sensor Gr/W A/C ON signal (if equipped) 6.Intake air temp. sensor Malfunction indicator lamp (“CHECK ENGINE”...
Page 420 6E-10 ENGINE AND EMISSION CONTROL SYSTEM SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE FUEL PUMP RELAY f f f f f f f f FUEL INJECTOR HO2S HEATER f f f f f f f f f f f f IAC VALVE IGNITION COIL WITH IGNITER f f f f...
Page 421 ENGINE AND EMISSION CONTROL SYSTEM 6E-11 DIAGNOSIS The engine and emission control system in this vehicle are con- trolled by ECM. ECM has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “On-Board Diagnostic System”...
Page 422 6E-12 ENGINE AND EMISSION CONTROL SYSTEM D When taking measurements at electrical connectors using a tes- ter probe, be sure to insert the probe from the wire harness side (backside) of the connector. 1. Connector 2. Probe D When connecting meter probe from terminal side of coupler be- cause it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection.
Page 423 4) Turn ignition switch ON position, leaving engine OFF. 5) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool oper- ator’s manual for further details. If communication between SUZUKI scan tool and ECM is not possible, check if SUZUKI scan tool is communicable by con- necting it to ECM in another vehicle.
Page 425 ENGINE AND EMISSION CONTROL SYSTEM 6E-15 DIAGNOSTIC TROUBLE CODE TABLE EXAMPLE: When throttle position sensor is defective (Code No. 13) DIAGNOSTIC MALFUNCTION INDICATOR TROUBLE LAMP (“CHECK ENGINE” DIAGNOSTIC ITEM DIAGNOSIS CODE NO. LIGHT) FLASHING PATTERN Go to DTC No.11 MANIFOLD ABSO- Manifold absolute pressure P0105 LUTE PRESSURE SENSOR CIRCUIT in...
Page 429 ENGINE AND EMISSION CONTROL SYSTEM 6E-19 STEP ACTION Main relay circuit check: Go to Step 6. “B/G” wire open. 1) Install main relay. 2) Measure voltage from “A7” terminal of ECM connector to ground. Is voltage within 10-14V? ECM power circuit check: Go to Step 7.
Page 430 6E-20 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.11 MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT (SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM) WIRING DIAGRAM 1. MAP sensor 2. MAP sensor connector 3. ECM connector (B) 4. ECM TROUBLE SHOOTING CAUTION: Do not connect from terminal “b” to “c” of MAP sensor connector. STEP ACTION Did you perform “ENGINE DIAGNOSTIC FLOW...
Page 431 ENGINE AND EMISSION CONTROL SYSTEM 6E-21 STEP ACTION 1) Remove MAP sensor. Clean air passage or re- Go to Step 6. 2) Visually inspect MAP sensor air pressure inlet place as necessary. passage for clogging. Was any blockage found? 1) Perform “MAP sensor inspection” in this section. Poor connection of MAP Faulty MAP sensor.
Page 432 6E-22 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.13 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE LOW OR HIGH) WIRING DIAGRAM 1. TP sensor 2. TP sensor connector 3. ECM connector (B) 4. ECM TROUBLE SHOOTING CAUTION: Do not connect from terminal “a” to “b” of TP sensor connector. STEP ACTION Did you perform “ENGINE DIAGNOSTIC FLOW...
Page 433 ENGINE AND EMISSION CONTROL SYSTEM 6E-23 STEP ACTION 1) Connect jumper wire from terminal “a” to “c” Go to Step 5. “Bl/Y” wire open. of TP sensor connector. Poor connection of ECM 2) Measure voltage from terminal “c” of TP sen- connector terminal.
Page 434 3) Run engine to normal operating temperature. recheck. 4) Maintain engine speed at 2000RPM for 60 se- conds. 5) Using data list function of SUZUKI scan tool, monitor oxygen sensor output voltage “02S” with engine running at 2000RPM. Does voltage switch below and above 0.55V?
Page 435 5) Run engine to normal operating temperature. 6) Maintain engine speed at 2000RPM for 60 se- recheck. conds. 7) Using data list function of SUZUKI scan tool, monitor oxygen sensor output voltage “02S” with engine running at 2000RPM. Does voltage switch below and above 0.55V? NOTE: Upon completion of inspection and repair work, perform “DTC Confirmation Procedure”...
Page 436 6E-26 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.15 CAMSHAFT POSITION SENSOR CIRCUIT (NO SIGNAL FROM CMP SENSOR WITH ECM RECEIVING 30 PLUSES FROM CKP SENSOR) WIRING DIAGRAM 1. CMP sensing rotor 2. CMP sensor 3. CMP sensor connector 4. Power supply from main relay 5.
Page 437 ENGINE AND EMISSION CONTROL SYSTEM 6E-27 STEP ACTION 1) Turn ignition switch OFF position. Go to Step 5. Faulty CMP sensor sig- 2) Remove CMP sensor. nal rotor. 3) Visually inspect CMP sensor signal rotor for damage with turning crankshaft. Is CMP sensor signal rotor in good condition? 1) Install a known-good CMP sensor.
Page 438 6E-28 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.16 VEHICLE SPEED SENSOR CIRCUIT (NO VEHICLE SPEED SENSOR SIGNAL EVEN THOUGH FUEL HAS BEEN CUT FOR MORE THAN 4 SECONDS) WIRING DIAGRAM 1. VSS sensing rotor 2. VSS 3. VSS connector 4. Power supply from main relay 5.
Page 439 ENGINE AND EMISSION CONTROL SYSTEM 6E-29 STEP ACTION 1) Remove VSS. Faulty VSS signal rotor. Poor connection of VSS 2) Visually inspect VSS sensor signal rotor for connector terminal. damage. If OK, substitute a Was any damage found? known-good VSS and recheck.
Page 440 6E-30 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.18 INTAKE AIR TEMPERATURE SENSOR CIRCUIT (SIGNAL VOLTAGE LOW OR HIGH) WIRING DIAGRAM 1. IAT sensor 2. IAT sensor connector 3. ECM connector 4. ECM TROUBLE SHOOTING STEP ACTION Did you perform “ENGINE DIAGNOSTIC FLOW Go to Step 2.
Page 441 ENGINE AND EMISSION CONTROL SYSTEM 6E-31 Fig. for Step 2 Fig. for Step 3...
Page 442 6E-32 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.19 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (SIGNAL VOLTAGE LOW OR HIGH) WIRING DIAGRAM 1. ECT sensor 2. ECT sensor connector 3. Combination meter 4. ECM connector 5. ECM TROUBLE SHOOTING STEP ACTION Did you perform “ENGINE DIAGNOSTIC FLOW Go to Step 2.
Page 443 ENGINE AND EMISSION CONTROL SYSTEM 6E-33 Fig. for Step 2 Fig. for Step 3...
Page 444 6E-34 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.21 ABS SIGNAL CIRCUIT (ABS SIGNAL INPUTTED AT ENGINE STARTING) WIRING DIAGRAM 1. ABS control module 2. ABS control module connector 3. ECM connector (A) 4. ECM TROUBLE SHOOTING STEP ACTION Did you perform “ENGINE DIAGNOSTIC FLOW Go to Step 2.
Page 445 ENGINE AND EMISSION CONTROL SYSTEM 6E-35 DTC NO.23 CRANKSHAFT POSITION SENSOR CIRCUIT (NO SIGNAL FROM CKP SENSOR EVEN THOUGH ENGINE STARTER SIGNAL HAS BEEN INPUTTED FOR MORE THAN 2 SECONDS) WIRING DIAGRAM 1. CKP sensing rotor 2. CKP sensor 3. CKP sensor connector 4.
Page 446 6E-36 ENGINE AND EMISSION CONTROL SYSTEM Fig. for Step 2...
Page 447 4) Run engine to normal operating temperature. 5) Maintain engine speed at 2000RPM for 60 seconds. 6) Using SUZUKI scan tool, monitor oxygen sensor output voltage with engine running at 2000RPM. 7) Confirm that oxygen sensor output voltage switches below and above 0.55V.
Page 448 6E-38 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-1 FUEL PUMP CIRCUIT CHECK WIRING DIAGRAM 1. Fuel pump 2. Fuel pump relay 3. Fuel pump relay connector 4. Power supply from main relay 5. ECM connector (A) 6. ECM 7. Ignition switch SYSTEM DESCRIPTION Fuel pump relay is turned ON for 2 sec.
Page 450 6E-40 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-2 FUEL INJECTOR CIRCUIT CHECK WIRING DIAGRAM 1. Fuel injector No.1 2. Fuel injector No.2 3. Fuel injector No.3 4. Fuel injector No.4 5. Fuel injector connector No.1 6. Fuel injector connector No.2 7.
Page 451 ENGINE AND EMISSION CONTROL SYSTEM 6E-41 STEP ACTION Does none of 4 injectors make operation sound at Go to Step 5. Faulty wire harness. Step 2? Faulty injector. Poor connection of con- nector. If OK, substitute a known-good ECM and recheck.
Page 452 6E-42 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-3 FUEL PRESSURE CHECK SYSTEM DIAGRAM 1. Fuel pump 2. Fuel filter 3. Fuel feed line 4. Fuel pressure regulator 5. Vacuum passage for fuel pressure regulator 6. Fuel return line SYSTEM DESCRIPTION Fuel pressure regulator keeps the fuel pressure applied to injector 290kPa higher than that in intake manifold at all times.
Page 453 ENGINE AND EMISSION CONTROL SYSTEM 6E-43 STEP ACTION 1) Turn ignition switch ON position, leaving engine Normal fuel pressure. Faulty fuel pump. OFF. 2) Check fuel pressure while blocking (pinching) fuel return hose. Is fuel pressure indicated within 441 – 637 kPa (4.5 –...
Page 454 OFF. Faulty EGR system. 3) Monitor closed throttle position (“CLOSE Faulty A/C signal. THROT POS”) parameter on SUZUKI scan Faulty engine accessory. tool. Does scan tool indicate “ON” when throttle valve is fully closed and then “OFF” when throttle valve is...
Page 455 3) Turn ignition switch ON position, leaving engine OFF. 4) Monitor closed throttle position (“CLOSE THROT POS”) parameter on SUZUKI scan tool. Does scan tool indicate “ON” when throttle valve is fully closed and then “OFF” when throttle valve is opened? 1) Perform “TP Sensor Inspection”...
Page 456 6E-46 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK SYSTEM AND WIRING DIAGRAM 1. Fuel tank 2. EVAP canister 3. EVAP canister purge valve 4. EVAP canister purge valve connector 5. To intake manifold 6. ECM connector (A) 7.
Page 457 ENGINE AND EMISSION CONTROL SYSTEM 6E-47 Fig. for Step 2 Fig. for Step 3 1. EVAP hose Fig. for Step 4...
Page 458 6E-48 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-6 EGR SYSTEM CHECK (IF EQUIPPED) WIRING DIAGRAM 1. EGR valve 2. EGR valve connector 3. Power supply from main relay 4. ECM connector (A) 5. ECM connector (B) 6. ECM SYSTEM DESCRIPTION When EGR valve stepper motor receives open (close) signal from ECM, it turns in the open (close) direction accord- ing to the number of steps and pushes out (pulls up) the rod which is in mesh with the worm of the stepper motor.
Page 459 Faulty A/C control mod- 2) Start engine and run it at idle. ule. 3) Monitor A/C signal (“A/C SWITCH”) parameter If OK, substitute a on SUZUKI scan tool. known-good ECM and 4) Turn A/C switch OFF. recheck. Does scan tool indicate OFF? 1) Run engine at idle.
Page 460 Go to Step 5. Substitute a known-good 2) Monitor A/C ON signal (“A/C MAGNET CLUT”) ECM and recheck. parameter on SUZUKI scan tool. 3) Turn A/C switch OFF. Does scan tool indicate OFF? 1) Run engine at idle. A/C signal circuit and “Gr/W”...
Page 461 ENGINE AND EMISSION CONTROL SYSTEM 6E-51 TABLE B-8 RADIATOR FAN CONTROL SYSTEM CIRCUIT CHECK WIRING DIAGRAM 1. Radiator fan motor 2. Radiator fan relay 3. Radiator fan relay connector 4. Power supply from main fuse box 5. Power supply from main relay 6.
Page 462 6E-52 ENGINE AND EMISSION CONTROL SYSTEM STEP ACTION 1) Turn ignition switch ON position, leaving engine Go to Step 6. Faulty “Bl/W”, “B/R” wire. OFF. 2) Measure voltage from “a” of radiator fan relay connector to ground, from “c” of radiator fan relay connector to ground.
Page 465 ENGINE AND EMISSION CONTROL SYSTEM 6E-55 ON-VEHICLE SERVICE 1. Air cleaner case 7. PCV valve 2. EVAP canister 8. PCV hose 3. EVAP canister purge hose 9. Fuel pressure regulator 4. Fuel feed hose 10. Fuel return hose 5. EVAP canister purge valve 11.
Page 466 6E-56 ENGINE AND EMISSION CONTROL SYSTEM GENERAL When hoses are disconnected and system components are re- moved for service, reinstall components properly, and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of hoses. ACCELERATOR CABLE AND PEDAL ADJUSTMENT 1) With throttle valve closed, check accelerator pedal play which should be within the following specification.
Page 467 ENGINE AND EMISSION CONTROL SYSTEM 6E-57 [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool to DLC with ignition switch OFF position. Special Tool (A): 09931-76011 (SUZUKI scan tool) (B): Mass storage cartridge (C): 09931-76030 (16/14 pin DLC cable) 2) Start engine and warm it up to normal operating temperature.
Page 468 6E-58 ENGINE AND EMISSION CONTROL SYSTEM NOTE: IAC duty can be checked roughly by using voltmeter. IAC duty to voltage relation is as follows. ON DUTY OFF DUTY VOLTMETER METER INDICATION METER INDICATION INDICATION 0.5 x V D “OFF DUTY METER” is such duty meter that indicates approx.
Page 469 ENGINE AND EMISSION CONTROL SYSTEM 6E-59 AIR INTAKE SYSTEM THROTTLE BODY ON-VEHICLE INSPECTION D Check that throttle valve lever moves smoothly. REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system. Refer to section 6B. 3) Disconnect accelerator cable from throttle body. 4) Disconnect electric connectors from TP sensor, MAP sensor and IAC valve.
Page 470 6E-60 ENGINE AND EMISSION CONTROL SYSTEM IDLE AIR CONTROL VALVE (IAC VALVE) REMOVAL 1) Remove throttle body. 2) Remove IAC valve from throttle body. 1. Throttle body 2. O-ring 3. IAC valve INSPECTION 1) Connect each connector to IAC valve MAP sensor and TP sen- sor.
Page 471 ENGINE AND EMISSION CONTROL SYSTEM 6E-61 VEHICLE SPEED SENSOR (VSS) ON-VEHICLE INSPECTION 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral. 3) Remove combination meter and disconnect combination con- nectors. 4) Connector voltmeter between “a” terminal of combination meter connector and body ground.
Page 472 6E-62 ENGINE AND EMISSION CONTROL SYSTEM FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION 1) Relieve fuel pressure in fuel feed line. Refer to “Fuel Pressure Relief Procedure” in Section 6. 2) Disconnect fuel feed hose from fuel delivery pipe. CAUTION: A small amount of fuel may be released when hose is disconnected.
Page 473: Fuel Pump
ENGINE AND EMISSION CONTROL SYSTEM 6E-63 FUEL PUMP ON-VEHICLE INSPECTION CAUTION: When fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking. 1) Remove filler cap and turn ignition switch ON position. Then fuel pump operating sound be heard from fuel filler for about 2 se- conds and stop.
Page 474: Fuel Pressure Regulator
6E-64 ENGINE AND EMISSION CONTROL SYSTEM FUEL PRESSURE REGULATOR ON-VEHICLE INSPECTION Perform fuel pressure inspection according to procedure de- scribed in “Fuel Pressure Inspection” in this section. REMOVAL 1) Relieve fuel pressure in fuel feed line. Refer to “Fuel Pressure Relief Procedure”...
Page 475: Fuel Injector
ENGINE AND EMISSION CONTROL SYSTEM 6E-65 FUEL INJECTOR ON-VEHICLE INSPECTION 1) Using sound scope or such, check operating sound of injector when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, go to “B-2 Fuel Injec- tor Circuit Check”...
Page 476 6E-66 ENGINE AND EMISSION CONTROL SYSTEM 1) Install injector and fuel pressure regulator to special tool (injec- tor checking tool). Special Tool (A): 09912-58421 2) Connect special tools (hoses and attachment) to hose and pipe of vehicle. Special Tool (B): 09912-58431 3) Connect special tool (test lead) to injector.
Page 477 ENGINE AND EMISSION CONTROL SYSTEM 6E-67 INSTALLATION 1) Replace injector O-ring with new one using care not to damage it. Install grommet to injector. 2) Check if cushion is scored or damaged. If it is, replace with new one. Install insulators and cushions to intake manifold. 3) Apply thin coat of fuel to O-rings and then install injectors into delivery pipe and intake manifold.
Page 478 6E-68 ENGINE AND EMISSION CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE (ECM) CAUTION: As ECM consists of precision parts, be careful not to ex- pose it to excessive shock. REMOVAL/INSTALLATION 1) Disconnect battery negative cable at battery. 2) Disable air bag system (if equipped). Refer to “Disabling the Air Bag System”...
Page 479: Engine Coolant Temperature Sensor
ENGINE AND EMISSION CONTROL SYSTEM 6E-69 INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1) Disconnect negative cable at battery. 2) Disconnect IAT sensor connector. 3) Remove IAT sensor from air cleaner case. Reverse above procedure in case of installation. 1. IAT sensor 2.
Page 480 6E-70 ENGINE AND EMISSION CONTROL SYSTEM INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t shown such characteristic as shown, replace ECT sensor. TP SENSOR INSPECTION 1) Disconnect negative cable at battery.
Page 481 ENGINE AND EMISSION CONTROL SYSTEM 6E-71 REMOVAL 1) Disconnect battery negative cable at battery. 2) Disconnect connector from TP sensor. 3) Remove TP sensor from throttle body. INSTALLATION 1) Install TP sensor to throttle body. Fit TP sensor to throttle body in such way that its holes are a little away from TP sensor screw holes as shown in left figure and turn TP sensor clockwise so that those holes align.
Page 482 6E-72 ENGINE AND EMISSION CONTROL SYSTEM REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative cable at battery. 2) Disconnect connector of heated oxygen sensor. 3) Remove heated oxygen sensor from exhaust manifold.
Page 483 ENGINE AND EMISSION CONTROL SYSTEM 6E-73 CRANKSHAFT POSITION SENSOR (CKP SENSOR) ON-VEHICLE INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect connector from CKP sensor. 3) Measure resistance between each terminal of CKP sensor. Resistance: 360 – 460W at 205C (685F) 4) Measure resistance between each terminal and ground.
Page 484 6E-74 ENGINE AND EMISSION CONTROL SYSTEM MAIN RELAY/FUEL PUMP RELAY/RADIATOR FAN RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove each relay from main fuse. 1. Main fuse box 2. Fuel pump relay 3. Main relay 4. Radiator fan relay 3) Check resistance between each two terminals as in table below.
Page 485 Check” in this section. EMISSION CONTROL SYSTEM EGR SYSTEM (IF EQUIPPED) SYSTEM INSPECTION [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch OFF position. Special tool (A): 09931-76011 (SUZUKI scan tool)
Page 486: Egr Valve
6E-76 ENGINE AND EMISSION CONTROL SYSTEM EGR VALVE ON-VEHICLE INSPECTION 1) Disconnect negative cable at battery. 2) Disconnect EGR valve connector. 3) Check resistance between the following terminals of EGR valve in each pair. Terminals Standard resistance A – B C –...
Page 487 ENGINE AND EMISSION CONTROL SYSTEM 6E-77 EVAP EMISSION CONTROL SYSTEM EVAP SYSTEM HOSES AND PIPES INSPECTION Check hoses and pipes for connection, leakage, clog and deterio- ration. Replace as necessary. EVAP CANISTER PURGE VALVE ON-VEHICLE INSPECTION 1) With the ignition switch OFF position, disconnect connector from EVAP canister purge valve.
Page 489: Pcv System
ENGINE AND EMISSION CONTROL SYSTEM 6E-79 PCV SYSTEM INSPECTION NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty for ob- structed PCV valve or hose hampers its accurate checking. 1.
Page 490 6E-80 ENGINE AND EMISSION CONTROL SYSTEM TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts kg-m lb-ft Delivery pipe bolts 17.0 Camshaft position sensor bolt Heated oxygen sensor 32.5 Fuel pressure regulator bolts Engine coolant temp. (ECT) sensor 11.0 IAC valve TP sensor CKP sensor SPECIAL TOOLS...
Page 491 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 492 6F-2 IGNITION SYSTEM GENERAL DESCRIPTION The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. D 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 493 IGNITION SYSTEM 6F-3 SYSTEM WIRING DIAGRAM 1. Ignition switch 6. CKP sensor 12. Sensed information D MAP sensor D Electric load signal 2. Main relay 7. No.1 spark plug D ECT sensor D Engine start signal 3. Ignition coil assembly for 8.
Page 494 6F-4 IGNITION SYSTEM DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will No spark or abnormal spark D Blown fuse for ignition coil not start or hard to start Replace. D Loose connection or disconnection of lead wire or Connect securely. high-tension cord(s) D Faulty high-tension cord(s) Replace.
Page 495 IGNITION SYSTEM 6F-5 STEP ACTION Ignition Coil Assembly Power Supply and Ground Go to Step 7. Repair or replace. Circuit Check 1) Check ignition coil assembly power supply (“B/W” wire) and ground circuit (“B” wire) for open and short. Are circuits in good condition? Ignition Coil Assembly Check Go to Step 8.
Page 496 6F-6 IGNITION SYSTEM ON-VEHICLE SERVICE IGNITION SPARK TEST 1) Place transmission gear shift lever in “ Neutral”, set parking brake, and block drive wheels. 2) Disconnect injector couplers and ignition coil couplers. WARNING: If the injector couplers are not disconnected, com- bustible gas will come out of the spark plug holes dur- ing this test and the vehicle can get fire .
Page 497 IGNITION SYSTEM 6F-7 HIGH-TENSION CORD REMOVAL 1) Remove high-tension cord from ignition coil assembly while gripping its cap. 2) Pull out high-tension cord from spark plug while gripping its cap. CAUTION: Pull out each connection by gripping cap portion so as not to damage their inside wire (resistive conduc- tor).
Page 498 D Before starting engine, shift transmission to “Neutral” and set parking brake. INSPECTION 1) When using SUZUKI scan tool, connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 499 IGNITION SYSTEM 6F-9 5) Fix ignition timing to initial one as follows: [Using SUZUKI scan tool] Select “MISC TEST” mode on SUZUKI scan tool and fix ignition timing to initial one. [Not using SUZUKI scan tool] 1. Monitor connector 2. Fuse box Disconnect scan tool from DLC, and connect “D”...
Page 500 D Test switch signal circuit D VSS 10) After checking Initial Ignition Timing, release ignition timing fixation by using SUZUKI scan tool or disconnect service wire from monitor connector. 11) With engine idling (test switch terminal ungrounded, throttle opening at closed position and car stopped), check that igni- tion timing fluctuates between 65 –...
Page 501 IGNITION SYSTEM 6F-11 IGNITION TIMING COMPENSATION FOR EN- GINE KNOCKING (FOR VEHICLE WITH IGNI- TION TIMING ADJUSTING RESISTER CONNECTOR) The ignition system basically needs no adjustment for ignition tim- ing. However, due to fuel quality or other reason (mainly counter- measure against knocking), the adjustment may be needed.
Page 502 6F-12 IGNITION SYSTEM TIGHTENING TORQUE SPECIFICATION Tightening Torque Fastening Parts Fastening Parts N·m kg-m lb-ft Spark plug 20.0 SPECIAL TOOLS 1. Storage case 2. Operator’s manual 3. Tech 1A 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8.
Page 503 CRANKING SYSTEM 6G-1 SECTION 6G CRANKING SYSTEM CONTENTS GENERAL DESCRIPTION ....6G-2 Performance Test ....6G-11 Cranking Circuit .
Page 504 6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT D The magnetic switch coils are magnetized when the ignition switch is closed.
Page 505: Starting Motor
CRANKING SYSTEM 6G-3 STARTING MOTOR Both of them consist of yoke assembly, armature assembly, over-running clutch assembly, magnetic switch assem- bly, front housing, rear housing, brush holder and drive lever. The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash.
Page 506 6G-4 CRANKING SYSTEM DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: D Starting motor does not run (or runs slowly) D Starting motor runs but fails to crank engine D Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..in battery, wiring harness, (including starting motor switch), starting motor or engine.
Page 507 CRANKING SYSTEM 6G-5 Condition Possible Cause Correction Starting motor If battery and wiring are satisfactory, running but too inspect starting motor D Insufficient contact of magnetic switch main slow (small torque) Replace magnetic switch. contacts D Layer short-circuit of armature Replace.
Page 508 6G-6 CRANKING SYSTEM UNIT REPAIR OVERHAUL DISMOUNTING AND REMOUNTING 1) Disconnect negative (–) battery lead at battery. 2) Disconnect magnetic switch lead wire and battery cable from starting motor terminals. 3) Remove 2 mounting bolts. 4) Remove starting motor. 5) To remount, reverse above procedure. DISASSEMBLY 1) Remove nut and disconnect lead wire from magnetic switch.
Page 509 CRANKING SYSTEM 6G-7 REASSEMBLY 1) Inspect component parts (Refer to INSPECTION) and replace with new ones as necessary. 2) Before installing over-running clutch, apply grease as shown in left figure and then fasten stop ring with snap ring. “A” : Grease 99000-25010 1.
Page 510 6G-8 CRANKING SYSTEM 7) Hook magnetic switch plunger with drive lever and then fasten magnetic switch assembly with nuts. 8) Connect lead wire as it was and then check magnetic switch for operation. NOTE: D Before installing nuts, make sure that plunger hook is connected with drive lever without fail.
Page 511 CRANKING SYSTEM 6G-9 D Hold-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’ terminal and coil case. If no continuity exists, coil is open and should be replaced. 1. Terminal ‘S’ BRUSH Measure length of brushes and replace them as necessary. Brush length Limit : 6.0 mm (0.236 in.) BRUSH HOLDER...
Page 512 6G-10 CRANKING SYSTEM D Check commutator for run-out with armature supported on V- 1. Armature 2. V-block blocks. Correct it by using lathe, if required. 3. Magnetic stand 4. Dial gauge Commutator out of round Limit (maximum value): 0.4 mm (0.015 in.) D Check for wear and replace armature if diameter is below limit.
Page 513 CRANKING SYSTEM 6G-11 PERFORMANCE TEST CAUTION: Each test must be performed within 3 – 5 seconds to avoid coil from burning. PULL-IN TEST Connect test leads as shown in left figure and check that pinion (over-running clutch) move outward. If it does not, replace magnetic switch.
Page 514 6G-12 CRANKING SYSTEM PINION (PLUNGER) RETURN TEST As a next step to the above, disconnect negative lead and check to make sure that pinion returns inward quickly. NO-LOAD PERFORMANCE TEST Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out.
Page 515 Magnetic switch operating voltage 8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Armature shaft. D Over-running clutch. SUZUKI SUPER GREASE A Lithium grease D Commutator end cap. (99000-25010) D Drive lever. SPECIAL TOOL 09900-06107 Snap ring pliers...
Page 516 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 517 6H-2 CHARGING SYSTEM GENERAL DESCRIPTION BATTERY The battery has three major functions in the electrical system. D It is a source of electrical energy for cranking the engine. D It acts as a voltage stabilizer for the electrical system. D It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Page 518 CHARGING SYSTEM 6H-3 CARE OF BATTERY WARNING: D Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. D Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted area with water immediately and thor- oughly.
Page 519 6H-4 CHARGING SYSTEM GENERATOR The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown below figure. The generator features are as follows: D Solid state regulator is mounted inside the generator. D All regulator components are enclosed into a solid mold.
Page 520 CHARGING SYSTEM 6H-5 1. Pulley 2. Pulley nut 3. Rotor fan 4. Stator coil B : Generator output (Battery terminal) 5. Stator core D : Dummy terminal 6. Field coil 7. Regulator E : Ground 8. Brush F : Field coil terminal 9.
Page 521 6H-6 CHARGING SYSTEM DIAGNOSIS BATTERY VISUAL INSPECTION Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious damage is noted, replace battery. Determine cause of damage and correct as needed. HYDROMETER TEST The direct method of checking the battery for state of charge is to carry out a high rate discharge test, which involves a special pre-...
Page 522 CHARGING SYSTEM 6H-7 GENERATOR CAUTION: D Do not mistake polarities of IG terminal and L terminal. D Do not create a short circuit between IG and L termi- nals. Always connect these terminals through a lamp. D Do not connect any load between L and E. D When connecting a charger or a booster battery to ve- hicle battery, refer to this section describing battery charging.
Page 523 6H-8 CHARGING SYSTEM UNDERCHARGED BATTERY This condition, as evidenced by slow cranking can be caused by one or more of the following conditions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and amme- ter.
Page 524 CHARGING SYSTEM 6H-9 Higher Voltage If voltage is higher than standard value, check ground of brush. If brush ground is correct, replace IC regulator. Lower Voltage If voltage is lower than standard value, proceed to following check. 2) Ground F terminal and start engine, then measure voltage at B terminal as shown in left figure.
Page 525 6H-10 CHARGING SYSTEM ON-VEHICLE SERVICE BATTERY JUMP STARTING IN CASE OF EMERGENCY WITH AUXILIARY (BOOSTER) BATTERY Both booster and discharged battery should be treated carefully when using jumper cables. Follow procedure outlined below, being careful not to cause sparks. WARNING: D Departure from these conditions or procedure de- scribed below could result in: 1) Serious personal injury (particularly to eyes) or...
Page 526 CHARGING SYSTEM 6H-11 With Charging Equipment CAUTION: When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equip- ment can cause serious damage to electrical system or electronic parts.
Page 527 6H-12 CHARGING SYSTEM GENERATOR 1. Battery 2. Positive cable 3. Negative cable REMOVAL 4. Retainer 1) Disconnect negative cable at battery. 2) Disconnect “B” terminal wire and coupler from generator. 3) Remove generator adjusting arm reinforcement. Loosen bolts A and remove generator (water pump) belt. 4) Remove bolts B and pivot bolt.
Page 528 CHARGING SYSTEM 6H-13 GENERATOR (WATER PUMP) BELT BELT TENSION INSPECTION 1) Inspect belt cracks, cuts, deformation, wear and cleanliness. 2) Check belt for tension. Belt is in proper tension when it deflects 6 to 8 mm (0.24 – 0.31 in.) under thumb pressure (about 10 kg or 22 lb.).
Page 529 6H-14 CHARGING SYSTEM UNIT REPAIR OVER HAUL GENERATOR 1. Pulley nut 2. Pulley 3. Space collar 4. Drive end frame 5. Stator 6. Stud bolt 7. Drive end bearing 8. Bearing retainer 9. Rotor 10. End housing bearing 11. Bearing cover 12.
Page 530 CHARGING SYSTEM 6H-15 DISASSEMBLY 1) Remove B terminal inner nut and insulator. 2) Remove rear end cover. 1. Rear end cover 3. B terminal inner nut 2. Insulator 3) Remove 2 screws and pull out brush holder assembly. 4) Remove 3 screws and IC regulator. 5) Remove brush holder cover from brush holder.
Page 531 6H-16 CHARGING SYSTEM 11) If required, use bearing puller to remove end housing bearing and bearing cover. CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller. 1. End housing bearing 2. Bearing puller 3.
Page 532 CHARGING SYSTEM 6H-17 INSPECTION Rotor Open Circuit Using ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Standard resistance: About 2.9 W 1. Rotor Ground Using ohmmeter, check that there is no continuity between slip ring and rotor.
Page 533 6H-18 CHARGING SYSTEM Brush Exposed Brush Length Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush. Refer to “Replace Brush” in this section. Exposed brush length “a” Standard : 10.5 mm (0.413 in.) Limit : 4.5 mm (0.331 in.)
Page 534 CHARGING SYSTEM 6H-19 Bearing Drive End Bearing Check that bearing is not rough or worn. End Housing Bearing Check that bearing is not rough or worn. When removal is necessary, refer to 6H-15. REPLACE BRUSH 1) Unsolder and remove brush and spring. 2) Run wire of new brush through the hole in the brush holder, and insert spring and brush into brush holder.
Page 535 6H-20 CHARGING SYSTEM ASSEMBLY 1) If end housing bearing is removed, install it. 2) Check end housing bearing turns smoothly. 1. End housing bearing 2. Rotor 3. Bearing cover 3) If stator is removed, install stator and tighten stud bolts. 4) If drive end bearing is removed, install it.
Page 536 CHARGING SYSTEM 6H-21 10) Install rectifier holder. Curl stator leads as shown in figure. CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades. Tightening Torque 1. Rectifier holder (a): 2.0 N m (0.2 kg-m, 1.5 lb-ft) 2.
Page 537 6H-22 CHARGING SYSTEM SPECIFICATIONS BATTERY Rated capacity 28 AH / 5 HR, 12 Volts Electrolyte 2.1 L (4.44 / 3.70 US / lmp pt) Electrolyte S.G. 1.28 when fully charged at 20_C (68_F) GENERATOR – 30 to 90 _C Rated voltage 12 V Permissible ambient (–...
Page 538 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS GENERAL DESCRIPTION ................6K-1 MAINTENANCE .
Page 539 6K-2 EXHAUST SYSTEM MAINTENANCE ON-VEHICLE SERVICE D Refer to Section 6A for removal and installation pro- WARNING: cedures of exhaust manifold. To avoid danger of being burned, do not D For replacement of exhaust pipe, muffler or any part touch exhaust system when system is hot. used to mount or connect them, be sure to hoist ve- Any service on exhaust system should be hicle and observe WARNING given at the left of this...
Page 540: Manual Transmission
MANUAL TRANSMISSION 7A-1 SECTION 7A MANUAL TRANSMISSION CONTENTS GENERAL DESCRIPTION ....7A- 2 Assembling Unit ..... . . 7A-18 Main shaft and input shaft .
Page 541 7A-2 MANUAL TRANSMISSION GENERAL DESCRIPTION 1. Input shaft 10. High speed synchronizer hub 19. Input shaft bearing retainer 2. Main shaft 11. 5th speed synchronizer hub 20. Low speed gear shift fork 3. Main shaft low gear 12. Reverse gear shaft 21.
Page 542 MANUAL TRANSMISSION 7A-3 1. Input shaft 18. Speed sensor rotor 35. High speed synchronizer hub assembly 2. Input shaft bearing 19. 5th gear needle bearing 36. High speed synchronizer ring 3. Front bearing 20. Main shaft bearing 37. Synchronizer spring 4.
Page 543 7A-4 MANUAL TRANSMISSION ON-VEHICLE SERVICE MAINTENANCE SERVICE OIL CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage ex- ists, correct or repair it. 3) Drain old oil and torque drain plug (1) as specified below after applying sealant to its thread.
Page 544 MANUAL TRANSMISSION 7A-5 GEAR SHIFT CONTROL LEVER AND CABLE 1. Shift control knob 2. Boot 3. Spacer 4. Cushion 5. Shift control cable assembly 6. Select control cable assembly 7. Control cable bracket 8. Grommet 9. Grommet plate 10. Washer 11.
Page 545: Extension Case
7A-6 MANUAL TRANSMISSION EXTENSION CASE Removal/Installation 1) Remove select cable lever (1) and gear shift stop bolt (2). 2) Remove shift & select shaft assembly (3). 3) Support engine/transmission assy on jack. 4) Disconnect vehicle speed sensor coupler and remove engine rear mounting.
Page 546 MANUAL TRANSMISSION 7A-7 8) Remove control cable end clips (1) and washers (2), and then disconnect gear shift cable (3) and select cable (4) from each lever. 9) Remove gear shift and select control cables from bracket (5). 10) Remove propeller shaft referring to “PROPELLER SHAFTS” section.
Page 547 7A-8 MANUAL TRANSMISSION REMOUNTING For remounting, reverse dismounting procedure. Use specified torques as given below. Tightening Torque (a) : 61 N·m (6.1kg-m, 44.0 Ib-ft) (b): 55 N·m (5.5kg-m, 40.0 Ib-ft) (c) : 25 N·m (2.5kg-m, 18.0 Ib-ft) NOTE: D To facilitate remounting, install rear mounting to transmis- sion after inserting input shaft into clutch disc.
Page 548 MANUAL TRANSMISSION 7A-9 UNIT REPAIR OVERHAUL DISASSEMBLING UNIT GEAR SHIFT & SELECT SHAFT ASSEMBLY 1) To disassembly component parts, use special tools (A) & (B) and 2.8 – 3.0 mm (0.11 in.) pin remover in addition. Special Tool (A): 09922-85811 (4.5 mm) (B): 09925-78210 (6.0 mm) 2) Clean all parts thoroughly, inspect them and replace with new ones as required.
Page 549 7A-10 MANUAL TRANSMISSION 4) Remove bolts fastening upper and lower cases together, sepa- rate the two, and take out main shaft assembly (2). Screwdriver or the like can be used to pry two cases apart. In such a case, do not stick screwdriver too far into between two mating faces, or faces may get damaged.
Page 550 MANUAL TRANSMISSION 7A-11 5) Remove countershaft reverse gear (1) and center bearing (3) with puller (2) and hydraulic press. 6) Remove countershaft from lower case. 7) Remove circlip (3) from countershaft front end and pull out bear- ing (2) by using special tool. Special Tool (B): 09913-60910 1.
Page 551 7A-12 MANUAL TRANSMISSION 4) Remove circlip retaining rear bearing (1) on main shaft. Re- move main shaft bearing using special tool. Special Tool: (A): 09913-65135 5) From main shaft, take off 5th gear, 5th speed synchronizer ring and 5th gear needle bearing. 6) Remove circlip retaining 5th speed synchronizer hub on main shaft.
Page 552 MANUAL TRANSMISSION 7A-13 10) Remove bearing washer, ball, low gear, low synchronizer ring and needle bearing from main shaft. 11) Remove circlip retaining low speed synchronizer hub on main shaft. 12) [In the case of press-fitting hub] CAUTION: Make sure to use flat side of puller to avoid causing damage to reverse gear teeth.
Page 553 7A-14 MANUAL TRANSMISSION 15) [In the case of press-fitting hub] CAUTION: Make sure to use flat side of puller to avoid causing damage to reverse gear teeth. Drive out high speed synchronizer sleeve and hub assembly (1) together with 3rd gear (2) and high speed synchronizer ring by using puller (3) and hydraulic press (4).
Page 554: Gear Shift Lever
MANUAL TRANSMISSION 7A-15 CAUTION: When removing yoke pin, be sure not to drive it out so far as to contact case. Or it will cause damage to case. 2) Using special tool, drive out spring pin (2) on high speed gear shift fork (1), and pull out shift shaft (4).
Page 555 7A-16 MANUAL TRANSMISSION Gear Shift Fork Shaft Visually check each gear shift fork shaft (High, Low and Reverse) where gear shift front arm contacts for wear. Worn shaft must be replaced. Gears Check each part for wear, damage or discoloration. Replace if found defective.
Page 556 MANUAL TRANSMISSION 7A-17 Bearing Check each part for wear, damage or discoloration. With ball bear- ing, check to ensure that it rotates smoothly and it does not make noise. Replace if found defective. Input Shaft Inspect cone (1) and dog clutch (2) for wear and damage. Inspect gear teeth (3) and splines (4) for wear and damage.
Page 557 7A-18 MANUAL TRANSMISSION Gear Shift Shafts Check the part of shaft as indicated in figure for uneven wear. Re- place shaft if uneven wear is noted. ASSEMBLING UNIT NOTE: D Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear. D Use new circlips on shaft for reinstallation.
Page 558 MANUAL TRANSMISSION 7A-19 1) Assemble low speed synchronizer hub (1), sleeve (2), springs (4) and keys (3). a) Slide hub in sleeve so that punch marked side of hub and groove machined side of sleeve face the same direction. b) Insert keys in hub slots with depression side of keys face center of hub.
Page 559 7A-20 MANUAL TRANSMISSION 4) If low speed sleeve and hub assembly is press-fitted, ensure that components are free from iron filings shaved off by press- fitting. Remove any iron filings from around the areas concerned by us- ing compressed air, if necessary. 5) Fit low speed hub circlip (1) into groove in main shaft.
Page 560 MANUAL TRANSMISSION 7A-21 8) Install ball (3) and washer (4). As figure shows, install washer so that its circumference cham- fered side faces center bearing (1) and its slot (2) comes over ball. Fit center bearing circlip. A: Low gear side B: Reverse gear side 9) Assemble 5th speed synchronizer hub (2), sleeve (1), springs (4) and keys (3).
Page 561 7A-22 MANUAL TRANSMISSION 10) Install reverse gear needle bearing and reverse gear (1). 11) [In the case of press-fitting hub] Using special tools, puller and hydraulic press, drive in 5th speed synchronizer sleeve and hub assembly (2) with punch marked side of hub directed to forward (reverse gear side). NOTE: D Hold reverse gear in its installing position by hand to prevent washer and ball from dropping off.
Page 562 MANUAL TRANSMISSION 7A-23 15) Press-fit main shaft rear bearing (2) and fit circlip into groove in main shaft (3). Special Tool (A): 09925-18011 16) Install speed sensor rotor (4) and fit circlip (1). 17) Assemble high speed synchronizer hub (2), sleeve (1), springs (4) and keys (3).
Page 563 7A-24 MANUAL TRANSMISSION 18) Install 3rd gear bearing and 3rd gear (1). 19) [In the case of press-fitting hub] CAUTION: Make sure synchronizer ring key slots (3) must be aligned with keys while press-fitting sleeve and hub assembly. Otherwise synchronizer ring may be dam- aged.
Page 564 MANUAL TRANSMISSION 7A-25 22) When installing bearing (1) to input shaft (2), bring it so that its groove for C-ring is in the rear and press-fit with special tool and press. Special Tool (A): 09925-18011 23) After fitting circlip (1), air-blow lubrication oil hole (2). 24) Install synchronizer ring (3), needle bearing (4) and input shaft (1).
Page 565 7A-26 MANUAL TRANSMISSION 3. Lower case 3) Press-fit reverse gear (1) and then 5th gear (2). NOTE: When press-fitting, hold countershaft with its front end set on wood blocks. Special Tool (A): 09913-80113 4) After press-fitting countershaft rear bearing (1), make sure to fit circlip securely.
Page 566 MANUAL TRANSMISSION 7A-27 SHIFT SHAFTS AND FORKS 1. Reverse gear shift fork 2. High speed gear shift fork 3. Low speed gear shift fork Note that 3 shift shafts individually have a locating ball and locating spring, and that 2 interlock balls and an interlock roller are used be- tween shafts as shown.
Page 567 7A-28 MANUAL TRANSMISSION 4) Install interlock ball and locating ball in upper case. After installing interlock roller in high speed gear shift shaft and insert shaft into upper case as described in 2) and 3). Fork (2) should installed in such direction as shown. Then drive shift spring pin (1) until it becomes flush with outer surface of fork.
Page 568 MANUAL TRANSMISSION 7A-29 5) Install upper case to lower case by matching 3 shift forks (1) with 3 grooves in synchronizer sleeve (2) on main shaft respectively. 6) Tighten case bolts to specification. Install ground cable through right-rear case bolt. Install gear control cable bracket (3) and back-up light switch harness clamp (4).
Page 569 7A-30 MANUAL TRANSMISSION INPUT SHAFT BEARING RETAINER 1) Install new oil seal (1) with special tool and hammer up to case surface, apply grease to oil seal lip. Special Tool (A): 09913-75820 (B): 09941-34513-004 “A”: Grease 99000-25010 2) Clean surface of retainer (2) to mate with transmission case and uniformly apply sealant.
Page 570 MANUAL TRANSMISSION 7A-31 GEAR SHIFT & SELECT SHAFT ASSEMBLY 1) Clean mating surface of both extension case (1) and gear shift guide case (3), coat mating surface of extension case with seal- ant evenly and install gear shift & select shaft assembly (2). “A”...
Page 571 40.0 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS D Oil seal lips SUZUKI SUPER GREASE A D Gear shift control lever (99000-25010) D Gear shift control cable end Lithium grease SUZUKI SUPER GREASE I D Input shaft spline front end...
Page 572 MANUAL TRANSMISSION 7A-33 SPECIAL TOOLS 09913-60910 09913-65135 09913-80113 09913-85210 Bearing puller Bearing puller Bearing installer Bearing installer 09922-85811 09924-74510 09925-18011 09940-51710 Spring pin remover Oil seal installer handle Bearing installer Bearing installer 09941-34513-004 09924-07710 09924-07720 Oil seal installer Synchronizer hub installer Synchronizer hub installer...
Page 573 CLUTCH 7C-1 SECTION 7C CLUTCH CONTENTS GENERAL DESCRIPTION ............... . 7C- 2 DIAGNOSIS .
Page 574 7C-2 CLUTCH GENERAL DESCRIPTION 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 tapering fingers pointing inward. The disc, carrying four torsional coil springs, is slidably mounted on the transmission input shaft with a serration fit.
Page 575 CLUTCH 7C-3 DIAGNOSIS Condition Possible Cause Correction D Improper clutch pedal free travel. Slipping Adjust free travel. D Worn or oily clutch disc facing. Replace disc. D Warped disc, pressure plate or flywheel Replace disc, clutch cover or surface. flywheel. D Weakened diaphragm spring.
Page 576 7C-4 CLUTCH ON-VEHICLE SERVICE CLUTCH PEDAL FREE TRAVEL 1) Depress clutch pedal, stop the moment clutch resistance is felt, and measure distance (clutch pedal free travel). Free travel should be within following specification. Pedal free travel “a”: 10 – 15 mm (0.4 – 0.6 in.) 1.
Page 577 CLUTCH 7C-5 CABLE ROUTING RH vehicle 1. Floor panel 2. Crossmember 3. Water hose 4. A/C hose (if equipped) 5. Brake pipe 6. Cable adjusting nut LH vehicle 7. Oil pan 8. Front case cap 9. Oil level gauge guide D When installing clutch pedal shaft arm to clutch pedal shaft, align punch marks as shown in figure.
Page 578 7C-6 CLUTCH UNIT REPAIR 1. Input shaft bearing 2. Flywheel 3. Clutch disc 4. Clutch cover 5. Clutch cover bolt 6. Release bearing 7. Release fork 8. Release fork clip 9. Release bearing clip 10. Return spring DISMOUNTING / REMOUNTING Refer to “MANUAL TRANSMISSION”...
Page 579 CLUTCH 7C-7 INSPECTION Input Shaft Bearing Check bearing for smooth rotation and replace it if abnormality is found. 1. Input shaft bearing Clutch Disc Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 580 7C-8 CLUTCH INSTALLATION NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly. 1) Install flywheel to crankshaft and tighten bolts to specification. Special Tool (A): 09924-17810 Tightening Torque (a): 78 N m (7.8 kg-m, 56.5 lb-ft) 1.
Page 581 CLUTCH 7C-9 CLUTCH RELEASE FORK REMOVAL 1) Remove release fork return spring and release fork clip. 2) Remove release fork together with release bearing. 1. Release fork 2. Release bearing 3. Return spring 4. Release fork clip INSPECTION Clutch release bearing Check clutch release bearing for smooth rotation and its clip for deflection or damage.
Page 582 7C-10 CLUTCH INSTALLATION Reverse removal procedure for installation noting followings. D Apply grease as shown in figure. “A” : Grease 99000-25010 “B” : Grease 99000-25210 D Install release bearing, return spring and clips to release fork as shown in figure. 1.
Page 583 2. Clutch cover bolts 16.5 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT D Clutch pedal shaft arm. SUZUKI SUPER GREASE A D Clutch release fork. (99000-25010) Lithium grease Lithium grease SUZUKI SUPER GREASE I Input shaft spline front end. (99000-25210)
Page 584 DIFFERENTIAL 7F-1 SECTION 7F DIFFERENTIAL CONTENTS GENERAL DESCRIPTION ............... . 7F- 2 DIAGNOSIS .
Page 585 7F-2 DIFFERENTIAL GENERAL DESCRIPTION The components of the differential are shown in figure below. The bevel gear drive is of hypoid design; pinion and gear have hypoid gear teeth. This means that the pinion is located slightly below the center of the bevel gear to permit the car body to be lowered in design, and that some wiping or sliding action occurs in tooth meshing between pinion and gear.
Page 586 DIFFERENTIAL 7F-3 DIAGNOSIS Condition Possible Cause Correction D Deteriorated or water mixed lubricant Gear noise Repair and replenish D Inadequate or insufficient lubricant Repair and replenish D Maladjusted backlash between bevel pinion and gear Adjust D Improper tooth contact in the mesh between bevel pinion Adjust or replace and gear D Loose bevel gear securing bolts...
Page 587: Oil Change
7F-4 DIFFERENTIAL ON-VEHICLE SERVICE OIL CHANGE 1) Remove oil drain plug and drain oil. 2) Reinstall drain plug and tighten it to specified tightening torque. Tightening Torque (a): 55 N·m (5.5 kg-m, 40.0 lb-ft) 3) Remove oil level & filler plug and fill differential housing with new specified oil.
Page 588 DIFFERENTIAL 7F-5 INSTALLATION Reverse removal procedure for installation, noting the following. D Before installing differential ass’y to axle housing, clean mating surfaces of differential carrier and housing and apply sealant to them. After installing it, tighten carrier bolts to specified torque. “A”: Sealant 99000-31110 Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
Page 589 7F-6 DIFFERENTIAL UNIT REPAIR DISASSEMBLY 1) Lock the flange immovable, and remove nut from the end of the bevel pinion shank. 2) Scribe marks on each cap bolted to the saddle portion of carrier case and holding down side bearing. The marks are to identify cap.
Page 590 DIFFERENTIAL 7F-7 6) Draw out side pinion shaft, as shown, and remove side pinions, side gears, spring washers and thrust washers. Special Tool (C): 09922-85811 NOTE: Do not mix up washers. Keep the original position in mind for installation. 7) Using special tools indicated below, extract left side bearing from differential case.
Page 591 7F-8 DIFFERENTIAL 2) Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate. NOTE: D When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge. D With dial gauge set, turn dummy back and forth by hand a couple of times and attain accurate 0 (zero) adjust- ment.
Page 592 DIFFERENTIAL 7F-9 5) Select adjusting shim(s) closest to calculated value from among following available sizes and put it in place and then press-fit rear bearings. Special Tool (D): 09940-51710 0.05, 0.1, 0.2, 0.3 and 0.5 mm Available shim thickness 0.002, 0.004, 0.008, 0.012 and 0.02 in.
Page 593 7F-10 DIFFERENTIAL 8) While tightening flange nut gradually with flange holder (special tool) and power wrench, set preload of pinion to specification. NOTE: D Before taking measurement with spring balance or torque wrench, check for smooth rotation by hand. D Bevel pinion bearing preload is adjusted by tightening bevel pinion nut to crush spacer.
Page 594 DIFFERENTIAL 7F-11 Right side Right side 1. Differential gear D Using similar procedure to the above, set dial gauge tip to gear shoulder. D Move gear up and down by hand and read dial gauge. 3) If thrust play is out of specification, select suitable thrust washer from among following available size, install it and check again that specified gear play is obtained.
Page 595 7F-12 DIFFERENTIAL 6) Install bevel gear to differential case. When mounting gear on case, be sure to apply thread lock ce- ment to these bolts before running them in. “A”: Cement 99000-32020 Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft)
Page 596 DIFFERENTIAL 7F-13 ASSEMBLING UNIT 1) Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable. 2) Install case assembly in carrier. 3) Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly. NOTE: Screw in each adjuster till it contacts bearing outer race so that outer race is prevented from inclining.
Page 597 7F-14 DIFFERENTIAL 6) Measure preload of pinion with spring balance or torque wrench and check composite preload of pinion bearing and side bear- ing. Special Tool (C): 09922-75222 NOTE: D Standard preload is within the range given in graph be- low, which should be read as follows.
Page 598 DIFFERENTIAL 7F-15 7) Torque bearing cap bolts to specification and install bearing lock plates. Apply thread lock cement to bearing lock plate bolt. Tightening Torque (a): 50 N·m (5.0 kg-m, 36.5 lb-ft) (b): 11.5 N·m (1.15 kg-m, 8.5 lb-ft) “A”: Thread lock cement 99000-32050 8) As final step, check gear tooth contact as follows.
Page 599 7F-16 DIFFERENTIAL TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY Outer end (Heel) Drive side Coast side NORMAL Inner end (Toe) HIGH CONTACT Gear Pinion is positioned too far from the center of drive bevel gear. 1. Increase thickness of pinion height adjusting shim and position pinion closer to gear center.
Page 600 DIFFERENTIAL 7F-17 BLANK...
Page 601 RECOMMENDED MATERIALS SUZUKI PRODUCTS THREAD LOCK CEMENT SUPER Thread lock cement 1333B Bevel gear bolts (99000-32020) SUZUKI LOCK CEMENT “1342” Thread lock cement Side gear lock plate bolts (99000-32050) SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) D Rear differential drain plug SUZUKI BOND NO.
Page 602 DIFFERENTIAL 7F-19 SPECIAL TOOLS 09900-20606 09913-85230 09900-20701 09913-60910 Dial gauge Bearing removing jig Magnetic stand Bearing/Gear puller 09922-66020 09922-75222 09924-36320 (For Front Diff) 09922-85811 Flange holder Preload adjuster Bevel pinion mounting dummy Spring pin remover 09924-74510 09930-40120 09940-51710 09930-40113 Installer attachment Attachment Bearing installer Rotor holder...
Page 603 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 604 8-2 BODY ELECTRICAL SYSTEM Seat Belt Warning Light ..............8-13 Rear Window Defogger (If Equipped) .
Page 605 BODY ELECTRICAL SYSTEM 8-3 GENERAL DESCRIPTION The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery. The electrical system utilizes negative ground polarity. CAUTIONS IN SERVICING When performing works related to electric systems, observe fol- lowing cautions for the purpose of protection of electrical parts and prevention of a fire from occurrence.
Page 606 8-4 BODY ELECTRICAL SYSTEM D When installing the wiring harness, fix it with clamps so that no slack is left. D When installing vehicle parts, be careful so that the wiring har- ness is not interfered with or caught by any other part. D To avoid damage to the harness, protect its part which may con- tact against a part forming a sharp angle by winding tape or the like around it.
Page 607 BODY ELECTRICAL SYSTEM 8-5 D When performing a work that produces a heat exceeding 805C in the vicinity of the electrical parts, remove the heat sensitive electrical part(s) beforehand. D Use care not to expose connectors and electrical parts to water which will be a cause of a trouble.
Page 608 8-6 BODY ELECTRICAL SYSTEM There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “G”). The dual-colored wire uses two color symbols (i.e. “G/Y”). The first symbol represents the base color of the wire (“G”...
Page 609 BODY ELECTRICAL SYSTEM 8-7 COMBINATION METER 1. Speedometer 2. Fuel lever meter 3. Water temperature meter 4. Turn signal pilot light (LH) 5. ABS warning light (if equipped) 6. CHECK ENGINE light 7. Turn signal pilot light (RH) 8. AIR BAG warning light (if equipped) 9.
Page 610 8-8 BODY ELECTRICAL SYSTEM WINDSHIELD WIPER AND WASHER 1. Wiper blade 2. Wiper arm 3. Wiper link 4. Wiper motor 5. Washer nozzle 6. Washer hose 7. Washer pump 8. Washer tank POWER WINDOW SYSTEM 1. Power window switch 2. Window actuator...
Page 611 BODY ELECTRICAL SYSTEM 8-9 POWER DOOR LOCK SYSTEM 1. Power door lock controller 2. Front door lock actuator 3. Joint connector 4. Rear door lock actuator 5. Back door lock actuator...
Page 612 8-10 BODY ELECTRICAL SYSTEM DIAGNOSIS HEADLIGHT Trouble Possible Cause Correction Headlights do not light up Bulb blown Check bulb Lighting or dimmer switch faulty Check headlight switch HEADLIGHT R and L fuses blown Check fuses and replace as necessary (If replace, check short circuit to ground) Wiring or grounding faulty Repair circuit Only one headlight does...
Page 613 BODY ELECTRICAL SYSTEM 8-11 TURN SIGNAL AND HAZARD WARNING LIGHTS Trouble Possible Cause Correction Flash rate high or one side Bulb blown on “flash rate high”-side Check bulb only flashes Incorrect bulb Check bulb Turn signal/hazard warning relay faulty Check relay Open circuit or high resistance existing Repair circuit between Combination switch (turn sig-...
Page 614: Brake Lights
8-12 BODY ELECTRICAL SYSTEM BRAKE LIGHTS Trouble Possible Cause Correction Brake lights do not light up Bulb(s) blown Check bulb STOP fuse blown Check fuse and replace as necessary (If replace, check short circuit to ground) Brake light switch faulty Check switch Wiring or grounding faulty Repair circuit...
Page 615: Oil Pressure Light
BODY ELECTRICAL SYSTEM 8-13 OIL PRESSURE LIGHT Trouble Possible Cause Correction Oil pressure warning light Bulb in combination meter blown Check bulb does not light up when IG METER fuse blown Check fuse and replace as necessary turn the ignition switch to (If replace, check short circuit to ground) on position at engine off Printed plate in combination meter...
Page 616: Power Door Lock System
8-14 BODY ELECTRICAL SYSTEM WINDSHIELD WIPER AND WASHER Trouble Possible Cause Correction Wiper malfunctions or WIPER WASHER fuse blown Check fuse and replace as necessary does not return to its origi- (If replace, check short circuit to ground) nal position Wiper motor faulty Check wiper motor Combination switch (wiper switch)
Page 617: Interior Lights
BODY ELECTRICAL SYSTEM 8-15 INTERIOR LIGHTS Trouble Possible Cause Correction Interior lights do not light Bulbs blown Replace RADIO DOME fuse blown Check fuse and replace as necessary (If replace, check short circuit to ground) Interior light switch faulty Check switch Door switch faulty Check switch Wiring or grounding...
Page 618 8-16 BODY ELECTRICAL SYSTEM ON-VEHICLE SERVICE LH steering vehicle shown HEADLIGHT HEADLIGHT SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH/CONTACT COIL AND COM- BINATION SWITCH ASSEMBLY in “STEERING WHEEL AND COLUMN” section for details. INSPECTION Use an ohmmeter to check the continuity at each switch position shown below.
Page 619 BODY ELECTRICAL SYSTEM 8-17 BULB REPLACEMENT WARNING: Don’t touch when the bulb is hot. 1) Disconnect negative (–) cable at battery. 2) Disconnect harness from bulb. 3) Remove socket cover and bulb. 4) Replace bulb and assemble all removed parts. 1.
Page 620 8-18 BODY ELECTRICAL SYSTEM HEADLIGHTS WITH LEVELING SYSTEM (IF EQUIPPED) SYSTEM INSPECTION CAUTION: Leveling switch and leveling actuator can not be checked by itself. It is strictly prohibited to connect volt- meter or ohmmeter to leveling switch and leveling actua- tor with couplers disconnected from it.
Page 621 BODY ELECTRICAL SYSTEM 8-19 TURN SIGNAL AND HAZARD WARNING LH steering vehicle shown LIGHT TURN SIGNAL LIGHT SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH/CONTACT COIL AND COM- BINATION SWITCH ASSEMBLY in “STEERING WHEEL AND COLUMN” section for details. INSPECTION Use an ohmmeter to check the continuity at each switch position shown below.
Page 622: Ignition Switch
8-20 BODY ELECTRICAL SYSTEM INSPECTION Connect battery and two test bulbs (12 V, 27 W) as shown. Unless a continued flash on and off is visible, replace relay. Reference flashing cycle: 60 – 120 cycle/minute 1. Hazard relay 2. Test bulb (12 V, 27 W) IGNITION SWITCH INSPECTION 1) Disconnect negative cable at battery.
Page 623 BODY ELECTRICAL SYSTEM 8-21 REAR FOG LIGHT (IF EQUIPPED) REAR FOG LIGHT SWITCH INSPECTION 1) Connect battery positive (+) lead to terminal (A) and negative (–) lead to terminal (B), (C). 2) Connect voltmeter positive (+) lead to terminal (D) and negative lead to negative battery terminal.
Page 624 8-22 BODY ELECTRICAL SYSTEM COMBINATION METER LH steering vehicle shown REMOVAL 1) Disconnect negative cable at battery. 2) Loosen steering column mounting screws and nuts. (Refer to “STEERING WHEEL AND COLUMN” section.) 3) Remove meter cluster panel. Make sure to disconnect all cou- plers of switches and wires of cigarette lighter on meter cluster.
Page 625 BODY ELECTRICAL SYSTEM 8-23 FUEL METER/FUEL GAUGE UNIT FUEL LEVEL METER INSPECTION 1) Remove combination meter, refer to combination meter in this section. 2) Connect battery terminals to combination meter terminals as shown. 3) Check that the fuel level meter operates as shown. Terminal (a) meter indicates open...
Page 626 8-24 BODY ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND SENSOR UNIT ENGINE COOLANT TEMPERATURE METER INSPECTION 1) Remove combination meter, refer to combination meter in this section. 2) Connect battery terminals to combination meter terminals as shown. 3) Check that the engine coolant temperature meter operates as shown.
Page 627: Oil Pressure Warning Light
BODY ELECTRICAL SYSTEM 8-25 INSTALLATION Reverse removal procedure for installation noting the following: Apply sealant to the thread of ECT sensor. Sealant 99000 - 31150 Tightening Torque (a) : 15 N·m (1.5 kg-m, 10.8 lb-ft) 1. ECT sensor unit OIL PRESSURE WARNING LIGHT OIL PRESSURE SWITCH INSPECTION Use an ohmmeter to check switch continuity.
Page 628 8-26 BODY ELECTRICAL SYSTEM SEAT BELT WARNING LIGHT (IF EQUIPPED) SEAT BELT SWITCH INSPECTION Refer to “SEAT BELT” section. REAR WINDOW DEFOGGER (IF EQUIPPED) DEFOGGER SWITCH INSPECTION Use a circuit tester to check defogger switch for continuity. If switch has no continuity between terminals, replace it. Terminal Defogger SW DEFOGGER WIRE...
Page 629 BODY ELECTRICAL SYSTEM 8-27 2) Locating damage in wire a. Touch voltmeter positive (+) lead to heat wire positive termi- nal end. b. Touch voltmeter negative (–) lead with a foil strip to heat wire positive terminal end, then move it along wire to the negative terminal end.
Page 630 8-28 BODY ELECTRICAL SYSTEM WINDSHIELD WIPER AND WASHER LH steering vehicle shown WIPER/WASHER SWITCH Removal and Installation Refer to “STEERING WHEEL AND COLUMN” section for details. Inspection Use a circuit tester to check the continuity at each switch position as shown below. Terminal Wire Color...
Page 631 BODY ELECTRICAL SYSTEM 8-29 2) Testing automatic stop action a) Connect 12V battery (+) terminal to terminal “A” of wiper mo- tor and (–) terminal to bracket (wiper ground) and let the mo- tor turn. b) Disconnect terminal “A” from battery, and let the motor stop. c) Connect terminal “A”...
Page 632 8-30 BODY ELECTRICAL SYSTEM POWER WINDOW CONTROL SYSTEM (IF EQUIPPED) Power Window Main Switch Inspect switch continuity between terminals. Driver Side Passenger Side Window Switch Window Switch Terminal Switch DU DD PU PD Position DOWN 1. Power window main switch 2.
Page 633 BODY ELECTRICAL SYSTEM 8-31 POWER DOOR LOCK SYSTEM LH steering vehicle shown Power Door Lock Controller INSPECTION 1) Remove door lock controller from vehicle. Disconnect coupler from door lock controller. Connect door lock controller terminal to 12V battery as shown. 2) Connect voltmeter as shown.
Page 634 8-32 BODY ELECTRICAL SYSTEM POWER DOOR LOCK ACTUATOR 1) Disconnect power door lock actuator coupler. 2) Connect 12V battery positive and negative terminals to the door lock actuator terminals shown below. If it does not follow the table’s operation, replace the faulty door lock actuator.
Page 635 BODY ELECTRICAL SYSTEM 8-33 Rear Door Operation UNLOCK LOCK Terminal RIGHT SIDE Door RIGHT SIDE Door LEFT SIDE Door LEFT SIDE Door REAR DOOR JUNCTION SWITCH INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove door trim and center pillar lower trim as necessary. 3) Disconnect body side coupler and door side coupler of rear door junction switch.
Page 636: Door Switch
8-34 BODY ELECTRICAL SYSTEM DOOR SWITCH INSPECTION Disconnect door switch coupler and check switch for continuity. If found defective, replace switch. ON position Continuity (door switch released OFF) OFF position No continuity (door switch pushed ON)
Page 637 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 638 9-2 BODY SERVICE ON-VEHICLE SERVICE FRONT DOOR Door mirror 1. Door panel 2. Door trim 3. Door sealing cover 4. Door inner weatherstrip 5. Door outer weatherstrip 6. Door opening weatherstrip 7. Door opening stopper 8. Door rear sash 9. Glass run 10.
Page 639 BODY SERVICE 9-3 FRONT DOOR GLASS AND WINDOW REGULATOR REMOVAL 1) Remove window regulator handle (if equipped). For its removal, pull off snap by using a cloth as shown. 2) Lower door glass fully. 1. Cloth 2. Regulator handle 3) Remove screw and then inside handle assembly from door trim by sliding it forward.
Page 640 9-4 BODY SERVICE INSPECTION D Check regulator sliding and rotating parts for greasing. D Check gear for wear or damage. D Check links for damage. INSTALLATION Reverse removal procedure to install front door glass and window regulator noting following points. D When installing glass to bottom channel, coat channel with soap water and tap it with a plastic hammer.
Page 641: Front Door Lock
BODY SERVICE 9-5 FRONT DOOR LOCK [A]: Without power door lock [B]: With power door lock Tightening torque: (a): 5.5 N·m (0.55 kg-m, 4.0 lb-ft) (b): 10 N·m (1.0 kg-m, 7.5 lb-ft) 1. Outside handle 2. Lock key cylinder 3. Inside handle 4.
Page 642 9-6 BODY SERVICE INSTALLATION Reverse removal sequence for installation while using care for fol- lowing items. D Install door latch striker. Move door latch striker up and down so that its shaft approxi- mately aligns with the center of groove of door latch. NOTE: Striker should be placed level and moved vertically.
Page 643: Front Door Assembly
BODY SERVICE 9-7 FRONT DOOR ASSEMBLY REMOVAL 1) Disconnect door harness couplers, and remove corrugation tube from body (if equipped). 1. Corrugation tube 2. Coupler 2) Remove stopper pin upward by tapping it with hammer. 1. Door open stopper 2. Pin 3) Using a jack, support door panel with a piece of wood placed 1.
Page 644 9-8 BODY SERVICE REAR (SLIDING) DOOR 1. Door panel 9. Door lower arm 17. Channel rubber 25. Door outside handle assembly 2. Door trim 10. Door upper arm 18. Bottom channel 26. Door lock knob 3. Door sealing cover 11. Door upper glass run 19.
Page 645 BODY SERVICE 9-9 REAR DOOR GLASS AND WINDOW REG- ULATOR REMOVAL 1) Remove inside handle. For its removal, pull off snap by using a cloth as shown in figure. 2) Remove inside lock knob. 3) Lower glass fully and remove outer weatherstrip. 1.
Page 646 9-10 BODY SERVICE INSTALLATION Reverse removal procedure to install rear door glass and window regulator noting following points. D When installing glass to bottom channel, coat channel with soap water and tap it with a plastic hammer. Glass-fitted position of bottom channel is as shown in the figure. Length “b”: 331.5 –...
Page 647: Rear Door Lock
BODY SERVICE 9-11 REAR DOOR LOCK [A]: Without power door lock [B]: With power door lock 1. Door outside handle 2. Door link ass’y 3. Door latch assembly 4. Door latch striker 5. Door inside handle 6. Door lock control rod 7.
Page 648 9-12 BODY SERVICE 1. Upper arm 2. Slide hinge 3. Lower arm 4. Door stopper 5. Shim Weather strip end set position 6. Door open stopper “a”: 115 " 20 mm 7. Door rail INSTALLATION Reverse the removal sequence to install rear door. NOTE: When replacing door, coat replacement door inside with wax for proper anticorrosion treatment.
Page 649 BODY SERVICE 9-13 3) Adjust slide hinge so that door rear surface and body surface align each other and at the same time clearance between door rear end and body is equal to clearance between rear door front end and front door rear end with the door closed. 4) Adjust the rear door stoppers and tighten the screws.
Page 650: Back Door
9-14 BODY SERVICE BACK DOOR [A]: Without power door lock [B]: With power door lock 1. Door panel 2. Door opening weatherstrip 3. Door window weatherstrip 4. Door window glass 5. Door hinge 6. Back door balancer 7. Door trim 8.
Page 651 BODY SERVICE 9-15 3) Remove back door balancer (first at its door-side and next at its body-side). WARNING: Handling of Back Door Balancer (Damper) D Do not disassemble balancer because its cylinder is filled with gas. D The gas itself is harmless but it may issue out of the hole together with chips generated by the drill.
Page 652 9-16 BODY SERVICE WINDSHIELD 1. Windshield 2. Molding 3. Windshield trim 4. Spacer 5. Stopper The windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For wind- shield glass replacement, it is important to use an adhesive which provides sufficient adhesion strength and to follow the proper pro- cedure.
Page 653 BODY SERVICE 9-17 Adhesive materials and tools required for removal and installation. D One component urethane adhesive and primers used in com- bination (For one sheet of windshield). Adhesive (300 g (14.1 oz.)) Primer for glass (15 g (0.5 oz.)) Primer for body (15 g (0.5 oz.)) D Eyeleteer D Piano string...
Page 654 9-18 BODY SERVICE 10) Cut adhesive all around glass with piano string. NOTE: Use piano string as close to glass as possible so as to pre- vent damage to body. 1. Piano string 3. Tape 2. Glass 4. Adhesive 11) Using knife, smooth adhesive remaining on body side so that it is 1 –...
Page 656 9-20 BODY SERVICE 6) Using new brush, apply sufficient amount of primer for glass along glass surface to be adhered to body. NOTE: D Be sure to refer to maker’s instruction for proper han- dling and drying time. D Do not apply primer on outside of ceramic coated sur- face.
Page 657 BODY SERVICE 9-21 8) Peel remaining paper from molding. 9) Holding rubber sucker grips, press glass onto body and place the glass securely by tapping glass surface and molding all around. NOTE: Use care not to damage glass surface or body. 1.
Page 658 9-22 BODY SERVICE BACK DOOR/QUARTER WINDOW GLASS Vehicle outside REMOVAL 1) Disconnect rear defogger coupler. 2) As window glass is fixed by means of window weatherstrip, re- move glass and weatherstrip together by removing end of weatherstrip little by little while pushing the entire glass from in- side toward outside as shown in the figure.
Page 659 BODY SERVICE 9-23 INSTRUMENT PANEL [Harness Location] WARNING: See WARNING at the beginning of this section. REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove glove box and column hole cover.
Page 660 9-24 BODY SERVICE HOOD REMOVAL 1) Remove mounting bolts to detach hood. 2) When removing hood hinge, remove cowl top garnish. INSTALLATION Reverse removal procedure to install hood. ADJUSTMENT D Fore-and-aft and right-and-left adjustment Loosen mounting bolts for adjustment. D Hood latch adjustment When installing hood latch, bring bolt at highest position of ob- long hole and move it in vertical direction for adjustment by refer- ring PANEL CLEARANCE.
Page 661: Front Fender
BODY SERVICE 9-25 FRONT FENDER 1. Front fender 2. Front fender lining 3. Fender attaching bolts 4. Fender lining attaching clip REMOVAL 1) Remove radiator grille. 2) Remove front bumper. 3) Disconnect connector of side turn signal lamp. 4) Remove front fender lining. 5) Remove front fender.
Page 662 9-26 BODY SERVICE BUMPERS NOTE: Fasteners are important attaching parts in that they could affect the performance of vital components and systems, an/or could result in major repair expense. They must be replaced with one of the same part num- ber or with an equivalent part if replacement becomes necessary.
Page 663 BODY SERVICE 9-27 HEAD LINING REMOVAL 1) Remove spot light. 2) Remove sunshade assembly. 3) Remove room light. 4) Remove assistant grips. 5) Remove inner trims covering head lining and door opening trim. 6) Remove head lining. INSTALLATION 1) Clean roof where adhesive of head lining will be attached. 2) Apply adhesive on recess of head lining and install it to body.
Page 664 9-28 BODY SERVICE SEATS 1. Right front seat back ass’y FRONT SEAT (VAN model) 2. Right front seat cushion ass’y 3. Left front seat back ass’y 4. Left front seat cushion ass’y 5. Right front seat inside adjuster 6. Right front seat outside adjuster 7.
Page 665 BODY SERVICE 9-29 FRONT SEAT (TRUCK model) 1. Seat cushion 2. Seat back 3. Seat back frame 4. Bracket Tightening torque NOTE: (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) Insert seat back frame into bracket surely. (c): 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Page 666 9-30 BODY SERVICE 2ND SEAT 2ND SEAT (for vehicle equipped with third seat) (for vehicle without third seat) 3RD SEAT 1. Blank 2. Reclining rod 3. Reclining ass’y 4. Seat lock 5. Striker Tightening Torque (a): 35 N·m (3.5 kg-m, 25.5 lb-ft) (b): 23 N·m (2.3 kg-m, 17.0 lb-ft) REMOVAL 1) Remove seat rail mounting bolts.
Page 667 BODY SERVICE 9-31 PANEL CLEARANCE 1. Hood – Fender : 2.7 – 4.7 mm (0.11 – 0.19 in.) 11. Back door – Side body 2. Hood – Head lamp : 5.4 – 7.4 mm (0.21 – 0.29 in.) outer panel : 4.6 –...
Page 668 9-32 BODY SERVICE ANTI-CORROSION TREATMENT Sealer is applied to the specific joints of a vehicle dur- WARNING: ing production. The sealer is intended to prevent dust Standard shop practices, particularly eye from entering the vehicle and serves also as an anti- protection, should be followed during the corrosion barrier.
Page 669 BODY SERVICE 9-33 When the welding or heating operation causes the Scrape the accessible places. If a standard putty knife original galvanization or other anticorrosive materials or scraper does not fit to the relevant place, consider to be burnt, the interior and under-body panel sur- to use a more flexible scraper to a place narrowly en- faces must be cleaned.
Page 670 9-34 BODY SERVICE SEALANT APPLICATION AREA Van model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...
Page 671 BODY SERVICE 9-35 Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...
Page 672 9-36 BODY SERVICE...
Page 673 BODY SERVICE 9-37 Truck model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...
Page 674 9-38 BODY SERVICE...
Page 675 BODY SERVICE 9-39 RUST-PROOF TREATMENT AREA...
Page 676 9-40 BODY SERVICE...
Page 677 BODY SERVICE 9-41 PLASTIC PARTS FINISHING Paintable plastic parts are ABS plastic parts. Painting Rigid or hard ABS plastic needs no primer coating. General acrylic lacquers can be painted properly over hard ABS plastic in terms of adherence. 1) Use cleaning solvent for paint finish to wash each part. 2) Apply conventional acrylic color lacquer to part surface.
Page 678 9-42 BODY SERVICE BODY DIMENSIONS Garnish installation clip hole b. b’ Hood hinge lower installation hole c. c’ Fender panel jig hole Front hood cushion installation hole Headlight installation hole f. f’ Front bumper installation hole g. g’ Front bumper installation hole Front lower crossmember jig hole Measurement Dimension Measurement...
Page 679 BODY SERVICE 9-43 a. a’ Roof panel front inner most end b. b’ Front hood hinge installation hole (upper side) Garnish installation clip hole Measurement Dimension Truck Measurement Length Measurement Length Position mm (in.) Position mm (in.) a – a’ 1099.9 (43.30) a –...
Page 680 9-44 BODY SERVICE d. Body outer panel jig hole e. Body outer panel jig hole f. Front door upper hinge installation hole (upper side) g. Front door striker installation hole (lower side) h. Front door lower hinge installation hole (lower side) i.
Page 681 BODY SERVICE 9-45 a. Body outer panel jig hole b. Front door upper hinge installation hole (upper side) c. Front door lower hinge installation hole (lower side) d. Front door striker installation hole (lower side) e. Body outer panel jig hole f.
Page 682 9-46 BODY SERVICE Roof panel cut part s. s’ Back door hinge installation hole t. t’ Rear combination lamp installation hole Rear floor clip installation hole (or punched part) v. v’ Pillar outer panel jig hole Measurement Dimension (The * mark shows the low roof model) Measurement Length Position...
Page 683 BODY SERVICE 9-47 UNDERBODY DIMENSIONS FOR VAN MODEL a. a’ Drain hole of floor front frame (j15) b. b’ Installation hole of front suspension frame (rear side) (j15) c. c’ Installation hole of compression rod bracket (inside) d. d’ Installation hole of engine mount bracket (outside) (j15) e.
Page 684 9-48 BODY SERVICE Projection Dimension Measurement Length from standard line “A” Length from standard line “B” Length from standard line “C” Position mm (in.) mm (in.) mm (in.) 135.4 ( 5.33) 369.0 (14.53) 562.0 ( 22.13) 119.0 ( 4.69) 369.0 (14.53) 783.6 ( 30.85)
Page 685 BODY SERVICE 9-49 FOR TRUCK MODEL a. a’ Drain hole of floor front frame (j15) b. b’ Installation hole of front suspension frame (rear side) (j15) c. c’ Installation hole of compression rod bracket (inside) d. d’ Installation hole of engine mount bracket (outside) Cabin back lower member hole (square hole) Engine mount installation hole on rear...
Page 686 9-50 BODY SERVICE Projection Dimension Measurement Length from standard line “A” Length from standard line “B” Length from standard line “C” Position mm (in.) mm (in.) mm (in.) 30.9 ( 1.22) 369.0 (14.53) 562.0 ( 22.13) 14.54 ( 0.57) 369.0 (14.53) 783.6 ( 30.85)
Page 687: Restraint System
D 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 in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 688 10-2 RESTRAINT SYSTEM GENERAL DESCRIPTION FRONT SEAT 2ND SEAT (IF EQUIPPED) 3RD SEAT (IF EQUIPPED) Type 1 Type 1 Type 2 Type 2 1. Driver side air bag (if equipped) 2. Passenger side air bag (if equipped) 3. Lap-shoulder seat belt with Emergency Locking Retractor (ELR) 4.
Page 689: Seat Belt
If these parts are replaced individually, such a locking condition may become unreliable. For this rea- son, SUZUKI will supply only the spare buckle and retractor assembly (or webbing) in a set part. Before servicing or replacing seat belts, refer to following precautionary items.
Page 690: Front Seat Belt
10-4 RESTRAINT SYSTEM FRONT SEAT BELT WARNING: Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. REMOVAL Remove front seat belts. Truck 1. Upper anchor 2. Lower anchor Tightening Torque 3.
Page 691 RESTRAINT SYSTEM 10-5 INSPECTION Seat belts and attaching parts can affect the vital components and systems of a vehicle. Therefore, they should be inspected carefully and replaced with genuine parts only. D Seat belt Its webbing or strap should be free from damage. D Retractor assembly with ELR It should lock webbing when pulled quickly.
Page 692 10-6 RESTRAINT SYSTEM Lap belt type Tightening Torque (a): 35 N m (3.5 kg-m, 25.5 lb-ft) 1. Anchor 2. Buckle 3. 2nd seat belt INSPECTION Check the 2nd seat belt in the same way as when inspecting front seat belt. (Refer to INSPECTION of FRONT SEAT BELT in this section.) INSTALLATION Install the 2nd seat belt observing the same precautions as when installing front seat belt.
Page 693 RESTRAINT SYSTEM 10-7 3RD SEAT BELT (IF EQUIPPED) WARNING: Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. REMOVAL Remove 3rd seat belts. Lap-shoulder belt type Lap belt type 1. Upper anchor 2.
Page 694 10-8 RESTRAINT SYSTEM TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts N·m kg-m lb-ft Upper and lower anchor bolt 25.5 Retractor assembly bolt 25.5 Retractor assembly screw 0.55 Buckle bolt 25.5...
Page 695 D Service on or around the air bag system components or wiring must be performed only by an au- thorized SUZUKI dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS of ON-VE- HICLE SERVICE in this section before performing service on or around the air bag system components or wiring.
Page 696 10B-2 AIR BAG SYSTEM DTC B1051 - Frontal crash detected Enabling air bag system ....10B-39 Handling and storage ....10B-40 (system activation command outputted) 10B-34...
Page 697 AIR BAG SYSTEM 10B-3 GENERAL DESCRIPTION With the air bag system which includes air bag(s) for the driver’s and passenger’s (if equipped) sides, the driver air bag (inflator) module is deployed from the center of the steering column and the passenger air bag (inflator) module from the top of the instrument panel in front of the front passenger seat (if equipped) in occur- rence of a front collision with an impact larger than a certain set val-...
Page 698 10B-4 AIR BAG SYSTEM SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS 1. Air bag harness 2. Fuse box 3. “AIR BAG” monitor coupler 4. DLC 5. Contact coil assembly 6. Driver air bag (inflator) module 7. Passenger air bag (inflator) module (if equipped) 8.
Page 699 AIR BAG SYSTEM 10B-5 SYSTEM WIRING DIAGRAM WIRE HARNESS COLOR : Black G/R : Green/Red : Yellow B/W : Black/White : Orange Y/B : Yellow/Black B/Bl : Black/Blue : Violet Y/R : Yellow/Red : Green V/G : Violet/Green : White “A”...
Page 700 The AIR BAG DIAGNOSTIC SYSTEM CHECK must always be the starting point of any air bag system diagnosis. The AIR BAG DIAGNOSTIC SYSTEM CHECK checks for proper “AIR BAG” warning lamp operation and checks for air bag diagnostic trouble codes (DTCs) using on-board diagnosis function or SUZUKI scan tool. USE OF SPECIAL TOOLS...
Page 701 AIR BAG SYSTEM 10B-7 Special Tool (Air Bag Driver/Passenger Load Tool) (B): 09932-75010 This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag (inflator) module deployment. The load tool has three connectors attached to its case which are electrically functional and serve as resistive load substitutions.
Page 702 10B-8 AIR BAG SYSTEM INTERMITTENTS AND POOR CONNECTIONS Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diag- nostic flow table, perform careful check of suspect circuits for: D Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 703 AIR BAG SYSTEM 10B-9 AIR BAG DIAGNOSTIC SYSTEM CHECK WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equip- ment other than that specified in this manual.
Page 704 1) Check DTC. Refer to DTC Air bag system is in good NOTE: CHECK. condition. See NOTE3 described below. 2) Not using SUZUKI scan tool: An intermittent trouble has oc- Is flashing patten no. 12 indi- curred at some place. cated? Check the connector harness, NOTE: etc.
Page 705 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool oper- ator’s manual for further details. 5) After completing the check, turn ignition switch to OFF position and disconnect SUZUKI scan tool from data link connector (DLC).
Page 706 DTC CLEARANCE Using SUZUKI scan tool 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (DLC) in the same manner as when making this connection for DTC check. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 707 ON. Therefore, it is not possible to identify any of them as to whether it is a current one or a history one. (But use of SUZUKI scan tool will make identification...
Page 708 10B-14 AIR BAG SYSTEM TABLE A – “AIR BAG” WARNING LAMP COMES ON STEADY TABLE B – “AIR BAG” WARNING LAMP DOES NOT COME ON TABLE C – “AIR BAG” WARNING LAMP FLASHES TABLE D – “AIR BAG” WARNING LAMP CANNOT INDICATE FLASHING PATTERN OF DTC :Air bag harness 1.
Page 709 AIR BAG SYSTEM 10B-15 DIAGNOSTIC FLOW TABLE Table A: STEP ACTION 1) Ignition switch OFF. Go to step 2. “Y/B” wire short to ground. 2) Remove and inspect “AIR BAG” fuse. After repair, replace “AIR 3) Is fuse good? BAG” fuse. 1) Disconnect SDM.
Page 710 10B-16 AIR BAG SYSTEM Table B: STEP ACTION 1) Set parking brake. Go to step 2. “B/W” wire, “IG METER” 2) Note combination meter when ignition switch fuse or J/B (between is turned ON. ignition switch and com- 3) Does the “BRAKE” indicator (warning lamp) bination meter) open or come ON? short to ground...
Page 711 AIR BAG SYSTEM 10B-17 Fig. for STEP 4 1. 16-pin connector (for combination meter) 2. “Or” wire terminal Special Tool (A): 09932-76010 NOTE: Upon completion of inspection and repair work, perform following items. 1) Reconnect all air bag system components, ensure all components are properly mounted. 2) Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected.
Page 712 10B-18 AIR BAG SYSTEM Table C: STEP ACTION 1) Check “AIR BAG” monitor coupler. Remove service wire. Go to step 2. 2) Is it connected diagnosis switch terminal and ground terminal in “AIR BAG” monitor coupler by service wire? 1) With ignition switch OFF, disconnect SDM. Substitute a known-good Repair short from “V”...
Page 713 AIR BAG SYSTEM 10B-19 Table D: STEP ACTION 1) Inspect connection between diagnostic switch Go to step 2. Properly connection terminal on “AIR BAG” monitor coupler and diagnostic switch termi- body ground by service wire. nal on “AIR BAG” moni- 2) Is it securely connected between them by ser- tor coupler and body vice wire?
Page 714 10B-20 AIR BAG SYSTEM TABLE E – SDM CANNOT COMMUNICATE THROUGH THE SERIAL DATA CIRCUIT :Air bag harness 1. From main fuse 7. SDM 2. Ignition switch 8. DLC 3. “IG METER” fuse in fuse box 9. To ECM, P/S control module (if equipped) and ABS control module 4.
Page 715 AIR BAG SYSTEM 10B-21 DIAGNOSTIC FLOW TABLE STEP ACTION 1) Make sure that SUZUKI scan tool is free Go to step 2. Properly connect SUZUKI from malfunction and correct cartridge for scan tool to DLC. air bag system is used.
Page 716 10B-22 AIR BAG SYSTEM DTC B1015 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH DTC B1016 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW DTC B1018 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND DTC B1019 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT 1.
Page 717 AIR BAG SYSTEM 10B-23 DIAGNOSTIC FLOW TABLE DTC B1015: STEP ACTION 1) With ignition switch OFF, disconnect passen- Go to step 2. 1) Ignition switch OFF. ger air bag (inflator) module connector be- 2) Replace passenger hind the glove box. air bag (inflator) mod- 2) Check proper connection to passenger air ule (Refer to PAS-...
Page 718 10B-24 AIR BAG SYSTEM DTC B1016: STEP ACTION 1) With ignition switch OFF, disconnect pas- Go to step 2. 1) Ignition switch OFF. senger air bag (inflator) module connec- 2) Replace passenger air tor behind the glove box. bag (inflator) module (Re- 2) Check proper connection to passenger fer to PASSENGER AIR air bag (inflator) module at terminals in...
Page 719 AIR BAG SYSTEM 10B-25 DTC B1018: STEP ACTION 1) With ignition switch OFF, disconnect pas- Go to step 2. 1) Ignition switch OFF. senger air bag (inflator) module connec- 2) Replace passenger air tor behind the glove box. bag (inflator) module (Re- 2) Check proper connection to passenger fer to PASSENGER AIR air bag (inflator) module at terminals in...
Page 720 10B-26 AIR BAG SYSTEM DTC B1019: STEP ACTION 1) With ignition switch OFF, disconnect passenger Go to step 2. 1) Ignition switch OFF. air bag (inflator) module connector behind the 2) Replace passenger air glove box. bag (inflator) module (Re- 2) Check proper connection to passenger air bag fer to PASSENGER AIR (inflator) module at terminals in “D”...
Page 721 AIR BAG SYSTEM 10B-27 DTC B1021 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH DTC B1022 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW DTC B1024 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND DTC B1025 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT 1.
Page 722 10B-28 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1021: STEP ACTION 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector located near the base of the steering column. 2) Check proper connection to contact coil at termi- nals in “B”...
Page 723 AIR BAG SYSTEM 10B-29 DTC B1022: STEP ACTION 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector located near the base of the steering column. 2) Check proper connection to contact coil at ter- minals in “B”...
Page 724 10B-30 AIR BAG SYSTEM DTC B1024: STEP ACTION 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector located near the base of the steering column. 2) Check proper connection to contact coil at termi- nals in “B”...
Page 725 AIR BAG SYSTEM 10B-31 DTC B1025: STEP ACTION 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector located near the base of the steering column. 2) Check proper connection to contact coil at ter- minals in “B”...
Page 726 10B-32 AIR BAG SYSTEM DTC B1032 – POWER SOURCE VOLTAGE LOW 1. From main fuse 2. Ignition switch 3. “AIR BAG” fuse in fuse box 4. SDM 5. Ground for air bag system CAUTION: D Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table.
Page 727 AIR BAG SYSTEM 10B-33 DIAGNOSTIC FLOW TABLE STEP ACTION 1) Measure voltage on battery. Go to step 2. Check Charging System 2) Is voltage 11 V or more? and repair as necessary. (Refer to DIAGNOSIS in SECTION 6H) 1) With ignition switch OFF, disconnect SDM. Go to step 4.
Page 728 10B-34 AIR BAG SYSTEM DTC B1051 – FRONTAL CRASH DETECTED (SYSTEM ACTIVATION COMMAND OUTPUTTED) DTC WILL SET WHEN: The SDM detects a frontal crash of sufficient force to warrant activation of the air bag system. (SDM outputs a de- ployment command.) TABLE TEST DESCRIPTION: STEP 1:Check that DTC B1051 has been set although air bag has not been deployed.
Page 729 AIR BAG SYSTEM 10B-35 REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT CAUTION: D All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be re- placed even if air bag system activation did not occur.
Page 730 10B-36 AIR BAG SYSTEM D Steering wheel and driver air bag (inflator) module – Check for damage or air bag (inflator) module fitness. – Check trim cover (pad surface) for cracks. – Check wire harness and connector for damage or tightness. If any faulty condition is found in above checks, replace faulty part.
Page 731 AIR BAG SYSTEM 10B-37 D Passenger air bag (inflator) module (if equipped) – Check for dents, cracks, damage or fitness. – Check trim cover for cracks or deformities. – Check harness and connector for damage or tightness. If any faulty condition is found in above checks, replace. D Air bag wire harness and connections –...
Page 732 Be sure to follow the instructions. WARNING: D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. D Do not modify the steering wheel, dashboard or any other air bag system components. Modifica- tions can adversely affect air bag system performance and lead to injury.
Page 733 AIR BAG SYSTEM 10B-39 DISABLING AIR BAG SYSTEM 1) Turn steering wheel so that vehicle’s wheels (front tires) and pointing straight ahead. 2) Turn ignition switch to “LOCK” position and remove key. 3) Remove “AIR BAG” fuse from fuse box. 4) Disconnect Yellow connector of contact coil and combination switch assembly.
Page 734 10B-40 AIR BAG SYSTEM 3) If equipped with passenger air bag (inflator) module, connect Yellow connector of passenger air bag (inflator) module, and be sure to lock connector with lock lever. i) Connect connector. ii) Lock connector with lock lever. 4) Install glove box.
Page 735 AIR BAG SYSTEM 10B-41 LIVE (UNDEPLOYED) AIR BAG (INFLATOR) MODULES Special care is necessary when handling and storing a live (unde- ployed) air bag (inflator) modules. The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, or an object in front of the air bag (inflator) module, to be thrown through the air in the unlikely event of an accidental deployment.
Page 736 10B-42 AIR BAG SYSTEM ALWAYS PLACE AIR BAG (INFLATOR) MODULE WARNING: ON WORKBENCH WITH TRIM COVER (AIR BAG When placing a live air bag (inflator) module on bench or OPENING) UP, AWAY FROM LOOSE OBJECTS. other surface, always face the bag up, away from the sur- face.
Page 737 AIR BAG SYSTEM 10B-43 AIR BAG WIRE HARNESS AND CONNECTORS Air bag wire harness can be identified easily as it is covered with a yellow and black protection tube. Be very careful when handling D When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly.
Page 738 10B-44 AIR BAG SYSTEM WARNING: During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. Neglecting them may result in personal in- jury or inactivation of the air bag system when neces- sary.
Page 739 AIR BAG SYSTEM 10B-45 PASSENGER AIR BAG (INFLATOR) MODULE (IF EQUIPPED) WARNING: D Never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. D Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work.
Page 740 10B-46 AIR BAG SYSTEM INSTALLATION 1) Install passenger air bag (inflator) module to vehicle. 2) Tighten passenger air bag (inflator) module attaching bolts to specified torque. Tightening Torque (a): 23 N·m (2.3 kg-m, 16.5 lb-ft) 3) Tighten passenger air bag (inflator) module attaching screws. 4) Connect negative cable to battery.
Page 741 AIR BAG SYSTEM 10B-47 AIR BAG (INFLATOR) MODULE DISPOSAL WARNING: Failure to follow proper air bag (inflator) module disposal procedures can result in air bag deploy- ment which may cause personal injury. Undeployed air bag (inflator) module must not be disposed of through normal refuse channels. The undeployed air bag (inflator) module contain substances that can cause severe illness or per- sonal injury if the sealed container is damaged during disposal.
Page 742 10B-48 AIR BAG SYSTEM 1) Turn ignition switch to “LOCK” position, remove key and put on safety glasses. 2) Check that there is no open, short or damage in special tool (de- ployment harness). If any faulty is found, do not use it and be sure to use new deployment harness.
Page 743 AIR BAG SYSTEM 10B-49 5) In case of driver air bag (inflator) module: i) Clear a space on the ground about 185 cm (6 feet) in diame- ter where the driver air bag (inflator) module is to be deployed. A paved, outdoor location where there is no activ- ity is preferred.
Page 744 10B-50 AIR BAG SYSTEM 6) Stretch the deployment harness from the driver or passenger For driver air bag (inflator) module air bag (inflator) module to its full length 10 m (33 ft). Special Tool (A): 09932-75030 7) Place a power source near the shorted end of the deployment harness.
Page 745 AIR BAG SYSTEM 10B-51 WARNING: D After deployment, the metal surfaces of the air bag (inflator) module will be very hot. Do not touch the metal areas of them for about 30 minutes after de- ployment. D Do not place the deployed air bag (inflator) module near any flammable objects.
Page 746 10B-52 AIR BAG SYSTEM 18) Dispose of the deployed air bag (inflator) module through nor- mal refuse channels after it has cooled for at least 30 minutes and tightly seal the air bag (inflator) module in a strong vinyl bag. (Refer to DEPLOYED AIR BAG (INFLATOR) MODULE DISPOSAL in this section for details.) 19) Wash your hands with mild soap and water afterward.
Page 747 AIR BAG SYSTEM 10B-53 DEPLOYMENT INSIDE VEHICLE For driver air bag (inflator) module Use this procedure when scrapping the entire vehicle including the air bag (inflator) module(s). CAUTION: When vehicle itself will be used again, deploy the air bag outside vehicle according to DEPLOYMENT OUTSIDE VEHICLE, for deploying it inside will cause the instru- ment panel, glove box and their vicinity to be deformed.
Page 748 10B-54 AIR BAG SYSTEM 8) Route deployment harness out the vehicle. 9) Verify that the inside of the vehicle and the area surrounding Driver side for left hand steering vehicle the vehicle are clear of all people and loose or flammable ob- jects.
Page 749 AIR BAG SYSTEM 10B-55 14) Separate the two banana plugs on the deployment harness. 15) Connect the deployment harness to the power source (12 V vehicle battery) to immediately deploy the air bag. 16) Disconnect the deployment harness from the power source (12 V vehicle battery) and short the two deployment harness leads together by fully seating one banana plug into the other.
Page 750 10B-56 AIR BAG SYSTEM DEPLOYED AIR BAG (INFLATOR) MODULE DISPOSAL WARNING: Failure to follow proper air bag (inflator) module disposal procedures can result in air bag deployment which may cause personal injury. The undeployed air bag (inflator) module must not be disposed of through normal refuse channels.
Page 751 AIR BAG SYSTEM 10B-57 TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts kg-m lb-ft SDM bolt Passenger air bag (inflator) module bolt (if equipped) 16.5 Refer to TIGHTENING TORQUE SPECIFI- Driver air bag (inflator) module bolt CATIONS in SECTION 3C. SPECIAL TOOLS 1.
Page 752 Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 1st Ed. February, 1999 2nd Ed. October, 2001 Printed in Japan Printing:...
Page 754 D Service on or around the air bag system ings. Pay special attention to the messages high- components must be performed only by lighted by these signal words. an authorized SUZUKI dealer. Please ob- serve all WARNINGS, CAUTIONS and WARNING: “Service Precautions” under “On-Vehicle Indicates a potential hazard that could result Service”...
Page 755 JS4DA32T 14116001 DA32T-116001 JS4DA32T Y4116001 It describes only different service information of the above applicable model as compared with GA413 SERVICE MANUAL. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any section, item or description not found in this supplement, refer to the related manuals mentioned in the next page.
Page 756 99501-76A00-XXX 4WD vehicle before the vehicle identifica- MANUAL FOR 4WD MODEL tion number mentioned in FOREWORD of this supplementary service manual. GA413 WIRING DIAGRAM MANUAL 99512-76A10-015 Vehicle produced on and after October 1, 2000. Refer to the WIRING DIAGRAM MANUAL for details.
Page 757 TABLE OF CONTENTS SECTION General Information GENERAL INFORMATION Maintenance and Lubrication Heater and Ventilation HEATING AND AIR CONDITIONING Air Conditioning Steering, Suspension, Wheels and Tires Wheel Alignment Manual Rack and Pinion Electrical Power Steering (P/S) System STEERING, SUSPENSION, Steering Wheel and Column WHEELS AND TIRES Front Suspension (2WD) Front Suspension (4WD)
Page 758 GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION NOTE: For the descriptions (items) not found in this section, refer to the Section 0A or 0A1 of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS FASTENER INFORMATION ............... 0A- 1 Metric Fasteners .
Page 759 0A-2 GENGERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
Page 760 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 761 0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 (54 000 d 90 000 k (54 000 miles), carry out the same services at the same intervals miles), carry out the same services at the same intervals Interval: Interval:...
Page 762 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same inter- Interval: vals respectively. This interval should be judged by odometer reading or (x 1,000) months, whichever comes first.
Page 763 0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 764 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-6 Exhaust System Inspection WARNING: To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust sys- tem 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: D Check rubber mountings for damage, deterioration, and out of...
Page 765 0B-6 MAINTENANCE AND LUBRICATION CHASSIS AND BODY ITEM 6-7’ Wheel Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to “WHEEL DISC, NUT AND BEAR- ING CHECK” in Section 3D. 2) Check rear wheel bearing for wear, damage, abnormal noise or rattles.
Page 766 MAINTENANCE AND LUBRICATION 0B-7 ITEM 6-10 Differential Oil (Front for 4WD and Rear) Inspection 1) Check differential for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove level plug of differential and check oil level. Oil level can be checked roughly by means of level plug hole.
Page 767 (Refer to OIL CHANGE in SECTION 7E front differential or 7F rear differen- tial for detail.) Water resistance chassis grease Clutch linkage pivot points (SUZUKI SUPER GREASE A 99000-25010) Door hinges Engine oil or water resistance chassis grease Engine oil or water resistance chassis grease...
Page 768 FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: D For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. D All front suspension fasteners are an important attaching part in that it could affect the perfor- mance of vital parts and systems, and/or could result in major repair expense.
Page 769 3D-2 FRONT SUSPENSION GENERAL DESCRIPTION The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the vehicle body by a strut support. The strut and strut support are isolated by a strut rubber support. A strut bearing is also installed a little lower to the strut rubber support.
Page 770 FRONT SUSPENSION 3D-3 ON-VEHICLE SERVICE STRUT DAMPER ASSEMBLY ASSEMBLY For the details, refer to the same item of the same section in service manual mentioned in FOREWORD of this manual noting the fol- lowing points. : Upper side D For cylindrical coil spring type, make sure that coil spring direc- A: Small 1.
Page 771 REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. D All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.
Page 772 3E-2 REAR SUSPENSION [A]: Type A 1. Rear coil spring 8. Rear axle [B]: Type B 2. Rear bump stopper 9. Bearing 3. Rear spring upper seat 10. Rear shaft oil seal Tightening Torque 4. Rear shock absorber 11. Brake drum (a): 80 N·m (8.0 kg-m, 58.0 lb-ft) 5.
Page 773 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 774 5-2 BRAKES GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. The brake pipes are connected to the master cylinder and they make two independent circuits.
Page 775 BRAKES 5-3 ON-VEHICLE SERVICE FRONT BRAKE HOSE/PIPE REMOVAL AND INSTALLATION 1) Raise and support vehicle properly. Remove wheel. This operation is not necessary when removing pipes connecting master cylinder and P valve. 2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose or pipe.
Page 776 5-4 BRAKES BRAKE PAD INSTALLATION For the details, refer to the same item of the same section in service manual mentioned in FOREWORD of this manual noting the fol- lowing. NOTE: See NOTE at the beginning of this section. Install shims to pads, then pad clips and pads to caliper carrier. NOTE: D In case of using a pad set including two brake pads with wear gauge, install the pads with wear gauge to body center...
Page 777 D 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 per- forming service on or near the air bag system components or wiring.
Page 778 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS On-Board Diagnostic System DTC P0136 HO2S Circuit Malfunction (Vehicle with EGR valve) ....6- 6 (Sensor-2) ......6-57 On-Board Diagnostic System (Vehicle DTC P0141 HO2S Heater Circuit Malfunction...
Page 779 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-3 GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 780 6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS PRECAUTION ON FUEL SYSTEM SERVICE HOSE CONNECTION D Work must be done with no smoking, in a well-ventilated area With short pipe, fit hose as far as it reaches pipe joint as shown. and away from any open flames. Hose D As fuel feed line (between fuel pump and fuel delivery pipe) is still under high fuel pressure even after engine was stopped, loosen-...
Page 781 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-5 FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, release fuel pressure as fol- lows.
Page 782 ECM memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool (Tech-1) (2) but also generic scan tool. (Diagnostic informa-...
Page 783 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-7 Warm-up Cycle A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22_C (40_F) from engine starting and reaches a minimum temperature of 70_C (160_F). Driving Cycle A “Driving Cycle”...
Page 784 Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) or generic scan tool to communicate with ECM. SUZUKI serial data line is used for SUZUKI scan tool (Tech-1) to Body ground communicate with immobilizer control module.
Page 785 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-9 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITHOUT EGR VALVE) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is run- ning, and indicates the result by turning on or flashing malfunction indicator lamp (1).
Page 786 ECM memory. D Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or ge- neric scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 787 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-11 D When connecting meter probe from terminal side of coupler be- cause it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection.
Page 788 6-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis referring to the complaint analysis.
Page 789 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-13 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 790 6-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS j Difficult Starting j Poor Driveability j No cranking j Hesitation on acceleration j No initial combustion j Back fire / jAfter fire j No combustion j Lack of power...
Page 791 5) After completing the check, turn ignition switch off and discon- nect scan tool from data link connector. [Without using SUZUKI scan tool] (Vehicle without EGR valve) 1) Check malfunction indicator lamp referring to “Malfunction Indi- cator Lamp Check” in this section.
Page 792 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool (Tech-1) to data link connector in the same manner as when making this connection for DTC check. 2) Turn ignition switch ON.
Page 793 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-17 DIAGNOSTIC TROUBLE CODE (DTC) TABLE (vehicle (vehicle DETECTING CONDITION DETECTING ITEM with without (DTC will set when detecting:) valve) valve) Low pressure-high vacuum-low voltage P0105 Manifold absolute pressure (or MAP sensor circuit shorted to ground) 1 driving 1 driving (No.11)
Page 794 6-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (vehicle (vehicle DETECTING CONDITION DETECTING ITEM with without (DTC will set when detecting:) valve) valve) flashing Misfire of such level as to cause damage to P0300 Random misfire detected during three way catalyst applicable P0301 Cylinder 1 misfire detected misfire...
Page 795 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-19 DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) P1620 ECU code not registered (No.84) P1621 No ECU code transmitted from Immobiliz- (No.83) er Control Module Refer to Section 8G Refer to Section 8G. P1622 Faulty in ECM (No.82)
Page 796 6-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS FAIL-SAFE TABLE 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. DETECTED ITEM FAIL-SAFE OPERATION (SYMPTOM) D ECM (PCM) uses value determined by throttle...
Page 797 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-21 VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil – – – – – level, leakage Section 0B D Engine coolant – – – – – level, leakage Section 0B D Fuel –...
Page 798 Section 6F. tor coupler to ground. See Fig. 2. When using SUZUKI scan tool, select “MISC” mode on SUZUKI scan tool and fix ignition timing to initial one. See Fig. 3. 2) Open the engine service hole cover behind the front seats and remove the inspection hole cap on the trans- mission case to observe ignition timing.
Page 799 Was injector operating sound heard from all injectors? Fig. 1 for Step 5 Fig. 2 for Step 6 Fig. 3 for Step 6 When not using SUZUKI scan tool: 1. Monitor connector When using SUZUKI scan tool 2. Fuse box Select “DATA...
Page 800 6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS ENGINE DIAGNOSIS TABLE Perform troubleshooting referring to following table when ECM has no DTC and no abnormality found in visual inspection and engine basic inspection previously. Condition Possible Cause Referring Item Hard Starting Ignition system out of order D Faulty ignition coil or high-tension cord (Engine cranks OK) Diagnosis in Section 6F.
Page 801 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-25 Condition Possible Cause Reference Item Engine has no power Engine overheating Refer to “Overheating” of this table. Ignition system out of order D Faulty ignition coil or high-tension cord Diagnosis in Section 6F. Engine and emission control system out of order.
Page 802 6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Engine hesitates Ignition system out of order D Faulty ignition coil or high-tension cords (Momentary lack of re- Diagnosis in Section 6F. sponse as the accelera- tor is depressed. Engine overheating Refer to “Overheating”...
Page 803 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-27 Condition Possible Cause Reference Item D Inoperative thermostat Overheating Thermostat in Section 6B. D Faulty radiator fan motor or its circuit Radiator fan control system check in Section 6E. D Loose or slip water pump belt ITEM1-1 Drive belt inspection and change in Section 0B.
Page 804 6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Excessive engine oil Oil entering combustion chamber D Sticky piston ring consumption Piston and cylinder in Section 6A. D Worn piston and cylinder Cylinders, pistons and piston rings in Section 6A.
Page 805 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-29 Condition Possible Cause Referring Item Excessive hydrocar- Ignition system out of order D Faulty ignition coil or high-tension cord bon (HC) emission or Diagnosis in Section 6F. Excessive carbon monoxide (CO) emis- Engine and Emission control system sion out of order.
Page 806 6-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS SCAN TOOL DATA As the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 807 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-31 SCAN TOOL DATA CONDITION REFERENCE VALUES DESIRED IDLE (DESIRED IDLE At idling with no load after warming up 750 r / min SPEED) TP SENSOR VOLT Throttle valve fully closed More than 0.1 V Ignition switch (THROTTLE POSITION ON/ engine...
Page 808 6-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS SCAN TOOL DATA DEFINITIONS FUEL SYSTEM (FUEL SYSTEM STATUS) MAF (MASS AIR FLOW RATE, gm/s, lb/min) Air/fuel ratio feedback loop status displayed as either It represents total mass of air entering intake manifold open or closed loop. Open indicates that ECM ignores which is computed based on signals from MAP sen- feedback from the exhaust oxygen sensor.
Page 809 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-33 CANIST PURGE DUTY (EVAP CANISTER FUEL PRES CONT VALVE (FUEL PRESSURE PURGE FLOW DUTY, %) CONTROL VALVE, ON/OFF) This parameter indicates valve ON (valve open) time ON : Fuel pressure control valve closes the passage rate within a certain set cycle of EVAP purge solenoid to intake manifold and open the air passage.
Page 810 6-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION OF ECM AND ITS CIRCUITS ECM and its circuits can be checked at ECM wiring connectors by measuring resistance. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with connec- tor disconnected from it.
Page 811 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-35 COMPONENT LOCATION 1. CO adjusting resistor (if equipped) a: MIL A: ECM 2. CMP sensor b: IAC valve B: A/C control module (if equipped) 3. HO2S-1 (if equipped) c: EVAP canister purge valve C: DLC 3-1.
Page 812 6-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON (BUT ENGINE AT STOP) CIRCUIT DESCRIPTION 1. Main fuse box 2. Ignition switch 3. Fuse box 4. Main relay 5.
Page 813 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-37 TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – LAMP REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION Diagnostic Trouble Code (DTC) check Go to Step 2 of ENGINE Go to Step 2.
Page 814 6-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE A-4 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – MIL DOES NOT FLASH, JUST REMAINS ON OR JUST REMAINS OFF EVEN WITH GROUNDING DIAGNOSIS SWITCH TERMINAL (VEHICLE WITH MONITOR CONNECTOR) WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to table A-1. INSPECTION STEP ACTION...
Page 815 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-39 TABLE A-5 ECM POWER AND GROUND CIRCUIT CHECK – MIL DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE DOESN’T START THOUGH IT IS CRANKED UP CIRCUIT DESCRIPTION 1. Main fuse box 2. Ignition switch 3.
Page 816 6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS STEP ACTION ECM Power Circuit Check Check ground circuits Go to Step 6. 1) Using service wire, ground terminal L20-8 and “BLK” and “BLK/BLU” measure voltage between terminal L20-2 and for open. ground at ignition switch ON. If OK, then substitute Is it 10 –...
Page 817 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-41 DTC P0105 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT (DTC No.11) MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D MAP sensor signal is 0.75 V or lower. D “BLU/YEL” circuit open D “LT GRN/RED” circuit open or shorted to ground (Low pressure –...
Page 818 6-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Check MAP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF.
Page 819 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-43 DTC P0110 (DTC No.18) INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low intake air temperature (High voltage-High resistance) D “LT GRN/BLK” circuit open or shorted to power. D High intake air temperature (Low voltage-Low resistance) D “BLU/YEL”...
Page 820 6-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch Check for intermittent OFF.
Page 821 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-45 DTC P0115 ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT (DTC No.19) MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low engine coolant temperature (High voltage-High resistance) D “LT GRN/WHT” circuit open or shorted D High engine coolant temperature (Low voltage-Low resistance) to power D “BLU/YEL”...
Page 822 6-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check ECT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent 2) Turn ignition switch ON.
Page 823 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-47 DTC P0120 (DTC No.13) THROTTLE POSITION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Signal voltage high D “BLU/YEL” circuit open D Signal voltage low D “GRY/YEL” circuit open or shorted to ground D “LT GRN/RED”...
Page 824 6-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Check TP Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch referring to “Intermittent...
Page 825 TABLE”. Check TP Sensor and Its Circuit. If OK, substitute a Go to Step 3. 1) Turn ignition switch OFF and connect SUZUKI scan tool to known-good ECM DLC. and recheck. 2) Turn ignition switch ON and check TP sensor output voltage when throttle valve is at idle position and fully opened.
Page 826 6-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS Fig. 1 for Step 2 Fig. 2 for Step 3 Closed Fully open (condition “A”) Throttle Opening...
Page 827 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-51 DTC P0130 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-1 (HO2S-1) DTC DETECTING CONDITION POSSIBLE CAUSE D When running at idle speed after engine warmed up D Heated oxygen sensor-1 malfunction D “BLU/YEL”, “BLU”...
Page 828 6-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than HO2S-1 Go to applicable DTC Go to Step 3. (DTC P0130)? Diag.
Page 829 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-53 DTC P0133 HEATED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE (SENSOR-1) WIRING DIAGRAM – Refer to DTC P0130 section. CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D When running at specified idle speed after engine D Heated oxygen sensor-1 malfunction warmed up and running at specified vehicle speed, response time (time to change from lean to rich or...
Page 830 6-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0134 (No.14) HEATED OXYGEN SENSOR (HO2S) CIRCUIT NO ACTIV- ITY DETECTED (SENSOR-1) WIRING DIAGRAM/CIRCUIT DESCRIPTION – Refer to DTC P0130 section. DTC DETECTING CONDITION POSSIBLE CAUSE D Engine warmed up. D “RED” or “BLU/YEL” circuit open or short D While running under other than high load and high D Heated oxygen sensor malfunction D Fuel system malfunction...
Page 831 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-55 DTC P0135 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-1) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-1 (HO2S-1) heater DTC DETECTING CONDITION POSSIBLE CAUSE D HO2S-1 heater circuit open or shorted to ground DTC will set when A or B condition is met. D ECM malfunction D Low voltage at terminal C23-6 when engine is running at high load.
Page 832 6-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go t o“ENGINE DIAG. FLOW TABLE”. Check HO2S-1 Heater Circuit. Intermittent trouble Go to Step 3. 1) Disconnect HO2S-1 electrical connector and ECM Check for intermittent electrical connectors with ignition switch OFF.
Page 833 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-57 DTC P0136 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-2 (HO2S-2) DTC DETECTING CONDITION POSSIBLE CAUSE D Exhaust gas leakage Engine is warmed up and HO2S-2 voltage is 4.5 V or more. D “RED”...
Page 834 6-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 835 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-59 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check exhaust system for leakage, loose Go to Step 3. Repair or replace. connection and damage. Is it good condition? Check HO2S-2 and Its Circuit.
Page 836 6-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0141 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-2) CIRCUIT DESCRIPTION 1. Heated oxygen sensor-2 (HO2S-2) heater DTC DETECTING CONDITION POSSIBLE CAUSE D HO2S-2 heater circuit open or shorted to DTC will set when A or B condition it met. A.
Page 837 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-61 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check HO2S-2 Heater Circuit. Intermittent trouble. Go to Step 3. 1) Disconnect HO2S-2 electrical connector and ECM Check for intermittent electrical connectors with ignition switch OFF.
Page 838 6-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0148 FUEL PRESSURE CONTROL VALVE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. Fuel pressure control valve DTC DETECTING CONDITION POSSIBLE CAUSE D “BLK/RED” circuit open or short Fuel pressure control valve circuit is opened or D “ORN/BLK”...
Page 839 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-63 DTC P0171 FUEL SYSTEM TOO LEAN DTC P0172 FUEL SYSTEM TOO RICH CIRCUIT DESCRIPTION [a]: Signal to decrease amount of fuel injection [b]: Signal to increase amount of fuel injection [c]: A/F mixture becomes leaner (Oxygen concentration increases) [d]: A/F mixture becomes richer (Oxygen concentration decreases)
Page 840 6-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester on a level road.
Page 841 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-65 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Is there DTC(s) other than fuel system Go to applicable Go to Step 3. (DTC P0171 / P0172)? DTC Diag.
Page 842 6-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS STEP ACTION Check engine coolant temp. sensor for performance Go to Step 9. Replace engine (See Section 6E). coolant temp. sensor. Is it in good condition? Check intake air temp. sensor for performance Go to Step 10. Replace intake air (See Section 6E).
Page 843 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-67 DTC P0300 RANDOM MISFIRE DETECTED (Misfire detected at 2 or more cylinders) DTC P0301 CYLINDER 1 MISFIRE DETECTED DTC P0302 CYLINDER 2 MISFIRE DETECTED DTC P0303 CYLINDER 3 MISFIRE DETECTED DTC P0304 CYLINDER 4 MISFIRE DETECTED 1.
Page 844 6-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC DETECTING CONDITION POSSIBLE CAUSE D Engine under other than high revolution condition D Engine overheating D Not on rough road D Vacuum leaks (air inhaling) from air intake system D Engine speed changing rate D Ignition system malfunction (spark plug(s), high- Below D Manifold absolute...
Page 845 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-69 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE“. Is there DTC other than Fuel system (DTC P0171 / P0172) and Go to applicable Go to Step 3.
Page 846 6-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS STEP ACTION Check PCV valve for clogging (See Section 6E). Go to Step 7. Replace PCV valve. Is it in good condition? Check EVAP Canister Purge Valve for Closing. Check EVAP control Go to Step 8. 1) Disconnect purge hose (1) from EVAP canister.
Page 847 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-71 DTC P0335 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT (DTC No.23) MALFUNCTION CIRCUIT DESCRIPTION 1. CKP sensing rotor 2. CKP sensor 3. CKP sensor connector 4. Shield wire 5. ECM connector (C23) 6. ECM DTC DETECTING CONDITION POSSIBLE CAUSE D NO CKP sensor signal for 2 seconds at engine crank- D CKP sensor circuit open or short.
Page 848 6-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION NOTE: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even though CKP sensor is in good condition. When starter motor fails to run and this DTC appears, check starter circuit first.
Page 849 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-73 DTC P0340 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION (DTC No.15) CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D The number of CMP sensor signal pulses is incorrect D CMP sensor circuit open or short. D Signal rotor teeth damaged.
Page 850 6-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check CMP Sensor and connector for proper installa- Go to Step 3. Correct. tion. Is CMP sensor installed properly and connector connected securely? Check Wire Harness and Connection.
Page 851 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-75 DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION CIRCUIT DESCRIPTION 1. EGR valve DTC DETECTING CONDITION POSSIBLE CAUSE D While running at specified vehicle speed after D EGR valve or its circuit D EGR passage engine warm-up D During deceleration (engine speed high with closed D ECM...
Page 852 6-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 853 Go to “ENGINE DIAG. FLOW TABLE”. EGR Valve Operation Check: Go to Step 3. Go to Step 4. 1) With ignition switch OFF, install SUZUKI scan tool. 2) Check EGR system referring to Section 6E. Is it in good condition? MAP Sensor Check: Intermittent trouble or Repair or replace.
Page 854 6-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD CIRCUIT DESCRIPTION 1. Heated oxygen sensor-1 2. Warm up three way catalytic converter 3. Three way catalytic converter 4. Heated oxygen sensor-2 5. To the sensor ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by HO2S-2.
Page 855 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-79 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 856 6-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0420 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Short Term Fuel Trim. Go to Step 3. Check fuel system. Did short term fuel trim vary within – 20% – +20% Go to DTC P0171/P0172 range in step 3) of DTC confirmation test? Diag.
Page 857 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-81 DTC P0443 PURGE CONTROL VALVE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. EVAP canister purge valve DTC DETECTING CONDITION POSSIBLE CAUSE D “GRN/YEL” circuit open or short Canister Purge control valve circuit is opened or D “BLK/RED” circuit open or short shorted.
Page 858 6-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0480 RADIATOR FAN CONTROL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal L20-11 when engine coolant D “RED/GRN” or “BLK/RED” circuit open or short D Radiator fan motor relay malfunction temp.
Page 859 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-83 DTC P0480 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. 1) With ignition switch OFF position, install SUZU- Radiator fan control sys- Go to Step3. KI scan tool.
Page 860 6-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0500 VEHICLE SPEED SENSOR (VSS) MALFUNCTION (DTC No.16) CIRCUIT DESCRIPTION 1. VSS 2. Combination meter 3. VSS connector DTC DETECTING CONDITION POSSIBLE CAUSE D VSS signal not inputted while vehicle running during D “BLK/YEL” circuit open D “YEL”...
Page 861 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-85 DTC P0500 INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Does speedometer indicate vehicle speed? Go to Step 3. Go to Step 4. Check Vehicle Speed Signal.
Page 862 6-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0505 IDLE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION 1. IAC valve 2. Main relay 3. Ignition switch 4. “IG COIL METER” fuse DTC DETECTING CONDITION POSSIBLE CAUSE D No closed signal to IAC valve is detected after D “BLK/RED”, “ORN”...
Page 863 Check Idle Air Control System. Intermittent trouble or Go to Step 3. When using SUZUKI scan tool: faulty ECM. 1) Connect SUZUKI scan tool to DLC with ignition Check for intermittent switch OFF, set parking brake and block drive referring to “Intermittent wheels.
Page 864 6-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P1450 BAROMETRIC PRESSURE SENSOR LOW/HIGH INPUT DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM WIRING DIAGRAM/CIRCUIT DESCRIPTION Barometric pressure sensor is installed in ECM. DTC DETECTING CONDITION POSSIBLE CAUSE D ECM (barometric pressure sensor) malfunction DTC P1450: D Barometric pressure sensor voltage is 4.7 V or higher, or 1.6 V or lower...
Page 865 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-89 STEP ACTION Check MAP Sensor Check air intake Replace MAP 1) Remove MAP sensor from intake manifold and connect system for air sensor. vacuum pump gauge to MAP sensor. See Fig. 1. being drawn in 2) Connect scan tool to DLC and turn ignition switch ON.
Page 866 6-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 1. Starter 2. Ignition switch (starter switch) 3. Main fuse DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal L20-31 when cranking D “BLK/YEL” circuit open D ECM malfunction engine or D High voltage at terminal L20-31 after starting engine.
Page 867 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-91 DTC P1510 ECM BACK-UP POWER SUPPLY MALFUNCTION CIRCUIT DESCRIPTION 1. Main fuse 2. Fuse box Battery voltage is supplied so that diagnostic trouble code memory, values for engine control learned by ECM, etc. are kept in ECM even when the ignition switch is turned OFF. DTC DETECTING CONDITION POSSIBLE CAUSE D Low voltage at terminal L20-12 after starting engine.
Page 868 6-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE B-1 FUEL INJECTOR CIRCUIT CHECK 1. No.1 injector 2. No.2 injector 3. No.3 injector 4. No.4 injector INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”.
Page 869 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-93 TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK 1. Ignition switch 2. Main relay 3. Main relay 4. Main fuse 5. Fuel pump relay 6. Fuel pump INSPECTION STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2.
Page 870 6-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS Fig. 1 for Step 2 Fig. 2 for Step 3 Fig. 3 for Step 4...
Page 871 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-95 TABLE B-3 FUEL PRESSURE CHECK 1. Injector 2. Delivery pipe 3. Fuel pump 4. Fuel filter 5. Fuel pump (A): Fuel pressure gauge (B): Hose (C): Attachment INSPECTION STEP ACTION Check Fuel Pressure (Refer to Section 6E for details). Go to Step 2.
Page 872 Go to Step 6. Repair or replace A/C 1 of Table B-5 A / C Signal Circuit Check, if signal circuit or A/C equipped. (A/C signal can be also checked by system. using SUZUKI scan tool.) Is it in good condition?
Page 873 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-97 STEP ACTION Check IAC system referring to Step 2 of DTC P0505 Go to Step 7. Go to Step 3 of DTC Diag. Flow Table. P0505 Diag. Flow Is check result satisfactory? Table. Was IAC duty less than about 3% (or more than about Check abnormal air Check TP sensor 97% for OFF duty meter) in Step 1 of this table?
Page 874 6-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE B-5 A/C SIGNAL CIRCUITS CHECK (VEHICLE WITH A/C) 1. A/C control module 2. A/C control module connector 3. ECM connector 4. ECM SYSTEM DESCRIPTION A/C control module transmits “A/C signal” to ECM when A/C ON conditions are satisfied on the A/C control module side.
Page 875 INSPECTION STEP ACTION Check Electric Load Signal Circuit. Electric load signal “RED/WHT” and/or 1) Connect SUZUKI scan tool to DLC with ignition switch circuit is in good “RED/YEL” circuit OFF. condition. open or short, Elec- 2) Start engine and select “DATA LIST” mode on scan tool.
Page 876 6-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS TABLE B-7 RADIATOR FAN CONTROL SYSTEM CHECK INSPECTION STEP ACTION Check Fan Control System. Radiator fan con- Go to Step 2. 1) Connect scan tool to DLC with ignition switch OFF. trol system is in 2) Start engine and select “DATA LIST”...
Page 877 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-101 Fig. 1 for Step 3 Fig. 2 for Step 4 1. Main fuse box 2. Fuel pump relay 3. Main relay 4. Radiator fan relay 1. Radiator cooling fan 2. Radiator cooling fan connector...
Page 878 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09917-47911 09930-88530 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1 A) kit 09931-76030 09932-76010 Mass storage cartridge 16 / 14 pin DLC cable Connector test adapter kit...
Page 879 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 880 6A-2 ENGINE MECHANICAL ON-VEHICLE SERVICE ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT -11. Camshaft -12. Camshaft oil seal -13. Rocker arm shaft -14. O-ring -15. Rocker shaft bolt -16. Rocker arm (IN) -17. Rocker arm No. 1 (EX) -18. Rocker arm No. 2 (EX) -19.
Page 881 ENGINE MECHANICAL 6A-3 UNIT REPAIR OVERHAUL ENGINE ASSEMBLY INSTALLATION 1) Combine engine with transmission. 2) Tighten engine mounting bracket bolts (R & L) and rear mount- ing nut as shown in the figure above. 3) Reverse removal procedure for installation. D Install generator bracket, A/C compressor and generator re- ferring to Section 1B and 6H.
Page 882 6A-4 ENGINE MECHANICAL 4) Adjust generator drive belt tension, referring to BELT TEN- SION INSPECTION in Section 6H. 5) Adjust A/C compressor belt tension, if equipped. Refer to Sec- tion 1B. 6) Connect gear shift cables to gear shift control lever, refer to GEAR SHIFT CONTROL INSTALLATION in Section 7A.
Page 883 ENGINE MECHANICAL 6A-5 MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 7. Crankshaft 12. Oil seal housing 2. Front oil seal 8. Thrust bearing 13. Housing bolt 3. Main bearing 9. Rear oil seal 14. Input shaft bearing 4. Bearing cap 10.
Page 884 6A-6 ENGINE MECHANICAL INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing and journal bearing caps installed.
Page 885 ENGINE MECHANICAL 6A-7 Main Bearings General information D Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. D Upper half of bearing has oil groove as shown in figure. Install this half with oil groove to cylinder block.
Page 886 6A-8 ENGINE MECHANICAL 5) Remove cap and using scale on gaging plastic envelope, mea- sure gaging plastic width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
Page 887 ENGINE MECHANICAL 6A-9 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent following cap bore diameters. Bearing cap bore diameter Alphabet stamped (without bearing) 49.000 –...
Page 888 6A-10 ENGINE MECHANICAL 4) From numerals stamped on crank webs of No.2 and No.3 cylin- ders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to jour- nal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
Page 889 ENGINE MECHANICAL 6A-11 D If necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 44.732 – 44.750 mm (1.7611 – 1.7618 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicu- lar to each other in order to check for out-of-round.
Page 890 6A-12 ENGINE MECHANICAL Flywheel D If ring gear is damaged, cracked or worn, replace flywheel. D If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. D Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout: 0.2 mm (0.0078 in.) Cylinder Block Distortion of gasketed surface...
Page 891 ENGINE MECHANICAL 6A-13 5) Rebore and hone cylinder to calculated dimension. NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores. 6) Measure piston clearance after honing.
Page 892 ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in the FOREWORD of this manual. MAINTENANCE COOLING SYSTEM SERVICE WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot.
Page 893 D 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” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 894 6E-2 ENGINE AND EMISSION CONTROL SYSTEM Vehicle Speed Sensor ....6E-32 EGR System ......6E-36 Main Relay, Fuel Pump Relay and EVAP Control System...
Page 895 ENGINE AND EMISSION CONTROL SYSTEM 6E-3...
Page 896 6E-4 ENGINE AND EMISSION CONTROL SYSTEM...
Page 897 ENGINE AND EMISSION CONTROL SYSTEM 6E-5...
Page 898 6E-6 ENGINE AND EMISSION CONTROL SYSTEM AIR INTAKE SYSTEM The main components of the air intake system are air distributed by the intake manifold (5) and finally drawn cleaner (1), air cleaner outlet hose (2), throttle body into each combustion chamber. (3), idle air control valve (4) and intake manifold (5).
Page 899 ENGINE AND EMISSION CONTROL SYSTEM 6E-7 FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank (1), pressure in the fuel feed line) is always kept a certain fuel pump (2), fuel filter (3), fuel pressure regulator amount higher than the pressure in the intake manifold (11), delivery pipe (9) and fuel injectors (10).
Page 900 6E-8 ENGINE AND EMISSION CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM D Idle speed control system The electronic control system consists of 1) various D Fuel pump control system sensors which detect the state of engine and driving D A/C control system (if equipped) conditions, 2) ECM which controls various devices ac- D Radiator fan control system cording to the signals from the sensors and 3) various...
Page 901 ENGINE AND EMISSION CONTROL SYSTEM 6E-9 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE ELECTRIC CONTROL DEVICE OUTPUT INPUT DIAGNOSIS SWITCH TERMINAL (VEHICLE WITHOUT EGR VALVE) BAROMETRIC PRESSURE SENSOR (VEHICLE WITH EGR VALVE) STOP LAMP SWITCH STARTER SWITCH f f f f f f f IGNITION SWITCH LIGHTING SWITCH REAR DEFOGGER SWITCH (IF EQUIPPED)
Page 902 6E-10 ENGINE AND EMISSION CONTROL SYSTEM...
Page 903 ENGINE AND EMISSION CONTROL SYSTEM 6E-11 CON- CON- TERMINAL WIRE COLOR CIRCUIT TERMINAL WIRE COLOR CIRCUIT NECTOR NECTOR BRN/BLK No.1 fuel injector Heater of HO2S-2 (if equipped) BRN/WHT No.3 fuel injector BLK/RED Power source – – BLK/RED Power source ORN/BLK Fuel pressure control valve –...
Page 904 6E-12 ENGINE AND EMISSION CONTROL SYSTEM ON-VEHICLE SERVICE ACCELERATOR CABLE ADJUSTMENT 1) With throttle valve closed, check accelerator pedal play which should be within following specification. Pedal play “a”: 2 – 7 mm (0.08 – 0.27 in.) If measured value is out of specification, adjust it to specification 1.
Page 905 ENGINE AND EMISSION CONTROL SYSTEM 6E-13 1) Connect SUZUKI scan tool to DLC with ignition switch OFF, if When using SUZUKI scan tool: it is available. 2) Warm up engine to normal operating temperature. 3) Check engine idle speed and “IAC duty” as follows: When using SUZUKI scan tool: a) Select “Data List”...
Page 906 6E-14 ENGINE AND EMISSION CONTROL SYSTEM IDLE MIXTURE INSPECTION/ADJUSTMENT (VEHICLE WITHOUT HEATED OXYGEN SEN- SOR) All vehicles not equipped with heated oxygen sensor are shipped with their CO% factory adjusted as follows. Engine idle mixture 0.5 – 1.5 % at specified idle speed (CO %) Idle mixture adjustment should never be changed from the original factory setting.
Page 907 ENGINE AND EMISSION CONTROL SYSTEM 6E-15 AIR INTAKE SYSTEM THROTTLE BODY 1. Throttle body 2. Accelerator cable bracket 3. MAP sensor 4. TP sensor 5. IAC valve 6. Coolant hoses : Do not reuse 7. Gasket ON-VEHICLE INSPECTION Check that throttle valve lever (1) moves smoothly. REMOVAL 1) Disconnect negative cable at battery.
Page 908 6E-16 ENGINE AND EMISSION CONTROL SYSTEM 5) Disconnect electric connector from TP sensor (1), MAP sensor (3) and IAC valve (2). 6) Remove throttle body (4) from intake manifold. 7) Disconnect engine coolant hoses from throttle body. DISASSEMBLY NOTE: While disassembling and assembling throttle body, use spe- cial care not to deform levers on throttle valve shaft or cause damage to any other parts.
Page 909 ENGINE AND EMISSION CONTROL SYSTEM 6E-17 2) Connect engine coolant hoses. 3) Install throttle body (4) and accelerator cable bracket to intake manifold and tighten bolts and nuts to specified torque. 4) Connect connectors to TP sensor (1), MAP sensor (3) and IAC valve (2) securely.
Page 910 6E-18 ENGINE AND EMISSION CONTROL SYSTEM IDLE AIR CONTROL VALVE (IAC VALVE) REMOVAL 1) Remove throttle body from intake manifold referring to “Throttle Body Removal” in this section. 2) Remove IAC valve from throttle body. INSPECTION 1) Connect each connector to IAC valve (1), TP sensor and MAP sensor.
Page 911 ENGINE AND EMISSION CONTROL SYSTEM 6E-19 FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure”...
Page 912 6E-20 ENGINE AND EMISSION CONTROL SYSTEM 9) Remove special tools from fuel delivery pipe. 10) Connect fuel feed hose to fuel delivery pipe and clamp it se- curely. 11) With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP ON-VEHICLE INSPECTION CAUTION:...
Page 913 ENGINE AND EMISSION CONTROL SYSTEM 6E-21 INSTALLATION 1) Install fuel pump to its bracket. 2) Install fuel pump to fuel tank and then install fuel tank to body according to procedure described in Section 6C. FUEL PRESSURE REGULATOR ON-VEHICLE INSPECTION Perform fuel pressure inspection according to procedure de- scribed in “Fuel Pressure Inspection”...
Page 914 6E-22 ENGINE AND EMISSION CONTROL SYSTEM INSTALLATION For installation, reverse removal procedure and note following pre- cautions. D Use new O-ring (1). D Apply thin coat of gasoline to O-ring to facilitate installation. D Tighten fuel pressure regulator bolts to specified torque. Tightening Torque (a): 10 N m (1.0 kg-m, 7.5 lb-ft)
Page 915 ENGINE AND EMISSION CONTROL SYSTEM 6E-23 REMOVAL 1) Relieve fuel pressure according to procedure described in Sec- tion 6. 2) Disconnect battery negative cable at battery. 3) Disconnect fuel injector couplers and release wire harness from clamps. 4) Remove fuel delivery pipe bolts (1). 5) Remove fuel injector(s) (2) from delivery pipe and intake man- ifold.
Page 916 6) Operate fuel pump and apply fuel pressure to injector as fol- lows: When using SUZUKI scan tool (for vehicle with EGR valve): a) Connect SUZUKI scan tool to DLC with ignition switch OFF. b) Turn ignition switch ON, clear DTC and select “MISC TEST” mode on SUZUKI scan tool.
Page 917 ENGINE AND EMISSION CONTROL SYSTEM 6E-25 INSTALLATION For installation, reverse removal procedure and note following pre- cautions. D Replace injector O-ring (1) with new one using care not to dam- age it. D Check if cushion (3) is scored or damaged. If it is, replace with new one.
Page 918 6E-26 ENGINE AND EMISSION CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE (ECM) CAUTION: As ECM consists of precision parts, be careful not to ex- pose it to excessive shock. REMOVAL 1) Disconnect battery negative cable at battery. 2) Disable air bag system, refer to “DISABLING THE AIR BAG SYSTEM”...
Page 919 ENGINE AND EMISSION CONTROL SYSTEM 6E-27 INSTALLATION Reverse removal procedure noting the followings: D Replace O-ring (2) with new one. D Connect MAP sensor connector (1) securely. THROTTLE POSITION SENSOR (TP SENSOR) INSPECTION 1) Disconnect negative cable at battery and connector from TP sensor.
Page 920 6E-28 ENGINE AND EMISSION CONTROL SYSTEM REMOVAL 1) Disconnect battery negative cable at battery. 2) Disconnect connector from TP sensor. 3) Remove TP sensor from throttle body. INSTALLATION 1) Install TP sensor (1) to throttle body. Fit TP sensor to throttle body in such way that its holes (3) are a little away from TP sensor screw holes (2) and turn TP sensor clockwise so that those holes align.
Page 921 ENGINE AND EMISSION CONTROL SYSTEM 6E-29 INSTALLATION Reverse removal procedure noting the following. D Clean mating surfaces of IAT sensor and air cleaner case. D Connect IAT sensor connector (1) securely. 1. IAT sensor 2. Air cleaner case ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) REMOVAL 1) Disconnect battery negative cable at battery.
Page 922 6E-30 ENGINE AND EMISSION CONTROL SYSTEM INSTALLATION Reverse removal procedure noting the following: D Clean mating surfaces of ECT sensor (1) and intake manifold. D Replace O-ring with new one. D Tighten ECT sensor (1) to specified torque. Tightening Torque (a): 15 N m (1.5 kg-m, 11.5 lb-ft) D Connect connector to ECT sensor (1) securely.
Page 923 ENGINE AND EMISSION CONTROL SYSTEM 6E-31 1) Disconnect negative cable at battery. Sensor-1 2) Hoist vehicle when removing sensor-2. 3) Disconnect connector of heated oxygen sensor and release its wire harness from clamp. 4) Remove heated oxygen sensor (1) from exhaust manifold or ex- haust No.1 pipe.
Page 924 6E-32 ENGINE AND EMISSION CONTROL SYSTEM CRANKSHAFT POSITION SENSOR (CKP SENSOR) INSPECTION Check CKP sensor referring to step 1 and 2 of DTC P0335 (No.23) Flow Table in Section 6. If malfunction is found, replace. REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect connector from CKP sensor (1).
Page 925 ENGINE AND EMISSION CONTROL SYSTEM 6E-33 MAIN RELAY, FUEL PUMP RELAY AND RADIATOR FAN CONTROL RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove main relay (3), fuel pump relay (2) and radiator fan con- trol relay (4) from main fuse box (1). 3) Check that there is no continuity between terminal “A”...
Page 926 6E-34 ENGINE AND EMISSION CONTROL SYSTEM RADIATOR FAN CONTROL SYSTEM SYSTEM INSPECTION WARNING: Keep hands, tools, and clothing away from radiator 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 ECM (and ECT sensor) with the ignition switch in the “ON”...
Page 927 ENGINE AND EMISSION CONTROL SYSTEM 6E-35 FUEL PRESSURE CONTROL VALVE INSPECTION 1) Disconnect negative cable at battery and connector from fuel pressure control valve. 2) Check resistance between two terminals of fuel pressure con- trol valve. Resistance of fuel pressure control valve: 37 – 44 W at 205C (685F) If resistance is as specified, proceed to next operation check.
Page 928 EMISSION CONTROL SYSTEM EGR SYSTEM (IF EQUIPPED) SYSTEM INSPECTION 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and then select “DATA LIST” mode on scan tool. 3) Make sure that vehicle condition is as following.
Page 929 ENGINE AND EMISSION CONTROL SYSTEM 6E-37 INSPECTION 1) Check resistance between following terminals of EGR valve (1) in each pair. Terminal Standard resistance A – B 20 – 24 W C – B F – E at 205C, 685F D – E If found faulty, replace EGR valve assembly.
Page 930 6E-38 ENGINE AND EMISSION CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EVAP CANISTER PURGE INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in neutral position and that parking brake lever is pulled all the way up. 1) Disconnect purge hose (1) from EVAP canister.
Page 931 ENGINE AND EMISSION CONTROL SYSTEM 6E-39 EVAP CANISTER PURGE VALVE INSPECTION Check EVAP canister purge valve referring to step 1 of DTC P0443 Flow Table. If found malfunction, replace. EVAP CANISTER INSPECTION WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor in- side EVAP canister is harmful.
Page 932 7. DLC cable adaptor 8. Self-test adaptor 09917-47911 09930-88530 09931-76011 Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech 1A) kit 09931-76030 Mass storage cartridge 16 / 14 pin DLC cable TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts...
Page 933 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 934 6F-2 IGNITION SYSTEM GENERAL DESCRIPTION The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. D 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 935 IGNITION SYSTEM 6F-3 SYSTEM WIRING DIAGRAM 1. Ignition switch 6. CKP sensor 12. Sensed information D MAP sensor D Electric load signal 2. Main relay 7. No.1 spark plug D ECT sensor D Engine start signal 3. Ignition coil assembly 8.
Page 936 6F-4 IGNITION SYSTEM DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will No spark or abnormal spark D Blown fuse for ignition coil not start or hard to start Replace. D Loose connection or disconnection of lead wire or Connect securely. high-tension cord(s) D Faulty high-tension cord(s) Replace.
Page 937 IGNITION SYSTEM 6F-5 STEP ACTION Ignition Coil Assembly Power Supply and Ground Go to Step 7. Repair or replace. Circuit Check 1) Check ignition coil assembly power supply (“BLK/WHT” wire) and ground circuit (“BLK” wire) for open and short. Are circuits in good condition? Ignition Coil Assembly Check Go to Step 8.
Page 938 6F-6 IGNITION SYSTEM ON-VEHICLE SERVICE IGNITION SPARK TEST 1) Place transmission gear shift lever in “ Neutral”, set parking brake, and block drive wheels. 2) Disconnect injector couplers and ignition coil couplers. WARNING: If the injector couplers are not disconnected, com- bustible gas will come out of the spark plug holes dur- ing this test and the vehicle can get fire .
Page 939 IGNITION SYSTEM 6F-7 HIGH-TENSION CORD REMOVAL 1) Remove high-tension cord from ignition coil assembly while gripping its cap. 2) Pull out high-tension cord from spark plug while gripping its cap. CAUTION: Pull out each connection by gripping cap portion so as not to damage their inside wire (resistive conduc- tor).
Page 940 D Before starting engine, shift transmission to “Neutral” and set parking brake. INSPECTION 1) When using SUZUKI scan tool, connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool)
Page 941 IGNITION SYSTEM 6F-9 5) Fix ignition timing to initial one as follows: [Using SUZUKI scan tool] Select “MISC TEST” mode on SUZUKI scan tool and fix ignition timing to initial one. [Not using SUZUKI scan tool] (Vehicle without EGR valve) 1.
Page 942 D Test switch signal circuit (if equipped) D VSS 9) After checking Initial Ignition Timing, release ignition timing fixation by using SUZUKI scan tool or disconnect service wire from monitor connector. 10) With engine idling (initial ignition timing not fixed, throttle open- ing at closed position and car stopped), check that ignition tim- ing fluctuates between 65 –...
Page 943 4. DLC cable (14/26 pin, 09931-76040) 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09930-76420 09931-76011 Mass storage cartridge Timing light (Dry cell type) SUZUKI scan tool (Tech 1A) kit 09931-76030 16/14 pin DLC cable...
Page 944 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 945 6H-2 CHARGING SYSTEM GENERAL DESCRIPTION GENERATOR 1. Pulley 2. Pulley nut 3. Rotor fan 4. Stator coil 5. Stator core 6. Field coil B : Generator output (Battery terminal) 7. Regulator D : Dummy terminal 8. Brush E : Ground 9.
Page 946 CHARGING SYSTEM 6H-3 DIAGNOSIS GENERATOR UNDERCHARGED BATTERY This condition, as evidenced by slow cranking or indicator clear with red dot can be caused by one or more of the following condi- tions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and amme- Ammeter between generator (B) ter.
Page 947 6H-4 CHARGING SYSTEM Higher Voltage If voltage is higher than standard value, check ground of brushes. If brushes are not grounded, replace IC regulator. Lower Voltage If voltage is below or in standard value, increase engine speed up to 2000 – 2500 rpm soon after starting engine with all electrical loads on, and read maximum value on ammeter immediately.
Page 948 CHARGING SYSTEM 6H-5 UNIT REPAIR OVERHAUL DISASSEMBLY AND REASSEMBLY 1. Pulley nut 2. Pulley 3. Bolt 4. Housing bolt 5. Front housing 6. Bearing 7. Retainer 8. Rotor 9. Stator 10. IC regulator 11. Brush 12. Rectifier 13. Rear housing 14.
Page 949 6H-6 CHARGING SYSTEM INSPECTION Rotor 1) Using ohmmeter, check for continuity between slip rings of ro- tor. If there is no continuity, replace rotor. Standard resistance: 2.3 – 2.7 W 1. Rotor 2) Using ohmmeter, check that there is no continuity between slip ring and rotor core.
Page 950 CHARGING SYSTEM 6H-7 Rectifier 1) Using ohmmeter, check continuity between each of upper and lower rectifier heatsinks and each diode lead. Check both directions by reversing probes of ohmmeter and there should be only one-way continuity in each case. If check result is not satisfactory, replace rectifier. 2) In the same manner as described in above step 1), check that there is only one-way continuity between both leads of diode trio.
Page 951 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM NOTE: D For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. D Whether following parts are used in the particular vehicle or not depends on specification. ON-VEHICLE SERVICE CAUTION: Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle.
Page 952 D 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” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 953 8-2 BODY ELECTRICAL SYSTEM ON-VEHICLE SERVICE HEADLIGHT HEADLIGHT SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH/CONTACT COIL AND COM- BINATION SWITCH ASSEMBLY in Section 3C. INSPECTION Use an ohmmeter to check the continuity at each switch position shown below. If any continuity is not obtained, replace combination switch (1).
Page 954 BODY ELECTRICAL SYSTEM 8-3 TURN SIGNAL AND HAZARD WARNING LIGHTS TURN SIGNAL LIGHT SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH/CONTACT COIL AND COM- BINATION SWITCH ASSEMBLY in Section 3C. INSPECTION Use an ohmmeter to check the continuity at each switch position shown below.
Page 955 8-4 BODY ELECTRICAL SYSTEM WINDSHIELD WIPER AND WASHER COMPONENTS FRONT WIPER AND WASHER 1. Wiper blade 2. Wiper arm 3. Wiper link 4. Wiper motor 5. Front washer nozzle 6. Front washer hose 7. Rear washer hose (if equipped) 8. Front washer pump 9.
Page 956 BODY ELECTRICAL SYSTEM 8-5 FRONT WIPER AND WASHER SWITCH REMOVAL AND INSTALLATION Refer to “COMBINATION SWITCH/CONTACT COIL AND COM- BINATION SWITCH ASSEMBLY” in Section 3C. INSPECTION Use a circuit tester to check the continuity at each switch position as shown below. If any continuity is not obtain, replace combination switch (1).
Page 957 8-6 BODY ELECTRICAL SYSTEM INTERMITTENT WIPER RELAY CIRCUIT (IF EQUIPPED) INSPECTION 1) Disconnect negative cable (–) at battery. 2) Disconnect combination switch lead wire coupler. 3) Turn the front wiper switch to INT position. 4) Connect battery positive terminal (+) to terminal “B3” and bat- tery negative terminal (–) to terminal “HE”.
Page 958 BODY ELECTRICAL SYSTEM 8-7 WASHER TANK AND WASHER PUMP REMOVAL 1) Disconnect battery (–) cable. 2) Remove washer tank (1) fitting screws. 3) Disconnect pump lead wire coupler and hose. 4) Remove washer tank (1). 5) Remove front washer pump (2) and rear washer pump (3) (if equipped).
Page 959 8-8 BODY ELECTRICAL SYSTEM Type 2: On Instrument Panel Check for continuity between terminals at each switch position as shown below. If check result is not as specified, replace. Terminal Wiper & Wiper Washer SW Washer ON Washer ON REAR WASHER PUMP (IF EQUIPPED) Refer to “WASHER TANK AND WASHER PUMP”...
Page 960: Immobilizer Control System
D 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” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 961 8G-2 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) PROCEDURE AFTER ECM SPECIAL TOOLS ..... . . 8G-28 REPLACEMENT ......8G-27 GENERAL DESCRIPTION The immobilizer control system designed to prevent vehicle bur-...
Page 962: Ignition Key
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-3 1. Coil antenna 2. Immobilizer Control Module 3. ECM 4. Immobilizer diagnostic coupler 4-1. Diagnostic output terminal 4-2. Ground terminal 5. Malfunction indicator lamp 6. Main relay 7. Ignition switch 8. Fuse 9. Main fuse 10.
Page 963 8G-4 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) IMMOBILIZER CONTROL MODULE Immobilizer Control Module is installed to the underside of the instrument panel at the driver’s seat side. As main functions, Immobilizer Control Module checks matching not only between the Transponder Code transmitted from the igni- tion key and that registered in Immobilizer Control Module (Up to 4 different Transponder codes can be registered.) but also be- tween the ECM/Immobilizer Control Module code transmitted from...
Page 964 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-5 With the diagnosis switch terminal of monitor coupler for ECM not grounded, the ignition switch turned ON (but the engine at stop) and regardless of the condition of the engine and emission control system, ECM indicates whether a trouble has occurred in the im- mobilizer control system or not by causing the malfunction indica- tor lamp to flash or turn ON.
Page 965 PRECAUTIONS IN DIAGNOSING TROUBLES PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE D Before identifying diagnostic trouble code indicated by malfunction indicator lamp or Suzuki scan tool, don’t dis- connect couplers from ECM, battery cable from battery, ECM ground wire harness from engine.
Page 966 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-7 DIAGNOSTIC FLOW TABLE STEP ACTION D If malfunction indicator lamp 1) Make sure that diagnosis switch terminal in Go to Step 3. monitor coupler is not grounded by service remains ON, go to Step 2. D If malfunction indicator lamp wire.
Page 967 8G-8 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DIAGNOSTIC TROUBLE CODE (DTC) CHECK (IMMOBILIZER CONTROL MODULE) 1) Using analog type voltmeter, connect positive probe to diagnos- tic output terminal and negative probe to ground of immobilizer diagnostic coupler with ignition switch turned ON. 2) Read deflection of voltmeter indicator which represents DTC as shown in example below and write it down.
Page 968 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-9 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (ECM) [Not using SUZUKI scan tool] 1) Using service wire, ground diagnostic switch terminal in monitor coupler. 2) Read DTC from flashing pattern of malfunction indicator lamp as shown in example below and write it down. For details of DTC, refer to ECM side in “Diagnostic Trouble Code Table”.
Page 969 (C): 09931-76030 (16/14 pin DLC cable) 3) Turn ignition switch ON. 4) Read DTC stored in ECM according to instructions displayed on Suzuki scan tool and print it or write it down. Refer to Suzuki scan tool operator’s manual for further details. NOTE: D When reading DTC stored in ECM using Suzuki scan tool, select “ECM”...
Page 970 To learn how to read diagnostic trouble code (DTC) from flashing of malfunction indicator lamp, refer to Section Malfunction Indicator lamp (indicated (indicated DIAGNOSTIC AREA DIAGNOSIS on Suzuki (MIL) flashing pattern by MIL) scan tool) This code appears when it is confirmed that...
Page 971 8G-12 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) TABLE A DTC IS NOT OUTPUT FROM DIAGNOSTIC OUTPUT TERMINAL 1. Main fuse 2. Main relay 3. Immobilizer Control Module 4. Immobilizer diagnostic coupler 4-1. Ground terminal 4-2. Diagnostic output terminal 5. To ECM STEP ACTION Check voltage between E64-2 terminal...
Page 972 Control Module match when ignition switch is ON. If they do not, DTC 11 is set. INSPECTION: Register ignition key with built-in transponder by using SUZUKI scan tool and performing following steps. 1) Register Transponder code in Immobilizer Control Module by performing procedure described in “How To Reg- ister Ignition Key”.
Page 973 8G-14 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC13 NO TRANSPONDER CODE TRANSMITTED OR COIL ANTENNA OPENED/SHORTED 1. Main fuse 2. Main relay 3. Immobilizer Control Module 4. Coil antenna 5. To ECM DESCRIPTION: Immobilizer Control Module energizes the coil antenna when the ignition switch is ON and reads Transponder code from the ignition key.
Page 974 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-15 STEP ACTION D “G/B” or “G” wire 1) Connect coil antenna coupler. Go to Step 8. 2) Is there continuity between Im- open D Poor coil anten- mobilizer Control Module coupler terminals E64-4 and E64-3? na-to-coupler (See Fig.
Page 975 8G-16 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC21 ECM/IMMOBILIZER CONTROL MODULE CODE NOT MATCHED (IMMOBILIZER CONTROL MODULE SIDE) DTC81 ECM/IMMOBILIZER CONTROL MODULE CODE NOT MATCHED (P1623) (ECM SIDE) DTC84 ECM/IMMOBILIZER CONTROL MODULE CODE NOT REGISTERED (P1620) DESCRIPTION: D DTC21 Immobilizer Control Module checks if ECM/Immobilizer Control Module code transmitted from ECM and that registered in Immobilizer Control Module match when ignition switch is ON.
Page 976 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-17 DTC22 IGNITION SWITCH CIRCUIT OPEN/SHORT 1. Main fuse 2. Ignition switch 3. Immobilizer Control Module DESCRIPTION: Immobilizer Control Module monitors ignition signal when the ignition switch is ON. This DTC is set when no ignition signal input is detected by Immobilizer Control Module.
Page 977 8G-18 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC23 NO ECM/IMMOBILIZER CONTROL MODULE CODE TRANSMITTED FROM ECM OR DLC CIRCUIT OPENED/SHORTED DTC83 NO ECM/IMMOBILIZER CONTROL MODULE CODE TRANSMITTED (P1621) FROM IMMOBILIZER CONTROL MODULE OR DLC CIRCUIT OPENED/SHORTED 1. Immobilizer Control Module 2. ECM DESCRIPTION: When the ignition switch is ON, Immobilizer Control Module requests ECM and ECM requests Immobilizer Control Module to transmit ECM/Immobilizer Control Module code.
Page 978 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-19 Fig. 1 for step 1 1. Immobilizer Control Module Fig. 2 for step 2 Connect to serial data link terminal (L20-9) of ECM coupler disconnected 1. Immobilizer Control Module coupler disconnected...
Page 979 8G-20 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) INSPECTION OF ECM, IMMOBILIZER CON- TROL MODULE AND ITS CIRCUIT ECM, Immobilizer Control Module and its circuit can be checked at ECM wiring couplers and Immobilizer Control Module wiring coupler by measuring voltage. Described here is only inspection of Immobilizer Control Module.
Page 980 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-21 Resistance Check 1) Disconnect Immobilizer Control Module couplers from Immobi- lizer Control Module with ignition switch OFF. CAUTION: Never touch terminals of Immobilizer Control Module itself or connect voltmeter or ohmmeter. 2) Check resistance between each terminal of couplers discon- nected.
Page 981 8G-22 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) ON-VEHICLE SERVICE PRECAUTIONS IN HANDLING IMMOBILIZER CONTROL SYSTEM D Don’t turn ON ignition switch with ignition key for immobilizer control system put together with another one or placed quite close to another one. Or the system may detect abnormal condi- tion and prevent engine from starting.
Page 982 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-23 IMMOBILIZER CONTROL MODULE Removal 1) Disconnect negative (–) cable at battery. 2) Disconnect coupler at Immobilizer Control Module. 3) Remove immobilizer control module. Installation Reverse removal procedure for installation. NOTE: After replacing Immobilizer Control Module, be sure to regis- ter Transponder code and ECM/Immobilizer Control Module code in Immobilizer Control Module and ECM/Immobilizer Control Module code in ECM by performing procedure de-...
Page 983 Control Module by using the following procedure. 1) Prepare SUZUKI scan tool and cartridge for immobilizer control system. 2) With ignition switch OFF, connect SUZUKI scan tool to data link connector (DLC) located on underside of instrument panel at driver’s seat side.
Page 984 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-25 5) Using SUZUKI scan tool, register Transponder code in Immobi- lizer Control Module by executing “ENT. TRANS COD (ENT. TP CODE)” command in SELECT MODE menu. 6) Make sure that malfunction indicator lamp lights when ignition switch is turned OFF once and then ON.
Page 985 2) Prepare ignition key with a built-in transponder. And then turn ignition switch ON by using it. 3) Using SUZUKI scan tool, clear all transponder codes registered in Immobilizer Control Module by executing “CLR. TRANS COD (CLEAR TP CODE)” command in SELECT MODE menu.
Page 986 Module code in ECM by executing “RECORD ECU (RECORD ECM/lCM)” command in SELECT MODE menu. NOTE: For operation procedure of SUZUKI scan tool, refer to SU- ZUKI scan tool operator’s manual. 3) Make sure that malfunction indicator lamp lights when ignition...
Page 987 5. Test lead/probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09931-76011 09931-76030 Immobilizer cartridge of SUZUKI scan tool (Tech 1A) kit 16/14 pin DLC cable version 1.1 or more Mass storage cartridge of version 1.6 or more...
Page 988 D 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 of GENERAL DESCRIPTION in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 989 9-2 BODY SERVICE METAL REPLACE PARTS FINISHING SEALANT APPLICATION AREA Van model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating Apply sealant to reverse side...
Page 990 BODY SERVICE 9-3 Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating...
Page 991 9-4 BODY SERVICE...
Page 992 BODY SERVICE 9-5 Truck model Smooth out sealant with a brush in the direction Wipe off excess sealant after application Apply under coating Apply sealant to reverse side...
Page 993 9-6 BODY SERVICE...
Page 994 BODY SERVICE 9-7 RUST-PROOF TREATMENT AREA...
Page 995 9-8 BODY SERVICE...
Page 996 BODY SERVICE 9-9 BODY DIMENSIONS SIDE PANEL [A]: Left side [B]: Right side Center member rear installation hole (left side) g. g’ Jig hole (O 6.5 mm (0.26 in.)) b. b’ Steering support member lower installation hole h. h’ Front door striker lower installation hole c.
Page 997 9-10 BODY SERVICE [A]: Left side [B]: Right side Center member rear installation hole (left side) f. f’ Rear door striker upper installation hole b. b’ Jig hole (O 6.5 mm (0.26 in.)) g. g’ Rear door stopper installation hole c.
Page 998 BODY SERVICE 9-11 UNDERBODY DIMENSIONS For van model...
Page 999 9-12 BODY SERVICE Hole Description Jig hole (O 10 mm (0.39 in.)) Engine mounting right side installation hole (for 2WD model) Jig hole (O 12 mm (0.47 in.)) Jig hole (O 7 mm (0.28 in.)) k (k’): Jig hole (O 15 mm (0.59 in.)) d (d’): Front suspension frame front installation hole l (l’):...
Page 1000 BODY SERVICE 9-13 For truck model...
Page 1001 9-14 BODY SERVICE Hole Description Jig hole (O 10 mm (0.39 in.)) Engine mounting right side installation hole (for 2WD model) Jig hole (O 12 mm (0.47 in.)) Jig hole (O 7 mm (0.28 in.)) k (k’): Deck mounting hole d (d’): Front suspension frame front installation hole l (l’):...
Page 1002 D Service on or around the air bag system components or wiring must be performed only by an au- thorized SUZUKI dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS of ON-VE- HICLE SERVICE in this section before performing service on or around the air bag system components or wiring.
Page 1003 10B-2 AIR BAG SYSTEM GENERAL DESCRIPTION SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS 1. Air bag harness 2. Fuse box 3. “AIR BAG” monitor coupler 4. DLC 5. Contact coil assembly 6. Driver air bag (inflator) module 7. Passenger air bag (inflator) module (if equipped) 8.
Page 1004 AIR BAG SYSTEM 10B-3 DIAGNOSIS REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT CAUTION: D All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be re- placed even if air bag system activation did not occur.
Page 1005 10B-4 AIR BAG SYSTEM D Steering wheel and driver air bag (inflator) module – Check for damage or air bag (inflator) module fitness. – Check trim cover (pad surface) for cracks. – Check wire harness and connector for damage or tightness. If any faulty condition is found in above checks, replace faulty part.
Page 1006 AIR BAG SYSTEM 10B-5 D Passenger air bag (inflator) module (if equipped) – Check for dents, cracks, damage or fitness. – Check trim cover for cracks or deformities. – Check harness and connector for damage or tightness. If any faulty condition is found in above checks, replace. D Air bag wire harness and connections –...
Page 1007 Be sure to follow the instructions. WARNING: D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation. D Do not modify the steering wheel, dashboard or any other air bag system components. Modifica- tions can adversely affect air bag system performance and lead to injury.
Page 1008 AIR BAG SYSTEM 10B-7 HOLDING AND STORAGE AIR BAG WIRE HARNESS AND CONNECTORS Air bag wire harness can be identified easily as it is covered with a yellow and black protection tube. Be very careful when handling D When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly.
Page 1009 10B-8 AIR BAG SYSTEM WARNING: During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. Neglecting them may result in personal in- jury or inactivation of the air bag system when neces- sary.
Page 1010 Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 1st Ed. October, 2000 Printed in Japan Printing: October, 2000...
Page 1011 D Service on or around the air bag system com- cial meanings. Pay special attention to the messages ponents must be performed only by an autho- highlighted by these signal words. rized SUZUKI dealer. Please observe all WARNINGS, CAUTIONS and “Service Precau- tions” under “On-Vehicle Service” in SEC- WARNING:...
Page 1012 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 (lubricant, sealants, etc.) as specified in each description.

Suzuki GA413 Service Manual

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