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Suzuki Wagon R Manual

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Table of Contents
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
WARNING:
Indicates a potential hazard that could result in
death or injury.
CAUTION:
Indicates a potential hazard that could result in
vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for authorized
Suzuki dealers and qualified service mechan-
ics only. Inexperienced mechanics or mechan-
ics without the proper tools and equipment
may not be able to properly perform the ser-
vices described in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.
WARNING:
For vehicles equipped with a Supplemental
Restraint Air Bag System:
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 CAU-
TIONS in SECTION 10B and Precautions, Air
Bag System Components and Wiring Loca-
tion View in SECTION 10B or before perform-
ing service on or around the air bag system
components or wiring. Failure to follow
WARNINGS could result in unintentional ac-
tivation of the system or could render the
system inoperative. Either of these two
conditions may result in severe injury.
D If the air bag system and another vehicle sys-
tem both need repair, Suzuki recommends
that the air bag system be repaired first, to
help avoid unintended air bag deployment.
D Do not modify the steering wheel, instru-
ment panel or any other air bag system com-
ponent (on or around air bag system compo-
nents or wiring). Modifications can adverse-
ly affect air bag system performance and
lead to injury.
D If the vehicle will be exposed to tempera-
tures over 93_C (200_F)(for example, during
a paint baking process), remove the air bag
system components (air bag (inflator) mod-
ules, SDM and/or seatbelt with pretension-
er) beforehand to avoid component damage
or unintended deployment.

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  • Page 1 D Service on and around the air bag system cial meanings. Pay special attention to the messages components or wiring must be performed highlighted by these signal words. only by an authorized SUZUKI dealer. Please observe all WARNINGS and CAU- WARNING: TIONS in SECTION 10B and Precautions, Air...
  • Page 2 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 TABLE OF CONTENTS SECTION GENERAL INFORMATION ENGINE General Information General Information and Engine Diagnosis Maintenance and Lubrication Engine Mechanical HEATING AND AIR Engine Cooling CONDITIONING Engine Fuel Heater and Ventilation Engine and Emission Air Conditioning Control System (If Equipped) Ignition System STEERING, SUSPENSION,...
  • Page 6: Table Of Contents

    GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ............. . . 0A- 2 PRECAUTIONS .
  • Page 7 0A-2 GENERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
  • Page 8 D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 9 0A-4 GENERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WARNING: WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BODY. Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment.
  • Page 10 GENERAL INFORMATION 0A-5 WARNING: D During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. D Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
  • Page 11 0A-6 GENERAL INFORMATION CAUTION: D Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under “Repair and Inspection Required after an Accident” in SECTION 10B. D When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, re- move those parts beforehand.
  • Page 12 GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
  • Page 13 0A-8 GENERAL INFORMATION D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position.
  • Page 14 GENERAL INFORMATION 0A-9 D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never dis- connect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
  • Page 15 0A-10 GENERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g.
  • Page 16 GENERAL INFORMATION 0A-11 D When connecting meter probe (2) from terminal side of cou- pler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its fe- male terminal open for connection. In case of such coupler as shown connect probe as shown to avoid opening female terminal.
  • Page 17 0A-12 GENERAL INFORMATION When checking system circuits including an electronic control unit such as ECM, TCM, ABS control module, etc., it is important to per- form careful check, starting with items which are easier to check. 1) Disconnect negative cable from battery. 2) Check each connector at both ends of the circuit being checked Sensor for loose connection.
  • Page 18 GENERAL INFORMATION 0A-13 Voltage check If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. 1) With all connectors connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.
  • Page 19 0A-14 GENERAL INFORMATION 4) Disconnect the connector included in circuit (connector B) and measure resistance between A-1 and body ground. To other parts If continuity is indicated, it means that the circuit is shorted to the ground between terminals A-1 and B-1. INTERMITTENTS AND POOR CONNECTION Most intermittents are caused by faulty electrical connections or wiring, although a sticking relay or solenoid can occasionally be at...
  • Page 20 GENERAL INFORMATION 0A-15 D Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to en- sure good contact tension by using the corresponding mating ter- minal. If contact tension is not enough, reform it to increase contact ten- sion or replace.
  • Page 21 0A-16 GENERAL INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is located on the front dash panel in the engine room. ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block. TRANSMISSION IDENTIFICATION NUMBER For M / T The number is located on the transmission case.
  • Page 22 GENERAL INFORMATION 0A-17 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. Air bag caution label Tire information placard Seat belt pretensioner warning label on retracter...
  • Page 23 0A-18 GENERAL INFORMATION VEHICLE LIFTING POINTS WARNING: D Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending on what part to be removed. D Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 24 GENERAL INFORMATION 0A-19 In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the wooden block (5) on the jack against front jacking bracket (1) or the center portion of rear axle (2). CAUTION: D Never apply jack against suspension parts (i.e., stabilizer (3), etc.), front bumper (4) or vehicle floor, otherwise it may...
  • Page 25 0A-20 GENERAL INFORMATION ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL ABBREVIATIONS : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Engine Control Module : Automatic Locking Retractor ECT Sensor...
  • Page 26 GENERAL INFORMATION 0A-21 : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch MAF Sensor : Mass Air Flow Sensor : Transmission Control Module (Air Flow Sensor, AFS, Air (A/T Controller, A/T Control Flow Meter, AFM) Module)
  • Page 27 GREASE E 99000-25050 1333B 99000-32020 Apply SUZUKI SUPER Apply THREAD LOCK GREASE H 99000-25120 1342 99000-32050 Apply SUZUKI SUPER GREASE I 99000-25210 Apply SUZUKI BOND NO. Do not reuse 1215 99000-31110 Apply SUZUKI BOND NO. Note on reassembly 1207C 99000-31150...
  • Page 28: Metric Fasteners

    GENERAL INFORMATION 0A-23 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are JIS-defined and ISO- defined metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. CAUTION: Even when the nominal diameter (1) of thread is the same, the thread pitch (2) or the width across flats (3) may vary be-...
  • Page 29 0A-24 GENERAL INFORMATION STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi- cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fasten- NOTE: D For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque...
  • Page 30 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 31 0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), Interval: carry out the same services at the same intervals respectively. This inter al sho ld be j dged b odometer This interval should be judged by odometer km (x 1,000) reading or months whichever comes first...
  • Page 32 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), Interval: carry out the same services at the same intervals respectively. Thi i t This interval should be judged by odometer ld b j d km (x 1,000) reading or months whichever comes first...
  • Page 33 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 34 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and adjusting belt tension. Water pump belt inspection 1) Remove engine under cover of right side from vehicle body. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
  • Page 35 0B-6 MAINTENANCE AND LUBRICATION ITEM 1-2 Camshaft Timing Belt Replacement Replace belt with new one. Refer to SECTION 6A1 for replacement procedure. CAUTION: D Do not bend or twist timing belt. D Do not allow timing belt to come into contact with oil, wa- ter, etc.
  • Page 36 MAINTENANCE AND LUBRICATION 0B-7 3) Loosen oil filter (1) by using oil filter wrench (Special tool). Special Tool (A): 09915-47330 4) Apply engine oil to new oil filter “O” ring. 5) Screw new filter on oil filter stand by hand until filter “O” ring con- tacts mounting surface.
  • Page 37: Engine Coolant Change

    0B-8 MAINTENANCE AND LUBRICATION ITEM 1-5 Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove radia- tor cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
  • Page 38 MAINTENANCE AND LUBRICATION 0B-9 ITEM 1-6 Exhaust System Inspection WARNING: To avoid danger of being burned, do not touch exhaust sys- tem when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance or vehicle is raised for oth- er service, check exhaust system as follows: D Check rubber mountings for damage and deterioration.
  • Page 39 0B-10 MAINTENANCE AND LUBRICATION IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1. FUEL SYSTEM ITEM 3-1 Air Cleaner Filter Inspection 1) Unclamp air cleaner case clamps. 2) Take cleaner filter out of air cleaner case. 3) Visually check that air cleaner filter is not excessively dirty, dam- aged or oily.
  • Page 40 MAINTENANCE AND LUBRICATION 0B-11 EMISSION CONTROL SYSTEM ITEM 4-1 PCV (Positive Crankcase Ventilation) Valve Inspection Check crankcase ventilation hoses and PCV hoses for leaks, cracks or clog, and PCV valve (1) for stick or clog. Refer to Section 6E for PCV valve checking procedure. ITEM 4-2 Fuel Evaporative Emission Control System Inspection WARNING:...
  • Page 41 0B-12 MAINTENANCE AND LUBRICATION ITEM 5-2 Brake Hoses and Pipes Inspection Perform this inspection where there is enough light and use a mirror as necessary. D Check brake hoses and pipes for proper hook-up, leaks, cracks, chafing, wear, corrosion, bends, twists and other damage. Replace any of these parts as necessary.
  • Page 42 MAINTENANCE AND LUBRICATION 0B-13 CHASSIS AND BODY ITEM 6-1 Clutch Pedal Free Travel Inspection (Cable type only) Check clutch pedal free travel “a”. Refer to SECTION 7C for proce- dure to check and adjust it. ITEM 6-2 Tire/Wheel Disc Inspection [Tire inspection] 1) Check tire for uneven or excessive wear, or damage.
  • Page 43 0B-14 MAINTENANCE AND LUBRICATION Wheel Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise or rattles. For details, refer to FRONT SUSPENSION INSPEC- TION of SECTION 3D. 2) Check rear wheel bearing for wear, damage abnormal noise or rattle.
  • Page 44 MAINTENANCE AND LUBRICATION 0B-15 3) Check steering linkage for looseness and damage. Repair or re- place defective parts, if any. 4) Check boots of steering linkage and steering gear case for dam- age (leaks, detachment, tear, etc.). If damage is found, replace defective boot with new one.
  • Page 45 0B-16 MAINTENANCE AND LUBRICATION ITEM 6-7 Automatic Transmission Fluid Inspection and Change [Fluid level inspection] 1) Inspect transmission case for evidence of fluid leakage. Repair leaky point, if any. 2) Make sure that vehicle is placed level for fluid level check. 3) Unclamp dipstick and pull out it.
  • Page 46 MAINTENANCE AND LUBRICATION 0B-17 ITEM 6-9 Ventilator Air Filter (if equipped) Inspection 1) Remove air filter from air inlet box or cooling unit referring to Sec- tion 1B. 2) Check filter for dirt. Replace excessively dirty filter. 3) Blow off dust by compressed air from air outlet side of filter. 4) Install filter to air inlet box or cooling unit referring to Section 1B.
  • Page 47 0B-18 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 48 MAINTENANCE AND LUBRICATION 0B-19 Steering Body, Wheels and Power Transmitting System D Check to ensure that steering wheel is free from in- Check that body, wheels and power transmitting sys- stability, or abnormally heavy feeling. tem are free from abnormal noise and abnormal D Check that the vehicle does not wander or pull to vibration or any other abnormal condition.
  • Page 50 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 51 1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heater and ventilation consist of the following parts. 1. Heater Unit 2. Air inlet box 3. Ventilator duct 4. Defroster nozzle 5. Ventilator outlet 6. Side ventilation air 7. Foot air 8. Front defroster air 9.
  • Page 52 HEATER AND VENTILATION 1A-3 DIAGNOSIS DIAGNOSIS TABLE Trouble Possible Cause Remedy Heater blower won’t work D Blower fuse blown Check for short to ground and replace even when its switch is fuse. D Blower resistor faulty Check resistor. D Blower switch faulty Check blower switch.
  • Page 53 1A-4 HEATER AND VENTILATION ON VEHICLE SERVICE HEATER UNIT 1. Heater core 2. Blower motor assembly 3. Blower resistor 4. Temperature door assembly 5. Mode door assembly 6. Mode lever 7. Temperature lever 8. Heater case REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system, disable air bag system.
  • Page 54 HEATER AND VENTILATION 1A-5 INSTALLATION Install heater unit by reversing removal procedure, noting the fol- lowing items. D When installing each part, be careful not to catch any cable or wir- ing harness. D Adjust heater control cable (refer to heater control lever assembly in this section).
  • Page 55 1A-6 HEATER AND VENTILATION INSTALLATION 1) Reverse removal procedure for installation. 2) Enable air bag system, if equipped. Refer to ENABLING AIR BAG SYSTEM in Section 10B. BLOWER MOTOR RESISTOR INSPECTION Measure each terminal-to-terminal resistance on resistor. Resistance H – Mh : Approx. 0.6 Ω Mh –...
  • Page 56 HEATER AND VENTILATION 1A-7 HEATER CONTROL LEVER ASSEMBLY 1. Heater control body assembly 2. Temperature control knob assembly (& A / C switch, if equipped) 3. Blower fan & defogger switch assembly 4. Bulb 5. Fresh air control cable 6. Mode control cable 7.
  • Page 57 1A-8 HEATER AND VENTILATION INSTALLATION LH VEHICLE 1) Reverse removal procedure for installation. 2) Adjust cables as follows. i) Move mode control knob (a), temperature control knob (b) and fresh air control knob (c) fully in arrow direction as shown in figure.
  • Page 58 HEATER AND VENTILATION 1A-9 BLOWER FAN & DEFOGGER SWITCH REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove ashtray, instrument center upper garnish (1), heater control knob (3), instrument center lower garnish (2) and radio or accessory case (if equipped). 3) Disconnect blower fan switch coupler.
  • Page 59 1A-10 HEATER AND VENTILATION AIR INLET BOX 1. Cooling unit packing 2. Dash packing 3. Packing 4. Drain hose 5. Blank 6. Door link 7. Air inlet door 8. Evaporator case 9. Air resistance board REMOVAL AND INSTALLATION Refer to “COOLING UNIT” in “AIR CONDITIONING” section. VENTILATION LOUVER REMOVAL AND INSTALLATION Remove ventilation louver (1) as shown in figure, and reverse re-...
  • Page 60 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 61 1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on LABEL (1) on the com- pressor. Also, it can be checked by the shape of the service (charge) valve (2).
  • Page 62 AIR CONDITIONING (OPTIONAL) 1B-3 MAJOR COMPONENTS AND LOCATION 1. Cooling unit 2. Compressor 3. Condenser assembly 4. Receiver / dryer 5. Discharge hose 6. Suction hose 7. Liquid pipe 8. Expansion valve 9. Side ventilation air 10. Center ventilation air 11.
  • Page 63 1B-4 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction Cool air does not come A/C system inoperative out (A/C system D No refrigerant Recover, evacuation and charging. improper operative) D Fuse blown Check “IG COIL” fuse, “HEATER” fuse and check for short circuit to ground.
  • Page 64 AIR CONDITIONING (OPTIONAL) 1B-5 Condition Possible Cause Correction Cool air does not come D Compressor faulty Check compressor. out or insufficient D Air in A/C system Replace receiver/dryer, and cooling (A/C system evacuation and charging. normal operative) D Air leaking from cooling unit or air duct Repair as necessary.
  • Page 65 1B-6 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT CHARGE CHARGE OF REFRIGERANT When the A/C inlet temperature is within 30 – 35_C. The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its maximum cooling ca- pacity for a few minutes.
  • Page 66 AIR CONDITIONING (OPTIONAL) 1B-7 DIAGNOSIS TEST 1) Confirm that vehicle and environmental conditions are as follows. – Vehicle is not exposed to direct sun. – Ambient temperature is within 15_C – 35_C (59_F – 95_F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
  • Page 67 1B-8 AIR CONDITIONING (OPTIONAL) 9) Check for each pressure of low side and high side if it is within shaded range of left graph. NOTE: Pressure registered on gauge varies with ambient temper- ature. Therefore, use left graphs when determining if pres- sures are normal or not.
  • Page 68 AIR CONDITIONING (OPTIONAL) 1B-9 DIAGNOSIS TEST TABLE TESTING RESULTS POSSIBLE CAUSE REMEDY Pressure high D Refrigerant overcharged D Recharge (“A” area of high side D Expansion valve frozen or clogged D Check expansion valve graph) D Clogged refrigerant passage of high side D Clean or replace D Condenser fan malfunction Insufficient...
  • Page 69 1B-10 AIR CONDITIONING (OPTIONAL) DETAIL DIAGNOSIS TABLE AT AMBIENT TEMPERATURE WITHIN 30 – 35_C (85 – 95_F) MANIFOLD kg / cm GAUGE CONDITION CAUSE CORRECTION 0.23 – 0.35 1.4 – 1.75 ––––––––– ––––––––– 2.3 – 3.5 14 – 17.5 Normal condition. 33 –...
  • Page 70 AIR CONDITIONING (OPTIONAL) 1B-11 WIRING CIRCUIT Main Main Main Main HEATER COIL 1. Blower motor 2. Blower resistor 3. Blower fan switch 4. Dual pressure switch 5. A / C switch 6. A / C blower motor relay 7. Radiator (and condenser) cooling fan relay 8.
  • Page 71 1B-12 AIR CONDITIONING (OPTIONAL) A/C SYSTEM INSPECTION OF ECM AND ITS Fig. A CIRCUITS ECM and its Circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers dis- connected from it.
  • Page 72 AIR CONDITIONING (OPTIONAL) 1B-13 ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL Measurement Terminal Wire Circuit Normal value Condition ground ECM ground for Ground to body E21-01 sensor circuit –0.5 – 0 volt Ignition switch ON (Fig A) (E21-10, E23-10) ECM ground for Ground to body E21-02...
  • Page 73 1B-14 AIR CONDITIONING (OPTIONAL) A/C COMPRESSOR DRIVE BELT INSPECTION 1) Check belt for wear and cracks, and replace as required. 2) Check belt tension by measuring how much it deflects when “a” pushed at intermediate point between compressor pulley (1) and crankshaft pulley (2) with about 100 N (10 kg, 22 lbs) force.
  • Page 74 AIR CONDITIONING (OPTIONAL) 1B-15 RECOVERY, EVACUATION AND CHARGING OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT Start evacuating Start evacuating Start evacuating Start evacuating Start evacuating 15 minutes (above 750 mmHg) Stop evacuating Inspect and repair connections Wait 10 minutes If gauge shows abnormal conditions Check system for pressure tightness...
  • Page 75 1B-16 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE NOTE: When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe the following instructions. D When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immedi- ately.
  • Page 76 AIR CONDITIONING (OPTIONAL) 1B-17 INSTALLATION Reverse removal sequence to install condenser, noting the follow- ing point. D If replace condenser, pour 15 cc of refrigerating oil to compressor suction-side. D Evacuate and charge system according to previously described procedure. INSPECTION Check the following.
  • Page 77 1B-18 AIR CONDITIONING (OPTIONAL) RADIATOR (AND CONDENSER) COOLING FAN MOTOR INSPECTION 1) Check continuity between each two terminals. If there is no continuity, replace radiator (and condenser) cooling fan motor. 2) Connect battery (1) to radiator (and condenser) cooling fan mo- tor coupler (2) as shown in figure, then check that the radiator (and condenser) cooling fan motor operates smoothly.
  • Page 78 AIR CONDITIONING (OPTIONAL) 1B-19 COOLING UNIT (EVAPORATOR) 1. Evaporator 2. Expansion valve 3. Evaporator case 4. Packing 5. Drain hose 6. Air inlet door 7. Evaporator thermistor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Recover refrigerant from refrigeration system by using recovery and recycling equipment.
  • Page 79 1B-20 AIR CONDITIONING (OPTIONAL) INSTALLATION Reverse removal sequence to install cooling unit, noting the follow- ing points. D If cooling unit or evaporator is replaced, pour 25 cc of refrigerating oil to compressor suction-side. D Install uniformly the padding (1) to installation hole. D Evacuate and charge system according to previously described procedure.
  • Page 80 AIR CONDITIONING (OPTIONAL) 1B-21 EXPANSION VALVE INSPECTION Refer to “Troubleshooting Procedure Using Manifold Gauge Set” earlier in this section for inspection. REMOVAL 1) Recover refrigerant from refrigeration system by using recovery and recycling equipment. 2) Loosen liquid pipe mounting bolt (1). 3) Loosen expansion attaching bolts (2) and remove expansion valve (3).
  • Page 81 1B-22 AIR CONDITIONING (OPTIONAL) A/C SWITCH INSPECTION 1) Remove heater control lever assembly, refer to “HEATER CON- TROL LEVER ASSEMBLY” in Section 1A. 2) Check following points for A/C switch. D Pull A/C Switch nob and check it there is continuity between terminals “A”...
  • Page 82 AIR CONDITIONING (OPTIONAL) 1B-23 A/C BLOWER FAN RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove A/C blower fan relay (1) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay. 4) Connect battery positive (+) terminal to terminal “b”...
  • Page 83 1B-24 AIR CONDITIONING (OPTIONAL) COMPRESSOR REMOVAL 1) RUN engine at idle speed with air conditioning ON for 10 min- utes. After that stop the engine. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system by using recov- ery and recycling equipment.
  • Page 84 AIR CONDITIONING (OPTIONAL) 1B-25 D Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION” in this section. CAUTION: Be sure to use HFC-134a (R-134a) compressor oil. NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Oil amount in compressor: 120 cm (120 cc, 7.5 in REPLENISHING COMPRESSOR OIL...
  • Page 85 1B-26 AIR CONDITIONING (OPTIONAL) MAGNET CLUTCH a. Front head bolt b. Front head bolt : Tighten bolt (a) first, and next (b). c. Armature plate bolt 1. Thermal switch 2. Compressor body 3. O-ring 4. Lip type seal 5. Front head 6.
  • Page 86 AIR CONDITIONING (OPTIONAL) 1B-27 REMOVAL 1) Remove compressor from vehicle. Refer to COMPRESSOR in this section. 2) Fix clutch plate (1) with special tool (A) and remove clutch plate bolt (2) and washer (3). Special Tool (A): 09991-06020 3) Using special tool (B) if necessary, remove clutch plate (1). Special Tool (B): 09991-06030 4) Remove shims from shaft.
  • Page 87 1B-28 AIR CONDITIONING (OPTIONAL) INSTALLATION 1) Install clutch coil (2). Protrusion on under side of clutch coil must match hole in com- pressor (3) to prevent movement and correctly locate lead wire. 2) Using special tool (C), install circlip (1) as shown. Special Tool (C): 09900-06107 3) Install clutch pulley (1).
  • Page 88 AIR CONDITIONING (OPTIONAL) 1B-29 LIP SEAL REMOVAL 1) Remove magnet clutch, referring to “MAGNET CLUTCH” in this section. 2) Remove front head (1) mounting bolts (a), (b). 3) Remove front head (1) by pushing cylinder shaft (2). PUSH NOTE: Be careful not to remove cylinder from front head. 4) Remove O-ring.
  • Page 89 1B-30 AIR CONDITIONING (OPTIONAL) 2) Coat special tool (F) surface with oil and place it on the shaft. Special Tool (F): 09991-06040 3) Install O-ring (2) to case. 4) Apply compressor oil to lip seal and O-ring. 5) Install front head (1). Special Tool (F): 09991-06040 6) Tighten front head mounting bolts (a), (b).
  • Page 90 AIR CONDITIONING (OPTIONAL) 1B-31 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Compressor oil COMPRESSOR OIL RS20 (150 cc) D O-ring (Refrigerant oil) 99000-99088 D Each Component REFRIGERANT DRUM (200 g) Refrigerant D Refrigerant charge 95794-50G00 SPECIAL TOOLS 09900-06107 Snap ring pliers...
  • Page 92: Steering, Suspension

    STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ..............FRONT END ALIGNMENT .
  • Page 93 3-2 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS GENERAL DIAGNOSIS Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
  • Page 94 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Reference Item Shimmy, Shake or D Tire or wheel out of balance Balance wheels or general balance Vibration procedure in Section 3F D Loosen wheel bearings Knuckle/Bearing in Section 3D and/or wheel bearing and wheel stud in Section D Worn tie rod ends Tie rod end in Section 3B...
  • Page 95 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Reference Item Rack and Pinion D Loose steering gear case bolts Manual rack and pinion assembly in Noise Section 3B (Rattle or Chuckle) D Worn rack bush Rack bushing in Section 3B D Rack and pinion adjustment Steering rack plunger in Section 3B Abnormal Noise,...
  • Page 96 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Condition Possible Cause Reference Item Low or Uneven Trim D Broken or sagging springs Strut damper assembly in Section 3D or Height coil spring in Section 3E Right-to-left trim D Over loaded Check loading height (H) difference D Incorrect springs Strut damper assembly in Section 3D or...
  • Page 97: Wear Indicators

    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 98 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 99 3-8 STEERING, SUSPENSION, WHEELS AND TIRES RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level rod 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 100 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ..... SECTION 3 Preliminary Checks Prior to Adjusting Front Alignment .
  • Page 101 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 102 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”...
  • Page 104 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 105 3B-2 MANUAL RACK AND PINION GENERAL DESCRIPTION The rack and pinion steering system consists of two components, the rack (1) and the pinion (2). When the steering wheel (3) is turned, the motion is transmitted to the steering shaft joint (4) and then to the pinion (2). Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear motion.
  • Page 106 MANUAL RACK AND PINION 3B-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. STEERING WHEEL 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 – 1.1 in.) If steering wheel play is not within specification, inspect as follows and replace if found defective.
  • Page 107 3B-4 MANUAL RACK AND PINION TIE ROD END BOOTS CHECK Inspect each boot for tear. If even a small tear is noted, replace with new one. STEERING SHAFT JOINT CHECK Check shaft joint for wear, breakage and other damage and replace if any defect exists.
  • Page 108 20. Steering shaft join LUBRICATION When inner parts of the steering gear case were dis- * SUZUKI SUPER GREASE (E) 99000- assembled, they should be washed clean before 25050, or Lithium grease (applicable for reassembly. It is recommended to use the grease as –40_C X 130_C or –40_F X 266_F)
  • Page 109 3B-6 MANUAL RACK AND PINION TIE ROD END REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove tie rod end nut (1) from steering knuckle. 3) Disconnect tie rod end from knuckle, using puller (1). 4) For ease of adjustment after installation, make marking (1) of tie rod end lock nut (2) position on tie rod end thread.
  • Page 110 MANUAL RACK AND PINION 3B-7 3) Inspect for proper toe (Refer to FRONT END ALIGNMENT). 4) After confirming proper toe, tighten tie rod end lock nut to speci- fied torque. Tightening Torque (a): 45 N m (4.5 kg-m, 32.5 lb-ft) 5) Tighten wheel to specified torque and lower hoist.
  • Page 111 3B-8 MANUAL RACK AND PINION MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL CAUTION: Be sure to set front wheels in straight direction and remove ignition key from key cylinder before these steps, otherwise contact coil of air bag system may get damaged. 1) Slide driver’s seat as far back as possible.
  • Page 112 MANUAL RACK AND PINION 3B-9 9) Remove steering gear case mount bolts (1), nuts (2) and gear case brackets, then remove gear case (3). INSTALLATION 1) Apply grease to inside of pinion packing and install pinion pack- ing onto pinion. Mount steering gear case (1) to body and tighten gear case mount bolts (2) and nuts (3) to specified torque.
  • Page 113 3B-10 MANUAL RACK AND PINION 7) Reinstall cover (1) removed previously to steering shaft joint. 8) Put back floor mat as it was. 9) Install both wheels and tighten wheel nuts to specified torque. Tightening Torque for wheel nuts: 85 N m (8.5 kg-m, 61.5 lb-ft) 10) Lower hoist.
  • Page 114 MANUAL RACK AND PINION 3B-11 RACK BOOT/TIE ROD REMOVAL 1) Remove steering gear case by performing Steps 1) – 9) in MANUAL RACK AND PINION REMOVAL of this section. 2) For ease of adjustment after installation, make marking (1) of tie rod end lock nut position of tie rod end thread.
  • Page 115 3B-12 MANUAL RACK AND PINION INSTALLATION 1) Install new tie rod (1) to rack (2). 2) Hold rack with soft jawed vise and tighten tie rod to specified torque. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) 3) Caulk a part of tie rod indicated in figure with punch (1). 4) Apply sealant to gear case groove “A”...
  • Page 116 MANUAL RACK AND PINION 3B-13 STEERING RACK PLUNGER REMOVAL 1) Remove rack boots and tie rods. 2) Loosen lock nut (1) with holding damper screw (2) with special tool. Special Tool (A): 09944-28320 3) Remove lock nut (1), rack damper screw (2), rack plunger spring (3) and rack plunger (4).
  • Page 117 3B-14 MANUAL RACK AND PINION STEERING PINION REMOVAL 1) Remove rack plunger as shown in STEERING RACK PLUNG- 2) Remove bearing plug with special tool. Special Tool (A): 09944-28310 3) Tap on position as shown with plastic hammer (2) to separate pinion assembly (1) from housing, and remove pinion assembly (1).
  • Page 118: Steering Rack

    MANUAL RACK AND PINION 3B-15 2) Apply grease to all around pinion teeth (1), pinion needle bear- ing, gear case, O-ring and gear case oil seal lip (2). Fill inside of pinion bearing plug (3) with grease. “A”: Grease E, 99000-25050 3) Apply thread lock cement to pinion bearing plug thread.
  • Page 119 3B-16 MANUAL RACK AND PINION INSPECTION Inspect for deflection, teeth wear, or damage, back surface wear or damage. Limit of rack deflection: 0.4 mm (0.016 in.) If deflection exceeds limit, replace rack. Do not use a wire brush when cleaning. INSTALLATION 1) Apply grease to entire teeth surface of rack and its periphery.
  • Page 120 MANUAL RACK AND PINION 3B-17 PINION BEARING REMOVAL 1) Remove rack from steering gear case, referring to STEERING RACK REMOVAL of this section. 2) Remove pinion bearing (1) from gear case with special tools as shown. Special Tool (A): 09921-20200 (B): 09930-30102 INSTALLATION 1) Apply grease to rollers of pinion bearing.
  • Page 121 MATERIAL SUZUKI PRODUCT D Sliding part of rack against steering housing (All around rack plunger and rack) Lithium Grease SUZUKI SUPER GREASE (E) D Sliding part against steering pinion (Should be applicable (Oil seal lip, needle bearing) (99000-25050) for – 40_C X 130_C)
  • Page 122 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 123 3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) GENERAL DESCRIPTION This electrical power steering (EPS) system consists of a P/S control module, a torque sensor and a motor assem- bly (with clutch incorporated) 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 124 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-3 WIRING DIAGRAM 1. Main fuse box 9. To vehicle speed sensor (VSS) 16. P / S control module 2. “EPS” fuse (30 A) 10. ECM / PCM 17. Motor assembly (with clutch incorporated) 3.
  • Page 125 3B1-4 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 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 SYS- TEM”...
  • Page 126 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-5 SYSTEM CHECK FLOW TABLE STEP ACTION 1) Record details of the problem (failure, Go to Step 2. Go to Step 3. 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 127 3B1-6 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) CUSTOMER QUESTIONNAIRE (EXAMPLE) Customer’s name: Model: VIN: Date of issue: Date Reg.: Date of problem: Mileage: D Steering wheel feels heavy D Vehicle pulls to one side during straight driving D Poor recovery from turns Problem Symptoms D Too much play in steering D Abnormal noise while vehicle is running: from motor, from rack and pinon,...
  • Page 128 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-7 “EPS” WARNING LAMP CIRCUIT CHECK FLOW TABLE CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table. STEP ACTION 1) Make sure that battery voltage is about 11 V or Go to Step 2.
  • Page 129 3B1-8 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) TABLE-A “EPS” WARNING LAMP DOES NOT LIGHT STEP ACTION Was “SYSTEM CHECK FLOW TABLE” Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. Are “EPS” fuses in good condition? Go to Step 3.
  • Page 130 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-9 Fig. for Step 3 Fig. for Step 4 Fig. for Step 6 Fig. for Step 7 Fig. for Step 8...
  • Page 131 3B1-10 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) TABLE-B “EPS” WARNING LAMP FLASHES STEP ACTION Was “SYSTEM CHECK FLOW TABLE” Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. 1) Check monitor coupler for P/S system. Remove service wire.
  • Page 132 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-11 TABLE-C “EPS” WARNING LAMP REMAINS ON (EVEN THOUGH DIAGNOSIS SWITCH TERMINAL GROUNDED) STEP ACTION Was “SYSTEM CHECK FLOW TABLE” Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. 1) Short diagnosis switch terminal to body ground Repair high resistance Go to Step 3.
  • Page 133 (C): 09931-76030 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 referring to SUZUKI SCAN TOOL OPERATOR’S MANUAL for further details. NOTE: If Suzuki scan tool cannot display DTC, perform “SERIAL DATA LINK CIRCUIT CHECK”...
  • Page 134 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-13 Example: When VSS circuit fail (DTC C1121) is set Turn ON “EPS” warning lamp Turn OFF TIME (sec.) NOTE: D When more than 2 DTCs are stored in memory, flashing for each DTC is repeated three times starting with the smallest DTC number in increasing order.
  • Page 135 DTC CLEARANCE USING SUZUKI SCAN TOOL 1) Turn ignition switch to OFF position. 2) After setting cartridge to SUZUKI scan tool, connect scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side.
  • Page 136 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-15 SERIAL DATA LINK CIRCUIT CHECK CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table. 1. Main fuse box 9. To vehicle speed sensor (VSS) 2. “EPS” fuse (30 A) 10.
  • Page 137 Go to Step 2. Go to “SYSTEM performed? CHECK FLOW TABLE” in this section. 1) Make sure that SUZUKI scan tool is free from Go to Step 3. Properly connect malfunction and correct cartridge for P/S SUZUKI scan tool to system is used.
  • Page 138 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-17 DTC TABLE CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table of each DTC. “EPS” light flashing pattern DIAGNOSTIC ITEM DIAGNOSTIC ITEM DIAGNOSIS DIAGNOSIS Model This code appears when Normal none of the other codes are...
  • Page 139 3B1-18 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1111 TORQUE SENSOR MAIN CIRCUIT FAIL DTC C1113 TORQUE SENSOR MAIN AND SUB CIRCUIT FAIL DTC C1115 TORQUE SENSOR SUB CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2.
  • Page 140 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-19 DTC C1114 TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2. “EPS” fuse (30 A) 7. Torque sensor 3. Ignition switch 8. P / S control module body ground 4.
  • Page 141 3B1-20 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1121/C1123/C1124 VSS CIRCUIT FAIL 1. Main fuse box 2. “EPS” fuse 3. Ignition switch 4. Circuit fuse box 5. “IG coil” fuse (15A) 6. Combination meter 7. Speedometer 8. “EPS” warning lamp 9.
  • Page 142 OPERATOR’S MANUAL”. recheck. “Br/Y” wire circuit. 3) Check engine speed. If OK, check engine Is proper engine speed indicated? speed signal of ECM/ PCM. NOTE 1: It is necessary for SUZUKI scan tool to perform STEP 4 of this table.
  • Page 143 3B1-22 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1141/C1142/C1143/C1144/C1145 MOTOR CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2. “EPS” fuse (30 A) 7. Motor assembly (with clutch incorporated) 3. Ignition switch 8. P / S control module body ground 4.
  • Page 144 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-23 DTC C1151 CLUTCH CIRCUIT FAIL 1. Main fuse box 6. P / S control module 2. “EPS” fuse (30 A) 7. Motor assembly (with clutch incorporated) 3. Ignition switch 8. P / S control module body ground 4.
  • Page 145 3B1-24 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) DTC C1153 P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAIL 1. Main fuse box 5. “IG coil” fuse (15A) 2. “EPS” fuse (30 A) 6. P / S control module 3. Ignition switch 7.
  • Page 146 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-25 INSPECTION OF P/S CONTROL MODULE AND ITS CIRCUITS P/S control module (1) and its circuits can be checked at P/S control module wiring couplers (2) 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 147 10 – 14 V Engine idling “EPS” light OFF Diagnosis switch terminal About 5 V Ignition switch is ON position SUZUKI scan tool – – Motor output 2 5 – 7 V Engine idling and steering wheel held at position for vehicle to run...
  • Page 148: Diagnostic System

    ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 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 (flashing pattern:12) is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in “DIAGNOSIS CHART”...
  • Page 149 3B1-28 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 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 150 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) 3B1-29 ON-VEHICLE SERVICE [LH] 1. Steering column assembly CAUTION: Never disassemble steering column assembly, remove torque sensor or motor assem- bly (with clutch incorporated). Performing any of these prohib- ited services will affect original performance of EPS system.
  • Page 151: Torque Sensor

    3B1-30 ELECTRICAL POWER STEERING (EPS) SYSTEM (IF EQUIPPED) TORQUE SENSOR ON-VEHICLE INSPECTION 1) Remove steering column lower cover. 2) Turn ignition switch to ON position. 3) Check voltage between terminals of torque sensor connector (1) with connecting it to P/S control module (2) and not running en- gine.
  • Page 152 1. Storage case 2. Operator’s manual 3. Tech 1A 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09931-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16/14 pin DLC cable...
  • Page 154 STEERING WHEEL AND COLUMN 3C-1 SECTION 3C STEERING WHEEL AND COLUMN WARNING: The procedures in this section must be followed in the order listed to temporarily disable the air bag system and prevent false diagnostic codes from setting. Failure to follow procedures could result in possible air bag system activation, personal injury or other- wise unneeded air bag system repairs.
  • Page 155 3C-2 STEERING WHEEL AND COLUMN GENERAL DESCRIPTION STEERING COLUMN This double tube type steering column has the following three important features in addition to the steering function: D The column is energy absorbing, designed to compress in a front-end collision. D The ignition switch and lock are mounted conveniently on this column.
  • Page 156 (if equipped)). Be sure to follow the instructions. WARNING: D If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 157: Handling Precaution

    3C-4 STEERING WHEEL AND COLUMN ENABLING AIR BAG SYSTEM 1) Turn ignition switch to “LOCK” and remove key. 2) Connect connector to contact coil assembly, and install steering column upper cover and lower cover. 3) Connect Yellow connector of passenger air bag (inflator) module if equipped, and be sure to lock connector with lock lever and close glove box panel.
  • Page 158 STEERING WHEEL AND COLUMN 3C-5 D If air bag (inflator) module was dropped from a height of 90 cm (3 ALWAYS CARRY AIR BAG (INFLATOR) MODULE ft) or more, it should be replaced. WITH TRIM COVER (AIR BAG OPENING) AWAY D When an abnormality is noted as existing in the live (undeployed) FROM BODY.
  • Page 159 3C-6 STEERING WHEEL AND COLUMN CONTACT COIL CABLE ASSEMBLY Do not turn contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counter- clockwise respectively), or coil will break. AIR BAG WIRE HARNESS AND CONNECTOR CAUTION: When an open in air bag wire harness, damaged wire har- ness, connector or terminal is found, replace wire harness,...
  • Page 160 STEERING WHEEL AND COLUMN 3C-7 ON-VEHICLE SERVICE 10. Steering column assembly 1. Driver air bag (inflator) module 11. Ignition switch assembly 2. Steering shaft bolt: 12. Immobilizer control module Apply thread lock 99000-32050 to all around 13. Ignition switch cylinder assembly thread part of steering shaft bolt.
  • Page 161 3C-8 STEERING WHEEL AND COLUMN DRIVER AIR BAG (INFLATOR) MODULE WARNING: When handling an air bag (inflator) module, be sure to read “Precautions” given earlier in this section and observe each instruction. Failure to follow them could cause a dam- age to the air bag (inflator) module or result in personal inju- REMOVAL 1) Disconnect negative battery cable at battery terminal.
  • Page 162 STEERING WHEEL AND COLUMN 3C-9 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) (1) being cracked D Terminal (2) being damaged D Air bag (inflator) module being damaged or having been exposed to strong impact (dropped) INSTALLATION...
  • Page 163: Steering Wheel

    3C-10 STEERING WHEEL AND COLUMN STEERING WHEEL CAUTION: Do not turn the contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively) with steering wheel removed, or coil will break. REMOVAL 1) Disconnect negative battery cable at battery terminal.
  • Page 164 STEERING WHEEL AND COLUMN 3C-11 4) From the position where contact coil became unable to turn any further (it stopped), turn it back clockwise about two and a half rotations and align center mark with alignment mark (1). INSTALLATION 1) Check that vehicle’s front tires are at straight-ahead position and contact coil is centered.
  • Page 165 3C-12 STEERING WHEEL AND COLUMN CONTACT COIL CABLE ASSEMBLY CAUTION: Do not turn contact coil more than allowable number of turns (about two and a half turns from the center position clockwise or counterclockwise respectively), or coil will break. REMOVAL 1) Disconnect negative battery cable at battery terminal.
  • Page 166 STEERING WHEEL AND COLUMN 3C-13 7) Remove contact coil cable assembly (1) from steering column. INSPECTION Check contact coil cable assembly wire harness for any signs of scorching, melting or other damage. If it is damaged, replace. INSTALLATION 1) Check to make sure that vehicle’s front tires are set at straight- ahead position and then ignition switch is at “LOCK”...
  • Page 167 3C-14 STEERING WHEEL AND COLUMN 4) Install steering column upper cover (1) and lower cover (2). 5) Install steering column hole cover (2) and instrument panel switch garnish (1). 6) Install steering wheel to steering column. Refer to “Steering Wheel” earlier in this section. 7) Connect battery negative cable.
  • Page 168 STEERING WHEEL AND COLUMN 3C-15 REMOVAL 1) Disconnect negative battery cable at battery terminal. 2) Disable air bag system. Refer to “Disabling Air Bag System” under “Precautions” earlier in this section. 3) Remove steering wheel and contact coil cable assembly. Refer to “Steering Wheel”...
  • Page 169 3C-16 STEERING WHEEL AND COLUMN 11) When disconnecting upper joint (3) from power steering col- umn shaft (2), make alignment marks (1) on column shaft and upper joint, and be sure to align marks (1) when reconnecting. INSPECTION Check steering column for damage and operation referring to CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE lat- er in this section.
  • Page 170 STEERING WHEEL AND COLUMN 3C-17 4) Install ignition switch assembly and immobilizer control module to steering column. 5) Install ignition switch cylinder assembly as follows. a) Push steering lock (2) down till it clicks, using screw driver (1), so that it is at unlock position. b) Turn ignition key of ignition switch cylinder assembly to “ACC”...
  • Page 171 3C-18 STEERING WHEEL AND COLUMN 4) Remove steering shaft joint bolts (1) and then remove steering Power steering Manual steering lower shaft (2). INSTALLATION Power steering Manual steering 1) Align flat part of steering lower shaft (2) or steering column (4) with bolt hole of upper joint (1) as shown.
  • Page 172 STEERING WHEEL AND COLUMN 3C-19 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering col- umn. CHECKING PROCEDURE 1) Check that two capsules (1) are attached to steering column bracket securely.
  • Page 173 3C-20 STEERING WHEEL AND COLUMN REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT THREAD LOCK 1342 Thread lock cement Steering shaft bolt (99000-32050)
  • Page 174 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 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 175 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 rubber mount. A strut bearing is also installed a little lower to the rubber mount.
  • Page 176 FRONT SUSPENSION 3D-3 DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STABILIZER BAR AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. STRUT ASSEMBLY CHECK 1) Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
  • Page 177 3D-4 FRONT SUSPENSION SUSPENSION CONTROL ARM/KNUCKLE CHECK Inspect control arm/knuckle for cracks, deformation or damage. Inspect control arm bushing for damage, wear or deterioration. SUSPENSION CONTROL ARM JOINT CHECK Cannot be separated 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage.
  • Page 178 FRONT SUSPENSION 3D-5 ON-VEHICLE SERVICE STABILIZER BAR AND/OR BUSHINGS REMOVAL 1) Hoist vehicle and allow the front suspension control arms (5) to hang free. 2) Remove front wheels. 3) Remove split pins (1) and then castle nuts (2). 4) Remove stabilizer bar mount bushing bracket bolts (9). 5) Remove stabilizer bar (6) from front suspension control arms (5).
  • Page 179 3D-6 FRONT SUSPENSION D Install mounting bracket (1) so that its oblong hole side (2) comes to the rear. Front D Tighten stabilizer bar bracket bolts to specified torque. Tightening torque for stabilizer bar bracket bolts: 45 N m (4.5 kg-m, 32.5 lb-ft) D After tightening castle nut (1) to specified torque, install new split pin (2) as shown.
  • Page 180 1. Strut nut 7. Bearing lower washer 13. Shock absorber: 2. Strut rock washer 8. Bearing spacer Apply SUZUKI SUPER GREASE A 3. Strut support 9. Coil spring upper seat 99000-25010 to sliding part of rod. 4. Bearing seal: 10. Coil spring seat 14.
  • Page 181 3D-8 FRONT SUSPENSION 8) Remove strut support nuts (1). Hold strut by hand so that it will not fall off. 9) Remove strut assembly. DISASSEMBLY 1) Using a spring compressor, compress the strut spring till its force pressing the spring seat is released. CAUTION: Use a commercially available spring compressor and fol- low the operation procedure described in the Instruction...
  • Page 182 FRONT SUSPENSION 3D-9 ASSEMBLY For assembly, reverse disassembly procedure, observing following instructions. D Apply grease to bearing seal, strut bearing and sliding part of strut rod. D Mate spring end with stepped part of spring lower seat as shown. D Install spring seat, mating stepped part of seat with spring upper end as shown.
  • Page 183 3D-10 FRONT SUSPENSION INSTALLATION D Install strut assembly by reversing REMOVAL procedure. CAUTION: Don’t twist brake hose when installing it. Install E-ring as far as it fits to bracket as shown. D Torque all fasteners to specification, referring to assembly figure on 3D-7.
  • Page 184 FRONT SUSPENSION 3D-11 STEERING KNUCKLE/BEARING : Tightening Torque : Do not reuse 1. Wheel hub 5. Dust cover 10. Ball stud bolt 14. Wheel hub nut 2. Circlip 6. Tie-rod end 11. Strut bracket bolt: 15. Brake disc 3. Wheel bearing: 7.
  • Page 185 3D-12 FRONT SUSPENSION 7) Pull out wheel hub (1) with special tools. Special Tool (A): 09943-17912 (B): 09942-15511 8) Remove tie-rod end nut and disconnect tie-rod end (2) from knuckle (1) with puller. CAUTION: Never reuse tie-rod end nut. Reused nut will not be locked securely. 9) Remove wheel speed sensor (1) from knuckle (if equipped).
  • Page 186 FRONT SUSPENSION 3D-13 2) Remove circlip (1). Special Tool (A): 09900-06108 3) Remove wheel bearing using special tool and hydraulic press. Special Tool (A): 09913-75810 CAUTION: D Never reuse wheel bearing. Reused bearing should have excessive play. D When replacing bearing, inner races or outer race, be sure to replace them with new ones as a set.
  • Page 187 3D-14 FRONT SUSPENSION 2) Install circlip (1). Special Tool (A): 09900-06108 3) Drive in dust cover (1) so that dimensions “a” and “b” become equal as shown. CAUTION: When drive in dust cover, be careful not to deform it. 4) Caulk with a punch. 5) Insert new stud (2) in hub hole.
  • Page 188 FRONT SUSPENSION 3D-15 2) Install knuckle (2) to ball stud (3) on suspension control arm (4) FORWARD and strut bracket (1). Installing direction of each bolt is as shown. Align knuckle bolt hole with ball stud groove and install ball stud bolt (5).
  • Page 189 3D-16 FRONT SUSPENSION 9) Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque. Tightening Torque (c): 175 N m (17.5 kg-m, 127.0 lb-ft) 10) Calk drive shaft nut as shown. Calking drive CAUTION: shaft nut Be careful while caulking nut so that no crack will occur...
  • Page 190 FRONT SUSPENSION 3D-17 SUSPENSION CONTROL ARM/BUSHING REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove split pin (12), stabilizer bar castle nut (10), washer (9) and bushing (8). FORWARD 3) Remove stabilizer bar mount bracket (right & left) bolts (5). 4) Remove ball stud bolt (2).
  • Page 191 3D-18 FRONT SUSPENSION INSTALLATION 1) Place suspension control arm onto flat surface side of special tool and install new bushing with special tool and oil hydraulic Press press as shown. Special Tool (A): 09943-77910 NOTE: D Before installing bushing, apply soap water on its circum- ference to facilitate installation.
  • Page 192 D Install stabilizer bar, referring to STABILIZER BAR INSTALLA- TION in this section. REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Outside inner race Lithic wheel bearing SUZUKI SUPER GREASE (A) D Bearing seal grease (99000-25010) D Strut bearing D Sliding part of strut rod...
  • Page 193 3D-20 FRONT SUSPENSION SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09900-06108 09913-61110 09913-75810 Hexagon wrench bit (6 mm) Snap ring pliers (closing type) Bearing puller Bearing installer 09924-84510-002 09925-88210 09940-53111 09942-15511 Bearing installer attachment Bearing puller attachment Bearing installer Sliding hammer 09943-17912 09945-26010...
  • Page 194 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 195 3E-2 REAR SUSPENSION GENERAL DESCRIPTION Rear suspension is Isolated Trailing Link (l.T.L.) type which 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 196 REAR SUSPENSION 3E-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. 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. WARNING: When handling rear shock absorber in which high-pressure gas is sealed, make sure to observe the following precau- tions.
  • Page 197 3E-4 REAR SUSPENSION REAR SUSPENSION FASTENERS CHECK Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to ON-VE- HICLE SERVICE in this section. WHEEL DISC, NUT & BEARING CHECK D Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced.
  • Page 198 REAR SUSPENSION 3E-5 ON-VEHICLE SERVICE 90 N m (9.0 kg-m) 1. Rear coil spring 10. Brake drum 17. Lateral rod body side bolt: 2. Rear bump stopper: 11. Circlip Insert from the direction as shown Apply soap water, when installing. 12.
  • Page 199 3E-6 REAR SUSPENSION LATERAL ROD REMOVAL 1) Hoist vehicle. 2) Remove lateral rod nuts (1). 3) Remove lateral rod (2). INSTALLATION 1) Install lateral rod (1) to rear axle and vehicle body (3) referring to figure for proper installing direction of bolt (4) and washer (2). Tighten nuts (5) temporarily by hand.
  • Page 200: Rear Shock Absorber

    REAR SUSPENSION 3E-7 REAR SHOCK ABSORBER REMOVAL 1) Hoist vehicle. Vehicle center side 2) Support rear axle (1) by using floor jack to prevent it from lower- ing. 3) Remove lower bolt (2). 4) Remove upper bolt (3) and nut (4). Then remove shock absorber (5).
  • Page 201 3E-8 REAR SUSPENSION 5) Remove shock absorber lower bolt (1). 6) Lower rear axle gradually as far down as where coil spring (1) can be removed. CAUTION: Be careful not to let rear axle down too much. It may cause damage to brake flexible hose and parking brake cable.
  • Page 202 REAR SUSPENSION 3E-9 6) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (a): 85 N m (8.5 kg-m, 61.5 lb-ft) 7) Lower hoist and vehicle in non-loaded condition, tighten absorb- er lower bolt (1) and lateral rod body side nut (2) to specified torque.
  • Page 203 3E-10 REAR SUSPENSION SPRING UPPER SEAT REMOVAL 1) Remove coil spring. For details, refer to COIL SPRING RE- MOVAL in this section. 2) Remove spring upper seat (1). INSTALLATION 1) Install spring upper seat (1). Vehicle body side NOTE: For proper installing direction of spring upper seat, refer to figure at left.
  • Page 204 REAR SUSPENSION 3E-11 5) Remove parking brake cable clamp (1). 6) Remove trailing arm rear bolts (1). 7) Remove trailing arm front bolt (2) and then remove trailing arm FORWARD (1). INSTALLATION 1) Install trailing arm (1) to vehicle body and rear axle, referring to Vehicle Vehicle figure for proper installing direction of bolts (2) and then tighten...
  • Page 205 3E-12 REAR SUSPENSION 3) Install parking brake cable clamp (1). 4) Install shock absorber (1) to rear axle (2). 5) Tighten shock absorber lower bolt (3) temporarily by hand. 6) Remove floor jack from rear axle. 7) Install wheel and tighten wheel nuts to specified torque. Tightening Torque for wheel nuts (a): 85 N m (8.5 kg-m, 61.5 lb-ft)
  • Page 206: Rear Axle

    REAR SUSPENSION 3E-13 REAR AXLE REMOVAL 1) Hoist vehicle and remove rear wheels (right & left). 2) Support rear axle (1) by using floor jack (2). 3) Remove rear brake drums (right & left). For details, refer to steps 2) to 6) of BRAKE DRUM REMOVAL in SECTION 5C. 4) Remove E-rings (2) (right &...
  • Page 207 3E-14 REAR SUSPENSION 8) Disconnect wheel speed sensor and lead wire clamps (right & left) (if equipped). 9) Remove shock absorber lower bolts (1) (right & left). 10) Remove LSPV spring (1) from rear axle (2) (if equipped). 11) Lower rear axle gradually as far down as where coil springs (1) (right &...
  • Page 208 REAR SUSPENSION 3E-15 14) While supporting rear axle at both ends (right & left), remove trailing arm rear side bolts and then remove rear axle from chassis by lowering floor jack gradually. INSTALLATION Install removed parts in reverse order of removal, noting the follow- ing points.
  • Page 209 3E-16 REAR SUSPENSION 6) Clean mating surface of rear axle (right & left) with brake back plate and apply water tight sealant as shown in figure. “A”: Sealant 99000-31090 7) Install brake back plates (1) and tighten back plate bolts (2) to specified torque.
  • Page 210 REAR SUSPENSION 3E-17 11) Install LSPV spring (1) to rear axle (2) (if equipped). Tightening Torque (a): 26 N·m (2.6 kg-m, 19.0 lb-ft) 12) Install brake drums (right & left). For details, refer to steps 3) to 8) of BRAKE DRUM INSTALLATION in Section 5C. 13) Fill reservoir with brake fluid and bleed brake system.
  • Page 211 3E-18 REAR SUSPENSION 18) Tighten right and left trailing arm rear nuts, shock absorber low- er bolts and lateral rod rear axle side nut to specified torque. NOTE: When tightening these nuts and bolts, be sure that vehicle is off hoist and in non loaded condition. Tightening Torque (e): 80 N·m (8.0 kg-m, 58.0 lb-ft) (f): 63 N·m (6.3 kg-m, 45.5 lb-ft)
  • Page 212 REAR SUSPENSION 3E-19 WHEEL BEARING AND WHEEL STUD REMOVAL 1) Remove rear brake drum, referring to REAR BRAKE DRUM RE- MOVAL in SECTION 5C. 2) Remove circlip (1). Special Tool (A): 09900-06108 3) Remove wheel bearing by using special tool and hydraulic press.
  • Page 213 (A): 09900-06108 4) Install brake drum and wheel, referring to BRAKE DRUM INSTALLATION in SECTION 5C. REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Brake fluid DOT4 Brake reservoir tank SEALING COMPOUND 366E Water tight sealant Join seam of rear axle and brake back plate...
  • Page 214 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 215 3F-2 WHEELS AND TIRES WARNING: kgf/cm Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emergencies, because handling may be seriously affected and may result in loss of control. It is recommended that new tires be installed in pairs on the same axle.
  • Page 216 WHEELS AND TIRES 3F-3 When the measured runout exceeds the specification and correc- tion by the balancer adjustment is impossible, replace the wheel. If the reading is affected by welding, paint or scratch, it should be ignored. Radial Lateral runout limit runout limit 2.0 mm 2.0 mm...
  • Page 217 3F-4 WHEELS AND TIRES INFLATION OF TIRES The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread wear, tire life and resistance to bruises. Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should be checked monthly or before any extended trip.
  • Page 218 WHEELS AND TIRES 3F-5 ON-VEHICLE SERVICE SERVICE OPERATIONS METRIC LUG NUTS AND WHEEL STUDS All models use metric lug nuts and wheel studs (size: M12 x 1.25). WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180_ (half a rotation). 2) Hoist vehicle. 3) Remove wheel.
  • Page 219: Balancing Wheels

    3F-6 WHEELS AND TIRES After mounting, inflate to specified pressure shown on tire placard so that beads are completely seated. WARNING: Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety hump and cause serious per- sonal injury.
  • Page 220 WHEELS AND TIRES 3F-7 GENERAL BALANCE PROCEDURES Deposits of mud, etc. must be cleaned from inside of rim. WARNING: Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain good balance. Each tire should be inspected for any damage, then balanced according to equipment manufacturer’s recommen- dation.
  • Page 222 FRONT DRIVE SHAFT 4-1 SECTION 4 FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ..............4- 1 DIAGNOSIS .
  • Page 223 4-2 FRONT DRIVE SHAFT ON-VEHICLE SERVICE Removal & Installation 1. Transmission 8. Tie-rod end nut 2. Drive shaft assembly 9. Ball stud bolt 3. Tie-rod end 10. Drive shaft nut 4. Suspension control arm 11. Wheel nut 5. Stabilizer 12. Washer 6.
  • Page 224 FRONT DRIVE SHAFT 4-3 Disassembly & Reassembly [A] : For M / T model [B] : For A / T model [C] : Both models 9. Differential (or center shaft) side joint 1. Right side drive shaft assembly (Constant velocity tripod joint): 2.
  • Page 225 4-4 FRONT DRIVE SHAFT REMOVAL CAUTION: To prevent breakage of boots, be careful not to bring them into contact with other parts when removing drive shaft as- sembly. 1) Undo caulking (1) and remove drive shaft nut (2). 2) Loosen wheel nuts. 3) Hoist vehicle.
  • Page 226 FRONT DRIVE SHAFT 4-5 INSPECTION D Check boots for breakage or deterioration. D Check wheel side joint for rattle or smooth movement. D Check differential side joint or center shaft side joint for smooth movement. If malfunction is found, replace. DISASSEMBLY For Tripod joint type drive shaft (right side) CAUTION:...
  • Page 227 4-6 FRONT DRIVE SHAFT 4) Remove spider (1) by using 3 arms puller (2). CAUTION: To prevent needle bearing of joint from being degreased, do not wash it if it is to be reused. 5) Remove boot small band, then pull out differential side boot from shaft.
  • Page 228 FRONT DRIVE SHAFT 4-7 2) Remove DOJ from shaft as follows. a) Fold over boot and remove old grease so that retaining ring (1) is accessible. b) Clamp drive shaft in soft jawed vise. Spread retaining ring using snap ring pliers (opening type) and tap DOJ of drive shaft using plastic hammer until retain- ing ring no longer engages in groove of shaft.
  • Page 229 4-8 FRONT DRIVE SHAFT INSPECTION D Check shaft and joint for damage, wear or bend. Replace them as necessary. D Check retaining ring and snap ring for breakage or deformation. Replace as necessary. ASSEMBLY For Tripod joint type drive shaft (right side) 1) Wash disassembled parts (except boots and needle bearing of spider).
  • Page 230 FRONT DRIVE SHAFT 4-9 8) Place new wheel side small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure. 9) Confirm that wheel side boot is not stretched or contracted and fasten boot small band (1) securely at that position. Special Tool (A): 09943-55010 10) Install damper (1) on drive shaft according to dimension speci-...
  • Page 231 4-10 FRONT DRIVE SHAFT 14) Fit boot to grooves of shaft and housing and adjust boot length to specification below. Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
  • Page 232 FRONT DRIVE SHAFT 4-11 7) Set new differential side small band (2) and differential side boot (1) on shaft temporarily. 8) Apply grease to DOJ and inside of housing. Use grease supplied with spare parts. “A”: Thermax grease/Color: Black Grease capacity: About 50 – 70 g (1.8 – 2.5 oz) 9) Place DOJ onto spline of drive shaft and drive onto drive shaft by using plastic hammer until retaining ring engages.
  • Page 233 4-12 FRONT DRIVE SHAFT D When installing left oil seal (1) and right oil seal (2), use care so that oil seals in proper direction and position as shown figure. Distance “a”: 11 – 12 mm (0.43 – 0.47 in.) “b”: 2 –...
  • Page 234 FRONT DRIVE SHAFT 4-13 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI BOND NO. 1215 Oil drain and filler/level plugs for manual Sealant (99000-31110) transmission SUZUKI SUPER GREASE A Lithium grease Center bearing side space of oil seal (99000-25010) SPECIAL TOOLS...
  • Page 236 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 237 5-2 BRAKES GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and four in rear). The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two independent circuits.
  • Page 238: Road Testing Brakes

    BRAKES 5-3 DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE FLUID Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid test brakes by making brake applications with both may cause the brake fluid to boil or the rubber compo- light and heavy pedal forces at various speeds to de- nents in the hydraulic system to deteriorate.
  • Page 239 5-4 BRAKES DIAGNOSIS TABLE Condition Possible Cause Correction Not enough D Brake oil leakage from brake lines. Locate leaking point and repair. braking force D Brake disc or pads stained with oil. Clean or replace. D Overheated brakes. Determine cause and repair. D Poor contact of shoes on brake drum.
  • Page 240 BRAKES 5-5 Condition Possible Cause Correction Excessive pedal D Partial brake system failure. Check brake systems and repair as travel (Pedal necessary. stroke too large) D Insufficient fluid in master cylinder Fill reservoirs with approved brake reservoirs. fluid. Check for leaks and air in brake systems.
  • Page 241 5-6 BRAKES Condition Possible Cause Correction Brake warning light D Parking brake applied. Release parking brake and check that turns on after brake warning light turns off. engine start D Insufficient amount of brake fluid. Add brake fluid. D Brake fluid leaking from brake line. Investigate leaky point, correct it and add brake fluid.
  • Page 242 BRAKES 5-7 CHECK AND ADJUSTMENT BLEEDING BRAKES CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. NOTE: For vehicle equipped with ABS, make sure that ignition switch turns off.
  • Page 243 5-8 BRAKES 4) When fluid pressure in the cylinder is almost depleted, retigh- ten bleeder plug. 5) Repeat this operation until there are no more air bubbles in hy- draulic line. 6) When bubbles stop, with depressing brake pedal, tighten bleeder plug.
  • Page 244: Excessive Pedal Travel Check

    BRAKES 5-9 BRAKE PEDAL FREE HEIGHT CHECK Peel off carpet and check brake pedal for free height. Brake pedal free height “a” from silencer (1) : 150 – 160 mm (5.9 – 6.3 in.) If it is not within specification, check and adjust the following items 1) to 4).
  • Page 245: Brake Pedal Play Check

    5-10 BRAKES BRAKE PEDAL PLAY CHECK Pedal play should be within specification. If out of specification, check brake light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective. Pedal play “d”: 1 –...
  • Page 246 BRAKES 5-11 BRAKE DISC CHECK Refer to item FRONT DISC BRAKE PAD INSPECTION of Section 5B for inspection point and procedure. BRAKE PAD CHECK Inspect pad linings periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through hole of caliper and check lining (1) thickness of each pad.
  • Page 247 5-12 BRAKES PARKING BRAKE INSPECTION AND ADJUSTMENT Inspection Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches. There should be 4 to 9 notches. Also, check if both right and left rear wheels are locked firmly.
  • Page 248: Flushing Brake Hydraulic System

    BRAKES 5-13 FLUSHING BRAKE HYDRAULIC SYSTEM It is recommended that entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in hydraulic system. Periodical change of brake fluid is also recommended. FLUID PRESSURE TEST (if equipped with LSPV) Test procedure for LSPV assembly is as follows.
  • Page 249 5-14 BRAKES 3) Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake then. It should be within specification given below. Front brake Rear brake 7,500 kPa 5,600 – 7,100 kPa 75 kg/cm 56 –...
  • Page 250: Booster Operation Check

    BRAKES 5-15 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 251 5-16 BRAKES Check Operation 1) With engine stopped, depress brake pedal several times with the same load and make sure that pedal travel doesn’t change. 2) Start engine while depressing brake pedal. If pedal travel in- creases a little, operation is satisfactory. But no change in pedal travel indicates malfunction.
  • Page 252 BRAKES 5-17 TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts kg-m lb-ft Brake pipe 4-way joint bolt Brake pipe flare nut 11.5 Front caliper 0.65 Brake bleeder plug Brake bleeder plug Wheel cylinder 0.85 LSPV mounting bolt 19.0 LSPV spring end nut 19.0 LSPV spring bracket screw Wheel nut...
  • Page 254 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 255 5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER GENERAL DESCRIPTION LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped) As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
  • Page 256 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3 DIAGNOSIS Refer to Section 5 BRAKES. CHECK AND ADJUSTMENT Refer to Section 5 BRAKES. ON-VEHICLE SERVICE CAUTION: D Lubricate rubber parts with clean, fresh brake fluid to ease assembly. D Do not use lubricated shop air on brake parts as damage to rubber components may result. D If any hydraulic component is removed or brake line disconnected, bleed the brake system.
  • Page 257 5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER For vehicle with ABS Viewed from A Viewed from B Right Right Front Front Front Front Right Right Front Right Front Front Front Front Front Front Front [A]: For left-hand steering vehicle [B]: For right-hand steering vehicle a –...
  • Page 258 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-5 For vehicle without ABS Viewed from A Viewed from B Right Front Front Right Front Front Front Front [A]: For left-hand steering vehicle [B]: For right-hand steering vehicle a – g: Clamp 1.
  • Page 259 5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER REAR BRAKE HOSE/PIPE REMOVAL 1) Raise and suitably support vehicle. Remove tire and wheel. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. INSTALLATION 1) Reverse removal procedure for brake hose or pipe installation procedure.
  • Page 260 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7 MASTER CYLINDER RESERVOIR CAUTION: Observe CAUTION at the beginning of ON-VEHICLE SER- VICE. NOTE: For right hand steering vehicle, remove and install master cyl- inder reservoir according to procedure of MASTER CYLINDER ASSEMBLY REMOVAL and INSTALLATION in this section.
  • Page 261 5A-8 BRAKES PIPE / HOSE / MASTER CYLINDER INSTALLATION 1) For vehicle with ABS, install pin washer retainer (1) to secondary reservoir port of master cylinder (2) if removed. 2) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with.
  • Page 262: Master Cylinder Assembly

    BRAKES PIPE / HOSE / MASTER CYLINDER 5A-9 MASTER CYLINDER ASSEMBLY 1. Master cylinder assembly 2. Grommet [A]: with ABS 3. O-ring [B]: without ABS 4. Pin washer retainer : Tightening Torque 5. Reservoir CAUTION: D Never disassemble master cylinder. Disassembly will spoil its original performance.
  • Page 263 5A-10 BRAKES PIPE / HOSE / MASTER CYLINDER INSPECTION Inspect each parts for wear, deterioration or damage, and replace parts if necessary. Inspect master cylinder for scoring, corrosion and smooth opera- tion. It is best to replace corroded cylinder. Corrosion can be identified as pits or excessive roughness. [A]: with ABS [B]: without ABS INSTALLATION...
  • Page 264 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-11 3) Install master cylinder to brake booster. 4) Torque master cylinder attaching nuts to specification. Tightening Torque (a): 13 N m (1.3 kg-m, 9.5 lb-ft) 5) Connect hydraulic lines and torque flare nuts to specification. Special Tool (A): 09950-78240 Tightening Torque...
  • Page 265: Brake Booster

    1. Brake master cylinder assembly 2. Brake booster assembly 3. Gasket 4. Push rod clevis 5. Nut 6. Clevis pin: Apply SUZUKI SUPER GREASE A 99000-25010 to clevis pin. 7. Clip 8. Nut 9. Brake vacuum hose : Tightening Torque...
  • Page 266 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-13 INSTALLATION NOTE: Check for push rod length referring to above BRAKE BOOST- ER INSPECTION. 3, “A” 1) Install new gasket and booster to dash panel as shown. Then connect booster push rod clevis (1) to pedal arm (2) with clevis pin (3) and clip (4).
  • Page 267 5A-14 BRAKES PIPE / HOSE / MASTER CYLINDER LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped) 1. LSPV bracket 26 N m (2.6 kg-m) 2. LSPV assembly 2-1. Spring 2-2. Spring bracket 2-3. Screw 3. Brake pipe m (0.5 kg-m) : Tightening Torque CAUTION: D Never disassemble LSPV assembly.
  • Page 268 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15 INSTALLATION NOTE: New LSPV assembly is supplied with held in specified spring length with adjusting block (1). Do not remove adjusting block until spring (2) installation position is adjusted. 1) Install LSPV assembly with bracket to vehicle body. 2) Torque each bolt and nut to specification as indicated respec- tively in figure.
  • Page 269 5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER INSPECTION & ADJUSTMENT 1) 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. D Vehicle is placed on level floor.
  • Page 270 BRAKE PEDAL AND BRAKE PEDAL BRACKET 1. Brake booster assembly 2. Push rod clevis 3. Brake pedal bracket 4. Clevis pin: Apply SUZUKI SUPER GREASE A 99000-25010 to clevis pin. 5. Clip 6. Stop light switch 7. Stop light switch coupler 8.
  • Page 271 5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of caliper Brake fluid DOT 4 or SAE J1704 and wheel cylinder when they are disassembled.
  • Page 272 FRONT BRAKE 5B-1 SECTION 5B FRONT BRAKE NOTE: All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary.
  • Page 273 5B-2 FRONT BRAKE GENERAL DESCRIPTION DISC BRAKE CALIPER ASSEMBLY This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
  • Page 274 FRONT BRAKE 5B-3 ON-VEHICLE SERVICE CAUTION: Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo- nents may result. If any component is removed or line disconnected, bleed the brake system. Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners. 1-1.
  • Page 275 5B-4 FRONT BRAKE FRONT DISC BRAKE PAD REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolts (1). 3) Remove E-ring from strut and then remove caliper (1) from cali- per carrier. NOTE: Hang removed caliper with a wire hook (2) or the like so as to prevent brake hose from bending and twisting exces- sively or being pulled.
  • Page 276 FRONT BRAKE 5B-5 Brake Disc Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replace- ment are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc sur- face, replace it.
  • Page 277 5B-6 FRONT BRAKE INSTALLATION CAUTION: Observe CAUTION at the beginning of ON-VEHICLE SER- VICE. 1) Install pads (1). NOTE: Install pad with sensor (2) to vehicle center side. 2) Install caliper (1) and torque caliper pin bolts (2) to specification. Tightening Torque (a): 30 N m (3.0 kg-m, 22.0 lb-ft)
  • Page 278 FRONT BRAKE 5B-7 FRONT DISC BRAKE CALIPER REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove brake flexible hose bolt (1) from caliper (2). As this will allow fluid to flow out of hose, have a container (3) ready before- hand.
  • Page 279 5B-8 FRONT BRAKE 2) Remove piston boot (1) prying it with a metal tool (2) (no sharp edge). CAUTION: Be careful not to damage inside (bore side) of cylinder. 3) Remove piston seal using a thin blade like a thickness gauge, etc.
  • Page 280 FRONT BRAKE 5B-9 Piston Seal Piston seal is used to seal piston and cylinder and to adjust clear- ance between pad and disc. Replace with a new one at every over- haul. Fit piston seal into groove in cylinder taking care not to twist Piston and Boot 1-grooved side directed pad side...
  • Page 281 5B-10 FRONT BRAKE INSTALLATION CAUTION: Observe CAUTION at the beginning of ON-VEHICLE SER- VICE. 1) Install caliper (1) to caliper carrier (2). 2) Torque caliper pin bolts (3) to specifications. Tightening Torque (a): 30 N m (3.0 kg-m, 22.0 lb-ft) NOTE: Make sure that boots are fit into groove securely.
  • Page 282 FRONT BRAKE 5B-11 INSPECTION Refer to FRONT DISC BRAKE PAD INSPECTION. INSTALLATION 1) Install disc to wheel hub. 2) Install caliper assembly to steering knuckle. 3) Torque caliper carrier bolts (1) to specification. Tightening Torque (a): 95 N m (9.5 kg-m, 69.0 lb-ft) 4) Torque front wheel nuts to specifications.
  • Page 283 5B-12 FRONT BRAKE REQUIRED SERVICE MATERIAL MATERIALS RECOMMENDED PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of caliper Brake fluid DOT 4 or SAE J1704 and wheel cylinder when they are disassembled. An equivalent of Molykote PG 54 Rubber grease plastislip or Molykote Q5-7544 To caliper guiding and locking pins.
  • Page 284 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 285 5C-2 PARKING AND REAR BRAKE GENERAL DESCRIPTION DRUM BRAKE ASSEMBLY The drum brake assembly is of leading and trailing type drum brake and has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. The parking brake is mechanical and applies brake force to only rear wheels by means of the cable, linkage and shoes.
  • Page 286 PARKING AND REAR BRAKE 5C-3 ON-VEHICLE SERVICE CAUTION: D Replace all components included in repair kits to service this drum brake. Lubricate parts as speci- fied. D If any hydraulic component is removed or brake line disconnected, bleed the brake system. D The torque values specified are for dry, unlubricated fasteners.
  • Page 287 5C-4 PARKING AND REAR BRAKE PARKING BRAKE LEVER REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove console box. 3) Block vehicle wheels and release parking brake lever. 4) Disconnect lead wire of parking brake switch at coupler. 5) Loosen parking brake cable adjusting nut (1). 6) Remove parking brake lever bolts (1) and then remove parking brake lever assembly (2) with equalizer (3).
  • Page 288 PARKING AND REAR BRAKE 5C-5 PARKING BRAKE CABLE 1. Parking brake lever assembly 6. Grommet 2. Equalizer 7. Parking brake cable bolt 3. Adjusting nut 8. Parking brake lever bolt 4. Parking cable bracket 5. Parking brake cable: Apply water tight sealant 99000-31090 to plate and : Tightening Torque cable contact.
  • Page 289 5C-6 PARKING AND REAR BRAKE INSTALLATION Install parts in reverse order of REMOVAL procedure, noting the fol- lowing. 1) Distinguish right side parking brake cable from left side one with its clamp width. Parking brake cable with narrow clamp should be installed to right side of vehicle.
  • Page 290 PARKING AND REAR BRAKE 5C-7 BRAKE DRUM REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove spindle cap (1) as shown (by hammering lightly at 3 locations around it so as not to deform or cause damage to seat- ing part of cap). 3) Uncalk spindle nut, remove spindle nut (1).
  • Page 291 5C-8 PARKING AND REAR BRAKE 7) Remove sensor ring (1) from brake drum (2) using special tools (if equipped with ABS). CAUTION: Pull out sensor ring from brake drum gradually and even- ly. Attempt to pull it out partially may cause it to be de- formed.
  • Page 292 PARKING AND REAR BRAKE 5C-9 Brake shoe Where lining is worn out beyond service limit, replace shoe. Thickness (lining + shoe rim) Standard : 5.5 mm (0.22 in.) Service limit : 2.6 mm (0.10 in.) If one of brake linings is to service limit, all linings must be replaced at the same time.
  • Page 293 5C-10 PARKING AND REAR BRAKE 3) Put flat head rod or the like between rod (1) and rachet (2) and pull rachet as shown to maximize clearance between shoe and drum. 4) Install brake drum after making sure that inside of brake drum and brake shoes are free from dirt and oil.
  • Page 294 PARKING AND REAR BRAKE 5C-11 BRAKE SHOE REMOVAL 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL. 2) Remove shoe hold down springs (1) by turning shoe hold down pins (2). 3) Remove return springs, brake shoes and strut. 4) Disconnect parking brake cable (1) from parking brake shoe le- ver (2).
  • Page 295 5C-12 PARKING AND REAR BRAKE INSPECTION Parking Shoe Lever Inspect brake shoe lever for smooth movement along shoe rim. If defective, correct or replace. Brake Strut D Check ratchet of brake strut (1) assembly for wear or damage. D Check shoe return spring, strut shoe return spring and shoe hold down spring for damage, corrosion and weakening.
  • Page 296 PARKING AND REAR BRAKE 5C-13 3) Install shoe hold down springs (2) by pushing them down in place and turning hold down pins (1). 4) For procedure hereafter, refer to steps 3) to 12) of BRAKE DRUM INSTALLATION in this section. WHEEL CYLINDER REMOVAL 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
  • Page 297 5C-14 PARKING AND REAR BRAKE INSPECTION Inspect wheel cylinder disassembled parts for wear, cracks, corro- sion or damage. NOTE: Clean wheel cylinder components with brake fluid. INSTALLATION 1) Take off bleeder plug cap from brake pipe and connect pipe (for pipes) to wheel cylinder just enough to prevent fluid from leak- ing.
  • Page 298 PARKING AND REAR BRAKE 5C-15 5) Remove brake back plate (1) from rear axle. INSTALLATION 1) Apply water tight sealant to mating surfaces of brake back plate and rear axle. “A”: Sealant 366E, 99000-31090 NOTE: In case of vehicle equipped with ABS, do not apply sealant around hole for wheel speed sensor.
  • Page 299 5C-16 PARKING AND REAR BRAKE 4) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut to specified torque. (Refer to steps 1) to 4) of WHEEL CYLINDER INSTALLATION in this section.) 5) Install brake shoes, referring to steps 1) to 3) of BRAKE SHOE INSTALLATION in this section.
  • Page 300 PARKING AND REAR BRAKE 5C-17 REQUIRED SERVICE MATERIALS MATERIALS RECOMMENDED PRODUCT D To fill master cylinder reservoir. D To clean and apply to inner parts of caliper Brake fluid DOT 4 or SAE J1704 and wheel cylinder when they are disassembled.
  • Page 302 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 303 5E1-2 ANTILOCK BRAKE SYSTEM (ABS) 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 has also the following function.
  • Page 304 ANTILOCK BRAKE SYSTEM (ABS) 5E1-3 SYSTEM SCHEMATIC 1. ABS hydraulic unit / control module assembly 2. ABS control module 3. ABS hydraulic unit 4. Fail safe relay 5. Pump motor relay 6. Stop lamp switch 7. “ABS” warning lamp 8. Brake warning lamp 9.
  • Page 305 5E1-4 ANTILOCK BRAKE SYSTEM (ABS) BRAKE HOSE/PIPE ROUTING For LH Steering Vehicle For RH Steering Vehicle 1. Brake master cylinder 2. ABS hydraulic unit / control module assembly 3. Front disk brakes 4. Rear drum brakes...
  • Page 306 ANTILOCK BRAKE SYSTEM (ABS) 5E1-5 ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY ABS control module is a component of ABS hydraulic unit/control module assembly and has the following functions. Self-Diagnosis Function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the “ABS”...
  • Page 307 5E1-6 ANTILOCK BRAKE SYSTEM (ABS) SYSTEM CIRCUIT...
  • Page 308 ANTILOCK BRAKE SYSTEM (ABS) 5E1-7...
  • Page 309 5E1-8 ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSIS To ensure that the trouble diagnosis is done accurately and smooth- ly, observe “Precautions in Diagnosing Troubles” and follow “ABS Diagnostic Flow Table”. PRECAUTIONS IN DIAGNOSING TROUBLES D If the vehicles was operated in any of the following ways, “ABS” warning lamp may light momentarily but this does not indicate anything abnormal in ABS.
  • Page 310 ANTILOCK BRAKE SYSTEM (ABS) 5E1-9 ABS DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION 1) Perform “Customer Complaint Analysis”. Go to Step 2. Go to Step 5. 2) Perform “Problem Symptom Confirmation”. 3) Perform “Diagnostic Trouble Code Check, Record and Clearance”.
  • Page 311 5E1-10 ANTILOCK BRAKE SYSTEM (ABS) 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 312 ANTILOCK BRAKE SYSTEM (ABS) 5E1-11 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.) Check warning lamps related to brake system referring to “Brake Warning Lamp Check”...
  • Page 313 5E1-12 ANTILOCK BRAKE SYSTEM (ABS) BRAKE WARNING LAMP CHECK NOTE: Perform this check on a level place. 1) Turn ignition switch ON with parking brake applied. 2) Check that brake warning lamp (1) is turned ON. 3) Release parking brake with ignition switch ON and check that brake warning lamp goes off.
  • Page 314 ANTILOCK BRAKE SYSTEM (ABS) 5E1-13 TABLE – A “ABS” WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON 1. Main fuse 2. Ignition switch 3. Circuit fuse 4. Combination meter 5. “ABS” warning lamp 6. Brake warning lamp 7.
  • Page 315 Perform diagnostic trouble code check. Is there any Go to Step 2. Go to Step 3. DTC (including code No.12, NO CODES on SUZUKI scan tool) exists? Does malfunction DTC (other than code No.12) exist at Go to Step 7 of “ABS Go to Step 3.
  • Page 316 ANTILOCK BRAKE SYSTEM (ABS) 5E1-15 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 monitor coupler 3-1. Diagnosis switch terminal 3-2.
  • Page 317 5E1-16 ANTILOCK BRAKE SYSTEM (ABS) TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAGNOSIS SWITCH TERMINAL CONNECTED TO GROUND. “ABS” warning lamp in combination meter ABS hydraulic unit / control module assembly Diagnosis monitor coupler 3-1. Diagnosis switch terminal 3-2.
  • Page 318 ANTILOCK BRAKE SYSTEM (ABS) 5E1-17 TABLE – E BRAKE WARNING LAMP CHECK-LAMP COMES “ON” STEADY CIRCUIT DESCRIPTION Brake warning lamp is controlled by parking brake switch, brake fluid level switch and ABS control module/hydrau- lic unit assembly through lamp driver module in combination meter. Refer to “TABLE-A” for circuit diagram. STEP ACTION 1) Make sure that:...
  • Page 319 5E1-18 ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE (DTC) CHECK (USING “ABS” WARNING LAMP) 1) Perform “ABS” WARNING LAMP CHECK described above. 2) Using service wire (1), connect diagnosis switch terminal (2) of monitor coupler (3) to ground (4). 3) Turn ignition switch ON. 4) Read flashing of “ABS”...
  • Page 320 2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool opera- tor’s manual for further details. 4) After completing the check, turn ignition switch off and discon- nect SUZUKI scan tool from DLC.
  • Page 321 DIAGNOSTIC TROUBLE CODE (DTC) TABLE CAUTION: Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” before starting diagnosis. (displayed (indicated by “ABS” ABS warning lamp flashing pattern DIAGNOSTIC ITEMS SUZUKI warning scan tool) lamp) NO DTC Normal C1021 C1025 Wheel speed sensor circuit...
  • Page 322 ANTILOCK BRAKE SYSTEM (ABS) 5E1-21 DTC 21, 22 – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 25, 26 – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 31, 32 – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 35, 36 – LEFT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING 1.
  • Page 323 5E1-22 ANTILOCK BRAKE SYSTEM (ABS) DTC 21, 22, 25, 26, 31, 32, 35 or 36 INSPECTION STEP ACTION 1) Disconnect applicable ABS wheel speed sensor Go to Step 2. Replace ABS wheel coupler with ignition switch OFF. speed sensor 2) Measure resistance between terminals of ABS assembly.
  • Page 324 ANTILOCK BRAKE SYSTEM (ABS) 5E1-23 DTC 41 – RIGHT-FRONT INLET SOLENOID CIRCUIT 45 – LEFT-FRONT INLET SOLENOID CIRCUIT 51 – RIGHT-REAR INLET SOLENOID CIRCUIT 55 – LEFT-REAR INLET SOLENOID CIRCUIT 42 – RIGHT-FRONT OUTLET SOLENOID CIRCUIT 46 – LEFT-FRONT OUTLET SOLENOID CIRCUIT 52 –...
  • Page 325 5E1-24 ANTILOCK BRAKE SYSTEM (ABS) DTC 57 – POWER SOURCE CIRCUIT 1. Ignition switch 2. Main fuse 3. ABS hydraulic unit / control module assembly 4. ABS hydraulic unit / control module connector DESCRIPTION The ABS control module monitors the power source voltage at terminal “E20-18”. When the power source voltage becomes extremely high or low, this DTC will be set.
  • Page 326 ANTILOCK BRAKE SYSTEM (ABS) 5E1-25 DTC 61 – ABS PUMP MOTOR CIRCUIT 1. ABS hydraulic unit / control module assembly 2. ABS pump motor relay 3. ABS pump motor 4. ABS fail safe relay 5. ABS hydraulic unit / control module connector DESCRIPTION The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition...
  • Page 327 5E1-26 ANTILOCK BRAKE SYSTEM (ABS) DTC 63 – ABS FAIL-SAFE RELAY CIRCUIT 1. Ignition switch 2. ABS hydraulic unit / control module assembly 3. ABS hydraulic unit / control module connector 4. To solenoid valves 5. To pump motor relay 6.
  • Page 328 ANTILOCK BRAKE SYSTEM (ABS) 5E1-27 DTC 71 – ABS CONTROL MODULE 1. ABS hydraulic unit / control module assembly 2. ABS pump motor relay 3. ABS pump motor 4. ABS fail safe relay 5. ABS hydraulic unit / control module connector DESCRIPTION This DTC will be set when an internal malfunction is detected in the ABS control module.
  • Page 329 ON. Then DTC will be set in ABS control module. ABS HYDRAULIC UNIT OPERATION CHECK (USING SUZUKI SCAN TOOL) 1) Remove steering column hole cover. 2) Connect SUZUKI scan tool (Tech-1) to data link connector (DLC) (1) with ignition switch OFF. Special Tool (A): 09931-76011 (SUZUKI scan tool)
  • Page 330 ANTILOCK BRAKE SYSTEM (ABS) 5E1-29 9) Perform the 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 331 5E1-30 ANTILOCK BRAKE SYSTEM (ABS) REMOVAL 1) Disconnect negative cable from battery. 2) For LH vehicle, remove air cleaner outlet pipe (1) referring to “Engine Mechanical” section. 3) Disconnect ABS hydraulic unit/control module assembly con- nector (1) by pulling up lock (2). 4) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly (3).
  • Page 332 ANTILOCK BRAKE SYSTEM (ABS) 5E1-31 INSTALLATION 1) Install hydraulic unit by reversing removal procedure. Tightening Torque (a): 16 N m (1.6 kg-m, 11.5 lb-ft) (b): 9 N m (0.9 kg-m, 6.5 lb-ft) (c): 9 N m (0.9 kg-m, 6.5 lb-ft) (d): 26 N m (2.6 kg-m, 18.0 lb-ft) 2) Bleed air from brake system referring to “BRAKE”...
  • Page 333 5E1-32 ANTILOCK BRAKE SYSTEM (ABS) FRONT WHEEL SPEED SENSOR 1. Left front wheel speed sensor 2. Clamp bolt 3. Grommet 4. Connector 5. Sensor ring OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch OFF. 2) Hoist vehicle a little. 3) Disconnect wheel speed sensor connector (1). 4) Disconnect wheel speed sensor grommet from vehicle body.
  • Page 334 ANTILOCK BRAKE SYSTEM (ABS) 5E1-33 REMOVAL 1) Disconnect negative cable from battery. 2) Disconnect front wheel speed sensor coupler (1). 3) Hoist vehicle and remove wheel. 4) Remove harness clamp bolts (2) and grommet (3). 5) Remove front wheel speed sensor (4) from knuckle. CAUTION: D Do not pull wire harness when removing front wheel speed sensor.
  • Page 335 5E1-34 ANTILOCK BRAKE SYSTEM (ABS) FRONT WHEEL SPEED SENSOR RING NOTE: The front wheel sensor ring can not be removed or replaced alone. If front wheel sensor ring needs to be replaced, replace it as a wheel side joint assembly of drive shaft. For removal and installation of wheel side joint assembly of drive shaft, refer to “FRONT DRIVE SHAFTS”...
  • Page 336 ANTILOCK BRAKE SYSTEM (ABS) 5E1-35 REAR WHEEL SPEED SENSOR 1. Left rear wheel sensor 2. Trailing arm 3. Sensor ring 4. Sensor coupler OUTPUT VOLTAGE INSPECTION 1) Turn ignition switch “OFF”. 2) Hoist vehicle. 3) Disconnect connector of wheel speed sensor. 4) Connect voltmeter between connector terminals.
  • Page 337 5E1-36 ANTILOCK BRAKE SYSTEM (ABS) REMOVAL 1) Disconnect negative cable from battery. 2) Hoist vehicle. 3) Disconnect rear wheel speed sensor coupler (1). 4) Detach ABS wheel sensor wire harness (2) from suspension frame (3). Do not detach crip of rear wheel speed sensor connector from vehicle body unless replacement is necessary.
  • Page 338 3. Tech 1A 4. DLC cable 5. Test lead/probe 6. Power source cable 7. DLC cable adapter 8. Self-test adapter 09931-76011 09931-76030 SUZUKI scan tool (Tech 1A) kit Mass storage cartridge 16/14 pin DLC cable 09950-78220 Flare nut wrench (10 mm)
  • Page 340 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
  • Page 341 6-2 ENGINE GENERAL INFORMATION DTC P0120 Throttle Position Circuit DTC P0443 Purge Control Valve Circuit Malfunction ......6- 51 Malfunction .
  • Page 342 ENGINE GENERAL INFORMATION 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 343 6-4 ENGINE GENERAL INFORMATION PRECAUTION ON FUEL SYSTEM SERVICE HOSE CONNECTION D Work must be done with no smoking, in a well-ventilated area and With short pipe, fit hose as far as it reaches pipe joint as away from any open flames. shown.
  • Page 344 ENGINE GENERAL INFORMATION 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 345 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 information...
  • Page 346 ENGINE 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” consists of engine startup and engine shutoff. 2 Driving Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC and freeze frame data) but the...
  • Page 347 Data Link Connector (DLC) DLC (1) is in compliance with SAEJ1962 in its installation position, the shape of connector and pin assignment. Serial data line (K line of ISO 9141) is used for SUZUKI scan tool (Tech-1) to communicate with ECM. Body ground...
  • Page 348 ENGINE 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 349 ECM memory. D Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool (Tech-1) or generic 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 350 ENGINE DIAGNOSIS 6-11 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. next page. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) and Freeze Frame Data 1) Print DTC and...
  • Page 351 6-12 ENGINE DIAGNOSIS 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 352 ENGINE DIAGNOSIS 6-13 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 353 1) Check malfunction indicator lamp referring to “Malfunction Indi- cator Lamp Check” in this section. 2) With the ignition switch OFF position, disconnect SUZUKI scan tool if connected and using service wire (1), ground diagnosis switch terminal (2) in monitor coupler (3).
  • Page 354 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. 3) Erase DTC and pending DTC according to instructions dis- played on scan tool.
  • Page 355 6-16 ENGINE DIAGNOSIS 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) circuit malfunction...
  • Page 356 ENGINE DIAGNOSIS 6-17 (vehicle (vehicle DETECTING CONDITION DETECTING ITEM with without (DTC will set when detecting:) valve) valve) P0325 Knock sensor circuit Knock sensor circuit low input 1 driving 1 driving (No.17) malfunction Knock sensor circuit high input cycle cycle P0335 Crankshaft position sensor 1 driving...
  • Page 357 6-18 ENGINE DIAGNOSIS DETECTING CONDITION DETECTING ITEM (DTC will set when detecting:) P0702 P1702 Internal Malfunction of TCM (No.52) P0705 Transmission Range Switch Circuit (No.34) Malfunction lP0710l Transmission Fluid Temperature No.36 Signal Circuit Malfunction No.38 P0715 Input/Turbine Speed Sensor (No.14) Circuit Malfunction P0720 A/T VSS Signal Circuit Malfunction...
  • Page 358 ENGINE DIAGNOSIS 6-19 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 D ECM uses value determined by throttle Manifold absolute pressure circuit...
  • Page 359 6-20 ENGINE DIAGNOSIS 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 – – – – – level, leakage Section 0B D A/T fluid –...
  • Page 360 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) Remove air cleaner bolt and clips and shift air cleaner position to observe ignition timing.
  • Page 361 6-22 ENGINE DIAGNOSIS Fig. 1 for Step 5 Fig. 2 for Step 6 Fig. 3 for Step 6 When not using SUZUKI scan tool: When using SUZUKI scan tool Select “DATA LIST” mode SELECT MENU F4: MISC TEST Fig. 4 for Step 6 Fig.
  • Page 362 ENGINE DIAGNOSIS 6-23 ENGINE DIAGNOSIS TABLE Perform troubleshooting referring to following table when ECM has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Referring Item Hard Starting Ignition system out of order (Engine cranks OK) D Faulty spark plug Spark plugs in Section 6F1...
  • Page 363 6-24 ENGINE DIAGNOSIS Condition Possible Cause] Referring Item Low oil pressure D Improper oil viscosity Engine oil and oil filter change in Section 0B D Malfunctioning oil pressure switch Oil pressure switch inspection in Section 8 D Clogged oil strainer Oil pan and oil pump strainer cleaning in Section 6A1 D Functional deterioration of oil pump...
  • Page 364 ENGINE DIAGNOSIS 6-25 Condition Possible Cause Referring Item Overheating D Inoperative thermostat Thermostat in Section 6B D Poor water pump performance Water pump in Section 6B D Clogged or leaky radiator Radiator in Section 6B D Improper engine oil grade Engine oil and oil filter change in Section 0B D Clogged oil filter or oil strainer...
  • Page 365 6-26 ENGINE DIAGNOSIS Condition Possible Cause Referring Item Engine hesitates Ignition system out of order (Momentary lack of D Spark plug faulty or plug gap out of adjustment Spark plugs in Section 6F1 response as D Leaky high-tension cord High-tension cords in Section 6F1 accelerator is Fuel system out of order depressed.
  • Page 366 ENGINE DIAGNOSIS 6-27 Condition Possible Cause Referring Item Engine has no Ignition system out of order power D Faulty spark plug Spark plugs in Section 6F1 D Faulty ignition coil with ignitor Ignition coil in Section 6F1 D Leaks, loose connection or disconnection of High-tension cords in Section 6F1 high-tension cord D Faulty knock sensor...
  • Page 367 6-28 ENGINE DIAGNOSIS Condition Possible Cause Referring Item Improper engine Ignition system out of order idling or engine D Faulty spark plug Spark plugs in Section 6F1 fails to idle D Leaky or disconnected high-tension cord High-tension cords in Section 6F1 D Faulty ignition coil with ignitor Ignition coil in Section 6F1 Fuel system out of order...
  • Page 368 ENGINE DIAGNOSIS 6-29 Condition Possible Cause Referring Item Excessive Ignition system out of order hydrocarbon (HC) D Faulty spark plug Spark plugs in Section 6F1 emission or carbon D Leaky or disconnected high-tension cord High-tension cords in Section 6F1 monoxide (CO) D Faulty ignition coil with ignitor Ignition coil assembly in Section Low compression...
  • Page 369 6-30 ENGINE DIAGNOSIS SCAN TOOL DATA As the da