MARUTI SUZUKI Zen Estilo 2018 Manual

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Volume 1

Precautions ........................................................ 00-i

Precautions ......................................................... 00-1

General Information ............................................ 0-i

General Information ........................................... 0A-1

Maintenance and Lubrication ............................. 0B-1

Engine ................................................................... 1-i

Precautions .......................................................... 1-1

Engine General Information and Diagnosis ....... 1A-1

Aux. Emission Control Devices .......................... 1B-1

Engine Electrical ................................................ 1C-1

Engine Mechanical ............................................ 1D-1

Engine Lubrication System ................................ 1E-1

Engine Cooling System ...................................... 1F-1

Fuel System ....................................................... 1G-1

Ignition System .................................................. 1H-1

Starting System ................................................... 1I-1

Charging System ................................................ 1J-1

Exhaust System .................................................. 1K-1

Suspension .......................................................... 2-i

Precautions ........................................................... 2-1

Suspension General Diagnosis .......................... 2A-2

Front Suspension ............................................... 2B-1

Rear Suspension ............................................... 2C-1

Wheels and Tires ............................................... 2D-1

Front Drive Shaft ................................................. 3-i

Front Drive Shaft ................................................ 3A-1

Brakes ................................................................... 4-i

Brakes ................................................................... 4-1

Brakes (With ABS) .............................................. 4A-1

ABS ..................................................................... 4B-1

Transmission ....................................................... 5-i

Manual Transmission .......................................... 5B-1

Clutch ................................................................. 5C-1

Volume 2

ecautions ........................................................ 00-i

Precautions ........................................................ 00-1

Steering ................................................................ 6-i

Steering General Diagnosis ............................... 6A-1

Steering Wheel and Column .............................. 6B-1

Electrical Power Steering System ..................... 6C-1

HVAC ...................................................................... 7-i

Precautions ........................................................... 7-1

Heater and Ventilation ........................................ 7A-1

Air Conditioning System ..................................... 7B-1

Restraint ............................................................... 8-i

Seat Belts ............................................................ 8A-1

Air Bag System ................................................... 8B-1

Body, Cab and Accessories ............................... 9-i

Precautions ........................................................... 9-1

Wiring Systems .................................................. 9A-**

(Refer wiring Diagram manual Part

No.99512M59K00-74E)

Lighting Systems ................................................ 9B-1

Instrumentation / Driver Info. / Horn .................. 9C-1

Wipers / Washers ............................................... 9D-1

Glass / Windows / Mirrors ................................... 9E-1

Security and Locks ............................................. 9F-1

Seats .................................................................. 9G-1

Interior Trim ........................................................ 9H-1

Hood / Fenders / Doors ...................................... 9J-1

Body Structure .................................................... 9K-1

Paint / Coatings ................................................... 9L-1

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Summary of Contents for MARUTI SUZUKI Zen Estilo 2018

Page 1: Table Of Contents
TABLE OF CONTENTS Volume 1 Volume 2 Precautions ............00-i ecautions ............00-i Precautions ............00-1 Precautions ............00-1 General Information ..........0-i Steering ..............6-i General Information ........... 0A-1 Steering General Diagnosis ....... 6A-1 Maintenance and Lubrication ......0B-1 Steering Wheel and Column ......
Page 2 IMPORTANT Warning/Caution/Note Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted bythese 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.
Page 3: Volume
FOREWORD This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul). VOLUME 1 contains General information, Engine, Suspension, Drive/Shaft, Brakes and Transmission/sections (Sections 0 –...
Page 4 TABLE OF CONTENTS 00-i Section 00 Precautions CONTENTS Precautions ............00-1 Air Bag Warning ......... 00-13 Precautions ............ 00-1 Air Bag System Service Warning ....00-13 Precautions for Vehicles Equipped with ..00-1 Fastener Caution ........00-13 General Precautions ........00-4 Suspension Caution ........
Page 6: Precautions
Precautions 00-1 Precautions Precautions Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System Warning: • • • • • The configuration of air bag system parts are as shown in the figure. When it is necessary to service (remove, reinstall and inspect) these parts, be sure to follow procedures described in Air Bag System section.
Page 7 00-2 Precautions Servicing and Handling Warning: Many of service procedures require disconnection of “A/BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules • • • • • For handling and storage of a live air bag (inflator) module,select a place where the ambient temperature below 65 °C (150 °F),without high humidity and away from electric...
Page 8 Precautions 00-3 Warning: • • • • • For handling and storage of a SDM, select a place where the ambient temperature below 65 °C (150°F), without high humidity and away from electric noise. • • • • • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM).
Page 9: General Precautions
00-4 Precautions Precautions 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: •...
Page 10 Precautions 00-5 Caution: • When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. •...
Page 11: Precautions For Catalytic Converter
00-6 Precautions Caution: • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly. • After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks.
Page 12: Precautions For Electrical Circuit Service
Precautions 00-7 Precautions For Electrical Circuit Service • When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get damaged. • Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P/S controller, etc.).
Page 13: Electrical Circuit Inspections Procedure
00-8 Precautions • When connecting meter probe (2) from terminal side of coupler (1) Since it can’t be connected from harness side, use extra care not to bend male terminal of coupler or force its female terminal open for connection. In case of such coupler as shown, connect probe as shown to avoid opening female terminal.
Page 14 Precautions 00-9 When checking system circuits including an electronic control unit such as ECM, TCM, ABS control module, etc., it is important to perform 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 for loose connection.
Page 15 00-10 Precautions 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 16: Intermittent And Poor Connection
Precautions 00-11 4) Disconnect the connector included in circuit (connector B) and measure resistance between A-1 and body ground. If continuity is indicated, it means that the circuit is shorted to the ground between terminals A-1 and B-1. Other wise it means that circuit is shorted to the ground between terminals B-1 and C-1.
Page 17 00-12 Precautions • Improperly formed or damaged terminals. Check each connector terminal in problem circuits carefully to ensure good contact tension by using the corresponding mating terminal. If contact tension is not enough, reform it to increase contact tension or replace. •...
Page 18: Air Bag Warning
Precautions 00-13 Air Bag Warning Warning: For vehicles equipped with Supplemental Restraint (Air Bag) System: • • • • • Service on and around the air bag system components or wiring must be performed only by an authorized MARUTI dealer. Refer to “Air Bag System Components, Wiring and Connectors Location: in Section 8B”...
Page 19: Wheels And Tires Caution
00-14 Precautions Wheels and Tires Caution Caution: 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 20 TABLE OF CONTENTS 0A-i Section 0A General Information CONTENTS General Information ........0A-1 Fuel Lines Inspection ........0B-9 General Description ........0A-1 Fuel Filter Replacement ......0B-9 Abbreviations ..........0A-1 Fuel Tank Inspection ........0B-10 Symbols ............0A-3 PCV Valve Inspection ........ 0B-10 Metric Information ........
Page 22: General Information
GENERAL INFORMATION 0A-1 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 Module : American Petroleum Institute : Engine Control Module : Automatic Transmission Fluid ECT Sensor : Engine Coolant Temperature...
Page 23: 0A-2 Generalinformation
0A-2 GENERALINFORMATION : Japanese Industrial Standard : Society of Automotive Engineers : Sensing and Diagnostic : Left Hand Module LSPV : Load Sensing Proportioning : Sequential Multiport Fuel Valve Injection SOHC : Single Over Head Camshaft MAF Sensor : Mass Air Flow Sensor (Air Flow Sensor, AFS, Air : Throttle Body Fuel Injection Flow Meter, AFM)
Page 24 GENERAL INFORMATION 0A-3...
Page 25: Metric Information
0A-4 GENERALINFORMATION Metric Information Metric Fasteners Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. Fastener Strength Identification Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class identification embossed on the head of each bolt.
Page 26 GENERAL INFORMATION 0A-5 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 27: Vehicle Lifting Points
0A-6 GENERALINFORMATION Vehicle Lifting Points Warning: • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 28 GENERAL INFORMATION 0A-7 In raising front vehicle end off the floor by jacking, be sure to apply jack against front jacking bracket (1). In raising rear vehicle end off the floor by jacking, be sure to apply jack against the center portion of rear axle (2). Caution: •...
Page 29: Vehicle Identification Number
0A-8 GENERALINFORMATION 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 (1) is punched on the cylinder block.
Page 30: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION 0B-1 Periodic Maintenance Schedule This table includes services as scheduled up to 80,000 km mileage. Interval: Beyond 80,000 km, carry out the same services at the same intervals This interval should be judged by respectively. odometer reading or months, whichever comes first.
Page 31: 0B-2 Maintenance And Lubrication
0B-2 MAINTENANCE AND LUBRICATION This table includes services as scheduled up to 80,000 km mileage. Interval: Beyond 80,000 km, carry out the same services at the same intervals This interval should be judged by respectively. odometer reading or months, Km (x 1,000) whichever comes first.
Page 32 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 80,000 km mileage. Interval: Beyond 80,000 km, carry out the same services at the same intervals This interval should be judged by respectively. odometer reading or months, Km (x 1,000) whichever comes first.
Page 33: Maintenance Service
0B-4 MAINTENANCE AND LUBRICATION Maintenance Service Engine Accessory Drive Belt Inspection Drive Belt Inspection and Replacement Warning: Disconnect negative cable at battery before checking and replacing belt tension. Water pump belt inspection 1) Disconnect negative cable from battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
Page 34: Camshaft Timing Belt Replacement
MAINTENANCE AND LUBRICATION 0B-5 Camshaft Timing Belt Replacement Replace belt with new one. Refer to SECTION 1D for replacement procedure. Caution: • Do not bent or twist timing belt. • Do not allow timing belt to come into contact with oil, water, etc.
Page 35 0B-6 MAINTENANCE AND LUBRICATION 3) Loosen oil filter (1) by using oil filter wrench (Special tool). Special Tool (A): 09915M47340 4) Apply engine oil to new oil filter “O” ring. 5) Screw new filter on oil filter stand by hand until filter “O” ring contacts mounting surface.
Page 36: Engine Coolant Change
MAINTENANCE AND LUBRICATION 0B-7 Engine Coolant Change Warning: To help avoid danger of being burned, do not remove radiator 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. Caution: When changing engine coolant, use mixture of 50% water and 50% ethylene-glycol base coolant (Anti-...
Page 37: Exhaust System Inspection
0B-8 MAINTENANCE AND LUBRICATION 5) Slowly pour specified amount of coolant to the base of radiator filler neck, and run engine, with radiator cap removed, until radiator upper hose is hot. This drives out any air which may still be trapped within cooling system. Add coolant as necessary until coolant level reaches filler throat of radiator.
Page 38: Spark Plug Replacement
MAINTENANCE AND LUBRICATION 0B-9 Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1. 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, damaged or oily.
Page 39: Fuel Tank Inspection
0B-10 MAINTENANCE AND LUBRICATION Fuel Tank Inspection Check fuel tank for damage, cracks, fuel leakage, corrosion and tank bolts looseness. If a problem is found, repair or replace. 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.
Page 40: Brake Hoses And Pipes Inspection
MAINTENANCE AND LUBRICATION 0B-11 Brake drums and shoes 1) Remove wheel and brake drum. 2) Check rear brake drums and brake linings for excessive wear and damage. At the same time, check wheel cylinders for leakage. Replace as necessary. For the details, refer to Section 4C. 3) Install brake drum and wheel.
Page 41: Brake Lever And Cable Inspection
0B-12 MAINTENANCE AND LUBRICATION Brake Lever and Cable Inspection Parking brake lever • Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking lever. • Check parking brake lever for proper operation and stroke, and adjust it if necessary.
Page 42: Wheel Discs Inspection
MAINTENANCE AND LUBRICATION 0B-13 [Wheel disc inspection] Inspect each wheel disc for dents, distortion and cracks. A disc in badly damaged condition must be replaced. [Tire rotation] Rotate tires referring to Section 2D. Wheel Bearing Inspection 1) Check front wheel bearing for wear, damage, abnormal noise or rattles.
Page 43: Steering System Inspection
0B-14 MAINTENANCE AND LUBRICATION Steering System Inspection 1) Check steering wheel for play and rattle, holding vehicle straight on ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.1 in.) 2) Check bolts and nuts for tightness and retighten them as necessary.
Page 44: Manual Transmission Oil Inspection And Change
MAINTENANCE AND LUBRICATION 0B-15 Manual Transmission Oil Inspection and Change Inspection 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove oil filler/level plug (1) of transmission. 4) Check oil level.
Page 45: Final Inspection
0B-16 MAINTENANCE AND LUBRICATION Gearshift or Select Lever (Transmission) Final Inspection Check gear shift or select lever for smooth shifting to Warning: all positions and for good performance of transmission When carrying out road tests, select a safe in any position. place where no man or no running vehicle is Brake seen so as to prevent any accident.
Page 46: Recommended Fluids And Lubricants
MAINTENANCE AND LUBRICATION 0B-17 Recommended Fluids And Lubricants Engine oil SE, SF, SG, SH or SJ (Refer to engine oil viscosity chart in item 1-4.) Engine coolant (Ethylene glycol base coolant) “Antifreeze/Anticorrosion coolant” Brake fluid GC 1500AA (Sunstar CCI) Manual transmission oil API GL-4, SAE75W-90 (Refer to Section 5B for detail) Door hinges Engine oil or water resistance chassis grease...
Page 48: Engine
TABLE OF CONTENS i-A Section 1 Engine CONTENTS Engine General Information and DTC P0112/0113: Intake Air Tempera- Diagnosis ............1A-1 ture Sensor Circuit ........1A-39 Precautions ........... 1A-1 DTC P0117/P0118: Engine Coolant Precautions on Engine Service ..... 1A-1 Temperature Circuit ........1A-40 Precautions in Diagnosing Trouble ....
Page 49 ii-A TABLE OF CONTENS Valve Spring Inspection ......1D-39 Engine Coolant Temperature (ECT) Sensor Removal, Inspection Pistons, Piston Rings, Connecting Rods and Cylinder Components ......1D-40 and Installation ..........1C-9 Pistons, Piston Rings, Connecting Rods Heated Oxygen Sensor On-Vehicle Inspection ........... 1C-10 and Cylinder Removal and Installation ..
Page 50 TABLE OF CONTENS iii-A Radiator Fan Control Relay ......1F-10 High-Tension Cord Removal, Inspection and Radiator Cooling Fan Relay Inspection ..1F-10 Installation ............ 1H-6 Radiator Cooling Fan Removal Spark Plug Removal, Inspection and Installation ..........1F-10 and Installation ..........1H-7 Radiator Removal, Inspection Ignition Coil Assembly (Including ignitor) and Installation ...........
Page 52: Precautions
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-1 Engine General Information and Diagnosis Precautions Precautions on Engine Service Caution: The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable engine performance. •...
Page 53: Engine Diagnosis General Description
1A-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS • A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation. • Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order.
Page 54 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-3 • If the above areas of engine and emission control system is free from any trouble after the engine start (while engine is running), malfunction indicator lamp turns OFF. • When ECM detects a trouble which has occurred in the above areas, it makes malfunction indicator lamp turn ON while the engine is running to warn driver of such occurrence of trouble.
Page 55: Engine And Emission Control System Description
1A-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS Serial data line (3) (K line of ISO 9141) is used forSUZUKI scan tool to communicate with ECM, Air bag SDM, BCM (Body electrical Control Module) and ABS control module. Engine and Emission Control System Description The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system.
Page 56: Air Intake System Description
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-5 Air Intake System The main components of the air intake system are air cleaner, air cleaner outlet hose, throttle body, IAC valve and intake manifold. The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air cleaner, passs through the throttle body, is distributed by the intake manifold and finally drawn into each combustion chamber.
Page 57 1A-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS...
Page 58 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-7...
Page 59 1A-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL ARRANGEMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) Speedometer Fuel injector No. 1 EPS. Fuel injector No. Vehicle speed sensor (VSS) Fuel injector No. 3 Manifold absolute pressure (MAP) sensor Fuel injector No. 4 Throttle position (TP) sensor Idle air control (IAC) valve Engine coolant temp.
Page 60 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-9 Terminal Arrangement of ECM (PCM) Coupler (viewed from harness side) Connector C50 Connector C50 TERMINAL WIRE COLOR CIRCUIT TERMINAL WIRE COLOR CIRCUIT BLANK WHITE-GREEN IGNITION COIL #2 BLANK YELLOW-RED IGNITION COIL #1 PINK-BLUE IGNITION TIMING BLANK ADJUSTMENT SWITCH BLANK...
Page 61: Engine And Emission Control Input/Output Table
1A-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS Terminal Arrangement of ECM (PCM) Coupler (viewed from harness side) Connector G01 Connector C52 TERMINAL WIRE COLOR CIRCUIT TERMINAL WIRE COLOR CIRCUIT RED-WHITE ELECTRIC LOAD 2 (+) VIOLET-YELLOW DIAGNOSIS OUTPUT GREEN-BLACK ELECTRIC LOAD (-) VIOLET-WHITE SERIAL DATA LINK BLANK...
Page 62: Schematic And Routing Diagram
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-11 Schematic and Routing Diagram Engine and Emission Control System Diagram...
Page 63 1A-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS Air Cleaner Ignition coil assembly EVAP canister purge valve (For No.1 and No.4 spark plugs) IAT sensor Ignition coil assembly TP sensor (For No.2 and No.3 spark plugs) IAC valve ECM (PCM) MAP sensor Radiator fan A/C evaporator temp.
Page 64: Component Location
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-13 Component Location Electronic Control System Components Location The electronic control system consists of 1) • Fuel injection control system various sensors which detect the state of • Idle speed control system engine and driving conditions, 2) ECM (PCM) •...
Page 65: Diagnostic Information And Procedures
1A-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS Diagnostic Information and Procedures Engine and Emision Control System Check Refer to the following pages for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis. complaint analysis.
Page 66 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-15 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. Customer Problem Inspection Form (Example) User name: Model:...
Page 67 1A-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS 2. Diagnostic Trouble Code (DTC) Check, Record and Clearance First, check DTC referring to “DTC Check” in this section. If DTC is indicated, print it or write it down and then clear it by referring to “DTC Clearance” in this section. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
Page 68 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-17 Engine Basic Inspection Flow Table Step Action Was "ENGINE DIAG. FLOW TABLE" performed ? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE". Check battery voltage. Go to Step 3. Charge or replace battery. Is it 11 V or more ? Is engine cranked ? Go to Step 4.
Page 69: Check
1A-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS Malfuntion Indicator Lamp (MIL) Check 1) Turn ON ignition switch (but engine at stop) and check that malfunction indicator lamp lights up. If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1 in this section. If lamp flashes, go to DIAGNOSTIC FLOW TABLE A-2 in this section.
Page 70 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-19 Diagnostic Trouble Tode (DTC) Table DIAGNOSTIC TROUBLE CODE NO. SUZUKI Diagnostic Item Detecting Condition SCAN TOOL Normal P0107 Manifold absolute pressure Low pressure-high vacuum-low voltage P0108 sensor circuit malfunction High Pressure-low vacuum-high voltage P0122 Throttle position sensor Throttle position circuit low input P0123...
Page 71: Engine Diagnosis Table
1A-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS ENGINE DIAGNOSIS TABLE Condition Possible Cause Reference Item Hard starting Engine and emission control system (Engine cranks OK) out of order. • Faulty CMP sensing rotor CMP sensing rotor inspection in section • Faulty idle air control system Diag.
Page 72 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-21 Condition Possible Cause Reference Item Improper engine Ignition system out of order. • Faulty spark plug Spark plugs in Section 1. idling or engine fails • Faulty ignition coil with ignitor Ignition coil in Section 1. to idle Fuel system out of order.
Page 73 1A-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item` Excessive detonation Engine overheating Refer to “Overheating” Section. (The engine makes Ignition system out of order. • sharp metallic knocks Faulty spark plug Spark plugs in Section 1. • that change with Improper ignition timing Ignition timing in Section 1.
Page 74 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-23 Condition Possible Cause Reference Item • Low oil pressure Improper oil viscosity Engine oil and oil filter change in Section 0B. • Malfunctioning oil pressure switch Oil pressure switch inspection in Section 1. • Clogged oil strainer Oil pan and oil pump strainer cleaning in Section 1.
Page 75 1A-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS Condition Possible Cause Reference Item Excessive nitrogen Fuel system out of order • oxides (NOx) Fuel pressure out of specification Fuel pressure check in Section 1. emission Engine and emission control system Check for absence of filler neck •...
Page 76: Malfunction Indicator Lamp Does Not Light At Ignition Switch
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-25 A-1 Malfunction Indicator Lamp Circuit Check (Malfunction indicator lamp does not light at ignition switch ON.) 1. Battery positive voltage 2. Main fuse 3. Ignition switch 4. “IG” fuse 5. Malfunction indicator lamp 6. Combination meter 7.
Page 77 1A-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS A-2 Malfunction Indicator Lamp Circuit Check (Malfunction indicator lamp flashes at ignition switch ON.) Step Action MIL Flashing Pattern Check Go to Step 2. Substitute a known-good 1) Turn ignition switch ON. ECM and recheck. Does lamp flashing pattern indicate diagnostic trouble code?
Page 78 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-27 A-3 ECM Power and Ground Circuit Check (Page 1 of 2) (Malfunction idicator lamp does not light at ignition switch ON and engine does not start though it is cranked up..) Step Action Main Relay Check Go to Step 5.
Page 79 1A-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS A-3 ECM (PCM) Power and Ground Circuit Check (Page 2 of 2) Step Action ECM Power Circuit Check Check ground circuits Go to Step 6. 1) Using service wire, ground terminal C50-15 and “B/O” and “B” for open. measure voltage between terminal C51-3 If OK, then substitute a (C51-2) and ground at ignition switch ON.
Page 80 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-29 DTC P0107 / P0108 : MAP Sensor Circuit (SingnaI Voltage Low, High or Performance Problem) Step Action 1) Disconnect MAP sensor coupler with ignition Go to Step 2. “Gr/R” wire open or short. switch OFF. Poor “C51-8”...
Page 81 1A-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS Note: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 1A-18 to confirm that the trouble has been corrected.
Page 82 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-31 DTC P0122 / P0123 : TP Sensor Circuit (Signal Voltage High or Low) Step Action 1) Disconnect TP sensor coupler with ignition Go to Step 2. “Gr/R” wire open or short. switch OFF. Poor “C51-9” connection. 2) Check voltage between “Gr/R”...
Page 83 1A-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS Note: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 1A-18 to confirm that the trouble has been corrected.
Page 84 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-33 DTC P0031 / P0032 : Heated Oxygen Sensor Control Circuit Low / High (Sensor) Step Action Was “Engine and Emission Go to Step 2. Go to “Engine and Control System Check” performed? Emission Control System Check: ”.
Page 85 1A-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action HO2S heater drive circuit check\ 1) Connect connector to HO2S with ignition Go to Step 7. “YEL/RED” wire is open switch turned OFF. circuit. 2) Turn ON ignition switch. 3) Measure voltage between “C51-07” terminal of ECM connector and vehicle body ground with connector disconnected from ECM.
Page 86 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-35 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected Step Action Was “Engine and Emission Control System Go to Step 2. Go to “Engine and Check” performed? Emission Control System Check: ”. HO2S output voltage check 1) Connect scan tool to DLC with ignition Intermittent trouble, Go to Step 3.
Page 87 1A-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS Step Action Wire circuit check 1) Disconnect connectors from ECM with Go to Step 6. “RED” wire is shorted to ignition switch turned OFF. ground circuit. 2) Measure resistance between “RED” wire terminal of HO2S connector and vehicle body ground.
Page 88 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-37 DTC P0340 : CMP Sensor Circuit (Sensor signal not inputted for 2 seconds at engine cranking) Note: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even through CMP sensor is in good condition.
Page 89 1A-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0500 : VSS Circuit (VSS signal not inputted although fuel is kept cut at lower than) Step Action Does speedometer indicate vehicle speed? “V” wire open. Go to Step 2. Poor “C51-34” connection. If OK, substitute a knowngood ECM (PCM) and recheck.
Page 90 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-39 DTC P0112 / P0113 : IAT Sensor Circuit (Signal voltage high or low) Step Action 1) Disconnect IAT sensor coupler with ignition Go to Step 2. “Lg/B” wire open or short. switch OFF. Poor “C51-16” connection. 2) Check voltage between “Lg/B”...
Page 91 1A-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS DTC P0117 / P0118 : ECT Sensor Circuit (Signal voltage high or low) Note: When DTC P0105/0120/0110/0115 are indicated together, it is possible that “O” wire is open or “C51-05” terminal connections are poor. Step Action 1) Disconnect ECT sensor coupler with ignition...
Page 92 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-41 Inspection of ECM (PCM) and its Circuits ECM (PCM) and its circuits can be checked at ECM (PCM) wiring couplers by measuring voltage and resistance. Caution: ECM (PCM) cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM (PCM) with couplers disconnected from it.
Page 93 1A-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C 50 - 01 Engine Starting Signal 1.5 V or less Ignition switch ON 6 - 12 V While Engine Cranking C50-02 Fuel Injector no. 4 10 - 14 V Ignition switch ON C50-03 Fuel Injector no.
Page 94 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-43 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-15 ECT sensor 2.5 - 3.0 V Engine coolant temp : at 20°C 0.6 - 0.9 V Engine coolant temp : at 80°C C51-16 IAT sensor 2.0 - 2.5 V IAT sensor ambient temp : at 20°C 0.4 - 0.6 V IAT sensor ambient temp : at 80°C...
Page 95 1A-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION G01-18 Blank G01-19 Blank G01-20 Blank G01-21 Blank G01-22 Blank G01-23 Blank G01-24 Blank G01-25 Blank G01-26 Blank G01-27 Blank G01-28 Blank G01-29 Blank G01-30 Blank G01-31 Blank Resistance Check 1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition switch OFF.
Page 96: B-1 Ecm Power And Ground Circuit Check
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-45 B-1 ECM Power and Ground Circuit Check 1. Main fuse box 5. "IG COIL" fuse 9. "FI" fuse 13. Map sensor 2. Ignition switch 6. ECM 10. “RADIO” fuse 14. A/C refrigerant pressure sensor 3.
Page 97 1A-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS Troubleshooting Note: • Before performing the trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”.
Page 98 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-47 Step Action Main relay circuit check Go to Step 11. Go to Step 8. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Using service wire, ground “C50-15” terminal of ECM connector and measure voltage between each “C51-02” and “C51-03”...
Page 99: Fuel Injector Circuit Check
1A-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS B-2 Fuel Injector and Its Circuit Check Fuel Injector Circuit Check Troubleshooting Note: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”.
Page 100 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-49 Ground Circuit Check: ”. Step Action Wire circuit check Go to Step 6. “BRN/YEL”, “BLU/WHT”, 1) Turn OFF ignition switch. “BLU/ORG” and/or 2) Disconnect connectors from ECM. “YEL/GRN” wire(s) are 3) Measure resistance between each “BLU/YEL”, shorted to ground.
Page 101: B-3 Fuel Pump And Its Circuit Check
1A-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS B-3 Fuel Pump and Its Circuit Check Troubleshooting Note: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”.
Page 102 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-51 Step Action Fuel pump relay check Go to Step 5. Faulty relay. 1) Check fuel pump relay referring to “Main Relay, Fuel Pump Relay, Starting Motor Control Relay and Throttle Actuator Control Relay Inspection: in Section 1C”. Is relay in good condition? Fuel pump relay drive signal check Go to Step 6.
Page 103 1A-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS B-4 Fuel Pressure Check (Page 1 of 2) Step Action 1) Release fuel pressure from fuel feed line. Go to Step 2. Go to Step 5. 2) Install fuel pressure gauge. 3) Check fuel pressure by repeating ignition switch ON and OFF.
Page 104 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-53 B-4 Fuel Pressure Check (Page 2 of 2) Step Action Was no fuel pressure applied in step 1? Go to Step 8. Go to Step 9. With fuel pump operated and fuel return hose blocked Faulty fuel pressure Shortage of fuel or fuel by pinching it, is fuel pressure applied?
Page 105: Idle Air Control System Check
1A-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS B-5 Idle Air Control System Check (Page 1 of 2) Step Action Check engine idle speed and IAC duty referring to Go to Step 2. Go to Step 4. “Idle Speed/IAC Duty Inspection” in this section Is idle speed within specification? Is IAC duty within specification in step 1? Go to Step 3.
Page 106 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-55 B-5 Idle Air Control System Check (Page 2 of 2) Step Action Check IAC system referring to step 10 of this table. Go to Step 9. Go to Step 12. Is check result satisfactory? Was IAC duty more than about 30% or ´40% (or Check parts or system Substitute a known-good...
Page 107: A/C Control Signal Check
1A-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS B-6 A/C Control Signal Check (if equipped) Step Action • 1) Check voltage at “G01-02” terminal under each A/C control signal is “Bl/R” wire open or short • condition given in table below. in good condition. Poor “G01-02"...
Page 108: B-7 Electric Load Signal Circuit Check
ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-57 B-7 Electric Load Signal Circuit Check Wiring Diagram Troubleshooting Note: • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection: ”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits: ”.
Page 109: System Check
1A-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS B-8 Radiator Fan Control System Check Step Action Check radiator fan control system referring to RFC system is in good Go to Step 2. section 1F. condition. Is it in good condition? Check RFC relay referring to section 1F. Go to Step 3.
Page 110 ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A-59 Repair Instructions Idle Speed/IAC Duty Inspection Before idle speed/IAC duty check, make sure of the following. • Lead wires and hoses of Electronic Fuel Injection system is connected securely. • Accelerator cable has some play, that is, it is not tight. •...
Page 111 1A-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS Special Tools TIGHTENING TORQUE SPECIFICATIONS FASTENING PARTS TIGHTENING TORQUE kg-m Ib-ft IAC value 0.35 TP sensor 0.25 ECT sensor O2 sensor 32.5 MAP sensor 0.20...
Page 112: Aux. Emission Control Devices
AUX. EMISSION CONTROL DEVICES 1B-1 Aux. Emission Control Devises EVAP Canister Purge Inspection Note: Before inspection, check to make sure that gear shift lever is in neutral position and that parking brake lever is pulled all the way up. 1) Warn up engine to normal operating temperature. 2) Disconnect purge hose from EVAP canister.
Page 113: Evap Canister Purge Valve Inspection
1B-2 AUX. EMISSION CONTROL DEVICES EVAP Canister Purge Valve Inspection [Using SUZUKI scan tool] 1) With ignition switch OFF, disconnect coupler from EVAP canister purge valve. 2) Check resistance between two terminals of EVAP canister purge valve. Resistance of EVAP canister purge valve: 30 –...
Page 114: Evap Canister Inspection
AUX. EMISSION CONTROL DEVICES 1B-3 3) Disconnect vacuum hoses from intake manifold and its pipe. 4) With coupler disconnected, blow into hose “A”. Air should not come out of hose “B”. 5) Connect 12V-battery to EVAP canister purge valve terminals. In this state, blow hose “A”.
Page 115: Pcv Hose Inspection
1B-4 AUX. EMISSION CONTROL DEVICES PCV System Note: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/ IAC duty, for obstructed PCV valve or hose hampers its accurate checking. PCV Hose Inspection Check hoses for connection, leakage, clog and deterioration.
Page 116: Engine Electrical
ENGINE ELECTRICAL DEVICES 1C-1 Engine Electrical Devices Repair Instructions Idle Air Control (IAC) Valve Operation Inspection Using SUZUKI scan tool 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): 99000M24120-426 (SUZUKI Scan tool) 2) Warm up engine to normal operating temperature.
Page 117: Installation
1C-2 ENGINE ELECTRICAL DEVICES switch is turned ON. Note: • This check should be performed by two people, one person turns on ignition switch while the other checks valve operation. • As valve operation is momentary, it may be overlooked. To prevent this, perform this operation check 3 times or more continuously.
Page 118: On-Vehicle Inspection
ENGINE ELECTRICAL DEVICES 1C-3 Electronic Control System ECM (PCM Caution: As ECM (PCM) consists of precision parts, be careful not to expose it to excessive shock. Removal 1) Disconnect battery negative cable at battery. 2) Open glove box and the remove clip. 3) While pressing glove box stopper, pull out glove box from instrument panel.
Page 119 1C-4 ENGINE ELECTRICAL DEVICES ALTITUDE BAROMETRIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (kPa(mmHg) 3.3 – 3.9 101.3 (760) 1000 3.2 – 3.8 97.7 (733) 3.1 – 3.7 2000 94.3 (707) 3000 3.0 – 3.6 90.9 (682) 4000 3.0 – 3.5 1219 87.7 (658) 5000 2.9 –...
Page 120: Inspection
ENGINE ELECTRICAL DEVICES 1C-5 MAP Sensor Inspection 1) Removal MAP sensor referring MAP sensor removal. 2) Connect 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect its positive terminal to “Vcc” terminal of sensor and negative terminal to “Ground” terminal.
Page 121 1C-6 ENGINE ELECTRICAL DEVICES TP Sensor On-Vehicle Inspection Inspection 1) Disconnect negative cable at battery and coupler from TP sensor. 2) Using ohmmeter, check resistance between terminals under each condition given in table below. Terminal Resistance Ω Between "Vcc" and 4 to 6 K "GND"...
Page 122 ENGINE ELECTRICAL DEVICES 1C-7 Adjustment 1) Loosen TP sensor screws. (NOT USING SUZUKI SCAN TOOL) TERMINAL ARRANGMENT OF ECM (PCM) COUPLER (VIEWED FROM HARNESS SIDE) 2) Connect SUZUKI scan tool to DLC with ignition switch OFF and check “TP SENSOR VOLT” value displayed on scan tool by using “DATA LIST”...
Page 123: Removal,Inspection And Installation
1C-8 ENGINE ELECTRICAL DEVICES IAT Sensor Removal, Inspection and Installation Removal 1) Disconnect battery negative cable at battery. 2) Disconnect coupler from IAT sensor. 3) Remove IAT sensor from air cleaner outlet hose. Inspection Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
Page 124 ENGINE ELECTRICAL DEVICES 1C-9 ECT Sensor Removal, Inspection and Installation Removal 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to Section 6B. 3) Disconnect coupler from ECT sensor. 4) Remove ECT sensor from water outlet pipe. Warning: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot.
Page 125: Heated Oxygen Sensor Removal And Installation
1C-10 ENGINE ELECTRICAL DEVICES Heated Oxygen Sensor Heater On-vehicle Inspection Inspect heated oxygen sensor referring to flow table of diagnostic trouble code P0130 / P0134 / P0135. 1) Disconnect sensor connector. 2) Using ohmmeter, measure resistance between terminals “VB” and “GND” of sensor connector. If found faulty, replace oxygen sensor.
Page 126: Camshaft Position (Cmp) Sensor Removal, Inspection And Installation
ENGINE ELECTRICAL DEVICES 1C-11 Camshaft Position (CMP) Sensor Removal, Inspection and Installation Removal 1) Disconnect nagative cable at battery. 2) Removal air cleaner assemblty (1). 3) Disconnect CMP sensor lead wire coupler (1). 4) Remove flange bolt (1) and pull out CMP sensor assembly (2).
Page 127 1C-12 ENGINE ELECTRICAL DEVICES Inspection CMP Sensor Resistance 1) Measure resistance of CMP sensor by using ohmmeter as shown in figure. Ω CMP sensor resistance: Approx. 230 (at 20 C / 68 2) If resistance is out of specification, replace CMP sensor. Signal Rotor Air Gap 1) Remove cap.
Page 128 ENGINE ELECTRICAL DEVICES 1C-13 Vehicle Speed Sensor (VSS) On-Vehicle Inspection 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral state. 3) Connect voltmeter between “C51-34” terminal of ECM (PCM) connector and body ground. 4) Turn ignition switch to ON position and turn front right tire slowly with front left tire locked.
Page 129 1C-14 ENGINE ELECTRICAL DEVICES Main Relay Inspection 1) Disconnect negative cable at battery. 2) Remove main relay from relay/fuse box. 3) Check resistance between each two terminals as in table below. If check results are as specified to next operation check. If not, replace.
Page 130 ENGINE ELECTRICAL DEVICES 1C-15 1) Warm up engine to normal operating temperature. 2) While listening to sound of injector by using sound scope or such, increase engine speed to higher than 3,000 r/min. 3) Check to make sure that sound to indicate operation of injector stops when throttle valve is closed instantly and it is heard again when engine speed is reduced to less than about 2,000 r/min.
Page 131: Special Tools
1C-16 ENGINE ELECTRICAL DEVICES SPECIAL TOOLS TIGHTENING TORQUE SPECIFICATIONS FASTENING PARTS TIGHTENING TORQUE kg-m Ib-ft IAC value 0.35 TP sensor 0.25 ECT sensor O2 sensor 32.5 MAP sensor 0.20...
Page 132: Engine Mechanical
ENGINE MECHANICAL 1D-1 Engine Mechanical General Description Engine Construction Description The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX 2/one cylinder).
Page 133: Diagnostic Information And Procedures
1D-2 ENGINE MECHANICAL Diagnostic Information and Procedures Compression Check Check compression pressure on all four cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. Note: After warming up engine, place transmission gear shift lever in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
Page 134: Engine Vacuum Check
ENGINE MECHANICAL 1D-3 7) Crank engine with fully charged battery, and read the highest pressure on compression gauge. Note: For measuring compression pressure, crank engine at least 250 r/min. by using fully charged battery. Compression pressure Standard 1200 kPa (12.0 kg/cm2, 170.0 psi) Limit 900 kPa (9.0 kg/cm2, 128.0 psi)
Page 135: Valve Lash (Clearance)
1D-4 ENGINE MECHANICAL 2) With engine stopped, disconnect EVAP canister purge vacuum hose from EVAP purge valve and connect 3-way joint, hose and special tool (vacuum gauge and joint) to EVAP purge valve and vacuum hose disconnected. Special Tool (A): 09915M67310 (B): 09918M08210 (C): Hose 09343M03087 (D): 3-way joint 09367M04002...
Page 136 ENGINE MECHANICAL 1D-5 5) If valve lash is out of specification, adjust it to specification by turning adjusting screw after loosening lock nut. After adjustment, tighten lock nut to specified torque while holding adjusting screw stationary, and then make sure again that valve lash is within specification.
Page 137: Repair Instructions
1D-6 ENGINE MECHANICAL Repair Instructions Air Cleaner Element Removal and Installation Removal 1) Remove air cleaner case clamps. 2) Remove air cleaner element from case. 3) Check air cleaner element for dirt. 4) If necessary, blow off dust by compressed air from air outlet side of element.
Page 138: Accelerator Cable Adjustment
ENGINE MECHANICAL 1D-7 Note: When installing cylinder head cover, use care so that cylinder head cover gasket or O-rings will not get out of place or fall off. 3) Install ignition coil assemblies with high-tension cord. 4) Connect PCV valve and breather hose to head cover. 5) Install air cleaner case.
Page 139: Throttle Body Components
1D-8 ENGINE MECHANICAL Throttle Body Components On-Vehicle Inspection Check that throttle valve lever moves smoothly. Throttle Body Removal, Disassembly Cleaning and Installation Removal 1) Disconnect negative cable at battery. 2) Drain cooling system referring to Section 6B. 3) Disconnect accelerator cable from throttle body. 4) Remove air cleaner outlet hose.
Page 140 ENGINE MECHANICAL 1D-9 5) Disconnect couplers from TP sensor, MAP sensor and IAC valve. 6) Remove throttle body from intake manifold. 7) Disconnect engine coolant hoses and EVAP canister purge valve hose from throttle body. Disassembly Note: While disassembling and assembling throttle body, use special care not to deform levers on throttle valve shaft or cause damage to any other parts.
Page 141 1D-10 ENGINE MECHANICAL Installation 1) Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket. 2) Install throttle body to intake manifold. 3) Connect engine coolant hoses and EVAP canister purge valve hose. 4) Connect couplers to TP sensor, MAP sensor and IAC valve securely.
Page 142: Throttle Body And Intake Manifold Components
ENGINE MECHANICAL 1D-11 Throttle Body and Intake Manifold Components Throttle Body and Intake Manifold Removal, Inspection and Installation Removal 1) Relieve fuel pressure according to fuel pressure relief procedure described in section 6. 2) Disconnect negative cable at battery. 3) Drain cooling system. WArning To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot.
Page 143 1D-12 ENGINE MECHANICAL 6) Disconnect accelerator cable from throttle body. 7) Disconnect following hoses: • Brake booster hose from intake manifold • Canister purge hose from EVAP canister purge valve • Engine cooling water (coolant) hose (outlet side) from throttle body •...
Page 144 ENGINE MECHANICAL 1D-13 Engine Mounting Components 23 N-m (2.3 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m)
Page 145: Engine Assembly Removal And Installation
1D-14 ENGINE MECHANICAL Engine Assembly Removal and Installation Removal 1) Drain coolant. 2) Drain engine oil and transmission oil, if necessary. 3) Remove exhaust pipe. Warning: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
Page 146 ENGINE MECHANICAL 1D-15 13) Disconnect following electric wires: • ECM • Fuse box • A/C dual pressure switch • A/C compressor • Ground cable at transmission 14) Remove generator belt and A/C compressor drive belt. 15) Remove A/C compressor with hose still attached (if equipped).
Page 147 1D-16 ENGINE MECHANICAL 23 N-m (2.3 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 18) Remove bolts indicated in figure. 19) Lower engine assembly together with transmission out of vehicle slowly and carefully. Installation Reverse the removal procedure Tightening torque...
Page 148 ENGINE MECHANICAL 1D-17 Installation 1) Install transmission to engine refer Fig. A. 2) Install engine assembly together with transmission to vehicle refer Fig. B. Fig. A Fig. B 23 N-m (2.3 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m) 55 N-m (5.5 kg-m)
Page 149: Timing Belt And Belt Tensioner Components
1D-18 ENGINE MECHANICAL Timing Belt and Belt Tensioner Components Timing Belt and Belt Tensioner Removal, Inspection and Installation Removal 1) Disconnect negative cable at battery. 2) Remove A/C compressor belt, if equipped. 3) Remove water pump pulley and water pump drive belt (1). 4) Remove crankshaft pulley (1) with crank shaft locked.
Page 150 ENGINE MECHANICAL 1D-19 7) Detach engine mounting (1) from engine mounting bracket. 8) Detach A/C compressor (1) from its bracket with hose connected and hung it. Then remove engine mount bracket (3) and A/C compressor bracket (2) (if equipped with A/C). 9) Remove timing belt outside cover.
Page 151 1D-20 ENGINE MECHANICAL Inspection • Inspect timing belt for wear or crack. Replace it as necessary. • Inspect tensioner for smooth rotation. Installation 1) Install crank pulley key (2) to crankshaft. Install crankshaft timing belt pulley (1) to crankshaft, if removed.
Page 152 ENGINE MECHANICAL 1D-21 4) Check that punch mark (2) on crankshaft timing belt pulley is aligned with arrow mark (1) on oil pump case. If not, align two marks by turning crankshaft but be careful not to turn it more than its allowable turning range which is described on previouspage.
Page 153 1D-22 ENGINE MECHANICAL 8) Attach hexagon wrench to belt tensioner hole and adjust belt tension to specified. (a) Measure timing belt tension by using special tool. Special Tool (A): 09919-56010 Belt tension under pressure 7 kg or 15.5 Ib “a”: 10.5 mm (0.413 in.) .
Page 154 ENGINE MECHANICAL 1D-23 12) Install crankshaft pulley (1). Fit hole of pulley to pin on crankshaft timing belt pulley, and tighten pulley bolts to specified torque. Tightening Torque (a): 83 N.m (8.3 kg-m, 61.0 lb-ft) 13) Adjust valve clearance as previously outlined. 14) Install water pump pulley (1) and water pump drive belt (2).
Page 155: Rocker Arms, Rocker Shaft And Camshaft Components
1D-24 ENGINE MECHANICAL Rocker Arms, Rocker Shaft and Camshaft Components Rocker Arms, Rocker Shaft and Camshaft Removal, Inspection and Installation Removal 1) Disconnect negative cable at battery. 2) Remove timing belt as previously outlined. 3) Remove camshaft timing belt pulley by using special tool. Special Tool (A): 09917M68221 4) Remove cylinder head cover as previously outlined.
Page 156 ENGINE MECHANICAL 1D-25 7) Remove rocker arm shaft (1) with intake rocker arms (2) and rocker arm spring (3). 8) Remove camshaft housing and camshaft. Note: To remove camshaft housing bolts, loosen them in such order as indicated in figure, a little at a time. Inspection Adjusting Screw and Rocker Arm If tip of adjusting screw (1) is badly worn, replace it.
Page 157 1D-26 ENGINE MECHANICAL Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm l.D. Difference between two readings is arm-to-shaft clearance on which a limit is specified. If limit is exceeded, replace shaft or arm, or both. Standard Limit Rocker arm I.D.
Page 158 ENGINE MECHANICAL 1D-27 Check clearance by using gaging plastic. The procedure is as follows. 1) Clean housing and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of camshaft (parallel to camshaft). 4) Install camshaft housing, referring to the following page.
Page 159 1D-28 ENGINE MECHANICAL Installation 1) Fill small amount of engine oil into arm pivot holding part of cylinder head. Install rocker arm (exhaust side) (1). 2) Apply engine oil to cams and journals on camshaft and put camshaft on cylinder head. Install camshaft housing to camshaft and cylinder head.
Page 160 ENGINE MECHANICAL 1D-29 4) Apply engine oil to rocker arm shaft and rocker arms. 5) Install rocker arm shaft, rocker arm (intake side) and rocker arm spring. 6) Install rocker arm shaft bolts and tighten them to specified torque. Tightening Torque (a): 23 N.m (2.3 kg-m, 17.0 lb-ft) 7) Install camshaft timing belt pulley to camshaft while fitting pin on camshaft into slot.
Page 161: Valves And Cylinder Head Components
1D-30 ENGINE MECHANICAL Valves and Cylinder Head Components Valves and Cylinder Head Removal and Installation Removal 1) Relieve fuel pressure according to fuel pressure relief procedure described in section 6. 2) Disconnect negative cable at battery. 3) Drain cooling system. 4) Remove intake manifold as previously outlined.
Page 162 ENGINE MECHANICAL 1D-31 5) Remove cylinder head cover as previously outlined. Loosen all valve lash adjusting screws fully. 6) Remove timing belt rocker arm shaft, rocker arm and camshaft as previously outlined. Support engine by engine supporting device and detach engine sling device.
Page 163 1D-32 ENGINE MECHANICAL 2) Check to make sure that oil jet (venturi plug) is installed and if it is, that it is not clogged. When installing it, be sure to tighten to specified torque. Tightening Torque (a): 5 N.m (0.5 kg-m, 4.0 lb-ft) 3) Apply engine oil to cylinder head bolts and tighten them gradually as follows.
Page 164 ENGINE MECHANICAL 1D-33 Values and Cylinder Head Disassembly and Assembly Disassembly 1) For ease in servicing cylinder head, remove exhaust manifold from cylinder head. 2) Using special tool (Valve lifter), compress valve springs and then remove valve cotters by using special tool (Forceps) as shown.
Page 165 1D-34 ENGINE MECHANICAL Assembly 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so remove burrs and make it truly round. Special Tool (A): 09916M34542 (B): 09916M37320 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100ˆC (176 to 212ˆF) so that head will not be distorted, and drive new valve guide into hole with special tools.
Page 166 ENGINE MECHANICAL 1D-35 4) Install valve spring seat to cylinder head. 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand.
Page 167 1D-36 ENGINE MECHANICAL Values and Value Guides Inspection Valve Guides Using a micrometer and caliper gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 168 ENGINE MECHANICAL 1D-37 • Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve.
Page 169: Cylinder Head Inspection
1D-38 ENGINE MECHANICAL • Valve seat repair: A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping. 1) EXHAUST VALVE SEAT: Use valve seat cutters to make two cuts as illustrated in figure.
Page 170: Valve Spring Inspection
ENGINE MECHANICAL 1D-39 • Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Page 171 1D-40 ENGINE MECHANICAL • Spring squareness: Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve spring andsquare. Valve springs found to exhibit a larger clearance than limit given below must be replaced. Valve spring squareness limit: 2.0 mm (0.079 in.) Piston, Piston Rings, Connecting Rods and Cylinder Components Piston, Piston Rings, Connecting Rods and Cylinder...
Page 172 ENGINE MECHANICAL 1D-41 Installation 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. Note: Do not apply oil between connecting rod and bearing or between bearing cap and bearing. 2) Install guide hoses over connecting rod bolts. These guide hoses protect crankpin and threads of rod bolt from damage during installation of connecting rod and piston assembly.
Page 173 1D-42 ENGINE MECHANICAL 6) Reverse removal procedure for installation, as previously outlined. 7) Adjust water pump drive belt tension, referring to section 8) Adjust A/C compressor belt tension, if equipped. Refer to section 0B. 9) Adjust intake and exhaust valve lashes as previously outlined.
Page 174: Pistons, Piston Rings, Connecting Rods And Cylinder Disassembly And Assembly . 1D-43
ENGINE MECHANICAL 1D-43 Pistons, Piston Rings, Connecting Rods and Cylinder Disassembly and Assembly Disassembly 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. • Ease out piston pin circlips (1), as shown. •...
Page 175 1D-44 ENGINE MECHANICAL Piston Cylinder Piston-to-cylinder Number Outer diameter Color Bore diameter clearance at the top (paint) (mark) 68.475 – 68.485 mm 0.02 – 0.04 mm (2.6959 – 2.6962 in.) 68.51 – 68.52 mm (0.0008 – (2.6973 – 2.6976 in.) 0.0015 in.) 68.465 –...
Page 176 ENGINE MECHANICAL 1D-45 Cylinder, Piston, Piston Pins and Connecting Rod Inspection Cylinder • Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston.
Page 177 1D-46 ENGINE MECHANICAL • Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance “a”...
Page 178 ENGINE MECHANICAL 1D-47 Piston Rings To measure end gap, insert piston ring (2) into cylinder bore and then measure the gap by using thickness gauge (1). If measured gap is out of specification, replace ring. Note: Decarbon and clean top of cylinder bore before inserting piston ring.
Page 179: Crank Pin And Connecting Rod Bearings Inspection
1D-48 ENGINE MECHANICAL Crank Pin and Connecting Rod Bearings Inspection • Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crankshaft or regrind crank pin referring to following step 6).
Page 180 ENGINE MECHANICAL 1D-49 5) Remove cap and using a scale on gaging plastic envelope, measure gaging plastic (1) width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit Bearing 0.020 –...
Page 181: Main Bearings, Crankshaft And Cylinder Block Components
1D-50 ENGINE MECHANICAL Main Bearings, Crankshaft and Cylinder Block Components...
Page 182: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
ENGINE MECHANICAL 1D-51 Main Bearings, Crankshaft and Cylinder Block Removal and Installation Removal 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (1) (for M/T vehicle). Special Tool (A): 09924-17810 3) Remove crankshaft pulley, timing belt and crankshaft timing pulley.
Page 183 1D-52 ENGINE MECHANICAL Installation Note: • All parts to be installed must be perfectly clean. • Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores. • Journal bearings, bearing caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets.
Page 184 ENGINE MECHANICAL 1D-53 5) Install new gasket and oil seal housing. Do not reuse gasket removed in disassembly. Apply engine oil to oil seal lip before installation. Tighten housing bolts to specification. Tightening Torque (a): 11 N.m (1.1 kg-m, 8.0 lb-ft) Note: As there are 2 types (long bolts (1) and short bolts (2)) of housing bolts, refer to figure for their correct use.
Page 185: Crankshaft Inspection
1D-54 ENGINE MECHANICAL Crankshaft Inspection Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing (1) and journal bearing caps installed.
Page 186: Main Bearings Inspection
ENGINE MECHANICAL 1D-55 Main Bearings Inspection General information • ´ Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. • Upper half of bearing (2) has oil groove (3) as shown in figure.
Page 187 1D-56 ENGINE MECHANICAL 5) Remove cap and using scale on gaging plastic envelope, measure gaging plastic width (1) at its widest point. If clearance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use of 0.25 mm undersize bearing.
Page 188 ENGINE MECHANICAL 1D-57 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (1, 2 and 3) represent following cap bore diameters. Alphabet stamped Bearing cap bore diameter (without bearing) 54.000 –...
Page 189 1D-58 ENGINE MECHANICAL 4) From numerals stamped on crank webs of No.2 and No.3 cylinders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be installed to journal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
Page 190: Rear Oil Seal Inspection
ENGINE MECHANICAL 1D-59 Limit on bow: 0.05 mm (0.0020 in.) Limit on twist: 0.10 mm (0.0039 in.) • If necessary, regrind crankshaft journal and select under- size bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 49.732 –...
Page 191: Flywheel Inspection
1D-60 ENGINE MECHANICAL Flywheel Inspection • If ring gear is damaged, cracked or worn, replace flywheel. • If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. • Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout: 0.2 mm (0.0078 in.) Cylinder Block Inspection Distortion of gasketed surface...
Page 192: Required Service Material
ENGINE MECHANICAL 1D-61 REQUIRED SERVICE MATERIALS...
Page 193 1D-62 ENGINE MECHANICAL...
Page 194: Engine Lubrication System
ENGINE LUBRICATION SYSTEM 1E-1 Engine Lubrication System General Description The oil pump for pressure-feeding lubrication oil to the running parts of the engine is of an internal gear type, in which an outer ring-like gear is internally meshed with an inner gear, there being a separating crescent-like stator between the two. The pump is mounted on the front end of the engine, and is driven by the crankshaft.
Page 195: Oil Pressure Check
1E-2 ENGINE LUBRICATION SYSTEM Oil Pressure Check Note : Prior to checking oil pressure, check following items. • Oil level in oil pan. If oil level is low, add oil up to Full level mark on oil level gauge. • Oil quality.
Page 196 ENGINE LUBRICATION SYSTEM 1E-3 5) Stop engine and remove oil pressure gauge. 6) Before reinstalling oil pressure switch, be sure to wrap its screw threads with sealing tape and tighten switch to specified torque. Note : If sealing tape edge is bulged out from screw threads of switch, cut it off.
Page 197: Oil Pan And Oil Pump Strainer Components
1E-4 ENGINE LUBRICATION SYSTEM Oil Pan and Oil Pump Strainer Components Oil Pan and Oil Pump Strainer Removal and Installation Removal 1) Drain engine oil by removing drain plug (1). 2) Remove clutch housing (torque converter housing for A/T) lower plate (1). 3) Disconnect exhaust pipe from exhaust manifold.
Page 198 ENGINE LUBRICATION SYSTEM 1E-5 Installation 1) Apply sealant to oil pan mating surface continuously as shown in figure. “A” Sealant: 99000-31150 2) Install oil pump strainer (1) and oil pan (2). Install new seal (3) to oil pump strainer in the position as shown in figure.
Page 199 1E-6 ENGINE LUBRICATION SYSTEM Oil Pan and Oil Pump Stainer Cleaning Cleaning ´ Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. ´ Clean oil pump strainer screen.
Page 200: Oil Pump Components
ENGINE LUBRICATION SYSTEM 1E-7 Oil Pump Components Oil Pump Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Remove timing belt as previously outlined. 3) Remove generator and its bracket. 4) Remove timing belt inside cover. 5) Remove oil pan and oil pump strainer as previously outlined. 6) Remove oil pump assembly (1) after removing bolts.
Page 201 1E-8 ENGINE LUBRICATION SYSTEM Installation 1) Install two oil pump pins (2) and oil pump gasket to cylinder block. Use a new gasket. 2) To prevent oil seal lip from being damaged or upturned when installing oil pump to crankshaft, fit special tool (Oil seal guide) to crankshaft (1), and apply engine oil to special tool.
Page 202: Oil Pump Disassembly, Inspection And Assembly
ENGINE LUBRICATION SYSTEM 1E-9 Oil Pump Disassembly, Inspection and Assembly Disassembly 1) Remove oil level gauge guide bolt and pull out guide from oilpump. 2) Remove rotor plate (1). Inspection • Check oil seal lip for fault or other damage. Replace as necessary.
Page 203 1E-10 ENGINE LUBRICATION SYSTEM Assembly 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, and inside surfaces of oil pump case and plate. 3) Install outer and inner rotors to pump case. 4) Install rotor plate.
Page 204: Engine Cooling System
ENGINE COOLING SYSTEM 1F-1 Engine Cooling System General Description Cooling System Description The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. Coolant Description Warning • Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir.
Page 205 1F-2 ENGINE COOLING SYSTEM Note • Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time as damage to cooling system could occur. • Coolant must be mixed with demineralized water or distilled water.
Page 206: Schematic And Routing Diagram
ENGINE COOLING SYSTEM 1F-3 Schematic and Routing Diagram Cooling System Circulation 1) While the engine is warmed up (Thermostat closed). coolant circulates as follows. 2) When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be cooled as well as the above flow circuit.
Page 207: Diagnostic Information And Procedures
1F-4 ENGINE COOLING SYSTEM Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis Condition Possible cause Correction / Reference Item Engine overheats Adjust or replace. Loose or broken water pump belt (Radiator fan operates) Check coolant level and add as necessary. Not enough coolant Faulty thermostat Replace.
Page 208: Coolant Level Check
ENGINE COOLING SYSTEM 1F-5 Coolant Level Check Coolant Level To check level, lift hood and look at “see-through” coolant reservoir tank. It is not necessary to remove radiator cap to check coolant level. Warning : To help avoid danger of being burned: •...
Page 209: Cooling System Draining
1F-6 ENGINE COOLING SYSTEM 4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity about 110 kPa (1.1 kg/cm2, 15. 6 psi). If replacement of cap is required, use a proper cap for this vehicle. Note : After installing radiator cap to radiator, make sure that the ear of cap lines is parallel to radiator.
Page 210 ENGINE COOLING SYSTEM 1F-7 3) Stop engine and drain coolant. 4) Close drain plug. Add water until system is filled and run engine until upper radiator hose is hot again. 5) Repeat steps 3) and 4) several times until drained liquid is nearly colorless.
Page 211: Cooling Water Pipes Or Hoses Removal And Installation
1F-8 ENGINE COOLING SYSTEM Cooling Water Pipes or Hoses Removal and Installa- tion Removal 1) Drain cooling system. 2) To remove these pipes or hoses, loosen clamp on each hose and pull hose end off. Installation Install removed parts in reverse order of removal procedure, noting the following.
Page 212 ENGINE COOLING SYSTEM 1F-9 Inspection 1) Make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat. 2) Check to make sure that valve seat is free from foreign matters which would prevent valve from seating tight. 4) Check thermostatic movement of wax pellet as follows: (1) Immerse thermostat in water, and heat water gradually.
Page 213: Radiator Fan Motor On-Vehicle
1F-10 ENGINE COOLING SYSTEM Radiator Fan Motor On-Vehicle Inspection Warning : Keep hands, tools and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch in the “ON”...
Page 214: Radiator Removal, Inspection And Installation
ENGINE COOLING SYSTEM 1F-11 5) Remove radiator inlet hose and reservoir hose. 6) Remove cooling fan mounting bolts (1). 7) Slide condenser with radiator, and then remove radiator cooling fan. Caution ! Be sure not to damage condenser outlet pipe. Installation Reverse removal procedure for installation noting the following.
Page 215: Water Pump - Generator Belt Tension Inspection And Adjustment
1F-12 ENGINE COOLING SYSTEM Inspection Check radiator for leakage or damage. Straighten bent fins, if any. Cleaning Clean frontal area of radiator cores. Installation Reverse removal procedures. Note : • • • • • Refill cooling system with proper coolant referring to COOLANT item of MAINTENANCE.
Page 216: Water Pump - Generator Belt Removal And Installation
ENGINE COOLING SYSTEM 1F-13 Water Pump / Generator Belt Removal and Installation Removal 1) Disconnect negative cable at battery. 2) Loosen drive belt adjusting bolt (2) and generator pivot bolts (3). When servicing car equipped with A/C, remove compressor drive belt before removing water pump belt (1). 3) Slacken belt by displacing generator and then remove it.
Page 217 1F-14 ENGINE COOLING SYSTEM Installation 1) Install new pump gasket (1) to cylinder block. 2) Install water pump (1) to cylinder block. Tightening Torque (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) 3) After installing water pump, install rubber seal (2). 4) Install belt tensioner, timing belt and timing belt outside cover according to procedure described in item “TIMING BELT AND TENSIONER”...
Page 218: Fuel System
FUEL SYSTEM 1G-1 Fuel System Precautions Precautions on Fuel System Service Warning Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk or fire and personal injury. • Disconnect negative cable at battery. •...
Page 219: Fuel Pump Description
1G-2 FUEL SYSTEM Fuel Pump Description The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel level gauge (2) is attached. Addition of the fuel pressure regulator makes it possible to maintain the fuel pressure at constant level and ECM controls compensation for variation in the intake manifold pressure.
Page 220: Schematic And Routing Diagram
FUEL SYSTEM 1G-3 Schematic and Routing Diagram Fuel Delivery System Diagram Diagnostic Information and Procedures Fuel Pressure Inspection WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. 1) Relieve fuel pressure in fuel feed line referring to “Fuel Pressure Relief Procedure: ”.
Page 221 1G-4 FUEL SYSTEM 4) Check that battery Voltage is 11 V. or more. 5) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4 times and then check fuel pressure. 6) Start engine and warm it up to normal operating temperature.
Page 222: Fuel Cut Operation Inspection
FUEL SYSTEM 1G-5 Fuel Cut Operation Inspection Note Before inspection, make sure that gear shift lever is in neutral position, A/C is OFF and parking brake lever is pulled all the way up. 1) Warm engine up to normal operating temperature. 2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to higher than 3,000 r/ min.
Page 223: Fuel Hose Disconnecting And Reconnecting1G-6
1G-6 FUEL SYSTEM Fuel Hose Disconnecting and Reconnecting Warning Before starting the following procedure, be sure to observe “Precautions on Fuel System Service: ” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in figure.
Page 224: Fuel Leakage Check Procedure
FUEL SYSTEM 1G-7 Fuel Pressure Relieve 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, relief fuel pressure as follows. 1) Place transmission gear shift lever in “Neutral”...
Page 225: Fuel Pipe Removal And Installation
1G-8 FUEL SYSTEM Fuel Pipe Removal and Installation Removal 1) Relieve fuel pressure in fuel feed line according to procedure on SECTION 6. 2) Disconnect negative cable at battery. 3) Remove steering gear box ass’y. Refer to SECTION 3B of this manual for details.
Page 226: Fuel Injector On-Vehicle Inspection
FUEL SYSTEM 1G-9 Fuel Injector On-Vehicle Inspection 1) Using sound scope or such, check operating sound of injector when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, preform “B-2 Fuel Injector and Its Circuit Check”...
Page 227 1G-10 FUEL SYSTEM 1) Install injector and fuel pressure regulator to special tool (injector checking tool). Special Tool (A): 09912M58421 2) Connect special tools (hoses and attachment) to pipes of vehicle. Special Tool (B): 09912M58431 3) Connect special tool (test lead) to injector. Special Tool (D): 09930M88530 4) Install suitable vinyl tube onto injector nozzle to prevent fuel...
Page 228: Fuel Filler Cap Inspection
FUEL SYSTEM 1G-11 Installation For installation, reverse removal procedure and note following precautions. • Replace injector O-ring with new one using care not to damage it. • Check if cushion is scored or damaged. If it is, replace with new one. •...
Page 229: Fuel Tank Removal, Inspection And Installation
1G-12 FUEL SYSTEM Fuel Tank Removal, Inspection and Installation Removal 1) Relieve fuel pressure in fuel feed line referring to this section. Caution : This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. 2) Disconnect negative cable at battery.
Page 230 FUEL SYSTEM 1G-13 8) Disconnect fuel vapor hose (1) and return hose (2) from pipes. 9) Lower fuel tank gradually while holding it horizontally and pull out coupler (1) at fuel pump. Inspection After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage.
Page 231 1G-14 FUEL SYSTEM 5) Connect fuel filler hose (1) to fuel tank (4) and breather hose (2) to fuel filler neck (3) and clamp hoses securely. Tightening Torque (a): 1.5 N·m (0.15 kg-m, 1.0 lb-ft) 6) Connect fuel vapor hose (1) and return hose (2) to fuel pipe. Clamp them securely.
Page 232: Fuel Tank Purging Procedure
FUEL SYSTEM 1G-15 Fuel Tank Purging Procedure Warning : This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank using heat of flame as an explosion resulting in personal injury could occur. Following procedure is used purging fuel tank. 1) After removing fuel tank, disconnect fuel feed hose (1), fuel vapor hose (2) and fuel return hose (3) from fuel pump assembly.
Page 233: Installation
1G-16 FUEL SYSTEM If above check result is not satisfactory, advance to DIAGNOSTIC FLOW TABLE B-3. 2) Fuel pressure should be felt at fuel return hose for 2 seconds after ignition switch ON. If fuel pressure is not felt, advance to DIAGOSTIC FLOW TABLE B-4.
Page 234 FUEL SYSTEM 1G-17 Fuel Pump Assembly (with Fuel Level Gauge and Fuel Cut Value ) Removal and Installation Warning : Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section. Removal 1) Remove fuel tank from vehicle. Refer to “Fuel Tank” in this section.
Page 235 1G-18 FUEL SYSTEM 3) Connect fuel feed hose (1), return hose (2) and fuel vapor hose (3) to fuel pump assembly. Caution : When connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
Page 236: Fuel Filter Removal And Installation
FUEL SYSTEM 1G-19 Fuel Filter Removal and Installation Removal 1) Relieve fuel pressure in fuel feed line referring to this section. Caution : This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. 2) Disconnect negative cable at battery.
Page 237: Fuel Pressure Regulator On Vehicle Inspection
1G-20 FUEL SYSTEM Fuel Pressure Regulator On-Vehicle Inspection Perform fuel pressure inspection according to procedure described in “Fuel Pressure Inspection” in this section. Removal 1) Relieve fuel pressure according to procedure described in this section. 2) Disconnect battery negative cable at battery. 3) Disconnect vacuum hose from fuel pressure regulator.
Page 238: Ignition System
IGNITION SYSTEM 1H-1 Ignition System General Description The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below and has an electronic ignition control system. • It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 239: Schematic And Routing Diagram
1H-2 IGNITION SYSTEM Schematic and Routing Diagram Ignition System Wiring Circuit Diagram...
Page 240: Component Location
IGNITION SYSTEM 1H-3 Component Location Ignition System Components Location OTHERS CONTROL DEVICES INFORMATION SENSORS A : ECM (PCM) a : Fuel injectors 1. MAP sensor B : PCV valve b : EVAP canister purge valve 2. TP sensor C : EVAP canister c : Fuel pump relay 3.
Page 241: Diagnostic Information And Procedures
1H-4 IGNITION SYSTEM Diagnostic Information and Procedures Ignition System Symptom Diagnosis Condition Possible Cause Correction Engine cranks, but will No spark • Blown fuse for ignition coil not start or hard to start Replace • Loose connection or disconnection of Connect securely lead wire or high-tension cord(s) •...
Page 242 IGNITION SYSTEM 1H-5 Diagnostic Information and Procedures Ignition System Sympton Diagnosis Step Action Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE” in section Ignition Spark Test Go to Step 11. Go to Step 3. 1) Check all spark plugs for condition and type referring to “Spark Plugs”...
Page 243: Ignition Spark Test
1H-6 IGNITION SYSTEM Ignition Spark Test 1) Remove air cleaner outlet hose (1) and disconnect breather hose (2) from cylinder head cover. 2) Disconnect all injector coupler (1) from injectors. Warning : Without disconnection of injector coupler, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.
Page 244: Spark Plug Removal, Inspection And Installation
IGNITION SYSTEM 1H-7 Inspection 1) Measure resistance of high-tension cord (1) by using ohmmeter. High-tension cord resistance: 10 – 22 k/m (3.0 – 6.7 k/ft) 2) If resistance exceeds specification, replace high-tension cord(s). Installation 1) Install high-tension cords (1) to spark plugs and ignition coil assemblies (2) while gripping each cap.
Page 245 1H-8 IGNITION SYSTEM Ignition Coil Assembly (Including Ignitor) Inspection 1) Disconnect negative cable at battery. 2) Remove air cleaner outlet hose and disconnect breather hose from cylinder head cover, if necessary. 3) Disconnect ignition coil coupler. 4) Disconnect high-tension cord from ignition coil assembly. 5) Remove ignition coil bolts and then pull out ignition coil assembly.
Page 246: Ignition Timing Inspection/Adjustment
IGNITION SYSTEM 1H-9 Ignition Timing Inspection Note : Before starting engine, place transmission gear shift lever in “Neutral” and set parking brake. Inspection/Adjustment 1) When using SUZUKI scan tool, connect SUZUKI scan tool to DLC with ignition switch OFF. Special Tool (A) : 99000M24120 - 426 (SUZUKI Scan tool) 2) Start engine and warm it up to normal operating temperature.
Page 247 1H-10 IGNITION SYSTEM 6) Set timing light to high-tension cord (1) of No.1 ignition coil. 7) Using timing light (5), check that ignition timing is within specification. Note : To check ignition timing, read it through the opening between water pump belt (2) and timing belt cover (3). The white mark at the center on timing belt cover (4) represents BTDC 5.
Page 248: Special Tools
IGNITION SYSTEM 1H-11 Special Tools...
Page 250: Starting System
STARTING SYSTEM 1I-1 Starting System Schematic and Routing Diagram Cranking System Circuit Diagram The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These componentsvare connected electrically. Only the starting motor will be covered in this section.
Page 251: Diagnosis
1I-2 STARTING SYSTEM Diagnostic Information and Procedure Diagnosis Possible symptoms due to starting system trouble would be as follows: • Starting motor does not run (or runs slowly) • Starting motor runs but fails to crank engine • Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..
Page 252: Cranking System Test
STARTING SYSTEM 1I-3 Condition Possible Cause Correction Starting motor If battery and wiring are satisfactory, inspect running but too starting motor • slow (small torque) Insufficient contact of magnetic switch main contacts Replace magnetic switch. • Layer short-circuit of armature Replace.
Page 253: Repair Instructions
1I-4 STARTING SYSTEM Hold-In Test While connected as the above with pinion out, disconnect negative lead from ‘M’ terminal (1) and check that pinion remains out. If not, replace magnetic switch. Pinion (Plunger) Return Test As a next step to the above, disconnect negative lead and check to make sure that pinion returns inward quickly.
Page 254 STARTING SYSTEM 1I-5 Starter Motor Disassembly and Reassembly Disassembly 1) Remove nut (2) and disconnect lead wire (1) from magnetic switch (3). 2) Remove 2 nuts (4) and then take out magnetic switch by pulling up its rear portion so as to inside hook is disconnected from drive lever.
Page 255 1I-6 STARTING SYSTEM Reassembly 1) Inspect component parts (Refer to INSPECTION) and replace with new ones as necessary. 2) Before installing over-running clutch (2) to armature (1), apply grease as shown in figure and then fasten stop ring (3) with snap ring (4).
Page 256 STARTING SYSTEM 1I-7 7) Hook magnetic switch plunger (3) with drive lever and then fasten magnetic switch assembly (1) with nuts (4). 8) Connect lead wire (5) as it was and then check magnetic switch for operation. Note: • Before installing nuts, make sure that plunger hook is connected with drive lever without fail.
Page 257: Starting Motor Components
1I-8 STARTING SYSTEM Starting Motor Components Both of them consist of yoke assembly, armature assembly, over-running clutch assembly, magnetic switch assembly. Iron housingm, rear housing, brush holder and drive lever. The magnetic switch assembly ans parts in the starting motor are enclosed in teh housings so that they will be protected against possible dirt and water splash.
Page 258: Starting Motor Inspection
STARTING SYSTEM 1I-9 Starting Motor Inspection Plunger Inspect plunger for wear. Replace if necessary. Magnetic Switch Push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary. • • • • • Pull-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’...
Page 259 1I-10 STARTING SYSTEM Armature • • • • • Ground Test Between commutator segment and armature core should be insulated. Use ohmmeter for inspection. • • • • • Open Circuit Test Check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced.
Page 260 STARTING SYSTEM 1I-11 Yoke Check field coil for continuity. There should be continuity between following terminals. • Between A terminals. • Between B terminals. • Between B terminal and C (bare metal part of yoke body). Over-Running Clutch Inspect pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction.
Page 261: Specifications
1I-12 STARTING SYSTEM Specification Voltage 12 volts Output 0.8 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length 10.0 mm (0.394 in.) Number of pinion teeth Performance Condition Guarantee No load characteristic 11.5 V 50 A maximum 6,000 rpm minimum Around at...
Page 262: Charging System
CHARGING SYSTEM 1J-1 Charging System General Description Battery The battery has three major functions in the electrical system. • It is a source of electrical energy for cranking the engine. • It acts as a voltage stabilizer for the electrical system. •...
Page 263 1J-2 CHARGING SYSTEM Care of Battery Warning : • Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. • Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted area with water immediately and thoroughly.
Page 264: Generator Description
CHARGING SYSTEM 1J-3 Generator Description The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown below figure. The generator features are as follows: • Solid state regulator is mounted inside the generator. •...
Page 265 1J-4 CHARGING SYSTEM...
Page 266: Battery Inspection
CHARGING SYSTEM 1J-5 Diagnostic Information and Procedure Battery Inspection Visual Inspection Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious damage is noted, replace battery. Determine cause of damage and correct as needed.
Page 267: Generator Test (Undercharged Battery)
1J-6 CHARGING SYSTEM Generator Test Underchared Battery This condition, as evidenced by slow cranking can be caused by one or more of the following conditions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and ammeter.
Page 268: Check
CHARGING SYSTEM 1J-7 Higher Voltage If voltage is higher than standard value, check ground of brush. If brush ground is correct, replace IC regulator. Lower Voltage If voltage is lower than standard value, proceed to following check. 2) Ground F terminal and start engine, then measure voltage at B terminal as shown in figure.
Page 269: Repair Instructions
1J-8 CHARGING SYSTEM Repair Instruction Jump Starting in Case of Emergency with Ausiliary (Booster) Battery Both booster and discharged battery should be treated carefully when using jumper cables. Follow procedure outlined below, being careful not to cause sparks. Warning : •...
Page 270: Battery Removal, Handling And Installation . 1J-9
CHARGING SYSTEM 1J-9 With Charging Equipment Caution : When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equipment can cause serious damage to electrical system or electronic parts.
Page 271: Generator Removal And Installation
1J-10 CHARGING SYSTEM Generator Removal and Installation Removal 1) Disconnect negative cable (1) at battery (2). 2) Remove adjusting bolt (1) and loosen pivot bolt (2). 3) Hoist vehicle. 4) Disconnect “B” terminal wire (3) and coupler (4) from generator (5).
Page 272: Generator Components
CHARGING SYSTEM 1J-11 Generator Component...
Page 273 1J-12 CHARGING SYSTEM Generator Disassembly and Assembly Disassembly 1) Remove B terminal inner nut (1) and insulator (2). 2) Remove 3 nuts (3) and remove rear end cover (4). 3) Remove 2 screws (1) and pull out brush holder assembly (2).
Page 274 CHARGING SYSTEM 1J-13 12) If required, use bearing puller (2) to remove end housing bearing (1) and bearing cover (3). Caution : Care must be exercised so as not to distort cooling fan blade while applying puller. 13) If required, remove 4 screws, retainer plate (1) and then drive out drive end bearing (2).
Page 275 1J-14 CHARGING SYSTEM 6) Place space collar and drive end frame (2) on pulley, and then install rotor (1) to drive end frame. 7) Install rear end frame to drive end frame. 8) Tighten nuts to specified torque. Tightening Torque (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft) 9) Install pulley (1) and tighten pulley nut with holding shaft using hexagonal box wrench (2) to specified torque.
Page 276: Generator Inspection
CHARGING SYSTEM 1J-15 12) Place IC regulator (1) together with brush holder (2) horizontally on rear end frame (3). 13) Install 5 screws. Tightening Torque (a): 2.0 N.m (0.2 kg-m, 1.5 lb-ft) 14) Install rear end cover (1). Tightening Torque (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft) 15) Install insulator (2) and tighten B terminal inner nut (3) to specified torque.
Page 277 1J-16 CHARGING SYSTEM Slip Rings • Check slip rings for roughness or scoring. If rough or scored, replace rotor. • Using a vernier caliper, measure slip ring diameter. Standard diameter: 14.4 mm (0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor.
Page 278 CHARGING SYSTEM 1J-17 Rectifier Positive Rectifier 1) Using an ohmmeter, connect one tester probe to the B terminal and the other to each rectifier terminal (P1–P4). 2) Reverse the polarity of tester probes and repeat step 1). 3) Check that one shows continuity and the other shows no continuity.
Page 279 1J-18 CHARGING SYSTEM End Housing Bearing Check that bearing is not rough or worn. When removal is necessary, refer to disassembly of UNIT REPAIR OVERHAUL. Replace Brush 1) Unsolder and remove brush and spring. 2) Run wire of new brush through the hole in the brush holder, and insert spring and brush into brush holder.
Page 280: Specifications
CHARGING SYSTEM 1J-19 Specifications Battery Rated capacity 28 AH/5 HR, 12 Volts Electrolyte 2.1 L (4.44/3.70 US/lmp pt) Electrolyte S.G. 1.24 when fully charged at 20 C (68 Generator Permissible ambient – 30 to 90 Rated voltage 12 V temperature (–...
Page 282: Exhaust System
EXHAUST SYSTEM 1K-1 Exhaust System General Description Exhaust System Description The exhaust system consists of an exhaust manifold, three- way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 283: Repair Instructions
1K-2 EXHAUST SYSTEM Repair Instructions Exhaust System Components Warning: To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool.
Page 284 EXHAUST SYSTEM 1K-3 On-Vehicle Service Warning : To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Exhaust Manifold Refer to Section 6A for removal and installation procedures of exhaust manifold.
Page 285: Exhaust Manifold Removal And Installation
1K-4 EXHAUST SYSTEM Exhaust Manifold Removal and Installation Warning: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. Removal 1) Disconnect negative cable at battery. 2) Disconnect oxygen sensor coupler (if equipped).
Page 286 EXHAUST SYSTEM 1K-5 Tightening Torque (b): 50 N.m (5.0 kg-m, 36.5 lb-ft) 4) Install upper cover to exhaust manifold. 5) Connect oxygen sensor connector and fit connector to bracket. 6) Connect negative cable at battery. 7) Check exhaust system for exhaust gas leakage.
Page 288: Suspension
TABLE OF CONTENTS 2-i Section 2 Suspension CONTENTS Precautions ............2A-1 Coil Spring ........... 2C- 7 Precautions ........... 2A-1 Bump Stopper ..........2C- 9 Precautions on Suspension ......2A-1 Spring Upper Seat ........2C-10 Trailing Arm ..........2C-10 Suspension General Diagnosis ..... 2A-2 Rear Axle ............
Page 290: Precautions
SUSPENSION GENERAL DIAGNOSIS 2A-1 Precautions Precautions Precautions on Suspension Suspension Caution Refer to “Suspension Caution: in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution: in Section 00”. General Precautions Refer to “General Precautions: in Section 00”. Vehicle Lifting Points Refer to “Vehicle Lifting Points: in Section 0A”.
Page 291: 2A-2 Suspension General Diagnosis
2A-2 SUSPENSION GENERAL DIAGNOSIS 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 292 SUSPENSION GENERAL DIAGNOSIS 2A-3 Condition Possible Cause Correction • Shimmy, Shake or Blister or bump on tire. Replace tire. • Vibration Excessively loaded radial runout of tire/ Replace tire or wheel. wheel assembly. • Disturbed front end alignment. Check and adjust front end alignment. •...
Page 293 2A-4 SUSPENSION GENERAL DIAGNOSIS Wheel Alignment Specifications Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Generally, the only adjustment required for front alignment is toe setting. Camber and caster can’t be adjusted. Therefore, should camber or caster be out of specification due to the damage caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be determined.
Page 294 SUSPENSION GENERAL DIAGNOSIS 2A-5 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 295 2A-6 SUSPENSION GENERAL DIAGNOSIS 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 296: Front Suspension
FRONT SUSPENSION 2B-1 Front Suspension Note: • • • • • 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 297 2B-2 FRONT SUSPENSION...
Page 298 FRONT SUSPENSION 2B-3...
Page 299: Diagnosis
2B-4 FRONT SUSPENSION Diagnosis Diagnosis Table Refer to Section 2. Stablizer 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 300: Suspension Control Arm/Steering Knuckle Check
FRONT SUSPENSION 2B-5 Suspension Control Arm/Steering 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 1) Check for smooth rotation. 2) Inspect ball stud for damage. 3) Inspect dust cover for damage.
Page 301: On-Vehicle Service
2B-6 FRONT SUSPENSION On-Vehicle Service Strut Assembly Removal Note: When disassembling strut assembly, loosen strut nut a little before removing strut assembly from vehicle. This will make disassembly easier. Note, however, nut must not be removed at this point.
Page 302 FRONT SUSPENSION 2B-7 3) Remove E-ring (1) securing brake hose, and then remove brake hose from strut bracket as shown. 4) Remove strut bracket bolts (2). 5) Disconnect main fuse box from its bracket. 6) Remove strut support nuts (1). Hold strut by hand so that it will not fall off.
Page 303 2B-8 FRONT SUSPENSION Reassembly Reverse disassembly procedure, and then note the following instruction. • Install coil spring so that paint mark on it comes to down. • Mate spring end with stepped part of spring lower seat (1) as shown. •...
Page 304 FRONT SUSPENSION 2B-9 Stablizer Bar Removal 1) Remove cotter pin (1), stabilizer bar nut (2) and washer (3). 2) Remove stabilizer bar mounting bracket bolts (1). 3) Remove stabilizer bar (1). Note: If it is hard to remove stabilizer bar, set tires in contact with ground (with suspension compressed).
Page 305 2B-10 FRONT SUSPENSION Installation 1) Install stabilizer bar (1) so that paint mark (2) on it comes to the right side of vehicle. 2) Install mount bracket (1) so that its oblong hole side (2) comes to the rear. 3) Align the inside edge (3) of mount bushing with the outside edge of paint as shown in figure.
Page 306: Wheel Hub And Steering Knuckle
FRONT SUSPENSION 2B-11 Wheel Hub and Steer\ing Knuckle Removal 1) Hoist vehicle and remove wheel. 2) Uncaulk drive shaft nut (1). 3) Depress foot brake pedal and hold it there. Remove drive shaft nut (1). 4) Remove caliper carrier bolts. 5) Remove caliper (1) with carrier.
Page 307 2B-12 FRONT SUSPENSION 7) Pull out wheel hub (1) with special tools. Special Tool (A): 09943M17912 (B): 09942M15511 8) Disconnect tie rod end (1) from steering knuckle (2) with special tool. Special Tool (A): 09913M65210 9) Loosen strut bracket nuts (1). 10) Remove ball stud bolt (1).
Page 308 FRONT SUSPENSION 2B-13 2) Remove circlip (1) from steering knuckle. 3) Using hydraulic press (1) and special tool, remove wheel bearing. Special Tool (A): 09913M75810 4) Remove wheel bearing inner race (1). Special Tool (A): 09913M61110 (B): 09925M88210 5) Remove hub bolts (1). Caution: Never remove bolt unless replacement is necessary.
Page 309 2B-14 FRONT SUSPENSION Reassembly 1) Face grooved rubber seal side (1) of new wheel bearing (2) upward as shown and press-fit new wheel bearing (2) into steering knuckle (3) using special tools and hydraulic press (4). Special Tool (A): 09913M75520 (B): 09951M18210 2) Install circlip (1) to steering knuckle (2).
Page 310 FRONT SUSPENSION 2B-15 5) Insert new stud bolt (1) in hub hole. Rotate stud bolt slowly to assure that serrations are aligned with those made by original bolt. Installation Reverse removal procedure for installation, and then note the following instruction. •...
Page 311: Suspension Control Arm/Bushing
2B-16 FRONT SUSPENSION • Connect tie rod end (1) to steering knuckle (2) and tighten tie rod end castle nut (3) to specified torque, and then install new split pin (4). Tightening Torque (a): 43 N·m (4.3 kg-m, 31.5 lb-ft) •...
Page 312 FRONT SUSPENSION 2B-17 4) Remove suspension control arm bolt (1). 5) Remove suspension control arm (2). 6) Pull out bushing (1) using special tool and oil hydraulic press (2) as shown. Special Tool (A): 09943M77910 Installation 1) Install new bushing (1) with special tool and oil hydraulic press (2) as shown.
Page 313 2B-18 FRONT SUSPENSION 3) Install ball stud (1) to steering knuckle (2). Align ball stud groove with knuckle bolt hole as shown. Then install ball stud bolt (3) from the direction as shown. Tighten ball stud bolt to specified torque. Tightening Torque (a): 60 N.m (6.0 kg-m, 43.5 lb-ft) 4) Install wheel and tighten wheel nuts to specified torque.
Page 314: Required Service Material
FRONT SUSPENSION 2B-19 Required Service Material Material Recommended Suzuki Product Lithium wheel bearing grease SUZUKI SUPER GREASE A Wheel bearing (99000-25010) Special Tools...
Page 316: Rear Suspension
REAR SUSPENSION 2C-1 Rear Suspension Note: • • • • • 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 317: General Description
2C-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.
Page 318: Diagnosis
REAR SUSPENSION 2C-3 Diagnosis Diagnosis Table Refer to SECTION 2. Rear Shock Absorber Check • Inspect for deformation or damage. • Inspect bushings for wear or damage. • 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 precautions.
Page 319: Bump Stopper And Spring Upper Seat Check
2C-4 REAR SUSPENSION Bump Stopper And Spring Upper Seat Check Inspect for cracks, deformation or damage. Replace any defective part. Rear Suspension Fasteners Check each bolt and nut fastening suspension parts for tightness. Tighten loose one, if any, to specified torque, referring to TIGHTENING TORQUE SPECIFICATIONS of this section.
Page 320: On-Vehicle Service
REAR SUSPENSION 2C-5 On-Vehicle Service Note: According to necessity, apply works to right and left parts.
Page 321: Lateral Rod
2C-6 REAR SUSPENSION Lateral Rod Removal 1) Hoist vehicle. 2) Remove lateral rod nuts (1) and bolt (2). 3) Remove lateral rod (3). Installation 1) Install lateral rod (1) to rear axle (2) and vehicle body (3) referring to figure for proper installing direction of nuts (4), bolt (5) and washer (6).
Page 322: Rear Shock Absorber
REAR SUSPENSION 2C-7 Rear Shock Absorber Removal 1) Hoist vehicle. 2) Support rear axle using floor jack to prevent it from lowering. 3) Remove shock absorber lower nut (1). 4) Remove shock absorber upper bolt (2) and nut (3), then remove shock absorber (4).
Page 323 2C-8 REAR SUSPENSION 5) Remove shock absorber lower nut (1), and then detach shock absorber lower end (2) from rear axle. 6) Lower rear axle (1) gradually as far down as where coil spring (2) 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 324: Bump Stopper
REAR SUSPENSION 2C-9 5) Install lateral rod (1) to vehicle body referring to figure for proper installing direction of bolt (2). Tighten nut (3) temporarily at this step. 6) Remove floor jack from rear axle. 7) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 8) Lower hoist and bounce vehicle up and down several times...
Page 325: Spring Upper Seat
2C-10 REAR SUSPENSION Spring Upper Seat Removal 1) Removal coil spring. For details, refer to COIL SPRING REMOVAL in this section. 2) Remove spring upper seat (1). Installation 1) Install spring upper seat (1). Note: For proper installing direction of spring upper seat, refer to figure.
Page 326 REAR SUSPENSION 2C-11 5) Remove parking brake cable clamp (1) from trailing arm (2). 6) Remove trailing arm center bolt (1) and rear bolt (2). 7) Remove trailing arm front bolt (1), and then remove trailing arm (2). Installation 1) Install trailing arm (1) to vehicle body and rear axle, referring to figure for proper installing direction of bolts (2).
Page 327 2C-12 REAR SUSPENSION 3) Install shock absorber lower end (1) to rear axle. Tighten shock absorber lower nut (2) temporarily at this step. 4) Install lateral rod (1) to vehicle body, refer to figure for proper installing direction of bolt (2). Tighten nut (3) temporarily at this step.
Page 328: Rear Axle
REAR SUSPENSION 2C-13 Rear Axle Removal 1) Hoist vehicle and remove rear wheel. 2) Support rear axle (1) using floor jack (2). 3) Remove brake flexible hose E-rings (1). 4) Remove parking brake cable clamp (1) from trailing arm. 5) Disconnect brake pipe flare nut (1) from wheel cylinder (2) and put bleeder plug cap (3) onto brake pipe (4) to prevent fluid from spilling.
Page 329 2C-14 REAR SUSPENSION 7) Remove lateral rod axle side nut (1), and then detach lateral rod (2) from rear axle. 8) Remove shock absorber lower nut (1) , and then detach shock absorber lower end (2) from rear axle. 9) Lower rear axle gradually as far down as where coil spring (1) can be removed.
Page 330 REAR SUSPENSION 2C-15 Installation 1) Place rear axle (1) on floor jack (2). Then install lateral rod (3) to rear axle (1) and tighten nut (4) temporarily at this step. 2) Install trailing arm (1) to rear axle in proper direction as shown in figure.
Page 331 2C-16 REAR SUSPENSION 7) Install brake back plate (1) and tighten back plate bolts (2) to specified torque. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 8) Connect brake pipe (1) to wheel cylinder (2) and tighten brake pipe flare nut (3) to specified torque. Tightening Torque (a): 16 N·m (1.6 kg-m, 11.5 lb-ft) Caution:...
Page 332: Wheel Bearing And Wheel Stud
REAR SUSPENSION 2C-17 13) Upon completion of all jobs, depress brake pedal with about 30 kg (66 lbs) load three to five times so as to obtain proper drum-to-shoe clearance. Adjust parking brake cable (for adjustment, see SECTION 5 in this manual.) 14) Lower hoist and bounce vehicle up and down several times to stabilize suspension.
Page 333 2C-18 REAR SUSPENSION 3) Remove wheel bearing using special tool and hydraulic press (1). Special Tool (A): 09951M76010 4) Remove wheel stud bolts (1) using hydraulic press (2) and general rod (3). Installation 1) Insert new stud in drum hole and rotate it slowly to assure serrations are aligned with those made by replaced bolt.
Page 334: Special Tools
REAR SUSPENSION 2C-19 Required Service Materials Materials Recommended Suzuki Product Brake fluid DOT3 Brake reservoir tank Water tight sealant SEALING COMPOUND 366E (99000-31090) Join seam of rear axle and brake plate Special Tools...
Page 336: Wheels And Tires
WHEELS AND TIRES 2D-1 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 337: Replacement Wheels
2D-2 WHEELS AND TIRES Warning: kg/cm2 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 338: Wheel Maintenance
WHEELS AND TIRES 2D-3 When the measured runout exceeds the specification and correction 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 Steel wheel 0.7 mm...
Page 339: Inflation Of Tires
2D-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 340: On-Vehicle Service
WHEELS AND TIRES 2D-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 341: Tire Repair
2D-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 personal injury.
Page 342: General Balance Procedures
WHEELS AND TIRES 2D-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 recommendation.
Page 343: Tire Diagnosis
2D-8 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, improper alignment. If the following conditions are noted, rotation is necessary: 1) Front tire wear is different from rear.
Page 344 WHEELS AND TIRES 2D-9 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 vehicle. If waddling end cannot be identified, substitute rear ones. 3) Road test again.
Page 345: Radial Tire Lead
2D-10 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)Tre constrection The way in which a tire is built can produce lead in a vehicle.
Page 346: Front Drive Shaft
FRONT DRIVE SHAFT 3-i Section 3 Front Drive Shaft CONTENTS General Description ......... 3A- 1 Disassembly (Tripod Jopint Type) ....3A- 5 Removal & Installation ........3A- 1 Disassembly (DOJ Type) ......3A- 6 Disassembly & Reassembly ......3A- 2 Inspection .............
Page 348: General Description
FRONT DRIVE SHAFT 3A-1 Front Drive Shaft General Description Removal & Installation...
Page 349: Disassembly & Reassembly
3A-2 FRONT DRIVE SHAFT Disassembly & Reassembly...
Page 350: Diagnosis
FRONT DRIVE SHAFT 3A-3 Diagnosis Diagnosis Table Condition Possible Cause Correction Abnormal Noise Worn or breakage drive shaft joint Replace. Drive Shaft Boot Check Inspect drive shaft boot for hear. If even a small tear is found, replace witha new one.
Page 351: On-Vehicle Service
3A-4 FRONT DRIVE SHAFT On-Vehicle Service Drive Shaft Assembly Removal 1) Undo caulking and remove drive shaft nut (1) and washer. 2) Hoist vehicle. 3) Remove wheel. 4) Remove tie-rod end split pin (1) and castle nut (2). 5) Disconnect tie-rod end (3) from steering knuckle (4) using special tool.
Page 352: Disassembly (Tripod Jopint Type)
FRONT DRIVE SHAFT 3A-5 10) Remove drive shaft assembly. Caution: To prevent breakage of boots, be careful not to bring them into contact with other parts, when removing drive shaft assembly. Disassembly For Tripod joint type drive shaft (Right side) 1) Remove differential side boot band (1), then take out tripod joint housing (2).
Page 353: Inspection
3A-6 FRONT DRIVE SHAFT For DOJ type drive shaft (Left side) 1) Remove boot band (1) of differential side joint. 2) Slide boot (1) toward the center of shaft and remove snap ring (2) from outer race, then take shaft out of outer race (3). 3) Wipe off grease from shaft and remove circlip (1) used to fix cage by using special tool.
Page 354: Reassembly (Tripod Jopint Type)
FRONT DRIVE SHAFT 3A-7 Reassembly Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. For Tripod joint type drive shaft (Right side) Caution: • • • • • To prevent any problem caused by washing solution, do not wash joint boots (1) and tripod joint (2) except its housing (3) and wheel side joint assembly (4).
Page 355 3A-8 FRONT DRIVE SHAFT 7) Install differential side boot (1) on shaft. Apply grease to tripod joint (2). Use green grease in tube included in spare parts. 8) Install tripod joint spider (3) on shaft, facing its chamfered spline inward (wheel side), then fasten it with circlip (4). Special Tool (A): 09900M06107 9) Apply grease to inside of outer race (1), then install housing,...
Page 356 FRONT DRIVE SHAFT 3A-9 For DOJ type drive shaft (Left side) Caution: • To prevent any problem caused by washing solution, do not wash joint boots (1). Degreasing of those parts with cloth is allowed. • To ensure full performance of joint as designed, apply specified volume grease in repair set to respective joint.
Page 357 3A-10 FRONT DRIVE SHAFT 7) Apply grease to entire surface of cage. Use gray grease in tube included in spare parts. 8) Insert cage into outer race and fit snap ring (1) into groove of outer race (2). Caution: Position opening of snap ring “c” so that it will not be lined up with a ball.
Page 358: Installation
FRONT DRIVE SHAFT 3A-11 Installation Caution: • To avoid excessive expansion of boot and consequential disconnection of joint in boot, do not pull differential side joint housing. • Protect boots from any damage, preventing them from unnecessary contact while installing drive shaft. •...
Page 359: Required Service Materials
3A-12 FRONT DRIVE SHAFT Required Service Materials Materials Recommended Suzuki Product Sealant SUZUKI BOND NO. 1215 (99000-31110) Oil drain and filler plug for manual transmission Special Tools...
Page 360 TABLE OF CONTENTS 4-i Section 4 Brakes CONTENTS Brakes ..............4-1 Brakes (with ABS) ..........4A-1 General Description ........... 4-1 General Description ......... 4A-1 Front Disc Brake Caliper Assembly ....4-2 Diagnosis ............4A-2 Rear Drum Brake Assembly ......4-3 Road Testing Brakes ........
Page 361 ii-4 TABLE OF CONTENTS Table-A ABS Warning Lamp Circuit Check-Lamp DTC C1046 Left-Front ........ 4B-20 Does Not Come “ON” At Ignition DTC C1051 Right-Rear Inlet Solenoid Switch On ............ 4B-12 Circuit ............4B-20 Table-B ABS Warning Lamp Circuit Check-Lamp DTC C1055 Left-Rear Inlet Solenoid Comes “ON”...
Page 362: Brakes
BRAKES 4-1 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 two in rear). The master cylinder is a tandem master cylinder. The brake pipes are connected to the master cylinder and they make two independent circuits.
Page 363: General Description
4-2 BRAKES Front Disc Brake Caliper Assembly General Description This caliper is mounted to the brake caliper carrier with two caliper pin bolts and has a single bore. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping action on the disc.
Page 364: Rear Drum Brake Assembly
BRAKES 4-3 Rear Drum Brake Assembly General Description The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained appropriate at all times. Caution: • • • • • Replace all components included in repair kits to service this drum brake. Lubricate parts as specified.
Page 365: Master Cylinder Assembly
4-4 BRAKES Master Cylinder Assembly Genral Description The master cylinder has two pistons and four piston cups. Its hydraulic pressure is produced in the primary (“a” in the figure below) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on the left front wheel brake and right rear wheel brake.
Page 366: Booster Assembly
BRAKES 4-5 Booster Assembly Genral Description The booster is located between the master cylinder and the brake pedal. It is so designed that the force created when the brake pedal is depressed is mechanically increased combined with the engine vacuum. Caution: When and after removing booster, never drop or deform it.
Page 367: Proportioning Valve
4-6 BRAKES Proportioning Valve The proportioning valve is included within the brake circuit which connects the master cylinder and the wheel brakes. It is installed on floor panel and controls the hydraulic pressure applied to the rear wheel brakes after predetermined pressure has been reached.
Page 368: Diagnosis
BRAKES 4-7 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 light and heavy pedal forces at various speeds to components in the hydraulic system to deteriorate.
Page 369: Diagnosis Table
4-8 BRAKES Diagnosis Table Condition Possible Cause Correction • Brake oil leakage from brake lines. Not enough braking Locate leaking point and repair. • Brake disc or pads stained with oil. force Clean or replace. • Overheated brakes. Determine cause and repair. •...
Page 370 BRAKES 4-9 Diagnosis Table Condition Possible Cause Correction • Partial brake system failure. Excessive pedal Check brake systems and repair travel (Pedal stroke as necessary. • Insufficient fluid in master cylinder too large) Fill reservoirs with approved brake reservoirs. fluid. Check for leaks and air in brake systems.
Page 371 4-10 BRAKES Diagnosis Table Condition Possible Cause Correction • Glazed shoe linings, or foreign matters Braking noise Repair or replace shoe linings. stuck to linings. • Worn or distorted shoe linings. Replace shoe linings (or pads). • Loose front wheel bearing. Replace wheel bearing.
Page 372: On-Vehicle Service
BRAKES 4-11 On Vehicle Service Brake Pedal Free Height Adjustment Peel off carpet & dash silencer and check brake pedal free height Brake pedal free height “a” from asphalt sheet : 190 mm (7.48 in.) If it is not within specification, check and adjust following items 1) to 4).
Page 373: Front Brake Disc Inspection
4-12 BRAKES Front Brake Disc Inspection Refer to BRAKE PAD in this section. Front Brake Pad Lining Inspection Inspect pad linings (1) periodically according to maintenance schedule whenever wheels are removed (for tire rotation or other reason). Take a look through each end (or hole) of caliper and check lining thickness of outside and inside pads.
Page 374: Brake Pedal Play Inspection
BRAKES 4-13 Brake Pedal Play Inspection Pedal play should be within specification below. If out of specification, check stop light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective. Pedal play ”f”: 1 –...
Page 375: Flushing Brake Hydraulic System
4-14 BRAKES If number of notches is out of specification, adjust cable by referring to adjustment procedure so as to obtain specified parking brake stroke. Note: Check tooth tip of each notch for damage or wear. If any damage or wear is found, replace parking brake lever.
Page 376: Bleeding Brakes
BRAKES 4-15 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. Bleeding operation is necessary to remove air whenever it entered hydraulic brake system. Hydraulic lines of brake system are based on the diagonal split system.
Page 377: Brake Hose And Pipe Inspection
4-16 BRAKES 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. Tightening Torque (b): 8.0 N·m (0.8 kg-m, 5.5 lb-ft) 7) Then attach bleeder plug cap. 8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage. 9) Replenish fluid into reservoir up to specified level.
Page 378: Repair
BRAKES 4-17 Repair Front Brake Hose/Pipe Removal 1) Raise and support vehicle properly. Remove tire and wheel. 2) Clean dirt and foreign material from both flexible hose ends and pipe end fittings. Remove brake flexible hose or pipe. Inspection 1) Install brake flexible hose or pipe by reversing removal procedure, nothing the following points. For installation, make sure that steering wheel is in straightforward position and flexible hose has not twist or kink.
Page 379: Rear Brake Hose/Pipe
4-18 BRAKES Rear Brake Hose/Pipe Removal 1) Raise and support vehicle properly. Remove tire and wheel. 2) Clean dirt and foreign material from both flexible hose ends and pipe end fittings. Remove brake flexible hose or pipe. Installation 1) Install brake flexible hose or pipe by reversing removal procedure, nothing the following points. Fill and maintain brake fluid level in reservoir.
Page 380: Parking Brake Lever
BRAKES 4-19 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 381: Parking Brake Cable
4-20 BRAKES Parking Brake Cable 1.Parking brake lever assembly 5.Parking brake cable: 2.Equalizer Apply water tight sealant 3.Adjusting nut 99000-31090 to plate and 4.Parking cable bracket cable contact. 6.Grommet : Tightening Torque Removal 1) Remove brake drum. (Refer to steps 1) to 5) of BRAKE DRUM REMOVAL in this section.) 2) Disconnect parking brake cable from brake shoe lever.
Page 382 BRAKES 4-21 Installation Install parts in reverse order of REMOVAL procedure, noting the following. 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. 2) Apply water tight sealant where plate and cable contact, and run parking brake cable (1) through brake back plate (2) and secure it with clip (3).
Page 383: Brake Pad
4-22 BRAKES Brake Pad Removal 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolt (1). 3) Remove caliper (1) from caliper carrier (4). Note: Hang removed caliper with a wire hook (2) or the like so as to prevent brake flexible hose from bending and twisting excessively or being pulled.
Page 384 BRAKES 4-23 Brake Disc Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replacement are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc surface, replace it.
Page 385: Caliper Assembly
4-24 BRAKES Caliper Assembly Removal 1) Hoist vehicle and remove wheel. 2) Remove E-ring (3). 3) Remove brake flexible hose (2) from caliper (1). As this will allow fluid to flow out of hose, have a container (4) ready beforehand. 4) Remove caliper pin bolts (1).
Page 386 BRAKES 4-25 2) Remove piston seal using a thin blade like a thickness gauge, etc. Caution: Be careful not to damage inside (bore side) of cylinder. Inspection Piston Boot Check boots for breakage, crack and damage. If defective, replace. Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth return of the piston.
Page 387 4-26 BRAKES Piston and Boot 1) Before inserting piston (2) into cylinder, install boot (1) onto piston as shown. 2) Fit boot as it is in figure into boot groove in cylinder with fingers. 3) Insert piston into cylinder by hand and fit boot in boot groove in piston.
Page 388 BRAKES 4-27 Caliper Before installing caliper (cylinder body) to carrier, check to ensure that pin can be moved smoothly in thrust direction. Note: Where temperature gets as low as – 30 C (– 22 F) in cold weather, use rubber grease whose viscosity varies very little even at –...
Page 389: Brake Disc
4-28 BRAKES Brake Disc Removal 1) Hoist vehicle and remove wheel. 2) Remove caliper assembly by removing carrier bolts. Caution: During removal, be careful not to damage brake flexible hose and not to depress brake pedal. Refer to REMOVAL of BRAKE PAD in this section. 3) Pull brake disc off by using 8 mm bolts (1).
Page 390: Brake Drum
BRAKES 4-29 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 seating part of cap). 3) Uncaulk spindle nut, remove spindle nut (1). 4) Release parking brake lever.
Page 391 4-30 BRAKES Inspection Brake Drum Inspect drum for cleanliness. Check wear of its braking surface by measuring its inside diameter. Brake drum inside diameter Standard : 180 mm (7.09 in.) Service limit : 182 mm (7.16 in.) Whenever brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves.
Page 392 BRAKES 4-31 Installation 1) Insert new stud in drum hole and rotate it slowly to assure serrations are aligned with those made by replaced bolt. 2) Put flat head rod or the like between rod (1) and ratchet (2) and pull ratchet as shown to maximize clearance between shoe and drum.
Page 393: Brake Shoe
4-32 BRAKES 10) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (b): 85 N·m (8.5 kg-m, 61.5 lb-ft) 11) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then lower vehicle and preform brake test (foot brake and parking brake).
Page 394 BRAKES 4-33 Brake Strut • Check ratchet of brake strut (1) assembly for wear or damage. • Check shoe return spring, strut shoe return spring and shoe hold down spring for damage, corrosion and weakening. Springs Inspect for damage or weakening. Inspect each part with arrow for rust.
Page 395: Wheel Cylinder
4-34 BRAKES Wheel Cylinder Removal 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL. 2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL. 3) Loosen brake pipe flare nut but only within the extent that fluid does not leak. 4) Remove wheel cylinder mounting bolts (1).
Page 396: Brake Back Plate
BRAKES 4-35 Brake Back Plate Removal 1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL in this section. 2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL in this section. 3) Perform steps 3) to 4) of WHEEL CYLINDER REMOVAL in this section.
Page 397 4-36 BRAKES 3) Apply water tight sealant where plate and cable contact, and run parking brake cable (2) through brake back plate (1) and “a” secure it with clip (3). “A”: Sealant 366E 99000-31090 4) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut to specified torque.
Page 398: Master Cylinder Assembly
BRAKES 4-37 Master Cylinder Assembly 1.Master cylinder reservoir cap 2.Master cylinder reservoir 3.Grommet: Apply brake fluid. 4.Master cylinder body: Apply brake fluid to inside of cylinder. 5.Secondary piston return spring: Apply brake fluid. 6.Secondary piston: Apply brake fluid. 7.Primary piston return spring: Apply brake fluid.
Page 399 4-38 BRAKES Disassembly 1) Remove reservoir pin (1) that fixes cylinder body and reservoir by using special tool. Special Tool (A): 09922M89810 2) Remove reservoir and 2 grommets. 3) Insert flat head rod or the like under each claw of stopper cap (1), straighten it and remove stopper cap.
Page 400 BRAKES 4-39 Assembly Caution: • Never use any mineral oil such as kerosene oil and gasoline when washing and assembling parts. • Check inside of cylinder wall, pistons and cups are free from any foreign objects such as dust and dirt and use care not to cause any damage with a tool during assembly.
Page 401 4-40 BRAKES Installation Note: Adjust booster piston rod length with special tool (Refer to BRAKE BOOSTER in this section.). 1) Install master cylinder as shown and tighten attaching nuts to specified torque. Tightening Torque (a): 13 N·m (1.3 kg-m, 9.5 lb-ft) 2) Attach hydraulic lines and tighten flare nuts to specified torque.
Page 402: Brake Booster
BRAKES 4-41 Brake Booster Removal 1) Remove master cylinder assembly, referring to MASTER CYLINDER ASSEMBLY in this section. 2) Disconnect vacuum hose (1) from booster (2). 3) Disconnect push rod clevis (3) from brake pedal arm. 4) Disconnect stop light switch coupler. 5) Remove brake pedal bracket (5) with brake pedal and stop light switch (4).
Page 403 4-42 BRAKES 1) Measure length of piston rod, i.e. distance between piston rod and mating surface of booster-to-master cylinder. Length of piston rod “c”: 10.1 – 10.4 mm (0.40 – 0.41 in.) 2) If measurement is out of specified value, adjust depth by turning adjusting screw of piston rod.
Page 404 BRAKES 4-43 Installation 1) Install booster (1) to dash panel. 2) Install push rod clevis (2) to push rod. 3) Adjust distance “a” between booster installation surface and the center of clevis pin hole to standard value, and then tighten lock nut (3) to specified torque.
Page 405 4-44 BRAKES Inspect Booster Operation 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.
Page 406 BRAKES 4-45 2) Start engine while depressing brake pedal. If pedal travel increases a little, operation is satisfactory. But no change in pedal travel indicates malfunction. Check Air Tightness Under Load 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed.
Page 407: Required Service Materials
4-46 BRAKES Required Service Materials MATERIALS RECOMMENDED (SUZUKI) PRODUCT • To fill master cylinder reservoir. • Brake fluid DOT 3 - GC1500 AA To clean and apply to inner parts of master cylinder, caliper and wheel cylinder when they are disassembled.
Page 408: Brakes (With Abs)
BRAKES (WITH ABS) 4A-1 Brakes (With ABS) General Discription When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two in front and two in rear). The master cylinder is a tandem master cylinder. The brake pipes are connected to the master cylinder and they make two independent circuits.
Page 409: Diagnosis
2-4A BRAKES (WITH ABS) Diagnosis Substandard or Contaminated Brake Road Testing Brakes Fluid Brakes should be tested on dry, clean, smooth and Improper brake fluid, mineral oil or water in the fluid reasonably level roadway which is not crowned. Road test brakes by making brake applications with both light may cause the brake fluid to boil or the rubber and heavy pedal forces at various speeds to determine...
Page 410: Diagnosis Table
BRAKES (WITH ABS) 4A-3 Diagnosis Table Condition Possible Cause Correction • Not enough braking Brake fluid leakage from brake lines. Locate leaking point and repair. • force Brake disc or pads stained with oil. Clean or replace. • Overheated brakes. Determine cause and repair.
Page 411 4-4A BRAKES (WITH ABS) Diagnosis Table Condition Possible Cause Correction • Condition Possible Partial brake system failure. Check brake systems and repair Cause Correction as necessary. • Excessive pedal Insufficient fluid in master cylinder Fill reservoirs with approved brake travel (Pedal stroke reservoirs.
Page 412 BRAKES (WITH ABS) 4A-5 Diagnosis Table Condition Possible Cause Correction • Braking noise Glazed shoe linings, or foreign matters Repair or replace shoe linings. stuck to linings. • Worn or distorted shoe linings. Replace shoe linings (or pads). • Loose front wheel bearing. Replace wheel bearing.
Page 413: On-Vehicle Service
6-4A BRAKES (WITH ABS) On Vehicle Service 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. Bleeding operation is necessary to remove air whenever it entered hydraulic brake system.
Page 414: Brake Hose And Pipe Inspection
BRAKES (WITH ABS) 4A-7 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. Tightening Torque (b): 8.0 N-m (0.8 kg-m, 5.5 lb-ft) 7) Then attach bleeder plug cap. 8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
Page 415: Booster Operation Inspection
8-4A BRAKES (WITH ABS) Booster Operation Inspection 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 416 BRAKES (WITH ABS) 4A-9 2) Start engine while depressing brake pedal. If pedal travel increases a little, operation is satisfactory. But no change in pedal travel indicates malfunction. Check Air Tightness Under Load 1) With engine running, depress brake pedal. Then stop engine while holding brake pedal depressed.
Page 417: Brake Hose/Pipe
10-4A BRAKES (WITH ABS) Brake Hose/Pipe Front Brake Hose/Pipe Removal 1) Raise and support vehicle properly. Remove tire and wheel. Note: This operation is not necessary when removing pipes connecting master cylinder. 2) Clean dirt and foreign material from both flexible hose ends and pipe end fittings.
Page 418 BRAKES (WITH ABS) 4A-11...
Page 419: Rear Brake Hose/Pipe
12-4A BRAKES (WITH ABS) Rear Brake Hose/Pipe Removal 1) Raise and support vehicle properly. Remove tire and wheel. 2) Clean dirt and foreign material from both flexible hose ends and pipe end fittings. 3) Drain brake fluid in reservior. Caution: Do not allow brake fluid to get on painted surface.
Page 420 BRAKES (WITH ABS) 4A-13...
Page 421: Front Brake
14-4A BRAKES (WITH ABS) Front Brake Caution: Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber components 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.
Page 422: Brake Pad
BRAKES (WITH ABS) 4A-15 Brake Pad Removal 1) Hoist vehicle and remove wheel. 2) Remove caliper pin bolts (1). 3) Remove caliper (1) from caliper carrier (4). Note: Hang removed caliper with a wire hook (2) or the like so as to prevent brake flexible hose from bending and twisting excessively or being pulled.
Page 423 16-4A BRAKES (WITH ABS) Brake Disc Check disc surface for scratches in wearing parts. Scratches on disc surface noticed at the time of specified inspection or replacement are normal and disc is not defective unless they are serious. But when there are deep scratches or scratches all over disc surface, replace it.
Page 424: Caliper Assembly
BRAKES (WITH ABS) 4A-17 Caliper Assembly Removal 1) Hoist vehicle and remove wheel. 2) Remove E-ring (3). 3) Remove brake flexible hose (2) from caliper (1). As this will allow fluid to flow out of hose, have a container (4) ready beforehand.
Page 425 18-4A BRAKES (WITH ABS) 2) Remove piston seal using a thin blade like a thickness gauge, etc. Caution: Be careful not to damage inside (bore side) of cylinder. Inspection Piston Boot Check boots for breakage, crack and damage. If defective, replace. Piston Seal Excessive or uneven wear of pad lining may indicate unsmooth return of the piston.
Page 426 BRAKES (WITH ABS) 4A-19 Assembly Reassemble front brake in reverse order of disassembly, noting the following points. Caution: • Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir. • Never use other fluid or thinner. •...
Page 427 20-4A BRAKES (WITH ABS) 4) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out. NOTE: Boot’s face B should be at the same level from cylinder’s face A all around.
Page 428: Brake Disc
BRAKES (WITH ABS) 4A-21 Brake Disc Removal 1) Hoist vehicle and remove wheel. 2) Remove caliper assembly by removing carrier bolts. Caution: During removal, be careful not to damage brake flexible hose and not to depress brake pedal. Refer to “REMOVAL of BRAKE PAD”...
Page 429: Rear Brake
22-4A BRAKES (WITH ABS) Rear Brake Caution: • Replace all components included in repair kits to service this drum brake. Lubricate parts as specified. • If any hydraulic component is removed or brake line disconnected, bleed the brake system. • The torque values specified are for dry, unlubricated fasteners.
Page 430: Brake Drum
BRAKES (WITH ABS) 4A-23 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 seating part of cap). 3) Uncaulk spindle nut, remove spindle nut (1).
Page 431 24-4A BRAKES (WITH ABS) Installation 1) Insert new stud in drum hole and rotate it slowly to assure serrations are aligned with those made by replaced bolt. 2) Put flat head rod or the like between rod (1) and ratchet (2) and pull ratchet as shown to maximize clearance between shoe and drum.
Page 432: Brake Shoe
BRAKES (WITH ABS) 4A-25 Inspection Brake Drum Inspect drum for cleanliness. Check wear of its braking surface by measuring its inside diameter. Brake drum inside diameter Standard : 180 mm (7.09 in.) Service limit : 182 mm (7.16 in.) Whenever brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves.
Page 433 26-4A BRAKES (WITH ABS) 10) Install wheel and tighten wheel nuts to specified torque. Tightening Torque (b): 85 N-m (8.5 kg-m, 61.5 lb-ft) 11) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then lower vehicle and preform brake test (foot brake and parking brake).
Page 434 BRAKES (WITH ABS) 4A-27 Brake Strut • Check ratchet of brake strut (1) assembly for wear or damage. • Check shoe return spring, strut shoe return spring and shoe hold down spring for damage, corrosion and weakening. Springs Inspect for damage or weakening. Inspect each part with arrow for rust.
Page 435: Wheel Cylinder
28-4A BRAKES (WITH ABS) Wheel Cylinder Removal 1) Remove brake drum referring to steps 1) to 5) of “BRAKE DRUM REMOVAL” in this section. 2) Remove brake shoe referring to steps 2) to 4) of “BRAKE SHOE REMOVAL” in this section. 3) Loosen brake pipe flare nut but only within the extent that fluid does not leak.
Page 436: Brake Back Plate
BRAKES (WITH ABS) 4A-29 4) Install bleeder plug cap taken off from pipe back to bleeder plug. 5) For procedure hereafter, refer to “BRAKE SHOE INSTALLATION” in this section. Note: Be sure to bleed brake system. (Refer to “BLEEDING BRAKES” in this section.) Brake Back Plate Removal 1) Remove brake drum referring to steps 1) to 5) of “BRAKE...
Page 437 30-4A BRAKES (WITH ABS) 3) Apply water tight sealant where plate and cable contact, and run parking brake cable (2) through brake back plate (1) and secure it with clip (3). “A”: Sealant 366E 99000-31090 4) Install wheel cylinder and tighten wheel cylinder bolts and brake pipe flare nut to specified torque, referring to steps 1) to 4) of “WHEEL CYLINDER INSTALLATION”...
Page 438: Master Cylinder Assembly
BRAKES (WITH ABS) 4A-31 Master Cylinder Assembly Caution: Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rubber components may result.
Page 439 32-4A BRAKES (WITH ABS) Removal 1) Disconnect reservoir lead wire coupler. 2) Clean around reservoir cap (2) and take out fluid with syringe or such. Disconnect brake pipes (3) from master cylinder (4). Caution: Do not allow brake fluid to get on painted surfaces. 4) Remove attaching nuts (5).
Page 440 BRAKES (WITH ABS) 4A-33 4) Pull out primary piston assembly straight so as not to cause any damage to inside of cylinder wall. 5) Pull out secondary piston assembly straight so as not to cause any damage to inside of cylinder wall and by tapping flange with a piece of wood or something soft.
Page 441 34-4A BRAKES (WITH ABS) 1) Apply brake fluid to inside of cylinder and contact surface of piston assemblies and insert secondary piston (2) and next primary piston (1) into cylinder body. Be sure to install piston cup in correct installation direction and straight into cylinder so that it is not caught.
Page 442 BRAKES (WITH ABS) 4A-35 Installation Note: Confirm booster piston rod length referring to “BRAKE BOOSTER” in this section. 1) Install master cylinder as shown and tighten attaching nuts to specified torque. Tightening Torque (a): 13 N-m (1.3 kg-m, 9.5 lb-ft) 2) Connect brake pipe to master cylinder and tighten flare nuts to specified torque.
Page 443: Brake Booster
36-4A BRAKES (WITH ABS) Brake Booster Caution: • Never disassemble brake booster. Disassembly will spoil its original function. If faulty condition is found, replace it with a new one. • The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is removed or brake line disconnected, bleed the brake system.
Page 444 BRAKES (WITH ABS) 4A-37 1) Measure length of piston rod, i.e. distance between piston rod and mating surface of booster-to-master cylinder. Length of piston rod “c”: 10.1–10.4 mm (0.40–0.41 in.) 2) If measurement is out of specified value, adjust length by turning adjusting screw of piston rod.
Page 445 38-4A BRAKES (WITH ABS) Installation 1) Install brake booster to dash panel. Install it according to the following procedure if clevis obstructs booster installation. a) Make marking (1) on clevis lock nut position of push rod thread if it is not marked. b) Remove clevis (2) if it is installed.
Page 446: Required Service Materials
BRAKES (WITH ABS) 4A-39 Required Service Materials Materials Recommended (Suzuki) Product • Brake fluid DOT 3 - GC1500 AA To fill master cylinder reservoir. • To clean and apply to inner parts of master cylinder, caliper and wheel cylinder when they are disassembled.
Page 448 ANTILOCK BRAKE SYSTEM 4B-1 Antilock Brake System Warning: For vehicle equipped with Supplemental Restraint (Air Bag) System: • Service on and around the air bag system components or wiring must be performed only by and authorized MARUTI dealer. Refer to “Air Bag System Components and Wiring Location View”...
Page 449: General Description
2-4B ANTILOCK BRAKE SYSTEM General Description Components/Parts Location and Brake Hose/Pipe Routing 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 450: System Schematic
ANTILOCK BRAKE SYSTEM 4B-3 System Schematic...
Page 451: Abs Hydraulic Unit Control Module
4-4B ANTILOCK BRAKE SYSTEM 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 component parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) hrough the ABS warning lamp as described below.
Page 452: System Circuit
ANTILOCK BRAKE SYSTEM 4B-5 System Circuit...
Page 453 6-4B ANTILOCK BRAKE SYSTEM 1. Battery 10. Terminal arrangement of connector E19 for ABS 18. Right-front wheel speed sensor hydraulic unit/control module assembly 2. Main fuses 11. ABS fail-safe relay (Solenoid valve relay) 19. Left-front wheel speed sensor 3. Ignition switch 12.
Page 454: Diagnosis
ANTILOCK BRAKE SYSTEM 4B-7 TERMINAL COLOR CIRCUIT Blank Brake switch E-19 Blank W/Bl Motor power supply Diagnosis To ensure that the trouble diagnosis is done accurately and smoothly, observe “PRECAUTIONS IN DIAGNOSING TROUBLES” and follow “ABS DIAGNOSTIC FLOW TABLE”. Precaution In Diagnosing Trouble •...
Page 455: Abs Diagnostic Table
8-4B ANTILOCK BRAKE SYSTEM ABS Diagnostic 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 456 ANTILOCK BRAKE SYSTEM 4B-9 1) MALFUNCTION ANALYSIS a) 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 457 10-4B ANTILOCK BRAKE SYSTEM c) Diagnostic Trouble Code (DTC) Check, Record and Clearance Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again when the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this step may mislead the diagnosis or make diagnosing difficult.
Page 458: Abs Warning Lamp Check
ANTILOCK BRAKE SYSTEM 4B-11 ABS Warning Lamp Check 1) Turn ignition switch ON. 2) Check that ABS warning lamp (1) comes ON for about 2 seconds and then goes off. If any faulty condition is found, advance to Diagnostic Flow Table- A, B, or C .
Page 459 12-4B ANTILOCK BRAKE SYSTEM Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “On” at Ignition Switch On Circuit Description Operation (ON/OFF) of ABS warning lamp is controlled by ABS control module through lamp driver module in combination meter. If the Antilock brake system is in good condition, ABS control module turns ABS warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.
Page 460 ANTILOCK BRAKE SYSTEM 4B-13 Table-B ABS Warning Lamp Circuit Check – Lamp Comes “On” Steady Refer to TABLE – A for System Circuit Diagram and Circuit Description. Inspection Step Action Perform diagnostic trouble code check. Using Go to Step 2. Go to Step 3 SUZUKI scan tool.
Page 461: Diagnostic Trouble Code (Dtc) Check (Using Suzuki Scan Tool)
14-4B ANTILOCK BRAKE SYSTEM Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch Is ON Step Action 1) Check for proper connection to ABS control Substitute a known- "E03-20 terminal module at ABS hydraulic unit / control module good ABS hydraulic shorted to ground.
Page 462 ANTILOCK BRAKE SYSTEM 4B-15 Diagnostic Trouble Code Clearence (Using Suzuki Scan Tool) Warning: When performing a driving test, select a safe place where there is neither any traffic nor any traffic accident possibility and be very careful during testing to avoid occurrence of an accident.
Page 463 16-4B ANTILOCK BRAKE SYSTEM Scan Tool Data The parameter data below are values measured with the scan tool when the normally operating vehicle is under the following conditions. When taking measurements for comparison by using the scan tool, be sure to check that the vehicle is under the fol- lowing conditions.
Page 464: Diagnostic Trouble Code (Dtc) Table
ANTILOCK BRAKE SYSTEM 4B-17 Diagnostic Trouble Code Table Caution: Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” before starting diagnosis. Diagnostic Items (displayed on SUZUKI scan tool) NO DTC Normal C1016 Brake lamp switch failure C1021 C1025 Wheel speed sensor circuit C1031 open or short C1035...
Page 465: Dtc C1021, Dtc C1022 Right-Front Wheel Speed Sensor Circuit Or Sensor Rotor
18-4B ANTILOCK BRAKE SYSTEM DTC C1021, DTC C1022 – Right-Front Wheel Speed Sensor Circuit Or Sensor Rotor DTC C1025, DTC C1026 – Left-Front Wheel Speed Sensor Circuit Or Sensor Rotor DTC C1031, DTC C1032 – Right-Rear Wheel Speed Sensor Circuit Or Sensor Rotor DTC C1035, DTC C1036 –...
Page 466 ANTILOCK BRAKE SYSTEM 4B-19 Inspection open or short 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. wheel speed sensor. Refer to “FRONT WHEEL SPEED SENSOR”...
Page 467: Dtc C1041 Right-Front Inlet Solenoid Circuit
20-4B ANTILOCK BRAKE SYSTEM DTC C1041 – Right-Front Inlet Solenoid Circuit DTC C1045 – Left-Front Inlet Solenoid Circuit DTC C1051 – Right-Rear Inlet Solenoid Circuit DTC C1055 – Left-Rear Inlet Solenoid Circuit DTC C1042 – Right-Front Outlet Solenoid Circuit DTC C1046 – Left-Front Outlet Solenoid Circuit DTC C1052 –...
Page 468: Dtc C1057 Power Source Circuit
ANTILOCK BRAKE SYSTEM 4B-21 DTC C1057 – Power Source Circuit Description The ABS control module monitors the power source voltage at terminal “E19-20”. When the power source voltage becomes extremely high or low, this DTC will be set. As soon as the voltage rises or lowers to the specified level, the set DTC will be cleared.
Page 469: Dtc C1061 Abs Pump Motor Circuit
22-4B ANTILOCK BRAKE SYSTEM DTC C1061– ABS Pump Motor Circuit Description The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition switch turned ON. It sets this DTC when the voltage at the monitor terminal does not become high/low according to ON/OFF commands to the motor relay of the module (does not follow these commands).
Page 470: Dtc C1063 Abs Fail-Safe Relay Circuit
ANTILOCK BRAKE SYSTEM 4B-23 DTC C1063 – ABS Fail-Safe Relay Circuit Description ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON. Also, immediately after ignition switch is turned ON, perform initial check as follows. Switch fail-safe relay in the order of OFF or ON and check if voltage changes to Low or High.
Page 471: Dtc C1071 Abs Control Module
24-4B ANTILOCK BRAKE SYSTEM DTC C1071 – ABS Control Module Description This DTC will be set when an internal malfunction is detected in the ABS control module. Inspection Step Action Clear all DTCs and check DTC. Go to Step 2. Could be a temporary Is it DTC 71? malfunction of the...
Page 472: Abs
ANTILOCK BRAKE SYSTEM 4B-25 On-Vehicle Service Precautions When connector is connected to ABS hydraulic unit/control module assembly, do not disconnect connectors of sensors with ignition switch ON. Then DTC will be set in ABS control module. ABS Hydraulic Unit Operation Check (Using Suzuki Scan Tool) 1) Check that basic brake system other than ABS is in good condition.
Page 473: Abs Hydraulic Unit/Control Module Assembly
26-4B ANTILOCK BRAKE SYSTEM ABS Hydraulic Unit / Control Module Assembly Caution: Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor.Performing any of these prohibited services will affect original performance of ABS hydraulic unit/control module assembly. 16 N.m.(1.6kg-m) 16 N.m.(1.6kg-m) 9 N.m.(0.9kg-m)
Page 474 ANTILOCK BRAKE SYSTEM 4B-27 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly (3). Special tool (A) : 09950M78220 NOTE: Put bleeder plug cap or the like onto pipe to prevent fluid from spilling.
Page 475: Front Wheel Speed Sensor
28-4B ANTILOCK BRAKE SYSTEM Front Wheel Speed Sensor Output Voltage Inspection 1) Turn ignition switch OFF. 2) Hoist vehicle a little. 3) Disconnect wheel speed sensor connector. 4) Connect voltmeter between connector (1) terminals. 5) While turning wheel by hand at a speed of approximately 1/2 to 1 rotation per second, check AC voltage of sensor.
Page 476 ANTILOCK BRAKE SYSTEM 4B-29 Reference When using oscilloscope for this check, check if peak-to-peak voltage (1) meets specification and waveform is complete. Peak-to-peak voltage at 1/2 to 1 rotation per second : 150 mV or more at 21 – 42 Hz Removal 1) Disconnect negative cable at battery.
Page 477: Front Wheel Speed Sensor Rotor
30-4B ANTILOCK BRAKE SYSTEM Installation 1) Check that no foreign material is attached to sensor (1) and sensor rotor (2). 2) Install it by reversing removal procedure. Tightening torque Front wheel speed sensor bolt (a) : 11 N-m (1.1 kg-m, 8.0 lb-ft) Caution: Do not pull or twist wire harness more than necessary when installing front wheel speed sensor.
Page 478: Rear Wheel Speed Sensor
ANTILOCK BRAKE SYSTEM 4B-31 Rear Wheel Speed Sensor Out Put Voltage Inspection 1) Turn ignition switch OFF. 2) Remove quarter inner trim (1). 3) Turn over floor carpet. 4) Hoist vehicle. 5) Disconnect connector of wheel speed sensor. 6) Connect voltmeter between connector (1) terminals. 7) While turning wheel at a speed of approximately 1/2 to 1 rotation per second, check AC voltage of sensor.
Page 479 32-4B ANTILOCK BRAKE SYSTEM Reference When using oscilloscope for this check, check if peak-to-peak voltage (1) meets specification and waveform is complete. Peak-to-peak voltage at 1/2 to 1 rotation per second : 120 mV or more at 20 Hz Removal 1) Disconnect negative cable at battery.
Page 480 ANTILOCK BRAKE SYSTEM 4B-33 Installation Reverse removal procedure for installation noting the following. • Check that no foreign material is attached to sensor and rotor (1). • Be sure to install wheel speed sensor (2) and its bolt at the correct (upper) position as shown in figure.
Page 481: Rear Wheel Speed Sensor Rotor
34-4B ANTILOCK BRAKE SYSTEM Rear Wheel Speed Sensor Rotor Removal 1) Remove rear wheel sensor from rear axle housing. 2) Remove brake drum referring to SECTION 5. 3) Remove sensor rotor (1) from brake drum (2) using special tools. Special tool (A) : 09913M75520 (B) : 09913M65135 Caution:...
Page 482 ANTILOCK BRAKE SYSTEM 4B-35 2) Install brake drum. Refer to SECTION 5. 3) Install rear wheel speed sensor (1) to rear axle housing. Tightening torque Rear wheel speed sensor (a) : 11 N-m (1.1kg-m, 8.0 lb-ft)
Page 483 36-4B ANTILOCK BRAKE SYSTEM Special Tool Note:"A": This kit includes the following items and substitutes for the Tech 1A kit. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8.
Page 484: Transmission
TABLE OF CONTENTS 5B-i Section 5 Transmission CONTENTS Manual Transmission ........5B-1 Differential assembly ........5B-26 General Description ........5B- 1 Assembling Unit ..........5B-28 Gear Shift Mechanism ........5B-3 Differential to left case ........5B-28 Diagnosis ............5B- 5 Fifth gear ............
Page 486: Manual Transmission
MANUAL TRANSMISSION 5B-1 Manual Transmission General Description The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shafts – input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 487 2-5B MANUAL TRANSMISSION...
Page 488: Gear Shift Mechanism
MANUAL TRANSMISSION 5B-3 Gear Shift Mechanism Movement of gear shift control lever is transmitted to gear shift shaft through gear shift control shaft, and gear shift & select shaft through gear shift arm and gear shift yoke, and then gear shift & select lever to each gear shift yoke, shaft and fork or arm.
Page 489 4-5B MANUAL TRANSMISSION 1) When gear is shifted to 5th speed, 5th & reverse gear shift cam (2) turns clockwise with gear shift & select shaft (1) and it is pushed up by cam guide return spring (3) to the position where interlock guide bolt (7) prevents the cam from being shifted to reverse straight.
Page 490: Diagnosis
MANUAL TRANSMISSION 5B-5 Diagnosis Condition Possible Cause Correction • Gears slipping out of Worn shift fork shaft Replace. • mesh Worn shift fork or synchronizer sleeve Replace. • Weak or damaged locating springs Replace. • Worn bearings on input shaft or countershaft Replace.
Page 491: On-Vehicle Service
6-5B MANUAL TRANSMISSION On-Vehicle Service Oil Change 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it. 3) Drain old oil and torque drain plug (2) as specified below. Apply sealant to thread of drain plug before installation.
Page 492: Differential Side Oil Seal
MANUAL TRANSMISSION 5B-7 Differential Side Oil Seal Replacement 1) Lift up vehicle and drain transmission oil. 2) Remove wheel, and then remove tie-rod end split pin (4) and castle nut (3). 3) Disconnect tie-rod end (1) from knuckle (2) by using special tool.
Page 493 8-5B MANUAL TRANSMISSION 9) Insert drive shaft joint to differential gear. Refer to Section 4A. Caution : • • • • • Be careful not to scratch oil seal lip with drive shaft joint while inserting. • • • • • Make sure to insert drive shaft joint fully and seat its snap ring as it was.
Page 494: Gear Shift Control Lever And Rod
MANUAL TRANSMISSION 5B-9 Gear Shift Control Lever and Rod...
Page 495: Vehicle Speed Sensor (Vss)
10-5B MANUAL TRANSMISSION Removal 1) Disconnect gear shift control shaft from gear shift lever by removing control shaft bolt and nut. 2) Loosen extension rod nut at transmission end and then move extension rod. 3) Remove console box. 4) Remove 4 control lever housing nuts and gear shift lever set with extension rod set from body.
Page 496: Dismounting Of Transmission
MANUAL TRANSMISSION 5B-11 Dismounting of Transmission Under Hood 1) Disconnect negative cable at battery. 2) Undo wiring harness clamps, disconnect back up light switch coupler, VSS coupler and ground cable. 3) Disconnect clutch cable from clutch release lever and bracket. 4) Disconnect gear shift and select control cables.
Page 497: Remounting
12-5B MANUAL TRANSMISSION Remounting Caution : Care should be taken not to scratch oil seal lip with drive shaft while raising transmission. Do not hit drive shaft joint with hammer when installing it into differential gear. Remount transmission in reverse order of dismounting procedure noting the following.
Page 498: Unit Repair Overhaul
MANUAL TRANSMISSION 5B-13 Unit Repair Overhaul Disassembling Unit Fifth Gear 1) Remove 8 bolts and take off transmission side cover. 2) Using special tool, remove circlip (1) and then hub plate (2). Caution : Care should be taken not to distort side cover when it is removed from left case.
Page 499: Gear Shifter, Main Shaft And Countershaft
14-5B MANUAL TRANSMISSION 6) Remove input shaft 5th gear, needle bearing and counter shaft 5th gear. Gear puller would be necessary if spline fitting of counter shaft 5th gear is tight. 9) Remove 5 screws and take off left case plate (1), and then remove bearing set shim (2).
Page 500 MANUAL TRANSMISSION 5B-15 7) Pull out gear shift & select shaft assembly (1). 8) Remove reverse shaft bolt (4) with washer. 9) Remove 11 case bolts from outside and another 4 from clutch housing side. 10) Tapping left case flanges with plastic hammer, remove left case. 11) Remove gear shift yoke (1).
Page 501: Right Case
16-5B MANUAL TRANSMISSION Right Case 1) Remove differential gear assembly from right case. 2) Remove bolt and then pull out speed sensor (1). 3) Remove input shaft oil seal (1) by using special tools (combination of bearing remover and sliding shaft). Special Tools (A): 09930M30102 (B): 09923M74510...
Page 502: Sub Assembly Service
MANUAL TRANSMISSION 5B-17 Sub Assembly Service Right Case 1) Install input shaft oil seal (1) facing its spring side upward. Use special tool and hammer for installation and apply grease to oil seal lip. “B”: SUZUKI SUPER GREASE A, 99000-25010 Special Tool (A): 09951M76010 2) Install countershaft R bearing cup (2) by using special tools...
Page 503: Left Case
18-5B MANUAL TRANSMISSION 6) Insert gear shift arm (1) in gear shift shaft (2), then fasten them with bolt applied with thread lock cement. Tightening Torque (c): 34 N.m (3.4 kg-m, 24.5 lb-ft) “A”: Thread lock 1322, 99000-32110 Left Case 1) If input oil gutter has been removed, install it with bolt applied with thread lock cement.
Page 504 MANUAL TRANSMISSION 5B-19 2) Drive out 5th gear spacer (1), L bearing (2) and 4th gear (3) all at once by using puller (4) and press. Caution : • • • • • To avoid gear tooth from being damaged, support it at flat side of bearing puller.
Page 505 20-5B MANUAL TRANSMISSION 4) Fit high speed synchronizer sleeve (1) to hub (2), insert 3 keys (3) in it and then set springs (4) as illustrated left. Note: • • • • • No specific direction is assigned to high speed synchronizer sleeve or each key but it is assigned as assembly.
Page 506: Countershaft Assembly
MANUAL TRANSMISSION 5B-21 9) Press-fit L bearing (1) by using special tool and hammer. Special Tool (C): 09925M98221 10) Using the same special tool, drive in 5th gear spacer. Caution : To prevent 5th gear spacer from being distorted because of excessive compression, do not press-fit it with L bearing at once.
Page 507 22-5B MANUAL TRANSMISSION 5) Apply puller (1) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (3) with gear by using press. 6) Disassemble synchronizer sleeve & hub assembly (3). 7) Take out needle bearing from shaft. 8) Remove R bearing cone (1) by using puller (2), metal stick (3) and press.
Page 508 MANUAL TRANSMISSION 5B-23 5) Install R bearing cone (1) by using special tool and hammer. Special Tool (A): 09923M78210 6) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring (1). Note: • • • • • Key slot width of 1st synchronizer ring is smaller than that of 2nd synchronizer ring (2).
Page 509: Gear Shifter
24-5B MANUAL TRANSMISSION 9) Press-fit 3rd gear (1) and spacer (2) by using special tool and press. Note: It is recommended to press-fit spacer and 3rd gear first, and then 4th gear later separately so that countershaft will not be compressed excessively. Special Tools (A): 09923M78210 (D): 09913M80112...
Page 510 MANUAL TRANSMISSION 5B-25 High Speed and Low Speed Gear Shift Shafts Inspection 1) Using feeler gauge, check clearance between fork and sleeve and replace those parts if it exceeds limit of 1.0 mm (0.039 in.) Note: For correct judgement of parts replacement, carefully inspect contact portion of fork and sleeve.
Page 511: Differential Assembly
26-5B MANUAL TRANSMISSION Differential Assembly Disassembly 1) Using special tool, remove right bearing (1). Special Tools (A): 09913M65810 (B): 09925M88210 2) Drive out speed sensor rotor (2) using puller and press. 3) Remove left bearing using puller while supporting its center shaft as described above.
Page 512 MANUAL TRANSMISSION 5B-27 Right side • Using similar procedure to the above, set dial gauge tip to gear shoulder. • Move gear up and down by hand and read dial gauge. 2) If thrust play is out of specification, select suitable thrust washer from among following available size, install it and check again that specified gear play is obtained.
Page 513: Assembling Unit
28-5B MANUAL TRANSMISSION 7) Hold differential assembly with aluminum plates placed on vise, install final gear and then tighten it with 8 bolts to specified torque. Caution : Use of any other bolts than specified ones is prohibited. Tightening Torque (a): 90 N.m (9.0 kg-m, 65.0 lb-ft) Assembling Unit Differential to Left Case...
Page 514 MANUAL TRANSMISSION 5B-29 5) Install reverse gear shift lever (2). Apply thread lock to bolts. Reverse gear shift arm (5) has to be joined with reverse gear shift lever (2) at the same time. Tightening Torque (a): 23 N.m (2.3 kg-m, 17.0 lb-ft) 6) Make reverse idler gear (1) with reverse gear shift lever (2), insert reverse gear shaft (3) into case (4) through idler gear (1) and then align A in shaft with B in case.
Page 515 30-5B MANUAL TRANSMISSION 11) Check locating spring for deterioration and replace with new one as necessary. Service Locating spring free length Standard Limit 5th & REV 33.8 mm 32.7 mm (Pink painted) (1.331 in.) (1.287 in.) High speed, Low speed 33.6 mm 32.5 mm (Green painted)
Page 516: Fifth Gear
MANUAL TRANSMISSION 5B-31 Fifth Gear 1) To seat countershaft L bearing cup (2) to bearing cone, tap cup by using special tool and plastic hammer. Special Tool (A): 09913M84510 2) Put a shim on bearing cup provisionally, place straight edge over it and compress it by hand through straight edge, and then measure “a”...
Page 517 32-5B MANUAL TRANSMISSION 5) Assemble 5th speed synchronizer sleeve (1) and hub (2) with keys (3) and springs (4). Note: Short side C in keys, long boss D in hub and chamfered spline F in sleeve should face inward (5th gear side). A = B C : Short side (Inward) D : Long boss (Inward)
Page 518 MANUAL TRANSMISSION 5B-33 10) Caulk nut at C with caulking tool and hammer. 11) Install synchronizer ring (1). 12) Fit 5th gear shift fork (2) to sleeve & hub assembly (3) and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.
Page 519: Gear Shift & Select Shaft Assembly
34-5B MANUAL TRANSMISSION Gear Shift & Select Shaft Assembly 1) If gear shift guide case (1) has been disassembled or replaced, tighten bolt as specified below. Also check breather (2) hole for clog. Tightening Torque (a): 23 N.m (2.3 kg-m, 17.0 lb-ft) 2) Clean mating surface of guide case and coat it with sealant evenly.
Page 520: Required Service Materials
MANUAL TRANSMISSION 5B-35 11) Check input shaft for rotation in each gear position. 12) Also confirm function of back up light switch in reverse position by using ohmmeter. Required Service Materials Materials Recommended Suzuki Products • Lithium grease SUZUKI SUPER GREASE A Oil seal lips •...
Page 521: Special Tools
36-5B MANUAL TRANSMISSION Special Tools...
Page 522 MANUAL TRANSMISSION 5B-37...
Page 524: 5C-2 Clutch
5C-2 CLUTCH General Description The clutch is a diaphragm-spring clutch of a dry single against the flywheel (with the disc in between), when disc type. The diaphragm spring is of a tapering-finger the clutch release bearing is held back. This is the type, which is a solid ring in the outer diameter part,with engaged condition of the clutch.
Page 525: Diagnosis
CLUTCH 5C-3 Diagnosis Condition Possible Cause Correction • Slipping Improper clutch pedal free travel Adjust free travel. • Worn or oily clutch disc facing Replace disc. • Warped disc, pressure plate or flywheel surface Replace disc, clutch cover or flywheel. •...
Page 526: Clutch
5C-4 CLUTCH On-Vehicle Service Maintenance Service Clutch Pedal Clutch Pedal Height Measure pedal height difference “a” using measure (3) and adjust clutch pedal (1) height so that it becomes almost same as brake pedal (2) height. Height difference “a”: 0 mm (0 in.) If clutch pedal height is not as specified above, adjust it by turning pedal stopper bolt (4).
Page 527 CLUTCH 5C-5 Clutch Cable Removal 1) Disconnect negative cable at battery. 2) Remove clutch cable joint lock nut (4) and clutch cable joint nut (1). 3) Remove joint pin (2) from clutch release cable (5). 4) Loosen A and disconnect clutch cable from clutch pedal upper side hook.
Page 528: Unit Repair Overhaul
5C-6 CLUTCH Unit Repair Overhaul Clutch Cover, Clutch Disc And Flywheel Dismounting/Remounting Refer to SECTION 1D. Removal 1) Hold flywheel stationary with special tool and remove clutch cover bolts (1), clutch cover (2) and clutch disc. Special Tool (A): 09924M17810 2) Pull out input shaft bearing (1) from flywheel (2) using special tool and wrench.
Page 529 CLUTCH 5C-7 Inspection Input Shaft Bearing Check input shaft bearing (1) for smooth rotation and replace it if abnormality is found. Clutch Disc Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 530 5C-8 CLUTCH Installation Note: Before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly. 1) Install flywheel (1) to crankshaft and tighten bolts (2) to specification. Special Tool (A): 09924M17810 Tightening Torque (a): 42 N.m (4.2 kg-m, 30.5 lb-ft) 2) Using special tool, install a new input shaft bearing to flywheel (1).
Page 531: Clutch Release System
CLUTCH 5C-9 Clutch Release System Removal 1) Remove release arm by removing its bolt. 2) Take out release bearing by turning release shaft. 3) Unhook return spring (1) using pliers. 4) Drive out No.2 bush using special tool and hammer. Release shaft seal will also be pushed out.
Page 532 5C-10 CLUTCH Inspection Clutch release bearing Check clutch release bearing (1) for smooth rotation. If abnormality is found, replace it. CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage. Clutch release shaft Check clutch release shaft (1) and its pin for deflection or damage. If abnormality is found, replace it.
Page 533 CLUTCH 5C-11 5) Caulk seal (1) at A using caulking tool and hammer. 6) Hook return spring (1). 7) Apply grease to release bearing (2) inside and release shaft arm (3), then set bearing. “A”: Grease 99000M25010 8) Apply small amount of grease to input shaft spline (4) and front end as well.
Page 534: Required Service Materials
5C-12 CLUTCH Required Service Materials Materials Recommended Suzuki Product • SUZUKI SUPER GREASE A Clutch cable hook and joint pin • (99000-25010)` Release shaft bushes and seal seal. • Release shaft arm. Lithium grease SUZUKI SUPER GREASE I (99000-25210) Input shaft spline front end. Special Tools...
Page 535: Pr Ecautions
TABLE OF CONTENTS 6-i Section 6 Steering Wheel and Column CONTENTS Steering General Diagnosis ....... 6- 1 DTC C1115 Torque sensor sub sensor Diagnosis ............6- 1 circuit failure ..........6C- 8 Diagnosis Table ..........6- 1 DTC C1114 Torque sensor 5V power supply circuit failure ........
Page 536 ii-6 TABLE OF CONTENTS...
Page 537: Steering General Diagnosis
STEERING GENERAL DIAGNOSIS 6-1 Steering General Diagnosis 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 538 6-2 STEERING GENERAL DIAGNOSIS Condition Possible Cause Correction • Erratic Steering Worn wheel bearings. Replace. • When Braking Broken or sagging springs. Replace coil spring. • Wheel tires are inflated unequally. Inflate tires to proper pressure. • Disturbed front end alignment. Check and adjust front end alignment.
Page 539: Steering Wheel And Column
STEERING WHEEL AND COLUMN 6B-1 Steering Wheel And Column Caution: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 540: General Description
2-6B STEERING WHEEL AND COLUMN General Description This double tube type steering column has the following three important features in addition to the steering function: • The column is energy absorbing, designed to compress in a front-end collision. • The ignition switch and lock are mounted conveniently on this column. •...
Page 541: Diagnosis
STEERING WHEEL AND COLUMN 6B-3 Diagnosis For maintenance service of the steering wheel and column, refer to SECTION 0B. For diagnosis of the steering wheel and column, refer to SECTION 6. For diagnosis of the air bag system, refer to SECTION 8B. Inspection And Repair Required After Accident After an accident be sure to perform checks, inspections and repairs referring to CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE in this section.
Page 542 4-6B STEERING WHEEL AND COLUMN SERVICE PRECAUTIONS For service precautions, refer to “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in SECTION 8B. SERVICE AND DIAGNOSIS For diagnosis and servicing, refer to “SERVICE AND DIAGNOSIS” under “SERVICE PRECAUTIONS” in SECTION DISABLING AIR BAG SYSTEM For disabling air bag system, refer to “DISABLING AIR BAG SYSTEM”...
Page 543 STEERING WHEEL AND COLUMN 6B-5 Inspection Warning: Never disassemble driver air bag (inflator) module or measure its resistance. Otherwise, personal injury may result. Caution: If air bag (inflator) module was dropped from a height of 90 cm (3 ft) or more, it should be replaced. Check air bag (inflator) module visually and if any of the following is found, replace it with a new one.
Page 544 6-6B STEERING WHEEL AND COLUMN Steering Wheel Removal 1) Disconnect negative cable at battery. Caution: Removal of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the combination switch) more than allowable number of turns (about two and a quarter turns from the center position clockwise or counterclockwise respectively), or coil will break.
Page 545: Centering Contact Coil
STEERING WHEEL AND COLUMN 6B-7 2) When install steering wheel, place match mark at the same position of new steering wheel as that of removed steering wheel. 3) Apply grease to contact plate (1) of steering wheel. “A”: Grease 99000-25290 4) Install steering wheel (1) onto shaft (2), aligning them by match marks (3).
Page 546 8-6B STEERING WHEEL AND COLUMN Contact Coil and Combination Switch Assembly Removal 1) Remove steering wheel from steering column referring to STEERING WHEEL in this section. 2) Remove dash side panel (1) (right side). 3) Remove steering column hole cover (1). 4) Remove steering column cover screws (1).
Page 547: Installation
STEERING WHEEL AND COLUMN 6B-9 7) Disconnect horn connector (1) from instrument panel harness. 8) Remove contact coil and combination switch assembly from steering column. Inspection Check contact coil harness (1) 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 straightahead position and then ignition switch is at “LOCK”...
Page 548: Steering Column Assembly And Steering
10-6B STEERING WHEEL AND COLUMN 5) Install steering column hole cover (1). 6) Install dash side panel (1) (right side). 7) Install steering wheel to steering column referring to STEERING WHEEL in this section. Steering Column Assembly And Steering Lower Shaft Note: When servicing steering column or any column- mounted component, remove steering wheel.
Page 549 STEERING WHEEL AND COLUMN 6B-11 4) Remove dash side panel (1) (right side). 5) Remove steering column hole cover (1). 6) Remove steering column cover screws (1). 7) Separate upper column cover (2) and lower column cover (3), then remove them. 8) Remove steering wheel contact coil and combination switch assembly (1) referring to STEERING WHEEL, CONTACT COIL and COMBINATION SWITCH ASSEMBLY in this section, if it...
Page 550: Installation
12-6B STEERING WHEEL AND COLUMN 10) Remove steering joint cover (1). 11) Remove joint bolt (steering column side) (2) and joint bolt (pinion shaft side) (3). 12) Make alignment mark (4) on joint of steering lower shaft to pinion shaft for a guide during reinstallation. 13) Remove steering column upper and lower nuts (1).
Page 551 STEERING WHEEL AND COLUMN 6B-13 2) Insert lower shaft (1) into pinion shaft (2) with matching marks (3). 3) Align flat part (4) of steering lower shaft (1) with bolt hole of joint (5) of steering column as shown, and then insert steering column assembly into steering lower shaft.
Page 552 14-6B STEERING WHEEL AND COLUMN 9) Tighten steering column upper and lower nuts (1, 2 and 3) to specified torque in the order (1) – (2) – (3) indicated in figure. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) 10) Tighten joint bolt (pinion shaft side) (4) and joint bolt (steering column side) (5) to specified torque in the order (4) –...
Page 553: Steering Lock Assembly (Ignition Switch)
STEERING WHEEL AND COLUMN 6B-15 Steering Lock Assembly (Ignition Switch) Removal 1) Remove steering column assembly (1) referring to REMOVAL of STEERING COLUMN ASSEMBLY AND STEERING LOWER SHAFT in this section. 2) Using center punch (1), loosen and remove steering lock mounting bolts (2).
Page 554: Checking Steering Column Assembly And Lower Shaft For Accident Damage
16-6B STEERING WHEEL AND COLUMN Checking Steering Column Assembly And Lower Shaft For Accident Damage Note: Vehicles involved in accidents resulting in body damage, where steering column has been impacted may have a damaged or misaligned steering column. Checking Procedure 1) Check each capsule (1) is attached to steering column bracket (2) securely.
Page 555: Required Service Material
STEERING WHEEL AND COLUMN 6B-17 Required Service Material Material Recommended Suzuki Product Grease SUZUKI GREASE CE=T Contact plate. (99000-25290) Special Tool...
Page 557: Electrical Power Steering System
ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-1 Electrical Power Steering (EPS) System General Description Components This electrical power steering (EPS) system consists of a P/S control module, a torque sensor, a motor assembly (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 558 6C-2 ELECTRICAL POWER STERRING (EPS) SYSTEM...
Page 559: Diagnosis
ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-3 Diagnosis The EPS system in this vehicle is controlled by P/S control module. P/S control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “ON-BOARD DIAGNOSTIC SYSTEM”...
Page 560: System Check Flow Table
6C-4 ELECTRICAL POWER STERRING (EPS) SYSTEM System Check Flow Table Step Action 1) Record details of the problem (failure, complaint) and Go to Step 2. Go to Step 3. 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 561 ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-5 Customer Questionnaire (Example) Customer’s Name: Model: VIN: Date of issue: Date of Reg: Date of Problem: Mileage: • Steering wheel feels heavy • Vehicle pulls to one side during straight driving • Poor recovery from turns •...
Page 562: Dtc Check
6C-6 ELECTRICAL POWER STERRING (EPS) SYSTEM DTC Check 1) Remove glove box. 2) Apply chocks to wheels, set shift lever to neutral position and pull parking brake fully. 3) Start engine. 4) Connect positive probe of analog type voltmeter (1) to diagnosis output terminal (2) and negative probe to ground terminal (3) of monitor coupler (4).
Page 563: Dtc Table
ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-7 DTC Table Caution: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table of each DTC. Example: When VSS circuit fail (DTC C21) is set High Voltage between diag- nosis switch ter- minal and ground terminal...
Page 564 6C-8 ELECTRICAL POWER STERRING (EPS) SYSTEM DTC C1111 Torque Sensor Main Sensor Circuit Failure DTC C1113 Torque Sensor Main And Sub Sensor Circuit Failure DTC C1115 Torque Sensor Sub Sensor Circuit Failure 1.To main fuse 5.P/S control module 2.Ignition switch 6.Torque sensor 3.“P/S”...
Page 565 ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-9 DTC C1114 Torque Sensor 5v Power Supply Circuit Failure 1.To main fuse 5.P/S control module 2.Ignition switch 6.Torque sensor 3.ªP/Sº fuse (30A) in fuse box 7.Connector ªE10º 4.ªIG COIL METERº fuse (15A) in fuse box 8.Connector ªX02º...
Page 566 6C-10 ELECTRICAL POWER STERRING (EPS) SYSTEM DTC C1121/C1123/C1124 Vss Circuit Failure Step Action Was “SYSTEM CHECK FLOW TABLE” performed? Go to Step 2. Go to “SYSTEM CHECK FLOW TABLE” in this section. 1) Ignition switch to OFF position Check intermit- Repair VSS or its 2) Remove steerin column hole cover.
Page 567 ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-11 DTC C1122 Engine Speed Signal Circuit Failure Step Action Was “SYSTEM CHECK FLOW TABLE” performed? Go to Step 2. Go to “SYSTEM CHECK FLOW TABLE” in this section. 1) Check proper connection to P/S control module Substitute a known- Repair poor connector and ECM at each “Br”...
Page 568 6C-12 ELECTRICAL POWER STERRING (EPS) SYSTEM DTC C1141/C1142/ C1143/C1144/C1145 Motor Circuit Failure Step Action Was “SYSTEM CHECK FLOW TABLE” performed? Go to Step 2. Go to “SYSTEM CHECK FLOW TABLE” in this section. 1) Remove steering column hole cover. Go to Step 3. Repair poor connec- 2) Check proper connection for 4-pin (“X01”) connector tion, high resistance,...
Page 569 ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-13 DTC C1151 Clutch Circuit Failure Step Action Was “SYSTEM CHECK FLOW TABLE” performed? Go to Step 2. Go to SYSTEM CHECK FLOW TABLE” in this section. 1) Remove steering column hole cover. Go to Step 3 Repair pooonnec- 2) Check proper connection for 4-pin (“X01”) tion,high resistance,...
Page 570 6C-14 ELECTRICAL POWER STERRING (EPS) SYSTEM DTC C1153 P/S Control Module Power Supply Circuit Failure Step Action Was “SYSTEM CHECK FLOW TABLE” performed? Go to Step 2. Go to “SYSTEM CHECK FLOW TABLE” in this section. 1) Remove steering column hole cover. Check intermittent Repair poor connec- 2) Check “P/S”...
Page 571 ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-15 Inspection of P/S Control Module Circuit 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 Voltage Check...
Page 572 6C-16 ELECTRICAL POWER STERRING (EPS) SYSTEM Terminal Circuit Normal Voltage Condition Number E10-1 P/S control module p$wer 10 – 14V – supply from battery E10-2 Ground – – E10-3 – – – E10-4 – – – E10-5 Diagnosis switch terminal Voltage deflection Engine idling 0 –14V...
Page 573: Trouble Diagnosis
ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-17 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 diagnostic system (self-diagnostic function). When DTC No. C1112/12 is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in “DIAGNOSIS CHART”...
Page 574: Steering Wheel Play Inspection
6C-18 ELECTRICAL POWER STERRING (EPS) SYSTEM Steering Wheel Play Inspection 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 play, holding vehicle in straight forward condition on the ground and with engine stopped.
Page 575: On-Vehicle Service
ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-19 On-Vehicle Service Steering Column Assembly Refer to Section 6 for removal and installation of steering column assembly but disconnect all couplers from P/S control module. Caution: Never disassemble steering column assembly, remove torque sensor or motor assembly (with clutch incorporated).
Page 576: Torque Sensor
6C-20 ELECTRICAL POWER STERRING (EPS) SYSTEM Torque Sensor On-Vehicle Inspection 1) Remove steering column hole cover. 2) Turn ignition switch to ON position. 3) Check voltage between terminals of torque sensor connector with connecting it to P/S control module and not running engine. If check result is not satisfactory, replace steering column assembly.
Page 577 ELECTRICAL POWER STERRING (EPS) SYSTEM 6C-21 5) Connect battery (1) between “X01-1” and “X01-2”. Check that motor rotates smoothly, then measure current between “X01- 1” and “X01-2” using ammeter (2) as shown in left figure. Standard current (reference value) : About 0.65 A If check result is not satisfactory, replace steering column assembly.
Page 579: Manual Rack And Pinion
MANUAL RACK AND PINION 6D-1 Manual Rack And Pinion Note: • All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 580: Steering Wheel Check
6D-2 MANUAL RACK AND PINION 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 – 1.18 in) If steering wheel play is not within specification, inspect as follows and replace if found defective.
Page 581: Tie Rod End Boot Check
MANUAL RACK AND PINION 6D-3 Tie Rod End Boot Check Inspect each boot for tear. If even a small tear or grease leakage 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 582 6D-4 MANUAL RACK AND PINION 1.Steering lower shaft 10.Rack damper screw: 21.Steering rack: 2.Steering lower shaft lower bolt Apply SUZUKI BOND No. 1207C Apply SUZUKI SUPER GREASE E 3.Steering gear case oil seal: 99000-31150 to thread of damper 99000-25050 to entire surface of rack. Apply SUZUKI SUPER GREASE E screw.
Page 583: Manual Rack And Pinion Assembly
MANUAL RACK AND PINION 6D-5 Manual Rack And Pinion Assembly Removal 1) Remove steering joint cover (1). 2) Make alignment marks (1) on joint of steering lower shaft to pinion shaft for a guide during reinstallation, and remove steering lower shaft lower bolt (2). 3) Loosen steering lower shaft upper bolt (3), but don’t remove.
Page 584: Disassembly
6D-6 MANUAL RACK AND PINION 8) Remove exhaust pipe (1). 9) Support engine with transmission jack (1) as shown. 10) Remove engine rear stopper bracket bolts (2). 11) Lower engine, and then remove manual rack and pinion assembly. Disassembly 1) For ease of adjustment after installation, make marking (1) on tie rod end lock nut position of tie rod thread.
Page 585 MANUAL RACK AND PINION 6D-7 5) Unbend bent part of tie rod lock washer (1) and remove tie rod (2) from steering rack (3). 6) Remove steering rack cap (4). 7) Remove rack damper screw lock nut (1), rack damper screw (2), rack plunger spring (3) and rack plunger (4).
Page 586 6D-8 MANUAL RACK AND PINION 10) Remove steering rack (1) from gear case (2) as shown. Caution: • Inside of steering rack bushing is coated with special coating. As it is damageable, be very careful not to cause damage to it when removing rack from steering gear case.
Page 587: Inspection
MANUAL RACK AND PINION 6D-9 Inspection Rack Plunger • Inspect rack plunger (1) for wear or damage. • Inspect rack plunger spring (2) for deterioration. If found defective, replace. Steering Pinion • Inspect teeth surface of steering pinion (1) for wear or damage. •...
Page 588: Reassembly
6D-10 MANUAL RACK AND PINION Reassembly Install in reverse order of disassembly, noting the following points. • Install pinion bearing oil seal to pinion bearing plug (1) using special tool. Special Tool (A): 09925M98210 • Apply grease to oil seal lip. Grease: 99000-25050 •...
Page 589 MANUAL RACK AND PINION 6D-11 • Apply grease to all around pinion teeth (1), pinion bearing (2) and gear case oil seal lip (3) as shown. “A”: Grease 99000-25050 • Fill inside (4) of pinion bearing plug (5) with grease. “A”: Grease 99000-25050 •...
Page 590 6D-12 MANUAL RACK AND PINION • Install new tie rod lock washer (1) as shown, and then install tie rod (2) to steering rack (3). Align straight part “A” of washer with flat part “B” of steering rack. • Tighten tie rod to specified torque. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) •...
Page 591 MANUAL RACK AND PINION 6D-13 Installation For installation, reverse removal procedure, note the following instructions. • Tighten rack and pinion assembly mounting bolts (1) to specified torque. Tightening Torque (a): 25 N·m (2.5 kg-m, 18.0 lb-ft) • Hoist engine with transmission jack (1), and then tighten engine rear stopper bracket bolts (2) to specified torque.
Page 592 6D-14 MANUAL RACK AND PINION • Tighten tie rod end lock nut (1) to specified torque. Tightening Torque (a): 45 N·m (4.5 kg-m, 32.5 lb-ft) • Insert steering lower shaft (1) to steering pinion shaft (2) with matching mark (3). •...
Page 593 MANUAL RACK AND PINION 6D-15 Required Service Materials Materials Recommended Suzuki Product • Sliding part of rack against steering housing (All around rack plunger, rack bushing and rack) • Lithium Grease Suzuki Super Greasee Sliding part against steering pinion (Should be applicable (99000-25050) (Oil seal lip, needle bearing) •...
Page 595: Hvac
TABLE OF CONTENTS 7A-i Section 7 HVAC CONTENTS A/C System Symptom Diagnosis ....7B-6 Precautions ..........Abnormal Noise Symptom Diagnosis Precautions ............7-1 of A/C System ..........7B-8 Precautions on HVAC ........7-1 A/C System Performance Inspection ... 7B-9 A/C System Inspection at ECM ....7B-15 Heater and Ventilation ........
Page 597: Precautions
HEATER AND VENTILATION 7A-1 Precautions Precautions Precautions on HVAC Air Bag Warning Refer to “Air Bag Warning: in Section 00”. A/C System Caution Refer to “A/C System Caution: Manual Type in Section 7B” . Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System: Manual Type in Section 7B”.
Page 598: Heater And Ventilation
HEATER AND VENTILATION 7A-1 Heater and Ventilation General Description Heater and Ventilation Construction Note The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 1. HVAC unit 6. Foot air 11. Center ventilation air 2.
Page 599: 7A-2 Heater And Ventilation
7A-2 HEATER AND VENTILATION Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground.
Page 600: Repair Instructions
HEATER AND VENTILATION 7A-3 Condition Possible cause Correction / Reference Item Incorrect Temperature control cable broken or Check temperature control cable. temperature output bent. Temperature control lever faulty. Check temperature control lever. Incorrect installation of temperature Check position and adjust it as necessary. control cable.
Page 601: Blower Motor Removal And Installation
7A-4 HEATER AND VENTILATION Installation Reverse removal procedure noting the following instructions. • Be careful not to catch any cable and wiring harness in inappropriate position. • Adjust control cables of HVAC control unit referring to “HVAC Control Unit Removal and Installation: ”. •...
Page 602: Blower Motor Resistor Removal And Installation
HEATER AND VENTILATION 7A-5 Blower Motor Resistor Removal and Installation Removal 1) Disconnect negative (–) cable from battery. 2) Disable air bag system referring to “Disabling Air Bag System: in Section 8B”. 3) Remove glove box from instrument panel. 4) Remove connector (1) from blower motor resistor (2), and then remove blower motor resistor from HVAC unit by removing screws (3).
Page 603: Hvac Control Unit Components
7A-6 HEATER AND VENTILATION HVAC Control Unit Components 1. Heater control body assembly 4. Bulb 7. Air intake selector 2. Air flow selector 5. Temperature control cable 8. Temperature selector 3. Blower speed selector 6. Air flow control cable 9. A/C switch (if equipped) HVAC Control Unit Removal and Installation Removal 1) Disconnect negative (–) cable at battery.
Page 604 HEATER AND VENTILATION 7A-7 Installation Reverse removal procedure noting the following instructions. • Connect temperature control cable, air intake cable and air flow control cable of HVAC control unit to links of HVAC unit. a. Set air flow selector (1) to “VENT” position and temperature selector (2) to “MAX COOL”...
Page 605: Blower Speed Selector Inspection
7A-8 HEATER AND VENTILATION Blower Speed Selector Inspection Check blower speed selector for each terminal to terminal continuity. If check result does not meet the following conditions, replace HVAC control unit.
Page 606: Center Ventilation Louver Removal And Installation
HEATER AND VENTILATION 7A-9 Center Ventilation Louver Removal and Installation Removal 1) Disconnect negative (–) cable from battery. 2) Disable air bag system referring to “Disabling Air Bag System: in Section 8B”. 3) Remove center ventilation louver (1) with garnish (2) from instrument panel, and then disconnect connector from hazard switch.
Page 607 7A-10 HEATER AND VENTILATION Passenger side ventilation louver Removal 1) Disconnect negative (–) cable from battery. 2) Disable air bag system referring to “Disabling Air Bag System: in Section 8B”. 3) Remove glove box from instrument panel. 4) Separate passenger side ventilation louver (1). Installation Reverse removal procedure.
Page 609: Air Conditioning System
AIR CONDITIONING SYSTEM 7B-1 Air Conditioning System Manual Type Precautions A/C System Caution Caution The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/ C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12). Be sure to check which refrigerant is used before any service work including inspection and maintenance.
Page 610 7B-2 AIR CONDITIONING SYSTEM General Descriptions Refrigerant Line 1. Suction hose 4. Expansion valve :Apply compressor oil (refrigenrant oil) to O-ring. :Apply compressor oil (refrigenrant oil) to O-ring. 2. Discharge hose 5. A/C refrigerant pressure switch :Apply compressor oil (refrigenrant oil) to O-ring. :Apply compressor oil (refrigenrant oil) to O-ring.
Page 611: Sub-Cool A/C System Description
AIR CONDITIONING SYSTEM 7B-3 Sub-Cool A/C System Description In the sub-cool A/C system (condenser integrated with receiver / dryer), the inside of the condenser is divided into the condensation part and the sub-cooler part, and the receiver / dryer is located between those. In the receiver / dryer, the refrigerant is separated into the vapor refrigerant and the liquid refrigerant.
Page 612: Schematic And Routing Diagram
7B-4 AIR CONDITIONING SYSTEM Schematic and Routing Diagram Major Components of A/C System Air flow diagram Major components of A/C system 1. HVAC unit 5. Discharge hose 9. Side ventilation air 13. Side defroster air 2. Compressor 6. Suction hose 10.
Page 613: A/C System Wiring Diagram
AIR CONDITIONING SYSTEM 7B-5 A/C System Wiring Diagram...
Page 614: Diagnostic Information And Procedures
7B-6 AIR CONDITIONING SYSTEM Diagnostic Information and Procedures A/C System Symptom Diagnosis Condition Possible cause Correction / Reference Item No cool air co mes No refrigerant Perform recovery, evacuation and charge out (A/C system referring to “Operation Procedure for does not operate) Refrigerant Charge: Manual Type”.
Page 615 AIR CONDITIONING SYSTEM 7B-7 Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C system normal Condenser clogged Check condenser referring to “Condenser operation) Assembly On-Vehicle Inspection: Manual Type”.
Page 616: Abnormal Noise Symptom Diagnosis Of A/C System
7B-8 AIR CONDITIONING SYSTEM Condition Possible cause Correction / Reference Item Check A/C evaporator and evaporator Insufficient air flow of A/C evaporator clogged or frosted cooled air temperature sensor referring to “Evaporator Inspection: Manual Type” and “Evaporator Temperature Sensor Inspection: Manual Type”. Air leaking from HVAC unit or air duct Repair as necessary.
Page 617: A/C System Performance Inspection
AIR CONDITIONING SYSTEM 7B-9 Abnormal Noise from Tension Pulley Condition Possible cause Correction / Reference Item Clattering noise is heard Worn or damaged bearing Replace tension pulley. from pulley Pulley cranks upon Cracked or loose bracket Replace or retighten bracket. contact Abnormal Noise from A/C Evaporator Condition...
Page 618 7B-10 AIR CONDITIONING SYSTEM 5) Warm up engine to the normal operating temperature and keep it at the specified idle speed. 6) Turn A/C switch ON, set blower speed selector at maximum speed position, temperature selector at maximum cold position, air flow selector at face position, and air intake selector at recirculation position.
Page 619 AIR CONDITIONING SYSTEM 7B-11 3500 3500 1000 1000 3000 3000 2500 2500 2000 2000 1500 1500 1000 1000 Low side and high side pressure example, Gauges should read as follows when ambient temperature is 30 C (86 Pressure on high pressure gauge (HI) 1780 –...
Page 620 7B-12 AIR CONDITIONING SYSTEM High pressure gauge Condition Possible cause Correction Pressure is higher than Refrigerant overcharged Recharge. acceptable range Expansion valve frozen or clogged Check expansion valve. (“A” area) Clogged refrigerant passage of high pressure side Clean or replace. Radiator cooling fan malfunction Check radiator cooling fan.
Page 621 AIR CONDITIONING SYSTEM 7B-13 Temperature near Air inlet of HVAC unit in C Thermometer at center duct Condition Possible cause Correction Crossing point is higher Insufficient or excessive charge of refrigerant Check refrigerant pressure. than acceptable range Dirty or bent A/C evaporator fins Clean or repair.
Page 622 7B-14 AIR CONDITIONING SYSTEM Condition Possible cause Correction Manifold gauge MPa (kg/cm2) (psi) Detail 0.23 – 0.36 1.24 – 1.52 Normal condition (2.3 – 3.6) (1.24 – 15.2) — — (33 – 51) (176 – 216) The low pressure side Dust particles or water Clean expansion valve.
Page 623: A/C System Inspection At Ecm
AIR CONDITIONING SYSTEM 7B-15 A/C System Inspection at ECM Voltage Check ECM and its circuits can be checked by measuring voltage with special tool connected. Caution: • Each terminal of the ECM connectors is sealed up with the grommet. Therefore, do not measure circuit voltage and resistance by inserting the tester’s probe into the sealed terminal at the harness side.
Page 624 7B-16 AIR CONDITIONING SYSTEM Terminal Wire Circuit Measurement Normal value Condition ground C50-15 Br/W Main relay drive Ground to 0.5 – 1.2 volt Ignition switch ON with engine engine stopped 0 volt Iginition switch OFF Blower fan motor switch and A/C Radiator (Condens 0-1 volt switch ON or engine coolant temp...
Page 625: Repair Instructions
AIR CONDITIONING SYSTEM 7B-17 Repair Instructions Operation Procedure for Refrigerant Charge Warning • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately - 6 °C (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may cause a serious injury.
Page 626 7B-18 AIR CONDITIONING SYSTEM Recovery When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environment. Note • After recovering refrigerant from system, the amount of removed compressor oil must be measured for replenishing compressor oil.
Page 627 AIR CONDITIONING SYSTEM 7B-19 Compressor oil is sealed in each new compressor by the amount required for A/C system. Therefore, when using a new compressor, drain the calculated amount of oil from it. “C” = “A” - ”B” — “C”: Amount of oil to be drained from new compressor. “A”: Amount of oil in a new compressor “B”: Amount of oil from old compressor Note:...
Page 628 7B-20 AIR CONDITIONING SYSTEM Note • If the system does not show a vacuum below - 100 kPa (- 1.0kg/cm , - 760 mm Hg, - 14.7 psi), close both valves, stop vacuum pump and watch movement of low pressure gauge.
Page 629 AIR CONDITIONING SYSTEM 7B-21 Caution: • The refrigerant container should not be heated up to 40 C (104 F) or over. • Refrigerant container should not be reversed in direction during refrigerant charge. Reversing in direction causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid refrigerant and the like.
Page 630 7B-22 AIR CONDITIONING SYSTEM c) Purge any air existing in center charging hose. When using refrigerant container tap valve, use the following procedure to purge air. Once fully tighten refrigerant container tap valve (1), and then loosen (open) plate nut (2) slightly. ii) Open low pressure side valve (3) of manifold gauge set (4) a little.
Page 631 AIR CONDITIONING SYSTEM 7B-23 Check A/C System for Refrigerant Leaks Whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in malfunction of lines and connections, it is advisable to check for leaks.
Page 632 7B-24 AIR CONDITIONING SYSTEM Condenser Assembly Removal and Installation Caution: Do not damage condenser fins. If condenser fin is bent, straighten it by using flat head screwdriver or pair of pliers. Removal 1) Disconnect negative (-ve) cable from battery. 2) Recover refrigerant from A/C system referring to “Operation Procedure for Refrigerant Charge: Manual Type”.
Page 633: Installation
AIR CONDITIONING SYSTEM 7B-25 Installation Reverse the removal procedure to install condenser noting the following instructions. • Replenish specified amount of compressor oil to compressor suction side referring to “Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge: Manual Type”. •...
Page 634 7B-26 AIR CONDITIONING SYSTEM 13. Heater core Fresh air inlet duct 14. Temperature control lever Blower upper case 15. Air flow control lever Air intake control actuator 16. Evaporator Blank 17. Blank Heater unit upper case 18. Expansion valve Foot duct 19.
Page 635: Evaporator Inspection
AIR CONDITIONING SYSTEM 7B-27 HVAC Unit Removal and Installation Removal 1) Disconnect negative (–) cable from battery. 2) Disable air bag system (if equipped) referring to “Disabling Air Bag System: in Section 8B”. 3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery”...
Page 636 7B-28 AIR CONDITIONING SYSTEM Removal 1) Disconnect negative (–) cable from battery. 2) Remove HVAC unit from vehicle body referring to “HVAC Unit Removal and In stallation: Manual Type”. 3) Remove evaporator temperature sensor (1) from evaporator by disassembling HVAC unit. Installation Reverse the removal procedure noting the following instruction.
Page 637 AIR CONDITIONING SYSTEM 7B-29 Expansion Valve Removal and Installation Removal 1) Recover refrigerant from the A/C system with recovery and recycling equipment referring to “Recovery” in “Operation Procedure for Refrigerant Charge: Manual Type”. 2) Loosen a bolt (1) and remove pipes from expansion valve (2). 3) Loosen bolts (3) and remove expansion valve.
Page 638: A/C Switch Inspection
7B-30 AIR CONDITIONING SYSTEM A/C Switch Inspection • Check that there is continuity between terminal (1) and terminal (2) when A/C switch is at ON position. • Check that there is no continuity between terminal (1) and terminal (2) when A/C switch is at OFF position. If check result does not meet the above conditions, replace HVAC control unit.
Page 639: Compressor Relay Inspection
AIR CONDITIONING SYSTEM 7B-31 Compressor Relay Inspection "a" "c" 1) Disconnect negative (–) cable from battery. 2) Remove compressor relay (1) from main fuse box. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay. "b"...
Page 640: Compressor Assembly Removal And Installation
7B-32 AIR CONDITIONING SYSTEM Compressor Assembly Removal and Installation Removal 1) Run engine at idle speed with A/C ON for 10 minutes. 2) Stop the engine. 3) Disconnect negative (-) cable from battery. 4) Recover refrigerant from the A/C system with recovery and recycling equipment referring to “Recovery”...
Page 641: Compressor Assembly Components
AIR CONDITIONING SYSTEM 7B-33 Compressor Assembly Components Magnet Clutch Inspection • Check armature plate and magnet clutch pulley for wear and oil soak respectively. • Check magnet clutch pulley bearing for noise, wear and grease leakage. • Measure magnet clutch coil for resistance at 20 C (68 F).
Page 642 7B-34 AIR CONDITIONING SYSTEM 3) Remove armature plate (1). 4) Remove shims from shaft. 5) Remove circlip (1) using special tool. Special tool (B): 09900M06107 6) Remove magnet clutch pulley (2). Note If it is difficult to remove magnetic clutch pulley by hand, use puller (1).
Page 643 AIR CONDITIONING SYSTEM 7B-35 Installation 1) Install magnet clutch coil (2) fitting protrusion (4) of magnet clutch coil onto hole (5) of compressor (3). 2) Install circlip (1) directing chamfer side (6) downward. Special tool (B): 09900M06107 3) Apply silicon grease to contact face of thermal switch. 4) Connect magnetic clutch lead wire clamp.
Page 644 7B-36 AIR CONDITIONING SYSTEM c) Connect battery positive terminal (+) to magnet clutch coil lead wire. d) Connect battery negative terminal (–) to compressor body assembly. (At this point, armature plate and magnet clutch pulley are kept in contact.) e) Disconnect battery negative terminal (–) to compressor body assembly.
Page 645 AIR CONDITIONING SYSTEM 7B-37 Thermal Switch Removal and Installation Removal 1) Disconnect negative (–) cable from battery. 2) Disconnect thermal switch connectors. 3) Remove thermal switch (1) from compressor assembly (2). Installation Reverse removal procedure noting the following. • Tighten thermal switch to the specified torque. Tightening torque Thermal switch (a): 12 N·m (1.2 kgf-m, 9.0 lb-ft) •...
Page 646 7B-38 AIR CONDITIONING SYSTEM Relief Valve Removal and Installation Removal 1) Recover refrigerant from the A/C system with recovery and recycling equipment referring to “Recovery” in “Operation Procedure for Refrigerant Charge: ”. 2) Remove compressor from compressor bracket assebly. 3) Remove relief valve (1) from compressor (2). Installation Reverse removal procedure noting the following instructions.
Page 647 AIR CONDITIONING SYSTEM 7B-39 Specifications Tightening Torque Specifications Fastening part Tightening torque kg-m lb-ft Cap bolt A/C refrigerant pressure sensor Armature plate bolt 11.0 Thermal switch Note The specified tightening torque is also described in the following. “Compressor Assembly Components: Manual Type” Reference: For the tightening torque of fastener not specified in this section, refer to “Fasteners In formation: in Section 0A”.
Page 649: Restraint
TABLE OF CONTENTS 8-i Section 8 Restraint CONTENTS Seat Belts ..........DTC B1021 - Driver Air Bag Initiator 8A-1 Circuit Resistance High ......8B-18 General Description ........8A-1 DTC B1022 - Driver Air Bag Initiator Seat Belt with ELR ........8A-1 Circuit Resistance Low .......
Page 651: Seat Belts
SEAT BELTS 8A-1 Seat Belts Caution: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 652: Front Seat Belt
SEAT BELTS 2-8A Front Seat Belt Warning: Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. Removal Remove front seat belts.
Page 653 SEAT BELTS 8A-3 Inspection Seat belts and attaching parts can affect the vital components and systems of a vehicle. Therefore, they should be inspected carefully and replaced with genuine parts only. • Seat belt Its webbing or strap should be free from damage. •...
Page 654 SEAT BELTS 4-8A Rear Seat Belt Warning: Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. Removal Remove rear seat belts. Inspection Check the rear seat belt in the same way as INSPECTION of FRONT SEAT BELT. Installation Install the rear seat belt observing the same precautions as INSTALLATION of FRONT SEAT BELT.
Page 655: Caution
AIR BAG SYSTEM 8B-1 Warning: Service on or around the air bag system components or wiring must be performed only by an authorized MARUTI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in this section before performing service on or around the air bag system compo-nents or wiring. Failure to follow WARNINGS could result in unintended activation of the system or could render the system inoperative.
Page 656: 8B-2 Air Bag System
8B-2 AIR BAG SYSTEM General description With the air bag system which includes air bags only for driver’s side, the driver air bag (inflator) module is deployed from the center of the steering column in occurrence of a front collision with an impact larger than a certain set value to supplement protection offered by the driver seat belt .
Page 657 AIR BAG SYSTEM 8B-3 System Components and Wiring Location View and Connectors...
Page 658 8B-4 AIR BAG SYSTEM System Wiring Diagram Terminal Arrangement of SDM (Viewed From Harness Side)
Page 659 AIR BAG SYSTEM 8B-5 SDM connector “L06” terminal description Terminal Circuit Terminal Circuit L06-1 Blank Q06-11 Blank L06-2 “Air Bag” warning lamp L06-12 Blank L06-3 Blank L06-13 Blank L06-4 Ignition switch (power source) L06-14 Data link connector (DLC) L06-5 Blank L06-15 Blank L06-6...
Page 660 8B-6 AIR BAG SYSTEM The adapter (1) will also give an idea of whether contact tension is sufficient, helping to find an open or intermittent open due to poor terminal contact. An SDM short bar release tool (2) is included in the connector test adapter kit.
Page 661 AIR BAG SYSTEM 8B-7 Intermittents and Poor Connection Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diagnostic flow table, perform careful check of suspect circuits for: • Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 662 8B-8 AIR BAG SYSTEM Air Bag Diagnostic System Check Warning: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equip- ment other than that specified in this manual.
Page 663 AIR BAG SYSTEM 8B-9 Air Bag Diagnostic System Check Flow Table Step Action 1) Make sure that battery Go to step 2. Proceed to “AIR BAG” WARNING voltage is about 11V or higher. LAMP DOES NOT COME ON in 2) Note “AIR BAG” warning this section.
Page 664 8B-10 AIR BAG SYSTEM DTC Check (Using SUZUKI ScanTool) 1) Turn ignition switch to OFF position. 2) After setting cartridge to SUZUKI scan tool, connect it to data link connector (DLC) located on underside of instrument panel at driver’s seat side. Special tool (1): SUZUKI scan tool 99000M24120-426 3) Turn ignition switch to ON position.
Page 665: Diagnosis
AIR BAG SYSTEM 8B-11 DTC Table Diagnosis Normal B1021 Resistance high B1022 Driver air Resistance low B1024 bag Circuit Short to ground B1025 Short to power circuit B1031 Power source To high Diagnose trouble according to B1032 voltage To Low diagnostic flow table corresponding to each code No B1051...
Page 666 8B-12 AIR BAG SYSTEM "Air Bag” Warning Lamp Circuit Trouble Diagnosis Table Wiring Diagram VIO/WHT Caution: • Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to SPECIAL TOOL in this section.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 667 AIR BAG SYSTEM 8B-13 “Air Bag” Warning Lamp Comes on Steady Without Flashing Table Test Description STEP 1 : Check “AIR BAG” fuse. STEP 2 : Check power source circuit. STEP 3 : Check “AIR BAG” warning lamp circuit. Diagnostic Flow Table Step Action 1) Ignition switch OFF...
Page 668 8B-14 AIR BAG SYSTEM “Air Bag” Warning Lamp Does Not Come On Table Test Description STEP 1 : Check combination meter power feed circuit. STEP 2 : Check electrical connection check mechanism in SDM connector. STEP 3 : Check “AIR BAG” warning lamp circuit. STEP 4 .Check “AIR BAG”...
Page 669 AIR BAG SYSTEM 8B-15 Special tool (A) : 09932M76010 Note: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected.
Page 670 8B-16 AIR BAG SYSTEM SDM Serial Data Circuit Trouble Diagnosis Table Wiring Diagram VIO/WHT VIO/WHT VIO/WHT Caution: • Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flowtable. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to SPECIAL TOOL in this section.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 671 AIR BAG SYSTEM 8B-17 Step Action 1) Check if communication is possible by trying Go to step 3. Repair open in common communication with other control module section of serial data circuit or ABS control module (if equipped)). (“VIO/WHT.” wire circuit) used by all controllers or Is it possible to communicate with other control short to ground or power...
Page 672 8B-18 AIR BAG SYSTEM DTC B1021 - Driver Air Bag Initiator Circuit Resistance High DTC B1022 - Driver Air Bag Initiator Circuit Resistance Low DTC B1024 - Driver Air Bag Initiator Circuit Short To Ground DTC B1025 - Driver Air Bag Initiator Circuit Short To Power Circuit Wiring Diagram L06-4 L06-10...
Page 673 AIR BAG SYSTEM 8B-19 Diagnostic Flow Table DTC B1021 : Driver Air Bag Initiator Circuit Resistance High Step Action 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector “L08” located near the base of the steering column.
Page 674 8B-20 AIR BAG SYSTEM Note: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to DTC CLEARANCE), if any. •...
Page 675 AIR BAG SYSTEM 8B-21 “L06-10” “L06-9” “L01” “L08” Special Tool (A): 09932M76010 (B): 09932M75010 (C): 09932M78340 Note: Upon completion of inspection and repair work ,perform the following items. • Reconnect all air bag system components, ensure all componets are property mounted. •...
Page 676 8B-22 AIR BAG SYSTEM DTC B1024 : Driver Air Bag Initiator Circuit Short to Ground Step Action 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector “L08” located near the base of the steering column.
Page 677 AIR BAG SYSTEM 8B-23 Note: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to DTC CLEARANCE), if any. •...
Page 678 8B-24 AIR BAG SYSTEM “L06-10” “L06-9” “L01” “L08” Special tool (A) : 09932M76010 (B) : 09932M75010 (C) : 09932M78340 Note: Upon completion of inspection and repair work, perform the following items. • Reconnect all air bag system components, ensure all components are properly mounted. •...
Page 679 AIR BAG SYSTEM 8B-25 DTC B1031 - Power Source Voltage High DTC B1032 - Power Source Voltage Low Wiring Diagram “L06” “L02” L06-4 L06-17 Caution: • • • • • Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flowtable.
Page 680 8B-26 AIR BAG SYSTEM Step Action 1) With ignition switch OFF, disconnect SDM Go to step 2. Check Charging System connector “L06”. and repair as necessary. 2) Check proper connection to SDM at “L06-4” (Refer to “DIAGNOSIS” terminal. in Section1J) 3) If OK then ignition switch ON, and then check voltage from “L06-4”...
Page 681 AIR BAG SYSTEM 8B-27 Step Action 1) With ignition switch OFF, disconnect “G48” Repair poor connection, Possibly faulty points are connector. high resistance in “RED” as follows. Check each of 2) Check proper connection at”G48-1"(“RED” or “BLK/YEL” circuit of air them and repair as wire) terminal in”G48"connector.
Page 682: Dtc B1051 - Frontal Crash Detected
8B-28 AIR BAG SYSTEM DTC B1051 - Frontal Crash Detected (System Activation Command outputed) Caution: Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table. DTC Will Set when TheSDM detects a frontal crash of sufficient force to warrant activation of the air bag system. (SDM outputs a deployment command.) Table Test Description STEP 1 :Checkthat DTC B1051 has been set although air bag has not been deployed.
Page 683 AIR BAG SYSTEM 8B-29 DTC B1061-”Air Bag” Warning Lamp Circuit Failure Wiring Diagram L06-2 L06-4 L06-17 Caution: • Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flowtable. • When measurement of resistance or voltage is required in this table, use a specified digital multimeter (Refer to SPECIAL TOOL in this section.) along with a correct terminal adapter from special tool (Connector test adapter kit).
Page 684: Dtc B1013 - System Specifications Different From Sdm Specifications
8B-30 AIR BAG SYSTEM Diagnostic Flow Table : Step Action 1) This DTC is set when there is a trouble in Gotostep2. Repair”AIR BAG”warning “AIR BAG” warning lamp circuit. Failure to lamp circuit. properly perform AIR BAG DIAGNOSTIC SYSTEM CHECK may also result in misdiagnosis.Therefore, check”AIR BAG”...
Page 685: On-Vehicle Service
AIR BAG SYSTEM 8B-31 On-Vehicle Service Service Precautions Service and Diagnosis WARNING/CAUTION labels are attached on each part of air bag system components (SDM and air bag (inflator) module). Be sure to follow the instructions. Warning: • If the air bag system and another vehicle system both need repair, Maurti recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 686: Disabling Air Bag System
8B-32 AIR BAG SYSTEM Disabling Air Bag System 1) Turn steering wheel so that vehicle’s wheels (front tires) and pointing straight ahead. 2) Turn ignition switch to “LOCK” position and remove key. 3) Remove “AIR BAG”fuse (2) from fuse box (1). 4) Disconnect Yellow connector (3) of contact coil and combination switch assembly.
Page 687: Handling And Storage
AIR BAG SYSTEM 8B-33 Handling and Storage Warning: Never power up air bag system when SDM is not rigidly attached to the vehicle. Otherwise, personal injury may result. Caution: After detecting one time of such collision as to meet deployment conditions, the SDM must not be used. Refer to “AIR BAG DIAGNOSTIC SYSTEM CHECK”...
Page 688 8B-34 AIR BAG SYSTEM Live (Undeployed) Air Bag (Inflator) Module Special care is necessary when handling and storing a live (undeployed) airbag (inflator) module. The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, or an object in front of the air bag (inflator) module, to be thrown through the air in the unlikely event of an accidental deployment.
Page 689 AIR BAG SYSTEM 8B-35 Deployed Air Bag (Inflator) Module Warning: • • • • • The air bag (inflator) module a immediately after deployment/activation is very hot. Wait for at least 30 minutes to cool it off before proceeding the work. •...
Page 690 8B-36 AIR BAG SYSTEM Repairs and Inspection Required After an Accident Caution: • All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be replaced even if air bag system activation did not occur.
Page 691 AIR BAG SYSTEM 8B-37 • Steering wheel driver air bag (inloator) module - Check for damage or air bag (inflator) module fitness. - Check trim cover (pad surface) for cracks. - Check wire harness and connector for damage or tightness. If any faulty condition is found in above checks, replace faultpart.
Page 692 8B-38 AIR BAG SYSTEM Warning: During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Be sure to read “SERVICE PRECAUTIONS” in this section before starting to work and observe every precaution during work. Neglecting them may result in personal injury or inactivation of the air bag system when necessary.
Page 693 AIR BAG SYSTEM 8B-39 Inspection Caution: • • • • • Do not connect a tester whatever type it may be. • • • • • Never repair or disassemble SDM (3). • • • • • If SDM has been dropped, or if there are cracks, dents or other defects in the case or plate, replace it with a new one.
Page 694: Air Bag (Inflator) Module Disposal
8B-40 AIR BAG SYSTEM Air Bag (Inflator) Module Disposal Warning: Failure to follow proper air bag (inflator) module disposal procedures can result in air bag deployment which may cause personal injury. Do not dispose of live (undeployed) air bag (inflator) modules because undeployed air bag (inflator) module/must not be disposed of through normal refuse channels.
Page 695: Deployment/Activation Outside Of Vehicle
AIR BAG SYSTEM 8B-41 Deployment/Activation Outside of Vehicle When you intend to return the vehicle to service, deploy the air bag (inflator) module(s) or activate seat belt pretensioner(s) outside of the vehicle. 1) Turn ignition switch to “LOCK” position and remove key. 2) Wear safety glasses during this deployment/activation procedure.
Page 696 8B-42 AIR BAG SYSTEM 6) Set air bag (inflator) module as follows, a) For driver air bag (inflator) module Clear space (3) on ground about 185 cm (6 ft) in diameter where driver air bag (inflator) module (1) for deployment. Paved, outdoor location where there is no activity is preferred.
Page 697 AIR BAG SYSTEM 8B-43 13) Notify all people in immediate area that you intend to deploy/ activate air bag (inflator) module or seat belt pretensioner. Note: • • • • • When air bag (inflator) module deploys, rapid gas expansion will create substantial report. Wear suitable ear protection.
Page 698 8B-44 AIR BAG SYSTEM 17) In the unlikely event that air bag (inflator) module or seat belt did not deploy/activate after following these procedures, proceed immediately with Step 23) through 26). If air bag (inflator) module did deploy or activate, proceed with Steps 18) through 22).
Page 699: Deployment/Activation Inside Of Vehicle
AIR BAG SYSTEM 8B-45 Deployment / Activation Inside of Vehicle When the vehicle will be destroyed, or salvaged for component parts, deploy the air bag modules and/or activate seat belt pretensioners installed on vehicle. Note: If equipped with the seat belt pretensioners, activate both side of seat belt pretensioners at the same time when using spe- cial tool (C).
Page 700 8B-46 AIR BAG SYSTEM 8) Route deployment harness (1) out of vehicle. 9) Verify that inside of vehicle and area surrounding vehicle are clear of all people and loose or flammable objects. 10) Stretch deployment harness (1) to its full length 10 m (33 ft). 11) Place 12 volts vehicle battery (2) near shorted end of deployment harness (1).
Page 701 AIR BAG SYSTEM 8B-47 Separate two banana plugs (1) on deployment harness (2). Connect deployment harness (2) to 12 volts vehicle battery (3)This will immediately deploy or activate air bag (inflator) module. Disconnect deployment harness (2) from 12 volts vehicle battery (3) and short two deployment harness leads together by fully seating one banana plug into the other.
Page 702: Deployed Air Bag (Inflator) Module Disposal
8B-48 AIR BAG SYSTEM 25) Temporarily store undeployed air bag (inflator) module referring to “SERVICE PRECAUTIONS” for details. 26) Contact MARUTI UDYOG LIMITED for further assistance. Deployed Air Bag (Inflator) Module Disposal Warning: Failure to follow proper air bag (inflator) module disposal procedures can result in air bag deployment which may cause personal injury.
Page 703: Tightening Torque Specification
AIR BAG SYSTEM 8B-49 • When disposing of the deployed air bag (inflator) module be sure to seal it in a vinyl bag. • When air bag (inflator) module have been deployed/ activated inside the vehicle which is going to be scrapped, leave them as installed to the vehicle.
Page 704 8B-50 AIR BAG SYSTEM 99000M24120-426 Warning: Be sure to use the specified digital multimeter. Otherwise, air bag (infiator) module deployment or personal injury may result. Note: • “A” : Digital multimeter specification : Maximum test current is 10 mA or less at minimum range of resistance measurement.
Page 705: Body, Cab And Accessories
TABLE OF CONTENS 9-i Section 9 Body, Cab and Accessories CONTENTS Instrumentation / Driver Info. / Horn ..... 9C-1 Precautions ............9-1 General Description ........9C-1 Precautions ............9-1 Combination Meter Circuit Diagram ... .9C-1 Precautions on Body, Cab and Accessories .. 9-1 Speedometer and VSS .......
Page 706 ii-9 TABLE OF CONTENS Diagnostic Information and Procedures ... 9E-2 Key Coding ............9F-5 Rear End door Window Defogger Symptom Ignition Switch Lock Cylinder ......9F-5 Diagnosis ............9E-2 Electrical Diagnosis ......... 9F-5 Power Window Control System Symptom Diagnosis ............9E-2 Seats ..............
Page 707: Lighting Systems
LIGHTENING SYSTEMS 9B-1 Lightening Systems Component Location Lighting System Location 5. Head light assembly 1.Headlight bulb 2.Sochat Cover 6. Front tog lamp (if equipred) 3.Clearance light bulb 7. Rear combination light 4.Turn signal bulb...
Page 708: Headlight
9B-2 LIGHTENING SYSTEMS Diagnostic Information and Procedures Headlight Trouble Possible Cause Correction Headlights do not light up Bulb blown Replace bulb Headlight switch faulty Replace combination switch HEAD R and L fuses blown Replace fuses to check for short Wiring or grounding faulty Repair circuit Only one headlight does Bulb blown...
Page 709: Brake Light
LIGHTENING SYSTEMS 9B-3 Back-up Light Trouble Possible Cause Correction Back-up lights do not light Bulb(s) blown Replace bulb (s) TURN / BACK fuse blown Replace fuse to check for short Back-up light switch faulty Replace switch Wiring or grounding faulty Repair circuit Back-up lights stay on Back-up light switch faulty...
Page 710: Bulb Replacement
9B-4 LIGHTENING SYSTEMS Bulb Replacement Warning: Don’t touch when the bulb is hot. 1) Disconnect negative cable at battery. 2) Disconnect harness from bulb. 3) Remove socket cover (1) and bulb (2). 4) Replace bulb and assemble all removed parts. Headlight Aiming With Screen Note: •...
Page 711: Combination Switch Assembly
LIGHTENING SYSTEMS 9B-5 Combination Switch Assembly Removal 1) Remove steering wheel from steering column 2) Remove dash side panel (1) (right side). 3) Remove steering column hole cover (1). 4) Remove steering column cover screws (1). 5) Separate upper cover (2) and lower cover (3), then remove them.
Page 712 9B-6 LIGHTENING SYSTEMS Installation 1) Check to make sure that vehicle’s front tires are set at straight- ahead position and then ignition switch is at “LOCK” position. 2) install combination switch assembly (1) to steering column. 3) Connect all connectors (2) to combination switch assembly (1).
Page 713 LIGHTENING SYSTEMS 9B-7 On-vehicle Service Headlight Headlight Switch Inspection 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below. If check result is not as specified, replace. Removal And Installation Refer to COMBINATION SWITCH ASSEMBLY in section 6B.
Page 714: Inspection
9B-8 LIGHTENING SYSTEMS Turn Signal And Hazard Warning Light Turn Signal Light Switch Inspection 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between terminals at each switch position shown below. TURN L’...
Page 715: License Lamp Assembly Removal And
LIGHTENING SYSTEMS 9B-9 License Lamp Assembly Removal and Installation Removal 1) Disconnect negative (-) cable at battery. 2) Remove rear bumper. Refer to “Front Bumper and Rear Bumper Components: in Section 9K” 3) Disconnect coupler (1) from license lamp assembly (2).
Page 716: Front Fog Light Bulb Replacement
9B-10 LIGHTENING SYSTEMS Front Fog Light Bulb Replacement Warning: • • • • • avoid danger being burned, don’t touch when the bulb is hot. • • • • • Don’t touch glass surface of bulb to avoid deteriorate case unclear when bulb light on at dirty condition.
Page 717: Headlight Leveling Switch (If Equipped) Inspection
LIGHTENING SYSTEMS 9B-11 Headlight Leveling Switch (If Equipped ) Inspection Check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Headlight Leveling Actuator Inspection (If Equipped ) 1) Make sure all headlight couplers and leveling actuator couplers are correctly connected.
Page 719: Combination Meter Circuit Diagram
INSTRUMENTATION/HORN DRIVER INFORMATION 9C-1 Instrumentation/Horn Driver Information General Descreption Combination Meter Circuit diagram CIRCUIT DIAGRAM TIMER CIRCUIT INCORPORATED IN THE BUZZER CIRCUIT METER SIDE 1 2 3 4 5 6 7 8 9 12 13 14 15 16 CONNECTOR K (16P) 1 2 3 4 5 6 7 8 9 12 13 CONNECTOR L (13P)
Page 720: Speedometer And Vss
9C-2 INSTRUMENTATION/HORN DRIVER INFORMATION Speedometer And VSS Trouble Possible Cause Correction Speedometer shows no oper- IG METER fuse blown Replace fuse to check for short ation or incorrect operation VSS faulty Replace VSS Printed plate in combination meter Replace printed plate faulty Wiring or grounding faulty Repair...
Page 721: Ignition Key Reminder / Light Reminder
INSTRUMENTATION/HORN DRIVER INFORMATION 9C-3 Ignition Key Remainder/Light Remainder Warning Buzzer (If Equipped) Trouble Possible Cause Correction Ignition key reminder/ Buzzer faulty Replace buzzer Light reminder warning Wiring or grounding faulty Repair circuit buzzer shows no sounding Driver side door switch faulty Replace door switch Ignition key switch faulty Replace ignition key switch...
Page 722: Switch Inspection
9C-4 INSTRUMENTATION/HORN DRIVER INFORMATION Switch Inspection Check for continuity between terminals at each switch position. If check result is not as specified, replace switch. Combination Meter Assembly Removal 1) Remove steering wheel from steering column referring to STEERING WHEEL in this section. 2) Remove dash side panel (1) (right side).
Page 723: Installation
INSTRUMENTATION/HORN DRIVER INFORMATION 9C-5 6) Disconnect connectors (1) from combination switch assembly (2). 7) Remove combination switch screws (3). 8) Remove combination switch (2) from steering column. 9) Remove instrument cluster panel (1). 10) Remove screws fastening combination meter. 11) Pull out combination meter (2) from instrument panel. 12) Disconnect combination meter couplers.
Page 724: Oil Pressure Switch Inspection
9C-6 INSTRUMENTATION/HORN DRIVER INFORMATION 5) Install steering column hole cover (1) 6) Install dash side panel (1) (right side). 7) Install steering wheel to steering column referring to STEERING WHEEL in this section. Oil Pressure Warning Light Oil Pressure Switch Inspection 1) Disconnect oil pressure switch (1) lead wire.
Page 725: Installation
INSTRUMENTATION/HORN DRIVER INFORMATION 9C-7 Check switch (1) for continuity. If check result is not as specified, replace switch. OFF position No continuity (parking brake released) ON position Continuity (parking brake lever pulled up) Door Switch (Front/Rear) Inspection Disconnect door switch coupler and check switch for continuity. If found defective, replace switch, ON position Continuity...
Page 726 9C-8 INSTRUMENTATION/HORN DRIVER INFORMATION Instrumentation and Driver Information Instrument Panel Removal 1) Disconnect Battary negative (–) cable at. 2) Remove steering column assembly (1). Refer to Section 3C. 3) Remove glove box (1) and hood latch release lever (2). 4) Remove both sides front pillar inner trim (1) and dash side trim(2).
Page 727 INSTRUMENTATION/HORN DRIVER INFORMATION 9C-9 5) Disconnect harness (1) and cables (2) from heater unit and air inlet box assembly. 6) Disconnect each connector (3) and cables which need to be disconnected for removal for instrument panel. 7) Remove instrument panel mounting bolts (1). 8) Remove instrument panel (2).
Page 729: Wipers / Washers
WIPERS / WASHERS 9D-1 Wipers / Washers Diagnostic Information and Procedures Front Wiper and Washer Symptom Diagnosis Condition Possible cause Correction / Reference Item Wiper malfunctions Circuit fuse blown Replace fuse and check for short circuit. Wiper motor faulty Check wiper motor referring to “Windshield Wiper Motor Inspection: ”.
Page 730: Repair Instructions
9D-2 WIPERS / WASHERS Repair Instructions Wipers and Washers 1 Wiper Nozzile 2 Washer nose Front Wiper/Washer Switch Inspection 1) Disconnect negative cable at battery, 2) Disconnect combination switch lead wire coupler. 3) Check for continuity between erminals at each switch position as shown below.
Page 731: Intermittent Wiper Relay Circuit
WIPERS / WASHERS 9D-3 Intermittent Wiper Relay Circuit Inspection 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Turn the front wiper switch to INT position. 4) Connect battery positive terminal to terminal “B3” and battery negative terminal to terminal “LO”.
Page 732: Washer Linked Operation
9D-4 WIPERS / WASHERS Washer Linked Operation Inspection 1) Disconnect negative cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Make sure that front wiper switch is at OFF position. 4) Connect battery positive terminal to terminal “B3” and battery negative terminal to terminal “Lo”.
Page 733 WIPERS / WASHERS 9D-5 Front Wiper Motor Inspection 1) As illustrated left, have a 12V battery and connect its (+) terminal to terminal “A”, and its (–) terminal to bracket (1) (wiper ground). If motor (2) rotates at a low revolution speed of 45 to 55 rpm, it is proper.
Page 735 GLASS / WINDOWS / MIRRORS 9E-1 Windshield The front windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For the Windshield replacement, it is important to use an adhesive which provides sufficient adhesion strength and to follow the proper procedure.
Page 736: 9E-2 Glass / Windows / Mirrors
9E-2 GLASS / WINDOWS / MIRRORS Diagnostic Information and Procedures Rear End door Window Defogger Symptom Diagnosis Condition Possible cause Correction / Reference Item Rear end door window Circuit fuse blown Replace fuse and check for short circuit. defogger does not Rear end door window defogger Check rear end door window defogger operate...
Page 737 GLASS / WINDOWS / MIRRORS 9E-3 Power Door Mirror Control System Symptom Diagnosis (If Equipped) Condition Possible cause Correction / Reference Item All power mirrors do not Circuit fuse blown Replace fuse and check for short circuit. operate Power door mirror switch faulty Check power door mirror switch referring to "...
Page 738: 9E-4 Glass / Windows / Mirrors
9E-4 GLASS / WINDOWS / MIRRORS Repair Instructions Windshield Removal and Installation Removal 1) Clean both inside and outside of glass and around it. 2) Remove wiper arms and garnish. 3) Using tape, cover body surface around glass to prevent any damage.
Page 739 GLASS / WINDOWS / MIRRORS 9E-5 10) Using knife (1), smoothen adhesive (2) remaining on body side (3) so that it is 1 to 2 mm thick all around. Note: Before using knife, clean it with alcohol or the like to remove oil from it.
Page 740 9E-6 GLASS / WINDOWS / MIRRORS 5) Install new molding (1) to glass (2). 6) Clean glass surface to be adhered to body with clean cloth. If cleaning solvent is used, let it dry for more than 10 minutes. Cleaning Area Distance from the edge of glass or molding “a”: 30 –...
Page 741 GLASS / WINDOWS / MIRRORS 9E-7 9) Apply adhesive (1) as shown in figure. Note: • Start from bottom side of glass (2). • Be careful not to damage primer. • Height of adhesive (1) applied to lower side should be higher than that of other three sides.
Page 742 9E-8 GLASS / WINDOWS / MIRRORS 11) Check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again. Note: •...
Page 743 GLASS / WINDOWS / MIRRORS 9E-9 Front Door Glass 6N.m(0.6kg-m) 6N.m(0.6kg-m) Window regulator handle Front door trim Front door weatherstrip Front door glass Front door glass run Front door glass sash Front window regulator assembly: Apply SUZUKI SUPER GREASE A 99000-25010 to sliding part Glass attaching screw...
Page 744 9E-10 GLASS / WINDOWS / MIRRORS Removal 1) Detach inside handle bezel (1). 2) Remove door inside pull handle case fitting screw. 3) Remove window regulator handle (1) (if equipped). For its removal, pull off snap by using a cloth (2) as shown in left figure.
Page 745 GLASS / WINDOWS / MIRRORS 9E-11 8) Remove door sash mounting bolts (1). 9) Remove glass attaching screws (2). 10) Take out door glass (3). Installation Reverse removal procedure to install door glass noting the following points: • Tighten glass attaching screws (1) to specified torque. Tighten rear screw first, then front screw.
Page 746: Front Door Window Regulator Removal
9E-12 GLASS / WINDOWS / MIRRORS Front Door Window Regulator Removal 1) Remove door glass, referring to steps 1) to 10) of FRONT DOOR GLASS REMOVAL in this section. 2) Disconnect power window motor lead wire at coupler and loosen clamp (if equipped). 3) Remove regulator mounting nuts (1) and take out regulator through hole (2) as shown in figure.
Page 747 GLASS / WINDOWS / MIRRORS 9E-13 Rear Door Glass 1.Door glass 2.Window regulator: Apply SUZUKI SUPER GREASE A (99000-25010) to sliding part 6 N.m (0.6 kg.m) 3.Glass run 4.Door trim 5.Door sealing cover 6 N.m (0.6 kg.m) 6.Window regulator handle 7.Door glass mounting screw 8.Side door trim handle Removal...
Page 748 9E-14 GLASS / WINDOWS / MIRRORS 4) Remove side door trim handle. 5) Remove door trim (1) with inside weatherstrip. With inside handle bezel (2) tilted as shown in figure, turn door trim (1) 90´ clockwise to remove it. And disconnect power window switch lead wire (if equipped).
Page 749: Rear Door Window Regulator Removal
GLASS / WINDOWS / MIRRORS 9E-15 • Secure door sealing cover (1) with adhesive (2). • Install door window regulator handle (1) so that it has a 45 angle when glass is fully closed, as shown in figure. Rear Door Window Regulator Removal 1) Remove door glass, referring to steps 1) to 12) of REAR DOOR GLASS REMOVAL in this section.
Page 750: Back Door Glass Removal And Installation
9E-16 GLASS / WINDOWS / MIRRORS Back Door Glass Removal and Installation Refer to “WINDSHIELD” section as removal and installation procedure are basically the same. However, note the following. Note: Observe the following precautions when applying adhesive (4) along glass (2) edge. •...
Page 751: Back Door Window Defogger Switch
GLASS / WINDOWS / MIRRORS 9E-17 Back Door Window Defogger Switch Inspection (If Equipped) 1) Check back door window defogger switch for operation as follows. a) Back door window defogger switch is built centre garnish. Remove centre garnish. b) Check that there is continuity between terminal (1) and terminal (2) of Defogger Switch when back door window defogger switch is at ON position.
Page 752: Power Window Main Switch Inspection
9E-18 GLASS / WINDOWS / MIRRORS 4) Touch voltmeter negative (–) lead to defogger wire ground terminal end (1). 5) Touch voltmeter positive (+) lead with a foil strip to defogger wire power source terminal end (2), then move it along wire to defogger wire ground terminal end (1).
Page 753 GLASS / WINDOWS / MIRRORS 9E-19 Switch for other window than driver side 1) Remove driver side door trim referring to step 1) to 4) of “Front Door Glass Removal and Installation: ”. 2) Remove power window main switch from door trim. 3) Check for continuity between terminals as shown below.
Page 754: Power Window Sub Switch Inspection
9E-20 GLASS / WINDOWS / MIRRORS Power Window Sub Switch Inspection 1) Remove front door trim from door panel. For front door trim, refer to Step 1) to 4) of “Front Door Glass Removal and Installation: ”.For rear door trim, refer to Step 1) to 4) of “Rear Door Glass Removal and Installation: ”.
Page 755: Security And Locks
SECURITY AND LOCKS 9F-1 Security And Locks Front Door Lock Assembly 1.Out side door handle 2.Door lock cylinder 3.Inside door handle 4.Door latch assembly: Apply SUZUKI SUPER GREASE A (99000-25010) to door latch sliding part. 5.Door latch striker 6.Door latch assembly mounting screws 7.Door latch striker mounting screws Removal 1) Raise window all the way up.
Page 756: Installation
9F-2 SECURITY AND LOCKS 4) Disconnect door opening control rod (2) from outside handle (1). 5) Disconnect door lock control rod (3) from door lock cylinder (4). 6) Remove door lock knob (5). 7) Remove door lock mounting screws (6) and door lock assembly (7).
Page 757: Installation
SECURITY AND LOCKS 9F-3 Rear Door Lock Assembly Removal 1) Raise window all the way up. 2) Remove door trim and door sealing cover, refer to step 1) to 7) of REAR DOOR GLASS REMOVAL in this section. 3) Disconnect door lock control rod (1). 4) Disconnect door opening control rod (2).
Page 758 9F-4 SECURITY AND LOCKS Back Door Lock Assembly 1.Back door lock cylinder 2.Back door lock actuator (if equipped) 3.Door latch assembly: Apply SUZUKI SUPER GREASE A (99000-25010) to door latch sliding part. 4.Door latch striker 5.Door latch striker mounting screws 6.Door latch assembly mounting bolts Removal 1) Remove back door trim.
Page 759: Key Coding
SECURITY AND LOCKS 9F-5 Key Coding Key Usage And Identification Key is used for ignition and door lock cylinder. Keys are cut on both edges to make them reversible. Key identification is obtained from five character key code stamped on key code tag. Using this key code, key code cutting combination can be determined from a code list (available to owners of key cut- ting equipment from suppliers).
Page 761: Seats
SEATS 9G-1 Seats Front Seats 35 N.m (3.5 kg.m) 35 N.m (3.5 kg.m) 23 N.m (2.3 kg.m) Removal Refer to above figure when removing and installing or disassembling and assembling front seat. Make sure to tighten each bolt as specified in above figure. (Right and left sides are symmetrical.) Installation Reverse removal procedure noting the following items for installation.
Page 762 9G-2 SEATS Rear Seats 40 - 54 N.m 40 - 54 N.m Removal and Installation Refer to above figure when removing and installing or disassembling and assembling rear seat.
Page 763: Interior Trim
INTERIOR TRIM 9H-1 Interior Trim Floor Carpet 1. Floor carpet 2. Dash panel silencer 3. Floor upper pad (if equipped) 4. NIL 5. Luggage floor silencer and Spare tire cover 6. Tool assembly 7. Jack 8. Air outlet valve9 9. Cowl Lid cover 10.
Page 764 9H-2 INTERIOR TRIM Head Lining Removal ( ) 1 1) Remove front interior light (1). 2) Remove head lining clip (2). 3) Remove sun visor (1). 4) Remove assistant grip (1). 5) Remove door opening trims (2) and quarter window trim (3). 6) Remove centre pillar trim upper and front piller trim.
Page 765 INTERIOR TRIM 9H-3 Installation Reverse removal procedure for installation, noting the following items. • Attach adhesive tape (1) to head lining (2) as shown in figure. • Tighten sun visor screw (1) to specified torque. Tightening Torque (a): 4 N·m (0.4 kg-m, 2.8 lb-ft) Required Service Material •...
Page 767: Hood / Fenders / Doors
HOOD / FENDERS / DOORS 9J-1 Hood / Fenders / Doors Hood Removal 1) Remove window washer hose (1) from hood (2). 2) Remove both side hood mounting bolts to detach hood (2). Installation Reverse removal procedure to install hood. Adjustment Hood position adjustment.
Page 768: Installation
9J-2 HOOD / FENDERS / DOORS Front Fender Removal 1) Remove front bumper. 2) Remove front fender lining (1). 3) Disconnect connector of side turn signal (or side marker) lamp. 4) Remove wiper arms and garnish. 5) Remove front fender (2). Installation Reverse removal procedure for installation.
Page 769 HOOD / FENDERS / DOORS 9J-3 Front Door RearDoor 1. Door panel 2. Door hinge: Apply SUZUKI SUPER GREASE A (99000-25010) to hinge rotating part 3. Door open stopper: Apply SUZUKI SUPER GREASE A (99000-25010) to stopper sliding part 4. Door open stopper pin 5.
Page 770: Installation
9J-4 HOOD / FENDERS / DOORS 5) Remove door assy by removing hinge mounting bolts (1). Installation Reverse removal procedure to install door assembly, noting the following points. Note: When replacing door, coat replacement door inside with wax for proper anti-corrosion treatment. Refer to UNDERCOATING/ ANTI-CORROSION COM- POUND APPLICATION AREA in this section.
Page 771 HOOD / FENDERS / DOORS 9J-5 Back Door Assembly Removal 1) Remove back door trim (1). 2) Remove wire harness connectors inside the back door.
Page 772 9J-6 HOOD / FENDERS / DOORS 3) Remove back door balancers (1) (first at its door-side and next at its body side, as shown). Warning: Handling of Back Door Balancer (Damper) • Do not disassemble balancer (1) because its cylinder is filled with gas.
Page 773: Body Structure
BODY STRUCTURE 9K-1 Body Structure Front Bumper Rear Bumper...
Page 774: Body Dimensions
9K-2 BODY STRUCTURE Body Dimensions Unit in mm...
Page 775 BODY STRUCTURE 9K-3 Unit in mm Unit in mm...
Page 776 9K-4 BODY STRUCTURE Unit in mm Unit in mm...
Page 777 BODY STRUCTURE 9K-5 Under Body Dimensions Unit in mm...
Page 778 9K-6 BODY STRUCTURE Unit in mm...
Page 779: Panel Clearance
BODY STRUCTURE 9K-7 Panel Clearance a 1.6 1.0 i 3.9 1.0 p 3.2 1.0 b 4.2+ q 3.2 1.0 j 7.8 1.0 c 5.1 1.0 k 5.1 1.0 r 7.8 1.5 e 6.5 1.0 l 5.5 1.0 s 4.5 1.0 t 4.2+ f 6.5 1.0 m 5.2 1.0...
Page 781 PAINT / COATINGS 9L-1 Paint and Coatings production. The sealer is intended to prevent dust Anti-Corrosion Treatment from entering the vehicle and serves also as an Warning: anticorrosion barrier. The sealer is applied to the door and hood hem areas and between panels. Correct Standard shop practices, particularly eye and reseal the originally sealed joints if damaged.
Page 782: 9L-2 Paint / Coatings
9L-2 PAINT / COATINGS When the welding or heating operation causes the Scrape the accessible places. If a standard putty knife original galvanization or other anti-corrosive materials or scraper does not fit to the elevant place, consider to be burnt, the interior and under-body panel surfaces to use a more flexible scraper to a place narrowly must be cleaned.
Page 783 PAINT / COATINGS 9L-3 Sealant Application Area...
Page 784 9L-4 PAINT / COATINGS...
Page 785 PAINT / COATINGS 9L-5...
Page 786 9L-6 PAINT / COATINGS...
Page 787: Plastic Parts Finishing
PAINT / COATINGS 9L-7 Plastic Parts Finishing Paintable plastic parts are ABS plastic parts. Painting Rigid or hand ABS plastic needs no primer coating. General acrylic lacquers can be painted properly over hard ABS plastic in terms of adherence. 1) Use cleaning solvent for paint finish to wash each part. 2) Apply conventional acrylic color lacquer to part surface.