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Suzuki Manuals
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WagonR+ RB413
Service manual
Suzuki WagonR+ RB413 Service Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Dutch
Fuse Number
Connector List
Table of Contents
Inhoud en Beschrijving Van Deze Handleiding
Van Toepassing Zijnde Modellen
Wees Voorzichtig Wanneer Uonderhoud Pleegt
Symbolen en Tekens
Afkortingen
Symbolen Voor Draadkleuren
Hoe Stekker-Layout Diagrammen Gelezen Moeten Worden (DEEL 8A-3)
Hoe Stekkers Worden Aangegeven en Hoe Deze Gelezen Moeten Worden
Hoe Installatieposities Van Eenheidsonderdelen Gelezen Moeten Worden (DEEL 8A-4)
Hoe de Aardingspunten Gelezen Moeten Worden (DEEL 8A-5)
Hoe Een Systeemschakelingsdiagram Gelezen Moet Worden (DEEL 8A-7)
Hoe de Lijst Van Stekkers en Aansluitingen Gelezen Moet Worden (DEEL 8A-8)
English
How to Use this Manual
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
Precautions
Diagnosis
Servicing and Handling
General Precautions
Precaution for CAN Communication System
Precaution for Wheel (with Tire) Removal
Precautions for Catalytic Converter
Precaution for Installing Mobile Communication Equipment
Precaution in Servicing Full-Time 4WD Vehicle
Precautions for Electrical Circuit Service
Electrical Circuit Inspection Procedure
Open Circuit Check
Continuity Check
Voltage Check
Intermittent and Poor Connection
Short Circuit Check (Wire Harness to Ground)
Engine Identification Number
Identification Information
Transmission Identification Number
Vehicle Identification Number
Warning, Caution and Information Labels
Vehicle Lifting Points
When Using Frame Contact Hoist
When Using Floor Jack
Abbreviations
Abbreviations and Symbols May be Used in this Manual
Symbols
Wire Color Symbols
Fastener Information
Metric Fasteners Information
Fastener Strength Identification
Standard Tightening Torque
Maintenance Schedule
Maintenance Schedule under Normal Driving Conditions
Maintenance Recommended under Severe Driving Conditions
A/C Compressor Drive Belt (if Equipped) Inspection
A/C Compressor Drive Belt (if Equipped) Replacement
Drive Belt Inspection (M13 Engine)
Drive Belt Replacement (M13 Engine)
Maintenance Service
Water Pump and Generator Drive Belt Inspection
Water Pump and Generator Drive Belt Replacement
A/C Compressor Drive Belt Inspection (if Equipped)
A/C Compressor Drive Belt Replacement
Drive Belt Inspection (G10 Engine)
Drive Belt Replacement (G10 Engine)
Water Pump Belt Inspection
Water Pump Belt Replacement
Camshaft Timing Belt Replacement (G10 Engine)
Engine Accessary Drive Belt Inspection (Z13DT Engine)
Engine Accessary Drive Belt Replacement (Z13DT Engine)
Valve Lash (Clearance) Inspection (M13
Water Pump and Generator Drive Belt Inspection
Water Pump and Generator Drive Belt Replacement
(M13 Engine)
Engine Oil and Oil Filter Replacement (G10/M13 Engines)
Engine Oil and Oil Filter Replacement (Z13DT Engine)
Engine Coolant Replacement
Exhaust System Inspection
Spark Plugs Replacement
Air Cleaner Filter Inspection (G10/M13 Engines)
Air Cleaner Filter Inspection (Z13DT Engine)
Air Cleaner Filter Replacement (G10/M13 Engines)
Distributor Cap and Rotor Inspection (G10 Engine)
Air Cleaner Filter Replacement (Z13DT Engine)
Fuel Filter Replacement (Z13DT Engine)
Fuel Lines and Connections Inspection
Water Draining of Fuel Filter (Z13DT Engine)
Brake Discs and Pads (Front) Inspection
Fuel Evaporative Emission Control System Inspection
Fuel Tank Inspection
PCV Valve Inspection
Brake Drums and Shoes (Rear) Inspection
Brake Fluid Replacement
Brake Hoses and Pipes Inspection
Brake Lever and Cable Inspection
Clutch Inspection
Tires Inspection
Suspension System Inspection
Wheel Bearing Inspection
Wheel Discs Inspection
Steering System Inspection
Drive Shaft (Axle) Boots Inspection
Manual Transmission Oil Inspection (G10/M13 Engines)
Manual Transmission Oil Replacement
Propeller Shafts (4WD) Inspection
Automatic Transmission Fluid Cooler Hose Inspection
Automatic Transmission Fluid Level Inspection
Automatic Transmission Fluid Replacement
Transfer Oil (4WD) and Rear Differential Oil (4WD) Inspection
Transfer Oil (4WD) and Rear Differential Oil (4WD) Replacement
All Latches, Hinges and Locks Inspection
Doors
Engine Hood
Ventilator Air Filter (if Equipped)
Final Inspection
General Description
Major Components and Location
On-Board Diagnostic System (Z13DT Engine Model)
Diagnosis
Diagnosis Table
Wiring Circuit
Diagnostic Trouble Code (DTC) Check (Z13DT Engine Model)
Diagnostic Trouble Code (DTC) Table (Z13DT Engine Model)
Heater Unit
On-Vehicle Service
Supplementary Heater (if Equipped) (Z13DT Engine)
Supplementary Heater Controller (if Equipped) (Z13DT Engine)
Supplementary Heater Relay (if Equipped) (Z13DT Engine)
Air Inlet Box
General Description
Major Components and Location
Diagnosis
General Diagnosis Table
Wiring Circuit
A/C System Inspection of ECM and Its Circuits (M13 Engine Model)
Compressor Drive Belt
Operation Procedure for Charging A/C with Refrigerant
Recovery, Evacuation and Charging
On-Vehicle Service
A/C Condenser Assembly
Procedure after ECM Replacement (Z13DT Engine Model)
Receiver / Dryer
Cooling Unit (Evaporator)
Dual Pressure Switch (M13 and G10 Engine Models)
Pressure Sensor (Z13DT Engine Model)
A/C Relay (Z13DT Engine)
A/C Compressor Relay
Compressor
Replenishing Compressor Oil
Magnet Clutch
Relief Valve (Z13DT Engine Model)
Required Service Material
Front Wheel Alignment
General Description
Diagnosis
Wheel Disc, Bolt & Bearing Check
On-Vehicle Service
Stabilizer Bar And/Or Bushings
Strut Assembly
Steering Knuckle / Bearing
Suspension Control Arm / Bushing
Tightening Torque Specifications
Required Service Material
Special Tool
General Description
Diagnosis
Wheel Disc, Bolt and Bearing Check
On-Vehicle Service
Lateral Rod
Coil Spring
Bump Stopper
Trailing Arm
Rear Axle (for 2WD Model)
Wheel Bearing (for 2WD Model)
Rear Axle Shaft and Wheel Bearing (for 4WD Model)
Rear Axle Housing (for 4WD Model)
Tightening Torque Specifications
Required Service Material
Special Tool
Front Drive Shaft Assembly Construction
On-Vehicle Service
Front Drive Shaft Assembly Removal and Installation
Front Drive Shaft Assembly Inspection
Front Drive Shaft Components
Front Drive Shaft Disassembly and Assembly
Front Drive Shaft Inspection
Center Shaft and Center Bearing Support Disassembly and Assembly (2WD Model with M13 Engine)
Tightening Torque Specification
Required Service Material
Special Tools
Front Drive Shaft Assembly Construction
On-Vehicle Service
Front Drive Shaft Assembly Removal and Installation
Front Drive Shaft Assembly Inspection
Front Drive Shaft Components
Front Drive Shaft Disassembly and Assembly
Front Drive Shaft Inspection
Special Tools
Tightening Torque Specification
Front Disc Brake Pad
On-Vehicle Service
Front Disc Brake Caliper
Front Brake Disc
Tightening Torque Specification
On-Vehicle Service
Parking Brake Cable Component Location
Brake Drum (for 2WD Model)
Brake Drum Removal and Installation (for 4WD Model)
Brake Back Plate (for 2WD Model)
Brake Back Plate (for 4WD Model)
Tightening Torque Specifications
Special Tools
General Information
Statement on Cleanliness and Care
Precaution
Precaution on Engine Service
Precaution on Fuel System Service
Fuel Pressure Relief Procedure
Fuel Leakage Check Procedure
Diagnosis
Engine Diagnosis General Description
On-Board Diagnostic System Description
Precaution in Diagnosing Trouble for Engine
Engine and Emission Control System Check
Customer Problem Inspection Form (Example)
Diagnostic Trouble Code (DTC) Check
Diagnostic Trouble Code (DTC) Clearance
Malfunction Indicator Lamp (MIL) Check
DTC Table
Fail-Safe Table
Visual Inspection
Engine Basic Inspection
Engine Symptom Diagnosis
Scan Tool Data
Inspection of ECM and Its Circuits
ON" with Ignition Switch on
DTC P0113 Intake Air Temperature Sensor Circuit High
DTC P0117 Engine Coolant Temperature Circuit Low
DTC P0118 Engine Coolant Temperature Circuit High
DTC P0121 Throttle Position Sensor Circuit Range/Performance
DTC P0122 Throttle Position Sensor Circuit Low
DTC P0123 Throttle Position Circuit High Input
DTC P0131 O2 Sensor (HO2S) Circuit Low Voltage (Sensor-1)
DTC P0132 O2 Sensor (HO2S) Circuit High Voltage (Sensor-1)
DTC P0133 O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
DTC P0134 O2 Sensor (HO2S) no Activity Detected (Sensor-1)
Circuit Low (Sensor-1)
DTC P0031 HO2S Heater Control
DTC P0032 HO2S Heater Control
DTC P0136 O2 Sensor (HO2S) Circuit (Sensor-2)
DTC P0037 HO2S Heater Control
DTC P0038 HO2S Heater Control
DTC P0171 System too Lean
DTC P0172 System too Rich
DTC P0300 Random Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
DTC P0327 Knock Sensor Circuit Low
DTC P0328 Knock Sensor Circuit High
DTC P0335 Crankshaft Position (CKP) Sensor Circuit
DTC P0340 Camshaft Position Sensor Circuit
DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected
DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected
DTC P0420 Catalyst System Efficiency below Threshold
DTC P0443 Evaporative Emission System Purge Control Valve Circuit
DTC P0480 Fan 1 (Radiator Cooling Fan) Control Circuit
DTC P0500 Vehicle Speed Sensor (VSS) Malfunction
DTC P0505 Idle Air Control System
DTC P1500 Starter Signal Circuit Malfunction
DTC P0107 Manifold Absolute Pressure Low Input
DTC P0108 Manifold Absolute Pressure High Input
DTC P0601 Internal Control Module Memory Check Sum Error
DTC P0602 Control Module Programming Error
DTC P1510 ECM Back-Up Power Supply Malfunction
DTC P1601 Can Communication Error
DTC P1603 TCM Trouble Code Detected
DTC P2227 Barometric Pressure Circuit Range/Performance
DTC P2228 Barometric Pressure
DTC P2229 Barometric Pressure
Engine Construction Description
General Description
Engine Lubrication Description
System Description
Variable Valve Timing (VVT) System Description
Cam Timing Sprocket
Oil Control Valve
Timing Advancing
Timing Holding
Targeted Timing Varying Operation
Timing Retarding
Compression Check
Diagnosis
Diagnosis Table
Engine Vacuum Check
Oil Pressure Check
Shim Replacement
Valve Lash (Clearance) Inspection
Air Cleaner Element Removal and Installation
On-Vehicle Service
Air Cleaner Element Inspection and Cleaning
Cylinder Head Cover Removal and Installation
Knock Sensor Removal and Installation
Throttle Body and Intake Manifold Components
Throttle Body Removal and Installation
Intake Manifold Removal and Installation
Exhaust Manifold Components
Exhaust Manifold Removal and Installation
Oil Pan and Oil Pump Strainer Components
Oil Pan and Oil Pump Strainer Removal and Installation
Engine Mountings Components
Engine Assembly Removal and Installation
Unit Repair Overhaul
Timing Chain Cover Components
Timing Chain Cover Removal and Installation
Oil Seal
Timing Chain Cover
Timing Chain Cover Inspection
Oil Control Valve
Oil Gallery Pipe
Oil Pump Components
Oil Pump Disassembly and Assembly
Oil Pump Removal and Installation
Oil Pump Assembly
Oil Pump Inspection
Oil Seal
Radial Clearance
Relief Valve Spring Free Length and Load
Side Clearance
Timing Chain and Chain Tensioner Components
Timing Chain and Chain Tensioner Removal and Installation
Crankshaft Timing Sprocket
Timing Chain and Timing Chain Tensioner Inspection
Timing Chain Tensioner
Timing Chain
Timing Chain No.1 Guide
Timing Chain Tensioner Adjuster
Camshaft, Tappet and Shim Components
Camshaft, Tappet and Shim Removal and Installation
Camshaft, Tappet and Shim Inspection
Intake Cam Timing Sprocket Assembly
Cam Wear
Camshaft Journal Wear
Camshaft Runout
Wear of Tappet and Shim
Valves and Cylinder Head Removal and Installation
Valves and Cylinder Head Disassembly and Assembly
Valve Guides
Valves
Valves and Cylinder Head Inspection
Cylinder Head
Valve Springs
Pistons, Piston Rings, Connecting Rods and Cylinders Components
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
Cylinder
Pistons
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection
Piston Pin
Piston Rings
Connecting Rod
Crank Pin and Connecting Rod Bearings
Main Bearings, Crankshaft and Cylinder Block Components
Main Bearings, Crankshaft and Cylinder
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
Block Inspection
Crankshaft
Main Bearing Cap No.1 Bolt
Main Bearings
Flywheel
Rear Oil Seal
Cylinder Block
Sensor Plate
Required Service Material
Tightening Torque Specification
Special Tool
Cooling System Circulation
General Description
Coolant
Diagnosis
Diagnosis Table
System Circuit Inspection
Coolant Level Check
Maintenance
Cooling System Flush and Refill
Engine Cooling System Inspection and Service
Water Pump/Generator Drive Belt Tension Inspection and Adjustment
Cooling System Components
On-Vehicle Service
Cooling System Draining
Cooling System Refill
Cooling Water Pipes or Hoses
Thermostat Inspection
Thermostat Removal and Installation
Radiator Removal and Installation
Installation
Radiator Cleaning
Radiator Cooling Fan Relay Inspection
Radiator Inspection
Radiator Cooling Fan Inspection
Water Pump/Generator Drive Belt Removal and Installation
Water Pump Removal and Installation
Engine Coolant Temperature Sensor (ECT Sensor) Inspection
Engine Coolant Temperature Sensor (ECT Sensor) Removal and Installation
Required Service Material
Water Pump Inspection
Tightening Torque Specification
Engine and Emission Control System Construction
General Description
Air Intake System Description
Fuel Delivery System Description
Electronic Control System Description
Accelerator Cable Adjustment
Idle Speed/Idle Air Control (IAC) Duty Inspection
On-Vehicle Service
Air Intake System
Throttle Body Components
Throttle Body On-Vehicle Inspection
Throttle Body Removal and Installation
Idle Air Control (IAC) Valve Operation Check
Throttle Body Cleaning
Idle Air Control (IAC) Valve Check
Installation
Oil Control Valve Inspection
Oil Control Valve Removal and Installation
Fuel Delivery System
Fuel Pressure Inspection
Fuel Pump with Pressure Regulator On-Vehicle Inspection
Fuel Injector On-Vehicle Inspection
Fuel Pump with Pressure Regulator Inspection
Fuel Pump with Pressure Regulator Removal and Installation
Fuel Injector Removal and Installation
Fuel Injector Inspection
Electronic Control System
Engine Control Module (ECM) Removal and Installation
Manifold Absolute Pressure Sensor (MAP Sensor) Inspection
Throttle Position Sensor (TP Sensor) On-Vehicle Inspection
Throttle Position Sensor (TP Sensor) Removal and Installation
Engine Coolant Temperature Sensor (ECT Sensor) Removal and Installation
Engine Coolant Temperature Sensor (ECT Sensor) Inspection
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection
And Installation
Camshaft Position Sensor (CMP Sensor) and Its Circuit Inspection
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal
Camshaft Position Sensor (CMP Sensor) Removal and Installation
Crankshaft Position Sensor (CKP Sensor) and Its Circuit Inspection
Installation
And Installation
Fuel Level Sensor Inspection
Knock Sensor Removal and Installation
Vehicle Speed Sensor (VSS) and Its Circuit Inspection
Vehicle Speed Sensor (VSS) Removal and Installation
Fuel Cut Operation Inspection
Main Relay, Fuel Pump Relay and Radiator Fan Relay Inspection
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
Radiator Fan Control System Inspection
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
EGR System Inspection
EGR Valve Inspection
EGR Valve Removal and Installation
Emission Control System
Evaporative Emission Control System Inspection
PCV System Inspection
Special Tool
Tightening Torque Specification
Ignition System Components Locator Diagram
Ignition System Construction
Ignition System Wiring Circuit Diagram
Diagnosis
Ignition System Diagnostic Flow Table
Reference Waveform
High-Tension Cords Removal and Installation
Ignition Spark Test
On-Vehicle Service
High-Tension Cords Inspection
Spark Plugs Removal and Installation
Spark Plugs Inspection
Ignition Coil Assembly (Including Ignitor) Inspection
Ignition Coil Assembly (Including Ignitor) Removal and Installation
Crankshaft Position (CKP) Sensor
Ignition Timing Inspection
Tightening Torque Specification
Manual Transaxle
Specifications
Functions
Transmission Control Module
Fail Safe Table
Visual Inspection
Automatic Transaxle Basic Check
Trouble Diagnosis Table
Trouble Diagnosis Table-1
Trouble Diagnosis Table-2
Trouble Diagnosis Table-3
Road Test
Manual Road Test
Engine Brake Test
Stall Test
Time Lag Test
Line Pressure Test
Diagnostic Flow Table A-3: "O/D
Diagnostic Flow Table A-4: "O/D
DTC P0722 Output Speed Sensor
DTC P0741/P0742 TCC Circuit Performance or Stuck OFF/TCC Circuit Stuck on
DTC P0785 Timing Solenoid
DTC P0962 Pressure Control Solenoid Control Circuit Low
DTC P0963 Pressure Control Solenoid Control Circuit High
DTC P0974/P0977 Shift Solenoid-A
DTC P1701 CAN Communication Error
DTC P1702 Internal Control Module Memory Check Sum Error
DTC P1703 CAN Invalid Data-TCM
DTC P2769 Torque Converter Clutch (TCC) Circuit Low
DTC P2770 Torque Converter Clutch (TCC) Circuit High
Scan Tool Data
Inspection of TCM and Its Circuits
Fluid Level Check at Normal Operating (Hot) Temperature (Hot Check)
Maintenance Service
On-Vehicle Service
Fluid Change
A/T Fluid Cooler Hoses
Selector Lever
Select Cable
Transmission Range Sensor (Shift Switch)
Output Shaft Speed Sensor (VSS)
Input Shaft Speed Sensor
Throttle Position Sensor
Engine Coolant Temperature Sensor
O/D off Switch
Solenoid Valves
Timing Solenoid Valve
Pressure Control Solenoid Valve
Transmission Control Module (TCM)
A/T Relay
Transmission Fluid Temperature Sensor
Differential Side Oil Seal
Automatic Transaxle Assembly
Precautions
Unit Repair
Part Inspection and Correction Table
Components
Unit Disassembly
Subassembly
Oil Pump Assembly
Assembly
2Nd Brake Piston Assembly
Transaxle Rear Cover Assembly
O/D and 2Nd Coast Brake Piston
Differential Assembly
Countershaft Assembly
Valve Body Assembly
Torque Converter Housing
Transaxle Case
Adjustment before Unit Assembly
Unit Assembly
Tightening Torque Specification
Special Tool
Required Service Material
Clutch Cable
On-Vehicle Service
Clutch Pedal and Clutch Pedal Bracket
Clutch Cover, Clutch Disc and Flywheel
Clutch Release Bearing / Shaft / Bush / Lever
Required Service Material
Tightening Torque Specification
Special Tool
Differential Unit
General Description
Differential Carrier and Drive Bevel Pinion
Required Service Material
Tightening Torque Specification
Special Tool
Combination Meter
General Description
Diagnosis
Low Engine Oil Level Warning Light Symptom Diagnosis for Z13DT Engine (if Equipped)
Low Fuel Warning System
On-Vehicle Service
General Description
ON-Board Diagnostic System
Precautions in Diagnosing Troubles
Diagnostic Flow Table
Diagnostic Trouble Code (DTC) Check
Diagnostic Trouble Code (DTC) Clearance
Diagnostic Trouble Code (DTC) Table
Inspection of Immobilizer Control Module and Its Circuits
DTC B3040 W-Line Communication Fail
DTC B3042 W-Line CKT Malf (Short to Ground)
DTC B3043 W-Line CKT Malf (Short to Battery)
DTC B3059 no Request from ECM
How to Register Ignition Key
On-Vehicle Service
Procedure after ECM Replacement
Procedure after Immobilizer Control Module Replacement
Registration Procedure of Immobilizer System Components
Special Tools
Electronic Ignition System
Key Cylinder Switch
Circuit
DTC C1035, DTC C1036 - Left-Rear
DTC C1041 - Right-Front Inlet Solenoid
DTC C1042 - Right-Front Outlet Solenoid
DTC C1045 - Left-Front Inlet Solenoid
DTC C1046 - Left-Front Outlet Solenoid
DTC C1051 - Right-Rear Inlet Solenoid
DTC C1052 - Right-Rear Outlet Solenoid
DTC C1055 - Left-Rear Inlet Solenoid
DTC C1056 - Left-Rear Outlet Solenoid
DTC C1057 - Power Source Circuit
DTC C1061 - ABS Pump Motor Circuit
Assembly
Low Fuel Warning Lamp
Front Seat
Rear Seat
Intermediate Shaft
Component Inspection
Transfer Assembly
DTC C1071 - ABS Control Module
Recommended Fluids and Lubricants
Fuel Injector
Manifold Absolute Pressure Sensor
Radiator Fan
Noise Suppressor
Disassembly and Assembly
Metric Fasteners
Engine Coolant Change
Refrigerant Recovery
Expansion Valve
Wear Indicators
Steering Rack
Diagnostic System
Torque Sensor
Handling Precaution
Steering Wheel
Rear Shock Absorber
Replacement Tires
Balancing Wheels
Road Testing Brakes
Substandard or Contaminated Brake Fluid
Brake Fluid Leaks
Excessive Pedal Travel Check
Brake Pedal Play Check
Brake Fluid Level Check
Flushing Brake Hydraulic System
Booster Operation Check
Master Cylinder Assembly
Brake Booster
Knock Sensor
Fuel Filler Cap
Egr System
Pcv System
Exhaust System
Vehicle Speed Sensor
Body Electrical System
Brake Lights
Oil Pressure Light
Oil Pressure Warning Light
Door Switch
Rear Wiper and Washer
Rear Wiper Arm
Front Door Window Regulator
Door Mirror
Rear Door Glass
Rear Door Window Regulator
Quarter Window
Front Door Assembly
Rear Door Assembly
Key Coding
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