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Zen Estilo 2018
MARUTI SUZUKI Zen Estilo 2018 Car Manuals
Manuals and User Guides for MARUTI SUZUKI Zen Estilo 2018 Car. We have
1
MARUTI SUZUKI Zen Estilo 2018 Car manual available for free PDF download: Manual
MARUTI SUZUKI Zen Estilo 2018 Manual (788 pages)
Brand:
MARUTI SUZUKI
| Category:
Automobile
| Size: 17 MB
Table of Contents
Table of Contents
1
Volume
3
Precautions
6
Precautions for Vehicles Equipped with
6
General Precautions
9
Precautions for Catalytic Converter
11
Precautions for Electrical Circuit Service
12
Electrical Circuit Inspections Procedure
13
Intermittent and Poor Connection
16
Air Bag Warning
18
Air Bag System Service Warning
18
Fastener Caution
18
Suspension Caution
18
Wheels and Tires Caution
19
Brake Caution
19
General Information
22
0A-2 Generalinformation
23
Metric Information
25
Vehicle Lifting Points
27
Vehicle Identification Number
29
Engine Identification Number
29
Maintenance and Lubrication
30
Periodic Maintenance Schedule
30
0B-2 Maintenance and Lubrication
31
Maintenance Service
33
Water Pump Belt Inspection and
33
Camshaft Timing Belt Replacement
34
Valve Lash (Clearance) Inspection
34
Engine Oil and Filter Change
34
Engine Coolant Change
36
Exhaust System Inspection
37
Spark Plug Replacement
38
Air Cleaner Filter Inspection
38
Air Cleaner Filter Replacement
38
Fuel Lines Inspection
38
Fuel Filter Replacement
38
Fuel Tank Inspection
39
Fuel Evaporative Emission Control System
39
Brake Hoses and Pipes Inspection
40
Brake Lever and Cable Inspection
41
Wheel Discs Inspection
42
Wheel Bearing Inspection
42
Drive Shaft (Axle) Boots Inspection
42
Suspension System Inspection
42
Steering System Inspection
43
Manual Transmission Oil Inspection and Change
44
All Latches, Hinges and Locks Inspection . 0B-15
44
Final Inspection
45
Recommended Fluids and Lubricants
46
Engine
48
Precautions
52
Engine General Information and Diagnosis
52
Precautions on Engine Service
52
Precautions in Diagnosing Trouble
52
General Description
52
Statement on Cleanliness and Care
52
Engine Diagnosis General Description
53
On-Board Diagnostic System Description
53
Engine and Emission Control System Description
55
Air Intake System Description
56
Engine and Emission Control Input/Output Table
61
Schematic and Routing Diagram
62
Engine and Emission Control System Diagram
62
Component Location
64
Electronic Control System Components Location
64
Diagnostic Information and Procedures
65
Check
69
Malfunction Indicator Lamp (MIL) Check
69
Engine Diagnosis Table
71
Malfunction Indicator Lamp Does Not Light at Ignition Switch
76
Malfunction Indicator Lamp Flasher
76
B-1 ECM Power and Ground Circuit Check
96
Fuel Injector Circuit Check
99
B-3 Fuel Pump and Its Circuit Check
101
Fuel Pressure Check
101
Idle Air Control System Check
105
A/C Control Signal Check
107
B-7 Electric Load Signal Circuit Check
108
System Check
109
Aux. Emission Control Devices
112
EVAP Canister Purge Inspection
112
Vacuum Passage Inspection
112
Vacuum Hose Inspection
112
EVAP Canister Purge Valve Inspection
113
EVAP Canister Inspection
114
PCV Hose Inspection
115
Engine Electrical
116
Engine Electrical Devices
116
Repair Instructions
116
Idle Air Control (IAC) Valve Operation Inspection
116
Idle Air Control (IAC) Valve On-Vehicle Inspection
116
Installation
117
On-Vehicle Inspection
118
Inspection
120
Removal,Inspection and Installation
123
Inspection
123
Heated Oxygen Sensor Removal and Installation
125
Camshaft Position (CMP) Sensor Removal, Inspection and Installation
126
Special Tools
131
Engine Mechanical
132
General Description
132
Engine Construction Description
132
Diagnostic Information and Procedures
133
Compression Check
133
Engine Vacuum Check
134
Valve Lash (Clearance)
135
Repair Instructions
137
Air Cleaner Element Removal and Installation
137
Cylinder Head Cover Removal and Installation
137
Accelerator Cable Adjustment
138
Throttle Body Components
139
Throttle Body Removal,Disassembly, Cleaning and Installation
139
Throttle Body and Intake Manifold Components
142
Throttle Body and Intake Manifold Removal,Inspection and Installation
142
Engine Assembly Removal and Installation
145
Timing Belt and Belt Tensioner Components
149
Timing Belt and Belt Tensioner Removal, Inspection and Installation
149
Rocker Arms, Rocker Shaft and Camshaft Components
155
Rocker Arms, Rocker Shaft and Camshaft Removal Inspection and Installation
155
Valves and Cylinder Head Components
161
Valves and Cylinder Head Removal and Installation
161
Cylinder Head Inspection
169
Valve Spring Inspection
170
Pistons, Piston Rings, Connecting Rods and Cylinder Disassembly and Assembly . 1D-43
174
Crank Pin and Connecting Rod Bearings Inspection
179
Main Bearings, Crankshaft and Cylinder Block Components
181
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
182
Crankshaft Inspection
185
Main Bearings Inspection
186
Rear Oil Seal Inspection
190
Flywheel Inspection
191
Cylinder Block Inspection
191
Required Service Material
192
Engine Lubrication System
194
General Description
194
Oil Pressure Check
195
Oil Pan and Oil Pump Strainer Components
197
Oil Pan and Oil Pump Strainer Removal and Installation
197
Oil Pump Components
200
Oil Pump Removal and Installation
200
Oil Pump Disassembly, Inspection and Assembly
202
Engine Cooling System
204
General Description
204
Cooling System Description
204
Coolant Description
204
Schematic and Routing Diagram
206
Cooling System Circulation
206
Diagnostic Information and Procedures
207
Engine Cooling Symptom Diagnosis
207
Coolant Level Check
208
Engine Cooling System Inspection and Cleaning
208
Cooling System Draining
209
Cooling System Flush and Refill
209
Cooling Water Pipes or Hoses Removal and Installation
211
Installation
211
Radiator Fan Motor On-Vehicle
213
Inspection
213
Radiator Fan Control Relay
213
Radiator Cooling Fan Removal and Installation
213
Radiator Removal, Inspection and Installation
214
Water Pump - Generator Belt Tension Inspection and Adjustment
215
Water Pump - Generator Belt Removal and Installation
216
Water Pump Removal and Installation
216
Fuel System
218
Precautions
218
Precautions on Fuel System Service
218
General Description
218
Fuel System Description
218
Fuel Delivery System Description
218
Fuel Pump Description
219
Schematic and Routing Diagram
220
Fuel Delivery System Diagram
220
Diagnostic Information and Procedures
220
Fuel Pressure Inspection
220
Fuel Cut Operation Inspection
222
Repair Instructions
222
Fuel System Components
222
Fuel Hose Disconnecting and Reconnecting1G-6
223
Fuel Leakage Check Procedure
224
Fuel Lines On-Vehicle Inspection
224
Fuel Pipe Removal and Installation
225
Fuel Injector On-Vehicle Inspection
226
Fuel Injector Removal, Inspection and Installation
226
Fuel Filler Cap Inspection
228
Fuel Tank Removal, Inspection and Installation
229
Fuel Tank Purging Procedure
232
Fuel Pump On-Vehicle Inspection
232
Installation
233
Fuel Filter Removal and Installation
236
Fuel Pressure Regulator on Vehicle Inspection
237
Ignition System
238
General Description
238
Schematic and Routing Diagram
239
Ignition System Wiring Circuit Diagram
239
Component Location
240
Ignition System Components Location
240
Diagnostic Information and Procedures
241
Ignition System Symptom Diagnosis
241
Ignition Spark Test
243
Repair Instructions
243
High-Tension Cord Removal, Inspection and Installation
243
Spark Plug Removal, Inspection and Installation
244
Inspection
244
Ignition Timing Inspection/Adjustment
246
Special Tools
248
Starting System
250
Schematic and Routing Diagram
250
Cranking System Circuit Diagram
250
Diagnosis
251
Cranking System Test
252
Repair Instructions
253
Starting Motor Dismounting and Remounting
253
Starting Motor Components
257
Starting Motor Inspection
258
Specifications
261
Charging System
262
General Description
262
Generator Description
264
Battery Inspection
266
Generator Symptom Diagnosis
266
Generator Test (Undercharged Battery)
267
Check
268
Generator Test (Overcharged Battery)
268
Repair Instructions
269
Battery Removal, Handling and Installation . 1J-9
270
Generator Removal and Installation
271
Generator Components
272
Generator Inspection
276
Specifications
280
Exhaust System
282
General Description
282
Exhaust System Description
282
Diagnostic Information and Procedures
282
Exhaust System Check
282
Repair Instructions
283
Exhaust System Components
283
Exhaust Manifold Removal and Installation
285
Suspension
288
Precautions
290
Precautions on Suspension
290
2A-2 Suspension General Diagnosis
291
Front Suspension
296
General Description
296
Diagnosis
299
Diagnosis Table
299
Strut Assembly Check
299
Suspension Control Arm/Steering Knuckle Check
300
Suspension Control Arm Joint Check
300
Wheel Disc, Nut and Bearing Check
300
On-Vehicle Service
301
Strut Assembly
301
Wheel Hub and Steering Knuckle
306
Suspension Control Arm/Bushing
311
Required Service Material
314
Special Tools
314
Rear Suspension
316
General Description
317
Diagnosis
318
Diagnosis Table
318
Rear Shock Absorber Check
318
Trailing Arm, Lateral Rod, Rear Axle and Coil Spring Check
318
Bump Stopper and Spring Upper Seat Check
319
Rear Suspension Fasteners
319
Wheel Disc, Nut and Bearing Check
319
On-Vehicle Service
320
Lateral Rod
321
Rear Shock Absorber
322
Coil Spring
322
Bump Stopper
324
Spring Upper Seat
325
Trailing Arm
325
Rear Axle
328
Wheel Bearing and Wheel Stud
332
Special Tools
334
Wheels and Tires
336
General Description
336
Tires
336
Wheels
336
Replacement Tires
336
Replacement Wheels
337
How to Measure Wheel Runout
337
Wheel Maintenance
338
Wheel Attaching Studs
338
Matched Tires and Wheels
338
Inflation of Tires
339
Tire Placard
339
Tire Rotation
339
On-Vehicle Service
340
Service Operations
340
Metric Lug Nuts and Wheel Studs
340
Wheel Removal
340
Tire Mounting and Demounting
340
Tire Repair
341
Balancing Wheels
341
General Balance Procedures
342
Off-Vehicle Balancing
342
On-Vehicle Balancing
342
Tire Diagnosis
343
Irregular and or Premature Wear
343
Wear Indicators
343
Radial Tire Waddle
343
Radial Tire Lead
345
Vibration Diagnosis
345
Front Drive Shaft
346
General Description
348
Removal & Installation
348
Disassembly & Reassembly
349
Diagnosis
350
Diagnosis Table
350
On-Vehicle Service
351
Drive Shaft Assembly
351
Removal
351
Disassembly (Tripod Jopint Type)
352
Inspection
353
Reassembly (Tripod Jopint Type)
354
Installation
358
Required Service Materials
359
Brakes
362
General Description
363
Front Disc Brake Caliper Assembly
363
Rear Drum Brake Assembly
364
Master Cylinder Assembly
365
Booster Assembly
366
Proportioning Valve
367
Diagnosis
368
Road Testing Brakes
368
Brake Fluid Leaks
368
Substandard or Contaminated Brake Fluid
368
Diagnosis Table
369
On-Vehicle Service
372
Brake Pedal Free Height Adjustment
372
Stop Light Switch Adjustment
372
Excessive Pedal Travel Check
372
Front Brake Disc Inspection
373
Front Brake Pad Lining Inspection
373
Rear Brake Shoe Inspection
373
Brake Pedal Play Inspection
374
Master Cylinder Inspection
374
Rear Drum Brake Shoe Adjustment
374
Parking Brake Inspection and Adjustment
374
Flushing Brake Hydraulic System
375
Bleeding Brakes
376
Brake Hose and Pipe Inspection
377
Brake Fluid Level Inspection
377
Repair
378
Front Brake Hose/Pipe
378
Rear Brake Hose/Pipe
379
Parking Brake Lever
380
Parking Brake Cable
381
Brake Pad
383
Caliper Assembly
385
Brake Disc
389
Brake Drum
390
Brake Shoe
393
Wheel Cylinder
395
Brake Back Plate
396
Master Cylinder Assembly
398
Brake Booster
402
Required Service Materials
407
Special Tools
407
Brakes (with ABS)
408
Diagnosis
409
Road Testing Brakes
409
Brake Fluid Leaks
409
Substandard or Contaminated Brake Fluid
409
Diagnosis Table
410
On-Vehicle Service
413
Bleeding Brakes
413
Brake Hose and Pipe Inspection
414
Brake Fluid Level Inspection
414
Booster Operation Inspection
415
Brake Hose/Pipe
417
Front Brake Hose/Pipe
417
Rear Brake Hose/Pipe
419
Front Brake
421
Brake Pad
422
Caliper Assembly
424
Brake Disc
428
Rear Brake
429
Brake Drum
430
Brake Shoe
432
Wheel Cylinder
435
Brake Back Plate
436
Master Cylinder Assembly
438
Brake Booster
443
Required Service Materials
446
Special Tools
446
General Description
449
Components/Parts Location and Brake Hose/Pipe Routing
449
System Schematic
450
ABS Hydraulic Unit Control Module
451
Self-Diagnosis Function
451
Fail-Safe Function
451
System Circuit
452
Diagnosis
454
Precaution in Diagnosing
454
ABS Diagnostic Table
455
ABS Warning Lamp Check
458
Diagnostic Trouble Code (DTC) Check (Using SUZUKI Scan Tool)
461
Diagnostic Trouble Code
461
Diagnostic Trouble Code (DTC) Table
464
DTC C1021, DTC C1022 Right-Front Wheel Speed Sensor Circuit or Sensor Rotor
465
DTC C1025, DTC C1026 Left-Front Wheel Speed Sensor Circuit or Sensor Rotor
465
DTC C1031, DTC C1032 Right-Rear Wheel Speed Sensor Circuit or Sensor Rotor
465
DTC C1035, DTC C 1036 Left-Rear Wheel Speed Sensor Circuit or Sensor Rotor
465
DTC C1041 Right-Front Inlet Solenoid Circuit
467
DTC C1045 Left-Front Inlet Solenoid Circuit
467
DTC C1051 Right-Rear Inlet Solenoid Circuit
467
DTC C1055 Left-Rear Inlet Solenoid Circuit
467
DTC C1042 Right-Front Outlet Solenoid Circuit
467
DTC C1052 Right-Rear Outlet Solenoid Circuit
467
DTC C1056 Left-Rear Outlet Solenoid Circuit
467
DTC C1057 Power Source Circuit
468
DTC C1061 ABS Pump Motor Circuit
469
DTC C1063 ABS Fail-Safe Relay Circuit
470
DTC C1071 ABS Control Module
471
Abs
472
On-Vehicle Service
472
Precautions
472
ABS Hydraulic Unit Operation Check (Using SUZUKI Scan Tool)
472
ABS Hydraulic Unit/Control Module Assembly
473
Front Wheel Speed Sensor
475
Front Wheel Speed Sensor Rotor
477
Rear Wheel Speed Sensor
478
Rear Wheel Speed Sensor Rotor
481
Special Tool
481
Transmission
484
Manual Transmission
486
General Description
486
Gear Shift Mechanism
488
Diagnosis
490
On-Vehicle Service
491
Oil Change
491
Differential Side Oil Seal
492
Gear Shift Control Lever and Rod
494
Vehicle Speed Sensor (VSS)
495
Dismounting of Transmission
496
Remounting
497
Unit Repair Overhaul
498
Disassembling Unit
498
Fifth Gear
498
Gear Shifter, Main Shaft and Countershaft
499
Right Case
501
Sub Assembly Service
502
Right Case
502
Left Case
503
Input Shaft Assembly
503
Countershaft Assembly
506
Gear Shifter
509
Differential Assembly
511
Assembling Unit
513
Differential to Left Case
513
Fifth Gear
516
Gear Shift & Select Shaft Assembly
519
Required Service Materials
520
Special Tools
521
5C-2 Clutch
524
General Description
524
Diagnosis
525
Clutch
526
On-Vehicle Service
526
Maintenance Service
526
Clutch Pedal
526
Clutch Cable
526
Unit Repair Overhaul
528
Clutch Cover, Clutch Disc and Flywheel
528
Clutch Release System
531
Required Service Materials
534
Special Tools
534
Pr Ecautions
535
Steering General Diagnosis
537
Diagnosis
537
Diagnosis Table
537
Steering Wheel and Column
539
General Description
540
Steering Wheel and Driver Air Bag (Inflator) Module
540
Diagnosis
541
Inspection and Repair Required after Accident
541
On-Vehicle Service
541
Centering Contact Coil
545
Installation
547
Steering Column Assembly and Steering
548
Installation
550
Steering Lock Assembly (Ignition Switch)
553
Checking Steering Column Assembly and Lower Shaft for Accident Damage
554
Required Service Material
555
Electrical Power Steering System
557
General Description
557
Diagnosis
559
On-Board Diagnostic System
559
System Check Flow Table
560
DTC Check
562
DTC Clearance
562
DTC Table
563
Trouble Diagnosis
573
Steering Wheel Play Inspection
574
Steering Force Inspection
574
On-Vehicle Service
575
Steering Column Assembly
575
P/S Control Module
575
Torque Sensor
576
Manual Rack and Pinion
579
General Description
579
Steering Wheel Check
580
Steering Rack Boot Check
580
Tie Rod End Boot Check
581
Steering Shaft Joint Check
581
Tie Rod End Check
581
On-Vehicle Service
581
Lubrication
581
Manual Rack and Pinion Assembly
583
Disassembly
584
Inspection
587
Reassembly
588
Special Tool
588
Hvac
595
Precautions
597
Heater and Ventilation
598
7A-2 Heater and Ventilation
599
Schematic and Routing Diagram
599
Heater and Ventilation Wiring Circuit Diagram
599
Diagnostic Information and Procedures
599
Repair Instructions
600
HVAC Unit Components
600
HVAC Unit Removal and Installation
600
Blower Motor Removal and Installation
601
Blower Motor Inspection
601
Blower Motor Resistor Removal and Installation
602
Blower Motor Resistor Inspection
602
Blower Motor Relay Inspection
602
HVAC Control Unit Components
603
HVAC Control Unit Removal and Installation
603
Blower Speed Selector Inspection
605
Center Ventilation Louver Removal and Installation
606
Side Ventilation Louver Removal and Installation
606
Air Conditioning System
609
Manual Type
609
Precautions
609
A/C System Caution
609
Precautions on Servicing A/C System
609
Refrigerant Type Identification
609
Sub-Cool A/C System Description
611
Schematic and Routing Diagram
612
Major Components of A/C System
612
A/C System Wiring Diagram
613
Diagnostic Information and Procedures
614
A/C System Symptom Diagnosis
614
Abnormal Noise Symptom Diagnosis of A/C System
616
A/C System Performance Inspection
617
A/C System Inspection at ECM
623
Repair Instructions
625
Installation
633
Evaporator Inspection
635
Installation
635
A/C Switch Inspection
638
Compressor Relay Inspection
639
Adjustment
639
Compressor Drive Belt Removal and Installation
639
Compressor Assembly Removal and Installation
640
Compressor Assembly Components
641
Magnet Clutch Inspection
641
Magnet Clutch Removal and Installation
641
Special Tool
641
Restraint
649
Seat Belts
651
General Description
651
Seat Belt with ELR
651
Seat Belt on Vehicle Service
651
Service Precautions
651
Service and Diagnosis
651
Front Seat Belt
652
Removal
652
Warning
652
Caution
655
8B-2 Air Bag System
656
General Description
656
Diagnosis
665
Table
665
DTC B1051 - Frontal Crash Detected
682
DTC B1013 - System Specifications Different from SDM Specifications
684
On-Vehicle Service
685
Service Precautions
685
Disabling Air Bag System
686
Enabling Air Bag System
686
Handling and Storage
687
Sdm
687
AIR BAG (Inflator) Module Disposal
694
Deployment/Activation Outside of Vehicle
695
Deployment/Activation Inside of Vehicle
699
Deployed Air Bag (Inflator) Module Disposal
702
Tightening Torque Specification
703
Body, Cab and Accessories
705
Lighting Systems
707
Component Location
707
Headlight
708
Brake Light
709
Repair Instructions
709
Bulb Replacement
710
Combination Switch Assembly
711
Inspection
714
License Lamp Assembly Removal and
715
Front Fog Light Assembly Removal and Installation (if Equipped)
715
Front Fog Light Bulb Replacement
716
Front Fog Light Switch Inspection
716
Front Fog Light Relay Inspection
716
Headlight Leveling Switch (if Equipped) Inspection
717
Headlight Leveling Actuator Inspection (if Equipped)
717
Combination Meter Circuit Diagram
719
Speedometer and VSS
720
Oil Pressure Light
720
Brake and Parking Brake Warning Light
720
Ignition Key Reminder / Light Reminder
721
Horn
721
Repair Instructions
721
Ignition Switch Removal and Installation
721
Switch Inspection
722
Installation
723
Oil Pressure Switch Inspection
724
Installation
725
Inspection
725
Wipers / Washers
729
Front Wiper and Washer Symptom Diagnosis
729
Repair Instructions
730
Wipers and Washers
730
Intermittent Wiper Relay Circuit
731
Washer Linked Operation
732
9E-2 Glass / Windows / Mirrors
736
9E-4 Glass / Windows / Mirrors
738
Repair Instructions
738
Windshield Removal and Installation
738
Front Door Window Regulator Removal
746
Installation
746
Rear Door Window Regulator Removal
749
Back Door Glass Removal and Installation
750
Back Door Window Defogger Switch
751
Inspection (if Equipped)
751
Back Door Window Defogger Wire
751
Power Window Main Switch Inspection
752
Power Window Sub Switch Inspection
754
Security and Locks
755
Installation
756
Installation
757
Key Coding
759
Ignition Switch Lock Cylinder
759
Electrical Diagnosis
759
Seats
761
Interior Trim
763
Hood / Fenders / Doors
767
Installation
767
Installation
768
Installation
770
Body Structure
773
Body Dimensions
774
Panel Clearance
779
9L-2 Paint / Coatings
782
Metal Replacement Parts Finishing
782
Plastic Parts Finishing
787
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