Page 1 Service on and around the air bag system ings. Pay special attention to the messages high- components or wiring must be performed lighted by these signal words. only by an authorized SUZUKI dealer. Please observe all WARNINGS and CAU- WARNING: TIONS in SECTION 10B and Precautions,...
Page 2 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 3 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION GENERAL INFORMATION ENGINE General Information General Information and Diag- Maintenance and Lubrication nosis Engine Mechanical (Type: HEATING AND AIR CONDI- K10A) TIONING Engine Cooling Heater and Ventilation Engine Fuel Air Conditioning Engine and Emission Control (If Equipped) System STEERING, SUSPENSION,...
Page 4: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ..............0A- 2 PRECAUTIONS .
Page 5: How To Use This Manual
0A-2 GENGERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
Page 6: Precautions
If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 7: Servicing And Handling
0A-4 GENGERAL INFORMATION SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY FROM BODY. WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature...
Page 8 GENERAL INFORMATION 0A-5 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 han- dling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM.
Page 9 0A-6 GENGERAL INFORMATION CAUTION: Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions un- der “Repair and Inspection Required after an Acci- dent”...
Page 10: General Precautions
GENERAL INFORMATION 0A-7 GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
Page 11 0A-8 GENGERAL INFORMATION When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be re- installed in the proper order and position.
Page 12: Precautions For Catalytic Converter
GENERAL INFORMATION 0A-9 When disconnecting vacuum hoses, attach a tag describ- ing 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. For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
Page 13: Precautions For Electrical Circuit Service
0A-10 GENGERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. 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 14: Electrical Circuit Inspection Procedure
GENERAL INFORMATION 0A-11 When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. Before measuring voltage to check for electrical system, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.
Page 15 0A-12 GENGERAL INFORMATION 3) Using a test male terminal, check both terminals of the circuit being checked for contact tension of its female terminal. Check contact tension by inserting and removing just for Check each terminal visually for poor contact (possibly caused once by dirt, corrosion, rust, entry of foreign object, etc.).
Page 16 GENERAL INFORMATION 0A-13 If measurements were taken as shown in the figure at the left and results were as listed below, it means that the circuit is open be- tween terminals B-1 and A-1. Voltage Between: C-1 and body ground: Approx. 5V B-1 and body ground: Approx.
Page 17: Intermittent And Poor Connection
0A-14 GENGERAL INFORMATION INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 18: Precaution For Installing Mobile Communication Equipment
GENERAL INFORMATION 0A-15 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Cit- izens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely affect electronic control system. Keep the antenna as far away as possible from the vehicle’s electronic control unit.
Page 19: Warning, Caution And Information Labels
0A-16 GENGERAL INFORMATION WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
Page 20: Vehicle Lifting Points
GENERAL INFORMATION 0A-17 VEHICLE LIFTING POINTS WARNING: Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending of 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 21 0A-18 GENGERAL INFORMATION In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the jack against front jacking bracket (1) or the center portion of rear axle (2). WARNING: Never apply jack against suspension parts (i.e., stabi- lizer, etc.) or vehicle floor, or it may get deformed.
Page 22: Abbreviations May Be Used In This Manual
GENERAL INFORMATION 0A-19 ABBREVIATIONS MAY BE USED IN THIS MANUAL : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Engine Control Module : Automatic Locking Retractor ECT Sensor : Engine Coolant Temperature...
Page 23 0A-20 GENGERAL INFORMATION : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch : Transmission Control Module MAF Sensor : Mass Air Flow Sensor (A/T Controller, A/T Control (Air Flow Sensor, AFS, Air Module) Flow Meter, AFM)
Page 24: Metric Information
GENERAL INFORMATION 0A-21 METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric. When replac- ing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 7T and radial line with the class identification embossed on the head of each bolt.
Page 25 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 26: Maintenance Schedule
0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the Interval: same services at the same intervals respectively. This interval should be judged by odometer This interval should be judged by odometer km ( 1,000)
Page 27 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the Interval: same services at the same intervals respectively. This interval should be judged by odometer This interval should be judged by odometer km ( 1,000)
Page 28 0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 29: Maintenance Service
MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and replacing belt tension. Water pump belt inspection 1) Inspect belt for cracks, cuts, deformation, wear and cleanliness. Replace if any defect exists.
Page 30 0B-6 MAINTENANCE AND LUBRICATION ITEM 1-2 Valve Lash Inspection Inspect intake and exhaust valve lash and adjust as necessary. Refer to Section 6A4 for valve lash inspection and adjustment pro- cedure. 1. Camshaft 2. Thickness gauge ITEM 1-4 Proper Engine Oil Viscosity Chart Engine Oil and Filter Change WARNING: New and used engine oil can be hazardous.
Page 31 MAINTENANCE AND LUBRICATION 0B-7 6) Tighten filter 3/4 turn from the point of contact with mounting sur- face using an oil filter wrench. Special Tool (A): 09915-47340 Tightening Torque (Reference) (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) 7) Replenish oil until oil level is brought to FULL level mark on dip- stick (oil pan and oil filter capacity).
Page 32 0B-8 MAINTENANCE AND LUBRICATION 6) Add coolant to reservoir so that its level aligns with Full mark. Then, reinstall cap to reservoir aligning match marks (1) on the reservoir and cap. CAUTION: When changing engine coolant, use mixture of 50% water and 50% ethylene-glycol base coolant (Anti- Freeze/Anti-corrosion coolant) for the market where ambient temperature falls lower than –16 C (3 F) in...
Page 33: Ignition System
MAINTENANCE AND LUBRICATION 0B-9 IGNITION SYSTEM ITEM 2-1 Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1. ITEM 2-2 Distributor Cap and Rotor Inspection 1) Remove air cleaner case. 2) Inspect distributor cap and rubber caps for cracks. 3) Inspect center electrode and terminals for wear.
Page 34: Emission Control System
0B-10 MAINTENANCE AND LUBRICATION ITEM 3-2 Fuel Lines Inspection Check fuel lines for loose connection, deterioration or damage which could cause leakage. Make sure all clamps are secure. Replace any damaged or deteriorated parts. There should be no sign of fuel leakage or moisture at any fuel con- nection.
Page 35: Brake
MAINTENANCE AND LUBRICATION 0B-11 BRAKE ITEM 5-1 Brake Discs, Pads, Drums and Shoes Inspection Brake discs and pads 1) Remove wheel and caliper but don’t disconnect brake hose from caliper. 2) Check front disc brake pads and discs for excessive wear, dam- age and deflection.
Page 36: Chassis And Body
0B-12 MAINTENANCE AND LUBRICATION ITEM 5-3 Brake Fluid Change Change brake fluid as follows. Drain existing fluid from brake system completely, fill system with specified fluid and carry out air purge operation. For air purging procedure, refer to Section 5. ITEM 5-4 “a”: Parking brake lever stroke: 7-9 notches (With 20 kg or...
Page 37 MAINTENANCE AND LUBRICATION 0B-13 ITEM 6-2 Tire and Wheel Disc Inspection [Tire inspection] 1) Check tire for uneven or excessive wear, or damage. If defec- tive, replace. 1. Wear indicator 2) Check inflating pressure of each tire and adjust pressure to specification as necessary.
Page 38 0B-14 MAINTENANCE AND LUBRICATION ITEM 6-4 Suspension System Inspection Inspect front strut and rear shock absorber for evidence of oil leakage, dents or any other damage on sleeves; and inspect an- chor ends for deterioration. Replace defective parts, if any. Check front and rear suspension systems for damaged, loose or missing parts;...
Page 39 MAINTENANCE AND LUBRICATION 0B-15 ITEM 6-6 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 40 0B-16 MAINTENANCE AND LUBRICATION [Fluid change] 1) Perform steps 1) and 2) of above Fluid Level inspection. 2) Change fluid with new specified fluid. For its procedure, refer to Section 7B. 1. Drain plug ITEM 6-8 All Latches, Hinges and Locks Inspection Doors Check that each door of front, rear and back doors opens and closes smoothly and locks securely when closed.
Page 41: Final Inspection
MAINTENANCE AND LUBRICATION 0B-17 FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is Clutch is completely released when depressing seen so as to prevent any accident.
Page 42: Recommended Fluids And Lubricants
0B-18 MAINTENANCE AND LUBRICATION Steering Meters and Gauge Check to ensure that steering wheel is free from in- Check that speedometer, odometer, fuel meter, tem- stability, or abnormally heavy feeling. perature gauge, etc. are operating accurately. Check that the vehicle does not wander or pull to Lights one side.
Page 43 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 44: General Description
1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets at places, right and left, along the windshield glass.
Page 45: Heater Unit
HEATER AND VENTILATION 1A-3 HEATER UNIT 1. Heater core 2. Blower motor assembly 3. Blower motor resistor 4. Temp door assembly 5. Mode door assembly 6. Mode lever 7. Temp lever assembly 8. Heater case...
Page 46: Air Inlet Box
1A-4 HEATER AND VENTILATION AIR INLET BOX 1. Cooling unit packing 2. Dash packing 3. Packing 4. Drain packing 5. Air resistance board 6. Door link 7. Air inlet door 8. Evaporator case HEATER CONTROL LEVER ASSEMBLY 1. Heater control lever assembly 2.
Page 47: Diagnosis
HEATER AND VENTILATION 1A-5 DIAGNOSIS DIAGNOSIS TABLE Trouble Possible Cause Remedy Heater blower won’t work Blower fuse blown Check for short to ground and replace even when its switch is fuse. Blower motor resistor faulty Check resistor. Blower fan switch faulty Check blower fan switch.
Page 48: On Vehicle Service
1A-6 HEATER AND VENTILATION ON VEHICLE SERVICE BLOWER MOTOR REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disable air bag system, if equipped. Refer to DISABLING AIR BAG SYSTEM in Section 10B. 3) Remove column hole cover. 4) Disconnect blower motor coupler. 5) Remove blower motor.
Page 49: Heater Control Lever Assembly
HEATER AND VENTILATION 1A-7 INSPECTION Measure each terminal-to-terminal resistance on resistor Resistance Me – Lo : 1.5–3.0 at 25 C (77 F) Me – Hi : 0.5–1.5 at 25 C (77 F) If measured resistance is incorrect, replace blower motor resistor. INSTALLATION 1) Reverse removal procedure for installation.
Page 50: Blower Fan Switch
1A-8 HEATER AND VENTILATION INSTALLATION 1) Reverse removal procedure for installation. 2) Adjust the following items. i) Move mode control lever (a), temperature control lever (b) and fresh air control lever (c) fully in arrow direction as shown in figure. ii) Push mode lever (d), temperature lever (e) and door link (f) fully in arrow direction and fix cable with clamp in position as shown in figure.
Page 51: Heater Unit
HEATER AND VENTILATION 1A-9 INSPECTION Check blower fan switch for each terminal-to-terminal continuity. For the detail refer to “WIRING CIRCUIT” earlier in this section. TERMINAL POSITION HEATER UNIT REMOVAL 1) Disconnect negative (–) cable at battery. 2) If equipped with air bag system disable air bag system. Refer to DISABLING AIR BAG SYSTEM in Section 10B.
Page 52: Ventilation Louver
1A-10 HEATER AND VENTILATION VENTILATION LOUVER REMOVAL AND INSTALLATION Remove ventilation louver (1) as shown in figure, and reverse re- moval sequence to install ventialtion louver. 2. Rag CAUTION: When the heater unit is disassembled and reassembled, locking force of the heater case lock may reduce. In such a case, tighten the heater case with a tapping screw (1) of M4 L16 as shown in the left figure, or air may leak from its joint section.
Page 53 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 54: Refrigerant Flow Of Air Conditioning System
1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION Whether the A/C in the vehicle being serviced uses HFC-134a or CFC-12 is indicated on LABEL on the compressor. Also, it can be checked by the shape of the service (charge) valve. HFC-134a CFC-12 1.
Page 55: Major Components And Location
AIR CONDITIONING (OPTIONAL) 1B-3 MAJOR COMPONENTS AND LOCATION 1. Cooling unit 2. Compressor 3. Condenser assembly 4. Receiver/dryer 5. Discharge hose 6. Suction hose 7. Receiver dryer outlet hose 8. Liquid pipe 9. Expansion valve 10. Ventilation air 11. Foot air 12.
Page 56: Diagnosis
1B-4 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction Cool air does not come out A/C system inoperative (A/C system improper No refrigerant Recover, evacuation and charging. operative) Fuse blown Check “TURN” fuse, “HEATER” fuse and check short circuit to ground. A/C switch faulty Check A/C switch.
Page 57 AIR CONDITIONING (OPTIONAL) 1B-5 Condition Possible Cause Correction Cool air does not come out Compressor faulty Check compressor. or insufficient cooling (A/C Air in A/C system Replace receiver/dryer, and evacua- system normal operative) tion and charging. Air leaking from cooling unit or air duct Repair as necessary.
Page 58: Quickly Checking Of Refrigerant Charge
1B-6 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT CHARGE CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its max. cooling capacity for a few minutes.
Page 59: Troubleshooting Procedure Using
AIR CONDITIONING (OPTIONAL) 1B-7 TROUBLESHOOTING PROCEDURE USING MANIFOLD GAUGE SET This procedure enables the technician to discover and repair cool- ing problems by having the pressures of both the high and low pressure sides indicated on the respective gauges of the manifold gauge set.
Page 60 1B-8 AIR CONDITIONING (OPTIONAL) MANIFOLD kg/cm CONDITION CAUSE CORRECTION GAUGE 0.15 – 0.25 1.37 – 1.57 1.5 – 2.5 14 – 16 Normal condition. 21.3 – 35.5 200 – 227 The low pressure side Dust particles or water Clean expansion valve. reads a negative pressure, droplets are either Replace it if it cannot be...
Page 61: Wiring Circuit
AIR CONDITIONING (OPTIONAL) 1B-9 WIRING CIRCUIT G/Or P/BI Br/W 1. Blower motor 2. Blower resistor 3. Blower & A/C switch 4. Dual pressure switch 5. ECT sensor 6. A/C Evaporator thermistor 7. Radiator (and condenser) cooling fan relay 8. Radiator (and condenser) cooling fan motor 9.
Page 62: A/C System Inspection Of Ecm And Its Circuits
1B-10 AIR CONDITIONING (OPTIONAL) A/C SYSTEM INSPECTION OF ECM AND ITS CIRCUITS ECM and its Circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from it.
Page 63: A/C Compressor Drive Belt Inspection
AIR CONDITIONING (OPTIONAL) 1B-11 TERMINAL CIRCUIT CONDITION NORMAL VALUE Radiator (and condens- A/C switch ON and Blower fan switch ON with en- er) cooling fan motor gine running or engine coolant temperature higher 0 – 1 volt relay output than preset temperature with ignition switch ON Except the above condition at ignition switch ON 10 –...
Page 64: Recovery, Evacuation And Charging
1B-12 AIR CONDITIONING (OPTIONAL) RECOVERY, EVACUATION AND CHARGING OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT Recharge 530 30 g of refrigerant in gas form REFRIGERANT RECOVERY When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharging it into atmosphere would cause adverse effect to envi- ronments.
Page 65: On-Vehicle Service
AIR CONDITIONING (OPTIONAL) 1B-13 ON-VEHICLE SERVICE CAUTION: When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe the following instructions. When disconnecting any line from the system, install a bling plug or cap to fitting of such line im- mediately.
Page 66: Receiver/Driver
1B-14 AIR CONDITIONING (OPTIONAL) INSPECTION Check the following. Condenser fins for leakage, blockage and damage Condenser fittings for leakage Clogged condenser fins should be washed with water, and should be dried with compressed air. NOTE: Be careful not to damage condenser fins. If condenser fin is bent, straighten it by using a screwdriver or pair of pliers.
Page 67: Radiator (And Condenser) Cooling Fan Motor
AIR CONDITIONING (OPTIONAL) 1B-15 RADIATOR (AND CONDENSER) COOLING FAN MOTOR INSPECTION Check continuity between each two terminals. If check results are continuity, proceed to next operation check. If not, replace. 1. Radiator (and condenser) cooling fan motor Connect battery to radiator (and condenser) cooling fan motor (1) as shown, then check that the radiator (and conderser) cooling fan motor operates smoothly.
Page 68: Cooling Unit
1B-16 AIR CONDITIONING (OPTIONAL) COOLING UNIT (EVAPORATOR) 1. Evaporator 2. A/C Evaporator thermistor (Evaporator temperature sensor) 3. Expansion valve 4. Evaporator case 5. Packing 6. Drain hose 7. Air inlet door 8. O-ring REMOVAL 1) Disconnect negative (–) cable at battery. 2) Recover refrigerant from refrigeration system by using recovery and recycling equipment.
Page 69: A/C Evaporator Thermistor
AIR CONDITIONING (OPTIONAL) 1B-17 Evacuate and charge system according to previously described procedure. Adjust heater control cable, refer to HEATER CONTROL LE- VER ASSEMBLY in HEATER AND VENTILATION section. Enable air bag system, if equipped. Install the cutting part of drain hose (2) downward as shown in figure.
Page 70: Expansion Valve
1B-18 AIR CONDITIONING (OPTIONAL) EXPANSION VALVE Refer to “Troubleshooting Procedure Using Manifold Gauge Set” earlier in this Section, 1. Expansion valve DUAL PRESSURE SWITCH INSPECTION 1) Check dual pressure switch (1) for continuity at normal temper- ature (approx. 25 C (77 F)) when A/C system has a proper charge of refrigerant and when A/C system (compressor) is un- der operation.
Page 71: Radiator (And Condenser) Cooling Fan Relay
AIR CONDITIONING (OPTIONAL) 1B-19 RADIATOR (AND CONDENSER) COOLING FAN RELAY INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove radiator cooling fan relay (1) from vehicle. 3) Connect battery positive (+) terminal to terminal “b” of relay. Connect battery negative (–) terminal “a” of relay. Check continuity between terminal “c”...
Page 72 1B-20 AIR CONDITIONING (OPTIONAL) Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION” in this Section. CAUTION: Be sure to use HFC-134a (R-134a) compressor oil NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Oil amount in compressor: 120 cm (120 cc, 7.5 in REPLENISHING COMPRESSOR OIL...
Page 73: Magnet Clutch
AIR CONDITIONING (OPTIONAL) 1B-21 MAGNET CLUTCH REMOVAL AND INSTALLATION Refer to AIR CONDITIONING BASIC MANUAL (99520-02130) 23 N·m (2.3 kg-m) 14 N·m (1.4 kg-m) a. Front head bolt b. Front head bolt : Tighten bolt (a) first, and 14 N·m (1.4 kg-m) next (b).
Page 74 1B-22 AIR CONDITIONING (OPTIONAL) REMOVAL 1) Remove compressor from vehicle. Refer to COMPRESSOR in this section. 2) Fix armature plate with special tool (A) and remove armature plate screw. Special Tool (A): 09991-06020 1. Armature plate 2. Screw NOTE: 3. Washer Do not reuse armature plate nut.
Page 75 AIR CONDITIONING (OPTIONAL) 1B-23 INSTALLATION 1) Install magnet clutch coil. Protrusion on under side of coil ring must match hole in com- pressor assembly to prevent movement ant correctly locate lead wire. 2) Using special tool (C), install snap ring as shown. Special Tool 1.
Page 76 1B-24 AIR CONDITIONING (OPTIONAL) LIP TYPE SEAL (SEIKO SEIKI COMPRESSOR) REMOVAL 1) Remove magnet clutch, referring to “MAGNET CLUTCH” in this section. 2) Remove front head mounting screw (10 pcs). 1. Front head 3) Remove front head by pushing cylinder shaft. NOTE: Be careful not to remove cylinder from case.
Page 77 AIR CONDITIONING (OPTIONAL) 1B-25 2) Coat special tool (F) surface with oil and place it on the shaft. Special Tool (F): 09991-06040 3) Install O-ring to case. 4) Apply A/C oil to lip seal and O-ring. 5) Install front head assembly. 1.
Page 78: Performance Test
1B-26 AIR CONDITIONING (OPTIONAL) PERFORMANCE TEST 1) Confirm that vehicle and environmental conditions are as fol- lows. – Vehicle is not exposed to direct sun. – Ambient temperature is within 15 C – 35 C (59 F – 95 F) 2) Connect high and low side charging hoses of manifold gauge to hose fittings of A/C component.
Page 79 AIR CONDITIONING (OPTIONAL) 1B-27 8) Check inlet port temperature-to-outlet port temperature rela- 68 20 tionship using graph at the left. 66.2 19 For example, if evaporator inlet port temperature is 25 C (77 F) 64.4 18 62.6 17 and center duct air outlet temperature is 8 C (46.4 F), their 60.8 16 crossing point is within acceptable range as shown in graph at 59 15...
Page 80 1B-28 AIR CONDITIONING (OPTIONAL) TESTING RESULTS POSSIBLE CAUSE REMEDY Pressure high Refrigerant overcharged Recharge (“A” area of high side Expansion valve frozen or clogged Check expansion valve graph) Clogged refrigerant passage of high side Clean or replace Insufficient Condenser fan malfunction Check condenser fan cooling of Dirty or bent condenser fins...
Page 81: Special Tools
AIR CONDITIONING (OPTIONAL) 1B-29 SPECIAL TOOLS 09900-06107 09991-06020 Snap ring pliers 09991-06010 09991-06030 Armature plate spanner (Opening type) Magnet clutch pulley installer Armature plate remover 09991-06040 09991-06050 Lip type seal protector Lip type seal installer...
Page 82 STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS ............... FRONT END ALIGNMENT .
Page 83 3-2 STEERING, SUSPENSION, WHEELS AND TIRES DIAGNOSIS GENERAL DIAGNOSIS Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defects which are found.
Page 84 STEERING, SUSPENSION, WHEELS AND TIRES 3-3 Condition Possible Cause Correction Shimmy, Shake or Tire or wheel out of balance. Balance wheels or replace tire and/or Vibration wheel. Loosen wheel bearings. Replace wheel bearing. Worn tie rod ends. Replace tie rod end. Worn lower ball joints.
Page 85 3-4 STEERING, SUSPENSION, WHEELS AND TIRES Condition Possible Cause Correction Rack and Pinion Loose steering gear case bolts. Tighten. Noise Worn rack bush. Replace. (Rattle or Chuckle) Rack and pinion adjustment. Check and adjust rack and pinion torque. Abnormal Noise, Worn, sticky or loose tie rod ends, lower Replace tie rod end, suspension arm, tie Front End...
Page 86 STEERING, SUSPENSION, WHEELS AND TIRES 3-5 Condition Possible Cause Correction Low or Uneven Trim Broken or sagging springs. Replace. Height Over loaded. Check loading. Right-to-left trim height Incorrect springs. Replace. (H) difference should be within 10 mm (0.4 in.) with curb weight.
Page 87 3-6 STEERING, SUSPENSION, WHEELS AND TIRES TIRE DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear has many causes. Some of them are: incorrect inflation pressures, lack of tire rotation, driving habits, im- proper alignment. If the following conditions are noted, rotation is necessary: 1) Front tire wear is different from rear.
Page 88 STEERING, SUSPENSION, WHEELS AND TIRES 3-7 1) Ride vehicle to determine whether the front or rear waddles. 2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end of ve- hicle.
Page 89 3-8 STEERING, SUSPENSION, WHEELS AND TIRES RADIAL TIRE LEAD “Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering wheel. Lead is usually caused by: 1) Incorrect alignment. 2) Uneven brake adjustment.
Page 90 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT CONTENTS DIAGNOSIS ......Preliminary Checks Prior to Adjusting Front Alignment .
Page 91 3A-2 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel.
Page 92 FRONT END ALIGNMENT 3A-3 STEERING ANGLE When tie rod or tie rod end was replaced, check toe and then also steering angle with turning radius gauge. If steering angle is not correct, check if right and left tie rods are equal in length “A”.
Page 93 MANUAL RACK AND PINION 3B-1 SECTION 3B MANUAL RACK AND PINION NOTE: All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 94: Diagnosis
3B-2 MANUAL RACK AND PINION DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STEERING WHEEL CHECK Check steering wheel for play and rattle, holding vehicle in straight forward condition on the ground. Steering wheel play “a”: 0 – 30 mm (0 – 1.18 in) If steering wheel play is not within specification, inspect as follows and replace if found defective.
Page 95: Tie Rod End Boot Check
ON-VEHICLE SERVICE LUBRICATION When inner parts of the steering gear case were disas- SUZUKI SUPER GREASE E (99000-25050) or sembled, they should be washed clean before reas- Lithium grease (applicable for –40 C ~ 130 C sembly. It is recommended to use the grease as given (–40 F ~ 266 F))
Page 96 40 N·m (4.5 kg-m) 95 N·m (9.5 kg-m) 25 N·m (2.5 kg-m) 1. Steering rack : Apply SUZUKI SUPER GREASE E 99000-25050 to entire surface of rack. 2. Tie-rod lock washer 3. Steering tie-rod : Apply SUZUKI SUPER GREASE E 99000-25050 to rack end ball joint.
Page 97: Manual Rack And Pinion Assembly
MANUAL RACK AND PINION 3B-5 MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE) REMOVAL 1) Remove steering joint cover (1). 2) Loosen steering shaft upper joint bolt (1). Then remove steering shaft lower joint bolt (2). 3) Remove steering lower joint from steering pinion. 4) Hoist vehicle and remove wheels.
Page 98 3B-6 MANUAL RACK AND PINION DISASSEMBLY 1) Remove steering gear case. 2) For ease of adjustment after installation, make marking (1) on tie rod end lock nut position of tie rod thread. 3) Loosen tie rod end lock nut and remove tie rod end. 4) Remove boot wire (1) and clip (2).
Page 99 MANUAL RACK AND PINION 3B-7 8) Remove pinion bearing plug (1) with special tool. Special Tool (43 mm socket) (A): 09944-26011 9) Tap on position as shown with plastic hammer (2) to separate pinion assembly (1) from housing. 10) Remove pinion assembly. 11) Remove rack from gear case (1).
Page 100 3B-8 MANUAL RACK AND PINION 12) Pull out pinion bearing (1) from gear case with special tools. Special Tools (A): 09921-20200 (B): 09930-30102 13) Remove oil seal (1) with special tool. Special Tool (A): 09913-50121...
Page 101 MANUAL RACK AND PINION 3B-9 INSPECTION Rack Plunger Inspect rack plunger (1) for wear or damage. Inspect rack plunger spring (2) for deterioration. In either case, if found defective, replace. Steering Pinion Inspect pinion teeth surface for wear or damage. Inspect oil seal (1) for damage.
Page 102 Special Tool (A): 09925-98210 Apply grease to oil seal lip. Grease: SUZUKI SUPER GREASE E (99000-25050) Apply grease to rollers of pinion bearing (1). Press-fit pinion bearing into gear case with special tool. After press-fitting, make sure that bearing rollers are installed properly.
Page 103 (a): 95 N·m (9.5 kg-m, 69.0 lb-ft) Apply grease lightly to sliding part of plunger against rack. Grease: SUZUKI SUPER GREASE E (99000-25050) Install rack plunger (3), rack plunger spring (2) and rack damper screw (1) and adjust rotation torque of pinion as follows.
Page 104 3B-12 MANUAL RACK AND PINION Install new tie rod lock washer (2) as shown and tie rod (3) to steering rack (1). Align clawed part “A” of washer with flat part “B” of steering rack. Tighten tie rod inside ball nut to specified torque. Tightening Torque “B”...
Page 105 MANUAL RACK AND PINION 3B-13 Install tie rod end lock nut and tie rod end to tie rod. Position lock nut to marking made in removal. “a” NOTE: When tie rod was replaced, measure length “a” on removed tie rod and use it on new replacement tie rod so as to posi- tion lock nut properly.
Page 106 3B-14 MANUAL RACK AND PINION Install tie rod ends (1) to knuckles (2) (R & L). Tighten each castle nut (3) until holes for split pin align but within specified torque and then bend new split pin (4) as shown. Tightening Torque (a): 43 N·m (4.3 kg-m, 31.5 lb-ft) NOTE:...
Page 107: Required Service Materials
Sliding part of rack against steering housing (All around rack plunger, rack bushing and rack) Sliding part against steering pinion Lithium Grease SUZUKI SUPER GREASE E (Oil seal lip, needle bearing) (Should be applicable (99000-25050) Steering rack and pinion gear teeth for –40 C~130 C)
Page 108 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Loca- tion View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 109: General Description
3B1-2 ELECTRICAL POWER STEERING (P/S) SYSTEM GENERAL DESCRIPTION COMPONENTS This power steering (P/S) system consists of a P/S control module, a torque sensor, a motor and clutch installed to the steering column. In this system, the P/S control module determines the level and direction of the assist force for the steering wheel according to the signals from the torque sensor and the vehicle speed, runs the motor so as to assist operation of the steering wheel.
Page 110: Wiring Diagram
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-3 WIRING DIAGRAM 1. To main fuse 7. ECM/PCM 13. Motor and clutch 2. Ignition switch 8. Monitor coupler 14. Torque sensor 3. “P/S” fuse (30A) in fuse box 9. Diagnosis output terminal (for P/S system) 15.
Page 111: Diagnosis
3B1-4 ELECTRICAL POWER STEERING (P/S) SYSTEM DIAGNOSIS The P/S 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 and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diagnosis according to SYSTEM CHECK FLOW TABLE.
Page 112: System Check Flow Table
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-5 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 113 3B1-6 ELECTRICAL POWER STEERING (P/S) SYSTEM CUSTOMER QUESTIONNAIRE (EXAMPLE) Customer’s name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: Steering wheel feels heavy Vehicle pulls to one side during straight driving Poor recovery from turns Problem Symptoms Too much play in steering Abnormal noise while vehicle is running: from motor, from rack and pinon,...
Page 114: Dtc Check
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-7 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 115: Dtc Table
3B1-8 ELECTRICAL POWER STEERING (P/S) SYSTEM 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 21) is set High Voltage between Diag. output terminal and ground ter- minal...
Page 116: Dtc 11 Torque Sensor Main Circuit Failure
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-9 DTC 11 TORQUE SENSOR MAIN CIRCUIT FAILURE DTC 13 TORQUE SENSOR MAIN AND SUB CIRCUIT FAILURE DTC 15 TORQUE SENSOR SUB CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6.
Page 117: Dtc 14 Torque Sensor 5V Power Supply Circuit Failure
3B1-10 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC 14 TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Torque sensor 3. “P/S” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 118: Dtc 16 Torque Sensor 8V Power Supply Circuit Failure
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-11 DTC 16 TORQUE SENSOR 8V POWER SUPPLY CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Torque sensor 3. “P/S” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 119: Dtc 21/23/24 Vss Circuit Failure
3B1-12 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC 21/23/24 VSS CIRCUIT FAILURE 1. To main fuse 2. Ignition switch 3. “P/S” fuse (30A) in fuse box 4. “IG METER” fuse (15A) in fuse box 5. Speedometer 6. Combination meter 7. To VSS 8.
Page 120: Dtc 22 Engine Speed Signal Circuit Failure
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-13 DTC 22 ENGINE SPEED SIGNAL CIRCUIT FAILURE 1. To main fuse 5. ECM/PCM 2. Ignition switch 6. P/S control module 3. “P/S” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box STEP ACTION Was “SYSTEM CHECK FLOW TABLE”...
Page 121: Dtc 41/42/43/44/45 Motor Circuit Failure
3B1-14 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC 41/42/43/44/45 MOTOR CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Motor and clutch 3. “P/S” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 122: Dtc 51 Clutch Circuit Failure
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-15 DTC 51 CLUTCH CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Motor and clutch 3. “P/S” fuse (30A) in fuse box 7. Connector “A” 4. “IG METER” fuse (15A) in fuse box 8.
Page 123: Dtc 53 P/S Control Module Power Supply Circuit Failure
3B1-16 ELECTRICAL POWER STEERING (P/S) SYSTEM DTC 53 P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAILURE 1. To main fuse 4. “IG METER” fuse (15A) in fuse box 2. Ignition switch 5. P/S control module 3. “P/S” fuse (30A) in fuse box 6.
Page 124: Inspection Of P/S Control Module Circuit
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-17 INSPECTION OF P/S CONTROL MODULE CIRCUITS P/S control module (1) and its circuits can be checked at P/S con- trol module wiring couplers (2) by measuring voltage and resis- tance. CAUTION: P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to P/S control module with coupler disconnected from it.
Page 125 3B1-18 ELECTRICAL POWER STEERING (P/S) SYSTEM TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ground – – P/S control module power supply 10 – 14V Ignition switch ON from back-up P/S control module power supply 10 – 14V Ignition switch ON from ignition switch Indicator deflection re- Ignition switch ON peated 0 –...
Page 126: Trouble Diagnosis (For Trouble Not Indicated By On-Board Diagnostic System)
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-19 TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON BOARD DIAGNOSTIC SYSTEM) This section describes trouble diagnosis of P/S system parts whose trouble is not indicated by the on-board diag- nostic system (self-diagnostic function). When DTC No.12 is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in DIAGNOSIS CHART in SECTION 3 are all in good condition, check the follow- ing power steering system parts which may be a possible cause for each symptom of the steering.
Page 127: Steering Wheel Inspection
3B1-20 ELECTRICAL POWER STEERING (P/S) 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 128: On-Vehicle Service
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-21 ON-VEHICLE SERVICE P/S CONTROL MODULE REMOVAL 1) Disconnect negative cable at battery. 2) Remove steering column hole cover. 3) Disconnect couplers (1) from P/S control module. 4) Remove P/S control module (2) from steering column assem- bly.
Page 129: Motor And Clutch
3B1-22 ELECTRICAL POWER STEERING (P/S) SYSTEM MOTOR AND CLUTCH ON-VEHICLE INSPECTION 1) Remove steering column hole cover. 2) Disconnect coupler (1) for motor and clutch from P/S control module with ignition switch OFF. 3) Check resistance between terminals of coupler (1) for motor and clutch.
Page 130 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” un- der “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring.
Page 131 3C-2 STEERING WHEEL AND COLUMN GENERAL DESCRIPTION This double tube type steering column has following three important features in addition to the steering function: The column is energy absorbing, designed to compress in a front-end collision. The ignition switch and lock are mounted conveniently on this column. With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
Page 132: Diagnosis
STEERING WHEEL AND COLUMN 3C-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 3. For diagnosis of the air bag system, refer to SECTION 10B. INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT [For vehicle without air bag system] After an accident be sure to perform checks, inspections and repairs described under CHECKING STEERING...
Page 133: Driver Air Bag (Inflator) Module (For Vehicle With Air Bag System)
3C-4 STEERING WHEEL AND COLUMN DRIVER AIR BAG (INFLATOR) MODULE (FOR VEHICLE WITH AIR BAG SYSTEM) WARNING: When handling an air bag (inflator) module, be sure to read SERVICE PRECAUTIONS in SECTION 10B and ob- serve each instruction. Failure to follow them could cause a damage to the air bag (inflator) module or result in personal injury.
Page 134: Steering Wheel
STEERING WHEEL AND COLUMN 3C-5 INSTALLATION 1) Check that horn wire is connected to horn connector (2) secure- 2) Connect yellow connector (1) of driver air bag (inflator) module (3) and horn connector in order a)–d) shown in the figure se- curely.
Page 135 3C-6 STEERING WHEEL AND COLUMN For vehicle with air bag system: For vehicle with air bag system Remove driver air bag (inflator) module from steering wheel. Refer to DRIVER AIR BAG (INFLATOR) MODULE in this sec- tion. 2) Remove steering shaft nut. 3) Make alignment marks (1) on steering wheel and shaft for a guide during reinstallation.
Page 136 For vehicle with air bag system 2) For vehicle without air bag system: a) Apply grease to contact plate (1) “A” of steering wheel. Grease: SUZUKI GREASE CE-T (99000-25290) b) Install steering wheel onto shaft, aligning them by match marks.
Page 137: Centering Contact Coil (For Vehicle With Air Bag System)
3C-8 STEERING WHEEL AND COLUMN CENTERING CONTACT COIL (FOR VEHICLE WITH AIR BAG SYSTEM) 1) Check that vehicle’s wheels (front tires) are set at straight- ahead position. 2) Check that ignition switch is at “LOCK” position. 3) Turn contact coil counterclockwise slowly with a light force till contact coil will not turn any further.
Page 138 STEERING WHEEL AND COLUMN 3C-9 3) Remove steering column cover screws (3 pcs) (1). 4) Loosen steering column mounting nuts. Refer to STEERING COLUMN in this section. 5) Separate upper cover (2) and lower cover (3), then remove them. * : Standard screw ** : Tapping screw 6) Remove combination switch/contact coil and combination switch assembly screws (1) and disconnect connectors (2) from...
Page 139 3C-10 STEERING WHEEL AND COLUMN 3) Install combination switch/contact coil and combination switch assembly (3) to steering column. NOTE: For vehicle with air bag system New contact coil and combination switch assembly is sup- plied with contact coil set and held at its center position with a lock pin (1) and seal (2).
Page 140: Steering Column Assembly
STEERING WHEEL AND COLUMN 3C-11 STEERING COLUMN ASSEMBLY CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on its end could col- lapse the steering shaft or loosen the plastic shear pins which maintain column length.
Page 141 3C-12 STEERING WHEEL AND COLUMN d) Loosen steering column mounting nuts (“A”, “B”, “C”). “C” “C” “A” “B” e) Remove steering column cover screws (1) (3 pcs.) f) Separate upper column cover (2) and lower column cover (3), then remove them. * : Standard screw ** : Tapping screw g) Disconnect connectors (1) from combination switch (2).
Page 142 STEERING WHEEL AND COLUMN 3C-13 6) Remove steering joint cover (1). 7) Remove joint bolt (steering column side) (2) and loosen joint bolt (pinion shaft side) (3). 8) Remove steering column mounting nuts (“A”, “B”, “C”). 9) Remove steering column from vehicle. “C”...
Page 143 3C-14 STEERING WHEEL AND COLUMN INSTALLATION CAUTION: After tightening steering column mounting nuts, shaft joint bolts should be tightened. Wrong tightening order above could cause a damage to shaft joint. 1) Be sure that front wheels and steering wheel are in straight for- ward state.
Page 144 STEERING WHEEL AND COLUMN 3C-15 7) Tighten mounting nuts to specified torque in the order “A” – “B” – “C” indicated in figure. “C”, (a) Tightening Torque “C”, (a) (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) 8) Tighten joint bolt (3) (pinion shaft side) first and then joint blot “A”, (a) “B”, (a) (2) (steering column side) to specified torque.
Page 145: Steering Lock Assembly (Ignition Switch)
3C-16 STEERING WHEEL AND COLUMN STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL 1) Remove steering column (1). Refer to STEERING COLUMN in this section. 2) Using center punch (1), loosen and remove steering lock mounting bolts (2). NOTE: Use care not to damage aluminum part of steering lock body with center punch.
Page 146: Steering Lower Shaft
STEERING WHEEL AND COLUMN 3C-17 STEERING LOWER SHAFT CAUTION: For vehicle with air bag system: Never turn steering wheel while steering lower shaft is removed. Should it have been turned and contact coil (on combina- tion switch) have got out of its centered position, it needs to be centered again.
Page 147: Checking Steering Column Assembly And Lower Shaft For Accident Damage
3C-18 STEERING WHEEL AND COLUMN CHECKING STEERING COLUMN AS- SEMBLY AND LOWER SHAFT FOR AC- CIDENT DAMAGE NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted (or air bag deployed) may have a damaged or misaligned steering col- umn.
Page 148: Required Service Material
STEERING WHEEL AND COLUMN 3C-19 REQUIRED SERVICE MATERIAL MATERIAL RECOMMENDED SUZUKI PRODUCT SUZUKI GREASE CE-T Grease To apply to contact plate. (99000-25290) SPECIAL TOOL 09944-36011 Steering wheel remover...
Page 149 FRONT SUSPENSION 3D-1 SECTION 3D 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 150 3D-2 FRONT SUSPENSION 2. Stabilizer bar 3. Steering knuckle 5. Suspension control arm 8. Tie rod 9. Brake disc...
Page 151 FRONT SUSPENSION 3D-3 1. Strut assembly 4. Wheel 5. Suspension control arm 6. Vehicle body 7. Drive shaft 8. Tie rod 9. Brake disc...
Page 152: Diagnosis
3D-4 FRONT SUSPENSION DIAGNOSIS DIAGNOSIS TABLE Refer to Section 3. STABILIZER BAR AND/OR BUSHING CHECK Inspect for damage or deformation. If defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. STRUT ASSEMBLY CHECK Inspect strut for oil leakage. If strut is found faulty, replace it as an assembly unit, because it can not be disassembled.
Page 153: Suspension Control Arm/Steering Knuckle Check
FRONT SUSPENSION 3D-5 SUSPENSION CONTROL ARM/STEERING KNUCKLE CHECK Inspect for cracks, deformation or damage. SUSPENSION CONTROL ARM BUSHING CHECK Inspect for damage, wear or deterioration. SUSPENSION CONTROL ARM JOINT CHECK • Check for smooth rotation. • Inspect ball stud for damage. •...
Page 154 3D-6 FRONT SUSPENSION By rotating wheel actually, check wheel bearing for noise and smooth rotation. If defective, replace bearing.
Page 155: On-Vehicle Service
FRONT SUSPENSION 3D-7 ON-VEHICLE SERVICE STRUT ASSEMBLY 50 N·m (5.0 kg-m) 23 N·m (2.3 kg-m) 1. Strut assembly 2. Coil spring 3. Bump stopper 4. Coil spring seat 100 N·m 5. Coil spring upper seat (10.0 kg-m) 6. Strut bearing 7.
Page 156 3D-8 FRONT SUSPENSION 5) Remove strut support nuts (1). Hold strut by hand so that it will not fall off. 6) Remove strut assembly. DISASSEMBLY 1) Using a spring compressor, compress the strut spring till its force pressing the spring seat is released. WARNING: Use a commercially available spring compressor and follow the operation procedure described in the...
Page 157 FRONT SUSPENSION 3D-9 ASSEMBLY For assembly, reverse disassembly procedure, observing follow- ing instructions. Mate spring end with stepped part of spring lower seat (2) as shown. Install spring upper seat (1), mating stepped part of seat with spring upper end as shown. Tighten strut nut to specified torque by using special tools.
Page 158: Stabilizer Bar And/Or Bushing
3D-10 FRONT SUSPENSION STABILIZER BAR AND/OR BUSHINGS 1. Stabilizer bar 2. Mount bracket 3. Mount bushing 4. Bushinig 5. Washer 6. Stabilizer bar nut 45 N·m (4.5 kg-m) 7. Stabilizer bar mounting bracket bolt 68 N·m (6.8 kg-m) 68 N·m (6.8 kg-m) : Tightening Torque : Do not reuse REMOVAL...
Page 159 FRONT SUSPENSION 3D-11 INSTALLATION For installation, reverse removal procedure, observing following instructions. Install stabilizer bar (2) so that paint mark (1) on it comes to the right side of vehicle. There is a paint mark (1) on the front of stabilizer bar. Install sta- bilizer bar mount bracket to outside of stabilizer bar at that mark.
Page 160: Wheel Hub And Steering Knuckle
3D-12 FRONT SUSPENSION WHEEL HUB AND STEERING KNUCKLE 1. Front wheel hub 2. Circlip 3. Wheel bearing 4. Steering knuckle 5. Drive shaft nut : Calk, after tightening. 6. Hub bolt : Tightening Torque 175 N·m (17.5 kg-m) : Do not reuse REMOVAL 1) Hoist vehicle and remove wheel.
Page 161 FRONT SUSPENSION 3D-13 8) Disconnect tie rod end (1) from steering knuckle (2) with spe- cial tool. Special Tool (A): 09913-65210 9) Loosen strut bracket nuts (1). 10) Remove ball joint bolt (1). 11) Remove strut bracket bolts from strut bracket and then steer- ing knuckle (2).
Page 162 3D-14 FRONT SUSPENSION 4) Remove hub bolts (1) with copper hammer or hydranlic press. CAUTION: Never remove bolt unless replacement is necessary Be sure to use a new bolt for replacement. ASSEMBL Y 1) Press-fit wheel bearing (1) by using special tool. Special Tool (A): 09913-75520 2) Install circlip (1).
Page 163 FRONT SUSPENSION 3D-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 For installation, reverse removal procedure, observing following instructions. Using special tool, drive wheel hub (1) into steering knuckle (2) and then install steering knuckle.
Page 164: Suspension Control Arm/Bushing
3D-16 FRONT SUSPENSION Install brake disc and brake caliper. Tighten brake caliper bolt to specified torque. Tightening torque for brake caliper 1, (a) 85 N·m (8.5 kg-m, 61.5 lb-ft) Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque. Tightening Torque (a): 175 N·m (17.5 kg-m, 127.0 lb-ft) Caulk drive shaft nut (1) as shown.
Page 165 FRONT SUSPENSION 3D-17 4) Remove suspension control arm bolt (1). 5) Remove suspension control arm (2) while removing stabilizer bar (3). DISASSEMBLY 1) Cut off collar of bushing (1) as shown. 2) Set collar cut section to special tool and remove bushing. Special Tool (A): 09943-77910 ASSEMBLY...
Page 166 3D-18 FRONT SUSPENSION INSTALLATION For installation, reverse removal procedure, observing following instructions. 1) Install body side of suspension control arm but tighten suspen- sion control arm bolt (1) only temporarily. 2) Install suspension control arm ball joint to steering knuckle. Align ball stud groove with steering knuckle bolt hole.
Page 167: Required Service Material
FRONT SUSPENSION 3D-19 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI SUPER GREASE A Lithic wheel bearing grease Wheel bearing (99000-25010) SPECIAL TOOLS 1. 09900-00411 Hexagon wrench socket 2. 09900-00414 09913-65210 09913-70122 09913-75520 Hexagon wrench bit 6 mm Tie rod end remover...
Page 168 REAR SUSPENSION 3E-1 SECTION 3E 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 169: General Description
3E-2 REAR SUSPENSION GENERAL DESCRIPTION Rear suspension is Isolated Trailing Link (l.T.L.) type which consists of coil springs, rear axle, shock absorbers, lateral rod and trailing arms. 63 N·m (6.3 kg-m) 85 N·m (8.5 kg-m) 175 N·m (17.5 kg-m) 65 N·m (6.5 kg-m) 25 N·m (2.5 kg-m) 50 N·m (5.0 kg-m) 90 N·m (9.0 kg-m)
Page 170: Diagnosis
REAR SUSPENSION 3E-3 DIAGNOSIS DIAGNOSIS TABLE Refer to SECTION 3. 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 highpres- sure gas is sealed, make sure to observe the following precautions.
Page 171: Bump Stopper/Spring Upper Seat Check
3E-4 REAR SUSPENSION BUMP STOPPER/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 TIGHT- ENING TORQUE SPECIFICATIONS of this section.
Page 172: On-Vehicle Service
REAR SUSPENSION 3E-5 ON-VEHICLE SERVICE 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) refer- ring to figure for proper installing direction of nuts, (4), bolt (5) and washer (6).
Page 173: Rear Shock Absorber
3E-6 REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL 1) Hoist vehicle. 2) Support rear axle (1) using floor jack to prevent it from lowering. Inside 3) Remove lower nut (2). 4) Remove upper bolt (3) and nut (4). Then remove shock absorb- er (5).
Page 174 REAR SUSPENSION 3E-7 6) Remove shock absorber lower nut (1). 7) Detach shock absorber lower side from rear axle. 8) 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.
Page 175: Bump Stopper
3E-8 REAR SUSPENSION 7) Install wheel (1) and tighten wheel nuts (2) to specified torque. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 2, (a) 8) Lower hoist and vehicle in non-loaded condition, tighten ab- sorber lower nut (1) and lateral rod right side nut (2) to specified torque.
Page 176: Spring Upper Seat
REAR SUSPENSION 3E-9 SPRING UPPER SEAT REMOVAL 1) Removal coil spring. For details, refer to COIL SPRING RE- MOVAL in this section. 2) Remove spring upper seat (1). INSTALLATION 1) Install spring upper seat (1). NOTE: Vehicle body For proper installing direction of spring upper seat, refer to side figure at left.
Page 177 3E-10 REAR SUSPENSION 6) Disconnect parking brake cable clamp (1) from trailing arm (2). 7) Remove trailing arm rear bolt (1) and center bolt (2). 8) Remove trailing arm front bolt (1) and then remove trailing arm (2). INSTALLATION 3, 4, 5 1) Install trailing arm (1) to vehicle body and rear axle, referring to Vehicle Vehicle...
Page 178 REAR SUSPENSION 3E-11 3) Install shock absorber (1) lower side to rear axle. Tighten shock absorber lower nut (2) temporaliry at this step. 4) Install lateral rod (1) to vehicle body, refer to figure for proper FORWARD installing direction of bolt (2). Tighten nut (3) temporaliry at this step.
Page 179: Rear Axle
3E-12 REAR SUSPENSION REAR AXLE REMOVAL 1) Hoist vehicle and remove rear wheels (right & left). 2) Support rear axle (1) using floor jack (2). 3) Remove rear brake drums (right & left). For details, refer to BRAKE DRUM REMOVAL in SECTION 5. 4) Remove E-ring (1) (right &...
Page 180 REAR SUSPENSION 3E-13 9) Remove shock absorber lower nuts (1) (right & left). 10) Detach shock absorber (2) lower sides (right & left) from rear axle. 11) Lower rear axle gradually as far down as where coil springs (1) (right & left) can be removed. 12) Remove coil springs (right &...
Page 181 3E-14 REAR SUSPENSION 2) Install trailing arms (1) (right & left) to rear axle in proper direc- tion as shown in figure. Vehicle Vehicle Tighten center trailing arm nut (2) and rear trailing arm nut (3) out side center side 2, 3 temporaliry at this step.
Page 182 REAR SUSPENSION 3E-15 8) Connect brake pipes (1) (right & left) to wheel cylinders (2) and tighten brake pipe flare nuts (3) to specified torque. 3, (a) Tightening Torque (a): 16 N · m (1.6 kg-m, 11.5 lb-ft) 9) Connect brake flexible hoses (2) to bracket on rear axle and secure it with E-rings (1).
Page 183: Wheel Bearing And Wheel Stud
3E-16 REAR SUSPENSION 16) Tighten center and rear trailing arm nuts (1), shock absorber lower nuts (2) and lateral rod left side nut (3) to specified torque 1, (a) (right and left). Tightening Torque (a): 80 N·m (8.0 kg-m, 58.0 lb-ft) (b): 25 N·m (2.5 kg-m, 18.5 lb-ft) (c): 50 N·m (5.0 kg-m, 36.5 lb-ft) 17) Check to ensure that brake drum is free from dragging and...
Page 184 REAR SUSPENSION 3E-17 4) Remove wheel stud bolts (1) using hydraulic press (2) and gen- eral rod (3). INSTALLATION 1) Insert new stud in drum hole and rotate it slowly to assure serra- tions are aligned with those made by replaced bolt. 2) Press-fit wheel bearing (1) with it’s seal side facing back plate side using special tools and hydraulic press.
Page 185 3E-18 REAR SUSPENSION REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT Brake fluid DOT3 Brake reservoir tank SEALING COMPOUND 366E Water tight sealant Join seam of rear axle and brake back plate (99000-31090) SPECIAL TOOLS 09913-76010 Rear wheel bearing 09942-15510 09943-17912...
Page 186 WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 187 3F-2 WHEEL AND TIRES kgf/cm WARNING: Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in emer- gencies, because 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 188 WHEELS AND TIRES 3F-3 When the measured runout exceeds the specification and correc- tion by the balancer adjustment is impossible, replace the wheel. If the reading is affected by welding, paint or scratch, it should be ignored. Radial Lateral runout limit runout limit 1.14 mm 1.40 mm...
Page 189 3F-4 WHEEL 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 190 WHEELS AND TIRES 3F-5 ON-VEHICLE SERVICE SERVICE OPERATIONS METRIC LUG NUTS AND WHEEL STUDS All models use metric lug nuts and wheel studs (size: M12 1.25). WHEEL REMOVAL 1) Loosen wheel nuts by approximately 180 (half a rotation). 2) Hoist vehicle. 3) Remove wheel.
Page 191 3F-6 WHEEL AND TIRES After mounting, inflate to specified pressure shown on tire pracard 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 seri- ous personal injury.
Page 192 WHEELS AND TIRES 3F-7 GENERAL BALANCE PROCEDURES Deposits of mud, etc. must be cleaned from inside of rim. WARNING: Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain good balance. Each tire should be inspected for any damage, then balanced according to equipment manufacturer’s recommen- dation.
Page 193 FRONT DRIVE SHAFT 4A-1 SECTION 4A FRONT DRIVE SHAFT CONTENTS GENERAL DESCRIPTION ............... . 4A- 2 Component .
Page 194: General Description
4A-2 FRONT DRIVE SHAFT GENERAL DESCRIPTION COMPONENT A constant velocity ball joint is used on the wheel side of front drive shaft and a constant velocity tripod joint on the differential side. The drive shaft can slide through the tripod joint in the extension/contraction direction. For left side drive shaft, a constant velocity double offset joint (DOJ) is used on the differential side.
Page 195: Diagnosis
FRONT DRIVE SHAFT 4A-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 tear. If even a small tear is noted, replace with new one.
Page 196: On-Vehicle Service
4A-4 FRONT DRIVE SHAFT ON-VEHICLE SERVICE DRIVE SHAFT ASSEMBLY REMOVAL 1) Undo caulking and remove drive shaft nut (1) and washer. A: Undo caulking 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) by using special tool.
Page 197 FRONT DRIVE SHAFT 4A-5 DISASSEMBLY For Tripod joint type drive shaft (Righ side) 1) Remove differential side boot band, then take out tripod joint housing (1). 2) Remove grease from shaft and take off snap ring (1) by using special tool, then pull out spider (2) from shaft. Special Tool (A): 09900-06107 CAUTION:...
Page 198 4A-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 and remove circlip (1) used to fix cage by using special tool (A).
Page 199 FRONT DRIVE SHAFT 4A-7 ASSEMBLY For Tripod joint type drive shaft (Right side) 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. Make sure that wheel side joint assembly (1) and tripod joint hous- ing (2) are washed thoroughly and air dried, and boots (3) are “B”...
Page 200 4A-8 FRONT DRIVE SHAFT 9) Apply grease to inside of outer race (1), then install housing, joint it with boot and fit boot to outer race. After fitting boot, insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
Page 201 FRONT DRIVE SHAFT 4A-9 For DOJ type drive shaft (Left side) 1) Wash disassembled parts (except boots). After washing. dry parts completely by blowing air. 2) Clean boots with cloth. Do not wash boots in degreaser, such as gasoline or kerosene, etc. Washing in degreaser causes deterioration of boot.
Page 202 4A-10 FRONT DRIVE SHAFT 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. 9) Apply grease to inside of outer race, and fit boot to outer race. After fitting boot, insert screwdriver into boot on outer race side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
Page 203 FRONT DRIVE SHAFT 4A-11 INSTALLATION CAUTION: To avoid excessive expansion of boot and consequen- tial disconnection of joint in boot, do not pull differen- tial side joint housing. Protect oil seals and boots from any damage, prevent- ing them from unnecessary contact while installing drive shaft.
Page 204: Required Service Materials
4A-12 FRONT DRIVE SHAFT REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUZUKI SUPER GREASE A Oil seal lips Lithium grease (99000-25010) SUZUKI BOND NO. 1215 Sealant Oil drain and filler plug for manual transmission (99000-31110) SPECIAL TOOLS 09900-06107 09913-65210 Snap ring pliers...
Page 205 BRAKES 5-1 SECTION 5 BRAKES NOTE: All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary.
Page 206 5-2 BRAKES DIAGNOSIS ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE Brakes should be tested on dry, clean, smooth and FLUID reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid test brakes by making brake applications with both may cause the brake fluid to boil or the rubber compo- light and heavy pedal forces at various speeds to de- nents in the hydraulic system to deteriorate.
Page 207 BRAKES 5-3 DIAGNOSIS TABLE Condition Possible Cause Correction Not enough Brake oil leakage from brake lines. Locate leaking point and repair. braking force Brake disc or pads stained with oil. Clean or replace. Overheated brakes. Determine cause and repair. Poor contact of shoes on brake drum. Repair for proper contact.
Page 208 5-4 BRAKES Condition Possible Cause Correction Dragging Master cylinder pistons not returning correctly. Repair master cylinder. brakes Restricted brake pipes or hoses. Check for soft hoses or damaged pipes (A very light and replace with new hoses and/or new drag is present double-walled steel brake piping.
Page 209 BRAKES 5-5 ON-VEHICLE SERVICE BRAKE PEDAL FREE HEIGHT ADJUSTMENT Brake pedal height varies according to installation position of booster push rod clevis and adjustment of stop light switch. After performing service concerning these items, be sure to adjust brake pedal height by referring to description of each item. BRAKE PEDAL PLAY INSPECTION Pedal play should be within specification below.
Page 210 5-6 BRAKES FRONT BRAKE PAD INSPECTION Inspect pad linings (1) periodically according to maintence sched- ule whenever wheels are removed (for tire rotation or other rea- son). Take a look through each end (or hole) of caliper and check “a” lining thickness of outside and inside pads.
Page 211 BRAKES 5-7 ADJUSTMENT NOTE: Make sure for following conditions before cable adjustment. No air is trapped in brake system. Brake pedal travel is proper. Brake pedal has been depressed a few times with about 30 kg (66 lbs) load. Parking brake lever has been pulled up a few times with about 20 kg force.
Page 212 5-8 BRAKES 4) If pedal travel doesn’t change, air tightness isn’t obtained. NO GOOD NOTE: If defective, inspect vacuum lines and sealing parts, and re- place any faulty part. When this has been done, repeat the entire test. Check Operation 1) With engine stopped, depress brake pedal several times with the same load and make sure that pedal travel doesn’t change.
Page 213 BRAKES 5-9 MASTER CYLINDER AND BRAKE FLUID LEVEL INSPECTION 1) Check master cylinder and reservoir tank for crack, damage and brake fluid leakage. If any faulty condition exists, correct or replace. 2) Check that brake fluid level is between MAX and MIN marks on reservoir tank.
Page 214 5-10 BRAKES AIR BLEEDING OF BRAKE SYSTEM CAUTION: Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Right brake Right wheel caliper cylinder Bleeding operation is necessary to remove air whenever it entered hydraulic brake system.
Page 215 BRAKES 5-11 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. Tightening torque for bleeder plug Front: 8.5 N·m (0.85 kg-m, 6.5 lb-ft) Rear: 8.0 N·m (0.8 kg-m, 6.0 lb-ft) 7) Then attach bleeder plug cap. 8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
Page 216 5-12 BRAKES FRONT BRAKE 27 N·m (2.7 kg-m) 8.5 N·m (8.5 kg-m) 8.5 N·m (0.85 kg-m) 1. Brake caliper carrier 2. Boot 3. Caliper 4. Disc brake piston 5. Piston seal : Apply fluid (Brake, power steering or automativc transmission fluid) 6.
Page 217 BRAKES 5-13 INSPECTION Brake Pad Check pad lining for wear. When wear exceeds limit, replace with new one. CAUTION: Never polish pad lining with sandpaper. If lining is pol- ished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lin- ing requires correction, replace it with a new one.
Page 218 5-14 BRAKES CALIPER ASSEMBLY REMOVAL 1) Loosen wheel nuts and with vehicle lifted up, remove wheels. 2) Remove flexible hose bolt (1) and washer. CAUTION: Keep end or disconnected hose in a container (2) so that brake fluid will not get on vehicle body or floor. 3) Remove caliper pin bolt and remove caliper from caliper carrier.
Page 219 BRAKES 5-15 2) Remove piston seal using a thin blade like a thickness gauge, etc. CAUTION: Be careful not to damage inside (bore side) of cylin- der. 3) Remove bleeder plug and cap from caliper. INSPECTION Pin Boot and Cylinder Boot Check boots for breakage, crack and damage.
Page 220 5-16 BRAKES Piston and Boot Before inserting piston (1) into cylinder, install new boot (2) onto piston as shown. Fit boot as it is in the figure into boot groove in cylinder with fin- gers. Insert piston into cylinder by hand and fit boot in boot groove in piston.
Page 221 BRAKES 5-17 BRAKE DISC REMOVAL 1) Hoist vehicle and remove wheel. 2) Remove caliper assembly by removing caliper carrier bolts (2 pcs). CAUTION: During removal, be careful not to damage brake flex- ible hose and not to depress brake pedal. NOTE: Hang removed caliper with a wire hook or the like so as to prevent brake hose from bending and twisting excessively...
Page 222 5-18 BRAKES INSTALLATION 1) Install brake disc to wheel hub. 2) Install caliper assembly to steering knuckle. 3) Tightening caliper carrier bolts to specified torque. Tightening Torque (a): 85 N·m (8.5 kg-m, 61.5 lb-ft) 4) Tighten wheel nuts temporarilly and lower lift. 5) Tighten front wheel nuts to specified torque.
Page 223 BRAKES 5-19 REAR BRAKE 8.5 N·m (0.85 kg-m) 10 N·m (1.0 kg-m) 23 N·m (2.3 kg-m) 1. Brake back plate : Apply SEALING COMPOUND 366E (99000-31090) to joint seam of brake back plate and rear axle 2. Brake shoe 3. Push nut 4.
Page 224 5-20 BRAKES BRAKE DRUM REMOVAL 1) With parking brake pulled up, lift vehicle and remove wheels. 2) Remove spindle cap (1). When removing cap with a chisel, tap it lightly at about 3 locations using care not to damage seat face of cap.
Page 225 BRAKES 5-21 INSPECTION Brake Drum Inspect brake drum for wear. If limit value of drum inner diameter is exceeded or uneven or stepped wear is excessive, replace drum. Drum inner diameter “a” Standard : 180 mm (7.09 in.) Limit : 182 mm (7.17 in.) “a”...
Page 226 5-22 BRAKES 5) Calk spindle nut (1) as shown. 6) Install spindle cap. NOTE: When installing spindle cap, hammer lightly several loca- tions on the collar of cap until collar comes closely into con- tact with brake durm. If fitting part of cap is deformed or damaged or if it is fitted loosely, replace with new one.
Page 227 BRAKES 5-23 5) Remove push nut (1). 6) Remove parking brake shoe lever (2) from shoe rim (3). INSPECTION 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.
Page 228 5-24 BRAKES 4) Remove wheel cylinder mounting bolts. Disconnect brake pipe from wheel cylinder and put bleeder plug cap (1) onto pipe to prevent fluid from spiling. INSPECTION Inspect wheel cylinder disassembled parts for wear, cracks, corro- sion or damage. NOTE: Clean wheel cylinder components with brake fluid.
Page 229 BRAKES 5-25 9) Install wheel and tighten wheel nuts to specified torque. Tightening torque for wheel nut 85 N·m (8.5 kg-m, 61.5 lb-ft) 10) Check to ensure that brake drum is free from dragging and proper braking is obtained. Then remove vehicle from hoist and perform brake test (foot brake and parking brake).
Page 230 5-26 BRAKES 3) 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). “A”: Sealant 99000-31090 4) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut to specified torque.
Page 231 BRAKES 5-27 RH steering vehicle 14 N·m (1.4 kg-m) 13 N·m (1.3 kg-m) 1. Reservoir tank 7. Secondary piston 11. Primary cup 2. Retainer : Apply brake fluid to : Confirm installing 3. Gromment contact surface of cup direction : Apply brake fluid 8.
Page 232 5-28 BRAKES MASTER CYLINDER RESERVOIR REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir. 3) Take out fluid with syringe or such. 4) Remove reservoir connector pin (2) or retainer (3) and reservoir (1). INSTALLATION 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with.
Page 233 BRAKES 5-29 2) Pull out piston assemblies by tapping flange with a piece of wood or something soft. NOTE: Do not drop piston. Do not cause any damage to inside of cylinder wall. RH steering vehicle 1) Pull out retainer (1) to remove reservoir (2). 2) Loosen and remove cap.
Page 234 5-30 BRAKES ASSEMBLY CAUTION: Never use any mineral oil such as kerosense oil and gasoline when washing and assembling parts. Check inside of cylinder wall, pistons and cup seals are free from any foreign objects such as dust and dirt and use case not to cause any damage with a tool du- ing assembly.
Page 235 BRAKES 5-31 4) Remove sleeve (1) from sleeve cup. Special Tool (A): 09900-06106 NOTE: Do not cause any damage to inside of sleve. If caused, replace primary piston assembly. 5) Install sleeve cup (3) and O-ring (2) to sleeve (1) such a direc- tion as shown.
Page 236 5-32 BRAKES 10) Install cap and tighten it to specified torque, then confirm the length “A”. Tightening Torque (a): 14 N·m (1.4 kg-m, 10.5 lb-ft) “A”: Less than 26 mm (1.02 in.) “A” INSPECTION AFTER ASSEMBLY (FOR RH STEERING VE- HICLE) 1) Install radiator cap test with special tool to master cylinder port (1).
Page 237 BRAKES 5-33 INSTALLATION NOTE: Check clearance between booster piston rod and primary pis- ton. (Refer to BRAKE BOOSTER INSPECTION AND ADJUST- MENT.) 1) Install master cylinder to booster and torque mounting nuts to specification. For RH steering vehicle, install push rod seal (1) and gasket to master cylinder (2).
Page 238 5-34 BRAKES INSTALLATION NOTE : Adjust clearance between booster piston rod and master cylinder piston. (Refer to BRAKE BOOSTER INSPECTION AND ADJUSTEMENT.) 3, (a) Check length of push rod clevis. 1) Install booster (4) to dash panel. Then connect push rod clevis (5) to pedal arm with clevis pin (2) and clip (6).
Page 239 BRAKES 5-35 INSPECTION AND ADJUSTMENT INSTALLATION POSITION OF PUSH ROD If push rod clevis (1) has been removed, adjust distance between 2, (a) booster installation surface (without including packing) and the center of clevis pin hole to standard value and tighten nut (2) to spe- cified torque.
Page 240 5-36 BRAKES BRAKE HOSE/PIPE FRONT BRAKE HOSE/PIPE REMOVAL 1) Raise and support vehicle properly. Remove tire and wheel. This operation is not necessary when removing pipes connecting master cylinder and P valve. 2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose or pipe.
Page 241 BRAKES 5-37 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 end and pipe end fittings. Remove brake flexible hose or pipe. INSTALLATION 1) Reverse brake flexible hose installation procedure. Fill and maintain brake fluid level in reservoir. Bleed brake system.
Page 242 5-38 BRAKES PARKING BRAKE CABLE REMOVAL 1) Raise, suitably support vehicle and remove wheel if necessary. 2) Remove parking brake cable. INSTALLATION 1) Install it by reversing removal procedure, noting the following points. Install clamps properly referring to figure below. Tighten bolts and nuts to specified torque.
Page 243 3. Pedal shaft nut 4. Pedal bracket bolt/nut : Tighten in alphabetical order 5. Stop light switch : Adjust clearance (0.5 – 1.5 mm) 6. Pedal boss bush : Apply SUZUKI SUPER GREASE : Tightening Torque A (99000-25010) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT •...
Page 244 5-40 BRAKES SPECIAL TOOLS 09922-89810 09900-20606 09900-20701 09942-15510 Spring pin remover Dial gauge Magnetic stand Sliding hammer 09952-46010 09943-17912 09951-18220 Master cylinder Brake drum remover Secondary cup installer 09952-16020 (Front wheel hup remover) attachment Booster piston rod adjuster...
Page 245 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 246 6-2 ENGINE Throughout this manual, the four cylinders of the engine are identified by numbers: No.1 (1), No.2 (2), No.3 (3) and No.4 (4) as counted from the crankshaft pulley side to the flywheel side. GENERAL INFORMATION ON ENGINE SERVICE THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELI-...
Page 247 ENGINE 6-3 PRECAUTION ON FUEL SYSTEM SERVICE With short pipe, fit hose as far as it reaches pipe Work must be done with no smoking, in a well-ventilated area joint as shown. and away from any open flames. As fuel feed line (between fuel pump and fuel pressure regula- tor) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or dis-...
Page 248 6-4 ENGINE FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, relieve fuel pressure as fol- lows. 1) Shift transmission gear shift lever to “Neutral”...
Page 249 ENGINE 6-5 ENGINE DIAGNOSIS This vehicle is equipped with an engine and emission control system, which controls A/F mixture, ignition timing, emission, etc. suitably to engine conditions by ECM/PCM. ECM/PCM has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing a trouble in the engine including this system, be sure to have understanding of the outline of ON- BOARD DIAGNOSTIC SYSTEM and each item in Precaution in Diagnosing Trouble and follow ENGINE DIAG- NOSTIC FLOW TABLE given in the following page to obtain correct result smoothly.
Page 250 6-6 ENGINE ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) Check, Record and 1) Print DTC or Go to Step 4.
Page 251 ENGINE 6-7 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 as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 252 6-8 ENGINE 2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE First, check DTC referring to DTC CHECK in SECTION 6E1. If DTC is indicated, print it or write it down and then clear it by referring to DTC CLEARANCE in SECTION 6E1. DTC indicates malfunction that occurred in the sys- tem but does not indicate whether it exists at present or it occurred in the past and the normal condition has been restored.
Page 253 ENGINE 6-9 5. TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 Customer Complaint Analysis and Step 2 DTC Check, confirm trouble symptoms. Also, reconfirm DTC according to DTC CONFIRMATION PROCEDURE in SECTION 6E1. 6. and 7. RECHECKING AND RECORD OF DTC Refer to DTC CHECK in SECTION 6E1 for checking procedure.
Page 254 6-10 ENGINE 9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in SECTION 6E1, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM/PCM or other part and repair or replace faulty parts.
Page 255 ENGINE 6-11 Condition Possible Cause Reference Item Engine has no power Engine overheating Refer to “Overheating” condition in this table. Ignition system out of order Defective spark plug Spark plugs in SECTION 6F1. Worn distributor terminals Distributor in SECTION 6F1. Leaks, loose connection or disconnection of High-tension cords in SECTION 6F1.
Page 256 6-12 ENGINE Condition Possible Cause Reference Item Engine hesitates Ignition system out of order (Momentary lack of Spark plug faulty or plug gap out of Spark plugs in SECTION 6F1. response when adjustment accelerator is Leaky high-tension cord High-tension cords in SECTION 6F1. depressed.
Page 257 ENGINE 6-13 Condition Possible Cause Reference Item Excessive detona- Engine overheating Refer to Overheating condition in this table. tion (The engine makes Ignition system out of order • sharp metallic Faulty spark plug Spark plugs in SECTION 6F1. • knocks that change Improper ignition timing Ignition timing in SECTION 6F1.
Page 258 6-14 ENGINE Condition Possible Cause Reference Item Excessive engine oil Oil entering combustion chamber consumption Sticky piston ring Piston cleaning in SECTION 6A4. Worn piston and cylinder Cylinders, pistons and piston ring inspection in SECTION 6A4. Worn piston ring groove and ring Piston and piston ring inspection in SECTION 6A4.
Page 259 ENGINE 6-15 Condition Possible Cause Referring Item Excessive Ignition system out of order hydrocarbon (HC) Defective spark plug emission or Leaky or loosely connected high-tension High-tension cords in SECTION 6F1. Excessive carbon cord monoxide (CO) Cracked rotor or cap in distributor Distributor in SECTION 6F1.
Page 260 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 261: General Description
6A4-2 ENGINE MECHANICAL GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 Both overhead camshafts are mounted over the cylin- stroke cycle gasoline unit equipped with its D.O.H.C. der head: they are driven from crankshaft through tim- (Double Overhead Camshaft) valve mechanism ar- ing chain and opens and closes its valves.
Page 262 ENGINE MECHANICAL 6A4-3...
Page 263: On Vehicle Service
6A4-4 ENGINE MECHANICAL ON VEHICLE SERVICE COMPRESSION CHECK Check compression pressure on all four cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral” (shift select lever to “P” range for A/T mod- el), and set parking brake and block drive wheels.
Page 264 ENGINE MECHANICAL 6A4-5 7) Disengage clutch (to lighten starting load on engine) for M/T model, and depress accelerator pedal all the way to make throttle valve full-open. 8) 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.
Page 265: Engine Vacuum Check
(vacuum gauge and joint) between intake manifold and vacuum hose disconnected. Special Tool (A): 09915-67310 (B): 09918-08210 SUZUKI GENUINE PARTS (C): Hose 09343-03087 (D): 3-way joint 09367-04002 3) Run engine at specified idle speed, and read vacuum gauge. Vacuum should be within following specification.
Page 266: Oil Pressure Check
ENGINE MECHANICAL 6A4-7 OIL PRESSURE CHECK NOTE: Prior to checking oil pressure, check the following items. Oil level in oil pan. If oil level is low, add oil up to Full level mark (hole) on oil level gauge. Oil quality. If oil is discolored, or deteriorated, change it.
Page 267 6A4-8 ENGINE MECHANICAL 6) Before reinstalling oil pressure switch (2), be sure to wrap its screw threads with sealing tape (1) and tighten switch to speci- fied torque. NOTE: If sealing tape edge is bulged out from screw threads of switch, cut it off.
Page 268: Valve Lash (Clearance)
ENGINE MECHANICAL 6A4-9 VALVE LASH (CLEARANCE) 1) Remove negative cable at battery. 2) Remove cylinder head cover referring to item “Cylinder Head cover” in this section. 3) Using 17 mm wrench, turn crankshaft pulley clockwise until cam lobes become perpendicular to shim faces at valves (valve No.s through are shown in figure) as shown in fig-...
Page 269 6A4-10 ENGINE MECHANICAL 2) Lift valve by turning crankshaft and then remove camshaft housing bolts (1) where the shim is to be replaced. 3) Install special tool with camshaft housing bolts as shown in fig- ure. Special Tool (A): 09916-67010 NOTE: Check that shim is not under pressure of special tool.
Page 270: Air Cleaner Element
ENGINE MECHANICAL 6A4-11 8) Install camshaft housing bolts (1) and tighten them to specified torque. 1, (a) Tightening Torque (a): 11 N·m (1.1 kg-m, 8.0 lb-ft) Check valve clearance again after adjusting it. 9) After checking and adjusting all valves, reverse removal proce- dure for installation.
Page 271: Air Cleaner Assembly And Resonator
6A4-12 ENGINE MECHANICAL AIR CLEANER ASSEMBLY AND RESONA- REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect breather hose (3) from air cleaner assembly (1). 3) Remove air cleaner assembly (1), resonator (2) and their hoses together by removing bolts and loosening clamps shown in fig- ure.
Page 272: Cylinder Head Cover
ENGINE MECHANICAL 6A4-13 CYLINDER HEAD COVER REMOVAL 1) Disconnect negative cable at battery. 2) Remove air cleaner assembly, resonator, hoses as previously outlined and air cleaner No. 2 bracket. 3) Remove cylinder head upper cover (1). 4) Disconnect oil level gauge. 5) Remove air cleaner No.1 bracket (1).
Page 273 6A4-14 ENGINE MECHANICAL 3) Connect high-tension cords to spark plugs as shown in figure. 4) Install air cleaner No.1 bracket (1). 5) Connect breather hose and PCV valve hose, then clamp them securely. 6) Install cylinder head upper cover and air cleaner No. 2 bracket. 7) Install air cleaner assembly and resonator, and clamp their hoses securely.
Page 274: Throttle Body And Intake Manifold
ENGINE MECHANICAL 6A4-15 THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 2. Throttle body 3. Gasket 4. Fuel pressure regulator 5. Fuel delivery pipe 6. Fuel injector 7. Upper stiffener No.1 8. Upper stiffener No.2 9. MAP sensor 10. IAT sensor 23 N·m (2.3 kg-m) 11.
Page 275 6A4-16 ENGINE MECHANICAL 6) Disconnect the following electric lead wires: EGR solenoid vacuum valve (if equipped) Injectors, TP sensor, IAT sensor, MAP sensor and IAC valve lead wires at the coupler EVAP canister purge valve 7) Disconnect the following hoses: Brake booster hose from intake surge tank Canister purge hose from purge valve Engine cooling water (coolant) hoses (inlet and outlet) from...
Page 276 ENGINE MECHANICAL 6A4-17 11) Remove intake manifold with throttle body from cylinder head, and then its gasket. INSTALLATION Reverse removal procedure for installation noting the followings. Use new intake manifold gasket. Tighten bolts and nuts to specified torque. Tightening Torque (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) (b): 23 N m (2.3 kg-m, 17.0 lb-ft)
Page 277: Oil Pan And Oil Pump Strainer
11 N·m (1.1 kg-m) 50 N·m (5.0 kg-m) 11 N·m (1.1 kg-m) 1. Oil pan: : Apply SUZUKI BOND No. 1207C 99000-31150 to mating surface. 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. Oil pan bolt and nut : Tightening Torque 7.
Page 278 ENGINE MECHANICAL 6A4-19 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 279 6A4-20 ENGINE MECHANICAL 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 seal (3) to oil pump strainer in the position as shown in figure.
Page 280: Exhaust Manifold
ENGINE MECHANICAL 6A4-21 EXHAUST MANIFOLD 23 N·m (2.3 kg-m) 45 N·m (4.5 kg-m) 1. Exhaust manifold 2. Exhaust manifold cover 3. Gasket 4. Heated oxygen sensor 5. Exhaust manifold bolt : Tightening Torque and nut : Do not reuse 6. Exhaust pipe bolt 50 N·m (5.0 kg-m) WARNING: To avoid danger of being burned, do not service exhaust...
Page 281 6A4-22 ENGINE MECHANICAL INSTALLATION 1) Install new gasket (1) to cylinder head. 2) Install exhaust manifold. Tighten bolts and nuts to specified torque. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 3) Install pipe gasket and install exhaust pipe to exhaust manifold. Before installing pipe gasket, check it for deterioration or dam- age, and replace as necessary.
Page 282: Crankshaft Pulley And Oil Seal
ENGINE MECHANICAL 6A4-23 CRANKSHAFT PULLEY AND OIL SEAL 100 N·m (10.0 kg-m) 1. Timing chain cover 2. Crankshaft pulley : Tightening Torque 3. Crankshaft pulley bolt : Do not reuse 4. Oil seal REMOVAL 1) Remove front bumper. 2) Disconnect negative cable at battery. 3) Remove water pump (generator) belt (1) and A/C compressor drive belt (2).
Page 283 6A4-24 ENGINE MECHANICAL INSTALLATION 1) Install new oil seal by using special tool. NOTE: When installing (new) oil seal, top it in until its surface is flash with edge of timing chain cover. Special Tool (A): 09911-97010 2) Install crankshaft pulley. Tighten bolt to specified torque.
Page 284: Timing Chain Cover
ENGINE MECHANICAL 6A4-25 TIMING CHAIN COVER 23 N·m (2.3 kg-m) 100 N·m (10.0 kg-m) 1. Timing chain cover: : Apply SUZUKI BOND No. 1207C 99000-31150 to mating surfaces. 2. Crankshaft pulley 11 N·m (1.1 kg-m) 3. Crankshaft pulley bolt 4. Oil seal 5.
Page 285 6A4-26 ENGINE MECHANICAL 4) Remove water pump (1) by removing water pump bolts (2). 5) Remove oil pan. Refer to “OIL PAN AND OIL PUMP STRAINER” in this section. 6) Remove cylinder head cover. Refer to “CYLINDER HEAD COVER” in this section. 7) Hold engine by using lifting device as shown in figure.
Page 286 ENGINE MECHANICAL 6A4-27 INSTALLATION Reverse removal sequence to install timing chain cover noting fol- lowing points. 1) Apply sealant “A” to area as shown in figure. “A” “A” “A”: Sealant 99000-31150 “A” “A” 2) Apply engine oil to oil seal lip, then install timing chain cover. Tighten bolts to specified torque.
Page 287 6A4-28 ENGINE MECHANICAL 8) Install crankshaft pulley (1). Tighten bolt to specified torque. Tightening Torque (a): 100 N·m (10.0 kg-m, 72.5 lb-ft) 9) Connect oil pressure switch connector. 10) Perform steps 3) – 6) of CRANKSHAFT PULLEY AND OIL SEAL INSTALLATION for procedure hereafter.
Page 288: Oil Pump
9. Retainer : Apply thin coat of 10. Circlip engine oil. 11. Center bolt 4. Timing chain cover: : Apply SUZUKI BOND No. 1207C 99000-31150 to mating surfaces. DISASSEMBLY 1) Remove rotor plate (1). 2) Remove outer rotor (1) and inner rotor (2).
Page 289 6A4-30 ENGINE MECHANICAL INSPECTION Check oil seal lip for fault or other damage. Replace as neces- sary. To replace oil seal, refer to “CRANKSHAFT PULLEY AND OIL SEAL” in this section. Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
Page 290 ENGINE MECHANICAL 6A4-31 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 291: Timing Chain And Chain Tensioner
6A4-32 ENGINE MECHANICAL TIMING CHAIN AND CHAIN TENSIONER 11 N·m (1.1 kg-m) 1. Crankshaft timing sprocket 2. Timing chain 3. Timing chain guide No.1: : Apply engine oil. 4. Timing chain tensioner: : Apply engine oil. 5. Pad 6. Timing chain tensioner link 7.
Page 292 ENGINE MECHANICAL 6A4-33 CAUTION: After timing chain is removed, never turn intake cam- shaft, exhaust camshaft and crankshaft independent- ly more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.
Page 293 6A4-34 ENGINE MECHANICAL Timing chain tensioner adjuster Check that latch (1) and tooth surface (2) are free from damage and latch functions properly. Timing chain guide Check shoe for wear or damage. INSTALLATION CAUTION: After timing chain is removed, never turn intake cam- shaft, exhaust camshaft and crankshaft independent- ly more than such an extent as shown.
Page 294 ENGINE MECHANICAL 6A4-35 3) Install timing chain by aligning dark blue plate of timing chain (1) and arrow on camshaft (2) as shown in figure. 4) Bring yellow plate of timing chain (4) into match with match mark on crankshaft timing sprocket (3). Then install crankshaft timing sprocket to crankshaft.
Page 295 6A4-36 ENGINE MECHANICAL 8) Install timing chain tensioner link (3). 9) Pull out stopper from adjuster. 1. Pad 2. Timing chain tensioner 10) Turn crankshaft clockwise by 2 revolutions and check that match marks are aligned as shown in figure. 1.
Page 296: Camshafts, Tappets And Shims
ENGINE MECHANICAL 6A4-37 CAMSHAFTS, TAPPETS AND SHIMS 1. Intake camshaft: : Apply engine oil to sliding surface of camshaft. 2. Exhaust camshaft: : Apply engine oil to sliding surface of camshaft. 3. Shim: : Size mark on it faces tappet side. 4.
Page 297 6A4-38 ENGINE MECHANICAL INSPECTION Cam Wear Using a micrometer, measure cam height “a”. If measured height is below its limit, replace camshaft. Cam height Standard Limit Intake cam 37.54 – 37.70 mm 37.41 mm (1.478 – 1.484 in.) (1.473 in.) Exhaust cam 37.05 –...
Page 298 ENGINE MECHANICAL 6A4-39 6) Remove housing, and using scale on gaging plastic envelop, measure gaging plastic width at its widest point. Standard Limit Journal 0.045 – 0.087 mm 0.12 mm clearance (0.0018 – 0.0034 in.) (0.0047 in.) 1. Gaging plastic 2.
Page 299 6A4-40 ENGINE MECHANICAL Measure cylinder head bore and tappet outside diameter to deter- mine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head. Item Standard Limit Tappet O.D. 26.959 – 26.975 mm – (1.0614 – 1.0620 in.) Cylinder head 27.000 –...
Page 300 ENGINE MECHANICAL 6A4-41 INSTALLATION 1) Install tappets and shims to cylinder head. Apply engine oil around tappet and then install it to cylinder head. 2) Install camshafts (1). NOTE : Before installing camshafts, turn crankshaft until key posi- tion faces upward. Refer to figure in page 6A4-34. Apply oil to sliding surface of each camshaft and camshaft jour- nal then install them as shown in figure.
Page 301 6A4-42 ENGINE MECHANICAL 5) Apply sealant “A” to intake camshaft end housing sealing sur- face area as shown in figure. “A”: Sealant 99000-31150 6) After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following numerical order in figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tight- ened to specified torque.
Page 302: Valves And Cylinder Head
10. Oil venturi plug 11. Cylinder head bolt: : Apply engine oil. 12. Camshaft housing bolt 13. Camshaft end housing: : Apply SUZUKI BOND No. : Tightening Torque 5 N·m (0.5 kg-m) 1207C 99000-31150 to : Do not reuse mating surfaces.
Page 303 6A4-44 ENGINE MECHANICAL DISASSEMBLY 1) For ease in servicing cylinder head, remove intake manifold with throttle body and exhaust manifold from cylinder head. 2) Remove tappets and shims as previously outlined. 3) Using special tool (Valve lifter), compress valve springs and then remove valve cotters (1) by using special tool (Forceps) as shown.
Page 304 ENGINE MECHANICAL 6A4-45 INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
Page 305 6A4-46 ENGINE MECHANICAL 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 306 ENGINE MECHANICAL 6A4-47 Valve seat repair: A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.
Page 307 6A4-48 ENGINE MECHANICAL Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at a total of 6 locations. If distortion limit, given below, is exceeded, correct gasketed surface with a surface plate and abrasive pa- per of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Page 308 ENGINE MECHANICAL 6A4-49 Valve Springs Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.
Page 309 6A4-50 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): 09916-34542 (B): 09916-37320 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100 C (176 to 212 F) so that head will not be distorted, and drive new valve guide into hole with special tools.
Page 310 ENGINE MECHANICAL 6A4-51 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. After installing, check to be sure that seal is properly fixed to valve guide.
Page 311 6A4-52 ENGINE MECHANICAL INSTALLATION 1) Remove old gasket and oil on mating surfaces and install new head gasket (1) as shown in figure, that is, “TOP” mark provided on gasket comes to crankshaft pulley side, facing up (toward cylinder head side). 2) Check to make sure that oil jet (venturi plug) is installed and if it is, that it is not clogged.
Page 312 ENGINE MECHANICAL 6A4-53 4) Apply engine oil to cylinder head bolts and tighten them gradu- ally as follows. (1) Tighten all bolts to 30 N m (3.0 kg-m, 21.5 lb-ft) according to numerical order in figure. (2) In the same manner as in (1), tighten them to 48 N m (4.8 kg-m, 34.5 lb-ft).
Page 313: Piston, Piston Rings, Connecting Rods
6A4-54 ENGINE MECHANICAL PISTON, PISTON RINGS, CONNECTING RODS 33 N·m (3.3 kg-m) 1. Top ring: 6. Connecting rod : Apply engine oil. bearing cap: : Apply engine oil 2. 2nd ring: except inner surface : Apply engine oil. of big end. 3.
Page 314 ENGINE MECHANICAL 6A4-55 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. Force piston pin out. CLEANING Clean carbon from piston head and ring grooves, using a suitable tool.
Page 315 6A4-56 ENGINE MECHANICAL INSPECTION Cylinders 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. Using a cylinder gauge, measure cylinder bore in thrust and ax- ial directions at two positions as shown in figure.
Page 316 ENGINE MECHANICAL 6A4-57 Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
Page 317 6A4-58 ENGINE MECHANICAL Piston Rings To measure end gap, insert piston ring (1) into cylinder bore and then measure the gap by using thickness gauge (2). If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
Page 318 ENGINE MECHANICAL 6A4-59 Crank Pin and Connecting Rod Bearings Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crank- shaft.
Page 319 6A4-60 ENGINE MECHANICAL 5) Remove cap and using a scale (2) on gaging plastic envelope, measure gaging plastic width (1) at the widest point (clearance). If clearance exceeds its limit, use new standard size bearings and remeasure clearance. Item Standard Limit Bearing 0.020 –...
Page 320 ENGINE MECHANICAL 6A4-61 1) Install piston pin to piston (1) and connecting rod (2): Arrow mark After applying engine oil to piston pin and piston pin holes in pis- ton and connecting rod, fit connecting rod to piston as shown in figure and insert piston pin to piston and connecting rod, and install piston pin circlips.
Page 321 6A4-62 ENGINE MECHANICAL 3) When installing piston and connecting rod assembly into cylin- der bore, point arrow mark on piston head to crankshaft pulley side. 1. Crankshaft pulley side 2. Flywheel side 4) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings.
Page 322: Unit Repair Overhaul
ENGINE MECHANICAL 6A4-63 UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Drain coolant. 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 323 6A4-64 ENGINE MECHANICAL 10) Release fuel pressure in fuel feed line. Refer to Section 6. 11) Disconnect following cables: Accelerator cable (1) from throttle body. Clutch cable (2), gear shift control cable (3) and gear select control cable (4) (M/T). Gear select cable (5) from transmission (A/T).
Page 324 ENGINE MECHANICAL 6A4-65 13) Disconnect following electric wires: High-tension cord (7) and CMP sensor (8). Engine oil pressure switch (19). Knock sensor (14). EGR solenoid vacuum valve (1). EVAP solenoid purge valve (2). Startor (15). Injector couplers (21). Back-up light switch (M/T) (22). A/C compressor switch (20).
Page 325 6A4-66 ENGINE MECHANICAL 14) Remove generator and its bracket. 15) Remove A/C compressor bracket with hose still attached (if equipped). NOTE: Suspend removed compressor at a place where no dam- age will be caused during removal and installation of en- gine assembly.
Page 326 ENGINE MECHANICAL 6A4-67 INSTALLATION 1) Install transmission to engine (M/T) 50 N·m (5.0 kg-m) 50 N·m (5.0 kg-m) (A/T) 20 N·m (2.0 kg-m) 50 N·m (5.0 kg-m) 70 N·m (7.0 kg-m) 50 N·m (5.0 kg-m) : Tightening Torque 2) Install engine assembly together with transmission to vehicle. 90 N·m (9.0 kg-m) RR MTG 55 N·m (5.5 kg-m)
Page 327 6A4-68 ENGINE MECHANICAL 3) Install generator and it’s bracket, and then adjust belt. Refer to Section 0B. 4) Install A/C compressor, and then adjust belt. Refer to Section 0B. 5) Connect cables, hoses, wires and couplers which were dis- connected in removal procedure. Adjust accelerator cable play, referring to Section 6E1.
Page 328: Main Bearings, Crankshaft And Cylinder Block
70 N·m (7.0 kg-m) 24 N·m (2.4 kg-m) 58 N·m (5.8 kg-m) 1. Cylinder block 2. Lower crankcase: : Apply SUZUKI BOND No. 1207C 99000-31150 to mating surfaces. 3. Crankshaft: : Apply engine oil to crankshaft journals. 4. Main bearing: : Apply engine oil to bearing inside surfaces.
Page 329 6A4-70 ENGINE MECHANICAL REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (drive plate for A/T). Special Tool (A): 09924-17810 3) Remove oil pan, oil pump strainer and oil filter. 4) Remove cylinder head cover as previously outlined. 5) Remove timing chain cover.
Page 330 ENGINE MECHANICAL 6A4-71 Crankshaft thrust play Tighten crankcase bolts according to next procedure. 1) Tighten bolts to 41 N·m (4.1 kg-m, 29.5 lb-ft) in order of their numbers. 2) Tighten bolts to 17 N·m (1.7 kg-m, 12.0 lb-ft) in order of their numbers.
Page 331 6A4-72 ENGINE MECHANICAL Main Bearings General information Upper half of bearing (2) has oil groove (3) as shown in figure. Install this half with oil groove to cylinder block (1). Inspection Check bearings for pitting, scratches, wear or damage. If any malcondition is found, replace both upper and lower halves. Never replace one half without replacing the other half.
Page 332 ENGINE MECHANICAL 6A4-73 5) Remove lower crankcase and using scale on gaging plastic en- velope, measure gaging plastic width at its widest point. If clear- ance exceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. New bearings should produce proper clearance.
Page 333 6A4-74 ENGINE MECHANICAL 2) Next, check bearing cap bore diameter without bearing. On low- er crankcase, five numerals are stamped as shown in figure. Three kinds of numerals (“1”, “2” and “3”) represent following cap bore diameters. Bearing cap bore diameter Alphabet stamped (without bearing) 49.000 –...
Page 334 ENGINE MECHANICAL 6A4-75 4) From numerals stamped on crank web of No. 2 cylinder and the numerals stamped on the inside of lower crankcase, determine new bearing to be installed to journal, by referring to table given below. For example, if numeral stamped on crank web is “1” and nu- meral stamped on mating surface is “2”, install a new standard bearing painted in “Black”...
Page 335 6A4-76 ENGINE MECHANICAL Cylinder Block Distortion of gasketed surface Using straightedge and thickness gauge, check gasketed surface for distortion and, if flatness exceeds its limit, correct it. Limit of distortion : 0.05 mm (0.020 in.) Honing or reboring cylinders 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
Page 336 ENGINE MECHANICAL 6A4-77 INSTALLATION NOTE: All parts to be installed must be thoroughly cleaned. Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, pis- ton rings and cylinder bores. Journal bearings, connecting rods, rod bearings, rod bear- ing caps, pistons and piston rings are in combination sets.
Page 337 6A4-78 ENGINE MECHANICAL 4) Install crankshaft to cylinder block. 5) Install lower crankcase to cylinder block. Tighten crankcase bolts according to next procedure. (1) Tighten bolts to 41 N·m (4.1 kg-m, 29.5 lb-ft) in order of their numbers. (2) Tighten bolts to 17 N·m (1.7 kg-m, 12.0 lb-ft) in order of their numbers.
Page 338 ENGINE MECHANICAL 6A4-79 8) Install pistons and connecting rods as previously outlined. 9) Install cylinder head assembly to cylinder block as previously outlined. 10) Install camshaft, crankshaft timing sprocket, timing chain, tim- ing chain cover, cylinder head cover, water pump, etc., as pre- viously outlined.
Page 339: Special Tools
6A4-80 ENGINE MECHANICAL SPECIAL TOOLS 09911-97010 09911-97020 09911-97030 09915-47340 Oil seal installator Oil seal guide Oil seal installer Oil filter wrench 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 09915-78211 Hose Oil pressure gauge 09915-67310 09915-77310 4. 09915-64550 attachment Attachment Vacuum gauge Oil pressure gauge...
Page 340: Required Service Material
09924-17810 Flywheel holder REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT SUZUKI BOND NO. 1207C Mating surfaces of cylinder block and oil pan. (99000-31150) Mating surfaces of cylinder block and timing chain cover. Sealant Mating surfaces of camshaft housings (No.6). Mating surfaces of crankcase...
Page 341 ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS GENERAL DESCRIPTION ............... . 6B- 2 Cooling System Circulation .
Page 342: General Description
6B-2 ENGINE COOLING GENERAL DESCRIPTION The cooling system consists of the radiator cap, radiator, coolant reservoir tank, hoses, water pump, cooling fan, thermostat. The radiator is of tube-and-fin type. COOLING SYSTEM CIRCULATION 1) While the engine is warmed up (thermostat closed), coolant circulates as follows. Throttle body Water pump Cylinder block...
Page 343: Diagnosis
ENGINE COOLING 6B-3 DIAGNOSIS Symptom Possible Cause Remedy Engine overheats Loose or broken water pump belt Adjust or replace. Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace. Faulty water pump Replace. Dirty or bent radiator fins Clean or remedy.
Page 344: Maintenance
6B-4 ENGINE COOLING MAINTENANCE COOLANT done even if freezing temperatures are not ex- pected. The coolant recovery system is standard. The coolant Add ethylene glycol base coolant when coolant has in the radiator expands with heat, and the overflow is to be added because of coolant loss or to provide collected in the reservoir tank.
Page 345: Coolant Level
ENGINE COOLING 6B-5 COOLANT LEVEL Coolant Level To check level, lift hood and look at “see-through” coolant reservoir tank. It is not necessary to remove radiator cap to check coolant level. WARNING: To help avoid danger of being burned: do not remove reservoir tank cap while coolant is boil- ing, and do not remove radiator cap while engine and radiator FULL...
Page 346: Cooling System Flush And Refill
6B-6 ENGINE COOLING 4) Using a pressure tester (1), check system and radiator cap (2) for proper pressure holding capacity about 90 kPa (0.9 kg/cm 12.8 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 347: Water Pump Belt Tension
ENGINE COOLING 6B-7 7) Remove reservoir tank (1) and remove cap (2) from reservoir tank and pour out any fluid, scrub and clean inside of tank with soap and water. Flush it well with clean water and drain. Reinstall tank. 8) Add 50/50 mixture of good quality ethylene glycol antifreeze FULL and water to radiator and tank.
Page 348: On-Vehicle Service
6B-8 ENGINE COOLING ON-VEHICLE SERVICE WARNING: Check to make sure that engine coolant temperature is cold before removing any part of cooling system. Also be sure to disconnect negative cord from battery terminal before removing any part. COOLING SYSTEM DRAINING 1) Remove radiator cap.
Page 349: Thermostat
ENGINE COOLING 6B-9 THERMOSTAT REMOVAL 1) Drain coolant and tighten drain plug. 2) Remove air cleaner case. 3) Remove radiator inlet hose at thermostat cap. 4) Remove thermostat cap (1). 5) Remove thermostat (2). INSPECTION 1) Make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat.
Page 350: Water Pump Belt
6B-10 ENGINE COOLING INSTALLATION 1) When positioning thermostat (1) on thermostat case (2), be sure to position it so that air bleed valve (3) comes at position as shown in figure. 2) Install thermostat cap to thermostat case. 3) Connect cooling water hose. 4) Fill cooling system (refer to page 6B-6, 6B-7).
Page 351: Radiator
ENGINE COOLING 6B-11 RADIATOR REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system by loosening drain plug (1) of radiator. 3) Disconnect coupler of cooling fan motor. 4) Remove front bumper (see SECTION 9). 5) Remove air cleaner case and air intake hose (see SECTION 6A4).
Page 352: Water Pump
6B-12 ENGINE COOLING 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. Refer to the figure at REMOVAL for tightening torque. After installation, check each joint for leakage.
Page 353 ENGINE COOLING 6B-13 REMOVAL 1) Disconnect negative cable at battery. 2) Drain coolant. 3) Remove front bumper (see Section 9). 4) Remove exhaust manifold. 5) Remove A/C compressor (1) from its bracket with hose still at- tached (if equipped), then remove A/C compressor belt. 6) Loosen drive belt adjusting bolt and generator pivot bolt, then remove water pump bolt.
Page 354: Required Service Materials
6B-14 ENGINE COOLING 2) Install water pump to cylinder block and tighten to specified torque. Tightening Torque (a): 22 N·m (2.2 kg-m, 16.0 lb-ft) 3) Connect oil pressure switch coupler and install clamp with its harness. 4) Install A/C compressor (1) to its bracket. 5) Tighten exhaust manifold bolts/nuts to specified torque.
Page 355 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 356 6C-2 ENGINE FUEL GENERAL DESCRIPTION FUEL SYSTEM The main components of the fuel system are fuel tank, fuel pump assembly (with fuel filter and fuel level gauge and fuel cut valve), fuel feed line, fuel return line and fuel vapor line. For the details of fuel flow and fuel vapor flow, refer to ENGINE AND EMISSION CONTROL SYSTEM section.
Page 357 ENGINE FUEL 6C-3 ON-VEHICLE SERVICE With short pipe, fit hose as far as it reaches pipe joint as shown. Pipe Hose WARNING: Before attempting service of any type on fuel system, fol- lowing cautions should be always observed. Disconnect negative cable at battery. Clamp DO NOT smoke, and place NO SMOKING signs near Clamp securely at a position 3 to 7...
Page 358 6C-4 ENGINE FUEL FUEL LINES Due to the fact that fuel feed line is under high pressure, use special care when servicing it. INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose crack and deterioration, or damage. Make sure all clamps are secure. Replace parts as needed.
Page 359 ENGINE FUEL 6C-5 5) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they were. 6) Remove pipes with clamp from vehicle. 7) Remove clamp from pipes. INSTALLATION 1) Install clamps to marked location on pipes. If clamp is deformed or its claw is bent or broken, replace it with new one.
Page 360 6C-6 ENGINE FUEL FUEL TANK REMOVAL WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section. 1) Relieve fuel pressure in fuel feed line according to procedure described in Section 6 page 6-4. 2) Disconnect negative cable at battery. 3) Hoist vehicle.
Page 361 ENGINE FUEL 6C-7 8) Support fuel tank (1) with jack (2) and remove bolts. 9) Lower fuel tank a little so as to disconnect wire harness at connector (1), then remove fuel tank (2). INSPECTION After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage.
Page 362 6C-8 ENGINE FUEL INSTALLATION 1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle. 2) Raise fuel tank (1) with jack and connect connector of fuel pump & gauge and clamp wire harness. Install fuel tank to vehicle.
Page 363 ENGINE FUEL 6C-9 6) Connect negative cable at battery. With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP ASSEMBLY (WITH FUEL FILTER, FUEL LEVEL GAUGE AND FUEL CUT VALVE) WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section.
Page 364 6C-10 ENGINE FUEL DISASSEMBLY/REASSEMBLY 2, “A” “A”: Apply oil 1. Bracket sub assembly (including fuel filter) 2, “A” 2. Grommet 3. Tube 4. Housing 5. Lead wire 6. Fuel level sensor (Fuel sender gauge) 7. Fuel pump 8. Cushion 9. Bracket 10.
Page 365 ENGINE FUEL 6C-11 3) Connect fuel breather hose (1), fuel vapor hose (2) and pipe joints (fuel feed line (3) and fuel return line (4)) to fuel pump as- sembly. CAUTION: When connecting joint, clean outside surface 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 366 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 367 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM Table B-8 electric load signals check ..6E1-43 Fuel pressure inspection ....6E1-64 Table B-9 A/C control signal check Fuel cut operation...
Page 368 ENGINE AND EMISSION CONTROL SYSTEM 6E1-3 GENERAL DESCRIPTION The engine and emission control system has 4 major Fuel delivery system includes fuel pump, delivery sub-systems: air intake system, fuel delivery system, pipe, fuel pressure regulator, fuel injectors, etc. electronic control system and emission control sys- Electronic control system includes, ECM/PCM, vari- tem.
Page 369 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM 1. Air cleaner 26. Fuel tank 2. IAT sensor 27. Fuel pump assembly 3. MAP sensor 28. Fuel pump relay 4. TP sensor 29. DLC 5. IAC valve 30. SDM (if equipped), EPS controller 6.
Page 370 ENGINE AND EMISSION CONTROL SYSTEM 6E1-5 SYSTEM FLOW CHART SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE FUEL PUMP RELAY FUEL INJECTOR HO2S HEATER IAC VALVE IGNITION COIL WITH IGNITER EGR VALVE EVAP CANISTER PURGE VALVE RADIATOR FAN RELAY MAIN RELAY...
Page 371 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM SYSTEM WIRING DIAGRAM Br/W TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) C13 C12 C11 C10 C9 C6 C5 B8 B7 B4 B3 A10 A9 C26 C25 C24 C23 C22 C21 C20 C19 C18 C17 C16 C15 C14 B16 B15 B14 B13 B12 B11 B10 B9 A22 A21 A20 A19 A18 A17 A16 A15 A14 A13 A12...
Page 372 ENGINE AND EMISSION CONTROL SYSTEM 6E1-7 1. Camshaft position sensor POSI- WIRE POSI- WIRE 2. Manifold absolute pressure sensor CIRCUIT CIRCUIT TION COLOR TION COLOR 3. Throttle position sensor 4. Engine coolant temperature sensor Power source Radiator fan control relay 5.
Page 373 6E1-8 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSIS The engine and emission control system in this vehicle are con- trolled by ECM/PCM. ECM/PCM has an On-Board Diagnostic sys- tem which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of ON-BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diag- nosis according to ENGINE DIAGNOSIS FLOW TABLE in SEC-...
Page 374 ENGINE AND EMISSION CONTROL SYSTEM 6E1-9 MALFUNCTION INDICATOR LAMP CHECK (“CHECK ENGINE” LIGHT) CHECK ENGINE 1) Turn ignition switch to ON position (but without running engine), check that malfunction indicator lamp (“CHECK ENGINE” light) lights up. If lamp does not light up, go to TABLE A-1 MALFUNC- TION INDICATOR LAMP CIRCUIT CHECK in this section.
Page 375 6E1-10 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE 1) Turn ignition switch to OFF position. 2) Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM/PCM memory and reconnect it. Time required to erase DTC: Ambient Time to cut power to ECM/PCM temperature...
Page 376 ENGINE AND EMISSION CONTROL SYSTEM 6E1-11 DIAGNOSTIC TROUBLE CODE TABLE EXAMPLE: When throttle position sensor is defective (Code No. 13) DIAGNOSTIC MALFUNCTION INDICATOR TROUBLE LAMP (“CHECK ENGINE” DIAGNOSTIC ITEM DIAGNOSIS CODE NO. LIGHT) FLASHING PATTERN Go to DTC No.11 MANIFOLD ABSO- Manifold absolute pressure LUTE PRESSURE SENSOR CIRCUIT in sensor...
Page 377 6E1-12 ENGINE AND EMISSION CONTROL SYSTEM TABLE A-1 MALFUNCTION INDICA TOR LAMP (MIL) CIRCUIT CHECK MIL DOES NOT COME ON AT IGNITION SWITCH ON BUT LEA VING ENGINE OFF WIRING DIAGRAM Br/W B/Br 1. Ignition switch 2. Malfunction indicator lamp (“CHECK ENGINE”...
Page 378 ENGINE AND EMISSION CONTROL SYSTEM 6E1-13 TABLE A-1 STEP ACTION Did you perform ENGINE DIAGNOSIS FLOW Go to Step 2. Go to ENGINE DIAG- TABLE in SECTION 6? NOSIS FLOW TABLE in SECTION 6. Test switch terminal circuit check: “V/W” wire shorted to Go to Step 3.
Page 379 6E1-14 ENGINE AND EMISSION CONTROL SYSTEM Fig. for Step 2 TABLE A-4 ECM/PCM POWER AND GROUND CIRCUIT CHECK MIL DOES NOT LIGHT AT IGNITION SWITCH ON AND ENGINE DOES NOT START THOUGH IT IS CRANKED UP TABLE A-4 STEP ACTION Did you perform TABLE A-1 MALFUNCTION IN- Go to Step 2.
Page 380 ENGINE AND EMISSION CONTROL SYSTEM 6E1-15 STEP ACTION ECM/PCM power circuit check: Go to Step 7. “B/R” wire open. 1) Connect jumper wire from “A22” terminal of ECM/PCM connector to ground. 2) Measure voltage from “A1” terminal of ECM/ PCM connector to ground and from “C15” ter- minal of ECM/PCM connector to ground.
Page 381 6E1-16 ENGINE AND EMISSION CONTROL SYSTEM DTC NO. 11 MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT (SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM) WIRING DIAGRAM 1. Manifold absolute pressure (MAP) sensor 2. MAP sensor connector 3. ECM/PCM Lg/R Gr/R TROUBLESHOOTING CAUTION: Do not connect from terminal “a” to “c” of MAP sensor connector. When code No.
Page 382 ENGINE AND EMISSION CONTROL SYSTEM 6E1-17 STEP ACTION 1) Remove MAP sensor. Clean air passage or re- Go to Step 6. 2) Visually inspect MAP sensor air pressure inlet place as necessary. passage for clogging. Was any clogging found? 1) Perform MAP SENSOR INSPECTION in this Poor connection of MAP Faulty MAP sensor.
Page 383 6E1-18 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.13 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE LOW OR HIGH) WIRING DIAGRAM 1. Throttle position (TP) sensor 2. TP sensor connector 3. ECM/PCM TROUBLESHOOTING CAUTION: Do not connect from terminal “a” to “c” of TP sensor connector. When code No.
Page 384 ENGINE AND EMISSION CONTROL SYSTEM 6E1-19 STEP ACTION Check TP sensor for adjusting properly by re- Go to Step 4. Adjust TP sensor. ferring TP SENSOR ADJUSTMENT. Is it adjusted properly? 1) Perform TP SENSOR INSPECTION in this Poor connection of TP Faulty TP sensor.
Page 385 6E1-20 ENGINE AND EMISSION CONTROL SYSTEM DTC NO.14 HEATED OXYGEN SENSOR CIRCUIT (SIGNAL VOLTAGE LOW) WIRING DIAGRAM 1. Heated oxygen sensor 2. Heated oxygen sensor connector 3. ECM/PCM connector 4. ECM/PCM 5. Power supply from main relay TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) TROUBLESHOOTING When code No.
Page 386 ENGINE AND EMISSION CONTROL SYSTEM 6E1-21 STEP ACTION Did you perform ENGINE DIAGNOSIS FLOW Go to Step 2. Go to ENGINE DIAGNO- TABLE in SECTION 6? SIS FLOW TABLE in SECTION 6. 1) Start engine. S and its circuit are Go to Step 3.
Page 387 6E1-22 ENGINE AND EMISSION CONTROL SYSTEM DTC NO. 15 CAMSHAFT POSITION SENSOR CIRCUIT (NO SIGNAL FROM CMP SENSOR WHILE CLANKING ENGINE FOR MORE THAN 4 SECONDS) WIRING DIAGRAM 1. Cam shaft position (CMP) sensing rotor 2. CMP sensor 3. CMP sensor connector 4.
Page 388 ENGINE AND EMISSION CONTROL SYSTEM 6E1-23 Blank...
Page 389 6E1-24 ENGINE AND EMISSION CONTROL SYSTEM DTC NO. 16 VEHICLE SPEED SENSOR CIRCUIT (NO VEHICLE SPEED SENSOR SIGNAL EVEN THOUGH FUEL HAS BEEN CUT FOR MORE THAN 4 SECONDS) WIRING DIAGRAM 1. VSS sensing rotor 2. VSS (vehicle speed sensor) 3.
Page 390 ENGINE AND EMISSION CONTROL SYSTEM 6E1-25 STEP ACTION 1) Remove VSS. Faulty VSS signal rotor. Poor connection of VSS 2) Visually inspect VSS sensor signal rotor for connector terminal. damage. If OK, substitute a Was any damage found? known-good VSS and recheck.
Page 391 6E1-26 ENGINE AND EMISSION CONTROL SYSTEM DTC NO. 17 KNOCK SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) WIRING DIAGRAM 1. ECM/PCM 2. Knock sensor 3. To other sensor 4. Knock sensor connector TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) TROUBLESHOOTING STEP ACTION...
Page 392 ENGINE AND EMISSION CONTROL SYSTEM 6E1-27 Fig. for Step 3...
Page 393 6E1-28 ENGINE AND EMISSION CONTROL SYSTEM DTC NO. 18 INTAKE AIR TEMPERATURE SENSOR CIRCUIT (SIGNAL VOLTAGE LOW OR HIGH) When code No. 11, 13, 14, 18 and 19 are indicated together, it is possible that “Or” wire is open or C14 terminal connections are poor.
Page 394 ENGINE AND EMISSION CONTROL SYSTEM 6E1-29 NOTE: Upon completion of inspection and repair work, perform DTC CONFIRMATION PROCEDURE in this sec- tion and confirm that the trouble has been corrected. Fig. for Step 2 Fig. for Step 3...
Page 395 6E1-30 ENGINE AND EMISSION CONTROL SYSTEM DTC NO. 19 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (SIGNAL VOLTAGE LOW OR HIGH) When code No. 11, 13, 14, 18 and 19 are indicated together, it is possible that “Or” wire is open or C14 terminal connections are poor.
Page 396 ENGINE AND EMISSION CONTROL SYSTEM 6E1-31 NOTE: Upon completion of inspection and repair work, perform DTC CONFIRMATION PROCEDURE in this sec- tion and confirm that the trouble has been corrected. Fig. for Step 2 Fig. for Step 3...
Page 397 6E1-32 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE WARNING: When performing road test, select a safe place where no other person or running vehicle is present so as to prevent any accident and be very careful while testing to ensure safety. Road test should be performed with 2 persons, a driver and a tester, on a level road.
Page 398 ENGINE AND EMISSION CONTROL SYSTEM 6E1-33 TABLE B-1 FUEL PUMP CIRCUIT CHECK 1. Battery 2. Fuse/relay box 3. Main relay 4. Fuel pump relay Br/W 5. Fuel pump 6. ECM/PCM B/Br TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) STEP ACTION Is fuel pump heard to operate 3 se-...
Page 399 6E1-34 ENGINE AND EMISSION CONTROL SYSTEM Fig. for Step 2...
Page 400 ENGINE AND EMISSION CONTROL SYSTEM 6E1-35 TABLE B-2 FUEL INJECTOR CIRCUIT CHECK 1. Battery 2. Main fuse box 3. Main relay 4. ECM/PCM Bl/W 5. No.1 injector 6. No.2 injector Br/W 7. No.3 injector 8. No.4 injector Br/W B/Br TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) STEP ACTION 1) Using sound scope, check each injector for oper-...
Page 401 6E1-36 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-3 FUEL PRESSURE CHECK 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. To intake manifold 5. Fuel pump assembly 6. Fuel tank Special Tool: (A): Gauge (09912-58441) (B): Hose (09912-58431) (C): 3-way joint (09912-58490) NOTE: Before using following flow table, check to make sure that battery voltage is higher than 11V.
Page 402 ENGINE AND EMISSION CONTROL SYSTEM 6E1-37 TABLE B-3 FUEL PRESSURE CHECK (CONTINUED) STEP ACTION With fuel pump operated and fuel return Faulty fuel pressure regu- Shortage of fuel or fuel pump hose blocked by pinching it, is fuel pres- lator. or its circuit defective (Refer to sure applied? TABLE B-1 FUEL PUMP CIR-...
Page 403 6E1-38 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-4 IAC SYSTEM CHECK 1. IAC valve 2. Intake air 3. Bypass air 4. To combustion chambers 5. Throttle body 6. To main relay 7. ECM/PCM 8. Monitor connector 9. Sensed information R/Bl B/Br TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) B14 B13...
Page 404 ENGINE AND EMISSION CONTROL SYSTEM 6E1-39 TABLE B-4 IAC SYSTEM CHECK (CONTINUED) STEP ACTION Is engine idle speed kept at specified IAC system is in good condi- Go to step 4. speed even with A/C switch turned ON? tion. Engine idle speed : 900 –...
Page 405 6E1-40 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-5 EGR SYSTEM CHECK B/Br 1. EGR valve 2. EGR back pressure transducer 3. Solenoid vacuum valve 4. ECM/PCM 5. MAP sensor 6. Sensed information 7. Intake air 8. Exhaust gas 9. To main relay TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) C11 C10 STEP...
Page 406 ENGINE AND EMISSION CONTROL SYSTEM 6E1-41 TABLE B-6 EVAP SYSTEM CHECK 1. EVAP canister purge valve 2. To main relay 3. ECM/PCM 4. Sensed information 5. Intake manifold 6. EVAP canister 7. Tank pressure control valve 8. Fuel vapor line 9.
Page 407 6E1-42 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-7 RADIATOR FAN CONTROL SYSTEM CHECK 1. Battery 2. Fuse/relay box 3. Ignition switch 4. Circuit fuse 5. Main relay 6. Radiator fan control relay Br/W 7. Radiator fan motor 8. ECM/PCM B/Br TERMINAL ARRANGEMENT OF ECM/PCM CONNECTOR (VIEWED FROM HARNESS SIDE) STEP ACTION...
Page 408 ENGINE AND EMISSION CONTROL SYSTEM 6E1-43 TABLE B-8 ELECTRIC LOAD SIGNALS CIRCUIT 1. Battery 2. Fuse/relay box 3. Ignition switch 4. Circuit fuse (REAR DEFOGGER) 5. Blower fan motor 6. Clearance light switch 7. Clearance light 8. Blower fan switch 9.
Page 409 6E1-44 ENGINE AND EMISSION CONTROL SYSTEM TABLE B-9 A/C CONTROL SIGNAL CHECK (IF EQUIPPED) 1. Battery 2. Main fuse box 3. Ignition switch 4. Circuit fuse 5. Blower fan motor 6. Blower fan switch 7. A/C switch 8. Dual pressure switch 9.
Page 410 ENGINE AND EMISSION CONTROL SYSTEM 6E1-45 TABLE B-9 A/C CONTROL SIGNAL CHECK (IF EQUIPPED) (CONTINUED) STEP ACTION 1) Check voltage at “A12” terminal under each condi- A/C control system “P/B” wire open or tion given in table below. circuits are in good short condition.
Page 411 6E1-46 ENGINE AND EMISSION CONTROL SYSTEM INSPECTION OF ECM/PCM AND ITS CIR- CUITS ECM/PCM (1) and its circuits can be checked at ECM/PCM wiring connectors by measuring voltage and resistance. CAUTION: ECM/PCM cannot be checked by itself. It is strictly pro- hibited to connect voltmeter or ohmmeter to ECM/PCM with connectors disconnected from it.
Page 412 ENGINE AND EMISSION CONTROL SYSTEM 6E1-47 — Not used — — 10 – 14 V Brake pedal depressed Stop light switch Stop light switch 0 – 1 V Brake pedal not depressed Deflects between Ignition switch ON and front wheel turned slowly with 0 V and 10 –...
Page 413 6E1-48 ENGINE AND EMISSION CONTROL SYSTEM 0 – 1 V Ignition switch ON MIL (Diagnosis output terminal) Deflects between Ignition switch ON and diagnosis switch terminal 0 V and 10 – 14 V grounded — Not used — — — Not used —...
Page 414 ENGINE AND EMISSION CONTROL SYSTEM 6E1-49 ON-VEHICLE SERVICE GENERAL When the emission control hoses are disconnected and the sys- tem’s components are removed for service, reinstall them properly. After service, making sure that hoses are routed and connected correctly. Refer to Emission Control Information Label (if equipped) for proper routing of hoses.
Page 415 6E1-50 ENGINE AND EMISSION CONTROL SYSTEM ACCELERATOR CABLE ADJUSTMENT With accelerator pedal depressed fully, check clearance between throttle lever (1) and lever stopper (2) (throttle body), it should be within following specification. Clearance “b” : 0.5 – 2.0 mm (0.02 – 0.07 in.) (With pedal depressed fully) With throttle valve closed, check accelerator pedal play, it should “a”...
Page 416 ENGINE AND EMISSION CONTROL SYSTEM 6E1-51 1) Disconnect scan tool from DLC if connected. 2) Warm up engine to normal operating temperature. 3) Stop engine and connect duty meter (3) between duty output terminal (5) and ground terminal (6) of monitor connector (1). 4) Using service wire (2), ground diagnosis switch terminal (4) in monitor connector 5) Set tachometer.
Page 417 6E1-52 ENGINE AND EMISSION CONTROL SYSTEM SENSOR TERMINAL ARRANGEMENT OF ECM/PCM COUPLER (VIEWED FROM HARNESS SIDE) MAP SENSOR OUTPUT VOLTAGE CHECK 1) Remove ECM/PCM according to previously outlined proce- dure. 2) Connect connectors to ECM/PCM securely. 3) With connector connected to ECM/PCM, connect digital type voltmeter as shown and check that ECM/PCM supply voltage 4.75 –...
Page 418 ENGINE AND EMISSION CONTROL SYSTEM 6E1-53 REMOVAL 1) Disconnect MAP sensor vacuum hose from intake manifold. 2) Disconnect connector from MAP sensor. 3) Remove MAP sensor (1). INSPECTION Arrange 3 new 1.5V batteries (1) in series (check that total voltage Vout is 3.5 –...
Page 419 6E1-54 ENGINE AND EMISSION CONTROL SYSTEM TP SENSOR ADJUSTMENT 1) Warm up engine to normal operating temperature. 2) Loosen TP sensor screws. 3) Remove ECM/PCM as previously outlined and with connectors connected to ECM/PCM, connect digital type voltmeter be- TERMINAL ARRANGEMENT OF ECM/PCM tween “C6”...
Page 420 ENGINE AND EMISSION CONTROL SYSTEM 6E1-55 INSPECTION 1) Disconnect negative cable at battery and connector from TP sensor. 2) Using tester, check resistance between terminals under each condition given in table below. TERMINAL CONDITION RESISTANCE Between “A” and –––––– 2.0 – 8.0 k “C”...
Page 421 6E1-56 ENGINE AND EMISSION CONTROL SYSTEM KNOCK SENSOR REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect connector of knock sensor. 3) Remove knock sensor (1) from cylinder block (2). NOTE: Be careful not to expose it to excessive shock. INSPECTION Inspect knock sensor, referring to flow table of diagnostic trouble code No.
Page 422 ENGINE AND EMISSION CONTROL SYSTEM 6E1-57 INSPECTION Immerse temperature sensing part of IAT sensor in water and mea- sure resistance between sensor terminals while heating water gradually. If measured resistance doesn’t show such characteristic as shown in the figure, replace IAT sensor. INSTALLATION Reverse removal procedure noting the following.
Page 423 6E1-58 ENGINE AND EMISSION CONTROL SYSTEM REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor should be re- moved when system is cool. 1) Disconnect negative cable at battery. 2) Disconnect connector of oxygen sensor. 3) Remove oxygen sensor (1) from exhaust manifold (2).
Page 424 ENGINE AND EMISSION CONTROL SYSTEM 6E1-59 ON-VEHICLE INSPECTION 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral state. 3) Connect voltmeter between “A18” terminal of ECM/PCM con- nector and body ground. 4) Turn ignition switch to ON position and turn rear right tire slowly with rear left tire locked.
Page 425 6E1-60 ENGINE AND EMISSION CONTROL SYSTEM ECM/PCM POWER SUPPLY SYSTEM MAIN RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove main relay (1) from fuse/relay box (2). 3) Check resistance between each two terminals as in table below. TERMINALS RESISTANCE Between A and B (Infinity)
Page 426 ENGINE AND EMISSION CONTROL SYSTEM 6E1-61 AIR INTAKE SYSTEM THROTTLE BODY ON-VEHICLE INSPECTION Check that throttle valve lever moves smoothly. REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system, referring to SECTION 6B. 3) Remove air cleaner inlet pipe (1), air cleaner assembly (2) and resonator (3).
Page 427 6E1-62 ENGINE AND EMISSION CONTROL SYSTEM CLEANING Clean passages (1) by blowing compressed air. NOTE: MAP sensor, TP sensor, or other components containing rubber must not be placed in a solvent or cleaner bath. A chemical reaction will cause these parts to swell, harden or get distorted.
Page 428 ENGINE AND EMISSION CONTROL SYSTEM 6E1-63 IAC VALVE ON-VEHICLE INSPECTION Inspect IAC valve, referring to TABLE B-5 IAC SYSTEM CHECK. INSPECTION “B” Check resistance between following terminals of IAC valve. “A” “C” Terminal Standard resistance “A” – “B” “B” – “C” 44.5 –...
Page 429 6E1-64 ENGINE AND EMISSION CONTROL SYSTEM FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION 1) Relieve fuel pressure in fuel feed line referring to SECTION 6. 2) Connect special tools and hose between fuel feed hose (1) and fuel feed pipe (2) as shown in the figure, and clamp hose se- curely to ensure no leaks occur while checking.
Page 430 ENGINE AND EMISSION CONTROL SYSTEM 6E1-65 FUEL CUT OPERATION INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up. 1) Warm up engine to normal operating temperature.
Page 431 6E1-66 ENGINE AND EMISSION CONTROL SYSTEM 2) Fuel pressure should be felt at fuel return hose (1) for 3 seconds after ignition switch is turned to ON position. If fuel pressure is not felt, to go to TABLE B-4 FUEL PRESSURE CHECK.
Page 432 ENGINE AND EMISSION CONTROL SYSTEM 6E1-67 3) Remove fuel pressure regulator (1) from delivery pipe (2). WARNING: A small amount of fuel may be released when fuel pressure regulator is disconnected from delivery pipe. Place a shop cloth under delivery pipe so that released fuel is absorbed in it.
Page 433 6E1-68 ENGINE AND EMISSION CONTROL SYSTEM FUEL INJECTOR ON-VEHICLE INSPECTION 1) Using sound scope (1) or such, check operating sound of injec- tor 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, check injector circuit (wire or connector) or injector.
Page 434: Special Tools
ENGINE AND EMISSION CONTROL SYSTEM 6E1-69 1) Install injector and fuel pressure regulator to special tool (injec- tor checking tool). NOTE: Remove grommet from injector, then install injector to spe- cial tool and tighten bolts by hand. Special Tool (A): 09912-58421 2) Connect special tools (hoses and attachment) to pipes of ve- hicle.
Page 435 6E1-70 ENGINE AND EMISSION CONTROL SYSTEM 9) Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should be at work). If fuel leaks more than following specification, replace injector. Fuel leakage: Less than 1 drop/min. INSTALLATION 1) Replace injector O-ring (1) with new one using care not to dam- age it.
Page 436 ENGINE AND EMISSION CONTROL SYSTEM 6E1-71 RADIATOR FAN CONTROL SYSTEM SYSTEM INSPECTION WARNING: Keep hands, tools, and clothing away from engine cool- ing fan to help prevent personal injury. This fan is electric type and can turn on whether or not the engine is run- ning.
Page 437 6E1-72 ENGINE AND EMISSION CONTROL SYSTEM 1) When engine is cool (coolant temperature is below 40 C (104 F)), start engine and race it (higher than about 2000 rpm), and check that EGR valve diaphragm (1) is not operating in this state.
Page 438 ENGINE AND EMISSION CONTROL SYSTEM 6E1-73 3) Connect vacuum pump gauge to nozzle “P” and plug nozzle “Q” with finger. “Q” “P” While blowing air into nozzle “A”, operate vacuum pump gauge (1) and check that vacuum is applied to back pressure transduc- Then stop blowing nozzle “A”...
Page 439 6E1-74 ENGINE AND EMISSION CONTROL SYSTEM EGR SOLENOID VACUUM VALVE INSPECTION 1) With ignition switch at OFF position, disconnect connector from EGR solenoid vacuum valve (1). 2) Measure resistance between two terminals of solenoid vacuum valve. Resistance: 36 – 44 at 20 C (68 F) If resistance is as specified, proceed to next operation check, If not, replace.
Page 440 ENGINE AND EMISSION CONTROL SYSTEM 6E1-75 4) Disconnect purge hose from “PURGE” side port of EVAP canis- ter. 5) Place finger against the end of disconnected hose and check that vacuum is not felt there when engine is running at idle speed.
Page 441 6E1-76 ENGINE AND EMISSION CONTROL SYSTEM 5) Connect 12 V-battery (1) to EVAP canister purge solenoid valve terminals. In this state, blow hose “A”. Air should come out of nozzle “B”. WARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful.
Page 442 ENGINE AND EMISSION CONTROL SYSTEM 6E1-77 PCV SYSTEM NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed, for obstructed PCV valve or hose hampers its accurate inspection. PCV HOSE INSPECTION Check hoses for connection, leakage, clog and deterioration.
Page 443 6E1-78 ENGINE AND EMISSION CONTROL SYSTEM TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening parts kg-m lb-ft TP sensor 0.25 IAC valve 0.25 Fuel pressure regulator IAT sensor 11.0 Knock sensor 17.0 SPECIAL TOOLS 1. Tool body & washer 2. Body plug 3.
Page 444 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Loca- tion View” under “General Description” in air bag system section in order to confirm wheth- er you are performing service on or near the air bag system components or wiring.
Page 445 6F1-2 IGNITION SYSTEM GENERAL DESCRIPTION The ignition system used for this vehicle has an electronic ignition control system and consists of the following parts. ECM (or PCM) It detects the engine condition 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 igniter.
Page 446 IGNITION SYSTEM 6F1-3 SYSTEM WIRING Br/W 1. To ignition switch 2. “IG METER” fuse 3. Ignition coil 4. Noise suppressor 5. Distributor 5-1.CMP sensor 6. Spark plug 7. Igniter 8. ECM (or PCM) 9. Monitor coupler...
Page 447 6F1-4 IGNITION SYSTEM DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil Replace not start or hard to start Loose connection or disconnection of lead wire or Connect securely high-tension cord(s) Faulty high-tension cord(s) Replace Faulty spark plug(s) Adjust, clean or replace Cracked rotor or cap...
Page 448 IGNITION SYSTEM 6F1-5 STEP ACTION Ignition Coil Power Supply And Ground Circuit Check Go to Step 8. Repair or replace. 1) Check ignition coil power supply (“BW” wire) circuit for open and short. Are circuits in good condition? Ignition Coil Check Go to Step 9.
Page 449 6F1-6 IGNITION SYSTEM IGNITION SPARK TEST 1) Remove air cleaner assembly (1) and resonator box (2). 2) Remove cylinder head upper cover. 3) Disconnect all injector couplers (1) from injectors (2). WARNING: Without disconnection of injector coupler, combus- tible gas may come out from spark plug holes during this test and may get ignited in engine room.
Page 450 IGNITION SYSTEM 6F1-7 INSPECTION 1) Measure resistance of high-tension cord (1) by using ohmmeter (2). High-tension cord resistance: 4 – 10 k /m (1.2 – 3.0 k /ft) 2) If resistance exceeds specification, inspect distributor terminal and replace high-tension cord(s) and /or distributor cap as re- quired.
Page 451 6F1-8 IGNITION SYSTEM NOISE SUPPRESSOR REMOVAL 1) Remove air cleaner assembly. 2) Unwrap tape from nose suppressor. 3) Disconnect coupler of noise suppressor (1). 4) Remove noise suppressor. 2. Starting motor INSPECTION Using ohmmeter (1), check to be sure that capasitor (Condenser) in noise suppressor (2) is not conductive.
Page 452 IGNITION SYSTEM 6F1-9 IGNITION COIL PRIMARY INSPECTION 1) Pull out high-tension cord by gripping its cap. 2) Disconnect ignition coil coupler. 3) Measure primary and secondary coil resistances. Ignition coil resistance (at 20 C, 68 F) Primary : Approx. 1 Secondary: Approx.
Page 453 6F1-10 IGNITION SYSTEM CMP Sensor Resistance 1) Disconnect distributor lead wire coupler (1). 2) Measure resistance of CMP sensor by using ohmmeter. CMPsensor resistance: Approx. 735 (at 20 C/68 F) 3) If resistance is out of specification, replace CMP sensor as fol- lows.
Page 454 IGNITION SYSTEM 6F1-11 4) If ignition timing is out of specification, remove air cleaner as- sembly then loosen flange bolt (1), adjust timing by turning dis- tributor assembly (2) while engine is running, and then tighten bolt. Tightening Torque (a): 13 N · m (1.3 kg-m, 9.5 lb-ft) 5) After tightening distributor flange bolt, recheck that ignition tim- ing is within specification.
Page 455 6F1-12 IGNITION SYSTEM DISTRIBUTOR UNIT 1. Cap 2. Cap seal 3. Cap screw 4. Rotor 5. Rotor screw 6. CMP sensor (Signal generator) 7. CMP sensor screw 8. Distributor flange bolt 9. Housing 10. O-ring DISMOUNTING 1) Remove air cleaner assembly (1). 2) Disconnect distributor lead wire coupler (1).
Page 456 IGNITION SYSTEM 6F1-13 REMOUNTING NOTE: • Before installing distributor, check to make sure that its O- ring (1) is in good condition. • If new O-ring (1) is to be installed, apply oil. 1) Install distributor without cap (2) to camshaft. Fit the dogs of distributor coupling into the slots of camshaft (3), when installing.
Page 457 CRANKING SYSTEM 6G-1 SECTION 6G CRANKING SYSTEM CONTENTS GENERAL DESCRIPTION ....6G- 2 Pinion and over-running clutch ..6G-10 Cranking Circuit ..... 6G- 2 Front housing bush .
Page 458 6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically as shown in figure below. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT In the circuit shown in figure below, the magnetic switch coils are magnetized when the ignition switch is closed.
Page 459 CRANKING SYSTEM 6G-3 STARTING MOTOR The starting motor consists of the following parts. 1. Front housing bush : Apply lithium grease 99000-25010 to inside. 2. Front housing 3. Snap ring 4. Stop ring 5. Over-running clutch : Apply lithium grease 99000-25010 to inside and outside of spline.
Page 460 6G-4 CRANKING SYSTEM 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 Starting motor does not stop running Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..
Page 461 CRANKING SYSTEM 6G-5 Condition Possible Cause Correction Starting motor If battery and wiring are satisfactory, running but too slow inspect starting motor (small torque) Insufficient contact of magnetic switch Replace magnetic switch. main contacts Layer short-circuit of armature Replace. Disconnected, burnt or worn commutator Repair commutator or replace armature.
Page 462 6G-6 CRANKING SYSTEM ON-VEHICLE SERVICE For overhauling of starting motor, it is recommended that compo- nent parts should be cleaned thoroughly. However, yoke, armature coil, over-running clutch, magnetic switch assembly, rubber or plastic parts are NOT ALLOWED to be washed in degreasing tank or with grease dissolving solvent.
Page 463 CRANKING SYSTEM 6G-7 3) Loosen 2 bolts and 2 screws to remove rear bracket. 4) Separate front housing (1) and armature (2) from yoke (3). 5) Draw brushes (1) out of holder (2). 6) Draw stop ring (1) toward clutch side and remove snap ring (2) and slide off over-running clutch (3).
Page 464 6G-8 CRANKING SYSTEM Inspect commutator (1) for wear. If below limit, replace armature. Commutator outside diameter Standard: 32 mm (1.26 in.) Limit : 31.4 mm (1.24 in.) Inspect commutator for insulator depth. Correct or replace if below limit. Commutator insulator depth A Standard: 0.4 –...
Page 465 CRANKING SYSTEM 6G-9 FIELD COIL Ground Test Check for continuity between brush and bare surface. If there is continuity, field windings are grounded. The yoke must be re- placed. BRUSH Check brushes for wear. If below limit, replace brush. Brush length Standard: 17 mm (0.67 in.) Limit : 11.5 mm (0.45 in.)
Page 466 6G-10 CRANKING SYSTEM PINION AND OVER-RUNNING CLUTCH Inspect pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and ro- tates smoothly in reverse direction. Replace if necessary. Inspect spline teeth (1) for wear or damage. Replace if necessary. Inspect pinion for smooth movement.
Page 467 CRANKING SYSTEM 6G-11 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’ terminal (1) and ‘M’ terminal (2). If no continuity exists, the coil is open and should be replaced.
Page 468 6G-12 CRANKING SYSTEM PERFORMANCE TEST CAUTION: Each test must be performed within 3–5 seconds to avoid coil from burning. WARNING: When preforming the following test, be sure to connect the battery and the starting motor with a lead wire of the same size as the cable that was originally used there.
Page 469 7 N·m (0.7 kg-m, 5.0 lb-ft) minimum Magnetic switch operating voltage 8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT Lithium grease SUZUKI SUPER GREASE A Front housing bush (99000-25010) Over-running clutch Drive lever Plunger Armature Armature shaft bush...
Page 470 CHARGING SYSTEM 6H-1 SECTION 6H CHARGING SYSTEM CONTENTS BATTERY GENERAL DESCRIPTION ..............6H - 2 CARE OF BATTERY .
Page 471: Battery
6H-2 CHARGING SYSTEM BATTERY GENERAL DESCRIPTION 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. It can, for a limited time, provide energy when the electrical load exceeds the output of the generator.
Page 472: Diagnosis
CHARGING SYSTEM 6H-3 2) Keep the battery cable connections clean. The cable connections, particularly at the positive (+) terminal post, tend to become corroded. The product of corrosion, or rust, on the mating faces of conductors resists the flow of cur- rent.
Page 473 6H-4 CHARGING SYSTEM As the S.G. varies with the temperature, if battery temperature is not at 20 C (68 F), you have to correct your S.G. reading (taken with your hydrometer) to the value at 20 C (68 F) and apply the corrected S.G.
Page 474: On-Vehicle Service
CHARGING SYSTEM 6H-5 ON-VEHICLE SERVICE JUMP STARTING IN CASE OF EMERGENCY WITH AUXILIARY (BOOSTER) BATTERY CAUTION: If vehicle is manual transmission model and has a cata- lytic converter, do not push or tow it to start. Damage to its emission system and/or to other parts may result. Both booster and discharged battery should be treated carefully when using jumper cables.
Page 475: Removal
6H-6 CHARGING SYSTEM WITH CHARGING EQUIPMENT CAUTION: When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equip- ment can cause serious damage to electrical system or electronic parts.
Page 476: Generator General Description
CHARGING SYSTEM 6H-7 GENERATOR GENERAL 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. 1. Generator with regulator assembly 5. Field coil (rotor coil) 2.
Page 477: Diagnosis
6H-8 CHARGING SYSTEM DIAGNOSIS CAUTION: Do not mistake polarities of IG terminal and L terminal. Do not create a short circuit between IG and L termi- nals. Always connect these terminals through a lamp. Do not connect any load between L and E. When connecting a charger or a booster battery to ve- hicle battery, refer to this section describing battery charging.
Page 478 CHARGING SYSTEM 6H-9 UNDERCHARGED BATTERY This condition, as evidenced by slow cranking can be caused by one or more of the following conditions even though indicator lamp may be operating normal. The following procedure also applies to cars with voltmeter and ammeter.
Page 479 6H-10 CHARGING SYSTEM 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 the following check. 2) Ground F terminal and start engine, then measure voltage at B terminal as shown in left figure.
Page 480: On-Vehicle Service
CHARGING SYSTEM 6H-11 ON-VEHICLE SERVICE REMOVAL 1) Disconnect negative cable (1) at battery (2). 2) Disconnect “B” terminal wire (1) and coupler (2) from generator (3). 3) Remove adjusting bolt (4) and loosen generator pivot bolt (5). 4) Remove generator with bracket (6).
Page 481: Disassembly
6H-12 CHARGING SYSTEM DISASSEMBLY 113 N·m (11.3 kg-m) 8.7 N·m (0.87 kg-m) 2.6 N·m (0.26 kg-m) 7.8 N·m (0.78 kg-m) 4.2 N·m (0.42 kg-m) 2.0 N·m (0.2 kg-m) 4.5 N·m (0.45 kg-m) 4.5 N·m (0.45 kg-m) 2.0 N·m (0.2 kg-m) 2.0 N·m (0.2 kg-m) 22 N·m (2.2 kg-m) 7 N·m (0.7 kg-m)
Page 482 CHARGING SYSTEM 6H-13 1) Remove B terminal inner nut (1) and insulator (2). 2) Remove rear end cover (3). 3) Remove 2 brush holder screws (1) and pull out brush holder as- sembly (2). 4) Remove 3 IC regulator screws (3) and IC regulator (4). 5) Remove brush holder cover (1) from brush holder (2).
Page 483 6H-14 CHARGING SYSTEM 8) Remove rear end frame bolts and nuts. 9) Drive out rear end frame (1) with rotor tapping rotor shaft (2) lightly by using plastic hammer (3). 10) Separate rear end frame from rotor evenly by using plastic hammer.
Page 484: Inspection
CHARGING SYSTEM 6H-15 INSPECTION ROTOR Open Circuit Using ohmmeter, check for continuity between slip rings of rotor (1). If there is no continuity, replace rotor. Standard resistance: About 2.9 Ground Using ohmmeter, check that there is no continuity between slip ring and rotor (1).
Page 485 6H-16 CHARGING SYSTEM BRUSH Exposed Brush Length “a” Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush. Refer to “Replace Brush” in this section. Exposed brush length “a” Standard : 10.5 mm (0.413 in.) Limit : 4.5 mm (0.331 in.)
Page 486: Replace Brush
CHARGING SYSTEM 6H-17 BEARING Drive End Bearing Check that the bearing is not rough or worn. End Housing Bearing Check that the bearing is not rough or worn. When removal is necessary, refer to 6H-14. REPLACE BRUSH 1) Unsolder and remove the brush and spring. 2) Run the wire of a new brush through the hole in the brush holder, and insert the spring and brush into the brush holder.
Page 487: Assembly
6H-18 CHARGING SYSTEM ASSEMBLY 1) If end housing bearing (1) is removed, install it. 2) Check end housing bearing turns smoothly. 3) If stator (1) is removed, install stator and tighten stud bolts (2). 4) If drive end bearing (3) is removed, install it. 2 (a) 5) Check drive end bearing turns smoothly.
Page 488 CHARGING SYSTEM 6H-19 10) Install rectifier holder (1). CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades. Tightening Torque (a): 2.0 N m (0.2 kg-m, 1.5 lb-ft) (b): 2.3 N m (0.23 kg-m, 1.7 lb-ft) 11) Install brush holder cover (1) to brush holder (2).
Page 489: Installation
6H-20 CHARGING SYSTEM INSTALLATION Reverse removal procedure giving specified tension to drive belt referring to SECTION 6B. Tightening Torque (a): 22 N · m (2.2 kg-m, 16.0 lb-ft) (b): 50 N · m (5.0 kg-m, 36.5 lb-ft) (c): 7 N · m (0.7 kg-m, 5.0 lb-ft) SPECIFICATIONS Rated voltage 12 V...
Page 490 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS GENERAL DESCRIPTION ..............6K-2 MAINTENANCE .
Page 491 6K-2 EXHAUST SYSTEM GENERAL DESCRIPTION The exhaust system consists of an exhaust manifold, exhaust pipes, a muffler and seals, gasket and etc., and ex- haust pipe has the three-way catalytic converter (TWC). 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 492 EXHAUST SYSTEM 6K-3 MAINTENANCE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. At every interval of periodic maintenance service, and when ve- hicle is raised for other service, check exhaust system as follows: Check rubber mountings for damage, deterioration, and out of position.
Page 493 6K-4 EXHAUST SYSTEM ON-VEHICLE SERVICE WARNING: To avoid the danger of being burned, do not touch the ex- haust 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 6A4 for removal and installation procedures of ex- haust manifold.
Page 494 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 495 7A-2 MANUAL TRANSMISSION GENERAL DESCRIPTION The transmission provides five forward speeds and one reverse speed by means of three synchronizers and three shaft-input shaft, countershaft and reverse gear shaft. All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement. 23 N·m (2.3 kg-m) 70 N·m (7.0 kg-m) 90 N·m (9.0 kg-m)
Page 496 MANUAL TRANSMISSION 7A-3 23 N·m (2.3 kg-m) 1. Input shaft 17. Washer 32. Low speed synchronizer key 2. Oil seal 18. 5th synchronizer spring 33. Circlip 3. Input shaft right bearing 19. 5th speed sleeve & hub 34. 2nd gear synchronizer ring 4.
Page 497 7A-4 MANUAL TRANSMISSION GEAR SHIFT MECHANISM The gear shifting control system consists of the following main parts. Movement of gear shift control lever is trans- mitted to gear shift & select shaft through gear shift and gear select cables. Gear shaft Gear select 23 N·m (2.3 kg-m) 23 N·m (2.3 kg-m)
Page 498 MANUAL TRANSMISSION 7A-5 DIAGNOSIS Condition Possible Cause Correction Gears slipping out of mesh Worn shift fork shaft Replace. Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating springs Replace. Worn bearings on input shaft or counter- Replace. shaft Worn chamfered tooth on sleeve and gear Replace sleeve and gear.
Page 499 7A-6 MANUAL TRANSMISSION ON-VEHICLE SERVICE [Right side] 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 fill new specified oil by specified amount (up to level hole).
Page 500 MANUAL TRANSMISSION 7A-7 DIFFERENTIAL SIDE OIL SEAL REPLACEMENT 1) Lift up vehicle and drain transmission oil. 2) Remove drive shaft joints from differential gear of transmission. Refer to Section 4A (DRIVE SHAFT) for procedure to discon- nect drive shaft joints. For differential side oil seal removal, it is not necessary to re- move drive shafts from steering knuckle.
Page 501 7A-8 MANUAL TRANSMISSION GEAR SHIFT CONTROL LEVER AND CABLE 13 N·m (1.3 kg-m) 6 N·m (0.6 kg-m) 6 N·m (0.6 kg-m) 1. Gear shift control lever knob : Apply thread lock cement 99000-25010 to joint seam of gear shift control lever. 2.
Page 502 MANUAL TRANSMISSION 7A-9 REMOVAL 1) Remove console box. 2) Disconnect gear shift & select control cables from gear shift lever assembly. 3) Remove 4 gear shift control cable guide nuts and gear shift lever assembly from body. 4) Disconnect shift & select cables from transmission. 5) Remove E-rings, cable grommet and cable clamp, and then remove shift &...
Page 503 7A-10 MANUAL TRANSMISSION TRANSMISSION ASSEMBLY DISMOUNTING 1) Disconnect negative cable at battery. 2) Remove battery and its tray. 3) Remove air cleaner box. 4) Disconnect gearshift control cable (1) and gear select control cable (2). 5) Remove E rings (3) and transmission control cable bracket (4). 6) Undo wiring harness clamps.
Page 504 MANUAL TRANSMISSION 7A-11 18) Remove engine rear mounting with stiffener and brackets. A: To vehicle body B: To engine lower case C: To T/M case 19) Remove engine left side mounting bracket nuts (1). 20) Lower vehicle and support transmission jack. 21) Remove lower side 2 transmission to engine bolt and nut.
Page 505 7A-12 MANUAL TRANSMISSION Set release arm (1) to release shaft aligning their pinching marks (2) and tighten bolt (3). Set each clamp for wiring securely. Fill transmission with oil as specified. Connect battery and check function of engine, clutch and trans- mission.
Page 506 MANUAL TRANSMISSION 7A-13 6) Remove 8 bolts and take off transmission side cover. 7) 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. 8) Remove shift fork plug (1) and guide ball.
Page 507 7A-14 MANUAL TRANSMISSION 13) Remove 5 screws (1) and take off left case plate (2), and then remove bearing set shim (3). 14) Remove reverse shaft bolt (1) with washer. 15) Remove 9 case bolts (2) from outside and another 5 from clutch housing side.
Page 508 MANUAL TRANSMISSION 7A-15 SUB ASSEMBLY SERVICE NOTE: Before installation, wash each dart and apply specified gear oil to sliding faces of bearing and gear. Use new circlips on shaft for installation. Don’t reuse cir- clips. RIGHT CASE DISASSEMBLY 1) Remove bolt and then pull out vehicle speed sensor (1) from right case (2).
Page 509 7A-16 MANUAL TRANSMISSION REASSEMBLY 1) Press-fit input shaft oil seal (1) facing its spring side upward. Use special tool and hammer for installation and apply grease to oil seal lip. “A”: Grease 99000-25010 Special Tool (A): 09924-74590 (B): 09924-74510 2) Pree-fit countershaft right bearing cup (2) by using special tools and hammer.
Page 510 MANUAL TRANSMISSION 7A-17 6) Insert vehicle speed sensor (1) applied with oil to its O ring and tighten it with bolt. Tightening Torque (a): 5 N · m (0.5 kg-m, 3.5 lb-ft) 7) Install countershaft right bearing cone into its cap. LEFT CASE DISASSEMBLY 1) Remove input oil gutter (1) from left case (2).
Page 511 7A-18 MANUAL TRANSMISSION 3) If input oil gutter (1) has been removed, install it with bolt (2) ap- plied with thread lock cement. 2, “A”, (a) “A”: Thread lock cement 99000-32110 Tightening Torque (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) INPUT SHAFT ASSEMBLY DISASSEMBLY 1) Remove input shaft right bearing (1) using bearing puller (2) and...
Page 512 MANUAL TRANSMISSION 7A-19 INSPECTION AND REASSEMBLY 1) Clean all components thoroughly, inspect them for any ab- normality and replace with new ones as necessary. 2) If synchronizer parts need to be repaired, check clearance “a” between ring (1) and gear (2), each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Page 513 7A-20 MANUAL TRANSMISSION 6) Install 3rd gear needle bearing, apply oil to it, then install 3rd gear (1) and synchronizer ring (2). 7) Drive in high speed sleeve & hub assembly (3) using special tool and hammer. NOTE: While press-fitting sleeve & hub assembly, make sure that synchronizer ring key slots are aligned with keys in sleeve &...
Page 514 MANUAL TRANSMISSION 7A-21 2) Apply puller (1) to 2nd gear (2) and drive out 3rd gear (3) and 3rd & 4th gear spacer (4) 2nd gear using press. Needle bearing would come out with 2nd gear. CAUTION: If compression exceeds 5 ton (11,000 lb), release com- pression once, reset puller support and then continue press work again.
Page 515 7A-22 MANUAL TRANSMISSION 4) Fit low speed synchronizer sleeve (1) to hub (2), insert 3 keys (3) in it and then set springs (4) as shown in left figure. NOTE: No specific direction is assigned to low speed synchro- nizer hub or each key but it is assigned as assembly. Clutch Size of low speed synchronizer keys and springs are the side...
Page 516 MANUAL TRANSMISSION 7A-23 8) Press-fit 3rd gear (1) and spacer (2) 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 Tool (A): 09913-80112 9) Press-fit 4th gear (1) using the same procedure as the above.
Page 517 7A-24 MANUAL TRANSMISSION HIGH SPEED AND LOW SPEED GEAR SHIFT SHAFTS Inspection 1) Using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit of 1.0 mm (0.039 in.). NOTE: For correct judgement of parts replacement, carefully in- spect contact position of fork and sleeve.
Page 518 MANUAL TRANSMISSION 7A-25 DIFFERENTIAL ASSEMBLY DISASSEMBLY 1) Using special tool, remove right bearing (1). Special Tool (A): 09913-65810 (B): 09925-88210 2) Drive out exciter ring (2) using puller and press. 3) Remove left bearing using puller while supporting its center shaft as described above.
Page 519 7A-26 MANUAL TRANSMISSION Right Side Right side Using similar procedure to above-mentioned procedure, set dial gauge tip to gear (1) shoulder. Move gear up and down by hand and read dial gauge. Special Tool (A): 09900-20606 (B): 09900-20701 2) If thrust play is out of specification, select suitable thrust washer from among the following available size, install it and check again that specified gear play is obtained.
Page 520 MANUAL TRANSMISSION 7A-27 REASSEMBLY 1) Join input shaft (1), countershaft (2), low speed gear shift shaft assembly (3) and high speed gear shift shaft assembly (4) all together, then install them into right case (5). NOTE: Input shaft right bearing on shaft can be installed into right case by tapping shaft with plastic hammer.
Page 521 7A-28 MANUAL TRANSMISSION 5) Clean mating surfaces of both right case (1) and left case (2), coat mating surface of left case with sealant evenly then mate it with right case. “A”: Sealant 99000-31110 6) Tighten case bolts (3) from outside to specified torque. Tightening Torque 4, (c), “B”...
Page 522 MANUAL TRANSMISSION 7A-29 12) Put a bearing set shim (1) on bearing cup (2) provisionally, place straight edge (3) over it and compress it by hand through straight edge, and then measure ™a∫ (Clearance between case surface (4) and straight edge) using feeler gauge (5). Clearance ™a∫: 0.08 ±...
Page 523 7A-30 MANUAL TRANSMISSION 15) Assemble 5th speed synchronizer sleeve (1) and hub (2) with keys (3) and springs (4). NOTE: Short Long side C side 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 524 MANUAL TRANSMISSION 7A-31 19) Caulk nut at C with caulking tool and hammer. 20) Install synchronizer ring. 21) Fit 5th gear shift fork (1) to sleeve & hub assembly (2) and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.
Page 525 7A-32 MANUAL TRANSMISSION 27) Clean mating surface of guide case. 28) Install gear shift and select shaft assembly (1) with new gasket into transmission and tighten it to specified torque. Tightening Torque (a): 23 N·m (2.3 kg-m, 17.0 lb-ft) 29) Install washer and gear shift interlock bolt (2) applied with seal- ant and then tighten it to specified torque.
Page 526 MANUAL TRANSMISSION 7A-33 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCTS Differential side oil seal lips SUZUKI SUPER GREASE A Gear shift control lever Lithium grease (99000-25010) Gear shift/select cable Gear shift shaft oil seal Oil drain plug SUZUKI BOND NO. 1215...
Page 527 7A-34 MANUAL TRANSMISSION 09913-80112/09925-98221 09924-74510 09924-74590 09925-68210 Bearing installer Installer attachment Oil seal installer Bearing outer race installer 09925-78210 09925-88210 09930-30102 09940-53111 Spring pin remover 6 mm Bearing puller attachment Sliding shaft Bearing installer 09941-64511 09951-16060 09951-76010 Bearing remover Bush remover Bearing installer...
Page 528 Service on or around Air Bag System Components or Wiring must be performed only by an authorized Suzuki dealer. Please observe all WARNINGS and SERVICE PRECAUTIONS in Section 9J under “On- Vehicle Service” and the Air Bag System Component and Wiring Location view in Section 9J before performing service on or around Air Bag System Components or Wiring.
Page 529 7B-2 AUTOMATIC TRANSMISSION GENERAL DESCRIPTION The automatic transmission consists of the hydraulic torque converter, electronically controlled 3-speed automatic transmission, counter shaft and differential. The transmission consists of 2 planetary gears, 2 disk clutches, 1 band brake, 1 disk brake and 1 one-way clutch. Its operation is controlled by selecting a position from 6 positions (P, R, N, D, 2 and L ranges) manually by means of the select lever installed on the compartment floor.
Page 530 8. Rear planetary gear assembly 9. Front planetary gear assembly : Apply oil (A/T fluid) 10. One-way clutch assembly : Apply SUZUKI SUPER GREASE C (99000-25030) 11. Counter shaft assembly 12. Output shaft assembly : Tightening Torque 13. Second brake band 14.
Page 531 7B-4 AUTOMATIC TRANSMISSION 50 N·m (5.0 kg-m) 28 N·m (2.8 kg-m) 7 N·m (0.7 kg-m) 7 N·m (0.7 kg-m) 7 N·m (0.7 kg-m) 19 N·m (1.9 kg-m) 3.5 N·m (0.35 kg-m) 7 N·m (0.7 kg-m) 8 N·m (0.8 kg-m) 8 N·m (0.8 kg-m) 8 N·m (0.8 kg-m) 7 N·m (0.7 kg-m) 13 N·m (1.3 kg-m)
Page 532 AUTOMATIC TRANSMISSION 7B-5 Item Specifications Torque Type 3-element, 1-step, 2-phase type converter Stall torque ratio Type Trochoid type oil pump Oil pump Drive system Engine driven Type Forward 3-step, reverse 1-step planetary gear type “P” range Gear in neutral, output shaft fixed, engine start “R”...
Page 533 7B-6 AUTOMATIC TRANSMISSION ELECTRIC SHIFT CONTROL SYSTEM POWER TRAIN CONTROL MODULE (PCM) The power train control module controls the shift solenoid A and the shift solenoid B by sending electric signals to them so as to attain automatic gear shift between the 1st and 2nd gears, and the 2nd and 3rd gears.
Page 534 AUTOMATIC TRANSMISSION 7B-7 CLUTCH/BRAKE FUNCTIONS 1. Input shaft 2. 2nd brake 3. Direct clutch 4. Forward clutch 5. Planetary unit (front) 6. Planetary unit (rear) 7. One-way clutch 8. First-reverse brake 9. Output shaft Part Name Function The forward clutch connects the input shaft and internal gear of the front planetary Forward clutch gear unit.
Page 535 7B-8 AUTOMATIC TRANSMISSION TABLE OF COMPONENT OPERATION Element 1st-reverse Forward clutch 2nd brake Direct clutch One-way clutch Gear position brake 3rd gear 2nd gear 1st gear (D and 2 range) 1st gear (L range) * in acceleration...
Page 536 AUTOMATIC TRANSMISSION 7B-9 AUTOMATIC SHIFT DIAGRAM Gear change points in D, 2 and L ranges vary depending on throttle opening as given below. km/h Shift Throttle opening Full open Full close (km/h) : Upshift : Downshift OPERATION OF SHIFT SOLENOIDS Range P, N &...
Page 537 7B-10 AUTOMATIC TRANSMISSION DIAGNOSIS When any failure has occurred in the automatic transmission, it is necessary to perform on vehicle test first, to lo- cate the cause of the failure and then determine whether to overhaul it or not. Once the automatic transmission has been disassembled without investigating the cause of the failure, not only the cause would be left unknown, but also a secondary failure could be induced.
Page 538 AUTOMATIC TRANSMISSION 7B-11 DIAGNOSIS TABLE Condition Possible Cause Correction Low fluid level. Fluid coming out of oil filler tube. Adjust fluid level. External fluid leak. Repair leak. Fluid coming out of Fluid level too high. Adjust level. oil filler tube. Coolant in transmission fluid.
Page 539 7B-12 AUTOMATIC TRANSMISSION Condition Possible Cause Correction Unable to run in L Fluid pressure leakage to forward clutch Replace. range, excessive due to worn or damaged input shaft slippage. seal ring. First reverse brake disc slippage. Replace. Damaged first reverse brake piston Replace.
Page 540 AUTOMATIC TRANSMISSION 7B-13 Condition Possible Cause Correction Noise when starting Fluid pressure leakage to forward clutch Replace. due to worn oil pump bushing. Low A/T fluid level. Fill A/T fluid to specified level. Abnormal noise in Low A/T fluid level. Fill A/T fluid to specified level.
Page 541 7B-14 AUTOMATIC TRANSMISSION STALL TEST This test is to check overall performance of automatic transmission and engine by measuring stall speed at D and R ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature and its level is between FULL and LOW. (Refer to “Fluid Level”...
Page 542 AUTOMATIC TRANSMISSION 7B-15 LINE PRESSURE TEST This test is to check fluid pressure system for operation by measur- ing fluid pressure in fluid pressure line. Make sure to perform this test only when transmission fluid is at normal operating tempera- ture.
Page 543 7B-16 AUTOMATIC TRANSMISSION 9) Possible causes for out-of-specification line pressure are as follows. Check each part which is suspected to be the cause. Test result Possible cause Fluid pressure is higher Defective vacuum diaphragm than standard value in Defective vacuum hose each range Fluid pressure is lower Defective vacuum diaphragm...
Page 544 AUTOMATIC TRANSMISSION 7B-17 TIME LAG TEST This test is to check conditions of clutch, 1st-reverse brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed before and behind front and rear wheels re- spectively, depress brake pedal.
Page 545 7B-18 AUTOMATIC TRANSMISSION ROAD TEST This test is to check if upshift and downshift take place at specified speeds while actually driving vehicle on a level road. WARNING: Carry out the test in very little traffic area to prevent an ac- cident.
Page 546 AUTOMATIC TRANSMISSION 7B-19 ON-BOARD DIAGNOSIS (SELF DIAGNOSIS) PCM has on-board diagnostic system (a system self-diagnosis function). Investigate where the trouble is by referring to “Diagnostic Flow Chart” and “Diagnostic Trouble Code” in this sec- tion. MALFUNCTION INDICATOR LAMP (“CHECK CHECK ENGINE”...
Page 547 7B-20 AUTOMATIC TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) CLEAR- ANCE 1) Disconnect negative cable from battery. 2) Leave the negative battery cable disconnected for more than 20 seconds. 3) Connect negative cable to battery. DIAGNOSTIC TROUBLE CODE NO. TABLE Refer to SECTION 6E1 for how to read DTC. Diagnostic Trouble Code Diagnostic Area Diagnosis...
Page 548 AUTOMATIC TRANSMISSION 7B-21 DTC 41 – SHIFT SOLENOID-A CIRCUIT DTC 42 – SHIFT SOLENOID-B CIRCUIT W/Bl wire harness “A” SOL-A “B” SOL-B W/BI W/R wire harness “S2” “S1” 1. Solenoid coupler 2. Transmission range switch Terminal arrangement of PCM coupler DTC 41 –...
Page 549 7B-22 AUTOMATIC TRANSMISSION DTC 42 – TROUBLE SHOOTING Step Action 1) Disconnect PCM coupler with ignition switch Poor connection at “S2” Go to Step 2. OFF. terminal of PCM coupler. 2) Check resistance between “S2” terminal If OK, substitute known- and engine ground.
Page 550 AUTOMATIC TRANSMISSION 7B-23 DTC 46 – TRANSMISSION RANGE SWITCH CIRCUIT To Comb. switch, Stop light switch, etc. To Back up light To J/B Bl/W To Comb. meter “N” “R” “D” “P” “L” “2” Terminal arrangement of PCM coupler DTC 46 – TROUBLE SHOOTING Step Action Transmission range switch signal check:...
Page 551 7B-24 AUTOMATIC TRANSMISSION ON VEHICLE SERVICE MAINTENANCE SERVICE CHANGING FLUID 1) Raise vehicle. 2) With transmission cool, remove drain plug and drain fluid. 3) Install drain plug gasket and drain plug to oil pan, and tighten drain plug to specification. Tightening Torque (a): 40 N m (4.0 kg-m, 29 lb-ft)
Page 552 AUTOMATIC TRANSMISSION 7B-25...
Page 553 7B-26 AUTOMATIC TRANSMISSION...
Page 554 AUTOMATIC TRANSMISSION 7B-27 OIL STRAINER 1) Drain transmission fluid. 2) Remove oil pan. 3) Remove oil strainer (1). 4) Clean oil strainer. 5) Install oil strainer (1) to lower valve body (2). Tightening Torque (a): 8 N m (0.8 kg-m) (5 mm bolt) (b): 3 N m (0.3 kg-m) (6 mm bolt) 6) Reinstall oil pan and refill transmission fluid.
Page 555 7B-28 AUTOMATIC TRANSMISSION SHIFT SOLENOID INSPECTION Disconnect connector (3) and measure resistance between termi- nal and body. Between solenoid A (1): terminal “1” and body. about 20 Between solenoid B (2): terminal “2” and body. about 16 “1” “2” VACUUM DIAPHRAGM AND PIPING INSPECTION Check pipe of vacuum diaphragm (2) for looseness, coming off or breakage.
Page 556 AUTOMATIC TRANSMISSION 7B-29 SELECT CABLE 6.5 N·m (0.65 kg-m) 13 N·m (1.3 kg-m) “A” 1. Select cable assembly 2. Bolt 3. Bolt 4. Cable bracket 5. Manual selector cable joint 6. Shift range switch 7 N·m (0.7 kg-m) 7. Nut “A”: Apply sealant SEALING COMPOUND 366E (99000-31090) : Tightening Torque...
Page 557 7B-30 AUTOMATIC TRANSMISSION Adjust select cable as follows: 1) Before tightening cable end nut, shift select lever to N range. 2) Also shift manual select lever (1) to N range. 3) Turn nut “A” by hand till it contacts manual select cable joint. 4) Then tighten nut “B”...
Page 558 AUTOMATIC TRANSMISSION 7B-31 INSTALLATION 1) Install shift range switch and tighten shift range switch mounting bolts temporarily. 2) Install select lever (1) to manual shift shaft and drive spring pin (2) into shaft. Special Tool (A): 09922-89810 3) Put a 3 mm pin (1) (drill, etc.) into hole in switch and positioning hole in manual shift shaft and fix shaft range switch (“N”...
Page 559 7B-32 AUTOMATIC TRANSMISSION TRANSMISSION UNIT REPAIR OVERHAUL 1. Torque converter 2. Input shaft 3. Oil pump 4. Second brake band 5. Direct clutch 6. Forward clutch 7. Front planetary gear 8. Planetary sun gear 9. One-way clutch 10. Rear planetary gear 11.
Page 560 AUTOMATIC TRANSMISSION 7B-33 CAUTION: As the automatic transmission consists of high level precision parts, be sure to observe the following cautions for handling them in disassembly and reassembly. Select a clean place free from dust or dirt for overhauling. Place a rubber mat on the working bench to protect parts. When separating case joints tap with a plastic hammer lightly.
Page 561 7B-34 AUTOMATIC TRANSMISSION PARTS INSPECTION AND CORRECTION Item Check for Correction Castings, machine Small scratch, burr Remove by using an oil stone. processed parts Deep scratch, groove Replace part in question. Clogged fluid passage Blow air or pass through wire and wash.
Page 562 AUTOMATIC TRANSMISSION 7B-35 DISMOUNTING 1) Take down engine with transmission (Refer to Section 6A4). 2) Remove torque converter housing lower plate. 3) Remove drive plate bolts (1). To lock drive plate (2), engage a proper size rod (3) with the drive plate gear.
Page 563 7B-36 AUTOMATIC TRANSMISSION TORQUE CONVERTER DIAGNOSIS STATOR ASSEMBLY FREEWHEELS If the stator roller clutch becomes ineffective, the stator assembly freewheels at all times in both directions. With this condition, the ve- hicle tends to have poor acceleration from a standstill. If poor accel- eration problems are noted, what to be checked first are that the ex- haust system is not blocked, the engine is running properly and the transmission is in 1st gear when starting out.
Page 564 AUTOMATIC TRANSMISSION 7B-37 DISASSEMBLY 1) Remove torque converter. 2) Remove transmission mounting bracket (1). 3) Remove select cable bracket (1). 4) Disconnect fluid filler tube. 5) Drive out spring pin (1) by using special tool and remove select lever (2). Special Tool (A): 09922-89810 6) Remove shift range switch (3).
Page 565 7B-38 AUTOMATIC TRANSMISSION 9) Remove clip (1) from solenoid terminal (2) and push solenoid terminal into case. Remove oil filler tube. 10) Remove bolt (1) and then oil cooler (2). 11) Place transmission unit with oil pan side facing up. Remove oil pan mounting bolts, tap around oil pan lightly with plastic ham- mer and remove it.
Page 566 AUTOMATIC TRANSMISSION 7B-39 15) Remove oil pump mounting bolts (one of them is hexagon bolt) and remove oil pump assembly (1) with special tools. CAUTION: Remove oil pump assembly with front side of oil pump facing forward. Special Tool (B) : 09918-48211 (C) : 09918-48220 NOTE: Use care not to lose oil pump thrust washer (2) and bearing...
Page 567 7B-40 AUTOMATIC TRANSMISSION 19) Remove front internal gear (1). 20) Remove front planetary gear (1). 21) Remove sun gear input drum (1). 22) Remove snap ring (1) and then remove one-way clutch (3) and rear planetary carrier (3) as an assembly. NOTE: Use care not to damage transmission case when remov- ing snap ring (1).
Page 568 AUTOMATIC TRANSMISSION 7B-41 24) Remove retaining plate (1) and first reverse brake (2). (4-friction plates, 4 separator plates and 2 cushion plates) 25) Remove side bearing housing (1) mounting bolts and then re- move housing (1). 26) Remove lower cover mounting bolts and then remove lower cover (1).
Page 569 7B-42 AUTOMATIC TRANSMISSION 28) Remove side cover (1) mounting bolts and after loosening side cover a little with plastic hammer, remove it by using special tool. CAUTION: Do not pry with a screwdriver inserted between mat- ing surfaces of case and side cover (1). Remove sealing material attached on mating surface of side cover (1) completely.
Page 570 AUTOMATIC TRANSMISSION 7B-43 33) Using special tool, push down spring retainer (2) and remove snap ring (3). CAUTION: With bearing inner race remover shaft fixed, tighten on nut side. Do not push down return spring (4) more than neces- sary. Special Tool (E) : 09926-98320 (F) : 09941-84510...
Page 571 7B-44 AUTOMATIC TRANSMISSION 37) Remove E-ring (1) and then remove parking lever (2) and park- ing rod (3) as an assembly. 38) Using special tools, remove band servo piston and snap ring. Special Tool (H) : 09916-14510 (I) : 09916-48210 1.
Page 572 AUTOMATIC TRANSMISSION 7B-45 Clutch or Brake Return Spring Assembly Evidence of extreme heat or burning in the area of clutch may have caused springs to take a heat set and would require their replace- ment. POSSIBLE CAUSES OF BURNING Forward and Direct Clutch Discs Stuck or leak in check ball in clutch piston.
Page 573 7B-46 AUTOMATIC TRANSMISSION SUB ASSEMBLY SERVICE OIL PUMP 9 N·m (0.9 kg-m) “A” 1. Outer rotor 2. Inner rotor 3. Oil seal 4. Oil pump cover 5. Oil pump cover seal ring 6. Cover seal “A”: Grease 99000-25030 : Tightening Torque DISASSEMBLY 1) Remove cover seal and then remove bolts.
Page 574 AUTOMATIC TRANSMISSION 7B-47 2) Remove inner rotor (1) and outer rotor (2). 3) Remove oil seal (1) from oil pump housing, using screwdriver. INSPECTION Check each component part for damage and abnormal wear. Measure side clearance of outer rotor and inner rotor (2) at 3 posi- tions each.
Page 575 Special Tool (A) : 09913-85210 Grease: SUZUKI SUPER GREASE C (99000-25030) Install inner rotor (1) and outer rotor (2) into housing by aligning their punch marks (3). Install oil pump housing (1) and oil pump cover by aligning knock pin positions.
Page 576 AUTOMATIC TRANSMISSION 7B-49 DIRECT CLUTCH 1. Thrust washer 2. Direct clutch drum 3. Oil seal ring 4. Oil seal ring 5. Direct clutch piston 6. Plate 7. Separator plate 8. Friction plate 9. Retaining plate 10. Snap ring 11. Clutch return spring 12.
Page 577 7B-50 AUTOMATIC TRANSMISSION DISASSEMBLY 1) After removing snap ring (1), remove retaining plate, friction plates, separator plates and cushion plate from direct clutch as- sembly (2). 2) Using special tool, and press (1) push down spring retainer and remove snap ring (2). CAUTION: Do not push down spring retainer more than necessary.
Page 578 AUTOMATIC TRANSMISSION 7B-51 ASSEMBLY Assemble parts in reverse order of disassembly, noting following points. Replace O-ring and oil seal with new parts. Apply A/T fluid to them before installing them to piston. When inserting piston into clutch drum, use care so that O-ring and oil seal do not come off or get distorted.
Page 579 7B-52 AUTOMATIC TRANSMISSION FORWARD CLUTCH 1. Race 2. Bearing 3. Ring 4. Input shaft 5. Oil seal ring 6. Oil seal ring 7. Piston 8. Cushion plate 9. Separator plate 10. Friction plate 11. Retaining plate 12. Snap ring 13. Piston return spring 14.
Page 580 AUTOMATIC TRANSMISSION 7B-53 DISASSEMBLY 1) After Removing snap ring, remove all plates (retaining plate, fric- tion plates, separator plates and cushion plates) from input shaft (1). 2) Using special tool, push down spring retainer and remove snap ring. CAUTION: Do not push down spring retainer more than necessary. Special Tool (A) : 09926-98350 3) Blow air (1) into oil hole (2) in input shaft (3) and remove piston.
Page 581 7B-54 AUTOMATIC TRANSMISSION ASSEMBLY Assemble parts in reverse order of disassembly, noting following points. Replace inner seal ring and seal ring with new parts. Apply A/T fluid to them before installation. When inserting forward clutch piston into input shaft drum, use care so that seal ring does not come off or get distorted.
Page 582 AUTOMATIC TRANSMISSION 7B-55 OUTPUT SHAFT 1. Output shaft 2. Reduction drive gear 3. Seal ring 4. Snap ring 5. Bearing 6. Shim DISASSEMBLY 1) Remove seal ring. 2) Using press (1), remove output shaft from reduction gear (2). 3) Remove snap ring (1) and then pull off bearing (2) toward the front.
Page 583 7B-56 AUTOMATIC TRANSMISSION COUNTER SHAFT 55 N·m (5.5 kg-m) 1. Bearing 2. Counter shaft : Tightening Torque 3. Reduction driven gear 4. Shim : Do no reuse 5. Nut DISASSEMBLY 1) Remove caulking from nut and remove nut and washer. 2) Using press (1), remove reduction driven gear (2).
Page 584 AUTOMATIC TRANSMISSION 7B-57 SECOND BRAKE 1. Second brake band 2. Spring 3. Piston 4. Inner seal ring 5. Outer seal ring 6. Servo retainer 7. O-ring 8. Circlip 9. Bolt 10. Nut INSPECTION Second brake band Check second brake band (1) visually for damage, wear, discolor- ation, etc.
Page 585 7B-58 AUTOMATIC TRANSMISSION DIFFERENTIAL ASSEMBLY 90 N·m (9.0 kg-m), “A” 1. Differential pinion 2. Differential gear 3. Side pinion shaft 4. Spring pin 5. Side pinion washer 6. Side gear washer (selection) 8. Differential case 9. Final gear “A”: Apply thread lock cement 10.
Page 586 AUTOMATIC TRANSMISSION 7B-59 3) Remove L bearing by using puller while supporting its center shaft. 4) Support differential case (1) with soft jawed vise and remove fi- nal gear bolts then take out final gear. 5) Using special tool and hammer, drive out differential side pinion shaft pin and then disassemble component parts.
Page 587 7B-60 AUTOMATIC TRANSMISSION Hold differential assembly with soft jawed vise (1), install final gear (2) and then tighten it with bolts (3) 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) 3, (a) INPUT SHAFT Inspection...
Page 588 AUTOMATIC TRANSMISSION 7B-61 PARKING LOCK PAWL Inspection Check parking lock pawl for damage. BEARING Inspection While turning bearing by hand, check if it turns smoothly without making abnormal noise.
Page 589 Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly. Use yellow petrolatum grease or Suzuki super grease C to retain parts in place. Be sure to install thrust bearings and races in correct direction and position as shown in figure below.
Page 590 AUTOMATIC TRANSMISSION 7B-63 1) Assemble parking rod (1) to manual detent lever (2), set them in case and install E-ring. 2) Put manual shaft (1) into bush and attach O-ring (2). Then apply A/T fluid to O-ring and set them in case. 3) Install manual shaft (1) and tighten lock bolt (2) to specified torque.
Page 591 7B-64 AUTOMATIC TRANSMISSION 6) Fit spring (1) into spring hole in first-reverse brake piston (2). Then using special tools, push down spring retainer (3) and install snap ring (4). Special Tool (A) : 09926-98320 (B) : 09941-84510 (C) : 09926-98370 CAUTION: Use care not to deform spring retainer.
Page 592 AUTOMATIC TRANSMISSION 7B-65 8) After inspection, install cushion plates (1), separator plates (2) and friction plates (3) in that order. CAUTION: Install retaining plate with its inner protrusion side fac- ing down. 9) Attach bearing to rear internal gear hub assembly (1) and set them in case.
Page 593 7B-66 AUTOMATIC TRANSMISSION 13) Install counter shaft into case. 14) Adjustment of counter shaft shim (3) and output shaft shim as follows. CAUTION: After replacing case or bearings for counter shaft and output shaft, make shim adjustment. Measure thickness of shim on output shaft side (1) as it is used as a spacer.
Page 594 When applying sealant, use a nozzle so that section of seal- ant as applied on rim is about 1.5 mm in diameter. “A”: SUZUKI BOND 1216 (99000-31160) Apply grease to shim, set it in case and tighten side cover (1) bolts to specified torque.
Page 595 Then install side bearing housing (1) with arrow mark (2) on it pointing case side as shown in left figure and tighten bolts to specified torque. Sealant: SUZUKI BOND 1216 (99000-31160) Tightening torque for side bearing housing bolt 19 N m (1.9 kg-m, 14.0 lb-ft)
Page 596 29) Install needle bearing (1) to front side of front internal gear (2) and race incorporated type bearing (3) to rear side. NOTE: To facilitate installation of bearing, apply grease (SUZUKI SUPER GREASE C: 99000-25030) to internal gear side of bearing.
Page 597 31) Install race incorporated type bearings (1) to both front and rear sides of sun gear input drum (2). NOTE: To facilitate installation of bearing, apply grease (SUZUKI SUPER GREASE C: 99000-25030) to internal gear side of bearing. 32) Install sun gear input drum (1) to direct clutch drum (2) by matching their splines.
Page 598 AUTOMATIC TRANSMISSION 7B-71 36) When case (3) and clutch (2) have been replaced, measure end play and if it is not as specified, replace bearing race and thrust washer. End play means clearance between T1 and T2 as indicated in left figure.
Page 599 Check input shaft for rotation. Tightening torque for oil pump mounting bolt 13 N m (1.3 kg-m, 9.5 lb-ft) “C”: SUZUKI BOND 1216 (99000-31160) “C” 39) Adjust brake band as follows. Loosen anchor end nut (1) as far as tip end and apply sealant to bolt.
Page 600 AUTOMATIC TRANSMISSION 7B-73 40) Blow air into band joint circuit of case to check piston (2) opera- tion. 41) Install control valve assembly. Pass solenoid terminal wire harness through terminal hole in case. With manual plate (1), pin (2) and dent in manual valve (3), also manual plate (2) and manual detent spring (4) position matched respectively, pass solenoid coupler over them and set terminal in case.
Page 601 1.5 mm in diameter and tighten to specified torque. Tightening torque for oil pan bolt m (0.7 kg-m, 5.0 lb-ft) “D”: SUZUKI BOND 1216 (99000-31160) CAUTION: Remove old gasket on mating surface of oil pan com- pletely.
Page 602 AUTOMATIC TRANSMISSION 7B-75 48) Install the following parts and tighten its bolt or nut to specified torque. Shift range switch Fluid filler tube Cooler hose joint Select cable bracket Mount bracket and mount 49) Install torque converter to input shaft. (1) Install torque converter, using care not to damage seal of oil pump.
Page 603 Parts lubrication when installing Side and bottom cover case SUZUKI BOND N0.1215 Sealant Side bearing housing (99000-31110) Oil pan SUZUKI SUPER GREASE C Retaining parts in place when (99000-25030) assembling Lithium grease Lithium grease SUZUKI SUPER GREASE A Cable ends...
Page 604 AUTOMATIC TRANSMISSION 7B-77 09918-48220 09918-48211 Oil pump remover 09922-85811 09925-37810 Oil pump remover attachment (M8) Spring pin remover 4.5 mm Oil pressure gauge set 09926-98320 09926-98370 09925-88210 Spring compressor 09926-98350 Spring compressor Bearing puller attachment No. 1 set Spring compressor No. 4 No.1 attachment 09927-87010 09941-84510...
Page 605 CLUTCH 7C-1 SECTION 7C CLUTCH CONTENTS GENERAL DESCRIPTION ....7C- 2 UNIT REPAIR OVERHAUL ... . 7C- 6 Clutch Cover, Clutch Disc and DIAGNOSIS .
Page 606 7C-2 CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm-spring clutch of a dry single Depressing the clutch pedal causes the release bear- disc type. The diaphragm spring is of a tapering-finger ing to advance and pushes on the tips of the tapered type, which is a solid ring in the outer diameter part, fingers of the diaphragm spring.
Page 607 CLUTCH 7C-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. Weakened diaphragm spring Replace clutch cover.
Page 608 7C-4 CLUTCH ON-VEHICLE SERVICE MAINTENANCE SERVICE CLUTCH PEDAL CLUTCH PEDAL STROKE (HEIGHT) Check clutch pedal stroke from full stroke end position (1) to free position (2). Clutch pedal stroke “a”: 130.2 2 mm (5.12 0.08 in.) 4, (a) If clutch pedal height is out of above specification, adjust it by turn- ing pedal stopper bolt (3).
Page 609 CLUTCH 7C-5 CLUTCH CABLE REMOVAL 1) Disconnect negative cable at battery. 2) Remove clutch cable joint nut (1). 3) Remove joint pin (2) from clutch release arm (3). 4) Turn a part of A to arrow mark direction and disconnect clutch cable from clutch pedal upper side hook.
Page 610 7C-6 CLUTCH UNIT REPAIR OVERHAUL CLUTCH COVER, CLUTCH DISC AND FLYWHEEL 1. Clutch disc : Apply lithium grease 99000-25210 to joint of input shaft 23 N·m (2.3 kg-m) 2. Clutch cover 3. Bolt 4. Release bearing : Apply lithium grease 99000-25010 to joint of clutch release shaft 5.
Page 611 CLUTCH 7C-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 612 7C-8 CLUTCH INSTALLATION 1) Install flywheel (1) to crankshaft and tighten bolts (2) to specifi- cation. Special Tool (A): 09924-17810 Tightening Torque (a): 68 N m (6.8 kg-m, 49.5 lb-ft) NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly.
Page 613 CLUTCH 7C-9 CLUTCH RELEASE SYSTEM REMOVAL 1) Remove release arm by loosening its bolt. 2) Take out release bearing by turning release shaft. 3) Unhook return spring using pliers. 4) Drive out No.2 bush using special tool and hammer. Release shaft seal will also be pushed out. Special Tool (A): 09922-46010 5) Remove release shaft (1) and return spring (2).
Page 614 7C-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 615 CLUTCH 7C-11 5) Caulk seal (1) at A using caulking tool and hammer. A: Caulking 6) Hook return spring (1). “A” “B” 7) Apply grease to release bearing (2) inside and release shaft arm (3), then set bearing. “A”: Grease 99000-25010 8) Apply small amount of grease to input shaft spline (4) and front end as well.
Page 616 7C-12 CLUTCH REQUIRED SERVICE MATERIALS RECOMMENDED MATERIAL SUZUKI PRODUCT Clutch cable hook and joint pin SUZUKI SUPER GREASE A Release shaft bushes and seal Release shaft bushes and seal. (99000-25010) Release shaft arm. Lithium grease SUZUKI SUPER GREASE I Input shaft spline front end.
Page 617 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 618 8-2 BODY ELECTRICAL SYSTEM Interior Lights ................8-11 Horn .
Page 619: General Description
BODY ELECTRICAL SYSTEM 8-3 GENERAL DESCRIPTION The body electrical components of this vehicle are designed to operate on 12 Volts power supplied by the battery. The electrical system utilizes negative ground polarity. CAUTIONS IN SERVICING When performing works related to electric systems, observe the following cautions for the purpose of protection of electrical parts and prevention of a fire from occurrence.
Page 620 8-4 BODY ELECTRICAL SYSTEM When installing the wiring harness, fix it with clamps so that no slack is left. When installing vehicle parts, be careful so that the wiring har- ness is not interfered with or caught by any other part. To avoid damage to the harness, protect its part which may con- tact against a part forming a sharp angle by winding tape or the like around it.
Page 621: Wire Color Symbols
BODY ELECTRICAL SYSTEM 8-5 When performing a work that produces a heat exceeding 80 C in the vicinity of the electrical parts, remove the heat sensitive electrical part(s) beforehand. Use care not to expose connectors and electrical parts to water which will be a cause of a trouble.
Page 622: Combination Meter
8-6 BODY ELECTRICAL SYSTEM COMBINATION METER 1. Speedometer 2. Fuel level meter 3. Water temperature meter 4. Turn signal pilot light (LH) 5. CHECK ENGINE light 6. Turn signal pilot light (RH) 7. High beam light 8. Oil pressure warning light 9.
Page 623: Diagnosis
BODY ELECTRICAL SYSTEM 8-7 DIAGNOSIS HEADLIGHT Trouble Possible Cause Correction Headlights do not light up Bulb blown Check bulb Lighting or dimmer switch faulty Check headlight switch HEADLIGHT R and L fuses blown Check fuses and replace as necessary (If replace, check short circuit to ground) Wiring or grounding faulty Repair circuit Only one headlight does...
Page 624: Back-Up Light
8-8 BODY ELECTRICAL SYSTEM BACK-UP LIGHT Trouble Possible Cause Correction Back-up lights do not light Bulb(s) blown Check bulb TURN BACK fuse blown Check fuse and replace as necessary (If replace, check short circuit to ground) Back-up light switch faulty Check switch Wiring or grounding faulty Repair circuit...
Page 625: Engine Coolant Temp. (Ect) Meter And Ect Sensor
BODY ELECTRICAL SYSTEM 8-9 ENGINE COOLANT TEMP. (ECT) METER AND ECT SENSOR Trouble Possible Cause Correction Engine coolant temp. me- IG METER fuse blown Check fuse and replace as necessary ter shows no operation or (If replace, check short circuit to ground) incorrect operation ECT meter faulty Check ECT meter...
Page 626: Wipers And Washers
8-10 BODY ELECTRICAL SYSTEM WIPERS AND WASHERS FRONT WIPER AND WASHER REAR WIPER AND WASHER (IF EQUIPPED) Trouble Possible Cause Correction Wiper malfunctions or WIPER WASHER fuse blown Check fuse and replace as necessary does not return to its origi- (If replace, check short circuit to ground) nal position Wiper motor faulty...
Page 627: Interior Lights
BODY ELECTRICAL SYSTEM 8-11 INTERIOR LIGHTS Trouble Possible Cause Correction Interior lights do not light Bulbs blown Replace RADIO DOME fuse blown Check fuse and replace as necessary (If replace, check short circuit to ground) Interior light switch faulty Check switch Door switch faulty Check switch Wiring or grounding...
Page 628: On-Vehicle Service
8-12 BODY ELECTRICAL SYSTEM ON-VEHICLE SERVICE HEADLIGHT COMPONENTS 1. Headlight assembly 2. Halogen bulb 3. Turn signal light socket 4. Position light socket 5. Socket cover 6. Turn signal light bulb 7. Position light bulb HEADLIGHT SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH, STEERING COLUMN AND STEERING SHAFT LOWER JOINT in Section 3C.
Page 629 BODY ELECTRICAL SYSTEM 8-13 HEADLIGHT REMOVAL 1) Disconnect negative cable at battery. 2) Remove front bumper. 3) Remove headlight mounting bolts. 4) Detach headlight assembly from vehicle. 5) Disconnect couplers from headlight assembly. 6) Remove headlight assembly. INSTALLATION Reverse removal procedure for installation. BULB REPLACEMENT WARNING: To avoid danger of being burned, don’t touch when the...
Page 630 8-14 BODY ELECTRICAL SYSTEM HEADLIGHT AIMING WITH SCREEN NOTE: Unless otherwise obligated by local regulations, adjust headlight aiming according to following procedure. After replacing headlight, be sure to adjust aiming. Before adjustment, make sure the following. a) Place vehicle on a flat surface in front of blank wall (screen) (1) ahead of headlight surface.
Page 631: Turn Signal And Hazard Warning Light
BODY ELECTRICAL SYSTEM 8-15 TURN SIGNAL AND HAZARD WARNING LIGHT TURN SIGNAL LIGHT SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH, STEERING COLUMN AND STEERING SHAFT LOWER JOINT in Section 3C. INSPECTION 1) Disconnect negative (–) cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Check continuity at each switch position shown below by using a circuit tester.
Page 632: Ignition Switch
8-16 BODY ELECTRICAL SYSTEM IGNITION SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH, STEERING COLUMN AND STEERING SHAFT LOWER JOINT in Section 3C. INSPECTION 1) Disconnect negative cable (–) at battery. 2) Remove steering column upper and lower cover. 3) Disconnect wiring main harness coupler from ignition switch. 4) Check continuity at each switch position by using circuit tester.
Page 633: Speed Meter/Sensor
BODY ELECTRICAL SYSTEM 8-17 SPEED METER/SENSOR VEHICLE SPEED SENSOR Refer to VEHICLE SPEED SENSOR in SECTION 6E of this manu- FUEL METER/FUEL LEVEL SENSOR (GAUGE UNIT) FUEL LEVEL METER INSPECTION 1) Disconnect Y/R lead wire going to fuel level sensor. 2) Turn ignition switch ON, and check that fuel meter indicates E.
Page 634: Engine Coolant Temperature Meter And Sensor For Meter
8-18 BODY ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND SENSOR FOR METER ENGINE COOLANT TEMPERATURE METER INSPECTION 1) Disconnect Y/Bl lead wire going to ECT sensor. 2) Turn ignition switch ON, and check that ECT meter indicates Y/Bl COOL. 3) Turn ignition switch OFF. 4) Ground Y/Bl lead wire through a 3.4 W test bulb (1) as illus- trated.
Page 635: Oil Pressure Warning Light
BODY ELECTRICAL SYSTEM 8-19 OIL PRESSURE WARNING LIGHT OIL PRESSURE SWITCH INSPECTION 1) Disconnect oil pressure switch (1) lead wire. 2) Check continuity between oil pressure switch terminal (2) and cylinder block (3) as shown. During Engine Running No continuity At Engine Stop Continuity FRONT...
Page 636 8-20 BODY ELECTRICAL SYSTEM DEFOGGER WIRE INSPECTION NOTE: When cleaning rear window glass, use a dry cloth to wipe it along heat wire (1) direction. When cleaning glass, do not use detergent or abrassive- containing glass cleaner. When measuring wire voltage, use a tester with negative probe (2) wrapped with a tin foil (3) which should be held down on wire by finger pressure.
Page 637: Wipers And Washers
BODY ELECTRICAL SYSTEM 8-21 DEFOGGER CIRCUIT REPAIR 1) Use white gasoline for cleaning. 2) Apply masking tape (1) at both upper and lower sides of heat wire (2) to be repaired. 3) Apply commercially-available repair agent (3) with a fine-tip brush (4).
Page 638 8-22 BODY ELECTRICAL SYSTEM FRONT WIPER/WASHER SWITCH REMOVAL AND INSTALLATION Refer to COMBINATION SWITCH, STEERING COLUMN AND STEERING SHAFT LOWER JOINT in Section 3C. SWITCH OPERATION INSPECTION 1) Disconnect negative cable (–) at battery. 2) Disconnect combination switch lead wire coupler. 3) Check continuity at each switch position as shown below by us- ing a circuit tester.
Page 639 BODY ELECTRICAL SYSTEM 8-23 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 bat- tery negative terminal (–) to terminal “HE”.
Page 640 8-24 BODY ELECTRICAL SYSTEM FRONT WASHER PUMP REMOVAL 1) Disconnect negative cable (–) at battery. 2) Remove washer tank fitting screws. 3) Disconnect pump lead wire coupler(s) and hose(s). 4) Remove washer tank. 5) Remove pump from tank. INSPECTION Connect battery (+) and (–) terminals to pump (+) and (–) terminals respectively to check pumping rate.
Page 641: Power Window Control System (If Equipped)
BODY ELECTRICAL SYSTEM 8-25 REAR WASHER PUMP INSPECTION Refer to FRONT WIPER AND WASHER INSPECTION in this sec- tion. REAR WIPER MOTOR INSPECTION 1) TESTING WIPER MOTOR As shown left, use a 12V battery to connect its ( + ) and (–) termi- nals to terminal “B”...
Page 642: Door Switch
8-26 BODY ELECTRICAL SYSTEM POWER WINDOW SUB SWITCH INSPECTION Inspect switch continuity between terminal. Terminal Switch Position E D C B A DOWN C B A E D DOOR SWITCH INSPECTION Check switch for continuity by using a circuit tester. If found defective, replace switch.
Page 643 Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un- der “General Description” in air bag system section in order to confirm whether you are perform- ing service on or near the air bag system components or wiring.
Page 644 9-2 BODY SERVICE GLASS, WINDOWS AND MIRROR FRONT DOOR GLASS 11-2 11-4 11-1 11-5 11-3 1. Front door inside handle 8. Front door glass run 2. Window regulator handle 9. Front door glass sash 3. Door inside lock knob 10. Front window regulator assembly 4.
Page 645 BODY SERVICE 9-3 REMOVAL 1) Detouch inside handle bezel (1). 2) Remove door mirror bezel. 3) Remove door inside pull handle case fitting screw. 4) Remove window regulator handle (1) (if equipped). For its removal, pull off snap by using a cloth (2) as shown in left figure.
Page 646 9-4 BODY SERVICE 9) Remove glass attaching screws (1). 10) Take out door glass (2). INSTALLATION Reverse removal procedure to install door glass noting the follow- ing points: Glass fitted position of bottom channel (1) is as shown in figure. 113.6 mm (4.5 in.) Adjust equalizer (1) of window regular so that measurement A and B are equal.
Page 647 BODY SERVICE 9-5 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 loos- en clamp (if equipped). 3) Loosen regulator mounting screws (1) and take out regulator through hole as shown in left figure.
Page 648 9-6 BODY SERVICE 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. 1.
Page 649 BODY SERVICE 9-7 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. 4) Remove rear view mirror, sunvisor, and front pillar trims (right &...
Page 650 9-8 BODY SERVICE 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 (1), clean it with alcohol or the like to remove oil from it. 11) When reusing windshield, remove the adhesive (1) from it, us- ing care not to damage primer coated surface (2).
Page 651 BODY SERVICE 9-9 5) Install new molding (1) to glass (2). 6) Clean glass (2) 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 652 9-10 BODY SERVICE 9) Apply adhesive (1) referring to figure at the left. NOTE: Start from bottom side of glass (2). “a” Be careful not to damage primer. Height of adhesive (1) applied to lower side should be high- “b” er than that of other three sides.
Page 653 BODY SERVICE 9-11 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: Do not use high pressure water.
Page 654 9-12 BODY SERVICE REAR DOOR GLASS 10-4 10-1 10-3 10-2 1. Rear door inside handle 2. Window regulator handle 3. Door inside lock knob 4. Rear door weatherstrip 5. Rear door sash 6. Rear window glass 7. Rear door glass run 8-1.
Page 655 BODY SERVICE 9-13 4) 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 win- dow switch lead wire (if equipped). 5) Remove door inside pull handle bracket (1).
Page 656 9-14 BODY SERVICE Secure door sealing cover with adhesive (1). Install door window regulator handle (1) so that it has a 45 angle when glass is fully closed, as shown in left figure. Front 45 25 REAR DOOR WINDOW REGULATOR REMOVAL 1) Remove door glass, referring to steps 1) to 8) of REAR DOOR GLASS REMOVAL in this section.
Page 657 BODY SERVICE 9-15 BACK DOOR GLASS REMOVAL 1) Remove rear wiper arm. 2) Disconnect rear defogger coupler. 3) As back door glass (2) is fixed by means of back door window weatherstrip (1), remove glass (2) and weatherstrip (1) together by removing end of weatherstrip (1) little by little while pushing the entire glass (2) from inside toward outside as shown in fig- ure.
Page 658 9-16 BODY SERVICE BODY STRUCTURE FRONT DOOR ASSEMBLY REMOVAL 1) Remove front fender. 2) Disconnect door harness lead wires at each coupler. 3) Remove stopper pin (1). 4) Support door panel using a jack with a piece of wood (1) placed between jack and panel, as shown.
Page 659 BODY SERVICE 9-17 REAR DOOR ASSEMBLY REMOVAL/INSTALLATION Follow procedures for Front Door removal/installation in this sec- tion. BACK DOOR ASSEMBLY 1. Back door panel assembly 2. Back door window glass 3. Weather strip 4. Weather strip 5. Back door trim 6.
Page 660 9-18 BODY SERVICE 3) Remove back door trim. 4) Remove wire harness connectors inside the back door. 5) 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 cylin- der is filled with gas.
Page 661 BODY SERVICE 9-19 HOOD INSPECTION Check that secondary latch operates properly (check that second- ary latch keeps hood from opening all the way even when pulling hood release handle inside vehicle.) Also check that hood opens and closes smoothly and properly and hood locks securely when closed.
Page 662 9-20 BODY SERVICE FRONT FENDER REMOVAL 1) Remove front bumper. 2) Remove front fender lining (1). 3) Remove front fender (2). INSTALLATION 1) Remove pad (1) from side body (2) and fender bracket (3), us- ing care not to damage painted surface. 2) Attach new pad (1) cutting appropriately size temporarily and adjust height with a knife so that fender becomes flush with side body.
Page 663 BODY SERVICE 9-21 BUMPERS Front bumper Rear bumper...
Page 664 9-22 BODY SERVICE BODY DIMENSIONS b’ d’ c’ h’ f’ j’ g’ i’ k’ : Hood rear seal installation hole h, h’ : Front fender installation hole b, b’ : Front fender installation hole i, i’ : Suspension control arm c, c’...
Page 665 BODY SERVICE 9-23 a’ b’ e’ f’ g’ h’ a, a’ : Front end of front windshield upper installation section j’ b, b’ : Front end of front windshield lower installation section : Hood rear seal installation hole i’ : Parking brake rear installation hole e, e’...
Page 666 9-24 BODY SERVICE a : Front door upper hinge installation hole g : Side sil scuff installation hole l : Assistant grip installation hole b : Front door lower hinge installation hole h : Door switch installation hole m : Side sil scuff installation hole c : Steering support member installation hole i : Jig hole ( 7) n : Rear seat belt installation hole...
Page 667 BODY SERVICE 9-25 UNDER BODY DIMENSIONS Unit: mm (in.) (12.28) (12.28) a’ 1168 (45.98) 330.4 330.4 (13.01) (13.01) b’ 49.5 (1.75) 668.2 (26.31) 504 (19.84) (12.72) (12.72) d’ 235 ( 9.25) (17.83) (17.83) e’ 750 (29.53) (15.75) (15.75) f’ 1095 (43.11) 466.5 466.5 (18.37)
Page 668 9-26 BODY SERVICE e’ f’ : Jack bracket installation hole : Front stabilizer bracket installation hole : Suspension control arm installation hole : Engine mounting installation hole : Jig hole (15 20) e, e’ : Jig hole ( 50) f, f’ : Jig hole ( 50) h’...
Page 669 BODY SERVICE 9-27 INSTRUMENTATION AND DRIVER INFORMA- TION INSTRUMENT PANEL WARNING: See WARNING at the beginning of this section. REMOVAL 1) Disconnect negative cable at battery. 2) Disable air bag system, if equipped. Refer to “Disable Air Bag System” in Section 10B. 3) Remove steering column hole cover, glove box and hood latch release lever.
Page 670 9-28 BODY SERVICE SEAT FRONT SEAT Tightening Torque (a): 35 N m (3.5 kg-m, 25.5 lb-ft) (b): 23 N m (2.3 kg-m, 16.5 lb-ft) REMOVAL AND INSTALLATION 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.
Page 671 BODY SERVICE 9-29 REAR SEAT Tightening Torque (a): 35 N m (3.5 kg-m, 25.5 lb-ft) REMOVAL AND INSTALLATION Refer to above figure when removing and installing or disassembling and assembling rear seat.
Page 672 9-30 BODY SERVICE PAINT AND COATINGS ANTI-CORROSION TREATMENT Sealer is applied to the specific joints of a vehicle dur- WARNING: ing production. The sealer is intended to prevent dust Standard shop practices, particularly eye from entering the vehicle and serves also as an anti- protection, should be followed during the corrosion barrier.
Page 673 BODY SERVICE 9-31 When the welding or heating operation causes the Scrape the accessible places. If a standard putty knife original galvanization or other anticorrosive materials or scraper does not fit to the elevant place, consider to be burnt, the interior and under-body panel sur- to use a more flexible scraper to a place narrowly en- faces must be cleaned.
Page 674 9-32 BODY SERVICE SEALANT APPLICATION AREA Wipe off excess Apply sealant to pointed area sealant after application DETAIL: Y Smooth out sealant Smooth out sealant with a brush in one with a brush in one direction direction VIEW: M VIEW: B Smooth out sealant with a brush in one direction...
Page 675 BODY SERVICE 9-33 Apply sealant to pointed area Make sure that the sealant covers completely end of flange SECT: F–F SECT: E–E Make sure that the sealant covers completely end of flange Make sure that the sealant covers completely end of flange between C and E VIEW: J Wipe off excess...
Page 676 9-34 BODY SERVICE Apply sealant to pointed area Wipe off excess sealant after application Wipe off excess VIEW: FF sealant after application Wipe off excess sealant after application Wipe off excess sealant after application Smooth out sealant with a brush in one direction VIEW: EE Do not sealant...
Page 677 BODY SERVICE 9-35 Apply sealant to pointed area Smooth out sealant with a brush in one direction VIEW: II Wipe off excess sealant after application Wipe off excess sealant after application VIEW: JJ VIEW: HH Wipe off excess Do not sealant sealant after to this area Be free from protrude of...
Page 678 9-36 BODY SERVICE Apply sealant to pointed area SECT: I–I Between F and H SECT: H–H SECT: A–A VIEW: K SECT: C–C Smooth out sealant Smooth out sealant DETAIL: Z with a brush in one with a brush in one direction direction VIEW: C...
Page 679 BODY SERVICE 9-37 UNDER COATING/ANTI-CORROSION COMPOUND APPLICATION AREA “A” “A” “A” “A” “A” “A” SECT: A–A SECT: G–G SECT: B–B SECT: D–D “A” “A” “A” “A” Do not fill drain hole Do not fill drain hole “B” SECT: F–F SECT: E–E SECT: CC–CC “A”: Apply rustproof wax (hot wax 50 m or more) “B”: Apply rustproof wax (high viscosity wax 50 m or more)
Page 680 9-38 BODY SERVICE “A” “B” “A” SECT: D–D “A” “A” “A” “A” “B” DETAIL: W SECT: A–A SECT: B–B SECT: C–C “B” “B” SECT: D–D “A” VIEW: Y “B” “A” “A” Apply undercoating in the arrow direction SECT: E–E “B” “A”: Apply undercoating (PVC, 300 m or more) DETAIL: U “B”: Do not apply undercoating...
Page 681 BODY SERVICE 9-39 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.
Page 682 9-40 BODY SERVICE SECURITY AND LOCKS FRONT 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 FRONT DOOR GLASS REMOVAL in this section. 3) Remove door opening control rod (1).
Page 683 BODY SERVICE 9-41 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 6) of REAR DOOR GLASS REMOVAL in this section. 3) Disconnect door lock control rod (1). 4) Disconnect door opening control rod (2).
Page 684 9-42 BODY SERVICE 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 685 BODY SERVICE 9-43 EXTERIOR AND INTERIOR TRIM FLOOR CARPET REMOVAL 1) Remove front seats and rear seat cushion. 2) Remove seat belt lower anchor bolts. 3) Remove dash side trims (1), front side sill scuffs (2), center pillar inner lower rims (3) and rear side sill scuffs (4). 4) Remove console box and parking brake lever cover.
Page 686 9-44 BODY SERVICE HEAD LINING REMOVAL 1) Remove sunchade assembly (1). 2) Remove sunchade holder (2) as shown in figure. 3) Remove inside rear view mirror (1). 4) Remove assistant grips (2). 5) Remove inner trims covering head lining (3) and door opening trims (4).
Page 687 Service on or around the air bag system components or wiring must be performed only by an au- thorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Ve- hicle Service” in air bag system section before performing service on or around the air bag system components or wiring.
Page 688: General Description
10-2 RESTRAINT SYSTEM GENERAL DESCRIPTION Type 1 Type 2 Seat belt with ELR and pretensioner Front seat Seat belt with ELR Driver and front passenger air bags 1. Front seat belt 2. Rear seat belt Seat belt with ELR or Rear seat Seat belt with A-ELR 3.
Page 689: Seat Belt Pretensioner (If Equipped)
RESTRAINT SYSTEM 10-3 Seat belt with ELR and pretensioner The seat belt with ELR and a pretensioner has a pretensioner mechanism which operates in linkage with the air bag in addition to the above described ELR. The pretensioner takes up the sag of the seat belt in occurrence of a front collision with an impact larger than a certain set value, thereby enhancing restraint performance.
Page 690: On-Vehicle Service
If these parts are replaced individually, such a locking condition may become unreliable. For this rea- son, SUZUKI will supply only the spare buckle and ELR (or webbing) in a set part. Before servicing or replacing seat belts, refer to following precautionary items.
Page 691: Front Seat Belt Without Pretensioner
RESTRAINT SYSTEM 10-5 FRONT SEAT BELT WITHOUT PRETENSIONER 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. 1. Upper anchor Tightening Torque 2. Lower anchor (a): 35 N·m (3.5 kg-m, 25.5 lb-ft) 3.
Page 692 10-6 RESTRAINT SYSTEM 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. Retractor assembly It should lock webbing when pulled quickly.
Page 693: Front Seat Belt With Pretensioner
RESTRAINT SYSTEM 10-7 FRONT SEAT BELT WITH PRETENSIONER WARNING: Never attempt to disassemble or repair the seat belt pretensioner (retractor assembly). If any abnormality is found, be sure to replace it with new one as an as- sembly. Be sure to read SERVICE PRECAUTIONS in this sec- tion, before starting to work and observe every pre- caution during work.
Page 694 10-8 RESTRAINT SYSTEM 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. Retractor assembly It should lock webbing when pulled quickly.
Page 695: Rear Seat Belt
RESTRAINT SYSTEM 10-9 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. 1. Upper anchor 2. Lower anchor Tightening Torque 3. Retractor assembly (a): 35 N·m (3.5 kg-m, 25.5 lb-ft) 4.
Page 696: Air Bag System
Service on or around the air bag system components or wiring must be performed only by an au- thorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Ve- hicle Service” in this section before performing service on or around the air bag system components or wiring.
Page 697 10B-2 AIR BAG SYSTEM DTC 25 - Driver air bag initiator Accident with deployment/activation circuit short to power circuit ... . 10B-25 - component replacement ... . 10B-41 DTC 31 - Power source voltage high .
Page 698 AIR BAG SYSTEM 10B-3 GENERAL DESCRIPTION With the air bag system which includes air bags (1, 2) for both the driver’s and passenger’s sides as well as the seat belt pretension- ers (3), the sag of the seat belt is taken up (for seat belt with preten- sioner), the driver air bag (inflator) module is deployed from the center of the steering column and the passenger air bag (inflator) module from the top of the instrument panel in front of the front pas-...
Page 699 10B-4 AIR BAG SYSTEM SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS 9 N·m (0.9 kg-m) 35 N·m (3.5 kg-m) CONNECTOR B, C CONNECTOR D CONNECTOR E CONNECTOR F, G 5.5 N·m (0.55 kg-m) 35 N·m (3.5 kg-m) 6 N·m (0.6 kg-m) CONNECTOR A 1.
Page 700 AIR BAG SYSTEM 10B-5 SYSTEM WIRING DIAGRAM WIRE HARNESS COLOR : Black Bl/O : Blue/Orange G/Y : Green/Yellow B/Y : Black/Yellow Bl/Y : Blue/Yellow : Red B/W : Black/White : Green : Violet : Blue G/O : Green/Orange Y/B : Yellow/Black Bl/R : Blue/Red G/R : Green/Red Y/R : Yellow/Red...
Page 701 10B-6 AIR BAG SYSTEM DIAGNOSIS 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 SPECIAL TOOLS of this section. Do not use a non-powered probe type tester.
Page 702 AIR BAG SYSTEM 10B-7 Special Tool (Air Bag Driver/Passenger Load Tool) (B): 09932-75010 This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag (inflator) module deployment and seat belt pretensioner activation. The load tool has three connectors attached to its case which are electrically functional and serve as resistive load substitutions.
Page 703 10B-8 AIR BAG SYSTEM INTERMITTENTS AND POOR CONNECTIONS Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diag- nostic flow table, perform careful check of suspect circuits for: Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 704 AIR BAG SYSTEM 10B-9 AIR BAG DIAGNOSTIC SYSTEM CHECK WARNING: To avoid deployment when troubleshooting the air bag system, do not use electrical test equipment such as a battery powered or AC powered voltmeter, ohmmeter, etc., or any type of electrical equip- ment other than that specified in SPECIAL TOOLS of this section.
Page 705 10B-10 AIR BAG SYSTEM AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE STEP ACTION 1) Make sure that battery voltage is Go to Step 2. “AIR BAG” warning lamp does about 11V or higher. not come ON. 2) Note “AIR BAG” warning lamp Proceed to TABLE B.
Page 706 AIR BAG SYSTEM 10B-11 DIAGNOSTIC TROUBLE CODE (DTC) CHECK 1) Check that malfunction indicator lamp (1) comes ON when igni- tion switch is turned ON. If it does not come ON, proceed to TABLE B. 2) Using service wire, ground diagnosis switch terminal (3) in “AIR BAG”...
Page 707 10B-12 AIR BAG SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) TABLE EXAMPLE: WHEN DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH (DTC 21) IS SET Turn ON Turn OFF DIAGNOSTIC TROUBLE CODE DIAGNOSIS DIAGNOSIS MODE Normal ––––– Resistance high Resistance low Passenger air bag circuit Short to ground Short to power circuit...
Page 708 AIR BAG SYSTEM 10B-13 DIAGNOSTIC TROUBLE CODE DIAGNOSIS DIAGNOSIS MODE Resistance high Resistance low Driver pretensioner retensioner circuit Short to ground Short to power circuit Resistance high Diagnose trouble Resistance low Passenger according to DIAGNOS- pretensioner retensioner TIC FLOW TABLE cor- TIC FLOW TABLE cor- circuit responding to each...
Page 709 10B-14 AIR BAG SYSTEM TABLE A – “AIR BAG” WARNING LAMP COMES ON STEADY WITHOUT FLASHING TABLE B – “AIR BAG” WARNING LAMP DOES NOT COME ON TABLE C – “AIR BAG” WARNING LAMP FLASHES TABLE D – “AIR BAG” WARNING LAMP CANNOT INDICATE DTC BY FLASHING :Air bag harness 1.
Page 710 AIR BAG SYSTEM 10B-15 DIAGNOSTIC FLOW TABLE: Table A – “AIR BAG” WARNING LAMP COMES ON STEADY WITHOUT FLASHING STEP ACTION 1) Ignition switch OFF. Go to Step 2. “R” wire short to ground. 2) Remove and inspect “AIR BAG” fuse. After repair, replace “AIR 3) Is fuse good? BAG”...
Page 711 10B-16 AIR BAG SYSTEM Table B – “AIR BAG” WARNING LAMP DOES NOT COME ON STEP ACTION 1) Set parking brake. Go to Step 2. “B/Y” wire, “B/W” wire, 2) Note combination meter when ignition switch “IG METER” fuse or is turned ON.
Page 712 AIR BAG SYSTEM 10B-17 Fig. for Step 4 Special Tool (A): 09932-76010 NOTE: Upon completion of inspection and repair work, perform following items. 1) Reconnect all air bag system components, ensure all components are properly mounted. 2) Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected.
Page 713 10B-18 AIR BAG SYSTEM Table C – “AIR BAG” WARNING LAMP FLASHES STEP ACTION 1) Check “AIR BAG” monitor coupler. Remove service wire. Go to Step 2. 2) Is it connected diagnosis switch terminal and ground terminal in “AIR BAG” monitor coupler by service wire? 1) With ignition switch OFF, disconnect SDM Substitute a known-good...
Page 714 AIR BAG SYSTEM 10B-19 Table D – “AIR BAG” WARNING LAMP CANNOT INDICATE DTC BY FLASHING STEP ACTION 1) Inspect connection between diagnostic switch Go to Step 2. Properly connection terminal on “AIR BAG” monitor coupler and diagnostic switch termi- body ground by service wire.
Page 715 10B-20 AIR BAG SYSTEM DTC 15 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH DTC 16 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW DTC 18 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND DTC 19 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT Bl/R 1.
Page 716 AIR BAG SYSTEM 10B-21 DIAGNOSTIC FLOW TABLE: DTC 15 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH STEP ACTION 1) With ignition switch OFF, disconnect passen- Go to Step 2. 1) Ignition switch OFF. ger air bag (inflator) module (“D”) connector 2) Replace passenger behind the glove box.
Page 717 10B-22 AIR BAG SYSTEM DTC 16 – PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW STEP ACTION 1) With ignition switch OFF, disconnect pas- Go to Step 2. 1) Ignition switch OFF. senger air bag (inflator) module (“D”) 2) Replace passenger air connector behind the glove box.
Page 718 AIR BAG SYSTEM 10B-23 DTC 18 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND STEP ACTION 1) With ignition switch OFF, disconnect pas- Go to Step 2. 1) Ignition switch OFF. senger air bag (inflator) module (“D”) con- 2) Replace passenger air nector behind the glove box.
Page 719 10B-24 AIR BAG SYSTEM DTC 19 – PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT STEP ACTION 1) With ignition switch OFF, disconnect passenger Go to Step 2. 1) Ignition switch OFF. air bag (inflator) module (“D”) connector behind 2) Replace passenger air the glove box.
Page 720 AIR BAG SYSTEM 10B-25 DTC 21 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH DTC 22 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW DTC 24 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND DTC 25 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT 1.
Page 721 10B-26 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE: DTC 21 – 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. (“B”) connector located near the base of the steering column.
Page 722 AIR BAG SYSTEM 10B-27 DTC 22 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW STEP ACTION 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 3. (“B”) connector located near the base of the steering column.
Page 723 10B-28 AIR BAG SYSTEM DTC 24 – 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. (“B”) connector located near the base of the steer- ing column.
Page 724 AIR BAG SYSTEM 10B-29 DTC 25 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT STEP ACTION 1) With ignition switch OFF, disconnect contact coil Go to Step 2. Go to Step 3. (“B”) connector located near the base of the steering column.
Page 725 10B-30 AIR BAG SYSTEM DTC 31 – POWER SOURCE VOLTAGE HIGH DTC 32 – POWER SOURCE VOLTAGE LOW 1. From main fuse 2. Ignition switch 3. “AIR BAG” fuse in fuse box 4. SDM 5. Ground for air bag system CAUTION: Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table.
Page 726 AIR BAG SYSTEM 10B-31 DIAGNOSTIC FLOW TABLE: DTC 31 – POWER SOURCE VOLTAGE HIGH STEP ACTION 1) With ignition switch OFF, disconnect SDM Go to Step 2. Check Charging System (“A”) connector. and repair as necessary. 2) Check proper connection to SDM at “A4” (Refer to DIAGNOSIS in terminal.
Page 727 10B-32 AIR BAG SYSTEM DTC 32 – POWER SOURCE VOLTAGE LOW STEP ACTION 1) Measure voltage on battery. Go to Step 2. Check Charging System 2) Is voltage 11 V or more? and repair as necessary. (Refer to DIAGNOSIS in SECTION 6H) 1) With ignition switch OFF, disconnect SDM (“A”) Go to Step 4.
Page 728 AIR BAG SYSTEM 10B-33 DTC 41 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH DTC 42 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW DTC 43 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND DTC 44 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT DTC 45 –...
Page 729 10B-34 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE: DTC 41 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH and 45 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH STEP ACTION 1) With ignition switch OFF, remove center Go to Step 2. 1) Ignition switch OFF. pillar inner garnish of applicable side 2) Replace seat belt preten- then disconnect seat belt pretensioner...
Page 730 AIR BAG SYSTEM 10B-35 DTC 42 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW and 46 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW STEP ACTION 1) With ignition switch OFF, remove center Go to Step 2. 1) Ignition switch OFF. pillar inner garnish of applicable side 2) Replace seat belt preten- then disconnect seat belt pretensioner sioner (retractor assem-...
Page 731 10B-36 AIR BAG SYSTEM DTC 43 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND and 47 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND STEP ACTION 1) With ignition switch OFF, remove center Go to Step 2. 1) Ignition switch OFF. pillar inner garnish of applicable side 2) Replace seat belt preten- then disconnect seat belt pretensioner...
Page 732 AIR BAG SYSTEM 10B-37 DTC 44 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT and 48 – PAS- SENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT STEP ACTION 1) With ignition switch OFF, remove center pillar Go to Step 2. 1) Ignition switch OFF.
Page 733 10B-38 AIR BAG SYSTEM DTC 51, 53 – FRONTAL CRASH DETECTED (SYSTEM ACTIVATION COMMAND OUTPUTTED) CAUTION: Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to flow table. DTC WILL SET WHEN: The SDM detects a frontal crash of sufficient force to warrant activation of the air bag system. (SDM outputs a de- ployment command.) TABLE TEST DESCRIPTION: STEP 1:Check that DTC 51, 53 has been set although air bag has not been deployed.
Page 734 AIR BAG SYSTEM 10B-39 DTC 61 – “AIR BAG” WARNING LAMP CIRCUIT FAILURE :Air bag harness 1. From main fuse 9. To ECM (or PCM) and ABS control module (if equipped) 5. “AIR BAG” fuse in fuse box 2. Ignition switch 10.
Page 735 10B-40 AIR BAG SYSTEM STEP ACTION 1) Clear DTC (Refer to DIAGNOSTIC Substitute a known- Recheck air bag system. TROUBLE CODE (DTC) LEARANCE). good SDM and recheck. Refer to AIR BAG DIAGNOS- 2) Check DTC (Refer to DIAGNOSTIC TIC SYSTEM CHECK. TROUBLE CODE (DTC) CHECK).
Page 736 AIR BAG SYSTEM 10B-41 REPAIRS AND INSPECTIONS 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 re- placed even if air bag system activation did not occur.
Page 737 10B-42 AIR BAG SYSTEM Steering wheel and driver air bag (inflator) module – Check for damage or air bag (inflator) module fitness. – Check trim cover (pad surface) for cracks. – Check wire harness and connector for damage or tightness. If any faulty condition is found in above checks, replace faulty part.
Page 738 AIR BAG SYSTEM 10B-43 Passenger air bag (inflator) module – Check for dents, cracks, damage or fitness. – Check trim cover for cracks or deformities. – Check harness and connector for damage or tightness. If any faulty condition is found in above checks, replace. Air bag wire harness and connections –...
Page 739 Be sure to follow the instructions. WARNING: If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 740 AIR BAG SYSTEM 10B-45 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 combina- tion switch assembly.
Page 741 10B-46 AIR BAG SYSTEM 3) If equipped with passenger air bag (inflator) module, connect Yellow connector (1) of passenger air bag (inflator) module, and be sure to lock connector with lock lever. a) Connect connector. b) Lock connector with lock lever. 4) Install glove box.
Page 742 AIR BAG SYSTEM 10B-47 LIVE (UNDEPLOYED) AIR BAG (INFLATOR) MODULES Special care is necessary when handling and storing a live (unde- ployed) air bag (inflator) modules. The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, or an object in front of the air bag (inflator) module, to be thrown through the air in the unlikely event of an accidental deployment.
Page 743 10B-48 AIR BAG SYSTEM WARNING: When placing a live air bag (inflator) module on bench or other surface, always face the bag up, away from the sur- face. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3).
Page 744 AIR BAG SYSTEM 10B-49 WARNING: For handling and storage of a live seat belt pretension- er, select a place where the ambient temperature be- low 65 C (150 F), without high humidity and away from electric noise. Never carry the seat belt pretensioner by the wire or connector of the pretensioner.
Page 745 10B-50 AIR BAG SYSTEM AIR BAG WIRE HARNESS AND CONNECTORS Air bag wire harness (1) can be identified easily as it is covered with a yellow protection tube. Be very careful when handling it. When an open in air bag wire harness (1), damaged wire har- ness, connector or terminal is found, replace wire harness, con- nectors and terminals as an assembly.
Page 746 AIR BAG SYSTEM 10B-51 WARNING: During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work. Neglecting them may result in personal in- jury or inactivation of the air bag system when neces- sary.
Page 747 10B-52 AIR BAG SYSTEM PASSENGER AIR BAG (INFLATOR) MODULE (IF EQUIPPED) WARNING: Never attempt to disassemble or repair the passenger air bag (inflator) module. If any abnormality is found, be sure to replace it with new one as an assembly. Be sure to read SERVICE PRECAUTIONS in this section before starting to work and observe every precaution during work.
Page 748 AIR BAG SYSTEM 10B-53 INSTALLATION 1) Install passenger air bag (inflator) module (2) to instrument pan- el (3). 2) Tighten passenger air bag (inflator) module attaching bolts to specified torque. Tightening Torque (a): 23 N·m (2.3 kg-m, 16.5 lb-ft) 3) Tighten passenger air bag (inflator) module attaching screws (4).
Page 749 10B-54 AIR BAG SYSTEM AIR BAG (INFLATOR) MODULE AND SEAT BELT PRETENSIONER DISPOSAL WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury. Undeployed air bag (inflator) module/inactivated seat belt pretensioner must not be disposed of through normal refuse channels.
Page 750 AIR BAG SYSTEM 10B-55 1) Turn ignition switch to “LOCK”, position remove key and put on safety glasses. 2) Check that there is no open, short or damage in special tool (de- ployment harness). If any faulty is found, do not use it and be sure to use new deployment harness.
Page 751 10B-56 AIR BAG SYSTEM WARNING: For handing and storage of a live seat belt pretension- er, select a place where the ambient temperature be- low 65 C (150 F), without high humidity and away from electric noise. Never carry the seat belt pretensioner by the wire or connector of the pretensioner.
Page 752 AIR BAG SYSTEM 10B-57 b) Place special tool (passenger air bag (inflator) module de- ployment fixture) on the ground in the space cleared in step i), if it has not already been placed there. Special Tool (B): 09932-75041 or 09932-75040 and 09932-75050 c) Fill plastic reservoir in fixture (special tool) with water or sand.
Page 753 10B-58 AIR BAG SYSTEM 6) Stretch the deployment harness from the driver or passenger For Driver Air Bag (Inflator) Module air bag (inflator) module to its full length 10 m (33 ft) (1). Special Tool (A): 09932-75030 7) Place a power source (3) near the shorted end of the deploy- ment harness.
Page 754 AIR BAG SYSTEM 10B-59 WARNING: After deployment/activation, the metal surfaces of the air bag (inflator) module and the seat belt pre- tensioner will be very hot. Do not touch the metal areas of them for about 30 minutes after deploy- ment/activation.
Page 755 10B-60 AIR BAG SYSTEM 18) Dispose of the deployed air bag (inflator) module and the acti- vated seat belt pretensioner through normal refuse channels after it has cooled for at least 30 minutes and tightly seal the air bag (inflator) module and the seat belt pretensioner in a strong vinyl bag.
Page 756 AIR BAG SYSTEM 10B-61 DEPLOYMENT/ACTIVATION INSIDE VE- For Driver Air Bag (Inflator) Module HICLE Use this procedure when scrapping the entire vehicle including the air bag (inflator) modules and seat belt pretensioners. CAUTION: When vehicle itself will be used again, deploy/activate the air bag and pretensioner outside vehicle according to DEPLOYMENT/ACTIVATION OUTSIDE VEHICLE, for For Passenger Air Bag (Inflator) Module...
Page 757 10B-62 AIR BAG SYSTEM 8) Route deployment harness out the vehicle. 9) Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable ob- jects. 10) Stretch (1) the deployment harness to its full length 10 m (33 ft).
Page 758 AIR BAG SYSTEM 10B-63 14) Separate the two banana plugs on the deployment harness. 15) Connect (1) the deployment harness to the power source (12 V vehicle battery) (2) to immediately deploy/activate the air bag or the pretensioner. 16) Disconnect the deployment harness from the power source (12 V vehicle battery) (2) and short (4) the two deployment har- ness leads together by fully seating one banana plug into the other.
Page 759 10B-64 AIR BAG SYSTEM DEPLOYED AIR BAG (INFLATOR) MODULE AND ACTIVATED SEAT BELT PRETENSION- ER DISPOSAL WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury.
Page 760 AIR BAG SYSTEM 10B-65 SPECIAL TOOLS 09932-75010 Air bag driver/passenger 09932-76010 09932-75030 load tool Connector test adapter kit Air bag deployment harness WARNING: Digital multimeter for 1. 09932-75041 (PAB deployment fixture) Be sure to use the specified which the maximum test digital multimeter.
Page 761 Prepared by Overseas Service Department 1st Ed. May, 1998 Printed in Japan Printing: May, 1999...

Suzuki RA410 Manual

Section 0A General Information

How to Use this Manual

Precautions

Identification Information

Warning, Caution and Information Labels

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Metric Information

Maintenance and Lubrication

Maintenance Schedule

Maintenance Service

Recommended Fluids and Lubricants

Section 1A Heater and Ventilation

General Description

Diagnosis

On Vehicle Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Recovery, Evacuation and Charging

On-Vehicle Service

Performance Test

Special Tools

Section 3B Manual Rack and Pinion

Diagnosis

General Description

On-Vehicle Service

Required Service Materials

Special Tools

Section 3B1 Electrical Power Steering (P/S) System

General Description

Diagnosis

On-Vehicle Service

Section 3C Steering Wheel and Column

Diagnosis

On-Vehicle Service

General Description

Checking Steering Column Assembly and Lower Shaft for Accident Damage

Required Service Material

Special Tool

Sectiond Front Suspension

Diagnosis

General Description

On-Vehicle Service

Required Service Material

Special Tools

Section 3E Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Section 4A Front Drive Shaft

Engine Mechanical

General Description

On Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Material

Section 6B Engine Cooling

General Description

Diagnosis

Maintenance

On-Vehicle Service

Required Service Materials

Special Tools

Section 6H Charging System

Battery

Generator General Description

Specifications

Section 8 Body Electrical System

General Description

Diagnosis

On-Vehicle Service

Quick Links

Chapters

Related Manuals for Suzuki RA410

Summary of Contents for Suzuki RA410