Page 1 Suzuki Swift Sport (RS416) 2004-2008 Service/Repair Manual This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnostic, disassembly, repair and installation procedures along with complete specifications and tightening references.
Page 2 Either of these two conditions may result in severe injury. • 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 3 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 as specified in each description.
Page 4 TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Transmission / Transaxle .......... 5-i General Information ..........0A-1 Precautions .............. 5-1 Maintenance and Lubrication ......... 0B-1 Automatic Transmission/Transaxle ......5A-1 Manual Transmission/Transaxle ......5B-1 Engine .................
Page 5: Table Of Contents
Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions for Electrical Circuit Service .... 00-8 Air Bag Warning ..........00-10 Precautions............00-1 Air Bag System Service Warning ...... 00-10 Precautions for Vehicles Equipped with a Fastener Caution..........00-10 Supplemental Restraint (Air Bag) System ..
Page 6: Precautions
• If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 7 Precautions: 00-2 Servicing and Handling WARNING Many of service procedures require disconnection of “A/BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger, Side and Curtain Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °C (150 °F), without high humidity and away from...
Page 8 00-3 Precautions: • Even when the accident was light enough not to WARNING cause air bags to activate, be sure to inspect system parts and other related parts according to instructions • For handling and storage of a SDM, select under “Repair and Inspection Required after Accident a place where the ambient temperature in Section 8B”.
Page 9: General Precautions
Precautions: 00-4 General Precautions • Be sure to observe following instructions S7RS0B0000002 when handling service materials such as The WARNING and CAUTION describe some general fuel, oil, fluid, coolant, grease, sealant, precautions that you should observe when servicing a thread lock cement, etc. Otherwise, your vehicle.
Page 10 When use of a certain type of lubricant, bond or first and then the negative cable, and replace the sealant is specified, be sure to use the specified type. terminal cover. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 I2RH01010030-01...
Page 11 Precautions: 00-6 • Be sure to use special tools when instructed. • For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump Special tool and injector without first releasing the fuel pressure, or (A): 09917-98221 fuel can be sprayed out under pressure.
Page 12: Warning For Wheel (With Tire) Removal
00-7 Precautions: Warning for Wheel (with tire) Removal Precautions for Installing Mobile S7RS0B0000003 Communication Equipment WARNING S7RS0B0000006 When installing mobile communication equipment such When removing any of these wheels installed as CB (Citizens-Band)-radio or cellular-telephone, be with wheel bolts, never remove all wheel sure to observe the following precautions.
Page 13: Precautions For Electrical Circuit Service
Precautions: 00-8 Precautions for Electrical Circuit Service • When connecting connectors, also hold connectors S7RS0B0000008 and put them together until they lock securely (a click • When replacing a fuse, make sure to use a fuse of the is heard). specified capacity.
Page 14 00-9 Precautions: • Be careful not to touch the electrical terminals of parts • When connecting meter probe (2) from terminal side which use microcomputers (e.g. electronic control unit of coupler (1) because it can’t be connected from like as ECM, PCM, P/S controller, etc.). The static harness side, use extra care not to bend male electricity from your body can damage these parts.
Page 15: Air Bag Warning
If the correct only by an authorized SUZUKI dealer. Refer part number fastener is not available, a to “Air Bag System Components, Wiring fastener of equal size and strength (or and Connectors Location in Section 8B”...
Page 16: Precaution For Vehicle Equipped With Esp® System
00-11 Precautions: Precaution for Vehicle Equipped with ESP® Brake Caution S7RS0B0000014 System CAUTION S7RS0B0000015 • When testing with any of the following equipments All brake fasteners are important attaching (when vehicle is tested by rotating wheels (tires) parts in that they could affect the under vehicle stop), be sure to deactivate ESP®...
Page 17 Precautions: 00-12 4) Using continuity check or voltage check the following Voltage Check procedure, check the wire harness for open circuit If voltage is supplied to the circuit being checked, voltage and poor connection with its terminals. Locate check can be used as circuit check. abnormality, if any.
Page 18: Intermittent And Poor Connection Inspection
00-13 Precautions: Short Circuit Check (Wire Harness to Ground) 4) Disconnect the connector included in circuit (connector-B) and measure resistance between “A- 1) Disconnect negative (–) cable at battery. 1” and body ground. If continuity is indicated, it 2) Disconnect connectors at both ends of the circuit to means that the circuit is shorted to the ground be checked.
Page 19 Precautions: 00-14 • Improperly formed or damaged terminals. • Wire insulation which is rubbed through, causing an Check each connector terminal in problem circuits intermittent short as the bare area touches other carefully to ensure good contact tension by using the wiring or parts of the vehicle.
Page 20 00-15 Precautions:...
Page 21 Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Lines and Connections Inspection ....0B-6 Fuel Filter Replacement ........0B-7 General Description ..........0A-1 Fuel Tank Inspection...........0B-7 Abbreviations ............0A-1 PCV Valve Inspection .........0B-7 Symbols .............. 0A-2 Fuel Evaporative Emission Control System Wire Color Symbols ..........
Page 22: General Information
0A-1 General Information: General Information General Information General Description Abbreviations EVAP Canister: Evaporative Emission Canister S7RS0B0101001 (Charcoal Canister) ABDC: After Bottom Dead Center 4WD: 4 Wheel Drive ABS: Anti-lock Brake System AC: Alternating Current GEN: Generator A/C: Air Conditioning GND: Ground A-ELR: Automatic-Emergency Locking Retractor GPS: Global Positioning System A/F: Air Fuel Mixture Ratio...
Page 23 WU-TWC: Warm Up Three Way Catalytic Converter Symbols S7RS0B0101002 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
Page 24 0A-3 General Information: There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “GRN”). The dual-colored wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of the wire (“GRN”...
Page 25 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 26 0A-5 General Information: Vehicle Lifting Points S7RS0B0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 27 General Information: 0A-6 When Using Floor Jack In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against front suspension frame WARNING (1) or rear jacking bracket (2). If the vehicle to be jacked up only at the front or rear end, be sure to block the wheels on ground in order to ensure safety.
Page 28 0A-7 General Information: Engine Supporting Points Vehicle Identification Number S7RS0B0101006 S7RS0B0101007 The number is punched close by the right side strut WARNING support in engine room and it is also attached on the left When using engine supporting device (1), be side of instrument panel depending on the vehicle sure to observe the followings.
Page 29 General Information: 0A-8 Component Location Warning, Caution and Information Labels Location S7RS0B0103001 The figure 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.
Page 30 0A-9 General Information: I4RS0B010002-03 1. Air bag label on driver air bag (inflator) module 6. Air bag label on SDM 2. Air bag label on combination switch and contact coil assembly 7. Pretensioner label on seat belt retractor 3. Air bag label on passenger air bag (inflator) module 8.
Page 31: Maintenance And Lubrication
Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S7RS0B0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S7RS0B0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
Page 32 0B-2 Maintenance and Lubrication: Km (x 1,000) Interval Miles (x 1,000) Months Fluid level (I: — — — Replace every 165,000 km (99,000 Automatic transaxle fluid Fluid change (R: miles) Fluid hose (I: — — — — — All latches, hinges and locks (I: —...
Page 33 Maintenance and Lubrication: 0B-3 Severe Maintenance Maintenance Maintenance interval condition code operation Every 30,000 km (18,000 miles) or – B – – E – – H Automatic transaxle fluid 24 months Every 15,000 km (9,000 miles) or 12 months – – C D – – – – HVAC air filter (if equipped) *2 Every 45,000 km (27,000 miles) or 36 months...
Page 34 0B-4 Maintenance and Lubrication: Accessory Drive Belt Replacement Before draining engine oil, check engine for oil leakage. S7RS0B0206002 If any evidence of leakage is found, make sure to correct Water Pump and Generator Drive Belt defective part before proceeding to the following work. Replace belt with new one referring to “Water Pump / 1) Drain engine oil by removing drain plug.
Page 35 Maintenance and Lubrication: 0B-5 4) Screw new filter on oil filter stand by hand until the 7) Check oil filter and drain plug for oil leakage. filter O-ring contacts mounting surface. 8) Start engine and run it for 3 minutes. Stop it and wait another 5 minutes before checking oil level.
Page 36: Air Cleaner Filter Replacement
0B-6 Maintenance and Lubrication: Exhaust System Inspection Air Cleaner Filter Inspection S7RS0B0206006 S7RS0B0206008 1) Remove air cleaner case clamps. WARNING 2) Take air cleaner filter out of case. To avoid danger of being burned, do not 3) Check that filter is not excessively dirty, damaged or touch exhaust system when it is still hot.
Page 37: Fuel Filter Replacement
Maintenance and Lubrication: 0B-7 Fuel Filter Replacement 2) Check disc brake pads and discs for excessive wear, S7RS0B0206011 damage and deflection. Replace parts as necessary. Fuel filter is installed in fuel pump assembly in fuel tank. For details, refer to “Front Disc Brake Pad Inspection Replace fuel filter or fuel pump assembly with new one, in Section 4B”, “Front Brake Disc Inspection in referring to “Fuel Pump Assembly Removal and...
Page 38: Brake Fluid Inspection
0B-8 Maintenance and Lubrication: Brake Fluid Inspection S7RS0B0206035 1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct. 2) Check fluid level. If fluid level is lower than the minimum level of reservoir, refilling is necessary. Fill reservoir with specified brake fluid.
Page 39: Tires Inspection
Maintenance and Lubrication: 0B-9 Tires Inspection Wheel Bearing Inspection S7RS0B0206020 S7RS0B0206022 1) Check tires for uneven or excessive wear, or 1) Check front wheel bearing for wear, damage, damage. If defective, replace. abnormal noise or rattles. For details, refer to “Front Refer to “Irregular and/or Premature Wear Wheel Hub, Disc, Nut and Bearing Check in Section Description in Section 2D”...
Page 40: Steering System Inspection
0B-10 Maintenance and Lubrication: Steering System Inspection Drive Shaft (Axle) Boots Inspection S7RS0B0206024 S7RS0B0206025 Check drive shaft boots (wheel side and differential side) 1) Check steering wheel for play and rattle, holding for leaks, detachment, tear or other damage. vehicle straight on ground. Replace defective parts as necessary.
Page 41: Automatic Transaxle Fluid Level Inspection
Maintenance and Lubrication: 0B-11 Automatic Transaxle Fluid Level Inspection Automatic Transaxle Fluid Cooler Hose S7RS0B0206028 Inspection 1) Inspect transaxle case for evidence of fluid leakage. S7RS0B0206030 Check automatic transaxle fluid cooler hose for fluid Repair leaky point, if any. leakage, cracks, damage and deterioration. 2) Make sure that vehicle is placed level for fluid level Replace hose and/or clamp if any faulty condition is check.
Page 42: Hvac Air Filter (If Equipped) Inspection
0B-12 Maintenance and Lubrication: HVAC Air Filter (If Equipped) Inspection Accelerator Pedal Operation S7RS0B0206032 Check that pedal operates smoothly without getting 1) Remove HVAC air filter from HVAC unit referring to caught or interfered by any other part. “HVAC Air Filter Removal and Installation (If Equipped) in Section 7A”.
Page 43: Specifications
Maintenance and Lubrication: 0B-13 • Check that the vehicle does not wander or pull to one Brake side. Foot brake Check the following: Engine • that brake pedal has proper travel, • Check that engine responds readily at all speeds. •...
Page 44: Special Tool
0B-14 Maintenance and Lubrication: Special Tool S7RS0B0208002 09915–47331 Oil filter wrench...
Page 45 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 Scan Tool Data ..........1A-33 Visual Inspection ..........1A-37 Precautions............. 1-1 Engine Basic Inspection........1A-38 Precautions for Engine.......... 1-1 Engine Symptom Diagnosis ......1A-41 Engine General Information and MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Diagnosis ..........
Page 46 1-ii Table of Contents DTC P0123: Throttle / Pedal Position Sensor DTC P1510: ECM Back-Up Power Supply / Switch “A” (Main) Circuit High ....... 1A-85 Malfunction............1A-143 DTC P0131 / P0132: O2 Sensor (HO2S) DTC P1603: TCM Trouble Code Detected ..1A-144 Circuit Low Voltage / High Voltage (Sensor- DTC P1674: CAN Communication (Bus Off 1) ..............1A-88...
Page 47 Table of Contents 1-iii EVAP Canister Purge Valve and Its Circuit Air Cleaner Element Inspection and Cleaning ..1D-10 Inspection............1B-2 Cylinder Head Cover Removal and Vacuum Passage Inspection ......1B-3 Installation ............1D-10 Vacuum Hose and Purge Valve Chamber Throttle Body and Intake Manifold Inspection............
Page 48 1-iv Table of Contents Engine Lubrication System .....1E-1 Precautions on Fuel System Service ....1G-1 General Description ..........1G-1 General Description ..........1E-1 Fuel System Description ........1G-1 Engine Lubrication Description ......1E-1 Fuel Delivery System Description ...... 1G-1 Diagnostic Information and Procedures.... 1E-2 Fuel Pump Description........
Page 49 Table of Contents 1-v Ignition Timing Inspection ........1H-8 Generator Test (Undercharged Battery Check)............... 1J-5 Specifications............1H-9 Generator Test (Overcharged Battery Check) ..1J-6 Tightening Torque Specifications......1H-9 Repair Instructions ..........1J-6 Special Tools and Equipment ......1H-9 Jump Starting in Case of Emergency....1J-6 Special Tool ............1H-9 Battery Dismounting and Remounting ....
Page 50: Precautions
1-1 Precautions: Precautions Engine Precautions Precautions for Engine S7RS0B1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions of ECM Circuit Inspection Refer to “Precautions of ECM Circuit Inspection in Section 1A”.
Page 51: Engine General Information And Diagnosis
• Diagnostic information stored in ECM memory can be that 12-volt electrical system is capable of violent and cleared as well as checked by using SUZUKI scan damaging short circuits. tool or OBD generic scan tool. Before using scan tool, When performing any work where electrical terminals read its Operator’s (Instruction) Manual carefully to...
Page 52: Precautions Of Ecm Circuit Inspection
1A-2 Engine General Information and Diagnosis: Precautions of ECM Circuit Inspection • Be sure to read “Precautions for Electrical Circuit S7RS0B1100003 Service in Section 00” before inspection and observe • ECM connectors are waterproofed. Each terminal of what is written there. the ECM connectors is sealed up with the grommet.
Page 53: Engine Diagnosis General Description
Diagnostic (OBD) System”. • It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. This vehicle is equipped with an engine and emission (Diagnostic information can be accessed by using a control system which are under control of ECM.
Page 54 1A-4 Engine General Information and Diagnosis: Driving Cycle detected. Utilizing this function, it is possible to know the A “Driving Cycle” consists of engine startup and engine order of malfunctions that have been detected. Its use is shutoff. helpful when rechecking or diagnosing a trouble. 2 Driving Cycle Detection Logic The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC) but...
Page 55 • Heated oxygen sensor For Hong Kong model, DTC can be read by not only • ECT sensor using SUZUKI scan tool but also displayed on • TP sensor odometer (5) of the combination meter. (i.e. when • APP sensor diagnosis switch terminal (3) is grounded with a service wire (4) and ignition switch is turned ON.) For...
Page 56: Data Link Connector (Dlc)
OBD serial data line (3) (K line of ISO 9141) is used for and controlled devices. SUZUKI scan tool or OBD generic scan tool to Emission control system includes EGR, EVAP and PCV system. communicate with ECM, Air bag SDM, HVAC control...
Page 57: Can Communication System Description
Engine General Information and Diagnosis: 1A-7 CAN Communication System Description S7RS0B1101005 The following control modules and sensors communicate each other. • ECM (2) • TCM (1) • BCM (4) • ABS control module (3) or ESP® control module (7) • Combination meter (5) •...
Page 58 1A-8 Engine General Information and Diagnosis: CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple control modules can communicate simultaneously.
Page 59: Air Intake System Description
Engine General Information and Diagnosis: 1A-9 Air Intake System Description S7RS0B1101006 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Description of Electric Throttle Body System”.), and intake manifold (4). The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner, distributed by the intake, and finally drawn into each combustion chamber.
Page 60: Description Of Electric Throttle Body System Calibration
1A-10 Engine General Information and Diagnosis: I4RS0B110007-02 6. CPU 11. APP sensor (main) signal 15. Drive signal of throttle actuator 7. Drive circuit of throttle actuator 12. APP sensor (sub) signal 16. Power supply of throttle actuator 9. From “TH MOT” fuse 13.
Page 61: Generator Control System Description
Engine General Information and Diagnosis: 1A-11 Generator Control System Description S7RS0B1101010 Generator Control System consists of a generator (1), electric load current sensor (7) located in the main fuse box (4) and ECM (5). ECM controls generated electricity (adjusting voltage of IC regulator (2)) so that it is suitable for the engine and electric load conditions.
Page 62: Electronic Control System Description
1A-12 Engine General Information and Diagnosis: Electronic Control System Description S7RS0B1101011 The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices. Functionally, it is divided into the following sub systems: •...
Page 63 Engine General Information and Diagnosis: 1A-13 Engine and Emission Control System Flow Diagram I7RS0B110004-01...
Page 64 1A-14 Engine General Information and Diagnosis: ECM Input / Output Circuit Diagram E23-45 BLU/ORN E23-35 E23-32 RED/YEL E23-37 E23-52 C37-45 LT GRN/RED E23-34 C37-44 LT GRN/BLK E23-36 C37-43 E23-51 C37-54 E23-50 C37-40 RED/YEL C37-20 C37-42 C37-41 C37-1 BLU/YEL C37-21 BLK/ORN C37-2 BLU/WHT GRN/BLK...
Page 65 Engine General Information and Diagnosis: 1A-15 [A]: Manual A/C model 24. ABS / ESP® control module 49. Radiator cooling fan motor [B]: Auto A/C model 25. TCM 50. “RDTR FAN” fuse 1. ECM 26. To other control module connected CAN 51.
Page 66 1A-16 Engine General Information and Diagnosis: Connector: C37 Terminal Wire color Circuit Terminal Wire color Circuit BLU/YEL Fuel injector No.1 output — — BLU/WHT Fuel injector No.2 output — — EGR valve (stepper motor coil GRN/ORN — — 2) output EGR valve (stepper motor coil GRN/RED —...
Page 67 Engine General Information and Diagnosis: 1A-17 Connector: E23 Terminal Wire color Circuit Terminal Wire color Circuit BLK/RED Main power supply Ground for ECM Power source for ECM internal Power supply of throttle WHT/RED RED/YEL memory actuator drive circuit CAN communication line (active high signal) for ABS/ —...
Page 68: Engine And Emission Control Input / Output Table
1A-18 Engine General Information and Diagnosis: Engine and Emission Control Input / Output Table S7RS0B1101012 ELECTRIC CONTROL DEVICE OUTPUT INPUT BAROMETRIC PRESSURE SENSOR STOP LAMP SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR BLOWER SWITCH A/C SWITCH A/C EVAP OUTLET AIR TEMP. SENSOR (Manual A/C model) ABS/ESP CONTROL MODULE (Wheel Speed Signal) ®...
Page 69: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-19 Schematic and Routing Diagram Engine and Emission Control System Diagram S7RS0B1102001 I7RS0B110010-01...
Page 70 1A-20 Engine General Information and Diagnosis: 1. Air cleaner 16. CMP sensor 31. Battery 2. EVAP canister purge valve 17. CKP sensor 32. A/C compressor relay 3. MAF and IAT sensor 18. Radiator cooling fan 33. A/C switch 4. TP sensor 19.
Page 71: Component Location
Engine General Information and Diagnosis: 1A-21 Component Location Electronic Control System Components Location S7RS0B1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I7RS0B110011-02 Information sensors Control devices Others 1.
Page 72: Diagnostic Information And Procedures
1A-22 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine and Emission Control System Check S7RS0B1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Page 73 Engine General Information and Diagnosis: 1A-23 Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition?
Page 74 1A-24 Engine General Information and Diagnosis: Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 75: Malfunction Indicator Lamp (Mil) Check
Engine General Information and Diagnosis: 1A-25 Step 2: DTC / Freeze Frame Data Check, Record and Step 10: Intermittent Problems Check Clearance Check parts where an intermittent trouble is easy to First, check DTC (including pending DTC), referring to occur (e.g., wire harness, connector, etc.), referring to “DTC Check”.
Page 76: Dtc Check
DTC stored in ECM and TCM is read and displayed at a time. Using Scan Tool 1) Prepare OBD generic scan tool or SUZUKI scan tool. 2) With ignition switch turned OFF, connect it to DLC (1) located on underside of instrument panel at driver’s seat side.
Page 77: Dtc Clearance
ECM connectors). Using Scan Tool • When the same malfunction (DTC) is not 1) Connect OBD generic scan tool or SUZUKI scan tool detected again during 40 engine warm-up to data link connector in the same manner as when cycles.
Page 78 1A-28 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) HO2S heater control circuit low 2 driving *P0031 Heater voltage is less than specification while heater ON. (Sensor-1) cycles HO2S heater control circuit Heater voltage is more than specification while heater 2 driving *P0032...
Page 79 Engine General Information and Diagnosis: 1A-29 Detecting condition DTC No. Detecting item (DTC will set when detecting:) O2 sensor (HO2S) circuit no Output voltage of HO2S-2 is more than specification after 2 driving *P0140 activity detected (Sensor-2) warming up engine. cycles Total fuel trim is larger than specification for specified time 2 driving...
Page 80 1A-30 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Starter signal is high voltage for specified time while 2 driving Starter relay circuit high *P0617 engine is running. cycles Battery voltage is higher than specification even through generator control is maximum regulation, or battery P0620 Generator control circuit voltage is lower than specification even through generator...
Page 81: Fail-Safe Table
Engine General Information and Diagnosis: 1A-31 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Throttle/pedal position sensor/ Output voltage of APP sensor (main) is higher than 1 driving *P2123 switch “D” (main) circuit high specification. cycle input Throttle/pedal position sensor/ Output voltage of APP sensor (sub) is lower than 1 driving...
Page 82 1A-32 Engine General Information and Diagnosis: DTC No. Detected item Fail-safe operation P0117 Engine coolant temperature circuit low • ECM controls actuators assuming that engine coolant temperature is 80 °C (176 °F). P0118 Engine coolant temperature circuit high • ECM operates radiator cooling fan. Throttle/pedal position sensor/switch/“A”...
Page 83: Scan Tool Data
Engine General Information and Diagnosis: 1A-33 DTC No. Detected item Fail-safe operation Throttle/pedal position sensor/switch/“D” (main) P2122 circuit low input Throttle/pedal position sensor/switch/“D” (main) • ECM turns off throttle actuator control relay and P2123 circuit high input throttle valve is fixed at the specified opening from Throttle/pedal position sensor/switch/“E”...
Page 84 1A-34 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values O2S B1 S1 At specified idle speed after warming up 0.1 – 0.95 V O2S B1 S1 ACT At specified idle speed after warming up ACTIVE O2S B1 S2 At 2000 r/min.
Page 85 Engine General Information and Diagnosis: 1A-35 Normal condition / Scan tool data Vehicle condition reference values Accelerator pedal released 1.4 – 1.8 V Ignition switch ON after TP SENSOR 2 VOLT Accelerator pedal depressed warmed up engine 3.58 – 4.76 V fully Accelerator pedal released 0.5 –...
Page 86 1A-36 Engine General Information and Diagnosis: O2S B1 S1 ACT (HEATED OXYGEN SENSOR-1, CANIST PRG DUTY (EVAP CANISTER PURGE FLOW ACTIVE / INACTIVE) DUTY, %) This parameter indicates activation condition of HO2S-1. This parameter indicates valve ON (valve open) time ACTIVE: Activating rate within a certain set cycle of EVAP canister purge INACTIVE: warming up or at stop...
Page 87: Visual Inspection
Engine General Information and Diagnosis: 1A-37 TP SENSOR 2 VOLT (THROTTLE POSITION SENSOR THROTTLE TARGET POSI (TARGET THROTTLE (SUB) OUTPUT VOLTAGE, V) VALVE POSITION, %) The TP sensor (sub) reading provides throttle valve Target throttle valve position is ECM internal parameter opening information in the form of voltage.
Page 88: Engine Basic Inspection
1A-38 Engine General Information and Diagnosis: Engine Basic Inspection S7RS0B1104009 This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been found in “Visual Inspection”. Follow the flow carefully. Step Action Was “Engine and Emission Control System Check” Go to Step 2.
Page 89 Check ignition timing Go to “Engine Symptom Check ignition control Diagnosis”. related parts referring to 1) Using SUZUKI scan tool, select “Misc Test” mode on “Ignition Timing SUZUKI scan tool and fix ignition timing to initial one. Inspection in Section 1H”.
Page 90 1A-40 Engine General Information and Diagnosis: Step Action Check fuel pump for operation Go to “Fuel Pressure Go to “Fuel Pump and Check”. Its Circuit Check”. Was fuel pump operating sound heard from fuel filler for about 2 seconds after ignition switch ON and stop? 12 Check ignition spark Go to Step 13.
Page 91: Engine Symptom Diagnosis
Engine General Information and Diagnosis: 1A-41 Engine Symptom Diagnosis S7RS0B1104010 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H”...
Page 92 1A-42 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noise – Piston, Worn piston, ring and cylinder bore “Cylinders, Pistons and Piston Rings ring and cylinder noise Inspection in Section 1D” NOTE Before checking mechanical noise, make sure that: •...
Page 93 Engine General Information and Diagnosis: 1A-43 Condition Possible cause Correction / Reference Item Poor gasoline mileage Leaks or loose connection of high- “High-Tension Cord Removal and Installation tension cord in Section 1H” Faulty spark plug (improper gap, heavy “Spark Plug Inspection in Section 1H” deposits and burned electrodes, etc.) Malfunctioning EGR valve “EGR Valve Inspection in Section 1B”...
Page 94 1A-44 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine hesitates – Spark plug faulty “Spark Plug Inspection in Section 1H” Momentary lack of Leaky high-tension cord “High-Tension Cord Inspection in Section 1H” response as accelerator Fuel pressure out of specification “Fuel Pressure Check”...
Page 95 Engine General Information and Diagnosis: 1A-45 Condition Possible cause Correction / Reference Item Engine has no power Faulty spark plug “Spark Plug Inspection in Section 1H” Faulty ignition coil with ignitor “Ignition Coil Assembly (Including ignitor) Inspection in Section 1H” Leaks, loose connection or “High-Tension Cord Removal and Installation disconnection of high-tension cord...
Page 96 1A-46 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation monoxide (CO) in Section 1H”...
Page 97: Mil Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)
Engine General Information and Diagnosis: 1A-47 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S7RS0B1104011 Wiring Diagram E23-3 E23-18 G28-31 G28-16 BLK/ORN RED/BLK C37-13 C37-12 BLK/WHT E23-29 C37-58 C37-15 C37-30 BLK/ORN BLK/YEL BLK/YEL BRN/WHT...
Page 98: Malfunction Indicator Lamp Remains On After Engine Starts
1A-48 Engine General Information and Diagnosis: Troubleshooting NOTE When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action MIL power supply check Go to Step 2.
Page 99: Dtc P0010: "A" Camshaft Position Actuator Circuit
Engine General Information and Diagnosis: 1A-49 Troubleshooting NOTE When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action DTC check Go to Step 2 of “Engine Go to Step 2.
Page 100 1A-50 Engine General Information and Diagnosis: Circuit Description Actual valve timing fails to become close to target advance level of each function although advance control function or retarded advance control function is at work. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of oil control valve is different from...
Page 101 Engine General Information and Diagnosis: 1A-51 Step Action Oil control valve electrical circuit for ground short Go to Step 9. “YEL/GRN” wire is check shorted to ground circuit. 1) Measure resistance between “C37-59” terminal of ECM connector and engine ground. Is resistance infinity? Oil control valve electrical circuit for short check Go to Step 9.
Page 102: Dtc P0011 / P0012: "A" Camshaft Position - Timing Over-Advanced Or System Performance / -Retarded
1A-52 Engine General Information and Diagnosis: DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System Performance / - Retarded S7RS0B1104014 System Description Actual value of advanced valve timing does not reach target value. Valve timing is advanced although ECM command is most retarding. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 103 Installation in Section temperature. 1D”. If OK, go to Step 5. 3) Select menu to DATA LIST. 4) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 5°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.
Page 104: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)
1A-54 Engine General Information and Diagnosis: DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S7RS0B1104015 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/RED C37-46 C37-10 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RS0C110006-03...
Page 105 Engine General Information and Diagnosis: 1A-55 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. HO2S-1 heater power circuit check Go to Step 3. “BLK/WHT” wire is open circuit or shorted to 1) Disconnect connector from HO2S-1 with ignition switch ground circuit.
Page 106: Dtc P0037 / P0038: Ho2S Heater Control Circuit Low / High (Sensor-2)
1A-56 Engine General Information and Diagnosis: DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) S7RS0B1104016 Wiring Diagram BLK/WHT E23-29 BLK/WHT RED/BLU C37-47 C37-11 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RS0C110007-01...
Page 107 Engine General Information and Diagnosis: 1A-57 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. HO2S-2 heater power circuit check Go to Step 3. “BLK/WHT” wire is open circuit or shorted to 1) Disconnect connector from HO2S-2 with ignition switch ground circuit.
Page 108: Dtc P0101: Mass Or Volume Air Flow Circuit Range / Performance
1A-58 Engine General Information and Diagnosis: DTC P0101: Mass or Volume Air Flow Circuit Range / Performance S7RS0B1104017 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-31 BLK BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED E23-16 BLK/RED C37-26 GRN/BLK C37-27 BLK/YEL...
Page 109 Engine General Information and Diagnosis: 1A-59 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 110 1A-60 Engine General Information and Diagnosis: Step Action MAF sensor output voltage check Poor “C37-26” and/or Go to Step 5. “C37-27” terminal 1) Turn OFF ignition switch. connection. 2) Remove ECM from its bracket with ECM connectors If OK, substitute a connected.
Page 111: Dtc P0102: Mass Or Volume Air Flow Circuit Low Input
Engine General Information and Diagnosis: 1A-61 Step Action 10 MAF sensor signal circuit check Faulty MAF and IAT “GRN/BLK” wire is open sensor. or high resistance 1) Measure resistance between “GRN/BLK” wire terminal circuit. of MAF and IAT sensor connector and “C37-26” terminal of ECM connector.
Page 112 1A-62 Engine General Information and Diagnosis: Step Action MAF sensor power supply voltage check Go to Step 4. “BLK/RED” wire is open circuit. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “BLK/RED”...
Page 113: Dtc P0103: Mass Or Volume Air Flow Circuit High Input
Engine General Information and Diagnosis: 1A-63 DTC P0103: Mass or Volume Air Flow Circuit High Input S7RS0B1104019 Wiring Diagram Refer to “DTC P0101: Mass or Volume Air Flow Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area MAF sensor output voltage is higher than 4.85 V for 0.5 seconds •...
Page 114: Dtc P0106: Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance
1A-64 Engine General Information and Diagnosis: Step Action MAF sensor signal circuit check Go to Step 7. “GRY/BLK” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure voltage between “GRY/BLK” wire terminal of MAF and IAT sensor connector and engine ground.
Page 115 Engine General Information and Diagnosis: 1A-65 DTC Confirmation Procedure NOTE Check to make sure that the following conditions are satisfied when using this “DTC Confirmation Procedure”. • Intake air temperature at engine start: –10 °C (14 °F) to 80 °C (176 °F) •...
Page 116: Dtc P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low Input
1A-66 Engine General Information and Diagnosis: DTC P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low Input S7RS0B1104021 Wiring Diagram Refer to “DTC P0106: Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance” DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Manifold absolute pressure sensor output voltage is lower...
Page 117: Dtc P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High Input
Engine General Information and Diagnosis: 1A-67 Step Action MAP sensor power supply circuit check Faulty A/C refrigerant “GRY/RED” wire is pressure sensor (if shorted to ground 1) Disconnect connectors from A/C refrigerant pressure equipped with A/C). circuit. sensor (if equipped with A/C) with ignition switch turned OFF.
Page 118 1A-68 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 119: Dtc P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance
Engine General Information and Diagnosis: 1A-69 Step Action Ground circuit check “ORN” wire is open or ECM grounds “E23-31”, high resistance circuit. “C37-58”, “C37-15” and/ 1) Measure resistance between “C37-55” terminal of ECM or “C37-30” circuit are connector and vehicle body ground. open or high resistance.
Page 120 1A-70 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference of maximum IAT minus minimum IAT is less than 0.3 °C • High resistance circuit (32.5 °F) while ECT is over 70 °C (158 °F) after 10 min from cold •...
Page 121 Engine General Information and Diagnosis: 1A-71 Step Action Wire harness check Go to Step 8. Go to Step 4. 1) Disconnect MAF and IAT sensor connector (1) with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor connector (1) at “BLK/YEL”...
Page 122: Dtc P0112: Intake Air Temperature Sensor 1 Circuit Low
1A-72 Engine General Information and Diagnosis: Step Action Ground circuit check Go to Step 10. Go to Step 9. 1) Connect connectors to ECM. 2) Check for proper connection of MAF and IAT sensor connector at “GRY/BLU” wire terminal. 3) Measure resistance between “GRY/BLU” wire terminal of MAF and IAT sensor connector and vehicle body ground with ignition switch turned OFF.
Page 123 Engine General Information and Diagnosis: 1A-73 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. IAT sensor and its circuit check Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition switch turned Check for intermittent OFF.
Page 124: Dtc P0113: Intake Air Temperature 1 Sensor Circuit High
1A-74 Engine General Information and Diagnosis: DTC P0113: Intake Air Temperature 1 Sensor Circuit High S7RS0B1104025 Wiring Diagram Refer to “DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area IAT sensor output voltage is higher than 4.85 V for 0.5 seconds •...
Page 125 Engine General Information and Diagnosis: 1A-75 Step Action IAT sensor voltage check Go to Step 7. Go to Step 4. 1) Disconnect connector from MAF and IAT sensor with ignition switch turned OFF. 2) Check for proper connection to MAF and IAT sensor at “BLK/YEL”...
Page 126: Dtc P0116: Engine Coolant Temperature Circuit Range / Performance
1A-76 Engine General Information and Diagnosis: Step Action Ground circuit check “GRY/BLU” wire and/or Faulty ECM ground “ORN” wire is open circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors circuit or high resistance substitute a known- connected.
Page 127 Engine General Information and Diagnosis: 1A-77 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 128 1A-78 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 9. Go to Step 6. 1) Disconnect ECT sensor connector with ignition switch turned OFF. 2) Check for proper connection to ECT sensor connector at “ORN” and “LT GRN” wire terminals. 3) If OK, then with ignition switch ON, measure voltage between “LT GRN”...
Page 129: Dtc P0117: Engine Coolant Temperature Circuit Low
Engine General Information and Diagnosis: 1A-79 Step Action 10 Ground circuit check “ORN” wire is high Faulty ECM ground resistance circuit. circuit. 1) Remove ECM from its bracket with ECM connectors connected. Poor “C37-55” If circuit is OK, connection. substitute a known- 2) Measure resistance between “C37-55”...
Page 130 1A-80 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 131: Dtc P0118: Engine Coolant Temperature Circuit High
Engine General Information and Diagnosis: 1A-81 DTC P0118: Engine Coolant Temperature Circuit High S7RS0B1104028 Wiring Diagram Refer to “DTC P0116: Engine Coolant Temperature Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area ECT sensor output voltage is higher than 4.85 V for 0.5 seconds •...
Page 132 1A-82 Engine General Information and Diagnosis: Step Action ECM voltage check “LT GRN” wire is open Go to Step 5. circuit. If wire and 1) Turn OFF ignition switch. connection are OK, go 2) Remove ECM from its bracket with ECM connectors to Step 5.
Page 133: Dtc P0122: Throttle / Pedal Position Sensor / Switch "A" (Main) Circuit Low
Engine General Information and Diagnosis: 1A-83 DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low S7RS0B1104029 Wiring Diagram C37-58 BLK/ORN BLK/WHT E23-29 C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-31 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 E23-45 BLU/ORN RED/YEL...
Page 134 1A-84 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 135: Dtc P0123: Throttle / Pedal Position Sensor / Switch "A" (Main) Circuit High
Engine General Information and Diagnosis: 1A-85 Step Action Wire harness check Go to Step 9. Go to Step 7. 1) Measure voltage between “GRN” wire terminal of electric throttle body connector and engine ground with ignition switch turned ON. Is voltage 4 – 6 V? Wire harness check Go to Step 8.
Page 136 1A-86 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 137 Engine General Information and Diagnosis: 1A-87 Step Action Wire harness check “GRN” wire is open or Go to Step 7. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “C37- 43”...
Page 138: Dtc P0131 / P0132: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-1)
1A-88 Engine General Information and Diagnosis: DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) S7RS0B1104031 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/RED C37-46 C37-10 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 139 Engine General Information and Diagnosis: 1A-89 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 140 1A-90 Engine General Information and Diagnosis: Step Action HO2S-1 ground check Go to Step 5. “YEL” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-1 with ignition switch Poor “C37-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-1 connector at ground.
Page 141: Dtc P0133: O2 Sensor (Ho2S) Circuit Slow Response (Sensor-1)
Engine General Information and Diagnosis: 1A-91 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) S7RS0B1104032 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Response time (time to change from lean to rich or from rich to lean) of HO2S-1 output Heated oxygen sensor-1 voltage is about 1 sec.
Page 142: Dtc P0134: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-1)
1A-92 Engine General Information and Diagnosis: DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1) S7RS0B1104033 Wiring Diagram Refer to “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)” DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S voltage is higher than 0.6 V for more than 1 min...
Page 143 Engine General Information and Diagnosis: 1A-93 Step Action HO2S-1 output voltage check Intermittent trouble. Go to Step 3. Check for intermittent 1) Connect scan tool to DLC with ignition switch turned referring to “Intermittent OFF. and Poor Connection 2) Warm up engine to normal operating temperature and Inspection in Section keep it at 2000 r/min.
Page 144: Dtc P0137 / P0138: O2 Sensor (Ho2S) Circuit Low Voltage / High Voltage (Sensor-2)
1A-94 Engine General Information and Diagnosis: DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2) S7RS0B1104034 Wiring Diagram BLK/WHT E23-29 BLK/WHT RED/BLU C37-47 C37-11 C37-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 145 Engine General Information and Diagnosis: 1A-95 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 146 1A-96 Engine General Information and Diagnosis: Step Action HO2S-2 ground check Go to Step 5. “YEL” wire is open or high resistance circuit. 1) Disconnect connector from HO2S-2 with ignition switch Poor “C37-57” terminal turned OFF. connection. Faulty ECM 2) Check for proper connection to HO2S-2 connector at ground.
Page 147: Dtc P0140: O2 Sensor (Ho2S) Circuit No Activity Detected (Sensor-2)
Engine General Information and Diagnosis: 1A-97 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) S7RS0B1104035 Wiring Diagram Refer to “DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)” DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area HO2S-2 voltage is higher than specified value after warming up engine...
Page 148: Dtc P0171 / P0172: Fuel System Too Lean / Rich
1A-98 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 4. “BRN” wire is high resistance circuit or 1) Turn OFF ignition switch. open circuit. Poor “C37- 2) Remove ECM from its bracket with ECM connectors 11”...
Page 149 Engine General Information and Diagnosis: 1A-99 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and print Freeze Frame Data or write them down using scan tool. 3) Clear DTC using scan tool. 4) Start engine and warm up to normal operating temperature. 5) Operate vehicle with condition as noted freeze frame data for 5 min.
Page 150: Dtc P0222: Throttle / Pedal Position Sensor / Switch "B" (Sub) Circuit Low
1A-100 Engine General Information and Diagnosis: Step Action HO2S-1 for performance check Substitute a known- Faulty HO2S-1 or its good ECM and recheck. circuit. 1) Check HO2S-1 referring to Step 3 of “DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)”.
Page 151 Engine General Information and Diagnosis: 1A-101 NOTE When DTC P0122 and P0222 are indicated together, it is possible that “RED” wire open circuit. DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds.
Page 152: Dtc P0223: Throttle / Pedal Position Sensor / Switch "B" (Sub) Circuit High
1A-102 Engine General Information and Diagnosis: Step Action ECM voltage check “RED” wire is open or Go to Step 5. high resistance circuit. 1) Turn OFF ignition switch. 2) Remove ECM from its bracket with ECM connectors connected. 3) Check for proper connection of ECM connector at “C37- 43”...
Page 153 Engine General Information and Diagnosis: 1A-103 NOTE When DTC P0123 and P0223 are indicated together, it is possible that “RED” wire shorted to power circuit and/or “BLK” wire open. DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool.
Page 154 1A-104 Engine General Information and Diagnosis: Step Action Wire harness check Substitute a known- “RED” wire is shorted to good ECM and recheck. power circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Check for proper connection of ECM connector at “C37- 43”...
Page 155: Dtc P0301, P0302, P0303, P0304
Engine General Information and Diagnosis: 1A-105 Step Action Electric throttle body check Substitute a known- Replace electric throttle good ECM and recheck. body. 1) Check TP sensor referring to “Throttle Position Sensor Performance Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”. Is output voltage within specified value? DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...
Page 156 1A-106 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 157: Dtc P0327 / P0328: Knock Sensor 1 Circuit Low / High
Engine General Information and Diagnosis: 1A-107 Step Action Engine mechanical system check Check wire harness and Repair or replace connection of ECM defective part. 1) Check engine mechanical parts or system which can ground, ignition system cause engine rough idle or poor performance. and fuel injector for •...
Page 158 1A-108 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 159: Dtc P0335: Crankshaft Position (Ckp) Sensor "A" Circuit
Engine General Information and Diagnosis: 1A-109 Step Action Knock sensor circuit for high resistance check Faulty knock sensor. “RED” wire is high resistance circuit. 1) Turn OFF ignition switch, measure resistance between “C37-56” terminal of ECM connector and “RED” wire terminal of knock sensor harness connector.
Page 160 1A-110 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 161: Dtc P0340: Camshaft Position (Cmp) Sensor "A" Circuit
Engine General Information and Diagnosis: 1A-111 Step Action Was terminal “B+” voltage in Step 3 within specification? Go to Step 7. “BLK/RED” wire is open circuit. If wire and connection are OK, substitute a known- good ECM and recheck. Engine start signal check Go to Step 8.
Page 162 1A-112 Engine General Information and Diagnosis: System Description The CMP sensor located on the transmission side of cylinder head consists of the signal generator (magnetic sensor) and signal rotor (intake camshaft portion). The signal generator generates reference signal through slits in the slit plate which turns together with the camshaft. Reference signal The CMP sensor generates 6 pulses of signals each of which has a different waveform length while the camshaft makes one full rotation.
Page 163 Engine General Information and Diagnosis: 1A-113 Step Action Wire harness and connection check Go to Step 7. Go to Step 4. 1) Disconnect connector from CMP sensor. 2) Check for proper connection to CMP sensor at “BLK/ RED”, “RED/YEL” and “BLK/ORN” wire terminals. 3) If OK, turn ON ignition switch and check voltage at “BLK/ RED”, “RED/YEL”...
Page 164: Dtc P0350: Ignition Coil Primary / Secondary Circuit
1A-114 Engine General Information and Diagnosis: DTC P0350: Ignition Coil Primary / Secondary Circuit S7RS0B1104043 Wiring Diagram BLK/WHT E23-29 BLK/WHT BLK/WHT C37-5 GRN/WHT GRN/YEL C37-6 C37-58 BLK/ORN C37-15 C37-30 E23-31 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 165 Engine General Information and Diagnosis: 1A-115 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 166: Dtc P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
1A-116 Engine General Information and Diagnosis: DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected S7RS0B1104044 System and Wiring Diagram I6RS0C110019-02 1. EGR valve 5. Fresh air 9. Ignition switch 2. Intake manifold 6. Exhaust gas 10.
Page 167 Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. Do you have SUZUKI scan tool? Go to Step 3. Go to Step 5.
Page 168: Dtc P0403: Exhaust Gas Recirculation Control Circuit
Action EGR valve operation check Go to Step 4. Go to Step 5. 1) With ignition switch turned OFF, install SUZUKI scan tool to DTC. 2) Check EGR system referring to “EGR System Inspection in Section 1B”. Is it in good condition?
Page 169 Engine General Information and Diagnosis: 1A-119 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 170: Dtc P0420: Catalyst System Efficiency Below Threshold
1A-120 Engine General Information and Diagnosis: DTC P0420: Catalyst System Efficiency below Threshold S7RS0B1104046 System and Wiring Diagram C37-10 C37-57 C37-11 BLU WHT I4RS0A110037-01 1. HO2S-1 3. Warm up three way catalytic converter 5. ECM 2. HO2S-2 4. Three way catalytic converter Circuit Description ECM monitors oxygen concentration in the exhaust gas which has passed the warm up three way catalytic converter by HO2S-2.
Page 171 Engine General Information and Diagnosis: 1A-121 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Response delay of HO2S-2 signal (shifting delay from rich to lean and • Exhaust gas leak from lean to rich with threshold at 0.45 V) compared to switching cycle •...
Page 172: Dtc P0443: Evaporative Emission System Purge Control Valve Circuit
1A-122 Engine General Information and Diagnosis: Step Action HO2S-2 output voltage check Replace exhaust Check “BRN” and / or manifold (built in warm “YEL” wires for open 1) Check output voltage of HO2S-2 referring to “DTC up three way catalytic and short, and P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / converter) and exhaust...
Page 173 Engine General Information and Diagnosis: 1A-123 DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 174: Dtc P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
1A-124 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 6. “BLU/BLK” wire is open circuit. 1) Connect connector to purge control valve with ignition switch turned OFF. 2) Turn ON ignition switch and measure voltage between “C37-29”...
Page 175 Engine General Information and Diagnosis: 1A-125 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Monitor signal of radiator cooling fan relay is different from • Radiator cooling fan relay circuit malfunction command signal. • Radiator cooling fan relay malfunction (1 driving cycle detection logic) •...
Page 176 1A-126 Engine General Information and Diagnosis: Step Action Wire circuit check Go to Step 4. Open wire in “BLK/RED” and/or “GRY” wire are 1) Disconnect radiator cooling fan relay No. 1 (1) from open circuit. individual circuit fuse box No.1 (2) with ignition switch turned OFF.
Page 177 Engine General Information and Diagnosis: 1A-127 Step Action Radiator cooling fan control No. 1 check Go to Step 9. Faulty ECM. 1) Run engine until ECT is over 97.5 °C, 207.5 °F. Substitute a known- good ECM and recheck. 2) Measure voltage between vehicle body ground and “E23-46”...
Page 178: Dtc P0500: Vehicle Speed Sensor "A" Malfunction
1A-128 Engine General Information and Diagnosis: Step Action 12 Wire circuit check Go to Step 13. “GRN” wire is shorted to ground circuit. 1) Disconnect radiator cooling fan control relay No. 2 and No. 3 from individual circuit fuse box No.1 with ignition switch turned OFF.
Page 179 Engine General Information and Diagnosis: 1A-129 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Vehicle speed signal is not input while fuel is cut at • Wheel speed sensor and/or its circuit deceleration for 4 seconds continuously at 3600 rpm or •...
Page 180: Dtc P0532: A/C Refrigerant Pressure Sensor "A" Circuit Low
1A-130 Engine General Information and Diagnosis: DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low S7RS0B1104052 Wiring Diagram GRY/RED GRY/RED C37-14 E23-55 BLK/ORN C37-58 E23-54 C37-15 C37-30 E23-31 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RS0C110024-03...
Page 181 Engine General Information and Diagnosis: 1A-131 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 182: Dtc P0533: A/C Refrigerant Pressure Sensor "A" Circuit High
1A-132 Engine General Information and Diagnosis: Step Action A/C refrigerant pressure sensor check Substitute a known- Faulty A/C refrigerant good ECM and recheck. pressure sensor. 1) Check A/C refrigerant pressure sensor referring to “A/C Refrigerant Pressure Sensor and Its Circuit Inspection in Section 7B”...
Page 183 Engine General Information and Diagnosis: 1A-133 Step Action A/C refrigerant pressure sensor power supply circuit Faulty MAP sensor. “GRY/RED” wire is open check or shorted to power circuit. 1) Disconnect connectors from MAP sensor with ignition switch turned OFF. 2) Turn ON ignition switch, measure voltage between engine ground and “GRY/RED”...
Page 184: Dtc P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
1A-134 Engine General Information and Diagnosis: DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance S7RS0B1104054 System Description Internal control module is installed in ECM. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC P0601:...
Page 185: Dtc P0616: Starter Relay Circuit Low
Engine General Information and Diagnosis: 1A-135 DTC P0616: Starter Relay Circuit Low S7RS0B1104055 Wiring Diagram BLK/WHT E23-29 GRN/WHT RED/WHT E23-30 [A]: YEL C37-48 YEL/GRN WHT/BLU [B]: YEL/GRN YEL/GRN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RS0C110025-01...
Page 186: Dtc P0617: Starter Relay Circuit High
1A-136 Engine General Information and Diagnosis: Step Action Signal circuit check Poor “C37-48” “YEL/GRN” wire is open connection or or high resistance 1) Turn OFF ignition switch. intermittent trouble. circuit. 2) Remove ECM from its bracket with ECM connectors Check for intermittent connected.
Page 187: Dtc P0620: Generator Control Circuit
Engine General Information and Diagnosis: 1A-137 Step Action Wire circuit check Go to Step 4. For A/T model, “YEL” or “YEL/GRN” wire is 1) Disconnect starting motor control relay in individual shorted to power circuit. circuit fuse box No.1 with ignition switch turned OFF. For M/T model, “YEL/ 2) Check for proper connection to starting motor control GRN”...
Page 188 1A-138 Engine General Information and Diagnosis: DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area • Battery voltage is higher than specification even through • Generator and/or its circuit generator control is maximum regulation (duty 100%). • Electric load current sensor •...
Page 189: Dtc P0625 / P0626: Generator Field Terminal Circuit Low / High
Engine General Information and Diagnosis: 1A-139 Step Action Generator control circuit check Go to Step 3. Repair or replace defective wire. 1) Disconnect connector from generator and ECM with ignition switch turned OFF. 2) Check for proper connection of wire terminal to generator connector and to ECM connector.
Page 190 1A-140 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool to DLC. 2) Turn ON ignition switch and clear DTC. 3) Make sure that all accessory switch is tuned OFF. 4) Start engine and warm it up to normal operating temperature (ECT approx. 90 – 95 °C, 193 – 203 °F). 5) Turn ON following accessory switch.
Page 191: Dtc P1501 / P1502: Electric Load Current Sensor Circuit Low / High
Engine General Information and Diagnosis: 1A-141 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High S7RS0B1104059 System and Wiring Diagram BLK/WHT E23-29 BLK/WHT C37-23 PNK/BLU BLK/ORN 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I5RS0C110014-01...
Page 192 1A-142 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 193: Dtc P1510: Ecm Back-Up Power Supply Malfunction
Engine General Information and Diagnosis: 1A-143 DTC P1510: ECM Back-Up Power Supply Malfunction S7RS0B1104060 Wiring Diagram WHT/RED E23-2 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I4RS0A110051-01 1. ECM 2. “RADIO” fuse 3.
Page 194: Dtc P1603: Tcm Trouble Code Detected
1A-144 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 195: Dtc P1674: Can Communication (Bus Off Error)
Engine General Information and Diagnosis: 1A-145 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 196 1A-146 Engine General Information and Diagnosis: Non ESP® model E23-3 E03-10 E23-18 E03-8 C34-17 C37-13 E03-6 C34-7 C37-12 E03-12 E46-1 E46-2 G28-8 G37-4 G28-10 G37-2 G49-19 G28-7 G37-1 WHT/BLK G49-18 G28-9 G37-3 RED/BLK 1716 1514 1312 1110 9 161514131211 10 9 8 7 2423 1817 2625...
Page 197 Engine General Information and Diagnosis: 1A-147 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 198: Dtc P1676: Can Communication (Reception Error For Tcm)
1A-148 Engine General Information and Diagnosis: DTC P1676: CAN Communication (Reception Error for TCM) S7RS0B1104064 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for TCM is •...
Page 199: Dtc P1678: Can Communication (Reception Error For Bcm)
Engine General Information and Diagnosis: 1A-149 DTC P1678: CAN Communication (Reception Error for BCM) S7RS0B1104065 Wiring Diagram Refer to “DTC P1674: CAN Communication (Bus Off Error)”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for BCM is •...
Page 200: Dtc P1685: Can Communication (Reception Error For Abs/Esp® Control Module)
1A-150 Engine General Information and Diagnosis: Step Action CAN communication circuit check Go to Step 7. Repair circuit. 1) Turn ignition switch to OFF position. 2) Disconnect connectors form ECM, BCM and ABS/ESP® control modules. 3) Check CAN communication circuit for open, short or high resistance.
Page 201 Engine General Information and Diagnosis: 1A-151 Troubleshooting Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”. DTC check in ECM Go to “DTC P1674: Go to Step 3. CAN Communication 1) Check ECM for DTC.
Page 202: Dtc P2101: Throttle Actuator Control Motor Circuit Range / Performance
1A-152 Engine General Information and Diagnosis: DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance S7RS0B1104067 Wiring Diagram C37-58 BLK/ORN BLK/WHT E23-29 C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-31 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 E23-45 BLU/ORN RED/YEL E23-32 YEL/BLU LT GRN/RED...
Page 203 Engine General Information and Diagnosis: 1A-153 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 204: Dtc P2102: Throttle Actuator Control Motor Circuit Low
1A-154 Engine General Information and Diagnosis: DTC P2102: Throttle Actuator Control Motor Circuit Low S7RS0B1104068 Wiring Diagram Refer to “DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Power supply voltage of throttle actuator control circuit is •...
Page 205: Dtc P2103: Throttle Actuator Control Motor Circuit High
Engine General Information and Diagnosis: 1A-155 Step Action Throttle actuator control relay circuit check Go to Step 6. “BLU/ORN” wire and/or “RED/YEL” wire is open 1) Disconnect connectors from ECM with ignition switch or high resistance. turned OFF. 2) Measure resistance at the following connector terminals. •...
Page 206: Dtc P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed
1A-156 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 207: Dtc P2119: Throttle Actuator Control Throttle Body Range / Performance
Engine General Information and Diagnosis: 1A-157 DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 208 1A-158 Engine General Information and Diagnosis: DTC Confirmation Procedure 1) With ignition switch turned OFF, connect scan tool. 2) Turn ON ignition switch and clear DTC using scan tool. 3) Keep the accelerator pedal at idle position for 2 seconds. 4) Keep the accelerator pedal at fully depressed position for 2 seconds.
Page 209: Dtc P2122: Throttle / Pedal Position Sensor / Switch "D" (Main) Circuit Low Input
Engine General Information and Diagnosis: 1A-159 Step Action Electric throttle body check Substitute a known- Replace electric throttle good ECM and recheck. body. 1) Check electric throttle body referring to” Electric Throttle Body Assembly and Its Circuit Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”.
Page 210 1A-160 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 211: Dtc P2123: Throttle / Pedal Position Sensor / Switch "D" (Main) Circuit High Input
Engine General Information and Diagnosis: 1A-161 Step Action Wire harness check Substitute a known- “BRN” wire is shorted to good ECM and recheck. ground circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “E23-35” terminal of ECM connector and engine ground.
Page 212 1A-162 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 213 Engine General Information and Diagnosis: 1A-163 Step Action Wire harness check Go to Step 7. “GRN” wire is shorted to “BRN” wire and/or 1) Disconnect connectors from ECM with ignition switch “RED” wire. turned OFF. 2) Check for proper connection of ECM connector at “E23- 35”, “E23-37”...
Page 214: Dtc P2127: Throttle Pedal Position Sensor / Switch "E" (Sub) Circuit Low Input
1A-164 Engine General Information and Diagnosis: DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input S7RS0B1104074 Wiring Diagram Refer to “DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Output voltage of APP sensor (sub) is less than specified...
Page 215 Engine General Information and Diagnosis: 1A-165 Step Action ECM voltage check Go to Step 7. Go to Step 5. 1) Disconnect connector from APP sensor with ignition switch turned OFF. 2) Check for proper connection to APP sensor at “RED”, “YEL”...
Page 216: Dtc P2128: Throttle / Pedal Position Sensor / Switch "E" (Sub) Circuit High Input
1A-166 Engine General Information and Diagnosis: Step Action 10 APP sensor check Substitute a known- Replace APP sensor. good ECM and recheck. 1) Check APP sensor (sub) referring to “APP Sensor Assembly Inspection in Section 1C”. Is output voltage within specified value? DTC P2128: Throttle / Pedal Position Sensor / Switch “E”...
Page 217 Engine General Information and Diagnosis: 1A-167 Step Action ECM voltage check Go to Step 6. Go to Step 5. 1) Disconnect connector from APP sensor with ignition switch turned OFF. 2) Check for proper connection to APP sensor at “RED”, “YEL”...
Page 218: Dtc P2135: Throttle / Pedal Position Sensor / Switch "A"/"B" (Main / Sub) Voltage Correlation
1A-168 Engine General Information and Diagnosis: Step Action Ground circuit check “WHT” wire is open or Faulty ECM ground high resistance circuit. circuit. If circuit is OK, 1) Remove ECM from its bracket with ECM connectors substitute a known- connected. good ECM and recheck.
Page 219 Engine General Information and Diagnosis: 1A-169 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Difference between the opening angle based on TP • Throttle position sensor (main) and (sub) circuit sensor (main) and the opening angle based on TP sensor •...
Page 220 1A-170 Engine General Information and Diagnosis: Step Action Wire harness check Go to Step 5. “RED” wire is shorted to other circuit. 1) Disconnect connectors from ECM with ignition switch turned OFF. 2) Measure resistance between “C37-43” terminal of ECM connector and engine ground.
Page 221: Dtc P2138: Throttle / Pedal Position Sensor / Switch "D"/"E" (Main / Sub) Voltage Correlation
Engine General Information and Diagnosis: 1A-171 DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage Correlation S7RS0B1104077 Wiring Diagram E23-35 E23-37 E23-52 E23-34 E23-36 E23-51 E23-50 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46...
Page 222 1A-172 Engine General Information and Diagnosis: DTC Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • Upon completion of inspection and repair work, perform “DTC Confirmation Procedure” and confirm that the trouble has been corrected.
Page 223: Dtc P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
Engine General Information and Diagnosis: 1A-173 Step Action Wire harness check Go to Step 7. “GRN” wire or “YEL” wire is shorted to other 1) Disconnect connectors from ECM with ignition switch circuit. turned OFF. 2) Check for proper connection of ECM connector at “E23- 37”, “E23-52”, “E23-36”...
Page 224 1A-174 Engine General Information and Diagnosis: DTC Confirmation Procedure DTC P2227: WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. •...
Page 225: Inspection Of Ecm And Its Circuits
Engine General Information and Diagnosis: 1A-175 Inspection of ECM and Its Circuits S7RS0B1104079 ECM and its circuits can be checked by measuring voltage, pulse signal and resistance with special tool connected. CAUTION ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with ECM connectors disconnected from it.
Page 226 1A-176 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 10 – 14 V Ignition switch turned ON. — *0 – 0.6 V ↑↓ 10 – 14 V Output signal is active low BLU/ Fuel injector No.1 (“Reference C37-1 Engine running at idle...
Page 227 Engine General Information and Diagnosis: 1A-177 Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V Ignition switch turned ON. *Deflects between over 0.5 V and under Oxygen signal of 0.45 V While engine running at C37-10 — HO2S-1 (“Reference 2,000 r/min.
Page 228 1A-178 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color 0 – 1 V or 4 – 5 V Ignition switch turned ON. — *0 – 0.6 V Sensor signal is pulse. ↑↓ Pulse frequency varies RED/ 4 –...
Page 229 Engine General Information and Diagnosis: 1A-179 Terminal Wire Circuit Normal voltage Condition Remarks color C37-32 — — — — — C37-33 — — — — — C37-34 — — — — — C37-35 — — — — — C37-36 — —...
Page 230 1A-180 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Ground of ECM for C37-50 — Below 0.3 V Ignition switch turned ON. — shield wire Ground of ECM for C37-51 — Below 0.3 V Ignition switch turned ON. —...
Page 231 Engine General Information and Diagnosis: 1A-181 Terminal Wire Circuit Normal voltage Condition Remarks color Ignition switch turned ON 0 – 0.8 V — with engine at stop. Output signal is pulse. *0 – 1 V Pulse frequency varies ↑↓ Engine revolution depending on engine E23-4 signal output for P/...
Page 232 1A-182 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Sensor signal is pulse. *0 – 1 V Pulse frequency varies ↑↓ Vehicle speed depending on vehicle E23-25 signal output for P/ 10 – 14 V Vehicle running.
Page 233 Engine General Information and Diagnosis: 1A-183 Terminal Wire Circuit Normal voltage Condition Remarks color BLU/ Throttle actuator E23-45 0 – 1 V Ignition switch turned ON. — control relay output Ignition switch turned ON, engine coolant temp.: below 95 °C (203 °F), or A/C refrigerant pressure (if 10 –...
Page 234 1A-184 Engine General Information and Diagnosis: Terminal Wire Circuit Normal voltage Condition Remarks color Engine running, A/C switch OFF and blower 1.38 – 1.52 V selector at OFF position, A/C refrigerant pressure: 800 kPa (116 psi) Engine running, A/C switch ON and blower A/C refrigerant selector at 1st position or 2.15 –...
Page 235 Engine General Information and Diagnosis: 1A-185 Reference waveform No.2 Reference waveform No.4 No.1 fuel injector signal (2) with engine idling EGR valve signal Measurement CH1: “C37-20” to “C37-58” CH1: “C37-4” to “C37-58” terminal CH2: “C37-1” to “C37-58” Measurement CH2: “C37-3” to “C37-58” Oscilloscope CH1: 5 V/DIV, CH2: 20 V/DIV terminal...
Page 236 1A-186 Engine General Information and Diagnosis: Reference waveform No.6 Reference waveform No.8 Ignition coil signal (1) with engine idling Generator field coil monitor signal (1) at engine idling Measurement Measurement CH1: “C37-6” to “C37-58” CH1: “C37-8” to “C37-58” terminal terminal Oscilloscope CH1: 2 V/DIV Oscilloscope...
Page 237 Engine General Information and Diagnosis: 1A-187 Reference waveform No.10 Reference waveform No.12 HOS2-1 signal (1) with engine idling HO2S-2 heater signal (4) with engine idling Measurement CH1: “C37-10” to “C37-57” Measurement CH1: “C37-11” to “C37-57” terminal CH2: “C37-46” to “C37-58” terminal CH2: “C37-47”...
Page 238 1A-188 Engine General Information and Diagnosis: Reference waveform No.14 Reference waveform No.16 No.3 fuel injector signal (2) with engine idling CMP sensor signal with engine idling Measurement CH1: “C37-20” to “C37-58” Measurement CH1: “C37-20” to “C37-58” terminal CH2: “C37-16” to “C37-58” terminal CH2: “C37-21”...
Page 239 Engine General Information and Diagnosis: 1A-189 Reference waveform No.18 Reference waveform No.20 MAF sensor signal (1) with engine racing EVAP canister purge valve signal Measurement CH1: “C37-26” to “C37-27” Measurement CH1: “C37-29” to “C37-58” terminal CH2: “C37-54” to “C37-55” terminal Oscilloscope CH1: 1 V/DIV, CH2: 1 V/DIV Oscilloscope...
Page 240 1A-190 Engine General Information and Diagnosis: Reference waveform No.21 Reference waveform No.22 Throttle actuator output signal with ignition switch turned Ignition coil signal and fuel injector signal with engine cranking Measurement CH1: “C37-45” to “C37-58” CH1: “C37-20” to “C37-58” terminal CH2: “C37-44”...
Page 241 Engine General Information and Diagnosis: 1A-191 Reference waveform No.24 Reference waveform No.26 MAP sensor signal (1) with engine racing Knock sensor signal at engine speed 4000 r/min. Measurement CH1: “C37-53” to “C37-55” Measurement CH1: “C37-56” to “C37-58” terminal CH2: “C37-54” to “C37-55” terminal Oscilloscope CH1: 2 V/DIV, CH2: 2 V/DIV...
Page 242 1A-192 Engine General Information and Diagnosis: Reference waveform No.30 Reference waveform No.28 Oil control valve signal with engine racing Ignition pulse (engine revolution) signal (2) with engine idling Measurement CH1: “C37-60” to “C37-59” terminal Measurement CH1: “C37-20” to “C37-58” Oscilloscope CH1: 5 V/DIV terminal CH2: “E23-4”...
Page 243 Engine General Information and Diagnosis: 1A-193 Reference waveform No.32 VSS signal at 30 km/h (19 mph) Measurement CH1: “E23-25” to “C37-58” terminal Oscilloscope CH1: 5 V/DIV, CH2: 5 V/DIV setting TIME: 40 ms/DIV • After warmed up to normal operating temperature Measurement condition •...
Page 244: Ecm Power And Ground Circuit Check
1A-194 Engine General Information and Diagnosis: Terminals Circuit Standard resistance Condition C37-3 to E23-1/16 EGR valve (stepping motor No.2 coil) 20 – 31 Ω C37-18 to E23-1/16 EGR valve (stepping motor No.4 coil) — C37-19 to E23-1/16 EGR valve (stepping motor No.3 coil) 2 –...
Page 245 Engine General Information and Diagnosis: 1A-195 Circuit Description When the ignition switch is turned ON, the main relay turns ON (the contact point closes) and the main power is supplied to ECM. Troubleshooting NOTE When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”.
Page 246 1A-196 Engine General Information and Diagnosis: Step Action Main relay circuit check Go to Step 7. Go to Step 6. 1) Connect connectors to ECM with ignition switch turned OFF. 2) Turn ignition switch to ON position. 3) Measure voltage between “E23-60” terminal of ECM connector and body ground.
Page 247 Engine General Information and Diagnosis: 1A-197 Step Action 10 Main relay check “BRN/WHT” wire is Replace main relay. open or high resistance 1) Check main relay referring to “Main Relay, Fuel Pump circuit. Relay and Starting Motor Control Relay Inspection in Section 1C”.
Page 248: Fuel Injector Circuit Check
1A-198 Engine General Information and Diagnosis: Fuel Injector Circuit Check S7RS0B1104081 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-31 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED BLK/RED E23-16 C37-1 BLU/YEL C37-2 BLU/WHT BLU/RED C37-16 C37-17 BLU/ORN 39 38 32 31 39 38 32 31...
Page 249 Engine General Information and Diagnosis: 1A-199 Troubleshooting NOTE When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Fuel injector check for operating sound Fuel injectors circuit is Go to Step 2.
Page 250: Fuel Pump And Its Circuit Check
1A-200 Engine General Information and Diagnosis: Fuel Pump and Its Circuit Check S7RS0B1104082 Wiring Diagram BLK/WHT BLK/WHT E23-29 BLK/WHT E23-15 GRN/WHT BLK/YEL C37-58 BLK/ORN BLK/RED C37-15 C37-30 E23-31 BLK/RED BLK/RED E23-1 BLK/YEL BLK/RED E23-16 BLK/YEL E23-60 BRN/WHT 39 38 32 31 39 38 32 31 54 53...
Page 251 Engine General Information and Diagnosis: 1A-201 Troubleshooting NOTE When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action Fuel pump control system check for operation Fuel pump circuit is in Go to Step 2.
Page 252 1A-202 Engine General Information and Diagnosis: Step Action Fuel pump relay drive signal check Go to Step 7. Substitute a known- good ECM and recheck. 1) Measure voltage within 2 second after ignition switch is turned ON. Is voltage 0 – 1 V? Wire circuit check Go to Step 8.
Page 253 Engine General Information and Diagnosis: 1A-203 Fuel Pressure Check S7RS0B1104083 System Diagram Special tool (A): 09912–58442 (B): 09912–58432 (C): 09912–58490 I3RM0A110081-01 1. Injector 2. Delivery pipe 3. Fuel filter and fuel pump...
Page 254: Fuel Pressure Check
1A-204 Engine General Information and Diagnosis: Troubleshooting NOTE Before using following flow, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 255: A/C System Circuits Check
Engine General Information and Diagnosis: 1A-205 A/C System Circuits Check S7RS0B1104084 Wiring Diagram E23-19 BLU/WHT BLK/YEL RED/BLK GRN/WHT E23-3 E23-18 C37-14 GRY/RED E23-55 WHT/BLU WHT/BLK E23-57 E23-54 BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED BLK/RED BLU/YEL E23-47 LT GRN E23-46 BLU/RED...
Page 256 1A-206 Engine General Information and Diagnosis: Troubleshooting NOTE • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. • When A/C evaporator outlet air temp. is below 2.5 °C (36.5 °F), A/C remains OFF (“E23-47” terminal voltage becomes 10 –...
Page 257 Engine General Information and Diagnosis: 1A-207 Step Action A/C evaporator outlet air temp. sensor check Go to Step 7. Faulty A/C evaporator outlet air temp. sensor 1) Disconnect connectors from ECM with ignition switch or its circuit. turned OFF. 2) Check for proper connection to “E23-57” and “E23-54” wire terminals of ECM connector.
Page 258 1A-208 Engine General Information and Diagnosis: Step Action A/C compressor relay circuit check Go to Step 12. Go to Step 13. 1) Measure voltage between “E23-47” wire terminal of ECM connector and vehicle body ground under following conditions respectively. Voltage between “E23-47” terminal of ECM connector and ground While engine running and A/C switch turned OFF: 10 –...
Page 259: Electric Load Signal Circuit Check
Engine General Information and Diagnosis: 1A-209 Electric Load Signal Circuit Check S7RS0B1104085 Wiring Diagram BLK/WHT E23-29 C37-58 BLK/ORN C37-15 C37-30 E23-31 BLK/YEL BLK/YEL BRN/WHT E23-60 12V 5V BLK/RED E23-1 BLK/YEL /BLU BLK/RED E23-16 BLK/YEL BLU/WHT E23-9 BLK/WHT E23-3 E23-18 32 31 39 38 32 31 39 38...
Page 260 1A-210 Engine General Information and Diagnosis: Step Action Electric load signal circuit check Electric load signal Check defective signal circuit is in good circuit. 1) Start engine and select “Data List” mode on scan tool. condition. 2) Check electric load signal under following conditions respectively.
Page 261 Engine General Information and Diagnosis: 1A-211 Radiator Cooling Fan Low Speed Control System Check S7RS0B1104086 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED BLK/RED E23-46 LT GRN BLU/RED BLU/RED C37-58 BLK/ORN C37-15 C37-30 BLU/BLK E23-31 L– H–...
Page 262: Radiator Cooling Fan Low Speed Control
1A-212 Engine General Information and Diagnosis: Troubleshooting WARNING Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch at the “ON”...
Page 263: Radiator Cooling Fan High Speed Control System Check
Engine General Information and Diagnosis: 1A-213 Radiator Cooling Fan High Speed Control System Check S7RS0B1104087 Wiring Diagram BLK/YEL BLK/YEL BRN/WHT E23-60 BLK/RED BLK/RED E23-1 BLK/YEL E23-16 BLK/RED BLK/RED E23-46 LT GRN BLU/RED BLU/RED C37-58 BLK/ORN C37-15 C37-30 BLU/BLK E23-31 L– H–...
Page 264 1A-214 Engine General Information and Diagnosis: Troubleshooting WARNING Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch at the “ON”...
Page 265 Engine General Information and Diagnosis: 1A-215 Step Action Radiator cooling fan No. 2 wire circuit check Go to Step 8. “BLU/BLK” wire is shorted to power supply 1) Turn ON ignition switch. circuit. 2) Measure voltage between “BLU/BLK” wire terminal of disconnected radiator cooling fan control relay No.
Page 266: Repair Instructions
“Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. 1) Connect SUZUKI scan tool to DLC (1) with ignition switch turned OFF. Special tool (A): SUZUKI scan tool...
Page 267: Special Tools And Equipment
58413). 09912–58490 09930–76420 3-way joint & hose Timing-light (dry cell type) 09933–06320 SUZUKI scan tool ECM check harness (120P) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 268: Aux. Emission Control Devices
Engine Diagnostic Information and Procedures EGR System Inspection S7RS0B1204001 1) Connect SUZUKI scan tool to data link connector (DLC) with ignition switch turned OFF. 2) Turn ON ignition switch and erase DTC using “CLEAR DTC” in “TROUBLE CODES” menu. 3) Start engine and warm it up to normal operating temperature, then select “DATA LIST”...
Page 269: Evap Canister Purge Valve And Its Circuit Inspection
2) Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire. If check result is not satisfactory, check vacuum hoses, EVAP canister purge valve, wire harness and connections.
Page 270: Vacuum Passage Inspection
1B-3 Aux. Emission Control Devices: Vacuum Passage Inspection S7RS0B1206003 Start engine and run it at idle speed. Disconnect vacuum hose (1) from EVAP canister purge valve (2). With finger placed against disconnected hose, check that vacuum is applied. If it is not applied, clean vacuum passage by blowing compressed air.
Page 271: Evap Canister Inspection
Aux. Emission Control Devices: 1B-4 EVAP Canister Inspection EGR Valve Inspection S7RS0B1206006 S7RS0B1206008 1) Check resistance between following terminals of WARNING EGR valve (1) in each pair. DO NOT SUCK nozzles on EVAP canister. If found faulty, replace EGR valve assembly. Fuel vapor inside EVAP canister is harmful.
Page 272: Pcv Valve Inspection
8) Install air cleaner assembly securely. Replace as necessary. I2RH0B120007-01 Special Tools and Equipment Special Tool S7RS0B1208001 09917–47011 SUZUKI scan tool Vacuum pump gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 273: Engine Electrical Devices
Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Repair Instructions ECM Removal and Installation Installation S7RS0B1306001 Reverse removal procedure noting the following: CAUTION • Connect connectors to ECM as follows. As ECM consists of precision parts, be a. Make sure that lock lever of ECM connector is careful not to expose it to excessive shock.
Page 274: Map Sensor Inspection
1C-2 Engine Electrical Devices: MAP Sensor Inspection Electric Throttle Body Assembly On-Vehicle S7RS0B1306002 Inspection 1) Remove air cleaner assembly. S7RS0B1306003 WARNING 2) Disconnect connector from MAP sensor. 3) Remove MAP sensor. Never touch throttle valve with finger while 4) Arrange 3 new 1.5 V batteries (2) in series (check ignition switch is turned ON and accelerator that total voltage is 4.5 –...
Page 275 Engine Electrical Devices: 1C-3 Throttle Valve Operation Check Electric Throttle Body Assembly Operation Check 1) Remove air cleaner outlet hose. 1) Remove air cleaner outlet hose. 2) Turn OFF ignition switch. 2) Turn ON ignition switch. 3) Move throttle valve with finger to its full open position 3) Depress accelerator pedal gradually and check that and check that it moves smoothly.
Page 276 1C-4 Engine Electrical Devices: TP Sensor Performance Check If sensor voltage is out of specified value and linear variation as the following graph, replace electric throttle 1) Remove air cleaner outlet hose. body assembly. 2) Turn OFF ignition switch. TP sensor output voltage 3) Disconnect connector from electric throttle body TP sensor (main) [C]: 0.45 –...
Page 277: Electric Throttle Body System Calibration
Engine Electrical Devices: 1C-5 Electric Throttle Body System Calibration APP Sensor Assembly Removal and Installation S7RS0B1306004 S7RS0B1306006 NOTE CAUTION If working the service described under the • Do not expose APP sensor assembly to “Precautions of Electric Throttle Body excessive shock like a dropping it. If APP System Calibration in Section 1A”...
Page 278: App Sensor Assembly Inspection
1C-6 Engine Electrical Devices: APP Sensor Assembly Inspection S7RS0B1306007 Check APP sensor (main and sub) output voltage as following steps. 1) For APP sensor (main), arrange 3 new 1.5 V batteries (1) in series (check that total voltage is 4.5 - 5.0 V) and connect its positive terminal to “Vin 1”...
Page 279: Ect Sensor Inspection
Engine Electrical Devices: 1C-7 HO2S-1 and HO2S-2 Heater On-Vehicle Installation Reverse removal procedure noting the following. Inspection S7RS0B1306010 • Clean mating surfaces of ECT sensor and thermostat 1) Disconnect sensor connector. case. 2) Using ohmmeter, measure resistance between • Check O-ring for damage and replace, if necessary. terminals “V ”...
Page 280: Cmp Sensor Removal And Installation
1C-8 Engine Electrical Devices: Camshaft Position (CMP) Sensor Inspection Installation Reverse removal procedure noting the following. S7RS0B1306013 • Tighten heated oxygen sensor to specified torque. Visual check Tightening torque • Check that O-ring is free from damage. Heated oxygen sensor (a): 45 N·m (4.5 kgf-m, •...
Page 281: Ckp Sensor Removal And Installation
Engine Electrical Devices: 1C-9 CKP Sensor Removal and Installation CKP Sensor Inspection S7RS0B1306014 S7RS0B1306015 Removal Visual check 1) Disconnect negative (–) cable at battery. • Check that O-ring is free from damage. 2) Remove generator drive belt refer to “Water Pump / Generator Drive Belt Removal and Installation in •...
Page 282: Knock Sensor Removal And Installation
1C-10 Engine Electrical Devices: Knock Sensor Removal and Installation Main Relay, Fuel Pump Relay and Starting Motor S7RS0B1306016 Control Relay Inspection Removal S7RS0B1306017 1) Disconnect negative (–) cable at battery. 1) Disconnect negative (–) cable at battery. 2) Hoist vehicle. 2) Remove main relay (1), fuel pump relay (3) and/or starting motor control relay (2) from individual circuit 3) Remove right side drive shaft referring to “Front...
Page 283: Maf And Iat Sensor On-Vehicle Inspection
Engine Electrical Devices: 1C-11 MAF and IAT Sensor On-Vehicle Inspection 10) If check result is not as specified above, cause may S7RS0B1306018 lie in wire harness, connector connection, MAF and NOTE IAT sensor or ECM. Before performed this inspection, be sure to read the “Precautions of ECM Circuit MAF and IAT Sensor Removal and Installation Inspection in Section 1A”.
Page 284: Maf And Iat Sensor Inspection
Electric Load Current Sensor On-Vehicle S7RS0B1306020 Inspection S7RS0B1306021 CAUTION Using SUZUKI Scan Tool Do not heat up MAF and IAT sensor more 1) Connect scan tool to DLC with ignition switch turned than 100 °C (212 °F). Otherwise, MAF and IAT OFF.
Page 285: Specifications
Engine Electrical Devices: 1C-13 Without Using SUZUKI Scan Tool If electric load current sensor circuit and charging system is in good condition, electric load current sensor 1) Measure sensor voltage between “C37-23” terminal (1) is faulty. of ECM connector and vehicle body ground referring to “Inspection of ECM and Its Circuits in Section 1A”.
Page 286: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine General Description Engine Construction Description S7RS0B1401001 The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves/one cylinder). The double overhead camshaft is mounted over the cylinder head;...
Page 287: Camshaft Position Control (Vvt Variable Valve Timing) System Description
Engine Mechanical: 1D-2 Camshaft Position Control (VVT Variable Valve Timing) System Description S7RS0B1401002 System Description The VVT system is an electronic control system which continuously vary and optimize the intake valve timing in response to the engine operating condition. The optimized intake valve timing produce such an air intake with high efficiency that both the higher power generation and lower fuel consumption can be attained in the whole engine speed range from low to high.
Page 288 1D-3 Engine Mechanical: Oil Control Valve The oil control valve switches and adjusts the hydraulic pressure applied to the cam timing sprocket by moving the spool valve (1) according to the duty pulse signals output from the ECM. By this operation, the intake valve timing is varied continuously.
Page 289: Diagnostic Information And Procedures
Engine Mechanical: 1D-4 Targeted Timing Varying Operation Driving condition Valve timing Target of control Effect To shorten the valve opening overlap in Engine running at idle Stabilization of the engine Most retarded order to prevent the exhaust gas speed rotation at idle speed. counterflow to intake manifold.
Page 290: Engine Vacuum Check
1D-5 Engine Mechanical: 11) Connect negative cable at battery. 15) Carry out Steps 12) through 14) on each cylinder to obtain 4 readings. 12) Install special tools (Compression gauge) into spark plug hole. 16) Disconnect negative cable at battery. 17) After checking, install spark plugs and ignition coil Special tool assemblies (2) with high-tension cord (3).
Page 291: Valve Lash (Clearance) Inspection
Engine Mechanical: 1D-6 6) Connect special tool (Vacuum gauge) to PCV hose 5) Check valve lashes with thickness gauge (4) (1). according to the following procedure. a) Check valve lashes at valves “1” and “7”. Special tool b) Turn camshafts by 90° (by turning crankshaft (A): 09915–67311 with wrench).
Page 292 1D-7 Engine Mechanical: Replacement of Shim 1) Close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside as shown in the figure. I6RS0B141028-01 4) Turn camshaft by approximately 90° clockwise and remove shim (3).
Page 293 Engine Mechanical: 1D-8 For example of intake side: 8) Lift valve by turning crankshaft counterclockwise (in When thickness of removed shim is 2.40 mm (0.094 opposite direction against above Step 4)) and in.), and measured valve clearance is 0.45 mm remove special tool.
Page 294: Repair Instructions
1D-9 Engine Mechanical: Repair Instructions Air Cleaner Components S7RS0B1406001 I7RS0B140001-01 1. Engine Cover 7. Air cleaner outlet hose : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 2. Cylinder head upper cover 8. Hose clamp : 3 N⋅m (0.3 kgf-m, 2.5 lb-ft) 3.
Page 295: Air Cleaner Element Inspection And Cleaning
Engine Mechanical: 1D-10 Air Cleaner Element Inspection and Cleaning S7RS0B1406003 Inspection Check air cleaner element for dirt. Replace excessive dirty element. Cleaning Blow off dust by compressed air from air outlet side of element. I2RH0B140033-01 10) Remove cylinder head cover (1) with cylinder head cover gasket (2).
Page 296 “A”: Water tight sealant 99000–31250 fall off. (SUZUKI Bond No.1207F) 4) Tighten cylinder head cover bolts as follows. a) Tighten cylinder head cover bolts to 3 N⋅m (0.3 kgf-m, 2.5 lb-ft) according to numerical order (“1”...
Page 297: Throttle Body And Intake Manifold Components
Engine Mechanical: 1D-12 Throttle Body and Intake Manifold Components S7RS0B1406005 I7RS0B140002-02 1. Intake manifold 6. Breather hose 11. PCV valve : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 2. Intake manifold gasket 7. EGR pipe 12. PCV valve seal : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) 3.
Page 298: Throttle Body On-Vehicle Inspection
1D-13 Engine Mechanical: Throttle Body On-Vehicle Inspection Installation S7RS0B1406006 1) Clean mating surfaces and install new throttle body Check electric throttle body assembly referring to gasket (1) to intake manifold. “Throttle Valve Operation Check” and “Electric Throttle Body Assembly Operation Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”.
Page 299: Throttle Body Cleaning
Engine Mechanical: 1D-14 Throttle Body Cleaning 7) Remove stiffener (1) and ground terminal (2) from S7RS0B1406008 intake manifold. Clean electric throttle body assembly referring to “Throttle Valve Visual Check” under “Electric Throttle Body Assembly On-Vehicle Inspection in Section 1C”. Intake Manifold Removal and Installation S7RS0B1406009 Removal 1) Remove cowl top plate referring to “Cowl Top...
Page 300 1D-15 Engine Mechanical: Installation • Install intake manifold rear stiffener (1) as shown in Reverse removal procedure for installation noting the figure. followings. • Connect ground terminal (2) to intake manifold to • Use new intake manifold gasket (1). specified torque. •...
Page 301: Engine Mountings Components
Engine Mechanical: 1D-16 Engine Mountings Components S7RS0B1406010 I6RS0C140014-02 [A]: View A 5. Engine left mounting No.2 bracket 12. To vehicle body [B]: For A/T model 6. Engine rear mounting : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) F: Vehicle front 7. Engine rear mounting No.1 bracket : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) 1.
Page 302: Engine Assembly Removal And Installation
1D-17 Engine Mechanical: Engine Assembly Removal and Installation 12) Disconnect the following electric wires: S7RS0B1406011 • MAP sensor (1) NOTE • ECT sensor (2) After replacing electric throttle body • EGR valve (3) assembly, perform calibration of throttle valve referring to “Electric Throttle Body •...
Page 303 Engine Mechanical: 1D-18 17) Disconnect right and left drive shaft joints from differential gear referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”. NOTE For engine and transaxle removal, it is not necessary to remove drive shafts from steering knuckle.
Page 304 1D-19 Engine Mechanical: 24) Before removing engine with transaxle from engine compartment, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transaxle. 25) Lower engine with transaxle from engine compartment. CAUTION 1, (a) Before lowering engine, to avoid damage to A/C compressor and clutch operating cylinder, make clearance by rising them.
Page 305: Timing Chain Cover Components
Engine Mechanical: 1D-20 15) Install A/C compressor to its bracket (if equipped) 19) Refill engine with engine oil referring to “Engine Oil referring to “Compressor Assembly Removal and and Filter Change in Section 0B”. Installation in Section 7B” or “Compressor Assembly 20) Refill transaxle with transaxle oil referring to“Manual Removal and Installation in Section 7B”.
Page 306: Timing Chain Cover Removal And Installation
1D-21 Engine Mechanical: 10. Copper washer : 30 N⋅m (3.0 kgf-m, 22.0 lb-ft) 11. Oil gallery pipe No.1 bolt : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) 12. Oil gallery pipe No.2 : Do not reuse. Timing Chain Cover Removal and Installation 5) Remove cylinder head cover referring to “Cylinder S7RS0B1406013 Head Cover Removal and Installation”.
Page 307 “B” to mating surface of timing 18.0 lb-ft) chain cover as shown in figure. Timing chain cover nut (b): 25 N·m (2.5 kgf-m, “A”: Water tight sealant 99000–31140 (SUZUKI 18.0 lb-ft) Bond No.1207B) 6) Apply engine oil to new O-rings (2) and install them “B”: Sealant 99000–31260 (SUZUKI Bond...
Page 308: Timing Chain Cover Inspection
1D-23 Engine Mechanical: Timing Chain Cover 8) Install new O-ring (1) to oil gallery pipes No.2 (2) and No.3 (3). Inspect strainer (1) of oil passage for driving intake cam timing sprocket assembly (VVT actuator). 9) Install oil gallery pipes No.2 and No.3 to cylinder If clog or foreign matter exists, clean strainer.
Page 309: Oil Control Valve Inspection
Engine Mechanical: 1D-24 Oil Control Valve Inspection S7RS0B1406016 Oil Control Valve 1) Inspect strainer (1) and mating surface (2) of oil control valve for clog or damage. Clean oil control valve if clog or foreign matter is present on strainer or mating surface of oil control valve.
Page 310: Timing Chain And Chain Tensioner Removal And Installation
1D-25 Engine Mechanical: Timing Chain and Chain Tensioner Removal Installation and Installation CAUTION S7RS0B1406018 After timing chain is removed, never turn Removal crankshaft and camshafts independently more than such an extent (“a”, “b”) as shown CAUTION in figure. After timing chain is removed, never turn If turned, interference may occur between crankshaft and camshafts independently piston and valves and valves themselves,...
Page 311 Engine Mechanical: 1D-26 3) Install timing chain by aligning dark blue plate (1) of 6) Apply engine oil to sliding surface of chain tensioner timing chain and triangle mark (2) on camshaft (1) and install chain tensioner and spacer. timing sprocket as shown in figure. Tighten tensioner bolt to specified torque.
Page 312: Timing Chain And Chain Tensioner Inspection
1D-27 Engine Mechanical: 8) Screw in plunger (1) by turning body (2) in arrow direction and install a retainer (3) (wire) to hold plunger in place. I2RH0B140065-01 9) Install timing chain tensioner adjuster assembly (1) with a retainer (2). Tighten adjuster bolts to specified torque and then remove a retainer from chain tensioner adjuster assembly.
Page 313: Camshaft, Tappet And Shim Components
Engine Mechanical: 1D-28 Crankshaft Timing Sprocket Timing Chain Check teeth of sprocket for wear or damage. Check timing chain for wear or damage. I2RH01140077-01 Timing Chain Tensioner Adjuster Check that tooth surface (1) are free from damage. I2RH0B140070-01 I2RH0B140071-01 Camshaft, Tappet and Shim Components S7RS0B1406020 I6RS0C140018-01 1.
Page 314: Camshaft, Tappet And Shim Removal And Installation
1D-29 Engine Mechanical: Camshaft, Tappet and Shim Removal and 4) Loosen camshaft housing bolts in such order as indicated in the figure and remove them. Installation S7RS0B1406021 “12” “13” “20” “21” “16” “17” “8” “9” CAUTION “2” • Keep working table, tools and hands clean “5”...
Page 315 Engine Mechanical: 1D-30 NOTE Installation 1) Install tappets and shims to cylinder head. Before installing camshafts, turn crankshaft Apply engine oil around tappet and then install it to until key position faces upward. cylinder head. Refer to “Timing Chain and Chain Tensioner Removal and Installation”.
Page 316: Camshaft, Tappet And Shim Inspection
1D-31 Engine Mechanical: Camshaft, Tappet and Shim Inspection 7) Install camshaft housing. S7RS0B1406022 8) Tighten camshaft housing bolts as follows. a) Apply engine oil to camshaft housing bolts. Intake Cam Timing Sprocket Assembly Fit intake cam timing sprocket assembly to camshaft (2) b) Tighten camshaft housing bolts by hand.
Page 317 Engine Mechanical: 1D-32 Camshaft Runout 6) Install camshaft housing as follows. Set camshaft between two “V” blocks, and measure its After applying engine oil to camshaft housing bolts, runout by using a dial gauge. tighten them temporarily first. Then tighten them as If measured runout exceeds limit, replace camshaft.
Page 318 1D-33 Engine Mechanical: If measured camshaft journal clearance exceeds Wear of Tappet and Shim limit, measure journal (housing) bore and outside Check tappet and shim for pitting, scratches, or damage. diameter of camshaft journal. Replace camshaft or If any malcondition is found, replace. cylinder head assembly whichever the difference from specification is greater.
Page 319: Valves And Cylinder Head Components
Engine Mechanical: 1D-34 Valves and Cylinder Head Components S7RS0B1406023 I4RS0A140015-01 1. Valve cotters 7. Exhaust valve 13. Cylinder head bolt (M8) : Be sure to tighten cylinder head bolt (M8) after securing the other cylinder head bolt (M10). 2. Valve spring retainer 8.
Page 320: Valves And Cylinder Head Removal And Installation
1D-35 Engine Mechanical: Valves and Cylinder Head Removal and Installation Installation 1) Clean mating surface of cylinder head and cylinder S7RS0B1406024 block. Remove oil, old gasket and dust from mating surface. Removal 2) Install knock pins (1) to cylinder block. 1) Remove engine assembly from vehicle referring to 3) Install new cylinder head gasket (2) to cylinder block.
Page 321 Engine Mechanical: 1D-36 5) Install cylinder head to cylinder block. NOTE Apply engine oil to new cylinder head bolts and • If they are reused, check thread diameters tighten them gradually as follows. of cylinder head bolt (1) for deformation a) Tighten cylinder head bolts (“1”...
Page 322: Valves And Cylinder Head Disassembly And Assembly
1D-37 Engine Mechanical: Valves and Cylinder Head Disassembly and 3) Release special tools (Valve lifter), and remove spring retainer and valve spring. Assembly S7RS0B1406025 4) Remove valve from combustion chamber side. 5) Remove valve stem seal (1) from valve guide and Disassembly valve spring seat (2).
Page 323 Engine Mechanical: 1D-38 3) Ream valve guide bore with special tool (5.5 mm Assembly reamer). After reaming, clean bore. 1) Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as Special tool to remove burrs and make it truly round.
Page 324 1D-39 Engine Mechanical: 6) Install valve to valve guide. 8) Using special tools (Valve lifter), compress valve Before installing valve to valve guide, apply engine spring and fit two valve cotters (1) into groove in oil to stem seal, valve guide bore and valve stem. valve stem.
Page 325: Valves And Valve Guides Inspection
Engine Mechanical: 1D-40 Valves and Valve Guides Inspection S7RS0B1406026 Valve Guide Valve stem-to-guide clearance 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 326 1D-41 Engine Mechanical: Valve head radial runout Valve seat repair Check each valve for radial runout with a dial gauge and A valve seat not producing a uniform contact with its “V” block. To check runout, rotate valve slowly. If runout valve or showing width of seating contact that is out of exceeds its limit, replace valve.
Page 327: Cylinder Head Inspection
Engine Mechanical: 1D-42 Cylinder Head Inspection S7RS0B1406027 • Remove all carbon deposits from combustion chambers. NOTE Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when decarbonizing. The same applies to valves and valve seats, too. I2RH0B140106-01 •...
Page 328: Valve Spring Inspection
1D-43 Engine Mechanical: Valve Spring Inspection Spring Squareness S7RS0B1406028 Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve Valve Spring Free Length and Preload spring and square. Valve springs found to exhibit a Referring to data, check to be sure that each spring is in larger clearance than limit must be replaced.
Page 329: Pistons, Piston Rings, Connecting Rods And Cylinders Components
Engine Mechanical: 1D-44 Pistons, Piston Rings, Connecting Rods and Cylinders Components S7RS0B1406029 I6RS0C140021-02 1. Top ring 6. Connecting rod bearing cap : Tighten15 N⋅m (1.5 kgf-m, 11.0 lb-ft), 45° : See “B” and 45° by the specified procedure. 2. 2nd ring 7.
Page 330: Pistons, Piston Rings, Connecting Rods And Cylinders Removal And Installation
1D-45 Engine Mechanical: Pistons, Piston Rings, Connecting Rods and 3) Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring Cylinders Removal and Installation compressor) to compress rings. Guide connecting S7RS0B1406030 rod into place on crankshaft. Removal Using a hammer handle, tap piston head to install 1) Remove engine assembly from vehicle referring to...
Page 331: Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly
Engine Mechanical: 1D-46 Pistons, Piston Rings, Connecting Rods and NOTE Cylinders Disassembly and Assembly Circlip should be installed with its cut part S7RS0B1406031 facing as shown in figure. Install so that circlip end gap comes within such range as Disassembly indicated by arrow.
Page 332: Cylinders, Pistons And Piston Rings Inspection
1D-47 Engine Mechanical: Cylinders, Pistons and Piston Rings Inspection Piston S7RS0B1406032 Visual inspection Inspect piston for faults, cracks or other damages. Cylinder Damaged or faulty piston should be replaced. Visual inspection Inspect cylinder walls for scratches, roughness or ridges Piston diameter which indicate excessive wear.
Page 333 Engine Mechanical: 1D-48 Piston clearance Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as follows. If it is out of specification, rebore cylinder and use oversize piston. NOTE Cylinder bore diameters used here are measured in thrust direction at two positions.
Page 334: Piston Pins And Connecting Rods Inspection
1D-49 Engine Mechanical: Piston Pins and Connecting Rods Inspection Connecting Rod S7RS0B1406033 Big-end side clearance Check big-end of connecting rod for side clearance, with Piston Pin rod fitted and connected to its crank pin in the normal Visual inspection manner. If measured clearance is found to exceed its Check piston pin, connecting rod small end bore and limit, replace connecting rod.
Page 335: Crank Pin And Connecting Rod Bearings Inspection
Engine Mechanical: 1D-50 Connecting rod bearing cap bolt deformation Out-of-round (Plastic deformation tightening bolt) A – B Measure each thread diameter of connecting rod Taper bearing cap bolt (1) at “A” on 32 mm (1.25 in.) from bolt a – b mounting surface and “B”...
Page 336 1D-51 Engine Mechanical: Connecting Rod Bearing Clearance 5) Remove cap and using a scale (1) on gauging plastic envelope (2), measure gauging plastic (2) 1) Before checking bearing clearance, clean bearing width at the widest point (clearance). and crank pin. If clearance exceed its limit, use a new standard size 2) Install bearing in connecting rod and bearing cap.
Page 337 Engine Mechanical: 1D-52 3) There are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in the figure. Each color indicated the following thickness at the center of bearing.
Page 338: Main Bearings, Crankshaft And Cylinder Block Components
1D-53 Engine Mechanical: Main Bearings, Crankshaft and Cylinder Block Components S7RS0B1406035 I6RS0C140025-02 1. CKP sensor 12. Input shaft bearing 23. Sensor plate bolt : See “A” 2. Knock sensor 13. Flywheel or drive plate 24. Oil pressure switch 3. Cylinder block 14.
Page 339: Main Bearings, Crankshaft And Cylinder Block Removal And Installation
Engine Mechanical: 1D-54 “A”: When servicing CKP sensor, refer to “CMP Sensor Removal and Installation in Section : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 1C”. “B”: Upper half of bearing has an oil groove. : Do not reuse. “C”: Apply sealant 99000-31250 to mating surface. : Apply engine oil to inside / sliding surface.
Page 340 1D-55 Engine Mechanical: Installation 2) Install piston cooling valves and nozzles, if removed. NOTE NOTE Install piston cooling valve while matching • Use new bearing cap No.1 bolts. They are piston cooling nozzle (1) to positioning (3) of deformed once they are used because they cylinder block when installed piston cooling are plastic deformation tightening bolts.
Page 341 22.0 lb-ft) according to numerical order as housing (1). shown by using a 12 corner socket wrenches. “A”: Water tight sealant 99000–31250 (SUZUKI b) In the same manner as in Step a), tighten them Bond No.1207F) to 50 N⋅m (5.0 kgf-m, 36.5 lb-ft).
Page 342: Crankshaft Inspection
1D-57 Engine Mechanical: Crankshaft Inspection 11) Install flywheel (drive plate for A/T). Using special tool, lock flywheel or drive plate, and S7RS0B1406037 tighten flywheel or drive plate bolts to specified Crankshaft Runout torque. Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly.
Page 343 Engine Mechanical: 1D-58 2) Tighten main bearing cap No.1 bolts (a) and main 3) Use a dial gauge to read displacement in axial bearing cap No.2 bolts (b) gradually as follows. (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with a) Tighten bolts (“1”...
Page 344: Main Bearings Inspection
1D-59 Engine Mechanical: Main Bearings Inspection 4) Tighten main bearing cap No.1 bolts (a) and main S7RS0B1406038 bearing cap No.2 bolts (b) gradually as follows. a) Tighten bolts (“1” through “10”) to 30 N⋅m (3.0 General Information kgf-m, 22.0 lb-ft) according to numerical order in •...
Page 345 Engine Mechanical: 1D-60 Selection of Main Bearings 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five Standard bearing alphabets are stamped as shown in figure. If bearing is in malcondition, or bearing clearance is out Three kinds of alphabets (“A”, “B”...
Page 346 1D-61 Engine Mechanical: 3) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as indicated in figure. Each color indicated the following thickness at the center of bearing. Standard size of crankshaft main bearing thickness Color Bearing thickness...
Page 347 Engine Mechanical: 1D-62 Undersize bearing (0.25 mm (0.0098 in.)) • 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in the figure. Each color represents the following thickness at the center of bearing.
Page 348: Sensor Plate Inspection
1D-63 Engine Mechanical: Main Bearing Cap No.1 Bolt Rear Oil Seal Inspection Measure each thread diameter main bearing cap No.1 S7RS0B1406040 Carefully inspect oil seal (1) for wear or damage. If its lip bolts (1) at “A” on 60 mm (2.36 in.) from seat side of is worn or damaged, replace it.
Page 349: Tightening Torque Specifications
Engine Mechanical: 1D-64 Honing or Reboring Cylinders 4) Rebore and hone cylinder to the following dimension. 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time. NOTE 2) Select oversized piston according to amount of Before reboring, install all main bearing caps cylinder wear.
Page 350 1D-65 Engine Mechanical: Tightening torque Fastening part Note N⋅m kgf-m lb-ft Connecting rod bearing cap bolt 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) and then retighten by turning through 45° twice Sensor plate bolt Piston cooling valve Main bearing cap No.1 bolt (a) 30 N⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) and then retighten by turning through 60°...
Page 351: Special Tools And Equipment
Engine Mechanical: 1D-66 Special Tools and Equipment Recommended Service Material S7RS0B1408001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Water tight sealant SUZUKI Bond No.1207B P/No.: 99000–31140 SUZUKI Bond No.1207F P/No.: 99000–31250 NOTE Required service material is also described in the following.
Page 352 1D-67 Engine Mechanical: 09916–34550 09916–37320 Reamer handle Valve guide outer reamer (10.5 mm) 09916–44910 09916–56011 Valve guide installer & Valve guide installer remover attachment (protrusion: 11.5 09916–58210 09916–67020 Valve guide installer handle Tappet holder (Overseas) 09916–67021 09916–77310 Tappet holder Piston ring compressor (50- 125 mm) 09916–84511 09917–68221...
Page 353: Engine Lubrication System
Engine Lubrication System: 1E-1 Engine Lubrication System Engine General Description Engine Lubrication Description In one path, oil reaches the crankshaft journal bearings. S7RS0B1501001 Oil from the crankshaft journal bearings is supplied to The oil pump is of a trochoid type, and mounted on the the connecting rod bearings by means of intersecting crankshaft.
Page 354: Diagnostic Information And Procedures
1E-2 Engine Lubrication System: Diagnostic Information and Procedures Oil Pressure Check 1) Remove front bumper referring to “Front Bumper S7RS0B1504001 and Rear Bumper Components in Section 9K”. WARNING 2) Remove engine front cover (1). To avoid danger of being burned, do not touch exhaust system when it is still hot.
Page 355: Repair Instructions
Engine Lubrication System: 1E-3 6) Start engine and warm engine up to normal operating temperature. NOTE Be sure to shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T vehicle), set parking brake and block drive wheels.
Page 356: Heat Exchanger On-Vehicle Inspection
1E-4 Engine Lubrication System: Heat Exchanger On-Vehicle Inspection Installation S7RS0B1506002 Reverse removal procedure for installation noting the • Check heat exchanger for deformation wear or followings. damage. • Use new stand bolt gasket. • Check heat exchanger for coolant leakage and oil •...
Page 357: Oil Pan And Oil Pump Strainer Components
Engine Lubrication System: 1E-5 Oil Pan and Oil Pump Strainer Components S7RS0B1506004 I4RS0A150002-01 1. Oil pan 6. Strainer bolt 11. Transaxle stiffener bolt : Apply sealant 99000-31260 to mating surface. 2. Strainer 7. Bracket bolt : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3.
Page 358 1) Install new O-rings (2) in the position as shown in figure and install oil pump strainer (1). “A”: Sealant 99000–31260 (SUZUKI Bond Tighten strainer bolt (3) first and then bracket bolt (4) No.1217G) to specified torque.
Page 359: Oil Pan And Oil Pump Strainer Cleaning
Engine Lubrication System: 1E-7 6) After fitting oil pan to cylinder block, run in securing 10) Install clutch housing lower plate (1). bolts and start tightening at the center: move wrench outward, tightening one bolt at a time. Tighten bolts and nuts to specified torque.
Page 360: Oil Pump Components
1E-8 Engine Lubrication System: Oil Pump Components S7RS0B1506007 I4RS0A150010-01 1. Rotor plate 6. Rotor plate bolt 10. Circlip 2. O-ring 7. Relief valve : 11 N⋅m (1.1 kgf-mm 8.0 lb-ft) 3. Outer rotor 8. Spring : Do not reuse. 4. Inner rotor 9.
Page 361: Oil Pump Inspection
Engine Lubrication System: 1E-9 Oil Pump Inspection Reassembly S7RS0B1506010 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner and outer rotors, Oil Seal oil seal lip portion, inside surfaces of oil pump case Check oil seal lip for fault or other damage.
Page 362 1E-10 Engine Lubrication System: Radial clearance Relief valve spring free length and load Check radial clearance between outer rotor (1) and case Check relief valve spring free length and load as shown (2) using thickness gauge (3). in the figure. If the measured valve spring length is lower If clearance exceeds its limit, replace outer rotor or case.
Page 363: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RS0B1508001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 NOTE Required service material is also described in the following.
Page 364: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System Engine General Description Cooling System Description S7RS0B1601001 The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. Coolant Description S7RS0B1601002 WARNING •...
Page 365: Schematic And Routing Diagram
Engine Cooling System: 1F-2 Coolant capacity For M/T model: • Engine, radiator and heater: 5.5 liters (11.62/9.68 US/lmp pt.) • Reservoir: 0.7 liters (1.48/1.23 US/lmp pt.) • Total: 6.2 liters (13.10/10.91 US/lmp pt.) For A/T model: • Engine, radiator and heater: 5.4 liters (11.41/9.50 US/lmp pt.) •...
Page 366 1F-3 Engine Cooling System: When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be cooled as follows. I6RS0C160002-01 1. Radiator inlet hose 6. Water pump 11. Heater core 2. Radiator outlet hose 7.
Page 367: Diagnostic Information And Procedures
Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis S7RS0B1604001 Condition Possible cause Correction / Reference Item Engine overheats Loose or broken water pump belt Adjust or replace. (Radiator fan operates) Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace.
Page 368: Repair Instructions
1F-5 Engine Cooling System: Repair Instructions Cooling System Components S7RS0B1606001 I7RS0B160004-01 F: Vehicle forward 10. Water outlet cap gasket 20. Heater outlet No.2 hose 30. Heat exchanger water pipe 1. Radiator 11. O-ring 21. Heater union 31. To cylinder head 2.
Page 369: Coolant Level Check
Engine Cooling System: 1F-6 Coolant Level Check NOTE S7RS0B1606002 After installing radiator cap to radiator, make WARNING sure that the ear of cap lines is parallel to radiator. To help avoid danger of being burned, do not remove radiator cap while engine and Cooling system and radiator cap holding radiator are still hot.
Page 370: Cooling System Flush And Refill
1F-7 Engine Cooling System: Cooling System Flush and Refill 7) Remove reservoir (1) and remove cap (2) from S7RS0B1606005 reservoir (1). WARNING 8) Pour out any fluid, scrub and clean inside of reservoir with soap and water. To help avoid danger of being burned, do not Flush it well with clean water and drain, Reinstall remove radiator cap while engine and reservoir.
Page 371: Thermostat Removal And Installation
Engine Cooling System: 1F-8 Thermostat Removal and Installation • Refill cooling system referring to Step 7) to 22) of S7RS0B1606007 “Cooling System Flush and Refill”. Removal • Verify that there is no coolant leakage at each 1) Drain coolant referring to “Cooling System Draining”. connection.
Page 372: Radiator Cooling Fan Motor On-Vehicle Inspection
1F-9 Engine Cooling System: Radiator Cooling Fan Motor On-Vehicle Radiator Cooling Fan Relay Inspection S7RS0B1606010 Inspection 1) Disconnect negative (–) cable at battery. S7RS0B1606009 1) Check low speed operation of radiator cooling fan as 2) Remove radiator cooling fan relay No.1 (1), No.2 (2) follows.
Page 373: Radiator Cooling Fan Removal And Installation
Engine Cooling System: 1F-10 Radiator Cooling Fan Removal and Installation Radiator On-Vehicle Inspection and Cleaning S7RS0B1606011 S7RS0B1606012 Inspection Removal Check radiator for leakage or damage. Straighten bent fins, if any. 1) Disconnect negative (–) cable at battery. 2) Disconnect connector (1) of cooling fan motor. Cleaning Clean frontal area of radiator cores.
Page 374: Water Pump Removal And Installation
Section 7B” or “Compressor Drive Belt Inspection and Adjustment in Section 7B”. “A”: Water tight sealant 99000–31250 (SUZUKI 6) Refill cooling system referring to Step 7) to 22) of Bond No.1207F) “Cooling System Flush and Refill”.
Page 375: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RS0B1608001 Material SUZUKI recommended product or Specification Note Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250...
Page 376: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions on Fuel System Service S7RS0B1700001 WARNING Before attempting service of any type on fuel system, the following should be always observed in order to reduce the risk of fire and personal injury. •...
Page 377: Fuel Pump Description
Fuel System: 1G-2 Fuel Pump Description S7RS0B1701003 The fuel pump (1) is an in-tank type electric pump. Incorporated in the pump assembly are; a fuel filter (2) and a fuel pressure regulator (3) are included and a fuel level gauge (4) is attached. Addition of the fuel pressure regulator to the fuel pump makes it possible to maintain the fuel pressure at constant level and ECM controls compensation for...
Page 378: Fuel Cut Operation Inspection
1G-3 Fuel System: Fuel Cut Operation Inspection 4) Check that battery voltage is 11 V or more. S7RS0B1704002 5) Measure fuel pressure at each condition. NOTE If measured pressure is out of specification, refer to Before inspection, make sure that gear shift “Fuel Pressure Check in Section 1A”...
Page 379: Repair Instructions
Fuel System: 1G-4 Repair Instructions Fuel System Components S7RS0B1706001 I6RS0C170003-01 1. Fuel tank 12. Fuel tank bolt 23. Main fuel level sensor 2. Fuel pump assembly 13. Fuel pump assembly bolt 24. To fuel vapor line 3. Breather hose 14. Fuel filler neck 25.
Page 380: Fuel Hose Disconnecting And Reconnecting
1G-5 Fuel System: Fuel Hose Disconnecting and Reconnecting S7RS0B1706002 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk or fire and personal injury. Be sure to connect and clamp each hose correctly as shown in figure. For Connection Other Than Quick Joint Clamp around fuel tank NOTE...
Page 381 Fuel System: 1G-6 Clamp other than around fuel tank [A]: With short pipe, fit hose as far as it reaches pipe joint as shown. [B]: With the following type pipe, fit hose as far as its peripheral projection as shown. [C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
Page 382: Fuel Pressure Relief Procedure
1G-7 Fuel System: Fuel Pressure Relief Procedure Fuel Lines On-Vehicle Inspection S7RS0B1706003 S7RS0B1706005 CAUTION CAUTION This work must not be done when engine is Due to the fact that fuel feed line (1) is under hot. If done so, it may cause adverse effect to high pressure, use special care when catalyst.
Page 383: Fuel Injector On-Vehicle Inspection
Fuel System: 1G-8 Installation Fuel Injector Removal and Installation S7RS0B1706008 1) Install clamps to marked location on pipes. If clamp is deformed, its claw is bent or broken, replace it with WARNING new one. Before starting the following procedure, be 2) Install pipes with pipe clamps to vehicle.
Page 384: Fuel Injector Inspection
1G-9 Fuel System: Fuel Injector Inspection Installation Reverse removal procedure for installation noting the S7RS0B1706009 following. WARNING • Replace injector O-ring (1) with new one using care Before starting the following procedure, be not to damage it. sure to observe “Precautions on Fuel System •...
Page 385: Fuel Filler Cap Inspection
“MISC TEST” mode on scan tool. specifications, replace. iii) Turn fuel pump ON by using scan tool. Fuel leakage Special tool Less than 1 drop/min. (A): SUZUKI scan tool I2RH0B170013-01 I4RS0A170021-01 Fuel Filler Cap Inspection b) When not using scan tool: S7RS0B1706010 WARNING Remove fuel pump relay from connector.
Page 386: Fuel Tank Inlet Valve Removal And Installation
1G-11 Fuel System: Fuel Tank Inlet Valve Removal and Installation 4) Remove fuel tank inlet valve (1) using flat head rod S7RS0B1706011 (2) or the like. WARNING CAUTION Before starting the following procedure, be Be careful not to damage fuel tank inlet valve sure to observe “Precautions on Fuel System (1) with flat head rod (2) or the like.
Page 387: Fuel Tank Inlet Valve Inspection
Fuel System: 1G-12 Fuel Tank Inlet Valve Inspection 7) Disconnect fuel pipe joint and fuel hoses (1) from S7RS0B1706012 fuel pipes (2) referring to “Fuel Hose Disconnecting and Reconnecting”. WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service”...
Page 388: Fuel Tank Inspection
1G-13 Fuel System: Installation 4) Connect fuel filler hose (1) and breather hose (2) to filler neck (3) as shown in figure, and clamp them CAUTION securely. • When connecting joint, clean outside Tightening torque surfaces of pipe where joint is to be Fuel filler hose clamp (a): 2 N·m (0.2 kgf-m, 1.5 inserted, push joint into pipe till joint lock lb-ft)
Page 389: Fuel Tank Purging Procedure
Fuel System: 1G-14 Fuel Tank Purging Procedure S7RS0B1706015 WARNING • Before starting the following procedure, be sure to observe “Precautions on Fuel System Service” in order to reduce the risk or fire and personal injury. • This purging procedure will not remove all fuel vapor.
Page 390: Main Fuel Level Sensor Removal And Installation
1G-15 Fuel System: 3) Remove fuel pump assembly (1) from fuel tank (2). 4) Connect fuel feed line (1) (pipe joint) to fuel pump assembly (2). I3RM0A170021-01 I4RS0A170014-01 5) Install fuel tank to vehicle. Refer to “Fuel Tank Installation Removal and Installation”. CAUTION Main Fuel Level Sensor Removal and When connecting joint, clean outside surface...
Page 391: Fuel Pump Inspection
Fuel System: 1G-16 Fuel Pump Inspection Removal S7RS0B1706019 1) Remove fuel pump assembly from fuel tank referring • Check fuel pump assembly for damage. to “Fuel Pump Assembly Removal and Installation”. • Check fuel suction filter for evidence of dirt and 2) Disconnect main fuel level sensor connector (3).
Page 392: Special Tools And Equipment
58413). 58413). 09912–58490 09919–47020 3-way joint & hose Quick joint remover 09930–88530 SUZUKI scan tool Injector test lead — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loop back adapter, 7.
Page 393: Ignition System
Ignition System: 1H-1 Ignition System Engine General Description Ignition System Construction S7RS0B1801001 The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below. • ECM It detects the engine and vehicle conditions through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power unit) in the ignition coil assembly.
Page 394: Schematic And Routing Diagram
1H-2 Ignition System: Schematic and Routing Diagram Ignition System Wiring Circuit Diagram S7RS0B1802001 BLK/WHT GRN/WHT C37-5 GRN/YEL C37-6 BLK/WHT E23-29 BLK/YEL BLK/YEL BRN/WHT E23-60 E23-1 BLK/RED BLK/RED BLK/YEL BLK/RED E23-16 BLK/RED C37-58 BLK/ORN RED/YEL C37-20 C37-15 C37-30 C37-21 E23-31 BLK/ORN 39 38 32 31 39 38...
Page 395: Component Location
Ignition System: 1H-3 Component Location Ignition System Components Location S7RS0B1803001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RS0C180001-01 1. ECM 7. ECT sensor 13. Data link connector 2.
Page 396: Diagnostic Information And Procedures
1H-4 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis S7RS0B1804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition coil Replace. not start or hard to start Loose connection or disconnection of Connect securely.
Page 397 Ignition System: 1H-5 Step Action Ignition coil assembly power supply and ground circuit Go to Step 7. Repair or replace. check 1) Check ignition coil assembly power supply and ground circuits for open and short. Are circuits in good condition? Ignition coil assembly check Go to Step 8.
Page 398: Repair Instructions
1H-6 Ignition System: Ignition Spark Test 5) Crank engine and check if each spark plug sparks. S7RS0B1804004 1) Remove air cleaner assembly with air intake pipe. 2) Disconnect all injector couplers from injectors. WARNING Without disconnection of injector couplers, combustible gas may come out from spark plug holes during this test and may get ignited in engine room.
Page 399: High-Tension Cord Inspection
Ignition System: 1H-7 High-Tension Cord Inspection Spark Plug Inspection S7RS0B1806002 S7RS0B1806004 Measure resistance of high-tension cord (1) by using CAUTION ohmmeter. If resistance exceeds specification, replace high-tension • When servicing the iridium / platinum cord(s). spark plugs (slender center electrode type plugs), do not touch the center electrode High-tension cord resistance to avoid damage to it.
Page 400: Ignition Coil Assembly (Including Ignitor) Removal And Installation
OFF. 3) Install high-tension cord (3) to ignition coil assembly Special tool while gripping its cap. (A): SUZUKI scan tool I4RS0B180003-01 I3RM0A180004-01 2) Start engine and warm it up to normal operating 4) Install cylinder head upper cover and air cleaner temperature.
Page 401: Specifications
• CKP sensor • CKP sensor plate Initial ignition timing Fixed with SUZUKI scan tool: 5 ± 3° BTDC (at • CMP sensor specified idle speed) • CMP sensor rotor tooth of camshaft Ignition order • VSS 1 –...
Page 402: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Cranking System Circuit Diagram S7RS0B1902001 I4RS0A190001-01 1. Pinion drive lever 6. Magnetic switch contacts 11. Ignition & Starter switch 2. Pinion & Over-running clutch 7. Pull-in coil 12. Battery 3. Magnetic switch 8.
Page 403 Starting System: 1I-2 Condition Possible cause Correction / Reference Item Motor not running (No Shift lever switch is not in P or N, or not Shift in P or N, or adjust switch. (A/T) operating sound of adjusted (A/T) magnetic switch) Battery run down Recharge battery.
Page 404: Cranking System Test
1I-3 Starting System: Cranking System Test Plunger and Pinion Return Test S7RS0B1904002 Disconnect negative lead from starting motor body. CAUTION Check that plunger and pinion return inward. If plunger and pinion don’t return, replace the magnetic Each test must be performed within 3 – 5 switch.
Page 405: Repair Instructions
Starting System: 1I-4 Repair Instructions Starting Motor Dismounting and Remounting S7RS0B1906001 I4RS0A190002-01 : 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) Dismounting 1) Disconnect negative (–) battery lead at battery. 2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) Detach shift &...
Page 406: Starting Motor Components
1I-5 Starting System: Starting Motor Components S7RS0B1906002 I4RS0A190003-01 1. Front housing 7. Plate 13. Planetary gear 19. Rear bush 2. Bush 8. Seal rubber 14. Packing 20. Starting motor battery cable nut 3. Pinion stop ring 9. Magnetic switch 15. Yoke 9.8 N⋅m (0.98 kgf-m, 7.0 lb-ft) 4.
Page 407: Starting Motor Inspection
Starting System: 1I-6 Starting Motor Inspection Hold-in coil open circuit test S7RS0B1906003 Check for continuity across magnetic switch “S” terminal (1) and coil case. If no continuity, coil is open and should Plunger be replaced. Inspect plunger for wear. Replace if necessary. I2RH01190011-01 Rear Bracket Bush I2RH01190008-01...
Page 408 1I-7 Starting System: Spring Inspect brush springs for wear, damage or other abnormal conditions. Replace if necessary. Brush spring tension Standard: 2.2 kg (4.85 lb) Limit: 0.6 kg (1.33 lb) Brush Holder • Check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for I2RH01190016-01...
Page 409 Starting System: 1I-8 • Check the commutator and armature core. If there is Pinion and Over-Running Clutch continuity, the armature is grounded and must be • Inspect the pinion for wear, damage or other abnormal replaced. conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction.
Page 410: Specifications
1I-9 Starting System: Specifications Cranking System Specifications S7RS0B1907001 Voltage 12 volts Output 1.2 kW Rating 30 seconds Direction of rotation Clockwise as viewed from pinion side Brush length Standard: 12.3 mm (0.48 in.) Limit: 7.0 mm (0.28 in.) Number of pinion teeth Performance Condition Guarantee...
Page 411: Charging System
Charging System: 1J-1 Charging System Engine General Description Battery Description Built-In Indicator (If Equipped) S7RS0B1A01001 The battery has a built-in temperature compensated The battery has three major functions in the electrical indicator in the top of the battery. This indicator is to be system.
Page 412: Generator Description
1J-2 Charging System: Generator Description S7RS0B1A01002 The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown below. I5JB0A1A0004-01 1. Pulley 6. Field coil 11. Rear housing IG: Ignition terminal 2. Pulley nut 7.
Page 413 Charging System: 1J-3 Charging System Circuit The generator features solid state regulator that it mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage is being controlled by ECM under some conditions while driving.
Page 414: Diagnostic Information And Procedures
1J-4 Charging System: Diagnostic Information and Procedures Battery Inspection S7RS0B1A04001 Common Causes of Failure A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test but fails to operate properly for no apparent reason, the following are some factors that may point to the cause of trouble: •...
Page 415: Generator Test (Undercharged Battery Check)
Charging System: 1J-5 Generator Test (Undercharged Battery Check) NOTE S7RS0B1A04003 Consideration should be taken that voltage This condition, as evidenced by slow cranking or will differ somewhat with regulator case indicator clear with dark or light yellow dot can be temperature as shown in figure.
Page 416: Generator Test (Overcharged Battery Check)
1J-6 Charging System: Generator Test (Overcharged Battery Check) 3) If measured voltage is higher than upper limit value, S7RS0B1A04004 proceed to disassemble generator. 1) To determine battery condition, refer to “Battery 4) Check ground of brushes. If brushes are not Description”.
Page 417: Battery Dismounting And Remounting
Charging System: 1J-7 With Charging Equipment Water Pump / Generator Drive Belt Tension Inspection and Adjustment CAUTION S7RS0B1A06003 WARNING When jump starting engine with charging equipment, be sure equipment used is 12- Disconnect negative cable at battery before volt and negative ground. Do not use 24-volt checking and adjusting belt tension.
Page 418: Water Pump / Generator Drive Belt Removal And Installation
1J-8 Charging System: Water Pump / Generator Drive Belt Removal and 3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tension to specification described Installation at step 2) by loosening / tightening generator adjust S7RS0B1A06004 Removal bolt (1).
Page 419: Generator Unit Components
Charging System: 1J-9 Generator Unit Components S7RS0B1A06005 I6RS0C1A0003-02 1. “B” terminal nut 5. Generator pivot bolt : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. “B” terminal wire 6. Generator belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 3. Connector 7. Generator : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft) 4.
Page 420: Generator Components
1J-10 Charging System: Generator Components S7RS0B1A06007 I4RS0B1A0007-01 1. Pulley nut 6. Drive end bearing 11. Rear housing 16. “B” terminal nut 2. Pulley 7. Bearing retainer 12. Rectifier : 118 N⋅m (11.8 kgf-m, 85.5 lb-ft) 3. Front housing 8. Rotor 13.
Page 421: Generator Inspection
Charging System: 1J-11 Generator Inspection S7RS0B1A06008 Rotor • Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or regulator.
Page 422 1J-12 Charging System: • Using an ohmmeter (1), check that there is no continuity between slip ring (2) and rotor core (3). If there is continuity, replace the rotor. I4RS0B1A0008-01 • Check slip rings for roughness or scoring. If rough or scored, replace the rotor. Stator Brush and Brush Holder Check each brush (1) for wear by measuring its length...
Page 423: Specifications
Charging System: 1J-13 Specifications Charging System Specifications S7RS0B1A07001 Battery Battery : 48AH/20H, 40.6AH/5H 12 V Nominal output 12 V Rated capacity 48 Ah/20 h 40.6 Ah/5 h Cold cranking amperes 300 A (DIN) Generator Type 80A type Rated voltage 12 V Nominal output Permissible max.
Page 424: Exhaust System
1K-1 Exhaust System: Exhaust System Engine General Description Exhaust System Description S7RS0B1B01001 The exhaust system consists of an exhaust manifold, three-way catalytic converter (TWC) in catalyst case, exhaust pipes, a muffler and seals, gasket and etc. The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
Page 425: Repair Instructions
Exhaust System: 1K-2 Repair Instructions Exhaust System Components S7RS0B1B06001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. I7RS0B1B0001-01 [A]: MT model 14.
Page 426: Exhaust Manifold Removal And Installation
1K-3 Exhaust System: Exhaust Manifold Removal and Installation S7RS0B1B06002 Removal WARNING To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down. 1) Disconnect negative cable at battery. 2) Remove engine cover.
Page 427: Exhaust Pipe And Muffler Removal And Installation
Exhaust System: 1K-4 2) Install new seal ring and connect exhaust No.1 pipe (1) to exhaust manifold. Tighten pipe fasteners to specified torque. Tightening torque Exhaust No.1 pipe bolt (a): 50 N·m (5.0 kgf-m, 36.5 lb-ft) 3) Install exhaust manifold stiffener (2). Tighten exhaust manifold stiffener bolts to specified torque.
Page 428 1K-5 Exhaust System: Specifications Tightening Torque Specifications S7RS0B1B07001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust manifold bolt 36.5 Exhaust manifold nut 36.5 Exhaust No.1 pipe bolt 36.5 Exhaust manifold stiffener bolt 36.5 Exhaust No.2 pipe bolt 31.0 NOTE The specified tightening torque is also described in the following.
Page 429 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Tightening Torque Specifications......2B-20 Special Tools and Equipment ......2B-21 Precautions............. 2-1 Special Tool ............2B-21 Precautions on Suspension ........2-1 Rear Suspension ........2C-1 Suspension General Diagnosis....2A-1 General Description ..........2C-1 Diagnostic Information and Procedures....2A-1 Rear Suspension Construction ......2C-1 Suspension, Wheels and Tires Symptom...
Page 430 2-ii Table of Contents Balancing Wheels Description ......2D-5 Tire Repair ............2D-8 Tire Repair for Emergency Repaired-Tire with Repair Instructions ..........2D-6 Sealant ..............2D-8 General Balance Procedures ......2D-6 Tire Rotation............2D-6 Specifications ............2D-9 Wheel Removal and Installation......2D-7 Wheels and Tires Specifications ......2D-9 Tire Mounting and Dismounting ......2D-8 Tightening Torque Specifications......2D-9...
Page 431: Precautions
Precautions: Precautions Suspension Precautions Precautions on Suspension S7RS0B2000001 Emergency Flat Tire Repair Kit handle Warning Refer to “Warning for Handling Emergency Flat Tire Repair Kit in Section 00”. Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”.
Page 432: Suspension General Diagnosis
2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension, Wheels and Tires Symptom Diagnosis S7RS0B2104001 Condition Possible cause Correction / Reference Item Vehicle pulls (Leads) Mismatched or uneven tires Replace tires. Tires not adequately inflated Adjust tire pressure. Broken or sagging coil springs Replace coil springs.
Page 433 Suspension General Diagnosis: 2A-2 Condition Possible cause Correction / Reference Item Body leans or sways in Loose stabilizer bar Tighten stabilizer bar bolts or nuts, or replace corners bushes. Faulty strut (shock absorber) or Replace strut (shock absorber) or tighten mounting mounting.
Page 434: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension General Description Front Suspension Construction S7RS0B2201001 I7RS0B220001-01 1. Strut assembly 8. Tie-rod : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) 2. Stabilizer bar 9. Brake disc : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Steering knuckle 10.
Page 435: Front Wheel Alignment Construction
Front Suspension: 2B-2 Front Wheel Alignment Construction • Check for loose of ball joints. Check tie-rod ends; if S7RS0B2201002 excessive looseness is noted, it must be corrected Among factors for front wheel alignment, only toe setting before adjusting. can be adjusted. Camber and caster are not adjustable. •...
Page 436 2B-3 Front Suspension: Adjustment 1) Loosen right and left tie-rod end lock nuts (1) first. 2) Rotate right and left tie-rods (2) by the same amount to align toe to specification. In this adjustment, the lengths “A” of both right and left tie-rod should be equal.
Page 437: Front Strut Assembly Components
Front Suspension: 2B-4 Reference Information Side slip 0 to IN 3.0 mm/m (0 to IN 0.118 in/3.3 ft) Side slip When checked with side slip tester, side slip should If side slip is greatly different, toe or front wheel satisfy following specification. alignment may not be correct.
Page 438 2B-5 Front Suspension: Tightening torque 5) Remove brake hose mounting bolt (1) and remove brake hose (2) from bracket and then wheel speed Strut bracket nut (a): 90 N·m (9.0 kgf-m, 65.5 lb-ft) sensor harness (3) from strut bracket as shown in Brake hose mounting bolt (c): 25 N·m (2.5 kgf-m, figure.
Page 439: Front Strut Assembly Disassembly And Assembly
Front Suspension: 2B-6 • Tighten wheel nuts to specified torque. Assembly For assembly, reverse disassembly procedure, noting Tightening torque the following instructions. Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft) 1) Compress coil spring with special tool (A) until total •...
Page 440: Front Strut Assembly Check
2B-7 Front Suspension: Front Strut Assembly Check 3) Install bump stopper onto strut rod. For installing direction, refer to the figure in “Front Suspension S7RS0B2206005 • Inspect strut for oil leakage, damage or deformation. Construction”. • If defect is found, replace strut as an assembly unit, 4) Pull strut rod as far up as possible and use care not because it can not be disassembled.
Page 441: Front Wheel Hub And Steering Knuckle Components
Front Suspension: 2B-8 Front Wheel Hub and Steering Knuckle Components S7RS0B2206006 I7RS0B220005-03 1. Front wheel hub 3. Wheel bearing 5. Drive shaft nut : 200 N⋅m (20.0 kgf-m, 145 lb-ft) : Face grooved rubber seal side to wheel hub. : Calk, after tightening. 2.
Page 442 2B-9 Front Suspension: 8) Loosen strut bracket nuts (1). 14) Remove wheel bearing outside inner race (1). 9) Remove ball joint bolt (3) and nut (4). Special tool 10) Remove strut bracket bolts from strut bracket and (C): 09913-65810 then steering knuckle (2). (D): 09913–85230 I6RS0C220004-01 15) Remove hub bolts (1) with copper hammer or...
Page 443 Front Suspension: 2B-10 2) Face grooved rubber seal side (1) of new wheel 5) Caulk more than 6 places with a punch. bearing (2) upward as shown in figure and press-fit it into knuckle (3) using special tool. Special tool (A): 09913-75510 (B): 09926–68310 (C): 09951–18210...
Page 444 2B-11 Front Suspension: 7) Install ball joint bolt (1) and nut (2) from the direction 11) Connect tie-rod end to steering knuckle and then as shown in figure. install cotter pin referring to “Tie-Rod End Removal and Installation in Section 6C”. 8) Tighten new suspension control arm ball joint nut (2) to specified torque.
Page 445: Front Wheel Hub, Disc, Nut And Bearing Check
Front Suspension: 2B-12 Front Wheel Hub, Disc, Nut and Bearing Check Suspension Control Arm / Bushing Removal S7RS0B2206008 and Installation • Inspect each wheel disc for dents, distortion and S7RS0B2206009 cracks. CAUTION A disc in badly damaged condition must be replaced. When removing and installing steering •...
Page 446: Suspension Control Arm / Bushing Disassembly And Assembly
2B-13 Front Suspension: Installation Tightening torque Suspension control arm front bolt (a): 95 N·m ( 1) Install suspension control arm as shown but tighten 9.5 kgf-m, 68.0 lb-ft) new suspension control arm bolts (1) only Suspension control arm rear bolt (b): 95 N·m ( temporarily.
Page 447: Suspension Control Arm / Steering Knuckle Check
Front Suspension: 2B-14 Suspension Control Arm / Steering Knuckle Assembly Check 1) Front bushing S7RS0B2206011 Press-fit front bushing (1) by using special tools and Inspect for cracks, deformation or damage. press (2). If defective, replace. Special tool (A): 09943–76310 Suspension Control Arm Bushing Check (B): 09913–75821 S7RS0B2206012 Inspect for damage, wear or deterioration.
Page 448: Front Suspension Frame, Stabilizer Bar And/Or Bushings Components
2B-15 Front Suspension: Front Suspension Frame, Stabilizer Bar and/or Bushings Components S7RS0B2206014 I6RS0C220016-01 A: View A 4. Stabilizer bar mounting 8. Suspension control arm mounting bolt : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft) bracket bolt 1. Stabilizer bar 5. Stabilizer joint 9.
Page 449 Front Suspension: 2B-16 4) Hoist vehicle and remove both wheels referring to 11) Remove engine rear mounting bolts (1) from engine “Wheel Removal and Installation in Section 2D”. rear mounting (2). 5) Remove cotter pins and tie-rod end nuts, and then disconnect both tie-rod ends from steering knuckles referring to “Tie-Rod End Removal and Installation in Section 6C”.
Page 450 2B-17 Front Suspension: 15) Remove stabilizer bar (1) and bushing from front 4) Mount steering gear case (1) to front suspension suspension frame (2). frame (2) and tighten gear case mounting No.1 bolts (3) and No.2 bolts (4) to specified torque. Tightening torque Steering gear case mounting No.1 bolt (a): 55 N·m (5.5 kgf-m, 40.0 lb-ft)
Page 451 Front Suspension: 2B-18 7) Tighten front suspension frame mounting bolts (a) to 11) Remove supporting device from engine. specified torque. 12) Install stabilizer joints (1), and tighten nuts to specified torque. Tightening torque When tightening, hold stud with special tools. Front suspension frame mounting bolt (a): 150 N·m (15.0 kgf-m, 108.5 lb-ft) Special tool...
Page 452: Front Suspension Frame Check
2B-19 Front Suspension: Front Stabilizer Bar, Bushing and/or Joint 13) Install suspension control arm referring to “Suspension Control Arm / Bushing Removal and Check Installation”. S7RS0B2206017 Stabilizer Bar 14) Connect couplers of torque sensor and P/S motor. Inspect for damage or deformation. 15) Connect tie-rod ends to knuckles (right &...
Page 453 Front Suspension: 2B-20 Specifications Tightening Torque Specifications S7RS0B2207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end lock nut 32.5 Strut bracket nut 65.5 Brake hose mounting bolt 18.0 Stabilizer joint nut 36.5 Strut nut 36.5 Wheel nut 61.5 Strut support lower nut 36.5 Suspension control arm ball joint nut...
Page 454: Special Tools And Equipment
2B-21 Front Suspension: Special Tools and Equipment Special Tool S7RS0B2208001 09900–00411 09900–00413 Hexagon bit socket Hexagon bit (5 mm) 09900–00414 09913–65810 Hexagon bit (6 mm) Crankshaft bearing puller 09913–75510 09913–75520 Bearing installer Bearing installer 09913–75821 09913–85230 Bearing installer attachment Bearing remover tool 09926–68310 09940–71431 Differential bevel pinion...
Page 455: Rear Suspension
Rear Suspension: 2C-1 Rear Suspension Suspension General Description Rear Suspension Construction S7RS0B2301001 I6RS0C230001-03 A: View A 7. Circlip 14. Spindle cap : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 1. Rear coil spring 8. Rear trailing arm bolt 15. Wheel hub : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 2.
Page 456: Repair Instructions
2C-2 Rear Suspension: Repair Instructions Rear Wheel Alignment Inspection Installation S7RS0B2306017 1) Install shock absorber (1), a pair of upper washers Measure toe and camber referring to “Front Wheel (2) and lower washer. Alignment Inspection and Adjustment in Section 2B”. Tighten new rear shock absorber upper nut (4) and NOTE lower nut temporarily at this step.
Page 457: Rear Shock Absorber Inspection
Rear Suspension: 2C-3 Rear Shock Absorber Inspection 2) Remove floor jack (2) from rear axle. S7RS0B2306002 3) Install rear wheels and tighten wheel nuts specified • Inspect for deformation or damage. torque. • Inspect bushings for wear or damage. Tightening torque •...
Page 458: Rear Shock Absorber Bush Removal And Installation
2C-4 Rear Suspension: Rear Shock Absorber Bush Removal and Rear Shock Absorber Bush Inspection S7RS0B2306004 Installation Inspect for cracks, deformation or damage. Replace any S7RS0B2306003 defective parts. Removal 1) Remove rear shock absorber referring to “Rear Shock Absorber Removal and Installation”. 2) Remove rear shock absorber bushes (1).
Page 459: Spring Upper Seat / Spring Lower Seat Inspection
Rear Suspension: 2C-5 Installation 3) Remove floor jacks from rear axle. 1) Install coil spring (1) on spring seat (2) of rear axle 4) Install wheels and tighten wheel nuts to specified and mate spring open end with stepped part (3) of torque.
Page 460: Spring Upper Seat And Lower Seat Removal And Installation
2C-6 Rear Suspension: Spring Upper Seat and Lower Seat Removal and Installation S7RS0B2306007 Removal 1) Remove coil spring referring to “Rear Coil Spring Removal and Installation”. 2) Remove spring upper seat (1) and lower seat (2). I4RS0A230017-01 A: Vehicle body side (Upper side) F: Vehicle front 3.
Page 461 Rear Suspension: 2C-7 3) Remove rear brake caliper assemblies (right & left) 9) Disconnect wheel speed sensor clamp and parking and brake discs (right & left). For details, refer to brake cable clamp from rear axle. Step 2) to 3) of “Removal” under “Rear Brake Disc Removal and Installation in Section 4C”.
Page 462 2C-8 Rear Suspension: 3) Install coil springs (right & left) on spring seats of rear 8) Install wheel speed sensor clamp and parking brake axle referring to “Spring Upper Seat and Lower Seat clamp and tighten parking brake clamp bolts (1) to Removal and Installation”...
Page 463: Trailing Arm, Rear Axle And Coil Spring Inspection
Rear Suspension: 2C-9 Trailing Arm, Rear Axle and Coil Spring 12) Fill reservoir with brake fluid and bleed brake system. For bleeding operation, see “Air Bleeding of Inspection Brake System in Section 4A”. S7RS0B2306009 • Inspect for cracks, deformation or damage. 13) Install wheel and tighten wheel nuts to specified •...
Page 464: Rear Wheel Hub Components
2C-10 Rear Suspension: Rear Wheel Hub Components S7RS0B2306011 I6RS0C230002-03 1. Spindle cap 4. Spindle : 175 N⋅m (17.5 kgf-m, 126.5 lb-ft) 2. Rear axle nut 5. Disc dust cover : 88 N⋅m (8.8 kgf-m, 64.0 lb-ft) :Calk, after Tightening 3. Rear wheel hub 6.
Page 465: Rear Wheel Disc, Bolt And Bearing Inspection
Rear Suspension: 2C-11 Installation • Caulk new rear axle nut (1) as shown. Install wheel hub by reversing removal procedure noting CAUTION the following instructions. Take care while staking nut. If a split occurs • Insert new wheel stud bolt in wheel hub hole and in staked area of nut, replace it with new one.
Page 466: Spindle Removal And Installation
2C-12 Rear Suspension: • Check noise and smooth rotation of wheel by rotating Installation wheel. If it is defective, replace bearing. 1) Install brake disc dust cover (1), spindle (2) and new spindle bolts (3) and then tighten spindle bolts to specified torque.
Page 467: Spindle Inspection
Rear Suspension: 2C-13 Spindle Inspection Rear Suspension Fasteners Inspection S7RS0B2306015 S7RS0B2306016 Check each bolt and nut fastening suspension parts for • Inspect for cracks, deformation or damage. tightness. Tighten loose one, if any, to specified torque Replace any defective part. referring to the figure in “Rear Suspension Construction”.
Page 468: Wheels And Tires
2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precaution for Emergency Flat Tire Repair Kit CAUTION S7RS0B2400001 WARNING • When tire repaired with Emergency Flat Tire Repair Kit is brought in, remove flat Flat tire repair sealant including in kit is tire repair sealant from tire and repair flat harmful.
Page 469: Wheels Description
Wheels and Tires: 2D-2 Wheels Description Lower than recommended pressure can cause: S7RS0B2401002 • Tire squeal on turns Wheel Maintenance • Hard Steering Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced. •...
Page 470: Irregular And/Or Premature Wear Description
2D-3 Wheels and Tires: Metric Lug Nuts and Wheel Studs All models use metric lug nuts and wheel studs. Metric lug nuts and wheel studs size M12 x 1.25 If broken stud or nut are found, be sure to replace both stud and nut with new one.
Page 471: Radial Tire Waddle Description
Wheels and Tires: 2D-4 Radial Tire Waddle Description S7RS0B2401005 Waddle is side to side movement at the front and/or rear of the vehicle. It is caused by the steel belt not being straight within the tire. It is most noticeable at a low speed, 8 to 48 kph (5 to 30 mph).
Page 472: Radial Tire Lead / Pull Description
2D-5 Wheels and Tires: Radial Tire Lead / Pull Description Balancing Wheels Description S7RS0B2401006 S7RS0B2401007 “Lead / Pull” is the deviation of the vehicle from a straight There are two types of wheel and tire balance: static and path on a level road even with no pressure on the dynamic.
Page 473: Repair Instructions
Wheels and Tires: 2D-6 Repair Instructions General Balance Procedures Tire Rotation S7RS0B2406001 S7RS0B2406002 Deposits of mud, etc. must be cleaned from inside of rim. To equalize wear, rotate tires according to figure. Radial tires should be rotated periodically. Set tire pressure. WARNING Stones should be removed from the tread in order to avoid operator injury during spin...
Page 474: Wheel Removal And Installation
2D-7 Wheels and Tires: Wheel Removal and Installation For installation, reverse removal procedure, noting the S7RS0B2406003 following. Removal • Wheel nuts must be tightened in sequence and to specified torque to avoid bending wheel or brake disc. WARNING NOTE Do not removal all of the wheel nuts at once, because all the wheels of this vehicle are Before installing wheels, remove any build- mounted by the wheel nuts.
Page 475: Tire Mounting And Dismounting
Wheels and Tires: 2D-8 Tire Mounting and Dismounting 1) Remove flat tire repair sealant from tire using plug S7RS0B2406004 (1), filler hose (2), sealant bottle (3) and extension CAUTION hose (4) in kit as follows. a) Remove plug from filler hose of sealant bottle. When installing tire which has arrow Then connect extension hose to tip of filler hose.
Page 476: Specifications
2D-9 Wheels and Tires: 2) Check tire if it can be repaired, referring to “Tire CAUTION Repair”. If it cannot be repaired, replace it with new Be sure to use new valve core. Otherwise, air one. leak may occur due to sealant attached to 3) Replace valve core of flat tire with new one if tire is valve core.
Page 477 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Front Drive Shaft Assembly On-Vehicle Inspection............3A-4 Precautions............. 3-1 Front Drive Shaft Assembly Removal and Precautions for Driveline / Axle ......3-1 Installation ............3A-4 Drive Shaft / Axle ........3A-1 Front Drive Shaft Disassembly and Reassembly ............3A-6 General Description ..........3A-1...
Page 478: Precautions
3-1 Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle S7RS0B3000001 Fastener Caution Refer to “Fastener Caution in Section 00”.
Page 479: Drive Shaft / Axle
Drive Shaft / Axle: 3A-1 Drive Shaft / Axle Driveline / Axle General Description Front Drive Shaft Construction S7RS0B3101001 A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side.
Page 480: Diagnostic Information And Procedures
3A-2 Drive Shaft / Axle: Diagnostic Information and Procedures Front Drive Shaft Symptom Diagnosis S7RS0B3104001 Condition Possible cause Correction / Reference Item Abnormal noise Worn or breakage of the drive shaft joint Replace. Worn or breakage of the center bearing Replace.
Page 481: Repair Instructions
Drive Shaft / Axle: 3A-3 Repair Instructions Front Drive Shaft Components S7RS0B3106001 I6RS0C310003-02...
Page 482: Front Drive Shaft Assembly On-Vehicle Inspection
3A-4 Drive Shaft / Axle: [A]: Right side drive shaft assembly (M/T model) 8. Wheel side joint (Constant velocity ball joint) : Apply black grease included in spare part to joint. [B]: Left side drive shaft assembly (M/T model) 9. Center shaft side joint (Constant velocity tripod joint) : Apply dark gray grease included in spare part to joint.
Page 483 Drive Shaft / Axle: 3A-5 8) Disconnect front suspension control arm ball joint Installation stud from steering knuckle. CAUTION 9) Pull out drive shaft joint as follows. • For differential side • Be careful not to damage oil seals and Using tire lever (1), pull out drive shaft joint (2) so boots when installing drive shaft.
Page 484: Front Drive Shaft Disassembly And Reassembly
3A-6 Drive Shaft / Axle: Front Drive Shaft Disassembly and Reassembly 2) Wipe off grease from shaft and take off snap ring (1) S7RS0B3106004 using snap ring pliers (2). Disassembly Tripod joint CAUTION • Disassembly of wheel side joint is not allowed.
Page 485 Drive Shaft / Axle: 3A-7 CAUTION Disassembly of wheel side joint is not allowed. If any noise or damage exists in it, replace it as assembly. 1) Remove differential side (or center shaft side) boot big band (1) as follows. •...
Page 486 3A-8 Drive Shaft / Axle: Reassembly 1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air. Tripod joint Judging from abnormality noted before disassembly and 2) Clean boots with cloth. what is found through visual check of component parts 3) Apply grease to wheel side joint.
Page 487 Drive Shaft / Axle: 3A-9 7) Fasten boot bands (1) securely using special tool as 8) Set new differential side (or center shaft side) small shown in figure. band and new differential side (or center shaft side) boot (1) on shaft temporarily, and then apply grease Distance “a”...
Page 488 3A-10 Drive Shaft / Axle: 11) Fit boot (1) to grooves of shaft and housing (2) adjust 14) Fasten differential side (or center shaft side) boot length to specification below. band. 12) Insert screw driver into boot and allow air to enter •...
Page 489 Drive Shaft / Axle: 3A-11 Judging from abnormality noted before disassembly and what is found through visual check of components parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that wheel side joint assembly and DOJ housing are washed thoroughly and air dried. Replace boot(s) with new one(s).
Page 490 3A-12 Drive Shaft / Axle: 10) Set new differential side (or center shaft side) small band and new differential side (or center shaft side) boot on shaft temporarily. 11) Drive in the cage (1) by using special tool. Special tool (A): 09913–84510 I5RS0B310011-02 16) Fit boot (1) to grooves of shaft and housing (2) adjust...
Page 491 Drive Shaft / Axle: 3A-13 18) Place differential side boot (or center shaft side) new big band (3) and new small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure. I5JB0A311006-01 19) Fasten differential side (or center shaft side) boot band.
Page 492: Center Shaft And Center Bearing Support Disassembly And Reassembly
Remove bearing support circlip (1) using snap ring pliers (2) and then remove center bearing “A”: Grease 99000–25011 (SUZUKI Super Grease from center bearing support. M/T model a) Remove bearing support circlip (1) using snap ring pliers (2) and then remove center bearing from center bearing support.
Page 493: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Recommended Service Material S7RS0B3108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 NOTE Required service material is also described in the following.
Page 494 3A-16 Drive Shaft / Axle:...
Page 495 Table of Contents 4- i Section 4 Brakes CONTENTS Precautions ..........4-1 Recommended Service Material .......4A-18 Precautions............. 4-1 Front Brakes ..........4B-1 Precautions for Brakes.......... 4-1 Repair Instructions ..........4B-1 Brake Control System and Diagnosis ... 4A-1 Front Disc Brake Components ......4B-1 Front Disc Brake Pad On-Vehicle Inspection..4B-2 Precautions............4A-1 Front Disc Brake Pad Removal and...
Page 496 4-ii Table of Contents Repair Instructions ..........4D-2 DTC U1073: Control Module Communication Parking Brake Inspection and Adjustment ..4D-2 Bus Off ............4E-25 Parking Brake Cable Removal and DTC U1100: Lost Communication with ECM Installation ............4D-3 (Reception Error)..........4E-27 Parking Brake Lever Removal and Installation ..4D-3 Repair Instructions ..........4E-28 Specifications............4D-4 ABS Hydraulic Unit Operation Check....4E-28...
Page 497 Table of Contents 4-iii ABS Warning Lamp Check ....... 4F-14 DTC C1073: Lost Communication With Yaw EBD Warning Lamp (Brake Warning Lamp) Rate / G Sensor Assembly......4F-45 Check.............. 4F-15 DTC C1075 / 1076 / 1078: Sensor Calibration DTC Check ............4F-15 Incomplete............
Page 498: Precautions
4-1 Precautions: Precautions Brakes Precautions Precautions for Brakes S7RS0B4000001 Suspension Caution Refer to “Suspension Caution in Section 00”. Wheels and Tires Caution Refer to “Wheels and Tires Caution in Section 00”. Brake Caution Refer to “Brake Caution in Section 00”. ESP®...
Page 499: Brake Control System And Diagnosis
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brakes Precautions Precautions on Brake S7RS0B4100001 Air Bag Warning Refer to “Air Bag System Service Warning in Section 00”. Brakes Diagnosis Note Refer to “Brakes Diagnosis Note”. General Description Brakes Construction S7RS0B4101001 When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two...
Page 500: Brake Pedal Foot Protection System Construction
4A-2 Brake Control System and Diagnosis: Brake Pedal Foot Protection System Construction S7RS0B4101004 Should a front crash occur and the engine push the dash panel toward the interior side, the brake pedal bracket is also pushed toward the interior side. In this case, the brake pedal lever comes off from the brake pedal, thereby preventing the brake pedal from moving rearward.
Page 501: Front Brake Hose / Pipe Construction
Brake Control System and Diagnosis: 4A-3 Front Brake Hose / Pipe Construction S7RS0B4101002 I7RS0B410003-01...
Page 502: Rear Brake Hose / Pipe Construction
4A-4 Brake Control System and Diagnosis: [A]: ABS model 6. Master cylinder 13. ESP® hydraulic unit [B]: ESP® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft) 1. From master cylinder primary to hydraulic unit 8.
Page 503: Brakes Symptom Diagnosis
Brake Control System and Diagnosis: 4A-5 If deterioration of rubber is evident, disassemble all If master cylinder piston seals are satisfactory, check for hydraulic parts and wash with alcohol. Dry these parts leakage or excessive heat conditions. If leakage is not with compressed air before assembly to keep alcohol out found, drain fluid, flush with brake fluid, refill and bleed of the system.
Page 504 4A-6 Brake Control System and Diagnosis: Condition Possible cause Correction / Reference Item Pedal pulsation (Pedal Damaged or loose wheel bearings Replace wheel bearings. pulsates when depressed Distorted steering knuckle or rear wheel Replace knuckle or rear wheel spindle. for braking) spindle Excessive disc lateral runout Check per instructions.
Page 505: Repair Instructions
Brake Control System and Diagnosis: 4A-7 Repair Instructions Brake Pedal Components 2) Check measurement between booster mounting S7RS0B4106019 surface and center of clevis pin hole. When booster CAUTION push rod clevis has been reinstalled, it is important that the measurement is adjusted (refer to “Brake Never disassemble brake pedalassembly.
Page 506: Excessive Pedal Travel Inspection
4A-8 Brake Control System and Diagnosis: Excessive Pedal Travel Inspection NOTE S7RS0B4106003 Be sure to use particular brake fluid either as 1) Start engine. indicated on reservoir cap of that vehicle or 2) Depress brake pedal a few times. recommended in owner’s manual which 3) With brake pedal depressed with approximately 300 comes along with that vehicle.
Page 507: Air Bleeding Of Brake System
Brake Control System and Diagnosis: 4A-9 Air Bleeding of Brake System 2) Remove bleeder plug cap. Attach a vinyl tube (1) to S7RS0B4106006 bleeder plug, and insert the other end into container CAUTION (2). Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface.
Page 508: Front Brake Hose / Pipe Removal And Installation
4A-10 Brake Control System and Diagnosis: Rear Brake Hose / Pipe Removal and 7) Then attach bleeder plug cap. Installation 8) After completing bleeding operation, apply fluid S7RS0B4106008 pressure to pipe line and check for leakage. CAUTION 9) Replenish fluid into reservoir up to specified level. Do not allow brake fluid to get on painted surfaces.
Page 509: Brake Hose And Pipe Inspection
Brake Control System and Diagnosis: 4A-11 Brake Hose and Pipe Inspection S7RS0B4106009 Hose The brake hose assembly should be checked for road hazard damage, for cracks and chafing of outer cover, for leaks and blisters. A light and mirror may be needed for an adequate inspection.
Page 510: Master Cylinder Assembly Removal And Installation
4A-12 Brake Control System and Diagnosis: Master Cylinder Assembly Removal and 7) Remove master cylinder and master cylinder seal. Installation Installation S7RS0B4106011 1) Install new master cylinder seal. CAUTION 2) Apply small amount of silicon grease (included in Do not allow brake fluid to get on painted spare parts) to piston rod.
Page 511: Master Cylinder Reservoir Removal And Installation
Brake Control System and Diagnosis: 4A-13 7) Remove reservoir bolt (1). 6) Connect clutch reservoir hose (1) to reservoir (2) and install reservoir hose clamp (3) (M/T model). 8) Remove reservoir (2) and grommets (3). I4RS0A410023-01 7) Fill reservoir with specified brake fluid up to its MAX I4RS0A410011-01 mark.
Page 512: Master Cylinder Assembly Disassembly And Assembly
4A-14 Brake Control System and Diagnosis: Assembly 6) Fill reservoir with specified fluid. 7) After completing the work, bleed air from brake and CAUTION clutch system referring to “Air Bleeding of Brake System” and “Air Bleeding of Clutch System in •...
Page 513: Master Cylinder Assembly Inspection
Brake Control System and Diagnosis: 4A-15 Master Cylinder Assembly Inspection 5) Apply small amount of rubber grease (included in spare parts) to mating surface of “a” (piston cup (3) S7RS0B4106014 Inspect all disassembled parts for wear or damage, and and piston guide (1)) and “b” piston guide (1) and O- replace parts if necessary.
Page 514: Booster Operation Inspection
4A-16 Brake Control System and Diagnosis: Booster Operation Inspection Check Operation S7RS0B4106016 1) With engine stopped, depress brake pedal several There are two ways to perform this inspection, with and times with the same load and make sure that pedal without a tester.
Page 515: Brake Booster Removal And Installation
Brake Control System and Diagnosis: 4A-17 2) Hold brake pedal depressed for 30 seconds. If pedal Installation height does not change, condition is good. But it isn’t 1) Loosen brake pedal bracket mounting bolt. if pedal rises. 2) Install booster (2) to dash panel. Then connect push rod clevis (3) to pedal arm with clevis pin (1) and clip (4).
Page 516 4A-18 Brake Control System and Diagnosis: 10) Check pedal height and play referring to “Brake Distance “a” between center of booster clevis pin Pedal Free Height Inspection” and “Brake Pedal hole and booster surface Play Inspection”. Standard: 114.5 – 115.5 mm (4.51 – 4.54 in.) 11) Check each installed part for fluid leakage and perform brake test.
Page 517: Front Brakes
Front Brakes: 4B-1 Front Brakes Brakes Repair Instructions Front Disc Brake Components S7RS0B4206001 I6RS0C420005-02 1. Caliper 9. Disk brake piston 17. Brake flexible hose : Apply brake fluid to contact surface of cylinder. 2. Caliper pin bolt 10. Pad spring : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 3.
Page 518: Front Disc Brake Pad On-Vehicle Inspection
4B-2 Front Brakes: Front Disc Brake Pad On-Vehicle Inspection 3) Remove caliper (1) from caliper carrier (2). S7RS0B4206002 Inspect pad linings (1) periodically according to NOTE maintenance schedule whenever wheels are removed Hang removed caliper (1) with a wire hook (4) (for tire rotation or other reason).
Page 519: Front Disc Brake Pad Inspection
Front Brakes: 4B-3 NOTE 2) Set brake pad springs (1), shim (2) and install brake pads (3). When pads are removed, visually inspect caliper for brake fluid leak. Correct leaky NOTE point, if any. Install right side brake pad with wear indicator (4) to vehicle center side.
Page 520: Front Disc Brake Caliper Disassembly And Assembly
4B-4 Front Brakes: Installation Front Disc Brake Caliper Disassembly and Assembly 1) Torque caliper pin bolts (a) to specification. S7RS0B4206006 NOTE Disassembly • Make sure that boots are fit into groove CAUTION securely. • If brake pads are replaced, use new caliper •...
Page 521 Front Brakes: 4B-5 Assembly 2) Before inserting piston (1) into cylinder, apply rubber Assemble parts in reverse order of disassembly, grease (included in repair kit) or brake fluid to new observing the following instructions. boot “a” and install it onto piston as shown. CAUTION •...
Page 522: Front Disc Brake Caliper Inspection
4B-6 Front Brakes: Front Brake Disc Removal and Installation 5) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not S7RS0B4206008 take it all out. CAUTION NOTE During removal, be careful not to damage brake flexible hose and not to depress brake Boot’s face (1) should be at the same level pedal.
Page 523: Front Brake Disc Inspection
Front Brakes: 4B-7 Front Brake Disc Inspection Installation S7RS0B4206009 1) Install disc to wheel hub. • Install wheel nuts to hub bolts and fasten to fix the 2) Install caliper assembly to steering knuckle. brake disc. 3) Torque caliper carrier bolts to specification. Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of Tightening torque...
Page 524: Specifications
4B-8 Front Brakes: Specifications Tightening Torque Specifications S7RS0B4207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Caliper pin bolt 19.0 Wheel nut 61.5 Flexible hose joint bolt 17.0 Bleeder plug Caliper carrier bolt 61.5 NOTE The specified tightening torque is also described in the following. “Front Disc Brake Components”...
Page 525: Rear Brakes
Rear Brakes: 4C-1 Rear Brakes Brakes Repair Instructions Rear Disc Brake Components S7RS0B4306001 I7RS0B430001-01 1. Caliper 11. Brake caliper carrier 21. Shaft cover : Apply rubber grease. 2. Caliper pin bolt 12. Caliper carrier bolt 22. Lever 3. Boot 13. Rear caliper bleeder plug 23.
Page 526: Rear Disc Brake Pad Removal And Installation
4C-2 Rear Brakes: Rear Disc Brake Pad Removal and Installation Installation S7RS0B4306002 1) Turn brake caliper piston clockwise to obtain NOTE clearance between brake disc and pads. When replacing brake pad, replace it on the Special tool right and left. (A): 09945–16060 Removal 1) Hoist vehicle and remove wheel.
Page 527: Rear Disc Brake Caliper Removal And Installation
Rear Brakes: 4C-3 Rear Disc Brake Caliper Removal and 6) With lug (1) of brake pad matched with dent (2) of brake piston, install caliper (3) to caliper carrier. Installation S7RS0B4306003 7) Tighten caliper pin bolts (4) to specified torque. CAUTION Tightening torque Do not allow brake fluid to get on painted...
Page 528 4C-4 Rear Brakes: 5) Remove caliper pin bolts (1). Installation 6) Remove caliper (2) from brake caliper carrier (3). 1) Install brake caliper carrier (1) to spindle (2). Tightening torque Brake caliper carrier bolt (a): 60 N·m (6.0 kgf-m, 43.5 lb-ft) I6RS0C430008-01 7) Disconnect parking brake cable (1) from lever (2) while rotating lever in direction of arrow.
Page 529 Rear Brakes: 4C-5 4) Pass parking brake cable (1) through bracket (3) of 8) Install brake cable clip (1) securely to bracket (2). caliper. 5) Hang parking brake cable on lever (2) as follows. NOTE Make sure that lever (4) contacts pin (5). I6RS0C430012-01 9) After reassembling brake lines, bleed air from them referring to “Air Bleeding of Brake System in Section...
Page 530: Rear Disc Brake Pad Inspection
4C-6 Rear Brakes: Rear Disc Brake Pad Inspection S7RS0B4306004 Check pad lining for wear. When wear exceeds limit, replace with new one. CAUTION Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc.
Page 531 Rear Brakes: 4C-7 Assembly 4) Install bleeder plug and cap to caliper. 5) Install new piston seal to caliper. CAUTION 6) Before inserting piston (2) into cylinder, install boot • Wash each part cleanly before installation (1) onto piston as shown. in the same fluid as the one used in master cylinder reservoir.
Page 532: Rear Disc Brake Caliper Inspection
4C-8 Rear Brakes: Rear Disc Brake Caliper Inspection Rear Flexible Hose Removal and Installation S7RS0B4306006 S7RS0B4306007 Pin Boot and Cylinder Boot Removal Check boots (1) for breakage, crack and damage. 1) Hoist vehicle and remove tire and wheel. If defective, replace. 2) Remove caliper (4) assembly referring to “Rear Disc Brake Caliper Disassembly and Assembly”.
Page 533: Rear Brake Disc Removal And Installation
Rear Brakes: 4C-9 Rear Brake Disc Removal and Installation Installation S7RS0B4306008 Install in reverse order of removal nothing the following. Removal • Tighten brake disc screws and caliper carrier bolts to 1) Hoist vehicle and remove wheel. specified torque. 2) Remove caliper assembly by removing caliper Tightening torque carrier bolts (1) (2 pcs).
Page 534 4C-10 Rear Brakes: • Using micrometer, measure thickness of brake disc. If limit value is exceeded, replace brake disc. Rear brake disc thickness Standard: 9 mm (0.354 in.) Limit: 8 mm (0.315 in.) I6RS0B431032-01 Specifications Tightening Torque Specifications S7RS0B4307001 Tightening torque Fastening part Note N⋅m...
Page 535: Special Tools And Equipment
Rear Brakes: 4C-11 Special Tools and Equipment Recommended Service Material S7RS0B4308001 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following. “Rear Disc Brake Components”...
Page 536: Parking Brake
4D-1 Parking Brake: Parking Brake Brakes General Description Parking Brake Cable Construction S7RS0B4401001 I6RS0B440001-01 T: Top side 3. Equalizer 8. Lever [C]: View [C] F: Front side 4. Parking cable bracket 9. Parking cable clamp bolt [D]: View [D] R: Right side 5.
Page 537: Repair Instructions
Parking Brake: 4D-2 Repair Instructions Parking Brake Inspection and Adjustment 1) Release parking brake lever (1). S7RS0B4406001 2) Loosen parking brake lever adjust nut (2) fully. Inspection Hold center of parking brake lever grip and pull it up with 200 N (20 kg, 44 lbs) force. With parking brake lever pulled up as shown, count ratchet notches.
Page 538: Parking Brake Cable Removal And Installation
4D-3 Parking Brake: Parking Brake Lever Removal and Installation 6) Release parking brake lever and then make sure that there is no drag in rear wheel. S7RS0B4406003 If there is, repeats go to step 2). Removal 7) Make sure that the number of notch is between 4 1) Remove console box.
Page 539: Specifications
Parking Brake: 4D-4 Installation 2) After all parts are installed, parking brake lever needs to be adjusted. Refer to “Parking Brake 1) Install in reverse order of removal procedure. Inspection and Adjustment”. Check equalizer inclined angle. 3) Check brake drum or disc for dragging and brake Tightening torque system for proper performance.
Page 540: Abs
Mobile Communication Equipment in Section 00” memory can be cleared as well as checked by using before inspection and handle CAN communication SUZUKI scan tool. Before using scan tool, read its line. Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and Precautions in On-Vehicle Service how to use it.
Page 541: General Description
ABS: 4E-2 General Description ABS Description ABS Hydraulic Unit / Control Module Assembly S7RS0B4501001 Description The ABS (Antilock Brake System) controls the fluid S7RS0B4501002 pressure applied to the wheel cylinder of each brake ABS control module is a component of ABS hydraulic from the master cylinder so that each wheel is not locked unit / control module assembly and has the following even when hard braking is applied.
Page 542: Can Communication System Description
4E-3 ABS: CAN Communication System Description S7RS0B4501003 Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. ABS communicates control data with each control module as follows. ABS Transmission Data Combination meter Torque request Wheel speed signal (front right) Wheel speed signal (front left) Wheel speed signal (rear right) ABS control...
Page 543: Schematic And Routing Diagram
ABS: 4E-4 Schematic and Routing Diagram ABS Schematic S7RS0B4502001 INPUT OUTPUT ABS control module Hydraulic unit Wheel speed sensor (LF) Pump motor Wheel speed sensor (LR) Pump motor driver (transistor) Wheel speed sensor (RF) Solenoid valve power supply driver (transistor) Wheel speed sensor (RR) LF inlet solenoid valve Battery Voltage...
Page 544: Abs Wiring Circuit Diagram
4E-5 ABS: 1. ABS hydraulic unit / control module assembly 8. Pump motor 15. Wheel speed sensor (Right-front) 2. ABS control module 9. Stop lamp switch 16. Wheel speed sensor (Left-front) 3. ABS hydraulic unit 10. ABS warning light 17. Wheel speed sensor (Right-rear) 4.
Page 545 ABS: 4E-6 1. Battery 12. Pump motor 23. Internal memory 2. Main fuse box 13. Solenoid valves 24. Solenoid valve driver (transistor) 3. Ignition switch 14. Right-rear wheel speed sensor 25. ECM 4. Circuit fuse box 15. Left-rear wheel speed sensor 26.
Page 546: Component Location
4E-7 ABS: Component Location ABS Components Location S7RS0B4503001 I6RS0C450005-01 1. ABS hydraulic unit / control module assembly 5. EBD warning light (Brake warning light) 2. Wheel speed sensors 6. Wheel speed sensor rings 3. Stop lamp switch 7. Data link connector 4.
Page 547: Rear Wheel Speed Sensor Components Location
ABS: 4E-8 Rear Wheel Speed Sensor Components Location S7RS0B4503003 I6RS0C450006-01 [A]: OK 1. Rear wheel speed sensor 3. Connector : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) [B]: NG 2. Sensor ring 4. Grommet Diagnostic Information and Procedures ABS Check S7RS0B4504001 Refer to the following items for the details of each step.
Page 548 4E-9 ABS: Step Action Check for intermittent problem Go to Step 4. Go to Step 7. 1) Check intermittent troubles referring to “Intermittent and Poor Connection Inspection in Section 00” and related circuit of trouble code recorded in Step 1. Does trouble recur? Final confirmation test Go to Step 3.
Page 549: Abs Warning Light Check
ABS: 4E-10 ABS Warning Light Check Problem symptom confirmation Check if what the customer claimed in “Customer S7RS0B4504002 1) Turn ignition switch ON. Questionnaire” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. 2) Check that ABS warning light (1) comes ON for (This step should be shared with the customer if about 2 seconds and then goes off.
Page 550 Inlet solenoid valve circuit 4) Read DTC according to instructions displayed on C1052 Outlet solenoid valve circuit SUZUKI scan tool and print it or write it down. Refer C1055 Inlet solenoid valve circuit to SUZUKI scan tool operator’s manual for further...
Page 551: Dtc Clearance
SUZUKI turn it) scan tool. • Turn OFF all electric loads (except ignition). 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection • No DTC. for DTC check.
Page 552: Abs Warning Light Does Not Come On At Ignition Switch
4E-13 ABS: ABS Warning Light Does Not Come ON at Ignition Switch ON S7RS0B4504008 Wiring Diagram WHT/RED E03-1 WHT/BLU E03-14 WHT/BLU GRN/ORN E03-7 RED/BLK E03-13 E03-26 BLK/ORN G28-8 G28-10 G37-2 G37-4 E46-1 E03-12 E46-2 E03-6 RED/BLK RED/BLK I6RS0C450007-01 [A]: ABS hydraulic unit / control module connector 5.
Page 553: Abs Warning Light Comes On Steady
ABS: 4E-14 Step Action Check CAN communication circuit between combination Go to Step 5. Repair or replace. meter and ABS control module referring to “DTC U1073: Control Module Communication Bus Off”. Is CAN communication circuit in good condition? 1) Remove combination meter with ignition switch turned Go to Step 6.
Page 554: Ebd Warning Light (Brake Warning Light) Comes On Steady
4E-15 ABS: Step Action 1) Turn ignition switch to OFF and measure resistance Go to Step 6. Ground circuit for ABS between each terminal of “E03-13”, “E03-26” and vehicle hydraulic unit / control body ground. module open or high resistance. Ω...
Page 555: Serial Data Link Circuit Check
ABS: 4E-16 Serial Data Link Circuit Check S7RS0B4504011 WHT/RED E03-1 E03-14 WHT/BLU WHT/BLU E03-7 GRN/ORN RED/BLK E03-13 E03-26 BLK/ORN G28-8 G28-10 G37-2 G37-4 E46-1 E03-12 E46-2 E03-6 PPL/WHT E03-5 I6RS0C450008-01 [A]: ABS hydraulic unit / control module connector (viewed from terminal side) 1.
Page 556: Circuit
4E-17 ABS: Step Action 1) Turn ignition switch to OFF position. Go to Step 6. Ground circuit for ABS hydraulic unit / control 2) Check for proper connection to ABS hydraulic unit / module open or high control module connector at terminals “E03-13” and resistance.
Page 557 ABS: 4E-18 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring S7RS0B4504012 Wiring Diagram E03-7 GRN/ORN E03-22 RED/BLK E03-21 E03-18 E03-19 WHT/BLK LT GRN E03-16 LT GRN/BLK...
Page 558 4E-19 ABS: DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. 1) Disconnect applicable ABS wheel speed sensor coupler Go to Step 3. Replace ABS wheel with ignition switch OFF. speed sensor assembly. 2) Measure resistance between terminals of ABS wheel speed sensor.
Page 559 ABS: 4E-20 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit S7RS0B4504013 Wiring Diagram WHT/BLU E03-14 E03-13...
Page 560: Dtc C1057: Power Source Circuit
4E-21 ABS: DTC C1057: Power Source Circuit S7RS0B4504014 Wiring Diagram WHT/BLU E03-14 E03-13 E03-26 I6RS0C450011-01 [A]: ABS hydraulic unit / control module connector 2. Main fuse box (viewed from terminal side) 1. Battery 3. ABS hydraulic unit / control module assembly DTC Detecting Condition The ABS control module monitors the power source voltage at terminal “E03-14”.
Page 561: Dtc C1061: Abs Pump Motor And/Or Motor Driver Circuit
ABS: 4E-22 Step Action 1) Measure voltage between terminals “E03-14” and “E03- Poor connection of Check charging system 13” with engine running. “E03-14” and/or “E03- referring to “Generator 13” terminals. If the Test (Overcharged ± Is voltage 18 1.0 V or less? terminals are in good Battery Check) in condition, substitute a...
Page 562: Dtc C1063: Solenoid Valve Power Supply Driver Circuit
4E-23 ABS: DTC C1063: Solenoid Valve Power Supply Driver Circuit S7RS0B4504016 Wiring Diagram GRN/ORN E03-7 WHT/BLU WHT/BLU E03-14 I6RS0C450013-01 [A]: ABS hydraulic unit / control module connector 5. Solenoid valve power supply driver (transistor) (viewed from terminal side) 1. Battery 6.
Page 563: Dtc C1071: Abs Control Module
ABS: 4E-24 DTC C1071: ABS Control Module S7RS0B4504017 Wiring Diagram WHT/RED E03-1 E03-14 WHT/BLU E03-13 E03-26 I6RS0C450014-01 [A]: ABS hydraulic unit / control module connector 2. Main fuse box 4. ABS hydraulic unit / control module assembly (viewed from terminal side) 1.
Page 564: Dtc U1073: Control Module Communication Bus Off
4E-25 ABS: DTC U1073: Control Module Communication Bus Off S7RS0B4504018 Wiring Diagram E23-3 E03-10 E23-18 E03-8 C34-17 C37-13 E03-6 C34-7 C37-12 E03-12 E46-1 E46-2 G28-8 G37-4 G28-10 G37-2 G49-19 G28-7 G37-1 WHT/BLK G28-9 G49-18 G37-3 RED/BLK 161514131211 10 9 8 7 1716 1514 1312...
Page 565 ABS: 4E-26 DTC Troubleshooting Step Action Was “ABS Check” performed? Go to Step 2. Go to “ABS Check”. 1) Check connection of connectors of all control modules Go to Step 3. Intermittent trouble. communicating by means of CAN. Check for intermittent 2) Recheck DTC.
Page 566: Dtc U1100: Lost Communication With Ecm (Reception Error)
4E-27 ABS: DTC U1100: Lost Communication with ECM (Reception Error) S7RS0B4504019 Wiring Diagram Refer to “DTC U1073: Control Module Communication Bus Off”. DTC Detecting Condition Reception error of communication data for ECM is detected more than specified time continuously. DTC Troubleshooting Step Action Was “ABS Check”...
Page 567: Repair Instructions
3) Lift up vehicle. Brake pedal (1) should be depressed and then select 4) Set transmission to neutral and release parking testing wheel by SUZUKI scan tool and the wheel (2) brake. should be turned by another person’s hand. At this...
Page 568: Abs Hydraulic Unit / Control Module Assembly Components
4E-29 ABS: ABS Hydraulic Unit / Control Module Assembly Components S7RS0B4506002 CAUTION Never disassemble ABS hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit / control module assembly.
Page 569 ABS: 4E-30 3) Using special tool, loosen flare nuts (1) and 4) Remove ABS hydraulic unit / control module with disconnect brake pipes (2) from ABS hydraulic unit / bracket from vehicle by removing three bracket bolts. control module assembly (3). 5) Remove bolt and pull out ABS hydraulic unit / control module assembly (1) from bracket (3) using flat end Special tool...
Page 570: Front / Rear Wheel Speed Sensor On-Vehicle Inspection
4E-31 ABS: 2) Bleed air from brake system referring to “Air 6) Measure voltage at resistance without wheel Bleeding of Brake System in Section 4A”. rotation. If voltage is out of specification, check sensor, 3) Check each installed part for fluid leakage and mating encoder and their installation conditions.
Page 571: Front Wheel Speed Sensor Removal And Installation
ABS: 4E-32 Front Wheel Speed Sensor Removal and Installation Installation 1) Check that no foreign material is attached to sensor S7RS0B4506006 (1) and sensor ring (2). 2) Install it by reversing removal procedure. Removal 1) Disconnect negative cable from battery. Tightening torque Front wheel speed sensor bolt (a): 25 N·m (2.5 2) Disconnect front wheel speed sensor coupler (1).
Page 572: Rear Wheel Speed Sensor Removal And Installation
4E-33 ABS: Rear Wheel Speed Sensor Removal and Installation Reverse removal procedure for installation noting the Installation following. S7RS0B4506008 • Check that no foreign material is attached to sensor Removal (1) and mating encoder (2). 1) Disconnect negative (–) cable from battery. •...
Page 573: Rear Wheel Speed Sensor Inspection
ABS: 4E-34 Rear Wheel Speed Sensor Inspection Rear Wheel Encoder On-Vehicle Inspection S7RS0B4506009 S7RS0B4506012 Refer to “Front Wheel Speed Sensor Inspection” since Before inspect rear wheel encoder, hoist vehicle and rear wheel speed sensor is the same as front wheel remove wheel.
Page 574: Specifications
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Special Tools and Equipment Special Tool S7RS0B4508001 09950–78220 SUZUKI scan tool Flare nut wrench (10 mm) — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3.
Page 575: Electronic Stability Program
• Diagnostic information stored in ESP® control module memory can be cleared as well as checked by using SUZUKI scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it.
Page 576: Precautions In Speedometer Test Or Other Tests
ESP® OFF switch or using SUZUKI scan tool to complete the tests correctly. When using SUZUKI scan tool, set to the “MISC. TEST” mode to stop the ESP® function. Refer to SUZUKI scan tool operator's manual for further details.
Page 577: Electronic Stability Program Construction
Electronic Stability Program: 4F-3 Electronic Stability Program Construction S7RS0B4601007 I7RS0B460001-03 1. ESP® control module 6. Steering angle sensor 11. ESP® OFF switch 2. Hydraulic unit 7. Stop lamp switch 12. Electronic signal 3. ECM 8. Yaw rate / G sensor 13.
Page 578 4F-4 Electronic Stability Program: I7RS0B460002-01 1. Master cylinder 5. Brake caliper (rear-left) 9. Outlet solenoid valve 2. Brake caliper (front-right) 6. Pump motor 10. Cut solenoid valve 3. Brake caliper (front-left) 7. Brake master cylinder pressure sensor 11. Low pressure solenoid valve 4.
Page 579: Esp® Hydraulic Unit / Control Module Assembly Description
Electronic Stability Program: 4F-5 Yaw rate / G sensor The yaw rate / G sensor consists of the yaw rate (angular velocity in the vehicle turning direction) sensor and right-left G (acceleration in right-left direction) sensor and is mounted to the P/S controller B/K at the lower part of the center console.
Page 580: Warning Lamp, Indicator Lamp Description
4F-6 Electronic Stability Program: Warning Lamp, Indicator Lamp Description S7RS0B4601003 There are five types of warning lamp and indicator lamp in instrument cluster, which are controlled by ESP® control module. They give warning / indication to driver by changing the modes light ON / blinking / light OFF. I6RS0B460002-01 1.
Page 581: Can Communication System For Electronic Stability Program Description
Electronic Stability Program: 4F-7 ESP® Control Module Reception Data Steering angle sensor Engine torque signal Accelerator pedal position signal Engine speed signal Brake pedal switch signal ESP® control Receive DATA module Brake fluid level switch signal Parking brake switch signal Steering angle signal Steering angle sensor related malfunction I7RS0B460005-01...
Page 582: Schematic And Routing Diagram
4F-8 Electronic Stability Program: Schematic and Routing Diagram Electronic Stability Program Schematic S7RS0B4602001 INPUT OUTPUT ESP® hydraulic unit/control module assembly Hydraulic unit Master cylinder pressure sensor ESP® control module Pump motor driver Pump motor (transistor) Solenoid valve power supply driver (transistor) Battery Voltage LF inlet solenoid valve LF outlet solenoid valve...
Page 583: Electronic Stability Program Wiring Circuit Diagram
Electronic Stability Program: 4F-9 Electronic Stability Program Wiring Circuit Diagram S7RS0B4602002 WHT/RED E85-32 E85-1 WHT/BLU WHT/BLU GRN/ORN E85-35 RED/BLK GRN/ORN WHT/RED PPL/WHT E85-33 RED/BLK RED/BLK PPL/WHT E85-13 E85-44 BLK/ORN GRN/WHT BLK/ORN E85-42 E85-46 BLU/RED E85-37 GRN/BLK E85-31 RED/BLK E85-29 WHT/BLK E85-25 E85-14 RED/BLK...
Page 584 4F-10 Electronic Stability Program: 7. Combination meter 20. Brake fluid level switch 33. Pump motor driver (transistor) 8. SLIP indicator lamp 21. Parking brake switch 34. Pump motor 9. ESP® OFF lamp 22. Yaw rate / G sensor assembly 35. Solenoid valve power supply driver (transistor) 10.
Page 585: Component Location
Electronic Stability Program: 4F-11 Component Location Electronic Stability Program Component Location S7RS0B4603001 I7RS0B460008-02 1. ABS fuse 7. Steering angle sensor 13. Encoder 2. ESP® warning lamp 8. ESP® hydraulic unit / control module 14. Yaw rate / G sensor 3. ESP® OFF lamp 9.
Page 586: Diagnostic Information And Procedures
4F-12 Electronic Stability Program: Diagnostic Information and Procedures Electronic Stability Program System Check S7RS0B4604001 Refer to the following items for the details of each step. Step Action Malfunction analysis Go to Step 4. Go to Step 2. 1) Perform “Customer complaint analysis: ”. 2) Perform “Problem symptom confirmation: ”.
Page 587 Electronic Stability Program: 4F-13 Customer questionnaire (Example) I6JB01460011-02 Problem symptom confirmation If symptom in “Customer Questionnaire” is found or reproduced in the vehicle, confirm the symptom is problem or not. (This step should be done with the customer if possible.) Check warning lamps related to brake system referring to “EBD Warning Lamp (Brake Warning Lamp) Check”, “ABS Warning Lamp Check”...
Page 588: Esp® Warning Lamp Check
4F-14 Electronic Stability Program: Step 2: Driving Test Test the vehicle at 40 km/h for more than a minute including left and right turns and check if any trouble symptom (such as ESP® warning lamp and/or ABS warning lamp) exists. If the malfunction DTC is confirmed at ignition switch ON, proceed to Step 3.
Page 589: Ebd Warning Lamp (Brake Warning Lamp) Check
I4RS0B450003-01 3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on I4RS0A450008-01 SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. NOTE If SUZUKI scan tool can not communicate ESP®...
Page 590 4F-16 Electronic Stability Program: DTC (displayed ESP® Detecting condition (DTC will on SUZUKI scan Diagnostic Items warning warning warning beset when detecting) tool) lamp lamp lamp Right-front wheel speed Abnormal wheel speed sensor C1022 sensor or encoder failure signal is detected.
Page 591 Electronic Stability Program: 4F-17 DTC (displayed ESP® Detecting condition (DTC will on SUZUKI scan Diagnostic Items warning warning warning beset when detecting) tool) lamp lamp lamp Right-front inlet solenoid C1041 valve circuit failure Right-front outlet solenoid C1042 valve circuit failure...
Page 592: Dtc Clearance
When performing a driving test, select a safe place where there is neither any traffic nor any traffic accident possibility and be very careful during testing to avoid occurrence of an accident. 1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection for DTC check.
Page 593: Fail-Safe Table
Electronic Stability Program: 4F-19 Fail-Safe Table S7RS0B4604023 When any of the following DTC(s) is detected, ESP® system is in fail-safe mode per its DTC and ABS, EBD and/or TCS / stability functions are deactivated until the resolution is applied. Fail-safe operation DTC No.
Page 594: Scan Tool Data
4F-20 Electronic Stability Program: NOTE • : Activated • X: Deactivated • *1: If two or more wheel speed sensor are defective, ABS warning lamp, EBD warning lamp and ESP® warning lamp are lit and all the control functions are deactivated. If one wheel speed sensor is defective, ABS warning lamp and ESP®...
Page 595: Visual Inspection
Electronic Stability Program: 4F-21 Stability control (ACTIVE, INACTIVE): This indicates ESP® off state (cont) (ESP® ON, ESP® OFF): State stability control in activation / deactivation. of ESP® OFF switch. TCS control (brake) (ACTIVE, INACTIVE): This Steering angle Sen (Neutral, NON newtral): This indicates brake function of TCS in activation / indicates steering wheel angle measured by steering deactivation.
Page 596: Esp® Warning Lamp Comes On Steady
4F-22 Electronic Stability Program: Troubleshooting Step Action Check warning lamp Substitute a known- Go to Step 2. good combination meter 1) Turn ignition switch to ON position. and recheck. If ESP® Do other warning lamps come ON? warning lamp remains OFF, substitute a known-good ESP®...
Page 597: Abs Warning Lamp Does Not Come On At Ignition Switch
Electronic Stability Program: 4F-23 Step Action Check ESP® control module power supply circuit Go to Step 5. “WHT/BLU” and/or “WHT/RED” circuit 1) Turn ignition switch to OFF position. open. 2) Check for proper connection to ESP® control module connector at terminals “E85-1” and “E85-32”. 3) If OK, then turn ignition switch to ON position and measure voltage between each terminal of “E85-1”, “E85-32”...
Page 598: Abs Warning Lamp Comes On Steady
4F-24 Electronic Stability Program: Circuit Description Operation (ON/OFF) of ABS warning lamp is controlled by ESP® control module through lamp driver module in combination meter. If antilock brake system is in good condition, ESP® control module turns ABS warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.
Page 599 Electronic Stability Program: 4F-25 Circuit Description EBD warning lamp (brake warning lamp) is controlled by ESP® control module and BCM through lamp driver module in combination meter. If EBD system is in good condition, ESP® control module turns EBD warning lamp ON at the ignition switch ON, keeps it ON for 2 seconds and then turns it OFF.
Page 600: Serial Data Link Circuit Check
4F-26 Electronic Stability Program: Serial Data Link Circuit Check S7RS0B4604012 Wiring Diagram WHT/RED E85-32 WHT/BLU E85-1 GRN/ORN E85-35 WHT/RED PPL/WHT E85-33 PPL/WHT RED/BLK E46-1 E85-13 E46-2 E85-44 G37-4 E85-16 G37-2 E85-47 G28-31 G28-10 G28-8 G28-16 BLK/ORN I6RS0B460012-01 [A]: ESP® control module connector (viewed 4.
Page 601 Electronic Stability Program: 4F-27 Step Action Check ESP® control module power supply circuit Go to Step 5. “WHT/BLU” and/or “WHT/RED” wire circuit 1) Turn ignition switch to OFF position. open. 2) Check for proper connection to ESP® control module connector at terminals “E85-1” and “E85-32”. 3) If OK, then turn ignition switch to ON position and measure voltage between each terminal of “E85-1”, “E85-32”...
Page 602: Dtc C1016: Stop Lamp Switch Circuit Failure
4F-28 Electronic Stability Program: Step Action Check serial data circuit Substitute a known- Check high resistance good ESP® hydraulic or open in “PPL/WHT” 1) Turn ignition switch to OFF position. unit / control module wire circuit for electronic 2) Check proper connection at “E85-33” (“PPL/WHT” wire) and recheck.
Page 603: Dtc C1017 / C1023: Yaw Rate / G Sensor Assembly Failure
Electronic Stability Program: 4F-29 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Vehicle behavior and stop lamp switch signal is disagreed • Back up light switch circuit for specified time. • Back up light switch • ECM •...
Page 604: Dtc C1018: Brake Fluid Level Switch Failure
4F-30 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 605: Dtc 1020: Master Cylinder Pressure Sensor Power Supply Failure
Electronic Stability Program: 4F-31 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check brake fluid level Go to Step 3. Replenish brake fluid to reservoir. 1) Check brake fluid level in reservoir. Is brake fluid level upper than the minimum level? DTC check for ESP®...
Page 606: Dtc C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed Sensor Circuit Or Encoder Failure
4F-32 Electronic Stability Program: DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed Sensor Circuit or Encoder Failure S7RS0B4604051 DTC C1021 / C1025 / C1031 / C1035: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit Failure DTC C1022 / C1026 / C1032 / C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor or Encoder Failure...
Page 607 Electronic Stability Program: 4F-33 Step Action Check wheel speed sensor circuit Go to Step 3. Repair or replace defective circuit. 1) Turn ignition switch OFF. 2) Disconnect connector from ESP® control module and applicable wheel speed sensor coupler. 3) Check for proper connection of ESP® control module and wheel speed sensor coupler.
Page 608: Dtc C1024: Steering Angle Sensor Circuit Failure
4F-34 Electronic Stability Program: Step Action Check wheel speed sensor Substitute a known- Replace wheel speed good ESP® hydraulic sensor and recheck. 1) Refer to “Front / Rear Wheel Speed Sensor On-Vehicle unit / control module Inspection”, check output voltage or waveform. assembly and recheck.
Page 609: Dtc C1028: Master Cylinder Pressure Sensor Circuit Failure
Electronic Stability Program: 4F-35 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Mechanical switch failure, failure in switch wiring is • ESP® OFF switch shorted to ground. • ESP® OFF switch circuit • ESP® control module DTC Troubleshooting Step Action Was “Electronic Stability Program Check”...
Page 610: Dtc C1034: Yaw Rate / G Sensor Assembly Power Supply Failure
4F-36 Electronic Stability Program: DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure S7RS0B4604032 Wiring Diagram WHT/RED E85-32 E85-1 WHT/BLU E85-35 GRN/ORN E84-2 RED/BLK E85-29 E84-1 WHT/BLK E85-25 E84-3 BLU/RED E85-37 GRN/BLK E84-5 E85-31 E85-16 E85-47 I7RS0B460009-01 [A]: ESP® control module connector (viewed from terminal side) 2.
Page 611: Dtc C1037: Steering Angle Sensor Power Supply Failure
Electronic Stability Program: 4F-37 Step Action Check yaw rate / G sensor assembly power supply Go to Step 5. “BLU/RED” wire circuit circuit is shorted to power circuit. 1) Turn ignition switch to OFF position. 2) Disconnect ESP® control module connector. 3) Check for proper connection to ESP®...
Page 612: Dtc C1038: Steering Angle Sensor Detect Rolling Counter Failure From Esp® Control Module
4F-38 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2 Go to “Electronic Stability Program System Check”. Check fuse Go to Step 3. Replace fuse and check for short circuit to 1) Check circuit fuses for steering angle sensor and its ground.
Page 613: Dtc C1039: Yaw Rate / G Sensor Assembly Internal Failure
Electronic Stability Program: 4F-39 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check DTC Go to applicable DTC Substitute a known- diag. flow. good steering angle 1) Connect scan tool to DLC with ignition switch turned sensor and recheck.
Page 614: Dtc C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Solenoid Circuit Failure
4F-40 Electronic Stability Program: DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Solenoid Circuit Failure S7RS0B4604052 DTC C1041 / C1045 / C1051 / C1055: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit Failure DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit Failure...
Page 615: Dtc C1057: Esp® Control Module Power Supply Circuit Failure
Electronic Stability Program: 4F-41 DTC C1057: ESP® Control Module Power Supply Circuit Failure S7RS0B4604053 Wiring Diagram WHT/BLU E85-1 E85-16 E85-47 I6RS0B460023-02 [A]: ESP® control module connector (viewed from terminal side) 2. Main fuse box 1. Battery 3. ESP® hydraulic unit / control module assembly DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area...
Page 616: Dtc C1061: Pump Motor And/Or Motor Driver Circuit Failure
4F-42 Electronic Stability Program: Step Action Check power supply circuit from battery Poor connection of Check charging system “E85-1”, “E85-16” and/ referring to “Generator 1) Measure voltage between terminals “E85-1” and “E85- or “E85-47” terminals. If Test (Overcharged 16”, “E85- 47" with engine running. the terminals are in Battery Check) in ±...
Page 617: Dtc C1063: Solenoid Valve Power Supply Driver Circuit Failure
Electronic Stability Program: 4F-43 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check ESP® control module power supply circuit Go to Step 3. “WHT/RED” circuit open. 1) Turn Ignition switch to OFF position. 2) Disconnect ESP®...
Page 618: Dtc 1071: Esp® Control Module Internal Defect
4F-44 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. Check power supply circuit from battery Go to Step 3. Check charging system referring to “Battery 1) Check battery voltage.
Page 619: Dtc C1073: Lost Communication With Yaw Rate / G Sensor Assembly
Electronic Stability Program: 4F-45 DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly S7RS0B4604038 Wiring Diagram E84-2 RED/BLK E85-29 E84-1 E85-25 WHT/BLK E84-3 BLU/RED E85-37 GRN/BLK E84-5 E85-31 I7RS0B460010-01 [A]: ESP® control module connector (viewed from 1. Yaw rate / G sensor assembly 3.
Page 620: Dtc C1075 / 1076 / 1078: Sensor Calibration Incomplete
4F-46 Electronic Stability Program: Step Action Check yaw rate / G sensor assembly Check ESP® control Yaw rate / G sensor module power and assembly was 1) Check yaw rate / G sensor assembly power and ground ground circuit. If circuits malfunction.
Page 621: Dtc C1090: Invalid Communication With Ecm
Electronic Stability Program: 4F-47 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to applicable DTC Go to Step 3. diag. flow. 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 622: Dtc C1091 / C1094: Ecm Data In Can Line Failure / Invalid Torque Control Communication With Ecm
4F-48 Electronic Stability Program: DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control Communication with S7RS0B4604041 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area C1091: • Engine control system ECM sent invalid signal to ESP® control module. •...
Page 623 Electronic Stability Program: 4F-49 DTC U1073: Control Module Communication Bus Off S7RS0B4604057 Wiring Diagram E23-3 E23-18 G50-9 G50-10 E85-46 E85-42 G28-8 G28-10 E85-13 E85-44 G28-9 G28-7 E46-2 E46-1 G42-19 G37-4 G42-18 G37-2 3938 32 31 5453 47 46 10 9 3 2 1 34 33 32 31 30 29 24 23...
Page 624: Dtc U1100: Lost Communication With Ecm (Reception Error)
4F-50 Electronic Stability Program: DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to Step 3. Intermittent trouble. Check for intermittent 1) Check connection of connectors of all control modules referring to “Intermittent communicating by means of CAN.
Page 625: Dtc U1126: Lost Communication With Steering Angle Sensor (Reception Error)
Electronic Stability Program: 4F-51 Step Action Check each control module connectors Go to Step 5. Check for intermittent trouble referring to 1) Check connection of connectors of all control modules “Intermittent and Poor communicating by means of CAN. Connection Inspection 2) Check DTC for ESP®.
Page 626: Dtc U1140: Lost Communication With Bcm (Reception Error)
4F-52 Electronic Stability Program: Step Action Check each control module connectors Go to Step 4. Check for intermittent trouble referring to 1) Check connection of connectors of all control modules “Intermittent and Poor communicating by means of CAN. Connection Inspection 2) Check DTC for ESP®.
Page 627 Electronic Stability Program: 4F-53 DTC Troubleshooting Step Action Was “Electronic Stability Program Check” performed? Go to Step 2. Go to “Electronic Stability Program System Check”. DTC check for ESP® Go to “DTC U1073: Go to Step 3. Control Module 1) Check DTC for ESP®. Communication Bus Is DTC U1140 and DTC U1073 detected together? Off”.
Page 628: Repair Instructions
Step off brake pedal (1) and then select testing 1) Check that basic brake system other than ESP® is wheel by SUZUKI scan tool and the wheel (2) in good condition. should be turned by another person’s hand. At this time, check whether the wheel locks due to brake 2) Check that battery voltage is 11 V or higher.
Page 629: Esp® Hydraulic Unit / Control Module Assembly On-Vehicle Inspection
SUZUKI Scan Tool) 1) Set steering wheel in straight-ahead position. 1) Set steering wheel in straight-ahead position. 2) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. 2) Connect battery terminals and/or fuse and start engine.
Page 630: Esp® Hydraulic Unit / Control Module Assembly Removal And Installation
4F-56 Electronic Stability Program: ESP® Hydraulic Unit / Control Module Assembly Removal and Installation S7RS0B4606037 CAUTION Never disassemble ESP® hydraulic unit / control module assembly loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ESP® hydraulic unit / control module assembly.
Page 631: Front / Rear Wheel Speed Sensor On-Vehicle Inspection
[A]: Front wheel speed sensor 3. “WHT” wire terminal [B]: Rear wheel speed sensor 4. “BLK” wire terminal 4) Connect SUZUKI Scan Tool. 1. Wheel speed sensor connector 5. Power supply (12 V) 5) Turn ignition switch to ON position. And SLIP 2.
Page 632: Front Wheel Speed Sensor Removal And Installation
4F-58 Electronic Stability Program: Front Wheel Speed Sensor Removal and 6) Measure voltage at resistance without wheel rotation. Installation If voltage is out of specification, check sensor, S7RS0B4606029 mating encoder and their installation conditions. Removal Voltage at the resistance (115 Ω) without wheel 1) Disconnect negative (–) cable from battery.
Page 633: Front Wheel Speed Sensor Inspection
Electronic Stability Program: 4F-59 Front Wheel Speed Sensor Inspection Installation S7RS0B4606030 Check sensor for damage. CAUTION If any malcondition is found, replace. Do not pull or twist wire harness more than necessary when installing front wheel speed sensor. 1) Check that no foreign material is attached to sensor(1) and mating encoder (2).
Page 634: Rear Wheel Speed Sensor Inspection
4F-60 Electronic Stability Program: 4) Hoist vehicle and remove wheel. 5) Remove harness clamp (1) and clamp bolts (2). 6) Remove rear wheel speed sensor (3) from knuckle. I6RS0B460036-02 Installation I6RS0B460037-02 CAUTION [A]: OK [B]: NG Do not pull or twist wire harness more than necessary when installing rear wheel speed Rear Wheel Speed Sensor Inspection sensor.
Page 635: Front Wheel Encoder On-Vehicle Inspection
If front wheel encoder needs refer to “Brakes Diagnosis Note in Section 4A”. to replaced, replace it as a front wheel 3) Connect SUZUKI scan tool to data link connector bearing. (DLC) (1) with ignition switch OFF. Special tool...
Page 636: Yaw Rate / G Sensor Assembly On-Vehicle Inspection
Right-up condition “DATA LIST” of SUZUKI scan tool. –0.1 ± 0.1 G Left-up condition If pressure displayed on SUZUKI scan tool is out of specification, replace ESP® hydraulic unit / control module assembly. Master cylinder pressure specification Brake pedal depressed 10 MPa (100 kg/cm , 1422 psi): 10 ±...
Page 637: Yaw Rate / G Sensor Assembly Removal And Installation
1) Calibrate yaw rate / G sensor assembly referring to “Sensor Calibration”. 2) Check yaw rate / G sensor assembly installation condition. 3) Connect SUZUKI scan tool to data link connector “a” (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool “a”...
Page 638: Yaw Rate / G Sensor Inspection
Before each inspection, confirm steering angle sensor calibration is completed. If calibration is incompleted, calibrate sensor referring to “Sensor Calibration”. 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool I6RS0B460041-02 3) Connect connector to yaw rate / G sensor assembly.
Page 639: Steering Angle Sensor Removal And Installation
2) Remove rear console box referring to “Console Box 3) Check “Steering angle Sen” under “DATA LIST” of Components in Section 9H”. SUZUKI scan tool in the following steering wheel conditions. 3) Disconnect ESP® OFF switch coupler. • Front wheels in straight-ahead position 4) Remove ESP®...
Page 640: Specifications
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation” Special Tools and Equipment Special Tool S7RS0B4608001 09956–02311 SUZUKI scan tool Brake pressure gauge — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5.
Page 641 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 No Gear Shift to 4th gear ........5A-41 No Lock-Up Occurs...........5A-42 Precautions............. 5-1 Transmission Warning Light Circuit Check – Precautions on Transmission / Transaxle ..... 5-1 Light Does Not Come “ON” at Ignition Switch Automatic Transmission/Transaxle..
Page 642 5-ii Table of Contents DTC P1878: Torque Converter Clutch Automatic Transaxle Unit Disassembly...5A-110 Shudder ............5A-75 Oil Pump Assembly Components ....5A-121 DTC P2762: Torque Converter Clutch (TCC) Oil Pump Assembly Disassembly and Pressure Control Solenoid Control Circuit Reassembly ..........5A-122 Range /Performance ........5A-76 Oil Pump Assembly Inspection .......5A-122 DTC P2763: Torque Converter Clutch Direct Clutch Assembly Components....5A-124...
Page 643 Table of Contents 5-iii Gear Shift Control Lever and Cable Special Tool ............5B-36 Components............5B-5 Clutch ............5C-1 Gear Shift Control Lever and Cable Removal and Installation ..........5B-6 General Description ..........5C-1 Gear Select Control Cable Adjustment ....5B-6 Clutch Construction..........5C-1 Back Up Light Switch Removal and Diagnostic Information and Procedures ....5C-2 Installation ............
Page 644: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions on Transmission / Transaxle S7RS0B5000001 Air Bag Warning Refer to “Air Bag System Service Warning in Section 00”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 5A”. Precautions for Disassembly and Reassembly Refer to “Precautions for Disassembly and Reassembly in Section 5A”.
Page 645 • Diagnostic information stored in TCM memory can be may occur and often time would be wasted. cleared as well as checked by using SUZUKI scan As the automatic transaxle consists of high precision tool or generic scan tool. Before using scan tool, read component, the following cautions should be strictly its Operator’s (Instruction) Manual carefully to have...
Page 646 5A-2 Automatic Transmission/Transaxle: • A new discs should be soaked in ATF at least 2 hours CAUTION before use. • Keep component parts in group for each subassembly and avoid mixing them up. Part Inspection and Correction Table • Clean all parts with cleaning solvent Part Inspect for Correction...
Page 647: General Description
Automatic Transmission/Transaxle: 5A-3 General Description A/T Description S7RS0B5101001 This automatic transaxle is electronic control full automatic transaxle with forward 4-speed and reverse 1-speed. The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an automatically controlled lock-up mechanism.
Page 648 5A-4 Automatic Transmission/Transaxle: 20 21 22 I3RM0B510001-01 1. Drive plate 11. 1st and reverse brake 21. Rear sun gear 2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear 3. Torque converter 13. Long planet pinion 23. Short planet pinion 4.
Page 649 Wet type multiple-disc brake... 3 sets One-way clutch... 2 sets Reduction gear ratio 1.023 Final gear reduction ratio 4.277 Lubrication Lubrication system Force feed system by oil pump Cooling Cooling system Radiator assisted cooling (water-cooled) Fluid used SUZUKI ATF 3317 or Mobil ATF 3309...
Page 650: Clutch / Brake / Planetary Gear Function Of Automatic Transaxle
5A-6 Automatic Transmission/Transaxle: Clutch / Brake / Planetary Gear Function of Automatic Transaxle S7RS0B5101002 I4RS0A510001-01 1. Input shaft and intermediate shaft 6. Long planet pinion 11. O/D and 2nd coast brake 16. Rear sun gear 2. Direct clutch 7. 1st and reverse brake 12.
Page 651: Table Of Component Operation
Automatic Transmission/Transaxle: 5A-7 Table of Component Operation S7RS0B5101003 Part Selector Gear Shift solenoid Shift solenoid TCC solenoid Forward Reverse position position Direct clutch valve-A (No.1) valve-B (No.2) valve clutch clutch × × × × Parking × × × Reverse × ×...
Page 652: Brake Interlock System Construction
DTC in its memory. slot unless select lever is in “P” range. • It is possible to communicate with TCM through data link connector (DLC) (3) by using SUZUKI scan tool Shift Lock Solenoid Manual Release (2). Diagnostic information can be checked and When push down shift lock solenoid valve release button erased by using SUZUKI scan tool.
Page 653: Can Communication System Description
Automatic Transmission/Transaxle: 5A-9 CAN Communication System Description S7RS0B5101007 Refer to “CAN Communication System Description in Section 1A” for CAN communication System description. TCM communicates control data with each control module as follows. TCM Transmission Data Combination meter Transmission oil temperarure signal Torque request signal Vehicle speed pulse signal...
Page 654: Schematic And Routing Diagram
5A-10 Automatic Transmission/Transaxle: Schematic and Routing Diagram Transmission Control Module (TCM) Wiring Diagram S7RS0B5102001 C35-6 LT GRN C34-11 C35-16 2.5V C34-12 BLK/RED C35-25 C34-16 BLK/ORN C34-15 BLK/YEL C34-7 C34-17 C34-14 BLU/BLK WHT/BLU C34-5 C34-3 WHT/BLK C34-4 C34-2 LT GRN/BLK LT GRN C34-24 WHT/RED C35-20...
Page 655 Automatic Transmission/Transaxle: 5A-11 Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve Solenoid Select Shift Shift Gear Timing lever solenoid solenoid Condition position solenoid solenoid position valve-A valve-B valve valve (No.1) (No. 2) × × Parking When vehicle is travelling forwards in ×...
Page 656: Automatic Gear Shift Table
5A-12 Automatic Transmission/Transaxle: Automatic Gear Shift Table S7RS0B5102002 Automatic gear shift schedule is shown in the following table. Test-drive the vehicle on a flat road in the D, 3, 2 position. 1. Shift Point in D, 3 or 2 position Throttle opening (%) Shift Vehicle speed km/h (mph)
Page 657: Component Location
Automatic Transmission/Transaxle: 5A-13 Component Location Electronic Shift Control System Components Location S7RS0B5103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RS0C510006-01 1. Engine 8. TCC pressure control solenoid valve (TCC 15.
Page 658 5A-14 Automatic Transmission/Transaxle: 6. Output shaft speed sensor 13. Shift solenoid valve-A (No.1) 20. Transmission warning light 7. Input shaft speed sensor 14. Transmission range sensor INPUT OUTPUT -Engine torque -ATF temp. -Engine speed -Torque request Gear shift control -Throttle position -Vehicle speed pulse -A/C compressor clutch -Transmission actual gear...
Page 659: Diagnostic Information And Procedures
Automatic Transmission/Transaxle: 5A-15 Diagnostic Information and Procedures A/T System Check S7RS0B5104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis. Was customer complaint analysis performed? DTC / freeze frame data check, record and clearance Print DTC or write them...
Page 660 5A-16 Automatic Transmission/Transaxle: Step 1. Customer Complaint Analysis Record details of the problem such as failure, complaint and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 661 Automatic Transmission/Transaxle: 5A-17 Step 2. DTC / Freeze Frame Data Check, Record and Clearance First, referring to “DTC Check”, check DTC and pending DTC. If DTC exists, print or write down DTC and freeze frame data and then clear malfunction DTC(s) by referring to “DTC Clearance”. Malfunction DTC indicates malfunction in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in the past and normal condition has been restored.
Page 662 5A-18 Automatic Transmission/Transaxle: Visual Inspection S7RS0B5104002 Visually check the following parts and systems. Inspection item Referring • A/T fluid ----- level, leakage, color “Automatic Transaxle Fluid Level Inspection in Section 0B” • A/T fluid hoses ----- disconnection, looseness, deterioration “A/T Fluid Cooler Hoses Replacement” •...
Page 663: Dtc Table
Automatic Transmission/Transaxle: 5A-19 DTC Table S7RS0B5104005 NOTE • A: Driving cycles when transmission warning light lighting and storing DTC in TCM memory. • *1: Transmission warning light does not light up but TCM detects and stores DTC. • For details of driving cycle, refer to “On-Board Diagnostic System Description”. Detecting condition DTC No.
Page 664: Dtc Check
TCM connector). • When the same malfunction (DTC) is not detected again during 40 engine warm-up cycles. 1) Turn ignition switch OFF. 2) Connect SUZUKI scan tool to data link connector (DLC) (1). Special tool I4RS0B510004-01 (A): SUZUKI scan tool 3) Read DTC according to instructions displayed on SUZUKI scan tool and write it down.
Page 665: Fail-Safe Table
Automatic Transmission/Transaxle: 5A-21 Fail-Safe Table S7RS0B5104008 This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sensor or its circuit fails. The following table shows the fail-safe function for each fail condition of sensor, solenoid or its circuit. DTC No.
Page 666 5A-22 Automatic Transmission/Transaxle: DTC No. Trouble area Fail-safe operation • Power supply for all solenoid valves is cut. • Gear position is fixed in 3rd gear. Internal control module memory check P1702 sum error • Line pressure control at gear shifting is inhibited. •...
Page 667: Scan Tool Data
Automatic Transmission/Transaxle: 5A-23 DTC No. Trouble area Fail-safe operation • Throttle opening used for line pressure control is assumed to be 100%. • Throttle opening used for gear shifting control is assumed to be 0%. • Engine revolution is assumed to be 0 RPM. •...
Page 668 5A-24 Automatic Transmission/Transaxle: Normal condition / reference Scan tool data Vehicle condition values ENGINE SPEED At engine idle speed Engine idle speed is displayed Ignition switch ON and engine stop 0 RPM INPUT SHAFT At 60 km/h (37.5 mile/h) constant speed, 20% or less 2300 RPM REVOLUTION throttle opening and 3rd gear (“3”...
Page 669 Automatic Transmission/Transaxle: 5A-25 Normal condition / reference Scan tool data Vehicle condition values While on gear upshifting with 25% or more throttle TORQUE opening REDUCTION SIGNAL Under condition of not shifting gear ENGINE COOLANT Engine coolant temperature is Ignition switch ON TEMPERATURE displayed AIR CONDITIONER...
Page 670: A/T Basic Check
5A-26 Automatic Transmission/Transaxle: TRANSAXLE RANGE AIR CONDITIONER SIGNAL Transaxle range detected by signal fed from ON: Signal which inform that air conditioner compressor transmission range sensor. is turned ON. OFF: Signal which inform that air conditioner D RANGE SIGNAL compressor is not turned ON. ON: Signal which TCM require ECM to increase idle speed ENGINE TORQUE SIGNAL (N⋅m)
Page 671: Road Test
Automatic Transmission/Transaxle: 5A-27 Step Action Proceed to “Trouble Diagnosis 2” in “A/T Symptom Repair or replace faulty Proceed to “Trouble Diagnosis”. parts. Diagnosis 3” in “A/T Symptom Diagnosis”. Is trouble identified? Road Test S7RS0B5104011 This test is to check if upshift, downshift and lock-up take place at specified speeds while actually driving vehicle on a level road.
Page 672 5A-28 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → 4 upshift fails to Malfunction of shift solenoid valve-B Inspect. If NG, replace. occur Malfunction of “3” position switch Inspect. If NG, replace. Malfunction of engine coolant Inspect. If NG, replace. temperature sensor Malfunction of output shaft speed Inspect.
Page 673: Manual Road Test
Automatic Transmission/Transaxle: 5A-29 Condition Possible cause Correction / Reference Item TCC (lock-up) function Malfunction of TCC pressure control Inspect. If NG, replace. pressure control does not solenoid valve operate Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of brake light switch Inspect.
Page 674: Engine Brake Test
5A-30 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item Operated gear is not Faulty valve body component Replace valve body assembly. correct Faulty clutch or brake Inspect clutch and brake. If any parts are faulty, replace them. Engine Brake Test S7RS0B5104013 WARNING Before test, make sure that there is no vehicle behind so as to prevent rear-end collision.
Page 675: Time Lag Test
Automatic Transmission/Transaxle: 5A-31 Troubleshooting Condition Possible cause Correction / Reference Item Lower than standard level Engine output torque failure Inspect and repair engine. in both “D” and “R” range Faulty one-way clutch of torque Replace torque converter. converter Higher than standard Malfunction of pressure control solenoid Inspect.
Page 676: Line Pressure Test
5A-32 Automatic Transmission/Transaxle: Troubleshooting Condition Possible cause Correction / Reference Item → “N” “D” time lag Malfunction of transmission fluid Inspect. If NG, replace. exceeds specification temperature sensor Malfunction of pressure control solenoid Inspect. If NG, replace valve body assembly. valve (Low line pressure) Faulty valve body component Replace valve body assembly.
Page 677: P" Range Test
Automatic Transmission/Transaxle: 5A-33 Troubleshooting Condition Possible cause Correction / Reference Item Higher than standard Malfunction of pressure control solenoid Inspect. If NG, replace valve body assembly. level in each range valve (Low line pressure) Faulty valve body component Replace valve body assembly. Lower than standard level Malfunction of pressure control solenoid Inspect.
Page 678: A/T Symptom Diagnosis
5A-34 Automatic Transmission/Transaxle: A/T Symptom Diagnosis S7RS0B5104018 Trouble Diagnosis 1 Electrical repair Condition Possible cause Correction / Reference Item Excessive shift shock Shift solenoid valve-A and/or -B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent.
Page 679 Automatic Transmission/Transaxle: 5A-35 Condition Possible cause Correction / Reference Item → Poor 2 3 shift Shift solenoid valve-A circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Output shaft speed sensor circuit faulty Inspect circuit for open, short and intermittent. If NG, repair.
Page 680 5A-36 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item → Poor 4 3 shift Shift solenoid valve-B circuit faulty Inspect circuit for open, short and intermittent. If NG, repair. Pressure control solenoid valve circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 681 Automatic Transmission/Transaxle: 5A-37 Condition Possible cause Correction / Reference Item Non operate TCC (lock- TCC pressure control solenoid valve Inspect circuit for open, short and intermittent. up) system circuit faulty If NG, repair. Shift solenoid valve-A and/or-B circuit Inspect circuit for open, short and intermittent. faulty If NG, repair.
Page 682 5A-38 Automatic Transmission/Transaxle: Trouble Diagnosis 2 On-vehicle repair Condition Possible cause Correction / Reference Item Unable to run in all range Faulty valve body component Replace valve body assembly. Excessive shift shock Engine abnormal condition Inspect and repair engine. Malfunction of shift solenoid valve-A Inspect.
Page 683 Automatic Transmission/Transaxle: 5A-39 Condition Possible cause Correction / Reference Item → Poor 3 4 shift Malfunction of shift solenoid valve-B Inspect. If NG, replace. Malfunction of timing solenoid valve Inspect. If NG, replace. Malfunction of output shaft speed Inspect. If NG, replace. sensor Malfunction of input shaft speed sensor Inspect.
Page 684 5A-40 Automatic Transmission/Transaxle: Condition Possible cause Correction / Reference Item Non operate TCC (lock- Malfunction of TCC solenoid valve Inspect. If NG, replace. up) system Malfunction of shift solenoid valve-A Inspect. If NG, replace. and/or -B Malfunction of output shaft speed Inspect.
Page 685: No Gear Shift To 4Th Gear
Automatic Transmission/Transaxle: 5A-41 Condition Possible cause Correction / Reference Item Non operate TCC (lock- Faulty torque converter Replace. up) system → Excessive “N” “D” time Faulty oil pump Inspect. If NG, replace. Faulty forward clutch Inspect. If NG, replace. Faulty one-way No.2 clutch Inspect.
Page 686: No Lock-Up Occurs
5A-42 Automatic Transmission/Transaxle: Step Action 1) Perform running test under the following conditions and Faulty shift solenoid “BRN” circuit shorted to measure voltage between terminal “C34-16” of TCM valve, circuit or power circuit or open, or connector and ground, terminal “C34-15” of TCM transaxle.
Page 687: Transmission Warning Light Circuit Check
Automatic Transmission/Transaxle: 5A-43 Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check DTC Go to applicable DTC Go to Step 3. diag. flow. Is DTC P0705, P0707, P0712, P0713, P0717, P0722, P0787, P0788, P0961, P0962, P0963, P0973, P0974, P0976, P0977, P1702, P1703, P1774, P1777, P2762, P2763 and/or P2764 detected? Brake light switch signal inspection...
Page 688: Dtc P0602: Control Module Programming Error
5A-44 Automatic Transmission/Transaxle: DTC P0602: Control Module Programming Error S7RS0B5104048 System Description Internal control module is installed in ECM. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Data programming error (1 driving cycle detection logic) DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch turned OFF.
Page 689 Go to Step 5. operation Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection in Section 00”. 2) Turn ignition switch ON and check transmission range signal (“P”, “R”, “N”, “D”, “3”, “2”...
Page 690: Dtc P0707: Transmission Range Sensor Circuit Low
5A-46 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor (switch) referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor (Shift Switch) Inspection “RED”, “GRN/ORN”, range sensor. and Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? shorted to power circuit or shorted each other.
Page 691 Go to Step 5. operation Check for intermittent Check by using SUZUKI scan tool: referring to “Intermittent 1) Connect SUZUKI scan tool to DLC with ignition switch and Poor Connection OFF. Inspection in Section 00” 2) Turn ignition switch ON and check transmission range signal (P, R, N, D, 3, 2 or L) on display when shifting select lever to each range.
Page 692: Dtc P0712: Transmission Fluid Temperature Sensor "A" Circuit Low
5A-48 Automatic Transmission/Transaxle: Step Action 1) Check transmission range sensor (switch) referring to “RED/BLK”, “PNK/BLK”, Replace transmission “Transmission Range Sensor (Shift Switch) Inspection “RED”, “GRN/ORN”, range sensor. and Adjustment”. “GRN”, “GRN/YEL” or “LT GRN/BLK” circuit Are check results satisfactory? open or short to ground. If wires and connections are OK, substitute a know-good TCM and...
Page 693: Dtc P0713: Transmission Fluid Temperature Sensor "A" Circuit High
Automatic Transmission/Transaxle: 5A-49 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory and start engine. 3) Keep engine running at idle speed for 10 minutes or more. 4) Stop vehicle and check DTC. DTC Troubleshooting Step Action...
Page 694 5A-50 Automatic Transmission/Transaxle: DTC Confirmation Procedure WARNING • When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. • Road test should be carried out with 2 persons, a driver and a tester, on a level road. 1) Connect scan tool to DLC with ignition switch OFF, if available.
Page 695: Dtc P0717: Input / Turbine Speed Sensor "A" Circuit Malfunction
Automatic Transmission/Transaxle: 5A-51 DTC P0717: Input / Turbine Speed Sensor “A” Circuit Malfunction S7RS0B5104027 Wiring Diagram C35-6 C35-16 2.5V I4RS0A510012-01 1. TCM 2. Input shaft speed sensor [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area No input shaft speed sensor signal is detected although...
Page 696: Dtc P0722: Output Speed Sensor Circuit No Signal
5A-52 Automatic Transmission/Transaxle: Step Action Inspect input shaft speed sensor “WHT” or “BLK” circuit Replace input shaft open or short. speed sensor. 1) Inspect input shaft speed sensor referring to “Input Shaft Speed Sensor Inspection”. Is result satisfactory? Check visually input shaft speed sensor and direct Intermittent trouble or Clean, repair or replace.
Page 697 Automatic Transmission/Transaxle: 5A-53 1) Connect scan tool to DLC with ignition switch OFF, if available. 2) Clear DTC in TCM memory and start engine. 3) Shift select lever to “D” range and drive vehicle at 50 km/h (31 mile/h) or more vehicle speed at least for 3 minutes. 4) Stop vehicle and check DTC.
Page 698: Dtc P0787: Shift / Timing Solenoid Low
5A-54 Automatic Transmission/Transaxle: DTC P0787: Shift / Timing Solenoid Low S7RS0B5104029 Wiring Diagram C34-14 BLU/BLK I4RS0A510014-01 1. TCM 3. A/T 2. Timing solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of timing solenoid valve TCM terminal is low although TCM...
Page 699 Automatic Transmission/Transaxle: 5A-55 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check timing solenoid valve resistance Go to Step 3. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1), (2) on transaxle.
Page 700: Dtc P0788: Shift / Timing Solenoid High
5A-56 Automatic Transmission/Transaxle: DTC P0788: Shift / Timing Solenoid High S7RS0B5104030 Wiring Diagram C34-14 BLU/BLK I4RS0A510014-01 1. TCM 3. A/T 2. Timing solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Voltage of timing solenoid valve TCM terminal is high...
Page 701 Automatic Transmission/Transaxle: 5A-57 Step Action Check timing solenoid valve resistance “BLU/BLK” circuit open. Replace timing solenoid valve or lead wire. 1) Turn ignition switch OFF. 2) Disconnect valve body harness connector (1), (2) on transaxle. 3) Check for proper connection to solenoid valve at “BLU/ BLK”...
Page 702: Dtc P0961: Pressure Control Solenoid "A" Control Circuit Range / Performance
5A-58 Automatic Transmission/Transaxle: DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance S7RS0B5104049 Wiring Diagram C34-4 C34-2 LT GRN/BLK I4RS0A510015-01 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 703 Automatic Transmission/Transaxle: 5A-59 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid valve resistance Go to Step 3. Replace pressure control solenoid valve or 1) Turn ignition switch OFF position. valve body harness.
Page 704: Dtc P0962: Pressure Control Solenoid "A" Control Circuit Low
5A-60 Automatic Transmission/Transaxle: DTC P0962: Pressure Control Solenoid “A” Control Circuit Low S7RS0B5104031 Wiring Diagram C34-4 C34-2 LT GRN/BLK I4RS0A510015-01 1. TCM 3. A/T 2. Pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Pressure control solenoid valve output voltage is too low...
Page 705 Automatic Transmission/Transaxle: 5A-61 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid valve resistance Go to Step 3. Replace pressure control solenoid valve or 1) Turn ignition switch OFF. valve body harness.
Page 706: Dtc P0963: Pressure Control Solenoid "A" Control Circuit High
5A-62 Automatic Transmission/Transaxle: Step Action Check pressure control solenoid valve circuit for open “GRY” or “LT GRN/BLK” Intermittent trouble or circuit open. faulty TCM. 1) Check resistance continuity between terminals “C34-2” and “C34-4” of disconnected harness side TCM Check for intermittent connector.
Page 707 Automatic Transmission/Transaxle: 5A-63 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check pressure control solenoid circuit for IG short Go to Step 3. “GRY” or “LT GRN/BLK” circuit shorted to power 1) Connect valve body harness connector.
Page 708: Dtc P0973 / P0976: Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low
5A-64 Automatic Transmission/Transaxle: DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low S7RS0B5104033 Wiring Diagram C34-16 BLK/YEL C34-15 16 15 I4RS0A510016-01 1. TCM 3. Shift solenoid valve-B (No.2) [A]: Terminal arrangement of TCM connector (Viewed from harness side) 2.
Page 709 Automatic Transmission/Transaxle: 5A-65 DTC Troubleshooting Step Action Was “Automatic Transaxle Diagnostic Flow Table” Go to Step 2. Go to “A/T System performed? Check”. Check shift solenoid valve resistance Go to Step 3. Replace applicable shift solenoid valve or valve 1) Turn ignition switch OFF. body harness.
Page 710: Dtc P0974 / P0977: Shift Solenoid "A" / Shift Solenoid "B" Control Circuit High
5A-66 Automatic Transmission/Transaxle: DTC P0974 / P0977: Shift Solenoid “A” / Shift Solenoid “B” Control Circuit High S7RS0B5104034 Wiring Diagram C34-16 BLK/YEL C34-15 16 15 I4RS0A510016-01 1. TCM 3. Shift solenoid valve-B (No.2) [A]: Terminal arrangement of TCM connector (viewed from harness side) 2.
Page 711 Automatic Transmission/Transaxle: 5A-67 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check shift solenoid valve circuit for IG short Go to Step 3. DTC P0974: “BRN” circuit shorted to power 1) Connect valve body harness connector.
Page 712: Dtc P1702: Internal Control Module Memory Check Sum Error
5A-68 Automatic Transmission/Transaxle: DTC P1702: Internal Control Module Memory Check Sum Error S7RS0B5104035 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Calculation of current data stored in TCM is not correct comparing with pre-stored checking data in TCM. DTC Confirmation Procedure 1) Connect scan tool to DLC with ignition switch OFF.
Page 713: Dtc P1723: Range Select Switch Malfunction
Automatic Transmission/Transaxle: 5A-69 DTC P1723: Range Select Switch Malfunction S7RS0B5104037 Wiring Diagram E23-3 E03-10 E23-18 E03-8 C34-17 C37-13 E03-6 C34-7 C37-12 E03-12 E46-1 E46-2 LT GRN LT01-8 1716 1514 1312 1110 9 161514131211 10 9 8 7 1817 2625 212019 2423 2322 5 4 3 2 1...
Page 714 Substitute a known- Go to Step 3. good TCM and recheck. 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. 2) Turn ignition switch ON and check “3” position switch signal on scan tool data display when shifting select lever to each range.
Page 715: Dtc P1774: Can Communication Bus Off
Automatic Transmission/Transaxle: 5A-71 DTC P1774: CAN Communication Bus Off S7RS0B5104038 Wiring Diagram E23-3 E03-10 E23-18 E03-8 C34-17 C37-13 E03-6 C34-7 C37-12 E03-12 E46-1 E46-2 G28-8 G37-4 G28-10 G37-2 G49-19 G28-7 G37-1 WHT/BLK G28-9 G49-18 G37-3 RED/BLK 161514131211 10 9 8 7 1716 1514 1312...
Page 716 5A-72 Automatic Transmission/Transaxle: DTC Troubleshooting NOTE Upon completion of inspection and repair work, perform “DTC Confirmation Procedure:” and confirm that the trouble has been corrected. Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”.
Page 717: Dtc P1777: Tcm Lost Communication With Ecm (Reception Error)
Automatic Transmission/Transaxle: 5A-73 DTC P1777: TCM Lost Communication with ECM (Reception Error) S7RS0B5104040 Wiring Diagram Refer to “DTC P1774: CAN Communication Bus Off” DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for ECM is detected more than specified •...
Page 718: Dtc P1778: Tcm Lost Communication With Bcm (Reception Error)
5A-74 Automatic Transmission/Transaxle: DTC P1778: TCM Lost Communication with BCM (Reception Error) S7RS0B5104041 Wiring Diagram Refer to “DTC P1774: CAN Communication Bus Off”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Reception error of communication data for BCM is detected more than specified •...
Page 719: Dtc P1878: Torque Converter Clutch Shudder
Automatic Transmission/Transaxle: 5A-75 DTC P1878: Torque Converter Clutch Shudder S7RS0B5104042 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area The acceleration slip control function stops when the variation in the output • Mismatching ATF revolution speed of the specified amplitude and specified cycle is detected •...
Page 720: Dtc P2762: Torque Converter Clutch (Tcc) Pressure Control Solenoid Control Circuit Range /Performance
5A-76 Automatic Transmission/Transaxle: DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance S7RS0B5104050 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019-01 1. TCM 3. A/T 2. TCC solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 721 Automatic Transmission/Transaxle: 5A-77 DTC Troubleshooting Step Action Was “A/T System Check” performed? Go to Step 2. Go to “A/T System Check”. Check TCC solenoid valve resistance Go to Step 3. Replace TCC solenoid valve or valve body 1) Turn ignition switch to OFF position. harness.
Page 722: Dtc P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High
5A-78 Automatic Transmission/Transaxle: DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High S7RS0B5104043 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019-01 1. TCM 3. A/T 2. TCC lock-up pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 723 Automatic Transmission/Transaxle: 5A-79 Step Action Check TCC solenoid valve circuit for IG short Go to Step 3. “WHT/BLU” or “WHT/ BLK” circuit shorted to 1) Connect valve body harness connector. power circuit. 2) Disconnect TCM connectors. 3) Check for proper connection to TCM at terminal “C34-3” and “C34-5”.
Page 724: Dtc P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit Low
5A-80 Automatic Transmission/Transaxle: DTC P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit Low S7RS0B5104044 Wiring Diagram C34-5 WHT/BLU C34-3 WHT/BLK I4RS0A510019-01 1. TCM 3. A/T 2. TCC pressure control solenoid valve [A]: Terminal arrangement of TCM connector (viewed from harness side) DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area...
Page 725 Automatic Transmission/Transaxle: 5A-81 Step Action Check TCC lock-up pressure control solenoid valve Go to Step 3. Replace TCC lock-up resistance pressure control solenoid valve or lead 1) Turn ignition switch OFF. wire. 2) Disconnect valve body harness connector (1), (2) on automatic transaxle.
Page 726: Inspection Of Tcm And Its Circuits
5A-82 Automatic Transmission/Transaxle: Inspection of TCM and Its Circuits S7RS0B5104045 TCM and its circuits can be checked at TCM wiring connectors by measuring voltage, pulse signal and resistance. CAUTION TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector disconnected from it.
Page 727 Automatic Transmission/Transaxle: 5A-83 Connector “C34” Standard Terminal Wire color Circuit Condition voltage Ground 0 – 1 V Ignition switch ON LT GRN/ Pressure control 0.6 – 1.0 V Ignition switch ON solenoid valve (–) TCC pressure control WHT/BLK 0.6 – 1.0 V Ignition switch ON solenoid valve (–) *0 –...
Page 728 5A-84 Automatic Transmission/Transaxle: Connector “C35” Standard Terminal Wire color Circuit Condition voltage Transmission range 8 – 14 V Ignition switch ON, select lever at “R” range sensor (“R” range) 0 – 1 V Ignition switch ON, select lever at other than “R” range —...
Page 729 Automatic Transmission/Transaxle: 5A-85 Reference waveform No. 1 Reference waveform No. 3 Pressure control solenoid valve signal at engine idling. CAN communication line (High & Low) signal at engine idling. Measurement CH1: “C34-4” to “C34-1” terminal Measurement CH1: “C34-7” to “C34-1” Oscilloscope CH1: 5 V/DIV terminal...
Page 730: Tcm Power And Ground Circuit Check
5A-86 Automatic Transmission/Transaxle: Reference waveform No. 5 Output shaft speed sensor signal at vehicle speed 60 km/h (37 mile/h). Measurement CH1: “C35-25” to “C34-1” terminal Oscilloscope CH1: 5 V/DIV setting TIME: 2 ms/DIV • After warmed up to normal operating temperature Measurement condition •...
Page 731: Brake Interlock System Inspection
Automatic Transmission/Transaxle: 5A-87 Troubleshooting Step Action Check TCM back-up power circuit Go to Step 2. “WHT/RED” circuit open or shorted to ground. 1) Disconnect TCM connector with ignition switch OFF. 2) Check for proper connection to TCM at “C34-24” terminal. 3) If OK, check voltage at terminal “C34-24”...
Page 732: Repair Instructions
Learning Control Initialization S7RS0B5106001 1) Connect san tool to DLC (1) with ignition switch OFF. Special tool (A): SUZUKI scan tool I4RS0B510004-01 2) Start engine and shift select lever to “P” range. 3) Select “Misc Test” mode on scan tool.
Page 733: A/T Fluid Level Check
FULL HOT (2) and LOW HOT (3). If it is (hot) temperature. Checking procedure itself is the same below LOW HOT, add SUZUKI ATF 3317 or Mobil as that described in “Level Check at Normal Operating ATF 3309 up to FULL HOT.
Page 734: A/T Fluid Change
Select Lever Assembly Removal and Installation I3RM0B510033-01 S7RS0B5106005 4) Lower vehicle and pour proper amount of SUZUKI Remove and install select lever referring to “Select Lever ATF 3317 or Mobil ATF 3309. Components.” When installing select lever noting the following.
Page 735: Select Lever Inspection
Automatic Transmission/Transaxle: 5A-91 Select Lever Inspection Shift Lock Solenoid Inspection S7RS0B5106007 S7RS0B5106009 Check select lever for smooth and clear-cut movement Check that shift lock solenoid rod (1) moves smoothly individually. If a malfunction is found, replace select lever when battery voltage is conducted and it moves back. If assembly.
Page 736: Select Cable Components
5A-92 Automatic Transmission/Transaxle: Select Cable Components S7RS0B5106011 I4RS0A510025-01 1. Select lever assembly 6. Clip 11. Lock 2. Select cable 7. Select cable retainer bolt : 23 N⋅m (2.0 kgf-m, 17.0 lb-ft) 3. Select cable retainer 8. Manual select lever pin : 5.0 N⋅m (0.55 kgf-m, 4.0 lb-ft) : Apply lithium grease 99000-25011 to all around pin (0.15 g) 4.
Page 737: Select Cable Adjustment
5) Shift select lever to “N” position. 6) Apply grease to select lever pin and install adjuster (cable end) to it. : Grease 99000–25011 (SUZUKI Super Grease 7) With both select lever and transmission range sensor kept each “N” position, drive cable end holder (1) in until it locks cable.
Page 738 5A-94 Automatic Transmission/Transaxle: 5) Turn ignition switch to LOCK position. 6) Remove parking brake cover and console box. 7) Detach cable end (1) from interlock cam (2) while pressing claws (3) of interlock cam boss. At this time, be careful not to cause damage to its claws.
Page 739: Transmission Range Sensor (Shift Switch) Inspection And Adjustment
Automatic Transmission/Transaxle: 5A-95 Transmission Range Sensor (Shift Switch) 5) Shift select lever to “N” position. Inspection and Adjustment NOTE S7RS0B5106015 1) Shift manual select lever (4) to “N” range. If select lever is in “P” position, shift select lever referring to “Select Lever Inspection”. 2) Check that needle direction shaped on lock washer (2) and “N”...
Page 740: Output Shaft Speed Sensor Removal And Installation
5A-96 Automatic Transmission/Transaxle: Output Shaft Speed Sensor Removal and Installation S7RS0B5106016 Removal 1) Disconnect negative cable at battery. 2) Disconnect output shaft speed sensor connector (2). 3) Remove output shaft speed sensor (1) by removing its bolt. I2RH0B510045-01 2) Check output shaft speed sensor driven gear (1) for wear.
Page 741: Input Shaft Speed Sensor Inspection
Automatic Transmission/Transaxle: 5A-97 7) Remove valve body assembly referring to Installation “Automatic Transaxle Unit Disassembly”. 1) Apply A/T fluid to input shaft speed sensor O-ring. 2) Install input shaft speed sensor (1) to A/T case and CAUTION tighten bolt to specified torque. When pulling solenoid wire harness out of Tightening torque transaxle case, take care not to damage...
Page 742: Transmission Fluid Temperature Sensor Inspection
5A-98 Automatic Transmission/Transaxle: Transmission Fluid Temperature Sensor Inspection S7RS0B5106021 Warm up transmission fluid temperature sensor (2). Check resistance between terminals of valve body harness connector (1). Thus make sure its resistance decrease as its temperature increase. Transmission fluid temperature sensor resistance 10 °C (50 °F): 5.8 –...
Page 743: Solenoid Valves (Shift Solenoid Valves, And Timing Solenoid Valve) Inspection
Automatic Transmission/Transaxle: 5A-99 Installation 4) Install oil strainer assembly (1). 1) Install shift solenoid valve-A (No.1) (1), shift solenoid Tightening torque valve-B (No.2) (2) and timing solenoid valve (3). Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft) Tightening torque Shift solenoid bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb- I2RH0B510059-01 5) Install new oil pan gasket (1) and oil pan (2).
Page 744 5A-100 Automatic Transmission/Transaxle: Operation Check Timing solenoid valve Shift solenoid valve-A (No.1) and -B (No.2) CAUTION CAUTION • Do not insert air gun against strainer installed on inlet of solenoid valve too • Do not insert air gun against strainer deeply, when blowing air into solenoid installed on inlet of solenoid valve too valve.
Page 745: Pressure Control Solenoid Valves (Pressure Control Solenoid And Tcc Pressure Control Solenoid) Removal And Installation
Automatic Transmission/Transaxle: 5A-101 Pressure Control Solenoid Valves (Pressure 9) Remove valve body assembly referring to “Automatic Transaxle Unit Disassembly”. Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation 10) Remove pressure control solenoid valve and TCC S7RS0B5106024 pressure control solenoid valve referring to “Valve Removal Body Assembly Disassembly and Reassembly”.
Page 746: Transmission Control Module (Tcm) Removal And Installation
5A-102 Automatic Transmission/Transaxle: Operation Check Check pressure control solenoid valves (Pressure control solenoid and TCC pressure control solenoid) operation in the either manner of the following. Using regulated DC power supply 1) Connect pressure control solenoid valve (1) with regulated DC power supply (2) as shown in figure. 2) Turn regulated DC power supply switch ON and increase voltage of power supply keeping current within 1.0 A.
Page 747: A/T Relay Inspection
Automatic Transmission/Transaxle: 5A-103 Installation Differential Side Oil Seal Replacement Reverse removal procedure noting the following. S7RS0B5106028 1) Lift up vehicle and drain automatic transaxle fluid. • Connect TCM connectors securely. 2) Remove drive shaft joints from differential gear of • If the vehicle is equipped with air bag system, be sure transaxle.
Page 748: A/T Fluid Cooler Hoses Replacement
A/T Fluid Cooler Hoses Replacement 4) Apply grease to new differential side oil seal lips. S7RS0B5106029 : Grease 99000–25030 (SUZUKI Super Grease C) The rubber hoses for the A/T fluid cooler should be checked at specified interval. If replacing them, be sure 5) Install new differential side oil seals (1) by using to note the following.
Page 749: Automatic Transaxle Unit Components
Automatic Transmission/Transaxle: 5A-105 Automatic Transaxle Unit Components S7RS0B5106030 I4RS0A510035-01 1. Drive plate 4. Torque converter 7. Transaxle and engine fastening nut 2. Drive plate bolt 5. Transaxle stiffener bolt : Tightening torque : Apply sealant 99000-31230 to thread. 3. Drive plate to torque converter bolt 6.
Page 750: Automatic Transaxle Unit Dismounting And Remounting
5A-106 Automatic Transmission/Transaxle: Automatic Transaxle Unit Dismounting and 4) Remove starting motor. Remounting 5) Remove bolts and nut fastening engine and S7RS0B5106031 transaxle, then detach transaxle from engine. Dismounting WARNING 1) Take down transaxle with engine. For its procedure, Be sure to keep transaxle with torque refer to “Engine Assembly Removal and Installation converter horizontal or facing up throughout in Section 1D”.
Page 751 Automatic Transmission/Transaxle: 5A-107 Remounting 4) Tighten transaxle stiffener bolts to specified torque. 1) Make sure that torque converter is installed correctly 5) Install transaxle housing lower plates (1). to transaxle. Tightening torque Refer to “Automatic Transaxle Unit Assembly”. Transaxle stiffener bolt (a): 55 N·m (5.5 kgf-m, 2) Attach transaxle to engine.
Page 752: Automatic Transaxle Assembly Components . 5A-108
5A-108 Automatic Transmission/Transaxle: Automatic Transaxle Assembly Components S7RS0B5106032 I6RS0C510016-04...
Page 753 A u t o m a t i c T r a n s m i s s i o n / T r a n s a x l e : 5 A - 1 0 9 1. Torque converter 37.
Page 754: Automatic Transaxle Unit Disassembly
5A-110 Automatic Transmission/Transaxle: Automatic Transaxle Unit Disassembly 4) Uncaulk lock washer (1), then remove lock nut (2) S7RS0B5106033 and lock washer. CAUTION • Thoroughly clean transaxle exterior before overhauling it. • Keep working table, tools and hands clean while overhauling. •...
Page 755 Automatic Transmission/Transaxle: 5A-111 12) Disconnect connectors (2) from solenoid valves and 8) Remove fluid cooler pipes (1) and pipe union (2). transmission fluid temperature sensor (1). 9) Remove fluid level gauge (3) and fluid filler tube (4). I4RS0A510027-01 13) Remove valve body assembly bolts. CAUTION Be careful not to let manual valve fall off when removing valve body assembly.
Page 756 5A-112 Automatic Transmission/Transaxle: 18) Remove accumulator pistons and springs. 15) Remove valve body harness (1). To remove C2 (1), C1 (2) and B1 (3) accumulator CAUTION pistons and springs, position rag on pistons to catch each piston. To remove pistons, force low-pressure When pulling valve body harness out of compressed air (1 kg/cm , 15 psi, 100 kPa, max) into...
Page 757 Automatic Transmission/Transaxle: 5A-113 19) Remove transaxle case plug (1). I2RH0B510098-01 25) Remove oil pump assembly (1). I2RH0B510095-01 20) Remove torque converter housing bolts. 21) Remove torque converter housing (1) while tapping around it lightly with plastic hammer. I2RH0B510099-01 26) Remove direct clutch assembly (1). I3RM0B510060-01 22) Remove breather hose (1).
Page 758 5A-114 Automatic Transmission/Transaxle: 28) Remove input shaft rear thrust bearing (1) and thrust 31) Remove governor apply No.2 gasket (1). bearing race (2). NOTE If input shaft rear thrust bearing is not found, it may have been taken out with direct clutch assembly.
Page 759 Automatic Transmission/Transaxle: 5A-115 35) Remove 2nd brake gasket (1). 37) Remove forward and reverse clutch assembly (1). I2RH0B510109-01 I2RH0B510111-01 36) Measure O/D and 2nd coast brake piston stroke. 38) Remove intermediate shaft thrust bearing front race If piston stroke exceeds specification, inspect and (1), thrust bearing (2) and rear race (3) from forward replace plates and discs.
Page 760 5A-116 Automatic Transmission/Transaxle: 40) Remove forward clutch hub (1). 43) Remove rear planetary sun gear subassembly (1) and one-way clutch No.1 assembly (2). I2RH0B510114-01 41) Remove rear sun gear thrust bearing (1) from I2RH0B510117-01 forward clutch hub (2). 44) Remove planetary gear thrust bearing (1). NOTE NOTE If rear sun gear thrust bearing is not found on...
Page 761 Automatic Transmission/Transaxle: 5A-117 47) Remove O/D and 2nd coast brake retaining plate snap ring (1). I2RH0B510124-01 51) Remove 2nd brake piston assembly (1). 52) Remove 2nd brake return spring subassembly (2). I2RH0B510120-01 48) Remove front planetary sun gear (1). I4RS0A510038-01 53) Remove 2nd brake separator plates (1), discs (2) I2RH0B510121-01 and retaining plate (3).
Page 762 5A-118 Automatic Transmission/Transaxle: 55) Remove one-way clutch outer race retainer (1). 58) Remove planetary gear assembly (1). I2RH0B510132-01 I2RH0B510129-01 59) Measure 1st and reverse brake piston stroke. 56) Check one-way clutch No.2 as follows. If piston stroke exceeds specified value, •...
Page 763 Automatic Transmission/Transaxle: 5A-119 60) Remove snap ring while the 1st and reverse brake 64) Secure reduction drive gear (1) with parking lock piston return springs are compressed using special pawl, then remove reduction drive gear nut. tool and hydraulic press. CAUTION CAUTION •...
Page 764 5A-120 Automatic Transmission/Transaxle: 67) Screwing 3 bolts (1), remove reduction drive gear 69) Remove parking lock pawl bracket (1). (2). CAUTION Screw 3 bolts into reduction drive gear uniformly, or reduction drive gear, bearing and transaxle case may be damaged. Bolt length 35 mm (1.38 in.) I2RH0B510142-01...
Page 765: Oil Pump Assembly Components
Automatic Transmission/Transaxle: 5A-121 75) Remove manual shift shaft oil seal (1). 74) Remove manual detent spring (1). I2RH0B510146-01 I2RH0B510147-01 Oil Pump Assembly Components S7RS0B5106034 I2RH0B510148-01 1. Oil seal 5. Oil pump drive gear : Apply automatic transaxle fluid. : Apply grease 99000-25030 to oil seal lip. 2.
Page 766: Oil Pump Assembly Disassembly And Reassembly
If clearance exceeds its Special tool standard value, replace oil pump assembly. (A): 09913–85210 Clearance between oil pump driven gear and oil “A”: Grease 99000–25030 (SUZUKI Super pump body Grease C) Standard: 0.10 – 0.17 mm (0.0039 – 0.0067 in.) I2RH0B510151-01 2.
Page 767 Automatic Transmission/Transaxle: 5A-123 2) Check tip clearance of both drive and driven gears. Using a feeler gauge, measure clearance between drive and driven gear tips. If clearance exceeds its standard value, replace oil pump assembly. Tip clearance between oil pump drive gear and oil pump driven gear Standard: 0.07 –...
Page 768: Direct Clutch Assembly Components
5A-124 Automatic Transmission/Transaxle: Direct Clutch Assembly Components S7RS0B5106037 I2RH0B510160-01 1. Input shaft front thrust bearing 6. Outer O-ring 11. Direct clutch retaining plate 2. Input shaft seal ring 7. Direct clutch return spring subassembly 12. Plate snap ring 3. Input shaft subassembly 8.
Page 769: Direct Clutch Assembly Disassembly And Reassembly
Automatic Transmission/Transaxle: 5A-125 Direct Clutch Assembly Disassembly and 5) Remove outer O-ring (1). Reassembly S7RS0B5106039 Disassembly 1) Remove plate snap ring (1) then remove direct clutch retaining plate, discs and separator plates. I2RH0B510165-01 2. Direct clutch piston 6) Remove inner O-ring (2). I2RH0B510162-01 2) Using special tool and hydraulic press, remove shaft snap ring (1).
Page 770 5A-126 Automatic Transmission/Transaxle: Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new seal ring and O-ring. Apply A/T fluid before installation. • Do not damage direct clutch return spring subassembly (1) and piston by pressing in direct clutch return spring subassembly passing through its original installing position over 0.7 mm (0.027 in.).
Page 771: Direct Clutch Assembly Inspection
Automatic Transmission/Transaxle: 5A-127 Direct Clutch Assembly Inspection Direct Clutch Piston S7RS0B5106040 Shake direct clutch piston lightly and check that check ball (1) is not stuck. Clutch Discs, Plates and Retaining Plate Blow in low pressure air (Max. 100 kPa, 1 kg/cm , 15 psi) Check that sliding surfaces of discs, separator plates to check ball to check that there is no leakage.
Page 772: Forward And Reverse Clutch Assembly Components
5A-128 Automatic Transmission/Transaxle: Forward and Reverse Clutch Assembly Components S7RS0B5106041 I3RM0B510061-01 1. Forward clutch balancer 8. Intermediate shaft seal ring 15. Forward clutch retaining plate 2. Forward clutch return spring 9. Reverse clutch plate snap ring 16. Forward clutch disc subassembly 3.
Page 773: Forward And Reverse Clutch Assembly Preliminary Check
Automatic Transmission/Transaxle: 5A-129 Forward and Reverse Clutch Assembly Forward and Reverse Clutch Assembly Preliminary Check Disassembly and Reassembly S7RS0B5106042 S7RS0B5106043 1) Install forward and reverse clutch assembly (1) to transaxle rear cover (2), blow in compressed air (400 Disassembly – 800 kPa, 4 – 8 kg/cm , 57 –...
Page 774 5A-130 Automatic Transmission/Transaxle: 4) Remove forward clutch balancer (1). 7) Apply compressed air (400 – 800 kPa, 4 – 8 kg/cm 57 – 113 psi) to oil hole (1) of transaxle rear cover to remove forward clutch drum (2). I2RH0B510180-01 5) Remove forward clutch return spring subassembly I2RH0B510183-01 (1).
Page 775 Automatic Transmission/Transaxle: 5A-131 Reassembly • Install forward clutch plate snap ring so that its both Reverse disassembly procedure for assembly, noting the ends would be positioned in correct locations as following points. shown in figure. • Before assembling, apply automatic transaxle fluid to component parts.
Page 776 5A-132 Automatic Transmission/Transaxle: • Install reverse clutch plate snap ring so that its both • Measure forward clutch piston stroke in the same manner as “Forward and Reverse Clutch Assembly ends would be positioned in correct locations as Preliminary Check”. shown in figure.
Page 777: Forward And Reverse Clutch Assembly Inspection
Automatic Transmission/Transaxle: 5A-133 Forward and Reverse Clutch Assembly Forward Clutch Piston Lip and Forward Clutch Balancer Lip Inspection Check each lip for wear, deformation, cut and/or S7RS0B5106044 hardening. If necessary, replace. Clutch, Discs, Separator Plates and Retaining Plate Check that sliding surfaces of discs, separator plates and retaining plate are not worn hard or burnt.
Page 778: 2Nd Brake Piston Assembly Components
5A-134 Automatic Transmission/Transaxle: 2nd Brake Piston Assembly Components S7RS0B5106045 I2RH0B510196-01 1. 2nd brake cylinder 3. Inner O-ring : Apply automatic transaxle fluid. 2. 2nd brake piston 4. Outer O-ring : Do not reuse. 2nd Brake Piston Assembly Disassembly and 2) Remove inner O-ring (1) and outer O-ring (2). Reassembly S7RS0B5106046 Disassembly...
Page 779: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Components
Automatic Transmission/Transaxle: 5A-135 Reassembly Reverse disassembly procedure for assembly, noting the following points. • Use new O-rings. Apply A/T fluid to the O-rings, before installation. • Install 2nd brake piston (1) to which A/T fluid is applied to 2nd brake cylinder (2). Do not damage O-ring when installing 2nd brake piston.
Page 780: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Disassembly And Reassembly
5A-136 Automatic Transmission/Transaxle: Transaxle Rear Cover (O/D and 2nd Coast Brake 4) Remove O/D and 2nd coast brake piston front O-ring (1) and rear O-ring (2). Piston) Assembly Disassembly and Reassembly S7RS0B5106048 Disassembly 1) Remove snap ring by using special tools and hydraulic press.
Page 781: Transaxle Rear Cover (O/D And 2Nd Coast Brake Piston) Assembly Inspection
Automatic Transmission/Transaxle: 5A-137 Transaxle Rear Cover (O/D and 2nd Coast Brake Reassembly Reverse disassembly procedure for assembly, noting the Piston) Assembly Inspection following points. S7RS0B5106049 • Use new seal rings and O-rings. Apply A/T fluid to O/D and 2nd Coast Brake Return Spring seal rings and O-rings before installation.
Page 782: Countershaft Assembly Components
5A-138 Automatic Transmission/Transaxle: Countershaft Assembly Components 2) Remove countershaft RH bearing (1) by using S7RS0B5106050 special tools. Special tool (A): 09913–61510 (B): 09926–58010 I2RH0B510211-01 Reassembly I2RH0B510209-01 1) Install new countershaft RH bearing (1) by using 1. Countershaft RH bearing 5. Bearing cap 2.
Page 783: Valve Body Assembly Components
Automatic Transmission/Transaxle: 5A-139 3) Install countershaft LH bearing (1) with special tools 2) Install reduction driven gear (1) with special tools and hydraulic press. and hydraulic press. Special tool Special tool (A): 09913–84510 (A): 09913–84510 (B): 09925–88210 (B): 09925–88210 I2RH0B510213-01 I2RH0B510214-01 Valve Body Assembly Components S7RS0B5106052...
Page 784: Valve Body Assembly Disassembly And Reassembly
5A-140 Automatic Transmission/Transaxle: Valve Body Assembly Disassembly and 4) Remove shift solenoid valve-A (1). Reassembly S7RS0B5106053 CAUTION When replacing pressure control solenoid valve and/or TCC pressure control solenoid valve, it is strictly required to replace it together with valve body assembly as a set. Replacing pressure control solenoid valve and/or TCC pressure control solenoid valve independently may cause excessive shift...
Page 785: Differential Assembly Components
Automatic Transmission/Transaxle: 5A-141 Reassembly Reverse disassembly procedure for assembly, noting the following points. • Shift solenoid valve-A and -B are identical • After applying A/T fluid to new O-rings, fit them to solenoid valves, then install solenoid valves to valve body.
Page 786: Differential Assembly Disassembly And Reassembly
5A-142 Automatic Transmission/Transaxle: Differential Assembly Disassembly and 4) Remove differential side LH bearing by using special tools. Reassembly S7RS0B5106055 Special tool (A): 09926–37610 Disassembly (B): 09926–37610–001 1) Remove final gear bolts (1), and then final gear (2). (C): 09926–37610–003 (D): 09926–37610–002 I2RH0B510225-01 2) Remove differential side RH bearing by using special tools.
Page 787: Differential Assembly Inspection
Automatic Transmission/Transaxle: 5A-143 2) As shown in figure, facing groove (2) side upward, install final driven gear (1) to differential case. I2RH0B510233-01 6) Install new differential side LH bearing (1) by using I2RH0B510230-01 special tool and hydraulic press. 3) Tighten final gear bolts (1) to specified torque. NOTE NOTE Replace differential side LH bearing together...
Page 788: Torque Converter Housing Disassembly And Reassembly
5A-144 Automatic Transmission/Transaxle: Torque Converter Housing Disassembly and 4) Remove countershaft RH bearing cup by using special tools. Reassembly S7RS0B5106057 Special tool (A): 09944–96011 Disassembly (B): 09942–15511 1) Remove fluid reservoir RH plate (1) and lubrication tube clamp (2). I2RH0B510239-01 5) Remove differential side RH bearing cup by using special tools.
Page 789 1) After applying A/T fluid to new O-rings, fit them to housing plugs. Finally install plugs to torque 5) Apply grease to oil seal lip. converter housing. : Grease 99000–25030 (SUZUKI Super Grease C) Tightening torque Torque converter housing plug (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
Page 790: Transaxle Case Disassembly And Reassembly
5A-146 Automatic Transmission/Transaxle: Transaxle Case Disassembly and Reassembly Reassembly S7RS0B5106058 1) Using special tools, assemble shim and differential side LH bearing cup. Disassembly 1) Remove differential side oil seal (1). NOTE Use shim with same thickness as the removed one. Special tool (A): 09924–74510 (B): 09944–88220...
Page 791: Automatic Transaxle Unit Inspection And Adjustment
Differential side oil seal installing depth “a”: 3.8 – 4.8 mm (0.15 – 0.19 in.) 4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C) I2RH0B510253-01 Brake return spring subassembly Measure free length of each brake return spring subassembly.
Page 792 5A-148 Automatic Transmission/Transaxle: One-way clutch No.1 assembly 3) Measure bearing preload (a) by using a special tool. 1) Install one-way clutch No.1 assembly (2) to rear Special tool planetary sun gear subassembly (1). (A): 09928–06050 2) Securing rear planetary sun gear subassembly, Differential side bearing preload (a) measured as ensure that one-way clutch No.1 assembly rotates starting torque...
Page 793 Automatic Transmission/Transaxle: 5A-149 Countershaft bearing preload 4) If bearing preload is out of specification, select shim with suitable thickness from among the list below 1) After applying A/T fluid to countershaft assembly (1) and replace it. Then adjust countershaft bearing and differential assembly (2), fit them.
Page 794: Automatic Transaxle Unit Assembly
3) Install parking lock pawl rod (2) to manual valve lever or rotating surfaces of the parts before (1). assembly. • Use Suzuki Super Grease “C” to retain parts in place. • Be sure to install thrust bearings and races in correct direction and position.
Page 795 Automatic Transmission/Transaxle: 5A-151 6) Install parking lock pawl bracket (1) to transaxle 9) Install 1st and reverse brake return spring case. subassembly (1) to transaxle case (2). Tightening torque Parking lock pawl bracket bolt (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) I2RH0B510265-01 10) Apply A/T fluid to 1st and reverse brake discs (2), separator plates (3) and retaining plate (1), then...
Page 796 5A-152 Automatic Transmission/Transaxle: 12) Install 1st and reverse brake plate snap ring so that 14) Install reduction drive gear (1) to transaxle case (3) its both ends would be positioned in correct locations by using special tools and hydraulic press. as shown in figure.
Page 797 Automatic Transmission/Transaxle: 5A-153 16) Install new planetary ring gear subassembly (1) to 17) Using a small torque wrench, while turning to reduction drive gear (3) by using special tools and counter drive gear 100 rpm and measure the hydraulic press. preload.
Page 798 5A-154 Automatic Transmission/Transaxle: 20) Check for correct installation of planetary gear 22) Install one-way clutch outer race retainer (1). assembly as follows. Measure the distance “a” by using micrometer caliper (1) and straightedge (2). If measured value is out of specification, remove planetary gear assembly and reinstall it properly.
Page 799 (1), install it to planetary gear assembly. I2RH0B510283-01 28) After applying A/T fluid to front sun gear thrust “A”: Grease 99000–25030 (SUZUKI Super bearing race (2), install it to front planetary sun gear Grease C) (1).
Page 800 5A-156 Automatic Transmission/Transaxle: 32) Apply A/T fluid to one-way clutch No.1 assembly (3) 35) After applying A/T fluid to rear sun gear thrust and install one-way clutch No.1 assembly (3) to rear bearing race (1), install it to rear planetary sun gear planetary sun gear subassembly (2).
Page 801 Automatic Transmission/Transaxle: 5A-157 38) After applying A/T fluid to intermediate shaft thrust 40) Check for correct installation of forward and reverse bearing rear race (3), thrust bearing (2) and front clutch assembly as follows. race (1), install them to forward and reverse clutch Measure distance “a”...
Page 802 46) Apply sealant to mating surface of transaxle rear cover (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 in.) in diameter. “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) “A” I2RH0B510298-01...
Page 803 Automatic Transmission/Transaxle: 5A-159 47) Install transaxle rear cover assembly on transaxle 52) After applying A/T fluid to differential assembly (1) case. and countershaft assembly (2), install them to transaxle case. 48) Install hook (2) to location shown in figure. 49) Tighten rear cover bolts (1). Tightening torque Rear cover bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft) I4RS0A510036-01...
Page 804 5A-160 Automatic Transmission/Transaxle: 55) After applying A/T fluid to input shaft front thrust bearing (1), install it to direct clutch assembly (2). “a” I2RH0B510308-01 56) Apply A/T fluid to direct clutch assembly (1). Install direct clutch assembly while rotating clockwise and counterclockwise frequently to fit clutch discs to mating hub.
Page 805 Special tool section is 1.2 mm (0.047 in.) in diameter. (A): 09900–20607 (B): 09900–20701 “A”: Sealant 99000–31230 (SUZUKI Bond No.1216B) Input shaft thrust play 0.3 – 0.9 mm (0.012 – 0.035 in.) When input shaft thrust play is out of specification,...
Page 806 5A-162 Automatic Transmission/Transaxle: 66) After applying A/T fluid to new O-ring, fit it to transaxle case plug (1). Then install the transaxle case plug to transaxle case (2). Tightening torque Transaxle case plug (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) I2RH0B510317-01 67) Install new O-rings to each accumulator piston and apply A/T fluid to them.
Page 807 Automatic Transmission/Transaxle: 5A-163 70) After applying A/T fluid to new governor apply No.1 72) Install manual valve rod (1) to manual valve lever (3) gasket (1), install it to transaxle case. and then install valve body assembly (2) to transaxle case.
Page 808 5A-164 Automatic Transmission/Transaxle: 74) Connect solenoid connectors to solenoid valves 76) Install oil cleaner magnets (1) in oil pan (2). identifying their installing positions by wire colors, NOTE and install transmission fluid temperature sensor to its clamp. If metal particles are attached to the magnets, clean them before installing.
Page 809 Automatic Transmission/Transaxle: 5A-165 81) After applying A/T fluid to new O-ring, fit it to fluid 84) Install transmission range sensor to transaxle case, filler tube. Then install fluid filler tube to transaxle tighten bolts temporarily at this step. case. Tightening torque Fluid filler tube bolt (d): 10 N·m (1.0 kgf-m, 7.5 lb-ft) I3RM0B510072-01...
Page 810 “a”: More than 19.9 mm (0.783 in.) • Check torque converter for smooth rotation. • Apply grease around cup (6) at the center of torque converter. “C”: Grease 99000–25011 (SUZUKI Super Grease A) I3RM0B510076-01 93) Install engine mounting LH bracket (1).
Page 811 Automatic Transmission/Transaxle: 5A-167 Specifications Tightening Torque Specifications S7RS0B5107001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft A/T fluid drain plug 12.5 Transmission range sensor bolt 0.55 Output shaft speed sensor bolt Input shaft speed sensor bolt 0.55 Valve body harness connector bolt Shift solenoid bolt Oil strainer bolt Oil pan bolt...
Page 812: Special Tools And Equipment
5A-168 Automatic Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S7RS0B5108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 SUZUKI Super Grease C P/No.: 99000–25030 Sealant SUZUKI Bond No.1216B P/No.: 99000–31230 NOTE Required service material is also described in the following.
Page 813 Automatic Transmission/Transaxle: 5A-169 09923–78210 09924–74510 Bearing installer Bearing and oil seal handle 09925–37811–001 09925–88210 Oil pressure gauge Bearing puller attachment 09925–98210 09925–98221 Input shaft bearing installer Bearing installer 09926–37610 09926–37610–001 Bearing remover Bearing puller 09926–37610–002 09926–37610–003 Bearing puller attachment Bearing remover attachment 09926–58010 09926–96030 Bearing remover attachment...
Page 814 Transfer bearing dummy 09951–18210 09952–06020 Oil seal remover & installer Dial gauge plate No.2 No. 2 SUZUKI scan tool — This kit includes following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6.
Page 815: General Description
Manual Transmission/Transaxle: 5B-1 Manual Transmission/Transaxle Transmission / Transaxle General Description Manual Transaxle Construction and Servicing S7RS0B5201001 The transaxle provides five forward speeds and one reverse speed by means of three synchromeshs and three shafts (input shaft, countershaft and reverse gear shaft). All forward gears are in constant mesh, and reverse uses a sliding idler gear arrangement.
Page 816 5B-2 Manual Transmission/Transaxle: I6RS0C520009-01 1. 5th speed sleeve & hub 8. Reverse idler gear 15. Countershaft 3rd gear 2. Input shaft 5th gear 9. Input shaft 16. Countershaft 2nd gear 3. Input shaft 4th gear 10. Right case 17. Low speed synchronizer sleeve & hub 4.
Page 817: Diagnostic Information And Procedures
5) Apply sealant to thread of drain plug (1), and tighten S7RS0B5206001 it to specified torque. 1) Before changing or inspecting oil, be sure to stop “A”: Sealant 99000–31260 (SUZUKI Bond engine and lift vehicle horizontally. No.1217G) 2) With vehicle lifted up, check oil level and leakage.
Page 818: Differential Side Oil Seal Replacement
7) Apply sealant to thread of level / filler plug, and then tighten it to specified torque. S7RS0B5206002 1) Lift up vehicle and drain transaxle oil. “A”: Sealant 99000–31260 (SUZUKI Bond 2) Remove front drive shaft and/or center shaft No.1217G) referring to “Front Drive Shaft Assembly Removal Tightening torque and Installation in Section 3A”.
Page 819: Gear Shift Control Lever And Cable Components
Manual Transmission/Transaxle: 5B-5 Gear Shift Control Lever and Cable Components S7RS0B5206003 I7RS0A521001-03 1. Gear shift control lever knob 9. Cable bracket 2. Cable bracket bolt 10. Clip Be sure to direct claw of clip to M/T side as shown in figure. 3.
Page 820: Gear Shift Control Lever And Cable Removal And Installation
5B-6 Manual Transmission/Transaxle: Gear Shift Control Lever and Cable Removal Gear Select Control Cable Adjustment S7RS0B5206005 and Installation 1) Release lock plate (1) which restricts moving of S7RS0B5206004 cable end holder (2). Removal 2) Push cable end holder (2) out from adjuster (4) using 1) Remove console box.
Page 821: Back Up Light Switch Removal And Installation
S7RS0B5206006 Removal lever securely. 1) Remove battery and tray with coolant reservoir. “A”: Grease 99000–25011 (SUZUKI Super 2) Disconnect back up light switch coupler (1). Grease A) 3) Remove back up light switch (2). 4) Push cable end holder (2) in the direction of A.
Page 822: Manual Transaxle Unit Components
5B-8 Manual Transmission/Transaxle: Manual Transaxle Unit Components S7RS0B5206008 I6RS0C520004-03 [A]: Forward 7. Engine left mounting bracket bolt and nuts 14. Clutch operating cylinder bolt 1. Engine 8. Clutch housing lower plate : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft) 2. Transaxle 9.
Page 823: Manual Transaxle Unit Dismounting And Remounting
Manual Transmission/Transaxle: 5B-9 Manual Transaxle Unit Dismounting and 12) Support engine using supporting device (1). Remounting CAUTION S7RS0B5206009 Dismounting Do not apply supporting device to projection 1) Drain coolant and transaxle oil. part A. If do so, it may be deformed. 2) Remove coolant reservoir with reservoir hose.
Page 824 5B-10 Manual Transmission/Transaxle: 16) Remove engine under covers. Remounting 17) Support transaxle with transmission jack. CAUTION 18) Remove transaxle to engine bolts and nut of lower side. • Care should be taken not to scratch oil seal lip with drive shaft while raising 19) Remove engine left mounting (1) with bracket (2).
Page 825: Gear Shift And Select Shaft Assembly Components
Removal “A”: Grease 99000–25011 (SUZUKI Super 1) Remove gear shift interlock bolt (1) and 5th to Grease A) reverse interlock guide bolt (2) from transaxle case.
Page 826: Gear Shift And Select Shaft Disassembly And Assembly
• Set new gear shift & select lever inner pin to specified torque. (8) and outer pin (9) facing each gap (“a”, “B”: Sealant 99000–31260 (SUZUKI Bond “b”) in the opposite direction as shown in No.1217G) figure.
Page 827: Manual Transaxle Assembly Components
Manual Transmission/Transaxle: 5B-13 Manual Transaxle Assembly Components S7RS0B5206013 I6RS0C520005-01 1. Transaxle right case 24. Shift fork bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 2. Transaxle left case 25. 5th gear shift fork : Apply sealant 99000-31260 to mating surface of left case and right case.
Page 828: Fifth Gear Disassembly And Assembly
5B-14 Manual Transmission/Transaxle: 11. Sensor cap 34. Washer 12. Oil gutter bolt 35. Side bearing retainer : Apply thread lock 99000-32110 to all around thread part of bolt. 13. Left case plate bolts 36. O-ring : Apply thread lock 99000-32110 to all around thread part of bolt. 14.
Page 829 Manual Transmission/Transaxle: 5B-15 Assembly c) Install synchronizer ring (1) to hub (2) as shown in figure. 1) Assemble 5th speed synchronizer sleeve (1), hub (2), 5th speed synchronizer levers (3) and synchronizer ring (4) as follows. I4RH01520055-01 2) Install 5th gear (1) to countershaft facing machined boss A inward.
Page 830: Manual Transaxle Assembly Disassembly And Reassembly
(5) on input shaft. (0.059 in.) in diameter, mate it with left case and then tighten bolts to specified torque. “B”: Sealant 99000–31260 (SUZUKI Bond No.1217G) Tightening torque Side cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
Page 831 Manual Transmission/Transaxle: 5B-17 13) Tapping input shaft end with plastic hammer, push it 5) Remove gear shift locating bolts (1) with washers, then take out locating springs and steel balls. out as assembly from case a little, then take out input shaft assembly (1), countershaft assembly (2), 6) Remove back up light switch (2).
Page 832 5B-18 Manual Transmission/Transaxle: 18) Remove differential bearing shim. 2) Join input shaft assembly (5), countershaft assembly (4), low speed gear shift shaft (2) and high speed 19) Remove differential side bearing outer race from left gear shift shaft (3) assemblies all together, then case (1) using special tools.
Page 833 1.5 mm (0.059 in.) in case. in diameter then mate it with left case (1). 5) Fasten reverse gear shift lever bolts after applying “B”: Sealant 99000–31260 (SUZUKI Bond thread lock cement. No.1217G) : Thread lock cement 99000–32110 (Thread Lock...
Page 834 5B-20 Manual Transmission/Transaxle: 9) Install side bearing retainer as follows. iii) Calculate clearance a – b, and select differential shim according to the following a) Install differential side bearing outer race to left table. case and then tap and accustom outer race using special tool and plastic hammer.
Page 835 Apply oil to new O-ring of side bearing retainer (3), and install side bearing retainer with new O- “A”: Sealant 99000–31260 (SUZUKI Bond ring to left case. No.1217G) e) Tighten side bearing retainer bolts (1) to Tightening torque specified torque.
Page 836 5B-22 Manual Transmission/Transaxle: 14) With putting a shim (2) on bearing outer race (3), 16) Place left case plate (2) inserting its end in groove of place straightedge (1) over it and compress it by shift guide shaft (4) and tighten bolts (1) to which hand through straightedge, and then measure thread lock cement has been applied.
Page 837: Transaxle Right Case Disassembly And Assembly
Use special tool (A): 09925–15410 and hammer for installation and apply grease to oil seal lip. “B”: Grease 99000–25011 (SUZUKI Super Grease A) Special tool (A): 09913–84510 3) If countershaft right bearing outer race (2) has been removed, install it using special tools and hammer.
Page 838: Transaxle Left Case Disassembly And Assembly
5B-24 Manual Transmission/Transaxle: Transaxle Left Case Disassembly and Assembly S7RS0B5206017 Disassembly 1) Replace differential side oil seal from left case referring to “Differential Side Oil Seal Replacement”, if necessary. 2) Remove input oil gutter (1) from left case, if necessary. I4RH01520028-01 Assembly 1) If input oil gutter (1) has been removed, install it with bolt to which thread lock cement has been applied.
Page 839: Input Shaft And Countershaft Components
Manual Transmission/Transaxle: 5B-25 Input Shaft and Countershaft Components S7RS0B5206018 I3RM0B521010-01 1. Input shaft 12. Input shaft left bearing 23. 2nd gear synchronizer center cone 2. Oil seal 13. Circlip 24. 2nd gear synchronizer inner ring : Apply grease 99000-25011 to oil seal lip. 3.
Page 840: Input Shaft Assembly Disassembly And Reassembly
5B-26 Manual Transmission/Transaxle: Input Shaft Assembly Disassembly and 5) Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) from input Reassembly shaft (1) using bearing puller (4) and hydraulic press. S7RS0B5206019 Disassembly CAUTION 1) Remove input shaft right bearing (2) from input shaft Make sure to use flat side of bearing puller to (1) using bearing puller (3) and hydraulic press.
Page 841 Manual Transmission/Transaxle: 5B-27 NOTE 3) Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as • While press-fitting sleeve & hub, make shown in figure. sure that synchronizer ring key slots are aligned with keys in sleeve &...
Page 842: Countershaft Assembly Disassembly And Reassembly
5B-28 Manual Transmission/Transaxle: 8) Press-fit left bearing (2) using special tool and 2) Apply bearing puller (5) to 2nd gear (4) and drive out hammer. 3rd & 4th gear spacer (2) and 3rd gear (3) together with 2nd gear from countershaft (1) using hydraulic Special tool press.
Page 843 Manual Transmission/Transaxle: 5B-29 5) Apply bearing puller (3) to 1st gear (2) and drive out 3) Fit low speed synchronizer sleeve (4) to hub (3), low speed synchronizer sleeve & hub assembly (1) insert 3 keys (2) in it and then set springs (1) as with 1st gear using hydraulic press.
Page 844 5B-30 Manual Transmission/Transaxle: 8) Press-fit 3rd gear (2) and spacer (1) using special 5) Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring. tools and hydraulic press. 6) Drive in low speed synchronizer sleeve & hub CAUTION assembly (1) using special tools and hammer.
Page 845: Synchronizer Parts Inspection
Manual Transmission/Transaxle: 5B-31 Synchronizer Parts Inspection Put the 2nd gear synchronizer outer ring (1), inner ring S7RS0B5206021 (3) and the cone (2) together and then measure the step Check clearance “a” between synchronizer ring (2) and difference between the outer ring and the inner ring. And gear (1), each chamfered tooth of gear, synchronizer also check each chamfered tooth of gear and ring and sleeve, then determine parts replacement.
Page 846: 5Th And Reverse Gear Shift Shafts Disassembly And Assembly
5B-32 Manual Transmission/Transaxle: 5th and Reverse Gear Shift Shafts Disassembly Gear Shift Shaft and Fork Inspection S7RS0B5206024 and Assembly Using feeler gauge, check clearance between fork (1) S7RS0B5206023 and sleeve (2) and replace those parts if it exceeds limit. Disassembly NOTE Disassemble component parts using special tool and For correct judgement of parts replacement,...
Page 847: Differential Components
Manual Transmission/Transaxle: 5B-33 Differential Components S7RS0B5206025 I6RS0C520007-01 1. Differential pinion washer 8. Final gear 2. Differential side pinion gear 9. Final gear bolt 3. Differential side gear 10. Differential pinion shaft 4. Side gear washer : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 5.
Page 848 5B-34 Manual Transmission/Transaxle: Assembly 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 all parts are clean. 1) Assemble differential gear and measure thrust play of differential gear as follows.
Page 849 Manual Transmission/Transaxle: 5B-35 6) Hold differential assembly with soft jawed vise (3), install final gear (2) as shown in figure and then tighten bolts (1) to specified torque. CAUTION Use of any other bolts than specified ones is prohibited. Tightening torque Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft) I4RS0A520043-01 Specifications...
Page 850: Special Tools And Equipment
5B-36 Manual Transmission/Transaxle: Special Tools and Equipment Recommended Service Material S7RS0B5208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 Sealant SUZUKI Bond No.1217G P/No.: 99000–31260 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 NOTE Required service material is also described in the following.
Page 851 Manual Transmission/Transaxle: 5B-37 09923–74510 09923–78210 Bearing puller (20-35 mm) Bearing installer 09924–07710 09924–07730 Synchronizer hub installer Bearing installer 09924–74510 09924–84510–004 Bearing and oil seal handle Bearing installer attachment 09925–15410 09925–78210 Oil seal installer Spring pin remover (6 mm) 09925–88210 09925–98210 Bearing puller attachment Input shaft bearing installer 09926–27610...
Page 852 5B-38 Manual Transmission/Transaxle: 09951–16080 Bearing installer...
Page 853: Clutch
Clutch: 5C-1 Clutch Transmission / Transaxle General Description Clutch Construction S7RS0B5301001 The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
Page 854: Diagnostic Information And Procedures
5C-2 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis S7RS0B5304001 Condition Possible cause Correction / Reference Item Slipping Improper clutch pedal free travel Replace master cylinder or clutch pedal arm. Worn or oily clutch disc facing Replace disc. Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
Page 855: Clutch Fluid Level Inspection
Clutch: 5C-3 Clutch Release Margin “C” Clutch Fluid Level Inspection S7RS0B5306002 1) Pull up parking brake fully and block wheels. Refer to “Brake Fluid Level Inspection in Section 4A”. 2) Start engine and keep engine at idle with neutral Clutch fluid specification gear position.
Page 856: Clutch Pedal Position (Cpp) Switch Removal And Installation
5C-4 Clutch: Clutch Pedal Position (CPP) Switch Removal 3) Depress clutch pedal several times, and then release clutch pedal, push snap ring (2) and pull pipe and Installation connector (1) one notch. S7RS0B5306004 Removal 1) Disconnect connector of CPP switch (1) with ignition switch OFF.
Page 857: Clutch Pedal Position (Cpp) Switch Inspection And Adjustment
Clutch: 5C-5 Clutch Pedal Position (CPP) Switch Inspection Adjustment With clutch pedal depressed, adjust switch (1) position and Adjustment so that clearance between end of thread and clutch S7RS0B5306005 pedal arm is within specification, and then tighten lock Inspection nut to specified torque. Check for resistance between terminals under each Clearance between end of thread and clutch pedal condition below.
Page 858: Clutch Fluid Pipe Removal And Installation
• Do not allow fluid to get on painted • Apply grease to push rod tip. surface. “A”: Grease 99000–25100 (SUZUKI Silicone • Do not allow pipe to contact hard against Grease) vehicle body or other parts. • Install each clamp securely.
Page 859: Clutch Operating Cylinder Removal And Installation
Clutch: 5C-7 Clutch Operating Cylinder Removal and • Apply grease to push rod tip. Installation “A”: Grease 99000–25100 (SUZUKI Silicone S7RS0B5306010 Grease) Removal 1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake master cylinder reservoir.
Page 860: Clutch Cover, Clutch Disc And Flywheel Components
5C-8 Clutch: 8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin. Clutch Cover, Clutch Disc and Flywheel Components S7RS0B5306013 I4RS0A530013-02 1. Flywheel 9. Clutch disc 2. Flywheel bolt 10. Clutch cover bolt 3. Clutch release shaft seal 11.
Page 861 Clutch: 5C-9 3) Pull out input shaft bearing (1) from flywheel (2), use Installation the following special tool if necessary. CAUTION Special tool Do not reuse flywheel bolts. Otherwise, bolts (A): 09921–26020 may loosen. Be sure to use new bolts with (B): 09930–30104 pre-coated adhesive.
Page 862: Clutch Cover, Clutch Disc And Flywheel Inspection
“Manual Transaxle Unit Dismounting and Remounting in Section 5B”. I4RS0A530019-01 “A”: Grease 99000–25210 (SUZUKI Super Grease I) NOTE When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the splines.
Page 863: Clutch Release System Removal And Installation
Release shaft seal will also be pushed out. Special tool Special tool (A): 09943–88211 (A): 09922–46010 (B): 09923–46030 4) Remove release shaft (1). “A”: Grease 99000–25011 (SUZUKI Super Grease A) I4RS0A530020-01 I3RM0A530016-01...
Page 864 (2), then set release bearing (1). 3) Apply grease to No.2 bush (1) inside and press-fit it using the same special tool as in removal. “A”: Grease 99000–25011 (SUZUKI Super Grease A) “A”: Grease 99000–25011 (SUZUKI Super Grease A) 7) Apply small amount of grease to input shaft (3) spline (0.3 g (0.01 oz)) and front end (0.15 g (0.005...
Page 865 Clutch: 5C-13 Clutch Release System Inspection Clutch Release Shaft S7RS0B5306017 Check clutch release shaft and its pin for deflection or damage. Clutch Release Bearing If abnormality is found, replace it. Check clutch release bearing for smooth rotation. If abnormality is found, replace it. CAUTION Do not wash release bearing.
Page 866: Special Tools And Equipment
5C-14 Clutch: Special Tools and Equipment Recommended Service Material S7RS0B5308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease A P/No.: 99000–25011 SUZUKI Silicone Grease P/No.: 99000–25100 SUZUKI Super Grease I P/No.: 99000–25210 NOTE Required service material is also described in the following.
Page 867 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering System Note .........6C-1 Precautions in Diagnosing Troubles ....6C-1 Precautions............. 6-1 General Description ..........6C-2 Precautions on Steering........6-1 P/S System Description ........6C-2 Steering General Diagnosis....6A-1 EPS Diagnosis General Description ....6C-3 On-Board Diagnostic System Description...6C-3 Precautions............6A-1 Schematic and Routing Diagram ......6C-4...
Page 868 6-ii Table of Contents Steering Wheel Play Check ......6C-39 Steering Rack Plunger Removal and Steering Force Check ........6C-39 Installation ............6C-45 Steering Rack Plunger Inspection .....6C-45 Repair Instructions ..........6C-40 P/S Control Module Removal and Installation...6C-46 Steering Gear Case Assembly Components ..6C-40 Torque Sensor and Its Circuit Inspection ..6C-46 Tie-Rod End Boot On-Vehicle Inspection ..6C-41 P/S Motor and Its Circuit Inspection ....6C-47...
Page 869: Precautions
Precautions: Precautions Steering Precautions Precautions on Steering S7RS0B6000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Air Bag System Service Warning Refer to “Air Bag System Service Warning in Section 00”. Precautions for Steering Diagnosis Refer to “Precautions for Steering Diagnosis in Section 6A”. Service Precautions of Steering Wheel and Column Refer to “Service Precautions of Steering Wheel and Column in Section 6B”.
Page 870 6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Precautions Precautions for Steering Diagnosis S7RS0B6100001 Since the problems in steering 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 871: Diagnostic Information And Procedures
Steering General Diagnosis: 6A-2 Diagnostic Information and Procedures Steering Symptom Diagnosis S7RS0B6104001 Condition Possible cause Correction / Reference Item Hard steering Tire not adequately inflated Inflate tires to proper pressure. Malfunction of power steering system Check and correct. Bind in tie-rod end ball studs or lower Replace tie-rod end or front suspension arm.
Page 872: Precautions
6B-1 Steering Wheel and Column: Steering Wheel and Column Steering Precautions Service Precautions of Steering Wheel and Enabling Air Bag System For enabling air bag system, refer to “Enabling Air Bag Column System in Section 8B”. S7RS0B6200001 For service precautions, refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Page 873: Diagnostic Information And Procedures
Steering Wheel and Column: 6B-2 Diagnostic Information and Procedures Checking Steering Column for Accident 3) Check steering shaft joints and shaft for any damages such as crack, breakage, malfunction or Damage excessive play. S7RS0B6204001 NOTE If anything is found faulty, replace as lower shaft Vehicles involved in accidents resulting in assembly or steering column assembly.
Page 874: Repair Instructions
6B-3 Steering Wheel and Column: Repair Instructions Steering Wheel and Column Construction S7RS0B6206001 I4RS0B620001-04 1. Driver air bag (inflator) module 8. Steering column lower cover 15. Audio control switch 2. Steering wheel 9. Steering column 16. Knee protector plate 3. Driver air bag (inflator) module mounting bolt 10.
Page 875: Steering Wheel Removal And Installation
Steering Wheel and Column: 6B-4 Steering Wheel Removal and Installation Installation S7RS0B6206002 CAUTION CAUTION Following 2 Steps (Step 1) and 2)) are Do not turn the contact coil more than prerequisite for installation of steering wheel. allowable number of turns (about two and a If steering wheel has been installed without half turns from the center position clockwise these 2 Steps, contact coil will break when...
Page 876: Contact Coil Cable Assembly Removal And Installation
6B-5 Steering Wheel and Column: Contact Coil Cable Assembly Removal and Installation Installation 1) Check to make sure that vehicle’s front tires are set S7RS0B6206003 at straight-ahead position and then ignition switch is at LOCK position. CAUTION 2) Install contact coil cable assembly to steering Do not turn contact coil more than allowable column securely.
Page 877: Centering Contact Coil Cable Assembly
Steering Wheel and Column: 6B-6 Centering Contact Coil Cable Assembly Contact Coil Cable Assembly Inspection S7RS0B6206004 S7RS0B6206005 Refer to “Contact Coil Cable and Its Circuit Check in 1) Check that vehicle’s wheels (front tires) are set at Section 8B”. straight-ahead position. 2) Check that ignition switch is at LOCK position.
Page 878: Steering Column Removal And Installation
6B-7 Steering Wheel and Column: Steering Column Removal and Installation Removal S7RS0B6206006 WARNING CAUTION Never rest a steering column assembly on Once the steering column is removed from the steering wheel with the air bag (inflator) the vehicle, the column is extremely module face down and column vertical.
Page 879: Steering Column Inspection
Steering Wheel and Column: 6B-8 Installation CAUTION After tightening steering column mounting nuts, shaft joint bolts should be tightened. Wrong tightening order could cause a damage to shaft joint. 1) Be sure that front wheels are in straight. 2) Install steering column assembly to lower and upper brackets.
Page 880: Ignition Switch Cylinder Assembly Removal And Installation (Non- Keyless Start Model)
6B-9 Steering Wheel and Column: Ignition Switch Cylinder Assembly Removal Steering Lock Assembly (Ignition Switch) and Installation (Non- Keyless Start Model) Removal and Installation S7RS0B6206008 S7RS0B6206009 Removal Removal 1) Disconnect negative (–) cable at battery. 1) Remove steering column. Refer to “Steering Column Removal and Installation”.
Page 881: Steering Lower Shaft Removal And Installation
Steering Wheel and Column: 6B-10 5) Tighten new bolts (1) until head of each bolt is Installation broken off. 1) Be sure that front wheels are in straight forward 6) Turn ignition key to “ACC” or “ON” position and state. check to be sure that steering shaft (2) rotates 2) Align flat part “A”...
Page 882: Specifications
6B-11 Steering Wheel and Column: Specifications Tightening Torque Specifications S7RS0B6207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Steering shaft nut 24.0 Steering column nut 10.5 Steering shaft joint bolt 18.5 NOTE The specified tightening torque is also described in the following. “Steering Wheel and Column Construction”...
Page 883: Precautions
Precautions in Diagnosing Troubles S7RS0B6300002 • Take a note of DTC indicated on the SUZUKI scan tool. • Before inspection, be sure to read “Precautions for Electrical Circuit Service in Section 00” and understand what is written there.
Page 884: General Description
6C-2 Power Assisted Steering System: General Description P/S System Description S7RS0B6301001 This power steering (P/S) system consists of a P/S control module (3), a torque sensor (4), a motor (5). In this system, the P/S control module determines the level and direction of the assist force for the steering wheel (1) according to the signals from the torque sensor and vehicle speed signal from ECM.
Page 885: Eps Diagnosis General Description
Power Assisted Steering System: 6C-3 EPS Diagnosis General Description S7RS0B6301002 The P/S system in this vehicle is controlled by the P/S control module. The 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 Description”...
Page 886: Schematic And Routing Diagram
6C-4 Power Assisted Steering System: Schematic and Routing Diagram EPS System Wiring Circuit Diagram S7RS0B6302001 E49-1 LT GRN E52-1 /BLK E51-1 E51-2 E49-2 RED/BLK G28-31 G28-25 E52-5 E52-18 E53-5 RED/ WHT/ E52-6 E53-7 E52-8 E53-2 E23-25 E52-4 E52-20 E53-6 RED/ E23-26 E52-14 E52-9...
Page 887 Power Assisted Steering System: 6C-5 Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side) Terminal Circuit Terminal Circuit Main power supply for internal memory E49-1 E52-9 Ground for torque sensors and EPS motor E49-2 Ground for P/S control module E52-10 —...
Page 888 6C-6 Power Assisted Steering System: Step Action Rechecking and record of DTC Go to Step 9. Go to Step 10. 1) Recheck for DTC referring to “DTC Check”. Is there any DTC(s)? Steering symptom diagnosis and P/S system Go to Step 11. Check and repair symptom diagnosis malfunction part(s), and...
Page 889 Power Assisted Steering System: 6C-7 Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 890: Eps" Warning Light Check
1) Turn ignition switch to OFF position. the end of the flow has been reached, check the parts of 2) Connect SUZUKI scan tool to data link connector the system suspected as a possible cause referring to (DLC) (1) located on underside of instrument panel “P/S System Symptom Diagnosis”...
Page 891: Dtc Clearance
4) Read DTC according to the instructions displayed on 1) Turn ignition switch to OFF position. SUZUKI scan tool. For further details, refer to 2) Connect SUZUKI scan tool to data link connector operator’s manual for SUZUKI scan tool. (DLC) (1) located on underside of instrument panel NOTE at driver’s seat side.
Page 892 6C-10 Power Assisted Steering System: Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) Vehicle speed signal is 0 km/h even though engine speed is • Vehicle speed signal circuit more than 4000 rpm for more than •...
Page 893: Scan Tool Data
Power Assisted Steering System: 6C-11 Detecting condition DTC No. Detecting item Trouble area (DTC will set when detecting) P/S motor circuit current too Measured motor drive current is 1 driving C1143 high more than 50 A. cycle Measured motor drive current is less than 2 A continuously for more than 3 seconds even though •...
Page 894: Visual Inspection
6C-12 Power Assisted Steering System: Scan Tool Data Definitions Motor Control (Motor Control Current, A) Based on the input signal, the P/S control module Battery Voltage determines the assist amount and controls the current to This parameter indicates battery positive voltage. the motor suitable for that assist amount.
Page 895: Serial Data Link Circuit Check
Power Assisted Steering System: 6C-13 Condition Possible cause Correction / Reference Item Vehicle pulls to one side Poor performance of torque sensor Check torque sensor referring to “Torque during straight driving Sensor and Its Circuit Inspection”. Steering gear case assembly faulty Replace.
Page 896 Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. 1) Make sure that SUZUKI scan tool is free from Go to Step 3. Connect SUZUKI scan malfunction and that correct program card (software) for tool to DLC properly.
Page 897: Eps" Warning Light Does Not Come On With Ignition Switch Turned On Before Engine Starts
Power Assisted Steering System: 6C-15 “EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts S7RS0B6304010 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E51-2 RED/BLK G28-31 G28-25 E52-5 E49-2 [A ] [B ] 12 13 14 15 16 17 18 19 20 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 32 31 30 29 28 27...
Page 898: Eps" Warning Light Remains On Steady After Engine Starts
1) Check DTC referring to “DTC Check”. Go to applicable DTC Go to Step 2. diag. flow. Is there any DTC(s) (NO CODES on SUZUKI scan tool)? 1) With ignition switch OFF, disconnect P/S control module Go to Step 3. Replace the P/S control connector (“E52”).
Page 899: Dtc C1113: Steering Torque Sensor (Main And Sub) Circuit Correlation
Power Assisted Steering System: 6C-17 DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation S7RS0B6304012 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E49-2 E51-2 E52-6 E53-7 E52-18 E53-5 E52-8 E53-2 [B ] [A ] E52-20 E53-6 E52-9 E53-4 12 13 14 15 16 17 18 19 20 E52-16 E53-1...
Page 900 6C-18 Power Assisted Steering System: Step Action Torque sensor signal (main) voltage check Go to Step 5. Torque sensor signal circuit is shorted to 1) Check for voltage between “E53-5” (“WHT” wire) other circuit. terminal and body ground with ignition switch ON. Is it about 0 V? Torque sensor signal (main) resistance check Go to Step 6.
Page 901 Power Assisted Steering System: 6C-19 DTC C1114: Steering Torque Sensor Reference Power Supply Circuit S7RS0B6304013 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E49-2 E51-2 E52-6 E53-7 E52-18 E53-5 E52-8 E53-2 [B ] [A ] E52-20 E53-6 E52-9 E53-4 12 13 14 15 16 17 18 19 20 E52-16 E53-1 E52-19...
Page 902 6C-20 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. diag. flow. Is DTC C1153 and/or DTC C1155 indicated together? Torque sensor 5 V reference power supply circuit Go to Step 4.
Page 903 Power Assisted Steering System: 6C-21 DTC C1117: Steering Torque Sensor Failure Signal Circuit Low S7RS0B6304014 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E49-2 E51-2 E52-6 E53-7 E52-18 E53-5 E52-8 E53-2 [A ] E52-20 E53-6 E52-9 E53-4 12 13 14 15 16 17 18 19 20 E53-1 E52-16 E52-19...
Page 904: Dtc C1118: Steering Torque Sensor Failure Signal Circuit High
6C-22 Power Assisted Steering System: DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable diag. Go to Step 3. flow. Is DTC C1113, C1114 and/or DTC C1119 indicated together? Torque sensor internal failure signal circuit check Go to Step 4.
Page 905 Power Assisted Steering System: 6C-23 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable diag. Go to Step 3. flow. Is DTC C1113, C1114 and/or DTC C1119 indicated together? Torque sensor internal failure signal voltage check Substitute a known- Go to Step 4.
Page 906 6C-24 Power Assisted Steering System: DTC C1119: Steering Torque Sensor Power Supply Circuit S7RS0B6304016 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E49-2 E51-2 E52-6 E53-7 E52-18 E53-5 E52-8 E53-2 [B ] [A ] E52-20 E53-6 E52-9 E53-4 12 13 14 15 16 17 18 19 20 E52-16 E53-1 E52-19...
Page 907 Power Assisted Steering System: 6C-25 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to DTC C1153 diag. Go to Step 3. flow. Is DTC C1153 indicated together? Torque sensor main power supply voltage check Go to Step 4.
Page 908: Dtc C1121 / C1123 / C1124: Vss Circuit Failure
6C-26 Power Assisted Steering System: DTC C1121 / C1123 / C1124: VSS Circuit Failure S7RS0B6304017 DTC C1121: No Vehicle Speed Signal (60 Seconds or More) DTC C1123: No Vehicle Speed Signal (30 Seconds or More) DTC C1124: Vehicle Speed Performance (Impossible Deceleration) Wiring Diagram E49-1 [B ]...
Page 909 Power Assisted Steering System: 6C-27 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to applicable DTC Go to Step 3. DTC Check for ECM referring to “DTC Check in Section 1A”. diag.
Page 910: Dtc C1122: Engine Speed Signal
6C-28 Power Assisted Steering System: DTC C1122: Engine Speed Signal S7RS0B6304018 NOTE DTC C1122 (engine speed signal failure) is indicated when ignition switch is at ON position and engine is not running, but means there is nothing abnormal if indication changes to a normal one when engine is started.
Page 911 Power Assisted Steering System: 6C-29 DTC Troubleshooting Step Action Was “EPS System Check” performed? Go to Step 2. Go to “EPS System Check”. DTC check Go to Step 3. Check intermittent trouble referring to 1) Clear DTC(s) referring to “DTC Clearance”. “Intermittent and Poor 2) Run engine at idle speed.
Page 912: Dtc C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure
6C-30 Power Assisted Steering System: DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure S7RS0B6304019 DTC C1141: P/S Motor Circuit Voltage DTC C1142: P/S Motor Circuit Range / Performance DTC C1143: P/S Motor Circuit Current Too High DTC C1145: P/S Motor Circuit Current Too Low Wiring Diagram E49-1...
Page 913 Power Assisted Steering System: 6C-31 DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area DTC C1141: • P/S motor circuit Voltage between both motor drive circuits is more than 8.5 • P/S motor V or less than 0.2 V for 0.5 seconds continuously while •...
Page 914: Dtc C1153: P/S Control Module Power Supply Circuit Voltage Low
6C-32 Power Assisted Steering System: DTC C1153: P/S Control Module Power Supply Circuit Voltage Low S7RS0B6304020 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E51-2 E49-2 [B ] [A ] 12 13 14 15 16 17 18 19 20 I7RS0B630011-01 [A]: Connector “E52”...
Page 915: Dtc C1155: P/S Control Module Failure
Power Assisted Steering System: 6C-33 DTC C1155: P/S Control Module Failure S7RS0B6304021 Wiring Diagram Refer to “DTC C1153: P/S Control Module Power Supply Circuit Voltage Low”. DTC Detecting Condition and Trouble Area DTC detecting condition Trouble area Internal memory (EEPROM) is data error. •...
Page 916 6C-34 Power Assisted Steering System: P/S Control Module Power Supply and Ground Circuit Check S7RS0B6304022 Wiring Diagram E49-1 LT GRN E52-1 /BLK E51-1 E51-2 E49-2 [B ] [A ] 12 13 14 15 16 17 18 19 20 I7RS0B630012-01 [A]: Connector “E52” (viewed from harness side) 2.
Page 917: P/S Control Module Power Supply And Ground Circuit Check
Power Assisted Steering System: 6C-35 Step Action P/S control module ground circuit check P/S Control Module “BLK” wire is open or Power Supply and high resistance circuit. 1) Connect connectors to P/S control module. Ground Circuit is in 2) Start engine. good condition.
Page 918 6C-36 Power Assisted Steering System: Voltage Check 1) Remove console box. 2) Check for voltage at each terminal with connectors connected to the P/S control module. NOTE As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or more when ignition switch is ON.
Page 919 Power Assisted Steering System: 6C-37 Terminal Wire color Circuit Normal voltage Remarks E52-11 PPL/WHT Data link connector — — *0 – 1 V ↑↓ 8 – 14 V (“Reference waveform No.30” E52-12 Engine speed signal Engine idling and “Reference waveform No.31” under “Inspection of ECM and Its Circuits in Section 1A”.)
Page 920 6C-38 Power Assisted Steering System: Reference waveform No.1 Reference waveform No.2 Motor output signal 1(1), Motor output signal 2(2), with Motor output signal 1(1), Motor output signal 2(2), with engine idling engine idling Measurement CH1: “E51-1” to vehicle body ground Measurement CH1: “E51-1”...
Page 921: Steering Wheel Play Check
Power Assisted Steering System: 6C-39 • Steering pinion or rack gear for wear or breakage Reference waveform No.3 Motor output signal 1(1), Motor output signal 2(2), with • Each part for looseness engine idling Steering wheel play “a” Measurement CH1: “E51-1” to vehicle body ground : 0 –...
Page 922: Repair Instructions
6C-40 Power Assisted Steering System: Repair Instructions Steering Gear Case Assembly Components S7RS0B6306001 1322 I7RS0B630013-02 1. Steering gear case 12. Steering gear case mounting No.3 bolt 23. Boot 2. Tie-rod lock washer 13. Gear rack side No.1 bracket 24. split pin 3.
Page 923: Tie-Rod End Boot On-Vehicle Inspection
Power Assisted Steering System: 6C-41 9. Tie-rod end nut 20. Gear rack side No.2 bracket : 9.5 N⋅m (0.95 kgf-m, 7.0 lb-ft) 10. Steering gear case mounting No.1 bolt 21. Steering gear case mounting No.2 bolt : Do not reuse. 11.
Page 924: Tie-Rod End Inspection
6C-42 Power Assisted Steering System: Steering Shaft Joint On-Vehicle Inspection 2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to specified torque. S7RS0B6306005 Check shaft joint for wear, breakage and any other 3) Bend new split pin (2). damage and replace if any defect exists.
Page 925: Steering Rack Boot Inspection
Power Assisted Steering System: 6C-43 Steering Rack Boot Inspection Installation S7RS0B6306007 1) Mount steering gear case (1) to front suspension Hoist vehicle. frame (2) and tighten gear case mounting No.1 bolts Inspect each boot for tear. A torn boot allows entry of (3), No.2 bolts (4) and No.3 bolts (5) to specified dust and water which can cause wear to steering rack torque.
Page 926 6C-44 Power Assisted Steering System: 6) Unbend bent part of tie-rod lock washer (1). 4) Apply sealant to gear case groove “A” indicated in figure. Position boot properly in grooves of gear case 7) Hold rack with soft jawed vise (3) and remove tie-rod (or rack side mount) and tie-rod.
Page 927: Steering Rack Plunger Removal And Installation
1.5 lb-ft) I4RS0A630045-01 Installation 1) Apply grease lightly to sliding part of plunger (1) against rack. “A”: Grease 99000–25050 (SUZUKI Super Grease E) I3RM0A630055-02 2) Install plunger and spring (2) as shown. 5) After adjustment, tighten lock nut to specified torque 3) Apply thread lock cement to rack damper screw (3) with holding damper screw at the position.
Page 928: P/S Control Module Removal And Installation
6C-46 Power Assisted Steering System: P/S Control Module Removal and Installation S7RS0B6306011 Removal 1) Disconnect negative cable at battery. 2) Remove console box. 3) Disconnect connectors (1) from P/S control module (2). 4) Disconnect connector from yaw rate / G sensor (ESP®...
Page 929: P/S Motor And Its Circuit Inspection
Power Assisted Steering System: 6C-47 P/S Motor and Its Circuit Inspection 5) Hoist vehicle. S7RS0B6306013 6) Connect “E51” connector to P/S control module with 1) Remove console box. ignition switch OFF position. 2) Disconnect motor connector (“E51”) from P/S control 7) Using ammeter (2), check that P/S motor (1) current module with ignition switch OFF.
Page 930: Specifications
6C-48 Power Assisted Steering System: Specifications Tightening Torque Specifications S7RS0B6307001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Tie-rod end nut 32.5 Tie-rod end lock nut 32.5 Wheel nut 61.5 Steering gear case mounting No.1 bolt 40.0 Steering gear case mounting No.2 bolt 40.0 Steering gear case mounting No.3 bolt 29.0...
Page 931: Special Tools And Equipment
Power Assisted Steering System: 6C-49 Special Tools and Equipment Recommended Service Material S7RS0B6308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI Super Grease E P/No.: 99000–25050 Silicone sealant Silicone sealant P/No.: 99000–31120 Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110...
Page 932 6C-50 Power Assisted Steering System:...
Page 933 Table of Contents 7- i Section 7 HVAC CONTENTS Precautions ..........7-1 Schematic and Routing Diagram ......7B-5 Major Components of A/C System......7B-5 Precautions............. 7-1 A/C System Wiring Diagram .......7B-6 Precautions on HVAC ........... 7-1 Diagnostic Information and Procedures ....7B-7 Heater and Ventilation......7A-1 A/C System Symptom Diagnosis ......7B-7 Abnormal Noise Symptom Diagnosis of A/C General Description ..........7A-1...
Page 934 7-ii Table of Contents Recommended Service Material ....... 7B-33 DTC B1562: Outside Air Temperature Sensor Special Tool ............7B-33 Signal Malfunction...........7B-66 DTC B1563: A/C Refrigerant Pressure Automatic Type .............7B-34 Sensor Signal Malfunction ......7B-66 Precautions............7B-34 Inspection of HVAC Control Module and Its A/C System Caution..........
Page 935 Table of Contents 7-iii Special Tools and Equipment ......7B-79 Special Tool ............7B-79...
Page 936: Precautions
7-1 Precautions: Precautions HVAC Precautions Precautions on HVAC S7RS0B7000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. A/C System Caution Refer to “A/C System Caution in Section 7B”. Precautions on Servicing A/C System Refer to “Precautions on Servicing A/C System in Section 7B”.
Page 937: General Description
Heater and Ventilation: 7A-1 Heater and Ventilation HVAC General Description Heater and Ventilation Construction S7RS0B7101001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I4RS0B710001-01 1. HVAC unit 5. Side ventilation air 9.
Page 938: Schematic And Routing Diagram
7A-2 Heater and Ventilation: 2. Ventilator duct 6. Foot air 10. Recirculation air 14. Resistance board 3. Defroster nozzle 7. Front defroster air 11. Center ventilation air 15. Rear duct (if equipped) 4. Heater core 8. Side defroster air 12. Air intake door Schematic and Routing Diagram Heater and Ventilation Wiring Circuit Diagram S7RS0B7102001...
Page 939: Diagnostic Information And Procedures
Heater and Ventilation: 7A-3 Diagnostic Information and Procedures Heater and Ventilation Symptom Diagnosis S7RS0B7104001 Condition Possible cause Correction / Reference Item Blower motor does not Fuse blown Check related fuses, and then check for short operate with blower circuit to ground. speed selector ON Blower motor relay faulty Check blower motor relay referring to “Blower...
Page 940: Repair Instructions
7A-4 Heater and Ventilation: Repair Instructions HVAC Unit Components Blower Motor Removal and Installation S7RS0B7106001 S7RS0B7106003 For manual type A/C, refer to “HVAC Unit Components in Section 7B”. Removal For automatic type A/C, refer to “HVAC Unit 1) Disconnect negative (–) cable from battery. Components in Section 7B”.
Page 941: Blower Motor Resistor Removal And Installation
Heater and Ventilation: 7A-5 6) Remove connector (1) from blower motor resistor • Check for operation and current. (2), and then remove blower motor resistor from a. Put blower motor (1) in a soft-jawed vise. HVAC unit by removing screws (3). b.
Page 942: Blower Motor Relay Inspection
7A-6 Heater and Ventilation: Blower Motor Relay Inspection S7RS0B7106007 1) Remove junction block assembly referring to “BCM (Included in Junction Block Assembly) Removal and Installation in Section 10B”. 2) Disconnect blower motor relay (1) from junction block assembly (2). 3) Check that there is no continuity between terminal “C”...
Page 943: Hvac Control Unit Removal And Installation
Heater and Ventilation: 7A-7 HVAC Control Unit Removal and Installation 7) Remove two connectors from HVAC control unit. S7RS0B7106009 8) Remove HVAC control unit (1) from instrument panel. Removal 1) Disconnect negative (–) cable at battery. NOTE 2) Disable air bag system referring to “Disabling Air Be careful not to damage HVAC control unit Bag System in Section 8B”.
Page 944 7A-8 Heater and Ventilation: b. Move temperature control lever (1) and air flow c. Fix temperature control inner cable (1) to pin of control plate (2) fully to the arrow direction. temperature control lever and air flow control inner cable (2) to pin of air flow control plate, and then fix each outer cable (3) to each cable lock clamp.
Page 945: Blower Speed Selector Inspection
Heater and Ventilation: 7A-9 Blower Speed Selector Inspection Air Intake Control Actuator Removal and S7RS0B7106010 Installation Check blower speed selector for each terminal to S7RS0B7106012 terminal continuity. If check result does not meet the following conditions, replace HVAC control unit. Removal 1) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and...
Page 946: Air Intake Control Actuator Inspection
7A-10 Heater and Ventilation: Air Intake Control Actuator Inspection Center Ventilation Louver Removal and S7RS0B7106013 Installation Check air intake control actuator as follows: S7RS0B7106014 Removal 1) Using service wire, connect battery positive terminal to “a” terminal and battery negative terminal to 1) Disconnect negative (–) cable from battery.
Page 947: Side Ventilation Louver Removal And Installation
Heater and Ventilation: 7A-11 Side Ventilation Louver Removal and Passenger side ventilation louver Installation Removal S7RS0B7106015 1) Disconnect negative (–) cable from battery. Driver side ventilation louver 2) Disable air bag system referring to “Disabling Air Removal Bag System in Section 8B”. 1) Disconnect negative (–) cable from battery.
Page 948: Hvac Air Filter Removal And Installation (If Equipped)
7A-12 Heater and Ventilation: HVAC Air Filter Removal and Installation (If HVAC Air Filter Inspection (If Equipped) S7RS0B7106017 Equipped) Check that filter is not excessively dirty, damage or oily, S7RS0B7106016 clean filter with compressed air from air outlet side of filter.
Page 949: Air Conditioning System
Air Conditioning System: Manual Type 7B-1 Air Conditioning System HVAC Manual Type Precautions A/C System Caution S7RS0B7210001 CAUTION • The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Page 950 7B-2 Air Conditioning System: Manual Type Refrigerant Line I4RS0B720001-02 1. Suction hose 4. Expansion valve : Apply compressor oil (refrigerant oil) to O-ring. : Apply compressor oil (refrigerant oil) to O-ring. 2. Discharge hose 5. A/C refrigerant pressure sensor : Apply compressor oil (refrigerant oil) to O-ring. : Apply compressor oil (refrigerant oil) to O-ring.
Page 951: General Description
Air Conditioning System: Manual Type 7B-3 General Description Refrigerant Type Identification S7RS0B7211001 Whether the A/C system in the vehicle uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on label (1) on the compressor. Also, it can be checked by the shape of the service (charge) valve (2). I4RS0A720002-01 [A]: HFC-134a (R-134a) [B]: CFC-12 (R-12)
Page 952: Sub-Cool A/C System Description
7B-4 Air Conditioning System: Manual Type Sub-Cool A/C System Description S7RS0B7211003 In the sub-cool A/C system (condenser integrated with receiver/dryer), the inside of the condenser is divided into the condensation part and the sub-cooler part, and the receiver/dryer is located between those. In the receiver/dryer, the refrigerant is separated into the vapor refrigerant and the liquid refrigerant.
Page 953: Schematic And Routing Diagram
Air Conditioning System: Manual Type 7B-5 Schematic and Routing Diagram Major Components of A/C System S7RS0B7212001 Airflow diagram I4RS0A720003-01 Major components of A/C system I4RS0B720002-01 1. HVAC unit 5. Discharge hose 9. Side ventilation air 13. Side defroster air 2. Compressor 6.
Page 954: A/C System Wiring Diagram
7B-6 Air Conditioning System: Manual Type A/C System Wiring Diagram S7RS0B7212002 BLK/YEL G19-6 BLK/WHT G19-7 G19-1 RED/BLK BLU/WHT G19-3 G19-2 G19-5 BRN/WHT G18-6 G18-5 GRN/WHT RED/BLK G18-14 G18-13 G18-9 G18-10 BLK/ORN G18-8 BLK/RED G18-7 RED/YEL G18-4 G18-3 BLU/WHT E23-19 E23-3 E23-18 BLK/YEL BLK/YEL...
Page 955: Diagnostic Information And Procedures
Air Conditioning System: Manual Type 7B-7 Diagnostic Information and Procedures A/C System Symptom Diagnosis S7RS0B7214001 Condition Possible cause Correction / Reference Item No cool air comes out (A/ No refrigerant Perform recovery, evacuation and charge C system does not referring to “Operation Procedure for operate) Refrigerant Charge”.
Page 956 7B-8 Air Conditioning System: Manual Type Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C system normal Condenser clogged Check condenser referring to “Condenser operation)
Page 957: Abnormal Noise Symptom Diagnosis Of A/C System
Air Conditioning System: Manual Type 7B-9 Condition Possible cause Correction / Reference Item Insufficient airflow of A/C evaporator clogged or frosted Check A/C evaporator and evaporator cooled air thermistor (evaporator temperature sensor) referring to “Evaporator Inspection” and “Evaporator Thermistor (Evaporator Temperature Sensor) Inspection”.
Page 958: A/C System Performance Inspection
7B-10 Air Conditioning System: Manual Type Abnormal Noise from Tension Pulley Condition Possible cause Correction / Reference Item Clattering noise is heard Worn or damaged bearing Replace tension pulley. from pulley Pulley cranks upon Cracked or loose bracket Replace or retighten bracket. contact Abnormal Noise from A/C Evaporator Condition...
Page 959 Air Conditioning System: Manual Type 7B-11 5) Warm up engine to the normal operating 10) Check for each pressure of low side and high side if temperature and keep it at the specified idle speed. it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective 6) Turn A/C switch ON, set blower speed selector at part referring to the following table.
Page 960 7B-12 Air Conditioning System: Manual Type High pressure gauge Condition Possible cause Correction Refrigerant overcharged Recharge. Expansion valve frozen or clogged Check expansion valve. Clogged refrigerant passage of high pressure side Clean or replace. Radiator cooling fan malfunction Check radiator cooling fan. Pressure is higher than (Insufficient cooling of condenser) acceptable range...
Page 961 Air Conditioning System: Manual Type 7B-13 11) Check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature near air inlet of HVAC unit is 30 °C (86 °F) and the one at air outlet of center ventilation louver is 17 °C (62.6 °F), their crossing point is within acceptable range as shown in the graph.
Page 962 7B-14 Air Conditioning System: Manual Type Condition Manifold gauge MPa (kg/cm ) (psi) Possible cause Correction Detail 0.27 – 0.43 1.59 – 1.94 (2.7 – 4.3) (15.9 – 19.4) Normal condition — — (38 – 61) (226 – 276) The low pressure side Clean expansion reads a negative Dust particles or water...
Page 963: A/C System Inspection At Ecm
Air Conditioning System: Manual Type 7B-15 Condition Manifold gauge MPa (kg/cm ) (psi) Possible cause Correction Detail Overcharged A/C Adjust refrigerant to system. specified amount. High pressure reading on Faulty condenser both low and high Clean condenser. cooling operation. pressure sides. Faulty radiator cooling Inspect and repair fan operation.
Page 964: Repair Instructions
7B-16 Air Conditioning System: Manual Type Repair Instructions Operation Procedure for Refrigerant Charge S7RS0B7216001 WARNING • Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately – 6 °C (21.2 °F) below freezing point.
Page 965 Air Conditioning System: Manual Type 7B-17 NOTE • After recovering refrigerant from system, the amount of removed compressor oil must be measured for replenishing compressor oil. • When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
Page 966 7B-18 Air Conditioning System: Manual Type NOTE When replacing other parts Replenish the following amount of oil to compressor. • If the system does not show a vacuum Amount of compressor oil to be replenished below –100 kPa (–1.0 kg/cm , –760 mmHg, Evaporator: 25 cm (25 ml, 0.85 US.
Page 967 Air Conditioning System: Manual Type 7B-19 Charge Charge proper amount of refrigerant accurately in accordance with the following procedure. CAUTION Specified amount of refrigerant 370 ± 20 g (13.0 ± 0.7 oz) • Because the sight glass is not used for this A/C system, do not perform an additional The initial charge of the A/C system is performed charge to the A/C system.
Page 968 7B-20 Air Conditioning System: Manual Type 7) When refrigerant container (1) is emptied, use the 8) After the system has been charged with specified amount (370 ± 20 g) of refrigerant or when low following procedure to replace it with a new refrigerant container.
Page 969: Condenser Assembly On-Vehicle Inspection
Air Conditioning System: Manual Type 7B-21 Condenser Assembly On-Vehicle Inspection Removal of Manifold Gauge Set S7RS0B7216002 Check the followings. WARNING • Clog of condenser fins High pressure side is under high pressure. If any clog is found, condenser fins should be washed Therefore, be careful not to get injured with water and should be dried with compressed air.
Page 970: Receiver/Dryer Removal And Installation
7B-22 Air Conditioning System: Manual Type 5) Remove condenser assembly (1) as shown. Installation Reverse the removal procedure noting the following instructions. • Replenish specified amount of compressor oil to compressor suction side referring to “When replacing other parts” in “Operation Procedure for Refrigerant Charge”.
Page 971: Hvac Unit Components
Air Conditioning System: Manual Type 7B-23 HVAC Unit Components S7RS0B7216005 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side 21 * 15 * 15 * 15 * 14 * 14 * 10 * 11 *...
Page 972: Hvac Unit Removal And Installation
7B-24 Air Conditioning System: Manual Type 2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing 3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever 21. Filter cover (if equipped) 4. HVAC Air filter (if equipped) 10.
Page 973: Evaporator Thermistor (Evaporator Temperature Sensor) Removal And Installation
Air Conditioning System: Manual Type 7B-25 Evaporator Thermistor (Evaporator Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation Temperature Sensor) Inspection S7RS0B7216008 S7RS0B7216009 Removal Check resistance between terminals of evaporator thermistor (1). 1) Disconnect negative (–) cable from battery. If check results are as not specified, replace evaporator 2) Remove HVAC unit from vehicle body referring to thermistor.
Page 974: Expansion Valve Removal And Installation
7B-26 Air Conditioning System: Manual Type Expansion Valve Removal and Installation A/C refrigerant pressure sensor voltage S7RS0B7216010 specifications (A/C refrigerant pressure measured by manifold gauge) Removal 0.8 MPa (8.0 kg/cm , 116 psi): 1.46 – 1.71 V 1) Recover refrigerant from the A/C system with 1.4 MPa (14 kg/cm , 203 psi): 2.28 –...
Page 975: A/C Switch Inspection
Air Conditioning System: Manual Type 7B-27 A/C Switch Inspection Compressor Drive Belt Inspection and S7RS0B7216014 Adjustment • Check that there is continuity between terminal (1) S7RS0B7216016 Inspection and terminal (2) when A/C switch is at ON position. • Check compressor drive belt (1) for wear, crack, •...
Page 976: Compressor Drive Belt Removal And Installation
7B-28 Air Conditioning System: Manual Type Compressor Drive Belt Removal and Installation S7RS0B7216017 Removal 1) Loosen tension pulley nut (1). 2) Loosen belt tension by loosening tension pulley adjusting bolt (2). 3) Remove compressor drive belt (3). I7RS0A721009-01 9) Remove compressor mounting bolts (1), and then remove compressor (2) from its bracket.
Page 977: Compressor Assembly Components
Air Conditioning System: Manual Type 7B-29 Compressor Assembly Components S7RS0B7216020 I4RS0A720037-01 1. Armature plate bolt 4. Circlip 7. Magnet clutch pulley : Do not reuse. 2. Compressor 5. Shim 8. Armature plate : 16 N⋅m (1.6 kgf-m, 11.5 lb-ft) 3. Relief valve 6.
Page 978 8) Remove thermal switch (1) from compressor using flat head (2). I4RS0A720043-01 3) Apply silicon sealant to contact face (2) of thermal switch (1) and then, install thermal switch to compressor (3). “A”: Silicon sealant 99000–34220 (SUZUKI SILICON SEALANT KE-347W (100g)) 2, “A” I5RS0C721011-01 I5RS0C721012-02...
Page 979: Relief Valve Inspection
Air Conditioning System: Manual Type 7B-31 e) Disconnect battery negative terminal (–) to 4) Install magnet clutch lead wire clamp. compressor body assembly. (At this point, 5) Install magnet clutch pulley (1). magnet clutch plate and magnet clutch pulley are 6) Install new circlip (2) directing chamfer side (3) not in contact.) upward.
Page 980: Relief Valve Removal And Installation
7B-32 Air Conditioning System: Manual Type Relief Valve Removal and Installation Installation S7RS0B7216030 Reverse removal procedure nothing the following instructions. Removal • Use new O-ring. 1) Recover refrigerant from the A/C system with • Apply compressor oil to O-ring. recovery and recycling equipment referring to •...
Page 981: Special Tools And Equipment
Air Conditioning System: Manual Type 7B-33 Special Tools and Equipment Recommended Service Material S7RS0B7218001 Material SUZUKI recommended product or Specification Note Compressor oil MATSUSHITADENKI GU10 P/No.: 99000–99015– Silicon sealant SUZUKI SILICON SEALANT KE- P/No.: 99000–34220 347W (100g) NOTE Required service material is also described in the following.
Page 982: Automatic Type
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC control module. Also, it can be checked by using SUZUKI scan tool. Before checking diagnostic information (diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read diagnostic information (diagnostic trouble code).
Page 983 Air Conditioning System: Automatic Type 7B-35 Electronic Control System Location NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. 10 * I5RS0C722001-01 1. ECT sensor 7. Blower motor 13. AUTO switch 19.
Page 984: Hvac Control Module Operation Description
7B-36 Air Conditioning System: Automatic Type Auto A/C Electronic Control Input / Output Table HVAC control module Temperature selector Data link connector MODE (air flow) selector Blower speed selector Air intake selector A/C refrigerant pressure sensor A/C switch AUTO switch Temperature control actuator ECT sensor Compressor...
Page 985: On-Board Diagnostic System Description
• CAN communication line trouble code (DTC) can be known by using When HVAC control module detects malfunction, the SUZUKI scan tool. For further details, refer to “AUTO” indicator lamp (1) flashes to warn and the “DTC Check”. diagnostic trouble code (DTC) is stored in the memory of the module.
Page 986: A/C System Wiring Diagram
7B-38 Air Conditioning System: Automatic Type A/C System Wiring Diagram S7RS0B7222002 BLK/YEL WHT/BLU RED/BLK RED/BLK BLU/YEL G52-16 WHT/RED G52-6 PNK/BLK G51-11 RED/YEL WHT/BLK G52-4 G51-12 BLK/YEL BLK/WHT G52-2 YEL/BLK G52-5 G51-8 BLU/RED G51-9 G52-8 RED/BLK G51-15 G51-17 GRN/RED G51-16 G52-11 BLK/ORN BRN/WHT G51-1...
Page 987: Diagnostic Information And Procedures
Air Conditioning System: Automatic Type 7B-39 4. Rear defogger relay 15. Evaporator temperature sensor 26. Radiator cooling fan relay No.1 37. Rear defogger switch 5. Rear defogger 16. Sunload sensor 27. Radiator cooling fan relay No.2 38. To BCM 6. Blower motor relay 17.
Page 988 7B-40 Air Conditioning System: Automatic Type Condition Possible cause Correction / Reference Item No cool air comes out Fuse blown Check related fuses, and then check for short (radiator cooling fan circuit to ground. motor does not operate) Wiring or grounding faulty Repair as necessary.
Page 989 Air Conditioning System: Automatic Type 7B-41 Condition Possible cause Correction / Reference Item Cool air does not come Insufficient or excessive charge of Check the amount of refrigerant and system out or insufficient cooling refrigerant for leaks. (A/C system normal Condenser clogged Check condenser referring to “Condenser operation)
Page 990: Abnormal Noise Symptom Diagnosis Of A/C System
Using SUZUKI Scan Tool 1) Turn ignition switch to OFF position. 4) Turn ignition switch to ON position. 2) Connect SUZUKI scan tool to data link connector 5) Read DTC displayed on SUZUKI scan tool. (DLC) (1) located on underside of instrument panel NOTE at driver’s seat side.
Page 991: Dtc Clearance
DTC(s) can not be cleared unless the problem(s) is fixed. Using SUZUKI Scan tool 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver’s seat side. I5RS0A722006-02...
Page 992: Dtc Table
5) Erase DTC according to instructions displayed on SUZUKI scan tool. NOTE To know how to use SUZUKI scan tool, refer to operator’s manual for SUZUKI scan tool. 6) After completing the clearance, turn ignition switch to OFF position, and then disconnect SUZUKI scan tool from DLC.
Page 993: Fail-Safe Table
Air Conditioning System: Automatic Type 7B-45 DTC No. (indicated Priority Priority of (displayed “AUTO” display display of display Diagnosis indicator (current SUZUKI HVAC (history lamp DTC) scan tool) control DTC) module) B1562 Outside air temperature sensor signal malfunction Flashed B1563 A/C refrigerant pressure sensor signal malfunction —...
Page 994: Scan Tool Data
7B-46 Air Conditioning System: Automatic Type Scan Tool Data S7RS0B7224007 As the data values given in the following are standard values estimated on the basis of values obtained from the normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good condition, there may be cases where the checked values do not fall within each specifies data range.
Page 995: Air Conditioning System Check
Air Conditioning System: Automatic Type 7B-47 Scan Tool Data Definitions AIR MIX POS SEN (TEMPERATURE CONTROL TEMP CONT SWITCH (TEMPERATURE ACTUATOR POSITION SENSOR): Input signal SELECTOR): Position of temperature control from position sensor in temperature control actuator selector of HVAC control module MODE POS SENSOR (AIR FLOW CONTROL CABIN TEMPERATURE: In-car temperature detected ACTUATOR POSITION SENSOR): Input signal...
Page 996 7B-48 Air Conditioning System: Automatic Type Description for Each Step Step 1. Customer complaint analysis Talk to customer, and then record details of the problem. Customer questionnaire (Example) I4RH01722014-01 NOTE The from is a standard sample. It should be modified according to conditions characteristic of each market.
Page 997: Dtc B1502: Inside Air Temperature Sensor And/Or Its Circuit Malfunction
Air Conditioning System: Automatic Type 7B-49 Step 7. Final confirmation test Confirm if the problem symptom is troubleshoot and the A/C system is free from any abnormal conditions. If there existed DTC, clear the DTC. Then, check if the DTC is still detected and if there is any other DTC. Visual Inspection S7RS0B7224009 Check visually the following parts and systems.
Page 998: Dtc B1503: A/C Evaporator Air Temperature Sensor And/Or Its Circuit Malfunction
7B-50 Air Conditioning System: Automatic Type Step Action Inside air temperature sensor signal circuit check Go to Step 3. “PNK/BLK” wire open or high resistance circuit. 1) Disconnect connector from HVAC control module with ignition switch turned OFF. 2) Check for proper connection to HVAC control module connector at “G52-6”...
Page 999 Air Conditioning System: Automatic Type 7B-51 DTC Detecting Condition and Trouble Area DTC Detecting Condition Trouble Area Evaporator temperature sensor signal voltage is higher than or lower than • Evaporator temperature sensor specified value for specified time continuously. circuit • Evaporator temperature sensor •...
Page 1000: Dtc B1504: Sunload Sensor And/Or Its Circuit Malfunction
7B-52 Air Conditioning System: Automatic Type Step Action Evaporator temperature sensor check HVAC control module Evaporator temperature faulty. sensor faulty. 1) Check evaporator temperature sensor referring to “Evaporator Thermistor (Evaporator Temperature Sensor) Inspection”. Is it in good condition? DTC B1504: Sunload Sensor and/or Its Circuit Malfunction S7RS0B7224012 Wiring Diagram G52-2...

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Swift sport 2008 Swift 2005

Suzuki Swift Sport 2004 Service & Repair Manual

Precautions

Precautions

Repair Instructions

Section 0 General Information

Specifications

Special Tools and Equipment

Section 1 Engine

Precautions

Engine General Information and Diagnosis

Precautions

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Aux. Emission Control Devices

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Electrical Devices

Repair Instructions

Specifications

Engine Mechanical

General Description

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Lubrication System

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

General Description

Engine Cooling System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

General Description

Ignition System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

General Description

Charging System

Diagnostic Information and Procedures

Repair Instructions

Specifications

Diagnostic Information and Procedures

Exhaust System

General Description

Repair Instructions

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