Page 1 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 2 When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 4 Table of Contents GENERAL INFORMATION TRANSMISSION, CLUTCH AND General Information DIFFERENTIAL Maintenance and Lubrication Manual Transmission HEATING AND AIR CONDITIONING Automatic Transmission Heater and Ventilation Clutch Air Conditioning Transfer STEERING, SUSPENSION, WHEELS Differential (Front) AND TIRES Differential (Rear) Steering, Suspension, Wheels and Tires ELECTRICAL SYSTEM Front End Alignment Electrical System...
Page 6: Table Of Contents
GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS Precautions............0A-2 Identification Information.......0A-6 Precaution for Vehicles Equipped with A Vehicle Identification Number .......
Page 7: Precautions
• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air bag sys- tem be repaired first, to help avoid unintended air bag system activation.
Page 8: Servicing And Handling
GENERAL INFORMATION 0A-3 Servicing and handling WARNING: Many of service procedures require disconnection of “AIR BAG” fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver and Passenger Air Bag (Inflator) Modules • For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise.
Page 9 0A-4 GENERAL INFORMATION WARNING: • During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system.
Page 10 GENERAL INFORMATION 0A-5 CAUTION: • Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys- tem parts and other related parts according to instructions under “REPAIR AND INSPECTION REQUIRED AFTER AN ACCIDENT” in SECTION 10B. •...
Page 11: Identification Information
0A-6 GENERAL INFORMATION Identification Information Vehicle Identification Number The vehicle body number is on the left side of instrument panel and punched on the chassis inside the tire housing on the right front side.
Page 12: Engine Identification Number
GENERAL INFORMATION 0A-7 Engine Identification Number The number is punched on the cylinder block. Engine Identification Number Specification A 100001 Sequential Number Engine Displacement (27 2.7 Liter) Engine Type Transmission Identification Number The A/T manufacture’s identification number is located on the transmission case as shown.
Page 13: Warning, Caution And Information Labels
0A-8 GENERAL INFORMATION Warning, Caution and Information Labels The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary. 1.
Page 14: Maintenance And Lubrication
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 15: Maintenance Schedule
0B-2 MAINTENANCE AND LUBRICATION Maintenance Schedule Maintenance Schedule under Normal Driving Conditions NOTE: • This interval should be judged by odometer reading or months, whichever comes first. • This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services at the same intervals respectively.
Page 16: Brakes
MAINTENANCE AND LUBRICATION 0B-3 (× 1,000) Interval Miles (× 1,000) Months CHASSIS AND BODY 6-1. Clutch (pedal and fluid level) – – – 6-2. Brake discs and pads (thickness, wear, damage) Brake drums and shoes (wear, damage) – – – 6-3.
Page 17: Maintenance Recommended Under Severe Driving Conditions
0B-4 MAINTENANCE AND LUBRICATION Maintenance Recommended under Severe Driving Conditions If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is recommended that applicable maintenance operation be performed at the particular interval as given in the chart below.
Page 18: Maintenance Service
MAINTENANCE AND LUBRICATION 0B-5 Maintenance Service Engine and Emission Control ITEM 1-1 Drive belt inspection and replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. WATER PUMP AND GENERATOR DRIVE BELT INSPEC- TION 1) Disconnect negative (–) cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness.
Page 19: Engine Oil And Filter Replacement
0B-6 MAINTENANCE AND LUBRICATION POWER STEERING PUMP AND/OR A/C COMPRESSOR DRIVE BELTS (IF EQUIPPED) INSPECTION 1) Disconnect negative (–) cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanli- ness. If any defect exists, replace. Check belt for tension. If belt tension is out of above specification, adjust it referring to Section 1B or 3B1.
Page 20 MAINTENANCE AND LUBRICATION 0B-7 1) Drain engine oil by removing drain plug. 2) After draining oil, wipe drain plug clean. Reinstall drain plug, and tighten it securely as specified below. Tightening torque Engine oil drain plug (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 3) Loosen oil filter by using oil filter wrench (special tool).
Page 21 0B-8 MAINTENANCE AND LUBRICATION 6) Replenish oil until oil level is brought to FULL level mark on dipstick. (oil pan and oil filter capacity). The filler inlet is at the top of the cylinder head cover. It is recommended to use engine oil of SE, SF, SG, SH or SJ grade.
Page 22 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 23 1A-2 HEATER AND VENTILATION General Description The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left) of the instrument panel, the hot air outlet at a place close to the feet, and the defroster air outlets at places, right and left, along the windshield glass.
Page 24: Heater And Ventilation 1A
HEATER AND VENTILATION 1A-3 Rear Duct 1. Heater unit 2. Rear duct REMOVAL 1) Disconnect negative (–) cable at battery. 2) Remove front and second seats. 3) Remove console box. 4) Take off carpet till rear duct is totally exposed. 5) Remove rear duct.
Page 25 1A-4 HEATER AND VENTILATION...
Page 26 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 27 1B-2 AIR CONDITIONING (OPTIONAL) Charging ............ 1B-22 Rear Blower Motor Relay and Solenoid Valve Relay..........1B-34 On-Vehicle Service ........1B-25 Rear A/C Main Switch........ 1B-34 Precaution..........1B-25 Rear Blower Motor Resistor....... 1B-35 Piping ............. 1B-25 Rear Blower Motor Switch ......1B-36 Handling refrigerant HFC-134a (R-134a) 1B-26 Rear A/C No.1 and No.2 Duct ....
Page 28: General Description
AIR CONDITIONING (OPTIONAL) 1B-3 General Description Refrigerant Type Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on LABEL on the com- pressor. Also, it can be checked by the shape of the service (charge) valve.
Page 29: Major Components And Location
1B-4 AIR CONDITIONING (OPTIONAL) Major Components And Location [A] : Dual A/C model 6. Receiver/dryer 13. Suction pipe 20. Ventilation air [B] : Single A/C model 7. Front expansion valve 14. Discharge pipe 21. Rear A/C air 1. Front cooling unit 8.
Page 30 AIR CONDITIONING (OPTIONAL) 1B-5 [A] : Dual A/C LH steering model 4. Condenser 11. Low pressure charge valve [B] : Dual A/C RH steering model 5. Sight glass 12. Floor liquid pipe [C] : Single A/C LH steering model 6. Refrigerant (dual) pressure sensor 13.
Page 31: Diagnosis
1B-6 AIR CONDITIONING (OPTIONAL) Diagnosis General Main A/C system (front A/C system) Condition Possible Cause Correction Cool air does not No refrigerant Perform recover, evacuation and come out (A/C system charging. does not operative) Fuse blown Check “IG METER”, “REAR DEFG” and “A/C”...
Page 32 AIR CONDITIONING (OPTIONAL) 1B-7 Condition Possible Cause Correction Cool air does not Insufficient or excessive charge of refrigerant Check charge of refrigerant. come out or insuffi- Refrigerant leak in system Check system for leaks. cient cooling (A/C sys- Condenser clogged Check condenser.
Page 33: Rear A/C System
1B-8 AIR CONDITIONING (OPTIONAL) Rear A/C system Condition Possible Cause Correction Cool air dose not come Solenoid valve relay faulty Check solenoid valve relay, and then out (Rear blower motor replace if necessary normal operative) Solenoid valve faulty Check solenoid valve, and then replace if necessary Diode in rear A/C harness faulty Check diode, and then replace rear A/C...
Page 34: Quickly Checking Of Refrigerant Charge (If Equipped With Sight Glass)
AIR CONDITIONING (OPTIONAL) 1B-9 Quickly Checking of Refrigerant Charge (If Equipped with Sight Glass) The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. 1) Run engine at fast idle. 2) Operate A/C at the following conditions for a few minutes.
Page 35: Performance Diagnosis
1B-10 AIR CONDITIONING (OPTIONAL) Performance Diagnosis 1) Confirm that vehicle and environmental conditions are as fol- lows. • Vehicle is not exposed to direct sun. • Ambient temperature is within 15 - 35 °C (59 - 95 °F). 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge (3) are firmly closed.
Page 36 AIR CONDITIONING (OPTIONAL) 1B-11 9) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to “PERFORMANCE DIAGNOSIS TABLE”. Example : Gauges should read as follows when ambient temperature is 30 °C (86 °F)
Page 37: Performance Diagnosis Table
1B-12 AIR CONDITIONING (OPTIONAL) Performance diagnosis table HIGH PRESSURE GAUGE Condition Possible Cause Correction Pressure high Refrigerant overcharged Recharge. (“A” area of high side Expansion valve frozen or clogged Check expansion valve. graph) Clogged refrigerant passage of high side Clean or replace. Condenser cooling fan malfunction (Insufficient cooling Check condenser cooling fan.
Page 38: Detail Diagnosis Table
AIR CONDITIONING (OPTIONAL) 1B-13 Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °F)) Condition Possible Cause Correction MANIFOLD Detail GAUGE (kg/cm (psi) 0.23 - 0.35 1.4 - 1.75 Normal condition – – (2.3 - 3.5) (14 - 17.5) (33 - 50) (200 - 249)
Page 39: Wiring Circuit
1B-14 AIR CONDITIONING (OPTIONAL) Wiring Circuit BLK/WHT RED/BLK RED/BLU YEL/GRN LT GRN PNK/BLK BLU/WHT PNK/BLU PNK/GRN PNK/WHT RED/BLK BLU/WHT BLU/WHT BLU/ORN YEL/GRN RED/BLK WHT/RED YEL/GRN RED/BLK RED/BLU YEL/BLU 1. Front blower motor main relay 10. Compressor relay 19. Battery 28. Solenoid valve relay 2.
Page 40: Inspection Of A/C Controller And Its Circuits
AIR CONDITIONING (OPTIONAL) 1B-15 Inspection of A/C Controller and Its Circuits CAUTION: A/C controller and ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to A/C controller and ECM with couplers disconnected from it. A/C Controller (1) and its circuits can be checked at A/C controller wiring couplers by measuring voltage.
Page 41 1B-16 AIR CONDITIONING (OPTIONAL) SYSTEM CIRCUIT AC-A-1 AC-A-7 AC-A-9 E61-8 AC-A-4 AC-B-2 AC-A-13 E61-17 AC-B-1 AC-A-16 AC-A-2 E61-22 A: To “FRONT BLOW” fuse 1. Front blower motor relay 6. Dual (refrigerant) pressure switch 11. Condenser cooling fan motor B: To “REAR DEFG” fuse 2.
Page 42 AIR CONDITIONING (OPTIONAL) 1B-17 A/C CONTROLLER VOLTAGE VALUES TABLE Measurement Terminal Wire Circuit Normal value Condition ground BLK/ Controller main Ground to Ignition switch ON with engine AC-A-1 10 – 14 V power supply engine (Fig B) stopped BLK/ Controller main Ground to body AC-A-2 –0.4 –...
Page 43 1B-18 AIR CONDITIONING (OPTIONAL) Measurement Terminal Wire Circuit Normal value Condition ground A/C evaporator temperature sen- 1.8 V sor temperature at approx. 15 °C (3520 Ω) (59 °F) with engine running A/C evaporator temperature sen- A/C evaporator sor temperature at approx. 4.5 °C temperature WHT/ Ground to...
Page 44: Refrigerant Recovery, Evacuation And Charging
AIR CONDITIONING (OPTIONAL) 1B-19 Refrigerant Recovery, Evacuation and Charging WARNING: • Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °C (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious injury.
Page 45: Recovery
1B-20 AIR CONDITIONING (OPTIONAL) Recovery NOTE: • When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment (1). Discharging it into atmo- sphere would cause adverse effect to environments. • When handling recovery and recycling equipment, be sure to follow the instruction manual for the equip- ment.
Page 46: Evacuating
AIR CONDITIONING (OPTIONAL) 1B-21 Evacuating Evacuating procedure CAUTION: Do not evacuate before recovering refrigerant in system. NOTE: Whenever opened (exposed to atmospheric air), air con- ditioning system must be evacuated by using a vacuum pump. The A/C system should be attached with a mani- fold gauge set, and should be evacuated for approx.
Page 47: Checking System For Pressure Leaks
1B-22 AIR CONDITIONING (OPTIONAL) Checking system for pressure leaks After completing the evacuation, close manifold gauge high pres- sure valve (HI) and low-pressure valve (LO) and wait 10 minutes. Verify that low-pressure gauge reading has not changed. CAUTION: If the gauge reading moves closer to “0”, there is a leak somewhere.
Page 48 AIR CONDITIONING (OPTIONAL) 1B-23 The initial charging of the A/C system is performed from the high- pressure side with the engine stopped. And next, this method must be followed by charging from the low- pressure side with the engine running. 1) Check to make sure that hoses are routed properly after evacuating the system.
Page 49 1B-24 AIR CONDITIONING (OPTIONAL) c) Purge any air existing in center charging hose When using refrigerant container tap valve, use following procedure to purge air. i) Once fully tighten refrigerant container tap valve and then loosen (open) plate nut slightly. ii) Open low pressure valve of manifold gauge set a little.
Page 50: On-Vehicle Service
AIR CONDITIONING (OPTIONAL) 1B-25 On-Vehicle Service WARNING: Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately. • DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
Page 51: Handling Refrigerant Hfc-134A
1B-26 AIR CONDITIONING (OPTIONAL) • Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible. • Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
Page 52: Replenishing Compressor Oil
AIR CONDITIONING (OPTIONAL) 1B-27 Replenishing compressor oil CAUTION: Be sure to use HFC-134a (R-134a) compressor oil. When replacing air conditioning parts with new ones, it is neces- sary to replenish oil by the amount supposedly remaining in each part. WHEN CHANGING GAS ONLY When it is unavoidable to change gas without replacing any com- ponent part for engine removal and installation or for some other reason, replenish 20 cm...
Page 53: Rear A/C Unit (Rear A/C Evaporator)
1B-28 AIR CONDITIONING (OPTIONAL) Rear A/C Unit (Rear A/C Evaporator) 1. Rear blower fan cover 6. Rear A/C unit mounting clip 11. Solenoid valve mounting bracket Do not reuse 2. Rear A/C unit mounting bush 7. Rear blower motor assembly 12.
Page 54: Rear Expansion Valve
AIR CONDITIONING (OPTIONAL) 1B-29 4) Loosen floor suction pipe and floor liquid pipe mounting bolt (1). 2. Muffler 5) Remove rear A/C No.1 duct (1). 6) Disconnect rear A/C unit wire couplers (2). 7) Remove rear A/C unit mounting bolts (3), and then remove rear A/C unit (4).
Page 55: Rear A/C Evaporator Temperature Controller
1B-30 AIR CONDITIONING (OPTIONAL) REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section. 2) Disconnect solenoid valve connector (1). 3) Loosen solenoid valve bracket mounting screws (2). 4) Remove rear liquid pipe and rear suction pipe bolt (1), and then disconnect rear liquid pipe (2) and rear suction pipe (3) with solenoid valve and its bracket from rear expansion valve (4).
Page 56: Refrigerant Pipes And Hoses
AIR CONDITIONING (OPTIONAL) 1B-31 INSPECTION 1) Connect battery positive (+) cable to terminal “b” and battery negative (–) cable to terminal “c” as shown. 2) Using ohmmeter, check continuity between terminal “a” and terminal “b” at specified temperature as shown. Rear A/C evaporator temperature controller specification : “A”...
Page 57: Solenoid Valve
1B-32 AIR CONDITIONING (OPTIONAL) Solenoid Valve REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section. 2) Disconnect solenoid valve connector (1). 3) Loosen solenoid valve flared nuts (2). 4) Remove solenoid valve bracket mounting screws (3), and then remove rear liquid pipe (4) and rear suction pipe (5) from rear expansion valve.
Page 58: Rear Blower Motor Assembly
AIR CONDITIONING (OPTIONAL) 1B-33 Rear Blower Motor Assembly REMOVAL 1) Remove solenoid valve referring to “SOLENOID VALVE” in this section. 2) Disconnect rear blower motor coupler (1). 3) Remove rear blower motor assembly (2) from rear A/C unit (3). INSPECTION 1) Check continuity between two terminal as shown.
Page 59: Rear Blower Motor Relay And Solenoid Valve Relay
1B-34 AIR CONDITIONING (OPTIONAL) Rear Blower Motor Relay and Solenoid Valve Relay INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove rear blower motor relay (1) and/or solenoid valve relay (2) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”.
Page 60: Rear Blower Motor Resistor
AIR CONDITIONING (OPTIONAL) 1B-35 INSPECTION • Check rear A/C main switch for each terminal-to-terminal continuity. If check results are not specified, replace rear A/C main switch. TERMINAL POSITION INSTALLATION Reverse removal procedure for installation. Rear Blower Motor Resistor REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section.
Page 61: Rear Blower Motor Switch
1B-36 AIR CONDITIONING (OPTIONAL) Rear Blower Motor Switch 1. Rear blower motor switch 5. Rear A/C air louver holder Install proper direction as shown in figure 2. Bulb 6. Rear A/C air louver 3. Bracket 7. Knob 4. Rear A/C air louver case INSPECTION •...
Page 62: Rear A/C No.1 And No.2 Duct
AIR CONDITIONING (OPTIONAL) 1B-37 Rear A/C No.1 and No.2 Duct Rear A/C No.1 duct REMOVAL 1) Remove rear A/C unit referring to “REAR A/C UNIT” in this section. 2) Remove rear A/C No.1 duct (1). INSTALLATION Reverse removal procedure to install rear A/C No.1 duct (1). Rear A/C No.2 duct CAUTION: Never remove rear A/C No.2 duct (2) from head lining.
Page 63: Compressor Assembly
1B-38 AIR CONDITIONING (OPTIONAL) Compressor Assembly CAUTION: None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a). For identification between these two types, refer to page 66. When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Page 64 AIR CONDITIONING (OPTIONAL) 1B-39 REMOVAL 1) Run engine at idle with A/C ON for 10 minutes. 2) Disconnect negative (–) cable at battery. 3) Recover refrigerant from refrigeration system using recovery and recycling equipment. NOTE: The amount of compressor oil at removed must be mea- sured and the same amount must be poured when install- ing the compressor.
Page 65 1B-40 AIR CONDITIONING (OPTIONAL) INSTALLATION CAUTION: Be sure to use HFC-134a (R-134a) compressor oil. Reverse removal procedure to install compressor assembly not- ing the following instructions. • If compressor was replaced, pour new compressor oil with the same amount as that drained from compressor. Refer to “REPLENISHING COMPRESSOR OIL”...
Page 66: Magnet Clutch
AIR CONDITIONING (OPTIONAL) 1B-41 Magnet Clutch 1. Armature plate bolt 3. Circlip 5. Shim (s) 7. Compressor body assembly 2. Armature plate 4. Magnet clutch 6. Magnet clutch coil 8. Magnet clutch assembly INSPECTION Check the following items. • Check no sigh of compressor oil leakage •...
Page 67 1B-42 AIR CONDITIONING (OPTIONAL) 5) Using special tool, remove circlip. Special tool (A) : 09900-06107 6) Remove magnet clutch lead wire clamp screw, and remove magnet clutch read wire ground terminal. 7) Remove magnet clutch with puller. NOTE: Be careful not to damage pulley when tapping magnet clutch.
Page 68 AIR CONDITIONING (OPTIONAL) 1B-43 4) Install magnet clutch (1). a) Set magnet clutch squarely over clutch installation boss. b) Place special tool onto clutch bearing. Ensure that edge rests only on inner race of bearing. Special tool (A) : 09991-06010 c) Install new circlip.
Page 69: Required Service Materials
1B-44 AIR CONDITIONING (OPTIONAL) Required Service Materials Recommended SUZUKI product Material (Part Number) Compressor oil (refrigerant oil) COMPRESSOR OIL (ND-OIL8, 250 cc) • O-ring (99000-27080) • Each component Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Refrigerant pipe (8 mm (0.31 in.)) Refrigerant pipe (12.7 mm (0.5 in.))
Page 70 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Information ........3A-1 On-Vehicle Service ......... 3A-1 Alignment Service Data (without Load) ..3A-1 Reference Information ........
Page 71 3A-2 FRONT END ALIGNMENT...
Page 72 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 73 3B1-2 POWER STEERING (P/S) SYSTEM General Description Power Steering (P/S) Pump Power steering (P/S) pump specification : The specification of this power steering pump is the same as the specification of the same section in the service manual mentioned in this manual except for data of relieved pressure shown below. Relieved pressure : 7850 kPa (78.5 kg/cm , 1116 psi)
Page 74 POWER STEERING (P/S) SYSTEM 3B1-3 Hydraulic Pressure in P/S Circuit Hydraulic pressure check 1) After cleaning joint of high pressure hose and P/S pump thoroughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose). CAUTION: Take care not to cause damage to A/C condenser during service operation, if equipped.
Page 75 3B1-4 POWER STEERING (P/S) SYSTEM 5) Check relief pressure. a) Increase engine speed to about 1500 r/min (rpm). Close gauge valve gradually while watching pressure increase indicated by gauge and take reading of relief pressure (maximum hydraulic pressure). When it is higher than specified values, possible cause is malfunction of relief valve.
Page 76 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On- Vehicle Service” in air bag system section before performing service on or around the air bag sys- tem components or wiring.
Page 77 3C1-2 AIR BAG STEERING WHEEL AND COLUMN General Description This double tube type steering column has the following three important features in addition to the steering func- tion: • The column is energy absorbing, designed to compress in a front-end collision. •...
Page 78 AIR BAG STEERING WHEEL AND COLUMN 3C1-3 Diagnosis For diagnosis of the steering wheel and steering column, refer to Section 3. For diagnosis of the air bag system, refer to Section 10B. Inspection and Repair Required after Accident After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and repairs described under “CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE”...
Page 79: Steering Column
3C1-4 AIR BAG STEERING WHEEL AND COLUMN Steering Column CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to dam- age. Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length leaning on the column assembly could cause it to bend or deform.
Page 80 AIR BAG STEERING WHEEL AND COLUMN 3C1-5 6) Remove steering upper shaft upper joint bolt (1) and nut (2) and disconnect steering upper shaft upper joint removing in arrow direction in the figure. 7) Remove steering column (1) mounting bolts (2 pieces) (2) and nuts (2 pieces) (3).
Page 81 3C1-6 AIR BAG STEERING WHEEL AND COLUMN 3) Install steering column assembly (1) with contacting upper side of lower bracket slits to mounting bolts. Tighten steering column lower mounting nuts (3) first and then upper mount- ing bolts (2) to specified torque. Tightening torque Steering column mounting bolts and nuts (b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Page 82 AIR BAG STEERING WHEEL AND COLUMN 3C1-7 Steering Upper Shaft Assembly CAUTION: Never turn steering wheel while steering upper shaft assembly is removed. Should it have been turned and contact coil (on combina- tion switch) have got out of its centered position, it needs to be centered again.
Page 83 3C1-8 AIR BAG STEERING WHEEL AND COLUMN INSPECTION Check steering shaft damage and operation referring to CHECK STEERING COLUMN AND STEERING UPPER SHAFT FOR ACCIDENT DAMAGE later in this section. INSTALLATION 1) Be sure that front tires and steering wheel are in straight ahead position.
Page 84 AIR BAG STEERING WHEEL AND COLUMN 3C1-9 6) Install steering upper shaft upper joint bolt (2) and nut (1). Tighten steering upper shaft upper joint nut (1) to specified torque. Tightening torque Steering upper shaft upper joint nut (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) 1, (a) Steering Lower Shaft Assembly...
Page 85 3C1-10 AIR BAG STEERING WHEEL AND COLUMN INSTALLATION 1) Be sure that front wheels and steering wheel are in straight ahead position. 2) Align flat part “A” of lower shaft assembly (1) with bolt hole “B” of shaft joint as shown in the figure. Then insert shaft joint (1) into lower shaft assembly (2).
Page 86 AIR BAG STEERING WHEEL AND COLUMN 3C1-11 Checking Steering Column and Steering Upper Shaft for Accident Damage NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted or air bag deployed, may have a damaged or misaligned steering column.
Page 87 3C1-12 AIR BAG STEERING WHEEL AND COLUMN • Take measurement “b” as shown in the figure. If it is shorter than specified length, replace steering upper shaft assembly with new one. “b” Steering upper shaft assembly length “b” : 419.0 ± 1.0 mm (16.50 ± 0.04 in.) Tightening Torque Specification Tightening torque Fastening part...
Page 88: Front Suspension
FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION CAUTION: • All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 89 3D-2 FRONT SUSPENSION Tightening Torque Specification...
Page 90: Rear Suspension
REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: • For the descriptions (items) not found in this section, refer to the same section of the Service Man- ual mentioned in the FOREWORD of this manual. • All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense.
Page 91 3E-2 REAR SUSPENSION 2) Remove circlip from axle shaft. 3) In order to remove retainer ring (1) from axle shaft (3), grind with a grinder two portion (2) of bearing retainer ring as illus- trated till it becomes thin. CAUTION: Be careful not to grind axle shaft.
Page 92 REAR SUSPENSION 3E-3 6) Remove stud bolt(s) (1) by using hydraulic press (2). INSTALLATION Install removed parts in reverse order of removal procedure, not- ing the following. 1) Aligning serrations between new stud bolt(s) (1) and flange (4), install new stud bolt(s) (1) by tightening nut (2) as shown in the figure.
Page 93 3E-4 REAR SUSPENSION 5) Apply grease “A” to axle shaft inner oil seal lip as shown in the figure. “A” : Grease 99000-25010 1. Axle housing 6) Apply water tight sealant “B” to mating surfaces of brake back plate and rear axle hub (2). “B”...
Page 94: Rear Axle Shaft Inner Oil Seal
REAR SUSPENSION 3E-5 Rear Axle Shaft Inner Oil Seal INSTALLATION 1) Using special tool drive in oil seal until it contacts oil seal pro- tector in axle housing. NOTE: • Make sure that oil seal is free from inclination as it is installed.
Page 95: Tightening Torque Specification
72.5 Wheel speed sensor bolt 15.5 Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Oil seal lip (99000-25010) Brake fluid DOT 3 • Brake reservoir tank Sealant SUZUKI BOND NO. 1215 • Joint seam of axle and brake back plate (99000-31110) •...
Page 96: Special Tool
REAR SUSPENSION 3E-7 Special Tool 09921-57810 09924-74510 09926-88310 09927-18411 Counter shaft holder Bush remover handle Oil seal installer Universal puller 09942-15510 09943-35512 09944-88210 Sliding hammer Brake drum remover Bearing installer...
Page 97 3E-8 REAR SUSPENSION...
Page 98: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: • For the descriptions (items) not found in this section, refer to the same section of the Service Man- ual mentioned in the FOREWORD of this manual. • All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense.
Page 99 3F-2 WHEELS AND TIRES...
Page 100: Oil Seal
FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-1 SECTION 4A2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS On-Vehicle Service........
Page 101: On-Vehicle Service
4A2-2 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL On-Vehicle Service Drive Shaft ASSEMBLY CAUTION: • To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed. • Bend each boot band against forward rotation. •...
Page 102 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-3 6) Install circlip (1) by using snap ring plier. 7) Apply grease to entire surface of cage. Use joint grease in tube included in spare part. 8) Insert cage into outer race and fit circlip (1) into groove of outer race.
Page 103 4A2-4 FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL Required Service Material Recommended SUZUKI product Material (Part Number) Lithium grease SUZUKI SUPER GREASE A • Drive shaft oil seal (99000-25010) • Wheel spindle part of differential side drive shaft (RH) Sealant SEALING COMPOUND 366E •...
Page 104: Propeller Shafts
PROPELLER SHAFTS 4B-1 SECTION 4B PROPELLER SHAFTS NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Description ........4B-1 Tightening Torque Specification ....4B-2 On-Vehicle Service.........
Page 105: Propeller Shaft
Front propeller shaft flange nuts 36.5 Rear propeller shaft flange nuts 46.5 Center support bolts 36.5 Required Service Material Recommended SUZUKI product Material (Part Number) Thread lock cement THREAD LOCK CEMENT SUPER 1322 • Rear propeller shaft flange bolts (99000-32110)
Page 106 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 107 5-2 BRAKES Diagnosis Diagnosis Table For the item not found in this column, refer to the same item of the same section in the service manual men- tioned in the FOREWORD of this manual. Condition Possible Cause Correction Brake warning light Parking brake applied Release parking brake and check turns on after engine...
Page 108 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 109: General Description
5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER General Description Master Cylinder Assembly The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the figure below) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber (“a”) acts on the rear wheel brakes.
Page 110: On-Vehicle Service
BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3 On-Vehicle Service Front Brake Hose/Pipe REMOVAL 1) Raise and suitably support vehicle. Remove tire and wheel. This operation is not necessary when removing pipes connecting master cylinder and flexible hose. 2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe. INSTALLATION 1) Reverse removal procedure for brake hose and pipe installation procedure.
Page 111 5A-4 BRAKES PIPE/HOSE/MASTER CYLINDER For RH steering vehicle [D]: View D 1. E-ring [a]: Clamp a 2. Flexible hose [b]: Clamp b 3. Hose washer [c]: Clamp d 4. Hose bolt T: Top side 5. Brake caliper F: Front side 6.
Page 112 BRAKES PIPE/HOSE/MASTER CYLINDER 5A-5 For LH steering vehicle [D]: View D 1. E-ring [a]: Clamp a 2. Flexible hose [b]: Clamp b 3. Hose washer [d]: Clamp d 4. Hose bolt T: Top side 5. Brake caliper F: Front side 6.
Page 113: Master Cylinder Reservoir
5A-6 BRAKES PIPE/HOSE/MASTER CYLINDER Master Cylinder Reservoir REMOVAL 1) Disconnect reservoir lead wire at coupler. 2) Clean outside of reservoir (1). 3) Take out fluid with syringe or such. 4) Remove reservoir stopper (3). 2. Master cylinder 5) Remove reservoir (1). NOTE: Do not allow brake fluid to get on painted surfaces.
Page 114: Master Cylinder Assembly
BRAKES PIPE/HOSE/MASTER CYLINDER 5A-7 Master Cylinder Assembly REMOVAL NOTE: Do not allow brake fluid to get on painted surfaces. 1) Disconnect reservoir lead wire (1) at coupler. 2) Clean around reservoir cap (2) and take out fluid with syringe or such. 3) Disconnect brake pipes from master cylinder (3) and ABS actuator (4).
Page 115: Brake Booster
5A-8 BRAKES PIPE/HOSE/MASTER CYLINDER Brake Booster 1. Brake master cylinder assembly 4. Push rod clevis 7. Clip 2. Brake booster assembly 5. Nut 8. Plate 3. Gasket 6. Clevis pin 9. Seal CLEARANCE BETWEEN BOOSTER PISTON ROD AND MASTER CYLINDER PISTON CHECK AND ADJUSTMENT The length of booster piston rod (1) is adjusted to provide speci- fied clearance “0”...
Page 116 BRAKES PIPE/HOSE/MASTER CYLINDER 5A-9 4) If measured depth is out of above specifications, adjust to specifications below by turning adjusting screw of piston rod. Special tool (F) : 09952-16021 Depth “d” of piston rod for adjustment : 16.3 – 16.6 mm (0.642 – 0.653 in.)
Page 117: Tightening Torque Specification
5A-10 BRAKES PIPE/HOSE/MASTER CYLINDER Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Brake flexible hose bolt (Brake caliper/2 way joint) 17.0 Brake hose / pipe bracket bolt ABS actuator bracket bolt Master cylinder attaching nut Booster nut Clevis nut 18.0 2-way joint mounting bolt Brake pipe flare nut...
Page 118 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 119: General Description
5C-2 PARKING AND REAR BRAKE General Description Drum Brake Assembly The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main- tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is depressed and when parking brake is applied on level road.
Page 120: On-Vehicle Service
PARKING AND REAR BRAKE 5C-3 On-Vehicle Service Parking Brake Cable 1. Parking brake switch 6. Equalizer 11. Color ring 16. Crossmember 21. Parking brake cable nut 2. Parking brake lever 7. Pin 12. Cable 17. Chassis frame Tightening torque 3. Parking brake lever bolt 8.
Page 121 5C-4 PARKING AND REAR BRAKE Cracked, scored, or grooved drum A cracked, drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will probably be neces- sary to resurface drum braking surface.
Page 122: Wheel Cylinder
PARKING AND REAR BRAKE 5C-5 Wheel Cylinder INSTALLATION For the details, refer to the same item of the same section in the service manual mentioned in the FOREWORD of this manual not- ing the following points. • Take off bleeder plug cap from brake pipe and connect pipe (or pipes) to wheel cylinder (1) just enough to prevent fluid from leaking.
Page 123 5C-6 PARKING AND REAR BRAKE 4) Tighten brake back plate nuts to specified torque. Tightening torque Brake back plate nut (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft) 5) Install wheel cylinder, and tighten wheel cylinder bolts and brake pipe flare nut (or nuts) to specified torque. Tightening torque Wheel cylinder bolt : 13.5 N·m (1.35 kg-m, 10.0 lb-ft)
Page 124: Tightening Torque Specification
PARKING AND REAR BRAKE 5C-7 Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Wheel cylinder bleeder plug 0.75 Parking brake lever bolt 17.0 Wheel cylinder bolt 13.5 1.35 10.0 Brake pipe flare nut 12.0 Brake back plate nut 36.5 Wheel nut 10.0...
Page 125 5C-8 PARKING AND REAR BRAKE...
Page 126 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 127 (Using SUZUKI Scan Tool)...... 5E2-29 DTC C1055 (DTC 55) – Rear Inlet ABS Hydraulic Unit Operation Check Solenoid Circuit........5E2-24 (Not Using Suzuki Scan Tool)....5E2-29 DTC C1042 (DTC 42) – Right-Front ABS Hydraulic Unit/Control Module Outlet Solenoid Circuit ......5E2-24 Assembly ..........
Page 128: General Description
ANTILOCK BRAKE SYSTEM (ABS) 5E2-3 General Description Components/Parts Location The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from the master cylinder so that each wheel is not locked even when hard braking is applied. This ABS has also the following function.
Page 129: Abs Hydraulic Unit/Control Module Assembly
5E2-4 ANTILOCK BRAKE SYSTEM (ABS) ABS Hydraulic Unit/control Module Assembly ABS control module is a component of ABS hydraulic unit/control module assembly and has the following functions. Self-diagnosis function ABS control module diagnoses conditions of the system compo- nent parts (whether or not there is any abnormality) all the time and indicates the results (warning of abnormality occurrence and DTC) through the ABS warning lamp as described below.
Page 130: Diagnosis
ANTILOCK BRAKE SYSTEM (ABS) 5E2-5 Diagnosis To ensure that the trouble diagnosis is done accurately and smoothly, observe “PRECAUTIONS IN DIAGNOSING TROU- BLES” and follow “ABS DIAGNOSTIC FLOW TABLE”. Precautions in Diagnosing Troubles • If the vehicles was operated in any of the following ways, ABS warning lamp may light momentarily but this does not indicate anything abnormal in ABS.
Page 131: Abs Diagnostic Flow Table
5E2-6 ANTILOCK BRAKE SYSTEM (ABS) ABS Diagnostic Flow Table Refer to the following pages for the details of each step. Step Action 1) Perform “Customer Complaint Analysis”. Go to Step 2. Go to Step 5. 2) Perform “Problem Symptom Confirmation”. 3) Perform “Diagnostic Trouble Code Check, Record and Clearance”.
Page 132 ANTILOCK BRAKE SYSTEM (ABS) 5E2-7 1) MALFUNCTION ANALYSIS a) Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 133 5E2-8 ANTILOCK BRAKE SYSTEM (ABS) b) Problem Symptom Confirmation Check if what the customer claimed in “CUSTOMER QUESTIONNAIRE” is actually found in the vehicle and if that symptom is found, whether it is identified as a failure. (This step should be shared with the cus- tomer if possible.) Check warning lamps related to brake system referring to “EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK”...
Page 134: Abs Warning Lamp Check
ANTILOCK BRAKE SYSTEM (ABS) 5E2-9 ABS Warning Lamp Check 1) Turn ignition switch ON. 2) Check that ABS warning lamp (1) comes ON for about 2 sec- onds and then goes off. If any faulty condition is found, advance to Diagnostic Flow Table-A, B, C or D.
Page 135: Diagnostic Trouble Code (Dtc) Check (Using Abs Warning Lamp)
5E2-10 ANTILOCK BRAKE SYSTEM (ABS) Diagnostic Trouble Code (DTC) Check (Using ABS Warning Lamp) 1) Perform ABS WARNING LAMP CHECK described above. 2) Using service wire (4), connect diagnosis switch terminal (2) of monitor coupler (1) to ground (3). 3) Turn ignition switch ON. 4) Read flashing of ABS warning lamp which represents DTC as shown in example below and write it down.
Page 136: Diagnostic Trouble Code (Dtc) Check (Using Suzuki Scan Tool)
2) Turn ignition switch ON. 3) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. 4) After completing the check, turn ignition switch off and dis- connect SUZUKI scan tool from DLC.
Page 137: Diagnostic Trouble Code (Dtc) Table
FLOW TABLE” in this section) and “DTC CHECK” and con- firm that normal DTC (DTC 12) is displayed ; not malfunction DTC. NOTE: It is also possible to clear DTC by using SUZUKI scan tool. Refer to Cartridge Manual for procedure to clear DTC. Diagnostic Trouble Code (DTC) Table CAUTION: Be sure to perform “ABS DIAGNOSTIC FLOW TABLE”...
Page 138 ANTILOCK BRAKE SYSTEM (ABS) 5E2-13 (displayed (indicated by ABS warning lamp flashing DIAGNOSTIC ITEMS on SUZUKI ABS warning pattern scan tool) lamp) C1022 C1026 Wheel speed sensor circuit or sensor ring C1032 C1036 C1041 Inlet solenoid valve circuit C1042 Outlet solenoid valve circuit...
Page 139: System Circuit
5E2-14 ANTILOCK BRAKE SYSTEM (ABS) System Circuit 1. Battery 11. ABS fail-safe transistor (Solenoid valve transistor) 21. To ECM and SDM (if equipped) 2. Main fuses 12. ABS pump motor transistor 22. Stop lamp 3. Ignition switch 13. Pump motor 23.
Page 140: Switch On
ANTILOCK BRAKE SYSTEM (ABS) 5E2-15 Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON 1. Main fuse 5. ABS warning lamp 9. Brake fluid level switch 2. Ignition switch 6. Brake warning lamp 10.
Page 141 Perform diagnostic trouble code check. Is there Go to Step 2. Go to Step 3. any DTC (including code No.12, NO CODES on SUZUKI scan tool) exists? Does malfunction DTC (other than code No.12) Go to Step 7 of “ABS Go to Step 3.
Page 142 ANTILOCK BRAKE SYSTEM (ABS) 5E2-17 Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch Is ON 1. ABS warning lamp in combination meter 3. Diagnosis monitor coupler 3-2. Diagnosis ground terminal 2. ABS hydraulic unit/control module assembly 3-1.
Page 143: Connected To Ground
5E2-18 ANTILOCK BRAKE SYSTEM (ABS) Table-D Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground 1. ABS warning lamp in combination meter 3. Diagnosis monitor coupler 3-2. Diagnosis ground terminal 2. ABS hydraulic unit/control module assembly 3-1.
Page 144: On" Steady
ANTILOCK BRAKE SYSTEM (ABS) 5E2-19 Table-E EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes “ON” Steady CIRCUIT DESCRIPTION EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS control module/hydraulic unit assembly through lamp driver module in combination meter. Refer to “TABLE – A” for circuit diagram.
Page 145: Dtc C1015 (Dtc 15) - G Sensor Circuit And 4Wd Lamp Circuit
5E2-20 ANTILOCK BRAKE SYSTEM (ABS) DTC C1015 (DTC 15) – G Sensor Circuit and 4WD Lamp Circuit 1. Ignition switch 3. ABS hydraulic unit/control module assembly 5. 4WD lamp 7. 4WD switch 2. G sensor 4. ABS hydraulic unit/control module connector 6.
Page 146 ANTILOCK BRAKE SYSTEM (ABS) 5E2-21 INSPECTION Step Action 1) Turn ignition switch ON. Go to Step 2. Replace bulb or repair its Does 4WD lamp turn ON when 4WD switch circuit. turns ON? 1) Ignition switch OFF. Go to Step 3. Repair 4WD control sys- 2) Check for proper connection to ECM (PCM) tem.
Page 147: Dtc C1021 (Dtc 21), Dtc C1022
5E2-22 ANTILOCK BRAKE SYSTEM (ABS) DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left-Front Wheel Speed Sensor Circuit or Sensor Ring DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right-Rear Wheel Speed Sensor Circuit or Sensor Ring DTC C1035 (DTC 35), DTC C1036 (DTC 36) –...
Page 148 ANTILOCK BRAKE SYSTEM (ABS) 5E2-23 INSPECTION Step Action 1) Disconnect applicable ABS wheel speed sensor coupler Go to Step 2. Replace ABS wheel with ignition switch OFF. speed sensor 2) Measure resistance between terminals of ABS wheel assembly. speed sensor. Refer to “FRONT WHEEL SPEED SEN- SOR”...
Page 149: Dtc C1041 (Dtc 41) - Right-Front Inlet Solenoid Circuit
5E2-24 ANTILOCK BRAKE SYSTEM (ABS) DTC C1041 (DTC 41) – Right-Front Inlet Solenoid Circuit DTC C1045 (DTC 45) – Left-Front Inlet Solenoid Circuit DTC C1055 (DTC 55) – Rear Inlet Solenoid Circuit DTC C1042 (DTC 42) – Right-Front Outlet Solenoid Circuit DTC C1046 (DTC 46) –...
Page 150: Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E2-25 DTC C1057 (DTC 57) – Power Source Circuit 1. Ignition switch 3. ABS hydraulic unit/control module assembly 2. Main fuse 4. ABS hydraulic unit/control module connector DESCRIPTION The ABS control module monitors the power source voltage at terminal “E136-18”. When the power source volt- age becomes extremely high or low, this DTC will be set.
Page 151: Dtc C1061 (Dtc 61) - Abs Pump Motor Circuit
5E2-26 ANTILOCK BRAKE SYSTEM (ABS) DTC C1061 (DTC 61) – ABS Pump Motor Circuit 1. ABS hydraulic unit/control module assembly 3. ABS pump motor 5. ABS hydraulic unit/control module connector 2. ABS pump motor relay 4. ABS fail safe relay DESCRIPTION The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the igni- tion switch turned ON.
Page 152: Dtc C1063 (Dtc 63) - Abs Fail-Safe Relay Circuit
ANTILOCK BRAKE SYSTEM (ABS) 5E2-27 DTC C1063 (DTC 63) – ABS Fail-Safe Relay Circuit 1. Ignition switch 3. ABS hydraulic unit/control module connector 5. Fail-safe relay 2. ABS hydraulic unit/control module assembly 4. To solenoid valves DESCRIPTION ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON.
Page 153: Dtc C1071 (Dtc 71) - Abs Control Module
5E2-28 ANTILOCK BRAKE SYSTEM (ABS) DTC C1071 (DTC 71) – ABS Control Module 1. ABS hydraulic unit/control module assembly 3. ABS pump motor 5. ABS hydraulic unit/control module connector 2. ABS pump motor relay 4. ABS fail safe relay DESCRIPTION This DTC will be set when an internal malfunction is detected in the ABS control module.
Page 154: On-Vehicle Service
ON. Then DTC will be set in ABS control mod- ule. ABS Hydraulic Unit Operation Check (Using SUZUKI Scan Tool) 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Turn ignition switch to ON position and check actuator opera- tion using “HYDRAULIC CONTROL TEST”...
Page 155 5E2-30 ANTILOCK BRAKE SYSTEM (ABS) 9) Perform following checks with help of another person. 10) Brake pedal (1) should be depressed. a) Ignition switch turned to ON position by one person. b) Wheel should be turned by another person’s hand. At this time, check that: •...
Page 156: Abs Hydraulic Unit/Control Module Assembly
ANTILOCK BRAKE SYSTEM (ABS) 5E2-31 ABS Hydraulic Unit/Control Module Assembly CAUTION: Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit/ control module assembly. 16 N·m (1.6 kg-m) N·m (1.0 kg-m) N·m (0.9 kg-m)
Page 157 5E2-32 ANTILOCK BRAKE SYSTEM (ABS) 3) Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit/control module assembly (3). Special tool 09950-78220 NOTE: Put bleeder plug cap onto pipe to prevent fluid from spill- ing.
Page 158: Rear Sensor Rotor (Retainer Ring)
ANTILOCK BRAKE SYSTEM (ABS) 5E2-33 Rear Sensor Rotor (Retainer Ring) REMOVAL 1) Remove rear axle shaft assembly. Refer to “REAR AXLE SHAFT” in Section 3E. 2) In order to remove sensor rotor (retainer ring) (2) from shaft (1), grind with a grinder one part “A” of the sensor rotor (retainer ring) as shown till it becomes thin.
Page 159: Tightening Torque Specification
Parking lever assembly mounting bolt : (f) 17.0 Special Tool 09950-78220 09931-76011 09931-76030 Flare nut wrench (10 mm) Tech 1A kit (SUZUKI scan Mass storage cartridge for 16/14 pin DLC cable for tool) Tech 1A Tech 1A (See NOTE A.)
Page 160 ANTILOCK BRAKE SYSTEM (ABS) 5E2-35 Tech 2 kit (SUZUKI scan tool) (See NOTE B.) NOTE: A. This kit includes the following items and substitutes for the Tech 2 kit. 1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe, 6. Power source cable, 7.
Page 161 5E2-36 ANTILOCK BRAKE SYSTEM (ABS)
Page 162 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 163 6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table A-4 Malfunction Indicator Lamp Circuit Malfunction ........6-1-82 Check – MIL Does Not Flash or Just DTC P0335 Crankshaft Position Sensor Remains ON Even with Grounding Circuit Malfunction ........6-1-84 Diagnosis Switch Terminal (Vehicle with DTC P0340 (DTC No.42) Camshaft Monitor Connector) ........
Page 164: General Information
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-3 General Information Statement of Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 165: Precaution On Fuel System Service
6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) • When disconnecting couplers, don’t pull wire harness but make sure to hold coupler itself. With lock type coupler, be sure to unlock before disconnection. Attempt to disconnect coupler without unlocking may result in damage to coupler. When connecting lock type coupler, insert it till clicking sound is heard and connect it securely.
Page 166: Fuel Pressure Relief Procedure
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-5 Fuel Pressure Relief Procedure CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, relief fuel pressure as fol- lows.
Page 167: Engine Diagnosis
(For the details, refer to description on Freeze frame data.) • It is possible to communicate by using not only SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.)
Page 168 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-7 WARM-UP CYCLE A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22°C (40°F) from engine starting and reaches a minimum temperature of 70 °C (160 °F).
Page 169 DLC (1) is in compliance with SAEJ1962 in its installation posi- tion, the shape of connector and pin assignment. K line of ISO 9141 is used for SUZUKI scan tool or generic scan tool to communicate with ECM (PCM), ABS control module and Air bag SDM.
Page 170: On-Board Diagnostic System (Vehicle With Monitor Connector)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-9 On-Board Diagnostic System (Vehicle with Monitor Connector) ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running, and indicates the result by turning on of flashing mal- function indicator lamp (1).
Page 171: Precaution In Diagnosing Trouble
ECM (PCM) memory. Such disconnection will erase memorized information in ECM (PCM) memory. • Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI scan tool or generic 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 172: Engine Diagnostic Flow Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-11 Engine Diagnostic Flow Table Refer to following pages for the detail of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis. plaint analysis. Was customer complaint analysis performed? DTC(s)/Freeze Frame Data Check Record DTC(s)/Freeze...
Page 173 6-1-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 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 anal- ysis and diagnosis.
Page 174 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-13 STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK First, check DTC, referring to “DIAGNOSTIC TROUBLE CODE CHECK” in this section. If DTC is indicated, record DTC and freeze frame data. After that clear DTC referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
Page 175 6-1-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) STEP 6. AND 7. RECHECKING AND RECORD OF DTC Refer to “DTC Check” in this section for checking procedure. STEP 8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE Perform basic engine check according to the “ENGINE BASIC INSPECTION FLOW TABLE” first. When the end of the flow table has been reached, check the parts of the system suspected as a possible cause referring to “ENGINE DIAGNOSIS TABLE”...
Page 176 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-15 STEP 9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM (PCM) or other part and repair or replace faulty parts.
Page 177: Malfunction Indicator Lamp (Mil) Check
“Diagnostic Flow Table A-2” for troubleshooting. Diagnostic Trouble Code (DTC) Check [Using SUZUKI scan tool] 1) Prepare generic scan tool or SUZUKI scan tool (2). 2) With ignition switch OFF, connect it to data link connector (DLC) (3) located on underside of instrument panel at driver’s seat side.
Page 178: Diagnostic Trouble Code (Dtc) Clearance
1) Check malfunction indicator lamp referring to “Malfunction Indicator Lamp Check” in this section. 2) With the ignition switch OFF position, disconnect SUZUKI scan tool if connected and using service wire (4), connect diagnosis switch terminal (1) to ground terminal (2) in moni- tor connector (3).
Page 179: Diagnostic Trouble Code (Dtc) Table
6-1-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) [Without using scan tool] 1) Turn the ignition switch OFF position. 2) Disconnect battery negative cable for specified time below to erase diagnostic trouble code stored in ECM memory and reconnect it. Time required to erase DTC: Ambient Time to cut power to ECM...
Page 180 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-19 (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) Response time of HO2S-1 output volt- HO2S circuit slow response 2 driving P0133 age between rich and lean is longer (Bank 1 - Sensor 1)
Page 181 6-1-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) Short term fuel trim or total fuel trim (short and long terms added) is larger 2 driving P0174 Fuel system too lean (Bank 2)
Page 182: For A/T System (Refer To Section 7B1 For Diagnosis)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-21 (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) Difference between desired idle speed Idle air control system mal- and actual idle speed continues to 2 driving P0505 function...
Page 183: For Immobilizer Control System (Refer To Section 8G For Diagnosis)
6-1-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) (vehicle (vehicle DETECTING CONDITION DTC NO. DETECTED ITEM without with (DTC will set when detecting : ) monitor monitor connector) connector) P0753 Monitor signal OFF is detected when 1 driving (No.61) Shift solenoid A (#1) electrical shift solenoid A (#1) is ON or monitor cycle applicable...
Page 184: Fail-Safe Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-23 Fail-Safe Table When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ECM (PCM) detects normal condition after that. DTC NO.
Page 185: Scan Tool Data
Be sure to use the timing light to check the ignition timing referring to Section 6F2. NOTE: • For asterisk (✱) marked item in “OTHER” column, item can be read only SUZUKI scan tool. • When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the neutral gear position and A/T gear to the “Park”...
Page 186 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-25 NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE INJ PULSE WIDTH B2 At specified idle speed with no load after 2.0 – 3.3 msec ✱ warming up. At 2500 r/min with no load after warming up. 2.2 –...
Page 187 6-1-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) NORMAL CONDITION/ SCAN TOOL DATA CONDITION OTHER REFERENCE VALUE PNP SIGNAL (Transmis- With ignition switch ON, selector lever in “P” P/N Range sion Range Switch) (for 4- or “N” position ✱ A/T) With ignition switch ON, selector lever in “R”, D Range “D”, “2”...
Page 188: Scan Tool Data Definitions
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-27 Scan tool data definitions COOLANT TEMP (Engine Coolant Temp., °C/°F) It is detected by engine coolant temp. sensor. INTAKE AIR TEMP (°C/°F) It is detected by intake air temp. sensor. DESIRE IDLE (Desired Idle Speed RPM) The desired idle speed is an ECM (PCM) internal parameter which indicates the ECM (PCM) requested idle.
Page 189 6-1-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TP SENSOR VOLT (TP Sensor Output Voltage, V) Throttle Position Sensor reading provides throttle valve opening information in the from of voltage. O2S B1 S1 (HO2S Bank 1 Sensor 1 Output Voltage, V) / O2S B2 S1 (HO2S Bank 2 Sensor 1 Output Voltage, V) It indicates output voltage of HO2S SENSOR 1 installed on exhaust manifold (pre-catalyst).
Page 190 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-29 EGR VALVE (%) This parameter indicates opening rate of EGR valve which controls the amount of EGR flow. A/C SWITCH (ON/OFF) ON : Command for operation being output from A/C amplifier to compressor. OFF : Command for operation not being output.
Page 191 6-1-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) SHIFT SOL #2 CON/MON (Shift Solenoid #2, B Command/monitor, ON/OFF) CON-ON : ON command being output to shift solenoid #2, B. CON-OFF : ON command not being output. MON-ON : Electricity being passed to shift solenoid #2, B. MON-OFF : Electricity not being passed.
Page 192: Engine Diagnosis Table
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-31 Engine Diagnosis Table Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality has been found in visual inspection and engine basic inspection previously. Condition Possible Cause Correction Hard starting Faulty idle air control system...
Page 193 6-1-32 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Condition Possible Cause Correction Improper engine idling Faulty spark plug Spark plugs in Section 6F2. or engine fails to idle Faulty ignition coil with ignitor Ignition coil in Section 6F2. Fuel pressure out of specification “DIAG.
Page 194 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-33 Condition Possible Cause Correction Surges Defective spark plug Spark plugs in Section 6F2. (Engine power varia- (excess carbon deposits, improper gap, and tion under steady burned electrodes, etc.) throttle or cruise. Variable fuel pressure “DIAG.
Page 195 6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Condition Possible Cause Correction Poor gasoline mileage Faulty spark plug (improper gap, heavy depos- Spark plugs in Section 6F2. its, and burned electrodes, etc.) Fuel pressure out of specification “DIAG. FLOW TABLE B-3” in this section.
Page 196 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-35 Condition Possible Cause Correction Engine noise Faulty hydraulic valve lash adjuster Hydraulic valve lash adjuster in (Note : Before check- Section 6A2. ing the mechanical Worn valve stem and guide Valves inspection in Section 6A2. noise, make sure the Weak or broken valve spring Valve springs inspection in Section...
Page 197: Inspection Of Pcm (Ecm) And Its Circuits
6-1-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Inspection of PCM (ECM) and its Circuits PCM (ECM) and its circuits can be checked at PCM (ECM) wiring couplers by measuring voltage and resistance. CAUTION: PCM/ECM cannot be checked by itself. It is strictly pro- hibited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.
Page 198 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-37 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Power source for CO adjusting E61-1 10 – 14 V Ignition switch ON resistor (if equipped) E61-2 Power source for back up 10 – 14 V Ignition switch ON and OFF E61-3 –...
Page 199 6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ignition switch ON, A/C not oper- A/C condenser fan motor relay E61-22 10 – 14 V ated and Engine coolant temp. : (if equipped) less than 113°C, 235°F For 3 sec.
Page 200 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-39 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION Ignition switch ON, Throttle valve at 0.5 – 1.2 V idle position C51-3-9 Throttle position sensor Ignition switch ON, Throttle valve at 3.4 – 4.7 V full open position 1.0 –...
Page 201 6-1-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION A/T input speed sensor (–) C51-1-10 About 2.5 V Ignition switch ON (A/T vehicle) A/T input speed sensor (+) C51-1-11 About 2.5 V Ignition switch ON (A/T vehicle) Deflects between Ignition switch ON, crankshaft C51-1-12...
Page 202 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-41 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION C51-2-1 Fuel injector No.2 10 – 14 V Ignition switch ON C51-2-2 Fuel injector No.1 C51-2-3 – – – 10 – 14 V Ignition switch ON Heater of HO2S-1 (bank 1) C51-2-4 At specified idle speed after engine (if equipped)
Page 203 6-1-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) RESISTANCE CHECK 1) Disconnect couplers (1) from ECM/PCM with ignition switch OFF. CAUTION: Never touch terminals of ECM/PCM itself or connect volt- meter or ohmmeter (2). 2) Check resistance between each pair of terminals of discon- nected couplers (1) as listed in following table.
Page 204: On" Or Dims At Ignition Switch On
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-43 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” or Dims at Ignition Switch ON (But Engine at Stop) WIRING DIAGRAM 1. MIL 2. To ignition switch 3. Main fuse 4.
Page 205 6-1-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action ECM power and ground circuit check : Go to Step 3. Go to “TABLE A-3 ECM Does engine start? (PCM) POWER AND GROUND CIRCUIT CHECK” in this section. If engine is not cranked, go to “DIAGNOSIS”...
Page 206: On (Vehicle With Monitor Connector)
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-45 Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch ON (Vehicle with Monitor Connector) WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. TROUBLESHOOTING Step Action MIL Flashing Pattern check: Go to Step 2. Go to “Diagnosis”...
Page 207 6-1-46 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table A-5 ECM (PCM) Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch ON and Engine Doesn’t Start Though It Is Cranked Up WIRING DIAGRAM 1. MIL 2. To ignition switch 3.
Page 208 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-47 INSPECTION Step Action Main relay operating sound check : Go to Step 5. Go to Step 2. Is operating sound of main relay heard at igni- tion switch ON? Fuse check : Go to Step 3.
Page 209: Dtc P0100 (Dtc No.33, 34) Mass Air Flow Circuit Malfunction
6-1-48 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction WIRING DIAGRAM 1. Main fuse 2. Main relay 3. ECM/PCM 4. Mass air flow sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the following conditions are detected for 5 •...
Page 210 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-49 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 211: Dtc P0110 (Dtc No.23, 25) Intake Air Temp. (Iat) Circuit Malfunction
6-1-50 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction WIRING DIAGRAM 1. IAT sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the conditions are detected for 5 sec. con- •...
Page 212 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-51 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Check IAT sensor and its circuit : Go to Step 3. Intermittent trouble.
Page 213: Dtc P0115 (Dtc No.14, 15) Engine Coolant Temp. Circuit Malfunction
6-1-52 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction WIRING DIAGRAM 1. ECT sensor 2. To combination (ECT) meter 3. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Any one of the conditions are detected for 5 sec.
Page 214 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-53 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Check ECT sensor and its circuit : Go to Step 3. Intermittent trouble.
Page 215: Dtc P0120 (Dtc No.21, 22) Throttle Position Circuit Malfunction
6-1-54 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction WIRING DIAGRAM 1. Throttle position sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following conditions are detected for 5 sec. continuously. •...
Page 216 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-55 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE”. Check TP sensor and its circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool to DLC with ignition Check for intermittent switch OFF and then turn ignition switch...
Page 217: Dtc P0121 Throttle Position Circuit Range/Performance Problem
6-1-56 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0121 Throttle Position Circuit Range/Performance Problem WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to DTC P0120. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Throttle opening change is smaller than specification •...
Page 218 Does voltage vary within specified value linearly as shown in the figure? Check TP sensor and its circuit (not using SUZUKI If voltmeter was used, Go to Step 6. scan tool) : check terminal C51-3-9 for 1) Turn ignition switch ON.
Page 219: Dtc P0130 (Dtc No.13) Ho2S-1 (Bank 1) Circuit Malfunction Or No Activity Detected
6-1-58 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or No Activity Detected WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-1 (Bank-1) DTC DETECTING CONDITION AND TROUBLE AREA NOTE: For vehicle with monitor connector, DTC will set when following only (*) mark condition is detected.
Page 220 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-59 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 221: Dtc P0133 Ho2S-1 (Bank 1) Circuit Slow Response
6-1-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action Short term fuel trim check : Intermittent trouble Go to DTC P0171/ 1) Run engine at 2000 r/min. for 60 sec. or faulty ECM P0172 Diag. Flow 2) With engine idling, check short term fuel trim displayed (PCM).
Page 222: Dtc P0135 Ho2S-1 (Bank 1) Heater Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-61 DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0130. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heater is HO2S-1 heater circuit electrically live (2 driving cycle detection logic).
Page 223 6-1-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action HO2S heater control circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “BLK” wire open, “BLU” heater relay. wire open or shorted to 2) With ignition switch ON leaving engine OFF, ground circuit...
Page 224: Dtc P0136 Ho2S-2 (Bank 1) Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-63 DTC P0136 HO2S-2 (Bank 1) Circuit Malfunction WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-2 (Bank-1) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected (2 driving •...
Page 225 6-1-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) NOTE: Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION PROCEDURE”. • Intake air temp. : – 8°C (18°F) or higher • Engine coolant temp. : – 8 – 110°C (18 – 230°F) •...
Page 226: Dtc P0141 Ho2S-2 (Bank 1) Heater Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-65 DTC P0141 HO2S-2 (Bank 1) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0136. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S-2 heater operates (2 HO2S-2 heater or its circuit driving cycle detection logic).
Page 227 6-1-66 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. HO2S-2 heater check : Go to Step 3. Replace HO2S-2. 1) Disconnect HO2S-2 coupler with ignition switch OFF.
Page 228: Dtc P0150 (Dtc No.26) Ho2S-1 (Bank 2) Circuit Malfunction Or No Activity Detected
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-67 DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or No Activity Detected WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-1 (Bank-2) DTC DETECTING CONDITION AND TROUBLE AREA NOTE: For vehicle with monitor connector, DTC will set when following only (*) mark condition is detected.
Page 229 6-1-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 230: Dtc P0153 Ho2S-1 (Bank 2) Circuit Slow Response
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-69 Step Action Short term fuel trim check : Intermittent trouble Go to DTC P0174/ 1) Run engine at 2000 r/min. for 60 sec. or faulty ECM P0175 Diag. Flow 2) With engine idling, check short term fuel trim displayed (PCM).
Page 231: Dtc P0155 Ho2S-1 (Bank 2) Heater Circuit Malfunction
6-1-70 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0155 HO2S-1 (Bank 2) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0150. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S heater is HO2S-1 heater circuit electrically live (2 driving cycle detection logic).
Page 232 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-71 Step Action HO2S heater control circuit check : Substitute a known-good Faulty HO2S heater relay 1) With ignition switch OFF, install HO2S ECM (PCM) and recheck. or “BLK” wire open, “BLU” heater relay. wire open or shorted to 2) With ignition switch ON leaving engine OFF, ground circuit, “BLK/RED”...
Page 233: Dtc P0156 Ho2S-2 (Bank 2) Circuit Malfunction
6-1-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0156 HO2S-2 (Bank 2) Circuit Malfunction WIRING DIAGRAM 1. HO2S heater relay 2. ECM (PCM) 3. HO2S-2 (Bank-2) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when any one of following conditions is detected (2 driving •...
Page 234 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-73 NOTE: Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION PROCEDURE”. • Intake air temp. : – 8°C (18°F) or higher • Engine coolant temp. : – 8 – 110°C (18 – 230°F) •...
Page 235: Dtc P0161 Ho2S-2 (Bank 2) Heater Circuit Malfunction
6-1-74 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0161 HO2S-2 (Bank 2) Heater Circuit Malfunction WIRING DIAGRAM Refer to DTC P0156. DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Following condition is detected when HO2S-2 heater operates (2 HO2S-2 heater or its circuit driving cycle detection logic).
Page 236 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-75 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. HO2S-2 heater check : Go to Step 3. Replace HO2S-2. 1) Disconnect HO2S-2 coupler with ignition switch OFF.
Page 237: Dtc P0171/P0172 Fuel System Too Lean/Rich (Bank 1)
6-1-76 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0171/P0172 Fuel System Too Lean/Rich (Bank 1) DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed (2 driving cycle • Vacuum leaks (air inhaling) detection logic).
Page 238 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-77 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Is there DTC (s) other than “DTC P0171/ Go to applicable DTC Go to Step 3.
Page 239: Dtc P0174/P0175 Fuel System Too Lean/Rich (Bank 2)
6-1-78 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0174/P0175 Fuel System Too Lean/Rich (Bank 2) DTC DETECTING CONDITION AND POSSIBLE CAUSE DTC DETECTING CONDITION TROUBLE AREA When running after engine warmed (2 driving cycle • Vacuum leaks (air inhaling) detection logic).
Page 240 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-79 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Is there DTC (s) other than “DTC P0174/ Go to applicable DTC Go to Step 3.
Page 241: Dtc P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder
6-1-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder 1 Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/Cylinder 4 Misfire Detected/Cyl- inder 5 Misfire Detected/Cylinder 6 Misfire Detected SYSTEM DESCRIPTION ECM (PCM) measures the angle speed of the crankshaft based on the pulse signal from the CKP sensor and CMP sensor for each cylinder.
Page 242 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-81 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Ignition system inspection : Go to Step 3. Faulty ignition coil, wire 1) Check spark plug and ignition spark of cylin- harness, or other system der where misfire occurs, referring to “IGNI-...
Page 243 6-1-82 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction CIRCUIT DESCRIPTION 1. Knock sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC will set when one of the following condition is •...
Page 244 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-83 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Knock sensor and its circuit check : Knock sensor and its cir- Go to Step 3.
Page 245: Dtc P0335 Crankshaft Position Sensor Circuit Malfunction
6-1-84 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0335 Crankshaft Position Sensor Circuit Malfunction WIRING DIAGRAM 1. CKP sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CKP sensor signal is not input while 100 pulses of CKP sensor circuit CMP sensor signal are input after engine start.
Page 246 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-85 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE” in this section. CKP sensor and its circuit resistance check : Go to Step 4. Go to Step 3.
Page 247: Dtc P0340 (Dtc No.42) Camshaft Position Sensor Circuit Malfunction
6-1-86 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction WIRING DIAGRAM 1. CMP sensor 2. To main relay 3. ECM (PCM) SYSTEM DESCRIPTION CMP sensor detects REF signal and POS signal. • REF signal : 4 pulses/1 revolution of camshaft. There are 2 different kinds of wavelength. Based on REF sig- nal, ECM (PCM) judges which cylinder is at TDC.
Page 248 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-87 DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA CMP sensor signal is not inputted for 3 sec. even though CMP sensor circuit engine start signal is being inputted. CMP sensor Engine starter signal circuit REF signal pattern is incorrect while POS signal varies.
Page 249 6-1-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action CMP sensor (REF) signal check : Go to Step 6. Faulty “YEL/GRN” wire 1) With ignition switch OFF, connect CMP sensor or CMP sensor. coupler. If OK, substitute a 2) Disconnect couplers from ignition coil assembly known-good ECM and fuel injectors.
Page 250: Dtc P0400 Exhaust Gas Recirculation Flow Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-89 DTC P0400 Exhaust Gas Recirculation Flow Malfunction SYSTEM/WIRING DIAGRAM 1. EGR valve 5. ECM (PC) 2. Intake manifold 6. MAP sensor 3. Exhaust gas 7. Main fuse 4. Sensed information 8. Main relay...
Page 251 6-1-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA During deceleration (engine speed high with closed • EGR valve throttle position) in which fuel cut is involved, difference • EGR passage in intake manifold pressure between when EGR valve is •...
Page 252 Go to Step 4. Go to Step 6. EGR valve operation check : Go to Step 5. Go to Step 6. 1) With ignition switch OFF, install SUZUKI scan tool. 2) Check EGR system referring to Section 6E2. Is it in good condition?
Page 253: Dtc P0403 (Dtc No.51) Exhaust Gas Recirculation Circuit Malfunction
6-1-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction WIRING DIAGRAM 1. Main fuse 4. ECM (PCM) 2. Main relay 3. EGR valve DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA High voltage is detected at EGR valve stepping motor EGR valve (stepping motor) or its circuit ECM...
Page 254 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-93 TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. EGR valve check : Go to Step 3. EGR valve malfunction. 1) With ignition switch OFF, disconnect connec- tor from EGR valve.
Page 255: Dtc P0420 Catalyst System Efficiency Below Threshold (Bank 1)
6-1-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) SYSTEM DIAGRAM 1. HO2S-1 (Bank-1) 4. TWC 2. HO2S-2 (Bank-1) 5. ECM (PCM) 3. WU-TWC CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1 and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume.
Page 256 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-95 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 257: Dtc P0430 Catalyst System Efficiency Below Threshold (Bank 2)
6-1-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) SYSTEM DIAGRAM 1. HO2S-1 (Bank-2) 4. TWC 2. HO2S-2 (Bank-2) 5. ECM (PCM) 3. WU-TWC CIRCUIT DESCRIPTION Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1 and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel injection volume.
Page 258 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-97 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 259: Dtc P0443 Evap Control System Purge Control Valve Circuit Malfunction
6-1-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction SYSTEM/WIRING DIAGRAM 1. Main fuse 3. EVAP canister purge valve 2. Main relay 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Monitor signal of EVAP canister purge valve is different...
Page 260 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-99 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool. 3) Start engine and warm up it completely. 4) Increase vehicle speed to 55 km/h (35 mph) or more.
Page 261: Evap Canister Purge System Inspection
6-1-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Evap canister purge system inspection 1) Warm up engine to normal operating temperature. 2) Hoist vehicle so that all wheels rotate freely. 3) Set M/T in “Neutral” or A/T in “P” position and parking brake. 4) Disconnect purge hose (1) from EVAP canister.
Page 262: Vacuum Hose Inspection
Replace as necessary. Evap canister purge valve and its circuit inspection 1) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF and disconnect vacuum hoses from each pipe. 2) Turn ignition switch ON, clear DTC and select “MISC TEST”...
Page 263 6-1-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 5) Connect 12 V-battery to EVAP canister purge valve (3) termi- nals. In this state, blow hose “A” (1). Air should come out of hose “B” (2). If check result is not as described, replace EVAP canister purge valve.
Page 264: Dtc P0460 Fuel Level Sensor Circuit High Input
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-103 DTC P0460 Fuel Level Sensor Circuit High Input WIRING DIAGRAM/CIRCUIT DESCRIPTION 1. Fuel level sensor 2. Fuel meter in combination meter 3. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Fuel level sensor output voltage higher than specified •...
Page 265 6-1-104 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) TROUBLESHOOTING Step Action Was “ENGINE DIAG. FLOW TABLE” per- Go to Step 2. Go to “ENGINE DIAG. formed? FLOW TABLE” in this section. Does fuel level meter in combination meter indi- Replenish fuel tank with Go to Step 3.
Page 266: Dtc P0500 (Dtc No.24) Vehicle Speed Sensor Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-105 DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction WIRING DIAGRAM 1. Speedometer 2. Vehicle speed sensor 3. Cruise control module (if equipped) 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Vehicle speed signal not inputted although fuel is kept •...
Page 267 6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 268 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-107 Step Action VSS visual inspection: Poor VSS connection or VSS Replace VSS. 1) Remove VSS referring to “TRANSFER” malfunction. section. If connection is OK, substi- 2) Check VSS drive and driven gears for tute a known-good VSS and damage and excessive wear.
Page 269: Dtc P0505 Idle Air Control System Malfunction
6-1-108 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P0505 Idle Air Control System Malfunction SYSTEM/WIRING DIAGRAM 1. Throttle body 3. ECM (PCM) 5. FIA valve 7. Main relay 2. Idle air control valve 4. Sensed information 6. Main fuse DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 270 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-109 DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO- CEDURE”. • Intake air temp. : – 8°C (18°F) or higher • Engine coolant temp. : – 8 – 110°C (18 – 230°F) •...
Page 271: Dtc P0601 (Dtc No.71) Internal Control Module Memory Check Sum Error
6-1-110 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action Was idle speed higher than specification in Check FIA valve for mal- Check parts or system Step 2? function. which can cause engine Check abnormal air inhal- low idle. ing from intake manifold, Check FIA valve for stuck.
Page 272: Dtc P1408 Manifold Absolute Pressure Sensor Circuit Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-111 DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction WIRING DIAGRAM 1. MAP sensor 2. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA • While engine is running after being warmed up and •...
Page 273 6-1-112 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up engine completely. 3) Run engine at idle speed for 1 min.
Page 274: Dtc P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Performance Problem
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-113 DTC P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Perfor- mance Problem SYSTEM DESCRIPTION Barometric pressure sensor is installed in ECM (PCM). DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P1450 : •...
Page 275: Dtc P1500 Engine Starter Signal Circuit Malfunction
6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) DTC P1500 Engine Starter Signal Circuit Malfunction WIRING DIAGRAM 1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch) 4. ECM (PCM) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA •...
Page 276: Dtc P1510 Ecm Back-Up Power Supply Malfunction
ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-115 DTC P1510 Ecm Back-Up Power Supply Malfunction WIRING DIAGRAM 1. Main fuse box 3. ECM (PCM) 2. To DLC CIRCUIT DESCRIPTION Battery voltage is supplied to keep DTC memory, values that ECM has learned to control engine, etc. in ECM even when ignition switch is turned OFF.
Page 277: Inspection
6-1-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table B-1 Fuel Pump Circuit Inspection WIRING DIAGRAM 1. To ignition switch 4. Fuel pump relay 2. Main fuse 5. Fuel pump 3. Main relay 6. ECM (PCM) INSPECTION CAUTION: Check to make sure that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness etc.
Page 278 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-117 Step Action Fuel pump relay check : “BLK/WHT” or “WHT/ Replace fuel pump relay. 1) Check fuel pump relay referring to “FUEL GRN” circuit open or poor PUMP RELAY INSPECTION” in Section E61-23 connection.
Page 279: Inspection
6-1-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) INSPECTION Step Action Check injector for operating sound : Go to Step 2. Go to Step 3. Using sound scope, check each injector for operating sound at engine cranking. Do all 6 injectors make operating sound? Wire harness check : Fuel injector circuit is in “PNK”, “PNK/BLK”, “PNK/...
Page 280 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-119 Table B-3 Fuel Pressure Inspection SYSTEM DIAGRAM 1. Injector 4. Fuel filter 2. Delivery pipe 5. Fuel pump 3. Fuel pressure regulator Special tool (A) : 09912-58441 (B) : 09912-58431 (C) : 09919-58421 INSPECTION NOTE: Before using the following flow table, check to make sure that battery voltage is higher than 11 V.
Page 281 6-1-120 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Step Action 1) Start engine and warm it up to normal oper- Normal fuel pressure. Clogged vacuum passage ating temperature. for fuel pressure regula- 2) Keep it running at specified idle speed. tor or faulty fuel pressure Is fuel pressure then within 210 –...
Page 282 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-121 Table B-4 Idle Air Control System Inspection WIRING DIAGRAM 1. Throttle body 3. ECM (PCM) 5. Main fuse 2. Idle air control valve 4. Sensed information 6. Main relay INSPECTION Step Action Check engine idle speed and IAC duty Go to Step 2.
Page 283 Go to Step 7. A/C signal circuit open or to Step 1 of “Table B-5”. (A/C signal can short, or A/C system mal- be also checked by using SUZUKI scan function. tool.) Is it in good condition? Check FIA valve.
Page 284 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-123 Table B-5 A/C Signal Circuits Inspection (If Equipped) WIRING DIAGRAM 1. A/C control module (amplifier) 2. ECM (PCM) INSPECTION Step Action Check A/C Signal Circuit. Go to Step 2. “YEL/BLK” circuit open or 1) Check voltage at terminal E61-17 with ignition short, Evaporative tem- switch ON.
Page 285 6-1-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If Equipped) WIRING DIAGRAM 1. To ignition switch 3. A/C fuse 5. A/C condenser fan motor 2. Main fuse 4. A/C condenser fan motor relay 6.
Page 286: Special Tool
Checking tool set (See NOTE “A”.) 09917-47011 09930-88521 09931-76011 Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan Mass storage cartridge for tool) (See NOTE “B”.) Tech 1A 09931-76030 14/16 pin DLC cable for Tech 2 kit (SUZUKI scan Tech 1A tool) (See NOTE “C”.)
Page 287 6-1-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Page 288 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 289: On-Vehicle Service
6A2-2 ENGINE MECHANICAL (H27 ENGINE) On-Vehicle Service Throttle Body and Intake Manifold 1. Air cleaner box 6. Intake manifold 11. Gasket 16. Throttle body bolt 2. Intake air hose 7. Intake manifold gasket 12. IAT sensor Tightening Torque 3. Intake air pipe 8.
Page 290 ENGINE MECHANICAL (H27 ENGINE) 6A2-3 REMOVAL 1) Release fuel pressure in fuel feed line by referring to Section CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. 2) Disconnect negative (–) cable at battery. 3) Drain coolant.
Page 291 6A2-4 ENGINE MECHANICAL (H27 ENGINE) 8) Disconnect accelerator cable (1) and A/T throttle cable (2) (for A/T vehicle) from throttle body. 9) Disconnect water hoses (3) from throttle body. 10) Disconnect injector wire (1) coupler. 11) Disconnect brake booster hose (2) from intake manifold. 12) Disconnect couplers of TP sensor (1) and IAC valve (2).
Page 292 ENGINE MECHANICAL (H27 ENGINE) 6A2-5 19) Disconnect hoses of heater, EVAP canister, fuel feed and fuel return. 1. Heater hose 2. Fuel feed hose 3. Fuel return hose 4. EVAP canister hose 20) Remove throttle body (1) and intake collector (2) from intake manifold (3).
Page 293 6A2-6 ENGINE MECHANICAL (H27 ENGINE) INSTALLATION 1) Install new intake manifold gaskets (1) to cylinder heads. 2) Install intake manifold (1). Tighten bolts and nuts to specified torque. Tightening torque Intake manifold bolt and nut (a) : 23 N·m (2.3 kg-m, 16.5 lb-ft) 3) Install throttle body (2) to intake collector (1) with new throttle body gasket.
Page 294 ENGINE MECHANICAL (H27 ENGINE) 6A2-7 6) Connect hoses of heater, EVAP canister, fuel feed and fuel return. 1. Heater hose 2. Fuel feed hose 3. Fuel return hose 4. EVAP canister hose 7) Install EGR pipe with new gaskets. 8) Connect hoses of EVAP canister purge valve and heater. 9) Connect hoses of PCV, breather and water.
Page 295 6A2-8 ENGINE MECHANICAL (H27 ENGINE) 16) Connect water hoses (3) to throttle body. 17) Connect accelerator cable (1) and A/T throttle cable (2) (for A/T vehicle) to throttle body. 18) Install surge tank pipe (2) to intake manifold with new gas- kets and intake air pipe (1) to throttle body.
Page 296: Exhaust Manifold
ENGINE MECHANICAL (H27 ENGINE) 6A2-9 26) Upon completion of installation, verify that there is no fuel leakage at each connection according to procedure described in Section 6. Exhaust Manifold WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot.
Page 297 6A2-10 ENGINE MECHANICAL (H27 ENGINE) 4) Disconnect EGR pipe from right (No.2) bank exhaust mani- fold if right side exhaust manifold is removed. 5) Remove oil level gauge guide (3) if left side exhaust manifold is removed. 6) Detach P/S pump assembly as following, if left side exhaust manifold is removed.
Page 298 ENGINE MECHANICAL (H27 ENGINE) 6A2-11 INSTALLATION 1) Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe. 2) Install exhaust manifolds. • Always install new bolts with pre-coated adhesive to the locations with ✱ mark. •...
Page 299 6A2-12 ENGINE MECHANICAL (H27 ENGINE) 7) Reverse removal procedure to install front propeller shaft if removed. When installing propeller shaft, align match mark (1). Use following specification to torque universal joint flange. Tightening torque Universal joint flange bolt (c) : 55 N·m (5.5 kg-m, 40.0 lb-ft) 8) Connect EGR pipe to left (No.1) bank exhaust manifold (1).
Page 300: Lh (No.1) Bank 2Nd Timing Chain And Chain Tensioner
ENGINE MECHANICAL (H27 ENGINE) 6A2-13 LH (No.1) Bank 2nd Timing Chain and Chain Tensioner 1. LH bank 2nd timing chain 5. Camshaft sprocket bolt 9. Timing chain tensioner adjuster No. 3 bolt 2. Timing chain tensioner adjuster No.3 6. Timing chain guide No.4 10.
Page 301: Camshaft And Valve Lash Adjuster
6A2-14 ENGINE MECHANICAL (H27 ENGINE) Camshaft and Valve Lash Adjuster 1. RH bank 2nd timing chain 6. LH bank intake camshaft 11. Timing chain guide No.5 2. RH bank exhaust camshaft 7. LH bank exhaust camshaft 12. Valve lash adjuster 3.
Page 302 ENGINE MECHANICAL (H27 ENGINE) 6A2-15 INSPECTION Cam wear Using a micrometer, measure cam height. If measured height is below its limit, replace camshaft. Intake cam height : Standard : 40.402 – 40.562 mm (1.5906 – 1.5969 in.) Limit : 40.300 mm (1.3581 in.) Exhaust cam height : Standard : 39.428 –...
Page 303 6A2-16 ENGINE MECHANICAL (H27 ENGINE) 6) Remove housing, and using scale (2) on gaging plastic (1) envelop, measure gaging plastic (1) width at its widest point. Camshaft journal clearance : Standard : 0.045 – 0.099 mm (0.0018 – 0.0039 in.) Limit : 0.12 mm (0.0047 in.) If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal.
Page 304: Valves And Cylinder Heads
ENGINE MECHANICAL (H27 ENGINE) 6A2-17 Valves and Cylinder Heads 1. Cylinder block 6. Exhaust valve 11. Valve stem oil seal 16. Cylinder head bolt (hex hole bolt) 2. RH bank cylinder head 7. Intake valve 12. Valve spring retainer Tightening Torque 3.
Page 305 6A2-18 ENGINE MECHANICAL (H27 ENGINE) INSPECTION Valve guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide.
Page 306 ENGINE MECHANICAL (H27 ENGINE) 6A2-19 5) Install cylinder head to block. After applying oil to cylinder head bolts, tighten them gradu- ally as follows. a) Tighten all bolts to 53 N·m (5.3 kg-m, 38.5 lb-ft) according to numerical order in the figure. b) In the same manner as in a), tighten them to 84 N·m (8.4 kg-m, 61.0 lb-ft).
Page 307 6A2-20 ENGINE MECHANICAL (H27 ENGINE) 12) Install oil pan and oil pump strainer. Refer to “OIL PAN AND OIL PUMP STRAINER” in this sec- tion. 13) Install cylinder head cover. Refer to “CYLINDER HEAD COVER” in this section. 14) Install exhaust manifold. Refer to “EXHAUST MANIFOLD”...
Page 308 ENGINE MECHANICAL (H27 ENGINE) 6A2-21 Piston, Piston Rings, Connecting Rods and Cylinders 1. Top ring 5. Connecting rod : 9. Piston pin circlip Tightening Torque Clean bearing installing surface when install. 2. 2nd ring 6. Connecting rod bearing cap : 10.
Page 309 6A2-22 ENGINE MECHANICAL (H27 ENGINE) INSPECTION Cylinders • Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use over size piston. • Using a cylinder gauge, measure cylinder bore in thrust and axial directions at 2 positions (1, 2) as shown in the figure.
Page 310 ENGINE MECHANICAL (H27 ENGINE) 6A2-23 • Piston clearance : Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, rebore cylinder and use oversize piston. Piston clearance : 0.02 –...
Page 311 6A2-24 ENGINE MECHANICAL (H27 ENGINE) ASSEMBLY 1) 2 sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder as follows. a) Each piston has stamped number (1 or 2) on its piston head.
Page 312 ENGINE MECHANICAL (H27 ENGINE) 6A2-25 NOTE: • Install circlip with its cut part facing as shown in the figure. • Install so that circlip end gap comes within such range as indicated by arrow “A”. 1. Piston 2. Arrow mark 3.
Page 313: Unit Repair Overhaul
6A2-26 ENGINE MECHANICAL (H27 ENGINE) Unit Repair Overhaul Engine Assembly REMOVAL 1) Release fuel pressure in fuel feed line. Refer to “FUEL PRESSURE RELIEF PROCEDURE” in Section 6. 2) Disconnect negative (–) cable at battery. 3) Remove engine hood. 4) Drain engine oil. 5) Drain coolant.
Page 314 ENGINE MECHANICAL (H27 ENGINE) 6A2-27 12) Disconnect the following electric lead wires : • Injector wire coupler • CMP sensor coupler • Ignition coil couplers • CKP sensor coupler • MAP sensor coupler • TP sensor (1) coupler • IAC valve (2) coupler •...
Page 315 6A2-28 ENGINE MECHANICAL (H27 ENGINE) 24) Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle) 25) Remove clutch housing lower plate. 26) Remove torque converter bolts (for A/T vehicle). 27) Remove starter motor. 28) Lower vehicle. 29) Support transmission.
Page 316 ENGINE MECHANICAL (H27 ENGINE) 6A2-29 3) Tighten bolts and nuts fastening cylinder block and transmis- sion to specified torque. Tightening torque Transmission to cylinder block bolt and nut (b) : 85 N·m (8.5 kg-m, 61.5 lb-ft) 1. Bolt (short) 2. Bolt (Long) 4) Remove lifting device 5) Tighten torque converter bolts to specified torque (for A/T vehicle).
Page 317: Main Bearings, Crankshaft And Cylinder Block
6A2-30 ENGINE MECHANICAL (H27 ENGINE) Main Bearings, Crankshaft and Cylinder Block 1. Cylinder block 6. Rear oil seal 11. O-ring [A]: Sealant application amount 2. Lower crankcase : 7. Flywheel (M/T) Drive plate 12. Clutch housing plate Tightening Torque Apply sealant 99000-31150 to lower (A/T) crankcase mating surface.
Page 318 ENGINE MECHANICAL (H27 ENGINE) 6A2-31 Main bearing clearance Check clearance by using gaging plastic (1) according to the fol- lowing procedure. 1) Remove crankcase. 2) Clean bearings and main journals. 3) Place a piece of gaging plastic to full width of bearing (paral- lel to crankshaft) on journal, avoiding oil hole.
Page 319 6A2-32 ENGINE MECHANICAL (H27 ENGINE) Selection of main bearings • STANDARD BEARING : If bearing is in malcondition, or bearing clearance is out of specification, select a new standard bearing according to the following procedure and install it. 1) First check journal diameter. As shown in the figure, crank web has stamped numbers and alphabet at the center.
Page 320 ENGINE MECHANICAL (H27 ENGINE) 6A2-33 3) There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in following colors at the position as shown in the figure. Each color indicates the following thickness at the center of bearing.
Page 321 6A2-34 ENGINE MECHANICAL (H27 ENGINE) • UNDERSIZE BEARING (0.25 mm) : 0.25 mm undersize bearing is available, in 5 kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as shown in the figure. Each color represents the following thickness at the center of bearing.
Page 322 ENGINE MECHANICAL (H27 ENGINE) 6A2-35 INSPECTION Honing or reboring cylinders 1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time. 2) Select oversized piston according to amount of cylinder wear. Oversize piston specification : Size Piston diameter Standard...
Page 323: Special Tool
6A2-36 ENGINE MECHANICAL (H27 ENGINE) Special Tool 09911-97810 09913-75510 09915-47310 09915-64510 Oil seal installer Bearing installer Oil filter wrench Compression gauge 09915-64530 09915-67010 09915-67310 09915-77310 Compression gauge hose Compression gauge Vacuum gauge Oil pressure gauge attachment (c) 09916-14510 09916-14910 09916-34541 09916-37810 Valve lifter Valve lifter attachment...
Page 324 ENGINE MECHANICAL (H27 ENGINE) 6A2-37 09916-84511 09917-68221 09917-87810 09917-98221 Forceps Camshaft lock holder Valve guide installer Valve stem seal installer 09918-08210 09919-28610 09924-17810 09926-58010 Vacuum gauge hose joint Protective sleeve Flywheel holder Bearing puller attachment 09944-36011 09911-97710 09915-76510 Steering wheel remover Oil seal guide Oil pressure gauge attachment...
Page 325 6A2-38 ENGINE MECHANICAL (H27 ENGINE)
Page 326: Engine Cooling
ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING NOTE: • For the descriptions (items) not found in this section, refer to the descriptions of H25 engine in the same section of service manual mentioned in the FOREWORD of this manual. CONTENTS Maintenance ............6B-2 Coolant............
Page 327 6B-2 ENGINE COOLING Maintenance Coolant Anti-freeze proportioning chart : °C –16 –36 Freezing temperature °F –33 Antifreeze/Anticorrosion coolant concentration ltr. 2.7/6.4 4.6/4.6 Ratio of compound to cooling water US pt 5.8/13.7 9.8/9.8 Imp. pt. 4.8/11.3 8.1/8.1 Coolant capacity : Engine, radiator Reservoir Total and heater...
Page 328: Engine Fuel
ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Description ........6C-1 On-Vehicle Service ........6C-2 Fuel System ..........
Page 329: Fuel Tank
6C-2 ENGINE FUEL On-Vehicle Service Fuel Tank REMOVAL 1) Relieve fuel pressure in fuel feed line referring to Section 6 or Section 6-1. CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. 2) Disconnect negative (–) cable at battery.
Page 330 ENGINE FUEL 6C-3 10) Disconnect fuel vapor hose and return hose from pipes. 11) Remove fuel tank protector (if equipped) from vehicle. 12) Lower fuel tank gradually while holding it horizontally and pull out coupler at fuel pump. 1. Fuel pump 2.
Page 331 6C-4 ENGINE FUEL INSTALLATION 1) Install fuel pump assembly, fuel cut valve and vapor control valve to fuel tank. Refer to “FUEL PUMP” in this section. 2) Connect fuel hoses to fuel tank, fuel cut valve, and vapor control valve, check valve and fuel pump assembly. After connecting, clamp hoses securely.
Page 332: Fuel Lines
ENGINE FUEL 6C-5 Fuel Lines Due to the fact that fuel feed line is under high pressure, this sys- tem requires special consideration for service. The feed pipe uses screw couplings and hose clamps. INSPECTION Visually inspect fuel lines for evidence of fuel leakage, hose cracking and deterioration, or damage.
Page 333 6C-6 ENGINE FUEL...
Page 334 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 335 6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Fuel injector.......... 6E2-26 Main relay ..........6E2-41 Electronic Control System......6E2-31 Fuel pump relay ........6E2-42 Engine control module (ECM)/ Fuel cut operation ........ 6E2-43 powertrain control module (PCM) ..6E2-31 Emission Control System......
Page 336: System Flow
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-3 System Flow...
Page 337: System Diagram
6E2-4 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) System Diagram...
Page 338 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-5 1. Air cleaner 22. Fuel level sensor 39. A/C controller (if equipped) 2. Intake air temp. sensor 23. Monitor connector (if equipped) 40. Data link connector/Immobilizer control mod- ule (if equipped) 3.
Page 339: Air Intake System
6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Air Intake System The main components of the air intake system are air cleaner, mass air flow sensor, air cleaner, intake air pipe, throttle body, intake collector, idle air control valve and intake manifold. The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com- bustion chamber.
Page 340: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-7 Fuel Delivery System The fuel delivery system consists of the fuel tank, fuel pump, fuel filter, fuel pressure regulator, delivery pipe and fuel injectors. The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector through the delivery pipe.
Page 341: Electronic Control System
6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Electronic Control System The electronic control system consists of 1) various sensors which detect the state of engine and driving condi- tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various controlled devices.
Page 342 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-9 WHT/BLU C51-2-19 C51-2-2 ORN/BLU C51-2-20 C51-2-1 PNK/BLK C51-2-30 C51-2-9 PNK/GRN C51-2-8 PNK/BLU GRY/GRN YEL/GRN C51-1-12 C51-2-22 YEL/BLU GRY/BLK C51-1-13 C51-2-21 GRY/YEL C51-3-26 BLU/BLK PPL/WHT C51-3-10 C51-2-15 LT GRN GRY/YEL C51-3-5 C51-2-14...
Page 343 6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) 1. Fuel injector No.1 17. “O/D OFF” lamp (A/T) 34. Power steering pressure switch 2. Fuel injector No.2 18.
Page 344 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-11 TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT C51-3-1 Intake air temp. (IAT) sensor C51-3-13 Power source for TP sensor C51-3-25 Ground for IAT sensor, MAP sensor and oxygen sensor (if equipped) C51-3-2 Engine coolant temp.
Page 345: Engine And Emission Control Input/Output Table
6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Engine and Emission Control Input/Output Table Input Function Output Main relay control Main relay Fuel pump control Fuel pump relay Injectors Injection control Idle air control IAC valve Ignition coil with igniter Ignition control MIL control...
Page 346: On-Vehicle Service
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-13 On-Vehicle Service 1. Brake booster hose pipe 8. EGR pipe (if equipped) 15. EVAP canister 2. Vacuum hose for fuel pressure regulator 9. Exhaust manifold 16. Tank pressure control valve 3.
Page 347: Accelerator Cable Adjustment
6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Accelerator Cable Adjustment 1) With throttle valve closed, check accelerator pedal play which should be within following specification. If measured value is out of specification, adjust accelerator cable (1) to specification with cable adjusting nut (2).
Page 348: Idle Speed/Idle Air Control (Iac) Duty Inspection
“Neutral” (shift selector lever to “P” range for A/T vehicle), and set parking brake and block drive wheels. [Using SUZUKI scan tool] 1) Connect SUZUKI scan tool to DLC with ignition switch OFF. Special tool (A) : SUZUKI scan tool 2) Warm up engine to normal operating temperature.
Page 349: [Not Using Suzuki Scan Tool] (Vehicle With Monitor Connector)
6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) [Not using SUZUKI scan tool] (vehicle with monitor connector) 1) Disconnect scan tool from DLC if connected. 2) Warm up engine to normal operating temperature. 3) Stop engine and connect duty meter (3) between duty output terminal and ground terminal of monitor connector (1).
Page 350: Idle Mixture Inspection/Adjustment
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-17 Idle mixture inspection/adjustment (vehicle without heated oxygen sensor) All vehicles not equipped with heated oxygen sensor are shipped with their CO % factory adjusted as follows. Engine idle mixture (CO %) 0.8 –...
Page 351: Air Intake System
6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Air Intake System Throttle body 1. Throttle body 4. Water hose 2. Intake collector 5. MAF sensor 3. Breather hose 6. TP sensor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Drain cooling system.
Page 352 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-19 6) Remove surge tank cover. Remove intake air pipe (1) and surge tank pipe (2). 7) Disconnect connectors of TP sensor and IAC valve. 8) Disconnect ground wire at connector. 9) Remove clamp bracket (1) and harness clamps from intake collector.
Page 353 6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) CLEANING CAUTION: • Do not blow compressed air through bypass air pas- sage with IAC valve installed to throttle body. This will cause IAC valve to malfunction. •...
Page 354: Idle Air Control Valve (Iac Valve)
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-21 14) Install strut tower bar (1) and tighten bolts. 15) Refill cooling system. 16) Connect negative (–) cable at battery. 17) Adjust accelerator cable and A/T throttle cable, refer to “ACCELERATOR CABLE ADJUSTMENT”...
Page 355: Fast Idle Air Valve
6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 3) Remove air cleaner outlet hose and remove IAC valve from throttle body. 4) Connect connector to IAC valve. 5) Check that plunger (1) of IAC valve moves once and then stops as soon as ignition switch (2) is turned OFF after cranking engine for 2 sec.
Page 356: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-23 Fuel Delivery System Fuel pressure inspection 1) Relieve fuel pressure in fuel feed line referring to “FUEL PRESSURE RELIEF PROCEDURE” in Section 6-1. 2) Disconnect fuel feed hose from (3) delivery fuel feed pipe (1). CAUTION: A small amount of fuel may be released when fuel feed hose is removed.
Page 357: Fuel Pump
6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 8) After checking fuel pressure, remove fuel pressure gauge (1). CAUTION: As fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to following pro- cedures.
Page 358: Fuel Pressure Regulator
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-25 REMOVAL Remove fuel tank from body according to procedure described in Section 6C and remove fuel pump from fuel tank. INSPECTION Check fuel pump filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in fuel tank.
Page 359: Fuel Injector
6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) INSTALLATION For installation, reverse removal procedure and note the follow- ings. • Use new O-ring. • Apply thin coat of gasoline to O-ring to facilitate installation. • Tighten fuel pressure regulator (1) bolts to specified torque. Tightening torque Fuel pressure regulator bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Page 360 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-27 REMOVAL 1) Relieve fuel pressure in fuel feed line referring to “FUEL PRESSURE RELIEF PROCEDURE” in Section 6-1. 2) Remove throttle body intake collector, refer to “THROTTLE BODY”...
Page 361 6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 1) Install injector (1) and fuel pressure regulator (2) to special tool (injector checking tool). NOTE: Remove grommet from injector, then install injector to special tool and tighten bolts by hand. Special tool (A) : 09912-58421 2) Connect special tools (hoses and attachment) to pipes of...
Page 362 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-29 INSTALLATION 1) Replace injector O-ring (1) with new one using care not to damage it. Install grommet (2) to injector. 2) Check if insulator (1) is scored or damaged. If it is, replace with new one.
Page 363 6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 5) Install fuel connect pipe (1) and tighten union bolts to speci- fied torque with new gaskets (3). Tightening torque Fuel connect pipe union bolt (b) : 30 N·m (3.0 kg-m, 22.0 lb-ft) 6) Install fuel feed pipe (2) and tighten union bolt to specified torque with new gaskets.
Page 364: Electronic Control System
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-31 Electronic Control System Engine control module (ECM)/powertrain control module (PCM) CAUTION: As ECM (PCM) consists of precision parts, be careful not to expose it to excessive shock. REMOVAL 1) Disconnect negative (–) cable from battery.
Page 365: Mass Air Flow Sensor (Maf Sensor)
6E2-32 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Mass air flow sensor (MAF sensor) INSPECTION NOTE: Use voltmeter with high-impedance (10 kΩ Ω Ω Ω /V minimum) or digital type voltmeter. 1) Connect voltmeter (1) to “B+” terminal of MAF sensor (2) coupler disconnected and ground (3).
Page 366 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-33 REMOVAL 1) Disconnect negative (–) cable at battery and coupler (1) from MAF sensor (3). 2) Remove air cleaner outlet hose (2) from throttle body and MAF sensor (3). 3) Remove MAF sensor from air cleaner case.
Page 367: Intake Air Temperature (Iat) Sensor
6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Intake air temperature (IAT) sensor REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disconnect IAT sensor coupler. 3) Remove IAT sensor from air cleaner case. INSPECTION Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.
Page 368: Throttle Position Sensor (Tp Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-35 Throttle position sensor (TP sensor) INSPECTION 1) Disconnect negative (–) cable at battery and coupler from TP sensor (4). 2) Using ohmmeter, check resistance between terminals under each condition given in table below.
Page 369: Engine Coolant Temperature Sensor (Ect Sensor)
6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Engine coolant temperature sensor (ECT sensor) REMOVAL 1) Disconnect negative (–) cable from battery. 2) Drain cooling system. 3) Disconnect coupler from ECT sensor (1). 4) Remove ECT sensor from water outlet cap (2). INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating...
Page 370: Heated Oxygen Sensor (Sensor 1)
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-37 Heated oxygen sensor (sensor 1) REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool. 1) Disconnect negative (–) cable from battery.
Page 371: Heated Oxygen Sensor (Sensor 2)
6E2-38 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) HEATER INSPECTION 1) Disconnect HO2S-1 or -2 coupler. 2) Using ohmmeter, measure resistance between terminals “VB” and “GND” of HO2S coupler (1). If found faulty, replace HO2S. NOTE: Temperature of HO2S affects resistance value largely.
Page 372: Vehicle Speed Sensor (Vss)
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-39 HEATER INSPECTION Refer to “HEATED OXYGEN SENSOR (SENSOR 1) HEATER INSPECTION” Vehicle speed sensor (VSS) ON-VEHICLE INSPECTION 1) Hoist vehicle. 2) Release parking brake lever, set transmission in neutral and transfer in “2H”.
Page 373 6E2-40 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) INSPECTION 1) Check sensor O-ring (1) for damage and deterioration. Replace as necessary. 2) Arrange 3 new 1.5 V batteries (2) in series and connect its positive terminal to “Vin” terminal of MAP sensor (1) and negative terminal to “Ground”...
Page 374: Fuel Level Sensor (Sender Gauge)
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-41 INSTALLATION 1) Confirm that vacuum passage on intake manifold is free from clog. 2) Apply engine oil to O-ring of sensor. 3) Install sensor (1) to intake manifold (2). 4) Connect connector to sensor (1) securely.
Page 375: Fuel Pump Relay
6E2-42 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 3) Check resistance between each two terminals as in table below. If check results are as specified, proceed to next operation check. If not, replace. Main relay resistance: TERMINALS RESISTANCE ∞...
Page 376: Fuel Cut Operation
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-43 Fuel cut operation INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in Neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up.
Page 377: Emission Control System
6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) Emission Control System EGR system (if equipped) EGR SYSTEM INSPECTION (USING SUZUKI SCAN TOOL) 1) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF. Special tool (A) : SUZUKI scan tool...
Page 378: Evap Canister
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-45 INSPECTION 1) Check resistance between following terminals of EGR valve (1) in each pair. If found faulty, replace EGR valve assembly. EGR valve resistance: Terminals Standard resistance A –...
Page 379: Vacuum Passage
6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 1) Disconnect vacuum hoses from EVAP canister and remove EVAP canister. 2) When air is blown into tank pipe, there should be no restric- tion of flow through purge pipe and air pipe. If operation differs from above description, EVAP canister must be replaced.
Page 380: Pcv System
ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-47 PCV System NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty for obstructed PCV valve or hose hampers its accu- rate checking.
Page 381: Pcv Hose
6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) PCV system NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses (6) before checking engine idle speed/ IAC duty for obstructed PCV valve or hose hampers its accurate checking.
Page 382 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-49 09917-47010 09930-88521 09931-76011 Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan Mass storage cartridge for tool) (See NOTE “B”.) Tech 1A 09931-76030 14/16 pin DLC cable for...
Page 383 6E2-50 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Page 384 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 385: General Description
6F2-2 IGNITION SYSTEM (FOR H27 ENGINE) General Description The ignition system is a direct ignition system. It consists of the parts as described below and has an electronic ignition control system. • ECM (or PCM) It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter (in ignition coil assembly).
Page 386: System Wiring
IGNITION SYSTEM (FOR H27 ENGINE) 6F2-3 System Wiring NOTE: For ECM (PCM) terminal assignment, refer to Section 6E2. 1. To ignition switch 8. Ignition coil assembly (For No.3 cylinder) 2. “IG COIL METER” fuse 9. Ignition coil assembly (For No.4 cylinder) 3.
Page 387: Diagnosis
6F2-4 IGNITION SYSTEM (FOR H27 ENGINE) Diagnosis Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil assembly Replace. not start or hard to Loose connection or disconnection of lead wire Connect securely. start (No spark) Faulty spark plug (s) Replace.
Page 388 IGNITION SYSTEM (FOR H27 ENGINE) 6F2-5 Step Action CMP Sensor Check Substitute a known-good Tighten CMP sensor bolt 1) Check CMP sensor. ECM (or PCM) and then or replace CMP sensor. Refer to Step 6 or 7 of “DTC P0340 DIAG. repeat Step 2.
Page 389: Ignition Spark Check
3) Check to be sure that idle speed is within specification. Refer to Section 6E2. 4) Connect SUZUKI scan tool to DLC (1) with ignition switch OFF, restart engine and fix ignition timing by using fixed spark mode of SUZUKI scan tool.
Page 390 5) Set timing light to ignition harness for No.1 cylinder. 6) Using timing light, check that timing observed from viewpoint is within specification. Initial ignition timing of viewpoint (when it is fixed by SUZUKI scan tool) : 5 ± 1° BTDC Ignition order : 1-6-5-4-3-2...
Page 391: On-Vehicle Service
6F2-8 IGNITION SYSTEM (FOR H27 ENGINE) On-Vehicle Service Ignition Coil Assembly (Igniter and Ignition Coil) REMOVAL 1) Remove ignition coil cover. 2) Disconnect ignition coil coupler. 3) Remove ignition coil bolt (1), and then pull out ignition coil assembly (2). INSPECTION Check ignition coil assembly for the following : •...
Page 392 IGNITION SYSTEM (FOR H27 ENGINE) 6F2-9 INSPECTION CAUTION: When servicing the iridium/platinum spark plugs (slender center electrode type plugs), do not touch the center electrode to avoid damage to it. The electrode is not strong enough against mechanical force as it is slender and its material is not mechanically tough.
Page 393: Cmp Sensor
6F2-10 IGNITION SYSTEM (FOR H27 ENGINE) CMP Sensor CAUTION: Disassembly is prohibited. If anything faulty is found, replace as an assembly unit. REMOVAL 1) Disconnect CMP sensor coupler (2). 2) Remove A/T fluid level gauge and filler tube. 3) Remove CMP sensor (1) by removing bolt (3). INSTALLATION NOTE: After installing CMP sensor, adjust ignition timing.
Page 394 IGNITION SYSTEM (FOR H27 ENGINE) 6F2-11 2) Install CMP sensor to camshaft. Fit the dog of CMP sensor coupling into the slots of cam- shaft, when installing. The dogs of CMP sensor coupling are offset. Therefore, if the dogs can not be fitted into the slots, turn the CMP sensor shaft by 180 degree and try again.
Page 395: Noise Suppressor
6F2-12 IGNITION SYSTEM (FOR H27 ENGINE) Noise Suppressor REMOVAL 1) Disconnect coupler of noise suppressor (1). 2) Remove noise suppressor (1) from harness (2). INSPECTION Using ohmmeter, check to be sure that capacitor (condenser) in noise suppressor is not conductive. If check result is not satisfactory, replace noise suppressor.
Page 396: Special Tool
IGNITION SYSTEM (FOR H27 ENGINE) 6F2-13 Special Tool 09930-76420 09931-76011 09931-76030 Timing light (Dry cell type) Tech 1A kit (SUZUKI scan 16/14 pin DLC cable for Mass storage cartridge for tool) (See NOTE “A”.) Tech 1A Tech 1A Tech 2 kit (SUZUKI scan tool) (See NOTE “B”.)
Page 397 6F2-14 IGNITION SYSTEM (FOR H27 ENGINE)
Page 398: Charging System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in Section 10B in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 399: General Description
6H-2 CHARGING SYSTEM General Description Generator B : Generator output (Battery terminal) L : Lamp terminal 5. Stator core 10. Rear end frame D : Dummy terminal 1. Pulley 6. Field coil 11. Drive end frame E : Ground 2. Pulley nut 7.
Page 400: Unit Repair Overhaul
CHARGING SYSTEM 6H-3 Unit Repair Overhaul Generator Assembly 1. Pulley nut 6. Driver end bearing 11. Wave washer 16. Regulator 21. Terminal plate 2. Pulley 7. Bearing retainer 12. Rear end frame 17. Brush 3. Drive end bearing 8. Rotor 13.
Page 401 6H-4 CHARGING SYSTEM • Using ohmmeter, check that there is no continuity between slip ring and rotor. If there is continuity, replace rotor. • Check slip rings for roughness or scoring. If rough or scored, replace rotor. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor.
Page 402 CHARGING SYSTEM 6H-5 Brush and brush holder Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush. Exposed brush length “a” Standard : 10.5 mm (0.413 in.) Limit : 1.5 mm (0.059 in.) Rectifier •...
Page 403: Specifications
6H-6 CHARGING SYSTEM Specifications Battery Battery type 55D23L 75D23L 95D26L Rated capacity AH/5HR, 12 Volts Electrolyte L (US/Imp.pt) 3.9 (8.24/6.86) 3.9 (8.24/6.86) 4.0 (8.53/7.04) Electrolyte S.G. 1.28 when fully charged at 20°C (68°F) Generator Type 105 A type Rated voltage 12 V Nominal output 105 A...
Page 404: Exhaust System
EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CAUTION: Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle. Use of LEADED FUEL will affect performance of the catalytic converter adversely to a great extent. NOTE: • For the descriptions (items) not found in this section, refer to the same section of service manual mentioned in the FOREWORD of this manual.
Page 405 6K-2 EXHAUST SYSTEM On-Vehicle Service Components TYPE WITH WELD BOLT AT MUFFLER FRONT FLANGE 1-1 Exhaust manifold (without WU-TWC) 4. Heated oxygen sensor-1 (if equipped) 7. Exhaust pipe bolt 11. Muffler tail pipe 1-2 Exhaust manifold (with WU-TWC) 5. Exhaust pipe gasket 8.
Page 406 EXHAUST SYSTEM 6K-3 TYPE WITHOUT WELD BOLT AT MUFFLER FRONT FLANGE 1-1 Exhaust manifold (without WU-TWC) 4. Heated oxygen sensor-1 (if equipped) 7. Exhaust pipe bolt 12. Muffler gasket 1-2 Exhaust manifold (with WU-TWC) 5. Exhaust pipe gasket 8. Muffler 13.
Page 407 6K-4 EXHAUST SYSTEM...
Page 408: Manual Transmission
MANUAL TRANSMISSION 7A1-1 SECTION 7A1 MANUAL TRANSMISSION NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS Unit Repair .............7A1-1 Unit Repair NOTE: This manual transmission (for H27 engine) is not equipped with C-ring of countershaft rear bearing.
Page 409 7A1-2 MANUAL TRANSMISSION...
Page 410 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 411 7B1-2 AUTOMATIC TRANSMISSION (4 A/T) Stall Test ........... 7B1-38 Solenoid Valves (Shift Solenoid Valves Line Pressure Test........7B1-39 and TCC Solenoid Valve) ......7B1-45 Road Test ..........7B1-40 MANUAL SELECTOR ASSEMBLY ..7B1-46 Manual Road Test........7B1-41 SELECT CABLE ........7B1-48 Time Lag Test ...........
Page 412: General Description
AUTOMATIC TRANSMISSION (4 A/T) 7B1-3 General Description Item Specifications Torque Type 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism) converter Stall torque ratio Oil pump Type Trochoid type oil pump Drive system Engine driven Gear Type Forward 4-step, reverse 1-step planetary gear type change Shift position “P”...
Page 413: Electronic Shift Control System
7B1-4 AUTOMATIC TRANSMISSION (4 A/T) Electronic Shift Control System BLU/YEL C51-1-14 5V 5V YEL/GRN C51-1-12 YEL/BLU C51-1-13 GRY/YEL C51-3-26 GRY/YEL C51-3-12 GRY/RED C51-3-13 RED/GRN C51-3-9 ORN/BLU C51-3-2 GRY/YEL C51-3-24 GRN/WHT E61-34 BLU/YEL C51-1-11 C51-1-10 BLU/GRN C51-1-21 C51-1-20 C51-1-23 17 16 15 C51-1-22 PPL/YEL E61-7...
Page 414: Automatic Gear Shift Diagram
AUTOMATIC TRANSMISSION (4 A/T) 7B1-5 Automatic gear shift diagram Automatic shift schedule as a result of shift control is shown below. In case that select lever is shifted to L at a higher than 55 km/h or 34 mile/h speed, 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that.
Page 415 7B1-6 AUTOMATIC TRANSMISSION (4 A/T) [NORMAL MODE] Shift 1 → → → → 2 2 → → → → 3 3 → → → → 4 4 → → → → 3 3 → → → → 2 2 → → → → 1 Throttle Full throttle km/h (mile/h)
Page 416: Diagnosis
OFF although DTC stored in its memory will remain.) • It is possible to communicate through DLC (3) by using not only SUZUKI scan tool (2). (Diagnostic information can be accessed by using a scan tool (2).) 2 DRIVING CYCLE DETECTION LOGIC Refer to Section 6-1 for details.
Page 417: On-Board Diagnostic System (Vehicle With Monitor Connector)
• It is possible to communicate through DLC by using not only SUZUKI scan tool (2) but also generic scan tool. (Diagnostic information can be accessed by using a scan tool.) • ECM also indicates trouble area in memory by means of flashing of malfunction indicator lamp (1) at the time of inspection.
Page 418: Precaution In Diagnosing Trouble
PCM memory. Such disconnec- tion will clear memorized information in PCM memory. • Using SUZUKI scan tool or also generic scan tool for vehicle without monitor connector, the diagnostic information stored in PCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (Instruction) Manual sup-...
Page 419: Automatic Transmission Diagnostic Flow Table
7B1-10 AUTOMATIC TRANSMISSION (4 A/T) Automatic Transmission Diagnostic Flow Table Refer to the following pages for the details of each step. Step Action Customer Complaint Analysis Go to Step 2. Perform customer com- 1) Perform customer complaint analysis refer- plaint analysis. ring to the next page.
Page 420 AUTOMATIC TRANSMISSION (4 A/T) 7B1-11 Step Action Final Confirmation Test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to the next page. Is there any problem symptom, DTC or abnor- mal condition? STEP 1.
Page 421 7B1-12 AUTOMATIC TRANSMISSION (4 A/T) STEP 10. CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to “INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in Step 2. STEP 11.
Page 422: Malfunction Indicator Lamp (Mil) Check
AUTOMATIC TRANSMISSION (4 A/T) 7B1-13 Malfunction Indicator Lamp (MIL) Check Refer to the same item in Section 6-1 for checking procedure. “O/D OFF” Lamp Check 1) Check that O/D off switch button is at OFF position (pushed). 2) Turn ignition switch ON. 3) Check that “O/D OFF”...
Page 423: Visual Inspection
7B1-14 AUTOMATIC TRANSMISSION (4 A/T) Diagnostic Trouble Code Table Refer to the same item in Section 6-1. Fail Safe Table Refer to the same item in Section 6-1. Visual Inspection Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION •...
Page 424: Trouble Diagnosis Table 1
AUTOMATIC TRANSMISSION (4 A/T) 7B1-15 Step Action Perform stall test, time rag test, line pressure test, Go to Step 5. Proceed to “TROUBLE engine brake test and “P” range test referring to DIAGNOSIS TABLE 3” in “STALL TEST”, “LINE PRESSURE TEST”, “ENGINE this section.
Page 425: Trouble Diagnosis Table 3
7B1-16 AUTOMATIC TRANSMISSION (4 A/T) GEAR SHIFT Condition Possible Cause Correction Poor 1–2 shift, exces- Regulator valve sticking Replace. sive slippage 1–2 shift valve sticking Replace. Shift solenoid valve-B sticking Replace. Intermediate coast modulator valve sticking Replace. Poor 2–3 shift, exces- 2–3 shift valve sticking Replace.
Page 426: Scan Tool Data
AUTOMATIC TRANSMISSION (4 A/T) 7B1-17 GEAR SHIFT Condition Possible Cause Correction Poor 1–2 shift, exces- Fluid pressure leakage to overdrive clutch due Replace. sive slippage to wear or breakage of O/D case seal ring Faulty second brake Replace. Broken O-ring of second brake piston Replace.
Page 427 7B1-18 AUTOMATIC TRANSMISSION (4 A/T) Table A-1 : No TCC Lock-Up Occurs SYSTEM DESCRIPTION PCM turns TCC solenoid OFF under any of the following conditions. • Brake pedal switch : ON • 4WD LOW switch : ON • Cruise control module : TCC OFF command signal is output (if equipped). •...
Page 428 AUTOMATIC TRANSMISSION (4 A/T) 7B1-19 Step Action “4WD LOW” switch signal inspection : Go to Step 6. Faulty “4WD LOW” switch With ignition switch ON, check voltage between or its circuit. C51-1-26 terminal of PCM coupler and ground. If OK, substitute a known- good PCM and recheck.
Page 429 7B1-20 AUTOMATIC TRANSMISSION (4 A/T) Table A-2 : No Gear Shift to O/D SYSTEM DESCRIPTION PCM does not shift to O/D gear under any of the following conditions. • O/D off switch : ON • 4WD LOW switch : ON •...
Page 430 AUTOMATIC TRANSMISSION (4 A/T) 7B1-21 Step Action “4WD LOW” switch signal inspection : Go to Step 6. Faulty “4WD LOW” switch With ignition switch ON, check voltage between or its circuit. C51-1-26 terminal of PCM coupler and ground. If OK, substitute a known- good PCM and recheck.
Page 431 7B1-22 AUTOMATIC TRANSMISSION (4 A/T) Table B-1 : “O/D OFF” Light Circuit Check (“O/D OFF” Light Doesn’t Light at Ignition Switch ON But Engine Starts Up) WIRING DIAGRAM 1. PCM 4. P/N change switch 2. Fuse 5. J/C 3. O/D off switch 6.
Page 432 AUTOMATIC TRANSMISSION (4 A/T) 7B1-23 Table B-2 : “O/D OFF” Light Circuit Check (“O/D OFF” Light Comes ON Steadily) WIRING DIAGRAM Refer to “TABLE B-1” in this section. TROUBLESHOOTING Step Action Check O/D off switch status. Go to Step 2. System is OK.
Page 433 7B1-24 AUTOMATIC TRANSMISSION (4 A/T) Table B-3 : “POWER” Light Circuit Check (“POWER” Light Doesn’t Light at Ignition Switch ON But Engine Starts Up) WIRING DIAGRAM 1. PCM 4. P/N change switch 2. Fuse 5. J/C 3. O/D off switch TROUBLESHOOTING Step Action...
Page 434 AUTOMATIC TRANSMISSION (4 A/T) 7B1-25 Table B-4 : “POWER” Light Circuit Check (“POWER” Light Comes ON Steadily) WIRING DIAGRAM Refer to “TABLE B-3” in this section. TROUBLESHOOTING Step Action Check Power/Normal change switch position. Go to Step 2. Set Power/Normal Is switch button at Normal position? change switch at Nor- mal position.
Page 435 7B1-26 AUTOMATIC TRANSMISSION (4 A/T) DTC P0705 (DTC NO.72) - Transmission Range Sensor (Switch) Circuit Mal- function WIRING DIAGRAM 1. PCM 3. J/C 2. Fuse 4. Transmission range sensor (switch) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA •...
Page 436 Go to Step 5. operation. Check for intermittent Check by using SUZUKI scan tool : referring to “INTER- 1) Connect SUZUKI scan tool to DLC with ignition MITTENT AND POOR switch OFF. CONNECTION” in 2) Turn ignition switch ON and check transmission Section 0A.
Page 437 7B1-28 AUTOMATIC TRANSMISSION (4 A/T) Step Action Check transmission range switch for installation posi- Go to Step 7. Adjust. tion. 1) Shift select lever to “N” range. 2) Check that “N” reference line on switch and center line on shaft are aligned. Are they aligned? Check transmission range switch (sensor) referring to “YEL”, “ORN/GRN”,...
Page 438: Dtc P0715 (Dtc No.76) - Input/Turbine Speed Sensor Circuit Malfunction
AUTOMATIC TRANSMISSION (4 A/T) 7B1-29 DTC P0715 (DTC NO.76) - Input/Turbine Speed Sensor Circuit Malfunction WIRING DIAGRAM 1. PCM 2. Input shaft speed sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Input speed sensor detected speed is lower than spec- Input speed sensor and its circuit ification while vehicle running under all of the following conditions :...
Page 439 7B1-30 AUTOMATIC TRANSMISSION (4 A/T) DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 440 AUTOMATIC TRANSMISSION (4 A/T) 7B1-31 Step Action Check visually input speed sensor and over- Intermittent trouble or Clean, repair or replace. drive clutch drum for the followings. faulty PCM. • No damage Check for intermittent • No foreign material attached referring to “INTERMIT- •...
Page 441: Dtc P0720 (Dtc No.75) Output Speed Sensor Circuit Malfunction
7B1-32 AUTOMATIC TRANSMISSION (4 A/T) DTC P0720 (DTC NO.75) Output Speed Sensor Circuit Malfunction WIRING DIAGRAM 1. PCM 2. Output shaft speed sensor DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA • With 4WD LOW switch OFF, no output shaft speed •...
Page 442 AUTOMATIC TRANSMISSION (4 A/T) 7B1-33 TROUBLESHOOTING Step Action Was “A/T DIAGNOSTIC FLOW TABLE” in this Go to Step 2. Go to “A/T DIAGNOSTIC section performed? FLOW TABLE” in this sec- tion. Output shaft speed sensor circuit check : Go to Step 4. Go to Step 3.
Page 443: Dtc P0743 (Dtc No.65/66) - Tcc (Lock-Up) Solenoid Electrical
7B1-34 AUTOMATIC TRANSMISSION (4 A/T) DTC P0743 (DTC NO.65/66) - TCC (Lock-Up) Solenoid Electrical WIRING DIAGRAM 1. PCM 2. Shift solenoid-A 3. Shift solenoid-B 4. TCC solenoid DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA Voltage at terminal C51-1-8 of PCM is high while TCC •...
Page 444 AUTOMATIC TRANSMISSION (4 A/T) 7B1-35 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 445: Dtc P0753 (Dtc No.61/62) Shift Solenoid-A (#1) Electrical Dtc P0758 (Dtc No.63/64) Shift Solenoid-B (#2) Electrical
7B1-36 AUTOMATIC TRANSMISSION (4 A/T) DTC P0753 (DTC NO.61/62) Shift Solenoid-A (#1) Electrical DTC P0758 (DTC NO.63/64) Shift Solenoid-B (#2) Electrical WIRING DIAGRAM 1. PCM 2. Shift solenoid-A 3. Shift solenoid-B 4. TCC solenoid DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA DTC P0753 (DTC NO.61/62):...
Page 446 AUTOMATIC TRANSMISSION (4 A/T) 7B1-37 DTC CONFIRMATION PROCEDURE WARNING: • When performing a road test, select a place where there is no traffic or possibility of a traffic acci- dent and be very careful during testing to avoid occurrence of an accident. •...
Page 447: Stall Test
7B1-38 AUTOMATIC TRANSMISSION (4 A/T) Stall Test This test is to check overall performance of automatic transmission and engine by measuring stall speed at “D” and “R” ranges. Be sure to perform this test only when transmission fluid is at normal operating temperature and its level is between FULL and LOW marks.
Page 448: Line Pressure Test
AUTOMATIC TRANSMISSION (4 A/T) 7B1-39 Line Pressure Test Purpose of this test is to check operating conditions of each part by measuring fluid pressure in fluid pressure line. Line pressure test requires following conditions. • Automatic fluid is at normal operating temperature (70 to 80 °...
Page 449: Road Test
7B1-40 AUTOMATIC TRANSMISSION (4 A/T) TROUBLESHOOTING Condition Possible cause Line pressure higher than standard level in each • Malfunctioning regulator valve range • Malfunctioning throttle valve • Maladjusted A/T throttle cable Line pressure lower than standard level in each • Defective O/D clutch range •...
Page 450: Manual Road Test
AUTOMATIC TRANSMISSION (4 A/T) 7B1-41 Manual Road Test This test check the gear being used in “L”, “2” or “D” range when driven with unoperated gear shift control system. Test drive vehi- cle on a level road. NOTE: Before this test, check diagnostic trouble code (DTC). 1) Disconnect shift solenoid coupler (1) valves on transmission.
Page 451: Engine Brake Test
7B1-42 AUTOMATIC TRANSMISSION (4 A/T) NOTE: • When repeating this test, be sure to wait at least minute after select lever is shifted back to “N” range. • Engine should be warmed up fully for this test. TROUBLESHOOTING Condition Possible cause When “N”...
Page 452: On-Vehicle Service
AUTOMATIC TRANSMISSION (4 A/T) 7B1-43 On-Vehicle Service Maintenance Service Fluid level LEVEL CHECK AT NORMAL OPERATING TEMPERATURE 1) Stop vehicle and place it level. 2) Apply parking brake and place chocks against wheels. 3) With selector at P position, start engine. 4) Warm up engine till fluid temperature reaches normal oper- ating temperature (70 –...
Page 453: Fluid Change
7B1-44 AUTOMATIC TRANSMISSION (4 A/T) LEVEL CHECK AT ROOM TEMPERATURE The fluid level check at room temperature (20 – 30 °C (68 – 86 °F)) performed after repair or fluid change before test driving is just preparation for level check of normal operating temperature. The checking procedure itself is the same as that described previ- ously.
Page 454: A/T Throttle Cable
AUTOMATIC TRANSMISSION (4 A/T) 7B1-45 A/T Throttle Cable ADJUSTMENT 1) Pull inner cable (3) by force of 2 N (0.2 kg, 0.45 lb) or less to be no slack of inner cable with A/T throttle cable (1) curved as shown in the figure. 2) Fix stopper (2) to inner cable (3) with clearance “c”.
Page 455: Manual Selector Assembly
7B1-46 AUTOMATIC TRANSMISSION (4 A/T) MANUAL SELECTOR ASSEMBLY 1. Manual lever assembly 4. Bulb filter 7. Shift lock solenoid (if equipped) 2. Select indicator assembly 5. Bulb 8. Manual selector assembly mounting bolt 3. Illumination assembly 6. knob assembly Tightening torque REMOVAL 1) Disconnect negative (–) cable at battery.
Page 456 AUTOMATIC TRANSMISSION (4 A/T) 7B1-47 INSPECTION • Check select lever for smooth and clear-cut movement and position indicator for correct indication. For operation of select lever, refer to left figure.
Page 457: Select Cable
7B1-48 AUTOMATIC TRANSMISSION (4 A/T) SELECT CABLE 1. Selector lever assembly 6. Washer 11. Transmission range switch assembly 2. Selector lever assembly mounting bolt 7. Clip 12. Transmission range switch mounting bolt 3. Selector cable 8. Manual select lever nut (transmission range switch side) 13.
Page 458: Unit Repair
AUTOMATIC TRANSMISSION (4 A/T) 7B1-49 Unit Repair NOTE: The service procedure to be described in this item is the same as that of H25 engine model except the following description. Refer to the same section of the Unit Repair Manual mentioned in FOREWORD of this manual for the description not found in this item.
Page 459: Forward Clutch
7B1-50 AUTOMATIC TRANSMISSION (4 A/T) 4) Blow air into fluid hole in O/D case (2) and remove brake pis- ton (1). 5) Remove brake piston inner ring and brake piston outer ring from brake piston. 6) Unsnap seal ring (1). 7) Remove 2 seal rings (1).
Page 460 AUTOMATIC TRANSMISSION (4 A/T) 7B1-51 DISASSEMBLY 1) After removing retaining ring (1), remove direct clutch input hub (2) and forward clutch hub (3). 2) Remove bearing race and thrust bearing. 1. Thrust bearing No. 2 2. Thrust forward clutch bearing 3.
Page 461 7B1-52 AUTOMATIC TRANSMISSION (4 A/T) 5) Remove retaining ring (1) and then remove direct clutch input hub. 6) Remove retaining ring and then remove all clutch discs. 7) Using special tool and hydraulic press, compress forward clutch piston return spring and remove retaining return spring.
Page 462 AUTOMATIC TRANSMISSION (4 A/T) 7B1-53 DIRECT CLUTCH DISASSEMBLY 1) Install direct clutch assembly (1) to center support (2) and with 4 – 8 kg/cm air pressure applied to second fluid hole from the left, measure stroke of direct clutch piston as shown in figure.
Page 463: Front Upper Valve Body
7B1-54 AUTOMATIC TRANSMISSION (4 A/T) 6) Install direct clutch cylinder to center support. Remove direct clutch piston by blowing air into the second hole from the left as shown in the figure. Also, remove direct clutch inner piston by blowing air into hole at the extreme right.
Page 464 AUTOMATIC TRANSMISSION (4 A/T) 7B1-55 LOWER VALVE BODY 1. Lower valve body 7. TCC (Lock-up) control valve plate 13. Primary regulator valve sleeve 2. Spring 8. TCC (Lock-up) control valve gasket 14. Primary regulator valve plunger 3. Pressure relief valve ball 9.
Page 465 7B1-56 AUTOMATIC TRANSMISSION (4 A/T) DISASSEMBLY 1) Remove bypass valve (1), bypass valve spring, check ball valve damping spring, valve body ball (2) and ball valve spring. 3. Check ball 4. Primary regulator valve sleeve retainer 5. Locating pin 2) Remove lower valve body plate (1) and lower valve body plate gasket.
Page 466 AUTOMATIC TRANSMISSION (4 A/T) 7B1-57 6) After removing shift solenoid valve (A & B) (1), remove sole- noid valve gasket, low coast modulator valve spring (2), inter coast modulator valve spring (3) and 2 intermediate coast modulator valves (4). 7) Pressing TCC (lock-up) control sleeve with finger and using magnet (1), remove locating pin and then remove TCC (lock- up) control sleeve, TCC (lock-up) control valve and TCC (lock-up) control valve spring.
Page 467 7B1-58 AUTOMATIC TRANSMISSION (4 A/T) ASSEMBLY Assemble each component by reversing disassembly procedure and noting the following points. • Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size.
Page 468: Unit Assembly
AUTOMATIC TRANSMISSION (4 A/T) 7B1-59 • Tighten TCC (lock-up) solenoid valve bolt to specified torque. Tightening torque TCC solenoid valve bolt : 5.5 N·m (0.55 kg-m, 4.0 lb-ft) 1. Solenoid valve No. 2 (TCC solenoid valve) 2. O-ring • Tighten pressure relief valve bolt to specified torque. Tightening torque Pressure relief valve bolt : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Page 469: Tightening Torque Specification
7B1-60 AUTOMATIC TRANSMISSION (4 A/T) Accumulator piston and spring specification : Piston outer Used for Spring free length “b” diameter “a” Upper spring 43.56 mm (1.715 in.) 31.80 – 31.85 mm Direct clutch accumulator (2) (1.252 – 1.254 in.) Lower spring 30.00 mm (1.181 in.) 31.80 –...
Page 470: Special Tool
• “A”: This kit includes the following items and substitutes for the Tech 2 kit. 1. Storage case, 2. Operator’s manual, 3. Suzuki scan tool, 4. DLC cable, 5. Test lead/probe, 6. Power source cable, 7. DLC cable adapter, 8. Self-test adapter •...
Page 471 7B1-62 AUTOMATIC TRANSMISSION (4 A/T)
Page 472 CLUTCH 7C1-1 SECTION 7C1 CLUTCH NOTE: The clutch of this model is the same as that of H25 engine in the construction and operation. Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for ser- vice procedure.
Page 473 7C1-2 CLUTCH...
Page 474 DIFFERENTIAL (FRONT) 7E-1 SECTION 7E DIFFERENTIAL (FRONT) NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in the FOREWORD of this manual. CONTENTS General Description ........7E-2 4WD Control System Inspection ....7E-6 4WD Control System........7E-2 On-Vehicle Service .........
Page 475: General Description
7E-2 DIFFERENTIAL (FRONT) General Description 4WD Control System System circuit 1. 4WD switch 4. Release valve 7. Front differential 10. To ignition switch 2. Air pump assembly 5. Pressure switch 8. Air hose and pipe 11. ECM or PCM 3. Pump motor 6.
Page 476: Diagnosis
DIFFERENTIAL (FRONT) 7E-3 Diagnosis Differential Assembly Diagnosis Table Condition Possible Cause Correction Gear noise Deteriorated or water mixed lubricant Repair and replenish. Inadequate or insufficient lubricant Repair and replenish. Maladjusted backlash between bevel pinion and gear Adjust. Improper tooth contact in the mesh between bevel pinion Adjust or replace.
Page 477: Flow Table
7E-4 DIFFERENTIAL (FRONT) Flow table Step Action Turn ON ignition switch (but engine at stop) and Go to step 2. A trouble has occurred check malfunction indicator lamp. at some place. Repair Does lamp light up? it referring to MALFUNCTION INDI- CATOR LAMP (“CHECK ENGINE”...
Page 478: 4Wd Control System Circuit Inspection
DIFFERENTIAL (FRONT) 7E-5 4WD Control System Circuit Inspection Voltage check Check for input or output voltage (voltage between each circuit and body ground) of ECM (PCM) with ECM (PCM) connector connected and ignition switch turned ON. TER- WIRE NORMAL CIRCUIT CONDITION MINAL COLOR...
Page 479: 4Wd Control System Inspection
Close air check side opening by using fuel hose (1) as blind plug. Special tool (A) : 09918-18110 SUZUKI GENUINE PARTS (B) : 09367-04002 NOTE: Use care not to bend any part of hose. 2) Turn ON ignition switch and shift transfer lever from 2H to 4H range.
Page 480: On-Vehicle Service
DIFFERENTIAL (FRONT) 7E-7 On-Vehicle Service Differential Mountings REMOVAL AND INSTALLATION 1) Lift up vehicle and turn steering wheel all way to the right. 2) Separate front mounting bracket R (2) from differential hous- ing (3) by removing bolts (1) from its lower part. 3) Remove front mounting bracket R (2) by removing mounting front bolt (4) from its upper part.
Page 481: Rear Mounting For Front Differential Carrier
7E-8 DIFFERENTIAL (FRONT) 6) Position slit in each bush (2) as shown when press-fitting it. Bush instillation position (angle “A”) : ° (slit alignment) 1. Front mounting bracket L 3. Front mounting bracket R 7) Position each bush to bracket as shown in the figure Bush installation position (length “a”) : 3.0 mm (0.12 in.) 1.
Page 482: Front Differential Assembly
DIFFERENTIAL (FRONT) 7E-9 Front Differential Assembly DISMOUNTING 1) Lift up vehicle and drain oil. 2) Disconnect air hose and breather hose from differential housing. 3) Before removing propeller shaft, give match marks (1) on joint flange and propeller shaft as shown in the figure. 4) Remove propeller shaft flange by removing its 4 bolts and suspend it with cord or the like.
Page 483 7E-10 DIFFERENTIAL (FRONT) 9) Using 2 large screwdrivers (4) as levers, pull out right side drive shaft joint (1) from differential (2) and dismount housing assembly from vehicle. CAUTION: During above work, use care not to cause damage to drive shaft boot. REMOUNTING For remounting, reverse dismounting procedure and use the fol- lowing tightening torque.
Page 484: Unit Repair
DIFFERENTIAL (FRONT) 7E-11 Unit Repair Refer to the same section of “UNIT REPAIR MANUAL” mentioned in “FOREWORD” of this manual. Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Front mounting bolts 61.5 Front mounting bracket bolts 36.5 Front drive shaft flange bolts 36.5 Propeller shaft flange bolts 36.5...
Page 485 7E-12 DIFFERENTIAL (FRONT)
Page 486 DIFFERENTIAL (REAR) 7F-1 SECTION 7F DIFFERENTIAL (REAR) CONTENTS General Description ........7F-2 Disassembling Unit ........7F-6 Component Inspection ........7F-9 Diagnosis ............7F-2 Sub-Assembly Adjustment and Reassembly 7F-9 Diagnosis Table ..........7F-2 Differential carrier........7F-10 On-Vehicle Service.......... 7F-3 Differential case ........7F-10 Precaution for Maintenance Service .....
Page 487: General Description
7F-2 DIFFERENTIAL (REAR) General Description The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle. It is set in the conven- tional type axle housing. The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory.
Page 488: On-Vehicle Service
DIFFERENTIAL (REAR) 7F-3 On-Vehicle Service 1. Universal joint flange 9. Differential carrier assembly 17. Bearing adjuster 25. Bolt 2. Hypoid gear set 10. Differential pinion 18. Lock plate 26. Bolt 3. Bevel pinion spacer 11. Differential gear 19. Pinion shaft No.2 27.
Page 489: Precaution For Maintenance Service
7F-4 DIFFERENTIAL (REAR) Precaution for Maintenance Service • When having driven through water, check immediately if water has entered (if so, oil is cloudy). Water mixed oil must be changed at once. • Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breather hoses.
Page 490: Rear Differential Assembly
DIFFERENTIAL (REAR) 7F-5 Rear Differential Assembly Dismounting 1) Lift up vehicle and drain oil from rear differential housing. 2) Remove rear brake drums and pull out right and left rear axle shafts. (Refer to “REAR AXLE SHAFT REMOVAL” of Section 3E.) 3) Before removing propeller shaft, give match marks (1) on joint flange and propeller shaft as shown.
Page 491: Unit Repair
7F-6 DIFFERENTIAL (REAR) 3) Install propeller shaft to joint flange aligning match marks and torque flange nuts to specification. Apply thread lock cement to thread part of bolt if reused. “A” : Cement 99000-32110 Tightening torque Propeller shaft flange nuts (a) : 60 N·m (6.0 kg-m, 43.5 lb-ft) 4) Install right and left rear axle shafts and drums.
Page 492 DIFFERENTIAL (REAR) 7F-7 b) Remove differential left case (2) from differential right case (1). c) Remove pinion shafts, differential gears, washers, differen- tial pinions, spring washers, thrust washers. 4) Using special tools, pull out differential side bearings (1). Special tool (C) : 09913-85230 (D) : 09913-61510 5) Remove drive bevel pinion (hypoid gear) assembly.
Page 493 7F-8 DIFFERENTIAL (REAR) b) Make mating marks (1) on drive bevel pinion and compan- ion flange. CAUTION: Don't make mating mark on the coupling surface of the flange. c) Remove companion flange from drive bevel pinion. Use special tool if it is hard to remove. Special tool (F) : 09913-65135 d) Remove drive bevel pinion with rear bearing, shim and...
Page 494: Component Inspection
DIFFERENTIAL (REAR) 7F-9 6) Using a hammer and brass bar (1), drive out front bearing outer race with bearing (2) and oil seal (3). 7) Drive out rear bearing outer race in the same way as in the step 6). Component Inspection •...
Page 495: Differential Carrier
7F-10 DIFFERENTIAL (REAR) Differential carrier For press-fitting drive bevel pinion bearing outer races, use spe- cial tools as shown in the figure. Special tool (A) : 09924-74510 (B) : 09926-68310 (C) : 09913-75510 1. Differential carrier Differential case 1) After applying differential oil to differential gear (4), pinions (5), pinion shafts (6), thrust washer (2) and spring washer (1), install them in differential right case (3).
Page 496 DIFFERENTIAL (REAR) 7F-11 4) In the same manner as described in Step 1), install thrust washer (2), spring washer (1) and differential gear (4). 3. Differential left case 5. Differential pinion 5) Install differential left case (1) and then tighten screws to specified torque.
Page 497: Differential Side Bearing
7F-12 DIFFERENTIAL (REAR) 9) Install special tool to differential case assembly and check that preload is within specification below. If preload exceeds specified value, check if foreign matter is caught or gear is damaged. Special tool (B) : 09928-06510 Side gear preload : Max.
Page 498: Drive Bevel Pinion
DIFFERENTIAL (REAR) 7F-13 Drive bevel pinion To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Page 499 7F-14 DIFFERENTIAL (REAR) 1) Install special tools with bearings and universal joint flange (2) to differential carrier (1). NOTE: This installation requires no spacer or oil seal. Special tool (E) : 09951-46010 (F) : 09926-78311-002 2) Tighten flange nut (1) so that specified bearing preload is obtained.
Page 500 DIFFERENTIAL (REAR) 7F-15 3) Set dial gauge to mounting dummy and make 0 (zero) adjustment on surface plate. NOTE: • When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge. •...
Page 501 7F-16 DIFFERENTIAL (REAR) 6) Select adjusting shim(s) (2) closest to calculated value from among following available sizes and put it in place and then press-fit rear bearing (1). Calculated valve “f” : Closest value to “e” (refer to Step 5).) Special tool (G) : 09925-18011 (H) : 09927-66010...
Page 502 DIFFERENTIAL (REAR) 7F-17 9) While tightening flange nut gradually with special tool and power wrench (4 - 10 magnification) (1), set preload of pinion to specification. NOTE: • Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand. •...
Page 503: Assembling Unit
7F-18 DIFFERENTIAL (REAR) Assembling Unit 1) Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable. 2) Install case assembly in carrier. 3) Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly. 4) Align match marks (1) on cap and carrier.
Page 504 DIFFERENTIAL (REAR) 7F-19 7) Measure preload of pinion bearing with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing. NOTE: • Before taking measurement with spring balance (1) or torque wrench (2), check for smooth rotation by hand. •...
Page 505 7F-20 DIFFERENTIAL (REAR) TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY NORMAL HIGH CONTACT Pinion is positioned too far from the center of drive bevel gear. 4) Increase thickness of pinion height adjusting shim and position pinion closer to gear center. 5) Adjust drive bevel gear backlash to specifica- tion.
Page 506: Tightening Torque Specification
• Bevel gear bolts SUPER 1322 • Differential case bolts (99000-32110) • Bevel gear mating surface • Propeller shaft flange bolt Lithium grease SUZUKI SUPER GREASE A Oil seal lips (99000-25010) Sealant SUZUKI BOND NO. 1215 • Rear differential drain plug (99000-31110) •...
Page 507: Special Tool
7F-22 DIFFERENTIAL (REAR) Special Tool 09900-20606 09900-20701 09913-61510 09913-65135 Dial gauge Magnetic stand Bearing puller Bearing puller 09922-76570 09913-75510 09913-85230 09922-66021 Attachment Bearing installer Bearing removing jig Flange holder 09922-75222 09922-76560 09924-74510 09925-18011 Preload checking tool Preload checking tool Installer attachment Bearing installer 09926-68310 09926-78311-002...
Page 508 DIFFERENTIAL (REAR) 7F-23 09928-06510 09930-40113 09930-40120 09944-66020 Differential torque Rotor holder Attachment Bearing installer checking tool 09951-16060 09951-18210 09951-46010 Lower arm bush remover Oil seal remover & Drive shaft oil seal installer No. 2 installer NOTE: This tool is constituent of tools with 09926-78311.
Page 509 7F-24 DIFFERENTIAL (REAR)
Page 510 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 511 8-2 BODY ELECTRICAL SYSTEM General Description WIRE COLOR SYMBOLS Symbol Wire Color Symbol Wire Color Black O, Or Orange Blue Brown White Green Yellow Gray Pink LT BLU Light blue Violet LT GRN Light green There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire.
Page 512 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 513: Combination Meter
8C-2 INSTRUMENTATION/DRIVER INFORMATION General Description Combination Meter 1. Tachometer 8. Multifunction indicator light 15. Charge warning light 2. Speedometer 9. Turn signal pilot light (RH) 16. Brake fluid level, parking brake and EBD warning light 3. Fuel level meter 10. AIR BAG warning light 17.
Page 514 INSTRUMENTATION/DRIVER INFORMATION 8C-3 COMBINATION METER INTERNAL CIRCUITS Air bag circuit EBD circuit CHECK A-11 A-12 A-3 B-13 B-2 B-3 B-4 B-5 or BRAKE or ABS ABS circuit C-10 ENGINE SPEED TACHO FUEL TEMP. POWER CRUISE METER METER METER METER if equipped A-13 A-8 B-12 B-11 B-10...
Page 515 8C-4 INSTRUMENTATION/DRIVER INFORMATION On-vehicle Service Fuel Meter/Fuel Gauge Unit Fuel level sensor (sender gauge) INSPECTION Remove fuel pump assembly referring to Section 6C. Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position. If measured value is out of specification, replace fuel sender gauge.
Page 516: Oil Pressure Light
INSTRUMENTATION/DRIVER INFORMATION 8C-5 Engine Coolant Temperature (ECT) Meter and Sensor Engine coolant temperature sensor REMOVAL AND INSTALLATION Refer to “ECT SENSOR” in Section 6E2. Oil Pressure Light Oil pressure switch REMOVAL AND INSTALLATION Refer to “OIL PRESSURE CHECK” in Section 6A2. Brake Warning Light Brake fluid level switch INSPECTION...
Page 517 8C-6 INSTRUMENTATION/DRIVER INFORMATION...
Page 518 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 519: General Description
8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS General Description Rear Wiper and Washer (If Equipped)
Page 520: On-Vehicle Service
WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-3 On-Vehicle Service Windshield Wipers Front wiper and washer Wiper motor • As shown in the figure, use a 12 V battery to connect its (+) terminal to terminal “A”, and its (–) terminal to “Black” lead wire (2).
Page 521: Rear Window Wiper And Washer (For Vehicle With Cruise Control System)
8D-4 WINDOWS, MIRRORS, SECURITY AND LOCKS Rear Window Wiper and Washer (For Vehicle with Cruise Control System) INSPECTION Rear Wiper and Washer Switch 1) Disconnect negative (–) cable at battery. 2) Disconnect combination switch lead wire coupler. 3) Use a circuit tester to check the continuity at each switch position. If any continuity is not obtained, replace switch.
Page 522 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 523: General Description
8E-2 CRUISE CONTROL SYSTEM General Description Cautions in Servicing Refer to Section 8. Symbols and Marks Refer to Section 8A. Abbreviations Refer to Section 8A. Wiring Color Symbols Refer to Section 8. Joint Connector Refer to Section 8. Fuse Box and Relay Refer to Section 8A.
Page 524: Cruise Control System
CRUISE CONTROL SYSTEM 8E-3 Cruise Control System The cruise control system is a device which maintains a preset vehicle speed while driving at a high speed, e.g., on a highway. It allows the driver to drive his vehicle at a constant speed of 40 km/h (25 mile/h) or higher without depressing the accelerator pedal (constant cruising).
Page 525: Components And Functions
8E-4 CRUISE CONTROL SYSTEM Components and functions Component Function Cruise control actuator Cruise control module: assembly with control mod- Executes centralized control by means of a microcomputer over all functions including setting a constant speed, resuming it, setting coast, limiting minimum speed and cancelling cruise control.
Page 526: Cancel Conditions
CRUISE CONTROL SYSTEM 8E-5 Component Function PCM – Overdrive and TCC When the throttle opening for the vehicle speed exceeds the specified value off command signal output during cruise control, the cruise control module sends this signal to PCM. PCM uses this signal as one of signals to control 4-A/T.
Page 527 8E-6 CRUISE CONTROL SYSTEM Condition Possible Cause Correction Vehicle speed can not Actuator cable play maladjusted or actua- Refer to “CRUISE CABLE PLAY be set. tor cable faulty INSPECTION AND ADJUSTMENT” in this section. Main switch, “COAST/SET”, “RESUME/ Refer to “CRUISE MAIN SWITCH, ACCEL”...
Page 528: Note On System Circuit Inspection
CRUISE CONTROL SYSTEM 8E-7 Condition Possible Cause Correction “RESUME/ACCEL” Main switch, “COAST/SET”, “RESUME/ Refer to “CRUISE MAIN SWITCH, switch fails to resume ACCEL” and “CANCEL” switch circuits COAT/SET, RESUME/ACCEL AND preset vehicle speed faulty CANCEL SWITCHES CIRCUITS after cruise control is CHECK”...
Page 529: Cruise Main Switch Indicator Lamp Circuit Check
8E-8 CRUISE CONTROL SYSTEM Cruise Main Switch Indicator Lamp Circuit Check Step Action Check Circuit for Short. “LT GRN/WHT” cir- Go to Step 2. 3) Disconnect connector from cruise control module with cuit is shorted to ignition switch OFF. ground. 4) Turn ignition switch ON.
Page 530: Cruise" Indicator Lamp Circuit Check
CRUISE CONTROL SYSTEM 8E-9 “Cruise” Indicator Lamp Circuit Check Step Action Check Circuit for Short. “GRN/YEL” circuit Go to Step 2. 1) Disconnect connector from cruise control module with is shorted to ignition switch OFF. ground. 2) Turn ignition switch ON. Does “CRUISE”...
Page 531: Cruise Main Switch, Coast/Set, Resume/Accel And Cancel Switches Circuits Check
8E-10 CRUISE CONTROL SYSTEM Cruise Main Switch, Coast/Set, Resume/Accel and Cancel Switches Circuits Check Step Action Switch Circuit Check Switch circuit is Go to Step 2. 1) Disconnect connector from cruise control module with ignition switch OFF. 2) Check for proper connection to cruise control module at terminal E132-8.
Page 532: Vss Circuit Check
CRUISE CONTROL SYSTEM 8E-11 VSS Circuit Check Step Action Vehicle Speed Sensor Circuit Check VSS circuit is OK. “BLU/YEL” cir- 1) Disconnect connector from cruise control module with cuit is open. ignition switch OFF. 2) Check for proper connection to cruise control module at terminal E132-1.
Page 533: Stop Lamp Switch (With Pedal Position Switch) Circuits Check
8E-12 CRUISE CONTROL SYSTEM Stop Lamp Switch (with Pedal Position Switch) Circuits Check Step Action Stop Lamp Switch (With Pedal Position Switch) Circuits Check Stop lamp switch Go to Step 2. 1) Disconnect connector from cruise control module with (with pedal position ignition switch OFF.
Page 534 CRUISE CONTROL SYSTEM 8E-13 Transmission Range Switch Circuit Check Step Action Transmission Range Switch Circuit Check Transmission range Go to Step 2. 1) Disconnect connector from cruise control module with switch circuit is OK. ignition switch OFF. 2) Check for proper connection to cruise control module at terminal E132-9.
Page 535 8E-14 CRUISE CONTROL SYSTEM Clutch Pedal Position Switch Circuit Check Step Action Clutch Pedal Position Switch Circuit Check Clutch pedal posi- Go to Step 2. 1) Disconnect connector from cruise control module with tion switch circuit is ignition switch OFF. 2) Check for proper connection to cruise control module at terminal E132-9.
Page 536: Throttle Valve Opening Signal Circuit Check
CRUISE CONTROL SYSTEM 8E-15 Throttle Valve Opening Signal Circuit Check Step Action Powertrain Control Module (PCM) Diagnostic Trouble Code Check and repair Go to Step 2. Check TP sensor refer- 1) Check PCM for DTC. ring to Section 6-1. Is there a DTC related to throttle position sensor? Throttle Valve Opening Signal Circuit Check Throttle valve Go to Step 3.
Page 537: Overdrive And Tcc Off Command Signal Circuit Check
8E-16 CRUISE CONTROL SYSTEM Overdrive and TCC off Command Signal Circuit Check Step Action Overdrive off Command Signal Circuit Check This signal circuit is Check “PNK/ 1) Disconnect connector from cruise control module with BLU” wire for ignition switch OFF. open and short.
Page 538: Cruise Control Module And Its Circuit Inspection
CRUISE CONTROL SYSTEM 8E-17 Cruise Control Module and Its Circuit Inspection CAUTION: Cruise control module can not be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to cruise control module with coupler disconnected from it. VOLTAGE CHECK Check for input or output voltage of control module (voltage between each circuit and body ground) with cruise control module connector connected.
Page 539 8E-18 CRUISE CONTROL SYSTEM RESISTANCE CHECK 4) Disconnect cruise control module connector from cruise con- trol module with ignition switch OFF. CAUTION: Never touch terminals of cruise control module itself or connect voltmeter or ohmmeter. 5) Check resistance between each pair of terminals of discon- nected connectors as shown in the following table.
Page 540: Cruise Cable Play Inspection And Adjustment
CRUISE CONTROL SYSTEM 8E-19 Cruise Cable Play Inspection and Adjustment INSPECTION AND ADJUSTMENT 1) Remove actuator cap. 2) With actuator lever (1) returned at original position (2) (Where lever does not move clockwise any further), check cruise cable for play. If it is out of specification, adjust it as follows Cruise Cable play “a”...
Page 541: Coast/Set, Resume/Accel And Cancel Switches
8E-20 CRUISE CONTROL SYSTEM Coast/Set, Resume/Accel and Cancel Switches CAUTION: Never disassemble combination switch assembly. Disas- sembly will spoil its original functions. These switches are built in the combination switch assembly. REMOVAL AND INSTALLATION Refer to “COMBINATION SWITCH” in Section 3C1. INSPECTION 1) Disable air bag system referring to “DISABLING AIR BAG SYSTEM”...
Page 542: Clutch Pedal Position (Cpp) Switch
CRUISE CONTROL SYSTEM 8E-21 Clutch Pedal Position (CPP) Switch REMOVAL 1) Disconnect CPP switch connector with ignition switch OFF. 2) Remove CPP switch from pedal bracket. 1. CPP switch for cruise control 2. Stop lamp switch 3. CPP switch for starter (if equipped) INSPECTION Check for resistance between terminals under each condition below.
Page 543: Stop Lamp Switch (With Pedal Position Switch)
8E-22 CRUISE CONTROL SYSTEM Stop Lamp Switch (with Pedal Position Switch) INSPECTION 1) Disconnect negative (–) cable at battery. 2) Disconnect stop lamp switch connector and remove stop lamp switch from pedal bracket. 3) Check switch (2 contacts) for resistance under each of the following each conditions.
Page 544: Cruise Control Actuator Assembly (With Control Module)
CRUISE CONTROL SYSTEM 8E-23 Cruise Control Actuator Assembly (with Con- trol Module) CAUTION: Never disassemble cruise control actuator assembly. Disassembly will spoil its original function. REMOVAL 1) Disconnect negative (–) cable at battery. 2) Disconnect connector from actuator assembly (2) (with con- trol module).
Page 545: Cruise Cable
8E-24 CRUISE CONTROL SYSTEM Cruise Cable 1. Actuator cap 4. Cruise cable 7. Clamp at member 2. Actuator assembly 5. Clamp 8. Accelerator pedal 3. Screw 6. Grommet 9. Member REMOVAL 1) Disconnect cruise cable from cruise control arm and accelerator bracket. 2) Remove actuator cap and disconnect cruise cable from actuator.
Page 546 • Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 547: Glass, Windows And Mirror
9-2 BODY SERVICE Glass, Windows and Mirror Quarter Window REMOVAL AND INSTALLATION Refer to “WINDSHIELD” in this section as removal and installa- tion procedures are basically the same. However, note the follow- ings. • Before applying primer to glass edge, install molding accord- ing to installing position shown in the figure.
Page 548: Body Structure
BODY SERVICE 9-3 Body Structure Under Body Dimensions h’ g’ a. Front bumper side installation hole i. 3rd mounting installation hole b. 1st mounting installation hole j. Lower rod installation hole c. Suspension frame front installation hole k. Upper rod installation inside hole d.
Page 549: Body Dimensions
9-4 BODY SERVICE Body Dimensions j’ h’ j’ i’ c’ d’ b’ c’ e’ f’ a. Front bumper installation clip hole g. Center member installation hole b (b’). Front bumper installation hole h (h’). Fender installation reference hole c (c’). Headlight installation hole i (i’).
Page 550 BODY SERVICE 9-5 b’ c’ m (m’) k (k’) g (g’) e (e’) b’ l (l’) h (h’) i (i’) j (j’) f (f’) d (d’) a. Garnish installation clip hole i (i’). Hole in rear door lower hinge in lower part b (b’).
Page 551 9-6 BODY SERVICE a. Hole in front door upper hinge at rear g. Hole in rear door lower hinge in lower part b. Hole in front door lower hinge at rear h. Assistant grip front installation hole c. Trim installation clip hole i.
Page 552 BODY SERVICE 9-7 b’ b’ g’ f’ f’ a. Clip hole in the center of head lining rear installation section e. Installation hole in uppermost part of lower hinge b (b’). Innermost end of roof panel installation section f (f’). Innermost end of rear floor tail member installation section c.
Page 553: Seat
9-8 BODY SERVICE Seat Second Seat 1. Head restraint 6. Rod 11. Seat adjuster cover 16. Rod belt (if equipped) 2. Head restraint guide 7. Seat reclining assembly cover 12. Cover Tightening torque 3. Seat back 8. Seat cushion 13. Adjuster extension bracket 4.
Page 554: Third Seat (If Equipped)
BODY SERVICE 9-9 Third Seat (If Equipped) 35 N·m (3.5 kg-m) 35 N·m (3.5 kg-m) 1. Head restraint 6. Reclining supporter Tightening torque 2. Head restraint guide 7. Seat reclining assembly 3. Seat back 8. Seat reclining assembly cover 4. Seat reclining knob 9.
Page 555: Paint And Coatings
9-10 BODY SERVICE Paint and Coatings Sealant Application Area “A” “A” (“B”) “A” (“B”) “A” “A” “A” “A” “A” “A” (“B”) “A” (“B”) “A” (“B”) “A” (“B”) “A” “A” K – K J – J “A” “B” “A” “A” H – H “A”...
Page 556 BODY SERVICE 9-11 “A” (“B”) “A” VIEW:Z “A” “A” “A” (“B”) E – E D – D 1. Cowl top panel “A” : Apply sealant 2. Dash panel “B” : Brush treatment 3. Cowl front panel 4. Front floor panel 5.
Page 557 9-12 BODY SERVICE “A” (“B”) “A” (“B”) “A” “A” C – C “A” (“B”) “A” “A” “A” L – L A – A B – B “A” “A” (“B”) “A” (“B”) “A” (“B”) VIEW:W 1. Rear quarter inner panel 5. Roof panel 9.
Page 558 BODY SERVICE 9-13 “A” (“B”) “A” “A” (“B”) “A” “A” (“B”) “A” VIEW:U VIEW:X “A” QQ – QQ “A” (“B”) “A” (“B”) M – M “A” (“B”) “A” VIEW:V (LH) “A” VIEW:V (RH) 1. Side body outer panel 3. Center floor gusset “A”...
Page 559 9-14 BODY SERVICE “C” “A” VIEW:FF VIEW:DD “D” “D” GG – GG “b” “A” “B” “B” “A” “b” “E” “A” VIEW:EE “a” “A” “B” “C” 15-20 mm “C” (0.59-0.79 in.) “E” “B” VIEW:BB VIEW:CC “A” AA – AA “A” “A” : Apply sealant “B”...
Page 560 BODY SERVICE 9-15 “C” “C” “A” “B” “A” “b” VIEW:LL VIEW:JJ “A” “A” “D” HH – HH “B” “A” “a” “A” VIEW:KK “B” “B” “A” “A” NN – NN MM – MM “b” “A” “a” OO – OO “D” “A” PP –...
Page 561 9-16 BODY SERVICE “A” “B” “B” “A” LL – LL “C” KK – KK “A” : Apply sealant “B” : Smooth out sealant with a brush “C” : Sealant width C more than 5 mm (0.20 in.)
Page 562: Undercoating/Anti-Corrosion Compound Application Area
BODY SERVICE 9-17 Undercoating/Anti-corrosion Compound Application Area “A” “A” “A” “A” “A” “a” “b” “a” “A” A – A D – D “B” “B” B – B C – C VIEW: Z “B” “a” : 200 mm (7.87 in.) 1. Side body outer “b”...
Page 563 9-18 BODY SERVICE “A” A – A “A” “A” “A” “B” “A” “B” “B” “A” VIEW: Z “B” “B” “a” “A” “A” “A” B – B “b” “B” “B” C – C “a” : 30 mm (1.18 in.) 1. Main floor 6.
Page 564: Exterior And Interior Trim
BODY SERVICE 9-19 Exterior and Interior Trim Floor Carpet 1. Front floor carpet 2. Dash panel insulation 3. Rear floor carpet Front floor carpet REMOVAL 1) Remove front and second seats. 2) Remove third seat cushion (if equipped). 3) Remove front and second seat belt lower anchor bolts. 4) Remove dash side trims (1), front side sill scuffs (2), center pillar inner lower trims (3), rear side sill scuffs (4) and rear quarter lower trims (5).
Page 565: Rear Floor Carpet (Without Third Seat Vehicle)
9-20 BODY SERVICE Rear floor carpet (without third seat vehicle) REMOVAL 1) Remove rear luggage mat end garnish (1), rear side sill scuff and rear quarter lower trims (2). 2) Remove luggage hook plate nut (3). 3) Remove rear floor carpet. INSTALLATION Reverse removal procedure for installation, noting the following.
Page 566 BODY SERVICE 9-21 CAUTION: Do not remove rear A/C No.2 duct (1) from head lining (2). If perform this prohibited service, head lining (2) will be broken. INSTALLATION Reverse removal procedure to install head lining noting the follow- ing instructions. •...
Page 567 9-22 BODY SERVICE...
Page 568: Restraint System
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 569 10-2 RESTRAINT SYSTEM General Description 1. Driver side seat belt with ELR and pretensioner 4. Second rear seat belt (RH) with A-ELR 7. Third rear seat belt (RH) with A-ELR (if equipped) (if equipped) 2. Front passenger side seat belt with ELR and pre- 5.
Page 570: Seat Belt
• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing ser- vice on or near the air bag system components or wiring.
Page 571 If these parts are replaced individually, such a locking condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and ELR (or webbing) in a set part.
Page 572: Front Seat Belt
SEAT BELT 10A-3 Front Seat Belt INSPECTION ON VEHICLE Seat belts with ALR As to seat belts with ALR (other than driver side seat belt), check them as follows in addition to above check. • With vehicle at stop, pull seat belt all the way out, let it retract a little and try to pull it. It should not be pulled out, that is, it should be locked where retracted.
Page 573 10A-4 SEAT BELT REMOVAL 1) Disconnect negative cable at battery. 2) Disable air bag system referring to “DISABLING AIR BAG SYSTEM” of “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B, if necessary. 3) Remove front pillar lower trim. 4) Disconnect Yellow connector for seat belt pretensioner, if necessary. a) Release locking of lock lever.
Page 574 SEAT BELT 10A-5 Seat belt switch Check driver side seat belt strap switch for continuity by using ohmmeter. Seat belt strap switch specification Without inserted buckle tongue to buckle catch: Terminal “A” and “B” : Continuity With inserted buckle tongue to buckle catch: ∞Ω) ∞Ω...
Page 575 10A-6 SEAT BELT Second Rear Seat Belt WARNING: Be sure to read “SERVICE PRECAUTIONS” in this section before starting to work and observe every precaution during work. 35 N·m (3.5 kg-m, 25.5 lb-ft) 35 N·m (3.5 kg-m, 25.5 lb-ft) 35 N·m (3.5 kg-m, 25.5 lb-ft) 35 N·m (3.5 kg-m, 25.5 lb-ft) 1.
Page 576 SEAT BELT 10A-7 Third Rear Seat Belt (If Equipped) WARNING: Be sure to read “SERVICE PRECAUTIONS” in this section before starting to work and observe every precaution during work. 35 N·m (3.5 kg-m, 25.5 lb-ft) 35 N·m (3.5 kg-m, 25.5 lb-ft) 35 N·m (3.5 kg-m, 25.5 lb-ft) 1.
Page 577 10A-8 SEAT BELT Tightening Torque Specification Tightening torque Fastening part N•m kg-m lb-ft Upper and lower anchor bolt 25.5 Retractor assembly bolt 25.5 Retractor assembly screw 0.55 Buckle bolt 25.5...
Page 578: Air Bag System
• Service on or around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On- Vehicle Service” in this section before performing service on or around the air bag system compo- nents or wiring.
Page 579 10B-2 AIR BAG SYSTEM DTC B1031 – Power Source Voltage DTC B1061 – “AIR BAG” Warning Lamp High............10B-33 Circuit Failure..........10B-47 DTC B1032 – Power Source Voltage DTC B1071 – Internal SDM Fault ..... 10B-48 Low ............10B-33 DTC B1013 – System Specifications DTC B1035 –...
Page 580: General Description
AIR BAG SYSTEM 10B-3 General Description With the air bag system which includes air bags for both the driver’s and passenger’s sides as well as the seat belt pretension- ers (if equipped), the sag of the seat belt is taken up (for seat belt with pretensioner), the driver air bag (inflator) module is deployed from the center of the steering column and the passenger air bag (inflator) module from the top of the instrument panel in front of...
Page 581: System Components And Wiring Location View And Connectors
10B-4 AIR BAG SYSTEM System Components and Wiring Location View and Connectors CONNECTOR “G27” CONNECTOR “Q02” CONNECTOR “Q05” CONNECTOR “Q06” CONNECTOR “Q07” CONNECTOR “Q11” CONNECTOR “Q01” CONNECTOR “Q12” CONNECTOR “Q03” 1. Air bag harness 7. Passenger air bag (inflator) module 13.
Page 582: System Wiring Diagram
AIR BAG SYSTEM 10B-5 System Wiring Diagram “Q03” BLU/BLK BLU/RED Q01-4 BLK/BLU BLK/WHT “Q01” BLK/WHT “Q06” “Q05” GRN/RED Q01-10 Q01-2 Q01-9 “Q07” YEL/RED Q01-7 Q01-8 “Q12” PPL/RED PPL/RED Q01-20 Q01-12 ORN/GRN ORN/GRN ORN/GRN Q01-19 SL+ ORN/BLU Q01-11 ORN/BLU ORN/BLU Q01-18 SL- YEL/GRN YEL/GRN YEL/GRN...
Page 583: Diagnosis
The AIR BAG DIAGNOSTIC SYSTEM CHECK must always be the starting point of any air bag system diagno- sis. The AIR BAG DIAGNOSTIC SYSTEM CHECK checks for proper “AIR BAG” warning lamp operation and checks for air bag diagnostic trouble codes (DTCs) using on-board diagnosis function or SUZUKI scan tool. Use of Special Tool...
Page 584 AIR BAG SYSTEM 10B-7 Special tool (B) : 09932-75010 (Air Bag Driver/Passenger Load Tool) This tool is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag (inflator) module deployment.
Page 585: Intermittents And Poor Connections
10B-8 AIR BAG SYSTEM Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring. When a check for proper connection is requested in a diagnostic flow table, perform careful check of suspect circuits for: • Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
Page 586: Air Bag Diagnostic System Check
STEP 4 : Check that “AIR BAG” warning lamp flashes 6 times after ignition switch is turned ON. STEP 6 : Check that history codes are in SDM memory. (using SUZUKI scan tool) STEP 7 : Check that history codes are in SDM memory. (using monitor coupler) STEP 9 : Check that current code is in SDM memory.
Page 587: Air Bag Diagnostic System Check Flow Table
Does “AIR BAG” warning lamp turn Go to step 5. Go to step 8. OFF, after flashing 6 times? Do you have SUZUKI scan tool? Go to step 6. Go to step 7. 1) Check DTC using SUZUKI scan Air bag system is in good An intermittent trouble has occurred tool.
Page 588: Dtc Check
3) Turn ignition switch to ON position. 4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer to SUZUKI scan tool operator’s manual for further details. If communication between scan tool and SDM is not possi- ble, proceed to Diagnostic Flow Table E (Serial data check circuit).
Page 589: Dtc Clearance
[C]: Code No.21 DTC Clearance Using SUZUKI scan tool 1) Turn ignition switch to OFF position. 2) Connect SUZUKI scan tool to data link connector (DLC) (1) in the same manner as when making this connection for DTC check. Special tool (A) : SUZUKI scan tool 3) Turn ignition switch to ON position.
Page 590 AIR BAG SYSTEM 10B-13 Not using SUZUKI scan tool 1) Turn ignition switch to ON position and wait about 6 seconds or more. 2) Using service wire, repeat shorting and opening between diagnosis switch terminal on “AIR BAG” monitor coupler and body ground 5 times at about 1 second intervals.
Page 591: Dtc Table
10B-14 AIR BAG SYSTEM DTC Table “AIR BAG” warning lamp flashing pattern Diagnosis MODE Normal – – B1015 Resistance high B1016 Resistance low Passenger air bag circuit B1018 Short to ground B1019 Short to power circuit B1021 Resistance high B1022 Resistance low Driver air bag Diagnose trou-...
Page 592 “AIR BAG” warning lamp remains on after ignition switch is turned ON. Therefore, it is not possible to identify any of them as to whether it is a current one or a history one. (But use of SUZUKI scan tool will make identification possible.) History DTC is set only.
Page 593 10B-16 AIR BAG SYSTEM Table A - “AIR BAG” Warning Lamp Comes ON Steady Table B - “AIR BAG” Warning Lamp Does Not Come ON Table C - “AIR BAG” Warning Lamp Flashes Table D - “AIR BAG” Warning Lamp Cannot Indicate Flashing Pattern of DTC WIRING DIAGRAM BLU/BLK BLU/RED...
Page 594 AIR BAG SYSTEM 10B-17 TABLE TEST DESCRIPTION Table A : STEP 1 : Check “AIR BAG” fuse. STEP 2 : Check power source circuit. STEP 3 : Check “AIR BAG” warning lamp circuit. Table B : STEP 1 : Check combination meter power feed circuit. STEP 2 : Check electrical connection check mechanism in SDM connector.
Page 595 10B-18 AIR BAG SYSTEM NOTE: Upon completion of inspection and repair work, perform following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected. Table B : Step Action...
Page 596 AIR BAG SYSTEM 10B-19 [A] Fig. for STEP 2/[B] Fig. for STEP 3 and 5/[C] Fig. for STEP 4 1. 16-pin connector (for combination meter) 2. “BLU” wire terminal Special tool (A) : 09932-75020 NOTE: Upon completion of inspection and repair work, perform following items. •...
Page 597 10B-20 AIR BAG SYSTEM Table D : Step Action 1) Inspect connection between diagnostic Go to step 2. Properly connection diag- switch terminal on “AIR BAG” monitor cou- nostic switch terminal on pler and body ground by service wire. “AIR BAG” monitor cou- Is it securely connected between them by ser- pler and body ground by vice wire?
Page 598 AIR BAG SYSTEM 10B-21 Table E - SDM Cannot Communicate through The Serial Data Circuit WIRING DIAGRAM BLU/BLK BLU/RED Q01-4 IG BLK/BLU BLK/WHT BLK/WHT Q01-2 PPL/WHT PPL/RED Q01-20 “G27” “Q02” PPL/RED Q01-15 “Q04” BLK/YEL Q01-17 [A]: Air bag harness 5. “AIR BAG” fuse 10.
Page 599 10B-22 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE Step Action 1) Make sure that SUZUKI scan tool is free from malfunc- Go to step 2. Properly connect SUZUKI tion and correct cartridge for air bag system is used. scan tool to DLC.
Page 600: Dtc B1015 - Passenger Air Bag Initiator Circuit Resistance High
AIR BAG SYSTEM 10B-23 DTC B1015 - Passenger Air Bag Initiator Circuit Resistance High DTC B1016 - Passenger Air Bag Initiator Circuit Resistance Low DTC B1018 - Passenger Air Bag Initiator Circuit Short to Ground DTC B1019 - Passenger Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM “Q01”...
Page 601 10B-24 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1015 : Step Action 1) With ignition switch OFF, disconnect passenger air Go to step 2. Ignition switch OFF. bag (inflator) module connector behind the glove box. Replace passenger air 2) Check proper connection to passenger air bag (infla- bag (inflator) module tor) module at terminals in “Q07”...
Page 602 AIR BAG SYSTEM 10B-25 DTC B1016: Step Action 1) With ignition switch OFF, disconnect passenger air Go to step 2. Ignition switch OFF. bag (inflator) module connector behind the glove box. Replace passenger air 2) Check proper connection to passenger air bag (infla- bag (inflator) module tor) module at terminals in “Q07”...
Page 603 10B-26 AIR BAG SYSTEM DTC B1018: Step Action 1) With ignition switch OFF, disconnect passenger air Go to step 2. Ignition switch OFF. bag (inflator) module connector behind the glove box. Replace passenger air 2) Check proper connection to passenger air bag (infla- bag (inflator) module tor) module at terminals in “Q07”...
Page 604 AIR BAG SYSTEM 10B-27 DTC B1019: Step Action 1) With ignition switch OFF, disconnect passenger Go to step 2. Ignition switch OFF. air bag (inflator) module connector behind the Replace passenger air glove box. bag (inflator) module 2) Check proper connection to passenger air bag (Refer to PASSENGER (inflator) module at terminals in “Q07”...
Page 605: Dtc B1021 - Driver Air Bag Initiator Circuit Resistance High
10B-28 AIR BAG SYSTEM DTC B1021 – Driver Air Bag Initiator Circuit Resistance High DTC B1022 – Driver Air Bag Initiator Circuit Resistance Low DTC B1024 – Driver Air Bag Initiator Circuit Short to Ground DTC B1025 – Driver Air Bag Initiator Circuit Short to Power Circuit WIRING DIAGRAM “Q01”...
Page 606 AIR BAG SYSTEM 10B-29 DIAGNOSTIC FLOW TABLE DTC B1021 : Step Action 1) With ignition switch OFF, disconnect contact coil con- Go to step 2. Go to step 3. nector located near the base of the steering column. 2) Check proper connection to contact coil at terminals in “Q06”...
Page 607 10B-30 AIR BAG SYSTEM DTC B1022 : Step Action 1) With ignition switch OFF, disconnect contact coil con- Go to step 2. Go to step 3. nector located near the base of the steering column. 2) Check proper connection to contact coil at terminals in “Q06”...
Page 608 AIR BAG SYSTEM 10B-31 DTC B1024 : Step Action 1) With ignition switch OFF, disconnect contact coil Go to step 2. Go to step 3. connector located near the base of the steering col- umn. 2) Check proper connection to contact coil at terminals in “Q06”...
Page 609 10B-32 AIR BAG SYSTEM DTC B1025 : Step Action 1) With ignition switch OFF, disconnect contact coil con- Go to step 2. Go to step 3. nector located near the base of the steering column. 2) Check proper connection to contact coil at terminals in “Q06”...
Page 610: Dtc B1031 - Power Source Voltage High
AIR BAG SYSTEM 10B-33 DTC B1031 – Power Source Voltage High DTC B1032 – Power Source Voltage Low WIRING DIAGRAM BLU/BLK BLU/RED Q01-4 Q01-17 “Q01” [A] : Air bag harness 2. Ignition switch 4. SDM 1. From main fuse 3. “AIR BAG” fuse 5.
Page 611 10B-34 AIR BAG SYSTEM DIAGNOSTIC FLOW TABLE DTC B1031 : Step Action 1) With ignition switch OFF, disconnect SDM Go to step 2. Check Charging System connector. and repair as necessary. 2) Check proper connection to SDM at “Q01-4” (Refer to DIAGNOSIS in terminal.
Page 612 AIR BAG SYSTEM 10B-35 Step Action 1) With ignition switch OFF, reconnect SDM Substitute a known-good Check Charging System connector. SDM and recheck. and repair as necessary. With ignition switch ON, is DTC B1032 current? (Refer to DIAGNOSIS in Section 6H) Fig.
Page 613: Dtc B1035 - Rh Forward Sensor Circuit Open Or Short To Ground
10B-36 AIR BAG SYSTEM DTC B1035 – RH Forward Sensor Circuit Open or Short to Ground DTC B1036 – RH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit DTC B1037 – LH Forward Sensor Circuit Open or Short to Ground DTC B1038 –...
Page 614 AIR BAG SYSTEM 10B-37 DTC B1036 and B1038 : STEP 1 : Check whether malfunction is in forward sensor. STEP 2 : Check if forward sensor circuit is shorted between two wires. STEP 3 : Check if forward sensor circuit is shorted to power circuit. DIAGNOSTIC FLOW TABLE DTC B1035 and B1037 : Step...
Page 615 10B-38 AIR BAG SYSTEM [A] Fig. for STEP 1/[B] Fig. for STEP 2/[C] Fig. for STEP 3 Special tool (A) : 09932-75020 NOTE: Upon completion of inspection and repair work, perform following items. • Reconnect all air bag system components, ensure all components are properly mounted. •...
Page 616 AIR BAG SYSTEM 10B-39 Step Action 1) Measure voltage from “Q01-13” terminal to Substitute a known-good Repair short from “ORN/ body ground and “Q01-14” terminal to body SDM and recheck. GRN” or “ORN/BLU” wire ground, or from “Q01-18” terminal to body circuit (between forward ground and “Q01-19”...
Page 617: Dtc B1041 - Driver Pretensioner Initiator Circuit Resistance High
10B-40 AIR BAG SYSTEM DTC B1041 – Driver Pretensioner Initiator Circuit Resistance High DTC B1042 – Driver Pretensioner Initiator Circuit Resistance Low DTC B1043 – Driver Pretensioner Initiator Circuit Short to Ground DTC B1044 – Driver Pretensioner Initiator Circuit Short to Power Circuit DTC B1045 –...
Page 618 AIR BAG SYSTEM 10B-41 DTC WILL SET WHEN DTC B1041 and B1045 : The resistance of driver or passenger seat belt pretensioner initiator circuit is above a specified value for speci- fied time. DTC B1042 and B1046 : The resistance of driver or passenger seat belt pretensioner initiator circuit is below a specified value for speci- fied time.
Page 619 10B-42 AIR BAG SYSTEM Fig. for STEP 1 and 2 1. Pretensioner harness Fig. for STEP 2 [A] : For DTC B1041 [B] : For DTC B1045 Special tool (A) : 09932-75020 (B) : 09932-75010 NOTE: Upon completion of inspection and repair work, perform following items. •...
Page 620 AIR BAG SYSTEM 10B-43 Step Action 1) With ignition switch OFF, disconnect SDM. Substitute a known-good DTC B1042 : 2) Check proper connection to SDM at termi- SDM and recheck. Repair short from “PNK” nals “Q01-11” and “Q01-12” or “Q01-6” and wire circuit to “WHT”...
Page 621 10B-44 AIR BAG SYSTEM DTC B1043 and B1047 : Step Action 1) With ignition switch OFF, remove center pil- Go to step 2. Ignition switch OFF. lar inner garnish of applicable side then dis- Replace seat belt pretensioner connect seat belt pretensioner connector. (Refer to Section 10A).
Page 622 AIR BAG SYSTEM 10B-45 NOTE: Upon completion of inspection and repair work, perform following items. • Reconnect all air bag system components, ensure all components are properly mounted. • Clear diagnostic trouble codes (Refer to DTC CLEARANCE), if any. • Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected. DTC B1044 and B1048 : Step Action...
Page 623: Dtc B1051 - Frontal Crash Detected
10B-46 AIR BAG SYSTEM Fig. for STEP 2 [A] : For DTC B1044 [B] : For DTC B1048 Special tool (A) : 09932-75020 (B) : 09932-75010 NOTE: Upon completion of inspection and repair work, perform following items. • Reconnect all air bag system components, ensure all components are properly mounted. •...
Page 624: Dtc B1061 - "Air Bag" Warning Lamp Circuit Failure
AIR BAG SYSTEM 10B-47 Step Action 1) Inspect front of vehicle and undercar- Replace components and Substitute a known-good riage for signs of impact. perform inspections as SDM and recheck. Are there signs of impact? directed in REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT in this section.
Page 625: Dtc B1071 - Internal Sdm Fault
10B-48 AIR BAG SYSTEM TABLE TEST DESCRIPTION STEP 1 : This test rechecks “AIR BAG” warning lamp operation. STEP 2 : This test rechecks whether an abnormality is in SDM. DTC B1061 : Step Action 1) This DTC is set when there is a trouble in Go to step 2.
Page 626: On-Vehicle Service
Be sure to follow the instructions. WARNING: • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 627: Disabling Air Bag System
10B-50 AIR BAG SYSTEM Disabling air bag system 1) Turn steering wheel so that vehicle's wheels (front tires) and pointing straight ahead. 2) Turn ignition switch to “LOCK” position and remove key. 3) Remove “AIR BAG” fuse from “AIR BAG” fuse box (1). 4) Disconnect Yellow connector (2) of contact coil and combina- tion switch assembly.
Page 628: Handling And Storage
AIR BAG SYSTEM 10B-51 3) Connect Yellow connector (1) of passenger air bag (inflator) module, and be sure to lock connector with lock lever. a) Connect connector. b) Lock connector with lock lever. 4) Install glove box. 5) Install “AIR BAG” fuse to “AIR BAG” fuse box. 6) Turn ignition switch to ON and verify that “AIR BAG”...
Page 629 10B-52 AIR BAG SYSTEM LIVE (UNDEPLOYED) AIR BAG (INFLATOR) MODULES Special care is necessary when handling and storing a live (unde- ployed) air bag (inflator) modules. The rapid gas generation produced during deployment of the air bag could cause the air bag (inflator) module, or an object in front of the air bag (inflator) module, to be thrown through the air in the unlikely event of an accidental deployment.
Page 630 AIR BAG SYSTEM 10B-53 WARNING: When placing a live air bag (inflator) module on bench or other surface, always face the bag up, away from the sur- face. As the live passenger air bag (inflator) module must be placed with its bag (trim cover) facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3).
Page 631 10B-54 AIR BAG SYSTEM WARNING: • For handling and storage of a live seat belt preten- sioner, select a place where the ambient temperature below 65° ° ° ° C (150° ° ° ° F), without high humidity and away from electric noise.
Page 632 AIR BAG SYSTEM 10B-55 AIR BAG WIRE HARNESS AND CONNECTOR Air bag wire harness (1) can be identified easily as it is covered with a yellow protection tube. Be very careful when handling it. • When an open in air bag wire harness (1), damaged wire harness, connector or terminal is found, replace wire har- ness, connectors and terminals as an assembly.
Page 633: Repairs And Inspections Required After An Accident
10B-56 AIR BAG SYSTEM Repairs and Inspections Required after an Accident CAUTION: • All air bag system components, including the electrical harness (component mounting points), must be inspected after an accident. If any components are damaged or bent, they must be replaced even if air bag system activation did not occur.
Page 634: Accident With Or Without Deployment/Activation - Component Inspections
AIR BAG SYSTEM 10B-57 Accident with or without deployment/activation - component inspections Certain air bag and restraint system components must be inspected after any crash, whether the air bag system activated or not. Those components are: • Steering column and shaft joints –...
Page 635 10B-58 AIR BAG SYSTEM • Instrument panel member, reinforcement and knee bolster & panel (1) (passenger) – Check for any distortion, bending, cracking or other dam- age. • If any faulty condition is found in above checks, replace. • Passenger air bag (inflator) module –...
Page 636 AIR BAG SYSTEM 10B-59 • Forward sensor – Check sensor (1), sensor bracket (2), and front panel (3) for damage bend or rust. – Check that connector (4) or lead wire (5) of forward sensor has a scorching, melting or damage. If any faulty condition is found in above checks, replace.
Page 637: Sdm
10B-60 AIR BAG SYSTEM WARNING: During service procedures, be very careful when han- dling a Sensing and Diagnostic Module (SDM). Be sure to read “Service Precautions” in this section before starting to work and observe every precaution during work. Neglecting them may result in personal injury or inactivation of the air bag system when neces- sary.
Page 638 AIR BAG SYSTEM 10B-61 INSPECTION CAUTION: • Do not connect a tester whatever type it may be. • Never repair or disassemble SDM. • If SDM has been dropped, it should be replaced. • Check SDM and SDM plate for dents, cracks or deformation. •...
Page 639: Forward Sensor
10B-62 AIR BAG SYSTEM Forward Sensor WARNING: During service procedures, be very careful when han- dling a sensor. • Never strike or jar a sensor. • Under some circumstances, it could cause improper operation of the air bag system. A sensor and mount- ing bracket bolts must be carefully torqued to assure proper operation.
Page 640 AIR BAG SYSTEM 10B-63 INSPECTION CAUTION: • Never disassemble forward sensor. • Sensor should be replaced when it was dropped from a height of 90 cm (3 ft) or more. • Check sensor (1) and its bracket (2) for dents, cracks, defor- mation or rust.
Page 641: Seat Belt Pretensioner
10B-64 AIR BAG SYSTEM 3) Connect forward sensor connector pushing connector inner (1) as shown. 4) Connect negative cable at battery. 5) Enable air bag system. Refer to “ENABLING AIR BAG SYS- TEM” in this section. Seat Belt Pretensioner Refer to “FRONT SEAT BELT” in Section 10A for removal, inspection and installation.
Page 642: Air Bag (Inflator) Module And Seat Belt Pretensioner Disposal
AIR BAG SYSTEM 10B-65 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury. Undeployed air bag (inflator) module/inactivated seat belt pretensioner must not be disposed of through normal refuse channels.
Page 643: Deployment/Activation Outside Vehicle
10B-66 AIR BAG SYSTEM Deployment/Activation Outside Vehicle Use this procedure when the vehicle itself is used again (only the air bag (inflator) module(s) and seat belt pretensioner(s) are dis- posed). 1) Turn ignition switch to “LOCK”, position remove key and put on safety glasses.
Page 644 AIR BAG SYSTEM 10B-67 WARNING: • For handing and storage of a live seat belt preten- sioner, select a place where the ambient temperature below 65° ° ° ° C (150° ° ° ° F), without high humidity and away from electric noise.
Page 645 10B-68 AIR BAG SYSTEM c) Fill plastic reservoir in fixture (special tool) with water or sand. This is necessary to provide sufficient stabilization of the fixture during deployment. d) Attach the passenger air bag (inflator) module in the fixture (special tool) using mounting attachment, hold-down bolts and nuts and M8 bolts and nuts (1).
Page 646 AIR BAG SYSTEM 10B-69 6) Stretch the deployment harness from the driver or passenger air bag (inflator) module to its full length 10 m (33 ft) (1). Special tool (A) : 09932-75030 7) Place a power source (3) near the shorted end of the deploy- ment harness.
Page 647 10B-70 AIR BAG SYSTEM WARNING: • After deployment/activation, the metal surfaces of the air bag (inflator) module and the seat belt pretensioner will be very hot. Do not touch the metal areas of them for about 30 minutes after deployment/activation. •...
Page 648 AIR BAG SYSTEM 10B-71 18) Dispose of the deployed air bag (inflator) module and the activated seat belt pretensioner through normal refuse chan- nels after it has cooled for at least 10 minutes and tightly seal the air bag (inflator) module and the seat belt pretensioner in a strong vinyl bag.
Page 649: Deployment/Activation Inside Vehicle
10B-72 AIR BAG SYSTEM Deployment/Activation Inside Vehicle Use this procedure when scrapping the entire vehicle including the air bag (inflator) modules and seat belt pretensioners. CAUTION: When vehicle itself will be used again, deploy/activate the air bag and pretensioner outside vehicle according to “DEPLOYMENT/ACTIVATION OUTSIDE VEHICLE”, for deploying/activating it inside will cause the instrument panel, glove box and their vicinity to be deformed.
Page 650 AIR BAG SYSTEM 10B-73 5) Check that there is no open, short or damage in special tool (deployment harness). If any faulty condition is found, do not use it and be sure to use new deployment harness. Special tool (A) : 09932-75030 6) Short (1) the two deployment harness leads together by fully seating one banana plug into the other.
Page 651 10B-74 AIR BAG SYSTEM 8) Route deployment harness out the vehicle. 9) Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects. 10) Stretch the deployment harness to its full length 10 m (33 ft) (1).
Page 652 AIR BAG SYSTEM 10B-75 14) Separate the two banana plugs on the deployment harness. 15) Connect (1) the deployment harness to the power source (12 V vehicle battery) (2) to immediately deploy/activate the air bag or the pretensioner. 16) Disconnect the deployment harness from the power source (12 V vehicle battery) (2) and short (4) the two deployment harness leads together by fully seating one banana plug into the other.
Page 653: Deployed Air Bag (Inflator) Module And Activated Seat Belt Pretensioner Disposal
10B-76 AIR BAG SYSTEM Deployed Air Bag (Inflator) Module and Acti- vated Seat Belt Pretensioner Disposal WARNING: Failure to follow proper air bag (inflator) module and seat belt pretensioner disposal procedures can result in air bag deployment and pretensioner activation which may cause personal injury.
Page 654: Tightening Torque Specification
Connector test adapter kit load tool ness tor) module deployment fixture 09931-76030 09931-76011 Digital multimeter 16/14 pin DLC cable for Tech-1A kit (SUZUKI scan Mass storage cartridge for (See NOTE “B” and Tech-1A tool) Tech-1A WARNING.) (See NOTE “A”.) Tech-2 kit (SUZUKI scan...
Page 655 10B-78 AIR BAG SYSTEM WARNING: Be sure to use the specified digital multimeter. Otherwise, air bag deployment or personal injury may result. NOTE: • “A” : This kit includes the following items and substitutes for the Tech-2 kit. 1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe, 6. Power source cable, 7.
Page 656 Prepared by Overseas Service Department 1st Ed. June, 2001 2nd Ed. Oct., 2001 Printed in Japan Printing: January, 2002...

This manual is also suitable for:

Grand vitara 1999 Sq416 2001 Sq420 2001 Sq625 2001 Grand vitara xl-7 2001

Suzuki GRAND VITARA XL-7 Owner's Manual

General Information

Precautions

Identification Information

Warning, Caution and Information Labels

Maintenance and Lubrication

Maintenance Schedule

Maintenance Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Refrigerant Recovery, Evacuation and Charging

On-Vehicle Service

Required Service Materials

Tightening Torque Specification

Special Tools

Section 3E Rear Suspension

Section 5A Brakes Pipe/Hose/Master Cylinder

General Description

On-Vehicle Service

Special Tool

Tightening Torque Specification

Section 5C Parking and Rear Brake

General Description

On-Vehicle Service

Tightening Torque Specification

Section 5E2 Antilock Brake System (Abs)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Special Tool

Section 6-1 Engine General Information and Diagnosis (H27 Engine)

General Information

Engine Diagnosis

Special Tool

Section 6A2 Engine Mechanical (H27 Engine)

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H27 Engine)

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Special Tool

Section 6F2 Ignition System (for H27 Engine)

General Description

Diagnosis

On-Vehicle Service

Special Tool

Quick Links

Chapters

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Summary of Contents for Suzuki GRAND VITARA XL-7