Page 1 D Service on and around the air bag system cial meanings. Pay special attention to the messages components or wiring must be performed highlighted by these signal words. only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and WARNING: Wiring Location View” under “General De- Indicates a potential hazard that could result scription”...
Page 2 And for any section, item or description not found in this service manual, refer to the related manuals below. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description.
Page 3 TABLE OF CONTENTS SECTION GENERAL INFORMATION General Information Maintenance and Lubrication HEATING AND AIR CONDITIONING Heater and Ventilation Air Conditioning STEERING, SUSPENSION, WHEELS AND TIRES Power Steering (P/S) System Rear Suspension DRIVE SHAFT/PROPELLER SHAFT Front Drive Shaft/Shaft Bearing, Oil Seal Propeller Shafts ENGINE Engine General Information and...
Page 4: 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 men- tioned in FOREWORD of this manual. CONTENTS PRECAUTIONS ................0A- 2 General Precautions .
Page 5: Precautions
0A-2 GENERAL INFORMATION PRECAUTIONS GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
Page 6 GENERAL INFORMATION 0A-3 D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position.
Page 7 0A-4 GENERAL INFORMATION D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never dis- connect the fuel line between the fuel pump and injector within 30 sec.
Page 8: Identification Information
GENERAL INFORMATION 0A-5 IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The number is punched on the chassis inside the tire housing on the right front side. ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block. TRANSMISSION IDENTIFICATION NUMBER M / T The number is located on the transmission case.
Page 9: Warning, Caution And Information Labels
0A-6 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. NOTE: 1.
Page 10: Fastener Information
GENERAL INFORMATION 0A-7 FASTENER INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. CAUTION: Note that both ISO and JIS type bolts and nuts are used for the engine assembly and related parts.
Page 11: Maintenance And Lubrication
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 12: Maintenance Schedule
0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry out the same services Interval: at the same intervals respectively. This interval should be judged by (x 1,000) odometer reading or months,...
Page 13 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry Interval: out the same services at the same intervals respectively. This interval should be judged by This interval should be judged by (x 1,000) odometer reading or months, whichever comes first.
Page 14: 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 rec- ommended that applicable maintenance operation be performed at the particular interval as given in the chart below. Severe condition code A –...
Page 15 MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE ITEM 1-1 Accessory Drive Belt Inspection and Replacement WARNING: All inspection and replacement are to be performed with ENGINE NOT RUNNING. Inspection 1) Disconnect negative cable at battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness using mirror under enough lighting.
Page 16 0B-6 MAINTENANCE AND LUBRICATION ITEM 1-2 Camshaft Timing Belt Replacement Replace belt with new one. Refer to “Timing Belt” in SECTION 6A3 for replacement procedure. CAUTION: D Do not bend or twist timing belt. D Do not allow timing belt to come into contact with oil, wa- ter, etc.
Page 17 MAINTENANCE AND LUBRICATION 0B-7 4) Apply engine oil to new oil filter O-ring. 5) Screw new filter on oil filter stand by hand. 6) Tighten filter to specified torque. Special Tool (A): 09915-46510 Tightening Torque (a): 14 N m (1.4 kg-m, 10.5 lb-ft) 1.
Page 18 0B-8 MAINTENANCE AND LUBRICATION ITEM 1-4 Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove degas- sing tank cap while engine and radiator are still hot. Scald- ing fluid and steam can be blown out under pressure if cap is taken off too soon.
Page 19: Fuel System
MAINTENANCE AND LUBRICATION 0B-9 ITEM 1-5 Exhaust System Inspection WARNING: To avoid danger of being burned, do not touch exhaust sys- tem when it is still hot. Any service on exhaust system should be performed when it is cool. Check exhaust system as follows: D Check rubber mountings for damage and deterioration.
Page 20 0B-10 MAINTENANCE AND LUBRICATION Air Cleaner Filter Inspection 1) Visually check that air cleaner filter is not excessively dirty, dam- aged or oily. 2) Clean filter with compressed air from air outlet side of filter (i.e., the side facing up when installed). ITEM 3-2 Fuel Lines and Connections Inspection 1) Visually inspect fuel lines and connections for evidence of fuel...
Page 21: Chassis And Body
MAINTENANCE AND LUBRICATION 0B-11 CHASSIS AND BODY ITEM 6-10 Manual Transmission Oil Inspection and Change Inspection 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove level plug of transmission.
Page 22 0B-12 MAINTENANCE AND LUBRICATION Fluid cooler hose change Replace inlet and outlet hoses of cooler hose and their clamps. For replacement procedure, refer to On-vehicle service in Section 7B1. ITEM 6-15 Power Steering (P/S) System Inspection (if equipped) 1) Visually check power steering system for fluid leakage and hose for damage and deterioration.
Page 23: Recommended Fluids And Lubricants
MAINTENANCE AND LUBRICATION 0B-13 RECOMMENDED FLUIDS AND LUBRICANTS Minimum quality level required is ; 5W-30 : API CF (except CF-2) or ACEA B3-98 Engine oil 15W-40 : API SG/CF (except CF-2) or ACEA B2-96 (Refer to engine oil viscosity chart in item 1-3) Ethylene-glycol base coolant Engine coolant (“Antifreeze/Anticorrosion coolant”)
Page 24 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 25: General Description
1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION SUPPLEMENTARY HEATER The supplementary heater which is operated by electricity is located in the heater unit near by the conventional type heater core and adds more heat to the air. The supplementary heater is designed to be turned off while the radiator fan is in operation even though the supple- mentary heater switch is in ON position by triggering the radiator fan signal relay.
Page 26: Wiring Circuit
HEATER AND VENTILATION 1A-3 WIRING CIRCUIT 1. Main fuse box 11. Radiator fan motor No.2 21. Condenser fan motor control relay 2. Generator 12. Blower fan relay 22. Condenser fan motor 3. Ignition switch 13. Blower motor 23. A / C controller 4.
Page 27: On-Vehicle Service
1A-4 HEATER AND VENTILATION ON-VEHICLE SERVICE SUPPLEMENTARY HEATER REMOVAL 1) Remove heater unit referring to HEATER UNIT REMOVAL in this section. 2) Detach clamp to separate heater unit upper and lower cases from each other. 3) Remove upper case and remove supplementary heater (1) from lower case (2).
Page 28: Radiator Fan Signal Relay
HEATER AND VENTILATION 1A-5 RADIATOR FAN SIGNAL RELAY INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove supplementary ceramic heater relay (1) from junction box (2). 3) Check that there is continuity between terminal “c” and “d”. If there is no continuity, replace relay. 4) Check that there is no continuity between terminal “c”...
Page 29 1A-6 HEATER AND VENTILATION INSPECTION D Check for switch and lamps by tester. If there is continuity between terminal as shown in table, supple- mentary heater switch (1) functions good. 2. Indicator lamp 3. Illumination lamp INSTALLATION Reverse removal procedure for installation.
Page 30 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 31: General Description
1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION MAJOR COMPONENTS AND LOCATION 1. Cooling unit 9. Expansion valve 17. Air inlet box 2. Compressor 10. Ventilation air 18. Dual (Refrigerant) pressure switch 3. Condenser assembly 11. Foot air 19. Low pressure charge valve 4.
Page 32: Diagnosis
AIR CONDITIONING (OPTIONAL) 1B-3 DIAGNOSIS GENERAL Condition Possible Cause Correction D No refrigerant Cool air won’t come out Recover, evacuation and charging. D Fuse blown (A /C system won’t Check “IG METER”, “REAR DEFG”, operative) “FRONT BLOW”, “25A A/C” fuses, and check for short circuit to ground.
Page 33 1B-4 AIR CONDITIONING (OPTIONAL) Condition Possible Cause Correction D Compressor faulty Cool air does not come Check compressor. D Air in A/C system out or insufficient Replace condenser dryer, and cooling (A/C system evacuation and charging. D Air leaking from cooling unit or air normal operative) Repair as necessary.
Page 34: Wiring Circuit
AIR CONDITIONING (OPTIONAL) 1B-5 WIRING CIRCUIT For LH model 1. Main fuse box 10. Radiator fan relay 3 (low) 19. A / C signal relay 2. Generator 11. Radiator fan motor No.2 20. Condenser fan motor relay 3. Ignition switch 12.
Page 35 1B-6 AIR CONDITIONING (OPTIONAL) For RH model 1. Main fuse box 10. Radiator fan relay 3 (low) 19. A / C signal relay 2. Generator 11. Radiator fan motor No.2 20. Condenser fan motor relay 3. Ignition switch 12. Blower motor relay 21.
Page 36: Inspection Of A/C Controller And Its Circuits
AIR CONDITIONING (OPTIONAL) 1B-7 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 system can be checked at A/C controller (1) and ECM wiring couplers by measuring voltage.
Page 37 1B-8 AIR CONDITIONING (OPTIONAL) SYSTEM CIRCUIT 8. A / C switch 15. Condenser fan motor A. To double relay 1. Blower motor relay 9. Compressor relay 16. A / C controller B. To “FRONT BLOW” fuse 2. Blower motor 10. Compressor 17.
Page 38 AIR CONDITIONING (OPTIONAL) 1B-9 A/C CONTROLLER VOLTAGE VALUES TABLE Termi- Wire Measurement Circuit Normal value Condition color ground Fulfill all the following conditions DBlower fan motor switch ON DFulfill either the following conditions – A / C switch ON – Defroster position or defroster / foot position switch ON (LH model only) Compressor –...
Page 39 1B-10 AIR CONDITIONING (OPTIONAL) ECM VOLTAGE VALUES TABLE Termi- Measurement Normal Wire Circuit Condition ground value –0.3 – 0.3 V Radiator fan state OFF with engine running Radiator fan Radiator fan C51 8 ECM ground C51-8 ECM ground Bl / B motor state 4 –...
Page 40: Compressor Drive Belt
AIR CONDITIONING (OPTIONAL) 1B-11 COMPRESSOR DRIVE BELT INSPECTION D Check compressor drive belt (1) for wear and cracks, and replace as necessary. D Check compressor drive belt (1) tension by measuring how much it deflects when pushed at intermediate point between compres- sor pulley (2) and crank shaft additional pulley (3) with about 100 N (10 kg) force after crankshaft additional pulley 1 rotating.
Page 41: On-Vehicle Service
1B-12 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE RELAYS NOTE: Refer to “RADIATOR FAN CONTROL SYSTEM” in Section 6E3 for radiator fan relay 1, radiator fan relay 2 and radiator fan relay 3. INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove condenser cooling fan motor relay (1), compressor relay (2), condenser cooling fan control relay (4) and/or A/C sig- nal relay (5) from vehicle.
Page 42: Compressor Assembly
AIR CONDITIONING (OPTIONAL) 1B-13 COMPRESSOR ASSEMBLY REMOVAL 1) Run engine at idle with A/C ON for 10 minutes. 2) Disconnect negative (–) cable at battery. 3) Remove air cleaner outlet hose (1). 4) Recover refrigerant from refrigeration system using recovery and recycling equipment.
Page 43: Required Service Material
6) Install air cleaner outlet hose. 7) Perform evacuation and charging referring to “REFRIGERANT RECOVERY, EVACUATION AND CHARGING” in this section. REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D O-ring COMPRESSOR OIL RS20 (150 cc) Compressor oil D Each component 99000-99088-00D0...
Page 44 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 45: General Description
3B1-2 POWER STEERING (P / S) SYSTEM GENERAL DESCRIPTION POWER STEERING (P/S) PUMP ASSEMBLY Power steering (P/S) pump specification: The specification of this P/S pump assembly 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 46: Hydraulic Pressure In P/S Circuit Check
POWER STEERING (P / S) SYSTEM 3B1-3 HYDRAULIC PRESSURE IN P/S CIRCUIT CHECK 1) After cleaning joint of high pressure hose and P/S pump thor- oughly, disconnect hose from pump and install special tool (oil pressure gauge, attachment and hose). Tighten each flare nut to specified torque.
Page 47 3B1-4 POWER STEERING (P / S) SYSTEM 5) Check relief pressure a) Increase engine speed to about 1,500 r/min (rpm). Close gauge valve gradually while watching pressure increase indi- cated by gauge and take reading of relief pressure (maxi- mum hydraulic pressure). Relief pressure: 7650 –...
Page 48: On-Vehicle Service
POWER STEERING (P / S) SYSTEM 3B1-5 ON-VEHICLE SERVICE POWER STEERING PUMP Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) (b):35 N m (3.5 kg-m, 25.5 lb-ft) [LH] (c): 25 N m (2.5 kg-m, 18.5 lb-ft) [RH] 1. Power steering pump assembly [LH] : For left hand steering vehicle 2.
Page 49 3B1-6 POWER STEERING (P / S) SYSTEM REMOVAL NOTE: Be sure to clean each joint of suction and discharge sides thoroughly before removal. 1) Remove suction hose from pump, then disconnect battery nega- tive cable. 2) Remove P/S fluid reservoir with suction hose. 1.
Page 50: Tightening Torque Specifications
43.5 Suction connector bolt Tie-rod end nut 35.0 REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS SUZUKI PRODUCT SUPER GREASE (A) D Oil seal lip of P/S pump pulley shaft Lithium grease (99000-25010)  D To fill P/S fluid reservoir An equivalent of DEXRON...
Page 51: Rear Suspension
REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: D 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. D 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 52 3E-2 REAR SUSPENSION REAR AXLE HOUSING INSTALLATION For the details, refer to the same item of the same section in the Ser- vice Manual mentioned in the FOREWORD of this manual noting following points. D Clean mating surfaces of axle housing (1) and differential carrier and apply sealant “A”...
Page 53 15.5 REQUIRED SERVICE MATERIAL Recommended SUZUKI product Material (Part Number) D Oil seal lip Lithium grease SUZUKI SUPER GREASE A (99000-25010) D Brake reservoir tank Brake fluid DOT 3 D Joint seam of axle and brake back Sealant SUZUKI BOND NO.1215...
Page 54 3E-4 REAR SUSPENSION SPECIAL TOOL 09942-15510 09943-35512 09944-88210 Sliding hammer Brake drum remover Bearing installer...
Page 55: 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 men- tioned in the FOREWORD of this manual. CONTENTS ON-VEHICLE SERVICE .
Page 56: Drive Shaft
4A2-2 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL ON-VEHICLE SERVICE DRIVE SHAFT ASSEMBLY CAUTION: D To prevent any problem caused by washing solution, do not wash joint boots. Degreasing of those parts with cloth is allowed. D Bend each boot band against forward rotation. D Do not squeeze or distort boot when fastening it with Wheel side bands.
Page 57 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 58 4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT Drive shaft oil seal SUZUKI SUPER GREASE A Lithium grease Wheel spindle part of differential side (99000-25010) drive shaft (RH) SEALING COMPOUND 366E Sealant...
Page 59: 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 men- tioned in the FOREWORD of this manual. CONTENTS ON-VEHICLE SERVICE ..............4B-2 Propeller Shaft .
Page 60: Propeller Shaft
4B-2 PROPELLER SHAFTS ON-VEHICLE SERVICE PROPELLER SHAFT INSTALLATION Reverse removal procedure to install propeller shaft. D Use following specification to torque universal joint flange bolts and nuts. Tightening Torque Front propeller shaft flange nuts: 50 N m (5.0 kg-m, 36.5 lb-ft) Rear propeller shaft flange bolts (a): 60 N m (6.0 kg-m, 43.5 lb-ft)
Page 61 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 62 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1112 (P0230) Fuel Pressure DTC P1108 Radiator Fan High Speed Monitoring Circuit Malfunction ..6- 42 Circuit Malfunction ....6- 56 DTC P0201 (P0200) Injector Circuit DTC P1109 Radiator Fan Low Speed...
Page 63: General Information
ENGINE GENERAL INFORMATION (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-3 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 64 6-4 ENGINE GENERAL INFORMATION (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) PRECAUTION ON FUEL SYSTEM SERVICE D Work must be done with no smoking, in a well-ventilated area and away from any open flames. D A small amount of fuel may be released after fuel line is discon- nected.
Page 65 ENGINE GENERAL INFORMATION (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-5 FUEL PRESSURE RELIEF PROCEDURE Refer to “Fuel Delivery System Precaution” in Section 6E3. FUEL LEAKAGE CHECK PROCEDURE After performing any service on fuel system, check to make sure that there are no fuel leakages as follows. 1) Turn ON ignition switch for 5 seconds (to operate fuel pump) and then turn it OFF.
Page 66: Engine Diagnosis
ECM (PCM) memory as freeze frame data. (For the details, refer to description on Freeze frame data.) D It is possible to communicate by using not only SUZUKI scan tool but also generic scan tool. (Diagnostic information can be ac- cessed by using a scan tool.)
Page 67 NOTE: Pending diagnostic trouble code can be read using generic scan tool or Euro mode of Suzuki scan tool. Pending DTC means a DTC detected and stored temporarily at 1 driving cycle of the DTC which is detected in the 2 driving cycle detection logic.
Page 68 DLC in compliance with SAE J1962 in its installation position, the serial data line shape of connector and pin assignment. K and L lines of ISO 9141 is used for SUZUKI scan tool or generic scan tool to communication with ECM (PCM), ABS control module and TCM. Body ground...
Page 69: Precaution In Diagnosing Trouble
(DTC, freeze frame data, etc.) stored in ECM (PCM) memory. D 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 70 6-10 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) and Freeze Frame 1) Print DTC and...
Page 71 NOTE: D If DTC P1112 (for Suzuki mode of Suzuki scan tool) or P0230 (for generic scan tool or Euro mode of Suzuki scan tool) is indicated in this step, proceed to Diag. flow table for DTC P1112/P0230 first.
Page 72: Customer Problem Inspection Form
6-12 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE) User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS VDifficult Starting VPoor Driveability VNo cranking VHesitation on acceleration VNo initial combustion VBack fire/After fire VPoor starting at (VCold/VWarm/VAlways) VLoss of power...
Page 73: Malfunction Indicator Lamp (Mil) Check
5) After completing the check, turn ignition switch off and discon- nect scan tool from data link connector. DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE 1) Connect generic scan tool or SUZUKI scan tool to data link con- nector in the same manner as when making this connection for DTC check.
Page 74: Fail-Safe Table
6-14 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 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 detects normal condition after that. DTC NO.
Page 75: Diagnostic Trouble Code (Dtc) Table
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-15 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DETECTING CONDITION DETECTING ITEM DRIVING (DTC will set when detecting:) CYCLE P0100 1 driving 1 driving Mass air flow sensor circuit malfunction Sensor output low or high voltage (P0100) cycle cycle...
Page 76 6-16 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DETECTING CONDITION DETECTING ITEM DRIVING (DTC will set when detecting:) CYCLE 1 driving Crankshaft position sensor Circuit Mal- Monitor signal of crankshaft position sensor is cycle P0335 – function lower or higher than specification (2 driving (P0335) cycles)
Page 77 ) marked item in DTC DRIVING CYCLE column, it is the number of driving cycle used for generic scan tool. D For “n” marked No. in DTC column, ignore this DTC though it may be indicated on Suzuki scan tool. It dose not affect engine and emission control system.
Page 78: Visual Inspection
6-18 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D Engine oil – – – – – level, leakage Section 0B D Engine coolant – – – – – level, leakage Section 0B D Fuel –...
Page 79: Engine Basic Check
Check immobilizer system malfunction as follows. Go to “DIAGNOSIS” Go to Step 8. 1) Execute Data List mode of Suzuki mode using ECM in Section 8G. application of Suzuki scan tool. Dose Suzuki scan tool indicate communication error...
Page 80: Engine Diagnosis Table
6-20 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 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 Reference Item Hard starting Fuel system out of order.
Page 81 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-21 Condition Possible Cause Reference Item Improper engine Intake system out of order. D Clogged air cleaner element idling or engine fails Clean or replace. D EGR throttle valve to idle Inspect and replace. Fuel system out of order.
Page 82 6-22 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) Condition Possible Cause Reference Item Abnormal knocking Fuel system out of order. D Fuel injection pipe – Cracks Replace. – Fuel leakage from joints Repair. D Faulty fuel injector Inspect and replace. –...
Page 83 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-23 Condition Possible Cause Reference Item D Insufficient coolant Overheating Replenish. D Loose water pump belt Adjust. D Inoperative thermostat Replace. D Poor water pump performance Replace. D Clogged or leaky radiator Flush, repair or replace. D Improper engine oil grade Replace with proper grade oil.
Page 84 6-24 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) Condition Possible Cause Reference Item Engine noise Valve noise. D Improper valve lash Note: Before check- Adjust. D Worn valve stem and guide ing the mechanical Replace. D Weak or broken valve spring noise, make sure Replace.
Page 85: Inspection Of Pcm (Ecm) And Its Circuits
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-25 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 prohib- ited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.
Page 86 6-26 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6) Install ECM cover (1) to ECM connector and tighten screw (5). 7) Install harness cover (2) to ECM connector assembly (3) by fas- tening clamp (4) and then lock ECM connector using lock lever (6).
Page 87: Resistance Check
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-27 Resistance Check 1) Disconnect couplers from ECM/PCM with ignition switch OFF. CAUTION: Never touch terminals of ECM/PCM itself or connect voltmeter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in the following table.
Page 88 6-28 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – MIL DOES NOT COME “ON” OR DIMS AT IGNITION SWITCH ON (BUT ENGINE AT STOP) WIRING DIAGRAM 1. ECM (PCM) 2. To ignition switch 3.
Page 89 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-29 TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – MIL REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. INSPECTION STEP ACTION DTC Check. Go to Step 2 of Go to Step 2. 1) With ignition switch OFF, install scan tool.
Page 90 6-30 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) TABLE A-3 INSPECTION STEP ACTION Double Relay Operating Sound Check: Go to Step 5. Go to Step 2. Is operating sound of double relay heard at ignition switch ON? Fuse Check: Go to Step 3. Check for short in Is main “FI”...
Page 91 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-31 DTC P0100 (DTC P0100) MASS AIR FLOW CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Mass air flow sensor 2. ECM 3. Ignition switch 4. “IG” fuse (20 A) 5. Main fuse DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE.
Page 92 6-32 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. MAF sensor power supply Check: Go to Step 3. Faulty “BLK/WHT” 1) With ignition switch OFF, disconnect MAF sensor wire.
Page 93: Problem
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-33 DTC P0101 (P0100) MAF SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM WIRING DIAGRAM Refer to DTC P0100. DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE.
Page 94 6-34 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0110 INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Mass air flow sensor 2. ECM DTC CONFIRMATION PROCEDURE 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) Turn OFF ignition switch, then ON.
Page 95 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-35 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent 2) Turn ignition switch ON.
Page 96: Dtc P0115 (Dtc P0115) Engine
6-36 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0115 (DTC P0115) ENGINE COOLANT TEMP. SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Engine coolant temperature sensor 2. ECM DTC CONFIRMATION PROCEDURE 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 run engine at idle speed for 10 sec.
Page 97: Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-37 DTC P0121 (DTC P0120) THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM DTC P0604 (P0120) THROTTLE POSITION SENSOR MONITORING SYSTEM MALFUNCTION WIRING DIAGRAM 1. Throttle position sensor 2. ECM 3. Brake lamp switch 4. “STOP” fuse (20 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 98 Is DTC below also indicated? (P0560) Diag. Flow Table. P1614 P0560 Check Wire Harness. Go to Step 4. “LT GRN” wire open, 1) Disconnect connector from TP sensor with “BRN”...
Page 99: Dtc P0180 Fuel Temp. Sensor Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-39 DTC P0180 FUEL TEMP. SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Fuel temperature sensor 2. ECM DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool and run engine at idle speed for 10 sec.
Page 100: Dtc P0190 (P0190) Fuel Rail Pressure Sensor Circuit Malfunction
6-40 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0190 (P0190) FUEL RAIL PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Fuel pressure sensor 2. ECM DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool and run engine at idle speed for 10 sec.
Page 101 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Check Wire Harness Go to Step 4.
Page 102: Dtc P0191 (P0230) Fuel Rail
6-42 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0191 (P0230) FUEL RAIL PRESSURE SENSOR/PRESSURE REGULATOR CONSISTENCY FUNCTION DTC P1112 (P0230) FUEL PRESSURE MONITORING CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. Fuel pressure regulator 3. Fuel pressure sensor 4. ECM 5.
Page 103 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-43 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Fuel Shortage Go to Step 3. Supply fuel into fuel 1) Is there enough fuel in fuel tank? tank.
Page 104 6-44 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0201 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 1 DTC P0202 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 2 DTC P0203 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 3 DTC P0204 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 4 WIRING DIAGRAM 1.
Page 105 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-45 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Fuel Injector Circuit For Short Go to Step 3. Short circuit between 1) With ignition switch OFF, disconnect ECM “PNK”...
Page 106 6-46 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0215 DOUBLE RELAY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Double relay fuse (30 A) 4. To radiator fan relay No.3 DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool.
Page 107 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-47 DTC P0230 FUEL PUMP SUPPLY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Fuel pump 4. “FUEL PUMP” fuse (15 A) 5. Double relay fuse (30 A) 6. To radiator fan relay No.3 DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 108: Dtc P0243 (P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem
6-48 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0243 (P0243) TURBO PRESSURE SOLENOID VALVE CIRCUIT RANGE/ PERFORMANCE PROBLEM WIRING DIAGRAM 1. Double relay 2. ECM 3. Boost pressure regulator solenoid valve 4. Fuel pump 5. “ENG” fuse (15 A) 6.
Page 109 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-49 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Is operating sound heard from fuel pump? Go to Step 3. Proceed to DTC P0230 Diag.
Page 110 6-50 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0245 (P0243)/P0246 (P0243) TURBO PRESSURE SOLENOID VALVE CIRCUIT RANGE/PERFORMANCE PROBLEM WIRING DIAGRAM Refer to DTC P0243 (P0243). TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”.
Page 111: Relay Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-51 DTC P0380 (P0380)/P1404 (P0380) PRE/POST HEAT RELAY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Pre post heating relay (control unit) 2. ECM 3. Glow plugs 4. Main fuse 5. From ignition switch DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 112: Dtc P0381 Glow Indicator Lamp Circuit Malfunction
Dose glow indicator lamp turn on? 1) Connect Suzuki scan tool to DLC. 2) Execute “Glow Indicator Lamp” in Misc Test. Dose glow indicator lamp flash? REFERENCE: As soon as ignition is switched on, ECM turns on glow indicator lamp for a period which depends on engine coolant temp.
Page 113: Dtc P0401 (P0903) Egr Solenoid Valve Flow Insufficient Defected
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-53 DTC P0401 (P0903) EGR SOLENOID VALVE FLOW INSUFFICIENT DETECTED DTC P0402 (P0903) EGR SOLENOID VALVE FLOW EXCESSIVE DETECTED DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool. 3) Run engine between 700 and 2700 rpm for 10 or more.
Page 114: Dtc P0403 (P0403) Egr Solenoid Valve Circuit Malfunction
6-54 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0403 (P0403) EGR SOLENOID VALVE CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. EGR solenoid valve 4. Booster pump 5. “ENG” fuse (15 A) 6. “FUEL PUMP” fuse (15 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 115: Dtc P1169 (P0170) Condenser Voltage Function 1
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-55 DTC P0561 (P0560) STABILIZATION OF SENSOR SUPPLY DTC P0603/P0606/P1171/P1617 ECM FUNCTION DTC P1169 (P0170) CONDENSER VOLTAGE FUNCTION 1 DTC P1170 (P0170) CONDENSER VOLTAGE FUNCTION 2 DTC P1101 (P0105) BAROMETRIC PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1.
Page 116: Dtc P1108 Radiator Fan High Speed Circuit Malfunction
6-56 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1108 RADIATOR FAN HIGH SPEED CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Radiator fan motor 1 2. Radiator fan relay 1 (High / Low) 3. Radiator fan relay 2 (High) 4. Radiator fan relay 3 (Low) 5.
Page 117: Dtc P1109 Radiator Fan Low Speed Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-57 DTC P1109 RADIATOR FAN LOW SPEED CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P1108. DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool. 3) Start engine and warm up completely.
Page 118: Dtc P1110 A/C Signal Circuit Malfunction
6-58 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1110 A/C SIGNAL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. A / C control module 2. ECM DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool. 3) Start engine and turn on A/C switch and heater blower fan switch.
Page 119: Dtc P1135 3Rd Piston Deactivator
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-59 DTC P1135 3RD PISTON DEACTIVATOR (INJECTION PUMP SOLENOID VALVE) CIRCUIT MALFUNCTION WIRING DIAGRAM C51-80 RED / GRN 1. Double relay 2. ECM 3. Injection pump solenoid valve (3rd piston deactivator) 4. Fuel pump 5.
Page 120: Dtc P1138 (P0230) Fuel Pressure Regulator Circuit Malfunction
6-60 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1138 (P0230) FUEL PRESSURE REGULATOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Fuel pressure regulator DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool.
Page 121: Dtc P1402 (P0510) Throttle Solenoid Valve Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-61 DTC P1402 (P0510) THROTTLE SOLENOID VALVE CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. EGR throttle solenoid valve 4. Fuel pump 5. “ENG” fuse (15 A) 6. “FUEL PUMP” fuse (15 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 122: Dtc P1511 Ignition Switch Circuit Malfunction
6-62 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1511 IGNITION SWITCH CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Ignition switch 2. ECM 3. “IG METER” fuse (20 A) 4. Main fuse DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool.
Page 123: Dtc P1519 Radiator Fan Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-63 DTC P1519 RADIATOR FAN CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P1108/P1109. TROUBLESHOOTING Proceed to DTC P1108 and P1109 TROUBLESHOOTING.
Page 124: Dtc P1606 Mil Circuit Malfunction
6-64 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1606 MIL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Malfunction indicator lamp (MIL) 2. ECM 3. Ignition switch 4. “IG” fuse (20 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool.
Page 125: Dtc P1608 Ect Warning Lamp Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-65 DTC P1608 ECT WARNING LAMP CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Engine coolant temperature warning lamp 2. ECM 3. Ignition switch 4. “IG” fuse (20 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool.
Page 126: Dtc P1614 (P0560) Sensor Supply Function
6-66 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P1614 (P0560) SENSOR SUPPLY FUNCTION WIRING DIAGRAM 1. Throttle position sensor 2. Fuel pressure sensor 3. Intake air pressure sensor 4. Camshaft position sensor 5. ECM DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF. 2) Turn ON ignition switch and clear DTC, pending DTC and freeze flame data by using scan tool.
Page 127 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Check Wire Harness Go to Step 4.
Page 128 6-68 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0335 (P0335) CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Crankshaft position sensor (Engine speed sensor) 2. ECM DTC CONFIRMATION PROCEDURE 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 run engine at idle speed for 10 sec.
Page 129 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-69 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. CKP Sensor and Its Circuit Resistance Check: Go to Step 4. Go to Step 3. 1) With ignition switch OFF, disconnect ECM coupler (C51).
Page 130 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Is engine cranked? Go to Step 4.
Page 131 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-71 STEP ACTION Check Wire Harness and Connection. Go to Step 7. “ORN /BLU” or 1) Disconnect connector from CMP sensor. “GRY/RED” wire 2) Check for proper connection to CMP sensor at open, short or poor each terminal.
Page 132 6-72 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0500 (P0500) VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Vehicle speed sensor 2. ECM 3. Ignition switch 4. “IG METER” fuse (20 A) 5. Main fuse 6. Combination meter DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
Page 133 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-73 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Does speedometer indicate vehicle speed? Faulty “BLU/YEL” Go to Step 3. wire or poor C51-19 connection.
Page 134 6-74 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0235 (P0235) INTAKE AIR PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Intake air pressure sensor 2. ECM DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
Page 135 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Intake Air Pressure Sensor Signal Check: Intermittent trouble or Go to Step 4.
Page 136 6-76 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) DTC P0560 (P0560) POWER SUPPLY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Ignition switch 4.“IG” fuse (20 A) 5. Main fuse 6. To radiator fan relay No.3 DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 137 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) 6-77 TABLE B-1 FUEL PUMP CIRCUIT INSPECTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Fuel pump 4. “FUEL PUMP” fuse (15 A) 5. Double relay fuse (30 A) 6. To radiator fan relay No.3 INSPECTION STEP ACTION...
Page 138 6-78 ENGINE DIAGNOSIS (RHZ ENGINE WITH SINGLE-CONNECTOR ECM) TABLE B-2 FUEL PRESSURE INSPECTION SYSTEM DIAGRAM (A): Gauge (B): Hose (C): Attachment 1. Fuel tank 2. Fuel pump 3. Fuel filter 4. Fuel temperature sensor 5. Fuel heater INSPECTION NOTE: Before using following flow table, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 139 4-7. Hose attachment-1 4-8. Hose attachment-2 09931-76011 Mass storage cartridge of 09931-76030 Tech 2 kit (SUZUKI scan tool) Tech 1A kit (SUZUKI scan tool) version 1.7 or more for See NOTE “A” below. 16 / 14 pin DLC cable Tech 1A See NOTE “B”...
Page 140 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 141: Dtc P0221 (P0220) Tp Range/Performance Problem
6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P1112 (P0230) Fuel Pressure DTC P1108 Radiator Fan High Speed Monitoring Circuit Malfunction ..6-1-21 Circuit Malfunction ....6-1-35 DTC P0201 (P0200) Injector Circuit DTC P1109 Radiator Fan Low Speed...
Page 142: General Information
ENGINE GENERAL INFORMATION AND DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-3 GENERAL INFORMATION Refer to “SECTION 6” in this manual. ENGINE DIAGNOSIS GENERAL DESCRIPTION Refer to “SECTION 6” in this manual. ON-BOARD DIAGNOSIS Refer to “SECTION 6” in this manual. PRECAUTION IN DIAGNOSING TROUBLE Refer to “SECTION 6”...
Page 143: Inspection Of Pcm (Ecm) And Its Circuits
6-1-4 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 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 prohib- ited to connect voltmeter or ohmmeter to PCM (ECM) with couplers disconnected from it.
Page 144 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-5 7) Install connector covers (1) to ECM harness connectors se- curely. 8) Tighten harness clamps (2) with ECM harness and ECM har- ness connector securely. 9) Connect ECM connector assemblies to ECM using connector lock lever securely.
Page 145: Resistance Check
6-1-6 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) Resistance Check 1) Disconnect couplers from ECM/PCM with ignition switch OFF. CAUTION: Do not touch terminals of ECM/PCM itself or connect voltmeter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in the following table.
Page 146: Ground Circuit Check
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-7 TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – MIL DOES NOT COME “ON” OR DIMS AT IGNITION SWITCH ON (BUT ENGINE AT STOP) WIRING DIAGRAM 1. ECM (PCM) 2. To ignition switch 3.
Page 147 6-1-8 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK – MIL REMAINS “ON” AFTER ENGINE STARTS WIRING DIAGRAM/CIRCUIT DESCRIPTION Refer to TABLE A-1. INSPECTION STEP ACTION DTC Check. Go to Step 2 of Go to Step 2. 1) With ignition switch OFF, install scan tool.
Page 148 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-9 TABLE A-3 INSPECTION STEP ACTION Double Relay Operating Sound Check: Go to Step 5. Go to Step 2. Is operating sound of double relay heard at ignition switch ON? Fuse Check: Go to Step 3. Check for short in Is main “FI”...
Page 149 6-1-10 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0100 (DTC P0100) MASS AIR FLOW CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Mass air flow sensor 2. ECM 3. Ignition switch 4. “IG” fuse (20 A) 5. Main fuse DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE.
Page 150 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-11 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. MAF sensor power supply Check: Go to Step 3. Faulty “BLK/WHT”, 1) With ignition switch OFF, disconnect MAF sensor “BLK”...
Page 151: Dtc P0101 (P0100) Maf Sensor Circuit Range/Performance Problem
6-1-12 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0101 (P0100) MAF SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM WIRING DIAGRAM Refer to DTC P0100. DTC CONFIRMATION PROCEDURE NOTE: Check to make sure that the following conditions are satisfied when using this DTC CONFIRMATION PRO- CEDURE.
Page 152 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-13 DTC P0110 INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Mass air flow sensor 2. ECM DTC CONFIRMATION PROCEDURE 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) Turn OFF ignition switch, then ON.
Page 153 6-1-14 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check IAT Sensor and Its Circuit. Go to Step 3. Intermittent trouble. 1) Connect scan tool with ignition switch OFF. Check for intermittent 2) Turn ignition switch ON.
Page 154: Dtc P0115 (Dtc P0115) Engine Coolant Temp. Sensor Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-15 DTC P0115 (DTC P0115) ENGINE COOLANT TEMP. SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Engine coolant temperature sensor 2. ECM DTC CONFIRMATION PROCEDURE 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 run engine at idle speed for 10 sec.
Page 155: Problem
6-1-16 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0121 (DTC P0120) THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM DTC P0604 (P0120) THROTTLE POSITION SENSOR MONITORING SYSTEM MALFUNCTION WIRING DIAGRAM 1. Throttle position sensor 2. ECM 3. Brake lamp switch 4. “STOP” fuse (20 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 156 Is DTC below also indicated? (P0560) Diag. Flow Table. P1614 P0560 Check Wire Harness. Go to Step 4. “LT GRN” wire open, 1) Disconnect connector from TP sensor with “BRN”...
Page 157: Dtc P0180 Fuel Temp. Sensor Circuit Malfunction
6-1-18 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0180 FUEL TEMP. SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Fuel temperature sensor 2. ECM DTC CONFIRMATION PROCEDURE 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 run engine at idle speed for 10 sec.
Page 158: Dtc P0190 (P0190) Fuel Rail Pressure Sensor Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-19 DTC P0190 (P0190) FUEL RAIL PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Fuel pressure sensor 2. ECM DTC CONFIRMATION PROCEDURE 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 run engine at idle speed for 10 sec.
Page 159 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Check Wire Harness Go to Step 4.
Page 160: Consistency Function
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-21 DTC P0191 (P0230) FUEL RAIL PRESSURE SENSOR/PRESSURE REGULATOR CONSISTENCY FUNCTION DTC P1112 (P0230) FUEL PRESSURE MONITORING CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. Fuel pressure regulator 3. Fuel pressure sensor 4. ECM 5.
Page 161 6-1-22 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Fuel Shortage Go to Step 3. Supply fuel into fuel 1) Is there enough fuel in fuel tank? tank.
Page 162: Dtc P0202 (P0200) Injector Circuit Malfunction Cylinder 2
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-23 DTC P0201 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 1 DTC P0202 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 2 DTC P0203 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 3 DTC P0204 (P0200) INJECTOR CIRCUIT MALFUNCTION CYLINDER 4 WIRING DIAGRAM 1.
Page 163 6-1-24 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Check Fuel Injector Circuit For Short Go to Step 3. Short circuit between 1) With ignition switch OFF, disconnect ECM “PNK”...
Page 164: Dtc P0215 Double Relay Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-25 DTC P0215 DOUBLE RELAY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Double relay fuse (30 A) 4. To radiator fan relay No.3 DTC CONFIRMATION PROCEDURE 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.
Page 165: Dtc P0230 Fuel Pump Supply Circuit Malfunction
6-1-26 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0230 FUEL PUMP SUPPLY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Fuel pump 4. “FUEL PUMP” fuse (15 A) 5. Double relay fuse (30 A) 6. To radiator fan relay No.3 DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 166: Dtc P0243 (P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-27 DTC P0243 (P0243) TURBO PRESSURE SOLENOID VALVE CIRCUIT RANGE/ PERFORMANCE PROBLEM WIRING DIAGRAM 1. Double relay 2. ECM 3. Boost pressure regulator solenoid valve 4. Fuel pump 5. “ENG” fuse (15 A) 6.
Page 167 6-1-28 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” Go to Step 2. Go to “ENGINE DIAG. performed? FLOW TABLE”. Is operating sound heard from fuel pump? Go to Step 3. Proceed to DTC P0230 Diag.
Page 168 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-29 DTC P0245 (P0243)/P0246 (P0243) TURBO PRESSURE SOLENOID VALVE CIRCUIT RANGE/PERFORMANCE PROBLEM WIRING DIAGRAM Refer to DTC P0243 (P0243). TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”.
Page 169: Relay Circuit Malfunction
6-1-30 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0380 (P0380)/P1404 (P0380) PRE/POST HEAT RELAY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Pre post heating relay (control unit) 2. ECM 3. Glow plugs 4. Main fuse 5. From ignition switch DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 170: Dtc P0381 Glow Indicator Lamp Circuit Malfunction
Dose glow indicator lamp turn on? 1) Connect Suzuki scan tool to DLC. 2) Execute “Glow Indicator Lamp” in Misc Test. Dose glow indicator lamp flash? REFERENCE: As soon as ignition is switched on, ECM turns on glow indicator lamp for a period which depends on engine coolant temp.
Page 171: Dtc P0402 (P0903) Egr Solenoid Valve Flow Excessive Detected
6-1-32 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0401 (P0903) EGR SOLENOID VALVE FLOW INSUFFICIENT DETECTED DTC P0402 (P0903) EGR SOLENOID VALVE FLOW EXCESSIVE DETECTED DTC CONFIRMATION PROCEDURE 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) Run engine between 700 and 2700 rpm for 10 or more.
Page 172: Dtc P0403 (P0403) Egr Solenoid Valve Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-33 DTC P0403 (P0403) EGR SOLENOID VALVE CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. EGR solenoid valve 4. Booster pump 5. “ENG” fuse (15 A) 6. “FUEL PUMP” fuse (15 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 173: Dtc P0561 Stabilization Of Sensor Supply
6-1-34 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0561 (P0560) STABILIZATION OF SENSOR SUPPLY DTC P0603/P0606/P1171/P1617 ECM FUNCTION DTC P1169 (P0170) CONDENSER VOLTAGE FUNCTION 1 DTC P1170 (P0170) CONDENSER VOLTAGE FUNCTION 2 DTC P1101 (P0105) BAROMETRIC PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1.
Page 174: Dtc P1108 Radiator Fan High Speed Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-35 DTC P1108 RADIATOR FAN HIGH SPEED CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Radiator fan motor 1 2. Radiator fan relay 1 (High / Low) 3. Radiator fan relay 2 (High) 4. Radiator fan relay 3 (Low) 5.
Page 175: Dtc P1109 Radiator Fan Low Speed Circuit Malfunction
6-1-36 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P1109 RADIATOR FAN LOW SPEED CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P1108. DTC CONFIRMATION PROCEDURE 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 completely.
Page 176: Dtc P1110 A/C Signal Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-37 DTC P1110 A/C SIGNAL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. A / C control module 2. ECM DTC CONFIRMATION PROCEDURE 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 turn on A/C switch and heater blower fan switch.
Page 177: Dtc P1135 3Rd Piston Deactivator
6-1-38 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P1135 3RD PISTON DEACTIVATOR (INJECTION PUMP SOLENOID VALVE) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Injection pump solenoid valve (3rd piston deactivator) 4. Fuel pump 5. “ENG” fuse (15 A) 6.
Page 178: Dtc P1138 (P0230) Fuel Pressure Regulator Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-39 DTC P1138 (P0230) FUEL PRESSURE REGULATOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Fuel pressure regulator DTC CONFIRMATION PROCEDURE 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.
Page 179: Dtc P1402 (P0510) Throttle Solenoid Valve Circuit Malfunction
6-1-40 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P1402 (P0510) THROTTLE SOLENOID VALVE CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. EGR throttle solenoid valve 4. Fuel pump 5. “ENG” fuse (15 A) 6. “FUEL PUMP” fuse (15 A) DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 180: Dtc P1511 Ignition Switch Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-41 DTC P1511 IGNITION SWITCH CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Ignition switch 2. ECM 3. “IG METER” fuse (20 A) 4. Main fuse DTC CONFIRMATION PROCEDURE 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.
Page 181: Dtc P1519 Radiator Fan Circuit Malfunction
6-1-42 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P1519 RADIATOR FAN CIRCUIT MALFUNCTION WIRING DIAGRAM Refer to DTC P1108/P1109. TROUBLESHOOTING Proceed to DTC P1108 and P1109 TROUBLESHOOTING.
Page 182: Dtc P1606 Mil Circuit Malfunction
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-43 DTC P1606 MIL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Malfunction indicator lamp (MIL) 2. ECM 3. Ignition switch 4. “IG” fuse (20 A) DTC CONFIRMATION PROCEDURE 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.
Page 183: Dtc P1608 Ect Warning Lamp Circuit Malfunction
6-1-44 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P1608 ECT WARNING LAMP CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Engine coolant temperature warning lamp 2. ECM 3. Ignition switch 4. “IG” fuse (20 A) DTC CONFIRMATION PROCEDURE 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.
Page 184: Dtc P1614 (P0560) Sensor Supply Function
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-45 DTC P1614 (P0560) SENSOR SUPPLY FUNCTION WIRING DIAGRAM 1. Throttle position sensor 2. Fuel pressure sensor 3. Intake air pressure sensor 4. Camshaft position sensor 5. ECM DTC CONFIRMATION PROCEDURE 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.
Page 185 6-1-46 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) STEP ACTION Check Fuel Pressure Sensor Circuit Go to Step 5. “LT GRN/BLK” wire 1) Disconnect connector from fuel pressure sensor shorted to other with ignition switch turned OFF. circuits. 2) Turn ON ignition switch. If wire are OK, 3) Check voltage between “LT GRN/BLK”...
Page 186 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Check Wire Harness Go to Step 4.
Page 187 6-1-48 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0335 (P0335) CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Crankshaft position sensor (Engine speed sensor) 2. ECM DTC CONFIRMATION PROCEDURE 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 run engine at idle speed for 10 sec.
Page 188 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-49 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. CKP Sensor and Its Circuit Resistance Check: Go to Step 4. Go to Step 3. 1) With ignition switch OFF, disconnect ECM coupler (E228).
Page 189 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Is engine cranked? Go to Step 4.
Page 190 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-51 STEP ACTION Check Wire Harness and Connection. Go to Step 7. “ORN /BLU” or 1) Disconnect connector from CMP sensor. “GRY/RED” wire 2) Check for proper connection to CMP sensor at open, short or poor each terminal.
Page 191: Dtc P0500 (P0500) Vehicle Speed Sensor Circuit Malfunction
6-1-52 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0500 (P0500) VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Vehicle speed sensor 2. ECM 3. Ignition switch 4. “IG METER” fuse (20 A) 5. Main fuse 6. Combination meter DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
Page 192 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-53 TROUBLESHOOTING STEP ACTION Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”. Does speedometer indicate vehicle speed? Faulty “BLU/YEL” Go to Step 3. wire or poor E228-15 connection.
Page 193: Dtc P0235 (P0235) Intake Air Pressure Sensor Circuit Malfunction
6-1-54 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0235 (P0235) INTAKE AIR PRESSURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Intake air pressure sensor 2. ECM DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
Page 194 OFF and then turn ignition switch ON. Table. 2) Dose scan tool indicate DTC as shown below? P1614 P0560 Intake Air Pressure Sensor Signal Check: Intermittent trouble or Go to Step 4.
Page 195: Dtc P0560 (P0560) Power Supply Circuit Malfunction
6-1-56 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) DTC P0560 (P0560) POWER SUPPLY CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Ignition switch 4.“IG” fuse (20 A) 5. Main fuse 6. To radiator fan relay No.3 DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 196: Inspection
ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) 6-1-57 TABLE B-1 FUEL PUMP CIRCUIT INSPECTION WIRING DIAGRAM 1. Double relay 2. ECM 3. Fuel pump 4. “FUEL PUMP” fuse (15 A) 5. Double relay fuse (30 A) 6. To radiator fan relay No.3 INSPECTION STEP ACTION...
Page 197 6-1-58 ENGINE DIAGNOSIS (RHZ ENGINE WITH TRIPLE-CONNECTOR ECM) TABLE B-2 FUEL PRESSURE INSPECTION SYSTEM DIAGRAM (A): Gauge (B): Hose (C): Attachment 1. Fuel tank 2. Fuel pump 3. Fuel filter 4. Fuel temperature sensor 5. Fuel heater INSPECTION NOTE: Before using following flow table, check to make sure that battery voltage is higher than 11 V. If battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in good condition.
Page 198: Special Tools
4-6. Body attachment-2 & washer 4-7. Hose attachment-1 4-8. Hose attachment-2 09931-76011 09931-76030 Mass storage cartridge for Tech 2 kit (SUZUKI scan tool) Tech 1A kit (SUZUKI scan tool) 16 / 14 pin DLC adapter for (See NOTE “A”.) Tech 1A Tech 1A (See NOTE “B”.)
Page 199: Engine Mechanical
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 200: Maintenance
6A3-2 ENGINE MECHANICAL (RHZ ENGINE) MAINTENANCE OIL LEVEL CHECK, OIL CHANGE AND OIL FILTER CHANGE Refer to “ENGINE” in Section 0B. ON-VEHICLE SERVICE COMPRESSION CHECK 1) Cool off engine if it is hot. 2) Disconnect negative cable at battery. 3) Disconnect ECM connector from ECM. 4) Remove all glow plugs referring to “GLOW PLUG”...
Page 201: Air Cleaner Element
ENGINE MECHANICAL (RHZ ENGINE) 6A3-3 11) Disconnect negative cable at battery. 12) Remove special tool and install all glow plugs referring to “GLOW PLUG” in Section 6E3. 13) Connect ECM connector to ECM. 14) Connect negative cable at battery. AIR CLEANER ELEMENT REMOVAL 1) Remove air cleaner case clamps.
Page 202: Cylinder Head Cover
6A3-4 ENGINE MECHANICAL (RHZ ENGINE) CYLINDER HEAD COVER REMOVAL 1) Disconnect negative cable at battery. 2) Remove TP sensor (Accelerator stroke sensor) from air clean- er case and intake air pressure sensor from strut tower bar. 3) Remove strut tower bar (1). 4) Remove intercooler and intercooler inlet hose referring to “IN- TERCOOLER”...
Page 203 ENGINE MECHANICAL (RHZ ENGINE) 6A3-5 INSTALLATION 1) Install cylinder head cover gasket (1) to cylinder head cover (2). NOTE: Be sure to check cylinder head cover gasket for deteriora- tion or any damage before installation and replace if found defective. 2) Install cylinder head cover to cylinder head.
Page 204: Intake Manifold
6A3-6 ENGINE MECHANICAL (RHZ ENGINE) INTAKE MANIFOLD 1. Throttle valve assembly 2. Elbow air divider 3. Intake manifold 4. Intake manifold gasket : Tightening Torque : Do not reuse REMOVAL 1) Remove exhaust manifold with turbocharger referring to “TURBOCHARGER” in Section 6E3. 2) Remove throttle valve assembly referring to “THROTTLE VALVE ASSEMBLY”...
Page 205: Exhaust Manifold
ENGINE MECHANICAL (RHZ ENGINE) 6A3-7 INSTALLATION Reverse removal procedure for installation noting following points. D Clean mating surfaces of intake manifold and cylinder head. D Use new intake manifold gasket. D Check to ensure that all removed parts are back in place. Rein- stall any necessary parts which have not been reinstalled.
Page 206: Timing Belt And Belt Tensioner (Engine With Camshaft Hub)
6A3-8 ENGINE MECHANICAL (RHZ ENGINE) TIMING BELT AND BELT TENSIONER (ENGINE WITH CAMSHAFT HUB) 1. Upper timing belt cover 2. Right timing belt cover 3. Lower timing belt cover 4. Timing belt 5. Camshaft timing belt pulley 6. Camshaft hub 7.
Page 207 ENGINE MECHANICAL (RHZ ENGINE) 6A3-9 7) Remove crankshaft pulley. If it is hard to remove, install crankshaft pulley bolt without washer and use special tools. Special Tool (A): 09944-36011 8) Remove timing belt covers. 9) Remove fuel filter assembly. 10) Turn crankshaft so that crank timing pulley key (7) turns up, and then lock camshaft hub (1) inserting special tool (A) into cylin- der head hole (2) as shown in figure.
Page 208 6A3-10 ENGINE MECHANICAL (RHZ ENGINE) INSPECTION D Inspect timing belt for wear or crack. Replace it as necessary. D Inspect timing belt tensioner and roller for smooth rotation. INSTALLATION 1) Install timing belt tensioner (1) and roller (2). Do not tighten timing belt tensioner bolt with wrench yet. Tighten by hand only at this time.
Page 209 ENGINE MECHANICAL (RHZ ENGINE) 6A3-11 5) Install timing belt (1) with camshaft timing belt pulley (2) turned clockwise within oblong hole (3) of camshaft timing belt pulley as shown in figure. 6) Fit special tool as shown in figure. Special Tool (A): 09919-56560/OUT0000138 7) Turn timing belt tensioner counterclockwise using special tool (B) until special tool (A) indicates 98 ±...
Page 210 6A3-12 ENGINE MECHANICAL (RHZ ENGINE) 12) Loosen camshaft timing belt pulley bolts (1). NOTE: Do not remove camshaft timing belt pulley bolts (1). 13) Fit special tool as shown. Special Tool (A): 09919-56560/OUT0000138 14) Turn timing belt tensioner counterclockwise using special tool (B) until special tool (A) indicates 54 ±...
Page 211 ENGINE MECHANICAL (RHZ ENGINE) 6A3-13 21) Install crankshaft pulley (1) with crankshaft locked by using flat end rod (2) or the like, apply sealant to crankshaft pulley bolt and tighten it gradually as follows. a) Tighten bolt to 40 N m (4.0 kg-m, 29.0 lb-ft) b) Tighten bolt to 195 N m (19.5 kg-m, 141 lb-ft) by turning it to...
Page 212: Timing Belt And Belt Tensioner (Engine Without Camshaft Hub)
6A3-14 ENGINE MECHANICAL (RHZ ENGINE) TIMING BELT AND BELT TENSIONER (ENGINE WITHOUT CAMSHAFT HUB) 1. Upper timing belt cover 7. Timing belt tensioner : Tightening Torque 2. Right timing belt cover 8. Roller 3. Lower timing belt cover 9. Timing belt cover bolt 4.
Page 213 ENGINE MECHANICAL (RHZ ENGINE) 6A3-15 7) Remove crankshaft pulley (1). If it is hard to remove, install crankshaft pulley bolt without washer and use special tools. Special tool (A): 09944-36011 8) Remove timing belt covers. 9) Turn crankshaft so that crank timing pulley key (2) turns up, and then lock camshaft timing belt pulley (1) inserting special tool (A) into cylinder head hole as shown in figure.
Page 214 6A3-16 ENGINE MECHANICAL (RHZ ENGINE) D Inspect timing belt tensioner and roller for smooth rotation. INSTALLATION 1) Check that camshaft timing belt pulley (3) is locked inserting special tool (A) into cylinder head hole as shown in figure. Special tool (A): 09910-26540/OUT0000151 2) Check that flywheel (MT) or drive plate (AT) is locked inserting special tool (B) into holes in both cylinder block and flywheel...
Page 215 ENGINE MECHANICAL (RHZ ENGINE) 6A3-17 7) Remove thickness gauge (2) or the like from crankshaft timing gear (1). 8) Remove special tool (C) and (D). 9) Fit special tool (A) as shown in figure. Special tool (A): 09919-56560/OUT0000138 10) Turn timing belt tensioner (1) in counterclockwise using special tool (B) until special tool (A) indicates 98 ±...
Page 216 6A3-18 ENGINE MECHANICAL (RHZ ENGINE) 17) Loosen crankshaft pulley bolt. NOTE: Do not remove crankshaft pulley bolt. 18) Loosen timing belt tensioner bolt (2). NOTE: Do not remove timing belt tensioner bolt (2). 19) Fit special tool (A) as shown. Special tool (A): 09919-56560/OUT0000138 20) Turn timing belt tensioner (1) counterclockwise using special...
Page 217 ENGINE MECHANICAL (RHZ ENGINE) 6A3-19 27) Check the following special tools installing procedures. If special tool(s) can not install, perform step 1) to step 25) again after removing timing belt. NOTE: Camshaft and crankshaft have to be pegged by special tools when removing crankshaft pulley.
Page 218: Oil Pressure Switch
6A3-20 ENGINE MECHANICAL (RHZ ENGINE) OIL PRESSURE SWITCH REMOVAL 1) Detach degassing tank from its bracket. 2) Disconnect oil pressure switch connector. 3) Remove oil pressure switch (1). INSTALLATION 1) Install oil pressure switch (1) with new gasket (2). 2) Tighten oil pressure switch. 3) Connect connector.
Page 219: Oil Pan And Oil Pump Strainer
ENGINE MECHANICAL (RHZ ENGINE) 6A3-21 OIL PAN AND OIL PUMP STRAINER 1. Oil pan: Apply sealant 1207C 99000-31150 to mating surface. 2. Strainer 3. O-ring 4. Gasket 5. Drain plug 6. Strainer bolt 7. Bracket bolt 8. Oil pan bolt 34 N m (3.4 kg-m, 24.5 lb-ft) : Do not reuse...
Page 220 6A3-22 ENGINE MECHANICAL (RHZ ENGINE) 8) Remove transmission fastening bolts (1). 9) Remove oil pan bolts. Bolt (1) at the rear of power steering pump bracket (2) should be loosened only. It is not possible to remove it due to interfer- ence with bracket.
Page 221 ENGINE MECHANICAL (RHZ ENGINE) 6A3-23 CLEANING D Clean oil pump strainer screen. D Clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dust from mating surfaces and in- side of oil pan. INSTALLATION 1) Apply sealant to oil pan mating surface continuously as shown in figure.
Page 222 6A3-24 ENGINE MECHANICAL (RHZ ENGINE) 3) Fit oil pan to cylinder block using bolt (1) at the position as shown in figure. 4) After fitting oil pan (1) to cylinder block, run in securing bolts (2) and start tightening at the center: move wrench outward, tighten- ing one bolt at a time.
Page 223 ENGINE MECHANICAL (RHZ ENGINE) 6A3-25 8) Install front differential housing according to installation proce- dure described in Section 7E. 9) Refill front differential housing with gear oil, referring to Section 10) Install steering gear box to vehicle referring to Section 3B1. 11) Install oil level gauge.
Page 224: Oil Pump
6A3-26 ENGINE MECHANICAL (RHZ ENGINE) OIL PUMP 1. Gasket holder plate: 6. Rotor Apply sealant 1207C 99000-31150 7. Relief valve to mating surface. 8. Relief spring 2. Oil pump chain 9. Retainer 3. Oil pump drive sprocket 10. Oil seal: 4.
Page 225 ENGINE MECHANICAL (RHZ ENGINE) 6A3-27 DISASSEMBLY Disassemble oil pump as shown in figure. CAUTION: Do not remove oil pump sprocket. Otherwise, oil pump sprocket and/or oil pump rotor shaft might be damaged. INSPECTION D Check rotor (3) and oil pump cases (1) (2) for excessive wear or damage.
Page 226 6A3-28 ENGINE MECHANICAL (RHZ ENGINE) ASSEMBLY 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to rotors and inside surface of each oil pump case. 3) Assemble oil pump. After assembling oil pump, check to be sure that rotor turns smoothly by hand.
Page 227 ENGINE MECHANICAL (RHZ ENGINE) 6A3-29 INSTALLATION 1) Install oil pump (1), oil pump chain (2) and oil pump drive sprock- et (3) all together to cylinder block. 2) Install sprocket key. 3) Apply sealant to mating surface of gasket holder plate. “A”...
Page 228: Camshaft And Valve Lash Adjusters
6A3-30 ENGINE MECHANICAL (RHZ ENGINE) CAMSHAFT AND VALVE LASH ADJUSTERS 10 N m (1.0 kg-m, 7.5 lb-ft) 45 N (4.5 kg-m, 32.5 lb-ft) 25 N m (2.5 kg-m, 18.0 lb-ft) 52 N m (5.2 kg-m, 37.5 lb-ft) 1. Camshaft housing: 7.
Page 229 ENGINE MECHANICAL (RHZ ENGINE) 6A3-31 5) Remove camshaft timing belt pulley bolt(s) (2) or camshaft hub bolts (1) (if equipped) by using special tool. Special Tool (A): 09910-26540/OUT0000151 6) Remove camshaft timing belt pulley (3) and camshaft hub (if equipped). [A]: Engine with camshaft hub [B]: Engine without camshaft hub 7) Loosen camshaft housing bolts in such order as indicated in...
Page 230: Valves And Cylinder Head
6A3-32 ENGINE MECHANICAL (RHZ ENGINE) VALVES AND CYLINDER HEAD 60 N m (6.0 kg-m, 43.5 lb-ft) and retighten 220_ 1. Valve cotters 9. Cylinder head 2. Valve spring retainer 10. Cylinder head gasket: 3. Valve spring “Thickness Identification” 4. Valve stem seal mark provided on gasket should 5.
Page 231 ENGINE MECHANICAL (RHZ ENGINE) 6A3-33 6) Remove intercooler air hoses. 7) Remove cylinder head cover referring to “CYLINDER HEAD COVER” in this section. 8) Disconnect vacuum hoses from throttle valve assembly, EGR valve and waste gate actuator. 9) Remove bracket (1) from water outlet box. 10) Remove fuel temperature sensor (2).
Page 232 6A3-34 ENGINE MECHANICAL (RHZ ENGINE) 18) Disconnect exhaust No.1 pipe (1) from turbocharger outlet pipe (2). 19) Loosen cylinder head bolts in such order as indicated in figure and remove them. 20) Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect what- ever necessary.
Page 233 ENGINE MECHANICAL (RHZ ENGINE) 6A3-35 4) Using special tool (Valve lifter), compress valve springs and then remove valve cotters (1) by using special tool (Forceps) as shown. Special Tool (A): 09916-14510 (B): 09916-14910 (C): 09916-84511 5) Release special tool, and remove spring retainer and valve spring.
Page 234 6A3-36 ENGINE MECHANICAL (RHZ ENGINE) INSTALLATION 1) Install valve rocker (1) with ball valve rocker (2) to cylinder head. Apply engine oil around valve rocker and ball valve rocker and then install them to cylinder head. 2) Apply sealant to mating surfaces of camshaft housing. “A”...
Page 235 ENGINE MECHANICAL (RHZ ENGINE) 6A3-37 6) Install camshaft timing pulley as follows. D For engine with camshaft hub a) Install camshaft hub (1), if removed. Tighten camshaft hub bolt (2) to specified torque by using special tool. Special tool (A): 09910-26540/OUT0000151 Tightening torque Camshaft hub bolt (a): 45 N·m (4.5 kg-m, 32.5 lb-ft) b) Install camshaft timing belt pulley (3) and tighten camshaft...
Page 236 6A3-38 ENGINE MECHANICAL (RHZ ENGINE) D Flatness of gasketed surface: Using a straightedge and thickness gauge, check surface at 6 locations in total. If distortion limit, given below, is exceeded, cor- rect gasketed surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place paper on and over surface plate, and rub gasketed surface against paper to grind off high spots.
Page 237 ENGINE MECHANICAL (RHZ ENGINE) 6A3-39 INSTALLATION 1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface. 2) Prepare optimum cylinder head gasket according to following procedure. a) As shown in figure, piston projects above cylinder block when it reaches top dead center.
Page 238 6A3-40 ENGINE MECHANICAL (RHZ ENGINE) 3) Install knock pins (1) to cylinder block. 4) Install new cylinder head gasket (2) to cylinder block. Thickness identification notch(es) (3) provided on gasket should come to oil filter side. A: Crankshaft pulley side B: Flywheel side 5) Check to make sure that length of cylinder head bolt as shown in figure does not exceed specified value.
Page 239 ENGINE MECHANICAL (RHZ ENGINE) 6A3-41 D Using new gasket (1), install water inlet box to cylinder block. D Install high pressure supply pipe. When tightening union nut, hold union nut of injection pump with special tool. Special Tool (A): 09950-76510/OUT0000148 Tightening Torque High pressure supply pipe union nut (a): 20 N...
Page 240: Piston, Piston Rings, Connecting Rods And Cylinders
6A3-42 ENGINE MECHANICAL (RHZ ENGINE) PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10.
Page 241 ENGINE MECHANICAL (RHZ ENGINE) 6A3-43 DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. D Ease out piston pin circlips (1), as shown. D Force piston pin out. CLEANING Clean carbon from piston head and ring grooves, using a suitable tool.
Page 242 6A3-44 ENGINE MECHANICAL (RHZ ENGINE) INSPECTION Cylinders D 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. ASSEMBLY 1) Install piston pin to piston (1) and connecting rod (2): After applying engine oil to piston pin and piston pin holes in pis- ton and connecting rod, fit connecting rod to piston so that bear- ing lock tab (3) and arrow mark (4) come on the same side and...
Page 243 ENGINE MECHANICAL (RHZ ENGINE) 6A3-45 INSTALLATION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) Install guide hoses over connecting rod bolts. These guide hoses protect crankpin and threads of rod bolt from damage during installation of connecting rod and piston assem- bly.
Page 244 6A3-46 ENGINE MECHANICAL (RHZ ENGINE) 6) Install oil partition (2) and oil level gauge lower guide (1). 7) Reverse removal procedure for installation, as previously out- lined. 8) Adjust generator belt tension, referring to Section 6H. 9) Adjust A/C compressor belt tension, if equipped. Refer to Sec- tion 1B.
Page 245: Unit Repair Overhaul
ENGINE MECHANICAL (RHZ ENGINE) 6A3-47 UNIT REPAIR OVERHAUL ENGINE ASSEMBLY REMOVAL 1) Disconnect negative cable at battery. 2) Remove engine hood after disconnecting windshield washer hose. 3) Remove TP sensor (Accelerator stroke sensor) and intake air pressure sensor, then remove strut tower bar (1). 4) Drain cooling system.
Page 246 6A3-48 ENGINE MECHANICAL (RHZ ENGINE) 10) Disconnect following hoses: D Brake booster hose (1) from vacuum pipe D Vacuum hoses from solenoid valves D Heater inlet and outlet hose (2) from pipe D Fuel feed hose (3) and return hose (4) from each pipe D A/T fluid hose clamp from bracket 11) With hose connected, detach A/C compressor and power steering pump from bracket if equipped.
Page 247 ENGINE MECHANICAL (RHZ ENGINE) 6A3-49 INSTALLATION 1) Lower engine assembly into engine compartment. 2) Tighten engine side mounting bracket nuts (R & L). Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) 3) Remove lifting device. 4) Reverse removal procedure for installation, noting following points.
Page 248: Main Bearings, Crankshaft And Cylinder Block
6A3-50 ENGINE MECHANICAL (RHZ ENGINE) MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 50 N (5.0 kg-m, 36.5 lb-ft) 10 N m (1.0 kg-m) 8. Main bearing cap No.1 9. Main bearing cap No.2 10. Main bearing cap No.3 11. Main bearing cap No.4 1.
Page 249 ENGINE MECHANICAL (RHZ ENGINE) 6A3-51 REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Remove following parts from engine as previously outlined. D Oil pan and oil pump strainer D Intake manifold and exhaust manifold D Cylinder head cover D Timing belt cover D Timing belt, belt tensioner, roller and crankshaft timing belt pulley...
Page 250 6A3-52 ENGINE MECHANICAL (RHZ ENGINE) Main Bearings General information D Upper half of bearing (1) has oil groove (2) as shown in figure. Install this half with oil groove to cylinder block. D On each main bearing cap, number is embossed as shown in fig- ure.
Page 251 ENGINE MECHANICAL (RHZ ENGINE) 6A3-53 INSTALLATION NOTE: D All parts to be installed must be perfectly clean. D Be sure to apply oil to crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pis- tons, piston rings and cylinder bores. D Journal bearings, bearing caps, connecting rods, rod bear- ings, rod bearing caps, pistons and piston rings are in com- bination sets.
Page 252 6A3-54 ENGINE MECHANICAL (RHZ ENGINE) 6) Install main bearing cap No.2 (1). 7) Apply sealant to the end of cylinder block as shown in figure. “A” Sealant: 99000-31140 8) Fit new bearing cap seal (1) to main bearing cap No.1 (2). 9) Attach special tools (A) and (B) to main bearing cap No.1 by us- ing bolt and washer (3).
Page 253 ENGINE MECHANICAL (RHZ ENGINE) 6A3-55 Install main bearing caps in the right place as shown figure. And then, tighten main bearing cap bolts as follows. a) Tighten bolts to 25 N·m (2.5 kg-m, 24.5 lb-ft) according to numerical order in figure. b) In the same manner as in step a), retighten them by turning through 60°.
Page 254 6A3-56 ENGINE MECHANICAL (RHZ ENGINE) 19) Install following parts to engine as previously outlined. Piston and connecting rod Cylinder head assembly Oil pump, oil pump drive sprocket and gasket holder plate Timing belt, belt tensioner, roller and crankshaft timing sprocket Timing belt cover Cylinder head cover Intake manifold and exhaust manifold...
Page 255: Special Tools
ENGINE MECHANICAL (RHZ ENGINE) 6A3-57 SPECIAL TOOLS 09919-46510 09910-26530 09916-96520 (OUT0000110) 09944-36011 (OUT0000160) Compression gauge Clamp pliers Steering wheel remover TDC rod positioner attachment 09919-56550 09910-26540 09919-56560 09913-56510 (OUT0000141) (OUT0000151) (OUT0000138) (OUT0000152) Tension lever Camshaft TDC positioner Tension measuring equipment Oil seal installer 1.
Page 256: Required Service Materials
(OUT0000012) Compression gauge Bearing cap seal support REQUIRED SERVICE MATERIALS RECOMMENDED SUZUKI PRODUCT D To apply to mating surfaces of cylinder block and oil pan. Sealant 1207C 99000-31150 D To apply to mating surfaces of cylinder block and gasket holder plate.
Page 257 ENGINE MECHANICAL (RHZ ENGINE) 6A3-59 TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening part Fastening art kg-m lb-ft Camshaft housing bolts 10.0 Cylinder head cover bolts 10.0 Oil pan bolts 16.0 11.5 Oil pan drain plug bolt 34.0 24.5 a) Tighten 60 N a) Tighten 6.0 kg-m a) Tighten 43.5 lb-ft Cylinder head bolts...
Page 258: Engine Cooling
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “System Components and Wiring Location View” under “General De- scription” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 259: General Description
6B-2 ENGINE COOLING GENERAL DESCRIPTION The cooling system consists of the degassing tank cap, radiator, degassing tank, hoses, water pump, cooling fan, thermostat. The radiator is of tube-and-fin type. COOLING SYSTEM CIRCULATION 1. Radiator 2. Thermostat 3. Engine oil cooler : When thermostat is open and close 4.
Page 260 ENGINE COOLING 6B-3 COOLANT DEGASSING TANK The degassing tank (1) consists of a “see-through” plastic tank, a hose and a degassing tank cap (2). During operation, the coolant circulates inside of the degassing tank constantly. As the coolant warms up and expands, the coolant level in the degassing tank rises.
Page 261: Cooling Fan
6B-4 ENGINE COOLING COOLING FAN The cooling fan is driven by electric motor, and the motor is acti- vated by ECM (and ECT sensor). WARNING: Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running.
Page 262: Diagnosis
ENGINE COOLING 6B-5 DIAGNOSIS Condition Possible cause Correction D Not enough coolant Engine overheats Check coolant level and add as necessary. D Faulty thermostat Replace. D Faulty water pump Replace. D Dirty or bent radiator fins Clean or remedy. D Coolant leakage on cooling system Repair.
Page 263: Maintenance
6B-6 ENGINE COOLING MAINTENANCE COOLANT LEVEL To check level, lift hood and look at “see-through” degassing tank (1). It is not necessary to remove degassing tank cap (2) to check cool- ant level. WARNING: To help avoid danger of being burned: D Do not remove degassing tank cap while coolant is “boil- ing”, and D Do not remove degassing tank cap while engine and radia-...
Page 264: Cooling System Flush And Refill
ENGINE COOLING 6B-7 4) Using a pressure tester (1), check system and degassing tank cap (2) for proper pressure holding capacity 110 kpa (1.1 kg/cm , 15.6 psi). If replacement of cap is required, use proper cap specified for this vehicle. NOTE: After installing degassing tank cap to degassing tank, make sure that it is closed certainly as shown in figure.
Page 265 6B-8 ENGINE COOLING 5) Fill the circuit slowly with water. 6) Loosen bleed screw (1) to bleed air and tighten it after con- firmation of overflow. 7) Run engine until upper radiator hose is hot again. 8) Repeat steps 3) and 7) several times until drained liquid is nearly colorless.
Page 266: On-Vehicle Service
ENGINE COOLING 6B-9 ON-VEHICLE SERVICE WARNING: D Check to make sure that engine coolant temperature is cold before removing any part of cooling system. D Also be sure to disconnect negative cord from battery ter- minal before removing any part. COOLING SYSTEM DRAINING 1) Remove degassing tank cap.
Page 267: Thermostat
6B-10 ENGINE COOLING THERMOSTAT REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system and tighten drain plug. 3) Remove intercooler referring to “INTERCOOLER” in Section 6E3. 4) Remove intercooler bracket (1) and vacuum pipe (2). 5) Remove thermostat cap (1) from water outlet box (2). 6) Remove thermostat (3).
Page 268: Radiator
ENGINE COOLING 6B-11 RADIATOR REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system by loosening drain plug of radiator. 3) Remove degassing tank (1) and its bracket. 4) When servicing A/T vehicle, place oil pan under radiator (1) and disconnect A/T fluid hoses (2), (3) from radiator.
Page 269: Radiator Fan Relay
6B-12 ENGINE COOLING INSPECTION Check radiator for leakage or damage. Straighten bent fins, if any. CLEANING Clean frontal area of radiator cores. INSTALLATION Reverse removal procedures, noting the followings. D Refill cooling system with proper coolant referring to “COOLANT” and steps 8) to 10) of “COOLING SYSTEM FLUSH AND REFILL” in this section.
Page 270: Water Pump
ENGINE COOLING 6B-13 WATER PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system by loosening drain plug of radiator. 3) Remove timing belt referring to “TIMING BELT AND BELT TEN- SIONER” in Section 6A3. 4) Remove water pump assembly (1). CAUTION: Do not disassemble water pump.
Page 271: Required Service Materials
6B-14 ENGINE COOLING REQUIRED SERVICE MATERIALS MATERIALS Ethylene glycol base coolant Engine cooling system for improving cooling efficiency (Anti-freeze/Anti-corrosion coolant) and for protection against rusting.
Page 272: Engine Fuel
ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CAUTION: Be sure to read “Precaution” in Section 6E before disconnecting fuel line or removing fuel system part(s). Failure to follow “Precaution” could result unneeded fuel system repairs. NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in FOREWORD of this manual.
Page 273 6C-2 ENGINE FUEL ON-VEHICLE SERVICE WATER DRAINING OF FUEL FILTER 1) Loose bleed screw (1). 2) Drain water. 3) Tighten bleed screw. 4) Check for fuel leakage. AIR BLEEDING OF FUEL SYSTEM Air bleeding must be carried out when fuel system has been disas- sembled or when vehicle ran out of fuel.
Page 274 ENGINE FUEL 6C-3 4) Remove cover (1), corrugated washer (2) and fuel filter ele- ment (3). 5) Remove fuel filter (4) from bracket (5) by unclipping and lifting fuel filter. 6) Clean fuel filter. CAUTION: Do not use compressed air to fuel filter and its element. INSTALLATION 1) Install fuel filter (1) to bracket (2).
Page 275 6C-4 ENGINE FUEL FUEL PUMP REMOVAL 1) Remove fuel filler cap to release fuel pressure in fuel feed line. 2) Disconnect negative cable at battery. 3) Hoist vehicle. 4) Disconnect fuel pump wire harness. 5) Disconnect inlet hose (1) and outlet hose (2). 6) Remove fuel pump (3).
Page 276: Fuel Tank
ENGINE FUEL 6C-5 2-WAY CHECK VALVE (TANK PRESSURE CONTROL VALVE) INSPECTION 1) Air should pass through 2-way check valve (1) smoothly from fuel tank side (Black side (2) of 2-way check valve) to Orange side (3) when blown hard. 2) From Orange side, even when blown softly, air should come out of Black side.
Page 277 6C-6 ENGINE FUEL 4) Disconnect filler hose (1) from fuel tank and breather hoses (2) from fuel filler neck. 5) Remove fuel tank inlet valve (3). Use care not to damage inlet valve when removing. 6) Drain fuel tank by pumping fuel out through fuel tank filler. Use hand operated pump device to drain fuel tank.
Page 278: Fuel Level Gauge
ENGINE FUEL 6C-7 FUEL LEVEL GAUGE REMOVAL 1) Remove fuel tank. Refer to “FUEL TANK” in this section. 2) Remove fuel level gauge (1) from fuel tank. INSPECTION Check fuel level gauge (1) for evidence of dirt and contamination. If present, clean and check for presence of dirt in fuel tank. INSTALLATION Reverse removal procedure for installation noting the followings.
Page 279 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 280 6E3-2 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) EGR System ......6E3-48 TIGHTENING TORQUE SPECIFICATIONS ....6E3-50 Vacuum Hose .
Page 281: General Description
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-3 GENERAL DESCRIPTION SYSTEM DIAGRAM 1. Air cleaner 18. EGR solenoid valve 2. MAF sensor 19. EGR valve 3. Turbocharger 20. Boost (Turbo) pressure regulator 4. Intercooler solenoid valve 5. TP sensor (Accelerator stroke sensor) 21.
Page 282: Air Intake System
6E3-4 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) AIR INTAKE SYSTEM 1. Air cleaner 2. MAF sensor 3. Air cleaner outlet hose 4. Turbocharger 5. Intercooler inlet hose 6. Intercooler 7. Intake air pressure sensor 8. Intercooler outlet hose 9. Throttle valve assembly 10.
Page 283: Fuel Delivery System
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-5 FUEL DELIVERY SYSTEM 1. Fuel tank 2. Fuel pump 3. Fuel filter 4. Fuel temperature sensor 5. Injection pump 6. Common rail (High pressure fuel injection rail) 7. Injector 8. Fuel heater : Fuel feed line : Fuel return line...
Page 284: Electronic Control System
6E3-6 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) ELECTRONIC CONTROL SYSTEM SYSTEM LOCATION DIAGRAM INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1. VSS (Installed on transfer) Injector A: ECM 2. MAF sensor (built-in intake air temp. sensor) Radiator fan relay 1 (High / Low) B: Pre post heating relay (control unit) 3.
Page 285: System Wiring Diagram
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-7 SYSTEM WIRING DIAGRAM For Vehicle Equipped with Single-Connector ECM...
Page 286 6E3-8 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) ECM CONNECTOR (TERMINAL ARRANGEMENT VIEWED FROM HARNESS SIDE) 1. ECM 2. ECM connector 1. Pre post heating relay (control unit) 14. Engine coolant temperature sensor 28. Glow indicator lamp 2. Glow plugs 15.
Page 287 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-9 For Vehicle Equipped with Triple-Connector ECM...
Page 288 6E3-10 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) ECM CONNECTOR (TERMINAL ARRANGEMENT VIEWED FROM HARNESS SIDE) 1. Pre post heating relay (control unit) 14. Engine coolant temperature sensor 28. Glow indicator lamp 2. Glow plugs 15. Crankshaft position sensor 29. Brake lamp switch 3.
Page 289: On-Vehicle Service
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-11 ON-VEHICLE SERVICE ACCELERATOR CABLE ADJUSTMENT 1) Check accelerator pedal play which should be within following specification. If measured value is out of specification, adjust it to specification with cable adjusting nut (1). Pedal play “a”: 2 –...
Page 290: Air Intake System
6E3-12 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) AIR INTAKE SYSTEM VACUUM HOSE ROUTING DIAGRAM 1. Vacuum pump 2. Throttle valve assembly 3. Intake air pressure sensor 4. EGR valve 5. EGR throttle solenoid valve 6. EGR solenoid valve 7. Boost (Turbo) pressure regulator solenoid valve 8.
Page 291: Intercooler
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-13 INTERCOOLER 1. Intercooler 2. Clamp 3. Intercooler outlet hose 4. Intercooler inlet hose REMOVAL 1) Loosen intercooler hose clamps. 2) Remove intercooler. INSTALLATION For installation, reverse removal procedure.
Page 292: Throttle Valve Assembly
6E3-14 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) THROTTLE VALVE ASSEMBLY INSPECTION 1) Remove intercooler and intercooler outlet hose. 2) Connect a vacuum pump gauge (Special Tool) to throttle valve assembly (1). Special Tool (A): 09917-47910 3) Gradually increase vacuum and check for throttle valve (2) op- eration.
Page 293: Egr Throttle Solenoid Valve
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-15 EGR THROTTLE SOLENOID VALVE REMOVAL 1) Disconnect negative cable at battery. 2) Remove air cleaner outlet hose. 3) Disconnect connector from throttle solenoid valve (1). 4) Disconnect vacuum hoses from throttle solenoid valve. 5) Remove throttle solenoid valve from bracket.
Page 294: Turbocharger
6E3-16 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) TURBOCHARGER 25 N (2.5 kg-m, 18.0 lb-ft) 30 N (3.0 kg-m, 22.0 lb-ft) 25 N (2.5 kg-m, 18.0 lb-ft) 20 N m (2.0 kg-m, 14.5 lb-ft) 1. Air cleaner outlet hose 2. Turbocharger outlet pipe 3.
Page 295 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-17 6) Remove turbocharger outlet pipe bolts and nuts. 7) Remove turbocharger bracket bolt (1). 8) Disconnect oil return pipe (2) and lubrication pipe (3) from turbocharger. 9) Remove EGR pipe referring to “EGR VALVE” in this section. 10) Remove exhaust manifold nuts (1).
Page 296: Boost Pressure Regulator Solenoid Valve
6E3-18 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) BOOST PRESSURE REGULATOR SOLENOID VALVE REMOVAL 1) Disconnect negative cable at battery. 2) Remove air cleaner outlet hose. 3) Disconnect connector from boost pressure regulator solenoid valve (1). 4) Disconnect vacuum hoses from boost pressure regulator sole- noid valve.
Page 297: Glow Plug
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-19 GLOW PLUG REMOVAL CAUTION: D Do not damage heating section of the glow plug. D Do not use glow plug that has been dropped from height of over 10 cm (4 in.). D When removing glow plug, first loosen it by using a tool so that one or more screw threads remain engaged, then loosen and remove by hand.
Page 298: Fuel Delivery System
6E3-20 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) FUEL DELIVERY SYSTEM WARNING D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage.
Page 299 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-21 30 N (3.0 kg-m, 22.0 lb-ft) 20 N (2.0 kg-m, 14.5 lb-ft) 1. Fuel injector 2. Sealing ring 3. Copper seal 4. Nut 5. Washer 6. Injector clamp 20 N 7.5 N 7.
Page 300: Low Pressure Fuel Supply System
6E3-22 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) LOW PRESSURE FUEL SUPPLY SYSTEM INSPECTION 1) Disconnect fuel feed hose (1) from fuel feed pipe. CAUTION: A small amount of fuel may be released when fuel feed hose is removed. Place container under the fuel feed hose or fuel feed pipe with a shop cloth so that released fuel is caught in container or absorbed in cloth.
Page 301: Fuel Pump
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-23 FUEL PUMP ON-VEHICLE INSPECTION 1) Check that fuel pump operating sound is heard from fuel pump for 5 seconds and then stop when turning on ignition switch. If above check result is not satisfactory, advance to “Diagnostic Flow Table B-1”...
Page 302: Fuel Injector
6E3-24 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) FUEL INJECTOR NOTE: There are two types of the fuel injector depending on the engine. When the fuel injector(s), one, two, three or all, is replaced, identify the fuel injector type by the identification mark “1” or “2”...
Page 303 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-25 5) Disconnect return hose (1) from injector. 6) Remove high pressure pipe. When loosening union nut of high pressure pipe, hold union nut of injector with wrench as shown. Special Tool (A): 09950-76510/OUT0000148 7) Remove nut (1) and washer (2), then remove injector (3) with its clamp (4).
Page 304 6E3-26 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) INSTALLATION 1) Install stud bolt (1) to cylinder head, if removed. Tightening Torque Fuel injector stud bolt (a): 7.5 N m (0.8 kg-m, 5.5 lb-ft) 2) Install new copper seal (2) and new sealing ring (3). 3) Install injector (4) with its clamp (5) to cylinder head.
Page 305: Common Rail
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-27 10) Install intercooler referring to “INTERCOOLER” in this section. 11) Connect negative cable at battery. 12) Check that fuel is not leaking by performing the procedure be- low. (1) Start engine and warm up to normal operating temperature. (2) Check fuel leakage after turning off ignition switch.
Page 306 6E3-28 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 8) Remove common rail (1). 9) Remove fuel pressure sensor (2) from common rail. INSTALLATION 1) Install fuel pressure sensor (2) to common rail (1). Tighten fuel pressure sensor to specified torque referring to “FUEL PRESSURE SENSOR”...
Page 307 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-29 6) Tighten union nuts of high pressure supply pipe and high pres- sure pipes to specified torque. When tightening each union nut, hold union nuts of injector and injection pump with wrench as shown. Special Tool (A): 09950-76510/OUT0000148 Tightening Torque...
Page 308: Injection Pump
6E3-30 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) INJECTION PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect each connector and detach wire harness protector (1). 3) Remove timing belt referring to “TIMING BELT AND BELT TEN- SIONER” in Section 6A3. 4) Loosen injection pump pulley nut (1) with pulley locked by using special tool.
Page 309 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-31 INSPECTION Fuel Pressure Regulator Check resistance between terminals of fuel pressure regulator. If found faulty, replace injection pump. Resistance of fuel pressure regulator: 2 – 3 Ω INSTALLATION For installation reverse removal procedure noting the following. D When tightening union nut of high pressure supply pipe, hold union nut of injection pump with wrench.
Page 310: Electronic Control System
6E3-32 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) ELECTRONIC CONTROL SYSTEM ENGINE CONTROL MODULE (ECM) CAUTION: As ECM consists of precision parts, be careful not to ex- pose it to excessive shock. For Vehicle Equipped with Single-Connector ECM REMOVAL 1) Disconnect negative cable at battery. 2) Disable air bag system (if equipped) referring to “Disabling the Air Bag System”...
Page 311 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-33 For Vehicle Equipped with Triple-Connector ECM REMOVAL 1) Disconnect negative cable at battery. 2) Disable air bag system (if equipped) referring to “Disabling the Air Bag System” in Air Bag System section. 3) Remove ECM cover clips and then remove ECM cover from bracket by pulling off the cover to the seat side.
Page 312: Mass Air Flow Sensor (Maf Sensor)
6E3-34 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) MASS AIR FLOW SENSOR (MAF SENSOR) INSPECTION NOTE: Use voltmeter with high-impedance (10 kΩ/V minimum) or dig- ital type voltmeter. 1) Connect voltmeter to “BLK/WHT” wire terminal of MAF sensor coupler disconnected and ground. 2) Turn ignition switch ON and check that voltage is battery volt- age.
Page 313: Throttle Position Sensor (Tp Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-35 3) Remove MAF sensor from air cleaner case. NOTE: Don’t disassemble MAF sensor. CAUTION: D Do not expose MAF sensor to any shock. D Do not blow compressed air by using air gun or the like. D Do not put finger or any other object into MAF sensor.
Page 314: Fuel Temperature Sensor Assembly
6E3-36 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) FUEL TEMPERATURE SENSOR ASSEMBLY REMOVAL 1) Disconnect negative cable at battery. 2) Remove intercooler referring to “INTERCOOLER” in this sec- tion. 3) Remove intercooler bracket (1). 4) Disconnect fuel temperature sensor connector, injector connec- tor, CMP sensor connector and injection pump solenoid valve connector.
Page 315 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-37 INSPECTION 1) Disconnect negative cable at battery. 2) Remove intercooler referring to “INTERCOOLER” in this sec- tion. 3) Remove fuel temperature sensor from its assembly. 4) Place sensor and a thermometer in water. Heat water gradually and verify that resistance between fuel temperature sensor ter- minals at following temperatures is as specified.
Page 316: Fuel (Rail) Pressure Sensor
6E3-38 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) FUEL (RAIL) PRESSURE SENSOR REMOVAL 1) Disconnect negative cable at battery. 2) Remove fuel filter assembly referring to Section 6C. 3) Disconnect connector from fuel pressure sensor (1). 4) Remove fuel pressure sensor from common rail (2). INSPECTION Measure resistance between sensor terminals (1) and (2).
Page 317: Engine Coolant Temperature Sensor (Ect Sensor)
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-39 ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system. 3) Remove intercooler and intercooler outlet hose. 4) Disconnect coupler (1) from ECT sensor. 5) Remove ECT sensor from water outlet box. INSPECTION Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals (1) and (2) while...
Page 318: Vss
6E3-40 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) ON-VEHICLE INSPECTION Check VSS and its circuits referring to flow table of diagnostic trouble code P0500 in following section. D For vehicle equipped with single-connector ECM : Section 6 D For vehicle equipped with triple-connector ECM : Section 6-1 REMOVAL, INSPECTION AND INSTALLATION Refer to “VSS Removal, Inspection and Installation”...
Page 319: Crankshaft Position Sensor
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-41 CRANKSHAFT POSITION SENSOR (ENGINE SPEED SENSOR) REMOVAL 1) Remove battery. 2) Disconnect connector from crankshaft position sensor. 3) Remove crankshaft position sensor (1) from transmission case. INSPECTION D Verify that resistance between terminals of CKP sensor is within specification.
Page 320: Absolute Pressure Sensor)
6E3-42 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) INTAKE AIR PRESSURE SENSOR (MANIFOLD ABSOLUTE PRESSURE SENSOR) REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect connector from intake air pressure sensor (1). 3) Remove intake air pressure sensor from strut tower bar. INSPECTION 1) Arrange 3 new 1.5 V batteries (2) in series and connect its posi- tive terminal to “Vin”...
Page 321: Radiator Fan Control System
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-43 RADIATOR FAN CONTROL SYSTEM System Inspection WARNING: Keep hands, tools, and clothing away from engine cooling fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch in the “ON”...
Page 322 6E3-44 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) RADIATOR FAN RELAY 1 (High/Low) Inspection 1) Disconnect negative cable at battery. 2) Remove radiator fan relay 1 (1) from bracket. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
Page 323 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-45 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay. 4) Connect battery positive (+) terminal to terminal “b” of relay. Connect battery negative (–) terminal “a” of relay. Check continuity between terminal “c”...
Page 324: Double Relay
6E3-46 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) DOUBLE RELAY REMOVAL 1) Disconnect negative cable at battery. 2) Remove double relay (1) from bracket. 3) Disconnect connector from double relay by pulling off lock (1). INSPECTION 1) Connect connector to double relay. 2) Remove “FUEL PUMP”...
Page 325: Pre Post Heating Relay (Control Unit)
ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-47 PRE POST HEATING RELAY (CONTROL UNIT) REMOVAL 1) Disconnect negative cable at battery. 2) Remove pre post heating control unit (1) from bracket. 3) Disconnect connector from pre post heating control unit by pushing lock (1).
Page 326: Egr System
6E3-48 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) EGR SYSTEM VACUUM HOSE INSPECTION Check hose for connection, leakage, clogs and deterioration. Re- place as necessary. EGR VALVE REMOVAL 1) Remove air cleaner outlet hose from turbocharger and MAF sensor. 2) Remove EGR pipe clamps (1) by using special tool. Special Tool (A): 09919-46510/OUT0000110 3) Remove EGR pipe (1) from EGR valve (2) and intake manifold.
Page 327 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-49 INSTALLATION For installation, reverse removal procedure noting the following. D Clean mating surfaces of EGR valve and exhaust manifold. D Use new gasket (1). D Tighten EGR valve nuts to specified torque. Tightening Torque EGR valve nut (a): 10 N m (1.0 kg-m, 7.5 lb-ft)
Page 328 6E3-50 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts kg-m lb-ft Vacuum pump bolt and nut 14.5 Exhaust manifold nut 18.0 Turbocharger nut 18.0 Turbocharger outlet pipe bolt and nut 22.0 Lubrication pipe union bolt 14.5 Glow plug Fuel injector clamp stud bolt...
Page 329 ENGINE AND EMISSION CONTROL SYSTEM (RHZ ENGINE) 6E3-51 SPECIAL TOOLS 1. 09912-58441 Pressure gauge 2. 09912-58431 Pressure hose 3. 09912-58450 Attachment 09912-58412 09912-58490 09916-50010 Fuel pressure gauge set 3 way joint and hose Fuel system, plug set 09919-56570 09919-56580 09917-47910 09919-46510 (OUT0000157) (OUT0000158)
Page 330 CRANKING SYSTEM 6G-1 SECTION 6G CRANKING SYSTEM (2.0 kW Reduction Type) NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION .
Page 331: General Description
6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT D The magnetic switch coils are magnetized when the ignition switch is closed.
Page 332: Starting Motor
CRANKING SYSTEM 6G-3 STARTING MOTOR The starting motor consists of parts shown in below. The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash. 1.
Page 333: Diagnosis
6G-4 CRANKING SYSTEM DIAGNOSIS Condition Possible Cause Correction Motor not running Operating sound of magnetic switch heard D Battery run down Recharge battery. D Battery voltage too low due to battery Replace battery. deterioration D Loose battery cable connections Retighten. D Burnt main contact point, or poor Replace magnetic switch.
Page 334: Unit Repair Overhaul
CRANKING SYSTEM 6G-5 UNIT REPAIR OVERHAUL DISMOUNTING AND REMOUNTING 1) Disconnect negative cable at battery. 2) Disconnect magnetic switch lead wire (“S” terminal) and battery cable from starting motor terminal (“B” terminal). 3) Remove strut tower bar. 4) Drain coolant. 5) Hoist vehicle.
Page 335: Inspection
6G-6 CRANKING SYSTEM INSPECTION 1. BRUSH D Check brushes for wear. Measure length of brushes and if below limit, replace brush. Brush length Standard 18.0 mm (0.71 in.) Limit 11.0 mm (0.43 in.) D Install brushes to each brush holder and check for smooth 1.
Page 336 CRANKING SYSTEM 6G-7 4. ARMATURE D Inspect commutator for dirt or burn. Correct with sandpaper or lathe, if necessary. D Check commutator for uneven wear with armature supported 1. Armature on V-blocks. If deflection of dial gauge pointer exceeds limit, 2.
Page 337 6G-8 CRANKING SYSTEM D Ground Test Check commutator and armature core. If there is continuity, ar- mature is grounded and must be replaced. D Open Circuit Test Check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced.
Page 338: Performance Test
CRANKING SYSTEM 6G-9 PERFORMANCE TEST CAUTION: Each test must be performed within 3 – 5 seconds to avoid coil from burning. 1) Pull-In Test Connect battery to magnetic switch as shown. Check that plunger and pinion move outward. If plunger and pinion don’t move, replace magnetic switch. NOTE: Before testing, disconnect lead wire from terminal “M”.
Page 339: Specifications
8 volts maximum REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Front bush D Plunger D Pinion drive lever SUZUKI SUPER GREASE A D Internal gear Lithium grease (99000-25010) D Planetary carrier shaft D Planetary gear D Ball TIGHTENING TORQUE SPECIFICATIONS...
Page 340 D Service on and around the air bag system components or wiring must be performed only by an au- thorized 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 341: Warning
6H-2 CHARGING SYSTEM ON-VEHICLE SERVICE GENERATOR BELT WARNING: Disconnect negative cable at battery before inspection, re- moving and installing Generator belt. INSPECTION D Verify that belt engages with pulley groove correctly. D Visually check for wear and damage on belt and pulley contact surface and damage on pulley.
Page 342 CHARGING SYSTEM 6H-3 2) With dynamic roller tensioner holes aligned by turning dynamic roller tensioner, insert special tool (B) into them. Special tool (B): 09919-56590/OUT0000142 1. Zero wear mark 2. Maximum wear mark 3) Loosen roller tensioner bolt (1) using special tool (C). Special tool (C): 09919-56620 4) Remove generator belt.
Page 343: Unit Repair Overhaul
6H-4 CHARGING SYSTEM 3) Using special tool (C), turn roller tensioner counterclockwise to until special tool (B) becomes free. With roller tensioner kept in that state, fix it by tightening roller tensioner bolt (1) to specified torque. Special tool (B): 09919-56590/OUT0000142 (C): 09919-56620 Tightening torque (a): 50 N...
Page 344: Disassembly And Reassembly
CHARGING SYSTEM 6H-5 DISASSEMBLY AND REASSEMBLY D Disassemble in numerical order shown in figure below and note the following. D For reassembly, reverse disassembly procedure. 1. Rear cover 2. D+ contact with capacitor 3. Rectifier 4. Regulator 5. Cover 6. Stator 7.
Page 345: Specifications
6H-6 CHARGING SYSTEM SPECIFICATIONS GENERATOR Type 150 A type Rated voltage 12 V Nominal output 150 A SPECIAL TOOLS 09919-56610/ OUT0000143 09919-56590/ OUT0000142 09919-56620 09932-96510 Belt tension lever Belt tensioner pin Belt tension adjuster wrench Pulley remover attachment...
Page 346: Exhaust System
EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS GENERAL DESCRIPTION ..............6K-1 MAINTENANCE .
Page 347 6K-2 EXHAUST SYSTEM MAINTENANCE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system as follows: D Check rubber mountings for damage, deterioration, and out of position.
Page 348 EXHAUST SYSTEM 6K-3 ON-VEHICLE SERVICE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. EXHAUST MANIFOLD Refer to “TURBOCHARGER”...
Page 349: Manual Transmission
MANUAL TRANSMISSION 7A2-1 SECTION 7A2 MANUAL TRANSMISSION CONTENTS GENERAL DESCRIPTION ....7A2- 2 MAIN SHAFT ASSEMBLY ... 7A2-26 COMPONENTS .
Page 350: General Description
7A2-2 MANUAL TRANSMISSION GENERAL DESCRIPTION The manual transmission consists of the input shaft, main shaft, countershaft and reverse idler shaft which are installed in the die-cast aluminum alloy and cast-iron cases. This transmission provides five forward speeds and one reverse speed. The 1st, 2nd and 3rd speeds are for speed reduction drive, 4th speed is for direct drive and 5th speed is for over drive.
Page 351: Components
MANUAL TRANSMISSION 7A2-3 COMPONENTS 1. Input shaft 2. Clutch release bearing 3. Clutch release fork 4. Clutch operating cylinder 5. Main shaft 3rd gear 6. Main shaft 2nd gear 7. Main shaft low gear 8. Front case 9. Main shaft reverse gear 10.
Page 352: Diagnosis
7A2-4 MANUAL TRANSMISSION DIAGNOSIS DIAGNOSIS TABLE Condition Possible Cause Correction Gear slipping out of Worn shift fork shaft Replace. mesh Worn shift fork or synchronizer sleeve Replace. Weak or damaged locating spring Replace. Worn bearings on input shaft or main shaft Replace.
Page 353: On-Vehicle Service
MANUAL TRANSMISSION 7A2-5 ON-VEHICLE SERVICE GEAR OIL INSPECTION AND CHANGE 1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally. 2) With vehicle lifted up, check oil level and leakage. If leakage ex- ists, correct or repair it. 3) Drain old oil and fill new specified oil as shown below by speci- fied amount (roughly up to level hole).
Page 354: Shift Control Levers
7A2-6 MANUAL TRANSMISSION SHIFT CONTROL LEVERS REMOVAL 1) Remove 4 screws at the front and rear and 2 clips at the center then take off front and rear center console boxes. NOTE: To remove clip, push in its center pin first. 2) Remove console box bracket (2) by removing bolts (1).
Page 355 MANUAL TRANSMISSION 7A2-7 3) If control lever locating bolts (1) are replaced or retightened, torque them as specified below. Replacing of control lever locating bolts (1) requires thread lock cement. “B”: Cement 99000-32110 Tightening torque Control lever locating bolt (a): 17 N m (1.7 kg-m, 12.5 lb-ft) 4) Apply grease to pivot portions and seat, then install shift control...
Page 356: Switches
7A2-8 MANUAL TRANSMISSION SWITCHES TRANSFER 4WD SWITCH REMOVAL AND INSTALLATION 1) Remove console box and lift transmission control lever boots No.2 and No.3. (Refer to “SHIFT CONTROL LEVERS” in this section.) 2) Remove transfer control lever boot No.2 (3), unclamp wiring on transfer case to free it and pull off coupler (1).
Page 357: 4Wd Switch And Back Up Light Switch Inspection
MANUAL TRANSMISSION 7A2-9 3) Replace back up light switch (1), connect and clamp as they were. Tightening torque Back up light switch (a): 45 N m (4.5 kg-m, 32.5 lb-ft) 4) Check switch for proper function with ignition switch turned ON and gear shifted to reverse position.
Page 358: Engine Rear Mounting
7A2-10 MANUAL TRANSMISSION ENGINE REAR MOUNTING When replacement of mounting parts are necessary, torque bolts as specified below. Tightening torque Engine rear mounting bolts (a): 50 N m (5.0 kg-m, 36.5 lb-ft) Engine rear mounting member bolts (b): 50 N m (5.0 kg-m, 36.5 lb-ft) [A]: Front side 1.
Page 359 MANUAL TRANSMISSION 7A2-11 ON LIFT 1) Drain oil from transmission and transfer. 2) Remove starting motor. 3) Give match marks (1) on joint flange and propeller shaft (3) as shown in figure. (front and rear) 4) Remove flange bolts (2) of rear propeller shaft universal joint and pull out propeller shaft (3).
Page 360 7A2-12 MANUAL TRANSMISSION 11) Lower transmission jack slowly, remove it from transmission and install auxiliary arm (2) to transmission jack (1). 12) Raise transmission jack until it touches transmission. 13) Disconnect couplers from 4WD switch, back up light switch and speed sensor assembly and release their harness from clamps.
Page 361: Remounting Of Transmission Unit
MANUAL TRANSMISSION 7A2-13 REMOUNTING OF TRANSMISSION UNIT Reverse dismounting procedure for remounting, and then note the following instruction. D Slant the rear of the engine down, using support device (1) and install transmission to engine. D Use specified torques as given below. Tightening torque Transmission to engine bolts and nuts (a): 55 N...
Page 362: Unit Repair
7A2-14 MANUAL TRANSMISSION UNIT REPAIR TRANSMISSION CASE COMPONENTS : Tightening Torque : Do not Reuse 1. Clutch housing 10. Oil plate bolt 15. 5th-reverse interlock cam comp. 2. Input shaft bearing retainer : Apply thread lock 99000-32110 to 16. Return spring low bolt : Apply sealant 99000-31110 to all around thread part of bolt.
Page 363: Input And Counter Shaft Components
MANUAL TRANSMISSION 7A2-15 INPUT AND COUNTER SHAFT COMPONENTS 1. Input shaft 2. Input shaft bearing 3. Input shaft roller bearing : Apply grease 99000-25010 to bearing roller. 4. Circlip 5. C-ring 6. 4th gear synchronizer ring 7. High speed sleeve 8.
Page 364: Gear Shifter Components
7A2-16 MANUAL TRANSMISSION GEAR SHIFTER COMPONENTS 1. Low gear shift shaft 2. Low speed gear shift fork 3. High and low speed gear shift fork bolt : Apply thread lock 99000-32110 to all around thread part of bolt. 4. Interlock pin 5.
Page 365: Unit Disassembly
MANUAL TRANSMISSION 7A2-17 UNIT DISASSEMBLY GEAR SHIFT LEVER CASE ASSEMBLY 1) Remove case plate. 2) With case supported with soft jawed vise, remove lever locating bolts (6). NOTE: Use aluminum plates between vise and case to protect case against damage. 3) Using special tool, drive spring pin (2) into gear shift arm (5) as far as the position shown in the figure.
Page 366 7A2-18 MANUAL TRANSMISSION 2) Remove back-up light switch (1). 3) Remove return spring low bolt (1) and return spring reverse bolt (2). 4) Remove gear shift shaft inner bolt (1) and plug (2). 5) Using bolt hole, pull gear shift inner shaft (2) and then remove gear shift shaft inner lever (1).
Page 367 MANUAL TRANSMISSION 7A2-19 6) After removing transmission case bolts, tapping transmission rear case (1) flanges with plastic hammer, remove transmission rear case. 7) Remove input shaft bearing retainer (1). 8) Remove C-ring (1) of input shaft bearing and C-ring (2) of count- er shaft front bearing.
Page 368 7A2-20 MANUAL TRANSMISSION 11) Remove locating screws (1), locating springs (2) and locating balls (3) as shown in the figure. 12) Remove low speed gear shift fork bolt (1). 13) Remove low gear shift shaft (2) and low speed gear shift fork (1).
Page 369 MANUAL TRANSMISSION 7A2-21 16) Remove high speed gear shift fork bolt (1). 17) Remove high speed gear shift shaft (2) and high speed gear shift fork (1). 18) Remove interlock pin (1) by using magnet (2). 19) After removing straight plug screw (1), remove compression spring (2) and ball (3) by using magnet from reverse gear shift link comp.
Page 370 7A2-22 MANUAL TRANSMISSION 21) Remove 5th & reverse guide shaft (1) from intermediate case (2). NOTE: When pulling 5th & reverse guide shaft (1), place hand so as to catch straight pin (3) dropping from reverse gear shift link comp. (4). 22) Remove circlip (1) from 5th gear shift shaft (2) as shown in the figure.
Page 371 MANUAL TRANSMISSION 7A2-23 26) Remove oil plate mounting bolts (1) and then remove oil plate (2) from intermediate case. 27) Remove circlip (1) from counter shaft. Special tool (A): 09900-06107 28) Remove bearing (1), spacer (2), counter shaft 5th gear (3) and counter shaft 5th gear needle bearing by using puller (4).
Page 372 7A2-24 MANUAL TRANSMISSION 31) Remove 5th & reverse synchronizer hub (1) by using puller (2). 32) Remove circlip (1) from main shaft (2) as shown in the figure. 33) Remove output bearing (1) and 5th gear (2) by using special tool.
Page 373 MANUAL TRANSMISSION 7A2-25 36) Remove C-ring (1) of counter shaft bearing and C-ring (2) of main shaft bearing. Special tool (A): 09900-06107 37) Pull off input shaft assembly (1), main shaft assembly (2) and counter shaft assembly (3) together from intermediate case (4) as shown in the figure.
Page 374: Input Shaft Assembly
7A2-26 MANUAL TRANSMISSION INPUT SHAFT ASSEMBLY Remove circlip of input shaft (1) and pull out bearing (2) with puller (3) and press. CAUTION: Sealed bearing must not be washed. MAIN SHAFT ASSEMBLY 1) Pull out needle bush (1), needle bearing (2), main shaft bearing (3) and low gear (4) together by using puller (5) and press (6).
Page 375: Counter Shaft Assembly
MANUAL TRANSMISSION 7A2-27 4) Remove circlip from front part of main shaft and pull out 3rd gear (1), needle bearing, 3rd gear synchronizer outer ring, cone ring, inner ring and high speed synchronizer sleeve/hub assembly (2) together by using puller (3) and press (4). 5) Remove high speed synchronizer sleeve from high speed syn- chronizer hub and then remove keys (1) and springs from high speed synchronizer hub by using slotted screwdriver or the like...
Page 376: 5Th And Reverse Synchronizer Ring
7A2-28 MANUAL TRANSMISSION 5TH AND REVERSE SYNCHRONIZER RING 1) Turn 5th gear synchronizer pull ring (1) around 45 degrees and then remove 5th gear synchronizer pull ring and 5th gear syn- chronizer cone ring from 5th gear synchronizer outer ring. 2) Remove 5th gear synchronizer outer ring from reverse brake ring (1) and then remove keys (2) and springs from reverse brake ring by using slotted screw driver or the like as shown in...
Page 377: Components Inspection
MANUAL TRANSMISSION 7A2-29 3) Remove pin by using special tool. Special tool (A): 09922-85811 4) Pull out interlock cam component (1). COMPONENTS INSPECTION INPUT SHAFT ASSEMBLY Check clearance “a” between synchronizer ring and gear, width of index protrusion “b” in synchronizer ring, key slot width “c” in high speed synchronizer hub and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary.
Page 378: Main Shaft Assembly
7A2-30 MANUAL TRANSMISSION MAIN SHAFT ASSEMBLY Check clearance “a” between synchronizer ring and gear, width of index protrusion “b” in synchronizer ring, key slot width “c” in high and low speed synchronizer hub and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Page 379 8MANUAL TRANSMISSION 7A2-31 D Check diameter of main shaft (1)/needle bush (2) and thickness of main shaft (1)/needle bush (2) flanges as shown in the figure. If measured value is out of specification, replace them (or it). Main shaft/needle bush specification (diameter and thickness): Measuring portion Standard...
Page 380: Counter Shaft And Reverse Idle Gear
7A2-32 MANUAL TRANSMISSION D Check 2nd gear (1) thrust clearance by using thickness gauge (2). If clearance is out of specification, repress or replace weary part. 2nd gear thrust clearance: Standard: 0.10 – 0.25 mm (0.004 – 0.009 in.) D Check low gear (1) thrust clearance by using thickness gauge (2). If clearance is out of specification, repress or replace weary part.
Page 381 MANUAL TRANSMISSION 7A2-33 D Using cylinder gauge (1), check inside diameter of counter shaft 5th gear (2). If measured value exceeds specification, replace gear. Counter shaft 5th gear diameter: Standard: 33.000 – 33.025 mm (1.2992 – 1.3002 in.) D Check oil clearance between reverse idle gear (2) and shaft (1) by measuring inside diameter of gear and diameter of shaft and calculate its clearance.
Page 382: Unit Assembly
7A2-34 MANUAL TRANSMISSION UNIT ASSEMBLY GEAR SHIFT LEVER CASE ASSEMBLY 1) Wash and inspect each part and replace if necessary. Also check item as described below and correct whatever necessary carefully by using reamer, oilstone and the like, wash it thor- oughly and reassemble it.
Page 383: Input Shaft Assembly
MANUAL TRANSMISSION 7A2-35 8) Install gear shift lever case (2) to transmission without using sealant for functional check. 9) Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in the figure. NOTE: D Apply thread lock cement “C”...
Page 384: Main Shaft Assembly
7A2-36 MANUAL TRANSMISSION 3) Apply grease to bearing roller (1) and install it to input shaft (2). Grease: 99000-25010 MAIN SHAFT ASSEMBLY NOTE: D Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear. D Use new circlips on shaft for installation.
Page 385 MANUAL TRANSMISSION 7A2-37 b) Align protrusion of synchronizer outer ring (2) into groove of synchronizer inner ring (1), then install synchronizer outer ring to 3rd gear (3) as shown in the figure. c) Align protrusion of synchronizer outer ring (1) into slot of syn- chronizer hub (2), and then attach high speed synchronizer sleeve and hub assembly to 3rd gear (3).
Page 386 7A2-38 MANUAL TRANSMISSION 6) Check 3rd gear (2) thrust clearance by using thickness gauge (1). If clearance is out of specification, repress or replace weary part. 3rd gear thrust clearance: Standard: 0.10 – 0.25 mm (0.004 – 0.009 in.) 7) Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
Page 387 MANUAL TRANSMISSION 7A2-39 c) Install 2nd gear (3), fitting slot of low speed synchronizer hub (1) in protrusion of synchronizer outer ring (2) as shown in the figure. 9) Install the needle bearing to the 2nd gear, then as the figure shows press fit 2nd gear low speed synchronizer sleeve and hub assembly (1), which was assembled in step “a”...
Page 388: Counter Shaft Assembly
7A2-40 MANUAL TRANSMISSION COUNTER SHAFT ASSEMBLY 1) Install counter shaft bearing (1) to counter shaft (2). 2) Set inner race (2) to counter shaft front bearing (1) and press-fit bearing with press and special tool. NOTE: When installing bearing, bring it so that its groove for circlip is in the front.
Page 389: Input Shaft Bearing Retainer And Oil Seal
MANUAL TRANSMISSION 7A2-41 INPUT SHAFT BEARING RETAINER AND OIL SEAL Install new oil seal (2) to bearing retainer (1) by using special tool as shown in the figure. Apply grease to oil seal lip. Grease: 99000-25010 Special tool (A): 09913-75821 (B): 09924-84510-004 TRANSIMISSION REAR CASE 1) Check that interlock cam component (1) moves smoothly in both...
Page 390: Transmission Intermediate Case And Front Case (Location Of Knock And Plug)
7A2-42 MANUAL TRANSMISSION 4) Apply sealant to thread of interlock cam plug (1) and tighten it to specification. “A”: Sealant 99000-31110 Tightening torque Interlock cam plug (a): 25 N m (2.5 kg-m, 18.0 lb-ft) 5) Install oil seal to rear case so that end surface of oil seal be- comes flush with that case.
Page 391 MANUAL TRANSMISSION 7A2-43 TRANSMISSION UNIT NOTE: D Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear. D Use new circlips on shaft for installation. Don’t reuse cir- clips. 1) Set intermediate case (1) to vise (3). Clean mating surfaces of intermediate case both sides, if inter- mediate case is reused.
Page 392 7A2-44 MANUAL TRANSMISSION 4) Align key slot of high speed synchronizer hub and protrusion of synchronizer ring and set input shaft assembly to main shaft as- sembly. Check that input assembly turns lightly. 5) Install counter shaft (1) and counter shaft bearing outer race (2) to intermediate case.
Page 393 MANUAL TRANSMISSION 7A2-45 8) Install reverse gear (1). 9) Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it. Circlip thickness specification: ID mark Circlip thickness 2.25 – 2.30 mm (0.0886 – 0.0905 in.) 2.30 –...
Page 394 7A2-46 MANUAL TRANSMISSION 11) Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it. Circlip thickness specification: ID mark Circlip thickness 2.31 – 2.36 mm (0.0909 – 0.0929 in.) 2.37 – 2.42 mm (0.0930 – 0.0952 in.) 2.43 –...
Page 395 MANUAL TRANSMISSION 7A2-47 14) Assemble reverse brake ring (1), springs (2), keys (3), 5th gear synchronizer outer ring (4), 5th gear synchronizer cone ring (5) and 5th gear synchronizer pull ring (6) according to the follow- ing procedure. a) Install springs (1) and keys (2) to reverse brake ring (3) as shown in the figure.
Page 396 7A2-48 MANUAL TRANSMISSION e) Turn 5th gear synchronizer pull ring (1) around 45 degrees as shown in the figure. f) Make sure that position of 5th gear synchronizer pull ring protrusion (1) is in the same position as the figure shows. It isn’t, turn 5th gear synchronizer pull ring again, setting the same position as figure shows.
Page 397 MANUAL TRANSMISSION 7A2-49 18) Install spacer and needle bearing (1). 19) Press-fit thrust washer (1) and counter shaft bearing (2) to counter shaft with press (3) and special tool. Special tool (A): 09940-54950 20) Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it.
Page 398 7A2-50 MANUAL TRANSMISSION 22) Install oil plate (1) to intermediate case. “A”: Cement 99000-32110 Tightening torque Oil plate mounting bolts (a): 19 N m (1.9 kg-m, 14.0 lb-ft) 23) Insert reverse idler shaft (2) into reverse idler gear (1) and inter- mediate case.
Page 399 MANUAL TRANSMISSION 7A2-51 27) Apply grease to straight pin (1) and install straight pin (1) to re- verse gear shift link comp. (2). “A”: Grease 99000-25010 28) Insert 5th reverse guide shaft (3) into intermediate case. 29) Install stopper (1) to intermediate case. “A”: Cement 99000-32110 Tightening torque Stopper mounting bolt (a): 25 N...
Page 400 7A2-52 MANUAL TRANSMISSION 33) Insert high gear shift shaft (1) into intermediate case (3) and high speed gear shift fork (2). 34) Apply thread lock cement to thread of fork bolt and tighten bolt to specification. “A”: Cement 99000-32110 Tightening torque High speed gear shift fork bolt (a): 20 N m (2.0 kg-m, 14.5 lb-ft)
Page 401 MANUAL TRANSMISSION 7A2-53 38) Apply thread lock cement to thred of fork bolt and tighten bolt to specification. “A”: Cement 99000-32110 Tightening torque Low speed gear shift fork bolt (a): 20 N m (2.0 kg-m, 14.5 lb-ft) 39) Install locating balls, locating springs and locating screws. “A”: Sealant 99000-31110 Tightening torque Locating spring screws (a): 25 N...
Page 402 7A2-54 MANUAL TRANSMISSION 44) Apply sealant to input shaft bearing retainer bolt and install in- put shaft bearing retainer (1), new gasket and its bolts. “A”: Sealant 99000-31110 Tightening torque Input shaft bearing retainer bolts (a): 25 N m (2.5 kg-m, 18.0 lb-ft) 45) Clean mating surface of rear case and apply sealant evenly to rear case side of intermediate case in the same manner as Step 41).
Page 403 MANUAL TRANSMISSION 7A2-55 48) Apply cement “A” to inner gear shift shaft bolt and plug and tighten them to specification. “A”: Cement: 99000-32110 Tightening torque Gear shift shaft inner bolt (a): 40 N m (4.0 kg-m, 29.0 lb-ft) Gear shift shaft inner plug (b): 19 N m (1.9 kg-m, 14.0 lb-ft) 49) Tighten return spring low bolt (Yellow) (2) and return spring re- verse bolt (Black) (1).
Page 404: Required Service Material
REQUIRED SERVICE MATERIAL Recommended SUZUKI product Material Material (Part Number) D Oil seal lips Lithium grease SUZUKI SUPER GREASE A D Gear shift lever bush (99000-25010) D Input shaft bearing roller D Straight pin D Straight plug screw Thread lock cement...
Page 405: Special Tool
MANUAL TRANSMISSION 7A2-57 SPECIAL TOOL 09913-75520 09940-51710 09940-54950 09913-75821 Bearing installer Bearing installer Bearing installer attachment Installer attachment 09924-84510-004 09925-78210 (6 mm) 09922-85811 (4.5 mm) 09940-53111 Bearing installer adapter (C) Spring pin remover Spring pin remover Bearing installer 09926-36510 09926-36510-001 09900-06107 09925-18011 Bearing remover...
Page 406 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 407 7B1-2 AUTOMATIC TRANSMISSION (4 A / T) DTC P0715 INPUT/TURBINE SOLENOID VALVES (SHIFT SPEED SENSOR CIRCUIT SOLENOID VALVES AND TCC MALFUNCTION ....7B1- 42 SOLENOID VALVE) .
Page 408: General Description
AUTOMATIC TRANSMISSION (4 A / T) 7B1-3 GENERAL DESCRIPTION This automatic transmission is a full automatic type with 3-speed plus overdrive (O/D). The torque converter is a 3-element, 1-step and 2-phase type and is equipped with an electronically controlled lock-up mechanism. The gear shift device consists of 3 sets of planetary gear units, 3 disc type clutches, 4 disc type brakes and 3 one-way clutches.
Page 409 7B1-4 AUTOMATIC TRANSMISSION (4 A / T) 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 410: Clutch/Brake Functions
AUTOMATIC TRANSMISSION (4 A / T) 7B1-5 CLUTCH/BRAKE FUNCTIONS 1. Overdrive clutch 2. Overdrive brake 3. Forward clutch 4. Direct clutch 5. Second coast brake 6. Second brake 7. Reverse brake 8. One-way clutch No.2 9. One-way clutch No.1 10. Overdrive one-way clutch 11.
Page 411: Table Of Component Operation
7B1-6 AUTOMATIC TRANSMISSION (4 A / T) TABLE OF COMPONENT OPERATION Element Reverse O / D One- One- Solenoid Solenoid Second O / D Forward Direct O / D Second one- brake valve-A valve A valve-B valve B coast coast clutch clutch clutch...
Page 412 AUTOMATIC TRANSMISSION (4 A / T) 7B1-7 ELECTRONIC SHIFT CONTROL SYSTEM The gear ratio change in “D” or “2” range and torque converter clutch operation are controlled by Transmission Control Module (TCM). Final gear Engine Torque converter Planetary gear reduction unit Oil pump Regulator valves Clutch and...
Page 413 7B1-8 AUTOMATIC TRANSMISSION (4 A / T) 1. TCM 8. 4WD low switch 15. A / T 22. Ignition switch 2. To tachometer 9. O / D off switch 16. Shift solenoid-A (Shift solenoid No.1) 23. Inhibitor switch 3. ECM 10.
Page 414: Operation Of Shift Solenoids And Tcc Solenoid
AUTOMATIC TRANSMISSION (4 A / T) 7B1-9 CHANGE MECHANISM The same select pattern shift lever is used as the floor type and fre- quently used “N” and “D” ranges are made selectable freely. [A]: Shift the select lever with its button pushed in. [B]: Shift the select lever without pushing its button.
Page 415 7B1-10 AUTOMATIC TRANSMISSION (4 A / T) 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 40 km/h or 25 mile/h speed, 2nd or 3rd gear is operated and then down shifts to 1st at a speed lower than that.
Page 416: Diagnosis
D When TCM detects a malfunction in A/T control system while the engine is running, it stores the malfunction area in its memory. D It is possible to communicate through DLC (2) by using SUZUKI scan tool (1). (Diagnostic information can be accessed by using a scan tool (1).)
Page 417: Precaution In Diagnosing Trouble
DTC stored in TCM memory. Such disconnection will clear memorized information in TCM memory. D Using SUZUKI scan tool, the diagnostic information stored in TCM memory can be checked and cleared as well. Before its use, be sure to read Operator’s (Instruction) Manual supplied with it carefully to have good understanding of its functions and usage.
Page 418: Automatic Transmission Diagnostic Flow Table
AUTOMATIC TRANSMISSION (4 A / T) 7B1-13 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 1) Perform customer complaint analysis referring complaint analysis.
Page 419 7B1-14 AUTOMATIC TRANSMISSION (4 A / T) 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 abnormal condition? STEP 1.
Page 420 AUTOMATIC TRANSMISSION (4 A / T) 7B1-15 STEP 10. CHECK FOR INTERMITTENT PROBLEM Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to “INTER- MITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in Step 2. STEP 11.
Page 421: O/D Off" Lamp Check
DIAGNOSTIC TROUBLE CODE (DTC) CHECK [Check DTC using SUZUKI scan tool] 1) Turn ignition switch OFF. 2) After setting cartridge, connect SUZUKI scan tool to data link connector (DLC) (1) located in underside of instrument panel at driver’s seat side.
Page 422 AUTOMATIC TRANSMISSION (4 A / T) 7B1-17 [Check DTC not using SUZUKI scan tool] 1) Turn ignition switch ON and make sure that “O/D OFF” lamp (1) is OFF in combination meter (with O/D off switch OFF). 2) Turn ignition switch OFF.
Page 423: Diagnostic Trouble Code Clearance
DIAGNOSTIC TROUBLE CODE CLEARANCE [Clear DTC using SUZUKI scan tool] 1) Turn ignition switch OFF 2) After setting cartridge, connect SUZUKI scan tool to data link connector (DLC) (1) located in underside of instrument panel at driver’s seat side. Special tool (A): SUZUKI scan tool 3) Turn ignition switch ON.
Page 424: Diagnostic Trouble Code Table
AUTOMATIC TRANSMISSION (4 A / T) 7B1-19 DIAGNOSTIC TROUBLE CODE TABLE SHIFT SOLENOID-A ELECTRICAL (CODE No.21) DTC NO. “O/D OFF” Lamp Flashing Detecting Items Pattern of DTC Using Not using (Not using scan tool) scan tool scan tool – Normal P0753 P0753 Shift solenoid-A (No 1) electrical...
Page 425: Fail Safe Table
7B1-20 AUTOMATIC TRANSMISSION (4 A / T) FAIL SAFE TABLE This function is provided by the safe mechanism that assures safe driveability even when the solenoid valve, sen- sor or its circuit fails. The table below shows the fail safe function for each fail condition of solenoid, solenoid or its circuit. DTC NO.
Page 426: Visual Inspection
AUTOMATIC TRANSMISSION (4 A / T) 7B1-21 VISUAL INSPECTION Visually check following parts and systems. INSPECTION ITEM REFERRING SECTION D A/ T fluid – – – – – level, leakage, color SECTION 0B D A/ T fluid hoses – – – – – disconnection, looseness, deterioration SECTION 7B1 D Accelerator cable –...
Page 427 7B1-22 AUTOMATIC TRANSMISSION (4 A / T) TROUBLE DIAGNOSIS TABLE 1 ELECTRICAL REPAIR Condition Possible cause Correction Inspect circuit for open, short and intermittent. Shift solenoid-B valve circuit faulty If NG, repair. Poor 1 ! 2 shift Poor 1 ! 2 shift Inspect referring to “DTC FLOW TABLE”of P0758 in this section.
Page 428: Trouble Diagnosis Table 1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-23 ELECTRICAL REPAIR (cont’d) Condition Possible cause Correction Pressure control solenoid valve Inspect circuit for open, short and intermittent. circuit faulty If NG, replace. Higher or lower stall speed Inspect referring to “DTC FLOW TABLE” of P0748 in this section.
Page 429 7B1-24 AUTOMATIC TRANSMISSION (4 A / T) TROUBLE DIAGNOSIS TABLE 3 OFF-VEHICLE REPAIR Condition Possible cause Correction Defect in torque converter Replace. Unable to run in all range Defective oil pump Inspect. If NG, replace. Seized or broken planetary gear Repair or replace.
Page 430: Road Test
AUTOMATIC TRANSMISSION (4 A / T) 7B1-25 ROAD TEST This test is to check if upshift and downshift take place at specified speed while actually driving vehicle on a level road. WARNING: D Carry out test in very little traffic area to prevent an accident. D Test requires 2 persons, a driver and a tester.
Page 431: Manual Road Test
7B1-26 AUTOMATIC TRANSMISSION (4 A / T) 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 vehicle on a level road. NOTE: Before this test, check diagnostic trouble code (DTC). 1) Disconnect shift solenoid connector (1) on transmission.
Page 432: Engine Brake Test
AUTOMATIC TRANSMISSION (4 A / T) 7B1-27 ENGINE BRAKE TEST WARNING: Before test, make sure that there is no vehicle behind so as to prevent rear-end collision. 1) While driving vehicle in 3rd gear of “D” range, shift select lever down to “2” range and check if engine brake operates.
Page 433 7B1-28 AUTOMATIC TRANSMISSION (4 A / T) TROUBLESHOOTING Condition Possible cause Correction Engine output torque failure Inspect and repair engine. Lower than standard level Defective one-way clutch of torque Replace. converter Defective pressure control solenoid Inspect. valve (Low line pressure) If NG, replace valve body assembly.
Page 434: Time Lag Test
AUTOMATIC TRANSMISSION (4 A / T) 7B1-29 TIME LAG TEST This test is to check conditions of clutch, reverse brake and fluid pressure. “Time lag” means time elapsed since select lever is shifted with engine idling till shock is felt. 1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
Page 435: Line Pressure Test
7B1-30 AUTOMATIC TRANSMISSION (4 A / T) 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. D Automatic fluid is at normal operating temperature (70 to 80 _C/ 158 –...
Page 436: "P" Range Test
AUTOMATIC TRANSMISSION (4 A / T) 7B1-31 TROUBLESHOOTING Condition Possible cause Correction Defective pressure control solenoid Inspect. Higher than standard level in valve If NG, replace valve body assembly. each range each range Defective primary regulator valve Replace valve body assembly. Defective pressure control solenoid Inspect.
Page 437 7B1-32 AUTOMATIC TRANSMISSION (4 A / T) TABLE A-1: NO GEAR SHIFT TO O/D SYSTEM DESCRIPTION TCM does not shift to O/D gear under any of the following conditions. D O/D off switch is ON. (“O/D OFF” lamp ON.) D 4WD low switch is ON. D Output shaft speed sensor is in faulty condition.
Page 438 AUTOMATIC TRANSMISSION (4 A / T) 7B1-33 TABLE A-2: NO LOCK-UP OCCURS SYSTEM DESCRIPTION TCM turns TCC solenoid OFF under any of the following conditions. D Brake light switch is ON. D 4WD low switch is ON. D Transmission fluid temperature sensor circuit is in faulty condition. (P0710) D Input shaft speed sensor is in faulty condition.
Page 439: O/D
7B1-34 AUTOMATIC TRANSMISSION (4 A / T) TABLE B-1: “O/D OFF” LAMP CIRCUIT CHECK (“O/D OFF” LAMP DOESN’T LIGHT AT IGNITION SWITCH ON) WIRING DIAGRAM 1. “O / D OFF” lamp 2. TCM 3. O / D off switch 4. To ignition 5.
Page 440 AUTOMATIC TRANSMISSION (4 A / T) 7B1-35 TABLE B-2: “O/D OFF” LAMP CIRCUIT CHECK (“O/D OFF” LAMP 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 441: Inspection Of Tcm And Its Circuits
7B1-36 AUTOMATIC TRANSMISSION (4 A / T) INSPECTION OF TCM AND ITS CIRCUITS TCM and its circuits can be checked at TCM wiring connectors by measuring voltage and resistance. CAUTION: TCM cannot be checked by itself, it is strictly prohibited to connect voltmeter or ohmmeter to TCM with connector dis- connected from it.
Page 442: Malfunction
AUTOMATIC TRANSMISSION (4 A / T) 7B1-37 DTC P0705 (DTC NO.34)TRANSMISSION RANGE SENSOR (SWITCH) CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. Transmission range sensor (switch) 3. Fuse box 4. To ignition DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Transmission range switch signal (P, R, N, D, 2 or L) D Transmission range sensor (switch) maladjusted.
Page 443 Go to Step 5. for operation. Check for intermittent Check by using SUZUKI scan tool: referring to 1) Connect SUZUKI scan tool to DLC with ignition “INTERMITTENT AND switch OFF. POOR CONNECTION” 2) Turn ignition switch ON and check transmission in Section 0A.
Page 444 AUTOMATIC TRANSMISSION (4 A / T) 7B1-39 Fig. for Step 3 Terminal E202-2 E202-1 E202-9 E202-8 E202-21 E202-20 Select lever position B + V B + V B + V B + V B + V B + V...
Page 445 7B1-40 AUTOMATIC TRANSMISSION (4 A / T) DTC P0710 (DTC NO.36/38) TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. Transmission fluid temperature sensor 2. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Engine speed is more than 400 rpm and engine...
Page 446 AUTOMATIC TRANSMISSION (4 A / T) 7B1-41 TROUBLESHOOTING Step Action Was “A/T DIAGNOSTIC FLOW TABLE” in this Go to Step 2. Go to “A/T section performed? DIAGNOSTIC FLOW TABLE” in this section. Check transmission fluid temperature sensor Intermittent trouble or Go to Step 3.
Page 447: Malfunction
7B1-42 AUTOMATIC TRANSMISSION (4 A / T) DTC P0715 (DTC NO.37) INPUT/TURBINE SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. Input shaft speed sensor 3. Terminal arrangement of TCM connector (viewed from harness side) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA The following condition is detected for one minute...
Page 448 AUTOMATIC TRANSMISSION (4 A / T) 7B1-43 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 449 7B1-44 AUTOMATIC TRANSMISSION (4 A / T) REFERENCE Connect oscilloscope between E202-5 (+) and E202-17 (–) of TCM connector connected to TCM and check input shaft speed sensor signal. [A]: Oscilloscope waveforms at specified idle speed in “p” range...
Page 450: Dtc P0720 Output Speed Sensor Circuit Malfunction 7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-45 DTC P0720 (DTC NO.31) OUTPUT SPEED SENSOR CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. Output shaft speed sensor 3. Terminal arrangement of TCM connector (viewed from harness side) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Output shaft speed sensor or its circuit...
Page 451 7B1-46 AUTOMATIC TRANSMISSION (4 A / T) DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 452 AUTOMATIC TRANSMISSION (4 A / T) 7B1-47 REFERENCE Connect oscilloscope between E202-4 (+) and E202-16 (–) of TCM connector connected to TCM and check output shaft speed sensor signal. [A]: Oscilloscope waveforms at about 40 km / h (25 mile / h)
Page 453: Dtc P0725 Engine Speed Input Circuit Malfunction 7B1
7B1-48 AUTOMATIC TRANSMISSION (4 A / T) DTC P0725 (DTC NO.35) ENGINE SPEED INPUT CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. ECM 3. Terminal arrangement of TCM connector (viewed from harness side) 4. Terminal arrangement of ECM connector (viewed from harness side) [A] For vehicle equipped with single- connector ECM [B] For vehicle equipped with triple-...
Page 454 AUTOMATIC TRANSMISSION (4 A / T) 7B1-49 TROUBLESHOOTING Step Action Was “A/T DIAGNOSTIC FLOW TABLE” in this Go to Step 2. Go to “A/T section performed? DIAGNOSTIC FLOW TABLE” in this section. Check engine speed input circuit. Go to Step 3. “BRN”...
Page 455 7B1-50 AUTOMATIC TRANSMISSION (4 A / T) DTC P0743 (DTC NO.25/26) TCC (LOCK-UP) SYSTEM ELECTRICAL WIRING DIAGRAM GRN / YEL 1. A / T 2. TCC (Lock-up) solenoid 3. TCM 4. Terminal arrangement of TCM connector (viewed from harness side) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 456 AUTOMATIC TRANSMISSION (4 A / T) 7B1-51 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 457: Dtc P0748 Pressure Control Solenoid Electrical 7B1
7B1-52 AUTOMATIC TRANSMISSION (4 A / T) DTC P0748 (DTC NO.41/42) PRESSURE CONTROL SOLENOID ELECTRICAL WIRING DIAGRAM 1. Pressure control solenoid valve 2. TCM 3. Terminal arrangement of TCM connector (viewed from harness side) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA D Pressure control solenoid output voltage is too high...
Page 458 AUTOMATIC TRANSMISSION (4 A / T) 7B1-53 TROUBLESHOOTING Step Action Was “A/T DIAGNOSTIC FLOW TABLE” in this Go to Step 2. Go to “A/T section performed? DIAGNOSTIC FLOW TABLE” in this section. Check pressure control solenoid circuit for short. Go to Step 3. “BLU/ORN”...
Page 459: Electrical
7B1-54 AUTOMATIC TRANSMISSION (4 A / T) DTC P0753 (DTC NO.21/22)/ SHIFT SOLENOID-A/SHIFT SOLENOID-B P0758 (DTC NO.23/24) ELECTRICAL WIRING DIAGRAM 1. A / T 2. Shift solenoid-A 3. Shift solenoid-B 4. TCM 5. Terminal arrangement of TCM connector (viewed from harness side) DTC DETECTING CONDITION AND TROUBLE AREA DTC DETECTING CONDITION TROUBLE AREA...
Page 460 AUTOMATIC TRANSMISSION (4 A / T) 7B1-55 DTC CONFIRMATION PROCEDURE WARNING: D When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Page 461: Malfunction
7B1-56 AUTOMATIC TRANSMISSION (4 A / T) DTC P1700 (DTC NO.32/33) ACCELERATION STROKE SIGNAL INPUT MALFUNCTION WIRING DIAGRAM 1. TCM 2. ECM 3. Terminal arrangement of TCM connector (viewed from harness side) 4. Terminal arrangement of ECM connector (viewed from harness side) [A] For vehicle equipped with single- connector ECM [B] For vehicle equipped with triple-...
Page 462 AUTOMATIC TRANSMISSION (4 A / T) 7B1-57 TROUBLESHOOTING Step Action Was “A/T DIAGNOSTIC FLOW TABLE” in this Go to Step 2. Go to “A/T section performed? DIAGNOSTIC FLOW TABLE” in this section. Check acceleration stroke signal input circuit for Go to Step 3. “BLU/WHT”...
Page 463: Malfunction Of Tcm
7B1-58 AUTOMATIC TRANSMISSION (4 A / T) DTC P1702 (DTC NO.52) INTERNAL MALFUNCTION OF TCM DTC DETECTING CONDITION TROUBLE AREA D TCM Calculations of current data stored in TCM is not correct comparing with pre-stored checking data in TCM. DTC CONFIRMATION PROCEDURE 1) Connect scan tool to DLC with ignition switch OFF.
Page 464: Dtc P1730 Engine Torque Signal Circuit Malfunction 7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59 DTC P1730 (DTC NO.64) ENGINE TORQUE SIGNAL CIRCUIT MALFUNCTION WIRING DIAGRAM 1. TCM 2. ECM 3. Terminal arrangement of TCM connector (viewed from harness side) 4. Terminal arrangement of ECM connector (viewed from harness side) [A] For vehicle equipped with single- connector ECM [B] For vehicle equipped with triple-...
Page 465 7B1-60 AUTOMATIC TRANSMISSION (4 A / T) TROUBLESHOOTING Step Action Was “A/T DIAGNOSTIC FLOW TABLE” in this Go to Step 2. Go to “A/T section performed? DIAGNOSTIC FLOW TABLE” in this section. Check engine torque signal circuit for open. Go to Step 3. “WHT”...
Page 466: On-Vehicle Service
AUTOMATIC TRANSMISSION (4 A / T) 7B1-61 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 operating temperature (70 –...
Page 467: Fluid Change
7B1-62 AUTOMATIC TRANSMISSION (4 A / T) LEVEL CHECK AT ROOM TEMPERATURE [For vehicle with dipstick with COLD level indicator] The fluid level check at room temperature performed after repair or FULL COLD fluid change before test driving is just preparation for level check of normal operating temperature.
Page 468: Oil Cooler Hoses
AUTOMATIC TRANSMISSION (4 A / T) 7B1-63 OIL COOLER HOSES When replacing them, be sure to note the followings. D to replace clamps at the same time D to insert hose as far as bulge of pipe 1. Radiator D to clamp hose securely 2.
Page 469: Select Cable
7B1-64 AUTOMATIC TRANSMISSION (4 A / T) INSTALLATION Reverse removal procedure to install. INSPECTION [A]: Shift the select lever Check select lever for smooth and clear-cut movement and position with its button pushed in. [B]: Shift the select lever indicator for correct indication. without pushing its button.
Page 470: Transmission Range Switch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-65 ADJUSTMENT 1) Before tightening cable end nut (4), shift select lever to “N”. 2) Also shift manual shift lever (2) to “N”. NOTE: D Make sure that nut (4) and cable joint (3) have clearance under above conditions.
Page 471: Input Shaft Speed Sensor
7B1-66 AUTOMATIC TRANSMISSION (4 A / T) INPUT SHAFT SPEED SENSOR INSPECTION Check input shaft speed sensor (1) for resistance between termi- nals of sensor or TCM connector. Input shaft speed sensor resistance: 560 – 680 Ω (at 20_C (68_F)) OUTPUT SHAFT SPEED SENSOR INSPECTION Check output shaft speed sensor (1) for resistance between termi-...
Page 472: Solenoid Valves (Shift Solenoid Valves, Tcc Solenoid Valve And Pressure Control Solenoid Valve)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-67 SOLENOID VALVES (SHIFT SOLENOID VALVES, TCC SOLENOID VALVE AND PRESSURE CONTROL SOLENOID VALVE) REMOVAL 1) Disconnect negative cable from battery. 2) Pull out fluid level gauge and lift up vehicle. 3) Remove exhaust No.2 pipe (1). 4) Disconnect front propeller shaft (2) from front differential.
Page 473 7B1-68 AUTOMATIC TRANSMISSION (4 A / T) D When shift solenoid valve (1) is connected to battery (2), confirm that shift solenoid valve is open condition by blowing air (50 – 200 kpa, 0.5 – 2.0 kg/cm , 7 – 28.5 psi) into solenoid valve as shown in the figure.
Page 474 AUTOMATIC TRANSMISSION (4 A / T) 7B1-69 Operation Check Check pressure control solenoid valve (1) operation in the either manner of the followings. [Using regulated DC power supply] 1) Connect pressure control solenoid valve (1) with regulated DC power supply (2) as shown in the figure. 2) Turn regulated DC power supply switch ON, increase voltage of power supply keeping current within 1.0 A.
Page 475: Acceleration Stroke Sensor
7B1-70 AUTOMATIC TRANSMISSION (4 A / T) ACCELERATION STROKE SENSOR INSPECTION Refer to Section 6E3 for inspection. TRANSMISSION CONTROL MODULE (TCM) CAUTION: TCM consists of highly precise parts, so when handling it , be careful not to expose to excessive shock. REMOVAL 1) Disconnect negative cable at battery.
Page 476: 4Wd Low Switch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-71 4WD LOW SWITCH INSPECTION 1) Disconnect negative cable (–) at battery. 2) Disconnect 4WD LOW switch coupler (2). 3) Check continuity between 4WD LOW switch (1) terminals. There should be continuity when transfer lever shifted to 4L posi- tion and should be infinity when transfer lever shifted to 4H or 2H positions.
Page 477: Automatic Transmission Assembly (With Transfer)
7B1-72 AUTOMATIC TRANSMISSION (4 A / T) AUTOMATIC TRANSMISSION ASSEMBLY (WITH TRANSFER) DISMOUNTING In Cabin 1) Remove console box. NOTE: To remove clip, push in its center pin first. 2) Remove boot cover (1) and boot No.2 (2). 3) Remove boot clamp (1) and then remove boot No.1 (2) from transfer gear shift lever case.
Page 478 AUTOMATIC TRANSMISSION (4 A / T) 7B1-73 In Engine Room 1) Remove battery and dipstick. 2) Disconnect CKP sensor connector. 3) Remove CKP sensor mounting bolt and then remove CKP sen- sor from torque converter housing. 4) Remove starter motor. But don’t disconnect its wiring harness. 5) Remove transmission to engine bolt.
Page 479 7B1-74 AUTOMATIC TRANSMISSION (4 A / T) 14) Remove rear mounting (1) by removing its bolts (2). NOTE: If automatic transmission is overhauled later on, draining A/T fluid at this point will facilitate work. Tightening torque A/T fluid drain plug (a): 20 N m (2.0 kg-m, 14.5 lb-ft) 15) Lower the transmission jack slowly.
Page 480 AUTOMATIC TRANSMISSION (4 A / T) 7B1-75 After Dismounting WARNING: Be sure to keep transmission and transfer assembly hori- zontal throughout the work. Should they be tilted, torque converter may fall off and cause personal injury and A/T fluid may flow out. 1) Remove breather hose.
Page 481 7B1-76 AUTOMATIC TRANSMISSION (4 A / T) Tighten bolts and nuts to specified torque. CAUTION: Do not reuse drive plate bolts. Otherwise, engine oil may leak. Be sure to use new bolts with pre-coated adhesive. “A”: Sealant 99000-31110 Tightening torque Torque converter mounting bolts (a): 65 N m (6.5 kg-m, 47.0 lb-ft)
Page 482: Unit Repair
AUTOMATIC TRANSMISSION (4 A / T) 7B1-77 UNIT REPAIR NOTE: Refer to the same section of the Unit Repair Manual mentioned in FOREWORD of this manual for the de- scriptions not found in this item. When repairing automatic transmission, it is necessary to conduct the on-vehicle test to investigate where the cause of the trouble lies first.
Page 483: Part Inspection And Correction Table
7B1-78 AUTOMATIC TRANSMISSION (4 A / T) PART INSPECTION AND CORRECTION TABLE Part Inspect for Correction Casted part, machined part Small flaw, burr Remove with oil stone. Deep or grooved flaw Replace part. Clogged fluid passage Clean with air or wire. Flaw on installing surface, residual gasket Remove with oil stone or replace part.
Page 484: Unit Disassembly
AUTOMATIC TRANSMISSION (4 A / T) 7B1-79 UNIT DISASSEMBLY 1) Extract torque converter. CAUTION: Remove torque converter as much straight as possible. Leaning it may cause to damage oil seal lip. 1. Torque converter 2. Converter housing 2) Remove output shaft speed sensor (1). 3) Remove 6 adapter case fixing bolts and then remove adaptor case (2).
Page 485 7B1-80 AUTOMATIC TRANSMISSION (4 A / T) 11) Check dimensions of overdrive (O/D) case surface and clutch cylinder surface for reassembly. 12) Remove overdrive (O/D) clutch assembly by holding input shaft (3). 13) Remove O/D case, bearing and bearing race. NOTE: Confirm direction of bearing and bearing race for reas- sembly.
Page 486 AUTOMATIC TRANSMISSION (4 A / T) 7B1-81 22) Place transmission upright as shown in the figure. NOTE: D To prevent transmission case from getting damaged, protect its contacting surface with stand by using shop cloth or the like. D A stand of such size as shown in the figure will facilitate work.
Page 487 7B1-82 AUTOMATIC TRANSMISSION (4 A / T) 27) Remove 2 bolts (1) from valve body side to remove center sup- port. 28) Remove center support assembly (1). 29) Remove retaining ring (1), planetary gear assembly and leaf spring. NOTE: D Use care not to cause damage to case when removing re- taining ring.
Page 488 AUTOMATIC TRANSMISSION (4 A / T) 7B1-83 32) Undo caulking of sleeve cover (1) by using moderate stick (2) and move sleeve cover. 33) Using a punch, drive out manual shift lever pin, pull out manual shift shaft (2) and remove manual shift lever (1). Then remove sleeve cover from manual shift lever (1).
Page 489: Sub-Assembly Repair
7B1-84 AUTOMATIC TRANSMISSION (4 A / T) SUB-ASSEMBLY REPAIR OVERDRIVE (CASE SIDE) 1. Sealing 2. Bearing 3. Bearing race 4. O / D case 5. Planetary ring gear 6. O-ring 7. Brake piston 8. Return spring 9. Retainer 10. Retaining ring 11.
Page 490 AUTOMATIC TRANSMISSION (4 A / T) 7B1-85 DISASSEMBLY 1) Measure clearance between retaining ring (1) and brake back- ing plate (2) with thickness gauge. If it is not within standard range, adjust it to standard clearance with selective brake plates shown below. Clearance between retaining ring and brake backing plate Standard: 0.75 –...
Page 491 7B1-86 AUTOMATIC TRANSMISSION (4 A / T) INSPECTION D Measure free length of piston return spring. Standard free length of piston return spring: 16.60 mm (0.654 in.) ASSEMBLY Install each component by reversing removal procedure and noting the following points. D When installing rear seal ring, use care not to open it too wide.
Page 492: Forward Clutch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-87 FORWARD CLUTCH 1. Input shaft 2. Piston 3. Return spring 4. O-ring 5. Retaining ring 6. Bearing race 7. Bearing 8. Clutch plate 9. Clutch disc 10. Froward clutch hub 11. Direct clutch input hub : Do not reuse.
Page 493 7B1-88 AUTOMATIC TRANSMISSION (4 A / T) 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 494 AUTOMATIC TRANSMISSION (4 A / T) 7B1-89 7) Using special tool and hydraulic press, compress forward clutch piston return spring and remove retaining return spring. Special tool (A): 09926-98310 CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform. 8) Remove forward clutch piston return spring.
Page 495 7B1-90 AUTOMATIC TRANSMISSION (4 A / T) INSTALLATION 1) Apply A/T fluid to forward input shaft O-rings, install forward clutch piston and piston return spring (2) to forward input shaft and then install return spring ring with special tool and hydraulic press.
Page 496: Direct Clutch
AUTOMATIC TRANSMISSION (4 A / T) 7B1-91 DIRECT CLUTCH 1. Bearing race 2. Bearing 3. Retaining ring 4. Clutch backing plate 5. Clutch disc 6. Clutch plate 7. Return spring 8. O-ring 9. Direct clutch piston 10. Direct clutch cylinder : Do not reuse.
Page 497 7B1-92 AUTOMATIC TRANSMISSION (4 A / T) 2) Remove direct clutch assembly from center support and then re- move retaining ring. 3) Remove clutch backing plate (1) and then remove clutch disc (3) and clutch plate (2). 4) Using special tool and hydraulic press (1), compress direct clutch piston return spring (3) and remove retaining return spring ring (2).
Page 498 AUTOMATIC TRANSMISSION (4 A / T) 7B1-93 INSPECTION Direct Clutch Piston Return Spring D Measure free length. Standard free length of direct clutch piston return spring: 15.13 mm (0.595 in.) Direct Clutch Piston D Shake piston to check that ball is not stuck. D Apply air pressure and check that there is no leakage.
Page 499: Center Support
7B1-94 AUTOMATIC TRANSMISSION (4 A / T) CENTER SUPPORT 1. Center support 2. O-ring 3. Second coast brake piston 4. Piston return spring 5. Snap ring 6. Second coast brake plate 7. Second coast brake disc 8. Clutch backing plate 9.
Page 500 AUTOMATIC TRANSMISSION (4 A / T) 7B1-95 DISASSEMBLY 1) Remove retaining ring. Special tool (A): 09920-76010 2) Pull out center support assembly (2) from planetary sun gear (1). 3) Apply 4 – 8 kg/cm air pressure into fluid hole at the extreme left and measure movement of second coast brake piston.
Page 501 7B1-96 AUTOMATIC TRANSMISSION (4 A / T) 6) Using special tool and hydraulic press, compress piston return spring and remove snap ring. CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to de- form.
Page 502 AUTOMATIC TRANSMISSION (4 A / T) 7B1-97 11) After removing retaining back plate ring, remove clutch back- ing plate, second brake plates and second brake discs. 12) Using special tool and hydraulic press, compress brake piston return spring and remove snap second brake ring. CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to de-...
Page 503 7B1-98 AUTOMATIC TRANSMISSION (4 A / T) 16) Remove second brake hub assembly (1) from planetary sun gear (2). 17) Remove 2 sun gear seal rings (1) from planetary sun gear. NOTE: Use care not to open sun gear seal ring more than neces- sary.
Page 504 AUTOMATIC TRANSMISSION (4 A / T) 7B1-99 D After installing each retaining backing plate ring, measure move- ment of brake piston again. If it is not within standard range, it is possible that ring is not installed properly. Then disassemble and reassemble again. Standard movement of second coast brake piston: 1.00 –...
Page 505: Planetary Gears And Output Shaft
7B1-100 AUTOMATIC TRANSMISSION (4 A / T) PLANETARY GEARS AND OUTPUT SHAFT 1. Inner shaft 11. Washer 21. Seal ring 2. Retaining ring 12. Front planetary ring gear 22. Brake applying tube 3. Reverse brake reaction plate 13. Retaining ring 4.
Page 506 AUTOMATIC TRANSMISSION (4 A / T) 7B1-101 DISASSEMBLY 1) Remove front planetary gear assembly (1) from output shaft as- sembly (2). 2) Remove rear planetary thrust washer (1), reverse brake backing plate (2), reverse brake disc (3) and reverse brake plate (4) from front planetary gear assembly.
Page 507 7B1-102 AUTOMATIC TRANSMISSION (4 A / T) 5) After removing retaining ring (1), remove front planetary ring gear (2), thrust bearing and rear planetary race. 6) Remove rear planetary thrust washer (1), rear planetary gear (2). 7) After removing retaining ring (2) from inner shaft (1), remove rear planetary ring gear (3) and thrust bearing assembly.
Page 508 AUTOMATIC TRANSMISSION (4 A / T) 7B1-103 D Install one-way clutch as shown in the figure. 1. Front planetary gear side D Install reverse brake reaction plate (2) to front planetary gear (1). With reverse brake reaction plate (2) fixed stationary, turn front planetary gear (1) clockwise to check that it locks and then coun- terclockwise to check that it turns smoothly.
Page 509: Valve Body Assembly
7B1-104 AUTOMATIC TRANSMISSION (4 A / T) VALVE BODY ASSEMBLY 1. Valve body assembly : Apply automatic transmission fluid. 2. Manual valve : Tightening torque. 3. Detent spring 4. Detent spring cover : Do not reuse. 5. Shift solenoid-B (No.2) valve 6.
Page 510 AUTOMATIC TRANSMISSION (4 A / T) 7B1-105 DISASSEMBLY 1) Remove detent spring (2), plate (1) and manual valve (3). 2) Remove shift solenoid-A valve (1) and shift solenoid-B valve (2). 3) Remove clamp (3), then remove TCC solenoid valve (4) and Pressure control solenoid valve (5).
Page 511: Unit Assembly
7B1-106 AUTOMATIC TRANSMISSION (4 A / T) UNIT ASSEMBLY 1) After applying A/T fluid to new O-rings, install them to reverse brake piston (3), reaction sleeve (2) and secondary reverse pis- ton (1). 2) install reverse brake piston assembly and brake piston return spring to transmission case, using care not to damage O-ring.
Page 512 AUTOMATIC TRANSMISSION (4 A / T) 7B1-107 5) Install brake applying tube (1) so that its lug fits in a in transmis- sion case. After installation, check that 4 lugs (3) along the un- derside of brake applying tube fit inside of reverse brake piston and leaf spring (2) is installed properly.
Page 513 7B1-108 AUTOMATIC TRANSMISSION (4 A / T) 9) Using screwdriver with vinyl tape or the like wound at its tip, install retaining reaction plate ring (1). After installation, check that ring is in groove securely. 10) After confirming that lugs of all brake plates and brake discs are in grooves securely, hold retaining direct clutch ring (1) of plan- etary sun gear, install center support assembly by aligning fluid holes (2) in center support and transmission case.
Page 514 AUTOMATIC TRANSMISSION (4 A / T) 7B1-109 14) Install forward clutch assembly by putting all lugs of direct clutch disc hub together and matching them with groove cut in direct clutch input hub, and at the same time aligning splines in forward clutch hub with inner shaft.
Page 515 7B1-110 AUTOMATIC TRANSMISSION (4 A / T) 19) When clutch disc or plate has been replaced, check height dif- ference between O/D case and O/D clutch cylinder by mea- suring it as shown in the figure. Standard height difference “a” between O/D case and O/D clutch cylinder: About 3.5 mm (0.138 in.) NOTE:...
Page 516 AUTOMATIC TRANSMISSION (4 A / T) 7B1-111 23) Apply 2 – 4 kg/cm air pressure into fluid holes in the figure as numbered and check operation sound of each part. (1) O/D clutch (2) O/D brake (3) Forward clutch (4) Direct clutch (5) Second coast brake (6) Second brake (7) Reverse brake...
Page 517 7B1-112 AUTOMATIC TRANSMISSION (4 A / T) 29) Align hole in manual shift shaft with that in manual shift lever and drive in new manual shift lever pin (1). 30) Align hole in sleeve cover with dent in manual shift lever and caulk securely with pin punch (1).
Page 518 AUTOMATIC TRANSMISSION (4 A / T) 7B1-113 Accumulator piston and spring specification: Piston outer Identification Used for Spring free length “b” diameter “a” painting Upper spring 58.96 mm (2.321 in.) Light blue 31.80 – 31.85 mm Direct clutch accumulator (2) Direct clutch accumulator (2) (1.252 –...
Page 519 7B1-114 AUTOMATIC TRANSMISSION (4 A / T) 36) Clamp wire harness (1) by wire harness clamp (2). 37) Install transmission temperature sensor (3) to sensor clamp (4). 38) Connect the following connector by referring to its color shown below. D Shift solenoid-A (No.1) connector (5) – Brown D Shift solenoid-B (No.2) connector (6) –...
Page 520 AUTOMATIC TRANSMISSION (4 A / T) 7B1-115 43) Install adapter case (1) with new adapter gasket to transmis- sion case and tighten adapter case bolts to specified torque. Tightening torque Adapter case bolt (a): 35 N m (3.5 kg-m, 25.5 lb-ft) 44) Apply A/T fluid to new O-ring and install it to output shaft speed sensor (1) and then install output shaft speed sensor (1) to adapter case (2).
Page 521: Bearing And Race Installation Diagram
7B1-116 AUTOMATIC TRANSMISSION (4 A / T) BEARING AND RACE INSTALLATION DIAGRAM...
Page 522: Tightening Torque Specification
AUTOMATIC TRANSMISSION (4 A / T) 7B1-117 TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening part Fastening art kg-m lb-ft Transmission case plug 0.75 A/T fluid drain plug 14.5 Transfer oil drain and level/filler plugs 17.0 Manual selector assembly bolts 13.5 Manual select lever nut Manual select cable end nut Transmission range sensor lock bolt 0.55...
Page 523: Required Service Material
Refer to Section 0B D Parts lubrication when installing D Solenoid valve O-ring D Retaining parts in place when assembling Lithium grease SUZUKI SUPER GREASE C D Oil seal lips (99000-25030) D Oil pump O-ring SUZUKI SUPER GREASE A Cable ends...
Page 524 1.7 or more for Bearing installer Oil pressure gauge 16 / 14 pin DLC Tech 1A. 09931-76011 Tech 1A kit (SUZUKI scan tool) 09940-53111 Tech 2 kit (SUZUKI scan tool) See NOTE “A” below. Bearing installer See NOTE “B” below.
Page 525 CLUTCH 7C1-1 SECTION 7C1 CLUTCH NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in the FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION ..............7C1-2 UNIT REPAIR .
Page 526 7C1-2 CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm-spring type clutch with a dry single disc. The diaphragm spring is of a tapering-finger type, which a solid ring is set in the outer diameter part, with a series of tapered fingers pointing inward. The clutch disc, which is positioned on the transmission input shaft with an involute spline fit, is a type called silent type.
Page 527 CLUTCH 7C1-3 UNIT REPAIR CLUTCH COVER, CLUTCH DISC AND FLYWHEEL 50 N·m (5.0 kg-m, 36.5 lb-ft) 1. Input shaft bearing 2. Flywheel 3. Clutch disc 4. Clutch cover 5. Bolt 6. Release bearing 7. Clutch release fork 8. Boot 9. Clip : Tightening Torque 10.
Page 528 7C1-4 CLUTCH INSPECTION Input Shaft Bearing and Release Bearing Check bearing for smooth rotation and replace it if abnormality is found. Clutch Disc Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Page 529 CLUTCH 7C1-5 INSTALLATION CAUTION: Do not reuse flywheel bolts. Otherwise, engine oil may leak. Be sure to use new bolts with pre-coated adhesive. NOTE: Before assembling, make sure that flywheel surface and pres- sure plate surface have been cleaned and dried thoroughly. 1) Install flywheel to crankshaft and tighten new bolts (2) to specification.
Page 530 7C1-6 CLUTCH 4) Install clip (2) to release fork (1) and apply grease. “A”: Grease 99000-25010 Then install release fork (1) and release bearing as shown in fig- ure. 5) Slightly apply grease to input shaft (3) and install clutch disc. “B”...
Page 531 16.5 REQUIRED SERVICE MATERIAL RECOMMENDED MATERIAL SUZUKI PRODUCT D Clutch master cylinder clevis pin. SUZUKI SUPER GREASE A D Release fork. (99000-25010) D Push rod tip of operating cylinder. Lithium grease SUZUKI SUPER GREASE I Input shaft spline front end.
Page 532 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 men- tioned in the FOREWORD of this manual. CONTENTS GENERAL DESCRIPTION ..............7E- 1 4WD CONTROL SYSTEM .
Page 533 7E-2 DIFFERENTIAL (FRONT) 4WD CONTROL SYSTEM When the 4WD switch is turned ON by shifting the transfer shift lever, 4WD controller actuates (energizes) the air pump assembly. Then positive pressure is sent from the air pump assembly to the actuator installed to the differen- tial case and causes the axle lock clutch and the free axle hub in the differential case to be engaged, resulting in the 4WD mode.
Page 534 DIFFERENTIAL (FRONT) 7E-3 System Circuit and Operation 1. 4WD switch 6. Transfer 2. Air pump assembly 7. Front differential 3. Pump motor 8. Air hose and pipe 4. Release valve 9. 4WD indicator lamp 5. Pressure switch 10. To ignition switch 11.
Page 535 7E-4 DIFFERENTIAL (FRONT) Components and Functions Component Function When the transfer shift lever is shifted to 4L or 4H position, this switch turns ON 4WD switch and causes the 4WD control system to turn ON, unless it is shifted to N or 2H within 1 second.
Page 536 DIFFERENTIAL (FRONT) 7E-5 DIAGNOSIS DIAGNOSIS TABLE DIFFERENTIAL ASSEMBLY Condition Possible Cause Correction D Deteriorated or water mixed lubricant Gear noise Repair and replenish D Inadequate or insufficient lubricant Repair and replenish D Maladjusted backlash between bevel Adjust pinion and gear D Improper tooth contact in the mesh between Adjust or replace bevel pinion and gear...
Page 537 7E-6 DIFFERENTIAL (FRONT) 4WD CONTROL SYSTEM DIAGNOSTIC FLOW TABLE Before performing the trouble diagnosis, check that the transfer and front differential are in good condition. [NOTES ON SYSTEM CIRCUIT INSPECTION] D Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before circuit inspection and observe what is written there.
Page 538 DIFFERENTIAL (FRONT) 7E-7 Step Action Check 4WD controller. Go to Step 8. Substitute a known- 1) Turn ignition switch ON. good 4WD controller 2) Check voltage between terminal E23-3 and and recheck. ground. Transfer lever is in “N” or “2H”: 0 – 1 V Transfer lever is in “4L”...
Page 539 7E-8 DIFFERENTIAL (FRONT) 4WD CONTROL CIRCUIT INSPECTION VOLTAGE CHECK Check for input or output voltage (voltage between each circuit and body ground) of 4WD controller with 4WD controller connector con- nected and ignition switch turned ON. NORMAL TER- WIRE CIRCUIT CONDITION MINAL COLOR...
Page 540 DIFFERENTIAL (FRONT) 7E-9 ON-VEHICLE SERVICE INSPECTION 4WD CONTROL SYSTEM 1) Install special tool to air hose connecting between air pump as- sembly and differential (actuator) as shown in figure. Tighten ad- justing screw of special tool as far as it stops. Close air check side opening by using fuel hose as blind plug.
Page 541 7E-10 DIFFERENTIAL (FRONT) ACTUATOR 1) Disconnect air hose from pump assembly and install special tool to air hose as shown in figure. Loosen adjusting screw of special tool. Special Tool (A): 09918-18111 2) Connect compressor air hose to special tool. Blow air and turn adjusting screw to obtain specified pressure.
Page 542 DIFFERENTIAL (FRONT) 7E-11 AIR PUMP ASSEMBLY Removal/Installation 1) Disconnect air hoses and coupler from air pump assembly. 2) Remove pump assembly by removing bolts. 3) Reverse removal procedure for installation. Tightening Torque (a): 13 N m (1.3 kg-m, 9.5 lb-ft) Inspection 1) Install special tool, voltmeter and battery to pump assembly as shown in figure.
Page 543: Removal And Installation
7E-12 DIFFERENTIAL (FRONT) REMOVAL AND INSTALLATION DIFFERENTIAL MOUNTINGS 1) Lift up vehicle and turn steering wheel all way to the right. 2) Separate front mounting bracket R (2) from differential housing (3) by removing bolts (1) from its lower part. 3) Remove mounting bracket R (2) by removing mounting front bolt (4) from its upper part.
Page 544 DIFFERENTIAL (FRONT) 7E-13 7) Position each bush to bracket as shown. Length “a”: 3.0 mm (0.12 in.) 1. Mounting bracket R 2. Mounting bracket L 8) Use following torque for reinstallation. Tightening Torque Front mounting bolt (a): 85 N m (8.5 kg-m, 61.5 lb-ft) Front mounting bracket bolt (b): 50 N m (5.0 kg-m, 36.5 lb-ft)
Page 545 7E-14 DIFFERENTIAL (FRONT) 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. 4) Remove propeller shaft flange by removing its 4 bolts and sus- pend it with cord or the like.
Page 546 DIFFERENTIAL (FRONT) 7E-15 9) Using 2 large screwdrivers (4) as levers, pull out right side drive shaft joint (1) from differential (2) and dismount housing assem- bly from vehicle. CAUTION: During above work, use care not to cause damage to drive shaft boot.
Page 547 7E-16 DIFFERENTIAL (FRONT) TIGHTENING TORQUE SPECIFICATION Tightening torque Fastening part Fastening art kg-m lb-ft Differential oil level/filler plug 17.0 Differential oil drain plug 17.0 Front mounting bolts 61.5 Front mounting bracket bolts 36.5 Front drive shaft flange bolts 36.5 Propeller shaft flange bolts 36.5 Pump assembly bolts Rear mounting bolt...
Page 548 DIFFERENTIAL (REAR) 7F-1 SECTION 7F DIFFERENTIAL (REAR) CONTENTS GENERAL DESCRIPTION ....7F- 2 COMPONENT INSPECTION ..7F- 9 SUB-ASSEMBLY ADJUSTMENT AND DIAGNOSIS .
Page 549: 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 convention- al 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 550: On-Vehicle Service
DIFFERENTIAL (REAR) 7F-3 ON-VEHICLE SERVICE 1. Universal joint flange 15. Thrust washer : Do not reuse. 2. Hypoid gear set 16. Differential side bearing : Tightening torque 3. Bevel pinion spacer 17. Bearing adjuster 4. Shim 18. Lock plate : Apply differential oil. 5.
Page 551: Precaution For Maintenance Service
7F-4 DIFFERENTIAL (REAR) PRECAUTION FOR MAINTENANCE SERVICE D When having driven through water, check immediately if water has entered (if so, oil is cloudy). Water mixed oil must be changed at once. D Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage and status of breath- er hoses.
Page 552: 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 553: Unit Repair
7F-6 DIFFERENTIAL (REAR) 3) Install propeller shaft to joint flange aligning match marks and torque flange bolts to specification. Apply thread lock cement to thread part of bolt if reused. “A”: Cement 99000-32110 Tightening torque Propeller shaft flange bolts (a): 60 N m (6.0 kg-m, 43.5 lb-ft) 4) Install right and left rear axle shafts and drums.
Page 554 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 555 7F-8 DIFFERENTIAL (REAR) b) Make mating marks (1) on drive bevel pinion and companion flange. CAUTION: Don’t make mating mark on the coupling surface of the flange. c) Press drive bevel pinion (2) by using rod (4) (approx. 22 mm (0.866 in.) in diameter) and press (5) then remove drive bevel pinion (2) and companion flange (3).
Page 556: Component Inspection
DIFFERENTIAL (REAR) 7F-9 7) Drive out rear bearing outer race in the same way as in the Step COMPONENT INSPECTION D Check companion flange for wear or damage. D Check bearings for wear or discoloration. D Check differential carrier for cracks. D Check drive bevel pinion and drive bevel gear for wear or cracks.
Page 557: Differential Case
7F-10 DIFFERENTIAL (REAR) 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). For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.
Page 558 DIFFERENTIAL (REAR) 7F-11 6) Clean and degrease mating surface of drive bevel gear (hypoid gear) (1). 7) Apply thread lock cement to hatched part of drive bevel gear (1) as shown in the figure. “A”: Cement 99000-32110 8) Put drive beval gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque.
Page 559: Differential Side Bearing
7F-12 DIFFERENTIAL (REAR) DIFFERENTIAL SIDE BEARING 1) Press-fit side bearing (1) with special tool and press. Special tool (A): 09944-66020 2) Hold bearing press-fitted in Step 1) with holder and press-fit side bearing on the other side. NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.
Page 560: 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 561 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 ob- tained.
Page 562 DIFFERENTIAL (REAR) 7F-15 3) Set dial gauge to mounting dummy and make 0 (zero) adjust- ment on surface plate. NOTE: D When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge. D With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.
Page 563 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 Available shim thickness:...
Page 564 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 specifi- cation. NOTE: D Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand. D On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
Page 565: 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 566 DIFFERENTIAL (REAR) 7F-19 7) Measure preload of pinion bearing with spring balance (1) or 3. Universal joint flange torque wrench (2) and check composite preload of pinion bear- 4. Socket with adapter ing and side bearing. NOTE: D Before taking measurement with spring balance (1) or torque wrench (2), check for smooth rotation by hand.
Page 567 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. 1) Increase thickness of pinion height adjusting shim and position pinion closer to gear center. 2) Adjust drive bevel gear backlash to specification. LOW CONTACT Pinion is positioned too close to the center of drive bevel gear.
Page 568: Tightening Torque Specification
D Differential case bolts Thread lock cement SUPER 1322 D Bevel gear mating surface (99000-32110) D Propeller shaft flange bolt SUZUKI SUPER GREASE A Lithium grease Oil seal lips (99000-25010) D Rear differential drain plug SUZUKI BOND NO.1215 D Mating surface of differential housing...
Page 569: Special Tool
7F-22 DIFFERENTIAL (REAR) SPECIAL TOOL 09900-20606 09900-20701 09913-61510 09922-76570 Dial gauge Magnetic stand Bearing puller Attachment 09913-75510 09913-85230 09922-66021 09922-75222 Bearing installer Bearing removing jig Flange holder Preload checking tool 09926-78311-002 09924-74510 09925-18011 09926-68310 Pinion mounting dummy Installer attachment Bearing installer Bearing installer (See NOTE.) 09928-06510...
Page 570 DIFFERENTIAL (REAR) 7F-23 09951-18210 09930-40120 09944-66020 09951-16060 Oil seal remover & installer Attachment Bearing installer Lower arm bush remover No.2 09951-46010 Drive shaft oil seal installer NOTE: This tool is constituent of tools with 09926-78311...
Page 571 D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 572: Combination Meter
8C-2 INSTRUMENTATION / DRIVER INFORMATION GENERAL DESCRIPTION COMBINATION METER 1. Tachometer 2. Speedometer 3. Fuel level meter 4. Engine coolant temperature meter 5. Turn signal pilot light (LH) 6. 4WD indicator 7. ABS warning light (if equipped) 8. Glow light 9.
Page 573 INSTRUMENTATION / DRIVER INFORMATION 8C-3 ON-VEHICLE SERVICE FUEL METER/FUEL GAUGE UNIT 1. Fuel level gauge FUEL LEVEL GAUGE 2. Fuel level gauge terminal 3. Fuel level gauge terminal INSPECTION 4. Float Remove fuel sender gauge referring to Section 6C of this manual. Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position.
Page 574: Immobilizer Control System
D Service on and around the air bag system components or wiring must be performed only by an autho- rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener- al Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring.
Page 575: General Description
8G-2 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) GENERAL DESCRIPTION The immobilizer control system is designed to prevent vehicle burglar and consists of following components. D Engine control module (ECM) D Immobilizer Control Module D Ignition key (with built-in transponder) D Coil antenna Operation of this system is as follows.
Page 576 Coil antenna – Serial data line between ECM and immobilizer control module – – Power supply PPL/ WHT Serial data line for Suzuki scan tool Serial data line between ECM and immobilizer control module Power control of ECM BLK/ WHT Ignition signal...
Page 577 8G-4 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) IGNITION KEY The ignition key for the immobilizer control system has a built-in transponder. Each transponder in the key has an each transmitting code (Transponder code). The code will transmitted from the key via the coil antenna to Immobilizer Control Module when the ignition switch is turned ON.
Page 578: On-Board Diagnostic System
(SELF-DIAGNOSIS FUNCTION) Immobilizer Control Module and ECM diagnoses troubles which may occur in the area including the following parts when the ignition switch is ON. It indicates the diagnosis result through Suzuki scan tool. D Ignition key (Transponder code) Immobilizer...
Page 579: Diagnosis
8G-6 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DIAGNOSIS Immobilizer Control Module have on-board diagnostic system (a system self-diagnosis function) as described previously. Investigate where the trouble is by referring to “IMMOBILIZER DIAGNOSTIC FLOW TABLE” and “DIAGNOSTIC TROUBLE CODE TABLE” on later pages. PRECAUTIONS IN DIAGNOSING TROUBLES [PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE]...
Page 580: Immobilizer Diagnostic Flow Table
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-7 IMMOBILIZER DIAGNOSTIC FLOW TABLE NOTE: After replacing with Immobilizer Control Module and/or ECM, register transponder code and ECU code ac- cording to “Procedure after Immobilizer Control Module Replacement” or “Procedure after ECM Replace- ment”. Otherwise, the accurate trouble diagnosis will not be assured. STEP ACTION Turn ignition switch to start engine.
Page 581: Diagnostic Trouble Code (Dtc) Check (Immobilizer Control Module)
DIAGNOSTIC TROUBLE CODE (DTC) CHECK (IMMOBILIZER CONTROL MODULE) 1) Turn ignition switch OFF. 2) After setting cartridge to Suzuki scan tool, connect it to data link connector (DLC) located on underside of instrument panel at driver’s seat side. Special Tool (A): Suzuki scan tool 3) Turn ignition switch OFF for 10 seconds and then ON.
Page 582: Diagnostic Trouble Code Table
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-9 DIAGNOSTIC TROUBLE CODE TABLE Immobilizer Control Module DIAGNOSTIC TROUBLE DETECTED ITEM DIAGNOSIS CODE NO. This code appears when none of the other NO DTC —— codes are identified. Transponder code not matched Transponder code not registered Fault in Immobilizer Control Module No transponder code transmitted from Diagnose trouble according to “DIAGNOSTIC...
Page 583 8G-10 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) TABLE A SCAN TOOL CAN NOT COMMUNICATE WITH IMMOBILIZER CONTROL MODULE 1. Main fuse 2. Ignition switch 3. Immobilizer Control Module 4. Data link connector (DLC) 5. “IG METER” fuse 6. “DOME” fuse STEP ACTION D “BLK/WHT”...
Page 584: Control Module
Read DTC according to “Diagnostic Replace ignition key. Go to “Immobilizer Trouble Code Check” section. Diag. Flow Table”. Does Suzuki scan tool indicate DTC 11 and/or 31 again? Fig. 1 for Step 2 Ignition key with built-in transponder DTC12 FAULT IN IMMOBILIZER CONTROL MODULE DESCRIPTION: This DTC is set when an internal fault is detected in Immobilizer Control Module.
Page 585: Dtc13 No Transponder Code Transmitted From Ignition Key
8G-12 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC13 NO TRANSPONDER CODE TRANSMITTED FROM IGNITION KEY DTC14 COIL ANTENNA CIRCUIT MALFUNCTION 1. Immobilizer Control Module 2. Coil antenna DESCRIPTION: Immobilizer Control Module energizes the coil antenna when the ignition switch is ON and reads Transponder code from the ignition key.
Page 586: Dtc41 Ecm Not Registered
Substitute a known-good ECM Go to “Immobilizer Diag. Trouble Code Check” section. and recheck. Flow Table”. Does Suzuki scan tool indicate DTC 41 again? Fig. 1 for Step 2 and 3 Fig. 2 for Step 2 and 3 1. ECM coupler 1.
Page 587: Dtc42 Serial Data Circuit Malfunction
8G-14 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) DTC42 SERIAL DATA CIRCUIT MALFUNCTION (BETWEEN IMMOBILIZER CONTROL MODULE AND ECM) [A] : For vehicle equipped with single-connector ECM [B] : For vehicle equipped with triple-connector ECM 1. Immobilizer control module 2. ECM DESCRIPTION If ECU code is not transmitted from ECM, Immobilizer Control Module sets DTC42.
Page 588: Dtc43 Ecu Code Not Matched
1) Register ECU code in immobilizer control Faulty ECM. Go to “Immobilizer Diag. module according to “Procedure after Flow Table”. Immobilizer Control Module Replacement” section. 2) Read DTC according to “Diagnostic Trouble Code Check” section. Does Suzuki scan tool indicate DTC 43 again?
Page 589: Inspection Of Immobilizer Control Module And Its Circuit
8G-16 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) INSPECTION OF IMMOBILIZER CONTROL MODULE AND ITS CIRCUIT Immobilizer Control Module and its circuit can be checked at Immo- bilizer Control Module wiring coupler by measuring voltage and re- sistance. Described here is only inspection of Immobilizer Control Module.
Page 590: Resistance Check
Power supply 10 – 14 V Ignition switch ON and OFF G09-4 – – Serial data line between Suzuki G09-5 scan tool and immobilizer control 4 – 5 V Ignition switch ON and OFF module Serial data line between ECM and G09-6 10 –...
Page 591: On-Vehicle Service
8G-18 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) ON-VEHICLE SERVICE PRECAUTIONS IN HANDLING IMMOBILIZER CONTROL SYSTEM D Don’t turn ON ignition switch with ignition key for immobilizer con- trol system put together with another one or placed quite close to another one. Or the system may detect abnormal condition and prevent engine from starting.
Page 592: Immobilizer Control Module
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-19 IMMOBILIZER CONTROL MODULE Removal 1) Disconnect negative (–) cable at battery. 2) Remove steering column hole cover. 3) Disconnect couplers. 4) Remove immobilizer control module. Installation Reverse removal procedure for installation NOTE: After replacing Immobilizer Control Module, be sure to register Transponder code and ECU code in Immobilizer Control Mod- ule by performing procedure described in “Procedure after Im- mobilizer Control Module Replacement”.
Page 593: How To Register Ignition Key
Control Module by executing “ENT. TRANS COD (Enter transponder code)” command in SELECT MODE menu. 6) Make sure that no DTC is displayed on Suzuki scan tool after ignition switch is turned OFF for 10 seconds or more and then...
Page 594: Procedure After Immobilizer Control Module Replacement
4) Using Suzuki scan tool, register Transponder code in Immobiliz- er Control Module by executing “ENT. TRANS COD (Enter transponder code)” command in SELECT MODE menu. 5) Using Suzuki scan tool, register ECU code in Immobilizer Con- trol Module by executing “IMMOBI CONT” command in RE- CORD ECU menu.
Page 595: Procedure After Ecm Replacement
8G-22 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 6) Make sure that no DTC is displayed on Suzuki scan tool after ignition switch is turned OFF for 10 seconds or more and then 7) If any other Transponder code for ignition key with a built-in trans- ponder needs to be registered, repeat above Steps 2), 4) and 6).
Page 596: Special Tools
D It takes 1 minute (max) until registration of ECU code to the ECM is completed. 3) Make sure that no DTC is displayed on Suzuki scan tool after ignition switch is turned OFF for 10 seconds or more and then...
Page 597 Prepared by 1st Ed. Feb., 2002 Printed in Japan Printing:...

Suzuki Grand Vitara XL-7 Service Manual

Section 0A General Information

Precautions

Identification Information

Warning, Caution and Information Labels

Fastener Information

Heater and Ventilation

General Description

Diagnosis

On-Vehicle Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

On-Vehicle Service

Required Service Material

Section 3B1 Power Steering (P/S) System

Section 6 Engine General Information and Diagnosis (Rhz Engine with Single-Connector Ecm)

General Information

Engine Diagnosis

Section 6-1 Engine General Information and Diagnosis (Rhz Engine with Triple-Connector Ecm)

General Information

Engine Diagnosis

Special Tools

Section 6A3 Engine Mechanical (Rhz Engine)

Maintenance

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Materials

Section 6B Engine Cooling

General Description

Diagnosis

Maintenance

On-Vehicle Service

Required Service Materials

Section 6E3 Engine and Emission Control System (Rhz Engine)

General Description

On-Vehicle Service

Section 6G Cranking System (2.0 Kw Reduction Type)

General Description

Diagnosis

Unit Repair Overhaul

Specifications

Required Service Material

Tightening Torque Specifications

Section 6H Charging System

Warning

On-Vehicle Service

Unit Repair Overhaul

Specifications

Special Tools

Section 7A2 Manual Transmission

General Description

Diagnosis

On-Vehicle Service

Unit Repair

Specification

Tightening Torque

Required Service Material

Special Tool

Quick Links

Chapters

Related Manuals for Suzuki Grand Vitara XL-7

Summary of Contents for Suzuki Grand Vitara XL-7